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Xerox Phaser 4600 Service Manual
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04/2016
4-156
Phaser 4600/4620/4622 Printer Service Manual
REP 2
8.10
Revised
4 Repairs and Adjustments
REP 28.10
Rear Seal
Filter
Part
s List on
PL 28.2
5 Item 12
Removal
1.
Remove the
Rear Door
,
REP 28.6
.
2.
Remove, but do not disconnect the Rear Door Fan,
REP 28.7
.
3.
Remove the filter from the door
,
Figure 1
.
Figure 1 Remove the Rear Seal Filter
277
279
Table of Contents
Introduction
3
Table of Contents
3
About this Manual
5
How to Use this Manual
5
Service Safety Summary
6
Symbols Used on the Product
7
Translation of Warnings
10
Phaser 4600/4620/4622 Overview
12
Printer Options
13
Control Panel Layout
15
Routine Maintenance Items
16
Consumables
16
1 Service Call Procedures
17
Service Call Procedures
19
SCP 1 Initial Actions
20
SCP 2 First Call Actions
20
SCP 3 Normal Call Actions
21
SCP 4 Fault Analysis
21
SCP 5 Subsystem Maintenance
22
SCP 6 Final Actions
23
SCP 7 Configurations and Options
24
3 Image Quality
99
IQ1 Image Quality Entry RAP
101
IQ2 Deletions (Line, Band, Spots)
102
IQ3 Unfused Image
103
IQ4 Resolution
104
IQ5 Skewed Image
105
IQ6 Light or Undertoned Print
106
IQ7 Spots
107
IQ8 Blank Print
108
IQ9 Black Print
109
IQ10 Process Streaks
110
IQ11 Scan Streaks
111
IQ12 Damaged Print
112
IQ13 Repeating Defects
113
IQ14 Residual Image
114
IQ15 Background
115
IQ16 Uneven Density
116
IQ17 Stains on Print Back
117
IQ18 Registration
118
IQ19 Curved Vertical Lines
118
IQS 1 Solid Area Density
119
Test Prints
119
IQS 2 Skew
120
IQS 3 Registration
120
IQS 4 Transparencies
121
IQS 5 Image Area
121
4 Repairs and Adjustments
123
REP 1.2 Fuser Drive Board
125
REP 1.3 Fuser Drive Board Assembly
125
Rep 1.4 Hvps
126
Rep 1.5 Smps
129
REP 1.6 Top/Rear Door Interlock Switch
132
REP 1.7 SMPS Fan
132
REP 2.1 Control Panel Assembly
133
REP 2.2 Control Panel Board
135
REP 3.4 MCU Board
137
REP 3.5 IP Board Cage
138
REP 3.6 IP Board
139
REP 4.1 Main Drive Assembly
141
REP 4.2 Tray 2 Feed Clutch
142
REP 4.3 Registration Clutch
144
REP 4.4 Feed Drive Assembly
145
REP 4.5 Right Side Chassis Fan
146
REP 6.1 Laser Unit
146
REP 7.0 Tray 1 Feeder Assembly
147
REP 7.3 Tray 1 Pick-Up Assembly
148
REP 7.5 Tray 1 Separator Assembly
150
REP 7.6 Tray 2 Feeder Assembly
152
REP 7.7 Tray 2 Lift Motor
158
REP 7.8 Tray 2 Lift Gear
158
REP 7.15 Tray 1 no Paper Sensor
159
REP 7.16 Tray 1 Feed Clutch
160
REP 7.20 Tray Separator Roller
160
REP 7.21 Tray Separator Clutch
161
REP 7.22 Tray Front Cover
161
REP 7.23 Tray Media Level Indicator
162
REP 7.24 Feeder Front Cover
163
REP 7.25 Feeder Right Cover
163
REP 7.26 Feeder Left Cover
164
REP 7.27 Feeder Rear Cover
164
REP 7.28 Feeder Board
165
REP 7.29 Feeder Lift Motor
165
REP 7.30 Feeder Size Switch
166
REP 7.31 Upper Option Harness
167
REP 7.32 Lower Option Harness
168
REP 7.33 Left Side Frame
169
REP 7.34 Right Side Frame
170
REP 7.35 Feeder no Paper Sensor
171
REP 7.36 Feeder no Paper Sensor Actuator
172
REP 7.37 Feeder Stack Height Sensor
174
REP 7.38 HCF Rear Cover
175
REP 7.39 HCF Right Cover
176
REP 7.40 HCF Left Cover
176
REP 7.41 HCF Caster
177
REP 7.42 HCF Reduction Gear Assembly
177
Repairs and Adjustments
177
REP 7.43 HCF Front Door Interlock Switch
178
REP 7.44 HCF Control Board
178
REP 7.45 HCF Lift Motor Assembly
179
REP 7.46 HCF Feed Clutch
179
REP 7.47 HCF Feed Drive Assembly
180
REP 7.48 HCF Feed Motor
180
REP 7.49 HCF Top Plate
181
REP 8.11 Registration Sensor
182
REP 8.12 Feed Sensor
183
REP 8.16 Shaft Frame Assembly
183
REP 8.24 Drum Cartridge CRUM Connector
185
REP 8.27 Registration Roller Assembly
186
REP 8.31 Registration Sensor Actuator
187
REP 8.32 Feed Sensor Actuator
188
REP 8.40 Feeder Take Away Clutch
190
REP 8.41 Feeder Feed Clutch
191
REP 8.42 Feeder Feed Drive Assembly
191
REP 8.43 Feeder Take Away Sensor Actuator
192
REP 8.44 Feeder Take Away Sensor
193
REP 8.45 Feeder Take Away Roller
194
REP 8.46 Feeder Feed Assembly
196
REP 8.47 HCF Feed Assembly
198
REP 8.48 HCF Lift Limit Switch
199
REP 8.49 HCF Take Away Sensor
199
REP 8.50 HCF no Paper Sensor
200
REP 8.51 HCF Stack Height Sensor
200
REP 8.52 Shaft Frame Assembly Transport Belt
201
REP 9.1 Transfer Roller
203
REP 9.2 ADC Sensor
204
REP 9.3 Waste Toner Cartridge Detect Sensor
205
REP 9.4 Left Side Chassis Fan
205
REP 9.5 Environmental Sensor
206
REP 9.6 Waste Toner Full Sensor
206
REP 9.7 Pipe Assembly
207
REP 9.8 Joint Board
208
REP 10.1 Duplex Unit
209
REP 10.4 Upper Option Harness
209
REP 10.5 Lower Option Harness
210
REP 10.6 Exit Assembly
211
REP 10.7 Stack Full Sensor
215
REP 10.8 Fuser Drive Assembly
216
REP 10.10 Fuser
220
REP 10.9 Duplex Drive Assembly
220
REP 10.11 Fuser Thermistor Assembly
221
REP 10.12 Fuser Thermostat
222
REP 10.13 Fuser Heat Lamp
223
REP 10.14 Fuser Gear
226
REP 10.15 Fuser Heat Roller and Bearings
230
REP 10.16 Fuser Pressure Roller and Bearings
236
REP 10.17 Fuser Release Drive Assembly
238
REP 10.18 Duplex Unit Detect Sensor
238
REP 10.19 Duplex Unit Timing Belt
239
REP 10.32 Exit Drive Assembly
240
REP 11.1 Mailbox Output Tray
241
REP 11.2 Mailbox Left Cover
242
REP 11.3 Mailbox Right Cover
242
REP 11.4 Mailbox Rear Door
243
REP 11.5 Mailbox Control Board
244
REP 11.6 Mailbox Drive Belts
244
REP 11.7 Mailbox Diverter Drive Assemblies
246
REP 11.8 Mailbox Diverter Home Position Sensor
246
REP 11.9 Mailbox Exit Gate Actuator
247
REP 11.10 Mailbox Exit Gate Cam Follower
248
REP 11.11 Mailbox Option Harness
249
REP 11.12 Mailbox Output Tray 4 Stack Full Sensor
249
REP 11.13 Mailbox Rear Door Interlock Switch
250
REP 11.14 Mailbox Transport Motor
251
REP 12.1 Finisher Left Cover
252
REP 12.2 Finisher Control Board
253
REP 12.3 Finisher Stacker Full Sensor
253
REP 12.5 Finisher Transport Drive Assembly
255
REP 12.6 Finisher Exit Gate Sensor
257
REP 12.7 Finisher Exit Gate Actuator
257
REP 12.8 Finisher Entrance Drive Belt
258
REP 12.9 Finisher Exit Gate Cam Shaft
260
REP 12.10 Left Tamper Home Position Sensor
261
REP 12.11 Finisher Right Cover
261
REP 12.12 Right Tamper Home Position Sensor
262
REP 12.13 Staple Cartridge Door Interlock Switch
263
REP 12.14 Stapler Assembly
264
REP 12.15 Stacker Drive Assembly
265
REP 12.16 Staple Interlock Switch
265
REP 12.17 Finisher Rear Door
266
REP 12.18 Finisher Top Cover
266
REP 12.19 Tamper Motor
267
REP 12.20 Finisher Rear Door Open Sensor
267
REP 12.21 Finisher Exit Sensor
268
REP 12.22 Finisher Exit Sensor Actuator
268
REP 12.23 Compile Tray Assembly
269
REP 12.24 Stacker Shield Assembly
270
REP 28.1 MCU Board Cover
271
REP 28.2 Right Cover
272
REP 28.3 Left Cover
272
REP 28.4 Front Cover
273
REP 28.5 Top Cover
274
REP 28.6 Rear Door
275
REP 28.7 Rear Door Fan
276
REP 28.8 Right Seal Filter
277
REP 28.9 USB Host Board
277
REP 28.10 Rear Seal Filter
278
5 Parts Lists
279
Serial Number Ranges
281
1.10 Hvps/Smps
282
1.15 Fuser Drive Board Assembly
283
2.10 Control Panel
284
3.10 Main Pwb's
285
4.10 Main Drives
286
6.10 Laser Unit
287
7.10 Paper Tray (Tray 2 & Optional Feeder)
288
7.15 Optional Feeder Main Covers
289
7.20 HCF Covers
290
7.25 HCF Assembly
291
8.10 Tray 1 Feeder Assembly
292
8.15 Tray 2 Pick-Up Assembly
293
8.20 Optional Feeder Pick-Up Assembly
294
8.25 HCF Pick-Up Assembly
295
8.30 Optional Feeder Main Drives
296
8.35 Optional Feeder Lift Assembly
297
8.40 Optional Feeder Feed Assembly
298
8.45 Registration Roller Assembly
299
8.50 Middle Frame Assembly
300
8.55 Upper Frame Assembly
301
9.10 Toner/Drum Cartridges
302
9.15 Waste Toner
303
10.10 Fuser Assembly (1 of 2)
304
10.11 Fuser Assembly (2 of 2)
305
10.15 Upper Fuser Bracket Assembly
306
10.20 Lower Fuser Exit Guide Assembly
307
10.25 Duplex Unit Assembly
308
10.30 Exit Assembly
309
11.10 Mailbox Covers
310
11.15 Mailbox Control Board
311
11.20 Mailbox Drive Belts
312
11.25 Mailbox Diverter Assembly
313
11.30 Mailbox Top Stacker Assembly
314
11.35 Mailbox Actuator Shield Assembly
315
11.40 Mailbox Base Assembly
316
12.10 Finisher Covers
317
12.15 Finisher Control Board
318
12.20 Finisher Stacker Shield Assembly
319
12.25 Finisher Stacker Drive Assembly
320
12.30 Finisher Compile Tray Eject Assembly
321
12.35 Finisher Compile Tray Assembly
322
12.40 Finisher Transport Drive Assembly
323
12.45 Finisher Stapler Assembly
324
28.10 Main Covers
325
28.15 Top Cover Assembly
326
28.20 Front Cover Assembly
327
28.25 Rear Door Assembly
328
Supplies/Customer Replaceable Units
329
Part Number Index
331
6 General Procedures and Information
333
GP 1 Diagnostics Entry and Exit
335
GP 2 Fault Codes and History Logs
335
GP 3 System Administration Tools
339
GP 4 Reports
341
GP 5 Firmware Upgrade
341
GP 6 Electrostatic Discharge Prevention
342
GP 7 Machine Specifications
342
GP 10 How to Check a Motor
343
GP 8 General Disassembly Precautions
343
GP 11 How to Check a Sensor
344
GP 12 How to Check a Solenoid or Clutch
345
GP 13 How to Check a Switch
345
GP 14 Separate System Modules
346
GP 15 How to Safely Lift or Move Heavy Modules
346
GP 16 Machine Lubrication
347
GP 17 Installation Space Requirements
347
GP 18 Glossary of Terms, Acronyms and Abbreviations
348
GP 19 Restriction of Hazardous Substances (Rohs)
355
GP 20 First Print Output Time
356
GP 21 Media Specifications
356
GP 22 Environmental Data
357
Dc131 NVM Read/Write
358
Dc132 NVM Reset
360
Dc305 UI Test
361
Dc330 Component Control
361
Dc612 Print Test Pattern
364
7 Wiring Data
365
Wd 1 Iot
367
WD 2 IP Board Interface
368
WD 4 MCU Board
369
WD 6 MCU Board
370
WD 8 Joint Board
371
WD 10 Laser Unit
372
Wd 11 Hvps
372
Wd 12 Smps
373
WD 13 500-Sheet Feeder
373
WD 14 500-Sheet Feeder Board
374
WD 16 2000-Sheet Feeder
375
WD 17 Finisher
376
WD 18 Mailbox
378
Phaser 4600/4620/4622 Operational Overview
383
Media Handling
384
Sensors
385
Xerographics
387
Major IOT Assemblies
391
520-Sheet Feeder
400
Phaser 4600/4620/4622 Options
400
2000-Sheet Feeder
403
Mailbox
404
Finisher
407
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Xerox Phaser 4600 Specifications
General
Brand
Xerox
Model
Phaser 4600
Category
Printer
Language
English
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