Page 1 Phaser 7400 ® color printer Service Manual Book 2: Options...
Page 3: Service Manual
® Phaser 7400 Color Printer Service Manual Book 2: Options Warning The following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing other than that contained in the operating instructions, unless you are qualified to do so.
Page 4 Copyright © 2005 Xerox Corporation. All Rights Reserved. Unpublished rights reserved under the copyright laws of the United States. Contents of this publication may not be reproduced in any form without permission of Xerox Corporation. Copyright protection claimed includes all forms of matters of copyrightable materials and information now...
Page 5: Service Terms
Service Terms Manual Terms Various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger present during a procedure or action. Be aware of all symbols and terms when they are used, and always read NOTE, CAUTION, and WARNING statements.
Page 6: Symbols Marked On The Product
Symbols Marked on the Product DANGER high voltage. Protective ground (earth) symbol. Hot surface on or in the printer. Use caution to avoid personal injury. The surface is hot while the printer is running. After turning off the power, wait 30 minutes. 30 min.
Page 7: Power Safety Precautions
Power Safety Precautions Power Source For 115 VAC printers, do not apply more than 135 volts RMS between the supply conductors or between either supply conductor and ground. For 230 VAC printers, do not apply more than 254 volts RMS between the supply conductors or between either supply conductor and ground.
Page 8: Electrostatic Discharge (Esd) Precautions
Electrostatic Discharge (ESD) Precautions Some semiconductor components, and the respective sub-assemblies that contain them, are vulnerable to damage by Electrostatic discharge (ESD). These components include Integrated Circuits (ICs), Large-Scale Integrated circuits (LSIs), field-effect transistors and other semiconductor chip components. The following techniques will reduce the occurrence of component damage caused by static electricity.
Page 9: Service Safety Summary
Service Safety Summary General Guidelines For qualified service personnel only: Refer also to the preceding Power Safety Precautions. Avoid servicing alone: Do not perform internal service or adjustment of this product unless another person capable of rendering first aid or resuscitation is present. Use care when servicing with power: Dangerous voltages may exist at several points in this product.
Page 10: Servicing Electrical Components
Servicing Electrical Components Before starting any service procedure, switch off the printer power and unplug the power cord from the wall outlet. If you must service the printer with power applied, be aware of the potential for electrical shock. Warning Do not touch any electrical component unless you are instructed to do so by a service procedure.
Page 11: Regulatory Specifications
Consult the dealer or an experienced radio/television technician for help. Any changes or modifications not expressly approved by Xerox could void the user's authority to operate the equipment. To ensure compliance with Part 15 of the FCC rules, use shielded interface cables.
Page 12: European Union
Xerox Corporation declares, under our sole responsibility, that the product to which this declaration relates is in conformity with the following standards and other normative documents:...
Page 13: Manual Organization
Manual Organization The Xerox Phaser 7400 Color Printer Service Manual is the primary document used for repairing, maintaining, and troubleshooting the printer. The manual is organized into two books. This volume, Book 2, Phaser 7400 Options includes an overview of option theory, option FRU replacement procedures, parts lists, and wiring diagrams.
Page 14 Book 1 - Print Engine Use Book 1 as your primary resource for understanding the operational characteristics of the print engine. Book 1 describes printer specifications, theory and includes information important to the diagnosis and repair of problems occurring in the print engine and attached options.
Page 15: Table Of Contents
Contents Service Terms ..........iii Symbols Marked on the Product .
Page 16 Sensors ..........2-25 Finisher Paper Path Sensors .
Page 17 Clear Tray [2][3][4][5][6] Riser Plate ..... 3-38 Out of Paper Load Tray [2][3][4][5][6] with [size][type] ..3-39 Finisher Lower Output Tray is Full, Unload Paper .
Page 18 No Paper in Tray [2][3][4][5][6] ......3-87 Staple Cartridge Is Empty ......3-88 Punch Waste Box is Full or Missing.
Page 19 Upper Right Cover Assembly ......5-37 Processing Tray Assembly ......5-38 Paddle Assembly .
Page 20 Staple/Fold Clock Sensor ......5-93 Folding Home Position Sensor......5-94 Folding Position Sensor .
Page 21 6 Parts List Using the Parts List ......... 6-2 Finisher Parts .
Page 22 7 Wiring Diagrams Plug/Jack Locator Diagrams ........7-2 Print Options Plug/Jack Designators .
Page 23: General Information
General Information In this chapter... Printer Introduction and Overview Printer Configurations Printer Options Specifications Section...
Page 24: Printer Introduction And Overview
Printer Introduction and Overview The Xerox Phaser 7400 Color Printer Service Manual is the primary document used to repair, maintain, and troubleshoot this printer. For manual updates, Service Bulletins, knowledge base, etc., see www.xerox.com/office/7400support. For further technical support, contact your assigned Xerox Technical Support for this product.
Page 25: Printer Configurations
Printer Configurations The Phaser 7400 Color Printer is available in five configurations. The main differences are standard memory, optional high-capacity feeders, duplexing (2-sided printing) capabilities, networking, Finisher capabilities, and internal Hard Drive. The following table lists the available configurations. Printer Configuration Features 7400N 7400DN...
Page 26: Parts Of The Finisher And Paper Trays
Parts of the Finisher and Paper Trays Front View s7400-552 Rear View s7400-533 Phaser 7400 Color Printer Options Service Manual...
Page 27: Printer Options
Printer Options Phaser 7400 Color Printer options include: 1,000-Sheet Finisher (with hole punch, staple, saddle-stitch, and inverter) 550-Sheet Feeder (LTA) 1650-Sheet Feeder (HCF) Duplex Unit Finisher The Finisher increases the output capacity of the printer by 1,000 sheets. Printer output is directed to the Finisher by way of the side exit. Depending on the job specifications, as paper enters the Finisher it is punched, stapled, offset and stacked.
Page 28: Duplex Unit
Duplex Unit The Duplex Unit adds two-sided printing. The Duplex Unit attaches into the left side above Tray 2 using two latches. s7400-305 550-Sheet Feeder The 550-Sheet Feeder increases the input capacity of the printer. The feeder attaches below Tray 2 with four screws. When used in combination with the 1650-Sheet Feeder, the 550-Sheet Feeder is installed between the printer and 1650-Sheet Feeder.
Page 29: 1650-Sheet Feeder
1650-Sheet Feeder The 1650-Sheet Feeder adds three, 550-sheet trays. Control signals reach the sheet feeder by a single connection. The sheet feeder is secured both to the print engine and the 550-Sheet Feeder. s7400-003 Specifications Consumable Life Specifications Size Product name Maintenance Items Staple Cartridge‘...
Page 30: Physical Dimensions And Clearances
Physical Dimensions and Clearances Finisher (including stand) Value Height: 1016 mm (40.0 in.) Width: 813 mm (32 in.) Depth: 595 mm (23.6in.) Weight: Approximately 55 kg (122 lb.) Finisher only 1650-Sheet Feeder Value Height: 401 mm (15.8 in.) Optional Paper Tray Assembly Width: 597 mm (23.5 in.) Depth:...
Page 31 Functional Specifications (Continued) Characteristic Specification 50 sheets Small size, 128 g/m x 48 Quantity of paper to be stapled Large size, 128 g/m x 25 25 sheets Large size, 128 g/m x 25 Stapling Two positions A3, B4, 11” x 17”, 8.5” x 14”, 8.5 x 13, A4, 8.5 x 11 R and Executive One at the back A3, B4, A4, A4R, B5...
Page 32: Finisher Environmental Specifications
Finisher Environmental Specifications Characteristic Specification Temperature Operating 10 to 32 C (50 to 89.6 Storage 0 to 4 C (32 to 109.4 Transport -10 to 43 C (-14 to 109.4 Humidity (RH) Relative Humidity (50 - 70% to assure the best print-quality) Operating 20 - 80% Storage...
Page 33: Theory Of Operation
Theory of Operation In this chapter... Operational Overview Finisher Overview Printer Options Finishing Process Summary Sensors Motors, Rollers, Solenoids, and Clutches Detecting Jams Power Supplies Section...
Page 34: Options Operational Overview
Options Operational Overview The Phaser 7400 Color Printer Options package consists of: Finisher: Punch Unit - Provides various punch hole (2, 3, and 4 hole) options. Staple Unit - Staples stacked paper for various media type and size. Saddle Unit - Delivers and folds stacked paper. Inverter - Physically inverts the paper for stacking or folding.
Page 35: Finisher Overview
Finisher Overview The Finisher increases the output capacity of the printer by 1,000 sheets. Printer output is directed to the Finisher by way of the side exit. Depending on the job specifications, as paper enters the Finisher it can be inverted, punched, stapled, offset and stacked.
Page 36: Punch Unit
Punch Unit The Punch Unit punches holes in sheets coming from the printer. It provides for 2-hole, 3-hole, and 4-hole punching. The unit installs into the pickup assembly of the finisher. Since the punch unit is not equipped with a paper feeding mechanism, the sheets from the printer move through the punch unit and feed system of the finisher.
Page 37 The Punch Unit consists of a die and hole punch (punch blade), which is driven by a a DC motor. The unit attaches to the eccentric cam of the punch shaft. A punch home position sensor detects the home position of the punch shaft to ensure that the punch motor stops exactly at its home position, the punch motor stops in relation to the count of clock pulses from the Punch Motor Clock Sensor.
Page 38: Staple Unit
Staple Unit The Staple Unit receives instructions from the printer through the Finisher Controller Board to initiate staple operation and deliver up to 50 sheets of paper (depending on the paper size) to the finisher staple subassembly. The unit mounts in the Finisher and, depending on the media selection, provides front stapling, rear stapling, dual stapling, and saddle stitching (center stapling with fold).
Page 39 The slide motor is then driven a specified number of pulses until the stapler reaches the rear standby position at the back of the machine. At this point, the unit enters the standby state. Stapler (Deliver Direction) Paper Stack Light-Shielding Plate Slide Home Position Sensor Slide Motor s7400-132...
Page 40: Saddle Unit
Saddle Unit The Saddle Unit stitches (center staples) up to 50 sheets (middle 2-point), then folds the stack in two in the Finisher. The Finisher Controller Board receives commands from the printer to control the following operations: Paper feed in - After alignment on the processing tray, the feed drive system inserts a stack of sheets between the stack delivery rollers.
Page 41 Paper Fold System The paper fold mechanism consists of a guide plate, paper fold rollers, and a paper pushing plate. The Staple/Fold Motor drives the guide plate, paper-fold rollers, and paper-pushing plate. A combination of gears and cams transfer the drive force while the Staple/Fold Motor Sensor monitors the operation.
Page 42: Inverter Unit
Inverter Unit The Inverter Unit receives paper from the printer and physically inverts the paper for stacking or folding. The Inverter is a self-enclosed unit which connects on a common base with the Finisher itself. The entire Finisher/Inverter can then physically connect to the printer and tray units with a sliding mount.
Page 43: Printer Options
Printer Options Duplex Unit The Duplex Unit adds two-sided printing. The Duplex Unit attaches to the left side above Tray 1 using two twist locks. Installation of the Duplex Unit requires that the Exit 2 Module also be added to provide reverse drive. Electrical connection to the printer is made by an interface cable.
Page 44: 1650-Sheet Feeder
1650-Sheet Feeder The 1650-Sheet Feeder combines three, 550-sheet trays. Control signals reach the 1650-sheet feeder through a single connection. The sheet feeder is secured to the print engine or 550-Sheet Feeder with four screws located under the front and rear edges of the tray.
Page 45: Finishing Process Summary
Finishing Process Summary The following illustration shows the various printing processes and process decisions that the finishing components handle on command from the printer. On Command from Printer Duplex? Duplexer Processing Print Engine Finisher Invert? Paper Inverted Punch? Punch Process 2 Hole 3 Hole 4 Hole Booklet Process...
Page 46: Inverting
The finishing processes include six major functions: Inverting Folding Punching Stacking Stapling Delivery Inverting The sole purpose of the inverter function is to position the paper for stacking or folding. On command from the printer, The Inverter receives paper from a printer or a Duplex Unit for inversion, if needed, and sent on to the Finisher.
Page 47 4-Hole Type - The punching operation for the first sheet ends when the punch shaft rotates 180 degrees and the Punch Home Position Sensor activates. The punching operation for the second sheet ends when the punch shaft rotates 180 degrees in reverse and the Punch Home Position Sensor activates. Punch Shaft At Rest Punch Shaft CCW Punch Shaft CCW...
Page 48 2-Hole, 3-Hole Type - To make two holes, the punching operation for the first sheet ends when the punch shaft rotates 180 degrees (half-circumference) and the Punch Home Position Sensor activates. At this time, the 3-hole punch rotates once on a half-circumference of the punch shaft. The punching operation for the second sheet ends when the punch shaft rotates 180 degrees counterclockwise and the Punch Home Position Sensor activates (half-circumference).
Page 49 When the punching operation ends, the Feed Motor moves the paper through the rest of the paper path. The Finisher Punch Transfer Motor then rotates in reverse to return the slide unit to home. For each sheet that arrives in succession, the Punch Slide Unit returns to its home position and repeat steps 1 through 4 (the following illustration shows the top view of the Punch Slide Unit in the Finisher).
Page 50: Folding
Folding Finisher paper fold rollers and a paper pushing plate are the main assemblies for the paper folding process when creating a booklet. Concurrent with the start of the stack feed roller rotation, the paper pushing plate pushes the middle of the paper stack into the gap between the paper fold rollers.
Page 51: Stacking
Stacking There are two types of stacking presented to the delivery tray: Simple Stacking - The unit pulls in the sheet to the processing tray and then delivers it to the delivery tray. s7400-122 Theory of Operation 2-19...
Page 52 Job offset - The machine places the sheet into the processing tray. It then moves the sheet to the front or the rear using the aligning plate. When it has deposited a specific number of sheets, it delivers them as a stacked set.) Results Of Offset Delivery (4 Jobs) 4th Set 3rd Set...
Page 53 When the number of sheets stacked on the processing tray reaches a specified value, the sheets are delivered in stack form. Even if the unit never reaches a specified value, stacked sheets are temporarily delivered when 25 sheets of large-size paper (300 mm or longer) or 50 sheets of small-size paper (299 mm or shorter) have been stacked.
Page 54 Stack Feed Roller (Upper) Stack Feed Roller (Lower) s7400-147 2-22 Phaser 7400 Color Printer Options Service Manual...
Page 55: Stapling
Stapling After stacking and alignment of paper on the processing tray is complete, the finisher controller board moves the stapler for stapling according to the specified stapling position. When the controller specifies rear 1-point stapling, the stapler does not move; it staples while in the standby position. If a different stapling option is selected, the stapler moves forward and the processing tray stopper leans to the forward position.
Page 56: Delivery
Delivery The Finisher Unit includes a Delivery Tray, and the Saddle Unit includes a Bind Tray. The Bind Tray is a fixed unit where all folded paper stacks are delivered. The Bind Tray includes a Bind Tray Sensor to detect the presence of paper. The delivery tray in the finisher unit moves up and down using a Lift Motor.
Page 57: Sensors
Sensors The Finisher/Inverter, Duplex Unit, and paper trays contain sensors of various types that perform a variety of functions. One group of sensors track the progress of the paper along the paper path and detects if a paper jam occurs. Other sensors stop printer activity if a door is open (interlock), detect the presence and size of media in the trays, and monitor the fusing temperature.
Page 58 Microswitches Microswitches are used primarily as paper size sensors and cover interlocks. They are in a normally open state, and close when actuated. A bank of microswitches detect paper size in the universal trays. Microswitches also employ hooks or catches for retention in the bracket or frame.
Page 59: Finisher Paper Path Sensors
Finisher Paper Path Sensors The following illustration identifies the various sensors located in the Finisher. Error reporting is dependent on these sensors as the paper moves through the paper path. Stapler Safety Interlock Switch Shift Lower Limit Sensor Shift Clock Sensor Upper Cover Sensor Joint Switch Front Alignment Plate...
Page 60 Sensor Function Sensor Function Joint Switch Prevents the power supply from placing hazardous voltages in accessible areas when the Finisher is undocks from the Printer. Front Door Switch Prevents the power supply from placing hazardous voltages in accessible areas when the Front Door (Door J) is removed. Front Door Sensor Detects when the Front Door is open or removed.
Page 61 Sensor Function (Continued) Sensor Function Folding Home Position Detects the positions of the paper fold rollers and the paper Sensor pushing plate. Bind Tray Sensor Detects when paper is present in the Saddle Unit’s bind tray. Folding Position Sensor Detects the leading edge of the paper stack. Note The punch assembly includes up to five light-receiving transistors (photosensor board) mounted over the inlet paper path of the Punch Unit.
Page 62: Inverter Sensors
Inverter Sensors The following illustration shows the general location of the Inverter sensors. The topics in this section describe the disassembly for each sensor.. Inverter Paper-in Sensor Inverter Upper Paper-present Sensor Inverter Door Open Interlock Switch Inverter Lower Paper-present Sensor Inverter Docking Sensor s7400-611...
Page 63: Duplex Sensors
Sensor Function (Continued) Sensor Function Inverter Upper Paper- Detects the leading edge of the selected paper size. Present Sensor Inverter Lower Paper- Detects the trailing edge of the selected paper size. Present Sensor Inverter Paper-in Sensor Detects the presence of media in the Inverter. Duplex Sensors The Duplex Unit receives media diverted to the Side Exit by the Exit Gate.
Page 64: Optional Tray Sensors
Duplex sensors include: Duplex Entrance Sensor Detects the leading edge of the media and signals the Duplex Motor to begin rotation in the forward direction. Duplex Reverse Sensor Detects media in the lower portion of the Duplex Unit and signals the Duplex Motor to reverse rotation.
Page 65: Motors, Rollers, Solenoids, And Clutches
Motors, Rollers, Solenoids, and Clutches Finisher Motors Paddle Motor Feed Motor Sliding Motor Delivery Motor Staple/Fold Motor Rear Alignment Motor Front Alignment Motor Shift Motor s7400-543 Theory of Operation 2-33...
Page 66 Punch Unit Solenoids and Motors Punching Motor Clock Sensor Punching Home Sensor Position Sensor PI3P PI1P PI2P Horizontal Registration Home Position Sensor M otor Feed Motor Punching Controller Board Punch Dust Full Punch Dust Full Photo Sensor LED Circuit Board Circuit board Photo Sensor Circuit board...
Page 67: Inverter Solenoids And Motors
Inverter Solenoids and Motors The Inverter motors move the rollers to move the media throughout the paper path. The Feeder Clutch, on command from the printer, engages the motors. The Inverter Solenoids, also on command from the printer, energize the upper and lower paper rollers.
Page 68: Duplex Solenoids, Rollers, And Motors
Duplex Solenoids, Rollers, and Motors The Duplex Unit receives media diverted to the Side Exit by the Exit Gate. The media is detected by the Duplex Entrance Sensor and drawn into the Duplex Unit. The media is inverted and exits the Duplex Unit just above Registration Roller #2. Media moves through the Duplex Unit using the following solenoids, rollers, and motors: Duplex Solenoid - Activates the Duplex Gate directing media to the Duplex Transport Rollers.
Page 69: Optional Tray Motors, Rollers, And Clutches
Optional Tray Motors, Rollers, and Clutches The following describes the paper path as it is fed from the optional Tray 3. Trays 4 through 6 function in the same manner. Media moves along the paper path as follows: Paper loaded in the tray is detected by the Paper Size Switches. The tray’s Lift Motor rotates lifting the sheet to the pre-feed position detected by the Level Sensor.
Page 70 Registration Roller #2 Registration Clutch #2 Registration Sensor #2 Registration Motor Tray 2 Registration Roller #3 Tray 3 Registration Clutch #3 Feed-Out Sensor #3 Registration Feed Roller Sensor #3 Pick Roller Feed Motor Retard Roller Registration Motor s7400-027 The paper supply and path for the optional trays involve these motors, rollers, and clutches: 2-38 Phaser 7400 Color Printer Options Service Manual...
Page 71 Registration Motor This motor drives the Registration Rollers to pull media from the tray into the paper path. Registration Clutch This clutch transfers Registration Motor drive to the Registration Roller. Registration Roller This roller aligns the leading edge of the sheet to correct any skew. Lift Motor This motor lifts the tray’s base plate raising the media to the pre-feed position.
Page 72: Detecting Jams
Detecting Jams The microprocessor (CPU) on the Finisher Controller Board checks for jams in the Finisher and other optional units. The CPU identifies a jam in reference to the presence or absence of paper at a specific sensor. In general, the Jam will be generated because of sensors from one or more of the following door locations (see illustration below).
Page 73: Finisher/Punch Power Supply
Finisher/Punch Power Supply When the printer is powered ON and connected to the finisher, it supplies the Finisher Controller Board with two channels of 24 VDC: one for the motors and clutches, and the other for conversion into 5 VDC in the regulator IC (IC1) of the Finisher Controller Board.
Page 74: Finisher Power Supply Protection
Finisher Power Supply Protection A circuit breaker (CB1) is available to protect the 24 VDC system that drives the motors against overcurrent conditions. The 24 VDC system drives the feed motor, paddle motor, and delivery motor. Punch Unit Power Supply Protection After the printer is powered ON, the Finisher Controller Board supplies the punch unit with 24 VDC and 5 VDC power.
Page 75: General Troubleshooting
General Troubleshooting In this chapter... Power On Self Test (POST) Service Diagnostics Error Message Table Troubleshooting the Options Section...
Page 76: Introduction
Introduction This section covers the startup, Service Diagnostics, and power supply operations of the Finisher, Inverter, Duplex Unit, and Paper Tray options to aid in troubleshooting problems. Troubleshooting procedures isolate a problem to a specific component or subassembly. If you go through the procedures and are still unable to solve the problem, re-read the “Theory of Operation”...
Page 77: Servicing Instructions
Servicing Instructions The service checklist below is an overview of the path a service technician should take when servicing the printer and printer optional equipment. Step 1 - Identify the Problem 1. Verify the reported problem does exist. Verify failure symptoms/behavior/noises with customer/end user.
Page 78: Jam Locator
Jam Locator The following illustrates the Door designators that key the jam location error codes and messages. Refer to this diagram when questions arise regarding the area of the jam. Door H Door F Door J Door G Door I Door C s7400-696 Phaser 7400 Color Printer Options Service Manual...
Page 79: Jam Detection Chart
Jam Detection Chart Inverter Eject Jam Jam 01 Jam 03 Jam 04 Jam 02 Jam 10 Inverter Feed Jam Inverter Front Stack Inverter Route Jam Inverter Reverse Stack Area Jam Jam 07 Jam 05 Jam 08 Jam 09 s7400-563 General Troubleshooting...
Page 80: Error Message Summary
Error Message Summary The Error Message Summary table below lists possible errors, along with the corresponding code, and page reference for the corrective procedure for the finisher, Duplex Unit, and paper trays. The Error column lists the error code for fatal or jam errors that appears in the Help text displayed by pressing the Help(?) button, listed on the printer’s Status page, or logged by the Service Usage Profile.
Page 81 Error Control Panel Message Page Close Door D 3-34 Close Finisher Door F 3-35 Close Finisher Door H 3-36 Close Finisher Door J 3-37 Tray and Media Errors Clear Tray [3][4][5][6] Riser Plate 3-38 Out of Paper Load Tray [3][4][5][6] with [size] [type] 3-39 Finisher Lower Output Tray is Full, Unload Paper 3-41...
Page 82 Error Control Panel Message Page Fatal Errors Duplex Interface Failure 3-45 Tray 3 Interface Failure 3-46 Tray 4 Interface Failure 3-46 Tray 5 Interface Failure 3-46 Tray 6 Interface Failure 3-46 Inverter Unit Interface Failure 3-47 Unsupported Duplex Unit ROM 3-48 Unsupported Tray 3 ROM 3-49...
Page 83 Error Control Panel Message Page Inverter Power Supply Error. 3-71 Tray 3 Firmware Error. Firmware error in Tray 3 Flash Memory. 3-72 Tray 4 Firmware Error. Firmware error in Tray 4 Flash Memory. 3-72 Tray 5 Firmware Error. Firmware error in Tray 5 Flash Memory. 3-72 Tray 6 Firmware Error.
Page 84 Error Control Panel Message Page Staple Cartridge Is Empty 3-88 Punch Waste Box is Full or Missing 3-89 Finisher Away From Base 3-90 Finisher Away From Printer 3-91 3-10 Phaser 7400 Color Printer Options Service Manual...
Page 85: Using The Troubleshooting Procedures
Using the Troubleshooting Procedures lists the error message(s) addressed by each Applicable Status Code(s) troubleshooting procedure. assist you in locating Applicable Parts Wiring and Plug/Jack References information available for a particular part or procedure. Follow each in a troubleshooting procedure sequentially in the order given Step until the problem is fixed or resolved.
Page 86: Measurement Techniques
Measurement Techniques Unless indicated otherwise, the instruction “switch On printer power” means for you to switch On printer power and let the printer proceed through Power On Self Test (POST) to a ‘Ready’ condition. Conventions used in this manual to represent connectors Jack Plug s7400-314...
Page 87: Troubleshooting The Finisher
Troubleshooting the Finisher Jam at Door C for Tray [3][4][5][6] Media reached the Feed-Out Sensor, but did not arrive at the Transfer Unit Entrance Sensor on time. This error represents a misfeed jam for media fed from an optional tray. Applicable Status Codes: Code C3: Jam at Door C for Tray 3...
Page 88 Troubleshooting Procedure Table Step Actions and Questions Check the following for evidence of fault, Clean or replace Go to Step 2. dirt, debris, or damage: the appropriate parts. Door C Feed Rollers Registration Rollers Transport Rollers Sensor Actuators Is there any damage or debris? Check the Option connection.
Page 89 Troubleshooting Procedure Table (Continued) Step Actions and Questions Check OPTRY24 Harness continuity. Go to Step 13. Replace the Disconnect the OPTRY24 Harness. OPTRY24 Is the OPTRY24 Harness conductive? Harness. Check the Registration Assembly. Replace the Go to Step 13. Is there a gap between the rollers? Registration Assembly (page 8-84).
Page 90: Jam At Door D Open Door D To Clear
Jam at Door D Open Door D to Clear Media reached Duplex Reverse Sensor, but did not leave the Duplex Unit on time. This error represents a misfeed jam inside the Duplex Unit. Applicable Status Code: Code D1: Jam at Door D Initial Actions: Ensure that the Duplex Unit is free of obstructions and fully seated.
Page 91: Jam In Duplex Unit
Jam in Duplex Unit Media reached Duplex Reverse Sensor, but did not leave the Duplex Unit on time. This error represents a misfeed jam inside the Duplex Unit. Applicable Status Code: Code D2: Jam in Duplex Unit Initial Actions: Cycle printer power. If the problem persists, follow the procedure below.
Page 92: Jam At Duplex Entrance
Jam at Duplex Entrance Media reached the Fuser Exit Sensor, but did not reach the Duplex Entrance Sensor on time. This error represents a jam at the Duplex entrance or in the Exit Assembly. Applicable Status Code: Code TC3: Jam at Duplex Entrance Initial Actions: Check for obstructions or debris in the output paper path.
Page 93 Troubleshooting Procedure Table (Continued) Step Actions and Questions Check for +24 V to the Duplex Motors. Go to Step 6. Go to Step 10. Disconnect DUPLEX on the Motor Driver Board. Is there +24 V at DUPLEX-6 <=> ground? Test the Fuser Motor. Go to Step 8.
Page 94: Jam At Finisher Punch Unit
Jam at Finisher Punch Unit Media did not clear the Finisher Entrance Sensor on time. This error represents a jam at the Finisher entrance. Applicable Status Code: Code FN1: Jam at Finisher Punch Initial Actions: Check for obstructions or debris in the paper path. Cycle printer power.
Page 95: Jam At Finisher Door H
Jam at Finisher Door H Media reached the Finisher Entrance Sensor, but did not clear the Inverter on time. This error represents a jam in the Finisher Inverter. Applicable Status Code: Code FN2: Jam at Finisher Door H Initial Actions: Check for obstructions or debris in the paper path.
Page 96: Jam At Finisher Upper Output Tray
Jam at Finisher Upper Output Tray Media remains in the upper output path. This error represents a jam in the Finisher. Applicable Status Code: Code FN4: Jam at Finisher Upper Output Tray Initial Actions: Check for obstructions or debris in the paper path. Cycle printer power.
Page 97: Jam At Finisher Saddle Stapler
Jam at Finisher Saddle Stapler Media remains in the buffer area. This error represents a jam in the Finisher. Applicable Status Code: Code FN5: Jam at Finisher Saddle Stapler Initial Actions: Check for obstructions or debris in the paper path. Cycle printer power.
Page 98: Jam At Finisher Upper Output Tray
Jam at Finisher Upper Output Tray Media remains in the Finisher offset rollers. This error represents a jam in the Finisher upper output path. Applicable Status Code: Code FN6: Jam at Finisher Upper Output Tray Initial Actions: Cycle printer power. If the problem persists, follow the procedure below.
Page 99: Jam At Finisher Stapler
Jam at Finisher Stapler Media remains in the Compiler Tray. This error represents a jam in the Finisher staple path. Applicable Status Code: Code FN7: Jam at Finisher Stapler Initial Actions: Cycle printer power. If the problem persists, follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References...
Page 100: Jam At Finisher Door G
Jam at Finisher Door G Jam detected in the saddle stitch path. Applicable Status Code: Code FN8: Jam at Finisher Door G Initial Actions: Cycle printer power. If the problem persists, follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Compiler Tray Options Map 7, Finisher Sensor Locator (1/2)
Page 101: Jam At Finisher Saddle Stapler
Jam at Finisher Saddle Stapler This error represents a jam in the Finisher staple path. Applicable Status Code: Code FN9: Jam at Finisher Saddle Stapler Initial Actions: Cycle printer power. If the problem persists, follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Compiler Tray...
Page 102: Jam At Finisher Upper Output Tray
Jam at Finisher Upper Output Tray Media remains in the Compiler Tray. This error represents a jam in the Finisher eject path. Applicable Status Code: Code FN10: Jam at Finisher Upper Output Tray Initial Actions: Cycle printer power. If the problem persists, follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References...
Page 103: Jam Inside Finisher
Jam Inside Finisher Media remains in the Inverter. These errors represent a jam in the Inverter path. Applicable Status Codes: Code: IN1: Media remains in the Inverter Lower Sensor. Code: IN2: Media remains in the Inverter Exit Sensor. Code: IN3: Media reached the Inverter Entrance Sensor, but did not reach the Inverter Exit Sensor on time.
Page 104: Jam At Finisher Entrance
Jam at Finisher Entrance Media remains in the Inverter Entrance Sensor. This error represents a jam in the Printer/Finisher interface. Applicable Status Codes: Code IN5: Media did not reach the Inverter Entrance Sensor following an Eject command from the printer. Code IN8: Media remains in the Inverter Entrance Sensor.
Page 105: Finisher Output Tray Jammed
Finisher Output Tray Jammed This error represents a failure of, or an obstruction in the Finisher Upper Output Tray’s up or down motion. Applicable Status Code: Code FT: Finisher Output Tray Jammed Initial Actions: Cycle printer power. If the problem persists, follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References...
Page 106 Troubleshooting Procedure Table (Continued) Step Actions and Questions Check for +24 V to the Shift Motor. Replace the Shift Replace the Disconnect CN6 from the Finisher Control Motor (page 5-59). Finisher Control Board. Board. If the error Is there +24 V CN6-1 <=> CN6-2? persists, go to Step 6.
Page 107: Close Right Door C For Tray [3][4][5][6]
Close Right Door C for Tray [3][4][5][6] The Door C Detect Sensor for one of the option trays indicates that Door C is open. Initial Actions: Ensure that the door is free of obstructions and fully closed. Verify that the Detect Sensor Actuator molded into the Door is not damaged. Cycle printer power.
Page 108: Close Left Door D
Close Left Door D The Door D Detect Sensor on the Duplex Unit indicates that Door D is open. Initial Actions: Ensure that the door is free of obstructions and fully closed. Verify that the Detect Sensor Actuator is not broken. Cycle printer power.
Page 109: Close Finisher Door F
Close Finisher Door F The Door F Interlock Switch indicates that Door F is open. Initial Actions: Ensure that the door is free of obstructions and fully closed. Verify that the actuator is not broken. Cycle printer power. If the problem persists, follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References...
Page 110: Close Finisher Door H
Close Finisher Door H The Upper Cover (Door H) Sensor indicates that Door H is open. Initial Actions: Ensure that the door is free of obstructions and fully closed. Verify that the actuator is not broken. Cycle printer power. If the problem persists, follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References...
Page 111: Close Finisher Door J
Close Finisher Door J The Front Cover (Door J) Sensor indicates that Door J is open. Initial Actions: Ensure that the door is free of obstructions and fully closed. Verify that the actuator is not broken. Cycle printer power. If the problem persists, follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References...
Page 112: Clear Tray [2][3][4][5][6] Riser Plate
Clear Tray [2][3][4][5][6] Riser Plate The Lift Motor failed to raise the media to the pre-feed position. For a Remove Paper error, the Level Sensor indicates Pre-Feed position or higher before a lift is executed Initial Actions: Remove the tray and inspect the tray cavity to ensure that it is free of obstructions or debris.
Page 113: Out Of Paper Load Tray [2][3][4][5][6] With [Size][Type]
Out of Paper Load Tray [2][3][4][5][6] with [size][type] The tray’s No Paper Sensor indicates the tray is empty. Initial Actions: Inspect the tray to ensure that it is free of obstructions, is loaded with supported media, and the guides are adjusted correctly. Cycle printer power.
Page 114: Finisher Lower Output Tray Is Full, Unload Paper
Finisher Lower Output Tray is Full, Unload Paper Initial Actions: Ensure that the output tray is empty and the actuator is in the correct position. Cycle printer power. If the problem persists, follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Saddle Stitch Bind Tray Options Map 7 Finisher Sensor Locator (1/2)
Page 115: Finisher Upper Output Tray Is Full, Unload Paper
Finisher Upper Output Tray is Full, Unload Paper Initial Actions: Ensure that the output tray is empty and the actuator is in the correct position. Cycle printer power. If the problem persists, follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Stack Full Sensor Options Map 7 Finisher Sensor Locator (1/2)
Page 116: Wrong Paper Size; Load Tray [3][4][5][6] With [Size][Type]
Wrong Paper Size; Load Tray [3][4][5][6] with [size][type] Tray [3] [4] [5] [6] paper size mismatch error. The Paper Size Switch indicates that the media loaded in the source tray does not match the size specified by the print job. Initial Actions: Inspect the tray to ensure that it is free of obstructions, is loaded with the expected media, and the guides are adjusted correctly.
Page 117: Wrong Paper Type Load Tray [3][4][5][6] With [Size][Type]
Wrong Paper Type Load Tray [3][4][5][6] with [size][type] The Media Thickness Sensor has detected a change in the media type (thickness) in the same tray, or reports a thickness value exceeding the reference. Initial Actions: Ensure the tray is free of obstructions and loaded with the expected media. Cycle printer power.
Page 118: Paper Not Available Load Tray [3][4][5][6] With [Size][Type]
Paper Not Available Load Tray [3][4][5][6] with [size][type] Tray [3] [4] [5] [6] paper type mismatch error. The Paper Size Switch indicates that the media loaded in the source tray does not match the size specified by the print job. Initial Actions: Inspect the tray to ensure that it is free of obstructions, is loaded with the expected media, and the guides are adjusted correctly.
Page 119: Duplex Interface Failure
Duplex Interface Failure Error occurs only after the detection of a properly installed and functioning Duplex Unit. Applicable Status Code: Code U12: Communication lost with Duplex Unit Initial Actions: Reseat the Duplex Unit Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References...
Page 120: Tray [3][4][5][6] Interface Failure
Tray [3][4][5][6] Interface Failure A communications failure has occurred in the option tray interface. Applicable Status Codes: Code U14: Tray 3 Interface Failure Code U13: Tray 4 Interface Failure Code U16: Tray 5 Interface Failure Code U17: Tray 6 Interface Failure Initial Actions: Cycle the printer's power.
Page 121: Inverter Unit Interface Failure
Inverter Unit Interface Failure A communication error has occurred in the Finisher Inverter. Applicable Status Code: Code U51: Inverter Unit Interface Failure. Initial Actions: Reseat the Finisher connections. Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References...
Page 122: Unsupported Duplex Unit Rom
Unsupported Duplex Unit ROM The installed Duplex Unit does not contain the correct firmware. Applicable Status Code: Code U34: Unsupported Duplex Unit ROM Initial Actions: Reseat the Duplex Unit. Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References...
Page 123: Unsupported Tray [3][4][5][6] Rom
Unsupported Tray [3][4][5][6] ROM The printer has detected an incompatible LTA or HCF assembly. Applicable Status Codes: Code U35: Unsupported Tray 3 ROM Code U36: Unsupported Tray 4 ROM Code U37: Unsupported Tray 5 ROM Code U38: Unsupported Tray 6 ROM Initial Actions: Reseat the Option Tray connector.
Page 124: Unsupported Inverter Unit Rom
Unsupported Inverter Unit ROM The printer has detected an incompatible Inverter assembly. Applicable Status Code: Code U50: Unsupported Inverter ROM Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Inverter Control Board Options Map 3 Inverter Controller Board Troubleshooting Procedure Table...
Page 125: Unsupported Finisher Unit Rom
Unsupported Finisher Unit ROM The printer has detected an incompatible Finisher. Applicable Status Code: Code U55: Unsupported Finisher Unit ROM Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Finisher Control Board Options Map 1 Finisher Controller Board Troubleshooting Procedure Table...
Page 126: Finisher Fold Position Sensor Failure
Finisher Fold Position Sensor Failure An error was detected with the Fold Position Sensor. Applicable Status Code: Code F131: Fold Position Sensor failure Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Fold Position Sensor...
Page 127: Finisher Paddle Failure
Finisher Paddle Failure An error was detected in the Finisher Paddle Motor. Applicable Status Code: Code F103: Paddle Motor failure Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Finisher Paddle Motor Options Map 1 Finisher Controller Board Finisher Control Board...
Page 128: Finisher Stapler Swing Motor Failure
Finisher Stapler Swing Motor Failure The Stapler Swing Home Position Sensor detected a Stapler Swing Motor error. Applicable Status Code: Code F106: Swing Motor Failure Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Stapler Swing Motor...
Page 129: Finisher Stack Handling Motor Failure
Finisher Stack Handling Motor Failure The Delivery Belt Home Position Sensor detected a Stack Handling error. Applicable Status Code: Code F111: Stack Handling Motor Failure Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Finisher Stack Handling Motor...
Page 130: Finisher Staple Motor Failure
Finisher Staple Motor Failure An error was detected in the Staple Motor. Applicable Status Code: Code F110: Staple Motor Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Finisher Staple Motor Options Map 1 Finisher Controller Board Finisher Control Board...
Page 131: Finisher Jog Motor Failure
Finisher Jog Motor Failure An error was detected in either the Front or Rear Alignment Motor. Applicable Status Code: Code F93: Jog Motor Failure Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Paddle Assembly...
Page 132: Finisher Lift Motor Failure
Finisher Lift Motor Failure The Paper Surface, Upper Limit, or Lift Motor Clock Sensor detected a Lift Motor error. Applicable Status Code: Code F115: Lift Motor Failure Initial Actions: Check the Tray lift mechanism for obstructions or damage. Cycle the printer's power. If the problem persists follow the procedure below.
Page 133 Troubleshooting Procedure Table (Continued) Step Actions and Questions Check all pins of the Inverter Interface Replace the Inverter Replace the cable. Cable for continuity. Power Supply Disconnect CN1 and CN2 from the Finisher (page 5-56). Control Board and the opposite end from the Inverter.
Page 134: Finisher Exit Failure
Finisher Exit Failure The Delivery Belt Home Position Sensor detected a Delivery Motor error. Applicable Status Code: Code F116: Delivery Motor Failure Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Finisher Delivery Motor Options Map 1 Finisher Controller Board...
Page 135: Finisher Punch Backup Ram Failure
Finisher Punch Backup RAM Failure An error was detected in the Punch Unit’s backup RAM. Applicable Status Code: Code F138: Punch Unit’s backup RAM failure Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Punch Control Board...
Page 136: Finisher Punch Communications Failure
Finisher Punch Communications Failure An communications error occurred with the Punch Unit. Applicable Status Code: Code F132: Punch Unit communications failure Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Finisher Control Board Print Engine Motor Driver Board (6/6) (see Book 1)
Page 137: Finisher Punch Unit Transfer Motor Failure
Finisher Punch Unit Transfer Motor Failure An error was detected in the Punch Transfer Motor. Applicable Status Code: Code F181: Punch Transfer Motor Failure Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Punch Transfer Motor...
Page 138: Finisher Punch Motor Failure
Finisher Punch Motor Failure An error was detected in the Punch Motor. Applicable Status Code: Code F134: Punch Motor Failure Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Punch Motor Options Map 2 Punch Controller Board Punch Control Board...
Page 139: Finisher Backup Ram Failure
Finisher Backup RAM Failure An error was detected in the Finisher’s backup RAM. Applicable Status Code: Code F137: Finisher’s backup RAM Failure Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Finisher Control Board Print Engine Motor Driver Board (6/6) (see Book 1)
Page 140: Finisher Punch Dust Sensor Failure
Finisher Punch Dust Sensor Failure An error was detected in the Punch Waste Sensor. Applicable Status Code: Code F139: Punch Waste Sensor Failure Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Punch Box Sensor Emitter Board...
Page 141 Troubleshooting Procedure Table (Continued) Step Actions and Questions Replace the Finisher Control Board Replace the Complete. (page 5-46). Engine Control Does the error still occur? Board (see Book General Troubleshooting 3-67...
Page 142: Printer Error - Contact Service; Report Fault [N]
Printer Error - Contact Service; report fault [n] The following procedures apply to codes associated with the Printer Error message. Finisher Punch Unit Counter at End of Life The Punch Count indicates that Punch Unit has reached its end of life. Applicable Status Code: Code F141: Punch Unit at End of Life...
Page 143: Finisher Staple Unit Counter At End Of Life
Finisher Staple Unit Counter at End of Life Applicable Status Code: Code F142: Staple Unit at End of Life Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Stapler Options Map 1 Finisher Controller Board Options Finisher Controller to Printer...
Page 144: Finisher Interface Error
Finisher Interface Error Applicable Status Code: Code F186: Finisher serial communications error. Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Finisher Control Board Print Engine Motor Driver Board (6/6) (see Book 1) Finisher Interconnect Cable Options Map 1 Finisher Controller Board Engine Control Board...
Page 145: Inverter Power Supply Failure
Inverter Power Supply Failure Applicable Status Code: Code I97: Inverter hardware error Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Inverter Power Supply Options Map 3 Inverter Controller Board Options Inverter Motors Troubleshooting Procedure Table Step Actions and Questions...
Page 146: Tray [3][4][5][6] Firmware Error
Tray [3][4][5][6] Firmware Error Applicable Status Codes: Code 221: Software error in Tray 3 Flash Memory. Code 222: Software error in Tray 4 Flash Memory. Code 223: Software error in Tray 5 Flash Memory. Code 224: Software error in Tray 6 Flash Memory. Initial Actions: Cycle the printer's power.
Page 147: Duplex Unit Firmware Error
Duplex Unit Firmware Error Applicable Status Code: Code 225: A firmware error with the Duplex Unit. Initial Actions: Reseat the Duplex Unit Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Duplex Unit Print Engine Map 5 (see Book 1) Motor Driver Board...
Page 148: Finisher Inverter Firmware Error
Finisher Inverter Firmware Error Applicable Status Code: Code 227: A software error with the Inverter’s Flash Memory. Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Inverter Control Board Print Engine Map 3 (see Book 1) Print Engine Motor Driver Board (6/6) (see Book 1)
Page 149: Tray [3][4][5][6] Flash Memory Failure
Tray [3][4][5][6] Flash Memory Failure Applicable Status Codes: Code 242: Hardware error in Tray 3 Flash Memory. Code 243: Hardware error in Tray 4 Flash Memory. Code 244: Hardware error in Tray 5 Flash Memory. Code 245: Hardware error in Tray 6 Flash Memory. Initial Actions: Cycle the printer's power.
Page 150: Duplex Unit Flash Memory Failure
Duplex Unit Flash Memory Failure Applicable Status Code: Code 246: Hardware failure with Duplex Unit Flash Memory. Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Duplex Unit Print Engine Map 5 (see Book 1) Motor Driver Board...
Page 151: Finisher Inverter Flash Memory Failure
Finisher Inverter Flash Memory Failure Applicable Status Code: Code 225: Hardware failure with Inverter Flash Memory. Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Inverter Control Board Options Map 3 Inverter Controller Board Troubleshooting Procedure Table Step Actions and Questions...
Page 152: Tray [3][4][5][6] Lift Motor Failure
Tray [3][4][5][6] Lift Motor Failure Applicable Status Codes: Code 911: The Tray 3 Lift Motor is not rotating. Code 912: The Tray 4 Lift Motor is not rotating. Code 913: The Tray 5 Lift Motor is not rotating. Code 914: The Tray 6 Lift Motor is not rotating.
Page 153 Troubleshooting Procedure Table (Continued) Step Actions and Questions Check for +24 V at OPTRY24. Replace the Go to Step 5. affected Option 1. Close the Interlock Switches. Control Board. 2. Disconnect OPTRY24. Is there +24 V at OPTRY24-1 and -2 <=> ground? Check all pins on the OPTRY24 Harness Go to Step 6.
Page 154: Duplex Unit Fan Failure
Duplex Unit Fan Failure The Duplex Fan rotation signal indicates the Duplex Fan has stopped rotating. Applicable Status Code: Code 918: The Duplex Fan has failed. Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References...
Page 155: +24V Not Available To The Duplex Unit
+24V Not Available to the Duplex Unit Abnormal current indicates that +24 V is not being supplied to the Duplex Unit. Applicable Status Code: Code 225: Duplex Unit is not receiving +24 V. Initial Actions: Reseat the Duplex Unit. Cycle the printer's power. If the problem persists follow the procedure below.
Page 156 Troubleshooting Procedure Table (Continued) Step Actions and Questions Check the LVPS +24 V output. Go to Step 6. Replace the LVPS (see book 1). 1. Close the Interlock Switches. 2. Disconnect CN2. Is there +24 V at CN2-1 and <=> ground? Check all pins of the DRV1 harness for Replace the Engine Replace the DRV1...
Page 157: Not Available To Tray [3][4][5][6]
+24 V Not Available to Tray [3][4][5][6] Voltage detection indicates that +24 V is not available to the indicated option tray. Applicable Status Codes: Code 924: Tray 3 not receiving +24 V Code 925: Tray 4 not receiving +24 V Code 926: Tray 5 not receiving +24 V Code 927:...
Page 158: Duplex Unit Clock Frequency Error
Duplex Unit Clock Frequency Error The clock frequency for the Duplex Unit Control Board CPU is inaccurate. Applicable Status Code: Code 931: The Duplex Unit’s CPU clock frequency is inaccurate. Initial Actions: Reseat the Duplex Unit. Cycle the printer's power. If the problem persists follow the procedure below.
Page 159: Finisher Inverter Clock Frequency Error
Finisher Inverter Clock Frequency Error The clock frequency for the Inverter Control Board CPU is inaccurate. Applicable Status Code: Code 932: The Inverter’s CPU clock frequency is inaccurate. Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References...
Page 160: Tray [3][4][5][6] Feeder Board Clock Frequency Error
Tray [3][4][5][6] Feeder Board Clock Frequency Error The clock frequency on the indicated Feeder Board is inaccurate. Applicable Status Codes: Code 933: Tray 3 Feeder Board CPU clock frequency is inaccurate. Code 934: Tray 4 Feeder Board CPU clock frequency is inaccurate. Code 935: Tray 5 Feeder Board CPU clock frequency is inaccurate.
Page 161: No Paper In Tray [2][3][4][5][6]
No Paper in Tray [2][3][4][5][6] The No Paper Sensor indicates that the named tray is empty. Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References No Paper Sensor Print Engine Map 12 (see Book 1) No Paper Actuator Print Engine Feeder Board (see Book 1)
Page 162: Staple Cartridge Is Empty
Staple Cartridge Is Empty The Stapler Self-Prime Sensor in the Staple Cartridge indicates no staples remain. Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Stapler Self-Prime Sensor Options Map 1 Finisher Controller Board Finisher Control Board Troubleshooting Procedure Table...
Page 163: Punch Waste Box Is Full Or Missing
Punch Waste Box is Full or Missing The Punch Box Sensor indicates the Punch Box is full or not installed in the Finisher. Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Punch Box Sensor Emitter Board...
Page 164: Finisher Away From Base
Finisher Away From Base The Finisher Switch indicates that the Finisher is detached from the Inverter. Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Joint Switch Options Map 7 Finisher Sensor Locator Finisher Control Board Options Finisher Controller to Switches...
Page 165: Finisher Away From Printer
Finisher Away From Printer The Inverter Docking (Joint) Switch indicates that the Finisher is detached from the printer. Initial Actions: Cycle the printer's power. If the problem persists follow the procedure below. Troubleshooting Reference Table Applicable Parts Wiring and Plug/Jack References Inverter Docking Sensor Options Map 9 Inverter Sensor Locator Inverter Control Board...
Page 166 3-92 Phaser 7400 Color Printer Options Service Manual...
Page 167: Adjustments And Calibrations
Adjustments and Calibrations In this chapter... Punch Unit Adjustments Staple Unit Adjustments Saddle Unit Adjustments Section...
Page 168: Punch Unit Adjustments
Punch Unit Adjustments Registering Punch Holes Perform the following steps to identify the type of punch unit and associated number of punch holes. The Punch Controller Board uses this switching information to identify and register the finisher type whenever you replace the board. To register the punch holes: Locate DIP switches SW1001, SW1002, and SW1003 and LEDs LED1001, LED1002, and LED1003 on the Punch Controller Board.
Page 169 Press Switch SW1002 on the Punch Controller Board to select the appropriate number of punch holes. Each press on SW1002 moves the selection through the following (repeatedly from top to bottom). Number of punch holes LED1001 LED1002 LED1003 2 holes (punch Unit-J1) 2/3 holes (punch Unit-K1) 4 holes (punch Unit-G1) 4 holes (punch Unit-H1)
Page 170: Adjusting Sensor Output After Sensor Replacement
Adjusting Sensor Output After Sensor Replacement Perform the following steps whenever you replace the Punch Controller Board, horizontal registration sensor (photosensor board/LED board), or waste full sensor (waste full photosensor board/waste full LED board): Locate DIP switches SW1001, SW1002, and SW1003 and LEDs LED1001, LED1002, and LED1003 on the Punch Controller Board.
Page 171: Adjusting Sensor Output After Ee-Prom Replacement
Adjusting Sensor Output After EE-PROM Replacement To adjust the sensor output after replacing the EE-PROM, use the following steps: Turn off the Phaser 7400 Color Printer. Locate DIP switches SW1001, SW1002, and SW1003 and LEDs LED1001, LED1002, and LED1003 on the Punch Controller Board. J1007 SW1001 SW1002...
Page 172: Stapler Unit Adjustments
Stapler Unit Adjustments Adjusting the Saddle Stitch Double Stapling Position To adjust the stapling position for middle 2-point stapling, you must match it with the folding position. If you have replaced the Finisher Controller Board, you must transfer the existing settings to the new board. Note Both the folding and stapling positions may vary for some types of paper.
Page 173: Adjusting The Stapler Phase
Press switches PSW1 or PSW2 on the Finisher Controller Board as necessary to move the stapling position to the proper location (pressing the switch once moves the stapling position about 0.14 mm): To move the stapling position in the "-" direction, press switch PSW1. To move the stapling position in the "+"...
Page 174 Remove the E-ring to detach the side cover of the staple clincher. Staple Clincher Side Cover Gear Cover Staple Driver s7400-203 Remove the two E-rings to remove the staple jam releasing gear, timing belt, and relay gear 1. Remove the spacer and spring at the back of the staple jam releasing gear.
Page 175 Remove the screw to remove the belt tensioner from its mounting post (also remove the spring). Staple Jam Releasing Gear Timing Belt Relay Gear 1 Belt Tensioner s7400-204 Remove the timing belt. Adjustments and Calibrations...
Page 176 Remove the E-ring to remove the staple position check gear. Staple Position Check Gear E-Ring Timing Belt s7400-205 4-10 Phaser 7400 Color Printer Options Service Manual...
Page 177 Turn the gear to align the round hole in the staple driver gear with the round hole at the back. Gear Staple Clincher Staple Driver Staple Driver Gear Hole s7400-206 Adjustments and Calibrations 4-11...
Page 178 Insert a pin with a diameter of approximately 2 mm (use recommended diameter size) in the round hole to secure the gear. Staple Clincher s7400-207 4-12 Phaser 7400 Color Printer Options Service Manual...
Page 179 Turn the gear to align the round hole in the staple clincher cam with the round hole at the back. Gear Staple Clincher Staple Clincher Cam Hole s7400-208 Adjustments and Calibrations 4-13...
Page 180 Insert a pin with a diameter of approximately 2 mm (use of a 2 mm Allen wrench as recommended) in the round hole to secure the gear. Staple Clincher Cam s7400-209 With the gears and cam fixed, install the timing belt on the gears. Gear Timing Belt Gear...
Page 181 Mount the staple position check gear so that the blue mark on the staple position check gear is aligned with the round hole in the frame. Reinstall the E-ring on the gear. Caution It is necessary to mount the gear at the correct position. The position where the blue mark aligns with the round hole is the home position for stapling.
Page 182 Assemble the spring, spacer, staple jam releasing gear, timing belt, and relay gear. Secure them with the E-ring. Spring Timing Belt Relay Gear Spacer E-Ring Staple Jam Releasing Gear s7400-212 Replace the front cover and two knobs and reinstall the Stapler Unit. 4-16 Phaser 7400 Color Printer Options Service Manual...
Page 183: Saddle Unit Adjustments
Saddle Unit Adjustments Adjusting the Folding Position If you replace the Finisher Controller Board, you must match the folding position to the stapling position. Perform the following steps: Locate DIP switch SW1 on the Finisher Controller Board. CN13 CN18 CN10 LED3 LED1 LED2...
Page 184: Adjusting The Phase Of The Saddle Unit Gear
After adjusting the folding position, set all bits of SW1 on the Finisher Controller Board to OFF (this action will ensure that the switch will no longer affect the settings). Enter the booklet mode of the printer and check whether the folding position is adjusted properly.
Page 185 With the paper fold rollers and saddle cam positioned as shown in the proceeding figure, mount gears as shown in the following figure. Align the mark (either one of the two marks) on the saddle cam drive gear with the mark on the relay gear. The relay gear is located on the half of the periphery where gears with a smaller face width are arranged).
Page 186 4-20 Phaser 7400 Color Printer Options Service Manual...
Page 187: Service Parts Disassembly
Service Parts Disassembly In this chapter... General Notes on Disassembly Overview Finisher Disassembly Inverter Disassembly Duplex Unit Disassembly Optional Paper Tray Disassembly Section...
Page 188: Overview
Overview This section contains the removal and replacement procedures for selected parts of the printer options package according to the Field Replaceable Units (FRUs) Parts List. Not all replacement procedures are included in this Service Manual. In most cases, to reinstall a part, simply reverse the removal procedure shown. In some instances, replacement notes are included providing special steps.
Page 189: Notations In The Disassembly Text
Notations in the disassembly text The notation “(item X)” points to a numbered callout in the illustration corresponding to the you disassembly procedure being performed. The notation “PLX.X.X” indicates that this component is listed in the FRU Parts List. Bold arrows in an illustration show direction of movement when removing or replacing a component.
Page 190: Standard Orientation
Standard Orientation When needed the orientation of the option is called out in the procedure for locating parts, refer to the orientation graphic for locating the right, left, front and back sides of the printer. Left Back Front Right s7400-339 Phaser 7400 Color Printer Options Service Manual...
Page 191: Finisher Disassembly
Finisher Disassembly The Finisher disassembly is presented in the following categories: Base Unit and Inverter Tray and Covers Subassemblies Field Replaceable Units Removing Inverter Base Unit from Finisher Release the hook attaching the Finisher to the Base Unit. Remove the two screws (metal, 6 mm) securing the Base Unit to the Finisher. Lift the Finisher from the four slots on the Base Unit.
Page 192: Undocking Inverter From Printer
Undocking Inverter from Printer Slide out the bar on the bottom of the Finisher Base Unit. Remove two screws (metal, 6 mm) holding the Inverter to the printer. Remove guide pins. Slide Inverter away from the printer. s7400-528 Phaser 7400 Color Printer Options Service Manual...
Page 193: Trays And Covers
Trays and Covers Paper Exit Tray Remove four screws (metal, 6 mm) and detach the Paper Exit Tray. Paper Tray s7400-527 Service Parts Disassembly...
Page 194: Front Door (Door J)
Front Door (Door J) Open the Front Door. Remove two screws (metal, 6 mm). While squeezing the plastic hooks, remove the fold jam release knob. Hooks Fold Jam Releasing Dial s7400-160 Press the release latch and slide the finisher away from the Finisher Base Unit. Phaser 7400 Color Printer Options Service Manual...
Page 195 To detach the Front Door, remove four screws (metal, 6 mm), pull the right side of the cover away from the Finisher, and then slide the cover to the left (moving the guide tab out of the slot on the cover). Front Door s7400-161 Service Parts Disassembly...
Page 196: Right Side Door (Door G)
Right Side Door (Door G) For diagnostic purposes, you may be instructed to open or close the Right Side Door on the Finisher. The illustration below identifies the location of the Right Side Door (Door G). Finisher Right Side Door (Door G) s7400-719 5-10 Phaser 7400 Color Printer Options Service Manual...
Page 197: Rear Cover
Rear Cover Remove the Paper Exit Tray (page 5-7). Press the release latch and slide the Finisher away from the base. Detach the cable from the Finisher to the Inverter (at the rear of the Finisher). s7400-697 Service Parts Disassembly 5-11...
Page 198 Remove two screws (metal, 6 mm) on the left side of the rear cover. Rear Cover Rear Cover s7400-162 Remove one screw (metal, 6 mm) on the right side of the rear cover. Slide the Rear Cover towards the right side of the Finisher and remove. 5-12 Phaser 7400 Color Printer Options Service Manual...
Page 199: Upper Cover (Door H)
Upper Cover (Door H) Remove the Paper Exit Tray (page 5-7). Remove the Rear Cover (page 5-11). Open the Upper Cover and turn the stopper strap retainer clip counter-clockwise, then remove the strap from the cover. Upper Cover Retainer Clip Stopper Strap s7400-163 Remove the screw (metal, 6 mm) and detach the Processing Tray Rear Cover.
Page 200 Detach the Upper Cover. Upper Cover Processing Tray Rear Cover s7400-164 5-14 Phaser 7400 Color Printer Options Service Manual...
Page 201: Processing Tray Upper Cover
Processing Tray Upper Cover Remove the Paper Exit Tray (page 5-7). Remove the Rear Cover (page 5-11). Remove the Upper Cover. (page 5-13). Disconnect the top end of the cable from the connector and free the cable from the harness. Remove the single screw (metal, 6 mm) holding the tray to the chassis.
Page 202 While lifting the Processing Tray Upper Cover, disconnect the other end of the cable from the connector underneath the tray. Replacement Note When replacing or reconnecting the connector, be sure the connection is firm and secure. Otherwise, you will receive a Paddle Motor error. Processing Tray Upper Cover Connector s7400-166...
Page 203: Inverter Front Covers
Inverter Front Covers Remove the Inverter and base unit from the Finisher (page 5-5). Press the release latch and slide the Finisher away from the printer. Remove two screws (metal flange, 10 mm) holding the Lower Front Cover to the chassis.
Page 204 Remove two screws (metal flange, 10 mm) from the left side and two screws from the right side of the Upper Front Cover. Remove one screw (metal flange, 10 mm) from the bottom of the Upper Front Cover. Carefully move the Finisher release latch out of the slot and remove the Upper Front Cover.
Page 205: Inverter Rear Covers
Inverter Rear Covers Remove the Inverter and base unit from the Finisher (page 5-5). Press the release latch and slide the Finisher away from the printer. Remove two screws (metal flange, 10 mm) holding the Lower Rear Cover to the chassis.
Page 206 Release the cover from the four tabs holding the cover to the frame. Pull the cover away from the frame. This will expose the boards, motors, and clutch units. Inverter Right Side Door (Door I) Upper Rear Cover s7400-490 5-20 Phaser 7400 Color Printer Options Service Manual...
Page 207: Inverter Left Side Door (Door F)
Inverter Left Side Door (Door F) For diagnostic purposes, you may be instructed to open or close the Left Side Door on the Inverter. The illustration below identifies the location of the Inverter Left Side Door (Door F). Inverter Left Side Door (Door F) s7400-718 Service Parts Disassembly 5-21...
Page 208: Inverter Right Side Door (Door I)
Inverter Right Side Door (Door I) For diagnostic purposes, you may be instructed to open or close the Right Side Door on the Inverter. The illustration below identifies the location of the Right Side Door (Door I). Inverter Right Side Door (Door I) Upper Rear Cover s7400-490 5-22...
Page 209: Inverter Top Cover
Inverter Top Cover Remove the Inverter and base unit from the Finisher (page 5-5). Remove the Inverter Front Covers (page 5-17). Remove the Inverter Rear Covers (page 5-19). Remove two black screws (self-tapping, 6 mm) on each side of the cover. Lift the cover up and away from the chassis.
Page 210: Units
Units Punch Unit The steps in this procedure show you how to remove the Punch Unit. Boss Hole Boss Boss Hole Boss Screw Punch Module Screw Screw (With Rosette) (Supplied With This Module) s7400-103 Remove the Paper Exit Tray (page 5-7). Remove the Front Door (page 5-8).
Page 211 Remove the screw (self-tapping, plastic 10 mm) to detach the Jam Processing Cover. Jam Processing Cover s7400-256 Service Parts Disassembly 5-25...
Page 212 Disconnect the connector. and remove the harness from the harness guide. Connector Harness Guide s7400-257 Remove the screw (metal flange, 6 mm) and Sensor Support Plate. From the left side view, disconnect the sensor connector. Connector Sensor Support Plate s7400-258 5-26 Phaser 7400 Color Printer Options Service Manual...
Page 213 Remove one screw (metal flange, 6 mm) and washer. Disconnect the connector (from the underside of the unit) and then the assembly. Remove the two screws (self-tapping, plastic 10 mm) to detach the base cover. Base Cover Connector s7400-259 Service Parts Disassembly 5-27...
Page 214 Remove the three screws (metal flange, 6 mm) to remove the Upper Transmission Sensor Unit and the Lower Transmission Sensor. Upper Transmission Sensor Unit Lower Transmission Sensor s7400-260 Remove the Punch Unit from the Finisher Punch Transfer Motor assembly. Finisher Punch Transfer Motor Assembly Punch Unit s7400-261 5-28...
Page 215: Staple Unit
Staple Unit Open the Front Door to gain access to the Staple Unit. Slide out the Staple Unit while pressing the stopper. Note Do not remove the Stapler Frame Shaft. If removed, the position where the staple driver (lower unit of the stapler) inserts the staple through the paper will shift from the position where the staple clincher (upper unit of the stapler) clinches staples.
Page 216: Staple/Fold Drive Unit
Staple/Fold Drive Unit Note The references indicate the connector on the Finisher Controller Board. Remove the Front Door (page 5-8) and slide out the Stapler Unit to the front. Remove the Rear Cover (page 5-11). Remove the screw (metal flange, 6 mm) and detach the Interface Retainer. Free the seven harness retainers, and disconnect the cable to connector CN18.
Page 217 Disconnect the cable connector (to CN10) behind the Punch Unit. Slide the Finisher away from the Inverter and then free the harness. Free the harness from the Edge Saddle and disconnect the two connectors (to CN18). Connector Edge Saddle s7400-227 Remove the two screws (metal flange, 6 mm), free the tab of the harness guide, and remove all connectors to clear the harness guide.
Page 218 Disconnect the connector to CN8 and the connector to CN6, and free the harness from the Edge Saddle. CN71 CN52 Edge Saddle s7400-229 Staple/Fold Motor Staple/Fold Clock Sensor 5-32 Phaser 7400 Color Printer Options Service Manual...
Page 219 Remove the five screws (metal, 10 mm), lift to free two hooks (one on each side, and remove the unit. Staple/Fold Drive Unit s7400-230 Service Parts Disassembly 5-33...
Page 220: Saddle Unit
Saddle Unit Remove the Paper Exit Tray (page 5-7). Remove the Front Door (page 5-8). Remove the Rear Cover (page 5-11). Open the Jam Removal Cover (Door I) and remove two screws (metal, 10mm) and the right stay. Turn the Fold Jam Releasing Dial Assembly to move the Paper Retaining Plate Assembly to the inside.
Page 221 Remove the Stop Ring and detach the Timing Belt. Stop Ring Timing Belt Connectors s7400-216 Disconnect the two connectors. Service Parts Disassembly 5-35...
Page 222 Remove the three screws (metal, 10mm) and slide out the Stapler Unit slightly to the front and remove the Saddle Unit. Stapler Unit Saddle Unit s7400-217 5-36 Phaser 7400 Color Printer Options Service Manual...
Page 223: Assemblies
Assemblies Upper Right Cover Assembly Remove the Front Door (page 5-8). Remove the Rear Cover (page 5-11). Remove two screws (metal, 6 mm) at the front and two screws at the rear of the assembly. Detach the assembly and lift up to remove. Upper Right Cover Assembly s7400-167 Service Parts Disassembly...
Page 224: Processing Tray Assembly
Processing Tray Assembly Remove the Processing Tray Upper Cover (page 5-15). Remove the Upper Right Cover Assembly (page 5-37). Remove the Side Guide (page 5-107). Remove the two screws (metal, 10 mm) and disconnect the following four connectors: CN36 to Clutch CN85 to Rear Alignment Motor CN63 to Front Alignment Motor CN57 to Delivery Motor...
Page 225 Pull the Processing Stopper Base to the front and free the hooks at the front and rear of the Processing Stopper. Hook Hook Processing Stopper Processing Stopper Processing Stopper Base s7400-219 Service Parts Disassembly 5-39...
Page 226 Release the two hooks of the harness retainer, remove three connectors and detach the motor harness. Motor Harness Hooks Connectors s7400-220 5-40 Phaser 7400 Color Printer Options Service Manual...
Page 227 Remove the Stop Ring and detach the Timing Belt. Caution A free-floating pin is inserted in the gear shaft that can easily fall into the chassis. Be careful when loosening or removing the belt from the gear. Disconnect the connector and free the harness from the Edge Saddle. Free-floating Pin Connector Timing Belt...
Page 228 Remove the two screws (metal flange, 6 mm), slide the Processing Tray Assembly to the rear, then lift it to detach. Caution Note the inset in the illustration below to find two screws on the chassis side holding the tray to the unit. You must remove these screws before you can free the unit.
Page 229: Paddle Assembly
Paddle Assembly Remove the Processing Tray Assembly (page 5-38). Place the assembly as shown. Caution Be sure to take care not to damage the aligning plates. Paddle Assembly Aligning Plates s7400-223 Service Parts Disassembly 5-43...
Page 230 Detach the Timing Belt and remove the two screws (metal flange, 6 mm). Timing Belt s7400-224 5-44 Phaser 7400 Color Printer Options Service Manual...
Page 231 Separate the Processing Tray Assembly and the Paddle Assembly as shown. Processing Tray Assembly Paddle Assembly s7400-225 Service Parts Disassembly 5-45...
Page 232: Boards
Boards Finisher Controller Board Remove the Rear Cover (page 5-11). Disconnect the 17 connectors and remove the screw (metal flange, 6 mm). Free the board retainer and detach the Finisher Controller Board. CN13 CN10 Board Retainer CN14 CN12 CN19 CN16 CN15 CN17 CN11...
Page 233: Home Position Board
Home Position Board Remove the Rear Cover (page 5-11). Remove the Front Door (page 5-8). Remove the Upper Cover (page 5-13). Open the Front Door and turn the knob on the stapler slide in the direction of the arrow to slide the stapler to the front-most position. Remove the Stapler Unit (page 5-108).
Page 234 Turn the knob on the stapler side in the direction of the arrow so that the fixing screw (metal, 10 mm) of the Slide Home Position Board is in view through the round hole. Slide Home Position PCB Fixing Screw s7400-252 Remove the fixing screw (metal, 10mm).
Page 235 Disconnect the connector. Remove the flexible cable retainer. Free the lock of the connector in the direction of the arrow, and then detach the flexible cable. Connector Lock Connector Flexible Cable Slide Home Position PCB Flexible Cable Retainer s7400-253 Detach the board. Service Parts Disassembly 5-49...
Page 236: Punch Control Board
Punch Control Board Remove the Rear Cover (page 5-11). Remove the Front Door (page 5-8). Remove the Upper Cover (page 5-13). Remove the two screws (metal flange, 6 mm). Disconnect the five connectors to remove the Punch Control Board. Punch Controller Board s7400-262 5-50 Phaser 7400 Color Printer Options Service Manual...
Page 237: Photo Sensor Board
Photo Sensor Board Remove the Rear Cover (page 5-11). Remove the Front Door (page 5-8). Remove the Upper Cover (page 5-13). Remove the Punch Motor Assembly (page 5-46). Remove the screw (metal flange, 6 mm). Remove the harness from the harness guide on the board, and then detach the cover.
Page 238 Disconnect the connector to remove the Photosensor Board. Photosensor Board Connector s7400-264 5-52 Phaser 7400 Color Printer Options Service Manual...
Page 239: Punch Led Board
Punch LED Board Remove the Rear Cover (page 5-11). Remove the Front Door (page 5-8). Remove the Upper Cover (page 5-13). Remove the Waste Case Box. Disconnect the connector. Remove the harness from the harness guide. Remove the metal screw (metal flange, 6 mm). Remove the screw (metal flange, 6 mm) to detach the base cover.
Page 240: Waste Full Led Board
Waste Full LED Board Remove the Rear Cover (page 5-11). Remove the Front Door (page 5-8). Remove the Upper Cover (page 5-13). Remove the screw (metal flange, 6 mm). Disconnect the connector to remove the board. Connector Waste-Full LED Board s7400-268 5-54 Phaser 7400 Color Printer Options Service Manual...
Page 241: Inverter Controller Board
Inverter Controller Board Remove the Inverter and base unit from the Finisher (page 5-5). Remove the Inverter Rear Covers (page 5-19). Disconnect all cables. Replacement Note It is a good idea to label all connectors to make sure that you replace each one in its proper plug during reassembly.
Page 242: Inverter Power Supply Board
Inverter Power Supply Board Remove the Inverter and base unit from the Finisher (page 5-5). Remove the Inverter Rear Covers (page 5-19). Remove the Inverter Controller Board (page 5-55). Disconnect all cables. Replacement Note It is a good idea to label all connectors to make sure that you replace each one in its proper plug during reassembly.
Page 243: Motors, Clutches, And Solenoids
Motors, Clutches, and Solenoids Punch Motor Remove the Rear Cover (page 5-11). Remove the Front Door (page 5-8). Remove the Upper Cover (page 5-13). Disconnect the connector J002 on the Punch Motor. Remove the two metal screws (metal flange, 6 mm) securing the motor to the chassis.
Page 244: Finisher Punch Transfer Motor
Finisher Punch Transfer Motor Remove the Rear Cover (page 5-11). Remove the Front Door (page 5-8). Remove the Upper Cover (page 5-13). Disconnect connector to the motor. Remove the harness from the harness guide. To remove the Finisher Punch Transfer Motor from the Punch Unit, remove the two metal screws (metal flange, 6 mm) securing the motor to the chassis and lift out.
Page 245: Lift Motor
Lift Motor Remove the Paper Exit Tray (page 5-7). Remove the Rear Cover (page 5-11). Remove the Upper Cover (page 5-13). Remove the Side Guide (page 5-107). Remove three screws (metal, 6 mm) from the Lift Motor cover box. Disconnect connector CN 70 from the cover box and motor, then lift the cover box (which includes motor and gear assembly) free from the chassis.
Page 246: Staple/Fold Motor
Staple/Fold Motor Remove the Paper Exit Tray (page 5-7). Remove the Rear Cover (page 5-11). Remove the Staple/Fold Drive Unit (page 5-30). Disconnect connector CN71 from the motor. Face the drive unit toward you and remove two screws (metal, 6 mm) holding the motor to the Staple/Fold Drive Unit.
Page 247: Slide Motor
Slide Motor Remove the Paper Exit Tray (page 5-7). Remove the Rear Cover (page 5-11). Remove the Staple Unit (page 5-29). With the Staple Unit facing you, disconnect connector CN72 from the motor. Slide the belt off of the motor gear. Remove two screws (metal, 4 mm) holding the motor to the Staple Unit.
Page 248: Feed Motor
Feed Motor Remove the Front Door(page 5-8). Remove the Rear Cover (page 5-11). Remove the Punch Unit (page 5-50). Open the harness retainer and disconnect the cable from connector CN56. Remove two small screws (metal flange, 6 mm) and detach the Feed Motor Unit. Feed Motor CN56 s7400-231...
Page 249: Paddle Motor
Paddle Motor Remove the Paper Exit Tray (page 5-7). Remove the Rear Cover (page 5-11). Remove the Upper Cover (page 5-13). Disconnect connector CN57 from motor wiring. Paddle Motor s7400-674 To remove the motor, remove two screws (metal, 6 mm), and list the unit free from the chassis.
Page 250: Delivery Motor
Delivery Motor Remove the Paper Exit Tray (page 5-7). Remove the Rear Cover (page 5-11). Remove the Side Guide (page 5-107). Refer to the illustration below to locate the Delivery Motor. Delivery Motor CN59 s7400-698 Slide the belt off of the motor gear. To remove the motor, first remove the 6-wire connector CN59 from the motor, and then remove two small screws (metal, 4 mm) holding the motor to the chassis.
Page 251: Alignment (Front And Rear) Motors
Alignment (Front and Rear) Motors Remove the Paper Exit Tray (page 5-7). Remove the Front Door (page 5-8). Remove the Rear Cover (page 5-11). Remove the Upper Cover (page 5-13). Remove the Side Guide (page 5-107). Refer to the illustration below to locate both Alignment Motors. Rear Alignment Motor Front Alignment Motor CN65...
Page 252: Binding Clutch
Binding Clutch Remove the Paper Exit Tray (page 5-7). Remove the Rear Cover (page 5-11). Remove the Staple/Fold Drive Unit (page 5-30). With Staple/Fold unit out of the way, you can now disconnect connector CN72 from the clutch. Remove the k-clips from the gear assembly of the clutch. Slide the belt off of the clutch gear.
Page 253: Inverter Upper Roller Motor
Inverter Upper Roller Motor Remove the Inverter and base unit from the Finisher (page 5-5). Remove the Inverter Rear Covers (page 5-19). Disconnect the 4-wire cable from the Inverter Controller Board connector labeled Motor_B. Be sure to lift the cable harness out of the cable guides. Remove one screw (metal flange, 6 mm) from the upper right (and its anti-vibration spring) and one screw from the lower left of the motor.
Page 254: Inverter Lower Roller Motor
Inverter Lower Roller Motor Remove the Inverter and base unit from the Finisher (page 5-5). Remove the Inverter Rear Covers (page 5-19). Disconnect the 4-wire cable from the inverter controller board connector labeled Motor_A. Be sure to lift the cable harness out of the cable guides. Remove the Inverter Controller Board (page 5-55).
Page 255: Inverter Feeder Clutch
Inverter Feeder Clutch Remove the Inverter and base unit from the Finisher (page 5-5). Remove the Inverter Rear Covers (page 5-19). Remove the Inverter Top Cover (page 5-23). Disconnect the two-wire connector from connector plug (FAN) on the Inverter Controller Board. Make sure you also pull the wires free from the cable guides. Remove the screw (metal flange, 6 mm) and anti-vibration spring from the lower left side of the clutch.
Page 256: Inverter Upper Roller Solenoid
Inverter Upper Roller Solenoid Remove the Inverter and base unit from the Finisher (page 5-5). Remove the Inverter Rear Covers (page 5-19). Remove the Top Cover (page 5-23). Disconnect the cable from the connector (CL2) on the Inverter Controller Board. Be sure you also free the cable harness from the cable guide.
Page 257: Inverter Lower Roller Solenoid
Inverter Lower Roller Solenoid Remove the Inverter and base unit from the Finisher (page 5-5). Remove the Inverter Rear Covers (page 5-19). Remove the Top Cover (page 5-23). Disconnect the cable from the Inverter Controller Board. Be sure you free the cable harness from the cable guide.
Page 258: Finisher Sensors And Switches
Finisher Sensors and Switches The topics in this section describe the disassembly for each sensor in the Finisher. See page 5-99 for details of the Inverter sensors within the Finisher. Stapler Safety Interlock Switch Shift Lower Limit Sensor Shift Clock Sensor Upper Cover Sensor Joint Switch Front Alignment Plate...
Page 259: Joint Switch
Joint Switch The Joint Switch is activated when the Finisher Unit connects to the printer. This switch opens to prevent the power supply from placing hazardous voltages in accessible areas when the Finisher is undocked from the printer. To replace: Remove the Paper Exit Tray (page 5-7).
Page 260: Front Door Switch And Sensor
Front Door Switch and Sensor The Front Door Sensor detects when the Front Door (Door J) is open or removed. The Front Door Interlock Switch will open to prevent the power supply from placing hazardous voltages in accessible areas when the Front Door is removed. To remove and replace the switch and/or the Sensor: Remove the Paper Exit Tray (page 5-7).
Page 261: Inlet Sensor
Inlet Sensor Remove the Upper Cover (page 5-13). Remove the Upper Right Cover Assembly (page 5-37). Remove the Feed Motor Unit (page 5-62). Remove the Feed Roller (page 5-109). Remove the screw (metal flange, 6 mm) and detach the Inlet Sensor. Bushing Inlet Sensor K-Clip...
Page 262: Tray Paper Sensor
Tray Paper Sensor The Tray Paper Sensor detects when the paper tray is removed from the Finisher. To remove and replace the Tray Paper Sensor: Remove the Paper Exit Tray (page 5-7). Remove the Front Door (page 5-8). Remove the Rear Cover (page 5-11). Remove the Upper Cover (page 5-13).
Page 263: Paper Surface Sensor
Paper Surface Sensor The Paper Surface Sensor detects media in the home position of the delivery tray. To remove and replace the Paper Surface Sensor: Remove the Paper Exit Tray (page 5-7). Remove the Front Door (page 5-8). Remove the Rear Cover (page 5-11). Remove the Upper Cover (page 5-13).
Page 264: Upper Cover Sensor
Upper Cover Sensor The Upper Cover Sensor detects when the Upper Cover (Door I) is open or removed. To remove and replace the Sensor: Remove the Paper Exit Tray (page 5-7). Remove the Front Door (page 5-8). Remove the Rear Cover (page 5-11). Remove the Upper Cover (page 5-13).
Page 265: Shift Limit Sensors
Shift Limit Sensors The Shift (Upper and Lower) Limit Sensors detect the upper and lower limits of the delivery tray stack. To remove and replace either of the sensors: Remove the Paper Exit Tray (page 5-7). Remove the Rear Cover (page 5-11). Remove the Upper Cover (page 5-13).
Page 266: Lift Motor Clock Sensor
Lift Motor Clock Sensor The Lift Motor Clock Sensor detects clock pulses for the stacking operation. To remove and replace the sensor: Remove the Paper Exit Tray (page 5-7). Remove the Rear Cover (page 5-11). Remove the Upper Cover (page 5-13). Remove the Side Guide (page 5-107).
Page 267: Stack Full Sensor
Stack Full Sensor The Stack Full Sensor detects over-stacking of media in the delivery tray. To remove and replace the sensor: Remove the Paper Exit Tray (page 5-7). Remove the Rear Cover (page 5-11). Remove the Upper Cover (page 5-13). Remove the Side Guide (page 5-107).
Page 268: Processing Tray Sensor
Processing Tray Sensor The Processing Tray Sensor detects the processing stack within the delivery path. To remove and replace the Processing Tray Sensor: Remove the Paper Exit Tray (page 5-7). Remove the Front Door (page 5-8). Remove the Rear Cover (page 5-11). Remove the Upper Cover (page 5-13).
Page 269: Aligning Plate Home Position Sensors
Aligning Plate Home Position Sensors The Aligning Plate Home Position Sensors (front and back) ensure that the size of the selected paper aligns properly with the entrance into the paper path. To remove and replace either Sensor: Remove the Paper Exit Tray (page 5-7). Remove the Front Door (page 5-8).
Page 270 Locate the rear sensor. Rear Alignment Plate Home Sensor Shift Limit Sensor Upper Shift Limit Sensor Lower Bind Tray Sensor s7400-707 To remove the Front or Rear Aligning Plate Home Position Sensor, first remove the 4-wire connector (CN23 for the front or CN36 for the rear), and then pinch the plastic tabs to pull the sensor free.
Page 271: Stack Feed Roller Home Position Sensor
Stack Feed Roller Home Position Sensor The Stack Feed Roller Home Position Sensor detects the initial home position of the stack feed. To remove and replace the sensor: Remove the Paper Exit Tray (page 5-7). Remove the Front Door (page 5-8). Remove the Rear Cover (page 5-11).
Page 272 To remove the sensor, disconnect CN41 from the sensor, remove one screw (metal, 4 mm), and then pull the sensor free. Swing Guide Home Position Sensor Stack Feed Roller Home Position Sensor Folding Home Position Sensor Folding Position Sensor s7400-659 To remove the sensor, disconnect CN41 from the sensor, remove one screw (metal, 4 mm), and then pull the sensor free.
Page 273: Waste Full Sensor
Waste Full Sensor Remove the Rear Cover (page 5-11). Remove the Front Door (page 5-8). Remove the Upper Cover (page 5-13). Remove the Punch Control Board (page 5-50). Remove the two screws (metal flange, 6 mm) to remove the controller board film.
Page 274 Disconnect the connector to remove the Waste-full Sensor Board. Connector Waste-Full Photosensor Board s7400-267 5-88 Phaser 7400 Color Printer Options Service Manual...
Page 275: Swing Guide Home Position Sensor
Swing Guide Home Position Sensor The Swing Guide Home Position Sensor detects the home position for the Swing Guide. To remove the sensor. Remove the Paper Exit Tray (page 5-7). Remove the Rear Cover (page 5-11). Remove the Upper Cover (page 5-13). Remove two screws (metal, 6 mm) and remove the swing guide cover.
Page 276: Delivery Belt Home Position Sensor
Delivery Belt Home Position Sensor The Delivery Belt Home Position Sensor detects the end location of the delivery rollers (sensor is off). To remove and replace the Delivery Belt Home Position Sensor: Remove the Paper Exit Tray (page 5-7). Remove the Front Door (page 5-8). Remove the Rear Cover (page 5-11).
Page 277: Paddle Home Position Sensor
Paddle Home Position Sensor The Paddle Home Position Sensor detects when it is necessary to drive the paddle and feed the next sheet of paper. To remove the sensor. Remove the Paper Exit Tray (page 5-7). Remove the Rear Cover (page 5-11). Locate the sensor (see illustration) and disconnect connector CN39.
Page 278: Stapler Safety Interlock Switch
Stapler Safety Interlock Switch The Stapler Safety Interlock Switch protects current overloads in case of a staple jam. This switch will open to remove voltage from the stapler unit. To remove and replace the switch: Remove the Paper Exit Tray (page 5-7). Remove the Front Door (page 5-8).
Page 279: Staple/Fold Clock Sensor
Staple/Fold Clock Sensor The Staple/Fold Clock Sensor counts timing pulses during staple and fold operations. To remove the sensor: Remove the Paper Exit Tray (page 5-7). Remove the Rear Cover (page 5-11). Locate the sensor (see illustration) and disconnect connector CN52. CN71 CN52 Edge Saddle...
Page 280: Folding Home Position Sensor
Folding Home Position Sensor The Folding Home Position Sensor detects the positions of the paper fold rollers and the paper pushing plate. To remove and replace the sensor: Remove the Paper Exit Tray (page 5-7). Remove the Front Door (page 5-8). Remove the Rear Cover (page 5-11).
Page 281 Locate the sensor (see illustration). Swing Guide Home Position Sensor Stack Feed Roller Home Position Sensor Folding Home Position Sensor Folding Position Sensor s7400-659 To remove the sensor, disconnect CN40 from the sensor, remove one screw (metal, 4 mm), and then pull the sensor free. Service Parts Disassembly 5-95...
Page 282: Folding Position Sensor
Folding Position Sensor The Folding Position Sensor detects the leading edge of the paper stack. To remove and replace the sensor: Remove the Paper Exit Tray (page 5-7). Remove the Front Door (page 5-8). Remove the Rear Cover (page 5-11). Remove the Upper Cover (page 5-13).
Page 283 Locate the sensor (see illustration). Swing Guide Home Position Sensor Stack Feed Roller Home Position Sensor Folding Home Position Sensor Folding Position Sensor s7400-659 To remove the sensor, disconnect CN40 from the sensor, remove one screw (metal, 4 mm), and then pull the sensor free. Service Parts Disassembly 5-97...
Page 284: Bind Tray Sensor
Bind Tray Sensor The Bind Tray Sensor detects when paper is present in the Saddle Unit’s bind tray. To remove and replace the sensor: Remove the Paper Exit Tray (page 5-7). Remove the Front Door (page 5-8). Remove the Rear Cover (page 5-11). Remove the Upper Cover (page 5-13).
Page 285: Inverter Sensors And Switches
Inverter Sensors and Switches The following illustration shows the general location of the Inverter sensors. The topics in this section describe the disassembly for each sensor. Inverter Paper-in Sensor Inverter Upper Paper-present Sensor Inverter Door Open Interlock Switch Inverter Lower Paper-present Sensor Inverter Docking Sensor...
Page 286: Inverter Docking Sensor
Inverter Docking Sensor The Inverter Docking Sensor detects when the Inverter interconnects with the Printer. To remove the sensor: Remove the Inverter and base unit from the Finisher (page 5-5). Remove the Inverter Rear Covers (page 5-19). Disconnect the 3-wire cable from the connector (SNSCN1) at the Inverter Controller Board.
Page 287: Inverter Door (Door F) Open Interlock Switch
Inverter Door (Door F) Open Interlock Switch The Inverter Door Open Interlock Switch detects when the Inverter Door (F) is open. To remove the switch: Remove the Inverter and base unit from the Finisher (page 5-5). Remove the Inverter Rear Covers (page 5-19). Remove the Top Cover (page 5-23).
Page 288: Inverter Upper Paper-Present Sensor
Inverter Upper Paper-Present Sensor The Inverter Upper Paper-Present Sensor detects the leading edge of the selected paper size. To remove the sensor: Remove the Inverter and base unit from the Finisher (page 5-5). Remove the Inverter Front Covers (page 5-17). Remove the Inverter Rear Covers (page 5-19).
Page 289 To remove the Upper Paper-Present Sensor, pull the connector off the sensor, pinch the plastic hooks together, and push the sensor free from the chassis. Inverter Upper Paper Present Sensor s7400-615 Service Parts Disassembly 5-103...
Page 290: Inverter Lower Paper-Present Sensor
Inverter Lower Paper-Present Sensor The Inverter Lower Paper-Present Sensor detects the trailing edge of the selected paper size. To remove the sensor: Remove the Inverter and base unit from the Finisher (page 5-5). Remove the Inverter Front Covers (page 5-17). Remove the Inverter Rear Covers (page 5-19).
Page 291 To remove the actuator from the top paper guide, pinch the plastic release tab to free the actuator. Inverter Lower Paper-present Sensor s7400-607 Service Parts Disassembly 5-105...
Page 292: Inverter Paper-In Sensor
Inverter Paper-in Sensor The Inverter Paper-in Sensor detects the presence of media in the Inverter. To remove the sensor: Remove the Inverter and base unit from the Finisher (page 5-5). Remove the Inverter Front Covers (page 5-17). Remove the Inverter Rear Covers (page 5-19). Remove the Top Cover (page 5-23).
Page 293: Guides And Rollers
Guides and Rollers Side Guide Remove the Paper Exit Tray (page 5-7). Remove the Front Door (page 5-8). Remove the Rear Cover (page 5-11). While gently holding the Rear Delivery Tray Support Plate (and track) to the side, remove three screws (metal, 10 mm) and one specialty screw (metal, 16 mm), from the Side Guide.
Page 294 Twist the guide slightly clockwise, free the engagement of the paper surface detecting lever (rear), and then remove the guide. Paper Surface Detecting Lever (Rear) Paper Surface Detecting Lever (Middle) Groove s7400-280 Replacement Note Be sure to insert the paper detecting lever in the groove of the paper surface. After completion of mounting, activate the paper detecting lever several times to make sure that side guide is mounted securely.
Page 295: Feed Roller
Feed Roller Remove the Upper Cover (page 5-13). Remove the Upper Right Cover Assembly (page 5-37). Remove the Feed Motor Unit (page 5-62). Remove the screw (metal flange, 6 mm). Remove the stop ring, and detach the bushing. Bushing K-Clip s7400-232 Service Parts Disassembly 5-109...
Page 296 Remove the two screws (metal flange, 6 mm). Remove the gear and detach the gear while releasing the latch. Remove the stop ring and detach the bushing. s7400-233 5-110 Phaser 7400 Color Printer Options Service Manual...
Page 297 Remove the Lower Paper Guide. Bushing Inlet Sensor K-Clip Lower Paper Guide s7400-234 Remove the Feed Roller. Feed Roller s7400-235 Service Parts Disassembly 5-111...
Page 298: Upper Stack Delivery Roller
Upper Stack Delivery Roller Remove the Paddle Assembly (page 5-46). Place the assembly as shown. Push up the Upper Stack Delivery Roller from below to free it from the shaft. Upper Stack Delivery Roller Assembly Gear s7400-236 5-112 Phaser 7400 Color Printer Options Service Manual...
Page 299 Shift the roller upwards and then push down to detach. Upper Stack Delivery Roller Shaft s7400-237 Service Parts Disassembly 5-113...
Page 300 In a similar manner, remove the Upper Stack Delivery Roller at the front. Note Be careful not to lose the gear pin in the roller. Upper Stack Delivery Rollers s7400-238 5-114 Phaser 7400 Color Printer Options Service Manual...
Page 301: Paddle
Paddle Remove the Paddle Assembly (page 5-46). Place the assembly as shown. Turn the gear in the direction of the arrow to move the upper stack delivery roller assembly upwards. Push up the safety guide from below to free one side of the safety guide from the shaft.
Page 302 Remove the Paddle in the direction of the arrow (see the following illustrations). Safety Guide Shaft s7400-240 Paddle s7400-241 5-116 Phaser 7400 Color Printer Options Service Manual...
Page 303: Lower Stack Delivery Roller Belt
Lower Stack Delivery Roller Belt Remove the Paddle Assembly (page 5-46) and separate it from the Processing Tray Assembly. Slide the front and rear tamper plate of the processing tray to the outside. Remove the processing tray stopper. Processing Tray Assembly Rear Aligning Plate Front Aligning Plate s7400-242...
Page 304 Remove the screw (metal flange, 6 mm) and detach the Front Paper Guide while freeing the two tabs. Processing Tray Stopper s7400-243 5-118 Phaser 7400 Color Printer Options Service Manual...
Page 305 Remove the screw, (metal flange, 6 mm) and while freeing the tab, remove the Rear Paper Guide. Front Paper Guide Hooks s7400-244 Rear Paper Guide Hook s7400-245 Service Parts Disassembly 5-119...
Page 306 Repeat Step 5 for the Front Guide. Bushing E-Ring E-Ring Bushing s7400-246 Lower Stack Delivery Roller Assembly s7400-247 Remove the two stop rings and move the two bushings to the inside. Remove the four screws (metal flange, 6 mm) then lift the Lower Stack Delivery Roller Assembly to detach.
Page 307 Remove the two delivery belts. Note Be sure to mount the belts so that the edges of the claws of the belts are flush. Delivery Belts Stack Delivery Roller s7400-248 Delivery Belt Hooks s7400-249 Service Parts Disassembly 5-121...
Page 308: Duplex Unit Disassembly
Duplex Unit Disassembly To view sensors, motors, solenoids, gears, belts, and boards in the Duplex Unit, you must first remove the following: Front Cover Assembly Bottom Plate Side Rails Note If you need to remove the Duplex Unit Controller Board for any of the following procedures, disconnect all connectors and remove one screw (self tapping, 6 mm) securing the board to the frame, and then pull free from the mounting post.
Page 309 Slide the front assembly mounting rod out of the slot. Caution Be careful not to lose the retaining springs when you remove the assembly mounting rod. Front Assembly Mounting Rod s7400-613 From the remaining plastic piece, carefully loosen the plastic from the metal support bar.
Page 310: Bottom Cover Plate
Bottom Cover Plate Removing the Bottom Cover Plate will expose the Duplex Controller Board, the fan, the two motors, five sensor switches, three belts, and the door solenoid. To remove the Bottom Cover Plate: Remove the Front Cover Assembly (page 5-122). Turn the Duplex unit over so that the bottom plate is facing up.
Page 311 Lift the bottom plate free from the chassis. Caution Be careful to keep the unit upside down so that you do not lose any of the retaining springs from the unit Bottom Plate Duplex Unit s7400-501 Service Parts Disassembly 5-125...
Page 312: Side Rails
Side Rails Removing the Side Rails exposes gears, belts, and the door solenoid. To remove the belts, remove only the left side rail using the following steps: Remove the Front Cover assembly (page 5-122). Slide the mounting slides to the rear of the side rail. Remove three screws (metal flange, 6 mm) fastening the side rail to the chassis and lift the rail free from the chassis.
Page 313: Paper Guides
Paper Guides Remove Front Door and Cover assembly (page 5-122). To remove either the Top Paper Guide or the Lower Paper Guide, lift the paper guide to the open position, loosen one end of the plastic insert, and lift away from the chassis.
Page 314: Duplex Motor Assembly
Duplex Motor Assembly Motor A and Motor B are assembled in one unit. Use the following steps to remove and replace the motor assembly: Remove the Front Door and Front Cover Assembly (page 5-122). Remove the right side rail (page 5-126). Lift the rubber belt free from the motor gears.
Page 315: Diverter Solenoid
Diverter Solenoid The Diverter Solenoid re-routes the paper in the opposite direction on its paper path during duplex operation. To remove the solenoid: Remove the Front Door and Front Cover Assembly (page 5-122). Remove the Left Side Rail (page 5-126). Disconnect the solenoid connector (CL1) from the Duplex Controller Board.
Page 316: Duplex Unit Sensors And Switches
Duplex Unit Sensors and Switches There are a total of five sensors for the various duplex interlocks and paper paths. Refer to the sensor locator illustration to locate the appropriate sensor. To remove any of the sensors: Remove the Front Cover Assembly (page 5-122). Disconnect the sensor connector (either SNSCN0 or SNSCN1) from the Duplex Unit Controller Board.
Page 317: Duplex Fan
Duplex Fan To remove the Duplex Fan: Remove the Front Cover Assembly (page 5-122). Disconnect the fan connector (FAN) from the Duplex Unit Controller Board. Lift the fan free from the plastic molding. Caution Be careful not to lose any of the retainer springs. Duplex Fan s7400-600 Service Parts Disassembly...
Page 318: Interconnect Connector
Interconnect Connector The Duplex Unit Connector transfers signals between the printer and the Duplex Controller Board. To remove the connector. Remove the Front Door and Front Cover Assembly (page 5-122). Disconnect the Duplex Connector plug from the controller (MAIN1). Free the cable harness from the chassis. Remove two screws (metal, 4 mm) from the connector and lift the connector and cable from the chassis.
Page 319: Paper Tray Disassembly
Paper Tray Disassembly The printer includes one 550-sheet tray. Below the single tray on the printer, the options tray includes one single tray (550-sheets) and 3 additional stacked trays (1650-sheets). Each tray is basically identical, except for some interconnecting hardware. The following subsections describe how to remove elements of an optional 550-sheet tray.
Page 320: Tray Covers And Tray Door (Door C)
Tray Covers and Tray Door (Door C) Note If optional trays are installed, either remove the printer from the optional tray(s), or lift the right hand side of the printer to provide sufficient clearance to remove 4 screws and pull the Tray Feeder from the frame. To remove or replace any of the clutches, motors, or sensors, you must first remove either or both the Rear Cover and the Right Side Cover (and in some cases, you will need to remove the tray itself on the front of the unit or open the Tray door, Door C).
Page 321 To locate and open Door C, see the following illustration. Door C s7400-717 Service Parts Disassembly 5-135...
Page 322: Tray Feeder
Tray Feeder Remove Tray 2. Remove the Right Side Cover and Rear Cover (page 5-134). Remove the paper tray. Remove 12 (metal, 10 and 6 mm) screws to remove the Tray 2 Feeder. Feeder Assembly Tray 3 s7400-691 5-136 Phaser 7400 Color Printer Options Service Manual...
Page 323: Registration Motor
Registration Motor Remove the Tray Feeder (page 5-136). Release the motor harness from the clamp. Disconnect the Registration Motor connector (P/J40) from the harness. Remove two (metal, 6 mm) screws that secure the Registration Motor to the Feeder. Registration Motor s7400-647 Service Parts Disassembly 5-137...
Page 324: Feed Motor
Feed Motor Remove the Tray 2 Feeder (page 5-136). Release the motor harness from the clamp. Disconnect the Feed Motor connector (P/J30) from the harness. Remove two (metal, 6 mm) screws that secure the Feed Motor to the Feeder. Feed Motor s7400-648 5-138 Phaser 7400 Color Printer Options Service Manual...
Page 325: Lift Motor
Lift Motor Remove the tray. Remove the Right Rear Cover (page 5-134). Disconnect the Lift Motor connector GDDC from the Motor Driver Board. Remove the two (metal, 6 mm) screws that secure the Lift Motor to the frame. Lift Motor s7400-690 Service Parts Disassembly 5-139...
Page 326: Registration Clutch
Registration Clutch Remove the Tray Feeder (page 5-136). Remove the E-clip that secures the clutch to the Registration Roller. Registration Clutch s7400-682 While holding the anti-rattle spring, remove the clutch from the roller shaft. 5-140 Phaser 7400 Color Printer Options Service Manual...
Page 327: Door C Detect Sensor
Door C Detect Sensor The Door C Detect Sensor is mounted on a carrier located beneath the Registration Rollers near the clutch. Caution Use care when removing the roller shaft bearings. The bearings use a small clip to lock into a notch near the end of each roller shaft. Use a small, flat-bladed screwdriver to release the clip from the shaft before attempting to remove the bearing.
Page 328: No Paper Sensor
No Paper Sensor Remove the Tray Feeder (page 5-136). Remove 4 (metal, 23 mm) screws that secure the brace. Release the hook that secures the No Paper Sensor housing to the feeder. Turn the housing over, and then release the hooks that secure the sensor to the housing.
Page 329: Registration Sensor #2
Registration Sensor #2 Remove the Tray Feeder (page 5-136). Remove the Registration Clutch #2 (page 5-140) Remove the Feeder Board Cover. Remove 4 (metal, 6 mm) screws that secure the feeder top. Feeder Top Feeder Assembly s7400-685 Service Parts Disassembly 5-143...
Page 330 Separate the feeder top, and then turn the top over to remove 2 (black, plastic 10 mm) screws that secure the sensor housing to the feeder. s7400-486 5-144 Phaser 7400 Color Printer Options Service Manual...
Page 331 Turn the feeder top upright, and release the 2 hooks that secure the sensor housing to the top of the feeder. Feed Out #2 Sensor Registration #2 Sensor Sensor Cover Feeder Assembly s7400-529 Release the hooks that secure the sensor in the housing. Disconnect the sensor connector (P/J42), and then remove the sensor.
Page 332: Feed-Out Sensor #2
Feed-Out Sensor #2 Remove the Tray Feeder (page 5-136). Remove the Registration Clutch #2 (page 5-140). Remove the Feeder Board Cover. Remove 4 (metal, 6 mm) screws that secure the feeder top. Feeder Top Feeder Assembly s7400-485 5-146 Phaser 7400 Color Printer Options Service Manual...
Page 333 Separate the feeder top, and then turn the top over to remove 2 (black, plastic 10 mm) screws that secure the sensor housing to the feeder. s7400-486 Turn the feeder top upright, and the release the 2 hooks that secure the sensor housing to the top of the feeder.
Page 334: Feeder Board
Feeder Board Remove the Tray Feeder (page 5-136). Remove 3 (metal, 10 mm) screws that secure the hand holds to the feeder. Hand Holds s7400-687 5-148 Phaser 7400 Color Printer Options Service Manual...
Page 335 Remove 1 (metal, 6 mm) screw that secures the Feeder Board Cover. Feeder Board s7400-688 Remove 1 (metal, 6 mm) screw that secures the Feeder Board to the Feeder. Disconnect the connectors (TRYSNS1, TRYSNS2, and PAPEND) to remove the board. Service Parts Disassembly 5-149...
Page 336: Tray Feed Rollers
Tray Feed Rollers Note Feed Roller (Pick, Feed. Retard) removal is identical for all Universal Trays. Since each roller is unique, match each replacement roller to the roller being removed. Remove Tray 2. Open Door B. Release the hook that secures each roller to the shaft. Feed Rollers s7400-689 5-150...
Page 337: Parts List
Parts List In this chapter... Using the Parts List Finisher Parts Duplex Unit Parts Tray Parts Section...
Page 338: Using The Parts List
Using the Parts List Only those parts listed with part numbers are available for order. Parts listed without part numbers are only available as part of a parent assembly or Service Kit. No.: The callout number from the exploded part diagram. Part Number: The material part number used to order specific parts.
Page 339: Finisher Parts
Finisher Parts The following pages show a parts locator diagram and parts list table for each unit of the Finisher. Parts List...
Page 340: Finisher Unit Assembly Diagram
Finisher Unit Assembly Diagram s7400-628 Phaser 7400 Color Printer Options Service Manual...
Page 341: Parts List 1.1 Finisher Unit Assembly Parts List
Parts List 1.1 Finisher Unit Assembly Parts List Finisher Unit Parts List ID # Part Number Name/Description 097S03363 Finisher, 3 hole 097S03364 Finisher 2/4 hole 050E23450 Base Unit 005K12430 Stack Motor Drive Assembly (Lift Motor and sensors) 005K12440 Drive Assembly (Delivery Motor Assembly) 848K00040 Bundle Support Cover (Paper Detector) 054K37780...
Page 342: Finisher External Parts Diagram
Finisher External Parts Diagram To C1 To B3 To B3 To B4 To B3 To B3 See B7 To B3 s7400-629 Phaser 7400 Color Printer Options Service Manual...
Page 343: Parts List 1.2 Finisher External Parts List
Parts List 1.2 Finisher External Parts List Finisher External Parts List ID # Part Number Name/Description 848K00040 Bundle Support Cover Assembly (Paper Detector) Parts List...
Page 344 Phaser 7400 Color Printer Options Service Manual...
Page 345: Finisher Internal Parts Diagram (1 Of 2)
Finisher Internal Parts Diagram (1 of 2) To B2 To B2 To B2 To B2 To B2 See B5 s7400-630 Parts List...
Page 346: Finisher Internal Parts Diagram (2 Of 2)
Finisher Internal Parts Diagram (2 of 2) See B6 To B2 s7400-631 6-10 Phaser 7400 Color Printer Options Service Manual...
Page 347: Parts List 1.3 Finisher Internal Parts List
Parts List 1.3 Finisher Internal Parts List Finisher Internal Parts List ID # Part Number Name/Description 137E16140 IC TLP1241 Photo Interrupter Parts List 6-11...
Page 348: Stack (Lift) Motor Drive Assembly Parts Diagram
Stack (Lift) Motor Drive Assembly Parts Diagram s7400-632 6-12 Phaser 7400 Color Printer Options Service Manual...
Page 349: Parts List 1.4 Stack (Lift) Motor Drive Assembly Parts List
Parts List 1.4 Stack (Lift) Motor Drive Assembly Parts List Stack (Lift) Motor Drive Assembly Parts List ID # Part Number Name/Description 005K12430 Stack Motor Drive Assembly (Lift Motor) Parts List 6-13...
Page 350: (Staple/Fold) Drive Assembly Parts Diagram
(Staple/Fold) Drive Assembly Parts Diagram s7400-633 6-14 Phaser 7400 Color Printer Options Service Manual...
Page 351: Parts List 1.5 (Staple/Fold) Drive Assembly Parts List
Parts List 1.5 (Staple/Fold) Drive Assembly Parts List Staple/Fold Drive Assembly Parts List ID # Part Number Name/Description 005K12440 Drive Assembly (Staple/Fold) Parts List 6-15...
Page 352: Bundle Support Cover Assembly Parts Diagram
Bundle Support Cover Assembly Parts Diagram s7400-634 6-16 Phaser 7400 Color Printer Options Service Manual...
Page 353: Parts List 1.6 Bundle Support Cover Parts List
Parts List 1.6 Bundle Support Cover Parts List Bundle Support Cover Assembly (Paper Detection) Parts List ID # Part Number Name/Description 848K00040 Bundle Support Cover (Paper Detection) Parts List 6-17...
Page 354: Dispose Assembly (Processing Tray) Parts Diagram
Dispose Assembly (Processing Tray) Parts Diagram See B9 s7400-63 6-18 Phaser 7400 Color Printer Options Service Manual...
Page 355: Parts List 1.7 Dispose Assembly (Processing Tray) Parts List
Parts List 1.7 Dispose Assembly (Processing Tray) Parts List Dispose Assembly (Processing Tray) Parts List ID # Part Number Name/Description 054K37780 Dispose Assembly (Processing Tray) Parts List 6-19...
Page 356: Paper Feeder (Paddle) Assembly Parts Diagram
Paper Feeder (Paddle) Assembly Parts Diagram 39-B 40-B 39-A 39-C 40-A 40-C 40-A 39-A 40-C 39-C 39-A 40-A 40-B 39-B s7400-636 6-20 Phaser 7400 Color Printer Options Service Manual...
Page 357: Parts List 1.8 Paper Feeder (Paddle) Assembly Parts List
Parts List 1.8 Paper Feeder (Paddle) Assembly Parts List Paper Feeder (Paddle) Assembly Parts List ID # Part Number Name/Description 059K52480 Paper Feeder (Paddle) Assembly Parts List 6-21...
Page 358: Puncher Assembly Parts Diagram
Puncher Assembly Parts Diagram See C2 To B2 s7400-642 6-22 Phaser 7400 Color Printer Options Service Manual...
Page 359: Parts List 1.9 Puncher Assembly Parts List
Parts List 1.9 Puncher Assembly Parts List Puncher Assembly Parts List Part Number Name/Description 109K02020 Puncher Controller Board Assy 848E05300 Dust-LED Board Unit 848E05310 Dust-PTR Board Unit 137E16140 IC TLP1241 Photo-Interrupter 848E05320 Panel - Dust Box 848E05330 Cover - Dust Box 127E15510 Motor - Stepping Parts List...
Page 360: Punch Total Assembly Diagram
Punch Total Assembly Diagram s7400-643 6-24 Phaser 7400 Color Printer Options Service Manual...
Page 361: Parts List 1.10 Punch Total Assembly Parts List
Parts List 1.10 Punch Total Assembly Parts List Punch Total Assembly Parts List Part Number Name/Description 084K35580 Puncher 2/3 holes XC 084K35590 Punch Unit 4 hole-F XC 137E16140 IC TLP1241 Photo Interrupter 180K00230 Punch Unit 2/3H XC 108K00240 Punch Unit 4H-F XC 127K55160 Motor - DC 960K32910...
Page 362 6-26 Phaser 7400 Color Printer Options Service Manual...
Page 363: Staple Unit Diagram (1 Of 2)
Staple Unit Diagram (1 of 2) s7400-640 Parts List 6-27...
Page 364: Staple Unit Diagram (2 Of 2)
Staple Unit Diagram (2 of 2) s7400-641 6-28 Phaser 7400 Color Printer Options Service Manual...
Page 365: Parts List 1.11 Staple Unit Parts List
Parts List 1.11 Staple Unit Parts List Staple Unit Parts List ID # Part Number Name/Description 029K04400 Staple Assembly Parts List 6-29...
Page 366: Fold Unit Diagram (1 Of 3)
Fold Unit Diagram (1 of 3) s7400-637 6-30 Phaser 7400 Color Printer Options Service Manual...
Page 367: Fold Unit Diagram (2 Of 3)
Fold Unit Diagram (2 of 3) See B4-No.18 s7400-638 Parts List 6-31...
Page 368: Fold Unit Diagram (3 Of 3)
Fold Unit Diagram (3 of 3) s7400-639 6-32 Phaser 7400 Color Printer Options Service Manual...
Page 369: Parts List 1.12 Fold Unit Parts List
Parts List 1.12 Fold Unit Parts List Fold Unit Parts List ID # Part Number Name/Description 054K37790 Fold Assembly Parts List 6-33...
Page 370: Inverter Parts Diagram (1 Of 3)
Inverter Parts Diagram (1 of 3) 6-34 Phaser 7400 Color Printer Options Service Manual...
Page 371: Inverter Parts Diagram (2 Of 3)
Inverter Parts Diagram (2 of 3) 17X4 12X4 s7400-62 Parts List 6-35...
Page 372: Inverter Parts Diagram (3 Of 3)
Inverter Parts Diagram (3 of 3) s7400-627 6-36 Phaser 7400 Color Printer Options Service Manual...
Page 373: Parts List 1.13 Inverter Parts List
Parts List 1.13 Inverter Parts List Inverter Parts List Part Number Name/Description 112K00720 Inverter and Base 031E11260 Guide-Sheet-L-Assy XOBG 110E20010 PWR unit-ACDC Switch 960K32850 On-Board Assy.-V72-3 117E29240 CONN Cord-Wire AMP3P-SW 106E00920 Photo-Interrupter 059E05480 Roller-Register 059E05490 Roller-Exit 059E05500 Roller-Main 055K37080 Plate-Guide-C-Assy 121E20450 Solenoid 127E15500...
Page 374: Duplex Unit Parts
Duplex Unit Parts Duplex Unit Parts Diagram 27 9 s7400-649 6-38 Phaser 7400 Color Printer Options Service Manual...
Page 375: Parts List 1.14 Duplex Unit Parts List
Parts List 1.14 Duplex Unit Parts List Duplex Unit Parts List Part Number Name/Description 084K35440 Duplex Unit Parts List 6-39...
Page 376: Optional Paper Tray Parts
Optional Paper Tray Parts 6-40 Phaser 7400 Color Printer Options Service Manual...
Page 377: Optional Tray Parts Diagram (1 Of 2)
Optional Tray Parts Diagram (1 of 2) s7400-610 Parts List 6-41...
Page 378: Optional Tray Parts Diagram (2 Of 2)
Optional Tray Parts Diagram (2 of 2) 89,90 88,91 41,42 s7400-592 6-42 Phaser 7400 Color Printer Options Service Manual...
Page 379: Parts List 1.15 Optional Tray Parts List
Parts List 1.15 Optional Tray Parts List Optional Tray Parts List ID # Part Number Name/Description 059K51750 Optional Tray Assembly (Single Tray) 059K52510 LTD Assembly (High-capacity feeder 050K61900 Optional feeder Note The LTD assembly and optional feeders are not referenced in the preceding diagram.
Page 380 6-44 Phaser 7400 Color Printer Options Service Manual...
Page 381: Wiring Diagrams
Wiring Diagrams In this chapter... Plug/Jack Designators Plug/Jack Locators Wiring Diagrams Section...
Page 382: Plug/Jack Locator Diagrams
Plug/Jack Locator Diagrams The P/J Locator diagrams show the location of primary connections within the option devices. Use these illustrations to locate connections called out in the troubleshooting procedures presented in Section 3. To find the location of a Plug or Jack: Locate the P/J connector designator in the first column of the table.
Page 383 Finisher/Plug/Jack Designators (Continued) Map Coord Remarks CN17 A-841 Connects to signal ground, transmit and receive data, DSR and DTR signals, and reset. CN18 E-834 Supplies 24 volts to the Slide motor. CN19 I-839 Connects to the full stack sensor. C-841 Folding position adjustment, middle 2-point stapling.
Page 384 Inverter Controller Board Plug/Jack Designator Map Coord Remarks SNSCN0 F-837 Connects to paper sensors. SNSCN1 E-837 Connects to Inverter Docking Sensor. SNSCN2 E-837 Connects to Door Open Interlock Switch (Door F). F-836 Connects to Lower Roller Solenoid. C-836 Connects to Paper Diverter Solenoid. D-836 Connects to diverter clutch.
Page 385 Paper Tray Controller Board Plug/Jack Designator Map Coord Remarks FFSNS F-837 Connects to TRYSNS1 and TRYSNS2 signals from the feeder board. F-836 Connects to the registration clutch. C-836 No connection. GDDC D-836 Connects to the Lift Motor. MOTOR-A C-837 Connects to the Feed Motor. MOTOR-B A-837 Connects to the Registration Motor.
Page 386 Finisher Sensor Designators (Continued) Map Coord Remarks CN73 F-838 Connects to the Full Stack Sensor CN30 E-838 Connects to the Processing Tray Sensor CN23 C-838 Connects to the Aligning Plate (Front) Home Position Sensor CN36 E-836 Connects to the Aligning Plate (Rear) Home Position Sensor CN41 F-837 Connects to the Stack Feed Roller Home Position Sensor...
Page 387 Map 1: Finisher Controller Board Locator Diagram CN13 CN18 CN10 LED1 LED3 LED2 PSW3 PSW1 PSW2 CN11 CN17 s7400-269 Wiring Diagrams...
Page 388 Map 2: Punch Controller Board Locator Diagram J1007 SW1001 SW1002 SW1003 LED1001 LED1002 LED1003 J1003 J1004 s7400-716 Phaser 7400 Color Printer Options Service Manual...
Page 389 Map 3: Inverter Controller Board Locator Diagram POWER SNSCN1 FLASH MAIN2 MAIN1 MOTOR A MOTOR B SNSCN2 SNSCN0 s7400-711 Wiring Diagrams...
Page 390 Map 4: Duplex Unit Controller Board Locator Diagram POWER SNSCN1 FLASH MAIN2 MAIN1 MOTOR A MOTOR B SNSCN2 SNSCN0 s7400-711 7-10 Phaser 7400 Color Printer Options Service Manual...
Page 391 Map 5: Paper Tray Controller Board Locator Diagram POWER SNSCN1 FLASH MAIN2 MAIN1 MOTOR A MOTOR B SNSCN2 SNSCN0 s7400-711 Wiring Diagrams 7-11...
Page 392 Map 6: Paper Tray Feeder Board Locator Diagram TRYSNS1 PAPEND TRYSNS2 s7400-603 7-12 Phaser 7400 Color Printer Options Service Manual...
Page 393 Map 7: Finisher Sensor Locator Diagram (1 of 2) CN49 CN24 CN48 CN23 CN73 CN52 CN47 CN25 CN39 s7400-733 Wiring Diagrams 7-13...
Page 394 Map 8: Finisher Sensor Locator Diagram (2 of 2) CN50 CN73 CN51 CN36 CN44 J2006 CN31 CN41 CN32 CN40 CN35 CN30 s7400-734 7-14 Phaser 7400 Color Printer Options Service Manual...
Page 395 Map 9: Inverter Sensor Locator Diagram P/J11 P/J10 SNSCN2 P/J13 P/J12 s7400-722 Wiring Diagrams 7-15...
Page 396: Finisher Wiring Diagrams
Finisher Wiring Diagrams Finisher/Punch Power Supply Wiring Diagram Front Door Switch Stapler Safety Joint Switch (JS) (FDSW) Switch (SSS) 24 V Motor 24 V Motor 24VP 24 V Circuit Breaker (CB1) Clutch Finisher Controller PCB Host Machine Sensor Regulator IC 24VL Logic System (IC1)
Page 397: Finisher Controller To Printer Wiring
Finisher Controller to Printer Wiring To Printer Finisher Controller Board CN20 FGND +24V PGND DC+24VP +24V CN20A SGND DC+24VL SGND N.C. SGND s7400-271 Wiring Diagrams 7-17...
Page 398: Finisher Controller To Sensors (1 Of 3)
Finisher Controller to Sensors (1 of 3) Finisher Controller +5VDC Board CN23 DC+5V FJHPS SGND Aligning Plate Home Position FJOG_HP Sensor (Front) +5VDC CN24 DC+5V SGND Upper Cover TOPCOV_S Sensor +5VDC CN25 DC+5V SGND Front Door FDOOR_S Sensor +5VDC CN28 CN29 CN30 DC+5V...
Page 399: Finisher Controller To Sensors (2 Of 3)
Finisher Controller to Sensors (2 of 3) Finisher Controller +5VDC Board CN16 CN37 CN38 CN39 DC+5V Bind_P Folding Bind_L Position Sensor CN16 CN37 CN38 CN40 DC+5V FHPS SGND Folding Home Position Bind_HP Sensor CN16 CN37 CN38 CN41 DC+5V FRHPS Stack Feed SGND Roller (Upper) Bind_ROL_HP...
Page 400: Finisher Controller To Sensors (3 Of 3)
Finisher Controller to Sensors (3 of 3) Finisher Controller +5VDC Board CN51 DC+5V SGND Paddle Home Position Sensor PDL_HP CN52 DC+5V Staple/Fold Bind_CLK Clock DC+5V Sensor CN53 CN54 CN55 DC+5V Swing Guide SGND Home Position BDL_ROL_HP Sensor +5VDC CN73 CN19 DC+5V SGND Full Stack...
Page 401: Finisher Controller To Motors
Finisher Controller to Motors Finisher Controller Board +12VDC CN10 CN56 CN56 Feed Motor DC+12V DC+12V FEEDMTR_A FEEDMTR_*A FEEDMTR_B FEEDMTR_*B +24VDC CN10 CN57 CN57 Paddle Motor DC+24V DC+24V PDLMTR_A PDLMTR_*A PDLMTR_B PDLMTR_*B +24VDC CN13 CN59 CN57 Delivery Motor DC+24V DC+24V EJCTMTR_A EJCTMTR_*A EJCTMTR_B EJCTMTR_*B...
Page 402: Finisher Controller To Switches
Finisher Controller to Switches Finisher Controller Board CN66 Stapler Safety Switch STAPLE_SAFE_SW FDOOR_SW CN68 Front Door Switch FDOOR_SW JOINT_SW +24VDC CN69 Joint Switch JOINT_SW DC+24VP CN70 CN70 CN70 CN70 Shift Motor SIFTMTR_1 SIFTMTR_0 CN71 CN71 Staple/Fold Motor BINDMTR_1 BINDMTR_0 +24VDC CN18 CN72 CN72...
Page 403: Finisher Controller To Stapler Sensors And Motors
Finisher Controller to Stapler Sensors and Motors Finisher Controller Stapler Unit Board +5VDC CN11 CN72A STPL_CNCT +5VDC STPL_HP STPL_HP HOOK_S SELF_P SGND +24VDC CN72B Slide Motor +24V +24V SLIDMTR_A SLIDMTR_*A SLIDMTR_B SLIDMTR_*B N.C. s7400-277 Wiring Diagrams 7-23...
Page 404: Finisher Controller To Punch Controller
Finisher Controller to Punch Controller Punch Finisher Controller Controller Board Board CN12 J2003 J1003 CN14 J2004 J1004 s7400-278 7-24 Phaser 7400 Color Printer Options Service Manual...
Page 405: Punch Controller To Sensors And Motors
Punch Controller to Sensors and Motors Punch Controller Board J1007 J2011 Photosensor PCB J1007 J2010 LED PCB J1005 J2006 Waste Full Photosensor PCB J1005 J2005 Waste Full LED PCB J1006 J2009 Punch Motor Clock Sensor J1006 J2008 Punch Home Position Sensor J1006 J2007 Horizontal...
Page 406: Inverter Sensors Wiring Diagram
Inverter Sensors Wiring Diagram Inverter Controller Inverter Board Docking Sensor SNSCN1 P/J13 SNS_5 SNS_4 SNS_3 +5VDC Door Open Interlock Switch SNSCN2 DC+5V COVOPN Lower Paper Present Sensor P/J12 SNSCN0 +5VDC SNSO_N DC+5V P/J11 SNSCN0 Paper In Sensor SNS1_N DC+5V P/J10 SNSCN0 Upper Paper Present Sensor SNS2_N...
Page 407: Inverter Motors, Solenoids, And Clutch Wiring Diagram
Inverter Motors, Solenoids, and Clutch Wiring Diagram Inverter MOTOR_A P/J30 Upper Feed Motor Controller MT_A1 Board MT_A2 MT_A3 MT_A4 MOTOR_B P/J31 Lower Feed Motor MT_B1 MT_B2 MT_B3 MT_B4 +24VDC DC+24V Lower Roller Solenoid +24VDC DC+24V Paper Diverter Solenoid +24VDC DC+24V Paper Entry Clutch +24VDC Inverter Power...
Page 408: Duplex Unit Wiring Diagrams
Duplex Unit Wiring Diagrams Duplex Unit Sensors and Interconnect Wiring Duplex Unit Interconnect Controller MAIN1 P/J70 Connector OPTPSIN Board OPTSCIKIN OPTSD +24VDC OPTSDR +5VDC +24V OPTCNT From Printer +24V +5VDC Cover Open Interlock Switch COVOPN DC+5V COVOPN Paper End Sensor SNSCN0 P/J81 +5VDC...
Page 409: Duplex Unit Motors And Solenoids
Duplex Unit Motors and Solenoids Duplexer MOTOR_A P/J60 Roller Motor Controller MT_A1 Board MT_A2 MT_A3 MT_A4 MOTOR_B P/J61 Reverse Roller Motor MT_B1 MT_B2 MT_B3 MT_B4 +24VDC DC+24V Diverter Solenoid +24VDC DC+24V s7400-713 Wiring Diagrams 7-29...
Page 410: Optional Tray Wiring Diagrams
Optional Tray Wiring Diagrams Paper Tray Sensors and Interconnect Wiring Feeder Board +5VDC TRYSNS2 P/J43 Feed-Out Sensor #3 HOP1 +5VDC TRYSNS2 P/J42 +5VDC Registration Sensor #3 TRYSNS2 P/J41 Door C Detect COVOPN-P +5VDC +5VDC PAPEND P/J44 +5VDC No Paper Sensor PAPEREND Paper Tray Controller Board +5VDC...
Page 411: Paper Tray Motors, Clutches, And Interconnect Wiring
Paper Tray Motors, Clutches, and Interconnect Wiring Paper Tray GDDC Lift Motor Controller P/J50 MT_A1 Board MT_A2 P/J51 MOTOR_A Feed Motor MT_A1 MT_A2 MT_A3 MT_A4 P/J52 MOTOR_B Registration Motor MT_B1 MT_B2 MT_B3 MT_B4 +24VDC DC+24V Registration Clutch P/J60 MAIN1 Interconnect OPTSIN_N Connector OPTSCLK_N...
Page 412 7-32 Phaser 7400 Color Printer Options Service Manual...
Page 413 Index Numerics Inverter Controller Board 5-55 Inverter Power Supply Board 5-56 1650-Sheet Feeder Paper Tray Feeder Board 5-149 dimensions Photosensor Board 5-52 overview Punch LED Board 5-53 5 VDC Power Supply 2-41 Waste Full LED Board 5-54 550-Sheet Feeder booklet 2-21 dimensions booklet mode...
Page 414 disconnecting base unit entrance jam error 3-18 Door C Entrance Sensor 2-31 jam error 3-13 fan failure error 3-80 open error 3-33 Fan removal 5-131 Door D firmware error 3-73 jam error 3-16 flash memory failure error 3-76 open error 3-34 front and rear duplex sensors 2-31...
Page 415 Feeder Board cover removal 5-143 Front Door Interlock Switch removal Feeder Board removal 5-148 5-74 Paper Tray Feeder Board parts Full Stack Sensor 2-21 Paper Tray Feeder diagram 7-12 Feeder Clutch, Inverter 2-35 Feed-Out Sensor, Paper Tray 2-32 2-37 guide removal Field Replaceable Units Paddle Guide 5-116...
Page 416 paper fold rollers 4-19 paper folding drive gear 4-19 Lift Motor paper pushing plate 2-18 Clock Sensor 2-24 paper retaining plate 5-34 Drive Assembly parts diagram 6-12 sensing 2-27 Drive Assembly parts list 6-13 Paper Tray Paper Tray theory 2-37 Feeder removal 5-136 theory...
Page 417 Punch LED Board removal 5-53 Delivery Belt Home Position Sensor Punch Unit 5-90 parts list 6-23 6-25 Door C Detect Sensor 5-141 punch assembly photosensors 2-29 Finisher Front Door Sensor 5-74 punch blade Finisher Upper Cover Sensor 5-78 Punch Home Position Sensor 2-15 Folding Home Position Sensor 5-94...
Page 418 Inverter Upper Roller Solenoid flash memory failure error 3-75 5-69 5-70 interface failure error 3-46 Specifications lift motor failure error 3-78 electrical no paper warning 3-87 environmental 1-10 optional trays 2-11 functional out of paper error 3-39 stacking process 2-19 Paper Exit Tray standard orientation unsupported ROM error...
Page 420 071-0876-00...

Xerox Paser 7400 Service Manual

1 General Information

2 Theory of Operation

3 General Troubleshooting

4 Adjustments and Calibrations

5 Service Parts Disassembly

6 Parts List

Quick Links

Troubleshooting

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Summary of Contents for Xerox Paser 7400