Xerox 4400DX - Phaser B/W Laser Printer User manual

Phaser 4400 Laser Printer Service Manual 1-1
General Information
The Xerox Phaser™ 4400 Laser Printer Service Manual is the primary document
used for repairing, maintaining and troubleshooting.
To ensure complete understanding of the product, participation in Xerox Phaser 4400
Service Training is recommended.
Section Contents
Phaser 4400 Laser Printer Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Printer Memory Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Monitoring Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Repackaging Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Parts of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Base Configuration Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Front Panel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Image Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Machine Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Menu Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
Printer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Media and Tray Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

1-2 Phaser 4400 Laser Printer Service Manual
Phaser 4400 Laser Printer Overview
The Phaser 4400 Laser Printer combines a monochrome print engine with an image
processor supporting PostScript 3 and PCL5e/6. The Phaser 4400 is a high
performance, 26 ppm desktop laser printer with a resolution up to 1200 x 1200 dpi.
Configurations
The Phaser 4400 is available in four configurations. A replaceable “Configuration
Upgrade Chip” holds configuration information that enables or disables built-in
features as described here.
Phaser 4400B The Phaser 4400B is the base configuration laser printer. The printer
comes standard with 32 Mbytes of memory, 600 x 600 dpi resolution, USB and
Parallel support, a built in Multi-Purpose Tray, and a 550-sheet universal paper tray.
Note: The Phaser 4400B reports 32 Mbytes of memory even though
it has a 64-Mbyte DIMM installed. In order to get the full
64 Mbytes of memory to be reported as well as activate other
features, users need to upgrade to the N-configuration with a
Configuration Upgrade Kit, part number 098S04703.
Phaser 4400N The Phaser 4400N is the networking configuration. This
configuration includes all the features of the 4400B, but comes with 64 Mbytes of
memory, built-in 10/100 Ethernet networking capabilities, and a resolution up to 1200
x 1200 dpi.
Phaser 4400DT The Phaser 4400DT includes all the features of the 4400N but
comes standard with built in auto-duplexing, and one added 550-sheet feeder.
Phaser 4400DXThe Phaser 4400DX includes all the features of the 4400DT, along
with a 20-Gbyte hard drive and a Stacker with offset.
Page Description Languages (PDL)
■PCL5e/6
■Adobe PostScript 3
■PDF
Resident Fonts
■39 PostScript Roman fonts available on all models, plus an additional 97
Roman fonts available with the optional Hard Drive.
■81 PCL fonts (more fonts are available with the optional internal Hard
Drive.)

Phaser 4400 Laser Printer Service Manual 1-3
Printer Memory Configuration
The printer features two slots which accept 32-, 64-, and 128-Mbyte SDRAM
DIMMs. All combinations except 32 Mbytes alone are allowed to a maximum of 256
Mbytes.
The Phaser 4400B reports 32 Mbytes of memory, even though it has a 64-Mbyte
DIMM installed. In order to get the full 64 Mbytes of memory to be reported as well
as activate other features, users must upgrade to the N-model with a Configuration
Upgrade Kit, part number 098S04703.
The Startup page and the Configuration pages list the amount of RAM installed in the
printer.
If the memory does not meet the following specifications, it is ignored by the printer.
■PC133 DRAM Standard
■144-Pin SODIMM
■Serial Presence Detect
■3.3 Volt
Monitoring Consumables
The status of printer consumables is available through the Supplies Info Menu.
Repackaging Information
If the printer must be returned to Xerox and the customer has not saved the shipping
box and all internal packaging, a repackaging kit is available for order from the local
Customer Support Center.
Repackaging Kit: part number 065-0606-00
Replaceable Items Print Life
Print Cartridge (rated at 5% image
coverage of letter-size paper)
High-Capacity 15,000
Toner wt. 620 g (1.36 lbs.)
Standard-Capacity 10,000
Toner wt. 420 g. (.9 lbs.)
Maintenance Kit (includes Fuser,
Transfer Roller, and nine rollers for Feed,
Retard, and Nudger Roller assemblies).
up to 200,000

1-4 Phaser 4400 Laser Printer Service Manual
Parts of the Printer
The parts of the printer are covered here in three groups:
■Base configuration components
■Internal components
■Printer options
Base Configuration Components
Front view of base configuration
No. Description
1. Paper exit slot
2. Standard Output Tray
3. Front panel
4. Front cover (shown closed)
5. Multi-Purpose Tray (MPT)
6. Multi-Purpose Tray extension
7. Power switch
8. Tray 1
9. Paper level gauge
1
2
3
4
5
6
7
89

Phaser 4400 Laser Printer Service Manual 1-5
Rear view of base configuration
No. Description
1. Option Cover
2. Rear cover release
3. Rear cover (shown closed)
4. Parallel connector
5. USB connector
6. Ethernet connector
7. Power cord receptacle
8. Left cover
9. Ventilation slots
8
9
1
2
3
6
7
4
5

1-6 Phaser 4400 Laser Printer Service Manual
Internal Components
Front and rear views with covers open
Printer Options
The following customer-installed options are available for the Phaser 4400 printer.
No. Description
1. Print Cartridge
2. Front cover (shown open)
3. Fuser
4. Rear door (shown open)
Option Customer
Order Number
Description
32-Mbyte DIMM 97S02923 32-Mbyte Memory
64-Mbyte DIMM 97S02912 64-Mbyte Memory
128-Mbyte DIMM 97S02913 128-Mbyte Memory
16-Mbyte Flash DIMM 97S02914 16-Mbyte Flash ROM for storage of fonts, forms, etc.
4400 Network
Upgrade Kit
98S04703 Configuration Upgrade Chip upgrades a Base printer
to a Network printer.
20+ Gbyte Hard Drive 97S02917 Adds hard disk capability to the printer:
■Stores fonts, forms, etc.
■Enables collation, proof, secure and save jobs.
■Provides user documentation, setup and care
videos, and printer drivers.
550-Sheet Feeder 97S02878 Provides 550-sheet additional input capacity when
used in conjunction with the 550-sheet Paper Tray.
You can install one or two 550-Sheet Feeders.
550-Sheet Paper Tray 109R00448 Used with the 550-Sheet Feeder. The Tray holds 550
sheets of paper.
Duplex Unit 97S02880 Provides duplex (two sided) printing capability.
Stacker 97S02881 Adds 500 sheet output capacity with offset capability.
Envelope Feeder 97S02879 Provides dedicated envelope feed.
1
2
3
4

Phaser 4400 Laser Printer Service Manual 1-7
Printer options
No. Description
1. 500-Sheet Stacker
2. Envelope feeder
3. 550-sheet feeder with tray 2
4. 550-sheet feeder with tray 3
5. Automatic duplex unit
1
2
3
4
s4400-346
5

1-8 Phaser 4400 Laser Printer Service Manual
Front Panel Configuration
The Front Panel consists of one tricolor LED, a display window and six functional
keys. These keys navigate the menu system, perform functions and select modes of
operation for the printer.
The LED (light emitting diode) above the Graphics Display can be green, yellow or
red, and can be off, blinking or steady.
LED indications:
Green — Ready to Print
Flashing Green — Receiving, Processing Data or Printing
Flashing Yellow — Warning
Flashing Red — Error (blinks in unison with Image Processor Health LED)
Phaser 4400 Front Panel Configuration
Front Panel Key Descriptions
1Status LED 5Up Arrow Key - scrolls up the menu
system
2Graphic front panel display 6Down Arrow Key - scrolls down the menu
system
3Cancel Key 7OK (select) Key
4Back Key 8INFO Key - for additional explanation or
help
1
3
4
6
8
7
5
2
s4400_006

Phaser 4400 Laser Printer Service Manual 1-9
Front Panel Shortcuts
Mode Press this selection at power-on
Skip execution of POST diagnostics OK
Print Service Menu Map INFO
Reset PostScript NVRAM BACK+OK
When “Password” appears, press UP +
DOWN keys within 2 seconds
Enter Service Diagnostics BACK+INFO

1-10 Phaser 4400 Laser Printer Service Manual
Image Processor Board
The following components must be transferred from the old board when installing a
new Image Processor Board in the printer:
■SDRAM DIMMs (Slot 1 on the left, slot 2 on the right)
■NVRAM
■Configuration Upgrade Chip
■Flash DIMM
See RRP 9.2 Image Processor Board on page 6-88 for information on replacing the
Image Processor Board.
Inside the printer on the Image Processor board are four LEDs shown in the figure.
DS210 illuminates when the e-net rate is set to 10 Mbits/sec (off indicates
100 Mbits/sec).
DS211 illuminates when a link is established.
DS380 is the HEALTH LED. The CPU flashes this LED to indicate that it is “alive”,
or in the case of a failure, the CPU flashes this LED (and the Front Panel LED, also)
with a code to help diagnose the problem.
DS390 is the CHECK STOP indicator, which illuminates when various fatal errors
occur in the CPU.

Phaser 4400 Laser Printer Service Manual 1-11
Rear Panel Configuration Interfaces
■IEEE 1284 parallel
■Ethernet 10/100BaseTx
■USB
On the Ethernet port, the green LED is a RECEIVE DATA indicator and the yellow
LED is a TRANSMIT DATA indicator.
Rear Panel DIP Switch Settings
Note: The DIP switch setting information presented here is meant
to provide a means of returning to as-shipped status in case
the switches have been inadvertently changed. Except in
extreme circumstances, the DIP switches should be left in the
Normal operating mode.
The DIP switches are defined as follows:
■Switches 1-2 select the modes of operation, as follows:
■Switch 3 selects whether the rear panel serial port presents PostScript or
vxWorks backchannel messages. OPEN presents PostScript; Closed presents
vxWorks.
■Switch 4 is an IP board Reset switch (normally OPEN).
Processor Information
The processor used on the Image Processor board is a 266 MHz PowerPC processor.
DIP Switch Settings
Mode of Operation SW1 SW2 SW3 SW4
Normal (or Customer) Open Open Open Open
Manufacturing Open Closed Open Open
Developer (no POST) Closed Closed Open Open
Disaster Recovery (vxWorks only) Closed Open Open Open

1-12 Phaser 4400 Laser Printer Service Manual
Machine Orientation
For servicing the Phaser 4400 Laser Printer, all references to machine orientation are
as illustrated below.
Machine Orientation

Phaser 4400 Laser Printer Service Manual 1-13
Menu Map
The menu map shown here lists the choices available when you select Menus, and is
printed when you select Print Menu Map from the top level of Menus. The order
of menus, items, and values found in the Menu Map is the order in which the menus,
items, and values are displayed when scrolling through the menu items.
Menus and items in this map marked with a numbered footnote do not appear on the
front panel display unless the associated option is installed in the printer. Items in this
map marked with an asterisk (*) do not appear on the base configuration 4400B.

1-14 Phaser 4400 Laser Printer Service Manual
Printer Specifications
Physical Specifications
Media and Tray Specifications
Refer to the “Paper Tips” pages shown beginning on page 1-15. You can print the
Paper Tips pages from the Front Panel by selecting Menus | Supplies Info
Menu | Print Paper Tips Page.
The following table lists the total paper capacities available with the three paper deck
combinations:
Note: Paper stack capacity applies to baseline paper:
Xerox 4200/4024 20 lb. Letter and RX 80 A4 (3R91720).
Physical Dimensions - Printer
Dimensions Value
Size and weight (not
including the Print
Cartridge, Image
Processor Board or any
options)
Width: 422 mm x Depth 439 mm x Height 413 mm (16.5 in. x
17.25 in. x 16.25 in.)
Weight: 25 Kg (55 lbs.)
Packaged Weight: 32.7 kg (72 lbs.)
Printer clearances
Clearances Value
Top (to closest
overhead object):
With Stacker 102 mm (4.0")
Without Stacker 292 mm (11.5")
Left: Minimum 12” or 300 mm
Right: 300 mm (12 in.)
Front: Minimum 600 mm (24 in.)
Rear: Minimum 600 mm (24 in.)
Mounting surface
flatness:
Horizontal bias within 5°of level
Maximum Paper Stack Capacity
Combination MBF
(standard)
1st deck
(standard)
2nd deck
(option)
3rd deck
(option)
Total
Capacity
1100 sheets 550 sheets — — 650 sheets
2100 sheets 550 sheets 550 sheets —1200 sheets
3100 sheets 550 sheets 550 sheets 550 sheets 1750 sheets

Phaser 4400 Laser Printer Service Manual 1-15
The Paper Tips Pages shown here list the supported paper and paper sizes, and
provide the paper specifications for the printer.
Paper Tips Page 1 of 3
550-Sheet Tray
Refer to the following tables to ensure the best print-quality and to avoid paper jams. For best results, use Xerox-branded paper as it is
guaranteed to produce excellent results on your Xerox PhaserTM 4400 Laser Printer. Print-quality and paper handling performance may
vary depending on vendor and type of paper used.
Note: If you change the type of paper or transparencies, you must specify the type on the front panel of the printer. For the Multi-Purpose Tray
or envelope feeder only: if you change the size of paper, also specify the size on the front panel.
Supported paper and paper sizes
Paper Type
Envelopes
Monarch (3.87 x 7.5 in.)
C5 (162 x 229 mm)
Transparencies
Letter (8.5 x 11 in.)
A4 (210 x 297 mm)
Capacity(2)
Multi-Purpose
Tray Envelope
Feeder Standard
Tray 500-Sheet
Stacker
Input Output
#10 Commercial (4.12 x 9.5 in.)
DL (110 x 220 mm)
B5 (176 x 250 mm)
A4 (210 x 297 mm)
Labels
Letter (8.5 x 11 in.)
(1) (1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
custom (1) custom
(1)
custom
(1)
custom
(1)
custom
(1)
custom
(1)
custom
(1)
custom
(1)
custom
550 100 75 500 500
= Short-edge feed (1) Simplex (one-sided) printing only. (2) Maximum capacity at 75 g/m (20 lb.) paper stock. Capacity is reduced for heavier/thicker stock.
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
2
Letter (8.5x 11 in.)
Executive (7.25x 10.5 in.)
US Folio (8.5x 13 in.)
Statement (5.5x 8.5 in.)
Legal (8.5x 14 in.)
A4 (210x 297 mm)
A6 (105x 148 mm)
B5 JIS (182x 257 mm)
Index Card (3x 5 in.)
A5 (148x 210 mm)
ISO B5 (176x 250 mm)
s4400_351

1-16 Phaser 4400 Laser Printer Service Manual
Paper Tips Page 2 of 3
Paper weights
The Phaser 4400 Laser Printer supports paper weights as follows:
• 16 - 130 lbs. (60 - 216 g/m ) simplex/one-sided
• 16 - 28 lbs. (60 - 105 g/m ) duplex/two-sided
Plain Paper: (60 - 120 g/m ) (16 - 32 lb.)
Card Stock: (120 - 216 g/m ) (32 - 130 lb.)
Paper tips
• If excessive jams occur, flip the paper in the tray or install fresh paper from a newly opened ream.
• Transparencies should be fanned prior to loading.
• Other size envelopes may be printed as custom paper sizes.
• Use only paper envelopes. Do not use envelopes with windows or metal clasps.
• Label media should be fanned prior to loading.
• Do not print to label stock once a label has been removed.
Simplex
Duplex
(two-sided)
550-Sheet Tray
182 - 216 mm
257 - 356 mm
10.12 - 14.0 in.
Multi-Purpose Tray
182 - 216 mm
7.16 - 8.5 in.
257 - 356 mm
10.12 - 14.0 in.
Envelope Feeder Standard Tray 500-Sheet Stacker
Length
Width
Length
148 - 356 mm 127 - 356 mm
148 - 254 mm
127 - 356 mm 148 - 356 mm
5.83 - 14.0 in. 5.0 - 14.0 in. 5.83 - 10.0 in. 5.0 - 14.0 in. 5.83 - 14.0 in.
7.16 - 8.5 in.
3.87 - 8.5 in. 3.0 - 8.5 in. 3.87 - 7.0 in. 3.0 - 8.5 in. 3.87 - 8.5 in.
98 - 216 mm 76 - 216 mm 98 - 178 mm 76 - 216 mm 98 - 216 mm
Width
Custom paper sizes
Input Output
Same as Input
Same as Input
---
---
TM
2
2
2
2
(one-sided)
s4400_352

Phaser 4400 Laser Printer Service Manual 1-17
Paper Tips Page 3 of 3
Ordering supplies
See www.xerox.com/officeprinting/4400supplies for information on ordering supplies.
Xerox Branded Paper
Item Paper Size Part Number
Plain Paper
Xerox Premier 80 A4 (210 x 297 mm) 3R91720
Xerox Premier 80 A5 (148 x 210 mm) 3R91832
Xerox 4024 DP statement Statement (5.5 x 8.5 in.) 3R2072
Xerox 4024 DP Letter (8.5 x 11 in.) 3R721
Xerox 4024 DP folio Folio (8.5 x 13 in.) 3R725
Xerox 4024 DP legal Legal (8.5 x 14 in.) 3R727
Transparencies
Xerox 3M Type L transparencies A4 (210 x 297 mm) 3R91334
Xerox Clear transparencies Letter (8.5 x 11 in.) 3R4446
Labels
Xerox A4 24-up label A4 (210 x 297 mm) 3R96178
Xerox Multi-purpose 30-up label Letter (8.5 x 11 in.) 3R12051
Replaceable Items
Item Part Number
Standard-Capacity Print Cartridge 113R00627
High-Capacity Print Cartridge 113R00628
Maintenance Kit
 
108R00497 for 110 V (60 Hz)
Contains: a Fuser Cartridge,
1 Transfer Roll, and 9 Feed Rollers.
108R00498 for 220 V (50 Hz)
s4400_353

1-18 Phaser 4400 Laser Printer Service Manual
Functional Specifications
Characteristic Specification
Printing process Recording System - Electro-photographic system (roller charging,
single component magnetic toner development)
Exposure System - Infrared Laser Diode Beam Scanning
Class 1 Laser Product
Class 3B Laser, rated at 5 mW output @ 780 nm
Fusing System - Heat and pressure
Resolution /
Addressability
600/1200 dots per inch (dpi), switchable at full engine speed.
Operating Modes Ready Mode: Ready to receive data.
Power Saver Mode: entered after a user-specified period of Print
Engine inactivity since completion of the last print to minimize
energy consumption.
Continuous Operating
Printing Speed
Paper Size Fuser Setting Duplex
Low Medium High Extra High (ipm)
Letter SEF 18 26 22 8 19
A4 SEF 18 25 22 8 18
Legal 14” SEF 18 21.5 18 7.5 16
Legal 13” SEF 18 21.5 18 7.5 16
Executive 18 26 22 8 19
B5 (JIS) SEF 18 26 22 8 19
Fuser Configuration
Temperature
Low - Medium setting High - Extra High setting
Range: 194-209°C/ Range: 197-212°C/
381-408°F 387-414°F
First Print Out
(Engine speed only)
Tray 1 (t sec) Tray 2 (sec) Tray 3 (sec) MPT (sec)
Paper Size Simp Dup Simp Dup Simp Dup Simp Dup
Letter 7.5 13.8/ 8.3 14.6/ 9.2 15.5/ 7.7 14.0/
14.6 15.4 16.3 14.8
A4 7.6 14.0/ 8.4 14.8/ 9.3 15.7/ 7.8 15.9/
15.4 16.2 17.1 17.3
Warm-up time From a cold start (22° C / 71.6° F ambient temperature) to READY
TO PRINT within 70 seconds.

Phaser 4400 Laser Printer Service Manual 1-19
Electrical Specifications
Environmental Specifications
Characteristic Specification
Power supply 120 VAC (98–140 VAC) 50/60 Hz (47 Hz – 63 Hz)
220/240 VAC (198–264 VAC) 50/60 Hz (47 Hz – 63 Hz)
Power consumption Maximum - 600 Watts
Printing - 525 Watts/hour or 1792 Btus/hour
Standby - 110 Watts/hour or 375 Btus/hour
Power Saver - 20 Watts/hour or 68 Btus/hour
Note: No electrical power is supplied to the Fuser assembly in
Power Saver Mode.
Characteristic Specification
Operating environment 5–35°C / 41–95° F @ 15% to 85% Relative Humidity (operating)
0 - 3100 meter (10171 ft.) above sea level
Storage environment
with a packed Print
Cartridge
Normal condition:12 months maximum at 0–35° C/32–95° F
@ 15–80% Relative Humidity with no condensation present
Severe condition: 1 month maximum at -20°to 0° C / -4°to 32° F or
35°to 40° C / 95 to104° F
@ 5–15 or 80–95% Relative Humidity with no condensation present
Storage environment
without a packed Print
Cartridge
Normal condition: 12 months maximum at -20 to -50° C / -4 to -58° F
@ 5-85% Relative Humidity with no condensation present
Severe condition: 48 hours maximum at 50–60° C / 122–140 ° F
@ 85-95% Relative Humidity with no condensation present
Heat Emission Maximum - 2730 BTU; Average - 1603; 102 (sleep mode)
Acoustic Noise (MPT
closed; options are
Duplex Unit, two
additional feeders,
Envelope Feeder,
Stacker)
Standby: 4.9 B (35.0 dB(A))
Power Saver: 0 dB above background noise
Printing (without options): 6.8 B (52.0 dB(A))
Printing (with options): 7.1 B (55.5 dB(A))
Dust Emission No more than 0.075 mg/m3 concentration.
Ozone Emission No more than 0.02 mg/m3 concentration, measured in accordance
with BAM Standard.

1-20 Phaser 4400 Laser Printer Service Manual