XEROX Phaser 7800, Service Manual & Parts List

Phaser ® 7800 Color Printer Phaser ® 7800 Service Manual Xerox Internal-Use Only

November 2011 Phaser 7800 Service Manual BUS Update 10/25/2011 - Xerox Internal Use Only Phaser 7800 Service Manual Service Documentation Phaser 7800 Service Manual 705P01307 BUS Update - 10/25/2011 November 2011 Xerox Corporation Content Development and Language Services - North America 26600 Parkway - Bldg. 60 P.O. Box 1000, M/S 7060-776 Wilsonville, OR 97070-1000 NOTICE: All service documentation is supplied to Xerox external customers for informational purposes only. Xerox service documentation is intended for use by certified, product trained service personnel only. Xerox does not warrant or represent that such documentation is complete, nor does Xerox represent or warrant that it will notify or provide to such customer any future changes to this documentation. Customer performed service of equipment, or modules, components or parts of such equipment may affect the warranty offered by Xerox with respect to such equipment. You should consult the applicable warranty for its terms regarding customer or third party provided service. If the customer services such equipment, modules, components or parts thereof, the customer releases Xerox from any and all liability for the customer actions, and the customer agrees to indemnify, defend and hold Xerox harmless from any third party claims which arise directly or indirectly from such service. © 2011 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 Unpublished rights reserved under the copyright laws of the United States.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 limita- tion, material generated from the software programs which are displayed on the screen such as styles, templates, icons, screen displays, looks, etc. Xerox technical training materials and service manuals are intended for use by authorized Xerox service technicians and service partners only and are not for resale. These materials may not be distributed, copied or otherwise reproduced without prior written consent from Xerox Corporation. XEROX® and XEROX and Design®, Phaser®, PhaserSMART®, PhaserMeter, CentreWare®, PrintingScout®, Walk-Up®, WorkCentre®, FreeFlow®, SMARTsend®, Scan to PC Desktop®, MeterAssistant®, SuppliesAssistant®, Xerox Secure Access Unified ID System®, Xerox Extensible Interface Platform®, ColorQube®, Global Print Driver®, and Mobile Express Driver® are trademarks of Xerox Corporation in the United States and/or other countries. Adobe® Reader®, Adobe Type Manager®, ATM™, Flash®, Macromedia®, Photoshop®, and PostScript® are trademarks of Adobe Systems Incorporated in the United States and/or other countries. Apple®, AppleTalk®, Bonjour®, EtherTalk®, Macintosh®, Mac OS®, and TrueType® 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. IBM® and AIX® are trademarks of International Business Machines Corporation in the United States and/or other countries. Microsoft®, Windows Vista®, Windows®, and Windows Server® are trademarks of Microsoft Corporation in the United States and other countries. Novell®, NetWare®, NDPS®, NDS®, IPX™, and Novell Distributed Print Services™ are trademarks of Novell, Inc. in the United States and other countries. SGI® and IRIX® are trademarks of Silicon Graphics International Corp. or its subsidiaries in the United States and/or other countries. Sun, Sun Microsystems, and Solaris are trademarks or registered trademarks of Oracle and/or its affiliates in the United States and other countries. UNIX® is a trademark in the United States and other countries, licensed exclusively through X/ Open Company Limited. As an ENERGY STAR® partner, Xerox Corporation has determined that this product meets the ENERGY STAR guidelines for energy efficiency. The ENERGY STAR name and logo are registered U.S. marks.

November 2011 Phaser 7800 Service Manual BUS Update 10/25/2011 - Xerox Internal Use Only

November 2011 i Phaser 7800 Service Manual Introduction BUS Update 10/25/2011 - Xerox Internal Use Only Introduction About this Manual ........................................................................................................... iii Organization .................................................................................................................... iii How to Use this Manual .................................................................................................. iv Power Safety ................................................................................................................... iv Service Safety Summary................................................................................................. iv Moving the Printer ........................................................................................................... vi Serial Number Format ..................................................................................................... vii Symbols Used on the Printer .......................................................................................... viii Electrostatic Discharge Precautions ............................................................................... x Regulatory Requirements ............................................................................................... x Translation of Warnings .................................................................................................. xii Phaser 7800 Overview .................................................................................................... xiii Printer Configurations ..................................................................................................... xiii Parts of Phaser 7800 ...................................................................................................... xiv Phaser 7800 Options ...................................................................................................... xvi Control Panel Configurations .......................................................................................... xviii Routine Maintenance Items ............................................................................................ xix Consumables .................................................................................................................. xx Specifications .................................................................................................................. xx Physical Dimensions and Clearances ............................................................................. xxv Toner Cartridge Life ........................................................................................................ xxvii Maintenance Function ..................................................................................................... xxvii Reference Pages and Troubleshooting Test Pages ....................................................... xxviii Acronyms and Abbreviations .......................................................................................... xxix

November 2011 ii Phaser 7800 Service Manual BUS Update 10/25/2011 - Xerox Internal Use Only Introduction

November 2011 iii Phaser 7800 Service Manual About this Manual, Organization Introduction BUS Update 10/25/2011 - Xerox Internal Use Only About this Manual The Phaser 7800 Service Manual is the primary document used for diagnosing, repairing, maintaining, and troubleshooting the printer. The Service Manual is the controlling publication for a service call. Information on using this document is found in the Introduction section. To ensure understanding of this product, complete the Xerox Service Training Program for this particular printer. Service Manual Revision Updates are issued as the printer changes or as corrections are identified. Technical Support Information For manual updates, Service Bulletins, knowledge base, and technical support, go to: • Xerox Global Service Net - https://www.xrxgsn.com/secure/main.pl For further technical support, contact your assigned Xerox Technical Support for this product. Organization The titles of the sections and a description of the information contained in each chapter are contained in the following paragraphs: Introduction and General Information This chapter contains documentation organization, symbology and nomenclature, translated warnings, safety symbols, regulatory requirements, and general information about the printer. Chapter 1 Service Call Procedures This chapter contains procedures to be taken during a service call and in what sequence they are to be completed. This is the entry level for all service calls. Chapter 2 Status Indicator RAPs This chapter contains descriptions of the diagnostic aids for troubleshooting that include Power On Self Test (POST), Fault Codes and Messages procedures. Chapter 3 Image Quality This chapter contains the diagnostic aids for troubleshooting image quality problems, as well as image quality specifications and image defect samples. Chapter 4 Repairs/Adjustments This chapter contains the removal, replacement, and adjustments procedures. Repairs Repairs include procedures for removal and replacement of spare parts listed in the Parts List. Use the repair procedures for the correct order of removal and replacement, for warnings, cautions, and notes. Adjustments Adjustments include procedures for adjusting the parts that must be within specification for the correct operation of the printer. Use the adjustment procedures for the correct sequence of operation for specifications, warnings, cautions and notes. Chapter 5 Parts List This chapter contains exploded views of the print engine and optional Field Replaceable Units (FRUs), as well as part numbers for orderable parts and illustrated Parts List. Chapter 6 General Troubleshooting This chapter contains details of the embedded Service Diagnostics test suite, as well as troubleshooting procedures for printer problems not related to a specific fault code. Chapter 7 Wiring Data This chapter contains drawings, lists of plug/jack locations, and diagrams of the power distribu- tion wire networks in the printer. Chapter 8 Theory of Operation This chapter contains detailed functional information on the print engine components.

November 2011 iv Phaser 7800 Service Manual How to Use this Manual, Service Safety Summary BUS Update 10/25/2011 - Xerox Internal Use Only Introduction How to Use this Manual Always start with the Service Call Procedures in Chapter 1. Perform Initial Actions and verify the problem, then follow the directions provided. Power Safety 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 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. Service Safety Summary General Safety The printer and recommended supplies have been designed and tested to meet strict safety requirements. Attention to the following information will ensure the continued safe operation of the printer. Electrical Safety • Use the power cord supplied with the printer. • Plug the power cord directly into a properly grounded electrical outlet. • Do not use a ground adapter plug to connect the printer to an electrical outlet that does not have a ground connection terminal. • Do not use an extension cord or power strip. • Do not place the printer in an area where people might step on the power cord. • Do not place objects on the power cord. • Do not block the ventilation openings. These openings are provided to prevent overheat- ing of the printer. • Do not drop paper clips or staples into the printer. The power cord is attached to the printer as a plug-in device on the side of the printer. If it is necessary to disconnect all electrical power from the printer, disconnect the power cord from the electrical outlet. WARNING Switch off the electricity to the machine. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury. DANGER: Mettez la machine hors tension. Déconnectez le cordon d'alimentation de l'alimentation du client lorsque vous réalisez des tâches qui ne nécessitent pas d'électric- ité. L'électricité peut être à l'origine de blessures, voire d'un accident mortel. Les pièces amovibles peuvent être à l'origine de blessures. AVVERTENZA: Spegnere la macchina. Scollegare il cavo di alimentazione dall'alimenta- tore quando si eseguono attività che non richiedono elettricità. L'elettricità può causare morte o lesioni personali. Le parti in movimento possono causare lesioni personali. VORSICHT: Schalten Sie die Stromversorgung der Maschine ab. Ziehen Sie das Stromk- abel ab, wenn Sie Aufgaben ausführen, für die keine Stromversorgung benötigt wird. Stromschläge können Todesfällen oder Verletzungen verursachen. Bewegliche Teile können zu Verletzungen führen. AVISO: Apague la electricidad de la máquina. Desconecte el cable de alimentación eléc- trica de la toma de pared mientras esté realizando tareas que no necesiten corriente. La electricidad puede causar daños o la muerte. Las partes móviles pueden causar daños. WARNING Do not switch on the electricity to the machine while a ground circuit is disconnected. Ground circuits ensure that the machine remains safe during a fault condition. DANGER: Ne pas mettre la machine sous tension si un circuit de mise à la masse est déconnecté. Les circuits de mise à la masse permettent de garantir la sécurité de la machine lors d'un incident. AVVERTENZA: Non accendere la macchina se uno dei conduttori di terra non è con- nesso. In caso di guasti elettrici, tali conduttori garantiscono la sicurezza del sistema. VORSICHT: Stromzufuhr zum Gerät nicht einschalten, wenn keine Erdung gegeben ist. AVISO: No encienda la máquina mientras esté deconectado algún circuito de tierra. Los circuitos de tierra mantienen la seguridad de la máquina en las situaciones de averías o errores. Maintenance Safety • Do not attempt any maintenance procedure that is not specifically described in the documentation supplied with the printer. • Do not use aerosol cleaners. The use of supplies that are not approved may cause poor performance and could create a hazardous condition. • Do not burn any consumables or routine maintenance items. For information on Xerox supplies recycling programs, go to www.xerox.com/gwa.

November 2011 v Phaser 7800 Service Manual Service Safety Summary Introduction BUS Update 10/25/2011 - Xerox Internal Use Only Operational Safety The printer and supplies were designed and tested to meet strict safety requirements. These include safety agency examination, approval, and compliance with established environmental standards. Pay attention to these safety guidelines to ensure the continued, safe operation of the printer. • Use the supplies specifically designed for your printer. The use of unsuitable materials may cause poor performance and a possible safety hazard. • Follow all warnings and instructions marked on, or supplied with, the printer, options and supplies. WARNING Use only Xerox materials and components. This product is safety certified using Xerox materials and components. The use of non Xerox materials and components may invali- date the safety certificate. DANGER: N'utilisez que des matières premières et des composants Xerox. La sécurité du produit est assurée dans le cadre de son utilisation avec des matières premières et des composants Xerox. L'utilisation de matières premières et de composants autres que ceux de Xerox risque d'invalider le certificat de sécurité. AVVERTENZA: Utilizzare solo materiali e componenti Xerox per avvalersi della certificazione di protezione. L'utilizzo di materiali e componenti non Xerox può rendere nulla la certificazione di protezione. VORSICHT: Verwenden Sie nur Materialien und Komponenten von Xerox. Dieses Produkt besitzt die Sicherheitszertifizierung bei Verwendung von Xerox-Materialien und -Komponenten. Die Verwendung von Materialien und Komponenten anderer Hersteller setzt möglicherweise das Sicherheitszertifikat außer Kraft. AVISO: Utilice solo los materiales y componentes Xerox. Este producto dispone de un certificado de seguridad si se utilizan los materiales y componentes Xerox. Este certificado de seguridad no será válido si se utilizan materiales y componentes que no sean de Xerox. NOTE: The Total Satisfaction Guarantee is available in the United States and Canada. Cover- age may vary outside these areas; please contact your local representative for details. 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 printer 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 printer. 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.

November 2011 vi Phaser 7800 Service Manual Moving the Printer BUS Update 10/25/2011 - Xerox Internal Use Only Introduction Moving the Printer • Use the power switch to turn Off the printer, and unplug all cables and cords. Do not turn the printer Off by pulling the power cord or using a power-strip with an On/Off switch. • The printer is heavy and must be lifted by three people. Figure 1 Printer Lifting Technique Repacking the Printer When shipping the printer, repack the printer using the original packing material and boxes or a Xerox packaging kit. Instructions for repacking the printer are included in the kit. If you do not have all the original packaging, or are unable to repackage the printer, contact your local Xerox service representative. CAUTION Failure to repackage the printer properly for shipment can result in damage to the printer. Dam- age to the printer caused by improper packaging is not covered by the Xerox warranty, service agreement, or Total Satisfaction Guarantee. Repacking Procedure 1. Remove the Imaging Unit (Y/M/C/K) (REP 8.1). 2. Remove the Toner Cartridge (Y/M/C/K) (REP 5.1). 3. Remove the Waste Cartridge (REP 8.9). 4. Remove the IBT Belt Cleaner Assembly (REP 6.1). 5. Remove the Front Cover Assembly and Inner Cover Assembly (REP 19.1). 6. Remove the Top Cover (REP 19.2). 7. Cut card board to 4 pieces at approximately 1 x 1.5 inch for each piece. 8. Cover the toner ports with the card boards. Figure 2 Covering the Toner Ports

XEROX Phaser 7800, Service Manual & Parts List

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