Xerox 4500 Service Manual
laser printer
Service
Manual
Phaser™ 4500
Phaser 4500 Laser Printer
Service Manual
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: January 2004
071-0867-00
Service Manual
iii
Contents
Service Terms ............................................................................. xiii
Product Terms ............................................................................xiv
Power Safety Precautions ........................................................... xv
Electrostatic Discharge (ESD) Precautions .................................. xvi
Service Safety Summary ............................................................ xvii
Regulatory Specifications ............................................................xix
1
General Information
Printer Introduction and Overview ............................................... 1-2
Technical Support Information .......................................... 1-2
Printer Configurations ................................................................. 1-3
Parts of the Printer...................................................................... 1-4
Front Panel .........................................................................................1-5
Image Processor Board .............................................................. 1-6
Consumables and Routine Maintenance Items ............................ 1-7
Supply Life Counters ........................................................ 1-8
Printer Specifications.................................................................. 1-9
Physical Dimensions and Clearances................................ 1-9
Functional Specifications ................................................ 1-10
Electrical Specifications .................................................. 1-11
Environmental Specifications .......................................... 1-11
Media and Tray Specifications ................................ ........ 1-12
Memory Requirements ................................................... 1-13
2
Theory of Operation
Overview of the Phaser 4500 Laser Printer .................................. 2-2
Summary of the Printing Process ...................................... 2-2
Paper Path of the Printer ............................................................ 2-5
Layout of Paper Transport Path ........................................ 2-6
Sensors ..................................................................................... 2-8
Major Assemblies and Functions .............................................. 2-12
Paper Tray .............................................................................2-12
Paper Feeder .........................................................................2-16
Control of Paper Size...................................................... 2-18
Xerographics .................................................................. 2-19
Fuser ............................................................................. 2-24
Fuser Control ................................................................. 2-26
Paper Exit Assembly ...................................................... 2-29
Drive .............................................................................. 2-30
Electrical ........................................................................ 2-31
Phaser 4500 Laser Printer
Printer Options ................................................................ ......... 2-34
Duplex Unit .................................................................... 2-34
Stacker .......................................................................... 2-37
Optional 550-Sheet Feeder ................................................... 2-41
3
Error Messages and Codes
Introduction ................................................................................ 3-2
Servicing Instructions ................................................................. 3-2
Using the Troubleshooting Procedures .............................. 3-4
General Notes on Troubleshooting .................................... 3-4
Accessing Fault Histories ..................................................3-6
Entry Level Fault Isolation Procedure ..........................................3-8
Service Diagnostics .................................................................... 3-9
Service Diagnostic Front Panel Button Descriptions .......... 3-10
Using Service Diagnostics .............................................. 3-10
System Start-Up and POST ...................................................... 3-16
Power On Self Test (POST) ................................................... 3-16
POST Faults .......................................................................... 3-17
LED Blink Patterns ......................................................... 3-17
POST Diagnostic Test Descriptions ................................. 3-18
Operating System and Application Problems ............................. 3-20
Macintosh Printing Problems .......................................... 3-20
Windows Printing Problems ............................................ 3-20
Network Problems .......................................................... 3-21
Error Messages and Codes Troubleshooting Procedures ............ 3-22
Main Motor Failure .......................................................... 3-26
Laser Unit Failure ........................................................... 3-27
Fuser Failure ......................................................................... 3-28
Fan Failure ............................................................................ 3-29
Engine Logic Board NVRAM Failure ...................................... 3-31
Jam At Tray N ........................................................................ 3-32
Jam at Tray N ........................................................................ 3-35
Jam At Top; Open Top Cover To Clear .................................. 3-38
Jam At Exit; Open Rear/Top Cover To Clear .......................... 3-41
Jam At Rear; Open Rear Cover To Clear. .............................. 3-43
Jam At Stacker; Open Rear Stacker Cover To Clear .............. 3-45
Jam At Rear; Open Duplex And Rear Cover To Clear ............. 3-47
Jam At Duplex; Open Duplex To Clear .................................. 3-49
Duplex Unit Error ............................................................ 3-50
Stacker Error ................................................................ .. 3-51
Tray 3 Failure\ Tray 3 or 4 Failure. ......................................... 3-52
Paper Size Jam ..................................................................... 3-54
Close Top Cover/Close Rear Cover....................................... 3-56
Close Duplex Unit Cover ................................................. 3-57
Close Stacker Cover .............................................................. 3-58
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Install or Reseat Print Cartridge ....................................... 3-59
Replace Print Cartridge .................................................. 3-60
No Paper in Tray 1/No Paper in Tray 2 ............................. 3-61
Tray 2 Paper Is Low ........................................................ 3-62
No Paper in Tray 3/No Paper in Tray 4 ............................. 3-63
Tray 3 Paper Is Low/Tray 4 Paper Is Low ......................... 3-64
Insert Tray 1/Insert Tray 2 ............................................... 3-65
Insert Tray 3/Insert Tray 4 ............................................... 3-66
Stacker Is Full, Unload Paper .......................................... 3-67
Standard Output Tray Is Full, Unload Paper ..................... 3-68
Replace Maintenance Kit ................................................ 3-69
Inoperable Printer. .......................................................... 3-70
No Recognition of Duplex Unit ........................................ 3-71
No Recognition of Stacker .............................................. 3-73
4
General Troubleshooting
Introduction ................................................................................ 4-2
Front Panel Troubleshooting ....................................................... 4-3
LCD/LED Display Error/Inoperable Buttons ....................... 4-3
DC Power Supply Troubleshooting .............................................. 4-4
LVPS (Low Voltage Power Supply) ................................... 4-4
DC-DC Converter .................................................................... 4-5
AC Power Supply Troubleshooting ..............................................4-7
No AC Power ........................................................................... 4-7
Print Engine Troubleshooting .................................................... 4-11
Main Motor ................................ ................................ ..... 4-11
Laser Unit Assembly ....................................................... 4-13
Fuser Assembly ............................................................. 4-16
Registration Sensor ........................................................ 4-18
No Paper Sensor ............................................................ 4-20
Low Paper Sensor .......................................................... 4-22
Toner Sensor ................................................................. 4-23
Output Tray Stack Full Sensor ............................................... 4-25
24 V Interlock ................................................................. 4-26
5 V Interlock, Interlock Switch Assembly .......................... 4-26
Rear Cover Switch.......................................................... 4-28
Interlock Switch Assembly .............................................. 4-29
Exit Motor PWBA ............................................................ 4-30
Exit Motor Assembly ....................................................... 4-31
Registration Clutch ......................................................... 4-32
Feed Clutches ....................................................................... 4-33
Left Tray Guide............................................................... 4-34
HVPS/Engine Logic Board .............................................. 4-35
Image Processor Isolation .............................................. 4-37
Image Processor Board ................................ .................. 4-38
Phaser 4500 Laser Printer
RAM DIMM Fault Isolation .............................................. 4-39
Electrical Noise .............................................................. 4-41
Optional 550-Sheet Feeder PWBA (Tray 3) ...................... 4-43
Optional 550-Sheet Feeder PWBA (Tray 4) ...................... 4-44
Optional 550-Sheet Feeder No Paper Sensor ........................ 4-45
Optional 550-Sheet Feeder Low Paper Sensor ...................... 4-47
Optional Feeder Paper Size Switch Assembly ....................... 4-49
Optional 550-Sheet Feeder Feed Clutch Assembly ................ 4-50
Optional 550-Sheet Feeder Turn Roller Clutch ................. 4-52
Duplex Unit PWBA ......................................................... 4-54
Duplex Unit Motor ........................................................... 4-55
Duplex Unit Sensor ......................................................... 4-56
Duplex Unit Switch ......................................................... 4-58
Stacker PWBA ....................................................................... 4-59
Stacker Motor Assembly ................................................. 4-60
Offset Motor Assembly ................................................... 4-61
Gate Solenoid Assembly................................................. 4-62
Stacker Rear Cover Switch.................................................... 4-63
Stacker Sensor ............................................................... 4-65
Stack Full Sensor (On Stacker PWBA) .................................. 4-67
Offset Sensor (On Stacker PWBA) ........................................ 4-69
5
Print-Quality Troubleshooting
Print-Quality Problems Overview ................................................ 5-2
Analyzing Test Prints ................................................................ .. 5-3
Deletions (Line, Band, Spots) ............................................ 5-6
Fusing .............................................................................. 5-7
Resolution ................................ ................................ ........ 5-9
Registration (Side-to-Side) ............................................. 5-10
Registration (Lead Edge-to-Trail Edge) ........................... 5-11
Skips/Smears ................................................................. 5-12
Spots ............................................................................. 5-13
Skew ................................................................ .............. 5-14
Other Print Defects ......................................................... 5-15
Print-Quality Troubleshooting.................................................... 5-16
Light (Undertoned) Print ................................................. 5-16
Blank Print (No print) ...................................................... 5-18
Black Prints ................................ ................................ .... 5-20
Vertical Deletions ........................................................... 5-21
Horizontal Deletions ....................................................... 5-23
Vertical Streaks ................................ .............................. 5-25
Horizontal Streaks .......................................................... 5-28
Spots ............................................................................. 5-30
Unfused Image ............................................................... 5-32
Damaged Print ............................................................... 5-35
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Resolution ................................ ................................ ...... 5-36
Spot Deletions ................................................................ 5-37
Repeating Defects .......................................................... 5-39
Residual Image. ............................................................. 5-40
Background .................................................................... 5-42
Uneven Density .............................................................. 5-43
Skewed Image ............................................................... 5-44
Registration .................................................................... 5-47
Skips and Smears ................................ .......................... 5-49
6
Adjustments and Calibrations
Service Test Prints ..................................................................... 6-2
Test Prints ........................................................................ 6-2
Engine Test Print .............................................................. 6-4
Adjustments ............................................................................... 6-5
Adjusting Laser Power (Image Density) .............................6-5
Checking Registration ......................................................6-5
Adjusting Simplex Registration ......................................... 6-7
Adjusting Duplex Registration ........................................... 6-8
Adjusting Fuser Temperature ............................................ 6-9
Resetting Fuser Life.................................................................. 6-10
Resetting Printer Values to the Factory Default Values ................ 6-11
Resetting Connection Setup Values ................................ 6-11
Resetting Paper Handling Setup Values ................................ 6-12
Resetting PostScript Setup Values .................................. 6-12
Resetting PCL Setup Values ................................................. 6-12
Resetting General Setup Values ........................................... 6-12
Resetting Front Panel Setup Values ...................................... 6-13
Resetting Printer Controls Setup Values .......................... 6-13
Resetting File Security Setup Values ..................................... 6-13
Resetting All Printer Default Settings (PostScript NVRAM) ..... 6-14
7
Cleaning and Maintenance
Service Preventive Maintenance Procedure ................................ 7-2
Recommended Tools .................................................................7-2
Cleaning ..................................................................................... 7-2
8
FRU Disassembly
Overview .................................................................................... 8-2
Standard Orientation of the Printer .................................... 8-2
General Notes on Disassembly ...................................................8-3
Preparation ...................................................................... 8-3
Notations in the Disassembly Text.....................................8-3
Print Engine: Covers ................................................................... 8-4
Phaser 4500 Laser Printer
Paper Exit Cover ..................................................................... 8-4
Paper Exit Rear Door .............................................................. 8-5
Rear Cover .............................................................................. 8-6
Right Cover ...................................................................... 8-7
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Phaser 4500 Laser Printer
Left Cover ........................................................................8-9
Top Cover Assembly, Front Panel ......................................... 8-10
Front Cover .................................................................... 8-12
Interlock Switch Assembly .............................................. 8-13
Print Engine: 150- or 550-Sheet Paper Cassette ........................ 8-15
Retard Roller and Holder ................................................ 8-15
Print Engine: 150-Sheet Feeder ................................................ 8-18
150-Sheet Feeder Assembly ................................................. 8-18
Nudger Roller, Feed Roller.............................................. 8-20
Nudger One-way Clutch .................................................. 8-22
Nudger Gear .......................................................................... 8-24
Feed Clutch, Registration Clutch ................................ ..... 8-26
Registration Sensor ........................................................ 8-27
No Paper Sensor ................................................................... 8-28
Toner Sensor Assembly.................................................. 8-30
Print Engine: 550-Sheet Paper Feeder ...................................... 8-31
550-Sheet Feeder Assembly ................................................. 8-31
Nudger Roller, Feed Roller.............................................. 8-32
Nudger One-way Clutch .................................................. 8-33
Nudger Gear .......................................................................... 8-34
Feed Clutch ........................................................................... 8-36
No Paper Sensor ................................................................... 8-38
Right Tray Guide ................................ ............................ 8-39
Left Tray Guide ............................................................... 8-41
Low Paper Sensor/Actuator ............................................ 8-42
Print Engine: Xerographics ....................................................... 8-44
Front Duct, Sub Fan........................................................ 8-44
Laser Unit Assembly ....................................................... 8-46
Laser Unit Shield Plate ................................................... 8-48
Print Cartridge Left Guide ............................................... 8-49
Fuser Harness Assembly ................................................ 8-50
Link Lever, Gear 3 Link .......................................................... 8-52
Fuser Assembly.............................................................. 8-54
Transfer Roller Assembly ................................................8-55
Transfer Chute ............................................................... 8-56
Print Cartridge Right Guide Assembly .............................. 8-58
Duplex Unit Opening Cover ............................................. 8-60
Print Engine: Paper Exit ............................................................ 8-61
Paper Exit Assembly....................................................... 8-61
Upper Exit Chute, Lower Exit Chute ...................................... 8-63
Exit Motor Assembly ....................................................... 8-64
Stack Full Sensor ........................................................... 8-65
Stack Full Actuator.......................................................... 8-66
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Print Engine: Frame and Drive .................................................. 8-67
Motor Cover ................................................................... 8-67
Main Motor ..................................................................... 8-69
Gear Assembly Housing ................................................. 8-71
Gear Assembly Plate .............................................................8-73
Print Engine: Electrical ............................................................. 8-75
LVPS Shield Plate .................................................................8-75
Exit Motor PWBA............................................................ 8-76
Low Voltage Power Supply (LVPS) ................................. 8-78
DC-DC Converter ..................................................................8-80
Power Switch, AC Power Harness Assembly ................... 8-81
Rear Cover Switch ......................................................... 8-83
Main Fan. ....................................................................... 8-84
Image Processor Shield Assembly .................................. 8-86
I/P Shield Window .......................................................... 8-87
HVPS Shield Plate .................................................................8-88
HVPS/Engine Logic Board .............................................. 8-89
Image Processor (I/P) Board ........................................... 8-91
Options: 550-Sheet Paper Feeder ................................................... 8-93
550-Sheet Paper Feeder Removal ........................................8-93
Right Cover Plate ........................................................... 8-95
Left Cover Plate ............................................................. 8-97
Option Paper Size Switch Assembly ................................ 8-99
Optional Feeder Drive Assembly ................................... 8-100
550-Sheet Feeder PWBA ................................................... 8-102
550-Sheet Feeder ................................................................8-104
Nudger Roller, Feed Roller ........................................... 8-106
Nudger One-way Clutch ............................................... 8-107
Nudger Gear ........................................................................8-108
Feed Clutch Assembly .........................................................8-110
Turn Roller Clutch ........................................................ 8-112
Retard Roller ................................................................ 8-113
Options: Duplex Unit............................................................... 8-115
Duplex Unit Removal .................................................... 8-115
Left Cover .................................................................... 8-117
Right Cover .................................................................. 8-118
Top Cover ................................ .................................... 8-119
Upper Assembly Housing ............................................. 8-120
Duplex Unit Lower Housing........................................... 8-121
Duplex Unit PWBA ....................................................... 8-123
Duplex Unit Fan ...................................................................8-124
Duplex Unit Sensor ...................................................... 8-126
Duplex Unit Roller ........................................................ 8-127
Duplex Unit Motor......................................................... 8-129
Duplex Unit Switch ....................................................... 8-131
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Phaser 4500 Laser Printer
Options: Stacker ................................ ................................ ..... 8-132
Stacker Removal .......................................................... 8-132
Stacker Rear Cover ............................................................. 8-133
Stacker Cover ...................................................................... 8-134
Stacker Front Cover ..................................................... 8-137
Stacker Tray Assembly ................................................. 8-138
Stack Full Actuator ....................................................... 8-139
Stacker PWBA ..................................................................... 8-142
Offset Motor Assembly ................................................. 8-144
Gate Solenoid Assembly ............................................... 8-145
Stacker Sensor and Actuator ........................................ 8-146
Stacker Rear Cover Interlock Switch ............................. 8-148
Lower Stacker Roller .................................................... 8-149
Upper Stacker Roller .................................................... 8-151
Stacker Motor Assembly ............................................... 8-154
9
Parts Lists
Serial Number Format ................................................................ 9-2
Using the Parts List..................................................................... 9-3
Print Engine Parts....................................................................... 9-4
Parts List 1.1 Covers ................................ ........................ 9-4
Parts List 2.1 150-Sheet Paper Cassette ........................... 9-6
Parts List 4.1 550-Sheet Paper Cassette ........................... 9-9
Parts List 5.1 150-Sheet Paper Feeder ............................ 9-12
Parts List 7.1 550-Sheet Paper Feeder ............................ 9-15
Parts List 8.1 Xerographics ................................ ............. 9-18
Parts List 10.1 Paper Exit (1/2) ........................................ 9-20
Parts List 10.2 Paper Exit (2/2) ........................................ 9-22
Parts List 11.1 Frame and Drive ...................................... 9-24
Parts List 12.1 Electrical ................................................. 9-26
Options ................................ ................................ .................... 9-29
Parts List 20.1 550-Sheet Paper Feeder (1/2) ................... 9-29
Parts List 20.2 550-Sheet Paper Feeder (2/2) ................... 9-32
Parts List 20.3 Optional 550-Sheet Paper Cassette ........... 9-34
Parts List 21.1 Duplex Unit .............................................. 9-37
Parts List 23.1 Stacker .................................................... 9-40
Xerox Supplies and Accessories ............................................... 9-43
10
Wiring Diagrams
Introduction .............................................................................. 10-2
Print Engine Plug/Jack Locator ................................................. 10-3
550-Sheet Feeder Plug/Jack Locator ...................................... 10-10
Duplex Unit Plug/Jack Locator ................................................ 10-12
Stacker Plug/Jack Locator ...................................................... 10-14
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Notations Used in Wiring Diagrams ..................................................
10-15
Print Engine Wiring Diagrams ..........................................................
10-17
Print Engine General Wiring Diagram .....................................
10-17
24 V Interlock, Rear Cover Switch, Main Motor, Sub Fan, Exit Motor
Assembly ........................................................................
10-18
Fuser Assembly, Power Switch ..............................................
10-20
Print Cartridge, Transfer Roller Assembly ...............................
10-21
150-Sheet Feeder, 550-Sheet Feeder, Main Fan ......................
10-22
Laser Unit, 5 V Interlock, Interlock Switch Assembly ..............
10-24
Paper Exit ............................................................................ 10-25
Image Processor Board, DC-DC Converter, Front Panel ...........
10-26
Optional 550-Sheet Feeder ...............................................................
10-27
550-Sheet Feeder General Wiring Diagram .............................
10-27
550-Sheet Feeder Signal Diagram ..........................................
10-28
Duplex Unit .....................................................................................
10-29
Duplex Unit General Wiring Diagram ......................................
10-29
Duplex Unit Signal Diagram ..................................................
10-30
Stacker ...........................................................................................
10-31
Stacker General Wiring Diagram ............................................
10-31
Stacker Signal Diagram .........................................................
10-32
A Appendix
Menu Map .................................................................................. A-2
Service Diagnostics Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Index
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Service Terms
Manual Terms
Various terms are used throughout this manual to either provide additional
information on a specific topic or to warn of possible danger present during a
procedure or action. Be aware of all symbols and terms when they are used, and
always read NOTE, CAUTION, and WARNING statements.
Consumable: Ink, toner, or print cartridge that is consumed. Customer is expected
to replace once consumed.
Routine Maintenance Item: Supply item or kit that has a limited life. Customer
is expected to replace at end-of-life.
Accessory: A single component or assembly that may be added to a printer;
however, it is NOT an option to the product.
Common Acronyms:
FRU: Field Replaceable Unit
PL: Corresponds to the FRU Parts List.
CRU: Customer Replaceable Unit
ESD: Electrostatic Discharge
Note
A note indicates an operating or maintenance procedure, practice or condition
that is necessary to efficiently accomplish a task.
A note can provide additional information related to a specific subject or add a
comment on the results achieved through a previous action.
Caution
A caution statement indicates an operating or maintenance procedure, practice or
condition that, if not strictly observed, results in damage to, or destruction of,
equipment.
Warning
A warning statement indicates an operating or maintenance procedure, practice
or condition that, if not strictly observed, results in injury or loss of life.
xiv
Phaser 4500 Laser Printer
Product Terms
Caution: A personal injury hazard exists that may not be apparent. For example, a
panel may cover the hazardous area.
Danger: A personal injury hazard exists in the area where you see the sign.
Symbols Marked on the Product
DANGER high voltage.
Protective ground (earth) symbol.
Hot surface on or in the printer. Use caution to avoid personal
injury.
The surface is hot while the printer is running. After turning off
the power, wait 30 minutes.
Avoid pinching fingers in the printer. Use caution to avoid
personal injury.
Use caution (or draws attention to a particular component).
Refer to the manual(s) for information.
0
30min.
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Power Safety Precautions
Power Source
For 110 VAC printers, do not apply more than 140 volts RMS between the supply
conductors or between either supply conductor and ground. Use only the specified
power cord and connector. For 220 VAC printers, do not apply more than 264 volts
RMS between the supply conductors or between either supply conductor and ground.
Use only the specified power cord. This manual assumes that the reader is a Xeroxcertified service technician.
Plug the three-wire power cord (with grounding prong) into a grounded AC outlet
only. If necessary, contact a licensed electrician to install a properly grounded outlet.
If the product loses its ground connection, contact with conductive parts may cause an
electrical shock.
Disconnecting Power
Turning the power off using the On/Off switch does not completely de-energize the
printer. You must also disconnect the printer power cord from the AC outlet. Position
the power cord so that it is easily accessible during servicing so that you may power
down the printer during an emergency.
■
Disconnect the power plug by pulling the plug, not the cord.
■
Disconnect the power cord in the following cases:
■
if the power cord or plug is frayed or otherwise damaged,
■
if any liquid or foreign material is spilled into the case,
■
if the printer is exposed to any excess moisture,
■
if the printer is dropped or damaged,
■
if you suspect that the product needs servicing or repair,
■
whenever you clean the product.
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Phaser 4500 Laser Printer
Electrostatic Discharge (ESD) Precautions
Some semiconductor components, and the respective sub-assemblies that contain
them, are vulnerable to damage by Electrostatic discharge (ESD). These components
include Integrated Circuits (ICs), Large-Scale Integrated circuits (LSIs), field-effect
transistors and other semiconductor chip components. The following techniques will
reduce the occurrence of component damage caused by static electricity.
Be sure the power is off to the chassis or circuit board, and observe all other safety
precautions.
■
Immediately before handling any semiconductor components assemblies, drain
the electrostatic charge from your body. This can be accomplished by touching an
earth ground source or by wearing a wrist strap device connected to an earth
ground source. Wearing a wrist strap will also prevent accumulation of additional
bodily static charges. Be sure to remove the wrist strap before applying power to
the unit under test to avoid potential shock.
■
After removing a static sensitive assembly from its anti-static bag, place it on a
grounded conductive surface. If the anti-static bag is conductive, you may ground
the bag and use it as a conductive surface.
■
Do not use freon-propelled chemicals. These can generate electrical charges
sufficient to damage some devices.
■
Do not remove a replacement component or electrical sub-assembly from its
protective package until you are ready to install it.
■
Immediately before removing the protective material from the leads of a
replacement device, touch the protective material to the chassis or circuit
assembly into which the device will be installed.
■
Minimize body motions when handling unpackaged replacement devices. Motion
such as your clothes brushing together, or lifting a foot from a carpeted floor can
generate enough static electricity to damage an electro-statically sensitive device
■
Handle ICs and EPROMs carefully to avoid bending pins.
■
Pay attention to the direction of parts when mounting or inserting them on
Printed Circuit Boards (PCB’s).
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Service Safety Summary
General Guidelines
For Xerox-certified service personnel only: Refer also to the preceding Power
Safety Precautions.
Avoid servicing alone: Do not perform internal service or adjustment of this
product unless another person capable of rendering first aid or resuscitation is present.
Use care when servicing with power: Dangerous voltages may exist at several
points in this product. To avoid personal injury, do not touch exposed connections and
components while power is on. Disconnect power before removing the power supply
shield or replacing components.
Do not wear jewelry: Remove jewelry prior to servicing. Rings, necklaces and
other metallic objects could come into contact with dangerous voltages and currents.
Power source: This product is intended to operate from a power source that will
not apply more then 264 volts rms for a 220 volt AC outlet or 140 volts rms for a 110
volt AC outlet between the supply conductors or between either supply conductor and
ground. A protective ground connection by way of the grounding conductor in the
power cord is essential for safe operation.
Warning Labels
Read and obey all posted warning labels. Throughout the printer, warning labels are
displayed on potentially dangerous components. As you service the printer, check to
make certain that all warning labels remain in place.
Safety Interlocks
Make sure all covers and the printer’s front panel are in place and all interlock
switches are functioning correctly after you have completed a printer service call. If
you bypass an interlock switch during a service call, use extreme caution when
working on or around the printer.
CLASS 1 LASER PRODUCT
The Phaser 4500 Laser Printer is certified to comply with Laser Product Performance
Standards set by the U.S. Department of Health and Human Services as a Class 1
Laser Product. This means that this is a class of laser product that does not emit
hazardous laser radiation; this is possible only because the laser beam is totally
enclosed during all modes of customer operation. When servicing the printer or laser
unit, follow the procedures specified in this manual and there will be no hazards from
the laser.
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Phaser 4500 Laser Printer
S7300-02
S7300-03
Servicing Electrical Components
Before starting any service procedure, switch off the printer power and unplug the
power cord from the wall outlet. If you must service the printer with power applied,
be aware of the potential for electrical shock.
Warning
Turning the power off by using the On/Off switch does not completely deenergize the printer. You must also disconnect the printer power cord from the
AC outlet. Position the power cord so that it is easily accessible during servicing.
Warning
Do not touch any electrical component unless you are instructed to do so by a
service procedure.
Servicing Mechanical Components
When servicing mechanical components within the printer, manually rotate drive
assemblies, rollers, and gears.
Warning
Do not try to manually rotate or manually stop the drive assemblies while any
printer motor is running.
Servicing Fuser Components
Warning
This printer uses heat to fuse the toner image to media. The Fuser Assembly is
VERY HOT. Turn the printer power off and wait at least 5 minutes for the Fuser
to cool before you attempt to service the Fuser Assembly or adjacent
components.
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Regulatory Specifications
Federal Communications Compliance
The equipment described in this manual generates and uses radio frequency energy. If
it is not installed properly in strict accordance with Xerox instructions, it may cause
interference with radio and television reception or may not function properly due to
interference from another device. However, there is no guarantee that interference
will not occur in a particular installation. If this equipment does cause harmful
interference to radio or television reception, which can be determined by turning the
equipment off and on, the user is encouraged to try to correct the interference by one
or more of the following measures:
■
Reorient or relocate the receiver (device being interfered with).
■
Increase the separation between the printer and the receiver.
■
Connect the printer into an outlet on a circuit different from that which the
receiver is connected.
■
Route the interface cables on the printer away from the receiver
■
Consult the dealer, Xerox service, or an experienced radio/television
technician for help.
Changes or modifications not expressly approved by Xerox can affect the emission
and immunity compliance and could void the user's authority to operate this product.
To ensure compliance, use shielded interface cables. A shielded parallel cable can be
purchased directly from Xerox at www.xerox.com/office/4500supplies.
Xerox has tested this product to internationally accepted electromagnetic emission
and immunity standards. These standards are designed to mitigate interference caused
or received by this product in a normal office environment. This product is also
suitable for use in a residential environment based on the levels tested.
In the United States this product complies with the requirements of an unintentional
radiator in part 15 of the FCC rules. Operation is subject to the following two
conditions: (1) this device may not cause harmful interference; (2) this device must
accept any interference received, including interference that may cause undesired
operation.
This digital apparatus does not exceed the Class B limits for radio noise emissions
from digital apparatus set out in the Radio Interference Regulations of the Canadian
Department of Communications, ICES-003.
Le présent appareil numérique n'émet pas de bruits radioélectrique dépassant les
limits applicables aux appareils numériques de la classe B prescrites dans le
Réglement sur le brouillage radioélectrique édicté par le ministere des
Communications du Canada, NMB-003.
xx
Phaser 4500 Laser Printer
Declaration of Conformity
Xerox Corporation, declares, under our sole responsibility that the printer to which
this declaration relates, is in conformity with the following standards and other
normative documents:
In the European Union
following the provisions of the Low Voltage Directive 73/23/EEC and its
amendments:
EN 60950
(IEC 60950)
“Safety of Information Technology Equipment including Electrical Business
Equipment”
following the provisions of the Electromagnetic Compatibility Directive 89/336/EEC
and its amendments:
EN 55022:1998
(CISPR 22)
EN 61000-3-2:1995
+A1:1998+A2:1998
(IEC 61000-3-2)
EN 61000-3-3:1995
(IEC 61000-3-3)
EN 55024:1998
(CISPR 24)
“Limits and Methods of measurement of radio interference
characteristics of Information Technology Equipment.” Class B.
“Part 3: Limits - Section 2: Limits for harmonic current emissions
(equipment input current less than or equal to 16A per phase).”
“Part 3: Limits - Section 3: Limitation of voltage fluctuations and flicker
in low-voltage supply systems for equipment with rated current less
than or equal to 16A.”
“Information technology equipment - Immunity characteristics - Limits
and methods of measurement. “
This product, if used properly in accordance with the user's instructions is neither
dangerous for the consumer nor for the environment. A signed copy of the
Declaration of Conformity for this product can be obtained from Xerox.
Service Manual
4you.com
General
Information
In this chapter...
■
Printer Introduction and Overview
■
Printer Configurations
■
Parts of the Printer
■
Front Panel
■
Image Processor Board
■
Consumables and Routine Maintenance Items
■
Printer Specifications
Chapter
1
1-2
Phaser 4500 Service Manual
Printer Introduction and Overview
The Xerox Phaser 4500 Laser Printer Service Manual is the primary document used
for repairing, maintaining, and troubleshooting the printer.
To ensure complete understanding of this product, participation in Xerox Phaser 4500
Service Training is strongly recommended. To service this product, Xerox
certification for this product is required.
Technical Support Information
s4500-001
For updates to the Service Manual, Service Bulletins, knowledge base, etc., go to
www.office.xerox.com/partners.
For further technical support, contact your assigned Xerox Technical Support for this
product.
[Type here]
Printer Configurations
A replaceable Configuration Card holds configuration information that enables or
disables the network features shown in the following table.
Printer Configuration
Features
4500B 4500N 4500DT 4500DX
Maximum Print Speed (Letter-size
Paper)
36 ppm 36 ppm 36 ppm 36 ppm
Memory 48 MB 64 MB 64 MB 64 MB
PostScript Fonts 39 39 39 39 +
97 on
hard drive
PCL5e/PCL6 Yes Yes Yes Yes
Job Pipelining Standard Standard Standard Standard
PDF Direct Print Yes Yes Yes Yes
Resolutions 600 dpi,
True 1200
dpi
600 dpi,
True 1200
dpi
600 dpi,
True 1200
dpi
600 dpi,
True 1200
dpi
USB, Parallel Yes Yes Yes Yes
Ethernet Capabilities Optional Standard Standard Standard
550-Sheet Feeder Optional Optional Standard Standard
Duplex Unit Optional Optional Standard Standard
Automatic 2-Sided Printing
(Requires Duplex Unit)
Optional Optional Standard Standard
Hard Drive Optional Optional Optional Standard
Job Collation
(Requires a Hard Drive)
Proof Print, Secure Print, Saved Jobs
(Requires a Hard Drive)
Optional Optional Optional Standard
Optional Optional Optional Standard
500-Sheet Stacker Optional Optional Optional Standard
1-4
Phaser 4500 Service Manual
Parts of the Printer
Front View
1
2
11
1. Paper stop
2. Front panel
3. Tray 1
3
4. On/Off switch
10
5. Tray 2
4
5
9
6. Optional Tray 3
7. Optional Tray 4
8. Paper gauge
6
7
8
4500-072
9. Print cartridge
10.Standard output tray
11.Optional 500-Sheet Stacker
Rear View
9
1
The Image Processor Board
8
contains items 1 - 4.
7
1. Parallel cable connector
2. Ethernet 10/100 Base-T
connector
6
3. USB connector
4. Configuration card
2
5
3
4
4500-073
5. Power receptacle
6. Optional Duplex Unit
7. Rear cover
8. Stacker rear cover
9. Stacker extension
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