Принтер xerox phaser 7400 ошибка s

Copyright © 2005 Xerox Corporation. All Rights Reserved. Unpublished rights reserved under the copyright laws of the United States. Contents of this publication may not be reproduced in any form without permission of Xerox Corporation.

Copyright protection claimed includes all forms of matters of copyrightable materials and information now allowed by statutory or judicial law or hereinafter granted, including without limitation, material generated from the software programs which are displayed on the screen such as styles, templates, icons, screen displays, looks, etc.

XEROX®, The Document Company®, the digital X®, CentreWare®, infoSMART®, Made For Each Other®, PagePack™, Phaser®, PhaserSMART®, and Walk-Up™ are trademarks of Xerox Corporation in the United States and/or other countries.

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HP-GL®, HP-UX®, and PCL®are trademarks of Hewlett-Packard Corporation in the United States and/or other countries.

IBM® and AIX® are trademarks of International Business Machines Corporation in the United States and/ or other countries.

Windows®, Windows NT®, Windows Server™, and Wingdings® are trademarks of Microsoft Corporation in the United States and/or other countries.

Novell®, NetWare®, NDPS®, NDS®, Novell Directory Services® , IPX™, and Novell Distributed Print Services™are trademarks of Novell, Incorporated in the United States and/or other countries.

SunSM, Sun Microsystems™, and Solaris® are trademarks of Sun Microsystems, Incorporated in the United States and/or other countries.

SWOP® is a trademark of SWOP, Inc.

UNIX® is a trademark in the United States and other countries, licensed exclusively through X/Open Company Limited.

As an ENERGY STAR® partner, Xerox Corporation has determined that this product meets the ENERGY STAR guidelines for energy efficiency. The ENERGY STAR name and logo are registered U.S. marks.

PANTONE® Colors generated may not match PANTONE-identified standards. Consult current PANTONE

Publications for accurate color. PANTONE® and other Pantone, Inc. trademarks are the property of Pantone, Inc. © Pantone, Inc., 2000.

Symbols Marked on the Product

DANGER high voltage.

Protective ground (earth) symbol.

Hot surface on or in the printer. Use caution to avoid personal injury.

0

The surface is hot while the printer is running. After turning off the power, wait 30 minutes.

30 min.

Avoid pinching fingers in the printer. Use caution to avoid personal injury.

Use caution (or draws attention to a particular component).

Refer to the manual(s) for information.

Electrostatic Discharge (ESD) Precautions

Some semiconductor components, and the respective sub-assemblies that contain them, are vulnerable to damage by Electrostatic discharge (ESD). These components include Integrated Circuits (ICs), Large-Scale Integrated circuits (LSIs), field-effect transistors and other semiconductor chip components. The following techniques will reduce the occurrence of component damage caused by static electricity.

Be sure the power is off to the chassis or circuit board, and observe all other safety precautions.

■Immediately before handling any semiconductor components assemblies, drain the electrostatic charge from your body. This can be accomplished by touching an earth ground source or by wearing a wrist strap device connected to an earth ground source. Wearing a wrist strap will also prevent accumulation of additional bodily static charges. Be sure to remove the wrist strap before applying power to the unit under test to avoid potential shock.

■After removing a static sensitive assembly from its anti-static bag, place it on a grounded conductive surface. If the anti-static bag is conductive, you may ground the bag and use it as a conductive surface.

■Do not use freon-propelled chemicals. These can generate electrical charges sufficient to damage some devices.

■Do not remove a replacement component or electrical sub-assembly from its protective package until you are ready to install it.

■Immediately before removing the protective material from the leads of a replacement device, touch the protective material to the chassis or circuit assembly into which the device will be installed.

■Minimize body motions when handling unpacked replacement devices. Motion such as your clothes brushing together, or lifting a foot from a carpeted floor can generate enough static electricity to damage an electro-statically sensitive device

■Handle IC’s and EPROM’s carefully to avoid bending pins.

■Pay attention to the direction of parts when mounting or inserting them on Printed Circuit Boards (PCB’s).

Servicing Electrical Components

Before starting any service procedure, switch off the printer power and unplug the power cord from the wall outlet. If you must service the printer with power applied, be aware of the potential for electrical shock.

Warning

Do not touch any electrical component unless you are instructed to do so by a service procedure.

S7300-02

Servicing Mechanical Components

When servicing mechanical components within the printer, manually rotate drive assemblies, rollers, and gears.

Warning

Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running.

S7300-03

Servicing Fuser Components

Warning

This printer uses heat to fuse the toner image to media. The Fuser is VERY HOT. Turn the printer power off and wait at least 5 minutes for the Fuser to cool before you attempt to service the Fuser or adjacent components.

European Union

Warning

This is a class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures.

Xerox Corporation declares, under our sole responsibility, that the product to which this declaration relates is in conformity with the following standards and other normative documents:

Low Voltage Directive 73/23/EEC as amended

EN 60950:2000

EN 60825-1:1994+A1:2001+A2:2002

Electromagnetic Compatibility Directive 89/336/EEC as amended

EN 55022:1998 +A1:2000 +A2:2003

EN 55024:1998 +A1:2000 +A2:2003

EN 61000-3-2:2000

EN 61000-3-3:1995 +A1:2001

Radio & Telecommunications Terminal Equipment Directive 1999/5/EC as amended

EN 300 330-2 V1.1.1

EN 300 440-2 V1.1.1

EN 300 489-3 V1.3.1

This product, if used properly in accordance with the user’s instructions, is neither dangerous for the consumer nor for the environment.

A signed copy of the Declaration of Conformity for this product can be obtained from Xerox.

Section 8 — Service Parts Disassembly: This section contains removal procedures for spare parts listed in the Parts List. A replacement procedure is included when necessary.

Section 9 — Parts List: This section contains exploded views of the print engine and option FRUs, as well as part numbers for orderable parts.

Section 10 — Wiring Diagrams: This section contains the plug/jack locations and the wiring diagrams for the print engine.

Appendix A — Reference: This section provides an illustration of the printer’s menu structure, a listing of printer status codes, and a list of Service Diagnostics tests.

Book 2 — Options

Use Book 2 as a reference when servicing printer options. Book 2 includes information important for the repair or replacement of option components. Use the troubleshooting procedures in Book 1 to diagnose and isolated the problem.

Book 2 contains these sections:

Introductory, Safety, and Regulatory Information: This section contains important safety information, regulatory requirements, and information about this manual.

Section 1 — General Information: This section contains an overview of the options available, configuration, specifications and consumables.

Section 2 — Theory of Operation: This section contains functional information on each option.

Section 3 — General Troubleshooting: This this section includes information and procedures for troubleshooting optional components.

Section 4 — Adjustments and Calibrations: This section provides procedures for the adjustment of print engine components.

Section 5 — Service Parts Disassembly: This section contains removal procedures for parts listed in the option’s Field Replaceable Units (FRUs) Parts List. A replacement procedure is included when necessary.

Section 6 — Parts Lists: This section contains exploded views of the option FRUs, as well as FRU part numbers.

Section 7 — Wiring Diagrams: This section contains option plug/jack locations and wiring diagrams.

2 Theory of Operation

Phaser 7400 Operational Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Imaging Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

LED Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Transfer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Print Process Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Printer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Print-Quality Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Color Registration Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Automatic Density Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Selective Control: Paper Pick . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Image Transfer Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Fuser Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Consumable Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Sensor Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Sensors in the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Sensor Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Paper Level Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Paper Present Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Transparent Media Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Automatic Media Thickness Detection . . . . . . . . . . . . . . . . . . . . 2-21

Paper Size Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Jam Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Interlock Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Toner Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Input Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Paper Fed from Tray 1 (MPT) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Paper Fed from Tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Paper Fed from Optional Trays . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Output Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37

Fuser and Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37

Top Output Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

Side Output Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

Finisher/Inverter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

Drive Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

Imaging Unit Drive Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

Transfer Unit Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

Fuser Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

Toner Dispense Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

Duplex Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

Jam in Duplex Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Jam at Door E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Jam Under Imaging Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Jam in Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Jam at Duplex Entrance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Jam at Finisher Punch Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Jam at Finisher Door H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Jam at Finisher Door H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Jam at Finisher Upper Output Tray . . . . . . . . . . . . . . . . . . . . . . 3-38 Jam at Finisher Saddle Stapler. . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 Jam at Finisher Upper Output Tray . . . . . . . . . . . . . . . . . . . . . . 3-40 Jam at Finisher Stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 Jam at Finisher Door G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 Jam at Finisher Saddle Stapler. . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 Jam at Finisher Upper Output Tray . . . . . . . . . . . . . . . . . . . . . . 3-44 Jam Inside Finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 Jam at Finisher Entrance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 Finisher Output Tray Jammed . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

Door and Cover Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49 Close Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49 Close Right Door A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50 Close Right Door B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51 Close Right Door C for Tray [3][4][5][6] . . . . . . . . . . . . . . . . . . 3-53 Close Left Door D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54 Close Left Door E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55 Close Finisher Door F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 Close Finisher Door H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57 Close Finisher Door J . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Consumable/Routine Maintenance Procedures . . . . . . . . . . . . . . . . . . . 3-59 Replace [C][M][Y][K] Toner Cartridge . . . . . . . . . . . . . . . . . . . . 3-59 Replace [C][M][Y][K] Imaging Unit . . . . . . . . . . . . . . . . . . . . . . 3-60 Replace Transfer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 Replace Waste Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62 Replace Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63 Install, Reseat or Lock [C][M][Y][K] Toner Cartridge . . . . . . . . 3-64 Install or Reseat [C][M][Y][K] Imaging Unit . . . . . . . . . . . . . . . 3-65 Install or Reseat Transfer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66 Install or Reseat Waste Cartridge. . . . . . . . . . . . . . . . . . . . . . . . 3-67 Install or Reseat Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68 Metered Toner Is not Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69 Replace Metered [C][M][Y][K] Toner Cartridge . . . . . . . . . . . . . 3-70

Unsupported Duplex Unit ROM . . . . . . . . . . . . . . . . . . . . . . . . 3-114 Unsupported Tray 2 ROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115 Unsupported Tray [3][4][5][6] ROM . . . . . . . . . . . . . . . . . . . . 3-116 Unsupported Inverter Unit ROM . . . . . . . . . . . . . . . . . . . . . . . 3-117 Unsupported Finisher Unit ROM . . . . . . . . . . . . . . . . . . . . . . . 3-118 Hard Drive Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119 Fuse Cut Error In Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120 Fuse Cut Error In Transfer Unit . . . . . . . . . . . . . . . . . . . . . . . . 3-121 Fuse Cut Error In [C][M][Y][K] Imaging Unit . . . . . . . . . . . . . . 3-122 Controller to Engine Communications Failure . . . . . . . . . . . . . 3-123 Finisher Fold Position Sensor Failure . . . . . . . . . . . . . . . . . . . . 3-124 Finisher Paddle Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125 Finisher Stapler Swing Motor Failure . . . . . . . . . . . . . . . . . . . . 3-126 Finisher Stack Handling Motor Failure . . . . . . . . . . . . . . . . . . . 3-127 Finisher Staple Motor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128 Finisher Jog Motor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129 Finisher Lift Motor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130 Finisher Exit Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132 Finisher Punch Side Registration Sensor Failure . . . . . . . . . . . 3-133 Finisher Punch Registration Sensor Failure . . . . . . . . . . . . . . . 3-134 Finisher Punch Backup RAM Failure . . . . . . . . . . . . . . . . . . . . 3-135 Finisher Punch Communications Failure . . . . . . . . . . . . . . . . . 3-136 Finisher Punch Unit Transfer Motor Failure . . . . . . . . . . . . . . . 3-137 Finisher Punch Motor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138 Finisher Backup RAM Failure . . . . . . . . . . . . . . . . . . . . . . . . . . 3-139 Finisher Punch Dust Sensor Failure . . . . . . . . . . . . . . . . . . . . . 3-140

Printer Error — Contact Service; report fault [n] . . . . . . . . . . . . . . . . . . 3-141 Finisher Punch Unit Counter at End of Life . . . . . . . . . . . . . . . 3-141 Finisher Staple Unit Counter at End of Life. . . . . . . . . . . . . . . . 3-142 Finisher Interface Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143 Inverter Power Supply Failure . . . . . . . . . . . . . . . . . . . . . . . . . 3-144 Fuser Thermistor Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-145 Job Offset Home Position Error . . . . . . . . . . . . . . . . . . . . . . . . 3-146 Control Panel Communications Failure . . . . . . . . . . . . . . . . . . 3-147 No Data to the [C][M][Y][K] LED Head . . . . . . . . . . . . . . . . . . 3-148 Motor Driver Board Communications Error . . . . . . . . . . . . . . . 3-149 Tray [3][4][5][6] Firmware Error . . . . . . . . . . . . . . . . . . . . . . . 3-150 Duplex Unit Firmware Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-151 Motor Driver Board Firmware Error . . . . . . . . . . . . . . . . . . . . . 3-152 Finisher Inverter Firmware Error . . . . . . . . . . . . . . . . . . . . . . . 3-153 CRUM Reader Board Failure . . . . . . . . . . . . . . . . . . . . . . . . . . 3-154 Tray [3][4][5][6] Flash Memory Failure . . . . . . . . . . . . . . . . . . 3-155 Duplex Unit Flash Memory Failure . . . . . . . . . . . . . . . . . . . . . . 3-156 Motor Driver Board Flash Memory Failure . . . . . . . . . . . . . . . . 3-157 Finisher Inverter Flash Memory Failure . . . . . . . . . . . . . . . . . . 3-158 Tray 2 Lift Motor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-159

Inoperable Printer Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Engine Power-Up Sequence (BIST) . . . . . . . . . . . . . . . . . . . . . . 4-12 Printer Continually Displays Warming Up… . . . . . . . . . . . . . . . . 4-13 Printer Displays Install or Reseat Imaging Unit . . . . . . . . . . . . . 4-13 Printer Displays Reseat Contoller Board . . . . . . . . . . . . . . . . . . 4-13 Printer Does Not Come to a Ready State . . . . . . . . . . . . . . . . . . 4-14

Paper Size Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 AC Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 DC Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 RAM Memory Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Media Jams and the Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Operating System and Application Problems . . . . . . . . . . . . . . . . . . . . 4-21

Macintosh Printing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Windows Printing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Network Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Network Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Network Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 USB Port Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

5 Print-Quality Troubleshooting

Print-Quality Problems Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Defects Associated with Specific Printer Components . . . . . . . . . 5-3 Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Analyzing the 100% Solid Fill Pages . . . . . . . . . . . . . . . . . . . . . . 5-4 Analyzing the Color Test Pages . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Analyzing the PS Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Analyzing the Color Step Pages . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Print-Quality Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Light Prints in All Colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Light Print in Only One Color . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Blank Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Mottled or Splotchy Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Unexpected Colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Repeating Bands, Lines, Marks, or Spots . . . . . . . . . . . . . . . . . 5-18 Random Bands, Lines, Marks, or Missing Spots . . . . . . . . . . . . 5-19 Random Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Background Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Residual Image, Ghosting or Hot Offset. . . . . . . . . . . . . . . . . . . 5-25 Incomplete Fusing or Cold Offset. . . . . . . . . . . . . . . . . . . . . . . . 5-27 Mis-Registration, Color Layers Not Correctly Registered. . . . . . 5-28 Toner on Back of Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 Image Not Centered or Positioned Correctly . . . . . . . . . . . . . . . 5-32 Process Direction Bands, Voids, or Streaks . . . . . . . . . . . . . . . . 5-34 Scan Direction Bands, Voids, or Streaks . . . . . . . . . . . . . . . . . . 5-35 Scan Direction Dark Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37 Process Direction Bands, Voids, or Streaks . . . . . . . . . . . . . . . . 5-38

Print Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

Lower Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

Right Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

Right Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

Left Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

Door B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

Left Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

Left Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21

Upper Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

Right Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23

Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

Trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

Tray 1 (MPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

Tray 1 (MPT) Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28

Tray 1 (MPT) Home Position Sensor . . . . . . . . . . . . . . . . . . . . . 8-30

OHP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31

Feed-Out Sensor #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32

Tray 1 (MPT) No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 8-33

Tray 1 (MPT) Feed Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34

Tray 2 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38

Registration Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

Feed Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40

Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41

Registration Clutch #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42

Door B Detect Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43

Tray 2 No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45

Registration Sensor #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47

Feed-Out Sensor #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50

Feeder Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53

Tray 2 Feed Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54

Side Output Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55

Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56

Job Offset Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56

Job Offset Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-59

Job Offset Home Position Sensor . . . . . . . . . . . . . . . . . . . . . . . 8-61

Top Output Chute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-63

Door A Latch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-64

Media Thickness Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-66

Temperature/Humidity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 8-67

Exit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-68

Exit Gate Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-70

Fuser Exit Sensor and Actuator . . . . . . . . . . . . . . . . . . . . . . . . . 8-71

Top Output Tray Stack Full Sensor. . . . . . . . . . . . . . . . . . . . . . . 8-72

Paper Size Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-139

Motor Driver Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-141

Imaging Unit Sensor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-142

Toner Supply Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-144

Imaging Unit Motor Mounting Plate. . . . . . . . . . . . . . . . . . . . . 8-145

CRUM Reader Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-146

CRUM Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-147

Registration Sensor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-148

Fuser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-149

Front Sensor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-150

Rear Sensor Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-151

9 Parts List

Serial Number Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Using the Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Print Engine Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Xerox Supplies and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-58

Service Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60

Feed Roller Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60

Sensor Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-61

Actuator Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-61

Screw Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-62

Hardware Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-62

Gear Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-63

Harness Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-64

10 Wiring Diagrams

Plug/Jack Locator Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Print Engine Plug/Jack Designators . . . . . . . . . . . . . . . . . . . . . . 10-2 Print Engine Plug/Jack Locators . . . . . . . . . . . . . . . . . . . . . . . . 10-4

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17 Notations Used in Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . 10-17 Print Engine Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19 Print Engine General Wiring (1/7) . . . . . . . . . . . . . . . . . . . . . . 10-19 Print Engine General Wiring (2/7) . . . . . . . . . . . . . . . . . . . . . . 10-20 Print Engine General Wiring (3/7) . . . . . . . . . . . . . . . . . . . . . . 10-21 Print Engine General Wiring (4/7) . . . . . . . . . . . . . . . . . . . . . . 10-22 Print Engine General Wiring (5/7) . . . . . . . . . . . . . . . . . . . . . . 10-23 Print Engine General Wiring (6/7) . . . . . . . . . . . . . . . . . . . . . . 10-24 Print Engine General Wiring (7/7) . . . . . . . . . . . . . . . . . . . . . . 10-25 Front Sensor Board (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26 Front Sensor Board (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27 Feeder Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28 Rear Sensor Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29 Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30

General

Information

In this chapter…

■Printer Introduction and Overview

■Printer Configurations

■Parts of the Printer

■Printer Options

■Specifications

Printer Introduction and Overview

The Xerox Phaser 7400 Color Printer Service Manual is the primary document used to repair, maintain, and troubleshoot this printer. For manual updates, Service Bulletins, knowledge base, etc., see www.xerox.com/office/7400support. For further technical support, contact your assigned Xerox Technical Support for this product.

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The Xerox Phaser 7400 Color Printer is a single pass, electrophotographic design, using light emitting diodes (LED) for image exposure. The Phaser 7400 supports PostScript 3 and PCL5c page description languages. Print performance for A4 paper is 40 pages per minute (ppm) monochrome, 36 ppm for full color in 1-sided or 2-sided modes. Full color prints are produced via consecutively transferring the subtractive primaries (cyan, magenta, yellow, and black) directly to paper. Resolutions of up to 600 x 1200 dots per inch (dpi), 32-level grayscale print is applicable at 600×600 dpi. The base configuration (Phaser 7400N) features USB 2.0 and 10/100baseT Ethernet Ports, 256 MB of memory, a 250-sheet multi-purpose Tray 1 (MPT), a 550-sheet input tray (Tray 2), a 500-sheet facedown Top Output Tray, and a 250-sheet faceup Side Output Tray.

Phaser 7400 printer options add memory, paper capacity and functionality. For configurations not originally equipped, an internal Hard Drive is available for font storage, storing print files, job collation, proof, personal, and secure print support. A selection of RAM memory upgrades are available to raise the installed quantity to the 1 GB maximum. A 1650-Sheet High-Capacity Feeder (HCF) is available with three, 550-sheet universal trays. A 550-Sheet Feeder (Tray 3) Lower Tray Assembly (LTA) is also available. On the output side, a 1000-Sheet Finisher provides punching, stapling, saddle stitch, and offset stacking raising the output total to 1750 sheets. A Duplex Unit is available to add automatic 2-sided printing for supported paper sizes from all trays.

Printer Configurations

The Phaser 7400 Color Printer is available in five configurations. The main differences are standard memory, optional high-capacity feeders, duplexing (2-sided printing) capabilities, networking, and internal Hard Drive. The following table lists the available configurations.

*All configurations have two memory slots supporting 256 MB and 512 MB cards, up to a maximum of 1 GB.

**Trays 1 and 2 are standard on all configurations. All configurations support

additional paper trays in the following combinations: One 550-Sheet Feeder (Tray 3)

One 1650-Sheet Feeder (Trays 3, 4, and 5 or 4,5, and 6)

One 550-Sheet Feeder (Tray 3) and one 1650-Sheet Feeder (Trays 4, 5, and 6)

*** Requires a Hard Drive and a total of 4 optional trays for fitment.

Metered Printing

Metered printing (PagePack), involves the combination of control software and specialized Toner Cartridges to meter printer activity for billing purposes. The Configuration page lists Metered Toner as Enabled when metering is enabled.

Metered Operation

When a metered printer is initialized at first power-up, the customer sets the printer to Metered operation using a unique, factory-supplied, 4-digit PIN. Once set to Metered operation, the control software performs the following:

1.The Mode and PIN-entered values in Engine Control Board NVRAM are set.

2.The Control Panel momentarily displays “Metered Toner is now enabled”, then returns to “Ready” (if no other errors).

3.The First Time Tips pages and the Configuration page are printed.

If an incorrect PIN is entered, “Incorrect numeric password” displays with a prompt “Retry” or “Do not retry.” Retry returns to the enter prompt, “Do not retry” returns to the Replace [C][M][Y][K] Toner Cartridge error message. The error persists until the correct PIN is entered.

Note

The Hidden Service menu provides an Enable Metered Toner option to restore the Metered mode parameters to NVRAM should they become lost or corrupt.

Metered Toner Cartridges

To support metered printing, metered Toner Cartridges are available in all four colors. When a metered Toner Cartridge is installed in a printer not set to Metered operation, the printer displays the Replace [C][M][Y][K] Toner Cartridge error. If a metered Toner Cartridge is placed into a printer manufactured before metering was available, the printer displays Replace Incorrect Toner Cartridge. All other combinations of normal or metered printer and cartridges are accepted without warning or error.

Diagnostics Mode

Service Diagnostics does not provide the utilities to set or clear Metered NVRAM values. Service Diagnostics does not check these values and does not display the current status of these values. However, the Configuration page does identify the printer setting as mentioned above.

Note

When replacing the Engine Control Board from a metered printer, exchange NVRAM devices or use the Save/Restore utilities in Service Diagnostics to preserve the NVRAM settings. The Mode and PIN-entered values are not affected by NVRAM reset utilities.

Parts of the Printer

Front View

Rear View

3

4

5

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Control Panel

The Control Panel contains one tricolor LED, a display window, and six function buttons. These buttons navigate the menu system shown on the display, perform various functions, and select operational modes for the printer.

LED Indicators:

Control Panel Button Descriptions

Up Arrow Button

Image Processor Board

Transfer the following components, if installed, to the new board when replacing the Image Processor Board.

Configuration Card

NVRAM

Hard Drive

Memory (RAM)

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Printer Options

Phaser 7400 Color Printer options include:

■20 GB Hard Drive

■Additional Memory

■550-Sheet Feeder (LTA)

■1650-Sheet Feeder (HCF)

■Duplex Unit

■1,000-Sheet Finisher (with hole punch, staple, saddle-stitch, and offset)

Hard Drive

A 20 GB Hard Drive is available to enable the Job Collation, Saved Jobs, Proof, Personal, and Secure Print options. The Hard Drive installs on the Image Processor Board with stand-offs and connects to the board with a single data/power connector. Hard Drive utilization appears on the Configuration page.

Additional Memory

The printer features two slots that accept 256 or 512 MB of high-speed DDR RAM. All combinations are allowed for 256, 512, 768 MB, up to the maximum of 1 GB. Memory modules must have the following characteristics:

■DDR PC2700 Memory Standard

■200-Pin SODIMM

■Unbuffered, Non-parity

■Serial Presence Detect

■2.5 Volt

■CL 2.5

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The Startup and Configuration pages list the amount of RAM installed in the printer. Installed memory not meeting the above specifications, is ignored by the printer.

Configuration Card

A Configuration Card identifies the printer configuration, stores shadowed nonCRUM consumable data, consumable life counts, and network configuration parameters.

550-Sheet Feeder

The 550-Sheet Feeder increases the input capacity of the printer. The Lower Tray Assembly (LTA) attaches below Tray 2. When used in combination with the 1650-Sheet Feeder, the 550-Sheet Feeder is installed between the printer and 1650Sheet Feeder. Up to four optional 550-Sheet Feeders per printer, totaling six universal trays (Trays 2~6), are allowed. However, when the 1650-Sheet Feeder High-Capacity Feeder (HCF) is installed, only one additional 550-Sheet Feeder is allowed between the HCF and printer. Electrical connection to the printer is made by a single interface connector.

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1650-Sheet Feeder

The 1650-Sheet Feeder adds three 550-sheet trays. Control signals reach the sheet feeder by a single connection.

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Duplex Unit

The Duplex Unit adds two-sided printing. The Duplex Unit is inserted into the printer’s left side just below the Side Output Tray. Electrical connection is made by an interface connector located inside the Duplex Unit cavity.

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Finisher

The Finisher increases the output capacity of the printer by 1,000 sheets. Printer output is directed to the Finisher by way of the side exit. Depending on the job specifications, as paper enters the Finisher it can be punched, stapled, offset and stacked depending on customer driver selections or Control Panel settings. The Finisher’s Inverter is used to flip the media over. Control signals reach the Finisher through a single connector.

Finisher

Inverter

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Maintenance Items

A maintenance item is a printer part or assembly that has a limited life, and requires periodic replacement.

Fuser

Transfer Belt

Imaging Unit

Waste Toner Reservoir

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Consumables

Consumables consist of the four toner cartridges used in the printer.

Toner Cartridge

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Specifications

Memory Specifications

Consumable Life Specifications

Internal counters track Consumables and Maintenance Items life usage. The Image Processor Board monitors these counters in order to display the near end-of-life and end-of-use messages.

Life ratings are based on A-size sheets at 5% coverage. Imaging Unit life ratings are based on average 3 page job length.

Electrical Specifications

Physical Dimensions and Clearances

Functional Specifications

Functional Specifications

First Print Output Time

First Print Output Time (FPOT) is defined as a time from receipt of the print command in Ready mode until the first page sourced from either Tray 1 or Tray 2 is delivered to the Output Tray. Sourcing media from the optional trays increases FPOT.

Note

This does not include the execution times for the Boot Loader or POST which vary depending on printer configuration.

*These conditions apply to the values in the table above: Printer at Ready

A4 LEF paper Plain paper mode

Image Specifications

Environmental Specifications

Media and Tray Specifications

The following table lists the paper sizes and weights supported in the printer trays.

Media and Tray Specifications

Media and Tray Specifications

*Some wrinkling and embossing may occur when printing envelopes.

Note

For duplex configured printers, auto-duplex operation is available through all trays. Refer to the Paper Tips page for information on which paper types can be used for 2-sided printing.

For more details about supported paper and other media, print the Paper Tips page:

1.On the Control Panel, select Information, and then press the OK button.

2.Select Information Pages, and then press the OK button.

3.Select Paper Tips, and then press the OK button to print.

Theory of

Operation

In this chapter…

■Overview

■Printer Controls

■Paper Path of the Printer

■Major Assemblies and Functions

Phaser 7400 Operational Overview

The Phaser 7400 Color Printer is a full-color LED printer using electrophotographic recording principals to place a full color image onto the print media. The system, as it appears in the following illustration, contains four Imaging Units comprised of a drum and developing unit for each color Cyan, Magenta, Yellow and Black (CMYK), and uses a Transfer Unit to transfer the toner image of each color onto print media producing full-color prints.

The figure below illustrates the relative position of components involved in the printing process.

Fuser

Imaging Unit

Transfer Unit

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