Page 1 OCUMENT OMPANY XEROX Phaser 790/DocuColor 2006 Service Manual March 2001 CAUTION 701P35949 Certain components in the Phaser 790/DocuColor 2006 are susceptible to damage from electrostatic discharge. Observe all ESD procedures to avoid component damage.
Page 2 While every care has been taken in the preparation of this manual, no liabil- the ROS opening. Do not look in the area of the ROS window if the ity will be accepted by Xerox Corporation arising out of any inaccuracies or power is On and the laser is energized.
Page 3 Introduction About this Manual ......................Organization ........................How to Use this Documentation ..................Symbology ........................Initial Issue Introduction 10/00 Phaser 790/DocuColor 2006...
Page 4 Introduction Initial Issue 10/00 Phaser 790/DocuColor 2006...
Page 5: About This Manual
Adjustments Adjustments include procedures for adjusting the parts that must be within specification for the This Service Manual is part of the multinational documentation system for the Phaser 790 correct operation of the system. Printer and DC 2006 Copier./Printer The Service Documentation is used in order to diagnose...
Page 6 CAUTION is always located in the text. Their definitions are as follows: The Phaser 790/Dc 2006 contains an invisible laser. There is no visual indication that the laser beam is present. During servicing, the machine is a Class 3B product because of WARNING the invisible laser.
Page 7 The instructions for using the ESD Field Service Kit can be found in ESD Field Service Kit Usage in the General Procedures section of the Service Documentation. Signal Nomenclature Refer to Figure 2 for an example of Signal Nomenclature. Initial Issue Introduction 10/00 Phaser 790/DocuColor 2006...
Page 8 Table 2 Logic Levels VOLTAGE H/L SPECIFICATIONS +5 VDC H= +3.00 TO +5.25 VDC L= 0.0 TO 0.8 VDC +24 VDC H= +23.37 TO +27.06 VDC L= 0.0 TO 0.8 VDC Introduction Initial Issue 10/00 Phaser 790/DocuColor 2006...
Page 9: Table Of Contents
1 Service Call Procedures Service Call Procedures....................Initial Actions Procedure ....................Call Flow Procedure ......................Cleaning Procedures....................... Final Actions........................Initial Issue Service Call Procedures 10/00 Phaser 790/DocuColor 2006...
Page 10 Service Call Procedures Initial Issue 10/00 Phaser 790/DocuColor 2006...
Page 11: Service Call Procedures
Service Strategy Purpose The service strategy for the Phaser 790 Printer and the DC 2006 Copier/Printer is to run to fail- The purpose of the Initial Actions section of the Service Call Procedures is to determine the ure. The Repair Analysis Procedures (RAPs) will be used to diagnose and repair any prob- reason for the service call and to identify and organize the actions which must be performed.
Page 12: Call Flow Procedure
The problem is intermittent. Go to the BSD and perform a resis- tance check of the wires in question. Gently pull on the wires to ensure that they are properly connected. Service Call Procedures Initial Issue 10/00 Call Flow Procedure Phaser 790/DocuColor 2006...
Page 13: Cleaning Procedures
Vacuum the Dry Ink Dispense units. tomer: Load Paper in Tray 1 with 8-1/2 x 11 inch (A4) or 11 x 17 inch, 24# Xerox COLOR Jam Sensors Xpressions or Colotech + 90 gms for the DC 2006 Copier/Printer, or Hammermill Clean the sensors with a dry cotton swab.
Page 14 Service Call Procedures Initial Issue 10/00 Cleaning Procedures, Final Actions Phaser 790/DocuColor 2006...
Page 15 009-343 PCDC Error RAP....................2-149 Imaging 009-344 Image Density Error RAP.................. 2-149 006-310 IIT Registration RAP ..................2-67 009-358 BTR 2 Home Position RAP ................2-150 006-311 Exposure Lamp RAP ..................2-69 Initial Issue Status Indicator RAPs 10/00 Phaser 790/DocuColor 2006...
Page 16 033-330/331/332 Software Error RAP ................2-214 033-340/341/342/343/344/345/350 ASIC Error RAP ............2-215 033-360/361/370/371 Memory Error RAP............... 2-215 033-380/390 1394 Failure RAP..................2-216 033-921/922/930/934/935/936/937 IOT/IIT Communication RAP ........2-216 033-940/941/943/944/945 SCSI Error RAP ..............2-217 Status Indicator RAPs Initial Issue 10/00 Phaser 790/DocuColor 2006...
Page 17: Initial Issue
011-701 Sorter Bin Jam RAP Load <size> 007-711 Tray 1 Paper Size Not Detected RAP 007-712 Tray 2 Paper Size Not Detected RAP 007-713 Tray 3 Paper Size Not Detected RAP Initial Issue Status Indicator RAPs 10/00 Fault Message/RAP Cross-Reference Phaser 790/DocuColor 2006...
Page 18 Status Indicator RAPs Initial Issue 10/00 Fault Message/RAP Cross-Reference Phaser 790/DocuColor 2006...
Page 19 Switch off the power. Remove the Rear Cover. Switch on the power. If AC Power is not mea- sured at J34-2 to terminal N on the Low Voltage Power Supply, replace the Low Voltage Power Supply (PL 11.1). Initial Issue Status Indicator RAPs 10/00 001-701 Phaser 790/DocuColor 2006...
Page 20 Figure 1 001-701 Circuit Diagram Status Indicator RAPs Initial Issue 10/00 001-701 Phaser 790/DocuColor 2006...
Page 21: Vdc Power Rap
Go to Flag 1. Refer to the +5 VDC Wirenet to troubleshoot a short circuit in the wires from P33. The Low Voltage Power Supply appears to be operating correctly. Initial Issue Status Indicator RAPs 10/00 001-702 Phaser 790/DocuColor 2006...
Page 22 Figure 1 001-702 Circuit Diagram Status Indicator RAPs Initial Issue 10/00 001-702 Phaser 790/DocuColor 2006...
Page 23: Vdc Interlocked Power Rap
Supply and the Left Front Cover Interlock for bent or broken pins or for dam- aged connectors (P/J70, P/J71, P/J97, and P/J91). Replace the Low Voltage Power Supply (PL 11.1). The Low Voltage Power Supply appears to be operating correctly. Initial Issue Status Indicator RAPs 10/00 001-703 Phaser 790/DocuColor 2006...
Page 24 Figure 1 001-703 Circuit Diagram Status Indicator RAPs Initial Issue 10/00 001-703 2-10 Phaser 790/DocuColor 2006...
Page 25: Front Cover Open Rap
The problem may be intermittent. Go to Flag 1 and Flag 2 and check for loose or damaged connections or damaged wires. If the problem persists, replace the Right Front Cover Interlock (PL 11.2). If the problem continues, replace the MCU PWB (PL 11.2). Initial Issue Status Indicator RAPs 10/00 001-704 Phaser 790/DocuColor 2006 2-11...
Page 26 Figure 1 001-704 Circuit Diagram Status Indicator RAPs Initial Issue 10/00 001-704 2-12 Phaser 790/DocuColor 2006...
Page 27: Ros +5 Vdc Switched Voltage Rap
Replace the Top Cover Interlock (PL 11.1). Go to Flag 1. Check the wire for an open circuit. The ROS +5 VDC Switched circuit appears to be functioning correctly. Initial Issue Status Indicator RAPs 10/00 001-705 Phaser 790/DocuColor 2006 2-13...
Page 28 Figure 1 001-705 Circuit Diagram Status Indicator RAPs Initial Issue 10/00 001-705 2-14 Phaser 790/DocuColor 2006...
Page 29: Area 1 Open Rap
The problem may be intermittent. Go to Flag 1 and Flag 2 and check for loose or damaged connections or damaged wires. If the problem persists, replace the Bypass Tray Interlock (PL 4.1). If the problem continues, replace the MCU PWB (PL 11.2). Initial Issue Status Indicator RAPs 10/00 001-706 Phaser 790/DocuColor 2006 2-15...
Page 30 Figure 1 001-706 Circuit Diagram Status Indicator RAPs Initial Issue 10/00 001-706 2-16 Phaser 790/DocuColor 2006...
Page 31: Area 2 Open Rap
The problem may be intermittent. Go to Flag 1 and Flag 2 and check for loose or damaged connections or damaged wires. If the problem persists, replace the Turn Chute Interlock (PL 3.3). If the problem continues, replace the MCU PWB (PL 11.2). Initial Issue Status Indicator RAPs 10/00 001-707 Phaser 790/DocuColor 2006 2-17...
Page 32 Figure 1 001-707 Circuit Diagram Status Indicator RAPs Initial Issue 10/00 001-707 2-18 Phaser 790/DocuColor 2006...
Page 33: Area 3 Open Rap
The problem may be intermittent. Go to Figure 1 and check for loose or damaged connections or damaged wires. If the problem persists, replace the Feeder Right Cover Interlock 1 and 2 (PL 13.2). If the problem continues, replace the Feeder PWB (PL 13.4). Initial Issue Status Indicator RAPs 10/00 001-708 Phaser 790/DocuColor 2006 2-19...
Page 34 Figure 1 001-708 Circuit Diagram Status Indicator RAPs Initial Issue 10/00 001-708 2-20 Phaser 790/DocuColor 2006...
Page 35: Area 4 Open Rap
The problem may be intermittent. Go to Flag 1 and Flag 2 and check for loose or damaged connections or damaged wires. If the problem persists, replace the Exit Chute Interlock (PL 9.2). If the problem continues, replace the MCU PWB (PL 11.2). Initial Issue Status Indicator RAPs 10/00 001-709 Phaser 790/DocuColor 2006 2-21...
Page 36 Figure 1 001-709 Circuit Diagram Status Indicator RAPs Initial Issue 10/00 001-709 2-22 Phaser 790/DocuColor 2006...
Page 37: Area 5 Open Rap
The problem may be intermittent. Go to Flag 1 and check for loose or damaged connections or damaged wires. If the problem persists, replace the MCU PWB (PL 11.2). Initial Issue Status Indicator RAPs 10/00 001-710 Phaser 790/DocuColor 2006 2-23...
Page 38 Figure 1 001-710 Circuit Diagram Status Indicator RAPs Initial Issue 10/00 001-710 2-24 Phaser 790/DocuColor 2006...
Page 39: Area 6 Open Rap
The problem may be intermittent. Go to Flag 1 and Flag 2 and check for loose or damaged connections or damaged wires. If the problem persists, replace the replace the Duplex Control- ler PWB (PL 15.6). Initial Issue Status Indicator RAPs 10/00 001-711 Phaser 790/DocuColor 2006 2-25...
Page 40 Figure 1 001-711 Circuit Diagram Status Indicator RAPs Initial Issue 10/00 001-711 2-26 Phaser 790/DocuColor 2006...
Page 41: Iit Dc Power Rap
Replace the Fuse. If the Fuse blows again, replace the IIT LVPS (PL 16.1). Go to the wirenets to check for any wires that may be open. Check the IIT LVPS connectors for any loose or damaged pins. Initial Issue Status Indicator RAPs 10/00 001-712 Phaser 790/DocuColor 2006 2-27...
Page 42 Figure 1 001-712 Circuit Diagram Status Indicator RAPs Initial Issue 10/00 001-712 2-28 Phaser 790/DocuColor 2006...
Page 43: Blank/Garbled Iot Display Rap
• Panel Harness (PL 12.1) • Control Panel (PL 1.2) • ESS PWB (PL 12.1) Initial Issue Status Indicator RAPs 10/00 002-310, 002-701 Phaser 790/DocuColor 2006 2-29...
Page 44 Figure 1 002-701 Circuit Diagram Status Indicator RAPs Initial Issue 10/00 002-701 2-30 Phaser 790/DocuColor 2006...
Page 45: Iot Control Panel Button/Led Rap
Ensure that the Initial Actions has been performed. If the problem continues, replace the Con- trol Panel (PL 1.2). If the problem continues, replace the ESS PWB (PL 12.1). Initial Issue Status Indicator RAPs 10/00 002-702 Phaser 790/DocuColor 2006 2-31...
Page 46 Status Indicator RAPs Initial Issue 10/00 002-702 2-32 Phaser 790/DocuColor 2006...
Page 47 Go to Flag 1. Check the wires between the Feeder PWB and the MCU PWB for an open circuit. • If the previous check is OK, replace the Feeder PWB (PL 13.4). • If the problem continues, replace the MCU PWB (PL 11.2). Initial Issue Status Indicator RAPs 10/00 003-310 Phaser 790/DocuColor 2006 2-33...
Page 48 Figure 1 003-310 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 003-310 2-34 Phaser 790/DocuColor 2006...
Page 49: Duplex Communications Failure Rap
Go to Flag 1. Check the wires between the Duplex Controller PWB and the MCU PWB for an open circuit. • If the previous check is OK, replace the Duplex Controller PWB (PL 15.6). • If the problem continues, replace the MCU PWB (PL 11.2). Initial Issue Status Indicator RAPs 10/00 003-311 Phaser 790/DocuColor 2006 2-35...
Page 50 Figure 1 003-311 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 003-311 2-36 Phaser 790/DocuColor 2006...
Page 51: Sorter Communications Failure Rap
Go to Flag 1 and check the wires for an open or short circuit. The wires are good. Repair the wires. Replace the Sorter Control PWB (PL 19.1). If the problem continues, replace the MCU PWB (PL 11.2) Initial Issue Status Indicator RAPs 10/00 003-312 Phaser 790/DocuColor 2006 2-37...
Page 52 Figure 1 003-311 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 003-312 2-38 Phaser 790/DocuColor 2006...
Page 53: Foreign Interface Rap
Go to Flag 3 and check the wires for an open or short circuit. The wires are good. Repair the wires. Replace the ESS PWB (PL 12.1). If the problem continues, replace the Foreign Interface. Initial Issue Status Indicator RAPs 10/00 003-333 Phaser 790/DocuColor 2006 2-39...
Page 54 Figure 1 003-333 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 003-333 2-40 Phaser 790/DocuColor 2006...
Page 55: Foreign Interface Compatibility Rap
Install the correct Foreign Interface. Go to Flag 1 and check the wires for an open or short circuit. The wires are good. Repair the wires. Replace the Foreign Interface. Initial Issue Status Indicator RAPs 10/00 003-334 Phaser 790/DocuColor 2006 2-41...
Page 56 Figure 1 003-334 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 003-334 2-42 Phaser 790/DocuColor 2006...
Page 57: Iot Nvm Ram Error Rap
Go to Flag 1. Check the wires for an open or short circuit. If the wires are good, replace the Communication PWB. If the problem continues, replace the MCU PWB (PL 11.2). Initial Issue Status Indicator RAPs 10/00 003-356 Phaser 790/DocuColor 2006 2-43...
Page 58 Figure 1 003-356 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 003-356 2-44 Phaser 790/DocuColor 2006...
Page 59: Iot Firmware Error Rap
Go to Flag 1 and check the connectors on the MCU PWB, P/J 84, and on the CRUM Con- 11.2). nector. • If the previous check is OK, replace the MCU PWB (PL 11.2). Initial Issue Status Indicator RAPs 10/00 003-400, 003-701 Phaser 790/DocuColor 2006 2-45...
Page 60 Figure 1 003-701 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 003-701 2-46 Phaser 790/DocuColor 2006...
Page 61: Paper Handling Motor Rap
The problem may be intermittent. Go to Figure 1 and check for loose or damaged connec- tions or damaged wires. If the problem persists, replace the replace the MCU PWB (PL 11.2). Initial Issue Status Indicator RAPs 10/00 004-320 Phaser 790/DocuColor 2006 2-47...
Page 62 Figure 1 004-320 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 004-320 2-48 Phaser 790/DocuColor 2006...
Page 63: Fuser Motor Rap
The problem may be intermittent. Go to Figure 1 and check for loose or damaged connec- tions or damaged wires. If the problem persists, replace the replace the MCU PWB (PL 11.2). Initial Issue Status Indicator RAPs 10/00 004-322 Phaser 790/DocuColor 2006 2-49...
Page 64 Figure 1 004-322 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 004-322 2-50 Phaser 790/DocuColor 2006...
Page 65 Go to Flag 1. Check for a short circuit to ground. If the wire is OK, replace the ADF Control PWB (PL 17.2). Replace the Nudger Home Sensor (PL 17.3). Initial Issue Status Indicator RAPs 10/00 005-210 Phaser 790/DocuColor 2006 2-51...
Page 66 NUDGER ROLL Figure 1 005-210 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 005-210 2-52 Phaser 790/DocuColor 2006...
Page 67: Adf Power Rap
Go to Flag 1. Check for an open circuit. If the wires are OK, go to the 001-712 RAP. Check the fuse on the ADF Control PWB (PL 17.2). If the Fuse is OK, replace the ADF Control PWB (PL 17.2). Initial Issue Status Indicator RAPs 10/00 005-211 Phaser 790/DocuColor 2006 2-53...
Page 68 Figure 1 005-211 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 005-211 2-54 Phaser 790/DocuColor 2006...
Page 69: Adf Communications Rap
Go to Flag 2. Check for an open circuit. If the wires are OK, replace the ADF Control PWB (PL 17.2). If the problem persists, replace the ICM Main PWB (PL 16.2). Initial Issue Status Indicator RAPs 10/00 005-220/221 Phaser 790/DocuColor 2006 2-55...
Page 70 Figure 1 005-220/221 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 005-220/221 2-56 Phaser 790/DocuColor 2006...
Page 71: Adf Fault Entry Rap
Exit Chute. Incomplete copy job. Copy job is never finished. Go to the 005-704 RAP Documents may or may not recirculate. IIT display never returns to READY TO COPY. Initial Issue Status Indicator RAPs 10/00 005-700 Phaser 790/DocuColor 2006 2-57...
Page 72: Adf Entrance Jam Rap
Go to Flag 3. Check for broken wires or loose pins. If the problem continues replace the ADF Control PWB (PL 17.2). If the problem remains, replace the ADF Drive Motor (PL 17.2). Status Indicator RAPs Initial Issue 10/00 005-701 Phaser 790/DocuColor 2006 2-58...
Page 73 Figure 1 005-701 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 005-701 Phaser 790/DocuColor 2006 2-59...
Page 74: Adf Exit Jam Rap
Damaged or missing Pinch Rolls • Damaged or incorrectly installed Antistatic Brush • Blockage or damage to the Exit Chute. • Wear or damage to the Exit Roll Pulleys or Belt Status Indicator RAPs Initial Issue 10/00 005-702 2-60 Phaser 790/DocuColor 2006...
Page 75 EXIT SENSOR EXIT MOTOR Figure 1 005-702 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 005-702 Phaser 790/DocuColor 2006 2-61...
Page 76: Adf No Feed Rap
Go to Flag 1. Check for an open circuit. There is +5 VDC from pin 1 to pin 3 of J711. Go to Flag 2. Check for an open circuit. Replace the Document Set Sensor (PL 17.5). Status Indicator RAPs Initial Issue 10/00 005-703 2-62 Phaser 790/DocuColor 2006...
Page 77 Figure 1 005-703 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 005-703 Phaser 790/DocuColor 2006 2-63...
Page 78: Unfinished Copy Job Rap
005-704 Unfinished Copy Job RAP Procedure Go to Flag 1 and Flag 2. Check the wires for an open circuit. If the wires are OK, replace the ICM Main PWB (PL 16.2). Status Indicator RAPs Initial Issue 10/00 005-704 2-64 Phaser 790/DocuColor 2006...
Page 79 Figure 1 005-704 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 005-704 Phaser 790/DocuColor 2006 2-65...
Page 80 Status Indicator RAPs Initial Issue 10/00 005-704 2-66 Phaser 790/DocuColor 2006...
Page 81 The problem seems to be intermittent. Go to Flag 1, Flag 2, and Flag 3. Check all connectors for loose or damaged pins. If the problem continues, replace the IIT Registration Sensor (PL 16.1). If the problem continues, replace the ICM Main PWB (PL 16.2). Initial Issue Status Indicator RAPs 10/00 006-310 Phaser 790/DocuColor 2006 2-67...
Page 82 Figure 1 006-310 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 006-310 2-68 Phaser 790/DocuColor 2006...
Page 83: Exposure Lamp Rap
• Replace the Lamp (PL 16.5). • Replace the ICM Main PWB (PL 16.2). • Replace the FLPS PWB (PL 16.2). • Replace the Scanner. Initial Issue Status Indicator RAPs 10/00 006-311 Phaser 790/DocuColor 2006 2-69...
Page 84 NOTE: The CCD is not field replaceable. If this Fault Code occurs, replace the following parts in the order shown: The FPC Cable (PL 16.3). The ICM Main PWB (PL 16.2). The Scanner. Status Indicator RAPs Initial Issue 10/00 006-312 2-70 Phaser 790/DocuColor 2006...
Page 85 Replace the Front Fan (PL 16.1). If the problem persists, replace the ICM Main PWB (PL 16.2). Replace the Rear Fan (PL 16.1). If the problem persists, replace the ICM Main PWB (PL 16.2). Initial Issue Status Indicator RAPs 10/00 006-313 Phaser 790/DocuColor 2006 2-71...
Page 86 Figure 1 006-313 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 006-313 2-72 Phaser 790/DocuColor 2006...
Page 87 Go to Flag 3 and check the wires for an open or short circuit. Replace the ROS (PL 5.1). If the problem continues, replace the MCU PWB (PL 11.2). Initial Issue Status Indicator RAPs 10/00 006-372 Phaser 790/DocuColor 2006 2-73...
Page 88 Figure 1 006-372 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 006-372 2-74 Phaser 790/DocuColor 2006...
Page 89 The problem may be intermittent. Go to Figure 1. Check for loose or damaged connections or damaged wires. If the wiring is OK, replace the Angle Sensor (PL 16.1). Of the problem per- sists, replace the ICM Main PWB (PL 16.2). Initial Issue Status Indicator RAPs 10/00 006-701 Phaser 790/DocuColor 2006 2-75...
Page 90 Figure 1 006-701 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 006-701 2-76 Phaser 790/DocuColor 2006...
Page 91 The problem may be intermittent. Go to Figure 1. Check for loose or damaged connections or damaged wires. If the wiring is OK, replace the Angle Sensor (PL 16.1). Of the problem per- sists, replace the ICM Main PWB (PL 16.2). Initial Issue Status Indicator RAPs 10/00 006-702 Phaser 790/DocuColor 2006 2-77...
Page 92 Figure 1 006-702 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 006-702 2-78 Phaser 790/DocuColor 2006...
Page 93 ICM Main PWB (PL 16.2). Reload if required (GP 8, GP 9, and GP 10). If reloading firmware does not resolve the prob- lem, replace the ICM Main PWB (PL 16.2). Initial Issue Status Indicator RAPs 10/00 006-703, 006-704 Phaser 790/DocuColor 2006 2-79...
Page 94 Check the wiring and connections to the IIT Lamp (PL 16.5). If the wires are OK, replace the Lamp. If the fault remains, replace the ICM Main PWB (PL 16.2). Status Indicator RAPs Initial Issue 10/00 006-906/907/908/909 2-80 Phaser 790/DocuColor 2006...
Page 95 Repair the wires. Connect the power cord and switch on the power. Replace the Environment Sensor (PL 11.2). Connect the power cord and switch on the power. If the problem continues, replace the MCU PWB (PL 11.2). Initial Issue Status Indicator RAPs 10/00 007-324 Phaser 790/DocuColor 2006 2-81...
Page 96 Figure 1 007-324 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 007-324 2-82 Phaser 790/DocuColor 2006...
Page 97 Go to Flag 2. Check the wire for an open circuit. If the wire is bad, repair it. If the wire is good, replace the Feeder Motor (PL 13.4), (REP 8.20). Replace the Feeder PWB (PL 13.4). Initial Issue Status Indicator RAPs 10/00 007-340 Phaser 790/DocuColor 2006 2-83...
Page 98 Figure 1 007-340 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 007-340 2-84 Phaser 790/DocuColor 2006...
Page 99 Replace the Duplex Controller PWB (PL 15.6). Check the Drive Mechanism, gears and pulleys for missing teeth and proper function. If the gears are good, Replace the Inverter Motor (PL 15.5). Initial Issue Status Indicator RAPs 10/00 007-341 Phaser 790/DocuColor 2006 2-85...
Page 100 Figure 1 007-341 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 007-341 2-86 Phaser 790/DocuColor 2006...
Page 101 Go to Flag 2. Check the wire for an open or short circuit to ground. The wires are good. Repair the wires. Ensure the connector PJ 102 is properly connected. Replace the MCU PWB (PL 11.2). Initial Issue Status Indicator RAPs 10/00 007-700 Phaser 790/DocuColor 2006 2-87...
Page 102 Figure 1 007-700 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 007-700 2-88 Phaser 790/DocuColor 2006...
Page 103 A3 (SEF) (+) 1.57 VDC Letter (LEF) (+) 2.49 VDC B5 (LEF) (+) 3.13 VDC Legal (SEF) (+) 4.09 VDC A4 (LEF) (+) 3.77 VDC B4 (SEF) (+) 2.81 VDC Initial Issue Status Indicator RAPs 10/00 007-701 Phaser 790/DocuColor 2006 2-89...
Page 104 Figure 1 007-701 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 007-701 2-90 Phaser 790/DocuColor 2006...
Page 105 A3 (SEF) (+) 1.57 VDC Letter (LEF) (+) 2.49 VDC B5 (LEF) (+) 3.13 VDC Legal (SEF) (+) 4.09 VDC A4 (LEF) (+) 3.77 VDC B4 (SEF) (+) 2.81 VDC Initial Issue Status Indicator RAPs 10/00 007-702 Phaser 790/DocuColor 2006 2-91...
Page 106 Figure 1 007-702 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 007-702 2-92 Phaser 790/DocuColor 2006...
Page 107 Go to Flag 1. Check the wires from the MCU PWB to the No Paper Sensor for an open or a short circuit to ground. If the wires are good, replace the MCU PWB (PL 11.2). Initial Issue Status Indicator RAPs 10/00 007-703 Phaser 790/DocuColor 2006 2-93...
Page 108 Figure 1 007-703 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 007-703 2-94 Phaser 790/DocuColor 2006...
Page 109 Enter code [DI-A4]. Press the Enter button. The display is “0”. Replace the No Paper Sensor (PL 13.5). If the problem continues, replace the Feeder PWB (PL 13.4). Replace the Feeder PWB (PL 13.4). Initial Issue Status Indicator RAPs 10/00 007-704 Phaser 790/DocuColor 2006 2-95...
Page 110 Figure 1 007-704 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 007-704 2-96 Phaser 790/DocuColor 2006...
Page 111 [DI-B4]. Press the Enter button. The display is “0”. Replace the No Paper Sensor (PL 13.5). If the problem continues, replace the Feeder PWB (PL 13.4). Replace the Feeder PWB (PL 13.4). Initial Issue Status Indicator RAPs 10/00 007-705 Phaser 790/DocuColor 2006 2-97...
Page 112 Figure 1 007-705 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 007-705 2-98 Phaser 790/DocuColor 2006...
Page 113 Repair or replace the Tray Empty Actuator (PL 4.3). Replace the Tray Empty Sensor (PL 4.3). If the problem continues, replace the MCU PWB (PL 11.2). Replace the MCU PWB (PL 11.2). Initial Issue Status Indicator RAPs 10/00 007-706 Phaser 790/DocuColor 2006 2-99...
Page 114 Figure 1 007-706 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 007-706 2-100 Phaser 790/DocuColor 2006...
Page 115 007-711 Tray 1 Paper Size Not Detected RAP • 007-712 Tray 2 Paper Size Not Detected RAP • 007-713 Tray 3 Paper Size Not Detected RAP Go to 008-701 Area 2 Jam RAP. Initial Issue Status Indicator RAPs 10/00 007-707 Phaser 790/DocuColor 2006 2-101...
Page 116 Go to Flag 2, Flag 3. Check the wires for an open or short to ground. If the wires are good, replace the Lift Plate Sensor (PL 4.2). If the problem continues, replace the MCU PWB (PL 11.2). Status Indicator RAPs Initial Issue 10/00 007-708 2-102 Phaser 790/DocuColor 2006...
Page 117 Figure 1 007-708 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 007-708 Phaser 790/DocuColor 2006 2-103...
Page 118 Switch off the power. Disconnect the power cord. Check the Feeder Drive Unit for worn, bound, or damaged gears in the Feeder Motor drive train. The gears are good. Replace the Feeder Drive Unit (PL 15.4). Replace the Feeder Motor (PL 13.4). Status Indicator RAPs Initial Issue 10/00 007-709 Phaser 790/DocuColor 2006 2-104...
Page 119 Figure 1 007-709 RAP Circuit Diagram (1 of 2) Initial Issue Status Indicator RAPs 10/00 007-709 Phaser 790/DocuColor 2006 2-105...
Page 120 Figure 2 007-709 RAP Circuit Diagram (2 of 2) Status Indicator RAPs Initial Issue 10/00 007-709 2-106 Phaser 790/DocuColor 2006...
Page 121 Switch off the power. Disconnect the power cord. Check the Feeder Drive Unit for worn, bound, or damaged gears in the Feeder Motor drive train. The gears are good. Replace the Feeder Drive Unit (PL 15.4). Replace the Feeder Motor (PL 13.4). Initial Issue Status Indicator RAPs 10/00 007-710 Phaser 790/DocuColor 2006 2-107...
Page 122 Figure 1 007-710 RAP Circuit Diagram (1 of 2) Status Indicator RAPs Initial Issue 10/00 007-710 2-108 Phaser 790/DocuColor 2006...
Page 123 Figure 2 007-710 RAP Circuit Diagram (2 of 2) Initial Issue Status Indicator RAPs 10/00 007-710 Phaser 790/DocuColor 2006 2-109...
Page 124 (+) 1.94 VDC Legal 14” (SEF) (+) 3.64 VDC B4 (SEF) (+) 2.45 VDC A3 (SEF) (+) 0.73 VDC 12” x 18” (SEF) (+) 0.48 VDC Ledger (SEF) (+) 0.97 VDC Status Indicator RAPs Initial Issue 10/00 007-711 Phaser 790/DocuColor 2006 2-110...
Page 125 Figure 1 007-711 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 007-711 Phaser 790/DocuColor 2006 2-111...
Page 126 A3 (SEF) (+) 1.57 VDC Letter (LEF) (+) 2.49 VDC B5 (LEF) (+) 3.13 VDC Legal (SEF) (+) 4.09 VDC A4 (LEF) (+) 3.77 VDC B4 (SEF) (+) 2.81 VDC Status Indicator RAPs Initial Issue 10/00 007-712 Phaser 790/DocuColor 2006 2-112...
Page 127 Figure 1 007-712 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 007-712 Phaser 790/DocuColor 2006 2-113...
Page 128 A3 (SEF) (+) 1.57 VDC Letter (LEF) (+) 2.49 VDC B5 (LEF) (+) 3.13 VDC Legal (SEF) (+) 4.09 VDC A4 (LEF) (+) 3.77 VDC B4 (SEF) (+) 2.81 VDC Status Indicator RAPs Initial Issue 10/00 007-713 Phaser 790/DocuColor 2006 2-114...
Page 129 Figure 1 007-713 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 007-713 Phaser 790/DocuColor 2006 2-115...
Page 130 Status Indicator RAPs Initial Issue 10/00 007-713 2-116 Phaser 790/DocuColor 2006...
Page 131 OHP Sensor (PL 4.6). Go go Flag 4. Check the wires for an open or a short circuit to ground. If the wires are good, replace the OHP Sensor (PL 4.6). Initial Issue Status Indicator RAPs 10/00 008-700 Phaser 790/DocuColor 2006 2-117...
Page 132 Figure 1 008-700 RAP Circuit Diagram (1 of 2) Status Indicator RAPs Initial Issue 10/00 008-700 2-118 Phaser 790/DocuColor 2006...
Page 133 Figure 2 008-700 RAP Circuit Diagram (2 of 2) Initial Issue Status Indicator RAPs 10/00 008-700 Phaser 790/DocuColor 2006 2-119...
Page 134 Replace the Duplex Controller PWB (PL 15.6). To to Flag 3. Check the wires for an open or a short circuit to ground. If the wires are good, replace the Duplex Drive Clutch (PL 15.4). Status Indicator RAPs Initial Issue 10/00 008-701 2-120 Phaser 790/DocuColor 2006...
Page 135 Figure 1 008-701 RAP Circuit Diagram (1 of 2) Initial Issue Status Indicator RAPs 10/00 008-701 Phaser 790/DocuColor 2006 2-121...
Page 136 Figure 2 008-701 RAP Circuit Diagram (2 of 2) Status Indicator RAPs Initial Issue 10/00 008-701 2-122 Phaser 790/DocuColor 2006...
Page 137 Go to Flag 1. Check the wires for an open or short circuit to ground. The wires are good. Repair the wires. Replace the Feed Out Sensor for Tray 2 Paper Feeder (PL 13.5). If the problem continues, replace the Feeder PWB (PL 13.4). Initial Issue Status Indicator RAPs 10/00 008-702 Phaser 790/DocuColor 2006 2-123...
Page 138 Figure 1 008-702 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 008-702 2-124 Phaser 790/DocuColor 2006...
Page 139 Check that the Upper and Lower Exit Rolls clean and the gears are free from damage (PL 9.2). • Check that the pinch rolls on the Exit Transport Cover are functioning properly (PL 9.2). Initial Issue Status Indicator RAPs 10/00 008-703 Phaser 790/DocuColor 2006 2-125...
Page 140 Figure 1 008-703 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 008-703 2-126 Phaser 790/DocuColor 2006...
Page 141 Duplex Controller PWB (PL 15.6). Enter [DO-A1]. The Inverter Entrance Clutch actuates. There is 0 VDC from J 139 pin 15 and machine frame. Replace the Duplex Controller PWB (PL 15.6). Initial Issue Status Indicator RAPs 10/00 008-704 Phaser 790/DocuColor 2006 2-127...
Page 142 Figure 1 008-704 RAP Circuit Diagram (1 of 2) Status Indicator RAPs Initial Issue 10/00 008-704 2-128 Phaser 790/DocuColor 2006...
Page 143 Figure 2 008-704 RAP Circuit Diagram (2 of 2) Initial Issue Status Indicator RAPs 10/00 008-704 Phaser 790/DocuColor 2006 2-129...
Page 144 Go to Flag 1and Flag 2. Check the wires for an open circuit. The wires are good. Repair the wires. Replace the Full Stack Sensor (PL 9.2). Replace the PWB (PL 11.2). Status Indicator RAPs Initial Issue 10/00 008-705 2-130 Phaser 790/DocuColor 2006...
Page 145 Figure 1 008-705 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 008-705 Phaser 790/DocuColor 2006 2-131...
Page 146 Repair the wires. Ensure that the OHP Sensor is free from contamination. Clean as required. If the problem continues, replace the OHP Sensor (PL 4.6). Replace the MCU PWB (PL 11.2). Status Indicator RAPs Initial Issue 10/00 008-706 2-132 Phaser 790/DocuColor 2006...
Page 147 Figure 1 008-706 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 008-706 Phaser 790/DocuColor 2006 2-133...
Page 148 The connector J 154 has a wire loop from J 154 pin 1 to pin 2. The connector J 154 is located in the Duplex Tray. If the wires and the connectors are good, replace the Duplex Con- trol PWB (PL 15.6). Status Indicator RAPs Initial Issue 10/00 008-707 2-134 Phaser 790/DocuColor 2006...
Page 149 Figure 1 008-707 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 008-707 Phaser 790/DocuColor 2006 2-135...
Page 150 Status Indicator RAPs Initial Issue 10/00 008-707 2-136 Phaser 790/DocuColor 2006...
Page 151 The problem appears to be intermittent. Check Flag 1 and Flag 2 for loose connections. If the wires are OK, replace the TR0 Sensor (PL 7.3). If the condition persists replace the MCU PWB (PL 11.2). Initial Issue Status Indicator RAPs 10/00 009-321 Phaser 790/DocuColor 2006 2-137...
Page 152 Figure 1 009-321 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 009-321 2-138 Phaser 790/DocuColor 2006...
Page 153 5 on the harness. Go to Flag 4. Check for an open circuit or a short circuit to frame ground. If the wire is OK, replace the MCU PWB (PL 11.2). Initial Issue Status Indicator RAPs 10/00 009-323 Phaser 790/DocuColor 2006 2-139...
Page 154 Figure 1 009-323 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 009-323 2-140 Phaser 790/DocuColor 2006...
Page 155 Monitor the voltage as the power-on selftest executes. The voltage is +5 VDC when power is switched on, and drops to less than 1 VDC for approxi- mately 5 seconds. Initial Issue Status Indicator RAPs 10/00 009-326 Phaser 790/DocuColor 2006 2-141...
Page 156 Figure 1 009-326 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 009-326 2-142 Phaser 790/DocuColor 2006...
Page 157 The circuit appears to be functioning correctly. Check the following: • Go to Figure 1. Check for loose or damaged connectors. • Ensure that the ADC Sensor is mounted correctly. Initial Issue Status Indicator RAPs 10/00 009-340 Phaser 790/DocuColor 2006 2-143...
Page 158 Figure 1 009-340 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 009-340 2-144 Phaser 790/DocuColor 2006...
Page 159 Go to Flag 1. Check for an open circuit. If the wire is OK, replace the ADC Sensor (PL 5.1). If the problem persists, replace the MCU PWB (PL 11.2). Go to the 009-340 RAP. Initial Issue Status Indicator RAPs 10/00 009-341 Phaser 790/DocuColor 2006 2-145...
Page 160 Figure 1 009-341 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 009-341 2-146 Phaser 790/DocuColor 2006...
Page 161 Go to Flag 4. Check for an open circuit. If the wire is OK, replace the HVPS (PL 11.1). If the problem persists, replace the MCU PWB (PL 11.2). Initial Issue Status Indicator RAPs 10/00 009-342 Phaser 790/DocuColor 2006 2-147...
Page 162 Figure 1 009-342 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 009-342 2-148 Phaser 790/DocuColor 2006...
Page 163 Switch off the power, then switch on the power. If the fault is still present, replace the MCU Procedure PWB (PL 11.2). Switch off the power, then switch on the power. If the fault is still present, replace the MCU PWB (PL 11.2). Initial Issue Status Indicator RAPs 10/00 009-343, 009-344 Phaser 790/DocuColor 2006 2-149...
Page 164 The circuit appears to be operating correctly. Go to Figure 1. Check for loose connections, dirty sensor, or damage to the gears, cam, or sensor actuator. Clean, repair, or replace as required (PL 7.4). Disconnect P/J 64. The BTR 2 Cam Clutch deenergized. Status Indicator RAPs Initial Issue 10/00 009-358 2-150 Phaser 790/DocuColor 2006...
Page 165 Figure 1 009-358 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 009-358 Phaser 790/DocuColor 2006 2-151...
Page 166: Btr 2 Bias Rap
Go to Flag 2, Flag 3, and Flag 5. Check for an open circuit or a short circuit to ground. If the wires are OK, replace the High Voltage Power Supply (PL 11.1). If the problem continues, replace the MCU PWB (PL 11.2). Status Indicator RAPs Initial Issue 10/00 009-359 2-152 Phaser 790/DocuColor 2006...
Page 167 Figure 1 009-359 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 009-359 Phaser 790/DocuColor 2006 2-153...
Page 168: Developer Fan Rap
Go to Flag 3. Check for a short circuit to frame ground. If the wire is OK, replace the MCU PWB (PL 11.2). Replace the Developer Fan (PL 11.1). Status Indicator RAPs Initial Issue 10/00 009-360 2-154 Phaser 790/DocuColor 2006...
Page 169 Figure 1 009-360 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 009-360 Phaser 790/DocuColor 2006 2-155...
Page 170: Toner Cartridge Detached Rap
The problem appears to be intermittent. Check for correct mounting of the sensor. Go to Figure 1. Check for loose or damaged connections. If the wires are OK, go to the 009-701 RAP. Status Indicator RAPs Initial Issue 10/00 009-700 2-156 Phaser 790/DocuColor 2006...
Page 171 FRONT Figure 1 009-700 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 009-700 Phaser 790/DocuColor 2006 2-157...
Page 172: Toner Cartridge Empty Rap
There is less than 1 VDC from J 56 pin 1 to frame ground. Go to Flag 2. Check for an open circuit. If the wire is OK, replace the MCU PWB (PL 11.2). Status Indicator RAPs Initial Issue 10/00 009-701 Phaser 790/DocuColor 2006 2-158...
Page 173 Figure 1 009-701 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 009-701 Phaser 790/DocuColor 2006 2-159...
Page 174: Waste Container Full Rap
The problem appears to be intermittent. Go to Figure 1. Check for loose or damaged connec- tions, or pinched wires. If the wires are OK, replace the Waste Toner Sensor (PL 5.1). If the problem persists, replace the MCU PWB (PL 11.2). Status Indicator RAPs Initial Issue 10/00 009-702 2-160 Phaser 790/DocuColor 2006...
Page 175 Figure 1 009-702 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 009-702 Phaser 790/DocuColor 2006 2-161...
Page 176: Waste Container Detached Rap
The problem appears to be intermittent. Go to Figure 1. Check for loose or damaged connec- tions, or pinched wires. If the wires are OK, replace the Toner Box Sensor (PL 5.1). If the prob- lem persists, replace the MCU PWB (PL 11.2). Status Indicator RAPs Initial Issue 10/00 009-703 2-162 Phaser 790/DocuColor 2006...

Xerox Phaser 790 Service Manual

Quick Links

3 Introduction

9 1 Service Call Procedures

15 2 Status Indicator Raps

233 3 Image Quality

255 4 Repairs And Adjustments

421 5 Parts List

423 Overview

504 Common Hardware

Chapters

3 Introduction

9 1 Service Call Procedures

15 2 Status Indicator Raps

233 3 Image Quality

255 4 Repairs And Adjustments

421 5 Parts List

423 Overview

504 Common Hardware

Also See for Xerox Phaser 790

Related Manuals for Xerox Phaser 790

Summary of Contents for Xerox Phaser 790

3
Introduction

9
1 Service Call Procedures

15
2 Status Indicator Raps

233
3 Image Quality

255
4 Repairs And Adjustments

421
5 Parts List

423
Overview

504
Common Hardware

3
Introduction

9
1 Service Call Procedures

15
2 Status Indicator Raps

233
3 Image Quality

255
4 Repairs And Adjustments

421
5 Parts List

423
Overview

504
Common Hardware