Xerox Phaser 4 400 User manual

Service
Manual
Phaser™
Laser Printer
4400

Warning
The following servicing instructions are for
use by qualified service personnel only. To
avoid personal injury, do not perform any
servicing other than that contained in the
operating instructions, unless you are qualified
to do so.
First Printing: June 2002
071-0861-00
PHASER™ 4400
LASER PRINTER
Service Manual
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Phaser 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
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xiv Phaser 4400 Laser Printer Service Manual
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
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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
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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
MonitoringConsumables.........................................1-3
RepackagingInformation.........................................1-3
Parts of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Base Configuration Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
InternalComponents ............................................1-6
PrinterOptions.................................................1-6
FrontPanelConfiguration ........................................1-8
ImageProcessorBoard.........................................1-10
Machine Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Menu Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
Printer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
PhysicalSpecifications..........................................1-14
Media and Tray Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
FunctionalSpecifications........................................1-18
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
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Phaser 4400 Laser Printer Service Manual 2-1
Error Messages and Codes
Introduction
This section covers troubleshooting procedures for the Phaser 4400 Laser Printer’s
front panel error messages. Only jams and fatal errors will produce an associated
numeric code. Error messages and codes are usually specific, making it important that
service personnel and users record errors exactly when reporting problems with the
printer.
Any error code associated with an error message or jam can be viewed by pressing the
INFOkey. Jam error are displayed at the beginning of the info menu, while engine
errors are display at the end.
Some procedures require running Service Diagnostics tests to verify a specific printer
assembly is operating correctly. Refer to Service Diagnostics on page 2-7.
To troubleshoot problems not associated with a front panel error message or code
such as ac power, or problems related to print-quality, refer to the section
Troubleshooting on page 3-1.
Section Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
ServiceFlowchart...............................................2-2
Service Technician Cautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Procedures....................................................2-3
VoltageMeasurements...........................................2-4
UsingFaultHistory..............................................2-5
Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
EnteringServiceDiagnostics......................................2-7
ServiceDiagnosticsMenuMap ....................................2-8
Using the Front Panel with Service Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . 2-9
EngineTestPrint ..............................................2-10
EngineNVRAMDefaultSettings ..................................2-10
Printer Error Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
IndexofErrors................................................2-11
ErrorMessageSummaries.......................................2-12
Image Processor POST Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58
FaultReportingDevices.........................................2-58
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Phaser 4400 Laser Printer Service Manual 3-1
Troubleshooting
Introduction
This section covers two types of troubleshooting procedures:
■Troubleshooting procedures for problems not directly associated with error
messages or codes
■Troubleshooting Procedures for Image-quality (IQ) problems
Troubleshooting procedures will normally isolate a problem to a specific component
or subassembly, in some cases including the wire harnesses.
In the Yes/No steps of the procedures, a Yes/No response will either lead you to the
next step or will indicate a corrective action. When you complete the indicated
corrective action, restart the System Check to verify that the problem has been
corrected.
Measurements
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 Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . .3-53
Index of Image-Quality Troubleshooting 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
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Phaser 4400 Laser Printer Service Manual 4-1
Tests Prints, Adjustments,
and NVRAM Reset
Service Test Prints
There are two test prints stored in the printer that are primarily intended for service
use. One is the Test Print that is accessible from the printer’s Printable Pages Menu
when you select Print Test Prints. The other is the Engine Test Print, which
is stored in the Engine Logic Board and is accessible through the Engine Test Print
menu in Service Diagnostics.
Section Contents
Service Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
TestPrint .....................................................4-2
EngineTestPrint ...............................................4-4
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Registration ...................................................4-5
FuserTemperature..............................................4-6
Resetting NVRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
CustomerMenuResets..........................................4-7
Service Diagnostics Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
FrontPanelShortcutReset .......................................4-8
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Phaser 4400 Laser Printer Service Manual 5-1
Cleaning and Maintenance
Service Preventive Maintenance
Procedure
Perform the following procedures whenever you check, service, or repair a printer.
Cleaning the printer, as outlined in the following steps, assures proper operation of the
printer and reduces the probability of having to service the printer in the future.
The frequency of use and the type of paper a customer prints on determines how
critical cleaning the machine is, record the number of sheets printed. You should
thoroughly inspect and clean these printers.
Recommended Tools
■ Toner vacuum cleaner
■ Clean water
■ Clean, dry, lint-free cloth
■ Black light protective bag
Cleaning
Caution: Never apply alcohol to any parts in the printer.
Note: Never use a damp cloth to clean up toner.
1. Record number of sheets printed.
2. Print several sheets of paper to check for problems or defects.
3. Turn off the printer and disconnect the Power Cord.
4. Remove the Top Cover and clean the Fan with a brush or dry cloth to remove
excess dust.
5. Remove any debris or foreign objects from the Transfer Roller, Fuser Assembly,
Laser Assembly, and paper path.
6. Vacuum out any loose toner from the interior of the printer with a Type II toner
vacuum only.
7. Remove and clean the paper trays.
8. Clean feeder rollers with a lint-free cloth lightly dampened with water.
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