Xerox Phaser 4600, Phaser 4620 Service Manual

Phaser® 4600/4620

Laser Printer

Phaser® 4600/4620

Service Manual

Xerox Internal-Use Only

Phaser 4600/4620 Printer Service Manual

Service Documentation

Phaser 4600/4620 Printer Service Manual

705P01287

Revision - Xerox Internal Use Only

5/2011

Xerox Corporation

Customer and Service Training and Information

26600 Parkway - Bldg. 60

P.O. Box 1000, M/S 7060-776

Wilsonville, OR 97070-1000

NOTICE: All service documentation is supplied to Xerox external customers for informational purposes only. Xerox service documentation is intended for use by certified, product trained service personnel only. Xerox does not warrant or represent that such documentation is complete, nor does Xerox represent or warrant that it will notify or provide to such customer any future changes to this documentation. Customer performed service of equipment, or modules, components or parts of such equipment may affect the warranty offered by Xerox with respect to such equipment. You should consult the applicable warranty for its terms regarding customer or third party provided service. If the customer services such equipment, modules, components or parts thereof, the customer releases Xerox from any and all liability for the customer actions, and the customer agrees to indemnify, defend and hold Xerox harmless from any third party claims which arise directly or indirectly from such service.

Unpublished rights reserved under the copyright laws of the United States.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.

© 2010 Xerox Corporation. All rights reserved. XEROX® and XEROX and design®, Phaser®, PhaserSMART®, DocuCard®, DocuSP®, FreeFlow® CentreWare®, infoSMART®, Made For Each Other®, PagePack™, ColorCube®, ProfitAccelertor™, and Walk-Up™ are trademarks of Xerox Corporation in the United States and/or other countries.

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As an ENERGY STAR® partner, Xerox Corporation has determined that this product meets the ENERGY STAR guidelines for energy efficiency. The ENERGY STAR name and logo are registered U.S. marks.

PANTONE® Colors generated may not match PANTONE-identified standards. Consult current PANTONE Publications for accurate color. PANTONE® and other Pantone, Inc. trademarks are the property of Pantone, Inc. © Pantone, Inc., 2000.

Introduction

About This Manual ..........................................................................................................	iii
How To Use This Manual................................................................................................	iii
Service Safety Summary.................................................................................................	iv
Symbols Used On The Product.......................................................................................	v
Voltage Measurement and Specifications.......................................................................	vi
Health and Safety Incident reporting...............................................................................	vi
Regulatory Specifications................................................................................................	vii
Translation of Warnings ..................................................................................................	viii
Phaser 4600/4620 Overview...........................................................................................	x
Printer Options ................................................................................................................	xi
Control Panel Layout.......................................................................................................	xiii
Routine Maintenance Items ............................................................................................	xiv
Consumables ..................................................................................................................	xiv

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Phaser 4600/4620 Printer Service Manual	i

About This Manual

The Phaser 4600/4620 Printer Service Manual is part of a multinational service documentation system organized in the standard Xerox EDOC service manual format. This manual is the primary document used for diagnosing, repairing, maintaining, and troubleshooting these systems. The Service Manual is the controlling publication for a service call. Information on using this document is found in the Introduction section. To ensure understanding of this product, complete the Xerox Service Training Program for this particular printer.

Organization

Section titles and the information contained in each is presented in the following paragraphs:

Section 1 Service Call Procedures

This section is used to start and complete a service call. The procedures in this section will either direct you to a Repair Analysis Procedure (RAP), or identify a faulty component or subassembly.

Section 2 Status Indicator Repair Analysis Procedures

This section contains the Repair Analysis Procedures (RAPs) and checkouts necessary to diagnose, isolate and repair faults other than image quality faults.

Section 3 Image Quality

This section contains the Image Quality Repair Analysis Procedures (IQ RAPs), checkouts and setup procedures necessary to diagnose, isolate and repair image quality faults.

Section 4 Repairs/Adjustments

This section contains the instructions for removal, replacement, and adjustment of parts within the machine.

Section 5 Parts List

This section contains the detailed and illustrated spare parts list. Any part that is spared or that must be removed to access a spared part is illustrated.

Section 6 General Procedures / Information

This section contains all other procedures, product specifications and general information.

Section 7 Wiring Data

This section contains the wiring diagrams.

Section 8 Accessories

This section contains details of any accessories that the machine may have.

Publication Comments Sheet

A Publication Comment Sheet is provided at the rear of the hardcopy manual.

How To Use This Manual

Always start with the Service Call Procedures, Section 1. Perform Initial Actions and verify the problem, then follow the directions given.

How to Differentiate Between Machine Variants

The machine will be identified in this manual by the model identifier 4600/4620.

When a procedure, parts list description or other reference is unique amongst different models of machine, the appropriate model designator is indicated. Any artwork is also specific.

NOTE: This manual services all configurations of the machine. Ignore references to options not installed on the machine.

Warnings, Cautions and Notes

WARNING

A warning is used whenever an operating or maintenance procedure, practice, condition or statement, if not strictly observed, could result in personal injury.

A translated version of all warnings is in Translation of Warnings.

CAUTION

A caution is used whenever an operation or maintenance procedure, practice, condition or statement, if not strictly observed, could result in damage to the equipment.

NOTE: A note is used where it is essential to highlight a procedure, practice, condition or statement.

Component Names

Names of parts that appear in the disassembly procedures may not be exactly the same as the names that appear on the part or listed in the Parts List. For example; a part called the Registration Chute Assembly may appear on the Parts List as Assembly, Chute REGI.

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Phaser 4600/4620 Printer Service Manual	iii

Service Safety Summary

General Guidelines

For qualified service personnel only: Refer also to the preceding Electrical Safety.

Avoid servicing alone: Do not perform internal service or adjustment of this product unless another person capable of rendering first aid or resuscitation is present.

Use care when servicing with power applied: 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.

Electrical Safety

•Use the Power Cord supplied with the printer.

•Plug the Power Cord directly into a properly grounded electrical outlet.

•Do not use a ground adapter plug to connect the printer to an electrical outlet that does not have a ground connection terminal.

•Do not use an extension cord or power strip.

•Do not place the system in an area where people might step on the power cord.

•Do not place objects on the power cord.

•Do not block the ventilation openings. These openings are provided to prevent overheating of the printer.

•Do not drop paper clips or staples into the printer.

Warning Labels

Read and obey all posted warning labels. Throughout the printer, warning labels are displayed on potentially dangerous components. As you service the printer, check to make certain that all

warning labels remain in place.

Safety Interlocks

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

Operational Safety

The printer and supplies were designed and tested to meet strict safety requirements. These include safety agency examination, approval, and compliance with established environmental standards.

Pay attention to these safety guidelines to ensure the continued, safe operation of the printer.

•Use the supplies specifically designed for your system. The use of unsuitable materials may cause poor performance and a possible safety hazard.

•Follow all warnings and instructions marked on, or supplied with, the system, options and supplies.

NOTE: The Total Satisfaction Guarantee is available in the United States and Canada. Coverage may vary outside these areas; please contact your local representative for details.

Maintenance Safety

•Do not attempt any maintenance procedure that is not specifically described in the documentation supplied with the printer.

•Do not use aerosol cleaners. The use of supplies that are not approved may cause poor performance and could create a hazardous condition.

•Do not burn any consumables or routine maintenance items. For information on Xerox supplies recycling programs, go to www.xerox.com/gwa.

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Service Safety Summary
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Symbols Used On The Product

The following precautionary symbols may appear on the machine.

This symbol indicates Danger High Voltage.

Figure 1 High Voltage Symbol

Protective Ground (Earth) symbol.

Figure 2 Protective Ground (Earth) Symbol

This symbol indicates hot surface. Use caution to avoid personal injury.

Figure 3 Hot Surface Symbol

The surface is hot while the printer is running. After turning off the power, wait 30 minutes.

Figure 4 Wait 30 Minutes Symbol

Avoid pinching fingers in the printer. Use caution to avoid personal injury.

Figure 5 Pinch Injury Symbol

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

Figure 6 Use Caution Symbol

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Phaser 4600/4620 Printer Service Manual	v

Voltage Measurement and Specifications

Measurements of DC voltage must be made with reference to the specified DC Common, unless some other point is referenced in a diagnostic procedure. All measurements of AC voltage should be made with respect to the adjacent return or ACN wire.

	Table 1 Voltage Measurement and Specifications
Voltage		Specification
Input Power 220 V		198 VAC TO 254 VAC
Input Power 100 V		90 VAC TO 135 VAC
Input Power 120 V		90 VAC TO 135 VAC
+5 VDC		+4.75 VDC TO +5.25 VDC
+24 VDC		+23.37 VDC TO +27.06 VDC

Logic Voltage Levels

Measurements of logic levels must be made with reference to the specified DC Common, unless some other point is referenced in a diagnostic procedure.

	Table 2 Logic Levels
Voltage		H/L Specification
+5 VDC		H = +3.00 V or greater
		L = below 0.8 V
+3.3V		H = +2 V or greater
		L =below 0.8 V

DC Voltage Measurement in RAPs

The RAPs have been designed so that when it is required to use the DMM to measure a DC voltage, the first test point listed is the location for the red (+) meter lead and the second test point is the location for the black meter lead. For example, the following statement may be found in a RAP.

There is +5 VDC from P/J7 to P/J68.

In this example, the red meter lead would be placed on P/J7 and the black lead on P/J68.

If a second test point is not given, it is assumed that the black meter lead may be attached to chassis ground.

Health and Safety Incident reporting

I. Summary

This section defines requirements for notification of health and safety incidents involving Xerox products (equipment and materials) at customer locations.

II. Scope

Xerox Corporation and subsidiaries worldwide.

III. Objective

To enable prompt resolution of health and safety incidents involving Xerox products and to ensure Xerox regulatory compliance.

IV. Definitions

Incident:

An event or condition occurring in a customer account that has resulted in injury, illness or property damage. Examples of incidents include machine fires, smoke generation, physical injury to an operator or service representative. Alleged events and product conditions are included in this definition.

V. Requirements

Initial Report:

1.Xerox organizations shall establish a process for individuals to report product incidents to Xerox Environment Health & Safety within 24 hours of becoming aware of the event.

2.The information to be provided at the time of reporting is contained in Appendix A (Health and Safety Incident Report involving a Xerox product).

3.The initial notification may be made by any of the following methods:

•For incidents in North America and Developing Markets West (Brazil, Mexico, Latin American North and Latin American South):

–Phone* Xerox EH&S at: 1-800-828-6571.

–Electronic mail Xerox EH&S at: [e-mail].

–Fax Xerox EH&S at: 1-585-422-6449 [intelnet 8*222 6449].

•For incidents in Europe and Developing Markets East (Middle East, Africa, India, China and Hong Kong):

–Phone* Xerox EH&S at: [phone].

–Electronic mail Xerox EH&S at: [e-mail].

–Fax Xerox EH&S at: [phone] [intelnet 8*668 3914].

*Initial notification made by phone must be followed within 24 hours by a completed incident report and sent to the indicated electronic mail address or fax number.

NOTE: If sending a fax, please also send the original via internal mail.

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	vi	Phaser 4600/4620 Printer Service Manual

Responsibilities for resolution:

1.Business Groups/Product Design Teams responsible for the product involved in the incident shall:

a.Manage field bulletins, customer correspondence, product recalls, safety retrofits.

b.Fund all field retrofits.

2.Field Service Operations shall:

a.Preserve the Xerox product involved and the scene of the incident inclusive of any associated equipment located in the vicinity of the incident.

b.Return any affected equipment/part(s) to the location designated by Xerox EH&S and/or the Business Division.

c.Implement all safety retrofits.

3.Xerox EH&S shall:

a.Manage and report all incident investigation activities.

b.Review and approve proposed product corrective actions and retrofits, if necessary.

c.Manage all communications and correspondence with government agencies.

d.Define actions to correct confirmed incidents.

Regulatory Specifications

Xerox has tested this product to electromagnetic emission and immunity standards. These standards are designed to mitigate interference caused or received by this product in a typical office environment.

United States (FCC Regulations)

The Phaser 4600/4620 has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a commercial installation. This equipment generates, uses, and can radiate radio frequency energy. If it is not installed and used in accordance with these instructions, it may cause harmful interference to radio communications. Operation of Class A equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his/her own expense. 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.

•Increase the separation between the equipment and receiver.

•Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.

•Consult the dealer or an experienced radio/television technician for help.

Any changes or modifications not expressly approved by Xerox could void the user's authority to operate the equipment. To ensure compliance with Part 15 of the FCC rules, use shielded interface cables.

Canada (Regulations)

This Class A digital apparatus (4600/4620) complies with Canadian ICES-003.

Cet appareil numérique (4600/4620) de la classe A est conforme à la norme NMB-003 du Canada.

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		Health and Safety Incident reporting, Regulatory
Phaser 4600/4620 Printer Service Manual	vii

European Union

CE Mark

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:

Figure 1 CE Symbol

December 12, 2006: Low Voltage Directive 2006/95/EC

December 15, 2004: Electromagnetic Compatibility Directive 2004/108/EC

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 cables.

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

Translation of Warnings

WARNING

Switch off the electricity to the machine. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury.

DANGER : Mettez la machine hors tension. Déconnectez le cordon d'alimentation de l'alimentation du client lorsque vous réalisez des tâches qui ne nécessitent pas d'électricité. L'électricité peut être à l'origine de blessures, voire d'un accident mortel. Les pièces amovibles peuvent être à l'origine de blessures.

AVVERTENZA: Spegnere la macchina. Scollegare il cavo di alimentazione dall'alimentatore quando si eseguono attività che non richiedono elettricità. L'elettricità può causare morte o lesioni personali. Le parti in movimento possono causare lesioni personali.

VORSICHT: Schalten Sie die Stromversorgung der Maschine ab. Ziehen Sie das Stromkabel ab, wenn Sie Aufgaben ausführen, für die keine Stromversorgung benötigt wird. Stromschläge können Todesfällen oder Verletzungen verursachen. Bewegliche Teile können zu Verletzungen führen.

AVISO: Apague la electricidad de la máquina. Desconecte el cable de alimentación eléctrica de la toma de pared mientras esté realizando tareas que no necesiten corriente. La electricidad puede causar daños o la muerte. Las partes móviles pueden causar daños.

WARNING

Do not work in a confined space. 1 m (39 inches) space is needed for safe working.

DANGER : Ne pas travailler dans un espace restreint. 1 mètre d'espace est nécessaire pour un dépannage en toute sécurité.

AVVERTENZA: Non lavorare in uno spazio limitato; è necessario uno spazio di almeno un metro attorno alla macchina per la sicurezza dell'operatore.

VORSICHT: Nur mit ausreichendem Bewegungsspielraum (1 m) arbeiten.

AVISO: No trabaje en un espacio reducido. Se necesita 1 metro de espacio para trabajar con seguridad.

WARNING

Use safe handling procedures when removing the module. Refer to GP 16. The module is heavy.

DANGER: Conformez-vous aux procédures de manipulation de sécurité pour le retrait du module. Reportez-vous à GP 16. Le module est lourd.

AVVERTENZA: Utilizzare procedure di gestione sicure durante la rimozione del modulo. Vedere GP 16. Il modulo è pesante.

VORSICHT: Verwenden Sie sichere Vorgehensweisen zum Entfernen des Moduls. Siehe auch GP 16. Das Modul ist sehr schwer.

AVISO: Utilice los procedimientos de seguridad cuando elimine el módulo. Consulte el GP 16. El módulo es pesado.

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Regulatory Specifications, Translation of Warnings
	viii	Phaser 4600/4620 Printer Service Manual

WARNING

Follow the service procedure exactly as written. Use of controls or adjustments other than those specified in this manual, may result in an exposure to invisible laser radiation. During servicing, the invisible laser radiation can cause eye damage if looked at directly.

DANGER : Les procédures de dépannage doivent être suivies à la lettre. Si les réglages ou vérifications ne sont pas effectués suivant les instructions de ce manuel, il peut y avoir un risque d'exposition dangereuse au faisceau laser. Celui-ci peut provoquer des lésions oculaires s'il est observé directement.

AVVERTENZA: Eseguire le procedure di servizio esattamente come descritto. L'utilizzo di dispositivi di controllo o di registrazione diversi da quelli riportati in questo manuale potrebbe comportare un'esposizione a radiazioni laser invisibili. Tali radiazioni possono danneggiare gli occhi se si guarda direttamente il fascio laser durante gli interventi di servizio.

VORSICHT: Die Wartungsarbeiten genau den Anweisungen entsprechend durchführen. Der Umgang mit Steueroder Bedienelementen, deren Verwendung nicht ausdrücklich in diesem Handbuch angewiesen wurde, kann dazu führen, dass unsichtbare Laserstrahlung frei gesetzt wird. Direkter Blickkontakt mit dem Laserstrahl kann bleibende Augenschäden verursachen.

AVISO: Siga los procedimientos de mantenimiento tal como están descritos. El uso de controles o ajustes no especificados en este manual puede tener como resultado la exposición a radiación láser invisible. Durante las operaciones de mantenimiento, la radiación de láser invisible puede causar daños en los ojos si se mira directamente a ella.

WARNING

USA and Canada. Do not install this machine in a hallway or exit route that does not have 1.12 m (44 inches) of space additional to the normal space requirements in front of the machine. To conform with fire regulations this additional 1.12 m (44 inches) of space is needed in front of the machine in hallway and exit routes.

DANGER : États-Unis et Canada. Si cette machine est installée dans un couloir ou une voie de sortie, 1,12 m (44 pouces) d'espace supplémentaire à l'espace normal doit être disponible devant la machine conformément aux normes de sécurité d'incendie.

AVVERTENZA: N/A

VORSICHT: N/A

AVISO: Estados Unidos y Canadá. No instale esta máquina en un corredor o ruta de salida que no tenga 1.12 m (44 pulgadas) de ancho delante de la máquina, sin incluir el espacio que ocupe la máquina. Este espacio adicional de 1.12 m (44 pulgadas) delante de la máquina en corredores y rutas de salida es necesario para cumplir los requisitos de las normas sobre incendios.

WARNING

Use only Xerox materials and components. This product is safety certified using Xerox materials and components. The use of non Xerox materials and components may invalidate the safety certificate.

DANGER : N'utilisez que des matières premières et des composants Xerox. La sécurité du produit est assurée dans le cadre de son utilisation avec des matières premières et des composants Xerox. L'utilisation de matières premières et de composants autres que ceux de Xerox risque d'invalider le certificat de sécurité.

AVVERTENZA: Utilizzare solo materiali e componenti Xerox per avvalersi della certificazione di protezione. L'utilizzo di materiali e componenti non Xerox può rendere nulla la certificazione di protezione.

VORSICHT: Verwenden Sie nur Materialien und Komponenten von Xerox. Dieses Produkt besitzt die Sicherheitszertifizierung bei Verwendung von Xerox-Materialien und -Komponenten. Die Verwendung von Materialien und Komponenten anderer Hersteller setzt möglicherweise das Sicherheitszertifikat außer Kraft.

AVISO: Utilice solo los materiales y componentes Xerox. Este producto dispone de un certificado de seguridad si se utilizan los materiales y componentes Xerox. Este certificado de seguridad no será válido si se utilizan materiales y componentes que no sean de Xerox.

WARNING

Do not touch the fuser while it is hot.

DANGER : Ne pas toucher au four pendant qu'il est encore chaud.

AVVERTENZA: Non toccare il fonditore quando è caldo.

VORSICHT: Fixierbereich erst berühren, wenn dieser abgekühlt ist.

AVISO: No toque el fusor mientras está caliente.

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Phaser 4600/4620 Printer Service Manual	ix

Phaser 4600/4620 Overview

Rear View

The Phaser 4600/4620 combines a monochrome laser print engine with a multi-purpose Tray 1 (bypass) and universal media tray, Tray 2. The Output Tray holds 500 20lb. sheets facedown. Phaser 4600/4620 options add memory, media capacity, and functionality. For models not originally equipped, a 160 GB Hard Drive is available. A memory upgrade raises the installed RAM to the 768 MB maximum. Configurations of up to four 520-Sheet Feeders, or an additional 2 520-sheet feeders and the high-capacity 2000-sheet feeder. On the output side, 500 sheet stapler/stacker or 4-bin, 400-sheet Mailbox are available, Figure 1.

Figure 2 shows features located at the rear of the system.

Front View

						Figure 2 Rear view
						Table 2 Rear View
	Figure 1 Front View			1.	Finisher Rear Door	6.	Power Switch
				2.	Rear Door	7.	Ethernet Connection
	Table 1 Front View			3.	Mailbox Rear Door	8.	Configuration Card Slot
1.	Finisher (Stacker & Stapler)	10.	Tray 2	4.	Waste Toner Cartridge Door	9.	USB Port
2.	Mailbox	11.	Front Door	5.	AC Input	10. Wireless Network Adaptor Slot
3.	Staple Cartridge Door	12.	Top Door
4.	IP Board Cover	13.	Control Panel
5.	Filter Cover	14.	Top Cover
6.	Printer Stand	15.	Toner Cartridge
7.	2000-Sheet Feeder	16.	Drum Cartridge
8.	Media level Indicator	17.	Tray 1 (bypass)
9.	520-Sheet Feeder(s)	18.	Tray 1 Media Extension
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Phaser 4600/4620 Overview
				x			Phaser 4600/4620 Printer Service Manual

Printer Options

Phaser 4600/4620 options include:

•Additional Memory (512 MB)

•Hard Disk

•Wireless network adaptor

•Printer stand

•520-sheet Feeder

•2000-sheet Feeder with casters

•Finisher with stapler, 500-sheet stacker.

•Mailbox, 4-bin, 400-sheets

Table 1 lists both Service and Sales part numbers for available options and accessories.

Table 1 Option and Accessory Part Numbers

Item	Service Part Number	Sales Part Number
520-Sheet Feeder	050K74180	097N01874
2000-Sheet Feeder	059K77920	097N01875
Finisher (500-sheet)	059K77910	097N01876
Mailbox (400-sheet)	050K74190	097N01877
Duplex Unit	022N02484	097N01923
Memory Upgrade	128K01770	097N01878
160MB Hard Disk	007N01651	097N01879
Wireless Network Adaptor	120K03640	097N01880
Stand	078K00870	097N01916

Hard Disk Drive

The Phaser 4600/4620 supports an internal 160 GB Hard Disk Drive mounted to the IP Board. Features enabled by Hard Drive installation include:

•Secure Print

•Proof Print

•Save Print

•Disk Collation

Additional Memory

The Phaser 4600/4620 IP Board includes 1 slot for a 512 MB DDR2 DIMM, Figure 1. Memory must meet these characteristics:

•200 Pin DDR2 SODIMM

•Unbuffered, Non-parity

The printer’s Configuration page lists the amount of RAM installed in the printer.

Figure 1 Optional memory

520-Sheet Feeder

The 520-sheet Feeder increases the input capacity of the printer and is attached to the printer underneath Tray 2. These additional tray combinations are supported:

•One 520-Sheet Feeder (Tray 3)

•Up to 4, 520-Sheet Feeders (Trays 3, 4, 5, and 6)

Figure 2 520-Sheet Feeder

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Phaser 4600/4620 Printer Service Manual	xi

2000-Sheet Feeder

The 2000-sheet Feeder increases the input capacity of the printer and is attached to the printer underneath Tray 2 or installed 520-sheet Feeders. These additional tray combinations are supported:

•One 2000-Sheet Feeder (Tray 3)

•Up to 2 520-Sheet Feeders (Trays 3, 4) and 1 2000-Sheet Feeder (Tray 5).

Figure 3 2000-Sheet Feeder

Mailbox

The Mailbox provides four 100-sheet output trays.

Figure 4 Optional Mailbox

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Finisher

The finisher provides a 500-sheet, offset Stacker Tray and includes a fixed-head stapler.

Figure 5 Finisher

Control Panel Layout

The Control Panel consists of one LED, a display window, a keypad, and several buttons. These buttons are used to navigate the menu system, perform functions, and select modes of operation for the printer. Table 1 lists the function of each control.

			Figure 1 Control Panel
		Table 1 Control Panel Features
1.	Display	Displays printer settings, status, messages and menus.
2.	Menu	Enters Menu Mode and scrolls through the available
		menus.
3.	Back	Sends you back one level in the menu.
4.	Status LED	•	Green: Printer is ready to print.
		•	Yellow: Startup sequence or error condition.
		•	Flashing:
			–	Yellow: Error Condition
			–	Green: Warming up or Receiving data
5.	OK	Accepts the selected settings.
6.	Keypad	Use to enter alphanumeric characters.
7.	Help (?)	Additional information.
8.	Energy Saver	Illuminates when the printer is in Power Saver mode. Press
		to enter or exit from Power Saver mode.
9.	Stop	Press to cancel the current activity.

Revision - Xerox Internal Use Only	5/2011	Introduction
		Printer Options, Control Panel Layout
Phaser 4600/4620 Printer Service Manual	xiii

Routine Maintenance Items

Table 1 Routine Maintenance Items

Item	Description	Print Life
1.	Pick and nudger Rollers	200,000 pages
2.	Separator Roller	100,000 pages
3.	Transfer Roller	100,000 images
4.	Fuser	200,000 images
5.	Feed Roller	100,000 pages

Consumables

The rated life expectancy of 4600/4620 consumables is listed in Table 1.

Table 1 Consumable Life Expectancy

Item	Description	Print Life
1.	Standard Toner Cartridge	20,000 cycles
	High Capacity Toner Cartridge	30,000 cycles
	Starter Toner Cartridge	10,000 cycles
2.	Drum Cartridge	60,000 cycles
3.	Waste Toner Cartridge	Provided with new Toner Cartridge
4.	Staple Cartridge	15,000
5.	Maintenance Kit (Fuser, Feed Rollers, Transfer	200,000 cycles
	Roller)

Introduction	5/2011	Revision - Xerox Internal Use Only
Routine Maintenance Items
	xiv	Phaser 4600/4620 Printer Service Manual

1 Service Call Procedures

Service Call Procedures..................................................................................................		1-3
SCP 1 Initial Actions........................................................................................................		1-4
SCP 2 First Call Actions..................................................................................................		1-4
SCP 3 Normal Call Actions .............................................................................................		1-5
SCP 4	Fault Analysis ......................................................................................................	1-5
SCP 5	Subsystem Maintenance .....................................................................................	1-6
SCP 6	Final Actions ........................................................................................................	1-7
SCP 7	Configurations and Options .................................................................................	1-8

Revision - Xerox Internal Use Only	5/2011	Service Call Procedures
Phaser 4600/4620 Printer Service Manual	1-1

Service Call Procedures

This section provides an overview of the steps a service technician should take to service the printer and attached options. The printer’s diagnostic routines report problems using error messages and fault codes displayed on the Control Panel, logged in the Service Usage Profile, or by flashing LEDs. These error indications serve as the entry point into the troubleshooting process. System problems not directly indicated by or associated with an error message or fault code are covered in Section 6, General Procedures. Print-quality problems are covered in Section 3, Image Quality.

The steps listed here are a guide for performing any service on this printer. If you choose not to use these steps, it is recommended that you start at the appropriate troubleshooting procedure and proceed from there. When servicing the printer, follow the safety measures detailed in the Service Safety Summary section.

1.Identify the problem.

•Verify the reported problem does exist.

•Check for any error codes and write them down.

•Print normal customer prints and service test prints.

•Make note of any print-quality problems in the test prints.

•Make note of any mechanical or electrical abnormalities present.

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

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

•View the Engine Error and Jam Histories under the Tools menu.

•Verify the AC input from the wall outlet is within specifications.

2.Inspect and clean the printer.

•Follow the cleaning instructions.

•Verify that the power cord is in serviceable condition.

•Restart the printer to check if the error reoccurs.

3.Find the cause of the problem.

•Use the troubleshooting procedures to find the root cause of the problem.

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

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

•Take voltage readings as instructed in the troubleshooting procedure.

4.Correct the problem.

•Use the Parts List to locate a part number.

•Use the Repair procedures to replace the part.

5.Final Checkout

•Test the printer to verify the problem is corrected and no new problems arose.

Accessing Engine Fault History

Listed below are three ways in which you can access fault history records.

1.Print (if possible) the Error Message report from the Troubleshooting menu. The error history is listed on the report.

NOTE: Error and fault code definitions of the codes appear in Section 2.

2.If the printer is connected to a network and has a TCP/IP address, view the printer’s web page using a web browser.

a.Open a web browser.

b.Enter the printer’s IP address as the URL.

c.Select Support --> Troubleshooting --> Diagnostics Logs and the fault history displays.

Revision - Xerox Internal Use Only	5/2011	Service Call Procedures
		Service Call Procedures
Phaser 4600/4620 Printer Service Manual	1-3

SCP 1 Initial Actions

Initial Actions are used to gather information on the machine performance

Start a service call with SCP 1 and end with SCP6 Final Actions.

Also refer to SCP 7 Configurations and Options.

Procedure

WARNING

Switch off the electricity to the machine. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury.

WARNING

Do not work in a confined space. 1m (39 inches) space is needed for safe working.

NOTE: Ignore any references in this manual to options not installed on the machine.

1.Take note of symptoms or error messages.

2.Ask the operator to describe or demonstrate the problem.

3.Make sure that:

a.The power cord is connected to the wall outlet and to the machine.

b.Paper is loaded correctly and all paper trays and covers are closed

c.If installed, the USB cable or network connection is installed correctly.

4.If available, check the machine service log book for any previous actions that may be relevant to the call.

5.If this is the first service call to this machine perform SCP 2 First Call Actions, otherwise go to SCP 3 Normal Call Actions.

SCP 2 First Call Actions

First Call Actions are used for the first service call.

Procedure

1.Check the machine configuration with the customer, refer to SCP 7 Machine Configurations and Options. Check that all required hardware and software is installed and/or enabled.

2.Check that all the relevant machine settings are correctly entered, refer to GP 4 System Administration Tools.

3.If a fault is present, go to SCP 3 Normal Call Actions. If there is no fault present, go to SCP 6 Final Actions.

4.Enter the machine details and the customer details in the service log.

Service Call Procedures	5/2011	Revision - Xerox Internal Use Only
SCP 1, SCP 2
	1-4	Phaser 4600/4620 Printer Service Manual

SCP 3 Normal Call Actions

Normal Call Actions are used to determine the reason for the service call.

Procedure

NOTE: If a fault message appears at any time. Refer directly to the RAP for the fault message and perform the procedure.

If possible, perform the following:

1.Review any defective print samples.

SCP 4 Fault Analysis

Fault Analysis is used to identify a fault.

Procedure

When diagnosing or repairing a fault in a particular subsystem, exercise the machine in all modes until the fault is determined. In the instance of finding more than one fault or failure, correct one fault before going to the next fault. If no fault is found, go to SCP 5 Subsystem Maintenance.

2.Determine that the user accessible settings are correct. If necessary refer to the user documentation.

3.Check all job queues and verify with the customer any requirement to print the documents in memory, before switching off the power or clearing memory.

4.Print the Customer Assistance Report (Call for Assistance), then record the total print count.

5.Go to SCP 4 Fault Analysis.

Fault Codes

If a fault code is displayed, go to the relevant RAP.

UI Faults

If the machine is on but the UI is blank, test the UI with dC330.

Stapler Faults

If the machine has a stapler fault, test the Stapler with dC330.

Image Quality Defects

If the image quality is defective, go to the IQ1 Image Quality Entry RAP.

For image quality specifications, refer to the following:

•IQS 1 Solid Area Density.

•IQS 2 Skew.

•IQS 3 Registration.

Additional Information

If necessary, refer to the following general procedures and information:

•GP 1 Diagnostics Entry

•GP 2 Fault Codes and History Files

•GP 3 System Administration Tools

•GP 4 Reports

•GP 5 Firmware Upgrade

•GP 6 Electrostatic Discharge Prevention

•GP 7 Machine Specifications

•GP 8 General Disassembly Precautions

•GP 9 Service Menu Map

•GP 10 How to Check a Motor

•GP 11 How to Check a Sensor

•GP 12 How to Check a Solenoid or Clutch

•GP 13 How to Check a Switch

•GP 14 Separate System Modules

•GP 15 How to Safely Move heavy Modules

•GP 16 Machine Lubrication

•GP 17 Installation Space Requirements

Revision - Xerox Internal Use Only	5/2011	Service Call Procedures
		SCP 3, SCP 4
Phaser 4600/4620 Printer Service Manual	1-5

•GP 18 Glossary of Terms

•GP 19 Restriction of Hazardous Substances (RoHS)

•GP 20 First Print Output Time

•GP 21 Media Specifications

•GP 22 Environmental Data

SCP 5 Subsystem Maintenance

Subsystem Maintenance contains information regarding the component life of the machine.

Procedure

WARNING

Switch off the electricity to the machine. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury.

1.Clean the Pick Rollers on every call.

2.Use the Control Panel to check maintenance item counters.

3.Compare the counter values to those listed in Consumables.

4.Advise the customer of any routine maintenance items that are approaching or over the service limit.

Inspection

Rollers

Replace the Rollers when you see any of the following defects:

•Flat spots

•Out of roundness

•Cracked rubber

•Loss of traction (tackiness) causing pick or feed failures

Gears

Replace Gears that show any signs of wear or damage. Look for these problems:

•Thinned gear teeth

•Bent or missing gear teeth; check especially where a metal gear drives a plastic gear.

•Fractured or cracked Gears (oil or incorrect grease on a plastic Gear can cause the Gear to crack).

Belts

There are rubber belts in the printer. Inspect the belts for wear. Look for these problems:

•Loose rubber particles below the belts indicate a worn belt.

•Missing teeth in the belts.

•Cracking or moderate fraying; a small amount of fraying is inevitable, so look for other signs of wear before replacing the belt.

Service Call Procedures

SCP 4, SCP 5

Lubrication

The printer is lubricated during assembly at the factory and does not require periodic lubrication. Some parts require lubrication following replacement. These parts are identified in the replacement procedures. When lubricating during replacement, use the grease approved for all Phaser printers.

CAUTION

Plastic parts will deteriorate when unspecified grease and chemicals are used. To avoid damage to the printer, use only Rheolube 768 grease.

•Rheolube 768 Grease: Part Number 070E00890

5/2011	Revision - Xerox Internal Use Only
1-6	Phaser 4600/4620 Printer Service Manual

Component Life

The design life of the major components are shown in Table 1. Environmental conditions and actual use will vary these factors. The component life shown in Table 1 is for reference only.

Table 1 Component Life Expectancies

Item	Description	Print Life
1.	Pick and nudger Rollers	200,000 pages
2.	Separator Roller	100,000 pages
3.	Transfer Roller	100,000 images
4.	Fuser	200,000 images
5.	Feed Roller	100,000 pages

HFSI

The High Frequency Service Items are shown in Table 2.

Table 2 High frequency service items

		Recommended
Item	Description	life	Reference
Drum Cartridge	The total sides of copies and prints	10k impressions	PL 9.10	Item 1
	after the last HFSI reset.
Tray 1 Pick Roller	Sheets fed from Tray 1 after last	150k feeds	PL 8.10	Item 3
	HFSI reset.
Tray 2 Pick Rollers	Sheets fed from Tray 2 after last	200k feeds	PL 8.15	Item 10
	HFSI reset.
Transfer Roller	Total prints after the last HFSI	100k impressions	PL 9.10	Item 2
	reset.
Fuser	Total prints after the last HFSI	200k impressions	PL 10.10 Item 1
	reset.

SCP 6 Final Actions

Final Actions are used to evaluate the total operation of the system and to identify the actions required to complete the service call.

Procedure

Complete the following, if a fault is identified, return to SCP 4 Fault Analysis:

•Perform the end of call subsystem maintenance actions, SCP 5 Subsystem Maintenance.

•Exercise the machine in all modes, printing from all trays. If a fault message is displayed or some other problem is evident, go to SCP 4 Fault Analysis.

•Make a print of a customer document.

•If any of the customers selections were changed, return them to the customers preferred settings. Refer to GP 4 System Administration Tools.

•At the first service and at any subsequent service where changes are made or options are added, print the configuration report and store it with machine log book. Discard any previous versions of the configuration report.

•Remove and destroy any copies of test patterns.

•Ensure the machine and service area are clean before leaving the customer premises.

•Provide customer training if required.

Revision - Xerox Internal Use Only	5/2011	Service Call Procedures
		SCP 5, SCP 6
Phaser 4600/4620 Printer Service Manual	1-7

SCP 7 Configurations and Options

Configurations and Options

Refer to Table 1 for basic configurations and options. This service manual covers all configurations. Within this manual ignore any references to options that are not installed.

Table 1 Phaser 4600/4620 Configurations

Features	4600N	4600DN	4600DT	4620DN	4620DT
Processor Speed	700 MHz	700 MHz	700 MHz	700 MHz	700 MHz
Memory*	256 MB	256 MB	256 MB	256 MB	256 MB
Print Speed	55 ppm, Letter	55 ppm, Letter	55 ppm, Letter	65 ppm, Letter	65 ppm, Letter
	52 ppm A4	52 ppm, A4	52 ppm, A4	62 ppm, A4	62 ppm, A4
PS3 Fonts (136)	Standard	Standard	Standard	Standard	Standard
PCL6 Fonts (80 Scalable, 9 Bitmap)	Standard	Standard	Standard	Standard	Standard
USB 2.0	Standard	Standard	Standard	Standard	Standard
Ethernet Interface	10/100 Base-TX	10/100 Base-TX	10/100 Base-TX	10/100 Base-TX	10/100 Base-TX
Tray 1 (100 sheet)	Standard	Standard	Standard	Standard	Standard
Tray 2 (520 sheet)	Standard	Standard	Standard	Standard	Standard
Tray 3 (520 sheet)	Optional	Standard	Standard	Optional	Standard
Tray 4 (520 sheet)	Optional	Optional	Optional	Optional	Optional
Tray 5 (2000 / 520-sheet)	Optional	Optional	Optional	Optional	Optional
Tray 6 (520-sheet)	Optional	Optional	Optional	Optional	Optional
Duplex	Not available	Standard	Standard	Standard	Standard
Mailbox (4-bin)	Optional	Optional	Optional	Optional	Optional
Finisher	Optional	Optional	Optional	Optional	Optional
Hard Disk Drive	Optional	Optional	Optional	Optional	Optional
Printer Stand	Optional	Optional	Optional	Optional	Optional
Wireless LAN	Optional	Optional	Optional	Optional	Optional
Printer Resolution	600 x 600 dpi	600 x 600 dpi	600 x 600 dpi	600 x 600 dpi	600 x 600 dpi
	1200 Class	1200 Class	1200 Class	1200 Class	1200 Class
* All configurations have one memory	slot supporting a 512 MB DDR2	DIMM, to a maximum 768 MB total.

Service Call Procedures	5/2011	Revision - Xerox Internal Use Only
SCP 7
	1-8	Phaser 4600/4620 Printer Service Manual

2 Status Indicator RAPS

01-100-00 Top Door Open RAP......................................................................................	2-3	07-510-00, 07-700-00 Paper Empty at Tray 6.................................................................	2-31
01-102-00 Rear Door Open RAP ....................................................................................	2-3	07-520-00 Tray 6 is Open RAP .......................................................................................	2-31
01-500-00 Finisher Door Open RAP ...............................................................................	2-4	07-530-00 Jam 0 in Tray 1 RAP......................................................................................	2-32
01-700-00 Stapler Door Open RAP ................................................................................	2-4	07-531-00, 07-630-00 Jam in Tray 6 RAP ......................................................................	2-32
01-900-00 Mailbox Rear Door Open RAP.......................................................................	2-5	07-710-00 HCF Out of Paper ..........................................................................................	2-33
03-100-00, 03-110-00 Finisher Interface Error RAP .......................................................	2-5	07-720-00 HCF Door is Open RAP .................................................................................	2-34
03-115-00 Mailbox Interface Error RAP ..........................................................................	2-6	07-730-00, 07-731-00 Jam in HCF RAP .........................................................................	2-35
03-120-00, 03-940-00 Tray 3 Communications Fault RAP .............................................	2-6	08-100-00 Jam 1 in Registration RAP.............................................................................	2-36
03-130-00, 03-950-00 Tray 4 Communications Fault RAP .............................................	2-7	08-110-00 Feed Motor Failure RAP ................................................................................	2-37
03-140-00, 03-960-00 Tray 5 Communications Fault RAP .............................................	2-7	08-200-00 Jam in Tray 2 RAP.........................................................................................	2-37
03-150-00, 03-965-00 Tray 6 Communications Fault RAP .............................................	2-8	08-300-00 Jam in Tray 3 RAP.........................................................................................	2-38
03-160-00, 03-990-00 HCF Communications Fault RAP................................................	2-8	08-400-00 Jam in Tray 4 RAP.........................................................................................	2-39
03-305-00 Configuration Card Not Present RAP ............................................................	2-9	08-450-00 Jam in Tray 5 RAP.........................................................................................	2-40
03-315-00, 03-325-00 Manufacturer ID RAP ..................................................................	2-9	08-500-00 Jam 2 in Fuser Exit RAP................................................................................	2-41
03-335-00 Configuration Card Not Configured RAP .......................................................	2-10	08-600-00 Jam 0 in Duplex Unit RAP .............................................................................	2-42
03-410-00 Tray 2 Paper Mismatch RAP .........................................................................	2-10	08-610-00 Jam 1 in Duplex Unit RAP .............................................................................	2-43
03-420-00 Tray 3 Paper Mismatch RAP .........................................................................	2-11	08-650-00 Duplex Unit Not Installed RAP .......................................................................	2-43
03-430-00 Tray 4 Paper Mismatch RAP .........................................................................	2-11	08-800-00 Jam in Tray 6 RAP.........................................................................................	2-44
03-440-00 Tray 5 Paper Mismatch RAP .........................................................................	2-12	08-850-00 Jam in HCF RAP............................................................................................	2-45
03-450-00 Tray 1 Paper Mismatch RAP .........................................................................	2-12	09-003-00 Developer Motor Failure RAP........................................................................	2-46
03-470-00 Tray 6 Paper Mismatch RAP .........................................................................	2-13	09-100-00 Toner Low RAP..............................................................................................	2-46
03-480-00 HCF Paper Mismatch RAP ............................................................................	2-13	09-200-00, 09-220-00 Toner Empty RAP........................................................................	2-47
03-600-00 Memory Failure RAP .....................................................................................	2-14	09-210-00, 09-270-00 Toner (ADC) Sensor Error RAP ..................................................	2-47
03-800-00 Hard Disk Drive Failure RAP .........................................................................	2-15	09-230-00, 09-250-00 Toner Cartridge CRUM Write/Read Error RAP ...........................	2-48
03-970-00 Software Lock Up RAP ..................................................................................	2-15	09-240-00 Toner Cartridge Communications Error RAP.................................................	2-48
04-100-00 Tray 2 Lift Error RAP .....................................................................................	2-16	09-271-00 Clean ID (ADC) Sensor RAP .........................................................................	2-49
04-110-00 Tray 6 Lift Error RAP .....................................................................................	2-16	09-290-00 Adjusting Image Quality RAP.........................................................................	2-49
04-200-00 Tray 3 Lift Error RAP .....................................................................................	2-17	09-300-00 Drum Warning RAP .......................................................................................	2-50
04-300-00 Tray 4 Lift Error RAP .....................................................................................	2-18	09-400-00 Replace Drum Cartridge RAP........................................................................	2-50
04-400-00 Tray 5 Lift Error RAP .....................................................................................	2-19	09-500-00 Toner Cartridge Not Installed RAP ................................................................	2-51
04-500-00 Main Motor Failure RAP ................................................................................	2-20	09-508-00 Waste Toner Cartridge Near Full RAP...........................................................	2-51
04-730-00 HCF Lift Error RAP ........................................................................................	2-21	09-589-00 Waste Toner Cartridge Full RAP ...................................................................	2-52
04-810-00 Rear Fan Failure RAP ...................................................................................	2-22	09-590-00 Waste Toner Cartridge Not Installed RAP .....................................................	2-52
04-930-00 Main Fan Failure RAP ...................................................................................	2-22	09-591-00 Waste Toner Full Sensor Error RAP..............................................................	2-53
06-100-00, 06-200-00 LSU Error RAP ............................................................................	2-23	09-600-00 Drum Cartridge Not Installed RAP .................................................................	2-53
07-110-00 Paper Empty at Tray 2 RAP ..........................................................................	2-23	09-700-00 Toner Supply Error RAP ................................................................................	2-54
07-120-00 Tray 2 is Open RAP.......................................................................................	2-24	09-800-00, 09-810-00 Invalid Toner Cartridge RAP........................................................	2-54
07-130-00 Jam 0 in Tray 2 RAP......................................................................................	2-24	09-900-00, 09-910-00 Invalid Drum Cartridge RAP ........................................................	2-55
07-210-00 Paper Empty at Tray 3 RAP ..........................................................................	2-25	09-920-00 Transfer Unit Error RAP.................................................................................	2-55
07-220-00 Tray 3 is Open RAP.......................................................................................	2-25	10-100-00, 10-200-00, 10-300-00 Fuser Thermal Errors RAP........................................	2-56
07-230-00, 07-231-00 Jam in Tray 3 RAP ......................................................................	2-26	10-308-00 Fuser Motor Error RAP ..................................................................................	2-56
07-310-00 Paper Empty at Tray 4...................................................................................	2-26	10-500-00, 10-510-00 Fuser End of Life RAP.................................................................	2-57
07-320-00 Tray 4 is Open RAP.......................................................................................	2-27	10-700-00, 10-710-00 Fuser Initial Fuse Error RAP........................................................	2-57
07-330-00, 07-331-00 Jam in Tray 4 RAP ......................................................................	2-27	12-100-00, 12-487-00 Jam at Finisher Entrance RAP ....................................................	2-58
07-410-00 Paper Empty at Tray 5...................................................................................	2-28	12-200-00 Jam 1 in Finisher RAP ...................................................................................	2-58
07-420-00 Tray 5 is Open RAP.......................................................................................	2-29	12-300-00, 12-488-00, 12-489-00 Jam in Finisher Exit RAP ..........................................	2-59
07-430-00, 07-431-00 Jam in Tray 5 RAP ......................................................................	2-29	12-500-00 Full Stack RAP...............................................................................................	2-59
07-500-00 Paper Empty in Tray 1 RAP...........................................................................	2-30	12-605-00 Staples Low RAP...........................................................................................	2-60
Revision - Xerox Internal Use Only	5/2011		Status Indicator RAPS
Phaser 4600/4620 Printer Service Manual		2-1

12-610-00, 12-855-00 Out of Staples RAP .....................................................................	2-60
12-715-00, 12-716-00 Front Jogger Home Fault RAP ....................................................	2-61
12-725-00, 12-726-00 Rear Jogger Home Fault RAP.....................................................	2-61
12-735-00, 12-736-00 Support Finger Home Fault RAP.................................................	2-62
12-750-00, 12-755-00 Stapler Fault RAP........................................................................	2-62
12-760-00, 12-770-00 Stacker Fault RAP.......................................................................	2-63
12-870-00 Stapler Safety Not Detected RAP..................................................................	2-63
12-906-00, 12-907-00 Jam in Mailbox Entrance RAP.....................................................	2-64
12-910-00, 12-920-00, 12-930-00, 12-940-00 Mailbox Bin Full ......................................	2-64
12-911-00, 12-921-00, 12-931-00, 12-941-00 Mailbox Bin Jam .....................................	2-65
12-912-00, 12-922-00, 12-932-00, 12-942-00 Mailbox Bin Jam .....................................	2-65
12-913-00, 12-923-00, 12-933-00, 12-943-00 Mailbox Bin Jam .....................................	2-66
12-915-00 Diverter Fault RAP.........................................................................................	2-66
12-925-00, 12-935-00 Upper Diverter Fault Home RAP .................................................	2-67
12-945-00, 12-955-00 Lower Diverter Fault Home RAP .................................................	2-67
15-110-00 Email Send Failed RAP .................................................................................	2-68
15-120-00 Invalid Recipient Email Address RAP............................................................	2-68
15-300-00 Network Connection Failure RAP ..................................................................	2-69
15-310-00, 15-600-00 Authentication Failure RAP .........................................................	2-69
15-320-00, 15-330-00 Mail Server Connection Failure RAP...........................................	2-70
15-700-00 DNS Error RAP..............................................................................................	2-70
17-100-00 IP Address Conflict RAP................................................................................	2-71
17-110-00 Connection Error RAP ...................................................................................	2-71
17-120-00 Server Not Found RAP ..................................................................................	2-72
17-200-00 Network Cable Disconnected RAP ................................................................	2-72
17-700-00, 17-710-00 BOOTP Server Error RAP...........................................................	2-73
17-800-00, 17-810-00 DHCP Server Error RAP .............................................................	2-73
17-900-00 802.1X Authentication Error RAP ..................................................................	2-74
17-910-00 Firmware Upgrade Fault RAP........................................................................	2-74

Status Indicator RAPS	5/2011	Revision - Xerox Internal Use Only
	2-2	Phaser 4600/4620 Printer Service Manual

01-100-00 Top Door Open RAP	01-102-00 Rear Door Open RAP
01-100-00 The Top Door is not latched.	01-102-00 The Rear Door is not latched.
BSD-Reference: WD 1	BSD-Reference: WD 1
Initial Actions	Initial Actions
• Close the Top Door.	• Close the Rear Door.
• Check for obstructions blocking the latch.	• Check for obstructions or bent pins in P/J61.

Procedure

WARNING

Switch off the electricity to the machine. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury.

Cycle system power. The error message is displayed.

YN

Complete.

Reseat the Toner Cartridge and close the Top Door. The error message is displayed.

YN

Complete.

Check the Top Door interlock actuators. The interlock actuators are undamaged.

YN

Replace the Top Door, REP 28.5.

Select dC330 code 01-100. The switch is operational (open/closed).

YN

Replace the Top Door Interlock Switch, REP 1.6.

Remove the Left Cover (REP 28.3) and check P/J45 and CN9 on the MCU Board. The connections are secure.

YN

Secure the connections.

Replace these components in order until the error is corrected.

1.Top Door Interlock Switch, PL 28.15 Item 2

2.MCU Board, PL 3.10 Item 3

Procedure

WARNING

Switch off the electricity to the machine. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury.

Cycle system power. The error message is displayed.

YN

Complete.

Close the Rear Door. The error message is displayed.

YN

Complete.

Check the Rear Door connection P/J63. The connector is undamaged.

YN

Repair or replace the Rear Door, REP 28.6.

Select dC330 code 01-300. The connection is operational (open/closed).

YN

Repair or replace the Rear Door, REP 28.6.

Remove the Right Cover (REP 28.2) and check CN4 on the Joint Board. The connection is secure.

YN

Secure the connections.

Replace these components in order until the error is corrected.

1.Rear Door, PL 28.25 Item 1

2.Joint Board, PL 9.15 Item 7

3.Exit Assembly, PL 10.30 Item 25

Revision - Xerox Internal Use Only	5/2011	Status Indicator RAPS
		01-100-00, 01-102-00
Phaser 4600/4620 Printer Service Manual	2-3

01-500-00 Finisher Door Open RAP

01-500-00 The Finisher Rear Door is not latched.

BSD-Reference: WD 17

Initial Actions

•Close the Finisher Rear Door.

•Check for obstructions blocking the sensor.

01-700-00 Stapler Door Open RAP

01-700-00 The Staple Cartridge Door is not latched securely.

BSD-Reference: WD 17

Initial Actions

•Close and latch the Staple Cartridge Door.

•Check for obstructions blocking the interlock switch.

Procedure

WARNING

Switch off the electricity to the machine. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury.

Cycle system power. The error message is displayed.

YN

Complete.

Check the Rear Door sensor actuator. The actuator is undamaged.

YN

Repair or replace the Finisher Rear Door, REP 12.17.

Select dC330 code 12-895. The sensor is operational (high/low).

YN

Remove the Finisher Top Cover (REP 12.18) and check the Finisher Rear Door Open Sensor (PL 12.35 Item 14). The sensor connection is secure.

Y N

Secure the Finisher Rear Door Open Sensor connection.

Check the Finisher option harness in the Finisher right cover. The harness is undamaged.

Y N

Repair or replace the Finisher option harness.

Replace the Finisher Rear Door Open Sensor, REP 12.20.

Replace these components in order until the error is corrected.

1.Finisher Rear Door Open Sensor, PL 12.35 Item 14

2.Finisher Control Board, PL 12.15 Item 2

3.IOT Upper Option Harness, PL 10.30 Item 24

4.MCU Board, PL 3.10 Item 3

Procedure

WARNING

Switch off the electricity to the machine. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury.

Cycle system power. The error message is displayed.

YN

Complete.

Check the Staple Cartridge Door interlock actuator. The actuator is undamaged.

YN

Repair or replace the Finisher right cover, REP 12.11.

Select dC330 code 12-870. The switch is operational (high/low).

YN

Replace the Staple Cartridge Door Interlock Switch, REP 12.13.

Remove the Finisher Right Cover (REP 12.11) and check the Staple Cartridge Door Interlock Switch (PL 12.45 Item 4). The switch connections are secure.

YN

Secure the Staple Cartridge Door Interlock Switch connections.

Check the Finisher option harness in the Finisher right cover. The harness is undamaged.

YN

Repair or replace the Finisher option harness.

Replace these components in order until the error is corrected.

1.Staple Cartridge Door Interlock Switch (PL 12.45 Item 4)

2.Finisher Control Board, PL 12.15 Item 2

3.IOT Upper Option Harness, PL 10.30 Item 24

4.MCU Board, PL 3.10 Item 3

Status Indicator RAPS	5/2011	Revision - Xerox Internal Use Only
01-500-00, 01-700-00
	2-4	Phaser 4600/4620 Printer Service Manual

01-900-00 Mailbox Rear Door Open RAP

01-900-00 The Mailbox Rear Door is not latched securely.

BSD-Reference: WD 18

Initial Actions

•Close the Mailbox Rear Door.

•Check for obstructions blocking the interlock switch.

Procedure

WARNING

Switch off the electricity to the machine. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury.

Cycle system power. The error message is displayed.

YN

Complete.

Check the Mailbox Rear Door interlock actuator. The actuator is undamaged.

YN

Repair or replace the Mailbox rear door, REP 11.4.

Select dC330 code 12-915. The switch is operational (high/low).

YN

Replace the Mailbox Rear Door Interlock Switch, REP 11.13.

Remove the Mailbox top cover (REP 11.12, step 5) and check the Rear Door Interlock Switch (PL 11.30 Item 4). The switch connections are secure.

YN

Secure the Mailbox Rear Door Interlock Switch connections.

Check the Mailbox option harness in the Mailbox right cover. The harness is undamaged.

YN

Repair or replace the Mailbox option harness, PL 11.15 Item 4.

Replace these components in order until the error is corrected.

1.Mailbox Rear Door Interlock Switch, PL 11.30 Item 4

2.Mailbox Control Board, PL 11.15 Item 1

3.IOT Upper Option Harness, PL 10.30 Item 24

4.MCU Board, PL 3.10 Item 3

03-100-00, 03-110-00 Finisher Interface Error RAP

03-100-00 Communications between the Finisher and IOT has failed.

03-110-00 Communications between the Finisher and IOT has failed.

BSD-Reference: WD 17

Initial Actions

•Reseat the Finisher on the IOT connection.

•Check for obstructions or damage to the interface connection.

Procedure

WARNING

Switch off the electricity to the machine. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury.

Cycle system power. The error message is displayed.

YN

Complete.

Remove the Finisher right cover (REP 12.11) and check the option harness. The harness is undamaged.

YN

Repair or replace the Finisher option harness.

Check the IOT Upper Option Harness. The harness is undamaged.

YN

Repair or replace the Upper Option Harness, REP 10.4.

Replace these components in order until the error is corrected.

1.Finisher Control Board, PL 12.15 Item 2

2.MCU Board, PL 3.10 Item 3

Revision - Xerox Internal Use Only	5/2011	Status Indicator RAPS
		01-900-00, 03-100-00, 03-110-00
Phaser 4600/4620 Printer Service Manual	2-5

03-115-00 Mailbox Interface Error RAP

03-115-00 Communications between the Mailbox and IOT has failed.

BSD-Reference: WD 18

Initial Actions

•Reseat the Mailbox on the IOT connection.

•Check for obstructions or damage to the interface connection.

Procedure

WARNING

Switch off the electricity to the machine. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury.

Cycle system power. The error message is displayed.

YN

Complete.

Remove the Mailbox right cover (REP 11.3) and check the option harness. The harness is undamaged.

YN

Repair or replace the Mailbox option harness, PL 11.15 Item 4.

Check the IOT Upper Option Harness. The harness is undamaged.

YN

Replace the Upper Option Harness, REP 10.4.

Replace these components in order until the error is corrected.

1.Mailbox Control Board, PL 11.15 Item 1

2.MCU Board, PL 3.10 Item 3

03-120-00, 03-940-00 Tray 3 Communications Fault RAP

03-120-00 A communication error has occurred between the MCU Board and Tray 3.

03-940-00 A communication error has occurred between the MCU Board and Tray 3.

BSD-Reference: WD 15

Initial Actions

•Lock the feeder to the IOT.

•Reseat the IOT on the Feeder.

•Check for obstructions blocking the option harness.

Procedure

WARNING

Use safe handling procedures when removing the module. Refer to GP 15. The module is heavy.

WARNING

Switch off the electricity to the machine. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury.

Cycle system power. The error message is displayed.

YN

Complete.

Remove the IOT from the Feeder and check the Feeder Option Connector. The connector is undamaged.

YN

Replace the Feeder Upper Option Harness, REP 7.31.

Check the Lower Option Harness. The harness is undamaged.

YN

Replace the Lower Option Harness, REP 10.5.

Replace these components in order until the error is corrected.

1.Feeder Board, PL 8.30 Item 7

2.MCU Board, PL 3.10 Item 3

Status Indicator RAPS	5/2011	Revision - Xerox Internal Use Only
03-115-00, 03-120-00, 03-940-00
	2-6	Phaser 4600/4620 Printer Service Manual

03-130-00, 03-950-00 Tray 4 Communications Fault RAP

03-130-00 A communication error has occurred between the MCU Board and Tray 4.

03-950-00 A communication error has occurred between the MCU Board and Tray 4.

BSD-Reference: WD 15

Initial Actions

•Lock the feeder to Tray 3.

•Reseat the IOT and Tray 3 on the Feeder.

•Check for obstructions blocking the option harnesses.

03-140-00, 03-960-00 Tray 5 Communications Fault RAP

03-140-00 A communication error has occurred between the MCU Board and Tray 5.

03-960-00 A communication error has occurred between the MCU Board and Tray 5.

BSD-Reference: WD 15

Initial Actions

•Lock the feeder to Tray 5.

•Reseat the IOT, Tray 3, and Tray 4 on the Feeder.

•Check for obstructions blocking the option harnesses.

Procedure

WARNING

Use safe handling procedures when removing the module. Refer to GP 15. The module is heavy.

WARNING

Switch off the electricity to the machine. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury.

Cycle system power. The error message is displayed.

YN

Complete.

Remove the IOT and Tray 3 from the Feeder. Check feeder option harness continuity. The harnesses are undamaged.

YN

Replace the damaged option harness.

Check the IOT option connector. The harness is undamaged.

YN

Replace the Lower Option Harness, REP 10.5.

Replace these components in order until the error is corrected.

1.Feeder Board, PL 8.30 Item 7

2.MCU Board, PL 3.10 Item 3

Procedure

WARNING

Use safe handling procedures when removing the module. Refer to GP 15. The module is heavy.

WARNING

Switch off the electricity to the machine. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury.

Cycle system power. The error message is displayed.

YN

Complete.

Remove the IOT, Tray 3, and Tray 4 from the Feeder. Check feeder option harness continuity.

The harnesses are undamaged.

YN

Replace the damaged option harness.

Check the IOT option harness. The harness is undamaged.

YN

Replace the Lower Option Harness, REP 10.5.

Replace these components in order until the error is corrected.

1.Feeder Board, PL 8.30 Item 7

2.MCU Board, PL 3.10 Item 3

Revision - Xerox Internal Use Only	5/2011	Status Indicator RAPS
		03-130-00, 03-950-00, 03-140-00, 03-960-00
Phaser 4600/4620 Printer Service Manual	2-7

03-150-00, 03-965-00 Tray 6 Communications Fault RAP

03-150-00 A communication error has occurred between the MCU Board and Tray 6.

03-965-00 A communication error has occurred between the MCU Board and Tray 6.

BSD-Reference: WD 15

Initial Actions

•Lock the feeder to Tray 6.

•Reseat the IOT, Tray 3, Tray 4, and Tray 5 on the Feeder.

•Check for obstructions blocking the option connections.

03-160-00, 03-990-00 HCF Communications Fault RAP

03-160-00 A communication error has occurred between the MCU Board and the HCF.

03-990-00 A communication error has occurred between the MCU Board and the HCF.

BSD-Reference: WD 16

Initial Actions

•Lock the feeder to the HCF.

•Reseat the IOT, Tray 3, Tray 4, on the HCF.

•Check for obstructions blocking the option connections.

Procedure

WARNING

Use safe handling procedures when removing the module. Refer to GP 15. The module is heavy.

WARNING

Switch off the electricity to the machine. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury.

Cycle system power. The error message is displayed.

YN

Complete.

Remove the IOT, Tray 3, Tray 4, and Tray 5 from the Feeder. Check feeder option connector continuity. The harnesses are undamaged.

YN

Replace the damaged option harness.

Check the IOT option connector. The harness is undamaged.

YN

Replace the Lower Option Harness, REP 10.5.

Replace these components in order until the error is corrected.

1.Feeder Board, PL 8.30 Item 7

2.MCU Board, PL 3.10 Item 3

Procedure

WARNING

Use safe handling procedures when removing the module. Refer to GP 15. The module is heavy.

WARNING

Switch off the electricity to the machine. Disconnect the power cord from the customer supply while performing tasks that do not need electricity. Electricity can cause death or injury. Moving parts can cause injury.

Cycle system power. The error message is displayed.

YN

Complete.

Remove the IOT and installed feeders from the HCF. Check the HCF option harness. The harness is undamaged.

YN

Replace the damaged option harness.

Check feeder option harness continuity for all feeders. The harnesses are undamaged.

YN

Replace the damaged option harness.

Check the IOT Lower Option Harness. The harness is undamaged.

YN

Replace the Lower Option Harness, REP 10.5.

Replace these components in order until the error is corrected.

1.HCF Control Board, PL 7.25 Item 18

2.MCU Board, PL 3.10 Item 3

Status Indicator RAPS	5/2011	Revision - Xerox Internal Use Only
03-150-00, 03-965-00, 03-160-00, 03-990-00
	2-8	Phaser 4600/4620 Printer Service Manual