Xerox 7700 RegiCon Fail

[Junkfood]

I just replaced the Laser Unit (P/N 116-1110-00) in a Xerox 7700 printer. I ran the “Coarse RegiCon Initialization” which completed without any problems. When I attempted to run the RegiCon #4 “Coarse Skew Adjustment” I frequently get a “DC685-4 Failed” message. The first time I got a “Passed” message I made the recommended turns to the adjusting screws (the first adjustments were very large numbers). On the second “Passed” message the adjustment numbers were very close. To get to a third “Passed” message I had to run the test a number of times and all the colors were within tolerance except for the Black (K), which I then adjusted for hopefully the final time. After the last adjustment of the Black (K) laser I could no longer get the “Passed” message, only the “Failed” message. I attempted to run the RegiCon #1 “Fine Skew Adjustment” but it would always fail as well. The printer was complaining about a low remaining life for the Yellow Print Drum so I swapped it with another Xerox 7700 nearby, but this did not help my situation. I swapped the Accumulator Belt and ran the Clean Accumulator Belt procedure, but this did not help either. I ran the “Solid Fill” test prints and the Yellow, Magenta, and Cyan pages looked just fine. I ran the “Improve Print-Quality?” procedures which all appeared to be fine, including the blank pages printed.

What am I missing to get this printer to pass the RegiCon tests?

 

[Michael52x]

Clear TechRep Faults. This will get the unit cleared of all the error mssgs. You may have to do several times to get them all. run the regicons from the start, and do each one.

"Impatience will reward you with dissatisfaction" RMS Cosmics'97

 

[Junkfood]

I went into the “Clear Tech Rep Faults” area of the Service Diagnostics section but none of the listed faults seemed to apply to the RegiCon tests. I selected each one anyway to clear each specific fault then re-ran the “Belt Edge Learn” test then the RegiCon #4 “Coarse Skew Adjustment” test only to have it still fail. Any other ideas? I really don’t want to have to swap out the entire printer. Thanks!

 

[CULTOFLON]

Have you got Service Bulletin 580 rev 2 ? This bulletin is the lastest procedure on doing Regicon. If you don't have it I can send it to you.

 

[Junkfood]

Thanks, but I do have SB 580 Rev 2. I can think nothing else to fix my problem other than to re-install the original Laser Scanner (even though it was getting the Polygon Motor error on power up) and starting all over from the very beginning.

 

[Junkfood]

For the final solution to this problem I took the Polygon Motor from the new Scanner Assembly and installed it into the old Scanner Assembly. I then started over with the alignment procedures but I skipped any adjustment during the “Coarse RegiCon Initialization” procedure and moved directly on to the RegiCon #4 “Coarse Skew Adjustment” procedure. Running RegiCon #4 gave me clicks around 85 for the Yellow, Magenta, and Cyan lasers and 50 for the Black. I adjusted each laser only half way to see if the changes made sense; and they did. I then completed the RegiCon #4 adjustment procedure, going through the procedure about five or six times to get the settings within tolerance. After that all the following alignment procedures fell right into place and the printer is now functioning properly and making beautiful prints.

Thank you all for your help and suggestions in this matter.