Xerox Phaser 4400 Service Manual

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Phaser Laser Printer

Service

Manual

™

4400

PHASER™ 4400 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: June 2002 071-0861-00

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 that might be present during a procedure or action. Be aware of all symbols and terms when they are used, and always read NOTE, CAUTION and WARNING messages.

Note: A NOTE may indicate an operating or maintenance

procedure, practice or condition that is necessary to efficiently accomplish a task. A NOTE may also provide additional information related to a specific subject or add a comment on the results achieved through a previous action.

Caution: A CAUTION indicates an operating or maintenance

procedure, practice or condition that, if not strictly observed, could result in damage to, or destruction of, equipment.

Warning: A WARNING indicates an operating, or maintenance

procedure, practice or condition that, if not strictly observed, could result in injury or loss of life.

PL: Corresponds to the FRU Parts List.

RRP: Corresponds to the FRU Disassembly Removal and Replacement Procedures.

Product Terms

Caution: A personal injury hazard exists that may not be apparent. For

example, a panel may cover the hazardous area.

Danger:

Phaser 4400 Laser Printer Service Manual iii

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.

30 min.

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.

iv Phaser 4400 Laser Printer Service Manual

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 qualified service technician.

Warning: 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

Warning: 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

Phaser 4400 Laser Printer Service Manual v

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.

Caution: 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 EPROM’s carefully to avoid bending pins.

■ Pay attention to the direction of parts when mounting or inserting them on

Printed Circuit Boards (PCB’s).

vi Phaser 4400 Laser Printer Service Manual

Service Safety Summary

General Guidelines

For qualified 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 covers and panel are in place and that 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 4400 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.

Phaser 4400 Laser Printer Service Manual vii

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 using the On/Off switch does not

Warning: Do not touch any electrical component unless you are

instructed to do so by a service procedure.

S7300-02

Servicing Mechanical Components

Manually rotate drive assemblies to inspect drive gears.

Warning: Do not try to manually rotate or manually stop the drive

assemblies while any printer motor is running.

S7300-03

Servicing Fuser Components

This printer uses heat to fuse the toner image to a sheet of paper. 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.

viii Phaser 4400 Laser Printer Service Manual

Regulatory Specifications

Federal Communications Commission 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/officeprinting/6200supplies

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.

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:

Phaser 4400 Laser Printer Service Manual ix

In the European Union

following the provisions of the Low Voltage Directive 73/23/EEC and its amendments:

EN 60950 (IEC 950) “Safety of Information Technology Equipment including Electrical

Business Equipment”

following the provisions of the Electromagnetic Compatibility Directive 89/336/EEC and its amendments:

EN55022:1998

(CISPR 22)

EN61000-3-2:1995

+A1:1998+A2:1998.

(IEC61000-3-2)

EN61000-3-3:1995

(IEC61000-3-3)

EN55024:1998

(CISPR 24)

CISPR 24 Immunity Phenomena

Electrostatic Discharge IEC61000-4-2:1995 6kV Contact, 10kV Air

Radio-Frequency Electromagnetic Field (radiated)

Fast Burst Transients IEC61000-4-4:1995 5/50 Tr/Th ns, 5kHz Rep. Freq

Line Surge IEC61000-4-5:1995 Combination wave

Radio-Frequency Electromagnetic Field (Conducted)

Line voltage dips IEC61000-4-11:1994 >95% dip for ½ cycle @ 50 Hz

Line voltage drop-out IEC61000-4-11:1994 >95% dropout for 250 cycles @ 50 Hz

“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. “

Basic Standard Test Specification

IEC61000-4-3:1995 80-1000 MHz, 3V/m, 80% AM @

1KHz

0.5kV on Signal Lines

1kV on AC Mains

2.0kV Common mode

2.0kV Differential mode

IEC61000-4-6:1996 0.15 - 80 MHz, 3V, 80% AM @ 1kHz

30% dip for 25 cycles @ 50 Hz

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.

x Phaser 4400 Laser Printer Service Manual

Safety Standards

Phaser 4400 satisfies the following safety standards:

Category Standard Satisfied

Laser Safety 100 V/120 V type is submitted to FDA 21 CFR

Ozone Density Does not exceed 0.02 ppm of ozone density TWA

Other standards 100 V/120 V type satisfies:

(Chapter 1, Subchapter J, Section 1010/1040).

220 V/240 V type is submitted to IEC 825 Class 1 Laser Product.

(Time Weight Average), measured according to ECMA 129 standard

UL 1950 3rd Edition, CSA C22.2 no. 950-M95 or equivalent, NOM

200 V/220 V satisfies:

IEC 950 including amendments 1,2,3 and 4, CE Directive 1, Nordic and other Agency Approval 2, CCIB

Notes:

1. When the controller is installed, the OEM customer shall be responsible for the submittal of CE and CCIB.

2. The OEM customer shall be responsible for the Nordic agency approvals including NEMKO, SEMKO, SETI and DEMKO.

Phaser 4400 Laser Printer Service Manual xi

xii Phaser 4400 Laser Printer Service Manual

Contents

General Information 1-1

Section Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Phaser 4400 Laser Printer Overview . . . . . . . . . . . . . . . . . . . . 1-2

Parts of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Machine Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Printer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Error Messages and Codes 2-1

Section Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Service Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Printer Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Image Processor POST Error Codes . . . . . . . . . . . . . . . . . . . 2-58

Troubleshooting 3-1

Section Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

Section Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Service Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Resetting NVRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Phaser 4400 Laser Printer Service Manual xiii

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

Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87

Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-101

Optional Paper Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-120

Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-141

Envelope Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-157

Parts Lists 7-1

Parts List Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Using the Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Theory of Operation 8-1

Section Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Print Process Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Print Process Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

The Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

Drive Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

Engine Logic Board and Front Panel Functions . . . . . . . . . . . 8-22

Image Processor Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23

Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

xiv Phaser 4400 Laser Printer Service Manual

Laser Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

Fuser Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26

Erase Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28

Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28

Duplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29

Envelope Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33

Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37

Option Feeder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42

Wiring Data 9-1

Section Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Base Engine Wiring Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

550-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22

Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26

Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31

Envelope Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37

Phaser 4400 Laser Printer Service Manual xv

xvi Phaser 4400 Laser Printer Service Manual

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

Phaser 4400 Laser Printer Service Manual 1-1

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

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.

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.

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.)

1-2 Phaser 4400 Laser Printer Service Manual

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.

Replaceable Items Print Life

Print Cartridge (rated at 5% image coverage of letter-size paper)

Maintenance Kit (includes Fuser, Transfer Roller, and nine rollers for Feed, Retard, and Nudger Roller assemblies).

High-Capacity 15,000

Toner wt. 620 g (1.36 lbs.)

Standard-Capacity 10,000

Toner wt. 420 g. (.9 lbs.)

up to 200,000

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

Phaser 4400 Laser Printer Service Manual 1-3

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

1-4 Phaser 4400 Laser Printer Service Manual

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

Phaser 4400 Laser Printer Service Manual 1-5

Internal Components

Front and rear views with covers open

No. Description

1. Print Cartridge

2. Front cover (shown open)

3. Fuser

4. Rear door (shown open)

Printer Options

The following customer-installed options are available for the Phaser 4400 printer.

Option Customer

Description

Order Number

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

20+ Gbyte Hard Drive 97S02917 Adds hard disk capability to the printer:

550-Sheet Feeder 97S02878 Provides 550-sheet additional input capacity when

550-Sheet Paper Tray 109R00448 Used with the 550-Sheet Feeder. The Tray holds 550

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.

98S04703 Configuration Upgrade Chip upgrades a Base printer

to a Network printer.

■ Stores fonts, forms, etc.

■ Enables collation, proof, secure and save jobs.

■ Provides user documentation, setup and care

videos, and printer drivers.

used in conjunction with the 550-sheet Paper Tray.

You can install one or two 550-Sheet Feeders.

sheets of paper.

1-6 Phaser 4400 Laser Printer Service Manual

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

s4400-346

Phaser 4400 Laser Printer Service Manual 1-7

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)

s4400_006

Phaser 4400 Front Panel Configuration

Front Panel Key Descriptions

Status LED

Graphic front panel display

Cancel Key

Back Key

Up Arrow Key - scrolls up the menu

system

Down Arrow Key - scrolls down the menu

system

OK (select) Key

INFO Key - for additional explanation or

help

1-8 Phaser 4400 Laser Printer Service Manual

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

Phaser 4400 Laser Printer Service Manual 1-9

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.

1-10 Phaser 4400 Laser Printer Service Manual

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:

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

■ 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.

Phaser 4400 Laser Printer Service Manual 1-11

Machine Orientation

For servicing the Phaser 4400 Laser Printer, all references to machine orientation are as illustrated below.

Machine Orientation

1-12 Phaser 4400 Laser Printer Service Manual

Menu Map

The menu map shown here lists the choices available when you select Menus, and is printed when you select 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.

Print Menu Map from the top level of Menus. The order

Phaser 4400 Laser Printer Service Manual 1-13

Printer Specifications

Physical Specifications

Physical Dimensions - Printer

Dimensions Value

Size and weight (not including the Print Cartridge, Image Processor Board or any options)

Printer clearances

Clearances Value

Top (to closest overhead object):

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:

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.)

With Stacker 102 mm (4.0") Without Stacker 292 mm (11.5")

Horizontal bias within 5° of level

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

Menu | Print Paper Tips Page

The following table lists the total paper capacities available with the three paper deck combinations:

Maximum Paper Stack Capacity

Combination MBF

(standard)

1 100 sheets 550 sheets — — 650 sheets

2 100 sheets 550 sheets 550 sheets — 1200 sheets

3 100 sheets 550 sheets 550 sheets 550 sheets 1750 sheets

Note: Paper stack capacity applies to baseline paper:

Xerox 4200/4024 20 lb. Letter and RX 80 A4 (3R91720).

1-14 Phaser 4400 Laser Printer Service Manual

1st deck (standard)

Menus | Supplies Info

2nd deck (option)

3rd deck (option)

Tota l Capacity

The Paper Tips Pages shown here list the supported paper and paper sizes, and provide the paper specifications for the printer.

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 Phaser 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.

4400 Laser Printer. Print-quality and paper handling performance may

Supported paper and paper sizes

Input Output

Paper Type

550-Sheet Tray

Multi-Purpose

Tray

A4 (210 x 297 mm) A5 (148 x 210 mm) A6 (105 x 148 mm)

ISO B5 (176 x 250 mm)

(1) (1)

(1)

custom

(1)

custom

B5 JIS (182 x 257 mm)

Index Card (3 x 5 in.)

Statement (5.5 x 8.5 in.)

---

custom

(1)

Executive (7.25 x 10.5 in.) Letter (8.5 x 11 in.) US Folio (8.5 x 13 in.) Legal (8.5 x 14 in.)

Envelopes

#10 Commercial (4.12 x 9.5 in.) Monarch (3.87 x 7.5 in.) DL (110 x 220 mm) C5 (162 x 229 mm) B5 (176 x 250 mm)

custom

custom custom

(1)

Transparencies

A4 (210 x 297 mm) Letter (8.5 x 11 in.)

(1)

Labels

A4 (210 x 297 mm) Letter (8.5 x 11 in.)

(2)

Capacity

= 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.

(1)

550 100 75 500 500

Envelope

Feeder

---

(1)

---

(1)

---

(1)

custom

(1)

---

Standard

Tray

(1)

500-Sheet

Stacker

---

(1)

s4400_351

Paper Tips Page 1 of 3

Phaser 4400 Laser Printer Service Manual 1-15

Custom paper sizes

550-Sheet Tray

(one-sided)

Simplex

Width

Length

Duplex

Width

Length

98 - 216 mm 76 - 216 mm 98 - 178 mm 76 - 216 mm 98 - 216 mm

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. 148 - 356 mm 127 - 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.

(two-sided)

182 - 216 mm

7.16 - 8.5 in. 257 - 356 mm

10.12 - 14.0 in.

Input Output

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

148 - 254 mm

---

127 - 356 mm 148 - 356 mm

Same as Input

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.

s4400_352

Paper Tips Page 2 of 3

1-16 Phaser 4400 Laser Printer Service Manual

Ordering supplies

See

www.xerox.com/officeprinting/4400supplies

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

for information on ordering supplies.

Replaceable Items

Item Part Number

Standard-Capacity Print Cartridge 113R00627

High-Capacity Print Cartridge 113R00628

Maintenance Kit

Contains: a Fuser Cartridge,



1 Transfer Roll, and 9 Feed Rollers.

s4400_353

108R00497

108R00498

for 110 V (60 Hz)

for 220 V (50 Hz)

Paper Tips Page 3 of 3

Phaser 4400 Laser Printer Service Manual 1-17

Functional Specifications

Characteristic Specification

Printing process Recording System - Electro-photographic system (roller charging,

Resolution / Addressability

Operating Modes Ready Mode: Ready to receive data.

Continuous Operating Printing Speed

Fuser Configuration Temperature

First Print Out (Engine speed only)

Warm-up time From a cold start (22° C / 71.6° F ambient temperature) to READY

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

600/1200 dots per inch (dpi), switchable at full engine speed.

Power Saver Mode: entered after a user-specified period of Print Engine inactivity since completion of the last print to minimize energy consumption.

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

Low - Medium setting High - Extra High setting

Range: 194-209°C/ Range: 197-212°C/

381-408°F 387-414°F

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

TO PRINT within 70 seconds.

1-18 Phaser 4400 Laser Printer Service Manual

Electrical 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.

Environmental Specifications

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

Storage environment without a packed Print Cartridge

Heat Emission Maximum - 2730 BTU; Average - 1603; 102 (sleep mode)

Acoustic Noise (MPT closed; options are Duplex Unit, two additional feeders, Envelope Feeder, Stacker)

Dust Emission No more than 0.075 mg/m3 concentration.

Ozone Emission No more than 0.02 mg/m3 concentration, measured in accordance

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

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

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))

with BAM Standard.

Phaser 4400 Laser Printer Service Manual 1-19

1-20 Phaser 4400 Laser Printer Service Manual

Error Messages and Codes

Section Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Service Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Service Technician Cautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Voltage Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Using Fault History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

Entering Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Service Diagnostics Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Using the Front Panel with Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Engine Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Engine NVRAM Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Printer Error Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

Index of Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Error Message Summaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Image Processor POST Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58

Fault Reporting Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

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 INFO key. 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.

Phaser 4400 Laser Printer Service Manual 2-1

Service Flowchart

The Service Flowchart outlines one possible approach to troubleshooting and repair of the printer. The Service Flowchart is an overview of the path a service technician could

take, using this technical manual, to service the printer and options.

If you choose not to use the Service Flowchart, it is recommended that you start at the appropriate troubleshooting table and proceed from there.

Step 1: Identify the Problem:

1. Verify the reported problem does exist.

2. Check for any error codes and write them down.

3. Print Test Prints.

4. Make note of any print-quality problems in the Test Prints.

5. Make note of any mechanical or electrical abnormalities present.

6. Make note of any unusual noise or smell coming from the printer.

7. Print a Usage Profile Report, if the printer is able to print.

8. View the fault history under the Service Tools Menu

9. Verify the AC input power supply is within proper specifications.

Step 2: Inspect and Clean the Printer:

1. Switch OFF printer power.

2. Disconnect the AC power cord from the wall outlet.

3. Verify the power cord is free from damage or short circuit and is connected properly.

4. Remove the Print Cartridge and protect it from light.

5. Inspect the printer interior and remove any foreign matter such as paper clips, staples, pieces of paper, dust or toner.

6. Clean the printer interior with a lint-free cloth, dampened slightly with cold water and mild detergent.

■ Do not use solvents or chemical cleaners to clean the printer interior.

■ Do not use any type of oil or lubricant on printer parts.

■ Use only an approved toner vacuum.

7. Clean all rubber rollers with a lint-free cloth, dampened slightly with cold water and mild detergent.

8. Inspect the interior of the printer for damaged wires, loose connections, toner leakage, and damaged or obviously worn parts.

9. If a Print Cartridge appears obviously damaged, replace with a new one.

Step 3: Find the Cause of the Problem:

1. Use the Print Engine Error Messages table (page 2-11) or POST Error Code table (page 2-58) to find the cause of the problem.

2. Use Diagnostics to check printer and optional components.

3. Use the Wiring Diagrams and Plug/Jack Locator to locate test points.

4. Take voltage readings at various test points as instructed in the appropriate troubleshooting procedure.

5. Use the Engine Logic Board Test Print on page 3-49, to isolate print capability problems between the print engine the Image Processor Board.

Step 4: Correct the Problem:

1. Use the Parts List to locate a part number

2. Use the Removal and Replacement Procedures to replace the part.

Step 5: Final Checkout:

1. Test the printer to be sure you have corrected the initial problem and there are no additional problems present.

2-2 Phaser 4400 Laser Printer Service Manual

Service Technician Cautionary Statements

■ Always turn off the printer and remove the AC power cord, unless instructed

to do otherwise in a procedure. This is particularly important when checking continuity between wiring.

■ If the printer is kept ON, never touch the conductive parts.

■ Wear an electrostatic discharge wrist strap to help prevent damage to the

sensitive electronics on the printer circuit boards.

■ Wait at least 5 minutes after you have switched OFF the printer power for

the Fuser to cool before you work on or around the Fuser.

■ If checking a specific part with the covers removed and the interlocks, safety

and power switches ON, laser beams may be irradiated from the Laser Unit causing a health hazard. Observe proper precautions at all times.

■ When using service diagnostics to turn motors, drives and/or gears, never

touch or interrupt the moving parts as damage to the printer will result.

Procedures

Using the Troubleshooting Procedures

1. Each Step in a Troubleshooting Procedure instructs you to perform a certain action

or procedure. The steps are to be followed sequentially in the order given until the problem is fixed or resolved.

2. The Actions and Questions box contains additional information and/or additional

procedures you must follow to isolate the problem.

3. When a procedure instructs you test a component using service diagnostics, see

Service Diagnostics on page 2-7 for the detailed steps and functions for testing

parts of the printer.

4. The action is followed by a question. If your response to the question is “Ye s” ,

then follow the instructions for a “Ye s ” reply. If your response to the question is “No”, then follow the instructions for a “No” reply.

5. Troubleshooting Procedures may ask you to take voltage readings or test for

continuity at certain test points within the printer. For detailed diagrams, refer to the section Wiring Data on page 9-1 for complete information on test point locations and signal names.

6. Troubleshooting Procedures often ask you to replace a printer component. The

section FRU Disassembly on page 6-1 provides detailed steps for removing and replacing all major parts of the printer. The section Parts Lists on page 7-1 details the location, quantity and part number for all spared parts of the printer.

Phaser 4400 Laser Printer Service Manual 2-3

General Notes on Troubleshooting

1. Unless indicated otherwise, the instruction “switch ON printer main power” means

for you to switch ON printer power and let the printer proceed through POST.

2. When instructed to take voltage, continuity or resistance readings on wiring

harness, proceed as follows: check P/J 232–1 to P/J 210–5 by placing the red probe (+) of your meter on pin 1 of P/J 232, and place the black probe (–) of your meter on pin 5 of P/J 210.

3. When you are instructed to take voltage readings between “P/J 232  P/J 210”

(without specified pin numbers), check all pins. Refer to the section Wiring Data on page 9-1 for the location of all wiring harnesses and pins.

4. When you are instructed to take a voltage reading, the black probe (–) is generally

connected to a pin that is either RTN (Return) or SG (Signal Ground). You can substitute any RTN pin or test point in the printer, and you can use FG (frame ground) in place of any SG pin or test point.

5. Unless a troubleshooting procedure instructs otherwise; before measuring voltages

make sure the printer is switched ON, the Imaging Unit and the paper trays are in place, and the interlock switches are actuated.

6. All voltage values given in the troubleshooting procedures are approximate values.

The main purpose of voltage readings is to determine whether or not a component is receiving the correct voltage value from the power supply and if gating (a voltage drop) occurs during component actuation. Gating signals may be nothing more than a pulse, resulting in a momentary drop in voltage that may be difficult or impossible to read on the average multi-meter.

7. When a Troubleshooting Procedure instructs you to replace a non-spared

component and that component is part of a parent assembly, you should replace the entire parent assembly.

Voltage 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.

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

2-4 Phaser 4400 Laser Printer Service Manual

Using Fault History

The printer keeps a record of engine errors and jams. You can access Fault History for either engine errors or jams in one of three ways:

■ View the Fault History at the Front Panel.

■ Print the printer’s Usage Profile.

■ View or print the Usage Profile from the printer’s web page, if the printer is

connected to a network.

The errors are presented as a series of one- or two-digit numeric codes. Use the tables in “Interpreting Fault History” to decipher the codes.

When an error first occurs, record the error message and code, then cycle power to the printer to see if the error recurs.

Accessing Fault History

1. View the printer’s fault history on the front panel.

a. Enter Menus, then select Support Menu | Service Tools

Menu | Fault History

b. Select

Engine Errors or Jam Errors to display the errors.

2. Print (if possible) the Usage Profile from the printer’s front panel Support

. Fault history information for Engine Errors and Jams is detailed in this

report log.

3. If the printer is connected to a network and has a TCP/IP address, view the

printer’s web page using a web browser.

a. Open a web browser.

b. Enter the printer’s IP address as the URL. c. Select the “Jobs” tab and click the Usage Profile link. You can then

click a link to view or to print the Usage Profile.

Phaser 4400 Laser Printer Service Manual 2-5

Interpreting Fault History Error Codes

The following tables provide a cross-reference of the numeric fault history codes to the Diagnostic Message and code found in Printer Error Messages on page 2-11. These numeric codes are displayed on the Front Panel for both Engine Errors and Jams; in the Usage Profile, the numeric codes are used only in the Engine Error Log (Item 262).

Fault History Codes for Engine Errors

Fault History Code

0 Fan Failure (U5) 6 Tray 2/3 Failure (E11)

1 Fuser Failure (U4) 7 Tray 1 Failure (C3)

2 Motor Failure (U1) 8 Tray 2 Failure (C3)

3 IOT NVM Failure (U6) 9 Tray 3 Failure (C3)

4 Stacker Failure (E9) 10 Tray 2 Failure (E11)

5 Laser failure (U2) — —

Error Fault

History Code

Error

Fault History Codes for Jams

Fault History Code

1 E7-1 12 E2-12

2 E7-2 13 E2-03

3 E7-3 14 E2-13

4 E4-0 15 E2-0E

Jam Code Fault

History Code

Jam Code

5 E4-2 16 E2-1E

6 E4-3 17 E6-1

7 E2-0M 18 E6-2

8 E2-1M 19 PSE-1

9 E2-01 20 E3-1

10 E2-11 21 E3-2

11 E2-02 22 E7-0

2-6 Phaser 4400 Laser Printer Service Manual

Service Diagnostics

The printer’s Service Diagnostics provide the ability to:

■ Print the Service Diagnostics Menu Map.

■ Check the current print engine status.

■ Start the Engine Test Print after selecting the print quantity, the source tray,

output tray, and simplex or duplex printing.

■ Test the functionality of printer motors and fans, solenoids, and clutches.

■ Test some portions of drive trains by engaging combinations of motors and

clutches or solenoids.

■ Test the functionality of sensors, switches, and options by manually toggling

each sensor or installing an option.

■ Perform NVRAM adjustments essential to the performance of the printer.

■ Check eight different print engine components.

■ Reset the PS NVRAM locations to factory defaults (see Resetting NVRAM

on page 4-7).

Entering Service Diagnostics

To enter Service Diagnostics:

While turning on power, press and hold Back + Info until the message “Entering Service Diagnostics” appears on the display, then release the keys. The Service Diagnostics Menu appears.

The Service Diagnostic menu has the following selections:

General Status — Provides current print engine status.

Engine Test Print — Starts the test print.

Motors/Fans Tests — Tests the functionality of the printer Motors/Fan.

Main Motor + Clutches/Sol Tests — Tests the functionality of the main

motor plus clutches or Solenoid at the same time.

Sensor Tests — Tests the functionality of sensors, switches, or the presence of

options by manually toggling each sensor or installing an option. Some of the sensor tests require cheating the front and/or rear door interlocks.

Note: The Service Diagnostics Sensor Tests do not include a check

of the Tray Stack Height Sensor. Refer to the Stack Height

Sensor Checkout on page 3-23.

Solenoid Tests — Tests the functionality of printer solenoids.

Clutch Tests — Tests the functionality of printer clutches.

Engine NVRAM Adjustments — Perform NVRAM adjustments essential to

the performance of the printer.

Phaser 4400 Laser Printer Service Manual 2-7

Component Checks — Tests print engine component functions.

NVRAM Access — Lets you reset the PS NVRAM locations to factory defaults.

Exit — Reboots the Printer out of Diagnostics.

Service Diagnostics Menu Map

The Service Diagnostics Menu Map lists the tests available for testing print engine parts and functions while diagnosing printer problems. When you enter Service Diagnostics, the menu items shown in bold type appear on the front panel. When you select one of these items, the list of individual tests appear.

Print Service Menu Map:

General Status:

Engine ROM Version Engine Print Counter Engine Configuration Print Resolution Read Fuser Temperature Read Fuser Set Temperature

Engine Test Print: Starts the test print. Print Test pattern Input tray Output tray Duplex Print Quantity

Motors/Fan Test:

Duplex Motor High Duplex Motor Low Exit Motor Forward Exit Motor Reverse High Exit Motor Reverse Low Main Motor Fan Motor High Speed Laser Scan Motor Stacker Motor Stacker Offset Motor

Main Motor + Clutch/Sol Tests: * Runs main drive motor with each individual clutch and MPT solenoid.

Sensor Tests:

manually toggling each sensor or installing an option. Front Cover Switch Rear Cover Switch

Paper Tray Size Read (display paper size, for trays) Print Cartridge Switch Toner Sensor Registration Sensor Exit Sensor (Fuser) Duplex Sensor Stacker Sensor Stacker Full Sensor Output Tray Full Sensor (Printer) Tray 1 Low Paper Sensor Tray 2 L Tray 3 Low Paper Sensor Tray 1 No Paper Sensor Tray 2 No Paper Sensor Tray 3 No Paper Sensor MPT No Paper Sensor Envelope Feeder No Paper Sensor Envelope Feeder Presence Duplex Unit Presence Stacker Unit Presence

Provides current print engine status.

Test the functionality for motors/fan.

Tests the functionality of sensors/switches/options by

ow Paper Sensor

Prints this page

Solenoid Tests:

*MPT Solenoid Stacker Direction Solenoid

Clutch tests:

*Registration Clutch *Tray 1 Feed Clutch *Tray 2 Feed Clutch *Tray 3 Feed Clutch *Tray 1 Turn Roll Clutch

*Tray 2 Turn Roll Clutch *Tray 3 Turn Roll Clutch *Envelope Feeder Clutch

Engine NVRAM Adjustments:

the performance of the printer. Laser Power Setting

MPT Paper Size Adjustment

Envelope Paper Size Adjustment

Tray 1 Process Direction

Tray 2 Process Direction Tray 3 Process Direction Envelope Feeder Process Direction MPT Process Direction Tray 1 Scan Direction Tray 2 Scan Direction Tray 3 Scan Direction Envelope Feeder Scan Direction MPT Scan Direction Duplex Process Direction Duplex Scan Direction

Component Checks: Laser Diode

Detack Saw Output Transfer Roll + Transfer Roll ñ

Developer Bias AC Developer Bias DC Charge Roll AC Charge Roll DC

NVRAM Access: This menu lets you reset the PS NVRAM locations to factory defaults. PostScript NVRAM Reset

Exit: For Service Use Only:

The Service menu functions are to be used by Xerox service personnel and authorized service providers. The p improper use of the built-in service tests.

Test the functionality of printer solenoids

Test the functionality of printer clutches.

Reboots Printer out of Diagnostics.

Perform NVRAM adjustments essential to

rinter can be damaged by

2-8 Phaser 4400 Laser Printer Service Manual

Using the Front Panel with Service Diagnostics

The keys on the Front Panel provide the user interface for Service Diagnostics. The keys and their functions are shown in Front Panel Configuration on page 1-8. After you enter Service Diagnostics, the Up and Down keys allow you to move or scroll the highlight up and down through a menu. When you have highlighted the item you want to select, press OK to enter the selection.

When you are selecting a page quantity in the Engine Test Print menu use the OK key to move the highlight to the right. then use the Up or Down key to change the value of the selected digit. when you have entered the desired quantity, use the Back key to enter the selection.

Note: If you moved past the digit you want to change, keep pressing

the OK key until the highlight wraps to the desired digit.

In most of the Service Diagnostics menus, use the Back key to exit a menu to the level just above. In most cases, scrolling to the end of a menu and selecting Exit takes you back to the Service Diagnostics Main Menu.

When you select Read Fuser Temperature from the General Status menu, the temperature is presented in hex values. The following table lists the temperatures that correspond to the hex values displayed.

Fuser Temperature Cross Reference Table

Hex value Tem p e ra t u re (°C / °F) Hex value Te m pe r a ture ( °C / °F)

EE 0°C / 32°F CA 140°C / 284F

FE 10°C / 50°F C6 145°C / 293°F

FD 20°C / 68°F C1 150°C / 302°F

FC 30°C / 86°F BD 155°C / 311°F

FB 40°C / 104°F B8 160°C / 320°F

F9 50°C / 122°F B3 165°C / 329°F

F7 60°C / 140°F AE 170°C / 338°F

F4 70°C / 158°F A9 175°C / 347°F

F0 80°C / 176°F A4 180°C / 356°F

EC 90°C / 194°F 99 190°C / 374°F

E7 100°C / 212°F 8F 200°C / 392°F

E1 110°C / 230°F 85 210°C / 410°F

DA 120°C / 248°F 7C 220°C / 428°F

D3 130°C / 266°F 72 230°C / 446°F

Phaser 4400 Laser Printer Service Manual 2-9

Engine Test Print

The Engine Test Print test pattern (shown on page 4-4) is stored in the Engine Logic Board and is accessible through Service Diagnostics. You can use the Engine Test Print to identify, repair, and validate the operability of printer xerographics and paper handling from all paper sources, options, and output destinations. When you select Engine Test Print from the main Service Diagnostics menu, the following selections are available:

Print Test Pattern — Starts the print

Input Tray — Allows you to select the paper source

Output Tray — Allows you to select the test print destination

Duplex — Turns duplexing on or off if the Duplex Unit is installed

Print Quantity — Allows you to select the number of test prints to run

Error and Jam Recovery

If the printer encounters a problem while printing the Engine Test Print, it halts printing and displays an error message on the Front Panel. Refer to the Diagnostic Messages in the Print Engine Error Messages table that follows. (The Diagnostic Messages also appear as secondary headings in the Troubleshooting Procedures.)

Printing resumes after the problem has been fixed.

Engine NVRAM Default Settings

The following table lists the defaults for each of the Engine NVRAM Adjustments except the paper size adjustments, which have no default settings.

NVRAM Default Table

Engine NVRAM Adjustment

Laser Power 10 0 - 15 Tray 2 Scan Direction 3 0 - 8

Tray 1 Process Direction

Tray 2 Process Direction

Tray 3 Process Direction

Envelope Process Direction

MPT Process Direction

Tray 1 Scan Direction

Default Value

8 0 - 15 Tray 3 Scan Direction 2 0 - 8

8 0 - 15 Envelope Scan Direction 4 0 - 8

8 0 - 15 MPT Scan Direction 6 0 - 8

8 0 - 15 Duplex Process

8 0 - 15 Duplex Scan Direction 4 0 - 8

4 0 - 8

Range Engine NVRAM

Adjustments

Direction

Default Value

8 0 - 15

Range

2-10 Phaser 4400 Laser Printer Service Manual

Printer Error Messages

Index of Errors

Front Panel Message Page

Jam Errors

Jam at Tray [#]. Open Tray [#] and Front Cover. Code: Jam E2-## 2-18

Jam at Envelope Feeder; Remove Feeder and Open Front Cover.

Code: Jam E2-#E

Jam at MPT; Open Front Cover to Clear. Code: Jam E2-0M

Code: Jam E2-1M

Jam at Front; Open Front Cover to Clear. Code: Jam E3-# 2-23

Jam At Exit; Open Rear Cover To Clear. Code: Jam E4-0

Code: Jam E4-2 Code: Jam E4-3

Jam at Stacker; Open Both Rear Covers to Clear. Code: Jam E6-# 2-27

Jam at Front/Rear; Open Front/Rear Cover to Clear. Code: Jam E7-1

Code: Jam E7-2 Code: Jam E7-3

Paper Size Jam; Check Size and Open Rear Cover to Clear. (PSE-1)

Code: Jam PSE-1

Door and Cover Errors

Close Front Cover/Close Rear Cover. 2-31

Consumable Errors

Install or Reseat Print Cartridge. 2-33

Replace Print Cartridge. 2-34

Toner is Low. 2-35

Maintenance Kit is Near End of Life. 2-36

Printer Option Errors

Install or Reseat the Duplex Unit. Code: E9-1 2-36

Stacker Failure. Code: E9-2 2-37

Install or Reseat the Envelope Feeder. Code: E9-E 2-37

Tray and Media Errors

Standard Output Tray is Full. Unload Paper. 2-38

Tray [#] Failure. Open and Close Tray [#]. C3-[#]E 2-43

Tray [#] Paper is Low. 2-39

Tray 2 (or Tray 3) Paper is Low. 2-40

Load MPT with [paper size] [paper type]. 2-51

No Paper in Tray [#]. 2-41

Media Mismatch Errors

Load Tray [#] with [paper size] [paper type]. 2-42

Front Panel Fatal Error Messages and Codes

Tray 2 or 3 Failure. Code: E11 2-52

Main Motor Failure. Code: U1 2-45

Laser Unit Failure. Code: U2 2-48

Fuser Failure. Code: U4 2-49

2-21

2-22

2-25

2-29

2-30

Phaser 4400 Laser Printer Service Manual 2-11

Index of Errors (cont'd.)

Front Panel Message Page

Fan Failure; Power Off Now. Code: U5 2-49

Engine Logic Board NVRAM Failure. Code: U6 2-50

Image Processor POST Error Codes 2-58

Error Message Summaries

Note: The messages listed in the “Diagnostic Message” column

appear only in Service Diagnostics while printing Engine Test Prints. The code numbers in these messages also appear as part of the Help information displayed when you press i.

Front Panel Message

Jam At Tray [#]; Open Tray [#] and Front Cover to Clear.

Press i.

Jam At Envelope Feeder; Remove Feeder and Open Front Cover to Clear.

Press i.

Jam At MPT; Open Front Cover To Clear.

Press i.

Diagnostic

Error Description Troubleshooting

Message

E2-01: Feed Jam E2-02 E2-03

E2-11: Feed Jam E2-12 E2-13

E2-0E: Feed Jam Paper arrives at

E2-1E: Feed Jam Paper does not

E2-0M: Feed Jam Paper arrives at

E2-1M: Feed Jam Paper does not

Paper arrives at Registration Sensor too early.

Paper does not arrive at Registration Sensor position within the specified time.

Registration Sensor too early.

arrive at Registration Sensor position within the specified time.

Registration Sensor too early.

arrive at REG Sensor position within the specified time.

Procedure

Open Tray [#].

Open Front Cover.

Clear Paper Path.

Go to Jam at Tray [#]. Open

Tray [#] and Front Cover. on page 2-18.

Remove Envelope Feeder.

Open Front Cover.

Clear Paper Path.

Go to Jam at Envelope

Feeder; Remove Feeder and Open Front Cover. on

page 2-21.

Open Front Cover and remove paper.

Go to Jam at MPT; Open

Front Cover to Clear. on

page 2-22.

2-12 Phaser 4400 Laser Printer Service Manual

Error Message Summaries (cont'd.)

Note: The messages listed in the “Diagnostic Message” column

appear only in Service Diagnostics while printing Engine Test Prints. The code numbers in these messages also appear as part of the Help information displayed when you press i.

Front Panel Message

Jam at Front; Open Front Cover to Clear.

Press i.

Jam At Exit; Open Rear Cover To Clear.

Press i.

Jam At Stacker; Open Both Rear Covers to Clear.

Press i.

Diagnostic

Error Description Troubleshooting

Message

E3-1: Registration Jam

E3-2: Registration Jam

E4-0: Exit Jam Paper leaves Exit

E4-2: Exit Jam 1. Paper late off Exit

E4-3: Exit Jam Custom Paper late

E6-1: Stacker Jam 1. Paper late to

E6-2: Stacker Jam 1. Paper late off

Paper Late to Fuser sensor after arrival at Registration Sensor.

Exit Sensor did not actuate within time after the Registration clutch is actuated.

1. Registration Sensor did not deactuate within time after actuation of Registration sensor.

2. Registration Sensor is actuated at power-on.

Sensor early.

Sensor.

2. Exit Sensor on at power-on.

off Exit Sensor, exceeding the specified time from Registration Sensor.

Stacker Sensor.

2. Stacker Sensor on at power-on.

Procedure

Open Front Cover.

Remove Print Cartridge.

Clear Paper Path.

Go to Jam at Front; Open

Front Cover to Clear. on page 2-23.

Open Rear Cover.

Clear Paper Path.

Go to Jam At Exit; Open

Rear Cover To Clear. on page 2-25.

Open Rear Cover.

Clear Paper Path.

Change Paper Setting in Custom Mode to correct size.

Go to Jam At Exit; Open

Rear Cover To Clear. on page 2-25.

Open Stacker Rear Door.

Clear Paper Path.

Open Printer Rear Cover. Clear Paper Path.

Go to Jam at Stacker; Open

Both Rear Covers to Clear. on page 2-27.

Phaser 4400 Laser Printer Service Manual 2-13

Error Message Summaries (cont'd.)

Note: The messages listed in the “Diagnostic Message” column

appear only in Service Diagnostics while printing Engine Test Prints. The code numbers in these messages also appear as part of the Help information displayed when you press i.

Front Panel Message

Jam At Front; Open Front Cover To Clear

Press i.

Jam At Rear; Open Rear Cover To Clear.

Press i.

Tray [#] Failure.

Open and Close Tray [#].

Press i.

No (Load) Paper In Envelope Feeder

Press i.

Load MPT MPT Paper Empty MPT is out of paper. Load paper into MPT.

Stacker Is Full, Unload Paper.

Press i.

Standard Output Tray is Full, Unload Paper.

Press i.

Diagnostic

Error Description Troubleshooting

Message

E7-0: Duplex Jam Paper arrives at

E7-1: Duplex Jam Paper late to Duplex

E7-2: Duplex Jam 1. Paper late off

E7-3: Duplex Jam Paper late to

C3-#E Tray [#] Not In ■ Tray [#] is not

Envelope Feeder Empty

Stacker Output Tray Full

Output Tray Full Top Tray is declared

Registration Sensor early from Duplex Sensor.

Sensor.

Duplex Sensor.

2. Duplex Sensor on at power-up.

Registration Sensor from Duplex Sensor.

detected

■ Tray motor failure

■ Harness problem

■ Stack height sensor

failure

Envelope Feeder is out of paper.

Several prints are delivered to the top tray after the Stacker Full Stack Sensor is actuated.

full when several prints are delivered to the top tray after the Full Stack Sensor is actuated.

Procedure

Open front cover.

Remove print cartridge.

Clear paper path.

Go to Jam at Front/Rear;

Open Front/Rear Cover to Clear. on page 2-29.

Open Rear Cover.

Remove Duplex Unit.

Clear paper path.

Go to Jam at Front/Rear;

Open Front/Rear Cover to Clear. on page 2-29.

Inspect and repair Tray [#].

Tray [#] Failure. Open and Close Tray [#]. on

page 2-43.

Load Paper into Envelope Feeder.

Go to Load Envelope

Feeder with [paper size] [paper type]. on page 2-55.

Go to Load MPT with

[paper size] [paper type]. on page 2-51.

Empty Stacker Tray.

Go to Stacker is Full,

Unload Paper. on

page 2-54.

Empty Top Tray.

Go to Standard Output Tray

is Full. Unload Paper. on

page 2-38.

2-14 Phaser 4400 Laser Printer Service Manual

Error Message Summaries (cont'd.)

Note: The messages listed in the “Diagnostic Message” column

appear only in Service Diagnostics while printing Engine Test Prints. The code numbers in these messages also appear as part of the Help information displayed when you press i.

Front Panel Message

No Paper In Tray [#]

Press i.

Load Tray [#] with [paper size] [paper type].

Close Front Cover

Close Rear Cover.

Press i.

Install or Reseat The Duplex Unit.

Press i.

Stacker Failure.

Press i.

Install or Reseat the Envelope Feeder

Press i.

Tray 2 or 3 Failure

Press i.

Tray 2 Failure

Press i.

Diagnostic

Error Description Troubleshooting

Message

Tray [#] Empty Tray [#] is out of

PSE-1: Paper Size Error

Close Front Cover/Close Rear Cover

E9-1: Duplex Unit Fail.

E9-2: Stacker Unit Fail

E9-E: Envelope Feeder Fail/Reinstall

E11: Tray 2/3 Fail Either Tray 2 or Tray

paper.

Paper Size Error. Load correct size paper in

1. Front cover

interlock is open.

2. Rear cover

interlock is open.

Duplex module removed while power is on.

Stacker removed while power is on.

Envelope feeder module removed while power-on.

3 was disconnected after power-on.

Procedure

Load paper into Tray [#].

Go to No Paper in Tray [#].

on page 2-41.

tray.

Go to Load Tray [#] with

[paper size] [paper type]. on

page 2-42

Close Front Cover.

Close Rear Cover.

Go to Close Front

Cover/Close Rear Cover.

on page 2-31.

Reinstall Duplex Module.

Go to Install or Reseat the

Duplex Unit. on page 2-36.

Reinstall Stacker.

Go to Stacker Failure. on page 2-37.

Reinstall Envelope Feeder.

Go to Install or Reseat the

Envelope Feeder. on

page 2-37.

Reinstall Feeder 2/3.

Go to Tray 2 or 3 Failure. on page 2-52.

Phaser 4400 Laser Printer Service Manual 2-15

Error Message Summaries (cont'd.)

Note: The messages listed in the “Diagnostic Message” column

appear only in Service Diagnostics while printing Engine Test Prints. The code numbers in these messages also appear as part of the Help information displayed when you press i.

Front Panel Message

Paper Size Jam; Check Size and Open Rear Cover To Clear.

Press i.

Install Or Reseat Print Cartridge

Press i.

Toner Is Low.

Press i.

Main Motor Failure

Press i.

Laser Unit Failure

Press i.

Diagnostic

Error Description Troubleshooting

Message

PSE-1: Paper Size Error

J3 Missing Print Cartridge.

J5 Toner Low. Toner Low is

U1 Motor Fail/Power Off

U2 Laser Fail/Power Off

There is a conflict between the size of the paper, which is detected by the Size Switches, and the length of paper the printer detects by the length of time the Registration Sensor is actuated.

1. Print Cartridge is not installed.

2. The installed Print Cartridge is not the correct one.

detected after 10 prints while Toner Sensor is on.

Main Motor speed is less than specified RPM after 1.3 seconds.

1.Transmitting /BD signal is longer than specified value for 10 sec. + t1.

2. The laser power does not reach the specified value.

3. Laser signal intervals become longer than the Fail time interval after Laser warm-up is completed.

Procedure

Correct the mismatch.

Open Rear Cover.

Go to Paper Size Jam;

Check Size and Open Rear Cover to Clear. (PSE-1) on

page 2-30.

Install the Print Cartridge, or replace with the correct Print Cartridge.

Go to Install or Reseat Print

Cartridge. on page 2-33.

Go to Toner is Low. on page 2-35.

Power Off and On.

Go to Main Motor Failure. on page 2-45.

Power Off and On.

Go to Laser Unit Failure. on page 2-48.

2-16 Phaser 4400 Laser Printer Service Manual

Error Message Summaries (cont'd.)

Note: The messages listed in the “Diagnostic Message” column

appear only in Service Diagnostics while printing Engine Test Prints. The code numbers in these messages also appear as part of the Help information displayed when you press i.

Front Panel Message

Fuser Failure

Press i.

Fan Failure

Power Off Now

Press i.

Engine Logic Board NVRAM Failure.

Press i.

Diagnostic Message

U4 Fuser Fail/Power Off

U5 Fan Fail/Power Off

U6 NVM Fail/Power Off

Error Description Troubleshooting

Procedure

■ Low temperature

trouble/Power off (Fuser temperature drops below the set temperature after the Fuser warm-up is complete).

■ Warm-up

fail/Power off (Fuser warm-up does not complete within 110 seconds).

■ STS Disconnection

fail/Power off (Thermistor circuit is detected to be open).

■ High Temperature

trouble/Power off (Fuser temperature rises above the set temperature).

■ Continuous heat

on/Power off (Heat rod is on for 10 seconds when the Main Drive Motor is stopped, after the Fuser warm-up is completed).

Main Fan has failed. Check the Main Fan.

1. Read error

detected during power-on.

2. Write Error

detected.

Go to Fuser Failure. on page 2-49.

Power Off and On.

Go to Fan Failure; Power

Off Now. on page 2-49.

Power Off and On.

Go to Engine Logic Board

NVRAM Failure. on

page 2-50).

Phaser 4400 Laser Printer Service Manual 2-17

Jam at Tray [#]. Open Tray [#] and Front Cover.

(E2-##: Feed Jam)

E2-0#: Paper arrives early to the Registration Sensor or is on the sensor at power-on.

E2-1#: Paper arrives late to the Registration Sensor.

Paper Jam/Misfeed Troubleshooting Procedure

Step Actions and Questions Yes No

1 Check the paper in all trays. Check for curled,

damaged, or damp paper and for paper that is out of specification.

Is the paper in good condition and does it meet specification?

2 Check all paper paths for contamination, paper, or

other obstructions.

Are all paper paths clean and free of obstructions?

3 1. Enter Service Diagnostics and select Test Print.

2. Run five prints from every paper tray.

Does the problem appear when printing from Tray 2 or 3?

4 1. Remove Tray 1 from the printer.

2. Check the Nudger Roller, Feed Roller, and Retard Roller for contamination and wear.

Are all rolls clean and in good condition?

5 1. Reinsert Tray 1 into the printer.

2. From the rear of the printer, watch the Tray 1 Bottom Plate.

Is the Bottom Plate raised fully and evenly?

6 From the rear of the printer, watch the paper feed as

you print a test print from Tray 1.

Do the Nudger Roller and Feed Roller rotate?

Is paper fed from the tray to the Turn Roller Assembly?

Go to step 2. Replace with

fresh dry paper that is within specifications.

Go to step 3. Remove con-

tamination or obstructions.

Go to step 9. Go to step 4.

Go to step 5. Clean or

replace the Nudger, Feed or Retard Roller as necessary (RRP 3.8 on

page 6-36/

RRP 2.1 on

page 6-18).

Go to step 6. Go to Tray

Motor Assembly Checkout on

page 3-26.

Go to step 7. Go to Tray 1

Feed Clutch

on page 3-29.

Go to step 8. Replace the

Retard, Nudger, and Feed Rollers (RRP 2.1 on

page 6-18 and

RRP 3.8 on

page 6-36).

2-18 Phaser 4400 Laser Printer Service Manual

Paper Jam/Misfeed Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

Does the Turn Roller Assembly move the paper to the Registration Sensor?

9 1. Remove Tray 1.

2. Check the paper chute at the front of the tray (the chute guides paper from Tray 2 to the Tray 1 turn rollers). Check for contamination, paper, or other obstructions.

Go to

Registration Sensor on

page 3-20.

Go to step

10.

Is the chute clean and free of obstructions?

Do the jams occur when feeding from Tray 3.

11 1. Remove Tray 2 and place the tray in Feeder 1.

2. Place Tray 1 in Feeder 2.

3. Enter Service Diagnostics and select Test Print.

4. Run 20 to 25 test prints from Tray 2.

Did all prints complete successfully?

12 1. Remove the tray currently in Feeder 2.

2. Check the Nudger and Feed Rollers in Feeder 2 for contamination and wear.

Go to step

14.

The paper tray currently in Feeder 1 appears to be defective. Go to step

18.

Go to step

13.

Are the Feed Rollers clean and in good condition?

13 Check the Tray 2 Turn Roller Assembly for

obstructions, contamination, or wear.

Are the Turn Rolls clean and in good condition?

14 Remove Tray 1 and Tray 2. Check the paper chute at

the front of both trays (the chute guides paper from Tray 3 to the Tray 2 turn rolls and from Tray 2 to the Tray 1 turn rollers). Check for contamination, paper, or other obstructions.

Replace the Feeder PWB (RRP 11.9 on

page 6-128).

If the problem persists, replace the Size PWB (RRP 11.19 on

page 6-139),

then the Engine Logic Board (RRP

9.3 on

page 6-89).

Go to step

15.

Is the chute clean and free of obstructions?

Go to Turn

Roller Clutch Assembly on

page 3-28.

Remove obstructions and clean chute. Replace paper tray if necessary (PL 2.1 on page 7-6).

Go to step 11.

Go to step 12.

Replace the Feed Rollers (RRP 11.11 on

page 6-130).

Remove the obstruction; clean, or replace the Turn Roller Assembly (RRP 11.8 on

page 6-127).

Remove obstructions and clean chute. Replace paper tray if necessary (PL 2.1 on page 7-6).

Phaser 4400 Laser Printer Service Manual 2-19

Paper Jam/Misfeed Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

15 1. Replace Tray 2.

2. Remove Tray 3 and place the tray in Feeder 1.

3. Place Tray 1 in Feeder 3.

4. Enter Service Diagnostics and select Test Print.

5. Run 20 to 25 test prints from tray 3.

Did all prints complete successfully?

16 1. Remove the tray currently in Feeder 3.

2. Check the Nudger and Feed Rolls in Feeder 3 for contamination and wear.

The paper tray currently in Feeder 1 appears to be defective. Go to step

19.

Go to step

17.

Are the Feed Rolls clean and in good condition?

17 Check the Tray 3 Turn Roller Assembly for

obstructions, contamination, or wear.

Go to step

20.

Are the Turn Rolls clean and in good condition?

18 Perform Tray Motor Assembly Checkout on page 3-26

to check the tray motor.

Does it operate correctly?

19 Perform Tray Motor Assembly Checkout on page 3-26

to check the tray motor.

Does it operate correctly?

20 Replace the Feeder PWB (RRP 11.9 on page 6-128). If

the problem persists, replace in this order:

■ Size PWB (RRP 11.19 on page 6-139)

■ Engine Logic Board (RRP 9.3 on page 6-89)

Check the paper tray for contamination, obstructions, broken or deformed parts. Replace the paper tray if necessary (PL 2.1 on

page 7-6).

Check the paper tray for contamination, obstructions, broken or deformed parts. Replace the paper tray if necessary (PL 2.1 on

page 7-6).

Go to step 16.

Replace the Feed Rolls (RRP 11.11 on

page 6-130).

Remove the obstruction, clean, or replace the Turn Roller Assembly (RRP 11.8 on

page 6-127).

Follow the repair advice in the checkout procedure.

2-20 Phaser 4400 Laser Printer Service Manual

Jam at Envelope Feeder; Remove Feeder and Open Front Cover.

(E2-#E: Feed Jam)

E2-0E: Paper arrives at Registration Sensor too early.

E2-1E: Paper does not arrive at Registration Sensor position within a specified time.

Envelope Feeder Jam Troubleshooting Procedure

Step Actions and Questions Ye s No

1 1. Remove all envelopes.

2. Check the Envelope Feeder and Printer for contamination, paper scraps, or other obstructions.

Is the printer and Envelope Feeder clean and free of obstructions?

2 Check the Feed Belts. Check for dirt or contamination

on the top side and the under side of the belt.

Are both sides of the belt clean?

3 1. Enter Service Diagnostics and select Clutch Tests.

2. Scroll to Envelope Feeder and press OK.

Can you hear the clutch energize?

4 1. Press Back.

2. Scroll to Main Motor+Clutch/Sol Tests and press OK.

3. Scroll to Motor+Envelope Feeder.

4. Press OK and watch the Feed Belts and Feed Rollers.

Do all the Feed Belts and Feed Rollers rotate?

5 Ensure the Envelope Feeder is installed properly and is

contacting the printer drive gear.

Is the Envelope Feeder installed correctly?

6 Remove the Envelope Feeder and check the feeder

drive gears.

Are all gears in good condition and operating properly?

Go to step 2. Clean feeder

Go to step 3. Replace the

Go to step 4. Go to

Go to step 7. Go to step 5.

Go to step 6. Reinstall the

Replace the Envelope Feed Clutch (RRP 13.12 on

page 6-168).

If the problem persists, Replace the Envelope Feeder PWB (RRP 13.3 on

page 6-159).

and remove all obstructions.

Feed Belts (RRP 13.17 on

page 6-176).

Envelope Feed Clutch

on page 3-38.

Envelope Feeder correctly.

Replace the gears as necessary (PL 12.2 on

page 7-32).

Phaser 4400 Laser Printer Service Manual 2-21

Envelope Feeder Jam Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

7 Perform Registration Sensor on page 3-20 to check the

Registration Sensor.

Is the Registration Sensor operating correctly?

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Jam at MPT; Open Front Cover to Clear.

(E2-#M: Feed Jam)

E2-0M: Paper arrives at REG sensor early.

E2-1M: Paper arrives at REG sensor late.

Feed Jam Procedure

Step Actions and Questions Yes No

1 1. Switch the printer power OFF.

2. Open the Front Cover.

3. Check the MPT Chute for contamination or obstructions.

Is the MPT free of contamination, paper, or other obstructions?

2 Check the MPT Feed Roller for contamination and

wear.

Is the feed roller clean and in good condition?

3 1. Enter Service Diagnostics and select Solenoid Tests.

2. Scroll to MPT and press OK.

Can you hear the solenoid energize?

4 1. Open the Front Cover and cheat the Front Cover

Interlock.

2. From the Service Diagnostics menu select Motors/Fans Tests and press OK.

3. Scroll to Main Motor and press OK.

Do the MPT drive gears rotate smoothly?

Go to step 2. Clean the

Go to step 3. Replace the

Go to step 4. Go to MPT

Go to step 5. Check, re-

Replace the Registration Sensor (RRP

5.4 on

page 6-61).

MPT and remove the paper or obstruction.

MPT Feed Roller (RRP

4.3 on

page 6-47).

Pick Up Solenoid on page 3-30.

pair, or replace the Drive Gear (PL 5.1 on

page 7-14),

Main Drive Gear Assembly (RRP 8.2 on

page 6-85),

or Main Motor Assembly (RRP 8.1 on

page 6-84)

as necessary.

2-22 Phaser 4400 Laser Printer Service Manual

Feed Jam Procedure (cont'd.)

Step Actions and Questions Yes No

5 1. Scroll to Main Motor + Clutch/Sol Tests and press

OK.

2. Select Main Motor + MPT Sol and press OK.

Do all of the following occur?

■ The Feed Roller Shaft rotates?

■ The Pick-up Cams move and allow the Bottom

Plate to contact the Feed Roller?

■ The Feed Roller Shaft stops after one complete

revolution?

6 1. Check the Registration Sensor (Registration Sensor

on page 3-20).

Is the Registration Sensor good?

Check the Registration Sensor (Registration

Sensor on

page 3-20).

If the problem persists, replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Remove the MPT Chute Assembly (RRP 4.1 on

page 6-44)

and repair or replace components as necessary.

Follow the repair advice in the Registration Sensor check.

Jam at Front; Open Front Cover to Clear.

(E3-#: Registration Jam)

E3-1: Paper is late to the Exit Sensor or paper is late off the Registration Sensor.

E3-2: Registration Sensor is actuated at power-on.

Registration Jam Troubleshooting Procedure

Step Actions and Questions Ye s No

1 1. Switch the printer power OFF.

2. Open the Front Cover and remove the Print Cartridge.

3. Check the printer for contamination, paper scraps, or other obstructions.

Go to step 2. Clean compo-

nents and remove all obstructions.

Is the paper path clean and free of obstructions?

2 1. Open the Rear Cover.

2. Remove the Duplex unit if installed.

3. Open the Fuser Access Cover.

4. Check for contamination, paper scraps, or other obstructions.

Go to step 3. Clean compo-

nents and remove all obstructions.

Is the paper path clean and free of obstructions?

3 1. Remove Fuser.

2. Rotate the Fuser Gear.

Does the Fuser Idler Gear rotate smoothly?

4 Check the paper in all trays.

Is the paper loaded in the paper trays damp, wrinkled, or damaged?

Go to step 4. Replace the

Replace with fresh, dry paper.

Fuser Assembly (RRP 6.2 on

page 6-66).

Go to step 5.

Phaser 4400 Laser Printer Service Manual 2-23

Registration Jam Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

Is the paper size used within specifications?

6 1. Reinstall the Fuser.

2. Close the Rear Cover.

3. Cheat the Front Cover Interlock.

4. Enter Service Diagnostics, select Clutch Tests, and press OK.

5. Select Registration and press OK.

Go to step 6. Replace with

Go to step 7. Go to

Can you hear the Registration Clutch energize?

7 1. Press Back to return to the top Diagnostics menu,

then select Main Motor+Clutch/Sol tests and press OK.

2. Select Motor+Registration and press OK.

Go to step 9. Go to step 8.

Do the Registration Rolls rotate smoothly?

8 Repair or replace as necessary:

■ Registration Rolls (RRP 5.6 on page 6-62)

■ Registration Clutch (RRP 5.5 on page 6-62)

■ Main Drive Gear Assembly (RRP 8.2 on page 6-85)

■ Main Motor Assembly (RRP 8.1 on page 6-84).

9 Perform Registration Sensor on page 3-20 to test the

Registration Sensor.

Go to step

10.

Is the Registration Sensor working correctly?

10 Perform Exit Sensor on page 3-34 to test the Exit

Sensor.

Go to step

11.

Is the Exit Sensor working correctly?

11 1. Enter Service Diagnostics (if necessary).

2. Select Engine Test Print and press OK.

3. Run test prints.

4. When the error code appears, inspect the position of lead edge of the paper.

Go to step

12.

Does the lead edge of the paper pass between the Transfer Roller and the Print Cartridge Drum?

Is the Detack Saw clean and free of contamination?

Go to step

13.

paper meeting size specifications.

Registration Clutch on

page 3-27.

Repair or replace the Registration Sensor as necessary (RRP 5.4 on

page 6-61).

Replace the Fuser Assembly (RRP 6.2 on

page 6-66).

Clean the Registration Rollers.

Clean the Detack Saw or Replace the Transport Chute Assembly (RRP 6.1 on

page 6-65).

2-24 Phaser 4400 Laser Printer Service Manual

Registration Jam Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

13 Inspect paper path between Transport Chute Assembly

and the Fuser Assembly.

Does the paper pass through the Fuser Assembly.

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Replace the Fuser Assembly (RRP 6.2 on

page 6-66).

Jam At Exit; Open Rear Cover To Clear.

(E4-#: Exit Jam)

E4-0: Paper leaves the Exit Sensor early.

E4-2: Paper leaves the Exit Sensor late.

The Exit Sensor is on at power-on.

E4-3: Custom paper late off the Exit Sensor within a specified time from the

Registration Sensor.

Exit Jam Troubleshooting Procedure

Step Actions and Questions Ye s No

1 Check the paper in the paper trays. Ensure that:

■ The paper is installed correctly and the end guide

touches the rear of the paper stack.

■ The paper is within specification.

■ If Custom Mode is used, the settings are correct.

Are all settings correct and is the paper within specification?

2 Check the paper path for contamination, paper, or other

obstructions.

Is the paper path clean and free of obstructions?

3 1. Enter Service Diagnostics and select Engine Test

Print.

2. Print 25 prints from Tray 1.

When the error code is displayed, is there paper on the Exit Sensor?

4 1. Open the Rear Cover and the Fuser Access Cover.

2. Check the Exit Sensor Actuator.

Does the actuator move freely and return to the home position when released?

Go to step 2. Install fresh

paper that is within specification or correct settings.

Go to step 3. Remove

obstructions and clean components as necessary.

Go to step 6. Go to step 4.

Go to step 5. Repair

actuator or replace the Fuser Assembly (RRP 6.2 on

page 6-66).

Phaser 4400 Laser Printer Service Manual 2-25

Exit Jam Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

5 1. Enter Service Diagnostics and select Sensor Tests.

2. Scroll to Exit Sensor (Fuser) and press OK.

3. Open the Fuser Access Cover and use a piece of paper to block and unblock the Exit Sensor.

Does the message on the display alternate

Replace Engine Logic Board (RRP

9.3 on

page 6-89).

between “With Paper” and “Without Paper” as you block and unblock the sensor?

6 Open the Rear Cover and check the Face Up Chute

Assembly for contamination or obstructions.

Go to step 7. Clean or

Is the chute assembly clean and free of obstructions?

7 1. Scroll to Motors/Fans Tests and press OK.

2. Scroll to Exit Motor Forward and press OK.

Go to step 8. Go to Exit

Does the Exit Motor rotate?

Do the Exit Rollers and Pinch Rollers (on the

Go to step 9. Replace the

Rear Cover) rotate smoothly?

9 Check the Fuser Assembly for obstructions or

contamination.

Go to step

10.

Is the Fuser clean and free of obstructions?

10 Check the Transport Chute for contamination or

obstructions.

Is the Transport Chute clean and free of obstructions?

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Go to Exit

Sensor on

page 3-34.

replace the Face Up Chute Assembly as necessary (PL 1.2 on

page 7-4).

Motor on

page 3-35.

Exit Rollers or Exit Chute Assembly as necessary (PL 7.1 on

page 7-18).

Clean or replace the Fuser Assembly (RRP 6.2 on

page 6-66),

as necessary.

Clean or replace the Transport Chute as necessary (RRP 6.1 on

page 6-65).

2-26 Phaser 4400 Laser Printer Service Manual

Jam at Stacker; Open Both Rear Covers to Clear.

(E6-#: Stacker Jam)

E6-1: Paper late to Stacker Sensor.

E6-2: Paper late off Stacker Sensor.

Stacker Jam Troubleshooting Procedure

Step Actions and Questions Ye s No

1 1. Open the printer Rear Cover and the Stacker Rear

Cover.

2. Check for paper or other obstructions in the paper path.

Is the printer free of jammed paper, paper scraps, or other obstructions?

2 1. Enter Service Diagnostics.

2. Select Engine Test Print and press OK

3. Scroll to Print Quantity and press OK.

4. Set the quantity 15 and press Back.

5. Scroll to Output Tray and press OK.

6. Press Down to select Stacker and press OK.

7. Scroll to Print Test Pattern and press OK.

Does the error code reappear?

3 1. Enter Service Diagnostics and select Sensor Tests.

2. Scroll to Stacker Sensor test and press OK.

3. Open the Stacker Rear Cover.

4. Press and release the Stacker Exit Sensor Actuator.

Does the message on the display alternate between “With Paper” and “Without Paper” as you press and release the actuator?

4 1. Remove the Left Interface Cover (RRP 1.1 on

page 6-6), Left Cover (RRP 1.2 on page 6-7), and the

Left Plate (RRP 1.11 on page 6-16).

2. On the Engine Logic Board, check the voltage between P/J35 pin 7 and frame ground as you actuate and deactuate the Stacker Exit Sensor Actuator.

Is the voltage +3.3 VDC when deactuated and

0.0 VDC when actuated?

5 1. Exit Sensor Tests and scroll to Motors/Fans Tests.

2. Scroll to Stacker Motor and press OK. The motor should run for about three seconds.

Does the Stacker Motor run?

Go to step 2. Clear all

Go to step 3. Problem

Go to step 5. Go to step 4.

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Go to step 8. Go to step 6.

jammed paper, paper scraps, and obstructions from the printer and the Stacker.

solved.

Replace the Stacker Exit Sensor (RRP

10.11 on

pa ge 6- 111).

If the problem persists, replace the Sta cker PWB (RRP 10.7 on

page 6-107).

Phaser 4400 Laser Printer Service Manual 2-27

Stacker Jam Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

6 1. Remove the Left Interface Cover (RRP 1.1 on

page 6-6), Left Cover (RRP 1.2 on page 6-7), and the

Left Plate (RRP 1.11 on page 6-16).

2. Enter Service Diagnostics and select Motors/Fans Te st s .

3. Scroll to Stacker Motor.

4. On the Engine Logic Board, measure the voltage between P/J35 pin 6 and frame ground as you press OK.

Go to step 7. Replace the

Does the voltage drop from +3.3 VDC to +0.5 VDC when OK is pressed?

7 1. Switch the printer power OFF.

2. Remove the Stacker from the printer (RRP 10.1 on

page 6-101) and turn the Stacker upside down.

3. Disconnect P/J210 from the Stacker PWB.

4. Check the resistance between pins 1 and 4, pins 1 and 6, pins 2 and 3, and pins 2 and 5 on the disconnected plug.

Replace the Stacker PWB (RRP 10.7 on

page 6-107).

Are all readings 70 ± 10 ohms?

8 1. Open the Stacker Rear Cover.

2. Press OK to run the Stacker Motor.

3. Check the Stacker rollers.

Go to step 9. Repair or

Are the Stacker Rollers rotating smoothly?

9 1. Switch the printer power OFF.

2. Remove the Stacker (RRP 10.1 on page 6-101).

3. Open the printer rear cover and check the movement of the Exit Gate.

Go to step

10.

Does the Exit Gate move freely in both directions when pressed and released?

10 1. Reinstall the Stacker.

Note: Each time the printer’s rear cover or front

cover is opened and closed with power applied, the printer performs a reset. At the completion of the reset, the Exit Gate toggles between fully open and fully closed positions.

2. Open the printer rear cover. Remove the Duplex Unit if installed.

3. Switch the printer power-on.

4. Cheat the Rear Cover Interlock and watch the Exit Gate at the end of reset.

5. Remove then replace the Rear Cover Interlock cheater.

Replace the Stacker PWB (RRP 10.7 on

page 6-107).

If the problem persists, replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Does the Exit Gate toggle at the completion of each reset?

Engine Logic Board (RRP

9.3 on

page 6-89).

Replace the Stacker Motor (RRP

10.8 on

page 6-108).

replace the Stacker Rollers as necessary (RRP 10.14 on

page 6-114/

RRP 10.15 on

page 6-115).

Repair or replace the Exit Gate as necessary (RRP 6.4 on

page 6-69).

Replace the Direction Solenoid (RRP 10.10 on

page 6-110).

If the problem persists, replace the Stacker PWB (RRP 10.7 on

page 6-107).

2-28 Phaser 4400 Laser Printer Service Manual

Jam at Front/Rear; Open Front/Rear Cover to Clear.

(E7-#: Duplex Jam)

E7-0: Paper arrives at the Registration Sensor early from the Duplex Sensor.

E7-1: Paper is late to the Duplex Sensor.

E7-2: Paper is late off the Duplex Sensor.

The Duplex Sensor is on at power-on.

E7-3: Paper is late to the Registration Sensor from the Duplex Sensor.

Duplex Jam Troubleshooting Procedure

Step Actions and Questions Ye s No

1 1. Open the printer and check for paper or other

obstructions in the paper path.

2. Remove the Duplex Unit and check the rear entrance chute to the Paper Handler.

Is the printer free of jammed paper, paper scraps, or other obstructions?

2 Check the Duplex Belt, Rollers, and gears. Check for

contamination, wear, and obstructions.

Are the Duplex rollers, gears, and belt clean and in good condition?

3 1. Reinstall the Duplex Unit and enter Service

Diagnostics.

2. Select Engine Test Print and press OK

3. Scroll to Print Quantity and press OK.

4. Set the quantity to 15 and press Back.

5. Scroll to Duplex and press OK. Set duplex to ON.

6. Scroll to Print Test Pattern and press OK.

Does the error code reappear?

4 1. Select Motors/Fans Tests.

2. Scroll to Duplex Motor High and press OK. The motor should run for about three seconds.

3. Scroll to Duplex Motor Low and press OK. The motor should run for about three seconds.

Can you hear the Duplex Motor run at both speeds?

Go to step 2. Clear all

Go to step 3. Replace

Clear the jam and press Back. Go to step 4.

Go to step 5. Go to step 6.

jammed paper, paper scraps, and obstructions from the printer.

components or Duplex Unit as necessary (RRP 12.1 on

page 6-141).

Problem solved.

Phaser 4400 Laser Printer Service Manual 2-29

Duplex Jam Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

5 1. Select Sensor Tests.

2. Select Duplex Sensor.

3. Open the Rear Cover and use a narrow strip of paper (approximately 1 inch wide) to actuate and deactuate the Duplex Sensor.

Does the message on the display alternate between “With Paper” and “Without Paper” as you press and release the actuator?

6 1. Remove the Duplex Unit, then remove the Duplex

Cover (RRP 12.3 on page 6-143).

2. Disconnect P/J38 from the Duplex PWB.

3. Measure the resistance on the disconnected plug between pin 1 and pin 2; between pin 1 and pin 3; between pin 1 and pin 4; and between pin 1 and pin 5.

Are all four readings between 30 and 37 ohms?

Perform

Registration Sensor on

page 3-20 to test the Registration Sensor.

Replace the Duplex PWB (RRP 12.4 on

page 6-144).

If the problem persists, replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Replace the Duplex Sensor (RRP

12.13 on

page 6-155).

If the problem persists, replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Replace the Duplex Motor Assembly (RRP 12.8 on

page 6-149).

Paper Size Jam; Check Size and Open Rear Cover to Clear. (PSE-1)

(PSE-1: Paper size error)

There is a conflict between the size of the paper detected by the printer, and the length of time the Registration Sensor is actuated.

Paper Size Error Troubleshooting Procedure

Step Actions and Questions Yes No

Does the problem appear when using Tray 1, 2, or 3?

2 1. Verify the size of paper currently in the MPT Tray.

2. Select Menus and press OK, then

3. Select Printer Setup Menu and press OK.

4. Select Tray Setup Menu and press OK.

5. Select MPT Setup Menu and press OK.

6. Select Change Paper Size and press OK.

Does the paper size checked in the MPT Setup Menu match the size actually in the MPT?

2-30 Phaser 4400 Laser Printer Service Manual

Go to step 3. Go to step 2.

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Set MPT size to the size of paper actually installed, then press OK.

Paper Size Error Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

Is the paper size in the problem tray within

Go to step 4. Replace with

printer specifications?

4 Check the side guides and the Paper Stack End Guide

in the problem tray.

Go to step 5. Properly set

Are all guides properly set for the size of paper installed?

5 Check the size cam on the left side of the paper tray

(see the Paper Size Actuators table below).

Go to step 6. Replace the

Are the cams in good condition (not broken) and do they move freely as the paper tray end guide is moved.

6 1. Reinstall the paper tray.

2. Enter Service Diagnostics and select Sensor Tests.

3. Scroll to Paper Tray Size Read and press OK.

4. Select “Tray 1 Size” and press OK.

5. Press “Back” and select another tray size until all installed trays are tested.

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Does the paper size displayed on the Front Panel display match the size of the paper actually loaded in the tray?

Close Front Cover/Close Rear Cover.

paper that meets specifications.

the guides.

paper tray (PL

2.1 on

page 7-6/PL

11. 1 o n

page 7-26).

Replace the Tray Size PWB (RRP 3.13 on

page 6-42/

RRP 11.19 on

page 6-139).

(Close Front Cover/Close Rear Cover)

Close Front/Rear Cover Troubleshooting Procedure

Step Actions and Questions Ye s No

1 1. Open and close the Front Cover.

2. Inspect the movement of the Interlock Switch.

Does the actuator tab on the Front Cover press down on the Interlock Switch lever?

2 1. Open and close the Rear Cover.

2. Inspect the movement of the Interlock Switch.

Does the actuator tab on the Rear Cover press down on the Interlock Switch lever?

3 1. Enter Service Diagnostics and select Sensor Tests.

2. Scroll to Rear Cover Switch test and press OK.

3. Open and close the Rear Cover.

Does the message on the display alternate between “Closed” and “Open” as you open and close the Rear Cover?

Phaser 4400 Laser Printer Service Manual 2-31

Go to step 2. Replace the

Front Cover Assembly (PL 1.1 on

page 7-2).

Go to step 3. Replace the

Rear Cover Assembly (PL 1.2 on

page 7-4).

Go to step 5. Go to step 4.

Close Front/Rear Cover Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

4 1. Switch the printer power OFF.

2. Remove the Left Interface Cover (RRP 1.1 on

page 6-6), Left Cover (RRP 1.2 on page 6-7), and the

Left Plate (RRP 1.11 on page 6-16).

3. Disconnect P/J30 from the Engine Logic Board.

4. Measure the resistance between pins 1 and 2 on the disconnected plug as you open and close the Rear Cover.

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Is there continuity when the Rear Cover is closed and infinity when the Rear Cover is open?

5 Open and close the Front Cover.

Does the message on the display alternate between “Closed” and “Open” as you open and close the Front Cover?

6 1. Switch the printer power OFF.

2. Remove the Left Interface Cover (RRP 1.1 on

page 6-6), Left Cover (RRP 1.2 on page 6-7), and the

Left Plate (RRP 1.11 on page 6-16).

3. Disconnect P/J284 from the LVPS PWB.

4. Measure the resistance between pins 1 and 2 on the disconnected plug as you open and close the Front Cover.

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Go to step 7. Check the

Is there continuity when the Front Cover is closed and infinity when the Front Cover is open?

7 1. Connect P/J284 to the LVPS.

2. Switch the printer power-on.

3. On the Engine Logic Board, check the voltage between P/J28 pin 1 and frame ground.

Is the voltage +24 VDC?

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Check the wiring between P/J30 and the Rear Cover Interlock Switch. Repair or replace the wiring or interlock switch (RRP 9.10 on

page 6-97)

as required.

Go to step 6.

wiring between P/J284 and the Front Cover Interlock Switch. Repair or replace the wiring or interlock switch (RRP

9.9 on

page 6-96)

as required.

Replace the LVPS (RRP

9.5 on

page 6-91).

2-32 Phaser 4400 Laser Printer Service Manual

Install or Reseat Print Cartridge.

(J3: Missing Print Cartridge)

1. Print Cartridge is not installed or seated correctly.

2. The installed Print Cartridge is not the correct one.

Print Cartridge Installation Troubleshooting Procedure

Step Actions and Questions Ye s No

1 1. Open the Front Cover and remove the Print

Cartridge.

2. Inspect the tab on the top center of the Print Cartridge that actuates the Print Cartridge Sensor Assembly.

Is the tab on the Print Cartridge intact?

2 Press and release the Print Cartridge Sensor Assembly

Actuator.

Does the Print Cartridge Sensor Assembly Actuator move smoothly?

3 1. Enter Service Diagnostics and select Sensor Tests.

2. Scroll to Print Cartridge Sensor test and press OK.

3. Insert and remove the Print Cartridge a few times.

Does the display alternate between “Not Installed” and “Installed” as you remove and replace the Print Cartridge?

4 1. Switch the printer power OFF.

2. Remove the Left Interface Cover (RRP 1.1 on

page 6-6), the Left Cover (RRP 1.2 on page 6-7), and

the Left Plate (RRP 1.11 on page 6-16).

3. Install the Print Cartridge. Leave the Front Cover open.

4. Disconnect P/J25 from the Engine Logic Board.

5. On the Engine Logic Board, check for continuity between J21-4 and J25-3, and J25-2 and J25-1 as you insert and remove the Print Cartridge.

Is there continuity between J25-4 and J25-3, and J25-2 and J25-1 when you insert the cartridge and no continuity when you remove the cartridge?

Is the Print Cartridge a Xerox Phaser 4400 Print Cartridge?

Go to step 2. Replace the

Go to step 3. Replace the

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Replace the Print Cartridge Sensor Assembly together with the harness (RRP 7.4 on

page 6-81).

Print Cartridge (PL

8.1 on

page 7-20).

Print Cartridge Sensor Assembly (RRP 7.3 on

page 6-81).

Go to step 4.

Go to step 5.

Replace Print Cartridge with a Xerox Phaser 4400 Print Cartridge (PL

8.1 on

page 7-20).

Phaser 4400 Laser Printer Service Manual 2-33

Replace Print Cartridge.

(J5: Toner Low)

The Print Cartridge is in a low toner condition.

Print Cartridge Low Toner Troubleshooting Procedure

Step Actions and Questions Yes No

1 Install a new Print Cartridge.

Does the Replace Print Cartridge message still appear?

2 1. Remove the Front Cover (RRP 1.6 on page 6-11) and

the Left Front Cover (RRP 1.7 on page 6-12).

2. Cheat the Front Cover Interlock Switch.

3. On the Connector PWB, check the voltage between P/J42 pin 4 and frame ground.

Is the voltage 0.0 VDC with the print cartridge installed and +3.3 VDC with the print cartridge removed?

3 Check the voltage between P/J42 pin 3 and pin 1.

Is the voltage +24 VDC?

4 On the Connector PWB, check the voltage between

P/J231 pin 11 and pin 12.

Is the voltage +24 VDC?

5 On the connector PWB, check the voltage between

P/J231 pin 9 and frame ground.

Is the voltage 0.0 VDC with the print cartridge installed and +3.3 VDC with the print cartridge removed?

Go to step 2. Problem

Go to step 5. Go to step 3.

Replace the Toner Sens or (RRP 5.2 on

page 6-59).

Replace the Connector PWB (RRP

9.7 on

page 6-94).

Check the Connector Harness Assembly. If OK, replace the Engine Logic Board (RRP 9.3 on

page 6-89).

solved.

Go to step 4.

Check the Connector Harness Assembly. If OK, replace the Engine Logic Board (RRP 9.3 on

page 6-89).

Replace the Connector PWB (RRP

9.7 on

page 6-94).

2-34 Phaser 4400 Laser Printer Service Manual

Toner is Low.

(J5: Toner Low)

The Print Cartridge is almost empty.

Print Cartridge Low Toner Troubleshooting Procedure

Step Actions and Questions Ye s No

1 Install a new Print Cartridge.

Does the Replace Print Cartridge message still appear?

2 1. Remove the Front Cover (RRP 1.6 on page 6-11) and

the Left Front Cover (RRP 1.7 on page 6-12).

2. Cheat the Front Cover Interlock Switch.

3. On the Connector PWB, check the voltage between P/J42 pin 4 and frame ground.

Is the voltage 0.0 VDC with the print cartridge installed and +3.3 VDC with the print cartridge removed?

3 Check the voltage between P/J42 pin 3 and pin 1.

Is the voltage +24 VDC?

4 On the Connector PWB, check the voltage between

P/J231 pin 11 and pin 12.

Is the voltage +24 VDC?

5 On the connector PWB, check the voltage between

P/J231 pin 9 and frame ground.

Is the voltage 0.0 VDC with the print cartridge installed and +3.3 VDC with the print cartridge removed?

Go to step 2. Problem

Go to step 5. Go to step 3.

Replace the Toner Sensor (RRP 5.2 on

page 6-59).

Replace the Connector PWB (RRP

9.7 on

page 6-94).

Check the Connector Harness Assembly. If OK, replace the Engine Logic Board (RRP 9.3 on

page 6-89).

solved.

Go to step 4.

Check the Connector Harness Assembly. If OK, replace the Engine Logic Board (RRP 9.3 on

page 6-89).

Replace the Connector PWB (RRP

9.7 on

page 6-94).

Phaser 4400 Laser Printer Service Manual 2-35

Maintenance Kit is Near End of Life.

Indicates that the parts that make up the Maintenance Kit (Fuser, Transfer Roller, Feed and Retard Rollers) are nearing the end of their rated useful life.

Maintenance Kit Troubleshooting Procedure

Step Actions and Questions Yes No

1 1. Install the Maintenance Kit in accordance with the

instructions included with it.

Does the warning message reappear?

2 Perform the Fuser Reset.

Does the warning message continue to appear?

3 Replace the following in order:

■ Engine Logic Board (RRP 9.3 on page 6-89)

■ Image Processor Board (RRP 9.2 on page 6-88)

■ Front Panel (RRP x.x on page 6-14).

Go to step 2. Problem

solved.

Go to step 3. Problem

solved.

Install or Reseat the Duplex Unit.

(E9-1: Duplex Unit Fail)

Duplex Unit was removed while power was on.

Duplex Unit Troubleshooting Procedure

Step Actions and Questions Yes No

1 1. Switch the printer power OFF.

2. Remove and reinstall the Duplex Unit.

3. Switch the printer power-on.

4. Print Configuration Pages.

Problem solved.

Go to step 2.

Is the Duplex Unit listed on the Configuration Page (2-sided Printing)?

2 1. Enter Service Diagnostics.

2. Select Sensor Tests and press OK.

3. Scroll to Duplex Unit Presence and press OK.

Does the display read “Installed” with the unit present, and “Not Installed” without the unit

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Go to step 3.

present?

3 Check the wiring harnesses.

Are the wiring harnesses in good condition?

Replace the Duplex PWB (RRP 12.4,

page 6-144).

If the problem persists, replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Replace the Duplex Harness Assembly, J32/P341 (RRP 9.12,

page 6-99).

2-36 Phaser 4400 Laser Printer Service Manual

Stacker Failure.

(E9-2: Stacker Unit Fail.)

Stacker has failed or was removed while power is on.)

Stacker removed while power is on.

Stacker Failure Troubleshooting Procedure

Step Actions and Questions Ye s No

1 1. Switch the printer power OFF.

2. Remove and reinstall the Stacker.

3. Switch the printer power-on.

4. Print a Configuration Page.

Is the Stacker listed on the Configuration Page?

2 1. Switch the printer power OFF.

2. Remove the Left Interface Cover (RRP 1.1 on

page 6-6), Left Cover (RRP 1.2 on page 6-7), and the

Left Plate (RRP 1.11 on page 6-16).

3. Remove the Stacker from the printer. Switch the printer power-on. On the Engine Logic Board, check the voltage between P/J35 pin 1 and frame ground.

Is the voltage 3.3 VDC.

3 1. Switch the printer power OFF.

2. Properly install the Stacker on the printer.

3. Switch the printer power-on.

4. On the Engine Logic Board, check the voltage between P/J35 pin 1 and frame ground.

Is the voltage 0.0 VDC.

Problem solved.

Go to step 3. Replace the

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Go to step 2.

Engine Logic Board (RRP

9.3 on

page 6-89).

Replace the Sta cker PWB (RRP 10.7

page 6-107).

Install or Reseat the Envelope Feeder.

(E9-E: Envelope Feeder Fail/Re-install.)

Envelope feeder failed or was removed while power is on.

Envelope Feeder Failure Troubleshooting Procedure

Step Actions and Questions Yes No

1 1. Switch the Printer power OFF.

2. Remove and reinstall the envelope feeder.

3. Switch the Printer power-on.

4. Print a Configuration Page.

Is the Envelope Feeder listed on the Configuration Pages?

2 1. Switch the Printer power OFF.

2. Remove the Left Interface Cover (RRP 1.1 on

page 6-6), Left Cover (RRP 1.2 on page 6-7), and

the Left Plate (RRP 1.11 on page 6-16).

3. Switch the Printer power-on.

4. Check the voltage on the Engine Logic Board between P/J23 Pin 4 and frame ground.

Is the voltage 0.0 VDC?

Phaser 4400 Laser Printer Service Manual 2-37

Problem solved.

Replace the Envelope Feeder PWB (RRP 13.3 on

page 6-159).

Go to step 2.

Go to step 3.

Envelope Feeder Failure Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

3 1. Switch the Printer power OFF.

2. Remove the Envelope Feeder.

3. Check for continuity between J418 Pin 3 (Envelope Connector Assembly) and P/J23 Pin 4 on the Engine Logic Board.

Replace the Envelope Feeder PWB (RRP 13.3 on

page 6-159).

Is there continuity between the two pins?

4 1. Remove the Front Cover (RRP 1.6 on page 6-11)

and the Left Front Cover (RRP 1.7 on page 6-12).

2. Check for continuity between P/J 41 Pin 6 on the Connector PWB and P/J 23 Pin 4.

Is there continuity between the two pins?

5 Check the Connector Harness Assembly for proper

connection and for defective wires.

Is the Harness in good condition?

Replace the Envelope Connector Assembly (RRP 4.10 on

page 6-56).

Replace the Connector PWB (RRP

9.7 on

page 6-94).

Standard Output Tray is Full. Unload Paper.

(Standard Output Tray Full)

Error message indicates the output tray is full.

Output Tray Full Troubleshooting Procedure

Go to step 4.

Go to step 5.

Repair or replace if necessary.

Step Actions and Questions Yes No

Is there a paper stack in the standard bin actuating the Output Tray Full Sensor?

Is the paper curled?

3 Lift and release the Output Tray Full Actuator a few

times.

Does the actuator move freely?

4 Replace paper in paper tray with fresh dry paper. Run

test prints.

Remove the paper stack.

Go to step 4. Go to step 3.

Go to step 5. Replace

Go to step 5. Problem

Go to step 2.

Output Tray Full Actuator (RRP 6.8 on

page 6-76)

or Output Tray Full Sensor (RRP

6.6 on

page 6-72),

as necessary.

solved.

Does the error code reappear?

2-38 Phaser 4400 Laser Printer Service Manual

Output Tray Full Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

5 1. Enter Service Diagnostics and select Sensor Tests.

2. Scroll to Output Tray Full Sensor and press OK.

3. Manually actuate and deactuate the Output Tray Full Actuator.

Does the message on the display alternate

Replace Engine Logic Board (RRP

9.3 on

page 6-89).

between “Full” and “Not Full” as you lift and release the actuator (the indication may have a short delay because of the sensor circuit)?

Tray [#] Paper is Low.

Paper stack in the Paper Tray Assembly is below 50 ±30 sheets.

Low Paper Troubleshooting Procedure

Step Actions and Questions Ye s No

1 Fill the tray in the affected position.

Does the message reappear?

2 1. Remove the affected tray Assembly.

2. Push up the Low Paper Actuator manually and then release.

The Low Paper Actuator moves smoothly.

3 1. Enter Service Diagnostics and select Sensor Tests.

2. Scroll to Tray [#] Low Paper Sensor and press OK.

3. Press the Low Paper Actuator manually and then release.

Does the message on the Front Panel display alternate between “Low” and “Not Low” as you press the Low Paper Actuator?

4 Check the wiring associated with the specific Low

Paper Sensor.

Is the wiring OK?

Go to step 2. Problem

Go to step 3. Repair or

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Replace the Low Paper Sensor (RRP 3.5,

page 6-32/

RRP 11.14,

page 6-133)

Go to Output

Tray Full Sensor on

page 3-22.

solved.

replace the Low Paper Sensor Assembly (RRP 3.5,

page 6-32/

RRP 11.14,

page 6-133).

Go to step 4.

Replace the faulty wiring.

Phaser 4400 Laser Printer Service Manual 2-39

Tray 2 (or Tray 3) Paper is Low.

Paper stack in Tray 2 and/or Tray 3 is below 50 ±30 sheets.

Low Paper (Tray 2 or Tray 3) Troubleshooting Procedure

Step Actions and Questions Yes No

1 Fill the affected paper tray with fresh paper.

Is the Error Message still displayed?

2 1. Remove the paper tray from affected Feeder

Assembly.

2. Manually push up and release the low paper actuator.

Does the low paper actuator move smoothly up and down?

3 1. Enter Service Diagnostics and select Sensor Tests.

2. Scroll to Tray 2 (or Tray 3) Low Paper Sensor and press OK.

3. Press and release the Low Paper Actuator.

Does the message on the Front Panel display alternate between Low and Not Low as you press and release the actuator?

4 1. Switch the printer power OFF.

2. Remove the Left Interface Cover (RRP 1.1 on

page 6-6), Left Cover (RRP 1.2 on page 6-7), and the

Left Plate (RRP 1.11 on page 6-16).

3. Switch the printer power-on.

4. On the Engine Logic Board, check the voltage between P/J33 pin 8 and frame ground.

Is the voltage +3.3 VDC?

5 On the Engine Logic Board, check the voltage between

P/J28 pin 10 and frame ground.

Is the voltage +3.3 VDC?

6 1. Enter Service Diagnostics and select Sensor Tests.

2. Scroll to Tray 2 (or Tray 3) Low Paper Sensor and press OK.

3. As you actuate the Low Paper Sensor, check the voltages at the following locations on the Engine Logic Board:

■For Tray 2, check between P/J33 pin 9 and frame

ground.

■For Tray 3, check between P/J33 pin 10 and frame

ground.

Does the voltage change from +3.3 VDC to 0.0 VDC?

Go to step 2. Problem

Go to step 3. Inspect the

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Go to step 6. Go to step 5.

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

solved.

Low Paper Actuator. Repair or replace as required.

Go to step 4.

Replace the LVPS (RRP

9.5 on

page 6-91).

Replace the Low Paper Sensor (RRP 11.14,

page 6-133)

for the affected tray. If the problem persists, replace the Feeder PWB (RRP 11.9,

page 6-128)

then the Size PWB (RRP 11.19,

page 6-139).

2-40 Phaser 4400 Laser Printer Service Manual

No Paper in Tray [#].

A tray (Tray 1, Tray 2, or Tray 3) incorrectly indicates that it is empty.

Tray [#] Empty Troubleshooting Procedure

Step Actions and Questions Yes No

Does the problem appear when using Tray 2 or Tray 3?

2 Check the paper level in Tray 1.

Is there paper in Tray 1?

3 1. Enter Service Diagnostics and select

Tes t Pr i n t .

2. Print a test print from Tray 1.

Does the error message reappear?

4 1. Remove Tray 1 from the printer.

2. Remove all paper from the tray.

3. Reinsert Tray 1 into the printer.

4. From the rear of the printer, watch the Tray 1 bottom plate.

Is the Bottom Plate is raised fully and evenly?

5 1. Remove Tray 1.

2. Manually actuate the Tray 1 No Paper sensor.

Does the No Paper Actuator move smoothly?

6 1. Enter Service Diagnostics and select

Sensor Tests.

2. Scroll to Tray 1 No Paper and press OK.

3. Manually actuate the Tray 1 No Paper Sensor.

Does the message on the display alternate between “With paper” and “Without paper” as you press and release the actuator?

7 Check the paper level in Tray 2/3.

Is there paper in the tray?

8 1. Enter Service Diagnostics and select

Tes t Pr i n t .

2. Print a test print from Tray 2/3.

Does the error message reappear?

9 Remove Tray 2/3 from the printer.

Remove all paper from the tray. Reinsert the Tray into the printer. From the rear of the printer, watch the tray bottom plate.

Is the Bottom Plate raised fully and evenly?

Go to step 7. Go to step 2.

Go to step 3. Load paper into

Go to step 4. Return to

Go to step 5. Go to Tray

Go to step 6. Replace the

Replace the Engine Logic Board (RRP 9.3 on

page 6-89).

Go to step 8. Load paper into

Go to step 9. Return to

Go to step 10. Go to Tray

Tray 1.

“Service Flowchart” and

restart.

Motor Assembly Checkout on

page 3-26.

Tray 1 No Paper Actuator (RRP

3.3 on

page 6-30).

Go to Tray 1 No

Paper Sensor

on page 3-22.

Tray 2/3.

“Service Flowchart” and

restart.

Motor Assembly Checkout on

page 3-26.

Phaser 4400 Laser Printer Service Manual 2-41

Tray [#] Empty Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

10 1. Remove Tray 2/3.

2. Manually actuate the No Paper Sensor.

Does the No Paper Actuator move smoothly?

11 1. Enter Service Diagnostics and select

Sensor Tests.

2. Scroll to Tray 2 No Paper or Tray 3 No Paper and press OK.

3. Manually actuate the Tray 2/3 No Paper Sensor.

Does the message on the display alternate between “With paper” and “Without paper” as you press and release the actuator?

Go to step 11. Replace the

Replace the Engine Logic Board (RRP 9.3 on

page 6-89).

Tray 2/3 No Paper Actuator (RRP 11.7 on

page 6-126).

Replace the following in order for the problem feeder assembly:

■ Feeder PWB

(RRP 11.9 on

page 6-128)

■ Size PWB

(RRP 11.19 on

page 6-139)

Load Tray [#] with [paper size] [paper type].

There is a conflict between the size of the paper detected by the Size Switches, and the length of paper detected by the length of time the Registration Sensor is actuated.

Paper Size Error Troubleshooting Procedure

Step Actions and Questions Yes No

Does the problem appear when using Tray 1, 2, or 3?

2 1. Verify the size of paper currently in the MPT Tray.

2. Select Menus and press OK, then

3. Select Printer Setup Menu and press OK.

4. Select Tray Setup Menu and press OK.

5. Select MPT Setup Menu and press OK.

Does the paper size checked in the MPT Setup Menu match the size actually in the MPT?

Is the paper size in the problem tray within printer specifications?

4 Check the side guides and the Paper Stack End Guide

in the problem tray.

Are all guides properly set for the size of paper installed?

5 Check the size cam on the left side of the paper tray

(see the Paper Size Actuators table below).

Are the cams in good condition (not broken) and do they move freely as the paper tray end guide is moved.

Go to step 2. Go to step 3.

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Go to step 4. Replace with

Go to step 5. Properly set

Go to step 6. Replace the

Set MPT size to the size of paper actually installed, then press OK.

paper that meets specifications.

the guides.

paper tray (PL

2.1 on

page 7-6/PL

11.1 on

page 7-26).

2-42 Phaser 4400 Laser Printer Service Manual

Paper Size Error Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

6 1. Reinstall the paper tray.

2. Enter Service Diagnostics and select Sensor Tests.

3. Scroll to Paper Tray Size Read and press OK.

4. Select “Tray 1 Size” and press OK.

5. Press “Back” and select another tray size until all installed trays are tested.

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Does the paper size displayed on the Front Panel display match the size of the paper actually loaded in the tray?

Paper Size Actuators

Actuator Cam Extended

To p X X

Middle X X X

Bottom X X

B5 SEF

A5 SEF

13" SEF

14" SEF

8.5" SEF

A4 SEF

Tray [#] Failure. Open and Close Tray [#].

(C3-[#]E Tray [#] Not In)

A Tray Assembly (Tray 1, 2, or 3) is not in place.

Tray Failure Troubleshooting Procedure

Replace the Tray Size PWB (RRP 3.13 on

page 6-42/

RRP 11.19 on

page 6-139).

Step Actions and Questions Ye s No

1 1. Enter Service Diagnostics,

2. Print a test print from every tray.

Go to step

11.

Go to step 2.

Does the Error Code specify Tray 2 or Tray 3?

2 Remove and reinstall Tray 1.

Does the C3 error code still appear?

3 Measure the voltage from the lower contact of the

Feeder Socket (P/J672) to frame ground.

Go to step 3. Problem

solved.

Go to step 8. Go to step 4.

Is the voltage +24 VDC?

4 Measure the voltage from P/J33 pin 6 on the Engine

Logic Board to frame ground.

Is the voltage +24 VDC?

5 1. Switch off the printer power.

2. Remove the Size Sensor Housing (RRP 3.11 on

page 6-40).

3. Measure continuity between the disconnected P/J33 pin 6 and P/J331 pin 12 on the Tray 1 Size PWB.

Is there continuity between the two pins?

Go to step 5. Go to DC

Power (LVPS) on

page 3-4.

Go to step 6. Repair or

replace Feeder Harness Assembly (PL 9.1 on

page 7-22).

Phaser 4400 Laser Printer Service Manual 2-43

Tray Failure Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

6 On the Tray 1 Size PWB, measure continuity between

P/J331 pin 12 to P/J61 pin 1.

Go to step 7. Replace the

Is there continuity between the two pins?

7 Check the wiring between P/J67 pin 5 on the Tray 1

Feeder PWB and the bottom pin on the Paper Feeder Socket (P/J672).

Is the wiring in good condition?

8 On the paper tray, measure the resistance between the

middle and bottom terminals on the Paper Feeder Socket.

Replace the Tray 1 Feeder PWB (RRP 3.9 on

page 6-37).

Go to step 9. Go to Tray

Is the resistance 90 ±15 ohms?

9 On the paper tray, measure the resistance between the

top and bottom terminals on the Paper Feeder Socket.

Go to step

10.

Is there continuity between the two pins?

10 Replace the following parts one at a time until the

problem is resolved:

■ Stack Height Sensor (RRP 3.4 on page 6-31)

■ Feeder PWB (RRP 3.9 on page 6-37)

■ Size 1 PWB (RRP 3.13 on page 6-42)

■ Engine Logic Board (RRP 9.3 on page 6-89)

11 Remove and reinstall the Tray indicated.

Does the C3 error code still appear?

12 1. Exchange Tray 1 with the Tray generating the “C3”

code.

2. Print a test print from each tray.

Go to step

12.

Go to step

19.

Does the error code now indicate a Tray 1 failure?

Does the error code indicate a Tray 2 failure?

14 1. Remove Tray 3 from the feeder.

2. Check the voltage between the lower terminal on the Paper Feeder Connector and frame ground.

Go to step

16.

Go to step

18.

Is the voltage +24 VDC?

15 Check the wiring harness between the Tray 2 Size

PWB (P/J53) and the Tray 3 Size PWB (P/J54).

Is the harness in good condition?

Replace the Tray 3 Siz e PWB (RRP

11.19 on

page 6-139),

then the Tray 3 Feeder PWB (RRP

11. 9 o n

page 6-128.

Tray 1 Size PWB (RRP

3.13 on

page 6-42).

Replace the Socket and Harness (PL

3.1 on

page 7-10.

Motor Assembly Checkout on

page 3-26.

Replace the Socket and Harness (PL

3.1 on

page 7-10.

Problem solved.

Go to step

13.

Go to step

14.

Go to step

15.

Replace the Size Harness Assembly (PL 11.1 on

page 7-27).

2-44 Phaser 4400 Laser Printer Service Manual

Tray Failure Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

16 1. Remove Tray 2 from the feeder.

2. Check the voltage between the lower terminal on the Feeder Connector and frame ground.

Go to step

18.

Is the voltage +24 VDC?

17 Check the wiring harness between the Tray 1 Size

PWB (P/J51) and the Tray 2 Size PWB (P/J52).

Is the harness in good condition?

18 Replace the following components, in order, until the

problem is resolved:

■ Stack Height Sensor (RRP 11.13 on page 6-132)

■ Feeder PWB (RRP 11.9 on page 6-128)

■ Size PWB (RRP 11.19 on page 6-139)

■ Engine Logic Board (RRP 9.3 on page 6-89)

19 Remove the tray now occupying the Tray 1 position

and continue with Tray Motor Assembly Checkout on page 3-26.

Replace the Tray 2 Size PWB (RRP

11.19 on

page 6-139)

then the Tray 2 Feeder PWB (RRP

11.9 on

page 6-128).

Main Motor Failure.

Go to step

17.

Replace the Size Harness Assembly (PL 11.1 on

page 7-27).

(U1 Motor Fail/Power Off)

Main Motor speed is less than specified RPM after 1.3 seconds.

There is a problem with the Main Motor.

Main Motor Failure Troubleshooting Procedure

Step Actions and Questions Ye s No

1 1. Switch the printer power OFF.

2. Remove the Left Interface Cover (RRP 1.1 on

page 6-6), the Left Cover (RRP 1.2 on page 6-7), and

the Left Plate (RRP 1.11 on page 6-16).

3. Open the Rear Cover and, if installed, remove the Duplex Unit.

4. Manually rotate the rotor of the Main Motor clockwise (as viewed from the left side of the printer).

Does the rotor of the Main Motor rotate smoothly?

2 1. Open the Front Cover and remove Print Cartridge.

2. Manually rotate the rotor of motor clockwise.

Does the rotor of the Main Motor rotate smoothly?

Phaser 4400 Laser Printer Service Manual 2-45

Go to step 5. Go to step 2.

Replace the Print Cartridge.

Go to step 3.

Main Motor Failure Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

3 1. Remove the Fuser Assembly (RRP 6.2 on

page 6-66).

2. Manually rotate the rotor of the Motor clockwise.

Does the rotor of the Main Motor rotate smoothly?

4 Remove the Main Motor (RRP 8.1 on page 6-84).

Manually rotate the rotor of the Motor clockwise.

Does the rotor of the Main Motor rotate smoothly?

5 Open the Front Cover and remove the Print Cartridge.

Rotate the Metal Registration Roller manually.

Replace the Fuser Assembly (RRP 6.2 on

page 6-66

Replace the Main Drive Gear Assembly (RRP 8.2 on

page 6-85)

Go to step 6. Replace the

Do the Metal and Rubber Registration Rolls rotate smoothly?

6 1. With the Front Cover open, cheat the Front Cover

Interlock.

2. Enter Service Diagnostics and select Motor/Fans Tests.

3. Scroll to Main Motor and press OK.

4. Visually inspect the Main Motor and Main Drive Gears.

Go to step 7. Go to RRP

Do the Main Motor and drive gears run smoothly and are all drive gears in good condition?

7 1. Press the Back key twice to return to top Menu.

2. Select Main Motor+Clutches/Sol Tests.

3. Scroll to Motor+MPT Sol and press OK.

Go to step 8. Replace the

Does the MPT Feed Roller Assembly rotate smoothly?

8 Scroll to Motor+Tray 1 Turn Roll and press OK.

Note: If optional feeders are installed, all turn rollers should actuate when you press OK.

Go to step 9. Repair or

Do all Turn Roller Shafts rotate smoothly?

Go to step 4.

Replace the Main Motor (RRP 8.1 on

page 6-84).

Registration Rolls (RRP

5.6 on

page 6-62)

or clutch (RRP 5.5 on

page 6-62),

as necessary.

8.1 on

page 6-84

and RRP 8.2 on

page 6-85.

MPT Feed Roller components as necessary (RRP 4.2,

page 6-45/

RRP 4.3,

page 6-47).

replace the appropriate Turn Roller Assembly (RRP 3.2,

page 6-29 or

RRP 11.8,

page 6-127).

2-46 Phaser 4400 Laser Printer Service Manual

Main Motor Failure Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

9 Scroll to Motor+Registration and press OK.

Does the Registration Roller rotate smoothly?

10 1. Remove paper from all paper trays.

2. Scroll to Motor+Tray 1 Feed and press OK.

Go to step

10.

Go to step

11.

Does the Main Motor rotate smoothly?

Does the printer have a Tray 2?

12 Scroll to Motor+Tray 2 Feed and press OK.

Does the Main Motor rotate smoothly?

Does the printer have a Tray 3?

14 Scroll to Motor+Tray 3 Feed and press OK.

Does the Main Motor rotate smoothly?

Go to step

12.

Go to step

13.

Go to step

14.

Go to Main

Motor Assembly on

page 3-15.

Repair or replace the Registration Rolls (RRP

5.6,

page 6-62)

as necessary.

Repair or replace the Tray 1 Feed Clutch or Feed Shaft (RRP 3.6,

page 6-33).

Replace the Main Motor Assembly (RRP 8.1,

page 6-84).

Repair or replace the Tray 2 Feed Clutch or Feed Shaft (RRP 11.10,

page 6-129).

Replace the Main Motor Assembly (RRP 8.1,

page 6-84).

Repair or replace the Tray 3 Feed Clutch or Feed Shaft (RRP 3.6,

page 6-33).

Phaser 4400 Laser Printer Service Manual 2-47

Laser Unit Failure.

(U2 Laser Fail/Power Off)

Laser Failure at warm-up:

■ Transmitting /BD signal is longer than specified value for 10 sec. + t1.

■ The laser power does not reach the specified value.

Laser Failure after warm-up:

■ Laser signal intervals become longer than the Fail time interval after Laser

warm-up is completed.

Laser Failure Troubleshooting Procedure

Step Actions and Questions Yes No

1 1. Enter Service Diagnostics and

2. Select Engine NVRAM Adjustments.

3. Scroll to Laser Power and press OK.

Is the value for Laser Power set to “10”?

2 Select Motors/Fans Tests then Laser Scan Motor.

Can you hear the Laser Scan Motor spin up?

3 1. Switch the printer power OFF.

2. Remove the Left Interface Cover (RRP 1.1 on

page 6-6), the Left Cover (RRP 1.2 on page 6-7), and

the Left Plate (RRP 1.11 on page 6-16).

3. Disconnect P/J21 from the Engine Logic Board. Switch the printer power-on.

4. On the Engine Logic Board, check the voltage between P21-6 and frame ground.

Is the voltage +5.0 VDC?

4 On the Engine Logic Board, check the voltage between

P25 pin 4 and frame ground.

Is the voltage +5.0 VDC?

5 On the Engine Logic Board, check the voltage between

P28 pin 7 and frame ground.

Is the voltage +5.0 VDC?

6 On the Engine Logic Board, check the voltage between

P25 pin 3 and frame ground.

Is the voltage +5.0 VDC?

Go to step 2. Set the value

Go to step 3. Go to Laser

Go to Laser

Assembly on

page 3-17.

Go to step 6. Go to step 5.

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

to 10. If the problem persists, replace the Engine Logic Board (RRP

9.3,

page 6-89).

Assembly on

page 3-17.

Go to step 4.

Replace the LVPS (RRP

9.5 on

page 6-91).

Go to Install

or Reseat Print Cartridge. on

page 2-33.

2-48 Phaser 4400 Laser Printer Service Manual

Fuser Failure.

(U4 Fuser Fail/Power Off)

■ Low temperature trouble/Power off (Fuser temperature drops below the set

temperature after the Fuser warm-up is complete.)

■ Warm-up fail/Power off (Fuser warm-up does not complete within 110

seconds.)

■ STS Disconnection fail/Power off (Thermistor circuit is detected to be

open).

■ High Temperature trouble/Power off (Fuser temperature rises above the set

temperature.)

■ Continuous heat on/Power off (Heat rod is on for 10 seconds when the Main

Drive Motor is stopped, after the Fuser warm-up is completed.)

Fuser Failure Troubleshooting Procedure

Step Actions and Questions Ye s No

1 Switch the printer power OFF. Wait a few minutes, then

switch the printer power-on.

Does the error message reappear?

2 Run 25 to 30 test prints.

Does the error message reappear?

Go to Fuser

Assembly on

page 3-18.

Go to Fuser

Assembly on

page 3-18.

Go to step 2.

Problem solved.

Fan Failure; Power Off Now.

(U5 Fan Fail/Power Off)

The printer is detecting incorrect fan rotation.

Fan Failure Troubleshooting Procedure

Step Actions and Questions Ye s No

1 Switch the printer power OFF, then ON.

Does the Fan rotate when the main power is switched on?

2 1. Switch the printer power OFF.

2. Remove the Left Interface Cover (RRP 1.1,

page 6-6), Left Cover (RRP 1.2, page 6-7), and Left

Plate (RRP 1.11, page 6-16).

3. Switch the printer power-on.

4. On the LVPS, check the voltage between P/J283 pin 1 and frame ground.

Is the voltage +19 ±1.9 VDC?

3 Check the voltage between P/J281 pin 13 and frame

ground.

Is the voltage +0.8 ±0.1VDC?

Phaser 4400 Laser Printer Service Manual 2-49

Go to step 4. Go to step 2.

Replace the Fan Assembly (RRP 9.1 on

page 6-87).

Replace the LVPS (RRP

9.5 on

page 6-91).

Go to step 3.

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Fan Failure Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

4 1. Enter Service Diagnostics and select Motors/Fans

Tests.

2. Scroll to Fan Motor High Speed and press OK.

Go to step 7. Go to step 5.

Does the Fan rotate at high speed?

5 1. Switch the printer power OFF.

2. Remove the Left Interface Cover (RRP 1.1,

page 6-6), Left Cover (RRP 1.2, page 6-7), and Left

Plate (RRP 1.11, page 6-16).

3. Enter Service Diagnostics and select Motors/Fans Tests and press OK.

4. Scroll to Fan Motor High Speed and press OK.

5. On the LVPS, check the voltage between P/J283 pin 1 and frame ground.

Replace the Fan Assembly (RRP 9.1 on

page 6-87).

Is the voltage +21.5 ±2.1 VDC?

6 1. On the LVPS, check the voltage between P/J281 pin

11 and frame ground.

2. With the Fan Motor High Speed test still highlighted, press OK.

Replace the LVPS ( R R P

9.5 on

page 6-91).

Does the voltage change from 0.8 VDC to 0.0 VDC when you press OK?

7 1. Switch the printer power OFF.

2. Remove the Left Interface Cover (RRP 1.1,

page 6-6), Left Cover (RRP 1.2, page 6-7), and Left

Plate (RRP 1.11, page 6-16).

3. On the LVPS, check the voltage between P/J283 pin 2 and frame ground.

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Is the voltage less than 1.0 VDC?

Go to step 6.

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Replace the Fan Assembly (RRP 9.1 on

page 6-87).

Engine Logic Board NVRAM Failure.

(U6 NVM Fail/Power Off)

There is problem with Non-Volatile RAM on the Engine Logic Board.

NVM Failure Troubleshooting Procedure

Step Actions and Questions Yes No

1 Switch the printer power OFF then ON.

Does the error message reappear?

2 To ensure that the problem is solved, switch the printer

power OFF and ON several times.

Does the error message reappear?

2-50 Phaser 4400 Laser Printer Service Manual

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Go to step 2.

Problem solved.

Load MPT with [paper size] [paper type].

(MPT Paper Empty)

Load MPT Troubleshooting Procedure

Step Actions and Questions Ye s No

1 1. Enter Service Diagnostics and select Sensor Tests.

2. Scroll to Sensor Input test and press OK.

3. Actuate and deactuate the MPT No Paper Sensor.

Does the Front Panel display alternate between “With Paper” and “Without Paper” as you press and release the actuator?

Does the actuator move freely and is it in good condition (not broken or damaged)?

3 1. Switch the printer power OFF.

2. Remove the Left Interface Cover (RRP 1.1 on

page 6-6), Left Cover (RRP 1.2 on page 6-7), and the

Left Plate (RRP 1.11 on page 6-16).

3. Switch the printer power-on.

4. On the Engine Logic Board, measure the voltage between P/J23 pin 14 and frame ground.

Is the voltage +3.3 VDC with the MPT No Paper Sensor deactuated and 0.0 VDC with the Sensor actuated?

4 1. Switch the printer power OFF.

2. Remove the Left Front Cover (RRP 1.7 on

page 6-12).

3. Switch the printer power-on.

4. On the Connector PWB, measure the voltage between P/J45 pin 3 and frame ground.

Is the voltage +3.3 VDC with the MPT No Paper Sensor deactuated and 0.0 VDC with the Sensor actuated?

5 Check the voltage between P/J45 pin 1 and frame

ground.

Is the voltage +1.2 ±0.1 VDC?

It appears that the MPT No Paper Sensor is working correctly. If a problem persists, replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Go to step 3. Replace the

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Replace the Connector PWB (RRP

9.7 on

page 6-94).

Replace the MPT No Paper Sensor (RRP

4.8,

page 6-53).

Go to step 2.

MPT No Paper Sensor Actuator (RRP 4.5 on

page 6-50).

Go to step 4.

Go to step 5.

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Phaser 4400 Laser Printer Service Manual 2-51

Tray 2 or 3 Failure.

(E11: Tray 2/3 Fail)

Tray 2 or 3 disconnected after power-on.

Controller does not recognize the Feeder Assembly.

Tray 2 or 3 Failure Troubleshooting Procedure

Step Actions and Questions Yes No

1 1. Check the alignment of the printer to the 550-Sheet

Feeder and the alignment of the top 550-Sheet Feeder to the second 550-Sheet Feeder, if installed.

2. Ensure that the connectors are properly aligned and properly connected.

Are all connectors properly aligned and connected?

2 1. Switch the printer power OFF.

2. Remove the Left Interface Cover (RRP 1.1 on

page 6-6), Left Cover (RRP 1.2 on page 6-7), and the

Left Plate (RRP 1.11 on page 6-16).

3. Switch the printer power-on.

4. On the Engine Logic Board, check the voltage between P/J33 pin 13 and frame ground.

Is the voltage +24 VDC?

3 On the Engine Logic Board, check the voltage between

P/J33 pin 6 and frame ground.

Is the voltage +24 VDC?

4 1. Remove Paper Tray 2.

2. Check the voltage between the bottom terminal on the mating connector on the Tray 2 feeder and frame ground.

Is the voltage +24 VDC?

5 1. Remove paper tray 1.

2. Check the voltage between the bottom terminal on the mating connector on the Tray 1 feeder and frame ground.

Is the voltage +24 VDC?

6 Check the resistance between the bottom and top

terminals of the mating connector on paper tray 1.

Is there continuity between the two pins?

Go to step 2. Reseat the

Go to step

10.

Go to step 4. Replace the

Go to step 8. Go to step 5.

Go to step 6. Replace the

Go to step 7. Replace the

feeders and printer to obtain proper alignment and connection.

Go to step 3.

Engine Logic Board (RRP

9.3 on

page 6-89).

Tray 1 Size PWB (RRP

3.13 on

page 6-42). If

the problem persists, replace the Tray 1 Feeder PWB (RRP 3.9 on

page 6-36).

paper tray mating connector (PL 2.2 on

page 7-8).

2-52 Phaser 4400 Laser Printer Service Manual

Tray 2 or 3 Failure Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

7 Check that the paper tray mating connector and the

feeder mating connector are properly aligned when tray 1 is inserted into the feeder.

Are the mating connectors properly connected when the paper tray is inserted?

8 Check the resistance between the bottom and top

terminals of the mating connector on the paper tray 2.

Replace the Tray 1 Size PWB (RRP

3.13 on

page 6-42). If

the problem persists, replace the Tray 1 Feeder PWB (RRP 3.9 on

page 6-37).

Go to step 9. Replace the

Is there continuity between the two pins?

9 Check that the paper tray mating connector and the

feeder mating connector are properly aligned when the tray is inserted into the feeder.

Are the mating connectors properly connected when the paper tray is inserted?

Does the printer have two optional 550-Sheet Feeders installed?

11 On the Engine Logic Board, check the voltage between

P/J33 pin 14 and frame ground.

Is the voltage +24 VDC?

Replace the Tray 2 Size PWB (RRP

11.19 on

page 6-139).

If the problem persists, replace the Tray 2 Feeder PWB (RRP 11.9 on

page 6-128).

Go to step

11.

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Repair or replace components as necessary.

paper tray mating connector (PL 2.2 on

page 7-8).

Repair or replace components as necessary.

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Go to step

12.

Phaser 4400 Laser Printer Service Manual 2-53

Tray 2 or 3 Failure Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

12 1. Remove Paper Tray 3.

2. Check the voltage between the bottom terminal on the mating connector on the Tray 3 feeder and frame ground.

Go to step

13.

Is the voltage +24 VDC?

13 Check the resistance between the bottom and top

terminals of the mating connector on paper tray 3.

Go to step

14.

Is there continuity between the two pins?

14 Check that the paper tray mating connector and the

feeder mating connector are properly aligned when the tray is inserted into the feeder.

Are the mating connectors properly connected when the paper tray is inserted?

Replace the Tray 3 Siz e PWB (RRP

11.19 on

page 6-139).

If the problem persists, replace the Tray 3 Feeder PWB (RRP 11.9 on

page 6-128).

Replace the Tray 3 Size PWB (RRP

11.19 on

page 6-139).

If the problem persists, replace the Tray 3 Feeder PWB (RRP 11.9 on

page 6-128).

Replace the paper tray mating connector (PL 2.2 on

page 7-8).

Repair or replace components as necessary.

Stacker is Full, Unload Paper.

(Stacker output tray full.)

Error message indicates the Stacker output tray is full.

Stacker Full Troubleshooting Procedure

Step Actions and Questions Yes No

Is there a paper stack in the offset bin actuating the Stack Full Sensor?

Is the paper curled?

2-54 Phaser 4400 Laser Printer Service Manual

Remove the paper stack.

Go to step 4. Go to step 3.

Go to step 2.

Stacker Full Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

3 Lift and release the Stack Full Actuator a few times.

Does the actuator move freely?

4 1. Replace paper in paper tray with fresh dry paper.

2. Run test prints.

Go to step 5. Replace

Stack Fu ll Actuator (RRP 10.12 on

page 6-112)

or Stack Full Sensor (RRP

10.13 on

page 6-113),

as necessary.

Go to step 5. Problem

solved.

Does the error code reappear?

5 1. Enter Service Diagnostics and select Sensor Tests.

2. Scroll to Stacker Full Sensor.

3. Manually actuate and deactuate the Stack Full Actuator.

Does the message on the display alternate

Replace Engine Logic Board (RRP

9.3 on

page 6-89).

Go to

Stacker Full Sensor on

page 3-37.

between “Full” and “Not Full” as you lift and release the actuator (the count may have a short delay because of the sensor circuit)?

Load Envelope Feeder with [paper size] [paper type].

(Envelope Feeder empty.)

Load Envelope Troubleshooting Procedure

Step Actions and Questions Yes No

1 1. Enter Service Diagnostics and select Sensor Tests.

2. Scroll to Envelope No Paper and press OK.

3. Press and release the Envelope Feeder No Paper Sensor Actuator.

Does the message on the display alternate between “With Paper” and “Without Paper” as you press and release the actuator?

2 1. Switch the Printer power OFF.

2. Remove the Left Interface Cover (RRP 1.1 on

page 6-6), Left Cover (RRP 1.2 on page 6-7), and

the Left Plate (RRP 1.11 on page 6-16).

3. Switch the Printer power-on.

4. On the Engine Logic Board check the voltage between P/J23 Pin 4 and the frame ground.

Is the voltage 0.0 VDC?

Phaser 4400 Laser Printer Service Manual 2-55

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Go to step 3. Go to Install

Go to step 2.

or Reseat the Envelope Feeder. on

page 2-37.

Load Envelope Troubleshooting Procedure (cont'd.)

Step Actions and Questions Yes No

3 Check the voltage between P/J23 Pin 3 and frame

ground.

Is the voltage 3.3 VDC with the Envelope Feeder No Paper Sensor de-actuated, and 0.0 VDC with the sensor actuated?

4 1. Switch the Printer power OFF and remove the

Envelope Feeder.

2. Check for continuity between J418 (Envelope Connector Assembly) and P/J23 Pin 3 on the Engine Logic Board.

Is there continuity between the pins?

5 1. Remove the Front Cover (RRP 1.6 on page 6-11)

and the Left Front Cover (RRP 1.7 on page 6-12).

2. Check for continuity between P/J41 Pin 5 on the Connector PWB and P/J23 Pin 3 on the Engine Logic Board.

Is there continuity between the pins?

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Replace the Envelope Feeder PWB (RRP 13.3 on

page 6-159).

If the problem persists, replace the Envelope Feeder No Paper Sensor (RRP 13.10 on

page 6-166).

Replace the Envelope Connector Assembly (RRP 4.10 on

page 6-56).

Go to step 4.

Go to step 5.

Check the Connector Harness Assembly for proper connection and for defective wires. Repair or replace if necessary. If Harness is in good condition, replace the Connector PWB (RRP

9.7 on

page 6-94).

2-56 Phaser 4400 Laser Printer Service Manual

Install or Reseat Print Cartridge.

(J3: Missing EP Cartridge)

1. Print Cartridge is not installed or seated correctly.

2. The installed Print Cartridge is not the correct one.

Print Cartridge Installation Troubleshooting Procedure

Step Actions and Questions Ye s No

1 1. Open the Front Cover and remove the Print

Cartridge.

2. Inspect the tab on the top center of the Print Cartridge that actuates the Print Cartridge Sensor Assembly.

Is the tab on the Print Cartridge intact?

2 Press and release the Print Cartridge Sensor Assembly

Actuator.

Does the Print Cartridge Sensor Assembly Actuator move smoothly?

3 1. Enter Service Diagnostics and select Sensor Tests.

2. Scroll to Print Cartridge Sensor test and press OK.

3. Insert and remove the Print Cartridge a few times.

Does the display alternate between “Not Installed” and “Installed” as you remove and replace the Print Cartridge?

4 1. Switch the printer power OFF.

2. Remove the Left Interface Cover (RRP 1.1 on

page 6-6), the Left Cover (RRP 1.2 on page 6-7), and

the Left Plate (RRP 1.11 on page 6-16).

3. Install the Print Cartridge. Leave the Front Cover open.

4. Disconnect P/J25 from the Engine Logic Board.

5. On the Engine Logic Board, check for continuity between J21-4 and J25-3, and J25-2 and J25-1 as you insert and remove the Print Cartridge.

Is there continuity between J25-4 and J25-3, and J25-2 and J25-1 when you insert the cartridge and no continuity when you remove the cartridge?

Is the Print Cartridge a Xerox Phaser 4400 Print Cartridge?

Go to step 2. Replace the

Go to step 3. Replace the

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Replace the Engine Logic Board (RRP

9.3 on

page 6-89).

Replace the Print Cartridge Sensor Assembly together with the harness (RRP 7.4 on

page 6-81).

Print Cartridge (PL

8.1 on

page 7-20).

Print Cartridge Sensor Assembly (RRP 7.3 on

page 6-81).

Go to step 4.

Go to step 5.

Replace Print Cartridge with a Xerox Phaser 4400 Print Cartridge (PL

8.1 on

page 7-20).

Phaser 4400 Laser Printer Service Manual 2-57

Image Processor POST Error Codes

The Image Processor Power-On Self-Test (POST) detects two major types of faults:

■ Hard faults are those that are known to prevent initialization of the operating

system used by the Image Processor board CPU.

■ Soft faults are those that are not a core resource to the operating system, and

do not prevent it from initializing and becoming available as a tool for troubleshooting. Soft faults are reported on the Startup Page after the system is running.

Fault Reporting Devices

There are four fault presentation devices: the health LED, the Front Panel LED, the Front Panel display, and the Start Page. (Refer to Image Processor Board on page 1-10 for the health LED location on the Image Processor Board.) These devices are used only after initial tests indicate they are functioning properly.

For hard faults:

■ The health LED blinks according to the fault code.

■ The Front Panel LED blinks in unison with the health LED.

■ The last posted message to the Front Panel display is present.

For soft faults:

■ All soft faults are printed on the Start Page.

LED Blink Patterns

For faults identified as hard faults, the POST firmware blinks the Health LED in a particular pattern of short and long blinks to identify the fault. A long blink is worth 5 and a short blink is worth 1. If a fault blink pattern is flashed as long, long, short, short, this is fault code 5+5+1+1=12. Note that for test 5, the blink pattern is five short blinks.

The exception to the pattern just described is a RAM test error. The RAM tests have a special blink pattern and the front panel displays front panel LED is on. If the RAM tests fail, the Image Processor Board health LED turns off, and the front panel LED is red. At 1/2-second intervals, the health LED and the front panel LED toggle continuously.

2-58 Phaser 4400 Laser Printer Service Manual

RAM Error. During power-on the

POST Error Code Table

LED Blink Code

1+1 2: I/O ASIC Image Processor Board ASIC failure. Go to Image

1+1+1 3: LOCAL BUS

1+1+1+1+1 5: Please Install

5+5 10: EEPROM 1. Switch off printer power.

5+5+1 11: ETHERNET

5+5+1+1 12: CPU

5+5+1+1+1 13: USB Image Processor parallel port failure, USB port failure,

5+5+1+1+1+1 14: REAL TIME

5+5+5 15: RAM DIMM RAM DIMM failure. Go to 15: RAM DIMM (RAM Error) on

5+5+5+1 16: RAM LIMIT Image Processor Board Timer failure. Go to Image

5+5+5+1+1+1 18: L2 CACHE

5+5+5+1+1+1+1 19: PCI BRIDGE Image Processor Board Timer failure. Go to Image

5+5+5+5 20: IDE DISK Hard disk failure.

5+5+5+5+1 21: PARALLEL

5+5+5+5+1+1 22: ENGINE

5+5+5+5+1+1+1 23: VIDEO DMA

Continuous 1/2 second interval

Front Panel

Comment

Message

Processor Isolation on page 3-31.

BRIDGE/FRONT PANEL

Configuration Chip.

PHY

INTERRUPTS

CLOCK

TEST

PORT

COMMAND

TEST

RAM Error Go to 15: RAM DIMM (RAM Error) on page 2-60.

Image Processor Board ASIC failure. Go to Image

Processor Isolation on page 3-31.

1. Switch off printer power.

2. Remove and re-install the Configuration Chip.

3. Switch on printer power.

4. If the error message persists, first replace the Configuration Chip, then the Image Processor Board.

2. Remove and re-install the NVRAM EEPROM.

3. Switch on printer power.

4. If the error message persists, first replace the NVRAM EEPROM, then the Image Processor Board (RRP 9.2 on page 6-88).

Image Processor parallel port failure, USB port failure, E-Net Port Failure.

Replace Image Processor Board (RRP 9.2 on page 6-88).

Go to Image Processor Isolation on page 3-31.

E-Net Port Failure.

Replace Image Processor Board (RRP 9.2 on page 6-88).

Image Processor Board Timer failure. Go to Image

Processor Isolation on page 3-31.

page 2-60.

Processor Isolation on page 3-31.

Image Processor Board Timer failure. Go to Image

Processor Isolation on page 3-31.

Replace the Hard Disk (PL 10.1 on page 7-24).

Replace the Image Processor Board (RRP 9.2 on

page 6-88).

Image Processor parallel port failure, USB port failure, E-Net Port Failure.

Image Processor Board Timer failure. Go to Image

Processor Isolation on page 3-31.

Image Processor Board Timer failure. Go to Image

Processor Isolation on page 3-31.

Image Processor Xerox Image Enhanced VDMA failure.

Image Processor Board Timer failure. Go to Image

Processor Isolation on page 3-31.

Phaser 4400 Laser Printer Service Manual 2-59

Start page Soft Fault Messages

The soft faults that are set by POST diagnostics will print a message on the Start Page in a gray box. The box is large enough to contain all the soft faults encountered, with the upper left corner of the box in the center of the Start Page, and extending to the right margin, similar to the one shown here.

Hardware Failure:

<device>:

General Failure

The following messages are substituted for <device>:

■ Real Time Clock: (for POST_DEV_RTC)

■ Ram Memory Slot 1 Checksum (for POST_DEV_DIMM)

■ Ram Memory Slot 2 Checksum (for POST_DEV_DIMM)

■ Ram Memory Slot 1 Rejected (for POST_DEV_DIMM)

■ Ram Memory Slot 2 Rejected (for POST_DEV_DIMM)

■ IDE Disk: (for POST_DEV_IDEOPT)

■ Parallel Port: (for POST_DEV_CENT)

15: RAM DIMM (RAM Error)

RAM DIMM Troubleshooting Procedure

Step Actions and Questions Yes No

1 1. Switch the printer power OFF.

2. Remove the Left Interface Cover (RRP 1.1 on

page 6-6).

3. Remove and re-install the RAM DIMM(s).

4. Switch the printer power-on.

Does the error code reappear?

Does the RAM DIMM meet the specifications listed on page 1-3?

Does the RAM function correctly?

Go to step 2. Problem

Go to step 3. Install a new

Problem solved.

solved.

RAM DIMM (PL 10.1

Electrical on

page 7-24).

Install a new RAM DIMM (PL 10.1

Electrical on

page 7-24).

2-60 Phaser 4400 Laser Printer Service Manual

Troubleshooting

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

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

Unless otherwise specified, the following voltage tolerances are used within this section:

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

Phaser 4400 Laser Printer Service Manual 3-1

Troubleshooting Procedures

Index of Troubleshooting Procedures

Verifying AC Power . . . . . . . . . . . . . . . . .3-2 Print Cartridge Sensor Assembly . . . . . 3-24

DC Power (LVPS). . . . . . . . . . . . . . . . . . .3-4

DC Power Loading . . . . . . . . . . . . . . . . . .3-6

Toner Sensor Failure . . . . . . . . . . . . . . . .3-8

Inoperative Printer . . . . . . . . . . . . . . . . . .3-9

Malfunctioning Front Panel. . . . . . . . . . .3-11

Inoperative Front Panel . . . . . . . . . . . . .3-13

Erratic Printer Operation. . . . . . . . . . . . .3-13

Power Supply . . . . . . . . . . . . . . . . . . . . .3-14

Main Motor Assembly. . . . . . . . . . . . . . .3-15

Laser Assembly . . . . . . . . . . . . . . . . . . .3-17

Fuser Assembly . . . . . . . . . . . . . . . . . . .3-18

Registration Sensor . . . . . . . . . . . . . . . .3-20

MPT No Paper Sensor . . . . . . . . . . . . . .3-21

Tray 1 No Paper Sensor. . . . . . . . . . . . .3-22

Output Tray Full Sensor . . . . . . . . . . . . .3-22

Stack Height Sensor Checkout. . . . . . . .3-23

Verifying AC Power

Tray Motor Assembly Checkout . . . . . . 3-26

Registration Clutch . . . . . . . . . . . . . . . . 3-27

Turn Roller Clutch Assembly. . . . . . . . . 3-28

Tray 1 Feed Clutch . . . . . . . . . . . . . . . . 3-29

MPT Pick Up Solenoid . . . . . . . . . . . . . 3-30

Image Processor Isolation. . . . . . . . . . . 3-31

High-Voltage Power Supply (HVPS)

Assembly. . . . . . . . . . . . . . . . . . . . . . . . 3-31

Electrical Noise . . . . . . . . . . . . . . . . . . . 3-33

Exit Sensor . . . . . . . . . . . . . . . . . . . . . . 3-34

Exit Motor . . . . . . . . . . . . . . . . . . . . . . . 3-35

550-Sheet Feeder Feed Clutch . . . . . . . 3-36

Stacker Full Sensor. . . . . . . . . . . . . . . . 3-37

Stacker Offset Operation Not Performed3-38

Envelope Feed Clutch . . . . . . . . . . . . . . 3-38

Envelope No Paper Sensor . . . . . . . . . . 3-39

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.

3-2 Phaser 4400 Laser Printer Service Manual

AC Power Testing Procedure

Step Actions and Questions Yes No

1. Disconnect the AC power cord from the wall outlet. for [115 VAC ]

2. Measure the AC voltage between AC Line and

Neutral, between AC Line and Ground, and between AC Neutral and Ground.

3. The voltage between Line and Neutral and between

Line and Ground should range from 90 to 140 VAC and the voltage between Neutral and Ground should be less than 3 VAC.

Go to step 4 Inform

Is the AC voltage within specification?

1. Disconnect the AC power cord from the wall outlet. for [220 VAC ]

2. Measure the AC voltage between Line and Neutral,

between AC Line and Earth/Ground, and between Neutral and Earth/Ground.

3. The voltage between Line and Neutral and between

Line and Earth/Ground should range from 198 to 264 VAC and the voltage between Neutral and Ground should be less than 3 VAC.

Go to step 2. Inform

Is the AC line voltage within specification?

1. Disconnect the AC power cord from the wall outlet. for [220 VAC ]

Go to step 2. Inform

customer of insufficient voltage or improper wiring.

2. Measure the AC voltage between Line and Neutral,

between AC Line and Earth/Ground, and between Neutral and Earth/Ground.

3. The voltage between Line and Neutral and between

Line and Earth/Ground should range from 198 to 264 VAC and the voltage between Neutral and Ground should be less than 3 VAC.

Is the AC line voltage within specification?

2 1. Check the continuity through all connections of the

power cord.

2. The measurement should be less than 10 ohms for

each connection.

Perform “DC

Power (LVPS)”

Replace the power cord (“PL 10.1

Electrical”).

Does continuity test per specification?

Phaser 4400 Laser Printer Service Manual 3-3

Xerox Phaser 4400 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual