Xerox Phaser 7400 Service Manual

Phaser® 7400

color printer

Service

Manual

Book 1: Print Engine

Phaser® 7400

Color Printer

Service Manual Book 1: Print Engine

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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 Unpublished rights reserved under the copyright laws of the United States.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 Other

, The Document Company®, the digital X®, CentreWare®, infoSMART®, Made For Each

, PagePack™, Phaser®, PhaserSMART®, and Walk-Up™ are trademarks of Xerox Corporation in

the United States and/or other countries.

Acrobat PostScript IntelliSelect

, Adobe® Reader®, Adobe Type Manager®, ATM™, Illustrator®, PageMaker®, Photoshop®,

, Adobe Brilliant® Screens, Adobe Garamond®, Adobe Jenson™, Birch®, Carta®,

, Mythos®, Quake®, and Tekton® are trademarks of Adobe Systems Incorporated in the

United States and/or other countries.

Apple

, AppleTalk®, EtherTalk®, LaserWriter®, LocalTalk®, Macintosh®, Mac OS®, TrueType®, Apple

Chancery

, Chicago®, Geneva®, Monaco®, New York® , and QuickDraw® are trademarks of Apple

Computer, Inc. in the United States and/or other countries.

HP-GL

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

other countries.

and AIX® are trademarks of International Business Machines Corporation in the United States and/

IBM or other countries.

Windows

, Windows NT®, Windows Server™, and Wingdings® are trademarks of Microsoft Corporation

in the United States and/or other countries.

, NetWare®, NDPS®, NDS®, Novell Directory Services® , IPX™, and Novell Distributed Print

Novell

™

Services

Sun

are trademarks of Novell, Incorporated in the United States and/or other countries.

, Sun Microsystems™, and Solaris® are trademarks of Sun Microsystems, Incorporated in the United

States and/or other countries.

is a trademark of SWOP, Inc.

SWOP

UNIX

is a trademark in the United States and other countries, licensed exclusively through X/Open

Company Limited.

NERGY STAR

As an E

TAR guidelines for energy efficiency. The ENERGY STAR name and logo are registered U.S. marks.

partner, Xerox Corporation has determined that this product meets the ENERGY

PANTONE Publications for accurate color. PANTONE

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

and other Pantone, Inc. trademarks are the property of

Pantone, Inc. © Pantone, Inc., 2000.

ii Phaser 7400 Color Printer Service Manual

Service Terms

Manual Terms

Various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger present during a procedure or action. Be aware of all symbols and terms when they are used, and always read NOTE, CAUTION, and WARNING statements.

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.

PHD: Imaging Unit

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.

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.

Safety 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.

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 Service Manual

Power Safety Precautions

Power Source

For 115 VAC printers, do not apply more than 135 volts RMS between the supply conductors or between either supply conductor and ground. For 230 VAC printers, do not apply more than 254 volts RMS between the supply conductors or between either supply conductor and ground. 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.

Safety 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 (PCB’s).

vi Phaser 7400 Color Printer 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.

Safety vii

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.

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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.

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

S7300-03

Servicing Fuser Components

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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.

viii Phaser 7400 Color Printer 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.

Safety ix

European Union

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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 Service Manual

Manual Organization

The 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 1, focuses on the print engine with the exception of providing complete diagnostic and troubleshooting procedure for the printer and all its options. Book 2 focuses on option repair and includes an overview of option theory, option Field Replaceable Unit (FRU) replacement procedures, parts lists, and wiring diagrams. Use Book 2 after you’ve isolated a problem internal to a specific option or when a problem arises at the engine/option interface.

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 procudures, parts lists, and wiring diagrams.

Book 1 contains these sections:

Introductory, Safety, and Regulatory Information: This section contains

important safety information and regulatory requirements.

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 it’s 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.

Safety xi

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:

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

xii Phaser 7400 Color Printer 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

Metered Printing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Parts of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Image Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Printer Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Hard Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Additional Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Configuration Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

550-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1650-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Duplex Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Finisher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Maintenance Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Memory Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Consumable Life Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Physical Dimensions and Clearances . . . . . . . . . . . . . . . . . . . . . 1-14

Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

First Print Output Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Image Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Media and Tray Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Contents xiii

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

xiv Phaser 7400 Color Printer Service Manual

Chassis Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

Basket Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

Waste Toner Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

Registration Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

Exit Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

Job Offset Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

Trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

Tray 1 (MPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

Universal Trays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

Universal Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

Side Output Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

Image Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

Engine Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

Registration Sensor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

LED Relay Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

Imaging Unit Sensor Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

Motor Driver Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

Feeder Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

HVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

LVPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

Front Sensor Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

Rear Sensor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

Solenoids and Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61

3 Error Messages and Codes

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Accessing Fault History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Status Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Service Usage Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Messages, Codes, and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Error Message Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Jam Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Error Message Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Using the Troubleshooting Procedures. . . . . . . . . . . . . . . . . . . . 3-15

Measurement Techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Jam Error Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Jam at Door A Open Door A to Clear . . . . . . . . . . . . . . . . . . . . . 3-17

Jam at Door A Open Door A to Clear . . . . . . . . . . . . . . . . . . . . . 3-19

Jam at Door A Misfeed at Tray 1 (MPT) . . . . . . . . . . . . . . . . . . . 3-20

Jam at Door B Misfeed at Tray 2. . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Jam at Door C for Tray [3][4][5][6] . . . . . . . . . . . . . . . . . . . . . . 3-23

Jam at Door D Open Door D to Clear . . . . . . . . . . . . . . . . . . . . . 3-25

Contents xv

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

xvi Phaser 7400 Color Printer Service Manual

Tray and Media Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

Clear Tray 1 (MPT) Riser Plate . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

Clear Tray [2][3][4][5][6] Riser Plate . . . . . . . . . . . . . . . . . . . . . 3-73

Out of Paper Load Tray 1(MPT) with [size] [type] . . . . . . . . . . . 3-74

Out of Paper Load Tray [2][3][4][5][6] with [size][type] . . . . . . 3-75

Manual Feed [size][type] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76

Top Output Tray Is Full, Unload Paper . . . . . . . . . . . . . . . . . . . .3-77

Left Side Output Tray Is Full, Unload Paper . . . . . . . . . . . . . . . . 3-78

Finisher Lower Output Tray is Full, Unload Paper . . . . . . . . . . . . 3-79

Finisher Upper Output Tray is Full, Unload Paper . . . . . . . . . . . . 3-80

Open Left Side Output Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81

Media Mismatch Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82

Wrong Paper Size; Load Tray 1 (MPT) with [size][type]. . . . . . . 3-82

Wrong Paper Size; Load Tray 2 with [size][type] . . . . . . . . . . . . 3-83

Wrong Paper Size; Load Tray [3][4][5][6] with [size][type]. . . . 3-84

Wrong Paper Type Load Tray [1 (MPT)][2][3][4][5][6] with

[size][type] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85

Paper Not Available Load Tray 1 (MPT) with [size] [type] . . . . . 3-86

Paper Not Available; Load Tray 2 with [size][type] . . . . . . . . . . . 3-87

Paper Not Available Load Tray [3][4][5][6] with [size][type] . . . 3-88

Configuration Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89

Invalid or Missing Configuration Card . . . . . . . . . . . . . . . . . . . . 3-89

Duplicate IP Address Detected . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89

Fatal Error Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90

Fuser Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90

Temp Sensor Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92

RH Sensor Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93

LED Over Temperature Failure . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94

Motor Overheating Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95

Engine Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96

Power Supply Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-97

Feeder Home Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98

Controller Fan Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99

Power Supply Fan Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100

Top Cover Cooling Fan Failure . . . . . . . . . . . . . . . . . . . . . . . . . 3-101

Imaging Unit Fan Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102

Transfer Unit Fan Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103

Engine Cavity Fan Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104

Duplex Interface Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105

Tray [3][4][5][6] Interface Failure. . . . . . . . . . . . . . . . . . . . . . . 3-106

Inverter Unit Interface Failure . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107

[C][M][Y][K] LED Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108

[C][M][Y][K] Imaging Unit Failure . . . . . . . . . . . . . . . . . . . . . . 3-109

Flash Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111

Fuser Fan Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112

Fuser 110v/220v Mismatch Failure. . . . . . . . . . . . . . . . . . . . . . 3-113

Contents xvii

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

xviii Phaser 7400 Color Printer Service Manual

Tray [3][4][5][6] Lift Motor Failure. . . . . . . . . . . . . . . . . . . . . . 3-160

Error in the Transfer Unit Belt. . . . . . . . . . . . . . . . . . . . . . . . . . 3-162

Duplex Unit Fan Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-163

+24V Not Available to the Duplex Unit . . . . . . . . . . . . . . . . . . . 3-164

Failure in the [C][M][Y][K] Imaging Unit Drum or Motor . . . . . 3-165

+24 V Not Available to Tray [3][4][5][6]. . . . . . . . . . . . . . . . . . 3-167

Failure in the Fuser Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-168

Failure in the Waste Toner Motor . . . . . . . . . . . . . . . . . . . . . . . 3-169

Motor Driver Board Clock Frequency Error. . . . . . . . . . . . . . . . 3-170

Duplex Unit Clock Frequency Error. . . . . . . . . . . . . . . . . . . . . . 3-171

Finisher Inverter Clock Frequency Error . . . . . . . . . . . . . . . . . . 3-172

Tray [3][4][5][6] Feeder Board Clock Frequency Error . . . . . . . 3-173

Waste Toner Transfer Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-174

[CM][YK] Toner Supply Failure. . . . . . . . . . . . . . . . . . . . . . . . . 3-176

Warning Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-177

No Paper in Tray 1 (MPT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-177

No Paper in Tray [2][3][4][5][6]. . . . . . . . . . . . . . . . . . . . . . . . 3-178

Left Side Output Tray is Closed. . . . . . . . . . . . . . . . . . . . . . . . . 3-179

Waste Cartridge is Almost Full . . . . . . . . . . . . . . . . . . . . . . . . . 3-180

Non-Xerox [C][M][Y][K] Toner Cartridge . . . . . . . . . . . . . . . . . 3-181

Staple Cartridge Is Empty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-182

Punch Waste Box is Full or Missing . . . . . . . . . . . . . . . . . . . . . 3-183

Finisher Away From Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-184

Finisher Away From Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-185

4 General Troubleshooting

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

System Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Power On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

POST Soft Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

POST Hard Fault Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Fault Isolation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Entry Level Fault Isolation Procedure . . . . . . . . . . . . . . . . . . . . . . 4-6

Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Using Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Service Diagnostics Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Service Diagnostics Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Control Panel Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

No Control Panel Display after Power Is Turned On . . . . . . . . . . 4-10

Control Panel LED Is On, Control Panel Display Is Blank . . . . . . 4-11

Contents xix

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

xx Phaser 7400 Color Printer Service Manual

6 Adjustments and Calibrations

Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Color Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Margin Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Automatic Density Control (ADC) Calibration . . . . . . . . . . . . . . . . 6-2

Automatic Thickness (ATS) Calibration. . . . . . . . . . . . . . . . . . . . . 6-4

Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Vertical and Horizontal Color Registration . . . . . . . . . . . . . . . . . . 6-5

Resetting NVRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Restore Factory Color Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Restore Previous Color Settings. . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Restore Factory Margins Settings. . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Resetting Connection Setup Defaults . . . . . . . . . . . . . . . . . . . . . . 6-7

Resetting PostScript Setup Defaults. . . . . . . . . . . . . . . . . . . . . . . 6-7

Resetting PCL Setup Values to Default. . . . . . . . . . . . . . . . . . . . . 6-7

Resetting Control Panel Setup Values to Default . . . . . . . . . . . . . 6-8

Resetting Printer Controls Values to Default. . . . . . . . . . . . . . . . . 6-8

Resetting All Printer Defaults (PostScript NVRAM) . . . . . . . . . . . 6-8

Service Diagnostics NVRAM Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Postscript NVRAM Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

CRU Counter Read . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

CRU Counter Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

7 Cleaning and Maintenance

Service Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Cleaning the Imaging Unit Contacts . . . . . . . . . . . . . . . . . . . . . . . 7-3

Cleaning the LED Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Cleaning the Feed Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

RIP (Repair, Inspect, and Prevent) Procedures . . . . . . . . . . . . . . 7-6

8 Service Parts Disassembly

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Standard Orientation of the Printer. . . . . . . . . . . . . . . . . . . . . . . . 8-5

General Notes on Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Notations in the Disassembly Text . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Fastener Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Maintenance Items and Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Imaging Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Toner Cartridge Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Transfer Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

Fuser Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

Contents xxi

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

xxii Phaser 7400 Color Printer Service Manual

Side Output Tray Detect Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 8-73

Side Output Tray Stack Full Sensor. . . . . . . . . . . . . . . . . . . . . . . 8-75

Door E Detect Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-77

Fuser Release Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-79

Registration Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8-80

Registration Shutter Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-81

ADC Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-82

Media Slack Sensor and Actuator. . . . . . . . . . . . . . . . . . . . . . . . 8-83

Registration Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-84

Registration Clutch #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-85

Waste Toner Auger Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-86

Waste Toner Reservoir Full Sensor. . . . . . . . . . . . . . . . . . . . . . . 8-88

Waste Toner Reservoir Auger Rotation Sensor. . . . . . . . . . . . . . 8-89

Waste Toner Auger Rotation Sensor. . . . . . . . . . . . . . . . . . . . . . 8-90

Transfer Unit Belt Rotation Sensor. . . . . . . . . . . . . . . . . . . . . . . 8-91

Lower Basket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-92

Basket Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-93

LED Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-100

Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-103

Transfer Unit Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-103

Toner Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-104

Imaging Unit Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-105

Fuser Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-106

Waste Toner Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-107

Imaging Unit Lift Uplink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-108

Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-111

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-111

Engine Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-112

Image Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-113

Card Cage Fan Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-114

Card Cage Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-115

Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-117

HVPS Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-118

High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-119

Housing Bias Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-120

Low Voltage Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-121

LVPS Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-124

LED Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-125

LED Relay Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-126

Top Cover Interlock Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-127

Waste Toner Reservoir Detect Switch. . . . . . . . . . . . . . . . . . . . 8-130

Door A Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-132

Imaging Unit Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-133

Transfer Unit Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-134

Top Cover Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-135

IP Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-138

Contents xxiii

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

xxiv Phaser 7400 Color Printer Service Manual

Motor Driver Board (1/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31

Motor Driver Board (2/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32

Motor Driver Board (3/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33

Motor Driver Board (4/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34

Motor Driver Board (5/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35

Motor Driver Board (6/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36

LED Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37

Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38

LVPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39

Fuser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40

Imaging Unit Sensor Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41

Image Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43

Reference

Phaser 7400 Menu Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Printer Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Service Diagnostics Menu Map (1/2). . . . . . . . . . . . . . . . . . . . . . . . . . . A-11

Service Diagnostics Menu Map (2/2). . . . . . . . . . . . . . . . . . . . . . . . . . . A-12

Service Diagnostics Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13

Mode Select Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-28

Obtaining Serial Back Channel Traces . . . . . . . . . . . . . . . . . . . . . . . . . . A-29

Preparing the Printer for Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30

Index

Contents xxv

General Information

In this chapter...

■ Printer Introduction and Overview

■ Printer Configurations

■ Parts of the Printer

■ Printer Options

■ Specifications

Section

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. 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 600x600 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.

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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.

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 Yes Ye s Ye s

10/100 Ethernet Port Ye s Ye s Yes 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 Yes Ye s Ye s Ye s Ye s

Banner Sizes Ye s Ye s Yes Ye s Ye s

Photo Modes 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

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

36/40 36/40 36/40 36/40 36/40

Optional Optional Yes Ye s Ye s

600x600x1 1200x600x1 600x600x5

General Information 1-3

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.

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