Page 1 Service Manual 701P28180 Phaser 7700 ® Color Laser Printer...
Page 3: Service Manual
Service Manual 701P28180 ® Phaser 7700 Color Laser Printer Warning The following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing other than that contained in operating instructions unless you are qualified to do so.
Page 4 Xerox technical training materials and service manuals are intended for use by authorized Xerox service technicians and service partners only and are not for resale. These materials may not be distributed, copied, or otherwise reproduced without prior written consent from Xerox Corporation.
Page 5: User Safety Summary
User Safety Summary Terms in Manual Various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger that might be present during a procedure or action. Be aware of all symbols and terms when they are used, and always read NOTE, CAUTION and WARNING messages.
Page 6: Power Source
Power Source For 110 VAC printers, DO NOT apply more than 127 volts RMS between the supply conductors or between either supply conductor and ground. Use only the specified power cord and connector. For 220 VAC printers, do not apply more than 240 volts RMS between the supply conductors or between either supply conductor and ground.
Page 7: Laser Components
Laser Components WARNING: This printer generates a laser beam as part of the printing process. The laser beam in this printer is invisible. Direct eye exposure to the laser beam may cause eye injury or blindness. To avoid permanent eye damage, follow these directions: Before starting any service procedure, switch off the printer power and unplug the power cord from the AC wall outlet.
Page 8: Safety Instructions
Safety Instructions Read all installation instructions carefully before you plug the product into a power source. Care of Product Disconnect the power plug by pulling the plug, not the cord. Disconnect the power plug if the power cord or plug is frayed or otherwise damaged, Or if any liquid or foreign material is spilled into the case, Or if the printer is exposed to any excess moisture,...
Page 9: Service Safety Summary
Service Safety Summary General Guidelines For qualified service personnel only: Refer also to the preceding Users Safety Summary. Do not service alone: Do not perform internal service or adjustment of this product unless another person capable of rendering first aid or resuscitation is present.
Page 10: Federal Communication Commision Compliance
Federal Communication Commision Compliance This equipment has been tested and found to comply with the limits set for a Class B digital device, as stated in Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference in a commercial installation.
Page 11: Canadian Notice
Canadian Notice This digital apparatus does not exceed the Class B limits for radio noise emissions from digital apparatus as described in the radio interference regulations of the Canadian Department of Communications. Note Installation of the Finisher and/or the Token Ring Interface results in a classification change to Class A.
Page 12: Esd Precautions
ESD Precautions Some semiconductor devices are easily damaged from static electricity. These components are Electrostatically Sensitive Devices (ESDs); examples include integrated circuits (ICs), Large-Scale Integrated circuits (LSIs), some field-effect transistors and semiconductor chip components. The following techniques reduce the occurrence of component damage caused by static electricity: CAUTION: Be sure the power is Off to the chassis or circuit board, and...
Page 13: Table Of Contents
Contents User Safety Summary ....................1-iii Terms in Manual ....................1-iii Terms on Product ..................... 1-iii Power Source ....................1-iv Power Supply and Electrical Components ............1-iv Mechanical Components ................... 1-iv Laser Components ..................... 1-v Fuser Components ..................... 1-v Safety Components .................... 1-v Warning Labels ....................
Page 14 General Information Phaser 7700 Printer Overview .................. 1-2 Printer RAM and Printer Capabilities ..............1-4 CRC Life Counter Behavior ................1-5 Engine Control Interface and Power Supply Boards .......... 1-6 Power Supplies ....................1-7 Engine Control and Image Processor Boards ............ 1-8 Auxiliary Feeder Control Board ................
Page 15 Fans On, Front Panel LED Never On ..............3-93 Fans On, Front Panel LED is Red, No Front Panel message ......3-93 Front Panel Continually Displays the Xerox Phaser 7700 Splash Screen ..3-93 Front Panel Continually Displays "warming up - please wait" Message ....3-93 Front Panel displays "Fatal Fault Encountered"...
Page 16 Windows Printing Problems ................3-104 Troubleshooting Network Problems .............. 3-105 Media Jams and the Paper Path ................3-106 Media-based Problems .................. 3-106 Multiple-sheet Pick ..................3-106 Mis-pick ......................3-106 Skewed Image ....................3-106 Damaged Prints ..................... 3-107 Fuser Jams ....................3-107 Exit Jams .......................
Page 17 Step 2: RegiCon #4 Coarse Skew Adjustment ..........4-135 Step 3: RegiCon #1 Fine Skew Adjustment ............4-137 Step 4: RegiCon #2 In/Out Skew Adjustment ..........4-138 Step 5: RegiCon #3 Center Skew Adjustment ..........4-139 Coarse RegiCon Initialization .................4-140 ATC Sensor Setup ....................4-142 Additional Information ...................4-142 Cleaning and Maintenance 5-143...
Page 18 Removal and Replacement Procedures 7-151 Rear Cover Assembly 7-154 Right Side Cover Assembly ..............7-155 Top Cover Assembly ................7-156 Front Panel Assembly ................7-157 Rear Cover, Top Rear Power Switch Cover and LH Rear Mid Cover ..7-158 Left-Hand Lower Cover Assembly ............7-160 Front Cover Assembly ................
Page 19 T1 and T3 High-voltage Power Supplies ..........7-208 3.3 VDC and 5 VDC Low-Voltage Power Supplies and Bracket ....7-210 LD Power Relay ..................7-211 +24 VDC Low-voltage Power Supply, Fan and Bracket ......7-212 T2 High-Voltage Power Supply ..............7-213 Chassis AC Power Assembly ..............7-214 Main Drive Assembly ................7-215 Accumulator Belt Drive Assembly ............7-217 Developer Drive Assembly ..............7-218...
Page 20 PL 8-20 Lift Components FRUs ..............8-268 PL 8-21 Wiring FRUs ..................8-270 PL 8-22 Auxiliary Feeder FRUs ..............8-272 PL 8-23 Lower Tray Deck (LTD) FRUs ............8-274 PL 8-24 Lower Tray Deck (LTD) FRUs (cont’d.) ..........8-276 PL 8-25 High-Capacity Feeder FRUs .............. 8-277 PL 8-26 High-Capacity Feeder FRUs (cont’d.) ..........
Page 21 Horizontal Transport Entrance Sensor and Top Tray Full Sensor ..11-328 Gate-In Solenoid Assembly ..............11-329 Finisher Covers ..................11-330 Stack Height-Sensor Assembly .............11-332 Stacker Paper-Sensor Assembly ............11-333 Set Clamp Clutch and Gear ..............11-334 Eject Roll Assembly ................11-335 Finisher Control Board, Bracket, and Shield .........11-336 Stacker Motor Assembly ...............11-338 Paddle Shaft ..................11-339 Paper Transport Motor (Motor Assembly Main) ........11-340...
Page 22 Phaser 7700 Color Laser Printer Service Manual...
Page 23 List of Tables Table 1-1 CRC Life ....................1-5 Table 1-2 Front Panel Key Descriptions ..............1-21 Table 1-3 Front Panel Shortcuts................1-22 Table 1-4 Rear Panel DIP Switch Settings............. 1-23 Table 1-5 Physical Dimensions of the Printer ............1-24 Table 1-6 Physical Dimensions of Lower Tray Feeder ...........
Page 24 Table 8-28 High-Capacity Feeder FRUs List (cont’d.) .......... 8-280 Table 8-29 High-Capacity Feeder FRUs (cont’d.) ..........8-281 Table 8-30 Kits ....................8-282 Table 8-31 Manual Packs & Service Manual............8-283 Table 8-32 Software .................... 8-284 Table 8-33 Supplies..................... 8-284 Table 8-34 Accessories ..................8-285 Table 8-35 Recommended Tools List ..............
Page 25 List of Figures Figure 1-1 The Phaser 7700 Color Laser Printer (shown with the High-Capacity Feeder) Figure 1-2 Engine Control Interface and Power Supply Boards ....... 1-6 Figure 1-3 Power Supplies ..................1-7 Figure 1-4 Engine Control and Image Processor Boards ......... 1-8 Figure 1-5 Auxiliary Feeder Control Board ...............
Page 26 Figure 7-6 Left-Hand Lower Cover Assembly ............7-160 Figure 7-7 Front Cover Assembly ................ 7-161 Figure 7-8 Fuser Front Cover ................7-162 Figure 7-9 Rear Shield ..................7-163 Figure 7-10 Rear Shield Bracket ................7-164 Figure 7-11 24 VDC Power Supply Shield ............7-165 Figure 7-12 MPT Assembly .................
Page 27 Figure 7-51 3.3 VDC and 5 VDC Low-Voltage Power Supplies ......7-210 Figure 7-52 LD Power Relay ................7-211 Figure 7-53 Low-voltage Power Supply, Fan and Bracket ........7-212 Figure 7-54 T2 High-Voltage Power Supply ............7-213 Figure 7-55 Chassis AC Power Assembly ............7-214 Figure 7-56 Main Drive Assembly ...............
Page 28 Figure 8-22 Auxiliary Feeder FRUs ............... 8-272 Figure 8-23 Lower Tray Deck (LTD) FRUs ............8-274 Figure 8-24 Lower Tray Deck (LTD) FRUs (cont’d.) ..........8-276 Figure 8-25 High-Capacity Feeder FRUs .............. 8-277 Figure 8-26 High-Capacity Feeder FRUs (cont’d.) ..........8-278 Figure 8-27 High-Capacity Feeder FRUs (cont’d.) ..........
Page 29 Figure 11-39 Electrical FRUs ................11-370 Figure 12-1 Block diagram of the Finisher ............12-372 Figure 12-2 Wiring diagram of the Finisher ............12-373 Phaser 7700 Color Laser Printer Service Manual xxvii...
Page 30 xxviii Phaser 7700 Color Laser Printer Service Manual...
Page 31: General Information
General Information The Phaser 7700 Color Laser Printer Service Manual is the primary document used for repairing and maintaining the Xerox Phaser 7700 Color Laser Printer. Certification for servicing of this product requires completion of the Phaser 7700 printer service training.
Page 32: Phaser 7700 Printer Overview
Phaser 7700 Printer Overview The Phaser 7700 Color Printer combines a single-pass, tandem-design, color laser, continuous-tone print engine with an image processor supporting Adobe’s PostScript 3 description language. The image processor features a bi-directional parallel interface, a USB port, and a 100baseT Ethernet port for host communication.
Page 33 The print job is not deleted after printing, it is stored on the hard drive for print on demand. This function requires the internal hard drive. Note For additional service information, refer to the Service CD-ROM or the Xerox Service Website: http://cpidserv.opbu.xerox.com. Phaser 7700 Color Laser Printer Service Manual...
Page 34: Printer Ram And Printer Capabilities
Printer RAM and Printer Capabilities The printer features two slots which accept 64, 128 and 256 Mbytes of SDRAM. All combinations are allowed for configurations of 128, 192, 256, 320, 384, and 512 Mbytes. 144 pin SODIMM Serial presence detect 3.3 volt 100 MHz PC100 or 133 MHz PC133 The Startup Page and the Configuration Page list the amount of RAM...
Page 35: Crc Life Counter Behavior
CRC Life Counter Behavior Internal counters track Customer-Replaceable Consumables (CRC) life usage and store the values in NVRAM. The Image Processor Board monitors these counters in order to display the near end-of-life and end-of-use messages. Table 1-1 CRC Life Accessory Shelf Life from Manufacturer Print Cartridge...
Page 36: Engine Control Interface And Power Supply Boards
Engine Control Interface and Power Supply Boards Engine Control Interface Board High Voltage Power Supply/ T1 Board High Voltage Power Supply/ T3 Board High Voltage Power Supply/ T2 Board AC Drive Board Noise Filter Board S7700-317 Figure 1-2 Engine Control Interface and Power Supply Boards Phaser 7700 Color Laser Printer Service Manual...
Page 37: Power Supplies
Power Supplies 24 V Low voltage power supply 24 V Low voltage power supply fan AC Power Chassis 3.3 V Low voltage power supply 5 V Low voltage power supply S7700-261 Figure 1-3 Power Supplies Phaser 7700 Color Laser Printer Service Manual...
Page 38: Engine Control And Image Processor Boards
Engine Control and Image Processor Boards Image Processor Board Engine Control Board S7700-381 Figure 1-4 Engine Control and Image Processor Boards Phaser 7700 Color Laser Printer Service Manual...
Page 39: Auxiliary Feeder Control Board
Auxiliary Feeder Control Board LTD Board (3T) HCF Board (TT) S7700-385 Figure 1-5 Auxiliary Feeder Control Board Phaser 7700 Color Laser Printer Service Manual...
Page 40: Print Engine Sensors And Switches
Print Engine Sensors and Switches Transfer Roller Sensor Tray 1 Take-Away Sensor Transparency Sensor Registration Sensor Paper On Belt Sensor MPT No Paper Sensor Tray 1 No Paper Sensor/Level Sensor MPT Paper Size Sensor S7700-287 Figure 1-6 Print Engine Sensors and Switches 1-10 Phaser 7700 Color Laser Printer Service Manual...
Page 41: Print Engine Sensors And Switches (Cont'd.)
Print Engine Sensors and Switches (cont’d.) Environment Accumulator Belt Sensor Edge Sensor Automatic Density Control Sensor Accumulator Belt Home Sensor Automatic Toner Correction Sensor Duplex K, C, M, Y Wait Sensor Tray 1 Paper Size Sensor Mark On Belt Sensor Waste Cartridge Full Sensor S7700-288...
Page 42: Auxiliary Feeder Sensors And Switches
Auxiliary Feeder Sensors and Switches Paper-Size Switch Assembly -Tray 2 Tray 4 Take-Away Sensor -Tray 3 Tray 3 Take-Away Sensor -Tray 4 Take-Away Sensor Paper-Size Switch Assembly -Tray 2 No-Paper Sensor/Level Sensor Paper-Size Switch Assembly Tray 2 -Tray 3 Tray 3 -Tray 4 Tray 4 Tray 3 Take-Away Sensor...
Page 43: Auxiliary Feeder Actuators And Clutches
Auxiliary Feeder Actuators and Clutches Left hand cover interlock switch actuator Paper feed sensor actuator tray 3 Paper detect One way sensor actuator clutch tray 2 tray 2 tray 3 tray 3 tray 4 tray 4 Friction clutch Paper feed tray2 sensor actuator tray 4...
Page 44: Print Engine Solenoids, Actuators, And Clutches
Print Engine Solenoids, Actuators, and Clutches CW Duplex Exit tray clutch full sensor actuator CCW Duplex clutch Registration clutch Feed clutch One way clutch Friction Paper detect clutch sensor actuator (tray 1) One way clutch Paper detect sensor actuator (MPT) S7700-387 Figure 1-10 Print Engine Solenoids, Actuators, and Clutches 1-14...
Page 45: Print Engine And Auxiliary Feeder Interlocks And Sensors
Print Engine and Auxiliary Feeder Interlocks and Sensors Right-hand cover Left-hand interlock switch cover interlock Main power switch switch Fuser-exit switch Front-cover- interlock switch Duplex cover switch Left hand lower cover sensor Waste-cartridge- interlock switch Transfer-roller- position sensor (behind transfer roller) Auxiliary- feeder-...
Page 46: Image Processor Board
Image Processor Board Processor J500 SODIMM2 Health LED SODIMM1 Hard Drive DIP Switches NVRAM (socketed) Ethernet Parallel S7700-258 Figure 1-12 Image Processor Board 1-16 Phaser 7700 Color Laser Printer Service Manual...
Page 47: Assemblies Of The Print Engine
Assemblies of the Print Engine Fuser assembly Detack Saw connector Paper feeder assembly Left-Hand lower cover assembly S7700-266 Figure 1-13 Assemblies of the Print Engine Phaser 7700 Color Laser Printer Service Manual 1-17...
Page 48: Assemblies Of The Print Engine (Cont'd.)
Assemblies of the Print Engine (cont’d.) Toner cartridge (4x) Developer Print cartridge plate housing assemblies (4x) Dispenser Waste cartridge assembly (4x) S7700-312 sensor holder Figure 1-14 Assemblies of the Print Engine (cont’d.) 1-18 Phaser 7700 Color Laser Printer Service Manual...
Page 49: Figure 1-15 Assemblies Of The Print Engine (Cont'd.)
Assemblies of the Print Engine (cont’d.) Exit transport assembly S7700-386 Figure 1-15 Assemblies of the Print Engine (cont’d.) Phaser 7700 Color Laser Printer Service Manual 1-19...
Page 50: Auxiliary Feeder Assemblies
Auxiliary Feeder Assemblies Paper feeder assembly (3X) S7700-368 Figure 1-16 Auxiliary Feeder Assemblies Note The High-Capacity Feeder has a Tandem Tray design with three Paper Feeder Assemblies, two on the left and one on the right side of the Printer. 1-20 Phaser 7700 Color Laser Printer Service Manual...
Page 51: Front Panel Description
Front Panel Description The Front Panel consists of one tricolor LED, a display window and six functional keys. These keys navigate the menu system, perform functions and select modes of operation for the printer. LED indicators Green = Ready to print/printing Flashing Green = Receiving or Processing Data Yellow = Warning Red = Fatal Error...
Page 52: Front Panel Shortcuts
Front Panel Shortcuts You can perform several service tasks by using the options shown in the table. Table 1-3 Front Panel Shortcuts Mode Press this selection at Power On Skip execution of POST diagnostics Print service diagnostics map INFO Reset PostScript NVRAM BACK+OK Password Bypass UP+DOWN...
Page 53: Rear Panel
Rear Panel Connectors The rear panel of the printer features the host interface connectors and DIP Switches: USB port Twisted Pair 10/100T Ethernet connector Bi-directional parallel (high-density connector) DIP Switches. The following figure illustrates the rear connections panel of the printer. Parallel DIP Switches Ethernet...
Page 54: Printer Specifications
Printer Specifications Physical Dimensions and Clearances Table 1-5 Physical Dimensions of the Printer Dimension Value Height 493 mm (19.4 in.) Print Engine 857 mm (48. in.) with lower tray deck Width 644 mm (25.4 in.) Depth 682 mm (26.9 in.) Weight 82 kg (180 lbs.) with consumables installed 122 kg (267 lbs.) with lower tray (high-capacity) feeder...
Page 55: Table 1-7 Functional Specifications
Table 1-7 Functional Specifications Characteristic Specification Printing Process The Printer uses laser print heads with an electrophotographic four-color (CMYK) tandem architecture and intermediate transfer printing process. Color Medium Four toner cartridges each containing one of four colors: CMYK Addressability 600 x 600 x 1-bit dpi (OHP) 1200 x 600 x 1-bit dpi (standard) 600 x 600 x 3-bit+1-level dpi (photo) Print Speed...
Page 56: Table 1-9 Environmental Specifications
Table 1-9 Environmental Specifications Characteristic Specification Temperature: Operating 10 to 32 Storage -20 to 50 Humidly: Operating 10 to 85% relative humidity Storage 30 to 85% relative humidity Altitude 0 to 2500 m (8000 ft.) at 25 Acoustic Noise Idle: 38.3 db Printing: 54.8 db with impulse noise of 63.3 db...
Page 57: Supported Paper Weights, Page Sizes And Print Area
Supported Paper Weights, Page Sizes and Print Area Supported Paper Sizes The table identifies the paper weights that can be placed in each tray: Laser Paper with the following weights: 60-90 g/m (16-24 lb. bond, 40-60 lb. book); Heavy Laser Paper with the following weights: 91-105 g/m (25-28 lb.
Page 58: Table 1-10 Specialty Paper
Table 1-10 Specialty Paper Paper Type and Size Tray 1 Trays Multi- High- 2- 4 Purpose Capacity Tray Feeder Phaser 7700 Premium • • Transparency Labels • Paper Envelopes (all sizes) • Table 1-11 Print Area Paper Page Size Image Area Margin Sides Top /...
Page 59 Table 1-11 Print Area (cont'd.) Paper Page Size Image Area Margin Sides Top / Bottom 305 x 430 mm 297 x 420 mm 5 mm 4 mm SRA3 320 x 450 mm 303 x 432 mm 9 mm 8.5 mm Official #10 4.13 x 9.5 in.
Page 60 1-30 Phaser 7700 Color Laser Printer Service Manual...
Page 61: Diagnostics, Error Codes And Messages
Diagnostics, Error Codes and Messages Error Messages The Control Panel displays error codes when it encounters certain system failures or anomalies otherwise undetected by the user. These error codes are discussed in this section. When an error code first occurs, cycle the printer power On to see if the error recurs.
Page 62: System Boot Sequence
System Boot Sequence The main power switch is turned On. The health LED turns On immediately. The boot loader checks for RAM present and functional - if not, it posts a very large “RAM ERROR” on the Front Panel and blinks the LED 1/2 second On/Off continuously.
Page 63: Post Faults
POST Faults There are two kinds of faults: Soft and Hard. A soft fault is any fault that is discovered by POST but does not prevent the operating system from initializing and becoming available as a tool for troubleshooting. These POST faults do not stop execution and are reported on the StartPage, in a red box, after the system is running.
Page 64: Post Diagnostics Test Descriptions
POST Diagnostics Test Descriptions Table 2-1 POST Diagnostics Test Descriptions Test Fault Code Description SDRAM (Hard) This test fails, if the boot loader finds no RAM present or faulty RAM. Boot loader posts the message “RAM error” to the front panel and blinks the front panel LED.
Page 65: Service Diagnostics
RegiCon when the customer has the PostScript startpage enabled. Note The Service Menu functions are to be used only by Xerox service personnel and authorized service providers. The printer can be damaged by the improper use of the built-in service tests.
Page 66: Service Diagnostics Test Menu Functions
Service Diagnostics Test Menu Functions Table 2-2 Service Diagnostics Test Menu Functions Test Front Panel Display Test Operation, Results and Function Definition Print Service Menu Map Prints the service diagnostics menu page General Status Provides current print engine status Engine ROM Engine Version is 3.60 Prints Current engine status.
Page 67 Table 2-2 Service Diagnostics Test Menu Functions (cont'd.) Test Front Panel Display Test Operation, Results and Function Definition Offset: None, Auto, Front, Rear Press Up/Down to change setting. Set a new offset? Media Type: Press Up/Down to change setting. Set New Media Type? Output Destination Press Up/Down to change setting.
Page 68 Table 2-2 Service Diagnostics Test Menu Functions (cont'd.) Test Front Panel Display Test Operation, Results and Function Definition Interlocks Front (or Right) Door is L H = Open (A) Left Upper Door L L = Closed (D) Duplex Cover is L (B) Left Lower Door is L (C) Optional Tray Left Cover L Jam Sensors...
Page 69 Table 2-2 Service Diagnostics Test Menu Functions (cont'd.) Test Front Panel Display Test Operation, Results and Function Definition Read Fuser Fuse 1 is Open 50 page fuse Fuses Fuse 2 is Open 90 day fuse Fuse 3 is Shorted Mis-Use fuse Open indicates Fuse is blown.
Page 70 Table 2-2 Service Diagnostics Test Menu Functions (cont'd.) Test Front Panel Display Test Operation, Results and Function Definition Print Cartridge Print Cart. Yellow is H H = Cartridge present Sensors Print Cart. Magenta is H L = No cartridge present Print Cart.
Page 71 Table 2-2 Service Diagnostics Test Menu Functions (cont'd.) Test Front Panel Display Test Operation, Results and Function Definition Steering Motor To avoid damaging the Caution: To avoid damaging the Accumulator Belt, remove! Accumulator Belt, it is recommended that you leave the belt installed and Do you wish to continue? perform the Belt Edge Learn test instead, Step 1: Belt Edge Learn on...
Page 72 Table 2-2 Service Diagnostics Test Menu Functions (cont'd.) Test Front Panel Display Test Operation, Results and Function Definition Offset Motor Direction: Forward Press Up/Down to change setting. Backward Developer Developer Motor is On CMY only Motor Turn Motor Off All Motors Off Caution Dispenser Disp.
Page 73 Table 2-2 Service Diagnostics Test Menu Functions (cont'd.) Test Front Panel Display Test Operation, Results and Function Definition Clutch Tests Tests functionality of clutches by activating one clutch at a time. Take-Away Clutch On All tests are activated by pressing Clutch Clutch Off Listen for the clutch.
Page 74 Table 2-2 Service Diagnostics Test Menu Functions (cont'd.) Test Front Panel Display Test Operation, Results and Function Definition RegiCon 685 Setup Refer to (Processes of the RegiCon Cycle Adjustment on page 4-127). RegiCon Results Refer to Processes of the RegiCon Display Adjustment on page 4-127.
Page 75 Table 2-2 Service Diagnostics Test Menu Functions (cont'd.) Test Front Panel Display Test Operation, Results and Function Definition NVRAM Access You can read or reset, selected NVRAM address locations. For all NVRAM access tests Service Diagnostics NVRAM Resets on page 6-149 PostScript NVRAM Refer to Service Diagnostics Reset...
Page 76: Error Codes And Messages Troubleshooting
Error Codes and Messages Troubleshooting Some Error Codes create “Tech Rep Faults” which must be cleared, see Clear Tech Rep Faults on page 6-149. Voltage Measurements Many voltage measurements are required for expeditious troubleshooting. The following illustration is provided at this location for your convenience in locating most of the connectors/pins from which voltage measurements are taken.
Page 77: Fuser Connector Pin Locations
Fuser Connector Pin Locations S7700-427 Fig 2-2 Fuser Connector Pin Locations Phaser 7700 Color Laser Printer Service Manual 2-47...
Page 78 Error Chain / Code Link Front Panel Message 06-380 ERROR 10 LASER UNIT FAILURE 06-381 06-382 06-383 06-385 Warning Do not operate the Laser Unit outside the printer. The invisible light from the laser can cause permanent eye damage. Remove Rear Cover (RRP 1, on page 7-154). Disconnect P400 (see figure page 2-46) and P401 (see figure page 2-46) on the Engine Con- trol Board.
Page 79 Error Chain / Code Link Front Panel Message 09-380 ERROR 12 YELLOW ATC SENSOR FAILURE Note If this failure reoccurs three times successively, an Engine NVRAM value is set preventing further printer use until the NVRAM Access / Clear Tech Rep Fault / Clear <09-380 ~ 09-383> is run. Note If necessary, enter Service Diagnostics Mode and run the “Clear Tech Rep Fault”...
Page 80 Error Chain / Code Link Front Panel Message 09-381 ERROR 13 MAGENTA ATC SENSOR FAILURE Note If this failure reoccurs three times successively, an Engine NVRAM value is set preventing further printer use until the NVRAM Access / Clear Tech Rep Fault / Clear <09-380 ~ 09-383> is run. Note If necessary, enter Service Diagnostics Mode and run the “Clear Tech Rep Fault”...
Page 81 Error Chain / Code Link Front Panel Message 09-382 ERROR 14 CYAN ATC SENSOR FAILURE Note If this failure reoccurs three times successively, an Engine NVRAM value is set preventing further printer use until the NVRAM Access / Clear Tech Rep Fault / Clear <09-380 ~ 09-383> is run. Note If necessary, enter Service Diagnostics Mode and run the “Clear Tech Rep Fault”...
Page 82 Error Chain / Code Link Front Panel Message 09-383 ERROR 15 BLACK ATC SENSOR FAILURE Note If this failure reoccurs three times successively, an Engine NVRAM value is set preventing further printer use until the NVRAM Access / Clear Tech Rep Fault / Clear <09-380 ~ 09-383> is run. Note If necessary, enter Service Diagnostics Mode and run the “Clear Tech Rep Fault”...
Page 83 Error Chain / Code Link Front Panel Message 09-342 ERROR 20 TRANSFER ROLLER CONTACT FAILURE Enter Service Diagnostics Mode. Perform the “2nd BTR Motor” test. Listen for a short run of the motor. Did the motor run? Yes No Remove the Left-Hand Rear Mid Cover (RRP 5, on page 7-158). Inspect the Left-Hand Cover Assembly wiring harness for damage and ensure all connectors are properly seated.
Page 84 Error Chain / Code Link Front Panel Message 04-346 ERROR 30 Accumulator Belt HOME POSITION TOOK TOO LONG. Note If this failure reoccurs three times successively, an Engine NVRAM value is set preventing further printer use until the NVRAM Access / Clear Tech Rep Fault / Clear <04-346>...
Page 85 Error Chain / Code Link Front Panel Message 04-346 ERROR 30 Accumulator Belt HOME POSITION TOOK TOO LONG (Continued) Repeat the “Agitator Motor” test while measuring the voltage at the Engine Control Board J404B-4 (see figure page 2-46) (RRP 42, on page 7-206). Does the voltage measure 0 VDC when the test is run and +24 VDC when the test is not run? Yes No...
Page 86 Error Chain / Code Link Front Panel Message 04-347 ERROR 31 Accumulator Belt HOME POSITION FAILURE Lower the Main Release Lever and return to the upright position to reestablish electrical connections to the belt. Open the RH Door and defeat the interlock switch. Look for rotation of the Accumulator Belt during the following test.
Page 87 Error Chain / Code Link Front Panel Message 04-347 ERROR 31 Accumulator Belt HOME POSITION FAILURE (Continued) Using a Type II toner vacuum cleaner, vacuum out the Waste Auger Assembly. Replace the Waste Toner Cartridge. Recheck the gear that drives the Accumulator Belt for freedom of rotation. Does it move freely now? Yes No Replace the Waste Auger Assembly (RRP 37, on page 7-199).
Page 88 Error Chain / Code Link Front Panel Message 04-348 ERROR 32 UNEXPECTED Accumulator Belt EDGE SENSOR FAILURE Remove the Accumulator Belt Assembly (RRP 51, on page 7-217). Inspect the connector for damage. Is the connector in good condition? Yes No Replace the Accumulator Belt Assembly (RRP 51, on page 7-217).
Page 89 Error Chain / Code Link Front Panel Message 09-350 ERROR 33 UNEXPECTED Accumulator Belt HOME SEN- SOR SIGNAL Remove the Accumulator Belt Assembly (RRP 35, on page 7-196). Inspect the connector for damage. Is the connector in good condition? Yes No Replace the Accumulator Belt Assembly (RRP 35, on page 7-196).
Page 90 Error Chain / Code Link Front Panel Message 10-348 ERROR 40 FUSER MAIN LAMP FAILURE Note If this failure reoccurs three times successively, an Engine NVRAM value is set preventing further printer use until the Clear Tech Rep Fault, Clear <10-348 & 10-350> is run. Switch printer power OFF.
Page 91 Error Chain / Code Link Front Panel Message 10-352 ERROR 42 FUSER STS (FRONT) WARM TIME FAILURE Switch printer power OFF. Remove the Fuser Assembly. Warning Fuser may be very hot. Use extreme caution to prevent burns. Measure the resistance between the Fuser Assembly connector P600-1 (see figure page 2-47) and P600-3 (see figure page 2-47).
Page 92 Error Chain / Code Link Front Panel Message 10-353 ERROR 43 FUSER SSR1 ON TIME FAILURE Switch printer power OFF. Remove the Fuser Assembly. Warning Fuser may be very hot. Use extreme caution to prevent burns. Measure the resistance between the Fuser Assembly connector P600-1 (see figure page 2-47) and P600-3 (see figure page 2-47).
Page 93 Error Chain / Code Link Front Panel Message 10-350 ERROR 44 FUSER SUB LAMP FAILURE Note If this failure reoccurs three times successively, an Engine NVRAM value is set preventing further printer use until the Clear Tech Rep Fault, Clear <09-380 ~ 09-383> is run. Switch printer power OFF.
Page 94 Error Chain / Code Link Front Panel Message 10-354 ERROR 46 FUSER STS (REAR) WARM TIME FAILURE Switch printer power OFF. Remove the Fuser Assembly. Warning Fuser may be very hot. Use extreme caution to prevent burns. Measure the resistance between the Fuser Assembly connector P600-1 and P600-3 (see fig- ure page 2-47).
Page 95 Error Chain / Code Link Front Panel Message 10-356 ERROR 47 FUSER SSR2 ON TIME FAILURE Switch printer power OFF. Remove the Fuser Assembly. Warning Fuser may be very hot. Use extreme caution to prevent burns. Measure the resistance between the Fuser Assembly connector P600-1 and P600-3 (see fig- ure page 2-47).
Page 96 Error Chain / Code Link Front Panel Message 10-398 ERROR 54 FAN FAILURE Enter Service Diagnostics Mode. Run the “Fuser Fan” test. Does the Fuser Fan operate? Yes No Remove the Rear Cover (RRP 1, on page 7-154), Rear Shield (RRP 9, on page 7-163) and the Rear Shield Bracket (RRP 11, on page 7-165).
Page 97 Error Chain / Code Link Front Panel Message 04-640 ERROR 60 DRUM MOTOR FAILURE Enter Service Diagnostics Mode and run the “Print Cartridge Motor” test. Does the motor run? Yes No Remove the Rear Cover (RRP 1, on page 7-154), the Rear Cover Shield (RRP 9, on page 7-163) and the Rear Shield Bracket (RRP 10, on page 7-164).
Page 98 Error Chain / Code Link Front Panel Message 09-360 ERROR 70 PRINT CARTRIDGE 1 COMMUNICATIONS 09-361 FAILURE 09-362 ERROR 70 PRINT CARTRIDGE 2 COMMUNICATIONS 09-363 FAILURE ERROR 70 PRINT CARTRIDGE 3 COMMUNICATIONS FAILURE ERROR 70 PRINT CARTRIDGE 4 COMMUNICATIONS FAILURE Swap the suspect print cartridge with any other cartridge.
Page 99 Error Chain / Code Link Front Panel Message 09-358 ERROR 78 WASTE TONER CARTRIDGE FULL DETECTION SENSOR FAILURE Remove the Waste Cartridge Sensor Holder without disconnecting the harnesses (RRP 23, on page 7-178). Measure the voltage between the yellow wire to the Waste Cartridge Full Sensor and frame ground and alternately interrupt the Waste Cartridge Full Sensor.
Page 100 Error Chain / Code Link Front Panel Message 04-358 ERROR 81 CONTROLLER TO ENGINE COMMUNICATIONS FAILURE Switch printer power Off. Remove the Image Processor Board, Image Processor Board Cover and the Image Processor Metal Cover and inspect the orange colored ribbon cable between the Relay Board and the Engine Control Board for proper connector seating.
Page 101 Error Chain / Code Link Front Panel Message One at a time, pull out and reinsert each paper tray. Listen for tray lift. Is there an Auxiliary Feeder (Lower Tray Deck or a High-capacity Feeder) installed? Yes No Refer to “Tray (1, 2, 3 or 4) Will Not Lift” section, page 3-95, in Troubleshooting. Do any of the Auxiliary Feeder (LTD or HCF) Trays lift correctly? Yes No Refer to “Auxiliary Feeder not recognized”...
Page 102 Error Chain / Code Link Front Panel Message 12-241 FINISHER ERROR 111 STAPLER MOVE SENSOR ON 12-242 FAILURE FINISHER ERROR 112 STAPLER MOVE SENSOR OFF FAILURE Open the Finisher Front Door. Defeat the Front Door Interlock Switch. Enter Service Diagnostics Mode. Run the Stapler “Move Front, Move Rear”...
Page 103 Error Chain / Code Link Front Panel Message 12-244 FINISHER ERROR 113 STAPLER FAILURE Open the Finisher Front Door. Verify the Stapler Carriage is its full home position. Enter Service Diagnostics Mode. Run the Stapler “Head Home” sensor test to verify home position. Does the sensor indicate home position? Yes No Remove the Finisher Rear Cover and the Board Cover (RRP 72, on page 11-330).
Page 104 Error Chain / Code Link Front Panel Message 12-244 FINISHER ERROR 113 STAPLER FAILURE (Continued) Does the sensor indicate the Stapler is ready? Yes No Remove the Finisher Front Cover (RRP 72, on page 11-330). Measure the voltage between Stapler Unit Assembly connector J886-3 (see figure page 2-46) and Finisher frame ground.
Page 105 Error Chain / Code Link Front Panel Message 12-254 FINISHER ERROR 116 STACKER HEIGHT SENSOR OFF FAILURE Is the Finisher Stacker Tray installed? Yes No Install Finisher Stacker Tray. Switch printer power Off, then On. Inspect the Stack Height Sensor Actuator for proper installation or damage. Is the Stack Height Sensor Actuator installed correctly and in good condition? Yes No Reinstall or replace the Stack Height Sensor Actuator.
Page 106 Error Chain / Code Link Front Panel Message 12-254 FINISHER ERROR 116 STACKER HEIGHT SENSOR OFF FAILURE (Continued) Measure the voltage at the Stack Height Sensor pin 3 (violet) and Finisher frame ground. Does the voltage measure 0 VDC? Yes No Measure the voltage between the Finisher Control Board P850B-4 (see figure page 2-46) and Finisher frame ground.
Page 107 Error Chain / Code Link Front Panel Message 12-255 FINISHER ERROR 117 STACKER TRAY FAILURE (Contin- ued) While watching the display, interrupt the Stack A and Stack B sensors. Does the display indicate H & L for both sensors? Yes No Does the display indicate H &...
Page 108 Error Chain / Code Link Front Panel Message 12-256 FINISHER ERROR 118 STAPLER FRONT CORNER SENSOR ON FAILURE (Continued) 12-257 FINISHER ERROR 119 STAPLER FRONT CORNER SENSOR OFF FAILURE (Continued) Does the voltage toggle between +5 VDC and 0 VDC? Yes No Measure the voltage at Front Corner Sensor pin 1 (gray).
Page 109 Error Chain / Code Link Front Panel Message 12-260 FINISHER ERROR 120 EJECT CLAMP HOME SENSOR ON FAILURE 12-262 FINISHER ERROR 121 EJECT CLAMP HOME SENSOR OFF FAILURE Remove the Finisher Rear Cover (RRP 72, on page 11-330). Remove the sensor from the top of the eject motor mount bracket (RRP 76, on page 11-335). Enter Service Diagnostics Mode.
Page 110 Error Chain / Code Link Front Panel Message 12-260 FINISHER ERROR 120 EJECT CLAMP HOME SENSOR ON FAILURE 12-262 FINISHER ERROR 121 EJECT CLAMP HOME SENSOR OFF FAILURE Measure the voltage at the Eject Clamp Home Sensor pin 3 (violet) and Finisher frame ground.
Page 111 Error Chain / Code Link Front Panel Message 12-267 FINISHER ERROR 122 DECURLER FAILURE Remove the Finisher Rear Cover (RRP 72, on page 11-330). Enter Service Diagnostics Mode. From the Main Menu, select “Sensor Tests/Finisher Sensors/Miscellaneous Manually rotate the Decurler Cam Shaft such that the photo interrupter toggles the Decurler Cam Home Sensor.
Page 112 Error Chain / Code Link Front Panel Message 12-267 FINISHER ERROR 122 DECURLER FAILURE (Continued) Measure the voltage at the Decurler Cam Home Sensor pin 3 (violet) and Finisher frame ground. Does the voltage measure 0 VDC? Yes No Measure the voltage between the Finisher Control Board P849-1 (see figure page 2-46) and Finisher frame ground.
Page 113 Error Chain / Code Link Front Panel Message 12-281 FINISHER ERROR 123 SET CLAMP FAILURE Remove the Finisher Rear Cover (RRP 72, on page 11-330). Enter Service Diagnostics Mode. From the Main Menu, select “Sensor Tests/Finisher Sensors/Miscellaneous.” Manually operate the Set Clamp Solenoid [see illustration in (RRP 75, on page 11-334) or (RRP 75, on page 11-334).
Page 114: Wiring Diagrams
Error Chain / Code Link Front Panel Message 12-281 FINISHER ERROR 123 SET CLAMP FAILURE (Continued) Measure the voltage at the Set Clamp Sensor pin 3 (violet) and Finisher frame ground. Does the voltage measure 0 VDC? Yes No Measure the voltage between the Finisher Control Board P849-7 (see figure page 2-46) and Finisher frame ground.
Page 115 Error Chain / Code Link Front Panel Message 07-250 TRAY COMMUNICATION FAILLURE Check the voltage on the Tray Module PWB between J 555-1 and ground. Is the voltage +5VDC? Yes No Using the wiring diagrams, check and repair the +5VDC circuits to Tray Module PWB J555-1.
Page 116 Error Chain / Link Code Front Panel Message 009-910 (K) TRAY COMMUNICATION FAILLURE 009-911 (M) 009-912 (C) 009-913 (Y) 1. Check the installation of the Print Cartridge. 2. Clear the Tech Rep Fault for errors 009-910 through 009-913 (refer to instructions below). 3.
Page 117: Troubleshooting
Printer does nothing when power is turned On Fan on, Front Panel LED never On Fan on, Front Panel LED on, no Front Panel message Front Panel continually displays Xerox Phaser 7700 splash screen Front Panel continually displays “WARMING UP” Front Panel displays “FATAL FAULT ENCOUNTERED”...
Page 118: Troubleshooting Network Problems
Troubleshooting Network Problems Operating System and Application Problems Macintosh printing problems Windows printing problems Media Jams and the Paper Path Media-based problems Multiple-sheet picks Mis-picks Skewed images Damaged prints Fuser Jams Exit Jams Print Image Quality Problems Light (undertones) prints (all colors) Blank Prints One color is faded Missing bands in direction of paper travel...
Page 119: Troubleshooting Power Supplies And Interlocks
Troubleshooting Power Supplies and Interlocks Troubleshooting AC Power Verify that the AC Input Voltage is present and within specifications. Verify that the Reset button on the GFI is depressed. Reconnect AC power. If the GFI trips immediately with the Power switch Off, disconnect AC power, remove the rear cover and metal shields.
Page 120: Troubleshooting The +3.3 Vdc And +5 Vdc Lvps
Troubleshooting the +3.3 VDC and +5 VDC LVPS Note Turn the printer power Off and disconnect the power cord. Remove the rear cover and rear shield. Disconnect the harnesses to connectors P501, P574, P801 and 2ndBTR of the T1 HVPS, remove 3 screws and lower the T1 HVPS to horizontal (RRP 44, on page 7-208).
Page 121: Interlock Circuit Diagram
Interlock Circuit Diagram PRINT CARTRIDGE CRUM CONNECTORS J631 P536 INTERFACE LVPS BOARD WASTE CARTRIDGE P537 INTLK SW LVPS POWER RELAY FRONT COVER INTLK SW R/H COVER INTLK SW LH COVER INTLK SW S7700-432 Figure 3-1 Circuit Diagram The +24 VDC Interlock Circuit The +24 VDC Interlock Circuit runs from the +24 VDC LVPS to the L/H Door Interlock Switch, the R/H Door Interlock Switch, and the Front Door Interlock Switch back to the Engine Control Interface Board, then into the Engine...
Page 122: The +5 Vdc Interlock Circuit
The +5 VDC Interlock Circuit The +5 VDC Interlock Circuit runs from the +5 VDC LVPS to the L/H Door Switch, then to the Engine Control Interface Board, out to the R/H Door Switch, back to the Engine Control Interface Board, out to the Front Door, through the coil of the LD Power Relay and back to the 5+ VDC LVPS.
Page 123: Troubleshooting When The Printer Does Not Come To A "Ready" State
Replace the Internal Hard Drive (RRP 40, on page 7-203). Replace the Image Processor Board (RRP 39, on page 7-202). Front Panel Continually Displays the Xerox Phaser 7700 Splash Screen Enter Service Diagnostics Mode. Refer to Entering Service Diagnostics Mode on page 2-35.
Page 124: Front Panel Displays "Fatal Fault Encountered" Message
Front Panel displays "Fatal Fault Encountered" message See procedure for "Error 81 Controller to Engine Communications Failure” on page 2-70. Troubleshooting - Printer Comes to a “Ready” State False LH Door, RH Door, or Front Door Open Messages See procedure for “Troubleshooting the Interlock Circuit", on page 3-91. False "Load Paper in Tray [1,2,3,4]"...
Page 125: Tray 1 Will Not Lift
Tray 1 Will Not Lift In order for Tray 1 to lift, the +24 VDC interlock circuit through the LH, RH and Front Doors must be complete, one or both of the top two Paper Size Switches must be closed, and the Tray Level Sensor must be deactuated. Determine if the Feed/Lift Motor operates normally, if the motor operates but does not sound right, or if the motor does not operate at all.
Page 126: Tray 2, 3 And 4 Will Not Lift Or Printer Will Not Recognize The Auxiliary Feeder
Tray 2, 3 and 4 Will Not Lift or Printer Will Not Recognize the Auxiliary Feeder There are two circuits connecting the printer to the auxiliary feeder: the Power Circuit and the Serial Data Link. Check that the auxiliary feeder is properly connected to the back of the printer.
Page 127: Troubleshooting The Toner Dispense/Auger/Developer System
Troubleshooting the Toner Dispense/Auger/Developer System Failures relating to Toner Dispense, Toner Auger, and Developer System include: False “Replace Toner Cartridge” message ATC Sensor errors 12, 13, 14, and 15 Faded or missing primary colors Checking the Toner Cartridge Ensure the Toner Cartridge is correctly installed and rotated into its opened position.
Page 128: Checking The Toner Auger System
Checking the Toner Auger System Power-up the printer in Service Diagnostics mode. Override the Front Cover Interlock Switch. Examine the toner port of the system in question. Usually, the port should be completely filled to the rim. s7700-558 Figure 3-3 Toner Cartridge If toner is not level at the port, then the toner in the Toner Dispense Assembly has been augered into the Developer but no fresh toner is being delivered from the Toner Cartridge to the Toner Dispense Assembly.
Page 129: Figure 3-4 Toner Dispense Assembly
Leaving the Toner Cartridge out of the printer, run the Toner Dispense Motor test for the system in question. Look at the far end of the Toner Cartridge cavity and observe the Dispense Motor Gear rotate. Also, look along the right side of the Toner Cartridge cavity. You should see the Drive Shaft of the Toner Auger System rotate as the Toner Motor operates.
Page 130: Figure 3-5 Toner Port
Print 2 to 3 Solid Fill prints using the primary color in question. The toner level at the port should drop as toner is augered into the Developer. Toner Port with Lowered Toner Level (Not Yet Refilled) s7700-559 Figure 3-5 Toner Port If the Drive Shaft rotates but the toner level at the port does not drop, replace the Toner Dispense Assembly (RRP 25, on page 7-180).
Page 131: Checking The Developer Atc Sensor
Checking the Developer ATC Sensor Power-up the printer in Service Diagnostics mode. Scroll to the Adjustment Calibration: Tone Up/Down menu item. Press OK. The test displays information regarding the Developer ATC Sensors. Press OK to read the values for each Developer. Examine the ATC values for primary color Developer you are troubleshooting.
Page 132: Checking The Developer
Checking the Developer If, after these checks, the problem still exists: Inspect the wiring harnesses leading to the Developer for nicks, pinched wiring, or poor connections. If the wiring harnesses are OK, replace the Developer (RRP 27, on page 7-185). After installing a new Developer, print 25 100% Solid Fill, A-size pages to ensure it prints correctly.
Page 133: Figure 3-6 Developer Housing
Bead Carryout (BCO) The ATC Sensor magnetically measures the ratio of toner particles to developer carrier beads, not the volume. Under a combination of rare circumstances and component tolerances, it is possible fo rthe carrier beads to be pulled from the Developer during printing; this is called bead carryout or BCO.
Page 134: Operation System And Application Problems
Operation System and Application Problems Macintosh Printing Problems Image Never Prints Printer acts as if it is receiving data, but nothing comes out of printer or it goes back to “Ready” mode without printing image. Power cycle the printer and print again. Make sure that the correct Phaser 7700 printer icon was selected in the Chooser.
Page 135: Troubleshooting Network Problems
Troubleshooting Network Problems The Phaser 7700 printer maintains 4 logs in memory detailing network functions. The logs contain TCP/IP, Netware and AppleTalk initialization events. The logs can also be accessed remotely via CentreWare. The logs list events chronologically. The log is limited in length; when the log is full the printer stops recording data to the log.
Page 136: Media Jams And The Paper Path
Media Jams and the Paper Path Media-based Problems Check that the correct type of media is being used; Supported Paper Weights, Page Sizes and Print Area on page 1-27 for the correct media types and weights. The customer should be using a quality laser printer paper.
Page 137: Damaged Prints
Accumulator Belt (usually appears with toner in creases or wrinkles). Fuser Jams Is the paper in good condition and appropriate for a laser printer? Is Xerox Series-7700 transparency film being used. Is the printer printing within its environmental specifications? Ensure that the loaded media matches the front panel settings.
Page 138: Print Image Quality Problems
Print Image Quality Problems Light (undertone) Prints (all colors) The overall image density is too light. Ensure that the correct color correction was set in the driver. Is the correct paper being used in the printer? Ensure that the loaded media matches the front panel settings. Verify the Bias Transfer Roller is not reaching its end-of-life by printing the Supplies Usage Page.
Page 139: One Color Is Faded Or Missing
One Color is Faded or Missing 3041-39 Is the Toner Low Message being displayed on the front panel? Under high toner-coverage conditions, toner may be depleted during the toner low state but before the toner out message is displayed. Ensure that the loaded media matches the front panel settings. Run the Calibrate for Paper routine.
Page 140: Missing Band In Direction Of Paper Travel
Missing Band in Direction of Paper Travel There are areas of the image that Leading Edge are extremely light or are missing entirely. These missing areas form wide bands that run along the page from leading edge to trailing edge in the direction of paper travel (B-size print shown).
Page 141: Streaks In Direction Of Paper Travel
Streaks in Direction of Paper Travel There are dark lines running along Leading Edge the page in the direction of paper travel from the leading edge to the trailing edge (B-size print shown). The printer displays no error code. Note A-size prints are processed through the printer with the short edge of the print...
Page 142: Streaks Parallel With The Leading Edge
Streaks Parallel with the Leading Edge There are dark lines running Leading Edge parallel with the leading edge of the print, perpendicular to direction of paper travel (B-size print shown). The printer displays no error code. Note A-size prints are processed through the printer with the short edge of the print parallel to the direction of the...
Page 143: Random Missing Spots
Random Missing Spots There are small areas of the image that are extremely light or are missing entirely. These missing areas form spots that are localized to small areas of the page. The printer displays no error code. A small number of occasional missing spots is normal.
Page 144: All Colors
All Colors Inspect the paper path. Inspect the Accumulator Belt Cleaner and replace if necessary (RRP 36, on page 7-198). Inspect the Bias Transfer Roller and replace if necessary (RRP 17, on page 7-172). Inspect the Fuser to see whether paper is wrapped around the Fuser. Replace the Fuser (RRP 19, on page 7-174).
Page 145: Background Contamination
Background Contamination There is toner contamination on all or most of the page. The contamination appears as a very light gray dusting. The printer displays no error code. Ensure that the loaded media matches the front panel settings. In some cases, switching the paper type setting, for example from Heavy Laser Paper to Thin Cover/Index, may improve...
Page 146: Unfused Image Or Image Easily Rubs Off Of Page
Unfused Image or Image Easily Rubs Off of Page The toner image is not completely fused to the paper. The image easily rubs off. The printer displays no error code. Make sure that the paper you are using is the correct type for the printer and is correctly loaded in the printer in the correct tray.
Page 147: Toner On Back Of Print
Toner on Back of Print There is toner on the back of the printed sheet of paper. Clean the printer interior. Inspect the paper that is loaded in the paper trays. Is the paper clean and free of toner? Ensure that the loaded media matches the front panel settings.
Page 148: Print Is Mottled
Print is Mottled The printed image has a mottled appearance. Ensure that the paper is in good condition and appropriate for a laser printer. Ensure that the loaded media matches the front panel settings. Also check the media selected in the printer driver.
Page 149: Image Mis-Registered On Paper
Image Mis-registered on Paper The image area is not centered on the page or the image is bleeding off of the page. The printer displays no error code. Run the configuration or Startup Page to verify the hard drive, application, and driver settings. From the front panel’s Printable Pages Menu, select Print Configuration Pages or Print...
Page 150: Residual Image Or Ghosting
Residual Image or Ghosting There are faint, ghostly images appearing on the page. The images may be either from a previous page or from the page currently being printed. The printer displays no error code. Make sure that the paper you are using is the correct type for the printer and is correctly loaded in the printer.
Page 151: Light Bands, Dark Bands, Or Mottled Prints
Light Bands, Dark Bands, or Mottled Prints An image void, dark bank or mottle in a primary CMYK color, or a visible area on the Developer Roller where toner is missing. Cause Narrow image voids or a dark band in the process direction can be caused by contamination in the Developer Assembly.
Page 152 3-122 Phaser 7700 Color Laser Printer Service Manual...
Page 153: Adjustments And Calibration
Adjustments and Calibration The engine firmware has several built-in diagnostic routines that perform various alignment and calibration procedures. The RegiCon 685 Adjustment procedures should be used whenever the technician removes or replaces the Laser Unit, the Print Cartridge Plate Assembly, the Mark-on-Belt Assembly, Developer Housing Assembly or where color registration is bad.
Page 154: Registration Control (Regicon) Adjustment Overview
Registration Control (RegiCon) Adjustment Overview The DC685 RegiCon tests are the means by which registration is accomplished. Registration means establishing the alignment of the four primary colors with regard to horizontal and vertical positioning, tilt or skew, length of lines and linearity. When the registration process is completed, all color planes are positioned properly.
Page 155: Coarse And Fine Skew Adjustments
Coarse and Fine Skew Adjustments Skew error is the mislevel of one or more of the four scan lines (C, M, Y & K). During the RegiCon #4 (Coarse) and RegiCon #1 (Fine) adjustments, the left side of each line is adjusted to be level with the right end. Figure 2: Skew Adjustment Reference Line S7700-461...
Page 156: Center Skew Adjustment
Center Skew Adjustment The Center Skew Adjustment (Magnification Balance) adjusts the linearity of the scan lines. During RegiCon #3, the printer measures a specific midpoint of each scan line and adjusts it to a horizontal reference midpoint. Figure 4: Magnification Balance Center Reference S7700-463 Figure 4-4 Center Skew Adjustment...
Page 157: Processes Of The Regicon Adjustment
Processes of the RegiCon Adjustment RegiCon is an engine resident algorithm that aligns the Magenta, Yellow, and Black lasers to the Cyan laser. Normally, the RegiCon procedure only needs to be performed if the Laser Unit has been replaced. The RegiCon procedures are listed in the Adjustment/Calibration Menu of Service Diagnostics as RegiCon 685 Setup Cycle, and are split into several sections.
Page 158 80 condition). Disable Netware before performing any RegiCon procedure in diagnostics. The Hard Disk Drive has the MFGstartjob snippet in the sys.start file. Download the usrstart_del.ps snippet to the printer. This snippet can be found on the Xerox website: http://cpidserv.opbu.xerox.com/products/Phaser7700/Phaser7700Snipp ets.html The MOB Sensor could be malfunctioning.
Page 159 Y:RADC Target=400 Ave RADC Trans=367 * (may be different and may change) Ideal LD Ill=251 * (may be different and may change) VBias=862 VBCR=0 M:RADC Target=400 Ave RADC Trans=450 * (may be different and may change) Ideal LD Illl=281 * (may be different and may change) VBias=862 VBCR=0 C:RADC Target=338 Ave RADC Trans=325 * (may be different and may change) Ideal LD Ill=293 * (may be different and may change) VBias=862...
Page 160: Registration Control Procedures
Registration Control Procedures Note For the following procedures you must perform certain steps prior to, during and after the tests are run. The following information is vital to the process and must be followed in order for each procedure to function properly. If the adjusting screws reach their maximum adjustment range either Clockwise or Counter Clockwise, center the adjusting position of the screws and restart the RegiCon procedure.
Page 161 Table 1 RegiCon Procedure (cont'd.) Step Actions and Questions Note: Turn “Netware” Off before running Scroll down using Go to step #8. any RegiCon procedures. the Down arrow button to view the Perform the RegiCon #1 Fine Skew results and Adjustment (page 4-137).
Page 162 Table 1 RegiCon Procedure (cont'd.) Step Actions and Questions Perform the RegiCon #3 Center Skew Verify the MOB Adjustment procedure (page 4-139). To Sensor is view the results, you must re-enter Service correctly Diagnostics by turning Off the printer, positioned in the pressing the Back and Info buttons center, then simultaneously, and switching the printer...
Page 163: Regicon Flowchart
RegiCon Flowchart Phaser 7700 Registration Control Adjustment (DC685 RegiCon Adjustment) Are all Check Print primary fill Set DIP switch Quality test prints 2 down Run Belt Edge Correct print Learn quality problem and reset. Correct Fault Pass? (Replace Accumulator Belt) Note 1: Do not make Run RegiCon #4 adjustments of 5 or...
Page 164: Step 1: Belt Edge Learn
Step 1: Belt Edge Learn Before doing skew adjustments, it is necessary to align the Accumulator Belt positioning system. A belt steering cam engages an arm on the Accumulator Belt cleaner to steer the belt. A belt edge sensor provides the real time feedback to steer the belt.
Page 165: Step 2: Regicon #4 Coarse Skew Adjustment
Step 2: RegiCon #4 Coarse Skew Adjustment From the Service Diagnostics menu, highlight the Adjustments/Calibration menu and press OK. Highlight Regi Con 685 Setup Cycle and press OK. At the prompt: Which DC685 procedure?, select #4 Coarse Skew Setup and press OK. At the prompt: Do DC685-4 Coarse Cycle?, highlight Yes and press OK.
Page 166 If RegiCon Coarse Skew Fails This indicates that the horizontal alignment is so far out of adjustment that a manual adjustment is required before the diagnostics test routines for fine skew can pass. Other possible problems; a Mark-On-Belt Sensor failure, Developer, Developer Bias Voltage, Print Cartridge, or Engine Control Board Failure.
Page 167: Step 3: Regicon #1 Fine Skew Adjustment
Step 3: RegiCon #1 Fine Skew Adjustment This process uses sensors to examine the RegiCon image on the belt and report what skew adjustments need to be made. A side effect of this test is that horizontal and vertical alignments are automatically done (if the test passed).
Page 168: Step 4: Regicon #2 In/Out Skew Adjustment
Step 4: RegiCon #2 In/Out Skew Adjustment This test makes "magnification" adjustments for registration. Magnification is the length of the scan line for the four colors, so that each scan line for each color is the same length. The data output can indicate PASSED, or READJUST (PASSED), or FAILED. If the result is READJUST, the indicated adjustment values for the skew adjustment should be done.
Page 169: Step 5: Regicon #3 Center Skew Adjustment
Step 5: RegiCon #3 Center Skew Adjustment This test adjusts magnification balance. There are no manual adjustments required after completing the test. Note To perform this test, move the Mark-On-Belt sensor to the CENTER position. After the test has been run, the Mark-On-Belt must be moved back to the home position.
Page 170: Coarse Regicon Initialization
Coarse RegiCon Initialization The Coarse RegiCon Initialization procedure is needed when either RegiCon 1 or 4 fail. If any one of the above conditions exist, perform a manual adjustment of the horizontal alignment. Run the Belt Edge Learn test (page 4-134). From the Adjustments/Calibrations menu, select Coarse RegiCon Init test.
Page 171: Figure 4-7 Grid 1-Dot Pattern Annotations
Note the leading edge of the paper when removing the test print from the tray. Use a pen or pencil to note the leading edge as the “TOP” of the print “Grid 1-Dot pattern annotations” on page 4-141. With “TOP” up, note the direction of scan from left to right as the “FAST ”...
Page 172: Atc Sensor Setup
ATC Sensor Setup The Automatic Toner Calibration (ATC) sensor measures the amount of toner in each developer. These sensors have an intrinsic gain and output value are stored in printer NVRAM. New values must be entered when a new Developer Housing Housing is installed.
Page 173: Cleaning And Maintenance
Cleaning and Maintenance Service Preventive Maintenance Procedure Perform the following procedures whenever you check, service, or repair a printer, Cleaning the printer, as outlined in the following steps, assures proper operation of the printer and reduces the probability of having to service the printer in the future.
Page 174 Phaser 7700 Color Laser Printer Service Manual 5-144...
Page 175: Resetting Nvram
Resetting NVRAM Resetting NVRAM returns all the image processor's NVRAM-stored parameters to their factory defaults except the print counts and the Adobe firmware serial number. You can reset both the PostScript and engine NVRAM the PostScript Menu or the Service Diagnostics Menu. PostScript NVRAM Resets Restore Factory Settings (color) You can reset settings for density and color balance to the factory-default...
Page 176: Restore Factory Settings (Margins)
Restore Factory Settings (margins) You can reset margin settings to the factory-default values. Caution Use caution when resetting your margins to the factory-default settings. Changing these settings back to factory defaults may not be the last-saved settings if you have previously calibrated your margins. From the Main Menu, highlight Support and press OK.
Page 177: Resetting Job Defaults
Resetting Job Defaults Resetting the job defaults resets the paper source, paper destination, job offset, stapling options, print-quality mode, 2-sided printing, image smoothing and tekcolor corrections to their default values. From the Main Menu, highlight Print Setup Menu and press OK. Highlight Job Defaults Menu and press OK.
Page 178: Resetting Belt Cleaner Assembly Life
Resetting Belt Cleaner Assembly Life Resetting the belt cleaner life is to be performed only if the Belt Cleaner Assembly was defective and or the assembly is replaced before an end-of-life or near end-of- life message. Do not to extend the life of the assembly. Doing so may cause premature failure of other internal printer components.
Page 179: Service Diagnostics Nvram Resets
Service Diagnostics NVRAM Resets PostScript NVRAM Reset Resetting the printer setup values resets the job defaults, front panel language, Intelligent Ready, multi-purpose setup, tray 1 - 4 setup, Startup Page, front panel intensity, front panel contrast, postscript error information and E timeout to their default values.
Page 180: Reset Engine Nvram
Reset Engine NVRAM Reset NVRAM allows PostScript to write stored data from the hard drive to engine NVRAM. You must restore engine NVRAM after replacing the Engine Control Board. Enter Service Diagnostics. Verify switch #2 is Down. Highlight NVRAM Access and press OK. Highlight Reset Engine NVRAM and press OK.
Page 181: Removal And Replacement Procedures
Removal and Replacement Procedures This topic illustrates how to remove and replace printer Field Replaceable Units (FRUs). For more detailed removal/replacement procedures, refer to the Phaser 7700 Color Laser Printer Service & Support Resources CD-ROM. For specific assemblies and parts, refer to the FRU Parts List on page 8-235. This section contains the removal and replacement procedures for selected parts of the printer.
Page 182 Contents RRP 1 Rear Cover Assembly ........7-154 RRP 2 Right Side Cover Assembly .
Page 183 RRP 42 Engine Control Board ........7-206 RRP 43 Engine Control Interface Board .
Page 184: Figure 7-1 Rear Cover Assembly
RRP 1 Rear Cover Assembly Figure 7-1 Rear Cover Assembly Removal Warning Turn Off the printer and disconnect the power cord. If an Auxiliary Feeder has been installed, open the Auxiliary Feeder Connection Cover and disconnect the Auxiliary Feeder wiring harness. Remove the four screws that secure the Rear Cover Assembly to the printer.
Page 185: Figure 7-2 Right Side Cover Assembly
RRP 2 Right Side Cover Assembly Right-Hand Door Tabs (4x) Finisher J800 S7700-033 Figure 7-2 Right Side Cover Assembly Removal Open the Front Cover. Remove the three screws that secure the Right Side Cover to the printer. One screw is located behind the Right-Hand door. Lightly press downward to release the four hidden tabs that are behind the right side cover, then pull the cover away from the printer.
Page 186: Figure 7-3 Top Cover Assembly
RRP 3 Top Cover Assembly Figure 7-3 Top Cover Assembly Removal Remove the Right Side Cover Assembly (RRP 2, on page 7-155). Remove the two screws visible on the right side of the Top Cover. Open the Front Cover and remove the front screw holding the Top Cover. Open the Image Processor Board Cover to gain access to the 4 thumb screws that secure the Image Processor Board metal cover.
Page 187: Figure 7-4 Control Panel Assembly
RRP 4 Front Panel Assembly Access Holes S7700-270 Figure 7-4 Control Panel Assembly Removal Warning Turn Off the printer and disconnect the power cord. Open the Front Door. Release the Front Panel Assembly by inserting a screwdriver or key into the two access holes indicated in the illustration and push the tangs inward to release.
Page 188: Figure 7-5 Top Rear Power Switch Cover And Left-Hand Rear Mid Cover
RRP 5 Rear Cover, Top Rear Power Switch Cover and LH Rear Mid Cover Left Hand, Rear, Mid Cover Cover, Top Rear, PS Rear Cover Cover, Left Hand Rear, Low S7700-092 Figure 7-5 Top Rear Power Switch Cover and Left-Hand Rear Mid Cover Removal Top Rear Power Switch Cover...
Page 189 Removal (cont’d.) Cover, Left-Hand Rear, Mid Remove one screw from the Left-Hand Rear Low Cover and remove the cover. Remove one screw from the Left-Hand Rear Mid Cover. Lift the cover up to release captive hooks then toward you out of the printer. 7-159 Phaser 7700 Color Laser Printer Service Manual...
Page 190: Figure 7-6 Left-Hand Lower Cover Assembly
RRP 6 Left-Hand Lower Cover Assembly S7700-010 Figure 7-6 Left-Hand Lower Cover Assembly Removal Open the Left-Hand Lower Cover Assembly. Disconnect the sensor (in the door) wiring harness plug at the rear and free the harness from the clamp near the rear pivot. With a flat tip screwdriver, pry out the pivot pin, then pry out the pivot pin expansion sleeve.
Page 191: Figure 7-7 Front Cover Assembly
RRP 7 Front Cover Assembly S7700-028 Figure 7-7 Front Cover Assembly Removal Open the Front Cover Assembly. Rotate the printer end of the strap 90 degrees and pull it straight out of the printer (both sides). Remove the screws that secure the hinges and slide the hinges off the locating pin (both sides) and remove the hinge.
Page 192: Figure 7-8 Fuser Front Cover
RRP 8 Fuser Front Cover S7700-029 Figure 7-8 Fuser Front Cover Removal Remove the Front Cover Assembly (RRP 7, on page 7-161). Remove two screws from the Fuser Front Cover and push upward and remove the cover. 7-162 Phaser 7700 Color Laser Printer Service Manual...
Page 193: Figure 7-9 Rear Shield
RRP 9 Rear Shield S7700-423 Figure 7-9 Rear Shield Removal Warning Turn Off the power and disconnect the power cord. Remove the Rear Cover (RRP 1, on page 7-154). Remove the seven screws securing the Rear Shield to the printer. Remove the shield.
Page 194: Figure 7-10 Rear Shield Bracket
RRP 10 Rear Shield Bracket S7700-422 Figure 7-10 Rear Shield Bracket Removal Remove the Rear Cover (RRP 1, on page 7-154). Remove the Rear Shield (RRP 9, on page 7-163). Remove the three screws securing the Rear Shield Bracket to the printer. Remove the Rear Shield Bracket.
Page 195: Figure 7-11 24 Vdc Power Supply Shield
RRP 11 24 VDC Power Supply Shield S7700-424 Figure 7-11 24 VDC Power Supply Shield Removal Remove the Rear Cover (RRP 1, on page 7-154). Remove the Rear Shield (RRP 9, on page 7-163). Remove the Rear Shield Bracket (RRP 10, on page 7-164). Remove the four screws securing the 24 VDC Power Supply Shield to the printer.
Page 196: Figure 7-12 Mpt Assembly
RRP 12 Multi-Purpose Tray (MPT) Assembly Figure 7-12 MPT Assembly Removal Note Complete MPT removal is not necessary when doing jobs such as shutter solenoid or main motor assembly replacement. Remove the two MPT screws (step 5 below), and let the MPT hang by the wire harness for partial removal.
Page 197: Figure 7-13 Multi-Purpose Tray Pick Rollers
RRP 13 Multi-Purpose Tray Paper Pick Rollers S7700-086 Figure 7-13 Multi-Purpose Tray Pick Rollers Removal Open the left side door. Locate the pick rollers near the duplex chute. Slide the white retainers away from the pick rollers. Slide the pick rollers off the retaining pins. Lift and remove the pick rollers.
Page 198: Figure 7-14 Left-Hand Cover Assembly (Left-Hand Door)
RRP 14 Left-Hand Cover Assembly (Left-Hand Door) Figure 7-14 Left-Hand Cover Assembly (Left-Hand Door) Partial Removal Partially remove the Multi-Purpose Tray (RRP 12, on page 7-166). Remove one screw from the plastic harness cover inside the empty MPT slot and remove the plastic cover. Open the Left-Hand Door.
Page 199: Figure 7-15 Damper Teeth Alignment
Remove the retaining clip off the restraint post. Support the Left-Hand Door, and then remove the restraining bracket from the door. While supporting the left side door, carefully lower it to 75-90° then remove the door by lifting it up off the pivot points. Replacement Reverse the above steps to install the Left-Hand Cover Assembly (Left-Hand Door).
Page 200: Figure 7-16 Duplex Chute
RRP 15 Duplex Chute S7700-430 Figure 7-16 Duplex Chute Removal Partially remove the Left-Hand Cover Assembly (Left Door) (RRP 14, on page 7-168). Rotate the Duplex Chute downward until the keyed pivot shaft can be removed from the pivot bracket. Remove the Duplex Chute.
Page 201: Figure 7-17 Duplex Unit Assembly
RRP 16 Duplex Unit Assembly Duplex Unit Cover CLIP S7700-094 Figure 7-17 Duplex Unit Assembly Removal Release the clip securing the Duplex Unit Cover and remove the cover. Loosen the two captive screws securing the Duplex Unit Assembly to the Left-Hand Cover Assembly and remove.
Page 202: Figure 7-18 Transfer Roller Assembly (2Nd Btr)
RRP 17 Transfer Roller Assembly (2nd BTR) S7700-458 Figure 7-18 Transfer Roller Assembly (2nd BTR) Special Tool required: 2.5 mm hex driver Removal Open the Left-Hand Cover Assembly (Left Door). Using a 2.5 mm hex driver, remove the four captive screws from the mounting brackets (2) at each end of the Transfer Roller Assembly.
Page 203: Figure 7-19 Inverter Transport Assembly
RRP 18 Duplex Transport Assembly E-clip S7700-030 Figure 7-19 Inverter Transport Assembly Removal Partially remove the Left-Hand Cover Assembly (Left Door) (RRP 14, on page 7-168). Remove the e-clip and remove the shaft. Remove the two screws that secure the Inverter Transport Assembly to the Left-Hand Door and remove the Inverter transport assembly.
Page 204: Figure 7-20 Fuser Unit
RRP 19 Fuser Unit S7700.031 Figure 7-20 Fuser Unit Removal Open the Left-hand Door. Caution The Fuser Unit may be hot. Unscrew the two thumb screws securing the Fuser Unit. Using the pull handles, pull the Fuser Unit out of the printer. 7-174 Phaser 7700 Color Laser Printer Service Manual...
Page 205: Figure 7-21 Registration Transport Assembly
RRP 20 Registration Transport Assembly Figure 7-21 Registration Transport Assembly Note Turn the printer power Off and unplug the power cord. Removal Partially remove the MPT. Remove the two screws from the plastic flanges that secure the assembly in the printer frame using a stubby screwdriver. Caution Note the wiring harness routing in the above figure.
Page 206: Figure 7-22 Shutter Solenoid Assembly
RRP 21 Shutter Solenoid Assembly Figure 7-22 Shutter Solenoid Assembly Removal Partially remove the MPT (RRP 12, on page 7-166). Partially remove the Left-Hand Cover Assembly (Left Door) (RRP 14, on page 7-168). Remove the Registration Transport Assembly (RRP 20, on page 7-175). Note Note the wiring.
Page 207: Figure 7-23 Tray 1 Feeder Assembly
RRP 22 Tray 1 Feeder Assembly and Paper Lift Motor S7700-009 Figure 7-23 Tray 1 Feeder Assembly Removal Remove the Left-Hand Lower Cover Assembly (RRP 6, on page 7-160). Open Tray 1 halfway. Disconnect the wiring harness. Remove the two screws holding the Tray 1 feeder assembly, not the screws securing the lower tray bracket.
Page 208: Figure 7-24 Waste Cartridge, Waste Cartridge Cover And Waste Cartridge Sensor Holder
RRP 23 Waste Cartridge Sensor Holder Waste Cartridge Cover Waste Cartridge C-Clip FRONT Waste Cartridge Sensor Holder S7700-015 Figure 7-24 Waste Cartridge, Waste Cartridge Cover and Waste Cartridge Sensor Holder Removal Open the Front Door. Open the Waste Cartridge Cover. Caution To avoid a toner spill and subesquent cleanup, use great care in removing the Waste Cartridge.
Page 209: Figure 7-25 Print Cartridge Plate Cover (Plastic)
RRP 24 Print Cartridge Plate Cover S7700-446 Figure 7-25 Print Cartridge Plate Cover (plastic) Removal Print Cartridge Plate Cover Open the Front Door. Remove Fuser Front Cover (RRP 8, on page 7-162). Lower the main lever. Remove the four screws. Remove the plastic Print Cartridge Plate Cover.
Page 210: Figure 7-26 Dispense Assembly
RRP 25 Dispense Assembly Figure 7-26 Dispense Assembly Removal Note After replacing the Print Cartridge Plate Assembly, you must perform the RegiCon adjustment to the printer ,on page 4-130. Caution Use only a type II toner vacuum to clean up toner spills. Note Have a large sheet of newspaper or something similar available to place the removed assemblies on.
Page 211 Pull the shut off gate of each toner cartridge toward you (approximately 3/4” [or 20mm]) to shut off the toner supply for each toner tube (see Figure 7-26, “Dispense Assembly,” on page 7-180). Caution Be careful when moving the stops. They are easily broken and may come out completely.
Page 212: Figure 7-27 Print Cartridge Plate Assembly
RRP 26 Print Cartridge Plate Assembly Removal Caution The Print Cartridges are very light sensitive. Store the Print Cartridge away from light. Do not touch the surface of the Print Cartridges. Remove the Print Cartridges Leave the main lever down. Remove the Waste Cartridge Sensor Holder (RRP 23, on page 7-178).
Page 213: Figure 7-28 Print Cartridge Plate Assembly (Cont'd.)
Figure 7-28 Print Cartridge Plate Assembly (cont’d.) Remove the Print Cartridge Plate Cover (RRP 24, on page 7-179). Remove the Dispense Assemblies (RRP 25, on page 7-180). Disconnect the wiring harnesses to all four Developer Housing Assemblies and remove them from under their retaining clips and dress the wires so they stick straight out the front of the printer.
Page 214 11.Disconnect the harness. 12.Remove the Print Cartridge Plate Assembly. Replacement. Note Ensure the developer assemblies are fully and evenly seated when reinstalling the Print Cartridge Plate Assembly. There is a locating pin at the back of each developer housing assembly. Note Lightly tug the wires to ensure that they are not pinched by the plate or developers while reinstalling.
Page 215: Figure 7-29 Developer Housing Assembly
RRP 27 Developer Housing Assembly Figure 7-29 Developer Housing Assembly Removal Note Complete removal of the Print Cartridge Plate Assembly is not required for removal of the Developer(s). Tilt the Print Cartridge Plate Assembly forward enough to allow the Developer(s) to be removed. Do not disconnect the Print Cartridge Plate harnesses.
Page 216: Figure 7-30 Developer Housing Assembly Recharge
RRP 28 New Developer Housing Assembly Charging Figure 7-30 Developer Housing Assembly Recharge Recharging a Developer Housing Assembly Caution If replacing a Developer Housing Assembly, write down the new ATC tag number. Remove the tear-off ATC tag number label, and adhere it to the appropriate print cartridge connector on the print cartridge plate assembly, then perform the procedure.
Page 217 Caution During this procedure, the Developer Housing Assembly must be kept in a level position at all times. It is recommended the Developer Housing Assembly be fully supported level by laying it on something like a large piece of cloth, paper towels or styrofoam hollowed out for the Developer Housing Assembly to lie on.
Page 218: Figure 7-31 Toner Dispense Motor Assembly
RRP 29 Toner Dispense Motor Assembly Figure 7-31 Toner Dispense Motor Assembly Removal Remove Right Cover (RRP 2, on page 7-155) and the Top Cover Assembly (RRP 3, on page 7-156). Remove the Dispense Housing Assemblies (RRP 25, on page 7-180). Remove the two screws that secure the Toner Dispense Motor Assembly to the printer frame.
Page 219: Figure 7-32 Steering Drive Assembly
RRP 30 Steering Drive Assembly S700-012 Figure 7-32 Steering Drive Assembly Removal Remove the Print Cartridges and Print Cartridge Plate Cover (RRP 24, on page 7-179). Disconnect the wiring harness. Remove the three screws and remove the Steering Drive Assembly. Note You may have to rotate the CAM gear to reinstall the Steering Drive Assembly.
Page 220: Figure 7-33 Waste Toner Agitator Motor Assembly
RRP 31 Waste Toner Agitator Motor Assembly S7700-016 Figure 7-33 Waste Toner Agitator Motor Assembly. Removal Remove the Print Cartridge Plate Cover (RRP 24, on page 7-179). Remove the Waste Cartridge Assemblies (RRP 23, on page 7-178). Disconnect the wiring harness to the motor. Remove the two screws that secure the Agitator Motor Assembly to the printer frame.
Page 221: Figure 7-34 Mark-On-Belt Sensor
RRP 32 Mark-On-Belt (MOB) Sensor Figure 7-34 Mark-On-Belt Sensor Removal Remove the Waste Cartridge Assembly (RRP 23, on page 7-178). Remove the Waste Toner Agitator Motor (RRP 31, on page 7-190). Remove left-hand inner cover. Disconnect the purple harness. Remove the wiring harness from three clips. Remove the one black screw and remove the Mark-On-Belt assembly Note If the Mark-On-Belt adjustment procedure (RegiCon...
Page 222: Figure 7-35 Exit Transport Assembly
RRP 33 Exit Transport Assembly S7700-084 Figure 7-35 Exit Transport Assembly Removal Remove the Rear Cover (RRP 1, on page 7-154). Remove Left-Hand Top Power Switch Cover (RRP 5, on page 7-158). Remove the Fuser Front Cover (RRP 8, on page 7-162). Open left-hand cover.
Page 223: Figure 7-36 Reconfigured Inverter
Reconfigured Inverter Transport Assembly (P/N 116-1161-00) Note When replacing the Inverter Transport Assembly, do not transfer any parts from the original assembly to the replacement asssembly. The replacement assembly will work correctly in the Phaser 7700 printer. Parts required for the Side Exit Exit Assembly (an option not available on the Phaser 7700) are no longer installed on the Inverter Transport Assembly (P/N 116-1161-00).
Page 224: Figure 7-38 Interlock Actuator And Spacers
The Interlock Actuator and two 0.5 mm spacers are now being added to the Inverter Transport Assembly packaging as a separate item (see Figure 7-38). If only the Interlock Actuator is broken, it can now be replaced individually. The 0.5 mm spacers should be placed between the Interlock Actuator and the Inverter Transport Assembly.
Page 225: Figure 7-39 Fuser Fan Assembly
RRP 34 Fuser Fan Assembly Locating Pin S7700-025 Figure 7-39 Fuser Fan Assembly Removal Remove the Rear Cover (RRP 1, on page 7-154). Remove the Top Cover (RRP 3, on page 7-156). Remove Right Side Cover (RRP 2, on page 7-155). Note Note the routing of the wiring harness.
Page 226: Figure 7-40 Accumulator Belt Assembly
RRP 35 Accumulator Belt Assembly Figure 7-40 Accumulator Belt Assembly 7-196 Phaser 7700 Color Laser Printer Service Manual...
Page 227 Removal Open the right cover door. Open the front cover and lower the main lever. Lift the Accumulator Belt locking lever and pull the assembly out of the printer. You need to hold the locking lever up until the white nylon handle is exposed.
Page 228: Figure 7-41 Belt Cleaner Assembly
RRP 36 Belt Cleaner Assembly S7700-022 Figure 7-41 Belt Cleaner Assembly Removal Open the right cover door. Open the front cover and lower the main lever. Lift the Accumulator Belt locking lever and pull the assembly out a few inches. Using a 2.5 mm hex driver remove the two screws on the left side of the belt cleaner assembly.
Page 229: Figure 7-42 Waste Auger Assembly
RRP 37 Waste Auger Assembly S7700-438 Figure 7-42 Waste Auger Assembly Removal Remove the Right Side Cover (RRP 2, on page 7-155). Remove Waste Toner Cartridge and lower the main lever. Remove Accumulator Belt assembly. Return the main lever to its upright position. Remove the two screws securing the Waste Auger Assembly.
Page 230: Figure 7-43 Laser Unit Assembly
RRP 38 Laser Unit Figure 7-43 Laser Unit Assembly 7-200 Phaser 7700 Color Laser Printer Service Manual...
Page 231: Figure 7-44 Laser Unit Label
Removal Remove the Rear Cover (RRP 1, on page 7-154). Remove the Right-Hand Cover (RRP 2, on page 7-155). Disconnect the wiring harnesses at engine board P400 and 401. Undo the retainers and undo the wiring harness. Note Note the routing of the laser unit wiring harness up to the engine control board.
Page 232: Figure 7-45 Image Processor Board Assembly
RRP 39 Image Processor Board Assembly NVRAM (socketed) S7700-454 Figure 7-45 Image Processor Board Assembly. Note Turn the printer power Off and unplug the printer. Caution The Image Processor Board is susceptible to ESD damage. Observe proper ESD procedures. Disconnect all communication cables. Remove the four screws and remove the image processor board.
Page 233: Figure 7-46 Internal Hard Drive
RRP 40 Internal Hard Drive Fig. 1 Fig. 2 S7700-434 Figure 7-46 Internal Hard Drive Caution The Internal Hard Drive is susceptible to ESD damage. Observe proper ESD procedures. Remove the Image Processor Board. See (RRP 39, on page 7-202). Using a T-10 torx bit, remove four screws on the bottom side of the Image Processor Board holding the Internal Hard Drive.
Page 234: Figure 7-47 Electrical Chassis Assembly
RRP 41 Electrical Chassis (Card Cage) Assembly Figure 7-47 Electrical Chassis Assembly Removal Caution Before removing the Electrical Chassis Assembly, it is recommended to store Engine NVRAM data on the Hard Drive (see Store Engine NVRAM on page 6-150). Remove the Right Cover (RRP 1, on page 7-154). Remove the Top Cover (RRP 3, on page 7-156).
Page 235 Undo the harness retainer. Disconnect the wiring harness to the relay board connector P300 and the front panel cable to P564. Remove the two mounting screws towards printer rear, but only loosen the two mounting screws towards the printer front. Note The two screws toward the printer front serve as a guide for reinstallation.
Page 236: Figure 7-48 Engine Control Board
RRP 42 Engine Control Board Engine Control Board S7700-457 Figure 7-48 Engine Control Board Removal Store the engine board NVRAM values to the hard drive (Store Engine NVRAM on page 6-150). Remove the Electrical Chassis (Card Cage) Assembly (RRP 41, on page 7-204) Disconnect the orange ribbon cable at the engine board connector P460.
Page 237: Figure 7-49 Engine Control Interface Board
RRP 43 Engine Control Interface Board Figure 7-49 Engine Control Interface Board Removal Method #1 Remove the Engine Control Board (RRP 42, on page 7-206). Disconnect the eight wiring harnesses. Note Two connectors (J537, J536) have locks to release before pulling on the harnesses. Remove the two screws that secure the Engine Control Interface Board mounting bracket to the printer frame.
Page 238: Figure 7-50 T1 And T3 High-Voltage Power Supplies
RRP 44 T1 and T3 High-voltage Power Supplies Figure 7-50 T1 and T3 High-voltage Power Supplies Removal Remove rear cover and shield (RRP 9, on page 7-163). Note Do not disconnect the T1 wire harness at P572 (blue connector). Disconnect the wiring harness at P/J501 and P/J574. Disconnect the high-voltage wires to the Transfer Roller and at DTS (J801).
Page 239 Replacement Note Connect the high-voltage 2nd BTR and P/J 801 wires before securing the assembly to the printer to ensure they are not forgotten. Note The grounding point requires the chrome plated screw (not a black screw). 7-209 Phaser 7700 Color Laser Printer Service Manual...
Page 240: Figure 7-51 3.3 Vdc And 5 Vdc Low-Voltage Power Supplies
RRP 45 3.3 VDC and 5 VDC Low-Voltage Power Supplies and Bracket Figure 7-51 3.3 VDC and 5 VDC Low-Voltage Power Supplies Removal Note If removing only one of the low-voltage power supplies, disconnect the associated wiring harness from the printer, and remove the 4 screws that secure the low-voltage power supply to the mounting bracket.
Page 241: Figure 7-52 Ld Power Relay
RRP 46 LD Power Relay Fig. 1 Fig. 2 S7700-431 Figure 7-52 LD Power Relay Removal Remove rear cover and shield (RRP 9, on page 7-163). Disconnect the wiring harness. Remove the two screws securing the LD power assembly. Remove the LD power assembly. 7-211 Phaser 7700 Color Laser Printer Service Manual...
Page 242: Figure 7-53 Low-Voltage Power Supply, Fan And Bracket
RRP 47 +24 VDC Low-voltage Power Supply, Fan and Bracket Figure 7-53 Low-voltage Power Supply, Fan and Bracket Removal Remove the rear cover and +24 VDC shield (RRP 11, on page 7-165). Remove the Top Power Switch Cover, Left-Hand Power Switch and Left-Hand Rear Mid Covers (RRP 6, on page 7-160).
Page 243: Figure 7-54 T2 High-Voltage Power Supply
RRP 48 T2 High-Voltage Power Supply Figure 7-54 T2 High-Voltage Power Supply Removal Remove the +24 VDC Power Supply and Bracket (RRP 11, on page 7-165). Disconnet the high-voltage wires from the KCMY connectors. Disconnect the wiring harness from J575 and J576. Remove the two screws that secure the 1 BTR assembly to the printer frame.
Page 244: Figure 7-55 Chassis Ac Power Assembly
RRP 49 Chassis AC Power Assembly S7700-439 Figure 7-55 Chassis AC Power Assembly Removal Note AC power (consists of the AC drive, noise filter and GFI assemblies and mounting bracket. Remove the T2 high-voltage power supply (RRP 48, on page 7-213). Remove T1 and T3 power supply assembly (RRP 44, on page 7-208).
Page 245: Figure 7-56 Main Drive Assembly
RRP 50 Main Drive Assembly Do NOT remove these 5 screws S7700-002 Figure 7-56 Main Drive Assembly Removal Remove the Fuser (RRP 18, on page 7-173). Remove the Multi-Purpose Tray (RRP 12, on page 7-166). Remove the T2 high-voltage power supply (RRP 48, on page 7-213). Disconnect the wiring harness.
Page 246 Note As the main drive assembly is being installed into position, make sure the gears are meshed with the mating gears by slightly rotating the main motor until the main motor bracket seats without stress, and flat against the frame. Rotate the main drive after installing the assembly to ensure it rotates freely, and ensure it is FLAT against the frame.
Page 247: Figure 7-57 Accumulator Belt Drive Assembly
RRP 51 Accumulator Belt Drive Assembly S7700-007 Figure 7-57 Accumulator Belt Drive Assembly Removal Remove the Rear Cover and Shield (RRP 9, on page 7-163). Lower the T1 and T3 power supply to horizontal (RRP 44, on page 7-208). Remove any components covering the motor which is mounted to the frame at the rear, top left corner.
Page 248: Figure 7-58 Developer Drive Assembly
RRP 52 Developer Drive Assembly S7700-008 Figure 7-58 Developer Drive Assembly Removal Remove the 3.3 VDC and 5 VDC Power Supply and bracket assembly (RRP 45, on page 7-210). Disconnect the wiring harness from the Developer Drive Assembly. Clear the high-voltage lines. Remove the two black screws securing the Developer Drive Assembly to the printer frame and remove from the printer.
Page 249: Figure 7-59 Print Cartridge Drive Assembly
RRP 53 Print Cartridge Drive Assembly S7700-006 Figure 7-59 Print Cartridge Drive Assembly Removal Remove the Rear Cover Assembly (RRP 1, on page 7-154). Remove the Right Cover Assembly (RRP 2, on page 7-155). Remove the 3.3 VDC and 5 VDC Low-voltage Power Supply Bracket Assembly (RRP 45, on page 7-210) Remove the 24 VDC Low-voltage Power Supply (RRP 47, on page 7-212).
Page 250: Figure 7-60 Tray 1 Paper-Select Switches
RRP 54 Tray 1 Paper-Select Switches S7700-442 Figure 7-60 Tray 1 Paper-Select Switches Remove the T1 and T3 high-voltage power supply (RRP 44, on page 7-208). Remove the 3.3 VDC and 5 VDC low-voltage power supply (RRP 45, on page 7-210). Disconnect the wiring harness from the tray 1 paper-select switches.
Page 251: Figure 7-61 Main Lever, Right-Hand And Left-Hand Jacks
RRP 55 Main Lever Assembly Right and Left-Hand Jacks S7700-455 Figure 7-61 Main Lever, Right-Hand and Left-Hand Jacks Removal - Main Lever Assembly Remove the Accumulator Belt Assembly (RRP 35, on page 7-196). Remove the Print Cartridges and protect from the light. Remove Fuser Front Cover (RRP 8, on page 7-162).
Page 252 Remove the two screws holding the Waste Auger Assembly. Remove the four screws holding the RH Lift Jack Bracket and remove from the printer. Note When reinstalling the RH Lift Jack Assembly install the screws as follows: Upper Left, Upper Right, then the lower screws.
Page 253: Figure 7-62 Lift Pin Alignment
Aligning Lift Jack Assembly Gears Visually examine both ends of the Accumulator Belt Assembly or Belt Lift Frame Assembly while operating the Lift Handle to determine if the left or right end is out of alignment. Then follow the applicable procedure in Main Lever Assembly Right and Left-Hand Jacks on page 7-221 to remove the affected Lift Jack Assembly.
Page 254: Figure 7-64 Cover Removed
Flip open the Cover Plate. s7700-563 Figure 7-64 Cover Removed Remove the tension spring. s7700-564 Figure 7-65 Tension Spring Location Align the triangle marks on the Gears and the Rack by lifting the Gear Assemblies on their mounting posts until they disengage from the rack and rotating them until the triangles align.
Page 255: Figure 7-67 Auxiliary Feeder Covers
RRP 56 Auxiliary Feeder Covers S7700-440 Figure 7-67 Auxiliary Feeder Covers Left Side Door Remove the four screws securing the left-hand outer cover and remove. Remove the screws securing the straps. Remove the one screw holding the front side pivot bracket and remove the left-hand door.
Page 256: Figure 7-68 High-Capacity Feeder (Hcf) Cover Assembly
RRP 57 Auxiliary Feeder Cover Assembly H Cover Interlock Switch RH Pivot Bracket 7700-105 Figure 7-68 High-Capacity Feeder (HCF) Cover Assembly Removal Open the High-Capacity Feeder (HCF) Cover Assembly. Remove one screw from each of the support straps. Remove one screw from the cover’s right-hand pivot bracket. Remove the cover assembly from the left-hand pivot.
Page 257: Rrp 58 High-Capacity Feeder (Hcf) Tray 3
RRP 58 High-Capacity Feeder (HCF) Tray 3 Figure 7-69 High-Capacity Feeder (HCF) Tray 3 Removal On the left side of the HCF, remove one screw from the Tray 3 Stopper bracket and remove the bracket. Pull Tray 3 out of the printer. 7-227 Phaser 7700 Color Laser Printer Service Manual...
Page 258: Figure 7-70 High-Capacity Feeder (Hcf) Tray 4 And Paper Transport
RRP 59 High-Capacity Feeder (HCF) Tray 4 and Paper Transport Figure 7-70 High-Capacity Feeder (HCF) Tray 4 and Paper Transport Removal Open Tray 4. Remove the two screws that secure the Tray 4 Stopper. Remove the two screws securing the paper transport, and slide it back in. Pull Tray 4 out of the printer.
Page 259: Figure 7-71 Ltd Control Or Hcf Control Board
RRP 60 Auxiliary Feeder Control Boards S7700-441 Figure 7-71 LTD Control or HCF Control Board Removal Remove the Rear Cover (RRP 1, on page 7-154). Disconnect the wire harnesses. Remove the four screws securing the control board and remove the board. 7-229 Phaser 7700 Color Laser Printer Service Manual...
Page 260: Figure 7-72 Transport Motor Assembly
RRP 61 Auxiliary Feeders Motor Assemblies HCF only transport motor S7700-110 Figure 7-72 Transport Motor Assembly Removal Remove Rear Cover (RRP 1, on page 7-154). Disconnect the wire harness. Remove the two screws securing the motor assembly. Remove the motor assembly. 7-230 Phaser 7700 Color Laser Printer Service Manual...
Page 261: Figure 7-73 Paper-Select Switches
RRP 62 Auxiliary Feeder Paper-Select Switches Universal Tray Paper Select Switch (3X) Universal Tray Assembly S7700-069 Figure 7-73 Paper-Select Switches Removal Remove the Paper Tray. Reaching inside the cabinet, disconnect the wire harness. LTD: 3 places. HCF: 1 place Reaching inside the cabinet, remove the 1 screw that secures the Paper-Select Switch.
Page 262: Figure 7-74 Paper Feed Motor Assembly And Chute (Lta & Hcf)
RRP 63 Auxiliary Feeder Paper Feed Motor Assembly Paper Feed Motor Assembly Trays 2 & 3 - HCF Trays 2, 3, & 4 - LTA LEFT SIDE Chute to Lower S7700-102 Figure 7-74 Paper Feed Motor Assembly and Chute (LTA & HCF) Removal Remove the Left-Hand Cover.
Page 263: Figure 7-75 Bracket Assembly, Gear Rh & Gear Lh (Hcf)
RRP 64 Bracket Assembly, Left-Hand and Right-Hand Gear (HCF) Bracket Assembly Gear LH (HCF) Bracket Assembly Gear RH (HCF) S7700-421 Figure 7-75 Bracket Assembly, Gear RH & Gear LH (HCF) Removal Remove the Rear Cover (RRP 1, on page 7-154). Remove the two screws securing the Bracket Assembly (Gear RH or Gear LH) to the frame.
Page 264 7-234 Phaser 7700 Color Laser Printer Service Manual...
Page 265: Fru Parts List
This topic provides a list of Field Replaceable Units (FRUs) for the Phaser 7700 Color Laser Printer. Changes to Xerox products are made to accommodate improved components as they become available. It is important when ordering parts to include the...
Page 266: Table 8-1 Accumulator Belt Frus List
PL 8-1 Accumulator Belt FRUs Right-Hand Side S7700-051 Figure 8-1 Accumulator Belt FRUs Table 8-1 Accumulator Belt FRUs List Parts Part Number Name and Description (vendor description) 016-1889-00 Accumulator Belt/cleaner Assembly Kit (Belt Assembly - IBT) 116-1207-00 Accumulator Belt Shipping Restraint 116-1094-00 Belt Cleaner Assembly (Cleaner Assembly IB) 116-1180-00...
Page 267: Pl 8-2 Left-Hand Door Frus
PL 8-2 Left-Hand Door FRUs S7700-042 Figure 8-2 Left-Hand Door FRUs Phaser 7700 Color Laser Printer Service Manual 8-237...
Page 268: Table 8-2 Left-Hand Door Frus List
Table 8-2 Left-Hand Door FRUs List Parts Part Number Name and Description (vendor description) 116-1161-00 Transport Assembly, Inverter 116-1182-00 Regi. Chute Assembly 116-1317-00 Left-Hand Cover only (Cover Assembly-L/H2) 016-1890-00 Transfer Roller (Roll Assembly 2nd E) 116-1098-00 Duplex Chute (DUP Chute) 116-1542-00 Damper, 1/2 Gear 116-1540-00...
Page 269: Table 8-3 Media Trays Frus List
PL 8-3 Media Trays FRUs S7700-048 Figure 8-3 Media Trays FRUs Table 8-3 Media Trays FRUs List Parts Part Number Name and Description (vendor description) 116-1091-00 Universal Paper Tray 116-1093-00 Universal Paper Tay Stopper Spacer Phaser 7700 Color Laser Printer Service Manual 8-239...
Page 270: Table 8-4 Duplex Unit Frus List
PL 8-4 Duplex Unit FRUs S7700-064 Figure 8-4 Duplex Unit FRUs Table 8-4 Duplex Unit FRUs List Parts Part Number Name and Description (vendor description) 116-1097-00 Duplex Unit (Transport Assembly - DU) 8-240 Phaser 7700 Color Laser Printer Service Manual...
Page 271: Table 8-5 Cover Frus List
PL 8-5 Cover FRUs S7700-058 Figure 8-5 Cover FRUs Table 8-5 Cover FRUs List Parts Part Number Name and Description (vendor description) 116-1178-00 Front Cover Assembly (Cover Assembly Front) Front Cover Magnet Strip Rod Cleaner Assembly Rod Cleaner Cleaner Base Label Label 116-1095-00...
Page 272: Table 8-6 Cover Frus (Cont'd.) List
PL 8-6 Cover FRUs (cont’d.) S7700-039 Figure 8-6 Cover FRUs (cont’d.) Table 8-6 Cover FRUs (cont’d.) List Parts Part Number Name and Description (vendor description) 116-1181-00 LH Lower Cover Assembly (Cov Assembly-LH Low) LH Lower Cover Earth Plate Magnet Pinch Roll Assembly Bracket Spring Pinch Roller...
Page 273: Figure 8-7 Cover Frus (Cont'd.)
PL 8-7 Cover FRUs (cont’d.) S7700-060 Figure 8-7 Cover FRUs (cont’d.) Phaser 7700 Color Laser Printer Service Manual 8-243...
Page 274: Table 8-7 Covers Frus List (Cont'd.)
Table 8-7 Covers FRUs List (cont’d.) Parts Part Number Name and Description (vendor description) 116-1179-00 Rear Cover Assembly (Cover Assembly Rear) Blind Cover 116-1190-00 Cover, Top Rear ps (Cover Top Rear) 116-1189-00 Cover, LH Rear Mid 116-1193-00 Cover, LH Front Low 116-1191-00 Cover, LH Rear Low 116-1188-00...
Page 275: Figure 8-8 Switch And Sensor Frus
PL 8-8 Switch and Sensor FRUs 3 3 3 3 S7700-407 Figure 8-8 Switch and Sensor FRUs Phaser 7700 Color Laser Printer Service Manual 8-245...
Page 276: Table 8-8 Switch And Sensor Frus List
Table 8-8 Switch and Sensor FRUs List Parts Part Number Name and Description (vendor description) 116-1299-00 Waste Cartridge Full Sensor (part of Sensor Kit) 116-1124-00 Mark-On-Belt (MOB) Sensor Assembly 116-1299-00 Automatic Toner Cal (ATC) Sensor Assembly (part of Sensor Kit) 116-1126-00 Paper-Select Switch Assembly (Switch Assembly PS) - Tray 2/3 Paper Size Switch (also 4/5 on LTA)
Page 277: Figure 8-9 Switch And Sensor Frus (Cont'd.)
PL 8-9 Switch and Sensor FRUs (cont’d.) S7700-415 Figure 8-9 Switch and Sensor FRUs (cont’d.) Phaser 7700 Color Laser Printer Service Manual 8-247...
Page 278: Table 8-9 Switch And Sensor Frus List (Cont'd.)
Table 8-9 Switch and Sensor FRUs List (cont’d.) Parts Part Number Name and Description (vendor description) 116-1210-00 Paper Detect Flag, MPT (part of Sensor Flag Kit) 116-1132-00 Laser Shutter Solenoid Assembly 116-1299-00 Paper Feed Sensor (part of Sensor Kit) - mounted on LH Lower Cover 116-1299-00 LH Lower Cover Sensor (part of Sensor Kit)
Page 279: Figure 8-10 Circuit Boards Frus
PL 8-10 Circuit Boards FRUs S7700-095 Figure 8-10 Circuit Boards FRUs Phaser 7700 Color Laser Printer Service Manual 8-249...
Page 280: Table 8-10 Circuit Board Frus List
Table 8-10 Circuit Board FRUs List Parts Part Number Name and Description (vendor description) 116-1145-00 Chassis Assembly, Elec (Chassis, E, B) 116-1144-00 Engine Control Board (PWBA MCU) 671-5268-02 Image Processor Board RAM SODIMM 156-4832-00 128 MB 156-4663-00 256 MB 650-4199-01 Internal Hard Drive, Programmed 7700 8-250 Phaser 7700 Color Laser Printer Service Manual...
Page 281: Pl 8-11 Power Supplies Frus
PL 8-11 Power Supplies FRUs 24 V LVPS 8, 9 24 V PS Fan (T2 HVPS) (T3 HVPS) 6, 7 5 V LVPS 4, 5 3.3 V LVPS (T1 HVPS) T1 Control bd S7700-053 Figure 8-11 Power Supplies FRUs Phaser 7700 Color Laser Printer Service Manual 8-251...
Page 282: Table 8-11 Power Supplies Frus List
Table 8-11 Power Supplies FRUs List Parts Part Number Name and Description (vendor description) 116-1146-00 High-Voltage Power Supply -T1(PSHVT1) T1 Control Board 116-1147-00 High-Voltage Power Supply -T2 (PSHVT2) 116-1148-00 High-Voltage Power Supply - T3 (PSHVT3) 116-1149-00 Low-Voltage Power Supply (3V), 110V (PSLV LF308) 116-1150-00 Low-Voltage Power Supply (3V), 220V (PSLV LF308 116-1151-00...
Page 283: Figure 8-12 Power Supplies Frus (Cont'd.)
PL 8-12 Power Supplies FRUs (cont’d.) AC drive bd Noise filer 1, 2 S7700-054 Figure 8-12 Power Supplies FRUs (cont’d.) Phaser 7700 Color Laser Printer Service Manual 8-253...
Page 284: Table 8-12 Power Supplies Frus List (Cont'd.)
Table 8-12 Power Supplies FRUs List (cont’d.) Parts Part Number Name and Description (vendor description) 116-1155-00 Chassis Assembly - AC Power, 110V Bracket AC Drive Board Clamp Noise filter GFI Breaker Wire harness Wire harness Wire harness Wire harness Screw Wire Harness 116-1156-00 Chassis assembly - AC Power, 220V...
Page 285: Figure 8-13 Motors/Drivers Frus
PL 8-13 Motors/Drivers FRUs REAR FRONT S7700-034 Figure 8-13 Motors/Drivers FRUs Phaser 7700 Color Laser Printer Service Manual 8-255...
Page 286: Table 8-13 Motors / Drivers Frus List
Table 8-13 Motors / Drivers FRUs List Parts Part Number Name and Description (vendor description) 116-1102-00 Print Cartridge Drive Assembly (Drive Assembly Drum) Motor Gear Bracket Assembly 116-1103-00 Accumulator Belt Drive Assembly (Drive Assembly IBT) Accumulator Motor Assembly Gear Bracket Assembly 116-1105-00 Main Drive Assembly (Drive Assembly main) 116-1106-00...
Page 287: Figure 8-14 Electrophotographic Components Frus
PL 8-14 Electrophotographic Components FRUs S7700-013 Figure 8-14 Electrophotographic Components FRUs Phaser 7700 Color Laser Printer Service Manual 8-257...
Page 288: Table 8-14 Electrophotographic Components Frus List
Table 8-14 Electrophotographic Components FRUs List Parts Part Number Name and Description (vendor description) 116-1110-00 Laser Unit (ROS Assembly) 116-1197-00 Print cartridge Plate Assembly 116-1118-00 Toner Dispense Base Assembly (Dispenser Base Assembly) Dispenser Base Gear Toner Dispense Motor (Y) Toner Dispense Motor (M) Toner Dispense Motor (C) Toner Dispense Motor (K) Shaft...
Page 289: Figure 8-15 Electrophotographic Components Frus (Cont'd.)
PL 8-15 Electrophotographic Components FRUs (cont’d.) Front ATC Sensor and Seal (4x) S7700-057 Figure 8-15 Electrophotographic Components FRUs (cont’d.) Phaser 7700 Color Laser Printer Service Manual 8-259...
Page 290: Table 8-15 Electrophotographic Components Frus List (Cont'd.)
Table 8-15 Electrophotographic Components FRUs List (cont’d.) Parts Part Number Name and Description (vendor description) 116-1115-00 Developer Housing Assembly (Hsg Assembly Deve) Developer Housing ATC Sensor Seal Note: requires one of the following: Developer, Black (Pkg Assembly DV K) 116-1111-00 Developer, Yellow (Pkg Assembly DV Y) 116-1112-00 Developer, Magenta (Pkg Assembly DV M)
Page 291: Pl 8-16 Multi-Purpose Tray Frus
PL 8-16 Multi-Purpose Tray FRUs S7700-045 Figure 8-16 Multi-Purpose Tray FRUs Phaser 7700 Color Laser Printer Service Manual 8-261...
Page 292: Table 8-16 Multi-Purpose Tray (Mpt) Frus List
Table 8-16 Multi-Purpose Tray (MPT) FRUs List Parts Part Number Name and Description (vendor description) 116-1157-00 Multi-Purpose Tray (MPT) Assembly 116-1158-00 MPT Tray Pinch Roller Assembly 1 (w 10,11, 13, 14,16) Pinch Roller Assembly 2 (w 13-17) Pinch Roller Assembly 3 (w 11, 13-16) 116-1159-00 Paper Pick Roller, MPT Feed Roller Assembly...
Page 293: Pl 8-17 Paper Feed Frus
PL 8-17 Paper Feed FRUs S7700-040 Figure 8-17 Paper Feed FRUs Phaser 7700 Color Laser Printer Service Manual 8-263...
Page 294: Table 8-17 Paper Feed Frus List
Table 8-17 Paper Feed FRUs List Parts Part Number Name and Description (vendor description) 116-1160-00 Paper Feeder Assembly (Feeder Assembly) Paper Feed Motor Assembly Roller Feed/Nudge/Retard 116-1109-00 Paper Feed Motor only (Motor Assembly) 116-1161-00 Transport Assembly, Inverter (Transport Inv) 116-1163-00 Roller Assembly, Feed/Nudge/Retard (Roll Assembly) 116-1164-00 Transport Assembly, Registration (Transport AV OPB)
Page 295: Figure 8-18 Paper Feed Frus (Cont'd.)
PL 8-18 Paper Feed FRUs (cont’d.) S7700-044 Figure 8-18 Paper feed FRUs (cont’d.) Phaser 7700 Color Laser Printer Service Manual 8-265...
Page 296: Table 8-18 Paper Feed Frus List (Cont'd.)
Table 8-18 Paper Feed FRUs List (cont’d.) Parts Part Number Name and Description (vendor description) 116-1165-00 Transport Assembly, Exit -OCT (Transport Assembly) Exit Cover Bearing Exit roller (OCT) Actuator Bracket Assembly Full Paper Stack Sensor Latch Assembly Spring Pinch Roller Pinch Roller LH Cover Interlock Switch Bracket...
Page 297: Table 8-19 Fans Frus List
PL 8-19 Fans FRUs S7700-408 Figure 8-19 Fans FRUs Table 8-19 Fans FRUs List Parts Part Number Name and Description (vendor description) 116-1176-00 Fuser Fan Assembly (Fan Fuser) 116-1175-00 24 VDC LVPS Fan Assembly (Fan Assembly PSLV) Phaser 7700 Color Laser Printer Service Manual 8-267...
Page 298: Pl 8-20 Lift Components Frus
PL 8-20 Lift Components FRUs S7700-050 Figure 8-20 Lift Components FRUs 8-268 Phaser 7700 Color Laser Printer Service Manual...
Page 299: Table 8-20 Lift Components Frus List
Table 8-20 Lift Components FRUs List Parts Part Number Name and Description (vendor description) 116-1198-00 Frame Lift Jack Assembly LH 116-1202-00 Main Latch Assembly 116-1204-00 Main Lever Assembly 116-1200-00 Hinge, Lever LH 116-1201-00 Hinge, Lever RH 116-1203-00 Pin, Main 116-1199-00 Frame Lift Jack Assembly RH Phaser 7700 Color Laser Printer Service Manual 8-269...
Page 300: Pl 8-21 Wiring Frus
PL 8-21 Wiring FRUs S7700-059 Figure 8-21 Wiring FRUs 8-270 Phaser 7700 Color Laser Printer Service Manual...
Page 301: Table 8-21 Wiring Frus List
Table 8-21 Wiring FRUs List Parts Part Number Name and Description (vendor description) 116-1223-00 Wire Harness - Dev Bias (Block Assembly In) 116-1312-00 Wire Harness - Charge Roller (Harness Assembly-BCR) 116-1307-00 Wire Harness - 1BTR - Y, M 116-1308-00 Wire Harness - 1BTR - C, K 116-1309-00 Wire Harness - 2BTR 116-1306-00...
Page 302: Figure 8-22 Auxiliary Feeder Frus
PL 8-22 Auxiliary Feeder FRUs S7700-409 Figure 8-22 Auxiliary Feeder FRUs 8-272 Phaser 7700 Color Laser Printer Service Manual...
Page 303: Table 8-22 Auxiliary Feeders Frus List
Table 8-22 Auxiliary Feeders FRUs List Parts Part Number Name and Description (vendor description) 116-1080-00 Lower Tray Deck (LTD) 116-1079-00 High-Capacity Feeder (HCF) 116-1184-00 Lower Tray Deck (LTD) cover LH (Cover Assembly LH 3) 116-1185-00 High-Capacity feeder (HCF) cover LH (Cover Assembly - H, T) 116-1091-00 Universal Paper Tray...
Page 304: Figure 8-23 Lower Tray Deck (Ltd) Frus
PL 8-23 Lower Tray Deck (LTD) FRUs S7700-107 Figure 8-23 Lower Tray Deck (LTD) FRUs 8-274 Phaser 7700 Color Laser Printer Service Manual...
Page 305: Table 8-23 Lower Tray Deck (Ltd) Frus List
Table 8-23 Lower Tray Deck (LTD) FRUs List Parts Part Number Name and Description (vendor description) 116-1100-00 Aux. Feeder Motor Assembly (Motor Assembly 3TM) 116-1219-00 LTD Control Board (PWB Assembly - 3TM) 116-1206-00 Caster, Locking 116-1221-00 Caster 116-1126-00 Switch Assy, Paper Select - Tray 2/3 Paper Size Switch (also 4/5 on LTA) 110K12990 (Phaser 7760...
Page 306: Table 8-24 Lower Tray Deck (Ltd) Frus List (Cont'd.)
PL 8-24 Lower Tray Deck (LTD) FRUs (cont’d.) S7700-459 Figure 8-24 Lower Tray Deck (LTD) FRUs (cont’d.) Table 8-24 Lower Tray Deck (LTD) FRUs List (cont’d.) Parts Part Number Name and Description (vendor description) 116-1167-00 Chute, Lower 116-1160-00 Feed Assembly, Paper 8-276 Phaser 7700 Color Laser Printer Service Manual...
Page 307: Table 8-25 High-Capacity Feeder Frus List
PL 8-25 High-Capacity Feeder FRUs S7700-412 Figure 8-25 High-Capacity Feeder FRUs Table 8-25 High-Capacity Feeder FRUs List Parts Part Number Name and Description (vendor description) 116-1100-00 Aux. Feeder Motor Assembly (Motor Assembly 3TM) 116-1220-00 HCF Control Board (PWB Assembly - TTM) 116-1206-00 Caster, Locking 116-1221-00...
Page 308: Table 8-26 High-Capacity Feeder Frus List (Cont'd.)
PL 8-26 High-Capacity Feeder FRUs (cont’d.) S7700-074 Figure 8-26 High-Capacity Feeder FRUs (cont’d.) Table 8-26 High-Capacity Feeder FRUs List (cont’d.) Parts Part Number Name and Description (vendor description) 116-1168-00 Chute to Lower (Chute F/O - Lower) 116-1169-00 Chute to Upper (Chute F/O - Upper) 116-1218-00 HFC tray 4 Feed out Sensor (Reflect Sensor GP2A25)) 116-1172-00...
Page 309: Table 8-27 High-Capacity Feeder Frus List (Cont'd.)
PL 8-27 High-Capacity Feeder FRUs (cont’d.) S7700-075 Figure 8-27 High-Capacity Feeder FRUs (cont’d.) Table 8-27 High-Capacity Feeder FRUs List (cont’d.) Parts Part Number Name and Description (vendor description) 116-1160-00 Paper Feeder Assembly (Feeder Assembly) 116-1173-00 Chute Assembly FO-HCF (Chute Assembly Inlet) 116-1167-00 Chute, Lower, HFC (Chute - Lower) Phaser 7700 Color Laser Printer Service Manual...
Page 310: Table 8-28 High-Capacity Feeder Frus List (Cont'd.)
PL 8-28 High-Capacity Feeder FRUs (cont’d.) S7700-413 Figure 8-28 High-Capacity Feeder FRUs (cont’d.) Table 8-28 High-Capacity Feeder FRUs List (cont’d.) Parts Part Number Name and Description (vendor description) 116-1127-00 HCF Paper-Select Paper-Select Switch Assembly (Switch Assembly PS) 110K11081 (Phaser 7760 compatible) 116-1126-00 Switch Assy, Paper-Select...
Page 311: Table 8-29 High-Capacity Feeder Frus (Cont'd.)
PL 8-29 High-Capacity Feeder FRUs (cont’d.) S7700-414 Figure 8-29 High-Capacity Feeder FRUs (cont’d.) Table 8-29 High-Capacity Feeder FRUs (cont’d.) Parts Part Number Name and Description (vendor description) 116-1171-00 Bracket Assembly, Gear LH (HFC) 116-1170-00 Bracket Assembly, Gear RH (HFC) Phaser 7700 Color Laser Printer Service Manual 8-281...
Page 312: Table 8-30 Kits
Kits Table 8-30 Kits Parts Part Number Name and Description (vendor description) 116-1210-00 Sensor Flag Kit (Sensor Actuator) Actuator (120E11971) Actuator Sensor (120E18141) Actuator Sensor (120E18160) 116-1211-00 Tray Roller Kit (Roll Assembly Kit) Pick, Nudge, Retard Rollers (22K56820) 116-1212-00 MPT Pick Roller Kit (Roll Assembly Kit) 116-1299-00 Sensor Kit (Sensor Kit DBP) Photo Sensor (130E82190)
Page 313: Table 8-31 Manual Packs & Service Manual
Manual Packs & Service Manual Table 8-31 Manual Packs & Service Manual Part Number Name and Description 061-4413-00 Manual Pack; English 061-4414-00 Manual Pack; French 061-4415-00 Manual Pack; Spanish 061-4416-00 Manual Pack; Brazilian/Portuguese 061-4430-00 Manual Pack; Italian 061-4431-00 Manual Pack; German 061-4432-00 Manual Pack;...
Page 314: Supplies And Accessories
When the control panel notifies you that a supply is low or needs to be replaced, make certain you have replacements on hand. To order supplies and accessories, contact your local dealer or visit the Xerox website: www.xerox.com/officeprinting/supplies/. Table 8-33 Supplies...
Page 315: Recommended Service Tools
Deck or High-Capacity Feeder. Recommended Service Tools The following service are recommended as a start for servicing the printer. As additional tools are needed visit the following URL for help: http://cpid.opbu.xerox.com/hardwaretools.html. Table 8-35 Recommended Tools List Part Number Description 003-0293-00 Driver, Magnetic 0.25”...
Page 316 8-286 Phaser 7700 Color Laser Printer Service Manual...
Page 317: Test Prints
Test Prints A variety of test prints are available to aid in determining the quality of output from the printer and to assist in troubleshooting print image quality problems. The topic “Troubleshooting” on page 3-87 discusses solutions to the problems shown in this section.
Page 318: Analyzing The Test Print
Analyzing the Test Print Test prints provide several uses in troubleshooting printer problems. Isolating problems to either the print engine or to the Image Processing Board and host software. Locating feed and paper transport problems. Detecting print-quality and image registration problems. Using Test Prints to Isolate a Problem to the Print Engine or to the Image Processing Board You can use test prints to determine if a problem is caused by a faulty print...
Page 319: Print Color Test Prints
Print Color Test Prints This color test print produces 6 prints, CMYK 4 on 4 off, a solid fill red, and 4 on 4 off bars. Interpreting Print Color Test Prints CYMK 4 on 4 off S7700-291 Phaser 7700 Color Laser Printer Service Manual 9-289...
Page 320 Interpreting Solid Fill Test Prints Non-uniformity in any one color may indicate a problem with the developer or print units. Light streaks in one color indicate developer or debris blocking the laser. Dark streaks in one color indicate a problem with the developer or print units.
Page 321: Diagnostics Mode
Diagnostics Mode Laser Check This is a gray print with all four colors turned on at about 25% fill. Things to look for: A hue shift that indicates one of the primary CMYK colors is missing. A missing primary indicates that the laser is faulty.
Page 322 Grid 1-dot This print is especially useful in the manual process of registration when the automatic process consistently fails due to excessive process and lateral margin adjustment. There are some printer/laser positioning situations where the intrinsic error in lateral margin offset is too great for the DC685-1 test to automatically compensate for, and a manual adjustment is required.
Page 323 Fast Scan 8 These four prints of the primary colors are test prints that seem to be intended to find any laser "ringing" behavior. The beam is stepped through 8 halftones in the scan line. Some people have noticed that there seem to be only 7 distinct bands.
Page 324 9-294 Phaser 7700 Color Laser Printer Service Manual...
Page 325 P570 P575 P571 TP407 P505 P502...
Page 326 PWBA J633 J626 R612 R613 R640 J119 J121 P537 J228 J104 J265 J219 J103 J285 J106 R611 R610 R617 R620 P536 J108 P800...
Page 327 INTERFACE...
Page 328 BOARD CONTROL ENGINE BOARD INTERFACE...
Page 329 BOAR INTERFACE...
Page 330 DTS) 2nd-BTR, (DEVE, HVPS BOARD CONTROL ENGINE...
Page 332 P/J566...
Page 343: Figure 11-1 Phaser 7700 Color Laser Printer With The Finisher Option
Phaser 7700 Finisher S7700-444 Figure 11-1 Phaser 7700 Color Laser Printer with the Finisher Option Phaser 7700 Color Laser Printer Service Manual 11-313...
Page 344: Finisher Overview
This Service Manual contains information useful in troubleshooting, repair and maintenance of the Finisher Option for the Xerox Phaser 7700 Color Laser Printer. This manual contains a Field Replacement Unit Parts List (FRU) and Removal and Replacement Procedures (RRPs). For information on troubleshooting and error codes for the finisher option see “Diagnostics, Error Codes and Messages”...
Page 345: General Information
General Information Table 11-1 Finisher Specifications Category Specification Configuration User installed option. The Finisher provides stapling (up to 50 sheets), print job offset and stacking up to 1,000 sheets of paper. The Finisher docks with the Printer and Stand. All Finisher operations are controlled by the Finisher Control Board.
Page 346 Table 11-1 Finisher Specifications (cont'd.) Category Specification Media Types Long-Edge Feed (LEF) Short-Edge Feed (SEF) B5A3 A4A4 LetterB4 8” x 10” Letter US Folio Legal Tabloid Media Weight 64 - 105 g/m (Thick/Thin paper) Stacker 1000 non-stapled sheets (20 lb. paper, letter/A4 or smaller) Capacity 500 unstapled sheets (20 lb.
Page 347: Figure 11-3 Assemblies Of The Finisher
Assemblies of the Finisher Staple Finisher Horizontal Transport Stacker Gate Unit Stand S7700-445 Figure 11-3 Assemblies of the Finisher Phaser 7700 Color Laser Printer Service Manual 11-317...
Page 348: Figure 11-4 Internal Assemblies Of The Finisher
Internal Assemblies of the Finisher Cam Bracket Assembly Exit Assembly Main Motor Finisher Control Board Decurler Stacker Motor Assembly Compiler Tray Staple Assembly Track S7700-372 Staple Unit Figure 11-4 Internal Assemblies of the Finisher 11-318 Phaser 7700 Color Laser Printer Service Manual...
Page 349: Figure 11-5 Horizontal Transport Sensor, Interlock And Switch Locator Map
Horizontal Transport Sensor, Interlock, and Switch Locator Map Gate In Solenoid H-Transport Entrance Sensor H-Transport Interlock Sensor IOT Face Down Tray Full Sensor H-Transport Exit Sensor S7700-447 Figure 11-5 Horizontal Transport Sensor, Interlock and Switch Locator Map Phaser 7700 Color Laser Printer Service Manual 11-319...
Page 350: Finisher Sensor, Interlock, And Switch Locator Map
Finisher Sensor, Interlock, and Switch Locator Map Stack Height Sensor Eject Clamp Home Sensor Decurler Cam Home Sensor Full Stack Sensor Set Clamp Home Sensor Rear Docking Interlock Sensor S7700-449 Figure 11-6 Finisher Sensor, Interlock, and Switch Locator Map 11-320 Phaser 7700 Color Laser Printer Service Manual...
Page 351: Figure 11-7 Finisher Sensor, Interlock, And Switch Locator
Finisher Sensor, Interlock, and Switch Locator Map Figure 11-7 Finisher Sensor, Interlock, and Switch Locator Phaser 7700 Color Laser Printer Service Manual 11-321...
Page 352 Blank Page 11-322 Phaser 7700 Color Laser Printer Service Manual...
Page 353: Removal And Replacement Procedures
Removal and Replacement Procedures This section details the removal and replacement procedures for the main assemblies of the Phaser 7700 Light Finisher. When replacing sensors, actuators, interlocks and/or switches: Refer to the appropriate Locator Map to identify the sensor. Remove the necessary cover (RRP 67, on page 11-325). Press down on the two locking tabs located at the top of the sensor, press up on the two locking tabs at the bottom of the sensor and remove the sensor.
Page 354: Figure 11-8 Horizontal Transport Assembly
RRP 66 Horizontal Transport Assembly Figure 11-8 Horizontal Transport Assembly Removal Unplug the Finisher from the printer. Lift the two hooks securing the Horizontal Transport Assembly to the Finisher. Remove the Horizontal Transport Assembly. 11-324 Phaser 7700 Color Laser Printer Service Manual...
Page 355: Figure 11-9 H-Transport Top Open, Front And Rear Covers
RRP 67 Horizontal Transport Top Open, Front, and Rear Cover S7700-452 Figure 11-9 H-Transport Top Open, Front and Rear Covers Removal Remove the Horizontal Transport Assembly (RRP 66, on page 11-324). Remove one screw securing the stopper. Remove two screws from the Horizontal Transport Front Cover and remove the cover.
Page 356: Figure 11-10 Horizontal Transport Entrance Upper Cover
RRP 68 Horizontal Transport Entrance Upper Cover Assembly Figure 11-10 Horizontal Transport Entrance Upper Cover Removal Remove the Horizontal Transport Assembly (RRP 66, on page 11-324). Remove the Front Cover (RRP 67, on page 11-325). Remove two screws securing the Rear Cover and remove. Remove the Gate-In Solenoid Assembly.
Page 357: Figure 11-11 Horizontal Transport Belts
RRP 69 Horizontal Transport Belts Figure 11-11 Horizontal Transport Belts Removal Remove the Horizontal Transport Covers (RRP 67, on page 11-325). Remove the KL-clips from the horizontal transport In and Out. Remove the bearings from the horizontal transport In and Out shafts. Remove one end of each horizontal transport belt roller support.
Page 358: Figure 11-12 H-Tra Entrance And Top Tray Full Sensor
RRP 70 Horizontal Transport Entrance Sensor and Top Tray Full Sensor Figure 11-12 H-Tra Entrance and Top Tray Full Sensor Removal Remove the Horizontal Transport Top Open and Front Cover (RRP 67, on page 11-325). Remove the two screws securing the Horizontal Transport Entrance Upper Cover (RRP 68, on page 11-326).
Page 359: Figure 11-13 H-Transport Gate-In Solenoid
RRP 71 Gate-In Solenoid Assembly Figure 11-13 H-Transport Gate-In Solenoid Removal Remove the Rear Cover (RRP 67, on page 11-325). Disconnect the ground wire from the solenoid housing. Remove the two screws and remove the Gate-In Solenoid Assembly. Phaser 7700 Color Laser Printer Service Manual 11-329...
Page 360: Figure 11-14 Finisher Covers
RRP 72 Finisher Covers Left Top Cover Rear Cover Left Panel Front Cover Left Cover S7700-396 Figure 11-14 Finisher Covers 11-330 Phaser 7700 Color Laser Printer Service Manual...
Page 361 Removal Remove the Horizontal Transport Assembly (RRP 66, on page 11-324). Remove one screw from the Left Panel and remove. Remove five screws from the Rear Cover. Clear the gear at the top of the Rear Cover and remove the cover. Open the Front Door.
Page 362: Figure 11-15 Stack Height-Sensor Assembly
RRP 73 Stack Height-Sensor Assembly Figure 11-15 Stack Height-Sensor Assembly Removal Remove the Horizontal Transport Assembly (RRP 66, on page 11-324). Remove the Top Cover (RRP 72, on page 11-330). Remove one screw from the Stack Height Sensor bracket. Press down on the two locking tabs located at the top of the sensor, press up on the two locking tabs at the bottom of the sensor and remove the sensor.
Page 363: Figure 11-16 Stacker Paper-Sensor Assembly
RRP 74 Stacker Paper-Sensor Assembly Figure 11-16 Stacker Paper-Sensor Assembly Removal Loosen the thumb screw and remove the Stacker Tray. Remove the four screws securing the Stacker Paper Sensor Assembly to the finisher. Remove two screws from the bottom of the assembly. Remove one screw on the sensor bracket.
Page 364: Figure 11-17 Set Clamp Clutch And Gear
RRP 75 Set Clamp Clutch and Gear Figure 11-17 Set Clamp Clutch and Gear Removal Remove the Rear Cover (RRP 72, on page 11-330). Remove the set clamp actuator. Remove one screw from the set clamp actuator retainer and remove. Remove the clutch collar and clutch.
Page 365: Figure 11-18 Eject Roll
RRP 76 Eject Roll Assembly Figure 11-18 Eject Roll Removal Remove the Rear and Left Covers (RRP 72, on page 11-330) . Remove Stack Paper Sensor Assembly (RRP 73, on page 11-332). Undo the intermediate connector. Remove the Right Cover. Remove the Set Clamp Clutch and Gear (RRP 75, on page 11-334).
Page 366: Figure 11-19 Finisher Control Board, Bracket, And Shield
RRP 77 Finisher Control Board, Bracket, and Shield Figure 11-19 Finisher Control Board, Bracket, and Shield 11-336 Phaser 7700 Color Laser Printer Service Manual...
Page 367 Removal Remove the Rear Cover (RRP 72, on page 11-330). Remove eight screws and loosen the two bottom screws. Remove Finisher Control Board Shield. Undo all the connectors. Remove two screws on the left. Loosen one screw on the right. Undo one connector.
Page 368: Figure 11-20 Stacker Motor Assembly
RRP 78 Stacker Motor Assembly Figure 11-20 Stacker Motor Assembly Removal Remove the Finisher Control Board Bracket and Shield (RRP 77, on page 11-336). Remove one connector. Remove three screws and remove the Stacker Motor Assembly. Note When reinstalling, ensure the gear is engaged and the sensor for the stacker is tripped.
Page 369: Figure 11-21 Paddle Shaft
RRP 79 Paddle Shaft Figure 11-21 Paddle Shaft Removal Remove the Rear, Left and Right Covers (RRP 72, on page 11-330). Remove the Cam Bracket Assembly (RRP 81, on page 11-341). Remove the Staple Unit (RRP 82, on page 11-342). Remove the e-clips from both ends of the shaft.
Page 370: Figure 11-22 Paper Transport Motor
RRP 80 Paper Transport Motor (Motor Assembly Main) Figure 11-22 Paper Transport Motor Removal Remove the Rear Cover (RRP 72, on page 11-330). Remove four screws. Undo the connector and lift the motor up and then out to free the belt. 11-340 Phaser 7700 Color Laser Printer Service Manual...
Page 371: Figure 11-23 Cam Bracket Assembly
RRP 81 Cam Bracket Assembly Figure 11-23 Cam Bracket Assembly Removal Remove the Rear and Top Covers (RRP 72, on page 11-330). Remove one screw securing the Decurler Cam Sensor. Remove one screw from the Eject Clamp Home Sensor. Disconnect the wiring harness from the Set Clamp Home Sensor. Remove the wiring harness from the bracket.
Page 372: Figure 11-24 Staple Unit Assembly
RRP 82 Staple Unit Assembly and Motor S7700-304 Figure 11-24 Staple Unit Assembly 11-342 Phaser 7700 Color Laser Printer Service Manual...
Page 373 Removal Staple Unit Assembly Remove the Front Cover (RRP 72, on page 11-330). Remove the two connectors to the Staple Unit. Remove two screws, note: one screw has a ground wire. Pull the Staple Unit Assembly down, tilt up and pull out towards the front. Staple Motor Remove the staple unit assembly.
Page 374: Figure 11-25 Compiler Tray
RRP 83 Compiler Tray Figure 11-25 Compiler Tray Removal Remove all covers (RRP 72, on page 11-330). Remove the Finisher Control Board Shield (RRP 77, on page 11-336). Disconnect P848 connector. Remove Set clamp solenoid connector. Remove the Staple Unit (RRP 82, on page 11-342). Remove two screws from the bottom of the tamper assembly, front and rear.
Page 375: Figure 11-26 Finisher Unit Main Assemblies Frus
Finisher FRU Parts List Finisher Unit Main Assemblies FRUs Figure 11-26 Finisher Unit Main Assemblies FRUs Phaser 7700 Color Laser Printer Service Manual 11-345...
Page 376: Table 11-2 Finisher Unit Main Assemblies Frus List
Table 11-2 Finisher Unit Main Assemblies FRUs List Part Number Description 116-1292-00 Gate Unit 116-1280-01 H-Transport Assembly Staple Finisher Screw Rack Assembly 116-1244-00 Right Cover 116-1278-00 Stacker Tray 116-1279-00 Thumb Screw Bracket 11-346 Phaser 7700 Color Laser Printer Service Manual...
Page 377: Table 11-3 Finisher Covers Frus List
Finisher Covers FRUs S7700-300 Figure 11-27 Finisher Covers FRUs Table 11-3 Finisher Covers FRUs List Part Number Description 116-1238-00 Front Cover 116-1239-00 Rear Cover 116-1236-00 Top Cover 116-1237-00 Left Cover 116-1245-00 Front Door Left Panel Hinge Magnet Phaser 7700 Color Laser Printer Service Manual 11-347...
Page 378: Figure 11-28 Finisher Stand Frus
Finisher Stand FRUs S7700-309 Figure 11-28 Finisher Stand FRUs 11-348 Phaser 7700 Color Laser Printer Service Manual...
Page 379: Table 11-4 Finisher Stand Frus List
Table 11-4 Finisher Stand FRUs List Part Number Description 116-1315-00 Front Rack Assembly (Item 2-10) Front Cover Knob Screw Screw Bracket Stopper Plate Spring Rail Foot Front Rack 116-1316-00 Rear Rack Assembly (Item 3-9, 12-14) Rear Cover Rack Cover Bracket Bottom Plate Phaser 7700 Color Laser Printer Service Manual 11-349...
Page 380: Figure 11-29 Gate Unit Frus
Gate Unit FRUs S7700-297 Figure 11-29 Gate Unit FRUs 11-350 Phaser 7700 Color Laser Printer Service Manual...
Page 381: Table 11-5 Gate Unit Frus List
Table 11-5 Gate Unit FRUs List Part Number Description 116-1292-00 No Gate Cover Bearing 116-1293-00 Gate Assembly (Item 4-14) In-Gate In-Gate Lever 116-1294-00 Gate Bracket Link Assembly Lever Assembly Lever Spring Gate Link Bearing Spring Exit Chute Chute Phaser 7700 Color Laser Printer Service Manual 11-351...
Page 382 Horizontal Transport Assembly FRUs S7700-298 Figure 11-30 Horizontal Transport Assembly FRUs 11-352 Phaser 7700 Color Laser Printer Service Manual...
Page 383: Table 11-6 Horizontal Transport Assembly Frus List
Table 11-6 Horizontal Transport Assembly FRUs List Part Number Description 116-1290-00 H-Transport Open Cover Assembly (Item 2-7) H-Transport Open Cover 116-1291-00 Magnetic Catch Screw Guide 116-1246-00 Roll Plate Spring Stopper 116-1289-00 Entrance Upper Cover Assembly (Item 10-12) Entrance Upper Cover Roll Plate Spring Screw...
Page 384: Figure 11-31 Horizontal Transport Assembly Frus (Cont'd.)
Horizontal Transport Assembly FRUs (cont’d.) S7700-299 Figure 11-31 Horizontal Transport Assembly FRUs (cont’d.) 11-354 Phaser 7700 Color Laser Printer Service Manual...
Page 385: Table 11-7 Horizontal Transport Assembly Frus List (Cont'd)
Table 11-7 Horizontal Transport Assembly FRUs List (cont’d.) Part Number Description H-Transport Roll (IN) H-Transport Roll (OUT) 116-1284-00 H-Transport Belt (REP 17.4.1) Roll Support Bearing (Ball) Harness Guide Cover 116-1644-00 H-Transport Entrance Sensor (REP 17.4.2) 116-1285-00 Top Tray Full Sensor (REP 17.4.2) 116-1247-01 H-Transport Exit Sensor 116-1286-00...
Page 386: Figure 11-32 Top Cover And Eject Roll Frus
Top Cover and Eject Roll FRUs S7700-301 Figure 11-32 Top Cover and Eject Roll FRUs 11-356 Phaser 7700 Color Laser Printer Service Manual...
Page 387: Table 11-8 Top Cover And Eject Roll Frus List
Table 11-8 Top Cover and Eject Roll FRUs List Part Number Description 116-1262-00 Top Open Cover Assembly Arm Assembly Bearing Bracket Spring Support Bracket Shaft 116-1302-00 Eject Pinch Roll Eject Chute 116-1272-00 Stack Height Sensor Assembly (Item 12-14) Actuator Bracket 116-1253-00 Stack Height Sensor Shaft, Set Clamp...
Page 388 Paper Transport Assembly FRUs BD BD S7700-302 Figure 11-33 Paper Transport Assembly FRUs 11-358 Phaser 7700 Color Laser Printer Service Manual...
Page 389: Table 11-9 Paper Transport Assembly Frus List
Table 11-9 Paper Transport Assembly FRUs List Part Number Description 116-1248-00 Actuator 116-1249-00 Clutch Assembly, Decurler Cam Shaft Bearing 116-1250-00 116-1302-00 Decurler Roll Assembly (REP 17.7.1) 116-1301-00 Gear (40Z / 20T) 116-1301-00 Gear (40Z) 116-1301-00 Gear (18Z / 21T) Shaft Bearing 116-1301-00 Gear (23Z / 52Z)
Page 390: Figure 11-34 Paper Transport Assembly Frus (Cont'd.)
Paper Transport Assembly FRUs (cont’d.) S7700-303 Figure 11-34 Paper Transport Assembly FRUs (cont’d.) 11-360 Phaser 7700 Color Laser Printer Service Manual...
Page 391: Table 11-10 Paper Transport Assembly Frus List (Cont'd.)
Table 11-10 Paper Transport Assembly FRUs List (cont’d.) Part Number Description 116-1266-00 Cam Bracket Assembly (Item 2-12, 14, 19) 116-1303-00 Pully 116-1303-00 Gear (15Z) 116-1271-00 Belt (REP 17.8.1) 116-1303-00 Gear (30Z) Collar 116-1303-00 Gear Pully Eject Motor 116-1303-00 Cam Gear 116-1303-00 Gear (42Z / 27Z) Set Clamp Solenoid...
Page 392: Figure 11-35 Staple Unit Assembly Frus
Staple Unit Assembly FRUs S7700-304 Figure 11-35 Staple Unit Assembly FRUs 11-362 Phaser 7700 Color Laser Printer Service Manual...
Page 393: Table 11-11 Staple Unit Assembly Frus List
Table 11-11 Staple Unit Assembly FRUs List Part Number Description 116-1255-00 Carriage Assembly (Item 2-6) Bracket Assembly 116-1256-00 Motor Assembly Stepping Gear Staple Remover Roll 116-1259-00 Staple Front Corner Sensor Plate 116-1254-00 Rail (REP 17.9.1) 116-1257-00 Staple Assembly (Item 11.12) (REP 17.9.2) Staple Cartridge Bracket...
Page 394: Figure 11-36 Compiler Tray Assembly Frus
Compiler Tray Assembly FRUs S7700-305 Figure 11-36 Compiler Tray Assembly FRUs 11-364 Phaser 7700 Color Laser Printer Service Manual...
Page 395: Table 11-12 Compiler Tray Assembly Frus List
Table 11-12 Compiler Tray Assembly FRUs List Part Number Description 116-1251-00 Compiler Tray Assembly (Item 2-15) 116-1252-00 Motor Assembly Tamper Plate 116-1253-00 Front /Rear Tamper Home Sensor Rack Actuator Tamper Assembly Finger Spring 116-1234-00 Compiler Paper Sensor Actuator Paper Guide 116-1269-00 Spring Wire Harness...
Page 396: Figure 11-37 Stacker Elevator Assembly Frus
Stacker Elevator Assembly FRUs S7700-306 Figure 11-37 Stacker Elevator Assembly FRUs 11-366 Phaser 7700 Color Laser Printer Service Manual...
Page 397: Table 11-13 Stacker Elevator Assembly Frus List
Table 11-13 Stacker Elevator Assembly FRUs List Part Number Description 116-1287-00 Stacker Motor Assembly 116-1276-00 Bracket Assembly Belt Clamp Bearing 116-1274-00 Gear (Rear) Actuator 116-1275-00 Gear (Front) Stacker Tray Bracket Assembly 116-1273-00 Rack Tray Guide 116-1270-00 Stack Paper Assembly (Item 12-16) 116-1253-00 Stack Paper Sensor Actuator...
Page 398: Figure 11-38 Exit Assembly Frus
Exit Assembly FRUs S7700-307 Figure 11-38 Exit Assembly FRUs 11-368 Phaser 7700 Color Laser Printer Service Manual...
Page 399: Table 11-14 Exit Assembly Frus List
Table 11-14 Exit Assembly FRUs List Part Number Description Gear (48Z) Bearing 116-1243-00 Exit Shaft Collar Gear (32Z / 18T) Bearing 116-1304-00 Paddle Gear Shaft (REP 17.12.1) Paddle Bearing Lower Exit Chute 116-1302-00 Pinch Roll (Exit 1) Pinch Roll (Exit 2) Pinch Roll (Exit 3) Upper Exit Chute 116-1313-00...
Page 400: Table 11-15 Electrical Frus List
Electrical FRUs S7700-308 Figure 11-39 Electrical FRUs Table 11-15 Electrical FRUs List Part Number Description Board Cover 116-1235-00 Finisher Board 116-1314-00 PWB Bracket DC Harness Cable 116-1233-00 Switch 116-1253-00 Docking Interlock Switch Plate Spring Bracket 11-370 Phaser 7700 Color Laser Printer Service Manual...
Page 403 BOARD FEEDER AUXILIARY...
Page 406 701P28180...

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Phaser 7700

Xerox 7700DX - Phaser Color Laser Printer Service Manual

Table of Contents

Phaser 7700 Finisher 11-313

General Information

Diagnostics, Error Codes and Messages

Finisher Wiring Diagrams

Wiring Diagrams

Troubleshooting

Adjustments and Calibration

Cleaning and Maintenance

Resetting NVRAM

Table of Contents

FRU Parts List

Test Prints

Removal and Replacement Procedures

Finisher FRU Parts List

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Xerox 7700DX - Phaser Color Laser Printer