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Phaser 4500
Xerox Phaser 4500 Service Manual
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Theory of Oper
ation
2-17
1.
P
a
per Siz
e Switch Assembly
7.
Metal Registration Roller
2.
Feed Clutch Assemb
ly
8.
No Paper Sensor
3.
Registration Clutch
9.
No Paper Actuator
4.
Rubber Registration Roller
10.Low P
aper Sensor
5.
Feed Roller
11.Low P
aper Actuator
6.
Registration Sensor
12.Nudger Roller
4500-022
1
2
3
4
5
6
7
8
9
10
11
12
51
53
Table of Contents
Default Chapter
3
Service Manual
3
Table of Contents
4
Service Terms
14
Product Terms
15
Symbols Marked on the Product
15
Power Safety Precautions
16
Power Source
16
Electrostatic Discharge (ESD) Precautions
17
General Guidelines
18
Service Safety Summary
18
Warning Labels
18
Servicing Electrical Components
19
Servicing Mechanical Components
19
Regulatory Specifications
20
Declaration of Conformity
21
In the European Union
21
General Information
22
Printer Introduction and Overview
23
Technical Support Information
23
Printer Configurations
24
Parts of the Printer
25
Front Panel
26
Image Processor Board
27
Consumables and Routine Maintenance Items
28
Supply Life Counters
29
Printer Specifications
30
Physical Dimensions and Clearances
30
Functional Specifications
31
Electrical Specifications
32
Environmental Specifications
32
Media and Tray Specifications
33
Memory Requirements
34
Theory of Operation
36
Overview of the Phaser 4500 Laser Printer
37
Summary of the Printing Process
37
Paper Path of the Printer
40
Layout of Paper Transport Path
41
Sensors
43
Major Assemblies and Functions
47
Paper Tray
47
Paper Lift Mechanism
50
Paper Feeder
51
Control of Paper Size
53
Xerographics
54
Laser Assembly
56
Laser Control
58
Transfer Roller Assembly
58
Fuser
59
Fuser Control
61
Paper Exit Assembly
64
Drive
65
Electrical
66
Printer Options
69
Duplex Unit
69
Stacker
72
Drive Transmission Path
72
Optional 550-Sheet Feeder
79
Error Messages and Codes
80
Introduction
81
Servicing Instructions
81
Using the Troubleshooting Procedures
83
General Notes on Troubleshooting
83
Accessing Fault Histories
85
Entry Level Fault Isolation Procedure
87
Service Diagnostics
88
Service Diagnostic Front Panel Button Descriptions
89
Using Service Diagnostics
89
System Start-Up and POST
95
Power on Self Test (POST)
95
POST Faults
96
Fault Reporting Devices
96
LED Blink Patterns
96
POST Diagnostic Test Descriptions
97
Operating System and Application Problems
99
Macintosh Printing Problems
99
Windows Printing Problems
99
Network Problems
100
Error Messages and Codes Troubleshooting Procedures
101
Main Motor Failure
105
Laser Unit Failure
106
Laser Fails at Warm-Up U2-1: Laser Fail/Power off
106
Laser Fails Motor Speed U2-2: Laser Fail/Power off
106
LD Power Is High U2-3: Laser Fail/Power off
106
LD Power Is Low U2-4: Laser Fail/Power off
106
Fuser Failure
107
Fuser High Temp
107
Fuser Low Temp
107
Fan Failure
108
Engine Logic Board NVRAM Failure
110
Jam at Tray N
111
Error Codes
111
Go to
112
Jam at Tray N
114
Go to
114
Go to
115
Jam at Top; Open Top Cover to Clear
117
Go to
119
Jam at Exit; Open Rear/Top Cover to Clear
120
Jam at Rear; Open Rear Cover to Clear
122
E6-1 Stacker Jam
122
Jam at Stacker; Open Rear Stacker Cover to Clear
124
E6-2 Stacker Jam
124
Go to
124
Go to
125
Jam at Rear; Open Duplex and Rear Cover to Clear
126
Jam at Duplex; Open Duplex to Clear
128
Duplex Unit Error
129
Stacker Error
130
Tray 3 Failure\ Tray 3 or 4 Failure
131
Paper Size Jam
133
Close Top Cover/Close Rear Cover
135
Close Duplex Unit Cover
136
Close Stacker Cover
137
Install or Reseat Print Cartridge
138
Replace Print Cartridge
139
No Paper in Tray 1/No Paper in Tray
140
Tray 2 Paper Is Low
141
No Paper in Tray 3/No Paper in Tray 4
142
Tray 3 Paper Is Low/Tray 4 Paper Is Low
143
Insert Tray 1/Insert Tray 2
144
Insert Tray 3/Insert Tray 4
145
Stacker Is Full, Unload Paper
146
Standard Output Tray Is Full, Unload Paper
147
Replace Maintenance Kit
148
Inoperable Printer
149
No Recognition of Duplex Unit
150
No Recognition of Stacker
152
General Troubleshooting
154
Introduction
155
Front Panel Troubleshooting
156
LCD/LED Display Error/Inoperable Buttons
156
DC Power Supply Troubleshooting
157
LVPS (Low Voltage Power Supply)
157
DC-DC Converter
158
AC Power Supply Troubleshooting
160
No AC Power
160
Print Engine Troubleshooting
164
Main Motor
164
Laser Unit Assembly
166
Fuser Assembly
169
Registration Sensor
171
No Paper Sensor
173
Low Paper Sensor
175
Toner Sensor
176
Output Tray Stack Full Sensor
178
24 V Interlock
179
5 V Interlock, Interlock Switch Assembly
179
Rear Cover Switch
181
Interlock Switch Assembly
182
Exit Motor PWBA
183
Exit Motor Assembly
184
Registration Clutch
185
Feed Clutches
186
Left Tray Guide
187
Hvps/Engine Logic Board
188
Image Processor Isolation
190
Image Processor Board
191
RAM DIMM Fault Isolation
192
Electrical Noise
194
Optional 550-Sheet Feeder PWBA (Tray 3)
196
Optional 550-Sheet Feeder PWBA (Tray 4)
197
Optional 550-Sheet Feeder no Paper Sensor
198
Optional 550-Sheet Feeder Low Paper Sensor
200
Optional Feeder Paper Size Switch Assembly
202
Optional 550-Sheet Feeder Feed Clutch Assembly
203
Optional 550-Sheet Feeder Turn Roller Clutch
205
Duplex Unit PWBA
207
Duplex Unit Motor
208
Duplex Unit Sensor
209
Duplex Unit Switch
211
Stacker PWBA
212
Stacker Motor Assembly
213
Offset Motor Assembly
214
Gate Solenoid Assembly
215
Stacker Rear Cover Switch
216
Stacker Sensor
218
Stack Full Sensor (on Stacker PWBA)
220
Offset Sensor (on Stacker PWBA)
222
Print-Quality Troubleshooting
224
Print-Quality Problems Overview
225
Analyzing Test Prints
226
Test Print
228
Deletions (Line, Band, Spots)
229
Fusing
230
Resolution
232
Registration (Side-To-Side)
233
Registration (Lead Edge-To-Trail Edge)
234
Skips/Smears
235
Spots
236
Skew
237
Other Print Defects
238
Print-Quality Troubleshooting
239
Light (Undertoned) Print
239
Blank Print (no Print)
241
Black Prints
243
Vertical Deletions
244
Horizontal Deletions
246
Vertical Streaks
248
Horizontal Streaks
251
Spots
253
Initial Actions
253
Unfused Image
255
Damaged Print
258
Resolution
259
Spot Deletions
260
Repeating Defects
262
Residual Image
263
Background
265
Uneven Density
266
Skewed Image
267
Registration
270
Skips and Smears
272
Adjustments and Calibrations
274
Service Test Prints
275
Test Prints
275
Engine Test Print
277
Adjustments
278
Adjusting Laser Power (Image Density)
278
Checking Registration
278
Adjusting Simplex Registration
280
Adjusting Duplex Registration
281
Adjusting Fuser Temperature
282
Resetting Fuser Life
283
Resetting Printer Values to the Factory Default Values
284
Resetting Connection Setup Values
284
Resetting Paper Handling Setup Values
285
Resetting Postscript Setup Values
285
Resetting PCL Setup Values
285
Resetting General Setup Values
285
Resetting Front Panel Setup Values
286
Resetting Printer Controls Setup Values
286
Resetting File Security Setup Values
286
Resetting All Printer Default Settings (Postscript NVRAM)
287
Cleaning and Maintenance
288
Service Preventive Maintenance Procedure
289
Recommended Tools
289
Cleaning
289
FRU Disassembly
290
Overview
291
Standard Orientation of the Printer
291
General Notes on Disassembly
292
Preparation
292
Notations in the Disassembly Text
292
Print Engine: Covers
293
Paper Exit Cover
293
Paper Exit Rear Door
294
Rear Cover
295
Right Cover
296
Left Cover
298
Top Cover Assembly, Front Panel
299
Replacement Notes
300
Front Cover
301
Interlock Switch Assembly
302
Print Engine: 150- or 550-Sheet Paper Cassette
304
Retard Roller and Holder
304
Replacement Note
305
Print Engine: 150-Sheet Feeder
307
150-Sheet Feeder Assembly
307
Nudger Roller, Feed Roller
309
Nudger One-Way Clutch
311
Nudger Gear
313
Feed Clutch, Registration Clutch
315
Registration Sensor
316
No Paper Sensor
317
Toner Sensor Assembly
319
Print Engine: 550-Sheet Paper Feeder
320
550-Sheet Feeder Assembly
320
Nudger Roller, Feed Roller
321
Nudger One-Way Clutch
322
Nudger Gear
323
Feed Clutch
325
No Paper Sensor
327
Right Tray Guide
328
Left Tray Guide
330
Low Paper Sensor/Actuator
331
Print Engine: Xerographics
333
Front Duct, Sub Fan
333
Laser Unit Assembly
335
Laser Unit Shield Plate
337
Print Cartridge Left Guide
338
Fuser Harness Assembly
339
Link Lever, Gear 3 Link
341
Fuser Assembly
343
Transfer Roller Assembly
344
Transfer Chute
345
Print Cartridge Right Guide Assembly
347
Duplex Unit Opening Cover
349
Print Engine: Paper Exit
350
Paper Exit Assembly
350
Upper Exit Chute, Lower Exit Chute
352
Exit Motor Assembly
353
Stack Full Sensor
354
Stack Full Actuator
355
Print Engine: Frame and Drive
356
Motor Cover
356
Main Motor
358
Gear Assembly Housing
360
Gear Assembly Plate
362
Print Engine: Electrical
364
LVPS Shield Plate
364
Exit Motor PWBA
365
Low Voltage Power Supply (LVPS)
367
DC-DC Converter
369
Power Switch, AC Power Harness Assembly
370
Rear Cover Switch
372
Main Fan
373
Image Processor Shield Assembly
375
I/P Shield Window
376
HVPS Shield Plate
377
Hvps/Engine Logic Board
378
Image Processor (I/P) Board
380
Options: 550-Sheet Paper Feeder
382
550-Sheet Paper Feeder Removal
382
Right Cover Plate
384
Left Cover Plate
386
Option Paper Size Switch Assembly
388
Optional Feeder Drive Assembly
389
550-Sheet Feeder PWBA
391
550-Sheet Feeder
393
Nudger Roller, Feed Roller
395
Nudger One-Way Clutch
396
Nudger Gear
397
Feed Clutch Assembly
399
Turn Roller Clutch
401
Retard Roller
402
Options: Duplex Unit
404
Duplex Unit Removal
404
Left Cover
406
Right Cover
407
Top Cover
408
Upper Assembly Housing
409
Duplex Unit Lower Housing
410
Duplex Unit PWBA
412
Duplex Unit Fan
413
Duplex Unit Sensor
415
Duplex Unit Roller
416
Duplex Unit Motor
418
Duplex Unit Switch
420
Options: Stacker
421
Stacker Removal
421
Stacker Rear Cover
422
Stacker Cover
423
Stacker Front Cover
426
Stacker Tray Assembly
427
Stack Full Actuator
428
Stacker PWBA
431
Offset Motor Assembly
433
Gate Solenoid Assembly
434
Stacker Sensor and Actuator
435
Stacker Rear Cover Interlock Switch
437
Lower Stacker Roller
438
Upper Stacker Roller
442
Stacker Motor Assembly
443
Parts Lists
444
Serial Number Format
445
Using the Parts List
446
Print Engine Parts
447
Parts List 1.1 Covers
447
Parts List 2.1 150-Sheet Paper Cassette
449
Parts List 4.1 550-Sheet Paper Cassette
452
Parts List 5.1 150-Sheet Paper Feeder
455
Parts List 7.1 550-Sheet Paper Feeder
458
Parts List 8.1 Xerographics
461
Parts List 10.1 Paper Exit (1/2)
463
Parts List 10.2 Paper Exit (2/2)
465
Parts List 11.1 Frame and Drive
467
Parts List 12.1 Electrical
469
Options
472
Parts List 20.1 550-Sheet Paper Feeder (1/2)
472
Parts List 20.2 550-Sheet Paper Feeder (2/2)
475
Parts List 20.3 Optional 550-Sheet Paper Cassette
477
Parts List 21.1 Duplex Unit
480
Parts List 23.1 Stacker
483
Xerox Supplies and Accessories
486
Wiring Diagrams
490
Introduction
491
Print Engine Plug/Jack Locator
492
550-Sheet Feeder Plug/Jack Locator
499
Duplex Unit Plug/Jack Locator
501
Stacker Plug/Jack Locator
503
Notations Used in Wiring Diagrams
504
Print Engine Wiring Diagrams
506
Print Engine General Wiring Diagram
506
Interlock, Rear Cover Switch, Main Motor, Sub Fan, Exit Motor Assembly
507
Fuser Assembly, Power Switch
509
Print Cartridge, Transfer Roller Assembly
510
150-Sheet Feeder, 550-Sheet Feeder, Main Fan
511
Laser Unit, 5 V Interlock, Interlock Switch Assembly
513
Paper Exit
514
Image Processor Board, DC-DC Converter, Front Panel
515
Optional 550-Sheet Feeder
516
550-Sheet Feeder General Wiring Diagram
516
550-Sheet Feeder Signal Diagram
517
Duplex Unit
518
Duplex Unit Signal Diagram
519
Stacker
520
Stacker General Wiring Diagram
520
Stacker Signal Diagram
521
A Appendix
522
Menu Map
522
Service Diagnostics Menu Map
525
Other manuals for Xerox Phaser 4500
Manual
5 pages
Quick Reference Guide
10 pages
Quick Guide
3 pages
Brochure
1 page
Network Guide
8 pages
Voluntary Product Accessibility Template
11 pages
Supplementary Guide
5 pages
Upgrade Guide
4 pages
User Guide
4 pages
Reference Guide
181 pages
4
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Xerox Phaser 4500 Specifications
General
Brand
Xerox
Model
Phaser 4500
Category
Printer
Language
English
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