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Xerox 7300N Service Manual - Page 255

Toner Detection

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Toner Detection The used toner amount is detected by counting the printed pixel numbers. The printer starts counting pixels after a "Toner Low" error is received by the printer and stores the count on the engine controller board EEPROM. When the "Toner Empty" condition is met, the consumed amount is set to 100%. The toner cartridge contains a stirring gear (which rotates at a constant rate), a stirring bar and a magnet on the stirring bar. The toner state is detected by measuring the contact time between the toner cartridge sensor actuator and the magnet on the stirring bar. Stirring Link gear Stirring bar S7300-142 Toner Full State The stirring bar turns with the stirring gear. Since the opposite side is in toner, the stirring bar turns by the force of the stirring gear even when the stirring magnet is placed in its highest position. Toner Cartridge Sensor Actuator Toner Low Sensor Sensor lever B Toner cartridge Theory of Operation Toner full state Stirring bar S7300-143 8-239

Section	Page
Cover Page	1
PHASER® 7300 COLOR PRINTER	3
Front Matter	3
Safety Terms	5
Manual Terms	5
Product Terms:	5
Power Safety Precautions	6
Power Source	6
Disconnecting Power	6
Electrostatic Discharge (ESD) Precautions	7
Service Safety Summary	8
General Guidelines	8
Warning Labels	8
Safety Interlocks	8
Servicing Electrical Components	9
Servicing Mechanical components	9
Servicing Fuser Components	9
RegulatoryInformation	10
Declaration of Conformity	11
In the European Union	11
Canadian Notice	12
Avis Canadien	12
European Notice	12
Hinweis	12
Table of Contents	13
General Information	17
Contents	17
The Phaser 7300 Color Printer Overview	18
Phaser 7300 Printer Configurations	19
Secure Prints, Proof Prints, Saved Prints and PDF Direct Printing	20
Power Saver Mode	20
Printer Memory and RAM Capabilities	21
Parts of the Printer	22
Print Engine Base Configuration	22
Printer Options - Lower Tray Deck (LTD) and Lower Tray Assembly (LTA)	23
Printer Options (cont’d) - Duplex Unit	24
1. Duplex Unit	24
Front Panel Configuration	25
Front Panel LED indicators:	25
Image Processor (IP) Board Components	26
1	26
2	26
3	26
4	26
5	26
6	26
Rear Panel Configuration of the IP Board	27
DIP Switches	28
Printer Specifications	29
Physical Dimensions - Print Engine	29
Physical Dimensions - Options	29
Printer Clearances	29
Functional Specifications	30
Print Speeds	30
Electrical Specifications	31
Environmental Specifications (cont'd.)	31
Media and Tray Specifications (cont'd.)	32
Error Messages and Codes	35
Accessing Error Codes and Fault History	35
1. Print (if possible) the Usage Profile Report Log from the printer’s front panel Support Menu. ...	35
2. View the printer’s fault history on the front panel.	35
3. If the printer is connected to a network and has a TCP/IP address, view the printer’s web page...	35
Error Messages and Codes Index	36
Service Flowchart	40
1 Verify the reported problem does exist.	40
2 Check for any error codes and write them down.	40
3 Print normal customer prints and service test prints.	40
4 Make note of any print quality problems in the test prints.	40
5 Make note of any mechanical or electrical abnormalities present.	40
6 Make note of any unusual noise or smell coming from the printer.	40
7 Print a Usage Profile Report, if the printer is able to print.	40
8 View the fault history under the Service Tools Menu	40
9 Verify the AC input power supply is within proper specifications by measuring the voltage at th...	40
1 Switch OFF printer power.	40
2 Disconnect the AC power cord from the wall outlet.	40
3 Verify the power cord is free from damage or short circuit and is connected properly.	40
4 Remove the Imaging Unit and protect it from light.	40
5 Inspect the printer interior and remove any foreign matter such as paper clips, staples, pieces...	40
6 Clean all rubber rollers with a lint-free cloth, dampened slightly with cold water and mild det...	40
7 Inspect the interior of the printer for damaged wires, loose connections, toner leakage, and da...	40
8 If a toner cartridge appears obviously damaged, replace with a new one.	40
1 Use the Error Messages and Codes and troubleshooting procedures to find the cause of the problem.	40
2 Use Diagnostics to check printer and optional components.	40
3 Use the Wiring Diagrams to locate test points.	40
4 Take voltage readings at various test points as instructed in the appropriate troubleshooting p...	40
5 Use the Service Test Prints to isolate problems with the Image Processor Board.	40
1 Use the Parts List to locate a part number	40
2 Use the Removal and Replacement Procedures to replace the part.	40
1 Test the printer to be sure you have corrected the initial problem and there are no additional ...	40
Using the Troubleshooting Procedures	41
1. Each Step in a Troubleshooting Procedure instructs you to perform a certain action or procedur...	41
2. The Actions and Questions box contains additional information and/or additional procedures you...	41
3. When a procedure instructs you to test a component using service diagnostics, See “Service Dia...	41
4. The action is followed by a question. If your response to the question is “Yes”, then follow t...	41
5. Troubleshooting Procedures may ask you to take voltage readings or test for continuity at cert...	41
6. Troubleshooting Procedures often ask you to replace a printer component. The section \	41
General Notes on Troubleshooting	41
1. Unless indicated otherwise, the instruction “cycle power to the printer” means for you to swit...	41
2. When instructed to take voltage, continuity or resistance readings on wiring harnesses, refer ...	41
3. All voltage values given in the troubleshooting procedures are approximate values. The main pu...	41
4. When a troubleshooting procedure instructs you to replace a non-spared component and that comp...	41
Service Diagnostics	42
Enter without rebooting the printer (Hidden Service Menu):	42
1. From the printer’s main menu, scroll to the Support Menu, press OK and then scroll to the Serv...	42
2. Hold down the Up Arrow key and press the Down Arrow key.	42
3. Scroll to Run Diagnostics and press OK.	42
Enter by rebooting the printer:	42
1. Turn the printer power OFF.	42
2. Hold down the Back and Information keys simultaneously and turn the printer back ON.	42
3. Continue to hold the keys until the following message is displayed on the front panel: Service...	42
4. The front panel displays the Service Diagnostics Menu.	42
Service Diagnostics Key Press and Function Table	42
Service Diagnostics Tests and Functions Table (cont'd.)	43
Error Messages and Codes Procedures	53
Jam at Top Cover	53
1	53
2	53
3	53
4	53
5	53
6	54
7	54
8	54
9	54
10	54
11	54
Jam at Door [A] [B] [C] [D] [E]	55
1	55
2	55
3	55
4	55
5	55
6	55
7	55
8	55
9	55
10	56
11	56
12	56
13	56
14	56
15	56
16	56
17	56
Jam at Duplex Unit	57
1	57
2	57
3	57
4	57
5	57
6	57
Misfeed at Tray [1] [2] [3] [4] [5]	58
1	58
2	58
3	58
4	58
5	58
6	58
Insert Tray [1] [2] [3] [4] [5]	59
1	59
2	59
3	59
4	59
E12: Top Output Tray is Full, Unload Paper	59
1	59
2	59
3	59
4	59
MPT Empty, Load Paper	60
1	60
2	60
3	60
4	60
Tray [1] [2] [3] [4] [5] Empty, Load Paper	60
1	60
2	60
3	60
4	60
Load MPT with [size] [type]	61
1	61
2	61
3	61
4	61
5	61
6	61
Load Tray [1] [2] [3] [4] [5] with [size] [type]	62
1	62
2	62
3	62
4	62
5	62
6	62
7	62
8	62
Adjust Tray [1] [2] [3] [4] [5] Size	63
1	63
2	63
3	63
4	63
5	63
6	63
Close Top Cover	64
1	64
2	64
3	64
4	64
5	64
6	64
7	64
Close Duplex Unit	65
1	65
2	65
3	65
4	65
5	65
Close Right Door A	65
1	65
2	65
3	65
4	65
Close Right Door [B] [C] [D] [E]	66
1	66
2	66
3	66
4	66
Open Left Side Output Tray	66
1	66
2	66
3	66
Humidity Too High to Print	67
1	67
2	67
Install or Reseat [CMYK] Imaging Unit	68
1	68
2	68
3	68
4	68
5	68
6	68
Replace [CMYK] Imaging Unit	68
1	68
2	68
3	68
Install or Reseat [CMYK] Toner Cartridge	69
1	69
2	69
3	69
4	69
5	69
6	69
Replace [CMYK] Toner Cartridge	69
1	69
2	69
3	69
4	69
Install or Reseat Fuser	70
1	70
2	70
Replace Fuser	70
1	70
2	70
Install or Reseat Transfer Unit	71
1	71
2	71
Replace Transfer Unit	71
1	71
2	71
3	71
T1: Fuser Upper Failure T2: Fuser Lower Failure	72
1	72
2	72
3	72
4	72
T29: Temp Sensor Failure	72
1	72
T30: RH Sensor Failure	73
1	73
T32: LED Over Temperature Failure	73
1	73
1	73
T34: IU Motor Overheating Failure	73
1	73
2	73
U0: Engine ROM Failure U1: Engine RAM Failure U2: Engine EEPROM Failure U3: Engine EEPROM Missing...	74
1	74
2	74
U6: Power Supply Failure	74
1	74
2	74
3	74
4	74
U7: Feeder Home Failure	75
1	75
2	75
3	75
4	75
U8: Controller Fan Failure (Electrical Card Cage)	75
1	75
2	75
3	75
U9: Power Supply Fan Failure	76
1	76
2	76
3	76
U12: Duplex Interface Failure	76
1	76
2	76
3	76
Tray [2] [3] [4] [5] Interface Failure	77
1	77
2	77
[Yellow] [Magenta] [Cyan] [Black] LED Failure	77
1	77
2	77
3	77
4	77
[Yellow] [Magenta] [Cyan] [Black] Imaging Unit Failure	78
1	78
2	78
3	78
4	78
5	78
6	78
7	78
8	78
9	79
10	79
11	79
U30: Flash Hardware Failure U31: Flash Software Failure	79
1	79
U32: Fuser Fan Failure	79
2	79
3	79
4	79
U33: Fuser 110v/220v Mismatch Failure	80
1	80
U34: Unsupported Duplex Unit ROM Failure	80
1	80
2	80
Unsupported Tray [2] [3] [4] [5] ROM Failure	80
1	80
W16: Fuse Cut Error in Fuser	81
1	81
2	81
W17: Fuse Cut Error in Transfer Unit	81
1	81
2	81
Fuse Cut Error in [CMYK] Imaging Unit	81
1	81
2	81
3	81
Troubleshooting	83
Contents	83
System Boot Sequence	84
1. When the main power switch is turned on, the health LED on the Image Processor Board turns on ...	84
2. The boot loader checks for RAM presence and functionality. If not present or functioning, it p...	84
3. The boot loader then runs POST diagnostics.	84
4. POST turns off the health LED.	84
5. POST checks the front panel.	84
6. If keys have been pushed, the front panel displays “Processing Input”.	84
7. The front panel LED cycles: Green, Yellow, Red, and then off.	84
8. The front panel turns on, the LED turns Green and the POST tests are finished.	84
Power On Self Test (POST)	84
POST Startup indications	84
POST Faults	85
Fault Reporting Devices	85
LED Blink Patterns	85
POST Diagnostics Test Descriptions	86
Printer Malefactions or Inoperable Printer Problems	87
No Front Panel Display After Power Switch is Turned ON.	87
1. Verify the AC power source, see “Measuring Power Supply Voltages” on page3-72.	87
2. Verify the +5 volt loop is complete, see “The +5 VDC Loop” on page3-74.	87
3. If the front panel has no display, backlighting or LED, replace the Front Panel and Wiring Har...	87
4. Check the Image Processor Board health LED for a front panel fault, see “POST Diagnostics Test...	87
5. Verify the Image Processor Board has not failed by performing Step 3 from the troubleshooting ...	87
6. Systematically remove all printer options to isolate a possible problem component.	87
The Printer Continuously Displays “Booting”, “Initializing” “Warming Up”, or will not come to a “...	87
1. Check for unreported jams within the printer and clear the jam area.	87
2. Power cycle the printer.	87
3. Verifying Image Processor Board failure:	87
Verifying Power Supply Operation	88
Measuring Power Supply Voltages	88
1. AC Input: With the DMM set to measure AC voltages, measure for power being supplied to the pri...	88
2. DC Output: With the DMM set to measure DC voltages, measure the voltages at the POWER connecto...	88
POWER Connector Pinout	88
Safety interlocks	89
The +5 VDC Loop	90
To verify the +5 volt loop is complete:	90
1. Test fuse F6 on the Engine Controller Board for continuity. If the fuse is blown (open circuit...	90
2. Verify all wiring harnesses are connected, seated correctly and not damaged. Replace any damag...	90
3. Check for continuity between the Engine Controller Board OPTN and the interconnect wiring harn...	90
4. Verify proper operation of the LVPS by bypassing the Engine Controller Board and the toner sen...	90
5. Replace the Low Voltage Power Supply if all other components are operating correctly.	90
Fuser Roller Resistances	91
Multi-Sheet Pick	92
1. Ensure the correct weight and type of media is loaded in the tray. See \	92
2. Verify that the media settings at the front panel and the driver settings match the media load...	92
3. Fan the media and reload into the tray.	92
4. Use service diagnostics to verify the printer is printing within its environmental specificati...	92
5. Ensure the media is correctly loaded in the tray and that the guides fit snug against the media.	92
6. Clean the pick and feed rollers with a clean, dry, lint-free wipe if debris is visible. Check ...	92
Media Skewing	92
1. Ensure the correct weight and type of media is loaded in the tray. See \	92
2. Make sure that the media is properly installed in the tray and that the guides fit snug agains...	92
3. Load a fresh ream of paper, or ensure that the media loaded is not torn, wrinkled, bent or oth...	92
4. Check for and remove any debris or obstructions in the paper path.	92
5. Verify that the registration rollers are in contact with one another along the entire length o...	92
6. If the problem occurs in only one tray or the MPT:	92
Operating System and Application Problems	93
Macintosh Printing Problems	93
Image Never Prints	93
1. Power cycle to the printer and try printing again.	93
2. Make sure that the correct Phaser 7300 printer icon was selected in the Chooser. Try printing ...	93
3. In the Chooser or the print dialog, switch background printing to off. Try printing the job ag...	93
4. If the error returns, turn ON the PostScript error handler through the front panel PostScript ...	93
5. Select the appropriate Phaser 7300 PPD with the LaserWriter Driver or application. Not selecti...	93
6. Select a different document from the application and try to print. If the PostScript error doe...	93
Image Prints in Black-and-white	93
1. Ensure the driver setting for the TekColor tab is not set to “Black & White”.	93
Image is Rotated 90 Degrees	93
1. In the application's Page Setup, make sure that the image is selected to print in portrait or ...	93
Windows printing problems	94
Image Never Prints	94
1. Power cycle to the printer and try printing again.	94
2. Try printing a test page from the printer driver’s properties dialog box.	94
3. Try printing from another application.	94
4. Try printing to another printer.	94
5. Try printing from another computer.	94
6. If the error returns, turn ON the PostScript error handler through the front panel PostScript ...	94
Image Prints in Black-and-white	94
1. Ensure the driver setting for the TekColor tab is not set to “Black & White”.	94
Image is Rotated 90 Degrees	94
1. In the application's Page Setup, make sure that the image is selected to print in portrait or ...	94
Network Problems	94
1. Enter normal ‘Customer Mode’.	94
2. From the main menu, highlight Support Menu and press OK.	94
3. Scroll and highlight Network Questions? and press OK.	94
4. Highlight the appropriate menu item from the list and select OK.	94
5. The page should now print.	94
Print-Quality Problems	95
BEFORE USING ANY TROUBLESHOOTING PROCEDURE FOR PRINT-QUALITY PROBLEMS, PERFORM THE FOLLOWING STEPS:	95
Repeating Defects Identification Chart	96
Light Prints in All Colors	97
1	97
2	97
3	97
4	97
5	97
6	97
7	97
8	98
9	98
10	98
11	98
Light Prints in Only One Color	99
1	99
2	99
3	99
4	99
5	99
6	99
7	99
8	100
9	100
10	100
Blank Prints	101
1	101
2	101
3	101
4	101
5	101
6	101
7	102
8	102
9	102
Mottled or Splotchy Prints	103
1	103
2	103
3	103
4	103
5	103
6	104
7	104
Unexpected Colors	105
1	105
2	105
3	105
4	105
5	105
6	105
7	106
8	106
9	106
10	106
11	106
12	106
13	106
14	106
Background Contamination	107
1	107