Xerox Phaser 4500, Phaser 4510 Service Manual

Service Manual

701P45760

Phaser 4500/4510

Laser Printers

arning

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.

Prepared By: Xerox Corporation XOG Worldwide Product Training and Information 26600 SW Parkway Wilsonville, OR 97070

Copyright © 2007 Xerox Corporation. All Rights Reserved. Unpublished rights reserved under the copyright laws of the United States. Contents of this publication may not be reproduced in any form without permission of Xerox Corporation.

Copyright protection claimed includes all forms of matters of copyrightable materials and information now allowed by statutory or judicial law or hereinafter granted, including without limitation, material generated from the software programs which are displayed on the screen such as styles, templates, icons, screen displays, looks, etc.

Xerox technical training materials and service manuals are intended for use by authorized Xerox service technicians and service partners only and are not for resale. These materials may not be distributed, copied or otherwise reproduced without prior written consent from Xerox Corporation.

XEROX PhaserSMART

Acrobat Adobe Garamond

, The Document Company®, the digital X®, CentreWare®, infoSMART®, Made For Each Other®, PagePack™, Phaser®,

, and Walk-Up™ are trademarks of Xerox Corporation in the United States and/or other countries.

, Adobe® Reader®, Adobe Type Manager®, ATM™, Illustrator®, PageMaker®, Photoshop®, PostScript®, Adobe Brilliant® Screens,

, Adobe Jenson™, Birch®, Carta®, IntelliSelect®, Mythos®, Quake®, and Tekton® are trademarks of Adobe Systems

Incorporated in the United States and/or other countries.

, AppleTalk®, Bonjour®, EtherTalk®, LaserWriter®, LocalTalk®, Macintosh®, Mac OS®, TrueType®, Apple Chancery®, Chicago®,

Apple

Geneva HP-GL IBM Windows Novell

, Monaco®, New York®, and QuickDraw® are trademarks of Apple Computer, Inc. in the United States and/or other countries.

, HP-UX®, and PCL®are trademarks of Hewlett-Packard Corporation in the United States and/or other countries.

and AIX® are trademarks of International Business Machines Corporation in the United States and/or other countries.

, Vista™, Windows Server™, and Wingdings® are trademarks of Microsoft Corporation in the United States and/or other countries.

, NetWare®, NDPS®, NDS®, Novell Directory Services®, IPX™, and Novell Distributed Print Services™are trademarks of Novell,

Incorporated in the United States and/or other countries.

, Sun Microsystems™, and Solaris™ are trademarks of Sun Microsystems, Incorporated in the United States and/or other countries.

Sun

SWOP UNIX As an E

guidelines for energy efficiency. The E

is a trademark of SWOP, Inc.

is a trademark in the United States and other countries, licensed exclusively through X/Open Company Limited.

NERGY STAR

partner, Xerox Corporation has determined that this product, when equipped with a duplex unit, meets the ENERGY STAR

NERGY STAR name and logo are registered U.S. marks.

PANTONE PANTONE

Colors generated may not match PANTONE-identified standards. Consult current PANTONE Publications for accurate color.

and other Pantone, Inc. trademarks are the property of Pantone, Inc. © Pantone, Inc., 2000. This product uses code for SHA-1 written by John Halleck, which is being used with his permission. This product includes an implementation of LZW licensed under U.S. Patent 4,558,302. Other marks are trademarks or registered trademarks of the companies with which they are associated.

ii Phaser 4500/4510 Service Manual

Service Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi

Product Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xii

Power Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

Electrostatic Discharge (ESD) Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv

Service Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv

Regulatory Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

1 General Information

Printer Introduction and Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Technical Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Printer Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

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

Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

Image Processor Board (Phaser 4500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Image Processor Board (Phaser 4510) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Consumables and Routine Maintenance Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Supply Life Counters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Printer Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

Physical Dimensions and Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Functional Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Electrical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13

Media and Tray Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Memory Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Contents

2 Theory of Operation

Overview of the Phaser 4500/4510 Laser Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Summary of the Printing Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Paper Path of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Layout of Paper Transport Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Major Assemblies and Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Paper Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Paper Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

Control of Paper Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Xerographics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Fuser Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

Paper Exit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Printer Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

Optional 550-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

Phaser 4500/4510 Laser Printer Service Manual iii

Contents

3 Error Messages and Codes

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Using the Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

General Notes on Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Accessing Fault Histories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Entry Level Fault Isolation Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Service Diagnostics Menu Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Service Diagnostic Control Panel Button Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Using Service Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

System Start-Up and POST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Power On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

POST Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

LED Blink Patterns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

POST Diagnostic Test Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Operating System and Application Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Macintosh Printing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Windows Printing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Network Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

Troubleshooting Procedures for Error Messages and Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Main Motor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Laser Unit Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

Fuser Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Fan Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Engine Logic Board NVRAM Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Jam At Tray N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Jam at Tray N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37

Jam At Top; Open Top Cover To Clear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40

Jam At Exit; Open Rear/Top Cover To Clear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43

Jam At Rear; Open Rear Cover To Clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Jam At Stacker; Open Rear Stacker Cover To Clear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 4 7

Jam At Rear; Open Duplex And Rear Cover To Clear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

Jam At Duplex; Open Duplex To Clear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51

Duplex Unit Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

Stacker Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

Tray 3 Failure/Tray 3 or 4 Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Paper Size Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56

Close Top Cover/Close Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Close Duplex Unit Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

Close Stacker Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-60

Install or Reseat Print Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

Replace Print Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

No Paper in Tray 1/No Paper in Tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-63

Tray 2 Paper Is Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-64

No Paper in Tray 3/No Paper in Tray 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-65

Tray 3 Paper Is Low/Tray 4 Paper Is Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-66

Insert Tray 1/Insert Tray 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

Insert Tray 3/Insert Tray 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

Stacker Is Full, Unload Paper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69

Standard Output Tray Is Full, Unload Paper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-70

Replace Maintenance Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

Inoperable Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72

No Recognition of Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73

No Recognition of Stacker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75

iv Phaser 4500/4510 Service Manual

4 General Troubleshooting

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Control Panel Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

LCD/LED Display Error/Inoperable Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

DC Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

LVPS (Low Voltage Power Supply). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

DC-DC Converter (P4500 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

AC Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

No AC Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Print Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Main Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Laser Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Fuser Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

Registration Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Low Paper Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Toner Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

Output Tray Full Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

24 V Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

5 V Interlock, Interlock Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25

Rear Cover Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Interlock Switch Assembly (P4500 only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

Exit Motor PWBA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

Exit Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Registration Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Feed Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

Left Tray Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

HVPS/Engine Logic Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Image Processor Isolation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

Image Processor Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

RAM DIMM Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

Optional 550-Sheet Feeder PWBA (Tray 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

Optional 550-Sheet Feeder PWBA (Tray 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

Optional 550-Sheet Feeder No Paper Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-41

Optional 550-Sheet Feeder Low Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

Optional Feeder Paper Size Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45

Optional 550-Sheet Feeder Feed Clutch Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

Optional 550-Sheet Feeder Turn Roller Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48

Duplex Unit PWBA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49

Duplex Unit Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

Duplex Unit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51

Duplex Unit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-53

Stacker PWBA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54

Stacker Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

Offset Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56

Gate Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57

Stacker Rear Cover Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58

Stacker Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59

Stacker Full Sensor (On Stacker PWBA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-60

Offset Sensor (On Stacker PWBA). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61

Contents

Phaser 4500/4510 Laser Printer Service Manual v

Contents

5 Print-Quality Troubleshooting

Print-Quality Problems Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Analyzing Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Deletions (Line, Band, Spots) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

Registration (Side-to-Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Registration (Lead Edge-to-Trail Edge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Skips/Smears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Spots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

Other Print Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Print-Quality Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Light (Undertoned) Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Blank Print (No print) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17

Black Prints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Vertical Deletions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Horizontal Deletions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25

Horizontal Streaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

Spots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-29

Unfused Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-31

Damaged Print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-34

Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-35

Spot Deletions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

Repeating Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

Residual Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

Background. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

Uneven Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-42

Skewed Image. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

Registration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

Skips and Smears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

6 Adjustments and Calibrations

Service Test Prints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

Test Prints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Engine Test Print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

Adjusting Laser Power (Image Density) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

Checking Registration (Margins). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Adjusting Simplex Registration (Margins). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Adjusting Duplex Registration (Margins). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Adjusting Fuser Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Resetting Fuser Life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Resetting Printer Values to the Factory Default Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

Resetting Connection Setup Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Resetting Paper Handling Setup Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Resetting PostScript Setup Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Resetting PCL Setup Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Resetting General Setup Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Resetting Control Panel Setup Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Resetting Printer Controls Setup Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Resetting File Security Setup Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Resetting All Printer Default Settings (PostScript NVRAM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

vi Phaser 4500/4510 Service Manual

7 Cleaning and Maintenance

Service Preventive Maintenance Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Recommended Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

8 FRU Disassembly

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Standard Orientation of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

General Notes on Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Notations in the Disassembly Text. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Print Engine: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Paper Exit Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4

Paper Exit Rear Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5

Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6

Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8

Top Cover Assembly, Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9

Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

Interlock Switch Assembly (P4500 only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12

Print Engine: 150- or 550-Sheet Paper Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

Retard Roller and Holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

Print Engine: 150-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

150-Sheet Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

Nudger Roller, Feed Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

Nudger One-way Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-17

Nudger Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

Feed Clutch, Registration Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

Registration Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21

Toner Sensor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23

Print Engine: 550-Sheet Paper Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-24

550-Sheet Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

Nudger Roller, Feed Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

Nudger One-way Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-26

Nudger Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27

Feed Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29

No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30

Right Tray Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-31

Left Tray Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33

Low Paper Sensor/Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34

Print Engine: Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35

Vacuum Duct (P4510). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35

Front Duct, Sub Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36

Laser Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38

Laser Unit Shield Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

Print Cartridge Left Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40

Fuser Harness Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42

Link Lever, Gear 3 Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43

Fuser Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-44

Transfer Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45

Transfer Chute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-46

Print Cartridge Right Guide Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47

Duplex Unit Opening Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-48

Contents

Phaser 4500/4510 Laser Printer Service Manual vii

Contents

Print Engine: Paper Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49

Paper Exit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-49

Upper Exit Chute, Lower Exit Chute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50

Exit Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51

Output Tray Full Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52

Stack Full Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-53

Print Engine: Frame and Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54

Motor Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54

Main Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55

Gear Assembly Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56

Gear Assembly Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58

Print Engine: Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-60

LVPS Shield Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-60

Exit Motor PWBA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-61

Low Voltage Power Supply (LVPS) (P4500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-62

DC-DC Converter (P4500). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-63

Low Voltage Power Supply (LVPS) (P4510) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-64

Power Switch, AC Power Harness Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-65

Rear Cover Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-67

Main Fan (P4500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-68

Main Fan (P4510) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-69

Image Processor Shield Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-70

I/P Shield Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-71

HVPS Shield Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-72

HVPS/Engine Logic Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-73

Image Processor (I/P) Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-75

Options: 550-Sheet Paper Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-78

550-Sheet Paper Feeder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-78

Right Cover Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-79

Left Cover Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-81

Option Paper Size Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-82

Optional Feeder Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-83

550-Sheet Feeder PWBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-85

550-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-86

Nudger Roller, Feed Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-87

Nudger One-way Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-88

Nudger Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-89

Feed Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-91

Turn Roller Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-92

Retard Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-93

Options: Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-95

Duplex Unit Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-95

Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-96

Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-97

Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-98

Upper Assembly Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-99

Duplex Unit Lower Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-100

Duplex Unit PWBA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-102

Duplex Unit Fan (P4500). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-104

Duplex Unit Fan (P4510). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-105

Duplex Unit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-106

Duplex Unit Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-107

Duplex Unit Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-109

Duplex Unit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 -110

viii Phaser 4500/4510 Service Manual

Options: Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-111

Stacker Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-111

Stacker Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-112

Stacker Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-113

Stacker Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-115

Stacker Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-116

Stack Full Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-117

Stacker PWBA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-119

Offset Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-120

Gate Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-121

Stacker Sensor and Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-122

Stacker Rear Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-123

Lower Stacker Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-124

Upper Stacker Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-126

Stacker Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-128

9 Parts Lists

Serial Number Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Using the Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Print Engine Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Parts List 1.1 Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Parts List 2.1 150-Sheet Paper Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

Parts List 4.1 550-Sheet Paper Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

Parts List 5.1 150-Sheet Paper Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12

Parts List 7.1 550-Sheet Paper Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-15

Parts List 8.1 Xerographics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18

Parts List 10.1 Paper Exit (1/2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-21

Parts List 10.2 Paper Exit (2/2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-23

Parts List 11.1 Frame and Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25

Parts List 12.1 Electrical (P4500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27

Parts List 12.1 Electrical (P4510) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31

Parts List 20.1 550-Sheet Paper Feeder (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31

Parts List 20.2 550-Sheet Paper Feeder (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34

Parts List 20.3 Optional 550-Sheet Paper Cassette. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36

Parts List 21.1 Duplex Unit (P4500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39

Parts List 21.1 Duplex Unit (P4510) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40

Parts List 23.1 Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43

Xerox Supplies and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46

Contents

10 Wiring Diagrams

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

Print Engine Plug/Jack Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

550-Sheet Feeder Plug/Jack Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12

Duplex Unit Plug/Jack Locator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 0-14

Stacker Plug/Jack Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16

Notations Used in Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17

Phaser 4500/4510 Laser Printer Service Manual ix

Contents

Print Engine Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19

P4500: General Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-19

P4510: General Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20

P4500: 24 V Interlock, Rear Cover Switch, Main Motor, Sub Fan, Exit Motor Assembly. . . . . . . . . . . . . . 10-21

P4510: 24 V Interlock, Rear Cover Switch, Main Motor, Sub Fan, Exit Motor Assembly. . . . . . . . . . . . . . 10-23

Fuser Assembly, Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25

Print Cartridge, Transfer Roller Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26

150-Sheet Feeder, 550-Sheet Feeder, Main Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27

Laser Unit, 5 V Interlock, Interlock Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29

Paper Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-30

Image Processor Board, DC-DC Converter (P4500), Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31

Optional 550-Sheet Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32

550-Sheet Feeder General Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32

550-Sheet Feeder Signal Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-33

Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34

Duplex Unit General Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-34

Duplex Unit Signal Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35

Stacker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-36

Stacker General Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36

Stacker Signal Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37

A Appendix

Phaser 4500 Menu Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Phaser 4510 Menu Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Service Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Index

x Phaser 4500/4510 Service Manual

Service Terms

Not

Manual Terms

Various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger present during a procedure or action. Be aware of all symbols and terms when they are used, and always read NOTE, CAUTION, and WARNING statements.

Consumable: Ink, toner, or print cartridge that is consumed. Customer is

expected to replace once consumed.

Routine Maintenance Item: Supply item or kit that has a limited life. Customer is

expected to replace at end-of-life.

Accessory: A single component or assembly that may be added to a printer;

howev er, it is NOT an option to the product. Throughout this manual any pieces of information that pertain to just the

Phaser 4500 are indicated with P4500, and those that pertain to just the Phaser 4510 are indicated with P4510. Those that apply to both models do not have either label.

Common Acronyms:

FRU: Field Replaceable Unit PL: Corresponds to the FRU Parts List. CRU: Customer Replaceable Unit ESD: Electrostatic Discharge

A note indicates an operating or maintenance procedure, practice or condition that is necessary to efficiently accomplish a task. A note can provide additional information related to a specific subject or add a comment on the results achieved through a previous action.

Caution

A caution statement indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, results in damage to, or destruction of, equipment.

arning

A warning statement indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, results in injury or loss of life.

Phaser 4500/4510 Laser Printer Service Manual xi

Product Terms

Symbols Marked on the Product

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

example, a panel may cover the hazardous area.

Danger: A personal injury haz ar d exists in the area where you see the sign.

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.

Use caution (or draws attention to a particular component). Refer to the manual(s) for information.

Do not touch the item.

xii Phaser 4500/4510 Service Manual

Power Safety Precautions

Power Source

Disconnecting Power

For 110 VAC printers, do not apply more than 135 volts RMS between the supply conductors or between either supply conductor and ground. Use only the specified power cord and connector. F or 220 VAC printers, do not apply more than 254 volts RMS betwe en the supply conductors or between either supply conductor and ground. Use only the specified po wer cord. This man ual assumes that the reader is a Xerox-certified service technician.

Plug the three-wire power cor d (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 it s ground connection, contact with conductive parts may cause an electrical shock.

Turning the power off using the On/Off switch does not completely deenergize the printer . You must also disconnect the printer pow er cord f rom 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 4500/4510 Laser Printer Service Manual xiii

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 el ectricity.

Be sure the power is off to the chassis or circuit board, and observe all other safety precautions.

■ Immediately before handling an y semiconductor componen ts assemblies ,

drain the electrostatic charge from your body. This can be accomplished by touching an earth ground source or by w earing 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 conductiv e surf ace . If the ant i-static bag is condu ctiv e , yo u 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 re placement component or e lectrical sub-assemb ly from

its protective package unt il 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 circu it assembly into which the device will be installed.

■ Minimize body motions when handling unpackaged replacement devices.

Motion such as your clothes brushing together, or lifting a foot from a carpeted floor can generate enough static electricity to damage an electro-statically sensitive device

■ Handle ICs and EPROMs carefully to avoid bending pins.

■ Pa y attention to the direction o f parts when mounting or inserting them on

Printed Circuit Boards (PCB’s).

xiv Phaser 4500/4510 Service Manual

Service Safety Summary

General Guidelines

For Xerox-certified service personnel only: Refer also to the preceding Power

Safety Precautions.

Avoid servicing alone: Do not perform intern al se rvice or adjustment of this

product unless another person capabl e 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 A C outlet or 140 vo lts rms for a 110 volt AC outlet betwee n the su pp ly con d uct or s or betwe en 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 display ed on potentially dangerous compon ents. As y ou service the printer, check to make certain that all warning labels remain in place.

Safety Interlocks

Make sure all covers and the printer’s control panel are in place and all interlock switches are functioning correctly af ter you have completed a printer service call. If you bypass an interlock switch during a service call, use extreme caution when working on or around the printer.

CLASS 1 LASER PRODUCT

The Phaser 4500/4510 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 4500/4510 Laser Printer Service Manual xv

Servicing Electrical Components

Before starting any service procedure, s witch off th e printer pow er 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.

arning

Turning the power off by using the On/Off switch does not completely deenergize the printer . You must also d isconnect the printer power cord from the AC outlet. P osition the powe r cord so that it is easily accessibl e during servicing.

arning

Do not touch any electrical component unless yo u are inst ructed to do so by a service procedure.

S7300-02

Servicing Mechanical Components

When servicing mechanical components within the printer, manually rotate drive assemblies, rollers, and gears.

arning

Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running.

Servicing Fuser Components

arning

This printer uses heat to fuse the toner ima g e to med ia. 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.

S7300-03

xvi Phaser 4500/4510 Service Manual

Regulatory Specifications

United States (Federal Communications Commision

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 differe nt fr om t hat which th e

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.

Canada

Changes or modifications not expressly approved by Xerox can affect the emission and immunity compliance and could void the user's authority to operate this product. To ensure compliance, use shielded interface cables. A shielded parallel cable can be purchased directly from Xerox at

www.xerox.com/office/4500supplies

Xerox has tested this product to internationally accepted electromagnetic emission and immunity standards. These standards are designed to mitigate interference caused or received by this product in a normal office environment. This product is a lso suit ab le 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 Class B digital apparatus complies with Canadian ICES-003. Cet appareil numérique de la classe B est comforme à la norme NMB-003 du

Canada.

Phaser 4500/4510 Laser Printer Service Manual xvii

European Union

January 1, 1995: Low Voltage Directive 73/23/EEC as amended by 98/68/

January 1, 1996: Electromagnetic Compatibility Directive 89/336/EEC March 9, 1999: Radio & Telecommunications T erminal Equipment Directiv e

This product, if used properly in accordance with the user's instructions, is neither dangerous for the consumer nor for the environment.

To ensure compliance with European Union regulations, use shielded interface cab les.

A signed copy of the Declaration of Conformity for this product can be obtained from Xerox.

The CE mark applied to this product symbolizes Xerox’s declaration of conformity with the following applicable Directives of the European Union as of the dates indicated:

EEC

1999/5/EC

xviii Phaser 4500/4510 Service Manual

General Information

In this chapter...

■ Printer Introduction and Overview

■ Printer Configurations

■ Parts of the Printer

■ Control Panel

■ Image Processor Board (Phaser 4500)

■ Image Processor Board (Phaser 4510)

■ Consumables and Routine Maintenance Items

■ Printer Specifications

Chapter

General Information

Printer Introduction and Overview

The Xerox Phaser 4500/4510 Laser Printer Service Manual is the primary document used for repairing, maintain ing, and troubleshooting the printer.

To ensure complete understanding of this product, participation in Xerox Phaser 4500/4510 Service Training is strongly recommended. To service this product, Xerox certification for this product is required.

Technical Support Information

For updates to the Service Manual, Service Bulletins, knowledge base, etc., go to www.office.xerox.com/partners

For further technical support, contact your assigned Xerox Technical Support for this product.

s4500-001

1-2 Phaser 4500/4510 Service Manual

Printer Configurations

General Information

A replaceable configuration card holds configuration information that enables or disables the network features shown in the following table.

Printer Configurations

Printer Configuration

Features

B N DT DX

Maximum print speed (letter-size paper)

P4500: P4510:

Memory

P4500: P4510:

PostScript fonts 39 39 39 39 + 97

36 ppm 45 ppm

48 MB 128 MB

36 ppm 45 ppm

64 MB 128 MB

36 ppm 45 ppm

64 MB 128 MB

36 ppm 45 ppm

64 MB 128 MB

on hard

drive PCL5e/PCL6 Yes Yes Yes Yes Job pipelining Standard Standard Standard Standard PDF direct print Yes Yes Yes Yes Resolutions 600 dpi,

T rue 1200

dpi USB, Parallel Yes Yes Yes Yes 10/100BaseTX Ethernet capabilities Optional Standard Standard Standard 550-sheet feeder (tray 3) Optional Optional Standard Standard 550-sheet feeder (tray 4) Optional Optional Optional Optional Automatic 2-sided printing

(requires duplex unit) Hard drive Optional Optional Optional Standard Job collation

(Requires a hard drive) Proof Print, Secure Print, Saved

Jobs (Requires a hard drive) 500-sheet stacker Optional Optional Optional Standard

Optional Optional Standard Standard

Optional Optional Optional Standard

600 dpi, True 1200 dpi

Phaser 4500/4510 Service Manual 1-3

General Information

4510-067

1 2

P4510

Parts of the Printer

Front View

1.Paper stop

2.Control panel

3.Tray 1

4.On/Off switch

5.Tray 2

6.Optional tray 3

Rear View

P4500

1 3

4510-072

7.Optional tray 4

8.Paper gauge

9.Print cartridge

10.Standard output tray

11.Optional 500-Sheet stacker

4510-073

Items 1 - 4 are mounted on the image processor board.

1.Ethernet 10/100 Base-T connector

2.Configuration card

3.USB connector

5.Power receptacle

6.Optional duplex unit

7.Rear cover

8.Stacker rear cover

9.Stacker extension

4.Parallel cable connector

1-4 Phaser 4500/4510 Service Manual

Control Panel

General Information

The control panel consists of one tricolor LED, a display window, and six functional buttons.

Phaser 4500

36 78

s4500-003

4 5

Phaser 4510

1 2

s4510-003

1.Status indicator LED 5.Up Arrow button - scrolls up the menu system

2.Graphic control panel display

6.Down Arrow button - scrolls down the menu system

3.Back button 7.OK (select) button

4.Cancel button 8.Information (i) (P4500) or Help (?) (P4510) button - for additional explanation or help

LED States

LED State Printer State

Green Ready to Print or in Power Saver mode Flashing Yellow Warning (but can still print) Flashing Green In Standby mode or busy (receiving data, processing data,

printing)

Flashing Red Error; cannot print

Phaser 4500/4510 Service Manual 1-5

General Information

Control Panel Shortcuts

Mode Buttons Pressed at Power On

Skip execution of POST diagnostics

Print Service Diagnostics Map Information Reset PostScript NVRAM Back + OK Password Bypass Up Arrow + Down Arrow Enter Service Diagnostics Back + Information

1-6 Phaser 4500/4510 Service Manual

Image Processor Board (Phaser 4500)

When installing a new image processor board in the printer, you must transfer the following parts from the old board:

■ Memory DIMMs

■ Hard drive (if installed)

■ NVRAM

■ Configuration card

General Information

2 3

4 5

1.Memory (RAM) DIMM 1 and DIMM 2 6.Parallel connector

2.Flash memory (optional) 7.Ethernet connector

3.Hard drive (optional) 8.USB connector

4.NVRAM 9.Health LED

5.Configuration card

8 5

s4500-251

Phaser 4500/4510 Service Manual 1-7

General Information

Image Processor Board (Phaser 4510)

When installing a new image processor board in the Phaser 4510 printer, y ou must transfer the following parts from the old board:

■ Memory DIMMs

■ Configuration card

■ NVRAM

■ Hard drive (if installed)

■ Flash memory (if installed)

5 4

1.Memory (RAM) DIMM 1 and DIMM 2 6.Parallel connector

2.Flash memory (optional) 7.Ethernet connector

3.Hard drive (optional) 8.USB connector

4.NVRAM 9.Health LED

s4510-251

5.Configuration Card

1-8 Phaser 4500/4510 Service Manual

Consumables and Routine Maintenance Items

Print Cartridge

Transfer Roller

Feed Rollers 3 per Paper Tray

General Information

Fuser

s4510-267

s4510-268

Phaser 4500/4510 Service Manual 1-9

General Information

Supply Life Counters

Internal counters track the usage of the Consumables and Routine Maintenance Items and store the values in NVRAM. The image pr ocessor board monitors these counters in order to displa y th e near end-of-life and endof-life messages.

Print life ratings are based on 5% coverage and an average job length of 4 pages.

Supply Print Life (Number of Images)

Consumables

Print cartridge, standardcapacity

Print cartridge, high-capacity 19,000

Routine Maintenance Items

Maintenance kit (consists of fuser, transfer roller, and 12 feed rollers)

10,000

200,000

1-10 Phaser 4500/4510 Service Manual

Printer Specifications

Physical Dimensions and Clearances

General Information

Print Engine Dimensions Value

Height 404 mm (15.9 in.) Width 422 mm (16.6 in.) Depth

Depth with paper cassette extended Weight (with 10-K print cartridge) 20.5 kg (45.2 lbs.) (P4500)

Clearances Value

Top 400 mm (16 in.) Left 210 mm (8 in.) Right 300 mm (12 in.) Front 480 mm (19 in.) Rear (with duplex unit installed) 230 mm (9 in.) Total Height requirement 820 mm (32 in.)

Mounting surface level tolerance ± 5°

550-Sheet Feeder Dimensions Value

Height (to top of feeder assembly) 143 mm (5.6 in.) Width 422 mm (16.6 in.) Depth

Depth with paper cassette extended

465 mm (18.3 in.) 524 mm (20.7 in.)

23.2 kg (51.0 lbs.) (P4510)

Add 9.6 cm (3.75 in.) for each 550-sheet feeder

452 mm (17.8 in.) 510 mm (20.1 in.)

Weight 6.3 kg (13.9 lbs.)

Duplex Unit Dimensions Value

Height 219 mm (8.6 in.) (P4500)

238 mm (9.4 in.) (P4510) Width 352 mm (13.8 in.) Depth 96 mm (3.8 in.) (P4500)

146 mm (5.8 in.) (P4510) Weight 1.9 kg (4.2 lbs.)

Stacker Dimensions Value

Height 226 mm (8.9 in.) Width 418 mm (16.4 in.) Depth

Depth with stacker tray extended Weight 2.6 kg (5.7 lbs.)

Phaser 4500/4510 Service Manual 1-11

312 mm (12.3 in.)

382 mm (15.1 in.)

General Information

Functional Specifications

Characteristic Specification

Printing process: Recording System: Electrophotography (roller charging,

magnetic monocomponent toner development) Exposure System: Semiconductor laser beam scanning Transfer System: Roller transfer system Fusing System: Thermal fixing using a heat roller

Resolution / Addressability

Print-Quality Modes Two choices: 600 x 600 dpi

Phaser 4500 Continuous operating printing speed

Phaser 4510 Continuous operating printing speed

Phaser 4500 First Print-Out from READY state (in seconds); Short Edge Feed

Phaser 4510 First Print-Out from READY state (in seconds); Short Edge Feed

600/1200 dpi

True 1200 x 1200 dpi

36 pages per minute for plain Letter paper, one-sided printing 34 pages per minute for A4 paper, one-sided printing

21 images per minute for Letter paper, 2-sided printing 21 images per minute for A4 paper, 2-sided printing)

45 pages per minute for plain Letter paper, one-sided printing 43 pages per minute for A4 paper, one-sided printing

27 images per minute for Letter paper, 2-sided printing 26 images per minute for A4 paper, 2-sided printing)

Paper Size

Letter A4

Paper Size

Letter A4

Mode

Simplex Duplex Simplex Duplex

Mode

Simplex Duplex Simplex Duplex

Tray 1

8.7

12.5

8.7

12.7

Tray 1

7.9

11.1

7.9

11.2

Tray 2

8.7

12.5

8.7

12.7

Tray 2

7.9

11.1

7.9

11.2

Tray 3

8.7

12.5

8.7

12.7

Tray 3

7.9

11.1

7.9

11.2

Tray 4

8.9

12.8

9.0

13.0

Tray 4

8.2

11.3

8.2

11.4

Phaser 4500 First Print-Out from sleep mode (in seconds); Short Edge Feed

Phaser 4510 First Print-Out from sleep mode (in seconds); Short Edge Feed

Warm-Up Time 17 seconds

1-12 Phaser 4500/4510 Service Manual

Paper Size

Letter A4

Paper Size

Letter A4

Mode

Simplex Duplex Simplex Duplex

Mode

Simplex Duplex Simplex Duplex

Tray 1

24.0

27.8

24.0

28.0

Tray 1

24.9

28.1

24.9

28.2

Tray 2

24.0

27.8

24.0

28.0

Tray 2

24.9

28.1

24.9

28.2

Tray 3

24.0

27.8

24.0

28.0

Tray 3

24.9

28.1

24.9

28.2

Tray 4

24.2

28.1

24.3

28.3

Tray 4

25.2

28.3

25.2

28.4

Electrical Specifications

Characteristic Specification

Primary Line Voltages 120 VAC nominal, min. 98 V, max. 140 V

General Information

220/240 VAC nominal, min. 198 V, max. 264 V

Primary Line Voltage Frequency Range

Maximum Power Consumption

Environmental Specifications

Characteristic Specification Temperature:

Operating Optimal Performance Range Transportation

Humidity (%RH)

Operating Transportation

50/60 Hz ± 3 Hz

P4500: 985 W @ 120 V

985 W @ 220/240 V

P4510: 1210 W @ 120 V

1270 W @ 220/240 V

5 to 35° C (41 to 95° F) 10 to 32° C (50 to 89.6° F)

-20 to 40° C (-4 to 104° F)

15 to 85 5 to 85

Altitude

Operating Transportation*

Acoustic Noise L

Idle Printing

* Air transportation in pressurized cargo space

WA(B)

0 to 3,500 meters (11,500 feet) 0 to 15,000 meters (49,200 feet)

Engine only

P4500: 4.00 B P4510: 5.00 B P4500: 6.62 B P4510: 6.95 B

With all options

— —

7.30 B

7.50 B

ENERGY STAR qualified printer

Phaser 4500/4510 Service Manual 1-13

General Information

Media and Tray Specifications

Trays Specifications

Printable Area

Supported Media Sizes

Supported Media Types and Weights

Supported Envelopes

All Within 4 mm of paper edge guaranteed.

Edge-to-edge printing supported.

Tray 1 Trays 2-4 Tray 1 Trays 2-4 Stacker

Width: 76.2 mm (3.0 in.) ~ 215.9 mm (8.5 in.) Width: 98.4 mm (3.9 in.) ~ 215.9 mm (8.5 in.) Length: 127.0 mm (5.0 in.) ~ 355.6 mm (14 in.) Length: 148.0 mm (5.8 in.) ~ 355.6 mm (14 in.) Width: 88.9 mm (3.5 in.) ~ 215.9 mm (8.5 in.) Length: 139.7 mm (5.5 in.) ~ 355.6 mm (14 in.)

All All

All All Tray 1 All All

Bond (P4500) 60-216 g/m

(P4510) 64-216 g/m Labels Transparency

Greeting Cards 190 g/m Index Card Stock 60-216 g/m Tag Stock 60-216 g/m Cover Stock 60-216 g/m

(70 lb. Cover)

(33-120 lb.)

(37-133 lb.)

(22-80 lb.)

All #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) (P4500 only)

(16-58 lb.)

(17.1-58 lb.)

Input Tray Capacity

Tray 1 Trays 2-4

150 sheets 550 sheets

Based on 75 g/m Capacity is reduced for heavier/thicker stock.

Output Tray Capacity

Standard Stacker

500 sheets 500 sheets

Duplex Unit Media Specifications

Input Tray Specifications

Width Tray 1

Trays 2-4

Height Tray 1

Trays 2-4

Supported

All

90 - 216 mm (3.5 - 8.5 in.) 98 - 216 mm (3.9 - 8.5 in.)

140 - 356 mm (5.5 - 14.0 in.) 148 - 356 mm (5.8 - 14.0 in.)

Bond P4500: 60-216 g/m

Media Types and Weights

Greeting Cards 190 g/m Index Card Stock 60-216 g/m Tag Card Stock 60-216 g/m Cover Stock 60-216 g/m

(20 lb. bond) paper stock.

P4510: 64-216 g/m

(70 lb. Cover)

(33-120 lb.)

(37-133 lb.)

(22-80 lb.)

(16-58 lb.)

(17.1-58 lb.)

1-14 Phaser 4500/4510 Service Manual

Memory Requirements

Phaser 4500

Characteristic Specification

General Information

Minimum required

Maximum supported

Supported type PC133 SDRAM in 144-pin SO-DIMM form

Phaser 4510

Characteristic Specification

Minimum required

Maximum supported

Supported type PC2700 DDR in 200-pin SO-DIMM form

64 MB – The Phaser 4500 B configuration reports 48 MB

256 MB – accepts modules of 64 or 128 MB in combinations to a total of 256 MB

128 MB

512 MB – accepts modules of 128 or 256 MB only in combinations to a total of 512 MB

Phaser 4500/4510 Service Manual 1-15

General Information

1-16 Phaser 4500/4510 Service Manual

Theory of Operation

In this chapter...

■ Overview of the Phaser 4500/4510 Laser Printer

■ Paper Path of the Printer

■ Sensors

■ Major Assemblies and Functions

■ Printer Options

Chapter

Theory of Operation

Overview of the Phaser 4500/4510 Laser Printer

Summary of the Printing Process

The Phaser 4500/4510 print process consists of the following steps:

1. Charge – The print cartridge contains a bias charge roller that uniformly

distributes a negative electrical charge over the photoconductive drum surface.

2. Exposure – The laser assembly scans the surf a ce of th e photocondu ctiv e

drum, which is located inside the print cartridge. The laser diode assembly produces a laser beam which is turned on and off according to a data signal. A 12-sided polygonal mirror in the scanner assembly is rotated at a specified speed. The laser beam is reflected off of the mirror and onto the drum surface through a series of lenses and mirrors. The laser beam scans the drum surface from o ne end to the other , neutralizing the negative charge to create one line of a latent image on the surface. The drum is rotated and the scan process is repeated to form an image on the drum surface.

3. Development – A magnetic roller in the print cartridge carries a thin layer

of toner supplied by an agit ator in the cartridge's toner compartment. The charging and metering (CM) blade inside the cartridge applies a negative charge to the toner and spreads the toner onto the magnetic roller. The negatively charged toner is transferred to the areas of the drum surface that have be en discharged.

4. Paper transport – Paper size sensors determine the length of the media.

Four tabs (one fix e d, three mo vable) located in the paper tray indicat e the location of the length guide and thereby identify the media size. Switches located in the left tray guides detect the position of four tabs located on the paper tray. The printer uses a three-roller system to pick paper. Two springs raise the tray's lift plate, along with the paper stack, against the nudger roller of the paper feeder assembly. To pick paper, the nudger roller advances the top sheet t o the fee d roller and retard roller. The retard roller prevents multi-picks. The feed roller advances the paper to the turn pinch rollers, which feed it to the registration rollers. The registration sensor is the first sensor to detect paper.

5. Transfer – The transfer roller is driv en b y a gear on the print cartridge. The

pressure of the transf er roller against the drum assists in driving the paper through the transfer area. The transfer roller applies a positive charge to the rear surface of the paper. The negatively charged toner image on the drum is attracted to the positive charge on the rear surface of the paper, causing the image to be transferred from the surface of the drum onto the paper.

6. Discharge – The detack saw, located on the transfer roller assembly,

helps to separate the paper by partially neutralizing the ch arge holding the paper to the drum.

7. Fusing – The paper is driven into the f user, which uses heat and pressure

rolls to melt and bond the toner onto the surface of the paper. Heat roller fingers inside the fuser peel off the leading edge of the paper from the Heat roller to prevent the paper from becoming wound around it. An exit sensor detects paper exiting from the fuser.

8. Cleaning – A cleaning blade in the print cartridge scrapes off toner

remaining on the drum surface after transfer has occurred. Then, the latent charge pattern remaining on the photoconductive drum is neutralized to prepare the drum for the next exposure cycle.

9. Paper exit – The paper is then advanced upward into the exit rollers and

into the selected output tray.

2-2 Phaser 4500/4510 Service Manual

10. Two-sided printing reverses the direction of the exit rollers to route the

paper through the duplex unit rollers and back to the registration roller. A sensor in the duplex unit detects the presence of paper.

Block Diagram of the Print Cycle

The block diagram of the print cycle shows the sequence of events for the xerographic process (dashed lines) and the paper flow (solid lines) into and out of the printer.

Charge

Exposure

Xerographic Cycle

Cycle Repeats for the Next Print

Development

Transport

Paper Enters

Transfer

Paper

Discharge

Cleaning

Theory of Operation

Two-sided

Printing

Fusing

Paper Exit

s4500-007

Components Associated with the Xerographic Process

This cut-away side view of the printer shows the location of individual components within the printer, and the major components that are directly related to the print cycle and to the paper path.

Paper

ransport

Pressure Roller

7. Fusing

6. Discharge

Detack Saw

Transfer Roller

5. Transfer

Print Cartridge

Heat Roller

Fuser Assembly

8. Cleaning

Cleaning Blade

Drum

Magnetic Roller

1. Charging

BCR

2. Exposure

Charge Metering Blade

3. Development

Laser Beam

Paper

s4500-008

Phaser 4500/4510 Service Manual 2-3

Theory of Operation

Paper Path of the Printer

Paper is supplied from Trays 1 and 2 or th e optional Trays 3 and 4, and is transported into the printer along the paper path shown below.

Optional 550-Sheet Feeder (Tray 4)

550-Sheet Tray

Nudger Roller

Feed Roller

Retard Roller

Turn Roller

Turn Pinch Roller

Optional 550-Sheet Feeder (Tray 3)

550-Sheet Tray

Nudger Roller

Feed Roller

Retard Roller

Turn Roller

Turn Pinch Roller

Rubber Registration Roller

Metal Registration Roller

Transfer Roller Assembly

Drum

Tray 2 Tray 1

Nudger Roller

Feed Roller

Retard Roller

Lower Stacker Roller

Pinch Roller

Upper Stacker Roller

Stacker Pinch Roller

Optional Stacker

Print Exit

Heat Roller

Pressure Roller

Fuser Assembly

Exit Roller

Exit Pinch Roller

500-sheet Exit Assembly

Duplex Roller

Pinch Roller

Optional Duplex Unit

s4500-017

2-4 Phaser 4500/4510 Service Manual

Layout of Paper Transport Path

This cross section of the printer shows the main components directly associated with the paper path and transport in the engine only.

Theory of Operation

1.Exit roller 8.Rubber registration roller

2.Exit pinch roller 9.Metal registration roller

3.Fuser assembly 10.Feed roller assemblies

4.Pressure roller 11.Retard roller assemblies

5.Heat roller 12.Nudger roller assemblies

6.Drum 13.Print cartridge

7.Transfer roller assembly 14.Laser assembly

s4500-018

Phaser 4500/4510 Service Manual 2-5

Theory of Operation

This cross section shows the additional components associated with paper transport when the 550-sheet feeders, the duplex unit, and the stacker are installed.

11 12

4500-019

1.Stacker pinch roller 8.Duplex pinch rollers

2.Lower stacker roller 9.Turn pinch rollers

3.Upper stacker roller 10.Turn roller assemblies

4.Upper stacker pinch roller 11.Feed roller assemblies

5.Exit roller 12.Retard roller assemblies

6.Exit pinch roller 13.Nudger roller assemblies

7.Duplex rollers

2-6 Phaser 4500/4510 Service Manual

Sensors

Theory of Operation

The printer contains a number of sensors of various types that perform a variety of functions. One group of sensors track the progress of the paper along the paper path, and detect if a paper jam occurs. Other sensors detect the presence of the print cartridge, stop printer activity if a door is open, and monitor the fusing temperature. The basic printer has 18 sensors, while a fully-optioned printer has 30 sensors.

The types of sensors in use vary with their function. In general, there are four basic type in use:

■ Photo

■ Microswitch

■ Soft Touch Sensors (STS)

■ Magnetic

Most of the photo sensors consist of a LED in one arm of a U-shaped holder, and a photo-transistor in the other arm. When nothing is betw een the arms of the sensor, light from the LED falls on the photo-receptor, turning it on. If the light is interrupted, the photo-transistor turns off. The on- or off-state of the transistor is used as a signal.

The microswitches are used primarily as interlocks in the printer. They are in a normally open state, and close when actuated. A bank of switches in a holder is used for detecting the size of paper in use in a tray. Cams in the tray close the switches in various combinations (see “Control of Paper Size” on page 2-17) to send a size signal to the controller.

The Soft Touch Sensor has a known value of resistance whose sensitivity varies with temperature.

The magnetic sensor detects the magnetic properties of the toner in the print cartridge.

A fifth sensor in use in the printer is the antenna used to communicate with the CRUM in the print cartr i dg e.

The list of Sensors and interlocks that follows gives each sensor by its name, lists which of the types it is, and briefly describes its function in the printer. The reference column lists manual pages where illustrations show the location of the sensor.

List of Sensors and interlocks

Name Type Function Reference

Paper low Mechanically

actuated photo sensor

Detects low paper condition in 550-Sheet trays 2, 3, and 4 (there is no low-paper

page 2-10 page 2-16

sensing in tray 1).

No paper Mechanically

actuated photo

Detects no paper condition in all trays.

Page 2-16

sensor

Paper size switches

Microswitch bank Detects the presence of a

tray and the paper size

Page 2-16 Page 2-41

setting of the tray.

Phaser 4500/4510 Service Manual 2-7

Theory of Operation

List of Sensors and interlocks

Name Type Function Reference

Registration sensor

Toner sensor Magnetic sensor Detects the presence of

Exit sensor Mechanically

Output tray full sensor

Temperature sensor

Rear cover switch

24 V interlock Microswitch Interrupts +24 V to the main

Mechanically actuated photo sensor

actuated photo sensor

Mechanically actuated photo sensor

Soft Touch Sensor Two of these monitor the

Microswitch Interrupts +24 V to the main

Detects the paper as it reaches the registration rollers.

toner in the print cartridge. Detects paper as it leaves

the fuser.

Detects when the standard output tray is full.

temperature of the Heat roller.

motor when the rear exit cover is open; in series with 24 V interlock.

motor when the top cover is open; in series with rear cover switch.

Page 2-10 Page 2-16

Page 2-16

Page 2-22

Page 2-27

Page 2-22

Page 2-30

T op cover switch (P4500 only)

Laser interlock (P4500 only)

5 V interlock Microswitch Interru pts +5 V to laser

Start of scan sensor

Fuser thermostat(s)

Stacker rear cover switch

Stacker sensor Mechanically

Microswitch Interrupts INTERLOCK BEF

to indicate the top cover is open.

Microswitch Interrupts +5 V to laser

diode; in series with 5 V interlock switch.

diode. In series with laser interlock.

Photo Detects the laser beam at the

start of a scan.

Thermostatic switche(s)

Microswitch Signals the HVPS/engine

actuated photo sensor

Interrupt AC power to the fuser heater in overtemp condition; P4500: two switches in series; P4510: single switch.

logic board that the stacker rear cover is open.

Senses the presence of paper in the stacker.

Page 2-30

Page 2-20

Page 2-22

Page 2-38

2-8 Phaser 4500/4510 Service Manual

Theory of Operation

List of Sensors and interlocks

Name Type Function Reference

Stacker offset sensor

Duplex unit switch

Duplex unit sensor

Stacker full sensor

Optional feeder paper size switch assembly

CRUM antenna Inductive magnetic

Mechanically actuated photo sensor

Microswitch Signals the HVPS/engine

Mechanically actuated photo sensor

Microswitch bank Detects the presence of a

code reader

Senses the position of the stacker offset chute.

logic board that the duplex unit rear cover is open.

Detects the presence of paper in the duplex unit.

Detects when the stacker output tray is full.

tray and the paper size setting of the tray.

Communicates with the print cartridge CRUM.

Page 2-38

Page 2-35

Page 2-38

Page 2-41

Phaser 4500/4510 Service Manual 2-9

Theory of Operation

Sensors in the Paper Path

9 10 11

12 13

1.Registration sensor 8.Tray 2 no paper sensor

2.Fuser exit sensor 9.Tray 2 low paper sensor

3.Output tray full 10.Tray 3 no paper sensor

4.Stacker sensor 11.Tray 3 low paper sensor

5.Stacker full 12.Tray 4 no paper sensor

s4500-270

6.Duplex unit sensor 13.Tray 4 low paper sensor

7.Tray 1 no paper sensor

2-10 Phaser 4500/4510 Service Manual

Major Assemblies and Functions

The functions of the main components of the Phaser 4500/4510 printer are described in the following sections:

■ Paper tr ay

■ Paper feeder

■ Print cartridge

■ Transfer roller assembly

■ Laser assembly

■ Fuser

■ 500-sheet paper exit

■ Drive

■ Electrical

Theory of Operation

Paper Tray

Paper trays include the 150-sheet and 550-sheet trays. Since they are functionally equivalent, only the 150-sheet tray is described here.

The trays adjust to a ccept various paper sizes. The end and side guides adjust to match paper sizes shorter than A4, or narrower than Letter. To accept paper longer than A4, the tray extension must be unlocked and pulled out, and the end and side guides adjusted to match the size.

Phaser 4500/4510 Service Manual 2-11

Theory of Operation

Paper Tray Functional Assemblies

s4500-021

1.Left-side paper guide assembly 5.R ight-side paper guide assembly

2.Bottom plate assembly 6.Extension lock

3.Bottom lock lever 7.End guide

4.Gear stopper

Left- and right-side paper guide assemblies The left and right paper guides

adjust to fit different paper widths . The guides hold th e paper in position in the tray.

Bottom plate assembly The bottom plate assembly is pushed up by the bottom

lift spring. The bottom plate is released b y unloc king th e bottom lo ck le v er and stopper gear . When the bottom plate assembly is pushed up, the supplied paper contacts the nudger roller.

Bottom lock lever and gear stopper These are at the rear of the tray (i.e., the

front end in the direction of travel of paper). How these components work is explained in “Paper Lift Mechanism” on page 2-14.

2-12 Phaser 4500/4510 Service Manual

Front

Theory of Operation

s4500-020

Extension lock The 150-sheet tray extends to accommodate different paper

lengths. The extension lock holds the extension in position.

End guide The end guide can be adjusted to different paper siz es by making a

forward or backward adjustment. It makes contact with the rear end of th e paper, an d holds the paper in position front-to-back in the paper tray.

Through the cam action of the sector gear and size rack, the position of the end guide is conve rted to up and down combinations of the three size switch links on the side of the tray. The links, when in contact with the paper size switches in the left tray guide, turn the switches on or off in combinations that correspond to the paper size.

Phaser 4500/4510 Service Manual 2-13

Theory of Operation

The paper sizes that can be automatically detected are as follows:

Type Size (mm × mm)

LETTER SEF 215.9 mm × 279.4 mm (8.5" x 14") LEGAL 14" SEF 215.9 mm × 355.6 mm (8.5" x 13") LEGAL 13" SEF 215.9 mm × 330.2 mm (8.5" x 11")

EXECUTIVE SEF 184.2 mm × 266.7 mm (7.25" x 10.5")

A4 SEF 210.0 mm × 297.0 mm (8.27" x 11.69")

B5 (JIS) SEF 182.0 mm × 257.0 mm (7.17" x 9.44")

A5 SEF 149.0 mm × 210.0 mm (5.83" x 8.27")

Paper Lift Mechanism

The Phaser 4500/4510 printer paper trays utilize a unique mechanical paper lift mechanism that eliminates the need for paper lift motors. The mechanism consists of a spring-loaded bottom plate assembly that lifts the paper stack upward to the paper feeder assembly.

When the tray is removed from the printer, a channel in the right tray guide pushes the bottom lock gear downward, lowering the bottom plate assembly until it is locked into place by a spring-loaded gear stopper, one-way loc k gear , and the bottom rack lock. The gear stopper engages the bottom lock gear, and the bottom rack lock engages the one-way lock gear, which prevents the bottom plate assembly from rising upward.

The gear stopper is released from the bottom lock gear when the tray is inserted into the printer. Once the gear stopper releases the bottom lock gear, the bottom rack lock holds the bottom plate assembly in place. Then, a metal tab located on the paper feeder assembly presses down on the bottom lock lever. This releases the bottom rack lock and allows the bottom plate assembly to raise the paper stack upward until it contacts the nudger roller and lifts the feeder assembly.

Once the feeder assemb ly is lifted b y the pa per stac k, the met al tab no longer contacts the lock lever. As paper is fed from the stack, the feeder assembly gradually lowers . When the tab contacts the bot tom lock le v er , the pap er stack raises. This process repeats until the tray is empty.

2-14 Phaser 4500/4510 Service Manual

Paper Feeder

Theory of Operation

Tray 1 and tray 2 are functionally equivalent in terms of the paper size switch assembly, no paper actuator, and no paper sensor. The component descriptions given here apply to both trays.

Since the low paper actuator and low pap er sensor are not part of tray 1, the description of these components applies to tray 2 only.

150-sheet/550-sheet feeder assembly This mechanism moves paper from the

paper tray into th e printer . The driving force fro m the main motor is transmitted via the feed clutch assembly to the feed roller and nudger roller, transporting paper from the tray into the printer.

No paper actuator This actuator is kept in a raised position by the paper in the

tray. If the tray runs out of paper, the no paper actuator drops and the flag of the no paper actuator moves from between the sensor ar m s, allowing the sensor to turn on.

No paper sensor This is a photo sensor that remains in the OFF state when

paper is present in the tra y. The sensor turns on when there is no paper in the tray and the flag on the no paper actuator moves out of the sensor.

Registration sensor The registration sensor is a photo sensor that detects

paper as it arrives at the registration rollers. The paper transported from the paper tray pushes up the actuator of the registration sensor, moving the flag out of the sensor.

Registration clutch This electromagnetic clutch turns on and off to drive the

rubber and metal registration rollers, which place the paper in position at the appropriate time for transfer of the developed image from the drum.

Low paper actuator When paper is low in the paper tra y installed in tray 2, the

arm of the low paper actuator is pushed up by the bottom plate assembly, moving the actuator flag out of the sensor. Low paper sensing occurs only in the 550-sheet feeders, which includes tray 2 and if installed, trays 3 and 4.

Low paper sensor This photo sensor remains in an OFF state until the paper

level in the tray drops sufficiently to move the low paper actuator flag out of the sensor.

Phaser 4500/4510 Service Manual 2-15

Theory of Operation

1.Paper size switch assembly 7.Metal registration roller

2.Feed clutch assembly 8.No paper sensor

3.Registration clutch 9.No paper actuator

4.Rubber registration roller 10.Low paper sensor

5.Feed roller 11.Low paper actuator

6.Registration sensor 12.Nudger roller

s4500-022

2-16 Phaser 4500/4510 Service Manual

Control of Paper Size

Not

Paper size switch assembly The switches in this assembly send signals that

indicates the paper size setting of the tray. Cams in the bottom of the tray are positioned by the tray’s end guide. At pre-define d pap er lengt hs, actuators on the side of the tray close or open th e switches in a pattern that is defined in the printer to correspond to one of the pre-set media sizes.

The following table provides the ON (1) or OFF (0) states of the switches in the paper size switch assembly, corresponding to the paper sizes of the paper tray.

Theory of Operation

The switches in the paper size switch assembly are denoted by “SW1”, “SW2”, “SW3”, and “SW4”, respectively, from the front side.

Paper Size Switch Assembly

Paper size

SW1 SW2 SW3 SW4

No cassette 0000

Executive SEF 0001

B5(JIS) SEF 0011

A5 SEF 0101

Legal14”SEF0111

Letter SEF 1001

A4 SEF 1101

Legal13”SEF1111

Phaser 4500/4510 Service Manual 2-17

Theory of Operation

Xerographics

Print Cartridge

The print cartridge is a customer-replaceable item that consists of the following components:

Drum The drum is an aluminum cylinder coated with a layer of

photoconductive material that retains electrical charges on its surface until exposed to light, when electrical conduction occurs.

Bias charge roller (BCR) The BCR uniformly distributes electrical charges over

the drum surface, and erases a charge pattern remaining from the previous cycle.

Magnet roller A thin layer of toner, supplied by the agitator in the toner

compartment, adheres to the surface of this roller, which transports the toner into the gap between the drum and magnet roller.

Charging and metering (CM) blade The CM blade spreads toner into a thin layer

over the magnet roller, and applies negative charges to the toner triboelectrically.

Cleaning blade The cleaning blade scrapes off toner remaining on the drum

surface after the transfer step.

1.Print cartridge 2.Transfer roller

2-18 Phaser 4500/4510 Service Manual

s4500-010

Laser Assembly

The laser assembly scans the surface of the drum with a laser beam. The laser assembly consists of three components: the laser diode (LD) assembly, the scanner assembly, and the start of scan (SOS) board.

Laser diode (LD) assembly The LD assembly produces a laser beam that is

turned on and off according to the print data signal. A single LD is used for 600 dpi, and a dual LD is used for 1200 dpi, generating one beam for 600 dpi and two beams for 1200 dpi.

Scanner assembly This assembly consists of a 12-sided polygonal mirror

mounted on the shaft of the scanner motor. As this mirror rotates, it reflects the beam onto the drum surface throu gh lenses and mirror s to scan the beam across the drum.

Start of scan (SOS) board When the laser beam strikes the sensor on the SOS

board, the signal generated indicates the initial po sition of the scan. The initial position where a scan is started on each line is detected. Depending on the print resolution selected, either one beam creates one line, or two beams create two lines at a time.

When the laser beam scans from one end of the drum surface to the other while being turned off and on, one line of a latent image is created. The resolution in the scanning direction (from right to left) is determined by the rotational speed of the scanner motor and by the speed at which the laser is modulated. The resolution in the process direction (from top to bottom) is determined by the number of the scan beams and the rotational speed of the print drum.

Conceptual Diagram of Image Creation by Scanning

Theory of Operation

Paper Path

600 Dots/Inch

600 Scans/Inch

s4500-011

Phaser 4500/4510 Service Manual 2-19

Theory of Operation

Laser Assembly Functional Parts

Laser Control

The scanner motor turns on when it receives a signal from the controller, and turns off after printing ends. The motor remains off in the standby and powersaving states.

There are two faults associated with the scanner motor speed: U2-1 Laser fails at warm-up, and U2-2, Laser fails motor speed.

Two other laser unit faults, U2-3 and U2-4, are associated with LD power. U23 occurs when LD power is too high, and U2-4 occurs when LD power is too low.

1.Start of scan PWB 3.Laser diode assembly

2.Scanner assembly

s4500-012

Transfer Roller Assembly

The transfer roller is held in conta ct with the drum of the print cartridge, and is driven by the drum gear. When the paper moves between the transfer roller and drum, the transfer roller applies a posit ive charge to the rear surface of the paper. The negatively charged toner image is attracted by the positive charge on the rear surface of the paper. Thus, the image is transferred from the surface of the drum to the surface of the paper.

The detack saw, located on the transf er roller assembly , h elps to se par ate t he paper from the drum surface.

2-20 Phaser 4500/4510 Service Manual

Fuser

Not

Theory of Operation

Heat roller The heat roller is a metal tube with a coated surface and a heater

assembly inside. As paper pa sses between the heat ro ller and pressure rolle r , the heat that is applied to the paper melts the toner and fuses it to the paper.

Pressure roller The pressure roller is a metal shaft coated with sponge rubber.

It maintains pressure on the paper passing between it and the heat roller. This pressure presses the melted toner against the paper.

Heater assembly

The heater assembly consists of two halogen lamps locat ed in the heat r oller. One lamp heats the entire length of heat roller, while the other, shorter rod heats the center . The lamps are controlled b y switching the neutral side of the power to each lamp; the lamps use a common hot line.

Temperature sensors These are Soft Touch Sensors (STS) having a known

value of resistance that varies with temperature. There are two temper ature sensors in the fuser. One is located at the center of heat roller, the other is located where the edge of a letter size sheet of paper comes through. The sensors monitor the temperature of each location to control lighting of the heater rods. The sensors are mounted in contact with the surface of the heat roller. Power to the heater rod is turned on and off using the signals from these sensors, so that the surface temperature of the heat roller can be maintained within a specified range. Thes e signals are also used to pro vide a first stage of overheat protection.

Thermostats The thermostats are connected in series with the heat roller

assembly, and provide a second level of overheat protection. If the first stage of overheat pr otection does not prevent the fuser from overheating, the thermostats cut off the power-supply circuit for the heater rod. If the paper type is set incorrectly, the pressure roller may melt and adhere. As a countermeasure against this, if the STS detect the higher temperature, but can not prevent the overheat, the thermostats cut power to prevent the pressure roller from melting and adhering.

The fuser in the Phaser 4510 uses a single thermostat switch instead of two to perform the same function.

Heat roller fingers These fingers peel off the leading edge of the paper from

the Heat roller to pre vent the paper from getting wound around the heat roller.

Heat roller diode The negative charge accumulated on the heat roller may

deteriorate the toner image on the paper during fixing . The heat roller diode discharges the charge to the frame ground.

Exit sensor This sensor detects the arrival of the paper at a detection point in

the exit area positioned behind the fuser. This sensor also detects the discharge of the paper from this point. When the sensor receives light (i.e., paper is present), the signal /EXIT is low.

Phaser 4500/4510 Service Manual 2-21

Theory of Operation

s4500-023

1.Exit motor assembly 5.Pressure roller

2.Exit sensor 6.Heat roller

3.Actuator 7.Thermostats (P4510 uses only one)

4.Temperature sensors

2-22 Phaser 4500/4510 Service Manual

Fuser Control

Temperature Control

Theory of Operation

The fuser heater control maintains the fuser at a pre-determined control temperature by turning the halogen lamp in the heat roller ON and OFF. The control temperature varies depending on whether or not the printer is at the Ready state, and whether the main motor is operating.

The fuser temperature is considered abnormal when the detected temperature exceeds 250° C, or falls below 130° C.

At the start of warm-up and when the main motor is at rest, the standby temperature is used as the fuser control temper ature . When the main mot or is operating except at warm-up, the running temperature is used as the fuser control temperature.

The running temperature and print speed depen d on t he med ia t ype sele ct ed for printing. The Phaser 4 500 uses f our tem perature set tings while the Ph aser 4510 uses six. Print speed slows down f or hea vy me dia such as card stoc k or envelopes, and specialty media such as transparencies. The following tables show the default assignments of temperature setting to media type. The temperature setting assignment for a media type can be changed as explained in “Adjusting Fuser Temperature” on page 6-8.

Phaser 4500 Fuser Temperature Default Settings

Media Type Name

Extra High

215°

High

210° C

Plain Paper X Letterhead Transparency Labels Colored Paper Card Stock Envelope Special

Phaser 4510 Fuser Temperature Default Settings

Media Type Name

Extra High

187° C

Very High

215° C

High

212° C

Medium

205° C

Plain Paper X Transparency Card Stock Envelope Labels

X Letterhead Preprinted Prepunched Colored Paper

Medium

205° C

Low

185° C

X X X

Low

190° C

Very Low

170° C

X X X X

Phaser 4500/4510 Service Manual 2-23

Theory of Operation

Fuser Warm-Up

The halogen lamp is turned on when the fuser warm-up begins. When the surface temper ature of the hea t roller (detect ed by t he thermistor) reaches the fuser control temperature (standby temperature), the fuser warm-up is ended.

Fuser Temperature Cycling

The fuser temperature does not remain at a single, constant value, but varies within a temperature range. The re are several ranges, which are summarized in the table. Except for Standby, the setting is determined by the media type selection.

Phaser 4500 Fuser Cycling Temperatures

Setting

Standby Lamp ON 180° C

Medium 1-100 pages:

High Lamp ON 210° C

Extra High Lamp ON 215° C

Low Lamp ON 185° C

Phaser 4510 Fuser Cycling Temperatures

Setting

Standby Lamp ON 180° C

Low 1-50 pages:

Medium 1-50 pages:

High Lamp ON 212° C

Very High Lamp ON 214° C

Extra High Lamp ON 187° C

Very Low Lamp ON 185° C

Temperature

Lamp OFF 185° C

Lamp ON 205° C Lamp OFF 206° C

Lamp OFF 211° C

Lamp OFF 216° C

Lamp OFF 186° C

Temperature

Lamp OFF 185° C

Lamp ON 190° C Lamp OFF 191° C

Lamp ON 210° C Lamp OFF 211° C

Lamp OFF 213° C

Lamp OFF 215° C

Lamp OFF 188° C

Lamp OFF 186° C

101-120 pages: Lamp ON 205° C Temp. decreases by.2 5°C per page

51-62 pages: Lamp ON 190° C T emp. decreases by .25° C per page

51-70 pages: Lamp ON 210° C T emp. decreases by .25° C per page

120 + pages: Lamp ON 200° C Lamp OFF 201° C

63 + pages: Lamp ON 187° C Lamp OFF 188° C

71 + pages: Lamp ON 205° C Lamp OFF 206° C

2-24 Phaser 4500/4510 Service Manual

Temperature Stabilization

The fuser automatically enters a stabilization process under two circumstances:

■ When the printer is processing thick paper.

After 50 impressions of continuous printing on thick paper (Thick Paper 1 mode), the fuser lamp turns off, the main motor stops, and the fans rotate at full speed until the temperature of both temperature sensors drops to 190° C or below. Then the printer continues printing the job. The process for Thick P aper 2 is the same, except that it occurs after 30 impressions of continuous printing on thick paper.

■ When the side fuser temperature sensor (STS) detects an abnormally

high temperature (over 245° C), the printer stops the print job and enters the cool-down process consisting of:

■ Clearing the paper path of all paper

■ Continuing to run the main motor (Time-out 200 sec.)

■ Running the fans at full speed

■ Controlling fuser temperature with short lamp

Theory of Operation

This process continues until the target control temperature of 180° C 185° C (Standby) is reached.

Fuser Problems (U4 Error Code)

Major causes of a U4 error include the following:

■ Warm-up failure – Fuser warm-up not complete within 110 seconds after

starting.

■ Cool-down error – Cool-down process not complete within 200 seconds.

■ Low trouble tempe rature – The fuser temper ature drop s to the lo w troub le

temperature (approximately current control temperature, minus approximately 25°C).

■ High trouble temper ature – The fuse r temperature rise s to the high troub le

temperature (approximately current control temperature, plus approximately 35°C).

■ STS circuit open

■ STS failure – The heat rod remains on for at least 10 seconds after warm-

up has completed.

Phaser 4500/4510 Service Manual 2-25

Theory of Operation

Power Shutoff to the Fuser

The printer shuts off power to the Fuser for the following reasons:

■ Fuser abnormality (U4)

■ Paper jam

■ Cover open — top, rear, duplex unit, stacker

■ Laser assembly (ROS) abnormality (U2)

■ CPU or NVRAM abnormality (U6)

■ Main motor assembly abnormality (U1)

■ Fan abnormality (U5)

■ Fuser Pause command issued

■ Xerographics failure

■ Duplex unit failure

■ Stacker failure

■ Option tray unit failure

2-26 Phaser 4500/4510 Service Manual

Paper Exit Assembly

The paper exit assembly discharges the printed paper out of the printer, sending it either to the standard output tray or to the optional stacker.

Exit motor assembly This motor drives the exit roller that conveys pap er to

each output tray. If the optional duplex unit is installed, this motor also reverses and inserts paper into the duplex unit.

Exit roller This roller transports the printed paper sent out from the Fuser, to

the standard output tray.

Output tray full sensor This sensor detects that the standard output tray is full,

using the stack full actuator.

Stacker exit gate This gate switches the paper transport path interlocking with

the stacker gate link. When the gate solenoid assembly installed in the optional stacker o per ates , the st ac ker gate link is pushed down by the spindle of the solenoid assembly. The gate blocks the normal paper output path and switches the output direction to the stacker output tray.

Theory of Operation

1.Output tray full sensor 3.Stacker exit gate

2.Exit roller 4.Exit motor assembly

s4500-024

Phaser 4500/4510 Service Manual 2-27

Theory of Operation

Drive

Gear assembly housing The gears in this housing transmit power from the main

motor to various parts of the printer.

Gear assembly plate This transmits power from the main motor to the print

cartridge.

Link lever This connects and disconnects the drive force from the main motor

to the fuser assembly. When the top cover is opened, the link lev er pushes up gear 8 in the gear assemb ly hou sing di sconne cting ge ar 9 and t hus , the fuser assembly. As the link lever moves up and down, gear 4 in the gear assembly plate moves right and left via g ear lin k 3, a nd d rive to the print cartridge drum is connected or disconnected.

1.Main motor 3.Gear assembly housing

2.Gear assembly plate 4.Link lever

s4500-025s4500-025

2-28 Phaser 4500/4510 Service Manual

Electrical

Theory of Operation

24 V interlock This safety switch interrupts 24 VDC from the LVPS to the

HVPS/engine logic board and main motor when the top cover is open. This switch operates in series with the rear cov er switch. See “Schematic Diagram of Phaser 4500 P ower Distribution and Interlocks” on page 2-31, or “Schematic Diagram of Phaser 4510 Power Distribution and Interlocks” on page 2-32.

5 V interlock This safety interrupts 5 VDC power from the LVPS to the LD

assembly of the laser assembly when the top cover is open. This interlock works in series with the laser interlock. See “Schematic Diagram of Phaser 4500 Po wer Distrib ution and I nterlocks” on page 2-31, or “Schematic Diagr am of Phaser 4510 P ower Distribution and Interlocks” on page 2-32.

Rear cover switch This safety switch interrupts 24 VDC from the LVPS to the

HVPS/engine logic board and main motor when the rear cover is open. This switch operates in series with the 24 V interlock. See “Schematic Diagram of Phaser 4500 Power Distribution and Interlocks” on page 2-31, or “Schematic Diagram of Phaser 4510 Power Distribution and Interloc ks” on page 2-32.

Main fan This vents air inside the printer to prevent an excessive rise in the

inside temperature.

Sub fan This fan takes outside air into the printer to prevent an excessive rise

in the inside temperature. This is mounted near the laser assembly in the center on the front side.

LVPS The low voltage power supply provides 5 V and 3.3 V for logic circuits,

5 V for the laser diode, and 24 V for motors and clutches. P4510: The LVPS board includes the DC-DC converter (described below) as an integral part.

HVPS/engine logic board The functions of the HVPS and engine controller are

brought together on a single circuit board. The HVPS provides high AC and DC voltages to the BCR (charging), magnet roller (development), tran sfer roller (transfer), and detack saw (peeling). The engine logic controls the printing operation according to the information obtained through communications with the image processor and from sensors an d switches.

Image processor board This receives data from the host computer, performs

printing, and controls the whole printer.

Exit motor PWBA This controls the exit motor assembly according to a signal

from the HVPS/engine logic board.

Interlock switch assembly This assembly consists of the following two safety

switches. See “Schematic Diag ram of Phaser 4500 Power Distribution and Interlocks” on page 2-31.

Top cover switch P4500: This safety interlock interrupts the INTERLOCK BEF

signal between the LVPS and the HVPS/engine logic board to indicate that the top cover is open.

Laser interlock P4500: This safety s witch interrupts 5 VDC from the LVPS to

the LD assembly of the laser assembly when the top cover is open. This switch operates in series with the 5 V interlock.

DC-DC converter The DC-DC converter uses 24 V and 3.3 V from the LVPS to

supply 5 V and 3.3 V to the image processor board. By using the 24 V, the DC-DC converter supplies additional power for the optional hard drive and several other subcircuits.

P4500: The DC-DC converter is on a separate circuit board from the LVPS. P4510: The DC-DC converter is an integral part of the LVPS.

Phaser 4500/4510 Service Manual 2-29

Theory of Operation

P4500P4510

1.LVPS (includes DC-DC converter in

7.5 V interlock

P4510)

2.Exit motor PWBA 8. 24 V interlock

s4510-026

3.Rear cover switch 9.Image processor board

4.Laser interlock (P4500 only) 10.HVPS/engine logic board

5.Top cover switch (P4500 only) 11.Sub fan

6.Main fan 12.DC-DC converter (separate board in P4500; integrated into LVPS in P4510)

2-30 Phaser 4500/4510 Service Manual

Theory of Operation

Opt. 550-Sheet

Feeder

Front Panel

Scanner

Laser

Motor

Unit

LDD

5V Interlock

Interlock Switch Assembly

Laser Interlock

Top Cover Switch

Fuser Assembly

Temperature Sensor Assembly

Thermostat

Heater Rod(850W)

Heater Rod(650W)

TEMP.

INTERLOCK BEF

Image

Processor

Data and Control

Converter

Scanner Motor Control

Fuser

Control

/HEAT ON (650W)

5VDC

3.3VDC

DC-DC

Interlock

/HEAT ON (800W)

24VDC

5VDC

Power Save

Control

24V

Opt. 550-Sheet

Feeder PWBA

Feeder 550

24VDC

3.3VDC

Opt. 550-Sheet

Feeder

PWBA

Feeder 550

24VDC

3.3VDC

Fuse

Rear Cover

Switch (24V)

24VDC AFT

5VDC

24VDC

Duplex Cover Open Switch

Optional

Duplex Unit

Duplex PWBA

24VDC

3.3VDC

Rear Cover

Open Switch

3.3VDC

HVPS Circuit

Main Motor Control

Main Motor

Motor

RTNRTN

24VDC AFT

Optional

Stacker

PWBA

24VDC

3.3VDC

MAIN MOTOR ON

MAIN MOTOR ALM

Fan Control

3.3VDC

Exit Motor PWBA

24VDC AFT

Main Fan

RTN

24VDC

FAN MAIN ALARM

Exit Motor Control

HVPS/ Engine Logic

CRU A, CRU B, INA, INB, /INA,

A, B, /A, /B, 24VDC AFT

Exit

Motor

RTN

Sub Fa

RTN

24VDC

/INB

FAN SUB ALARM

LVPS

Heater

Control

AC N

AC L

Fuse

Power

Switch

Fuse

Low Voltage

Generation

24VDC Supply

5VDC Supply

24VDC

Inlet

FG SG

3.3VDC Supply

Fuse

s4500-027

Schematic Diagram of Phaser 4500 Power Distribution and Interlocks

Phaser 4500/4510 Service Manual 2-31

Theory of Operation

Front Panel

Laser

Unit

Fuser Assembly

Temperature

Sensor Assembly

Heater Rod(850W)

Heater Rod(650W)

Scanner

Motor

LDD

Interlock

Thermostat

TEMP.

Image

Processor

Data and Control

Scanner Motor

Control

Fuser

Control

INTERLOCK BEF

/HEAT ON (650W)

5VDC

3.3VDC

5VDC

Interlock

/HEAT ON (800W)

24VDC

Power Save

Control

24V

Opt. 550-Sheet

Feeder

PWBA

Feeder 550

24VDC

3.3VDC

Opt. 550-Sheet

Feeder PWBA

Feeder 550

24VDC

3.3VDC

Fuse

Rear Cover

Switch (24V)

24VDC AFT

Duplex Cover Open Switch

Duplex Unit

5VDC

24VDC

3.3VDC

Optional

Duplex

PWBA

3.3VDC

24VDC

3.3VDC

Main Motor

Motor

24VDC AFT

Rear Cover

Open Switch

Optional

Stacker

PWBA

24VDC

3.3VDC

HVPS Circuit

Main Motor

Control

MAIN MOTOR ON

RTNRTN

Main Fan

RTN

FAN MAIN ALARM

24VDC

Fan

Control

Exit Motor

Control

HVPS/

Engine

Logic

3.3VDC

CRU A,CRU B, INA,INB

PWBA

RTN

24VDC AFT

Motor

Exit Motor

MAIN MOTOR ALM

Sub Fan

RTN

24VDC

/INA,/INB A,B,/A,/B,

Exit

FAN SUB ALARM

LVPS

Heater

Control

AC N

AC L

Fuse

Power

Switch

Fuse

Low Voltage

Generation

24VDC Supply

24VDC

3.3VDC 24VDC

5VDC

Supply

Inlet

FG SG

3.3VDC Supply

Fuse

Schematic Diagram of Phaser 4510 Power Distribution and Interlocks

DC-DC

Converter

s4510-027

2-32 Phaser 4500/4510 Service Manual

Printer Options

Duplex Unit

Theory of Operation

Three options are available for the Phaser 4500/4510 printer:

■ Duplex unit

■ Stacker

■ 550-sheet feed er

Paper transport information for the option s is discussed earlier in this chapter.

The duplex unit used on the Phaser 4510 differs from the one used on the Phaser 4500. While the two units fun ction e xactl y the same , the y use dif f erent motors due to the difference in speed, and they are shaped differently due to the change in the location of the cooling fan.

Drive Transmission Path

The rotating force of the duplex unit motor is transmitted by various gears to components requiring mechanical drive as shown in this flow chart and the gear layout that follows.

$UPLEX5NIT-OTOR

)DLE'EAR

2OLLER'EAR

)DLE'EAR

)DLE'EAR

)DLE'EAR

2OLLER'EAR

)DLE'EAR

2OLLER'EAR

S

Phaser 4500/4510 Service Manual 2-33

Theory of Operation

Gear Layout

1.Roller gears 4.Idle gear 77

2.Idle gear 29 5.Duplex unit motor

3.Idle gear 47 6.Idle gear 57/37

Functional Components

Two-sided printing is enabled by mounting the duplex unit on the rear side of the base engine.

Duplex unit switch This switch detects that the duplex unit lower housing and

duplex unit housing cover are closed.

Duplex unit sensor This sensor detects the presence or absence of paper in the

duplex unit.

Duplex unit fan This fan vents air within the duple x unit an d takes in out side air ,

to prevent abnormal temperature rise in the duplex unit.

Duplex roller This roller feeds the paper having the printed first surface back

into the printer through the duplex unit, to pr int on the seco n d sur face.

Duplex unit PWBA The CPU on the duplex unit PWBA receives instructions

from the HVPS/engine logic board and information from sensors and switches, and controls paper transport through the duplex unit.

Duplex unit motor This motor drives the three duplex rollers, which transport

the paper through the duplex unit.

s4500-029

2-34 Phaser 4500/4510 Service Manual

Phaser 4500 and 4510 Duplex Units

Theory of Operation

P4500

P4510

s4500-030

1.Duplex unit rollers 4.Duplex unit PWBA

2.Duplex unit sensor 5.Duplex unit switch

3.Duplex unit fan 6.Duplex unit motor

s4510-030

Phaser 4500/4510 Service Manual 2-35

Theory of Operation

Stacker

Drive Transmission Path

The rotating force of the stacker motor assembly is transmitted by various gears to components requiring mechanical driving force as shown in this flow chart and the gear layout that follows.

Gear Layout

Gear 45

Gear 19

Lower OCT Roller

OCT Motor Assy

Gear 19/37

Offset Motor Assy

Cam Gear

Gear 45

Gear 19

Upper OCT Roller

s4500-031

s4500-032

1.Gear 45 4.Stacker motor assembly

2.Gear 19 5.Gear 19

3.Gear 19/37

2-36 Phaser 4500/4510 Service Manual

Paper Transport Path

When the stacker is inst alled on the printer , the pap er is transported as shown in the illustration on page 2-6. The main components that transport paper through the stacker are shown in the diagram on page 2-4

Functional Components

Offset output is enabled by mounting the stacker on top of the 500-sheet paper exit.

Stacker motor assembly This motor drives the lower stacker roller and upper

stacker roller, which transport printed paper to the stacker tray.

Offset motor assembly This motor drives the offset chute assembly via the gear

cam.

Gate solenoid assembly This solenoid switches the output paper path between

the standard and stacker paper output trays. When the gate solenoid assembly activates, the solenoid armature pushes the stacker Gate Link to operate the stacker exit gate, which reroutes the paper to the stacker paper output tray.

Stacker PWBA The CPU on the stacker PWBA receives instructions from the

HVPS/engine logic board and information from sensors and switches, and controls paper transport through the stacker.

Stacker rear cover switch This switch detects when the stacker rear cover is

open.

Stacker sensor This sensor detects the presence or absence of paper in the

stacker.

Stacker full sensor This sensor is located on the stacker PWBA, and detects

when the stacker output tray is full, using the stack full actuator.

Offset Sensor This sensor is located on the stacker PWBA, and detects an

offset operation, using the actuator in the Offset Chute.

Lower stacker roller This roller transports the printed paper coming out of the

Fuser to the Upper stacker roller.

Upper stacker roller This roller discharges the printed paper sent from the

Lower stacker roller into the stacker paper output tray.

Offset chute assembly This assembly is driven by the offset motor assembly

and Cam gear to mov e right and left during pap er output to off set the output of the printer.

Theory of Operation

Phaser 4500/4510 Service Manual 2-37

Theory of Operation

1.Stacker motor assembly 7.Offset motor assembly

s4500-033

2.Upper stacker roller 8.Gate solenoid assembly

3.Rear cover switch 9.Offset chute assembly

4.Full Stack Sensor 10.Stacker sensor

5.Offset Sensor 11.Lower stacker roller

6.Stacker PWBA

2-38 Phaser 4500/4510 Service Manual

Optional 550-Sheet Feeder

Drive Transmission Path

The rotating force of the feeder motor is transmitted by various gears to components requiring mechanical driving force as shown in this flow chart and the gear layout that follows.

Theory of Operation

Feeder Motor

Optional Feeder Gear 2

Optional Feeder Gear 3

Optional Feeder Gear 4

Optional Feeder Gear 5 Feed Clutch Assembly

Optional Feeder Gear 6

Turn Roll Clutch

Gear Layout

s4500-034

s4500-035

1.Optional feeder gear 6 5.Feeder motor

2.Turn roller clutch 6.Optional feeder gear 2

3.Feed clutch 7.Optional feeder gear 3

4.Optional feeder gear 4 8.Optional feeder gear 5

Phaser 4500/4510 Service Manual 2-39

Theory of Operation

Functional Components

The paper tray used in the optional feeder is identical to the 550-Sheet paper tray used by the base engine, so the description of the paper tray is omitte d here.

Option paper size switch assembly A bank of switches for setting the size of

paper supplied from each paper tray is mounted in the left tray gu ide . A signal indicating the paper size is transmitted as a voltage to the HVPS/engine logic board.

No paper actuator This actuator is kept in a raised position by the paper in the

tray. If the paper tray runs out of paper, the no paper actuator drops and the flag of the no paper actuator moves from between the sensor arms, allowing the sensor to turn on.

No paper sensor This is a photo sensor that remains in the OFF state when

paper is present in the tra y. The sensor turns on when there is no paper in the tray and the flag on the no paper actuator moves out of the sensor.

Low paper actuator When paper is low in the paper tray, the arm of the low

paper actuator is pushed up by the bottom plate assembly, moving the actuator flag out of the sensor.

Low paper sensor This photo sensor remains in an OFF state until the paper

level in the tray drops sufficiently to move the low paper actuator flag out of the sensor.

Optional 550-sheet feeder This is a mechanism for supplying paper from the

paper tray into the printer. The driving force from the feeder motor is transmitted via the feed clutch assembly to the feed roller and nudger roller, transporting paper from the tray into the printer.

As the nudger roller picks up paper and t he paper level lowers, the position of the nudger roller drops accordingly. The lowered nudger roller pushes down the lock lever of the bottom plate assembly, releasing it. The spring below the bottom plate assembly pushes it up and lifts the paper, which lifts the nudger support assembly off of the lock lever of the bottom plate assembly stopping its upward motion.

Turn roller This roller, working with the turn pinch roller, advances the paper

picked b y the n udger and feed rollers into the printer. The feeder motor drives the turn roller through the turn roller clutch.

550-sheet feeder PWBA A CPU installed in the 550-sheet feeder PWBA

receives instructions from the HVPS/engine logic board and from sensors and switches; the CPU controls feeding operation in the 550-sheet feeder.

2-40 Phaser 4500/4510 Service Manual

Theory of Operation

1.Optional 550-sheet feeder 5.Low paper sensor

2.Turn roller 6.Low paper actuator

s4500-036

3.No paper actuator 7.550-sheet feeder PWBA

4.No paper sensor 8.Option paper size switch assembly

Phaser 4500/4510 Service Manual 2-41

Theory of Operation

2-42 Phaser 4500/4510 Service Manual

Error Messages and Codes

In this chapter...

■ Introduction

■ Servicing Instructions

■ Entry Level Fault Isolation Procedure

■ Service Diagnostics

■ System Start-Up and POST

■ Operating System and Application Problems

■ Troubleshooting Procedures for Error Messages and Codes

■ Inoperable Printer

Chapter

Error Messages and Codes

Introduction

Servicing Instructions

This chapter covers troubleshooting procedures for problems in the Phaser 4500/4510 that generate error messages or fault codes or both that appear on the control panel or in the Service Usage Profile report, and serves as the entry point into the troubleshooting process. Troubleshooting of problems not directly indicated b y or associated with an er ror message or f ault code is covered in “General Troubleshooting” on page 4-1. Print quality problems are covered in “Print-Quality Troubleshooting” on page 5-1.

This set of instructions is an overview of the path a service technician should take, using this man ual, t o se rvice the print engine and options . If y ou choose not to use the instructions, it is recommended that you start at the appropriate troubleshooting table and proceed from there.

Always follow the safety measures detailed in “Service Safety Summary” on page xv when servicing the printer.

Step 1: Identify the Problem:

1.Verify the reported problem does exist.

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

3.Print normal customer prints and service 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 Service Usage Profile, if the printer is able to print.

8.View the Engine Error and Jam Histories under the Service Tools Menu

9.Verify the AC input power supply is within proper specifications by measuring the voltage at the electric outlet while the printer is running.

3-2 Phaser 4500/4510 Service Manual

Error Messages and Codes

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 loose toner.

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

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

8.Use only an approved toner vacuum.

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

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

11.If the print cartridge appears obviously damaged, replace with a new one.

Step 3: Find the Cause of the Problem:

1.Use the Error Messages and Codes and troubleshooting procedures to find the cause of the problem.

2.Use Service Diagnostics to check the printer and optional components.

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

4.Take voltage readings as instructed in the appropriate troubleshooting procedure.

Step 4: Correct the Problem:

1.Use the Parts List to locate a part number

2.Use the FRU Disassembly procedures to replace the part.

Step 5: Final Checkout

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

Phaser 4500/4510 Service Manual 3-3

Error Messages and Codes

Using the Troubleshooting Procedures

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

certain action or procedure. Follow the steps 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 to test a component using service

diagnostics, see “Service Diagnostics” on page 3-7 for the detailed steps and functions for testing p arts of the printer.

4. The action is followed by a question. If your response to the questio n is

“Yes”, then follow the instructions for a “Yes” reply . If y our respo nse to the question is “No”, then follo w the instructions for a “No” reply.

5. Troubleshooting Procedures frequently ask you to take voltage readings

or test for continuity at certain test points within the printer. For detailed diagrams, see chapter 10, Wiring Diagrams for complete information on test point locations and signal names.

6. Troubleshooting Procedures often ask you to replace a printer

component. Chapter 8 FRU Disassembly provides detailed steps for removing and replacing all major parts of the printer. Chapter 9, Parts Lists details the location and part number for all spared parts of the printer.

General Notes on Troubleshooting

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

power” means f or you to switch ON printer power and let the printer proceed through POST to a ‘Ready’ condition.

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 met er on pin 1 of P/ J 232 , a nd pla ce th e black probe (–) of your meter on pin 5 of P/J 210.

3. When you are instructed to take resistance readings between

“P/J 232 <=> P/J 210” (without specified pin numbers), check all pins. See “Wiring Diagrams” on page 10-1 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 gr ound) in place of any SG pin or test point. To locate connectors or test points, see “Wiring Diagrams” on page 10-1 for more information.

5. Before measuring vo ltages make su re the printer is swit ched ON, the print

cartridge and the paper trays are in place, and the interlock switches are actuated, unless a troubleshooting procedure instructs otherwise.

6. All voltage value s 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.

3-4 Phaser 4500/4510 Service Manual

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

Stated Measured

+3.3 VDC +3.135 to +3.465 VDC +5.0 VDC +4.75 to +5.25 VDC +24.0 VDC +21.6 to +26.4 VDC

0.0 VDC Less than +0.5 VDC

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.

Accessing Fault Histories

■ Print (if possible) the Service Usage Profile.

a. At the printer’s control panel, go to the Troubleshooting Menu and b. From the Service Tools menu select Service Usage Profile. The

Or...

Error Messages and Codes

select Service Tools. fault histories are detailed in this report log.

■ View the printer’s fault history on the control panel.

■ Go to Troubleshooting Menu --> Service Tools --> Engine Error

History or Jam History.

Refer to the Error Message Summary tables that begin on page 3-21 to interpret the numeric codes that appear in the printed or displayed fault histories.

Phaser 4500/4510 Service Manual 3-5

Error Messages and Codes

Entry Level Fault Isolation Procedure

Use this procedure to quickly determine the general area of the printer in which the problem is located.

Troubleshooting Procedure

Steps Actions and Questions Yes No

1 Switch the printer OFF then ON.

Does the printer display READY TO PRINT on the control panel within 1 minute?

2 Does the printer display an error

message or code?

3 Is the control panel LCD/LED Display

defective, or the buttons inoperable?

4 Run Test Prints from all input trays:

1.In the Main Menu, select Troubleshooting and press the OK button.

2.Select Print Quality Problems and press the OK button.

3.Select Test Prints and press the OK button.

Does the printer display an error message or code while printing?

Go to Step 4 Go to step 2

Go to the procedure for that error message or code.

Go to Control panel Troubleshooting procedure

Go to the procedure for that error message or code.

Go to step 3

Go to step 4

Go to step 5

5 Does the printer produce the test

prints?

6 Evaluate the test prints.

Does the print quality meet or exceed the print quality specifications?

7 Enter Service Diagnostics and

generate Print Engine Test Prints from all input trays.

Does the printer produce the test prints?

8 Request the customer to send a print

job from their application.

Did the job print successfully?

3-6 Phaser 4500/4510 Service Manual

Go to step 6 Go to step 7

Go to step 8 Go to “Print-

Quality Troubleshooting ” on page 5-1

Go to “Image Processor Isolation” on page 4-33

Problem solved; return to Final Checkout in the “Servicing Instructions” on page 3-2.

Go to “Inoperable Printer” on page 3-72

Go to “Operating System and Application Problems” on page 3-19

Service Diagnostics

Entering without rebooting the printer:

Error Messages and Codes

The Phaser 4500/4510 Laser Printer has built-in diagnostics to aid in troubleshooting problems with the printer. The Service Diagnostics Menu provides a means to test sensors, motors, switches, clutches, fans and solenoids. Diagnostics also contain built-in test prints , printer status and some NVRAM access.

Service Diagnostics are to be executed through the control panel by a certified service technician only. Service Diagnostics can be entered one of two ways:

1. From the printer’s main menu, scroll to Troubleshooting and press the

OK button, then scroll to Service Tools and press the OK button.

2. Hold down both the Up and Down arrow b uttons f or ab out three seconds .

When the hidden Service Diagnostics menu appears, scroll to Run

Service Diagnostics and press the OK button.

Entering by rebooting the printer:

1. Turn the printer power OFF.

2. Hold down the Back and Information (P4500) or Help (P4510) buttons

simultaneously and turn the printer back ON.

3. Continue to hold the buttons until the following message is displayed on

the control panel: Entering Service Diagnostics, and then release the buttons.

4. The control panel displays the Service Diagnostics Menu.

You can print a Service Diagnostics Menu Map by highlighting

Menu Map, and pressing the OK button. The printer will run through POST

and return to Ready. You will need to re-enter service diagnostics.

Print Service

Phaser 4500/4510 Service Manual 3-7

Error Messages and Codes

Service Diagnostics Menu Map

Print Service Menu Map Prints this page.

General Status

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

Provides current print engine status.

Engine Test Print Configures print parameters and initiates the

test print.

Print Test Pattern Input Tray Output Tray Duplex Print Quantity Print Resolution

Engine NVRAM Adjustments Perform NVRAM Adjustments

essential to the performance of the printer.

Laser Power Tray 1 Process Direction Tray 2 Process Direction Tray 3 Process Direction Tray 4 Process Direction Tray 1 Scan Direction Tray 2 Scan Direction Tray 3 Scan Direction Tray 4 Scan Direction Duplex Process Direction Duplex Scan Direction

Motors/Fans Tests Tests the functionality of motors/fans.

Duplex Motor High Duplex Motor Low Exit Motor Forward Exit Motor Reverse High Exit Motor Reverse Low Main Motor Fan Motors High Speed Fan Motors Stop Laser Scan Motor Stacker Motor Stacker Offset Motor Tray 3 Feed Motor Tray 4 Feed Motor

Main Motor+Clutch/Sol Tests Runs main drive motor with

each individual clutch.

Motor + Registration Roll Motor + Tray 1 Feed Motor + Tray 2 Feed Motor + Tray 3 Feed Motor + Tray 4 Feed Motor + Tray 3 Turn Roll Motor + Tray 4 Turn Roll

Sensor Tests Tests the functionality of sensors/switches/

options by manually toggling each sensor or installing an option.

Top Cover Switch Rear Cover Switch Duplex Cover Switch Stacker Cover Switch Paper Tray Size Read

Tray 1 Size Tray 2 Size Tray 3 Size

Tray 4 Size Print Cartridge Switch Toner Sensor Registration Sensor Exit Sensor (Fuser) Duplex Sensor Stacker Sensor Stacker Full Sensor Output Tray Full Sensor Tray 2 Low Paper Tray 3 Low Paper Tray 4 Low Paper Tray 1 No Paper Tray 2 No Paper Tray 3 No Paper Tray 4 No Paper Duplex Unit Presence Stacker Unit Presence

Solenoid Tests Tests the functionality of printer solenoids.

Stacker Gate Solenoid

Clutch Tests Tests the functionality of printer clutches.

Registration Roll Tray 1 Feed Tray 2 Feed Tray 3 Feed Tray 4 Feed Tray 3 Turn Roll Tray 4 Turn Roll

Controller NVRAM Access Resets the PS NVRAM locations

to factory defaults.

Reset PostScript NVRAM Factory Reset NVRAM

Exit Exits service diagnostics and reboots the printer.

For Authorized Service Personnel Use Only. Service Menu

functions are to be used by Xerox service personnel and authorized service providers only. The printer can be damaged by improper use of the built-i

n service tests.

3-8 Phaser 4500/4510 Service Manual

Service Diagnostic Control Panel Button Descriptions

Button Function BACK Returns to the prior higher level menu structure, if available.

If help text is displayed on the control panel, pressing BACK will restore the current menu item and remove the help text.

CANCEL Terminates the current test.

Cancels current INFO display.

Error Messages and Codes

INFO (P4500) or HELP (P4510)

UP Scrolls up one menu item within a menu list. This control does not

DOWN Scrolls down one menu item within a menu list.

OK Enters the highlighted menu. Executes the current test item.

Using Service Diagnostics

Most of the diagnostic tests are straightforward and require no additional explanation, b ut there are some t hat r equire t hat specific cond itions b e met to achieve meaningful results. These instructions cover each of the test groups, listing special instructions, conditions, or other information necessary to successfully interpret the results of the diagnostic tests.

Provides help information, if available. Pressing again restores the current menu item and removes the help text.

‘wrap’. Used to increment data in tests requiring user input.

This control does not ‘wrap’, the end of a menu list is designated by three asterisks. Used to decrement data in tests requiring user input.

Used to select a data value entered by the user.

General Status

The General Status tests provide information about the current status of the printer. These values are read-only and cannot be changed.

Engine ROM Version Lists the version number of the code stored in the engine

ROM and its checksum value.

Engine Print Count Lists the printer’s life count, th e number of prints made since

the printer’s activation. This page count is reset if the HVPS/engine logic board is replaced.

Engine Configuration Lists the configurations set for the engine . This report is of

very limited use to the service technician; it is mainly intended for manufacturing use.

Print Resolution Reports the current print resolution setting for the engine test

print. The default setting when entering diagn ostics is 1200 dpi.

Read Fuser Temperature Shows the current fuse r temperature in degrees C.

Reports the fuser temperature only in the Standby mode.

Phaser 4500/4510 Service Manual 3-9

Error Messages and Codes

Engine Test Print

You can use Engine Test Print (see “Engine Test Print” on page 6-4) to identify, repair, and validate the operability of printer Xerographics and paper handling from all paper sources, options, and output destinations.

Print Test Pattern Starts the print. Input Tray Lets you select the tray used as paper source. Output Tray Lets you select the output location. Duplex Turns two-sided printing on or off if the duplex unit is installed. Print Quantity Allows you to select the number of test prints to run. Use the OK

button to select which digit to change, use the UP or DOWN buttons to change the value of the digit, and use the Back button to set the selection. If Duplex is set to ON, the quantity selected indicat es the number of two-sided prints.

Print Resolution Allows you to select either 600 or 1200 dpi as the print

resolution for engine test prints . The default setting when entering diagnostics is 1200.

Engine NVRAM Adjustments

These adjustments allow you to change printer settings th at control the po wer of the laser beam, and that control the registration of the image on the paper.

Laser Power Adjusts the power of the laser beam. Adjustment is done on a

scale of 0-8, with 4 being the factory def ault.

Tray 1/2/3/4 Process Direction Adjusts the image registration in the process

direction on paper coming from one of the paper trays. Increasing or decreasing the set value by one number moves the leading edge of the print area 0.5 mm closer to or farther from the edge of the paper.

Tray 1/2/3/4 Scan Direction Adjusts the image registration in the scan direction

on paper coming from one of the paper tr a ys. In creasing or decreasing t he set value by one number moves the side edge of the print area 0.5 mm closer to or farther from the edge of the paper.

Duplex Process Direction Adjusts the image registration in the process direction

on paper coming from the duplex unit. Increasing or decreasing the set value by one number moves the leading edge of the print area 0.5 mm closer to or farther from the edge of the pape r.

Duplex Scan Direction Adjusts the image registration in the scan direction on

paper coming from the duplex unit. Increasing or decreasing the set value by one number moves the leading edge of the print area 0.5 mm closer to or farther from the edge of the pape r.

Motors/Fan Test

Individually turns on each drive motor or fan. In each case except the stacker offset motor, the sound of the motor running is the indication that the ite m passed or failed the test. In the case of the stac ker offset motor, the motion of the offset chute is the indicator.

Duplex Motor (All tests) The test runs the motor about three seconds, then

stops it. The test runs the motor e ven when the duple x u nit is open or a printer cover is open.

3-10 Phaser 4500/4510 Service Manual

Error Messages and Codes

Not

Exit Motor (All tests) The test runs the motor about three seconds, then stops

it. Print engine top and rear covers m ust be closed and print cartridge must be installed for the motor to run.

Main Motor The test runs the motor for one minute or until you press the Back

button to stop it. Print engine top and rear covers must be closed and print cartridge must be installed for the motor to run.

Fan Motor High Speed The test runs the main and sub fans for about three

seconds, then returns them to low speed. The test runs with covers open.

Fan Motor Stop The test stops the main and sub fans for about three seconds,

then turns them on again at low speed. The test runs with covers open.

Laser Scan Motor The test runs the motor about three seconds, then stops it.

The test runs with covers open.

Stacker Motor The test runs the motor about three seconds, then stops it. The

test runs with print engine covers open.

Stacker Offset Motor The test runs the motor to move the chute once in each

direction. The test runs with covers open.

Tray 3/4 Feed Motor The test runs the motor about three seconds, then stops it.

The test runs with print engine covers open. Atte mpting to test a tray that is not installed results in an “Option Not Installed” message.

Main Motor + Clutch/Sol Tests

Runs the main motor and activates the clutch selected to test the drive.

Tray 1/2/3/4 Feed Tests the drive to the feeder in the selected tray. Tray 3/4 Turn Roller Tests the drive to the turn roller in the selected tray.

These tests feed a sheet of paper into the registration roller nip that must be cleared following the test.

Sensor Tests

Tests the functionality of sensors/switches/options when the sensor or switch is manually toggled, or when either the duplex unit or stacker is installed.

Top Cover Switch Tests the circuit (not just a single swit ch) affected by opening

the top cover. The prin t ca rtridge must be installe d an d the re ar cover closed for this test to be effective. Toggle the switch by opening and closing the top cover. “Open” or “Closed” indications appear on the control panel.

Rear cover switch Tests the circuit (not just a single switch) aff ected b y opening

the rear cover. The print cartridge must be installed and the top cover closed for this test to be effective. Toggle the switch by opening and closing the rear cover. “Open” or “Closed” indications appear on the control panel.

Duplex Cover Switch Tests the circuit affected by opening the duplex unit.

Toggle the switch by opening the duplex unit rear cover.

Stacker Cover Switch Tests the circuit affected by opening the stacker rear

cover.

Paper Tray Size Read Displays the paper size selected by the position of the

paper end guide in the paper tray. This test only tests the operation of the paper size switch assembly. It does not recognize custom paper sizes.

Phaser 4500/4510 Service Manual 3-11

Error Messages and Codes

Print Cartridge Switch Checks for the presence of the print cartridge. Toggle the

switch by partially removing the print cartridge. Displays “Installed” or “Not installed”

Toner Sensor Checks that there is toner in the print cartridge. Displays “Toner

Normal” when the print cartridge with toner is in place, and displays “Toner Low” when the print cartridge is partially removed or the toner quantity is low.

Registration Sensor Reports the status of the registration sensor. Reports

“Without paper” when the actuator is in the resting position, an d reports “With paper” when the actuator is moved by paper in transport.

Exit Sensor (Fuser) Reports the status of the exit sensor in the fuser. Reports

“Without paper” when the actuator is in the resting position, an d reports “With paper” when the actuator is moved by paper in transport. You can manually toggle the sensor by opening the exit gate on the fuser and pushing the actuator near the center of the fuser.

Duplex Sensor Reports the status of the duplex sensor. Reports “Without

paper” when the actuator is in the resting position, and reports “With paper” when the actuator is moved by paper in the duplex unit. You can manually toggle the sensor by remo ving the inner chute (b lac k plastic) and pressing the actuator, which is just right of center.

Stacker Sensor Reports the status of the stacker sensor. Reports “Without

paper” when the actuator is in the resting position, and reports “With paper” when the actuator is moved by paper in the stacker. You can manually toggle the sensor by opening the stacker rear cover and pressing the actuator.

Stacker Full Sensor Reports the status of the stacker full sensor in the stacker.

Reports “Not Full” when the actuator is in the resting position, and reports “Full” when the actuator is raised by paper accumu lating on the stac ker outpu t tray. You can manually toggle the sensor by lifting the actuator bail at the stacker exit slot.

Output Tray Full Sensor Reports the status of the output tray full sensor in the

standard output tra y. Reports “Not Full” when the actuator is in the resting position, and reports “Full” when the actuator is raised by p aper accum ulating on the standard output tray. You can manually toggle the sensor by lifting the actuator bail at the standard output exit slot.

Tray 2/3/4 Low Paper Tests the operation of the Low Paper sensor in the 550-

sheet feeders. Reports “Not Low” in the resting position, and “Low” when lifted. You can test the sensor by removing all but three or f our sheet s of paper from the cassette in that tray and reinserting it. Or you can remove the cassette, reach into the tray cavity, and operate the actuator manually. The actuator is located near the top and rear of the cavity on right side.

Tray 1/2/3/4 No Paper Tests the operation of the No Paper sensor in each tray.

Reports “Without Paper” in the resting position, and “With Paper” when lifted. You can test the sensor by removing all paper from the cassette in that tray and reinserting it. Or you can remove the cassette, reach into the tray cavity, and operate the actuator manually. The actuator is located at the top and rear of the cavity in the center.

Duplex Unit Presence Reports whether the duplex unit is “Installed” or “Not

Installed.” You can test by removing or installing the duplex unit and restarting the printer, then running the Duplex Unit Presence test.

Stacker Unit Presence Repor ts wh et he r th e sta cker is “Installed” or “Not

Installed.” You can test by removing or installing the stacker and restarting the printer, then running the stacker Unit Presence test.

3-12 Phaser 4500/4510 Service Manual

Sensor Locations in the Paper Path

Error Messages and Codes

9 10 11

12 13

1.Registration sensor 8.Tray 2 no paper sensor

2.Fuser exit sensor 9.Tray 2 low paper sensor

3.Output tray full 10.Tray 3 no paper sensor

4.Stacker sensor 11.Tray 3 low paper sensor

5.Stacker full 12.Tray 4 no paper sensor

s4500-270

6.Duplex unit sensor 13.Tray 4 low paper sensor

7.Tray 1 no paper sensor

Phaser 4500/4510 Service Manual 3-13

Error Messages and Codes

Not

Solenoid Test

Tests the functionality of the printer’s only solenoid.

Stacker Gate Solenoid This test is available at all times, but runs only when a

stacker is installed. Attempting to run the test without a stacker results in the “Option not installed.” message. You can view the stacker Gate operation by opening the rear cover.

Clutch tests

Tests the functionality of the printer clutches. The audible click of the clutch engaging is the only indicator of success. The feed and turn roller clutches listed here can be tested in conjunction with the main motor.

Registration Roller Tests the clutch that couples drive power to the registration

roller.

Tray 1/2/3/4 Feed Tests the clutch that couples drive power to the feed roller for

the selected tray.

Tray 3/4 Turn Roller Tests the clutch that couples drive power to the turn roller

for the selected tray.

Controller NVRAM Access (NVRAM Reset)

This menu allows you to reset the PostScript NVRAM locations to factory defaults.

Refer to “Resetting All Printer Default Set tings (PostScript NVRAM)” on page 6-13 for more details.

Reset PostScript NVRAM Resets the PS NVRAM. Yo u ar e pr om p te d to conf irm

your decision to perform a reset operation.

Factory Reset NVRAM Allows you to reset the PS NVRAM locations to factory

defaults. This tests is password protected to allow access only to certified Service Personnel. The password to access the reset functions is 4370. To enter the password, you use the OK button to move from digit to digit on the display, you use the Up and Down Arrow buttons the change the value of the digit, and when the password is correct, you use the Back button to enter the selection. After you enter the password, you are prompted to confirm your decision to perform a reset operation.

Exit

Reboots the Printer out of Service Diagnostics

3-14 Phaser 4500/4510 Service Manual

System Start-Up and POST

Power On Self Test (POST)

The following tests are performed when the printer is powered on, after the boot loader runs, and before the operating system is loaded and initialized.

POST diagnostics are intended to provide a quick means of isolating a defective subsystem associated with the image processor board and SDRAM. POST returns control to the boot loader and the operating system is loaded. The operating system then loads the imaging processing software. If POST detected any soft err ors , a messa ge is printed in a g r ay box on the start page. If POST detects any hard errors, both the control panel and health LED blink the error code pattern, see “LED Blink Patterns” on page 3-16.

POST Startup indications

■ At power-on the hardware default is to turn on the IP board ‘health’ LED.

Error Messages and Codes

■ The image processor board ‘health’ LED is turned off.

■ The control panel display is reset (addressable area becomes “gray”).

■ The Red LED turns on.

■ The backlight is turned on (normal intensity), with nominal contrast

display for 1/4 second.

■ The control panel display ar ea is turned on, dark black for 1/4 second.

■ The control panel display is cleared for 1/4 second.

■ The backlight is turned off with nominal intensity for 1/4 second.

■ The POST Vn.nn message appears, and tests are quickly executed.

■ If any tests fa il, the co ntro l pa nel scr een f r eezes with the name of the test

displayed and the line posted is “Call Customer Service”.

■ After the POST tests have finished running, the Xerox ‘splash screen’ is

posted to the control panel and PostScript begins initialization.

Phaser 4500/4510 Service Manual 3-15

Error Messages and Codes

POST Faults

There are two kinds of faults: soft and hard. A soft fault is any fault that is discovered by POST, but does not prevent the

operating system from initializing and becoming available as a tool for troubleshooting. These POST faults do not stop execution and are reported on the Start Page in a gray box after the system is running.

A hard fault is any fault discovered by POST that prevents the operating system from initializing successfully. A hard fault prevents the system from further execution and is halted with blinking LEDs (control panel and health LED). The test name of the test that failed is displayed on the control panel.

Fault Reporting Devices

There are four fault presentation devices.

■ All soft faults are printed on the StartPage.

For hard faults:

■ The health LED flashes according to the fault code.

LED Blink Patterns

■ The control panel LED flashes in unison with the health LED.

■ The last posted message to the graphic control panel is present.

For faults identified as hard faults, the POST firmware causes the PS health LED to blink in a particular pattern to identify the fault. There are short and long blinks. 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, which indicates a failure in the CPU interrupt test. See “POST Diagnostic T est Descriptions” on page 3-17.

The exception to the abov e pattern is a RAM test error. The RAM tests hav e a special blink pattern and the control panel displa ys “RAM Error”. During pow er up the control panel LED is on. If the RAM tests fail, the image processor board health LED is turned off, and the control panel LED is red. At 1/2second intervals, the health LED and the control panel LED toggle continuously.

3-16 Phaser 4500/4510 Service Manual

POST Diagnostic Test Descriptions

Fault

Test

Code Description

Error Messages and Codes

SDRAM

Real Time Clock

I/O ASIC

Memory

EEPROM Ethernet CPU

Interrupts USB

Real Time Clock

10 11

(Hard) This test fails if the boot loader finds no RAM present or faulty RAM.

Boot loader posts the message “RAM ERROR” to the control panel and blinks the control panel LED at an even rate.

(Soft) Synchronizes an internal counter to the rollover of the seconds count in the Real Time Clock chip.

(Hard) This test determines if the I/O chip is functioning properly.

(Hard) This test checks 64-bit reads and writes to memory.

(Hard) This test checks addressing of the EEPROM. (Hard) This test checks the ethernet core. (Hard) This test checks that each interrupt source to

the CPU is functioning. (Hard) This test checks that the USB core is

functioning properly. (Soft) Ensures that the Real Time Clock is

functionally tested.

RAM DIMM Presence

Install more RAM

Too much RAM

IDE Disk

Engine Command

Real Time Clock

(Soft) This test examines bad or incompatible RAM DIMMs.

(Soft) Checks that there is at least 64 MB of memory installed and ignores more than 512 MB.

(Soft) Checks that there is no more than 512 Mbytes of memory installed.

(Soft) Checks the disk controller core, and runs a DIAGNOSE command on the hard drive.

(Hard) Checks communication between the image processor board and the HVPS/engine logic board

(Soft) Checks to ensure that the seconds count in the Real Time Clock chip is incrementing at onesecond intervals +/-2%.

Phaser 4500/4510 Service Manual 3-17

Error Messages and Codes

POST Error Code Table

LED Blink Code

1 RAM ERROR No RAM present, or faulty RAM. Continuous 1/2

1+1+1 3: I/O ASIC Image processor board ASIC failure. Go to “Image

1+1+1+1 4: MEMORY Checks installed memory: walking ones address,

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

5+5+1 11: ETHERNET

5+5+1+1 12: CPU

Control Panel Message Comment

second interval LED blink.

Processor Isolation” on page 4-33.

walking one and complement data. Tests RAM memory above diagnostics code and data addresses. Go to “RAM DIMM Fault Isolation” on page 4-35.

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 (Go to page 4-34).

Image processor E-Net port failure.

PHY

INTERRUPTS

Replace image processor board (page 8-75). Replace image processor board (page 8-75).

5+5+1+1+1 13: USB Image processor USB port failure.

Replace image processor board (page 8-75).

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

CLOCK

5+5+5 15: RAM

DIMM

5+5+5+1 16: INSTALL

MORE RAM

5+5+5+1+1 17:TOO MUCH

RAM

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

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

COMMAND

Image processor board timer failure. Remove and reinstall the configuration card. If the problem persists, replace the image processor board (page 8-75).

RAM DIMM failure. Go to “RAM DIMM Fault Isolation” on page 4-35.

Not enough valid memory installed to support operation. Install additional RAM. Go to “RAM DIMM Fault Isolation” on page 4-35.

T oo much RAM can excessively load the processor bus, causing system failure. Remove some RAM. Go to “RAM DIMM Fault Isolation” on page 4-35.

Replace the hard disk (part of image processor removal on page 8-75). Replace the image processor board (page 8-75).

Communication with print engine has failed. Check ribbon cable to HVPS/engine logic board. Go to “Image Processor Isolation” on page 4-33.

3-18 Phaser 4500/4510 Service Manual

Operating System and Application Problems

Troubleshooting tips and more information are also available on the Xerox web site at: www.xerox.com/office/support

Macintosh Printing Problems

Image Never Prints

1. Printer acts as if it is receiving data, but nothing comes out of the printer

or it goes back to “Ready” mode without printing. The most lik ely cause is a PostScript error occurred in the printer.

2. Po wer cycle the printer and try printing again.

3. Make sure that the cor rect Ph aser 4500/4510 printer icon w as selected in

the Chooser. Try printing the job again.

4. In the Chooser or the print dialog, switch background printing to off. Try

printing the job again.

5. If the error returns, turn ON the PostScript error handler through the

control panel P ostScript Error Inf o in the Support menu, or CentreWare IS and print the document again. Take note of the information on the error page that just printed.

6. Select the appropriate Phaser 4500/4510 PPD with the LaserWriter

Driver or application. Not selecting the appropriate PPD can cause PostScript errors.

7. Select a different document from the application and try to print. If the

PostScript error does not occur, then the original document may be causing the problem.

8. Image is rotated 90 degrees.

9. In the application's Page Setup, make sure that the image is selected to

print in portrait or landscape orientation to match the document. Also, ensure the selected paper size is correct.

Error Messages and Codes

Windows Printing Problems

Image Never Prints

1. Try printing a test page from the printer driver’s properties dialog box.

2. Try printing from another application.

3. Try printing to another printer.

4. Try printing from another computer.

5. If the error returns, turn ON the PostScript error handler through the

control panel PostScript Error Info in the Support menu, or CWIS and print the document again. Take note of the information on the error page that just printed.

Phaser 4500/4510 Service Manual 3-19

Error Messages and Codes

Network Problems

The printer maintains four (P4510) or six (P4500) logs in memory detailing network functions. The logs contain TCP/IP, NetWare (P4500 only) and AppleTalk initialization events. The logs can also be accessed remotely via CentreWare.

The logs list events chronologically. The log is limited in length; when the log is full the printer stops recording data to the log. The logs are stored on the hard drive so only new data is stored each time the printer’s power is cycled.

There is a Connection Setup Page, Configuration Page and a network reset available for troubleshooting Network problems.

To Print an Event Log or Runtime Log:

1. P4500: From the main menu, select the Troubleshooting Menu, then

select Network Log Pages.

P4510: From the main menu, select the Troubleshooting Menu, then

Network Problems, then Network Log Pages.

2. Highlight the appropriate menu item from the list and select the OK

button.

3. The page should now print.

3-20 Phaser 4500/4510 Service Manual

Troubleshooting Procedures for Error Messages and Codes

The Error Message Summary tables that follow are the lead-ins to the procedures that follow in subsequent pages. There are two tabl es because the Engine Error and Jam Error codes are no t the same for both printers. The Control Panel Message column lists the error message that appears on the control panel when the error occurs during normal operation. The Diagnostic Message column lists the error message that appears when the error occurs during use of Service Diagnostics. The Engine Errors column lists the code number that appears in fault histories, either on the control panel display when you view Engine Error History or in the Service Usage Profile at line 262 Engine Error Log. The Jam Errors column lists the code that appears on the control panel display when you view Jam History for the Phaser 4500 or the Printer Status page for the Phaser 4510. The Procedure to Use column lists the page number of the troubleshooting procedure for that error.

For the Phaser 4510 printer, refer to the “Service Code Table” on page A-6, which maps the engine error and jam error codes to specific error messages.

The procedures that follow the table are named with the messages that appear on the control panel when an error occurs. The error codes listed in the procedure are the fault codes displayed in Service Diagnostics along with the fault condition that produced the code.

Error Messages and Codes

Phaser 4500 Error Message Summary

Control Panel Message Diagnostic Message

“Engine Logic Board NVRAM Failure\ Press i”

“Main Motor Failure\ Press i”

“Laser Unit Failure\ Press i”

U6: NVM Fail 3 — Go to

U1: Motor Fail/Power Off

Laser Fails at warm-up U2-1: Laser Fail/Power Off

Laser Fails Motor Speed U2-2: Laser Fail/Power Off

LD Power is high U2-3: Laser Fail/Power Off

LD Power is low U2-4: Laser Fail/Power Off

Engine Errors

Jam Errors

2—Go to

5—Go to

Procedure to Use

page 3-33.

page 3-28.

page 3-29

“Fuser Failure\ Press i” Fuser High Temp

U4-1: Fuser Fail/Power Off

Phaser 4500/4510 Service Manual 3-21

1—Go to

page 3-30

Error Messages and Codes

Phaser 4500 Error Message Summary

Engine

Control Panel Message Diagnostic Message

“Fuser Failure\ Press i” Fuser Low Temp

U4-2: Fuser Fail/Power Off

“Fuser Failure\ Press i” Fuser Overheat in

Stand-by U4-3: Fuser Fail/Power Off

“Fuser Failure\Press i” Fuser Fails at warm-up

U4-4: Fuser Fail/ Power Off

“Fuser Failure\Press i” Fuser Thermistor

Failure U4-5: Fuser Fail/ Power Off

“Toner Is Low\ Press i” J5: Toner Low — — Go to

“Fan Failure\ Power Off Now\ Press i”

U5: Fan Fail/ Power Off 0 — Go to

Errors

Jam Errors

1—Go to

Procedure to Use

page 3-30.

“Toner

Sensor” on

page 4-22

page 3-31.

“Install Or Reseat print cartridge\ Press i”

“Replace Print Cartridge\ Press i”

“Close Top Cover\ Press i”

“Close Rear Cover\ Press i”

“Jam At Tray N; Remove Trays And Open Top Cover To Clear\ Press i “

“Jam At T op; Open Top Cover To Clear\ Press i”

“Jam At Exit; Open Rear Cover To Clear\ Press i”

J3: Missing Print Cartridge

— — — Go to

Top Cover Open — — Go to

Rear cover open — — Go to

E2-01 Feed Jam E2-02 Feed Jam E2-03 Feed Jam E2-04 Feed Jam

E2-11 Feed Jam E2-12 Feed Jam E2-13 Feed Jam E2-14 Feed Jam

E3-1 Reg. Jam E3-2 Reg. Jam

E4-2 Exit Jam — 5 Go to

E4-3 Exit Jam — 5 Go to

——Go to

page 3-61.

page 3-62.

page 3-58.

2 3 4

Go to page 3-34.

Go to page 3-37.

page 3-40.

page 3-43.

—1

—6Go to

“Jam At Exit; Open T op Cover To Clear\ Press i”

3-22 Phaser 4500/4510 Service Manual

E4-0 Exit Jam — 5 Go to

page 3-43.

Phaser 4500 Error Message Summary

Error Messages and Codes

Control Panel Message Diagnostic Message

“Jam At Duplex; Open Duplex To Clear\ Press i “

“Jam At Rear; Open Duplex And Rear Cover To Clear\ Press i “

“Jam At Duplex; Open Duplex To Clear\ Press i “

“Jam At Rear; Open Rear Cover To Clear\ Press i “

“Jam At Stacker; Open Rear Stacker Cover To Clear\ Press i “

“Paper Size Jam; Check Paper Tray Guides And Open Rear Cover To Clear\ Press i”

E7-0 Duplex Jam — 7 Go to

E7-1 Duplex Jam — 7 Go to

E7-2 Duplex Jam — 7 Go to

E7-3 Duplex Jam — 7 Go to

E6-1 Stacker jam — 8 Go to

E6-2 Stacker Jam — 9 Go to

PSE-1 Paper Size Error — 10 Go to

Engine Errors

Jam Errors

Procedure to Use

page 3-51.

page 3-49.

page 3-45.

page 3-47.

page 3-56.

“Insert Tray 1\ Press i” Tray 1 Out — — Go to

page 3-67

“Insert Tray 2\ Press i” Tray 2 Out — — Go to

page 3-67

“Insert Tray 3\ Press i” Tray 3 Out — — Go to

page 3-68

“Insert Tray 4\ Press i” Tray 4 Out — — Go to

page 3-68

“Tray 2 Paper Is Low\ Press i”

“Tray 3 Paper Is Low\ Press i”

“Tray 4 Paper Is Low\ Press i”

“No Paper in Tray 1\ Press i”

“No Paper in Tray 2\ Press i”

“No Paper in Tray 3\ Press i”

N/A — — Go to

page 3-64

N/A — — Go to

page 3-66

N/A — — Go to

page 3-66

Tray 1 empty — — Go to

page 3-63.

Tray 2 empty — — Go to

page 3-63.

Tray 3 empty — — Go to

page 3-65.

“No Paper in Tray 4\ Press i”

Phaser 4500/4510 Service Manual 3-23

Tray 4 empty — — Go to

page 3-65.

Error Messages and Codes

Phaser 4500 Error Message Summary

Engine

Control Panel Message Diagnostic Message

“Maintenance Kit is Near End of Life\ Press i”

“Replace Maintenance Kit”

“Stacker Is Full, Unload Paper\ Press i”

“Standard Output Tray Is Full, Unload Paper\ Press i”

“Tray 3 Failure\ Press i” E11-1 Tray 3 unit fail — 6 Go to

“Tray 3 or 4 Failure\ Press i”

“Duplex Unit Failure\ Press i”

“Stacker Unit Failure\ Press i”

“Close Duplex Unit Cover\ Press i”

N/A — — —

N/A — — Go to

Stacker output tray full — — Go to

Output tray full — — Go to

E11-2 Tray 3 or 4 unit fail

E9-1 Duplex unit fail — 8 Go to

E9-2 Stacker unit fail — 4 Go to

Duplex cover open — — Go to

Errors

Jam Errors

—7Go to

Procedure to Use

page 3-71.

page 3-69

page 3-70

page 3-54

page 3-52.

page 3-53.

page 3-59.

“Close Stacker cover\ Press i”

“Invalid Configuration Card\ Press i”

“Configuration Card Missing\ Press i”

Stacker cover open — — Go to

page 3-60.

N/A — — —

3-24 Phaser 4500/4510 Service Manual

Xerox Phaser 4500, Phaser 4510 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Service Terms

Product Terms

Power Safety Precautions

Electrostatic Discharge (ESD) Precautions

Service Safety Summary

Regulatory Specifications

General Information

Printer Introduction and Overview

Technical Support Information

Printer Configurations

Parts of the Printer

Control Panel

Image Processor Board (Phaser 4500)

Image Processor Board (Phaser 4510)

Consumables and Routine Maintenance Items

Supply Life Counters

Printer Specifications

Physical Dimensions and Clearances

Functional Specifications

Electrical Specifications

Environmental Specifications

Media and Tray Specifications

Memory Requirements

Theory of Operation

Overview of the Phaser 4500/4510 Laser Printer

Summary of the Printing Process

Paper Path of the Printer

Layout of Paper Transport Path

Sensors

Major Assemblies and Functions

Paper Tray

Paper Feeder

Control of Paper Size

Xerographics

Fuser

Fuser Control

Paper Exit Assembly

Drive

Electrical

Printer Options

Duplex Unit

Stacker

Optional 550-Sheet Feeder

Error Messages and Codes

Introduction

Servicing Instructions

Using the Troubleshooting Procedures

General Notes on Troubleshooting

Accessing Fault Histories

Entry Level Fault Isolation Procedure

Service Diagnostics

Service Diagnostics Menu Map

Service Diagnostic Control Panel Button Descriptions

Using Service Diagnostics

System Start-Up and POST

Power On Self Test (POST)

POST Faults

LED Blink Patterns

POST Diagnostic Test Descriptions

Operating System and Application Problems

Macintosh Printing Problems

Windows Printing Problems

Network Problems

Troubleshooting Procedures for Error Messages and Codes