Xerox Phaser 7700 Service Manual

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®
P H A S E R
7 7 0 0
C O L O R P R I N T E R
Service Guide
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.
This printing: November 2001
071-0860-01

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Summary of Contents for Xerox Phaser 7700

  • Page 1 ® P H A S E R 7 7 0 0 C O L O R P R I N T E R Service Guide 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 2: 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 NOTE , CAUTION and WARNING messages.
  • Page 3 Power Supply and Electrical Components: Before starting any service procedure, switch off the printer power and unplug the power cord from the wall outlet. If you must service the printer with power applied, be aware of the potential for electrical shock. Do not touch any electrical component unless you are instructed to do so by a service procedure.
  • Page 4 Fuser Components: WARNING: This printer uses heat to fuse the toner image to a sheet of paper. The Fuser Assembly is very hot. Switch off printer power and wait at least 30 minutes for the Fuser to cool before you attempt to service the Fuser Assembly or adjacent components.
  • Page 5 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.
  • Page 6 Federal Communications Commission 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 7 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 8: 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 observe all other safety precautions.
  • Page 10: Table Of Contents

    Contents General Information Phaser 7700 Printer overview ..................1-2 Printer RAM and printer capabilities ..............1-4 CRC life counter behavior ................1-5 Print Engine Control Boards and Power Supplies ..........1-6 Auxiliary Feeder Control Board ...............1-9 Print Engine Sensors and Switches ..............1-10 Auxiliary Feeders Sensors and Switches ............1-12 Print Engine Solenoids, Actuators and Clutches ...........1-14...
  • Page 11 Fans on, Front Panel LED never on .............. 3-92 Fans on, Front Panel LED is red, no Front Panel message ......3-92 Front Panel continually displays the Xerox Phaser 7700 splash screen ..3-92 Front Panel continually displays "warming up - please wait" message ..3-92 Front Panel displays "Fatal Fault Encountered"...
  • Page 12 Service preventive maintenance procedure ............5-129 Recommended tools ..................5-129 Cleaning ......................5-130 Resetting NVRAM 6-131 PostScript NVRAM Resets ..................6-131 Service Diagnostics NVRAM Resets ..............6-135 PostScript NVRAM Reset ................6-135 Clear Tech Rep Faults ...................6-135 Reset CRU Life Counters ................6-135 Reset Engine NVRAM .................6-136 Store Engine NVRAM ..................6-136 Removal and Replacement Procedures 7-137...
  • Page 13 PL 8-1 Accumulator Belt FRUs ..............8-216 PL 8-2 Left-Hand Door FRUs ..............8-217 PL 8-3 Media Trays FRUs ................8-218 PL 8-4 Duplex Unit FRUs ................8-219 PL 8-5 Cover FRUs ..................8-220 PL 8-6 Cover FRUs (cont’d.) ............... 8-221 Phaser 7700 Color Laser Printer...
  • Page 14 9-265 Analyzing the Test Print ................9-266 Print Color Test Prints ..................9-267 Diagnostics Mode ..................9-269 Wiring Diagrams 10-273 Phaser 7700 Finisher 11-291 Finisher Overview ....................11-292 General Information ...................11-293 Assemblies of the Finisher .................11-295 Internal Assemblies of the Finisher ..............11-296 Service Quick Reference Guide - Table of Contents...
  • Page 15 Paddle Shaft ..................11-317 Paper Transport Motor (Motor Assembly Main) ........ 11-318 Cam Bracket Assembly ............... 11-319 Staple Unit Assembly and Motor ............11-320 Compiler Tray ..................11-322 Finisher FRU Parts List 11-323 Finisher Wiring Diagrams 12-353 Phaser 7700 Color Laser Printer...
  • Page 16 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 printer ........1-24 Table 1-6 Physical dimensions of lower tray feeder...... 1-24 Table 1-7 Printer Clearances............
  • Page 17 Table 11-11 Paper Transport (cont’d.) ........11-341 Table 11-12 Staple Unit Assembly..........11-343 Table 11-13 Compiler Tray Assembly ........11-345 Table 11-14 Stacker Elevator Assembly ........11-347 Table 11-15 Exit Assembly ............11-349 Table 11-16 Electrical..............11-351 viii Phaser 7700 Color Laser Printer...
  • Page 18 List of Figures Figure 1-1 The 7700 Color Laser Printer (w / High-Cap Feeder) ..1-1 Figure 1-2 Engine Control Interface Board and Power Supplies ..1-6 Figure 1-3 Power Supplies ............... 1-7 Figure 1-4 Print Engine Control Boards .......... 1-8 Figure 1-5 Auxiliary Feeder Control Board ........
  • Page 19 Figure 7-41 Laser Unit Label ............7-185 Figure 7-42 Image Processor Board Assembly......7-186 Figure 7-43 Internal Hard Drive ..........7-187 Figure 7-44 Electrical Chassis Assembly ........7-188 Figure 7-45 Engine Control Board ..........7-190 Phaser 7700 Color Laser Printer...
  • Page 20 Figure 7-46 Engine Control Interface Board ....... 7-191 Figure 7-47 T1 and T3 High-voltage Power Supplies ....7-192 Figure 7-48 3.3 VDC and 5 VDC Low-Voltage Power Supplies 7-194 Figure 7-49 LD Power Relay ............7-195 Figure 7-50 Low-voltage Power Supply, Fan and Bracket ..7-196 Figure 7-51 T2 High-Voltage Power Supply .......
  • Page 21 Figure 8-28 High-Capacity Feeder FRUs (cont’d.) ..... 8-259 Figure 8-29 High-Capacity Feeder FRUs (cont’d.) ..... 8-260 Figure 11-1 Phaser 7700 Color Laser Printer w / Finisher ..11-291 Figure 11-2 Dimensions of the Finisher ........11-293 Figure 11-3 Assemblies of the Finisher ........11-295 Figure 11-4 Internal Assemblies of the Finisher .......
  • Page 22 Figure 11-28 Finisher Stand ............11-328 Figure 11-29 Gate Unit .............. 11-330 Figure 11-30 Horizontal Transport ..........11-332 Figure 11-31 Horizontal Transport (cont’d.) ......11-334 Figure 11-32 Top Cover and Eject Roll ........11-336 Figure 11-33 Paper Transport Assembly ........11-338 Figure 11-34 Paper Transport (cont’d.) ........
  • Page 23 Phaser 7700 Color Laser Printer...
  • Page 24: General Information

    General Information The Phaser 7700 Color Laser Printer Service Quick Reference Guide 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 25: Phaser 7700 Printer Overview

    1000-sheet, high-capacity stapler/stacker is available with the Lower Tray Deck or High-Capacity Feeder. The printer is marketed in three versions: The Phaser 7700 DN Printer comes standard with 128 Mbytes of RAM. The Phaser 7700 GX Printer features 256 Mbytes of RAM, a three-tray Lower Tray Deck, and PhaserMatch 7700 ICC Color Matching Software.
  • Page 26 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. For additional service information, refer to the Note Service CD-ROM or the Xerox Service Website: http://cpidserv.opbu.xerox.com. Service Quick Reference Guide - General Information...
  • Page 27: Printer Ram And Printer Capabilities

    The printer features two slots each which can contain a 64-, 128-, or 256-Mbyte SDRAM. Any slot may be used for any size memory module. SDRAM memory totalling beyond 512 Mbytes will be ignored. For acceptable memory, see “Supplies and accessories” on page 8-263. Phaser 7700 Color Laser Printer...
  • Page 28: 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 29: Print Engine Control Boards And Power Supplies

    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 Board and Power Supplies Phaser 7700 Color Laser Printer...
  • Page 30: Figure 1-3 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 Service Quick Reference Guide - General Information...
  • Page 31: Figure 1-4 Print Engine Control Boards

    Image Processor Board Engine Control Board S7700-381 Figure 1-4 Print Engine Control Boards Phaser 7700 Color Laser Printer...
  • Page 32: Auxiliary Feeder Control Board

    Auxiliary Feeder Control Board LTD Board (3T) HCF Board (TT) S7700-385 Figure 1-5 Auxiliary Feeder Control Board Service Quick Reference Guide - General Information...
  • Page 33: Print Engine Sensors And Switches

    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...
  • Page 34: Figure 1-7 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 Figure 1-7 Print Engine Sensors and Switches (cont’d.) 1-11 Service Quick Reference Guide - General Information...
  • Page 35: Auxiliary Feeders Sensors And Switches

    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 Tray 4 Take-Away Sensor S7700-316 Figure 1-8 Auxiliary Sensors and Switches 1-12 Phaser 7700 Color Laser Printer...
  • Page 36: Figure 1-9 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 tray 3 tray 4 Paper detect...
  • Page 37: Print Engine Solenoids, Actuators And Clutches

    CCW Duplex clutch Registration 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 (cont’d.) 1-14 Phaser 7700 Color Laser Printer...
  • Page 38 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- left-hand cover-interlock switch S7700-390 Figure 1-11 Print Engine and Auxiliary Feeder Interlocks and Sensors 1-15 Service Quick Reference Guide - General Information...
  • Page 39: 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...
  • Page 40: 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 1-17 Service Quick Reference Guide - General Information...
  • Page 41: Figure 1-14 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...
  • Page 42: Figure 1-15 Assemblies Of The Print Engine (Cont'd.)

    Exit transport assembly S7700-386 Figure 1-15 Assemblies of the Print Engine (cont’d.) 1-19 Service Quick Reference Guide - General Information...
  • Page 43: Figure 1-16 Auxiliary Feeder Assemblies

    (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...
  • Page 44: 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 45: Table 1-3 Front Panel Shortcuts

    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 Enter Service Diagnostics BACK+INFO 1-22 Phaser 7700 Color Laser Printer...
  • Page 46: 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 47: Specifications

    Weight 23.5 kg (52 lbs.) 5.0 cm 10.0 cm (1.96 in.) (4.0 in.) 36.8 cm 42.5 cm (14.5 in.) (16.7 in.) 160.4 cm (63.1 in.) 106.1 cm (41.8 in.) S7700-417 Table 1-7 Printer Clearances 1-24 Phaser 7700 Color Laser Printer...
  • Page 48: Table 1-8 Functional Specifications

    Table 1-8 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 49: Table 1-10 Environmental Specifications

    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 1-26 Phaser 7700 Color Laser Printer...
  • Page 50: 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 51: Table 1-11 Specialty Paper

    205 x 305 mm 5 mm 5 mm Oficio 215 x 340 mm 205 x 330 mm 5 mm 5 mm B6 JIS 128 x 182 mm 118 x 172 mm 5 mm 5 mm 1-28 Phaser 7700 Color Laser Printer...
  • Page 52 Table 1-12 Print area (cont'd.) Margins Paper Page size Image area Top / Sides Bottom B5 JIS 182 x 257 mm 172 x 247 mm 5 mm 5 mm B4 JIS 257 x 364 mm 247 x 354 mm 5 mm 5 mm 305 x 430 mm 297 x 420 mm...
  • Page 53 1-30 Phaser 7700 Color Laser Printer...
  • Page 54: 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 power on the printer to see if the error recurs.
  • Page 55: System Boot Sequence

    If Post detected any soft errors a message is printed in a red box on the start page. If POST detects any hard errors both the front panel and health Led blink the error code pattern, see LED Blink Patterns on page 3-33. 2-32 Phaser 7700 Color Printer...
  • Page 56: 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 57: Post Diagnostics Test Descriptions

    (Soft) Checks the disk controller core, and runs a DIAGNOSE command on the hard drive. Note If the fault code indicates 12, you must check the front panel to see if the test name is “CPU Interrupts” or “IDE Disk” before beginning troubleshooting. 2-34 Phaser 7700 Color Printer...
  • Page 58: 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 59: Service Diagnostics Test Menu Functions

    1. Highlight Yes and press OK. 1. Press UP/Down to Adjust. 2. Press OK to accept new value and Backlight On? exit. Jam Info No Static Jam Detected Location of Jam Static Jam: area name 2-36 Phaser 7700 Color Printer...
  • Page 60 Table 3-2 Service Diagnostics Test Menu Functions (cont'd.) Test Front Panel Display Test Operation, Results and Function Definition Built-In Test Prints Prints pre-defined images stored in the engine firmware for troubleshooting image quality problems. Paper Path For Print Laser Check only: Selects tray, count of/continuous sheets, Options simplex/duplex, offset, media type/weight, finisher, staple.
  • Page 61 Overhead Projection Sensor Sensor Right OHP is L L = Paper or OHP present H = Paper or OHP Band not present Duplex Sensor Duplex is L H = Paper present L = Paper not present 2-38 Phaser 7700 Color Printer...
  • Page 62 Table 3-2 Service Diagnostics Test Menu Functions (cont'd.) Test Front Panel Display Test Operation, Results and Function Definition Tray Feed Feed Out #1 is L H = Paper present Sensors Take Away (F/O #2) is L L = Paper not present Feed Out #3 is L Feed Out #4 is L Stack Full...
  • Page 63 Print Cartridge Print Cart. Yellow is H H = Cartridge present Sensors Print Cart. Magenta is H L = No cartridge present Print Cart. Cyan is H Print Cart. Black is H Engineering use only 2-40 Phaser 7700 Color Printer...
  • Page 64 Table 3-2 Service Diagnostics Test Menu Functions (cont'd.) Test Front Panel Display Test Operation, Results and Function Definition Finisher Sensors Interlocks Optional - only if Finisher is installed Left-Hand Cover is L H = Open, actuated or paper present Top Cover is L Docking is H L = Closed, deactuated or no paper Horiz.
  • Page 65 Motor Turn Motor Off All Motors Off Caution Dispenser Disp. Motor: Yellow Only run this test once per power cycle to avoid Motors Magenta excessive toner forced Cyan inside the developer and Black destroying it. 2-42 Phaser 7700 Color Printer...
  • Page 66 Table 3-2 Service Diagnostics Test Menu Functions (cont'd.) Test Front Panel Display Test Operation, Results and Function Definition Agitator Motor Motor On Press OK to run test. Motor Off Fuser Fan Fuser/Power Supply Fan is On Press Up/Down to change setting. Turn Motor Off All Motors Off Paper Path/No...
  • Page 67 For details on performing the RegiCon procedures, Registration Control Procedures on page 4-117 Belt Edge Learn Refer to (Processes of the RegiCon adjustment on page 4-117). RegiCon 685 Setup Refer to (Processes of the RegiCon Cycle adjustment on page 4-117). 2-44 Phaser 7700 Color Printer...
  • Page 68 Table 3-2 Service Diagnostics Test Menu Functions (cont'd.) Test Front Panel Display Test Operation, Results and Function Definition RegiCon Results Refer to Processes of the RegiCon Display adjustment on page 4-117. ATC Sensor Setup Refer to ATC Sensor Setup on page 4-127.
  • Page 69 Refer to Reset Engine NVRAM NVRAM on page 6-136. Are you sure? Store Engine **Writes data to HD** Refer to Store Engine NVRAM NVRAM on page 6-136. Are you sure? Exit Exits to PostScript without running POST. 2-46 Phaser 7700 Color Printer...
  • Page 70: 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 6-135. 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 71: Fig 3-2 Fuser Connector Pin Locations

    Fuser Connector Pin Locations S7700-427 Fig 3-2 Fuser Connector Pin Locations 2-48 Phaser 7700 Color Printer...
  • Page 72 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 7-140). Disconnect P400 (see figure page 3-47) and P401 (see figure page 3-47) on the Engine Con- trol Board.
  • Page 73 Replace the Developer Housing Assembly (RRP 27, on page 7-171). Replace the Engine Control Board (RRP 42, on page 7-190). Note Run approximately 10 pages of solid fill full-page prints of this primary color to ensure this error is cleared. 2-50 Phaser 7700 Color Printer...
  • Page 74 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 75 Replace the Developer Housing Assembly (RRP 27, on page 7-171). Replace the Engine Control Board (RRP 42, on page 7-190). Note Run approximately 10 pages of solid fill full-page prints of this primary color to ensure this error is cleared. 2-52 Phaser 7700 Color Printer...
  • Page 76 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 77 Perform the “2nd BTR Motor” several times. Does the voltage toggle between +5 VDC and 0 VDC when the test is run? Yes No Replace the Transfer Roller Retract Sensor. Replace the Engine Control Board (RRP 42, on page 7-190). 2-54 Phaser 7700 Color Printer...
  • Page 78 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 79 Inspect the belt steering mechanism to determine if it is operable. It may be necessary to query the user for additional information as to likely causes. If the problem persists, replace the Engine Control Board (RRP 42, on page 7-190). 2-56 Phaser 7700 Color Printer...
  • Page 80 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 81 LH door for foreign object or damage parts. It may be necessary to query the user for additional information as to likely causes. If the problem persists, replace the Engine Control Board (RRP 42, on page 7-190). 2-58 Phaser 7700 Color Printer...
  • Page 82 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 7-200). Inspect the connector for damage. Is the connector in good condition? Yes No Replace the Accumulator Belt Assembly (RRP 51, on page 7-200).
  • Page 83 If the problem persists, replace the Engine Control Interface Board (RRP 43, on page 7-191). 09-351 ERROR 34 Accumulator Belt DRIVE LOGIC FAILURE Replace the Accumulator Belt Drive Assembly (RRP 35, on page 7-180). If the problem persists, replace the Engine Control Board (RRP 42, on page 7-190) 2-60 Phaser 7700 Color Printer...
  • Page 84 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 85 Reinstall the Fuser. Switch printer power ON. Does the Fuser get warm? Yes No Replace the Chassis AC Power Assembly (RRP 49, on page 7-198). Replace the Engine Control Board (RRP 42, on page 7-190). 2-62 Phaser 7700 Color Printer...
  • Page 86 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 3-48) and P600-3 (see figure page 3-48).
  • Page 87 Does the resistance measure between 20K and 100K ohms? Yes No Repair or replace the wiring harness between the Engine Control Board and the Fuser. Replace the Engine Control Board (RRP 42, on page 7-190). 2-64 Phaser 7700 Color Printer...
  • Page 88 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 3-48).
  • Page 89 Reinstall the Fuser. Switch printer power ON. Does the Fuser get warm? Yes No Replace the Chassis AC Power Assembly (RRP 49, on page 7-198). Replace the Engine Control Board (RRP 42, on page 7-190). 2-66 Phaser 7700 Color Printer...
  • Page 90 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 7-140), Rear Shield (RRP 9, on page 7-149) and the Rear Shield Bracket (RRP 11, on page 7-151).
  • Page 91 Does the voltage still measure +5 VDC at P407-1? Yes No Replace the Print Cartridge Drive Assembly (RRP 53, on page 7-202). Replace the Engine Control Board (RRP 42, on page 7-190). Replace the Engine Control Board (RRP 43, on page 7-191). 2-68 Phaser 7700 Color Printer...
  • Page 92 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 93 Replace the Engine Control Board (RRP 42, on page 7-190). 04-341 ERROR 80 ENGINE LOGIC BOARD FAILURE 04-343 Switch printer power OFF, then ON. If the problem persists, replace the Engine Control Board (RRP 42, on page 7-190). 2-70 Phaser 7700 Color Printer...
  • Page 94 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 95 Replace the Finisher Control Board. If the problem persists, replace Printer Engine Control Board (RRP 42, on page 7-190). If the problem continues to persist, verify the ground continuity between Finisher frame ground and Printer frame ground. 2-72 Phaser 7700 Color Printer...
  • Page 96 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 11-310).
  • Page 97 Motor Assembly Tamper [PL10-15, item 2] for the appropriate motor per error code. • Tamper Home Sensor [PL 10-15, item 4] for the appropriate sensor per error code. • Finisher Controller Board (RRP 77, on page 11-316). • Compiler Tray Assembly [PL 10-15, item 1]. 2-74 Phaser 7700 Color Printer...
  • Page 98 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 99 Yes No Replace the Finisher Control Board (RRP 77, on page 11-316). Problem solved. Drive the Stacker Tray to its highest position using the Motor Up test. From the Main Menu, select “Sensor Tests/Finisher Sensors/Stacker. 2-76 Phaser 7700 Color Printer...
  • Page 100 Error Chain / Code Link Front Panel Message 12-255 FINISHER ERROR 117 STACKER TRAY FAILURE (Continued) 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 101 Repair or replace the wiring harness between the Finisher Control Board and the Front Corner Sensor. Replace the Finisher Control Board (RRP 77, on page 11-316). Replace the Finisher Control Board (RRP 77, on page 11-316). 2-78 Phaser 7700 Color Printer...
  • Page 102 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 11-310). Remove the sensor from the top of the eject motor mount bracket (RRP 76, on page 11-315). Enter Service Diagnostics Mode.
  • Page 103 Repair or replace the wiring harness between the Finisher Control Board and the Eject Clamp Home Sensor. Replace the Finisher Control Board (RRP 77, on page 11-316). Replace the Finisher Control Board (RRP 77, on page 11-316). 2-80 Phaser 7700 Color Printer...
  • Page 104 Error Chain / Code Link Front Panel Message 12-267 FINISHER ERROR 122 DECURLER FAILURE Remove the Finisher Rear Cover (RRP 72, on page 11-310). 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 105 Repair or replace the wiring harness between the Finisher Control Board and the Decurler Cam Home Sensor. Replace the Finisher Control Board (RRP 77, on page 11-316). Replace the Finisher Control Board (RRP 77, on page 11-316). 2-82 Phaser 7700 Color Printer...
  • Page 106 Error Chain / Code Link Front Panel Message 12-281 FINISHER ERROR 123 SET CLAMP FAILURE Remove the Finisher Rear Cover (RRP 72, on page 11-310). 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 11-314) or (RRP 75, on page 11-314).
  • Page 107: Wiring Diagrams

    Replace the Stapler Assembly (RRP 82, on page 11-322). • Replace the Finisher Control Board (RRP 77, on page 11-316). • Perform a continuity check on the wiring harness between the Finisher Control Board and the Stapler [Refer to the Finisher Wiring Diagram]. 2-84 Phaser 7700 Color Printer...
  • Page 108: Troubleshooting

    For error codes and messages Diagnostics, Error Codes and Messages on page 3-31 The Phaser 7700 Printer has built-in diagnostics to aid in troubleshooting problems with the printer. The Service Diagnostics Menu provides a means to test sensors, motors and solenoids. Diagnostics also contains built-in test prints, and calibration and cleaning procedures.
  • Page 109 Random missing spots Random spotting Repetitive mark appears on each print Background contamination Infused image or image rubs off easily Toner on back of print Image is mis-registered on paper Residual image or ghosting 3-86 Phaser 7700 Color Laser Printer...
  • Page 110: Troubleshooting Power Supplies And Interlocks

    Troubleshooting Power Supplies and Interlocks Troubleshooting AC Power Verify that the AC Input Voltage is present and correct. 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 111: Troubleshooting The Low-Voltage Power Supplies

    If no voltage is present replace the LVPS. If the voltage returns check the harness, Image Processor Board, Engine Board and Relay Board for shorts. 3-88 Phaser 7700 Color Laser Printer...
  • Page 112: Troubleshooting The 24 Vdc Lvps

    Troubleshooting the 24 VDC LVPS Note Switch off power and disconnect the power cord. Note The 24 VDC LVPS requires a 5VDC enable signal to operate. Ensure proper operation of the 5 VDC LVPS before proceeding. Remove the rear cover and 24 VDC PS metal shield. Connect AC Power and switch the printer on.
  • Page 113: Interlock Circuit Diagram

    If +24VDC is not present, see Troubleshooting the 24 VDC LVPS on page 3-89 to verify the 24 VDC LVPS is working. If working, then check the LH Cover Interlock Switch, the RH Cover Interlock Switch and the Front Cover Interlock Switch. 3-90 Phaser 7700 Color Laser Printer...
  • Page 114: 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 115: Troubleshooting When The Printer Does Not Come To A "Ready" State

    Replace the Internal Hard Drive (RRP 40, on page 7-187). Replace the Image Processor Board (RRP 39, on page 7-186). Front Panel continually displays the Xerox Phaser 7700 splash screen Enter Service Diagnostics Mode. Refer to Entering Service Diagnostics Mode: on page 3-35 Watch the Front Panel during the "initializing"...
  • Page 116: Troubleshooting - Printer Comes To A "Ready" State

    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 3-90 False "Load Paper in Tray [1,2,3,4]" Message In order for the printer to recognize paper in the paper tray, one or both of the top two Paper Size Switches must be closed, the Tray Level Sensor must be actuated by the lift mechanism and the No Paper Sensor must be deactuated.
  • Page 117: Tray 1 Will Not Lift

    Feed/Lift Motor with one from another tray and retest. Inspect the wiring harness for damage and continuity. Replace the Auxiliary Feeder Control Board (RRP 60, on page 7-210). Replace the Engine Control Board (RRP 42, on page 7-190). 3-94 Phaser 7700 Color Laser Printer...
  • Page 118: 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. From the Front Panel check to see if the auxiliary feeder is recognized by the printer.
  • Page 119: Operation System And Application Problems

    “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. Try printing the job again. In the Chooser or the print dialog, switch background printing to off. Try printing the job again.
  • Page 120: 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 121: Media Jams And The Paper Path

    The customer should be using a quality laser printer paper. The printer may have trouble picking slick-finish paper. Only Phaser 7700 series transparency film should be used in this printer. Inspect the paper for bent, torn, or folded corners. Ensure that the correct media type is set in the front panel.
  • Page 122 Damaged prints The printed page exits the printer either wrinkled, creased, or torn. The printer neither jams nor displays an error code. Stop the paper in the paper path to determine where the media becomes damaged. Feed paper through the printer from each of the available trays. Is the paper damaged when fed out of one tray but not when fed out of the others? If so, inspect the tray for damage, ensure that the media guides are set correctly and verify that the proper media is being used.
  • Page 123 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. Are the margins on the page greater than 3 mm? Check the fuser area for debris.
  • Page 124: 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 125 Inspect the high-voltage wiring harness and power supply. Repair/replace as necessary. Replace the Laser Unit (RRP 38, on page 7-184). Replace the T3 High-Voltage Power Supply (RRP 44, on page 7-192). Replace the T2 High-Voltage Power Supply (RRP 48, on page 7-197). 3-102 Phaser 7700 Color Laser Printer...
  • Page 126 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 127 Improve Print-Quality?, then select Remove Print Smears. Replace the Developer Housing Assembly (RRP 27, on page 7-171). Remove the print cartridge and (with a flashlight) check for debris along the edge of the developer housing. 3-104 Phaser 7700 Color Laser Printer...
  • Page 128 Streaks parallel with the leading edge There are dark lines running parallel Leading Edge 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 paper path --...
  • Page 129 Inspect the Bias Transfer Roller and replace if necessary (RRP 17, on page 7-158). Inspect the Fuser to see whether paper is wrapped around the Fuser. Replace the Fuser (RRP 19, on page 7-160). 3-106 Phaser 7700 Color Laser Printer...
  • Page 130 Repetitive mark appears on each print 3041-48 An identical mark or image appears on each, or every other, printed image. From the front panel’s Support Menu, select Improve Print-Quality?, then select Remove Print Smears. This function passes several blank sheets of paper through the printer to clean the fuser rollers.
  • Page 131 If the background contamination is a primary color (and that primary color is missing from the print), the high-voltage wire leading to that color’s developer housing is grounded. Inspect the high-voltage wiring harnesses. 3-108 Phaser 7700 Color Laser Printer...
  • Page 132 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 133 3041-54 tray, clean the rollers in that tray. Run the Calibrate for Margins routine. From the front panel’s Support Menu, select Improve Print-Quality?, then select Calibrate Margins Menu. 3-110 Phaser 7700 Color Laser Printer...
  • Page 134 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 135 3-112 Phaser 7700 Color Laser Printer...
  • Page 136: Adjustments And Calibration

    NVRAM see “Resetting NVRAM” on page 6-131 Internal Hard Drive The Phaser 7700 Printer has a standard hard drive installed in every printer. The hard drive boots most of the firmware. There is a special file on the hard drive that stores the specific calibration values for various sensors and for the unique positioning of the laser in the printer.
  • Page 137: Registration Control (Regicon) Adjustment Overview

    Cyan. Figure 1: Horizontal and Vertical Margins M, Y , K Cyan S7700-460 Figure 4-1 Coarse RegiCon Initialization Note Cyan is the reference color to which all other colors are aligned. 4-114 Phaser 7700 Color Laser Printer...
  • Page 138: Figure 4-2 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 139: Figure 4-4 Center Skew Adjustment

    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 4-116 Phaser 7700 Color Laser Printer...
  • Page 140: Processes Of The Regicon Adjustment

    Processes of the RegiCon adjustment The test procedures should be performed in the following order. Each test must be successful before proceeding to the next. Refer to the RegiCon Flowchart on page 4-118. Check print-quality - this process checks the printer’s ability to print with no image defects.
  • Page 141: 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)
  • Page 142: 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 143: Step 2: Regicon #4 Coarse Skew Adjustment

    Skew Corr. M: 7 clicks CW Skew Corr. C: -5 clicks CCW Skew Corr. K: -12 clicks CCW Note If the test procedure passes, no adjustments need be made. Continue directly to RegiCon #1 (Fine Skew Adjustments). 4-120 Phaser 7700 Color Laser Printer...
  • Page 144 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 145: Step 3: Regicon #1 Fine Skew Adjustment

    Skew Corr. M: 7 clicks CW Skew Corr. C: -5 clicks CCW Skew Corr. K: -12 clicks CCW If RegiCon #1 Fine Skew test fails, see “If RegiCon Coarse Skew Fails” on page 4-121 4-122 Phaser 7700 Color Laser Printer...
  • Page 146: 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 147: Step 5: Regicon #3 Center Skew Adjustment

    "wedge-fit" when in position for the number 3 "center" position. If the Mark-On-Belt sensor not correctly positiond, it can cause the test to fail. Recheck the MOB sensor position and run the test again. 4-124 Phaser 7700 Color Laser Printer...
  • Page 148: 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 4-119). From the Adjustments/Calibrations menu, select Coarse RegiCon Init test.
  • Page 149: Figure 4-7 Grid 1-Dot Pattern Annotations

    1 mm of the Cyan line. If not, repeat. It may be necessary to closely inspect the Color Solid Fill Prints to determine if the image quality is acceptable. 4-126 Phaser 7700 Color Laser Printer...
  • Page 150: 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 151 4-128 Phaser 7700 Color Laser Printer...
  • Page 152: 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 153: Cleaning

    Clean the laser window with the cleaning wand, following the details labelled in the inside of the front door. Open left side door and clean up any toner inside. Remove and clean the paper trays. Clean pick rollers with a dry, lint-free cloth. 5-130 Phaser 7700 Color Laser Printer...
  • Page 154: 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 values.
  • Page 155 From the Main Menu, highlight Support and press OK. Highlight Service Tools Menu and press OK. Reset NVRAM is displayed, press OK. Highlight Reset NVRAM and Reset Printer NOW and press OK to reset all the settings to default. 6-132 Phaser 7700 Color Laser Printer...
  • Page 156 Resetting engine NVRAM Resetting (restoring) the engine NVRAM values resets the RegiCon color, margin and A4/B5 selection paper settings to default. This is NOT the diagnostics reset. To restore data stored on the hard drive to NVRAM, see “Clear Tech Rep Faults” on page 6-135.
  • Page 157 From the Main Menu, highlight Supplies Info Menu and press OK. Highlight Reset Transfer Roller Life and press OK. Reset Transfer Roller Life NOW is displayed, press OK to reset the Accumulator Belt life. 6-134 Phaser 7700 Color Laser Printer...
  • Page 158: 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 NERGY timeout to their default values.
  • Page 159: Reset Engine Nvram

    You must store engine NVRAM values to the Internal Hard Drive after replacement of the Internal Hard Drive. Enter Service Diagnostics. Highlight NVRAM Access and press OK. Highlight Store Engine NVRAM and press OK. 6-136 Phaser 7700 Color Laser Printer...
  • Page 160: Removal And Replacement Procedures

    This section covers the print engine and Auxiliary Feeders only. For Removal and Replacement of the Finisher, see the Phaser 7700 Light Finisher on page 11-303. Service Quick Reference Guide - Removal & Replacement Procedures...
  • Page 161 RRP 43 Engine Control Interface Board ......7-191 7-138 Phaser 7700 Color Laser Printer...
  • Page 162 RRP 44 T1 and T3 High-voltage Power Supplies ..... . . 7-192 RRP 45 3.3 VDC and 5 VDC Low-Voltage Power Supplies and Bracket..7-194 RRP 46 LD Power Relay .
  • Page 163: Rear Cover Assembly

    Remove the four screws that secure the Rear Cover Assembly to the printer. Pull the top edge of the Rear Cover Assembly about one inch away from the printer, and push down to release the cover. 7-140 Phaser 7700 Color Laser Printer...
  • Page 164: 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 165: Top Cover Assembly

    Open the Image Processor Board Cover to gain access to the 4 thumb screws that secure the Image Processor Board metal cover. Remove the Image Processor Board metal cover. Disconnect the front panel cable from the Relay Board P564. Remove the Top Cover. 7-142 Phaser 7700 Color Laser Printer...
  • Page 166: Front 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 167: Rear Cover, Top Rear Power Switch Cover And Lh Rear Mid Cover

    There is a hidden captive tab on the front and side of this cover that resists the upward pull. Place your finger on the front side of the cover to release the tab and pull towards you. 7-144 Phaser 7700 Color Laser Printer...
  • Page 168 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. Service Quick Reference Guide - Removal &...
  • Page 169: 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. Remove the Left-Hand Lower Cover Assembly. 7-146 Phaser 7700 Color Laser Printer...
  • Page 170: 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 171: Fuser

    RRP 8 Fuser Front Cover S7700-029 Figure 7-8 Fuser Front Cover Removal Remove the Front Cover Assembly (RRP 7, on page 7-147). Remove two screws from the Fuser Front Cover and push upward and remove the cover. 7-148 Phaser 7700 Color Laser Printer...
  • Page 172: Rear Shield

    RRP 9 Rear Shield S7700-423 Figure 7-9 Rear Shield Removal Warning Switch off the power and disconnect the power cord. Remove the Rear Cover (RRP 1, on page 7-140). Remove the seven screws securing the Rear Shield to the printer. Remove the shield.
  • Page 173: Rear Shield Bracket

    Remove the Rear Cover (RRP 1, on page 7-140). Remove the Rear Shield (RRP 9, on page 7-149). Remove the three screws securing the Rear Shield Bracket to the printer. Remove the Rear Shield Bracket. 7-150 Phaser 7700 Color Laser Printer...
  • Page 174: 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 7-140). Remove the Rear Shield (RRP 9, on page 7-149). Remove the Rear Shield Bracket (RRP 10, on page 7-150). Remove the four screws securing the 24 VDC Power Supply Shield to the printer.
  • Page 175: Multi-Purpose Tray (Mpt) Assembly

    MPT. Raise the Duplex Chute by reaching into the MPT installation hole. Caution When reinstalling the MPT, make certain you DO NOT pinch the wire between the left bracket and the left screw hole. 7-152 Phaser 7700 Color Laser Printer...
  • Page 176: Multi-Purpose Tray Paper 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 177: Left-Hand Cover Assembly (Left-Hand Door)

    Open the Left-Hand Door. Note Note how the wiring harness is routed through the access hole. Disconnect the three wiring harnesses and slip the wiring harnesses through the access hole one connector at a time. 7-154 Phaser 7700 Color Laser Printer...
  • Page 178: 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 179: Duplex Chute

    Partially remove the Left-Hand Cover Assembly (Left Door) (RRP 14, on page 7-154). Rotate the Duplex Chute downward until the keyed pivot shaft can be removed from the pivot bracket. Remove the Duplex Chute. 7-156 Phaser 7700 Color Laser Printer...
  • Page 180: 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 181: Transfer Roller Assembly (2Nd Btr)

    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. Remove the assembly. Replacement Note Make sure the mounting brackets are seated on the locating pins as the screws are installed. 7-158 Phaser 7700 Color Laser Printer...
  • Page 182: Duplex 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 7-154). 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 183: Fuser Unit

    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. 7-160 Phaser 7700 Color Laser Printer...
  • Page 184: Registration Transport Assembly

    RRP 20 Registration Transport Assembly Figure 7-21 Registration Transport Assembly Note Turn the printer off and unplug the power. Removal Partially remove the MPT. Partially remove the Left-Hand Cover Assembly (Left Door) (RRP 14, on page 7-154). Remove the Left-Hand Cover Assembly retaining clip and restraining bracket, and with caution allow the door to drop down out of the way.
  • Page 185: Shutter Solenoid Assembly

    Remove the black Print Cartridge. While reinstalling the shutter solenoid assembly, with a flashlight, view where the Solenoid Lever engages the notch in the shutter plate. Tighten the mounting screw and reconnect the wiring harness. 7-162 Phaser 7700 Color Laser Printer...
  • Page 186: Tray 1 Feeder Assembly And Paper Lift Motor

    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 7-146). 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 187: Waste Cartridge Sensor Holder

    RRP 23 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 7-164 Phaser 7700 Color Laser Printer...
  • Page 188: Print Cartridge Plate Cover

    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 7-148). Lower the main lever. Remove the four screws. Remove the plastic Print Cartridge Plate Cover.
  • Page 189: Dispense Assembly

    Leave the main lever down. 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 7-166). 7-166 Phaser 7700 Color Laser Printer...
  • Page 190 Caution Be careful when moving the stops. They are easily broken and may come out completely. Remove the screw holding each dispense assembly to the printer. Remove the dispense assembly by pulling both the top and bottom sections evenly away from the printer. Note The flexible tubing is not secure and can come apart during removal and replacement causing toner spillage.
  • Page 191: Figure 7-27 Print Cartridge Plate Assembly

    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 7-164). S7700-013 Figure 7-27 Print Cartridge Plate Assembly 7-168 Phaser 7700 Color Laser Printer...
  • Page 192: 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 7-165). Remove the Dispense Assemblies (RRP 25, on page 7-166). 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 193 Failure to align the holes with the pins prior to tightening screws could result in bending the plate. Note Center the connectors flat against the wire guide with the yellow developer connector further to the right. 7-170 Phaser 7700 Color Laser Printer...
  • Page 194: Figure 7-29 Developer Housing Assembly

    RRP 27 Developer Housing Assembly Figure 7-29 Developer Housing Assembly Removal Note After replacing the Print Cartridge Plate Assembly, you must perform the RegiCon adjustment to the printer ,on page 4-117. Note Complete removal of the Print Cartridge Plate Assembly is not required for removal of the Developer(s).
  • Page 195: Figure 7-30 Developer Housing Assembly Recharge

    See ATC Sensor Setup on page 4-127. Note It is easy to spill toner in this procedure. Use only a type II toner vacuum to clean up any spilled toner. 7-172 Phaser 7700 Color Laser Printer...
  • Page 196 Place the Developer Housing Assembly (new or used) to be recharged on large piece of newspaper or cloth. 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 197: Figure 7-31 Toner Dispense Motor Assembly

    Remove the Dispense Housing Assemblies (RRP 25, on page 7-166). Remove the two screws that secure the Toner Dispense Motor Assembly to the printer frame. Disconnect the wiring harness from each motor. Remove the Toner Dispense Motor Assembly. 7-174 Phaser 7700 Color Laser Printer...
  • Page 198: 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 7-165). 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 199: Figure 7-33 Waste Toner Agitator Motor Assembly

    Remove the Print Cartridge Plate Cover (RRP 24, on page 7-165). Remove the Waste Cartridge Assemblies (RRP 23, on page 7-164). Disconnect the wiring harness to the motor. Remove the two screws that secure the Agitator Motor Assembly to the printer frame. 7-176 Phaser 7700 Color Laser Printer...
  • Page 200: 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 7-164). Remove the Waste Toner Agitator Motor (RRP 31, on page 7-176). 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 DC685-3) is...
  • Page 201: Figure 7-35 Exit Transport Assembly

    Remove the one screw securing the Transport Assembly Cover and remove the cover. Disconnect the harnesses to the Transport Assembly and the left-hand cover interlock connector. Remove the three screws securing the Transport Assembly and remove. 7-178 Phaser 7700 Color Laser Printer...
  • Page 202: Figure 7-36 Fuser Fan Assembly

    RRP 34 Fuser Fan Assembly Locating Pin S7700-025 Figure 7-36 Fuser Fan Assembly Removal Remove the Rear Cover (RRP 1, on page 7-140). Remove the Top Cover (RRP 3, on page 7-142). Remove Right Side Cover (RRP 2, on page 7-141). Note Note the routing of the wiring harness.
  • Page 203: Figure 7-37 Accumulator Belt Assembly

    RRP 35 Accumulator Belt Assembly Figure 7-37 Accumulator Belt Assembly 7-180 Phaser 7700 Color Laser Printer...
  • Page 204 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 205: Figure 7-38 Belt Cleaner Assembly

    Never run the printer without the belt cleaner installed or severe damage to the Accumulator Belt will occur. Caution Ensure that the Accumulator Belt is fully inserted or severe NEVER FORCE THE MAIN printer damage will result. LEVER! 7-182 Phaser 7700 Color Laser Printer...
  • Page 206: Figure 7-39 Waste Auger Assembly

    RRP 37 Waste Auger Assembly S7700-438 Figure 7-39 Waste Auger Assembly Removal Remove the Right Side Cover (RRP 2, on page 7-141). 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 207: Figure 7-40 Laser Unit Assembly

    RRP 38 Laser Unit Figure 7-40 Laser Unit Assembly 7-184 Phaser 7700 Color Laser Printer...
  • Page 208: Figure 7-41 Laser Unit Label

    Removal Remove the Rear Cover (RRP 1, on page 7-140). Remove the Right-Hand Cover (RRP 2, on page 7-141). 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 209: Figure 7-42 Image Processor Board Assembly

    Note Remove the image processor top cover and the metal plate to inspect that the image processor board is fully seated when reinstalling. 7-186 Phaser 7700 Color Laser Printer...
  • Page 210: Figure 7-43 Internal Hard Drive

    RRP 40 Internal Hard Drive Fig. 1 Fig. 2 S7700-434 Figure 7-43 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 7-186). Using a T-10 torx bit, remove four screws on the bottom side of the Image Processor Board holding the Internal Hard Drive.
  • Page 211: Figure 7-44 Electrical Chassis Assembly

    Seven of these harnesses are in front of the controller board. The other two are on the left side. Note Two of the engine control connectors have connector locks. There is one harness clip to release. 7-188 Phaser 7700 Color Laser Printer...
  • Page 212 Undo the harness retainer. Disconnect the wiring harness to the relay board connector P300 and the front panel cable to P564. only loosen Remove the two mounting screws towards printer rear, but two mounting screws towards the printer front. Note The two screws toward the printer front serve as a guide for reinstallation.
  • Page 213: Figure 7-45 Engine Control Board

    Restore engine NVRAM values from the hard drive (Reset Engine NVRAM on page 6-136). Write the stored NVRAM values to the engine board using the Service Diagnostics procedure (Reset Engine NVRAM on page 6-136). 7-190 Phaser 7700 Color Laser Printer...
  • Page 214: Figure 7-46 Engine Control Interface Board

    RRP 43 Engine Control Interface Board Figure 7-46 Engine Control Interface Board Removal Method #1 Remove the Engine Control Board (RRP 42, on page 7-190). Disconnect the eight wiring harnesses. Note Two connectors (J537, J536) have locks to release before pulling on the harnesses.
  • Page 215: Figure 7-47 T1 And T3 High-Voltage Power Supplies

    Disconnect the T3 high-voltage wire harness at P581 and remove the wiring harness from the clip grommet. Remove the high-voltage power supply assembly. Disconnect the interconnecting wiring harness at P573 on the T3 power supply board. Remove the appropriate power supply board(s) from the assembly. 7-192 Phaser 7700 Color Laser Printer...
  • Page 216 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). Service Quick Reference Guide - Removal & Replacement Procedures 7-193...
  • Page 217: Figure 7-48 3.3 Vdc And 5 Vdc Low-Voltage Power Supplies

    Lower the T1 and T3 power supply to horizontal (RRP 44, on page 7-192). Disconnect P/Js 8, 12, 15 & 16 from the low-voltage power supplies. Loosen the four screws the secure the mounting bracket to the frame. Lift the bracket up and out to remove. 7-194 Phaser 7700 Color Laser Printer...
  • Page 218: Figure 7-49 Ld Power Relay

    RRP 46 LD Power Relay Fig. 1 Fig. 2 S7700-431 Figure 7-49 LD Power Relay Removal Remove rear cover and shield (RRP 9, on page 7-149). Disconnect the wiring harness. Remove the two screws securing the LD power assembly. Remove the LD power assembly. Service Quick Reference Guide - Removal &...
  • Page 219: Figure 7-50 Low-Voltage Power Supply, Fan And Bracket

    Disconnect the wiring harness at P502, P505, and P2 from the 24 VDC power supply and the fan motor wiring harness P214. Remove the 1 screw at the top of the bracket and loosen the remaining four screws in slots. Remove the power supply and bracket assembly. 7-196 Phaser 7700 Color Laser Printer...
  • Page 220: Figure 7-51 T2 High-Voltage Power Supply

    RRP 48 T2 High-Voltage Power Supply Figure 7-51 T2 High-Voltage Power Supply Removal Remove the 24 VDC Power Supply and Bracket (RRP 11, on page 7-151). 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 221: Figure 7-52 Chassis Ac Power Assembly

    Disconnect the AC wires from P15 and P16 on the Noise Filter board. Clear the wiring harnesses from their retaining clips. Remove the seven screws securing the Chassis Assembly to the printer frame. Remove the complete assembly from the printer frame. 7-198 Phaser 7700 Color Laser Printer...
  • Page 222: Figure 7-53 Main Drive Assembly

    RRP 50 Main Drive Assembly Do NOT remove these 5 screws S7700-002 Figure 7-53 Main Drive Assembly Removal Remove the Fuser (RRP 18, on page 7-159). Remove the Multi-Purpose Tray (RRP 12, on page 7-152). Remove the T2 high-voltage power supply (RRP 48, on page 7-197). Disconnect the wiring harness.
  • Page 223: Figure 7-54 Accumulator Belt Drive Assembly

    Remove any components covering the motor which is mounted to the frame at the rear, top left corner. Remove the three screws that secures the motor and bracket assembly to the frame and remove the assembly. 7-200 Phaser 7700 Color Laser Printer...
  • Page 224: Figure 7-55 Developer Drive Assembly

    RRP 52 Developer Drive Assembly S7700-008 Figure 7-55 Developer Drive Assembly Removal Remove the 3.3 VDC and 5 VDC Power Supply and bracket assembly (RRP 45, on page 7-194). 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 225: Figure 7-56 Print Cartridge Drive Assembly

    (now accessible after removing the Right Cover Assembly). Remove the remaining seven screws that secure the Print Cartridge Drive Assembly to the printer frame. Lift the Print Cartridge Drive Assembly up and out of the printer. 7-202 Phaser 7700 Color Laser Printer...
  • Page 226: Figure 7-57 Tray 1 Paper-Select Switches

    RRP 54 Tray 1 Paper-Select Switches S7700-442 Figure 7-57 Tray 1 Paper-Select Switches Remove the T1 and T3 high-voltage power supply (RRP 44, on page 7-192). Remove the 3.3 VDC and 5 VDC low-voltage power supply (RRP 45, on page 7-194).
  • Page 227: Figure 7-58 Main Lever, Right-Hand And Left-Hand Jacks

    LH Lift Jack Assembly racks are even. Hold the Main Lever in a horizontal position. Slide the Main Lever gears under the Lift Jack Assembly racks and lift into position. Insert the clevis pins. 7-204 Phaser 7700 Color Laser Printer...
  • Page 228 Remove RH Cover Assembly (RRP 2, on page 7-141). Remove the Main Lever. Remove the e-clips and washers from the RH Lift Jack Assembly roller guides. Remove the four screws that hold the RH Lift Jack Bracket and remove the bracket.
  • Page 229: Figure 7-59 Auxiliary Feeder Covers

    Remove the screws securing the straps. Remove the one screw holding the front side pivot bracket and remove the left-hand door. REAR COVER Remove the four screws securing the cover. Remove the Rear Cover. 7-206 Phaser 7700 Color Laser Printer...
  • Page 230: Figure 7-60 High-Capacity Feeder (Hcf) Cover Assembly

    RRP 57 Auxiliary Feeder Cover Assembly LH Cover Interlock Switch RH Pivot Bracket S7700-105 Figure 7-60 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 231: Rrp 58 High-Capacity Feeder (Hcf) Tray 3

    Figure 7-61 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. 7-208 Phaser 7700 Color Laser Printer...
  • Page 232: Rrp 59 High-Capacity Feeder (Hcf) Tray 4 And Paper Transport

    RRP 59 High-Capacity Feeder (HCF) Tray 4 and Paper Transport Figure 7-62 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 233: Figure 7-63 Ltd Control Or Hcf Control Board

    Figure 7-63 LTD Control or HCF Control Board Removal Remove the Rear Cover (RRP 1, on page 7-140). Disconnect the wire harnesses. Remove the four screws securing the control board and remove the board. 7-210 Phaser 7700 Color Laser Printer...
  • Page 234: Figure 7-64 Transport Motor Assembly

    RRP 61 Auxiliary Feeders Motor Assemblies HCF only transport motor S7700-110 Figure 7-64 Transport Motor Assembly Removal Remove Rear Cover (RRP 1, on page 7-140). Disconnect the wire harness. Remove the two screws securing the motor assembly. Remove the motor assembly. Service Quick Reference Guide - Removal &...
  • Page 235: Figure 7-65 Paper-Select Switches

    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. LTD: 3 places. HCF: 1 place 7-212 Phaser 7700 Color Laser Printer...
  • Page 236: Rrp 63 Auxiliary Feeder Paper Feed Motor Assembly

    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 7-66 Paper Feed Motor Assembly and Chute (LTA & HCF) Removal Remove the Left-Hand Cover.
  • Page 237: Figure 7-67 Bracket Assembly, Gear Rh & Gear Lh (Hcf)

    Remove the Rear Cover (RRP 1, on page 7-140). Remove the two screws securing the Bracket Assembly (Gear RH or Gear LH) to the frame. Remove the Bracket Assembly. Replacement Note There are locating pins for each Bracket. 7-214 Phaser 7700 Color Laser Printer...
  • Page 238: Fru Parts List

    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 following...
  • Page 239: Table 8-1 Accumulator Belt Frus List

    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 Waste auger assembly 8-216 Phaser 7700 Color Laser Printer...
  • Page 240: Table 8-2 Left-Hand Door Frus List

    PL 8-2 Left-Hand Door FRUs S7700-042 Figure 8-2 Left-Hand Door FRUs 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 Left-Hand Cover Assembly (Cover Assembly-L/H2) Regi. chute assembly 016-1890-00 Transfer roller (Roll Assembly 2nd E) 016-1098-00 Duplex Chute (DUP Chute) 116-1542-00...
  • Page 241: 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 tray stopper spacer 8-218 Phaser 7700 Color Laser Printer...
  • Page 242: 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) Service Quick Reference Guide - FRU Parts Lists 8-219...
  • Page 243: Table 8-5 Cover Frus List

    116-1095-00 Right cover (Cover Assembly - R MN) 116-1187-00 Front cover strap (Strip) 116-1116-00 Laser lens cleaner assembly (Cleaner Rod Assembly) 116-1117-00 Laser lens cleaner base (Cleaner Assembly Base) 116-1317-00 Cover Assy LH PH2 8-220 Phaser 7700 Color Laser Printer...
  • Page 244: 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 245: Figure 8-7 Cover Frus (Cont'd.)

    PL 8-7 Cover FRUs (cont’d.) S7700-060 Figure 8-7 Cover FRUs (cont’d.) 8-222 Phaser 7700 Color Laser Printer...
  • Page 246: Table 8-7 Covers Frus (Cont'd.) List

    Table 8-7 Covers FRUs (cont’d.) List 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 247: 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 8-224 Phaser 7700 Color Laser Printer...
  • Page 248: 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) 116-1299-00...
  • Page 249: Figure 8-9 Switch And Sensor Frus

    PL 8-9 Switch and Sensor FRUs S7700-415 Figure 8-9 Switch and Sensor FRUs 8-226 Phaser 7700 Color Laser Printer...
  • Page 250: Table 8-9 Switch And Sensor Frus List

    Table 8-9 Switch and Sensor FRUs List 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 251: Figure 8-10 Circuit Boards Frus

    PL 8-10 Circuit Boards FRUs S7700-095 Figure 8-10 Circuit Boards FRUs 8-228 Phaser 7700 Color Laser Printer...
  • Page 252: 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 Service Quick Reference Guide - FRU Parts Lists 8-229...
  • Page 253: Figure 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 8-230 Phaser 7700 Color Laser Printer...
  • Page 254: 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 bd 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 255: Figure 8-12 Power Supplies Frus (Cont'd.)

    PL 8-12 Power Supplies FRUs AC drive bd Noise filer 1, 2 S7700-054 Figure 8-12 Power Supplies FRUs (cont’d.) 8-232 Phaser 7700 Color Laser Printer...
  • Page 256: Table 8-12 Power Supplies Frus (Cont'd.) List

    Table 8-12 Power supplies FRUs (cont’d.) List 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 257: Figure 8-13 Motors/Drivers Frus

    PL 8-13 Motors/Drivers FRUs REAR FRONT S7700-034 Figure 8-13 Motors/Drivers FRUs 8-234 Phaser 7700 Color Laser Printer...
  • Page 258: 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 259: Figure 8-14 Electrophotographic Components Frus

    PL 8-14 Electrophotographic Components FRUs S7700-013 Figure 8-14 Electrophotographic components FRUs 8-236 Phaser 7700 Color Laser Printer...
  • Page 260: Print Cartridge Plate Assembly

    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 261: Pl 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.) 8-238 Phaser 7700 Color Laser Printer...
  • Page 262: Developer Housing Assembly

    Table 8-15 Electrophotographic components FRUs (cont’d.) List 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 263: Figure 8-16 Multi-Purpose Tray Frus

    PL 8-16 Multi-Purpose Tray FRUs S7700-045 Figure 8-16 Multi-Purpose Tray FRUs 8-240 Phaser 7700 Color Laser Printer...
  • Page 264: 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 265: Figure 8-17 Paper Feed Frus

    PL 8-17 Paper Feed FRUs S7700-040 Figure 8-17 Paper Feed FRUs 8-242 Phaser 7700 Color Laser Printer...
  • Page 266: 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 267: Figure 8-18 Paper Feed Frus

    PL 8-18 Paper Feed FRUs (cont’d.) S7700-044 Figure 8-18 Paper feed FRUs 8-244 Phaser 7700 Color Laser Printer...
  • Page 268: Table 8-18 Paper Feed Frus (Cont'd.) List

    Table 8-18 Paper feed FRUs (cont’d.) List 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 269: Figure 8-19 Fans

    PL 8-19 Fans S7700-408 Figure 8-19 Fans 8-246 Phaser 7700 Color Laser Printer...
  • Page 270: Table 8-19 Fans List

    Table 8-19 Fans 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) Service Quick Reference Guide - FRU Parts Lists 8-247...
  • Page 271: Figure 8-20 Lift Components Frus

    PL 8-20 Lift Components FRUs S7700-050 Figure 8-20 Lift Components FRUs 8-248 Phaser 7700 Color Laser Printer...
  • Page 272: 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 Service Quick Reference Guide - FRU Parts Lists 8-249...
  • Page 273: Figure 8-21 Wiring Frus

    PL 8-21 Wiring FRUs S7700-059 Figure 8-21 Wiring FRUs 8-250 Phaser 7700 Color Laser Printer...
  • Page 274: 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 275: Figure 8-22 Auxiliary Feeder Frus

    PL 8-22 Auxiliary Feeder FRUs S7700-409 Figure 8-22 Auxiliary Feeder FRUs 8-252 Phaser 7700 Color Laser Printer...
  • Page 276: 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 277: 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 8-254 Phaser 7700 Color Laser Printer...
  • Page 278: 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 Service Quick Reference Guide - FRU Parts Lists 8-255...
  • Page 279: Table 8-25 High-Capacity Feeder Frus

    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 Caster 116-1099-00 Transport motor assembly (Motor Assembly TTM) 8-256 Phaser 7700 Color Laser Printer...
  • Page 280: 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 281: Table 8-27 High-Capacity Feeder Frus List (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) 8-258 Phaser 7700 Color Laser Printer...
  • Page 282: 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-SelectPaper-Select switch assembly (Switch Assembly PS) 116-1126-00 Switch Assy, Paper-Select Service Quick Reference Guide - FRU Parts Lists 8-259...
  • Page 283: 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) 8-260 Phaser 7700 Color Laser Printer...
  • Page 284: 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-snr (120E18141) Actuator-snr (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 285: Table 8-31 Manual Packs/Service Manual

    Manual Pack; Finnish 061-4440-00 Manual Pack; Czech 061-4441-00 Manual Pack; Hungarian 061-4442-00 Manual Pack; Polish 061-4444-00 Manual Pack; Korean 061-4445-00 Manual Pack; International English 061-4448-00 Manual Pack; Japanese 071-0860-00 Phaser 7700 Service Quick Reference Guide 8-262 Phaser 7700 Color Laser Printer...
  • Page 286: Table 8-32 Software

    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 287: Table 8-34 Accessories

    Driver, Magnetic 0.25” drive (no bits), 8” shank 003-0335-00 Tip, #1 Philips Bit, 0.25” drive 003-0336-00 Tip, #2 Philips Bit, 0.25” drive 640600 Mag 27020 Tip, 2.5 mm Hex Bit, 0.25” drive 600T2123 Hex Nutdriver, 5.5 mm (magnetic) 8-264 Phaser 7700 Color Laser Printer...
  • Page 288: 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 3-85 discusses solutions to the problems shown in this section.
  • Page 289: Analyzing The Test Print

    If not, please do so now. Enter Printer Diagnostics and generate a test print. Follow the paper along the paper path to locate the cause of the problem. 9-266 Phaser 7700 Color Laser Printer...
  • Page 290: 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 9-267 Service Quick Reference Guide - Test Prints...
  • Page 291 Weak colors may also be caused by a defective high-voltage power supply. If all colors are weak, this could indicate a problem with the ADC or second transfer systems. S7700-289 “Worm tracks” or wrinkles may be caused by the fuser. 9-268 Phaser 7700 Color Laser Printer...
  • Page 292: 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. S7700-290 9-269 Service Quick Reference Guide - Test Prints...
  • Page 293 Until toner is evenly deposited on the developer roller, RegiCon cannot pass. Things to look for: A “mottled” color, especially on the red and green pages. S7700-292 9-270 Phaser 7700 Color Laser Printer...
  • Page 294 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 295 7 distinct bands. Maybe one of the bands is 0% fill? Things to look for: Within a bar, any “ringing” that indicates the laser is not capable of making a solid bar of the same halftone. S7700-294 9-272 Phaser 7700 Color Laser Printer...
  • Page 296 P570 P575 P571 TP407 P505 P502...
  • Page 297 PWBA J633 J626 R612 R613 R640 J119 J121 P537 J228 J104 J265 J219 J103 J285 J106 J150 R611 R610 R617 R623 R620 P536 J108 P800...
  • Page 314: Phaser 7700 Finisher

    Phaser 7700 Finisher S7700-444 Figure 11-1 Xerox Phaser 7700 Color Laser Printer with the Finisher Option Highlighted. 11-291 Service Quick Reference Guide - Finisher...
  • Page 315: Finisher Overview

    This Service Quick Reference Guide contains information useful in troubleshooting, repair and maintenance of the Finisher Option for the Xerox Phaser 7700 Color Laser Printer. This Guide contains a Field Replacement Unit Parts List (FRU) and Removal and Replacement Procedures (RRPs).
  • Page 316: Table 11-2 Finisher Specifications

    The Printer provides +24 VDC to the Finisher. The Finisher’s power requirements supply provides all required DC voltages throughout the Finisher Option. The Phaser 7700 Light Finisher shall meet FCC part 15, subpart B, Class A. CISPR22 Class A. Dimensions:...
  • Page 317 1000 non-stapled sheets (20 lb. paper, letter/A4 or smaller) 500 unstapled sheets (20 lb. paper, over size Letter/A4) 300 unstapled sheets (Mix Stack / loading large on small) 50 stapled sets Staple Cartridge 5000 staples Capacity 11-294 Phaser 7700 Color Laser Printer...
  • Page 318: 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 11-295 Service Quick Reference Guide - Finisher...
  • Page 319: Figure 11-4 Internal Assemblies Of The Finisher

    Internal Assemblies of the Finisher Exit Assembly Cam Bracket 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 11-296 Phaser 7700 Color Laser Printer...
  • Page 320: Horizontal Transport Sensor, Interlock And Switch Locations

    Horizontal Transport Sensor, Interlock and Switch Locations 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 11-297 Service Quick Reference Guide - Finisher...
  • Page 321: Figure 11-6 Finisher Sensor, Interlock, And Switch Locator

    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 11-298 Phaser 7700 Color Laser Printer...
  • Page 322: 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 11-299 Service Quick Reference Guide - Finisher...
  • Page 323 Blank Page 11-300 Phaser 7700 Color Laser Printer...
  • Page 324: 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 303).
  • Page 325: 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. 11-302 Phaser 7700 Color Laser Printer...
  • Page 326: 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 302). Remove one screw securing the stopper. Remove two screws from the Horizontal Transport Front Cover and remove the cover.
  • Page 327: Figure 11-10 Horizontal Transport Entrance Upper Cover

    Remove the Horizontal Transport Assembly (RRP 66, on page 302). Remove the Front Cover (RRP 67, on page 303). Remove two screws securing the Rear Cover and remove. Remove the Gate-In Solenoid Assembly. Remove four screws securing the Entrance Upper Cover Assembly. 11-304 Phaser 7700 Color Laser Printer...
  • Page 328: Figure 11-11 H-Transport Belts

    RRP 69 Horizontal Transport Belts Figure 11-11 H-Transport Belts Removal Remove the Horizontal Transport Covers (RRP 67, on page 303). 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 329: Figure 11-12 H-Tra Entrance And Top Tray Full Sensor

    Top Tray Sensor Disconnect the wiring harness. Remove one screw and remove the sensor bracket and sensor. Replacement Note When replacing the sensor be sure the harness guide is engaged into the cover. 11-306 Phaser 7700 Color Laser Printer...
  • Page 330: 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 303). Disconnect the ground wire from the solenoid housing. Remove the two screws securing the Gate-In Solenoid Assembly and remove. 11-307 Service Quick Reference Guide - Finisher...
  • Page 331: 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 11-308 Phaser 7700 Color Laser Printer...
  • Page 332 Removal Remove the Horizontal Transport Assembly (RRP 66, on page 302). 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 333: Figure 11-15 Stack Height-Sensor Assembly

    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. 11-310 Phaser 7700 Color Laser Printer...
  • Page 334: 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 335: Figure 11-17 Set Clamp Clutch And Gear

    When replacing, after installing the clutch collar you need to depress the clutch solenoid and rotate the set clamp shaft 1/4 revolution Counter-Clockwise. Then install the set clamp actuator. Then rotate the clutch until the solenoid snaps into position. 11-312 Phaser 7700 Color Laser Printer...
  • Page 336: 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 308). Remove Stack Paper Sensor Assembly (RRP 73, on page 310). Undo the intermediate connector. Remove the Right Cover. Remove the Set Clamp Clutch and Gear (RRP 75, on page 312). Remove both KL-clips from the Set Clamp Shaft.
  • Page 337: 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 11-314 Phaser 7700 Color Laser Printer...
  • Page 338 Removal Remove the Rear Cover (RRP 72, on page 308). 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 339: Figure 11-20 Stacker Motor Assembly

    Remove the Finisher Control Board Bracket and Shield (RRP 77, on page 314). Remove one connector. Remove three screws securing the Stacker Motor Assembly and remove. Note When reinstalling, ensure the gear is engaged and the sensor for the stacker is tripped. 11-316 Phaser 7700 Color Laser Printer...
  • Page 340: 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 308). Remove the Cam Bracket Assembly (RRP 81, on page 319). Remove the Staple Unit (RRP 82, on page 320). Remove the e-clips from both ends of the shaft.
  • Page 341: Figure 11-22 Paper Transport Motor

    Main) Figure 11-22 Paper Transport Motor Removal Remove the Rear Cover (RRP 72, on page 308). Remove four screws. Undo the connector and lift the motor up and then out to free the belt. 11-318 Phaser 7700 Color Laser Printer...
  • Page 342: 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 308). 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 343: Figure 11-24 Staple Unit Assembly

    RRP 82 Staple Unit Assembly and Motor S7700-050 Figure 11-24 Staple Unit Assembly 11-320 Phaser 7700 Color Laser Printer...
  • Page 344 Removal Staple Unit Assembly Remove the Front Cover (RRP 72, on page 308). 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 345: Figure 11-25 Compiler Tray

    Remove two screws from the bottom of the tamper assembly, front and rear. Push the wiring harness into the printer frame. Tilt the carriage up and slide straight back letting the carriage drop down in the frame, then slide straight out the stapler cavity. 11-322 Phaser 7700 Color Laser Printer...
  • Page 346: Finisher Fru Parts List

    Finisher FRU Parts List 11-323 Service Quick Reference Guide - Finisher...
  • Page 347: Figure 11-26 Main Assemblies

    Finisher Unit Figure 11-26 Main Assemblies 11-324 Phaser 7700 Color Laser Printer...
  • Page 348: Table 11-3 Finisher Unit Main Assemblies

    Table 11-3 Finisher Unit Main Assemblies Part Number Description 116-1292-00 Gate Unit 116-1280-00 H-Transport Assembly Staple Finisher Screw Rack Assembly 116-1244-00 Right Cover 116-1278-00 Stacker Tray 116-1279-00 Thumb Screw Bracket 11-325 Service Quick Reference Guide - Finisher...
  • Page 349: Figure 11-27 Finisher Covers

    Finisher Covers S7700-300 Figure 11-27 Finisher Covers 11-326 Phaser 7700 Color Laser Printer...
  • Page 350: Table 11-4 Finisher Covers

    Table 11-4 Finisher Covers 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 11-327 Service Quick Reference Guide - Finisher...
  • Page 351: Figure 11-28 Finisher Stand

    Finisher Stand S7700-309 Figure 11-28 Finisher Stand 11-328 Phaser 7700 Color Laser Printer...
  • Page 352: Table 11-5 Finisher Stand

    Table 11-5 Finisher Stand 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 11-329 Service Quick Reference Guide - Finisher...
  • Page 353: Figure 11-29 Gate Unit

    Gate Unit S7700-297 Figure 11-29 Gate Unit 11-330 Phaser 7700 Color Laser Printer...
  • Page 354: Table 11-6 Gate Unit

    Table 11-6 Gate Unit 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 11-331 Service Quick Reference Guide - Finisher...
  • Page 355: Figure 11-30 Horizontal Transport

    Horizontal Transport Assembly S7700-298 Figure 11-30 Horizontal Transport 11-332 Phaser 7700 Color Laser Printer...
  • Page 356: Table 11-7 Horizontal Transport Assembly

    Table 11-7 Horizontal Transport Assembly 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 116-1259-00 H-Transport Front Cover...
  • Page 357: Figure 11-31 Horizontal Transport (Cont'd.)

    Horizontal Transport Assembly (cont’d.) S7700-299 Figure 11-31 Horizontal Transport (cont’d.) 11-334 Phaser 7700 Color Laser Printer...
  • Page 358: Table 11-8 Horizontal Transport Assembly (Cont'd.)

    Table 11-8 Horizontal Transport Assembly (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 116-1247-00 H-Transport Entrance Sensor (REP 17.4.2) 116-1285-00 Top Tray Full Sensor (REP 17.4.2) 116-1247-00 H-Transport Exit Sensor 116-1286-00...
  • Page 359: Figure 11-32 Top Cover And Eject Roll

    Top Cover and Eject Roll S7700-301 Figure 11-32 Top Cover and Eject Roll 11-336 Phaser 7700 Color Laser Printer...
  • Page 360: Table 11-9 Top Cover And Eject Roll

    Table 11-9 Top Cover and Eject Roll 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 Link 116-1264-00...
  • Page 361: Figure 11-33 Paper Transport Assembly

    Paper Transport Assembly BD BD S7700-302 Figure 11-33 Paper Transport Assembly 11-338 Phaser 7700 Color Laser Printer...
  • Page 362: Table 11-10 Paper Transport

    Table 11-10 Paper Transport 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) 116-1265-00 Belt 116-1242-00...
  • Page 363: Figure 11-34 Paper Transport (Cont'd.)

    Paper Transport (cont’d.) S7700-303 Figure 11-34 Paper Transport (cont’d.) 11-340 Phaser 7700 Color Laser Printer...
  • Page 364: Table 11-11 Paper Transport (Cont'd.)

    Table 11-11 Paper Transport (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 Bracket Wire Harness...
  • Page 365: Figure 11-35 Staple Unit

    Staple Unit Assembly S7700-304 Figure 11-35 Staple Unit 11-342 Phaser 7700 Color Laser Printer...
  • Page 366: Table 11-12 Staple Unit Assembly

    Table 11-12 Staple Unit Assembly 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 367: Figure 11-36 Compiler Tray Assembly

    Compiler Tray Assembly S7700-305 Figure 11-36 Compiler Tray Assembly 11-344 Phaser 7700 Color Laser Printer...
  • Page 368: Table 11-13 Compiler Tray Assembly

    Table 11-13 Compiler Tray Assembly 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 End Guide 11-345...
  • Page 369: Figure 11-37 Stacker Elevator Assembly

    Stacker Elevator Assembly S7700-306 Figure 11-37 Stacker Elevator Assembly 11-346 Phaser 7700 Color Laser Printer...
  • Page 370: Table 11-14 Stacker Elevator Assembly

    Table 11-14 Stacker Elevator Assembly 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 Bracket...
  • Page 371: Figure 11-38 Exit Assembly

    Exit Assembly S7700-307 Figure 11-38 Exit Assembly 11-348 Phaser 7700 Color Laser Printer...
  • Page 372: Table 11-15 Exit Assembly

    Table 11-15 Exit Assembly 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 Compiler Entrance Sensor...
  • Page 373: Figure 11-39 Electrical

    Electrical S7700-308 Figure 11-39 Electrical 11-350 Phaser 7700 Color Laser Printer...
  • Page 374: Table 11-16 Electrical

    Table 11-16 Electrical 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 11-351 Service Quick Reference Guide - Finisher...
  • Page 375 11-352 Phaser 7700 Color Laser Printer...

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