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Phaser 790
Xerox Phaser 790 User Manual
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10/
00
2-2
04
Ph
aser
790
/D
ocu
C
olo
r 20
06
011-7
06
Initia
l Is
sue
Stat
us I
ndica
tor RA
Ps
01
1-706
Cannot
Select Sort
er RAP
Co
ntrol
Logi
c did not
dete
ct the S
orter
.
Procedur
e
Go to
Flag
1.
Ch
eck the w
ires f
or an op
en circ
uit.
The
wire
s ar
e goo
d.
YN
Repair the wires.
Re
plac
e the Sor
ter C
ontr
ol PWB
(P
L 19.1)
.
Re
plac
e the MCU P
WB (P
L 1
1.2).
217
219
Table of Contents
Introduction
3
About this Manual
5
Organization
5
How to Use this Documentation
5
Symbology
5
1 Service Call Procedures
9
Table of Contents
9
Initial Actions Procedure
11
Service Call Procedures
11
Call Flow Procedure
12
Cleaning Procedures
13
Final Actions
13
2 Status Indicator Raps
15
Fault Message/Rap Cross-Reference
17
VDC Power RAP
21
VDC Interlocked Power RAP
23
Initial Issue
17
Status Indicator Raps
17
Front Cover Open RAP
25
ROS +5 VDC Switched Voltage RAP
27
Area 1 Open RAP
29
Area 2 Open RAP
31
Area 3 Open RAP
33
Area 4 Open RAP
35
Area 5 Open RAP
37
Area 6 Open RAP
39
IIT DC Power RAP
41
Blank/Garbled IOT Display RAP
43
IOT Control Panel Button/Led RAP
45
Duplex Communications Failure RAP
49
Sorter Communications Failure RAP
51
Foreign Interface RAP
53
Foreign Interface Compatibility RAP
55
IOT NVM RAM Error RAP
57
Copy/Print Cartridge Error RAP
59
IOT Firmware Error RAP
59
Paper Handling Motor RAP
61
Fuser Motor RAP
63
ADF Power RAP
67
ADF Communications RAP
69
ADF Fault Entry RAP
71
ADF Entrance Jam RAP
72
ADF Exit Jam RAP
74
ADF no Feed RAP
76
Unfinished Copy Job RAP
78
Exposure Lamp RAP
83
BTR 2 Bias RAP
166
Developer Fan RAP
168
Toner Cartridge Detached RAP
170
Toner Cartridge Empty RAP
172
Waste Container Full RAP
174
Waste Container Detached RAP
176
Belt Cleaner RAP
178
Fuser Low/Under Temperature Condition RAP
182
Fuser Temperature Not Detected RAP
184
Fuser Overheat Error RAP
186
Fuser Fan Error RAP
188
Exit Chute Fan Failure RAP
190
Area 5 Jam RAP
192
Faulty Temperature Sensor RAP
194
Faulty Entrance Sensor RAP
196
Faulty Fuser Exit Sensor RAP
198
Faulty Fuser Chute Fan RAP
200
Faulty Exchange Solenoid RAP
202
Sorter bin Jam RAP
207
Sorter Cover Open RAP
210
Sorter Transport Jam RAP
212
Sorter Noise RAP
214
Full Sensor RAP
216
Cannot Select Sorter RAP
218
ESS Hard Drive Error RAP
221
ASIC Access Error RAP
222
ESS RAM (Bank 2) RAP
223
Ess Rom Rap
223
ESS NVM RAM Failure RAP
224
Interface Error RAP
224
IOT to ESS Communication Failure RAP
225
IOT/IIT Disconnection RAP
227
IOT/IIT Communication RAP
228
Software Error RAP
228
ASIC Error RAP
229
Memory Error RAP
229
Failure RAP
230
IOT/IIT Communication RAP
230
SCSI Error RAP
231
3 Image Quality
233
IQ1 IOT Image Quality Entry RAP
235
IQ2 IIT Image Quality Entry RAP
237
IQ3 Low Image Density RAP
238
IQ4 High Density RAP
239
IQ5 Solid Black (or Other Color) Sheet RAP
239
IQ6 Blank (or Nearly Blank) Sheet RAP
240
IQ7 Residual Image (Ghosting) RAP
242
IQ8 IOT Background RAP
244
IQ9 Deletions RAP
246
IQ10 Color-To-Color Misregistration RAP
248
IQ11 IOT Skew RAP
248
IQ12 IIT Skew RAP
249
IQ13 Moire RAP
249
IQ14 Process Direction Bands, Streaks, and Smears RAP
250
IQ15 Unfused Copy RAP
250
IQ16 Repeating Bands, Streaks, Spots, and Smears RAP
251
IQ17 Uneven Density/Mottle RAP
252
IQ18 Spots RAP
253
4 Repairs and Adjustments
255
Rep 1.1 Lvps
259
Rep 1.2 Hvps
259
REP 1.3 Top Cover Interlock
260
REP 1.4 Developer Fan
260
Rep 1.5 Mcu Pwb
261
REP 1.6 Right Front Cover Interlock
262
REP 1.7 Left Front Cover Interlock
262
REP 1.8 Environment Sensor
263
Rep 1.9 Ess Pwb
264
REP 1.10 ESS Fan
265
REP 1.11 Controller Chassis
265
REP 1.12 Communication PWB
266
REP 1.13 Hard Disk Drive Assembly
267
REP 4.1 Paper Handling Drive Unit
269
REP 4.2 Fuser Drive Unit
270
REP 4.3 Fuser Motor
271
REP 4.4 Paper Handling Motor
271
REP 4.5 Drive Motor PWB
272
REP 4.6 Process Drive Unit
273
REP 4.7 Rotary Motor
274
REP 4.8 Rotary Motor PWB
274
REP 4.10 Developer Clutch
275
REP 4.9 Dispense Clutch
275
REP 5.1 ADF Assembly
277
REP 5.2 ADF Drive Motor
278
REP 5.3 Counterbalance
278
REP 5.4 Feed Roll
279
REP 5.5 Nudger Roll
280
REP 5.6 Registration Roll
283
REP 5.7 Document Transport Assembly
285
REP 5.8 Platen Belt
286
REP 5.9 ADF Exit Motor
287
REP 5.10 ADF Exit Sensor and Exit Tray Interlock
288
REP 6.1 Platen Glass
291
REP 6.2 Right Cover
291
REP 6.3 Left Cover
292
REP 6.4 Rear Cover
292
REP 6.5 Angle Sensor
293
REP 6.6 Platen Switch
293
REP 6.7 Registration Sensor
294
REP 6.8 IIT Low Voltage Power Supply (LVPS)
295
REP 6.9 Fan
295
Repairs and Adjustments
295
REP 6.10 APS Sensor
296
REP 6.11 PWB Box
297
REP 6.12 PWB Box Cover
299
Rep 6.13 Ips Pwb
299
REP 6.14 ICM Main PWB
300
REP 6.15 Extension PWB
301
REP 6.16 Advanced Features Memory PWB
301
REP 6.17 Front / Rear Cable Assembly
302
REP 6.18 Carriage Motor
303
REP 6.19 Belt
304
REP 6.20 Lamp
304
REP 6.21 Full-Rate Carriage Assembly
305
Rep 6.22 Flps Pwb
305
REP 6.23 Control Panel Assembly
306
REP 7.1 Size Switch PWB
307
REP 7.2 Sensor Bracket
307
REP 7.3 no Paper Sensor Assembly
308
REP 7.4 no Paper Sensor
308
REP 7.5 Low Paper Sensor
309
REP 7.6 Tray 1 Assembly / Paper Tray Assembly / Oversize Tray Assembly
309
REP 7.7 Tray 1 Front Snubber
310
REP 7.8 Oversize Tray Front Snubber
310
REP 8.1 Turn Roll
313
REP 8.2 Feed Roll
314
REP 8.3 Feed Roll Assembly
315
REP 8.4 Turn Clutch
316
REP 8.5 Feed Solenoid
317
REP 8.6 Bypass Tray/Registration Assembly
318
REP 8.7 Bypass Tray Feed Assembly
318
REP 8.8 Tray Housing
319
REP 8.9 Main Paper Handling Frame Assembly
319
REP 8.10 Lift Plate Sensor
320
REP 8.11 Lift Frame Assembly
320
REP 8.12 Tray Empty Sensor
321
REP 8.13 Pitch Sensor
321
REP 8.14 Stack Height Sensor
322
REP 8.15 Preregistration Clutch
323
REP 8.16 Preregistration Roll
323
REP 8.17 Registration Clutch
324
REP 8.18 Registration Rubber Roll
324
REP 8.19 Size Switch PWB
325
REP 8.20 Feeder Motor
326
REP 8.21 Feeder PWB
326
REP 8.22 Feeder Drive Unit/Low Paper Sensor
327
REP 8.23 Paper Feeder Assembly
328
REP 8.24 Takeaway Clutch
329
REP 8.25 Nudger Solenoid
329
REP 8.26 Turn Clutch
330
REP 8.27 Duplex Tray Assembly
330
REP 8.28 Duplex Entrance Sensor
331
REP 8.29 Duplex Exit Sensor
332
REP 8.30 Duplex Drive Clutch
334
REP 8.31 Front Belt
334
REP 8.32 Rear Belt
335
REP 8.33 Inverter Upper Assembly
335
REP 8.34 Exit Roll
336
REP 8.35 Inverter/Lower Assembly
337
REP 8.36 Inverter Motor
337
REP 8.37 Inverter Sensor
339
REP 8.38 Duplex Controller PWB
340
REP 8.39 Duplex Nip Solenoid
341
REP 8.40 Exit Transport Assembly
342
REP 8.41 Full Stack Sensor
343
REP 8.42 Exit Chute Interlock
343
REP 8.43 Top Exit Sensor
344
REP 9.1 Copy/Print Cartridge
345
REP 9.2 Waste Container
345
Rep 9.3 Ros
346
REP 9.4 ADC Sensor
348
REP 9.5 Locating Rail
349
REP 9.6 Waste Toner Sensor
350
REP 9.7 Toner Box Sensor
350
REP 9.8 Erase Lamp
351
REP 9.9 Dry Ink Cartridge
351
REP 9.10 Developer Housing
352
REP 9.11 Rotary Sensor
353
REP 9.12 Rotary Frame
354
REP 9.13 Cartridge Sensor
356
REP 9.14 Developer Tie Plate
357
REP 9.15 Tension Lever
357
REP 9.16 IBT Assembly
358
REP 9.17 Belt Cleaner
359
REP 9.18 BTR 2 Assembly
360
REP 9.19 BTR 2 Cam Assembly
361
REP 9.20 Auger
362
REP 9.21 IBT Belt
363
REP 9.22 TR0 Sensor
365
REP 9.23 BTR 2 Cam Clutch
365
REP 10.1 Fuser Assembly
367
REP 10.2 Main Fuser Assembly
367
REP 10.3 Upper Guide Assembly
368
REP 10.4 Upper Plate
369
REP 10.5 Heat Roll Heat Lamp
370
REP 10.6 Pressure Roll Heat Lamp
371
REP 10.7 Lower Guide Assembly
371
REP 10.8 Front Fuser Exit Sensor
372
REP 10.9 Rear Fuser Exit Sensor
372
REP 10.10 Heat Roll
373
REP 10.11 Pressure Roll
374
REP 10.12 Temperature Sensor
375
REP 10.13 Exchange Chute
376
REP 10.14 Exchange Solenoid
377
REP 10.15 Cleaner Cam Solenoid
377
REP 10.16 Cleaner Cam Shaft
378
REP 10.17 Exit Roll
379
REP 10.18 Fuser Entrance Sensor
380
REP 10.19 Fuser Chute Fan
381
REP 11.1 Sorter
383
REP 11.2 Bottom Cover
383
REP 11.3 Sorter Control PWB
384
REP 11.4 Sorter Transport Motor
385
REP 11.5 Sensor Receiver
386
REP 11.6 Sensor Transmitter
386
REP 11.7 Sorter Path Sensor
387
REP 11.8 Full Sensor
387
REP 11.9 bin Drive Motor
388
REP 11.10 Front / Rear Gear Shaft
389
REP 11.11 Front / Rear bin Cam
389
REP 11.12 bin Cam Switch
390
REP 11.13 bin Home Switch
390
REP 11.14 bin Tray(S)
391
REP 11.15 Docking Interlock
391
REP 14.1 Front Cover Assembly
393
REP 14.2 Front MID Cover
393
REP 14.3 Front Lower Cover
394
REP 14.4 Top Cover Assembly
395
REP 14.5 Inner Covers
396
REP 14.6 Rear Cover
397
REP 14.7 Filter
398
REP 14.8 Left Lower Cover
398
REP 14.10 Control Panel
399
REP 14.9 Right Cover
399
REP 14.11 Right Lower Cover
400
ADJ 3.1 Hard Disk Drive Assembly
401
ADJ 3.2 ESS PWB Initialization
401
ADJ 5.1 ADF Side Registration
402
ADJ 5.2 ADF Lead Edge Registration
403
ADJ 5.3 ADF Height
404
ADJ 5.4 ADF Front-To-Rear Positioning
405
ADJ 6.1 IIT Magnification
407
ADJ 6.2 IIT Half-Rate and Full-Rate Carriage Adjustment
408
ADJ 6.3 IIT Lead Edge Registration
411
ADJ 6.4 IIT Side Registration
412
ADJ 6.5 ICM Main PWB Adjustment
413
ADJ 6.6 IIT Auto-Shading
413
ADJ 6.7 B* Correction
414
ADJ 8.1 Printer Registration
415
ADJ 9.1 Developer Spacing
416
ADJ 10.1 Fuser Nip
418
ADJ 11.1 Sorter bin Cam Position
419
5 Parts List
421
Overview
423
Introduction
423
Subsystem Information
424
Symbology
425
PL 1.1 Front and Left Covers
427
PL 1.2 Rear, Right and Top Covers
428
PL 1.3 Base Frame (1 of 2)
429
PL 1.4 Base Frame (2 of 2)
430
PL 2.1 Paper Tray
431
PL 3.1 Tray 1 Paper Feeder (1 of 3)
432
PL 3.2 Tray 1 Paper Feeder (2 of 3)
433
PL 3.3 Tray 1 Paper Feeder (3 of 3)
434
PL 4.1 Bypass Tray/ Paper Transport (1 of 7)
435
PL 4.2 Bypass Tray/ Paper Transport (2 of 7)
436
PL 4.3 Bypass Tray/ Paper Transport (3 of 7)
437
PL 4.4 Bypass Tray/ Paper Transport (4 of 7)
438
PL 4.5 Bypass Tray/ Paper Transport (5 of 7)
439
PL 4.6 Bypass Tray/ Paper Transport (6 of 7)
440
PL 4.7 Bypass Tray/ Paper Transport (7 of 7)
441
PL 5.1 Xerographics
442
PL 6.1 Development (1 of 2)
443
PL 6.2 Development (2 of 2)
444
PL 7.1 IBT (1 of 5)
445
PL 7.2 IBT (2 of 5)
446
PL 7.3 IBT (3 of 5)
447
PL 7.4 IBT (4 of 5)
448
PL 7.5 IBT (5 of 5)
449
PL 8.1 Fusing (1 of 7)
450
PL 8.2 Fusing (2 of 7)
451
PL 8.3 Fusing (3 of 7)
452
PL 8.4 Fusing (4 of 7)
453
Parts List
454
PL 8.5 Fusing (5 of 7)
454
PL 8.6 Fusing (6 of 7)
455
PL 8.7 Fusing (7 of 7)
456
PL 9.1 Paper Exit (1 of 2)
457
PL 9.2 Paper Exit (2 of 2)
458
PL 10.1 Drives
459
PL 11.1 Electrical (1 of 2)
460
PL 11.2 Electrical (2 of 2)
461
Pl 12.1 Ess
462
PL 13.1 Optional Feeder Assembly (1 of 9)
463
PL 13.2 Optional Feeder Assembly (2 of 9)
464
PL 13.3 Optional Feeder Assembly (3 of 9)
465
PL 13.4 Optional Feeder Assembly (4 of 9)
466
PL 13.5 Optional Feeder Assembly (5 of 9)
467
PL 13.6 Optional Feeder Assembly (6 of 9)
468
PL 13.7 Optional Feeder Assembly (7 of 9)
469
PL 13.8 Optional Feeder Assembly (8 of 9)
470
PL 13.9 Optional Feeder Assembly (9 of 9)
471
PL 14.1 OHP Transparency Tray Assembly (1 of 2)
472
PL 14.2 OHP Transparency Tray Assembly (2 of 2)
473
PL 14.3 Oversize Tray
474
PL 15.1 Duplex Assembly (1 of 7)
475
PL 15.2 Duplex Assembly (2 of 7)
476
PL 15.3 Duplex Assembly (3 of 7)
477
PL 15.4 Duplex Assembly (4 of 7)
478
PL 15.5 Duplex Assembly (5 of 7)
479
PL 15.6 Duplex Assembly (6 of 7)
480
PL 15.7 Duplex Assembly (7 of 7)
481
PL 16.1 Platen Glass and IIT
482
PL 16.2 PWB Box
483
Pl 16.3 CCD
484
PL 16.4 Carriage Motor and Carriage Cable
485
PL 16.5 Full Rate Carriage and Half Rate Carriage
486
PL 16.6 Top Cover and Control Panel
487
PL 16.7 Control Panel Assembly
488
PL 17.1 Document Exit Tray, Covers
489
PL 17.2 Counterbalance, Drive Motor, PWB
490
PL 17.3 Registration,Feed,Nudger Roll, Nudger Home Sensor
491
PL 17.4 Feeder Upper Chute Assembly, Interlock Switch
492
PL 17.5 Feeder Lower Chute, Registration Sensor
493
PL 17.6 Document Transport, Platen Belt
494
PL 17.7 Exit Roll, Exit Motor, Exit Sensor
495
PL 17.8 Platen Glass, ADF Harness
496
PL 18.1 Stand
497
PL 19.1 Sorter Cover, Control PWB
498
PL 19.2 Feed Motor, LVPS (1 of 2)
499
PL 19.3 Feed Motor, LVPS (2 of 2)
500
PL 19.4 bin Drive Motor, Lead Cam/Switch
501
PL 19.5 Tray Support, bin Tray
502
PL 19.6 Sorter Support
503
Common Hardware
504
Part Number Index
505
6 General Procedures and Information
511
General Procedures
513
Gp 1 Diagnostic Mode (Iot)
513
Gp 2 Component Control (Iot)
514
Gp 3 Setting Iot Parameters and Life Counters
518
Gp 4 Reading or Writing to Iot Nvm
521
Gp 5 Setting up Meters
521
Gp 6 Initializing Data (Iot)
522
Gp 7 Changing Service Password (Iot
522
Gp 8 Iot Software Installation
523
Gp 9 Ess Software Installation (Iot)
524
Gp 11 Checking the Billing Meters
526
Gp 14 Printing a Configuration Page
526
Gp 15 Printing Internal Test Patterns (Iot)
527
Gp 16 Visual Calibration
528
Gp 17 Foreign Interface
529
Gp 18 Identifying Pin 1 on a Double Plug
529
Gp 19 Diagnostic Mode (Iit)
530
Gp 20 Setting Iit Parameters
531
Gp 21 Component Control (Iit)
532
Gp 22 Printing Internal Test Patterns (Iit
532
Gp 23 Fuser Baffle Cleaning Procedure
533
Product Specifications
535
General Product Specifications
535
Iot Specifications
535
Adf Specifications
537
Sorter Specifications
540
Tools and Supplies
541
Common Tools
541
Product Tools and Test Patterns
541
Cleaning Materials
542
Machine Consumables
542
Change Tag Index
543
Change Tag Introduction
543
Processor (P) Tags
544
Scanner Tags
544
VDC Wirenet (1 Of)
572
VDC Wirenet (2 Of)
573
VDC Wirenet (3 Of)
574
VDC Interlocked Wirenet (1 Of)
575
VDC Interlocked Wirenet (2 Of)
576
VDC Interlocked Wirenet (3 Of)
577
DC Com Wirenet (1 Of)
578
DC Com Wirenet (2 Of)
579
DC Com Wirenet (3 Of)
580
DC Com Wirenet (4 Of)
581
DC Com Wirenet (5 Of)
582
VDC (Iit) Wirenet
583
Bsd 6.2 and
610
Bsd 11.1/Bsd
651
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Xerox Phaser 790 Specifications
General
Brand
Xerox
Model
Phaser 790
Category
Copier
Language
English
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