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Xerox Phaser 790, Service Manual

The Xerox Phaser 790 is a high-quality printer known for its reliability and performance. Ensure your device is in top condition by downloading the Service Manual for free from manualshive.com. This manual provides detailed instructions on maintenance and troubleshooting to keep your Phaser 790 running smoothly.

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4-103

Phaser 790/DocuColor 2006

REP 9.14, REP 9.15

Repairs and Adjustments

Initial Issue

REP 9.14 Developer Tie Plate 

Parts List on PL 1.3 

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 Top Cover Assembly (REP 14.4).

3.

Remove the Rear Cover (REP 14.6).

4.

Remove the Copy/Print Cartridge (REP 9.1).

5.

Remove the Tension Lever (REP 9.15).

6.

Remove the Left Inner Cover Assembly and IBT Inner Cover (REP 14.5).

7.

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.

Figure 1 Removing the Developer Tie Plate

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.

Figure 1 Removing the Tension Lever

1

Remove the 
screws at front 
and rear

2

Remove the Developer 
Tie Plate from the top of 
the machine

1

Open the Front 
Cover Assembly

2

Turn the lever, 
remove the 
screw, then 
remove the 
Tension Lever

Summary of Contents for Phaser 790

Page 1: ...790 DocuColor 2006 Service Manual THE DOCUMENT COMPANY XEROX CAUTION Certain components in the Phaser 790 DocuColor 2006 are susceptible to damage from electrostatic discharge Observe all ESD procedur...

Page 2: ...d 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...

Page 3: ...10 00 i Phaser 790 DocuColor 2006 Introduction Initial Issue Introduction About this Manual iii Organization iii How to Use this Documentation iii Symbology iii...

Page 4: ...10 00 ii Phaser 790 DocuColor 2006 Initial Issue Introduction...

Page 5: ...lacement 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 adjustmen...

Page 6: ...he 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 conta...

Page 7: ...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 eliminat...

Page 8: ...ond 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...

Page 9: ...aser 790 DocuColor 2006 Service Call Procedures Initial Issue 1 Service Call Procedures Service Call Procedures 1 3 Initial Actions Procedure 1 3 Call Flow Procedure 1 4 Cleaning Procedures 1 5 Final...

Page 10: ...10 00 1 2 Phaser 790 DocuColor 2006 Initial Issue Service Call Procedures...

Page 11: ...tify 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...

Page 12: ...for contamination glazing wear dam age or binding A Fault Code or message is constantly displayed Y N The problem is Image Quality Y N The problem is in the ADF Y N The problem is in the Scanner Y N...

Page 13: ...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 1 Ensure that the e...

Page 14: ...10 00 1 6 Phaser 790 DocuColor 2006 Cleaning Procedures Final Actions Initial Issue Service Call Procedures...

Page 15: ...F No Feed RAP 2 62 005 704 Unfinished Copy Job RAP 2 64 Imaging 006 310 IIT Registration RAP 2 67 006 311 Exposure Lamp RAP 2 69 006 312 FPC CCD RAP 2 70 006 313 IIT Cooling Fans RAP 2 71 006 372 Star...

Page 16: ...11 700 Sorter Not In Correct Position RAP 2 191 011 701 Sorter Bin Jam RAP 2 193 011 702 Sorter Cover Open RAP 2 196 011 703 Sorter Transport Jam RAP 2 198 011 704 Sorter Noise RAP 2 200 011 705 Full...

Page 17: ...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...

Page 18: ...10 00 2 4 Phaser 790 DocuColor 2006 Fault Message RAP Cross Reference Initial Issue Status Indicator RAPs...

Page 19: ...C 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...

Page 20: ...10 00 2 6 Phaser 790 DocuColor 2006 001 701 Initial Issue Status Indicator RAPs Figure 1 001 701 Circuit Diagram...

Page 21: ...32 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 PL 11 1 Switch off t...

Page 22: ...10 00 2 8 Phaser 790 DocuColor 2006 001 702 Initial Issue Status Indicator RAPs Figure 1 001 702 Circuit Diagram...

Page 23: ...it 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 N 5 0 VDC is measu...

Page 24: ...10 00 2 10 Phaser 790 DocuColor 2006 001 703 Initial Issue Status Indicator RAPs Figure 1 001 703 Circuit Diagram...

Page 25: ...code 73 Press the Item Enter button The display indicates 0 Y N Go to Flag 1 and Flag 2 and check the wires for an open circuit If the wires are good replace the Right Front Cover Interlock PL 11 2 If...

Page 26: ...10 00 2 12 Phaser 790 DocuColor 2006 001 704 Initial Issue Status Indicator RAPs Figure 1 001 704 Circuit Diagram...

Page 27: ...5 1 on the ROS Assembly and machine frame Y N With the Top Cover Interlock still actuated 5 VDC is measured between FS2 blue wire on the Top Cover Interlock and machine frame Y N 5 VDC is measured bet...

Page 28: ...10 00 2 14 Phaser 790 DocuColor 2006 001 705 Initial Issue Status Indicator RAPs Figure 1 001 705 Circuit Diagram...

Page 29: ...al 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...

Page 30: ...10 00 2 16 Phaser 790 DocuColor 2006 001 706 Initial Issue Status Indicator RAPs Figure 1 001 706 Circuit Diagram...

Page 31: ...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 In...

Page 32: ...10 00 2 18 Phaser 790 DocuColor 2006 001 707 Initial Issue Status Indicator RAPs Figure 1 001 707 Circuit Diagram...

Page 33: ...Go to Flag 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 d...

Page 34: ...10 00 2 20 Phaser 790 DocuColor 2006 001 708 Initial Issue Status Indicator RAPs Figure 1 001 708 Circuit Diagram...

Page 35: ...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 In...

Page 36: ...10 00 2 22 Phaser 790 DocuColor 2006 001 709 Initial Issue Status Indicator RAPs Figure 1 001 709 Circuit Diagram...

Page 37: ...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...

Page 38: ...10 00 2 24 Phaser 790 DocuColor 2006 001 710 Initial Issue Status Indicator RAPs Figure 1 001 710 Circuit Diagram...

Page 39: ...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...

Page 40: ...10 00 2 26 Phaser 790 DocuColor 2006 001 711 Initial Issue Status Indicator RAPs Figure 1 001 711 Circuit Diagram...

Page 41: ...ire 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...

Page 42: ...10 00 2 28 Phaser 790 DocuColor 2006 001 712 Initial Issue Status Indicator RAPs Figure 1 001 712 Circuit Diagram...

Page 43: ...place 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 o...

Page 44: ...10 00 2 30 Phaser 790 DocuColor 2006 002 701 Initial Issue Status Indicator RAPs Figure 1 002 701 Circuit Diagram...

Page 45: ...ons 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 Actio...

Page 46: ...10 00 2 32 Phaser 790 DocuColor 2006 002 702 Initial Issue Status Indicator RAPs...

Page 47: ...s 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 f...

Page 48: ...10 00 2 34 Phaser 790 DocuColor 2006 003 310 Initial Issue Status Indicator RAPs Figure 1 003 310 RAP Circuit Diagram...

Page 49: ...at 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 f...

Page 50: ...10 00 2 36 Phaser 790 DocuColor 2006 003 311 Initial Issue Status Indicator RAPs Figure 1 003 311 RAP Circuit Diagram...

Page 51: ...ons 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 R...

Page 52: ...10 00 2 38 Phaser 790 DocuColor 2006 003 312 Initial Issue Status Indicator RAPs Figure 1 003 311 RAP Circuit Diagram...

Page 53: ...WB 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 circu...

Page 54: ...10 00 2 40 Phaser 790 DocuColor 2006 003 333 Initial Issue Status Indicator RAPs Figure 1 003 333 RAP Circuit Diagram...

Page 55: ...n 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...

Page 56: ...10 00 2 42 Phaser 790 DocuColor 2006 003 334 Initial Issue Status Indicator RAPs Figure 1 003 334 RAP Circuit Diagram...

Page 57: ...re 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 PWB If the problem occurs again replace the MCU PWB...

Page 58: ...10 00 2 44 Phaser 790 DocuColor 2006 003 356 Initial Issue Status Indicator RAPs Figure 1 003 356 RAP Circuit Diagram...

Page 59: ...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 Cartridg...

Page 60: ...10 00 2 46 Phaser 790 DocuColor 2006 003 701 Initial Issue Status Indicator RAPs Figure 1 003 701 RAP Circuit Diagram...

Page 61: ...frame Y N 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...

Page 62: ...10 00 2 48 Phaser 790 DocuColor 2006 004 320 Initial Issue Status Indicator RAPs Figure 1 004 320 RAP Circuit Diagram...

Page 63: ...ace 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 betw...

Page 64: ...10 00 2 50 Phaser 790 DocuColor 2006 004 322 Initial Issue Status Indicator RAPs Figure 1 004 322 RAP Circuit Diagram...

Page 65: ...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 81...

Page 66: ...10 00 2 52 Phaser 790 DocuColor 2006 005 210 Initial Issue Status Indicator RAPs Figure 1 005 210 RAP Circuit Diagram NUDGER ROLL...

Page 67: ...er RAP ADF Motor Power Error Procedure Remove the ADF Rear Cover There is 24 VDC from pin 11 to pin 12 on J811 Y N Go to Flag 1 Check for an open circuit If the wires are OK go to the 001 712 RAP Chec...

Page 68: ...10 00 2 54 Phaser 790 DocuColor 2006 005 211 Initial Issue Status Indicator RAPs Figure 1 005 211 RAP Circuit Diagram...

Page 69: ...when power is switched on Y N 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...

Page 70: ...10 00 2 56 Phaser 790 DocuColor 2006 005 220 221 Initial Issue Status Indicator RAPs Figure 1 005 220 221 RAP Circuit Diagram...

Page 71: ...ooting 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 R...

Page 72: ...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 t...

Page 73: ...10 00 2 59 Phaser 790 DocuColor 2006 005 701 Status Indicator RAPs Initial Issue Figure 1 005 701 RAP Circuit Diagram...

Page 74: ...age 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...

Page 75: ...10 00 2 61 Phaser 790 DocuColor 2006 005 702 Status Indicator RAPs Initial Issue Figure 1 005 702 RAP Circuit Diagram EXIT SENSOR EXIT MOTOR...

Page 76: ...F 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 Y N Replace the ADF Con...

Page 77: ...10 00 2 63 Phaser 790 DocuColor 2006 005 703 Status Indicator RAPs Initial Issue Figure 1 005 703 RAP Circuit Diagram...

Page 78: ...790 DocuColor 2006 005 704 Initial Issue Status Indicator RAPs 005 704 Unfinished Copy Job RAP Procedure Go to Flag 1 and Flag 2 Check the wires for an open circuit If the wires are OK replace the ICM...

Page 79: ...10 00 2 65 Phaser 790 DocuColor 2006 005 704 Status Indicator RAPs Initial Issue Figure 1 005 704 RAP Circuit Diagram...

Page 80: ...10 00 2 66 Phaser 790 DocuColor 2006 005 704 Initial Issue Status Indicator RAPs...

Page 81: ...rame Y N 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 vo...

Page 82: ...10 00 2 68 Phaser 790 DocuColor 2006 006 310 Initial Issue Status Indicator RAPs Figure 1 006 310 RAP Circuit Diagram...

Page 83: ...16 5 item 17 The Lamp Connector J535 is seated correctly Y N Re seat the Lamp Connector J535 If the problem persists replace the FLPS PWB PL 16 5 Inspect connector P J 140 on the FPC CCD The connecto...

Page 84: ...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...

Page 85: ...PWB Y N Replace the ICM Main PWB PL 16 2 NOTE Remove 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 V...

Page 86: ...10 00 2 72 Phaser 790 DocuColor 2006 006 313 Initial Issue Status Indicator RAPs Figure 1 006 313 RAP Circuit Diagram...

Page 87: ...the ROS Cover Disconnect J 123 from the ROS Measure the resistance between the following plug jack pins P J 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...

Page 88: ...10 00 2 74 Phaser 790 DocuColor 2006 006 372 Initial Issue Status Indicator RAPs Figure 1 006 372 RAP Circuit Diagram...

Page 89: ...red 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 approx...

Page 90: ...10 00 2 76 Phaser 790 DocuColor 2006 006 701 Initial Issue Status Indicator RAPs Figure 1 006 701 RAP Circuit Diagram...

Page 91: ...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...

Page 92: ...10 00 2 78 Phaser 790 DocuColor 2006 006 702 Initial Issue Status Indicator RAPs Figure 1 006 702 RAP Circuit Diagram...

Page 93: ...t remains replace the IPS PWB PL 16 2 If this does not resolve the problem replace the ICM Main PWB PL 16 2 006 704 System Error 093 XXX RAP Procedure Ensure that the correct levels of firmware are in...

Page 94: ...r 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 erro...

Page 95: ...er 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 powe...

Page 96: ...10 00 2 82 Phaser 790 DocuColor 2006 007 324 Initial Issue Status Indicator RAPs Figure 1 007 324 RAP Circuit Diagram...

Page 97: ...e 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 th...

Page 98: ...10 00 2 84 Phaser 790 DocuColor 2006 007 340 Initial Issue Status Indicator RAPs Figure 1 007 340 RAP Circuit Diagram...

Page 99: ...nd 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 proble...

Page 100: ...10 00 2 86 Phaser 790 DocuColor 2006 007 341 Initial Issue Status Indicator RAPs Figure 1 007 341 RAP Circuit Diagram...

Page 101: ...Ensure that PJ 16 on the MCU PWB 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 Y N Go to Flag 2 Check the wire for an open...

Page 102: ...10 00 2 88 Phaser 790 DocuColor 2006 007 700 Initial Issue Status Indicator RAPs Figure 1 007 700 RAP Circuit Diagram...

Page 103: ...ires are good Y N Repair the wires 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...

Page 104: ...10 00 2 90 Phaser 790 DocuColor 2006 007 701 Initial Issue Status Indicator RAPs Figure 1 007 701 RAP Circuit Diagram...

Page 105: ...ort circuit to ground The wires are good Y N Repair the wires 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 i...

Page 106: ...10 00 2 92 Phaser 790 DocuColor 2006 007 702 Initial Issue Status Indicator RAPs Figure 1 007 702 RAP Circuit Diagram...

Page 107: ...erly 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 wi...

Page 108: ...10 00 2 94 Phaser 790 DocuColor 2006 007 703 Initial Issue Status Indicator RAPs Figure 1 007 703 RAP Circuit Diagram...

Page 109: ...tor 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 N Check the following Go to Flag 1 Check the wires for an open circuit Go...

Page 110: ...10 00 2 96 Phaser 790 DocuColor 2006 007 704 Initial Issue Status Indicator RAPs Figure 1 007 704 RAP Circuit Diagram...

Page 111: ...er 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 N Check the following Go to Flag 1 Check the wires for an...

Page 112: ...10 00 2 98 Phaser 790 DocuColor 2006 007 705 Initial Issue Status Indicator RAPs Figure 1 007 705 RAP Circuit Diagram...

Page 113: ...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 g...

Page 114: ...10 00 2 100 Phaser 790 DocuColor 2006 007 706 Initial Issue Status Indicator RAPs Figure 1 007 706 RAP Circuit Diagram...

Page 115: ...hat 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 Sel...

Page 116: ...23 The Lift Plate goes up Y N Check the following Check the lift 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 M...

Page 117: ...10 00 2 103 Phaser 790 DocuColor 2006 007 708 Status Indicator RAPs Initial Issue Figure 1 007 708 RAP Circuit Diagram...

Page 118: ...r PL 13 4 The Lift Plate in Tray 2 moved up Y N 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...

Page 119: ...10 00 2 105 Phaser 790 DocuColor 2006 007 709 Status Indicator RAPs Initial Issue Figure 1 007 709 RAP Circuit Diagram 1 of 2...

Page 120: ...10 00 2 106 Phaser 790 DocuColor 2006 007 709 Initial Issue Status Indicator RAPs Figure 2 007 709 RAP Circuit Diagram 2 of 2...

Page 121: ...r PL 13 4 The Lift Plate in Tray 3 moved up Y N 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...

Page 122: ...10 00 2 108 Phaser 790 DocuColor 2006 007 710 Initial Issue Status Indicator RAPs Figure 1 007 710 RAP Circuit Diagram 1 of 2...

Page 123: ...10 00 2 109 Phaser 790 DocuColor 2006 007 710 Status Indicator RAPs Initial Issue Figure 2 007 710 RAP Circuit Diagram 2 of 2...

Page 124: ...ort circuit to ground The wires are good Y N Repair the wires Replace the MCU PWB PL 11 2 Connect PJ 102 on the Size Switch PWB Actuate and hold switches SW1 and SW2 on the Size Switch PWB There is 3...

Page 125: ...10 00 2 111 Phaser 790 DocuColor 2006 007 711 Status Indicator RAPs Initial Issue Figure 1 007 711 RAP Circuit Diagram...

Page 126: ...e the MCU PWB PL 11 2 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 Y N Go to Flag 1 Chec...

Page 127: ...10 00 2 113 Phaser 790 DocuColor 2006 007 712 Status Indicator RAPs Initial Issue Figure 1 007 712 RAP Circuit Diagram...

Page 128: ...e the MCU PWB PL 11 2 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 Y N Go to Flag 1 Chec...

Page 129: ...10 00 2 115 Phaser 790 DocuColor 2006 007 713 Status Indicator RAPs Initial Issue Figure 1 007 713 RAP Circuit Diagram...

Page 130: ...10 00 2 116 Phaser 790 DocuColor 2006 007 713 Initial Issue Status Indicator RAPs...

Page 131: ...the wire for an open circuit If the wire is good replace the MCU PWB PL 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...

Page 132: ...10 00 2 118 Phaser 790 DocuColor 2006 008 700 Initial Issue Status Indicator RAPs Figure 1 008 700 RAP Circuit Diagram 1 of 2...

Page 133: ...10 00 2 119 Phaser 790 DocuColor 2006 008 700 Status Indicator RAPs Initial Issue Figure 2 008 700 RAP Circuit Diagram 2 of 2...

Page 134: ...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 obstruction...

Page 135: ...10 00 2 121 Phaser 790 DocuColor 2006 008 701 Status Indicator RAPs Initial Issue Figure 1 008 701 RAP Circuit Diagram 1 of 2...

Page 136: ...10 00 2 122 Phaser 790 DocuColor 2006 008 701 Initial Issue Status Indicator RAPs Figure 2 008 701 RAP Circuit Diagram 2 of 2...

Page 137: ...ires 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 PW...

Page 138: ...10 00 2 124 Phaser 790 DocuColor 2006 008 702 Initial Issue Status Indicator RAPs Figure 1 008 702 RAP Circuit Diagram...

Page 139: ...rcuit to ground The wire is good Y N Repair the wire There is 5 VDC from J 161 pin 6 to ground Y N Replace the Top Exit Sensor PL 9 2 If the problem continues replace the MCU PWB PL 11 2 Replace the M...

Page 140: ...10 00 2 126 Phaser 790 DocuColor 2006 008 703 Initial Issue Status Indicator RAPs Figure 1 008 703 RAP Circuit Diagram...

Page 141: ...eck 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 DO A0 The Invert...

Page 142: ...10 00 2 128 Phaser 790 DocuColor 2006 008 704 Initial Issue Status Indicator RAPs Figure 1 008 704 RAP Circuit Diagram 1 of 2...

Page 143: ...10 00 2 129 Phaser 790 DocuColor 2006 008 704 Status Indicator RAPs Initial Issue Figure 2 008 704 RAP Circuit Diagram 2 of 2...

Page 144: ...Sensor Bracket Procedure Enter the diagnostic mode Enter Code DI 15 The display indicates a 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...

Page 145: ...10 00 2 131 Phaser 790 DocuColor 2006 008 705 Status Indicator RAPs Initial Issue Figure 1 008 705 RAP Circuit Diagram...

Page 146: ...r a short circuit to ground The wire is 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...

Page 147: ...10 00 2 133 Phaser 790 DocuColor 2006 008 706 Status Indicator RAPs Initial Issue Figure 1 008 706 RAP Circuit Diagram...

Page 148: ...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...

Page 149: ...10 00 2 135 Phaser 790 DocuColor 2006 008 707 Status Indicator RAPs Initial Issue Figure 1 008 707 RAP Circuit Diagram...

Page 150: ...10 00 2 136 Phaser 790 DocuColor 2006 008 707 Initial Issue Status Indicator RAPs...

Page 151: ...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 TR0 Sensor There is 5...

Page 152: ...10 00 2 138 Phaser 790 DocuColor 2006 009 321 Initial Issue Status Indicator RAPs Figure 1 009 321 RAP Circuit Diagram...

Page 153: ...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 th...

Page 154: ...10 00 2 140 Phaser 790 DocuColor 2006 009 323 Initial Issue Status Indicator RAPs Figure 1 009 323 RAP Circuit Diagram...

Page 155: ...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 Y...

Page 156: ...10 00 2 142 Phaser 790 DocuColor 2006 009 326 Initial Issue Status Indicator RAPs Figure 1 009 326 RAP Circuit Diagram...

Page 157: ...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...

Page 158: ...10 00 2 144 Phaser 790 DocuColor 2006 009 340 Initial Issue Status Indicator RAPs Figure 1 009 340 RAP Circuit Diagram...

Page 159: ...ircuit If the wire is OK go to the 001 703 RAP Access the Digital Output Test GP 2 Enter code 0E 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...

Page 160: ...10 00 2 146 Phaser 790 DocuColor 2006 009 341 Initial Issue Status Indicator RAPs Figure 1 009 341 RAP Circuit Diagram...

Page 161: ...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 5 and Flag 12 Check for an open circuit If the wire is OK replace th...

Page 162: ...10 00 2 148 Phaser 790 DocuColor 2006 009 342 Initial Issue Status Indicator RAPs Figure 1 009 342 RAP Circuit Diagram...

Page 163: ...Switch off the power then switch on the power If the fault is still present replace the MCU PWB PL 11 2 009 344 Image Density Error RAP Image density measured by PCDC method of first 70 mm of lead edg...

Page 164: ...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 displa...

Page 165: ...10 00 2 151 Phaser 790 DocuColor 2006 009 358 Status Indicator RAPs Initial Issue Figure 1 009 358 RAP Circuit Diagram...

Page 166: ...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 requ...

Page 167: ...10 00 2 153 Phaser 790 DocuColor 2006 009 359 Status Indicator RAPs Initial Issue Figure 1 009 359 RAP Circuit Diagram...

Page 168: ...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 PW...

Page 169: ...10 00 2 155 Phaser 790 DocuColor 2006 009 360 Status Indicator RAPs Initial Issue Figure 1 009 360 RAP Circuit Diagram...

Page 170: ...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 f...

Page 171: ...10 00 2 157 Phaser 790 DocuColor 2006 009 700 Status Indicator RAPs Initial Issue Figure 1 009 700 RAP Circuit Diagram FRONT...

Page 172: ...the Developer Clutch PL 10 1 Access the Digital Output Test GP 2 Enter code 21 Press the Item Enter button There is less than 1 VDC from J 56 pin 1 to frame ground Y N Go to Flag 2 Check for an open c...

Page 173: ...10 00 2 159 Phaser 790 DocuColor 2006 009 701 Status Indicator RAPs Initial Issue Figure 1 009 701 RAP Circuit Diagram...

Page 174: ...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...

Page 175: ...10 00 2 161 Phaser 790 DocuColor 2006 009 702 Status Indicator RAPs Initial Issue Figure 1 009 702 RAP Circuit Diagram...

Page 176: ...t 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...

Page 177: ...10 00 2 163 Phaser 790 DocuColor 2006 009 703 Status Indicator RAPs Initial Issue Figure 1 009 703 RAP Circuit Diagram...

Page 178: ...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 ge...

Page 179: ...10 00 2 165 Phaser 790 DocuColor 2006 009 704 Status Indicator RAPs Initial Issue Figure 1 009 704 RAP Circuit Diagram...

Page 180: ...10 00 2 166 Phaser 790 DocuColor 2006 009 704 Initial Issue Status Indicator RAPs...

Page 181: ...ted 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 t...

Page 182: ...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 measure...

Page 183: ...10 00 2 169 Phaser 790 DocuColor 2006 010 353 356 357 Status Indicator RAPs Initial Issue Figure 1 010 353 RAP Circuit Diagram...

Page 184: ...en P 72 pin 2 and pin 4 when the Temperature Sensor is at approximately room tempera ture Y N Replace the Temperature Sensor PL 8 2 Reconnect P J 72 A resistance of approximately 200k ohms is measured...

Page 185: ...10 00 2 171 Phaser 790 DocuColor 2006 010 354 Status Indicator RAPs Initial Issue Figure 1 010 354 RAP Circuit Diagram...

Page 186: ...nuity 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 rep...

Page 187: ...10 00 2 173 Phaser 790 DocuColor 2006 010 355 Status Indicator RAPs Initial Issue Figure 1 010 355 RAP Circuit Diagram...

Page 188: ...lace 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...

Page 189: ...10 00 2 175 Phaser 790 DocuColor 2006 010 358 Status Indicator RAPs Initial Issue Figure 1 010 358 RAP Circuit Diagram...

Page 190: ...ircuit 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...

Page 191: ...10 00 2 177 Phaser 790 DocuColor 2006 010 359 Status Indicator RAPs Initial Issue Figure 1 010 359 RAP Circuit Diagram...

Page 192: ...or 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...

Page 193: ...10 00 2 179 Phaser 790 DocuColor 2006 010 700 Status Indicator RAPs Initial Issue...

Page 194: ...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 Y N Go to Flag 1 Check the wiring for a...

Page 195: ...10 00 2 181 Phaser 790 DocuColor 2006 010 701 Status Indicator RAPs Initial Issue Figure 1 010 701 RAP Circuit Diagram...

Page 196: ...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...

Page 197: ...10 00 2 183 Phaser 790 DocuColor 2006 010 702 Status Indicator RAPs Initial Issue Figure 1 010 702 RAP Circuit Diagram...

Page 198: ...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...

Page 199: ...10 00 2 185 Phaser 790 DocuColor 2006 010 703 Status Indicator RAPs Initial Issue Figure 1 010 703 RAP Circuit Diagram...

Page 200: ...he Digital Output DO test from the Control Panel Enter code 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...

Page 201: ...10 00 2 187 Phaser 790 DocuColor 2006 010 704 Status Indicator RAPs Initial Issue Figure 1 010 704 RAP Circuit Diagram...

Page 202: ...en 45 and 50 ohms Y N 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 F...

Page 203: ...10 00 2 189 Phaser 790 DocuColor 2006 010 705 Status Indicator RAPs Initial Issue Figure 1 010 705 RAP Circuit Diagram...

Page 204: ...10 00 2 190 Phaser 790 DocuColor 2006 010 705 Initial Issue Status Indicator RAPs...

Page 205: ...nd 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 Contr...

Page 206: ...10 00 2 192 Phaser 790 DocuColor 2006 011 700 Initial Issue Status Indicator RAPs Figure 1 011 700 RAP Circuit Diagram...

Page 207: ...move the two screws on the Bin Cam Switch from under the Bin Cam Assembly so as to be able to actuate and deactuate the switch Measure the voltage between J 4 1 of the Sorter Control PWB and GND Actua...

Page 208: ...8 Check for an open circuit The wires are good Y 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...

Page 209: ...10 00 2 195 Phaser 790 DocuColor 2006 011 701 Status Indicator RAPs Initial Issue Figure 1 011 701 RAP Circuit Diagram...

Page 210: ...N 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 Con...

Page 211: ...10 00 2 197 Phaser 790 DocuColor 2006 011 702 Status Indicator RAPs Initial Issue Figure 1 011 702 RAP Circuit Diagram...

Page 212: ...ontrol 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 P...

Page 213: ...10 00 2 199 Phaser 790 DocuColor 2006 011 703 Status Indicator RAPs Initial Issue Figure 1 011 703 RAP Circuit Diagram...

Page 214: ...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 N There is 5 VDC between J35 4 of the Low Voltage Power Supply and GND...

Page 215: ...10 00 2 201 Phaser 790 DocuColor 2006 011 704 Status Indicator RAPs Initial Issue Figure 1 011 704 RAP Circuit Diagram...

Page 216: ...a short circuit to ground The wire is good Y N Repair the wire There is 5 VDC between J 2 4 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...

Page 217: ...10 00 2 203 Phaser 790 DocuColor 2006 011 705 Status Indicator RAPs Initial Issue Figure 1 011 705 RAP Circuit Diagram...

Page 218: ...Status Indicator RAPs 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 Y N Repair the wires Replac...

Page 219: ...10 00 2 205 Phaser 790 DocuColor 2006 011 706 Status Indicator RAPs Initial Issue Figure 1 011 706 RAP Circuit Diagram...

Page 220: ...10 00 2 206 Phaser 790 DocuColor 2006 011 706 Initial Issue Status Indicator RAPs...

Page 221: ...h off the power then switch on the power If the problem still exists replace the ESS PWB PL 12 1 016 312 ESS Hard Drive Error RAP Control Logic detected an ESS Hard Drive error Procedure Switch off th...

Page 222: ...ower then switch on the power If the problem still exists replace the ESS PWB PL 12 1 016 315 ESS RAM Bank 1 RAP Control Logic detected an ESS RAM Read Write Check error from Bank 1 Procedure Switch o...

Page 223: ...re Switch off the power Reseat the Memory module in Slot 2 Switch on the power If the fault remains replace the Memory module in Slot 2 PL 12 1 If the problem still exists replace the ESS PWB PL 12 1...

Page 224: ...016 330 Communication error between the ESS and Network Interface 1394 PWBs 016 331 Network Interface 1394 PWB Flash ROM Boot Module checksum error 016 332 Network Interface 1394 PWB RAM read write t...

Page 225: ...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 Swi...

Page 226: ...10 00 2 212 Phaser 790 DocuColor 2006 016 370 Initial Issue Status Indicator RAPs...

Page 227: ...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...

Page 228: ...out 033 227 The Control Logic detects an Async transaction retry error 033 228 The Control Logic detects a 1394 PWB link chip error Initial Actions Check the cables and connections between the IIT and...

Page 229: ...tected 033 344 An ASIC_Y read write error was detected 033 345 An ASIC_M read write error was detected 033 350 An SCSI_CHIP read write error was detected Procedure Switch the power off then on If the...

Page 230: ...n 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 retr...

Page 231: ...ntrol Logic detects a a message reject has been received 033 945 The Control Logic detects a SCSI DMA transmission failure Initial Actions Check the following Verify that the SCSI cable between the PC...

Page 232: ...10 00 2 218 Phaser 790 DocuColor 2006 033 940 941 943 944 945 Initial Issue Status Indicator RAPs...

Page 233: ...RAP 3 7 IQ6 Blank or Nearly Blank Sheet RAP 3 8 IQ7 Residual Image Ghosting RAP 3 10 IQ8 IOT Background RAP 3 12 IQ9 Deletions RAP 3 14 IQ10 Color to Color Misregistration RAP 3 16 IQ11 IOT Skew RAP...

Page 234: ...10 00 3 2 Phaser 790 DocuColor 2006 Initial Issue Image Quality...

Page 235: ...ntrue colored areas on the copy or print The most common example is a deletion caused by the tenting of paper from mishandling or moisture or by dents or defects in the IBT Go to the IQ9 RAP Drum Defe...

Page 236: ...d to the other Streaks are generally shorter than lines and are of nonuniform width along their length They may have a more ragged or fuzzy appearance than lines Go to the IQ16 RAP Residual Image A to...

Page 237: ...rform 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...

Page 238: ...ess the Item Enter button The Developer Clutch energizes Y N 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...

Page 239: ...on 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 th...

Page 240: ...cuit 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 Immediatel...

Page 241: ...10 00 3 9 Phaser 790 DocuColor 2006 IQ6 Image Quality Initial Issue Figure 1 IQ6 RAP Circuit Diagram...

Page 242: ...t 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...

Page 243: ...10 00 3 11 Phaser 790 DocuColor 2006 IQ7 Image Quality Initial Issue Figure 1 IQ7 RAP Circuit Diagram...

Page 244: ...ridge Remove the rear cover Select Print Configuration Page from the menu Measure the voltage from the A terminal on the HVPS to frame ground as the print is processing The voltage cycles from 0 VDC t...

Page 245: ...10 00 3 13 Phaser 790 DocuColor 2006 IQ8 Image Quality Initial Issue...

Page 246: ...y 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...

Page 247: ...10 00 3 15 Phaser 790 DocuColor 2006 IQ9 Image Quality Initial Issue Figure 1 IQ9 RAP Circuit Diagram...

Page 248: ...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...

Page 249: ...heck 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 IQ13 Moire RAP Th...

Page 250: ...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 rou...

Page 251: ...g 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 Repl...

Page 252: ...nt Cartridge Check the continuity between the BCR Contact PL 5 1 and terminal A on the HVPS There is continuity Y N Replace the BCR Wire PL 11 1 and or the BCR Connector PL 5 1 Open the Front Cover Ch...

Page 253: ...n on every 11 X17 in A3 print Y N 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 Clean...

Page 254: ...10 00 3 22 Phaser 790 DocuColor 2006 IQ18 Initial Issue Image Quality...

Page 255: ...on Sensor 4 40 REP 6 8 IIT Low Voltage Power Supply LVPS 4 41 REP 6 9 Fan 4 41 REP 6 10 APS Sensor 4 42 REP 6 11 PWB Box 4 43 REP 6 12 PWB Box Cover 4 45 REP 6 13 IPS PWB 4 45 REP 6 14 ICM Main PWB 4...

Page 256: ...am Clutch 4 111 Fusing REP 10 1 Fuser Assembly 4 113 REP 10 2 Main Fuser Assembly 4 113 REP 10 3 Upper Guide Assembly 4 114 REP 10 4 Upper Plate 4 115 REP 10 5 Heat Roll Heat Lamp 4 116 REP 10 6 Press...

Page 257: ...153 ADJ 6 2 IIT Half Rate and Full Rate Carriage Adjustment 4 154 ADJ 6 3 IIT Lead Edge Registration 4 157 ADJ 6 4 IIT Side Registration 4 158 ADJ 6 5 ICM Main PWB Adjustment 4 159 ADJ 6 6 IIT Auto S...

Page 258: ...10 00 4 4 Phaser 790 DocuColor 2006 Initial Issue Repairs and Adjustments...

Page 259: ...frame when Installing 1 Reinstall the LVPS in the reverse order of removal Figure 1 Removing the LVPS REP 1 2 HVPS Parts List on PL 11 1 Removal WARNING To avoid personal injury or shock do not perfor...

Page 260: ...eloper 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...

Page 261: ...4 Remove the Right Cover REP 14 9 5 Remove the ESS PWB and Plate as a unit REP 1 9 figure 1 of the procedure only 6 Remove the Controller Chassis REP 1 11 CAUTION Observe the ESD Procedures when remov...

Page 262: ...ight 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 elect...

Page 263: ...r 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...

Page 264: ...nd 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 t ain proper machine operation The following steps direct y...

Page 265: ...oval Figure 1 Removing 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 elec...

Page 266: ...wer 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 Commu...

Page 267: ...o 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...

Page 268: ...10 00 4 14 Phaser 790 DocuColor 2006 REP 1 13 Initial Issue Repairs and Adjustments...

Page 269: ...ine Power Cord 2 Remove the Rear Cover REP 14 6 3 Remove the HVPS REP 1 2 4 Remove the Drive Motor PWB REP 4 5 5 Remove the Paper Handling Motor REP 4 4 6 Remove the Paper Handling Drive Unit Figure 1...

Page 270: ...connect the machine Power Cord 2 Remove the Rear Cover REP 14 6 3 Remove the Fuser Assembly REP 10 1 4 Remove the Fuser Motor REP 4 3 5 Remove the LVPS REP 1 1 6 Remove the Fuser Drive Unit Figure 1 R...

Page 271: ...of removal Figure 1 Removing the Fuser Motor REP 4 4 Paper Handling Motor Parts List on PL 10 1 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switc...

Page 272: ...ies 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 P...

Page 273: ...ect 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...

Page 274: ...tor 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 machin...

Page 275: ...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 di...

Page 276: ...10 00 4 22 Phaser 790 DocuColor 2006 REP 4 9 REP 4 10 Initial Issue Repairs and Adjustments...

Page 277: ...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...

Page 278: ...Different loads are applied to each side of the ADF For this reason the Counterbalance parts are unique for each side When replacing the Counterbalances do not mix the left Counterbal ance parts with...

Page 279: ...ne power and disconnect the machine Power Cord 2 Remove the ADF Front Cover 3 Remove the ADF Rear Cover 4 Remove the Lower Chute Figure 1 Figure 1 Removing the Lower Chute 5 Remove the Feed Roll Figur...

Page 280: ...d 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 R...

Page 281: ...r Roll Assembly parts Figure 3 Figure 3 Removing Nudger Roll Retaining Parts 1 Open the Feeder Cover 2 Loosen the screw 3 Remove the Lower Chute by moving the chute in the direction indicated 1 Remove...

Page 282: ...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 Figure 5 One Wa...

Page 283: ...d 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 Figure 1 Removing the Feeder Lower Cover 6 Rem...

Page 284: ...l The front spring is the stron ger thicker spring 9 Remove the Registration Roll Figure 3 Figure 3 Removing the Registration Roll Replacement 1 Perform the procedure for removal in reverse 2 Perform...

Page 285: ...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 Figure 1 Removing the Document Transport...

Page 286: ...e the Platen Belt Figure 1 Figure 1 Removing the Platen Belt Replacement 1 Perform the procedure for removal in reverse Pay close attention to the following steps 2 Align the Shaft Support Figure 2 Fi...

Page 287: ...nt Cover and Rear Cover 3 Remove the ADF Exit Motor Figure 1 Figure 1 Removing the ADF Exit Motor Replacement 1 Perform the procedure for removal in reverse Pay close attention to the following steps...

Page 288: ...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 Figure 1 Removing the Outer Exit Chute Assembly...

Page 289: ...n 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 Figure 4 Replacing the Outer Exit Chute...

Page 290: ...10 00 4 36 Phaser 790 DocuColor 2006 REP 5 10 Initial Issue Repairs and Adjustments...

Page 291: ...1 Figure 1 Removing the Platen Glass Replacement 1 Perform the procedure for removal in reverse REP 6 2 Right Cover Parts List on PL 16 6 Removal 1 Remove the Right Cover Figure 1 Figure 1 Removing th...

Page 292: ...t Cover Replacement 1 Perform the procedure for removal in reverse 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 Figure 1 R...

Page 293: ...e procedure for removal in reverse 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...

Page 294: ...er and disconnect the machine Power Cord 2 Remove the Left Cover REP 6 3 3 Remove the Rear Cover REP 6 4 4 Remove the bracket containing the power receptacles Figure 1 Figure 1 Removing the Bracket an...

Page 295: ...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 m...

Page 296: ...lectrical 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 Figure 1 Removing the Cover 4...

Page 297: ...n 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 6 Remove the connector cover Figure 1 Figure 1 Remo...

Page 298: ...nectors 10 Remove the screws holding the PWB Box to the IIT Frame Figure 4 Figure 4 Accessing the PWB Box 11 Slide the PWB Box from the IIT Frame Figure 5 Figure 5 Removing the PWB Box Replacement 1 P...

Page 299: ...st 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...

Page 300: ...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 Re...

Page 301: ...nents Use of the ESD Field Service Kit is required 4 Remove the Extension PWB Figure 1 Figure 1 Removing the Extension PWB Replacement 1 Perform the procedure for removal in reverse REP 6 16 Advanced...

Page 302: ...nal 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 f...

Page 303: ...P 6 23 9 Reinstall the Platen Glass REP 6 1 REP 6 18 Carriage Motor 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...

Page 304: ...removal in reverse 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 m...

Page 305: ...y 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...

Page 306: ...r 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 Pan...

Page 307: ...erse 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 elect...

Page 308: ...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 Switch off the mac...

Page 309: ...sembly Figure 1 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 i...

Page 310: ...erse CAUTION The area of the Tray 1 Front Snubber that 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...

Page 311: ...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 S...

Page 312: ...10 00 4 58 Phaser 790 DocuColor 2006 REP 7 8 Initial Issue Repairs and Adjustments...

Page 313: ...ccess the Turn In Chute Figure 1 Figure 1 Accessing the Turn In Chute CAUTION Use care not to damage the hinges of the Turn In Chute during removal and replacement 5 Remove the Turn In Chute Figure 2...

Page 314: ...2 or the Duplex Tray 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 sha...

Page 315: ...EP 8 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 8 Remove the Feed Roll Assembly Fi...

Page 316: ...move 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 caus...

Page 317: ...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 performi...

Page 318: ...e 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 Byp...

Page 319: ...orm 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 Ass...

Page 320: ...y 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 p...

Page 321: ...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 activiti...

Page 322: ...8 6 3 Remove the Bypass Tray Feed Assembly REP 8 7 4 Remove the Top Frame Figure 1 Figure 1 Removing the Top Frame 5 Remove the Stack Height Sensor Figure 1 Figure 2 Removing the Stack Height Sensor R...

Page 323: ...erse REP 8 16 Preregistration Roll Parts List on PL 4 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 m...

Page 324: ...edure for removal in reverse REP 8 18 Registration Rubber Roll Parts List on PL 4 7 Removal WARNING To avoid personal injury or shock do not perform repair activities with the power switch on or elect...

Page 325: ...ne 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...

Page 326: ...s 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...

Page 327: ...hine power and disconnect the machine Power Cord 2 Remove the Feeder Rear Cover 3 Remove the Feeder Drive Unit Figure 1 Figure 1 Removing the Feeder Drive Unit 4 Remove the Low Paper Sensor Figure 2 F...

Page 328: ...REP 14 11 3 Remove the Feeder Right Cover Remove the Feeder Chute Figure 1 Figure 1 Removing the Feeder Right Cover Feeder Chute 4 Remove the Paper Feeder Assembly Figure 2 Figure 2 Removing the Pape...

Page 329: ...P 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 Sw...

Page 330: ...Removing the Turn Clutch Replacement 1 Perform the removal procedure in reverse REP 8 27 Duplex Tray Assembly Parts List on PL 15 3 Removal WARNING To avoid personal injury or shock do not perform re...

Page 331: ...he 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 Figure 1 Removing the Duplex Regis...

Page 332: ...Duplex Tray Assembly REP 8 27 3 Remove the Front Cover of the Duplex Tray Assembly 4 Remove the Duplex Registration Chute Figure 1 Figure 1 Removing the Duplex Registration Chute 5 Remove the Rail Ass...

Page 333: ...re 4 Removing the Exit Chute 8 Remove the Duplex Exit Sensor Figure 5 Figure 5 Removing the Duplex Exit Sensor Replacement 1 Perform the removal procedure in reverse 1 Disconnect the connectors 2 Remo...

Page 334: ...oval 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 ma...

Page 335: ...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 r...

Page 336: ...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 Figure 1 Removing the Exit Cover 4 Remove the Exit Roll Figu...

Page 337: ...er Assembly Figure 1 Figure 1 Removing the Inverter Lower Assembly Replacement 1 Perform the removal procedure in reverse REP 8 36 Inverter Motor Parts List on PL 15 5 Removal WARNING To avoid persona...

Page 338: ...UTION 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 1 Remove the four screws...

Page 339: ...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 Figure 1 Removing the Inverter Roll 5 Remove the Inverter Sensor Fi...

Page 340: ...e Inverter Lower Assembly REP 8 35 4 Remove the Rear Inverter Cover Figure 1 Figure 1 Removing the Rear Inverter Cover CAUTION The PWB components are highly susceptible to damage from electrostatic di...

Page 341: ...over 5 Remove the Inverter Lower Assembly REP 8 35 6 Remove the Lower Chute Figure 1 Figure 1 Removing the Lower Chute 7 Remove the Duplex Nip Solenoid Figure 2 Figure 2 Removing the Duplex Nip Soleno...

Page 342: ...the Transport Cover can be easily damaged Use care when performing the following step 4 Remove the Exit Transport Cover Figure 1 Figure 1 Removing the Transport Cover 5 Remove the Exit Transport Asse...

Page 343: ...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...

Page 344: ...vities 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 t...

Page 345: ...ioning marks Reinstall the Copy Print Cartridge in the reverse order of removal Figure 1 Removing the Copy Print Cartridge REP 9 2 Waste Container Parts List on PL 5 1 Removal WARNING To avoid persona...

Page 346: ...tivities 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 Prepare to...

Page 347: ...e 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...

Page 348: ...5 Remove the IBT Assembly REP 9 16 6 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 Develope...

Page 349: ...1 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 R...

Page 350: ...ure 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 elect...

Page 351: ...ies 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...

Page 352: ...eful not to drop the screws during the removal Be aware that the Rotary Frame can turn when the following step is performed After removing be sure to lay the Developer Housing in a horizontal position...

Page 353: ...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 Figure 1 Removing the Fan Duct and Developer Frame...

Page 354: ...Inner Cover Assembly REP 14 5 7 Remove the Rear Cover REP 14 6 8 Remove all Dry Ink Cartridges REP 9 9 9 Remove the Left Front Cover Interlock REP 1 7 10 Remove all Developer Housings REP 9 10 11 Remo...

Page 355: ...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 R...

Page 356: ...REP 14 4 3 Access the Cartridge Sensor Figure 1 Figure 1 Accessing the Cartridge Sensor 4 Remove the Cartridge Sensor Figure 2 Replacement CAUTION Securely route the harness in the hooks of the Senso...

Page 357: ...amage 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...

Page 358: ...ion Lever REP 9 15 5 Remove the Inner Covers REP 14 5 6 Remove the Fuser Assembly REP 10 1 7 Remove the Belt Cleaner REP 9 17 8 Remove the BTR 2 Assembly REP 9 18 9 Open the Bypass Tray Registration A...

Page 359: ...nnect 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 t...

Page 360: ...Remove the Belt Cleaner REP 9 17 CAUTION Do not touch the 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 Repla...

Page 361: ...e Tension Lever REP 9 15 5 Remove the Left Inner Cover Assembly REP 14 5 6 Remove the Fuser Assembly REP 10 1 7 Remove the Belt Cleaner REP 9 17 8 Remove the BTR 2 Assembly REP 9 18 9 Remove the BTR C...

Page 362: ...sembly REP 9 16 11 Remove the BTR 2 Cam Assembly REP 9 19 12 Remove the Right Cover REP 14 9 NOTE Toner may spill from the Auger during the removal Spread paper on the frame below the Auger and be car...

Page 363: ...g the removal Oil from your hands can contaminate the IBT Belt 3 Remove the IBT Assembly REP 9 16 4 Remove the Rails Figure 1 Figure 1 Removing the Rails 5 Reinstall the Tension Lever and lift the Pus...

Page 364: ...re 3 Removing the IBT Belt 10 Remove the IBT Belt from the Assembly Figure 4 Removing the IBT Belt Replacement CAUTION Be careful not to damage or dirty the IBT Belt during the reinstallation 1 Clean...

Page 365: ...Sensor in the reverse order of removal Figure 1 Removing the TR0 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 activiti...

Page 366: ...10 00 4 112 Phaser 790 DocuColor 2006 REP 9 22 REP 9 23 Initial Issue Repairs and Adjustments...

Page 367: ...L 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 disconne...

Page 368: ...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 Re...

Page 369: ...the following step the Fuser Front Frame and Fuser Rear 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...

Page 370: ...t 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 con...

Page 371: ...Lamp in the reverse order of removal 2 Check the Fuser Nip ADJ 10 1 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 i...

Page 372: ...re 1 Removing 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...

Page 373: ...Plate REP 10 4 5 Remove the Heat Roll Heat Lamp REP 10 5 CAUTION 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...

Page 374: ...ll REP 10 10 9 Prepare to remove the Pressure Roll Figure 1 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 Rem...

Page 375: ...Plate REP 10 4 5 Remove the Heat Roll Heat Lamp REP 10 5 6 Remove the Pressure Roll Heat Lamp REP 10 6 7 Remove the Lower Guide Assembly REP 10 7 8 Remove the Heat Roll REP 10 10 9 Remove the Pressur...

Page 376: ...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 CAUT...

Page 377: ...rse order of removal 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...

Page 378: ...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 5 Remove the Cleaner Cam Solenoid REP 10 15 CAUTION Be sure...

Page 379: ...EP 8 30 3 Remove the Fuser Assembly REP 10 1 4 Remove the Main Fuser Assembly REP 10 2 CAUTION The rear Exit Roll Bearing remains but is not secured to the tray when the following step of the procedur...

Page 380: ...2 Remove the Fuser Assembly REP 10 1 3 Prepare to remove the Fuser Entrance Sensor Figure 1 Figure 1 Preparing to Remove the Fuser Entrance Sensor 4 Remove the Fuser Entrance Sensor Figure 2 Replaceme...

Page 381: ...hine Power Cord 2 Remove the Fuser Assembly REP 10 1 3 Prepare to remove the Fuser Chute Fan Figure 1 Figure 1 Preparing to Remove the Fuser Chute Fan 4 Remove the Fuser Chute Fan Figure 2 Replacement...

Page 382: ...10 00 4 128 Phaser 790 DocuColor 2006 REP 10 19 Initial Issue Repairs and Adjustments...

Page 383: ...EP 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 Swit...

Page 384: ...t 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...

Page 385: ...sconnect the motor connector from the PWB and release the wires Figure 1 Figure 1 Disconnecting the Motor 5 Remove the Sorter Transport Motor Figure 2 Figure 2 Removing the Sorter Transport Motor Repl...

Page 386: ...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...

Page 387: ...ement 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...

Page 388: ...er 4 Disconnect the motor connector from the PWB and release the wires Figure 1 Figure 1 Disconnecting the Motor 5 Remove the Bin Drive Motor Figure 2 Figure 2 Removing the Bin Drive Motor Replacement...

Page 389: ...l 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 machi...

Page 390: ...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 activi...

Page 391: ...Removing the Bin Trays Replacement 1 Perform the procedure for removal in reverse 2 Perform a Sorter Bin Cam Position Adjustment ADJ 11 1 on the Front Bin Cam REP 11 15 Docking Interlock Parts List on...

Page 392: ...10 00 4 138 Phaser 790 DocuColor 2006 REP 11 14 REP 11 15 Initial Issue Repairs and Adjustments...

Page 393: ...embly in the reverse order of removal Figure 1 Removing the Front Cover Assembly REP 14 2 Front Mid Cover Parts List on PL 1 1 Removal WARNING To avoid personal injury or shock do not perform repair a...

Page 394: ...pplied 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 Figure 1 Removing the Front Lower Cover Re...

Page 395: ...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 The two screws at the rea...

Page 396: ...r Assembly REP 14 4 4 Remove the Copy Print Cartridge REP 9 1 5 Remove the Tension Lever REP 9 15 CAUTION When the inner covers are removed the Front Cover Assembly is supported by the left and right...

Page 397: ...sconnect the machine Power Cord 2 Open the Exit Transport Assembly 3 Remove the Rear Cover Figure 1 Replacement CAUTION Be careful not to pinch the harness when reinstalling the Rear Cover 1 Reinstall...

Page 398: ...r 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...

Page 399: ...val 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 electr...

Page 400: ...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...

Page 401: ...equipped with a Scanner remove the 1394 PWB PL 12 1 4 Jumper the two pins of J 8 on the ESS PWB 5 Switch on the machine power 6 Enter the Diagnostic Mode IOT GP 1 the display will indicate VERSION INF...

Page 402: ...re 2 a If the results are less than nominal move the tray toward the front b If the results are greater than nominal move the tray toward the rear Figure 2 Adjusting Side Registration 2 Perform the ch...

Page 403: ...edge to the top of Step 3 on the LE2 scale is 10 0mm 2 5 Figure 1 Figure 1 Test Pattern Orientation Adjustment 1 Enter Diagnostic Mode IIT GP 19 2 Enter Systemdata R W and press the Select button 3 En...

Page 404: ...achine power and disconnect the machine Power Cord 2 Using shim stock create a 1 4mm shim to use as a thickness gauge 3 Remove the ADF Rear Cover 4 Set the Shim in the positions indicated in Figure 1...

Page 405: ...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...

Page 406: ...ar Frame to the front end of the Paper Side Guide Figure 3 Figure 3 Taking Measurements 6 If the measurement is not within specifications perform the adjustment 1 Remove the screws 2 2 Lift the tray a...

Page 407: ...egistration ADJ 5 1 ADF Lead Edge Registration ADJ 5 2 IIT Lead Edge Registration ADJ 6 3 IIT Side Registration ADJ 6 4 Check 1 Using the Copier Setup Test Pattern 82E8220 make two copies with the mac...

Page 408: ...ver REP 6 2 5 Remove the Left Cover REP 6 3 6 Remove the Rear Cover REP 6 4 7 Remove the Control Panel Assembly REP 6 23 NOTE Two positioning tools are provided inside the Control Panel Assembly 8 Rem...

Page 409: ...Positioning Tools 12 Tighten the one set screw on the front Capstan Pulley Figure 5 Figure 5 Tightening the Capstan Set Screw 13 Use the tools to adjust the front side of the Full Rate Carriage Assemb...

Page 410: ...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 Le...

Page 411: ...Test Pattern Indications 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 4 Change the values...

Page 412: ...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 4 Chang...

Page 413: ...f a standard white sheet This adjustment should be performed whenever the following conditions are true After making changes to the ADF settings After replacing the IIT Main PWB After replacing the Pl...

Page 414: ...ay 1 2 Place Test Pattern 82E13030 on the Platen Glass and close the cover or ADF 3 At the Control Panel select Original Type Use the arrow keys to select Color and press the Select button 4 Select Te...

Page 415: ...the first page 5 Check the side to side and top to bottom registration Figure 1 6 Repeat steps 1 5 for each tray and option tray 7 Compare the average value calculated to the value displayed in Table...

Page 416: ...ence of the white tracking roll with your fin 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 sur...

Page 417: ...he measurement is within specification Rotary Latch White Tracking Roll White Seal 1 Measure the distance that the mark on the White Tracking Roll moved from the White Seal The specification is 3 0 to...

Page 418: ...ve 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 If the measurement is not in specification p...

Page 419: ...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...

Page 420: ...10 00 4 166 Phaser 790 DocuColor 2006 ADJ 11 1 Initial Issue Repairs and Adjustments...

Page 421: ...5 33 PL 8 5 Fusing 5 of 7 5 34 PL 8 6 Fusing 6 of 7 5 35 PL 8 7 Fusing 7 of 7 5 36 Paper Exit PL 9 1 Paper Exit 1 of 2 5 37 PL 9 2 Paper Exit 2 of 2 5 38 Drives PL 10 1 Drives 5 39 Electrical PL 11 1...

Page 422: ...der Lower Chute Registration Sensor 5 73 PL 17 6 Document Transport Platen Belt 5 74 PL 17 7 Exit Roll Exit Motor Exit Sensor 5 75 PL 17 8 Platen Glass ADF Harness 5 76 Stand PL 18 1 Stand 5 77 Sorter...

Page 423: ...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 lis...

Page 424: ...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 sect...

Page 425: ...the tag number within the circle Figure 1 Information on the modification is in the Change Tag Index Figure 1 With Tag Symbol A Tag number within a circle having a shaded bar and pointing to an item...

Page 426: ...e tag number within the circle Figure 3 Information on the modification is in the Change Tag Index Figure 3 Entire Drawing With Tag Symbol A tag number within a circle with no apex and having a shaded...

Page 427: ...e Plate Not Spared 5 048E52291 Front Lower Cover REP 14 3 6 802K11970 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 Lev...

Page 428: ...0 Right Lower Cover REP 14 11 3 Rear Cover Assembly Not Spared 4 802E05291 Rear Cover REP 14 6 5 053K91391 Filter REP 14 7 6 802E05311 Option Hinge Cover 7 802K17122 Top Cover Assembly REP 14 4 8 Top...

Page 429: ...ot Spared 5 Developer Outer Seal Not Spared 6 DL Bracket Not Spared 7 DL Bracket Assembly Not Spared 8 PWB Support Not Spared 9 Developer Seal Not Spared 10 Connector 5P Not Spared 11 Connector 3P Not...

Page 430: ...ket 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 Not Spared 11 Feeder Frame Not S...

Page 431: ...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 Lock Plate P O PL 2 1 Item 1 11 Right Rear Guide Plate P O PL 2 1 Item 1 12 Left Rear...

Page 432: ...K07770 Size Switch PWB REP 7 1 6 Sensor Bracket Not 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...

Page 433: ...Description 1 Upper Turn Chute Assembly Not Spared 2 Upper Turn Chute Not Spared 3 Pinch Roll Not Spared 4 Pinch Spring Not Spared 5 Pinch Spring Housing Not Spared 6 Magnet Catch Not Spared 7 802E05...

Page 434: ...Turn Gear Cover Not Spared 7 Turn Gear S Not Spared 8 Turn Gear M Not Spared 9 Turn Gear D Not Spared 10 059K04840 Feed Roll Assembly REP 8 3 11 Feed Shaft P O PL 3 3 Item 10 12 Feed Roll Kit REP 8 2...

Page 435: ...ss Tray Feed Assembly P O PL 4 1 Item 5 PL 4 1 Item 6 REP 8 8 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...

Page 436: ...ared 7 Lift Down Actuator Not Spared 8 162K53330 Bypass Tray Harness 9 Gear 28 Not Spared 10 130E82190 Lift Plate Sensor REP 8 10 11 Damper Not Spared 12 Tray Bracket Not Spared 13 Lift Plate Not Spar...

Page 437: ...istration 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...

Page 438: ...tem 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...

Page 439: ...4 Item 1 4 Feed Shaft P O PL 4 4 Item 1 5 Nudger Retard Roll P O PL 4 4 Item 1 6 Nudger Gear 17 P O PL 4 4 Item 1 7 Idler Gear 20 P O PL 4 4 Item 1 8 Feed Gear 14 P O PL 4 4 Item 1 9 Nudger Clutch P O...

Page 440: ...stration Frame P O PL 4 6 Item 1 3 162K53280 Registration Harness 4 121K23430 Preregistration Clutch REP 8 15 5 Paper Handler P O PL 4 6 Item 1 6 Bearing P O PL 4 6 Item 1 7 Rear Rail P O PL 4 6 Item...

Page 441: ...lutch REP 8 17 6 Bearing P O PL 4 6 Item 1 7 059K14380 Registration Rubber Roll REP 8 18 8 Registration Metal Roll 9 Gear P O PL 4 6 Item 1 10 Bearing P O PL 4 6 Item 1 11 Bearing P O PL 4 6 Item 1 12...

Page 442: ...Connector Not Spared 8 Rail Clamp 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...

Page 443: ...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 Not Spared 8 130E83060 Rotary Sensor REP 9 11 9 Cart...

Page 444: ...9 5 600K87140 Developer Housing K REP 9 10 ADJ 9 1 Phaser 790 600K87300 Developer Housing K REP 9 10 ADJ 9 1 DocuColor 2006 6 600K12112 Developer Housing C REP 9 10 ADJ 9 1 Phaser 790 600K87330 Devel...

Page 445: ...pared 5 Clamp Not Spared 6 006K85500 Auger REP 9 20 7 802K12301 Panel 8 042K92160 Belt Cleaner REP 9 17 9 802K14462 BTR 2 Assembly REP 9 18 10 011E09640 Tension Lever REP 9 15 11 015K43080 IBT Rear Br...

Page 446: ...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...

Page 447: ...oll 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 TR0 Sensor REP 9 22 10 BTR 1 P O PL 7 2...

Page 448: ...Item 1 6 Gear P O PL 7 4 Item 1 7 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 BTR Cam P O PL 7 4 Item 1 12 I...

Page 449: ...Front Arm P O PL 7 5 Item 1 6 Rear Arm P O PL 7 5 Item 1 7 BTR 2 Cleaner P O PL 7 5 Item 1 8 Support Bearing 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 Cle...

Page 450: ...Parts List PL 8 1 Fusing 1 of 7 Item Part Description 1 Fuser Assembly Not Spared REP 10 1 2 600K85412 Main Fuser 110v 600K85422 Main Fuser 220v 3 050K43340 Fuser Tray 220v 050K43330 Fuser Tray 110v...

Page 451: ...user 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 O PL 8 2 Item 1 12 Nut P O PL 8 2 Item 1 13 038K85073 Lower Guide Assembly REP 10 7 14 Exi...

Page 452: ...8 Fuser Nip Bearing P O PL 8 2 Item 1 9 Gear P O PL 8 2 Item 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 H...

Page 453: ...er 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 003E39791 Fuser Knob 9 Fuser Knob Bearing P O PL 8 4 Item...

Page 454: ...ail 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 PL 8 4 Item 1 PL 8 5 Item 5 7 Exchange Solenoid PL 8 5 Item 5 REP 10 14 8 Idler...

Page 455: ...ser Tray Cap Not Spared 4 130E81970 Fuser Entrance Sensor REP 10 18 5 Harness Not Spared 6 Sensor Bracket Not Spared 7 Actuator Not Spared 8 Spring Not Spared 9 Bottom Cover Not Spared 10 127E81620 Fu...

Page 456: ...Bracket P O PL 8 7 Item 3 5 Clamp P O PL 8 7 Item 3 6 Gear P O PL 8 7 Item 3 7 Gear P O PL 8 7 Item 3 8 Bearing P O PL 8 7 Item 3 9 Shaft P O PL 8 7 Item 3 10 Gear P O PL 8 7 Item 3 11 Cleaner Cam Ge...

Page 457: ...Phaser 790 DocuColor 2006 PL 9 1 Parts List Initial Issue 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 Lowe...

Page 458: ...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 Item 18 3 Kit 10 Gear P O PL 9 2 Item 18 8 Kit 11 Front...

Page 459: ...Spared 4 127K25400 Fuser Motor REP 4 3 5 127K25410 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...

Page 460: ...EP 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...

Page 461: ...2 Item Part Description 1 160K75041 MCU PWB REP 1 5 2 160K61500 Communication PWB REP 1 12 3 110K98810 Right Front Cover Interlock REP 1 6 4 110E94380 Left Front Cover Interlock REP 1 7 5 130K60530 En...

Page 462: ...2K42090 Panel Harness 4 160K74642 ESS Rev 8 PWB REP 1 9 5 144E00440 Memory 256MB 144E00430 Memory 128MB 144E00420 Memory 64MB 6 121K26500 Hard Disk Drive Assembly REP 1 13 ADJ 3 1 7 IDE Cable P O PL 1...

Page 463: ...lor 2006 PL 13 1 Parts List Initial Issue 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...

Page 464: ...r 2 802E15720 Feeder Rear Cover 3 Feeder Rear Harness Cover Not Spared 4 Shaft Not Spared 5 802E05191 Feeder Left Cover 6 802E15530 Feeder Right Cover 7 110E93440 Feeder Right Cover Interlock 1 Feeder...

Page 465: ...eder Assembly 3 of 9 Item Part Description 1 059K18770 Paper Feeder Assembly 2 Size Switch Assembly Not Spared 3 Bracket Not Spared 4 110K07040 Size Switch PWB REP 8 19 5 Feeder Frame Not Spared 6 Bra...

Page 466: ...0 4 007K85422 Feeder Drive Unit REP 8 22 5 Bracket Not Spared 6 Stopper Not Spared 7 Stopper Not Spared 8 Harness Not Spared 9 160K74520 Feeder PWB REP 8 21 10 Bracket Not Spared 11 Shaft Not Spared 1...

Page 467: ...Nudger 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...

Page 468: ...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 N...

Page 469: ...er 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 1 9 Retard Shaft P O PL 13 5 Item 1 10 Retard Support P O PL 13 5 Item 1 11 059K08840 Retard Roll 12 Shaft P O PL 1...

Page 470: ...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 P O PL 13 8 Item 1 9 Extension Spring P O PL 13 8 Item 1 10 Side End Label P O PL 13 8 Item 1 11 Label P O PL 13...

Page 471: ...13 8 Item 1 5 Lift Plate P O PL 13 8 Item 1 6 Guide Spring P O PL 13 8 Item 1 7 End Guide Actuator P O PL 13 8 Item 1 8 Side Guide Actuator P O PL 13 8 Item 1 9 Spring P O PL 13 8 Item 1 10 Level P O...

Page 472: ...10 00 5 52 Phaser 790 DocuColor 2006 PL 14 1 Initial Issue Parts List PL 14 1 OHP Transparency Tray Assembly 1 of 2 Item Part Description 1 050K42460 OHP Transparency Tray Assembly...

Page 473: ...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 Transparency Tray Front Snubber REP 7 8 10 Snubber Stopper P O PL 14 2 Item 1 11 Rear Guid...

Page 474: ...ft 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 Stopper P O PL 14 3 Item 1 11 Rear Guide P O P...

Page 475: ...Duplex Final Assembly Not Spared 2 059K18960 Inverter Upper Assembly 3 059K19050 Duplex Tray Assembly 4 059K19120 Inverter Lower Assembly 5 Lower Chute Assembly Not Spared 6 Lower Chute Not Spared 7 1...

Page 476: ...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...

Page 477: ...uplex 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...

Page 478: ...x Drive Clutch REP 8 30 7 Gear P O PL 15 3 Item 1 8 Collar P O PL 15 3 Item 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...

Page 479: ...127K29160 Inverter Motor REP 8 36 6 Invert Chute Assembly P O 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...

Page 480: ...5 Gear P O PL 15 5 Item 1 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 054K18400 Baffle 10 Chute P O PL 15 5 Item 1 11 160K70540 Duplex Controller PWB REP 8 38 12 H...

Page 481: ...211 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 Fowar...

Page 482: ...10 IIT 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 1...

Page 483: ...ist Initial Issue 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 160K69575 ICM Main PWB REP 6 14 ADJ 6 5 5 160K62210 Extension P...

Page 484: ...10 00 5 64 Phaser 790 DocuColor 2006 PL 16 3 Initial Issue Parts List PL 16 3 CCD Item Part Description 1 160K67350 FPC Cable 2 Cover Not Spared 3 Screw Not Spared...

Page 485: ...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 12...

Page 486: ...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 Pu...

Page 487: ...red 7 003E52460 Hinge 8 004K92440 Cushion 9 802K13810 Right Cover REP 6 2 10 802K13821 Left Cover REP 6 3 11 Side Cover Not Spared 12 802K13831 Rear Cover REP 6 4 13 Sheet Not Spared 14 Filter Not Spa...

Page 488: ...Issue Parts List PL 16 7 Control Panel Assembly Item Part Description 1 Front Cover Not Spared 2 Cover Not Spared 3 Panel Cover Not Spared 4 Panel PWB Not Spared 5 Frame Not Spared 6 Control Panel PWB...

Page 489: ...17 1 Item 5 9 892E19630 Label 10 892E19620 Label 11 152K63490 Harness 12 140K60480 Document Set Indicator 13 892E19610 Label Size 14 Entrance Tray P O PL 17 1 Item 5 15 026P63574 Screw 16 Rear Cover...

Page 490: ...ulley Assembly 4 020E16180 Pulley 5 068K78200 Bracket 6 Bracket P O PL 17 2 Item 3 7 013E81880 Bearing 8 Shaft P O PL 17 2 Item 3 9 020K93300 Pulley 10 020E90660 Pulley 11 023E08520 Belt 12 023E08510...

Page 491: ...earing 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 Item 28 REP 5 4 15 013E81370 Bearing 16 007K91871 Gear 1...

Page 492: ...er 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...

Page 493: ...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 8 026...

Page 494: ...ADJ 5 4 2 Transport Frame Not 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 Deflector Not Spared 10 007E...

Page 495: ...7K25420 ADF Exit Motor REP 5 9 6 105E94661 Antistatic Brush 7 026E17760 Screw 8 110K94420 Exit Tray Interlock REP 5 10 9 130K83020 ADF Exit Sensor REP 5 10 10 Bracket Not Spared 11 026E82620 Screw 12...

Page 496: ...10 00 5 76 Phaser 790 DocuColor 2006 PL 17 8 Initial Issue Parts List PL 17 8 Platen Glass ADF Harness Item Part Description 1 090K92740 Platen Glass...

Page 497: ...ser 790 DocuColor 2006 PL 18 1 Parts List Initial Issue PL 18 1 Stand Item Part Description 1 802K17230 Stand Assembly 2 Adjuster Not Spared 3 Nut Not Spared 4 Caster Not Spared 5 Screw Not Spared 6 F...

Page 498: ...1 Item 1 4 802E13310 Rear Cover 5 Serial Number Plate Not Spared 6 802E13320 Top Cover 7 Bearing Not Spared 8 110K10740 Sorter Top Cover Interlock 9 Plate Spring Not Spared 10 Harness Not Spared 11 16...

Page 499: ...e Not Spared 3 Upper Brace Not Spared 4 105E05930 Antistatic Brush 5 Upper Chute Assembly Not Spared 6 054K17830 Upper Chute 7 Pinch Roll Not Spared 8 Label Not Spared 9 Label Not Spared 10 127E82330...

Page 500: ...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...

Page 501: ...ared 3 006K21260 Rear Gear Shaft REP 11 10 4 006K21270 Front Gear Shaft REP 11 10 5 Bevel Gear Not Spared 6 Bearing Not Spared 7 Shaft Not Spared 8 007E62620 Gear 9 008K91280 Rear Bin Cam REP 11 11 AD...

Page 502: ...Tray P O PL 19 5 Item 1 3 Front Frame P O PL 19 5 Item 1 4 Rear Frame P O PL 19 5 Item 1 5 Front Pad P O PL 19 5 Item 1 6 Rear Pad P O PL 19 5 Item 1 7 Frame Top Not Spared 8 Support Not Spared 9 809...

Page 503: ...2 Cart Base Assembly Not Spared 3 Cart Base Not Spared 4 Rear Cart Support Not Spared 5 Lower Cart Support Not Spared 6 Cart Side Not Spared 7 Mounting Bracket Not Spared 8 001E58350 Sorter Rail 9 Ra...

Page 504: ...3W18055 Tapping Screw AY 153W27650 Tapping Screw AZ 153W27655 Tapping Screw BA 153W27850 Tapping Screw BB 153W28050 Tapping Screw BC 158W27651 Screw BD 158W27655 Screw BE 158W27855 Screw BF 158W28055...

Page 505: ...70 PL 10 1 007K85080 PL 10 1 007K85422 PL 13 4 007K86440 PL 19 2 007E88100 PL 17 3 007K91871 PL 17 3 008K91270 PL 19 4 008K91280 PL 19 4 008K91550 PL 7 1 PL 7 4 008E92010 PL 17 3 008E92020 PL 17 3 009...

Page 506: ...PL 17 1 026E74100 PL 15 1 026K80571 PL 5 1 026E82620 PL 17 4 PL 17 5 PL 17 7 029E30560 PL 8 6 036K90890 PL 17 2 036K90900 PL 17 2 Table 1 Part Number Index Part Number Part List 038K85073 PL 8 2 038K8...

Page 507: ...2 105E10010 PL 16 5 105K15680 PL 11 1 105K15690 PL 11 1 105K18600 PL 11 1 105K18750 PL 16 1 Table 1 Part Number Index Part Number Part List 105K18760 PL 16 1 105E92310 PL 17 5 105E94661 PL 17 7 107E06...

Page 508: ...1 130K61010 PL 16 1 130K61311 PL 9 2 130K61380 PL 17 5 130K61390 PL 19 3 130E81150 PL 17 5 130E81600 PL 13 5 130E81970 PL 13 4 Table 1 Part Number Index Part Number Part List PL 3 1 PL 4 3 PL 8 2 PL 8...

Page 509: ...0K85430 PL 8 2 600K85480 PL 8 3 600K85500 PL 1 1 600K85510 PL 1 1 600K85730 PL 16 4 Table 1 Part Number Index Part Number Part List 600K99500 PL 17 3 600K99510 PL 17 3 802E05130 PL 13 2 802E05191 PL 1...

Page 510: ...1 802K17230 PL 18 1 802K25990 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 892E196...

Page 511: ...n Page 6 16 GP 15 Printing Internal Test Patterns IOT 6 17 GP 16 Visual Calibration 6 18 GP 17 Foreign Interface 6 19 GP 18 Identifying Pin 1 on a Double Plug 6 19 GP 19 Diagnostic Mode IIT 6 20 GP 20...

Page 512: ...03 01 6 2 Phaser 790 DocuColor 2006 General Procedures and Information...

Page 513: ...eral 9 is displayed 2 Use the Right arrow to move the cursor one place to the right 3 Repeat step 1 and step 2 until 9999 is displayed 4 Press the Item Enter button to input the password Menu Options...

Page 514: ...nd then re enter the code to check for a change of state The following table lists the digital input codes Table 1 Digital Input Codes DI Code Component Signal BSD Ref 06 Feed Ready Not used 15 Full S...

Page 515: ...Nudger Sensed L 5 VDC 7 4 B6 Feed Out Sensor Tray 3 Paper Feed Out Sensed L 5 VDC 8 4 C0 Feeder Right Cover Interlock 1 Feeder Right Cover Interlock 1 Closed L 5 VDC 1 4 C1 Feeder Right Cover Interlo...

Page 516: ...Check signal state with DMM refer to BSD 9 3 for connection 9 3 11 Rotary Motor Rotary Motor On L 5 VDC Check signal state with DMM refer to BSD 9 3 for connection 9 3 17 Exchange Solenoid Exchange S...

Page 517: ...t Codes DO Code Component Signal BSD Ref 74 ROS NOTE see WARNINGS and CAUTIONS Polygon Motor 6 2 75 Cartridge Sensor Cartridge Sensor On H 5 VDC Check signal state with DMM refer to BSD 9 3 for connec...

Page 518: ...ss the Up Arrow or Down Arrow button to select the Menu Number for the param eter to be set from the Table 1 b Press the Item Enter button to display the current value of the parameter selected c Pres...

Page 519: ...BTR2 Offset Postcard 3 5 1 2C BTR2 Offset Envelope 3 5 1 2D Country 0 01 0 Table 2 Side to Side Registration Offsets Value 221 220 219 218 217 216 215 214 213 212 211 210 Offset mm 2 1 2 0 1 9 1 8 1 7...

Page 520: ...ct 10 Belt Cleaner Increments the same for color and b w based upon the deactuation of the Fuser Exit Sensor The value incre ments 1 for sheets less than 219 mm in process length and 2 if length is gr...

Page 521: ...4 Press the Up or Down Arrow button to toggle the display between METER CLEAR NO and METER CLEAR YES 5 Select the appropriate response then press the Item Enter button The display will change to METER...

Page 522: ...the Item Enter button GP 7 Changing Service Password IOT The purpose is to change the password Procedure 1 Enter the Diagnostic Mode GP 1 2 Press the Menu button until CHANGE PASSWORD is displayed 3 P...

Page 523: ...y observing the spaces or lack of spaces a Select Start Programs and MSDOS Command Prompt b Type in cd then press the Enter key The display will show c c Type in cd temp then press the Enter key d Typ...

Page 524: ...r power b Simultaneously press and hold the Down Arrow 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...

Page 525: ...tablish communications with the Scanner a In Hyperterminal select Call Disconnect and then Call Connect b Press the Enter key once or twice for the login prompt to appear c Type in the user name tsuba...

Page 526: ...ntative to print a machine 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 m...

Page 527: ...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 20 Prints a...

Page 528: ...from your previous selections Perform step 8 again until you are able to select circles within the desired 1 to 8 range 10 When all the values are entered and accepted by VISUALCAL PRINT GRAYS YES is...

Page 529: ...ace Refer to the 003 333 Foreign Interface RAP in Section 2 GP 18 Identifying Pin 1 on a Double Plug The purpose is to locate pin 1 on a double plug configuration Procedure 1 Hold the plug as shown in...

Page 530: ...menu is displayed Auto diag Systemdata R W ClearMem Memory R W TestPrint Diag Code 10 Figure 1 below shows the Scanner Control Panel Figure 1 The Scanner Control Panel Exiting the Diagnostic Mode To...

Page 531: ...button Table 1 IIT Registration and Magnification Parameters Chain Link Item Min Default Max Remarks 715 3 IIT Lead Edge Regis tration ADJ 6 3 1 47h FFh Variation 0 0423 mm Step 4 IIT Side Registratio...

Page 532: ...of Color Mode 0 and Pattern 6 ALWAYS creates jams at the nip of the fuser This pattern generates process black up to the lead edge of sheet the resulting sheet will not go through the fuser nip 5 Use...

Page 533: ...y media through the open nip to protect the exit switch actuators and static elimination brushes 5 Remove a Xerox Fuser Cleaning Solvent Pad from its foil pouch Carefully insert the folded pad between...

Page 534: ...03 01 6 24 Phaser 790 DocuColor 2006 GP 23 General Procedures and Information...

Page 535: ...Class B ANSI C63 4 11 4D 220 240 V type ESG EN55022 CISPR Publication 22 Class B Table 1 Product Codes Product Code DC 2006 Copier Printer 110 VAC VF8 DC 2006 Copier Printer 220 VAC VF9 Phaser 790 110...

Page 536: ...ay are as follows Printer Speed There are three speed modes that the print engine considers for fusing speed in printing on dif ferent paper types The speed mode is determined by the controller accord...

Page 537: ...ts Per Minute Sheet Type Size Black White Color Plain paper 8 5 x 11 inch A4 8 5 x 14 inch B4 26 ppm 6 ppm Plain paper 11 x 17 inch A3 13 8 ppm 3 ppm Transparency or thick paper 8 5 x 11 inch A4 8 5 x...

Page 538: ...able indicates the R E factors to use when enlarging or reducing from a specific size document to a specific size copy Table 3 ADF Size Sensing ESG Document Size 4 mm Sensed Size 11 14 9 SEF 11 17 280...

Page 539: ...tion 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 Table 4 Platen Mode Document Sizes Document orientation Document size mm NASG ESG Postcard SE...

Page 540: ...heets Side Output Tray Bin 1 Print mode Transparencies 100 sheets Bin 2 Bin 10 Copy mode only sort by set 30 sheets Table 2 Paper Handling Capability Stacker Tray Side Output Tray Size Dimensions Weig...

Page 541: ...in servicing the DC 2006 and Phaser 790 Table 1 Common Tools Description Part Number Digital Multimeter DMM 600T02020 DMM Lead Kit 600T02030 ESD Kit 600T42001 Diagonal Pliers 600T40903 Mini Flashlight...

Page 542: ...17 ALL Cleaning Towels 035P03191 600S04372 NASG ESG Drop Cloth 035P01737 ALL Cotton Swab 035P02162 ALL Table 1 Consumables List for the DC 2006 Description Part Number NASG Black Dry Ink Cartridge 006...

Page 543: ...multinational applicability classification codes and permanent or temporary modification information Classification Codes A tag number may be required to identify differences between parts that canno...

Page 544: ...2006 General Procedures and Information Processor P Tags NOTE At the time of publication no Change Tags had been issued to this subsystem Scanner Tags NOTE At the time of publication no Change Tags ha...

Page 545: ...olor 2006 General Procedures and Information Sorter Tags NOTE At the time of publication no Change Tags had been issued to this subsystem ADF Tags NOTE At the time of publication no Change Tags had be...

Page 546: ...03 01 6 36 Phaser 790 DocuColor 2006 General Procedures and Information...

Page 547: ...2 2 7 47 BSD 3 1 7 48 BSD 3 2 7 49 BSD 3 3 7 50 BSD 3 4 7 51 BSD 3 5 7 52 BSD 3 6 7 53 BSD 3 7 7 54 BSD 4 1 7 55 BSD 4 2 7 56 BSD 5 1 7 57 BSD 5 2 7 58 BSD 5 3 7 59 BSD 5 3 7 60 BSD 5 4 7 61 BSD 5 5...

Page 548: ...10 00 7 2 Phaser 790 DocuColor 2006 Initial Issue Wiring Data...

Page 549: ...CU PWB Figure 2 17 ESS PWB Figure 3 17 MCU PWB Figure 2 18 ESS PWB Figure 3 18 MCU PWB Figure 2 19 MCU PWB Figure 2 20 ESS PWB Figure 3 20 MCU PWB Figure 2 21 ESS PWB Figure 3 21 MCU PWB Figure 2 22 M...

Page 550: ...4 Intermediate Connector for Duplex Option Figure 7 Figure 9 Table 1 Plug Jack Location List Plug Jack Number Location Figure Number 139 Duplex Control PWB Figure 9 140 IIT Figure 16 140 Duplex Contro...

Page 551: ...gure 11 235 Size Switch Assembly Tray 2 Figure 11 236 Size Switch Assembly Tray 3 Figure 11 237 Feeder Right Cover Interlock 1 Figure 10 Table 1 Plug Jack Location List Plug Jack Number Location Figur...

Page 552: ...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...

Page 553: ...10 00 7 7 Phaser 790 DocuColor 2006 Plug Jack Locations Wiring Data Initial Issue Figure 1 194 193 192 191 81 F187 2 85 84 86 116 83 88 WHITE...

Page 554: ...10 00 7 8 Phaser 790 DocuColor 2006 Plug Jack Locations Initial Issue Wiring Data Figure 2 100 105 107 106 207 101 103 21 23 20 17 18 22 19 16 10 14 15 12 66 P91 97 BLACK 109...

Page 555: ...10 00 7 9 Phaser 790 DocuColor 2006 Plug Jack Locations Wiring Data Initial Issue Figure 3 317 16 15 25 34 24 33 28 20 18 17 14 21 8 12 11...

Page 556: ...10 00 7 10 Phaser 790 DocuColor 2006 Plug Jack Locations Initial Issue Wiring Data Figure 4 98 93 205 209 206 204 94 210 208 95 203 J91 201 202...

Page 557: ...10 00 7 11 Phaser 790 DocuColor 2006 Plug Jack Locations Wiring Data Initial Issue Figure 5 T4 T3 57 F187 1 122 121 125 124 123 197 87 199 198...

Page 558: ...10 00 7 12 Phaser 790 DocuColor 2006 Plug Jack Locations Initial Issue Wiring Data Figure 6 82 195 245 246 247 52 C A 51 F D 42 CN1 48 49 50 132 211 41 32 35 33 34 104 103 FS1 FS2 47 55...

Page 559: ...10 00 7 13 Phaser 790 DocuColor 2006 Plug Jack Locations Wiring Data Initial Issue Figure 7 58 56 CN2 63 70 64 P71 102 148 101 134...

Page 560: ...10 00 7 14 Phaser 790 DocuColor 2006 Plug Jack Locations Initial Issue Wiring Data Figure 8 F250 721 T2 T1 117 167 165 112 166 161 111 163 80 62 76 75 74 J71 72 79 78 BLUE 722 E1 158...

Page 561: ...10 00 7 15 Phaser 790 DocuColor 2006 Plug Jack Locations Wiring Data Initial Issue Figure 9 150 152 139 141 142 140 134 144 151 75 147 158 153...

Page 562: ...10 00 7 16 Phaser 790 DocuColor 2006 Plug Jack Locations Initial Issue Wiring Data Figure 10 239 227 241 242 230 228 240 229 238 237 WHITE WHITE 4 WIRES BLUE WHITE BLUE 214 216 217 215 212 213 218...

Page 563: ...10 00 7 17 Phaser 790 DocuColor 2006 Plug Jack Locations Wiring Data Initial Issue Figure 11 236 233 222 226 225 221 234 235...

Page 564: ...10 00 7 18 Phaser 790 DocuColor 2006 Plug Jack Locations Initial Issue Wiring Data Figure 12 223 224 219 220 231 232 TRAY 2 TRAY 3 TRAY 2 TRAY 2 TRAY 3 TRAY 3...

Page 565: ...10 00 7 19 Phaser 790 DocuColor 2006 Plug Jack Locations Wiring Data Initial Issue Figure 13 155 149 154 160 146 159 145...

Page 566: ...10 00 7 20 Phaser 790 DocuColor 2006 Plug Jack Locations Initial Issue Wiring Data Figure 14 711 712 713 709 714 812 816 814 815 J220 813 719 718 811...

Page 567: ...10 00 7 21 Phaser 790 DocuColor 2006 Plug Jack Locations Wiring Data Initial Issue Figure 15 91 N1 718...

Page 568: ...10 00 7 22 Phaser 790 DocuColor 2006 Plug Jack Locations Initial Issue Wiring Data Figure 16 719 140 150A B 717 CN1 CN2 716...

Page 569: ...10 00 7 23 Phaser 790 DocuColor 2006 Plug Jack Locations Wiring Data Initial Issue Figure 17 603 602 P220 211 210 151 150 200 140 320 250 2 5 330 310 300 290 110 130 100 120...

Page 570: ...10 00 7 24 Phaser 790 DocuColor 2006 Plug Jack Locations Initial Issue Wiring Data Figure 18 133 10 SN1 5 7 8 4 6 2 10 5 3 1 9 201...

Page 571: ...d 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 componen...

Page 572: ...10 00 7 26 Phaser 790 DocuColor 2006 Initial Issue Wiring Data 5 VDC Wirenet 1 of 3 Figure 1 5 VDC 1 of 3...

Page 573: ...10 00 7 27 Phaser 790 DocuColor 2006 Wiring Data Initial Issue 5 VDC Wirenet 2 of 3 Figure 1 5 VDC 2 of 3...

Page 574: ...10 00 7 28 Phaser 790 DocuColor 2006 Initial Issue Wiring Data 5 VDC Wirenet 3 of 3 Figure 1 5 VDC 3 of 3...

Page 575: ...10 00 7 29 Phaser 790 DocuColor 2006 Wiring Data Initial Issue 24 VDC Interlocked Wirenet 1 of 3 Figure 1 24 VDC Interlocked 1 of 3...

Page 576: ...10 00 7 30 Phaser 790 DocuColor 2006 Initial Issue Wiring Data 24 VDC Interlocked Wirenet 2 of 3 Figure 1 24 VDC Interlocked 2 of 3...

Page 577: ...10 00 7 31 Phaser 790 DocuColor 2006 Wiring Data Initial Issue 24 VDC Interlocked Wirenet 3 of 3 Figure 1 24 VDC Interlocked 3 of 3...

Page 578: ...10 00 7 32 Phaser 790 DocuColor 2006 Initial Issue Wiring Data DC Com Wirenet 1 of 5 Figure 1 DC Com 1 of 5...

Page 579: ...10 00 7 33 Phaser 790 DocuColor 2006 Wiring Data Initial Issue DC Com Wirenet 2 of 5 Figure 1 DC Com 2 of 5...

Page 580: ...10 00 7 34 Phaser 790 DocuColor 2006 Initial Issue Wiring Data DC Com Wirenet 3 of 5 Figure 1 DC Com 3 of 5...

Page 581: ...10 00 7 35 Phaser 790 DocuColor 2006 Wiring Data Initial Issue DC Com Wirenet 4 of 5 Figure 1 DC Com 4 of 5...

Page 582: ...10 00 7 36 Phaser 790 DocuColor 2006 Initial Issue Wiring Data DC Com Wirenet 5 of 5 Figure 1 DC Com 5 of 5...

Page 583: ...10 00 7 37 Phaser 790 DocuColor 2006 Wiring Data Initial Issue 5 VDC IIT Wirenet Figure 1 5 VDC IIT...

Page 584: ...10 00 7 38 Phaser 790 DocuColor 2006 Initial Issue Wiring Data 24 VDC IIT Wirenet Figure 1 24 VDC IIT...

Page 585: ...the 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 m...

Page 586: ...10 00 7 40 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 1 1 Figure 1 Main Power On...

Page 587: ...10 00 7 41 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 1 2 Figure 1 Interlock Switching...

Page 588: ...10 00 7 42 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 1 3 Figure 1 Transport Cover Position Monitoring...

Page 589: ...10 00 7 43 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 1 4 Figure 1 Tray Module Cover Position Monitoring...

Page 590: ...10 00 7 44 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 1 5 Figure 1 Duplex Module Cover Position Monitoring...

Page 591: ...10 00 7 45 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 1 6 Figure 1 IIT Main Power On...

Page 592: ...10 00 7 46 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 2 1 Figure 1 Control Panel...

Page 593: ...10 00 7 47 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 2 2 Figure 1 IIT Control Panel...

Page 594: ...10 00 7 48 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 3 1 Figure 1 Machine Self Test...

Page 595: ...10 00 7 49 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 3 2 Figure 1 IIT Machine Self Test...

Page 596: ...10 00 7 50 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 3 3 Figure 1 CRUM and Billing...

Page 597: ...10 00 7 51 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 3 4 Figure 1 Tray Module Communication...

Page 598: ...10 00 7 52 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 3 5 Figure 1 Duplex Module Communication...

Page 599: ...10 00 7 53 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 3 6 Figure 1 BSD 3 6 Sorter Communication...

Page 600: ...10 00 7 54 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 3 7 Figure 1 BSD 3 7 Foreign Interface...

Page 601: ...10 00 7 55 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 4 1 Figure 1 BSD 4 1 Main Drive Control...

Page 602: ...10 00 7 56 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 4 2 Figure 1 Mechanical Drives...

Page 603: ...10 00 7 57 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 5 1 Figure 1 ADF Document Sensing and Interlock Monitoring...

Page 604: ...10 00 7 58 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 5 2 Figure 1 ADF Document Feeding...

Page 605: ...10 00 7 59 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 5 3 Figure 1 Document Transportation 1 of 2...

Page 606: ...10 00 7 60 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 5 3 Figure 1 Document Transportation 2 of 2...

Page 607: ...10 00 7 61 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 5 4 Figure 1 Document Exit...

Page 608: ...10 00 7 62 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 5 5 Figure 1 ADF Communication...

Page 609: ...10 00 7 63 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 6 1 Figure 1 Laser Image Scanning...

Page 610: ...10 00 7 64 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 6 2 and 6 3 Figure 1 Laser Control Polygon Motor Control...

Page 611: ...10 00 7 65 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 6 4 Figure 1 Document Illumination...

Page 612: ...10 00 7 66 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 6 5 Figure 1 Image Input...

Page 613: ...10 00 7 67 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 6 6 Figure 1 Carriage Control...

Page 614: ...10 00 7 68 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 7 1 Figure 1 Tray 1 Paper Supply 1 of 2...

Page 615: ...10 00 7 69 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 7 1 Figure 1 Tray 1 Paper Supply 2 of 2...

Page 616: ...10 00 7 70 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 7 2 Figure 1 Bypass Paper Supply 1 of 2...

Page 617: ...10 00 7 71 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 7 2 Figure 1 Bypass Paper Supply 2 of 2...

Page 618: ...10 00 7 72 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 7 3 Figure 1 Tray 2 Paper Supply 1 of 2...

Page 619: ...10 00 7 73 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 7 3 Figure 1 Tray 2 Paper Supply 2 of 2...

Page 620: ...10 00 7 74 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 7 4 Figure 1 Tray 3 Paper Supply 1 of 2...

Page 621: ...10 00 7 75 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 7 4 Figure 1 Tray 3 Paper Supply 2 of 2...

Page 622: ...10 00 7 76 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 8 1 Figure 1 Tray 1 Paper Feeding...

Page 623: ...10 00 7 77 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 8 2 Figure 1 Bypass Tray Feeding...

Page 624: ...10 00 7 78 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 8 3 Figure 1 Tray 2 Paper Feeding...

Page 625: ...10 00 7 79 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 8 4 Figure 1 Tray 3 Paper Feeding...

Page 626: ...10 00 7 80 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 8 5 Figure 1 Feeder Drive Control...

Page 627: ...10 00 7 81 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 8 6 Figure 1 Registration...

Page 628: ...10 00 7 82 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 8 7 Figure 1 Registration Mechanism...

Page 629: ...10 00 7 83 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 9 1 Figure 1 Charging and Exposure...

Page 630: ...10 00 7 84 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 9 2 Figure 1 BSD 9 2 Drum Drive...

Page 631: ...10 00 7 85 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 9 3 Figure 1 Developer Rotary Control 1 of 2...

Page 632: ...10 00 7 86 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 9 3 Figure 1 Developer Rotary Control 2 of 2...

Page 633: ...10 00 7 87 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 9 4 Figure 1 Development 1 of 2...

Page 634: ...10 00 7 88 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 9 4 Figure 1 Development 2 of 2...

Page 635: ...10 00 7 89 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 9 5 Figure 1 Dispense Control...

Page 636: ...10 00 7 90 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 9 6 Figure 1 IBT Belt Drive and 1st Transfer...

Page 637: ...10 00 7 91 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 9 7 Figure 1 2nd Transfer and IBT Belt Cleaning...

Page 638: ...10 00 7 92 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 9 8 Figure 1 Belt Cleaning and BTR 2 Retract Advance Switching 1 of 2...

Page 639: ...10 00 7 93 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 9 8 Figure 1 Belt Cleaning and BTR 2 Retract Advance Switching 2 of 2...

Page 640: ...10 00 7 94 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 9 9 Figure 1 Drum Cleaning and Toner Reclaim...

Page 641: ...10 00 7 95 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 10 1 Figure 1 Fusing...

Page 642: ...10 00 7 96 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 10 2 Figure 1 Fusing Heat Control...

Page 643: ...10 00 7 97 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 10 3 Figure 1 Fusing Air Control...

Page 644: ...10 00 7 98 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 10 4 Figure 1 Exit Transportation 1 of 2...

Page 645: ...10 00 7 99 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 10 4 Figure 1 Exit Transportation 2 of 2...

Page 646: ...10 00 7 100 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 10 5 Figure 1 Invert and Duplex Transport 1 of 2...

Page 647: ...10 00 7 101 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 10 5 Figure 1 Invert and Duplex Transport 2 of 2...

Page 648: ...10 00 7 102 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 10 6 Figure 1 Invert Mechanism...

Page 649: ...10 00 7 103 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 10 7 Figure 1 Duplex Feeding...

Page 650: ...10 00 7 104 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 10 8 Figure 1 Duplex Drive Control...

Page 651: ...10 00 7 105 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 11 1 BSD 11 2 Figure 1 Sorter DC Power Generation and Top Cover Docking Interlock and Sorter Communication...

Page 652: ...10 00 7 106 Phaser 790 DocuColor 2006 Initial Issue Wiring Data BSD 11 3 Figure 1 Sorter Transportation...

Page 653: ...10 00 7 107 Phaser 790 DocuColor 2006 Wiring Data Initial Issue BSD 11 4 Figure 1 Bin Drive Control...

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