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Xerox Phaser 790 Service Manual

Xerox Phaser 790 Service Manual

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Phaser 790/DocuColor 2006

Service Manual

March 2001

701P35949

T

D

HE

OCUMENT

XEROX

C

OMPANY

Certain components in the Phaser 790/DocuColor

2006 are susceptible to damage from electrostatic

discharge. Observe all ESD procedures to avoid

component damage.

CAUTION

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Summary of Contents for Xerox Phaser 790

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...
Page 177 Figure 1 009-703 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 009-703 Phaser 790/DocuColor 2006 2-163...
Page 178: Belt Cleaner Rap
Check the Input Bracket Assembly and the Cleaner Cam for binding or damage. Clean, repair or replace as required (PL 8.1, PL 8.6, PL 8.7). The Belt Cleaner appears to be functioning correctly. Return to the RAP that sent you here. Status Indicator RAPs Initial Issue 10/00 009-704 2-164 Phaser 790/DocuColor 2006...
Page 179 Figure 1 009-704 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 009-704 Phaser 790/DocuColor 2006 2-165...
Page 180 Status Indicator RAPs Initial Issue 10/00 009-704 2-166 Phaser 790/DocuColor 2006...
Page 181 If the Fuser area is clean and without apparent damage, excessive wear or damaged connec- tions or wires, go to 010-701 Faulty Temperature Sensor RAP to troubleshoot the problem. Initial Issue Status Indicator RAPs 10/00 010-317 Phaser 790/DocuColor 2006 2-167...
Page 182: Fuser Low/Under Temperature Condition Rap
Go to Flag 3 and Flag 4. Check for an open circuit. Repair or replace the Fuser Con- nector Harness or the Main Harness (PL 11.1), or the Fuser Harness (PL 8.5) as required. Reconnect the power cord and switch on power to the Copier/Printer. Status Indicator RAPs Initial Issue 10/00 010-353/356/357 Phaser 790/DocuColor 2006 2-168...
Page 183 Figure 1 010-353 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 010-353/356/357 Phaser 790/DocuColor 2006 2-169...
Page 184: Fuser Temperature Not Detected Rap
Repair or replace the Fuser Harness (PL 8.5) or the Main Harness (PL 11.1) as required. If the wiring is OK and the problem persists, replace the Temperature Sensor (PL 8.2). If the problem still persists, replace the MCU PWB (PL 11.2). Status Indicator RAPs Initial Issue 10/00 010-354 2-170 Phaser 790/DocuColor 2006...
Page 185 Figure 1 010-354 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 010-354 Phaser 790/DocuColor 2006 2-171...
Page 186: Fuser Overheat Error Rap
The measured voltage is approximately +4.5VDC and momentarily goes to approximately +3.2VDC, then recovers, when the Item/Enter button is pressed. Replace the MCU PWB (PL 11.2). Go to 010-701 Faulty Temperature Sensor RAP to troubleshoot the problem. Status Indicator RAPs Initial Issue 10/00 010-355 2-172 Phaser 790/DocuColor 2006...
Page 187 Figure 1 010-355 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 010-355 Phaser 790/DocuColor 2006 2-173...
Page 188: Fuser Fan Error Rap
Go to Flag 3. Check for an open circuit. Repair or replace the Main Harness (PL 11.1) as required. If the wiring is OK, replace the MCU PWB (PL 11.2). Replace the Fuser Fan (PL 9.2). Status Indicator RAPs Initial Issue 10/00 010-358 2-174 Phaser 790/DocuColor 2006...
Page 189 Figure 1 010-358 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 010-358 Phaser 790/DocuColor 2006 2-175...
Page 190: Exit Chute Fan Failure Rap
Go to Flag 2. Check for an open circuit. Repair or replace the Main Harness (PL 11.1) as required. If the wiring is OK, replace the MCU PWB (PL 11.2). Replace the Exit Chute Fan (PL 9.2). Status Indicator RAPs Initial Issue 10/00 010-359 2-176 Phaser 790/DocuColor 2006...
Page 191 Figure 1 010-359 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 010-359 Phaser 790/DocuColor 2006 2-177...
Page 192: Area 5 Jam Rap
ADJ 10.1 Fuser Nip. If the problem persists, replace the Fuser Assembly (PL 8.1). Inspect the Heat Roll and the Pressure Roll for damage or excessive wear. Replace as required (PL 8.3). Status Indicator RAPs Initial Issue 10/00 010-700 2-178 Phaser 790/DocuColor 2006...
Page 193 Initial Issue Status Indicator RAPs 10/00 010-700 Phaser 790/DocuColor 2006 2-179...
Page 194: Faulty Temperature Sensor Rap
Repair or replace the Fuser Harness (PL 8.5) or the Main Harness (PL 11.1) as required. If the wiring is OK and the problem persists, replace the Temperature Sensor (PL 8.2). If the problem still persists, replace the MCU PWB (PL 11.2). Status Indicator RAPs Initial Issue 10/00 010-701 2-180 Phaser 790/DocuColor 2006...
Page 195 Figure 1 010-701 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 010-701 Phaser 790/DocuColor 2006 2-181...
Page 196: Faulty Entrance Sensor Rap
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 Fuser Entrance Sensor (PL 8.6). If the problem persists, replace the MCU PWB (PL 11.2). Status Indicator RAPs Initial Issue 10/00 010-702 2-182 Phaser 790/DocuColor 2006...
Page 197 Figure 1 010-702 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 010-702 Phaser 790/DocuColor 2006 2-183...
Page 198: Faulty Fuser Exit Sensor Rap
(which includes a portion of the wiring for the Fuser Exit Sensors) as required. If the wiring is OK, replace the Rear Fuser Exit Sensor (PL 8.2). If the problem persists, replace the MCU PWB (PL 11.2). Status Indicator RAPs Initial Issue 10/00 010-703 Phaser 790/DocuColor 2006 2-184...
Page 199 Figure 1 010-703 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 010-703 Phaser 790/DocuColor 2006 2-185...
Page 200: Faulty Fuser Chute Fan Rap
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 Fuser Chute Fan (PL 8.6). If the problem per- sists, replace the MCU PWB (PL 11.2). Status Indicator RAPs Initial Issue 10/00 010-704 2-186 Phaser 790/DocuColor 2006...
Page 201 Figure 1 010-704 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 010-704 Phaser 790/DocuColor 2006 2-187...
Page 202: Faulty Exchange Solenoid Rap
The problem may be intermittent. Go to Figure 1. Check for loose or damaged connections or damaged wires. Also check for continuity. If the wiring is OK, replace the Exchange Solenoid Assembly (PL 8.5). If the problem continues, replace the MCU PWB (PL 11.2). Status Indicator RAPs Initial Issue 10/00 010-705 2-188 Phaser 790/DocuColor 2006...
Page 203 Figure 1 010-705 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 010-705 Phaser 790/DocuColor 2006 2-189...
Page 204 Status Indicator RAPs Initial Issue 10/00 010-705 2-190 Phaser 790/DocuColor 2006...
Page 205 Go to Flag 1. Check the harness for a short circuit. If the harness is OK, replace the Dock- ing Interlock (PL 19.6). The docking interlock appears to be operating normally. Check the alignment between the docking mechanism and the Docking Interlock. Initial Issue Status Indicator RAPs 10/00 011-700 Phaser 790/DocuColor 2006 2-191...
Page 206 Figure 1 011-700 RAP Circuit Diagram Status Indicator RAPs Initial Issue 10/00 011-700 2-192 Phaser 790/DocuColor 2006...
Page 207: Sorter Bin Jam Rap
The meter changes state from a Low (0 VDC) to a High (+5 VDC). Repair the wire. The voltage remains Low (0 VDC). Replace the Sensor Receiver (PL 19.2). Initial Issue Status Indicator RAPs 10/00 011-701 Phaser 790/DocuColor 2006 2-193...
Page 208 Remove the paper in Bin 1. Access the Digital Output (DO) test from the Control Panel. Enter code [D6]. Press the Item/Enter button. The display is 0. Replace the Sensor Receiver (PL 19.2). Replace the Sorter Control PWB (PL 19.1). Status Indicator RAPs Initial Issue 10/00 011-701 Phaser 790/DocuColor 2006 2-194...
Page 209 Figure 1 011-701 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 011-701 Phaser 790/DocuColor 2006 2-195...
Page 210: Sorter Cover Open Rap
Replace the Sorter Control PWB (PL 19.1). This indicates that the Top Cover and the Top Cover Interlock are working correctly. If the prob- lem persists, replace the Sorter Control PWB (PL 19.1). Status Indicator RAPs Initial Issue 10/00 011-702 2-196 Phaser 790/DocuColor 2006...
Page 211 Figure 1 011-702 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 011-702 Phaser 790/DocuColor 2006 2-197...
Page 212: Sorter Transport Jam Rap
Deactuate the Sorter Path Sensor actuator. There is 0 VDC between J 2-2 and GND Replace the Sorter Path Sensor (PL 19.3). Replace the Sorter Control PWB (PL 19.1). Status Indicator RAPs Initial Issue 10/00 011-703 2-198 Phaser 790/DocuColor 2006...
Page 213 Figure 1 011-703 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 011-703 Phaser 790/DocuColor 2006 2-199...
Page 214: Sorter Noise Rap
There is +5 VDC between J35-4 of the Low Voltage Power Supply and GND. Replace the LVPS (PL 11.1). Go to Flag 1. Check for an open circuit. Replace the Sorter Control PWB (PL 19.1). Status Indicator RAPs Initial Issue 10/00 011-704 2-200 Phaser 790/DocuColor 2006...
Page 215 Figure 1 011-704 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 011-704 Phaser 790/DocuColor 2006 2-201...
Page 216: Full Sensor Rap
Place 5 sheets of paper in the Stack Tray. Access the Digital Input (DI) test from the Control Panel. Enter code [D0]. Press the Item/Enter button. The display is 0. Replace the Full Sensor (PL 19.3). Replace the Sorter Control PWB (PL 19.1). Status Indicator RAPs Initial Issue 10/00 011-705 2-202 Phaser 790/DocuColor 2006...
Page 217 Figure 1 011-705 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 011-705 Phaser 790/DocuColor 2006 2-203...
Page 218: Cannot Select Sorter Rap
Go to Flag 1. Check the wires for an open circuit. The wires are good. Repair the wires. Replace the Sorter Control PWB (PL 19.1). Replace the MCU PWB (PL 11.2). Status Indicator RAPs Initial Issue 10/00 011-706 2-204 Phaser 790/DocuColor 2006...
Page 219 Figure 1 011-706 RAP Circuit Diagram Initial Issue Status Indicator RAPs 10/00 011-706 Phaser 790/DocuColor 2006 2-205...
Page 220 Status Indicator RAPs Initial Issue 10/00 011-706 2-206 Phaser 790/DocuColor 2006...
Page 221: Ess Hard Drive Error Rap
Switch off the power. Check for a loose connection at the HDD connector. Switch on the power. (PL 12.1). If the fault remains, replace the Hard Disk Drive (PL 12.1). If the problem still exists, replace the ESS PWB (PL 12.1). Initial Issue Status Indicator RAPs 10/00 016-310, 016-312 Phaser 790/DocuColor 2006 2-207...
Page 222: Asic Access Error Rap
Switch off the power. Reseat the Memory module in Slot 1. Switch on the power. If the fault (PL 12.1). remains, replace the Memory module in Slot 1 (PL 12.1). If the problem still exists, replace the ESS PWB (PL 12.1). Status Indicator RAPs Initial Issue 10/00 016-313, 016-315 2-208 Phaser 790/DocuColor 2006...
Page 223: Ess Ram (Bank 2) Rap
Switch off the power then switch on the power. If the problem still exists, replace the ESS PWB remains, replace the Memory module in Slot 2 (PL 12.1). If the problem still exists, replace the (PL 12.1). ESS PWB (PL 12.1). Initial Issue Status Indicator RAPs 10/00 016-316, 016-317 Phaser 790/DocuColor 2006 2-209...
Page 224: Ess Nvm Ram Failure Rap
Switch off the power then switch on the power. If the fault remains, replace the 1394 PWB (PL 12.1). If the problem still exists, replace the ESS PWB (PL 12.1). Status Indicator RAPs Initial Issue 10/00 016-323/324/325, 016-330/331/332/333/334/335/336 2-210 Phaser 790/DocuColor 2006...
Page 225: Iot To Ess Communication Failure Rap
Switch off the power and reconnect the network, switch the power on. Replace the hard drive (PL 12.1) Initial Issue Status Indicator RAPs 10/00 016-370 Phaser 790/DocuColor 2006 2-211...
Page 226 021- 210/ 211 Accessories Error Improper value detected in accessory Procedure Perform the following: Switch off the power and switch the power on. If the problem persists, replace the ICM PWB (PL 16.2) Status Indicator RAPs Initial Issue 10/00 016-370 2-212 Phaser 790/DocuColor 2006...
Page 227: Iot/Iit Disconnection Rap
Remove the Right Cover (REP 14.9). Verify that the 1394 PWB is correctly installed. If the PWB is installed correctly and the problem still exists, replace the 1394 PWB (PL 12.1). If the problem continues, replace the ICM Main PWB (PL 16.2). Initial Issue Status Indicator RAPs 10/00 033-210, 033-211/212 Phaser 790/DocuColor 2006 2-213...
Page 228: Iot/Iit Communication Rap
PWB is installed correctly and the problem still exists, replace the 1394 PWB (PL 12.1). If the problem continues, replace the ICM Main PWB (PL 16.2). Procedure Check the scanner lamp harness and lamp. If problem persists, replace the ICM Main PWB (PL16.2) Status Indicator RAPs Initial Issue 10/00 033-221/222/223/224/225/226/226/227/228, 033-330/ 2-214 Phaser 790/DocuColor 2006...
Page 229: Asic Error Rap
033-345: An ASIC_M read/write error was detected. 033-350: An SCSI_CHIP read/write error was detected. Procedure Switch the power off, then on. If the fault remains, replace the ICM Main PWB (PL 16.2). Initial Issue Status Indicator RAPs 10/00 033-340/341/342/343/344/345, 033-360/361/370/371 Phaser 790/DocuColor 2006 2-215...
Page 230: Failure Rap
Remove the Right Cover (REP 14.9). Verify that the 1394 PWB is correctly installed. If the PWB is installed correctly and the problem still exists, replace the 1394 PWB (PL 12.1). If the problem continues, replace the ICM Main PWB (PL 16.2). Status Indicator RAPs Initial Issue 10/00 033-380/390, 033-921/922/930/934/935/936/937 2-216 Phaser 790/DocuColor 2006...
Page 231: Scsi Error Rap
If the problem was not corrected in the Initial Actions of this RAP, replace the SCSI PWB. If the problem still exists, replace the ICM Main PWB (PL 16.2). Initial Issue Status Indicator RAPs 10/00 033-940/941/943/944/945 Phaser 790/DocuColor 2006 2-217...
Page 232 Status Indicator RAPs Initial Issue 10/00 033-940/941/943/944/945 2-218 Phaser 790/DocuColor 2006...
Page 233 IQ14 Process Direction Bands, Streaks, and Smears RAP ..........3-18 IQ15 Unfused Copy RAP ....................3-18 IQ16 Repeating Bands, Streaks, Spots, and Smears RAP..........3-19 IQ17 Uneven Density/Mottle RAP................... 3-20 IQ18 Spots RAP......................3-21 Initial Issue Image Quality 10/00 Phaser 790/DocuColor 2006...
Page 234 Image Quality Initial Issue 10/00 Phaser 790/DocuColor 2006...
Page 235: Iq1 Iot Image Quality Entry Rap
Only the black portions of a color image are printed Go to the 009-704 RAP Mottle Areas of solid, or high density coverage that are reproduced with a surface that resembles marble. Go to the IQ17 RAP Initial Issue Image Quality 10/00 Phaser 790/DocuColor 2006...
Page 236 A toner image that remains on the photoreceptor or IBT after cleaning. The next image is placed on top of the residual image and Go to the IQ7 RAP both images are transferred to the next copy. Unfused prints Image can be rubbed off with little or no pressure Go to the IQ15 RAP Image Quality Initial Issue 10/00 Phaser 790/DocuColor 2006...
Page 237: Iq2 Iit Image Quality Entry Rap
Clean the Document Glass Repetitive, irregular-shaped marks that occur when Place a transparency between the document and the glass making copies of glossy photographs. These marks are most noticeable in large low-density or highlight areas. Initial Issue Image Quality 10/00 Phaser 790/DocuColor 2006...
Page 238: Iq3 Low Image Density Rap
Replace the Developer Housing (PL 6.2). Check the continuity between the BCR Contact (PL 5.1) and terminal A on the HVPS. There is continuity. Replace the BCR Wire (PL 11.1) and/or the BCR Connector (PL 5.1). Image Quality Initial Issue 10/00 Phaser 790/DocuColor 2006...
Page 239: Iq4 High Density Rap
Replace the Copy/Print Cartridge (PL 5.1). If the problem remains, replace the MCU PWB (PL • Replace the Dry Ink Cartridge (PL 6.2) if not done previously 11.2). • Replace the Developer Housing (PL 6.2). Initial Issue Image Quality 10/00 IQ4, IQ5 Phaser 790/DocuColor 2006...
Page 240: Iq6 Blank (Or Nearly Blank) Sheet Rap
Connect the DVM between the F terminal on the HVPS and frame ground. Access the Digital Output Test (GP 2). Enter code 0A. Press the Item/Enter button. Roughly -1000 measured. There is less than 1 VDC from J 42 pin 10 on the HVPS to ground. Image Quality Initial Issue 10/00 Phaser 790/DocuColor 2006...
Page 241 Figure 1 IQ6 RAP Circuit Diagram Initial Issue Image Quality 10/00 Phaser 790/DocuColor 2006...
Page 242: Iq7 Residual Image (Ghosting) Rap
Clean the Rolls. Adjust the Fuser Nip (ADJ 10.1). If the problem persists, go to the 010-701 RAP to troubleshoot the Temperature Sensor. If this does not resolve the problem, replace the Main Fuser assembly (PL 8.1). Image Quality Initial Issue 10/00 3-10 Phaser 790/DocuColor 2006...
Page 243 Figure 1 IQ7 RAP Circuit Diagram Initial Issue Image Quality 10/00 Phaser 790/DocuColor 2006 3-11...
Page 244: Iq8 Iot Background Rap
Check the Developer Roll Spacing (ADJ 9.1) for the affected color. • Check the end-of-life counter (GP 3) for the Dry Ink Cartridge. If it is at or near end-of-life, replace it (PL 6.2). Image Quality Initial Issue 10/00 3-12 Phaser 790/DocuColor 2006...
Page 245 Initial Issue Image Quality 10/00 Phaser 790/DocuColor 2006 3-13...
Page 246: Iq9 Deletions Rap
There is + 5 VDC from J 86 pin 2 to frame ground. Go to Flag 1. Check for an open circuit. If the wire is OK, replace the MCU PWB (PL 11.2). Image Quality Initial Issue 10/00 Phaser 790/DocuColor 2006 3-14...
Page 247 Figure 1 IQ9 RAP Circuit Diagram Initial Issue Image Quality 10/00 Phaser 790/DocuColor 2006 3-15...
Page 248: Iq10 Color-To-Color Misregistration Rap
Check the Registration Springs, Registration Rubber Roll, and Preregistration Roll for wear or contamination (PL 4.7). If the problem continues, replace the Main Paper Handling Frame Assembly (PL 4.1). Image Quality Initial Issue 10/00 IQ10, IQ11 3-16 Phaser 790/DocuColor 2006...
Page 249: Iq12 Iit Skew Rap
Feed Roll and Registration Roll (PL 17.3) for wear or contamination. Clean/replace as required. Check/adjust IIT Lead Edge Registration (ADJ 6.3) and IIT Side Registration (ADJ 6.4). Initial Issue Image Quality 10/00 IQ12, IQ13 Phaser 790/DocuColor 2006 3-17...
Page 250: Iq14 Process Direction Bands, Streaks, And Smears Rap
Remove the ROS (PL 5.1). Check the ROS window for damage or contamination. Clean or replace as required. If the problem remains, replace the Copy/Print Cartridge (PL 5.1). If this does not resolve the problem, replace the ROS (PL 5.1). Image Quality Initial Issue 10/00 IQ14, IQ15 3-18 Phaser 790/DocuColor 2006...
Page 251: Iq16 Repeating Bands, Streaks, Spots, And Smears Rap
Check the Fuser Nip (ADJ 10.1). Go to the 010-701 RAP. 264 mm. Photoreceptor Drum Check the surface of the drum for contamination or damage. Clean or replace the Copy/Print Cartridge as required. (PL 5.1) Initial Issue Image Quality 10/00 IQ16 Phaser 790/DocuColor 2006 3-19...
Page 252: Iq17 Uneven Density/Mottle Rap
There is continuity. Replace the Copy/Print Cartridge (PL 5.1). Remove the ROS. Examine the window for contamination. The ROS window is clean. Image Quality Initial Issue 10/00 IQ17 Phaser 790/DocuColor 2006 3-20...
Page 253: Iq18 Spots Rap
Check the Copy/Print Cartridge for dirt or damage. Clean or replace as required(PL 5.1). Go to the IQ16 RAP. Ensure that the original is free from the defect. Clean the Platen Glass and Lens. Initial Issue Image Quality 10/00 IQ18 Phaser 790/DocuColor 2006 3-21...
Page 254 Image Quality Initial Issue 10/00 IQ18 3-22 Phaser 790/DocuColor 2006...
Page 255 REP 8.19 Size Switch PWB .................... 4-71 REP 6.7 Registration Sensor ..................4-40 REP 8.20 Feeder Motor ....................4-72 REP 6.8 IIT Low Voltage Power Supply (LVPS) ............. 4-41 REP 8.21 Feeder PWB ....................4-72 Initial Issue Repairs and Adjustments 10/00 Phaser 790/DocuColor 2006...
Page 256 REP 10.1 Fuser Assembly ....................4-113 ADJ 5.1 ADF Side Registration ..................4-148 REP 10.2 Main Fuser Assembly ..................4-113 ADJ 5.2 ADF Lead Edge Registration................4-149 REP 10.3 Upper Guide Assembly ................... 4-114 Repairs and Adjustments Initial Issue 10/00 Phaser 790/DocuColor 2006...
Page 257 ADJ 6.7 B* Correction ..................... 4-160 ADJ 8.1 Printer Registration.................... 4-161 ADJ 9.1 Developer Spacing .................... 4-162 ADJ 10.1 Fuser Nip ......................4-164 ADJ 11.1 Sorter Bin Cam Position .................. 4-165 Initial Issue Repairs and Adjustments 10/00 Phaser 790/DocuColor 2006...
Page 258 Repairs and Adjustments Initial Issue 10/00 Phaser 790/DocuColor 2006...
Page 259: Rep 1.1 Lvps
(2) Disconnect the six con- nectors Disconnect the Remove the screws Connectors Loosen the lower screws Figure 1 Removing the HVPS Figure 1 Removing the LVPS Initial Issue Repairs and Adjustments 10/00 REP 1.1, REP 1.2 Phaser 790/DocuColor 2006...
Page 260: Rep 1.3 Top Cover Interlock
Disconnect the connec- Figure 1 Removing the Top Cover Interlock tor. Then, disengage the harness from the duct Figure 1 Removing the Developer Fan Repairs and Adjustments Initial Issue 10/00 REP 1.3, REP 1.4 Phaser 790/DocuColor 2006...
Page 261: Rep 1.5 Mcu Pwb
5C XX XX XX 004D 5C XX XX XX 0046 60 XX XX XX 004C 60 XX XX XX Check / Adjust the IOT Registration (ADJ 8.1). Perform VisualCal (GP16). Initial Issue Repairs and Adjustments 10/00 REP 1.5 Phaser 790/DocuColor 2006...
Page 262: Rep 1.6 Right Front Cover Interlock
Cover Interlock Remove the screw Unhook the switch from the frame Figure 1 Removing the Left Front Cover Interlock Figure 1 Removing the Right Front Cover Interlock Repairs and Adjustments Initial Issue 10/00 REP 1.6, REP 1.7 Phaser 790/DocuColor 2006...
Page 263: Rep 1.8 Environment Sensor
NOTE: The screw that secures the Environment Sensor also secures the ground wire. Reinstall the Environment Sensor in the reverse order of removal. Disconnect the Compress the connector standoffs Remove the Environment Sensor Figure 1 Removing the Environment Sensor Initial Issue Repairs and Adjustments 10/00 REP 1.8 Phaser 790/DocuColor 2006...
Page 264: Rep 1.9 Ess Pwb
EPROM at a time, in order to avoid a mixup of the EPROMs and possible machine malfunc- tion. 5. Switch off the power and remove the jumper. Switch power on and check IIT Magnification ADJ6.1, and IIT Registration ADJ6.3 and adjust administrator settings. Repairs and Adjustments Initial Issue 10/00 REP 1.9 4-10 Phaser 790/DocuColor 2006...
Page 265: Rep 1.10 Ess Fan
ESS Fan Loosen the Open the Bypass Tray / four lower Registration Assembly screws Figure 1 Removing the Controller Chassis Figure 1 Removing the ESS Fan Initial Issue Repairs and Adjustments 10/00 REP 1.10, REP 1.11 Phaser 790/DocuColor 2006 4-11...
Page 266: Rep 1.12 Communication Pwb
Remove the Bypass Tray / Registration Assembly (REP 8.10). Remove the Communication PWB (Figure 1). Replacement Reinstall the Communication PWB in the reverse order of removal. Remove the Communication Figure 1 Removing the Communication PWB Repairs and Adjustments Initial Issue 10/00 REP 1.12 4-12 Phaser 790/DocuColor 2006...
Page 267: Rep 1.13 Hard Disk Drive Assembly
Slide the Hard Disk Drive Assembly toward the right, and remove the Hard Disk Drive Assembly. Replacement Reinstall the Hard Disk Drive Assembly in the reverse order of removal. Adjust the Hard Disk Drive Assembly (ADJ 3.1). Initial Issue Repairs and Adjustments 10/00 REP 1.13 Phaser 790/DocuColor 2006 4-13...
Page 268 Repairs and Adjustments Initial Issue 10/00 REP 1.13 4-14 Phaser 790/DocuColor 2006...
Page 269: Rep 4.1 Paper Handling Drive Unit
Motor PWB Bracket Remove the two supports from the Remove the Paper Handling Paper Handling Drive Unit Drive Unit Figure 1 Removing the Paper Handling Drive Unit Initial Issue Repairs and Adjustments 10/00 REP 4.1 Phaser 790/DocuColor 2006 4-15...
Page 270: Rep 4.2 Fuser Drive Unit
Reinstall the Fuser Drive Unit in the reverse order of removal. Remove the K- clip Remove the five screws Remove the screw securing the Drive Clamp-N Figure 1 Removing the Fuser Drive Unit Repairs and Adjustments Initial Issue 10/00 REP 4.2 4-16 Phaser 790/DocuColor 2006...
Page 271: Rep 4.3 Fuser Motor
Remove the Paper Handling screws Motor Remove the screws Disconnect the con- nector Figure 1 Removing the Fuser Motor Figure 1 Removing the Paper Handling Motor Initial Issue Repairs and Adjustments 10/00 REP 4.3, REP 4.4 Phaser 790/DocuColor 2006 4-17...
Page 272: Rep 4.5 Drive Motor Pwb
Reinstall the Drive Motor PWB in the reverse order of removal. Remove the Drive Motor PWB Remove the screws Disconnect the four connec- tors Figure 1 Removing the Drive Motor PWB Repairs and Adjustments Initial Issue 10/00 REP 4.5 4-18 Phaser 790/DocuColor 2006...
Page 273: Rep 4.6 Process Drive Unit
Align the positioning boss of the printer frame with the positioning hole of the Process Drive Unit before securing the unit. Remove the screws Disconnect the connectors Figure 1 Removing the Process Drive Unit Initial Issue Repairs and Adjustments 10/00 REP 4.6 Phaser 790/DocuColor 2006 4-19...
Page 274: Rep 4.7 Rotary Motor
Remove the screws Disconnect the connectors Remove the Remove the Rotary Rotary Motor Motor Figure 1 Removing the Rotary Motor Figure 1 Removing the Rotary Motor PWB Repairs and Adjustments Initial Issue 10/00 REP 4.7, REP 4.8 4-20 Phaser 790/DocuColor 2006...
Page 275: Rep 4.9 Dispense Clutch
Remove the screws Remove the Developer Clutch Remove the Figure 1 Removing the Dispense Clutch screws Figure 1 Removing the Developer Clutch Initial Issue Repairs and Adjustments 10/00 REP 4.9, REP 4.10 Phaser 790/DocuColor 2006 4-21...
Page 276 Repairs and Adjustments Initial Issue 10/00 REP 4.9, REP 4.10 4-22 Phaser 790/DocuColor 2006...
Page 277: Rep 5.1 Adf Assembly
Perform an ADF Side Registration adjustment (ADJ 5.1) Perform an ADF Lead Edge Registration adjustment (ADJ 5.2) Perform an ADF Height adjustment (ADJ 5.3) Perform an ADF Front-to-rear Positioning adjustment (ADJ 5.4) Initial Issue Repairs and Adjustments 10/00 REP 5.1 Phaser 790/DocuColor 2006 4-23...
Page 278: Rep 5.2 Adf Drive Motor
Perform the procedure for removal in reverse. Perform an ADF Side Registration adjustment. (ADJ 5.1) Perform an ADF Lead Edge Registration adjustment. (ADJ 5.2) Perform an ADF Height adjustment. (ADJ 5.3) Repairs and Adjustments Initial Issue 10/00 REP 5.2, REP 5.3 4-24 Phaser 790/DocuColor 2006...
Page 279: Rep 5.4 Feed Roll
Figure 2 Removing the Feed Roll Loosen the screw Remove the Lower Chute by moving the chute in the direction indicated Figure 1 Removing the Lower Chute Initial Issue Repairs and Adjustments 10/00 REP 5.4 Phaser 790/DocuColor 2006 4-25...
Page 280: Rep 5.5 Nudger Roll
Move the Drive Motor in Roll, and tighten the direction indicated the screw Loosen two screws and reduce the belt tension Figure 1 Reducing Drive Belt Tension Repairs and Adjustments Initial Issue 10/00 REP 5.4, REP 5.5 4-26 Phaser 790/DocuColor 2006...
Page 281 Nudger moving the chute in the direction Home Sensor and indicated remove the sensor Figure 3 Removing Nudger Roll Retaining Parts Figure 2 Removing the Lower Chute Initial Issue Repairs and Adjustments 10/00 REP 5.5 Phaser 790/DocuColor 2006 4-27...
Page 282 Nudger Roll Rotates freely Locked in in this direction this direction Remove the Nudger Roll Figure 5 One Way Clutch Rotation Figure 4 Removing the Nudger Roll Repairs and Adjustments Initial Issue 10/00 REP 5.5 4-28 Phaser 790/DocuColor 2006...
Page 283: Rep 5.6 Registration Roll
Figure 2 Removing the Drive Pulley/Gear Remove the two retaining screws, then remove the Feeder Lower Cover Figure 1 Removing the Feeder Lower Cover Remove the left Counterbalance. (REP 5.3) Initial Issue Repairs and Adjustments 10/00 REP 5.6 Phaser 790/DocuColor 2006 4-29...
Page 284 Figure 3 Removing the Registration Roll Replacement Perform the procedure for removal in reverse. Perform an ADF Side Registration adjustment (ADJ 5.1) Perform an ADF Lead Edge Registration adjustment (ADJ 5.2) Repairs and Adjustments Initial Issue 10/00 REP 5.6 4-30 Phaser 790/DocuColor 2006...
Page 285: Rep 5.7 Document Transport Assembly
Loosen the three screws retaining the Document Transport Assembly Remove the Document Transport Assembly by moving it in the direction indicated Figure 1 Removing the Document Transport Assembly Initial Issue Repairs and Adjustments 10/00 REP 5.7 Phaser 790/DocuColor 2006 4-31...
Page 286: Rep 5.8 Platen Belt
Remove the Platen Belt Platen Belt tension Figure 1 Removing the Platen Belt Proper belt positioning Improper belt positioning Figure 3 Proper Alignment of the Platen Belt Repairs and Adjustments Initial Issue 10/00 REP 5.8 4-32 Phaser 790/DocuColor 2006...
Page 287: Rep 5.9 Adf Exit Motor
Remove one screw Loosen one screw Remove the wire harness from the clamps Remove the ADF Exit Motor (together with the Belt) Figure 1 Removing the ADF Exit Motor Initial Issue Repairs and Adjustments 10/00 REP 5.9 Phaser 790/DocuColor 2006 4-33...
Page 288: Rep 5.10 Adf Exit Sensor And Exit Tray Interlock
Figure 2 Removing the Exit Chute Remove the Outer Exit Chute Assembly by moving the assembly in the direction indicated Figure 1 Removing the Outer Exit Chute Assembly Repairs and Adjustments Initial Issue 10/00 REP 5.10 4-34 Phaser 790/DocuColor 2006...
Page 289 Remove the screw holding the Exit Tray Interlock and ADF Exit Sensor mounting bracket Figure 3 Removing the Exit Tray Interlock or ADF Exit Sensor Figure 4 Replacing the Outer Exit Chute Assembly. Initial Issue Repairs and Adjustments 10/00 REP 5.10 Phaser 790/DocuColor 2006 4-35...
Page 290 Repairs and Adjustments Initial Issue 10/00 REP 5.10 4-36 Phaser 790/DocuColor 2006...
Page 291: Rep 6.1 Platen Glass
Figure 1 Removing the Right Cover Figure 1 Removing the Platen Glass Replacement Replacement Perform the procedure for removal in reverse. Perform the procedure for removal in reverse. Initial Issue Repairs and Adjustments 10/00 REP 6.1, REP 6.2 Phaser 790/DocuColor 2006 4-37...
Page 292: Rep 6.3 Left Cover
Figure 1 Removing the Left Cover Figure 1 Removing the Rear Cover Replacement Replacement Perform the procedure for removal in reverse. Perform the procedure for removal in reverse. Repairs and Adjustments Initial Issue 10/00 REP 6.3, REP 6.4 4-38 Phaser 790/DocuColor 2006...
Page 293: Rep 6.5 Angle Sensor
Figure 1 Removing the Angle Sensor Figure 1 Removing the Platen Switch Replacement Replacement Perform the procedure for removal in reverse. Perform the procedure for removal in reverse. Initial Issue Repairs and Adjustments 10/00 REP 6.5, REP 6.6 Phaser 790/DocuColor 2006 4-39...
Page 294: Rep 6.7 Registration Sensor
Remove the screw Figure 2 Removing the Registration Sensor Replacement Perform the procedure for removal in reverse. Figure 1 Removing the Bracket and Power Receptacles Repairs and Adjustments Initial Issue 10/00 REP 6.7 4-40 Phaser 790/DocuColor 2006...
Page 295: Rep 6.8 Iit Low Voltage Power Supply (Lvps)
Figure 1 Removing the IIT LVPS Replacement Figure 1 Removing the Fan Perform the procedure for removal in reverse. Replacement Perform the procedure for removal in reverse. Initial Issue Repairs and Adjustments 10/00 REP 6.8, REP 6.9 Phaser 790/DocuColor 2006 4-41...
Page 296: Rep 6.10 Aps Sensor
Disconnect the connector Figure 2 Removing the APS Sensor Replacement Perform the procedure for removal in reverse. Remove the screws (8) and the cover Figure 1 Removing the Cover Repairs and Adjustments Initial Issue 10/00 REP 6.10 4-42 Phaser 790/DocuColor 2006...
Page 297: Rep 6.11 Pwb Box
(3) underneath the Ribbon Cable Figure 2 Disconnecting the Connectors Remove the screws (2) and connector cover Figure 1 Removing the Connector Cover Initial Issue Repairs and Adjustments 10/00 REP 6.11 Phaser 790/DocuColor 2006 4-43...
Page 298 10. Remove the screws holding the PWB Box to the IIT Frame (Figure 4). Replacement Perform the procedure for removal in reverse. Remove the screw Remove the screw Figure 4 Accessing the PWB Box Repairs and Adjustments Initial Issue 10/00 REP 6.11 4-44 Phaser 790/DocuColor 2006...
Page 299: Rep 6.12 Pwb Box Cover
Figure 1 Removing the PWB Box Cover Replacement Perform the procedure for removal in reverse. Figure 1 Removing the IPS PWB Replacement Perform the procedure for removal in reverse. Initial Issue Repairs and Adjustments 10/00 REP 6.12, REP 6.13 Phaser 790/DocuColor 2006 4-45...
Page 300: Rep 6.14 Icm Main Pwb
Remove the screws (11) and the ICM Main PWB by moving it in the direction indicated Remove the connector screws (8) Figure 1 Removing the ICM Main PWB Repairs and Adjustments Initial Issue 10/00 REP 6.14 4-46 Phaser 790/DocuColor 2006...
Page 301: Rep 6.15 Extension Pwb
Memory PWB Cover indicated Figure 1 Removing the Advanced Features Memory Cover Figure 1 Removing the Extension PWB Replacement Perform the procedure for removal in reverse. Initial Issue Repairs and Adjustments 10/00 REP 6.15, REP 6.16 Phaser 790/DocuColor 2006 4-47...
Page 302: Rep 6.17 Front / Rear Cable Assembly
Memory PWB Figure 2 Removing the Advanced Features Memory PWB Replacement Perform the procedure for removal in reverse. Figure 1 Removing the Front / Rear Cable Assembly Repairs and Adjustments Initial Issue 10/00 REP 6.16, REP 6.17 4-48 Phaser 790/DocuColor 2006...
Page 303: Rep 6.18 Carriage Motor
Reinstall the Left Cover (REP 6.3). Replacement Reinstall the Control Panel Assembly (REP 6.23). Perform the procedure for removal in reverse. Reinstall the Platen Glass (REP 6.1). Initial Issue Repairs and Adjustments 10/00 REP 6.17, REP 6.18 Phaser 790/DocuColor 2006 4-49...
Page 304: Rep 6.19 Belt
Lamp by turning it in the direction indicated Replacement Perform the procedure for removal in reverse. Figure 1 Removing the Lamp Replacement Perform the procedure for removal in reverse. Repairs and Adjustments Initial Issue 10/00 REP 6.19, REP 6.20 4-50 Phaser 790/DocuColor 2006...
Page 305: Rep 6.21 Full-Rate Carriage Assembly
D isconnect the lamp connector. Disconnect ribbon cable connector by sliding the connector body away from PWB. Figure 1 Removing the FLPS PWB Replacement Perform the procedure for removal in reverse. Initial Issue Repairs and Adjustments 10/00 REP 6.21, REP 6.22 Phaser 790/DocuColor 2006 4-51...
Page 306: Rep 6.23 Control Panel Assembly
Control Panel Assembly by moving it in the direction indicated Disconnect the connector Figure 1 Removing the Control Panel Assembly Replacement Perform the procedure for removal in reverse. Repairs and Adjustments Initial Issue 10/00 REP 6.23 4-52 Phaser 790/DocuColor 2006...
Page 307: Rep 7.1 Size Switch Pwb
NOTE: Prior to replacement, partially pull out Tray 1 and (if present) the Duplex Tray. Perform the procedure for removal in reverse. Close Tray 1 and the Duplex Tray. Initial Issue Repairs and Adjustments 10/00 REP 7.1, REP 7.2 Phaser 790/DocuColor 2006 4-53...
Page 308: Rep 7.3 No Paper Sensor Assembly
Replacement Perform the procedure for removal in reverse. NOTE: When installing the No Paper Actuator, the Actuator must be positioned directly above the No Paper Sensor. Repairs and Adjustments Initial Issue 10/00 REP 7.3, REP 7.4 4-54 Phaser 790/DocuColor 2006...
Page 309: Rep 7.5 Low Paper Sensor
NOTE: Install the sensor so that the positioning boss on the No Paper Sensor Assembly is aligned with the positioning hole of the Low Paper Sensor. Initial Issue Repairs and Adjustments 10/00 REP 7.5, REP 7.6 Phaser 790/DocuColor 2006 4-55...
Page 310: Rep 7.7 Tray 1 Front Snubber
Parts List on PL 14.2 Removal Remove the Oversize Tray Assembly. (REP 7.6) Set the Bottom Plate to the raised position by actuating the Plate Link. (Figure 1) Repairs and Adjustments Initial Issue 10/00 REP 7.7 4-56 Phaser 790/DocuColor 2006...
Page 311 Install the Front Guide to the exact position from which it was removed. Initial Issue Repairs and Adjustments 10/00 REP 7.8 Phaser 790/DocuColor 2006 4-57...
Page 312 Repairs and Adjustments Initial Issue 10/00 REP 7.8 4-58 Phaser 790/DocuColor 2006...
Page 313: Rep 8.1 Turn Roll
Figure 2 Removing the Turn In Chute Open the Turn Chute Cover Figure 1 Accessing the Turn In Chute Initial Issue Repairs and Adjustments 10/00 REP 8.1 Phaser 790/DocuColor 2006 4-59...
Page 314: Rep 8.2 Feed Roll
Perform the procedure for removal in reverse. NOTE: Install the Feed Roll in accordance with the rotation direction indicated by the arrow on the side of the Feed Roll. Repairs and Adjustments Initial Issue 10/00 REP 8.1, REP 8.2 4-60 Phaser 790/DocuColor 2006...
Page 315: Rep 8.3 Feed Roll Assembly
Feed Shaft Guide and remove the Feed Shaft Guide See WARNING Remove the Feed Spring Remove the E-ring and remove the Feed Gear Figure 1 Removing the Feed Roll Assembly Initial Issue Repairs and Adjustments 10/00 REP 8.3 Phaser 790/DocuColor 2006 4-61...
Page 316: Rep 8.4 Turn Clutch
Disconnect the Turn Clutch. (Figure 1) Disconnect the connector Figure 2 Removing the Turn Clutch Replacement Perform the procedure for removal in reverse. Figure 1 Disconnecting the Turn Clutch Repairs and Adjustments Initial Issue 10/00 REP 8.4 4-62 Phaser 790/DocuColor 2006...
Page 317: Rep 8.5 Feed Solenoid
Perform the procedure for removal in reverse. Install the Feed Solenoid so that the teeth of the Feed Gear mesh with the armature. Figure 1 Removing the Option Bracket Initial Issue Repairs and Adjustments 10/00 REP 8.5 Phaser 790/DocuColor 2006 4-63...
Page 318: Rep 8.6 Bypass Tray/Registration Assembly
Bypass Tray Feed Assembly Replacement Perform the procedure for removal in reverse. Figure 1 Accessing the Bypass Tray Feed Assembly Replacement Perform the procedure for removal in reverse. Repairs and Adjustments Initial Issue 10/00 REP 8.6, REP 8.7 4-64 Phaser 790/DocuColor 2006...
Page 319: Rep 8.8 Tray Housing
Install from the front arm, while being careful not to pinch the harness. Figure 1 Removing the Main Paper Handling Frame Assembly Replacement Perform the procedure for removal in reverse. Initial Issue Repairs and Adjustments 10/00 REP 8.8, REP 8.9 Phaser 790/DocuColor 2006 4-65...
Page 320: Rep 8.10 Lift Plate Sensor
Perform the procedure for removal in reverse. NOTE: Install so that the boss of the Bypass Tray Frame is aligned with the hole on the left side of the Lift Frame Assembly. Repairs and Adjustments Initial Issue 10/00 REP 8.10, REP 8.11 4-66 Phaser 790/DocuColor 2006...
Page 321: Rep 8.12 Tray Empty Sensor
Figure 1 Removing the Tray Empty Sensor Figure 1 Removing the Pitch Sensor Replacement Replacement Perform the procedure for removal in reverse. Perform the procedure for removal in reverse. Initial Issue Repairs and Adjustments 10/00 REP 8.12, REP 8.13 Phaser 790/DocuColor 2006 4-67...
Page 322: Rep 8.14 Stack Height Sensor
Perform the procedure for removal in reverse. Open the wire clips and release the wires on the bottom side of the Top Frame. Remove the frame Figure 1 Removing the Top Frame Repairs and Adjustments Initial Issue 10/00 REP 8.14 4-68 Phaser 790/DocuColor 2006...
Page 323: Rep 8.15 Preregistration Clutch
Preregistration Replacement Clutch Perform the procedure for removal in reverse. Figure 1 Removing the Preregistration Clutch Replacement Perform the procedure for removal in reverse. Initial Issue Repairs and Adjustments 10/00 REP 8.15, REP 8.16 Phaser 790/DocuColor 2006 4-69...
Page 324: Rep 8.17 Registration Clutch
Figure 1 Removing the Registration Rubber Roll Replacement Perform the procedure for removal in reverse. Figure 1 Removing the Registration Clutch Replacement Perform the procedure for removal in reverse. Repairs and Adjustments Initial Issue 10/00 REP 8.17, REP 8.18 4-70 Phaser 790/DocuColor 2006...
Page 325: Rep 8.19 Size Switch Pwb
Remove the Size Switch PWB. (Figure 1) Disconnect the connector Remove two screws and the Bracket Remove the screw and the Size Switch PWB Typical Figure 1 Removing the Size Switch PWB Initial Issue Repairs and Adjustments 10/00 REP 8.19 Phaser 790/DocuColor 2006 4-71...
Page 326: Rep 8.20 Feeder Motor
Install the jumper plug from the removed PWB to the same location on the replacement PWB. (See the Note Figure 1.) Perform the removal procedure in reverse. Repairs and Adjustments Initial Issue 10/00 REP 8.20, REP 8.21 4-72 Phaser 790/DocuColor 2006...
Page 327: Rep 8.22 Feeder Drive Unit/Low Paper Sensor
Perform the removal procedure in reverse. all connectors. Release the wires from the clips Remove the four screws and remove the Feeder Drive Unit Figure 1 Removing the Feeder Drive Unit Initial Issue Repairs and Adjustments 10/00 REP 8.22 Phaser 790/DocuColor 2006 4-73...
Page 328: Rep 8.23 Paper Feeder Assembly
Figure 2 Removing the Paper Feeder Assembly Replacement Perform the removal procedure in reverse. Remove the five screws and the Feeder Right Cover Figure 1 Removing the Feeder Right Cover / Feeder Chute Repairs and Adjustments Initial Issue 10/00 REP 8.23 4-74 Phaser 790/DocuColor 2006...
Page 329: Rep 8.24 Takeaway Clutch
Figure 1 Removing the Nudger Solenoid Replacement Replacement Perform the removal procedure in reverse. Perform the removal procedure in reverse. Make sure the solenoid plunger is properly seated to the Link. Initial Issue Repairs and Adjustments 10/00 REP 8.24, REP 8.25 Phaser 790/DocuColor 2006 4-75...
Page 330: Rep 8.26 Turn Clutch
Assembly straight out from the machine Replacement Perform the removal procedure in reverse. Figure 1 Removing the Duplex Tray Assembly Replacement Perform the removal procedure in reverse. Repairs and Adjustments Initial Issue 10/00 REP 8.26, REP 8.27 4-76 Phaser 790/DocuColor 2006...
Page 331: Rep 8.28 Duplex Entrance Sensor
Duplex Registration Chute Figure 2 Removing the Duplex Entrance Sensor Replacement Perform the removal procedure in reverse. Disconnect the connector Figure 1 Removing the Duplex Registration Chute Initial Issue Repairs and Adjustments 10/00 REP 8.28 Phaser 790/DocuColor 2006 4-77...
Page 332: Rep 8.29 Duplex Exit Sensor
Chute Support in the Remove the direction indicated screw Disconnect the connector Figure 1 Removing the Duplex Registration Chute Figure 3 Removing the Chute Support Repairs and Adjustments Initial Issue 10/00 REP 8.29 4-78 Phaser 790/DocuColor 2006...
Page 333 Duplex Exit Sensor Disconnect the connectors Figure 5 Removing the Duplex Exit Sensor Replacement Perform the removal procedure in reverse. Figure 4 Removing the Exit Chute Initial Issue Repairs and Adjustments 10/00 REP 8.29 Phaser 790/DocuColor 2006 4-79...
Page 334: Rep 8.30 Duplex Drive Clutch
Perform the removal procedure in reverse. When installing the belt, make sure that the bottom of the belt is dressed below the pulley and above the collar (2 places). (Figure 1) Repairs and Adjustments Initial Issue 10/00 REP 8.30, REP 8.31 4-80 Phaser 790/DocuColor 2006...
Page 335: Rep 8.32 Rear Belt
Entrance Roll Gear (Figure 1). of the assembly Figure 1 Removing the Inverter Upper Assembly Replacement Perform the removal procedure in reverse. Initial Issue Repairs and Adjustments 10/00 REP 8.32, REP 8.33 Phaser 790/DocuColor 2006 4-81...
Page 336: Rep 8.34 Exit Roll
Figure 2 Removing the Exit Roll Replacement Perform the removal procedure in reverse. Release the cover from the retaining tab Figure 1 Removing the Exit Cover Repairs and Adjustments Initial Issue 10/00 REP 8.34 4-82 Phaser 790/DocuColor 2006...
Page 337: Rep 8.35 Inverter/Lower Assembly
Inverter Cover Loosen the thumb screws Figure 1 Removing the Inverter/Lower Assembly Figure 1 Removing the Rear Inverter Cover Replacement Perform the removal procedure in reverse. Initial Issue Repairs and Adjustments 10/00 REP 8.35, REP 8.36 Phaser 790/DocuColor 2006 4-83...
Page 338 When installing the bracket, use care not to pinch the wires between the mounting surface and the bracket, or damage could occur. Perform the removal procedure in reverse. Repairs and Adjustments Initial Issue 10/00 REP 8.36 4-84 Phaser 790/DocuColor 2006...
Page 339: Rep 8.37 Inverter Sensor
Chute E-ring, and bearing Figure 2 Removing the Inverter Sensor Replacement Perform the removal procedure in reverse. Remove the E-ring and bearing Figure 1 Removing the Inverter Roll Initial Issue Repairs and Adjustments 10/00 REP 8.37 Phaser 790/DocuColor 2006 4-85...
Page 340: Rep 8.38 Duplex Controller Pwb
Disconnect the connectors Figure 2 Removing the Duplex Controller PWB Replacement Remove the Rear Perform the removal procedure in reverse. Inverter Cover Figure 1 Removing the Rear Inverter Cover Repairs and Adjustments Initial Issue 10/00 REP 8.38 4-86 Phaser 790/DocuColor 2006...
Page 341: Rep 8.39 Duplex Nip Solenoid
When replacing the Lower Chute, make sure the guide pins at the rear of the chute are positioned to the locating holes in the frame. Remove the screw and pull the Lower Chute from the machine Figure 1 Removing the Lower Chute Initial Issue Repairs and Adjustments 10/00 REP 8.39 Phaser 790/DocuColor 2006 4-87...
Page 342: Rep 8.40 Exit Transport Assembly
(and at the bottom, below the fan) are positioned over the edge of the frame. (Figure 3) Frame Edge Plastic Ears Figure 1 Removing the Transport Cover Figure 3 Exit Transport Assembly Positioning Repairs and Adjustments Initial Issue 10/00 REP 8.40 4-88 Phaser 790/DocuColor 2006...
Page 343: Rep 8.41 Full Stack Sensor
Figure 1 Removing the Exit Chute Interlock Figure 1 Removing the Full Stack Sensor Replacement Replacement Perform the removal procedure in reverse. Perform the removal procedure in reverse. Initial Issue Repairs and Adjustments 10/00 REP 8.41, REP 8.42 Phaser 790/DocuColor 2006 4-89...
Page 344: Rep 8.43 Top Exit Sensor
Remove the Top Exit Sensor (Figure 1). Release the locking tabs and remove the Top Exit Sensor Disconnect the connector Figure 1 Removing the Top Exit Sensor Replacement Perform the removal procedure in reverse. Repairs and Adjustments Initial Issue 10/00 REP 8.43 4-90 Phaser 790/DocuColor 2006...
Page 345: Rep 9.1 Copy/Print Cartridge
Reinstall the Waste Container in the reverse order of removal. Replacement [Steps 1-4 are for the Phaser 790 Copy/Print Cartridge only] Push the Waste Container in securely until it hooks into place. Remove the Copy/Print Cartridge from the packaging following instructions on exterior.
Page 346: Rep 9.3 Ros
Prepare to remove the ROS (Figure 1). Remove the screws Release the har- ness from the clamp, then remove the cover Disconnect the con- nectors Figure 1 Preparing to Remove the ROS Repairs and Adjustments Initial Issue 10/00 REP 9.3 4-92 Phaser 790/DocuColor 2006...
Page 347 Reinstall the ROS in the reverse order of removal. Remove the ROS Disconnect the Connector Lift to access the bottom of the ROS Figure 2 Removing the ROS Initial Issue Repairs and Adjustments 10/00 REP 9.3 Phaser 790/DocuColor 2006 4-93...
Page 348: Rep 9.4 Adc Sensor
Reinstall the ADC Sensor in the reverse order of removal. Remove the Move the sensor e-ring toward the rear to disengage it from the frame Figure 1 Removing the ADC Sensor Repairs and Adjustments Initial Issue 10/00 REP 9.4 4-94 Phaser 790/DocuColor 2006...
Page 349: Rep 9.5 Locating Rail
Be careful not to touch IBT Belt, or damage the harnesses or Magnetic Roll surface of the Developer Housing while removing the Locating Rail. Remove the Locating Rail (Figure 2). Initial Issue Repairs and Adjustments 10/00 REP 9.5 Phaser 790/DocuColor 2006 4-95...
Page 350: Rep 9.6 Waste Toner Sensor
Waste Toner Sensor Disconnect the connector Disengage the harness from the clamp Figure 1 Removing the Waste Toner Sensor Figure 1 Removing the Toner Box Sensor Repairs and Adjustments Initial Issue 10/00 REP 9.6, REP 9.7 4-96 Phaser 790/DocuColor 2006...
Page 351: Rep 9.8 Erase Lamp
Pull the harness through the hole Remove the Dry Ink Figure 1 Removing the Erase Lamp Cartridge Figure 1 Removing the Dry Ink Cartridge Initial Issue Repairs and Adjustments 10/00 REP 9.8, REP 9.9 Phaser 790/DocuColor 2006 4-97...
Page 352: Rep 9.10 Developer Housing
Check the Developer Spacing (ADJ 9.1). Disengage the har- ness from the Rotary Latch Remove the Rotary Latch Disconnect the con- nectors (Brown is on top) Figure 1 Removing the Rotary Latch Repairs and Adjustments Initial Issue 10/00 REP 9.10 4-98 Phaser 790/DocuColor 2006...
Page 353: Rep 9.11 Rotary Sensor
Remove the Rotary Sensor screw Figure 2 Removing the Rotary Sensor Remove the Fan Duct and Fan together Figure 1 Removing the Fan Duct and Developer Frame Initial Issue Repairs and Adjustments 10/00 REP 9.11 Phaser 790/DocuColor 2006 4-99...
Page 354: Rep 9.12 Rotary Frame
17. Remove the LVPS (REP 1.1). 18. Remove the Fuser Drive Unit (REP 4.2). 19. Remove the Developer Clutch (REP 4.10). 20. Remove the Developer Tie Plate (REP 9.14). Repairs and Adjustments Initial Issue 10/00 REP 9.12 4-100 Phaser 790/DocuColor 2006...
Page 355 Move the frame forward, and lift to remove the Rotary Frame Remove the e-ring and the rear bear- Remove the front bearing Figure 2 Removing the Rotary Frame Initial Issue Repairs and Adjustments 10/00 REP 9.12 Phaser 790/DocuColor 2006 4-101...
Page 356: Rep 9.13 Cartridge Sensor
Disengage the wires from the hook the sensor on the Cartridge Sensor Plate Disconnect the con- nector Figure 2 Removing the Cartridge Sensor Figure 1 Accessing the Cartridge Sensor Repairs and Adjustments Initial Issue 10/00 REP 9.13 4-102 Phaser 790/DocuColor 2006...
Page 357: Rep 9.14 Developer Tie Plate
Tie Plate from the top of screws at front the machine and rear Open the Front Cover Assembly Figure 1 Removing the Tension Lever Figure 1 Removing the Developer Tie Plate Initial Issue Repairs and Adjustments 10/00 REP 9.14, REP 9.15 Phaser 790/DocuColor 2006 4-103...
Page 358: Rep 9.16 Ibt Assembly
IBT Belt with your hands. (Hold the assembly by the ribs on either side.) 11. Remove the IBT Assembly (Figure 1). Figure 1 Removing the IBT Assembly Replacement Reinstall the IBT Assembly in the reverse order of removal. Repairs and Adjustments Initial Issue 10/00 REP 9.16 4-104 Phaser 790/DocuColor 2006...
Page 359: Rep 9.17 Belt Cleaner
Belt Cleaner, and be careful not to spill dry ink. Remove the Belt Cleaner (Figure 1). Pull pin toward rear to disengage Figure 1 Removing the Belt Cleaner Initial Issue Repairs and Adjustments 10/00 REP 9.17 Phaser 790/DocuColor 2006 4-105...
Page 360: Rep 9.18 Btr 2 Assembly
Pull the pin toward the rear and hold during the next step Grab at these points Figure 1 Removing the BTR 2 Assembly Figure 2 Replacing the Belt Cleaner Repairs and Adjustments Initial Issue 10/00 REP 9.17, REP 9.18 4-106 Phaser 790/DocuColor 2006...
Page 361: Rep 9.19 Btr 2 Cam Assembly
Disconnect the sen- sor connector Remove the Remove the bracket screws Remove the BTR 2 Cam Assembly from the front Figure 1 Removing the BTR 2 Cam Assembly Initial Issue Repairs and Adjustments 10/00 REP 9.19 Phaser 790/DocuColor 2006 4-107...
Page 362: Rep 9.20 Auger
NOTE: After removing the Auger, place it on paper in case toner is spilled. 18. Remove the Auger (Figure 1). Replacement Reinstall the Auger in the reverse order of removal. Repairs and Adjustments Initial Issue 10/00 REP 9.20 4-108 Phaser 790/DocuColor 2006...
Page 363: Rep 9.21 Ibt Belt
Remove the Rail Remove the screws at front and rear Remove the collar Figure 1 Removing the Rails Reinstall the Tension Lever, and lift the Push In Lever while turning. Initial Issue Repairs and Adjustments 10/00 REP 9.21 Phaser 790/DocuColor 2006 4-109...
Page 364 Be careful not to damage or dirty the IBT Belt during the reinstallation. Clean the Push In Shaft of all foreign matter or lubrication prior to reinstalling the IBT Belt. Reinstall the IBT Belt in the reverse order of removal. Repairs and Adjustments Initial Issue 10/00 REP 9.21 4-110 Phaser 790/DocuColor 2006...
Page 365: Rep 9.22 Tr0 Sensor
Remove the E-ring Remove the BTR 2 Cam Clutch Disconnect the sensor connector Figure 1 Removing the BTR 2 Cam Clutch Figure 1 Removing the TR0 Sensor Initial Issue Repairs and Adjustments 10/00 REP 9.22, REP 9.23 Phaser 790/DocuColor 2006 4-111...
Page 366 Repairs and Adjustments Initial Issue 10/00 REP 9.22, REP 9.23 4-112 Phaser 790/DocuColor 2006...
Page 367: Rep 10.1 Fuser Assembly
Open the Fuser TRAY OPTION: Assembly Open the Duplex Tray Remove the screw Figure 1 Removing the Fuser Assembly Figure 1 Removing the Main Fuser Assembly Initial Issue Repairs and Adjustments 10/00 REP 10.1, REP 10.2 Phaser 790/DocuColor 2006 4-113...
Page 368: Rep 10.3 Upper Guide Assembly
Reinstall the Upper Guide Assembly in the reverse order of removal. Remove the Screws Remove the Upper Guide Assembly Open the Fuser Assembly Figure 1 Removing the Upper Guide Assembly Repairs and Adjustments Initial Issue 10/00 REP 10.3 4-114 Phaser 790/DocuColor 2006...
Page 369: Rep 10.4 Upper Plate
Temperature Remove the Upper Plate Sensor from sticker at front the plate and rear Remove the screws (4) Remove the Upper Plate Figure 1 Removing the Upper Plate Initial Issue Repairs and Adjustments 10/00 REP 10.4 Phaser 790/DocuColor 2006 4-115...
Page 370: Rep 10.5 Heat Roll Heat Lamp
Remove the Fuser Front Cover Remove the Heat Roll Heat Lamp from the rear Remove the Fuser Rear Cover Figure 1 Removing the Heat Roll Heat Lamp Repairs and Adjustments Initial Issue 10/00 REP 10.5 4-116 Phaser 790/DocuColor 2006...
Page 371: Rep 10.6 Pressure Roll Heat Lamp
Roll Heat Lamp Figure 1 Removing the Lower Guide Assembly from the rear Remove the Fuser Rear Cover Figure 1 Removing the Pressure Roll Heat Lamp Initial Issue Repairs and Adjustments 10/00 REP 10.6, REP 10.7 Phaser 790/DocuColor 2006 4-117...
Page 372: Rep 10.8 Front Fuser Exit Sensor
Unhook the sensor from the Bottom Plate and remove the Front Fuser Exit Sensor Figure 1 Removing the Front Fuser Exit Sensor Figure 1 Removing the Rear Fuser Exit Sensor Repairs and Adjustments Initial Issue 10/00 REP 10.8, REP 10.9 4-118 Phaser 790/DocuColor 2006...
Page 373: Rep 10.10 Heat Roll
Remove the Ring front and at rear, securing the Gear until the bottom of at the rear screw is aligned with bottom of nut Figure 1 Removing the Heat Roll Initial Issue Repairs and Adjustments 10/00 REP 10.10 Phaser 790/DocuColor 2006 4-119...
Page 374: Rep 10.11 Pressure Roll
Figure 1 Preparing to Remove the Pressure Roll CAUTION Be sure not to damage the surface of the Pressure Roll while removing the roll. 10. Remove the Pressure Roll (Figure 2). Repairs and Adjustments Initial Issue 10/00 REP 10.11 4-120 Phaser 790/DocuColor 2006...
Page 375: Rep 10.12 Temperature Sensor
Remove the Tempera- ture Sensor Disconnect the Remove the connectors Fuser Front Frame Remove the Fuser Rear Frame Remove the screw Remove the screw Figure 1 Removing the Temperature Sensor Initial Issue Repairs and Adjustments 10/00 REP 10.12 Phaser 790/DocuColor 2006 4-121...
Page 376: Rep 10.13 Exchange Chute
Reinstall the Exchange Chute in the reverse order of removal. Remove the Fuser Front Rail Remove the screws Figure 1 Removing the Exchange Chute Repairs and Adjustments Initial Issue 10/00 REP 10.13 4-122 Phaser 790/DocuColor 2006...
Page 377: Rep 10.14 Exchange Solenoid
Remove the Fuser Rear Rail Figure 1 Removing the Cleaner Cam Solenoid together with Disconnect the the Gear Cover connector Figure 1 Removing the Exchange Solenoid Initial Issue Repairs and Adjustments 10/00 REP 10.14, REP 10.15 Phaser 790/DocuColor 2006 4-123...
Page 378: Rep 10.16 Cleaner Cam Shaft
Cleaner Cam Shaft Figure 2 Positioning the Cleaner Cam Solenoid Remove the screws. Then, remove the Fuser Front Rail Figure 1 Removing the Cleaner Cam Shaft Repairs and Adjustments Initial Issue 10/00 REP 10.15, REP 10.16 4-124 Phaser 790/DocuColor 2006...
Page 379: Rep 10.17 Exit Roll
Exit Roll Remove the Exit Gear and Exit Bearing from the Exit Roll Remove the Exit Roll Figure 1 Removing the Exit Roll Initial Issue Repairs and Adjustments 10/00 REP 10.17 Phaser 790/DocuColor 2006 4-125...
Page 380: Rep 10.18 Fuser Entrance Sensor
Fuser Entrance Sensor Figure 2 Removing the Fuser Entrance Sensor Remove the screws, and then remove the Bottom Cover Figure 1 Preparing to Remove the Fuser Entrance Sensor Repairs and Adjustments Initial Issue 10/00 REP 10.18 4-126 Phaser 790/DocuColor 2006...
Page 381: Rep 10.19 Fuser Chute Fan
Fuser Chute Fan Figure 2 Removing the Fuser Chute Fan Remove the screws, and then remove the Bottom Cover Figure 1 Preparing to Remove the Fuser Chute Fan Initial Issue Repairs and Adjustments 10/00 REP 10.19 Phaser 790/DocuColor 2006 4-127...
Page 382 Repairs and Adjustments Initial Issue 10/00 REP 10.19 4-128 Phaser 790/DocuColor 2006...
Page 383: Rep 11.1 Sorter
Figure 1 Removing the Bottom Cover Figure 1 Removing the Sorter Replacement Replacement Perform the procedure for removal in reverse. Perform the procedure for removal in reverse. Initial Issue Repairs and Adjustments 10/00 REP 11.1, REP 11.2 Phaser 790/DocuColor 2006 4-129...
Page 384: Rep 11.3 Sorter Control Pwb
See NOTE - Disconnect the connectors (9) Figure 1 Removing the Sorter Control PWB Replacement Perform the procedure for removal in reverse. Repairs and Adjustments Initial Issue 10/00 REP 11.3 4-130 Phaser 790/DocuColor 2006...
Page 385: Rep 11.4 Sorter Transport Motor
Disconnect the Sorter Transport Motor connector, release the wires from the harness and feed the wires back through the Sorter to the motor Figure 1 Disconnecting the Motor Figure 3 Motor Support Positioning Initial Issue Repairs and Adjustments 10/00 REP 11.4 Phaser 790/DocuColor 2006 4-131...
Page 386: Rep 11.5 Sensor Receiver
Perform the procedure for removal in reverse. Remove the screws (2) and sensor Figure 2 Removing the Sensor Transmitter Replacement Perform the procedure for removal in reverse. Repairs and Adjustments Initial Issue 10/00 REP 11.5, REP 11.6 4-132 Phaser 790/DocuColor 2006...
Page 387: Rep 11.7 Sorter Path Sensor
Perform the procedure for removal in reverse. Viewed from below Disconnect the connector Figure 1 Removing the Sorter Path Sensor Replacement Perform the procedure for removal in reverse. Initial Issue Repairs and Adjustments 10/00 REP 11.7, REP 11.8 Phaser 790/DocuColor 2006 4-133...
Page 388: Rep 11.9 Bin Drive Motor
Disconnect the Bin Drive Motor, release the wires from the harness, to notch and feed the wires back through the Sorter to the Bin Drive Motor Figure 1 Disconnecting the Motor Figure 3 Motor Support Positioning Repairs and Adjustments Initial Issue 10/00 REP 11.9 4-134 Phaser 790/DocuColor 2006...
Page 389: Rep 11.10 Front / Rear Gear Shaft
Perform the procedure for removal in reverse. Perform the procedure for removal in reverse. Perform a Sorter Bin Cam Position Adjustment (ADJ 11.1) Perform a Sorter Bin Cam Position Adjustment (ADJ 11.1) Initial Issue Repairs and Adjustments 10/00 REP 11.10, REP 11.11 Phaser 790/DocuColor 2006 4-135...
Page 390: Rep 11.12 Bin Cam Switch
Figure 1 Removing the Bin Home Switch Figure 1 Removing the Bin Cam Switch Replacement Replacement Perform the procedure for removal in reverse. Perform the procedure for removal in reverse. Repairs and Adjustments Initial Issue 10/00 REP 11.12, REP 11.13 4-136 Phaser 790/DocuColor 2006...
Page 391: Rep 11.14 Bin Tray(S)
Figure 1 Removing the Bin Trays Replacement Perform the procedure for removal in reverse. Perform a Sorter Bin Cam Position Adjustment (ADJ 11.1) on the Front Bin Cam. Initial Issue Repairs and Adjustments 10/00 REP 11.14, REP 11.15 Phaser 790/DocuColor 2006 4-137...
Page 392 Repairs and Adjustments Initial Issue 10/00 REP 11.14, REP 11.15 4-138 Phaser 790/DocuColor 2006...
Page 393: Rep 14.1 Front Cover Assembly
Open the knurled screw Tray 1 Assembly Figure 1 Removing the Front Mid Cover Open the Front Cover Assembly Figure 1 Removing the Front Cover Assembly Initial Issue Repairs and Adjustments 10/00 REP 14.1, REP 14.2 Phaser 790/DocuColor 2006 4-139...
Page 394: Rep 14.3 Front Lower Cover
Remove the Front Lower Cover (Figure 1). Insert the hooks into the frame Remove the Front Lower Cover Figure 2 Inserting the Hooks Remove the two screws Figure 1 Removing the Front Lower Cover Repairs and Adjustments Initial Issue 10/00 REP 14.3 4-140 Phaser 790/DocuColor 2006...
Page 395: Rep 14.4 Top Cover Assembly
Top Cover Switch is actuated correctly. port Assem- Open the Front Disengage the Cover Control Panel Assembly from the Top Cover Assembly Figure 1 Removing the Top Cover Assembly Initial Issue Repairs and Adjustments 10/00 REP 14.4 Phaser 790/DocuColor 2006 4-141...
Page 396: Rep 14.5 Inner Covers
Remove the IBT Remove the Left Inner Inner Cover Cover Assembly Figure 2 Removing the Left Inner Cover Assembly Remove the screws Figure 1 Removing the IBT Inner Cover Repairs and Adjustments Initial Issue 10/00 REP 14.5 4-142 Phaser 790/DocuColor 2006...
Page 397: Rep 14.6 Rear Cover
Figure 3 Removing the Right Inner Cover Replacement Reinstall the Inner Covers in the reverse order of removal. Remove the Rear Cover Remove the six screws Figure 1 Removing the Rear Cover Initial Issue Repairs and Adjustments 10/00 REP 14.5, REP 14.6 Phaser 790/DocuColor 2006 4-143...
Page 398: Rep 14.7 Filter
Filter Remove the two screws Remove the Left Lower Cover Figure 1 Removing the Filter Figure 1 Removing the Left Lower Cover Repairs and Adjustments Initial Issue 10/00 REP 14.7, REP 14.8 4-144 Phaser 790/DocuColor 2006...
Page 399: Rep 14.9 Right Cover
Control Panel Compress the hooks to disengage the Control Panel Remove the three screws Figure 1 Removing the Right Cover Figure 1 Removing the Control Panel Initial Issue Repairs and Adjustments 10/00 REP 14.9, REP 14.10 Phaser 790/DocuColor 2006 4-145...
Page 400: Rep 14.11 Right Lower Cover
Replacement Reinstall the Right Lower Cover in the reverse order of removal. Remove the Right Lower Cover Remove the three screws Figure 1 Removing the Right Lower Cover Repairs and Adjustments Initial Issue 10/00 REP 14.11 4-146 Phaser 790/DocuColor 2006...
Page 401: Adj 3.1 Hard Disk Drive Assembly
12. Remove the jumper from J 8 on the ESS PWB. 13. If necessary, reinstall the 1394 PWB (PL 12.1). 14. Reinstall the Right Cover (REP 14.9). Initial Issue Repairs and Adjustments 10/00 ADJ 3.1, ADJ 3.2 Phaser 790/DocuColor 2006 4-147...
Page 402: Adj 5.1 Adf Side Registration
Press the Select button to verify the value has changed. Figure 1 ADF Side Registration Check Table 1 Minimum Initial Maximum Remarks Settings Range 0.04mm/Step Perform the check again. Repairs and Adjustments Initial Issue 10/00 ADJ 5.1 4-148 Phaser 790/DocuColor 2006...
Page 403: Adj 5.2 Adf Lead Edge Registration
LE2 scale is 10.0mm ± 2.5 (Figure 1) Table 1 Minimum Initial Maximum Remarks 10.0mm ± 2.5 Settings Value 0.16mm/Step Lead Edge Perform the check again. Paper Feed Direction Figure 1 Test Pattern Orientation Initial Issue Repairs and Adjustments 10/00 ADJ 5.2 Phaser 790/DocuColor 2006 4-149...
Page 404: Adj 5.3 Adf Height
The gap between the Shim and Mylar is between 0 and 0.2 mm Figure 1 Verifying the Side Guide Gap If the gap is incorrect, perform an adjustment. Repairs and Adjustments Initial Issue 10/00 ADJ 5.3 4-150 Phaser 790/DocuColor 2006...
Page 405: Adj 5.4 Adf Front-To-Rear Positioning
Figure 1 Removing the Lower Chute causing document jams. Open the ADF and tighten the screws loosened in Figure 2. Repeat the checks and make sure the gap is correct. Initial Issue Repairs and Adjustments 10/00 ADJ 5.3, ADJ 5.4 Phaser 790/DocuColor 2006 4-151...
Page 406 19mm Figure 2 Removing the Entrance Tray Figure 3 Taking Measurements Remove the Transport Assembly. (REP 5.7) If the measurement is not within specifications perform the adjustment. Repairs and Adjustments Initial Issue 10/00 ADJ 5.4 4-152 Phaser 790/DocuColor 2006...
Page 407: Adj 6.1 Iit Magnification
Perform the check again. Place paper of each size in the ADF, make a test copy and check it for skew. Perform the ADF Side Registration Adjustment. (ADJ 5.1) Initial Issue Repairs and Adjustments 10/00 ADJ 5.4, ADJ 6.1 Phaser 790/DocuColor 2006 4-153...
Page 408: Adj 6.2 Iit Half-Rate And Full-Rate Carriage Adjustment
10. Loosen the set screws (4) on the front and rear Capstan Pulleys. (Figure 3) Loosen the screw (1) Stopper Remove the screws (2) and Stopper Figure 1 Positioning Tool Storage Location Figure 3 Capstan Pulley Set Screws Repairs and Adjustments Initial Issue 10/00 ADJ 6.2 4-154 Phaser 790/DocuColor 2006...
Page 409 Figure 6 Adjusting the Front Side of the Full-Rate Carriage Assembly Figure 4 Installing the Positioning Tools 12. Tighten the one set screw on the front Capstan Pulley. (Figure 5) Figure 5 Tightening the Capstan Set Screw Initial Issue Repairs and Adjustments 10/00 ADJ 6.2 Phaser 790/DocuColor 2006 4-155...
Page 410 19. Reinstall the Left Cover (REP 6.3). 20. Reinstall the Right Cover. (REP 6.2). 21. Reinstall the Platen Glass (REP 6.1). 22. Reinstall the ADF (REP 5.1) or Platen Cover. Repairs and Adjustments Initial Issue 10/00 ADJ 6.2 4-156 Phaser 790/DocuColor 2006...
Page 411: Adj 6.3 Iit Lead Edge Registration
Remarks Settings Range 0.04mm/Step 10.0mm ± 2.0 Lead Edge Perform the check again. Paper Feed Direction Figure 1 Test Pattern Indications Adjustment Enter Diagnostic Mode (IIT) (GP 19). Initial Issue Repairs and Adjustments 10/00 ADJ 6.3 Phaser 790/DocuColor 2006 4-157...
Page 412: Adj 6.4 Iit Side Registration
Figure 1 ADF Side Registration Check Adjustment Enter Diagnostic Mode (IIT) (GP 19). Enter Systemdata R/W and press the Select button. Enter Chain 715 and Link 3 and confirm the present values. Repairs and Adjustments Initial Issue 10/00 ADJ 6.4 4-158 Phaser 790/DocuColor 2006...
Page 413: Adj 6.5 Icm Main Pwb Adjustment
Enter Diag- Code and press the Select button. Select DC No and enter 945. Press the Down Arrow to select subcode and enter 20. 10. Press Select, then press Start. 11. Exit Diagnostics. Initial Issue Repairs and Adjustments 10/00 ADJ 6.5, ADJ 6.6 Phaser 790/DocuColor 2006 4-159...
Page 414: Adj 6.7 B* Correction
Enter Diag-Code and press the Select button. Select DC No and enter 945. Press the Down Arrow to select subcode and enter 10. 10. Press Select, then press Start. 11. Exit Diagnostics. Repairs and Adjustments Initial Issue 10/00 ADJ 6.7 4-160 Phaser 790/DocuColor 2006...
Page 415: Adj 8.1 Printer Registration
Figure 1 Measuring the Side-to-Side and Top-to-Bottom Registration Table 1 Nominal Registration Values for Comparison of Measurements Media Size Side-to-Side Top-to-Bottom 8.5 x 11 inch 133 mm 41 mm 132 mm 46.5 mm Initial Issue Repairs and Adjustments 10/00 ADJ 8.1 Phaser 790/DocuColor 2006 4-161...
Page 416: Adj 9.1 Developer Spacing
White Seal. a huge change in image position, with the image shifted to being nearest the lead edge. Check the Developer Spacing (Figure 1). Repairs and Adjustments Initial Issue 10/00 ADJ 8.1, ADJ 9.1 4-162 Phaser 790/DocuColor 2006...
Page 417 If the distance measured is not within specification, perform the adjustment. Figure 2 Adjusting the Developer Spacing Perform the check again, starting with step 5. Repeat until the measurement is within specification. Initial Issue Repairs and Adjustments 10/00 ADJ 9.1 Phaser 790/DocuColor 2006 4-163...
Page 418: Adj 10.1 Fuser Nip
7.0 mm and the difference between the two measurements is less than or equal to 0.3 mm Figure 2 Adjusting the Fuser Nip Figure 1 Checking the Fuser Nip Repairs and Adjustments Initial Issue 10/00 ADJ 10.1 4-164 Phaser 790/DocuColor 2006...
Page 419: Adj 11.1 Sorter Bin Cam Position
Move the bevel gear upward and engage it with the upper Gear. Install the KL-Clip as shown in Figure 2. Switch actuated Reattach the Spring. Reinstall the Sorter Rear/Front Cover. Holes aligned Figure 1 Bin Cam Positioning Initial Issue Repairs and Adjustments 10/00 ADJ 11.1 Phaser 790/DocuColor 2006 4-165...
Page 420 Repairs and Adjustments Initial Issue 10/00 ADJ 11.1 4-166 Phaser 790/DocuColor 2006...
Page 421 PL 16.5 Full Rate Carriage and Half Rate Carriage ............5-66 PL 8.4 Fusing (4 of 7)...................... 5-33 PL 16.6 Top Cover and Control Panel ................5-67 PL 8.5 Fusing (5 of 7)...................... 5-34 PL 16.7 Control Panel Assembly..................5-68 Initial Issue Parts List 10/00 Phaser 790/DocuColor 2006...
Page 422 PL 19.4 Bin Drive Motor, Lead Cam/Switch ..............5-81 PL 19.5 Tray Support, Bin Tray..................5-82 PL 19.6 Sorter Support ....................5-83 Common Hardware Common Hardware ......................5-84 Part Number Index ......................5-85 Parts List Initial Issue 10/00 Phaser 790/DocuColor 2006...
Page 423: Overview
If a part or assembly has an associated repair or adjustment procedure, the procedure number will be listed at the end of the part description in the parts lists e.g. (REP 5.1, ADJ 5.3) Initial Issue Parts List 10/00 Introduction Phaser 790/DocuColor 2006...
Page 424: Subsystem Information
Change Tag Index tells you which kit or piece parts you need. Whenever you install a Tag kit or all the piece parts that make up a Tag, mark the appropriate number on the Tag matrix. Parts List Initial Issue 10/00 Subsystem Information Phaser 790/DocuColor 2006...
Page 425: Symbology
(Figure 2). by the tag number within the circle (Figure 1). Information on the modification is in the Change Tag Index. Figure 2 Without Tag Symbol Figure 1 With Tag Symbol Initial Issue Parts List 10/00 Symbology Phaser 790/DocuColor 2006...
Page 426 Index. (Figure 4). Figure 3 Entire Drawing With Tag Symbol Figure 4 Entire Drawing Without Tag Symbol Parts List Initial Issue 10/00 Symbology Phaser 790/DocuColor 2006...
Page 427: Pl 1.1 Front And Left Covers
Rotary Latch Spring (P/O PL 1.1 Item 7) 802K12480 IBT Inner Cover (REP 14.5) 802K17151 Right Inner Cover (REP 14.5) 802E05350 Left Lower Cover (REP 14.8) 600K85500 LP Name Plate 600K85510 CP Name Plate Initial Issue Parts List 10/00 PL 1.1 Phaser 790/DocuColor 2006...
Page 428: Pl 1.2 Rear, Right And Top Covers
Top Cover (P/O PL 1.2 Item 7) – Stopper Cover (P/O PL 1.2 Item 7) 802K16990 Control Panel (IOT) (REP 14.10) – Right Hand Cover (Not Spared) 802E05331 Left Option Hinge Cover Parts List Initial Issue 10/00 PL 1.2 Phaser 790/DocuColor 2006...
Page 429: Pl 1.3 Base Frame (1 Of 2)
Bushing (Not Spared) – Bushing (Not Spared) – Frame Clamp-L (Not Spared) – Frame Clamp-M (Not Spared) – Frame Clamp-U (Not Spared) – Clamp (Not Spared) – Rear Plate (Not Spared) Initial Issue Parts List 10/00 PL 1.3 Phaser 790/DocuColor 2006...
Page 430: Pl 1.4 Base Frame (2 Of 2)
Fuser Rear Guide (Not Spared) – Fuser Front Guide (Not Spared) – Fuser Rear Spring (Not Spared) – Fuser Front Spring (Not Spared) – Edge Saddle-U (Not Spared) – Lower Chute (Not Spared) Parts List Initial Issue 10/00 PL 1.4 5-10 Phaser 790/DocuColor 2006...
Page 431: Pl 2.1 Paper Tray
Tray Housing (P/O PL 2.1 Item 1) – Sector Gear (P/O PL 2.1 Item 1) – Sector Gear Spring (P/O PL 2.1 Item 1) – Tray Bottom Cover (P/O PL 2.1 Item 1) Initial Issue Parts List 10/00 PL 2.1 Phaser 790/DocuColor 2006 5-11...
Page 432: Pl 3.1 Tray 1 Paper Feeder (1 Of 3)
Feed Idler Gear (Not Spared) 121E84500 Feed Solenoid (REP 8.5) – Feed Bearing (Not Spared) – Turn Gear D (Not Spared) – Turn Gear L (Not Spared) 110E97970 Low Paper Sensor (REP 7.5) Parts List Initial Issue 10/00 PL 3.1 5-12 Phaser 790/DocuColor 2006...
Page 433: Pl 3.2 Tray 1 Paper Feeder (2 Of 3)
Pinch Spring Housing (Not Spared) – Magnet Catch (Not Spared) 802E05560 Turn Chute Cover – Outer Turn Chute (Not Spared) – Inner Turn Chute (Not Spared) 830E19490 Turn Cover Stopper Initial Issue Parts List 10/00 PL 3.2 Phaser 790/DocuColor 2006 5-13...
Page 434: Pl 3.3 Tray 1 Paper Feeder (3 Of 3)
Bearing (Not Spared) – Feed Gear (Not Spared) 009E71750 Feed Spring 110E93440 Turn Chute Interlock 121K23790 Turn Clutch (REP 8.4) – Turn Gear Shaft (Not Spared) – Bearing (Not Spared) Parts List Initial Issue 10/00 PL 3.3 5-14 Phaser 790/DocuColor 2006...
Page 435: Pl 4.1 Bypass Tray/ Paper Transport (1 Of 7)
PL 4.1 Item 6) – Bypass Tray Guide Switch (P/O PL 4.1 Item 5, PL 4.1 Item 6) – Harness (P/O PL 4.1 Item 5, PL 4.1 Item 6) Initial Issue Parts List 10/00 PL 4.1 Phaser 790/DocuColor 2006 5-15...
Page 436: Pl 4.2 Bypass Tray/ Paper Transport (2 Of 7)
Gear 12/44 (P/O PL 4.2 Item 15) – Gear 10/20 (P/O PL 4.2 Item 15) – Lift Motor (P/O PL 4.2 Item 15) – Motor Frame (P/O PL 4.2 Item 15) – Clamp (Not Spared) Parts List Initial Issue 10/00 PL 4.2 5-16 Phaser 790/DocuColor 2006...
Page 437: Pl 4.3 Bypass Tray/ Paper Transport (3 Of 7)
Preregistration Spring 2 (Not Spared) – Preregistration Spring 1 (Not Spared) – Lock Pin (Not Spared) – Tray Spring (Not Spared) – Top Frame (Not Spared) – Clamp (Not Spared) Initial Issue Parts List 10/00 PL 4.3 Phaser 790/DocuColor 2006 5-17...
Page 438: Pl 4.4 Bypass Tray/ Paper Transport (4 Of 7)
Friction Clutch (P/O PL 4.4 Item 1) – Top Frame (P/O PL 4.4 Item 1) – Bearing (P/O PL 4.4 Item 1) – Retard Roll (P/O PL 4.4 Item 1) Parts List Initial Issue 10/00 PL 4.4 5-18 Phaser 790/DocuColor 2006...
Page 439: Pl 4.5 Bypass Tray/ Paper Transport (5 Of 7)
Top Frame (P/O PL 4.4 Item 1) – Preregistration Idler Gear (P/O PL 4.4 Item 1) – Bearing (P/O PL 4.4 Item 1) – Bearing (P/O PL 4.4 Item 1) Initial Issue Parts List 10/00 PL 4.5 Phaser 790/DocuColor 2006 5-19...
Page 440: Pl 4.6 Bypass Tray/ Paper Transport (6 Of 7)
(P/O PL 4.6 Item 1) – Sensor Bracket (P/O PL 4.6 Item 1, PL 4.6 Item 8) 130E82650 Registration Sensor, OHP Sensor – Gear (P/O PL 4.6 Item 1, PL 4.6 Item 8) Parts List Initial Issue 10/00 PL 4.6 5-20 Phaser 790/DocuColor 2006...
Page 441: Pl 4.7 Bypass Tray/ Paper Transport (7 Of 7)
Lower Registration Chute – Gear 16 (P/O PL 4.6 Item 1) – Gear 24 (P/O PL 4.6 Item 1) – Gear 26 (P/O PL 4.6 Item 1) 600K68610 Registration Spring Kit Initial Issue Parts List 10/00 PL 4.7 Phaser 790/DocuColor 2006 5-21...
Page 442: Pl 5.1 Xerographics
Waste Toner Sensor (REP 9.6) – Locating Rail (Not Spared) (REP 9.5) – Locating Rail Assembly (Not Spared) 122K93100 Erase Lamp (REP 9.8) 130K60440 ADC Sensor (REP 9.4) 600K68620 BCR Connecter Kit Parts List Initial Issue 10/00 PL 5.1 5-22 Phaser 790/DocuColor 2006...
Page 443: Pl 6.1 Development (1 Of 2)
Rotary Sensor (REP 9.11) – Cartridge Sensor Assembly (Not Spared) – Developer Discharge Holder (Not Spared) 600K85301 Developer Contact Plate – Cartridge Sensor Plate (Not Spared) 130E82830 Cartridge Sensor (REP 9.13) Initial Issue Parts List 10/00 PL 6.1 Phaser 790/DocuColor 2006 5-23...
Page 444: Pl 6.2 Development (2 Of 2)
6) (REP 9.9) – Dry Ink Cartridge K (REF: Section 6) (REP 9.9) 600K87140 Developer Housing K (REP 9.10 ADJ 9.1) Phaser 790 – 600K87300 Developer Housing K (REP 9.10 ADJ 9.1) DocuColor 2006 600K12112 Developer Housing C (REP 9.10 ADJ 9.1) Phaser 790...
Page 445: Pl 7.1 Ibt (1 Of 5)
– BTR 1 Contact Wire (P/O PL 7.1 Item 11) – BTR 2 Contact Wire (P/O PL 7.1 Item 11) 015K43090 IBT Front Bracket 802K12990 IBT Assembly (REP 9.16) Initial Issue Parts List 10/00 PL 7.1 Phaser 790/DocuColor 2006 5-25...
Page 446: Pl 7.2 Ibt (2 Of 5)
– Spacer (P/O PL 7.2 Item 1) – Shaft (P/O PL 7.2 Item 1) – Rail (P/O PL 7.2 Item 1) – Retard Spring (P/O PL 7.2 Item 1) Parts List Initial Issue 10/00 PL 7.2 5-26 Phaser 790/DocuColor 2006...
Page 447: Pl 7.3 Ibt (3 Of 5)
Rail (P/O PL 7.2 Item 1) – Collar (P/O PL 7.2 Item 1) – Clamp (P/O PL 7.2 Item 1) – Harness (P/O PL 7.2 Item 1) – Retard Spring (Not Spared) Initial Issue Parts List 10/00 PL 7.3 Phaser 790/DocuColor 2006 5-27...
Page 448: Pl 7.4 Ibt (4 Of 5)
Torque Gear Assembly (P/O PL 7.4 Item 1) – Gear Shaft (P/O PL 7.4 Item 1) – Torque Gear (P/O PL 7.4 Item 1) – Gear (P/O PL 7.4 Item 1) Parts List Initial Issue 10/00 PL 7.4 5-28 Phaser 790/DocuColor 2006...
Page 449: Pl 7.5 Ibt (5 Of 5)
Item 1) – Gear (P/O PL 7.5 Item 1) – Gear (P/O PL 7.5 Item 1) – Gear (P/O PL 7.5 Item 1) – Insulator (P/O PL 7.5 Item 1) Initial Issue Parts List 10/00 PL 7.5 Phaser 790/DocuColor 2006 5-29...
Page 450: Pl 8.1 Fusing (1 Of 7)
Main Fuser 220v 050K43340 Fuser Tray 220v – 050K43330 Fuser Tray 110v – Jam Removal Label (Not Spared) – Caution Label (Not Spared) 695E84762 Shipping Spacer/ Pad (Not Shown) Parts List Initial Issue 10/00 PL 8.1 5-30 Phaser 790/DocuColor 2006...
Page 451: Pl 8.2 Fusing (2 Of 7)
Pinch Rolls – Seal (P/O PL 8.2 Item 1) 600K85430 Upper Plate (REP 10.4) – Heater Wire (P/O PL 8.2 Item 1) – Adjusting Screw (P/O PL 8.2 Item Initial Issue Parts List 10/00 PL 8.2 Phaser 790/DocuColor 2006 5-31...
Page 452: Pl 8.3 Fusing (3 Of 7)
Shaft (P/O PL 8.2 Item 1) – Front Cam (P/O PL 8.2 Item 1) – Rear Cam (P/O PL 8.2 Item 1) 600K85480 Heat Roll Hardware Kit (REP 10.10 ADJ 10.1) Parts List Initial Issue 10/00 PL 8.3 5-32 Phaser 790/DocuColor 2006...
Page 453: Pl 8.4 Fusing (4 Of 7)
Exit Roll Pin (P/O PL 8.4 Item 1) 059K14430 Exit Roll (REP 10.17) 007E60300 Exit Gear – Exit Bearing (P/O PL 8.4 Item 1) 054E10561 Exchange Chute (REP 10.13) Initial Issue Parts List 10/00 PL 8.4 Phaser 790/DocuColor 2006 5-33...
Page 454: Pl 8.5 Fusing (5 Of 7)
Idler Gear (P/O PL8.5 Item 5) – Clamp (P/O PL 8.5 Item 5) – Ground Contact Spring (P/O PL 8.4 Item 1) – Gear Cover (P/O PL 8.4 Item 1) 162K53250 Fuser Harness Parts List Initial Issue 10/00 PL 8.5 5-34 Phaser 790/DocuColor 2006...
Page 455: Pl 8.6 Fusing (6 Of 7)
127E81620 Fuser Chute Fan (REP 10.19) – Fuser Paper Guide (Not Spared) – Horizontal Chute (Not Spared) 029E30560 Cleaner Cam Follower 019E33881 Holder – Ground Contact Spring (Not Spared) Initial Issue Parts List 10/00 PL 8.6 Phaser 790/DocuColor 2006 5-35...
Page 456: Pl 8.7 Fusing (7 Of 7)
Rear Bearing (P/O PL 8.7 Item 3) 121E87040 Cleaner Cam Solenoid (REP 10.15) – Cleaner Cam Shaft (Not Spared) (REP 10.16) – Pin (Not Spared) – Cleaner Cam (Not Spared) – Front Bearing (Not Spared) Parts List Initial Issue 10/00 PL 8.7 5-36 Phaser 790/DocuColor 2006...
Page 457: Pl 9.1 Paper Exit (1 Of 2)
PL 9.1 Paper Exit (1 of 2) Item Part Description – Exit Transport Assembly (Not Spared) (REP 8.40) 054K17770 Exit Transport Cover 050K27592 Lower Exit Tray Initial Issue Parts List 10/00 PL 9.1 Phaser 790/DocuColor 2006 5-37...
Page 458: Pl 9.2 Paper Exit (2 Of 2)
Top Exit Sensor (REP 8.43) 110E93440 Exit Chute Interlock (REP 8.42) – Harness (Not Spared) 127E81940 Fuser Fan 127E81951 Exit Chute Fan 130K61311 Full Stack Sensor (REP 8.41) 600K68750 Exit Upper Roller Kit Parts List Initial Issue 10/00 PL 9.2 5-38 Phaser 790/DocuColor 2006...
Page 459: Pl 10.1 Drives
Process Drive Unit (REP 4.6) 121K21141 Developer Clutch (REP 4.10) 121K23260 Dispense Clutch (REP 4.9) 160K61490 Rotary Motor PWB (REP 4.8) 127K28300 Rotary Motor 110V (REP 4.7) – 127K31700 Rotary Motor 220V Initial Issue Parts List 10/00 PL 10.1 Phaser 790/DocuColor 2006 5-39...
Page 460: Pl 11.1 Electrical (1 Of 2)
Clamp (Not Spared) – Bias Charge Roll (BCR) Wire (Not Spared) – Developer Wire (Not Spared) 162K53100 Main Harness 162K53130 Fuser Connector Harness 117K31400 Power Cord 110v 162K55490 Sorter Harness Parts List Initial Issue 10/00 PL 11.1 5-40 Phaser 790/DocuColor 2006...
Page 461: Pl 11.2 Electrical (2 Of 2)
Communication PWB (REP 1.12) 110K98810 Right Front Cover Interlock (REP 1.6) 110E94380 Left Front Cover Interlock (REP 1.7) 130K60530 Environment Sensor (REP 1.8) 162K53120 Paper Handling Contactor Harness 162K61050 ROS Harness Initial Issue Parts List 10/00 PL 11.2 Phaser 790/DocuColor 2006 5-41...
Page 462: Pl 12.1 Ess
Hard Disk Drive (P/O PL 12.1 Item – Bracket (Not Spared) – Plate (P/O PL 12.1 Item 12) – Cover (P/O PL 12.1 Item 12) 015K48720 Plate Assembly 160K69652 1394 PWBA Parts List Initial Issue 10/00 PL 12.1 5-42 Phaser 790/DocuColor 2006...
Page 463: Pl 13.1 Optional Feeder Assembly (1 Of 9)
PL 13.1 Optional Feeder Assembly (1 of 9) Item Part Description – Optional Feeder Assembly (Not Spared) – Optional Feeder Chassis Assembly (Not Spared) 050K42600 Paper Tray Assembly (REP 7.6) Initial Issue Parts List 10/00 PL 13.1 Phaser 790/DocuColor 2006 5-43...
Page 464: Pl 13.2 Optional Feeder Assembly (2 Of 9)
Feeder Right Cover Interlock 1, Feeder Right Cover Interlock 2 162K54131 Cover Interlock Harness – Clamp (Not Spared) – Feeder Chute (Not Spared) 830E19490 Feeder Chute Support 017K92350 Caster Parts List Initial Issue 10/00 PL 13.2 5-44 Phaser 790/DocuColor 2006...
Page 465: Pl 13.3 Optional Feeder Assembly (3 Of 9)
110K07040 Size Switch PWB (REP 8.19) – Feeder Frame (Not Spared) – Bracket (Not Spared) – Clamp (Not Spared) – Clamp (Not Spared) – Ground Contact Spring (Not Spared) Initial Issue Parts List 10/00 PL 13.3 Phaser 790/DocuColor 2006 5-45...
Page 466: Pl 13.4 Optional Feeder Assembly (4 Of 9)
Bracket (Not Spared) 162K54090 Feeder Harness 162K54120 Size Harness 130E81970 Low Paper Sensor (REP 8.22) 162K54140 Upper Feeder Harness 162K54150 Lower Feeder Harness – Lift Clutch (P/O PL 13.4) Parts List Initial Issue 10/00 PL 13.4 5-46 Phaser 790/DocuColor 2006...
Page 467: Pl 13.5 Optional Feeder Assembly (5 Of 9)
Clamp (P/O PL 13.5 Item 1) – Clamp (P/O PL 13.5 Item 1) – Harness (P/O PL 13.5 Item 1) 130E81600 No Paper Sensor – Front Frame (P/O PL 13.5 Item 1) Initial Issue Parts List 10/00 PL 13.5 Phaser 790/DocuColor 2006 5-47...
Page 468: Pl 13.6 Optional Feeder Assembly (6 Of 9)
(REP 8.26) – Clamp (P/O PL 13.5 Item 1) – Gear (P/O PL 13.5 Item 1) – Gear (P/O PL 13.5 Item 1) – Bearing (P/O PL 13.5 Item 1) Parts List Initial Issue 10/00 PL 13.6 5-48 Phaser 790/DocuColor 2006...
Page 469: Pl 13.7 Optional Feeder Assembly (7 Of 9)
– Gear (P/O PL 13.5 Item 1) – Bearing (P/O PL 13.5 Item 1) – Nylon Washer (P/O PL 13.5 Item 1) – E-Ring (P/O PL 13.5 Item 1) Initial Issue Parts List 10/00 PL 13.7 Phaser 790/DocuColor 2006 5-49...
Page 470: Pl 13.8 Optional Feeder Assembly (8 Of 9)
Rear Plate (P/O PL 13.8 Item 1) – Tray Front Cover (P/O PL 13.8 Item – Pad (P/O PL 13.8 Item 1) – Gear Drive Pin (P/O PL 13.8 Item Parts List Initial Issue 10/00 PL 13.8 5-50 Phaser 790/DocuColor 2006...
Page 471: Pl 13.9 Optional Feeder Assembly (9 Of 9)
Side Guide Plate (P/O PL 13.8 Item – Side Guide (P/O PL 13.8 Item 1) – Bottom Pad (P/O PL 13.8 Item 1) – Guide Plate (P/O PL 13.8 Item 1) Initial Issue Parts List 10/00 PL 13.9 Phaser 790/DocuColor 2006 5-51...
Page 472: Pl 14.1 Ohp Transparency Tray Assembly (1 Of 2)
PL 14.1 OHP Transparency Tray Assembly (1 of 2) Item Part Description 050K42460 OHP Transparency Tray Assembly Parts List Initial Issue 10/00 PL 14.1 5-52 Phaser 790/DocuColor 2006...
Page 473: Pl 14.2 Ohp Transparency Tray Assembly (2 Of 2)
End Guide – Guide Stopper (P/O PL 14.2 Item 1) – Transparency Tray Size Actuator (P/O PL 14.2 Item 1) – Tray Bottom Cover (P/O PL 14.2 Item 1) Initial Issue Parts List 10/00 PL 14.2 Phaser 790/DocuColor 2006 5-53...
Page 474: Pl 14.3 Oversize Tray
Lock Plate (P/O PL 14.3 Item 1) 038K85490 End Guide – Guide Stopper (P/O PL 14.3 Item 1) 120E12930 Oversize Tray Actuator – Tray Bottom Cover (P/O PL 14.3 Item 1) Parts List Initial Issue 10/00 PL 14.3 5-54 Phaser 790/DocuColor 2006...
Page 475: Pl 15.1 Duplex Assembly (1 Of 7)
Lower Chute Assembly (Not Spared) – Lower Chute (Not Spared) 121K21570 Duplex Nip Solenoid (REP 8.39) – Spring (Not Spared) – Clamp (Not Spared) 021E97232 Cover 026E74100 Mounting Screws Initial Issue Parts List 10/00 PL 15.1 Phaser 790/DocuColor 2006 5-55...
Page 476: Pl 15.2 Duplex Assembly (2 Of 7)
Shaft (P/O PL 15.2 Item 1) – Spring Latch (P/O PL 15.2 Item 1) 022K57450 Exit Roll (REP 8.34) – Antistatic Brush (P/O PL 15.2 Item 1, PL 15.2 Item 12) Parts List Initial Issue 10/00 PL 15.2 5-56 Phaser 790/DocuColor 2006...
Page 477: Pl 15.3 Duplex Assembly (3 Of 7)
Pulley (P/O PL 15.3 Item 1) – Stopper (P/O PL 15.3 Item 1) 019E34500 Sheet Clamp – Alignment Chute (Not Spared) – Antistatic Brush (Not Spared) – Bracket (Not Spared) Initial Issue Parts List 10/00 PL 15.3 Phaser 790/DocuColor 2006 5-57...
Page 478: Pl 15.4 Duplex Assembly (4 Of 7)
Plate Guide (P/O PL 15.3 Item 1) – Pulley (P/O PL 15.3 Item 1) – Bearing (P/O PL 15.3 Item 1) – Bearing (P/O PL 15.3 Item 1) – Cable Clamp (Not Spared) Parts List Initial Issue 10/00 PL 15.4 5-58 Phaser 790/DocuColor 2006...
Page 479: Pl 15.5 Duplex Assembly (5 Of 7)
Harness (P/O PL 15.5 Item 1) – Spring (P/O PL 15.5 Item 1) 830E56720 Cover Support – Clamp (P/O PL 15.5 Item 1) – Cable Clamp (P/O PL 15.5 Item 1) Initial Issue Parts List 10/00 PL 15.5 Phaser 790/DocuColor 2006 5-59...
Page 480: Pl 15.6 Duplex Assembly (6 Of 7)
Harness (P/O PL 15.5 Item 1) 802E12181 Inverter Front Cover 121K23790 Inverter Entrance Clutch – Gear (P/O PL 15.5 Item 1) 022K57520 Inverter Roll – Clamp (P/O PL 15.5 Item 1) Parts List Initial Issue 10/00 PL 15.6 5-60 Phaser 790/DocuColor 2006...
Page 481: Pl 15.7 Duplex Assembly (7 Of 7)
Gear (P/O PL 15.5 Item 1) – Bearing (P/O PL 15.5 Item 1) – Clamp (P/O PL 15.5 Item 1) – Pinch Roll Shaft Pin (P/O PL 15.5 Item 1) Initial Issue Parts List 10/00 PL 15.7 Phaser 790/DocuColor 2006 5-61...
Page 482: Pl 16.1 Platen Glass And Iit
127E82280 Fan (REP 6.9) – Bracket (Not Spared) 130K58120 APS Sensor (REP 6.10) – Cover (Not Spared) – Guard (Not Spared) – Bracket (Not Spared) – Damper (Not Spared) Parts List Initial Issue 10/00 PL 16.1 5-62 Phaser 790/DocuColor 2006...
Page 483: Pl 16.2 Pwb Box
Lower Box (Not Spared) 160K67840 IPS PWB (REP 6.13) 160K69575 ICM Main PWB (REP 6.14 ADJ 6.5) 160K62210 Extension PWB (REP 6.15) – IIT ICM PWB Lithium Battery (Not Spared) Initial Issue Parts List 10/00 PL 16.2 Phaser 790/DocuColor 2006 5-63...
Page 484: Pl 16.3 Ccd
PL 16.3 CCD Item Part Description 160K67350 FPC Cable – Cover (Not Spared) – Screw (Not Spared) Parts List Initial Issue 10/00 PL 16.3 5-64 Phaser 790/DocuColor 2006...
Page 485: Pl 16.4 Carriage Motor And Carriage Cable
413W10350 Bearing 023E19320 Belt 127K29610 Carriage Motor (REP 6.18) 009E62830 Spring 017E92060 Foot – Front Bracket (Not Spared) – Rear Bracket (Not Spared) 600K85730 IIT Cable Kit (ADJ 6.2) Initial Issue Parts List 10/00 PL 16.4 Phaser 790/DocuColor 2006 5-65...
Page 486: Pl 16.5 Full Rate Carriage And Half Rate Carriage
Insulator (P/O PL 16.5 Item 1) 105E10010 FLPS PWB (REP 6.22) – Guide (P/O PL 16.5 Item 1) – Clamp (Not Spared) – Carriage (Not Spared) – Clamp (Not Spared) Parts List Initial Issue 10/00 PL 16.5 5-66 Phaser 790/DocuColor 2006...
Page 487: Pl 16.6 Top Cover And Control Panel
– 802K16912 Control Panel Assembly 220v (REP 6.23) 162K56731 AC Switch/Harness 117K31200 Power Cord 220v – Power Cord 110v (Not Spared) 162K60280 Cable 1.0m – I/F PWB (Not Spared) Initial Issue Parts List 10/00 PL 16.6 Phaser 790/DocuColor 2006 5-67...
Page 488: Pl 16.7 Control Panel Assembly
Cover (Not Spared) – Panel Cover (Not Spared) – Panel PWB (Not Spared) – Frame (Not Spared) – Control Panel PWB (Not Spared) – Speaker (Not Spared) – Stopper (Not Spared) Parts List Initial Issue 10/00 PL 16.7 5-68 Phaser 790/DocuColor 2006...
Page 489: Pl 17.1 Document Exit Tray, Covers
Magnet (P/O PL 17.1 Item 1) – Label Fax (Not Spared) – Label Caution (Not Spared) – ADF Assembly (REP 5.1 ADJ 5.1 ADJ 5.2 ADJ 5.3 ADJ 5.4 ) Initial Issue Parts List 10/00 PL 17.1 Phaser 790/DocuColor 2006 5-69...
Page 490: Pl 17.2 Counterbalance, Drive Motor, Pwb
ADF Drive Motor (REP 5.2) 162K60410 Drive Harness – Clamp (Not Spared) 160K11571 ADF Control PWB – Support (Not Spared) – Support (Not Spared) 108E93270 Fuse (4A 125v) – Safety Cover (Not Spared) Parts List Initial Issue 10/00 PL 17.2 5-70 Phaser 790/DocuColor 2006...
Page 491: Pl 17.3 Registration,Feed,Nudger Roll, Nudger Home Sensor
Nudger Home Sensor – Bracket (P/O PL 17.3 Item 26) 059E90580 Tension Bearing 130K82790 Nudger Home Sensor Assembly 600K99500 Registration Roll Kit (ADJ 5.1 ADJ 5.2) 600K99510 Feed Roll Kit Initial Issue Parts List 10/00 PL 17.3 Phaser 790/DocuColor 2006 5-71...
Page 492: Pl 17.4 Feeder Upper Chute Assembly, Interlock Switch
Spring – Nudger Chute (P/O PL 17.4 Item 1) – Guard (P/O PL 17.4 Item 1) – Guard (P/O PL 17.4 Item 1) 121E90450 Magnet 110K94790 Feeder Cover Interlock Parts List Initial Issue 10/00 PL 17.4 5-72 Phaser 790/DocuColor 2006...
Page 493: Pl 17.5 Feeder Lower Chute, Registration Sensor
Bracket (P/O PL 17.5 Item 11) – Clamp (Not Spared) 026E82620 Screw 130K82780 Document Set Sensor (ADJ 5.4) – Bracket (Not Spared) 130K61380 Registration Sensor Assembly (ADJ 5.4) – Harness (Not Spared) Initial Issue Parts List 10/00 PL 17.5 Phaser 790/DocuColor 2006 5-73...
Page 494: Pl 17.6 Document Transport, Platen Belt
Rear Roll (Not Spared) – Roll No 1 (Not Spared) – Roll No 2 (Not Spared) – Front Roll (Not Spared) 013E80970 Bearing – ADF Main Framie (Not Spared) Parts List Initial Issue 10/00 PL 17.6 5-74 Phaser 790/DocuColor 2006...
Page 495: Pl 17.7 Exit Roll, Exit Motor, Exit Sensor
Pulley (Not Spared) – Exit Chute (Not Spared) 054K87731 Exit Chute Cover Assembly – Exit Chute Cover (P/O PL 17.7 Item 022K30330 Pinch Roll 022K30360 Pinch Roll – Harness (Not Spared) Initial Issue Parts List 10/00 PL 17.7 Phaser 790/DocuColor 2006 5-75...
Page 496: Pl 17.8 Platen Glass, Adf Harness
PL 17.8 Platen Glass, ADF Harness Item Part Description 090K92740 Platen Glass Parts List Initial Issue 10/00 PL 17.8 5-76 Phaser 790/DocuColor 2006...
Page 497: Pl 18.1 Stand
PL 18.1 Stand Item Part Description 802K17230 Stand Assembly – Adjuster (Not Spared) – Nut (Not Spared) – Caster (Not Spared) – Screw (Not Spared) – Foot (Not Spared) Initial Issue Parts List 10/00 PL 18.1 Phaser 790/DocuColor 2006 5-77...
Page 498: Pl 19.1 Sorter Cover, Control Pwb
Harness Assembly (Not Spared) – Plate (Not Spared) – Harness (Not Spared) – Front Frame (Not Spared) – Rear Frame (Not Spared) – Sorter Assembly (Not Spared) (REP 11.1) Parts List Initial Issue 10/00 PL 19.1 5-78 Phaser 790/DocuColor 2006...
Page 499: Pl 19.2 Feed Motor, Lvps (1 Of 2)
Pinch Roll (Not Spared) – Label (Not Spared) – Label (Not Spared) 127E82330 Sorter Transport Motor (REP 11.4) 049E48940 Support 007E39240 Gear 013E85600 Bearing 022K61790 Exit Roll 130E84410 Sensor Receiver (REP 11.5) Initial Issue Parts List 10/00 PL 19.2 Phaser 790/DocuColor 2006 5-79...
Page 500: Pl 19.3 Feed Motor, Lvps (2 Of 2)
130K86470 Sorter Path Sensor (REP 11.7) 130K61390 Sensor Transmitter (REP 11.6) 130E84420 Full Sensor (REP 11.8) – Lower Guide (Not Spared) – Bracket (Not Spared) – Bracket (Not Spared) Parts List Initial Issue 10/00 PL 19.3 5-80 Phaser 790/DocuColor 2006...
Page 501: Pl 19.4 Bin Drive Motor, Lead Cam/Switch
Front Bin Cam (REP 11.11 ADJ 11.1) 013E85600 Bearing 110K10730 Bin Cam Switch (REP 11.12) 110K10750 Bin Home Switch (REP 11.13) – Harness (Not Spared) – Bracket (Not Spared) Initial Issue Parts List 10/00 PL 19.4 Phaser 790/DocuColor 2006 5-81...
Page 502: Pl 19.5 Tray Support, Bin Tray
– Aligner (Not Spared) 050E16780 Bin Tray 1-7 (REP 11.14 ADJ 11.1) 050K42580 Bin Tray 8, 9 (REP 11.14 ADJ 11.1) 050K42700 Bin Tray 10 (REP 11.14 ADJ 11.1) Parts List Initial Issue 10/00 PL 19.5 5-82 Phaser 790/DocuColor 2006...
Page 503: Pl 19.6 Sorter Support
Mounting Bracket (Not Spared) 001E58350 Sorter Rail – Rail Plate (Not Spared) – Harness (Not Spared) 017E94420 Caster 110K10750 Docking Interlock (REP 11.15) – Label (Not Spared) 802E14341 Cover Initial Issue Parts List 10/00 PL 19.6 Phaser 790/DocuColor 2006 5-83...
Page 504: Common Hardware
Tapping Screw 158W36855 Screw 153W17855 Tapping Screw 158W36663 Screw 153W18055 Tapping Screw 102W35851 Screw 153W27650 Tapping Screw – Screw 153W27655 Tapping Screw 153W27850 Tapping Screw 153W28050 Tapping Screw 158W27651 Screw Parts List Initial Issue 10/00 Common Hardware 5-84 Phaser 790/DocuColor 2006...
Page 505: Part Number Index
007E88100 PL 17.3 PL 15.4 007K91871 PL 17.3 019E93510 PL 17.3 008K91270 PL 19.4 019K94190 PL 2.1 008K91280 PL 19.4 019K97140 PL 14.2 008K91550 PL 7.1 PL 14.3 Initial Issue Parts List 10/00 Part Number Index Phaser 790/DocuColor 2006 5-85...
Page 506 PL 17.5 054E15200 PL 4.7 PL 17.7 054E15670 PL 4.7 029E30560 PL 8.6 054K17770 PL 9.1 036K90890 PL 17.2 054K17830 PL 19.2 036K90900 PL 17.2 054K18400 PL 15.6 Parts List Initial Issue 10/00 Part Number Index 5-86 Phaser 790/DocuColor 2006...
Page 507 105E10010 PL 16.5 121K23260 PL 10.1 105K15680 PL 11.1 121K23430 PL 4.6 105K15690 PL 11.1 PL 4.7 105K18600 PL 11.1 121K23790 PL 13.6 105K18750 PL 16.1 PL 15.6 Initial Issue Parts List 10/00 Part Number Index Phaser 790/DocuColor 2006 5-87...
Page 508 PL 17.5 160K69574 PL 16.2 130K61390 PL 19.3 160K69652 PL 12.1 130E81150 PL 17.5 160K69840 PL 16.1 130E81600 PL 13.5 160K70540 PL 15.6 130E81970 PL 13.4 160K74520 PL 13.4 Parts List Initial Issue 10/00 Part Number Index 5-88 Phaser 790/DocuColor 2006...
Page 509 PL 8.2 802K16901 PL 16.6 600K85480 PL 8.3 802K16911 PL 16.6 600K85500 PL 1.1 802K16990 PL 1.2 600K85510 PL 1.1 802K17122 PL 1.2 600K85730 PL 16.4 802K17141 PL 1.1 Initial Issue Parts List 10/00 Part Number Index Phaser 790/DocuColor 2006 5-89...
Page 510 PL 15.5 892E19610 PL 17.1 892E19620 PL 17.1 892E19630 PL 17.1 Late Part Additions 110K10750 PL 19.6 160K78300 PL 12.1 162K63040 PL 19.1 600K86970 PL 7.2 695E84762 PL 8.1 Parts List Initial Issue 10/00 Part Number Index 5-90 Phaser 790/DocuColor 2006...
Page 511 6-31 Cleaning Materials ......................6-32 Machine Consumables....................6-32 Change Tag Index Change Tag Introduction....................6-33 Processor (P) Tags ......................6-34 Scanner Tags ........................6-34 Sorter Tags ........................6-35 ADF Tags ........................6-35 General Procedures and Information 03/01 Phaser 790/DocuColor 2006...
Page 512 General Procedures and Information 03/01 Phaser 790/DocuColor 2006...
Page 513: Gp 1 Diagnostic Mode (Iot)
Figure 1 The Control Panel Use the Up and Down arrow buttons to enter data onto the display. Use the Right and Left arrow buttons to move the cursor right or left. General Procedures and Information 03/01 GP 1 Phaser 790/DocuColor 2006...
Page 514: Gp 2 Component Control (Iot)
Front Fuser Exit Sensor Sheet at Front Fuser Exit Sensor (L) +5 10.4 Bypass Tray Interlock Bypass Tray Inserted (L) +5 VDC Sensor OHP MSI Not used Optional Sorter Not used General Procedures and Information 03/01 GP 2 Phaser 790/DocuColor 2006...
Page 515 Bin Cam Switch Bin Cam Switch Closed (L) +5 VDC 11.4 Docking Interlock Docking Interlock Closed (L) +5 VDC 11.1 Receiver Sensor Paper In Bin Sensed (H) +5 VDC 11.3 General Procedures and Information 03/01 GP 2 Phaser 790/DocuColor 2006...
Page 516 WARNINGS and CAUTIONS Check signal state with DMM (refer to BSD Handling Motor 9.3 for connection) Motor On (L) +5 VDC (full speed unless stacked with code DO-57 or DO-62) General Procedures and Information 03/01 GP 2 Phaser 790/DocuColor 2006...
Page 517 Check signal state with DMM (refer to BSD Nudger Solenoid Tray3 Nudger Solenoid On (L) +24 VDC 9.5for connection) Feeder Motor NOTE: see WARNINGS and CAUTIONS Feeder Motor On (L) +24 VDC General Procedures and Information 03/01 GP 2 Phaser 790/DocuColor 2006...
Page 518: Gp 3 Setting Iot Parameters And Life Counters
Unused Side-to-Side Registration 0.10 mm Table 2 Table 2 18 - 21 Unused Top-to-Bottom (Tray 1) 0.17 mm Top-to-Bottom (Tray 2) 0.17 mm Top-to-Bottom (Tray 3) 0.17 mm General Procedures and Information 03/01 GP 2, GP 3 Phaser 790/DocuColor 2006...
Page 519 To change or reset the value of a counter, press the Item Enter button when LIFE COUNT RESET is displayed. The display will change to allow you to enter a menu num- ber from the Table 3. Then perform the following steps: General Procedures and Information 03/01 GP 3 Phaser 790/DocuColor 2006...
Page 520 2, if the color reset following replacement. is required. IBT Belt Each TR0 signal increments Counter must be manually the counter by 2, if the color reset following replacement. is required. General Procedures and Information 03/01 GP 3 6-10 Phaser 790/DocuColor 2006...
Page 521: Gp 4 Reading Or Writing To Iot Nvm
Wait until the message, PLEASE POWER OFF is displayed before switching off the power. Exit the Diagnostic Mode. 10. Verify that the meters have been reset by checking the Billing Meters 11). General Procedures and Information 03/01 GP 4, GP 5 Phaser 790/DocuColor 2006 6-11...
Page 522: Gp 6 Initializing Data (Iot)
The machine will update any changes that were made in diagnostics. When the update is complete, the following message will appear: PLEASE POWER OFF 10. Switch off then switch on the machine power. The new password will be enabled. General Procedures and Information 03/01 GP 6, GP 7 6-12 Phaser 790/DocuColor 2006...
Page 523: Gp 8 Iot Software Installation
(filename in this case will be the actual name of the MCU software file you intend to download) Do not press the Enter key At the Printer press the Item Enter button. The Printer will enter the Waiting state to receive data from the PC. General Procedures and Information 03/01 GP 8 Phaser 790/DocuColor 2006 6-13...
Page 524: Gp 9 Ess Software Installation (Iot)
Press the Menu button until INSTALL UPGRADES is displayed. Press the Item Enter button. Press the DOWN ARROW button to select FILE SYSTEM. Do not press the Item Enter button. General Procedures and Information 03/01 GP 9 6-14 Phaser 790/DocuColor 2006...
Page 525 Press the Enter key once or twice, for the login prompt to appear. Type in the user name, tsubaki in lower case letters. Press the Enter key, for the command prompt, TBK> to appear. Begin downloading: General Procedures and Information 03/01 GP 10 Phaser 790/DocuColor 2006 6-15...
Page 526: Gp 11 Checking The Billing Meters
B/W COPY IMAGES XX TOTAL COPY/PRINT IMAGES XX 2 COLOR COPY IMAGES XX COLOR PRINT IMAGES XX COLOR COPY IMAGES XX TOTAL PRINT IMAGES XX TOTAL COPY IMAGES XX General Procedures and Information 03/01 GP 11, GP 14 6-16 Phaser 790/DocuColor 2006...
Page 527: Gp 15 Printing Internal Test Patterns (Iot)
Prints a solid pattern of densities from 0% to 100% for cyan, magenta, yellow, and black dry ink respectively Prints a rectangular pattern filled entirely in 100% black dry ink to use in adjusting the Fuser Nip (ADJ 10.1) General Procedures and Information 03/01 GP 15 Phaser 790/DocuColor 2006 6-17...
Page 528: Gp 16 Visual Calibration
If you have entered any number other than 0, BEST PATCH (COL) is displayed. Press the Up and Down arrow buttons to select the letter or name of the column that corresponds to your circled selection. General Procedures and Information 03/01 GP 16 6-18 Phaser 790/DocuColor 2006...
Page 529: Gp 17 Foreign Interface
Hold the plug as shown in Figure With the plug held as shown, Pin 1 is located here Figure 1 Identifying Pin 1 on a Double Plug General Procedures and Information 03/01 GP 17, GP 18 Phaser 790/DocuColor 2006 6-19...
Page 530: Gp 19 Diagnostic Mode (Iit)
Exit Button Start Button Paper Supply Features Selection Button Buttons Reduce/Enlarge Number Buttons Quality Scroll Buttons Select Button Adjustment Reduce/Enlarge Button Selection Buttons Figure 1 The Scanner Control Panel General Procedures and Information 03/01 GP 19 6-20 Phaser 790/DocuColor 2006...
Page 531: Gp 20 Setting Iit Parameters
Table 2 ADF Registration Parameters Chain Link Item Default Max Remarks ADF Lead Edge Regis- Variation: tration (ADJ 5.2) 0.1557 mm / Step ADF Side Registration Variation: (ADJ 5.1) 0.0423 mm / Step General Procedures and Information 03/01 GP 20 Phaser 790/DocuColor 2006 6-21...
Page 532: Gp 21 Component Control (Iit)
3 - B/W (Text/Photo) 4 - Color Patch 4 - B/W (Text) 5 - Lab Gradation 5 - B/W (Photo) 6 - Gradation in Main Scan Direction General Procedures and Information 03/01 GP 21, GP 22 6-22 Phaser 790/DocuColor 2006...
Page 533: Gp 23 Fuser Baffle Cleaning Procedure
Insert a single sheet of transparency media through the open nip to protect the exit switch actuators and static elimination brushes. Remove a Xerox Fuser Cleaning Solvent Pad from its foil pouch.Carefully insert the folded pad between the transparency and the Fuser Baffle.
Page 534 General Procedures and Information 03/01 GP 23 6-24 Phaser 790/DocuColor 2006...
Page 535: General Product Specifications
DC 2006 Copier/Printer 220 VAC Feeder 22 in. (560 mm) 23.7 IN. (602 mm) 11.5 IN. (292 mm) 46.6 lb. (21. 2 Kg.) Phaser 790 110 VAC Cabinet 22 in. (560 mm 27 in. (686 mm) 18.9 in. (479 mm) 39.6 lb.
Page 536 Medium Speed Mode: Prints at medium speed to ensure the correct fusing on heavy weight papers (greater than 28 lb. or 105 gsm) and black and white transparencies. This mode is also used to enhance the glossy touch of plain paper. General Procedures and Information 03/01 IOT Specifications 6-26 Phaser 790/DocuColor 2006...
Page 537: Adf Specifications
5.5 × 8.5 (140 × 216) 8.5 × 5.5 LEF 8.5 × 5.5 (216 × 140) A4 (210 × 297) A4 SEF A4 (297 × 210) A4 LEF General Procedures and Information 03/01 IOT Specifications, ADF Specifications Phaser 790/DocuColor 2006 6-27...
Page 538 A4 → A3, B5 → B4 5.5 x 8.5 → 8.5 x 14 8.5 x 13 → A2 A5 → A3 5.5 x 8.5 → 11 x 17 A6 → A3 General Procedures and Information 03/01 ADF Specifications, IIT (Scanner) Specifications 6-28 Phaser 790/DocuColor 2006...
Page 539 8.5 x 14 SEF 215.9 x 355.6 B4 SEF 257 x 364 8th Opening SEF 267 x 388 A3 SEF 297 x 420 11 x 17 SEF 297.4 x 431.8 General Procedures and Information 03/01 IIT (Scanner) Specifications Phaser 790/DocuColor 2006 6-29...
Page 540: Sorter Specifications
6.9 x 9.8 inch (176 x 250 mm) LEF 64 - 98 gsm A5 LEF 5.8 x 8.2 inch (148 x 210 mm) LEF 64 - 98 gsm 8.2 x 5.8 inch (210 x 148 mm) SEF General Procedures and Information 03/01 Sorter Specifications 6-30 Phaser 790/DocuColor 2006...
Page 541: Common Tools
Common Tools Product Tools and Test Patterns The following table lists the common tools required for servicing the DC 2006 and Phaser 790. The following table lists the product specific tools and test patterns required for use in servicing the DC 2006 and Phaser 790.
Page 542: Cleaning Materials
Yellow Dry Ink Cartridge 006R90310 Copy/Print Cartridge 013R90140 Waste Container 008R12571 The following table lists the consumables required for the Phaser 790. Table 2 Consumables List for the Phaser 790 Description Part Number Black Dry Ink Cartridge 006R01009 Cyan Dry Ink Cartridge...
Page 543: Change Tag Introduction
The classification codes and their descriptions are listed in the table below. Table 1 Classification Code Description Mandatory Tag Tag not installed in the field Optional Tag Repair Tag General Procedures and Information 03/01 Change Tag Introduction Phaser 790/DocuColor 2006 6-33...
Page 544: Processor (P) Tags
Scanner Tags NOTE: At the time of publication, no Change Tags had been issued to this subsystem. NOTE: At the time of publication, no Change Tags had been issued to this subsystem. General Procedures and Information 03/01 6-34 Phaser 790/DocuColor 2006...
Page 545 ADF Tags NOTE: At the time of publication, no Change Tags had been issued to this subsystem. NOTE: At the time of publication, no Change Tags had been issued to this subsystem. General Procedures and Information 03/01 Phaser 790/DocuColor 2006 6-35...
Page 546 General Procedures and Information 03/01 6-36 Phaser 790/DocuColor 2006...
Page 547 BSD 11.4 ......................... 7-107 BSD 5.3 ........................... 7-60 BSD 5.4 ........................... 7-61 BSD 5.5 ........................... 7-62 BSD 6.1 ........................... 7-63 BSD 6.2 and 6.3......................7-64 BSD 6.4 ........................... 7-65 BSD 6.5 ........................... 7-66 Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006...
Page 548 Wiring Data Initial Issue 10/00 Phaser 790/DocuColor 2006...
Page 549 Fuser Harness Intermediate Connector Figure 8 ESS PWB Figure 3 Fuser Chute Fan Figure 8 MCU PWB Figure 2 ADC Sensor Assembly Figure 1 ESS PWB Figure 3 Developer Fan Figure 6 Initial Issue Wiring Data 10/00 Plug/Jack Locations Phaser 790/DocuColor 2006...
Page 550 (IIT) Intermediate Connector Figure 6 Sorter Receiver Sensor Figure 18 Sorter Intermediate Connector Figure 18 Bypass Tray Intermediate Connector Figure 4 Intermediate Connector for Duplex Option Figure 7, Figure 9 Wiring Data Initial Issue 10/00 Plug/Jack Locations Phaser 790/DocuColor 2006...
Page 551 Developer Contact Plate Assembly Figure 1 Size Switch Assembly (Tray 3) Figure 11 F250 Connects Pressure Roll Heater and Heat Roll Figure 8 Heater Feeder Right Cover Interlock 1 Figure 10 Initial Issue Wiring Data 10/00 Plug/Jack Locations Phaser 790/DocuColor 2006...
Page 552 Figure 6 IIT LVPS Figure 15 Sorter Path Sensor Figure 18 Heat Roll Heater Figure 8 Pressure Roll Heater Figure 8 IBT Rear Bracket Figure 5 IBT Rear Bracket Figure 5 Wiring Data Initial Issue 10/00 Plug/Jack Locations Phaser 790/DocuColor 2006...
Page 553 WHITE F187-2 Figure 1 Initial Issue Wiring Data 10/00 Plug/Jack Locations Phaser 790/DocuColor 2006...
Page 554 BLACK Figure 2 Wiring Data Initial Issue 10/00 Plug/Jack Locations Phaser 790/DocuColor 2006...
Page 555 Figure 3 Initial Issue Wiring Data 10/00 Plug/Jack Locations Phaser 790/DocuColor 2006...
Page 556 Figure 4 Wiring Data Initial Issue 10/00 Plug/Jack Locations 7-10 Phaser 790/DocuColor 2006...
Page 557 F187-1 Figure 5 Initial Issue Wiring Data 10/00 Plug/Jack Locations Phaser 790/DocuColor 2006 7-11...
Page 558 Figure 6 Wiring Data Initial Issue 10/00 Plug/Jack Locations 7-12 Phaser 790/DocuColor 2006...
Page 559 Figure 7 Initial Issue Wiring Data 10/00 Plug/Jack Locations Phaser 790/DocuColor 2006 7-13...
Page 560 F250 BLUE Figure 8 Wiring Data Initial Issue 10/00 Plug/Jack Locations 7-14 Phaser 790/DocuColor 2006...
Page 561 Figure 9 Initial Issue Wiring Data 10/00 Plug/Jack Locations Phaser 790/DocuColor 2006 7-15...
Page 562 BLUE WHITE WHITE 4 WIRES BLUE WHITE Figure 10 Wiring Data Initial Issue 10/00 Plug/Jack Locations 7-16 Phaser 790/DocuColor 2006...
Page 563 Figure 11 Initial Issue Wiring Data 10/00 Plug/Jack Locations Phaser 790/DocuColor 2006 7-17...
Page 564 TRAY 2 TRAY 3 TRAY 2 TRAY 3 TRAY 2 TRAY 3 Figure 12 Wiring Data Initial Issue 10/00 Plug/Jack Locations 7-18 Phaser 790/DocuColor 2006...
Page 565 Figure 13 Initial Issue Wiring Data 10/00 Plug/Jack Locations Phaser 790/DocuColor 2006 7-19...
Page 566 J220 Figure 14 Wiring Data Initial Issue 10/00 Plug/Jack Locations 7-20 Phaser 790/DocuColor 2006...
Page 567 Figure 15 Initial Issue Wiring Data 10/00 Plug/Jack Locations Phaser 790/DocuColor 2006 7-21...
Page 568 150A/B Figure 16 Wiring Data Initial Issue 10/00 Plug/Jack Locations 7-22 Phaser 790/DocuColor 2006...
Page 569 P220 Figure 17 Initial Issue Wiring Data 10/00 Plug/Jack Locations Phaser 790/DocuColor 2006 7-23...
Page 570 Figure 18 Wiring Data Initial Issue 10/00 Plug/Jack Locations 7-24 Phaser 790/DocuColor 2006...
Page 571 DC Com- mon. Components are labeled with the BSD number in which they appear. Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-25...
Page 572: Vdc Wirenet (1 Of)
+5 VDC Wirenet (1 of 3) Figure 1 +5 VDC (1 of 3) Wiring Data Initial Issue 10/00 7-26 Phaser 790/DocuColor 2006...
Page 573: Vdc Wirenet (2 Of)
+5 VDC Wirenet (2 of 3) Figure 1 +5 VDC (2 of 3) Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-27...
Page 574: Vdc Wirenet (3 Of)
+5 VDC Wirenet (3 of 3) Figure 1 +5 VDC (3 of 3) Wiring Data Initial Issue 10/00 7-28 Phaser 790/DocuColor 2006...
Page 575: Vdc Interlocked Wirenet (1 Of)
+24 VDC Interlocked Wirenet (1 of 3) Figure 1 +24 VDC Interlocked (1 of 3) Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-29...
Page 576: Vdc Interlocked Wirenet (2 Of)
+24 VDC Interlocked Wirenet (2 of 3) Figure 1 +24 VDC Interlocked (2 of 3) Wiring Data Initial Issue 10/00 7-30 Phaser 790/DocuColor 2006...
Page 577: Vdc Interlocked Wirenet (3 Of)
+24 VDC Interlocked Wirenet (3 of 3) Figure 1 +24 VDC Interlocked (3 of 3) Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-31...
Page 578: Dc Com Wirenet (1 Of)
DC Com Wirenet (1 of 5) Figure 1 DC Com (1 of 5) Wiring Data Initial Issue 10/00 7-32 Phaser 790/DocuColor 2006...
Page 579: Dc Com Wirenet (2 Of)
DC Com Wirenet (2 of 5) Figure 1 DC Com (2 of 5) Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-33...
Page 580: Dc Com Wirenet (3 Of)
DC Com Wirenet (3 of 5) Figure 1 DC Com (3 of 5) Wiring Data Initial Issue 10/00 7-34 Phaser 790/DocuColor 2006...
Page 581: Dc Com Wirenet (4 Of)
DC Com Wirenet (4 of 5) Figure 1 DC Com (4 of 5) Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-35...
Page 582: Dc Com Wirenet (5 Of)
DC Com Wirenet (5 of 5) Figure 1 DC Com (5 of 5) Wiring Data Initial Issue 10/00 7-36 Phaser 790/DocuColor 2006...
Page 583: Vdc (Iit) Wirenet
+5 VDC (IIT) Wirenet Figure 1 +5 VDC (IIT) Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-37...
Page 584 +24 VDC (IIT) Wirenet Figure 1 +24 VDC (IIT) Wiring Data Initial Issue 10/00 7-38 Phaser 790/DocuColor 2006...
Page 585 Each functional chain is represented by a BSD or a group of BSDs. A BSD is a func- tional flow diagram containing electrical circuit information and mechanical inputs and outputs. The functional flow is from left to right (inputs on the left and outputs on the right). Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-39...
Page 586 BSD 1.1 Figure 1 Main Power On Wiring Data Initial Issue 10/00 7-40 Phaser 790/DocuColor 2006...
Page 587 BSD 1.2 Figure 1 Interlock Switching Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-41...
Page 588 BSD 1.3 Figure 1 Transport Cover Position Monitoring Wiring Data Initial Issue 10/00 7-42 Phaser 790/DocuColor 2006...
Page 589 BSD 1.4 Figure 1 Tray Module Cover Position Monitoring Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-43...
Page 590 BSD 1.5 Figure 1 Duplex Module Cover Position Monitoring Wiring Data Initial Issue 10/00 7-44 Phaser 790/DocuColor 2006...
Page 591 BSD 1.6 Figure 1 IIT Main Power On Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-45...
Page 592 BSD 2.1 Figure 1 Control Panel Wiring Data Initial Issue 10/00 7-46 Phaser 790/DocuColor 2006...
Page 593 BSD 2.2 Figure 1 IIT Control Panel Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-47...
Page 594 BSD 3.1 Figure 1 Machine Self Test Wiring Data Initial Issue 10/00 7-48 Phaser 790/DocuColor 2006...
Page 595 BSD 3.2 Figure 1 IIT Machine Self Test Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-49...
Page 596 BSD 3.3 Figure 1 CRUM and Billing Wiring Data Initial Issue 10/00 7-50 Phaser 790/DocuColor 2006...
Page 597 BSD 3.4 Figure 1 Tray Module Communication Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-51...
Page 598 BSD 3.5 Figure 1 Duplex Module Communication Wiring Data Initial Issue 10/00 7-52 Phaser 790/DocuColor 2006...
Page 599 BSD 3.6 Figure 1 BSD 3.6 Sorter Communication Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-53...
Page 600 BSD 3.7 Figure 1 BSD 3.7 Foreign Interface Wiring Data Initial Issue 10/00 7-54 Phaser 790/DocuColor 2006...
Page 601 BSD 4.1 Figure 1 BSD 4.1 Main Drive Control Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-55...
Page 602 BSD 4.2 Figure 1 Mechanical Drives Wiring Data Initial Issue 10/00 7-56 Phaser 790/DocuColor 2006...
Page 603 BSD 5.1 Figure 1 ADF Document Sensing and Interlock Monitoring Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-57...
Page 604 BSD 5.2 Figure 1 ADF Document Feeding Wiring Data Initial Issue 10/00 7-58 Phaser 790/DocuColor 2006...
Page 605 BSD 5.3 Figure 1 Document Transportation (1 of 2) Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-59...
Page 606 BSD 5.3 Figure 1 Document Transportation (2 of 2) Wiring Data Initial Issue 10/00 7-60 Phaser 790/DocuColor 2006...
Page 607 BSD 5.4 Figure 1 Document Exit Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-61...
Page 608 BSD 5.5 Figure 1 ADF Communication Wiring Data Initial Issue 10/00 7-62 Phaser 790/DocuColor 2006...
Page 609 BSD 6.1 Figure 1 Laser Image Scanning Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-63...
Page 610: Bsd 6.2 And
BSD 6.2 and 6.3 Figure 1 Laser Control/Polygon Motor Control Wiring Data Initial Issue 10/00 7-64 Phaser 790/DocuColor 2006...
Page 611 BSD 6.4 Figure 1 Document Illumination Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-65...
Page 612 BSD 6.5 Figure 1 Image Input Wiring Data Initial Issue 10/00 7-66 Phaser 790/DocuColor 2006...
Page 613 BSD 6.6 Figure 1 Carriage Control Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-67...
Page 614 BSD 7.1 Figure 1 Tray 1 Paper Supply (1 of 2) Wiring Data Initial Issue 10/00 7-68 Phaser 790/DocuColor 2006...
Page 615 BSD 7.1 Figure 1 Tray 1 Paper Supply (2 of 2) Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-69...
Page 616 BSD 7.2 Figure 1 Bypass Paper Supply (1 of 2) Wiring Data Initial Issue 10/00 7-70 Phaser 790/DocuColor 2006...
Page 617 BSD 7.2 Figure 1 Bypass Paper Supply (2 of 2) Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-71...
Page 618 BSD 7.3 Figure 1 Tray 2 Paper Supply (1 of 2) Wiring Data Initial Issue 10/00 7-72 Phaser 790/DocuColor 2006...
Page 619 BSD 7.3 Figure 1 Tray 2 Paper Supply (2 of 2) Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-73...
Page 620 BSD 7.4 Figure 1 Tray 3 Paper Supply (1 of 2) Wiring Data Initial Issue 10/00 7-74 Phaser 790/DocuColor 2006...
Page 621 BSD 7.4 Figure 1 Tray 3 Paper Supply (2 of 2) Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-75...
Page 622 BSD 8.1 Figure 1 Tray 1 Paper Feeding Wiring Data Initial Issue 10/00 7-76 Phaser 790/DocuColor 2006...
Page 623 BSD 8.2 Figure 1 Bypass Tray Feeding Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-77...
Page 624 BSD 8.3 Figure 1 Tray 2 Paper Feeding Wiring Data Initial Issue 10/00 7-78 Phaser 790/DocuColor 2006...
Page 625 BSD 8.4 Figure 1 Tray 3 Paper Feeding Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-79...
Page 626 BSD 8.5 Figure 1 Feeder Drive Control Wiring Data Initial Issue 10/00 7-80 Phaser 790/DocuColor 2006...
Page 627 BSD 8.6 Figure 1 Registration Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-81...
Page 628 BSD 8.7 Figure 1 Registration Mechanism Wiring Data Initial Issue 10/00 7-82 Phaser 790/DocuColor 2006...
Page 629 BSD 9.1 Figure 1 Charging and Exposure Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-83...
Page 630 BSD 9.2 Figure 1 BSD 9.2 Drum Drive Wiring Data Initial Issue 10/00 7-84 Phaser 790/DocuColor 2006...
Page 631 BSD 9.3 Figure 1 Developer Rotary Control (1 of 2) Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-85...
Page 632 BSD 9.3 Figure 1 Developer Rotary Control (2 of 2) Wiring Data Initial Issue 10/00 7-86 Phaser 790/DocuColor 2006...
Page 633 BSD 9.4 Figure 1 Development (1 of 2) Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-87...
Page 634 BSD 9.4 Figure 1 Development (2 of 2) Wiring Data Initial Issue 10/00 7-88 Phaser 790/DocuColor 2006...
Page 635 BSD 9.5 Figure 1 Dispense Control Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-89...
Page 636 BSD 9.6 Figure 1 IBT Belt Drive and 1st Transfer Wiring Data Initial Issue 10/00 7-90 Phaser 790/DocuColor 2006...
Page 637 BSD 9.7 Figure 1 2nd Transfer and IBT Belt Cleaning Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-91...
Page 638 BSD 9.8 Figure 1 Belt Cleaning and BTR 2 Retract/Advance Switching (1 of 2) Wiring Data Initial Issue 10/00 7-92 Phaser 790/DocuColor 2006...
Page 639 BSD 9.8 Figure 1 Belt Cleaning and BTR 2 Retract/Advance Switching (2 of 2) Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-93...
Page 640 BSD 9.9 Figure 1 Drum Cleaning and Toner Reclaim Wiring Data Initial Issue 10/00 7-94 Phaser 790/DocuColor 2006...
Page 641 BSD 10.1 Figure 1 Fusing Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-95...
Page 642 BSD 10.2 Figure 1 Fusing Heat Control Wiring Data Initial Issue 10/00 7-96 Phaser 790/DocuColor 2006...
Page 643 BSD 10.3 Figure 1 Fusing Air Control Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-97...
Page 644 BSD 10.4 Figure 1 Exit Transportation (1 of 2) Wiring Data Initial Issue 10/00 7-98 Phaser 790/DocuColor 2006...
Page 645 BSD 10.4 Figure 1 Exit Transportation (2 of 2) Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-99...
Page 646 BSD 10.5 Figure 1 Invert and Duplex Transport (1 of 2) Wiring Data Initial Issue 10/00 7-100 Phaser 790/DocuColor 2006...
Page 647 BSD 10.5 Figure 1 Invert and Duplex Transport (2 of 2) Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-101...
Page 648 BSD 10.6 Figure 1 Invert Mechanism Wiring Data Initial Issue 10/00 7-102 Phaser 790/DocuColor 2006...
Page 649 BSD 10.7 Figure 1 Duplex Feeding Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-103...
Page 650 BSD 10.8 Figure 1 Duplex Drive Control Wiring Data Initial Issue 10/00 7-104 Phaser 790/DocuColor 2006...
Page 651: Bsd 11.1/Bsd
BSD 11.1/BSD 11.2 Figure 1 Sorter DC Power Generation and Top Cover/Docking Interlock and Sorter Communication Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-105...
Page 652 BSD 11.3 Figure 1 Sorter Transportation Wiring Data Initial Issue 10/00 7-106 Phaser 790/DocuColor 2006...
Page 653 BSD 11.4 Figure 1 Bin Drive Control Initial Issue Wiring Data 10/00 Phaser 790/DocuColor 2006 7-107...

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