Page 1 P H A S E R ® 7 8 0 C O L O R L A S E R P R I N T E R Servic e Re f e re n c e Gu id e Warning The following servicing instructions are for use by qualified service personnel only.
Page 2: Users Safety Summary
Users safety summary Terms in CAUTION Conditions that can result in damage to the product. manual: WARNING Conditions that can result in personal injury or loss of life. Power source: For 110 VAC printers, Do not apply more than 130 volts RMS between the supply conductors or between either supply conductor and ground.
Page 3 Symbols as marked on product: DANGER high voltage: Protective ground (earth) terminal: Use caution. Refer to the manual(s) for information: Laser use caution. Refer to the manual(s) for information: WARNING: If the product loses the ground connection, usage of knobs and controls (and other conductive parts) can cause an electrical shock.
Page 4 Service safety summary For qualiﬁed service personnel only: Refer also to the preceding Users Safety Summary. Do not service alone: Do not perform internal service or adjustment of this product unless another person capable of rendering ﬁrst aid or resuscitation is present. Use care when servicing with power on: Dangerous voltages may exist at several points in this product.
Page 6: Table Of Contents
Contents General Information Phaser 780 overview Memory considerations Print engine assemblies The image processor Front panel Rear panel Network card LEDs Specifications Regulatory specifications Safety Energy Star certification Error Codes and Messages Troubleshooting System power-up sequence Print engine troubleshooting Printer will not power up Erratic printer operation Making a print engine only test print Printing and print quality problems...
Page 7 Print is mottled Image mis-registered on paper Color layer not correctly registered Color representation not correct Oil stain or gloss variation on print Random spotting Media jams and the paper path Skewed image Damaged prints Inoperative lower tray feeder Power problems All front panel indicators remain off.
Page 8 Key FRU Disassembly Paper feeder Feeder registration chute Feeder registration clutch Registration brake clutch Feeder metal registration roller Feeder rubber registration roller Feeder pre-registration clutch Feeder pre-registration rollers Paper-pick turn roller Paper feed drive gear train Paper-feed motor Multi-purpose tray roller assembly Multi-purpose tray pick rollers Auto-density calibration sensor Developer assembly...
Page 9 FRU List Supplies and accessories Test Prints Wiring Diagrams Phaser 780 Color Printer...
Page 10 Figures The Phaser 780 printer (shown with optional Lower Tray Assembly) 1 Internal features of the print engine 5 Circuit boards of the print engine 6 Motors of the print engine 7 Sensors and switches on the print engine 8 Solenoids and clutches on the print engine 9 Features of the image processor board 10 Printer front panel 11...
Page 11 Removing the second bias transfer roller cam assembly 124 Removing the fuser assembly 125 Removing the fuser-drive gear train 127 Removing the lower exit assembly 129 Removing the stack full sensor 130 Removing the low voltage power supply 131 Removing the high voltage power supply 132 Removing the image processor 133 Removing the image processor chassis 134 Removing the print engine control board 135...
Page 12 Wiring 4 – Engine control board, used cartridge sensor, cartridge sensor, carousel sensor, developer clutch, developer fan, toner dispense motor 204 Wiring 5 – Engine control board, low voltage power supply, carousel motor board, rotary motor 205 Wiring 6 – Engine control board, low voltage power supply, bias transfer roller cam solenoid accumulator belt sensor, paper feeder motor, process motor 206 Wiring 7 –...
Page 13 Tables Memory and features sets 3 Physical dimensions of printer 14 Physical dimensions of lower tray feeder 14 Printer clearances 14 Functional specifications 15 Electrical specifications 16 Environmental specifications 16 Diagnostic tests 69 Printer cover FRUs 139 Paper feeder FRUs 141 Multi-purpose tray cover FRUs 143 Multi-purpose tray FRUs 145 Paper feeder cover FRUs 147...
Page 14: General Information
General Information This service guide contains information useful to verify operation, troubleshoot, repair, adjust, and maintain a Tektronix Phaser® 780 Color Printer. To ensure complete understanding of the product, we recommend participation in Phaser 780 service training, if available. 3041-01 The Phaser 780 printer (shown with optional Lower Tray Assembly) Service Guide...
Page 15: Phaser 780 Overview
Phaser 780 overview The Phaser 780 Color Printer combines a color laser, continuous-tone print engine with an image processor supporting Adobe’s PostScript 3 page description language. The image processor features a bi-directional parallel interface and a 10baseT Ethernet port for host communication. Optional network adapter cards to the image processor allow the printer to communicate on networks using LocalTalk, Ethernet 100baseT or Token Ring protocols.
Page 16: Memory Considerations
Memory considerations The base printer features 32 Mbytes of RAM in one connector and features two additional DIMM connectors which accept 16-, 32-, 64-, or 128 Mbytes RAM DIMMs. The printer can use any off-the-shelf RAM meeting these speciﬁcations: 168 pin DIMM Synchronous DRAM 3.3 volt 9 nsec speed...
Page 17 Print the Conﬁguration Page and check the item “installed RAM” to see what type of RAM is installed. For example: Installed RAM: 96 Mbytes Mem slot 1: SDRAM/parity/64 MB/KMM366S824AT Mem slot 1: empty This is a list of DRAM SIMMs that are branded for use by Tektronix at the time this guide was published: Size Maker...
Page 18: Print Engine Assemblies
Print engine assemblies Developer Laser assemblies unit Carousel assembly Paper feeder Fuser Media tray 1 Multi-purpose tray Accumulator belt cleaner Imaging unit Second bias transfer roller Accumulator belt assembly 3041-02 Internal features of the print engine Service Guide...
Page 19: Circuit Boards Of The Print Engine
Image processor board Engine control board Carousel motor board Low Voltage Power Supply (LVPS) Network High Voltage card board 3041-04 Circuit boards of the print engine Phaser 780 Color Printer...
Page 20: Motors Of The Print Engine
Image processor Toner Process drive dispense assembly motor Developer fan Fuser fan Carousel motor Paper feed drive gear train Process Paper feed motor motor 3041-03 Motors of the print engine Service Guide...
Page 21: Sensors And Switches On The Print Engine
Carousel Top cover Exit Exit door sensor switch sensor sensor Auto-density Right front calibration cover switch Used toner sensor cartridge sensor Waste cartridge full sensor Full stack Waste cartridge sensor sensor Accumulator Left front belt home cover sensor switch Paper size Toner sensor cartridge...
Page 22: Solenoids And Clutches On The Print Engine
Registration clutch Second bias transfer roller solenoid Developer clutch Pre-Registration clutch Registration Multi-purpose brake clutch pick-up solenoid Multi-purpose tray clutch 3041-06 Solenoids and clutches on the print engine Service Guide...
Page 23: The Image Processor
The image processor Real Time Clock / NVRAM SCSI DIMMS riser card NVRAM Network card Postscript Font code ROM DIMM Boot DIMM 3041-07 Features of the image processor board Phaser 780 Color Printer...
Page 24: Front Panel
Front panel These front panel features are found on the printer: A two-line, 40-character LCD Six push buttons Five LEDs LCD. The LCD serves two purposes: Displaying current image processor and print engine status information and displaying an interactive menu. Status information includes image processor status such as Ready, Processing and Printing.
Page 25: Rear Panel
Rear panel Connectors The rear panel of the printer features the host interface connectors: Bi-directional parallel (high-density connector). Twisted Pair 10baseT Ethernet connector. RX indicator (green); blinks while the network card is receiving data. The LED is off steady while no data is being received.
Page 26: Printer Rear Panel With The Optional Ethernet Card
The Token Ring network card has two LED indicators: Connection (yellow); off when the printer is not inserted into the Token Ring, blinks while the printer is attempting to insert itself into the Token Ring, on when the printer is properly inserted in the ring. Ring Speed (green);...
Page 27: Specifications
Speciﬁcations Table 1 Physical dimensions of printer Dimension Value Height 49.2 cm (19 in) without lower tray feeder 90.6 (36 in) with lower tray feeder Width 69.1 cm (27.2 in) Depth 64.1 cm (24.2 in) Weight 73.6 kg (161 lbs) with consumables installed 97.1 kg (213 lbs) with lower tray feeder and consumables Table 2 Physical dimensions of lower tray feeder Dimension...
Page 28 Table 4 Functional speciﬁcations Characteristic Speciﬁcation Printing process Electro-photographic, four color (CMYK), two transfer printing using modulated (on/off) laser beam scanning. Imaged is fused to paper using heat and pressure with silicone oil lubricant. Color medium Four toner cartridges each containing one of four colors: cyan, magenta, yellow or black.
Page 29 Table 5 Electrical speciﬁcations Characteristic Speciﬁcation Primary line voltage 100/120 VAC (+/- 10%) 220/240 VAC (+/- 10%) Primary voltage frequency 47 to 63 Hz range Power consumption EnergyStar: 20 watts Standby: 100 watts 1000 watts with fuser on Ready: 100 watts 1000 watts with fuser on Printing: 1100 watts Table 6 Environmental speciﬁcations...
Page 30: Regulatory Specifications
Regulatory speciﬁcations Safety EN60950 CB Report by Third Party GOST and TUV certiﬁcation UL1950 Nationally Recognized Test Lab (NRTL) certiﬁed CSA 950 SCC recognized test lab certiﬁed EN55022 (CISPR 22) Class B EN50082-1:1994 Susceptibility EN61000-3-2 AC Mains Harmonic Distortion EN61000-3-3 AC Mains Voltage Flicker EN61000-4-2:1993 ESD EN61000-4-4:1993 Fast Burst Transients EN61000-4-5:1993 Line Surge...
Page 31 Phaser 780 Color Printer...
Page 32: Error Codes And Messages
Error Codes and Messages The following table list error codes and messages reported by the print engine control board. Error code Description Corrective action message Laser Unit There is a problem with the laser unit. Test the top cover and right front cover switches for Error The engine control board did not receive...
Page 33 Error code Description Corrective action message Image The image density readings indicate a Power cycle the printer Ensure the toner cartridges Density Error problem. The engine control board are fully functional and (Error 12) detected that the printer image density relatively full of toner.
Page 34 Error code Description Corrective action message Auto- There is problem with the auto-density Power cycle the printer Check the auto-density density calibration. The engine control board calibration sensor for Calibration detected that the auto-density contamination from toner. Error calibration sensor LED output signal is Replace the sensor, if (Error 13) below speciﬁed range.
Page 35 Error code Description Corrective action message Second Bias The engine control board detected that Check the wiring from the high voltage power supply to Transfer the measured current value thru the the second bias transfer roller Roller Error second bias transfer roller was not within Replace the second (Error 24) speciﬁcation.
Page 36 Error code Description Corrective action message Fuser There is a problem with the fuser. The Open the fuser door and ensure the fuser connectors Temperature engine control board senses an open are properly seated. Error temperature sensor circuit. Close the fuser and power (Error 42) cycle the printer.
Page 37 Error code Description Corrective action message Process There is a problem with the process Test the process drive assembly Motor Error motor. the engine control board did not Test the +24 VDC at P/J (Error 61) receive a signal from the accumulator 32-11 and frame ground.
Page 38 Error code Description Corrective action message Imaging Unit The wrong imaging unit is installed in Power cycle the printer Replace the imaging unit with ID Error the printer. The engine control board a new cartridge (Error 73) detected that the installed imaging unit Replace the engine control is incompatible with the printer.
Page 39 Error code Description Corrective action message Image Image density exceeded design Power cycle the printer Print a less complex, color Contains Too speciﬁcations. image to determine if it is Much The engine control board detected that overly dense. Coverage the ﬁrst 70mm of the lead edge of the Replace the engine control four color image about to be printed board...
Page 40 Error code Description Corrective action message Replace Cyan image density is too low. The Replace the cyan toner cartridge Cyan Toner engine control board detected that the Test the toner/developer Cartridge auto-density calibration sensor reads dispense motor the cyan patch density as being below Test the auto-density speciﬁcation and that the reading is calibration sensor...
Page 41 Error code Description Corrective action message Waste The waste toner box is almost full. The Replace the waste toner box Replace the engine control Cartridge engine control board detected that the board Almost Full waste toner box is almost full and will soon need to be replaced.
Page 42 Error code Description Corrective action message Media Low in The engine control board detected that Add paper to tray 4 Check for a damaged or Tray 4 the tray 4 low paper sensor is actuated. missing sensor actuator. Replace the tray 4 low sensor Replace the engine control board Media Low in...
Page 43 Error code Description Corrective action message Load Media Tray 3 is out of paper. The engine control Load paper into Tray 3 Test the tray’s paper empty in Tray 3 board detected that the paper empty sensor sensor in tray 3 is actuated. Replace the lower feeder circuit board Replace the lower feeder...
Page 44 Error code Description Corrective action message Clear Jam At There is a problem near the registration Clear jammed paper from the printer A, B sensor. The engine control board Check that the media tray detected that the registration sensor did and ensure it is correctly not actuate within the speciﬁed time loaded...
Page 45 Error code Description Corrective action message Clear Jam At The engine control board detected that Clear jammed paper from the printer the media exit sensor did not actuate Inspect and clean the exit within the speciﬁed time after the fuser rollers exit sensor actuated.
Page 46 Error code Description Corrective action message Install The magenta toner cartridge is either Reseat the magenta toner cartridge. Power cycle the Magenta not installed or not installed correctly. printer Toner The engine control board did not receive Replace the magenta toner Cartridge a signal from the cartridge sensor when cartridge...
Page 47 Error code Description Corrective action message Install The engine control board did not detect Reseat the tray into the third feeder slot Tray 3 a Paper Tray installed in Tray 3 slot. Inspect the tray’s switch actuators for damage Inspect the lower feeder-to-printer connections Replace the paper size sensor assembly...
Page 48 Error code Description Corrective action message Second Bias The engine control board detected that Power cycle the printer Replace the high voltage Transfer the measured current value across power supply Roller Error second bias transfer roller was not within Replace the engine control speciﬁcations.
Page 49 Error code Description Corrective action message Printer The second bias transfer roller has Use diagnostics to verify the print count Maintenance reached end of life. The engine control Replace the second bias Required board detected that second bias transfer transfer roller roller has completed over 100,000 Replace the engine control images.
Page 50 Error code Description Corrective action message Close Left The engine control board detected that Reseat the fuser Inspect the fuser mating Fuser Unit the fuser interlock circuit is open. connectors for proper ﬁt Replace the engine control board Close Exit The engine control board detected that Close the exit cover Replace the exit chute switch...
Page 51 Error code Description Corrective action message Empty the The engine control board detected that Remove the prints from output tray Top Output the full stack sensor is actuated for more Inspect for damage the Tray than 12 seconds. output tray full sensor. Replace if necessary Replace the engine control board...
Page 52: Troubleshooting
Troubleshooting System power-up sequence The main power switch is turned on. (Or the front cover is opened and then closed or diagnostics are exited.) The print engine reads the Customer Replaceable Unit Memory (CRUM). The print engine determines that all the CRUs are in place, except for the toner cartridges.
Page 53: Print Engine Troubleshooting
Print engine troubleshooting Printer will not power up When you switch on the printer, the control panel does not light, the fans do not rotate, the carousel motor does not cycle, and the printer does not go into warm- 110VAC IN Check Inspect the AC Power Cord.
Page 54: Erratic Printer Operation
Measure the voltage between P33-3 on the low voltage power supply and frame ground, and between P32-11 on the low voltage power supply and frame ground. Do you eventually measure +5 VDC between P33-3 and frame ground, and +24 VDC between P32-11 and frame ground? If yes, replace the component that is loading down the power supply.
Page 55: Making A Print Engine Only Test Print
Making a print engine only test print Using the image processor. Turn off the printer. Remove the right side panel to access the image processor board. Locate switch 4 of S930 on the image processor board. Closing switch 4 bypasses the image processor board and places the engine control board into test mode upon power up.
Page 56: Printing And Print Quality Problems
Printing and print quality problems Initial checks and actions Does the printer display an error code? If so go to “Error Codes and Messages” on page 19. Is the AC power provided at the wall outlet within recommended speciﬁcations? Is the printer properly gounded through the AC wall outlet? Is the printer located in an area where the temperature and humidity are stable and within speciﬁcations? Is the printer located in an area free of dust?
Page 57: Light (Undertone) Prints
Light (undertone) prints The overall image density is too light. The printer displays no error code. Inspect the paper that is loaded in the paper tray. Check that the paper is not wrinkled or moist. Also ensure it is the correct weight. Card stock must be feed from the multi-purpose tray.
Page 58: Blank Prints
Blank prints The entire image area is blank. The printer displays no error code. Generate a test print. Is the test print blank? If no, reload the printer driver software or replace the image processor board. Remove the imaging unit. Inspect the empty imaging unit cavity for a sheet of paper that could be blocking the...
Page 59: Monochrome Prints
Monochrome prints 3041-38 No color is present in a color print, only the black layer is printed. The printer displays no error code. In some cases, depending on the nature of the failure, only a portion of the print may be monochrome while the remainder of the print is in color.
Page 60: Black Prints
Black prints The entire image area is black. The printer displays no error code. Power cycle the printer, if an error 10 is detected replace the laser scanner unit. Replace the engine control board. Print Service Test Print 1. Is the test print completely black? If no, reload the printer driver software or replace the image processor...
Page 61: Missing Band In Direction Of Paper Travel
Missing band in direction of paper travel There are areas of the image that are Leading Edge 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 62: Missing Bands In Parallel To The Leading Edge
Inspect the image on the paper just before the paper enter the fuser. Is there a normal test print image, without any band deletions, visible on the sheet of paper? If not, replace the second bias transfer roller. Generate a test print and slide the fuser assembly out of the printer just as the sheet of paper exits the fuser.
Page 63 Inspect the image on the drum. Is there a normal test print image, without any band deletions, visible on the drum? If yes, go to Step 6. If not, replace the imaging unit. Inspect the image on the surface of the accumulator belt? Is there a normal test print image, without any horizontal band deletions, visible on the surface of the accumulator belt? If no, replace the accumulator belt.
Page 64: 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 parallel to...
Page 65: Streaks Parallel With The Leading Edge
Turn the carousel frame and inspect the magnet roller of each of the four developer assemblies. Do the magnet rollers of each developer assembly appear smooth, evenly formed, without any low spots, and without obvious contamination? If not, replace the defective developer assembly. Replace the high voltage power supply.
Page 66: Banding
Remove the top cover. Turn the carousel frame and inspect the magnet roller of each of the four developer assemblies. Do the magnet rollers of each developer assembly appear smooth, evenly formed, without any low spots, and without obvious contamination? If not, replace the defective developer assembly.
Page 67: 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 68: Random Spotting
Random spotting 3041-47 There are spots of toner randomly scattered across the page. The printer displays no error code. Slide the paper feeder out of the printer and inspect the top of the registration chute assembly. Is the top of the registration chute assembly free of toner and foreign debris? If not, remove and inspect the waste toner cartridge.
Page 69: Repetitive Mark Appears On Each Print
Repetitive mark appears on each print 3041-48 An identical mark or image appears on each, or every other, printed image. If spots repeat every 264 mm (10.4 in.) or appear to move in the direction of paper travel from print to print, replace the imaging unit. If a defect repeats in exactly the same place on successive prints, replace the accumulator belt assembly.
Page 70: Background Contamination
Replace the imaging unit. Excessive duplexing of the same image can cause ghost images on the imaging unit drum from fuser oil contamination. Inspect the image on the surface of the accumulator belt? Is there a normal test print image, without ghosts, visible on the surface of the accumulator belt? If a ghost is present, visually inspect the operation of the cleaner cam solenoid and the cleaner cam guides located on the fuser assembly.
Page 71: 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. Is the image density very light? If light, but not blank, go to the earlier topic “Light (undertone) prints”...
Page 72: Print Is Mottled
Open the front cover and inspect the back of the sheet of paper. Is the back of the sheet clean and free of toner? If not, replace the second bias transfer roller and if necessary also replace the accumulator belt cleaner assembly.
Page 73: 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. Is the correct weight paper correctly loaded in the tray(s) or multi-purpose tray? Ensure the paper guides are correctly set.
Page 74: Color Representation Not Correct
Color representation not correct The color of the printed image is completely different than the computer image. The printer displays no error code. Ensure driver settings are correct. Reload the printer driver software. Clean and inspect the auto- density calibration sensor. Test the sensor using the printer’s built-in diagnostics.
Page 75: Random Spotting
Random spotting There are spots of toner randomly scattered across the page. Slide the paper feeder out of the printer and inspect the top of the registration chute assembly. Is the top of the registration chute assembly free of toner? If not, remove and inspect the waste toner cartridge.
Page 76: Media Jams And The Paper Path
Media jams and the paper path Skewed image The image area is twisted or is not parallel with the sides of the page. The printer neither jams nor displays an error code. Check that the paper tray’s metal hooks (at the corners of the leading edge of the paper in the tray) are not bent or deformed.
Page 77: Damaged Prints
Damaged prints The printed page exits the printer either wrinkled, creased, or torn. The printer neither jams nor displays an error code. The following components are associated with this speciﬁc problem. One or more of these components may have failed partially or completely. If you cannot isolate the problem, replace each component listed below, one at a time, until the problem disappears.
Page 78: Inoperative Lower Tray Feeder
Inoperative lower tray feeder The lower tray feeder does not work at all, the lower tray feeder does not attempt to feed paper, and the problem is not identiﬁed by a displayed error code. Ensure the printer driver is conﬁgured with the “optional trays” installed.
Page 79: Front Panel Indications
Front panel indications Media tray indicates missing or empty when it is not If there is media in the tray, then check the media sensors. If the lower feeder is available, switch trays to verify the source of the problem Check to see if the paper-empty sensor is broken.
Page 80: Image Is Rotated 90 Degrees
Image is rotated 90 degrees In the application's Page Setup, make sure that the image is selected to print in portrait or landscape orientation to match the document. Also ensure the selected paper size is correct. Ensure that the printer can print by printing an internal front panel test print.
Page 81: Printing From Windows 3.1 Produces The Message "Problem Writing Device Lpt1: Cancel Or Retry
Printing from Windows 3.1 produces the message “Problem writing device LPT1: Cancel or Retry”. Option #1: Select Printers, and click Conﬁgure. Change the port selection from LPT1 to LPT1.OS2. The MODE command disables DOS timeouts. The LPT1.OS2 selection forces Windows to print through DOS instead of directly to the printer. Option #2: The solution above does not allow users to spool documents using the PrintManager.
Page 82: Running Built-In Diagnostics
Running built-in diagnostics The printer diagnostic interface consists of a front panel containing a 2 line by 40 character LCD display and six buttons. For diagnostics, the front panel switches are identiﬁed as 1 through 6 with switch 1 being the left-most switch and switch 6 being the right-most switch.
Page 83 Table 1 Diagnostic tests Test Sub-tests Detail Sensors Belt Home Sensor Carousel Home Sensor Waste Cartridge Sensor Waste Cartridge Full Sensor Full Stack Sensor Exit Sensor New Toner Sensor Toner Cartridge Present Sensor Paper Feeder Interlock MPT Long Paper Sense MPT Paper Sensor MPT Edge Sensor Registration Sensor...
Page 84 Table 1 Diagnostic tests Test Sub-tests Detail Sensors (cont.) Tray 1 Low Sensor Tray 1 Empty Tray 2 Low Sensor Tray 2 Empty Tray 3 Low Sensor Tray 3 Empty Tray 4 Low Sensor Tray 4 Empty Auto-density Calibration Pass/Fail test of sensor Sensor and its wiper solenoid;...
Page 85 Table 1 Diagnostic tests Test Sub-tests Detail Motor/Solenoids (cont.) Tray 3 Feed Clutch Tray 4 Feed Clutch Rear Fan Slow/Fast Speed Fuser Fan Slow/Fast Speed Erase lamp On/Off Fuser Lamp (heater) On/Off Front Panel Front Panel Display Front Panel LEDs Life Data Save Life Count The Save function copies...
Page 86: Adjustments
Adjustments This topic discusses using the front panel’s interactive mode to review and change the printer’s operation. It also contains the procedures to calibrate the printer after you replace key Field Replaceable Units and to evaluate the printer's functionality. Printing test prints The prints printed via the front panel the are generated by the image processor.
Page 87: Print Engine Calibration
Print engine calibration Generally, only one print engine calibration is required. Usually, if you note a print defect, replacing a toner cartridge, a developer or the imaging unit or perhaps the paper feeder corrects the problem. Adjusting for impulse banding Impulse banding is a print artifact that occurs on prints when the developer roller comes into contact with the drum.
Page 88: Adjusting For Impulse Banding
Developer Place mark on roller After carousel rotation white roller mark should move 2mm Install shim Lift up slightly to install shim Toner 3041-32 Adjusting for impulse banding Service Guide...
Page 89 Phaser 780 Color Printer...
Page 90: Cleaning And Maintenance
Cleaning and Maintenance Service preventive maintenance procedure Whenever you check, service, or repair a printer, you should perform the following procedures. 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 91: Cleaning
Cleaning Caution Never apply alcohol on the second bias transfer roller. Never apply alcohol to the fuser rollers. Turn off the printer. Remove the imaging unit and cover it to protect it from the light. Remove the toner cartridges. Slide out the fuser. Remove the paper tray.
Page 92: 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. Caution Resetting NVRAM will also reset the network card’s NVRAM. If possible, copy down all network parameters or print the Conﬁguration Page.
Page 93 Phaser 780 Color Printer...
Page 94: Key Fru Disassembly
Key FRU Disassembly This topic illustrates how to remove and replace key printer Field Replaceable Units (FRUs). Refer to the later topic “FRU List” on page 137 for a list of the printer’s FRUs. For more detailed removal/replacement procedures refer to the Phaser 780 Service CD-ROM.
Page 95: Paper Feeder
Paper feeder Slide the paper feeder far enough out of the printer so you can reach the assembly rails. Push in on the front rail latch as you slide the front of the paper feeder out far enough to disengage the latch. Push in on the rear rail latch as you slide the rear of the paper feeder out far enough to disengage the latch.
Page 96: Feeder Registration Chute
Feeder registration chute Slide the paper feeder out of the printer. You do not need to remove the paper feeder. Remove the E-ring securing the rear arm of the registration chute to the paper feeder. Remove the screw securing the ground wire to the chute. Remove the wire.
Page 97: Feeder Registration Clutch
Feeder registration clutch Remove the paper feeder as described in “Paper feeder” on page 82. Turn over the paper feeder and disconnect the wiring harness from the registration clutch. Open the registration chute. Remove the E-ring securing the registration clutch to the rear of the metal registration roller.
Page 98: Registration Brake Clutch
Registration brake clutch Remove the paper feeder as described in “Paper feeder” on page 82. Turn the paper feeder over and disconnect the wiring harness from the registration brake clutch. Remove the three screws securing the registration brake clutch assembly to the side of the paper feeder. Remove the assembly. Remove the E-ring securing the registration brake clutch to the clutch shaft and remove the clutch.
Page 99: Feeder Metal Registration Roller
Feeder metal registration roller Remove the feeder registration clutch as described in “Feeder registration chute” on page 83. Remove the registration brake clutch as described in “Registration brake clutch” on page 85. Remove the E-ring securing the out gear at the front end of the metal registration roller.
Page 100: Feeder Rubber Registration Roller
Feeder rubber registration roller Remove the feeder metal registration roller. Remove the E-ring at the front of the rubber registration roller securing the gear to the roller. Remove the gear. Remove the E-ring securing the rear of the rubber registration roller to the paper feeder.
Page 101: Feeder Pre-Registration Clutch
Feeder pre-registration clutch Remove the paper feeder. Remove the feeder registration chute. Turn over the paper feeder and disconnect the wiring harness from the feeder pre-registration clutch. Remove the two screws securing the feeder pre-registration gear assembly to the paper feeder. Remove the gear assembly. Remove the E-rings securing the feeder pre-registration clutch and the pre-registration gear to the pre-registration support.
Page 102: Feeder Pre-Registration Rollers
Feeder pre-registration rollers Remove the feeder pre-registration clutch as explained in the previous procedure. Slide the blue feeder pre-registration knob off the feeder pre- registration shaft. Remove two screws securing the multi-purpose tray out holder to the paper feeder. Pull the holder away from the feeder. Remove the E-ring and front bearing securing the front of the feeder registration shaft to the paper feeder frame.
Page 103: Removing The Feeder Pre-Registration Roller
Front bearing Idler gear Pre-registration knob Out holder Pre-registration gear 2 Pre-registration roll shaft 780-5-38 Removing the feeder pre-registration roller Phaser 780 Color Printer...
Page 104: Paper-Pick Turn Roller
Paper-pick turn roller Remove Tray 1 from the printer. Remove the paper feeder. Remove the two screws securing the turn chute to the printer frame. Remove the turn chute. Remove the paper-pick turn chute. Remove the two screws securing the tray stopper to the printer frame. Remove the stopper.
Page 105: Paper Feed Drive Gear Train
Paper feed drive gear train Remove the high voltage poser supply as described in “High voltage power supply” on page 132. Slide the paper feeder out of the printer. Remove the screw securing the wire clip to the paper-feed drive gear train.
Page 106: Paper-Feed Motor
Paper-feed motor Remove the rear cover. Disconnect the wiring harness from the paper-feed motor. Remove the four screws securing the paper-feed motor to the fuser drive gear train. Remove the motor. Remove the two motor supports. Reverse these steps to install the paper-feed motor. Paper feed motor Motor...
Page 107: Multi-Purpose Tray Roller Assembly
Multi-purpose tray roller assembly Remove the multi-purpose tray top, front and rear covers. Unhook the pick-up spring from the pick-up gear. Release the latches holding the pick-up gear to the pick-up shaft. Slide the pick-up gear, pick-up cam gear, and lever stopper off the shaft. Remove the E-ring securing the rear shaft bearing to the rear of the multi-purpose tray.
Page 108: Multi-Purpose Tray Pick Rollers
Multi-purpose tray pick rollers Note Replace the pick rollers as a set. Remove the multi-purpose tray top cover. Release the latch holding the front pick roller core to the pick up shaft and slide the core away from the front pick roller. Slide the front pick roller toward the front roller core, so the pick up roll clears the locking pin.
Page 109: Removing The Multi-Purpose Tray Pick Rollers
Reverse these steps to install the multi-purpose tray pick rollers. Note the arrows molded into the sides of the pick roller; ensure they are oriented the correct direction upon installation. Latch Pick-up rollers Printer front Front core rollers Rear core rollers 780-5-26 Removing the multi-purpose tray pick rollers Phaser 780 Color Printer...
Page 110: Auto-Density Calibration Sensor
Auto-density calibration sensor Caution Protect the accumulator belt with a sheet of paper. Remove the imaging unit. Remove the inner cover. Disconnect the wiring harness from the auto-density calibration sensor. Remove the E-ring securing the front of the auto-density calibration sensor to the front of the printer frame.
Page 111: Removing The Auto-Density Calibration Sensor
Rear cutout Auto-density calibration sensor 780-5-48 Removing the auto-density calibration sensor Phaser 780 Color Printer...
Page 112: Developer Assembly
Developer assembly Open the front cover. Remove the toner cartridge of the developer assembly to be removed. Remove the imaging unit. Remove the top cover and inner cover. Remove the screw securing the carousel latch to the front of the printer frame.
Page 113: Removing A Developer Assembly
Carousel latch Developer assembly Shoulder screw Remove shipping developer cover before installing new developer assembly 780-5-53 Removing a developer assembly Phaser 780 Color Printer...
Page 114: Developer Clutch
Developer clutch Remove the carousel motor board as described in “Carousel motor board” on page 108. Disconnect the wiring harness from the developer clutch. Remove the fuser drive train gear as described in “Fuser drive gear train” on page 126. Remove the four screws securing the developer clutch to the printer frame.
Page 115: Developer Tie Plate
Developer tie plate Remove the lower exit assembly as described in “Lower exit assembly” on page 128. Remove the rear cover. Remove the inner cover. Remove the wire and wire clamp from the developer tie plate. Remove the two screws securing the developer tie plate to the rear of the printer frame.
Page 116: Removing The Developer Tie Plate
Developer tie plate Wire clamp 780-5-82 Removing the developer tie plate Service Guide...
Page 117: Toner/Developer Dispense Motor
Toner/developer dispense motor Remove the carousel motor board as described in “Carousel motor board” on page 108. Remove the two screws securing the toner/developer dispense motor to the printer frame. Slide the toner/developer dispense motor up and slightly to the left to free the motor shaft gear from the frame.
Page 118: Carousel Assembly
Carousel assembly Remove each developer assembly. Remove the knob screw. Remove the screw securing the knob in place. Release the knob latch by inserting a screwdriver blade through the slot in the front of the knob. Remove the carousel motor. Remove the toner/developer dispense motor.
Page 119: Removing The Carousel Assembly
Screw Carousel assembly Front bearing Rear bearing 780-5-54 Removing the carousel assembly Phaser 780 Color Printer...
Page 120: Carousel Motor
Carousel motor Remove the rear cover. Disconnect the wiring harness from the carousel motor. Remove the three screws securing the carousel motor to the printer frame. Remove the motor. Reverse these steps to install the carousel motor. Wiring harness Carousel motor 780-5-78 Removing the carousel motor Service Guide...
Page 121: Carousel Motor Board
Carousel motor board Remove the rear cover. Remove the wiring harnesses from the carousel motor board. Remove the screw securing the carousel motor board to the printer frame. Remove the board. Reverse these steps to install the carousel motor board. Wiring harness Carousel motor board 780-5-79...
Page 122: Carousel Sensor
Carousel sensor Remove the developer fan duct. Remove the screw securing the carousel sensor plate to the printer frame. Remove the plate, along with the attached carousel sensor, from the frame. Disconnect the wiring harness from the carousel sensor. Squeeze the three latches securing the sensor to the plate and remove the sensor.
Page 123: Laser Unit
Laser unit Remove the top cover. Remove the eight screws securing the laser unit cover to the printer frame and remove the cover. Disconnect the wiring harnesses from the laser diode board. Disconnect the wiring harness from the start-of-scan sensor board. Remove the four screws securing the laser unit to the printer frame.
Page 124: Removing The Laser Unit
Laser cover Laser unit 780-5-47 Removing the laser unit Service Guide...
Page 125: Erase Lamp Rail Assembly
Erase lamp rail assembly Remove the imaging unit. Remove the laser unit as described in “Laser unit” on page 110. Disconnect the wiring harness from the waste cartridge full sensor. Disconnect the wiring harness from the waste cartridge sensor. Free the wiring harnesses from the wire clamps. Disconnect the wiring harness from the erase lamp.
Page 126: Removing The Erase Lamp Rail Assembly
Disconnect wiring harnesses Wire clamps Erase lamp rail assembly 780-5-50 Removing the erase lamp rail assembly Service Guide...
Page 127: Erase Lamp
Erase lamp Remove the erase lamp rail assembly as described in “Erase lamp rail assembly” on page 112. Release the three latches holding the erase lamp assembly to the erase lamp rail assembly. Remove the lamp. Reverse these steps to install the erase lamp. Erase lamp Erase lamp latch 780-5-49...
Page 128: Process Drive Unit
Process drive unit Remove the imaging unit. Remove the paper feeder. Remove the paper feeder drive assembly. Remove the erase lamp rail assembly. Disconnect the wiring harness leading to the process motor. Unhook the wires from the wire harness clip attached to the process drive unit. Remove the screw securing the high voltage power supply bracket.
Page 129: Removing The Process Drive Unit
Accumulator belt bracket Process drive unit High voltage power supply bracket Wiring harness 780-5-77 Removing the process drive unit Phaser 780 Color Printer...
Page 130: Waste Auger Assembly
Waste auger assembly Caution Be careful not to spill waste toner from the auger assembly. Vacuum the auger before removal. Remove the accumulator belt assembly. Remove second bias transfer roller assembly. Remove the paper-feed motor. Remove the fuser drive gear train to access the screw securing the plastic bracket holding the water auger housing.
Page 131: Removing The Waste Auger Assembly
Waste auger drive assembly Waste auger assembly 780-5-64 Removing the waste auger assembly Phaser 780 Color Printer...
Page 132: Accumulator Belt Assembly
Accumulator belt assembly Remove the high voltage power supply. Remove the erase lamp rail assembly. Remove the paper feeder. Remove the process drive unit. Remove the auto-density calibration sensor. Reach through the paper feeder cavity and disconnect the wiring harness from the accumulator belt sensor. Move the waste auger assembly for clearance.
Page 133: Removing The Accumulator Belt Assembly
Spring loaded collar Bearing fits in hole Accumulator belt assembly Accumulator belt assembly 780-5-59 Removing the accumulator belt assembly Phaser 780 Color Printer...
Page 134: Accumulator Belt Cleaner Assembly
Accumulator belt cleaner assembly Remove the fuser assembly as described in “Fuser assembly” on page 125. Open the front cover. Reach through the empty fuser cavity and hold the bottom of the belt cleaner assembly. Loosen the two screws securing the cleaner support to the printer frame.
Page 135: Second Bias Transfer Roller Assembly
Second bias transfer roller assembly Remove the fuser assembly as described in “Fuser assembly” on page 125. Remove the accumulator belt cleaner assembly as described in the topic “Accumulator belt cleaner assembly” on page 121. Reach through the empty fuser cavity and slide the second bias transfer roller assembly out of the second bias transfer roller front and rear brackets and out of the printer.
Page 136: Second Bias Transfer Roller Cam Assembly
Second bias transfer roller cam assembly Remove the second bias transfer roller assembly as described in “Second bias transfer roller assembly” on page 122. Remove the second bias transfer roller cam assembly as described in “Second bias transfer roller cam assembly” on page 123. Remove the waste auger assembly as described in “Waste auger assembly”...
Page 137: Removing The Second Bias Transfer Roller Cam Assembly
Wiring harness Second bias transfer roller cam assembly 780-5-60 Removing the second bias transfer roller cam assembly Phaser 780 Color Printer...
Page 138: Fuser Assembly
Fuser assembly Turn off the printer and open the top media tray. Remove the screw securing the fuser assembly to the printer frame. Slide the fuser assembly a few inches out of the printer. Lift the end of the fuser assembly and pull the assembly out of the printer.
Page 139: Fuser Drive Gear Train
Fuser drive gear train Remove the fuser unit. Remove the low voltage power supply. Remove the paper feed drive gear train. Remove the wire harness from the paper-feed motor bracket. Remove the screw securing the paper-feed motor bracket to the fuser- drive gear train and remove the bracket.
Page 140: Removing The Fuser-Drive Gear Train
Fuser drive gear train E ring Paper feed motor bracket Auger assembly 780-5-74 Removing the fuser-drive gear train Service Guide...
Page 141: Lower Exit Assembly
Lower exit assembly Remove the left door by pushing in on its front hinge to free it from the printer. Disconnect the wiring harnesses near the top rear of the lower exit assembly. Remove the ﬁve screws securing the lower exit assembly to the printer frame.
Page 142: Removing The Lower Exit Assembly
Lower exit assembly Wiring harness 780-5-68 Removing the lower exit assembly Service Guide...
Page 143: Full Stack Sensor
Full stack sensor Open the left door. Remove the screw securing the full stack sensor and its bracket. Squeeze the four latches securing the full stack sensor to the bracket. Disconnect the sensor’s connector P/J 167 Reverse these steps to install the full stack sensor. Full stack sensor 780-5-158...
Page 144: Low Voltage Power Supply
Low voltage power supply Remove the rear cover. Disconnect the wiring harness from the top of the low voltage power supply. All the wiring harnesses plugs are held in place with locking levers. Disconnect the remaining wiring harnesses from the low voltage power supply.
Page 145: High Voltage Power Supply
High voltage power supply Remove the rear cover. Disconnect the wiring harnesses from the bottom of the high voltage power supply. Disconnect the ﬁve high-voltage wiring harness from the high voltage power supply. Remove the four screws securing the high voltage power supply to the high voltage power supply brackets.
Page 146: Image Processor
Image processor Disconnect all interface cables connecting to the image processor. Remove the right cover. Disconnect all wiring harnesses from the image processor. Remove the 10 screws securing the image processor to the image processor chassis. Pull the image processor away from the chassis, disconnecting the image processor from the engine control board.
Page 147: Image Processor Chassis
Image processor chassis Remove the image processor fan. Remove the image processor as descried in “Image processor” on page 133. Loosen, but do not remove, the four screws securing the bottom of the image processor chassis assembly to the printer frame. Remove the ﬁve screws securing the top of the image processor chassis assembly to the printer frame.
Page 148: Print Engine Control Board
Print engine control board Perform the Life Date: Save Life Count described in “Running built-in diagnostics” on page 69 to save the information stored in the print engine control board NVRAM in the image processor board. Remove the image processor chassis. Disconnect the nine wiring harnesses connected to the print engine control board.
Page 149 Phaser 780 Color Printer...
Page 150: Fru List
FRU List This topic provides a list of ﬁeld replaceable units for the Phaser 780 Color Printer. Changes to Tektronix products are made to accommodate improved components as they become available. It is important when ordering parts to include the following information: Component's part number Product type or model number...
Page 151: Printer Cabinet Frus
Z780-5-119 Printer cabinet FRUs Phaser 780 Color Printer...
Page 152: Printer Cover Frus
Table 1 Printer cover FRUs Parts Part number Serial number Qty Name and description Effective Discont’d 118-9714-00 Front cover assembly kit Front cover Hinge plate Front cover strap Hardware 118-9733-00 Inner cover (includes 3a and 3b) 118-9715-00 Carousel latch kit Carousel latch lever Carousel latch spring Carousel latch assembly...
Page 153: Paper Feeder Frus
Z780-5-120 Paper feeder FRUs Phaser 780 Color Printer...
Page 154: Paper Feeder Frus
Table 2 Paper feeder FRUs Parts Part number Serial number Qty Name and description Effective Discont’d 118-9747-00 Size switch board 118-9742-00 Feed gear 118-9743-00 Feed spring 118-9744-00 Feed solenoid 118-9717-00 Paper pick rollers 118-9718-00 Turn roller assembly kit Turn gear pin Turn arm spring Turn rear bearing Turn assembly...
Page 155: Multi-Purpose Tray Cover Frus
780-5-121 Multi-purpose tray cover FRUs Phaser 780 Color Printer...
Page 156: Multi-Purpose Tray Cover Frus
Table 3 Multi-purpose tray cover FRUs Parts Part number Serial number Qty Name and description Effective Discont’d 118-9748-00 Multi-purpose tray left (front) cover 118-9749-00 Multi-purpose tray right (rear) cover 118-9751-00 Multi-purpose tray/extender 118-9750-00 Multi-purpose tray holder 118-9720-00 Multi-purpose tray assembly (items 1 thru 4) Service Guide...
Page 157: Multi-Purpose Tray Frus
780-5-122 Multi-purpose tray FRUs Phaser 780 Color Printer...
Page 158: Multi-Purpose Tray Frus
Table 4 Multi-purpose tray FRUs Parts Part number Serial number Qty Name and description Effective Discont’d 118-9763-00 Multi-purpose tray pad kit 118-9752-00 Multi-purpose tray edge sensor 118-9754-00 Multi-purpose tray paper sensor actuator 118-9827-00 Multi-purpose tray paper sensor 118-9756-00 Multi-purpose tray pick-up cam gear 118-9757-00 Multi-purpose tray cam gear spring 118-9758-00...
Page 159: Paper Feeder Cover Frus
780-5-123 Paper feeder cover FRUs Phaser 780 Color Printer...
Page 160: Paper Feeder Cover Frus
Table 5 Paper feeder cover FRUs Parts Part number Serial number Qty Name and description Effective Discont’d 118-9766-00 Paper feeder turn chute 118-9765-00 Paper feeder cover 118-9865-00 paper feeder assembly Service Guide...
Page 161: Paper Feeder Frus
780-5-124 Paper feeder FRUs Phaser 780 Color Printer...
Page 162: Paper Feeder Frus
Table 6 Paper feeder FRUs Parts Part number Serial number Qty Name and description Effective Discont’d 118-9771-00 Registration rubber roller 118-9768-00 Feeder pre-registration roller 118-9770-00 Registration clutch 118-9721-00 Registration spring kit Rear spring (black) Front spring (silver) 118-9769-00 Pre-registration clutch 118-9767-00 Pre-registration knob 118-9752-00...
Page 163: Imaging Frus
780-5-125 Imaging FRUs Phaser 780 Color Printer...
Page 164: Imaging Frus
Table 7 Imaging FRUs Parts Part number Serial number Qty Name and description Effective Discont’d 118-9774-00 Laser unit 118-9778-00 Erase lamp 118-9777-00 Auto-density calibration sensor assembly 118-9722-00 Bias charge roller connector kit with wiring harness 118-9779-00 Waste cartridge full sensor 118-9780-00 Waste cartridge installed sensor 118-9781-00...
Page 165: Developer Frus
780-5-126 Developer FRUs Phaser 780 Color Printer...
Page 166: Developer Frus
Table 8 Developer FRUs Parts Part number Serial number Qty Name and description Effective Discont’d 118-9782-00 Developer assembly, Black 118-9783-00 Developer assembly, Cyan 118-9784-00 Developer assembly, Magenta 118-9785-00 Developer assembly, Yellow 116-0073-00 Developer shim kit (1 each of 4 sizes) Service Guide...
Page 167: Carousel Frus
780-5-127 Carousel FRUs Phaser 780 Color Printer...
Page 168: Carousel Frus
Table 9 Carousel FRUs Parts Part number Serial number Qty Name and description Effective Discont’d 118-9787-00 Toner cartridge presence sensor 118-9724-00 Developer contact assembly 118-9820-00 Carousel knob 118-9723-00 Carousel assembly kit Carousel knob Carousel front bearing Carousel frame Carousel rear bearing 118-9788-00 New toner cartridge sensor 118-9786-00...
Page 169: Accumulator Belt Assembly Frus
780-5-128 Accumulator belt assembly FRUs Phaser 780 Color Printer...
Page 170: Accumulator Belt Assembly Frus
Table 10 Accumulator belt assembly FRUs Parts Part number Serial number Qty Name and description Effective Discont’d 118-9790-00 Tension lever 118-9726-00 Belt cleaning assembly kit Cleaner support assembly Belt cleaner 118-9791-00 Second bias transfer roller cam assembly 118-9789-00 Accumulator belt assembly 118-9793-00 Waste auger assembly 118-9792-00...
Page 171: Fuser Assembly Frus
780-5-129 Fuser assembly FRUs Phaser 780 Color Printer...
Page 172: Fuser Assembly Frus
Table 11 Fuser assembly FRUs Parts Part number Serial number Qty Name and description Effective Discont’d 118-9886-01 Fuser, 110 VAC 118-9887-01 Fuser, 220 VAC 016-1866-00 Fuser roll cartridge 118-9986-00 Fuser tray release lever 118-9727-00 Fuser assembly 110V 118-9728-00 Fuser assembly 220V Service Guide...
Page 173: Paper Exit Frus
780-5-130 Paper exit FRUs Phaser 780 Color Printer...
Page 174: Paper Exit Frus
Table 12 Paper exit FRUs Parts Part number Serial number Qty Name and description Effective Discont’d 118-9798-00 Lower exit assembly 118-9799-00 Upper exit assembly 118-9800-00 Exit tray assembly Service Guide...
Page 175: Paper Exit Frus
780-5-131 Paper exit FRUs Phaser 780 Color Printer...
Page 176: Paper Exit Frus
Table 13 Paper exit FRUs Parts Part number Serial number Qty Name and description Effective Discont’d 118-9729-00 Exit upper roller kit Exit idler gear Exit spur gear Exit rear bearing Exit-3 roller Exit front bearing Exit-2 roller 118-9802-00 Exit door switch 118-9801-00 Media exit sensor with ﬂag 118-9803-00...
Page 177: Drive Frus
780-5-132 Drive FRUs Phaser 780 Color Printer...
Page 178: Drive Frus
Table 14 Drive FRUs Parts Part number Serial number Qty Name and description Effective Discont’d 118-9804-00 Paper feed drive assembly 118-9806-00 Process drive assembly Process motor (part of process drive assembly) 118-9809-00 Carousel motor board 118-9810-00 Toner/developer dispense motor 118-9811-00 Developer clutch 118-9730-00 Paper feed motor assembly kit...
Page 179: Electronic (Rear) Frus
Part of Carousel FRU Part 2 Part of Imaging FRU Part 4 780-5-133 Electronic (rear) FRUs Phaser 780 Color Printer...
Page 180: Electronic (Rear) Frus
Table 15 Electronic (rear) FRUs Parts Part number Serial number Qty Name and description Effective Discont’d 118-9873-00 High voltage power supply board 118-9731-00 Developer fan kit Developer fan Developer fan duct 118-9816-00 Top cover switch 118-9817-00 Fuser connector, Main 119-5871-00 Low voltage power supply, 110 VAC 119-5872-00 Low voltage power supply, 220 VAC...
Page 181: Electronics (Front) Frus
780-5-134 Electronics (front) FRUs Phaser 780 Color Printer...
Page 182: Electronic (Front) Frus
Table 16 Electronic (front) FRUs Parts Part number Serial number Qty Name and description Effective Discont’d 118-9822-00 Front cover switch, right 118-9821-00 Front cover switch, left 118-9815-00 Exit connector-8 118-9814-00 Exit connector -4 118-9824-00 Video harness 118-9825-00 Laser unit harness 118-9796-00 Engine control board 118-9823-00...
Page 183: Image Processor Frus
780-5-135 Image processor FRUs Phaser 780 Color Printer...
Page 184: Image Processor Frus
Table 17 Image processor FRUs Parts Part number Serial number Qty Name and description Effective Discont’d 118-9826-00 Image processor fan 118-9885-00 Front panel harness 671-4303-80 Image processor board 156-4759-00 RAM DIMM, 32 Mbytes 156-4765-00 RAM DIMM, 64 Mbyte 156-4780-00 RAM DIMM, 128 Mbyte 671-4759-00 Font ROM SIMM, Kanji 671-4687-00...
Page 185: Optional Lower Feeder Cabinet Frus
780-5-136 Optional lower feeder cabinet FRUs Phaser 780 Color Printer...
Page 186: Optional Lower Feeder Cabinet Frus
Table 18 Optional lower feeder cabinet FRUs Parts Part number Serial number Qty Name and description Effective Discont’d 118-9923-00 Lower feeder front cover 118-9926-00 Lower feeder left cover 118-9924-00 Lower feeder rear cover 118-9925-00 Lower feeder harness cover 118-9928-00 Lower feeder chute assembly 118-9929-00 Lower feeder chute support 118-9927-00...
Page 187: Optional Feeder Frus
10: Items 1 thru 9 780-5-137 Optional Feeder FRUs Phaser 780 Color Printer...
Page 188: Optional Feeder Frus
Table 19 Optional feeder FRUs Parts Part number Serial number Qty Name and description Effective Discont’d 118-9931-00 Lower feeder assembly 118-9934-00 Lower feeder gear assembly 118-9933-00 Lower feeder motor 118-9936-00 Lower feeder interface harness 118-9935-00 Lower feeder circuit board 118-9747-00 Lower feeder paper size sensor 118-9932-00 Lower feeder turn-in chute...
Page 189: Supplies And Accessories
Supplies and accessories Table 20 Supplies and accessories Parts Part number Serial number Qty Name and description Effective Discont’d 016-1678-00 Toner Cartridge, Black 016-1679-00 Toner Cartridge, Cyan 016-1680-00 Toner Cartridge, Magenta 016-1681-00 Toner Cartridge, Yellow 016-1864-00 Imaging Unit Cartridge 016-1865-00 Imaging Unit Waste Cartridge 016-1866-00 Standard Fuser Roll Cartridge...
Page 190 Table 20 Supplies and accessories Parts Part number Serial number Qty Name and description Effective Discont’d 063-3040-20 User Guide, Italian 063-3040-30 User Guide, German 063-3040-40 User Guide, Spanish 063-3040-05 User Guide, Russian 063-3041-00 Quick Reference Guide, Service 063-3094-00 Setup Guide, English 063-3094-10 Setup Guide, French 063-3094-20...
Page 191 Table 20 Supplies and accessories Parts Part number Serial number Qty Name and description Effective Discont’d 003-1633-00 IC PLCC Extractor Tool 065-0574-00 Repackaging Kit 650-3572-01 Rebanding Kit 650-3971-00 Recycle kit for developer assemblies, California only 003-1496-00 Vacuum cleaner, 110/115 VAC 003-1497-00 Vacuum cleaner, 220/240 VAC 003-1498-00...
Page 192: Test Prints
Test Prints This topic illustrates the test prints produced by the print engine. It also illustrates a number of defective prints and the reason for the defects. The topic “Printing and print quality problems” on page 43 discusses solutions to the problems shown in this appendix.
Page 193 Interpreting Service Print 2 Service print 2 should always be printed on B-size paper. Color registration. The thin lines should not be above or below the think line. Preferable they should be centered. Blur. The lines should be crisp and sharp with no “fuzzy”...
Page 194 Interpreting Service Print 4 Service print 2 should always be printed on B-size paper. The print reveals repeating defects that can be traced back to defects on the printers belts, drum or rollers. Look for repeating defects inline down the print. Refer to the topic “Repetitive mark appears on each print”...
Page 195 Interpreting Sevice Print 6: Magenta Calibration Page Service print 6 is a 100% magenta solid ﬁll. Refer to the topic “Printing and print quality problems” on page 43 for solution to any print problems detected. Look for voids, repeating spots and banding. This solid ﬁll is also useful for ﬂushing out defective magenta toner.
Page 196 Interpreting Sevice Print 8: Black Calibration Page Service print 8 is a 100% black solid ﬁll. Refer to the topic “Printing and print quality problems” on page 43 for solution to any print problems detected. Look for voids, repeating spots and banding. This solid ﬁll is also useful for ﬂushing out defective black toner.
Page 197 Phaser 780 Color Printer...
Page 198: Wiring Diagrams
Wiring Diagrams J 42 HIGH VOLTAGE POWER SUPPLY J 16 J 41 LOW VOLTAGE J 35 POWER SUPPLY J 32 J 33 (BCR) BIAS CHARGE ROLLER J 79 J 195 J 196 SECOND J 21 J 12 J 97 J 191 J 192 J 193 J 194 J 70 RIGHT J 72...
Page 199: Plug/Jack Locations - 1
Plug/Jack Locations - 1 Map & Coordinates Connected to... Other end connected to... Map 2-D205 Engine control board Map 2-E205 Engine control board Image processor board Map 2-D205 Engine control board Low voltage power supply P/J33 Map 2-D205 Engine control board Laser Diode board P/J122 Map 2-D204 Engine control board...
Page 200: Plug/Jack Locations - 2
Plug/Jack Locations - 2 Map & Coordinates Connected to... Other end connected to... Map 6-E609 Mounted on Paper feed motor board Map 6-E608 Mounted on Paper feed motor board Map 6-D608 Process Motor Low voltage power supply P/J32 Map 6-D607 Process Motor Engine control board P/J17 Map 7-E708...
Page 201: Plug/Jack Locations - 3
Plug/Jack Locations - 3 Map & Coordinates Connected to... Other end connected to... Map 8-I813 P/J74 Fuser tray assembly P/J71 Map 8-H807 Fuser exit sensor Fuser assembly P/J72B Map 8-F813 P/J117 fuser entry sensor Fuser assembly P/J76A Map 8-F813 P/J76 Fuser tray assembly P/J71 Map 8-G808 CRU switch assembly...
Page 202: Plug/Jack Locations - 4
Plug/Jack Locations - 4 Map & Coordinates Connected to... Other end connected to... Map 4-G409 P/J90B Paper feeder P/J91 Map 4-G409 P/J90A Loop Map 2-D211 Paper feeder Engine control board P/J20 Map 4-E408 Map 4-E409 Multi-purpose tray assembly P/J92B Paper feeder P/J91 Map 4-E409 Multi-purpose tray assembly Paper feeder P/J92A...
Page 203: Fuser Fan
Plug/Jack Locations - 5 Map & Coordinates Connected to... Other end connected to... Map 2-E213 Tray no paper sensor P/J 101 Map 4-D409 Registration brake clutch P/J109A 109A Map 4-D409 P/J109 Paper feeder P/J91 110A Map 4-G408 P/J110B Paper feeder P/J91 110B Map 4-G408 P/J94A, P/J95A, &...
Page 204: Plug/Jack Locations - 6
Plug/Jack Locations - 6 Map & Coordinates Connected to... Other end connected to... 161B Map 8-D805 P/J161A Top Exit sensor P/J165 Exit Chute switch P/J166 163A Map 7-G707 P/J163B Engine control board P/J17 Map 8-D805 163B Map 8-D805 P/J163A Full Stack sensor P/J167 Map 8-F804 Top exit sensor P/J161B...
Page 205: Plug/Jack Locations - 7
Plug/Jack Locations - 7 Map & Coordinates Connected to ... Other end connected to ... Map 4-G409 Multi-purpose tray long no paper Multi-purpose tray Assembly P/J92B sensor P/J207 Map 4-F409 Multi-purpose tray assembly P/J92B P/J204 P/J205 P/J206 Map 6-F608 Carousel motor board Engine control board P/J16 Map 6-F607 Carousel motor board...
Page 206: Map 1 - Wiring Routing At The Top And Front Of The Printer
The following illustrations detail the proper means of routing and dressing printer wiring. Incorrect wiring dressing can result in wires pinched by cabinet panels or damaged by moving parts of the printer. 83, 83A 116, 116A 86, 86A F422 84, 84A 81, 81A 3041-10 Map 1 –...
Page 207: Map 2 - Wire Routing Around The Engine Control Board
22, 22A 105, 105A 103, 103A 106, 106A 101, 101A 104, 104A 3041-11 Map 2 – Wire routing around the engine control board Phaser 780 Color Printer...
Page 208: Map 3 - Wiring Routing Around The Image Processor Board
3041-12 Map 3 – Wiring routing around the image processor board Service Guide...
Page 209: Map 4 - Wiring Routing Around The Paper Feeder
94, 94A 110A, 110B 95, 95A 201A, 201B 202A, 202B 109, 109A 113A, 113B 92A, 92B 90A, 90B 3041-13 Map 4 – Wiring routing around the paper feeder Phaser 780 Color Printer...
Page 210: Map 5 - Wire Routing Around The Laser Scanner And High Voltage Power Supply
197, 197A F421 F423 3041-14 Map 5 – Wire routing around the laser scanner and high voltage power supply Service Guide...
Page 211: Map 6 - Wire Routing At The Rear Of The Printer
195, 195A 82, 82A (CN4) 132, 132A 50(CN2) 131, 131A 49(CN1) 103A (CN3) 3041-15 Map 6 – Wire routing at the rear of the printer Phaser 780 Color Printer...
Page 212: Map 7 - Wire Routing Around The Power Supply
161A 163A 111A 63, 63A 56.56A 71, 71A 3041-16 Map 7 – Wire routing around the power supply Service Guide...
Page 213: Map 8 - Wire Routing Around The Fuser
161A, 161B 163A, 163B F791 77, 77A 111A, 111B 62, 62A 80, 80A 78A, 72A, 72B 69A, 76, 76A 3041-17 Map 8 – Wire routing around the fuser Phaser 780 Color Printer...
Page 214: Wiring 1 - Low Voltage Power Supply, Laser Unit, And Interlock Switches
ENGINE LOW VOLTAGE POWER SUPPLY CONTROL BOARD PAPER FEEDER LASER UNIT 3041-19 Wiring 1 – Low voltage power supply, laser unit, and interlock switches Service Guide...
Page 215: Wiring 2 - Engine Control Board, Auto-Density Calibration Sensor, Erase Lamp, Waste Toner Sensor
3041-20 Wiring 2 – Engine control board, auto-density calibration sensor, erase lamp, waste toner sensor Phaser 780 Color Printer...
Page 216: Wiring 3 - Low Voltage Power Supply, Engine Control Board, High-Voltage Power Supply And Imaging Components
ENGINE HIGH VOLTAGE POWER SUPPLY CONTROL BOARD VOLTAGE POWER SUPPLY BIAS 2ND BIAS TRANSFER CHARGE ROLLER CAM ASSY FIRST ROLLER BIAS TRANSFER CONNECTOR ROLLER ASSY BIAS PLATE FIRST BIAS DEVELOPER ASSY TRANSFER ROLLER ACCUMULATOR BELT ASSY SECOND SECOND BIAS BIAS TRANSFER TRANSFER ROLLER...
Page 217: Wiring 4 - Engine Control Board, Used Cartridge Sensor, Cartridge Sensor, Carousel Sensor, Developer Clutch, Developer Fan, Toner Dispense Motor
ENGINE CONTROL BOARD CAROUSEL SENSOR CAROUSEL HOME SENSED(H) 5VDC TONER DISPENSE MOTOR ASSY TONER DISPENSE MOTOR ON(L) 24VDC 3041-22 Wiring 4 – Engine control board, used cartridge sensor, cartridge sensor, carousel sensor, developer clutch, developer fan, toner dispense motor Phaser 780 Color Printer...
Page 218: Wiring 5 - Engine Control Board, Low Voltage Power Supply, Carousel Motor Board
ENGINE CAROUSEL MOTOR CONTROL BOARD CAROUSEL MOTOR BOARD ASSY CAROUSEL MOTOR HOLD (L) 5VDC CAROUSEL MOTOR ON (L) 5VDC CAROUSEL MOTOR CLOCK LOW VOLTAGE POWER SUPPLY 3041-23 Wiring 5 – Engine control board, low voltage power supply, carousel motor board, rotary motor Service Guide...
Page 219: Wiring 6 - Engine Control Board, Low Voltage Power Supply, Bias Transfer Roller Cam Solenoid Accumulator Belt Sensor, Paper Feeder Motor, Process Motor
ENGINE CONTROL BIAS TRANSFER ROLLER CAM SOLENOID BOARD ACCUMULATOR SENSOR PAPER FEEDER LOW VOLTAGE POWER SUPPLY 3041-24 Wiring 6 – Engine control board, low voltage power supply, bias transfer roller cam solenoid accumulator belt sensor, paper feeder motor, process motor Phaser 780 Color Printer...
Page 220: Wiring 7 - Engine Control Board, Low Voltage Power Supply, Fuser, Oil Roll Assembly
LOW VOLTAGE POWER SUPPLY PRESSURE HEAT ROLLER ROLLER ENGINE CONTROL BOARD 3041-25 Wiring 7 – Engine control board, low voltage power supply, fuser, oil roll assembly Service Guide...
Page 221: Wiring 8 - Engine Control Board, Fuser Assembly, Environment Sensor
ENGINE CONTROL BOARD 3041-26 Wiring 8 – Engine control board, fuser assembly, environment sensor Phaser 780 Color Printer...
Page 222: Wiring 9 - Engine Control Board, Paper Size Switch Board, Feed Solenoid, No Paper Sensor, Low Paper Sensor
ENGINE PAPER SIZE SWITCH CONTROL ASSY BOARD 3041-27 Wiring 9 – Engine control board, paper size switch board, feed solenoid, no paper sensor, low paper sensor Service Guide...
Page 223: Wiring 10 - Engine Control Board, Paper Feeder
ENGINE CONTROL PAPER FEEDER BOARD FRONT TRANSPARENCY SENSOR REAR TRANSPARENCY SENSOR 3041-28 Wiring 10 – Engine control board, paper feeder Phaser 780 Color Printer...
Page 224: Wiring 11 - Engine Control Board, Paper Feeder, Multi-Purpose Tray
PAPER FEEDER MULTI-PURPOSE TRAY MULTI-PURPOSE TRAY EDGE SENSOR ENGINE CONTROL BOARD MULTI-PURPOSE TRAY EDGE PAPER SENSED (L) 5VDC MULTI-PURPOSE TRAY OHP SENSED (L) 5VDC MULTI-PURPOSE MULTI-PURPOSE TRAY TRAY OHP SENSOR LONG PAPER SENSED (L) 5VDC MULTI-PURPOSE TRAY LONG N/P SENSOR MULTI-PURPOSE TRAY SHORT N/P SENSOR MULTI-PURPOSE TRAY...
Page 225: Wiring 12 - Engine Control Board, Top Exit Sensor, Media Exit Switch, Full Stack Sensor, Fuser Fan
ENGINE CONTROL BOARD MEDIA EXIT SWITCH ON (L) 5VDC 3041-30 Wiring 12 – Engine control board, top exit sensor, media exit switch, full stack sensor, fuser fan Phaser 780 Color Printer...
Page 226: Wiring 13 - Engine Control Board, Image Processor Board, Front Panel, Image Processor
ENGINE CONTROL BOARD IMAGE PROCESSOR BOARD IMAGE PROCESSOR FAN FRONT PANEL 3041-31 Wiring 13 – Engine control board, image processor board, front panel, image processor fan Service Guide...
Page 227: Wiring 14 - Lower Tray Assembly Master Wiring Diagram
BOARD 1 BOARD 2 BOARD 4 BOARD 3 3041-59 Wiring 14 – Lower Tray Assembly master wiring diagram Phaser 780 Color Printer...
Page 228: Wiring 15 - Engine Control Board And Low Voltage Power Supply To Lower Tray
3041-60 Wiring 15 – Engine control board and low voltage power supply to Lower Tray Assembly feeder board Service Guide...
Page 229: Wiring 16 - Lower Tray Assembly Feeder Board To Feeder Chute Switch, Size Switches And Feeder Motor
3041-61 Wiring 16 – Lower Tray Assembly feeder board to feeder chute switch, size switches and feeder motor Phaser 780 Color Printer...
Page 230: Wiring 17 - Lower Tray Assembly Feeder Board To No Paper Sensors And Low Paper Sensors
3041-62 Wiring 17 – Lower Tray Assembly feeder board to no paper sensors and low paper sensors Service Guide...
Page 231: Wiring 18 - Lower Tray Assembly Feeder Board To Feed Solenoids And Turn Chutes
3041-63 Wiring 18 – Lower Tray Assembly feeder board to feed solenoids and turn chutes Phaser 780 Color Printer...
Page 232 Service Guide...
Page 233 Phaser 780 Color Printer...

This manual is also suitable for:

Phaser 780

Tektronix Z780N - Phaser 780 Color Laser Printer Reference Manual

General Information

Error Codes and Messages

Troubleshooting

Adjustments

Cleaning and Maintenance

Resetting NVRAM

Key FRU Disassembly

Quick Links

Troubleshooting

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Summary of Contents for Tektronix Z780N - Phaser 780 Color Laser Printer