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Xerox 7700DX - Phaser Color Laser Printer Service Manual

Other manuals for 7700DX - Phaser Color Laser Printer: User Manual, Advanced Features And Troubleshooting Manual
Manual is about: Service Manual

Summary of 7700DX - Phaser Color Laser Printer

  • Page 1

    Service manual phaser ® 7700 701p28180 color laser printer.

  • Page 3: Service Manual

    Warning the following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing other than that contained in operating instructions unless you are qualified to do so. This printing: december 2006 service manual 701p28180 phaser ® 7...

  • Page 4

    Ii phaser 7700 color printer service manual prepared by: xerox corporation xog worldwide product training and information 26600 sw parkway wilsonville, or 97070 © 2006 by xerox corporation. All rights reserved. Unpublished rights reserved under the copyright laws of the united states. Contents of th...

  • Page 5: User Safety Summary

    Phaser 7700 color printer service manual iii user safety summary terms in manual various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger that might be present during a procedure or action. Be aware of all symbols and te...

  • Page 6: Power Source

    Iv phaser 7700 color printer service manual power source for 110 vac printers, do not apply more than 127 volts rms between the supply conductors or between either supply conductor and ground. Use only the specified power cord and connector. For 220 vac printers, do not apply more than 240 volts rms...

  • Page 7: Laser Components

    Phaser 7700 color printer service manual v laser components warning : this printer generates a laser beam as part of the printing process. The laser beam in this printer is invisible. Direct eye exposure to the laser beam may cause eye injury or blindness. To avoid permanent eye damage, follow these...

  • Page 8: Safety Instructions

    Vi phaser 7700 color printer service manual safety instructions read all installation instructions carefully before you plug the product into a power source. Care of product disconnect the power plug by pulling the plug, not the cord. ■ disconnect the power plug if the power cord or plug is frayed o...

  • Page 9: Service Safety Summary

    Phaser 7700 color printer service manual vii service safety summary general guidelines for qualified service personnel only: refer also to the preceding users safety summary. Do not service alone: do not perform internal service or adjustment of this product unless another person capable of renderin...

  • Page 10

    Viii phaser 7700 color printer service manual federal communication commision compliance this equipment has been tested and found to comply with the limits set for a class b digital device, as stated in part 15 of the fcc rules. These limits are designed to provide reasonable protection against harm...

  • Page 11: Canadian Notice

    Phaser 7700 color printer service manual ix canadian notice this digital apparatus does not exceed the class b limits for radio noise emissions from digital apparatus as described in the radio interference regulations of the canadian department of communications. Note installation of the finisher an...

  • Page 12: Esd Precautions

    X phaser 7700 color printer service manual esd precautions some semiconductor devices are easily damaged from static electricity. These components are electrostatically sensitive devices (esds); examples include integrated circuits (ics), large-scale integrated circuits (lsis), some field-effect tra...

  • Page 13: Contents

    Phaser 7700 color laser printer service manual xi contents user safety summary .............................................................................................. 1-iii terms in manual ............................................................................................... 1-iii te...

  • Page 14: General Information

    Xii phaser 7700 color laser printer service manual general information 1-1 phaser 7700 printer overview .................................................................................. 1-2 printer ram and printer capabilities ................................................................. 1-4 cr...

  • Page 15: Troubleshooting

    Phaser 7700 color laser printer service manual xiii entering service diagnostics mode .................................................................2-35 service diagnostics test menu functions ........................................................2-36 error codes and messages troubleshooting .....

  • Page 16: Adjustments And Calibration

    Xiv phaser 7700 color laser printer service manual windows printing problems .......................................................................... 3-104 troubleshooting network problems .............................................................. 3-105 media jams and the paper path .............

  • Page 17: Cleaning And Maintenance

    Phaser 7700 color laser printer service manual xv step 2: regicon #4 coarse skew adjustment ...............................................4-135 step 3: regicon #1 fine skew adjustment ....................................................4-137 step 4: regicon #2 in/out skew adjustment ..................

  • Page 18: 7-151

    Xvi phaser 7700 color laser printer service manual removal and replacement procedures 7-151 rear cover assembly 7-154 right side cover assembly .................................................................... 7-155 top cover assembly .................................................................

  • Page 19: Fru Parts List

    Phaser 7700 color laser printer service manual xvii t1 and t3 high-voltage power supplies .................................................7-208 3.3 vdc and 5 vdc low-voltage power supplies and bracket ...............7-210 ld power relay .................................................................

  • Page 20: Test Prints

    Xviii phaser 7700 color laser printer service manual pl 8-20 lift components frus ..................................................................... 8-268 pl 8-21 wiring frus .................................................................................... 8-270 pl 8-22 auxiliary feeder frus ....

  • Page 21: Finisher Fru Parts List

    Phaser 7700 color laser printer service manual xix horizontal transport entrance sensor and top tray full sensor ..........11-328 gate-in solenoid assembly ...................................................................11-329 finisher covers .........................................................

  • Page 22

    Xx phaser 7700 color laser printer service manual.

  • Page 23: List of Tables

    Phaser 7700 color laser printer service manual xxi list of tables table 1-1 crc life .................................................................................................. 1-5 table 1-2 front panel key descriptions ................................................................ 1-21 tab...

  • Page 24

    Xxii phaser 7700 color laser printer service manual table 8-28 high-capacity feeder frus list (cont’d.) .......................................... 8-280 table 8-29 high-capacity feeder frus (cont’d.) ................................................. 8-281 table 8-30 kits ...............................

  • Page 25: List of Figures

    Phaser 7700 color laser printer service manual xxiii list of figures figure 1-1 the phaser 7700 color laser printer (shown with the high-capacity feeder) 1-1 figure 1-2 engine control interface and power supply boards ............................... 1-6 figure 1-3 power supplies .......................

  • Page 26

    Xxiv phaser 7700 color laser printer service manual figure 7-6 left-hand lower cover assembly ...................................................... 7-160 figure 7-7 front cover assembly ........................................................................ 7-161 figure 7-8 fuser front cover ........

  • Page 27

    Phaser 7700 color laser printer service manual xxv figure 7-51 3.3 vdc and 5 vdc low-voltage power supplies ............................ 7-210 figure 7-52 ld power relay ............................................................................... 7-211 figure 7-53 low-voltage power supply, fan an...

  • Page 28

    Xxvi phaser 7700 color laser printer service manual figure 8-22 auxiliary feeder frus ....................................................................... 8-272 figure 8-23 lower tray deck (ltd) frus ........................................................... 8-274 figure 8-24 lower tray deck (lt...

  • Page 29

    Phaser 7700 color laser printer service manual xxvii figure 11-39 electrical frus ............................................................................. 11-370 figure 12-1 block diagram of the finisher .......................................................... 12-372 figure 12-2 wiring diagra...

  • Page 30

    Xxviii phaser 7700 color laser printer service manual.

  • Page 31: General Information

    Phaser 7700 color laser printer service manual 1-1 general information the phaser 7700 color laser printer service manual is the primary document used for repairing and maintaining the xerox phaser 7700 color laser printer. Certification for servicing of this product requires completion of the phase...

  • Page 32

    1-2 phaser 7700 color laser printer service manual phaser 7700 printer overview the phaser 7700 color printer combines a single-pass, tandem-design, color laser, continuous-tone print engine with an image processor supporting adobe’s postscript 3 description language. The image processor features a ...

  • Page 33

    Phaser 7700 color laser printer service manual 1-3 proof jobs a proof job is a specific case of a multiple-copy job. With a proof job, the customer assigns a password and copy account at the client workstation before printing. The first set of prints are printed immediately. The original number of r...

  • Page 34

    1-4 phaser 7700 color laser printer service manual printer ram and printer capabilities the printer features two slots which accept 64, 128 and 256 mbytes of sdram. All combinations are allowed for configurations of 128, 192, 256, 320, 384, and 512 mbytes. ■ 144 pin sodimm ■ serial presence detect ■...

  • Page 35: Crc Life Counter Behavior

    Phaser 7700 color laser printer service manual 1-5 crc life counter behavior internal counters track customer-replaceable consumables (crc) life usage and store the values in nvram. The image processor board monitors these counters in order to display the near end-of-life and end-of-use messages. Ta...

  • Page 36

    1-6 phaser 7700 color laser printer service manual engine control interface and power supply boards figure 1-2 engine control interface and power supply boards high voltage power supply/ t2 board ac drive board noise filter board gfi high voltage power supply/ t3 board high voltage power supply/ t1 ...

  • Page 37: Power Supplies

    Phaser 7700 color laser printer service manual 1-7 power supplies figure 1-3 power supplies s7700-261 24 v low voltage power supply 24 v low voltage power supply fan 3.3 v low voltage power supply 5 v low voltage power supply ac power chassis.

  • Page 38

    1-8 phaser 7700 color laser printer service manual engine control and image processor boards figure 1-4 engine control and image processor boards s7700-381 engine control board image processor board.

  • Page 39

    Phaser 7700 color laser printer service manual 1-9 auxiliary feeder control board figure 1-5 auxiliary feeder control board s7700-385 ltd board (3t) hcf board (tt).

  • Page 40

    1-10 phaser 7700 color laser printer service manual print engine sensors and switches figure 1-6 print engine sensors and switches s7700-287 transfer roller sensor tray 1 take-away sensor paper on belt sensor transparency sensor registration sensor mpt no paper sensor tray 1 no paper sensor/level se...

  • Page 41

    Phaser 7700 color laser printer service manual 1-11 print engine sensors and switches (cont’d.) figure 1-7 print engine sensors and switches (cont’d.) s7700-288 accumulator belt edge sensor accumulator belt home sensor duplex wait sensor automatic toner correction sensor k, c, m, y environment senso...

  • Page 42: Ltd

    1-12 phaser 7700 color laser printer service manual auxiliary feeder sensors and switches figure 1-8 auxiliary feeder sensors and switches s7700-316 2 3 4 2 3 4 paper-size switch assembly -tray 2 paper-size switch assembly -tray 3 -tray 4 paper-size switch assembly -tray 2 -tray 3 -tray 4 take-away ...

  • Page 43: Ltd

    Phaser 7700 color laser printer service manual 1-13 auxiliary feeder actuators and clutches figure 1-9 auxiliary feeder actuators and clutches paper feed sensor actuator tray 3 paper feed sensor actuator tray 4 one way clutch tray 2 tray 3 tray 4 friction clutch tray2 tray 3 tray 4 paper detect sens...

  • Page 44

    1-14 phaser 7700 color laser printer service manual print engine solenoids, actuators, and clutches figure 1-10 print engine solenoids, actuators, and clutches s7700-387 cw duplex clutch ccw duplex clutch registration clutch paper detect sensor actuator (mpt) paper detect sensor actuator (tray 1) ex...

  • Page 45

    Phaser 7700 color laser printer service manual 1-15 print engine and auxiliary feeder interlocks and sensors figure 1-11 print engine and auxiliary feeder interlocks and sensors s7700-390 auxiliary- feeder- left-hand cover-interlock switch left-hand cover interlock switch left hand lower cover senso...

  • Page 46: Image Processor Board

    1-16 phaser 7700 color laser printer service manual image processor board figure 1-12 image processor board j500 sodimm2 processor health led hard drive dip switches nvram (socketed) ethernet usb parallel sodimm1 s7700-258.

  • Page 47

    Phaser 7700 color laser printer service manual 1-17 assemblies of the print engine figure 1-13 assemblies of the print engine s7700-266 fuser assembly detack saw connector paper feeder assembly left-hand lower cover assembly.

  • Page 48

    1-18 phaser 7700 color laser printer service manual assemblies of the print engine (cont’d.) figure 1-14 assemblies of the print engine (cont’d.) s7700-312 developer housing assemblies (4x) dispenser assembly (4x) print cartridge plate waste cartridge sensor holder toner cartridge (4x) k c m y.

  • Page 49

    Phaser 7700 color laser printer service manual 1-19 assemblies of the print engine (cont’d.) figure 1-15 assemblies of the print engine (cont’d.) s7700-386 exit transport assembly.

  • Page 50: Auxiliary Feeder Assemblies

    1-20 phaser 7700 color laser printer service manual auxiliary feeder assemblies figure 1-16 auxiliary feeder assemblies note the high-capacity feeder has a tandem tray design with three paper feeder assemblies, two on the left and one on the right side of the printer. Paper feeder assembly (3x) s770...

  • Page 51: Front Panel Description

    Phaser 7700 color laser printer service manual 1-21 front panel description the front panel consists of one tricolor led, a display window and six functional keys. These keys navigate the menu system, perform functions and select modes of operation for the printer. Led indicators ■ green = ready to ...

  • Page 52: Front Panel Shortcuts

    1-22 phaser 7700 color laser printer service manual front panel shortcuts you can perform several service tasks by using the options shown in the table. Table 1-3 front panel shortcuts mode press this selection at power on skip execution of post diagnostics ok print service diagnostics map info rese...

  • Page 53: Rear Panel

    Phaser 7700 color laser printer service manual 1-23 rear panel connectors the rear panel of the printer features the host interface connectors and dip switches: ■ usb port ■ twisted pair 10/100t ethernet connector ■ bi-directional parallel (high-density connector) ■ dip switches. The following figur...

  • Page 54: Printer Specifications

    1-24 phaser 7700 color laser printer service manual printer specifications physical dimensions and clearances table 1-5 physical dimensions of the printer dimension value height 493 mm (19.4 in.) print engine 857 mm (48. In.) with lower tray deck width 644 mm (25.4 in.) depth 682 mm (26.9 in.) weigh...

  • Page 55

    Phaser 7700 color laser printer service manual 1-25 table 1-7 functional specifications characteristic specification printing process the printer uses laser print heads with an electrophotographic four-color (cmyk) tandem architecture and intermediate transfer printing process. Color medium four ton...

  • Page 56

    1-26 phaser 7700 color laser printer service manual table 1-9 environmental specifications characteristic specification temperature: operating storage 10 to 32 o c -20 to 50 o c humidly: operating storage 10 to 85% relative humidity 30 to 85% relative humidity altitude 0 to 2500 m (8000 ft.) at 25 o...

  • Page 57

    Phaser 7700 color laser printer service manual 1-27 supported paper weights, page sizes and print area supported paper sizes the table identifies the paper weights that can be placed in each tray: laser paper with the following weights: 60-90 g/m 2 (16-24 lb. Bond, 40-60 lb. Book); heavy laser paper...

  • Page 58

    1-28 phaser 7700 color laser printer service manual table 1-10 specialty paper paper type and size tray 1 trays 2- 4 multi- purpose tray high- capacity feeder phaser 7700 premium transparency • • labels • paper envelopes (all sizes) • table 1-11 print area paper page size image area margin top / bot...

  • Page 59

    Phaser 7700 color laser printer service manual 1-29 ra3 305 x 430 mm 297 x 420 mm 5 mm 4 mm sra3 a 320 x 450 mm 303 x 432 mm 9 mm 8.5 mm official #10 envelope 4.13 x 9.5 in. 105 x 241 mm 3.73 x 9.1 in. 95 x 231 mm .2 in. 5 mm .2 in. 5 mm #9 1/2 booklet 9 x 12 in. 8.6 x 11.6 in. .2 in. .2 in. Dl enve...

  • Page 60

    1-30 phaser 7700 color laser printer service manual.

  • Page 61: Diagnostics, Error Codes and

    Phaser 7700 color laser printer service manual 2-31 diagnostics, error codes and messages error messages the control panel displays error codes when it encounters certain system failures or anomalies otherwise undetected by the user. These error codes are discussed in this section. When an error cod...

  • Page 62: System Boot Sequence

    2-32 phaser 7700 color laser printer service manual system boot sequence 1. The main power switch is turned on. The health led turns on immediately. 2. The boot loader checks for ram present and functional - if not, it posts a very large “ram error” on the front panel and blinks the led 1/2 second o...

  • Page 63: Post Faults

    Phaser 7700 color laser printer service manual 2-33 post faults there are two kinds of faults: soft and hard. A soft fault is any fault that is discovered by post but does not prevent the operating system from initializing and becoming available as a tool for troubleshooting. These post faults do no...

  • Page 64

    2-34 phaser 7700 color laser printer service manual post diagnostics test descriptions note if the fault code indicates 12, you must check the front panel to see if the test name is “cpu interrupts” or “ide disk” before beginning troubleshooting. Table 2-1 post diagnostics test descriptions test fau...

  • Page 65: Service Diagnostics

    Phaser 7700 color laser printer service manual 2-35 service diagnostics service diagnostics are to be executed by the service technician through the front panel. The dip switches should be set to service mode while performing functions of the service diagnostics menu. Entering service diagnostics mo...

  • Page 66

    2-36 phaser 7700 color laser printer service manual service diagnostics test menu functions table 2-2 service diagnostics test menu functions test front panel display test operation, results and function definition print service menu map prints the service diagnostics menu page general status provid...

  • Page 67

    Phaser 7700 color laser printer service manual 2-37 offset: none, auto, front, rear set a new offset? Yes no press up/down to change setting. Media type: set new media type? Yes no press up/down to change setting. Output destination change output setting? Yes no press up/down to change setting. Note...

  • Page 68

    2-38 phaser 7700 color laser printer service manual interlocks front (or right) door is l (a) left upper door l (d) duplex cover is l (b) left lower door is l (c) optional tray left cover l h = open l = closed jam sensors lh low cover area is h lh cover area is h lh fuser area is h duplex cover area...

  • Page 69

    Phaser 7700 color laser printer service manual 2-39 read fuser fuses fuse 1 is open fuse 2 is open fuse 3 is shorted 50 page fuse 90 day fuse mis-use fuse open indicates fuse is blown. Accum mob sensor mob sensor is l accumulator mark-on-belt engineering use only belt edge sensor edge is nnn (curren...

  • Page 70

    2-40 phaser 7700 color laser printer service manual print cartridge sensors print cart. Yellow is h print cart. Magenta is h print cart. Cyan is h print cart. Black is h h = cartridge present l = no cartridge present engineering use only finisher sensors interlocks left-hand cover is l top cover is ...

  • Page 71

    Phaser 7700 color laser printer service manual 2-41 steering motor to avoid damaging the accumulator belt, remove! Do you wish to continue? Yes no motor on motor off please cycle power to the printer now! Caution: to avoid damaging the accumulator belt, it is recommended that you leave the belt inst...

  • Page 72

    2-42 phaser 7700 color laser printer service manual offset motor direction: forward backward press up/down to change setting. Developer motor developer motor is on turn motor off all motors off cmy only dispenser motors disp. Motor: yellow magenta cyan black caution only run this test once per power...

  • Page 73

    Phaser 7700 color laser printer service manual 2-43 clutch tests tests functionality of clutches by activating one clutch at a time. Take-away clutch clutch on clutch off all tests are activated by pressing ok. Listen for the clutch. Test times out after 1 second. Developer clutch clutch on clutch o...

  • Page 74

    2-44 phaser 7700 color laser printer service manual regicon 685 setup cycle refer to (processes of the regicon adjustment on page 4-127). Regicon results display refer to processes of the regicon adjustment on page 4-127. Atc sensor setup refer to atc sensor setup on page 4-142. Trc adjust engineeri...

  • Page 75

    Phaser 7700 color laser printer service manual 2-45 nvram access you can read or reset, selected nvram address locations. For all nvram access tests service diagnostics nvram resets on page 6-149 postscript nvram reset refer to service diagnostics nvram resets on page 6-149. Clear tech rep faults cl...

  • Page 76: Voltage Measurements

    2-46 phaser 7700 color laser printer service manual error codes and messages troubleshooting some error codes create “tech rep faults” which must be cleared, see clear tech rep faults on page 6-149. Voltage measurements many voltage measurements are required for expeditious troubleshooting. The foll...

  • Page 77

    Phaser 7700 color laser printer service manual 2-47 fuser connector pin locations fig 2-2 fuser connector pin locations 6 9 3 12 5 8 2 11 4 7 1 10 s7700-427.

  • Page 78

    2-48 phaser 7700 color laser printer service manual error code chain / link front panel message 10 06-380 06-381 06-382 06-383 06-385 error 10 laser unit failure warning do not operate the laser unit outside the printer. The invisible light from the laser can cause permanent eye damage. Remove rear ...

  • Page 79

    Phaser 7700 color laser printer service manual 2-49 12 09-380 error 12 yellow atc sensor failure note if this failure reoccurs three times successively, an engine nvram value is set preventing further printer use until the nvram access / clear tech rep fault / clear is run. Note if necessary, enter ...

  • Page 80

    2-50 phaser 7700 color laser printer service manual 13 09-381 error 13 magenta atc sensor failure note if this failure reoccurs three times successively, an engine nvram value is set preventing further printer use until the nvram access / clear tech rep fault / clear is run. Note if necessary, enter...

  • Page 81

    Phaser 7700 color laser printer service manual 2-51 14 09-382 error 14 cyan atc sensor failure note if this failure reoccurs three times successively, an engine nvram value is set preventing further printer use until the nvram access / clear tech rep fault / clear is run. Note if necessary, enter se...

  • Page 82

    2-52 phaser 7700 color laser printer service manual 15 09-383 error 15 black atc sensor failure note if this failure reoccurs three times successively, an engine nvram value is set preventing further printer use until the nvram access / clear tech rep fault / clear is run. Note if necessary, enter s...

  • Page 83

    Phaser 7700 color laser printer service manual 2-53 20 09-342 error 20 transfer roller contact failure enter service diagnostics mode. Perform the “2nd btr motor” test. Listen for a short run of the motor. Did the motor run? Yes no remove the left-hand rear mid cover (rrp 5, on page 7-158). Inspect ...

  • Page 84

    2-54 phaser 7700 color laser printer service manual 30 04-346 error 30 accumulator belt home position took too long. Note if this failure reoccurs three times successively, an engine nvram value is set preventing further printer use until the nvram access / clear tech rep fault / clear is run. Ensur...

  • Page 85

    Phaser 7700 color laser printer service manual 2-55 30 04-346 error 30 accumulator belt home position took too long (continued) a b c d e repeat the “agitator motor” test while measuring the voltage at the engine control board j404b-4 (see figure page 2-46) (rrp 42, on page 7-206). Does the voltage ...

  • Page 86

    2-56 phaser 7700 color laser printer service manual 31 04-347 error 31 accumulator belt home position failure lower the main release lever and return to the upright position to reestablish electrical connections to the belt. Open the rh door and defeat the interlock switch. Look for rotation of the ...

  • Page 87

    Phaser 7700 color laser printer service manual 2-57 31 04-347 error 31 accumulator belt home position failure (continued) a b c d using a type ii toner vacuum cleaner, vacuum out the waste auger assembly. Replace the waste toner cartridge. Recheck the gear that drives the accumulator belt for freedo...

  • Page 88

    2-58 phaser 7700 color laser printer service manual 32 04-348 error 32 unexpected accumulator belt edge sensor failure remove the accumulator belt assembly (rrp 51, on page 7-217). Inspect the connector for damage. Is the connector in good condition? Yes no replace the accumulator belt assembly (rrp...

  • Page 89

    Phaser 7700 color laser printer service manual 2-59 33 09-350 error 33 unexpected accumulator belt home sen- sor signal remove the accumulator belt assembly (rrp 35, on page 7-196). Inspect the connector for damage. Is the connector in good condition? Yes no replace the accumulator belt assembly (rr...

  • Page 90

    2-60 phaser 7700 color laser printer service manual 40 10-348 error 40 fuser main lamp failure note if this failure reoccurs three times successively, an engine nvram value is set preventing further printer use until the clear tech rep fault, clear is run. Switch printer power off. Remove the fuser ...

  • Page 91

    Phaser 7700 color laser printer service manual 2-61 42 10-352 error 42 fuser sts (front) warm time failure switch printer power off. Remove the fuser assembly. Warning fuser may be very hot. Use extreme caution to prevent burns. Measure the resistance between the fuser assembly connector p600-1 (see...

  • Page 92

    2-62 phaser 7700 color laser printer service manual 43 10-353 error 43 fuser ssr1 on time failure switch printer power off. Remove the fuser assembly. Warning fuser may be very hot. Use extreme caution to prevent burns. Measure the resistance between the fuser assembly connector p600-1 (see figure p...

  • Page 93

    Phaser 7700 color laser printer service manual 2-63 44 10-350 error 44 fuser sub lamp failure note if this failure reoccurs three times successively, an engine nvram value is set preventing further printer use until the clear tech rep fault, clear is run. Switch printer power off. Remove the fuser a...

  • Page 94

    2-64 phaser 7700 color laser printer service manual 46 10-354 error 46 fuser sts (rear) warm time failure switch printer power off. Remove the fuser assembly. Warning fuser may be very hot. Use extreme caution to prevent burns. Measure the resistance between the fuser assembly connector p600-1 and p...

  • Page 95

    Phaser 7700 color laser printer service manual 2-65 47 10-356 error 47 fuser ssr2 on time failure switch printer power off. Remove the fuser assembly. Warning fuser may be very hot. Use extreme caution to prevent burns. Measure the resistance between the fuser assembly connector p600-1 and p600-3 (s...

  • Page 96

    2-66 phaser 7700 color laser printer service manual 54 10-398 error 54 fan failure enter service diagnostics mode. Run the “fuser fan” test. Does the fuser fan operate? Yes no remove the rear cover (rrp 1, on page 7-154), rear shield (rrp 9, on page 7-163) and the rear shield bracket (rrp 11, on pag...

  • Page 97

    Phaser 7700 color laser printer service manual 2-67 60 04-640 error 60 drum motor failure enter service diagnostics mode and run the “print cartridge motor” test. Does the motor run? Yes no remove the rear cover (rrp 1, on page 7-154), the rear cover shield (rrp 9, on page 7-163) and the rear shield...

  • Page 98

    2-68 phaser 7700 color laser printer service manual 70 71 72 73 09-360 09-361 09-362 09-363 error 70 print cartridge 1 communications failure error 70 print cartridge 2 communications failure error 70 print cartridge 3 communications failure error 70 print cartridge 4 communications failure swap the...

  • Page 99

    Phaser 7700 color laser printer service manual 2-69 78 09-358 error 78 waste toner cartridge full detection sensor failure remove the waste cartridge sensor holder without disconnecting the harnesses (rrp 23, on page 7-178). Measure the voltage between the yellow wire to the waste cartridge full sen...

  • Page 100

    2-70 phaser 7700 color laser printer service manual 81 04-358 error 81 controller to engine communications failure switch printer power off. Remove the image processor board, image processor board cover and the image processor metal cover and inspect the orange colored ribbon cable between the relay...

  • Page 101

    Phaser 7700 color laser printer service manual 2-71 one at a time, pull out and reinsert each paper tray. Listen for tray lift. Is there an auxiliary feeder (lower tray deck or a high-capacity feeder) installed? Yes no refer to “tray (1, 2, 3 or 4) will not lift” section, page 3-95, in troubleshooti...

  • Page 102

    2-72 phaser 7700 color laser printer service manual 111 112 12-241 12-242 finisher error 111 stapler move sensor on failure finisher error 112 stapler move sensor off failure open the finisher front door. Defeat the front door interlock switch. Enter service diagnostics mode. Run the stapler “move f...

  • Page 103

    Phaser 7700 color laser printer service manual 2-73 113 12-244 finisher error 113 stapler failure open the finisher front door. Verify the stapler carriage is its full home position. Enter service diagnostics mode. Run the stapler “head home” sensor test to verify home position. Does the sensor indi...

  • Page 104

    2-74 phaser 7700 color laser printer service manual 113 12-244 finisher error 113 stapler failure (continued) does the sensor indicate the stapler is ready? Yes no remove the finisher front cover (rrp 72, on page 11-330). Measure the voltage between stapler unit assembly connector j886-3 (see figure...

  • Page 105

    Phaser 7700 color laser printer service manual 2-75 116 12-254 finisher error 116 stacker height sensor off failure is the finisher stacker tray installed? Yes no install finisher stacker tray. Switch printer power off, then on. Inspect the stack height sensor actuator for proper installation or dam...

  • Page 106

    2-76 phaser 7700 color laser printer service manual 116 12-254 finisher error 116 stacker height sensor off failure (continued) a b c d measure the voltage at the stack height sensor pin 3 (violet) and finisher frame ground. Does the voltage measure 0 vdc? Yes no measure the voltage between the fini...

  • Page 107

    Phaser 7700 color laser printer service manual 2-77 117 12-255 finisher error 117 stacker tray failure (contin- ued) while watching the display, interrupt the stack a and stack b sensors. Does the display indicate h & l for both sensors? Yes no does the display indicate h & l for one sensor? Yes no ...

  • Page 108

    2-78 phaser 7700 color laser printer service manual 118 119 12-256 12-257 finisher error 118 stapler front corner sensor on failure (continued) finisher error 119 stapler front corner sensor off failure (continued) a b c does the voltage toggle between +5 vdc and 0 vdc? Yes no measure the voltage at...

  • Page 109

    Phaser 7700 color laser printer service manual 2-79 120 121 12-260 12-262 finisher error 120 eject clamp home sensor on failure finisher error 121 eject clamp home sensor off failure remove the finisher rear cover (rrp 72, on page 11-330). Remove the sensor from the top of the eject motor mount brac...

  • Page 110

    2-80 phaser 7700 color laser printer service manual 120 121 12-260 12-262 finisher error 120 eject clamp home sensor on failure finisher error 121 eject clamp home sensor off failure a b c d measure the voltage at the eject clamp home sensor pin 3 (violet) and finisher frame ground. Does the voltage...

  • Page 111

    Phaser 7700 color laser printer service manual 2-81 122 12-267 finisher error 122 decurler failure remove the finisher rear cover (rrp 72, on page 11-330). Enter service diagnostics mode. From the main menu, select “sensor tests/finisher sensors/miscellaneous manually rotate the decurler cam shaft s...

  • Page 112

    2-82 phaser 7700 color laser printer service manual 122 12-267 finisher error 122 decurler failure (continued) a b c d measure the voltage at the decurler cam home sensor pin 3 (violet) and finisher frame ground. Does the voltage measure 0 vdc? Yes no measure the voltage between the finisher control...

  • Page 113

    Phaser 7700 color laser printer service manual 2-83 123 12-281 finisher error 123 set clamp failure remove the finisher rear cover (rrp 72, on page 11-330). Enter service diagnostics mode. From the main menu, select “sensor tests/finisher sensors/miscellaneous.” manually operate the set clamp soleno...

  • Page 114

    2-84 phaser 7700 color laser printer service manual 123 12-281 finisher error 123 set clamp failure (continued) a b c d measure the voltage at the set clamp sensor pin 3 (violet) and finisher frame ground. Does the voltage measure 0 vdc? Yes no measure the voltage between the finisher control board ...

  • Page 115

    Phaser 7700 color laser printer service manual 2-85 error code chain / link front panel message 124 07-250 tray communication faillure check the voltage on the tray module pwb between j 555-1 and ground. Is the voltage +5vdc? Yes no using the wiring diagrams, check and repair the +5vdc circuits to t...

  • Page 116

    2-86 phaser 7700 color laser printer service manual error code chain / link front panel message 125 009-910 (k) 009-911 (m) 009-912 (c) 009-913 (y) tray communication faillure 1. Check the installation of the print cartridge. 2. Clear the tech rep fault for errors 009-910 through 009-913 (refer to i...

  • Page 117: Troubleshooting

    Phaser 7700 color laser printer service manual 3-87 troubleshooting for error codes and messages, refer to diagnostics, error codes and messages on page 2-31. The phaser 7700 printer has built-in diagnostics to aid in troubleshooting problems with the printer. The service diagnostics menu provides a...

  • Page 118

    3-88 phaser 7700 color laser printer service manual troubleshooting network problems operating system and application problems ■ macintosh printing problems ■ windows printing problems media jams and the paper path ■ media-based problems ■ multiple-sheet picks ■ mis-picks ■ skewed images ■ damaged p...

  • Page 119: Troubleshooting Ac Power

    Phaser 7700 color laser printer service manual 3-89 troubleshooting power supplies and interlocks troubleshooting ac power 1. Verify that the ac input voltage is present and within specifications. 2. Verify that the reset button on the gfi is depressed. 3. Reconnect ac power. If the gfi trips immedi...

  • Page 120

    3-90 phaser 7700 color laser printer service manual troubleshooting the +3.3 vdc and +5 vdc lvps note turn the printer power off and disconnect the power cord. 1. Remove the rear cover and rear shield. 2. Disconnect the harnesses to connectors p501, p574, p801 and 2ndbtr of the t1 hvps, remove 3 scr...

  • Page 121: Interlock Circuit Diagram

    Phaser 7700 color laser printer service manual 3-91 interlock circuit diagram the +24 vdc interlock circuit the +24 vdc interlock circuit runs from the +24 vdc lvps to the l/h door interlock switch, the r/h door interlock switch, and the front door interlock switch back to the engine control interfa...

  • Page 122

    3-92 phaser 7700 color laser printer service manual the +5 vdc interlock circuit the +5 vdc interlock circuit runs from the +5 vdc lvps to the l/h door switch, then to the engine control interface board, out to the r/h door switch, back to the engine control interface board, out to the front door, t...

  • Page 123: “Ready” State

    Phaser 7700 color laser printer service manual 3-93 troubleshooting when the printer does not come to a “ready” state printer does nothing when power switched on refer to troubleshooting ac power on page 3-89. Fans on, front panel led never on ■ check the image processor board dip switches see you c...

  • Page 124

    3-94 phaser 7700 color laser printer service manual front panel displays "fatal fault encountered" message see procedure for "error 81 controller to engine communications failure” on page 2-70. Troubleshooting - printer comes to a “ready” state false lh door, rh door, or front door open messages see...

  • Page 125: Tray 1 Will Not Lift

    Phaser 7700 color laser printer service manual 3-95 tray 1 will not lift in order for tray 1 to lift, the +24 vdc interlock circuit through the lh, rh and front doors must be complete, one or both of the top two paper size switches must be closed, and the tray level sensor must be deactuated. 1. Det...

  • Page 126

    3-96 phaser 7700 color laser printer service manual tray 2, 3 and 4 will not lift or printer will not recognize the auxiliary feeder there are two circuits connecting the printer to the auxiliary feeder: the power circuit and the serial data link. 1. Check that the auxiliary feeder is properly conne...

  • Page 127: System

    Phaser 7700 color laser printer service manual 3-97 troubleshooting the toner dispense/auger/developer system failures relating to toner dispense, toner auger, and developer system include: ■ false “replace toner cartridge” message ■ atc sensor errors 12, 13, 14, and 15 ■ faded or missing primary co...

  • Page 128

    3-98 phaser 7700 color laser printer service manual checking the toner auger system 1. Power-up the printer in service diagnostics mode. 2. Override the front cover interlock switch. 3. Examine the toner port of the system in question. Usually, the port should be completely filled to the rim. Figure...

  • Page 129

    Phaser 7700 color laser printer service manual 3-99 5. Leaving the toner cartridge out of the printer, run the toner dispense motor test for the system in question. Look at the far end of the toner cartridge cavity and observe the dispense motor gear rotate. Also, look along the right side of the to...

  • Page 130

    3-100 phaser 7700 color laser printer service manual 6. Print 2 to 3 solid fill prints using the primary color in question. The toner level at the port should drop as toner is augered into the developer. Figure 3-5 toner port 7. If the drive shaft rotates but the toner level at the port does not dro...

  • Page 131

    Phaser 7700 color laser printer service manual 3-101 checking the developer atc sensor 1. Power-up the printer in service diagnostics mode. 2. Scroll to the adjustment calibration: tone up/down menu item. Press ok. The test displays information regarding the developer atc sensors. Press ok to read t...

  • Page 132: Checking The Developer

    3-102 phaser 7700 color laser printer service manual checking the developer if, after these checks, the problem still exists: 1. Inspect the wiring harnesses leading to the developer for nicks, pinched wiring, or poor connections. 2. If the wiring harnesses are ok, replace the developer (rrp 27, on ...

  • Page 133

    Phaser 7700 color laser printer service manual 3-103 bead carryout (bco) the atc sensor magnetically measures the ratio of toner particles to developer carrier beads, not the volume. Under a combination of rare circumstances and component tolerances, it is possible fo rthe carrier beads to be pulled...

  • Page 134: Windows Printing Problems

    3-104 phaser 7700 color laser printer service manual operation system and application problems macintosh printing problems image never prints printer acts as if it is receiving data, but nothing comes out of printer or it goes back to “ready” mode without printing image. 1. Power cycle the printer a...

  • Page 135

    Phaser 7700 color laser printer service manual 3-105 troubleshooting network problems the phaser 7700 printer maintains 4 logs in memory detailing network functions. The logs contain tcp/ip, netware and appletalk initialization events. The logs can also be accessed remotely via centreware. The logs ...

  • Page 136: Media-Based Problems

    3-106 phaser 7700 color laser printer service manual media jams and the paper path media-based problems 1. Check that the correct type of media is being used; supported paper weights, page sizes and print area on page 1-27 for the correct media types and weights. The customer should be using a quali...

  • Page 137: Damaged Prints

    Phaser 7700 color laser printer service manual 3-107 damaged prints the printed page exits the printer either wrinkled, creased, or torn. The printer neither jams nor displays an error code. 1. Stop the paper in the paper path to determine where the media becomes damaged. 2. Feed paper through the p...

  • Page 138: Blank Prints

    3-108 phaser 7700 color laser printer service manual print image quality problems light (undertone) prints (all colors) the overall image density is too light. 1. Ensure that the correct color correction was set in the driver. 2. Is the correct paper being used in the printer? 3. Ensure that the loa...

  • Page 139

    Phaser 7700 color laser printer service manual 3-109 one color is faded or missing 1. Is the toner low message being displayed on the front panel? Under high toner-coverage conditions, toner may be depleted during the toner low state but before the toner out message is displayed. 2. Ensure that the ...

  • Page 140

    3-110 phaser 7700 color laser printer service manual missing band in direction of paper travel there are areas of the image that are extremely light or are missing entirely. These missing areas form wide bands that run along the page from leading edge to trailing edge in the direction of paper trave...

  • Page 141

    Phaser 7700 color laser printer service manual 3-111 streaks in direction of paper travel there are dark lines running along the page in the direction of paper travel from the leading edge to the trailing edge (b-size print shown). The printer displays no error code. Note a-size prints are processed...

  • Page 142

    3-112 phaser 7700 color laser printer service manual streaks parallel with the leading edge there are dark lines running parallel with the leading edge of the print, perpendicular to direction of paper travel (b-size print shown). The printer displays no error code. Note a-size prints are processed ...

  • Page 143: Random Missing Spots

    Phaser 7700 color laser printer service manual 3-113 random missing spots there are small areas of the image that are extremely light or are missing entirely. These missing areas form spots that are localized to small areas of the page. The printer displays no error code. A small number of occasiona...

  • Page 144: All Colors

    3-114 phaser 7700 color laser printer service manual all colors 1. Inspect the paper path. 2. Inspect the accumulator belt cleaner and replace if necessary (rrp 36, on page 7-198). 3. Inspect the bias transfer roller and replace if necessary (rrp 17, on page 7-172). 4. Inspect the fuser to see wheth...

  • Page 145: Background Contamination

    Phaser 7700 color laser printer service manual 3-115 background contamination there is toner contamination on all or most of the page. The contamination appears as a very light gray dusting. The printer displays no error code. 1. Ensure that the loaded media matches the front panel settings. In some...

  • Page 146

    3-116 phaser 7700 color laser printer service manual unfused image or image easily rubs off of page the toner image is not completely fused to the paper. The image easily rubs off. The printer displays no error code. 1. Make sure that the paper you are using is the correct type for the printer and i...

  • Page 147: Toner On Back Of Print

    Phaser 7700 color laser printer service manual 3-117 toner on back of print there is toner on the back of the printed sheet of paper. 1. Clean the printer interior. 2. Inspect the paper that is loaded in the paper trays. Is the paper clean and free of toner? 3. Ensure that the loaded media matches t...

  • Page 148: Print Is Mottled

    3-118 phaser 7700 color laser printer service manual print is mottled the printed image has a mottled appearance. 1. Ensure that the paper is in good condition and appropriate for a laser printer. 2. Ensure that the loaded media matches the front panel settings. Also check the media selected in the ...

  • Page 149

    Phaser 7700 color laser printer service manual 3-119 image mis-registered on paper the image area is not centered on the page or the image is bleeding off of the page. The printer displays no error code. 1. Run the configuration or startup page to verify the hard drive, application, and driver setti...

  • Page 150: Residual Image Or Ghosting

    3-120 phaser 7700 color laser printer service manual residual image or ghosting there are faint, ghostly images appearing on the page. The images may be either from a previous page or from the page currently being printed. The printer displays no error code. 1. Make sure that the paper you are using...

  • Page 151

    Phaser 7700 color laser printer service manual 3-121 light bands, dark bands, or mottled prints an image void, dark bank or mottle in a primary cmyk color, or a visible area on the developer roller where toner is missing. Cause narrow image voids or a dark band in the process direction can be caused...

  • Page 152

    3-122 phaser 7700 color laser printer service manual.

  • Page 153: Adjustments And Calibration

    Phaser 7700 color laser printer service manual 4-123 adjustments and calibration the engine firmware has several built-in diagnostic routines that perform various alignment and calibration procedures. The regicon 685 adjustment procedures should be used whenever the technician removes or replaces th...

  • Page 154

    4-124 phaser 7700 color laser printer service manual registration control (regicon) adjustment overview the dc685 regicon tests are the means by which registration is accomplished. Registration means establishing the alignment of the four primary colors with regard to horizontal and vertical positio...

  • Page 155: In/out Skew Adjustment

    Phaser 7700 color laser printer service manual 4-125 coarse and fine skew adjustments skew error is the mislevel of one or more of the four scan lines (c, m, y & k). During the regicon #4 (coarse) and regicon #1 (fine) adjustments, the left side of each line is adjusted to be level with the right en...

  • Page 156: Center Skew Adjustment

    4-126 phaser 7700 color laser printer service manual center skew adjustment the center skew adjustment (magnification balance) adjusts the linearity of the scan lines. During regicon #3, the printer measures a specific midpoint of each scan line and adjusts it to a horizontal reference midpoint. Fig...

  • Page 157: Check Print-Quality

    Phaser 7700 color laser printer service manual 4-127 processes of the regicon adjustment regicon is an engine resident algorithm that aligns the magenta, yellow, and black lasers to the cyan laser. Normally, the regicon procedure only needs to be performed if the laser unit has been replaced. The re...

  • Page 158

    4-128 phaser 7700 color laser printer service manual if any regicon routine appears to run correctly, but does not return any results: 1. You did not wait 10 seconds after the display indicated “ready to print” before re-booting the printer. 2. “netware” was not disabled. 3. If the printer is runnin...

  • Page 159

    Phaser 7700 color laser printer service manual 4-129 y:radc target=400 ave radc trans=367 * (may be different and may change) ideal ld ill=251 * (may be different and may change) vbias=862 vbcr=0 m:radc target=400 ave radc trans=450 * (may be different and may change) ideal ld illl=281 * (may be dif...

  • Page 160

    4-130 phaser 7700 color laser printer service manual registration control procedures note for the following procedures you must perform certain steps prior to, during and after the tests are run. The following information is vital to the process and must be followed in order for each procedure to fu...

  • Page 161

    Phaser 7700 color laser printer service manual 4-131 3 note: turn “netware” off before running any regicon procedures. Perform the regicon #1 fine skew adjustment (page 4-137). To view the results, you must re-enter service diagnostics by turning off the printer, pressing the back and info buttons s...

  • Page 162

    4-132 phaser 7700 color laser printer service manual 5 perform the regicon #3 center skew adjustment procedure (page 4-139). To view the results, you must re-enter service diagnostics by turning off the printer, pressing the back and info buttons simultaneously, and switching the printer on. Do the ...

  • Page 163: Regicon Flowchart

    Phaser 7700 color laser printer service manual 4-133 regicon flowchart figure 4-5 regicon flowchart phaser 7700 registration control adjustment (dc685 regicon adjustment) are all primary fill test prints ok? No run belt edge learn pass? Correct fault (replace accumulator belt) no yes yes run regicon...

  • Page 164: Step 1: Belt Edge Learn

    4-134 phaser 7700 color laser printer service manual step 1: belt edge learn before doing skew adjustments, it is necessary to align the accumulator belt positioning system. A belt steering cam engages an arm on the accumulator belt cleaner to steer the belt. A belt edge sensor provides the real tim...

  • Page 165

    Phaser 7700 color laser printer service manual 4-135 step 2: regicon #4 coarse skew adjustment 1. From the service diagnostics menu, highlight the adjustments/calibration menu and press ok. 2. Highlight regi con 685 setup cycle and press ok. 3. At the prompt: which dc685 procedure?, select #4 coarse...

  • Page 166

    4-136 phaser 7700 color laser printer service manual if regicon coarse skew fails this indicates that the horizontal alignment is so far out of adjustment that a manual adjustment is required before the diagnostics test routines for fine skew can pass. Other possible problems; a mark-on-belt sensor ...

  • Page 167

    Phaser 7700 color laser printer service manual 4-137 step 3: regicon #1 fine skew adjustment this process uses sensors to examine the regicon image on the belt and report what skew adjustments need to be made. A side effect of this test is that horizontal and vertical alignments are automatically do...

  • Page 168

    4-138 phaser 7700 color laser printer service manual step 4: regicon #2 in/out skew adjustment this test makes "magnification" adjustments for registration. Magnification is the length of the scan line for the four colors, so that each scan line for each color is the same length. The data output can...

  • Page 169

    Phaser 7700 color laser printer service manual 4-139 step 5: regicon #3 center skew adjustment this test adjusts magnification balance. There are no manual adjustments required after completing the test. Note to perform this test, move the mark-on-belt sensor to the center position. After the test h...

  • Page 170

    4-140 phaser 7700 color laser printer service manual coarse regicon initialization the coarse regicon initialization procedure is needed when either regicon 1 or 4 fail. If any one of the above conditions exist, perform a manual adjustment of the horizontal alignment. 1. Run the belt edge learn test...

  • Page 171

    Phaser 7700 color laser printer service manual 4-141 ■ note the leading edge of the paper when removing the test print from the tray. Use a pen or pencil to note the leading edge as the “top” of the print “grid 1-dot pattern annotations” on page 4-141. With “top” up, note the direction of scan from ...

  • Page 172: Atc Sensor Setup

    4-142 phaser 7700 color laser printer service manual atc sensor setup the automatic toner calibration (atc) sensor measures the amount of toner in each developer. These sensors have an intrinsic gain and output value are stored in printer nvram. New values must be entered when a new developer housin...

  • Page 173: Cleaning and Maintenance

    Phaser 7700 color laser printer service manual 5-143 cleaning and maintenance service preventive maintenance procedure perform the following procedures whenever you check, service, or repair a printer, cleaning the printer, as outlined in the following steps, assures proper operation of the printer ...

  • Page 174

    5-144 phaser 7700 color laser printer service manual.

  • Page 175: Resetting Nvram

    Phaser 7700 color laser printer service manual 6-145 resetting nvram resetting nvram returns all the image processor's nvram-stored parameters to their factory defaults except the print counts and the adobe firmware serial number. You can reset both the postscript and engine nvram the postscript men...

  • Page 176: Resetting Engine Nvram

    6-146 phaser 7700 color laser printer service manual restore factory settings (margins) you can reset margin settings to the factory-default values. Caution use caution when resetting your margins to the factory-default settings. Changing these settings back to factory defaults may not be the last-s...

  • Page 177: Resetting Job Defaults

    Phaser 7700 color laser printer service manual 6-147 resetting job defaults resetting the job defaults resets the paper source, paper destination, job offset, stapling options, print-quality mode, 2-sided printing, image smoothing and tekcolor corrections to their default values. 1. From the main me...

  • Page 178

    6-148 phaser 7700 color laser printer service manual resetting belt cleaner assembly life resetting the belt cleaner life is to be performed only if the belt cleaner assembly was defective and or the assembly is replaced before an end-of-life or near end-of- life message. Do not to extend the life o...

  • Page 179: Postscript Nvram Reset

    Phaser 7700 color laser printer service manual 6-149 service diagnostics nvram resets postscript nvram reset resetting the printer setup values resets the job defaults, front panel language, intelligent ready, multi-purpose setup, tray 1 - 4 setup, startup page, front panel intensity, front panel co...

  • Page 180: Reset Engine Nvram

    6-150 phaser 7700 color laser printer service manual reset engine nvram reset nvram allows postscript to write stored data from the hard drive to engine nvram. You must restore engine nvram after replacing the engine control board. 1. Enter service diagnostics. Verify switch #2 is down. 2. Highlight...

  • Page 181: Removal and Replacement

    Phaser 7700 color laser printer service manual 7-151 removal and replacement procedures this topic illustrates how to remove and replace printer field replaceable units (frus). For more detailed removal/replacement procedures, refer to the phaser 7700 color laser printer service & support resources ...

  • Page 182: Contents

    7-152 phaser 7700 color laser printer service manual contents rrp 1 rear cover assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-154 rrp 2 right side cover assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-155 rrp 3 top cover asse...

  • Page 183

    Phaser 7700 color laser printer service manual 7-153 rrp 42 engine control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-206 rrp 43 engine control interface board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-207 rrp 44 t1 and t3 high-voltage p...

  • Page 184: Rrp 1 Rear Cover Assembly

    7-154 phaser 7700 color laser printer service manual rrp 1 rear cover assembly removal warning turn off the printer and disconnect the power cord. 1. If an auxiliary feeder has been installed, open the auxiliary feeder connection cover and disconnect the auxiliary feeder wiring harness. 2. Remove th...

  • Page 185

    Phaser 7700 color laser printer service manual 7-155 rrp 2 right side cover assembly removal 1. Open the front cover. 2. Remove the three screws that secure the right side cover to the printer. One screw is located behind the right-hand door. 3. Lightly press downward to release the four hidden tabs...

  • Page 186: Rrp 3 Top Cover Assembly

    7-156 phaser 7700 color laser printer service manual rrp 3 top cover assembly removal 1. Remove the right side cover assembly (rrp 2, on page 7-155). 2. Remove the two screws visible on the right side of the top cover. 3. Open the front cover and remove the front screw holding the top cover. 4. Open...

  • Page 187: Rrp 4 Front Panel Assembly

    Phaser 7700 color laser printer service manual 7-157 rrp 4 front panel assembly removal warning turn off the printer and disconnect the power cord. 1. Open the front door. 2. Release the front panel assembly by inserting a screwdriver or key into the two access holes indicated in the illustration an...

  • Page 188: And Lh Rear Mid Cover

    7-158 phaser 7700 color laser printer service manual rrp 5 rear cover, top rear power switch cover and lh rear mid cover removal top rear power switch cover warning turn off the printer and disconnect the power cord. 1. Remove the rear cover (rrp 1, on page 7-154). 2. Open the left-hand door. 3. Loo...

  • Page 189

    Phaser 7700 color laser printer service manual 7-159 removal (cont’d.) cover, left-hand rear, mid 5. Remove one screw from the left-hand rear low cover and remove the cover. 6. Remove one screw from the left-hand rear mid cover. 7. Lift the cover up to release captive hooks then toward you out of th...

  • Page 190

    7-160 phaser 7700 color laser printer service manual rrp 6 left-hand lower cover assembly removal 1. Open the left-hand lower cover assembly. 2. Disconnect the sensor (in the door) wiring harness plug at the rear and free the harness from the clamp near the rear pivot. 3. With a flat tip screwdriver...

  • Page 191: Rrp 7 Front Cover Assembly

    Phaser 7700 color laser printer service manual 7-161 rrp 7 front cover assembly removal 1. Open the front cover assembly. 2. Rotate the printer end of the strap 90 degrees and pull it straight out of the printer (both sides). 3. Remove the screws that secure the hinges and slide the hinges off the l...

  • Page 192: Rrp 8 Fuser Front Cover

    7-162 phaser 7700 color laser printer service manual rrp 8 fuser front cover removal 1. Remove the front cover assembly (rrp 7, on page 7-161). 2. Remove two screws from the fuser front cover and push upward and remove the cover. Figure 7-8 fuser front cover s7700-029.

  • Page 193: Rrp 9 Rear Shield

    Phaser 7700 color laser printer service manual 7-163 rrp 9 rear shield removal warning turn off the power and disconnect the power cord. 1. Remove the rear cover (rrp 1, on page 7-154). 2. Remove the seven screws securing the rear shield to the printer. 3. Remove the shield. Figure 7-9 rear shield s...

  • Page 194: Rrp 10 Rear Shield Bracket

    7-164 phaser 7700 color laser printer service manual rrp 10 rear shield bracket removal 1. Remove the rear cover (rrp 1, on page 7-154). 2. Remove the rear shield (rrp 9, on page 7-163). 3. Remove the three screws securing the rear shield bracket to the printer. 4. Remove the rear shield bracket. Fi...

  • Page 195

    Phaser 7700 color laser printer service manual 7-165 rrp 11 24 vdc power supply shield removal 1. Remove the rear cover (rrp 1, on page 7-154). 2. Remove the rear shield (rrp 9, on page 7-163). 3. Remove the rear shield bracket (rrp 10, on page 7-164). 4. Remove the four screws securing the 24 vdc p...

  • Page 196

    7-166 phaser 7700 color laser printer service manual rrp 12 multi-purpose tray (mpt) assembly removal note complete mpt removal is not necessary when doing jobs such as shutter solenoid or main motor assembly replacement. Remove the two mpt screws (step 5 below), and let the mpt hang by the wire har...

  • Page 197

    Phaser 7700 color laser printer service manual 7-167 rrp 13 multi-purpose tray paper pick rollers removal 1. Open the left side door. Locate the pick rollers near the duplex chute. 2. Slide the white retainers away from the pick rollers. 3. Slide the pick rollers off the retaining pins. 4. Lift and ...

  • Page 198: Door)

    7-168 phaser 7700 color laser printer service manual rrp 14 left-hand cover assembly (left-hand door) partial removal 1. Partially remove the multi-purpose tray (rrp 12, on page 7-166). 2. Remove one screw from the plastic harness cover inside the empty mpt slot and remove the plastic cover. 3. Open...

  • Page 199

    Phaser 7700 color laser printer service manual 7-169 5. Remove the retaining clip off the restraint post. 6. Support the left-hand door, and then remove the restraining bracket from the door. 7. While supporting the left side door, carefully lower it to 75-90° then remove the door by lifting it up o...

  • Page 200: Rrp 15 Duplex Chute

    7-170 phaser 7700 color laser printer service manual rrp 15 duplex chute removal 1. Partially remove the left-hand cover assembly (left door) (rrp 14, on page 7-168). 2. Rotate the duplex chute downward until the keyed pivot shaft can be removed from the pivot bracket. 3. Remove the duplex chute. Fi...

  • Page 201

    Phaser 7700 color laser printer service manual 7-171 rrp 16 duplex unit assembly removal 1. Release the clip securing the duplex unit cover and remove the cover. 2. Loosen the two captive screws securing the duplex unit assembly to the left-hand cover assembly and remove. Figure 7-17 duplex unit ass...

  • Page 202

    7-172 phaser 7700 color laser printer service manual rrp 17 transfer roller assembly (2nd btr) special tool required: 2.5 mm hex driver removal 1. Open the left-hand cover assembly (left door). 2. Using a 2.5 mm hex driver, remove the four captive screws from the mounting brackets (2) at each end of...

  • Page 203

    Phaser 7700 color laser printer service manual 7-173 rrp 18 duplex transport assembly removal 1. Partially remove the left-hand cover assembly (left door) (rrp 14, on page 7-168). 2. Remove the e-clip and remove the shaft. 3. Remove the two screws that secure the inverter transport assembly to the l...

  • Page 204: Rrp 19 Fuser Unit

    7-174 phaser 7700 color laser printer service manual rrp 19 fuser unit removal 1. Open the left-hand door. Caution the fuser unit may be hot. 2. Unscrew the two thumb screws securing the fuser unit. 3. Using the pull handles, pull the fuser unit out of the printer. Figure 7-20 fuser unit s7700.031.

  • Page 205

    Phaser 7700 color laser printer service manual 7-175 rrp 20 registration transport assembly note turn the printer power off and unplug the power cord. Removal 1. Partially remove the mpt. 2. Remove the two screws from the plastic flanges that secure the assembly in the printer frame using a stubby s...

  • Page 206

    7-176 phaser 7700 color laser printer service manual rrp 21 shutter solenoid assembly removal 1. Partially remove the mpt (rrp 12, on page 7-166). 2. Partially remove the left-hand cover assembly (left door) (rrp 14, on page 7-168). 3. Remove the registration transport assembly (rrp 20, on page 7-17...

  • Page 207: Motor

    Phaser 7700 color laser printer service manual 7-177 rrp 22 tray 1 feeder assembly and paper lift motor removal 1. Remove the left-hand lower cover assembly (rrp 6, on page 7-160). 2. Open tray 1 halfway. 3. Disconnect the wiring harness. 4. Remove the two screws holding the tray 1 feeder assembly, ...

  • Page 208

    7-178 phaser 7700 color laser printer service manual rrp 23 waste cartridge sensor holder removal 1. Open the front door. 2. Open the waste cartridge cover. Caution to avoid a toner spill and subesquent cleanup, use great care in removing the waste cartridge. 3. Remove the waste cartridge. 4. Remove...

  • Page 209

    Phaser 7700 color laser printer service manual 7-179 rrp 24 print cartridge plate cover removal print cartridge plate cover 1. Open the front door. 2. Remove fuser front cover (rrp 8, on page 7-162). 3. Lower the main lever. 4. Remove the four screws. 5. Remove the plastic print cartridge plate cove...

  • Page 210: Rrp 25 Dispense Assembly

    7-180 phaser 7700 color laser printer service manual rrp 25 dispense assembly removal note after replacing the print cartridge plate assembly, you must perform the regicon adjustment to the printer ,on page 4-130. Caution use only a type ii toner vacuum to clean up toner spills. Note have a large sh...

  • Page 211

    Phaser 7700 color laser printer service manual 7-181 5. Pull the shut off gate of each toner cartridge toward you (approximately 3/4” [or 20mm]) to shut off the toner supply for each toner tube (see figure 7-26, “dispense assembly,” on page 7-180). Caution be careful when moving the stops. They are ...

  • Page 212

    7-182 phaser 7700 color laser printer service manual rrp 26 print cartridge plate assembly removal caution the print cartridges are very light sensitive. Store the print cartridge away from light. Do not touch the surface of the print cartridges. 1. Remove the print cartridges 2. Leave the main leve...

  • Page 213

    Phaser 7700 color laser printer service manual 7-183 4. Remove the print cartridge plate cover (rrp 24, on page 7-179). 5. Remove the dispense assemblies (rrp 25, on page 7-180). 6. Disconnect the wiring harnesses to all four developer housing assemblies and remove them from under their retaining cl...

  • Page 214

    7-184 phaser 7700 color laser printer service manual 11. Disconnect the harness. 12. Remove the print cartridge plate assembly. Replacement. Note ensure the developer assemblies are fully and evenly seated when reinstalling the print cartridge plate assembly. There is a locating pin at the back of e...

  • Page 215

    Phaser 7700 color laser printer service manual 7-185 rrp 27 developer housing assembly removal note complete removal of the print cartridge plate assembly is not required for removal of the developer(s). Tilt the print cartridge plate assembly forward enough to allow the developer(s) to be removed. ...

  • Page 216: Charging

    7-186 phaser 7700 color laser printer service manual rrp 28 new developer housing assembly charging recharging a developer housing assembly caution if replacing a developer housing assembly, write down the new atc tag number. Remove the tear-off atc tag number label, and adhere it to the appropriate...

  • Page 217

    Phaser 7700 color laser printer service manual 7-187 caution during this procedure, the developer housing assembly must be kept in a level position at all times. It is recommended the developer housing assembly be fully supported level by laying it on something like a large piece of cloth, paper tow...

  • Page 218

    7-188 phaser 7700 color laser printer service manual rrp 29 toner dispense motor assembly removal 1. Remove right cover (rrp 2, on page 7-155) and the top cover assembly (rrp 3, on page 7-156). 2. Remove the dispense housing assemblies (rrp 25, on page 7-180). 3. Remove the two screws that secure th...

  • Page 219

    Phaser 7700 color laser printer service manual 7-189 rrp 30 steering drive assembly removal 1. Remove the print cartridges and print cartridge plate cover (rrp 24, on page 7-179). 2. Disconnect the wiring harness. 3. Remove the three screws and remove the steering drive assembly. Note you may have t...

  • Page 220

    7-190 phaser 7700 color laser printer service manual rrp 31 waste toner agitator motor assembly removal 1. Remove the print cartridge plate cover (rrp 24, on page 7-179). 2. Remove the waste cartridge assemblies (rrp 23, on page 7-178). 3. Disconnect the wiring harness to the motor. 4. Remove the tw...

  • Page 221

    Phaser 7700 color laser printer service manual 7-191 rrp 32 mark-on-belt (mob) sensor removal 1. Remove the waste cartridge assembly (rrp 23, on page 7-178). 2. Remove the waste toner agitator motor (rrp 31, on page 7-190). 3. Remove left-hand inner cover. 4. Disconnect the purple harness. 5. Remove...

  • Page 222

    7-192 phaser 7700 color laser printer service manual rrp 33 exit transport assembly removal 1. Remove the rear cover (rrp 1, on page 7-154). 2. Remove left-hand top power switch cover (rrp 5, on page 7-158). 3. Remove the fuser front cover (rrp 8, on page 7-162). 4. Open left-hand cover. 5. Remove t...

  • Page 223

    Phaser 7700 color laser printer service manual 7-193 reconfigured inverter transport assembly (p/n 116-1161-00) note when replacing the inverter transport assembly, do not transfer any parts from the original assembly to the replacement asssembly. The replacement assembly will work correctly in the ...

  • Page 224

    7-194 phaser 7700 color laser printer service manual the interlock actuator and two 0.5 mm spacers are now being added to the inverter transport assembly packaging as a separate item (see figure 7-38). If only the interlock actuator is broken, it can now be replaced individually. The 0.5 mm spacers ...

  • Page 225: Rrp 34 Fuser Fan Assembly

    Phaser 7700 color laser printer service manual 7-195 rrp 34 fuser fan assembly removal 1. Remove the rear cover (rrp 1, on page 7-154). 2. Remove the top cover (rrp 3, on page 7-156). 3. Remove right side cover (rrp 2, on page 7-155). Note note the routing of the wiring harness. Note it is easier to...

  • Page 226

    7-196 phaser 7700 color laser printer service manual rrp 35 accumulator belt assembly figure 7-40 accumulator belt assembly.

  • Page 227

    Phaser 7700 color laser printer service manual 7-197 removal 1. Open the right cover door. 2. Open the front cover and lower the main lever. 3. Lift the accumulator belt locking lever and pull the assembly out of the printer. You need to hold the locking lever up until the white nylon handle is expo...

  • Page 228: Rrp 36 Belt Cleaner Assembly

    7-198 phaser 7700 color laser printer service manual rrp 36 belt cleaner assembly removal 1. Open the right cover door. 2. Open the front cover and lower the main lever. 3. Lift the accumulator belt locking lever and pull the assembly out a few inches. 4. Using a 2.5 mm hex driver remove the two scr...

  • Page 229

    Phaser 7700 color laser printer service manual 7-199 rrp 37 waste auger assembly removal 1. Remove the right side cover (rrp 2, on page 7-155). 1. Remove waste toner cartridge and lower the main lever. 2. Remove accumulator belt assembly. 3. Return the main lever to its upright position. 4. Remove t...

  • Page 230: Rrp 38 Laser Unit

    7-200 phaser 7700 color laser printer service manual rrp 38 laser unit figure 7-43 laser unit assembly.

  • Page 231

    Phaser 7700 color laser printer service manual 7-201 removal 1. Remove the rear cover (rrp 1, on page 7-154). 1. Remove the right-hand cover (rrp 2, on page 7-155). 2. Disconnect the wiring harnesses at engine board p400 and 401. 3. Undo the retainers and undo the wiring harness. Note note the routi...

  • Page 232

    7-202 phaser 7700 color laser printer service manual rrp 39 image processor board assembly note turn the printer power off and unplug the printer. Caution the image processor board is susceptible to esd damage. Observe proper esd procedures. 1. Disconnect all communication cables. 2. Remove the four...

  • Page 233

    Phaser 7700 color laser printer service manual 7-203 rrp 40 internal hard drive figure 7-46 internal hard drive caution the internal hard drive is susceptible to esd damage. Observe proper esd procedures. 1. Remove the image processor board. See (rrp 39, on page 7-202). 2. Using a t-10 torx bit, rem...

  • Page 234

    7-204 phaser 7700 color laser printer service manual rrp 41 electrical chassis (card cage) assembly removal caution before removing the electrical chassis assembly, it is recommended to store engine nvram data on the hard drive (see store engine nvram on page 6-150). 1. Remove the right cover (rrp 1...

  • Page 235

    Phaser 7700 color laser printer service manual 7-205 7. Undo the harness retainer. Disconnect the wiring harness to the relay board connector p300 and the front panel cable to p564. 8. Remove the two mounting screws towards printer rear, but only loosen the two mounting screws towards the printer fr...

  • Page 236

    7-206 phaser 7700 color laser printer service manual rrp 42 engine control board removal 1. Store the engine board nvram values to the hard drive (store engine nvram on page 6-150). 2. Remove the electrical chassis (card cage) assembly (rrp 41, on page 7-204) 3. Disconnect the orange ribbon cable at...

  • Page 237

    Phaser 7700 color laser printer service manual 7-207 rrp 43 engine control interface board removal method #1 1. Remove the engine control board (rrp 42, on page 7-206). 2. Disconnect the eight wiring harnesses. Note two connectors (j537, j536) have locks to release before pulling on the harnesses. 3...

  • Page 238

    7-208 phaser 7700 color laser printer service manual rrp 44 t1 and t3 high-voltage power supplies removal 1. Remove rear cover and shield (rrp 9, on page 7-163). Note do not disconnect the t1 wire harness at p572 (blue connector). 1. Disconnect the wiring harness at p/j501 and p/j574. 2. Disconnect ...

  • Page 239

    Phaser 7700 color laser printer service manual 7-209 replacement note connect the high-voltage 2nd btr and p/j 801 wires before securing the assembly to the printer to ensure they are not forgotten. Note the grounding point requires the chrome plated screw (not a black screw)..

  • Page 240: Supplies And Bracket

    7-210 phaser 7700 color laser printer service manual rrp 45 3.3 vdc and 5 vdc low-voltage power supplies and bracket removal note if removing only one of the low-voltage power supplies, disconnect the associated wiring harness from the printer, and remove the 4 screws that secure the low-voltage pow...

  • Page 241: Rrp 46 Ld Power Relay

    Phaser 7700 color laser printer service manual 7-211 rrp 46 ld power relay removal 1. Remove rear cover and shield (rrp 9, on page 7-163). 2. Disconnect the wiring harness. 3. Remove the two screws securing the ld power assembly. 4. Remove the ld power assembly. Figure 7-52 ld power relay fig. 2 fig...

  • Page 242: And Bracket

    7-212 phaser 7700 color laser printer service manual rrp 47 +24 vdc low-voltage power supply, fan and bracket removal 1. Remove the rear cover and +24 vdc shield (rrp 11, on page 7-165). 2. Remove the top power switch cover, left-hand power switch and left-hand rear mid covers (rrp 6, on page 7-160)...

  • Page 243

    Phaser 7700 color laser printer service manual 7-213 rrp 48 t2 high-voltage power supply removal 1. Remove the +24 vdc power supply and bracket (rrp 11, on page 7-165). 2. Disconnet the high-voltage wires from the kcmy connectors. 3. Disconnect the wiring harness from j575 and j576. 4. Remove the tw...

  • Page 244

    7-214 phaser 7700 color laser printer service manual rrp 49 chassis ac power assembly removal note ac power (consists of the ac drive, noise filter and gfi assemblies and mounting bracket. 1. Remove the t2 high-voltage power supply (rrp 48, on page 7-213). 2. Remove t1 and t3 power supply assembly (...

  • Page 245

    Phaser 7700 color laser printer service manual 7-215 rrp 50 main drive assembly removal 1. Remove the fuser (rrp 18, on page 7-173). 1. Remove the multi-purpose tray (rrp 12, on page 7-166). 2. Remove the t2 high-voltage power supply (rrp 48, on page 7-213). 3. Disconnect the wiring harness. Note th...

  • Page 246

    7-216 phaser 7700 color laser printer service manual note as the main drive assembly is being installed into position, make sure the gears are meshed with the mating gears by slightly rotating the main motor until the main motor bracket seats without stress, and flat against the frame. Rotate the ma...

  • Page 247

    Phaser 7700 color laser printer service manual 7-217 rrp 51 accumulator belt drive assembly removal 1. Remove the rear cover and shield (rrp 9, on page 7-163). 2. Lower the t1 and t3 power supply to horizontal (rrp 44, on page 7-208). 3. Remove any components covering the motor which is mounted to t...

  • Page 248

    7-218 phaser 7700 color laser printer service manual rrp 52 developer drive assembly removal 1. Remove the 3.3 vdc and 5 vdc power supply and bracket assembly (rrp 45, on page 7-210). 2. Disconnect the wiring harness from the developer drive assembly. 3. Clear the high-voltage lines. 4. Remove the t...

  • Page 249

    Phaser 7700 color laser printer service manual 7-219 rrp 53 print cartridge drive assembly removal 1. Remove the rear cover assembly (rrp 1, on page 7-154). 2. Remove the right cover assembly (rrp 2, on page 7-155). 3. Remove the 3.3 vdc and 5 vdc low-voltage power supply bracket assembly (rrp 45, o...

  • Page 250

    7-220 phaser 7700 color laser printer service manual rrp 54 tray 1 paper-select switches 1. Remove the t1 and t3 high-voltage power supply (rrp 44, on page 7-208). 1. Remove the 3.3 vdc and 5 vdc low-voltage power supply (rrp 45, on page 7-210). 2. Disconnect the wiring harness from the tray 1 paper...

  • Page 251: Right and Left-Hand Jacks

    Phaser 7700 color laser printer service manual 7-221 rrp 55 main lever assembly right and left-hand jacks removal - main lever assembly 1. Remove the accumulator belt assembly (rrp 35, on page 7-196). 2. Remove the print cartridges and protect from the light. 3. Remove fuser front cover (rrp 8, on p...

  • Page 252

    7-222 phaser 7700 color laser printer service manual 8. Remove the two screws holding the waste auger assembly. 9. Remove the four screws holding the rh lift jack bracket and remove from the printer. Note when reinstalling the rh lift jack assembly install the screws as follows: upper left, upper ri...

  • Page 253

    Phaser 7700 color laser printer service manual 7-223 aligning lift jack assembly gears visually examine both ends of the accumulator belt assembly or belt lift frame assembly while operating the lift handle to determine if the left or right end is out of alignment. Then follow the applicable procedu...

  • Page 254

    7-224 phaser 7700 color laser printer service manual 2. Flip open the cover plate. Figure 7-64 cover removed 3. Remove the tension spring. Figure 7-65 tension spring location 4. Align the triangle marks on the gears and the rack by lifting the gear assemblies on their mounting posts until they disen...

  • Page 255

    Phaser 7700 color laser printer service manual 7-225 rrp 56 auxiliary feeder covers left side door 1. Remove the four screws securing the left-hand outer cover and remove. 2. Remove the screws securing the straps. 3. Remove the one screw holding the front side pivot bracket and remove the left-hand ...

  • Page 256

    7-226 phaser 7700 color laser printer service manual rrp 57 auxiliary feeder cover assembly removal 1. Open the high-capacity feeder (hcf) cover assembly. 2. Remove one screw from each of the support straps. 3. Remove one screw from the cover’s right-hand pivot bracket. 4. Remove the cover assembly ...

  • Page 257

    Phaser 7700 color laser printer service manual 7-227 rrp 58 high-capacity feeder (hcf) tray 3 removal 1. On the left side of the hcf, remove one screw from the tray 3 stopper bracket and remove the bracket. 2. Pull tray 3 out of the printer. Figure 7-69 high-capacity feeder (hcf) tray 3.

  • Page 258: Paper Transport

    7-228 phaser 7700 color laser printer service manual rrp 59 high-capacity feeder (hcf) tray 4 and paper transport removal 1. Open tray 4. 2. Remove the two screws that secure the tray 4 stopper. 3. Remove the two screws securing the paper transport, and slide it back in. 4. Pull tray 4 out of the pr...

  • Page 259

    Phaser 7700 color laser printer service manual 7-229 rrp 60 auxiliary feeder control boards removal 1. Remove the rear cover (rrp 1, on page 7-154). 2. Disconnect the wire harnesses. 3. Remove the four screws securing the control board and remove the board. Figure 7-71 ltd control or hcf control boa...

  • Page 260

    7-230 phaser 7700 color laser printer service manual rrp 61 auxiliary feeders motor assemblies removal 1. Remove rear cover (rrp 1, on page 7-154). 2. Disconnect the wire harness. 3. Remove the two screws securing the motor assembly. 4. Remove the motor assembly. Figure 7-72 transport motor assembly...

  • Page 261

    Phaser 7700 color laser printer service manual 7-231 rrp 62 auxiliary feeder paper-select switches removal 1. Remove the paper tray. 2. Reaching inside the cabinet, disconnect the wire harness. Ltd: 3 places. Hcf: 1 place 3. Reaching inside the cabinet, remove the 1 screw that secures the paper-sele...

  • Page 262: Assembly

    7-232 phaser 7700 color laser printer service manual rrp 63 auxiliary feeder paper feed motor assembly removal 1. Remove the left-hand cover. 2. Open the tray halfway. 3. Disconnect the wiring harness. 4. Remove the two screws holding the tray 1 feeder assembly, not the screws securing the lower tra...

  • Page 263: Right-Hand Gear (Hcf)

    Phaser 7700 color laser printer service manual 7-233 rrp 64 bracket assembly, left-hand and right-hand gear (hcf) removal 1. Remove the rear cover (rrp 1, on page 7-154). 2. Remove the two screws securing the bracket assembly (gear rh or gear lh) to the frame. 3. Remove the bracket assembly. Replace...

  • Page 264

    7-234 phaser 7700 color laser printer service manual.

  • Page 265: Fru Parts List

    Phaser 7700 color laser printer service manual 8-235 fru parts list this topic provides a list of field replaceable units (frus) for the phaser 7700 color laser printer. Changes to xerox products are made to accommodate improved components as they become available. It is important when ordering part...

  • Page 266

    8-236 phaser 7700 color laser printer service manual pl 8-1 accumulator belt frus figure 8-1 accumulator belt frus table 8-1 accumulator belt frus list parts part number qty name and description (vendor description) 1 016-1889-00 1 accumulator belt/cleaner assembly kit (belt assembly - ibt) 2 116-12...

  • Page 267: Pl 8-2 Left-Hand Door Frus

    Phaser 7700 color laser printer service manual 8-237 pl 8-2 left-hand door frus figure 8-2 left-hand door frus 1 2a 2 s7700-042 3 8 9 5 6 7 4.

  • Page 268

    8-238 phaser 7700 color laser printer service manual table 8-2 left-hand door frus list parts part number qty name and description (vendor description) 1 116-1161-00 1 transport assembly, inverter 2 2a 116-1182-00 116-1317-00 1 1 regi. Chute assembly left-hand cover only (cover assembly-l/h2) 3 016-...

  • Page 269: Pl 8-3 Media Trays Frus

    Phaser 7700 color laser printer service manual 8-239 pl 8-3 media trays frus figure 8-3 media trays frus table 8-3 media trays frus list parts part number qty name and description (vendor description) 1 116-1091-00 1 universal paper tray 2 2a 116-1093-00 1 2 universal paper tay stopper spacer 2a x s...

  • Page 270: Pl 8-4 Duplex Unit Frus

    8-240 phaser 7700 color laser printer service manual pl 8-4 duplex unit frus figure 8-4 duplex unit frus table 8-4 duplex unit frus list parts part number qty name and description (vendor description) 1 116-1097-00 1 duplex unit (transport assembly - du) 1 s7700-064.

  • Page 271: Pl 8-5 Cover Frus

    Phaser 7700 color laser printer service manual 8-241 pl 8-5 cover frus figure 8-5 cover frus table 8-5 cover frus list parts part number qty name and description (vendor description) 1 116-1178-00 1 1 2 2 1 1 1 1 1 front cover assembly (cover assembly front) front cover magnet strip rod cleaner asse...

  • Page 272

    8-242 phaser 7700 color laser printer service manual pl 8-6 cover frus (cont’d.) figure 8-6 cover frus (cont’d.) table 8-6 cover frus (cont’d.) list parts part number qty name and description (vendor description) 1 116-1181-00 029e31600 (compatible with phaser 7760) 1 1 1 2 1 1 2 1 1 1 2 1 1 2 lh lo...

  • Page 273

    Phaser 7700 color laser printer service manual 8-243 pl 8-7 cover frus (cont’d.) figure 8-7 cover frus (cont’d.) s7700-060 7 12 8 10 9 11 2 3 4 5 1 6.

  • Page 274

    8-244 phaser 7700 color laser printer service manual table 8-7 covers frus list (cont’d.) parts part number qty name and description (vendor description) 1 116-1179-00 1 1 rear cover assembly (cover assembly rear) blind cover 2 116-1190-00 1 cover, top rear ps (cover top rear) 3 116-1189-00 1 cover,...

  • Page 275

    Phaser 7700 color laser printer service manual 8-245 pl 8-8 switch and sensor frus figure 8-8 switch and sensor frus s7700-407 6 5 3 3 3 3 2 4 1 7 9 8.

  • Page 276

    8-246 phaser 7700 color laser printer service manual table 8-8 switch and sensor frus list parts part number qty name and description (vendor description) 1 116-1299-00 1 waste cartridge full sensor (part of sensor kit) 2 116-1124-00 1 mark-on-belt (mob) sensor assembly 3 116-1299-00 1 automatic ton...

  • Page 277

    Phaser 7700 color laser printer service manual 8-247 pl 8-9 switch and sensor frus (cont’d.) figure 8-9 switch and sensor frus (cont’d.) s7700-415 4 7 8 3 1 2 5 6 9.

  • Page 278

    8-248 phaser 7700 color laser printer service manual table 8-9 switch and sensor frus list (cont’d.) parts part number qty name and description (vendor description) 1 116-1210-00 1 paper detect flag, mpt (part of sensor flag kit) 2 116-1132-00 1 laser shutter solenoid assembly 3 116-1299-00 1 paper ...

  • Page 279: Pl 8-10 Circuit Boards Frus

    Phaser 7700 color laser printer service manual 8-249 pl 8-10 circuit boards frus figure 8-10 circuit boards frus s7700-095 2 1 3 5 4.

  • Page 280

    8-250 phaser 7700 color laser printer service manual table 8-10 circuit board frus list parts part number qty name and description (vendor description) 1 116-1145-00 1 chassis assembly, elec (chassis, e, b) 2 116-1144-00 1 engine control board (pwba mcu) 3 671-5268-02 1 image processor board 4 156-4...

  • Page 281

    Phaser 7700 color laser printer service manual 8-251 pl 8-11 power supplies frus figure 8-11 power supplies frus s7700-053 11 24 v lvps 8, 9 13 24 v ps fan 6, 7 5 v lvps 13 4, 5 3.3 v lvps 1 (t1 hvps) r w 2 (t2 hvps) 3 (t3 hvps) 10 t1 control bd.

  • Page 282

    8-252 phaser 7700 color laser printer service manual table 8-11 power supplies frus list parts part number qty name and description (vendor description) 1 116-1146-00 1 1 high-voltage power supply -t1(pshvt1) t1 control board 2 116-1147-00 1 high-voltage power supply -t2 (pshvt2) 3 116-1148-00 1 hig...

  • Page 283

    Phaser 7700 color laser printer service manual 8-253 pl 8-12 power supplies frus (cont’d.) figure 8-12 power supplies frus (cont’d.) s7700-054 4 ac drive bd 2 4 16 noise filer bd gfi w 3 1, 2.

  • Page 284

    8-254 phaser 7700 color laser printer service manual table 8-12 power supplies frus list (cont’d.) parts part number qty name and description (vendor description) 1 116-1155-00 1 1 1 1 1 1 1 1 1 1 1 1 chassis assembly - ac power, 110v bracket ac drive board clamp noise filter gfi breaker wire harnes...

  • Page 285: Pl 8-13 Motors/drivers Frus

    Phaser 7700 color laser printer service manual 8-255 pl 8-13 motors/drivers frus figure 8-13 motors/drivers frus v v 4 v 3 2 bm v v x 1 s7700-034 rear 15 v l 9 8 10 13 14 x front 7.

  • Page 286

    8-256 phaser 7700 color laser printer service manual table 8-13 motors / drivers frus list parts part number qty name and description (vendor description) 1 116-1102-00 1 1 1 print cartridge drive assembly (drive assembly drum) motor gear bracket assembly 2 116-1103-00 1 1 1 accumulator belt drive a...

  • Page 287

    Phaser 7700 color laser printer service manual 8-257 pl 8-14 electrophotographic components frus figure 8-14 electrophotographic components frus 3 s7700-013 1 2.

  • Page 288

    8-258 phaser 7700 color laser printer service manual table 8-14 electrophotographic components frus list parts part number qty name and description (vendor description) 1 116-1110-00 1 laser unit (ros assembly) 2 116-1197-00 1 print cartridge plate assembly 3 116-1118-00 1 1 4 1 1 1 1 4 toner dispen...

  • Page 289

    Phaser 7700 color laser printer service manual 8-259 pl 8-15 electrophotographic components frus (cont’d.) figure 8-15 electrophotographic components frus (cont’d.) s7700-057 1 1 1 1 atc sensor and seal (4x) front 5 4 3 2.

  • Page 290

    8-260 phaser 7700 color laser printer service manual table 8-15 electrophotographic components frus list (cont’d.) parts part number qty name and description (vendor description) 1 116-1115-00 116-1111-00 116-1112-00 116-1113-00 116-1114-00 1 1 1 1 developer housing assembly (hsg assembly deve) deve...

  • Page 291

    Phaser 7700 color laser printer service manual 8-261 pl 8-16 multi-purpose tray frus figure 8-16 multi-purpose tray frus 1 s7700-045 2 3 5 4.

  • Page 292

    8-262 phaser 7700 color laser printer service manual table 8-16 multi-purpose tray (mpt) frus list parts part number qty name and description (vendor description) 1 116-1157-00 1 multi-purpose tray (mpt) assembly 2 116-1158-00 1 mpt tray pinch roller assembly 1 (w 10,11, 13, 14,16) pinch roller asse...

  • Page 293: Pl 8-17 Paper Feed Frus

    Phaser 7700 color laser printer service manual 8-263 pl 8-17 paper feed frus figure 8-17 paper feed frus 2 v s7700-040 4 15 ba v s s bd bb 1 v m v v v a a 3.

  • Page 294

    8-264 phaser 7700 color laser printer service manual table 8-17 paper feed frus list parts part number qty name and description (vendor description) 1 116-1160-00 116-1109-00 1 1 3 paper feeder assembly (feeder assembly) paper feed motor assembly roller feed/nudge/retard paper feed motor only (motor...

  • Page 295

    Phaser 7700 color laser printer service manual 8-265 pl 8-18 paper feed frus (cont’d.) figure 8-18 paper feed frus (cont’d.) s7700-044 1 2.

  • Page 296

    8-266 phaser 7700 color laser printer service manual t table 8-18 paper feed frus list (cont’d.) parts part number qty name and description (vendor description) 1 116-1165-00 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 transport assembly, exit -oct (transport assembly) exit cover bearing pin exit roll...

  • Page 297: Pl 8-19 Fans Frus

    Phaser 7700 color laser printer service manual 8-267 pl 8-19 fans frus figure 8-19 fans frus table 8-19 fans frus list parts part number qty name and description (vendor description) 1 116-1176-00 1 fuser fan assembly (fan fuser) 2 116-1175-00 1 24 vdc lvps fan assembly (fan assembly pslv) s7700-408...

  • Page 298

    8-268 phaser 7700 color laser printer service manual pl 8-20 lift components frus figure 8-20 lift components frus s7700-050 1 6 v 4 5 3 6 7 2.

  • Page 299

    Phaser 7700 color laser printer service manual 8-269 table 8-20 lift components frus list parts part number qty name and description (vendor description) 1 116-1198-00 1 frame lift jack assembly lh 2 116-1202-00 1 main latch assembly 3 116-1204-00 1 main lever assembly 4 116-1200-00 1 hinge, lever l...

  • Page 300: Pl 8-21 Wiring Frus

    8-270 phaser 7700 color laser printer service manual pl 8-21 wiring frus figure 8-21 wiring frus s7700-059 7 8 6 v v v 4 3 2 1 v v v v v v v v 5 v.

  • Page 301

    Phaser 7700 color laser printer service manual 8-271 table 8-21 wiring frus list parts part number qty name and description (vendor description) 1 116-1223-00 1 wire harness - dev bias (block assembly in) 2 116-1312-00 1 wire harness - charge roller (harness assembly-bcr) 3 116-1307-00 1 wire harnes...

  • Page 302

    8-272 phaser 7700 color laser printer service manual pl 8-22 auxiliary feeder frus figure 8-22 auxiliary feeder frus s7700-409 2 5 7 3 6 4 1.

  • Page 303

    Phaser 7700 color laser printer service manual 8-273 table 8-22 auxiliary feeders frus list parts part number qty name and description (vendor description) 1 116-1080-00 1 lower tray deck (ltd) 2 116-1079-00 1 high-capacity feeder (hcf) 3 116-1184-00 1 lower tray deck (ltd) cover lh (cover assembly ...

  • Page 304

    8-274 phaser 7700 color laser printer service manual pl 8-23 lower tray deck (ltd) frus figure 8-23 lower tray deck (ltd) frus 1 4 3 4 3 s7700-107 2 5.

  • Page 305

    Phaser 7700 color laser printer service manual 8-275 table 8-23 lower tray deck (ltd) frus list parts part number qty name and description (vendor description) 1 116-1100-00 1 aux. Feeder motor assembly (motor assembly 3tm) 2 116-1219-00 1 ltd control board (pwb assembly - 3tm) 3 116-1206-00 2 caste...

  • Page 306

    8-276 phaser 7700 color laser printer service manual pl 8-24 lower tray deck (ltd) frus (cont’d.) figure 8-24 lower tray deck (ltd) frus (cont’d.) table 8-24 lower tray deck (ltd) frus list (cont’d.) parts part number qty name and description (vendor description) 1 116-1167-00 1 chute, lower 2 116-1...

  • Page 307

    Phaser 7700 color laser printer service manual 8-277 pl 8-25 high-capacity feeder frus figure 8-25 high-capacity feeder frus table 8-25 high-capacity feeder frus list parts part number qty name and description (vendor description) 1 116-1100-00 1 aux. Feeder motor assembly (motor assembly 3tm) 2 116...

  • Page 308

    8-278 phaser 7700 color laser printer service manual pl 8-26 high-capacity feeder frus (cont’d.) figure 8-26 high-capacity feeder frus (cont’d.) table 8-26 high-capacity feeder frus list (cont’d.) parts part number qty name and description (vendor description) 1 116-1168-00 1 chute to lower (chute f...

  • Page 309

    Phaser 7700 color laser printer service manual 8-279 pl 8-27 high-capacity feeder frus (cont’d.) figure 8-27 high-capacity feeder frus (cont’d.) table 8-27 high-capacity feeder frus list (cont’d.) parts part number qty name and description (vendor description) 1 116-1160-00 2 paper feeder assembly (...

  • Page 310

    8-280 phaser 7700 color laser printer service manual pl 8-28 high-capacity feeder frus (cont’d.) figure 8-28 high-capacity feeder frus (cont’d.) table 8-28 high-capacity feeder frus list (cont’d.) parts part number qty name and description (vendor description) 1 116-1127-00 110k11081 (phaser 7760 co...

  • Page 311

    Phaser 7700 color laser printer service manual 8-281 pl 8-29 high-capacity feeder frus (cont’d.) figure 8-29 high-capacity feeder frus (cont’d.) table 8-29 high-capacity feeder frus (cont’d.) parts part number qty name and description (vendor description) 1 116-1171-00 1 bracket assembly, gear lh (h...

  • Page 312: Kits

    8-282 phaser 7700 color laser printer service manual kits table 8-30 kits parts part number qty name and description (vendor description) 116-1210-00 1 1 1 1 sensor flag kit (sensor actuator) actuator (120e11971) actuator sensor (120e18141) actuator sensor (120e18160) 116-1211-00 1 3 tray roller kit...

  • Page 313

    Phaser 7700 color laser printer service manual 8-283 manual packs & service manual table 8-31 manual packs & service manual part number qty name and description 061-4413-00 1 manual pack; english 061-4414-00 1 manual pack; french 061-4415-00 1 manual pack; spanish 061-4416-00 1 manual pack; brazilia...

  • Page 314: Software

    8-284 phaser 7700 color laser printer service manual software supplies and accessories when the control panel notifies you that a supply is low or needs to be replaced, make certain you have replacements on hand. To order supplies and accessories, contact your local dealer or visit the xerox website...

  • Page 315: Recommended Service Tools

    Phaser 7700 color laser printer service manual 8-285 recommended service tools the following service are recommended as a start for servicing the printer. As additional tools are needed visit the following url for help: http://cpid.Opbu.Xerox.Com/hardwaretools.Html. Table 8-34 accessories part numbe...

  • Page 316

    8-286 phaser 7700 color laser printer service manual.

  • Page 317: Test Prints

    Phaser 7700 color laser printer service manual 9-287 test prints a variety of test prints are available to aid in determining the quality of output from the printer and to assist in troubleshooting print image quality problems. The topic “troubleshooting” on page 3-87 discusses solutions to the prob...

  • Page 318: Analyzing The Test Print

    9-288 phaser 7700 color laser printer service manual analyzing the test print test prints provide several uses in troubleshooting printer problems. ■ isolating problems to either the print engine or to the image processing board and host software. ■ locating feed and paper transport problems. ■ dete...

  • Page 319: Print Color Test Prints

    Phaser 7700 color laser printer service manual 9-289 print color test prints this color test print produces 6 prints, cmyk 4 on 4 off, a solid fill red, and 4 on 4 off bars. Interpreting print color test prints cymk 4 on 4 off s7700-291.

  • Page 320

    9-290 phaser 7700 color laser printer service manual interpreting solid fill test prints non-uniformity in any one color may indicate a problem with the developer or print units. Light streaks in one color indicate developer or debris blocking the laser. Dark streaks in one color indicate a problem ...

  • Page 321: Diagnostics Mode

    Phaser 7700 color laser printer service manual 9-291 diagnostics mode laser check this is a gray print with all four colors turned on at about 25% fill. Things to look for: a hue shift that indicates one of the primary cmyk colors is missing. A missing primary indicates that the laser is faulty. Hal...

  • Page 322

    9-292 phaser 7700 color laser printer service manual grid 1-dot this print is especially useful in the manual process of registration when the automatic process consistently fails due to excessive process and lateral margin adjustment. There are some printer/laser positioning situations where the in...

  • Page 323

    Phaser 7700 color laser printer service manual 9-293 fast scan 8 these four prints of the primary colors are test prints that seem to be intended to find any laser "ringing" behavior. The beam is stepped through 8 halftones in the scan line. Some people have noticed that there seem to be only 7 dist...

  • Page 324

    9-294 phaser 7700 color laser printer service manual.

  • Page 325: Wiring Diagrams

    Ph aser 77 00 c o lo r laser pri n te r servi ce manu al 10- 295 wiring diagrams hi-cap or lower t ray assy 10 9 p460 p46 p70 5 motor driver motor driver motor driver p405 p406 p408 p41 1 p409 j126 j127 j128 j568 image processor board relay bd front panel polygon motor laser unit laser fan agitator ...

  • Page 326

    10 -29 6 p h aser 7 700 col o r l aser pri n ter servi ce manu al b loc k d ia g ram o f the p rin t en gine s7700-405-b j121 j119 4 4 5 8 3 3 2 2 2 2 5 5 11 t ray 1 feed out sensor j155 j156 j231 j109 r129 r221 r234 r620 r130 j1 15 r131 r132 environment sensor cleaner solenoid adc sensor mob sensor...

  • Page 327

    Phaser 7 7 0 0 col o r l aser pri n ter servi ce man u al 10 -29 7 2 1 1 2 3 1 2 3 1 2 1 2 3 1 2 3 3 2 1 1 2 1 2 1 2 1 4 m 3 2 1 6 5 4 m 3 2 1 6 5 4 j538 j626b 14 10272, 24, gr y j538 j626b 23 10272, 24, gr y j538 j626a 57 10272, 24, yel j538 j626a 66 10272, 24, yel j538 j626a 75 10272, 24, yel j538...

  • Page 328

    10 -29 8 p h aser 7 700 col o r l aser pri n ter servi ce manu al laser unit laser unit mp a pol ygon mo t m j535a j535a j535a j535a j535a j535a j535a j535a j535a j535a j535a j535a j535a j535b j535b j535b j535b j535b j535b j535b j535b j535b j535b j535b j535b j535b j535b j535b j535b j535b j535b j535b...

  • Page 329

    Phaser 7 7 0 0 col o r l aser pri n ter servi ce man u al 10 -29 9 m 2 1 4 3 j222 1061, 26, 0rn 4 1 +24v r222 m 2 5 4 1 r207 m 2 5 4 3 1 r208 r608 r223 r224 r225 r226 m 2 1 4 3 r214 fuser f a n m m m m dispense mo t or (y) dispense mo t or (m) dispense mo t or (c) dispense mo t or (k) bel t steer mo...

  • Page 330

    10 -30 0 p h aser 7 700 col o r l aser pri n ter servi ce manu al j203 11 mainmo t$on 1007,24,yel j407a j203 22 mainmo t$speed 1007,24,yel j407a j203 33 j407a j203 44 +24v(intlk) 1007,24,orn j407a j203 55 24vr t n 1007,24,vio j407a j203 66 j407a j203 77 j407a j203 88 mainmo t#f ail 1007,24,yel j407a...

  • Page 331

    Phaser 7 7 0 0 col o r l aser pri n ter servi ce man u al 10 -30 1 l vps - 24v l vps - 3.5v l vps - 5v 220v onl y main lamp sub lamp fuser unit (2/2) ac input ac output fuser lamp flk ac l vps pwba–noise fil ter gfi main sw 3 1 j2 4 op2c ac(h) 1015, 18, blk j2 t3 3 op2c ac(n) 1015, 18, wht j2 1 j2 n...

  • Page 332

    10 -30 2 p h aser 7 700 col o r l aser pri n ter servi ce manu al a ux feeder hca or l td (2/2) print car tridge pla te (2/2) w aste car tridge intlk sw fr ont co ver intlk sw r/h co ver intlk sw intlk/po wer lvps 3.5v lvps 5v lvps 24v s7700-284 rela y bo ard fr ont p anel interf a c e bo ard engine...

  • Page 333

    Phaser 7 7 0 0 col o r l aser pri n ter servi ce man u al 10 -30 3 t he f o llo w in g il lus tr a tion s deta il the pr ope r mea n s of r o u tin g an d dr e s s in g pr in te r wir ing. Inc o rr ec t wi ri ng dr es si ng ca n r e s u lt in wir e s p inc he d b y ca bin e t p ane ls , a s s e m b ...

  • Page 334

    10 -30 4 p h aser 7 700 col o r l aser pri n ter servi ce manu al laser unit wiring h ar n ess.

  • Page 335

    Phaser 7 7 0 0 col o r l aser pri n ter servi ce man u al 10 -30 5 to ner dispen se b ase assemb ly.

  • Page 336

    10 -30 6 p h aser 7 700 col o r l aser pri n ter servi ce manu al . Wirin g harness - 3.3 v d c l v p s an d p rint car trid g e drive mo tor.

  • Page 337

    Phaser 7 7 0 0 col o r l aser pri n ter servi ce man u al 10 -30 7 wirin g harness – t o ner car trid g e mo tor s (r ear of prin ter).

  • Page 338

    10 -30 8 p h aser 7 700 col o r l aser pri n ter servi ce manu al wiring h ar n ess – de velop er drive mo tor and t ra y 1 p ap er -s elect s w itc h.

  • Page 339

    Phaser 7 7 0 0 col o r l aser pri n ter servi ce man u al 10 -30 9 wirin g harness – mu lti p u rpo se t ra y (mp t ) an d left -hand co ver assemb ly (lh door ).

  • Page 340

    10 -31 0 p h aser 7 700 col o r l aser pri n ter servi ce manu al wiring h ar n ess – fr ont l eft-hand c o rner v ie w.

  • Page 341

    Phaser 7 7 0 0 col o r l aser pri n ter servi ce man u al 10 -31 1 wirin g harness – l o w er t ra y a ssem b ly boar d an d lo wer t ra y mot o r assemb ly.

  • Page 342

    10 -31 2 p h aser 7 700 col o r l aser pri n ter servi ce manu al.

  • Page 343: Phaser 7700 Finisher

    Phaser 7700 color laser printer service manual 11-313 phaser 7700 finisher figure 11-1 phaser 7700 color laser printer with the finisher option s7700-444.

  • Page 344: Finisher Overview

    11-314 phaser 7700 color laser printer service manual this service manual contains information useful in troubleshooting, repair and maintenance of the finisher option for the xerox phaser 7700 color laser printer. This manual contains a field replacement unit parts list (fru) and removal and replac...

  • Page 345: General Information

    Phaser 7700 color laser printer service manual 11-315 general information table 11-1 finisher specifications category specification configuration user installed option. The finisher provides stapling (up to 50 sheets), print job offset and stacking up to 1,000 sheets of paper. The finisher docks wit...

  • Page 346

    11-316 phaser 7700 color laser printer service manual media types long-edge feed (lef) short-edge feed (sef) b5a3 a4a4 letterb4 8” x 10” letter us folio legal tabloid media weight 64 - 105 g/m 2 (thick/thin paper) stacker capacity 1000 non-stapled sheets (20 lb. Paper, letter/a4 or smaller) 500 unst...

  • Page 347: Assemblies Of The Finisher

    Phaser 7700 color laser printer service manual 11-317 assemblies of the finisher figure 11-3 assemblies of the finisher s7700-445 gate unit horizontal transport staple finisher stacker stand.

  • Page 348

    11-318 phaser 7700 color laser printer service manual internal assemblies of the finisher figure 11-4 internal assemblies of the finisher exit assembly main motor finisher control board decurler compiler tray stacker motor assembly staple assembly track cam bracket assembly staple unit s7700-372.

  • Page 349: Locator Map

    Phaser 7700 color laser printer service manual 11-319 horizontal transport sensor, interlock, and switch locator map figure 11-5 horizontal transport sensor, interlock and switch locator map iot face down tray full sensor h-transport entrance sensor gate in solenoid h-transport interlock sensor h-tr...

  • Page 350

    11-320 phaser 7700 color laser printer service manual finisher sensor, interlock, and switch locator map figure 11-6 finisher sensor, interlock, and switch locator map s7700-449 rear eject clamp home sensor stack height sensor decurler cam home sensor docking interlock sensor set clamp home sensor f...

  • Page 351

    Phaser 7700 color laser printer service manual 11-321 finisher sensor, interlock, and switch locator map figure 11-7 finisher sensor, interlock, and switch locator.

  • Page 352

    11-322 phaser 7700 color laser printer service manual blank page.

  • Page 353: Removal and Replacement

    Phaser 7700 color laser printer service manual 11-323 removal and replacement procedures this section details the removal and replacement procedures for the main assemblies of the phaser 7700 light finisher. When replacing sensors, actuators, interlocks and/or switches: ■ refer to the appropriate lo...

  • Page 354

    11-324 phaser 7700 color laser printer service manual rrp 66 horizontal transport assembly removal 1. Unplug the finisher from the printer. 2. Lift the two hooks securing the horizontal transport assembly to the finisher. 3. Remove the horizontal transport assembly. Figure 11-8 horizontal transport ...

  • Page 355: Rear Cover

    Phaser 7700 color laser printer service manual 11-325 rrp 67 horizontal transport top open, front, and rear cover removal 1. Remove the horizontal transport assembly (rrp 66, on page 11-324). 2. Remove one screw securing the stopper. 3. Remove two screws from the horizontal transport front cover and...

  • Page 356: Assembly

    11-326 phaser 7700 color laser printer service manual rrp 68 horizontal transport entrance upper cover assembly removal 1. Remove the horizontal transport assembly (rrp 66, on page 11-324). 2. Remove the front cover (rrp 67, on page 11-325). 3. Remove two screws securing the rear cover and remove. 4...

  • Page 357

    Phaser 7700 color laser printer service manual 11-327 rrp 69 horizontal transport belts removal 1. Remove the horizontal transport covers (rrp 67, on page 11-325). 2. Remove the kl-clips from the horizontal transport in and out. 3. Remove the bearings from the horizontal transport in and out shafts....

  • Page 358: Top Tray Full Sensor

    11-328 phaser 7700 color laser printer service manual rrp 70 horizontal transport entrance sensor and top tray full sensor removal 1. Remove the horizontal transport top open and front cover (rrp 67, on page 11-325). 2. Remove the two screws securing the horizontal transport entrance upper cover (rr...

  • Page 359

    Phaser 7700 color laser printer service manual 11-329 rrp 71 gate-in solenoid assembly removal 1. Remove the rear cover (rrp 67, on page 11-325). 2. Disconnect the ground wire from the solenoid housing. 3. Remove the two screws and remove the gate-in solenoid assembly. Figure 11-13 h-transport gate-...

  • Page 360: Rrp 72 Finisher Covers

    11-330 phaser 7700 color laser printer service manual rrp 72 finisher covers figure 11-14 finisher covers s7700-396 front cover left panel left top cover rear cover left cover.

  • Page 361

    Phaser 7700 color laser printer service manual 11-331 removal 1. Remove the horizontal transport assembly (rrp 66, on page 11-324). 1. Remove one screw from the left panel and remove. 2. Remove five screws from the rear cover. 3. Clear the gear at the top of the rear cover and remove the cover. 4. O...

  • Page 362

    11-332 phaser 7700 color laser printer service manual rrp 73 stack height-sensor assembly removal 1. Remove the horizontal transport assembly (rrp 66, on page 11-324). 2. Remove the top cover (rrp 72, on page 11-330). 3. Remove one screw from the stack height sensor bracket. 4. Press down on the two...

  • Page 363

    Phaser 7700 color laser printer service manual 11-333 rrp 74 stacker paper-sensor assembly removal 1. Loosen the thumb screw and remove the stacker tray. 2. Remove the four screws securing the stacker paper sensor assembly to the finisher. 3. Remove two screws from the bottom of the assembly. 4. Rem...

  • Page 364

    11-334 phaser 7700 color laser printer service manual rrp 75 set clamp clutch and gear removal 1. Remove the rear cover (rrp 72, on page 11-330). 2. Remove the set clamp actuator. 3. Remove one screw from the set clamp actuator retainer and remove. 4. Remove the clutch collar and clutch. 5. Remove t...

  • Page 365: Rrp 76 Eject Roll Assembly

    Phaser 7700 color laser printer service manual 11-335 rrp 76 eject roll assembly removal 1. Remove the rear and left covers (rrp 72, on page 11-330) . 2. Remove stack paper sensor assembly (rrp 73, on page 11-332). 3. Undo the intermediate connector. 4. Remove the right cover. 5. Remove the set clam...

  • Page 366

    11-336 phaser 7700 color laser printer service manual rrp 77 finisher control board, bracket, and shield figure 11-19 finisher control board, bracket, and shield.

  • Page 367

    Phaser 7700 color laser printer service manual 11-337 removal 1. Remove the rear cover (rrp 72, on page 11-330). 2. Remove eight screws and loosen the two bottom screws. 3. Remove finisher control board shield. 4. Undo all the connectors. 5. Remove two screws on the left. 6. Loosen one screw on the ...

  • Page 368

    11-338 phaser 7700 color laser printer service manual rrp 78 stacker motor assembly removal 1. Remove the finisher control board bracket and shield (rrp 77, on page 11-336). 2. Remove one connector. 3. Remove three screws and remove the stacker motor assembly. Note when reinstalling, ensure the gear...

  • Page 369: Rrp 79 Paddle Shaft

    Phaser 7700 color laser printer service manual 11-339 rrp 79 paddle shaft removal 1. Remove the rear, left and right covers (rrp 72, on page 11-330). 2. Remove the cam bracket assembly (rrp 81, on page 11-341). 3. Remove the staple unit (rrp 82, on page 11-342). 4. Remove the e-clips from both ends ...

  • Page 370: Main)

    11-340 phaser 7700 color laser printer service manual rrp 80 paper transport motor (motor assembly main) removal 1. Remove the rear cover (rrp 72, on page 11-330). 2. Remove four screws. 3. Undo the connector and lift the motor up and then out to free the belt. Figure 11-22 paper transport motor.

  • Page 371

    Phaser 7700 color laser printer service manual 11-341 rrp 81 cam bracket assembly removal 1. Remove the rear and top covers (rrp 72, on page 11-330). 2. Remove one screw securing the decurler cam sensor. 3. Remove one screw from the eject clamp home sensor. 4. Disconnect the wiring harness from the ...

  • Page 372

    11-342 phaser 7700 color laser printer service manual rrp 82 staple unit assembly and motor figure 11-24 staple unit assembly s7700-304 k v bg v ba ba v v v 3 12 11 13 4 6 6 4 5 2 7 8 1 10 9.

  • Page 373

    Phaser 7700 color laser printer service manual 11-343 removal staple unit assembly 1. Remove the front cover (rrp 72, on page 11-330). 2. Remove the two connectors to the staple unit. 3. Remove two screws, note: one screw has a ground wire. 4. Pull the staple unit assembly down, tilt up and pull out...

  • Page 374: Rrp 83 Compiler Tray

    11-344 phaser 7700 color laser printer service manual rrp 83 compiler tray removal 1. Remove all covers (rrp 72, on page 11-330). 2. Remove the finisher control board shield (rrp 77, on page 11-336). 3. Disconnect p848 connector. 4. Remove set clamp solenoid connector. 5. Remove the staple unit (rrp...

  • Page 375: Finisher Fru Parts List

    Phaser 7700 color laser printer service manual 11-345 finisher fru parts list finisher unit main assemblies frus figure 11-26 finisher unit main assemblies frus.

  • Page 376

    11-346 phaser 7700 color laser printer service manual table 11-2 finisher unit main assemblies frus list no. Part number qty description 1 116-1292-00 1 gate unit 2 116-1280-01 1 h-transport assembly 3 staple finisher 4 screw 5 rack assembly 6 116-1244-00 1 right cover 7 116-1278-00 1 stacker tray 8...

  • Page 377: Finisher Covers Frus

    Phaser 7700 color laser printer service manual 11-347 finisher covers frus figure 11-27 finisher covers frus table 11-3 finisher covers frus list no. Part number qty description 1 116-1238-00 1 front cover 2 116-1239-00 1 rear cover 3 116-1236-00 1 top cover 4 116-1237-00 1 left cover 5 116-1245-00 ...

  • Page 378: Finisher Stand Frus

    11-348 phaser 7700 color laser printer service manual finisher stand frus figure 11-28 finisher stand frus s7700-309 8 8 4 4 4 6 6 7 7 3 3 14 4 5 9 9 10 15 2 12 13 1 11 u u u u w w.

  • Page 379

    Phaser 7700 color laser printer service manual 11-349 table 11-4 finisher stand frus list no. Part number qty description 1 116-1315-00 1 front rack assembly (item 2-10) 2 front cover 3 knob screw 4 screw 5 bracket 6 stopper 7 plate spring 8 rail 9 foot 10 front rack 11 116-1316-00 1 rear rack assem...

  • Page 380: Gate Unit Frus

    11-350 phaser 7700 color laser printer service manual gate unit frus figure 11-29 gate unit frus s7700-297 10 9 8 14 7 13 3 6 5 4 15 16 1 2 a s b a s b s s s.

  • Page 381

    Phaser 7700 color laser printer service manual 11-351 table 11-5 gate unit frus list no. Part number qty description 1. 116-1292-00 no gate cover 2. Bearing 3 116-1293-00 1 gate assembly (item 4-14) 4 in-gate 5 in-gate lever 6 116-1294-00 1 gate bracket 7 link assembly 8 lever assembly 9 lever 10 sp...

  • Page 382

    11-352 phaser 7700 color laser printer service manual horizontal transport assembly frus figure 11-30 horizontal transport assembly frus s7700-298 a c b 15 10 12 11 12 12 18 13 14 17 bn bn y 20 16 bn bn c 19 b a 2 8 3 7 7 5 7 7 6 5 3 bn 4 4 1 9.

  • Page 383

    Phaser 7700 color laser printer service manual 11-353 table 11-6 horizontal transport assembly frus list no. Part number qty description 1 116-1290-00 1 h-transport open cover assembly (item 2-7) 2 h-transport open cover 3 116-1291-00 magnetic catch 4 screw 5 guide 6 116-1246-00 1 roll 7 plate sprin...

  • Page 384

    11-354 phaser 7700 color laser printer service manual horizontal transport assembly frus (cont’d.) figure 11-31 horizontal transport assembly frus (cont’d.) s7700-299 b a c d a b 1 7 5 c d 4 5 4 5 2 3 8 6 30 31 9 10 11 20 19 6 15 14 16 13 17 18 27 28 20 21 24 23 22 25 26 29 ba ba ba bb bb ba ba v v ...

  • Page 385

    Phaser 7700 color laser printer service manual 11-355 table 11-7 horizontal transport assembly frus list (cont’d.) no. Part number qty description 1 h-transport roll (in) 2 h-transport roll (out) 3 116-1284-00 1 h-transport belt (rep 17.4.1) 4 roll 5 support 6 bearing (ball) 7 harness guide 8 cover ...

  • Page 386

    11-356 phaser 7700 color laser printer service manual top cover and eject roll frus figure 11-32 top cover and eject roll frus s7700-301 5 6 16 9 8 7 4 1 x s ba s x 5 6 25 9 8 7 12 4 x ba ay x 11 b a a b c d 13 14 15 28 3 23 3 20 3 2 19 18 17 22 23 10 26 s bd ba v bd ba ba ba bd 27 3 bd c d 24 27 28...

  • Page 387

    Phaser 7700 color laser printer service manual 11-357 table 11-8 top cover and eject roll frus list no. Part number qty description 1 116-1262-00 1 top open cover assembly 2 arm assembly 3 bearing 4 bracket 5 spring 6 support 7 bracket 8 shaft 9 116-1302-00 1 eject pinch roll 10 1 eject chute 11 116...

  • Page 388

    11-358 phaser 7700 color laser printer service manual paper transport assembly frus figure 11-33 paper transport assembly frus s7700-302 14 13 15 16 17 ba ba e e e bb z 1 2 8 bd bd bd bd bd ba 12 10 3 9 11 6 be 7 12 3 5 4 bd bd bd be 6 5.

  • Page 389

    Phaser 7700 color laser printer service manual 11-359 table 11-9 paper transport assembly frus list no. Part number qty description 1 116-1248-00 1 actuator 2 116-1249-00 1 clutch assembly, decurler cam 3 cam 4 shaft 5 bearing 6 116-1250-00 1 arm 7 116-1302-00 1 decurler roll assembly (rep 17.7.1) 8...

  • Page 390

    11-360 phaser 7700 color laser printer service manual paper transport assembly frus (cont’d.) figure 11-34 paper transport assembly frus (cont’d.) s7700-303 13 17 18 15 10 20 16 14 11 3 2 5 6 7 9 19 8 12 4 v bc bd ba ba x v v v x v 1.

  • Page 391

    Phaser 7700 color laser printer service manual 11-361 table 11-10 paper transport assembly frus list (cont’d.) no. Part number qty description 1 116-1266-00 1 cam bracket assembly (item 2-12, 14, 19) 2 116-1303-00 1 pully 3 116-1303-00 1 gear (15z) 4 116-1271-00 1 belt (rep 17.8.1) 5 116-1303-00 1 g...

  • Page 392: Staple Unit Assembly Frus

    11-362 phaser 7700 color laser printer service manual staple unit assembly frus figure 11-35 staple unit assembly frus s7700-304 k v bg v ba ba v v v 3 12 11 13 4 6 6 4 5 2 7 8 1 10 9.

  • Page 393

    Phaser 7700 color laser printer service manual 11-363 table 11-11 staple unit assembly frus list no. Part number qty description 1 116-1255-00 1 carriage assembly (item 2-6) 2 bracket assembly 3 116-1256-00 1 motor assembly stepping 4 gear 5 staple remover 6 roll 7 116-1259-00 1 staple front corner ...

  • Page 394

    11-364 phaser 7700 color laser printer service manual compiler tray assembly frus figure 11-36 compiler tray assembly frus s7700-305 8 7 4 6 5 10 11 15 14 13 12 2 7 3 5 6 4 9 8 9 8 9 8 9 s s s s s s s s s s 1.

  • Page 395

    Phaser 7700 color laser printer service manual 11-365 table 11-12 compiler tray assembly frus list no. Part number qty description 1 116-1251-00 1 compiler tray assembly (item 2-15) 2 116-1252-00 1 motor assembly tamper 3 plate 4 116-1253-00 1 front /rear tamper home sensor 5 rack 6 actuator 7 tampe...

  • Page 396

    11-366 phaser 7700 color laser printer service manual stacker elevator assembly frus figure 11-37 stacker elevator assembly frus s7700-306 a a b b 18 19 9 1 bd bd v v x x v bd bd bd v v x s y 3 4 4 4 5 6 18 10 16 12 14 13 15 17 20 21 8 22 4 7 21 2 11.

  • Page 397

    Phaser 7700 color laser printer service manual 11-367 table 11-13 stacker elevator assembly frus list no. Part number qty description 1 116-1287-00 1 stacker motor assembly 2 116-1276-00 1 bracket assembly belt 3 clamp 4 bearing 5 116-1274-00 1 gear (rear) 6 actuator 7 116-1275-00 1 gear (front) 8 s...

  • Page 398: Exit Assembly Frus

    11-368 phaser 7700 color laser printer service manual exit assembly frus figure 11-38 exit assembly frus s7700-307 17 16 14 9 15 10 13 11 8 2 3 1 6 4 5 6 ba ba v v v v v v v v v v ba ba v 12 7.

  • Page 399

    Phaser 7700 color laser printer service manual 11-369 table 11-14 exit assembly frus list no. Part number qty description 1 gear (48z) 2 bearing 3 116-1243-00 1 exit shaft 4 collar 5 gear (32z / 18t) 6 bearing 7 116-1304-00 1 paddle gear shaft (rep 17.12.1) 8 paddle bearing 9 lower exit chute 10 116...

  • Page 400: Electrical Frus

    11-370 phaser 7700 color laser printer service manual electrical frus figure 11-39 electrical frus table 11-15 electrical frus list no. Part number qty description 1 board cover 2 116-1235-00 1 finisher board 3 116-1314-00 1 rom 4 pwb bracket 5 dc harness 6 cable 7 116-1233-00 1 switch 8 116-1253-00...

  • Page 401: Finisher Wiring Diagrams

    Ph aser 7 7 0 0 co lo r l ase r pri n ter ser vi ce m an u al 12- 371 finisher wiring diagrams t h is s e c ti on is co mpr is ed o f tw o di ag ra ms : 1) t h e f in is her b lo c k d iagr am and 2) t he f ini sh er wi ri n g di agr am. Bo th ap pea r beg in n ing on the ne xt pag e an d f a c e e ...

  • Page 402

    12 -37 2 p h aser 7 700 col o r l aser pri n ter servi ce manu al f ig u re 12- 1 blo c k d iag ram o f t h e f in ish er stac k height sensor t op co v e r inter loc k switch f ront co v e r inter loc k switch compiler entr ance sensor set clamp p a ddle solenoid set clamp home sensor eject clamp h...

  • Page 403

    Phaser 770 0 col o r laser pri n ter s er vi ce man u al 12- 373 f ig u re 1 2 -2 w ir ing dia g ra m of the finis h e r j669 j669 j669 j669 j669 j669 j669 7 8 6 5 3 4 2 1 ho tline&tra y option#det tra y clk + 1 2 3 4 5 6 7 8 9 j549b j549b j549b j549b j549b j549b j549b j549b j549b j549b j549b j549b ...

  • Page 404

    12 -37 4 p h aser 7 700 col o r l aser pri n ter servi ce manu al.

  • Page 406

    701p28180