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Phaser 790/DocuColor 2006 Service Manual

1. Adjust by moving the Entrance Tray Assembly to either the front or the rear as needed Figure 2 a Ifthe results are less than nominal move the tray toward the front b Ifthe results are greater than nominal move the tray toward the rear 3 1 Tighten the Loosenthe screws 2 screws 2 Move the tray 0 205002A WOL Figure 2 Adjusting Side Registration 2 Perform the check again and repeat the adjustment as required 3 Perform a fine adjustment as follows At a Enter Diagnostic Mode IIT GP 19 oe b Enter Systemdata R W and press the Select button 00mm c Enter Chain 715 and Link 7 and confirm the present values gt 10 0mm 4 Change the values as required based on the measurement results When the measure ment is greater than nominal reduce the value when the measurement is less than nom m inal increase the value Change the values as follows P 10 NOTE To enter a letter hexadecimal value press the asterisk key prior to entering each letter value then press the appropriate numerical key as follows A21 2 D 4 5
2. Figure 1 007 710 RAP Circuit Diagram 1 of 2 FEEDER PWB PL13 4 5 21 86 1 NUDGER NUDGER 5VDC o 9 SENSOR SENSOR PL13 5 SENSED p32 1 4222 J242 P242 D 4215 FEEDER PWB GRY GRY PL13 4 P35 LVPS 6 2215 v P242 0 2222 4222 j GRY GRY 1 I 1 1 1 12 44 13 2 VDO GRY GRY 4 P214 DC COM DO B8 x P218 FEEDER MOTOR P216 ON 4217 D 24VDC 12 5VDC P213 BLU FEEDER EDER MOTOR PWB i J239 FAIL J217 2 4 11 P212 P21 BLU DC COM f P215 1 I L LIFT 24VDC CLUTCH PL13 4 00 83 LIFT CLUTCH LOW VOLTAGE POWER 4216 ON C J234 P234 SUPPLY 107 1 2 1 P11 1 LT GRY 1 132 J211 211 4243 DS COM 24VDC INTERLOCKED 9 4 9 2 1 l ORN L GRY A 24VDC 24VDC 5 INTERLOCKED i i DO B7 SOLENOID NUDGER SOLENOID PL13 6 pa POETE 4210 242 J226 2 P226 BLU GRY GRY i i DC COM DCCOM 1 1 1 10 6 10 2 GRY GRY 24VDC INTERLOCKED T707020A WOL Status Indicator RAPs 007 710 10 00 2 108 Initial Issue Phaser 790 Do
3. Table 1 Items for the IOT Parameters b Press the Item Enter button Default Maximum Minimum The display will change to show LIFE COUNT xx which represents the menu num Menu No Function Value Value Value Unit ber you selected and also displays XXXXXXX which represents the counter value in numbers and not in Xs 19 Top to Bottom Bypass Tray 28 64 0 0 17 mm d Use the Up and Down Arrow buttons to change the value as required or to reset the 1A Top to Bottom Duplex Tray 17 64 0 0 17 mm counter to 0 15 Mismatch Enable 0 0 0 Enable e Press the Item Enter button 1 Disable 10 1 Unused Table 3 Life Counters Be 2 Offset Plain Paper Menu Function Remarks Life Reset id PTRA Ofset Transparency 3 i 0 Drum Cartridge TRO Sensor counts Records Each TRO signal increments i unts 1 1 22 PTR2 Offset Heavy Weight 3 all Drum IBT cycles includ the counter by 2 Information is 25 BTR2 Offset Coated Paper 13 5 1 ing cycle up power on etc stored on the drum cartridge 2a BTR2 Offset Label 3 5 1 CRUM and meter Cartridge 2B BTR2 Offset Postcard 3 5 1 life warning is at 90K life end is 26 BTR2 Offset Envelope 3 5 1 at 110K 2D Country 0 01 0 1 Dry Ink Cartridge Y Cumulative Dispense Time Automatically reset with new 100 cart
4. MCU PWB DRIVE MOTOR PAPER HANDLING PL11 2 r amp 3 PWB PL10 1 ra MOTOR J18 MOTOR CLOCK 450 12 Gay 4 MOTOR CLOCK CN2 i 50 53 MOTOR CLOCK die 11 MOTOR ONE 2 MOTOR CLOCK GRY 7 r MOTOR SPEED 1 x L 5 VDC 3 22 HALL ELEMENT 1 HALL EFFECT 227 HALL ELEMENT 1 5 7 22 SPEED Secon MOTOR SPEED 2 SENSN NE ON D 5 VDC ELEMENT 2 GRY L HALL ELEMENT 2 DC COM J49 2 ELEMENT 3 ORN 4 HALL ELEMENT 3 24 VDC INTERLOCKED DC COM VIO 2 7 DC COM 4 gt DC COM MCU PWB Y PL11 2 il 5 VDC 450 J18 PAPER HANDLING MOTOR FAIL H 5 VDC 6 04 320 GRY GRY P u DRIVE 1 MOTOR PWB P10 P16 P19 P22 P18 SNI P14 P17 DRIVE MOTOR amp P15 MCUPWB P20 BEER J49 J50 mmm HANDLING P12 MOTOR P11 P21 1704001 A WOL Figure 1 004 320 RAP Circuit Diagram Status Indicator RAPs 10 00 Initial Issue 004 320 2 48 Phaser 790 DocuColor 2006 004 322 Fuser Motor RAP The Control Logic detected that the Fuser Motor is not functioning Initial Actions Check the connectors on the Drive Motor PWB and the Fuser Motor Ensure that they are cor rectly seated Procedure Switch off the power
5. How to use the Plug Jack Location List Plug Jack Number Location Figure Number The Plug Jack Location List Table 1 is provided to locate plugs jacks or other terminating devices Locate the desired termination device in the first column Plug Jack Number of the 21 MCU PWB Figure 2 list Refer to the third column Figure Number to determine the figure number of the electrical 22 MCU PWB Figure 2 termination device The Location column supplies other helpful information such as source 23 MCU PWB Figure 2 and or destination of the cable 24 ESS PWB Figure 3 Table 1 Plug Jack Location List 25 ESS PWB Figure 3 Plua dack 28 ESS PWB Figure 3 ug Jac Number Location Figure Number 32 Low Voltage Power Supply Figure 6 1 Sorter Controller PWB Figure 18 39 ESS RWE Figures rter Controller igu 5 ud PWB E TIS 33 Low Voltage Power Supply Figure 6 1 3 Son oli PWB eure 18 25 ESS Flore rter Controller i ios 34 Low Voltage Power Supply Figure 6 4 Sorter Controller PWB Figure 18 35 Low Voltage Power Supply Figure 6 5 Connects Control Panel and ICM Main PWB IIT Figure 17 41 High Voltage Power Supply Figure 6 5 Full Sensor Sorter Figure 18 42 High Voltage Power Supply Figure 6 5 Sorter Controller PWB Figure 18 8 Sorter Controller PWB Fioure 18 47 Fuse
6. TURN PL11 2 CHUTE INTERLOCK EX 01 84 5 VDC m x 2 3 P J109 P108 J108 CLOSED L 5 VDC J17 _ 2 27 GRY GRY i 2 GRY 4 GRY DC COM lt EI o 3 1 TURN CHUTE INTERLOCK P19 P22 18 15 MCU PWB P20 P12 23 P11 P21 0 T701005 Figure 1 001 707 Circuit Diagram Status Indicator RAPs 10 00 Initial Issue 001 707 2 18 Phaser 790 DocuColor 2006 001 708 Area 3 Open RAP Initial Actions Perform the following Ensure the Right Cover is fully closed Check the actuators for both Feeder Right Cover Switches Ensure they are not broken or damaged Procedure Access the Digital Input DI test from the Control Panel Enter code CO Press the Item Enter button The display indicates 0 Y N Remove the Feeder Rear Cover PL 13 2 Less than 1 0 VDC is measured between J217 8 on the Feeder PWB and machine frame Go to 1 Check the wires for an open circuit If the wires are good replace the Feeder Right Cover Interlock 1 PL 13 2 Replace the Feeder PWB PL 13 4 Enter code C1 Press the Item Enter button The display indicates 0 Remove the Feeder Rear Cover Less than 1 0 is measured between J217 10 on the Feeder PWB and machine frame Go to 2 Check the wires for
7. Table 1 Abbreviation Meaning A3 297 x 420 Millimeters 4 210 x 297 Millimeters A5 148 x 210 Millimeters AD Auto Duplex AWG American Wire Gauge EMI Electro Magnetic Induction GB Giga Byte KB Kilo Byte M Millimeters MOD Magneto Optical Drive NOHAD Noise Ozone Heat Air Dirt PL Part List P O Part of R E Reduction Enlargement REF Refer to SCSI Small Computer Systems Interface W With W O Without Table 2 Operating Companies Abbreviation Meaning NASG North American Solutions Group ESG European Solutions Group Symbology Symbology used in the Parts List section is identified in the Symbology section Service Procedure Referencing If a part or assembly has an associated repair or adjustment procedure the procedure number will be listed at the end of the part description in the parts lists e g REP 5 1 ADJ 5 3 Initial Issue Phaser 790 DocuColor 2006 10 00 Parts List Introduction Subsystem Information Use of the Term Assembly The term assembly will be used for items in the part number listing that include other itemized parts in the part number listing When the word assembly is found in the part number listing there will be a corresponding item number on the illustrations followed by a bracket and a listing of the contents of the assembly Brackets A bracket is used when an assembly or kit is spared but is not shown in the ill
8. Figure 1 008 704 RAP Circuit Diagram 1 of 2 2 DUPLEX INVERTER DI 90 CONTROLLER DUPLEX SENSOR PAPER AT RWB PL15 5 INVERTER PL15 6 CONTROLLER INVERTE PWB L 5VDC PL15 6 1 4158 P144 3 J144 J139 3 GRY GRY i 1 gt 5VDC 1 1 4139 J144 5 1 144 J158 4 GRY 1 GRY I l 1 2 T GRY ORY i 4 j DC COM EV DO AQ INVERTER INVERTER PL13 3 PL15 5 l 71 5 01 96 5VDC GRY INVERTER MOTOR FAIL 922 J194 P134 J142 Y J147 H 5VDC 194 4 16 1 46 8 1 SEE L2 MOT 4 GRY 24VDC DEM INTERLOCKED N GRY INVERTER 20 4 A15 A2 15 GRY cry ENTRANCE 24VDC ENTER CLUTCH i PL15 6 1 2 AAS GRY 1 1 1 1 DC COM I I I 1 I 24VDC 24VDC INTERLOCKED INTERLOCKED 14 I I I I GRY 274 p AB8 A94 8 24VDC FORWARD GRY p Te RN INTLK DO A3 CLUTCH FORWARD PL15 7 1 CLUTCH ON 28 10 L7 4L 00324400 J150 2 150 GRY GRY GRY 24vDC DC COM n E l 1 24VDC INTLK 6 T708004A WOL Status Indicator RAPs 008 704 10 00 2 128 Initial Issu
9. NOTE For all ADF Jam messages displayed on the Scanner Display go to the 005 700 RAP etnis message is displayed For all Scanner Error messages displayed on the Scanner Display which do not have Load size In Bypass Tray 007 706 Bypass Tray Empty RAP associated Fault Code RAP go to the 006 703 RAP Load size In Tray 1 007 703 Tray 1 Empty RAP For all System Error 093 XXX messages displayed on the Scanner Display go to the 006 Load size In Tray 2 007 704 Tray 2 Empty RAP 704 RAP Load size In Tray 3 007 705 Tray 3 Empty RAP If the message on the IOT display contains a numeric fault code go to the RAP for that code Order Copy Print Cartridge 003 701 Copy Print Cartridge Error To find the appropriate RAP for an unclearable message that does not contain a fault code go Reload size in Bypass Tray 007 708 Bypass Tray Lift RAP to Table 1 Locate the message in column one and go to the RAP listed in column two Reload size in Tray 2 007 709 Tray 2 Lift Up RAP Reload size In Tray 3 007 710 Tray 3 Lift Up RAP Tabie Replace Copy Print Cartridge 003 701 Copy Print Cartridge Error RAP If this message is displayed Go to this RAP Waste Container Full 009 702 Waste Container Full RAP Check Loading of tray In Use 007 707 Paper Length Mismatch RAP Check Sorter Position 011 700 Sorter Not In Correct Position RAP Clear Jam In Area 1 008 700 Area 1 Jam R
10. LVPS J82 J41 HVPS ORN 9 1 9 4 9 6 9 7 MCU PWB J21 214 4123 6 13 ROS ORN GRY 62 J16 481 1 22 2 5 ADC SENSOR ASSEMBLY GRY 95 J17 J103 P103 294 2 1 FEED SOLENOID GRY 84 i J104 P104 n 81 2 TURN CLUTCH GRY 81 J18 J55 P55 194 2 DISPENSE ASSEMBLY CLUTCH GRY 94 156 P56 212 2 1 DEVELOPER CLUTCH ASSEMBLY i GRY 93 1 463 P63 4 23 1 2 BTR CAM CLUTCH 24 VDC GRY 98 INTERLOCKED J19 71 J74 J75 P75 gt A9 A2 2 2 LOWER INVERTER SOLENOID GRY 10 5 i 462 P62 124 1 10 1 224 CLEANER CAM SOLENOID GRY GRY 9 8 1 1 1 I J74 P74 20 1 B2 B9 2 2 EXCHANGE SOLENOID GRY GRY 10 4 J20 P91 J91 194 P94 23 86 89 2 REGISTRATION CLUTCH GRY GRY ASSEMBLY 87 495 P95 25 L B4 B11 25 52 51 PREREGI STRATION CLUTCH i GRY GRY ASSEMBLY 8 7 J202 P202 272 1 2 13 2 1 FEED CLUTCH GRY GRY 82 DUPLEX CONTROL J22 134 P134 4142 bw 139 4147 194 16 1 7 16 9 INVERTER MOTOR ASSEMBLY GRY GRY 10 7 1 1 1 20 GRY 15 2 1 mls J150 P150 10 2 1 FORWARD CLUTCH L 24 21 A14 14 GRY 10 6 GRY Hr dec ce me 2 CONTINUED CONTINUED 1728004A WOL Figure 1 24 VDC Interlocked 1 of 3 Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 29 24 VDC Interlocked Wirenet 2 of 3
11. J71 2 J71 1 P71 1 P71 2 WHT BLK BLK WHT Ir d 10 1 10101 jo 1 n n L n n n 4718 gt 71 PHA lt Da P71B En E n n n n n n 1 G 8110 ME 10 FUSER b d CHUTE 71 4 FAN YEL P71 4 p 71 3 71 3 YEL VEL LOCATING LOCATING POST FUSER SIDE IOT SIDE POST T710011A WOL Figure 1 010 704 RAP Circuit Diagram Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 187 010 704 010 705 Faulty Exchange Solenoid RAP The Exchange Solenoid failed to operate correctly causing an error message or a Fault Code to be displayed Initial Actions NOTE The resistance value of the Exchange Solenoid should measure approximately 45 50 ohms from the center Blue wire to either of the other two wires The resistance value mea sured from the Red wire to the White wire should be approximately 90 95 ohms Procedure CAUTION Do not select more than one 1 Diagnostic Code at a time or damage to the solenoid will Manually place the Exchange Chute in the DOWN position so that paper will be directed to the Top Exit Tray Solenoid in PUSH position Access the Digital Output DO test from the Control Panel Enter code 18 Press the Item Enter button The Exchange Solenoid pulls in or attempts to pull in the Exchange Chute makes an audible sound as it moves or attempts to move
12. FEEDER PWB PL13 4 2 LVPS PWB PL11 1 FEEDER MOTOR 24 DO B8 PL13 4 FEEDER PWB INTLK FEEDER PL134 T 24VDC MOTOR ON J32 P211 J211 J213 4217 1 24 0 1239 9 1 125 T toD ORN BLU BLU FEEDER I I I I 24 VDC I MOTOR FAIL 1 I I I 24VDC DC COM I INTLK I J239 H 45VDOC J217 5 2 INTLK 14 l MOT Y 11 097 340 1 1 1 DC COM 1 d 1 BLU 1 BLU 12 Y 2 S 1 I 6 I VO I BLU 1 24VDC I 1 1 1 1 2 INTLK 1 DC 1 1 1 1 1 13 4 1 DC COM DC COM BLU 1 1 1 1 1 1 1 1 1 1 1 1 DC COM 1 1 1 1 14 Y Y 4 l VIO BLU DC COM DC COM FEEDER PWB 214 P34 P218 P32 P216 P213 s PS FEEDER PWB P212 P217 P33 FEEDER MOTOR Sf P215 LL o 0707004A WOL Figure 1 007 340 RAP Circuit Diagram Status Indicator RAPs 007 340 Initial Issue Phaser 790 DocuColor 2006 10 00 2 84 007 341 Inverter Motor Fail RAP The Control Logic has detected an Inverter Motor Fail H 5 VDC signal Initial Actions Ensure that the Upper and the Lower Inverter Assemblies are properly closed Procedure Enter diagnostic code DO AO The Inverter Motor operates Y There is 24 VDC from 4 139 pin 9 to printer frame Y N There is 24 VDC from J 142 Pin 16 to printer frame Y N Go the Flag 2 Check the wires for an open or short circuit to ground
13. Remove the screw Remove the screw Figure 4 Accessing the PWB Box 0106033A WOL 11 Slide the PWB Box from the IIT Frame Figure 5 1 Slide out and remove the PWB Box from the IIT Frame 0106034 A WOL Figure 5 Removing the PWB Box Replacement 1 Perform the procedure for removal in reverse Repairs and Adjustments REP 6 11 10 00 4 44 Initial Issue Phaser 790 DocuColor 2006 REP 6 12 PWB Box Cover Parts List on PL 16 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the PWB Box REP 6 11 3 Remove the PWB Box Cover Figure 1 1 Remove the screws 14 and the PWB Box Cover 0 106035A NOL Figure 1 Removing the PWB Box Cover Replacement 1 Perform the procedure for removal in reverse REP 6 13 IPS PWB Parts List on PL 16 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the PWB Box REP 6 11 3 Remove the PWB Box Cover REP 6 12 CAUTION The PWB components are highly susceptible to damage from electrostatic discharge ESD and extreme care should be used when handling the
14. B E F G H J 5 5 ADF COMMUNICATION 1 ICM MAIN ICM MAIN ADF CONTROL PWB PWB PWB PL17 2 PL16 2 PL16 2 ADE 5 VDC COMMUNICATION LINE COMMUNICATION LINE RECEIVER TRANSMITTER RETURN RETURN 2 RESET 5 VDC ADF INSTALLED 3 X L 5 VDC 4 5 6 1705706 A WOL Figure 1 ADF Communication Wiring Data 10 00 Initial Issue 7 62 Phaser 790 DocuColor 2006 6 1 LASER IMAGE SCANNING MCU PWB PL11 2 SOS PWB lt 5 VDC 5 START OF SCAN SIGNAL LASER SCANNER 3 62 MODULATED LASER BEAM LASER SCAN 9 1 IMAGE 4 POLYGON 6 3 MOTOR DRIVE m EE 5 6 T706701 A WOL Figure 1 Laser Image Scanning Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 63 BSD 6 2 and 6 3 1 2 ROS 5 VDC SWITCHED 6 2 LASER CONTROL BRN MCU PWB PL11 2 ROS PL5 1 LD UNIT LASER DIODE MODULATED LASER BEAM 6 1 VIDEO DATA RED VIDEO DATA COM GRY LASER ENABLE GRY LASER POWER CONTROL GRY V REF GRY GRY DC COM 6 3 POLYGON MOTOR CONTROL MCU PWB POLYGON MOTOR ON L 24 VDC POLYGON MOTOR MOTOR DRIVE
15. gt 66 CLEANER CAM SOLENOID SOLENOID ON J19 13 524 P71 d 462 2 PL amp 7 GRY ORN DC 1 12 1 1810 89 4 GRY BLU 24 INTLK 3 BTR 2 CAM CLUTCH 701 174 BTR 2 CAM J18 CLUTCH ON J63 P63 J64 1 24 GRY 1 1 BLU 1 DC COM 5VDC 1 2 541 1 C DI 76 1 GRY BLU 2 CAM HOME 323 4 2 86 8 09 3581 1 1 i ec eec ene e eset 1 1 1 i 9 GRY 5 1 7 1 5VDC DC COM 6 1709709A WOL Figure 1 Belt Cleaning and BTR 2 Retract Advance Switching 1 of 2 Wiring Data 10 00 Initial Issue 7 92 Phaser 790 DocuColor 2006 BELT CLEANER BELT CLEANER RETRACT ADVANCE MECHANISM DRIVE 1 107 BTR 2 CLEANER CLEANER POSITION 97 a SWITCHING 2 v 3 4 BTR2 POSITION 97 a SWITCHING 5 6 2 T709710A WOL Figure 1 Belt Cleaning and BTR 2 Retract Advance Switching 2 of 2 Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 93 BSD 9 9 D J 9 9 DRUM CLEANING AND TONER RECLAIM 42 CLEANER
16. FUSER ENTRANCE SENSOR m T r 2 4 10 C3 10 n jo 1 jo L n n L L 471 B lt gt JAA P71A alla gt 71 n n n 1 10 1 10 d Kel I gt FUSER 171 44 77 ev CHUTE YEL P71 4 FAN 171 3 71 3 YEL LOCATING YEL YEL LOCATING POST FUSER SIDE IOT SIDE POST T710009A WOL Figure 1 010 702 RAP Circuit Diagram Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 183 010 702 010 703 Faulty Fuser Exit Sensor RAP One of the following conditions exists or was detected The Fuser Exit Sensor did not detect paper within a specified period of time after the Regi Clutch was energized The Fuser Exit Sensor did not detect the absence of paper within a specified period of time after it detected the presence of paper sensor actuated too long Initial Actions Check the actuators for both Fuser Exit Sensors Ensure that they move freely and are not damaged Procedure Access the Digital Input DI test from the Control Panel Enter code 25 Press the Item Enter button The Display is 1 Y Go to Flag 2 and Flag 8 Check for a short circuit to ground Repair or replace the Main Harness PL 11 1 the Fuser Harness PL 8 5 or the Temperature Sensor PL 8 2 which includes a portion of the wiring for the Fuser Exit Sensors as required If the wiring is OK replace the MCU PWB PL 11 2
17. 6 33 Initial Issue 10 00 General Procedures and Information Phaser 790 DocuColor 2006 6 1 General Procedures and Information 10 00 Initial Issue 6 2 Phaser 790 DocuColor 2006 GP 1 Diag nostic Mode IOT For example to enter the password default password is 9999 Entering the Diagnostic Mode 1 The cursor should be under the far left position Use the Up or Down arrow to scroll until the numeral 9 is displayed Use the Right arrow to move the cursor one place to the right Repeat step 1 and step 2 until 9999 is displayed Press the Item Enter button to input the password Menu Options When the correct password has been entered the first menu item is displayed Press the 1 Switch off the power 2 2 Press and hold the Up arrow and the Down arrow on the IOT Control Panel 3 3 While pressing the two buttons switch on the power Do not release the buttons 4 4 Release the buttons when the display flashes the following THHHHHHHHHHHHHHHHHE THHHHHHHEHHHHHHHHHEE The machine will execute a series of initialization and self test routines When the machine is ready to accept diagnostic commands the following will be displayed INPUT PASSWORD Navigation Figure 1 below shows and describes the Control Panel On Line Menu Button Indicator Arrow Buttons Control Panel 7552 Off Line Button Screen Menu button to scroll through the menu choices Table 1 lists the available menu items
18. DRIVE MOTOR PWB 5 PL10 1 F2 FUSER MOTOR PL10 1 MOTOR CLOCK 1 447 motor CRY 112 sam L2 MOT 49 1 MOTOR CLOCK ig GRY ay 4 ELEMENT 1 9 HALL EFFECT poc GRY ELEMENT 5 ELEMENT 1 Y 8 SPEED GRY SENSING i HALL ELEMENT 2 1 HALLELEMENT ze ll HALL ELEMENT 327 8 1 Y 5 1 HALL ELEMENT 3 9 Y 4 DC COM SRY 3 aay 10 7 VDC 1 2 GRY Y L11 Lr DC COM MCU PWB 1 12 PL11 2 GRY 5 VDC gt FUSER MOTOR FAIL H 5 VDC J18 3 7 04 322 GRY GRY 2 DRIVE 1 MOTOR PWB FUSER P10 P19 P22 P18 e MOTOR P44 P17 DRIVE 2 MOTOR amp P15 MCUPWB P20 PWB J49 J50 12 P23 EH P11 P21 1704002 A NOL Figure 1 004 322 RAP Circuit Diagram Status Indicator RAPs 10 00 Initial Issue 004 322 2 50 Phaser 790 DocuColor 2006 005 210 Nudger Home RAP The signal Nudger Home L is not detected within 1 second after ADF Drive Motor is ener gized Procedure Switch off the power Remove the ADF Rear Cover Observe the Nudger Roll as the power is Switched on The Nudger Roll Rotates Y N The ADF Drive Motor energized Y N Switch off the power Disconnect the belt from the ADF Drive Motor Switch on the power The ADF Drive Motor energizes Y N There is 24 VDC from pin 1 and from pin 6 of J 812 to frame ground Y N Replace the ADF Control PWB PL 17 2 Go to Flag 3 Check for
19. d gt lt 5 10 1 10101 n 1 m m J71 B lt gt J71A 71 gt 71 n m 1 10 1 10 SM ac 2 d J71 4 471 3 71 3 71 4 YEL YEL YEL YEL LOCATING FUSER SIDE IOT SIDE LOCATING POST POST Figure 1 010 701 RAP Circuit Diagram Usu NUNG UNS Ne ONG 10 317 10 353 10 354 10 355 10 356 10 357 TEMPERATURE SENSOR T710008A WOL Initial Issue Phaser 790 DocuColor 2006 10 00 2 181 Status Indicator RAPs 010 701 010 702 Faulty Entrance Sensor RAP The Fuser Entrance Sensor did not detect paper within a specified period of time after a sheet was available at the sensor An Entrance Sensor error was declared Initial Actions Check the actuator for the Fuser Entrance Sensor Ensure that it moves freely and is not dam aged Procedure Access the Digital Input DI test from the Control Panel Enter code 24 Press the Item Enter button The Display is 1 Y N Go to Flag 1 Check for a short circuit to ground Repair or replace the Fuser Harness PL 8 5 as required If the wiring is OK replace the Fuser Entrance Sensor PL 8 6 If the problem persists replace the MCU PWB PL 11 2 Open Area 5 Tape down the actuator of the Fuser Entrance Sensor Close Area 5 Access the Digital Input DI test from the Control Panel Enter code 24 Press the Item Enter button The Display is
20. MCU PWB FEEDER PWB PL11 2 PL13 4 J22 pre REG 1132 P132 GRY GRY START 3 GRY GRY A GRY FLAG 1 i GRY DCCOM GRY GRY DC COM VPP GRY NC 7 7 T GRY 0 FEEDER PWB Figure 1 003 310 RAP Circuit Diagram MCU PWB PL11 2 J212 P132 4132 mE 222 GRY GRY READY 003510 GRY GRY 72 o P10 mm P214 P16 P19 P22 P18 p P17 P218 Su P14 P15 MCU PWB P20 FEEDER P23 12 11 21 ae P217 215 T703002 A WOL Status Indicator RAPs 10 00 2 34 Initial Issue Phaser 790 DocuColor 2006 003 311 Duplex Communications Failure RAP The Control Logic detected a communication failure with the Duplex Controller PWB Initial Actions Ensure that connector P J 142 is properly seated on the Duplex Controller PWB Remove the ESS PWB REP 1 9 and check the P J 22 on the MCU PWB Ensure that it is properly seated on the PWB Procedure Perform the following Go to Flag 1 Check the wires between the Duplex Controller PWB and the MCU PWB for an open circuit If the previous check is OK replace the Duplex Controller PWB P
21. T705001 A WOL Figure 1 005 211 RAP Circuit Diagram Status Indicator RAPs 005 211 10 00 Initial Issue 2 54 Phaser 790 DocuColor 2006 005 220 221 ADF Communications RAP ADF Communication Error Procedure There is 5 VDC from pin 9 to pin 10 on J811 N Go to Flag 4 Check for an open circuit If the wires are OK replace the ICM Main PWB PL 16 2 Switch off the power Remove the ADF Rear Cover Switch on the power The red LED CR2 flashes when power is switched on Y Go to Flag 3 Check for an open circuit If the wire is OK replace the ADF Control PWB PL 17 2 If the problem persists replace the ICM Main PWB PL 16 2 Switch off the power then switch on the power The green LED CR3 flashes when power is Switched on Y Go to Flag 1 Check for an open circuit If the wires are OK replace the ADF Control PWB PL 17 2 If the problem persists replace the ICM Main PWB PL 16 2 Go to Flag 2 Check for an open circuit If the wires are OK replace the ADF Control PWB PL 17 2 If the problem persists replace the ICM Main PWB PL 16 2 Initial Issue 10 00 Phaser 790 DocuColor 2006 2 55 Status Indicator RAPs 005 220 221 ICM MAIN PWB ICM MAIN ADF CONTROL PWB PWB PL17 2 PL16 2 PL16 2 2 lE 5 VDC COMMUNICATION COMMUNICATION J220 LINE J811 LINE J220 1 RECEIVER TRANSMITTER YEL 1 YEL RETURN RETURN Y
22. Remove the screws 3 and the Right Cover 0106037A WOL 0106041A WOL Figure 1 Removing the Platen Glass Figure 1 Removing the Right Cover Replacement Replacement 1 Perform the procedure for removal in reverse 1 Perform the procedure for removal in reverse Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 37 REP 6 1 REP 6 2 REP 6 3 Left Cover Parts List on PL 16 6 Removal 1 Remove the Left Cover Figure 1 Figure 1 Removing the Left Cover Replacement 1 Perform the procedure for removal in reverse 1 Remove the screws 4 and the Left Cover 0106038A WOL REP 6 4 Rear Cover Parts List on PL 16 6 Removal 1 Remove the ADF REP 5 1 or Platen Cover 2 Remove the Rear Cover Figure 1 2 Remove the plastic strips 3 Remove the Rear eh Cover 1 Remove the screws 6 0106042A WOL Figure 1 Removing the Rear Cover Replacement 1 Perform the procedure for removal in reverse Repairs and Adjustments REP 6 3 REP 6 4 10 00 Initial Issue 4 38 Phaser 790 DocuColor 2006 REP 6 5 Angle Sensor Parts List on PL 16 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Rear Cover REP 6 4 3 Remove the Angle Sensor Figur
23. 5 VDC Lao 1 GRY 67 GRY 4 1 1 1 I 1 DCCOM 1 GRY GRY LOW PAPER SENSOR 2 80 LOW PAPER DC COM SENSED H 5VDC me 1 GRY 5 5VDC 2 J216 5 VDC 423 GRY 1 DC COM 5 GRY 6 DC COM 1707707 A WOL Figure 1 Tray 3 Paper Supply 2 of 2 Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 75 BSD 8 1 8 1 TRAY 1 PAPER FEEDING TRAY 1 PAPER FEED MECHANISM 42 FEED DRIVE Em am EM 2 TRAY 1 PAPER STACK FEED PAPER 59 POSITIONED TRAY 1 87 TRANSPORT __ ROLLDRIVE Em EN EN EM EM EN NN NN NN EN GN MCU PWB DO 1B FEED SOLENOID 7 ON D 24 J103 2 P103 4 T GRY GRY DC i i i GRY 2 29 1 4 24 VDC INTLK DO 1C TURN CLUTCH 5 ON L 24 VDC 1104 2 P104 GRY I 1 GRY 5 1 6 T708700A WOL Figure 1 Tray 1 Paper Feeding Wiring Data 10 00 Initial Issue 7 76 Phaser 790 DocuColor 2006 BSD 8 2 87 BYPASS FEED DRIVE m m m m mw 8 6 BYPASS PAPER 2 72 STACK POSITIONED BYPASS EEED PAPER 3 DO 20 ON D 224 Je 4 420 ms GRY
24. GRY 25 24 VDC INTERLOCKED POLYGON MOTOR DRIVE 6 1 Figure 1 Laser Control Polygon Motor Control T706702 A WOL Wiring Data 10 00 7 64 Initial Issue Phaser 790 DocuColor 2006 BSD 6 4 6 4 DOCUMENT ILLUMINATION ICM MAIN PWB FLPS PWB LAMP PL16 2 330 001 PL16 5 PL16 5 2 EXPOSURE LAMP ON L 22 J120 EVD J534 4535 22 21 VOLTAGE 65 ncco I REGULATOR 3 NC ILLUMINATION 22 EXPOSURE LAMP LS D x 6 6 2 N C 3 A n 2 42 A 1 22 v 4 L4 i 1 ba 2232 Z 5 5 b rayc 1 22 Z 6 5 COOLING AIR 222 I 7 22a i 5 2 v DC COM 22222 FAN 1 ICM CONTROL 2 424 VDC 330 001 PL16 1 7 MAIN PANEL LU RN J150 J150B 330 100 FERE PE d 3 91508 J150A Jaso PL16 2 206 GRY RED MOT ejfe 2 2 dc 22 5 WHT GRY 6 313 22 1 GRY BLK 2 2 DC COM J151 22 22 2 WHT rd 222 FAN 330 001 PL16 1 VS 2 FAN 2 ON H 24 VDC T RED MOT 1 LS 3 2 1 BLK P4 DC COM T
25. GRY GRY lt 2 ip 5 VDC 8 GRY 1 GRY L DC COM SNbe T VIO GND DC COM ris 2 GN YL 35 GNIYL j FOREIGN INTERFACE PRESENT L 5 VDC YEL VIO Figure 1 003 334 RAP Circuit Diagram Status Indicator RAPs 003 334 10 00 2 42 Initial Issue Phaser 790 DocuColor 2006 003 356 IOT NVM RAM Error RAP The system detected an IOT NV RAM error at power on Procedure Switch the power off then switch the power on The fault code occurs Y N the problem seems to be intermittent reseat all connectors on the MCU PWB If the problem occurs again replace the MCU PWB PL 11 2 Go to Flag 1 Check the wires for an open or short circuit If the wires are good replace the Communication PWB If the problem continues replace the MCU PWB PL 11 2 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 43 003 356 MCU PWB COMMUNICATION PL11 2 PWB qu PL11 2 J23 J66 GRY 13 GRY GRY 13 GRY Y 5 B5 GRY 5 VDC T DC COMMUNICATION PWB 4 PIO p19 P22 18 P14 17 15 P20 MCU PWB P23 P12 P11 P21 o 9 o 1703004 A WOL Figure 1 0
26. Remove the screws 2 and sensor O18007A WOL Figure 2 Removing the Sensor Transmitter Replacement 1 Perform the procedure for removal in reverse Repairs and Adjustments REP 11 5 REP 11 6 Initial Issue Phaser 790 DocuColor 2006 10 00 4 132 REP 11 7 Sorter Path Sensor Parts List on PL 19 3 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Bottom Cover REP 11 2 3 Remove the Sorter Path Sensor Figure 1 Release the locking tabs and remove Sorter Path Sensor Viewed from below Disconnect the connector 0 111008A WOL Figure 1 Removing the Sorter Path Sensor Replacement 1 Perform the procedure for removal in reverse REP 11 8 Full Sensor Parts List on PL 19 3 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Bottom Cover REP 11 2 3 Remove the Full Sensor Figure 1 Remove the screw and the Full Senso m 1 Disconnect the Remove the screw and connector sensor bracket 0 1110094 WOL Figure 1 Removing the Full Sensor Replacement 1 Perform the procedure for removal i
27. c E Figure 1 Test Pattern Orientation 0201105A WOL Adjustment 1 Enter Diagnostic Mode IIT GP 19 2 Enter Systemdata R W and press the Select button 3 Enter Chain 715 and Link 6 and confirm the present values 4 Change the values as required based on the measurement results If Under Registration occurs decrease the value If Over Registration occurs increase the value Change the values as follows NOTE To enter a letter Hexadecimal value press the asterisk key prior to entering each letter value then press the appropriate numerical key as follows A21 2 D 4 5 F 6 a Enter the new value and press Start b Press the Select button to verify the value has changed Table 1 Minimum Initial Maximum Remarks Settings Value 0 6Eh C2h 0 16mm Step 5 Perform the check again Initial Issue 10 00 Phaser 790 DocuColor 2006 4 149 Repairs and Adjustments ADJ 5 2 ADJ 5 3 ADF Height Purpose The purpose is to adjust the height of the Counterbalance and ensure reliable ADF Document Feed NOTE This procedure gives instructions for adjusting the left side Counterbalance However the same procedure applies to the Counterbalance on the right side CAUTION An excessive ADF gap can cause problems with document skew and document jams Insuffi cient ADF gap can cause imperfect rotation of the Drive Motor when under a load
28. 1 Remove the screw and the Size Switch PWB 0108058A WOL Figure 1 Removing the Size Switch PWB Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 71 REP 8 19 REP 8 20 Feeder Motor Parts List on PL 13 4 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Feeder Rear Cover 3 Remove the Feeder Motor Figure 1 1 Disconnect the connector Remove the four screws and the Feeder Motor 0108063A WOL Figure 1 Removing the Feeder Motor Replacement 1 Perform the removal procedure in reverse REP 8 21 Feeder PWB Parts List on PL 13 4 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Feeder Rear Cover CAUTION The PWB components are highly susceptible to damage from electrostatic discharge ESD and extreme care should be used when handling these components Use of the ESD Field Service Kit is required 3 Remove the Feeder PWB Figure 1 NOTE The jumper plug should be installed to the same location on the replacement PWB 1 beu Disconnect the connec
29. two screws at the rear are also used to secure the Rear Cover Assembly Be sure to press the Top Cover Assembly down and securely tighten the left screw in order to ensure that the Top Cover Switch is actuated correctly 5 Rotate and remove the 3 Top Cover Assembly Lift and 4 with the Control Panel Remove the four screws Securing the cover actuator 6 Disconnect the connector 2 7 Open the Exit Trans 7 port Assem bly 1 Open the 7 Front Cover Disengage the Control Panel from the Top Cover Assembly 0140012A WOL Figure 1 Removing the Top Cover Assembly Initial Issue 10 00 Phaser 790 DocuColor 2006 4 141 Repairs and Adjustments REP 14 4 REP 14 5 Inner Covers 7 Remove the Left Inner Cover Assembly Figure 2 Parts List on PL 1 1 Removal 1 WARNING Remove the screw To avoid personal injury or shock do not perform repair activities with the power switch securing th hing on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 2 Tray 1 Assembly the three 3 Remove the Top Cover Assembly REP 14 4 4 Remove the Copy Print Cartridge REP 9 1 5 Remove the Tension Lever REP 9 15 CAUTION A When the inner covers are removed the Front Cover Assembly is supported by the left and right hinges 2 only Be careful not to place a load on the Front Cover Assembly
30. R E value Size 35 gt 50 5 64 11 x 17 8 5 x 11 70 4 B4 B5 78 8 5 x 14 68 5 11 81 4 gt 4 B5 5A5 86 4 6 5 gt 4 97 4 58 5 11 115 5 gt 4 4 5 122 4 6 4 5 gt 5 127 8 5 x 13 129 8 5 x 1111 x 17 141 A4 A3 5 gt 4 154 5 5 x 8 58 5 x 14 180 8 5 x 13 2 200 5 220 5 5 8 5511 x 17 282 General Procedures and Information ADF Specifications IIT Scanner Specifications 10 00 6 24 Initial Issue Phaser 790 DocuColor 2006 Magnification Accuracy The magnification specifications and associated image distortion for Copy mode are shown in the following table Table 3 Scanner Magnification Specification Magnification Specification 25 49 9 1 0 50 99 9 1 0 100 1 0 100 1 200 1 5 200 1 400 2 2 Platen Mode Size Detection The IIT recognizes the following standard document sizes in Platen mode Table 4 Platen Mode Document Sizes Document Document orientation size mm NASG ESG Postcard SEF 100 x 148 Post Card 101x152 ALT 2 A6 SEF 105 x 148 ALT 3 x B6 SEF 128 x 182 x x B6 LEF 182 x 128 A5 SEF 148 x 210 x x A5 LEF 210 x 148 x x 5 5 x 8 5 SEF 140 x 215 9 x 5 5 x 8 5 LEF 215 9x 140 x x B5 SEF 215 9 x x x 279 4 B5 LEF 279 4 x x x 215 9
31. 0108003A WOL Figure 2 Removing the Turn Clutch Replacement 1 Perform the procedure for removal in reverse 0108005A WOL Figure 1 Disconnecting the Turn Clutch Repairs and Adjustments 10 00 Initial Issue REP 8 4 4 62 Phaser 790 DocuColor 2006 REP 8 5 Feed Solenoid Parts List on PL 3 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Rear Cover REP 14 6 WARNING Use extreme care when working in the vicinity of the Option Bracket The edges of the Option Bracket may be very sharp and could cause serious injury CAUTION The Option Bracket and printer are connected by a harness Be careful not to cause damage to the wires when performing the following 3 Remove the Option Bracket Figure 1 1 Remove the two Screws and remove the Option Bracket 4 Replacement 1 Remove the Feed Solenoid Figure 2 2 Release the wires from the clip Disconnect the connector 3 Remove the screw and Feed Solenoid 0108006A WOL Figure 2 Removing the Feed Solenoid Perform the procedure for removal in reverse 2 Install the Feed Solenoid so that the teeth of the Feed Gear mesh with the armature 0108005A WOL Figure 1 Removing the Option Bracket Initial Iss
32. 18 A 32 Pl P17 17 H6 P15 MCU PWB P20 15 1514 P12 Ab PH Al PE 3 816 Bl 1 Figure 1 007 706 RAP Circuit Diagram BYPASS TRAY FEED ASSY 0707008A WOL Status Indicator RAPs 007 706 10 00 2 100 Initial Issue Phaser 790 DocuColor 2006 007 707 Paper Length Mismatch RAP Initial Actions Ensure that the paper tray is properly loaded with paper and the side guides are in the proper position Procedure Determine which paper tray is being used when the problem occurs Remove all the paper from that tray and reload with fresh paper Ensure that all the paper in the tray is of the same size The problem continues Y N Instruct the customer how to properly load the paper trays Select Copy mode Select the paper Tray in which the fresh paper was loaded The paper size indicated on the display is the same as the paper size loaded in the paper Tray Y N Go to the appropriate RAP 007 711 Tray 1 Paper Size Not Detected RAP 007 712 Tray 2 Paper Size Not Detected RAP 007 713 Tray 3 Paper Size Not Detected RAP Go to 008 701 Area 2 Jam RAP Initial Issue Phaser 790 DocuColor 2006 10 00 2 101 Status Indicator RAPs 007 707 007 708 Bypass Tray Lift RAP Initial Actions Ensure that paper is placed in the Bypass Tray Procedure Enter the diagnostic mode Enter DO 23 The Lift Plate goes up Check the following Check the lif
33. 341 GRY 2 24 VDC INTLK 3 11 124 3 GRY 3 Low voLTAGE POWER SUPPLY FL 11 1 24 IBT MODULE IMAGE ON 9 7 IBT BELT 94 DEVELOPED MAGE 92 DRIVE ma ma m ma m m um um mr T 709707 A WOL Figure 1 IBT Belt Drive and 1st Transfer Wiring Data 10 00 Initial Issue 7 90 Phaser 790 DocuColor 2006 9 7 2ND TRANSFER AND IBT BELT CLEANING MCU PWB PL 11 2 MCU PWB HIGH VOLTAGE 1 PL11 2 _ POWER SUPPLY DO 0A 11 1 2 BIAS ON BTR 2 BIAS du D 24 VDC 442 2 442 MONITOR 10 CONTROL 12 2 BIAS CONTROL 2 2ND TRANSFER AND BELT CLEANING MECHANISM RECLAIMED TONER 3 42 AUGER 104 DRIVE UNFUSED m m m NE ma DRINT 4 IMAGE ON IBT BELT 8 6 REGISTERED PAPER k Ld CLEANER m POSITION SWITCHING 5 98 BTR 2 POSITION SWITCHING Ld 6 EF T709708A WOL Figure 1 2nd Transfer and IBT Belt Cleaning Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 91 MCU PWB PL11 2 9 8 BELT CLEANING AND BTR 2 RETRACT ADVANCE SWITCHING 1 OF 2 CLEANER
34. GE SUS 0108025A WOL Figure 1 Removing the Tray Empty Sensor Replacement 1 Perform the procedure for removal in reverse REP 8 13 Pitch Sensor Parts List on PL 4 3 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine Switch off the machine power and disconnect the machine Power Cord 2 Remove the Bypass Tray Registration Assembly REP 8 6 3 Remove the Bypass Tray Feed Assembly REP 8 7 4 Remove the Pitch Sensor Figure 1 2 v Remove the screw and the Pitch Sensor lt 1 m Disconnect the connector 7 Es 0108026A WOL Figure 1 Removing the Pitch Sensor Replacement 1 Perform the procedure for removal in reverse Initial Issue Phaser 790 DocuColor 2006 10 00 4 67 8 12 8 13 Repairs and Adjustments REP 8 14 Stack Height Sensor Parts List on PL 4 4 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 2 3 4 Open the wire clips and release the wires on the bottom side of the Top Frame Remove the frame Switch off the machine power and disconnect the machine Power Cord Remove the Bypass Tray Registration Assembly REP 8 6 Remove the Bypass Tray Feed Assembly REP 8 7 Remove the Top Frame Fi
35. N Remove the Fuser Assembly REP 10 1 Check the resistance between J71 B4 and 71 B10 The resistance is between 45 and 50 ohms Go to Flag 4 Check for an open circuit Repair or replace the Fuser Harness PL 8 5 as required If the wiring is OK replace the Exchange Solenoid Assembly PL 8 5 Go to Flag 3 and Flag 5 Check for an open circuit Repair or replace the Main Harness PL 11 1 as required If the wiring is OK replace the MCU PWB PL 11 2 Enter Stop DO Test from the Control Panel Enter code 18 Press the Item Enter button Select DO 17 and press the Item Enter button Exchange Solenoid pushes out attempts to push out the Exchange Chute makes an audible sound as it moves or attempts to move Remove the Fuser Assembly REP 10 1 Check the resistance between J71 B8 and J71 B9 The resistance is between 45 and 50 ohms Y Go to Flag 2 Check for an open circuit Repair or replace the Fuser Harness PL 8 5 as required If the wiring is OK replace the Exchange Solenoid Assembly PL 8 5 Go to Flag 1 Check for an open circuit Repair or replace the Main Harness PL 11 1 as required If the wiring is OK replace the MCU PWB PL 11 2 The problem may be intermittent Go to Figure 1 Check for loose or damaged connections or damaged wires Also check for continuity If the wiring is OK replace the Exchange Solenoid Assembly PL 8 5 If the problem continues replace the MCU PWB PL
36. REP 8 30 Duplex Drive 4 80 REP 10 12 Temperature REPR 8 31 Front Belt n L 4 80 REP 10 13 Exchange REP 8 32 Rear Belt 4 81 REP 10 14 Exchange Solenoid REP 8 33 Inverter Upper Assembly 4 81 REP 10 15 Cleaner Cam Solenoid REP 8 34 Exit Roll 482 REP 10 16 Cleaner Cam Shaft REP 8 35 Inverter Lower Assembly 4 83 10 17 terere REP 8 36 Inverter Motor u uu entren e i hee ire 4 83 REP 10 18 Fuser Entrance REP 8 37 Inverter Sensor 485 REP 10 19 Fuser Chute Fan cen terree e eene e eet n e exo n de ade REP 8 38 Duplex Controller 4 86 REP 8 39 Duplex Nip Solenoid diaeta 487 Sorter 8 40 Exit Transport Assembly tenete tentent tnn 4 88 11 1 4 129 REP Fill Stack Sensor aan ctl tee dena 4 89 rune ee 1129 REP 8 42 Exit Chute Interlock 8o DHEDULSSORO Control PWB cum qiue taciti eaaa 22 1 8 43 Exit Sensor enne nennen tenes 4 90 REP 11 4 Sorter Transport Motor a nnne ne
37. See Replacement Step 2 Remove the E ring Pulley and Belt 0108049A WOL Figure 1 Removing the Front Belt Replacement 1 Perform the removal procedure in reverse 2 When installing the belt make sure that the bottom of the belt is dressed below the pulley and above the collar 2 places Figure 1 Repairs and Adjustments REP 8 30 REP 8 31 10 00 Initial Issue Phaser 790 DocuColor 2006 REP 8 32 Rear Belt Parts List on PL 15 4 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Duplex Tray Assembly REP 8 27 3 Remove the Rear Belt Figure 1 Collar Entrance Roll Gear Remove the Duplex Drive Clutch REP 8 30 Do not separate parts 0108050A WOL Figure 1 Removing the Rear Belt Replacement 1 Perform the removal procedure in reverse 2 When installing the belt make sure that the belt is dressed above the collar near the Entrance Roll Gear Figure 1 REP 8 33 Inverter Upper Assembly Parts List on PL 15 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Inverter Upper Assembly Figure 1
38. 22 5VDC 72 6 gt z 62 72 1 1 3 8 B5 B6 16 7 GRY ut 4 4 2 6 5 17 GRY GRY i 2 gt DC COM 4 gt 7 MESSAGE CLEAR JAM IN AREA 5 P J71 PIN CONFIGURATION J71 2 J71 1 P71 1 P71 2 o 1 1 T7 T T T WHT BLK BLK a WHT QAM p22 T 251814 30734 b d 17 1 1 4 14 1 6 10 1 28r 1 2 niin 815 MCU PWB a 15 m J71B P71A ana P71B P12 M6 PIL Al P23 oo n n 5 3 BIG B pot 10 1 19 REAR EXIT o o T o 4 SENSOR 471 4 lt J71 3 71 3 lt 71 4 YEL YEL YEL YEL LOCATING FUSER SIDE IOT SIDE N LOCATING FRONT EXIT POST POST SENSOR Figure 1 010 703 RAP Circuit Diagram T710010A WOL Initial Issue Phaser 790 DocuColor 2006 10 00 2 185 Status Indicator RAPs 010 703 010 704 Faulty Fuser Chute Fan RAP Use this procedure to troubleshoot an intermittent or faulty Fuser Chute Fan No Fault Code or Error Message is associated with the failure of this component Initial Actions Ensure that there are no obstructions or physical conditions that might inhibit normal fan oper ation Ensure that the Exit Transport Assembly PL 9 2 is installed correctly and has mechanical drive Procedure Access the Digital Output DO test from the Control Panel Enter code
39. ICM MAIN PWB PL16 2 J130 PIN 1 PIN 11 PLATEN SWITCH PL16 1 REAR OF ICM MAIN PWB 5 VDC PLATEN OPEN J130 P719 J719 V J719 P719 L 5 VDC J130 5 2 ovo 1 11 GRY BLK BLK GRY Figure 1 006 702 RAP Circuit Diagram PLATEN SWITCH T706003 A WOL Status Indicator RAPs 006 702 10 00 2 78 Initial Issue Phaser 790 DocuColor 2006 006 703 Scanner Error RAP 006 704 System Error 093 XXX RAP Procedure Procedure iini n A then If IPS PWB PL 16 2 If this does Ensure that the correct levels of firmware are installed for all components of the system 2 Reload if required GP 8 GP 9 and GP 10 If reloading firmware does not resolve the prob lem replace the ICM Main PWB PL 16 2 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 79 006 703 006 704 006 906 907 908 909 RAP 006 906 Control Logic detected an AOC1 error at job start or initialization 006 907 Control Logic detected an AGC error 006 908 Control Logic detected an OE Pixel Judgement error 006 909 Control Logic detected an Auto Gradation correction error Procedure Check the wiring and connections to the IIT Lamp PL 16 5 If the wires are OK replace the Lamp If the fault remains replace the ICM Main PWB PL 16 2 Status Indicator RAPs 10 00 Initial Issue 006 906 907 908 909 2 80 Phaser 790 Docu
40. LEE E HERR CU be bee ode dere 5 84 Part Number Index ee ettet eco atte ee ena ox eene rear ves aks 5 85 Parts List 10 00 Initial Issue 5 2 Phaser 790 DocuColor 2006 Introduction Overview The Parts List section identifies all part numbers and the corresponding location of all spared subsystem components Organization Parts Lists Each item number in the part number listing corresponds to an item number in the related illustration All the parts in a given subsystem of the machine will be located in the same illustration or in a series of associated illustrations Electrical Connectors and Fasteners This section contains the illustrations and descriptions of the plugs jacks and fasteners used in the machine A part number listing of the connectors is included Common Hardware The common hardware is listed in alphabetical order by the letter or letters used to identify each item in the part number listing and in the illustrations Dimensions are in millimeters unless otherwise identified Part Number Index This index lists all the spared parts in the machine in numerical order Each number is followed by a reference to the parts list on which the part may be found Other Information Abbreviations Abbreviations are used in the parts lists and the exploded view illustrations to provide information in a limited amount of space The following abbreviations are used in this manual
41. MCU PWB BYPASS TRAY PL11 2 INTERLOCK 4 1 5 VDC gt BYPASS TRAY J207 INSERTED L 5VDC GRY 4 i 2 28 GRY 4 Figure 1 001 706 Circuit Diagram DC COM lt lt BYPASS TRAY INTERLOCK 14 15 12 P16 P19 P22 18 P17 MCU PWB P20 223 P11 P21 T701007 A WOL Status Indicator RAPs 001 706 10 00 2 16 Initial Issue Phaser 790 DocuColor 2006 001 707 Area 2 Open RAP Initial Actions Perform the following Check the actuator for the Turn Chute Interlock Ensure it is not broken or damaged Ensure the Turn Chute is closed Procedure Access the Digital Input DI test from the Control Panel Enter code 84 Press the Item Enter button The display indicates 0 Y N Go to Flag 1 and Flag 2 Check the wires for an open circuit If the wires are good replace the Turn Chute Interlock PL 3 3 If the problem continues replace the MCU PWB PL 11 2 The problem may be intermittent Go to Flag 1 and Flag 2 and check for loose or damaged connections or damaged wires If the problem persists replace the Turn Chute Interlock PL 3 3 If the problem continues replace the MCU PWB PL 11 2 Initial Issue Phaser 790 DocuColor 2006 10 00 2 17 Status Indicator RAPs 001 707 MCU PWB
42. Open Area 5 Actuate the Front Fuser Exit Sensor by handcranking paper onto the actuator Close Area 5 Close Area 5 Access the Digital Input DI test from the Control Panel Enter code 25 Press the Item Enter button The Display is 0 Y Go to Flag 1 Flag 3 and Flag 4 Check for an open circuit or a short circuit to ground Repair or replace the Main Harness PL 11 1 the Fuser Harness PL 8 5 or the Temper ature Sensor PL 8 2 which includes a portion of the wiring for the Fuser Exit Sensors as required If the wiring is OK replace the Front Fuser Exit Sensor PL 8 2 If the prob lem persists replace the MCU PWB PL 11 2 Open Area 5 Remove paper from the Front Fuser Sensor actuator Close Area 5 Access the Digital Input DI test from the Control Panel Enter code 4B Press the Item Enter button The Display is 1 Y Go to Flag 5 and Flag 7 Check for a short circuit to ground Repair or replace the Main Harness PL 11 1 the Fuser Harness PL 8 5 or the Temperature Sensor PL 8 2 which includes a portion of the wiring for the Fuser Exit Sensors as required If the wiring is OK replace the MCU PWB PL 11 2 Open Area 5 Actuate the Front Fuser Exit Sensor by handcranking paper onto the actuator Close Area 5 Close Area 5 Access the Digital Input DI test from the Control Panel Enter code 4B Press the Item Enter button The Display is 0 Y Go to Flag 6 Check for an open circuit or a short circuit t
43. P91 105 100 0735001A WOL Figure 2 Initial Issue Phaser 790 DocuColor 2006 c 6 5 8 2 317 5 27 TEM L VY Y Wiring Data Plug Jack Locations 10 00 7 9 Initial Issue Phaser 790 DocuColor 2006 203 95 208 94 205 204 J91 201 93 202 206 209 0735003A WOL Figure 4 Initial Issue Phaser 790 DocuColor 2006 10 00 7 10 Wiring Data Plug Jack Locations 123 197 87 199 125 198 121 122 F187 1 0735004A WOL Figure 5 Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 11 Plug Jack Locations 55 42 Z 82 CN1 48 2250 47 103 A ue ee 4 49 34 50 e 132 41 211 104 33 35 0735005A WOL Figure 6 Wiring Data 10 00 Initial Issue Plug Jack Locations 7 12 Phaser 790 DocuColor 2006 58 56 P71 34 1 64 CN2 148 Figure 7 Wiring Data Plug Jack Locations 10 00 7 13 Initial Issue Phaser 790 DocuColor 2006 80 0735007A WOL Figure 8 Initial Issue Phaser 790 DocuColor 2006 10 00 7 14 Wiring Data Plug Jack Locations 0735008A WOL Figure 9 Wiring Data Plug Jack Lo
44. 442 1 1 13 HVPS GRY 9 1 9 4 9 6 9 7 J17 J108 P108 J109 2 2 1 2 TURN CHUTE SWITCH GRY GRY 1 6 P161 J161 J165 104 7 2 2 EXIT SENSOR GRY GRY 10 4 i i J166 12 1 1225 2112 2 EXIT CHUTE SWITCH GRY GRY 13 1 1 1 L 4 J112 P112 16 1 8 3 EXIT CHUTE FAN GRY GRY 10 3 RR 4 poe NEN S CONTINUED CONTINUED 1728007A NOL Figure 1 DC Com 1 of 5 Wiring Data 10 00 Initial Issue 7 32 Phaser 790 DocuColor 2006 DC Com Wirenet 2 of 5 DC COM 2 OF 5 WIRENET CONTINUED CONTINUED TENERA iN MCU PWB LVPS J17 J111 P111 FUSER FAN 1 2 GRY 10 3 J87 3 CARTRIDGE SENSOR GRY 94 86 P86 26 2 ERASE LAMP ASSEMBLY GRY 99 J197 P197 J191 28 1 2 1 RIGHT FRONT COVER SWITCH GRY 12 J19 P71 J71 J76 P76 J117 5 6 5 2 2 2 FUSER IN SENSOR GRY 10 1 J78 P78 P78 J78 P71 J19 oy 7 2 1 2 1 8 MCU PWB GRY 1 GRY GRY GRY GRY 12 472 72 s J721 DC COM 17 B5 B6 2 4 2 FRONT FUSER EXIT SENSOR SRY GRY vo LJ 10 4 J18 J245 J722 n 4 2 ROTARY MOTOR PWB _________ 2 REAR FUSER EXIT SENSOR GRY 9 4 VIO 10 4 J52 14 5 PROCESS DRIVE A
45. RIGHT FRONT COVER TOP INTERLOCK COVER PL11 2 INTERLOCK ROS LOW VOLTAGE PL11 1 ASSEMBLY POWER SUPPLY PL5 1 J32 J193 J194 P195 J195 FS1 FS2 4195 Pigs ROS SVDC PL11 1 SWITCHED ote 1 1 2 1 BRN BLU BLU BRN BRN 5 VDO 3 2 1 2194 BLU YEL BRN J4 BRN J193 VIEW OF RIGHT FRONT COVER INTERLOCK FROM REAR P32 P32 P34 LOW VOLTAGE LIP35 POWER SUPPLY TOP COVER P33 INTERLOCK T701004 A WOL Figure 1 001 705 Circuit Diagram Initial Issue 10 00 Phaser 790 DocuColor 2006 2 14 Status Indicator RAPs 001 705 001 706 Area 1 Open RAP Initial Actions Perform the following Check the actuator for the Bypass Tray Interlock Ensure it is not broken or damaged Ensure the Bypass Tray is closed and is in the operating position Procedure Access the Digital Input DI test from the Control Panel Enter code 77 Press the Item Enter button The display indicates 0 Y N Go to Flag 1 and Flag 2 Check the wires for an open circuit If the wires are good replace the Bypass Tray Interlock PL 4 1 If the problem continues replace the MCU PWB PL 11 2 The problem may be intermittent Go to Flag 1 and Flag 2 and check for loose or damaged connections or damaged wires If the problem persists replace the Bypass Tray Interlock PL 4 1 If the problem continues replace the MCU PWB PL 11 2 Initial Issue Phaser 790 DocuColor 2006 10 00 2 15 Status Indicator RAPs 001 706
46. Remove the E ring and Turn Clutch REP 8 27 Duplex Tray Assembly Parts List on PL 15 3 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Duplex Tray Assembly Figure 1 0108043A WOL Release the catches and pull the Duplex Tray Assembly straight out from the machine 0108047A WOL Figure 1 Removing the Duplex Tray Assembly Replacement 1 Perform the removal procedure in reverse Repairs and Adjustments REP 8 26 REP 8 27 Initial Issue Phaser 790 DocuColor 2006 10 00 4 76 REP 8 28 Duplex Entrance Sensor 5 Remove the Duplex Entrance Sensor Figure 2 Parts List on PL 15 3 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord tu Remove the Duplex Tray Assembly REP 8 27 lt 2 3 Remove the Front Cover of the Duplex Tray Assembly 4 Remove the Duplex Registration Chute Figure 1 2 lt gt 1 Release the locking amp 2 tabs and remove the Disconnect the Remove the two Duplex Entrance connector Sensor screws and the Duplex Registration Chute 0108058A WOL Figure 2 Removing the D
47. Replace the Dispense Clutch PL 10 1 WARNING HIGH VOLTAGE Exercise care when making the voltage checks in the following steps Access the Digital Output Test GP 2 Enter code OC Press the Item Enter button There 15 between 450 and 600 VDC from the C terminal on the HVPS to frame ground Y N There is less than 1 VDC from J 42 pin 4 to frame ground Y Go to Flag 5 and Flag 12 Check for an open circuit If the wire is OK replace the MCU PWB PL 11 2 Go to Flag 4 Check for an open circuit If the wire is OK replace the HVPS PL 11 1 If the problem persists replace the MCU PWB PL 11 2 Access the DO Stop Test Enter code OC Press the Item Enter button Re access the DO Test Enter code OD Press the Item Enter button There is between 600 and 700 VAC from the C terminal on the HVPS to frame ground N There is less than 1 VDC from J 42 pin 3 to frame ground Y Go to Flag 5 and Flag 12 Check for an open circuit If the wire is OK replace the MCU PWB PL 11 2 Go to Flag 4 Check for an open circuit If the wire is OK replace the HVPS PL 11 1 If the problem persists replace the MCU PWB PL 11 2 A Run a copy of the Test Page Switch off the power while the print is being developed Pull out the Print Copy Cartridge Examine the surface of the drum for a developed image Part of a developed image is present on the drum Y N Access the Digital Output Test GP 2 Enter code OE Press the
48. This symbol indicates that a surface can be hot Use caution when reaching in the machine to avoid touching the hot surfaces Introduction 10 00 Initial Issue Phaser 790 DocuColor 2006 A m Danger label indicates where electrical currents exist when the machine is closed and operat ing Use caution when reaching in the machine These symbols indicate components that may be damaged by Electrostatic Discharge ESD 0700002A RAP Electrostatic Discharge ESD Field Service Kit The purpose of the ESD Protection Program is to preserve the inherent reliability and quality of electronic components that are handled by the Field Service Personnel This program is being implemented now as a direct result of advances in microcircuitry technology as well as a new acknowledgment of the magnitude of the ESD problem in the electronics industry today This program will reduce Field Service costs that are charged to PWB failures Ninety percent of all PWB failures that are ESD related do not occur immediately Using the ESD Field Service Kit will eliminate these delayed failures and intermittent problems caused by ESD This will improve product reliability and reduce callbacks The ESD Field Service Kit should be used whenever Printed Wiring Boards or ESD sensitive components are being handled This includes activities like replacing or reseating of circuit boards or connectors The kit should also be used in order to prevent additional d
49. 0016005A WOL Parts List 10 00 Initial Issue PL 16 5 5 66 Phaser 790 DocuColor 2006 PL 16 6 Top Cover and Control Panel Item Part Description 1 802K14870 Platen Cover 2 Actuator Spared 3 Stopper Not Spared 4 Magnet Not Spared 5 048E18040 Pocket Cover 6 Handle Spared 7 003 52460 8 004K92440 Cushion 9 802K13810 Right Cover REP 6 2 10 802K13821 Left Cover 6 3 11 Side Cover Not Spared 12 802K13831 Rear Cover REP 6 4 13 Sheet Spared 14 Filter Not Spared 15 Filter Not Spared 16 802K16900 Control Panel Assembly 110v REP 6 23 802K16910 Control Panel Assembly 220v REP 6 23 17 162K56731 Switch Harness 18 117K31200 Power 19 Power Cord Not Spared 20 162K60280 Cable 1 0m 21 PWB Not Spared h o 1 x 18 19 16 Exploded on PL16 7 20 0016006A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 67 PL 16 6 PL 16 7 Control Panel Assembly Item Part 1 O Q G IS Description Front Cover Not Spared Cover Not Spared Panel Cover Not Spared Panel PWB Not Spared Frame Not Spared Control Panel PWB Not Spared Speaker Not Spared Stopper Not Spared 0016007A WOL Parts List PL 16 7 10 00 5 68 Initial Issue Phaser 790 DocuColor 2006 PL 17 1 Document Exit Tray Covers Item Part Description
50. 1 Y N Go to Flag 2 Check the wire for a short circuit to ground The wire is good Y N Repair the wire There is 5 VDC from J 161 pin 6 to ground Y Replace the Top Exit Sensor PL 9 2 If the problem continues replace the MCU PWB PL 11 2 Replace the MCU PWB PL 11 2 Go to Flag 1 Check the wires for an open or a short circuit to ground If the wires are good replace the Top Exit Sensor PL 9 2 If the problem continues replace the MCU PWB PL 11 2 Perform the following Check that the Exit Transport Assembly is mounted to the machine properly and that the Exit Transport gears front and rear are properly engaged and free from damage PL 9 2 Check that the Upper and Lower Exit Rolls clean and the gears are free from damage PL 9 2 Check that the pinch rolls on the Exit Transport Cover are functioning properly PL 9 2 Initial Issue 10 00 Phaser 790 DocuColor 2006 2 125 Status Indicator RAPs 008 703 MCU PWB PL11 2 MCU PWB PL11 2 DI 16 1 TOP EXIT 5VDC SENSOR TOP EXIT PL9 2 SENSOR 1 2165 161 gt 6 4161 L 5VDC J17 44 OVD GRY GRY J161 go 8 1 Piet GRY i GRY 1 10 v 7 2 4 GRY GRY DC COM UPPER EXIT ROLL TOP EX
51. 24 VDC INTERLOCKED 2 OF 3 WIRENET LVPS CONTINUED DUPLEX CONTROL PWB J139 J151 P151 n 124 2 REVERSE CLUTCH GRY 10 6 J152 P452 1451 2 ENTER CLUTCH GRY 10 6 J141 P134 J134 J148 P148 12 n T B5 812 p gt 2 2 DUPLEX GATE SOLENOID GRY 1 GRY 10 5 i 4151 P451 J149 P149 10 1 87 8101 1 2 ALIGNER DRIVE CLUTCH GRY GRY GRY 10 7 24 VDC FEEDER PWB INTERLOCKED 432 9211 211 9213 9214 9241 P241 J225 P225 9 4 0 6 0 4 2 UDGER SOLENOID ASSEMBLY ORN BLU GRY GRY 8 3 24 VDC i J227 P227 INTERLOCKED 24 4 24 2 TURN CLUTCH ASSEMBLY I GRY GRY 83 I J229 P229 4 4 1 2 4 4 2 TAKEAWAY CLUTCH ASSEMBLY GRY GRY 8 3 J215 J242 P242 J226 P226 0 1 256 0 1 2 UDGER SOLENOID ASSEMBLY GRY GRY 8 4 4228 P228 2 4 2 2 URN CLUTCH ASSEMBLY GRY GRY 84 1 y 1 9230 P230 S CLUTCH ASSEMBLY GRY GRY 8 J216 J233 P233 T4 2 LIFT UP CLUTCH GRY 73 J234 P234 9 1 2 LIFT UP CLUTCH GRY 74 J217 J239 14 4 FEEDER MOTOR ASSEMBLY BLU 85 24 VDC INTERLOCKED L L d CONTINUED T728005A WOL Figure 1 24 VDC Interlocked 2 of 3 Wiring Data 10 00 Ini
52. 3 and the Fan bracket Remove the from the applicable fan Screws 2 and the Fan 1 Disconnect the applicable fan connector and release the wires from the clips 0106005A WOL Figure 1 Removing the Fan Replacement 1 Perform the procedure for removal in reverse Initial Issue Phaser 790 DocuColor 2006 Repairs and Adjustments REP 6 8 REP 6 9 10 00 4 41 REP 6 10 APS Sensor 4 Remove the APS Sensor Figure 2 Parts List on PL 16 1 Removal 1 Release the locking tabs and remove the APS Sensor WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Platen Glass REP 6 1 3 Remove the Cover Figure 1 Disconnect the connector 0106006A WOL Figure 2 Removing the APS Sensor Replacement 1 Perform the procedure for removal in reverse 1 Remove the screws 8 and the cover 0 106039A WOL Figure 1 Removing the Cover Repairs and Adjustments 10 00 Initial Issue REP 6 10 4 42 Phaser 790 DocuColor 2006 REP 6 11 PWB Box 8 Disconnect five connectors from the ICM Main PWB Figure 2 Parts List on PL 16 1 Removal 1 WARNING On the righ
53. ADC NSED SE VOLTAGE J16 _ P12 P16 P19 MCU PWB P11 P22 P21 PWB L11 2 SS DO 56 DISPENSE CLUTCH ON L 24VDC 455 55 LUTCH SSY L10 1 TROU J13 201 GRY 19 GRY 24VDC 20 06 DEVELOPER AC BIAS ON 44 16 L 24VDC N HVPS PL11 1 3 AC BIAS GRY DC COM DEVELOPER AC BIAS CONTROL CONTROL GRY DO 0C DEVELOPER DC BIAS ON L 24VDC GRY DC COM DEVELOPER GRY DO 0E L 24VDC DC BIAS CONTROL BCR BIAS ON gt ee DC BIAS CONTROL 4 4 BCR CONTROL GRY BCR BIAS CONTROL GRY GRY DC COM DC COM RED Figure 1 009 342 RAP Circuit Diagram T 709011A WOL Status Indicator RAPs 009 342 10 00 2 148 Initial Issue Phaser 790 DocuColor 2006 009 343 PCDC Error RAP 009 344 Image Density Error RAP PCDC cal count below 100 Image density measured by PCDC method of first 70 mm of lead edge of image exceeds design spec 280 Procedure Switch off the power then switch on the power If the fault is still present replace the MCU Procedure PWB PL 11 2 Switch off the power then swit
54. DO A4 REVERSE REVERSE CLUTCH CLUTCH ON PL15 7 D 24VDC J151 GRY 1 2AVDC N INTERLOCKED 2 GRY 10 7 INVERT DRIVE NEM EM EH EM NEM NN EM EH THE 24VDC INTERLOCKED VOLTAGE IS NOT AVAILABLE WITH THE FUSER DRAWER OPEN T710705A WOL Figure 1 Invert Mechanism Wiring Data 10 00 Initial Issue 7 102 Phaser 790 DocuColor 2006 BSD 10 7 J DUP CONTROL PWB DUP CONTROL PL15 6 PWB PL15 6 21 94 DUPLEX TRAY 156 P154 2 J154 J155 J134 7 P134 SET 1 5 0 GRY GRY GRY GRY GRY DUPLEX FEED MECHANISM ALIGNER ROLL 10 5 DRIVE DUP CONTROL DUPLEX PWB DRIVE DO A2 CLUTCH DUPLEX DRIVE 5115 4 CLUTCH ON g 0141 L 24VDC 1 4 p J194 9155 5 J149 GRY GRY epe 2 24VDC 9 INTERLOCKED 10 GRy 0 24VDC 42 DUPLEX FEED DRIVE m m m m m EN AH EM EN EM EN RN 1 THE 24VDC INTERLOCKED VOLTAGE IS _ NOT AVAILABLE WITH THE FUSER 6 DRAWER OPEN T710706A WOL Figure 1 Duplex Feeding Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 103 BSD 10 8 10 8 DUPLEX DRIVE CONTROL DU
55. N Go go 1 Check the wires for an open or a short circuit to ground The wires good Y Repair the wires Replace the Size Switch PWB PL 3 1 Actuate and hold switches SW3 SW4 the Size Switch PWB There is 0 97 0 10 VDC from J 102 pin 1 to ground Y Go go Flag 1 Check the wires for an open or a short circuit to ground The wires good Y Repair the wires Replace the Size Switch PWB PL 3 1 Replace the MCU PWB PL 11 2 Table 1 Tray 1 Size Sensing Switch PWB ANALOG PAPER SIZE PAPER SIZE SW VOLTAGE OUT SW1 SW2 SW3 4 Tray Out OFF OFF OFF OFF 0 24 VDC B5 LEF ON ON OFF OFF 3 15 VDC A4 LEF OFF ON OFF OFF 1 21 VDC Letter LEF ON OFF ON OFF 2 67 VDC A4 SEF OFF ON ON ON 1 94 VDC Legal 14 SEF ON ON ON OFF 3 64 VDC B4 SEF OFF ON OFF ON 2 45 VDC A3 SEF OFF OFF ON OFF 0 73 VDC 12 x 18 SEF OFF OFF OFF ON 0 48 VDC Ledger SEF OFF OFF ON ON 0 97 VDC Status Indicator RAPs 007 711 10 00 2 110 Initial Issue Phaser 790 DocuColor 2006 SIZE SWITCH PWB PL3 1 MCU PWB PL11 2 NERO ANALOG J102 SEE TABLE J16 29 GRY o 1 1 UT 11 17 1 7 o 0 M pig 18 Z7 pig 1238 pg 18 9 pig 1 P17
56. Nr GRY 4 14 L 5VDC 1 MOT DC COM LAC GRY YEL 14 v 116 4 GRY A 1 RED 5VDC r 5 WHT 5VDC i DC COM ORN 1 1 42 23 VIO PL11 1 33 do 2 1 24 INTLK Am DC COM LEM 16 P19 15 MCU PWB P12 P11 P22 P18 P17 P20 P23 P21 Figure 1 009 326 RAP Circuit Diagram T 709000 A WOL Status Indicator RAPs 009 326 10 00 2 142 Initial Issue Phaser 790 DocuColor 2006 009 340 ADC Cleaning Failure RAP Output of ADC sensor is below limit immediately after cleaning Procedure Access the Digital Output Test GP 2 Enter code 67 Press the Item Enter button There 1 an audible click from the ADC Solenoid approximately every second Y N Access the DO Stop Test Enter code 67 Press the Item Enter button There 1 24 VDC from J 81 pin 1 to frame ground Y There is 24 VDC from 4 81 pin 2 to frame ground Y N Go to Flag 2 Check for an open circuit If the wire is OK replace the MCU PWB PL 11 2 Replace the ADC Sensor PL 5 1 Access the Digital Output Test GP 2 Enter code 67 Press the Item Enter button There is less than 1 VDC from J 81 pin 1 to frame ground Y Go to Flag 1 Check for an open circuit If the wire is OK replace the MCU
57. Phaser 790 DocuColor 2006 10 00 2 175 Status Indicator RAPs 010 358 010 359 Exit Chute Fan Failure RAP The Exit Chute Fan has failed to operate correctly An Exit Chute Fan rotation error has been declared Initial Actions Ensure that there are no obstructions or physical conditions that might inhibit normal fan oper ation Procedure Access the Digital Output DO test from the Control Panel Enter code 85 Press the Item Enter button The Exit Chute Fan rotates Y N 24VDC is measured between P 161 3 and frame ground DC Common Y N Go to Flag 1 Check for an open circuit or a short circuit to ground Repair or replace the Main Harness PL 11 1 as required If the wiring is OK replace the MCU PWB PL 11 2 Go to Flag 3 Check for an open circuit Repair or replace the Main Harness PL 11 1 as required If the wiring is OK replace the Exit Chute Fan PL 9 2 The Fault Code is still present or re occurs The problem may be intermittent Go to Figure 1 Check for loose or damaged tions or damaged wires Also check for continuity If the wiring is OK replace the Exit Chute Fan PL 9 2 If the problem persists replace the MCU PWB PL 11 2 is measured between P 161 2 and frame ground DC Common Y N Go to Flag 2 Check for an open circuit Repair or replace the Main Harness PL 11 1 as required If the wiring is OK replace the MCU PWB PL 11 2 Replace the Exit
58. Purpose The purpose is to provide cleaning procedures to be performed at every call Procedure CAUTION Do not use any solvents unless directed to do so by the Service Manual General Cleaning Use a dry lint free cloth or a lint free cloth moistened with water for all cleaning unless directed otherwise by the Service Manual Wipe with a dry lint free cloth if a moistened cloth is used 1 Feed Components Rolls and Pads Follow the General Cleaning procedure above 2 Dry Ink Dispense Units Vacuum the Dry Ink Dispense units 3 Jam Sensors Clean the sensors with a dry cotton swab 4 IBT Cleaning Check the IBT Belt surface and wipe with a dry lint free cloth If the surface is excessively dirty replace the IBT Belt PL 7 2 5 Fuser Components best cleaned when hot Wipe with a lint free cloth 6 Scanner a Switch off the power and allow the Exposure Lamp to cool off b Using the optical Cleaning Cloth clean the front and rear of the Document Glass Document Cover White Reference Strip Reflector and Mirror Clean the Exposure Lamp with a clean cloth and Film Remover 7 ADF Check the paper path for debris or damage Clean the rolls with a clean cloth and Film Remover as required 8 Sorter Check the paper path for debris or damage Clean the Sorter with a dry lint free cloth Final Actions Purpose The intent of this procedure is to be used as a guide to follow at the end of every service call Procedure
59. Repair the wires Ensure the connector 236 is properly connected Replace the Feeder PWB PL 13 4 Y sd Flag 2 Check the wire for an open or short circuit to ground The wires are Replace the Size Switch PWB PL 13 3 H TOT Replace the Feeder PWB PL 13 4 A B C Table 1 Tray 3 Size Sensing Size Switch PWB ANALOG PAPER SIZE PAPER SIZE SW VOLTAGE OUT SW1 2 SW3 SW4 Tray Out OFF OFF OFF OFF 4 76 VDC Ledger SEF OFF ON OFF OFF 3 45 VDC A3 SEF ON OFF ON OFF 1 57 VDC Letter LEF OFF ON ON ON 4 2 49 VDC B5 LEF OFF ON OFF ON 3 13 VDC Legal SEF OFF OFF ON OFF 4 09 VDC A4 LEF OFF OFF ON ON 3 77 VDC B4 SEF OFF ON ON OFF 2 81 VDC Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 91 007 702 SIZE SWITCH PWB PL13 3 SIZE SWITCH VOLTAGE SEE TABLE J217 5 SIZE SWITCH PWB FOR TRAY 3 214 2222574 32 1 J236 x P216 S2 32 1 ss 3 FEEDER 32 1 PWB SIZE PWB TRAY 2 amp 3 S4 P215 a 128 REAR VIEW T707014A WOL Figure 1 007 702 RAP Circuit Diagram Status Indicator RAPs 10 00 Initial Issue 007 702 2 92 Phaser 790 DocuColor 2006 007 703 Tray 1 Empty RAP The Tray 1 No Paper Sensed signal is detected by the control logic Initial Actio
60. m m EM EM EM EM GRY 4 GRY 524 MOTOR CLOCK 2 MOTOR ON L 5 VDC id 113 2 I I ge 4 GRY 22 4 221 PALL ELEMENT 1 HALL EFFECT GRY ELEMENT COM 20 57 521 HALL ELEMENT 1 SPEED 2 2 l MOTORSPEEDO 4 GRY SENSING 1 ELEMENT 2 G 22 I GRY HALL ELEMENT 2 Z DO 62 E GR DC COM ELEMENT 3 ee ON L 5 VDC HALL ELEMENT 3 08 MCU PWB 77 8 GRY 9 EN PL11 2 2222 oA DE VOM mE 10 5 27 7 GRY 222 7 VDC 41 FUSER MOTOR 2 22 3 P we GRY FAIL 5 418 Z 22 DC COM J49 DC COM 42 GRY 004 322 RN 2 ps GRY J9 FUSER MOTOR FAIL H 5 VDC PAPER HANDLING gt 25 b 6 SRY MOTOR FAIL H 2 KA 24 VDC PAPER HANDLING MOTOR FAIL H 5 VDC 5 VDC INTERLOCKED 72 6 004 320 A GRY GRY VIO PAPER HANDLING 2 L 224 MOTOR DC COM 22 PL10 1 4 MOTOR CLOCK 2 PAPER HANDLING MOTOR CLOCK MOTOR DRIVE EM EN EH EN EN MOTOR CLOCK ELEMENT 1 HALL EFFECT ELEMENT 4 HALL ELEMENT 1 SPEED SENSING 5 ELEMENT 2 HALL ELEMENT 2 HALL ELEMENT 3 ELEMENT 3 DC COM 7 VDC 6 DC COM T704701 A WOL Figure 1 BSD 4 1 Main Drive Control Initial Issue 10 00 Wir
61. 1 Remove the e ring and the rear bear ing 2 Remove the front bearing 0109026A WOL Figure 2 Removing the Rotary Frame Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 101 REP 9 12 REP 9 13 Cartridge Sensor Parts List on PL 6 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Top Cover Assembly REP 14 4 3 Access the Cartridge Sensor Figure 1 2 Disengage the wires from the hook on the Cartridge Sensor Plate Disconnect the con nector 0109027A WOL Figure 1 Accessing the Cartridge Sensor 4 Remove the Cartridge Sensor Figure 2 Replacement CAUTION Securely route the harness in the hooks of the Sensor Plate and Rotary Latch so there is no slack in the harness 1 Reinstall the Cartridge Sensor in the reverse order of removal 3 1 Remove the Cartridge Remove the screw Sensor securing the Car sy 2 Remove the tridge Sensor Plate Screw securing the sensor 0109028A WOL Figure 2 Removing the Cartridge Sensor Repairs and Adjustments REP 9 13 10 00 4 102 Initial Issue Phaser 790 DocuColor 2006 REP 9 14 Developer Tie Plate Parts List on PL 1 3 Removal WARNING To avoid personal injury or shock do not perform repair
62. 4 Change the values as required based on the measurement results Figure 1 When the measurement is short reduce the value when the measurement is long increase the value Change the values as follows NOTE To enter a letter Hexadecimal value press the asterisk key prior to entering each letter value then press the appropriate numerical key as follows A21 2 D 4 5 F 6 a new value and press Start b Press the Select button to verify the value has changed Table 1 Minimum Initial Maximum Remarks Settings Range 0 47h FFh 0 04mm Step 5 Perform the checks again Repairs and Adjustments 10 00 ADJ 6 4 4 158 Initial Issue Phaser 790 DocuColor 2006 ADJ 6 5 ICM Main PWB Adjustment Purpose The purpose is to ensure that registration magnification and image quality are restored after replacing the ICM Main PWB Adjustment 1 Perform the following adjustments ADJ 6 6 IIT Auto Shading Purpose The purpose is to adjust the correction values so the shading correction will function correctly for changes in the spectrum characteristics of a standard white sheet This adjustment should be performed whenever the following conditions are true After making changes to the ADF settings a Lead Edge Registration ADJ 6 3 After replacing the IIT Main PWB b Side Registration 6 4 After replacing the Platen Glass c Magnifica
63. 6 Remove the IBT Inner Cover Figure 1 2 3 IBT Remove the Left Inner Cover Assembly 0140015B WOL Figure 2 Removing the Left Inner Cover Assembly 1 Remove the Screws 0140016B WOL Figure 1 Removing the IBT Inner Cover Repairs and Adjustments 10 00 Initial Issue REP 14 5 4 142 Phaser 790 DocuColor 2006 8 Remove the Right Inner Cover Figure 3 2 Remove the two screws Remove the Right Inner Cover Figure 3 Removing the Right Inner Cover Replacement 1 Reinstall the Inner Covers in the reverse order of removal REP 14 6 Rear Cover Parts List on PL 1 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 1 2 Open the Exit Transport Assembly Remove the 3 Remove the Rear Cover Figure 1 Screw securing Replacement the hinge CAUTION Be careful not to pinch the harness when reinstalling the Rear Cover 1 Reinstall the Rear Cover in the reverse order of removal 2 two screws at the top are also used to secure the Top Cover Assembly Be sure 10 press the Top Cover Assembly down and securely tighten the left screw in order to ensure that the Top Cover Switch is actuated correctly 1 Remove the Option Hinge Cover 0140017B WOL Remove the Rear Cover Remove the six screws
64. A WHT 2 n 4 10 1 10 n 1 n n n n EJEA n m n J71B J71A ELLE n n n n EE n n 1 alio eles se 71 kL I gt a 14 erm N P71 4 2 7 171 3 71 3 YEL LOCATING LOCATING Fost FUSER SIDE IOT SIDE POST T 1000 TA WO Figure 1 010 353 RAP Circuit Diagram Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 169 010 353 356 357 010 354 Fuser Temperature Not Detected RAP The Fuser Temperature cannot be correctly sensed by the Temperature Sensor A Fuser Tem perature error was declared Initial Actions Inspect the Fuser area for debris and other signs of wear breakage or excessive heat dam age Perform any necessary cleaning or maintenance in the Fuser area If the problem persists continue with this RAP Procedure Ensure that you have performed the Initial Actions above If the Fuser area is clean and without apparent damage or excessive wear proceed by pulling out Area 5 A resistance of approximately 200k ohms is measured between J71 pin B4 and J71 pin B6 when the Temperature Sensor is at room temperature Y Disconnect P J72 A resistance of approximately 200k ohms is measured between P 72 pin 2 and pin 4 when the Temperature Sensor is at approximately room tempera ture Replace the Temperature Sensor PL 8 2 Reconnect P J 72 A resistance of approximately 200k ohms is me
65. FEEDER RIGHT COVER SWITCH 14 FEEDER MOTOR ASSEMBLY T728011A WOL Wiring Data 10 00 7 36 Initial Issue Phaser 790 DocuColor 2006 5 VDC IIT Wirenet 5 VDC IIT WIRENET IIT LVPS ICM MAIN PWB ADF CONTROL PWB 91 P100 P220 P610 P670 J810 J814 J711 5 VDC 5s ME 9 9 9 9 4 DOCUMENT SET SENSOR GRY GRY GRY GRY RY 5 1 6 J712 GRY 4 ADF REGISTRATION SENSOR RY 4713 4 NUDGER HOME SENSOR RY 52 J815 J718 4 ADF EXIT SENSOR RY 54 J816 J709 DOCUMENT SET INDICATOR RY 5 1 P200 J5 vci 4 CONTROL PANEL PWB RY 8 3 RY 22 J130 J718 4 3 ADF EXIT SENSOR RY J716 9 IIT REGISTRATION SENSOR RY 1728013 A WOL Figure 1 5 VDC IIT Initial Issue Wiring Data Phaser 790 DocuColor 2006 10 00 7 37 24 VDC IIT Wirenet 24 VDC IIT WIRENET IIT LVPS ICM MAIN PWB ADF CONTROL PWB P91 P100 P220 P610 P670 810 F1 J812 ISI SE 24 BN 1 on 11 gt Wer 4 ORN BLK 53 J813 1 ADF EXIT MOTOR WHT BLK 54 4 Te CARRIAGE MOTOR 2 6 2 1728012 A WOL Figure 1 24 VDC IIT Wiring Data 10 00 Initial Issue 7 38 Phaser 790 DocuColor 2006 BSDs Purpose The Block Schematic Diagrams BSDs show the
66. Figure 2 Removing the Exit Transport Assembly Replacement 1 Perform the removal procedure in reverse 2 When replacing the Exit Transport Assembly make sure that the plastic ears at the top and at the bottom below the fan are positioned over the edge of the frame Figure 3 Plastic Ears 0108070A WOL Figure 3 Exit Transport Assembly Positioning Repairs and Adjustments REP 8 40 10 00 Initial Issue 4 88 Phaser 790 DocuColor 2006 REP 8 41 Full Stack Sensor Parts List on PL 9 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Top Cover Assembly REP 14 4 3 Remove the Full Stack Sensor Figure 1 2 ee Remove the screw and Full Stack Sensor 1 Disconnect the connector 0108016A WOL Figure 1 Removing the Full Stack Sensor Replacement 1 Perform the removal procedure in reverse REP 8 42 Exit Chute Interlock Parts List on PL 9 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Exit Transport Assembly REP 8 40 3 Remove the Exit Chute Interlock Figure 1 2 Release the locking tabs and remove the
67. Go to Flag 1 Check the wire for a short circuit to ground If the wire is good replace the IIT Registration Sensor PL 16 1 While monitoring the voltage a P J 130 8 turn the flywheel CCW The voltage at P J130 8 goes to less than 1 0 VDC Y N Go to Flag 1 and Flag 2 Check the wires for an open circuit If the wires are good replace the IIT Registration Sensor PL 16 1 Switch off the power Disconnect the power cord Reconnect P J 110 Switch on the power 24 VDC is measured at P J110 1 and P J110 2 to frame Y N Replace the ICM Main PWB PL 16 2 24 VDC is measured at P J 130 3 P J130 4 P J130 5 and P J130 6 to frame Y N Go to Flag 3 Check the wires for an open circuit If the wires are good replace the Car riage Motor The problem seems to be intermittent Go to Flag 1 Flag 2 and Flag 3 Check all connectors for loose or damaged pins If the problem continues replace the IIT Registration Sensor PL 16 1 If the problem continues replace the ICM Main PWB PL 16 2 Initial Issue 10 00 Phaser 790 DocuColor 2006 2 67 Status Indicator RAPs 006 310 ICM MAIN PWB PL 16 2 3 CARRIAGE MOTOR PL16 4 J110 RED AN YEL BLU BN ORN 24 VDC BLK WHT ICM MAIN PWB REGISTRATION REGISTRATION 2 SENSOR SENSED 5 VDC 2 006 310 27 2 EEEEEEEEA J130 GRY 1 GRY Figure 1 006 310
68. Motor PWB 2 CLA Remove the gt lt Screws lt 25 O 2 ALD 6 gt Pj e Disconnect the four connec tors f 20 Figure 1 Removing the Drive Motor PWB 0101024A WOL Repairs and Adjustments 10 00 REP 4 5 4 18 Initial Issue Phaser 790 DocuColor 2006 REP 4 6 Process Drive Unit Parts List on PL 10 1 Removal m the Pro WARNING cess Drive Unit To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Rear Cover REP 14 6 3 Remove the Process Drive Unit Figure 1 Replacement CAUTION Failure to align the positioning boss of the printer frame with the positioning hole of the Process Drive Unit during the replacement could cause problems 1 Align the positioning boss of the printer frame with the positioning hole of the Process Drive Unit before securing the unit 2 Remove the Screws 1 Disconnect the connectors Figure 1 Removing the Process Drive Unit 0101025A WOL Initial Issue 10 00 Phaser 790 DocuColor 2006 4 19 Repairs and Adjustments REP 4 6 REP 4 7 Rotary Motor Parts List on PL 10 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the mac
69. REP 5 6 Registration Roll 7 Remove the ADF Registration Roll Drive Pulley Gear Figure 2 Parts List on PL 17 3 Removal 2 Reduce the belt tension and disengage the Belt from the Pulley Gear WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the ADF Front Cover and Rear Cover 3 Remove the Document Transport Assembly REP 5 7 4 Remove the ADF Assembly from the scanner REP 5 1 5 Remove the Feeder Lower Cover Figure 1 Feeder Lower Cover 1 Loosen screws and raise the Idler Pulley lt 2 Remove the E Clip Pulley Gear and washer 0105012A WOL Figure 2 Removing the Drive Pulley Gear L 1 Remove the two retaining screws then remove the Feeder Lower Cover 0105011A WOL Figure 1 Removing the Feeder Lower Cover 6 Remove the left Counterbalance REP 5 3 Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 29 REP 5 6 8 Move the Registration Pinch Roll away from the Registration Roll CAUTION Tension Springs are of different strengths for the front and rear Be careful not to mix the front and rear springs when removing them from the Registration Roll The front spring is the stron ger thicker spring 9 Remove the Registration Roll Figure 3 4 Remove the Registration Roll
70. Table 1 Menu Items Menu Item Explanation DI TEST see 2 DO TEST see GP 2 STOP DO TEST see 2 IOT PARAM SET see GP 3 IOT NVM R W see GP 4 PATTERN PRINTING see GP 15 INSTALL MCU see GP 8 INSTALL 1394 F W see GP 8 METER see GP 5 METER SETUP see GP 5 INITIALIZING DATA see GP 6 CHANGE PASSWORD see GP 7 RESET ADMIN PASSWORD see GP 7 DIAG EXIT see GP 1 Exit Exiting the Diagnostic Mode To exit from IOT diagnostics perform the following Scroll through the menu until DIAG EXIT is displayed 2 Press the Item Enter button The following message will appear Processing WRITING DATA Indicator Item Enter Button PLEASE WAIT Error 3 The machine will update any changes that were made in diagnostics When the update is Indicator Clear Stop Button complete the following message will appear PLEASE POWER OFF 0740002A WOL 4 Switch off the power Figure 1 The Control Panel Use the Up and Down arrow buttons to enter data onto the display Use the Right and Left arrow buttons to move the cursor right or left Initial Issue 10 00 General Procedures and Information Phaser 790 DocuColor 2006 6 3 GP 1 GP 2 Component Control IOT Table 1 Digital Input Codes The purpose is to displa
71. nennen 2 49 Area Gidan RAP A wa nen E AA A eua 008 705 Top Tray Full D Document Transportation 008 706 eic LL be ct e 2 132 005 210 Nudger Home 2 51 008 707 Duplex Tray Open RAP uu uu rna asahan un tenen tenter ferente tei dte 2 134 005 211 ADF Power RAP 2 53 005 220 221 ADF Communications 255 Xerographies 009 321 TRO Sensor RAP eene e Ite ee sasay te Leere b ties 2 137 005 700 Fault Entry RAP erecto niece eee teens 2 57 009 323 Process Motor a 2 139 005 701 ADF Entrance Jam RAP 2 58 009 326 Rotary Motor aaa 2 141 005 702 ADF Exit Jam 2 60 009 340 ADC Cleaning Failure 2 143 005 703 ADF No Feed RAP 2 62 009 341 ADC Sensor Background RAP 2 145 005 704 Unfinished Copy Job 2 64 009 342 Patch Error RAP Imaging 009 343 PC DC EOT RA P eerie tie dep IR YR oen EE iR Paga 2 149 006 310 IIT Registration 2 67 009 344 Image Density Error 2 149 006 311 Exposure Lamp 2 69 009 358 BTR 2 Home Position 2 150 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 009 359 BIER 2 Bias RAP uu La tonne ere enn Ee dene ied 2 152 009
72. 0 206003A WOL Figure 5 Tightening the Capstan Set Screw Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 155 ADJ 6 2 14 Use the tools to adjust the rear side of the Full Rate Carriage Assembly Figure 7 2 Install it at the rear of the Full Rate Carriage Assembly 3 Tighten the screw 1 at the rear of the Full Rate Carriage Assembly Remove the positioning tool at the front of the Full Rate Carriage Assembly 0206006AWOL Figure 7 Adjusting the Rear Side of the Full Rate Carriage Assembly 15 Remove the positioning tools from the assembly and install them to their mounting posi tion inside the Control Panel housing 16 Tighten the remaining set screws on the front and rear Capstan Pulleys 17 Reinstall the Control Panel Assembly REP 6 23 18 Reinstall the Rear Cover REP 6 4 19 Reinstall the Left Cover REP 6 3 20 Reinstall the Right Cover REP 6 2 21 Reinstall the Platen Glass REP 6 1 22 Reinstall the ADF REP 5 1 or Platen Cover Repairs and Adjustments 10 00 6 2 4 156 Initial Issue Phaser 790 DocuColor 2006 ADJ 6 3 IIT Lead Edge Registration 2 Enter Systemdata R W and press the Select button Purpose 3 Enter Chain 715 and Link 3 and confirm the present values h ition in the IIT I directi Change the values as required based on the measurement results Figure 1 When the The purpose is to achieve the proper home position in the
73. 0140002A WOL Figure 1 Removing the Rear Cover Initial Issue Phaser 790 DocuColor 2006 10 00 Repairs and Adjustments 4 143 REP 14 5 REP 14 6 REP 14 7 Filter Parts List on PL 1 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Filter Figure 1 Replacement 1 Reinstall the Filter in the reverse order of removal 2 FRONT Lift and remove the Filter 1 Disengage the hooks of the cover from the Filter 2 0140003A WOL Figure 1 Removing the Filter REP 14 8 Left Lower Cover Parts List on PL 1 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine Switch off the machine power and disconnect the machine Power Cord Remove the Tray 1 Assembly REP 7 6 Remove the Front Lower Cover REP 14 3 Remove the Rear Cover REP 14 6 Remove the Left Lower Cover Figure 1 Replacement 1 Reinstall the Left Lower Cover in the reverse order of removal Qv ds oi I 1 Remove the two Screws Remove the Left Lower Cover 0140004A WOL Figure 1 Removing the Left Lower Cover Repairs and Adjustments REP 14 7 REP 14 8 10 00 4 144 Initial Issue Phaser 790 DocuColo
74. 1 050K41980 Document Exit Tray Assembly 2 Exit Tray Extension P O PL 17 1 142 4 25 Item 1 3 Exit Tray P O PL 17 1 Item 1 516 8 11 14 4 121E90640 Interlock Magnet 16 17 18 5 050K42110 Entrance Tray Assembly 6 Document Guide P O PL 17 1 Item 19 20 21 5 7 Spring P O PL 17 1 Item 5 8 Plate P O PL 17 1 Item 5 PL17 1 Item 5 15 9 892E19630 Label 17 19 24 10 892 19620 Label PL17 2 Item 1 2 11 152063490 17 19 21 rev 12 140K60480 Document Set Indicator 13 892E19610 Label Size PL17 3 Item 4 14 Entrance Tray P O PL 17 1 Item 5 PL17 4 Item 1 15 026P63574 Screw m 1 16 Rear Cover Assembly Not Spared PL17 5 Ite 17 Cover Not Spared PL17 6 Item 1 17 18 Seal Spared 19 802014670 Front Cover Assembly PL17 2 Item 3 1116 20 Cover P O PL 17 1 Item 19 PL17 3 Item 1 3 21 Magnet P O PL 17 1 Item 19 5 22 25 26 22 003K91881 Thumb Screw 23 059 17851 Feeder Assembly PL17 4 4 24 059K16181 Feeder Assembly PL17 5 Item 2 4 25 Magnet P O PL 17 1 Item 1 8 9 11 12 26 Label Fax Not Spared PL17 6 Item 16 27 Label Caution Not Spared _ 28 ADF Assembly 5 1 ADJ 5 1 PL17 7 177 1 ADJ 5 2 ADJ 5 3 ADJ 5 4 L 12 14 15 19 0017001A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 69 PL 17 1 PL 17 2 Counterbalance Drive Motor PWB Item Part Description 1 036K90900 Right Counterbalance REP 5 3 AD
75. 2 Remove the Screws 8 3 Remove the Upper Guide Assembly Open the Fuser Assembly 0110002A WOL Figure 1 Removing the Upper Guide Assembly Repairs and Adjustments 10 00 REP 10 3 4 114 Initial Issue Phaser 790 DocuColor 2006 REP 10 4 Upper Plate Parts List on PL 8 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Main Fuser Assembly REP 10 2 3 Remove the Upper Guide Assembly REP 10 3 CAUTION When the Upper Plate is removed in the following step the Fuser Front Frame and Fuser Hear Frame will no longer be secured Be careful not to damage the Heat Lamps One of the front screws and one of the rear screws also secure the wires for the Heat Roll Heat Lamp Be careful not to damage the surface of the Heat Roll with a screwdriver or other tools when disengaging the Temperature Sensor 4 Remove the Upper Plate Figure 1 Replacement 1 Reinstall the Upper Plate in the reverse order of removal 1 Unhook the har lt 5 2 ness from the Disengage the Remove the Upper Plate Temperature sticker at front pO c Sensor from and rear the plate 3 Remove the screws 4 4 Remove the Upper Plate 0110003A WOL Figure 1 Removing the Upper Plate Initial Issue 10 00 Repairs and Adjustment
76. 5VDC J214 DC COM J241 FEED OUT 74 19 7 P241 3 SENSED P GRY j GRY I 2 J223 P241 J241 L 5 VDC J214 8 5VDC I GRY GRY 9 9 t gt GRY GRY 5VDC 2 2 TRAY 2 PAPER FEEDING FEEDER PWB 1 2 PETS FEEDER PWB FEED OUT SENSOR PL13 4 PL13 5 DC COM D1 B6 5VDC 223 9215 4242 242 4224 FEED OUT 7 9 7 3 SENSED 1 1 1 GRY i GRY i 2 J224 P242 3 8 4242 L 5 VDC J215 8 1 5VDC 1 I 1 GRY GRY 9 m 92 Y 21 99 GRY GRY a 7 5VDC TRAY 3 PAPER FEEDING o o Ended FEEDOUT P218 P216 FEEDER PWB TRAY 2 PAPER FEEDER ASSY P212 217 215 TRAY 3 PAPER FEEDER ASSY FEEDOUT SENSOR T708009A WOL Figure 1 008 702 RAP Circuit Diagram Status Indicator RAPs 10 00 Initial Issue 008 702 2 124 Phaser 790 DocuColor 2006 008 703 Area 4 Jam RAP The Control Logic has detected the signal Paper at Top Exit Sensor L 5 VDC at the incorrect time Initial Actions Open the Top Left Cover and remove any paper from area 4 Ensure that the Top Left Cover is securely closed Ensure that the Top Left Cover front and rear magnets are in position Ensure that the Top Exit Sensor Actuator operates correctly Procedure Enter diagnostic code DI 16 The display indicates a
77. 64 Press the Item Enter button The Fuser Chute Fan energizes Y N Remove the Fuser Assembly REP 10 1 5VDC is available from P71 A2 to P71 A1 Y N Go to Flag 1 Check for an open circuit Repair or replace the Fuser Harness PL 8 5 as required If the wiring is OK replace the MCU PWB PL 11 2 Go to Flag 2 Check for an open circuit Repair or replace the Fuser Harness PL 8 5 as required If the wiring is OK replace the Fuser Chute Fan PL 8 6 The problem may be intermittent Go to Figure 1 Check for loose or damaged connections or damaged wires If the wiring is OK replace the Fuser Chute Fan PL 8 6 If the problem per sists replace the MCU PWB PL 11 2 Status Indicator RAPs 010 704 10 00 2 186 Initial Issue Phaser 790 DocuColor 2006 MCU PWB DO 64 PL11 2 FUSER CHUTE FAN ON Jh 1019 L 5VDC 71 Y J80 2 J80 E GRY GRY i BLK 9 I I GRY L A2 A9 y L2 GRY RED 5VAC 1 o o 1 1 T T mI Ta T P 5 16 18 4 p 18 Z pig D 911 14 P17 17 6 15 MCU PWB P20 15 5 14 P12 M6 Pas 371 B16 8 P2 o o 1 o P J71 PIN CONFIGURATION FUSER J71 P71 ENTRANCE SENSOR
78. 8 Label Not Spared 9 Label Not Spared 10 127E82330 Sorter Transport Motor REP 11 4 11 049E48940 Support 12 007E39240 Gear 13 013E85600 Bearing 14 022K61790 Exit Roll 15 130E84410 Sensor Receiver REP 11 5 0019002A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 79 PL 19 2 PL 19 3 Feed Motor LVPS 2 of 2 Item Part Description 1 048E27040 Bottom Cover REP 11 2 2 038K85280 Entrance Guide 3 013E85600 Bearing 4 023E12590 Belt 5 059K04780 Entrance Roll 6 020E22140 Pulley 7 130K86470 Sorter Path Sensor REP 11 7 8 130K61390 Sensor Transmitter REP 11 6 9 130E84420 Full Sensor REP 11 8 10 Lower Guide Not Spared 11 Bracket Not Spared 12 Bracket Not Spared 0019003A WOL Parts List 10 00 Initial Issue PL 19 3 5 80 Phaser 790 DocuColor 2006 PL 19 4 Bin Drive Motor Lead Cam Switch Item Part Description 1 127E82340 Bin Drive Motor REP 11 9 2 049E48940 Support Not Spared 3 006K21260 Rear Gear Shaft REP 11 10 4 006K21270 Front Gear Shaft REP 11 10 5 Bevel Gear Not Spared 6 Bearing Spared 7 Shaft Not Spared 8 007E62620 Gear 9 008K91280 Rear Bin Cam REP 11 11 ADJ 11 1 10 008K91270 Front Bin Cam REP 11 11 ADJ 11 1 11 013E85600 Bearing 12 110K10730 Bin Cam Switch REP 11 12 13 110K10750 Bin Home Switch REP 11 13 14 Harness Spared 15 Bracket Not Spared 00019004A WOL Initial Issue 10 00 Parts List
79. Be careful not to damage the surface of the Heat Roll while removing the roll 6 Remove the Heat Roll Figure 1 Replacement 1 Reinstall the Heat Roll in the reverse order of removal 2 Check the Fuser Nip ADJ 10 1 CRYO 4 5 Remove the Ring securing Disengage the roll at the the Gear at the front then front by moving it toward remove the Bearing the rear then remove the Heat Roll 3 Remove the rear Gear and Bearing 7 2 Remove the Ring securing the Gear atthe rear Loosen the screw at front and at rear until the bottom of screwis aligned with bottom of nut 0110009A WOL Figure 1 Removing the Heat Roll Initial Issue 10 00 Phaser 790 DocuColor 2006 4 119 Repairs and Adjustments REP 10 10 REP 10 11 Pressure Roll Parts List on PL 8 3 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine Switch off the machine power and disconnect the machine Power Cord Remove the Main Fuser Assembly REP 10 2 Remove the Upper Guide Assembly REP 10 3 Remove the Upper Plate REP 10 4 Remove the Heat Roll Heat Lamp REP 10 5 Remove the Pressure Roll Heat Lamp REP 10 6 Remove the Lower Guide Assembly REP 10 7 Remove the Heat Roll REP 10 10 Prepare to remove the Pressure Roll Figure 1 Oo QU D OX OI SOO 1 2 Remove the Fuser Entry Plate 1
80. Disconnect the connector Remove the Inverter Upper Assembly 2 Depress the release catches on both the top and the underside of the assembly 0108044A WOL Figure 1 Removing the Inverter Upper Assembly Replacement 1 Perform the removal procedure in reverse Initial Issue Phaser 790 DocuColor 2006 10 00 Repairs and Adjustments REP 8 32 REP 8 33 REP 8 34 Exit Roll 4 Remove the Exit Roll Figure 2 Parts List on PL 15 2 5 Remove the E ring WARNING and bearing To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Inverter Upper Assembly REP 8 33 3 Remove the Exit Cover Figure 1 3 Remove the cover 1 Remove the Exit Roll Remove the I two screws one each side Remove the E ring gear and bearing 0108046A WOL m Figure 2 Removing the Exit Roll 8 Replacement 1 Perform the removal procedure in reverse Release the cover from the retaining tab 0108045A WOL Figure 1 Removing the Exit Cover Repairs and Adjustments 10 00 Initial Issue REP 8 34 4 82 Phaser 790 DocuColor 2006 REP 8 35 Inverter Lower Assembly Parts List on PL 15 5 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1
81. Exit Chute Switch Disconnect the connector 0108021A WOL Figure 1 Removing the Exit Chute Interlock Replacement 1 Perform the removal procedure in reverse Initial Issue Phaser 790 DocuColor 2006 10 00 4 89 REP 8 41 REP 8 42 Repairs and Adjustments REP 8 43 Top Exit Sensor Parts List on PL 9 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Exit Transport Assembly REP 8 40 3 Remove the Top Exit Sensor Figure 1 2 Release the locking tabs and remove the Top Exit Sensor Disconnect the connector 0108020A WOL Figure 1 Removing the Top Exit Sensor Replacement 1 Perform the removal procedure in reverse Repairs and Adjustments 10 00 REP 8 43 4 90 Initial Issue Phaser 790 DocuColor 2006 REP 9 1 Copy Print Cartridge Parts List on PL 5 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord CAUTION Be careful not to touch the surface of the Copy Print Cartridge when removing the cartridge After removing be sure to lay the Copy Print Cartridge in the horizontal position in a safe place that is not exposed to light 2 Remo
82. Front Exchange Stopper 4 Remove the screw and the Rear Exchange Stopper e y gt a 229 J us 2 Mee 18 EU Remove the 4 22222 pz Exchange Chute from the right side gt 2 Remove the Fuser Front Rail Remove the Screws 0110012A WOL Figure 1 Removing the Exchange Chute Repairs and Adjustments 10 00 Initial Issue REP 10 13 4 122 Phaser 790 DocuColor 2006 REP 10 14 Exchange Solenoid Parts List on PL 8 5 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord Remove the Exit Tray Assembly REP 8 30 Remove the Fuser Assembly REP 10 1 Remove the Main Fuser Assembly REP 10 2 Remove the Exchange Chute REP 10 13 CAUTION The Fuser Rear Rail and Fuser Tray Assembly are connected by a harness Be careful not to pull too far apart while disassembling the components The gear is no longer secured when the EXCHANGE BRACKET is removed Be careful not to allow the gear to fall out while disassembling the components 6 Remove the Exchange Solenoid Figure 1 Replacement 1 Reinstall the Exchange Solenoid in the reverse order of removal CRYO 1 Remove the 4 screws Remove the screws to remove the Exchange Solenoid Assem emove the screws to remove the Exch
83. Fuser Baffle P O PL 8 2 Item 1 16 Tie Bracket P O PL 8 2 1 17 Shaft P O PL 8 2 Item 1 18 Front Cam P O PL 8 2 Item 1 19 Rear Cam P O PL 8 2 Item 1 20 600K85480 Heat Roll Hardware Kit REP 10 10 ADJ 10 1 0008003A WOL Parts List 10 00 Initial Issue PL 8 3 5 32 Phaser 790 DocuColor 2006 PL 8 4 Fusing 4 of 7 Item Part Description 1 K4334 Fuser Tray Assem 050K43340 ys ay Assembly 220v ADJ 4 4 2 17 and PL8 5 050K43330 Fuser Tray Assembly 110v ADJ 10 1 2 Fuser Tray Subassmebly P O PL 8 4 Item 1 3 004E09760 Damper 4 011E10200 Fuser Tray Handle 5 Fuser Tray Cap P O PL 8 4 Item 1 6 Connector P O PL 8 4 Item 1 7 Rear Exchange Stopper P O PL 8 4 Item 1 8 003 39791 Fuser Knob 9 Fuser Knob Bearing P O PL 8 4 Item 1 10 Fuser Knob Bearing P O PL 8 4 Item 1 11 007E51650 Fuser Knob Gear 12 007E51660 Exit Knob Gear 13 Exit Roll Pin P O PL 8 4 Item 1 E 14 059K14430 Exit Roll REP 10 17 15 15 007E60300 Exit Gear 16 16 Exit Bearing P O PL 8 4 Item 1 17 054E10561 Exchange Chute REP 10 13 0008004A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 33 PL 8 4 PL 8 5 Fusing 5 of 7 Item Part Description 1 Front Exchange Stopper P O PL 8 4 Item 1 2 Fuser Tray Subassembly P O PL 8 4 Item 1 3 Fuser Front Rail P O PL 8 4 Item 1 4 Fuser Rear Rail P O PL 8 4 Item 1 5 121K21821 Exchanged Solenoid Assembly 6 Exchange Bracket P O
84. Go to Flag 1and Flag 2 Check the wires for an open circuit The wires are good Repair the wires Replace the Full Stack Sensor PL 9 2 Replace the PWB PL 11 2 Status Indicator RAPs 10 00 008 705 2 130 Initial Issue Phaser 790 DocuColor 2006 MCU PWB PL11 2 1 MCU PWB DI 15 5VDC PL11 2 TOP TRAY FULL P163 J163 L 556 GRY GRY 5VDCVDC T a J17 163 3 2163 GRY GRY 1 3 14 1 7 FULL STACK SENSOR DC COM a 1 17 2 o PIO 34 18 222191254 18 Z pig 13 32 P14 1 17 15 28 1 PIS MCU PWB P20 15 15 14 P12 416 PI A Fas 816 8 3 EXIT TRANSPORT 21 ASSEMBLY o 1 1708006A WOL Figure 1 008 705 RAP Circuit Diagram Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 131 008 705 008 706 OHP Sensor RAP The Control Logic has sensed the signal Sensed 1 5 VDC at an incorrect time Initial Actions Pull out the Bypass Tray Paper Transport Assembly and remove the OHP transparency from the Registration Paper Transport Procedure Enter the diagnostic mode Enter code DI 27 The display indicates a 1 Y N Go to Flag 2 Check the wire for a short circuit to ground The wire is
85. Heat Roll Heat Lamp Pressure Roll 10 2 menu and deactuated using the STOP DO TEST menu Therefore to deactuate an actu Pressure Roll Heat Heat Lamp L 5 VDC ated component you must first go back to the STOP DO TEST menu and select the com Lamp ponent again 4C MCU PWB Not used 6 following table lists the digital output codes 2 Paper Pandling Motor Not used 53 Fuser Motor Paper Motor On 1 5 VDC 4 1 Table 2 Digital Output Codes Handling Motor DO Code Component Signal BSD Ref 54 Drive Unit Procass Motor On L 7 27 VDC 9 2 56 Dispense Clutch Dispense Clutch On L 24 VDC 9 5 00 Process Drive Unit Process Motor Speed 0 9 2 57 Fuser Motor Paper Motor Speed 0 L 5 VDC 41 06 Process Drive Unit Process Motor Speed 1 9 2 Handling Motor 07 Optional Feeder Flag 3 4 60 Developer Fan Developer Fan High Speed 9 4 08 Optional Feeder Start 3 4 61 Developer Fan Developer Fan On H 24 VDC 9 4 09 Duplex Option Start 3 5 62 Fuser Motor Paper Motor Speed 1 On L 5 VDC 4 1 0A HVPS 2 Bias On L 24 VDC 9 7 Handling Motor 0B HVPS BTR 1 Bias On L 24 VDC 9 6 63 Fuser Fan Fuser Fan On H 24 VDC 10 3 0C HVPS Developer DC Bias On 1 24 VDC 9 4 64 Fuser Chute Fan Fuser Chute Fan On 1 5 VDC 10 3 00 HVPS Developer AC Bias On 1 24 VDC 9 4 65 Fuser Fan Fuser Fan High Speed H 24 VDC 10 3 HVPS BCR DC 1 24 VDC 9 1 66 Cleaner Cam Solenoid Cleaner Cam Solenoid On 1 24 VDC 9 8 10 Rotary Motor Rotary
86. If the wires are good replace the MCU PWB PL 11 2 Go to Flag 1 Check the wires for an open or a short circuit to ground If the wires are good replace the Duplex Controller PWB PL 15 6 If the problem continues replace the Inverter Motor PL 15 6 There is 0 VDC from J 139 pin 7 to printer frame Y Replace the Duplex Controller PWB PL 15 6 Go to Flag 1 Check the wires for and open circuit The wires are good Y N Repair the wires Replace the Inverter Motor PL 15 5 There is 0 VDC from Inverter Motor J 147 pin 4 to the printer frame Y N Replace the Duplex Controller PWB PL 15 6 Check the Drive Mechanism gears and pulleys for missing teeth and proper function If the gears are good Replace the Inverter Motor PL 15 5 Initial Issue 10 00 Phaser 790 DocuColor 2006 2 85 Status Indicator RAPs 007 341 DUPLEX MCU PWB DUPLEX INVERTER PL11 2 CONTROLLER PWB MOTOR PL15 6 15 6 DO AO PL15 5 8 J139 147 5VDC 19 22 INTLK J134 A46 P134 Y J142 Tj GRY 3 01 96 BEGOM i INVERTER MOTOR L2 MOT 44147 ra SVDC J139 6 00 341 24VDC GRY AK 2
87. L 24VDC GRY SRY 10 358 1 1 5 L 207 GRY DC COM EXIT CHUTE DO 85 FAN ap EXTCHUTE PLU mE 4 FANON 21 86 324VDC 3 6 P161 112 3 EXIT CHUTE GRY GRY FAN FAIL 2 4112 161 7 j 09 9VDC GRY GRY 6 16 8 3 GRY GRY 1710702A WOL Figure 1 Fusing Air Control Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 97 BSD 10 4 J17 J163 r3 1 J MCU PWB PRINT TO PL11 2 TOP EXIT TRAY 21 15 SENSORY TOP TRAY PL9 2 FULL L 5VDC 1 9167 P163 3 GRY GRY GRY 15 CAUTION 7 DO NOT SELECT MORE 2 THAN ONE 1 DIAGNOSTIC CODE AT A TIME OR DAMAGE TO THE SOLENOID WILL OCCUR GRY 29 EXCHANGE SOLENOID PUSH SHEET TO TOP EXIT TRAY PULL SHEET TO INVERTER DUPLEX D etr AT i TRAY TOP EXIT SENSOR TOR EAT 3 THE 24VDC INTERLOCKED PL9 2 VOLTAGE IS NOT 3 J165 P1641 J17 AVAILABLE WITH THE 1 RY 3 6 FUSER DRAWER OPEN FUSER TRAY ASSEMBLY 4 PL8 4 EXCHANGE SOLENOID PL8 5 DO 17 1 ZR EXCHANGE e un J19 D P71 J71 74 s 8 GRY 5 SHEET TO INVERTER 5 35 i 1 UPPER AE 24VDC ASSY 1 INTERLOCKED 2 1 GRY GRY DO 18 i ES SOLENOID PULL L 24VDC GRY Bt 0 GRY 6 T710703A WOL Figure 1 Exit Transpo
88. NVM R W is displayed menged 3 Press the Item Enter button until the ADDRESS screen is displayed than 219 mm advances 2x 4 Press the Up Arrow or Down Arrow button to display the address to be checked Color less than 219 mm 5 Press the Item Enter button to display the current value advances 4x and longer 6 Use the Up Arrow or Down Arrow button to change the value as required than 219 mm advances 8x 7 Press the Item Enter button to change the value 5 Unused 8 Press the Menu button to return to the DIAG EXIT screen then press the Item Enter but 9 BTR2 Increments the same for Counter must be manually ton to write the new value into NVM color and b w based upon reset following replacement the deactuation of the Fuser Information was originally Exit Sensor The value incre intended to enable replace ments 1 for sheets less than ment at prescribed intervals 219 the process length This feature is disabled in this and 2 if greater than 219 mm product 10 Belt Cleaner Increments the same for Counter must be manually color and b w based upon the reset following replacement deactuation of the Fuser Exit Information was originally Sensor The value incre intended to enable replace ments 1 for sheets less than ment at prescribed intervals 219 mm in process length This feature is disabled in this and 2 if length is greater than product 219 mm 11 Unused 12 Unused 13 Developer Y Each TRO signal incre
89. OK and 6 Establish communications with the Scanner a Hyperterminal select Call Disconnect and then Call Connect b Press the Enter key once or twice for the login prompt to appear c the user name tsubaki in lower case letters d Press the Enter key for the command prompt gt to appear 7 Begin downloading download and press the Enter key The Scanner Control Panel will display the message Downloading b Hyperterminal on the PC select Transfer Send File and then the Send File dia logue screen will appear General Procedures and Information 10 00 Initial Issue GP 9 GP 10 6 12 Phaser 790 DocuColor 2006 filename specify the name of file to be downloaded to the Scanner Protocol select Xmodem Press the Send or press the Enter key to start Press the Scanner switch once at the rear of scanner The downloading will com mence and the Scanner Control Panel will display the message Downloading The Tools button on the scanner should be blinking during the download e GP 11 Checking the Billing Meters The purpose is to display the number of prints or copies made Procedure 1 Enter the Diagnostic Mode GP 1 aur Ven 2 Press the Menu button until METER is displayed 8 Download of the files is complete when the Scanner Control Panel indicates the mes 8 Press the Item Enter button READ MASTER is displa
90. P O PL 2 1 Item 1 17 Tray Housing P O PL 2 1 Item 1 18 Sector Gear P O PL 2 1 Item 1 19 Sector Gear Spring PL 2 1 Item 1 20 Tray Bottom Cover P O PL 2 1 Item 1 0002001A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 11 PL 2 1 PL 3 1 Tray 1 Paper Feeder 1 of 3 Item Part Description 1 Bracket Clamp Not Spared 2 Harness Spared 3 Size Bracket Assembly Not Spared 4 Size Switch Bracket Spared 5 110K07770 Size Switch PWB REP 7 1 6 Sensor Bracket Spared REP 7 2 7 No Paper Sensor Assembly Not Spared REP 7 3 8 No Paper Bracket Not Spared 9 130E81970 No Paper Sensor REP 7 4 10 No Paper Actuator Not Spared 11 Stopper Not Spared 12 Feed Shaft Guide Not Spared 13 Feed Idler Gear Not Spared 14 121E84500 Feed Solenoid REP 8 5 15 Feed Bearing Not Spared 16 Turn Gear D Not Spared 17 _ Turn Gear L Not Spared 18 110E97970 Low Paper Sensor REP 7 5 10 0003001A WOL Parts List 10 00 Initial Issue PL 3 1 5 12 Phaser 790 DocuColor 2006 PL 3 2 Tray 1 Paper Feeder 2 of 3 Item 1 A Part 802E05560 830E19490 Description Upper Turn Chute Assembly Not Spared Upper Turn Chute Not Spared Pinch Roll Not Spared Pinch Spring Not Spared Pinch Spring Housing Not Spared Magnet Catch Not Spared Turn Chute Cover Outer Turn Chute Not Spared Inner Turn Chute Not Spared
91. PL 16 1 The Front Fan operates normally Y Disconnect connector J 150 Blue on the ICM Main PWB 24 VDC is measured between J150 pin 1 and pin 3 on the ICM Main PWB Y N Replace the ICM Main PWB PL 16 2 NOTE Hemove the Platen Cover for easier access to intermediate connector J 150A B Reconnect connector J 150 on the ICM Main PWB Disconnect connector J150A 24 VDC is measured between J150A 1 and pin 3 Y N Go to Flag 1 Check for an open circuit or a short circuit to ground Repair or replace the wiring as required Replace the Front Fan PL 16 1 If both Fans operate normally but the Fault Code persists go to Flag 2 5 VDC is mea sured between J 151 2 and GND Go to 3 5 VDC is measured between J 150 2 Grey wire and GND Y N The problem may be intermittent Go to Figure 1 Check for loose or damaged con nections or damaged wires If the wiring is OK replace the Fans PL 16 1 time If the problem persists replace the ICM Main PWB PL 16 2 Replace the Front Fan PL 16 1 If the problem persists replace the ICM Main PWB PL 16 2 Replace the Rear Fan PL 16 1 If the problem persists replace the ICM Main PWB PL 16 2 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 71 006 313 ICM MAIN PWB PL16 2 FAN ICM CONTROL PL16 1 5 MAIN PANEL FRONT FAN ON H FR
92. PRESENT L 5 VDC We 10 YEL VIO 2 DC COM 35 1703005 A WOL Figure 1 003 333 RAP Circuit Diagram Status Indicator RAPs 10 00 Initial Issue 003 333 2 40 Phaser 790 DocuColor 2006 003 334 Foreign Interface Compatibility RAP This Fault Code indicates that a compatibility problem was detected between the ESS PWB and the Foreign Interface an incorrect Foreign Interface device may be installed Procedure Switch the IOT power off then on Fault Code 003 334 is still present Y N If intermittent performance is suspected perform the following Check the connections between the ESS PWB and the Foreign Interface and the interconnecting harness Reseat the P J 17 connector on the ESS PWB and P J 905 on the Foreign Interface The Foreign Interface device is the correct device for the P790 DC2006 Y N Install the correct Foreign Interface Go to Flag 1 and check the wires for an open or short circuit The wires are good Y Repair the wires Replace the Foreign Interface Initial Issue 10 00 Phaser 790 DocuColor 2006 2 41 Status Indicator RAPs 003 334 RS422 ESS PWB PL12 1 5 VDC FOREIGN INTERFACE J17 COMMUNICATION LINE J905 1 P905 TRANSMITTER YEL 1 YEL 5 RETURN 5 111 GRY GRY GRY i COMMUNICATION LINE i YE YEL WE s i A A 4 i 1 RETURN 5
93. Phaser 790 DocuColor 2006 3 9 106 IQ7 Residual Image Ghosting RAP Initial Actions Check the end of life counter for the Copy Print Cartridge GP 3 If the unit is at or near end of life replace the Copy Print Cartridge PL 5 1 If the problem occurs only with certain types of media ensure that the media in use is within specification and that the customer is aware of correct operation of print driver If the distance between the intended image and the residual image has a fixed rate of rep etition go to the IQ16 RAP Return to this procedure if the problem persists Procedure Access the Digital Output Test GP 2 Enter code 71 Press the Item Enter button Remove the Copy Print Cartridge The Erase lamp is lit Y N There is 5 VDC from pin 2 to pin 1 on J 86 Y N There is 5 VDC from J 86 pin 2 to frame ground Y N Go to Flag 1 Check for an open circuit If the wire is OK replace the MCU PWB PL 11 2 Go to Flag 2 Check for an open circuit If the wire is OK replace the MCU PWB PL 11 2 Replace the Erase Lamp PL 5 1 Remove the Fuser Examine the Heat Roll and Pressure Roll for evidence of toner offsetting There is Toner adhering to the Heat Roll or Pressure Roll Y N Check for a residual image on the IBT Belt Ensure that the Belt Cleaner is operating cor rectly go to the 009 704 RAP to troubleshoot Cleaner problems If the problem persists replace the Copy Print Cartridge PL 5 1 Cle
94. Phaser 790 DocuColor 2006 5 81 PL 19 4 PL 19 5 Tray Support Bin Tray Description Stack Tray Assembly ADJ 11 1 Stack Tray P O PL 19 5 Item 1 Front Frame P O PL 19 5 Item 1 Rear Frame P O PL 19 5 Item 1 Front Pad P O PL 19 5 Item 1 Rear Pad P O PL 19 5 Item 1 Frame Top Not Spared Support Not Spared Spring Aligner Not Spared Bin Tray 1 7 REP 11 14 ADJ 11 1 Bin Tray 8 9 REP 11 14 ADJ 11 1 Bin Tray 10 REP 11 14 ADJ 11 1 1 2 6 0019005A WOL Item Part 1 050K42680 2 3 EE 4 5 6 7 8 9 809 27480 10 11 050E16780 12 050K42580 13 050K42700 Parts List PL 19 5 10 00 5 82 Initial Issue Phaser 790 DocuColor 2006 PL 19 6 Sorter Support Item Part Description 1 Cart Assembly Not Spared 2 Cart Base Assembly Spared 3 Cart Base Spared 4 Rear Cart Support Spared 5 Lower Cart Support Not Spared 6 Cart Side Spared 7 Mounting Bracket Not Spared 8 001E58350 Sorter Rail 9 Rail Plate Spared 10 Harness Not Spared 11 017E94420 Caster 12 Docking Interlock Not Spared REP 11 15 13 Label Not Spared 14 802 14341 0019006A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 83 PL 19 6 Common Hardware BD 158W27655 Screw BE 158W27855 Screw Item Part Description BF 158W28055 Screw A 102W27651 Screw BG 158W28255 Screw B 102W28251 Screw BH 158W28655 Screw C 102W2845
95. Press the Item Enter button A3 Forward Clutch Forward Clutch On L 24 VDC 10 6 4 The following menu items become available and pressing the Up Arrow or Down Arrow 14 Reverse Clutch Reverse Clutch On L 24 VDC 10 6 button will toggle the display to scroll through them Duplex Nip Solenoid Duplex Nip Solenoid Push L 24 10 5 CTRL VAL SET selecting this item allows you to select menu items and set or reset A6 Duplex Nip Solenoid Duplex Nip Solenoid Pull L 24 10 5 the values for Ihe parameters sis shown in he Table 1 BO Takeaway Clutch Tray Takeaway Clutch L 24 VDO 83 LIFE COUNT SET selecting this item allows you to select menu items and view the 2 current value of the counters shown in the Table 3 LIFE COUNT RESET selecting this item allows you to select menu items and B1 Takeaway Clutch Tray Takeaway Clutch On L 24 VDC 8 4 change the value of the counters shown in the Table 3 B Press the Item Enter button when the desired selection is displayed in order to make a B2 Lift Up Clutch Tray 2 Lift Up Clutch On L 24 VDC 7 8 selection B3 Lift Up Clutch Tray 3 Lift Up Clutch On L 24 VDC 5 set up IOT parameters press the Item Enter button when CTRL VAL SET is dis B4 Turn Clutch Tray 2 Turn Clutch 24 VDC 8 3 played Then perform the following steps B5 Turn Clutch Tray 3 Turn Clutch On L 24 VDC 84 a Pressthe Up Arrow or Down Arrow button to select the Menu Number
96. QU J71 3 P71 3 YEL YEL YEL peu LOCATING FUSER SIDE IOT SIDE POST T710002A WOL Figure 1 010 355 RAP Circuit Diagram Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 173 010 355 010 358 Fuser Fan Error RAP The Fuser Fan has failed to operate correctly A Fuser Fan rotation error has been declared Initial Actions Ensure that there are no obstructions or physical conditions that might inhibit normal fan oper ation Procedure Access the Digital Output DO test from the Control Panel Enter code 63 Press the Item Enter button The Fuser Fan rotates Y 24VDC is measured between P 111 4 and frame ground DC Common Y Go to Flag 1 and Flag 4 Check for an open circuit Repair or replace the Main Har ness PL 11 1 as required If the wiring is OK replace the MCU PWB PL 11 2 Go to Flag 1 Check for an open circuit Repair or replace the Main Harness PL 11 1 as required If the wiring is OK replace the Fuser Fan PL 9 2 NOTE By executing DO 63 and DO 65 at the same time the Fuser Fan should rotate at a higher speed From the Control Panel enter code 65 Press the Item Enter button The speed of the Fuser Fan increases Y N Less than 1 is measured between P 111 3 and frame ground DC Common Y N Go to Flag 2 Check for an open circuit Repair or replace the Main Harness PL 11 1 as required If the wiring is OK replace the MCU PWB PL 11 2 Replace th
97. Remove the supports from the Paper Handling F Paper Handling Drive Unit Drive Unit 0101020A WOL Figure 1 Removing the Paper Handling Drive Unit Initial Issue 10 00 Phaser 790 DocuColor 2006 4 15 Repairs and Adjustments REP 4 1 REP 4 2 Fuser Drive Unit Parts List on PL 10 1 Se To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 4 Switch off the machine power and disconnect the machine Power Cord Remove the Remove the Rear Cover REP 14 6 Fuser Drive Remove the Fuser Assembly REP 10 1 Unit Remove the Fuser Motor REP 4 3 Remove the LVPS REP 1 1 Remove the Fuser Drive Unit Figure 1 Replacement Removal WARNING 9 m N a CAUTION Be careful not to pinch the harness when reinstalling the Fuser Drive Unit 1 Reinstall the Fuser Drive Unit in the reverse order of removal Remove the K EP 3 Remove the five Screws 1 Remove the screw securing the Drive Clamp N 0101021A WOL Figure 1 Removing the Fuser Drive Unit Repairs and Adjustments 10 00 Initial Issue REP 4 2 4 16 Phaser 790 DocuColor 2006 REP 4 3 Fuser Motor REP 4 4 Paper Handling Motor Parts List on PL 10 1 Parts List on PL 10 1 Removal Removal WARNING WARNING To avoid personal injury or shock do not perform repair activities with the power switch To avoid personal injury or shock do not perform repair
98. SW4 on the Size Switch PWB There is 3 13 40 10 VDC from J 235 pin 2 to machine ground Y Go to Flag 1 Check the wires for an open or a short circuit to ground The wires are good Y N Repair the wires Replace the Size Switch PWB PL 13 3 Replace the MCU PWB PL 11 2 gt Table 1 Tray 2 Size Sensing Switch PWB ANALOG PAPER SIZE PAPER SIZE SW VOLTAGE OUT SW1 SW2 SW3 4 Tray Out OFF OFF OFF OFF 4 76 VDC Ledger SEF OFF ON OFF OFF 3 45 VDC A3 SEF ON OFF ON OFF 1 57 VDC Letter LEF OFF ON ON ON 2 49 VDC B5 LEF OFF ON OFF ON 3 13 VDC Legal SEF OFF OFF ON OFF 4 09 VDC A4 LEF OFF OFF ON ON 3 77 VDC B4 SEF OFF ON ON OFF 2 81 VDC Status Indicator RAPs 007 712 10 00 2 112 Initial Issue Phaser 790 DocuColor 2006 P214 P218 Fes FEEDER PWB P212 P215 P216 217 SIZE SWITCH PWB PL13 3 SIZE SWITCH VOLTAGE SEE TABLE SIZE SWITCH PWB FOR TRAY2 SIZE PWB TRAY2 amp 3 S4 REAR VIEW T707015A WOL Figure 1 007 712 RAP Circuit Diagram Initial Issue Phaser 790 DocuColor 2006 10 00 Status Indicator RAPs 2 113 007 712 007 713 Tray 3 Paper Size Not Detected RAP The Control Logic detected that the wrong size paper is feeding from Tray 3 Initial Actions Ensure t
99. Sensor 0 101007B WOL Figure 1 Removing the Environment Sensor Initial Issue 10 00 Phaser 790 DocuColor 2006 4 9 Repairs and Adjustments REP 1 8 REP 1 9 ESS PWB Parts List on PL 12 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Right Cover REP 14 9 3 Ifthe machine is equipped with a Scanner remove the 1394 PWB PL 12 1 4 Prepare to remove the ESS PWB Figure 1 1 5 Disconnect the three Remove the ESS PWB and Plate connectors 4 Remove the four screws securing the plate a CAUTION Observe the ESD Procedures when removing the ESS PWB 5 Remove the ESS PWB Figure 2 Replacement CAUTION The EPROMs at location U39 and U40 on the new ESS PWB will not be used The EPROMs from the ESS PWB removed from the machine will be installed on the new ESS PWB to main tain proper machine operation The following steps direct you to remove and replace one EPROM at a time in order to avoid a mixup of the EPROMs and possible machine malfunc tion 1 Remove the EPROM at location U39 from the old ESS PWB and install it onto the new ESS PWB at location U39 2 Remove the EPROM at location U40 from the old ESS PWB and install it onto the new ESS PWB at location U40 3 Reinstall the ESS PWB and the
100. There is between 160 and 240 ohms from pin B2 to pin B9 on J71 Y N Go to Flag 1 and Flag 2 Check for an open circuit If the wires are OK replace the Cleaner Cam Solenoid PL 8 7 Go to Flag 3 and Flag 4 Check for an open circuit Replace the Cleaner Cam Solenoid PL 8 7 If the problem continues replace the MCU PWB PL 11 2 Remove the Fuser Assembly Rotate the upper most gear on the Input Bracket Assembly PL 8 7 clockwise Both Cleaner Cam Followers raise and lower as the gear is turned Y Check the Input Bracket Assembly and the Cleaner Cam for binding or damage Clean repair or replace as required PL 8 1 PL 8 6 PL 8 7 Rotate the gear counterclockwise Both Cleaner Cam Followers lower and stay in the down position as the gear is turned Check the Input Bracket Assembly and the Cleaner Cam for binding or damage Clean repair or replace as required PL 8 1 PL 8 6 PL 8 7 Pull in on the actuator of the Cleaner Cam Solenoid as you rotate the gear counterclockwise Both Cleaner Cam Followers raise and lower as the gear is turned Y N Check the Input Bracket Assembly and the Cleaner Cam for binding or damage Clean repair or replace as required PL 8 1 PL 8 6 PL 8 7 The Belt Cleaner appears to be functioning correctly Return to the RAP that sent you here Status Indicator RAPs 10 00 009 704 2 164 Initial Issue Phaser 790 DocuColor 2006 P O BELT CLEANER ASSY P O FUSE
101. move it in the B direction to lower the ADF The ADF will raise or lower about 0 75mm with each turn of the adjustment Screw The registration marks on the Counterbalance may be used at the time of adjustment A Direction B Direction Adjustment Screw Scale 0 2050054 WOL Figure 3 Adjusting the ADF Height CAUTION If the screws are not tightened sufficiently the height of the Counterbalance may change causing document jams 3 Open the ADF and tighten the screws loosened in Figure 2 4 Repeat the checks and make sure the gap is correct ADJ 5 4 ADF Front to Rear Positioning Purpose The purpose is to adjust the right side Counterbalance make the appropriate front to back positioning of the ADF Assembly and correct skew problems Check WARNING To avoid personal injury or shock do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Lower Chute Figure 1 2 1 Loosen Open the Feeder the screw 2 Remove Lower Chute by moving the chute in the direction indicated 0105004 A WOL Figure 1 Removing the Lower Chute Initial Issue Phaser 790 DocuColor 2006 10 00 4 151 Repairs and Adjustments ADJ 5 3 ADJ 5 4 3 Remove the Entrance Tray Assembly Figure 2 5 Measure the distance from the ADF Rear Frame to
102. your PC 8 Enter the Diagnostic Mode GP 1 then wait for the Printer to initialize 2 Configuration Page GP 14 to confirm the current Printer software version 9 When DI TEST appears on the display press the Menu button until INSTALL 1394 F W is This is the software date and version number found after the heading Printer Informa displayed Do not press the Item Enter button at this time tion Controller FW Date VX XX 10 On the PC prepare the DOS window as before substituting the new filename for the NOTE At the end of this procedure another Configuration Page will be printed and the 1394 software to be downloaded Do not press the Enter key updated version of the software will be compared to the first Configuration Page printed to 11 At the Printer press the Item Enter button The Printer display will read DOWNLOAD determine that this software installation procedure was successful MODE READY TO RECEIVE 3 Connect the Printer to the PC with the parallel cable NOTE A timeout will result if the following data transfer from the PC is not performed 4 Ensure that the Printer Parallel Port is on a Press the Menu button until PORT SETUP is displayed 12 Atthe PC press the Enter key The PC display will read 1 file s copied The Control b Press the Item Enter button until PARALLEL PORT is displayed Panel on the Printer will change to display DOWNLOAD 1394 RECEIVING DATA When AAT the download is complete t Con
103. 1 Check the following Check the Developer Roll spacing ADJ 9 1 for the affected developer Clean the HV contact for the developer in question Replace the Dry Ink Cartridge if not done previously Replace the Developer Housing PL 6 2 Image Quality 10 00 103 3 6 Initial Issue Phaser 790 DocuColor 2006 IQ4 High Density RAP Initial Actions Check the end of life counters for the Dry Ink Cartridges and the Copy Print Cartridge GP 3 Replace if required Perform VisualCal If this does not resolve the problem continue with this RAP Procedure The problem involves a single color only Y N Remove the Rear Cover Observe the Dispense Clutch as a test print is being made The Dispense Clutch remains energized constantly Y N Go to the 009 340 RAP to check the functioning of the ADC Sensor Go to the 009 342 RAP to troubleshoot the Dispense Clutch Check the following Check the Developer Roll spacing ADJ 9 1 for the affected developer Clean the HV contact for the developer in question Replace the Dry Ink Cartridge PL 6 2 if not done previously Replace the Developer Housing PL 6 2 IQ5 Solid Black or other Color Sheet RAP Procedure WARNING HIGH VOLTAGE Exercise care when making the voltage check in the following step CAUTION Do not allow DO OE to run for more than 10 seconds As soon as the measurement is com plete use the DO Stop Test to cancel switch off the bias Access the Digital
104. 1 PL 13 2 Optional Feeder Assembly 2 of 9 Item Part Description 1 802 05130 Feeder Front Cover 2 802E15720 Feeder Rear Cover 3 Feeder Rear Harness Cover Spared 4 Shaft Not Spared 5 802 05191 Feeder Cover 6 802 15530 Feeder Right Cover 7 110E93440 Feeder Right Cover Interlock 1 Feeder Right Cover Interlock 2 8 162K54131 Cover Interlock Harness 9 Clamp Not Spared 10 Feeder Chute Not Spared 11 830E19490 Feeder Chute Support 12 017K92350 Caster 1 S S 1 0013002A WOL Parts List 10 00 Initial Issue PL 13 2 5 44 Phaser 790 DocuColor 2006 PL 13 3 Optional Feeder Assembly 3 of 9 Item Part Description 2 43 4 059K15182 Paper Feeder Assembly Size Switch Assembly Not Spared Bracket Not Spared 110K07040 Size Switch PWB REP 8 19 Feeder Frame Not Spared Bracket Not Spared Clamp Not Spared Clamp Not Spared Ground Contact Spring Not Spared O1 I EXPLODED ON PL13 5 PL13 6 PL13 7 0013003A WOL Initial Issue Phaser 790 DocuColor 2006 10 00 Parts List 5 45 PL 13 3 PL 13 4 Optional Feeder Assembly 4 of 9 Item Part Description 4 18 1 Feeder Frame Not Spared 2 Clamp Not Spared 3 127K28260 Feeder Motor REP 8 20 4 007K85422 Feeder Drive Unit REP 8 22 5 Bracket Not Spared 6 Stopper Not Spared 7 Stopper Not Spared 8 Harness Spared 9 160K74520 Feede
105. 1 diagonally to WITHOUT DUPLEX remove the Fuser TRAY OPTION Assembly Remove screw and remove the cover WITH DUPLEX TRAY OPTION Open the Duplex Tray REP 10 2 Main Fuser Assembly Parts List on PL 8 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Main Fuser Assembly Figure 1 Replacement 1 Reinstall the Main Fuser Assembly in the reverse order of removal 2 Reset Main Fuser Assembly counter refer to Section 6 General Procedures 3 4 Remove the rear Er NOUS the screws front screw 5 Remove the Main Fuser Assembly 2 Disconnect the connectors Open the Fuser Assembly 3 Remove the screw 0110000A WOL 0110001A WOL Figure 1 Removing the Fuser Assembly Figure 1 Removing the Main Fuser Assembly Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 113 REP 10 1 REP 10 2 REP 10 3 Upper Guide Assembly Parts List on PL 8 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Upper Guide Assembly Figure 1 Replacement 1 Reinstall the Upper Guide Assembly in the reverse order of removal
106. 10 00 2 74 Initial Issue Phaser 790 DocuColor 2006 006 701 Angle Sensor RAP The Angle Sensor circuit has failed to operate correctly Initial Actions Procedure Remove the Rear Cover REP 6 4 Disconnect connector 4 130 from the ICM Main PWB 5 VDC is measured between J130 pin 2 and pin 1 on the ICM Main PWB Y Replace the ICM Main PWB PL 16 2 Reconnect connector J 130 to the ICM Main PWB 5 VDC is measured between J130 pin 2 and pin 1 Y N Go to Flag 2 Check for a short circuit to ground If the wiring is OK replace the Angle Sensor PL 16 1 Actuate the Angle Sensor The measured voltage drops to approximately 1 2 VDC or less N Go to 1 Check for an open circuit or a short circuit to ground If the wiring is OK replace the angle sensor PL 16 1 If the problem persists replace the replace the ICM Main PWB PL 16 2 The problem may be intermittent Go to Figure 1 Check for loose or damaged connections or damaged wires If the wiring is OK replace the Angle Sensor PL 16 1 Of the problem per sists replace the ICM Main PWB PL 16 2 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 75 006 701 ICM MAIN PWB PL 16 2 ANGLE SENSOR ANGLE SENSOR J 18 ACTUATED 0 5 vpo 130 GRY 2 ICM MAIN PWB PL16 2 J130 GRY GRY REAR OF ICM MAIN PWB J130 sees eee esee J130 PIN 1 PIN 11 T706002 A WOL Figure 1 006 7
107. 10 00 Initial Issue 1 2 Phaser 790 DocuColor 2006 Service Call Procedures Service Strategy The service strategy for the Phaser 790 Printer and the DC 2006 Copier Printer is to run to fail ure The Repair Analysis Procedures RAPs will be used to diagnose and repair any prob lems Problems that occur in the Basic Printer mode will be repaired before problems that occur when using the accessories Image quality problems should be repaired after all other problems are repaired Service Call Procedures The Service Call Procedures are a guide for performing any service on the Phaser 790 Printer and the DC 2006 Copier Printer The procedures are designed to be used with the Phaser 790 Printer and the DC 2006 Copier Printer Service Manual Perform each step in order Initial Actions The Initial Actions gather information about the condition of the machine and the problem that caused the service call Call Flow Call Flow summarizes the sequence of the Service Call Procedures Initial Actions Procedure Purpose The purpose of the Initial Actions section of the Service Call Procedures is to determine the reason for the service call and to identify and organize the actions which must be performed Procedure 1 Gather the information about the service call and the condition of the copier printer a Question the operator s Ask about the location of the most recent paper jams Ask about the image quality and the general perform
108. 11 2 Check the Duplex Entrance and Exit Chute for obstructions Clean the Duplex Entrance Roll and Exit Roll PL 15 3 Enter the diagnostic mode and enter DO A2 There is 0 VDC from J 141 pin 9 to ground Y N Replace the Duplex Controller PWB PL 15 6 To to Flag 3 Check the wires for an open or a short circuit to ground If the wires are good replace the Duplex Drive Clutch PL 15 4 Status Indicator RAPs 10 00 Initial Issue 008 701 2 120 Phaser 790 DocuColor 2006 DUPLEX DUPLEX CONTROLLER CONTROLLER PWB PWB PL15 6 PL15 6 1 DUPLEX 1 ENTRANCE SENSOR 01 91 PL15 3 DUPLEX 5VDC ENTRANCE 6 1 B6 ee 5 159 3 1 P159 3 145 3 SENSOR 1145 P159 J159 4155 J134 P134 5VDC J141 DECON i 1 i dg i i 2 2 2 Y 6 GRy 85 12 GRY 5 44 1813 B4 t lu Z 1 L 4 1 1 GRY GRY GRY 4 4 5VAC MCU PWB MCU PL41 2 PWB REGI STRATION PL11 2 SENSOR PL4 6 DI 29 5VDC REGISTRATION SENSED L 5VDC J93 J91 P91 J20 DC COM 2 GRY B5 B10 GRY 19 DUPLEX CONTROLLER 3 DUPLEX PWB DRIVE PL15 6 CLUTCH PL15 4 DO A2 DUPLEX DRIVE CLUTCH ON J141 L 24VDC J134 W J155 J149 P149 9 4 GRY P134 894 pu GRY 1 23b 1 1 1 1 1 1 1 I 1 154 24 2 14 COM I I
109. 11 2 Status Indicator RAPs 10 00 Initial Issue 010 705 2 188 Phaser 790 DocuColor 2006 MCU PWB EXCHANGE PL11 2 1 SOLENOID SOLENOID PL8 5 19 19 PUSH L 24vDC P71 2 Y J74 3 P74 I GRY 1 I GRY RED i i i l I 24VDC 9 21 INTERLOCKED 545 gi z 2 d lt 4 GRY GRY BLU 24 i 0 1 1 1 2 EXCHANGE SOLENOID PULL L 24VDC 21 B1 B10 x L 1 GRY GRY WHT DC COM 1 CAUTION Lo DO NOT SELECT MORE THAN ONE 1 DIAGNOSTIC CODE AT A TIME OR DAMAGE TO TH SOLENOID WILL OCCUR 2 24VDC INTERLOCK VOLTAGE IS NOT AVAILABLE WITH THE FUSER DRAWER OPEN P J71 PIN CONFIGURATION 9712 J71 1 P71 1 P71 2 1 1 171 TE 17 1 12 2 d i mm WHT BLK BLK WHT PIO 34 pr T8 222191234 18 24 p18T2 3211 P17 1 al 11 16 Joa B fa 1 1 2873 1 E nra PIS MCU PWB P20 n 8 J71B JAA P71B 1514 ao thc n n P12 M6 PU M ojja 3 X 4 816 P21 J71 4 J71 3 P71 3 P71 4 YEL YEL YEL YEL LOCATIN FUSER SIDE IOT SIDE OCATING POST POST EXCHANGE SOLENOI
110. 2 Adjust the Fuser Nip Figure 2 3 Perform the check again 1 Turn the screw at front or rear CLOCKWISE to increase or COUN TERCLOCKWISE to decrease the width of the nip 0110023A WOL to 0 3 mm Figure 2 Adjusting the Fuser Nip 0110022A WOL Figure 1 Checking the Fuser Nip Repairs and Adjustments 10 00 Initial Issue ADJ 10 1 4 164 Phaser 790 DocuColor 2006 ADJ 11 1 Sorter Bin Cam Position Purpose The purpose is to allow the Sorter Bin Cam to rise and lower the Bin Trays correctly NOTE The Front and Rear Bin Cams are virtually identical However the Rear Bin Cam has a Switch Actuator attached For this reason this adjustment procedure is written to apply to both Bin Cams When adjusting the Front Bin Cam disregard any references to the switch actuator Check WARNING To avoid personal injury or shock do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Sorter Rear Front Cover 3 Remove the rear front Bin Spring 4 Be sure that all Bin Trays are in the lowest position If they are not move them after removing the Bin Cam Assembly 5 Verify the Bin Cam positioning Figure 1 a Verify that each of the Bin Tray arms is fully inserted to the groove in the Bin Cam b Verify that the hole in the Bin Cam Shaft and t
111. 2 4 Phaser 790 DocuColor 2006 001 701 AC Power RAP Initial Actions Ensure AC Power is available at the wall receptacle Ensure the Power Cord is good Replace the Power Cord if it is defective PL 11 1 Procedure Switch off the power Remove the Rear Cover Switch on the power If AC Power is not mea sured at J34 2 to terminal N on the Low Voltage Power Supply replace the Low Voltage Power Supply PL 11 1 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 5 001 701 LOW VOLTAGE POWER SUPPLY 484 2 MAIN SWITCH ote Po N i LOW VOLTAGE POWER SUPPLY P33 BE N 2 P34 1 LOW VOLTAGE 1 35 POWER SUPPLY L T701000 A WOL Figure 1 001 701 Circuit Diagram Initial Issue Status Indicator RAPs 10 00 Phaser 790 DocuColor 2006 001 701 2 6 001 702 5 VDC Power RAP Initial Actions Ensure AC Power is available at the wall receptacle Ensure the Power Cord is good Replace the Power Cord if it is defective PL 11 1 Procedure Switch off the power Remove the Rear Cover Switch on the power 5 VDC is measured between J33 1 and J33 4 Y N Switch off the power Disconnect J32 and J33 from the Low Voltage Power Supply Switch on the power 5 VDC is measured between P33 1 and P33 4 on the Low Voltage Power Supply Y N Replace the Low Voltage Power Supply
112. 21 29 5VDC 491 91 m REGISTRATION 18 B11 4 33 SENSED 4 2 493 J91 Bs 1 91 D J20 5 1 I AUN GRY T GRY B9 B64 1 1 1 1 1 1 1 1 20 1 EN 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 SENSOR 5VDC PLAG i i 5VDC I I J98 01 27 15 B14 Bit r3 1 1 OHPSENSED i 2 498 L 82 gt L46 ea 1 DC COM LB12 B3 L1 GRY GRY MI x 17 5VDC 1708001A WOL Figure 1 008 700 RAP Circuit Diagram 1 of 2 Status Indicator RAPs 10 00 Initial Issue 008 700 2 118 Phaser 790 DocuColor 2006 REGISTRATION TRANSPORT REGISTRATION TRANSPORT REGISTRATION CLUTCH PRE REGISRATION CLUTCH REGISTRATION P10 SENSOR P16 P19 P22 P18 P14 P17 OHP SENSOR FEED CLUTCH P15 MCU PWB P20 P12 PH 23 21 9 o T708000A WOL Figure 2 008 700 RAP Circuit Diagram 2 of 2 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 119 008 700 008 701 Area 2 Jam RAP The Control Logic has detected the signal Duplex Entrance Sensor L 5 VDC or the Control Logic did not detect the signal Registration Sensed 1 5 VDC within the set time limit Initial Actions Pull out the Duplex Tray Assembly and remove all papers Open the Right Duplex Cover and remove any paper from this a
113. 28 1 P O PL 4 2 Item 15 18 Gear 12 44 P O PL 4 2 Item 15 E 19 Gear 10 20 P O PL 4 2 Item 15 6 20 Lift Motor P O PL 4 2 15 21 Motor Frame P O PL 4 2 Item 15 22 Clamp Not Spared 5 7 3 0004002A WOL Parts List 10 00 Initial Issue PL 4 2 5 16 Phaser 790 DocuColor 2006 PL 4 3 Bypass Tray Paper Transport 3017 2 13 and Item Part Description 4 4 PL4 5 1 Feed Assembly Not Spared 2 Preregistration Chute Not Spared 3 Preregistration Spring Housing Not Spared 4 Pinch Roll Not Spared 5 130E81970 Tray Empty Sensor REP 8 12 6 130E82650 Pitch Sensor REP 8 13 7 120E17680 Tray Empty Actuator 8 Preregistration Spring 2 Not Spared 9 Preregistration Spring 1 Not Spared 10 Lock Pin Not Spared 11 Tray Spring Not Spared 12 Top Frame Not Spared 13 Clamp Not Spared 0004003A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 17 PL 4 3 PL 4 4 Bypass Tray Paper Transport 4 of 7 Item Part Description 1 2 14 1 001K69743 Feed Frame Assembly 2 Stack Height Sensor Bracket P O PL 4 4 Item 1 3 130E82190 Stack Height Sensor REP 8 14 4 Bearing P O PL 4 4 Item 1 5 Friction Clutch P O PL 4 4 Item 1 6 Feed Roll P O PL 4 4 Item 1 7 Nudger Support P O PL 4 4 Item 1 8 Retard Shaft P O PL 4 4 Item 1 9 Support Shaft P O PL 4 4 Item 1 10 Retard Spring P O PL 4 4 Item 1 11 Friction Clutch P O PL 4
114. 360 Developer Fan 2 154 009 700 Toner Cartridge Detached RAP 2 156 009 701 Toner Cartridge Empty 2 158 009 702 Waste Container Full 2 160 009 703 Waste Container Detached RAP 2 162 009 704 Belt Cleaner 2 164 Fusing and Copy Transportation 010 317 Temperature Sensor Circuit Error 2 167 010 353 356 357 Fuser Low Under Temperature Condition RAP 2 168 010 354 Fuser Temperature Not Detected RAP 010 355 Fuser Overheat Error 010 358 Fan Error RAD ueri een en ennt e ce e a nr enn 010 359 Exit Chute Fan Failure sess 010 700 Area 5 teret e re A ee eee 010 701 Faulty Temperature Sensor 010 702 Faulty Entrance Sensor a a 010 703 Faulty Fuser Exit Sensor 010 704 Faulty Fuser Chute Fan RAP 010 705 Faulty Exchange Solenoid RAP Sorter 011 700 Sorter Not In Correct Position 2 191 011 701 Sorter Bin r ccepit nero cra Lorna a nri orhoi Sarr EE Sai 2 193 011 702 Sorter Cover Open RAP 2 196 011 703 Sorter Transport Jam RAP 2 198 011 704
115. 4 Reinstall the Right Cover REP 6 2 Reinstall the Left Cover REP 6 3 Replacement Reinstall the Control Panel Assembly REP 6 23 1 Perform the procedure for removal in reverse Reinstall the Platen Glass REP 6 1 Figure 1 Removing the Carriage Motor cs Qn OT d coc Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 49 REP 6 17 REP 6 18 REP 6 19 Belt Parts List on PL 16 4 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Carriage Motor REP 6 18 3 Remove the Belt Figure 1 1 Remove the Belt 0106016A WOL Figure 1 Removing the Belt REP 6 20 Lamp Parts List on PL 16 5 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Platen Glass REP 6 1 3 Move the Full rate Carriage so that it is aligned with the notches in the center of the scan ner frame 4 Remove the Lamp Figure 1 Scanner frame Notches 1 2 Remove the screw and then remove the Lamp by turning it in the direction indicated Replacement 0106017A WOL 1 Perform the procedure for removal in reverse
116. 5 WHT ORN 1 1 RTN RTN 5 5 VIO RTN 6 6 VIO 5 LAE 5 VDC 1 1 GRY 3 3 VDC RTN 7 7 E 1 1 RTN 3 3 4d 14 VDC VIO 1 1 RTN RTN PEEL IGI 8 FUSE P J T701011 A WOL Figure 1 001 712 Circuit Diagram Status Indicator RAPs 10 00 Initial Issue 001 712 2 28 Phaser 790 DocuColor 2006 002 310 IIT Control Panel Failure RAP The IIT Control Panel has failed Procedure Check the cable between the ICM Main PWB and the Control Panel for any pinched wires Check the connectors for any loose or damaged pins If the harness and connectors are good replace the Control Panel Assembly PL 16 6 002 701 Blank Garbled IOT Display RAP Initial Actions Remove the Right Cover REP 14 9 in order to check the LEDs on the ESS PWB Figure 1 LED D5 red LED should not be lit and LED D4 green LED should be lit If LED D5 is lit or is flashing replace the ESS PWB PL 12 1 Procedure The Control Panel is blank Y N Reseat the Panel Harness between the ESS PWB and the Control Panel If the problem continues replace the following components in the order listed until the problem is resolved Panel Harness PL 12 1 Control Panel PL 1 2 ESS PWB PL 12 1 NOTE The following voltage measurement is made at the solder points for J11 on the ESS PWB Refer to the Circuit Diagram for the correct location to make the measurements 5 VDC is measu
117. 5 66 PL 8 4 Fusing 4 of 7 5 33 PL 16 6 Top Cover and Control 5 67 PL 8 5 Fusing 5 of 7 5 34 PL 16 7 Control Panel Assembly a tette teet teens 5 68 Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 ADF PL 17 1 Document Exit Tray 5 69 PL 17 2 Counterbalance Drive Motor PWB 5 70 PL 17 3 Registration Feed Nudger Roll Nudger Home Sensor as Cb PL 17 4 Feeder Upper Chute Assembly Interlock Switch 5 72 PL 17 5 Feeder Lower Chute Registration 5 73 PL 17 6 Document Transport Platen 5 74 PL 17 7 Exit Roll Exit Motor Exit Sensor 58 75 PL 17 8 Platen Glass ADF Harness 5 76 Stand PL 18 1 Stand een mee ee eee di er 5 77 Sorter PL 19 1 Sorter Cover Control PWB 5 78 19 2 Motor EVPS 1 0 2 2 2 25 eere terere eene te 5 79 PL 19 3 Feed Motor LVPS 2 of 2 a ener 5 80 PL 19 4 Bin Drive Motor Lead Cam Switch 5 81 PL 19 5 Tray Support Bin 5 82 PL 19 6 Sorter Support eene nennen nennen ennt nennen nnne 5 83 Common Hardware Common Hardware
118. 5 VDC from 4 814 pin 5 to frame ground Y Disconnect P J 712 There is 5 from 4 814 pin 5 to frame ground Y Go to Flag 4 Check for a short circuit If the wire is OK replace the ADF Con trol PWB PL 17 2 Replace the ADF Registration Sensor PL 17 5 Open the Upper Chute Cover Insert a sheet of paper into the Registration Chute until it blocks the ADF Registration Sensor There is less than 1 VDC from J 814 pin 5 to frame ground Y N There is 5 VDC from pin 6 to pin 4 of J814 Y N Replace the ADF Control PWB PL 17 2 There is 5 VDC from pin 1 to pin 3 of J 712 Y N Go to Flag 5 Check for an open circuit Replace the ADF Registration Sensor PL 17 5 The Gear PL 17 3 on the outboard end of the Feed Roll REP 5 4 and the Pulley PL 17 2 on the inboard end of the Nudger Roll REP 5 5 contain one way clutches Ensures that these parts are installed correctly and that the clutch functions per the descriptions in the repair procedures The Gear and Pulley are OK Clean repair reinstall or replace as required Check the following for wear damage or dirt Drive Belts PL 17 2 Feed Roll PL 17 3 Registration Roll PL 17 3 i Retard Rolls PL 17 4 Platen Belt Bearings and Drive Gear PL 17 6 Ensure that the Nudger Chute PL 17 4 moves freely The checks are good Y N Clean repair or replace as required Go to Flag 3 Check for broken wires or loose pi
119. 9 8 L g 1 168 1 10 3 GRY GRY GRY GRY GRY GRY 5 VDC J145 1 ALIGNER SENSOR GRY J146 ALIGNER OUT SENSOR FEEDER GRY PWB 482 J211 P211 J213 J214 J241 P241 4219 13 3 2 3 3 13 3 NO PAPER SENSOR BRN BLU f GRY I I GRY 4221 TRAY 2 LOW PAPER SENSOR if m GRY RU GRY I i 1223 1 FEEDOUT SENSOR M GRY ies GRY 4215 1242 242 4220 n 3 18 8 4 NO PAPER SENSOR 1 GRY 1 1 GRY J222 2 6 1 40 6 TRAY 3 LOW PAPER SENSOR GRY GRY 4224 2 9 1 1 FEEDOUT SENSOR GRY GRY n TNR CONTINUED T728002A WOL Figure 1 5 VDC 2 of 3 Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 27 5 VDC Wirenet 3 of 3 5 3 OF 3 WIRENET CONTINUED NM ERE ERE FEEDER PWB 1216 2231 3 NUDGER SENSOR 4232 42 4 NUDGER SENSOR GRY J217 J235 34 SIZE SWITCH ASSEMBLY BLU 1 1 9236 4 6 SIZE SWITCH ASSEMBLY BLU 5 VDC T728003A WOL Figure 1 5 VDC 3 of 3 Wiring Data 10 00 Initial Issue 7 28 Phaser 790 DocuColor 2006 24 VDC Interlocked Wirenet 1 of 3 24 VDC INTERLOCKED 1 OF 3 WIRENET
120. A Fault Code or message is constantly displayed N The problem is Image Quality Y The problem is in the ADF Y The problem is in the Scanner Y The problem is in the Sorter Y The problem is noise Y The problem is intermittent Go to the BSD and perform a resis tance check of the wires in question Gently pull on the wires to ensure that they are properly connected A D B C D Go to the area where the noise is being generated and troubleshoot that area If a sorter fault code is present go to the RAP associated with that fault code If a sorter message is present go to the Section 2 Fault Message RAP Cross Reference Table Check for mechanical binding Check the ADF Document Sensors for debris or damage Check that the document mechanical drives and feed rolls are free from wear dam age contamination and binding Check the paper path sensors for debris or damage Check that paper is loaded in all trays correctly Check the paper path mechanical drives and rolls for contamination glazing wear dam age or binding Go to the IQ1 Image Quality Entry RAP If a fault code is displayed go to the Fault Code RAP for the Fault Code that is displayed If a message is displayed go to the Fault Message RAP Cross Reference in Section 2 Service Call Procedures 10 00 Call Flow Procedure 1 4 Initial Issue Phaser 790 DocuColor 2006 Cleaning Procedures
121. ANGLE 28 7 DC COM SENSOR ICM MAIN PWB 330 001 APS SENSOR APS SENSOR 22 5 VDC ON H 5 330 001 77 4130 vDC 717 1 9717 47178 GY APE SENSOR DOCUMENT a 24 GRY GRY S7 47178 4717 P717 SENSED 1 5 VDC 2 2 2 1 5 222 GRY GRY 2 E 5 2 4 GRY 3 GRY 22 Es DC COM 7 T706707 A WOL Figure 1 Image Input Wiring Data 10 00 Initial Issue 7 66 Phaser 790 DocuColor 2006 6 6 CARRIAGE CONTROL 1 ICM MAIN PWB CARRIAGE PL16 2 MOTOR PL16 4 2 m mmm mmm mm IIT REGISTRATION SENSOR 3 ICM MAIN PWB PL16 2 REGISTRATION 330 100 4 SENSOR REGISTRATION SENSOR SENSED 1 5 VDC 5 6 1706708 A WOL Figure 1 Carriage Control Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 67 BSD 7 1 A B D E F G H J 7 1 TRAY 1 PAPER SUPPLY 1 OF 2 PAPER SIZE SWITCH ASSY PL3 1 1 TRAY 1 SENSOR AND SWITCHES PS Sees swt D A 1 c Sw2 4BIT Y SIZE SWITCH ANALOG SENSED J102 VOLTAGE J16 29 2 GRY SWA 1 1 1 322772 3 27 GRY 2
122. An image defect that has an appearance similar to a horizontal traffic light The marks usually appear in a group of four and each mark is a different primary color arranged in this sequence yellow magenta cyan and black Replace the Copy Print Cartridge PL 5 1 Front to Rear Density Variation The uneven development of toner on the copy or print from one area to another Typically this results in change in density from front to rear and sometimes from lead edge to trail edge Go to the IQ17 RAP Fuser Offset Random or repeating spots or patches of toner with a corresponding set of white spots where toner has been lifted from the print Go to the IQ18 RAP High Frequency Bands Repeating 1 2 mm interval bands that are most noticeable in low density 20 30 halftone areas of the copy These bands run perpendicular to process direction Go to the IQ16 RAP High Image Density A condition that results when too much toner of a single color or combination of colors is developed on the copy or print This results in darker copies or prints for the single color toner or the color that results from the combination of colors Go to 104 Hollow Spots These defects are small usually black ring shaped defects with hollow centers They may be round or irregular and may appear randomly on lead edge trail edge or in center of page Go to the IQ18 RAP Irregular Streak or Deletion in Process Direc
123. Assembly REP 8 26 4 Remove the Sensor Bracket REP 7 2 WARNING Use extreme care when working in the vicinity of the exposed metal frame parts The edges of the parts may be very sharp and could cause serious injury 5 Remove the Feed Roll Figure 1 1 See WARNING Insert your hand in the opening provided for the Tray 1 Assembly and unhook and remove the Feed Roll 0108004A WOL Figure 1 Removing the Feed Roll Replacement 1 Perform the procedure for removal in reverse NOTE Install the Feed Roll in accordance with the rotation direction indicated by the arrow on the side of the Feed Roll Repairs and Adjustments REP 8 1 REP 8 2 10 00 Initial Issue Phaser 790 DocuColor 2006 REP 8 3 Feed Roll Assembly Replacement Parts List on PL 3 3 1 Perform the procedure for removal in reverse Removal 2 When installing verify that the Feed Gear teeth are stopped by the armature of the Feed Solenoid WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine Switch off the machine power and disconnect the machine Power Cord Remove the Rear Cover Assembly REP 14 6 Remove the HVPS REP 1 2 Remove the Paper Handling Drive Assembly REP 4 1 Remove the Feed Solenoid REP 8 5 Remove the Sensor Bracket REP 7 2 Remove the Feed Roll REP 8 2 WARNING Use extreme care when working in the vicinity of the expos
124. Assembly 6 of 9 Item Part Description 1 Feed Bracket P O PL 13 5 Item 1 2 Rear Frame P O PL 13 5 Item 1 3 121K23790 Takeaway Clutch REP 8 24 4 Nudger Lever P O PL 13 5 1 5 Lever Plate P O PL 13 5 Item 1 6 Gear P O PL 13 5 Item 1 7 Stopper P O PL 13 5 Item 1 8 Link P O PL 13 5 Item 1 9 Front Frame P O PL 13 5 Item 1 10 Takeaway Roll P O PL 13 5 Item 1 11 121K21560 Nudger Solenoid REP 8 25 12 Spring P O PL 13 5 Item 1 13 Clamp P O PL 13 5 Item 1 14 Bearing P O PL 13 5 Item 1 15 Turn Clutch P O PL 13 5 Item 1 REP 8 26 16 Clamp P O PL 13 5 Item 1 17 Gear P O PL 13 5 Item 1 18 Gear P O PL 13 5 Item 1 19 Bearing P O PL 13 5 Item 1 TO PL13 5 17 14 TO PL13 5 10 9 PL13 7 0013006A WOL Parts List 10 00 Initial Issue PL 13 6 5 48 Phaser 790 DocuColor 2006 PL 13 7 Optional Feeder Assembly 7 of 9 Item Part Description 4 5 22 1 Front Frame P O PL 13 5 1 2 2 Spring P O PL 13 5 Item 1 8 8 15 3 Lower Chute P O PL 13 5 Item 1 4 Lower Frame Assembly P O PL 13 5 Item 1 5 Lower Frame P O PL 13 5 Item 1 6 Retard Lever P O PL 13 5 Item 1 7 Spring P O PL 13 5 Item 1 8 Retard Assembly P O PL 13 5 Item TO PL13 5 1 ITEM 9 Retard Shaft P O PL 13 5 Item 1 10 Retard Support P O PL 13 5 1 11 059K08840 Retard Roll 12 Shaft P O PL 13 5 Item 1 13 Friction Clu
125. B1 p GRY GRY S BIS GRY INTERLOCK DI 2B 2 491 91 9201 5 PITCH SENSED 9 A6 pm 9 6 L 5VDC 2 J204 P201 7 8 J201 J91 7 8 91 GRY GRY GRY 8 1 7 8 6 1708701A WOL Figure 1 Bypass Tray Feeding Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 77 BSD 8 3 A TRAY 2 85 B 8 3 TRAY 2 PAPER FEEDING TRAY2 PAPER FEED MECHANISM FEEDING EM NEN EN TRAY 2 73 PAPER STACK POSITIONED FEEDER PWB PL13 4 11 DO B6 NUDGER SOLENOID ASSY 214 ON D 24 J241 Y GRY 24VDC DCCOM INTERLOCKED P 24VDC GRY DO B4 TURN CLUTCH ASSY ON L 24 VDC GRY 24VDC NTERLOCKED GRY DO B0 TAKEAWAY CLUTCH ASSY ON L 24 VDC GRY 24VDC NTERLOCKED GRY FEED OUT SENSOR PL13 5 J T 1 1 1 T 1 1 1 L 1 1 1 1 1 1 T 2 J228 P241 9241 DI A6 PAPER FEED OUT SENSED L 5 VDC TRAY 2 FEED PAPER FEEDER PWB PL13 4 5VDC ud GRY Figure 1 Tray 2 Paper Feeding GRY TRAY 2 PAPER
126. BSD 3 6 Sorter Communication Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 53 3 7 FOREIGN INTERFACE 1 FOREIGN ESS PWB INTERFACE PL12 1 5 VDC J17 COMMUNICATION LINE 7905 P905 3 YEL YEL YEL 2 RS422 9 6 RETURN 1 1 GRY GRY GRY Al 3 3 COMMUNICATION LINE 5 RECEIVER r9 YEL CR15 x E TE 4 Pt RETURN tal 3 GRY GRY 1 GRY rd 5 VDC TP L7 4 L8 GRY l 8 DC COM 2 5 VDC E E GND L4 2 DECOM J GN YL 4 FOREIGN INTERFACE PRESENT 1 5 VDC lant 10 YEL VIO 1 DC COM 5 6 1703707 A WOL Figure 1 BSD 3 7 Foreign Interface Wiring Data 10 00 Initial Issue 7 54 Phaser 790 DocuColor 2006 4 1 MAIN DRIVE CONTROL DRIVE MOTOR PWB FUSER MOTOR MCU PWB PL10 1 PL104 1 PL14 2 448 MOTOR CLOCK 34 12 1 42 GRY d yg J1 woroRcLock 50 MOTOR CLOCK ra FUSER MOTOR DRIVE 12 11 1 2 MOT
127. Billing 6 13 GP 14 Printing a Configuration 6 14 GP 15 Printing Internal Test Patterns IOT 6 14 GP 16 Vis al Calibration ciiin 6 15 GP 17 Foreign 6 16 GP 18 Identifying Pin 1 on a Double Plug 6 16 GP 19 Diagnostic Mode 1 6 17 GP 20 Setting IIT Parameters 6 18 GP 21 Component Control IIT 6 18 GP 22 Printing Internal Test Patterns 6 19 Product Specifications General Product 6 21 IOT Specifications 6 22 ADF Specifications 6 24 IIT Scanner Specifications 6 25 Sorner Specifications Ps 6 27 Tools and Supplies err tere cu dese UA aede dt 6 29 Product Tools and Test Patterns 6 29 Cleaning Materials 6 30 Machine Gonsumables ce e eee Da D I der d 6 30 Change Tag Index Change Tag IntroductiOn 54 2 iet eer trt eee di eter enden 6 31 Processor P Tags 6 32 Scanner 6 32 Sorter Tags 6 33 ADF teer C eoe AAT aaa
128. Check WARNING To avoid personal injury or shock do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord Using shim stock create a 1 4mm shim to use as a thickness gauge Remove the ADF Rear Cover Set the Shim in the positions indicated in Figure 1 and close the ADF Verify that the gap between the Side Guide of the Platen Glass and the frame of the Transport Assembly is 1 4 0 2 Figure 1 Shim Wa Positions Adjustment CAUTION Be sure to loosen the screws on both the left and right side Counterbalances The ADF Frame will warp if attempting to make the adjustment with the Counterbalance screws only loosened on one side 1 Open the ADF and loosen the Counterbalance screws in two places each side Figure 2 Loosen the screws 4 two on each Counterbalance 0 2050044 WOL Figure 2 Loosening the Counterbalance Mylar Frame Shim Side Guide The gap between the Shim and Mylar is between 0 and 0 2 mm 0 205003A WOL Figure 1 Verifying the Side Guide Gap 6 Ifthe gap is incorrect perform an adjustment Repairs and Adjustments 10 00 Initial Issue ADJ 5 3 4 150 Phaser 790 DocuColor 2006 2 Close the ADF and adjust the gap between the Side Guide and the Transport Assembly Frame using the adjustment screw Figure 3 a Move the screw in A direction to raise the ADF
129. Chute Fan PL 9 2 Status Indicator RAPs 10 00 010 359 2 176 Initial Issue Phaser 790 DocuColor 2006 PL9 2 EXIT CHUTE FAN MOT 2 T O P112 T710006A WOL 010 359 Status Indicator RAPs Figure 1 010 359 RAP Circuit Diagram 10 00 2 177 8 gt 518 82 2 E at SPS se 8028 75 m a ES E gt amp _ S amp Siac a d L E e e 8 5 m Xd 0 be Le amp Joo a a V 55 MCU PWB PL11 2 14 1 15 10 359 1 1 16 816 5VDC 15 Phaser 790 DocuColor 2006 Initial Issue 010 700 Area 5 Jam RAP One of the following conditions exists or was detected The Fuser Exit Sensor does not detect paper within a specified period of time after the Reg Clutch is energized The trail edge of a sheet was not detected by the Fuser Exit Sensor within a specified period of time after the lead edge was detected The Fuser Exit Sensor does not detect a sheet within a specified period of time after the Fuser Entrance Sensor detects a sheet Static Jam A sheet remains over the Fuser Entrance Sensor or the Fuser Exit Se
130. Collar P O PL 7 2 Item 1 16 Clamp P O PL 7 2 Item 1 17 Harness P O PL 7 2 Item 1 18 Retard Spring Not Spared 0007003A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 27 PL 7 3 PL 7 4 IBT 4 of 5 Item Part Description 1 2 20 1 008K91550 2 Cam Assembly 2 121K22730 2 Cam Clutch REP 9 23 3 4 19 3 Cam Assembly PL 7 4 1 4 BTR 2 Cam Sensor P O PL 7 4 8 9 15 Item 1 5 Gear Shaft P O PL 7 4 Item 1 17 18 19 6 Gear P O PL 7 4 Item 1 4 Bearing P O PL 7 4 Item 1 8 BTR Cam Assembly P O PL 7 4 Item 1 9 BTR Actuator P O PL 7 4 Item 1 10 Cam Shaft P O PL 7 4 Item 1 11 Outer Cam P O PL 7 4 Item 1 15 12 Inner BTR PL 7 4 Item 1 13 Pin P O PL 7 4 Item 1 14 Bearing P O PL 7 4 Item 1 15 Gear P O PL 7 4 Item 1 16 Bracket P O PL 7 4 Item 1 17 Torque Gear Assembly P O PL 7 4 13 Item 1 18 Gear Shaft P O PL 7 4 Item 1 N 44 19 Torque Gear P O PL 7 4 Item 1 2 20 Gear P O PL 7 4 1 20 18 0007004A WOL Parts List 10 00 Initial Issue PL 7 4 5 28 Phaser 790 DocuColor 2006 PL 7 5 IBT 5 of 5 Item Part Description 1 802K14462 2 Assembly 1 2 17 2 BTR 2 P O PL 7 5 Item 1 3 Bearing P O PL 7 5 1 4 BTR Housing P O PL 7 5 Item 1 5 Front Arm P O PL 7 5 1 6 Rear Arm P O PL 7 5 Item 1 7 BTR 2 Cleaner P O PL 7 5 Item 1 8 Support Beari
131. Connects ICM Main PWB and IIT LVPS Figure 17 151 Reverse Clutch Figure 9 101 Intermediate Connector Figure 2 Figure 7 152 Enter Clutch Figure 9 102 Size Switch Assembly Tray 1 Figure 7 153 CAB Interlock Figure 9 103 Feed Solenoid Tray 1 Figure 6 154 Intermediate Connector Figure 13 103 Feed Solenoid Tray 1 Figure 2 155 Intermediate Connector Figure 13 104 Turn Clutch Figure 6 158 Inverter Sensor Figure 9 105 Environment Sensor Figure 2 159 Intermediate Connector Figure 13 106 Low Paper Sensor Figure 2 160 Intermediate Connector Figure 13 107 Tray No paper Sensor Figure 2 161 Exit Harness Intermediate Connector Figure 8 109 Turn Chute Interlock Figure 2 163 Full Stack Sensor Figure 8 110 IIT Carriage Motor Figure 17 165 Top Exit Sensor Figure 8 111 Fuser Fan 1 Figure 8 166 Exit Chute Interlock Figure 8 112 Exit Chute Fan Figure 8 167 Full Stack Sensor Figure 8 116 Intermediate Connector Figure 1 191 Right Front Cover Interlock Figure 1 117 Fuser In Sensor Figure 8 192 Right Front Cover Interlock Figure 1 120 Connects ICM Main PWB and FLPS PWB Figure 17 193 Right Front Cover Interlock Figure 1 121 ROS Assembly Figure 5 194 Right Front Cover Interlock Figure 1 122 ROS Assembly Figure 5 195 Intermediate Connector Figure 6 123 ROS Assembly Figure 5 197 Intermediate Connector Figure 5 124 ROS Assembly Figure 5 198 Left Front Cover Interlock Figure 5 125 ROS Assembly Figure 5 199 Left Front Cover Interlock Figure 5 130 ICM Main PWB Figure 17 200 Connects
132. Diagnostic Mode IIT GP 19 3 Use the up down left and right arrow buttons to highlight the Self Diag menu and press the Select button 4 Use the up down left and right arrow buttons to highlight the Test Print menu and press the Select button The following will be displayed Color Mode Pattern 5 Use the number buttons to enter the number for the Color Mode value from Table 1 on the Color Mode amp Pattern screen 6 Use the Down Arrow button to scroll down to Pattern 7 Usethe number buttons to enter the number for the Patterns value from Table 1 8 Press the Select button 9 Press the Start button NOTE For every Color Mode 0 5 there are six possible test patterns that can be printed with the exception of Color Mode 1 Color Mode 1 is not available with Patterns 4 5 and 6 Color Modes 3 4 or 5 with Pattern 5 will yield a blank page Table 1 Menu of Test Patterns Color Mode Patterns 0 Color Test Photo 1 Grid 1 Color Photographic Paper 2 Gradation in Main Scan Direction 2 Color Print Photo 3 Gradation in Sub Scan Direction 3 B W Text Photo 4 Color Patch 4 B W Text 5 Lab Gradation 5 B W Photo 6 Gradation in Main Scan Direction Initial Issue 10 00 General Procedures and Information Phaser 790 DocuColor 2006 6 19 GP 22 General Procedures and Information 10 00 Initial Issue GP 22 6 20 Phaser 790 DocuColor 2006 General Product Specifications Product Codes The product codes ar
133. Disconnect the spring 3 9 Remove the E ring and Takeaway Clutch from the Takeaway Roll 0108041A WOL Figure 1 Removing the Takeaway Clutch Replacement 1 Perform the removal procedure in reverse REP 8 25 Nudger Solenoid Parts List on PL 13 6 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Paper Feeder Assembly REP 8 23 3 Remove the Nudger Solenoid Figure 1 1 Disconnect the connector 2 x Remove the screw and Solenoid 0108042A WOL Figure 1 Removing the Nudger Solenoid Replacement 1 Perform the removal procedure in reverse 2 Make sure the solenoid plunger is properly seated to the Link Initial Issue Phaser 790 DocuColor 2006 10 00 4 75 REP 8 24 REP 8 25 Repairs and Adjustments REP 8 26 Turn Clutch Parts List on PL 13 6 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Paper Feeder Assembly REP 8 23 3 Remove the Turn Clutch Figure 1 1 Disconnect the connector Figure 1 Removing the Turn Clutch Replacement 1 Perform the removal procedure in reverse
134. Enter button to reset the meters as required Verify that the meters have been reset by checking the Billing Meters GP 11 Initial Issue 10 00 General Procedures and Information Phaser 790 DocuColor 2006 6 9 GP5 GP6 GP 7 Changing Service Password The purpose is to change the password Procedure 1 2 3 10 Enter the Diagnostic Mode GP 1 Press the Menu button until CHANGE PASSWORD is displayed Press the Item Enter button NOTE In the following step XXXX refers to the currently assigned password The following message is displayed CHANGE PASSWORD XXXX Change the password to the new password desired then press the Item Enter button INPUT AGAIN is displayed Re enter the new password again then press the Item Enter button DONE is displayed Press the Menu button to scroll until DIAG EXIT is displayed Press the Item Enter button The following message will appear WRITING DATA PLEASE WAIT The machine will update any changes that were made in diagnostics When the update is complete the following message will appear PLEASE POWER OFF Switch off then switch on the machine power The new password will be enabled GP 8 IOT Software Installation The purpose is to load reload or upgrade IOT software relative to the MCU PWB and 1394 PWB Procedure Preparing to Download Software 1 Ensure that the software file to be downloaded resides on your PC If not copy the new software to
135. Front Mid COWet I T nu WT NM iui 4 139 REP 9 14 Developer Tie Plate 4 103 14 3 gt eder SSS A OS S 4 140 REP 9 15 Tension Lever 4 103 REP 14 4 Top Cover 4 141 REP 9 16 IBT Assembly ipu Alaz 9 12 imunu aan a e a A 4 105 jid 4 MN 9 18 Z Assembly tec te D te RD e Tete abi idet tee 4 106 20254552 enon REP 9 19 2 Cam Assembly 4 107 BEL i S a ajo Ic 5 KE i 14510 Control Panel cree sete toten E 4 145 9 22 TRO Sensor eee eee nene el ee re enel 4 111 REP 14 11 Right Lower RC 4 146 9 23 2 ede DE s 4 111 Adjustments Fusing ADJ 3 1 Hard Disk Drive Assembly nennen nennen 4 147 10 1 Fuse r Assembly ed cce t en e ende 4 113 ADJ 3 2 ESS PWB Initialization REP 10 2 Main Fuser 4 113 ADJ 5 1 ADF Side Registr
136. GRY 3 3 132 J21 J14 2 12 ROS POLYGON MOTOR GRY 1 J17 J82 2 24 4 DEVELOPER FAN DC COM GRY GRY 94 J41 f 3 3 HVPS i 9 1 9 4 9 6 9 7 451 113 1 PROCESS DRIVE ASSEMBLY 9 2 449 10 DRIVE MOTOR PWB 41 J83 J246 8 ROTARY MOTOR PWB 9 3 FEEDER PWB 32 9211 P211 J213 J214 J241 1 P241 J219 b 4 4 145 1 3 NO PAPER SENSOR 14 vo i BLU GRY GRY l i i i J221 12 112 3 L2 423 12 44 3 TRAY 2 LOW PAPER SENSOR BLU i GRY i i GRY i 4223 4 7 3 FEEDOUT SENSOR GRY GRY CONTINUED 1728010A WOL Figure 1 DC Com 4 of 5 Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 35 DC Com Wirenet 5 of 5 DC COM 5 OF 5 WIRENET CONTINUED FEEDER PWB J215 J242 P242 J220 5 GRY GRY i 4222 4 1 1 2 1 M GRY GRY 1 1 1 4224 7 1 1 9 1 7 GRY GRY J216 4231 2 1 4232 5 1 GRY J217 J235 BLU 1 4236 4 BLU J240 P240 J237 7 BLU GRY 4238 9 1 1 BLU GRY J239 13 BLU Figure 1 DC Com 5 of 5 NO PAPER SENSOR 7 4 TRAY 3 LOW PAPER SENSOR FEEDOUT SENSOR 84 NUDGER SENSOR 73 NUDGER SENSOR 74 SIZE SWITCH ASSEMBLY 73 SIZE SWITCH ASSEMBLY 74 FEEDER RIGHT COVER SWITCH 14
137. I GRY 24VDC i INTERLOCKED L 1 1 10 GRY B7 B10 24VDC INTLK T708002A WOL Figure 1 008 701 RAP Circuit Diagram 1 of 2 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 121 008 701 REGISTRATION SENSOR DUPLEX DRIVE CLUTCH DUPLEX ENTRANCE SENSOR DUPLEX TRAY BYPASS TRAY PAPER TRANSPORT 4 3 T5 o o 1 1 17 1 7 o 1 139 15 P140 P10 34 pig 18 222191254 pg 16 2T p18 13 3071 1 12 18 pi 14 16 P141 om 1 12 43 DUPLEX 5 MCU PWB B 16 15 CONTROLLER M PWB 15 nc P12 A6 PH Al P23 2 41 3 1 816 Bt p21 o o o 20 1708003A WOL Figure 2 008 701 RAP Circuit Diagram 2 of 2 Status Indicator RAPs 10 00 Initial Issue 008 701 2 122 Phaser 790 DocuColor 2006 008 702 Area 3 Jam RAP The Control Logic has detected the signal Feed Out Sensed L 5 at an incorrect time This signal can originate from the Tray 2 Feed Out Sensor or the Tray 3 Feed Out Sensor Initial Actions Open the Feeder Chute on the lower right side of the machine and remove any paper Ensure that the front and rear Feeder Chute magnets are present Check that the Feeder Chute closes completely Procedure Put a sheet of paper in the Paper Feeder for Tray 2 to cover the Feed Out Sensor Close th
138. ICM Main PWB and Control Panel PWB Figure 17 132 Intermediate Connector Figure 6 IIT 133 Sorter Intermediate Connector Figure 18 201 Sorter Receiver Sensor Figure 18 134 Intermediate Connector for Duplex Option Figure 7 Figure 9 201 Bypass Tray Intermediate Connector Figure 4 Wiring Data 10 00 Initial Issue Plug Jack Locations 7 4 Phaser 790 DocuColor 2006 Table 1 Plug Jack Location List Table 1 Plug Jack Location List Plug Jack Plug Jack Number Location Figure Number Number Location Figure Number 202 Feed Clutch Bypass Tray Figure 4 238 Feeder Right Cover Interlock 2 Figure 10 203 Empty Sensor Figure 4 239 Feeder Motor Assembly Figure 10 204 Pitch Sensor Figure 4 240 Feeder Motor Assembly Figure 10 205 Intermediate Connector Figure 4 241 Intermediate Connector Tray 2 Figure 10 206 Bypass Tray Guide Switch Figure 4 242 Intermediate Connector Tray 3 Figure 10 207 Bypass Tray Interlock Figure 2 245 Rotary Motor PWB Figure 6 208 Lift Motor Assembly Figure 4 246 Rotary Motor PWB Figure 6 209 Stack Height Sensor Figure 4 247 Rotary Motor PWB Figure 6 210 Lift Plate Sensor Figure 4 317 Control Panel Figure 3 210 SCSI Connector Figure 17 320 Connects ICM Main PWB and
139. IIT DG POWer RAP cient eie ehe E irc he en nt 2 27 007 702 Tray Open 007 703 Tray 1 Empty RAP User Interface 007 704 Tray 2 Empty 002 310 IIT Control Panel Failure 2 29 007 705 Tray 3 Empty 002 701 Blank Garbled IOT Display 2 29 007 706 Bypass Tray Empty RAP 002 702 IOT Control Panel Button LED 2 31 007 707 Paper Length Mismatch Machine Run Control 0 M E 003 310 Feeder Communications Failure 2 33 Hs 007 710 Tray 3 Lift Up 003 311 Duplex Communications Failure 2 35 007 711 Tray 1 Paper Size Not Detected 003 312 Sorter Communications Failure RAP 2 37 007 712 Tray 2 Paper Size Not Detected 0037993 eS 2 39 007 713 Tray 3 Paper Size Not Detected RAP 003 334 Foreign Interface Compatibility 2 41 y pea 003 356 IOT NVM RAM Error 7 2 43 Paper Transportation 003 400 IOT Firmware Error 2 45 008 700 Area 1 Jam RAP 003 701 Copy Print Cartridge Error 2 45 008 701 Area 2 Jam Start Print Power 008 702 Area 3 Jam RAP 008 703 Area 4 Jam RAP 004 320 Paper Handling Motor 2 47 004 322 Fuser Motor RAP
140. INSERTED L 5 VDC 4 5 NOTES 2 5 0 FAULT MESSAGE DISPLAYED WHEN SIGNAL IS H CLOSE AREA 2 e FAULT MESSAGE DISPLAYED WHEN SIGNAL IS H CLOSE AREA 4 6 FAULT MESSAGE DISPLAYED WHEN SIGNAL IS CLOSE AREA 1 T701703 A WOL Figure 1 Transport Cover Position Monitoring Wiring Data 10 00 Initial Issue 7 42 Phaser 790 DocuColor 2006 1 4 TRAY MODULE COVER POSITION MONITORING 1 FEEDER PWB PL13 4 FEEDER RIGHT COVER 2 50 INTERCOCK A FEEDER RIGHT COVER vDC PL13 2 INTERLOCK 1 CLOSED 5 P240 34 J240 L 5 VDC 2 3 BLU qi 2 BLU FEEDER RIGHT COVER D4 c1 INTERLOCK 2 i FEEDER RIGHT COVER PL13 2 INTERLOCK 2 CLOSED 1 5 p 9 BLU 3 BLU 4 5 NOTES FAULT MESSAGE DISPLAYED WHEN SIGNAL IS CLOSE AREA 3 6 1701704 A WOL Figure 1 Tray Module Cover Position Monitoring Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 43 1 5 DUPLEX MODULE POSITION MONITORING DUPLEX CONTROLLER 2 5 PWB PL15 6 21 93 2 CAB INTERLOCK CLOSED L 5 VDC GRY GRY NOTES O FAULT MESSAGE DISPLAYED WHEN SIGNAL IS H CLOSE AREA 6 5 6 T701705 A WOL Figure 1 Duplex Module Cover Position Monitoring Wiring Data 10 00 Initial Issue 7 44 Phaser 790 DocuColor 2006 1 6 IIT MAIN POWER ON LVPS PL16 1 AC SWITCH HARNE
141. If the prob lem persists replace the MCU PWB PL 11 2 Status Indicator RAPs 009 703 10 00 2 162 Initial Issue Phaser 790 DocuColor 2006 FAULT CONDITION MESSAGE MCU PWB PL11 2 1 lt TONER BOX Lunn V I P P L SENSOR DI 52 1 5VDC PL5 1 TONER BOX SET P83 J83 P116 J116 L 5VDC J22 3 1 6 1 17 INSTALL WASTE CONTAINER GRY DPE 0 GRY dam 5VDC 16 4 DC TONER BOX SENSOR P16 P19 P22 P18 P17 P15 MCU PWB P20 P12 11 RS P21 T 709005 A WOL Figure 1 009 703 RAP Circuit Diagram Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 163 009 703 009 704 Belt Cleaner RAP Initial Actions Open the Fuser Assembly Check for wear or damage to the Cleaner Cam Followers PL 8 6 Ensure that the Belt Cleaner Assembly is installed correctly and freely moves up and down Check for obvious damage to the mylar shield or cleaning blade Procedure Reinstall the Belt Cleaner Assembly and Fuser Assembly Access the Digital Output Test GP 2 Enter code 66 Listen for an audible click as the Item Enter button is pressed The Cleaner Cam Solenoid energizes N Remove the Controller Chassis REP 1 11 Disconnect J19 from the MCU PWB There is between 160 and 240 ohms from pin 13 to pin 12 on J19
142. If the problem persists or if the fault is declared for all colors proceed with this RAP Procedure The problem exists for a single color only Y N Access the Digital Output Test GP 2 Enter code 53 Press the Item Enter button Enter code 56 Press the Item Enter button The Dispense Clutch energizes Y N Access the DO Stop Test Enter code 56 Press the Item Enter button There is 24 VDC from J 55 pin 1 to frame ground N There is 24 VDC from J 55 pin 2 to frame ground Go to Flag 5 Check for an open circuit If the wire is OK replace the MCU PWB PL 11 2 Replace the Dispense Clutch PL 10 1 Access the Digital Output Test GP 2 Enter code 56 Press the Item Enter button There is less than 1 VDC from J 55 pin 1 to frame ground Y Go to Flag 4 Check for an open circuit If the wire is OK replace the MCU PWB PL 11 2 Replace the Dispense Clutch PL 10 1 Access the Digital Output Test GP 2 Enter code 53 Press the Item Enter button Enter code 21 Press the Item Enter button The Developer Clutch energizes Y N Access the DO Stop Test Enter code 21 Press the Item Enter button There is 24 VDC from J 56 pin 1 to frame ground Y There is 24 VDC from J 56 pin 2 to frame ground N Go to Flag 3 Check for an open circuit If the wire is OK replace the MCU PWB PL 11 2 Replace the Developer Clutch PL 10 1 Access the Digital Output Test GP 2 Enter code 21 Press the
143. Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 3 Plug Jack Locations Table 1 Plug Jack Location List Table 1 Plug Jack Location List Plug Jack Plug Jack Number Location Figure Number Number Location Figure Number 83 Toner Box Sensor Figure 1 139 Duplex Control PWB Figure 9 84 Intermediate Connector Figure 1 140 IIT Figure 16 85 CRUM Assembly Figure 1 140 Duplex Control PWB Figure 9 86 Erase Lamp Assembly Figure 1 141 Duplex Control PWB Figure 9 87 Cartridge Sensor Figure 5 142 Duplex Control PWB Figure 9 88 Waste Toner Sensor Figure 1 144 Duplex Control PWB Figure 9 91 IIT LVPS Figure 15 145 Aligner Sensor Figure 13 J91 Fuser Intermediate Connector Figure 4 146 Aligner Out Sensor Figure 13 P91 Fuser Intermediate Connector Figure 2 147 Inverter Motor Figure 9 93 Registration Sensor Figure 4 148 Duplex Nip Solenoid Figure 7 94 Registration Clutch Assembly Figure 4 149 Aligner Drive Clutch Figure 13 95 Preregistration Clutch Assembly Figure 4 150 Forward Clutch Figure 9 97 Intermediate Connector Figure 2 150 IIT Front Fan Figure 17 98 OHP Sensor Figure 4 150A B IIT Front Fan Intermediate Connector Figure 16 100 BTR 2 Cam Sensor Figure 2 151 IIT Rear Fan Figure 17 100
144. Item Enter button There is between 400 and 700 VDC from terminal of the HVPS to frame ground Y There is between 250VDC and 350VDC present Access the Digital Output Test GP 2 Enter code OE Press the Item Enter button There is less than 1 VDC from pin 1 to pin 13 of J 42 on the HVPS Y N Go to Flag 2 Check for an open circuit If the wire is OK replace the MCU PWB PL 11 2 Go to Flag 3 Check for an open circuit or a short circuit to ground If the wires are OK replace the HVPS PL 11 1 If the problem persists replace the MCU PWB PL 11 2 Go to Flag 3 Check for an open circuit or a short circuit to ground Go to Flag 10 Check for an open circuit If the wires are OK check the BCR connector PL 5 1 and the bias connector on the Copy Print Cartridge for damage or contamination Clean repair or replace as required If the problem persists replace the Copy Print Cartridge PL 5 1 The ADC Sensor is dirty Y N Go to Flag 1 Check for an open circuit If the wire is OK replace the ADC Sensor PL 5 1 If the problem persists replace the MCU PWB PL 11 2 Go to the 009 340 RAP Go to Flag 1 Check for an open circuit If the wire is OK replace the ADC Sensor PL 5 1 A Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 147 009 342 ADC SENSOR ASSY PL5 1 ADC ADC PWB 2 SENSOR YEL Fal 3 4 GRY J81
145. Item Enter button There is less than 1 VDC from J 56 pin 1 to frame ground A B C 1 Replace the Developer Clutch PL 10 1 WARNING HIGH VOLTAGE Exercise care when making the voltage checks in the following steps Access the Digital Output Test GP 2 Enter code OC Press the Item Enter button There is between 450 and 600 VDC from the C terminal on the HVPS to frame ground Y There is less than 1 VDC from J 42 pin 4 to frame ground Y Go to Flag 8 and Flag 10 Check for an open circuit If the wire is OK replace the MCU PWB PL 11 2 Go to Flag 9 Check for an open circuit If the wire is OK replace the HVPS PL 11 1 If the problem persists replace the MCU PWB PL 11 2 Access the DO Stop Test Enter code OC Press the Item Enter button Re access the DO Test Enter code OD Press the Item Enter button There is between 600 and 700 VAC from the C terminal on the HVPS to frame ground Y N There is less than 1 VDC from J 42 pin 3 to frame ground Y N Go to Flag 6 Check for an open circuit If the wire is OK replace the MCU PWB PL 11 2 Go to Flag 5 Check for an open circuit If the wire is OK replace the HVPS PL 11 1 If the problem persists replace the MCU PWB PL 11 2 Perform the following actions in the sequence shown Go to Flag 11 Check for an open circuit Go to Flag 1 Check for an open circuit Replace the HVPS PL 11 1 Replace the ADC Sensor PL 5 1 Re
146. J 57 Y N Go to Flag 2 Check for an open circuit or a short circuit to frame ground If the wires are OK replace the MCU PWB PL 11 2 Clean the TRO Sensor and the reflective strip on the IBT Belt If the problem persists replace the TRO Sensor PL 7 3 The problem appears to be intermittent Check Flag 1 and Flag 2 for loose connections If the wires are OK replace the TRO Sensor PL 7 3 If the condition persists replace the MCU PWB PL 11 2 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 137 009 321 TRO SENSOR PL7 3 e o ES v MCU PWB PL11 2 C DI 42 1 TRO SENSOR ON 454 L SVDC 16 2 2 gt 2 GRY E 1 13 14 j GRY 3 14 34 GRY ee P16 P19 P22 P18 Pg 15 MCU PWB P20 11 s P21 Figure 1 009 321 RAP Circuit Diagram T 709003 A WOL Status Indicator RAPs 009 321 10 00 2 138 Initial Issue Phaser 790 DocuColor 2006 009 323 Process Motor RAP Control Logic detected the signal Process Motor Fail 5VDC Procedure Access the Digital Output Test GP 2 Enter code 54 Press the Item Enter button The Pro cess Motor energizes N There is less than 1 VDC from 52 pin 2 to J 52 pin 5 on the Process Drive Unit PL 10 1 Go to 2 Check for an open circuit or a short circuit to frame ground If the wires
147. Make a print of the Test Page GP 14 As the print is being processed listen to the Rotary Motor Open the Front Door immediately after the 4th index is heard Remove the Copy Print Cartridge and examine the image on the IBT Belt The image on the belt has acceptable density Make a print of the Test Page 14 As the print is being processed open the Front Door Remove the Copy Print Cartridge and examine the image on the drum The image on the drum has acceptable density Y Switch off the power Remove the Top Cover and the Copy Print Cartridge Check the continuity between the BCR Contact PL 5 1 and terminal A on the HVPS There is continuity Y Replace the BCR Wire PL 11 1 and or the BCR Connector PL 5 1 Open the Front Cover Check the continuity between the Developer Contact Plate PL 6 1 and terminal C on the HVPS There is continuity Replace the Developer Wire PL 11 1 and or Developer Contact Plate PL 6 1 Remove the ROS Cover Reinstall the Copy Print Cartridge Check for continu ity between the machine frame and the thin strip of uncoated metal at the inboard edge of the xerographic drum There is continuity Y N Replace the Copy Print Cartridge PL 5 1 Remove the ROS Examine the window for contamination The ROS window is clean A B Y N Remove contaminants using a soft dry lint free cloth and minimal pres sure If the window is damaged replace the ROS P
148. Motor Low Speed 1 5 9 3 67 ADC Sensor ADC Solenoid On L 24 VDC 9 5 70 BTR 2 Cam Clutch 2 Clutch On L 24 _ 98 11 Rotary Motor Rotary Motor On 1 5 9 3 71 Erase Lamp Erase Lamp On H 5 VDC 9 9 17 Exchange Solenoid Exchange Solenoid Push 1 24 VDC 10 4 72 ADC Sensor ADC LED L 5 VDC 9 5 18 Exchange Solenoid Exchange Solenoid Pull L 24 VDC 110 4 74 ROS Not used z 19 Inverter Solenoid Inverter Solenoid Push L 24 VDC 10 5 75 Cartridge Sensor Cartridge Sensor On H 5 VDC 9 3 1A Inverter Solenoid Inverter Solenoid Pull L 24 VDC 10 5 77 Sorter Option Installed Start 11 2 Initial Issue 10 00 General Procedures and Information Phaser 790 DocuColor 2006 6 5 GP 2 Table 2 Digital Output Codes GP 3 Setting IOT Parameters and Life Counters DO Code Component Signal BSD Ref The purpose is to display set up and or reset the parameters stored in the NVM of the IOT 84 LVPS Energy Star On 1 1 85 Exit Chute Fan Exit Chute Fan On H 24 VDC 10 3 Procedure Inverter Motor Inverter Motor On 5 VDC 10 8 1 Enter the Diagnostic Mode GP 1 A1 Enter Clutch Enter Clutch On L 24 VDC 10 6 2 Press the Menu button until PARAM SET is displayed A2 Duplex Drive Clutch Duplex Drive Clutch On L 24 10 7 3
149. O Y N Go to Flag 2 Check for an open circuit Repair or replace the Fuser Harness PL 8 5 as required If the wiring is OK replace the Fuser Entrance Sensor PL 8 6 If the problem persists replace the MCU PWB PL 11 2 The problem may be intermittent Go to Figure 1 Check for loose or damaged connections or damaged wires If the wiring is OK replace the Fuser Entrance Sensor PL 8 6 If the problem persists replace the MCU PWB PL 11 2 Status Indicator RAPs 10 00 010 702 2 182 Initial Issue Phaser 790 DocuColor 2006 FUSER MCU PWB ENTRANCE i PL11 2 SENSOR PL8 6 DI 24 5VDC SHEET AT FUSER m ENTRANCE P76 4 J76 9711 6 L 5VDC 19 6 RED GRY GRY 5VDC ES MESSAGE CLEAR JAM IN i AREA 5 P 2 13 vr n A WHT GRY 2 2 24 A5 A6 5 BLU GRY GRY 4 DC COM 25 o o T 171 111 177 1 17770 P10 34 s 4 19 24 pig 15 32 p 17 17116 1 2873 1 P15 MCU PWB P20 15 151 P12 M6 PI AI P23 3 I B16 BI P21 o T P J71 PIN CONFIGURATION c 79 m 71 1 71 2 P a WHT BLK BLK WHT
150. O PL 8 2 Item 1 12 Nut P O PL 8 2 Item 1 13 038K85073 Lower Guide Assembly REP 10 7 14 Exit Lower Guide P O PL 8 2 Item 1 15 Actuator Stopper P O PL 8 2 Item 1 16 Fuser Exit Actuator P O PL 8 2 Item 1 17 Fuser Exit Spring P O PL 8 2 Item 1 18 Fuser Rear Cover P O PL 8 2 Item 1 19 Fuser Front Cover P O PL 8 2 1 20 038K85081 Upper Guide Assembly REP 10 3 21 Upper Guide Sub P O PL 8 2 1 22 059K15021 Pinch Rolls 23 Seal P O PL 8 2 Item 1 24 600085430 Upper Plate REP 10 4 25 Heater Wire P O PL 8 2 Item 1 26 Adjusting Screw P O PL 8 2 Item 1 0008002A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 31 PL 8 2 PL 8 3 Fusing 3 of 7 Item Part Description 20 5 9 10 1 Heater Wire P O PL 8 2 Item 1 2 7 2 Fuser Front Frame P O PL 8 2 Item 1 3 Fuser Rear Frame P O PL 8 2 10 1 4 059K15010 Pressure Roll REP 10 11 ADJ 10 1 5 013E87470 Bearing 2 Kit ADJ 10 1 6 Fuser Entry Plate P O PL 8 2 1 7 059K15030 Heat Roll ADJ 10 1 8 Fuser Nip Bearing P O PL 8 2 Item 1 9 Gear P O PL 8 2 20 10 Ring P O PL 8 2 Item 20 2 Kit 11 007E58991 Gear 12 007E60321 Gear 13 126K11330 Heat Roll Heat Lamp 220v REP 10 5 ADJ 10 1 126K11290 Heat Roll Heat Lamp 110v REP 10 5 ADJ 10 1 14 126K11340 Pressure Roll Heat Lamp 220v REP 10 6 ADJ 10 1 126 11300 Pressure Roll Heat Lamp 110v REP 10 6 ADJ 10 1 15
151. Output Test GP 2 Enter code OE Press the Item Enter button There between 400 and 600 VDC from the A terminal of the HVPS to frame ground Y Go to the 009 341 RAP to troubleshoot the BCR bias circuitry is Remove the Copy Print Cartridge Use a folded sheet of paper to block the light from the ROS Reinstall the Copy Print Cartridge Make a test print The defect remains Y N Replace the ROS PL 5 1 If the problem persists replace the MCU PWB PL 11 2 Replace the Copy Print Cartridge PL 5 1 If the problem remains replace the MCU PWB PL 11 2 Initial Issue Phaser 790 DocuColor 2006 10 00 3 7 Image Quality 104 195 IQ6 Blank or Nearly Blank Sheet RAP Initial Actions Check the end of life counters for the Dry Ink Cartridge and the Copy Print Cartridge GP 3 Replace if required Procedure WARNING HIGH VOLTAGE Exercise caution when performing the voltage checks in this procedure Remove the Rear Cover Connect the DVM between frame ground and the C terminal on the HVPS Print the Test Page GP 14 The voltage cycles between 0 VDC and roughly 500 VDC as the print is being made Y N Check the ROS for debris or dirt blocking the window Replace the ROS PL 5 1 Print the Test Page GP 14 After the third time that the Rotary Motor indexes open the Front Door Remove the Copy Print Cartridge There is a partial toner image on the drum Y N Go to the 009 342 RAP to troubleshoot th
152. P2 SN1 DO C2 MID SPEED I EE E DO C1 HIGH SPEED RED SWITCHED SORTER 4 CH DO C0 MOTOR MOTOR 5 VDC 3 Y 135 PET SORTER MOTOR YEL ON H 24 VDC 9 x DC COM VIO MOT DC COM GRY TRA DC COM L3 gt SORTER ERE J1 J9 SENSOR J3 SORTER J5 CONTROL PWB J10 J2 6 25 JZ m SORTER MOTOR Initial Issue Phaser 790 DocuColor 2006 10 00 2 199 Status Indicator RAPs 011 704 Sorter Noise RAP There is noise emanating from the Sorter at power up Procedure There is 5 VDC between J 8 10 of the Sorter Control PWB and GND Y There is 5 VDC between J35 4 of the Low Voltage Power Supply and GND Replace the LVPS PL 11 1 Go to Flag 1 Check for an open circuit Replace the Sorter Control PWB PL 19 1 Status Indicator RAPs 011 704 10 00 2 200 Initial Issue Phaser 790 DocuColor 2006 SORTER CONTROL Low PL194 VOLTAGE 4 POWER 1 SUPPLY TA PL11 1 P35 135 P133 4133 Pe J8 4 10 10 1 i 5 VDC 5 VDC J1 J9 J3 SORTER J5 CONTROL PWB J10 tn 42 6 JT O SORTER CONTROL PWB T711C Figure 1 011 704 RAP Circuit Diagram Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 201 011 704 011 705 Full Sensor RAP The Sorter Control
153. PL 11 2 Y N There is 24 VDC from J 33 pin 7 to J 33 pin 8 on the Low Voltage Power Replace the Rotary Sensor PL 6 1 Supply Rotate the Rotary Frame until the actuator is no longer blocking the Rotary Sensor Less than Go to the 001 703 RAP 1 VDC is measured Y N Go to Flag 1 Check for an open circuit There is 5 VDC from J 58 pin 1 to J 58 pin 3 on the Rotary Sensor Y N There is 5 VDC from pin 5 to pin 4 on J 245 Go to Flag 2 Check for an open circuit If the wires are OK replace the MCU PWB Y N PL 11 2 Go to Flag 4 Check for an open circuit If the wires are OK replace the MCU I PWB PL 11 2 There is less than 1 VDC from P58 pin 2 to P58 pin 3 Y N Switch off the power Connect the DVM from pin 2 to pin 4 on J 245 Switch on the Replace the Rotary Sensor PL 6 1 power Monitor the voltage as the power on selftest executes The voltage is 5 VDC when power is switched on and drops to less than 1 VDC for approxi Go to Flag 3 Check for an open circuit If the wire is OK replace the MCU PWB PL mately 5 seconds 11 2 Y N Go to Flag 6 Check for an open circuit or a short circuit to ground If the wire is Check for obstructions between the Base Frame and the Rotary Frame OK replace the MCU PWB PL 11 2 Examine the Front and Rear Bearings for the Rotary Frame PL 6 1 for wear or contamination that may inhibit rotation Clean or replace as required Switch off the power Connect the DVM from pin 3 to pin 4 on J 245 Sw
154. PL19 3 SENSOR 51 gt i RED Ute b i 5 ANS A FULL 3 BLU on SENSOR gt TO STACKER TRAY TRANSMITTER 10 1 SENSOR FUSED PRINT SORTER PATH DI D1 4 SORTER R SENSED H CONTROL SN1 45 VDC SORTER CONTROL PWB 2 PWB PL19 1 PL19 1 5 VDC 2 2 2 2 BLU 5 Bi ANSOR 01 00 5 VDC PAPER 2 DO C4 48 L 5 VDC E DO C3 LOW SPEED 3 ar S DO C2 MID SPEED 24 VDC DO C1 HIGH SPEED SORTER mE i SWITCHED DO C0 MOTOR ON 1 gt MOTOR RED SORTER MOTOR 1192 45 VDC An ON H 24 VDC 2 1 DCCOM 6 4 GRY T711701 A WOL Figure 1 Sorter Transportation Wiring Data Initial Issue 10 00 7 106 Phaser 790 DocuColor 2006 BSD 11 4 11 4 BIN DRIVE CONTROL SORTER CONTROL PWB 4 PL19 1 SORTER BIN DRIVE CONTROL BIN CAM MOTOR SWITCH 24 VDC DO C6 PL19 4 01 04 SWITCHED BIN SWITCH T CLOSED L 5 VDC D ON 20 RED DC COM DO C5 BIN HOME 424VDC BIN DRIVE MOTOR SWITCH SWITCHED DOWN 1 24 VDC 2 PL19 4 01 03 BLU BIN HOME SWITCH CLOSED 1 5 VDC BRN 3 4 5 E BIN CAM BIN HOME SWITCH SWITCH 6 T711702 A WOL Figure 1 Bin Drive Control Initial Issue Wiring Data Phaser 790 DocuColor 2006 10 00 7 107
155. PWB Y N There is 24 VDC from 213 pin 1 to ground on the Feeder PWB Y Go to Flag 5 Ensure that the connectors PJ 32 PJ 211 and PJ 213 are prop erly connected Check the wires for an open or a short circuit to ground Switch off the power Disconnect the power cord Replace the Feeder PWB PL 15 4 There is 24 VDC from 217 pin 12 to ground the Feeder PWB Go to 1 and 2 Check for an open circuit or a short circuit to ground The wires are good Y Repair the wires Replace the Feeder Motor PL 13 4 Switch off the power Pull out and reinstall Tray 2 Switch on the power There is 0 VDC from PJ 217 pin 12 to ground Y N Replace the Feeder PWB PL 15 4 Switch off the power Disconnect the power cord Check the Feeder Drive Unit for worn bound or damaged gears in the Feeder Motor drive train The gears are good Replace the Feeder Drive Unit PL 15 4 Replace the Feeder Motor PL 13 4 The Lift Plate in Tray 3 moved up Y Switch off the power Disconnect the power cord Check the Feeder Drive Unit for worn bound or damaged gears in the Feeder Motor drive train The gears are good Y N Replace the Feeder Drive Unit PL 15 4 Replace the Feeder Motor PL 13 4 A There is 5 VDC from J 215 pin 5 to ground on the Feeder PWB Y Go to Flag 3 and Flag 4 Check the wires for an open circuit The wires are good Y Repair the wires Ensure tha
156. Plate 0001001A WOL Initial Issue 10 00 Parts rist Phaser 790 DocuColor 2006 5 7 PL 1 1 PL 1 2 Rear Right and Top Covers Item Part Description 1 802K25830 Right Cover REP 14 9 2 802bE05370 Right Lower Cover REP 14 11 3 Rear Cover Assembly Not Spared 4 802 05291 Rear Cover REP 14 6 5 053K91391 Filter REP 14 7 6 802 05311 Option Hinge Cover 7 802K17122 Cover Assembly REP 14 4 8 Top Cover PL 1 2 7 9 Stopper Cover P O PL 1 2 7 10 802K16990 Control Panel IOT REP 14 10 11 Right Hand Cover Spared 12 802 05331 Left Option Hinge Cover 0001002A WOL Parts List 10 00 Initial Issue PL 1 2 5 8 Phaser 790 DocuColor 2006 PL 1 3 Base Frame 1 of 2 Item Part Description 1 Base Frame Hi Assembly Not 1 2 20 and PL1 4 Spared 2 Base Frame Assembly Not 71 4 6 Spared 3 Developer Plate Not Spared REP 9 14 4 Clamp Not Spared 5 Developer Outer Seal Spared 6 DL Bracket Spared 7 DL Bracket Assembly Not Spared 8 PWB Support Not Spared 9 Developer Seal Spared 10 Connector 5P Not Spared 11 Connector 3P Not Spared 12 Connector 8P Not Spared 13 Connector 4P Not Spared 14 Bushing Not Spared 15 Bushing Not Spared 16 Frame Clamp L Not Spared 17 Frame Clamp M Not Spared 18 Frame Clamp U Not Spared 19 Clamp Not Spared 20 Rear Spared 9 0001003A WOV I
157. Rear side Remove components in the specified order E Clip Gear E Clip and Bearing Front side Remove the E Clip and Bearing See CAUTION Remove the front and rear Tension Springs 0105013A WOL Figure 3 Removing the Registration Roll Replacement 1 Perform the procedure for removal in reverse 2 Perform an ADF Side Registration adjustment ADJ 5 1 3 Perform an ADF Lead Edge Registration adjustment ADJ 5 2 Repairs and Adjustments 10 00 Initial Issue REP 5 6 4 30 Phaser 790 DocuColor 2006 REP 5 7 Document Transport Assembly Replacement Parts List on PL 17 6 1 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the ADF Front Cover 3 Remove the Document Transport Assembly Figure 1 1 Loosen the three screws retaining the Document Transport Assembly 2 Remove the Document Transport Assembly by moving it in the direction indicated 0105014A WOL Figure 1 Removing the Document Transport Assembly Perform the procedure for removal in reverse Perform an ADF Front to rear Positioning adjustment ADJ 5 4 Initial Issue 10 00 Phaser 790 DocuColor 2006 4 31 Repairs and Adjustments REP 5 7 REP 5 8 Platen Belt Parts List on PL 17 6 1 2 Removal WARNING To avoid personal injury
158. Screws 2 Remove the Rear Inverter Cover 0108052A WOL Figure 1 Removing the Rear Inverter Cover CAUTION The PWB components are highly susceptible to damage from electrostatic discharge ESD and extreme care should be used when handling these components Use of the ESD Field Service Kit is required 5 Remove the Duplex Controller PWB Figure 2 A Remove the four Screws and the Duplex Controller PWB Disconnect the connectors 0108055A WOL Figure 2 Removing the Duplex Controller PWB Replacement 1 Perform the removal procedure in reverse Repairs and Adjustments REP 8 38 Initial Issue Phaser 790 DocuColor 2006 10 00 4 86 REP 8 39 Duplex Nip Solenoid Parts List on PL 15 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 7 Remove the Duplex Nip Solenoid Figure 2 2 Disconnect the spring 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove Tray 1 Assembly REP 7 6 3 Remove the Duplex Tray Assembly REP 8 27 4 Remove the Feeder Left Cover 5 Remove the Inverter Lower Assembly REP 8 35 6 Remove the Lower Chute Figure 1 Viewed inside the front of the machine 1 1 AH Disconnect the Rel connector eleas
159. Sorter Noise 2 200 011 705 Full Sensor tre 2 202 011 706 Cannot Select Sorter 2 204 Imaging Control 016 310 Font ROM Checksum Error 2 207 016 312 ESS Hard Drive Error 2 207 016 313 ASIC Access Error RAP 016 315 ESS RAM Bank 1 RAP 016 316 ESS RAM Bank 2 RAP 016 317 ESS ROM tivo eet t Idee iere aa Bn edad reper ree pda 016 323 324 325 ESS NVM RAM Failure 2 210 016 330 331 332 333 334 335 336 Interface Error RAP 2 210 016 370 IOT to ESS Communication Failure RAP 2 211 IIT Communications 033 210 Printer Detection 7 033 211 212 IOT IIT Disconnection 033 221 222 223 224 225 226 226 227 228 IOT IIT Communication RAP 033 330 331 332 Software Error 033 340 341 342 343 344 345 350 ASIC Error 033 360 361 370 371 Memory Error 033 380 390 1394 Failure 033 921 922 930 934 935 936 937 IOT IIT Communication RAP 033 940 941 943 944 945 SCSI Error Status Indicator RAPs 10 00 Initial Issue 2 2 Phaser 790 DocuColor 2006 Fault Message RAP Cross Reference Table 1
160. Switch off the machine power and disconnect the machine Power Cord 2 Remove the Feeder Left Cover 3 Remove the Inverter Lower Assembly Figure 1 REP 8 36 Inverter Motor Parts List on PL 15 5 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Inverter Lower Assembly REP 8 35 3 Remove the Rear Inverter Cover Figure 1 1 Loosen two Screws 1 Disconnect the connector Remove the Rear Inverter Cover 0108052A WOL Loosen the thumb screws 00401030 Figure 1 Removing the Inverter Lower Assembly Figure 1 Removing the Rear Inverter Cover Replacement 1 Perform the removal procedure in reverse Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 83 REP 8 35 REP 8 36 4 Remove the Inverter Motor Figure 2 3 Disconnect the connector and remove the Inverter Motor 2 1 Remove two screws and Remove the move the bracket just far four screws enough to allow the from the motor to be removed Inverter Motor 0108053A WOL Figure 2 Removing the Inverter Motor Replacement CAUTION When installing the bracket use care not to pinch the wires between the mounting surface and the bracket or damage could occur 1 Perform the removal procedure in reverse Repairs and Ad
161. The gears are good Replace the Feeder Drive Unit PL 15 4 Replace the Feeder Motor PL 13 4 The Lift Plate in Tray 2 moved up Y Switch off the power Disconnect the power cord Check the Feeder Drive Unit for worn bound or damaged gears in the Feeder Motor drive train The gears are good Y N Replace the Feeder Drive Unit PL 15 4 Replace the Feeder Motor PL 13 4 A There is 5 VDC from J 214 pin 5 to ground on the Feeder PWB Y Go to Flag 3 and Flag 4 Check the wires for an open circuit The wires are good Y Repair the wires Ensure that PJ 241 PJ 221 and PJ 214 are properly connected Check the Nudger Solenoid linkage to the Nudger Roll for proper operation The linkage is good Y Replace the Paper Feeder Assembly for Tray 2 PL 13 3 Replace the Nudger Sensor PL 15 5 Enter diagnostic code DO B6 The Nudger Solenoid energizes Y There is 24 VDC from J 214 pin 11 to ground on the Feeder PWB Y N There is 24 VDC from 4 214 pin 10 to ground on the Feeder PWB Y N Replace the Feeder PWB PL 13 4 Go to 7 Check the wires for an open or a short circuit to ground The wires are good N Repair the wires Ensure that PJ 241 225 PJ 214 are properly con nected Inspect the Nudger Solenoid plunger for contamination Clean as required Inspect the Nudger linkage for damage or binding If damaged replace the Nudger Solenoid PL 13 6 or replace th
162. Turn Cover Stopper 0003002A WOL Initial Issue Phaser 790 DocuColor 2006 10 00 5 13 Parts List PL 3 2 PL 3 3 Tray 1 Paper Feeder 3 of 3 Item Part Description 1 Feeder Assembly Not Spared 1 2 21 2 Turn In Chute Not Spared 3 Harness Not Spared 10 n 14 4 059K14390 Roll REP 8 1 5 Turn Front Bearing Not Spared 6 Turn Gear Cover Spared 7 Turn Gear S Spared 8 Turn Gear M Spared 9 Turn Gear D Spared 10 059K04840 Feed Roll Assembly REP 8 3 11 Feed Shaft P O PL 3 3 10 12 600K73770 Feed Roll Kit REP 8 2 13 Feed Core Roll P O PL 3 3 10 14 Feed Roll Guide P O PL 3 3 10 15 Bearing Spared 16 Feed Gear Spared 17 009E71750 Feed Spring 18 110E93440 Chute Interlock 19 121K23790 Clutch REP 8 4 20 Turn Gear Shaft Not Spared 21 Bearing Spared 0003003A WOL Parts List 10 00 Initial Issue PL 3 3 5 14 Phaser 790 DocuColor 2006 PL 4 1 Bypass Tray Paper Transport 1 of 7 5 4 PLACES 13 5 46 19 Item Part Description 8 15 1 Latch Arm Not Spared EXPLODED 2 _ Paper Handling Bracket Not Spared 3 110E93440 Bypass Tray Interlock 4 001K73551 Main Paper Handling Frame Assembly REP 8 9 5 Bypass Tray Registration Assembly REP 8 6 6 050K42570 Bypass Tray Assembly 7 Nylon Washer P O PL 4 1 Item 5 PL 4 1 Item 6 8 Bypass
163. WOL Figure 1 008 706 RAP Circuit Diagram Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 133 008 706 008 707 Duplex Tray Open RAP The Control Logic did not detect a Duplex Tray Set L 5 VDC signal Initial Actions Push in the Duplex Tray Assembly Procedure Go to Flag 1 Check the wires for an open Check the pins in the connectors for proper connec tion The connector J 154 has a wire loop from J 154 pin 1 to pin 2 The connector J 154 is located in the Duplex Tray If the wires and the connectors are good replace the Duplex Con trol PWB PL 15 6 Status Indicator RAPs 10 00 Initial Issue 008 707 2 134 Phaser 790 DocuColor 2006 141 DUPLEX CONTROLLER PWB P142 Figure 1 008 707 RAP Circuit Diagram 1 DUP CONTROL PWB DUP CONTROL PL15 6 PWB P15 6 01 94 5VDC DUPLEX TRAY P134 J134 De J141 J154 P155 155 J134 P134 L 5VDC J141 I GRY 5 Es GRY 1 A 2 GRY 1 T GRE P a f DC COM S P139 P142 T708005A WOL Initial Issue Phaser 790 DocuColor 2006 10 00 2 135 Status Indicator RAPs 008 707 Status Indicator RAPs 10 00 Initial Issue 008 707 2 136 Phaser 790 DocuColor 2006 009 321 TRO Sensor RAP The TRO Sensor did not detect the IBT Belt in the home position within the specified time Procedure Access the Digital Output Test GP 2
164. Wiring Data Phaser 790 DocuColor 2006 7 47 3 1 MACHINE SELF TEST MCU PWB ESS PWB ESS FAN PL11 2 PL12 1 PL12 1 WARM AIR x RESET SWITCH 1 EEPROM U36 EEPROM U38 EEPROM U40 RAM SLOT 64MB MEMORY RAM2 SLOT 64 128 MEMORY ROM HARD DISK IDE CENTRONICS IEEE 1284 COMPATIBILITY NIBBLE ECP MODE TEST PIN JES TCP IP NETWARE ETHER TALK ETHERNET 100 TX 1 T T703702A WOL Figure 1 Machine Self Test Wiring Data 10 00 Initial Issue 7 48 Phaser 790 DocuColor 2006 A D E J 3 2 IIT MACHINE SELF TEST OPTION ICM MAIN PWB EXTENSION ADVANCED 1 PL16 2 PWB FEATURES PL16 2 MEMORY PWB PL16 1 P1 P1 i S2 SCSI 2 IPS PWB PL16 2 P1 3 RS232C DIP SWITCH 512 123456789 SCSIUE ON OFF 813 SCSI I F 4 45 IEEE 1394 514 45678 IEEE 1394 5 EEPROM 95 BATTERY BT1 6 T703701A WOL Figure 1 IIT Machine Self Test Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 49 3 3 CRUM AND BILLING MCU PW
165. Wiring Data Phaser 790 DocuColor 2006 7 71 BSD 7 3 B D E F G H 7 3 TRAY 2 PAPER SUPPLY 1 OF 2 PAPER SIZE SWITCH PWB PL13 3 TRAY 2 PAPER STACK MECHANISM D A CONVERTER 1 FEEDER PWB SIZE SWITCH ANALOG 2 4235 VOLTAGE J217 2 BU r 2 3 OPERATOR LOADED TRAY 2 PAPER 8 3 PAPER STACK POSITIONED 4 FEEDER PWB PL13 4 FEEDER x DRIVE ASSY PL13 4 DO B2 LIFT UP 24VDC CLUTCH 5 332 P211 J213 ON L 24VDC ecu Tao ORN BLU 1 1 1 1 1 1 1 1 1 1 1 1 24 1 1 1 I 1 1 1 1 24VDC 1 1 INTLK 2 3 2 BLU 6 T707702A WOL Figure 1 Tray 2 Paper Supply 1 of 2 Wiring Data 10 00 Initial Issue 7 72 Phaser 790 DocuColor 2006 7 3 TRAY 2 PAPER SUPPLY 2 OF 2 FEEDER PWB PL13 4 FEEDER PWB PL13 4 DI A4 NO PAPER SENSED J241 2 p241 H 5VDC J214 4 429 ___________ GRY GRY I 1 2 1 1 1 1 1 1 1 1 1 1 1 2241 5VDC P241 28 241 I 223 GRY 1 DC COM 18 NUDGER 1 1 I SRY SENSOR 1 1 I 1 1 1 1 DI A6 l PL13 5 1 1 NUDGER I 3 gt SENSED i 1 1 5VDC I I i 2 221 5 11 5 GRY GRY 1 I 1 1 1 1 I I I I 1 1 I 5 VDC 4221 1 1 GRY GRY 1 4 1 1 1 1 I DCCOM Ja GRY GRY LOW PAPER SENSOR DI A
166. Y F 6 Edge of copy VEN a Enter the new value and pigse Start b Press the Select button to the value has changed Figure 1 ADF Side Registration Check Table 1 Minimum Initial Maximum Remarks Settings Range 0 47h FFh 0 04mm Step 5 Perform the check again Repairs and Adjustments 10 00 Initial Issue ADJ 5 1 4 148 Phaser 790 DocuColor 2006 ADJ 5 2 ADF Lead Edge Registration Purpose The purpose is to set the Lead Edge of the document so it stops correctly in relation to the Registration Guide NOTE Verify that the Printer Registration Adjustment ADJ 8 1 on the is within specifica tion before performing this adjustment Check 1 Using the Copier Setup Test Pattern 82E8220 make two 11x17 copies with the machine Color Mode set to Black 10096 magnification and Platen Mode 2 Using the second sample copy from step 1 as the document make a copy from the ADF 3 Check the copy Verify that the distance from the lead edge to the top of Step 3 on the LE2 scale is 10 0mm x 2 5 Figure 1 b 3 2 5 LeadEdge ________ 10 20 Feed Directian
167. activities with the power switch on or electrical power applied to the machine on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Rear Cover REP 14 6 2 Remove the Rear Cover REP 14 6 3 Remove the Fuser Motor Figure 1 3 Remove the Drive Motor PWB REP 4 5 Replacement 4 Remove the Paper Handling Motor Figure 1 1 Reinstall the Fuser Motor in the reverse order of removal Replacement 3 1 Reinstall the Paper Handling Motor in the reverse order of removal Remove the Fuser Motor 2 2 Remove the v d Remove the Paper Handling Screws Motor eT Remove the Screws ao Disconnect the con nector 0101022A WOL 0101023A WOL Figure 1 Removing the Fuser Motor Figure 1 Removing the Paper Handling Motor Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 17 REP 4 3 REP 4 4 REP 4 5 Drive Motor PWB Parts List on PL 10 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Rear Cover REP 14 6 3 Remove the Drive Motor PWB Figure 1 Replacement 1 Reinstall the Drive Motor PWB in the reverse order of removal 3 Remove the Drive
168. alignment between the docking mechanism and the Docking Interlock Initial Issue 10 00 Phaser 790 DocuColor 2006 2 191 Status Indicator RAPs 011 700 SORTER CONTROL PWB PL19 1 LOW SORTER VOLTAGE CONTROL POWER PWB DOCKING SUPPLY PL19 INTERLOCK 5 VDC SM PL19 6 D DS DOCKING INTERLOCK 485 P133 J133 P8 48 J6 P6 Pio CLOSED 1 5 VDC J10 P40 Pe 6 VIO GRY 1 BLK BLK WHT 22 DC COM ce y EN E 1 BRN BRN 5 VDC aq GRN A DC COM J1 J9 SORTER JS CONTROL PWB SORTER J5 CONTROL PWB DOCKING J10 F1 F2 INTERLOCK J2 6 J7 mM 7711000 Figure 1 011 700 RAP Circuit Diagram Status Indicator RAPs 10 00 Initial Issue 011 700 2 192 Phaser 790 DocuColor 2006 011 701 Sorter Bin Jam RAP Sorter Control PWB logic did not detect paper at the Sorter Path Sensor within 600 ms the same amount of time allowed for the bins to move one level after the last sheet has left the Sorter Path Sensor Initial Actions Check the Sorter Transport Motor Belt for damage and correct tension Also check the Bin Drive Motor Assembly for broken or worn gears Procedure NOTE Prior to replacing a component unplug the connectors to the components Bin Cam Switch and Bin Drive Motor Check the connectors for broken bent and dirty pins Unplug a
169. any directory e g Temp on the hard disk NOTE Ensure that there are no other versions of the software file you intend to copy on your PC Print a Configuration Page GP 14 to confirm the current Printer software version This is the number found after the heading Engine FW Version X X XX for the MCU PWB and FW Version VX XX found after the heading 1394 IF NOTE At the end of this procedure another Configuration Page will be printed and the updated version of the software will be compared to the first Configuration Page printed to determine that this software installation procedure was successful Connect the Printer to the PC with the parallel cable Ensure that the IOT Parallel Port is on a Press the Menu button until I O PORT SETUP is displayed b Press the Item Enter button until PARALLEL PORT is displayed Use the Up and Down Arrow buttons to ensure that PARALLEL PORT ON is dis played d Press the Clear Stop button to return the machine to READY Executing the Download 1 Enter the Diagnostics mode then wait for the Printer to initialize GP 1 2 When DI TEST appears on the display press the Menu button until INSTALL MCU is displayed Do not press the Item Enter button at this time 3 PC prepare the DOS window NOTE Type the entries as shown while carefully observing the spaces or lack of spaces a Select Start Programs and MSDOS Command Prompt b in then press
170. b a P e be b ned a E Ra d 4 24 REP 8 3 Eeed Roll Assembly uuu u pt tee pn et ern Ee Eger bcp cee 4 61 REP 5 3 Counterbalance 424 REP 8 4 465 Sana Ce mapya mia Ta een 4 62 REP 5 4Ee6d ROlI uu ua Lene eere d e eee cadente Merida 4 25 REP 8 5 Solenoid ente rhet edite deban ite b benda 4 63 REP 5 5 N dger Roll 5 ionem te Cn ee een RR 4 26 REP 8 6 Bypass Tray Registration 4 64 5 6 Registration ie Miele Gi e etre i e 4 29 REP 8 7 Bypass Tray Feed 4 64 5 7 Document Transport ASSEMDIy 4 31 REP 8 8 Tray Housing uenire 4 65 REP 5 8 Platen Belt 4 32 REP 8 9 Main Paper Handling Frame Assembly 4 65 REPS IADE EXIEMOIOT 2 3 i este a rco e tr ron dva 4 33 8 10 Lift Plate 4 66 REP 5 10 ADF Exit Sensor and Exit Tray 22 20 4 34 REP 8 11 Lift Frame 4 66 REP 8 12 Tray Empty Sensor 4 67 Imaging 8 13 Pitch Sensor tette tette ttt 4 67 REP 6 1 Platen Glass 4 37 REP 8 14 Stack Height Sensor I ttes 4 68 REP 6 2 Right Cover 4 37 8 15 Preregistration 4 69 REP 6 3 Bee 4 38 8 16
171. background to light characters on dark background Press the Tools button Press the Down Arrow button to highlight Administrator menu Press the Select button Press the Down Arrow button until SelfDiag is highlighted Press the Select button The following menu is displayed Auto diag Systemdata R W 2 ClearMem Memory R W TestPrint Diag Code 10 Figure 1 below shows the Scanner Control Panel Paper Supply Copy Button R E Preset i Indicators Menu Arrow Tools Button Control Panel Buttons Screen Original Lighten top Button Type Darken Button Button Clear All Button 7 iy e ee 7T OOO 4 a DOO EU Y Contrast Dial Advanced Paper Supply Features Exit Button Start Button Selection Button Buttons Reduce Enlarge Scroll Baans 4 Numper Buttons Reduce Enlarge B justment Selection Buttons utton 0740003A WOL Figure 1 The Scanner Control Panel 1 Ensure that the Scanner display reads Ready to copy 2 While continuing to hold the 0 key press the Start button The display will reverse from 3 Press the Tools button If a diagnostic test is under way press the Exit button to stop the on going test Press the Exit button until the Choose and Press Select Administrator menu screen Initial Issue 10 00 Phaser 790 DocuColor 2006 6 17 General Procedures and Inf
172. broken wires or damaged pins at J 812 If the wires and connector are OK replace the ADF Control PWB PL 17 2 If the problem continues replace the ADF Drive Motor PL 17 2 Check for binding or damage to the one way Pulleys PL 17 2 Check for loose or damaged Belts or Pulleys PL 17 2 PL 17 3 Remove the ADF Front Cover PL 17 1 Block and unblock the Nudger Home Sensor as you monitor the voltage from J 814 pin 8 to frame ground The voltage is 5 VDC when the sor is blocked and less than 1 VDC when the sensor is not blocked Y N The voltage is always less than 1 VDC Y Disconnect P J 713 There is 5 VDC from pin 1 to pin 3 J 713 There is 5 VDC from pin 9 to pin 7 on J 814 Y Go to Flag 2 Check for a short circuit If the wires are OK replace the ADF Control PWB PL 17 2 Go to Flag 2 Check for an open circuit Replace the Nudger Home Sensor PL 17 3 Disconnect P J 713 The voltage changes to 5 VDC Y N Go to Flag 1 Check for a short circuit to ground If the wire is OK replace the ADF Control PWB PL 17 2 Replace the Nudger Home Sensor PL 17 3 A A Check that the Actuator for the Nudger Home Sensor PL 17 3 is installed correctly and is free from damage If the Actuator is OK replace the ADF Control PWB PL 17 2 Initial Issue Phaser 790 DocuColor 2006 10 00 Status Indicator RAPs 005 210 NUDGER ROLL ADF CONTROL PWB P
173. caught in the gears 2 Rei Il the Rotary Sensor in the reverse order of removal Removal einsta y i V V WARNING To avoid personal injury or shock do not perform repair activities with the power switch 2 Mr M Bus or electrical power applied to the machine Disconnect the sen 6 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Rear Cover REP 14 6 3 Remove the Fan Duct and Fan in order to access the Rotary Sensor Figure 1 4 Remove the Rotary Sensor Figure 2 1 Remove the 1 Remove the Screw 2 Remove the Fan Duct and Fan together 0109022A WOL Figure 1 Removing the Fan Duct and Developer Frame sor connector Screw Unhookthe tabs and remove the Rotary Sensor 0109011A WOL Figure 2 Removing the Rotary Sensor Initial Issue 10 00 Phaser 790 DocuColor 2006 4 99 Repairs and Adjustments REP 9 11 REP 9 12 Rotary Frame Parts List on PL 6 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine DU Or as oo 11 12 13 14 15 16 17 18 19 20 Switch off the machine power and disconnect the machine Power Cord Remove the Front Cover Assembly REP 14 1 Remove the Top Cover Assembly REP 14 4 Remove the Copy Print Cartridge REP 9 1 Remove the Tension Lever REP 9 15 Remove the Left
174. d E ERO ERR e ER V EM e 4 41 REP 1 1 LVPS 4 5 6 10 APS SOlSQI Lan L t ilu de eere tese ttes 4 42 REP 1 2 HVPS 4 5 REP 6 11 PWB BOX ino be t eie RR 4 43 REP 1 3 Top Cover Interlock n tnter nnne 4 6 6 12 BOX eben eret ier om ri hee eei a a uere 4 45 REP 1 4 Developers set ertet er Grote o CRAT OR esos 4 6 REP 6 13APS PWB3 ettet eet de Seah bel eade re edd buie 4 45 REPIS MCU PWB aem eee diremit 4 7 REP 6 14 ICM Main PWB 4 46 1 6 Right Front Cover 4 8 REP 6 15 Extension 4 47 REP 1 7 Left Front Cover Interlock 4 8 6 16 Advanced Features Memory 4 47 1 8 Environment Sensor 1000111 n 4 9 REP 6 17 Front Rear Cable 4 48 REP1 9 ESS PWB nmt biete os e ibtd edt vene ok 4 10 HEP 6 18 Carriage Motor en bate teet be tenete qatapas 4 49 REP 1 10 ESS Fan 4 11 REP 6 19 Belt 4 50 REP 1 11 Controller Chassis 4 11 6 20 e ee e o ed EUR 4 50 1 12 Communication 412 REP 6 21 Full rate Carriage 4 51 1 13 Hard Disk Drive Assembly 2 4 13 REP 6 22 FLPS PWB s
175. do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord Remove the Bypass Tray Registration Assembly REP 8 6 Remove the Main Paper Handling Frame Assembly REP 8 9 Remove the Preregistration Clutch REP 8 15 Remove the Preregistration Roll Figure 1 Qv 00 19 2 Remove the E ring gear clip and bearing 1 Remove the Bearing 9 3 je Lift the front of the Preregistration Roll remove the Roll 0108029A WOL Figure 1 Removing the Preregistration Roll Replacement 1 Perform the procedure for removal in reverse Initial Issue Phaser 790 DocuColor 2006 10 00 Repairs and Adjustments REP 8 15 REP 8 16 REP 8 17 Registration Clutch REP 8 18 Registration Rubber Roll Parts List on PL 4 7 Parts List on PL 4 7 Removal Removal WARNING WARNING To avoid personal injury or shock do not perform repair activities with the power switch To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Bypass Tray Registration Assembly REP 8 6 3 Remove the Main Paper Handling Assembly REP 8 9 4 Remove the Registra
176. good Y N Repair the wire Ensure that PJ 20 PJ 91 and PJ 98 are properly connected Replace the OHP Sensor PL 4 6 If the problem continues replace the MCU PWB PL 11 2 Actuate the OHP Sensor by placing a white piece of paper over the OHP Sensor on the Paper Transport Close the Bypass Tray Paper Transport Enter code 01 27 The display cates a 0 Y N Go to Flag 1and Flag 2 Check for an open circuit The wires are good Y N Repair the wires Ensure that the OHP Sensor is free from contamination Clean as required If the problem continues replace the OHP Sensor PL 4 6 Replace the MCU PWB PL 11 2 Status Indicator RAPs 10 00 008 706 2 132 Initial Issue Phaser 790 DocuColor 2006 MCU PWB PL11 2 1 2 MCU PWB OHP SENSOR 01 27 5VDC PL11 2 PL4 6 OHP SENSOR SENSED L 5VDC 2 298 2 J20 6 VE GRY GRY Ah J20 91 91 98 17 Y 1 812 5 1 GRY 1 1 1 I I L L 5VDC GRY s 91 GRY 152 Y DC COM 1 71 17 1 2 o PIO 34 pig 18 271912 54 p22 18 24 pig T 327 1 P14 174 16 28 E 15 MCU PWB P20 15 14 18 12 PH A Den 3 1 B16 P21 1 SENSOR BYPAS PAPER TRANSPORT T708007A
177. is interlocked and will become inter Ledger 11 x 17 inch 279 4 x 431 8 mm SEF 60 128 gsm rupted when the Sorter Top Cover is opened or when the machine switches to the Power B4 10 1 x 14 3 inch 257 0 x 364 0 mm SEF 60 128 gsm Saver Sleep mode LGL 8 5 x 14 inch 215 9 x 355 6 mm SEF 60 128 gsm 4 11 7 8 3 inch 297 x 210 LEF 60 128 gsm Sorter Capacity and Output 297 x 9 The Sorter has 10 Bi d a Stacker Tray Duri ly jobs the Sorter can sort by set or AFR Bo 2102 e Sorter has ins and a Stacker Tray During copy only jobs the y stack by page or high capacity stack mode can be selected Transparencies can be run to the LIR S ED eae S LEF Sorten gsm Side Output Tray default or run to the Stacker Tray LTR R 8 5 x 11 inch 215 9 x 279 4 mm SEF 60 128 gsm B5 LEF 6 9 x 9 8 inch 176 x 250 mm LEF 64 98 gsm In Print mode the only available tray for all outputs is the Side Output Tray Bin 1 A5 LEF 5 8 x 8 2 inch 148 x 210 mm LEF 64 98 gsm T s 8 2 5 8 inch 210 148 mm SEF n a Table 1 indicates the capacities and available modes of operation for the various output devices in the Sorter Table 2 lists the sizes and weight range for the Stacker Tray and Side Output Tray Table 3 provides this information for Bins 2 10 Table 1 Device Modes Capacity Stacker Tray Copy mode only Stack by set 500 sheets transparencies Side Output Tray Bin 1 Print mode Transparencies 100 shee
178. mi ma m m ma ma m ma ma m ma ma m m m m mms NEP m 1 97 RECLAIMED TONER 2 ZONE G3 MCU PWB PL11 2 00 711 ERASE LAMP ON 2 jn SEDE J86 NE P86 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 22 GRY 3 ZONE B1 MCU PWB 4 PL11 2 052 J 5VDC TONER BOX SET P116 2116 GRY 1 1 2 51 5 422 J116 P116 P83 bx i WASTE TONER GRY is ta DM 5 VDC GRY 12 2 24 qq 1 5 1 1 1 8 FAULT MESSAGE GRY INSTALL WASTE CONTAINER 1 1 1 6 6 FAULT MESSAGE GRY REPLACE WASTE CONTAINER 2 T709711A WOL Figure 1 Drum Cleaning and Toner Reclaim Wiring Data 10 00 Initial Issue 7 94 Phaser 790 DocuColor 2006 BSD 10 1 10 1 FUSING 1 10 2 102 H R HEATER E ES THERMOSTAT HEAT Y ps Ez gt EN Pr Es sad 10 2 P RHEATER HEAT H R 10 2 TEMPERATURE 2 97 UNFUSED PRINT 3 m m m m m m m m m um m FUSER 01 24 ENTRANCE E El AT FUSER ENTRANCE P76 J76 J71 p71 D 5VDC J19 1 88 AS GRY GRY T710700A WOL Figure 1 Fusing Initial Issue 10 00 Wiring Data Phaser 790 DocuColor
179. not warrant or represent that such documentation is complete nor does Xerox represent or warrant that it will notify or provide to such customer any future changes to this documentation Customer performed service of equipment or mod ules components or parts of such equipment may affect the warranty offered by Xerox with respect to such equipment You should consult the applicable warranty for its terms regarding customer or third party provided service If the customer services such equipment modules components or parts thereof the customer releases Xerox from any and all liability for the customer actions and the customer agrees to indemnify defend and hold Xerox harmless from any third party claims which arise directly or indirectly from such service WARNING This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruc tions documentation may cause interference to radio communica tions It has been tested and found to comply with the limits for a Class A computing device pursuant to subpart J of part 15 of FCC rules which are designed to provide reasonable protection against such interference when operated in a commercial environment Oper ation of this equipment in a residential area is likely to cause interfer ence in which case the user at his own expense will be required to correct the interference WARNING This machine contains an invisible laser Th
180. occur at a fixed interval on each print N The spots occur in the same location on every letter size print Y N The spots occur in the same location on every other letter size print or in the same location on every 11 X17 in A3 print The problem is Fuser offset Y N CAUTION Do not use a vacuum cleaner or any solvents in the following step Damage to the Belt Cleaner will result Remove the Belt Cleaner REP 9 17 Carefully clean the cleaning blade and the Mylar shield with a soft brush or a lint free cloth Brush away any accumulation of toner on the foam seal and the outside surfaces Wipe the surface of the IBT Belt with a lint free cloth If the problem continues replace the Belt Cleaner PL 7 1 Check the Fuser Nip ADJ 10 1 Check the Heat Roll and Pressure Roll for dirt damage or toner buildup Clean or replace as required PL 8 3 Check the IBT Belt for dirt or damage Clean or replace as required PL 7 2 Check the Copy Print Cartridge for dirt or damage Clean or replace as required PL 5 1 Go to the IQ16 RAP Ensure that the original is free from the defect Clean the Platen Glass and Lens Initial Issue 10 00 Phaser 790 DocuColor 2006 3 21 Image Quality 1018 Image Quality 10 00 Initial Issue 1018 3 22 Phaser 790 DocuColor 2006 4 Repairs and Adjustments Electrical 69 nc tae e dg
181. or damaged Ensure the Exit Chute is closed Procedure Access the Digital Input DI test from the Control Panel Enter code 74 Press the Item Enter button The display indicates 0 Y N Go to Flag 1 and Flag 2 Check the wires for an open circuit If the wires are good replace the Exit Chute Interlock PL 9 2 If the problem continues replace the MCU PWB PL 11 2 The problem may be intermittent Go to Flag 1 and Flag 2 and check for loose or damaged connections or damaged wires If the problem persists replace the Exit Chute Interlock PL 9 2 If the problem continues replace the MCU PWB PL 11 2 Initial Issue Phaser 790 DocuColor 2006 10 00 2 21 Status Indicator RAPs 001 709 MCU PWB EXIT CHUTE INTERLOCK PL11 2 PL9 2 0674 5 VDC EXIT CHUTE J166 P161 1 J161 CLOSED L 5 n 2 GRY 4 GRY i 2 4 5 12 GRY A DC COM 2 EXIT CHUTE INTERLOCK s P10 P16 P19 P22 P18 214 15 MCU PWB P20 12 Fes P11 P21 T701006 A WOL Figure 1 001 709 Circuit Diagram Initial Issue 10 00 2 22 Phaser 790 DocuColor 2006 Status Indicator RAPs 001 709 001 710 Area 5 Open RAP The Control Logic detected that the Fuser Drawer in not fully closed Initial Actions Perform the following Ensure that the Fuser Assembly
182. or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the ADF Front Cover 3 Remove the Document Transport Assembly REP 5 7 4 Remove the Platen Belt Figure 1 1 Loosen the front and rear screws Replacement Perform the procedure for removal in reverse Pay close attention to the following steps Align the Shaft Support Figure 2 1 Install the shaft support so its hole aligns with the raised dimple punched in the frame 0105016A WOL Figure 2 Alignment of the Shaft Support 3 Both sides of Platen Belt must be set in Pulleys as shown in Figure 3 2 Move the front and 3 rear shaft supports Remove the Platen Belt to reduce the Platen Belt tension 0105015A WOL Figure 1 Removing the Platen Belt Proper belt positioning Improper belt positioning 0105017A WOL Figure 3 Proper Alignment of the Platen Belt Repairs and Adjustments 10 00 Initial Issue REP 5 8 4 32 Phaser 790 DocuColor 2006 REP 5 9 ADF Exit Motor Replacement Parts List on PL 17 7 1 Perform the procedure for removal in reverse Pay close attention to the following steps 2 Install the motor by aligning the previously scribed mark Removal 3 sure that the belt is properly engaged with the pulley and drive gear WARNING To avoid personal injury or shock do not perform repair activiti
183. page filled with cyan dry ink at 20 density M 2096 Prints an entire 11 x 17 inch A3 page filled with magenta dry ink at 20 density Y 2096 Prints an entire 11 x 17 inch A3 page filled with yellow dry ink at 2096 density 2096 Prints an entire 11 17 inch page filled with black dry ink at 2096 density CMY 2096 Prints an entire 11 x 17 inch A3 page filled with cyan magenta and yellow dry ink at 2096 density respectively GRADATION Prints a solid pattern of densities from 096 to 10096 for cyan magenta yellow and black dry ink respectively NIP Prints a rectangular pattern filled entirely in 10096 black dry ink to use in adjusting the Fuser Nip ADJ 10 1 General Procedures and Information 10 00 Initial Issue GP 14 GP 15 6 14 Phaser 790 DocuColor 2006 GP 16 Visual Calibration The purpose is to adjust the color visually if you have color problems such as insufficient amounts of one or more colors or excessive amounts of one or more colors Procedure 1 2 3 4 10 11 12 13 Ensure that Ready is displayed on the Control Panel with no warning messages Press the Menu button until VISUALCAL is displayed Press the Item Enter button PRINT LIMITS YES is displayed Press the Item Enter button PRINTING LIMITS PAGE is displayed and after a few moments the page is delivered to the Output Tray Under normal lighting evaluate the Black Start row view the page at an angle for the best
184. present on the Front Bin Cam Release the bottom of the Bin Cam from its retaining clip 0 111012A WOL Figure 1 Removing the Front Rear Bin Cam Replacement 1 Perform the procedure for removal in reverse 2 Perform a Sorter Bin Cam Position Adjustment ADJ 11 1 Initial Issue Phaser 790 DocuColor 2006 10 00 4 135 Repairs and Adjustments REP 11 10 REP 11 11 REP 11 12 Bin Cam Switch Parts List on PL 19 4 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Rear Cover 3 Remove the Bin Cam Switch Figure 1 1 Disconnect the wires Remove the Screw and the Bin Cam Switch 0 111013A WOL Figure 1 Removing the Bin Cam Switch Replacement 1 Perform the procedure for removal in reverse REP 11 13 Bin Home Switch Parts List on PL 19 4 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Rear Cover 3 Remove the Bin Home Switch Figure 1 1 Disconnect the wires Release the locking tabs and remove the Bin Home Switch 0 111013A WOL Figure 1 Removing the Bin Home Switch Replacement 1 Perform the procedure for removal in re
185. screws and the Exit Chute 2 1 Release the locking tabs and Disconnect the remove the Duplex Exit Sensor connectors 0108067A WOL Figure 5 Removing the Duplex Exit Sensor Replacement 1 Perform the removal procedure in reverse 0108060A WOL Figure 4 Removing the Exit Chute Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 79 REP 8 29 REP 8 30 Duplex Drive Clutch Parts List on PL 15 4 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Duplex Tray Assembly REP 8 27 3 Remove the Duplex Drive Clutch Figure 1 1 Disconnect the connector Remove the Duplex Drive Clutch from the Bracket Release the wires 3 from the clamp Remove the two screws and the Bracket 0108048A WOL Figure 1 Removing the Duplex Drive Clutch Replacement 1 Perform the removal procedure in reverse REP 8 31 Front Belt Parts List on PL 15 4 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Duplex Tray Assembly REP 8 27 3 Remove the Front Cover of the Duplex Tray Assembly 4 Remove the Front Belt Figure 1
186. the Enter key The display will show gt c cd temp then press the Enter key d C Temp COPY b filename filename in this case will be the actual name of the MCU software file you intend to download e not press the Enter key 4 At the Printer press the Item Enter button The Printer will enter the Waiting state to receive data from the PC General Procedures and Information 10 00 Initial Issue GP 7 GP 8 6 10 Phaser 790 DocuColor 2006 NOTE A timeout will result if the following data transfer from the PC is not performed within 30 seconds GP 9 ESS Software Installation IOT The purpose is to load reload or upgrade ESS software 5 At the PC press the Enter key The display will read 1 file s copied The Control Panel on the Printer will display DOWNLOADING When the download is complete the Control Procedure Panel will display DOWNLOADING SUCCESSFUL Preparing to Download Software If the download was not successful the Control Panel will display the message FIRM 1 Ensure that the software file to be downloaded resides on your PC If not copy the new WARE INSTALL FAILED The procedure will have to be repeated software to CATemp 6 Switch off then switch on the printer power to exit the Diagnostics mode 7 Print a Configuration Page GP 14 to confirm the successful download of the MCU PWB NOTE Ensure that there are no other versions of the software file you intend to copy on software
187. the High Voltage Power Supply PL 11 1 If the problem continues replace the MCU PWB PL 11 2 Status Indicator RAPs 10 00 009 359 2 152 Initial Issue Phaser 790 DocuColor 2006 1 MCU PWB HIGH VOLTAGE PL11 2 MCUPWE POWER SUPPLY PL11 2 DO 0A 3 BIR PL11 1 BTR 2 BIAS 4 16 L 24 VDC 2 442 MONITOR x C GRY BTR2 12 GRY CONTROL 2 LLL BTR 2 BIAS BTR 2 CONTROL 31 dabis GRY VZ DC m IBT ASSEMBLY BTR 2 BIAS poo T4 CONTACT ROLL PL 7 2 5 RED ROLL PL 7 2 IBT BELT PL 7 2 QJ BTR 2 PL 7 5 GND CONTACT SPRING PL 7 5 FH gt 16 19 22 P18 17 NS ops MCU PWB P20 CONTACT ROLL L P12 P23 P21 BACKUP ROLL BTR 2 T 709006 A WOL Figure 1 009 359 RAP Circuit Diagram Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 153 009 359 009 360 Developer Fan RAP Control Logic detects the signal Fan Alarm L 5 VDC Procedure Access the Digital Output Test GP 2 Enter code 61 Press the Item Enter button The Developer Fan energizes Y There is 24 VDC from pin 4 to pin 1 on J 82 Y Disconnect J 82 There is 24 VDC from pin 4 to pin 1 on J 82 Go to Flag 1 Check for an open circuit If the wires are OK replace the MCU P
188. value as required h Press the Item Enter button to write the new value i Scroll the menu until DIAG EXIT is displayed then press the Item Enter button j Wait until the message PLEASE POWER OFF is displayed and then switch off and Switch on the power 4 Perform the check again Table 2 Printer Registration Items for the Parameters Default Maximum Minimum Menu No Function Value Value Value Unit 11 Side To Side Registration 8 28 244 12 10 50 mm Table 3 16 Top To Bottom Tray 1 30 64 0 0 17 mm 17 Top To Bottom Tray 2 37 64 0 0 17 mm 18 Top To Bottom Tray 3 35 64 0 0 17 mm 19 Top To Bottom Bypass Tray 28 64 0 0 17 mm 1A Top To Bottom Duplex Tray 17 64 0 0 17 mm Table 3 Minimum Value Expansion from Table 2 Menu No 11 Value 28 27 126 125 24 23 22 21 20 19 18 17 16 15 Entered Offset 3 5 mm 10 0 9 5 49 0 8 5 8 0 7 5 47 0 46 5 46 0 5 5 5 0 4 5 4 0 Value 114 13 111 10 109 108 107 106 05 104 03 102 01 Entered Offset 3 0 42 5 2 0 1 5 1 0 0 5 O 0 5 1 0 1 5 2 0 2 5 3 0 8 5 mm Value 00 255 254 253 252 251 250 249 248 247 246 245 244 Entered 1 62 1C3 164 5 6 12 8 6 10 11 C12 Offset 4 0 4 5 5 0 5 5 6 0 6 5 7 0 7 5 8 0 8 5 9 0 9 5 10 0 mm ADJ 9 1 Developer Spacing Purpos
189. when LIFE 5 Printer 1 ka 1 Not required or recommended COUNT SET is displayed The display will change to allow you to enter a menu number cacalon User Exit from the Table 3 Then perform the following steps Sensor Use the Up and Down Arrow buttons to enter a menu number from the table 6 Unused b Press the Item Enter button c display will change to show LIFE COUNT xx which represents the menu num ber you selected and also displays XXXXXXX which represents the counter value in numbers and not in Xs 8 change or reset the value of a counter press the Item Enter button when LIFE COUNT RESET is displayed The display will change to allow you to enter a menu num ber from the Table 3 Then perform the following steps a Use the Up and Down Arrow buttons to enter a menu number from the table Initial Issue 10 00 General Procedures and Information Phaser 790 DocuColor 2006 6 7 GP 3 Table 3 Life Counters GP 4 Reading or Writing to IOT NVM Menu No Function Remarks Life Reset The purpose is to read and or change the values in the IOT NVM 7 Printer 2 Value increments with each Provides a cumulative count of deactuation of the Fuser Exit the number of color separa Procedure Sensor and is multiplied by tions produced by the system 1 Enter the Diagnostic Mode GP 1 following for b w less Reset is not required or recom 2 Press the Menu button until
190. 0 GRY GRY 22 11 GRY GRY 5 VDC 5 VDC 9 GRY DC COM DC COM 1 8 GRY GRY 1 4 XX P84 CRUM CONNECTOR Figure 1 003 701 RAP Circuit Diagram P10 P14 P45 P12 P16 P19 P22 P18 P17 MCU PWB P20 P23 P11 P21 T703001 A WOL Status Indicator RAPs 003 701 10 00 2 46 Initial Issue Phaser 790 DocuColor 2006 004 320 Paper Handling Motor RAP The Control Logic detected that the Paper Handling Motor is not functioning Initial Actions Check the connectors on the Drive Motor PWB Ensure that they are correctly seated Procedure Switch off the power then switch on the power The 04 320 fault code is declared at the end of self test Go to Flag 2 and check the harness between the Drive Motor and the Paper Han dling Motor for damaged wires or connector pins If the wires are OK replace the Paper Handling Motor PL 10 1 If the problem continues replace the Drive Motor PWB PL 10 1 Access the Digital Output DO test from the Control Panel Enter code 53 Press the Item Enter button The Paper Handling Motor energizes Access the DO Stop Test from the Control Panel Enter code 53 Press the Item Enter button 5 VDC is measured between J50 2 on the Drive Motor PWB and machine
191. 0 00 Repairs and Adjustments Phaser 790 DocuColor 2006 REP 1 1 REP 1 2 REP 1 3 Top Cover Interlock Parts List on PL 11 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Top Cover Assembly REP 14 4 3 Remove the Rear Cover REP 14 6 4 Remove the Top Cover Interlock Figure 1 Replacement 1 Reinstall the Top Cover Interlock in the reverse order of removal 3 Remove the Top Cover Interlock 9 REP 1 4 Developer Fan Parts List on PL 11 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Rear Cover REP 14 6 3 Remove the Developer Fan Figure 1 Replacement CAUTION Install the Developer Fan so that the manufacturer s label on the surface faces towards the out side 1 Attach the harness securely when reinstalling the Developer Fan 2 Reinstall the Developer Fan in the reverse order of removal 3 Remove the Developer Fan 2 2 s I the Spread the fan connector duct hooks J Eu lt a 271 21 0101002A WOL 1 Figure 1 Removing the Top Cover Interlock harnes
192. 0 PL 17 6 110K07770 PL 3 1 059K14300 PL 13 5 110K07831 PL 11 1 059K14380 PL 4 7 110K10730 PL 19 4 059K14390 PL 3 3 110K10740 PL 19 1 059K14400 PL 4 7 110K10750 PL 19 4 059K14430 PL 8 4 110E93440 PL 13 2 059K15010 PL 8 3 PL 9 2 059K15021 PL 8 2 PL 4 1 059K15030 PL 8 3 PL 3 3 059K15182 PL 13 3 PL 15 6 PL 13 5 110E94380 PL 11 2 059K16181 PL 17 1 110K94420 PL 17 7 059K17250 PL 13 5 110K94790 PL 17 4 059K17851 PL 17 1 110K94900 PL 16 1 059K18960 PL 15 1 110E97970 PL 3 1 PL 15 2 110K98810 PL 11 2 059K19050 PL 15 1 113K81450 PL 5 1 PL 15 3 117E19831 PL 16 5 059K19120 PL 15 1 117K31200 PL 16 6 PL 15 5 117K31400 PL 11 1 059E90580 PL 17 3 120E12930 PL 14 3 059K91200 PL 17 7 120E17680 PL 4 3 062K09721 PL 5 1 121K21141 PL 10 1 064K91350 PL 7 2 121K21560 PL 13 6 PL 7 3 121K21570 PL 15 1 068E10210 PL 16 1 121K21821 PL 8 5 068K78200 PL 17 2 121K22250 PL 15 2 090K92740 PL 16 1 121K22260 PL 15 4 PL 17 8 121K22730 PL 7 4 105E05930 PL 19 2 121K23181 PL 12 1 105E10010 PL 16 5 121K23260 PL 10 1 105K15680 PL 11 1 121K23430 PL 4 6 105K15690 PL 11 1 PL 4 7 105K18600 PL 11 1 121K23790 PL 13 6 105K18750 PL 16 1 PL 15 6 Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 87 Part Number Index Table 1 Part Number Index Table 1 Part Number Index Part Number Part List Part Number Part List PL 15 7 P
193. 0 PL 8 2 802K16900 PL 16 6 600K85480 PL 8 3 802K16910 PL 16 6 600K85500 PL 1 1 802K16990 PL 1 2 600K85510 PL 1 1 802K17122 PL 1 2 600K85730 PL 16 4 802K17141 PL 1 1 Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 89 Part Number Index Table 1 Part Number Index Part Number Part List 802K17151 PL 1 1 802K17230 PL 18 1 802K17430 PL 7 1 PL 7 2 802K18200 PL 19 1 802K18401 PL 1 1 802K25820 PL 15 2 802K25830 PL 1 2 802K25970 PL 15 3 809E27480 PL 19 5 830E19490 PL 13 2 PL 3 2 830E56720 PL 15 5 892E19610 PL 17 1 892E19620 PL 17 1 892E19630 PL 17 1 Parts List 10 00 Initial Issue Part Number Index 5 90 Phaser 790 DocuColor 2006 General Procedures 6 General Procedures and Information GP 1 Diagnostic Mode 2 6 3 GP 2 Gomponent Control 6 4 GP Setting IOT Parameters and Life 6 6 GP 4 Reading or Writing to IOT NVM du 6 8 GP 5 Setting nire 6 9 GP 6 Initializing Data IO T 4 42 e dede sta 6 9 GP 7 Changing Service Password IOT 6 10 GP 8 IOT Software 6 10 GP 9 ESS Software Installation 6 11 GP 10 IIT Software Installation 6 12 GP 11 Checking the
194. 007 39240 PL 19 2 PL 19 4 007E51650 PL 8 4 PL 19 3 007E51660 PL 8 4 013E87470 PL 8 3 007E58991 PL 8 3 013E92760 PL 17 7 007E60300 PL 8 4 013E94561 PL 17 3 007E60321 PL 8 3 015E32720 PL 17 3 007E62620 PL 19 4 015K43080 PL 7 1 007K81110 PL 17 3 015K43090 PL 7 1 007K81980 PL 17 3 015K48720 PL 12 1 007E83141 PL 17 6 015K49580 PL 8 7 007E83250 PL 17 3 017E92060 PL 16 4 007K85070 PL 10 1 017K92350 PL 13 2 007K85080 PL 10 1 017E94420 PL 19 6 007K85422 PL 13 4 019E33881 PL 8 6 007K86440 PL 19 2 019E34500 PL 15 3 007E88100 PL 17 3 PL 15 4 007K91871 PL 17 3 019E93510 PL 17 3 008K91270 PL 19 4 019K94190 PL 2 1 008K91280 PL 19 4 019K97140 PL 14 2 008K91550 PL 7 1 PL 14 3 Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 85 Part Number Index Table 1 Part Number Index Table 1 Part Number Index Part Number Part List Part Number Part List 020E16180 PL 17 2 038K85073 PL 8 2 020E22140 PL 19 3 038K85081 PL 8 2 020E33800 PL 16 4 038K85280 PL 19 3 020E90660 PL 17 2 038K85490 PL 14 2 020E93230 PL 17 7 PL 14 3 020K93300 PL 17 2 PL 2 1 020K93310 PL 17 3 038E88420 PL 14 2 020K93320 PL 17 2 PL 14 3 020K94970 PL 16 4 041K94070 PL 16 5 021E97232 PL 15 1 041K94100 PL 16 5 022K30330 PL 17 7 042K92110 PL 7 1 022K30360 PL 17 7 048E18040 PL 16 6 022K39700 PL 17 6 048 27040 PL 19 3 022K39710 PL 17 6
195. 01 RAP Circuit Diagram Status Indicator RAPs 10 00 Initial Issue 006 701 2 76 Phaser 790 DocuColor 2006 006 702 Platen Switch RAP The Platen Switch circuit has failed to operate correctly Initial Actions Visually check to ensure that the magnet that actuates the Platen Switch is securely in place Procedure Remove the Rear Cover REP 6 4 Disconnect connector P J 719 5 VDC is measured between P J 719 pin 1 GND DC Common Go to 1 Check for an open circuit or a short circuit to ground If the wiring is OK replace the ICM Main PWB PL 16 2 Continuity is measured between J 719 pins 1 and 2 with the Platen Open Y N Replace the Platen Switch PL 16 1 An open circuit is measured between J 719 pins 1 and 2 with the Platen Closed Replace the Platen Switch PL 16 1 Go to Flag 2 Continuity is measured between J 719 pin 2 and J130 pin 10 on the ICM Main PWB Y Repair or replace the wiring as required If the problem persists replace the Platen Switch PL 16 1 If the problem still persists replace the ICM Main PWB PL 16 2 The problem may be intermittent Go to Figure 1 Check for loose or damaged connections or damaged wires If the wiring is OK replace the Angle Sensor PL 16 1 Of the problem per sists replace the ICM Main PWB PL 16 2 Initial Issue Phaser 790 DocuColor 2006 10 00 2 77 Status Indicator RAPs 006 702 ICM MAIN PWB PL16 2 MAGNET
196. 03 356 RAP Circuit Diagram Status Indicator RAPs 10 00 Initial Issue 003 356 2 44 Phaser 790 DocuColor 2006 003 400 IOT Firmware Error RAP The system detected an IOT firmware error Procedure Switch the power off then switch the power on The Fault Code occurs Y N If the problem seems to be intermittent reseat all connectors on the MCU If the problem occurs again Perform GP 8 IOT Software Installation If the problem is still not resolved replace the MCU PWB PL 11 2 Perform GP 8 IOT Software Installation If the problem continues replace the MCU PWB PL 11 2 003 701 Copy Print Cartridge Error RAP The Control Logic detected an error with the Copy Print Cartridge CRUM Initial Actions If the Copy Print Cartridge is due to be replaced refer to REP 9 1 and replace the car tridge Check the CRUM connector on the Copy Print Cartridge Ensure that the contacts are clean and not damaged Replace the Copy Print Cartridge if required PL 5 1 Procedure Perform the following Go to Flag 1 and check the connectors on the MCU PWB P J 84 and on the CRUM Con nector If the previous check is OK replace the MCU PWB PL 11 2 Initial Issue 10 00 Phaser 790 DocuColor 2006 2 45 Status Indicator RAPs 003 400 003 701 CRUM PL5 1 CRUM CONNECTOR PL5 1 MCU PWB PL11 2 lt 1 J85 P84 J84 J22 1
197. 048E52291 PL 1 1 022K57450 PL 15 2 049E48940 PL 19 2 022K57460 PL 15 3 PL 19 4 022K57470 PL 15 3 050E16780 PL 19 5 022K57481 PL 15 4 050K27592 PL 9 1 022K57500 PL 15 7 050K41980 PL 17 1 022K57510 PL 15 5 050K42110 PL 17 1 022K57520 PL 15 6 050K42172 PL 14 3 022K61790 PL 19 2 050K42460 PL 14 1 023E08500 PL 17 2 PL 14 2 023E08510 PL 17 2 050K42472 PL 2 1 023E08520 PL 17 2 050K42570 PL 4 1 023E12590 PL 19 3 050K42580 PL 19 5 023E15690 PL 17 6 050K42600 PL 13 1 023E15810 PL 17 7 PL 13 8 023E19270 PL 15 4 050K42680 PL 19 5 023E19280 PL 15 4 050K42700 PL 19 5 023E19320 PL 16 4 050K43330 PL 8 1 026E17760 PL 17 7 PL 8 4 026P63574 PL 17 1 050K43340 PL 8 1 026E74100 PL 15 1 PL 8 4 026K80571 PL 5 1 053K91391 PL 1 2 026E82620 PL 17 4 054E10561 PL 8 4 PL 17 5 054E15200 PL 4 7 PL 17 7 054E15670 PL 4 7 029E30560 PL 8 6 054K17770 PL 9 1 036K90890 PL 17 2 054K17830 PL 19 2 036K90900 PL 17 2 054K18060 PL 15 6 Parts List 10 00 Initial Issue Part Number Index 5 86 Phaser 790 DocuColor 2006 Table 1 Part Number Index Table 1 Part Number Index Part Number Part List Part Number Part List 054E84730 PL 17 4 105K18760 PL 16 1 054 87731 PL 17 7 105E92310 PL 17 5 059K04780 PL 19 3 105E94661 PL 17 7 059K04840 PL 3 3 107E06650 PL 17 3 059K08840 PL 13 7 108E93270 PL 17 2 059K13330 PL 17 7 110K07040 PL 13 3 059K1344
198. 06 5 59 PL 15 5 PL 15 6 Duplex Assembly 6 of 7 Item Part Description 1 5 Gear P O PL 15 5 Item 1 10 2 Turn P O PL 15 5 Item 1 3 Pinch Roll P O PL 15 5 Item 1 4 110E93440 Cab Interlock 15 5 Gear P O PL 15 5 Item 1 5 6 Gear P O PL 15 5 Item 1 7 Gear P O PL 15 5 Item 1 8 Gear P O PL 15 5 Item 1 9 054K18060 Baffle 10 Chute P O PL 15 5 Item 1 11 160K70540 Duplex Controller PWB REP 8 38 12 Harness P O PL 15 5 Item 1 13 Bearing P O PL 15 5 Item 1 14 Harness P O PL 15 5 Item 1 15 802 12181 Inverter Front Cover 16 121K23790 Inverter Entrance Clutch 17 Gear P O PL 15 5 Item 1 18 022K57520 Inverter Roll 19 Clamp P O PL 15 5 1 0015006A WOL Parts List 10 00 Initial Issue PL 15 6 5 60 Phaser 790 DocuColor 2006 PL 15 7 Duplex Assembly 7 of 7 Item Part Description 1 Spring P O PL 15 5 Item 1 2 Turn Baffle P O PL 15 5 Item 1 3 802 12211 Rear Inverter Cover 4 Clutch Cover P O PL 15 5 Item 1 5 Pinch Roll P O PL 15 5 Item 1 6 022K57500 Inverter Roll 7 Gear P O PL 15 5 Item 1 8 Link P O PL 15 5 Item 1 9 121K23790 Reverse Clutch Foward Clutch 10 Gear P O PL 15 5 Item 1 11 Shaft P O PL 15 5 Item 1 12 Gear P O PL 15 5 Item 1 13 Bearing P O PL 15 5 Item 1 14 Clamp P O PL 15 5 Item 1 15 Pinch Roll Shaft Pin P O PL 15 5 Item 1 13 1 0015007A WOL Initial Issue 10 00 Parts List Ph
199. 1 Ensure that the exterior of the copier printer and the adjacent area are clean Use a dry cloth or a cloth moistened with water to clean the copier printer Do not use solvents 2 Check the supply of consumables Ensure that an adequate supply of consumables is available according to local operating procedures 3 Conduct any operator training that is needed Ensure that the operator understands that the VisualCal procedure in the Operator Manual should be used to adjust the colors Ensure that the operator can perform the VisualCal procedure reference the GP 16 Visual Calibration procedure Complete the Service Log 5 Perform the following steps to make a copy of the Demonstration Original for the Cus tomer a Load Paper in Tray 1 with 8 1 2 x 11 inch A4 or 11 x 17 inch 248 Xerox COLOR Xpressions or Colotech 90 gms for the DC 2006 Copier Printer or Hammermill Laser Print 24 for the Phaser 790 b Place Test Pattern 82E13030 on the glass with the short edge of the test pattern reg istered to the left edge of the glass Select Tray 1 and make a single copy c Printa Configuration Page GP 14 d Printa test page for the printer only e Present the copies to the customer 6 155 copy credits as needed 7 Discuss the service call with the customer to ensure that the customer understands what has been done and is satisfied with the results of the service call Initial Issue Phaser 790 DocuColor 2006 10 00 S
200. 1 009 358 RAP Circuit Diagram Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 151 009 358 009 359 BTR 2 Bias RAP The output current monitor value for BTR 2 bias is outside of the allowable range Procedure There is 24 VDC from J 42 pin 10 to J 42 pin 13 on the High Voltage Power Supply Y Go to Flag 1 and Flag 5 Check for an open circuit or a short circuit to frame ground If the wires are OK replace the MCU PWB PL 11 2 Access the Digital Output Test GP 2 Enter code 0A Press the Item Enter button There is less than 1 VDC from pin 10 to pin 13 on J 42 Y N Replace the MCU PWB PL 11 2 Remove the BTR 2 Assembly PL 7 5 Check the following Check for dirt or damage to the BTR 2 Roll Ensure that the BTR 2 Cleaner is correctly installed Check for damage or corrosion on the Ground Contact Spring Clean repair or replace as required The fault code is still declared Y N The problem is resolved Remove the IBT Assembly PL 7 2 Check the following Go to Flag 4 Check for continuity Check for contamination of or damage to the Contact Roll and the Backup Roll Check for toner buildup on the IBT Belt and between the Contact Roll and the Backup Roll Clean repair or replace as required The fault code is still declared Y N The problem is resolved Go to Flag 2 Flag 3 and Flag 5 Check for an open circuit or a short circuit to ground If the wires are OK replace
201. 1 1 5 40 Phaser 790 DocuColor 2006 PL 11 2 Electrical 2 of 2 Item Part Description 1 160K75040 MCU PWB 1 5 2 160K61500 Communication PWB REP 1 12 3 110098810 Right Front Cover Interlock REP 1 6 4 110E94380 Left Front Cover Interlock REP 1 7 7 5 130K60530 Environment Sensor REP 1 8 6 162K53120 Paper Handling Contactor Harness 7 162K61050 ROS Harness 3 0011002A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 41 PL 11 2 PL 12 1 ESS Item Part Description 1 Controller Chassis Not Spared REP 1 11 2 127E81670 ESS Fan REP 1 10 3 162K42090 Panel Harness 4 160K74641 ESS PWB REP 1 9 5 144E00440 Memory 256 144E00430 Memory 128MB 144E00420 Memory 64 6 121K23181 Hard Disk Drive Assembly REP 1 13 ADJ 3 1 7 IDE Cable P O PL 12 1 Item 6 8 Hard Disk Drive P O PL 12 1 Item 6 9 Bracket Not Spared 10 P O PL 12 1 Item 12 11 Cover P O PL 12 1 Item 12 12 015K48720 Plate Assembly 13 160K69650 1394 PWBA 7 0012001A WOL Parts List 10 00 Initial Issue PL 12 1 5 42 Phaser 790 DocuColor 2006 PL 13 1 Optional Feeder Assembly 1 of 9 Item Part Description 1 Optional Feeder Assembly Not Spared 2 Optional Feeder Chassis Assembly Not Spared 3 050K42600 Paper Tray Assembly REP 7 6 EXPLODED ON PL13 2 PL13 3 PL13 4 EXPLODED ON PL13 8 PL13 9 0013001A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 43 PL 13
202. 1 2 Initial Issue Phaser 790 DocuColor 2006 10 00 2 143 Status Indicator RAPs 009 340 ADC SENSOR ASSY PL5 1 MCU PWB PL11 2 ADC PWB 4 00 72 MCU PWB ADC LED ON PL11 2 J16 L 5VDC 481 5 gt P81 GRY YEL ca I SENSED i p81 J81 VOLTAGE J16 1 3 4 20 09 340 20 67 1 1 YEL GRY ADC i ADC SOLENOID ON SOLENOID L 24VDC GRY YEL YEL GRY 1 1 1 1 YEL ADC SENSOR ASSY P10 P19 P22 P18 P14 rae P15 MCU PWB P20 P12 P11 P23 T 709002 A WOL Figure 1 009 340 RAP Circuit Diagram Status Indicator RAPs 10 00 Initial Issue 009 340 2 144 Phaser 790 DocuColor 2006 009 341 ADC Sensor Background RAP Control Logic has determined that the ADC sensor output while measuring non imaged area is higher than specification Procedure WARNING HIGH VOLTAGE Exercise care when making the voltage check in the following step CAUTION Do not allow DO OE to run for more than 10 seconds As soon as the measurement is com plete use the DO Stop Test to cancel switch off the bias Access the Digital Output Test GP 2 Enter code OE Press the Item Enter button There is between 400 and 600 VDC from the A terminal of the HVPS to frame ground Y N There is between
203. 1 Duplex Assembly 1 of 7 Item Part Description 1 42 1 Duplex Final Assembly Not Spared 2 059K18960 Inverter Upper Assembly 5 6 9 3 059K19050 Duplex Tray Assembly 4 059K19120 Inverter Lower Assembly 5 Lower Chute Assembly Not Spared 6 Lower Chute Not Spared 7 121K21570 Duplex Nip Solenoid REP 8 39 8 Spring Not Spared 9 Clamp Not Spared 10 021E97232 Cover 11 026E74100 Mounting Screws 2 EXPLODED ON PL15 2 EXPLODED ON PL15 5 PL15 6 PL15 7 EXPLODED ON PL15 3 PL15 4 0015001A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 55 PL 15 1 PL 15 2 Duplex Assembly 2 of 7 Item Part Description 1 059K18960 Inverter Upper Assembly REP 1 2 17 8 33 2 Ground Contact Spring P O PL 12 4 10 11 17 15 2 Item 1 3 Duplex Gate P O PL 15 2 Item 1 4 Bearing P O PL 15 2 Item 1 5 Gear P O PL 15 2 Item 1 6 121K22250 Inverter Solenoid 7 Gear P O PL 15 2 Item 1 8 Gear P O PL 15 2 Item 1 9 Exit Chute P O PL 15 2 Item 1 10 Exit Cover P O PL 15 2 Item 1 PL 15 2 Item 12 11 Pinch Roll P O PL 15 2 Item 1 PL 15 2 Item 12 12 802K25820 Exit Cover Assembly 13 Shaft PL 15 2 Item 1 14 Shaft P O PL 15 2 Item 1 15 Spring Latch P O PL 15 2 Item 1 16 022K57450 Exit Roll REP 8 34 17 Antistatic Brush PL 15 2 Item 1 PL 15 2 Item 12 0015002A WOL Parts List 10 00 Initial Issue PL 15 2 5 56 Phaser 790 DocuColor 2006 PL 15
204. 1 Screw BJ 158W35855 Screw D 112W27651 Screw BK 201W21251 Nut E 112W27659 Screw BL 251W15251 gt Washer F 112W27851 Screw BM 251W21251 Washer G 112W28059 Screw BN 251W24451 Washer H 112W28251 Screw BP 251W29251 Washer J 112W28451 Screw BR 252W24250 Nylon Washer K 112W35853 Screw BS 252W24350 Nylon Washer L 112L36253 Screw BT 252W26350 Nylon Washer M 113W15551 Screw BU 252W27350 Nylon Washer N 113W20457 Screw BV 252W29450 Nylon Washer P 113W20557 Screw BW 252W31450 Nylon Washer R 113W20657 Screw BX 271W28850 Dowel Pin S 113W20857 Screw BY 285W15851 Spring Pin T 113W21057 Screw BZ 285W16251 Spring Pin U 113W21257 Screw CA 285W16653 Spring Pin V 113W27451 Screw CB 285W28251 Spring Pin w 113W27551 Screw CC 285W29351 Spring Pin X 113W27651 Screw CD 354W13251 E Clip Y 113W27851 Screw CE 354W15251 E Clip Z 113W28056 Screw CF 354W19251 E Clip AA 113W28451 Screw 354W21251 E Clip AB 113W28651 Screw CH 354W21254 KL Clip AC 113W28851 Screw CJ 354W24251 E Clip AD 113W29751 Screw CK 354W24254 KL Clip AE 113W35557 Screw CL 354W26251 E Clip AF 113W35657 Screw CM 354W27251 AG 113W35851 Screw CN 354W28251 E Clip AH 113W35857 Screw CP 354W29251 E Clip AJ 113W36057 Screw CR 354W33251 E Clip AK 113W36257 Screw CS 356W29251 C Clip AL 113W36851 Screw CT 351W29250 AM 113W38257 Screw CU 351W41250 132W45050 Screw CV 251W26250 Nylon Washer AP 141W27451 Set Screw CW 252W31550 Nylon Washer AR 141W27651 Set Scre
205. 1 to notch Disconnect the Sorter Transport Motor connector release the wires from the harness and feed the wires back through the Sorter to the motor 01033101 Figure 1 Disconnecting the Motor D 1110054 Figure 3 Motor Support Positioning Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 131 REP 11 4 REP 11 5 Sensor Receiver Parts List on PL 19 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Sensor Receiver Figure 1 2 Disconnect the connector and remove the Sensor Receiver 1 Remove the screw plastic washer 0 111006A WOL Figure 1 Removing the Sensor Receiver Replacement 1 Perform the procedure for removal in reverse REP 11 6 Sensor Transmitter Parts List on PL 19 3 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Bottom Cover REP 11 2 3 Disconnect the connector Figure 1 Disconnect the connector and release the wires from the harness 0111014A WOL Figure 1 Disconnecting the Connector 4 Remove the Sensor Transmitter Figure 2 9
206. 125 1 on the ROS Y N Go to the 001 705 ROS 5 VDC Switched Voltage RAP Switch off the power Disconnect J 121 from the ROS Measure the resistance between the fol lowing plug jack pins e J 14 5 on the MCU PWB to J121 3 J14 4 on the MCU PWB to J121 4 J14 7 on the MCU PWB to 121 1 All measurements are less than 1 0 Ohm Y N Go to Flag 3 and check the wires for an open or short circuit Replace the ROS PL 5 1 If the problem continues replace the MCU PWB PL 11 2 Initial Issue 10 00 Phaser 790 DocuColor 2006 2 73 Status Indicator RAPs 006 372 LD UNIT LASER DIODE 3125 MCU PWB 111 2 ROS 5 VDC SWITCHED J14 LASER ENABLE 1121 5 3 LASER GRY CONTROL j HE LASER POWER CONTROL ge GRY 1 y VREF 2 GRY 1 1 1 1 1 1 1 1 1 1 1 1 1 POLYGON MOTOR MOTOR POLYGON MOTOR 1 dun DRIVE 1 24 VDC 114 3 GRY B 24 VDC INTERLOCKED 15 t E GRY 24 VDC dez DC COM INTERLOCKED GRY 1 PD DC COM GRY 5 5 P10 22 15 MCU PWB P18 P17 P20 P23 P21 Figure 1 006 372 RAP Circuit Diagram T706004 A WOL Status Indicator RAPs 006 372
207. 18 1015 Unfused Copy 3 18 IQ16 Repeating Bands Streaks Spots and Smears RAP 3 19 IQ17 Uneven Density Mottle 3 20 IQ18 Spots ee c eet e Uie 3 21 Initial Issue 10 00 Image Quality Phaser 790 DocuColor 2006 3 1 Image Quality 10 00 Initial Issue 3 2 Phaser 790 DocuColor 2006 101 IOT Image Quality Entry RAP The purpose of this RAP is to serve as the entrance vehicle into the Image Quality RAPs sec tion All Image Quality RAPs must be accessed through this RAP The RAP will have you evaluate the copies made during the Call Flow procedure for image quality defects It will refer you to the Image Quality Analysis RAPs the Image Quality Defect section in order to diagnose and repair any image quality problems Initial Actions Copy mode only go to the IQ2 RAP Procedure that is listed Table 1 Image Quality Defects Check for the presence of the defect in Copy mode and in Print mode If the problem occurs in Go to Table 1 Compare the prints for any of the listed defects Perform the corrective action Defect Description Corrective Action ADC Patch printout A residual image of one or more of the ADC patches that runs in the process direction Go to the 009 704 RAP Background Undesirable toner deposits on the copy or print The toner deposits can be localized or may cover the entire copy or print Depending on the density of the
208. 2 P815 P814 P816 ADF DRIVE e m MOTOR T705003 A WOL Figure 1 005 701 RAP Circuit Diagram Initial Issue Phaser 790 DocuColor 2006 10 00 Status Indicator RAPs 2 59 005 701 005 702 ADF Exit Jam RAP Procedure Remove the ADF Rear Cover Enter Copy mode Place a sheet of paper into the Entrance Tray Press the Start button The ADF Exit Motor energizes Switch off the power Disconnect the belt from the ADF Exit Motor Switch on the power The ADF Exit Motor energizes Y There is 24 VDC from pin 1 and from pin 6 of J 813 to frame ground N Replace the ADF Control PWB PL 17 2 Go to Flag 3 Check for broken wires or damaged pins at J 813 If the wires and connector are OK replace the ADF Control PWB PL 17 2 If the problem contin ues replace the ADF Exit Motor PL 17 7 Check for binding or damage to the Upper and Lower Exit Rolls and Bearings PL 17 7 There is 5 VDC from J 815 pin 2 to frame ground Y N Disconnect P J 718 There is 5 VDC from J 815 pin 2 to frame ground Y N Go to Flag 1 Check for a short circuit If the wire is OK replace the ADF Control PWB PL 17 2 Replace the ADF Exit Sensor PL 17 7 Remove the Exit Chute Cover PL 17 7 Press and hold the actuator for the ADF Exit Sensor There is less than 1 VDC from J 815 pin 2 to frame ground N There is 5 VDC from pin 3 to pin 1 of J 815 Replace the ADF Control
209. 2 Perform the procedure for removal in reverse Perform ICM Main PWB Adjustment ADJ 6 5 Repairs and Adjustments 10 00 REP 6 14 4 46 Initial Issue Phaser 790 DocuColor 2006 REP 6 15 Extension PWB REP 6 16 Advanced Features Memory PWB Parts List on PL 16 2 Parts List on PL 16 1 Removal Removal WARNING WARNING To avoid personal injury or shock do not perform repair activities with the power switch To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the PWB Box REP 6 11 2 3 Remove the PWB Box Cover REP 6 12 CAUTION The PWB components are highly susceptible to damage from electrostatic discharge ESD and extreme care should be used when handling these components Use of the ESD Field Service Kit is required 4 Remove the Extension PWB Figure 1 e 1 Remove the four screws and the Extension by DF moving it in the direction gt indicated ee 5 2 Remove the Advanced Features Memory PWB Cover Figure 1 t T X 1 1 1 s 0 2 TI T Remove the two screws retaining the Advanced Features Remove the Advanced Features Memor
210. 2 Figure 10 CN1 IIT Figure 16 230 Takeaway Clutch Assembly Tray 3 Figure 10 CN1 Motor Drive PWB Figure 6 231 Low Paper Sensor Tray 2 Figure 12 CN2 IIT Figure 16 232 Low Paper Sensor Tray 3 Figure 12 CN2 Paper Handling Motor Assembly Figure 7 233 Feeder Drive Assembly Tray 2 Figure 11 E1 Commoning Connector Figure 8 234 Feeder Drive Assembly Tray 3 Figure 11 F187 1 BCR Assembly Figure 5 235 Size Switch Assembly Tray 2 Figure 11 F187 2 Developer Contact Plate Assembly Figure 1 236 Size Switch Assembly Tray 3 Figure 11 F250 Connects Pressure Roll Heater and Heat Roll Figure 8 237 Feeder Right Cover Interlock 1 Figure 10 Heater Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 5 Plug Jack Locations Table 1 Plug Jack Location List Plug Jack Number Location Figure Number A HVPS Figure 6 C HVPS Figure 6 D HVPS Figure 6 F HVPS Figure 6 FS1 Top Cover Interlock Figure 6 FS2 Top Cover Interlock Figure 6 N1 IIT LVPS Figure 15 SN1 Sorter Path Sensor Figure 18 T1 Heat Roll Heater Figure 8 T2 Pressure Roll Heater Figure 8 T3 IBT Rear Bracket Figure 5 T4 IBT Rear Bracket Figure 5 Wiring Data 10 00 Initial Issue Plug Jack Locations 7 6 Phaser 790 DocuColor 2006 Wiring Data Plug Jack Locations 18 22 19 20 23 21 97 BLACK Kas EN S 33 Y 14 ip gt e
211. 2006 7 95 BSD 10 2 A B H MCU PWB PL11 2 TEMPERATURE SENSOR ASSY 00 47 LVPS 1 PL8 2 P R HEATER PL41 1 J34 TEMP H R HEATER ON 1 WT 4 72 271 p SENSED YOLTAGE 15 3 421 D 5006 432 5 104 HR GRY 1 GRY GRY TEMPERATURE h m 2 86 B5 BESAN GRY GRY 2 MAIN FUSER ASSY 3 PL8 1 P R HEATER HEAT THERMAL 10 1 THER ES ai eee ae H R 4 UPPER PLATE HEATER H R HEATER 10 1 104 PL8 2 E 2 THERMAL FUSE 5 MAIN SWITCH 6 1710701A WOL Figure 1 Fusing Heat Control Wiring Data 10 00 Initial Issue 7 96 Phaser 790 DocuColor 2006 BSD 10 3 10 3 FUSING AIR CONTROL B FUSER COOLING FANS DO 64 FUSER CHUTE 1 FAN ON L 5VDC 0 19 GRY 2 WARM AIR EXHAUST 3 4 DO 63 FUSER FAN ON 01 85 47 417 24VDC J111 4 E USER E d DO 65 GRY FAN FUSER FAN 24VDC HIGH SPEED 5VDC J17 46 2 gt 48
212. 250 VDC and 350 VDC present There is 24 VDC from pin 1 to pin 3 on J41 Go to 4 Check for an open circuit If the wire is OK go to the 001 703 RAP Access the Digital Output Test GP 2 Enter code OE Press the Item Enter button There is less than 1 VDC from pin 1 to pin 13 of J 42 on the HVPS Y Go to Flag 2 Check for an open circuit If the wire is OK replace the MCU PWB PL 11 2 Go to Flag 3 Check for an open circuit or a short circuit to ground If the wires are OK replace the HVPS PL 11 1 If the problem persists replace the MCU PWB PL 11 2 Go to Flag 3 Check for an open circuit or a short circuit to ground Go to Flag 5 Check for an open circuit If the wires are OK check the BCR connector PL 5 1 and the bias con nector on the Copy Print Cartridge for damage or contamination Clean repair or replace as required If the problem persists replace the Copy Print Cartridge PL 5 1 The ADC Sensor is dirty Y Go to Flag 1 Check for an open circuit If the wire is OK replace the ADC Sensor PL 5 1 If the problem persists replace the MCU PWB PL 11 2 Go to the 009 340 RAP Initial Issue 10 00 Phaser 790 DocuColor 2006 2 145 Status Indicator RAPs 009 341 ADC SENSOR ASSY PL5 1 HVPS PWB SENSOR MGU PWB PL11 1 2 PL11 2 5 ao DO 0E 2 1 DC ON J42 14 16 L 24 0 4 137 G
213. 3 Screw Remove the TRO Sensor 229 1 Disconnect the sensor connector 0109037A WOL Figure 1 Removing the TRO Sensor REP 9 23 BTR 2 Cam Clutch Parts List on PL 7 4 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Rear Cover REP 14 6 3 Remove the BTR 2 Cam Clutch Figure 1 Replacement 1 Reinstall BTR 2 Cam Clutch in the reverse order of removal 1 Disconnect the connector 2 Remove the two screws securing the bracket 3 Remove the E ring 4 Remove the BTR 2 Cam Clutch 0109038A WOL Figure 1 Removing the BTR 2 Cam Clutch Initial Issue Phaser 790 DocuColor 2006 10 00 4 111 Repairs and Adjustments REP 9 22 REP 9 23 Repairs and Adjustments 10 00 Initial Issue REP 9 22 REP 9 23 4 112 Phaser 790 DocuColor 2006 REP 10 1 Fuser Assembly Parts List on PL 8 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Exit Tray Assembly REP 8 30 3 Remove the Fuser Assembly Figure 1 Replacement 1 Reinstall the Fuser Assembly in the reverse order of removal 4 Pull out and lift
214. 3 Remove the LVPS REP 1 1 CAUTION The Size Switch Bracket and printer are connected by a harness Handle the assembly care fully to avoid damaging the harness 4 Remove the Size Switch Bracket Figure 1 2 Disconnect the Size Switch connector Remove the screw and then remove the Size Switch PWB l 1 Remove the two screws securing the Size Switch Bracket 445760594 wo Figure 1 Removing the Size Switch PWB Replacement NOTE Prior to replacement partially pull out Tray 1 and if present the Duplex Tray 1 Perform the procedure for removal in reverse 2 Close Tray 1 and the Duplex Tray REP 7 2 Sensor Bracket Parts List on PL 3 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Tray 1 Assembly REP 7 6 3 Remove the Front Mid Cover REP 14 2 or the Duplex Tray Assembly REP 8 27 4 Remove the Sensor Bracket Figure 1 j Release the wires from 2 the clip Disconnect the connector and release the wires from 2 PA the wire clamp 4 on the frame Remove the Sensor Bracket 1 Remove the screw securing the Sensor Bracket 0107010A WOL Figure 1 Removing the Sensor Bracket Replacement 1 Perform the procedure for removal in reverse NOTE When installing dres
215. 3 Duplex Assembly 3 of 7 Item Part Description 1 059K19050 Duplex Tray Assembly REP 8 27 1 26 2 Chute P O PL 15 3 Item 1 PL15 4 3 022K57460 Entrance Roll 4 022K57470 Exit Roll 7 8 9 5 162K55450 Duplex Tray Harness 10 49 11 6 Entrance Chute P O PL 15 3 Item n 15 16 19 7 Exit Chute P O PL 15 3 Item 1 8 Harness P O PL 15 3 Item 1 9 130E82650 Duplex Entance Sensor Duplex Exit Sensor REP 8 28 REP 8 29 10 Registration Chute Assembly P O PL 15 3 Item 1 11 Harness P O PL 15 3 Item 1 12 Gear P O PL 15 3 Item 1 13 Chute Support P O PL 15 3 Item 1 14 802K25970 Front Cover 15 Rail Assembly P O PL 15 3 Item 1 16 _ Stopper P O PL 15 3 Item 1 17 Stopper P O PL 15 3 1 18 Plate Guide P O PL 15 3 Item 1 19 Spring P O PL 15 3 1 20 Bearing PL 15 3 Item 1 21 Pulley P O PL 15 3 Item 1 22 Stopper P O PL 15 3 Item 1 23 019E34500 Sheet Clamp 24 Alignment Chute Not Spared 25 Antistatic Brush Not Spared 26 Bracket Not Spared 0015003A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 57 PL 15 3 PL 15 4 Duplex Assembly 4 of 7 Item Part Description 1 Chute P O PL 15 3 Item 1 2 022K57481 Registration Roll 3 Spring P O PL 15 3 Item 1 4 Bracket P O PL 15 3 Item 1 5 Shaft P O PL 15 3 Item 1 6 121K22260 Duplex Drive Clutch REP 8 30 7 Gear P O PL 15 3 Item 1 8 Collar P O PL 15 3 I
216. 356 A Fuser Lamp error has been declared because both Fuser Lamps have been turned on for more than 60 consecutive seconds in an effort to maintain a Ready Condi tion 010 357 The Temperature Sensor detected that the Fuser did not reach operating tem perature within a specified period of time A Fuser Warm Up Timeout error has been declared Initial Actions Inspect the Fuser area especially around the Temperature Sensor for any damage foreign material debris or other signs of wear Perform any necessary cleaning or maintenance in the Fuser area If the problem persists continue with this RAP NOTE Before beginning the Procedure below remove the Inverter Upper Assembly REP 8 33 and the Fuser Tray Handle PL 8 4 Procedure Switch on power to the copier printer A glow can be seen coming from the area of the Heat Roll and Pressure Roll Heat Lamps when power is applied viewed from the left side of the copier printer just above the green Fuser Nip Handle Y N Remove the Rear Cover REP 14 6 Switch off power to the Copier Printer and disconnect the power cord Continuity can be measured between J 34 1 and J34 2 on the Low Voltage Power Supply LVPS Y Remove the Fuser Assembly REP 10 1 Continuity can be measured between P 79 1 and P79 2 on the Main Fuser Assembly Y N Remove the Upper Plate REP 10 4 Check for continuity directly across the Pressure Roll Heat Lamp and the Heat Roll Heat Lamp If continuity is NOT me
217. 356 l 10 357 2727 e 4 1 171 111 17 1 12 o 2 PIO 34 pig 18 22 pig 1234 18 21 18 13 32 P14 P17 171116 7 2873 1 P15 MCU PWB P20 15 15 12 Al6 P Al P23 TEMPERATURE SENSOR I B16 221 1 P J71 PIN CONFIGURATION J71 P71 J71 2 J71 1 P71 1 P71 2 WHT BLK gt WHT zn oe Ex 10 10101 211 m a J71 B lt gt J71A 71 lt gt 71 m Ll 1 10 1 10 Pas M hel b D d J71 4 471 3 71 3 71 4 YEL YEL YEL YEL LOCATING FUSER SIDE IOT SIDE LOCATING POST POST T710008A WOL Figure 1 010 354 RAP Circuit Diagram Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 171 010 354 010 355 Fuser Overheat Error RAP The sensed Fuser Temperature has exceeded the maximum allowable temperature A Fuser Overheat error was declared Initial Actions Inspect the Fuser area especially around the Temperature Sensor for any damage foreign material debris or other signs of wear breakage or excessive heat damage Perform any nec essary cleaning or maintenance in the Fuser area If the problem persists continue with this RAP NOTE The Thermal Fuse and the Thermostat are physically located on the Upper Plate PL 8 2 Procedure Remove the Rear Cover REP 14 6 Switch off the Copier Printer and disconnect the power cord Continuity is measured between J 34 1 and J34 2 on the Low Voltage Power Sup ply Y Continu
218. 4 3 J107 P101 J101 5 J16 MCUPWB GRY XS GRY z PL11 2 Cx 5VAC Y 216 y Do 2 07 GRY 9 GRY 7 v i 31 GRY 22 DC COM 7 o 71 7 o ____ PIO 34 pig 18 22 pig 12 36 pzz 18 7T pig 32 7 P14 P17 B 17 H6 2801 P15 MCU PWB P20 15 15 14 P12 PH A 529 5 1 I B16 B 1 T707001A WOL Status Indicator RAPs 007 703 10 00 2 94 Initial Issue Phaser 790 DocuColor 2006 007 704 Tray 2 Empty RAP The Control Logic detected the signal No Paper Sensed 5VDC Initial Actions Put paper into Tray 2 and ensure that the paper is loaded properly Procedure Remove paper from Tray 2 Check that the No Paper actuator is operating properly The actuator is present and operates smoothly Replace the No Paper Sensor Actuator PL 13 5 Access the Digital Input DI Test from the control panel Enter code DI A4 Press the Enter button The display is 1 Y Check the following Go to Flag 1 Check the wires for an open circuit Go to Flag 2 Check the wires for an open or a short circuit to ground If the wires are good replace the No Paper Sensor PL 13 5 Put 200 sheets of paper into Tray 2 Close the paper tray Access the Digital Input DI Test from the control panel Enter code DI A4 Press the Enter button The display is 0 Y N Replace the No Paper Sensor PL 13 5 If the problem continues replace th
219. 4 51 REP 6 23 Control Panel Assembly 4 52 Drives REP 4 1 Paper Handling Drive 4 15 Paper Supply 4 2 F ser Drive Unit 3 1 e ree 4 16 REP 7 1 Size Switch PWB 252 er sce eroe derer d pest Eun nin Xx Re 4 53 REP 4 3 Fuser Motor 4 17 REP 7 2 Sensor Bracket det etate dade ia 4 53 REP 4 4 Paper Handling MOtOr eter 4 17 REP 7 3 No Paper Sensor Assembly 4 54 REP 4 5 Drive Motor P WB ee i eee Een trente ene eed i ee Tee ped 4 18 7 4 No Paper Sensor erede re ertet trend 4 54 REP 4 6 Process Drive Unit 419 HEP 7 5 Low Pap r SOhsQr 4 niteretur teles ti el ee eel et 4 55 4 7 Rotary Motor i aceite Me eee o oia aaa oa feug 4 20 7 6 Tray 1 Assembly Paper Tray Assembly Oversize Tray Assembly 4 55 REP 4 8 Rotary Motor 2 4 2 2 402 20000000000000 000000000000 4 20 7 7 Tray 1 Front nennen 4 56 REP 4 9 Dispense Clutch 4 21 REP 7 8 Oversize Tray Front 4 56 REP 4 10 Developer Clutch 4 21 Paper Feed ADF Roll 5 a eee dite Ree ede 4 59 5 u uuu unn yuna eter tp e ehe 4 23 HEP 8 2 Eeed Holl erem IEEE Rer HT ee neg 4 60 2 Drive MOIOL i ect e card ee i o Pr
220. 4 Item 1 12 Top Frame P O PL 4 4 Item 1 13 Bearing P O PL 4 4 Item 1 14 Retard Roll P O PL 4 4 Item 1 0004004A WOL Parts List 10 00 Initial Issue PL 4 4 5 18 Phaser 790 DocuColor 2006 PL 4 5 Bypass Tray Paper Transport 5 of 7 Item Part 1 Q Description Nudger Support P O PL 4 4 Item 1 Bearing P O PL 4 4 Item 1 Nudger Shaft P O PL 4 4 Item 1 Feed Shaft P O PL 4 4 Item 1 Nudger Retard Roll P O PL 4 4 Item 1 Gear 17 P O PL 4 4 Item 1 Idler Gear 20 P O PL 4 4 Item 1 Feed Gear 14 P O PL 4 4 Item 1 Nudger Clutch P O PL 4 4 Item 1 Nudger Spring P O PL 4 4 Item 1 Feed Clutch P O PL 4 4 Item 1 Top Frame P O PL 4 4 Item 1 Preregistration Idler Gear P O PL 4 4 Item 1 Bearing P O PL 4 4 Item 1 Bearing P O PL 4 4 Item 1 0004005A WOL Initial Issue Phaser 790 DocuColor 2006 10 00 5 19 Parts List PL 4 5 PL 4 6 Bypass Tray Paper Transport 6 of 7 1 2 11 and PL4 7 Item Part Description 1 001K73551 Main Paper Handling Frame 8 9 11 Assembly 2 Registration Frame P O PL 4 6 Item 1 3 162K53280 Registration Harness 4 121 23430 Clutch REP 8 15 4 5 Paper Handler P O PL 4 6 Item 1 E 6 Bearing P O PL 4 6 Item 1 6 7 Rear Rail P O PL 4 6 Item 1 8 Paper Handling Sensor Assembly P O PL 4 6 Item 1 9 Sensor Bracket P O PL 4 6 Item 1 PL 4 6 Item 8 10 130 82650 Registration Sens
221. 5 6 If the problem continues replace the Inverter Sensor PL 15 5 Enter DO A3 The Forward Clutch actuates Y There is 0 VDC from J 139 pin 11 on the Duplex Controller PWB to ground N Replace the Duplex Controller PWB PL 15 6 Go to Flag 5 Check the wires for an open or short circuit to ground If the wires are good replace the Forward Clutch PL 15 7 If the problem continues replace the Duplex Con troller PWB PL 15 6 Enter 00 0 The Inverter Motor operates Y N Go to Flag 4 Check that the connectors J 139 and PJ 147 are properly connected Check the wires for an open or a short circuit to machine frame The wires and the connec tors are good Y N Repair the wires or the connectors Go to the Inverter Motor Assembly There is 24 VDC from 147 pin 1 and pin 3 Y N Go to Flag 6 Check the wire for an open or a short circuit to GND If the wires are good replace the Duplex Controller PWB PL 15 6 Replace the Inverter Motor Assembly PL 15 5 If the problem continues replace the Duplex Controller PWB PL 15 6 Enter DO A1 The Inverter Entrance Clutch actuates Y There is 0 VDC from J 139 pin 15 and machine frame Y Replace the Duplex Controller PWB PL 15 6 A B Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 127 008 704
222. 5 J206 A14 A1 14 5 2 2 MANUAL BYPASS GUIDE SWITCH GRY GRY GRY 7 2 TRAY EMPTY SENSCR M GRY EE GRY een GRY 12 2 1 1 1 1 1 PITCH SENSOR t GRY rA9 A6 nir GRY 82 i J209 1 1 1 1 LEVEL SENSOR M GRY GRY cus GRY 3 72 i i i J210 4 124 LA3 A124 1 3 _12 3 LIFT PLATE SENSOR GRY GRY GRY 12 998 4 154 814 B4 3 OHP SENSOR GRY 8 6 993 n 18 811 84 3 REGISTRATION SENSOR GRY 8 6 CONTINUED CONTINUED 1728009A WOL Figure 1 DC Com 3 of 5 Wiring Data 10 00 Initial Issue 7 34 Phaser 790 DocuColor 2006 DC Com Wirenet 4 of 5 DC COM 4 OF 5 WIRENET CONTINUED CONTINUED Oo 71 MCU PWB LVPS 422 J84 P84 J85 4 84 4 8 COMMUNICATION PWB GRY GRY 8 3 i J116 P116 J88 12 6 3 WASTE TONER SENSOR GRY GRY 9 9 i i 483 4 16 SRY PEERS NN 2 2 TONER BOX SENSOR 9 9 J23 J207 1 5 2 REGISTRATION BYPASS SWITCH GRY 13 i J105 4 3 ENVIRONMENT SENSOR GRY 74 J100 7 3 BTR CAM SENSOR GRY 9 8 1 J66 40 i 6 CRUM CONNECTOR ASSEMBLY
223. 7 PL 17 8 Platen Glass ADF Harness Item Part Description 1 090K92740 Platen Glass 1 0017008A WOL Parts List 10 00 Initial Issue PL 17 8 5 76 Phaser 790 DocuColor 2006 PL 18 1 Stand Item Part Description 1 802K17230 Stand Assembly 2 Adjuster Not Spared 3 Nut Not Spared 4 Caster Spared 5 Screw Not Spared 6 Foot Not Spared 2 0018001A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 77 PL 18 1 PL 19 1 Sorter Cover Control PWB Item Part Description 1 802K18200 Front Cover Assembly 2 Front Cover P O PL 19 1 Item 1 3 Label P O PL 19 1 Item 1 4 802E13310 Rear Cover 5 Serial Number Plate Not Spared 6 802 13320 Cover 7 Bearing Spared 8 110K10740 Sorter Top Cover Interlock 9 Plate Spring Not Spared 10 Harness Spared 11 160K68050 Sorter Control PWB REP 11 3 12 Harness Assembly Not Spared 13 Plate Not Spared 14 Harness Not Spared 15 Front Frame Not Spared 16 Rear Frame Not Spared 17 Sorter Assembly Not Spared REP 11 1 0019001A WOL Parts List 10 00 Initial Issue PL 19 1 5 78 Phaser 790 DocuColor 2006 PL 19 2 Feed Motor LVPS 1 of 2 Item Part Description 5 6 7 1 007K86440 Gear 2 Lower Guide Not Spared 3 Upper Brace Not Spared 4 105 05930 Antistatic Brush 5 Upper Chute Assembly Not Spared 6 054K17830 Upper Chute 7 Pinch Roll Not Spared
224. 7 Parts Lists PL 9 2 Paper Exit 2 of 2 cete 5 38 Frame and Covers Drives PL 1 1 Front and Left Covers 5 7 PE 10 1 DrlVes dert inter bii inerti cnn eei Fiir 5 39 in 1 2 d s s Covers ER Electrical 1 39 Base Framo 1 0 2 ni ee eh e a Pei oe e feed PL 11 1 Electrical 1 of 2 5 40 PL 1 4 Base Frame 2 of 2 neret uu u 5 10 PL 11 2 Electrical 2 of 2 5 41 amp Electronic Sub System ESS Pl 12 T ESS uincere eerie ode cede det aha aaa edd e le 5 42 Tray 1 Paper Feeder 3 Optional Feeder PL 32 Tray 1 20 8 848 PL134 Optional Feeder Assembly of 9 549 PL 3 3 Tray 1 Paper Feeder 3 of 3 0 544 PL 13 2 Optional Feeder Assembly 2 of 9 9 44 PL 13 3 Optional Feeder Assembly 3 of 9 5 45 Bypass Tray Paper Transport PL 13 4 Optional Feeder Assembly 4 of 9 5 46 PL 4 1 Bypass Tray Paper Transport 1 of 7 5 15 PL 13 5 Optional Feeder Assembly 5 of 9 5 47 PL 4 2 Bypass Tray Paper Transport 2 of 7 5 16 PL 13 6 Optional Feeder Assembly 6 of 9 5 48 PL 4 3 Bypass Tray Paper Transport 3 of 7 5 17 PL 13 7 Optional Feeder Assembly 7 of 9 5 49 PL 4 4 Bypass Tray Paper Transport 4 of 7 5 18 PL 13 8 Optional Feeder Assembly 8 of 9 5 50 PL 4 5 Bypass Tray Paper Transport 5 of 7 5 19 PL 13 9 Optional Feeder Assembly 9 of 9 5 51 PL 4 6 Bypass Tray Paper Transport 6 7 5 20 O
225. 7 um BRN GRY d J191 i 9 i 28 LOW VOLTAGE YEL GRY 4 POWER SUPPLY SOCOM PL14 1 J32 J193 57 J194 2 227 22 2 4 BRN INTERLOCK 5 VDC FUSER ote Ac 6 2 HARNESS 2 P195 J195 FS1 X Fs2J195 Pies 50545 0 PL8 5 o Vg SANDE ORN BLU BLU BRN 2 BRN J71 P7 J70 P70 J33 4 2 7 T ORN 9 YEL 3 YEL 1 REGISTRATION HARNESS PL4 6 MCU PWB PL11 2 J91 91 197 P97 DI 62 5 VDC 2 2 5 4 I YEL YEL P78 Un e 471 71 J19 22 0 r 2 ME LEON GRY GRY sss G ss as 12052 LA7 A4 7 os GRY GRY 4 22 22 EI LEFT DC COM INTERLOCK PL11 2 5 14 ENERGY STAR L SIGNAL N BRN NOTES 0 REFER TO 24 WIRENET INTERLOCKED FOR 6 DISTRIBUTION 2 FAULT MESSAGE DISPLAYED WHEN SIGNAL IS H CLOSE FRONT COVER FAULT MESSAGE DISPLAYED WHEN SIGNAL IS H DA CLOSE ARENS T701702 A WOL Figure 1 Interlock Switching Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 41 1 3 TRANSPORT COVER POSITION MONITORING 1 MCU PWB TURN PL11 2 CHUTE INTERLOCK 01 84 5 VDC PL3 3 2 3 Dos M TURN CHUTE P CLOSED L 5 VDC GRY 2 GRY DC COM EXIT CHUTE INTERLOCK 01 74 EXIT CHUTE CLOSED L 5 VDC GRY 3 BYPASS TRAY 22 INTERLOCK 01 77 PL4 1 BYPASS TRAY
226. 706706 A WOL Figure 1 Document Illumination Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 65 BSD 6 5 OPERATOR 6 5 IMAGE INPUT MAIN PWB DOCUMENT J140 J440 CCP J140 J140 y 797 SIGNAL 7 7 7 7 0000 222 2 7 YR 2016 22 213 CLS NON 006 312 94 lt 2 2 222 AIR ILLUMINATION Ry LENS CCD 2 2 BED 2 2 S te ach 4 5 gt CABLE FPC CABLE 64 COOLING DC PL16 3 7 PL16 3 2 72 k 14 72 227 ANGLE 330 100 5 VDC 226 22 SENSOR ANGLE SENSOR P Gis J718 SENSED L 5 VDC J130 2 ex GRY 222 SENSOR hy 222 ri 2 22 J130 J718 3 4 T gt 1 vA 4 GRY IP i 72 5 1 1 3 1 2 22 GRY gt gt 2 4 22 V t 1 HC E PLATEN Z SWITCH 330 100 V 2 16 1 252 i P719 J719 J719 EATEN ou d 10 2 2 44 006 300 4 GRY BLK BLK GRY VU
227. 8 LAT A02 Y L7 cry 1 DC EL Y las Ag 1 24VDC He CON INTLK LOWER INVERTER ASSEMBLY 14 41 111 17527 12 a2 14 3 Ta 1 P139 15 P140 PIO 34 18 2221912 34 16 24 pig T3 32 1 12 13 2 5 1 17 14 H6 P141 28r 1 12 13 DUPLEX 5 MCU PWB 20 16 15 CONTROLLER 15L Ja PWB 15 9142 P12 M6 PH A P25 21 ec B16 B Y o o T O INVERTER MOTOR C 170701 1A WOL Figure 1 007 341 RAP Circuit Diagram Status Indicator RAPs 10 00 Initial Issue 007 341 2 86 Phaser 790 DocuColor 2006 007 700 Tray 1 Open RAP The Control Logic detected the absence of the analog signal Size Switch Sensed Voltage for Tray 1 Initial Actions Ensure that Paper Tray 1 is closed Procedure The Paper Tray is properly seated and fully closed Perform the following Inspect the paper tray rails and cavity for obstructions Inspect the paper tray paper end guide for proper operation If the end guide does not operate the Size Actuator replace the Paper Tray PL 2 1 Remove the Size Switch PWB REP 7 1 Do not disconnect the connectors on the Size Switch PWB Place the Size Switch PWB so that it does not short circuit to the machine frame Rein stall the Tray 1 Size Switch Bracket PL 3 1 Reinstall the Low Voltage Power Supply Connect the Power Cord Switch on the power There is 0 24 VDC from J 102 pin 1 on the Size Switch PWB and GND Y Go to Flag 1 Chec
228. 8 4 OPERATOR _ LOADED TRAY1 PAPER 84 PAPER STACK POSITIONED 5 6 22 T707700A WOL Figure 1 Tray 1 Paper Supply 1 of 2 Wiring Data 10 00 Initial Issue 7 68 Phaser 790 DocuColor 2006 MCU PWB 1 PL11 2 3 _ _ PAPER PL3 1 01 61 LOW PAPER SENSED L 5VDC 34 416 0001 5 Pi0i J106 2 i 2 3106 P1014 2 101 316 GRY GRY GRY GRY done s L 1 1 1 I 2 1 01 60 1 3 TRAY NO PAPER I 1 1 SENSED 5VDC 1 3 3 GRY ui GRY 1 ENVIRONMENT SENSOR PL11 2 ENVIRONMENT SENSOR J101 5 P101 07 4 5 2105 HUMI VOLTAGE J23 p 105 4 GRY 3 1 1 1 I ENVIRONMENT SENSOR 1 41 TEMP VOLTAGE 1 GRY 4 5 6 T707704A WOL Figure 1 Tray 1 Paper Supply 2 of 2 Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 69 7 2 BYPASS PAPER SUPPLY 1 OF 2 BYPASS TRAY ASSY OPERATOR LOADED 4 PAPER LIFT MOTOR ASSY BYPASS PAPER STACK 82 POSITIONED PL4 2 BYPASS 120 SIGNALO 91 491 _ 1208 21 B7 2 1 2 GRY 1 GRY 1 1 ma m m m BYPASS I SIGNAL 1 ps 1 2 b GRY GRY 1 MCU PWB PL11 2 3 5VDC 01 75 BYPASS GUIDE UP L 5VDC J208 5 o o 1 4206 P205 gt ____ 205 P201 2 43 20 91 ara
229. 8 5 x 13 SEF 215 9 x 330 2 8 5 14 SEF 215 9 355 6 B4 SEF 257 x 364 x x 8th Opening SEF 267 x 388 x A3 SEF 297 x 420 x x 11x 17 SEF 297 4 x x x 431 8 NOTE Mix Mode only Default is A6S Postcard S is selectable 3 Default is Postcard S A6 S is selectable Scanner Alignment Following are the scanner alignment specifications Table 5 Reg Skew Specifications Item Application Specification Registration Lead Edge 0 5 mm Registration Side Edge 0 5 mm Skew Lead Edge 0 7 mm 200 Skew Side Edge 1 4 mm 390 Linearity fast scan n a 1 0 mm 200 Linearity slow scan n a 0 4 mm First Copy Output Time FCOT Parameters AE Off ACS Off A4 SEF Tray 1 Black White 11 5 sec or less Full color 25 6 sec or less Initial Issue Phaser 790 DocuColor 2006 10 00 6 25 General Procedures and Information IIT Scanner Specifications Sorter Specifications The Sorter is an optional accessory which connects to the left side of the copier printer and Table 3 Bins 2 10 Capacities is 30 Sheets in Modes receives finished copies from the printer Size Dimensions Weight Sorter Electrical Requirements A3 11 7 x 16 5 inch 297 x 420 mm SEF 60 128 gsm The sorter receives 24 VDC from the IOT The 24 VDC
230. 818 81 S 1 ENVIRONMENT SENSOR MCU PWB PL11 2 27 007 324 4105 HUMI VOLTAGE 423 GRY ENVIRONMENT SENSOR TEMP VOLTAGE GRY Figure 1 007 324 RAP Circuit Diagram ENVIRONMENT SENSOR 0707005A WOL Status Indicator RAPs 007 324 10 00 2 82 Initial Issue Phaser 790 DocuColor 2006 007 340 Feeder Motor Fail RAP The control logic has detected the signal Feeder Motor Fail H 5 VDC Procedure Enter DO B8 The Feeder Motor is operating Y There is 24 VDC from 4 213 pin 1 on the Feeder PWB to printer frame Y N Go to Flag 1 Check the wires for an open or a short circuit to ground Repair the wires Enter DO B8 There is 0 VDC from J 217 pin 12 to printer frame Y N Replace the Feeder PWB PL 13 4 Replace the Feeder Motor PL 13 4 If the problem continues replace the Feeder PWB PL 13 4 There is 0 VDC from J 239 pin 4 to printer frame Y N Go to Flag 2 Check the wire for an open circuit If the wire is bad repair it If the wire is good replace the Feeder Motor PL 13 4 REP 8 20 Replace the Feeder PWB PL 13 4 Initial Issue 10 00 Phaser 790 DocuColor 2006 2 83 Status Indicator RAPs 007 340
231. 9 6 the Printer press the Item Enter button The Printer will enter the WAITING state to GP 10 IIT Software Installation receive data from the PC The purpose is to load reload or upgrade IIT software NOTE A timeout will result if the following data transfer from the PC is not performed within 30 seconds Procedure 7 At the PC press the Enter key The display will read 1 file s copied The Control Panel CAUTION on the Printer will display DOWNLOADING During the download the length of the line The software Installation procedure commences from a Scanner power off condition Once the will indicate the time progress When the download is complete the Control Panel will dis procedure for downloading has started do not switch off the power until all steps have been play PROCESSING FILE completed and you have been instructed to do so If the download was not successful the Control Panel will display the message FIRM 1 Verify the software file version on the Scanner WARE INSTALL FAILED The procedure will have to be repeated 2 Prepare the Scanner for download 8 When PROCESSING FILE is complete the display will read INSTALL FILE SYSTEM a With a ballpoint pen or similar instrument such as a small screwdriver press and 9 Press the Clear Stop button to exit and reboot the system hold the switch located between the two SCSI connectors at the rear of the Scan 10 After the files are updated press the MENU button to access the CLEAR
232. 9 REP 14 10 REP 14 11 Right Lower Cover Parts List on PL 1 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Right Lower Cover Figure 1 Replacement 1 Reinstall the Right Lower Cover in the reverse order of removal 2 Remove the Right Lower Cover 1 Remove the three screws mp 0140007A WOL Figure 1 Removing the Right Lower Cover Repairs and Adjustments 10 00 REP 14 11 4 146 Initial Issue Phaser 790 DocuColor 2006 ADJ 3 1 Hard Disk Drive Assembly Purpose The purpose is to reload the software for correct machine operation after replacing the HDD Adjustment 1 Reload the ESS software System sys located on your EPSS CD using the directions in GP 9 ESS Software Installation IOT ADJ 3 2 ESS PWB Initialization Purpose The purpose is to initialize the ESS PWB for the correct market Adjustment 1 2 3 4 5 6 10 11 12 13 14 Switch off the machine power Remove the Right Cover REP 14 9 If the machine is equipped with a Scanner remove the 1394 PWB PL 12 1 Jumper the two pins of J 8 on the ESS PWB Switch on the machine power Enter the Diagnostic Mode IOT GP 1 the display will indicate VERSION INFO indicat ing that the system is ready Press th
233. 90008A WOL Figure 1 Removing the Erase Lamp REP 9 9 Dry Ink Cartridge Parts List on PL 6 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the appropriate Dry Ink Cartridge Figure 1 CAUTION After removing be sure to lay the Dry Ink Cartridge in its horizontal position in a safe place Replacement 1 Place the arrow on the end of the Dry Ink Cartridge facing toward the top in order to insert the cartridge 2 Reinstall the Dry Ink Cartridge in the reverse order of removal 2 Lift and hold the lever during the following step 3 Turn the knob to access the car tridge to be removed 1 Open the Front Cover Assembly Turn the knob to release the cartridge Remove the Dry Ink Cartridge 0090009A WOL Figure 1 Removing the Dry Ink Cartridge Initial Issue Phaser 790 DocuColor 2006 10 00 Repairs and Adjustments REP 9 8 REP 9 9 REP 9 10 Developer Housing 8 Remove the Developer Housing Figure 2 Parts List on PL 6 2 3 Removal Move housing towards the front lift at front and remove the Developer Housing WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 2 1 Switch off the machine pow
234. AP Clear Jam In Area 2 008 701 Area 2 Jam RAP Clear Jam In Area 3 008 702 Area 3 Jam RAP Clear Jam In Area 4 008 703 Area 4 Jam RAP Clear Jam In Area 5 010 700 Area 5 Jam RAP Clear Jam In Area 6 008 704 Area 6 Jam RAP Clear Jam In Duplex Tray 008 707 Duplex Tray Jam RAP Close Area 1 001 706 Area 1 Open RAP Close Area 2 001 707 Area 2 Open RAP Close Area 3 001 708 Area 3 Open RAP Close Area 4 001 709 Area 4 Open RAP Close Area 5 001 710 Area 5 Open RAP Close Area 6 001 711 Area 6 Open RAP Close Duplex Tray 008 707 Duplex Tray Open RAP Close Front Cover 001 704 Front Cover Open RAP Close Paper Tray 1 007 700 Tray 1 Open RAP Close Paper Tray 2 007 701 Tray 2 Open RAP Close Paper Tray 3 007 702 Tray 3 Open RAP Close Sorter Cover 011 702 Sorter Top Cover Open RAP Empty Sorter Bins 011 701 Sorter Bin Jam RAP Empty Stacker Tray 011 705 Full Sensor RAP Empty Top Tray 008 705 Top Tray Full RAP Install color Ink Cartridge 009 700 Toner Cartridge Detached RAP Install Copy Print Cartridge 003 701 Copy Print Cartridge Error RAP Install Waste Container 009 703 Waste Container Detached RAP Jam in Sorter 011 701 Sorter Bin Jam RAP Load size 007 711 Tray 1 Paper Size Not Detected RAP 007 712 Tray 2 Paper Size Not Detected RAP 007 713 Tray 3 Paper Size Not Detected RAP Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 3 Fault Message RAP Cross Reference Status Indicator RAPs 10 00 Initial Issue Fault Message RAP Cross Reference
235. APs Phaser 790 DocuColor 2006 2 87 007 700 o 1 U1 11 17 1 7 o PIO 34 pug 18 27 pig 12 34 18 A pig 19 20 1 P14 n ns 2801 PIS MCU PWB P20 15 14 15 P12 416 Pl A 16 21 o 1 SIZE 1 52 54 2102 SIZE SWITCH PWB PL3 1 Figure 1 007 700 RAP Circuit Diagram REAR VIEW MCU PWB PL11 2 SIZE SWITCH VOLTAGE 1105 SEE TABLE ue d GRY SIZE SWITCH T707013A WOL Status Indicator RAPs 007 700 10 00 2 88 Initial Issue Phaser 790 DocuColor 2006 007 701 Tray 2 Open RAP The Control Logic detected the absence of the analog signal Size Switch Sensed Voltage for Tray 2 Initial Actions Ensure that Paper Tray 2 is closed Procedure The Paper Tray is properly seated and fully closed Y N Perform the following Inspect the paper tray rails and cavity for obstructions Inspect the paper tray paper end guide for proper operation If the end guide does not operate the Size Actuator replace the Paper Tray PL 13 9 Remove the Size Switch PWB REP 8 19 Do not disconnect the connectors on the Size Switch PWB Place the Size Switch PWB so that it does not short to the machine frame Connect the Power Cord Switch on the power There is 44 76 40 10 VDC from J 235 pin 2 on the Size Switch PWB and GND A
236. Assembly REP 10 2 CAUTION The rear Exit Roll Bearing remains but is not secured to the tray when the following step of the procedure is performed Be careful not to lose the bearing 5 Remove the Exit Roll Figure 1 Replacement 1 Reinstall the Exit Roll in the reverse order of removal 1 Remove the e ring 2 Move the gear and then remove the Pin Move the Bearing and then disen gage the Exit Roll Remove the Exit Gear and Exit Bearing from the Exit Roll Remove the Exit Roll 0110017 WOL Figure 1 Removing the Exit Roll Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 125 REP 10 17 REP 10 18 Fuser Entrance Sensor 4 Remove the Fuser Entrance Sensor Figure 2 Parts List on PL 8 6 Replacement 1 Reinstall the Fuser Entrance Sensor in the reverse order of removal Removal WARNING 1 To avoid personal injury or shock do not perform repair activities with the power switch Disengage and on or electrical power applied to the machine remove the Sensor 1 Switch off the machine power and disconnect the machine Power Cord Bracket 18 2 Remove the Fuser Assembly REP 10 1 3 Prepare to remove the Fuser Entrance Sensor Figure 1 3 1 2 Remove the screws Remove the Fuser Paper 2 Guide and Horizontal Chute Disconnect the 3 connector Disengage and remove the Fuser Entrance Sensor 0110019A WOL Figure 2 Removing the Fuser Entrance Sensor 3 gt R
237. B PL 19 1 If the problem continues replace the MCU PWB PL 11 2 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 37 003 312 MCU PWB Figure 1 003 311 RAP Circuit Diagram SORTER CONTROL PWB 112 MCU PWB PL19 1 PL11 2 J10 10 START P133 J133 48 ED d on GRY T RED 48 P8 J133 P133 COMMUNICATION LINE TRANSMITTER i COMMUNICATION E RECEIVER TRANSMITTER T AO T T GRY Ua UNE PT E i234 725 734 NE GRY 5 15wHT me EE RETURN RETURN ON EE ORN GRY GRY 6 11 154 1 uam o P10 P22 P18 J9 P16 9 P14 x P17 J3 SORTER P15 J5 CONTROL MCU PWB F1 F2 P12 21 7 jg 4 o Status Indicator RAPs 003 312 10 00 2 38 Initial Issue Phaser 790 DocuColor 2006 003 333 Foreign Interface RAP This Fault Code indicates that a communications failure was detected between the ESS PWB and the Foreign Interface Procedure Switch the IOT power off then on Fault Code 003 333 is still present Y N If
238. B C Replace the Feeder PWB PL 13 4 Replace the Size Switch PWB PL 13 3 Press and hold switch number SW1 and SW3 on the Size Switch PWB There is 1 57 0 10 VDC from J 235 pin 2 on the Size Switch PWB to GND Y There is 5 VDC from J 235 pin 1 on the Size Switch PWB to ground Y Go to Flag 2 Check the wire for an open or short circuit to ground The wires are good Repair the wires Ensure the connector PJ 235 is properly connected Replace the Feeder PWB PL 13 4 Replace the Size Switch PWB PL 13 3 Press and hold switch number SW2 and SWA on the Size Switch PWB There is 3 13 40 10 VDC from J 235 pin 2 on the Size Switch PWB to ground Y N Y M There is 5 VDC from J 235 pin 1 on the Size Switch PWB to ground Go to Flag 1 Check the wires for an open or a short circuit to ground The wires Y N Go to 2 Check the wire for open or short circuit to ground The wires ood Repair the wires Ensure that PJ 217 on the Feeder PWB and PJ 235 on the Size 9 N Switch PWB are properly connected Repair the wires Ensure the connector PJ 235 is properly connected cR 5 VDC from J 235 pin 1 on the Size Switch PWB to ground Replace the Feeder PWB PL 13 4 sd Flag 2 Check the wire for an open or short circuit to ground The wires are Replace the Size Switch PWB PL 13 3 H N Replace the Feeder PL 13 4 Repair th
239. B COMMUNICATION PL11 2 PWB PL11 2 o o 4 3 2 1 5 6 CRUM CONNECTOR 5 1 T703703A WOL Figure 1 CRUM and Billing Wiring Data 10 00 Initial Issue 7 50 Phaser 790 DocuColor 2006 3 4 TRAY MODULE COMMUNICATION MCU PWB PL11 2 PRE REGI J132 GRY DO 8 START GRY TXD FEEDER PWB PL13 4 MCU PWB PL11 2 GRY DO 7 FLAG GRY DC COM GRY Figure 1 Tray Module Communication 003 310 T703704A WOL Initial Issue Phaser 790 DocuColor 2006 10 00 7 51 Wiring Data MODULE COMMUNICATION FEEDER PWB PL13 4 MCU PWB PL11 2 PRE REGI 2 GRY DO 9 START GRY P134 J134 14 RAD GRY D1 83 READY GRY T703705A WOL Figure 1 Duplex Module Communication Wiring Data 10 00 7 52 Initial Issue Phaser 790 DocuColor 2006 3 6 SORTER COMMUNICATION 1 MCU PWB SORTER CONTROL PWB BUT42 MCU PWB PL19 1 PL11 2 120 77 P10 start P133 4133 5 1 GRY RED P8 2133 P133 COMMUNICATION LINE P10 J10 TRANSMITTER COMMUNICATION RECEIVER TRANSMITTER 44 LINE DE GRY 2 og RETURN RETURN GRY GRY 1 1 15 15 3 4 5 6 T703706 A WOL Figure 1
240. CIFICATIONS 5 VDC H 3 00 TO 5 25 VDC L 0 0 TO 0 8 VDC 24 VDC H 23 37 TO 27 06 VDC L 0 0 TO 0 8 VDC DC Voltage Measurements in RAPs The RAPs have been designed so that when it is required to use the DMM to measure voltage the first test point listed is the location for the red meter lead and the second test point is the location for the black meter lead For example the following statement may be found in a RAP There is 5 VDC from TP7 to TP68 In this example the red meter lead would be placed on TP7 and the black meter lead on TP68 Another example of a statement found in a RAP might be There is 15 VDC from TP21 to TP33 In this example the red meter lead would be placed on TP21 and the black meter lead would be placed on TP33 If a second test point is not given it is assumed that the black meter lead may be attached to the copier frame Introduction 10 00 vi Initial Issue Phaser 790 DocuColor 2006 1 Service Call Procedures Service eode ee Cg tte e D Edidi vto D te 1 3 Initial Actions Procedure oom voa de e ned fees 1 3 Gall Fl w Procedure oie eren Sika aires OR dee ddr de rae Me DU Re d 1 4 Cleaning Procedures 1 5 Final dE Pen uia erred aa a 1 5 Initial Issue 10 00 Service Call Procedures Phaser 790 DocuColor 2006 1 1 Service Call Procedures
241. COM J11 5 VDC 1702000 A WOL Figure 1 002 701 Circuit Diagram Status Indicator RAPs 10 00 Initial Issue 002 701 2 30 Phaser 790 DocuColor 2006 002 702 IOT Control Panel Button LED RAP Initial Actions Reseat the connectors on the cable between the ESS PWB and the Control Panel P J34 and P J 317 Check for any loose or damaged pins in the harness connectors Procedure Ensure that the Initial Actions has been performed If the problem continues replace the Con trol Panel PL 1 2 If the problem continues replace the ESS PWB PL 12 1 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 31 002 702 Status Indicator RAPs 10 00 Initial Issue 002 702 2 32 Phaser 790 DocuColor 2006 003 310 Feeder Communications Failure RAP The Control Logic detected a communication failure with the Feeder PWB Initial Actions Ensure that connector P J 212 is properly seated on the Feeder PWB Remove the ESS PWB REP 1 9 and check the P J 22 on the MCU PWB Ensure that it is properly seated on the PWB Procedure Perform the following Go to Flag 1 Check the wires between the Feeder PWB and the MCU PWB for an open circuit If the previous check is OK replace the Feeder PWB PL 13 4 If the problem continues replace the MCU PWB PL 11 2 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 33 003 310
242. Color 2006 007 324 Environment Sensor RAP The control logic has detected an open circuit in the Environment Sensor Initial Actions Ensure that the Environment Sensor is free of dust and dirt Procedure Switch off the power Disconnect the power cord Go to REP 1 8 and remove the Duplex Tray Assembly from the copier printer Check that the P J 105 connector on the Environment Sen sor board is properly connected The P J 105 connector is good Y N Connect the P J 105 connector Connect the power cord and switch on the power Go to REP 1 11 and remove the Controller Chassis to gain access to the MCU PWB connec tors Go to Flag 1 Check the wires for an open or a short circuit to ground The wires are good Y N Repair the wires Connect the power cord and switch on the power Replace the Environment Sensor PL 11 2 Connect the power cord and switch on the power If the problem continues replace the MCU PWB PL 11 2 Initial Issue 10 00 Phaser 790 DocuColor 2006 2 81 Status Indicator RAPs 007 324 MCU PWB ENVIRONMENT PL11 2 SENSOR PL11 2 5VDC 423 evpc 4105 GRY 1 1 1 1 DCCOM M GRY DC COM 1 1 J 1 17 1 12 PIO 34 pig 18 221912 54 18 9 21813 327 P14 P17 UL 2 281 1 P15 MCU PWB P20 15 14 15 12 16 1751
243. D LOW PAPER SENSED 5VDC J216 5 GRY 5 J216 5 VDC J231 1 GRY I 2 3 1 1 1 1 i GRY 6 T707706A WOL Figure 1 Tray 2 Paper Supply 2 of 2 Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 73 BSD 7 4 A B D E F G H J 7 4 TRAY 3 PAPER SUPPLY 1 OF 2 TRAY 3 PAPER STACK MECHANISM D A 1 FEEDER PWB SIZE SWITCH ANALOG VOLTAGE J236 J217 2 5 BLU 2 3 OPERATOR ET LOADED TRAY 3 PAPER 8 4 PAPER STACK POSITIONED 4 FEEDER PWB PL13 4 FEEDER DRIVE ASSY PL13 4 DO 83 LIFT UP CLUTCH 5 i ON L 424vDc 9234 P234 1 10 GRY 24VDC 24VDC INTLK 9 GRY 24VDC INTLK 6 T707703A WOL Figure 1 Tray 3 Paper Supply 1 of 2 Wiring Data 10 00 Initial Issue 7 74 Phaser 790 DocuColor 2006 7 4 TRAY 3 PAPER SUPPLY 2 OF 2 FEEDER PWB PL13 4 FEEDER PWB PL13 4 DI B4 L NO SENSED 5 2220 J242 5 140242 _ 5 0 4215 1 GRY GRY I I 1 2 5VDC 1 1 1 I 1 1 I 1 1 1 1215 5 VDC P242 4242 3 r 18 gt i GRY 1 5 i i 1 8 1 1 I 1 s 1 D3 NUDGER 1 1 I 172275 GRY SENSOR 01 86 I NUDGER 3 DC COM I I I SENSED I I I 1 1 1 1 1 2 J222 15 11 D SVDC GRY GRY 1 I I I I I 5VDC l I I I I I I 1 1 1 1
244. D ASSEMBLY 1710012A WOL Figure 1 010 705 RAP Circuit Diagram Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 189 010 705 Status Indicator RAPs 10 00 Initial Issue 010 705 2 190 Phaser 790 DocuColor 2006 011 700 Sorter Not In Correct Position RAP Sorter Control PWB logic has detected that the Sorter is not docked correctly Initial Actions Ensure that the Sorter is completely and correctly docked by pushing the Sorter all the way against the IOT Ensure that the Rear Cart Support PL 19 6 is secured to the Rail Plate PL 19 6 Procedure NOTE Prior to replacing a component unplug the connectors to the components Docking Interlock Switch Check the connectors for broken bent and dirty pins Unplug and plug in the connectors several times to remove contaminants due to oxidation Remove the Front and Rear Covers from the Sorter Measure voltage between J 6 1 of the Sorter Control PWB and GND Ensure that the Sorter is pushed all the way against the IOT Then move the Sorter to the left The meter changes state from a Low 0 VDC to a High 5 Y The voltage remains Low 0 VDC Y Go to Flag 1 Check the harness for an open circuit If the harness is OK replace the Docking Interlock PL 19 6 Go to Flag 1 Check the harness for a short circuit If the harness is OK replace the Dock ing Interlock PL 19 6 The docking interlock appears to be operating normally Check the
245. DGE DEVELOPER DO BIAS 27 101 9 Y 4 GRY FX i DEVELOPER DC BIAS CONTROL P16 P19 P22 P18 r 10 P14 1 13 GRY P15 MCU PWB 20 DC COM L DC COM P12 P11 ez Figure 1 009 701 RAP Circuit Diagram Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 159 009 701 009 702 Waste Container Full RAP Control Logic detects that the Waste Container is full Initial Actions Check the Waste Container Replace if required If the message is displayed with an empty or partially full Waste Container or if the Waste Container is full but the message is not displayed continue with this RAP Procedure Access the Digital Input Test GP 2 Enter code 51 Press the Item Enter button The display is 0 Y N Disconnect J 116 There is 5 VDC from J 116 pin 4 to J 116 pin 6 Y N Go to Flag 4 Check for an open circuit or a short circuit to ground If the wires are OK replace the MCU PWB PL 11 2 There is 5 VDC from J 116 pin 5 to J 116 pin 6 Y Go to Flag 3 Check for an open circuit or a short circuit to ground If the wire is OK replace the MCU PWB PL 11 2 Remove the Locating Rail REP 9 5 Check the harness of the Waste Toner Sensor Flag 1 and Flag 2 If the wires are OK replace the Waste Toner Sensor PL 5 1 Remove the Waste Container Block the Waste Toner Sensor Access t
246. DO 75 PL6 1 4 SVDC CARTRIDGE PN L DI 67 5VDC SENSOR ON CARTRIDGE 57 _ H 5VDC 487 5 SENSED GRY 2 587 L SVDC J17 4 GRY 3 3 L GRY DC COM 0 43 5VDC ROTARY HOME SENSOR SENSED PL6 1 2 458 H 5VDC 216 45 5 2 GRY J16 i 158 PU GRY TEC NOTE FAULT MESSAGE DISPLAYED WHEN 4 3 SIGNAL IS INSTALL INK 6 L CARTRIDGE DC COM T 709703 A WOL Figure 1 Developer Rotary Control 2 of 2 Wiring Data Initial Issue 10 00 7 86 Phaser 790 DocuColor 2006 BSD 9 4 9 4 DEVELOPMENT 10F 2 DEVELOPER PL11 2 FAN MCU PWB 24 VDC PL11 2 DEVELOPER FAN ON S 21 417 H 24VDC 1825 2201 GRY 00 60 RED DEVELOPER TAN i i DLE 1 5VDC 8 gt 7 GRY 25 54 BRN Mer FAN ALARM DC COM 82 Ly 5 VDC 317 3 2 23 i i WHT GRY 24 11 4 2 GRY iu BLK DC COM DEVELOPER DO 21 CLUTCH ASSY DEVELOPER CLUTCH ON cc 22 4118 L 24VDC 456 2 P56 GRY BLU DC COM i i 21 25274 GRY BLU 24 VDC INTLK 3 HIGH VOLTAGE 00 00 POWER SUPPLY DEVELOPER AC BIAS ON 11418 L 24VDC 442 4 AC BIAS GRY SWITCHING DC COM DEVELOPER git AC BIAS CONTROL ue GRY I 4 DO 0C DEVELOPER DC BIAS
247. Direction 0 205008A WOL Table 1 Minimum Initial Maximum Remarks Figure 4 Adjusting Front to back Positioning Settings Range 0 23h 46h 0 1 Step 5 Repeat the checks and confirm that the measurement is within specification 5 Perform the check again 6 Place paper of each size in the ADF make test copy and check it for skew 7 Perform the ADF Side Registration Adjustment ADJ 5 1 Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 153 ADJ 5 4 ADJ 6 1 ADJ 6 2 IIT Half Rate and Full Rate Carriage Adjustment Purpose The purpose is to maintain the appropriate parallelism in the positioning relationship for the Full Rate Half Rate Carriage Adjustment WARNING To avoid personal injury or shock do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine Remove the ADF REP 5 1 or Platen Cover Remove the Platen Glass REP 6 1 Remove the Right Cover REP 6 2 Remove the Left Cover REP 6 3 Remove the Rear Cover REP 6 4 Remove the Control Panel Assembly REP 6 23 OF boom e Switch off the machine power and disconnect the machine Power Cord NOTE Two positioning tools are provided inside the Control Panel Assembly 8 Remove the Stopper and the two positioning tools from inside the Control Panel housing Figure 1 Front Panel 3 Remove the Adjustment Tools 2 Stopper Remove the screws 2 and Stopp
248. Disconnect J 87 Access the Digital Output Test GP 2 Enter code 75 Press the Item Enter button There is VDC from J 87 1 to J 87 pin 3 Y Go to Flag 1 Check for an open circuit If the wires are OK replace the MCU PWB PL 11 2 Replace the Cartridge Sensor PL 6 1 The problem appears to be intermittent Check for correct mounting of the sensor Go to Figure 1 Check for loose or damaged connections If the wires are OK go to the 009 701 RAP Status Indicator RAPs 10 00 009 700 2 156 Initial Issue Phaser 790 DocuColor 2006 MCU PWB MCU PWB CARTRIDGE SENSOR PL13 2 DO 75 1 PL 6 1 5VDC CARTRIDGE C DI 67 1 5VDC SENSOR ON CARTRIDGE x _ H SVDC 487 o 5 SENSED GRY 2287 H 5VDC XT 4 GRY 3 3 GRY DC COM NOTE FAULT MESSAGE DISPLAYED WHEN SIGNAL IS L INSTALL CYMK INK CARTRIDGE CARTRIDGE SENSOR N FRONT x P16 P19 P22 P18 P15 MCU PWB P20 P11 Fes P21 T 709008 A WOL Figure 1 009 700 RAP Circuit Diagram Initial Issue 10 00 Phaser 790 DocuColor 2006 2 157 Status Indicator RAPs 009 700 009 701 Toner Cartridge Empty RAP ADC sensor detects a drop in Toner Concentration TC that is not restored by dispense oper ation Initial Actions If a single color is declaring the fault replace the Dry Ink cartridge
249. DocuColor 2006 2 205 011 706 Status Indicator RAPs 10 00 Initial Issue 011 706 2 206 Phaser 790 DocuColor 2006 016 310 Font ROM Checksum Error RAP 016 312 ESS Hard Drive Error RAP Control Logic detected a Font ROM checksum error Control Logic detected an ESS Hard Drive error Procedure Procedure Switch off the power then switch on the power If the problem still exists replace the ESS PWB Switch off the power Check for a loose connection at the HDD connector Switch on the power PL 12 1 If the fault remains replace the Hard Disk Drive PL 12 1 If the problem still exists replace the ESS PWB PL 12 1 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 207 016 310 016 312 016 313 ASIC Access Error RAP 016 315 ESS RAM Bank 1 RAP Control Logic detected a ASIC Access error Control Logic detected an ESS RAM Read Write Check error from Bank 1 Procedure Procedure Switch off the power then switch on the power If the problem still exists replace the ESS PWB Switch off the power Reseat the Memory module in Slot 1 Switch on the power If the fault PL 12 1 remains replace the Memory module in Slot 1 PL 12 1 If the problem still exists replace the ESS PWB PL 12 1 Status Indicator RAPs 10 00 Initial Issue 016 313 016 315 2 208 Phaser 790 DocuColor 2006 016 316 ESS RAM Bank 2 RAP 016 317 ESS ROM RAP Control Logic detected an ESS RAM Read Write Check error from Bank 2 Control Logic d
250. EF OFF ON OFF OFF 3 45 VDC A3 SEF ON OFF ON OFF 1 57 VDC Letter LEF OFF ON ON ON 2 49 VDC B5 LEF OFF ON OFF ON 3 13 VDC Legal SEF OFF OFF ON OFF 4 09 VDC A4 LEF OFF OFF ON ON 3 77 VDC B4 SEF OFF ON ON OFF 2 81 VDC Status Indicator RAPs 007 713 10 00 2 114 Initial Issue Phaser 790 DocuColor 2006 SIZE SWITCH PWB PL13 3 SIZE SWITCH VOLTAGE SEE TABLE J217 5 SIZE SWITCH PWB FOR TRAY 3 214 2222574 32 1 J236 x P216 S2 32 1 ss 3 FEEDER 32 1 PWB SIZE PWB TRAY 2 amp 3 S4 P215 a 128 REAR VIEW T707014A WOL Figure 1 007 713 RAP Circuit Diagram Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 115 007 713 Status Indicator RAPs 10 00 Initial Issue 007 713 2 116 Phaser 790 DocuColor 2006 008 700 Area 1 Jam RAP The Registration Sensor or the OHP Sensor in the Bypass Tray Assembly transport has detected a Registration Sensed 1 5 VDC or an Sensed 1 5 VDC at the incorrect time Initial Actions Check for any obstructions in the paper path in the Bypass Tray Assembly and the Regis tration transport PL 4 6 Procedure Pull out the Bypass Tray Assembly Place a strip of paper over the left sensor Registration Sensor PL 4 6 Push in the Bypass Tray A
251. EL YEL 1 RESET H 5 VDC 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ADF CONTROL PWB 811 P813 CR2 W RED U2 P812 BRAS Z P815 P814 P816 ICM PWB T705000 A WOL Figure 1 005 220 221 RAP Circuit Diagram Status Indicator RAPs 10 00 Initial Issue 005 220 221 2 56 Phaser 790 DocuColor 2006 005 700 ADF Fault Entry RAP Procedure Use the following table to troubleshoot ADF problems that do not generate a fault code Table 1 Problem description Troubleshooting ADF not recognized Copies made from Platen Glass even with documents in the Entrance Tray Go to the 005 703 RAP Entrance Jam First sheet of set jammed in Registra tion Chute Go to the 005 701 RAP Exit Jam First Sheet of set stalled on glass or jammed in Exit Chute Go to the 005 702 RAP Incomplete copy job Copy job is never finished Documents may or may not recirculate IIT display never returns to READY TO COPY Go to the 005 704 RAP Initial Issue Phaser 790 DocuColor 2006 10 00 2 57 Status Indicator RAPs 005 700 005 701 ADF Entrance Jam RAP Procedure The green LED of the Document Set Indicator is always lit Remove the ADF Rear Cover There is
252. Ensure the Top Cover is correctly positioned and is actuating the Top Cover Interlock Procedure Switch off the power Remove the Rear Cover Switch on the power 5 VDC is measured between J32 22 on the Low Voltage Power Supply and machine frame Y N Replace the Low Voltage Power Supply PL 11 1 Remove the Top Cover Actuate the Top Cover Interlock 5 VDC is measured between J125 1 on the ROS Assembly and machine frame Y N With the Top Cover Interlock still actuated 5 is measured between FS2 blue wire on the Top Cover Interlock and machine frame Y 5 VDC is measured between FS1 blue wire on the Top Cover Interlock and machine frame Y 5 VDC is measured between J194 1 blue wire on the Right Front Cover Interlock and machine frame 45 VDC is measured between J193 1 brown wire on the Right Front Cover Interlock and machine frame Y Go to Flag 3 Check the wire for an open circuit Replace the Right Front Cover Interlock PL 11 2 Go to Flag 2 Check the wire for an open circuit Replace the Top Cover Interlock PL 11 1 Go to Flag 1 Check the wire for an open circuit The ROS 5 VDC Switched circuit appears to be functioning correctly Initial Issue 10 00 Phaser 790 DocuColor 2006 2 13 Status Indicator RAPs 001 705
253. Enter code 54 Press the Item Enter button The Pro cess Motor energizes Y N Go to the 009 323 RAP Access the Digital Output Stop routine Enter code 54 Press the Item Enter button Remove the Copy Print Cartridge Cheat the Left Front Cover Interlock Access the Digital Output Test GP 2 Reenter code 54 Press the Item Enter button The IBT Belt rotates Y N Switch off the power Remove the Process Drive Unit Check the gear on the IBT Drive Roll PL 7 3 for damage or contamination If the gear is OK replace the Process Drive Unit PL 10 1 NOTE Ensure that the reflective patch on the IBT Belt is not blocking the TRO Sensor Use the DO component control code 54 to move the Belt if required Access the DO Stop routine Enter code 54 Press the Item Enter button Access the Digital Input Test GP 2 Enter code 42 Press the Item Enter button The display is 1 Y N Disconnect J 57 from the TRO Sensor There is 5 VDC from pin 1 to pin 2 of J 57 Y N Go to Flag 1 Check for an open circuit or a short circuit to frame ground If the wire is OK replace the MCU PWB PL 11 2 Clean the TRO Sensor and the reflective strip on the IBT Belt If the problem persists replace the TRO Sensor PL 7 3 Use a reflective surface such as an extendable inspection mirror to block the TRO Sensor Re enter code 42 Press the Item Enter button The display is 0 Y N Disconnect J 57 from the TRO Sensor There is 5 VDC from pin 1 to pin 3 of
254. Extension PWB Figure 17 211 Bypass Tray Intermediate Connector Figure 6 602 I F Connector for IOT Figure 17 211 SCSI Connector Figure 17 603 Connector for IOT Figure 17 212 Feeder PWB Figure 10 709 Document Set LED Figure 14 213 Feeder PWB Figure 10 711 Document Set Sensor Figure 14 214 Feeder PWB Figure 10 712 ADF Registration Sensor Figure 14 215 Feeder PWB Figure 10 713 ADF Nudger Home Sensor Figure 14 216 Feeder PWB Figure 10 714 Feeder Cover Interlock Figure 14 217 Feeder PWB Figure 10 716 IIT Figure 16 218 Feeder PWB Figure 10 717 IIT Figure 16 219 No Paper Sensor Tray 2 Figure 12 718 ADF Exit Sensor Figure 14 J220 DADF to ICM Main PWB Connector Figure 14 718 IIT Figure 15 P220 ICM Main PWB Connector for DADF Figure 17 719 IIT Figure 16 220 No Paper Sensor Tray 3 Figure 12 719 Exit Tray Interlock Figure 14 221 Low Paper Sensor Tray 2 Figure 11 721 Front Fuser Exit Sensor Figure 8 222 Low Paper Sensor Tray 3 Figure 11 722 Rear Fuser Exit Sensor Figure 8 223 Feedout Sensor Tray 2 Figure 12 811 ADF Harness connection to Scanner Figure 14 224 Feedout Sensor Tray 3 Figure 12 812 ADF Drive Motor Figure 14 225 Nudger Solenoid Assembly Tray 2 Figure 11 813 ADF Exit Motor Figure 14 226 Nudger Solenoid Assembly Tray 3 Figure 11 814 ADF Control PWB Figure 14 227 Turn Clutch Assembly Tray 2 Figure 10 815 ADF Control PWB Figure 14 228 Turn Clutch Assembly Tray 3 Figure 10 816 ADF Control PWB Figure 14 229 Takeaway Clutch Assembly Tray
255. FEED DRIVE 1 TRANSPORT MECHANISM EN EN EN EM EN m RN mm n m ma mm ma m m m PRE REGISTRATION 86 ROLL DRIVE k EN NEN EN NEN REGISTRATION 86 ROLL DRIVE NEN NEN NN 2 42 TRANSPORT DRIVE m EN NEN EUN 3 TRAY1 TRANSPORT ROLL DRIVE EE NEN NEN NN 4 MCU PWB DO 1F PRE REGISTRATION PRE REGISTRATION CLUTCH ASSY CLUTCH ON PL4 6 2520 9 24 0 acy GRY GRY 1 24VDC 222 SWITCHED 2 fy 5 1 DO 1E REGISTRATION d I REGISTRATION CLUTCH ASSY 24706 11 CLUTCH ON PL4 7 L 424VDC WW 241 22 IGRY GRY 1 224 1 2 A i 24VDC Z 25 SWITCHED GRY 6 5222 gt D 1708706A WOL Figure 1 Registration Mechanism Wiring Data 10 00 Initial Issue 7 82 Phaser 790 DocuColor 2006 MCU PWB PL11 2 DO 0E BCR DC ON L 24VDC HIGH VOLTAGE POWER SUPPLY PL11 1 BCR CONTROL GRY DC BCR DC CONTROL GRY LOW VOLTAGE POWER SUPPLY PL11 1 DRUM MODULE Figure 1 Charging and Exposure EXPOSED DRUM T709700A WOL Initial Issue Phaser 790 DocuColor 2006 10 00 7 83 Wiring Data 9 2 DRUM DRIVE PROCESS DRIVE ASSY MCU PWB PL10 1 PL11 2 PL11 2 PROCESS MOTOR LDO 54 01 72 1 PROCESS MOT
256. FULL SENSOR Status Indicator RAPs Initial Issue Phaser 790 DocuColor 2006 10 00 2 203 011 705 011 706 Cannot Select Sorter RAP Control Logic did not detect the Sorter Procedure Go to Flag 1 Check the wires for an open circuit The wires are good Repair the wires Replace the Sorter Control PWB PL 19 1 Replace the MCU PWB PL 11 2 Status Indicator RAPs 10 00 Initial Issue 011 706 2 204 Phaser 790 DocuColor 2006 MCU PWB SORTER CONTROL PWB PL142 MCU PWB PL19 1 PL11 2 00 77 P10 START 133 0133 P8 J8 EDS a GRY rO ARED 10 48 P8 J133 P133 COMMUNICATION LINE P10 J10 TRANSMITTER COMMUNICATION 1 RECEIVER TRANSMITTER VIO 4 GRY 4 Lo LNE g 1 P ud GRY 21 5WHT EE EE EE Bales 24 RETURN NN EX RETURN GRY GRY 155 6 11 1 o o 17 11 o P10 P22 P18 J9 P16 P19 B J8 SORTER P15 J5 CONTROL MCU PWB PWB J10 F1 F2 P12 21 7 jg 4 o Figure 1 011 706 RAP Circuit Diagram Initial Issue 10 00 Status Indicator RAPs Phaser 790
257. Face Up B W prints Approximately 10 9 seconds Face Up Color prints Approximately 25 9 seconds Face Down B W prints Approximately 13 9 seconds Face Down Color prints Approximately 28 9 seconds Image Loss Following are the image loss specifications Table 10 Image Loss Specifications ADF Specifications ADF Physical Characteristics Table 1 ADF Dimensions and Weights Dimension US Metric Width 24 640 mm Depth 20 5 535 mm Height 9 130 mm Weight ADF only 31 Ib 14 kg ADF Electrical Specifications Frequency 50 60 Hz 2 Input Voltage 5 VDC and 24 VDC supplied by 101 Power Consumption 120 Watts ADF System Capability Document Size Maximum 11 x 17 A3 Minimum 5 5 8 5 A5 The ADF recognizes standard document sizes as shown Table 2 and Table 3 Table 2 ADF Size Sensing NASG Copy Portion Specification Top Edge 4 0 mm or less Right Edge 4 0 mm or less Left Edge 4 0 mm or less Bottom Edge 4 0 mm or less Document Size 4 mm Sensed Size 11x17 11x17 280x432 11x14 9 SEF 11x17 280x432 8 5x14 SEF 8 5x14 216x356 8 5x13 SEF 8 5x14 216x356 8 5x12 4 SEF 8 5 11 SEF 8 5 11 216 280 8 5 11 LEF 11 8 5 280 216 8 10 5 8 11 216 280 8x10 LEF 11x8 5 280x216 8 5x5 5 SEF 5 5x8 5 140x216 8 5x5 5 LEF 8 5x5 5 216x140 A4 SEF A4 210x297 A4 LEF A4 297x210
258. Figure 1 Removing the Lamp Replacement 1 Perform the procedure for removal in reverse Repairs and Adjustments 10 00 Initial Issue REP 6 1 9 REP 6 20 4 50 Phaser 790 DocuColor 2006 REP 6 21 Full rate Carriage Assembly Parts List on PL 16 5 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Platen Glass REP 6 1 3 Remove the Full rate Carriage Figure 1 3 Remove the screws 2 and the Full rate Carriage 2 1 Disconnect the Ribbon Position the Full rate Carriage to the Cable center position near the frame cut outs O10SOTSADVOL Figure 1 Removing the Full rate Carriage Assembly Replacement 1 Perform the procedure for removal in reverse REP 6 22 FLPS PWB Parts List on PL 16 5 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Platen Glass REP 6 1 CAUTION The PWB components are highly susceptible to damage from electrostatic discharge ESD and extreme care should be used when handling these components Use of the ESD Field Service Kit is required 3 Remove the FLPS PWB Figure 1 2 Perform a Full Half rate Carriage
259. Guide Lock Knob P O PL 13 8 Item 1 4 Max Label P O PL 13 8 Item 1 2 1 5 Lift Plate P O PL 13 8 Item 1 6 _ Guide Spring P O PL 13 8 Item 1 7 5 End Guide Actuator P O PL 13 8 SS Item 1 7 8 Side Guide Actuator P O PL 13 8 Item 1 9 Spring P O PL 13 8 Item 1 10 Level P O PL 13 8 Item 1 11 End Guide Link PL 13 8 Item 1 12 End Guide PL 13 8 Item 1 13 End Guide Plate P O PL 13 8 Item 5 1 14 Side Guide Plate P O PL 13 8 1 15 Side Guide P O PL 13 8 Item 1 16 Bottom Pad P O PL 13 8 1 17 Guide Plate P O PL 13 8 Item 1 12 2 s lt lt EE i Z Yi 1 Sap oy 154 i Reset 13 S 14 11 S 0015009A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 51 PL 13 9 PL 14 1 OHP Transparency Tray Assembly 1 of 2 Item Part Description 1 050K42460 OHP Transparency Tray Assembly 0014001A WOL Parts List 10 00 Initial Issue PL 14 1 5 52 Phaser 790 DocuColor 2006 PL 14 2 OHP Transparency Tray Assembly 2 of 2 Item Part Description 1 050K42460 Transparency Tray Assembly 2 Tray Housing P O PL 14 2 Item 1 3 Link Spring P O PL 14 2 1 4 Plate Link P O PL 14 2 Item 1 5 Transparency Lift Plate P O PL 14 2 Item 1 6 Tray Lift Spring P O PL 14 2 Item 1 7 Front Guide Assembly P O PL 14 2 Item 1 8 038E88420 Front Guide 9 019K97140 Transparen
260. ISUALCAL PRINT GRAYS YES is displayed Press the Item Enter button PRINTING GRAY BALANCE PAGE is displayed and after a few moments the page is delivered to the Output Tray a Select the color patch that is most like the gray that surrounds the color patches b Circle your selection BEST PATCH ROW is displayed Press the Up and Down arrow buttons to enter the number of the row that corresponds to your circled selection Press the Item Enter button and perform one of the following steps a If you have entered any number other than 0 BEST PATCH COL is displayed i Press the Up and Down arrow buttons to select the letter or name of the column that corresponds to your circled selection 14 ii Press the Item Enter button PRINTING GRAY BALANCE PAGE is displayed and after a few moments the page is delivered to the Output Tray iii Select the color patch that is most like the gray and perform steps 12 and 13 again b Ifyou have entered 0 PRINT COLOR TEST YES is displayed i Press the Item Enter button and after a few moments the Comparison Page is delivered to the Output Tray NOTE The Comparison Page allows you to see the changes that you made during the VISUALCAL adjustment On the page are four rows of color photographs The first row and the third row show the color setup before you selected VISUALCAL Rows two and four show the color setup after the VISUALCAL adjustment was completed Now you must decide which setup i
261. IT SENSOR 1 17 1 11 2 o GEARS PIO 34 pig 18 22219 23 18 24 pig i 17 17816 D 28 1 P15 MCU PWB P20 LOWER EXIT ROLL 15 15 14 P12 M6 PH A 12 3 1 1 816 8 P21 o 1 EXIT TRANSPORT ASSEMBLY GEARS 1708008A WOL Figure 1 008 703 RAP Circuit Diagram Status Indicator RAPs 10 00 Initial Issue 008 703 2 126 Phaser 790 DocuColor 2006 A 008 704 Area 6 Jam RAP The Control Logic had detected the signal Inverter Sensor Sensed 1 5 VDC at an incorrect time Go to Flag 3 Check the wires for an open or short circuit to ground If the wires are good replace the Inverter Entrance Clutch PL 15 6 If the problem continues replace the Duplex Controller PWB PL 15 6 Check for worn bound or damaged gears in the Inverter drive train Replace as necessary PL Initial Actions 15 6 Clear the jam from the Lower Inverter Assembly Check that the Lower Inverter Door Assembly is closed properly Check for contamination on the Inverter Rolls Procedure Switch off the power Remove the Lower Inverter Assembly REP 8 35 Remove the Inverter Rear Cover Install the Inverter Assembly Check that the Inverter Sensor Actuator is operating properly Close the Inverter Chute Enter diagnostic code DI 90 The display indicates a 1 Y Go to Flag 1 and Flag 2 Check the wire for a short circuit to ground If the wire is good replace the Duplex Controller PWB PL 1
262. Initial Issue Phaser 790 DocuColor 2006 10 00 6 23 General Procedures and Information IOT Specifications ADF Specifications Table 3 ADF Size Sensing ESG Document Size 4 mm Sensed Size 11x14 9 SEF 11x17 280x432 8 5x14 SEF 8 5x14 216x356 8 5x13 SEF 8 5x14 216x356 8 5x12 4 SEF A3 297x420 B4 SEF B4 257x364 A4 SEF A4 210x297 A4 LEF A4 297x210 B5 SEF B5 182x257 B5 LEF B5 257x182 A5 SEF 5 148x210 A5 LEF 5 210x148 Document Weight Document Tray Capacity 50 documents 38 100 gsm 40 documents 101 138 gsm Duplex 50 gsm 110 gsm Size Mixed Mode In this mode sizes from 5 5x8 5 A5 to 11x17 A3 can be mixed Registration Lead edge 2 5 mm Side edge 3 mm Skew 2 5 mm IIT Scanner Specifications Following are the Scanner specifications Magnification R E Factors Magnification is variable in 196 increments from 2590 to 40096 Six preset R E factors are also available the following table shows the preset R E factors available Table 1 R E Presets NASG ESG 6490 7090 7890 8196 10096 86 129 100 154 115 200 141 The following table indicates the factors to use when enlarging or reducing from a specific size document to a specific size copy Table 2 Common R E Factors Original size
263. Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 73 PL 17 5 PL 17 6 Document Transport Platen Belt Item Part Description 1 Document Transport Assembly Not Spared REP 5 7 ADJ 5 4 2 Transport Frame Spared 3 059K13440 Pinch Roll 4 Collar Not Spared 5 004E98270 Damper 6 022K39710 Idler Roll 7 023E15690 Platen Belt 8 022K39700 Drive Roll 9 10 007E83141 Gear 11 Screw Not Spared 12 Rear Roll Not Spared 13 Roll No 1 Not Spared 14 Roll No 2 Not Spared 15 Front Roll Not Spared 16 013E80970 Bearing 17 ADF Main Framie Not Spared 0017006A WOL Parts List 10 00 Initial Issue PL 17 6 5 74 Phaser 790 DocuColor 2006 PL 17 7 Exit Roll Exit Motor Exit Sensor Item Part Description 1 059K91200 Upper Exit Roll 2 013E92760 Bearing 3 020 93230 Pulley 4 023E 15810 Belt 5 127K25420 ADF Exit Motor REP 5 9 6 105E94661 Antistatic Brush 7 026E17760 Screw 8 110 94420 Exit Tray Interlock REP 5 10 9 130K83020 ADF Exit Sensor REP 5 10 10 Bracket Not Spared 11 026E82620 Screw 12 059K13330 Lower Exit Roll 13 Pulley Not Spared 14 Exit Chute Not Spared 15 054K87731 Exit Chute Cover Assembly 16 Exit Chute Cover P O PL 17 7 Item 15 17 022K30330 Pinch Roll 18 022K30360 Pinch Roll 19 Harness Spared 0017007A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 75 PL 17
264. Inner Cover Assembly REP 14 5 Remove the Rear Cover REP 14 6 Remove all Dry Ink Cartridges REP 9 9 Remove the Left Front Cover Interlock REP 1 7 Remove all Developer Housings REP 9 10 Remove the Rotary Sensor REP 9 11 Remove the Fuser Assembly REP 10 1 Remove the Exit Transport Assembly REP 8 40 Remove the Rotary Motor PWB REP 4 8 Remove the Rotary Motor REP 4 7 Remove the Dispense Clutch REP 4 9 Remove the LVPS REP 1 1 Remove the Fuser Drive Unit REP 4 2 Remove the Developer Clutch REP 4 10 Remove the Developer Tie Plate REP 9 14 21 Remove the Rotary Knob Figure 1 2 Disengage the knob with a screwdriver 1 Remove the screw 3 Remove the Rotary Knob Figure 1 Removing the Rotary Knob 0109025A WOL Repairs and Adjustments REP 9 12 10 00 4 100 Initial Issue Phaser 790 DocuColor 2006 WARNING The Rotary Frame is very heavy Be careful not to drop or touch other components while removing the Rotary Frame CAUTION Keep the front shaft of the Rotary Frame from falling from the machine while performing the fol lowing step by keeping the front of the Rotary Frame supported 22 Remove the Rotary Frame Figure 2 Replacement 1 Reinstall the Rotary Frame in the reverse order of removal 3 Disengage the front shaft 4 Move the frame forward and lift to remove the Rotary Frame
265. J 5 1 ADJ 5 2 ADJ 5 3 2 036K90890 Left Counterbalance REP 5 3 ADJ 5 1 ADJ 5 2 ADJ 5 3 3 020K93320 Pulley Assembly 4 020E16180 Pulley 5 068K78200 Bracket 6 Bracket PL 17 2 Item 3 7 013E81880 Bearing 8 Shaft P O PL 17 2 Item 3 9 020K93300 Pulley 10 020E90660 Pulley 11 023 08520 12 023 08510 Belt 13 013E81940 Bearing 14 009 48250 Spring 15 023 08500 16 127K29890 ADF Drive Motor REP 5 2 17 162K60410 Drive Harness 18 Clamp Not Spared 19 160K11571 ADF Control PWB 20 Support Spared 21 Support Not Spared 22 108E93270 Fuse 4A 125v 23 Safety Cover Not Spared 0017002A WOL Parts List 10 00 Initial Issue PL 17 2 5 70 Phaser 790 DocuColor 2006 PL 17 3 Registration Feed Nudger Roll Nudger Home Sensor 26 23 24 Item Part Description 27 t 11 1 x Registration Pinch Roll P O PL 17 3 27 28 14 17 2 008 92010 Front Cam 3 008 92020 Rear Cam 4 019E93510 Push Rivet 5 012E93430 Link 6 013E94561 Bearing 7 009E28580 Spring 8 005E80250 C Ring 9 013E82290 Bearing 10 009E39080 Spring 11 ADF Registration Roll P O PL 17 3 Item 27 REP 5 6 12 013E80970 Bearing 13 007E88100 Gear 14 Feed Roll P O PL 17 3 28 REP 5 4 15 013E81370 Bearing 16 007K91871 Gear 17 Nudger Roll P O PL 17 3 Item 28 REP 5 5 18 020693310 Pulley 19 007K81110 Gear 20 007K81980 Gear 21 007E83250 Gear 22 015E32720 Actuator 23 107E06650 Nudger Home Sen
266. J19 71 J71 J76 P76 4117 4 1 7 4 3 FUSER IN SENSOR GRY GRY GRY 10 1 980 P80 9 A2 A9 2 FUSER CHUTE FAN t GRY GRY 10 3 J48 J245 5 ROTARY MOTOR PWB GRY 93 J20 491 91 4201 P201 J204 8 7 8 PITCH SENSOR GRY 82 1 1 1 1 1 9209 11 1 A4 Ati L 4 11 STACK HEIGHT SENSOR 1 GRY 1 1 1 1 GRY 72 1 1 1 1 1 LIFT PLATE SENSOR 4 142 GRY 14 GRY 72 1 1 1 198 1723 812 83 OHP SENSOR GRY GRY 8 6 J93 leet trei ro REGISTRATION SENSOR 20 GE B9 B6 ay 2 Leen t o CONTINUED CONTINUED 1728001A WOL Figure 1 5 VDC 1 of 3 Wiring Data Initial Issue 10 00 7 26 Phaser 790 DocuColor 2006 5 VDC Wirenet 2 of 3 5 VDC 2 OF 3 WIRENET OMNE c LVPS MCU PWB CONTINUED J23 J105 4 64 1 ENVIRONMENT SENSOR GRY 74 1 J100 1 gt BTR CAM SENSOR GRY 9 9 1 465 4 142 5 CRUM CONNECTOR ASSEMBLY GRY 33 DUPLEX CONTROL PWB 422 J134 P184 J142 J141 P134 J134 J155 P155 J159 P159 M rory AOA Gay 4 ery 1818 BA aay f GRY 3 5 VDC i i i l i 1 I J160 P160 26 4 1
267. L Figure 1 001 710 Circuit Diagram Status Indicator RAPs 10 00 Initial Issue 001 710 2 24 Phaser 790 DocuColor 2006 001 711 Area 6 Open RAP The Control Logic has detected that area 6 is open Initial Actions Perform the following Ensure that the Inverter Chute PL 15 5 is fully closed Ensure that the actuator for the CAB Interlock is not broken Repair any obvious defects Procedure Access the Digital Input DI test from the Control Panel Enter code 93 Press the Item Enter button The display indicates 0 Y N Go to Flag 1 and Flag 2 Check the wires for a open circuit If the wires are good replace the Duplex Controller PWB PL 15 6 The problem may be intermittent Go to Flag 1 and Flag 2 and check for loose or damaged connections or damaged wires If the problem persists replace the replace the Duplex Control ler PWB PL 15 6 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 25 001 711 DUPLEX A CONTROLLER PWB PL15 6 CAB INTERLOCK PL15 6 1 D93 5 VDC CAB INTERLOCK 5 4153 CLOSED L 5 VDC 4139 E GRY 2 4 4 5 GRY DC COM Le INTERLOCK Figure 1 001 711 Circuit Diagram P139 P140 P142 DUPLEX CONTROLLER PWB T701009 A WOL Status Indicator RAPs 001 711 10 00 2 26 Initia
268. L Figure 1 007 708 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10 00 2 103 007 708 007 709 Tray 2 Lift Up RAP The Control Logic has detected that Tray 2 is not in position to feed paper Initial Actions Check that the tray lift mechanism within paper Tray 2 functions correctly Procedure Switch off the power Pull out and reinstall Tray 2 Remove the Upper Rear Cover and the Lower Rear Cover Observe the Feed Motor Switch on the power The Feed Motor operates when the machine starts self test Y There is 24 VDC from 217 pin 14 to ground on the Feeder PWB Y N There is 24 VDC from 213 pin 1 to ground on the Feeder PWB Y Go to Flag 5 Ensure that the connectors PJ 32 PJ 211 and PJ 213 are prop erly connected Check the wires for an open or a short circuit to ground Switch off the power Disconnect the power cord Replace the Feeder PWB PL 15 4 There is 24 VDC from 217 pin 12 to ground the Feeder PWB Go to 1 and 2 Check for an open circuit or a short circuit to ground The wires are good Y Repair the wires Replace the Feeder Motor PL 13 4 Switch off the power Pull out and reinstall Tray 2 Switch on the power There is 0 VDC from PJ 217 pin 12 to ground Y N Replace the Feeder PWB PL 15 4 Switch off the power Disconnect the power cord Check the Feeder Drive Unit for worn bound or damaged gears in the Feeder Motor drive train
269. L 11 2 Go to Flag 4 Check the wires for an open or a short circuit to ground If the wires are good replace the OHP Sensor PL 4 6 Go go Flag 4 Check the wires for an open or a short circuit to ground If the wires are good replace the OHP Sensor PL 4 6 A NOTE Listen close to the Bypass Tray in order to hear the clutches engage when the diagnos tic output codes are entered It may be necessary to stop a diagnostic output code and start it again several times in order to hear the clutches energize Enter DO 1F The Pre Registration Clutch engaged Y Remove the Bypass Tray Assembly from the machine Disconnect P 95 located on the underside of the Registration Transport There is 180 Ohms or less from P 95 pin 2 to pin 1 Y N Replace the Pre Registration Clutch Assembly PL 4 6 Go to Flag 8 and Flag 5 Check the wires for an open or short circuit to ground If the wires are good replace the MCU PWB PL 11 2 Clean the Pre Registration Roll the Registration Metal Roll and the Registration Rubber Roll PL 4 7 Install the Bypass Tray Assembly Enter DO 1E The Registration Clutch engaged Y Remove the Bypass Tray Assembly from the machine Disconnect P 94 located on the underside of the Registration Transport There is 180 Ohms or less from P 94 pin 2 to pin 1 Y Replace the Registration Clutch Assembly PL 4 7 Go to Flag 9 and Flag 6 Check the wires for an open or short circuit to ground If t
270. L 15 6 If the problem continues replace the MCU PWB PL 11 2 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 35 003 311 DUPLEX MCU PWB CONTROLLER PWB MCU PWB PL11 2 PL15 6 PL11 2 J22 J134 P134 J142 29 PRE RES A6 A114 6 GRY GRY START 30 12 5 GRY 1 GRY J142 Y P134 J134 RD J22 3 A14 32 TXD i i GRY i GRY 31 A4 A132 4 003 311 GRY GRY ya READY E 34 PCCM aig 1 GRY GRY GRY GRY 1 DC COM DC COM vpp 2140 GRY 2 GRY NC 3 DC o DUPLEX CONTROLLER P139 P140 S o 5 PWB P10 P16 pig P22 P18 8 DUPLEX P14 P17 CONTROLLER PL P15 MCU PWB P20 3 P12 P23 E P11 1703003 A WOL Figure 1 003 311 RAP Circuit Diagram Status Indicator RAPs 10 00 Initial Issue 003 311 2 36 Phaser 790 DocuColor 2006 003 312 Sorter Communications Failure RAP The Sorter Control Logic did not successfully receive the Start signal from the MCU PWB Procedure Go to Flag 1 and check the wires for an open or short circuit The wires are good Y N Repair the wires Replace the Sorter Control PW
271. L 3 1 PL 3 3 PL 4 3 121E84500 PL 3 1 PL 8 2 121E87040 PL 8 7 PL 8 6 121E90450 PL 17 4 130E82190 PL 4 2 121E90640 PL 17 1 PL 4 4 122E91950 PL 16 5 130E82650 PL 13 5 122K93100 PL 5 1 PL 4 6 126K11290 PL 8 3 PL 4 3 126K11300 PL 8 3 PL 15 3 126K11330 PL 8 3 130E82730 PL 15 5 126K11340 PL 8 3 PL 9 2 127K25400 PL 10 1 130K82780 PL 17 5 127K25410 PL 10 1 130K82790 PL 17 3 127K25420 PL 17 7 130E82830 PL 6 1 127K27450 PL 10 1 130E82980 PL 5 1 127K28260 PL 13 4 130 83020 PL 17 7 127K28300 PL 10 1 130E83060 PL 6 1 127K29160 PL 15 5 130E84270 PL 7 3 127K29440 PL 16 1 130E84410 PL 19 2 127K29610 PL 16 4 130E84420 PL 19 3 127K29890 PL 17 2 130K86470 PL 19 3 127K31700 PL 10 1 130E91010 PL 5 1 127E81620 PL 8 6 140K60480 PL 17 1 127E81670 PL 12 1 144E00420 PL 12 1 127E81940 PL 9 2 144E00430 PL 12 1 127E81951 PL 9 2 144E00440 PL 12 1 127E82330 PL 19 2 152K63490 PL 17 1 127E82340 PL 19 4 160K11571 PL 17 2 130K58120 PL 16 1 160K56510 PL 10 1 130K60440 PL 5 1 160K61490 PL 10 1 130K60530 PL 11 2 160K61500 PL 11 2 130K60721 PL 8 2 160K62210 PL 16 2 130K61001 PL 16 1 160K67350 PL 16 3 130K61010 PL 16 1 160K67840 PL 16 2 130K61311 PL 9 2 160K68050 PL 19 1 130 61380 PL 17 5 160K69571 PL 16 2 130 61390 PL 19 3 160K69650 PL 12 1 130E81150 PL 17 5 160K69840 PL 16 1 130E81600 PL 13 5 160K70540 PL 15 6 130E81970 PL 13 4 160K74520 PL 13 4 Parts List 10 00 Initial Issue Part Number Index 5 88 Phaser 790 DocuColor 2006 Table 1 Part Number Index Table 1 Part N
272. L 5 1 WARNING HIGH VOLTAGE Exercise caution when measuring High Voltage in the following step Reinstall the ROS and Top covers Remove the Rear Cover Switch on the power Print the Configuration Page from the Main Menu Measure the voltage from terminal C on the HVPS to frame ground The voltage cycles between 0 VDC and roughly 500 VDC Y N Go to the 009 342 RAP to troubleshoot the HVPS Replace the Copy Print Cartridge PL 5 1 Replace the IBT Belt PL 7 2 If the problem remains replace the IBT Assembly PL 7 1 Replace the BTR 2 Assembly PL 7 1 If the problem continues replace the IBT Assem bly PL 7 1 Check the following If there is a gradation in density from front to rear check the Developer Roll spacing ADJ 9 1 for the affected developer Clean the HV contact for the developer in question Replace the Dry Ink Cartridge if not done previously Replace the Developer Housing PL 6 2 Image Quality 10 00 1017 3 20 Initial Issue Phaser 790 DocuColor 2006 1018 Spots RAP Initial Actions Ensure that the paper in use is fresh dry and within specification for weight and quality Compare the spots against the samples in the Image Quality Defects supplement If the defect matches the Debris Centered Deletions sample go to the IQ9 RAP If the defect matches the Drum Defect sample replace the Copy Print Cartridge PL 5 1 Procedure The defect occurs in Copy mode only Y N The spots
273. L17 2 DRIVE MOTOR PL17 2 14 z A 6 1 A 24 VDC ADF DRIVE MOTOR ON 5 VDC A i 24V CLOCK P y NUOGER HOME 5 gt I 13 SENSED H 5 VDC 1 ADF DRIVE MOTOR ON YEL I 24 CLOCK gt 3 I gt i ADF DRIVE MOTOR ON 2 24V CLOCK F 7 ORN ORN ADF DRIVE MOTOR ON NUDGER HOME ae 24V CLOCK SENSOR 0 PL17 3 BRN BRN 2 25 ADF CONTROL PWB FA CR2 P811 P813 RED CR3 GRN P812 U2 m P815 P814 P816 1705002 A WOL Figure 1 005 210 RAP Circuit Diagram Status Indicator RAPs 10 00 Initial Issue 005 210 2 52 Phaser 790 DocuColor 2006 005 211 ADF Power RAP ADF Motor Power Error Procedure Remove the ADF Rear Cover There is 24 VDC from pin 11 to pin 12 on J811 Y Go to Flag 1 Check for an open circuit If the wires are OK go to the 001 712 RAP Check the fuse on the ADF Control PWB PL 17 2 If the Fuse is OK replace the ADF Control PWB PL 17 2 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 53 005 211 ICM MAIN PWB PL16 2 ADF CONTROL PWB PL17 2 ADF CONTROL PWB P813 CR2 RED U2 P815 F1 CR3 P811 GRN P812 2 P814 P816 ICM PWB
274. LM 24V RED RED I ADF DRIVE MOTOR ON ja 24Y CLOCI OR 3 ADF DRIVE MOTOR ON 24V CLOC ICM MAIN PWB PL16 2 5 VDC DOCUMENT READY 4811 L 5 VDC YEL 4 5 6 T705703 A WOL Figure 1 Document Transportation 1 of 2 Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 59 BSD 5 3 ADF CONTROL PWB PL17 2 5 VDC REGISTRATION ADF CONTROL SENSOR PWB DOCUMENT AT ADF REGISTRATION SENSOR L J814 4712 J814 6 GRY 1 2 YEL 5 Q 3 1 5 VIO 2 DC COM FEED ROLL DRIVE om w T705704 A WOL Figure 1 Document Transportation 2 of 2 Wiring Data 10 00 Initial Issue 7 60 Phaser 790 DocuColor 2006 A B D E F G H J DOCUMENT TO EXIT 5 4 DOCUMENT EXIT TRAY 1 ADF CONTROL EXIT MOTOR PWB PL17 7 PL17 2 2 IT MOTOR ON 24 EXIT DRIVE IT MOTOR ON 24V m m m m m m m NH NH NH UH MOTOR ON 24V ADF CONTROL 3 IT MOTOR ON 24 m PL17 2 5 VDC 2 DOCUMENT AT EXIT SENSOR L 5 VDC 1 YEL 4 EXIT SENSOR PL17 7 EXIT TRAY INTERLOCK PL17 7 5 MAGNET EXIT TRAY INTERLOCK m id 4719 OPEN 5 VDC 1 YEL 6 T705705 A WOL Figure 1 Document Exit Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 61
275. M 42 40 40 1 BRN BRN 5 VDC E441 3 GRN 14 DC COM SORTER TOP COVER INTERLOCK 4 DOCKING INTERLOCK 11 2 SORTER COMMUNICATION SORTER CONTROL PWB 5 MCU PWB MCU PWB PL11 2 PL11 2 DO 77 J10 P10 START 282193 48 GRY pe REDS J8 J133 P133 COMMUNICATION LINE F101910 COMMUNICATION i RECEIVER TRANSMITTER r 4 Vio 4 GRY 4 TRANSMITTER i 2 LINE 2 i i 3 hop GRY WHT T E an b 1 ME L51 RETURN Ld RETURN 524 EE ORN GRY 6 GRY BLK 6 11 a 159 DC SOM 1711700 A WOL Figure 1 Sorter DC Power Generation and Top Cover Docking Interlock and Sorter Communication Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 105 BSD 11 3 A B D E G H J 11 3 SORTER TRANSPORTATION SORTER CONTROL PWB RECEIVER PL19 1 SENSOR SORTER PL19 2 0606 TONDE CONTROL PWB PAPER IN BIN SENSED PL194 J10 P10 45 ypg P201 4201 4201 P201 5 VDC P10 J10 5 1 RED BLU 5 g DC COM 5 RECEIVER 2 77 vio SENSOR 44 77 TO SORTER 2 TRANSMITTER SORTER lt EIS SENSOR PATH 20
276. NING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine REP 4 10 Developer Clutch Parts List on PL 10 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Rear Cover REP 14 6 2 Remove the Rear Cover REP 14 6 3 Remove the Fuser Motor REP 4 3 3 Remove the Fuser Assembly REP 10 1 4 Remove the Rotary Motor PWB REP 4 8 4 Remove the Fuser Motor REP 4 3 5 Remove the Dispense Clutch Figure 1 5 Remove the Rotary Motor PWB REP 4 8 Replacement 6 Remove the LVPS 1 1 1 Reinstall the Dispense Clutch in the reverse order of removal 7 Remove the Fuser Drive Unit REP 4 2 8 Remover the Developer Clutch Figure 1 1 4 Replacement Remove the Slide the gear to the notch in the 1 Reinstall the Developer Clutch in the reverse order of removal ground wire frame hole and remove the Dis Screw 2 1 Disconnect the connector and free the Discon harness nect the connector d 3 tet ue Remove the screws EF 1 0101028A WOL Remove the 1724 Developer Figure 1 Removing the Dispense Clutch Rem
277. NING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Front Cover or Rear Cover as required NOTE The removal procedure for both the Front and Rear Gear Shafts are the same 3 Remove the Front Rear Gear Shaft Figure 1 1 Release the Gear Shaft 2 from the retainers Remove the Gear Shaft 111011A WOL Figure 1 Removing the Front Rear Gear Shaft Replacement 1 Perform the procedure for removal in reverse 2 Perform a Sorter Bin Cam Position Adjustment ADJ 11 1 REP 11 11 Front Rear Bin Cam Parts List on PL 19 4 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Front Cover or Rear Cover as required NOTE The removal procedure for both the Front and Rear Bin Cams are the same 3 Remove the Front Rear Bin Cam Figure 1 3 NOTE Retain the KL 1 clip top and bottom bearings and gear for Release the later reinstallation Bin Cam Remove the KL clip Spring and move the Bin Cam downward to free it from the Gear and top D LA retainer Z gt 4 Ex Remove the 5 NOTE The Bin Cam Switch Actuator is not
278. NVRAM ner PARAMETERS selection Switch on the main power 11 Press the Item Enter button NO is displayed Press the Up Arrow button to change NO When the message Ready to Download appears on the Scanner Control Panel to YES and then press the Item Enter button to enable the change The message release the switch CLEAR NVRAM SUCCESSFUL will appear and then change to CLEAR NVRAM 3 Connect the PC to the Scanner at the serial port of the Scanner with an RS 232 C cable PARAMETERS 4 PC setup the Hyperterminal or other software as follows 12 Press the Clear Stop button to reboot the Printer a Select Start Programs Accessories Hyperterminal Hyperterminal 13 Print the Configuration Page GP 14 and verify that the version yymmdd has been b When the Hyperterminal dialogue box opens type in Comm port updated Select OK or press the Enter key d When the Connect to dialogue box opens select the appropriate Com port and select OK or press the Enter key e When the Port Settings dialogue box opens setup the following parameters i Bits per second 115200 if results are not satisfactory change the rate as required ii Data bits 8 iii Parity None iv Stopbits 1 v Flow Control None vi Select OK or press the Enter key 5 Set up ASCII for Local Echo Scanner does not echo back input characters Therefore this must be set to ON a SelectFile Properties Settings and ASCII Setup b Select Echo Typed Characters Locally
279. ON 401 L 24vDC 14 DC BIAS GRY i CONTROL DC COM DEVELOPER DC BIAS CONTROL 8 16 i H 5 LOW VOLTAGE POWER SUPPLY PL11 1 J32 441 5 T709704 A WOL Figure 1 Development 1 of 2 Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 87 M IS 9 4 DEVELOPMENT 2 OF 2 DEVELOPER MECHANISM a HOT AIR 1 ZONE E1 93 POSITIONED 1 DEVELOPER DEVELOPMENT 9 6 DEVELOPED IMAGE EN 9 p DEVELOPED 9 5 s IMAGE TO ADC 4 5 DEVELOPER mi m matu ma ma __ 91 EXPOSED DRUM N 6 22 1709705A WOL Figure 1 Development 2 of 2 10 00 Initial Issue 7 88 Phaser 790 DocuColor 2006 Wiring Data BSD 9 5 D E F G H J 9 5 DISPENSE CONTROL ADC SENSOR MCU PWB ASSY PL11 2 MCU PWB PL5 1 DISPENSE 1 PL11 2 SENSOR FA is DO 72 s 561 PL10 1 CDO 72 J I 5 H lt 9 DIBPENSE ADC LED ON J84 P84 CLUTCH ON 55 L 5VDC DISPENSE 20 L 24VDC NO GRY TIMER 1 GRY 1 1 i i i i i 00 671 ADC aay 12 44 ADC P81 SEN
280. ONT FAN PWB PL16 7 J150A J150B FAIL H 5 M IAE 133 J150B J150A 182 GRY RED MOT 2 2 2 WHT GRY GRY BLK REAR FAN FAIL H 5 VDC 4151 WHT FAN PL16 1 2 REAR FAN ON 24 RED MOT BLK REAR FAN FRONT FAN T706006 A WOL Figure 1 006 313 RAP Circuit Diagram Status Indicator RAPs 10 00 Initial Issue 006 313 2 72 Phaser 790 DocuColor 2006 006 372 Start of Scan Error RAP During or after warm up the Start of Scan SOS signal is longer than specified Procedure Switch off the power Remove the IOT Top Cover Assembly REP 14 4 Remove the Control ler Chassis REP 1 11 Switch on the power Cheat the Top Cover Interlock Approxi mately 4 VDC is measured between J 14 11 and J14 10 on the MCU PWB Go to 1 and check the wire for a short circuit to ground If the wire is good replace the MCU PWB PL 11 2 24 VDC is measured between J 14 13 and J14 10 on the MCU PWB Y N Replace the MCU PWB PL 11 2 Switch off the power Remove the ROS Cover Disconnect J 123 from the ROS Measure the resistance between the following plug jack pins 14 11 on the MCU PWB to J123 3 P J14 13 on the MCU PWB to J123 1 P J14 12 on the MCU PWB to J123 2 P J14 10 on the MCU PWB to J123 4 All the measurements are less than 1 0 Ohm Y N Go to Flag 1 and Flag 2 Check the wires for an open circuit Reconnect J 123 Switch on the power 5 VDC is measured at J
281. OR ON PROCESS MOTOR FAIL L 7 27VDC 5VDC GRY GRY PROCESS MOTOR 09 323 SPEEDO PROCESS MOTOR CLOCK GRY GRY PROCESS MOTOR SPEED 1 GRY DRUM DRIVE MECHANISM LOW VOLTAGE POWER SUPPLY PL11 1 m ma m um w E ma m ma m SPEEDO SPEED1 H H L H L L 1709701 A WOL Figure 1 BSD 9 2 Drum Drive Wiring Data 10 00 Initial Issue 7 84 Phaser 790 DocuColor 2006 9 3 DEVELOPER ROTARY CONTROL 1 2 MCU PWB PL11 2 ROTARY MOTOR CLOCK J245 ROTARY MOTOR PWB PL10 1 DO 11 ROTARY MOTOR L 5VDC DO 10 ROTARY MOTOR LOW SPEED L 5VDC ROTARY MOTOR PL10 1 LOW VOLTAGE POWER SUPPLY PL11 1 24 INTLK y VDC Figure 1 Developer Rotary Control 1 of 2 T 709702 A WOL Initial Issue Phaser 790 DocuColor 2006 10 00 7 85 Wiring Data BSD 9 3 L M N R 5 9 3 DEVELOPER ROTARY CONTROL 2 0 2 DEVELOPER ROTARY FRAME OPERATOR SET 2 TONER CARTRIDGE DISPENSE CLUTCH POSITIONED 34 DEVELOPER Y 3 MCU PWB c PL11 2 MCU PWB CARTRIDGE SENSOR PL11 2
282. P 1 9 Remove the Controller Chassis Figure 1 Replacement 1 Reinstall the Controller Chassis in the reverse order of removal oRONM 4 Lift to disengage then remove the Controller Chassis 3 Remove the five upper screws 1 Loosen the Open the Bypass Tray four lower Registration Assembly Screws 0101010A WOL 0101009A WOL Figure 1 Removing the Controller Chassis Figure 1 Removing the ESS Fan Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 11 REP 1 10 REP 1 11 REP 1 12 Communication PWB Parts List on PL 11 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Bypass Tray Registration Assembly REP 8 10 3 Remove the Communication PWB Figure 1 Replacement 1 Reinstall the Communication PWB in the reverse order of removal E N o Disconnect the NS Compress the connector N two standoffs 7 2 SSA 2 9 Remove the Communication PWB 0 101012 WOL Figure 1 Removing the Communication PWB Repairs and Adjustments 10 00 Initial Issue REP 1 12 4 12 Phaser 790 DocuColor 2006 REP 1 13 Hard Disk Drive Assembly Parts List on PL 12 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power s
283. P CONTROL PWB DO AO INVERTER MOTOR gt 7 J189 ON H 5VDC INVERTER INVERT IN 106 DRIVE DUP CONTROL mom m m PL156 77 7 INVERT 10 6 INVERTER MOTOR com 4 4147 FAIL H 5VDC J139 6 2 GRY m m m m m m m m INVERTROLL 10 5 DRIVE 1 EM M 3 24VDC INTERLOCKED 24VDC 4 0 THE 24VDC INTERLOCKED VOLTAGE IS NOT AVAILABLE WITH THE FUSER DRAWER OPEN 5 6 T710707A WOL Figure 1 Duplex Drive Control Wiring Data 10 00 Initial Issue 7 104 Phaser 790 DocuColor 2006 BSD 11 1 BSD 11 2 11 1 SORTER DC POWER GENERATION AND TOP COVER DOCKING INTERLOCK TU SORTER CONTROE24 VDC VOLTAGE PWB INTLK PL19 1 ALL FOWER SORTER SUPPLY SORTER TOP CONTROL PL11 1 PWB COVER 101 02 INTERLOCK SORTER TOP COVER 424 VDC J85 P183 J133 Pa 8 7 7 pz 37 cf 7 2 COM NO 1 ORN PNK RED BLK P o MEE CH11 24 VDC NE EE ALL DOCKING DECOM 2 r 8 8 INTERLOCK VIO ju BLU 0105 5 VDC NP 46 P10 J10 JO P10 P6 J6 5 9 9 BK 2 a COM NO 2 WHT mE E l CH11 DC COM ALL DC CO
284. P14 11 1 2801 REAR VIEW 15 MCU PWB P20 27 511 HG 272 ce 12 M6 816 lt gt 21 SIZE SWITCH B SIZE 81 82 SWITCH S3 S4 J102 1707013A WOL Figure 1 007 711 RAP Circuit Diagram Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 111 007 711 007 712 Tray 2 Paper Size Not Detected RAP The Control Logic detected that the wrong size paper is feeding from Tray 2 Initial Actions Ensure that the paper in Tray 2 is properly installed and that the tray side and end guides are positioned to touch the paper in the tray Procedure Switch off the power Disconnect the Power Cord Remove the Size Switch PWB PL 13 3 Place the Size Switch PWB so that it does not short circuit to the machine frame Connect the Power Cord Disconnect PJ 235 from the Size Switch PWB Switch on the power There is 5 VDC from J 235 pin 1 to machine ground Y Go to Flag 2 Check the wires for an open or a short circuit to ground The wires are good N Repair the wires Replace the MCU PWB PL 11 2 A Connect PJ 235 on the Size Switch PWB Actuate and hold switches SW1 and SW3 on the Size Switch PWB There is 1 57 0 10 VDC from J 235 pin 2 to machine ground N Go to Flag 1 Check the wires for an open or a short circuit to ground The wires are good Y N Repair the wires Replace the Size Switch PWB PL 13 3 Actuate and hold switches SW2
285. P1737 NASG 008R12571 Waste Container ESG 35P1737 ESG Cotton Swab 35P2162 NASG The following table lists the consumables required for the Phaser 790 35P2162 ESG Table 2 Consumables List for the Phaser 790 Part Number Description Location 6R1009 Black Dry Ink Cartridge NASG 6R1009 Black Dry Ink Cartridge ESG 6R1010 Cyan Dry Ink Cartridge NASG 6R1010 Cyan Dry Ink Cartridge ESG 6R1011 Magenta Dry Ink Cartridge NASG 6R1011 Magenta Dry Ink Cartridge ESG 6R1012 Yellow Dry Ink Cartridge NASG 6R1012 Yellow Dry Ink Cartridge ESG 138575 Copy Print Cartridge NASG 138575 Copy Print Cartridge ESG 08R12571 Waste Container NASG 08R12571 Waste Container ESG General Procedures and Information 10 00 Initial Issue Cleaning Materials Machine Consumables 6 30 Phaser 790 DocuColor 2006 Change Tag Introduction Important modifications to the machine are identified by a tag number which is recorded on a tag matrix label attached to the inside of Front Cover or inside the Front Door This section describes all of the tags associated with the machine as well as multinational applicability classification codes and permanent or temporary modification information Classification Codes A tag number may be required to identify differences between parts that cannot be inter changed or differences in diagnostic repair installation or adjustment procedures A tag number may also be required to identify the presence of optional hardware special non volatile mem
286. P2 J20 5 I I GRY i GRY I I I 1 1 pc 1 I I DC COM L1 144 LAT Ld 4 GRY 1 GRY GRY i i i 1 1 1 I 101 66 i TRAY EMPTY i I I I SENSED 8VDC I 5 10 4 as 10 4 5 GRY 1 I GRY 1 GRY 1 1 1 1 1 1 1 1 1 I I I 1 1 1 I 1 1 1 1 5 201 4203 4 1 I 1 Ec lare GRY GRY I i 1 1 1 1 1 1 2 I I I 1 I 1 1 1 I 1 1 1 1 I I 14 nd 1 ____ 14 GRY GRY GRY 6 T707701A WOL Figure 1 Bypass Paper Supply 1 of 2 Wiring Data 10 00 Initial Issue 7 70 Phaser 790 DocuColor 2006 1 0 28 HEIGHT 10 5 J201 401 A15 P 1 SENSED L 5VDC GRY 1 I 1 GRY 1 1 2 I 1 1 DI 2A DI 2C 1 LIFT PLATE 35 SENSED 1 5VDC J209 GRY GRY GRY I mE 1 1 1 1 I GRY I 3 1 I I 1 1 DC COM 2 3 1 12 GRY I GRY I I I 4 14 14 1 4 1 GRY GRY I I I I 1 t 1 1 1 9 6 4 AQ 4 DE COM GRY 1 GRY 1 GRY 1 1 I I 1 l 1 1 11 4 LAM Aa 55306 5 GRY GRY GRY 6 T707705A WOL Figure 1 Bypass Paper Supply 2 of 2 Initial Issue 10 00
287. PL 11 1 Switch off the power Reconnect J32 to the Low Voltage Power Supply Switch on the power 5 VDC is measured between P33 1 and P33 4 on the Low Voltage Power Supply Go to Flag 2 Refer to the 5 Wirenet to troubleshoot a short circuit in the wires from P32 Go to 1 Refer to the 5 VDC Wirenet to troubleshoot a short circuit in the wires from P33 The Low Voltage Power Supply appears to be operating correctly Initial Issue Phaser 790 DocuColor 2006 10 00 2 7 Status Indicator RAPs 001 702 LOW VOLTAGE POWER SUPPLY P34 LOW VOLTAGE POWER SUPPLY P32 P35 1 1 2 z 2 2 t m m m gt 5 5 gt gt gt gt i e N e 6 gt kei ir n o 2 2 S R A w o o o eo o oe o un ui gt Q gt n z ae gt gt 89 n gt u og Dy 22 ood T701001 A WOL 702 Circuit Diagram Figure 1 001 Initial Issue Phaser 790 DocuColor 2006 10 00 Status Indicator RAPs 001 702 2 8 001 703 24 VDC Interlocked Power Initial Actions Ensure the Left Front Cover the Registration Bypass Tray Drawer and the Main Fuser Assem bly are closed and in the correct
288. PL 8 4 Item 1 PL 8 5 Item 5 7 Exchange Solenoid P O PL 8 4 Item 5 PL 8 5 Item 5 REP 10 14 8 Idler Gear P O PL 8 4 Item 5 PL 8 5 Item 5 9 Idler Gear P O PL 8 4 Item 5 PL 8 5 Item 5 10 Idler Gear P O PL 8 4 Item 5 PL 8 5 Item 5 11 Clamp P O PL 8 4 Item 5 PL 8 5 Item 5 12 Ground Contact Spring P O PL 8 4 Item 1 13 Gear Cover P O PL 8 4 Item 1 14 162K53250 Fuser Harness 0008005A WOL Parts List 10 00 Initial Issue PL 8 5 5 34 Phaser 790 DocuColor 2006 PL 8 6 Fusing 6 of 7 Item Part Description 1 Fuser Tray Subassembly Not 1 2 15 and PL8 7 Spared 2 Fuser Tray Not Spared 3 Fuser Tray Cap Not Spared 4 130E81970 Fuser Entrance Sensor REP 10 18 5 Harness Not Spared 6 Sensor Bracket Spared 7 Actuator Not Spared 8 Spring Not Spared 9 Bottom Cover Spared 10 127E81620 Fuser Chute Fan REP 10 19 11 Fuser Paper Guide Not Spared 12 Horizontal Chute Not Spared 13 029E30560 Cleaner Cam Follower 14 019E33881 Holder 15 Ground Contact Spring Spared 0008006A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 35 PL 8 6 PL 8 7 Fusing 7 of 7 Item Part Description 1 Ground Contact Spring Spared 2 Fuser Tray Not Spared 3 L 12 3 015K49580 Input Bracket Assembly 4 Front Bracket P O PL 8 7 3 5 Clamp P O PL 8 7 Item 3 6 Gear P O PL 8 7 3 7 Gear P O PL 8 7 Item 3 8 Beari
289. PWB DO 1A 0 PL156 INVERTER 1 34 SOLENOID GRY PULL L 24VDC 0 90 5VDC GRY ne as INVERTER SHEET AT Y SENSOR INVERTER SENSOR 2 PL15 5 J158 P144 3 J144 L 5VDC 8 gt GRY GRY GRY SOLENOID DO A5 PL15 1 DUP CONTROL PWB DUP NIP PL15 6 SOLENOID PUSH 24 VDC J134 J148 B6 B11 13 1139 J144 1 P144 J158 3 GRY GRY i GRY GRY S INTERLOCKED i 3 GRY 2 cry 2 CRY BS 2 DO A6 1 DUP SOLENOID PULL 1 24 VDC I SHEET FROM aay B4 B13 SRY FUSER PRINT TO BOTTOM EXIT TRAY OR SORTER DUPLEX TRAY ASSY IMAGE SIDE UP 8 6 4 PL15 3 PAPER INVERTER INVERT IN 10 6 ROLLDRIVE JASSY ay CAUTION m m m m DO NOT SELECT MORE THAN ONE 1 E DAMAGE THE SOLENOID WILL 5 10 6 TRI ROLL OCCUR DRIVE um um um EE BM 25 NVERTER SOLENOID PUSH SHEET BOTTOM TRAY OR SORTER PULL SHEET TO INVERTER DUPLEX TRANSPORT DUPLEX SOLENOID PUSH OPEN PULL CLOSED INVERT ROLL 10 7 AREA THE 24VDC INTERLOCKED VOLTAGE IS DRIVE BELOW 4 NOT AVAILABLE WITH THE FUSER 6 EN M HUM TRAY 1 DRAWER OPEN IMAGE SIDE DOWN 107 ALINER ROLL DRIVE EM Em EE EN EE EN EN EN EE EN EN EH 1710704A WOL Figure 1 Invert an
290. PWB PL 11 2 Replace the ADC Sensor PL 5 1 Access the DO Stop Test Enter code 67 Press the Item Enter button Remove the IBT Inner Cover PL 1 1 in order to access P J 81 Reinstall the Copy Print Cartridge Access the Digital Input Test GP 2 Enter code 72 Press the Item Enter button Monitor the voltage from J 81 pin 4 to frame ground as the Copy Print Cartridge is removed The voltage changes from between 3 and 4 VDC when the Copy Print Cartridge is installed to less than 1 VDC when the Copy Print Cartridge is removed Y N There is 5 VDC from pin 6 to pin 3 on J 81 Y N Go to Flag 3 Check for an open circuit If the wires are OK replace the MCU PWB PL 11 2 There is less than 1 VDC from J 81 pin 5 to frame ground Y N Go to Flag 4 Check for an open circuit If the wire is OK replace the MCU PWB PL 11 2 Go to Flag 5 Check for an open circuit or a short circuit to ground If the wire is OK replace the ADC Sensor PL 5 1 If the problem remains replace the MCU PWB PL 11 2 The circuit appears to be functioning correctly Check the following Go to Figure 1 Check for loose or damaged connectors Ensure that the ADC Sensor is mounted correctly Examine the wiper attached to the ADC Solenoid make sure that it is intact and free from damage or contamination If the problem remains replace the ADC Sensor PL 5 1 If this does not resolve the fault replace the MCU PWB PL 1
291. PWB PL 17 2 There is 5 from pin 1 to pin 3 of J 718 Y N Go to Flag 2 Check for an open circuit Replace the ADF Exit Sensor PL 17 7 Check for the following conditions PL 17 7 Worn or dirty Exit Rolls Damaged or missing Pinch Rolls Damaged or incorrectly installed Antistatic Brush Blockage or damage to the Exit Chute Wear or damage to the Exit Roll Pulleys or Belt Status Indicator RAPs 10 00 005 702 2 60 Initial Issue Phaser 790 DocuColor 2006 1 ADF EXIT ADF CONTROL PWB MOTOR PL17 2 J813 AN UB PL17 7 1 WHT WHT DOCUMENT AT 5 VDC EXIT SENSOR 8 4 24 NDC J718 J718 L 5 VDC J815 BLK BLK 1 2 ADF EXIT MOTOR YEL ON 24V CLOCK 4 1 gt 1 2 Y i ORN ORN ADF EXIT MOTOR wor fpes uL i d ON 24V CLOCK Y BLU BLU ADF EXIT MOTOR EXIT SENSOR 13 ON 24V CLOCK Y PLI7 7 YEL YEL ADF EXIT MOTOR ON 24V CLOCK A VIO 3 RED RED 1 1 i GR 3 DOCUMENT S ENS ADF CONTROL PWB F1 EXIT SENSOR CR3 P811 P813 CR2 GRN RED U2 P812 P815 P814 P816 EXIT MOTOR T705005 A WOL Figure 1 005 702 RAP Circuit Diagram Initial Issue Phaser 790 DocuColor 2006 Status Indicator RAPs 005 702 10 00 2 61 005 703 ADF No Feed RAP Procedure Ope
292. PWB incorrectly detected that the Stack Tray is full Procedure Remove any paper from the Stack Tray Access the Digital Input DI test from the Control Panel Enter code 00 Press the Item Enter button The display is 1 Go to 2 Check the wires for a short circuit to ground The wire is good Y Repair the wire There is 5 VDC between J 2 4 of the Sorter Control PWB and GND Y Replace the Sorter Control PWB PL 19 1 Go to Flag 1 Check for an open circuit The wires are good Y N Repair the wires Replace the Full Sensor PL 19 3 If the problem persists replace the Sorter Control PWB PL 19 1 Place 5 sheets of paper in the Stack Tray Access the Digital Input DI test from the Control Panel Enter code DO Press the Item Enter button The display is 0 Replace the Full Sensor PL 19 3 Replace the Sorter Control PWB PL 19 1 Status Indicator RAPs 10 00 011 705 2 202 Initial Issue Phaser 790 DocuColor 2006 SORTER J 49 43 SORTER 45 CONTROL PWB J10 F1 F2 J2 6 38 JZ m NM SORTER CONTROL PWB Figure 1 011 705 RAP Circuit Diagram CONTROL PWB SORTER PL19 1 CONTROL FULL SENSOR PWB PL19 3 1 00 5 VDC PL19 1 PAPER SENSED z J2 P2 J5 48 L 5 VDC P2 J2 E amp 73 2 5 0 WHT DC i i amp 1 RED cur 2
293. Parallel Adjustment ADJ 6 2 Remove the screws 2 and partially remove the PWB by moving it in the 2 direction indicated Disconnect the connectors 2 and completely remove the PWB 0106019A WOL Figure 1 Removing the FLPS PWB Replacement 1 Perform the procedure for removal in reverse Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 51 REP 6 21 REP 6 22 REP 6 23 Control Panel Assembly Parts List on PL 16 6 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Right Cover REP 6 2 3 Remove the Left Cover REP 6 3 4 Remove the Control Panel Assembly Figure 1 2 Remove the four screws and the Control Panel Assembly by moving it in the direction indicated 1 Disconnect the connector 0106020A WOL Figure 1 Removing the Control Panel Assembly Replacement 1 Perform the procedure for removal in reverse Repairs and Adjustments 10 00 Initial Issue REP 6 23 4 52 Phaser 790 DocuColor 2006 REP 7 1 Size Switch PWB Parts List on PL 3 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Rear Cover Assembly REP 14 6
294. Perform the procedure for removal in reverse CAUTION The area of the Oversize Tray Front Snubber that comes in contact with the paper is easily bent Use care when handling the front snubber 2 When installing the Oversize Tray Front Snubber make sure that the Bottom Plate is situ ated under the tab on the top of the snubber and that the snubber is fully seated to the slot in the side of the tray 3 Install the Front Guide to the exact position from which it was removed Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 57 REP 7 8 Repairs and Adjustments 10 00 Initial Issue REP 7 8 4 58 Phaser 790 DocuColor 2006 REP 8 1 Turn Roll CAUTION Parts List on PL 3 3 Use care not to damage the hinges of the Turn In Chute during removal and replacement 5 Remove the Turn In Chute Figure 2 Removal WARNING 1228 3 See CAUTION Bend To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 the Turn In Chute 1 Switch off the machine power and disconnect the machine Power Cord Remove the screw 2 Remove the Tray 1 Assembly REP 7 6 securing the Turn retaining hole Pivot 3 Remove the Front Mid Cover REP 14 2 or the Duplex Tray Assembly REP 8 27 Cover Stopper the chute at the front 4 Access the Turn In Chute Figure 1 the Turn Turn In Chute Remove three screws and the Right Lower Remov
295. Preregistration 4 69 REP 6 4 Hear tton Dei pete 4 38 REP 8 17 Registration Clutch 4 70 REP 6 5 Angle Sensor 439 REP 8 18 Registration Rubber Roll tnnc 4 70 REP 6 6 Platen Switch 4 39 8 19 Size Switch 4 71 REP 6 7 Registration Sensor 4 40 REP 8 20 Feeder Motor 4 72 6 8 IIT Low Voltage Power Supply sss 4 41 REP 8 21 Feeder PWB 4 72 Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 REP 8 22 Feeder Drive Unit Low Paper 4 73 10 4 Upper d Deere dde zs REP 8 23 Paper Feeder Assembly tes 4 74 REP 10 5 Heat Roll Heat REP 8 24 Takeaway Clutch s 475 REP 10 6 Pressure Roll Heat Lamp REP 8 25 Nudger 4 75 REP 10 7 Lower Guide REP 8 26 Turn 4 76 REP 10 8 Front Fuser Exit REP 8 27 Duplex Tray Assembly 476 REP 10 9 Rear Fuser Exit Sensor REP 8 28 Duplex Entrance Sensor 477 REP 10 10 Heat Roll REP 8 29 Duplex Exit Sensor 478 REP 10 11 Pressure Roll
296. R ASSY MCU PWB PL11 2 DO 66 CLEANER CAM SOLENOID ON Lp ES 71 d GRY DC COM 810 TERR GRY B9 24 VDC INTLK 16 19 P22 P18 P14 P17 15 MCU PWB P20 P12 P11 F28 2 T 709013 A WOL Figure 1 009 704 RAP Circuit Diagram Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 165 009 704 Status Indicator RAPs 10 00 Initial Issue 009 704 2 166 Phaser 790 DocuColor 2006 010 317 Temperature Sensor Circuit Error RAP A disconnection open circuit has been detected in the Temperature Sensor circuit Initial Actions Inspect the Fuser area for debris and other signs of wear breakage or damage Look for loose or damaged connections or damaged wires Procedure If the Fuser area is clean and without apparent damage excessive wear or damaged connec tions or wires go to 010 701 Faulty Temperature Sensor RAP to troubleshoot the problem Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 167 010 317 010 353 356 357 Fuser Low Under Temperature Condition RAP 010 353 A Fuser low temperature error has been declared One of the following condi tions exist abnormally low fuser temperature has been detected by the Temperature Sensor the Fuser On signal remains on too long normal operating temperature cannot be maintained 010
297. RAP Circuit Diagram CARRIAGE MOTOR IIT REGISTRATION SENSOR REAR OF ICM MAIN PWB 9130 T706001 A WOL Status Indicator RAPs 006 310 10 00 2 68 Initial Issue Phaser 790 DocuColor 2006 006 311 Exposure Lamp RAP The CCD does not detect any light from the Lamp Initial Actions Ensure that Mirrors 1 2 and 3 PL 16 5 are in place and not damaged or blocked with debris Procedure Access IIT Diagnostics from the IIT control panel Enter code 330 001 and enter a value of 1 for parameter 1 Press the Start button The Lamp lights normally Y N Inspect the Ribbon Cable between the ICM Main and the FLPS PWB PL 16 5 The connections are good and the cable is not damaged Y N Re seat the connectors If the problem persists replace the Ribbon Cable PL 16 5 Ensure that the Lamp s connector J535 is seated on the FLPS PWB PL 16 5 item 17 The Lamp Connector J535 is seated correctly Re seat the Lamp Connector 535 If the problem persists replace the FLPS PWB PL 16 5 Inspect connector P J 140 on the FPC CCD The connector appears securely con nected and undamaged Re seat connector If the problem persists replace FPC Cable PL 16 3 Perform the following Replace the Lamp PL 16 5 Replace the ICM Main PWB PL 16 2 Replace the FLPS PWB PL 16 2 Replace the Scanner PL TBD The problem may be intermittent Check all cable and P J co
298. ROLL DRIVE 86 1708702A WOL 86 Wiring Data 10 00 7 78 Initial Issue Phaser 790 DocuColor 2006 BSD 8 4 A B D E F G H J iios 8 4 TRAY 3 PAPER FEEDING 8 5 PAPER TRAY 3 PAPER FEED MECHANISM m m m m m mm m AM AM NM m m mom m EUN EN EM GM EM mn 1 3 lt gt 73 PAPER STACK 3 2 2 POSITIONED 25 9 PAPER ROLL 86 B lt DRIVE a um XA o 9 2 Weta e NUDGER SOLENOID ASSY ON 2 11 4245 jaaa We COM 424VDC a INTERLOCKED oe TRAY 3 86 1 1 1 e d FEED PAPER I DO B5 I 3 24VDC TURN CLUTCHASSY Z 24 0 pla GRY 3 24VDC i 2 aai INTERLOCKED 1 4 223 GRY 1 DO B1 1 Z 24 TAKEAWAY 4 Z CLUTCHASSY LP 1 424 4 gt 154 L 1 GRY I I DC COM 24VDC I 22 INTERLOCKED 1 T T T GRY 1 1 1 1 1 1 1 1 1 1 1 j 5 FEEDER PWB FEED OUT SENSOR PL13 4 1 1 I PL13 5 01 86 PAPER FEED OUT 11 SENSED T r9 0 5 4241 l GRY 6 1708703A WOL Figure 1 Tray 3 Paper Feed
299. RY CONTROL AD SENSED P81 3 _ 4 J81 VOLTAGE 216 20 09 341 i SRY 12 BCR DC CONTROL 12 22 GRY H 1 113 GRY ADC SENSOR DC 24 VDC INTLK 187 1 15 P12 ___ P10 P16 P19 MCU PWB P11 _ 22 18 17 20 23 21 Figure 1 009 341 RAP Circuit Diagram T 709010 A WOL Status Indicator RAPs 009 341 10 00 2 146 Initial Issue Phaser 790 DocuColor 2006 009 342 Patch Error RAP ADC sensor output measuring Cin 5096 patch area is lower than spec after adjustment Procedure Access the Digital Output Test GP 2 Enter code 53 Press the Item Enter button Enter code 56 Press the Item Enter button The Dispense Clutch energizes Y N Access the DO Stop Test Enter code 56 Press the Item Enter button There is 424 VDC from J 55 pin 1 to frame ground Y There is 24 VDC from J 55 pin 2 to frame ground Go to Flag 9 Check for open circuit If the wire is OK replace the MCU PWB PL 11 2 Replace the Dispense Clutch PL 10 1 Access the Digital Output Test GP 2 Enter code 56 Press the Item Enter button There is less than 1 VDC from J 55 pin 1 to frame ground Y Go to Flag 8 Check for an open circuit If the wire is OK replace the MCU PWB PL 11 2
300. Remove the screw Remove the Bearings from the Pressure 1 Roll Remove the Pres 6 sure Roll Remove the Fuser Baffle Remove screws lt gt 0 110010B WOL Figure 2 Removing the Pressure Roll Remove the Shaft Replacement Reinstall the Pressure Roll in the reverse order of removal 2 Install the Fuser Baffle so that the frames at both sides touch against the Heat Roll Bear Remove the 2 ings as shown in Figure 1 sets of bearings 3 Check the Fuser Nip ADJ 10 1 and cams 4 Loosen the Nip adjustment Remove the screw at front screw at front and and rear rear 0 110025A WOL Figure 1 Preparing to Remove the Pressure Roll CAUTION Be sure not to damage the surface of the Pressure Roll while removing the roll 10 Remove the Pressure Roll Figure 2 Repairs and Adjustments 10 00 Initial Issue REP 10 11 4 120 Phaser 790 DocuColor 2006 REP 10 12 Temperature Sensor Parts List on PL 8 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine Switch off the machine power and disconnect the machine Power Cord Remove the Main Fuser Assembly REP 10 2 Remove the Upper Guide Assembly REP 10 3 Remove the Upper Plate REP 10 4 Remove the Heat Roll Heat Lamp REP 10 5 Remove the Pressure Roll Heat Lamp REP 10 6 Remove the Lower Guide Assembly REP 10 7 Remove the Heat Roll REP 10 10 9 Remove the Pressure
301. Roll REP 10 11 10 Remove the Temperature Sensor Figure 1 Replacement 1 Reinstall the Temperature Sensor in the reverse order of removal 2 Install the harness on the Fuser Bottom Plate so that there is no slack in the harness 3 Check the Fuser Nip ADJ 10 1 69 Or as oo Na 6 Remove the Tempera 5 ture Sensor Disconnect the connectors Remove the Fuser Front Frame 4 Remove the Fuser Rear Frame Remove the Screw 3 Remove the screw L b 0110011A Figure 1 Removing the Temperature Sensor Initial Issue 10 00 Phaser 790 DocuColor 2006 4 121 Repairs and Adjustments REP 10 12 REP 10 13 Exchange Chute Parts List on PL 8 4 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Exit Tray Assembly REP 8 30 3 Remove the Fuser Assembly REP 10 1 4 Remove the Main Fuser Assembly REP 10 2 CAUTION Be careful not to damage the front or rear hinges of the Exchange Chute while removing the chute 5 Remove the Exchange Chute Figure 1 Replacement CAUTION Insert the U shaped parts on the front and rear of the Exchange Chute securely into the plunger when installing the chute 1 Reinstall the Exchange Chute in the reverse order of removal 3 Remove the screw Then remove the
302. SED 446 2 4 SOLENOID ON i A VOLTAGE Tg 24VDC 03 24VDC YEL GRY INTLK 2 GRY YEL 1 1 i ADC Le iu SOLENOID 09 340 GRY 09 341 09 342 wu 09 343 2 5 09 344 GRY YEL 2222 1 1 1 1 3 2 GRY YEL 1 4 1 7 I DISPENSE 33 CLUTCH AUTO DENSITY CONTROL i 1 4 NOTE 1 Y 9 09 340 OUTPUT OF ADC SENSOR BELOW SPECIFICATION AFTER CLEANING 1 09 341 SENSOR MEASUREMENT OF NON IMAGED AREA 15 HIGHER THAN SPECIFICATION 1 SENSOR MEASUREMENT OF 5 09 342 DATCH IS LOWER THAN SPECIFICATION AFTER ADJUSTMENT 09 343 PCDC CALIBRATION COUNT IS LOWER THAN SPECIFICATION DEVELOPED 09 344 IMAGE DENSITY OF LEAD EDGE IMAGE EXCEEDS 28096 TO ADC y 6 1709706A WOL Figure 1 Dispense Control Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 89 9 6 IBT BELT DRIVE AND 15 TRANSFER HIGH VOLTAGE POWER SUPPLY MEU PWB PL11 1 PL11 2 CDO 0B 77 BTR1 BIAS ON 016 L 24VDC J42 7 BTR 1 LAC GRY CONTROL DC 1 i BTR 1 BIAS i 5 MONITOR D GRY D WHT TRO SENSOR RIR RIAR PES C DI 42 1 5VDC M ETC 18 i x EJ 277 pc 5 2 487 Pet 2 2 84 446 09 321 ZZ Z GRY a 222244
303. SS PL16 6 LOW ICM MAIN VOLTAGE PWB GENERATION PL16 2 MAIN SWITCH 2 7 gt 2 24 VDC FF WHT 3 4 3 3VDC 5 6 Figure 1 IIT Main Power On Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 45 2 1 CONTROL PANEL PANEL HARNESS PL12 2 CONTROL PANEL PL1 2 PN PN RW PN EN PN DO PN D1 PN D2 PN D3 PN 04 0m 00 PN D5 PN D6 PN 07 KEYEN SWITCH DRIVER LCD DRIVER LCD 16X2 LINE LCD BANK ERROR DATA ONLINE MENU ONLINE CANCEL jm s N o Figure 1 Control Panel 7702701A WOL Wiring Data 10 00 7 46 Initial Issue Phaser 790 DocuColor 2006 2 2 IIT CONTROL PANEL CONTROL PANEL ASSEMBLY PL16 7 CONTROL PANEL PWB PANEL SWITCH LED PWB ICM MAIN PWB PL16 2 3 002 310 ICM MAIN PWB PL16 2 4 SPEAKER 5 6 1702702A WOL Figure 1 IIT Control Panel Initial Issue 10 00
304. SSEMBLY TEMPERATURE SENSOR GRY 92 ASSEMBLY 10 2 J50 n 8 5 DRIVE MOTOR PWB GRY 41 pacti nm as CONTINUED CONTINUED T728008 A WOL Figure 1 DC Com 2 of 5 Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 33 DC Com Wirenet 3 of 5 DC COM 3 OF 5 WIRENET CONTINUED a ios 832222 eee o omes MCU PWB DUPLEX LVPS 2 CONTROL PWB J22 J134 P134 J142 J139 J144 P144 J158 4 224 A18 A4 4 13 2 2 2 2 INVERTER SENSOR GRY GRY 1 GRY GRY 10 5 1 1 1 1 1 1 1 1 53 23 1 12 5 1 1 12 GRY 1 4 2 CABINTERLOCK i i GRY 1 5 24 AN J147 2 8 4 2 INVERTER MOTOR i GRY 10 7 27 8 9 r 8 GRY 1 GRY J141 P134 J134 J155 J154 P154 2 8 1 B9 B8 4 4 3 2 DUPLEX TRAY SET 28 A7 A10 7 GRY 1 GRY GRY 10 7 GRY GRY 1 1 4159 159 64 1611 6 1 Ls 3 GRY GRY GRY GRY 1 1 1 J160 P160 8 1814 3 1 8 3 GRY GRY GRY GRY DC COM J145 L 5 ALIGNER SENSOR DC GRY 10 5 J146 3 ALIGNER OUT SENSOR GRY 10 5 J20 J201 P91 J201 P201 J205 P20
305. Sensor PL 7 3 Process Drive Unit PL 10 1 Rotary Motor PL 10 1 Check the mounting of the Developer Housing for the affected color Ensure that it is installed correctly and that it is free from damage Repair or replace as required PL 6 2 IQ11 IOT Skew RAP Initial Actions Reload fresh dry paper of the correct specification in all trays If the problem remains continue with this RAP Procedure Make 5 prints from each tray including the Bypass Tray The defect is present on prints from all trays Y N The skew is from Tray 1 Y N The skew is from the Bypass Tray Y N Switch Tray 2 and Tray 3 The defect moves with the tray Y N Check the Feed Roll PL 13 5 Nudger Roll PL 13 5 and Retard Roll PL 13 7 of the affected feeder for wear damage or contamination Clean repair or replace as required Examine the Paper Tray from which the defect is printed Ensure that the paper guides and the Bottom Plate are free from damage Clean repair or replace as required PL 13 9 Check the following Bottom Plate PL 4 2 for damage or binding Feed Roll PL 4 4 for wear contamination Nudger Retard Roll PL 4 5 for wear or contamination Check the Feed Roll Assembly PL 3 3 and the Pinch Rolls PL 3 2 for wear or contami nation Select Print Configuration Page from the menu Open the front door after the lead edge of the print has passed the nip of the Registration Roll Fully e
306. TAGE ON L 24VDC POWER J216 J233 P233 SUPPLY 8 1 21 LT 1 GRY I I 1 DC COM I 1 I 9 032 4211 P211 213 M 24 Is S T T l ORN GRY 1 I A 24 24 NUDGER INTERLOCKED i 20 86 SOLENOID i i NUDGER SOLENOID PL13 6 ON 24006 J241 P241 J225 P225 12 7151 r5 114 T 2 T vio BLU i GRY i GRY 1 1 1 1 1 DC COM DC COM 10 L 6 10 L2 GRY GRY 24VDC 5 INTERLOCKED 1707019A WOL Figure 1 007 709 RAP Circuit Diagram 1 of 2 Initial Issue Status Indicator RAPs Phaser 790 DocuColor 2006 10 00 2 105 007 709 FEEDER MOTOR NUDGER SOLENOID TRAY 2 PAPER FEEDER ASSY NUDGER SENSOR Figure 2 007 709 RAP Circuit Diagram 2 of 2 LIFT CLUTCH FEEDER DRIVE UNIT T707021A WOL Status Indicator RAPs 10 00 007 709 2 106 Initial Issue Phaser 790 DocuColor 2006 007 710 Tray 3 Lift Up RAP The Control Logic has detected that Tray 3 is not in position to feed paper Initial Actions Check that the tray lift mechanism within paper Tray 3 functions correctly Procedure Switch off the power Pull out and reinstall Tray 3 Remove the Upper Rear Cover and the Lower Rear Cover Observe the Feed Motor Switch on the power The Feed Motor operates when the machine starts self test Y There is 24 VDC from 217 pin 14 to ground on the Feeder
307. TE Upon selecting a code a time out will occur after 30 seconds if no activity is lock sensed and root message 74 Exit Chute Interlock Exit Chute Closed 1 5 13 5 following table lists the digital input codes 75 Bypass Tray Guide Bypass Guide Up L 5 VDC 7 2 Switch Table 1 Digital Input Codes 76 BTR 2 Cam Sensor 2 Cam Home 1 5 VDC 9 8 DI Code Component Signal BSD Ref 77 Bypass Tray Interlock Tray Inserted L 5 VDC 1 3 06 Feed Ready Not used 80 Optional Sorter Not used 15 Full Stack Sensor Top Tray Full 1 5 VDC 10 4 82 24 VDC to MCU PWB Not used 25 16 Top Exit Sensor Sheet at Top Exit Sensor L 5 10 4 83 Duplex Option Ready 3 5 24 Fuser Entrance Sensor Sheet at Fuser Entrance L 5 VDC 10 1 84 Turn Chute Interlock Turn Chute Closed L 5 VDC 1 3 25 Front Fuser Exit Sensor Sheet at Front Fuser Exit Sensor L 5 10 4 85 Fuser Fan Fuser Fan Fail H 5 VDC 10 3 VDC 86 Exit Chute Fan Exit Chute Fan Fail H 5 VDC 10 3 26 Sensor OHP MSI Not used B 87 Developer Fan Fan Alarm 9 4 27 OHP Sensor Front OHP Sensed 5 VDC 8 6 90 Inverter Sensor Sheet at Inverter Sensor 5 10 5 28 OHP Sensor Rear Not used 5 91 Duplex Entrance Sensor Duplex Entrance Sensor L 5 VDC 10 5 29 Registration Sensor Registration Sensed L 5 VDC 8 6 92 Duplex Exit Sensor Duplex Exit Sensor L 5 VDC 10 5 2A Bottom Plate Sensor Lift Plate Sensed 1 5 VDC 7 2 93 Cab Interlock Cab In
308. THE DOCUMENT COMPANY XEROX Phaser 790 DocuColor 2006 Service Manual 0730002A WOL October 2000 CAUTION 701P35949 Certain components in the Phaser 790 DocuColor 2006 are susceptible to damage from electrostatic discharge Observe all ESD procedures to avoid component damage Prepared by Xerox Corporation Global Knowledge amp Language Services 800 Phillips Road Bldg 845 17S Webster New York 14580 9791 USA 2000 by Xerox Corporation All rights reserved Copyright protection claimed includes all forms and matters of copyrightable material and infor mation now allowed by statutory or judicial law or hereinafter granted including without limitation material generated from the software programs that are displayed on the screen such as styles templates icons screen displays looks etc XEROX DocuLock Protect Until Forever XEROX The Document Company the stylized X and the identifying product names and numbers herein are trademarks of XEROX CORPORA TION Other company trademarks are also acknowledged NOTICE While every care has been taken in the preparation of this manual no liabil ity will be accepted by Xerox Corporation arising out of any inaccuracies or omissions NOTICE All service documentation is supplied to Xerox external customers for infor mational purposes only Xerox service documentation is intended for use by certified product trained service personal only Xerox does
309. TROL PWB MOTOR SWITCH SWITCH J2 R Figure 1 011 701 RAP Circuit Diagram Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 195 011 701 011 702 Sorter Cover Open RAP Sorter Control PWB logic has detected that the Sorter Top Cover is open Initial Actions Switch off the Copier Printer then switch on the Copier Printer to try and clear the Close Sorter Cover Message If the message does not clear or clears momentarily and then returns con tinue with this RAP Procedure Measure the voltage between J 7 1 of the Sorter Control PWB and GND Ensure that the Top Cover is closed and then opened The voltage is at first High 24 VDC and then goes Low 0 VDC Y The voltage between J7 1 of the Sorter Control PWB and GND remains High 24 VDC Y N There is 24 VDC between J7 2 of the Sorter Control PWB and GND Y N There is 24 VDC between J 8 7 of the Sorter Control PWB and GND Y N Go to Flag 2 Check the wires for an open circuit The fuse may be blown Replace the fuse PL 19 1 on the Sorter Control PWB with a fuse of the same rating If the problem persists replace the Sorter Con trol PWB PL 19 1 Go to Flag 1 Check the wires for an open circuit If the wiring is OK ensure that the Top Cover physically actuates the Interlock Replace the Top Cover PL 19 1 as required Replace the Sorter Control PWB PL 19 1 This indicates that the Top Cover and the Top Cover Int
310. Tray Feed Assembly 0108012A WOL Replacement 1 Perform the procedure for removal in reverse Figure 1 Accessing the Bypass Tray Feed Assembly Replacement 1 Perform the procedure for removal in reverse Repairs and Adjustments 10 00 Initial Issue REP 8 6 REP 8 7 4 64 Phaser 790 DocuColor 2006 REP 8 8 Tray Housing Parts List on PL 4 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Bypass Tray Registration Assembly REP 8 6 3 Remove the Bypass Tray Feed Assembly REP 8 7 4 Remove the Tray Housing Figure 1 2 Remove the rear arm of the Tray Housing by pushing on the housing tray arm until the boss is free from its retaining hole 1 Remove the front arm of the Tray Housing Disconnect the from the Bypass Tray Assembly and remove connector the Tray Housing 0108009A WOL Figure 1 Removing the Tray Housing Replacement 1 Install from the front arm while being careful not to pinch the harness REP 8 9 Main Paper Handling Frame Assembly Parts List on PL 4 6 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Bypass Tray Registration As
311. Tray Feed Assembly P O PL 4 1 Item 5 PL 4 1 Item 6 REP EXPLODED 2 ON PL 42 9 Base Assembly P O PL 4 1 Item 5 PL 4 1 Item 6 REP 8 7 10 Tray Bottom P O PL 4 1 Item 5 PL 4 1 Item 6 11 Tray Extension P O PL 4 1 Item 5 PL 4 1 Item 6 12 Tray Housing P O PL 4 1 Item 5 PL 4 1 Item 6 13 Guide Holder P O PL 4 1 Item 5 PL 4 1 Item 6 14 Guide Gear P O PL 4 1 Item 5 PL 4 1 Item 6 15 Registration Guide P O PL 4 1 Item 5 PL 4 1 Item 6 16 Guide Spring P O PL 4 1 Item 5 PL 4 1 Item 6 17 Spring Washer P O PL 4 1 Item 5 PL 4 1 Item 6 18 Bypass Tray Guide Switch P O PL 4 1 Item 5 PL 4 1 Item 6 19 Harness P O PL 4 1 5 PL 4 1 Item 6 EXPLODED ON PL 4 6 0004001A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 15 PL 4 1 PL 4 2 Bypass Tray Paper Transport 2 of 7 1 2 22 Item Part Description 1 Bypass Tray Base Assembly Not 15 16 21 Spared 2 Bypass Frame Not Spared 3 Bottom Plate Not Spared 4 Pad Spared 5 Sleeve Bearing Spared 6 Lift Shaft Not Spared 7 Lift Down Actuator Not Spared 8 162053330 Bypass Tray Harness 9 Gear 28 Not Spared 10 130E82190 Lift Plate Sensor REP 8 10 11 Damper Spared 12 Tray Bracket Spared 13 Lift Plate Not Spared 14 Clamp Not Spared 15 001 69770 Lift Frame Assembly REP 8 11 16 Gear 12 28 2 P O PL 4 2 Item 15 9 17 Gear 12
312. UMENT AT SET SENSOR L 5 VDC YEL 2 4 FEEDER COVER J 4 CLOSED 1 5 VDC 2 3 VIO YEL Figure 1 ADF Document Sensing and Interlock Monitoring J816 DOCUMENT SET L 5 VDC J709 DOCUMENT SET INDICATOR PL17 1 YEL AAS xx CSA 8 705701 A WOL Initial Issue Phaser 790 DocuColor 2006 10 00 7 57 Wiring Data BSD 5 2 D E F J 5 2 ADF DOCUMENT FEEDING 1 OPERATOR LOADED ADF FED DOCUMENT q DOCUMENT 2 53 NUDGER 4 3 ROLL DRIVE E EN EH EH EH EN _ m mmm mm m m mm m m m mma m 4 ADF CONTROL ADF CONTROL PWB PWB PL17 2 PL17 2 NUDGER HOME 3713 ie aa 039 3842 GRY 2 2 YEL 5 1 gt i x 5 i 22 VIO NUDGER HOME SENSOR mE PL17 3 6 T705702 A WOL Figure 1 ADF Document Feeding Wiring Data 10 00 Initial Issue 7 58 Phaser 790 DocuColor 2006 5 3 DOCUMENT TRANSPORTATION 1 OF 2 ADF DRIVE 1 MOTOR PL17 2 NUDGER 52 ROLL DRIVE m wm Um ADF CONTROL PWB PL17 2 ICM MAIN PWB jii PL16 2 DOCUMENT 5 VDO WHT WHT 4220 4811 3 xD 2 6 6 BLK BL ADF DRIVE MOTOR ON at 24 PEED ROLL YEL YEL DRIVE ADF DRIVE MOTOR ON
313. WB PL 11 2 Replace the Developer Fan PL 11 1 Replace the Developer Fan PL 11 1 Access the Digital Output Test GP 2 Enter code 60 Press the Item Enter button The Developer Fan runs faster Y N Go to Flag 2 Check for an open circuit If the wire is OK replace the MCU PWB PL 11 2 There is less than 1 VDC from pin 2 to pin 1 on the Developer Fan Connector J 82 N The problem appears to be intermittent Go to Figure 1 Check the wiring for loose or damaged connectors pinched wires or contamination If the wires are OK replace the Developer Fan PL 11 1 If the problem continues replace the MCU PWB PL 11 2 Disconnect J 82 There is 5 VDC from pin 2 to pin 1 on J 82 Y N Go to Flag 3 Check for a short circuit to frame ground If the wire is OK replace the MCU PWB PL 11 2 Replace the Developer Fan PL 11 1 Status Indicator RAPs 009 360 10 00 2 154 Initial Issue Phaser 790 DocuColor 2006 MCU PWB DEVELOPER FAN 24 VDC 20 61 INTLK DEVELOPER FAN ON PETI gt 21 7 24VDC J82 T GRY 20 60 5VDC HIGH SPEED ON gt 22 24 GRY J17 23 09 360 DC I DC COM 0687 FAN ALARM L 5VDC GRY 16 19 22 18 P14 pH opts MCU PWB P20 12 p11 T709004 A WOL Figure 1 009 360 RAP Circuit Diagra
314. achine configuration page 1 Press the Menu button on the Printer until PRINT PAGES FROM LIST appears on the display 2 Pressing the Up or Down Arrow buttons displays the following menu items PRINT CONFIGURATION PRINT TEST PATTERN PRINT EVENT LOG PRINT DEMO PAGE PRINT JOB LOG PRINT PCL FONT LIST PRINT PS FONT LIST PRINT MENU HELP PRINT TEST PAGE 3 Press the Item Enter button until PRINT CONFIGURATION appears on the display 4 Press the Item Enter button to print the page 5 Configuration report will be delivered to the tray GP 15 Printing Internal Test Patterns The purpose is to print the built in test patterns Procedure Enter the Diagnostics Mode GP 1 Press the Menu button until PATTERN PRINTING is displayed Press the Item Enter button Load the appropriate paper into Paper Tray 1 Use the Up and Down arrow buttons to scroll through the menu of test patterns Table 1 Press the Item Enter button to select a test pattern to print The machine will enter PROCESSING JOB FROM TRAY 1 mode and deliver the test pattern Menu Options Table 1 displays the menu of test patterns available SUO gis Table 1 Menu of Test Patterns Test Patterns Details GRID IOT Prints an IOT built in grid pattern on 8 5 x 11 inch A4 paper GRID ESS Prints an ESS built in grid pattern on 11 x 17 inch A3 paper C 2096 Prints an entire 11 x 17 inch A3
315. activi 3 If there isa problem in the Basic Printer Mode go to the Call Flow Procedure lies are also performed in the Final Actions 4 If there are no problems in the Basic Printer Mode go to the Final Actions Initial Issue 10 00 Service Call Procedures Phaser 790 DocuColor 2006 1 3 Service Call Procedures Initial Actions Procedure Call Flow Procedure This procedure should be performed at every service call Procedure The copier printer is capable of making a copy print to the Output Tray The copier printer is capable of making a copy print to the Top Tray Y N The problem is in the paper path Y N A Fault Code or a message is constantly displayed Y N The Display is blank or garbled Y N If one or more of the buttons or LEDs does not function go to the 002 702 IOT Control Panel Button LED RAP Go to the 002 701 Blank Garbled IOT Display RAP If a fault code is displayed go to the Fault Code RAP for the Fault Code that is displayed If a message is displayed go to the Fault Message RAP Cross Reference in Section 2 Check the paper path sensors for debris or damage Check that paper is loaded in all trays correctly Check the paper path mechanical drives and rolls for contamination glazing wear dam age or binding The copier is capable of making a copy print to the Top Tray Check the paper path mechanical drives and rolls for contamination glazing wear dam age or binding
316. activities with the power switch on or electrical power applied to the machine Switch off the machine power and disconnect the machine Power Cord Remove the Top Cover Assembly REP 14 4 Remove the Rear Cover REP 14 6 Remove the Copy Print Cartridge REP 9 1 Remove the Tension Lever REP 9 15 Remove the Left Inner Cover Assembly and IBT Inner Cover REP 14 5 Remove the Exit Transport Assembly REP 8 40 CAUTION Be careful not to damage the connectors attached to the rear frame of the printer while remov ing the plate 8 Remove the Developer Tie Plate Figure 1 Replacement 1 Reinstall the Developer Tie Plate in the reverse order of removal DIO meo ch REP 9 15 Tension Lever Parts List on PL 7 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Tension Lever Figure 1 Replacement 1 Reinstall the Tension Lever in the reverse order of removal 2 Turn the lever remove the Screw then remove the Tension Lever 5 1 2 Remove the Developer Remove the screws SERGI Tie Plate from the top of aN and tear the machine 1 Open the Front Cover Assembly 0090012A WOL Figure 1 Removing the Tension Lever 0109029A WOL Figure 1 Removing the Developer Tie Plate Initial Issue 10 00 Repairs and A
317. al power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Rear Cover REP 14 6 3 Remove the LVPS Figure 1 Replacement CAUTION Be careful not to get the harness caught in the gears or damaged on sharp sheet metal when installing the LVPS Be sure to hook the LVPS securely on the left side of the frame when Installing 1 Reinstall the LVPS in the reverse order of removal REP 1 2 HVPS Parts List on PL 11 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Rear Cover REP 14 6 3 Remove the HVPS Figure 1 Replacement CAUTION Be careful not to get the harness caught in the gears or damaged on sharp sheet metal when installing the HVPS 1 Reinstall the HVPS in the reverse order of removal emove the L 3 VPS Remove the 0 HVPS 3 Remove the I upper screws 7 e 246 gt 27 MD Qu 2 1 2 Disconnect the six con nectors gt 1 Pu Disconnect the amp the screws Connectors Loosen the lower 0101001A WOL Screws 0101000A WOL Figure 1 Removing the HVPS Figure 1 Removing the LVPS Initial Issue 1
318. alculated value is 2 5 mm greater than or less than the nominal value in the table per 1 form the adjustment Using a 150 mm scale measure and record the side to side regis tration on each of the three prints 2 Calculate the average side to side registration value of the three mea Y surements 0 208000 WOL Figure 1 Measuring the Side to Side and Top to Bottom Registration Table 1 Nominal Registration Values for Comparison of Measurements Media Size Side to Side Top to Bottom 8 5 x 11 inch 133 mm 41 mm A4 132 mm 46 5 mm Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 161 ADJ 8 1 Adjustment 1 Calculate the difference between the average measured value and the nominal values as displayed in the Table 1 2 Calculate the required adjustment value allowing 1 unit increment to equal 0 17 mm of change in top to bottom registration or 0 50 mm of change in side to side registration 3 Prepare to adjust the printer registration a Enter the Diagnostic Mode IOT GP 1 b Press the Menu button until IOT PARAM SET is displayed c Press the Item Enter button d Press the Up Arrow or Down Arrow button until CTRL VAL SET is displayed then press the Item Enter button e Using the Up Arrow and Down Arrow buttons select the Menu Number from the Table 2 f Press the Enter button to display the current value of that parameter g Using the Up Arrow and Down Arrow buttons change the
319. amage when circuit boards are returned for repair The instructions for using the ESD Field Service Kit can be found in ESD Field Service Kit Usage in the General Procedures section of the Service Documentation Signal Nomenclature Refer to Figure 2 for an example of Signal Nomenclature FEED CLUTCH ON t L 24 VOC Nes SIGNAL NAME LOGIC STATE LOGIC VOLTAGE WHEN SIGNAL WHEN SIGNAL 15 AVAILABLE IS AT HIGH STATE SOME SIGNALS MAY BE IN THE 7 STATE WHEN THEY ARE AVAILABLE INTERLOCK SENSOR LED IL SIGNAL NAME INDICATES THAT THE SIGNAL I PULSED INFORMATION T700002A RAP Figure 2 Signal Nomenclature Initial Issue 10 00 Phaser 790 DocuColor 2006 Voltage Measurement and Specifications Measurements of DC voltage must be made with reference to the specified DC Common unless some other point is referenced in a diagnostic procedure All measurements of AC volt age should be made with respect to the adjacent return or ACN wire Table 1 Voltage Measurement and Specifications VOLTAGE SPECIFICATION INPUT POWER 220 V 198 VAC TO 242 VAC INPUT POWER 100 V 90 VAC TO 135 VAC INPUT POWER 120 V 90 VAC TO 135 VAC 5 VDC 4 75 VDC TO 5 25 VDC 24 VDC 23 37 VDC TO 27 06 VDC Logic Voltage Levels Measurements of logic levels must be made with reference to the specified DC Common unless some other point is referenced in a diagnostic procedure Table 2 Logic Levels VOLTAGE H L SPE
320. an open circuit If the wires are good replace the Feeder Right Cover Interlock 2 PL 13 2 Replace the Feeder PWB PL 13 4 The problem may be intermittent Go to Figure 1 and check for loose or damaged connections or damaged wires If the problem persists replace the Feeder Right Cover Interlock 1 and 2 PL 13 2 If the problem continues replace the Feeder PWB PL 13 4 Initial Issue Phaser 790 DocuColor 2006 10 00 2 19 Status Indicator RAPs 001 708 FEEDER FEEDER PWB RIGHT PL13 4 COVER INTERLOCK DI CO 1 TT FEEDER RIGHT COVER INTERLOCK 1 J237 P240 J240 CLOSED L 5 VDC J217 2 8 GRY BLU 7 GRY BLU DC COM FEEDER 1 RIGHT COVER INTERLOCK 2 i DS FEEDER RIGHT iv VDC COVER INTERLOCK 2 J238 CLOSED L 5 VDC 4 10 GRY BLU ls 2 GRY BLU 4 DC COM 2 FEEDER RIGHT COVER INTERLOCK 1 FEEDER RIGHT COVER INTERLOCK 2 Figure 1 001 708 Circuit Diagram P214 P218 P216 P213 FEEDER PWB P212 P217 P215 T701008 A WOL Status Indicator RAPs 001 708 10 00 2 20 Initial Issue Phaser 790 DocuColor 2006 001 709 Area 4 Open RAP Initial Actions Perform the following Check the actuator for the Exit Chute Interlock Ensure it is not broken
321. an the Rolls Adjust the Fuser Nip ADJ 10 1 If the problem persists go to the 010 701 RAP to troubleshoot the Temperature Sensor If this does not resolve the problem replace the Main Fuser assembly PL 8 1 Image Quality 107 10 00 3 10 Initial Issue Phaser 790 DocuColor 2006 MCU PWB ERASE LAMP PL11 2 ASSY PL5 1 ON J17 J86 P86 S 251 r tSv BC 12 11 1 1 1 1 1 1 x 1 1 1 x 264 1 21 2 GRY DC COM 2 10 16 19 P22 P18 FA P15 MCU PWB P20 P12 al 21 Figure 1 IQ7 RAP Circuit Diagram ERASE LAMP T 730001 A WOL Initial Issue Phaser 790 DocuColor 2006 10 00 3 11 Image Quality 107 108 IOT Background RAP Initial Actions Check the end of life counter GP 3 for the Copy Print Cartridge If it is at or near end of life replace it PL 5 1 Perform VisualCal GP 16 If this does not resolve the problem continue with this RAP Procedure The problem is Single Color Background Y N Remove the Copy Print Cartridge Examine the face of the ADC Sensor The ADC Sen Sor is clean Y N Go to the 009 340 RAP to troubleshoot the ADC Sensor Solenoid Examine the IBT Belt for excessive dirt damage or uncleaned toner The IBT Belt is clean Y N Go to the 009 704 Belt Cleaner RAP Remove the ROS REP 9 3 Examine the ROS wi
322. ance of the copier printer including any unusual sounds or other indications if applicable b Check that the power cords are in good condition correctly plugged into the power Source and free from any defects that would be a safety hazard Repair or replace the power cords as required Check that the circuit breakers are not tripped c Ensure that all paper trays are loaded with paper Inspect any rejected copies Inquire as to or otherwise determine the paper quality and weight The specified paper for optimum image quality for the Phaser 790 Printer is Hammermill Laser Print 24 The specified paper for optimum image quality for the DC 2006 Copier Printer is 24 Xerox COLOR Xpressions or Colotech 90 gms Look for any damage to the copies oil marks image quality defects or other indications of a problem e Record the billing meter readings f Check the Service Log for any recent activities that are related to the problem that caused the service call or any secondary problem Cleaning Procedures 2 Check the Image Quality by performing the Visual Calibration GP 16 The cleaning procedures list what needs to be cleaned at each service call a Run four copies of the 82E13030 Test Pattern b Check the image quality If the customer has identified any Image Quality Defects or Final Actions problems go to the IQ1 Image Quality Entry RAP The Final Actions will test the copier printer and return it to the customer Administrative
323. and Adjustments REP 11 14 REP 11 15 Repairs and Adjustments 10 00 Initial Issue REP 11 14 REP 11 15 4 138 Phaser 790 DocuColor 2006 REP 14 1 Front Cover Assembly Parts List on PL 1 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Open the Tray 1 Assembly 3 Remove the Front Cover Assembly Figure 1 Replacement 1 Reinstall the Front Cover Assembly in the reverse order of removal 3 Remove the two screws 4 Remove the Front Cover Assembly and Hinge Plates Remove the two screws Pa REP 14 2 Front Mid Cover Parts List on PL 1 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Front Mid Cover Figure 1 Slide the cover toward the right and then remove the Front Mid Cover 2 1 Remove the Open the Tray 1 knurled screw Assembly 0140009A WOL Open the Front Figure 1 Removing the Front Mid Cover Cover Assembly Figure 1 Removing the Front Cover Assembly Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 139 REP 14 1 REP 14 2 REP 14 3 Front Lower Cover Pa
324. ange Solenoid 2 Remove the Fuser Rear Rail 3 together with Disconnect th the Gear Cover connector 0110013A WOL Figure 1 Removing the Exchange Solenoid REP 10 15 Cleaner Cam Solenoid Parts List on PL 8 7 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Exit Tray Assembly REP 8 30 3 Remove the Fuser Assembly REP 10 1 4 Remove the Main Fuser Assembly REP 10 2 CAUTION The Fuser Rear Rail and Fuser Tray Assembly are connected by a harness Be careful not to pull too far apart while disassembling the components 5 Remove the Cleaner Cam Solenoid Figure 1 5 Remove the screws to remove the Cleaner Cam Solenoid 2 Remove the Fuser Rear Rail with the Gear Cover Remove the screws Then remove the Input Bracket Assembly Disconnect the connector 0110014A WOL Figure 1 Removing the Cleaner Cam Solenoid Initial Issue Phaser 790 DocuColor 2006 10 00 4 123 Repairs and Adjustments REP 10 14 REP 10 15 Replacement 1 Position the Cleaner Cam Solenoid correctly Figure 2 2 Reinstall the Cleaner Cam Solenoid in the reverse order of removal 1 Armature touches the spring clutch with arma ture at the vacuum posi tion 0110015A WOL Figure 2 Positioning the Cleaner Ca
325. are OK replace the MCU PWB PL 11 2 There is 24 VDC from J 51 pin 2 to J 51 pin 1 Y There is 24 VDC from 4 32 pin 7 to J 32 pin 11 Y N Go to the 001 703 RAP Go to Flag 1 Check for an open circuit Go to Flag 2 Check for an open circuit or a short circuit to frame ground If the wires are OK replace the Process Drive Unit PL 10 1 Access the Digital Output Stop routine Enter code 54 Press the Item Enter button Remove the Print Copy Cartridge Cheat the Left Front Cover Interlock Access the Digital Output Test GP 2 Reenter code 54 Press the Item Enter button The IBT Belt rotates Switch off the power Remove the Process Drive Unit Check the gear on the IBT Drive Roll PL 7 3 for damage or contamination If the gear is OK replace the Process Drive Unit PL 10 1 There is less than 1 VDC from J 52 pin 1 to J 52 pin 5 on the Process Drive Unit PL 10 1 Disconnect P J 52 from the Process Drive Unit There is 5 VDC from J 52 pin 1 to J 52 pin 5 on the harness Go to Flag 3 Check for an open circuit If the wire is OK replace MCU PWB PL 11 2 Replace the Process Drive Unit PL 10 1 There is between 1 5 and 3 5 VAC from J52 pin 6 to J52 pin 5 on the Process Drive Unit PL 10 1 Y N Disconnect P J52 from the Process Drive Unit There is 5 from J 52 pin 6 to J52 pin 5 on the harness Y N Go to Flag 4 Check for an open circuit or a short circuit to frame groun
326. aser 790 DocuColor 2006 5 61 PL 15 7 PL 16 1 Platen Glass and IIT Item Part Description 1 090K92740 Platen Glass REP 6 1 2 Bracket Not Spared 3 Right Plate Not Spared 4 130K61001 Angle Sensor REP 6 5 5 110 94900 Platen Switch REP 6 6 6 130K61010 Registration Sensor REP 6 7 7 068E10210 Support 8 Bracket Not Spared 9 160K69840 Advanced Features Memory PWB REP 6 16 10 162K60970 Harness 11 162K56420 Sensor Harness 12 162K56430 Harness 13 105K18750 IIT LVPS 110v REP 6 8 105 18760 IIT LVPS 220v REP 6 8 14 Guide Not Spared 15 PWB Box Not Spared REP 6 11 16 127K29440 Fan REP 6 9 17 Bracket Not Spared 18 130K58120 APS Sensor REP 6 10 19 lt Cover Not Spared 20 Guard Not Spared 21 Bracket Not Spared 22 Damper Spared 15 Exploded on PL16 2 Se 9 2 0016001A WOL Parts List 10 00 Initial Issue PL 16 1 5 62 Phaser 790 DocuColor 2006 PL 16 2 PWB Box Item Part Description 1 PWB Box Cover Not Spared 2 Lower Box Not Spared 3 160K67840 IPS PWB REP 6 13 4 160K69571 ICM Main PWB REP 6 14 ADJ 6 5 5 160K62210 Extension PWB REP 6 15 6 IIT ICM PWB Lithium Battery Not Spared 3 0016002A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 63 PL 16 2 PL 16 3 CCD Item Part Description 1 160K67350 Cable 2 Cover Not Spared 3 Screw Not Spared 0016003A WOL Parts List 10 00 Init
327. asured replace the Heat Lamps as required PL 8 3 Also check for conti nuity directly across the Thermal Fuse and the Thermostat If continuity is NOT measured across either component replace the Upper Plate PL 8 2 Go to Flag 1 and Flag 2 Check for an open circuit The wiring is OK Y N Repair or replace the Fuser Connector Harness or the Main Harness PL 11 1 or the Fuser Harness PL 8 5 as required Go to Flag 3 and Flag 4 Check for an open circuit Repair or replace the Fuser Con nector Harness or the Main Harness PL 11 1 or the Fuser Harness PL 8 5 as required Reconnect the power cord and switch on power to the Copier Printer NOTE Line Voltage 110VAC for a 60 Hz System Line Voltage 220VAC for a 50 Hz System Line Voltage is measured between J 34 1 and J34 2 on the LVPS Y N Access the Digital Output DO test from the Control Panel Enter code 47 Press the Item Enter button The Display is O Y N Check the wire between J 32 2 on the LVPS and J 21 3 on the MCU PWB for an open circuit or a short circuit to ground Repair or replace the Fuser Connec tor Harness or the Main Harness PL 11 1 as required If the wiring is OK replace the MCU PWB PL 11 2 Replace the Low Voltage Power Supply PL 11 1 The problem may be intermittent Go to Figure 1 Check for loose or damaged connec tions or damaged wires If the wiring is OK go to 010 701 Faulty Temperature Sensor RAP to troubleshoot t
328. asured between J71 B4 and B6 when the Temperature Sensor is at approximately room tempera ture Y N Go to Flag 1 Check the wiring for an open circuit or a short circuit to ground Repair or replace the Fuser Harness PL 8 5 as required If the problem persists replace the Temperature Sensor PL 8 2 If the problem still persists replace the MCU PWB PL 11 2 Go to Flag 2 Check for an open circuit or a short circuit to ground Repair or replace the Main Harness PL 11 1 as required If the wiring is OK replace the MCU PWB PL 11 2 The problem may be intermittent Go to Figure 1 Check for loose or damaged connections or damaged wires Repair or replace the Fuser Harness PL 8 5 or the Main Harness PL 11 1 as required If the wiring is OK and the problem persists replace the Temperature Sensor PL 8 2 If the problem still persists replace the MCU PWB PL 11 2 Status Indicator RAPs 10 00 010 354 2 170 Initial Issue Phaser 790 DocuColor 2006 15 MCU PWB SENSOR PL8 2 27 VOLTAGE 72 J72 J71 P71 J19 uem GRY ed Bes GRY y 10 317 i 10 353 bo de 2 ZU f 10 354 1 10 355 DC COM 10
329. ation Fiia Separate IU 10 3 Upper Guide Assembly dex 4114 ADJ 5 2 ADF Lead Edge Registration innere 52425 Repairs and Adjustments 10 00 Initial Issue Phaser 790 DocuColor 2006 ADJ 5 3 ADF HelQglibs uat Dee te ed bete Pr dei odes Deed seed 4 150 ADJ 5 4 ADF Front to Rear Positioning essen 4 151 ADJ 6 1 IIT Magnification ADJ 6 2 IIT Half Rate and Full Rate Carriage 4 154 ADJ 6 3 IIT Lead Edge 4 157 ADJ 6 4 IIT Side Registration 4 158 ADJ 6 5 ICM Main PWB Adjustment 4 159 ADJ 6 6 IIT Auto Shading 4 159 ADJ 6 7 Correction rire qala eae ia 4 160 ADJ 8 1 Printer 4 161 ADJ 9 1 Developer Spacing 4 162 ADJ 10 1 Fuser 4 164 ADJ 11 1 Sorter Bin Cam Position Saya ennt ntn 4 165 Initial Issue 10 00 Phaser 790 DocuColor 2006 4 3 Repairs and Adjustments Repairs and Adjustments 10 00 Initial Issue 4 4 Phaser 790 DocuColor 2006 REP 1 1 LVPS Parts List on PL 11 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electric
330. background it is referred to as low medium high or very high background It may occur in all colors single colors or any combination of single colors Go to the IQ8 RAP Black or other Color Prints An image is reproduced as solid black or color from lead edge to trail edge and from front to rear The ROS Border may or may not be visible NOTE None of the image from the original is visible in the copy or print Go to the IQ5 RAP Blank Print Virtually no toner developed onto the copy or print This defect should not be confused with extremely low image density where some development actually occurs Go to the IQ6 RAP Color Misregistration in Process Direction Multi colored images that should be superimposed are offset in the process direction Go to the IQ10 RAP Color Misregistration Perpendicular to Process Direction Multi colored images that should be superimposed are offset perpendicular to process direction Go to the IQ10 RAP Debris Centered Deletions Sections of low density or missing image in the areas surrounding Toner agglomerates Go to the IQ9 RAP Deletions The undesirable absence of toner from the copy or print This defect can show as white light or untrue colored areas on the or print The most common example is a deletion caused by the of paper from mishandling or moisture or by dents or defects in the IBT Go to the IQ9 RAP Drum Defect
331. ble 600T2058 Mini Flashlight 60011824 Parallel Cable 600T2065 Ergonomic Tool 60012123 Laptop AC Adapter Power Cord 600T2018 2mm Hex Wrench 600T41102 Needle Nose Pliers 600T40901 Long assorted shim stock 600T41511 Brush 600T41901 150mm Ruler 600T41503 Initial Issue 10 00 General Procedures and Information Phaser 790 DocuColor 2006 6 29 Common Tools Product Tools and Test Patterns Cleaning Materials Table 1 Cleaning Materials Machine Consumables The following table lists the consumables required for the DC 2006 Table 1 Consumables List for the DC 2006 Description Part Number Cleaning fluid 43P48 NASG Part Number Description Location 802 Formula A 8R90034 ESG 6R994 Black Dry Ink Cartridge NASG Film remover 43 45 NASG 6R90307 Black Dry Ink Cartridge ESG 8 oz 8R90176 ESG 6R995 Cyan Dry Ink Cartridge NASG Lens mirror cleaner 43P81 NASG 6R90308 Cyan Dry Ink Cartridge ESG 8R90178 ESG 6R996 Magenta Dry Ink Cartridge NASG Lint free white 19P3025 NASG 6R90309 Magenta Dry Ink Cartridge ESG cleaning cloth 19P3025 ESG 6R997 Yellow Dry Ink Cartridge NASG Lint free Optics 499790417 NASG 6R90310 Yellow Dry Ink Cartridge ESG Cleaning Cloth 499T90417 ESG 138574 Copy Print Cartridge NASG Cleaning towels 35P3191 NASG 13R90140 Copy Print Cartridge ESG 60084372 ESG 008R12568 Waste Container NASG Drop cloth 35
332. bly PL 7 1 90 mm Feed Roll TBD 134 mm Fuser Heat Roll Remove the Fuser Assembly Check the rolls for dam Fuser Pressure Roll age nicks wear or cuts or contamination Clean or replace as required PL 8 1 Check the Fuser Nip ADJ 10 1 Go to the 010 701 RAP 264 mm Drum Check the surface of the drum for contamination or damage Clean or replace the Copy Print Cartridge as required PL 5 1 Initial Issue 10 00 Image Quality Phaser 790 DocuColor 2006 3 19 1016 IQ17 Uneven Density Mottle RAP This RAP troubleshoots the causes of output images showing image density that varies from inboard to outboard edges or randomly throughout the print Initial Actions Replace the paper in use with fresh dry paper of the correct specification Determine if the Copy Print Cartridge or any of the Dry Ink Cartridges are approaching end of life GP 3 Replace if necessary Perform VisualCal If this does not resolve the problem continue with this RAP Procedure Make a print of the Test Page GP 14 The defect involves a single color Y N Make a print of the Test Page Open the Front Door when the lead edge of the print begins to protrude from the Fuser Exit nip Open the Fuser and examine the partially fused sheet The defect is present in both the fused and unfused portion of the sheet Y N Perform the Fuser Nip Adjustment ADJ 10 1 If the problem continues replace the Main Fuser Assembly PL 8 1
333. cations 10 00 7 15 Initial Issue Phaser 790 DocuColor 2006 240 WHITE 4 WIRES 228 BLUE 230 WHITE Figure 10 Wiring Data 10 00 Initial Issue Plug Jack Locations 7 16 Phaser 790 DocuColor 2006 235 234 221 225 226 222 233 236 0735016A WOL Figure 11 Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 17 Plug Jack Locations 231 TRAY2 232 TRAY 3 219 2 220 TRAYS 223 TRAY2 224 TRAY3 0735015A WOL Figure 12 Initial Issue Phaser 790 DocuColor 2006 10 00 7 18 Plug Jack Locations Wiring Data 0735010A WOL Figure 13 Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 19 Plug Jack Locations e Figure 14 Initial Issue Phaser 790 DocuColor 2006 10 00 7 20 Wiring Data Plug Jack Locations 0735012A WOL Figure 15 Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 21 Plug Jack Locations g Plug Jack Locations Wiring Data 290 10 e 210 0735014A WOL Figure 17 Wiring Data Plug Jack Locations 10 00 7 23 Initial Issue Phaser 790 D
334. ceiver PL 19 2 Replace the Sorter Control PWB PL 19 1 Status Indicator RAPs 10 00 Initial Issue 011 701 2 194 Phaser 790 DocuColor 2006 SORTER CONTROL PWB PL19 1 SORTER 3 BIN DRIVE EB SWITCH 24 DO C6 e ad PWB PL19 4 0 04 5 VDC SWITCHED PL19 4 PL19 1 w BIN DRIVE MOTOR UP BIN CAM SWITCH J P9 MR CLOSED L 5 12 41 37 Vs 1 L 24 VDC 25 COM A No D E RED VIO ORN EE DO C5 BIN Home 24VDC BIN DRIVE MOTOR 45 SWITCHED DOWN L 24 PL194 01 03 E seen pa 517 BIN HOME SWITCH ME CLOSED L 5 VDC i 4 NO SRN 3 2 DC COM 2 7 DC COM SORTER CONTROL PWB RECEIVER PL19 1 SENSOR SORTER 7 192 DI D6 5 VDC CONTROL PWB PAPER IN BIN SENSED PL19 1 J10 P10 5 ype 201 J201 J201 P2001 5 VDC P10 J10 3 RED BLU 5V0C i GRY 4 RECEIVEI DC COM SENSOR 13 TRANSMITTER 6 gt SENSOR PL19 3 J5 P5 14 RED Iw 5VDC 1 2 1 BLU DC COM ele Ji J9 TRANSMITTER SENSOR SORTER J5 CONTROL PWB J10 F1 F2 SORTER BIN DRIVE BIN HOME BIN CAM CON
335. ch letter value then press the appropriate numerical key as follows 1 B 2 330 100 Platen Switch Platen Open 5 VDC 65 C 3 D 4 5 F 6 330 001 APS Sensor APS Sensor Document Sensed L 5 6 5 VDC Table 1 IIT Registration and Magnification Parameters 330 100 Registration Sensor IIT Registration Sensor L 5 6 6 Chain Link ltem Min Default Max Remarks VDC 715 13 Lead Edge Regis 1 47h FFh Variation tration ADJ 6 3 0 0423 mm Step 4 IIT Side Registration 0 47h FFh Variation ADJ 6 4 0 0423 mm Step 2 IIT Magnification 0 23h 46h Variation ADJ 6 1 Magnification X 0 196 Step Magnification X 96 5 103 5 Table 2 ADF Registration Parameters Chain Link Min Default Remarks 715 16 ADF Lead Edge Regis 0 6Eh C2h Variation tration ADJ 5 2 0 1557 mm Step 7 ADF Side Registration 0 47h FFh Variation ADJ 5 1 0 0423 mm Step 7 To exit from the program a Press the Exit button until the Choose and Press Select Administrator menu screen is displayed b Press the Tools button General Procedures and Information 10 00 Initial Issue GP 20 GP 21 6 18 Phaser 790 DocuColor 2006 GP 22 Printing Internal Test Patterns IIT The purpose of the Internal Test Patterns procedure is to enable the IIT to print out various modes of black and white or color prints in several patterns Procedure 1 Load paper in the Bypass Tray 2 Enter the
336. ch on the power If the fault is still present replace the MCU PWB PL 11 2 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 149 009 343 009 344 009 358 BTR 2 Home Position RAP Y N The BTR 2 Cam Sensor does not detect the cam in the home position within the specified time Replace the BTR 2 Cam Clutch PL 7 4 Go to Flag 3 Check for a short circuit to ground If the wire is OK replace the MCU PWB PL Procedure The BTR 2 Cam Clutch is always energized Y N Access the Digital Output Test GP 2 Enter code 53 Press the Item Enter button Enter code 70 Press the Item Enter button The BTR 2 Cam Clutch energizes Y Disconnect P J 64 There is 24 VDC from pin 4 to pin 1 on J 64 Y N There is 24 VDC from pin 4 to frame ground Y Go to Flag 4 Check for an open circuit If the wire is OK replace the MCU PWB PL 11 2 Go to Flag 3 Check for an open circuit If the wire is OK replace the MCU PWB PL 11 2 Replace the BTR 2 Cam Clutch PL 7 4 Access the DO Stop Test Enter code 53 Press the Item Enter button Enter code 70 Press the Item Enter button Remove the BTR 2 Assembly REP 9 18 in order to access the BTR 2 Cam Rotate the cam so that the BTR 2 Cam Sensor is not blocked Access the Digital Input Test GP 2 Enter code 76 Press the Item Enter button The display is 1 Y N Disconnect P J 100 Reenter code 76 The display is 1 Y N Go to Flag 1 Check for a sh
337. ct the Power Cord Remove the Size Switch PWB PL 13 3 Do not disconnect the connectors on the Size Switch PWB Place the Size Switch PWB so that it does not short circuit to the machine frame Connect the Power Cord Switch on the power There is 4 76 0 10 VDC from J 236 pin 2 on the Size Switch PWB GND Y Go to Flag 1 Check the wires for an open or a short circuit to ground The wires are good Y N Repair the wires Ensure that PJ 217 on the Feeder PWB and PJ 236 on the Size Switch PWB are properly connected There is 5 VDC from J 236 pin 1 on the Size Switch PWB to ground A B C Replace the Feeder PWB PL 13 4 Replace the Size Switch PWB PL 13 3 Press and hold switch number SW1 and SW3 on the Size Switch PWB There is 1 57 0 10 VDC from J 236 pin 2 on the Size Switch PWB to GND Y There is 5 VDC from J 236 pin 1 on the Size Switch PWB to ground Y Go to Flag 2 Check the wire for an open or short circuit to ground The wires are good Repair the wires Ensure the connector 4 236 is properly connected Replace the Feeder PWB PL 13 4 Replace the Size Switch PWB PL 13 3 Press and hold switch number SW2 and SWA on the Size Switch PWB There is 3 13 0 10 VDC from J 236 pin 2 on the Size Switch PWB to ground Y There is 5 VDC from J 236 pin 1 on the Size Switch PWB to ground Y N Go to Flag 2 Check the wire for an open or short circuit to ground The wires are good N
338. cuColor 2006 LIFT CLUTCH gt x a ui FEEDER MOTOR 3 PAPER FEEDER ASSY NUDGER SOLENOID NUDGER SENSOR T707022A WOL Figure 2 007 710 RAP Circuit Diagram 2 of 2 007 710 10 00 Status Indicator RAPs 2 109 Phaser 790 DocuColor 2006 Initial Issue 007 711 Tray 1 Paper Size Not Detected RAP The Control Logic detected that the wrong size paper is feeding from Tray 1 Initial Actions Ensure that the paper in Tray 1 is properly installed and that the tray side and end guides are positioned to touch the paper in the tray Procedure Switch off the power Disconnect the Power Cord Remove the High Voltage Power Supply PL 11 1 Remove the Tray 1 Size Bracket Assembly PL 3 1 Remove the Size Switch PWB PL 3 1 from the Bracket Assembly Place the Size Switch PWB so that it does not short circuit to the machine frame Install the Tray 1 Size Switch Bracket Install the High Voltage Power Sup ply Connect the Power Cord Disconnect PJ 102 from the Size Switch PWB Switch on the power There is 5 VDC from J 102 pin 2 to machine ground N Go to 2 Check the wires for an open or a short circuit to ground The wires good Y Repair the wires Replace the MCU PWB PL 11 2 A Connect 102 on the Size Switch PWB Actuate and hold switches SW1 and SW2 on the Size Switch PWB There is 3 15 40 10 VDC from J 102 1 to machine ground
339. cy Tray Front Snubber REP 7 8 10 Snubber Stopper P O PL 14 2 Item 1 11 Rear Guide P O PL 14 2 Item 1 12 Guide Spring P O PL 14 2 Item 1 13 Left Rear Guide Plate P O PL 14 2 Item 1 14 Right Rear Guide Plate P O PL 14 2 Item 1 15 Lock Plate P O PL 14 2 Item 1 16 038K85490 Guide 17 Guide Stopper P O PL 14 2 Item 1 18 Transparency Tray Size Actuator P O PL 14 2 Item 1 19 Tray Bottom Cover P O PL 14 2 Item 1 0014002A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 53 PL 14 2 PL 14 3 Oversize Tray Item Part Description 1 050K42172 Oversize Tray Assembly REP 7 6 2 Tray Housing P O PL 14 3 Item 1 3 Lift Spring P O PL 14 3 Item 1 4 Plate Link P O PL 14 3 Item 1 5 Oversize Lift Plate P O PL 14 3 Item 1 6 Tray Lift Spring P O PL 14 3 Item 1 7 Front Guide Assembly P O PL 14 3 Item 1 8 038E88420 Front Guide 9 019K97140 Oversize Tray Front Snubber REP 7 8 10 Snubber P O PL 14 3 Item 1 11 Rear Guide P O PL 14 3 Item 1 12 Guide Spring P O PL 14 3 Item 1 13 Left Rear Guide Plate P O PL 14 3 Item 1 14 Right Rear Guide Plate P O PL 14 3 Item 1 15 Lock Plate P O PL 14 3 Item 1 16 038K85490 End Guide 17 Guide Stopper P O PL 14 3 Item 1 18 120E12930 Oversize Tray Actuator 19 Tray Bottom Cover P O PL 14 3 Item 1 0 014003A WOL Parts List 10 00 Initial Issue PL 14 3 5 54 Phaser 790 DocuColor 2006 PL 15
340. d If the wire is OK replace the MCU PWB PL 11 2 A the Process Drive Unit PL 10 1 The problem appears to be intermittent Check Flag 1 Flag 2 Flag 3 and Flag 4 for loose con nectors or damaged wires If the wires are OK replace the Process Drive Unit PL 10 1 If the condition persists replace the MCU PWB PL 11 2 Initial Issue Phaser 790 DocuColor 2006 10 00 2 139 Status Indicator RAPs 009 323 PROCESS DRIVE UNIT 1 PL10 1 MCU PWB PL11 2 PROCESS L DO 54 MOTOR 7 PROCESS MOTOR ON J18 J52 L 7 27VDC 5 MOTOR 1 GRY DRIVE DC PROCESS MOTOR SPEED 0 6 3 GRY PROCESS MOTOR i gv SPEED 1 AE GRY COM i 1 1 22 4 GRY ze S 21 pc LvPS 1 PL11 1 J32 J51 F4 ORN 1 24 VDC INTLK 114 VIO DC COM MCU PWB PL11 2 27777 5VDC 0672 1 PROCESS MOTOR FAIL J52 5VDC J18 gt 1 r18 09 323 VILL GRY 5 6 K PROCESS MOTOR CLOCK 3 GRY LZ P16 P19 P22 P18 P17 P15 MCU PWB 20 P12 pas P21 Figure 1 009 323 RAP Circuit Diagram T 709001 A WOL Status Indicator RAPs 009 323 10 00 2 140 Initial Issue Phaser 790 DocuColor 2006 009 326 Rotary Motor RAP One of the fo
341. d Duplex Transport 1 of 2 Wiring Data 10 00 Initial Issue 7 100 Phaser 790 DocuColor 2006 BSD 10 5 DUP CONTROL PWB PL15 6 L M N P 8 T 10 5 INVERT AND DUPLEX TRANSPORT 2 OF 2 DUP CONTROL DUPLEX PWB 01 91 5 DUPLEX 5VDC J141 P134 611 Be 5 0159 3 P159 SENSOR 5 GRY J145 P159 5 J159 J155 pe gy 134 D 5 0 GRY GRY GRY 13 B4 7 3 one GRY GRY EE EN i 2 92 PEN E 2160 160 EXT B14 B3 gay 8 17003 SENSOR v VE 2 J146 P160 J160 Lg EX L 5VDC 2 DRE 11 GRY GRY Gry 82 GRY 816 B1 GRY GRY GRY Figure 1 Invert and Duplex Transport 2 of 2 T 10708A WOL Initial Issue Phaser 790 DocuColor 2006 10 00 7 101 Wiring Data BSD 10 6 A B D E F G H J 10 6 INVERT MECHANISM INVERT IN MECHANISM INVERT IN ROLL 10 5 DRIVE EN EUN 107 INVERT IN DRIVE 2 DUP CONTROL PWB DO A1 ENTER CLUTCH ON L 24VDC GRY 2 15 24 a INTERLOCKED GRY J152 4 20 FORWARD CLUTCH ON EE 27 INVERT MECHANISM L 24VDC GRY 24VDC lt INTERLOCKED GRY 4150 1 TRI ROLL 10 5 DRIVE
342. de 7 25 7 71 5 VDC Wirenet 103 7 26 7 72 5 VDC Wirenet 2 of 3 7 27 7 78 5 VDC Wirenet 3 of 7 28 7 74 24 VDC Interlocked Wirenet 1 of 3 7 29 7 75 24 VDC Interlocked Wirenet 2963 7 30 7 76 24 VDC Interlocked Wirenet 3 013 1 1 1 0 1 a 7 31 2 77 DC Com Wirenet 1 015 7 32 7 78 DC Com Wirenet 2 of 5 7 33 7 79 DC Com Wirenet 3 of 5 7 34 7 80 DC Com Wirenet 4 05 7 35 7 81 DG Gom Wirenet 7 36 7 82 5 VDC IIT Wirenet e 7 37 7 83 24 VDE IIT Wiro Ot xe nette en t tete t e e etd 7 38 7 84 BSDs ion 7 39 7 87 7 40 7 88 7 41 7 89 7 42 7 90 7 43 7 91 7 44 7 92 7 45 7 93 7 46 7 94 ir BSD 10 1 sus 77 95 E55 7 96 R55 7 97 751 BSD 10 44 7 98 7 52 BSD 10 4 7 99 7 53 BSD 10 5 7 100 7 54 RIDES 7 101 7 55 BSD 10 6 irre EXER Pee LEE DERE 7 102 7 56 BSD 10 7 7 103 7 57 BSD 10 8 wae 7 104 7 58 2 E 7 105 7 59 7 106 7 60 7 107 7 61 7 62 7 63 7 64 7 65 7 66 Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 1 Wiring Data 10 00 Initial Issue 7 2 Phaser 790 DocuColor 2006 Plug Jack Locations Table 1 Plug Jack Location List
343. distribution of electrical and mechanical power Each functional chain is represented by a BSD or a group of BSDs A BSD is a func tional flow diagram containing electrical circuit information and mechanical inputs and outputs The functional flow is from left to right inputs on the left and outputs on the right Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 39 1 1 MAIN POWER ON 1 MCU PWB PL11 2 LOW VOLTAGE POWER SUPPLY PL11 1 d ENERGY 12 2 gt ENERGY STAR SIGNAL 412 STARON J32 ENERGY 18 BRN BRN 16 STAR lt YEL CONTROL 2 MAIN SWITCH 5 5 DC 13 3 ot 2 d D 4 5 NOTES 0 REFER TO 5 VDC WIRENET FOR DISTRIBUTION 2 REFER TO DC COM WIRENET FOR DISTRIBUTION 1701701 A WOL Figure 1 Main Power On Wiring Data 10 00 Initial Issue 7 40 Phaser 790 DocuColor 2006 1 2 INTERLOCK SWITCHING RIGHT FRONT MCU PWB 1 COVER PL11 2 INTERLOCK 01 73 PL11 2 RIGHT FRONT COVER CLOSED 7 4192 1 5VDC 4197 197 417 3 ge 2
344. djustments Phaser 790 DocuColor 2006 4 103 REP 9 14 REP 9 15 REP 9 16 IBT Assembly Parts List on PL 7 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch 1 on or electrical power applied to the machine Lift slightly and remove Switch off the machine power and disconnect the machine Power Cord the IBT Assembly Remove the Rear Cover REP 14 6 Remove the Copy Print Cartridge REP 9 1 Remove the Tension Lever REP 9 15 Remove the Inner Covers REP 14 5 Remove the Fuser Assembly REP 10 1 Remove the Belt Cleaner REP 9 17 Remove the BTR 2 Assembly REP 9 18 Open the Bypass Tray Registration Assembly 0 Disconnect the ADC Sensor and TRO Sensor connectors CAUTION Ensure that the IBT Belt does not touch any other components during the removal Never touch the surface of the IBT Belt with your hands Hold the assembly by the ribs on either side 0109030A WOL 11 Remove the IBT Assembly Figure 1 Figure 1 Removing the IBT Assembly Replacement 1 Reinstall the IBT Assembly in the reverse order of removal D 0 OP BI S Oo ook Repairs and Adjustments 10 00 Initial Issue REP 9 16 4 104 Phaser 790 DocuColor 2006 REP 9 17 Belt Cleaner Parts List on PL 7 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect
345. e Phaser 790 DocuColor 2006 2 14 3 1 INVERTER 1 2139 15 140 12 13 CLUTCH P141 20 CONTROLLER US 142 FORWARD CLUTCH 2 1 zi 1 17 1 17 1 12 INVERTER PID 34 pup 18 22 pig 1234 18 24 pig 13 1 i MOTOR P14 P17 17 16 1 P15 MCU PWB P20 814 C 15 12 M6 PH M re INVERTER LOWER ASSEMBLY 1 B16 B1 P21 1708010A WOL Figure 2 008 704 RAP Circuit Diagram 2 of 2 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 129 008 705 Top Tray Full RAP The Control Logic has sensed the signal Top Tray Full 1 5 Initial Actions Remove any paper from the Top Tray Unlock the Full Stack Sensor Actuator so that the Actuator will operate properly Ensure that the Sensor and Actuator are properly installed into the Sensor Bracket Procedure Enter the diagnostic mode Enter Code DI 15 The display indicates 1 Y N Go to Flag 2 Check the wire for a short circuit to ground The wire is good Y N Repair the wire Ensure that PJ 17 PJ 161 and PJ 167 are properly connected Replace the Full Stack Sensor PL 9 2 If the problem continues replace the MCU PWB PL 11 2 Actuate the Full Stack Sensor Actuator The display indicates a 0 Y N
346. e The purpose is to ensure that the Developer Housing is at the correct distance from the Copy Print Cartridge Check WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Top Cover Assembly REP 14 4 3 Release the Rotary Latch Turn the Rotary Frame clockwise until the magnetic roll of the target Developer Housing is at the top Continue to turn until the Rotary Latch catches in the notch of the Rotary Frame CAUTION Do not touch the surface surface around circumference of the white tracking roll with your gers while performing the following step If you accidentally touch the surface of the tracking roll with your fingers or if oily substances get on the surface wipe the roll clean with a clean cloth 4 Clean the White Tracking Roll in front of the target Developer Assembly in front of the Magnetic Roll with a clean cloth Figure 1 5 Make a mark on the White Tracking Roll at the edge of the White Seal in front of the tar get Developer Assembly in front of the Magnetic Roll If a mark already exists on the White Tracking Roll rotate the roll to align the mark with the edge of the White Seal Figure 1 CAUTION Turn the Rotary Frame as slowly as possible while performing the following step Turning the Rotary Frame too fast will prod
347. e Feeder Chute Enter diagnostic code DI A6 The display indicates a 0 Y N Go to Flag 3 Check the wires for an open or a short circuit to ground The wires are good Y N Repair the wires Go to Flag 1 Check the wires for an open or a short circuit to ground If the wires are good Replace Feed Out Sensor for Tray 2 Paper Feeder PL 13 5 If the problem contin ues replace the Feeder PWB PL 13 4 Remove the paper from the Paper Feeder for Tray 2 Put a sheet of paper in the Paper Feeder for Tray 3 to cover the Feed Out Sensor Close the Feeder Chute Enter diagnostic code DI B6 The display indicates a 0 Y N Go to Flag 4 Check the wires for an open or a short circuit to ground The wires are good Y N Repair the wires Go to Flag 2 Check the wires for an open or a short circuit to ground If the wires are good replace the Feed Out Sensor for Tray 3 Paper Feeder PL 13 5 If the problem con tinues replace the Feeder PWB PL 13 4 Go to Flag 1 Check the wires for an open or short circuit to ground The wires are good Y N Repair the wires Replace the Feed Out Sensor for Tray 2 Paper Feeder PL 13 5 If the problem continues replace the Feeder PWB PL 13 4 Initial Issue 10 00 Phaser 790 DocuColor 2006 2 123 Status Indicator RAPs 008 702 FEEDER PWB FEEDER PWB FEED OUT SENSOR PL13 4 PL13 5 DC COM I 01
348. e IIT GP 19 Enter Diag Code and press the Select button Select DC No and enter 945 Press the Down Arrow to select subcode and enter 10 Press Select then press Start Exit Diagnostics o gig gt Repairs and Adjustments 10 00 Initial Issue ADJ 6 7 4 160 Phaser 790 DocuColor 2006 ADJ 8 1 Printer Registration The purpose is to adjust the side to side and top to bottom registration of the printer to a nom value This procedure should be performed before adjustment of the IIT Scanner Registra or 2006 tion y 3 oto EE Measure and record Check the top to bottom 1 Load fresh 11 inch A4 paper long edge feed into paper Tray 1 registration on each 2 Using the Menu button scroll to PRINT PAGES FROM LIST and press the Enter button 3 Using the Arrow Up and Arrow Down buttons select PRINT MENU HELP and then press the Item Enter button A series of pages will be printed For this adjustment you will only use the first page 4 4 Repeat to create three prints of the first page Calculate the average top to 5 Check the side to side and top to bottom registration Figure 1 bottom registra 6 Repeat steps 1 5 for each tray and option tray tion value of the 7 Compare the average value calculated to the value displayed in Table 1 If the average Me measure c
349. e 1 1 Disconnect the connector 2 Remove the screw and the Angle Sensor Figure 1 Removing the Angle Sensor Replacement 1 Perform the procedure for removal in reverse Pu REP 6 6 Platen Switch Parts List on PL 16 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord Remove the Platen Glass REP 6 1 Remove the Control Panel Assembly REP 6 23 Remove the Platen Switch Figure 1 e EAM Remove the screw and the Platen Switch 2 3 4 1 Disconnect the connector and release the wires from the clip 0106001 A WOL 0106002A WOL Figure 1 Removing the Platen Switch Replacement 1 Perform the procedure for removal in reverse Initial Issue Phaser 790 DocuColor 2006 Repairs and Adjustments REP 6 5 REP 6 6 10 00 4 39 REP 6 7 Registration Sensor Parts List on PL 16 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 2 3 4 Switch off the machine power and disconnect the machine Power Cord Remove the Left Cover REP 6 3 Remove the Rear Cover REP 6 4 Remove the bracket containing the power receptacles Figure 1 1 Remove the screws 2 and the bracket containing the power rec
350. e Developer bias Connect the DVM between the D terminal on the HVPS and frame ground Access the Digital Output Test GP 2 Enter code 0B Press the Item Enter button Roughly 80 VDC is mea sured Y N There is less than 1 VDC from J 42 pin 7 on the HVPS to ground Y N Go to Flag 1 Check for an open circuit If the wire is OK replace the MCU PWB Go to Flag 3 Check for an open circuit or a short circuit to ground If the wires are OK replace the High Voltage Power Supply PL 11 1 Exit the diagnostic mode Make a print of the Test Page GP 14 Listen for the sound of the Rotary Frame moving Immediately after hearing the 4th indexing of the Rotary Frame open the Front Door and remove the Copy Print Cartridge Examine the IBT Belt There is a toner image of the Test Page on the belt Y N Check the installation and operation of the BTR 2 Cam Assembly and the Belt Cleaner PL 7 1 If these assemblies are OK remove the IBT Assembly PL 7 1 Check for dirt or damage to the BTR 1 and BTR 1 Plate Wire PL 7 3 Clean repair or replace as required WARNING HIGH VOLTAGE Exercise caution when performing the voltage checks in this procedure Connect the DVM between the F terminal on the HVPS and frame ground Access the Digital Output Test GP 2 Enter code OA Press the Item Enter button Roughly 1000 VDC is measured Y There is less than 1 VDC from J 42 pin 10 on the HVPS to ground A Y N Go to Flag 4 Check for a
351. e Feeder PWB PL 13 4 Replace the Feeder PWB PL 13 4 Initial Issue Phaser 790 DocuColor 2006 10 00 2 95 Status Indicator RAPs 007 704 FEEDER PWB Figure 1 007 704 RAP Circuit Diagram TRAY 2 PAPER FEEDER ASSY PL13 4 2 DI A4 5VDC NO PAPER SENSOR PL13 5 J219 P241 J241 5VDC J214 PL13 4 7 GRY GRY 2 Ah 5VDC ee 4214 241 4241 4219 3 1 T 3 1 Y 1 T GRY I GRY 237 1 1 1 1 1 1 1 1 3 GRY GRY DC COM Q WN o o P214 P218 P216 Y NO PAPER 9 SENSOR P213 FEEDER 1 PWB Tee P212 Enc BS M Y 2 215 2 o T707006A WOL Status Indicator RAPs 007 704 10 00 2 96 Initial Issue Phaser 790 DocuColor 2006 007 705 Tray 3 Empty RAP The Control Logic detected the signal No Paper Sensor Sensed 5VDC Initial Actions Put paper into Tray 3 and ensure that the paper is loaded properly Procedure Remove Paper Tray Check that the No Paper Actuator is operating properly The Actua tor is present and operates smoothly Y N Replace the No Paper Sensor Actuator PL 13 5 Access the Digital Input DI Test from the control panel Enter code DI B4 Press the Enter button The display is 1 Y Chec
352. e Fuser Fan PL 9 2 The Fault Code is still present or re occurs Y N The problem may be intermittent Go to Figure 1 Check for loose or damaged connec tions or damaged wires Also check for continuity If the wiring is OK replace the Fuser Fan PL 9 2 If the problem persists replace the MCU PWB PL 11 2 is measured between P 111 2 and frame ground DC Common Y N Go to Flag 3 Check for an open circuit Repair or replace the Main Harness PL 11 1 as required If the wiring is OK replace the MCU PWB PL 11 2 Replace the Fuser Fan PL 9 2 Status Indicator RAPs 10 00 Initial Issue 010 358 2 174 Phaser 790 DocuColor 2006 Figure 1 010 358 RAP Circuit Diagram MCU PWB PL11 2 FUSER FAN PL9 1 DO 63 FAN ON J17 H 24VDC P111 J111 13 1 1 2470 1 DO 65 1 1 i FAN HI SPD I L 24VDC I 18 2 1 24VDC 1 1 1 I 1 1 DC COM 20 Pa 44 v MOT I 5VDC DC COM DI 85 1 AN FAIL a 3 5VDC 10 358 2 3 2 5 o 1 71 111 17 1 7 5 34 pig 18 22 pig 12 34 18 7T pigT 328 P14 P17 2871 P15 MCU PWB P20 15 m4 12 16 PH A P23 3 1 FUSER FAN 1 B16 E 1 T710005A WOL Initial Issue
353. e Manual Revision The Service Manual will be updated as the machine changes or as problem areas are identi fied Organization This Service Manual is divided into nine sections The titles of the sections and a description of the information contained in each section are contained in the following paragraphs Section 1 Service Call Procedures This section contains procedures that determine what actions are to be taken during a service call on the machine and in what sequence they are to be completed This is the entry level for all service calls Section 2 Status Indicator RAPs This section contains the diagnostic aids for troubleshooting the Fault Code and non Fault Code related faults with the exception of copy quality problems Section 3 Image Quality This section contains the diagnostic aids for troubleshooting any copy quality problems as well as copy quality specifications and copy defect samples Section 4 Repairs Adjustments This section contains all the Adjustments and Repair procedures Repairs Repairs include procedures for removal and replacement of parts which have the following special conditions When removal or replacement cannot be determined from the exploded view of the Parts List When there is a cleaning or a lubricating activity associated with the procedure When the part requires an adjustment after replacement When a special tool is required for removal or replacement Use the repair procedures f
354. e Menu button until CHANGE DEFAULT LOCALE is displayed Press the Item Enter button Press the Up or Down Arrow buttons to scroll through the following market selection menu UNITEDSTATES EUROPE JAPAN UNKNOWN UNITEDSTATES2 EUROPE2 JAPAN2 Press the Item Enter button when the appropriate market is displayed Exit the Diagnostic Mode IOT GP 1 Switch off the machine power Remove the jumper from J 8 on the ESS PWB If necessary reinstall the 1394 PWB PL 12 1 Reinstall the Right Cover REP 14 9 Initial Issue Phaser 790 DocuColor 2006 10 00 4 147 Repairs and Adjustments ADJ 3 1 ADJ 3 2 ADJ 5 1 ADF Side Registration Adjustment Purpose The purpose is to adjust the front rear positioning of documents fed from the ADF onto the Platen Glass and to check the positioning of images relative to paper NOTE Verify that the Printer Registration Adjustment ADJ 8 1 on the IOT is within specifica tion before performing this adjustment Check 1 Using the Copier Setup Test Pattern 82E8220 make two 11x17 A3 copies with the machine Color Mode set to Black magnification set to 100 and in Platen Mode 2 Using the second sample copy from step 1 as the document make a copy from the ADF 3 Check the copy Verify that the distance from the side edge to the top of Step 3 on the and SES scales is 10 0mm 3 Figure 1 100mm Paper Feed Direction SE2
355. e Paper Feeder Assembly PL 13 3 Replace the Feeder PWB PL 13 4 There is 24 VDC from 4 216 pin 8 to ground on the Feeder PWB There is 24 VDC from 216 pin 7 to ground on the Feeder PWB Y Replace the Feeder PWB PL 13 4 Go to Flag 6 Check for an open circuit The wires are good Y N Repair the wires Replace the Feeder PWB PL 13 4 Replace the Feeder Drive Unit PL 13 4 A Status Indicator RAPs 10 00 Initial Issue 007 709 2 104 Phaser 790 DocuColor 2006 FEEDER PWB PL13 4 P3 00 5 5VDC NUDGER 259 SENSOR NUDGER PL13 5 SENSED 5 4221 J241 __ D SVbC LWPS FEEDER PWB GRY GRY PL13 4 P3 lt Ez 4224 P241 16 4281 4221 GRY GRY 1 112 J PONDS GRY GRY S l o o 4 P214 218 DC COM ez DO B8 P216 FEEDER MOTOR P213 J217 9N O 24VDC y 1239 FEEDER 12 5VDC PWB BLU FEEDER MOTOR DC COM 1589 FAIL H 5VDC 3217 212 P21 13 2 wor 4 11 BLU BLU P215 DC COM 24VDC INTERLOCKED 14 1 1 LIFT 24VDC CLUTCH PL13 4 DO B2 LIFT CLUTCH LOW VOL
356. e Toner Sensor 0090006A WOL Figure 1 Removing the Waste Toner Sensor REP 9 7 Toner Box Sensor Parts List on PL 5 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Locating Rail REP 9 5 3 Remove the Toner Box Sensor Figure 1 Replacement 1 Remove all slack from the harness before securing the harness 2 Reinstall the Toner Box Sensor in the reverse order of removal 3 Unhook the sensor from the rail 4 2 Remove the Toner Disconnect the connector Box Sensor 1 Disengage the harness from the clamp 0090007A WOL Figure 1 Removing the Toner Box Sensor Repairs and Adjustments REP 9 6 REP 9 7 10 00 Initial Issue Phaser 790 DocuColor 2006 REP 9 8 Erase Lamp Parts List on PL 5 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Locating Rail REP 9 5 3 Remove the Erase Lamp Figure 1 Replacement 1 Reinstall the Erase Lamp in the reverse order of removal 3 Remove the Erase Lamp 2 Unhookthe lamp from the rail by compressing the tabs 1 Pull the harness through the hole 00
357. e measured in the check is greater than 3 0 to 5 0 mm move the spacer up If the distance measured in the check is less than 3 0 to 5 0 mm move the spacer down 2 Rotate the Rotary Frame until the frame is down in the position shown 3 Loosen the 2 screws securing the adjustment spacer 0 209001A WOL Figure 2 Adjusting the Developer Spacing 2 Perform the check again starting with step 5 Repeat until the measurement is within specification Initial Issue Phaser 790 DocuColor 2006 10 00 4 163 Repairs and Adjustments ADJ 9 1 ADJ 10 1 Fuser Nip Purpose The purpose is to adjust the fuser nip in order to ensure correct fusing of documents Check 1 Ensure that the machine is in the Ready condition 2 several Internal Nip Test Pattern copies for the check GP 15 3 Open the Fuser Assembly 4 Insert one of the copies into the nip with image side up and using the thumb wheel advance the black copy into the nip 5 Leave the copy between the rolls 6 Remove the copy after 10 to 20 seconds 7 Check the Fuser Nip Figure 1 Measure the width of the impression left by the nip 8 Ifthe measurement is not in specification perform the adjustment 1 Measure the width of the nip at points A and B 2 Check The width of the nip is 7 0 mm and the difference between the two measurements is less than or equal Adjustment 1 Remove the Upper Guide Assembly REP 10 3
358. e procedure for removal in reverse 2 Perform an ADF Side Registration adjustment ADJ 5 1 3 Perform an ADF Lead Edge Registration adjustment ADJ 5 2 4 Perform an ADF Height adjustment ADJ 5 3 5 Perform an ADF Front to rear Positioning adjustment ADJ 5 4 Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 23 REP 5 1 REP 5 2 ADF Drive Motor Parts List on PL 17 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the ADF Rear Cover 3 Remove the ADF Drive Motor Figure 1 2 1 Remove the Disconnect the connector and ground wire Use a scribe to mark off the ADF Drive Motor bracket position Remove the ADF Drive Motor Remove three screws and remove the Drive Belt 0105002A WOL Figure 1 Removing the ADF Drive Motor Replacement 1 Perform the procedure for removal in reverse 2 Install the motor using the previously scribed marks to set the proper belt tension REP 5 3 Counterbalance Parts List on PL 17 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine CAUTION Different loads are applied to each side of the ADF For this reason the Counterbalance parts are unique for each side When r
359. e shown in Table 1 Table 1 Product Codes Product Code DC 2006 Copier Printer 110 VAC VF8 DC 2006 Copier Printer 220 VAC VF9 Phaser 790 110 VAC VF6 Phaser 790 220 VAC VF7 Installation Space Requirements Figure 1 illustrates the space requirements for adequate ventilation and space needed for replacing the supplies IOT Specifications Printer Size and Weight The following table shows dimensions and weights of the printer and options Table 1 Unit Width Depth Height Weight Printer 25 5 in 650 mm 25 4 in 646 mm 21 8 554 mm 156 6 Ib 71 2 Feeder 22 in 560 mm 23 7 IN 602 mm 11 5 IN 292 mm 46 6 Ib 21 2 Kg Cabinet 22 in 560 mm 27 in 686 mm 18 9 in 479 mm 39 6 Ib 18 Kg Electrical Specifications The input line voltage and frequency specifications are as follows Table 2 Electrical Specifications Input Voltage Power Supply Fuser 5 100 100 to 120 10 90 to 135 100 50 Hz 3 Hz 60 Hz 3 Hz Spine 120 VAC 100 to 120 7 10 90 to 135 VAC 120 794 mm 50 Hz 3 Hz 60 Hz 3 Hz gt 4 220 VAC 220 to 240 1095 198 to 264 220 VAC 26 inches 50 Hz 3 Hz 60 H
360. e the 5 wires from the Le clips gt E pr ond 3 Remove the screw and the Duplex Nip Solenoid 0108069A WOL 2 Figure 2 Removing the Duplex Nip Solenoid Release the wires from the Replacement clip 1 Perform the removal procedure in reverse 2 When replacing the Lower Chute make sure the guide pins at the rear of the chute are p ii positioned to the locating holes in the frame Sy Remove the screw and pull the Lower Chute from the machine 0108068A WOL Figure 1 Removing the Lower Chute Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 87 REP 8 39 REP 8 40 Exit Transport Assembly Parts List on PL 9 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Top Cover REP 14 4 3 Remove the Rear Cover REP 14 6 CAUTION The plastic hinges of the Transport Cover can be easily damaged Use care when performing the following step 4 Remove the Exit Transport Cover Figure 1 S 0108014 A WOL Figure 1 Removing the Transport Cover 5 Remove the Exit Transport Assembly Figure 2 Remove the five screws and the Exit Transport Assem 1 bly as shown Disconnect the connectors 2 0108065A WOL
361. e the Upper Turn Cover Chute Assembly by pushing on the boss on the front side of the chute and pulling out eek ward on the assembly 0108002A WOL Figure 2 Removing the Turn In Chute Bi Open the Turn Chute Cover DIOS TRE WUR Figure 1 Accessing the Turn In Chute Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 59 REP 8 1 6 Remove the Turn Roll Figure 3 1 2 4 Remove two Remove two Slide the Turn Roll Screws and the screws and the forward and remove paper tray Stopper Outer Turn Chute it from the Turn PL 3 1 Clutch Pivot the rear outward and remove the Turn 3 Remove the E ring securing the Turn Roll Slide the Turn Front Bearing towards the rear of the machine 0108003A WOL Figure 3 Removing the Turn Roll Replacement 1 Perform the procedure for removal in reverse NOTE When installing the Stopper for the paper tray position the paper tray and secure the Stopper to the position where it securely holds the paper tray in place REP 8 2 Feed Roll Parts List on PL 3 3 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Tray 1 Assembly REP 7 6 3 Remove the Front Mid Cover REP 14 2 or the Duplex Tray
362. e wires A B C Table 1 Tray 2 Size Sensing Size Switch PWB ANALOG PAPER SIZE PAPER SIZE SW VOLTAGE OUT SW1 SW2 SW3 54 Tray Out OFF OFF OFF OFF 4 76 VDC Ledger SEF OFF ON OFF OFF 3 45 VDC A3 SEF ON OFF ON OFF 1 57 VDC Letter LEF OFF ON ON ON 2 49 VDC B5 LEF OFF ON OFF ON 3 13 VDC Legal SEF OFF OFF ON OFF 4 09 VDC A4 LEF OFF OFF ON ON 3 77 VDC B4 SEF OFF ON ON OFF 2 81 VDC Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 89 007 701 P214 P218 Fes FEEDER PWB P212 P215 P216 217 SIZE SWITCH PWB PL13 3 SIZE SWITCH VOLTAGE SEE TABLE SIZE SWITCH PWB FOR TRAY2 SIZE PWB TRAY2 amp 3 S4 REAR VIEW 1707015A WOL Figure 1 007 701 RAP Circuit Diagram Status Indicator RAPs 10 00 Initial Issue 007 701 2 90 Phaser 790 DocuColor 2006 007 702 Tray 3 Open RAP The Control Logic detected the absence of the analog signal Size Switch Sensed Voltage for Tray 3 Initial Actions Ensure that Paper Tray 3 is closed Procedure The Paper Tray is properly seated and fully closed Perform the following Inspect the paper tray rails and cavity for obstructions Inspect the paper tray paper end guide for proper operation If the end guide does not operate the Size Actuator replace the Paper Tray PL 14 2 Switch off the power Disconne
363. e wires are OK replace the ICM Main PWB PL 16 2 Status Indicator RAPs 10 00 Initial Issue 005 704 2 64 Phaser 790 DocuColor 2006 ADF CONTROL PWB PL17 2 ICM MAIN PWB PL16 2 PL16 2 DOCUMENT EXCHANGE 45 VDC J220 D 5 VDC J811 6 TEL DOCUMENT READY J811 L 5 VDC J220 DC COM YEL DC COM ADF CONTROL PWB CR3 P811 P813 CR2 W RED U2 P812 P815 P814 P816 1705006 A WOL Figure 1 005 704 RAP Circuit Diagram Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 65 005 704 Status Indicator RAPs 10 00 Initial Issue 005 704 2 66 Phaser 790 DocuColor 2006 006 310 IIT Registration RAP The Control Logic has not detected the signal IIT Registration Sensor Sensed 5 VDC at the correct time Initial Actions Check the Carriage Motor drive components including the Belt PL 16 4 and the Front and Rear Cables PL 16 4 Procedure Switch off the power Disconnect the power cord Remove the IIT Rear Cover REP 6 4 Remove the IIT Right Cover REP 6 2 Disconnect P J 110 Carriage Motor connector from the ICM Main PWB Turn the bronze flywheel on the Carriage Motor ia a CW direction in order to drive the Carriage all the way to the right as viewed from the rear of the IIT Connect the power cord and switch on the power 5 VDC is measured at P 130 8 to frame Y
364. ead edge slow scan direction measurement is short reduce the value when the measurement is long increase the y value Change the values as follows IIT lead edge registration affects the entire accuracy regarding document size detection and other document positions NOTE To enter a letter Hexadecimal value press the asterisk key prior to entering each letter value then press the appropriate numerical key as follows A21 2 D 4 5 Check F 6 1 Using the Copier Setup Test Pattern 82E8220 make two copies with the machine set to a Enter the new value and press Start Tray 1 A3 and 10096 magnification 2 Check the second copy Verify that the distance from the lead edge of the copy to the indi cated point is 10 2 0mm Figure 1 Table 1 b Press the Select button to verify the value has changed Minimum Initial Maximum Remarks Settings Range 1 47h FFh 0 04mm Step I t2 0 Lead Edge 5 Perform the check again e N Paper Feed Diag
365. ect the sen Sor connector 2 1 Remove the Remove the bracket Screws e 7 Remove the BTR 2 Cam Assembly from the front 0109031A WOL Figure 1 Removing the BTR 2 Cam Assembly Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 107 REP 9 19 REP 9 20 Auger Parts List on PL 7 1 1 2 Removal Remove the screws Remove the Auger securing the bracket WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine Switch off the machine power and disconnect the machine Power Cord Open the Bypass Tray Registration Assembly REP 8 6 Remove the Locating Rail REP 9 3 Remove the Fuser Assembly REP 10 1 Remove the Belt Cleaner REP 9 17 Remove the BTR 2 Assembly REP 9 18 Remove the BTR Cam Clutch REP 9 23 Remove the HVPS REP 1 2 9 Remove the Process Drive Unit REP 4 6 10 Remove the IBT Assembly REP 9 16 11 Remove the BTR 2 Cam Assembly REP 9 19 12 Remove the Right Cover REP 14 9 Ol NOTE Toner may spill from the Auger during the removal Spread paper on the frame below the Auger and be careful not to spill toner DI Or aS ON 0109032A WOL Figure 1 Removing the Auger 13 Remove the screw securing the Auger at the rear of the printer 14 Remove the screw and KL Clip securing the Auger inside the printer lower side 15 Remove the screw securin
366. ection Bands Streaks and Smears RAP Procedure The defect occurs every print letter size Y N The defect occurs every second print letter size Y If the defect occurs intermittently examine the Developer Housings for evidence of toner clumping If clumping is found replace the Developer Housing PL 6 2 Remove the Belt Cleaner PL 7 1 Inspect the cleaning blade and Mylar seal for damage Clean or replace as required Go to the 009 704 RAP to check the function of the Belt Cleaner If the Belt Cleaner is OK check the IBT Belt PL 7 2 for damage or contamination Clean or replace as required The defect is a process direction deletion Y N Remove the Fuser Assembly PL 8 1 Examine the Heat Roll and Pressure Roll for dam age or contamination Clean or replace as required PL 8 3 Adjust the Fuser Nip ADJ 10 1 If the Fuser is OK replace the Copy Print Cartridge PL 5 1 Enter diagnostic mode GP 1 Access the Pattern Printing routine Print a copy of the 2096 coverage pattern for all colors The defect is present for all colors Y Replace the Developer Housing PL 6 2 for the affected color Remove the ROS PL 5 1 Check the ROS window for damage or contamination Clean or replace as required If the problem remains replace the Copy Print Cartridge PL 5 1 If this does not resolve the problem replace the ROS PL 5 1 1915 Unfused Copy RAP Initial Actions Replace the paper in use with fre
367. ed metal frame parts The edges of the parts may be very sharp and could cause serious injury 8 Remove the Feed Roll Assembly Figure 1 meo c 4 Remove the Feed Roll Assembly by sliding it forward until the rear is free from the frame then pivot it to remove the front Remove the Feed Roll Assembly together with the gear and bearing intact 3 Remove the screw holding the Feed Shaft Guide and remove the Feed Shaft Guide See WARNING Remove the Feed Spring Remove the E ring and remove the Feed Gear 0108007A WOL Figure 1 Removing the Feed Roll Assembly Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 61 REP 8 3 REP 8 4 Turn Clutch 5 Remove the Turn Clutch Figure 2 Parts List on PL 3 3 Removal 1 The Turn Clutch is retained by WARNING the Turn Roll After the Turn To avoid personal injury or shock do not perform repair activities with the power switch Roll is removed remove the Turn Clutch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Rear Cover REP 14 6 3 Remove the Turn Roll REP 8 1 WARNING Use extreme care when working in the vicinity of the Option Bracket The edges of the Option Bracket may be very sharp and could cause serious injury 4 Disconnect the Turn Clutch Figure 1 1 Disconnect the connector
368. eloper Housing for the affected color Check for toner bridging uneven brush or loose High Voltage terminals Clean repair or replace as required PL 6 2 Image Quality 10 00 108 3 12 Initial Issue Phaser 790 DocuColor 2006 Initial Issue 10 00 Image Quality Phaser 790 DocuColor 2006 3 13 108 IQ9 Deletions RAP Initial Actions Reload the machine with fresh dry paper of the correct specifications If the problem occurs when using heavyweight paper ensure that the correct selections are being made on the print driver If the problem is not resolved continue with this RAP NOTE Small white deletions with a sharp edge are usually caused by Fuser offsetting Go to the IQ18 Spots RAP Procedure The problem is debris centered deletions small area deletions surrounding a dark speck Y Enter diagnostic mode GP 1 Access the Pattern Printing routine Print a copy of the 2096 coverage pattern for all colors The defect is present for all colors Replace the Developer Housing PL 6 2 for the affected color Make several prints of the Test Page GP 14 The defect is present in approximately the same location on all letter size prints Y N The defect is present in the same location on every A3 11 x 17 in print or on every other letter size print Y Rotate the IBT Tension Lever back and forth as you examine the IBT Belt There is clearance between the Push In Shaft PL 7 2 and IBT Belt when the T
369. em still exists replace the 1394 PWB PL 12 1 If the problem continues replace the ICM Main PWB PL 16 2 Status Indicator RAPs 033 221 222 223 224 225 226 226 227 228 033 330 10 00 2 214 Initial Issue Phaser 790 DocuColor 2006 033 340 341 342 343 344 345 350 ASIC Error RAP 033 340 033 341 033 342 033 343 033 344 033 345 033 350 An ASIC_A read write error was detected An ASIC_B read write error was detected An ASIC read write error was detected An ASIC_S read write error was detected An ASIC_Y read write error was detected An ASIC M read write error was detected An SCSI CHIP read write error was detected Procedure Switch the power off then on If the fault remains replace the ICM Main PWB PL 16 2 033 360 361 370 371 Memory Error RAP 033 360 A std SDRAM read write error was detected 033 361 An optional SDRAM read write error was detected 033 370 An EEPROM error was detected 033 371 An SRAM error was detected Procedure Switch the power off then on If the fault remains replace the ICM Main PWB PL 16 2 Initial Issue Phaser 790 DocuColor 2006 10 00 Status Indicator RAPs 2 215 033 340 341 342 343 344 345 033 360 361 370 371 033 380 390 1394 Failure RAP 033 921 922 930 934 935 936 937 IOT IIT Communication 033 380 A 1394 PWB initilization error was detected RAP 033 921 The Control Logic detects a disconnection 033 380 A 1394 PWB hardware failure was d
370. emove the screws and then remove the Bottom Cover 0110018A WOL Figure 1 Preparing to Remove the Fuser Entrance Sensor Repairs and Adjustments 10 00 Initial Issue REP 10 18 4 126 Phaser 790 DocuColor 2006 REP 10 19 Fuser Chute Fan 4 Remove the Fuser Chute Fan Figure 2 Parts List on PL 8 6 Replacement 1 Reinstall the Fuser Chute Fan in the reverse order of removal Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch 1 on or electrical power applied to the machine the 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Fuser Assembly REP 10 1 3 Prepare to remove the Fuser Chute Fan Figure 1 2 Disengage the harness 1 2 from the clamps Remove the Fuser Paper Guide and Horizontal Chute Remove the screws Disengage and remove the Fuser Chute Fan 01100218 WOL Figure 2 Removing the Fuser Chute Fan 3 Remove the screws and then remove the Bottom Cover 0110020A WOL Figure 1 Preparing to Remove the Fuser Chute Fan Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 127 REP 10 19 Repairs and Adjustments 10 00 Initial Issue REP 10 19 4 128 Phaser 790 DocuColor 2006 REP 11 1 Sorter Parts List on PL 19 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the mach
371. ension Lever is in the locked position Repair replace the IBT Assembly PL 7 2 Reinstall the Copy Print Cartridge Connect the DVM between the D terminal on the HVPS and frame ground Access the Digital Output Test GP 2 Enter code 0B Press the Item Enter button Roughly 80 VDC is measured Y N Go to the 106 RAP to troubleshoot BTR 1 bias circuits Replace the IBT Belt PL 7 2 Replace the IBT Belt PL 7 2 Access the Digital Output Test GP 2 Enter code 71 Press the Item Enter button Remove the Copy Print Cartridge The Erase lamp is lit There is 5 VDC from pin 2 to pin 1 on J 86 Y There is 5 VDC from J 86 pin 2 to frame ground Y Go to Flag 1 Check for an open circuit If the wire is OK replace the MCU PWB PL 11 2 A B C D A B C D Go to Flag 2 Check for an open circuit If the wire is OK replace the MCU PWB PL 11 2 Replace the Erase Lamp PL 5 1 Examine the surface of the photoreceptor drum in the Copy Print Cartridge Check for dents scratches or contamination such as fingerprints etc The drum is clean and free from damage Y N Clean or replace the Copy Print Cartridge PL 5 1 as required Remove the ROS Examine the ROS window for dirt or damage Clean or replace as required If the problem remains replace the Copy Print Cartridge PL 5 1 If this does not resolve the problem replace the ROS PL 5 1 Examine the spot in the cente
372. ent if not strictly observed could result in personal injury CAUTION A Caution is used whenever an operating or maintenance procedure a practice condition or statement if not strictly observed could result in damage to the equipment NOTE A Note is used whenever it is necessary to highlight an operating or maintenance pro cedure practice condition or statement Flags The Flag symbol indicates a reference point into a Circuit Diagram from a RAP Instructions will be given to check for an open circuit a short circuit or an intermittent condition Note This symbol refers to notes which are found on the same page as the Circuit Diagram Parts List In this symbol example PL2 1 refers to the Parts List on which the part can be found Adjustments The adjustment symbol refers to an procedure in the Adjustment section of this Manual Test Points Test Stakes Test Holes This symbol is used to indicate that a test point test stake or test hole is available for access ing a signal line The prefix before the identification number indicates whether the access is a test point TP a test stake TS or a test hole TH Bracket The bracket symbol indicates a Component Control Code selection in a Diagnostic Program Machine Safety Icons The following safety icons are displayed on the machine WARNING The Phaser 790 Dc 2006 contains an invisible laser There is no visual indication that the laser beam is present Du
373. eplacing the Counterbalances do not mix the left Counterbal ance parts with the right NOTE Replacement steps are identical for both the left and the right sides of the Counterbal ance Switch off the machine power and disconnect the machine Power Cord Remove the ADF Assembly REP 5 1 Remove the ADF Rear Cover Remove the Counterbalance Figure 1 Pa Suns 1 Remove four screws retaining the Counterbalance Remove the Counterbalance 0105003A WOL Figure 1 Removing the Counterbalance Replacement 1 Perform the procedure for removal in reverse 2 Perform an ADF Side Registration adjustment ADJ 5 1 3 Perform an ADF Lead Edge Registration adjustment ADJ 5 2 4 Perform an ADF Height adjustment ADJ 5 3 Repairs and Adjustments REP 5 2 REP 5 3 10 00 4 24 Phaser 790 DocuColor 2006 Initial Issue REP 5 4 Feed Roll 5 Remove the Feed Roll Figure 2 Parts List on PL 17 3 2 3 Removal Remove Remove the WARNING 1 Gear KL Clip Remove the To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine KL Clip 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the ADF Front Cover Cu O 3 Remove the ADF Rear Cover lt 4 Remove the Lower Chute Figure 1 227 1 Open the Feeder Cover Remove the Feed Roll together with bearings by moving it in the di
374. eptacles 0106040A WOL Figure 1 Removing the Bracket and Power Receptacles 5 Remove the Registration Sensor Figure 2 3 Remove the Registration Sensor Disconnect the connector Remove the screw 0106003A WOL Figure 2 Removing the Registration Sensor Replacement 1 Perform the procedure for removal in reverse Repairs and Adjustments REP 6 7 10 00 Initial Issue 4 40 Phaser 790 DocuColor 2006 REP 6 8 IIT Low Voltage Power Supply LVPS Parts List on PL 16 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Rear Cover REP 6 4 3 Remove the IIT LVPS Figure 1 1 Disconnect the connectors 2 Remove the Screws 6 and the IIT LVPS 0106004A WOL Figure 1 Removing the IIT LVPS Replacement 1 Perform the procedure for removal in reverse REP 6 9 Fan Parts List on PL 16 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Platen Glass REP 6 1 3 Remove the Right Cover REP 6 2 NOTE The removal procedure is identical for both fans 4 Remove the Fan Figure 1 2 Remove the screws 2
375. er Figure 1 Positioning Tool Storage Location 1 Loosen the screw 1 0 201103A WOL 9 Prepare the Full Rate Carriage for adjustment Figure 2 2 Loosen the two screws on the Full Rate Carriage Assembly Position the Full Rate Carriage to the center position near the frame cut outs 0 206004A WOL Figure 2 Preparing the Full Rate Carriage for Adjustment 10 Loosen the set screws 4 on the front and rear Capstan Pulleys Figure 3 0 206005A WOL Figure 3 Capstan Pulley Set Screws Repairs and Adjustments ADJ 6 2 10 00 Initial Issue 4 154 Phaser 790 DocuColor 2006 NOTE Use the screws removed from the Stopper in figure 1 to mount the Positioning tools to 13 Use the tools to adjust the front side of the Full Rate Carriage Assembly Figure 6 their respective positions in the IIT 11 Install the positioning tools in front and rear locations on the Half Rate Carriage Assem bly Figure 4 2 Install it at the front of the Full Rate Carriage Assembly 1 Install the Positioning Tools 2 Tighten the screw 1 at the front of the Full Rate Carriage Assembly 1 Remove the positioning tool at the front of the Half Rate Carriage Assembly 0 206006A WOL Figure 6 Adjusting the Front Side of the Full Rate Carriage Assembly 0 206002A WOL Figure 4 Installing the Positioning Tools 12 Tighten the one set screw on the front Capstan Pulley Figure 5
376. er Control PWB and GND Y N Replace the Sorter Control PWB PL 19 1 Replace the Sorter Transport Motor PL 19 2 Check that the Sorter Path Sensor actuator is operating correctly The actuator is present and actuating correctly Y N Replace the Sorter Path Sensor PL 19 3 Actuate the Sorter Path Sensor There is 5 VDC between J 2 2 of the Sorter Control PWB and GND Y N Go to Flag 2 Check the wires for a short circuit to ground The wire is good Y N Repair the wire There is 5 VDC between J 2 1 of the Sorter Control PWB and GND Y N Replace the Sorter Control PWB PL 19 1 Go to Flag 1 Check for an open circuit The wires are good Y N Repair the wires Replace the Sorter Path Sensor PL 19 3 If the problem persists replace the Sorter Control PWB PL 19 1 Deactuate the Sorter Path Sensor actuator There is 0 VDC between J 2 2 and GND Y N Replace the Sorter Path Sensor PL 19 3 Replace the Sorter Control PWB PL 19 1 Status Indicator RAPs 10 00 011 703 2 198 Initial Issue Phaser 790 DocuColor 2006 SORTER CONTROL SORTER CONTROL PWB Figure 1 011 703 RAP Circuit Diagram PWB PL19 1 SORTER PATH H SORTER PETS S SN1 J2 2 5 CONTROL 2 BH 2 a C PL19 1 Ee DO C4 MEM DO C3 LOW SPEED J2
377. er and disconnect the machine Power Cord Rotate the 2 Remove the Top Cover Assembly REP 14 4 Rotary Frame until the Devel 3 Remove the Copy Print Cartridge REP 9 1 oper Housing to 4 Remove the Tension Lever REP 9 15 be removed is at 5 Remove the Left Inner Cover Assembly REP 14 5 6 Remove the Dry Ink Cartridge REP 9 9 from the Developer Housing to be removed CAUTION 1 Be careful not to damage the Magnetic Roll of the Developer Housing during the removal Be careful not to drop the screws during the removal Be aware that the Rotary Frame can turn when the following step is performed 0109010A WOL After removing be sure to lay the Developer Housing in a horizontal position in a safe place 7 Remove the Rotary Latch Figure 1 Figure 2 Removing the Developer Housing Replacement 2 1 Reinstall the Developer Housing in the reverse order of removal 2 Rotate the Rotary Frame to install the screw after reinstalling the Developer Housing 3 Check the Developer Spacing ADJ 9 1 Disengage the har ness from the Rotary Latch 4 Remove the Rotary Latch 1 Disconnect the con nectors Brown is on top 0109018A WOL Figure 1 Removing the Rotary Latch Repairs and Adjustments 10 00 Initial Issue REP 9 10 4 98 Phaser 790 DocuColor 2006 REP 9 11 Rotary Sensor Replacement Parts List on PL 6 1 1 Secure the harness so that the harness does not get
378. ere is no visual indication that the laser beam is present During servicing the machine is a Class 3B product because of the invisible laser the laser beam could cause eye damage if looked at directly Service procedures must be followed exactly as written without change The service representative must observe the established local laser safety precautions when ser vicing the machine Do not place tools with a reflective surface into the ROS opening Do not look in the area of the ROS window if the power is On and the laser is energized Introduction About this Manual tsei did de etie iii Organization iii How to Use this iii Symbology x u Last eei a e Ede UR ee iii Initial Issue 10 00 Introduction Phaser 790 DocuColor 2006 i Introduction 10 00 Initial Issue ii Phaser 790 DocuColor 2006 About this Manual This Service Manual is part of the multinational documentation system for the Phaser 790 Printer and DC 2006 Copier Printer The Service Documentation is used in order to diagnose machine malfunctions adjust components and has information which is used to maintain the product in superior operating condition It is the controlling publication for a service call Infor mation on its use is found in the Introduction of the Service Documentation This manual contains information that applies to NASG and ESG copiers Servic
379. erlock are working correctly If the prob lem persists replace the Sorter Control PWB PL 19 1 Status Indicator RAPs 011 702 2 196 10 00 Initial Issue Phaser 790 DocuColor 2006 SORTER CONTROL PWB PL18 1 LOW SORTER VOLTAGE CONTROL SORTER TOP POWER 25 PWB COMER SUPPLY PL19 4 INTERLOCK SORTER TOP COVER 424 VDC PL11 1 135 P133 133 pa ua PL19 1 INTERLOCK CLOSED H Bs s 24 VDC T n rd 2 COM 1 ORN NE PNK RED BLK 20 24 VDC ae DC M Lgl 14 VIO BLU DC COM DC COM J1 49 43 SORTER J5 CONTROL PWB J10 i 42 6 JZ SORTER CONTROL PWB DOCKING INTERLOCK Figure 1 011 702 RAP Circuit Diagram Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 197 011 702 011 703 Sorter Transport Jam RAP Sorter Control PWB logic did not detect paper at the Sorter Path Sensor within a specified time after the Fuser Exit Sensor detected paper Initial Actions Check for an obstruction in the Sorter paper path Repair as required Check for contamination or damage on the Exit Rolls PL 19 2 Clean or replace as required Procedure Access the Digital Output DO test from the Control Panel Enter code CO Press the Item Enter button The Sorter Transport Motor runs Y N There is 24 VDC between J 1 1 of the Sort
380. erse REP 8 11 Lift Frame Assembly Parts List on PL 4 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord Remove the Bypass Tray Registration Assembly REP 8 6 Remove the Bypass Tray Feed Assembly REP 8 7 Remove the Tray Housing REP 8 8 Remove the Lift Frame Assembly Figure 1 Qv 00 19 2 Remove three screw and the Lift Frame Assembly Disconnect the connector 0108024A WOL Figure 1 Removing the Lift Frame Assembly Replacement 1 Perform the procedure for removal in reverse NOTE Install so that the boss of the Bypass Tray Frame is aligned with the hole on the left side of the Lift Frame Assembly Repairs and Adjustments REP 8 10 REP 8 11 10 00 Initial Issue Phaser 790 DocuColor 2006 REP 8 12 Tray Empty Sensor Parts List on PL 4 3 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Bypass Tray Registration Assembly REP 8 6 3 Remove the Bypass Tray Feed Assembly REP 8 7 4 Remove the Tray Empty Sensor Figure 1 1 2 Disconnect Release the the connector locking tabs and remove the Tray Empty Sensor
381. ervice Call Procedures Cleaning Procedures Final Actions Service Call Procedures 10 00 Initial Issue Cleaning Procedures Final Actions 1 6 Phaser 790 DocuColor 2006 Fault Message Cross reference 2 Status Indicator RAPs 006 312 FPC COD RAR iere tere E see 2 70 Fault Message RAP Cross Reference eee nnns 2 3 006 313 IIT Cooling Fans RAP 2 71 006 372 Start of Scan Error 2 73 Standby Power 006 701 Angle Sensor RAP 2 75 001 701 Power RAP u ananassa aa n Dea ndo e herd ge n poa 2 5 006 702 Platen Switch RAP 2 77 001 02 35 VDO Power RAP e e restet e eter e or e or ee a 2 7 006 703 Scanner Error RAP 2 79 001 703 24 VDC Interlocked Power RAP 2 9 006 704 System Error 093 XXX 2 79 001 704 Front Cover Open 2 11 006 906 907 908 909 AA a u e en 2 80 001 705 ROS 5 VDC Switched Voltage RAP 2 13 0012706 Area TODO RAP cent ele e cte ere dle eerte erts 2 15 Paper Supply 001 707 Area 2 Open RAP aite ene ete reni ede Tere eee geret 2 17 007 324 Environment Sensor 001 708 Area 3 Open 2 19 007 340 Feeder Motor Fail RAP 001 709 Area 4 Open 2 21 007 341 Inverter Motor Fail 001 710 Area 5 Open M 2 23 007 700 Tray 1 Open 001 711 Area 6 Open ascen e e di abbr i Ee ede 2 25 007 701 Tray 2 Open RAP 001 712
382. es with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the ADF Front Cover and Rear Cover 3 Remove the ADF Exit Motor Figure 1 1 Use a scribe to mark the Exit Motor 2 bracket top Disconnect and bottom the connector from the PWB S LY 5 Remove one screw SS 54 Loosen one Screw 3 Remove the wire harness from the clamps Remove the ADF Exit Motor together with the Belt 0105018A WOL Figure 1 Removing the ADF Exit Motor Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 33 REP 5 9 REP 5 10 ADF Exit Sensor and Exit Tray Interlock 4 Parts List on PL 17 7 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the ADF Front Cover and Rear Cover 3 Remove the Outer Exit Chute Assembly Figure 1 1 Remove four Screws retaining the Outer Exit Chute Assembly Remove the Outer Exit Chute Assembly by moving the assembly in the direction indicated 0105019A Figure 1 Removing the Outer Exit Chute Assembly Remove the Exit Chute Figure 2 Loosen the two retaining Figure 2 Removing the Exit Chute 2 Remove the Exit Chute by moving it in the direction i
383. etected 9 i 033 922 The Control Logic detects no printer Procedure Switch the power off then on If the fault remains replace the ICM Main PWB PL 16 2 033 930 The Control Logic detects a 1394 PWB communication time out 033 934 The Control Logic detects a 1394 PWB reconnection failure 033 935 The Control Logic detects an Async transaction time out 033 936 The Control Logic detects an Async transaction retry error 033 937 The Control Logic detects a 1394 PWB link chip error Initial Actions Check the cables and connections between the IIT and the IOT Ensure that the cables are secure Exit then re enter Copy Mode If this does not resolve the problem switch the power off then on Verify that the problem still exists Procedure Remove the Right Cover REP 14 9 Verify that the 1394 PWB is correctly installed If the PWB is installed correctly and the problem still exists replace the 1394 PWB PL 12 1 If the problem continues replace the ICM Main PWB PL 16 2 Status Indicator RAPs 10 00 Initial Issue 033 380 390 033 921 922 930 934 935 936 937 2 216 Phaser 790 DocuColor 2006 033 940 941 943 944 945 SCSI Error RAP 033 940 The Control Logic detects a SCSI parity error 033 941 The Control Logic detects that an About Message has been received 033 943 The Control Logic detects a SCSI bus reset 033 944 The Control Logic detects a a message reject has been received 033 945 The Control Logic detect
384. etected a ESS Main Program ROM checksum error Procedure Procedure Switch off the power Reseat the Memory module in Slot 2 Switch on the power If the fault Switch off the power then switch on the power If the problem still exists replace the ESS PWB remains replace the Memory module in Slot 2 PL 12 1 If the problem still exists replace the PL 12 1 ESS PWB PL 12 1 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 209 016 316 016 317 016 323 324 325 ESS NVM RAM Failure RAP 016 330 331 332 333 334 335 336 Interface Error RAP 016 323 The Control Logic detected an ESS NVRAM billing failure 016 330 Communication error between the ESS and Network Interface 1394 PWBs 016 324 The Control Logic detected ESS NVRAM e billing failure 016 331 Network Interface 1394 PWB Flash ROM Boot Module checksum error 016 325 The Control Logic detected an ESS NVRAMS print log failure 016 332 Network Interface 1394 PWB RAM read write test error Procedure 016 333 Network Interface 1394 PWB Flash ROM Application Module checksum error Replace the ESS PWB PL 12 1 P 016 334 Network Interface 1394 PWB MAC address checksum error 016 335 Network Interface 1394 PWB Ethernet RAM read write parity error 016 336 Network Interface 1394 PWB internal loopback test error Procedure Switch off the power then switch on the power If the fault remains replace the 1394 PWB PL 12 1 If the problem st
385. for the param B6 Nudger Solenoid Tray2 Nudger Solenoid 1 24 VDC 8 3 eter to be set from the Table 1 B7 Nudger Solenoid Tray3 Nudger Solenoid 1 24 VDC 8 4 Press the Item Enter button to display the current value of the parameter selected B8 Feeder Motor Feeder Motor On L 24 VDC 8 5 Press the Up Arrow or Down Arrow button to set the value as required B9 Option Feeder Unused Press the Item Enter button to update the new value or press the Clear Stop button CO Sorter Feed Motor On 11 3 to return to the IOT PARAM SET display without updating the data el Sorter Feed Motor Hi speed us Table 1 Items for the IOT Parameters C2 Sorter Feed Motor Mid speed 11 3 En o spoed Menu Function Value Value Value Unit C4 Sorter Feed Motor Super Low speed 11 3 C5 Bin Drive Motor Bin Drive Motor Down 11 4 01 Cycle Down Wait Timer 0 255 0 C6 Bin Drive Motor Bin Drive Motor Up 11 4 02 Hold Wait Timer 2 255 0 03 Duplex Mode 0 1 0 04 07 Unused 08 Set Toner Density Yellow 3 5 1 09 Set Toner Density Magenta 3 5 1 0A Set Toner Density Cyan 3 5 1 0B Set Toner Density Black 3 5 1 0C 10 Unused 11 Side to Side Registration 8 28 244 12 0 50 mm Table 2 18 21 Unused 16 Top to Bottom Tray 1 30 64 0 0 17 mm 17 Top to Bottom Tray 2 37 64 0 0 17 mm 18 Top to Bottom Tray 3 35 64 0 0 17 mm General Procedures and Information 10 00 Initial Issue GP 2 GP 3 6 6 Phaser 790 DocuColor 2006
386. frame Go to Flag 3 and check the wires for an open circuit If the wires are good replace the MCU PWB PL 11 2 Access the Digital Output DO test from the Control Panel Enter code 53 Press the Item Enter button The voltage at J50 2 goes to less than 1 0 VDC Y N Replace the MCU PWB PL 11 2 24 VDC is measured between J49 2 on the Drive Motor PWB and machine frame Y N Go to Flag 4 and check the wires for an open circuit refer to the 24 VDC Inter locked Wirenet Go to Flag 2 and check the harness between the Drive Motor PWB and the Paper Han dling Motor for damaged wires or connector pins If the wires are OK replace the Paper Handling Motor PL 10 1 If the problem continues replace the Drive Motor PWB PL 10 1 If the problem can not be resolved replace the MCU PWB PL 11 1 Check the following Go to Flag 1 and check the wire for an open circuit Go to Flag 2 and check the harness between the Drive Motor PWB and the Paper Han dling Motor for damaged wires or connector pins The problem may be intermittent Go to Figure 1 and check for loose or damaged connec tions or damaged wires If the problem persists replace the replace the MCU PWB PL 11 2 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 47 004 320
387. g distributed Find the wirenet for that power and locate the terminal board on the wirenet Use the wirenet to troubleshoot any power distribution wiring not shown on the CD Use of the Block Schematic Diagrams Block Schematic Diagrams BSDs are included in Section 7 Wiring Data of the Service Man ual The BSDs show the functional relationship of the electrical circuitry to any mechanical or non mechanical inputs or outputs throughout the machine Inputs and outputs such as motor drive mechanical linkages operator actions and air flow are shown The BSDs will provide an overall view of how the entire subsystem such as ADF works It should be noted that the BSDs no longer contain an Input Power Block referring to Chain 1 It will be necessary to refer to the Wirenets in order to trace a wire back to its source Symbology The following reference symbols are used throughout the documentation Initial Issue Phaser 790 DocuColor 2006 10 00 Introduction Warnings Cautions and Notes Warnings Cautions and Notes will be found throughout the Service Documentation The words WARNING or CAUTION may be listed on an illustration when the specific component associated with the potential hazard is pointed out however the message of the WARNING or CAUTION is always located in the text Their definitions are as follows WARNING A Warning is used whenever an operating or maintenance procedure a practice condi tion or statem
388. g the Auger inside the printer upper side 16 Free the harness from the clamp of the P H Drive Assembly 17 Remove the two screws securing the IBT Rear Bracket Assembly and remove the IBT Rear Bracket Assembly NOTE After removing the Auger place it on paper in case toner is spilled 18 Remove the Auger Figure 1 Replacement 1 Reinstall the Auger in the reverse order of removal Repairs and Adjustments 10 00 Initial Issue REP 9 20 4 108 Phaser 790 DocuColor 2006 REP 9 21 IBT Belt 6 Parts List on PL 7 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Open the Bypass Tray Registration Assembly REP 8 6 CAUTION Be careful not to touch the surface of the IBT Belt during the removal Oil from your hands can contaminate the IBT Belt 3 Remove the Assembly REP 9 16 4 Remove the Rails Figure 1 4 Remove the screws at front and rear 5 Remove the Rail Remove the Shaft Figure 2 A 44 Su gt L lt ZOO 0109034A WOL Figure 2 Removing the Shaft 7 Turn the Tension Lever lift the arm to which the Push In Shaft is attached and remove the Tension Lever 8 Push in the metal cams on both sides of the Transfer Assembly insert a hexagonal screwdriver into the hole on the s
389. gears to the fuser area Replace as required PL 8 3 the output pages from the copier printer are wrinkled or unevenly fused top to bottom check adjust ADJ 10 1 Fuser Nip If the problem persists replace the Fuser Assembly PL 8 1 Inspect the Heat Roll and the Pressure Roll for damage or excessive wear Replace as required PL 8 3 Status Indicator RAPs 010 700 10 00 2 178 Initial Issue Phaser 790 DocuColor 2006 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 179 010 700 010 701 Faulty Temperature Sensor RAP The Temperature Sensor has failed to read the Fuser Temperature correctly A Temperature Sensor error has been declared Initial Actions Inspect the Fuser area for debris and other signs of wear breakage or excessive heat damage Procedure Pull out Area 5 A resistance of approximately 200k ohms is measured between J71 pin B4 and J71 pin when the Temperature Sensor is at room temperature Disconnect P J 72 A resistance of approximately 200 ohms is measured between P72 pin 2 and pin 4 when the Temperature Sensor is at approximately room temper ature N Replace the Temperature Sensor PL 8 2 Reconnect P J 72 A resistance of approximately 200k ohms is measured between J71 B4 and B6 when the Temperature Sensor is at approximately room tempera ture Go to Flag 1 Check the wiring for an open circuit or a short circuit to ground Repair or replace t
390. gure 1 E 2 J Disconnect screws and partially the connector remove the Top Frame 1 Remove the three 1 0108027A WOL Figure 1 Removing the Top Frame 5 Remove the Stack Height Sensor Figure 1 1 Remove the Retard Spring from the Top Frame Remove the screw and the Stack Height Sensor Bracket Release the locking tabs and remove the Stack Height Sensor 0108028A WOL Figure 2 Removing the Stack Height Sensor Replacement 1 Perform the procedure for removal in reverse Repairs and Adjustments REP 8 14 10 00 4 68 Initial Issue Phaser 790 DocuColor 2006 REP 8 15 Preregistration Clutch Parts List on PL 4 6 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Bypass Tray Registration Assembly REP 8 6 3 Remove the Main Paper Handling Assembly REP 8 9 4 Remove the Preregistration Clutch Figure 1 1 Disconnect the connector and release the wires from the clip Remove the E ring and the Preregistration Clutch 0108050A WOL Figure 1 Removing the Preregistration Clutch Replacement 1 Perform the procedure for removal in reverse REP 8 16 Preregistration Roll Parts List on PL 4 7 Removal WARNING To avoid personal injury or shock
391. hat the paper in Tray 3 is properly installed and that the tray side and end guides are positioned to touch the paper in the tray Procedure Switch off the power Disconnect the Power Cord Remove the Size Switch PWB PL 13 3 Place the Size Switch PWB so that it does not short circuit to the machine frame Connect the Power Cord Disconnect PJ 236 from the Size Switch PWB Switch on the power There is 5 VDC from J 236 pin 1 to machine ground Y Go to Flag 2 Check the wires for an open or a short circuit to ground The wires are good N Repair the wires Replace the MCU PWB PL 11 2 A Connect PJ 236 on the Size Switch PWB Actuate and hold switches SW1 and SW3 on the Size Switch PWB There is 1 57 0 10 VDC from J 236 pin 2 to machine ground N Go to Flag 1 Check the wires for an open or a short circuit to ground The wires are good Y N Repair the wires Replace the Size Switch PWB PL 13 3 Actuate and hold switches SW2 SW4 on the Size Switch PWB There is 3 13 40 10 VDC from J 236 pin 2 to machine ground Go to Flag 1 Check the wires for open or a short circuit to ground The wires are good Y N Repair the wires Replace the Size Switch PWB PL 13 3 Replace the MCU PWB PL 11 2 gt Table 1 Tray 3 Size Sensing Switch PWB ANALOG PAPER SIZE PAPER SIZE SW VOLTAGE OUT SW1 SW2 SW3 4 Tray Out OFF OFF OFF OFF 4 76 VDC Ledger S
392. he wires are good replace the MCU PWB PL 11 2 Install the Bypass Tray Assembly Enter DO 30 The Feed Clutch engaged Y N Remove the Bypass Tray Assembly from the machine Disconnect P 202 There is 180 Ohms or less from P 202 pin 2 to pin 1 Y N Replace the Feed Clutch PL 4 5 Go to Flag 10 and Flag 7 Check the wires for an open or short circuit to ground If the wires are good replace the MCU PWB PL 11 2 Check that there are no obstructions on the Turn Roll Chute PL 3 3 Clean the Turn Roll Clean the Nudger Roll the Retard Roll and the Friction Clutch rubber roll PL 4 4 A Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 117 008 700 MCU PWB DO 1F PRE REGISTRATION PL11 2 PRE REGISTRATION CLUTCH ASSY CLUTCH ON PL4 6 J20 D 24VDC P91 J91 J95 P95 26 SEV B3 B12 SEV 21 DC COM 2 GRY 25 65 B4 B11 9 DO 1E REGISTRATION REGISTRATION CLUTCH ASSY 24VDC CEUTCHAON PL4 7 L 24VDC J94 P94 DD 244 5 5 B10 24 DC COM 24VDC 2 INTLK 234 B6 GRY 6 24VDC DO 20 FEED CLUTCH CLUTCH ON L 24 gt 287 G6RY DC COM 24VDC INTLK P 24VDC MCU PWB PL11 2 2 SEE EN
393. he DI Test Enter code 51 Press the Item Enter button The display is 1 Y N Disconnect P J 116 Access the DI Test Enter code 51 Press the Item Enter button The display is 1 Y N Go to Flag 3 Check for a short circuit If the wire is OK replace the MCU PWB PL 11 2 Remove the Locating Rail REP 9 5 Check the harness of the Waste Toner Sensor Flag 1 and Flag 2 If the wires are OK replace the Toner Box Sensor PL 5 1 The problem appears to be intermittent Go to Figure 1 Check for loose or damaged connec tions or pinched wires If the wires are OK replace the Waste Toner Sensor PL 5 1 If the problem persists replace the MCU PWB PL 11 2 Status Indicator RAPs 10 00 Initial Issue 009 702 2 160 Phaser 790 DocuColor 2006 0651 J WASTE TONER WASTE TONER SENSOR FULL PL5 1 488 116 4116 5VDC 32 NOTE T2 ST GRY 1 1 1 52 O FAULT CONDITION MESSAGE AA 2 4 REPLACE WASTE CONTAINER 1 1 1 1 i i 1 9 41 RY TA 5VDC 34 4 6 12 GRY a DC COM LL IL J P16 P19 P22 P18 WASTE TONER SENSOR PI P15 MCU PWB P20 P12 11 23 21 T 709009 A WOL Figure 1 009 702 RAP Circuit Diagram Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 161 009 702 009 703 Waste Container Detached RAP Contr
394. he Fuser Harness PL 8 5 as required If the problem persists replace the Temperature Sensor PL 8 2 If the problem still persists replace the MCU PWB PL 11 2 Go to Flag 2 Check for an open circuit or a short circuit to ground Repair or replace the Main Harness PL 11 1 as required If the wiring is OK replace the MCU PWB PL 11 2 The problem may be intermittent Go to Figure 1 Check for loose or damaged connections or damaged wires Repair or replace the Fuser Harness PL 8 5 or the Main Harness PL 11 1 as required If the wiring is OK and the problem persists replace the Temperature Sensor PL 8 2 If the problem still persists replace the MCU PWB PL 11 2 Status Indicator RAPs 10 00 010 701 2 180 Initial Issue Phaser 790 DocuColor 2006 MCU PWB H f secon PL8 2 2 TEMP VOLTAGE P72 J72 J71 P71 J19 43 GRY DS E GRY 15 4 2 B6 B5 DECOM 7 GRY GRY DC COM 1 1 171 111 17 1 12 o PIO 34 pig 18 22 pig 1234 18 21 18 15 32 P14 P17 17 116 28 1 P15 MCU PWB P20 15 22 15 14 P12 Alb PH P23 3 I B16 B P21 1 P J71 PIN CONFIGURATION J71 P71 J71 2 J71 1 P71 1 P71 2 WHT BLK BLK WHT
395. he IBT Belt or BTR 2 Assembly or allow the BTR 2 Assembly to touch other components during the removal 3 Remove the BTR 2 Assembly Figure 1 Replacement 1 Reinstall BTR 2 Assembly in the reverse order of removal 2 Push the BTR 2 Assembly firmly into place 2 Remove the BTR 2 Assembly from the left side of machine NN Grab at these points 0090014 A WOL Figure 1 Removing the BTR 2 Assembly Repairs and Adjustments REP 9 17 REP 9 18 10 00 Initial Issue 4 106 Phaser 790 DocuColor 2006 REP 9 19 BTR 2 Cam Assembly Parts List on PL 7 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine Switch off the machine power and disconnect the machine Power Cord Remove the Rear Cover REP 14 4 Remove the Copy Print Cartridge REP 9 1 Remove the Tension Lever REP 9 15 Remove the Left Inner Cover Assembly REP 14 5 Remove the Fuser Assembly REP 10 1 Remove the Belt Cleaner REP 9 17 Remove the BTR 2 Assembly REP 9 18 9 Remove the BTR Cam Clutch REP 9 23 10 Open the Bypass Tray Registration Assembly 11 Remove the IBT Assembly REP 9 16 12 Remove the BTR 2 Cam Assembly Figure 1 Replacement 1 Reinstall the BTR 2 Cam Assembly in the reverse order of removal C mU Or aS oo 4 Reach in from the front and remove the three screws 3 Disconn
396. he No Paper Sensor Assembly 0107012A WOL Replacement VR 1 Perform the procedure for removal in reverse ond aperSensor Replacement 1 Perform the procedure for removal in reverse NOTE When installing the No Paper Actuator the Actuator must be positioned directly above the No Paper Sensor Repairs and Adjustments 10 00 Initial Issue REP 7 3 REP 7 4 4 54 Phaser 790 DocuColor 2006 REP 7 5 Low Paper Sensor Parts List on PL 3 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Oi dvo Switch off the machine power and disconnect the machine Power Cord Remove the Tray 1 Assembly REP 7 6 Remove the Front Mid Cover REP 14 2 or the Duplex Tray Assembly REP 8 27 Remove the Sensor Bracket REP 7 2 Remove the Low Paper Sensor from the No Paper Sensor Assembly Figure 1 2 Remove the screw and the Low Paper Sensor Disconnect the connector and release the wires from the clip 0107015A WOL Figure 1 Removing the Low Paper Sensor Replacement 1 Perform the procedure for removal in reverse NOTE Install the sensor so that the positioning boss on the No Paper Sensor Assembly is aligned with the positioning hole of the Low Paper Sensor REP 7 6 Tray 1 Assembly Paper Tray Assembly Oversize Tray Assembly Parts List on PL 2 1 PL 13 1 PL 14 3 Removal 1 Remo
397. he problem If the problem persists replace the Main Fuser or the Fuser Tray PL 8 1 The problem may be intermittent Go to 010 701 Faulty Temperature Sensor RAP to trouble shoot the problem If the problem persists replace the Main Fuser or the Fuser Tray PL 8 1 A Status Indicator RAPs 10 00 Initial Issue 010 353 356 357 2 168 Phaser 790 DocuColor 2006 MEM DNE MAN FUSER ASSY DO 47 LVPS 2222 P R HEATER J34 ACN P71 1 P79 J79 T2 HEATER H R HEATER ON T WHT 2 2 War 2 25 WHT D 5VDC 232 i mm 9 1 A LC 5VDC I F250 UR 2227 i UPPER PLATE HEATER 22 Em i THERMO THERMAL I STAT FUSE 7 P71 J71 Pa 2 ACH 1 1 L4 1 L T1 ono 74 d BLK BLK P 4 1 1 171 111 17 1 12 P32 a n 18 22 pig 12 54 19 327 1 2 e gt 17 P34 Pid 171 16 P32 28 1 P15 MCU PWB P20 15 P35 LVPS 13 22 21 P12 416 PH M 2 I 816 o P33 i P J71 PIN CONFIGURATION J71 P71 L o J71 2 J71 1 P71 1 4 P71 2 WHT 2d BLK BLK 4
398. he sorter frame align c Verify that the Bin Cam Switch Rear Bin Cam only is in the actuated position by the raised portion of the switch actuator on the Bin Shaft Adjustment 1 Align the hole in the Bin Shaft with the hole in the Sorter Frame Figure 2 77 152 Move the gear 0 downward Bin Spring 1 Remove the KL Clip 3 Rotate the Bin Cam Assembly until the holes are aligned as shown in Figure 1 0201102A WOL Figure 2 Adjusting the Bin Cam 2 Verify that the Bin Cam Switch is actuated by the raised portion of the switch actuator on the Bin Shaft Rear Bin Cam only B 3 Move the bevel gear upward and engage it with the upper Gear 2 4 Install the KL Clip as shown in Figure 2 Switch actuated 5 Reattach the Spring 6 Reinstall the Sorter Rear Front Cover Holes aligned 287 0 201101A WOL Figure 1 Bin Cam Positioning Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 165 ADJ 11 1 Repairs and Adjustments 10 00 Initial Issue ADJ 11 1 4 166 Phaser 790 DocuColor 2006 5 Parts List Overview C e te e eer t e e te e put 5 35 5 3 PL 8 7 Fusing 7 of 7 5 36 Subsystem Information 5 4 AIEE 5 5 Paper Exit PI 93 PaperExIE T Of 2 pie e dene teer e Ee deeds 5 3
399. heck the continuity between the Developer Contact Plate PL 6 1 and terminal C on the HVPS There is continuity Y N Replace the Developer Wire PL 11 1 and or Developer Contact Plate PL 6 1 Remove the ROS Cover Reinstall the Copy Print Cartridge Check for continu ity between the machine frame and the thin strip of uncoated metal at the inboard edge of the xerographic drum There is continuity Y N Replace the Copy Print Cartridge PL 5 1 Remove the ROS Examine the window for contamination The ROS window is clean Y Remove contaminants using a soft dry lint free cloth and minimal pres sure If the window is damaged replace the ROS PL 5 1 WARNING HIGH VOLTAGE Exercise caution when measuring High Voltage in the following step Reinstall the ROS and Top covers Remove the Rear Cover Switch on the power Print the Configuration Page from the Main Menu Measure the voltage from terminal C on the HVPS to frame ground The voltage cycles between 0 VDC and roughly 500 VDC Y Go to the 009 342 RAP to troubleshoot the HVPS Replace the Copy Print Cartridge PL 5 1 Replace the ADC Sensor PL 5 1 If the problem persists replace the ROS PL 5 1 If this does not resolve the problem replace the MCU PWB PL 11 2 Replace the IBT Belt PL 7 2 If the problem remains replace the IBT Assembly PL 7 1 Replace the BTR 2 Assembly PL 7 1 If the problem continues replace the IBT Assem bly PL 7
400. hine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Rear Cover REP 14 6 3 Remove the Rotary Motor Figure 1 Replacement CAUTION Be careful not to pinch the harness when reinstalling the Rotary Motor 1 Reinstall the Rotary Motor in the reverse order of removal 1 Disconnect the connector lt l REP 4 8 Rotary Motor PWB Parts List on PL 10 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Rear Cover REP 14 6 CAUTION The Rotary Motor PWB and printer remain connected by a harness Be careful not to pull too far apart while performing the removal steps 3 Remove the Rotary Motor PWB Figure 1 Replacement 1 Reinstall the Rotary Motor PWB in the reverse order of removal 1 Remove the screw 2 Separate the Rotary Motor PWB away from the printe 2 Remove the screws 3 Disconnect the connectors 4 3 Remove the Remove the Rotary Rotary Motor Motor PWB 0101026A WOL 0101027 Figure 1 Removing the Rotary Motor Figure 1 Removing the Rotary Motor PWB Repairs and Adjustments Initial Issue REP 4 7 REP 4 8 10 00 Phaser 790 DocuColor 2006 REP 4 9 Dispense Clutch Parts List on PL 10 1 Removal WAR
401. ial Issue Phaser 790 DocuColor 2006 PL 16 3 5 64 PL 16 4 Carriage Motor and Carriage Cable Item Part Description 1 Drive Shaft Not Spared 2 Pulley Not Spared 3 Front Cable P O PL 16 4 Item 14 REP 6 17 ADJ 6 2 4 Rear Cable P O PL 16 4 Item 14 REP 6 17 ADJ 6 2 5 020E33800 Pulley 6 020K94970 Pulley 7 413W10350 Bearing 8 023E19320 Belt 9 127 29610 Carriage Motor REP 6 18 10 009 62830 Spring 11 017E92060 Foot 12 Front Bracket Not Spared 13 Rear Bracket Spared 14 600K85730 Cable Kit ADJ 6 2 0016004A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 65 PL 16 4 PL 16 5 Full Rate Carriage and Half Rate Carriage 1 2 4 7 16 18 Item Part Description 1 041K94070 Full Rate Carriage Assembly REP 6 21 ADJ 6 2 2 122E91950 Lamp REP 6 20 3 117E19831 Ribbon Cable 4 No 1 Mirror P O PL 16 5 Item 1 5 Clip Not Spared 6 041K94100 Half Rate Carriage Assembly ADJ 6 2 7 Clip P O PL 16 5 Item 1 8 No 2 Mirror P O PL 16 5 Item 6 9 No 3 Mirror P O PL 16 5 Item 6 10 Pulley P O PL 16 5 Item 6 11 Pulley P O PL 16 5 Item 6 12 Pulley P O PL 16 5 Item 6 13 Shaft P O PL 16 5 Item 6 14 004E06560 Bearing 15 Guide Not Spared 16 Insulator PL 16 5 1 17 105E10010 FLPS PWB REP 6 22 18 Guide P O PL 16 5 Item 1 19 Clamp Not Spared 20 Carriage Not Spared 21 Clamp Not Spared
402. ial Issue PL 9 2 5 38 Phaser 790 DocuColor 2006 PL 10 1 Drives Item Part Description 1 007K85070 Paper Handling Drive Unit REP 4 1 2 007K85080 Fuser Drive Unit REP 4 2 3 Drive Motor Assembly Not Spared 4 127K25400 Fuser Motor REP 4 3 5 127K25410 gt Paper Handling Motor REP 4 4 6 160K56510 Drive Motor PWB REP 4 5 7 Motor PWB Bracket Not Spared 8 Motor PWB Support Not Spared 9 Clamp Not Spared 10 127K27450 Process Drive Unit REP 4 6 11 121K21141 Developer Clutch REP 4 10 12 121K23260 Dispense Clutch REP 4 9 13 160K61490 Rotary Motor PWB REP 4 8 14 127K28300 Rotary Motor 110V REP 4 7 127 31700 Rotary Motor 220V 0010001A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 39 PL 10 1 PL 11 1 Electrical 1 of 2 Item Part Description 1 105K15680 Low Voltage Power Supply LVPS 110v REP 1 1 105K18600 Low Voltage Power Supply LVPS 220V REP 1 1 2 105K15690 High Voltage Power Supply HVPS REP 1 2 3 110K07831 Top Cover Interlock REP 1 3 4 Duct Not Spared 5 Developer Fan Not Spared REP 1 4 6 Bracket Not Spared 7 Clamp Not Spared 8 Bracket Not Spared 9 Clamp Not Spared 10 Bias Charge Roll BCR Wire Not Spared 11 Developer Wire Spared 12 162K53100 Main Harness 13 162K53130 Fuser Connector Harness 14 117K31400 Power Cord 110v 15 162K55490 Sorter Harness 0011001A WOL Parts List 10 00 Initial Issue PL 1
403. icates 0 Go to 1 and 2 and check the wires for an open circuit If the wires are good replace the Right Front Cover Interlock PL 11 2 If the problem continues replace the MCU PWB PL 11 2 The problem may be intermittent Go to Flag 1 and Flag 2 and check for loose or damaged connections or damaged wires If the problem persists replace the Right Front Cover Interlock PL 11 2 If the problem continues replace the MCU PWB PL 11 2 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 11 001 704 RIGHT FRONT COVER INTERLOCK RIGHT FRONT MCU PWB COVER PL11 2 INTERLOCK PL11 2 1 5 VDC d RIGHT FRONT COVER x Z J192 J197 34 P197 CLOSED L 85 VDC J17 5 1 BRN n am GRY E J191 i 1 2 1425 28 YEL GRY DC COM 2 J191 BLU YEL BRN 4 BRN J192 VIEW OF RIGHT FRONT COVER INTERLOCK FROM REAR o SES P10 pi P22 P18 P14 P 5 P20 P12 P23 P11 P21 Figure 1 001 704 Circuit Diagram T701003 A WOL Status Indicator RAPs 001 704 10 00 2 12 Initial Issue Phaser 790 DocuColor 2006 001 705 ROS 5 VDC Switched Voltage RAP Initial Actions Check the following Ensure the Right Front Cover is closed
404. ide and lock the metal cam 1 5 Remove the Rail Remove the screws front and rear 2 Remove the collar 0109033A WOL Figure 1 Removing the Rails 5 Reinstall the Tension Lever and lift the Push In Lever while turning Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 109 REP 9 21 9 Stand the IBT Assembly with its rear side at the bottom 3S Figure 3 Removing the IBT Belt 10 Remove the IBT Belt from the Assembly 0109035A WOL Figure 4 Removing the IBT Belt Replacement CAUTION 0109036A WOL Be careful not to damage or dirty the IBT Belt during the reinstallation Clean the Push In Shaft of all foreign matter or lubrication prior to reinstalling the IBT Belt 1 2 Reinstall the IBT Belt in the reverse order of removal Repairs and Adjustments REP 9 21 10 00 4 110 Initial Issue Phaser 790 DocuColor 2006 REP 9 22 TRO Sensor Parts List on PL 7 3 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 RON Switch off the machine power and disconnect t he machine Power Cord Open the Bypass Tray Registration Assembly REP 8 6 Remove the IBT Assembly REP 9 16 Remove the Rail Remove the TRO Sensor Figure 1 Replacement 1 Reinstall the TRO Sensor in the reverse order of removal 2 Remove the
405. igure 2 Removing the Advanced Features Memory PWB Replacement 1 Perform the procedure for removal in reverse 0106014A WOL Figure 1 Removing the Front Rear Cable Assembly Repairs and Adjustments 10 00 Initial Issue REP 6 16 REP 6 17 4 48 Phaser 790 DocuColor 2006 Replacement REP 6 18 Carriage Motor 1 Install the Front Rear Cable Assembly Figure 2 Parts List on PL 16 4 3 1 Removal Attach Springto Insert the cable end into WARNING the end of the the groove in the To avoid personal injury or shock do not perform repair activities with the power switch cable bracket and route the on or electrical power applied to the machine cableas shown 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Carriage Motor Figure 1 3 Remove the screws 3 and the Carriage Motor by moving it in the direction indicated Wrap the cable around the pulley five times Make sure the sphere in 2 the middle of the cable is positioned in the groove in the pulley 0106015A WOL Figure 2 Routing the Cable Assembly CAUTION Verify that the cable is not twisted and that the Cable Assembly is not contacting any surround ing components or wires Disconnect the Reinstall the Full rate Carriage REP 6 21 Spring Move the Full rate Carriage by hand to verify proper operation Disconnect the connector 0106016A WOL Perform a Full Half rate Carriage Parallel Adjustment ADJ 6 2 Reinstall the Rear Cover REP 6
406. ill exists replace the ESS PWB PL 12 1 Status Indicator RAPs 10 00 Initial Issue 016 323 324 325 016 330 331 332 333 334 335 336 2 210 Phaser 790 DocuColor 2006 016 370 IOT to ESS Communication Failure RAP The Control Logic detected an IOT to ESS communication failure Procedure Perform the following Switch off the power Remove the Right Cover in order to access the ESS PWB Remove and reseat the ESS PWB Switch on the power If the problem is still present replace the ESS PWB PL 12 1 If the problem continues replace the MCU PWB PL 11 2 Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 211 016 370 Status Indicator RAPs 10 00 Initial Issue 016 370 2 212 Phaser 790 DocuColor 2006 033 210 Printer Detection RAP Connection with the printer failed Procedure Switch off the power then switch on the power If the fault is still present replace the ICM Main PWB PL 16 2 033 211 212 IOT IIT Disconnection RAP 033 211 The Control Logic detects a disconnection 033 212 The Control Logic detects no printer Initial Actions Check the cables and connections between the IIT and the IOT Ensure that the cables are Secure Exit then re enter the Copy mode if this does not resolve the problem switch the power off then on Verify that the problem still exists Procedure Remove the Right Cover REP 14 9 Verify that the 1394 PWB is correctly installed If the PWB
407. ine power and disconnect the machine Power Cord 2 Remove the Sorter from the IOT Figure 1 1 25 Disconnect the connector Loosen the thumb screws 2 and separate the sorter from the IOT 0 111001A WOL Figure 1 Removing the Sorter Replacement 1 Perform the procedure for removal in reverse REP 11 2 Bottom Cover Parts List on PL 19 3 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Bottom Cover Figure 1 2 Pull the Entrance guide slots from their retainers in the Bottom Cover and remove the Entrance Guide 1 Disconnect the ground wire from the Entrance Guide Remove the screws 2 and the Bottom Cover 0 111002A WOL Figure 1 Removing the Bottom Cover Replacement 1 Perform the procedure for removal in reverse Initial Issue Phaser 790 DocuColor 2006 10 00 Repairs and Adjustments 4 129 REP 11 1 REP 11 2 REP 11 3 Sorter Control PWB Parts List on PL 19 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Front Cover CAUTION The PWB components are highly susceptible to damage from electrostatic discha
408. ing Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 79 FEEDER PWB PL13 4 FEEDER MOTOR PL13 4 FEEDER DI C3 MOTOR ON FEEDER L 24VDC MOTOR FAIL m 5VDC BLU FEEDER DRIVE MECHANISM TRAY2 83 PAPER FEEDING TRAY3 84 PAPER FEEDING m 1708704A WOL Figure 1 Feeder Drive Control Wiring Data 10 00 Initial Issue 7 80 Phaser 790 DocuColor 2006 BSD 8 6 8 6 REGISTRATION REGISTRATION PAPER TRANSPORTATION 1 87 REGISTRATION 1 ROLL DRIVE m mm mum NEN NEN NEN NM Um REGISTERED 82 AA PEED PAPER 2 87 PRE REGISTRATION ROLL DRIVE ER EE EM DUPLEX 105 FEED PAPER 3 MCU PWB PL11 2 TRAY1 FEED PAPER 21 29 REGISTRATION SENSED 18 L 5VDC J20 49 MCU PWB PL11 2 5VDC DC COM 5VDC 83 TRAY2 PAPER ROLL DRIVE 4 21 27 SENSED L 5 TRAY2 8 3 FEED PAPER 15 QE T cris uu RS miro SM GRY 8 4 TRAY3 PAPER 5 ROLL DRIVE mE m 8 4 TRAYS FEED PAPER 6 1708705A WOL Figure 1 Registration Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 81 BSD 8 7 A B D E F H J 8 7 REGISTRATION MECHANISM BYPASS 82
409. ing Data Phaser 790 DocuColor 2006 7 55 BSD 4 2 4 2 MECHANICAL DRIVES FUSER DRIVE UNIT DEVELOPER DRIVE 1 PL10 1 41 FUSER MOTOR DRIVE mum NEM EN EN EN 10 4 DRIVE mum mH EN 2 FUSER 10 1 DRIVE EAM EE EH EH BELT CLEANER 9 8 DRIVE Em EE EH EM EH 2ND BTR 9 8 RETRACT DRIVE E EM 3 AUGER 9 7 DRIVE ER EM EM EN NN PAPER HANDLING DRIVE UNIT PL10 1 CLEANER 9 9 4 DRIVE NEN NEN EN EM mm EN EN NN TRANSPORT 8 7 DRIVE PAPER EM EN EM EM EM m m m m m A 5 HANDLING 41 MOTOR DRIVE DUPLEX 10 7 EE AN a ma mE mE mE mm mmm m mmm mm FEED DRIVE EN EE NE 6 FEED 8 1 DRIVE Em EM EM EM Em EM EM NE NH EN m T704702A WOL Figure 1 Mechanical Drives Wiring Data 10 00 Initial Issue 7 56 Phaser 790 DocuColor 2006 5 1 ADF DOCUMENT SENSING AND INTERLOCK MONITORING ADF CONTROL PWB PL17 2 ADF CONTROL PWB DOCUMENT SET PL17 2 SENSOR 4 G J714 P714 FEEDER COVER INTERLOCK PL17 4 oo DOC
410. intermittent performance is suspected perform the following Check the connections between the ESS PWB and the Foreign Interface and the interconnecting harness Reseat the P J 17 connector on the ESS PWB and P J 905 on the Foreign Interface Go to Flag 1 and check the wires for an open or short circuit The wires are good Repair the wires There is 5 VDC between J905 8 and machine frame Y N There is 5 VDC between J 17 7 and machine frame Y Replace the ESS PWB PL 12 1 Go to Flag 2 and check the wire for an open circuit Go to Flag 3 and check the wires for an open or short circuit The wires are good Y Repair the wires Replace the ESS PWB PL 12 1 If the problem continues replace the Foreign Interface Initial Issue 10 00 Phaser 790 DocuColor 2006 2 39 Status Indicator RAPs 003 333 ESS PWB FOREIGN PL12 1 INTERFACE 5 VDC 17 COMMUNICATION LINE 4905 4 905 gt TRANSMITTER YEL 1 5422 5 edie a 22 5 IP Be RETURN DO GRY GRY GRY 3 COMMUNICATION LINE 6 RECEIVER gt YEL YEL CR15 P 4 i i Y RETURN GRY GRY GRY lt 2 5 VDC d E GRY GRY d DC COM ry PE Y GND GN YL o FOREIGN INTERFACE ie
411. is fully closed Ensure that the Fuser Assembly is mounted correctly and securely Repair any obvious defects Procedure Access the Digital Input DI test from the Control Panel Enter code 62 Press the Item Enter button The display indicates 0 Y N Go to Flag 1 and check the wire for a open circuit If the wire is good replace the MCU PWB PL 11 2 The problem may be intermittent Go to Flag 1 and check for loose or damaged connections or damaged wires If the problem persists replace the MCU PWB PL 11 2 Initial Issue 10 00 Phaser 790 DocuColor 2006 2 23 Status Indicator RAPs 001 710 MCU PWB PL11 2 21 62 px t FUSER INSTALLED P78 478 L 5 VDC J71 71 J19 5 GRY GRY GRY i i 1 v i i 1 2 S A7 A4 aY 7 si DC COM P J71 PIN CONFIGURATION J71 P71 J71 2 J71 1 P71 1 P71 2 WHT BLK BLK WHT g 7 o o o dd st 52 Mm P14 P16 P19 P22 P18 Ej 5 P17 Jn B lt gt JAA P71A oHa gt P71 a alid MCU PWB P20 12 1 10 J 23 hel 1 2 11 54 471 4 Oo J71 3 P71 3 P71 4 5 YEL YEL YEL YEL FUSER SIDE IOT SIDE LOCATING LOCATING POST POST T701010 A WO
412. is installed correctly and the problem still exists replace the 1394 PWB PL 12 1 If the problem continues replace the ICM Main PWB PL 16 2 Initial Issue Phaser 790 DocuColor 2006 10 00 2 213 Status Indicator RAPs 033 210 033 211 212 033 221 222 223 224 225 226 226 227 228 IOT IIT Communication RAP 033 221 033 222 033 223 033 224 033 225 033 226 033 227 033 228 The Control Logic detects a 1394 PWB communication time out The Control Logic detects a 1394 PWB communication error The Control Logic detects a 1394 PWB connection time out The Control Logic detects a 1394 PWB reconnection time out The Control Logic detects a 1394 PWB reconnection failure The Control Logic detects an Async transaction time out The Control Logic detects an Async transaction retry error The Control Logic detects a 1394 PWB link chip error Initial Actions Check the cables and connections between the IIT and the IOT Ensure that the cables are Secure 033 330 331 332 Software Error RAP An XPro software error was detected Procedure Replace the IPS PWB PL 16 2 If the problem remains replace the ICM Main PWB PL 16 2 Exit then re enter Copy Mode If this does not resolve the problem switch the power off then on Verify that the problem still exists Procedure Remove the Right Cover REP 14 9 Verify that the 1394 PWB is correctly installed If the PWB is installed correctly and the probl
413. itch on the If the problem persists replace the Rotary Motor PWB PL 10 1 If the problem remains unre power Monitor the voltage as the power on selftest executes The voltage is 5 solved replace the Rotary Motor PL 10 1 VDC when power is switched on and drops to between 2 and 3 VDC for If the problem remains unresolved or if erratic or intermittent operation is observed go to Fig approximately 5 seconds ure 1 and check the harnesses shown for loose or damaged connectors If the wires are OK Y N replace the MCU PWB PL 11 2 Go to Flag 5 Check for an open circuit or a short circuit to ground If the wire is OK replace the MCU PWB PL 11 2 Switch off the power Connect the DVM from pin 1 to pin 4 on J 245 Switch on the power Monitor the voltage as the power on selftest executes The voltage is 5 VDC when power is switched on and drops to less than 1 VDC for approxi mately 5 seconds A Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 141 009 326 ROTARY MOTOR PWB MCU PWB PL10 1 PL11 2 MOTOR DRIVE ROTARY MOTOR 01 43 777 Meats CLOCK J245 4 ROTARY HOME T GRY W lt ROTARY SENSOR SENSED DC COM MOTOR ns gad 416 15 69 326 8 PL101 GRY k ROTARY MOTOR ON j L 5VDC J247 B 2 2 15 44 GRY 1 ORN r2 DCCOM 7 E M BLU ROTARY MOTOR 34 v 44 LOW SPEED ON
414. ith the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Main Fuser Assembly REP 10 2 3 Remove the Upper Guide Assembly REP 10 3 CAUTION Be careful not to damage the surface of the Pressure Roll while removing the Lower Guide Assembly 4 Remove the Lower Guide Assembly Figure 1 Replacement CAUTION Do not damage the Fuser Exit Actuators and ensure that the actuators do not interfere with the Fuser Exit Sensors and fall out while installing the Lower Guide Assembly 1 Reinstall the Lower Guide Assembly in the reverse order of removal 1 Remove the Screw Remove the Lower Guide Assembly 0110006A WOL Figure 1 Removing the Lower Guide Assembly Initial Issue Phaser 790 DocuColor 2006 10 00 4 117 Repairs and Adjustments REP 10 6 REP 10 7 REP 10 8 Front Fuser Exit Sensor Parts List on PL 8 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine Switch off the machine power and disconnect the machine Power Cord Remove the Main Fuser Assembly REP 10 2 Remove the Upper Guide Assembly REP 10 3 Remove the Lower Guide Assembly REP 10 7 Remove the Front Fuser Exit Sensor Figure 1 Replacement 1 Reinstall the Front Fuser Exit Sensor in the reverse order of removal Qi dS veo or
415. itial Actions Load paper into the Bypass Tray Check the Bypass Tray and ensure that the Tray Empty Actuator is present and functions properly Procedure Load paper into the Bypass Tray Access the Digital Input DI Test from the Control Panel Enter code DI 66 Press the Enter button The display indicates 0 Y N Go to Flag 1 Check the wires for an open or a short circuit to ground The wires are good Y Repair the wires Check the Bypass tray and ensure that the Tray Empty Actuator is present and functions properly The Tray Empty Sensor Actuator is good Y N Repair or replace the Tray Empty Actuator PL 4 3 Replace the Tray Empty Sensor PL 4 3 If the problem continues replace the MCU PWB PL 11 2 Replace the MCU PWB PL 11 2 Initial Issue Phaser 790 DocuColor 2006 10 00 2 99 Status Indicator RAPs 007 706 MCU PWB PL11 2 5VDC EMPTY 066 SENSOR TRAY EMPTY PL4 3 J203 P201 J201 J1 P91 SENSED 5VDC J20 1 r5 104 5 A104 5 GRY GRY DC COM 1 1 3 1 1 1 4 A A11 GRY 2 1 1 Y Y GRY 12 SRY i ale GRY 1 5VDC EMPTY SENSOR 1 1 17 1 7 o 34 pig 18 21912
416. ity is measured between J71 1 and J71 2 Y Continuity is measured between J 79 1 and J79 2 Y Remove the Upper Plate REP 10 4 Check for continuity directly across the Pressure Roll Heat Lamp and the Heat Roll Heat Lamp If continuity is NOT measured replace the Heat Lamps as required PL 8 3 Also check for conti nuity directly across the Thermal Fuse and the Thermostat If continuity is NOT measured across either component replace the Upper Plate PL 8 2 Go to Flag 1 Check for an open circuit Repair or replace the Fuser Harness PL 8 5 as required Go to Flag 2 Check for an open circuit Repair or replace the Fuser Connector Harness or the Main Harness PL 11 1 as required Disconnect the connector from J 32 on the Low Voltage Power Supply LVPS An open cir cuit NO continuity is measured between J32 2 of the disconnected connector and GND Y A short circuit is causing the Heater signal to be constantly available Repair or replace the Main Harness PL 11 1 as required If the problem persists replace the MCU PWB PL 11 2 Reconnect J 32 to the LVPS Access the Digital Output DO test from the Control Panel Enter code 47 Measure the voltage between J 32 2 of the LVPS and GND Press the Item Enter button The measured voltage is approximately 4 5 and momentarily goes to approximately 3 2 then recovers when the Item Enter button is pressed Y N Replace the MCU PWB PL 11 2 G
417. justments 10 00 REP 8 36 4 84 Initial Issue Phaser 790 DocuColor 2006 REP 8 37 Inverter Sensor 5 Remove the Inverter Sensor Figure 2 Parts List on PL 15 5 5 Removal Disconnect the WARNING connector To avoid personal injury or shock do not perform repair activities with the power switch Chute on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Feeder Left Cover 3 Remove the Inverter Lower Assembly REP 8 35 4 Remove the Inverter Roll Figure 1 Release the locking tabs and remove the a Inverter Sensor 3 Remove the Inverter Roll 2 or the Remove the two screws E ring a and the Chute bearing 0108054A WOL Figure 2 Removing the Inverter Sensor Replacement 1 Perform the removal procedure in reverse 2 Remove the E ring and bearing 0108062A WOL Figure 1 Removing the Inverter Roll Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 85 REP 8 37 REP 8 38 Duplex Controller PWB Parts List on PL 15 6 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord Remove the Feeder Left Cover Remove the Inverter Lower Assembly REP 8 35 2 3 4 Remove the Rear Inverter Cover Figure 1 1 Loosen two
418. k the following Go to Flag 1 Check the wires for an open circuit Go to Flag 2 Check the wires for an open or a short circuit to ground If the wires are good replace the No Paper Sensor PL 13 5 Actuate the No Paper Actuator Access the Digital Input DI Test from the control panel Enter code DI B4 Press the Enter button The display is 0 Y N Replace the No Paper Sensor PL 13 5 If the problem continues replace the Feeder PWB PL 13 4 Replace the Feeder PWB PL 13 4 Initial Issue Phaser 790 DocuColor 2006 10 00 2 97 Status Indicator RAPs 007 705 FEEDER Figure 1 007 705 RAP Circuit Diagram TRAY 3 PAPER FEEDER ASSY PWB PL13 4 2 2 84 5VDC NO PAPER NO PAPER SENSOR SENSED PL13 5 J220 P242 J242 85 925 FEEDER 2 2 14 2 PWB GRY GRY PL13 4 5VDC M A J215 J242 P242 J220 5VDC 3 1 1 gt GRY GRY Ee 1 1 DC COM 1 3 GRY GRY DC COM P214 P218 P216 NO PAPER FEEDER SENSOR PWB P217 P215 T707007A WOL Status Indicator RAPs 007 705 10 00 2 98 Initial Issue Phaser 790 DocuColor 2006 007 706 Bypass Tray Empty RAP The Control Logic has detected a Tray Empty Sensor Sensed H 5 VDC In
419. k the wires for an open or a short circuit to ground The wires are good Repair the wires Ensure that PJ 16 on the MCU and PJ 102 on the Size Switch PWB are properly connected There is 5 VDC from J 102 pin 2 on the Size Switch PWB to ground N Go to 2 Check the wire for open or short circuit to ground The wires are good Y Repair the wires Replace the MCU PWB PL 11 2 Replace the Size Switch PWB PL 3 1 Press and hold switch number SW1 and SW3 on the Size Switch PWB There is 42 67 0 10 VDC from J 102 pin 1 on the Size Switch PWB to GND B Replace the Size Switch PWB PL 3 1 Press and hold switch number SW2 SWA on the Size Switch PWB There is 2 43 40 10 VDC from J 102 pin 1 on the Size Switch PWB to ground N There is 5 VDC from 102 pin 2 on the Size Switch PWB to ground Y N Go to Flag 2 Check the wire for an open or short circuit to ground The wires are good Y Repair the wires Ensure the connector PJ 102 is properly connected Replace the MCU PWB PL 11 2 Replace the Size Switch PWB PL 3 1 Replace the MCU PWB PL 11 2 Y N There is 5 VDC from J 102 pin 2 on the Size Switch PWB to ground Y N Go to Flag 2 Check the wire for an open or short circuit to ground The wires are good Y N Repair the wires Ensure the connector PJ 102 is properly connected Replace the MCU PWB PL 11 2 A Initial Issue 10 00 Status Indicator R
420. l Issue Phaser 790 DocuColor 2006 001 712 IIT DC Power RAP Initial Actions Ensure AC power is available at the wall outlet Ensure that the AC Power Cord is securely connected to the system Procedure Remove the Rear Cover REP 6 4 from the IIT Check the following voltages at P91 Figure 1 on the IIT LVPS P91 1 Orange Wire for 24 VDC P91 2 Orange Wire for 24 P91 3 Gray Wire for 5 VDC P91 4 Gray Wire for 3 5 VDC All of the voltage are available Y N All of the voltages are missing Y N Check the pins on connector P J91 Look for loose or damaged pins If the connector is OK replace the IIT LVPS PL 16 1 Check the Fuse Figure 1 on the IIT LVPS The Fuse is defective Y N AC line voltage is available between JN1 1 and JN1 2 Figure 1 Y Replace the AC Switch Harness PL 16 6 Replace the IIT LVPS PL 16 1 Replace the Fuse If the Fuse blows again replace the IIT LVPS PL 16 1 Go to the wirenets to check for any wires that may be open Check the IIT LVPS connectors for any loose or damaged pins Initial Issue Phaser 790 DocuColor 2006 10 00 2 27 Status Indicator RAPs 001 712 IIT LVPS ICM MAIN PWB PL16 1 PL16 2 AC SWITCH HARNESS LOW VOLTAGE PL16 6 GENERATION J92 J91 424 J100 1 24 1 r1 BLK VDC ORN 1 1 2 2 24 VDC I
421. lamp 2 Not Spared 9 Rail Clamp 1 Not Spared 10 Copy Print Cartridge REF Section 6 REP 9 1 11 Xerographics Cartridge P O PL 5 1 Item 10 12 Waste Container REF Section 6 REP 9 2 13 160K81230 CRUM P O PL 5 1 Item 10 Phaser 790 14 Harness Not Spared 15 130E82980 Toner Box Sensor REP 9 7 16 130E91010 Waste Toner Sensor REP 9 6 17 Locating Rail Not Spared REP 9 5 18 Locating Assembly Not Spared 19 122K93100 Erase Lamp REP 9 8 20 130K60440 ADC Sensor REP 9 4 21 600K68620 BCR Connecter Kit 0 005001A WOL Parts List 10 00 Initial Issue PL 5 1 5 22 Phaser 790 DocuColor 2006 PL 6 1 Development 1 of 2 Item Part Description 1 003K84303 Rotary Knob 2 Rotary Frame Not Spared REP 9 12 ADJ 9 1 3 Rotary Front Bearing Not Spared 4 Rotary Rear Bearing Not Spared 5 600K69091 Rotary Latch 6 Rotary Sensor Assembly Not Spared 7 Rotary Sensor Plate Spared 8 130 83060 Rotary Sensor 9 11 9 Cartridge Sensor Assembly Not Spared 10 Developer Discharge Holder Not Spared 11 600K85301 Developer Contact Plate 12 Cartridge Sensor Plate Spared 13 130E82830 Cartridge Sensor REP 9 13 0006001A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 23 PL 6 1 PL 6 2 Development 2 of 2 Item Part Description 1 Dry Ink Cartridge Y REF Section 6 REP 9 9 2 Dry Ink Cartridge M REF Section 6 REP 9 9 3 Dry Ink Car
422. llowing situations occurred The Rotary Sensor did not detect the Rotary Frame Assy in the home position within 6 seconds from the signal Rotary Motor On During a print job the speed of rotation deviated by more than the allowable amount Initial Actions Ensure that the Rotary Frame Assembly can be rotated manually Ensure that there are no obstructions before attempting to test the motor under power Procedure Remove the rear cover Monitor the Rotary Motor as the power on selftest executes The Y N Go to Flag 7 Check for an open circuit or a short circuit to ground If the wire is OK replace the MCU PWB PL 11 2 Replace the Rotary Motor PWB PL 10 1 If the problem persists replace the Rotary Motor PL 10 1 Check the gears on the Rotary Motor PL 10 1 and the Rotary Frame PL 6 1 for dam age or contamination Clean repair or replace as required Remove the Top Cover Connect the DVM from J 58 pin 2 to frame ground Rotate the Rotary Frame until the actuator on the rear of the frame is blocking the Rotary Sensor PL 7 2 45 VDC is measured Y N Developer Frame rotates Disconnect P 58 from the Rotary Sensor There is 5 VDC from J 58 pin 2 on the Y N Rotary Sensor Harness to frame ground The Rotary Motor energized Y N Y N Go to Flag 4 Check for a short circuit to frame ground If the wire is OK replace the There is 24 VDC from 4 246 pin 3 to J 246 pin 1 on the Rotary Motor PWB MCU PWB
423. m Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 155 009 360 009 700 Toner Cartridge Detached RAP Control Logic does not detect the presence of one or more Dry Ink cartridges Initial Actions If the fault is reported for a single cartridge check the outboard end of the cartridge for dirt or debris If the fault is displayed for all cartridges continue with this RAP Procedure NOTE The output of the Cartridge Sensor is high when blocked and low when unblocked Access the Digital Output Test GP 2 Enter code 75 Press the Item Enter button Access the Digital Input Test GP 2 Enter code 67 Press the Item Enter button The display is 1 Y N CAUTION Do not allow the UI PWB to come in contact with the metal frame of the machine Remove the Top Cover but keep the UI connected to the ESS Disconnect J 87 Access the Digital Output Test GP 2 Enter code 75 Press the Item Enter button Access the Digital Input Test GP 2 Enter code 67 Press the Item Enter button The display is 1 Y N Go to Flag 2 Check for a short circuit If the wire is OK replace the MCU PWB PL 11 2 Replace the Cartridge Sensor PL 6 1 Remove a Dry Ink cartridge Turn the Rotary Assembly until the space for the missing cartridge is under the sensor approximately 15 degrees past vertical Enter code 75 Press the Item Enter button The display is 0 Remove the Cover but keep the UI connected to the ESS
424. m Solenoid REP 10 16 Cleaner Cam Shaft Parts List on PL 8 7 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord Remove the Exit Tray Assembly REP 8 30 Remove the Fuser Assembly REP 10 1 Remove the Main Fuser Assembly REP 10 2 Remove the Cleaner Cam Solenoid REP 10 15 CAUTION Be sure not to drop and lose the Cleaner Cam Pin when removing the Cleaner Cam Shaft 6 Remove the Cleaner Cam Shaft Figure 1 Replacement 1 Reinstall the Cleaner Cam Shaft in the reverse order of removal NOTE The right left direction of the cam must be adjusted after installing it 2 Remove the e ring Cleaner Cam Pin and Front Bearing 3 Remove the Cleaner Cam Shaft Remove the Screws Then remove the Fuser Front Rail 0110016A WOL Figure 1 Removing the Cleaner Cam Shaft Repairs and Adjustments 10 00 Initial Issue REP 10 15 REP 10 16 4 124 Phaser 790 DocuColor 2006 REP 10 17 Exit Roll Parts List on PL 8 4 Repair WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Exit Tray Assembly REP 8 30 3 Remove the Fuser Assembly REP 10 1 4 Remove the Main Fuser
425. ments Counter must be manually the counter by 2 if the color reset following replacement is required 14 Developer M Each TRO signal increments Counter must be manually the counter by 2 if the color reset following replacement is required 15 Developer C Each TRO signal increments Counter must be manually the counter by 2 if the color reset following replacement is required 16 Developer K Each TRO signal increments Counter must be manually the counter by 2 if the color reset following replacement is required 20 IBT Belt Each TRO signal increments Counter must be manually the counter by 2 if the color reset following replacement is required 9 Press the Menu button to return to DIAG EXIT and press the Item Enter button to write to the NVM Initial Issue Phaser 790 DocuColor 2006 General Procedures and Information 10 00 3 GP 4 6 8 GP 5 Setting up Meters The purpose is to reset the meters to zero Procedure 1 Enter the Diagnostic Mode GP 1 GP 6 Initializing Data IOT The purpose is to clear the data from NVM or SLAVE memory Procedure CAUTION 2 Press the Menu button until METER SETUP is displayed Do not perform this procedure unless instructed to do so by the Service Manual The Service 3 Press the Item Enter button METER CLEAR NO is displayed Manual will provide the specific directions for clearing the NVM or SLAVE memory as required 4 Press the Up o
426. n ADF moves toward the rear ADF Lead Edge Registration ADJ 5 2 Direction B ADF moves toward the front sa piod Edge Registration ADJ 6 3 4 Tighten the screws in 6 locations then tighten the two screws on the Left side of the 11 Side Registration ADJ 6 4 Counterbalance Check 1 Using the Copier Setup Test Pattern 82E8220 make two copies with the machine set to Tray 1 11 17 A3 and 100 magnification E 2 Using the second copy from step 1 align the scale located at the middle of the copy with the scale at the middle of the test pattern 3 Verify that the 400mm increment on the copy matches the 400mm increment 4 0mm B Dieci on the test pattern irection Adjustment 1 Enter Diagnostic Mode IIT GP 19 2 Highlight Systemdata R W and press the Select button 3 Under Chain enter 715 and then press the down arrow to highlight Link Under Link enter 2 Press the Select button to display the Current dat values 4 Change the values as required based on the measurement results When the measure ment is short reduce the value when the measurement is long increase the value Screws 6 Change the values as follows NOTE To enter a letter Hexadecimal value press the asterisk key prior to entering each letter value then press the appropriate numerical key as follows A21 2 D 4 5 F 6 a Enter the new value and press Start b Press the Select button to verify the value has changed A
427. n then close the Upper Chute Cover The ADF Drive Motor cycles Y Go to Flag 3 Check for an open circuit If the wire is OK replace the ADF Control PWB PL 17 2 If the problem remains replace the ICM Main PWB PL 16 2 Use a test lead or a jumper wire to short J 814 pin 2 to ground The Document Set Indica tor lights Replace the ADF Control PWB PL 17 2 Disconnect P J 711 There is 5 VDC from pin 2 of J711 to frame ground Y Go to Flag 1 Check for an open circuit There is 5 from pin 1 to pin 3 of J711 Y N Go to Flag 2 Check for an open circuit Replace the Document Set Sensor PL 17 5 Status Indicator RAPs 005 703 10 00 2 62 Initial Issue Phaser 790 DocuColor 2006 DOCUMENT SET ADF CONTROL PWB PL17 2 SENSOR 12 DOCUMENT AT 5 VDC 2 SETSENSOR 00002 L 5 vDC r ICM MAIN YEL PWB PL16 2 GRY 2 ADF INSTALLED D 5 VDC J220 YEL 2 SET SENSOR ADF CONTROL PWB CR3 P811 l P813 CR2 RED U2 P812 P815 P814 P816 1705004 A WOL Figure 1 005 703 RAP Circuit Diagram Initial Issue Status Indicator RAPs Phaser 790 DocuColor 2006 10 00 2 63 005 703 005 704 Unfinished Copy Job RAP Procedure Go to Flag 1 and Flag 2 Check the wires for an open circuit If th
428. n open circuit If the wire is OK replace the MCU PWB Go to Flag 5 Check for an open circuit or a short circuit to ground If the wire is OK replace the High Voltage Power Supply PL 11 1 Go to Flag 7 Check for an open circuit If the wire is OK examine the BTR 2 Assembly PL 7 5 and the and the Backup Roll and Contact Roll in the IBT Assembly for damage or contam ination Clean repair or replace as required PL 7 2 Image Quality 106 10 00 Initial Issue Phaser 790 DocuColor 2006 HIGH VOLTAGE POWER SUPPLY PL11 1 PL11 2 lt 1 DO 0B BTR1 BIAS ON J16 L 24 Y J42 7 BTR 1 GRY CONTROL G 1 BIAS MONITOR 9 GRY lt lt WHT BTR 1 BIAS CONTROL Y 1g GRY 1 DO 0A lt 4 BTR2 BIAS ON i L 24 VDC 10 2 GRY I CONTROL i lt i BTR 2 BIAS CONTROL 44 BTR 1 GRY 1 6 1 s IBT ASSEMBLY 2 BIAS Y T4 CONTACT ROLL PL 7 2 GRY ACKUP ROLL PL 7 2 IBT BELT PL 7 2 BTR 2 PL 7 5 GND CONTACT SPRING PL 7 5 MD CONTACT ROLL 16 P19 P22 P18 f N 17 1 LJ P15 MCU PWB P20 BACKUP ROLL P12 P11 BTR2 21 T 730000 A WOL Figure 1 196 RAP Circuit Diagram Initial Issue 10 00 Image Quality
429. n reverse Initial Issue Phaser 790 DocuColor 2006 Repairs and Adjustments 10 00 REP 11 7 REP 11 8 4 133 Remove the Bin Drive Motor Figure 2 REP 11 9 Bin Drive Motor 5 Parts List on PL 19 4 Removal WARNING EA J c To avoid personal injury or shock do not perform repair activities with the power LA lt gt lt switch on or electrical power applied to the machine L Ej 1 Switch off the machine power and disconnect the machine Power Cord 1 EJ 2 Remove the Rear Cover 1 3 os 3 Remove the Front Cover Pinch the Motor Support to E 4 Disconnect the motor connector from the PWB and release the wires Figure 1 release it from the Sorter and 7 21 lt remove the support and motor lt S XN gt lt TH S amp 0 11010A WOL Figure 2 Removing the Bin Drive Motor Replacement 1 Perform the procedure for removal in reverse 2 Make sure the Support is properly positioned to the Motor Figure 3 Tab positioned to notch 0 111014A WOL Disconnect the Bin Drive Motor release the wires from the harness 1 and feed the wires back through the Sorter to the Bin Drive Motor Figure 1 Disconnecting the Motor 10 00 4 134 Figure 3 Motor Support Positioning 01005A AOL Initial Issue Phaser 790 DocuColor 2006 Repairs and Adjustments REP 11 9 REP 11 10 Front Rear Gear Shaft Parts List on PL 19 4 Removal WAR
430. nd plug in the connectors several times to remove contaminants due to oxidation The resistance created by the contaminants will change the Machine Timing measured in ms which is inca pable of being observed with a multi meter Observe the Sorter Bins during power up and initialization of the Sorter The Sorter Bins ini tialize correctly Y N Remove the Front and Rear Covers from the Sorter Remove the two screws on the Bin Home Switch from under the Bin Assembly so as to be able to actuate and deactuate the Switch Measure the voltage between J 4 3 of the Sorter Control PWB and GND Actuate and deactuate the switch The meter changes state from a Low 0 VDC to a High 5 Y The voltage remains Low 0 VDC Go to 2 and check the harness for an open circuit If the harness is OK replace the Bin Home Switch PL 19 4 There is 5 VDC between J 8 10 and GND Y N Refer to the 5 VDC wirenet and check the wires for an open circuit to the Sorter Control PWB Y N Go to Flag 1 and check the harness for an open circuit If the harness is OK replace the Bin Cam Switch PL 19 4 There is 5 VDC between J 8 10 and GND Y N Refer to the 5 VDC wirenet and check the wires for an open circuit to the Sorter Control PWB Go to Flag 1 and check the wires for a short circuit If the harness is OK replace the Bin Cam Switch PL 19 4 If the problem persists replace the Sorter Contr
431. ndi cated 0105020A WOL Repairs and Adjustments 10 00 REP 5 10 4 34 Initial Issue Phaser 790 DocuColor 2006 5 Remove the Exit Tray Interlock or ADF Exit Sensor Figure 3 2 If replacing the Exit Tray Interlock disconnect the connector and remove the screw and the interlock 3 If replacing the ADF Exit Sensor dis connect the connector and remove the sensor Remove the screw holding the Exit Tray Interlock and ADF Exit Sensor mounting bracket 0105021A WOL Figure 3 Removing the Exit Tray Interlock or ADF Exit Sensor Replacement 1 Perform the procedure for removal in reverse Pay close attention to the following step 2 When replacing the Outer Exit Chute Assembly tighten the screws while holding the chute edge in arrow direction indicated in Figure 4 0105022A WOL Figure 4 Replacing the Outer Exit Chute Assembly Initial Issue Phaser 790 DocuColor 2006 10 00 4 35 Repairs and Adjustments REP 5 10 Repairs and Adjustments 10 00 Initial Issue REP 5 10 4 36 Phaser 790 DocuColor 2006 REP 6 1 Platen Glass REP 6 2 Right Cover Parts List on PL 16 1 Parts List on PL 16 6 Removal Removal 1 Remove the ADF REP 5 1 or Platen Cover 1 Remove the Right Cover Figure 1 2 Remove the Platen Glass Figure 1 1 Remove the screws 2 and the Right Plate 2 Lift the Platen Glass from the right hand side and remove
432. ndow The ROS window is clean and undamaged Y N Remove contaminants using a soft dry lint free cloth Use minimal pressure when cleaning If the window is scratched or damaged replace the ROS PL 5 1 WARNING HIGH VOLTAGE Exercise care when making the voltage check in the following steps Reinstall the ROS and the Copy Print Cartridge Remove the rear cover Select Print Configuration Page from the menu Measure the voltage from the terminal on the HVPS to frame ground as the print is processing The voltage cycles from 0 VDC to roughly 500 VDC Y N Go to the 009 341 RAP to troubleshoot the BCR bias circuit Select Print Configuration Page from the menu Measure the voltage from the C termi nal on the HVPS to frame ground as the print is processing The voltage cycles from 0 VDC to roughly 500 VDC Y N Go to the 009 342 RAP to troubleshoot the Developer bias circuit Replace the IBT Belt PL 7 2 If this does not resolve the problem replace the Copy Print Cartridge PL 5 1 If the problem persists replace the MCU PWB PL 11 2 Check the following Check the Developer Roll Spacing ADJ 9 1 for the affected color Check the end of life counter GP 3 for the Dry Ink Cartridge If it is at or near end of life replace it PL 6 2 Access the IOT PARAM SET menu See GP 3 Reset the toner density for the affected color to the default value 3 Perform VisualCal If the problem continues examine the Dev
433. nect the machine Power Cord 2 Remove the Top Cover Assembly REP 14 4 3 Prepare to remove the ROS Figure 1 1 Remove th screws 0 4 4 Remove the Screws Release the har ness from the clamp then remove the cover 3 Disconnect the con nectors 0109021A WOL Figure 1 Preparing to Remove the ROS Repairs and Adjustments 10 00 Initial Issue REP 9 3 4 92 Phaser 790 DocuColor 2006 CAUTION Be careful not to touch the window of the ROS window from which laser beam is emitted or other working components such as the motor shaft when removing the ROS The ROS and the Locating Rail are connected by a harness Be careful not to pull them too far apart when removing the ROS 4 Remove the ROS Figure 2 Replacement CAUTION Be careful that the harness does not touch the Scanner Motor shaft in the ROS or get pinched between the ROS and frame during reinstallation of the ROS 1 Reinstall the ROS in the reverse order of removal 3 Remove the ROS Disconnect the Connector Lift to access the bottom of the ROS 0090003A WOL Figure 2 Removing the ROS Initial Issue 10 00 Phaser 790 DocuColor 2006 4 93 Repairs and Adjustments REP 9 3 REP 9 4 ADC Sensor Parts List on PL 5 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine Switch off the machine power and di
434. ner and a soft lint free cloth If the problem persists replace the ICM Main PWB PL 16 2 Misregistration Skew Go to the IQ12 RAP Go to 1013 RAP Patterns in the image areas of the print that have the appearance of a screen or grid overlaying the image The pattern may be uniform or nonuniform in area or shape Newton Rings Clean the Document Glass Repetitive irregular shaped marks that occur when Place a transparency between the document and the glass making copies of glossy photographs These marks are most noticeable in large low density or highlight areas Initial Issue 10 00 Image Quality Phaser 790 DocuColor 2006 3 5 102 IQ3 Low Image Density RAP This RAP troubleshoots the causes of output images showing image density lower than speci fication Initial Actions Replace the paper in use with fresh dry paper of the correct specification Determine if the Copy Print Cartridge or any of the Dry Ink Cartridges are approaching end of life GP 3 Replace if necessary Examine the ADC Sensor If it is dirty go to the 009 340 RAP Perform VisualCal If this does not resolve the problem continue with this RAP Procedure Make a print of the Test Page GP 14 The defect involves a single color Y N Make a print of the Test Page GP 14 Open the Front Door when the lead edge of the print begins to protrude from the Fuser Exit nip Open the Fuser and examine the par tially fused shee
435. ng P O PL 7 5 Item 1 9 Support Plate P O PL 7 5 Item 1 10 BTR Spring P O PL 7 5 Item 1 11 m Cleaner Spring P O PL 7 5 Item 1 12 Ground Contact Spring PL 7 5 Item 1 13 Ground Contact Plate P O PL 7 5 Item 1 14 Gear P O PL 7 5 1 15 Gear P O PL 7 5 1 16 Gear P O PL 7 5 1 17 Insulator P O PL 7 5 Item 1 0007005A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 29 PL 7 5 PL 8 1 Fusing 1 of 7 Part 1 600K85411 600K85421 050K43340 050K43330 Description Fuser Assembly Not Spared REP 10 1 Main Fuser 110v Main Fuser 220v Fuser Tray 220v Fuser Tray 110v Jam Removal Label Not Spared Caution Label Not Spared 2 EXPLODED ON PL8 1 PL8 2 0008001A WOL Parts List PL 8 1 10 00 5 30 Initial Issue Phaser 790 DocuColor 2006 PL 8 2 Fusing 2 of 7 Item Part Description 1 2 26 and PL8 3 1 600K85411 Main Fuser Assembly 110v REP 10 2 ADJ 10 1 13 14 17 600K85421 Main Fuser Assembly 220v REP 10 2 20 21 22 2 _ Bottom Plate P O PL 8 2 Item 1 3 130E81970 Front Fuser Exit Sensor Rear Fuser Exit Sensor REP 10 8 REP 10 9 4 _ Heater Seal P O PL 8 2 Item 1 5 _ Washer P O PL 8 2 Item 1 6 130K60721 Temperature Sensor REP 10 12 7 x Fuser Front Frame P O PL 8 2 Item 1 8 Fuser Rear Frame P O PL 8 2 Item 1 9 Nip Spring P O PL 8 2 Item 1 10 003E53300 Fuser Nip Handle 11 Nip Plate P
436. ng P O PL 8 7 Item 3 9 Shaft P O PL 8 7 3 10 Gear P O PL 8 7 3 11 Cleaner Cam Gear P O PL 8 7 Item 3 12 Rear Bearing P O PL 8 7 Item 3 13 121 87040 Cleaner Cam Solenoid REP 10 15 14 Cleaner Cam Shaft Not Spared REP 10 16 15 Pin Not Spared 16 Cleaner Cam Spared 17 Front Bearing Not Spared 0008007A WOL Parts List 10 00 Initial Issue PL 8 7 5 36 Phaser 790 DocuColor 2006 PL 9 1 Paper Exit 1 of 2 Item Part Description 1 Exit Transport Assembly Not Spared REP 8 40 2 054K17770 Exit Transport Cover 3 050K27592 Lower Exit Tray EXPLODED ON PL9 2 1 0009001A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 37 PL 9 1 PL 9 2 Paper Exit 2 of 2 Item Part Description 1 Exit Transport Assembly Not Spared 2 Exit Chute Not Spared 3 Catch Magnet Not Spared 4 Pinch Roll Not Spared 5 Lower Exit Roll P O PL 9 2 Item 18 6 Upper Exit Roll P O PL 9 2 Item 18 7 Bearing P O PL 9 2 Item 18 2 Kit 8 Bearing P O PL 9 2 Item 18 2 Kit 9 Gear P O PL 9 2 18 3 Kit 10 Gear P O PL 9 2 Item 18 8 Kit 11 Front Plate Not Spared 12 130E82730 Exit Sensor REP 8 43 13 110 93440 Exit Chute Interlock REP 8 42 14 Harness Spared 15 127E81940 Fuser Fan 16 127E81951 Exit Chute Fan 17 130 61311 Full Stack Sensor REP 8 41 18 600K68750 Exit Upper Roller Kit 0009002 WOL Parts List 10 00 Init
437. nitial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 9 PL 1 3 PL 1 4 Base Frame 2 of 2 Item Part Description 1 Duplex Connector Bracket Not Spared 2 Base Frame Not Spared 3 Saddle Not Spared 4 Cover Bracket Not Spared 5 Clamp Not Spared 6 Right Hand Lower Bracket Not Spared 7 Paper Handling Guide Bracket Not Spared 8 Bracket Not Spared 9 Clamp Not Spared 10 Frame Foot Spared 11 Feeder Frame Not Spared 12 Bushing Not Spared S 13 Fuser Rear Guide Not Spared k 14 Fuser Front Guide Not Spared 15 Fuser Rear Spring Not Spared 7 16 Fuser Front Spring Not Spared 17 Edge Saddle U Spared 18 Lower Chute Not Spared 0001004A WOL Parts List 10 00 Initial Issue PL 1 4 5 10 Phaser 790 DocuColor 2006 PL 2 1 Paper Tray Item Part Description 1 050K42472 Tray 1 Assembly REP 7 6 2 Lift Plate P O PL 2 1 Item 1 3 Tray Spring PL 2 1 Item 1 4 Front Guide Assembly P O PL 2 1 Item 1 5 Front Guide P O PL 2 1 Item 1 6 B Snubber Stopper P O PL 2 1 Item 1 7 019K94190 Tray 1 Front Snubber REP 7 7 8 Rear Guide P O PL 2 1 Item 1 9 Guide Spring P O PL 2 1 Item 1 10 B Lock Plate P O PL 2 1 Item 1 11 Right Rear Guide Plate P O PL 2 1 Item 1 12 Left Rear Guide Plate P O PL 2 1 Item 1 13 Plate Link P O PL 2 1 Item 1 14 Plate Link Spring P O PL 2 1 Item 1 15 038K85490 Guide 16 Tray Size Actuator
438. nnections between the ICM Main PWB and the other components in the circuit Lamp FLPS PWB and CCD Look for loose or damaged connectors or damaged wiring Repair as required If all connections and wiring appear in good condition undamaged and securely connected perform the following Replace the Lamp PL 16 5 Replace the ICM Main PWB PL 16 2 Replace the FLPS PWB PL 16 2 Replace the Scanner Initial Issue 10 00 Phaser 790 DocuColor 2006 2 69 Status Indicator RAPs 006 311 006 312 FPC CCD RAP The FPC CCD does not provide the correct output when originals are scanned Procedure NOTE The CCD is not field replaceable If this Fault Code occurs replace the following parts in the order shown 1 FPC Cable PL 16 3 2 The ICM Main PWB PL 16 2 3 The Scanner Status Indicator RAPs 10 00 Initial Issue 006 312 2 70 Phaser 790 DocuColor 2006 006 313 IIT Cooling Fans RAP The Front or Rear Cooling Fan or both Fans failed to operate correctly A Fan Fail error has been declared Procedure Remove the Right Cover REP 6 2 Access the IIT Self Diagnostics from the IIT control panel Enter code 330 001 and enter a value of 4 for parameter 1 Press the Start button The Rear Fan operates normally Y Disconnect connector J 151 from the ICM Main PWB 24 VDC is measured between J151 pin 1 and pin 3 on the ICM Main PWB Y Replace the ICM Main PWB PL 16 2 Replace the Rear Fan
439. nnen 4 131 REP 11 5 Sensor R CeiVer 4 132 Xerographics REP 11 6 Sensor 4 132 REP 9 1 Copy Print Cartridge tsa occidere sepe Ane edes 4 91 1 7 Soner Path Sensor i uui eene a 4 133 REP 9 2 Waste Container 4 91 11 8 F l a da ee ee a uda tossed 4 133 REP 9 3 ROS 492 11 9 Bin Drive MOIOL 45 eei rrt tree 4 134 REP 9 4 ADC Sensori 4 94 REP 11 10 Front Rear Gear are a e aeei 4 135 REP 95 Locating cece e ee ng c id 4 95 REP 11 11 Front Rear Bin Gam roig een e eee 4 135 REP 9 6 Waste Toner Sensor 496 REP 11 12 Bin Cam Switch REP 9 7 Toner Box Sersor irr rente tree rn eni reet 4 96 REP 11 13 Bin Home Switch ananassa trentaine 4 136 REP 9 8 Erase 4 97 rote ree eb ERE ait kasta unease 4 137 REP 9 9 Dry Ink Gartridge eere ce rete ce co i eit ee X RR 4 97 REP 11 15 Docking 2 aor Pe ede ve ex Ent ence ep penes 4 137 REP 9 10 Developer Housing 4 98 Covers 00222722 9 13 Sasori Devin hat ele ota setts Aan 4 102 REP 14 2
440. ns Check that the Tray 1 Lift Plate functions without binding Ensure the Tray 1 is filled with 250 sheets of paper Ensure paper is properly loaded in the Tray Ensure the paper Tray is closed Procedure Check that the actuator on the No Paper Sensor for Tray 1 functions properly The Actuator is good Y N Replace the Tray 1 No Paper Actuator PL 3 1 Enter diagnostic code DI 60 The display indicates a 1 Y N There is 5 VDC from J 101 3 to J 101 4 Y N Go to Flag 1 Check the wires and connector PJ 101 from the No Paper Sensor to the MCU PWB for and open circuit or a short circuit to ground replace the MCU PWB PL 11 2 The wires are good Y N Repair the wires Replace the No Paper Sensor PL 4 3 If the problem continues replace the MCU PWB PL 11 2 Replace the MCU PWB PL 11 2 Go to 1 Check the wires from the MCU PWB to the No Paper Sensor for an open or a short circuit to ground If the wires are good replace the MCU PWB PL 11 2 Initial Issue 10 00 Phaser 790 DocuColor 2006 2 93 Status Indicator RAPs 007 703 MCU PWB TRAY 1 AREA SENSOR BRACKET NO PAPER SENSOR Figure 1 007 703 RAP Circuit Diagram PL11 2 NO PAPER 5 VDC SENSOR 01 60 NO PAPER PL
441. ns If the problem continues replace the ADF Control PWB PL 17 2 If the problem remains replace the ADF Drive Motor PL 17 2 A There is 5 VDC from pin 3 to pin 1 of J814 Y N Replace the ADF Control PWB PL 17 2 There is 5 VDC from pin 1 to pin 3 of J 711 Y N Go to Flag 2 Check for an open circuit Disconnect P J 711 There is 5 VDC from J 814 pin 2 to frame ground Y N Go to Flag 1 Check for a short circuit If the wire is OK replace the ADF Control PWB PL 17 2 Replace the Document Set Sensor PL 17 5 A Status Indicator RAPs 10 00 Initial Issue 005 701 Phaser 790 DocuColor 2006 ADF CONTROL PWB DOCUMENT SET 1 PL17 2 SENSOR 4711 PL17 5 r3 DOCUMENT AT ADF DRIVE SENSOR MOTOR gt J711 L 5 VDC J814 J812 424 PL17 2 1 YEL 1 WHT WAT i 24 VDC BL BLK GRY ADF DRIVE MOTOR ON 24 CLOC 1 YEL i Me ADF DRIVE MOTOR ON 24 CLOC 2 RED ADF DRIVE MOTOR REGISTRATION E 24 CLOC SENSOR DOCUMENT AT OR ORN LiT S REGISTRATION SENSOR ADF DRIVE MOTOR ON i dio D 5 VDC 24V CLOC 2 YE BR BRN i 1 REGISTRATION SENSOR ADF CONTROL PWB CR3 P811 P813 CR2 GRN DOC SET SENSOR RED U2 81
442. nsor A problem in the Sorter has triggered an Area 5 Fault Message Initial Actions Check the actuators for the Fuser Entrance Sensor and for both Fuser Exit Sensors Ensure that the actuators move freely and are not damaged Ensure that Area 5 is correctly and securely closed If no paper is present in the fuser but the message Clear Jam in Area 5 is displayed go to 010 702 Faulty Entrance Sensor RAP to troubleshoot the problem If Sorting has been selected for the copy print job and there is a jammed sheet that has exited the Fuser and is entering the Sorter go to 011 703 Sorter Transport Jam RAP to troubleshoot the problem Procedure 1 Check the paper in the paper trays for excessive curl or other damage Load fresh paper as required Run a test print from the IOT Control Panel If the jammed paper is entering Area 4 but the message Clear Jam in Area 5 is displayed inspect the drive gears on the Exit Transport Assembly Area 4 and replace as required PL 9 2 If the drives are OK but the problem continues go to the Faulty Fuser Exit Sensor RAP 010 703 If the copy print exits to the lower exit tray face up or to the Sorter but the mes sage Clear Jam in Area 4 is displayed go to the Faulty Exchange Solenoid RAP 010 705 Examine the jammed copy print _ If there is a streak line blur perpendicular to the process direction that occurs 95 5 mm from the lead edge of the paper inspect the drive
443. o 4 N E 4 ET 0201105A WOL Figure 1 Test Pattern Indications Adjustment 1 Enter Diagnostic Mode IIT GP 19 Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 157 ADJ 6 3 ADJ 6 4 IIT Side Registration Purpose The purpose is to achieve the proper home positioning for the IIT side direction Primary Scan ner IIT Side Registration enhances the overall precision of document related size detection accu racy as well as document positioning Check 1 Using the Copier Setup Test Pattern 82E8220 make two copies with the machine set to Tray 1 A3 and 10096 magnification 2 Check the second copy Verify that the distance from the side edge to the top of Step 3 on the SE2 and 5 scales is 10 0mm 2 5 Figure 1 Sinn T Paper Feed Direction i EI P 1 i Edge of copy 0201104A WOL Figure 1 ADF Side Registration Check Adjustment 1 Enter Diagnostic Mode IIT GP 19 2 Enter Systemdata R W and press the Select button 3 Enter Chain 715 and Link 3 and confirm the present values
444. o ground Repair or replace the Main Harness PL 11 1 the Fuser Harness PL 8 5 or the Temperature Sensor PL 8 2 which includes a portion of the wiring for the Fuser Exit Sensors as required If the wiring is OK replace the Rear Fuser Exit Sensor PL 8 2 If the problem persists replace the MCU PWB PL 11 2 A The problem may be intermittent Go to Figure 1 Check for loose or damaged connections or damaged wires If the wiring is OK replace the Front Fuser Exit Sensor PL 8 2 If the prob lem continues replace the Rear Fuser Exit Sensor PL 8 2 If the problem still persists replace the MCU PWB PL 11 2 A Status Indicator RAPs 10 00 Initial Issue 010 703 2 184 Phaser 790 DocuColor 2006 MCU PWB 5 PL11 2 01 25 5VDC FRONT FUSER SHEET AT FRONT EXIT SENSOR FUSER EXIT SENSOR x 4721 P72 5 472 411 YEL GRY GRY 01 48 7 REAR FUSER i SHEET AT REAR 5 EXIT SENSOR FUSER EXIT SENSOR Z PL8 2 L 5VDC i i 5 1 B3 8 14 YEL GRY GRY GRY i 22
445. o to 010 701 Faulty Temperature Sensor RAP to troubleshoot the problem Status Indicator RAPs 10 00 Initial Issue 010 355 2 172 Phaser 790 DocuColor 2006 MCU PWB LVPS HEATER DO 47 11 1 DR HEATER J34 22 Y Y P79 J79 12 H R HEATER ON 7 WET 2 2 guo 24 Wr J21 L 5VDC 382 4 2 GRY 1 F250 HIR MAIN UPPER PLATE HEATER SWITCH PL8 2 I THERMO THERMAL ACH Y 71 J71 Y STAT FUSE BLK BLK BLK Fx 1 1 17 1 111 12 18 Z pg 123 pg T8 27515 32M E P3 P14 17118 P32 28 1 P15 MCU PWB P20 14 1 P35 LVPS 15 12 PH M 1 816 8 m P33 P21 1 P J71 CONFIGURATION 471 P71 J71 2 ES J71 1 P71 1 P71 2 WHT 2 BLK BLK WHT id v a 10 C 1 10 n 411 n n n n n n n n J71 B lt gt JAA P71A ae gt P71 n n n n n n 1 10 1 10 ar d tu n dg J71 4 eet 2 3 YEL pn 8 71 4
446. ocuColor 2006 lt 5 WS ENS 20 C REEL NTRS Wirenets How to Use Wirenets The wirenets in this section show the distribution of all DC voltages and DC Common used throughout the printer copier The wirenets are designed to interface with the circuit diagrams and the BSDs If a voltage is missing from the circuit diagram or BSD locate the component that is missing the voltage and follow the wirenet back to the source of the voltage or DC Com mon Components are labeled with the BSD number in which they appear Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 25 5 VDC Wirenet 1 of 3 5 VDC 1 OF 3 WIRENET MCU PWB ESS PWB LVPS 933 J12 11 J11 3 7 A1 BRN 1 1 1 2 8 A2 BRN 9 B1 BRN B2 3 3 232 J22 J84 P84 185 1 2 95 3 COMMUNICATIONS PWB BRN GRY 33 J116 P116 488 4 14 1 4 3 WASTE TONER SENSOR GRY GRY 99 J14 J124 3 ROS GRY 61 J16 J58 16 ROTARY SENSOR GRY 93 i J54 P54 J57 244 3 TRO SENSOR 7 GRY GRY 96 1 481 P81 18 3 ADC SENSOR ASSEMBLY 5 VDC 95 J102 28 SIZE SWITCH ASSEMBLY GRY 74
447. ol Logic does not detect the presence of the Waste Container Initial Actions Check that the Waste Container is present and is installed correctly Procedure Access the Digital Input Test GP 2 Enter code 52 Press the Item Enter button The display is 0 Y Y N Disconnect P J 116 There is 5 VDC from J 116 pin 3 to J 116 pin 2 Y N Go to Flag 4 Check for an open circuit or a short circuit to ground If the wires are OK replace the MCU PWB PL 11 2 There is 5 VDC from J 116 pin 1 to J 116 pin 2 Y Go to Flag 3 Check for an open circuit or a short circuit to ground If the wire is OK replace the MCU PWB PL 11 2 Remove the Locating Rail REP 9 5 Check the harness of the Toner Box Sensor Flag 1 and Flag 2 If the wires are OK replace the Toner Box Sensor PL 5 1 Remove the Waste Container Access the DI Test Enter code 52 Press the Item Enter but ton The display is 1 N Disconnect P J 116 Access the DI Test Enter code 52 Press the Item Enter button The display is 1 Y N Go to Flag 3 Check for a short circuit If the wire is OK replace the MCU PWB PL 11 2 Remove the Locating Rail REP 9 5 Check the harness of the Toner Box Sensor Flag 1 and Flag 2 If the wires are OK replace the Toner Box Sensor PL 5 1 The problem appears to be intermittent Go to Figure 1 Check for loose or damaged connec tions or pinched wires If the wires are OK replace the Toner Box Sensor PL 5 1
448. ol PWB PL 19 1 Reinstall the Bin Cam Switch Access the Digital Output DO test from the Control Panel Enter code C6 Press the Item Enter button The Bin Drive Motor energizes and the Bins move up one 1 Bin There is 24 VDC between 9 3 on the Sorter Control PWB and GND Y Go to 011 702 Sorter Cover Open RAP Go to Flag 3 and check the wire for an open circuit If OK replace the Bin Drive Motor PL 19 4 Enter Stop DO Test from the Control Panel Enter code C6 Press the Item Enter button Access the Digital Output DO test from the Control Panel Enter code C5 Press the Item Enter button The Bin Drive Motor energizes and the Bins move down one 1 Bin Y N There is 24 VDC between J 9 3 on the Sorter Control PWB and GND Y N Go to 011 702 Sorter Open RAP Go to Flag 4 and check the wire for an open circuit If OK replace the Bin Drive Motor PL 19 4 Enter Stop DO Test from the Control Panel Enter code C5 Press the Item Enter button Place a piece of paper in Bin 1 Access the Digital Output DO test from the Control Panel Enter code D6 Press the Item Enter button The Display is 1 Go to Flag 2 and check the harness for an short circuit If the harness is OK replace Y N the Bin Home Switch PL 19 4 If the problem persists replace the Sorter Control There is 45 VDC between J 10 4 of the Sorter Control PWB and GND PWB PL 19 1 Y N Go to Flag 5 Check for a
449. or OHP Sensor 11 Gear P O PL 4 6 Item 1 PL 4 6 Item 8 0004006A WOL Parts List 10 00 Initial Issue PL 4 6 5 20 Phaser 790 DocuColor 2006 PL 4 7 Bypass Tray Paper Transport 7 of 7 Item Part Description 19 412 13 1 Gear W 20 P O PL 4 6 Item 1 2 Registration Frame P O PL 4 6 Item 1 3 059014400 Preregistration Roll REP 8 16 4 Gear P O PL 4 6 Item 1 5 121K23430 Registration Clutch REP 8 17 6 Bearing P O PL 4 6 Item 1 E 7 059K14380 Registration Rubber Roll REP 8 18 KL 8 Registration Metal Roll 1 9 Gear P O PL 4 6 1 10 Bearing P O PL 4 6 Item 1 16 11 Bearing P O PL 4 6 1 12 Front Spring P O PL 4 6 Item 1 PL 4 7 19 13 Rear Spring P O PL 4 6 Item 1 PL 4 7 19 14 054E15200 Upper Registration Chute 15 054E15670 Lower Registration Chute 16 Gear 16 P O PL 4 6 Item 1 17 Gear 24 P O PL 4 6 Item 1 18 Gear 26 P O PL 4 6 Item 1 19 600068610 Registration Spring Kit 0004007A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 21 PL 4 7 PL 5 1 Xerographics Item Part Description 2 43 4 1 062009721 ROS 9 3 2 ROS Cover Assembly Not Spared 3 ROS Not Spared 10 1 11 13 4 Saddle Bushing Not Spared f 5 113K81450 Customer Replaceable Unit Module 18 4 8 9 14 17 CRUM Connector 2 6 026K80571 Receptacle 4 7 7 Bias Charge Roll Connector Not Item 10 Spared 8 Rail C
450. or the correct order of removal and replacement for warnings cau tions and notes Adjustments Adjustments include procedures for adjusting the parts that must be within specification for the correct operation of the system Use the adjustment procedures for the correct sequence of operation for specifications warn ings cautions and notes Section 5 Parts Lists This section contains the Printer Copier Parts List Section 6 General Procedures Information This section contains General Procedures Diagnostic Programs and Copier Information Section 7 Wiring Data This section contains drawings lists of plug jack locations and diagrams of the power distribu tion wire networks in the machine Individual wire networks are shown in the Circuit Diagrams contained in Section 2 This section also contains the Block Schematic Diagrams How to Use this Documentation The Service Call Procedures in Section 1 describe the sequence of activities used during the Service call The call must be entered using these procedures Use of the Circuit Diagrams Circuit Diagrams CDs are included in Sections 2 Status Indicator RAPs and 3 Image Qual ity RAPs of the Service Manual All wirenets with the exception of power distribution wirenets are shown on the CDs Power distribution wirenets are shown in Section 7 Wiring Data of the Service Manual The power distribution wirenets on the CDs will end at the terminal board for the power bein
451. ormation GP 19 GP 20 Setting IIT Parameters GP 21 Component Control IIT The purpose is to set up and display the parameters stored in the NVM of the IIT The purpose is to display the logic state of input signals and to energize output components Procedure Procedure 1 Enter the Diagnostic Mode IIT GP 19 1 Enter the Diagnostic Mode IIT 19 2 Highlight Systemdata R W then press the Select button 2 Navigate to Diag Code and press the Select button 3 Enter the Chain number press the Down Arrow button then enter the Link number 3 The following table lists the component control codes 4 Press the Item Enter button to confirm the present values 5 Change the parameter values as required Refer to Table 1 and Table 2 Code 8 Sub Component Signal BSD Ref 6 Tochange the values Code a Press the Down Arrow button 330 001 Exposure Lamp Exposure Lamp 1 5 6 4 b Press the C button 330 001 Fan 1 Fan 1 On 24 VDC 6 4 c Enter the new value using the number buttons 330 001 2 2 24 6 4 d Press the Start button 330 100 Fan 1 Fan Fail 6 4 e Press the Select button to verify that the value has changed 330 001 APS Sensor APS Sensor On H 5 VDC 6 5 NOTE To enter a letter hexadecimal value press the asterisk key prior to entering Angie Sensor Angie Sensor Sensed Lyy5 VDC 52 ea
452. ort circuit to ground If the wire is OK replace the MCU PWB PL 11 2 Replace the BTR 2 Cam Sensor PL 7 4 Rotate the cam so that the BTR 2 Cam Sensor is blocked Reenter code 76 The dis play is 0 Y N Disconnect P J 100 There is 5 VDC from pin 1 to pin 3 on J 100 Y N Go to Flag 2 Check for an open circuit If the wires are OK replace the MCU PWB PL 11 2 Replace the BTR 2 Cam Sensor PL 7 4 The circuit appears to be operating correctly Go to Figure 1 Check for loose connections dirty sensor or damage to the gears cam or sensor actuator Clean repair or replace as required PL 7 4 Disconnect P J 64 The BTR 2 Cam Clutch deenergized 11 2 Status Indicator RAPs 10 00 009 358 2 150 Initial Issue Phaser 790 DocuColor 2006 MCU PWB BTR 2 CAM 2 DO 70 CLUTCH icu E 2 20 77 se HAMON lem 244 2 BLU DC COM BTR 2 CAM 23 12 Ly SENSOR 5VDC BLU PL74 0176 PES BTR2CAM HOME 2 INTLK 2 100 L 5VDC 8 09 358 i 1 i _9 VO GRY L GRY 1 5VDC 2 DC COM PIRE SAM SENSOR BTR 2 CAM CLUTCH P10 P19 22 18 P17 P15 MCU PWB P20 P12 11 21 T 709007 A WOL Figure
453. ory programming or whether mandatory modifications have been installed Each tag number is given a classification code to identify the type of change that the tag has made The classification codes and their descriptions are listed in the table below Table 1 Classification Code Description M Mandatory Tag N Tag not installed in the field R Repair Tag Initial Issue 10 00 General Procedures and Information Phaser 790 DocuColor 2006 6 31 Change Tag Introduction Processor P Tags Scanner Tags NOTE At the time of publication no Change Tags had been issued to this subsystem NOTE At the time of publication no Change Tags had been issued to this subsystem General Procedures and Information 10 00 Initial Issue 6 32 Phaser 790 DocuColor 2006 Sorter Tags ADF Tags NOTE At the time of publication no Change Tags had been issued to this subsystem NOTE At the time of publication no Change Tags had been issued to this subsystem Initial Issue 10 00 General Procedures and Information Phaser 790 DocuColor 2006 6 33 General Procedures and Information 10 00 Initial Issue 6 34 Phaser 790 DocuColor 2006 7 Wiring Data Plug Jack Location 858 6 6 C M 7 67 Pl g dack LOGations iie e diet oe teta eee 7 3 7 68 7 69 Wirenets 7 70 eee ede eh eei te oe e ie dede
454. ove the Clutch Screws 0101029A WOL Figure 1 Removing the Developer Clutch Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 21 REP 4 9 REP 4 10 Repairs and Adjustments 10 00 Initial Issue REP 4 9 REP 4 10 4 22 Phaser 790 DocuColor 2006 REP 5 1 ADF Assembly Parts List on PL 17 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Disconnect the ADF connector at the rear of the scanner WARNING The ADF Assembly weighs about 11kg Assistance may be required to move or remove the ADF Attempting to move the ADF without assistance could result in serious injury CAUTION Handle the ADF by the front and rear sides Handling the assembly by the left and right sides will cause the ADF frame to be deformed CAUTION After the ADF is removed orient the unit on a work surface so the ADF weight is not applied directly to the counter balances Otherwise the ADF frame could be deformed 3 Remove the ADF Assembly Figure 1 Slotted Hole 2 0 Remove the two Thumb Screws aS 2 See CAUTION Remove the ADF by moving it towards the rear of the machine until the slotted holes allow the ADF to be lifted straight up off the retaining pins 0105001A WOL Figure 1 Removing the ADF Replacement 1 Perform th
455. ower Cord Remove the Top Cover Assembly REP 14 4 Remove the Xerographics Cartridge REP 9 1 Remove the Left Inner Cover Assembly REP 14 5 Remove the Left Front Cover Interlock Figure 1 Replacement Qv oi I CAUTION Ensure that the harness is correctly routed when Installing the Left Front Cover Interlock 1 Reinstall the Left Front Cover Interlock the reverse order of removal 1 Disconnect the connectors at the interlock Brown is on top 3 Remove the Left Front Cover Interlock 2 Remove the screw 0101006A WOL Figure 1 Removing the Left Front Cover Interlock Repairs and Adjustments REP 1 6 REP 1 7 10 00 Initial Issue Phaser 790 DocuColor 2006 REP 1 8 Environment Sensor Parts List on PL 11 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Bypass Tray Registration Assembly REP 8 10 CAUTION Be careful not to touch the IBT Belt surface while removing the Environment Sensor 3 Remove the Environment Sensor Figure 1 Replacement NOTE The screw that secures the Environment Sensor also secures the ground wire 1 Reinstall the Environment Sensor in the reverse order of removal 2 1 Compress the standoffs Disconnect the connector 3 Remove the Environment
456. place the MCU PWB PL 11 2 Remove the Developer Housing PL 6 2 for the affected color Check for damage to the drive gears debris or clogs Ensure that the bias contact is free from damage or contamination Clean repair or replace as required Y Go to Flag 2 Check for an open circuit If the wire is OK replace the MCU PWB PL 11 2 Status Indicator RAPs 10 00 Initial Issue 009 701 2 158 Phaser 790 DocuColor 2006 CU PWB B PL11 2 7 DEVELOPER A T e e 5 Ud Lb lt CLUTCH NT gt DEVELOPER PE n JE font CLUTCH ON m 22 J18 1 24VDC 456 2 256 os sa Xp GRY BLU 74 Aha 21 x 2 1 GRY BLU 24VDC 1 3 DISPENSE DO 56 CLUTCH ADC SENSOR ASSY 77 I 4 Do Ser PL10 1 PL5 1 i ADC ADC 204 L J55 4 2 255 PWB SENSOR E 27 GRY 1 27 1 1 1 d 2 1 d 2 19 GRY BLU 24VDC 227 INTLK 5 1 ADC DO 0D HVPS SENSED DEVELOPER PL11 1 P81 5 J81 VOLTAGE J16 5 gt AC BIAS ON YEL GRY 11216 D 24VDC J42 4 Ac BIAS r GRY CONTROL ADCOM 1 i 1 1 7 DEVELOPER AC BIAS E CONTROL Y TM 1 I FAULT MESSAGE DISPLAYED 27 GRY REPLACE CYMK INK CARTRI
457. ponent Signal BSD Ref B6 Feed Out Sensor Tray 3 Paper Feed Out Sensed 1 5 VDC 8 4 1B Feed Solenoid Feed Solenoid On 1 24 VDC 8 1 Feeder Right Cover Feeder Right Cover Interlock 1 Closed 1 4 1C Turn Clutch Turn Clutch On L 24 VDC 8 1 Interlock 1 L 5 VDC 1E Registration Clutch Registration Clutch On L 24 87 C1 Feeder Right Cover Feeder Right Cover Interlock 2 Closed 1 4 Preregistration Clutch Preregistration Clutch On L 24 VDC 8 7 Interlock 2 L 5 VDC 20 Bypass Tray Feed Feed Clutch On L 24 VDC 8 2 C2 24 VDC to Optional Not used Clutch Feeder 21 Developer Clutch Developer Clutch L 24 VDC 94 C3 Feeder Motor Feeder Motor Fail H 5 VDC 8 5 25 PWB Not used E DO Sorter Full Sensor Paper Sensed L 5 VDC 11 3 23 Lift Motor Bypass Signal 72 D1 Sorter Path Sensor Paper Sensed 1 5 VDC 11 3 2D Lift Motor Bypass Signal 0 72 D2 Sorter Top Cover Inter Sorter Top Cover Interlock Closed H 11 1 2E Lift Motor Bypass Signal 1 72 MCU PWB Not used m D3 Bin Home Switch Bin Home Switch Closed L 5 VDC 11 4 36 MCU PWB Norused 04 Bin Cam Switch Bin Cam Switch Closed 1 5 VDC 11 4 PWB 05 Docking Interlock Docking Interlock Closed L 5 11 1 44 ROS D6 Receiver Sensor Paper In Bin Sensed H 5 VDC 11 3 46 MCU PWB Not used NOTE In the digital output test mode each component is actuated using the DO TEST ae Heat Roll Heat Lamp
458. position Ensure that the actuator for the Left Front Cover Interlock is not broken Procedure Switch off the power Remove the Rear Cover Switch on the power 24 is measured between J32 5 on the Low Voltage Power Supply and machine frame Y N 45 0 VDC is measured between J32 18 and machine frame Y Approximately 4 4 VDC is measured between J32 16 and machine frame Y N Go to Flag 6 Check the wire for an open circuit If the wire is good replace the MCU PWB PL 11 2 Replace the Low Voltage Power Supply PL 11 1 5 0 VDC is measured between J33 9 on the Low Voltage Power Supply and machine frame Y 5 0 VDC is measured between J199 1 brown wire on the Left Front Cover Interlock and machine frame N Go to Flag 5 Check the wire for an open circuit 45 0 VDC is measured between J198 1 yellow wire on the Left Front Cover Interlock and machine frame Replace the Left Front Cover Interlock PL 11 1 Check the following Go to Flag 2 Flag 3 and Flag 4 Check the wires for an open circuit If the wires are good check the connectors between the Low Voltage Power Supply and the Left Front Cover Interlock for bent or broken pins or for dam aged connectors P J70 P J71 P J97 and P J91 Replace the Low Voltage Power Supply PL 11 1 The Low Voltage Power Supply appears to be operating correctly Initial Issue Phaser 790 DocuColor 2006 10 00 2 9 Sta
459. ptional Tray Assemblies PL 4 7 Bypass Paper Transport 7 5 21 Bid T OHP Transparency Tray Assembly 5 52 Xerographics PL 14 2 Transparency Tray Assembly 2 of 2 5 53 PL 5 1 Xerographics renda e ted ipea a o ed 5 22 PL 14 3 Oversize Tray nnne ter nine eene nre e ferente eer d ferien 5 54 Development Options PL 6 1 Development 1 of 2 5 23 PL 15 1 Duplex Assembly 107 5 55 PL 6 2 Development 2 of 2 5 24 PL 15 2 Duplex Assembly 207 5 56 PL 15 3 Duplex Assembly of 7 5 57 IBT Intermediate Image Belt PL 15 4 Duplex Assembly 4 of 7 5 58 NEAN 5 25 15 5 Duplex Assembly 5 017 5 59 PL 7 2 2085 5 26 15 6 Duplex Assembly 6067 5 60 PL 7 3 IBT 3 45 9 27 15 7 Duplex Assembly 707 5 61 P ZCOPIBISGLOPb enc re M LE DE 5 28 IS6 PS T uu aseo Heo ed as ee tec tata b d be a at eds 5 29 PL 16 1 Platen Glass and IIT 5 62 Fusing PL 16 2 PWB 5 63 PI 8 1 Busing ei 5 30 CIE cs rnm E 5 64 PL 8 2 Fusing 207 5 31 PL 16 4 Carriage Motor and Carriage Cable 5 65 PL 8 3 Fusing 3 017 a 5 32 PL 16 5 Full Rate Carriage and Half Rate Carriage
460. r 2006 REP 14 9 Right Cover Parts List on PL 1 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Open the Front Cover Assembly 3 Remove the Right Cover Figure 1 Replacement 1 Align the hooks of the Right Cover with the holes on the back of the printer 2 Reinstall the Right Cover in the reverse order of removal 2 Move the cover towards the rear and remove the Right Cover 1 Remove the three screws 0140005A WOL Figure 1 Removing the Right Cover REP 14 10 Control Panel Parts List on PL 1 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Top Cover Assembly together with the Control Panel REP 14 4 CAUTION Be careful not to damage the hooks of the Control Panel during the removal 3 Remove the Control Panel Figure 1 Replacement 1 Reinstall the Control Panel in the reverse order of removal 2 Remove the Control Panel 1 Compress the hooks to disengage the Control Panel 0140006A WOL Figure 1 Removing the Control Panel Initial Issue Phaser 790 DocuColor 2006 10 00 4 145 Repairs and Adjustments REP 14
461. r Down Arrow button to toggle the display between METER CLEAR 1 Enter the Diagnostic Mode GP 1 and METER CLEAR YES 2 Press the Menu button until INITIALIZING DATA is displayed 5 Select the appropriate response then press the Item Enter button The display will 3 Press the Item Enter button change to METER COPY NO 4 OTNVM CLEAR NO willbe displayed 6 The Up or Down Arrow button toggles the display between METER COPY NO and 5 Use the up or down arrow buttons to change from NO to YES METER COPY YES Sleet the appropriate response 6 Press the Enter button If METER COPY NO is selected the display will default to the following 7 IOT SLAVE CLEAR NO will be displayed a SHOW IN USR MODE NO 8 Use the up or down arrow buttons to change from NO to YES b SHOW IN USR MODE MODE2 9 Press the Item Enter button c SHOW IN USR MODE MODF1 NOTE The asterisk in selection a represents meter counts currently shown METER COPY YES is selected the display will read METER COPY M TOS M refers to master memory and S refers to slave memory Press the Up or Down Arrow button to toggle the display between METER COPY M TO S and METER COPY S TO M NOTE Selecting METER COPY M TO S takes the master values from the machine and writes to the slave memory Selecting METER COPY S TO M takes the slave memory val ues and writes them to the machine master memory 7 Select the appropriate meter mode 8 Press the
462. r Motor Figure 6 7 cooler PWB 919 18 48 Drive Motor PWB Figure 6 8 ESS PW 919 3 49 Drive Motor PWB Figure 6 8 Sorter Controller PWB e 18 50 Drive Motor PWB Figure 6 ntroller i 51 Process Drive Assembly Figure 6 9 Sorter Controller PWB Figure 18 10 MCU PWB 52 Process Drive Assembly Figure 6 igu H 55 Dispense Clutch Assembly Figure 6 10 Sorter Controller PWB Figure 18 10 Sorter Intermediate Gonnector 56 Developer Clutch Assembly Figure 7 1 4 ESS EWE 3 57 TRO Sensor Figure 5 igu 12 ESS PWB 9 E3 58 Rotary Sensor Figure 7 1 15 MCU PWB 5 62 Cleaner Cam Solenoid Figure 8 1 14 ESS PWB 915 3 63 Intermediate Connector Figure 7 oO WE 91 5 64 BTR 2 Cam Clutch Figure 7 ESSPWE 919 66 Communication PWB Figure 2 15 MCU PWB 915 5 70 Intermediate Connector Figure 7 16 ESS PWB 915 3 J71 Intermediate Connector Figure 8 16 MCU PWB 91 5 P71 Intermediate Connector Figure 7 17 ESS PWB 915 3 72 Intermediate Connector Figure 8 17 MCU PWB 915 5 74 Exchange Solenoid Figure 8 1 18 ESS PWB e 3 75 Lower Inverter Solenoid Figure 8 Figure 9 18 MCU PWB 915 5 76 Intermediate Connector Figure 8 19 MCU PWB 5 78 Intermediate Connector Figure 8 1 20 ESS PWB e 3 79 Fuser Harness Intermediate Connector Figure 8 1 20 MCU PWB 915 5 80 Fuser Chute Fan Figure 8 51 ESS PWB 915 3 81 ADC Sensor Assembly Figure 1 1 82 Developer Fan Figure 6 Initial
463. r PWB REP 8 21 10 Bracket Not Spared 11 Shaft Not Spared 12 Bracket Not Spared 13 162K54090 Feeder Harness 14 162K54120 Size Harness 15 130E81970 Low Paper Sensor REP 8 22 16 162K54140 Upper Feeder Harness 17 162K54150 Lower Feeder Harness E 18 Lift Clutch P O PL 13 4 1 EXPLODED ON PL13 2 0013004A WOL Parts List 10 00 Initial Issue PL 13 4 5 46 Phaser 790 DocuColor 2006 PL 13 5 Optional Feeder Assembly 5 of 9 2 22 and Item Part Description PL13 6 PL13 7 1 059K15182 Paper Feeder Assembly REP 8 23 2 Sheet Clamp P O PL 13 5 1 3 Upper Feeder Frame P O PL 13 5 Item 1 4 Rear Frame PL 13 5 Item 1 5 Support PL 13 5 Item 1 6 059K14300 _ Roll 7 No Paper Sensor Actuator P O PL 13 5 Item 1 8 Rear Upper Chute P O PL 13 5 Item 1 9 Front Upper Chute P O PL 13 5 Item 1 10 Spacer P O PL 13 5 Item 1 11 Nudger Sensor P O PL 13 5 Item 1 12 059K17250 Feed Roll 13 130E82650 Feed Out Sensor 14 Spring P O PL 13 5 Item 1 15 Bearing P O PL 13 5 Item 1 16 Bearing P O PL 13 5 Item 1 17 Bushing P O PL 13 5 Item 1 18 lt Clamp P O PL 13 5 Item 1 H 19 2 Clamp P O PL 13 5 Item 1 20 Harness P O PL 13 5 Item 1 21 130E81600 No Paper Sensor 22 Front Frame P O PL 13 5 Item 1 10 TO PL13 6 TO PL13 6 TO PL13 7 0013005A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 47 PL 13 5 PL 13 6 Optional Feeder
464. r of the DCD Check the Developer spacing ADJ 9 1 for the affected color If the check is OK replace the Developer Housing PL 6 2 and Dry Ink Car tridge for the affected color Image Quality 109 10 00 3 14 Phaser 790 DocuColor 2006 Initial Issue ERASE LAMP ASSY MCU PWB PL11 2 PL5 1 EMA es ON J17 J86 S 25r H SVDC 12 dn i 1 1 1 264 11 21 GRY DC COM 10 P16 P19 15 MCU PWB P12 P11 P22 P18 P17 P20 P23 P21 Figure 1 199 RAP Circuit Diagram ERASE LAMP T 730001 A WOL Initial Issue Phaser 790 DocuColor 2006 10 00 3 15 Image Quality 109 IQ10 Color to Color Misregistration RAP Procedure The problem is misregistration in the process direction Y N Remove the Copy Print Cartridge Move the Tension Lever to the locked position Check that there is adequate tension on the IBT Belt to prevent inboard to outboard movement of the belt The IBT Belt is secure Y N Repair or replace the IBT Assembly as required PL 7 2 Check that the ROS is securely mounted and that the ROS window is not dirty or dam aged If the problem persists replace the ROS PL 5 1 The problem involves a single color Y Check that the following components are securely mounted Rotary Sensor PL 6 1 TRO
465. re 50 F 10 C to 95 F 35 Relative Humidity 15 TO 85 No condensation Altitude 0 10 000 ft 3100 m Levelness Maximum level difference 5 mm or less front to back Maximum level difference 10 mm or less right to left Warm up Time 100V 8 minutes 45 seconds or less 20 C 68 F 60 110V 8 minutes 45 seconds or less 20 C 68 F 60 220V 8 minutes 30 seconds or less 20 C 68 F 60 Paper Supply Specifications Copy Paper Weight Capability Tray 1 16 lb 64 gsm through 28 Ib 105 gsm Trays 2 3 16 Ib 64 gsm through 32 Ib 134 gsm Bypass Tray 16 10 64 gsm through 60 250 gsm Paper Tray Capacity 20 Ib 80 gsm Tray1 250 sheets Trays 2 3 500 sheets Bypass Tray 150 sheets Paper Cassette Type Paper sizes and orientation loadable in each tray are as follows Table 6 Recognized Paper Sizes NASG ESG 8x10 LEF A4 LEF A4 LEF 215x279 LEF 8 5x11 LEF A3 SEF A3 SEF 215x279 SEF 8 5x11 SEF B4 ISO SEF 9x12 SEF 215x315 SEF 8 5x13 SEF 215x330 SEF 8 5x14 SEF 215x356 SEF A4 SEF A4 SEF 11x17 SEF 279x432 SEF Table 7 Recommended Paper Mode NASG Market ESG Market For B W 4024DP 20 80 gsm Premier 3R91720 3R91721 For Color Color Xpressions Colortech Plus 93 24 bond 90 gsm 3R5464 3R94641 A4 3R5465 3R94642 A3 Printer Speed There are three speed modes that
466. rea Procedure Ensure that there are no bits of paper or other obstructions on the Duplex Entrance Sensor PL 15 3 Enter the diagnostic mode and enter DI 91 The display indicates 1 Y N Go to Flag 4 Check the wire for a short circuit to ground If the wire is good replace the Duplex Entrance Sensor PL 15 3 If the problem continues replace the Duplex Control ler PWB PL 15 6 Insert a piece of paper over the Duplex Entrance Sensor Close the Duplex Tray Enter the diagnostic code DI 91 The display indicates a 0 Y N Go to Flag 1 Check the wires for a short circuit to ground If the wires are good replace the Duplex Entrance Sensor PL 15 3 If the problem continues replace the Duplex Con troller PWB PL 15 6 Ensure that there are not bits of paper or other obstructions on the Registration Sensor PL 4 6 Enter the diagnostic mode and enter DI 29 The display indicates a 1 Y N Go to Flag 5 Check the wire for a short circuit to ground If the wire is good replace the Registration Sensor PL 4 6 If the problem continues replace the MCU PWB PL 11 2 Insert a piece of paper over the Registration Sensor Close the Bypass Tray Paper Transport Enter the diagnostic code DI 29 The display indicates a 0 Y N Go to Flag 2 Check the wires for a short circuit to ground If the wires are good replace the Registration Sensor PL 4 6 If the problem continues replace the MCU PWB PL
467. rection indicated 0105005A WOL Figure 2 Removing the Feed Roll Remove the Lower Chute by moving the chute in the direction indicated 0105004A WOL Figure 1 Removing the Lower Chute Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 25 REP 5 4 Replacement 1 Perform the procedure for removal in reverse During replacement pay close attention to the following step 2 The One Way Clutch is attached to the Gear Install the Gear so that the shaft rotates freely in counterclockwise CCW direction and it is locked in the clockwise CW direc tion Figure 3 Rotates freely in this direction Locked in this direction 0105006A Figure 3 One Way Clutch Rotation REP 5 5 Nudger Roll Parts List on PL 17 3 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the ADF Front Cover 3 Remove the ADF Rear Cover 4 Reduce the tension of Nudger Feed Roll Drive Belt Figure 1 1 Use a scribe to mark the motor position then remove the three screws o the Drive Motor Loosen the screw holding the Belt Tension Idler Roll raise the Idler Roll and tighten the screw Move the Drive Motor in the direction indicated Loosen two screws and reduce the belt tension 0105007A WOL Figure 1 Reducing Dri
468. red between J11 pins A2 B1 and B2 on the ESS PWB to machine frame Y N Go to the 001 702 5 Power Reseat the Panel Harness between the ESS PWB and the Control Panel If the problem con tinues replace the following components in the order listed until the problem is resolved Panel Harness PL 12 1 Control Panel PL 1 2 ESS PWB PL 12 1 Initial Issue Phaser 790 DocuColor 2006 10 00 2 29 Status Indicator RAPs 002 310 002 701 ESS PWB CONTROL PL12 1 PANEL PANEL HARNESS PL1 2 J34 PL12 1 4817 15 15 i 1 19 16 16 2 20 D5 RED LED 17 17 434 D4 GREEN LED 18 18 PN AO Xx DS e 32 3 1 5 484 J33 4 PN_RW 4 28 420 J18 Ld PN EN 5 J17 PN DO ESS PWB i FXIO 1 LE PN 01 id PN D2 L 8 J16 J14 39 8 PN D3 9 T 5 10 PN D4 10 11 ERES 11 124 PN_D6 12 PN 07 13 13 KEYEN 14 5 VDC 5 VDC 5 VDC ij PA 5 VDC hag U19 DC Q 0 5 VDC DC COM 2 feoeo S DC COM 20 20 De
469. remaining components 3 Remove the ESS PWB from the plate D ad 2 4 GF 3 OA Remove the four upper Screws 15 EM oan the four JA screws 2 Remove the four lower screws 0101008A WOL Figure 1 Preparing to Remove the ESS PWB Remove the screw 0101011A WOL Figure 2 Removing the ESS PWB Repairs and Adjustments 10 00 Initial Issue REP 1 9 4 10 Phaser 790 DocuColor 2006 REP 1 10 ESS Fan Parts List on PL 12 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Top Cover Assembly REP 14 4 3 Remove the Right Cover REP 14 9 4 Remove the ESS Fan Figure 1 Replacement CAUTION Ensure that the wire harness is not pinched when installing the harness 1 Reinstall the ESS Fan in the reverse order of removal E 1 Remove the screws Disconnect the connector Remove the ESS Fan REP 1 11 Controller Chassis Parts List on PL 12 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine Switch off the machine power and disconnect the machine Power Cord Remove the Top Cover Assembly REP 14 4 Remove the Right Cover REP 14 9 Remove the ESS PWB RE
470. results a Select the left most circle that you can distinguish from background and draw a cir cle around it b Select the left most circle that you can distinguish from the background on the next row Black End and draw a circle around it If you cannot see any circle in the row write 9 next to the row d If you see all the circles in a row write 0 next to the row Repeat step 5 for each of the color rows drawing circles around your preferred selections or recording a 9 or 0 next to the row For the 30 Match row hold the sheet at arms length Select the circle that best matches the background and draw a circle around it BLACK START 4 is displayed on the Control Panel Press the Up and Down arrow but tons to enter the number that corresponds to the value that you selected on the first row a When the desired number is displayed press the Item Enter button BLACK END 4 is displayed b Press the Up and Down arrow buttons to enter the number that corresponds to the value that you selected on the next row Press the Item Enter button CYAN START 4 is displayed Repeat step 8 for each of the color rows and for the 3096 Match row NOTE If a 9 or 0 was entered for any row VISUALCAL will generate another Print Limits Page containing the adjustments from your previous selections Perform step 8 again until you are able to select circles within the desired 1 to 8 range When all the values are entered and accepted by V
471. rge ESD and extreme care should be used when handling these components Use of the ESD Field Service Kit is required NOTE Take note of the connector positioning prior to disconnecting all connectors This will simplify reinstallation later 3 Remove the Sorter Control PWB Figure 1 2 Release the PWB from the standoffs and remove the assembly ay See NOTE Disconnect the connectors 9 0 111003A WOL Figure 1 Removing the Sorter Control PWB Replacement 1 Perform the procedure for removal in reverse Repairs and Adjustments 10 00 REP 11 3 4 130 Initial Issue Phaser 790 DocuColor 2006 REP 11 4 Sorter Transport Motor 5 Parts List on PL 19 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord Remove the Sorter Transport Motor Figure 2 2 Remove the Rear Cover 3 Remove the Front Cover 4 Disconnect the motor connector from the PWB and release the wires Figure 1 1 Pinch the Motor Support to release it from the Sorter and remove the support and motor 0 1110044 WOL Figure 2 Removing the Sorter Transport Motor Replacement 1 Perform the procedure for removal in reverse 2 Make sure the Support is properly positioned to the Motor Figure 3 Tab positioned
472. ridge replacement Condi xd Nr tion checked at power 6 ea to the following list for the offsets in mm of the setting from the default in the sequence Cartridge life warn 2969 ing at 9080 and life end at 10K Table 2 2 Dry Ink Cartridge Cumulative Dispense Time Automatically reset with new M 100 msec cartridge replacement Condi ei E 28 27 126 25 24 23 122 21 20 19 18 17 16 15 tion checked at power on mere sequence Cartridge life warn Offset 1 10 0 9 5 9 0 8 5 8 0 7 5 7 0 6 5 6 0 45 5 145 0 44 5 44 0 43 5 ing at 9080 and life end at 10K Dry Ink Cartridge C Cumulative Dispense Time Automatically reset with new Value 14 13 12 11 10 09 08 07 06 05 04 03 02 01 100 msec cartridge replacement Condi Entered tion checked at power on Offset 3 0 2 5 42 0 1 5 1 0 0 5 0 0 5 1 0 1 5 2 0 2 5 3 0 3 5 sequence Cartridge life warn mm ing at 9080 and life end at 10K Value 100 255 254 253 252 251 250 249 248 247 246 245 244 4 Dry Ink Cartridge K Cumulative Dispense Time Automatically reset with new Entered 1 2 3 4 5 166 7 8 9 10 11 12 100 msec cartridge replacement Condi Offset 4 0 4 5 5 0 5 5 6 0 6 5 7 0 7 5 8 0 8 5 9 0 1 9 5 10 0 tion checked at power on mm sequence Cartridge life warn ing at 9080 and life end at 10K 7 To view the current values of the counters press the Item Enter button
473. ring servicing the machine is a Class 3B product because of the invisible laser the laser beam could cause eye damage if looked at directly Service procedures must be followed exactly as written without change The service representa tive must observe the established local laser safety precautions when servicing the machine Do not place tools with a reflective surface in the area of the Charge Corotron or the ROS opening Do not look in the area of the ROS window if the power is On and the laser is energized The following symbol and statement appear on a label in the machine The symbol by itself or the symbol and the statement may also appear in the service documentation and in the training program When this symbol appears the service representative is warned that conditions exist that could result in exposure to the laser beam WARNING Do not try to bypass any laser interlocks for any reason Permanent eye damage could result if the laser is accidentally directed into your eye Figure 1 Laser Hazard Symbol Laser Hazard Statement DANGER INVISIBLE LASER RADIATION WHEN OPEN AVOID DIRECT EXPOSURE TO BEAM CAUTION The use of controls or adjustments other than those specified in the Laser Safety Training Pro gram may result in an exposure to dangerous laser radiation For additional information review the Laser Safety Training program An arrow points to the location to install to gain access to or to release an object
474. rtation 1 of 2 Wiring Data 10 00 Initial Issue 7 98 Phaser 790 DocuColor 2006 BSD 10 4 10 4 EXIT TRANSPORTATION 2 OF 2 MCU PWB i PL11 2 s 01 25 SHEET AT EXIT SENSOR lt E FUSER EXIT SENSOR PL8 2 L 5VDC MGU PWB 1 3721 5 13472 I J71 pn PL11 2 REAR FUSER i DI 4B 5VDC EXIT SHEET AT REAR SENSOR FUSER EXIT SENSOR PL8 2 P 8 i L 5VDC 16 19 71 pg 65 71 J72 4 72 J721 3 GRY GRY GRY GRY 1 2 VIO i 1 i 23 DC COM 17 2 cry 85 B6 GRY T710709A WOL_ Figure 1 Exit Transportation 2 of 2 Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 99 BSD 10 5 A B D E F G H J 10 5 INVERT AND DUPLEX TRANSPORT 1 OF 2 DO 19 MCU PWB INVERTER 1 SOLENOID PL11 2 SOLENOID T ius J19 P SH L 24VDC P7 aig ay 571 475 3 P75 1 GRY E GRY 24VDC lt i INTERLOCKED 129 GRY LAS Ags GRY DUP CONTROL
475. rter than lines and are of nonuniform width along their length They may have a more ragged or fuzzy appearance than lines Residual Image A toner image that remains on the photoreceptor or IBT after cleaning The next image is placed on top of the residual image and to the 107 RAP both images are transferred to the next copy Unfused prints Image can be rubbed off with little or no pressure Go to the IQ15 RAP Image Quality 10 00 Initial Issue 01 3 4 Phaser 790 DocuColor 2006 IQ2 IIT Image Quality Entry RAP Initial Actions This RAP is for troubleshooting IIT Scanner ADF problems only Before proceeding verify Clean the Lens the top and bottom surface of the Platen Glass and Mirrors with Lens and that the defect is present in Copy mode only If the defect is present in Print mode go to the Mirror Cleaner and a soft lint free cloth IQ1 RAP Procedure Compare the defective copies with the descriptions listed in Table 1 Perform the corrective action listed for that defect Table 1 Defect Corrective Action Background Clean the Platen Belt Perform the Auto shading adjustment ADJ 6 6 Perform the B adjustment ADJ 6 7 Blurred or Streaked Copy Ensure that the Platen Glass is installed correctly Check adjust the carriage alignment ADJ 6 2 R E error Check adjust IIT magnification ADJ 6 1 Deletions Clean the Lens the top and bottom surface of the Platen Glass and all Mirrors with Lens and Mirror Clea
476. rts List on PL 1 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Open the Tray 1 Assembly 3 Remove the Front Lower Cover Figure 1 2 Remove the Front Lower Cover Replacement 1 Insert the four hooks in the places provided on the frame Figure 2 2 Reinstall the Front Lower Cover in the reverse order of removal 1 Insert the hooks into the frame 0140011A WOL Figure 2 Inserting the Hooks 1 gt Remove the two lt screws 0140010 WOL Figure 1 Removing the Front Lower Cover Repairs and Adjustments 10 00 Initial Issue REP 14 3 4 140 Phaser 790 DocuColor 2006 REP 14 4 Top Cover Assembly Parts List on PL 1 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord CAUTION Do not perform step 3 in the art if the machine is not equipped with a full stack detection func tion The Top Cover Assembly and printer are connected by a harness Be careful not to pull too far apart when performing the following 2 Remove the Top Cover Assembly Figure 1 Replacement 1 Reinstall the Top Cover Assembly in the reverse order of removal 2
477. s 1 Disconnect the connector Unhook the sensor from the Bottom Plate and remove the Front Fuser Exit Sensor REP 10 9 Rear Fuser Exit Sensor Parts List on PL 8 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine Switch off the machine power and disconnect the machine Power Cord Remove the Main Fuser Assembly REP 10 2 Remove the Upper Guide Assembly REP 10 3 Remove the Lower Guide Assembly REP 10 7 Remove the Rear Fuser Exit Sensor Figure 1 Replacement 1 Reinstall the Rear Fuser Exit Sensor in the reverse order of removal oRONM 1 Disconnect the connector Unhook the sensor from the Bottom Plate and remove the Rear Fuser Exit Sensor 0110007 A WOL 0110008A WOL Figure 1 Removing the Front Fuser Exit Sensor Figure 1 Removing the Rear Fuser Exit Sensor Repairs and Adjustments 10 00 Initial Issue REP 10 8 REP 10 9 4 118 Phaser 790 DocuColor 2006 REP 10 10 Heat Roll Parts List on PL 8 3 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord Remove the Main Fuser Assembly REP 10 2 Remove the Upper Guide Assembly REP 10 3 Remove the Upper Plate REP 10 4 Remove the Heat Roll Heat Lamp REP 10 5 CAUTION
478. s Phaser 790 DocuColor 2006 4 115 REP 10 4 REP 10 5 Heat Roll Heat Lamp Parts List on PL 8 3 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Main Fuser Assembly REP 10 2 3 Remove the Upper Guide Assembly REP 10 3 4 Remove the Upper Plate REP 10 4 CAUTION Be careful not to touch the surface of the Heat Roll Heat Lamp while removing the lamp Con tamination from hands can damage the lamp The connector for the Heat Roll Heat Lamp is tightly connected Be careful not to damage the lamp when disconnecting the connector The gear is no longer secured when the Fuser Rear Cover is removed Be careful not to allow the gear to fall out while removing the cover 5 Remove the Heat Roll Heat Lamp Figure 1 Replacement 1 Reinstall the Heat Roll Heat Lamp in the reverse order of removal 2 Check the Fuser Nip ADJ 10 1 3 1 Free the harness and Remove disconnect the con the screw then nector remove the handle 2 Remove the Fuser Front Remove the Heat Roll Heat Lamp from the rear Remove the Fuser Rear Cover 0110004 A WOL Figure 1 Removing the Heat Roll Heat Lamp Repairs and Adjustments 10 00 REP 10 5 4 116 Initial Issue Phaser 790 DocuColor 2006 REP 10 6 Pressure Roll Heat Lamp Par
479. s a SCSI DMA transmission failure Initial Actions Check the following Verify that the SCSI cable between the PC and the Scanner is installed correctly Verify that the terminator switch is in the correct position Switch the PC power off then on Verify that the problem still exists Procedure If the problem was not corrected in the Initial Actions of this RAP replace the SCSI PWB If the problem still exists replace the ICM Main PWB PL 16 2 Initial Issue 10 00 Phaser 790 DocuColor 2006 2 217 Status Indicator RAPs 033 940 941 943 944 945 Status Indicator RAPs 10 00 Initial Issue 033 940 941 943 944 945 2 218 Phaser 790 DocuColor 2006 3 Image Quality IQ1 IOT Image Quality Entry 3 3 IQ2 IIT Image Quality Entry 3 5 Low Image Density ertt eren ennt cet 3 6 IQ4 Highi Density RAP acetone eel a 3 7 105 Solid Black or other Color Sheet 3 7 106 Blank or Nearly Blank Sheet 3 8 107 Residual Image Ghosting 3 10 IQ8 IOT Background RAP wee 3 12 IQ9 Deletions u emere e pert HE E 3 14 1010 Color to Color Misregistration 3 16 1011 IOT Skew 3 16 1012 IIT Skew RAP 3 17 1913 Re cree ttes 3 17 1014 Process Direction Bands Streaks and Smears 3
480. s from the duct 0101003A WOL Figure 1 Removing the Developer Fan Repairs and Adjustments 10 00 Initial Issue REP 1 3 REP 1 4 Phaser 790 DocuColor 2006 REP 1 5 MCU PWB Parts List on PL 11 2 Removal Remove the four Screws WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine CAUTION Before replacing the MCU PWB record the machine values and then reload these values after replacement if required 3 If possible record the values stored in the machine history GP 3 and GP 11 Remove the Switch off the machine power and disconnect the machine Power Cord MCU PWB Remove the Top Cover Assembly REP 14 4 Remove the Right Cover REP 14 9 Remove the ESS PWB and Plate as a unit REP 1 9 figure 1 of the procedure only Remove the Controller Chassis REP 1 11 CAUTION Observe the ESD Procedures when removing the MCU PWB 7 Remove the MCU PWB Figure 1 Replacement 1 Disconnect the 12 connectors DOU Be Crime CAUTION 0101004A WOL For proper machine operation order and install new MCU PWB from distribution If a new MCU PWB from distribution is installed and the machine still does not function correctly you must remove the EPROM at location U2 from the original MCU PWB and install it on the new MCU PWB If a new MCU PWB is not available and you must use a PWB removed from another machine yo
481. s preferred Evaluate the Comparison Page and perform one of the following steps a If you are satisfied with your adjustments press the Item Enter button VISUALCAL is displayed The system saves your changes and after a few moments READY is displayed b If you are not satisfied with your adjustments press the Down arrow button and ensure that NO is displayed Press the Item Enter button APPLY CHANGES DEFAULT COLOR is displayed The system erases your adjustments returns to the color default settings and after a few moments READY is displayed Initial Issue Phaser 790 DocuColor 2006 10 00 General Procedures and Information GP 16 GP 17 Foreign Interface GP 18 Identifying Pin 1 on a Double Plug Refer to the 003 333 Foreign Interface RAP in Section 2 The purpose is to locate pin 1 on a double plug configuration Procedure 1 the plug as shown in Figure 1 AC 5 2 Figure 1 Identifying Pin 1 a Double Plug With the plug held as shown Pin 1 is located here 07400018 WOL General Procedures and Information 10 00 Initial Issue GP 17 GP 18 6 16 Phaser 790 DocuColor 2006 GP 19 Diagnostic Mode IIT Exiting the Diagnostic Mode Entering the Diagnostic Mode To exit from IIT diagnostics mode perform the following 1 Switch on the power to the Scanner Press and hold the 0 key for at least three seconds dark characters light
482. s the harness so it will not interfere with moving parts Initial Issue Phaser 790 DocuColor 2006 10 00 Repairs and Adjustments REP 7 1 REP 7 2 REP 7 3 No Paper Sensor Assembly REP 7 4 No Paper Sensor Parts List on PL 3 1 Parts List on PL 3 1 Removal Removal WARNING WARNING To avoid personal injury or shock do not perform repair activities with the power switch To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Tray 1 Assembly REP 7 6 2 Remove the Tray 1 Assembly REP 7 6 3 Remove the Front Mid Cover REP 14 2 or the Duplex Tray Assembly REP 8 27 3 Remove the Front Mid Cover REP 14 2 or the Duplex Tray Assembly REP 8 27 4 Remove the Sensor Bracket REP 7 2 4 Remove the Sensor Bracket REP 7 2 5 Remove the No Paper Sensor Assembly Figure 1 5 Remove the No Paper Sensor Assembly REP 7 3 6 Remove the No Paper Sensor Figure 1 ey P 22 lt gt T d Q 7 EP 2 Disconnect the 22 connector ZI Le 2 1 Unhook the No Paper l Sensor Assembly from the 1 Sensor Bracket and Release the remove the assembly locking tabs and remove the No Paper Sensor from the Sensor 0107011A WOL Bracket Figure 1 Removing t
483. sconnect the machine Power Cord Remove the Top Cover Assembly REP 14 4 Remove the Tension Lever REP 9 15 Remove the Copy Print Cartridge REP 9 1 Remove the IBT Assembly REP 9 16 Remove the Left Inner Cover Assembly and the IBT Inner Cover REP 14 5 CAUTION Be careful not to damage the surface of the IBT Belt or Magnetic Roll of the Developer Housing when removing the ADC Sensor 7 Remove the ADC Sensor Figure 1 Replacement 1 Securely mount the shaft of the ADC Sensor on the frame 2 Reinstall the ADC Sensor in the reverse order of removal Q Or gs o 4 Disengage the rear AD end of sensor from the frame 5 Remove the ADC Sensor 1 Disconnect the connector and disengage the harness from the clamps Remove the e ring Move the sensor toward the rear to disengage it from the frame 0090004A WOL Figure 1 Removing the ADC Sensor Repairs and Adjustments REP 9 4 10 00 Initial Issue 4 94 Phaser 790 DocuColor 2006 REP 9 5 Locating Rail Parts List on PL 5 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord Remove the Top Cover Assembly REP 14 4 Remove the Copy Print Cartridge REP 9 1 Remove the ROS REP 9 3 Prepare to remove the Locating Rail Figure 1 O
484. se components Use of the ESD Field Service Kit is required 4 Remove the IPS PWB Figure 1 1 Remove the screws 4 and the IPS PWB by mov ing it in the direction indi cated 0106008A WOL Figure 1 Removing the IPS PWB Replacement 1 Perform the procedure for removal in reverse Initial Issue Phaser 790 DocuColor 2006 Repairs and Adjustments 10 00 REP 6 12 REP 6 13 4 45 REP 6 14 ICM Main PWB Parts List on PL 16 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the PWB Box REP 6 11 3 Remove the PWB Box Cover REP 6 12 CAUTION The PWB components are highly susceptible to damage from electrostatic discharge ESD and extreme care should be used when handling these components Use of the ESD Field Service Kit is required CAUTION Be sure to record the current NVM values for IIT Lead Registration IIT Side Registration IIT Magnification and Auto Shading before replacing the ICM MAIN PWB After replacing the ICM MAIN PWB enter the previously recorded data back into the machine 4 Remove the ICM Main PWB Figure 1 2 Remove the screws 11 and the ICM Main PWB by moving it in the direction indicated Remove the connector screws 8 0106009A WOL Figure 1 Removing the ICM Main PWB Replacement 1
485. sembly REP 8 6 3 Remove the Main Paper Handling Frame Assembly Figure 1 ax 2 Remove the two screws from Zi E 227 Handling Frame Assembly Remove the screws from each end and Separate the Main Paper Handling Frame Assembly Disconnect the two connectors on the underside and one at the opposite end of the assembly 0108022A WOL Figure 1 Removing the Main Paper Handling Frame Assembly Replacement 1 Perform the procedure for removal in reverse Initial Issue Phaser 790 DocuColor 2006 10 00 Repairs and Adjustments 4 65 REP 8 8 REP 8 9 REP 8 10 Lift Plate Sensor Parts List on PL 4 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine Switch off the machine power and disconnect the machine Power Cord Remove the Bypass Tray Registration Assembly REP 8 6 Remove the Bypass Tray Feed Assembly REP 8 7 Remove the Tray Housing REP 8 8 Remove the Lift Frame Assembly REP 8 11 Remove the Lift Plate Sensor Figure 1 QU Or ds o Net 3 Disconnect the connector 4 Release the locking tabs and remove the Lift Plate Sensor Lift and remove the Bottom Plate Set the Lift Down Actuator to the up position and secure it 0108023A WOL Figure 1 Removing the Lift Plate Sensor Replacement 1 Perform the procedure for removal in rev
486. sh dry paper of the correct specification Procedure Check the following Check the Temperature Sensor PL 8 2 for contamination or incorrect mounting Clean repair or replace as required Check the Heat Roll and Pressure Roll PL 8 3 for damage toner offsetting or incorrect installation Clean repair or replace as required Check adjust the Fuser Nip ADJ 10 1 Image Quality 1014 1015 10 00 3 18 Initial Issue Phaser 790 DocuColor 2006 IQ16 Repeating Bands Streaks Spots and Smears RAP Procedure Measure the distance between the repeating defects Locate the distance on the table below Perform the indicated repair actions Table 1 Repeating Defects Repetition spacing Component s Repair Actions 4 mm High Frequency Band Check adjust the Developer Roll Spacing ADJ 9 1 ing Check for damage or contamination to gears on shafts of Rotary Motor Developer Clutch and Dispense Clutch PL 10 1 28 mm Developer Magnet Roll Check Developer roll bias for floating or shorting out Replace Developer Housing PL 6 2 if required 44 mm BCR Roll Replace the Copy Print Cartridge PL 5 1 59 mm BTR 1 Roll Check for intermittent bias contact to Copy Print Car tridge Replace the Copy Print Cartridge PL 5 1 88 mm BTR 2 Backup Roll Check the BTR 2 Assembly for damage or contamina tion Clean repair or replace as required PL 7 1 BTR 2 Roll Replace the IBT Assem
487. short circuit to ground The wire is good Y N The Bin Home Switch appears to be working normally Check the Bins for proper align Repair the wire ment If the problem continues replace the Sorter Control PWB PL 19 1 There is 5 VDC between J 5 1 of the Sorter Control PWB and GND Y N Remove the Front and Rear Covers from the Sorter Remove the two screws on the Bin Cam Go to Flag 6 Check for an open circuit or a short circuit to ground The wire Switch from under the Bin Cam Assembly so as to be able to actuate and deactuate the switch is good Measure the voltage between J 4 1 of the Sorter Control PWB and GND Actuate and Y N deactuate the switch The meter changes state from a Low 0 VDC to a High 5 VDC Repair the wire Y N The voltage remains Low 0 VDC Replace the Sensor Receiver PL 19 2 A D Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 193 011 701 B C D There is 5 VDC between P 10 3 and GND Y N Go to Flag 7 Check for an open circuit The wire is good Y N Repair the wire Go to Flag 8 Check for an open circuit The wires are good N Repair the wires Replace the Sorter Control PWB PL 19 1 Replace the Sensor Receiver PL 19 2 Replace the Sorter Control PWB PL 19 1 Remove the paper in Bin 1 Access the Digital Output DO test from the Control Panel Enter code D6 Press the Item Enter button The display is 0 Y N Replace the Sensor Re
488. sor 24 Bracket P O PL 17 3 26 25 059E90580 Tension Bearing 26 130K82790 Nudger Home Sensor Assembly 27 600K99500 Registration Roll Kit ADJ 5 1 ADJ 5 2 28 600K99510 Feed Roll Kit 0017003A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 71 PL 17 3 PL 17 4 Feeder Upper Chute Assembly Interlock Switch Item Part Description 1 802K14680 ADF Upper Chute Cover Assembly 2 Upper Cover P O PL 17 4 Item 1 3 Plate P O PL 17 4 Item 1 4 026E82620 Screw 5 Plate P O PL 17 4 Item 1 6 Upper Chute Assembly P O PL 17 4 Item 1 7 600K84250 Retard Roll Kit 2 Kit 8 009E26941 Spring 9 009E31711 Spring 10 054E84730 Upper Chute 11 009E64490 Spring 12 Nudger Chute P O PL 17 4 Item 1 13 Guard P O PL 17 4 1 14 Guard P O PL 17 4 Item 1 15 121E90450 Magnet 16 110K94790 Feeder Cover Interlock 0017004 A WOL Parts List 10 00 Initial Issue PL 17 4 5 72 Phaser 790 DocuColor 2006 PL 17 5 Feeder Lower Chute Registration Sensor Item Part Description 1 Lower Chute Not Spared 2 Registration Chute Not Spared 3 105E92310 Antistatic Brush 4 002E61020 Lower Cover 5 130E81150 ADF Registration Sensor ADJ 5 4 6 Bracket P O PL 17 5 Item 11 7 Clamp Not Spared 8 026E82620 Screw 9 130K82780 Document Set Sensor ADJ 5 4 10 Bracket Not Spared 11 130K61380 Registration Sensor Assembly ADJ 5 4 12 Harness Spared 0017005A WOL
489. ssembly Enter diagnostic component control code DI 29 Registration Sensor The display indicates 0 Pull out the Bypass Tray Assembly and remove the strip of paper from the Registration Sensor Push in the Bypass Tray Assembly Enter diagnostic component control code DI 29 The display indicates 1 N Remove the Bypass Tray Registration Assembly REP 8 6 There is 5 VDC from P91 pin B9 to pin B11 Y Go to Flag 1 Check the wire for an open circuit If the wire is good replace the MCU PWB PL 11 2 Go to Flag 2 Check the wires for an open or a short circuit to ground If the wires are good replace the Registration Sensor PL 4 6 Go to Flag 2 Check the wires for an open or a short circuit to ground If the wires are good replace the Registration Sensor PL 4 6 Pull out the Bypass Tray Assembly Place a strip of paper over the right sensor OHP Sensor PL 4 6 Push in the Bypass Tray Assembly Enter diagnostic component control code DI 27 The display indicates 0 Pull out the Bypass Tray Assembly and remove the strip of paper from the OHP Sensor Push in the Bypass Tray Assembly Enter diagnostic component control code 01 27 The display indicates 1 Pull out the Bypass Tray Assembly and remove it from the machine REP 8 6 There is 5 VDC from P91 pin B12 to Pin B14 Y Go to Flag 3 Check the wire for an open circuit If the wire is good replace the MCU PWB P
490. t The low density defect is present in both the fused and unfused portion of the sheet Y N Perform the Fuser Nip Adjustment ADJ 10 1 If the problem continues replace the Main Fuser Assembly PL 8 1 Make a print of the Test Page GP 14 As the print is being processed listen to the Rotary Motor Open the Front Door immediately after the 4th index is heard Remove the Copy Print Cartridge and examine the image on the IBT Belt The image on the belt has acceptable density Y Make a print of the Test Page GP 14 As the print is being processed open the Front Door Remove the Copy Print Cartridge and examine the image on the drum The image on the drum has acceptable density Access the Digital Output Test GP 2 Enter code 53 Press the Item Enter button Enter code 56 Press the Item Enter button The Dispense Clutch energizes Go to the 009 342 RAP to troubleshoot the Dispense Clutch Access the Digital Output Test GP 2 Enter code 53 Press the Item Enter button Enter code 21 Press the Item Enter button The Developer Clutch energizes Y Go to the 009 701 RAP to troubleshoot the Developer Clutch Switch off the power Remove the Top Cover and the Copy Print Cartridge Check the continuity between the BCR Contact PL 5 1 and terminal A on the HVPS There is continuity Y Replace the BCR Wire PL 11 1 and or the BCR Connector PL 5 1 A C D B C D Open the Front Cover C
491. t PJ 242 PJ 222 and PJ 215 are properly connected Check the Nudger Solenoid linkage to the Nudger Roll for proper operation The linkage is good Y Replace the Paper Feeder Assembly for Tray 2 PL 13 3 Replace the Nudger Sensor PL 15 5 Enter diagnostic code DO B7 The Nudger Solenoid energizes Y There is 24 VDC from J 215 pin 11 to ground on the Feeder PWB Y N There is 24 VDC from 4 215 pin 10 to ground on the Feeder PWB Y N Replace the Feeder PWB PL 13 4 Go to 7 Check the wires for an open or a short circuit to ground The wires are good N Repair the wires Ensure that PJ 242 PJ 226 PJ 215 are properly con nected Inspect the Nudger Solenoid plunger for contamination Clean as required Inspect the Nudger linkage for damage or binding If damaged replace the Nudger Solenoid PL 13 6 or replace the Paper Feeder Assembly PL 13 3 Replace the Feeder PWB PL 13 4 There is 24 VDC from J 216 pin 10 to ground on the Feeder PWB There is 24 VDC from 216 pin 9 to ground on the Feeder PWB Y Replace the Feeder PWB PL 13 4 Go to Flag 6 Check for an open circuit The wires are good Y N Repair the wires Replace the Feeder PWB PL 13 4 Replace the Feeder Drive Unit PL 13 4 A Initial Issue 10 00 Status Indicator RAPs Phaser 790 DocuColor 2006 2 107 007 710
492. t comes in contact with the paper is easily bent Use care when handling the Front Snubber 2 When installing the Tray 1 Front Snubber make sure that the Bottom Plate is situated under the tab on the top of the snubber and that the snubber is fully seated to the slot in the side of the tray 3 Install the Front Guide to the exact position from which it was removed REP 7 8 Oversize Tray Front Snubber Parts List on PL 14 2 Removal 1 Remove the Oversize Tray Assembly REP 7 6 2 Set the Bottom Plate to the raised position by actuating the Plate Link Figure 1 Repairs and Adjustments 10 00 Initial Issue REP 7 7 4 56 Phaser 790 DocuColor 2006 CAUTION The area of the Oversize Tray Front Snubber that comes in contact with the paper is easily bent Use care when handling the front snubber CAUTION The Front Guide mounting position is critical to proper operation Prior to removing the Front Guide take note of its mounting position 3 Remove the Oversize Tray Front Snubber Figure 2 2 Squeeze the locking tabs of the Snubber Stopper with a pair of needle nose pliers and remove the stopper Remove two screws and remove the Front Guide Assembly Unlock the Bottom Plate by moving the plate link as shown 0107007A WOL Figure 1 Unlocking the Bottom Plate See CAUTION Remove the Oversize Tray Front Snubber 0107002A WOL Figure 2 Removing the Oversize Tray Front Snubber Replacement 1
493. t mechanism gears for broken teeth or broken gears Go to Flag 1 Check the wires for an open or short circuit to ground Replace the Lift Motor PL 4 2 Replace the MCU PWB PL 11 2 Go to Flag 2 Flag 3 Check the wires for an open or short to ground If the wires are good replace the Lift Plate Sensor PL 4 2 If the problem continues replace the MCU PWB PL 11 2 Status Indicator RAPs 10 00 Initial Issue 007 708 2 102 Phaser 790 DocuColor 2006 Phaser 790 DocuColor 2006 MCU PWB PL11 2 LIFT MOTOR PL4 2 DO 23 J20 POT 0 y 78 J91 J208 P208 88 7 1 2 1 1 GRY i GRY I 1 1 DC COM I wor BYPASS I I 1 SIGNAL 1 1 1 22 CEN B7 Bor 77 1 2 21 COM MCU PWB PL11 2 5VDC DI 2A LIFT PLATE 2 SENSOR SENSOR PET 2210 2201 201 Jat Po SENSED D 8VDC J20 13 2 A13 A2 3 GRY GRY UE 1 1 12 84 GRY GRY 14 1 GRY GRY 5VDC 3 LIFT MOTOR o 1 TT mI 7 34 18 pig 1234 18 24 prg 323 15 17 17 16 25 BYPASS TRAY P15 WCU PWB FEED ASSY 15 1514 12 6_ __ Pas LIFT PLATE T 816 B4 SENSOR e 2 po 0707010A WO
494. t side of the To avoid personal injury or shock do not perform repair activities with the power switch Scanner disconnect the Ribbon Cable and on or electrical power applied to the machine connectors 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Platen Glass REP 6 1 3 Remove the ADF Assembly REP 5 1 4 Remove the Right Cover from the Scanner REP 6 2 5 Remove the Rear Cover from the Scanner REP 6 4 2 6 Remove the Advanced Features Memory PWB REP 6 16 7 Remove the connector cover Figure 1 2 3 At the rear of the Scanner disconnect b NM the connectors 3 ndomesth the Ribbon Cable py m 0106029A WOL 1 Figure 2 Disconnecting the Connectors Remove the screws 2 and connector cover 0106028A WOL Figure 1 Removing the Connector Cover Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 43 REP 6 11 9 Disconnect the connectors from the ICM Main PWB right rear Figure 3 U K Lua 1 Disconnect the connectors 3 at the rear of the right side 0106030A WOL Figure 3 Disconnecting the IIT ICM PWB Connectors 10 Remove the screws holding the PWB Box to the IIT Frame Figure 4
495. tch P O PL 13 5 1 14 Gear P O PL 13 5 Item 1 15 Gear P O PL 13 5 Item 1 16 Collar P O PL 13 5 Item 1 S 17 Bearing PL 13 5 1 18 Bearing P O PL 13 5 Item 1 19 Gear P O PL 13 5 Item 1 20 B Bearing P O PL 13 5 Item 1 21 Nylon Washer P O PL 13 5 Item 1 22 E Ring P O PL 13 5 Item 1 0012007A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 49 PL 13 7 PL 13 8 Optional Feeder Assembly 8 of 9 Item Part Description 1 2 19 and PL13 9 1 050K42600 Paper Tray Assembly 2 Tray Housing P O PL 13 8 Item 1 3 Paper Guide P O PL 13 8 1 4 Lift Shaft P O PL 13 8 1 5 Gear P O PL 13 8 Item 1 6 Gear P O PL 13 8 Item 1 7 Gear P O PL 13 8 Item 1 8 Gear PL 13 8 Item 1 9 Extension Spring P O PL 13 8 Item 1 10 Side End P O PL 13 8 Item 1 11 Label P O PL 13 8 1 12 Bearing P O PL 13 8 1 13 Spring P O PL 13 8 1 14 Spring P O PL 13 8 Item 1 15 Rail P O PL 13 8 Item 1 16 Rear Plate P O PL 13 8 Item 1 17 Tray Front Cover P O PL 13 8 Item 1 18 Pad P O PL 13 8 Item 1 19 Gear Drive Pin PL 13 8 Item 1 0013008A WOL Parts List 10 00 Initial Issue PL 13 8 5 50 Phaser 790 DocuColor 2006 PL 13 9 Optional Feeder Assembly 9 of 9 4 tS Item Part Description 1 Paper Guide P O PL 13 8 Item 1 2 Tray Housing P O PL 13 8 Item 1 15 3 Side
496. tem 1 9 Gear P O PL 15 3 Item 1 10 Gear P O PL 15 3 Item 1 11 Coupling P O PL 15 3 Item 1 12 Gear P O PL 15 3 Item 1 13 Gear P O PL 15 3 Item 1 14 Gear P O PL 15 3 Item 1 15 023E19270 Rear Belt REP 8 32 16 023E19280 Front Belt REP 8 31 17 019E34500 18 Plate Guide P O PL 15 3 Item 1 19 Pulley P O PL 15 3 Item 1 20 Bearing P O PL 15 3 Item 1 21 Bearing P O PL 15 3 Item 1 22 Cable Clamp Not Spared 0015004A WOL Parts List 10 00 Initial Issue PL 15 4 5 58 Phaser 790 DocuColor 2006 PL 15 5 Duplex Assembly 5 of 7 Item Part Description 1 059K19120 Inverter Lower Assembly REP 8 35 1 2 19 PL5 5 PL15 6 2 Turn Baffle P O PL 15 5 Item 1 3 Inverter Motor Assembly P O PL 3 4 5 15 5 Item 1 4 Bracket P O PL 15 5 Item 1 6 U 16 5 127K29160 Inverter Motor REP 8 36 6 Invert Chute Assembly PL 15 5 Item 1 7 Chute P O PL 15 5 Item 1 8 Pinch Roll P O PL 15 5 Item 1 9 Inverter Chute P O PL 15 5 Item 1 10 Catch Magnet P O PL 15 5 1 11 130E82730 Inverter Sensor REP 8 37 12 Bearing PL 15 5 Item 1 13 022K57510 Inverter Roll 14 Gear P O PL 15 5 Item 1 15 Harness P O PL 15 5 Item 1 16 Spring P O PL 15 5 1 17 830E56720 Cover Support 18 Clamp P O PL 15 5 Item 1 19 Cable Clamp P O PL 15 5 1 5 16 0015005A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 20
497. tem Part Description 1 802K17430 Assembly REP 9 16 1 2 18 and PL7 3 5 064 91350 rr 9 21 7 3 1 18 and PL7 3 ransfer Mechanism Assembly P O PL 7 2 Item 1 denied 4 Frame P O PL 7 2 Item 1 5 Idler Roll P O PL 7 2 Item 1 6 Bearing P O PL 7 2 Item 1 7 Idler Roll Flange P O PL 7 2 Item 1 8 Backup Roll P O PL 7 2 Item 1 9 Contact Roll Bearing P O PL 7 2 Item 1 10 Front Bearing Holder P O PL 7 2 Item 1 11 Rear Bearing Holder P O PL 7 2 Item 1 12 Contact Roll P O PL 7 2 1 13 Bearing Holder P O PL 7 2 Item 1 14 Contact Roll Spring P O PL 7 2 Item 1 15 Spacer P O PL 7 2 1 16 Shaft P O PL 7 2 Item 1 17 Rail P O PL 7 2 Item 1 18 Retard Spring P O PL 7 2 Item 1 0007002A WOL Parts List 10 00 Initial Issue PL 7 2 5 26 Phaser 790 DocuColor 2006 PL 7 3 IBT 3 of 5 Item Part Description 10 1 064K91350 IBT Belt oy 2 IBT Frame P O PL 7 2 Item 1 12 3 BTR 1 Plate Wire P O PL 7 2 Item 1 4 Drive Roll Flange P O PL 7 2 Item 1 5 Drive Roll Bearing P O PL 7 2 Item 1 6 Tension Roll Bearing P O PL 7 2 Item 1 7 IBT Tension Roll P O PL 7 2 Item 1 8 Tension Roll Flange P O PL 7 2 Item 1 9 130E84270 TRO Sensor REP 9 22 10 BTR 1 P O PL 7 2 Item 1 11 1 Bearings P O PL 7 2 Item 1 12 Spring P O PL 7 2 Item 1 13 IBT Drive Roll P O PL 7 2 Item 1 14 Rail P O PL 7 2 Item 1 15
498. terlock Closed 1 5 VDC 1 5 2B Stack Height Sensor Stack Height Sensed L 5 VDC 7 2 94 Duplex Tray Duplex Tray Set L 5 VDC 10 7 2C Level Sensor Lift Plate Sensed 1 5 VDC 7 2 95 24 VDC to Optional Not used 2 35 ESS PWB Not used Duplex 3B ESS PWB Not used 96 Inverter Motor Inverter Motor Fail H 5 VDC 10 8 42 TRO Sensor TRO Sensor 1 5 VDC 9 6 Low Paper Sensor Tray 2 Paper 5 VDC 43 Rotary Sensor Home Sensed H 5 VDC 9 3 4 No Paper Sensor 2 Paper Sensed 5 VDC 7 8 4B Rear Fuser Exit Sensor Sheet at Rear Fuser Exit Sensor L 5 10 4 A5 Nudger Sensor Tray 2 Nudger Sensed 1 5 VDC 7 3 VDC A6 Feed Out Sensor Tray 2 Paper Feed Out Sensed 5 VDC 83 50 ROS Assembly Not used 5 BO Low Paper Sensor Tray 3 Low Paper Sensed 5 VDC 7 4 51 Waste Toner Sensor Waste Toner Full H 5 VDC 9 9 B4 No Paper Sensor Tray 3 No Paper Sensed H 5 VDC 7 4 52 Toner Box Sensor Toner Box Set L 5 VDC 9 9 B5 Nudger Sensor Tray 3 Nudger Sensed L 5 VDC 7 4 General Procedures and Information 10 00 Initial Issue GP 2 6 4 Phaser 790 DocuColor 2006 Table 1 Digital Input Codes Table 2 Digital Output Codes DI Code Component Signal BSD Ref DO Code Com
499. the front end of the Paper Side Guide Figure 3 q NOTE Make sure the ruler is positioned 1 at a right angle to the frame Remove the gt 2 SEP A iN 2 O Remove the tray 1 Take a measurement at Lift the tray and disconnect the the point close to the Tie 2 n Plate left to right The 0205006A WOL distance shouldbe 19mm 0 205007A WOL Figure 2 Removing the Entrance Tray Figure 3 Taking Measurements 4 Remove the Transport Assembly REP 5 7 6 Ifthe measurement is not within specifications perform the adjustment Repairs and Adjustments 10 00 Initial Issue ADJ 5 4 4 152 Phaser 790 DocuColor 2006 Adjustment CAUTION If the screws on both the left and right side Counterbalances are not loosened the ADF Frame will warp 1 Loosen the screws at 6 places Figure 4 ADJ 6 1 IIT Magnification Purpose The purpose is to achieve the correct magnification in the slow scan direction vertical in 10096 copy mode The following adjustments must be performed prior to performing this adjustment 2 Loosen the screws 2 used to mount the bottom of the left side Counterbalance to the ADF frame 5 Printer Registration ADJ 8 1 3 Rotate the adjustment screw on the right side Counterbalance to change the ADF posi ADF Side Redi ion ADJ 5 1 tioning Figure 4 199 Directio
500. the machine Power Cord 2 Remove the Fuser Assembly REP 10 1 CAUTION Be careful not to touch the IBT Belt Assembly or cleaning blade of the Belt Cleaner Assembly Do not allow the Cleaning Blade to come in contact with any other parts NOTE Dry Ink may spill from the Belt Cleaner during the removal Place paper on the frame below the Belt Cleaner and be careful not to spill dry ink 3 Remove the Belt Cleaner Figure 1 2 Remove the Belt Cleaner 1 Pull pin toward rear to disengage 0109039A WOL Figure 1 Removing the Belt Cleaner Initial Issue 10 00 Phaser 790 DocuColor 2006 4 105 Repairs and Adjustments REP 9 17 Replacement 1 Reinstall the Belt Cleaner Figure 2 2 Reset the Belt Cleaner counter counter clear 4 Fully seat the Belt Cleaner 2 Pull the pin toward the rear and hold during the next step Figure 2 Replacing the Belt Cleaner Align the dot on frame at left end with the line on the Belt Cleaner With the flat of E ring at the top of the pin push the shaft into the slot above the dot on frame 0109015A WOL REP 9 18 BTR 2 Assembly Parts List on PL 7 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Belt Cleaner REP 9 17 CAUTION Do not touch t
501. the print engine considers for fusing speed in printing on dif ferent paper types The speed mode is determined by the controller according to print mode and paper type instructions from the ESS 1 Standard Mode Prints at the maximum speed of the machine 2 Medium Speed Mode Prints at medium speed to ensure the correct fusing on heavy weight papers greater than 28 Ib or 105 gsm and black and white transparencies This mode is also used to enhance the glossy touch of plain paper 3 Low Speed Mode Prints at low speed when printing color on transparencies This mode is also used to enhance the glossy touch of heavy weight paper General Procedures and Information IOT Specifications 10 00 Initial Issue 6 22 Phaser 790 DocuColor 2006 The following table shows the prints per minute generated with the associated paper types and sizes Table 8 Prints Per Minute Sheet Type Size Black amp White Color Plain paper 8 5 x 11 inch 4 26 ppm 6 ppm 8 5 x 14 inch B4 Plain paper 11 17 inch 13 8 ppm 3 ppm Transparency 8 5x 11 inch A4 14 8 ppm 1 3 ppm thick paper 8 5 x 14 inch B4 First Print Out Time FPOT With the machine in Ready mode the time from the print designation from the driver on the PC until the trail edge of the first sheet exits the IOT is shown as follows Table 9 First Print Out Time FPOT Output Tray Print Mode FPOT
502. then switch on the power The 04 322 fault code is declared at the end of self test Y N Go to Flag 2 and check the harness between the Drive Motor PWB and the Fuser Motor for damaged or loose wires or connector pins If the wires are OK replace the Fuser Motor PL 10 1 If the problem continues replace the Drive Motor PWB PL 10 1 Access the Digital Output DO test from the Control Panel Enter code 53 Press the Item Enter button The Fuser Motor energizes Y N Go to Flag 2 and check the harness between the Drive Motor PWB and the Fuser Motor for damaged wires or connector pins If the wires are OK replace the Fuser Motor PL 10 1 If the problem continues replace the Drive Motor PWB PL 10 1 If the problem can not be resolved replace the MCU PWB PL 11 1 Check the following Go to Flag 1 and check the wire for an open circuit Go to Flag 2 and check the harness between the Drive Motor PWB and the Fuser Motor for damaged wires or connector pins The problem may be intermittent Go to Figure 1 and check for loose or damaged connec tions or damaged wires If the problem persists replace the replace the MCU PWB PL 11 2 Initial Issue 10 00 Phaser 790 DocuColor 2006 2 49 Status Indicator RAPs 004 322
503. tial Issue 7 30 Phaser 790 DocuColor 2006 24 VDC Interlocked Wirenet 3 of 3 24 VDC INTERLOCKED 3 OF 3 WIRENET CONTINUED REGUM LVPS J32 461 7 2 PROCESS DRIVE ASSEMBLY ORN 9 2 1 J49 24 VDC 8 2 DRIVE MOTOR PWB INTERLOCKED ORN 41 J33 J246 7 3 ROTARY MOTOR PWB ORN 9 3 T728006A WOL Figure 1 24 VDC Interlocked 3 of 3 Initial Issue 10 00 Wiring Data Phaser 790 DocuColor 2006 7 31 DC Com Wirenet 1 of 5 DC COM 1 OF 5 WIRENET LvPS 932 J125 02 ROS LD ASSEMBLY 6 2 MCU PWB ESS PWB 933 J12 P1 J11 6 4 VIO A4 1 4 B3 B4 3 3 482 J14 J124 17 8 4 ROS SOS PWB GRY 6 1 J121 2 6 1 2 ROS LD ASSEMBLY GRY 6 2 i J123 104 4 ROS POLYGON MOTOR GRY 2 J16 J58 144 3 ROTARY SENSOR GRY 9 3 154 P54 J57 2 263 3 TRO SENSOR DC COM GRY GRY 9 6 1 481 P81 n 213 3 4 ADC SENSOR ASSEMBLY GRY 9 5 1 J102 1 27 1 3 SIZE SWITCH ASSEMBLY GRY 74 J101 P101 J107 1 34 4 He ee 2 TRAY NO PAPER SENSOR 1 GRY 74 1 1 J106 P106 34 1 1 54 2 LOW PAPER SENSOR GRY GRY 74
504. tion Streaks Usually medium width streaks of or shifts in color most noticeable in low density 20 30 halftone areas of the copy A deletion in the form of a single streak that runs from the lead edge to the trail edge of the copy Go to the IQ14 RAP Low Image Density A condition that results when too little toner of a single color or combination of colors is developed on the copy or print This results in lighter copies or prints for the single color toner or the color that results from the combination of color toners Go to 103 RAP Misregistration Skew The position of the image relative to the top edge and side edge of the paper is not within specification Go to the IQ11 RAP Missing Colors Only the black portions of a color image are printed Go to the 009 704 RAP Mottle Areas of solid or high density coverage that are reproduced with a surface that resembles marble Go to the IQ17 RAP Initial Issue 10 00 Image Quality Phaser 790 DocuColor 2006 3 3 IQ1 Table 1 Image Quality Defects Defect Description Corrective Action Regular repeating Bands Streaks A defect that repeats at an interval from14 to 264 mm is most noticeable in low density 20 30 halftone areas of the copy and to the 1016 RAP Spots or Smears runs perpendicular to process direction Lines and bands are generally uniform in shape from one end to the other Streaks are generally sho
505. tion ADJ 6 1 When smears or altered sequences are noted with white standard paper d Auto Shading ADJ 6 6 When problems with fogged or scattered copies occur e B Correction ADJ 6 7 Adjustment f ADF Side Registration ADJ 5 1 1 Place 11x17 A3 paper in Tray 1 9 ADF Lead Edge Registration ADJ 5 2 2 Completely cover the Platen Glass with at least 10 sheets of white 11x17 A3 paper and close the cover or ADF 3 Control Panel select Original Type Use the arrow keys to select Color and press the Select button 4 Select Text Photo and press the Select button 5 Press Start to make a copy 6 Enter Diagnostic Mode IIT GP 19 7 Enter Diag Code and press the Select button 8 Select DC No and enter 945 9 Press the Down Arrow to select subcode and enter 20 10 Press Select then press Start 11 Exit Diagnostics Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 159 ADJ 6 5 ADJ 6 6 ADJ 6 7 B Correction Purpose The purpose is to read the color test pattern on the platen glass and correct the sensitivity imbalance of the CCD Blue Sensor Adjustment 1 Place 11 x 17 inch paper in Tray 1 2 Place Test Pattern 82E13030 on the Platen Glass and close the cover ADF 3 Atthe Control Panel select Original Type Use the arrow keys to select Color and press the Select button Select Text Photo and press the Select button Press Start to make a copy Enter the Diagnostic Mod
506. tion Clutch Figure 1 1 Disconnect the connector 2 Remove the E ring and remove the Registration Clutch 0108031A WOL Figure 1 Removing the Registration Clutch Replacement 1 Perform the procedure for removal in reverse Qv 00 19 Remove the Bypass Tray Registration Assembly REP 8 6 Remove the Main Paper Handling Assembly REP 8 9 Remove the Registration Clutch REP 8 17 Remove the Registration Rubber Roll Figure 1 3 Remove the Registration Rubber Roll 1 Remove the bearing Remove the E ring gear and bearing 0108032A WOL Figure 1 Removing the Registration Rubber Roll Replacement 1 Perform the procedure for removal in reverse Repairs and Adjustments 10 00 REP 8 17 REP 8 18 4 70 Initial Issue Phaser 790 DocuColor 2006 REP 8 19 Size Switch PWB Replacement Parts List on PL 13 3 1 Perform the removal procedure in reverse Removal 2 Return the bracket to the exact position from which it was removed WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Feeder Rear Cover NOTE Note the positioning of the bracket prior to removing it 3 Remove the Size Switch PWB Figure 1 2 Disconnect the connector Remove two Screws and the Bracket
507. tors 6 Remove the four Screws and the Feeder PWB 0108037A WOL Figure 1 Removing the Feeder PWB Replacement 1 Install the jumper plug from the removed PWB to the same location on the replacement PWB See the Note Figure 1 2 Perform the removal procedure in reverse Repairs and Adjustments REP 8 20 REP 8 21 10 00 4 72 Phaser 790 DocuColor 2006 Initial Issue REP 8 22 Feeder Drive Unit Low Paper Sensor 4 Remove the Low Paper Sensor Figure 2 Parts List on PL 13 4 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Feeder Rear Cover 3 Remove the Feeder Drive Unit Figure 1 2 Remove the two screws and the Low Paper Sensor 0108039A WOL Disconnect the connector Ms ESI Figure 2 Removing the Low Paper Sensor Take note of their locations Replacement and disconnect 1 Perform the removal procedure in reverse all connectors Release the wires from the clips Remove the four screws and remove the Feeder Drive Unit 0108064A WOL Figure 1 Removing the Feeder Drive Unit Repairs and Adjustments REP 8 22 Initial Issue 10 00 Phaser 790 DocuColor 2006 4 73 REP 8 23 Paper Feeder Assembly Parts List on PL 13 5 Removal WARNING To avoid personal inj
508. tridge C REF Section 6 REP 9 9 4 Dry Ink Cartridge K REF Section 6 REP 9 9 5 802K12002 Developer Housing K REP 9 10 ADJ 9 1 802 15851 Developer Housing REP 9 10 ADJ 9 1 6 802K12112 Developer Housing C REP 9 10 ADJ 9 1 802 15881 Developer Housing C REP 9 10 ADJ 9 1 7 802K12082 Developer Housing M REP 9 10 ADJ 9 1 802 15871 Developer Housing M REP 9 10 ADJ 9 1 8 802K15861 Developer Housing Y REP 9 10 ADJ 9 1 802K12052 Developer Housing Y REP 9 10 ADJ 9 1 0006002A WOL Parts List 10 00 Initial Issue PL 6 2 5 24 Phaser 790 DocuColor 2006 PL 7 1 IBT 1 of 5 Item Part Description 1 008K91550 2 Cam Assembly REP 9 19 2 BTR Rear Bracket Assembly Not Spared 3 Rear Bracket Spared 4 Rear Bearing Not Spared 5 Clamp Not Spared EXPLODED ON PL 6 006K85500 Auger REP 9 20 75 7 802 12301 8 042K92110 Cleaner REP 9 17 9 802K14462 BTR 2 Assembly REP 9 18 10 011E09640 Tension Lever REP 9 15 11 015K43080 Rear Bracket Assembly 12 Rear Bracket P O PL 7 1 Item 11 13 Contact Spring P O PL 7 1 Item 11 14 BTR 1 Contact Wire PL 7 1 Item 11 15 BTR 2 Contact Wire P O PL 7 1 Item 11 16 015K43090 IBT Front Bracket 17 802K17430 Assembly REP 9 16 1 EXPLODED ON PL7 4 EXPLODED ON PL7 2 PL7 3 0007001A WOL Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 25 PL 7 1 PL 7 2 IBT 2 of 5 I
509. trol Panel wil display DOWNLOAD 1394 DONE kO 1 OP ane Down Arrow Buttons To ensure that PARALLEL PORTON is dis 13 Switch off then switch on the printer power to exit the Diagnostics mode d the Clear Stop button to return the machine to READY 14 Print a Configuration Page GP 14 to confirm the successful download of the 1394 PWB Executing the Download software 1 Prepare the Printer for ESS Software installation a Switch off the Printer power b Simultaneously press and hold the Arrow Down and Clear Stop buttons c Switch on the Printer power d Release the buttons after the row of pound signs appears on the display 2 Upon completion of self test VERSION INFO will be displayed 3 Press the Menu button until INSTALL UPGRADES is displayed Press the Item Enter button 4 Press the DOWN ARROW button to select FILE SYSTEM Do not press the Item Enter button 5 Onthe PC prepare the DOS window NOTE Type the entries as shown while carefully observing the spaces or lack of spaces a Select Start Programs and MSDOS Command Prompt b then press the Enter key The display will show gt c cd temp then press the Enter key d COPY b filename filename in this case will be the actual name of the MCU software file you intend to download e not press the Enter key Initial Issue 10 00 General Procedures and Information Phaser 790 DocuColor 2006 6 11 GP 8 GP
510. ts Bin 2 Bin 10 Copy mode only sort by set 30 sheets Table 2 Paper Handling Capability Stacker Tray Side Output Tray Size Dimensions Weight A3 11 7 x 16 5 inch 297 x 420 mm SEF 60 200 gsm Ledger 11 x 17 inch 279 4 x 431 8 mm SEF 60 200 gsm B4 10 1 x 14 3 inch 257 0 x 364 0 mm SEF 60 200 gsm LGL 8 5 x 14 inch 215 9 x 355 6 mm SEF 60 200 gsm A4 11 7 x 8 3 inch 297 x 240 mm LEF 60 200 gsm A4 R 8 3 x 11 7 inch 210 x 297 mm SEF 60 200 gsm LTR 11 x 8 5 inch 279 4 x 215 9 mm LEF 60 200 gsm LTR R 8 5 x 11 inch 215 9 x 279 4 mm SEF 60 200 gsm B5 LEF 6 9 x 9 8 inch 176 x 250 mm LEF 64 98 gsm A5 LEF 5 8x 8 2 inch 148 x 210 mm LEF 64 98 gsm 8 2 x 5 8 inch 210 x 148 mm SEF n a General Procedures and Information 10 00 Initial Issue Sorter Specifications 6 26 Phaser 790 DocuColor 2006 Common Tools Product Tools and Test Patterns The following table lists the common tools required for servicing the DC 2006 and Phaser 790 The following table lists the product specific tools and test patterns required for use in servicing the DC 2006 and Phaser 790 Table 1 Common Tools Description Part Number Table 1 Digital Multimeter DMM 60072020 Description Part Number DMM Lead Kit 60012030 Color Test Pattern 82E13030 ESD Kit 600742001 Copier Set up Test Pattern 82E8220 Diagonal Pliers 600740903 Serial Ca
511. ts List on PL 8 3 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Main Fuser Assembly REP 10 2 3 Remove the Upper Guide Assembly REP 10 3 4 Remove the Upper Plate REP 10 4 CAUTION Be careful not to touch the surface of the Pressure Roll Heat Lamp while removing the lamp Contamination from hands can damage the lamp The connector for the Pressure Roll Heat Lamp is tightly connected Be careful not to damage the lamp when disconnecting the connector The gear is no longer secured when the Fuser Rear Cover is removed Be careful not to allow the gear to fall out while removing the cover 5 Remove the Pressure Roll Heat Lamp Figure 1 Replacement 1 Reinstall the Pressure Roll Heat Lamp in the reverse order of removal 2 Check the Fuser ADJ 10 1 2 3 Remove the Fuser T Free the harness Front Cover and disconnect the connector Remove the screw then remove the handle Remove the screw 6 Remove the Pres sure Roll Heat Lamp from the rear 4 Remove the Fuser Rear Cover 0110005A WOL Figure 1 Removing the Pressure Roll Heat Lamp REP 10 7 Lower Guide Assembly Parts List on PL 8 2 Removal WARNING To avoid personal injury or shock do not perform repair activities w
512. tus Indicator RAPs 001 703 LEFT FRONT COVER INTERLOCK LOW VOLTAGE POWER SUPPLY PL11 1 r4 1 482 FUSER 5 HARNESS 5 4 1 ORN PL8 5 6 Y 24 VDC SRN 371 P7 170 P70 J83 Y 4 2 9 ORN YEL 1 1 1 8 D a ORN 3 1 4 Y YEL YEL ORN BYPASS TRAY HARNESS PL4 2 3 LOW J91 J97 P97 VOLTAGE RE AL 4 POWER YEL YEL SUPPLY i YEL YEL LEFT FRONT MCU PWB LOW VOLTAGE COVER PL11 2 POWER SUPPLY INTERLOCK PL11 1 PL11 1 ENERGY STAR J12 SIGNAL 132 ENERGY 132 J199 22 J198 16 STAR 18 YEL CONTROL BRN YEL DC COM c zd 5 VDC n 5 10 P16 P19 P22 18 2 P34 P14 17 LOW VOLTAGE P20 BOWER SUPPLY P23 P33 F 9 P33 P11 P21 1 1701002 A WOL Figure 1 001 703 Circuit Diagram Status Indicator RAPs 001 703 10 00 2 10 Initial Issue Phaser 790 DocuColor 2006 001 704 Front Cover Open RAP Initial Actions Ensure the Right Front Cover is closed and that the actuator for the interlock is not damaged Procedure Access the Digital Input DI test from the Control Panel Enter code 73 Press the Item Enter button The display ind
513. u must remove the EPROM from the original MCU PWB and install it on the replacement MCU PWB 1 Reinstall the MCU PWB in the reverse order of removal Figure 1 Removing the MCU PWB Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 7 REP 1 5 REP 1 6 Right Front Cover Interlock Parts List on PL 11 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine Switch off the machine power and disconnect the machine Power Cord Remove the Top Cover Assembly REP 14 4 Remove the Right Cover REP 14 9 Remove the ESS PWB REP 1 9 Remove the Controller Chassis REP 1 11 Remove the Right Front Cover Interlock Figure 1 Replacement 9 m N NOTE Ensure that the Right Front Cover Interlock is installed securely 1 Reinstall the Right Front Cover Interlock in the reverse order of removal 1 Disconnect the connectors 3 Remove the Right Front Cover Interlock 2 2 2 7 Unhook the switch f from the frame 0101005A WOL Figure 1 Removing the Right Front Cover Interlock REP 1 7 Left Front Cover Interlock Parts List on PL 11 2 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine Switch off the machine power and disconnect the machine P
514. uce a discrepancy in the amount of position change thus mak ing it impossible to get an accurate reading Visually inspect to make sure the black drum flange and tracking roll touch each other while turning If you do not raise the lever of the Rotary Latch in the following step the lever and tracking roll will touch This will allow the tracking roll to turn and you will not be able to accurately deter mine the amount of position change NOTE The tracking roll is rotated when the black drum flange and tracking roll touch in the fol lowing step of the procedure 6 Release the Rotary Latch which prevents the Developer Housing from turning Turn the Rotary Frame as slowly as possible 360 degrees clockwise This will allow you to mea sure how much the position has changed by how far the mark has moved from the edge of the White Seal 7 Check the Developer Spacing Figure 1 Repairs and Adjustments ADJ 8 1 ADJ 9 1 10 00 4 162 Initial Issue Phaser 790 DocuColor 2006 White Tracking Rak White Seal X Measure the distance that the mark on the White Tracking Roll moved from the White Rotary Latch Seal The specification is 3 0 to 5 0 mm 0 209000A WOL Figure 1 Checking the Developer Spacing 8 If the distance measured is not within specification perform the adjustment Adjustment 1 Adjust the Developer Spacing Figure 2 1 Lift up the Rotary Latch 5 Tighten the screws 4 If the distanc
515. ue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 63 REP 8 5 REP 8 6 Bypass Tray Registration Assembly Parts List on PL 4 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Bypass Tray Registration Assembly Figure 1 1 Remove the two screws securing the Bypass Tray Registration Assembly to the front and rear rails and remove the assembly by pulling it straight out 0108008A WOL Figure 1 Removing the Bypass Tray Registration Assembly REP 8 7 Bypass Tray Feed Assembly Parts List on PL 4 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Bypass Tray Registration Assembly REP 8 6 CAUTION The Bypass Tray Feed Assembly and Base Assembly are connected by a harness Be careful not cause damage to the wires when performing the following 3 Remove the Bypass Tray Feed Assembly Figure 1 3 1 Remove four screws H bly and turn it on its harness so it is facing bottom side up next to the Base Assembly Bypass Tray Feed Assembly Remove the two screws securing the Bypass
516. umber Index Part Number Part List Part Number Part List 160K74641 PL 12 1 600K99500 PL 17 3 160K75040 PL 11 2 600K99510 PL 17 3 160K81230 PL 5 1 802 05130 PL 13 2 162K42090 PL 12 1 802E05191 PL 13 2 162K53100 PL 11 1 802E05291 PL 1 2 162K53120 PL 11 2 802 05311 PL 1 2 162K53130 PL 11 1 802 05331 PL 1 2 162K53250 PL 8 5 802E05350 PL 1 1 162K53280 PL 4 6 802 05370 PL 1 2 162K53330 PL 4 2 802E05560 PL 3 2 162K54090 PL 13 4 802K11970 PL 1 1 162K54120 PL 13 4 802K12002 PL 6 2 162K54131 PL 13 2 802K12052 PL 6 2 162K54140 PL 13 4 802K12082 PL 6 2 162K54150 PL 13 4 802K12112 PL 6 2 162K55450 PL 15 3 802 12181 PL 15 6 162K55490 PL 11 1 802E12211 PL 15 7 162K56420 PL 16 1 802K12301 PL 7 1 162K56430 PL 16 1 802K12480 PL 1 1 162K56731 PL 16 6 802bE13310 PL 19 1 162K60280 PL 16 6 802 13320 PL 19 1 162K60410 PL 17 2 802K13810 PL 16 6 162K60970 PL 16 1 802 13821 PL 16 6 162K61050 PL 11 2 802 13831 PL 16 6 413W10350 PL 16 4 802 14341 PL 19 6 600K68610 PL 4 7 802K14462 PL 7 1 600K68620 PL 5 1 PL 7 5 600K68750 PL 9 2 802K14670 PL 17 1 600K69091 PL 6 1 802K14680 PL 17 4 600K73770 PL 3 3 802K14870 PL 16 6 600K84250 PL 17 4 802 15530 PL 13 2 600K85301 PL 6 1 802 15720 PL 13 2 600K85411 PL 8 1 802K15851 PL 6 2 PL 8 2 802K15861 PL 6 2 600K85421 PL 8 1 802K15871 PL 6 2 PL 8 2 802 15881 PL 6 2 600K8543
517. uplex Entrance Sensor Replacement 1 Perform the removal procedure in reverse Disconnect the connector 0108057A WOL Figure 1 Removing the Duplex Registration Chute Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 77 REP 8 28 REP 8 29 Duplex Exit Sensor 5 Parts List on PL 15 3 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Duplex Tray Assembly REP 8 27 3 Remove the Front Cover of the Duplex Tray Assembly 4 Remove the Duplex Registration Chute Figure 1 2 Remove the two Screws and the Duplex Registration Chute Remove the Rail Assembly Figure 2 1 Remove the screws and remove the Rail Assembly 0108059A Figure 2 Removing the Rail Assembly 6 Remove the Chute Support Figure 3 2 Press and hold the Ma lt release tab while 1 4 moving the Chute Remove the 1 screw 1 Disconnect the connector 0108057A WOL Figure 1 Removing the Duplex Registration Chute 0108061A WOL Figure 3 Removing the Chute Support Repairs and Adjustments 10 00 Initial Issue REP 8 29 4 78 Phaser 790 DocuColor 2006 7 Remove the Exit Chute Figure 4 8 Remove the Duplex Exit Sensor Figure 5 1 Disconnect the connector Remove two
518. ury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Right Lower Cover REP 14 11 3 Remove the Feeder Right Cover Remove the Feeder Chute Figure 1 2 Remove the Feeder Chute Remove the five screws and the Feeder Right Cover 0108066A WOL Figure 1 Removing the Feeder Right Cover Feeder Chute 4 Remove the Paper Feeder Assembly Figure 2 MS 1 Remove the two screws and the Right Hand Lower Bracket NOTE This step is only neces sary if removing the feeder positioned closest to the top of the machine Disconnect the connector Remove two screws and the Paper Feeder Assembly 0108040A WOL Figure 2 Removing the Paper Feeder Assembly Replacement 1 Perform the removal procedure in reverse Repairs and Adjustments REP 8 23 10 00 4 74 Phaser 790 DocuColor 2006 Initial Issue REP 8 24 Takeaway Clutch Parts List on PL 13 6 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Paper Feeder Assembly REP 8 23 3 Remove the Takeaway Clutch Figure 1 Remove the two screws and separate the Bracket from the Paper Feeder 1 Assembly
519. ustration The item number of the assembly or kit precedes the bracket the item numbers of the piece parts follow the bracket Tag The notation W Tag in the parts description indicates that the part configuration has been updated Check the change Tag index in the General Information section of the Service Data for the name and purpose of the modification In some cases a part or assembly may be spared in two versions with the Tag and without the Tag In those cases use whichever part is appropriate for the configuration of the machine on which the part is to be installed If the machine does not have a particular Tag and the only replacement part available is listed as W Tag install the Tag kit or all of the piece parts The Change Tag Index tells you which kit or piece parts you need Whenever you install a Tag kit or all the piece parts that make up a Tag mark the appropriate number on the Tag matrix Parts List 10 00 Subsystem Information 5 4 Initial Issue Phaser 790 DocuColor 2006 Symbology A Tag number within a circle having a shaded bar and pointing to an item number shows that MT m the configuration of the part shown is the configuration before the part was changed by the Tag A Tag number within a circle pointing to an item number shows that the part has been changed number within the circle Figure 2 by the tag number within the circle Figure 1 Information on the modification is in the Change Tag Inde
520. v ROS 3 Disengage the harness from the clamps 2 4 1 Disconnect the connectors Disengage the harness from the clamps 0 109019B WOL Figure 1 Preparing to Remove the Locating Rail CAUTION Be careful not to touch IBT Belt or damage the harnesses or Magnetic Roll surface of the Developer Housing while removing the Locating Rail 6 Remove the Locating Rail Figure 2 Replacement CAUTION Be careful not to touch IBT Belt or damage the harnesses or Magnetic Roll surface of the Developer Housing while reinstalling the Locating Rail 1 Reinstall the Locating Rail in the reverse order of removal 1 Loosen the rear Screws 2 Remove the Locating Rail Remove the front through the front screws 0109005A WOL Figure 2 Removing the Locating Rail Initial Issue Phaser 790 DocuColor 2006 10 00 4 95 Repairs and Adjustments REP 9 5 REP 9 6 Waste Toner Sensor Parts List on PL 5 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Locating Rail REP 9 5 3 Remove the Waste Toner Sensor Figure 1 Replacement 1 Remove all slack from the harness before securing the harness 2 Reinstall the Waste Toner Sensor in the reverse order of removal 2 Unhook the sensor from the rail 3 Remove the Wast
521. ve Belt Tension Repairs and Adjustments 10 00 REP 5 4 REP 5 5 4 26 Initial Issue Phaser 790 DocuColor 2006 5 Remove the Lower Chute Figure 2 6 Remove Nudger Roll Assembly parts Figure 3 1 2 A Open the Feeder Cover Remove the E Clip Sensor Actuator Gear Remove the E Clip Pulley Belt Pulley and Bearing 1 Remove the Lower Chute by Remove the screw moving the chute in the direction retaining the Nudger indicated Home Sensor and 0105004A WOL remove the sensor 0105008A WOL Figure 3 Removing Nudger Roll Retaining Parts Figure 2 Removing the Lower Chute Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 27 REP 5 5 7 Remove the Nudger Roll Figure 4 1 Remove the two screws retaining the Entrance Tray and move the tray away from the Nudger Roll to allow room to remove the Nudger Roll Remove the Nudger Roll 0105009A WOL Figure 4 Removing the Nudger Roll Replacement 1 Perform the procedure for removal in reverse Pay close attention to the following step 2 The One Way Clutch is attached to the Pulley at the rear end of shaft Install the shaft so it rotates freely in CCW direction and it is locked in CW direction Figure 5 Rotates freely Locked in in this direction S3 this direction 0105010 A WOL Figure 5 One Way Clutch Rotation Repairs and Adjustments REP 5 5 Initial Issue 10 00 4 28 Phaser 790 DocuColor 2006
522. ve the Copy Print Cartridge Figure 1 Replacement 1 Accurately align the Rail Assembly and Copy Print Cartridge using the positioning marks 2 Reinstall the Copy Print Cartridge in the reverse order of removal 4 Remove the Copy Print Cartridge 3 Turn the lever to the Unlock posi tion Open the Front Cover 0090001A WOL Figure 1 Removing the Copy Print Cartridge REP 9 2 Waste Container Parts List on PL 5 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord CAUTION After removing be sure to lay the Waste Container in the horizontal position in a safe place 2 Remove the Waste Container Figure 1 Replacement 1 Reinstall the Waste Container in the reverse order of removal 2 Push the Waste Container in securely until it hooks into place 3 Remove the Waste Container Push down to release the container Open the Front Cover 0090002A WOL Figure 1 Removing the Waste Container Initial Issue Phaser 790 DocuColor 2006 10 00 Repairs and Adjustments REP 9 1 REP 9 2 REP 9 3 ROS Parts List on PL 5 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and discon
523. ve the Tray 1 Assembly Paper Tray Assembly or Oversize Tray Assembly typically in the following manner a While pulling the paper tray straight out of the machine lift the front of the tray to remove it from the machine Replacement 1 Perform the procedure for removal in reverse Initial Issue Phaser 790 DocuColor 2006 10 00 4 55 Repairs and Adjustments REP 7 5 REP 7 6 REP 7 7 Tray 1 Front Snubber CAUTION The area of the Tray 1 Front Snubber that comes in contact with the paper is easily Use Parts List on PL 2 1 care when handling the front snubber Removal 1 Remove the Tray 1 Assembly REP 7 6 2 Bottom Plate to the raised position by actuating the Plate Link Figure 1 CAUTION The Front Guide mounting position is critical to proper operation Prior to removing the Front Guide take note of its mounting position 3 Remove the Tray 1 Front Snubber Figure 2 2 Squeeze the locking tabs of the Snubber Stopper with a pair of needle nose pliers and remove the stopper Remove two screws and remove the Front Guide Assembly See CAUTION Remove the Tray 1 Front Snubber Unlock the Bottom Plate by moving the plate link as shown 0107007A WOL Figure 1 Unlocking the Bottom Plate 0107002A WOL Figure 2 Removing the Tray 1 Front Snubber Replacement 1 Perform the procedure for removal in reverse CAUTION The area of the Tray 1 Front Snubber tha
524. verse Repairs and Adjustments REP 11 12 REP 11 13 10 00 Initial Issue 4 136 Phaser 790 DocuColor 2006 REP 11 14 Bin Tray s Parts List on PL 19 5 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord Remove the Front Cover Disconnect the Front Bin Cam Spring Disengage the bottom of the Front Bin Cam from its retaining clip Remove the Bin Tray Figure 1 Qiu 457700 I Remove the Screws 2 and the Frame Top from the Front Frame Remove the Bin Tray s 0 111015A WOL Figure 1 Removing the Bin Trays Replacement 1 Perform the procedure for removal in reverse 2 Perform Sorter Bin Cam Position Adjustment ADJ 11 1 on the Front Bin Cam REP 11 15 Docking Interlock Parts List on PL 19 6 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Docking Interlock Figure 1 1 Remove the screws 2 Disconnect the wires and remove the Docking Interlock 0 111016A WOL Figure 1 Removing the Docking Interlock Replacement 1 Perform the procedure for removal in reverse Initial Issue Phaser 790 DocuColor 2006 10 00 4 137 Repairs
525. w CX 112W36053 Screw AS 141W28051 Set Screw CY 271W21250 Dowel Pin AT 141W35651 Set Screw CZ 158W35655 Screw AU 153W16055 Tapping Screw DA 158W27663 Screw AV 153W17655 Tapping Screw DB 158W36855 Screw AW 153W17855 Tapping Screw DC 158W36663 Screw AX 153W18055 Tapping Screw DD 102W35851 Screw AY 153W27650 Tapping Screw KL Screw AZ 153W27655 Tapping Screw BA 153W27850 Tapping Screw BB 153W28050 Tapping Screw BC 158W27651 Screw Parts List 10 00 Initial Issue Common Hardware 5 84 Phaser 790 DocuColor 2006 Part Number Index Table 1 Part Number Index Part Number Part List Table 1 Part Number Index PL74 Part Number Part List 008E92010 PL 17 3 001E58350 PL 19 6 008E92020 PL 17 3 001K69743 PL 4 4 009E26941 PL 17 4 001K69770 PL 4 2 009E28580 PL 17 3 001K73551 PL 4 1 009E31711 PL 17 4 PL 4 6 009E39080 PL 17 3 002E61020 PL 17 5 009E48250 PL 17 2 003E39791 PL 8 4 009E62830 PL 16 4 003E52460 PL 16 6 009E64490 PL 17 4 003E53300 PL 8 2 009E71750 PL 3 3 003K84303 PL 6 1 011E09640 PL 7 1 003K91881 PL 17 1 011E10200 PL 8 4 004E06560 PL 16 5 012E93430 PL 17 3 004E09760 PL 8 4 013E80970 PL 17 3 004K92440 PL 16 6 PL 17 6 004E98270 PL 17 6 013E81370 PL 17 3 005E80250 PL 17 3 013E81880 PL 17 2 006K21260 PL 19 4 013E81940 PL 17 2 006K21270 PL 19 4 013E82290 PL 17 3 006K85500 PL 7 1 013E85600 PL 19 2
526. witch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord 2 Remove the Right Cover REP 14 9 3 Remove the Hard Disk Drive Assembly a Disconnect the ribbon cable connector from the ESS PWB b Release the upper and lower tab locks c Slide the Hard Disk Drive Assembly toward the right and remove the Hard Disk Drive Assembly Replacement 1 Reinstall the Hard Disk Drive Assembly in the reverse order of removal 2 Adjust the Hard Disk Drive Assembly ADJ 3 1 Initial Issue Phaser 790 DocuColor 2006 10 00 4 13 Repairs and Adjustments REP 1 13 Repairs and Adjustments 10 00 Initial Issue REP 1 13 4 14 Phaser 790 DocuColor 2006 REP 4 1 Paper Handling Drive Unit Parts List on PL 10 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine Dapy Switch off the machine power and disconnect the machine Power Cord Remove the Rear Cover REP 14 6 Remove the HVPS REP 1 2 Remove the Drive Motor PWB REP 4 5 Remove the Paper Handling Motor REP 4 4 Remove the Paper Handling Drive Unit Figure 1 Replacement 1 Reinstall the Paper Handling Drive Unit in the reverse order of removal 2 Disengage the wires from the clamp 3 1 Remove the Remove the screws 4 screw securing the Motor PWB Bracket 5 4 Remove the two
527. x WTPI A29WIJI o zoos 52064 eso eu Figure 2 Without Tag Symbol Figure 1 With Tag Symbol Initial Issue 10 00 Parts List Phaser 790 DocuColor 2006 5 5 Symbology A tag number within a circle with no apex shows that the entire drawing has been changed by A tag number within a circle with no apex and having a shaded bar shows that the entire the tag number within the circle Figure 3 Information on the modification is in the Change Tag drawing was the configuration before being changed by the tag number within the circle Index Figure 4 zoos 2 2007 eso eu so ec 1 Figure 3 Entire Drawing With Tag Symbol Figure 4 Entire Drawing Without Tag Symbol Parts List 10 00 Initial Issue Symbology 5 6 Phaser 790 DocuColor 2006 PL 1 1 Front and Left Covers Item Part Description 1 802K18401 Front Cover Assembly REP 14 1 2 Front Cover P O PL 1 1 Item 1 3 Cover Support P O PL 1 1 Item 1 4 Hinge Plate Not Spared 5 048E52291 Front Lower Cover REP 14 3 6 802011970 Front Middle Cover REP 14 2 7 802K17141 Left Inner Cover Assembly REP 14 5 8 Left Inner Cover P O PL 1 1 Item 7 9 Rotary Latch Lever P O PL 1 1 Item 7 10 Rotary Latch Spring P O PL 1 1 Item 7 11 802K12480 IBT Inner Cover REP 14 5 12 802K17151 Right Inner Cover REP 14 5 13 802E05350 Left Lower Cover REP 14 8 14 600K85500 Name Plate 15 600 85510 Name
528. xtend the Bypass Tray Observe the feed while manually rotating the drive components The sheet is skewed at the Registration Roll Y N Replace the ROS PL 5 1 Check the Registration Springs Registration Rubber Roll and Preregistration Roll for wear or contamination PL 4 7 If the problem continues replace the Main Paper Handling Frame Assembly PL 4 1 Image Quality 1010 IQ11 10 00 Initial Issue Phaser 790 DocuColor 2006 1012 IIT Skew RAP Procedure Make a copy in Platen mode The defect is present Y N The problem is Skew Y N Check adjust ADF Side Registration ADJ 5 1 and ADF Lead Edge Registration ADJ 5 2 Check adjust the ADF Height ADJ 5 3 and ADF Front to Rear Positioning ADJ 5 4 If the problem continues check the Feed Roll and Registration Roll PL 17 3 for wear or contamination Clean replace as required Check adjust IIT Lead Edge Registration ADJ 6 3 and IIT Side Registration ADJ 6 4 1013 Moire RAP This defect is defined as patterns on the copy that have the appearance of a screen or grid overlaying the image This pattern may be uniform or non uniform in area and shape Procedure Switch between photo modes to determine which mode minimizes the defect Decrease the Sharpness level Reduce or enlarge the copy slightly Rotate the original on the platen by 90 degrees Initial Issue 10 00 Phaser 790 DocuColor 2006 3 17 Image Quality 1012 1013 1014 Process Dir
529. y PWB Cover 0106031A WOL Figure 1 Removing the Advanced Features Memory Cover 0106010A WOL Figure 1 Removing the Extension PWB Replacement 1 Perform the procedure for removal in reverse Initial Issue 10 00 Repairs and Adjustments Phaser 790 DocuColor 2006 4 47 REP 6 15 REP 6 16 CAUTION The PWB components are highly susceptible to damage from electrostatic discharge ESD and extreme care should be used when handling these components Use of the ESD Field Service Kit is required 3 Remove the Advanced Features Memory PWB Figure 2 REP 6 17 Front Rear Cable Assembly Parts List on PL 16 4 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or electrical power applied to the machine 1 Switch off the machine power and disconnect the machine Power Cord NOTE The front and rear Cable Assemblies are mirror image Therefore this procedure is used for the removal replacement of either of the assemblies 2 Remove the Platen Glass REP 6 1 3 Remove the Right Cover REP 6 2 4 Remove the Left Cover REP 6 3 5 Remove the Rear Cover REP 6 4 6 Remove the Control Panel Assembly REP 6 23 7 Remove the Full Rate Carriage REP 6 21 8 Remove the Front Rear Cable Assembly Figure 1 1 the Spring and remove the Cable Assembly 1 222 Remove the Advanced Features Memory PWB 0106032A WOL F
530. y the logic state of input signals and to energize output components DI Code Component Signal BSD Ref 53 MCU Check Not used ax Procedure 54 MCU PWB Dipswitch _ Not used 1 Enter the Diagnostic Mode GP 1 S1 2 Press the Menu button to scroll through the menu choices The three choices to use for 60 Tray No Paper Sensor Tray No Paper Sensed H 5 VDC 7 1 component control are Tray 1 DI TEST use this selection for diagnostic checks of digital input components 61 Low Paper Switch Low Paper Sensed 1 5 VDC 7 1 DO TEST use this selection for switching on the output components 62 Fuser Assembly Fuser Installed L 5 VDC 1 2 STOP DO TEST use this selection for switching off the output components 66 Empty Sensor Bypass Empty Sensed 5 VDC 7 2 3 Press the Item Enter button to select the appropriate test mode Tray 4 Use the Up Arrow and Down Arrow buttons to navigate within the test mode 67 Cartridge Sensor Cartridge Sensed L 5 VDC 9 3 NOTE The component control function for Input Codes is not dynamically displayed 0 Fuser Motor Molor ESTE VDE vd You must first enter the code and validate the state Next actuate or deactuate the input A Paper Handling Motor Paper Handling Motor Fail H 5 VDC 4 1 component and then re enter the code to check for a change of state 72 Process Drive Unit Process Motor Fail H 5 VDC 9 2 73 Right Front Cover Inter Front Cover Closed L 5 11 2 NO
531. yed sage Downloading Done B qe download more 4 Press the Item Enter button W 1 2 4 5 Use the Up and Down arrow buttons to scroll through the menu of billing meter values a Prepare the Scanner for download again as per step 1 of this procedure Table 1 b back to Disconnect Connect Transfer Send Files and repeat 10 After all files required have been downloaded to the Scanner switch off the power and bis sa bd 2 edes id represent the values that have been counted then switch on the power and will appear as numerals on the display 11 Verify that the software was downloaded to the Scanner Table 1 Billing Meter Values a Switch off then switch on the Scanner power Category b Press the Tools button c Select Maintener menu then press the Select button COLOR PRINT SM IMAGES XX d Enter the password 9999 is the default COLOR COPY SM IMAGES XX e Press select then scroll down to Version Info COLOR PRINT LG IMAGES XX f Press the Select button COLOR COPY LG IMAGES XX Scroll d ify the fil B W PRINT IMAGES g croll down to verify the file version B W COPY IMAGES TOTAL COPY PRINT IMAGES XX 2 COLOR COPY IMAGES XX COLOR PRINT IMAGES XX COLOR COPY IMAGES XX TOTAL PRINT IMAGES XX TOTAL COPY IMAGES XX Initial Issue 10 00 General Procedures and Information Phaser 790 DocuColor 2006 6 13 GP 10 GP 11 GP 14 Printing a Configuration Page The purpose is to allow the Service Representative to print a m
532. z 3 Hz 660 mm Lo EI Table 3 Voltage Frequency of Operation E Power Voltage Frequency Hz NASG 110V 1096 60 I ESG 220 240V 10 50 67 EME EMI Grounding 1702 mm 36 inches Leakage protection 914 4 mm Double Insulated Construction D Electrical Noise mm gt 100 V type JPN VCCI Class 1 compliance ra 120 V type NASG 15 subpart Class B ANSI C63 4 11 4D Y 220 240 V type ESG 55022 CISPR Publication 22 Class B 0740000A WOL Figure 1 Installation Space Requirements Initial Issue 10 00 General Procedures and Information Phaser 790 DocuColor 2006 6 21 General Product Specifications Specifications Machine Power Consumption The power consumption of the print engine including the 500 sheet feeder and Duplex Tray at the rated voltage in each operating mode is as follows Table 4 Power Consumption Mode Watt Hours Fuser On Fuser Off Running color 600 or less 1200 watts n a Running b w 960 or less 1220 watts n a Ready 250 or less 1100 watts 100 watts Save 200 or less 1100 watts 100 watts Sleep 60 or less n a 60 watts Environmental Specifications Audible Noise Table 5 Audible Noise Continuous Noise Impulse Noise Stand by 57 db n a Copy Cycle 72 db 77 db Ozone Generation Maximum 0 01 ppm time weighted average Operating Range Temp amp RH Temperatu

Phaser 790/DocuColor 2006 Service Manual

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