Xerox Paser 7400 Book 2: Options
Phaser® 7400
color printer
Service
Manual
Book 2: Options
®
W
Phaser
7400
Color Printer
Service Manual
Book 2: Options
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The following servicing instructions are for use by qualified service
personnel only. To avoid personal injury, do not perform any servicing other
than that contained in the operating instructions, unless you are qualified to
do so.
First Printing: August 2005
071-0876-00
Copyright © 2005 Xerox Corporation. All Rights Reserved. Unpublished rights reserved under the
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1-ii Phaser 7400 Color Printer Options Service Manual
Service Terms
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Manual Terms
Various terms are used throughout this manual to either provide additional
information on a specific topic or to warn of possible danger present during a
procedure or action. Be aware of all symbols and terms when they are used, and
always read NOTE, CAUTION, and WARNING statements.
Common Acronyms:
The following list defines the acronyms that may be found in this manual.
ADC: Automatic Density Control MCU: Engine Control Board
BTR: Bias Transfer Roller NCS: Non-Contact Sensor
CRUM: Customer Replaceable Unit
Monitor
CTD: Toner Density Control PL: Corresponds to the FRU Parts List.
ESD: Electrostatic Discharge ROS: Laser Scanning Unit
IDT: Intermediate Transfer Unit RTC: Charge Roller
Note
A note indicates an operating or maintenance procedure, practice or condition
that is necessary to efficiently accomplish a task.
A note can provide additional information related to a specific subject or add a
comment on the results achieved through a previous action.
Caution
A caution indicates an operating or maintenance procedure, practice or condition
that, if not strictly observed, results in damage to, or destruction of, equipment.
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A warning indicates an operating or maintenance procedure, practice or
condition that, if not strictly observed, results in injury or loss of life.
PHD: Imaging Unit
Product Terms
Caution: A personal injury hazard exists that may not be apparent. For example, a
panel may cover the hazardous area.
Danger: A personal injury hazard exists in the area where you see the sign.
Phaser 7400 Color Printer Options Service Manual iii
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
30 min.
The surface is hot while the printer is running. After turning off
the power, wait 30 minutes.
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.
iv Phaser 7400 Color Printer Options Service Manual
Power Safety Precautions
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Power Source
For 115 VAC printers, do not apply more than 135 volts RMS between the supply
conductors or between either supply conductor and ground. For 230 VAC printers, do
not apply more than 254 volts RMS between the supply conductors or between either
supply conductor and ground. Use only the specified power cord and connector. This
manual assumes that the reader is a qualified service technician.
Plug the three-wire power cord (with grounding prong) into a grounded AC outlet
only. If necessary, contact a licensed electrician to install a properly grounded outlet.
If the product loses its ground connection, contact with conductive parts may cause an
electrical shock. A protective ground connection by way of the grounding conductor
in the power cord is essential for safe operation.
Disconnecting Power
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Turning the power off using the power switch does not completely de-energize
the printer. You must also disconnect the power cord from the printer’s AC inlet.
Disconnect the power cord by pulling the plug, not the cord.
Disconnect the power cord in the following cases:
■ if the power cord or plug is frayed or otherwise damaged,
■ if any liquid or foreign material is spilled into the product,
■ if the printer is exposed to any excess moisture,
■ if the printer is dropped or damaged,
■ if you suspect that the product needs servicing or repair,
■ whenever you clean the product.
Phaser 7400 Color Printer Options Service Manual v
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.
vi Phaser 7400 Color Printer Options Service Manual
Service Safety Summary
General Guidelines
For qualified service personnel only: Refer also to the preceding Power Safety
Precautions.
Avoid servicing alone: Do not perform internal service or adjustment of this
product unless another person capable of rendering first aid or resuscitation is present.
Use care when servicing with power: Dangerous voltages may exist at several
points in this product. To avoid personal injury, do not touch exposed connections and
components while power is on. Disconnect power before removing the power supply
shield 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.
Warning Labels
Read and obey all posted warning labels. Throughout the printer, warning labels are
displayed on potentially dangerous components. As you service the printer, check to
make certain that all warning labels remain in place.
Safety Interlocks
Make sure all covers are in place and all interlock switches are functioning correctly
after you have completed a printer service call. If you bypass an interlock switch
during a service call, use extreme caution when working on or around the printer.
Phaser 7400 Color Printer Options Service Manual vii
Servicing Electrical Components
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W
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.
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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.
arning
Do not try to manually rotate or manually stop the drive assemblies while any
printer motor is running.
S7300-03
viii Phaser 7400 Color Printer Options Service Manual
Regulatory Specifications
Xerox has tested this product to electromagnetic emission and immunity standards.
These standards are designed to mitigate interference caused or received by this
product in a typical office environment.
United States (FCC Regulations)
This equipment has been tested and found to comply with the limits for a Class A
digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to
provide reasonable protection against harmful interference when the equipment is
operated in a commercial environment. This equipment generates, uses, and can
radiate radio frequency energy. If it is not installed and used in accordance with these
instructions, it may cause harmful interference to radio communications. Operation
of this equipment in a residential area is likely to cause harmful interference in which
case the user will be required to correct the interference at his/her own expense.
If this equipment does cause harmful interference to radio or television reception,
which can be determined by turning the equipment off and on, the user is encouraged
to try to correct the interference by one or more of the following measures:
■ Reorient or relocate the receiver.
■ Increase the separation between the equipment and receiver.
■ Connect the equipment into an outlet on a circuit different from that to which the
receiver is connected.
■ Consult the dealer or an experienced radio/television technician for help.
Any changes or modifications not expressly approved by Xerox could void the user's
authority to operate the equipment. To ensure compliance with Part 15 of the FCC
rules, use shielded interface cables.
Canada (Regulations)
This Class A digital apparatus complies with Canadian ICES-003.
Cet appareil numérique de la classe A est conforme à la norme NMB-003 du Canada.
Phaser 7400 Color Printer Options Service Manual ix
European Union
W
arning
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.
x Phaser 7400 Color Printer Options Service Manual
Manual Organization
The Xerox Phaser 7400 Color Printer Service Manual is the primary document used
for repairing, maintaining, and troubleshooting the printer. The manual is organized
into two books. This volume, Book 2, Phaser 7400 Options includes an overview of
option theory, option FRU replacement procedures, parts lists, and wiring diagrams.
Use this volume after you’ve isolated a problem internal to a specific option or when a
problem arises at the engine/option interface. Use Book 1 for diagnostic and
troubleshooting procedures for the printer and all its 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 section provides troubleshooting
methods for situations where no error indicator is available.
Section 4 - Adjustments and Calibrations: This section provides procedures
for the adjustment of print engine components.
Section 5 - Service Parts Disassembly:
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.
This section contains removal
Phaser 7400 Color Printer Options Service Manual xi
Book 1 - Print Engine
Use Book 1 as your primary resource for understanding the operational characteristics
of the print engine. Book 1 describes printer specifications, theory and includes
information important to the diagnosis and repair of problems occurring in the print
engine and attached options. Book 1 also provides detailed print engine replacement
procedures, parts lists, and wiring diagrams.
Book 1 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
printer’s operation, configuration, specifications, and consumables.
Section 2 - Theory of Operation: This section contains detailed functional
information on print engine components.
Section 3 - Error Codes and Messages: This section describes the resident
diagnostics available to assist the troubleshooting process. These diagnostics include
error codes and messages and Service Usage Profile data stored in the printer. This
section provides complete troubleshooting information for the print engine and all
options.
Section 4 - General Troubleshooting: Troubleshooting discussions cover the
operation of Power On Self Test (POST), Service Diagnostics, In addition, this
section includes troubleshooting methods for situations where no error indicator is
available.
Section 5 - Print-Quality Troubleshooting: This section focuses on techniques
to correct image quality problems associated with printer output.
Section 6 - Adjustments and Calibrations: This section provides procedures
for the adjustment of print engine components.
Section 7 - Cleaning and Maintenance: This section provides periodic cleaning
procedures for the printer.
Section 8 - FRU Disassembly:
parts listed in the print engine’s Field Replaceable Units (FRUs) Parts List. A
replacement procedure is included when necessary.
Section 9 - Parts Lists: This section contains exploded views of the print engine
FRUs as well as part numbers for items available as FRUs. Part numbers for printer
options and accessories are also included.
Section 10 - Wiring Diagrams: This section contains the plug/jack locations and
the wiring diagrams for the print engine.
This section contains removal procedures for
Appendix A - Menu Maps: This section provides an illustration of the front-panel
menu as well as a listing of the Service Diagnostics tests available.
xii Phaser 7400 Color Printer Options Service Manual
Contents
Service Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Symbols Marked on the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Power Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
Electrostatic Discharge (ESD) Precautions. . . . . . . . . . . . . . . . . . . . . . . . . vi
Service Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii
Regulatory Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Manual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
1 General Information
Printer Introduction and Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Printer Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Parts of the Finisher and Paper Trays. . . . . . . . . . . . . . . . . . . . . . 1-4
Printer Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Finisher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Duplex Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
550-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1650-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Consumable Life Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Finisher Electrical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Physical Dimensions and Clearances . . . . . . . . . . . . . . . . . . . . . . 1-8
Finisher Functional Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Finisher Environmental Specifications . . . . . . . . . . . . . . . . . . . . 1-10
2 Theory of Operation
Options Operational Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Finisher Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Punch Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Staple Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Saddle Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Inverter Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Printer Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Duplex Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
550-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
1650-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Finishing Process Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Inverting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Punching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Folding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Stapling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Table of Contents xiii
Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Finisher Paper Path Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Inverter Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Duplex Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Optional Tray Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Motors, Rollers, Solenoids, and Clutches . . . . . . . . . . . . . . . . . . . . . . . 2-33
Finisher Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Inverter Solenoids and Motors. . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Duplex Solenoids, Rollers, and Motors . . . . . . . . . . . . . . . . . . . 2-36
Optional Tray Motors, Rollers, and Clutches . . . . . . . . . . . . . . . 2-37
Detecting Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Finisher/Punch Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Finisher Power Supply Protection . . . . . . . . . . . . . . . . . . . . . . . 2-42
Punch Unit Power Supply Protection. . . . . . . . . . . . . . . . . . . . . 2-42
3 General Troubleshooting
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Using Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Jam Locator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Jam Detection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Error Message Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Using the Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . 3-11
Measurement Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Troubleshooting the Finisher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Jam at Door C for Tray [3][4][5][6]. . . . . . . . . . . . . . . . . . . . . . 3-13
Jam at Door D Open Door D to Clear. . . . . . . . . . . . . . . . . . . . . 3-16
Jam in Duplex Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Jam at Duplex Entrance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Jam at Finisher Punch Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Jam at Finisher Door H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Jam at Finisher Upper Output Tray . . . . . . . . . . . . . . . . . . . . . . 3-22
Jam at Finisher Saddle Stapler. . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Jam at Finisher Upper Output Tray . . . . . . . . . . . . . . . . . . . . . . 3-24
Jam at Finisher Stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Jam at Finisher Door G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Jam at Finisher Saddle Stapler. . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Jam at Finisher Upper Output Tray . . . . . . . . . . . . . . . . . . . . . . 3-28
Jam Inside Finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Jam at Finisher Entrance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Finisher Output Tray Jammed . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Close Right Door C for Tray [3][4][5][6] . . . . . . . . . . . . . . . . . . 3-33
Close Left Door D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Close Finisher Door F. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Close Finisher Door H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Close Finisher Door J. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
xiv Phaser 7400 Color Printer Options Service Manual
Clear Tray [2][3][4][5][6] Riser Plate. . . . . . . . . . . . . . . . . . . . . 3-38
Out of Paper Load Tray [2][3][4][5][6] with [size][type] . . . . . . 3-39
Finisher Lower Output Tray is Full, Unload Paper. . . . . . . . . . . . 3-40
Finisher Upper Output Tray is Full, Unload Paper . . . . . . . . . . . . 3-41
Wrong Paper Size; Load Tray [3][4][5][6] with [size][type]. . . . 3-42
Wrong Paper Type Load Tray [3][4][5][6] with [size][type]. . . . 3-43
Paper Not Available Load Tray [3][4][5][6] with [size][type] . . . 3-44
Duplex Interface Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Tray [3][4][5][6] Interface Failure. . . . . . . . . . . . . . . . . . . . . . . . 3-46
Inverter Unit Interface Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Unsupported Duplex Unit ROM. . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Unsupported Tray [3][4][5][6] ROM . . . . . . . . . . . . . . . . . . . . . 3-49
Unsupported Inverter Unit ROM . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Unsupported Finisher Unit ROM. . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Finisher Fold Position Sensor Failure . . . . . . . . . . . . . . . . . . . . . 3-52
Finisher Paddle Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
Finisher Stapler Swing Motor Failure . . . . . . . . . . . . . . . . . . . . . 3-54
Finisher Stack Handling Motor Failure . . . . . . . . . . . . . . . . . . . . 3-55
Finisher Staple Motor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Finisher Jog Motor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Finisher Lift Motor Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
Finisher Exit Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
Finisher Punch Backup RAM Failure. . . . . . . . . . . . . . . . . . . . . . 3-61
Finisher Punch Communications Failure. . . . . . . . . . . . . . . . . . . 3-62
Finisher Punch Unit Transfer Motor Failure . . . . . . . . . . . . . . . . 3-63
Finisher Punch Motor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Finisher Backup RAM Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Finisher Punch Dust Sensor Failure . . . . . . . . . . . . . . . . . . . . . . 3-66
Printer Error - Contact Service; report fault [n] . . . . . . . . . . . . . . . . . . . 3-68
Finisher Punch Unit Counter at End of Life . . . . . . . . . . . . . . . . . 3-68
Finisher Staple Unit Counter at End of Life . . . . . . . . . . . . . . . . . 3-69
Finisher Interface Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
Inverter Power Supply Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Tray [3][4][5][6] Firmware Error . . . . . . . . . . . . . . . . . . . . . . . . 3-72
Duplex Unit Firmware Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
Finisher Inverter Firmware Error. . . . . . . . . . . . . . . . . . . . . . . . . 3-74
Tray [3][4][5][6] Flash Memory Failure . . . . . . . . . . . . . . . . . . . 3-75
Duplex Unit Flash Memory Failure . . . . . . . . . . . . . . . . . . . . . . . 3-76
Finisher Inverter Flash Memory Failure. . . . . . . . . . . . . . . . . . . . 3-77
Tray [3][4][5][6] Lift Motor Failure. . . . . . . . . . . . . . . . . . . . . . . 3-78
Duplex Unit Fan Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
+24V Not Available to the Duplex Unit . . . . . . . . . . . . . . . . . . . . 3-81
+24 V Not Available to Tray [3][4][5][6]. . . . . . . . . . . . . . . . . . . 3-83
Duplex Unit Clock Frequency Error. . . . . . . . . . . . . . . . . . . . . . . 3-84
Finisher Inverter Clock Frequency Error . . . . . . . . . . . . . . . . . . . 3-85
Tray [3][4][5][6] Feeder Board Clock Frequency Error. . . . . . . . 3-86
Table of Contents xv
No Paper in Tray [2][3][4][5][6] . . . . . . . . . . . . . . . . . . . . . . . . 3-87
Staple Cartridge Is Empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
Punch Waste Box is Full or Missing. . . . . . . . . . . . . . . . . . . . . . 3-89
Finisher Away From Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
Finisher Away From Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91
4 Adjustments and Calibrations
Punch Unit Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Registering Punch Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Adjusting Sensor Output After Sensor Replacement . . . . . . . . . . 4-4
Adjusting Sensor Output After EE-PROM Replacement . . . . . . . . 4-5
Stapler Unit Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Adjusting the Saddle Stitch Double Stapling Position . . . . . . . . . 4-6
Adjusting the Stapler Phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Saddle Unit Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Adjusting the Folding Position . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Adjusting the Phase of the Saddle Unit Gear . . . . . . . . . . . . . . . 4-18
5 Service Parts Disassembly
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
General Notes on Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Notations in the disassembly text . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Fastener Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Standard Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Finisher Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Removing Inverter Base Unit from Finisher . . . . . . . . . . . . . . . . . 5-5
Undocking Inverter from Printer . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Trays and Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Paper Exit Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Front Door (Door J). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Right Side Door (Door G) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Upper Cover (Door H) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Processing Tray Upper Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Inverter Front Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Inverter Rear Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Inverter Left Side Door (Door F) . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Inverter Right Side Door (Door I). . . . . . . . . . . . . . . . . . . . . . . . 5-22
Inverter Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Punch Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Staple Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Staple/Fold Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Saddle Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
xvi Phaser 7400 Color Printer Options Service Manual
Upper Right Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Processing Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Paddle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Finisher Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Home Position Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Punch Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Photo Sensor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Punch LED Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Waste Full LED Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
Inverter Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
Inverter Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Motors, Clutches, and Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Punch Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Finisher Punch Transfer Motor. . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
Staple/Fold Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
Slide Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
Feed Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
Paddle Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
Delivery Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
Alignment (Front and Rear) Motors . . . . . . . . . . . . . . . . . . . . . . 5-65
Binding Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
Inverter Upper Roller Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Inverter Lower Roller Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Inverter Feeder Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
Inverter Upper Roller Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
Inverter Lower Roller Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71
Finisher Sensors and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
Joint Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
Front Door Switch and Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
Inlet Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
Tray Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
Paper Surface Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
Upper Cover Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
Shift Limit Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
Lift Motor Clock Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80
Stack Full Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81
Processing Tray Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
Aligning Plate Home Position Sensors . . . . . . . . . . . . . . . . . . . . 5-83
Stack Feed Roller Home Position Sensor . . . . . . . . . . . . . . . . . . 5-85
Waste Full Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87
Swing Guide Home Position Sensor. . . . . . . . . . . . . . . . . . . . . . 5-89
Delivery Belt Home Position Sensor. . . . . . . . . . . . . . . . . . . . . . 5-90
Paddle Home Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91
Stapler Safety Interlock Switch. . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
Table of Contents xvii
Staple/Fold Clock Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93
Folding Home Position Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . 5-94
Folding Position Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96
Bind Tray Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-98
Inverter Sensors and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99
Inverter Docking Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100
Inverter Door (Door F) Open Interlock Switch . . . . . . . . . . . . . 5-101
Inverter Upper Paper-Present Sensor . . . . . . . . . . . . . . . . . . . 5-102
Inverter Lower Paper-Present Sensor . . . . . . . . . . . . . . . . . . . 5-104
Inverter Paper-in Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-106
Guides and Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107
Side Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107
Feed Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-109
Upper Stack Delivery Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-112
Paddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115
Lower Stack Delivery Roller Belt . . . . . . . . . . . . . . . . . . . . . . . 5-117
Duplex Unit Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-122
Front Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-122
Bottom Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-124
Side Rails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-126
Paper Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-127
Duplex Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-128
Diverter Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-129
Duplex Unit Sensors and Switches . . . . . . . . . . . . . . . . . . . . . 5-130
Duplex Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-131
Interconnect Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-132
Paper Tray Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-133
Options Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-133
Tray Covers and Tray Door (Door C) . . . . . . . . . . . . . . . . . . . . 5-134
Tray Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-136
Registration Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-137
Feed Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-138
Lift Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-139
Registration Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-140
Door C Detect Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-141
No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-142
Registration Sensor #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-143
Feed-Out Sensor #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-146
Feeder Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-148
Tray Feed Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-150
xviii Phaser 7400 Color Printer Options Service Manual
6 Parts List
Using the Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Finisher Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Duplex Unit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Optional Paper Tray Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Finisher Unit Assembly Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Parts List 1.1 Finisher Unit Assembly Parts List. . . . . . . . . . . . . . 6-5
Finisher External Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Parts List 1.2 Finisher External Parts List . . . . . . . . . . . . . . . . . . . 6-7
Finisher Internal Parts Diagram (1 of 2) . . . . . . . . . . . . . . . . . . . . 6-9
Finisher Internal Parts Diagram (2 of 2) . . . . . . . . . . . . . . . . . . . 6-10
Parts List 1.3 Finisher Internal Parts List . . . . . . . . . . . . . . . . . . 6-11
Stack (Lift) Motor Drive Assembly Parts Diagram . . . . . . . . . . . 6-12
Parts List 1.4 Stack (Lift) Motor Drive Assembly Parts List . . . . 6-13
(Staple/Fold) Drive Assembly Parts Diagram . . . . . . . . . . . . . . . 6-14
Parts List 1.5 (Staple/Fold) Drive Assembly Parts List . . . . . . . . 6-15
Bundle Support Cover Assembly Parts Diagram. . . . . . . . . . . . . 6-16
Parts List 1.6 Bundle Support Cover Parts List. . . . . . . . . . . . . . 6-17
Dispose Assembly (Processing Tray) Parts Diagram . . . . . . . . . 6-18
Parts List 1.7 Dispose Assembly (Processing Tray) Parts List. . 6-19
Paper Feeder (Paddle) Assembly Parts Diagram. . . . . . . . . . . . . 6-20
Parts List 1.8 Paper Feeder (Paddle) Assembly Parts List . . . . . 6-21
Puncher Assembly Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . 6-22
Parts List 1.9 Puncher Assembly Parts List . . . . . . . . . . . . . . . . 6-23
Punch Total Assembly Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Parts List 1.10 Punch Total Assembly Parts List . . . . . . . . . . . . 6-25
Staple Unit Diagram (1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Staple Unit Diagram (2 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Parts List 1.11 Staple Unit Parts List . . . . . . . . . . . . . . . . . . . . . 6-29
Fold Unit Diagram (1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Fold Unit Diagram (2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Fold Unit Diagram (3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Parts List 1.12 Fold Unit Parts List . . . . . . . . . . . . . . . . . . . . . . . 6-33
Inverter Parts Diagram (1 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Inverter Parts Diagram (2 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Inverter Parts Diagram (3 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Parts List 1.13 Inverter Parts List. . . . . . . . . . . . . . . . . . . . . . . . 6-37
Duplex Unit Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Parts List 1.14 Duplex Unit Parts List. . . . . . . . . . . . . . . . . . . . . 6-39
Optional Tray Parts Diagram (1 of 2) . . . . . . . . . . . . . . . . . . . . . 6-41
Optional Tray Parts Diagram (2 of 2) . . . . . . . . . . . . . . . . . . . . . 6-42
Parts List 1.15 Optional Tray Parts List . . . . . . . . . . . . . . . . . . . 6-43
Table of Contents xix
7 Wiring Diagrams
Plug/Jack Locator Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Print Options Plug/Jack Designators . . . . . . . . . . . . . . . . . . . . . . 7-2
Finisher Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Finisher/Punch Power Supply Wiring Diagram . . . . . . . . . . . . . 7-16
Finisher Controller to Printer Wiring . . . . . . . . . . . . . . . . . . . . . 7-17
Finisher Controller to Sensors (1 of 3). . . . . . . . . . . . . . . . . . . . 7-18
Finisher Controller to Sensors (2 of 3). . . . . . . . . . . . . . . . . . . . 7-19
Finisher Controller to Sensors (3 of 3). . . . . . . . . . . . . . . . . . . . 7-20
Finisher Controller to Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Finisher Controller to Switches . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Finisher Controller to Stapler Sensors and Motors . . . . . . . . . . 7-23
Finisher Controller to Punch Controller . . . . . . . . . . . . . . . . . . . 7-24
Punch Controller to Sensors and Motors. . . . . . . . . . . . . . . . . . 7-25
Inverter Sensors Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . 7-26
Inverter Motors, Solenoids, and Clutch Wiring Diagram . . . . . . 7-27
Duplex Unit Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Duplex Unit Sensors and Interconnect Wiring . . . . . . . . . . . . . . 7-28
Duplex Unit Motors and Solenoids . . . . . . . . . . . . . . . . . . . . . . 7-29
Optional Tray Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Paper Tray Sensors and Interconnect Wiring. . . . . . . . . . . . . . . 7-30
Paper Tray Motors, Clutches, and Interconnect Wiring . . . . . . . 7-31
Index
xx Phaser 7400 Color Printer Service Manual
General
Information
In this chapter...
■ Printer Introduction and Overview
■ Printer Configurations
■ Printer Options
■ Specifications
Section
1
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
technical support, contact your assigned Xerox Technical Support for this product.
www.xerox.com/office/7400support. For further
s7400-301
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. Resolutions of up to 600 x 1200 dots per inch (dpi), 32-level grayscale
print is applicable at 600x600 dpi. The base configuration (Phaser 7400N) features
USB 2.0 and 10/100baseT Ethernet Ports, 256 MB of memory, a 250-sheet multipurpose Tray 1 (MPT), a 550-sheet input tray (Tray 2), a 500-sheet face-down Top
Output Tray, and a 250-sheet face-up 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 stitching, and offset stacking, which raises the output total to 1750
sheets. A Duplex Unit is available to add automatic, 2-sided printing for supported
paper sizes from all trays.
1-2 Phaser 7400 Color Printer Options Service Manual
Printer Configurations
The Phaser 7400 Color Printer is available in five configurations. The main
differences are standard memory, optional high-capacity feeders, duplexing (2-sided
printing) capabilities, networking, Finisher capabilities, and internal Hard Drive. The
following table lists the available configurations.
Printer Configuration
Features
7400N 7400DN 7400DT 7400DX 7400DXF
Max Print Speed (ppm)
color / monochrome
Hard Drive for Secure,
Proof, Personal, and
Saved Print Jobs
Standard Memory* 256 MB 256 MB 512 MB 512 MB 512 MB
USB Port Ye s Ye s Ye s Ye s Ye s
10/100 Ethernet Port Ye s Ye s Ye s Ye s Ye s
RAM Collation Ye s Ye s Ye s Ye s Ye s
Duplex Unit Optional Ye s Ye s Ye s Ye s
PostScript / PCL Fonts Ye s Ye s Ye s Ye s Ye s
Resolutions (dpi):
Standard
Enhanced
Photo
Tray 1 (MPT)** Ye s Ye s Ye s Ye s Ye s
Optional Trays ** Optional Optional 1 x 550 3 x 550 4 x 550
36/40 36/40 36/40 36/40 36/40
Optional Optional Ye s Ye s Ye s
600x600x1
1200x600x1
600x600x5
600x600x1
200x600x1
600x600x5
600x600x1
1200x600x1
600x600x5
600x600x1
1200x600x1
600x600x5
600x600x1
1200x600x1
600x600x5
550-Sheet Feeder** Optional Optional Ye s Optional Ye s
1650-Sheet Feeder** Optional Optional Optional Ye s Ye s
1000-Sheet Finisher*** Optional Optional Optional Optional Ye s
* 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 total of 4 optional trays for fitment.
General Information 1-3
Parts of the Finisher and Paper Trays
Front View
Rear View
s7400-552
1-4 Phaser 7400 Color Printer Options Service Manual
s7400-533
Printer Options
Phaser 7400 Color Printer options include:
■ 1,000-Sheet Finisher (with hole punch, staple, saddle-stitch, and inverter)
■ 550-Sheet Feeder (LTA)
■ 1650-Sheet Feeder (HCF)
■ Duplex Unit
Finisher
The Finisher increases the output capacity of the printer by 1,000 sheets. Printer
output is directed to the Finisher by way of the side exit. Depending on the job
specifications, as paper enters the Finisher it is punched, stapled, offset and stacked.
The Finisher has two cables; one to hook up to the printer, and another to connect to
the Inverter. The Finisher also includes its own power supply.
The Finisher includes a separate Inverter unit to position paper from the printer before
the paper reaches the finisher unit for final stacking.
Finisher
Inverter
General Information 1-5
s7400-306
Duplex Unit
The Duplex Unit adds two-sided printing. The Duplex Unit attaches into the left side
above Tray 2 using two latches.
s7400-305
550-Sheet Feeder
The 550-Sheet Feeder increases the input capacity of the printer. The feeder attaches
below Tray 2 with four screws. When used in combination with the 1650-Sheet
Feeder, the 550-Sheet Feeder is installed between the printer and 1650-Sheet Feeder.
Up to four optional 550-Sheet Feeders per printer, totaling six universal trays (Trays
2~6), is allowed. However, when the 1650-Sheet Feeder (HCF) is installed, only one
additional 550-Sheet Feeder is allowed between the HCF and the printer. Electrical
connection to the printer is made by a single interface connector.
1-6 Phaser 7400 Color Printer Options Service Manual
s7400-001
1650-Sheet Feeder
The 1650-Sheet Feeder adds three, 550-sheet trays. Control signals reach the sheet
feeder by a single connection. The sheet feeder is secured both to the print engine and
the 550-Sheet Feeder.
s7400-003
Specifications
Consumable Life Specifications
Maintenance Items
Staple Cartridge‘ 5000 staples x3 AR-SC2
Size Product name
Finisher Electrical Specifications
Characteristic Specification
Primary line
voltages
Primary line
voltage
frequency range
110-127 V Printer - 12 amp circuit
220-240 V Printer - 6 amp circuit
100-120 V Printer - 50/60 Hz + 2 Hz
220-240 V Printer - 50/60 Hz + 2 Hz
Power
consumption
60 watts
(finishing)
General Information 1-7
12 Watts
(standby)
Physical Dimensions and Clearances
Finisher (including stand) Value
Height: 1016 mm (40.0 in.)
Width: 813 mm (32 in.)
Depth: 595 mm (23.6in.)
Weight: Approximately 55 kg (122 lb.) Finisher only
1650-Sheet Feeder Value
Height: 401 mm (15.8 in.) Optional Paper Tray Assembly
Width: 597 mm (23.5 in.)
Depth: 599 mm (23.6 in.)
Weight: Approximately 53.6 kg (117 lb.)
550-Sheet Feeder Value
Height: 109 mm (4.3 in.) Optional Paper Tray Assembly
Width: 597 mm (23.5 in.)
Depth: 599 mm (23.6 in.)
Weight: 16 kg (36 lb.)
Surface Value
Tilt tolerance: Within 50 mm side to side.
Finisher Functional Specifications
Functional Specifications
Characteristic Specification
Transport Speed 34 - 45 PPM
Transport Reference Center Reference
Tray Typ e
(number of trays)
Upper Tray Lift-up/down offset tray
Lower tray Book tray for saddle stitch
Non-staple
1,000 sheets (Small size)
500 sheets (Large size)
Capacity of paper exit
and load
Staple sort
Max
Large size
Small size
1-8 Phaser 7400 Color Printer Options Service Manual
30 sheets
1,000 sheets (Small size)
500 sheets: (Large size)
A3, B4, 11” x 17”, 8.5” x 11”
A4R, B5, B5R, A5R, 8.5 x
11 R and Executive
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