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 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.
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
e
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 Manualxi
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.
0
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.
xiiPhaser 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 Manualxiii
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).
xivPhaser 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 Manualxv
Servicing Electrical Components
W
W
W
W
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
xviPhaser 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 Manualxvii
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
xviiiPhaser 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
1
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
.
1-2Phaser 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
BNDTDX
Maximum print speed (letter-size
paper)
P4500:
P4510:
Memory
P4500:
P4510:
PostScript fonts39393939 + 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/PCL6YesYesYesYes
Job pipeliningStandardStandardStandardStandard
PDF direct printYesYesYesYes
Resolutions600 dpi,
(requires duplex unit)
Hard driveOptionalOptionalOptionalStandard
Job collation
(Requires a hard drive)
Proof Print, Secure Print, Saved
Jobs (Requires a hard drive)
500-sheet stackerOptionalOptionalOptionalStandard
OptionalOptionalStandardStandard
OptionalOptionalOptionalStandard
OptionalOptionalOptionalStandard
600 dpi,
True 1200
dpi
600 dpi,
True 1200
dpi
600 dpi,
True
1200 dpi
Phaser 4500/4510 Service Manual1-3
General Information
4510-067
8
9
6
5
7
1
2
3
4
P4510
Parts of the Printer
Front View
1
2
11
3
10
4
9
5
6
1.Paper stop
2.Control panel
3.Tray 1
4.On/Off switch
5.Tray 2
6.Optional tray 3
Rear View
P4500
4
1
3
2
7
8
4510-072
7.Optional tray 4
8.Paper gauge
9.Print cartridge
10.Standard output tray
11.Optional 500-Sheet stacker
9
8
7
6
5
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
1-4Phaser 4500/4510 Service Manual
Control Panel
6
3
8
General Information
The control panel consists of one tricolor LED, a display window, and six
functional buttons.
45
Phaser 4500
OK
12
36 78
s4500-003
45
Phaser 4510
12
7
s4510-003
1.Status indicator LED5.Up Arrow button - scrolls up the menu system
2.Graphic control panel
display
6.Down Arrow button - scrolls down the menu
system
3.Back button7.OK (select) button
4.Cancel button8.Information (i) (P4500) or Help (?) (P4510)
button - for additional explanation or help
LED States
LED StatePrinter State
GreenReady to Print or in Power Saver mode
Flashing YellowWarning (but can still print)
Flashing GreenIn Standby mode or busy (receiving data, processing data,
printing)
Flashing RedError; cannot print
Phaser 4500/4510 Service Manual1-5
General Information
Control Panel Shortcuts
ModeButtons Pressed at Power On
Skip execution of POST
diagnostics
Print Service Diagnostics MapInformation
Reset PostScript NVRAM Back + OK
Password BypassUp Arrow + Down Arrow
Enter Service DiagnosticsBack + Information
OK
1-6Phaser 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
1
6
2
3
4
5
9
1.Memory (RAM) DIMM 1 and DIMM 26.Parallel connector
2.Flash memory (optional)7.Ethernet connector
3.Hard drive (optional) 8.USB connector
4.NVRAM 9.Health LED
5.Configuration card
7
8
5
s4500-251
Phaser 4500/4510 Service Manual1-7
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)
1
5
4
3
9
2
1.Memory (RAM) DIMM 1 and DIMM 26.Parallel connector
2.Flash memory (optional)7.Ethernet connector
3.Hard drive (optional) 8.USB connector
4.NVRAM 9.Health LED
7
5
8
6
s4510-251
5.Configuration Card
1-8Phaser 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 Manual1-9
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.
SupplyPrint Life (Number of Images)
Consumables
Print cartridge, standardcapacity
Print cartridge, high-capacity19,000
Routine Maintenance Items
Maintenance kit (consists of
fuser, transfer roller, and 12
feed rollers)
10,000
200,000
1-10Phaser 4500/4510 Service Manual
Printer Specifications
Physical Dimensions and Clearances
General Information
Print Engine DimensionsValue
Height404 mm (15.9 in.)
Width422 mm (16.6 in.)
Depth
Depth with paper cassette extended
Weight (with 10-K print cartridge)20.5 kg (45.2 lbs.) (P4500)
ClearancesValue
Top400 mm (16 in.)
Left210 mm (8 in.)
Right300 mm (12 in.)
Front480 mm (19 in.)
Rear (with duplex unit installed)230 mm (9 in.)
Total Height requirement820 mm (32 in.)
Mounting surface level tolerance± 5°
550-Sheet Feeder DimensionsValue
Height (to top of feeder assembly)143 mm (5.6 in.)
Width422 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.)
Weight6.3 kg (13.9 lbs.)
Duplex Unit DimensionsValue
Height219 mm (8.6 in.) (P4500)
238 mm (9.4 in.) (P4510)
Width352 mm (13.8 in.)
Depth96 mm (3.8 in.) (P4500)
146 mm (5.8 in.) (P4510)
Weight1.9 kg (4.2 lbs.)
Stacker DimensionsValue
Height226 mm (8.9 in.)
Width418 mm (16.4 in.)
Depth
Depth with stacker tray extended
Weight2.6 kg (5.7 lbs.)
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 ModesTwo 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 Time17 seconds
1-12Phaser 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
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