Xerox Phaser 4 400 User manual

Service
Manual
Phaser™
Laser Printer
4400

haser 4400 Laser Printer Service Manual xiii
Contents
General Information 1-1
SectionContents.................................... 1-1
Phaser 4400 Laser Printer Overview . . . . . . . . . . . . . . . . . . . . 1-2
PartsofthePrinter .................................. 1-4
MachineOrientation ................................ 1-12
Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Printer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Error Messages and Codes 2-1
SectionContents.................................... 2-1
Introduction........................................ 2-1
Service Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
PrinterErrorMessages.............................. 2-11
Image Processor POST Error Codes . . . . . . . . . . . . . . . . . . . 2-58
Troubleshooting 3-1
SectionContents.................................... 3-1
Introduction........................................ 3-1
Measurements ..................................... 3-1
Troubleshooting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Image-Quality Checkout Procedures . . . . . . . . . . . . . . . . . . . 3-41
Image-Quality Troubleshooting Procedures . . . . . . . . . . . . . . 3-53
Tests Prints, Adjustments, and NVRAM Reset 4-1
SectionContents.................................... 4-1
ServiceTestPrints .................................. 4-1
Adjustments ....................................... 4-5
ResettingNVRAM................................... 4-7

xiv
Cleaning and Maintenance 5-1
Service Preventive Maintenance Procedure . . . . . . . . . . . . . . . 5-1
FRU Disassembly 6-1
List of Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Covers and Trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Tray1 ...........................................6-18
Paper Feed (Tray 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Paper Feed (MPT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
Paper Transportation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
Exit Assembly and Fuser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
Xerographics......................................6-79
MainDrive........................................6-84
Electrical.........................................6-87
Stacker .........................................6-101
Optional Paper Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-120
DuplexUnit......................................6-141
Envelope Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-157
Parts Lists 7-1
PartsListIndex.....................................7-1
UsingthePartsLists.................................7-1
Theory of Operation 8-1
SectionContents....................................8-1
PrintProcessOverview...............................8-3
PrintProcessDescription .............................8-5
The Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
DriveFlow........................................8-14
Engine Logic Board and Front Panel Functions . . . . . . . . . . . 8-22
ImageProcessorBoard..............................8-22
PowerSupplies....................................8-23
Interlocks.........................................8-24

Phaser 4400 Laser Printer Service Manual xv
LaserControl ..................................... 8-25
FuserControl ..................................... 8-26
EraseCycle....................................... 8-28
FanControl....................................... 8-28
DuplexPrinting.................................... 8-29
Envelope Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
Stacker .......................................... 8-37
Option Feeder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
Wiring Data 9-1
SectionContents.................................... 9-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Base Engine Wiring Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
550-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
DuplexUnit....................................... 9-26
Stacker ....... ............................ 9-31
Envelope Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37

Phaser 4400 Laser Printer Service Manual 3-1
Troubleshooting
Introduction
This section covers two ty ubleshooting procedures:
■Troubleshooting proce problems not directly associated with error
messages or codes
■Troubleshooting Proce mage-quality (IQ) problems
Troubleshooting procedu rmally isolate a problem to a specific component
or subassembly, in some ding the wire harnesses.
In the Yes/No steps of the s, a Yes/No response will either lead you to the
next step or will indicate e action. When you complete the indicated
corrective action, restart t Check to verify that the problem has been
corrected.
Measureme
Power and signal grounds are connected to frame ground. You can perform all circuit
troubleshooting using the metal frame (chassis) as the grounding point. If you need
more information to locate connectors or test points, refer to Wiring Data on page 9-1.
Unless otherwise specified, the following voltage tolerances are used within this
section:
Section Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Index of Troubleshooting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Image-Quality Checkout Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41
Index of Image-Quality Checkout Procedures . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Image-Quality Troublesh ocedures . . . . . . . . . . . . . . . . . . . . . . . .3-53
Index of Image-Quali ooting Procedures . . . . . . . . . . . . . . . . . . . 3-53
Voltage Measurements
Stated Measured Stated Measured
+3.3 VDC +3.0 to 3.6 VDC +24.0 VDC +21.6 to +26.4 VDC
+5.0 VDC +4.8 to +5.2 VDC 0.0 VDC Less than +0.5 VDC

3-2 Phaser 4400 Laser Printer Service Manual
Troubleshooting Procedures
Verifying AC Power
There is a possible problem with AC power.
Warning: Improper connection of the grounding conductor can
result in the risk of electrical shock.
The following must be observed:
■Never use a ground adapter plug to connect the machine to a power source.
■Never attempt any maintenance function that is not specifically called out in
the service procedures.
■Never remove any covers that are fastened with screws, unless so instructed
in the service procedures.
Caution: If any of the voltage measurements are not as specified in
the following steps, the cause must be corrected. Caution
the customer NOT to connect the machine to the wall
outlet. Advise the customer that a licensed electrician must
correct the wiring. Do not attempt to correct the wiring
yourself. If you later find the condition has not been
corrected, inform your manager in writing of the improper
wiring.
Index of Troubleshooting Procedures
Verifying AC Power . . . . . . . . . . . . . . . . .3-2 Print Cartridge Sensor Assembly . . . . . 3-24
DCPower(LVPS)...................3-4 Tray Motor Assembly Checkout . . . . . . 3-26
DC Power Loading . . . . . . . . . . . . . . . . . .3-6 Registration Clutch . . . . . . . . . . . . . . . . 3-27
Toner Sensor Failure . . . . . . . . . . . . . . . .3-8 Turn Roller Clutch Assembly. . . . . . . . . 3-28
Inoperative Printer . . . . . . . . . . . . . . . . . .3-9 Tray 1 Feed Clutch . . . . . . . . . . . . . . . . 3-29
Malfunctioning Front Panel. . . . . . . . . . .3-11 MPT Pick Up Solenoid . . . . . . . . . . . . . 3-30
Inoperative Front Panel . . . . . . . . . . . . .3-13 Image Processor Isolation. . . . . . . . . . . 3-31
Erratic Printer Operation. . . . . . . . . . . . .3-13 High-Voltage Power Supply (HVPS)
Assembly........................3-31
PowerSupply.....................3-14 Electrical Noise . . . . . . . . . . . . . . . . . . . 3-33
Main Motor Assembly. . . . . . . . . . . . . . .3-15 ExitSensor ......................3-34
Laser Assembly . . . . . . . . . . . . . . . . . . .3-17 ExitMotor .......................3-35
Fuser Assembly . . . . . . . . . . . . . . . . . . .3-18 550-Sheet Feeder Feed Clutch . . . . . . . 3-36
Registration Sensor . . . . . . . . . . . . . . . .3-20 Stacker Full Sensor . . . . . . . . . . . . . . . . 3-37
MPT No Paper Sensor . . . . . . . . . . . . . .3-21 Stacker Offset Operation Not Performed3-38
Tray 1 No Paper Sensor. . . . . . . . . . . . .3-22 Envelope Feed Clutch . . . . . . . . . . . . . . 3-38
Output Tray Full Sensor . . . . . . . . . . . . .3-22 Envelope No Paper Sensor. . . . . . . . . . 3-39
Stack Height Sensor Checkout. . . . . . . .3-23

Phaser 4400 Laser Printer Service Manual 6-1
ssembly
This section contains step emoval procedures for a specific component or
assembly. Numbers in the ns refer to steps in the procedure. For example: if
step 3 in a procedure instr o remove a screw, the screw in the illustration is
labeled 3. Unless a specif ment procedure is included, reassembly is the
reverse of disassembly.
Illustrations are used to a ith the procedures. You should refer to the
specific Parts List illustra under the repair title) for locating most
components within a proc
Caution: Always rein orrect type and size screws. Using the
wrong screw age tapped holes.
Caution: Do not use e orce to either remove or install a part.
Locations, such as left, ri or rear, given in the repairs assume you are facing
the printer front panel.
The Print Cartridge should be removed and stored in a dark, safe place when
performing any procedure where screws or components may damage the cartridge
and where exposure to light could degrade performance.
List of Procedures
Covers and Trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
RRP1.1LeftInterfaceCover ......................................6-6
RRP1.2LeftCover..............................................6-7
RRP1.3OptionCover............................................6-8
RRP1.4TopCoverAssembly......................................6-9
RRP 1.5 Right Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
RRP1.6FrontCoverAssembly ...................................6-11
RRP1.7LeftFrontCover........................................6-12
RRP 1.8 Rear Cover Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
RRP 1.9 Front Panel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
RRP1.10InterlockCover........................................6-15
RRP1.11LeftPlate.............................................6-16
RRP1.12PlateHandle..........................................6-17
Tray1........................................................6-18
RRP 2.1 Retard Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
RRP 2.2 Friction Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
RRP2.3RetardSpring..........................................6-22
RRP2.4MotorAssembly ........................................6-24
RRP 2.5 Paper Feeder Connector and Socket Guide. . . . . . . . . . . . . . . . . . .6-26

XEROX Phaser 4400 service manual
XEROX Phaser 4400 service manual
XEROX Phaser 4400 service manual
XEROX Phaser 4400 service manual
XEROX Phaser 4400 service manual
XEROX Phaser 4400 service manual
XEROX Phaser 4400 service manual
XEROX Phaser 4400 service manual
XEROX Phaser 4400 service manual