Xerox Phaser 4400 Service Manual

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

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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

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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.

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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

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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

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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

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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.

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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.

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Machine Orientation

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

Machine Orientation

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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

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Xerox Phaser 4400 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual