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.
, Phaser®, and Made for Each Other® are registered trademarks of
Tektronix, Inc. TekColor™, PhaserShare™, PhaserMatch™, PhaserLink™,
Finepoint™ and PhaserPrint™ are trademarks of Tektronix, Inc.
RealSUPPORT
SM
and TekColor CareSM are service marks of Tektronix, Inc.
Other marks are trademarks or registered trademarks of the companies with
which they are associated.
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 250 volts RMS between the supply conductors or between either
supply conductor and ground. Use only the specified power cord and
connector.Refer to a qualified service technician for changes to the cord or
connector.
Operation of product:
technician to replace fuses inside the product. Do not operate without the covers
and panels properly installed. Do not operate in an atmosphere of explosive
gases.
Safety instructions:
product into a power source.
Terms on
product:
CAUTIONConditions that can result in damage to the product.
WARNINGConditions that can result in personal injury
or loss of life.
For 110 VAC printers, Do not apply more than 130 volts RMS
Avoid electric shock by contacting a qualified service
WARNINGTurning the power off using the On/Off switch does
not de-energize the printer. You must remove the power cord to
disconnect the printer from the mains. Keep the power cord
accessible for removal in case of an emergency.
Read all installation instructions carefully before you plug the
CAUTIONA personal injury hazard exists that may not be
apparent. For example, a panel may cover the hazardous area.
Also applies to a hazard to property including the product itself.
DANGERA personal injury hazard exists in the area where
you see the sign.
Care of product:
Disconnect the power plug if the power cord or plug is frayed or otherwise
damaged, if you spill anything into the case, if product is exposed to any excess
moisture, if product is dropped or damaged, if you suspect that the pr oduct needs
servicing or repair, and whenever you clean the product.
Ground the product:
grounded AC outlets only. If necessary, contact a licensed electrician to install a
properly grounded outlet.
Disconnect the power plug by pulling the plug, not the cord.
Plug the three-wire power cord (with grounding prong) into
Symbols as marked on product:
DANGER high voltage:
Protective ground (earth) terminal:
Use caution. Refer to the manual(s) for information:
!
Laser use caution. Refer to the manual(s) for information:
WARNING:
controls (and other conductive parts) can cause an electrical shock. Electrical
product may be hazardous if misused.
If the product loses the ground connection, usage of knobs and
Service safety summary
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 rendering first aid or resuscitation is present.
Use care when servicing with power on:
Dangerous voltages may exist at several
points in this product. To avoid personal injury, do not touch exposed
connections and components while power is on.
Disconnect power before removing the power supply shield, soldering, or
replacing components.
Do not wear jewelry:
Remove jewelry prior to servicing. Rings, necklaces, and
other metallic objects could come into contact with dangerous voltages and
currents.
Power source:
This product is intended to operate from a power source that will
not apply more than 250 volts rms between the supply conductors or between
either supply conductor and ground. A protective ground connection by way of
the grounding conductor in the power cord is essential for safe operation.
This product is certified under IEC 825 as a Class 1 Laser Product.
DANGER:
Invisible laser radiation
when open and interlock
defeated.
AVOID DIRECT
EXPOSURE TO BEAM.
PELIGRO:
Cuando se abre y se
invalida el bloqueo, se
producen radiaciones
invisibles de láser.
EVITESE LA
´
EXPOSICION
DIRECTA A TALES
RAYOS.
CAUTION:
Invisible laser radiation
when open and
interlocks defeated.
AVOID DIRECT
EXPOSURE TO BEAM.
VARNING:
Osynlig laserstrálning när denna
del är öppnad och
spärrar är
urkopplade.
STRÅLEN
ÄR FARLIG.
VORSICHT:
Unsichtbare Laserstrahlung,
wenn Abdeckung geöffnet
und Sicherheitsverriegelung
überbrückt.
NICH DEM STRAHL
AUSSETZEN.
VAROI:
Näkymätön
avattaessa ja
suojalukitus
ohitettaessa olet
alttiina lasersäteilylle.
ÄLÄ KATSO
SÄTEESEN.
ATTENTION:
Rayonnement laser invisible
dangereux en cas
d'ouverture et lorsque
la sécurité est neutralisée.
EXPOSITION DANGEREUSE
AU FAISCEAU.
VARNING:
Osynlig laserstrálning
när denna del är
öppnad och spärrar är
urkopplade.
BETRAKTA EJ
STRÅLEN.
ADVARSEL:
Usynlig laserstràling
ved abning når
sikkerhedsafbrydere
er ude af funktion.
UNDGÅ UD
ÆTTELSE FOR
STRÅLING.
Class 3B
ADVARSEL:
Usynlig laserstraling
nar deksel åpnes og
sikkerhedslas brytes.
UNNGÅ
EKSPONERING
FOR STRÅLEN.
PJQT4521ZA
9008-78
Contents
General Information 1
Phaser 780 overview 2
Memory considerations 3
Print engine assemblies 5
The image processor 10
Front panel 11
Rear panel 12
Network card LEDs 12
Specifications 14
Regulatory specifications 17
Safety 17
EMC 17
Energy Star certification 17
Error Codes and Messages 19
Troubleshooting 39
System power-up sequence 39
Print engine troubleshooting 40
Printer will not power up 40
Erratic printer operation 41
Making a print engine only test print 42
Printing and print quality problems 43
Initial checks and actions 43
Light (undertone) prints 44
Blank prints 45
Monochrome prints 46
Black prints 47
One color is faded 47
Missing band in direction of paper travel 48
Missing bands in parallel to the leading edge 49
Streaks in direction of paper travel 51
Streaks parallel with the leading edge 52
Banding 53
Edge of print is wrinkled with an area of ragged discoloration. 53
Random missing spots 54
Random spotting 55
Repetitive mark appears on each print 56
Residual image or ghosting 56
Background contamination 57
Unfused image or image easily rubs off of page 58
Toner on back of print 58
Service Guide
vii
Print is mottled 59
Image mis-registered on paper 60
Color layer not correctly registered 60
Color representation not correct 61
Oil stain or gloss variation on print 61
Random spotting 62
Media jams and the paper path 63
Skewed image 63
Damaged prints 64
Inoperative lower tray feeder 65
Power problems 65
All front panel indicators remain off. The printer does not initialize
upon power-up 65
Front panel indications 66
Media tray indicates missing or empty when it is not 66
Macintosh printing problems 66
Image never prints 66
Image prints in black-and-white 66
Image is rotated 90 degrees 67
Windows printing problems 67
Image never prints 67
Blue color on the screen is printing too purple. 67
Printing from Windows 3.1 produces the message “Problem writing
device LPT1: Cancel or Retry”. 68
Workstation printing problems 68
Image never prints 68
Running built-in diagnostics 69
Adjustments 73
Printing test prints 73
Print service test prints 73
Printing the configuration page 73
Printing the demonstration pages 73
Print engine calibration 74
Adjusting for impulse banding 74
Cleaning and Maintenance 77
Service preventive maintenance procedure 77
Recommended tools 77
Cleaning 78
Resetting NVRAM 79
viii
Phaser 780 Color Printer
Key FRU Disassembly 81
Paper feeder 82
Feeder registration chute 83
Feeder registration clutch 84
Registration brake clutch 85
Feeder metal registration roller 86
Feeder rubber registration roller 87
Feeder pre-registration clutch 88
Feeder pre-registration rollers 89
Paper-pick turn roller 91
Paper feed drive gear train 92
Paper-feed motor 93
Multi-purpose tray roller assembly 94
Multi-purpose tray pick rollers 95
Auto-density calibration sensor 97
Developer assembly 99
Developer clutch 101
Developer tie plate 102
Toner/developer dispense motor 104
Carousel assembly 105
Carousel motor 107
Carousel motor board 108
Carousel sensor 109
Laser unit 110
Erase lamp rail assembly 112
Erase lamp 114
Process drive unit 115
Waste auger assembly 117
Accumulator belt assembly 119
Accumulator belt cleaner assembly 121
Second bias transfer roller assembly 122
Second bias transfer roller cam assembly 123
Fuser assembly 125
Fuser drive gear train 126
Lower exit assembly 128
Full stack sensor 130
Low voltage power supply 131
High voltage power supply 132
Image processor 133
Image processor chassis 134
Print engine control board 135
Service Guide
ix
FRU List 137
Supplies and accessories 176
Test Prints 179
Wiring Diagrams 185
x
Phaser 780 Color Printer
Figures
The Phaser 780 printer (shown with optional Lower Tray Assembly) 1
Internal features of the print engine 5
Circuit boards of the print engine 6
Motors of the print engine 7
Sensors and switches on the print engine 8
Solenoids and clutches on the print engine 9
Features of the image processor board 10
Printer front panel 11
Printer rear panel with the optional Ethernet card 13
Adjusting for impulse banding 75
Removing the paper feeder 82
Removing the registration chute 83
Removing the registration clutch 84
Removing the registration brake clutch 85
Removing the metal registration roller 86
Removing the rubber registration roller 87
Removing the feeder pre-registration clutch 88
Removing the feeder pre-registration roller 90
Removing the paper-pick turn roller 91
Removing the paper-feed drive gear train 92
Removing the paper-feed motor 93
Removing the multi-purpose tray roller assembly 94
Removing the multi-purpose tray pick rollers 96
Removing the auto-density calibration sensor 98
Removing a developer assembly 100
Removing the developer clutch 101
Removing the developer tie plate 103
Removing the toner/developer dispense motor 104
Removing the carousel assembly 106
Removing the carousel motor 107
Removing the carousel motor board 108
Removing the carousel sensor 109
Removing the laser unit 111
Removing the erase lamp rail assembly 113
Removing the erase lamp 114
Removing the process drive unit 116
Removing the waste auger assembly 118
Removing the accumulator belt assembly 120
Removing the accumulator belt cleaner assembly 121
Removing the second bias transfer roller assembly 122
Service Guide
xi
Removing the second bias transfer roller cam assembly 124
Removing the fuser assembly 125
Removing the fuser-drive gear train 127
Removing the lower exit assembly 129
Removing the stack full sensor 130
Removing the low voltage power supply 131
Removing the high voltage power supply 132
Removing the image processor 133
Removing the image processor chassis 134
Removing the print engine control board 135
Printer cabinet FRUs 138
Paper feeder FRUs 140
Multi-purpose tray cover FRUs 142
Multi-purpose tray FRUs 144
Paper feeder cover FRUs 146
Paper feeder FRUs 148
Imaging FRUs 150
Developer FRUs 152
Carousel FRUs 154
Accumulator belt assembly FRUs 156
Fuser assembly FRUs 158
Paper exit FRUs 160
Paper exit FRUs 162
Drive FRUs 164
Electronic (rear) FRUs 166
Electronics (front) FRUs 168
Image processor FRUs 170
Optional lower feeder cabinet FRUs 172
Optional Feeder FRUs 174
Print engine wiring diagram 185
Map 1 – Wiring routing at the top and front of the printer 193
Map 2 – Wire routing around the engine control board 194
Map 3 – Wiring routing around the image processor board 195
Map 4 – Wiring routing around the paper feeder 196
Map 5 – Wire routing around the laser scanner and high voltage power supply 197
Map 6 – Wire routing at the rear of the printer 198
Map 7 – Wire routing around the power supply 199
Map 8 – Wire routing around the fuser 200
Wiring 1 – Low voltage power supply, laser unit, and interlock switches 201
Wiring 2 – Engine control board, auto-density calibration sensor, erase lamp, waste
toner sensor 202
Wiring 3 – Low voltage power supply, engine control board, high-voltage power
supply and imaging components 203
xii
Phaser 780 Color Printer
Wiring 4 – Engine control board, used cartridge sensor, cartridge sensor, carousel
sensor, developer clutch, developer fan, toner dispense motor 204
Wiring 5 – Engine control board, low voltage power supply, carousel motor board,
rotary motor 205
Wiring 6 – Engine control board, low voltage power supply, bias transfer roller cam
solenoid accumulator belt sensor, paper feeder motor, process motor 206
Wiring 7 – Engine control board, low voltage power supply, fuser, oil roll assembly
207
Wiring 8 – Engine control board, fuser assembly, environment sensor 208
Wiring 9 – Engine control board, paper size switch board, feed solenoid, no paper
sensor, low paper sensor 209
Wiring 10 – Engine control board, paper feeder 210
Wiring 11 – Engine control board, paper feeder, multi-purpose tray 211
Wiring 12 – Engine control board, top exit sensor, media exit switch, full stack sensor,
fuser fan 212
Wiring 13 – Engine control board, image processor board, front panel, image processor
fan 213
Wiring 14 – Lower Tray Assembly master wiring diagram 214
Wiring 15 – Engine control board and low voltage power supply to Lower Tray
This service guide contains information useful to verify operation, troubleshoot,
repair, adjust, and maintain a Tektronix Phaser® 780 Color Printer.
To ensure complete understanding of the product, we recommend participation
in Phaser 780 service training, if available.
The Phaser 780 printer (shown with optional Lower Tray Assembly)
Service Guide
3041-01
1
Phaser 780 overview
The Phaser 780 Color Printer combines a color laser, continuous-tone print engine
with an image processor supporting Adobe’s PostScript 3 page description
language. The image processor features a bi-directional parallel interface and a
10baseT Ethernet port for host communication. Optional network adapter cards
to the image processor allow the printer to communicate on networks using
LocalTalk, Ethernet 100baseT or Token Ring protocols. The Ethernet network
card supports EtherTalk 100baseT, Novell and TCP/IP. With the Token Ring
network card, the printer supports Token Ring protocols. The network cards are
sometimes referred to as “smart cards” because each houses its own processor for
executing specific on-board protocols; only data is transferred from the installed
smart card to the printer’s image processor board. The PCL printer language is
also supported.
The printer is marketed in three versions:
Phaser 780 N
The
printer contains 136 standard, built-in fonts. The standard Phaser 780 prints at a
resolution of 600 x 600 dots-per-inch on A and B-size media. The base printer
does not support grayscale printing.
Phaser 780 GN
The
600 x 1200 dpi. It also contains 136 fonts. The graphics printers supports 16 level
grayscale printing as well as printing oversize-B images.
Phaser 780 P
The
features as the GN printer. In addition, the Plus version Phaser 780 supports
image pipelining for greater throughput, a print collation mode, and a “check
print before proceeding with job” mode. The plus printer also feature a SCSIcompatible interface to connect to an external hard disk drive for additional font
storage. The hard disk drive is also required for print collation of multiple copy
multi-page prints. A scanner can also be connected to the Plus printer’s SCSI port
to give the printer the ability to optically copy color images.
RAM memory in the printers can be supplemented with one or two additional 32, 64-, or 128-Mbyte RAM DIMMs; the maximum usable capacity is 192 Mbytes
Print speeds depend on the chosen resolution and selected media. For r esolutions
of 600 x 600 (standard), in color, the printer prints at 4 A-size pages per minute
(ppm) on paper . Monochrome printing (Fast Monochr ome) is at 16 ppm on paper .
Transparency film printing is always 2 ppm.
The printers support printing on A-, A4-, A5-, B-, B4, B5, SRA3, A3-, 13 x 19 in.
and Legal-sized paper from a 250-sheet tray. An optional three-tray second feeder
(called the Lower Tray Assembly) is available with additional 250-sheet standard
media trays. The printer features a built-in multi-purpose tray from which
specialty media, cardstock and envelopes can be fed. The printer also supports
manual feeding using the multi-purpose tray.
(Standard) comes standard with 64 Mbytes of RAM. The
(Graphics) features 96 Mbytes of RAM and can print at
(Plus) features 192 Mbytes of RAM and supports the same
After being idle for the selected amount of time the printer switches into its
Energy Star mode where it consumes less than 45 watts of power. It “awakens”
upon receiving data at any of its ports.
2
Phaser 780 Color Printer
Memory considerations
The base printer features 32 Mbytes of RAM in one connector and features two
additional DIMM connectors which accept 16-, 32-, 64-, or 128 Mbytes RAM
DIMMs. The printer can use any off-the-shelf RAM meeting these specifications:
■
168 pin DIMM
■
Synchronous DRAM
■
3.3 volt
■
9 nsec speed
■
Valid on-board Serial Presence Detect ROM.
Upon power-up, the image processor interrogates the 256 byte Serial Presence
Detect ROM which describes the DIMM in great detail, with details such as data
width, clock delay, number of address columns and row, refresh rate and more. If
the DIMM does not meet the required specifications it will be ignored; no error
message will be reported.
With more memory the printer gains the capabilities of printing at higher
resolutions, printing without having to use image compression (which trades off
less installed RAM for longer image processing time) and dual frame buffers for
printing one image while processing a second image (which gives greater
printing throughput). With additional RAM memory, the printer’s capabilities
increase as detailed in the following table:
These front panel features are found on the printer:
■
A two-line, 40-character LCD
■
Six push buttons
■
Five LEDs
LCD.
The LCD serves two purposes: Displaying current image processor and
print engine status information and displaying an interactive menu. Status
information includes image processor status such as
Printing
Jam
. Print engine status includes messages such as
, and
Toner Low
.
Ready, Processing
Out of paper, Paper
The interactive menu can only be entered while the printer is idle and r eady. The
interactive menu has two modes, review and modify. Customers can review and
modify certain NVRAM, I/O ports and peripheral parameters.
and
Buttons.
Button 6, the left-most button, is an
Exit key used to cancel an operation
while in the interactive menu. The functions of the remainder of the buttons are
defined by the particular menu or function being displayed on the LCD. The
bottom row of the LCD labels the current function of each button.
Ready
Print MenuSelect
3041-18
Printer front panel
Service Guide
11
Rear panel
Connectors
The rear panel of the printer features the host interface connectors:
■
Bi-directional parallel (high-density connector).
■
Twisted Pair 10baseT Ethernet connector. RX indicator (green);
while the network card is receiving data. The LED is
data is being received. If the LED is
on steady
, then a problem (probably
off steady
hardware) has occurred at the network hub.
■
SCSI high-density connector (external hard disk drive or optical scanner
only).
With the addition of a network card, the printer can feature either of these groups
of connectors:
■
ThinNet (100base2) and Twisted Pair (100baseT) Ethernet connectors.
This is Option P1.
■
LocalTalk connector. This is Option P3.
■
Unshielded Twisted Pair (10baseT) and shielded Twisted Pair (DB-9)
Token Ring connectors. This is Option P4.
Network card LEDs
blinks
while no
The Ethernet network card has four LED indicators:
■
TX indicator (yellow); blinks while data is transmitted to the host. The
LED is off while no data is being sent.
■
Twisted Pair (100baseT) and ThinNet (100base2). RX indicator (green);
blinks
while the network card is receiving data. The LED is
while no data is being received. If the LED is
on steady
off steady
, then a problem
(probably hardware) has occurred at the network hub.
■
TP Link. On steady indicates good circuit to nearest port; off indicates
no circuit.
■
100 MBS. Ethernet speed is 100 MBS when lit.
Note
Do not use both Ethernet connectors at the same time. With a
Ethernet or Token Ring network card installed, the 10baseT port
is disabled.
12
Phaser 780 Color Printer
The Token Ring network card has two LED indicators:
■
Connection (yellow);
blinks
Ring,
Ring,
■
Ring Speed (green);
(MBPS),
■
When both LEDs blink, a network card failure has occurred.
while the printer is attempting to insert itself into the Token
on
when the printer is properly inserted in the ring.
on
when the card is set for 16 MBPS.
off
when the printer is not inserted into the Token
off
when the card is set for 4 megabits-per-second
The following figure illustrates the rear panel of the printer.
SCSI port
Parallel port
10 base T ethernet port
Slot for network card & IDE hard drive
TX
RX
16
INS
10Base2
LocalTalk®
Mbs
UTP
10/100Base-TX
100
Mbs
TP
LINK
TX
RX
TM
Series B
Ethernet Card
PhaserShare
Ethernet
card
TX
RX
TM
Series B
PhaserShare
LocalTalk Card
LocalTalk
card
Printer rear panel with the optional Ethernet card
STP
TM
Series B
PhaserShare
Token Ring Card
Token Ring
card
Service Guide
Internal
hard drive
3041-08
13
Specifications
Table 1 Physical dimensions of printer
DimensionValue
Height49.2 cm (19 in) without lower tray feeder
Width69.1 cm (27.2 in)
Depth64.1 cm (24.2 in)
Weight73.6 kg (161 lbs) with consumables installed
90.6 (36 in) with lower tray feeder
97.1 kg (213 lbs) with lower tray feeder and consumables
Table 2 Physical dimensions of lower tray feeder
DimensionValue
Height41.4 cm (16.3 in)
Width56 cm (22 in)
Depth56 cm (22 in)
Weight23.5 kg (52 lbs)
Table 3 Printer clearances
DimensionValue
Top40.0 cm (15.7 in)
Left50.3 cm (20 in)
Right55.1 cm (21.5 in)
Front83.5 cm (33 in)
Rear
BottomNo obstructions underneath that could block cooling vents
Mounting surface flatnessFront feet less than 5 mm above or below rear feet
Mounting surface dimensions
14
Phaser 780 Color Printer
15.0 cm (6 in)
Left feet less than 10 mm above or below right feet
Level surface with dimensions of at least 79 cm (31 in.) by
152 cm (60 in.).
Table 4 Functional specifications
CharacteristicSpecification
Printing processElectro-photographic, four color (CMYK), two transfer printing using
Color mediumFour toner cartridges each containing one of four colors: cyan,
Addressability600 x 600 dpi and 600 x 1200 dpi
Print speedTime from paper load to paper eject:
Minimum margins
Usable papers sizes
Usable paper weights75 to 105 g/m
Tray capacitiesMain tray:
modulated (on/off) laser beam scanning. Imaged is fused to paper
using heat and pressure with silicone oil lubricant.
magenta, yellow or black. The toner is a nonmagnetic, dual
component contact medium.
A-size:
Four color: 4 pages per minute
Monochrome: 16 pages per minute
Transparency: 2 pages per minute
B-size:
Four color: 2 pages per minute
Monochrome: 8 pages per minute
Transparency: 1 page per minute
5 mm(0.2 in.) on all sides, except for Tabloid Plus (13 x 19 in.)
media which has a bottom margin of 25 mm (1 in.)
64 to 220 g/m2(80 lb) using the multi-purpose tray
Standard paper: 250 sheets
Transparency: 100 sheets
Lower feeder trays:
Standard paper: 250 sheets
Multi-purpose tray:
Standard paper/Letterhead: 150 sheets
Transparency: 50 sheets
Label: 50 sheets
Postcard: 75
Envelope: 30
Glossy/Coated: 75
Index: 30
Fabric Transfer: one at a time
Service Guide
15
Table 5 Electrical specifications
CharacteristicSpecification
Primary line voltage100/120 VAC (+/- 10%)
Primary voltage frequency
range
Power consumptionEnergyStar: 20 watts
220/240 VAC (+/- 10%)
47 to 63 Hz
Standby: 100 watts
1000 watts with fuser on
Ready: 100 watts
1000 watts with fuser on
Printing: 1100 watts
Table 6 Environmental specifications
CharacteristicSpecification
Temperature:
Operating
Non-operating
Storage
Humidly:
Operating
Non-operating
Storage
0 to 32oC (41 to 90oF)
-20 to40oC (-4 to 104oF)
-20 to40oC (-4 to 104oF)
15 to 85% relative humidity
5 to 85% relative humidity
5 to 85% relative humidity
Altitude
Operating:
Non-operating
Vibration
Operating:
Non-operating
Shock-non-operating
Acoustic Noise
Idle:
Printing:
16
Phaser 780 Color Printer
0 to 3000 m (9900 ft.) at 25
0 to 15000 m (50,000 ft.)
Will withstand 0.5G excitation, 5 to 100 Hz, 3 axes for up to 50 minutes
with no impairment or subsequent damage.
0.5 g, 25 minute sweep, 5-100 Hz, 100-200 sec/sweep cycles
The printer may have any corner raised and dropped 5 cm (2 in.)
without impairment of operation.
38.3 db
54.8 db with impulse noise of 63.3 db
o
C
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