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Xerox 7700DX - Phaser Color Laser Printer, Service Manual


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Summary of Contents for 7700DX - Phaser Color Laser Printer

Page 1: ...Service Manual Phaser 7700 701P28180 Color Laser Printer...

Page 2: ......

Page 3: ...qualified service personnel only To avoid personal injury do not perform any servicing other than that contained in operating instructions unless you are qualified to do so This printing December 200...

Page 4: ...are trademarks of Xerox Corporation in the United States and or other countries Adobe Reader Adobe Type Manager ATM and PostScript are trademarks of Adobe Systems Incorporated in the United States an...

Page 5: ...o efficiently accomplish a task A NOTE may also provide additional information related to a specific subject or add a comment on the results achieved through a previous action CAUTION A CAUTION indica...

Page 6: ...the cord or connector WARNING If the product loses the ground connection usage of controls and other conductive parts can cause an electrical shock Power Supply and Electrical Components Before start...

Page 7: ...This printer uses heat to fuse the toner image to a sheet of paper The Fuser Assembly is very hot Turn Off the printer power and wait at least 30 minutes for the Fuser to cool before you attempt to s...

Page 8: ...d or plug is frayed or otherwise damaged Or if any liquid or foreign material is spilled into the case Or if the printer is exposed to any excess moisture Or if the printer is dropped or damaged Or if...

Page 9: ...el between the supply conductors or between either supply conductor and ground A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation Class...

Page 10: ...itch the equipment off to determine if it is the true cause of the interference If the equipment is the cause of the interference the user should try to minimize the interference by taking one or more...

Page 11: ...ue est conforme aux limites mission de bruits radio lectriques pour les appareils de classe B stipul s das le r glement sur le brouillage radio letrique du Minist re des Communcations du Canada Europe...

Page 12: ...removing an ESD equipped assembly place it on a conductive surface such as aluminum foil or the static bag to prevent accumulation of an electrostatic charge Do not use freon propelled chemicals Thes...

Page 13: ...ponents 1 v Fuser Components 1 v Safety Components 1 v Warning Labels 1 v Safety Instructions 1 vi Care of Product 1 vi Ground the Product 1 vi Service Safety Summary 1 vii General Guidelines 1 vii Cl...

Page 14: ...terlocks and Sensors 1 15 Image Processor Board 1 16 Assemblies of the Print Engine 1 17 Assemblies of the Print Engine cont d 1 18 Assemblies of the Print Engine cont d 1 19 Auxiliary Feeder Assembli...

Page 15: ...s Nothing When Power Switched On 3 93 Fans On Front Panel LED Never On 3 93 Fans On Front Panel LED is Red No Front Panel message 3 93 Front Panel Continually Displays the Xerox Phaser 7700 Splash Scr...

Page 16: ...Random Spotting 3 113 Single Color 3 113 All Colors 3 114 Repetitive Mark Appears on Each Print 3 114 Background Contamination 3 115 Unfused Image or Image Easily Rubs Off of Page 3 116 Toner on Back...

Page 17: ...RAM 6 145 PostScript NVRAM Resets 6 145 Restore Factory Settings color 6 145 Restore Previous Settings color 6 145 Restore Factory Settings margins 6 146 Reset Calibrations color margins paper 6 146 R...

Page 18: ...Duplex Transport Assembly 7 173 Fuser Unit 7 174 Registration Transport Assembly 7 175 Shutter Solenoid Assembly 7 176 Tray 1 Feeder Assembly and Paper Lift Motor 7 177 Waste Cartridge Sensor Holder 7...

Page 19: ...ntrol Boards 7 229 Auxiliary Feeders Motor Assemblies 7 230 Auxiliary Feeder Paper Select Switches 7 231 Auxiliary Feeder Paper Feed Motor Assembly 7 232 Bracket Assembly Left Hand and Right Hand Gear...

Page 20: ...cessories 8 284 Recommended Service Tools 8 285 Test Prints 9 287 Analyzing the Test Print 9 288 Print Color Test Prints 9 289 Diagnostics Mode 9 291 Wiring Diagrams 10 295 Phaser 7700 Finisher 11 313...

Page 21: ...y 11 332 Stacker Paper Sensor Assembly 11 333 Set Clamp Clutch and Gear 11 334 Eject Roll Assembly 11 335 Finisher Control Board Bracket and Shield 11 336 Stacker Motor Assembly 11 338 Paddle Shaft 11...

Page 22: ...xx Phaser 7700 Color Laser Printer Service Manual...

Page 23: ...8 6 Cover FRUs cont d List 8 242 Table 8 7 Covers FRUs List cont d 8 244 Table 8 8 Switch and Sensor FRUs List 8 246 Table 8 9 Switch and Sensor FRUs List cont d 8 248 Table 8 10 Circuit Board FRUs Li...

Page 24: ...11 3 Finisher Covers FRUs List 11 347 Table 11 4 Finisher Stand FRUs List 11 349 Table 11 5 Gate Unit FRUs List 11 351 Table 11 6 Horizontal Transport Assembly FRUs List 11 353 Table 11 7 Horizontal...

Page 25: ...1 15 Assemblies of the Print Engine cont d 1 19 Figure 1 16 Auxiliary Feeder Assemblies 1 20 Figure 1 17 Front Panel 1 21 Figure 1 18 Printer Rear Connections 1 23 Figure 1 19 Printer Clearances 1 24...

Page 26: ...er plastic 7 179 Figure 7 26 Dispense Assembly 7 180 Figure 7 27 Print Cartridge Plate Assembly 7 182 Figure 7 28 Print Cartridge Plate Assembly cont d 7 183 Figure 7 29 Developer Housing Assembly 7 1...

Page 27: ...ure 7 70 High Capacity Feeder HCF Tray 4 and Paper Transport 7 228 Figure 7 71 LTD Control or HCF Control Board 7 229 Figure 7 72 Transport Motor Assembly 7 230 Figure 7 73 Paper Select Switches 7 231...

Page 28: ...ansport Belts 11 327 Figure 11 12 H Tra Entrance and Top Tray Full Sensor 11 328 Figure 11 13 H Transport Gate In Solenoid 11 329 Figure 11 14 Finisher Covers 11 330 Figure 11 15 Stack Height Sensor A...

Page 29: ...Phaser 7700 Color Laser Printer Service Manual xxvii Figure 11 39 Electrical FRUs 11 370 Figure 12 1 Block diagram of the Finisher 12 372 Figure 12 2 Wiring diagram of the Finisher 12 373...

Page 30: ...xxviii Phaser 7700 Color Laser Printer Service Manual...

Page 31: ...ce Manual is the primary document used for repairing and maintaining the Xerox Phaser 7700 Color Laser Printer Certification for servicing of this product requires completion of the Phaser 7700 printe...

Page 32: ...f paper The printer features a built in 100 sheet multi purpose tray from which specialty media card stock larger format paper and envelopes can be fed The printer also supports manual feeding using t...

Page 33: ...l Hard Drive through power cycles Secure Jobs Secure printing allows the customer to defer printing of a job until a matching password is entered from the control panel The customer assigns the passwo...

Page 34: ...f memory does not meet the above specifications it will be ignored by the printer With more memory the printer gains the capabilities of printing without having to use image compression which trades l...

Page 35: ...m Manufacturer Print Cartridge 15 Months 24k color mode K in B W mode 31 2k B W mode on CMY units Toner Cartridge Black Extended Standard 24 Months 24 Months 12k at 5 coverage 5k at 5 coverage Toner C...

Page 36: ...ace and Power Supply Boards Figure 1 2 Engine Control Interface and Power Supply Boards High Voltage Power Supply T2 Board AC Drive Board Noise Filter Board GFI High Voltage Power Supply T3 Board High...

Page 37: ...er Printer Service Manual 1 7 Power Supplies Figure 1 3 Power Supplies S7700 261 24 V Low voltage power supply 24 V Low voltage power supply fan 3 3 V Low voltage power supply 5 V Low voltage power su...

Page 38: ...1 8 Phaser 7700 Color Laser Printer Service Manual Engine Control and Image Processor Boards Figure 1 4 Engine Control and Image Processor Boards S7700 381 Engine Control Board Image Processor Board...

Page 39: ...Phaser 7700 Color Laser Printer Service Manual 1 9 Auxiliary Feeder Control Board Figure 1 5 Auxiliary Feeder Control Board S7700 385 LTD Board 3T HCF Board TT...

Page 40: ...e Sensors and Switches Figure 1 6 Print Engine Sensors and Switches S7700 287 Transfer Roller Sensor Tray 1 Take Away Sensor Paper On Belt Sensor Transparency Sensor Registration Sensor MPT No Paper S...

Page 41: ...1 7 Print Engine Sensors and Switches cont d S7700 288 Accumulator Belt Edge Sensor Accumulator Belt Home Sensor Duplex Wait Sensor Automatic Toner Correction Sensor K C M Y Environment Sensor Automa...

Page 42: ...nd Switches S7700 316 2 3 4 2 3 4 Paper Size Switch Assembly Tray 2 Paper Size Switch Assembly Tray 3 Tray 4 Paper Size Switch Assembly Tray 2 Tray 3 Tray 4 Take Away Sensor No Paper Sensor Level Sens...

Page 43: ...ction clutch tray2 tray 3 tray 4 Paper detect sensor actuator tray 2 tray 3 tray 4 Left hand cover interlock switch actuator One way clutch tray 2 tray 3 Left hand cover interlock switch actuator Pape...

Page 44: ...Clutches Figure 1 10 Print Engine Solenoids Actuators and Clutches S7700 387 CW Duplex clutch CCW Duplex clutch Registration clutch Paper detect sensor actuator MPT Paper detect sensor actuator tray 1...

Page 45: ...r Interlocks and Sensors S7700 390 Auxiliary feeder left hand cover interlock switch Left hand cover interlock switch Left hand lower cover sensor Transfer roller position sensor behind transfer rolle...

Page 46: ...r 7700 Color Laser Printer Service Manual Image Processor Board Figure 1 12 Image Processor Board J500 SODIMM2 Processor Health LED Hard Drive DIP Switches NVRAM socketed Ethernet USB Parallel SODIMM1...

Page 47: ...Color Laser Printer Service Manual 1 17 Assemblies of the Print Engine Figure 1 13 Assemblies of the Print Engine S7700 266 Fuser assembly Detack Saw connector Paper feeder assembly Left Hand lower co...

Page 48: ...ice Manual Assemblies of the Print Engine cont d Figure 1 14 Assemblies of the Print Engine cont d S7700 312 Developer housing assemblies 4x Dispenser assembly 4x Print cartridge plate Waste cartridge...

Page 49: ...Phaser 7700 Color Laser Printer Service Manual 1 19 Assemblies of the Print Engine cont d Figure 1 15 Assemblies of the Print Engine cont d S7700 386 Exit transport assembly...

Page 50: ...Auxiliary Feeder Assemblies Figure 1 16 Auxiliary Feeder Assemblies Note The High Capacity Feeder has a Tandem Tray design with three Paper Feeder Assemblies two on the left and one on the right side...

Page 51: ...icators Green Ready to print printing Flashing Green Receiving or Processing Data Yellow Warning Red Fatal Error Figure 1 17 Front Panel Table 1 2 Front Panel Key Descriptions 1 LED Power Status 5 Up...

Page 52: ...eral service tasks by using the options shown in the table Table 1 3 Front Panel Shortcuts Mode Press this selection at Power On Skip execution of POST diagnostics OK Print service diagnostics map INF...

Page 53: ...ns panel of the printer Figure 1 18 Printer Rear Connections Table 1 4 Rear Panel DIP Switch Settings Function Switch 1 Switch 2 Switch 3 Switch 4 Normal Customer operating mode UP UP UP UP Service mo...

Page 54: ...y deck Width 644 mm 25 4 in Depth 682 mm 26 9 in Weight 82 kg 180 lbs with consumables installed 122 kg 267 lbs with lower tray high capacity feeder Table 1 6 Physical Dimensions of Lower Tray Feeder...

Page 55: ...e Legal SEF 13 pages per minute Duplex Letter A4 LEF 18 pages per minute Tabloid A3 SEF 8 pages per minute Legal SEF 9 pages per minute Minimum Margins 5 mm 0 2 in on all sides Tray Capacities Main Tr...

Page 56: ...cations Characteristic Specification Temperature Operating Storage 10 to 32o C 20 to 50o C Humidly Operating Storage 10 to 85 relative humidity 30 to 85 relative humidity Altitude 0 to 2500 m 8000 ft...

Page 57: ...x 32 40 lb bond and Thick Cover Index with the following weights 170 220 g m2 65 80 lb cover 100 110 lb Index Paper Size Universal Tray 1 Universal Trays 2 4a a Thin Cover Index paper cannot be used i...

Page 58: ...m m 2 in 5 mm 2 in 5 mm US Folio 8 5 x 13 in 8 1 x 12 6 in 2 in 2 in Legal 8 5 x 14 in 216 x 356 mm 8 1 x 13 6 in 2 in 2 in Tabloid 11 x 17 in 279 x 432 mm 10 4 x 16 4 in 269 x 432 mm 2 in 5 mm 2 in...

Page 59: ...25 x 176 mm 115 x 166 mm 5 mm 5 mm B5 Envelope 176 x 250 mm 166 x 240 mm 5 mm 5 mm B4 Envelope 250 x 353 mm 240 x 343 mm 5 mm 5 mm C6 Envelope 114 x 162 mm 104 x 152 mm 5 mm 5 mm C5 Envelope 162 x 229...

Page 60: ...1 30 Phaser 7700 Color Laser Printer Service Manual...

Page 61: ...number is always represented as a pair with the chain first and the link second Chain A three digit identifier of a major attribute counter or assembly Link A three digit identifier of a specific com...

Page 62: ...he LED turns Green and the POST tests are run Power On Self Test POST The following tests are performed when the printer is powered On after the boot loader runs and before the operating system is loa...

Page 63: ...hes according to the fault code The front panel LED flashes in unison with the health LED The last posted message to the graphic front panel is present All soft faults are printed on the StartPage whe...

Page 64: ...nel is unplugged a hard fault is indicated by the heath LED I O ASIC 3 Hard This test determines if the I O chip is functioning properly Memory 4 Hard This test checks 64 bit reads and writes to memor...

Page 65: ...the switches before the printer is switched On to enter the selected mode Note When performing the Registration Control Procedures Processes of the RegiCon Adjustment on page 4 127 you must set the sw...

Page 66: ...t temperature Fault List No Faults Detected nn nnn Fault Text Power up only current static condition not a history log Front Panel Adjust Adjust Contrast Yes No Backlight On Yes No Adjust Value 1 15 8...

Page 67: ...Prints 6 pages of 100 solid fill for Yellow Magenta Cyan Black Red and Green Print Grid 1 dot Grid Init Startup Imaging Delivering Finishing Grid Done This print displays the four primary color lines...

Page 68: ...RANS This is the FIN EJECT Engineering use only Engineering use only POB Sensor POB Sensor is L Paper on Belt Sensor L Paper present H Paper not present Registration Sensor Registration Sensor is H L...

Page 69: ...r not full Tray Sensors Tray 1 Do you want auto media lift Yes No Tray 1 SW1 4 HHHL Letter Level H NoPaper L Tray 2 same as tray 1 Tray 3 no data available if HCF is installed Tray 4 same as tray 3 Th...

Page 70: ...ront Home is H Stapler Head Home is L Low is L Ready is L Move is L Front Corner is H Miscellaneous IOT Reg Clutch is H Eject Home is L Set Clamp Home is L Decurler Cam Position L Optional only if Fin...

Page 71: ...Belt Motor To avoid damaging the Accumulator Belt remove Do you wish to continue Yes No Motor On Motor Off Please cycle power to printer now Caution To avoid damaging the Accumulator Belt it is recom...

Page 72: ...ange setting Paper Path No Pick NoPaperRun Init Runs a complete print cycle only no paper is picked and no toner is dispensed Finisher Motors Optional Miscellaneous Main Eject Forward Eject Release St...

Page 73: ...ineering use only Shutter Solenoid Solenoid On Solenoid Off Press OK to run test ADC Shutter Open Solenoid On Solenoid Off ADC Automatic Density Correction Press OK to run test ADC Shutter Close Solen...

Page 74: ...Laser Power Check Y OK M OK C OK K OK YMCK OK YMCK CycUp OK This tests the laser output PWM Mapping Data Read Engineering use only Coarse RegiCon Init Refer to Coarse RegiCon Initialization on page 4...

Page 75: ...8 10 350 Error Code 30 Error Codes 12 13 14 15 Engineering Use Only Engineering Use Only Error Codes 40 and 44 CRU Life Counters Engineering Use Only Reset Engine NVRAM Writes data to Eng NVM from Har...

Page 76: ...illustration is provided at this location for your convenience in locating most of the connectors pins from which voltage measurements are taken Cross references links are provided Figure 2 1 Voltage...

Page 77: ...Phaser 7700 Color Laser Printer Service Manual 2 47 Fuser Connector Pin Locations Fig 2 2 Fuser Connector Pin Locations 6 9 3 12 5 8 2 11 4 7 1 10 S7700 427...

Page 78: ...egiCon Adjustment Procedure beginning on page 4 124 If the problem persists replace the Engine Control Board RRP 42 on page 7 206 11 06 372 ERROR 11 LASER UNIT POLYGON MOTOR FAILURE Note If this failu...

Page 79: ...on the Engine Control Board Does the voltage measure 5 VDC Yes No Replace the Engine Control Board Remove the Rear Cover RRP 1 on page 7 154 and Rear Shield RRP 9 on page 7 163 Measure the voltage at...

Page 80: ...voltage at P534 6 see figure page 2 46 on the Engine Control Board Does the voltage measure 5 VDC Yes No Replace the Engine Control Board Measure the voltage at P534 0 see figure page 2 46 on the Engi...

Page 81: ...534 9 see figure page 2 46 on the Engine Control Board Does the voltage measure 5 VDC Yes No Replace the Engine Control Board RRP 42 on page 7 206 Measure the voltage at P534 7 see figure page 2 46 on...

Page 82: ...534 12 see figure page 2 46 on the Engine Control Board Does the voltage measure 5 VDC Yes No Replace the Engine Control Board RRP 42 on page 7 206 Measure the voltage at P534 10 see figure page 2 46...

Page 83: ...Yes No Replace the Transfer Roller Retract Sensor Replace the Engine Control Board RRP 42 on page 7 206 21 09 343 ERROR 21 TRANSFER ROLLER RETRACT FAILURE Enter Service Diagnostics Mode Perform the 2...

Page 84: ...No Remove the Accumulator Belt Assembly RRP 35 on page 7 196 CautionRemoving the Accumulator Belt Assembly allows ambient light into the print cartridge area Avoid exposing the print cartridge drums...

Page 85: ...that drives the Accumulator Belt Does it move freely now Yes No Replace the Accumulator Belt Drive Assembly RRP 51 on page 7 217 Replace the Waste Auger Assembly RRP 37 on page 7 199 Run the Accumula...

Page 86: ...ger relatively clear of toner Yes No Note It is easy to spill toner in the next step Remove the Waste Toner Cartridge Run the Agitator Motor Test Does the Waste Toner Agitator Motor rotate Yes No Meas...

Page 87: ...ste Auger Assembly RRP 37 on page 7 199 Run the Accumulator Belt Motor test Does the Accumulator Belt Motor rotate Yes No Inspect P530 see figure page 2 46 on the Engine Control Interface Board for pr...

Page 88: ...VDC Yes No Measure the voltage between the Engine Control Interface Board P533A 3 see figure page 2 46 and frame ground Does the voltage measure 5 VDC Yes No Replace the Engine Control Board RRP 42 on...

Page 89: ...me ground Does the voltage measure 5 VDC Yes No Replace the Engine Control Board RRP 42 on page 7 206 If the problem persists replace the Engine Control Interface Board RRP 43 on page 7 207 Measure th...

Page 90: ...ine Control Board Does the resistance measure between 20K and 100K ohms Yes No Repair or replace the wiring harness between the Engine Control Board and the Fuser Replace the Engine Control Board RRP...

Page 91: ...e page 2 47 and P600 6 see figure page 2 47 Does the resistance measure between 20K and 100K ohms Yes No Replace the Fuser Assembly Reinstall Fuser Remove the Rear Cover RRP 1 on page 7 154 Rear Shiel...

Page 92: ...age 2 47 and P600 6 see figure page 2 47 Does the resistance measure between 20K and 100K ohms Yes No Replace the Fuser Assembly Reinstall Fuser Remove the Rear Cover RRP 1 on page 7 154 Rear Shield R...

Page 93: ...e resistance measure between 20K and 100K ohms Yes No Repair or replace the wiring harness between the Engine Control Board and the Fuser Replace the Engine Control Board RRP 42 on page 7 206 45 10 35...

Page 94: ...d P600 9 see figure page 2 47 Does the resistance measure between 20 ohms and 100 ohms Yes No Replace the Fuser Assembly Reinstall Fuser Remove the Rear Cover RRP 1 on page 7 154 Rear Shield RRP 9 on...

Page 95: ...nd P600 9 see figure page 2 47 Does the resistance measure between 20K and 100K ohms Yes No Replace the Fuser Assembly Reinstall Fuser Remove the Rear Cover RRP 1 on page 7 154 Rear Shield RRP 9 on pa...

Page 96: ...age 7 206 If the problem persists repair or replace the harness between Engine Control Board and the Fuser Fan Replace the Fuser Fan Assembly RRP 34 on page 7 195 Remove the Rear Cover RRP 1 on page 7...

Page 97: ...Control Board RRP 42 on page 7 206 Measure the voltage at the Print Engine Controller Interface Board P407 6 see figure page 2 46 and frame ground Does the voltage measure 24 VDC Yes No Replace the En...

Page 98: ...y inspect the connector damage Is the connector damaged Yes No Measure the voltage between pin 4 of the suspect print cartridge connector and frame ground Does the voltage measure 3 3 VDC Yes No Measu...

Page 99: ...d and the Waste Cartridge Full Sensor Repair or replace the harness as necessary Measure the voltage between the violet wire to the Waste Cartridge Full Sensor and frame ground Does the voltage measur...

Page 100: ...lem persists replace the Engine Controller Board RRP 42 on page 7 206 83 04 362 ERROR 83 ENGINE LOGIC BOARD NVRAM FAILURE Replace the Engine Control Board RRP 42 on page 7 206 If the problem persists...

Page 101: ...gh capacity Feeder installed Yes No Refer to Tray 1 2 3 or 4 Will Not Lift section page 3 95 in Troubleshooting Do any of the Auxiliary Feeder LTD or HCF Trays lift correctly Yes No Refer to Auxiliary...

Page 102: ...r Remove the Finisher Rear Cover RRP 42 on page 7 206 and the Board Cover RRP 42 on page 7 206 Measure the voltage between Finisher Board connector P852 7 see figure page 2 46 and Finisher frame groun...

Page 103: ...etween Finisher Board connector P852 1 see figure page 2 46 and Finisher frame ground Does the voltage measure 5 VDC Yes No Disconnect to the Stapler Unit Assembly Measure again the voltage between Fi...

Page 104: ...wiring between the Stapler Unit Assembly and the Finisher Control Board Replace the Finisher Control Board Replace the Finisher Control Board If the problem persists replace printer Engine Control Bo...

Page 105: ...Cover RRP 72 on page 11 330 Measure the voltage between the Finisher Control Board P850B 5 see figure page 2 46 and Finisher frame ground Again manually actuate the Stack Height Sensor Does the voltag...

Page 106: ...the Finisher Control Board and the Stack Height Sensor Note There is an intermediate connector in this harness J870 behind the Front Cover Remove Front Door to repair replace the harness Replace the F...

Page 107: ...ock Enter Service Diagnostics Mode From the Motors Fans Tests Finisher Motors Stapler Move Motor test menu select Move Front to move the Stapler to the front of the Finisher From the Main Menu select...

Page 108: ...ring harness between the Finisher Control Board and the Front Corner Sensor Measure the voltage at the Front Corner Sensor pin 3 violet and Finisher frame ground Does the voltage measure 0 VDC Yes No...

Page 109: ...age between the Finisher Control Board P849 5 see figure page 2 46 and Finisher frame ground Again manually actuate the Stack Height Sensor Does the voltage toggle between 5 VDC and 0 VDC Yes No Measu...

Page 110: ...d P849 4 see figure page 2 46 and Finisher frame ground Does the voltage measure 0 VDC Yes No Replace the Finisher Control Board RRP 77 on page 11 336 Repair or replace the wiring harness between the...

Page 111: ...am Shaft such that the photo interrupter toggles the Decurler Cam Home Sensor Does the voltage toggle between 5 VDC and 0 VDC Yes No Measure the voltage at the Decurler Cam Home Sensor pin 2 yellow an...

Page 112: ...46 and Finisher frame ground Does the voltage measure 0 VDC Yes No Replace the Finisher Control Board RRP 77 on page 11 336 Repair or replace the wiring harness between the Finisher Control Board and...

Page 113: ...e the solenoid to enable manual operation of the Set Clamp Home Sensor and observe the display for toggling between H and L of the Set Clamp Home Sensor Does the voltage toggle between 5 VDC and 0 VDC...

Page 114: ...R 124 COMMUNICATION FAILURE There are no diagnostics routines or test procedures for problems involving serial communica tions It is recommended to address the following suspect components assemblies...

Page 115: ...all of the resistances indicate continuity Yes No Check for broken wires or bad contacts on connections that are not 1 ohm or less Change the following parts in the order of priority as listed 1 Inte...

Page 116: ...ire or poor contact between the Print Cartridge and the Engine Control Board Yellow J 151 to J 405 Magenta J 152 to J 405 Cyan J 153 to J 405 Black J 154 to J 405 5 Replace the Eingine Control Board R...

Page 117: ...bleshooting power supply problems disconnect the Auxiliary Feeder or Finisher if installed and restart the printer Verify the problem is still present or refer to the appropriate Option troubleshootin...

Page 118: ...maged prints Fuser Jams Exit Jams Print Image Quality Problems Light undertones prints all colors Blank Prints One color is faded Missing bands in direction of paper travel Streaks in direction of pap...

Page 119: ...connector at the bottom of the 3 3 VDC 5 VDC and 24 VDC LVPS if not present replace the AC Drive Board Note The GFI Noise Filter and AC Drive Board are all part of the AC Electrical Chassis see RRP 49...

Page 120: ...or shorts Troubleshooting the 24 VDC LVPS Note Turn the printer power Off and disconnect the power cord Note The 24 VDC LVPS requires a 5 VDC enable signal to operate Ensure proper operation of the 5...

Page 121: ...and printer power On check for 24 VDC between P535 2 of the Engine Control Interface Board and frame ground 2 If 24 VDC is not present see Troubleshooting the 24 VDC LVPS on page 3 90 to verify the 24...

Page 122: ...door is closed completing the 24 VDC circuit and the Engine Control Board interrogates the Print Cartridge NVRAM If the Print Cartridges are present then the Waste Toner Cartridge is missing by defau...

Page 123: ...nel LED is Red No Front Panel message Replace the Front Panel Cable RRP 4 on page 7 157 Replace the Front Panel RRP 4 on page 7 157 Replace the Internal Hard Drive RRP 40 on page 7 203 Replace the Ima...

Page 124: ...e No Paper Sensor Lever while observing the display 4 Verify continuity of the wiring between the No Paper Sensor and the Control Board 5 If the problem is with Tray 2 3 or 4 replace the Auxiliary Fee...

Page 125: ...ontrol Board RRP 42 on page 7 206 Tray 2 3 or 4 Will Not Lift In order for a paper tray to lift the 24 VDC interlock circuit through the LH Door of the Auxiliary Feeder must be complete one or both of...

Page 126: ...ry feeder Board P541 1 2 3 4 5 and 6 5 Replace the Auxiliary Feeder Control Board RRP 60 on page 7 229 6 Replace the Engine Control Board RRP 42 on page 7 206 Printer Will Not Recognize the Finisher T...

Page 127: ...rtridge 1 Ensure the Toner Cartridge is correctly installed and rotated into its opened position 2 Remove the Toner Cartridge in question 3 Inspect the cartridge s cap to ensure it is securely taped i...

Page 128: ...ould be completely filled to the rim Figure 3 3 Toner Cartridge 4 If toner is not level at the port then the toner in the Toner Dispense Assembly has been augered into the Developer but no fresh toner...

Page 129: ...otor Gear rotate Also look along the right side of the Toner Cartridge cavity You should see the Drive Shaft of the Toner Auger System rotate as the Toner Motor operates Inspect the Drive Shaft mechan...

Page 130: ...in question The toner level at the port should drop as toner is augered into the Developer Figure 3 5 Toner Port 7 If the Drive Shaft rotates but the toner level at the port does not drop replace the...

Page 131: ...15 A size pages of 100 Solid Fills of the primary color you are troubleshooting 7 Turn Off the printer and then power up the printer in Service Diagnostics mode 8 Re run the Adjustment Calibration To...

Page 132: ...Sensor Setup Test Backup the new engine NVRAM values to the printer s hard drive using the NVRAM Access menu s Store Engine NVRAM menu item Replacement ATC Sensors and the ATC Sensor on a replacement...

Page 133: ...will be augered into the Developer Housing no error message will necessarily be displayed Printing of that primary color will get progressively lighter and lighter In such a case the Developer Housing...

Page 134: ...rint driver dialog box make sure the Color Grayscale option has been selected 2 Check the version 3 Ensure the driver setting TekColor is not set to Monochrome mode Image is Rotated 90 Degrees 1 In th...

Page 135: ...is full the printer stops recording data to the log The logs are stored on the Hard Drive so only new data is stored each time the printer s power is cycled There is a Connection Setup Page Configurat...

Page 136: ...r a laser printer quality office laser printer paper works best 2 Ensure that the printer is printing within its environmental specifications by using the built in service diagnostics temperature test...

Page 137: ...the problem disappears Fuser Accumulator Belt usually appears with toner in creases or wrinkles Fuser Jams 1 Is the paper in good condition and appropriate for a laser printer 2 Is Xerox Series 7700...

Page 138: ...the Bias Transfer Roller RRP 17 on page 7 172 8 Replace the High voltage Power Supply RRP 44 on page 7 208 Blank Prints The entire image area is blank 1 Generate a 100 Solid Fill Test print from the f...

Page 139: ...s and closes using the Service Diagnostics Shutter Solenoid test 6 Inspect and test the toner auger system Ensure that the toner auger motor operates Ensure that the toner dispense assembly is carryin...

Page 140: ...ed through the printer with the short edge of the print parallel to the direction of the paper path making print artifacts parallel to the short edge of the print 1 Clean the laser windows with the cl...

Page 141: ...Pages Menu select Print Supplies Page 2 Run the solid fill test pages From the front panel s Printable Pages Menu select Service Pages then select Print Solid Fill Pages If the missing bands only occ...

Page 142: ...having a high moisture content 2 Does the band repeat at a specific interval If so troubleshoot using the Repeating Defects topic 3 Run the Remove Print Smears routine From the front panel s Support...

Page 143: ...front panel settings 3 Run the Calibrate for Paper routine From the front panel s Support Menu select Improve Print Quality then select Calibrate for Paper Menu 4 Run the solid fill test pages From th...

Page 144: ...each or every other printed image 1 From the front panel s Support Menu select Improve Print Quality then select Remove Print Smears This function passes several blank sheets of paper through the prin...

Page 145: ...aper routine From the front panel s Support Menu select Improve Print Quality then select Calibrate for Paper Menu Note Printing on some specialty papers such as some glossy finish papers may show bac...

Page 146: ...rintable Pages Menu select Print Paper Tips Page 2 Make sure that the paper loaded in the tray matches the paper type selected on the printer s front panel 3 If the problem continues set the paper typ...

Page 147: ...aded in the paper trays Is the paper clean and free of toner 3 Ensure that the loaded media matches the front panel settings In some cases switching the paper type setting for example from Heavy Laser...

Page 148: ...media selected in the printer driver 3 For specialty papers experiment with alternate paper type settings such as Heavy Laser Paper Thick Cover Index and others 4 Run the Calibrate for Paper routine F...

Page 149: ...ont panel s Printable Pages Menu select Print Configuration Pages or Print Startup Page 2 Is the correct weight paper loaded in the tray or multi purpose tray 3 Ensure that the paper guides are set to...

Page 150: ...s set the paper type in the front panel to the next heaviest type of paper than what you are using Below is a list of paper types from the heaviest weight to the lightest Thick Cover Index Thin Cover...

Page 151: ...y Mottled prints can be a result of bead carryout Bead carryout is when most of the beads in the Developer are carried out of the Developer Assembly into the Waste Toner Cartridge Procedure 1 Replace...

Page 152: ...3 122 Phaser 7700 Color Laser Printer Service Manual...

Page 153: ...e firmware There is a special file on the hard drive that stores the specific calibration values for various sensors and for the unique positioning of the laser in the printer During manufacturing the...

Page 154: ...image problem see Print Image Quality Problems on page 3 108 The printer registration process consists of the Belt Edge Learn Coarse Skew Adjustment Fine Skew Adjustment In Out Skew Adjustment and Cen...

Page 155: ...de of each line is adjusted to be level with the right end In Out Skew Adjustment The In Out Skew Adjustment Magnification ensures that all four scan lines are the same length During RegiCon 2 the pri...

Page 156: ...Adjustment Magnification Balance adjusts the linearity of the scan lines During RegiCon 3 the printer measures a specific midpoint of each scan line and adjusts it to a horizontal reference midpoint...

Page 157: ...moves freely without contacting any other parts 3 If RegiCon appears to run correctly but No Results is displayed one of the Sensors on the MOB Sensor Assembly or the Laser could have failed or the u...

Page 158: ...re re booting and did not get any results verify that the MOB Sensor is operating correctly by running the ADC Output check from the Adjustments Calibration menu The test provides results that indicat...

Page 159: ...djusting position of the screws and restart the RegiCon procedure The adjusting screws have 18 complete turns from fully CW to fully CCW To adjust the screws to the center position turn the screw to e...

Page 160: ...he screws to the center position turn the screw to either limit and then turn it back 9 complete turns Table 1 RegiCon Procedure Step Actions and Questions Yes No 1 Print the Grid 1 Dot print from Dia...

Page 161: ...f this occurs center the adjusting position of the screws and restart the RegiCon procedure The adjusting screws have 18 complete turns from fully CW to fully CCW To adjust the screws to the center po...

Page 162: ...MOB Sensor 6 Print the Grid 1 Dot print from Diagnostics Do all the colors align Complete follow the Store Engine NVRAM procedure page 6 150 Reconnect all cables and turn Netware back on before call c...

Page 163: ...Adjust mirrors for values greater than 5 to 5 No Pass No Troubleshoot repair and start over Yes All results 5 to 5 Run RegiCon 2 Pass Move MOB Sensor to Center position No No Yes Yes Run RegiCon 3 Pas...

Page 164: ...n place The belt WILL walk off the rollers and be permanently damaged 1 From the Service Diagnostics Menu highlight the Adjustments Calibrations menu and press OK 2 Highlight Belt Edge Learn and press...

Page 165: ...s Mode 6 Enter Adjustments Calibration Regi Con 685 Results Display and press OK 7 Wait until the test results are displayed as follows Note If the block counts are not the same number as presented he...

Page 166: ...itialization procedure on page 4 140 This adjusts the horizontal alignment closer and allows RegiCon 4 to pass After Coarse RegiCon Initialization is complete perform RegiCon 4 Coarse Skew Adjustment...

Page 167: ...test Wait for approximately 10 seconds after the motors turn off and the display indicates Ready To Print then cycle power and enter Service Diagnostics 5 Enter Adjustments Calibration Regi Con 685 Re...

Page 168: ...hen cycle power and enter Service Diagnostics 5 Enter Adjustments Calibration Regi Con 685 Results and press OK 6 Wait until the test results are displayed as follows Note If the block counts are not...

Page 169: ...otors turn off then cycle power and enter Service Diagnostics To display the results or continue you must re enter Service Diagnostics Mode 10 Enter Adjustments Calibration Regi Con 685 Results and pr...

Page 170: ...the magnification or magnification balance values so select No to Reset Mag Bal Values Yes No Note In all the following steps Cyan is the reference line and cannot be adjusted so you need to adjust al...

Page 171: ...nit test This time answer No to the Set Factory Defaults Yes No but answer Yes to the Do you want to adjust NVRAM Yes No question Answer No to Set Skew Error threshold Yes No Answer Fast to the Which...

Page 172: ...new values 1 Enter Service Diagnostics 2 Highlight Adjustments Calibrations menu and press OK 3 Highlight ATC Sensor Setup Test and press OK 4 Note the current values for the tag numbers on the front...

Page 173: ...horoughly inspect and clean these printers Recommended Tools Toner vacuum cleaner Clean water Clean dry lint free cloth Black light protective bag Cleaning Caution Never apply alcohol to the fuser rol...

Page 174: ...5 144 Phaser 7700 Color Laser Printer Service Manual...

Page 175: ...Support and press OK 2 Highlight Improve Print Quality and press OK 3 Highlight Calibrate Colors Menu and press OK 4 Highlight Restore Factory Settings and press OK 5 Highlight Restore Factory Settin...

Page 176: ...ality and press OK 3 Highlight Reset Calibrations and press OK 4 Highlight Reset Calibrations NOW and press OK to reset the color margins and paper transfer settings to factory defaults Resetting All...

Page 177: ...t speed to their default values 1 From the Main Menu highlight Network Setup Menu and press OK 2 Highlight Reset Network Setup and press OK 3 Reset Network Setup NOW is displayed press OK Resetting Ac...

Page 178: ...ghlight Reset Belt Cleaner Life and press OK 3 Reset Cleaner Life NOW is displayed press OK to reset the Accumulator Belt life Resetting Transfer Roller Life Resetting the transfer roller life is to b...

Page 179: ...can occur during normal operation and the normal procedure is to isolate and repair the problem However with these particular faults an additional step is required A value has been written in the engi...

Page 180: ...RAM and writes values to the hard drive It overwrites NVRAM values stored on the hard drive You must store values to the hard drive before any of the following parts are replaced or procedures perform...

Page 181: ...fer to the FRU Parts List on page 8 235 This section contains the removal and replacement procedures for selected parts of the printer Not all Replacement Procedures are included in this Quick Referen...

Page 182: ...x Transport Assembly 7 173 RRP 19 Fuser Unit 7 174 RRP 20 Registration Transport Assembly 7 175 RRP 21 Shutter Solenoid Assembly 7 176 RRP 22 Tray 1 Feeder Assembly and Paper Lift Motor 7 177 RRP 23 W...

Page 183: ...tor Belt Drive Assembly 7 217 RRP 52 Developer Drive Assembly 7 218 RRP 53 Print Cartridge Drive Assembly 7 219 RRP 54 Tray 1 Paper Select Switches 7 220 RRP 55 Main Lever Assembly Right and Left Hand...

Page 184: ...uxiliary Feeder has been installed open the Auxiliary Feeder Connection Cover and disconnect the Auxiliary Feeder wiring harness 2 Remove the four screws that secure the Rear Cover Assembly to the pri...

Page 185: ...three screws that secure the Right Side Cover to the printer One screw is located behind the Right Hand door 3 Lightly press downward to release the four hidden tabs that are behind the right side cov...

Page 186: ...ight side of the Top Cover 3 Open the Front Cover and remove the front screw holding the Top Cover 4 Open the Image Processor Board Cover to gain access to the 4 thumb screws that secure the Image Pro...

Page 187: ...ase the Front Panel Assembly by inserting a screwdriver or key into the two access holes indicated in the illustration and push the tangs inward to release 3 Lift up the panel slightly and unplug the...

Page 188: ...ver RRP 1 on page 7 154 2 Open the Left Hand Door 3 Loosen one screw from the Top Rear Cover 4 There is a hidden captive tab on the front and side of this cover that resists the upward pull Place your...

Page 189: ...59 Removal cont d Cover Left Hand Rear Mid 5 Remove one screw from the Left Hand Rear Low Cover and remove the cover 6 Remove one screw from the Left Hand Rear Mid Cover 7 Lift the cover up to release...

Page 190: ...er Assembly 2 Disconnect the sensor in the door wiring harness plug at the rear and free the harness from the clamp near the rear pivot 3 With a flat tip screwdriver pry out the pivot pin then pry out...

Page 191: ...over Assembly 2 Rotate the printer end of the strap 90 degrees and pull it straight out of the printer both sides 3 Remove the screws that secure the hinges and slide the hinges off the locating pin b...

Page 192: ...rinter Service Manual RRP 8 Fuser Front Cover Removal 1 Remove the Front Cover Assembly RRP 7 on page 7 161 2 Remove two screws from the Fuser Front Cover and push upward and remove the cover Figure 7...

Page 193: ...163 RRP 9 Rear Shield Removal Warning Turn Off the power and disconnect the power cord 1 Remove the Rear Cover RRP 1 on page 7 154 2 Remove the seven screws securing the Rear Shield to the printer 3 R...

Page 194: ...r Shield Bracket Removal 1 Remove the Rear Cover RRP 1 on page 7 154 2 Remove the Rear Shield RRP 9 on page 7 163 3 Remove the three screws securing the Rear Shield Bracket to the printer 4 Remove the...

Page 195: ...r Shield RRP 9 on page 7 163 3 Remove the Rear Shield Bracket RRP 10 on page 7 164 4 Remove the four screws securing the 24 VDC Power Supply Shield to the printer 5 Remove the 24 VDC Power Supply Shie...

Page 196: ...en assembling be sure the wire harness is behind the mounting tab 2 Release the wiring harness clip from the printer s frame 3 Pull the MPT Assembly wiring harness through the access hole 4 Close the...

Page 197: ...Pick Rollers Removal 1 Open the left side door Locate the pick rollers near the duplex chute 2 Slide the white retainers away from the pick rollers 3 Slide the pick rollers off the retaining pins 4 Li...

Page 198: ...aint post 5 Support the Left Hand Door then remove the restraining bracket from the door 6 Carefully lower the Left Hand Door until it stops Complete Removal 1 Remove the MPT RRP 12 on page 7 166 2 Re...

Page 199: ...eplacement 1 Reverse the above steps to install the Left Hand Cover Assembly Left Hand Door Caution When reinstalling the Left Hand Door reach underneath the door and hold the black plastic duplex chu...

Page 200: ...uplex Chute Removal 1 Partially remove the Left Hand Cover Assembly Left Door RRP 14 on page 7 168 2 Rotate the Duplex Chute downward until the keyed pivot shaft can be removed from the pivot bracket...

Page 201: ...Unit Assembly Removal 1 Release the clip securing the Duplex Unit Cover and remove the cover 2 Loosen the two captive screws securing the Duplex Unit Assembly to the Left Hand Cover Assembly and remov...

Page 202: ...Left Hand Cover Assembly Left Door 2 Using a 2 5 mm hex driver remove the four captive screws from the mounting brackets 2 at each end of the Transfer Roller Assembly 3 Remove the assembly Replacement...

Page 203: ...lly remove the Left Hand Cover Assembly Left Door RRP 14 on page 7 168 2 Remove the e clip and remove the shaft 3 Remove the two screws that secure the Inverter Transport Assembly to the Left Hand Doo...

Page 204: ...Manual RRP 19 Fuser Unit Removal 1 Open the Left hand Door Caution The Fuser Unit may be hot 2 Unscrew the two thumb screws securing the Fuser Unit 3 Using the pull handles pull the Fuser Unit out of...

Page 205: ...e two screws from the plastic flanges that secure the assembly in the printer frame using a stubby screwdriver Caution Note the wiring harness routing in the above figure Make certain the wires are ro...

Page 206: ...e wiring harness from the front frame connector 6 Note the locating pin then loosen the one screw that secures the assembly to the frame and remove the shutter solenoid assembly Replacement Caution It...

Page 207: ...securing the lower tray bracket 5 Remove the Tray 1 feeder assembly Note Some wiggling may be required to disengage the gears Removal of the Motor 1 Disconnect the wiring harness from the motor 2 Rem...

Page 208: ...ste Cartridge 3 Remove the Waste Cartridge 4 Remove the e clip and remove cover 5 Remove the screw securing the waste cartridge pivot hinge and remove the hinge 6 Remove the Waste Cartridge Sensor Hol...

Page 209: ...e Plate Cover Removal Print Cartridge Plate Cover 1 Open the Front Door 2 Remove Fuser Front Cover RRP 8 on page 7 162 3 Lower the main lever 4 Remove the four screws 5 Remove the plastic Print Cartri...

Page 210: ...er or something similar available to place the removed assemblies on Note The dispense assemblies overlap and must be removed in the following order Y M C K then reinstalled K C M Y 1 Open the Front D...

Page 211: ...Dispense Assembly on page 7 180 Caution Be careful when moving the stops They are easily broken and may come out completely 6 Remove the screw holding each dispense assembly to the printer 7 Remove th...

Page 212: ...rint Cartridges are very light sensitive Store the Print Cartridge away from light Do not touch the surface of the Print Cartridges 1 Remove the Print Cartridges 2 Leave the main lever down 3 Remove t...

Page 213: ...guide located on the lower left side of the assembly 8 Remove the six chrome plated screws that secure the plate to the frame Note Stop here if only replacing developers Complete removal of the Print...

Page 214: ...tly tug the wires to ensure that they are not pinched by the plate or developers while reinstalling Caution Be very careful not to catch any of the wires on the left hand side of the plate while re in...

Page 215: ...moved Do not disconnect the Print Cartridge Plate harnesses 1 Partially remove the Print Cartridge Plate Assembly RRP 26 on page 7 182 2 Remove the desired Developer Housing Assembly RRP 27 on page 7...

Page 216: ...ATC tag number label and adhere it to the appropriate print cartridge connector on the print cartridge plate assembly then perform the procedure See ATC Sensor Setup on page 4 142 Note It is easy to...

Page 217: ...eloper mix Carefully pour the entire contents of Developer mix as evenly as possible over the two augers Do not let the developer mix accumulate heavily on the roller Keep the Developer Housing Assemb...

Page 218: ...55 and the Top Cover Assembly RRP 3 on page 7 156 2 Remove the Dispense Housing Assemblies RRP 25 on page 7 180 3 Remove the two screws that secure the Toner Dispense Motor Assembly to the printer fra...

Page 219: ...e the Print Cartridges and Print Cartridge Plate Cover RRP 24 on page 7 179 2 Disconnect the wiring harness 3 Remove the three screws and remove the Steering Drive Assembly Note You may have to rotate...

Page 220: ...emove the Print Cartridge Plate Cover RRP 24 on page 7 179 2 Remove the Waste Cartridge Assemblies RRP 23 on page 7 178 3 Disconnect the wiring harness to the motor 4 Remove the two screws that secure...

Page 221: ...le harness 5 Remove the wiring harness from three clips 6 Remove the one black screw and remove the Mark On Belt assembly Note If the Mark On Belt adjustment procedure RegiCon DC685 3 is being perform...

Page 222: ...on page 7 158 3 Remove the Fuser Front Cover RRP 8 on page 7 162 4 Open left hand cover 5 Remove the one screw securing the Transport Assembly Cover and remove the cover 6 Disconnect the harnesses to...

Page 223: ...ts required for the Side Exit Exit Assembly an option not available on the Phaser 7700 are no longer installed on the Inverter Transport Assembly P N 116 1161 00 The revised configuration is shown in...

Page 224: ...erter Transport Assembly packaging as a separate item see Figure 7 38 If only the Interlock Actuator is broken it can now be replaced individually The 0 5 mm spacers should be placed between the Inter...

Page 225: ...move Right Side Cover RRP 2 on page 7 155 Note Note the routing of the wiring harness Note It is easier to re install the wire harness if the Fuser Fan and plastic mounting bracket are removed from th...

Page 226: ...7 196 Phaser 7700 Color Laser Printer Service Manual RRP 35 Accumulator Belt Assembly Figure 7 40 Accumulator Belt Assembly...

Page 227: ...ccumulator Belt assembly is heavy Use the white nylon handle when removing the assembly from the printer Do not get fingerprints on the belt Note Metal tabs allow the Accumulator Belt to be laid on a...

Page 228: ...ew inches 4 Using a 2 5 mm hex driver remove the two screws on the left side of the belt cleaner assembly 5 Remove the belt cleaner assembly Replacement Caution Never run the printer without the belt...

Page 229: ...Return the main lever to its upright position 4 Remove the two screws securing the Waste Auger Assembly 5 Shift the Waste Auger Assembly to remove the drive shaft from the bearing and remove the wast...

Page 230: ...7 200 Phaser 7700 Color Laser Printer Service Manual RRP 38 Laser Unit Figure 7 43 Laser Unit Assembly...

Page 231: ...e the routing of the laser unit wiring harness up to the engine control board 4 Remove the two screws securing the laser unit in the printer Caution The laser unit is heavy 5 Pull the Laser Unit out o...

Page 232: ...s and remove the image processor board 3 Remove the Internal Hard Drive RRP 40 on page 7 203 4 Remove the socketed NVRAM chip located near the parallel port connector from the board just removed and u...

Page 233: ...Board See RRP 39 on page 7 202 2 Using a T 10 torx bit remove four screws on the bottom side of the Image Processor Board holding the Internal Hard Drive 3 Slide the Internal Hard Drive away from the...

Page 234: ...emove the Top Cover RRP 3 on page 7 156 3 Remove the Rear Cover RRP 5 on page 7 158 4 Remove all three Shields RRP 10 on page 7 164 5 Remove the Image Processor Board RRP 39 on page 7 202 6 Disconnect...

Page 235: ...en the gap in each of the two white nylon retainers to ensure that they successfully engage the interface board bracket Mis alignment prevents a good connection to the interface board 1 Tilt and inser...

Page 236: ...P460 4 Remove the 8 screws securing the engine control board metal shield and remove the shield 5 Remove the remaining six screws and remove the engine board Note When reinstalling the Engine Control...

Page 237: ...mounting bracket from the printer frame Method 2 1 Lower the HVPS assembly to a horizontal position 2 Disconnect the eight wiring harnesses Note Two connectors J537 J536 have locks to release before p...

Page 238: ...tilt the entire high voltage assembly down Note If complete removal is not required there is a restraining strap on the back side of the assembly to hold the assembly in a horizontal position 4 Disco...

Page 239: ...ce Manual 7 209 Replacement Note Connect the high voltage 2nd BTR and P J 801 wires before securing the assembly to the printer to ensure they are not forgotten Note The grounding point requires the c...

Page 240: ...harness from the printer and remove the 4 screws that secure the low voltage power supply to the mounting bracket 1 Lower the T1 and T3 power supply to horizontal RRP 44 on page 7 208 2 Disconnect P...

Page 241: ...11 RRP 46 LD Power Relay Removal 1 Remove rear cover and shield RRP 9 on page 7 163 2 Disconnect the wiring harness 3 Remove the two screws securing the LD power assembly 4 Remove the LD power assembl...

Page 242: ...e 7 160 Note If only the power supply needs to be removed disconnect the wiring harness and loosen the 2 screws that secure the power supply to the PS mounting bracket 3 Disconnect the wiring harness...

Page 243: ...Power Supply and Bracket RRP 11 on page 7 165 2 Disconnet the high voltage wires from the KCMY connectors 3 Disconnect the wiring harness from J575 and J576 4 Remove the two screws that secure the 1st...

Page 244: ...assembly RRP 44 on page 7 208 3 Disconnect the wiring harnesses P15 and P16 the AC drive wiring harness P43 and the individual wires at J39 J40 J41 and J47 of the AC drive board 4 Disconnect the AC wi...

Page 245: ...harness Note There are 5 brass screws that hold the main drive assembly together DO NOT remove these screws 4 Remove the five black screws that secure the complete main drive assembly to the printer f...

Page 246: ...l the main motor bracket seats without stress and flat against the frame Rotate the main drive after installing the assembly to ensure it rotates freely and ensure it is FLAT against the frame It is e...

Page 247: ...page 7 163 2 Lower the T1 and T3 power supply to horizontal RRP 44 on page 7 208 3 Remove any components covering the motor which is mounted to the frame at the rear top left corner 4 Remove the thre...

Page 248: ...RRP 45 on page 7 210 2 Disconnect the wiring harness from the Developer Drive Assembly 3 Clear the high voltage lines 4 Remove the two black screws securing the Developer Drive Assembly to the printer...

Page 249: ...pply RRP 48 on page 7 213 6 Disconnect the wiring harness to the Print Engine Drive Assembly 7 Remove the two screws securing the finisher connector now accessible after removing the Right Cover Assem...

Page 250: ...er supply RRP 44 on page 7 208 1 Remove the 3 3 VDC and 5 VDC low voltage power supply RRP 45 on page 7 210 2 Disconnect the wiring harness from the tray 1 paper select switches 3 Remove the two screw...

Page 251: ...screw and washer and remove the RH Handle Pivot Pin 8 Remove the Main Lever Assembly Removal RH Jack Assembly Caution Ensure that the Lift Frame Assembly is fully lifted and the RH and LH Lift Jack As...

Page 252: ...7 175 7 Remove the Mark On Belt MOB Sensor Assembly RRP 32 on page 7 191 8 Reach inside the LH cover cavity and remove the black print cartridge rail by pushing on the rail slot while pulling on the...

Page 253: ...Right and Left Hand Jacks on page 7 221 to remove the affected Lift Jack Assembly Once the assembly is removed check the alignment of the Lift Pins as shown in Figure xyz The center of both Pins shoul...

Page 254: ...ing Figure 7 65 Tension Spring Location 4 Align the triangle marks on the Gears and the Rack by lifting the Gear Assemblies on their mounting posts until they disengage from the rack and rotating them...

Page 255: ...four screws securing the left hand outer cover and remove 2 Remove the screws securing the straps 3 Remove the one screw holding the front side pivot bracket and remove the left hand door Rear Cover 1...

Page 256: ...High Capacity Feeder HCF Cover Assembly 2 Remove one screw from each of the support straps 3 Remove one screw from the cover s right hand pivot bracket 4 Remove the cover assembly from the left hand...

Page 257: ...Manual 7 227 RRP 58 High Capacity Feeder HCF Tray 3 Removal 1 On the left side of the HCF remove one screw from the Tray 3 Stopper bracket and remove the bracket 2 Pull Tray 3 out of the printer Figu...

Page 258: ...HCF Tray 4 and Paper Transport Removal 1 Open Tray 4 2 Remove the two screws that secure the Tray 4 Stopper 3 Remove the two screws securing the paper transport and slide it back in 4 Pull Tray 4 out...

Page 259: ...60 Auxiliary Feeder Control Boards Removal 1 Remove the Rear Cover RRP 1 on page 7 154 2 Disconnect the wire harnesses 3 Remove the four screws securing the control board and remove the board Figure 7...

Page 260: ...xiliary Feeders Motor Assemblies Removal 1 Remove Rear Cover RRP 1 on page 7 154 2 Disconnect the wire harness 3 Remove the two screws securing the motor assembly 4 Remove the motor assembly Figure 7...

Page 261: ...the Paper Tray 2 Reaching inside the cabinet disconnect the wire harness LTD 3 places HCF 1 place 3 Reaching inside the cabinet remove the 1 screw that secures the Paper Select Switch LTD 3 places HCF...

Page 262: ...Note Some wiggling may be required to disengage the gears Removal of the Motor 1 Disconnect the wiring harness from the motor 2 Remove the two screws securing the motor to the feeder bracket 3 Lift th...

Page 263: ...the Rear Cover RRP 1 on page 7 154 2 Remove the two screws securing the Bracket Assembly Gear RH or Gear LH to the frame 3 Remove the Bracket Assembly Replacement Note There are locating pins for each...

Page 264: ...7 234 Phaser 7700 Color Laser Printer Service Manual...

Page 265: ...sequence number of the printer produced on that day The serial number is coded as follows JLxxDMY J indicates the headquarter country of the manufacturing company Japan L indicates the modification le...

Page 266: ...tor Belt FRUs List Parts Part Number Qty Name and Description vendor description 1 016 1889 00 1 Accumulator Belt cleaner Assembly Kit Belt Assembly IBT 2 116 1207 00 1 Accumulator Belt Shipping Restr...

Page 267: ...Phaser 7700 Color Laser Printer Service Manual 8 237 PL 8 2 Left Hand Door FRUs Figure 8 2 Left Hand Door FRUs 1 2a 2 S7700 042 3 8 9 5 6 7 4...

Page 268: ...2 2a 116 1182 00 116 1317 00 1 1 Regi Chute Assembly Left Hand Cover only Cover Assembly L H2 3 016 1890 00 1 Transfer Roller Roll Assembly 2nd E 4 116 1098 00 1 Duplex Chute DUP Chute 5 116 1542 00...

Page 269: ...3 Media Trays FRUs Figure 8 3 Media Trays FRUs Table 8 3 Media Trays FRUs List Parts Part Number Qty Name and Description vendor description 1 116 1091 00 1 Universal Paper Tray 2 2a 116 1093 00 1 2...

Page 270: ...Printer Service Manual PL 8 4 Duplex Unit FRUs Figure 8 4 Duplex Unit FRUs Table 8 4 Duplex Unit FRUs List Parts Part Number Qty Name and Description vendor description 1 116 1097 00 1 Duplex Unit Tra...

Page 271: ...1 1 1 1 Front Cover Assembly Cover Assembly Front Front Cover Magnet Strip Rod Cleaner Assembly Rod Cleaner Cleaner Base Label Label 2 116 1095 00 1 Right Cover Cover Assembly R MN 3 116 1187 00 1 Fro...

Page 272: ...ts Part Number Qty Name and Description vendor description 1 116 1181 00 029E31600 compatible with Phaser 7760 1 1 1 2 1 1 2 1 1 1 2 1 1 2 LH Lower Cover Assembly Cov Assembly LH Low LH Lower Cover Ea...

Page 273: ...Phaser 7700 Color Laser Printer Service Manual 8 243 PL 8 7 Cover FRUs cont d Figure 8 7 Cover FRUs cont d S7700 060 7 12 8 10 9 11 2 3 4 5 1 6...

Page 274: ...r 2 116 1190 00 1 Cover Top Rear ps Cover Top Rear 3 116 1189 00 1 Cover LH Rear Mid 4 116 1193 00 1 Cover LH Front Low 5 116 1191 00 1 Cover LH Rear Low 6 116 1188 00 1 Tray Module Connector Cover Co...

Page 275: ...Phaser 7700 Color Laser Printer Service Manual 8 245 PL 8 8 Switch and Sensor FRUs Figure 8 8 Switch and Sensor FRUs S7700 407 6 5 3 3 3 3 2 4 1 7 9 8...

Page 276: ...C Sensor Assembly part of Sensor Kit 4 116 1126 00 110K12990 Phaser 7760 compatible 1 Paper Select Switch Assembly Switch Assembly PS Tray 2 3 Paper Size Switch also 4 5 on LTA 5 116 1299 00 1 Transpo...

Page 277: ...Phaser 7700 Color Laser Printer Service Manual 8 247 PL 8 9 Switch and Sensor FRUs cont d Figure 8 9 Switch and Sensor FRUs cont d S7700 415 4 7 8 3 1 2 5 6 9...

Page 278: ...rt of Sensor Kit mounted on LH Lower Cover 4 116 1299 00 1 LH Lower Cover Sensor part of Sensor Kit 5 116 1299 00 1 Transfer Roller Position Sensor part of Sensor Kit mounted on Left Hand Cover behind...

Page 279: ...Phaser 7700 Color Laser Printer Service Manual 8 249 PL 8 10 Circuit Boards FRUs Figure 8 10 Circuit Boards FRUs S7700 095 2 1 3 5 4...

Page 280: ...Part Number Qty Name and Description vendor description 1 116 1145 00 1 Chassis Assembly Elec Chassis E B 2 116 1144 00 1 Engine Control Board PWBA MCU 3 671 5268 02 1 Image Processor Board 4 156 4832...

Page 281: ...Laser Printer Service Manual 8 251 PL 8 11 Power Supplies FRUs Figure 8 11 Power Supplies FRUs S7700 053 11 24 V LVPS 8 9 13 24 V PS Fan 6 7 5 V LVPS 13 4 5 3 3 V LVPS 1 T1 HVPS R W 2 T2 HVPS 3 T3 HVP...

Page 282: ...ge Power Supply T3 PSHVT3 4 116 1149 00 1 Low Voltage Power Supply 3V 110V PSLV LF308 5 116 1150 00 1 Low Voltage Power Supply 3V 220V PSLV LF308 6 116 1151 00 1 Low Voltage Power Supply 5 VDC 110V PS...

Page 283: ...Phaser 7700 Color Laser Printer Service Manual 8 253 PL 8 12 Power Supplies FRUs cont d Figure 8 12 Power Supplies FRUs cont d S7700 054 4 AC drive bd 2 4 16 Noise filer bd GFI W 3 1 2...

Page 284: ...sembly AC Power 110V Bracket AC Drive Board Clamp Noise filter GFI Breaker Wire harness Wire harness Wire harness Wire harness Screw Wire Harness 2 116 1156 00 1 1 1 1 1 1 1 1 1 1 1 1 Chassis assembly...

Page 285: ...Phaser 7700 Color Laser Printer Service Manual 8 255 PL 8 13 Motors Drivers FRUs Figure 8 13 Motors Drivers FRUs V V 4 V 3 2 BM V V X 1 S7700 034 REAR 15 V L 9 8 10 13 14 X FRONT 7...

Page 286: ...lt Drive Assembly Drive Assembly IBT Accumulator Motor Assembly Gear Bracket Assembly 3 116 1105 00 1 Main Drive Assembly Drive Assembly main 4 116 1106 00 116 1107 00 1 1 1 Developer Drive Assembly D...

Page 287: ...Phaser 7700 Color Laser Printer Service Manual 8 257 PL 8 14 Electrophotographic Components FRUs Figure 8 14 Electrophotographic Components FRUs 3 S7700 013 1 2...

Page 288: ...Name and Description vendor description 1 116 1110 00 1 Laser Unit ROS Assembly 2 116 1197 00 1 Print cartridge Plate Assembly 3 116 1118 00 1 1 4 1 1 1 1 4 Toner Dispense Base Assembly Dispenser Base...

Page 289: ...7700 Color Laser Printer Service Manual 8 259 PL 8 15 Electrophotographic Components FRUs cont d Figure 8 15 Electrophotographic Components FRUs cont d S7700 057 1 1 1 1 ATC Sensor and Seal 4x Front 5...

Page 290: ...Assembly Hsg Assembly Deve Developer Housing ATC Sensor Seal Note requires one of the following Developer Black Pkg Assembly DV K Developer Yellow Pkg Assembly DV Y Developer Magenta Pkg Assembly DV...

Page 291: ...Phaser 7700 Color Laser Printer Service Manual 8 261 PL 8 16 Multi Purpose Tray FRUs Figure 8 16 Multi Purpose Tray FRUs 1 S7700 045 2 3 5 4...

Page 292: ...ription 1 116 1157 00 1 Multi Purpose Tray MPT Assembly 2 116 1158 00 1 MPT Tray Pinch Roller Assembly 1 w 10 11 13 14 16 Pinch Roller Assembly 2 w 13 17 Pinch Roller Assembly 3 w 11 13 16 3 116 1159...

Page 293: ...Phaser 7700 Color Laser Printer Service Manual 8 263 PL 8 17 Paper Feed FRUs Figure 8 17 Paper Feed FRUs 2 V S7700 040 4 15 BA V S S BD BB 1 V M V V V A A 3...

Page 294: ...ed Motor only Motor Assembly 2 116 1161 00 1 Transport Assembly Inverter Transport Inv 3 116 1163 00 1 Roller Assembly Feed Nudge Retard Roll Assembly 4 116 1164 00 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 Tra...

Page 295: ...Phaser 7700 Color Laser Printer Service Manual 8 265 PL 8 18 Paper Feed FRUs cont d Figure 8 18 Paper feed FRUs cont d S7700 044 1 2...

Page 296: ...65 00 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Transport Assembly Exit OCT Transport Assembly Exit Cover Bearing Pin Exit roller OCT Actuator Bracket Assembly Full Paper Stack Sensor Latch Assembly S...

Page 297: ...267 PL 8 19 Fans FRUs Figure 8 19 Fans FRUs Table 8 19 Fans FRUs List Parts Part Number Qty Name and Description vendor description 1 116 1176 00 1 Fuser Fan Assembly Fan Fuser 2 116 1175 00 1 24 VDC...

Page 298: ...8 268 Phaser 7700 Color Laser Printer Service Manual PL 8 20 Lift Components FRUs Figure 8 20 Lift Components FRUs S7700 050 1 6 V 4 5 3 6 7 2...

Page 299: ...t Number Qty Name and Description vendor description 1 116 1198 00 1 Frame Lift Jack Assembly LH 2 116 1202 00 1 Main Latch Assembly 3 116 1204 00 1 Main Lever Assembly 4 116 1200 00 1 Hinge Lever LH...

Page 300: ...8 270 Phaser 7700 Color Laser Printer Service Manual PL 8 21 Wiring FRUs Figure 8 21 Wiring FRUs S7700 059 7 8 6 V V V 4 3 2 1 V V V V V V V V 5 V...

Page 301: ...1 116 1223 00 1 Wire Harness Dev Bias Block Assembly In 2 116 1312 00 1 Wire Harness Charge Roller Harness Assembly BCR 3 116 1307 00 1 Wire Harness 1BTR Y M 4 116 1308 00 1 Wire Harness 1BTR C K 5 11...

Page 302: ...8 272 Phaser 7700 Color Laser Printer Service Manual PL 8 22 Auxiliary Feeder FRUs Figure 8 22 Auxiliary Feeder FRUs S7700 409 2 5 7 3 6 4 1...

Page 303: ...cription 1 116 1080 00 1 Lower Tray Deck LTD 2 116 1079 00 1 High Capacity Feeder HCF 3 116 1184 00 1 Lower Tray Deck LTD cover LH Cover Assembly LH 3 4 116 1185 00 1 High Capacity feeder HCF cover LH...

Page 304: ...8 274 Phaser 7700 Color Laser Printer Service Manual PL 8 23 Lower Tray Deck LTD FRUs Figure 8 23 Lower Tray Deck LTD FRUs 1 4 3 4 3 S7700 107 2 5...

Page 305: ...e and Description vendor description 1 116 1100 00 1 Aux Feeder Motor Assembly Motor Assembly 3TM 2 116 1219 00 1 LTD Control Board PWB Assembly 3TM 3 116 1206 00 2 Caster Locking 4 116 1221 00 2 Cast...

Page 306: ...er Tray Deck LTD FRUs cont d Figure 8 24 Lower Tray Deck LTD FRUs cont d Table 8 24 Lower Tray Deck LTD FRUs List cont d Parts Part Number Qty Name and Description vendor description 1 116 1167 00 1 C...

Page 307: ...pacity Feeder FRUs List Parts Part Number Qty Name and Description vendor description 1 116 1100 00 1 Aux Feeder Motor Assembly Motor Assembly 3TM 2 116 1220 00 1 HCF Control Board PWB Assembly TTM 3...

Page 308: ...6 High Capacity Feeder FRUs List cont d Parts Part Number Qty Name and Description vendor description 1 116 1168 00 1 Chute to Lower Chute F O Lower 2 116 1169 00 1 Chute to Upper Chute F O Upper 3 11...

Page 309: ...pacity Feeder FRUs cont d Table 8 27 High Capacity Feeder FRUs List cont d Parts Part Number Qty Name and Description vendor description 1 116 1160 00 2 Paper Feeder Assembly Feeder Assembly 2 116 117...

Page 310: ...h Capacity Feeder FRUs cont d Table 8 28 High Capacity Feeder FRUs List cont d Parts Part Number Qty Name and Description vendor description 1 116 1127 00 110K11081 Phaser 7760 compatible 2 HCF Paper...

Page 311: ...eder FRUs cont d Figure 8 29 High Capacity Feeder FRUs cont d Table 8 29 High Capacity Feeder FRUs cont d Parts Part Number Qty Name and Description vendor description 1 116 1171 00 1 Bracket Assembly...

Page 312: ...Retard Rollers 22K56820 116 1212 00 1 MPT Pick Roller Kit Roll Assembly Kit 116 1299 00 1 Sensor Kit Sensor Kit DBP Photo Sensor 130E82190 Sensor trn full 130E91010 Sensor Assembly Edge A 130K60830 Se...

Page 313: ...an 061 4432 00 1 Manual Pack Simplified Chinese 061 4433 00 1 Manual Pack Traditional Chinese 061 4434 00 1 Manual Pack Russian 061 4435 00 1 Manual Pack Dutch 061 4436 00 1 Manual Pack Swedish 061 44...

Page 314: ...artridge 016 1883 00 Customer Replaceable Consumable CRC 4 Print cartridge Kit 016 1890 00 Customer Replaceable Unit 1 Transfer roller 116 1094 00 Maintenance Item 1 Belt cleaner assembly 116 1889 00...

Page 315: ...ys 1 4 N A Universal Tray 7700TD A Lower Tray Deck N A Includes three Universal trays 7700HCF A High Capacity Feeder N A Includes one Universal tray and two High Capacity Letter A4 trays 7700FNS A Fin...

Page 316: ...8 286 Phaser 7700 Color Laser Printer Service Manual...

Page 317: ...ages and Print Solid Fill Pages 1 From the main menu scroll to and then select Support Menu Improve print quality 2 Select Print Color Test Pages or Print Solid Fill Pages The Service Diagnostics Menu...

Page 318: ...does not occur when you print from Diagnostics the problem may be in the Image Processing Board in the print driver software or in the application software on the host computer 5 If the problem occurs...

Page 319: ...r Laser Printer Service Manual 9 289 Print Color Test Prints This color test print produces 6 prints CMYK 4 on 4 off a solid fill red and 4 on 4 off bars Interpreting Print Color Test Prints CYMK 4 on...

Page 320: ...nits Repeating spots in one color indicate a problem with the print unit Non repeating spots in all colors indicate problems with the transfer belt Things to look for Uniformity in each color Streaks...

Page 321: ...Black Red and Green This print sequence is very useful in determining if there is any streaking of usually yellow or cyan that has interfered with RegiCon registration control When you get DC685 1 re...

Page 322: ...ments Calibrations Menu Coarse RegiCon Init Test is required to make these adjustments manually before the DC685 1 test can pass When the YMK vertical lines are within 1 2 mm of the cyan line DC685 1...

Page 323: ...ntended to find any laser ringing behavior The beam is stepped through 8 halftones in the scan line Some people have noticed that there seem to be only 7 distinct bands Maybe one of the bands is 0 fil...

Page 324: ...9 294 Phaser 7700 Color Laser Printer Service Manual...

Page 325: ...233 J213 J232 J210 J133 3 3 8 8 8 J153 J154 J152 J151 Crum K Crum C Crum M Crum Y P622 P624 P631 4 To P406 To P536 P800 2 6 40 26 30 16 30 9 2 Power Switch Noise Filter GFI AC in HV Cont P510 3 3V LVP...

Page 326: ...Clutch Duplex Motor Duplex Open Switch Duplex Wait Sensor Steering Motor Accumulator Belt Motor Edge Sensor Home Sensor L H Low Door Open Sensor Tray 1 No Paper Sensor Tray 1 Level Sensor R H OHP Sen...

Page 327: ...2 B N C N C J 1 0 2 6 1061 26 YEL J 1 0 2 5 1061 26 VIO P 2 1 5 4 1061 26 BLU J 6 3 3 B J 6 3 3 B 8 J 6 3 3 B P 2 1 5 3 1061 26 ORN J 6 3 3 B P 2 5 1 2 1061 26 BLU J 6 3 3 B P 2 5 1 1 7 1061 26 ORN J...

Page 328: ...6 5 4 3 2 1 7 6 5 4 3 2 1 7 7 4 5 6 7 8 9 6 5 4 3 2 1 3 2 1 9 8 7 1 0 1 1 1 2 1 2 1 1 1 0 1 2 3 4 5 OCTMOT CCW OCTMOT CW 5VRTN 5V 3 3V 24V 5VRTN MNOP SNR 5V FM0T NB FM0T NA FM0T COMB INTLK FM0T COMA...

Page 329: ...L O N C J 5 3 1 B 2 7 J 5 3 1 B 1 8 10272 26 ORN 10272 26 BLU J 2 2 3 2 4 V J 2 2 3 E L O N K FINISHER UNIT 1 2 OPTIONAL PRINT CARTRIDGE PLATE 1 2 INTERFACE BOARD TAKE AWAY CL R E G I U N I T R E G I...

Page 330: ...7 24VRTN 1 0 2 7 2 2 4 V I O R 2 0 4 1 2 3 SHUTTER SOL J 4 0 9 3 24VRTN 1 0 2 7 2 2 4 V I O J 4 0 9 2 24V INTLK 1 0 2 7 2 2 4 O R N J 4 0 9 1 24V INTLK 1 0 2 7 2 2 4 O R N J 5 0 1 13 J 5 0 1 12 J 5 0...

Page 331: ...1 0 J 4 2 2 J 4 2 1 1 J 4 2 3 2 3 4 F S 5 8 1015 14 WHT F S 3 9 F S 5 9 1015 14 BLK F S 4 0 AC NUT AC HOT 1015 14 BLK 1015 14 WHT F S 4 7 J 6 0 0 UL1015 3KV 14 WHT FUSER LAMP 576W 3 F S 4 7 J 2 6 1 35...

Page 332: ...EL P 6 2 2 J 4 0 5 A 8 1 3 3VRTN 1061 26 VIO P 6 2 2 J 4 0 5 A 7 2 CRUM DATAC 1061 26 YEL P 6 2 2 J 4 0 5 A 6 3 CRUM CLKC 1061 26 YEL P 6 2 2 J 4 0 5 A 5 4 CRUM PWRC 1061 26 YEL P 6 2 2 J 4 0 5 A 4 5...

Page 333: ...Phaser 7700 Color Laser Printer Service Manual 10 303 ontrol Board and 24 VDC LVPS Board rear view of printer...

Page 334: ......

Page 335: ...Phaser 7700 Color Laser Printer Service Manual 10 305...

Page 336: ......

Page 337: ...Phaser 7700 Color Laser Printer Service Manual 10 307 ors rear of printer...

Page 338: ......

Page 339: ...Phaser 7700 Color Laser Printer Service Manual 10 309 MPT and Left Hand Cover Assembly LH Door...

Page 340: ......

Page 341: ...Phaser 7700 Color Laser Printer Service Manual 10 311 ly Board and Lower Tray Motor Assembly...

Page 342: ......

Page 343: ...Phaser 7700 Color Laser Printer Service Manual 11 313 Phaser 7700 Finisher Figure 11 1 Phaser 7700 Color Laser Printer with the Finisher Option S7700 444...

Page 344: ...ting and error codes for the finisher option see Diagnostics Error Codes and Messages on page 2 31 Topics such as the Finisher theory of operation and Configuration Page details etc are located on the...

Page 345: ...ntrol Board Paper Feed Paper leaving the Exit section of the Printer is fed to the Paper catch area then directly into the Horizontal Transport The Horizontal Transport then delivers the paper to the...

Page 346: ...Tabloid Media Weight 64 105 g m2 Thick Thin paper Stacker Capacity 1000 non stapled sheets 20 lb paper letter A4 or smaller 500 unstapled sheets 20 lb paper over size Letter A4 300 unstapled sheets M...

Page 347: ...Phaser 7700 Color Laser Printer Service Manual 11 317 Assemblies of the Finisher Figure 11 3 Assemblies of the Finisher S7700 445 Gate Unit Horizontal Transport Staple Finisher Stacker Stand...

Page 348: ...anual Internal Assemblies of the Finisher Figure 11 4 Internal Assemblies of the Finisher Exit Assembly Main Motor Finisher Control Board Decurler Compiler Tray Stacker Motor Assembly Staple Assembly...

Page 349: ...l Transport Sensor Interlock and Switch Locator Map Figure 11 5 Horizontal Transport Sensor Interlock and Switch Locator Map IOT Face Down Tray Full Sensor H Transport Entrance Sensor Gate In Solenoid...

Page 350: ...nisher Sensor Interlock and Switch Locator Map Figure 11 6 Finisher Sensor Interlock and Switch Locator Map S7700 449 Rear Eject Clamp Home Sensor Stack Height Sensor Decurler Cam Home Sensor Docking...

Page 351: ...Phaser 7700 Color Laser Printer Service Manual 11 321 Finisher Sensor Interlock and Switch Locator Map Figure 11 7 Finisher Sensor Interlock and Switch Locator...

Page 352: ...11 322 Phaser 7700 Color Laser Printer Service Manual Blank Page...

Page 353: ...ssemblies of the Phaser 7700 Light Finisher When replacing sensors actuators interlocks and or switches Refer to the appropriate Locator Map to identify the sensor Remove the necessary cover RRP 67 on...

Page 354: ...al RRP 66 Horizontal Transport Assembly Removal 1 Unplug the Finisher from the printer 2 Lift the two hooks securing the Horizontal Transport Assembly to the Finisher 3 Remove the Horizontal Transport...

Page 355: ...izontal Transport Front Cover and remove the cover 4 Remove the hinge screw and remove the Top Open Cover 5 Remove two screws securing the Horizontal Transport Rear Cover 6 Remove the Horizontal Trans...

Page 356: ...Remove the Horizontal Transport Assembly RRP 66 on page 11 324 2 Remove the Front Cover RRP 67 on page 11 325 3 Remove two screws securing the Rear Cover and remove 4 Remove the Gate In Solenoid Assem...

Page 357: ...rt In and Out 3 Remove the bearings from the horizontal transport In and Out shafts 4 Remove one end of each horizontal transport belt roller support 5 Remove the belts Replacement Note When reinstall...

Page 358: ...ver pry up on the locking tab while pressing firmly towards the entrance end of the transport 4 Disconnect the wiring harness connector 5 Press down on the two locking tabs located at the top of the s...

Page 359: ...29 RRP 71 Gate In Solenoid Assembly Removal 1 Remove the Rear Cover RRP 67 on page 11 325 2 Disconnect the ground wire from the solenoid housing 3 Remove the two screws and remove the Gate In Solenoid...

Page 360: ...11 330 Phaser 7700 Color Laser Printer Service Manual RRP 72 Finisher Covers Figure 11 14 Finisher Covers S7700 396 Front Cover Left Panel Left Top Cover Rear Cover Left Cover...

Page 361: ...emove two screws from the Left Cover and lift up and out to remove 7 Loosen the four screws securing the Top Cover 8 Remove the left portion of the top cover assembly 9 Open the top door and remove th...

Page 362: ...rt Assembly RRP 66 on page 11 324 2 Remove the Top Cover RRP 72 on page 11 330 3 Remove one screw from the Stack Height Sensor bracket 4 Press down on the two locking tabs located at the top of the se...

Page 363: ...ing the Stacker Paper Sensor Assembly to the finisher 3 Remove two screws from the bottom of the assembly 4 Remove one screw on the sensor bracket 5 Press down on the two locking tabs located at the t...

Page 364: ...e set clamp actuator retainer and remove 4 Remove the clutch collar and clutch 5 Remove the gear Replacement Note When replacing after installing the clutch collar you need to depress the clutch solen...

Page 365: ...n page 11 330 2 Remove Stack Paper Sensor Assembly RRP 73 on page 11 332 3 Undo the intermediate connector 4 Remove the Right Cover 5 Remove the Set Clamp Clutch and Gear RRP 75 on page 11 334 6 Remov...

Page 366: ...11 336 Phaser 7700 Color Laser Printer Service Manual RRP 77 Finisher Control Board Bracket and Shield Figure 11 19 Finisher Control Board Bracket and Shield...

Page 367: ...Loosen one screw on the right 7 Undo one connector 1 Loosen the outer screws located at the bottom of the Finisher Control Board cover 2 Remove the eight remaining cover screws 3 Remove the Finisher C...

Page 368: ...l 1 Remove the Finisher Control Board Bracket and Shield RRP 77 on page 11 336 2 Remove one connector 3 Remove three screws and remove the Stacker Motor Assembly Note When reinstalling ensure the gear...

Page 369: ...Assembly RRP 81 on page 11 341 3 Remove the Staple Unit RRP 82 on page 11 342 4 Remove the e clips from both ends of the shaft 5 Remove the gear and bushing from the front end of the shaft 6 Remove th...

Page 370: ...ice Manual RRP 80 Paper Transport Motor Motor Assembly Main Removal 1 Remove the Rear Cover RRP 72 on page 11 330 2 Remove four screws 3 Undo the connector and lift the motor up and then out to free t...

Page 371: ...wiring harness from the Set Clamp Home Sensor 5 Remove the wiring harness from the bracket 6 Disconnect the wiring harness from the Eject Motor 7 Remove four screws from the bracket and remove the Ca...

Page 372: ...11 342 Phaser 7700 Color Laser Printer Service Manual RRP 82 Staple Unit Assembly and Motor Figure 11 24 Staple Unit Assembly S7700 304 K V BG V BA BA V V V 3 12 11 13 4 6 6 4 5 2 7 8 1 10 9...

Page 373: ...330 2 Remove the two connectors to the Staple Unit 3 Remove two screws note one screw has a ground wire 4 Pull the Staple Unit Assembly down tilt up and pull out towards the front Staple Motor 1 Remo...

Page 374: ...isconnect P848 connector 4 Remove Set clamp solenoid connector 5 Remove the Staple Unit RRP 82 on page 11 342 6 Remove two screws from the bottom of the tamper assembly front and rear 7 Push the wirin...

Page 375: ...Phaser 7700 Color Laser Printer Service Manual 11 345 Finisher FRU Parts List Finisher Unit Main Assemblies FRUs Figure 11 26 Finisher Unit Main Assemblies FRUs...

Page 376: ...isher Unit Main Assemblies FRUs List No Part Number Qty Description 1 116 1292 00 1 Gate Unit 2 116 1280 01 1 H Transport Assembly 3 Staple Finisher 4 Screw 5 Rack Assembly 6 116 1244 00 1 Right Cover...

Page 377: ...isher Covers FRUs Table 11 3 Finisher Covers FRUs List No Part Number Qty Description 1 116 1238 00 1 Front Cover 2 116 1239 00 1 Rear Cover 3 116 1236 00 1 Top Cover 4 116 1237 00 1 Left Cover 5 116...

Page 378: ...11 348 Phaser 7700 Color Laser Printer Service Manual Finisher Stand FRUs Figure 11 28 Finisher Stand FRUs S7700 309 8 8 4 4 4 6 6 7 7 3 3 14 4 5 9 9 10 15 2 12 13 1 11 U U U U W W...

Page 379: ...List No Part Number Qty Description 1 116 1315 00 1 Front Rack Assembly Item 2 10 2 Front Cover 3 Knob Screw 4 Screw 5 Bracket 6 Stopper 7 Plate Spring 8 Rail 9 Foot 10 Front Rack 11 116 1316 00 1 Rea...

Page 380: ...11 350 Phaser 7700 Color Laser Printer Service Manual Gate Unit FRUs Figure 11 29 Gate Unit FRUs S7700 297 10 9 8 14 7 13 3 6 5 4 15 16 1 2 A S B A S B S S S...

Page 381: ...List No Part Number Qty Description 1 116 1292 00 No Gate Cover 2 Bearing 3 116 1293 00 1 Gate Assembly Item 4 14 4 In Gate 5 In Gate Lever 6 116 1294 00 1 Gate Bracket 7 Link Assembly 8 Lever Assembl...

Page 382: ...or Laser Printer Service Manual Horizontal Transport Assembly FRUs Figure 11 30 Horizontal Transport Assembly FRUs S7700 298 A C B 15 10 12 11 12 12 18 13 14 17 BN BN Y 20 16 BN BN C 19 B A 2 8 3 7 7...

Page 383: ...ransport Open Cover 3 116 1291 00 Magnetic Catch 4 Screw 5 Guide 6 116 1246 00 1 Roll 7 Plate Spring 8 Stopper 9 116 1289 00 Entrance Upper Cover Assembly Item 10 12 10 Entrance Upper Cover 11 Roll 12...

Page 384: ...ual Horizontal Transport Assembly FRUs cont d Figure 11 31 Horizontal Transport Assembly FRUs cont d S7700 299 B A C D A B 1 7 5 C D 4 5 4 5 2 3 8 6 30 31 9 10 11 20 19 6 15 14 16 13 17 18 27 28 20 21...

Page 385: ...1644 00 1 H Transport Entrance Sensor REP 17 4 2 10 116 1285 00 1 Top Tray Full Sensor REP 17 4 2 11 116 1247 01 1 H Transport Exit Sensor 12 116 1286 00 1 Gate In Solenoid Assembly Item 13 18 13 Gate...

Page 386: ...l Top Cover and Eject Roll FRUs Figure 11 32 Top Cover and Eject Roll FRUs S7700 301 5 6 16 9 8 7 4 1 X S BA S X 5 6 25 9 8 7 12 4 X BA AY X 11 B A A B C D 13 14 15 28 3 23 3 20 3 2 19 18 17 22 23 10...

Page 387: ...Shaft 9 116 1302 00 1 Eject Pinch Roll 10 1 Eject Chute 11 116 1272 00 1 Stack Height Sensor Assembly Item 12 14 12 1 Actuator 13 Bracket 14 116 1253 00 1 Stack Height Sensor 15 Shaft Set Clamp 16 Li...

Page 388: ...Color Laser Printer Service Manual Paper Transport Assembly FRUs Figure 11 33 Paper Transport Assembly FRUs S7700 302 14 13 15 16 17 BA BA E E E BB Z 1 2 8 BD BD BD BD BD BA 12 10 3 9 11 6 BE 7 12 3 5...

Page 389: ...2 116 1249 00 1 Clutch Assembly Decurler Cam 3 Cam 4 Shaft 5 Bearing 6 116 1250 00 1 Arm 7 116 1302 00 1 Decurler Roll Assembly REP 17 7 1 8 116 1301 00 1 Gear 40Z 20T 9 116 1301 00 1 Gear 40Z 10 116...

Page 390: ...7700 Color Laser Printer Service Manual Paper Transport Assembly FRUs cont d Figure 11 34 Paper Transport Assembly FRUs cont d S7700 303 13 17 18 15 10 20 16 14 11 3 2 5 6 7 9 19 8 12 4 V BC BD BA BA...

Page 391: ...3 00 1 Pully 3 116 1303 00 1 Gear 15Z 4 116 1271 00 1 Belt REP 17 8 1 5 116 1303 00 1 Gear 30Z 6 Collar 7 116 1303 00 1 Gear Pully 8 Eject Motor 9 116 1303 00 1 Cam Gear 10 116 1303 00 1 Gear 42Z 27Z...

Page 392: ...11 362 Phaser 7700 Color Laser Printer Service Manual Staple Unit Assembly FRUs Figure 11 35 Staple Unit Assembly FRUs S7700 304 K V BG V BA BA V V V 3 12 11 13 4 6 6 4 5 2 7 8 1 10 9...

Page 393: ...Description 1 116 1255 00 1 Carriage Assembly Item 2 6 2 Bracket Assembly 3 116 1256 00 1 Motor Assembly Stepping 4 Gear 5 Staple Remover 6 Roll 7 116 1259 00 1 Staple Front Corner Sensor 8 Plate 9 11...

Page 394: ...64 Phaser 7700 Color Laser Printer Service Manual Compiler Tray Assembly FRUs Figure 11 36 Compiler Tray Assembly FRUs S7700 305 8 7 4 6 5 10 11 15 14 13 12 2 7 3 5 6 4 9 8 9 8 9 8 9 S S S S S S S S S...

Page 395: ...ription 1 116 1251 00 1 Compiler Tray Assembly Item 2 15 2 116 1252 00 1 Motor Assembly Tamper 3 Plate 4 116 1253 00 1 Front Rear Tamper Home Sensor 5 Rack 6 Actuator 7 Tamper Assembly 8 Finger 9 Spri...

Page 396: ...Laser Printer Service Manual Stacker Elevator Assembly FRUs Figure 11 37 Stacker Elevator Assembly FRUs S7700 306 A A B B 18 19 9 1 BD BD V V X X V BD BD BD V V X S Y 3 4 4 4 5 6 18 10 16 12 14 13 15...

Page 397: ...ket Assembly Belt 3 Clamp 4 Bearing 5 116 1274 00 1 Gear Rear 6 Actuator 7 116 1275 00 1 Gear Front 8 Stacker Tray Bracket Assembly 9 116 1273 00 1 Rack 10 Tray Guide 11 116 1270 00 1 Stack Paper Asse...

Page 398: ...11 368 Phaser 7700 Color Laser Printer Service Manual Exit Assembly FRUs Figure 11 38 Exit Assembly FRUs S7700 307 17 16 14 9 15 10 13 11 8 2 3 1 6 4 5 6 BA BA V V V V V V V V V V BA BA V 12 7...

Page 399: ...2 Bearing 3 116 1243 00 1 Exit Shaft 4 Collar 5 Gear 32Z 18T 6 Bearing 7 116 1304 00 1 Paddle Gear Shaft REP 17 12 1 8 Paddle Bearing 9 Lower Exit Chute 10 116 1302 00 1 Pinch Roll Exit 1 11 Pinch Rol...

Page 400: ...ble 11 15 Electrical FRUs List No Part Number Qty Description 1 Board Cover 2 116 1235 00 1 Finisher Board 3 116 1314 00 1 ROM 4 PWB Bracket 5 DC Harness 6 Cable 7 116 1233 00 1 Switch 8 116 1253 00 1...

Page 401: ...Service Manual 12 371 Finisher Wiring Diagrams This section is comprised of two diagrams 1 The Finisher Block Diagram and 2 The Finisher Wiring Diagram Both appear beginning on the next page and face...

Page 402: ...Clutch Compiler Paper Sensor Front Tamper Motor Front Tamper Home Sensor Rear Tamper Home Sensor Rear Tamper Motor Docking Interlock Sensor Staple Front Corner Sensor Stapler Move Sensor Stapler Head...

Page 403: ...1061 26 VIO 1061 26 YEL 1061 26 GRY 1 2 3 1061 26 VIO 1061 26 YEL 1061 26 GRY 10 11 12 3 2 1 5VRTN TLEVEL SNR 5V 7 8 8 1061 26 VIO 1061 26 YEL 1061 26 GRY 1 2 3 1061 26 VIO 1061 26 YEL 1061 26 GRY 7 8...

Page 404: ...12 374 Phaser 7700 Color Laser Printer Service Manual...

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