Xerox Phaser 4500 Service Manual
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Xerox Phaser 4500 Service Manual

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Table of Contents

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  • Page 1 Phaser 4500 ™ laser printer Service Manual...

  • Page 3: Service Manual

    Phaser 4500 Laser Printer Service Manual Warning The following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing other than that contained in the operating instructions, unless you are qualified to do so.

  • Page 4: Table Of Contents

    2 Theory of Operation Overview of the Phaser 4500 Laser Printer ..... . . 2-2 Summary of the Printing Process ......2-2 Paper Path of the Printer .
  • Page 5 Close Stacker Cover ........3-58 Install or Reseat Print Cartridge ......3-59 Phaser 4500 Laser Printer...
  • Page 6 Replace Print Cartridge ....... 3-60 No Paper in Tray 1/No Paper in Tray 2 ....3-61 Tray 2 Paper Is Low .
  • Page 7 Repeating Defects ........5-39 Phaser 4500 Laser Printer...
  • Page 8 Residual Image........5-40 Background .
  • Page 9 Stack Full Actuator ........8-66 viii Phaser 4500 Laser Printer...
  • Page 10 Print Engine: Frame and Drive ....... . 8-67 Motor Cover ........8-67 Main Motor .
  • Page 11 Parts List 23.1 Stacker....... . 9-40 Xerox Supplies and Accessories ......9-43 10 Wiring Diagrams Introduction.
  • Page 12 Notations Used in Wiring Diagrams......10-15 Print Engine Wiring Diagrams ....... 10-17 Print Engine General Wiring Diagram.
  • Page 13 Phaser 4500 Laser Printer...

  • Page 14: Service Terms

    Service Terms Manual Terms Various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger 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.

  • Page 15: Product Terms

    The surface is hot while the printer is running. After turning off the power, wait 30 minutes. 30 min. Avoid pinching fingers in the printer. Use caution to avoid personal injury. Use caution (or draws attention to a particular component). Refer to the manual(s) for information. Phaser 4500 Laser Printer...

  • Page 16: Power Safety Precautions

    For 220 VAC printers, do not apply more than 264 volts RMS between the supply conductors or between either supply conductor and ground. Use only the specified power cord. This manual assumes that the reader is a Xerox- certified service technician.

  • Page 17: Electrostatic Discharge (Esd) Precautions

    Handle ICs and EPROMs carefully to avoid bending pins. Pay attention to the direction of parts when mounting or inserting them on Printed Circuit Boards (PCB’s). Phaser 4500 Laser Printer...

  • Page 18: Service Safety Summary

    CLASS 1 LASER PRODUCT The Phaser 4500 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;...

  • Page 19: Servicing Electrical Components

    This printer uses heat to fuse the toner image to media. 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. xviii Phaser 4500 Laser Printer...

  • Page 20: Regulatory Specifications

    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.

  • Page 21: Declaration Of Conformity

    Declaration of Conformity Xerox Corporation, declares, under our sole responsibility that the printer to which this declaration relates, is in conformity with the following standards and other normative documents: In the European Union following the provisions of the Low Voltage Directive 73/23/EEC and its...

  • Page 22: General Information

    General Information In this chapter... Printer Introduction and Overview Printer Configurations Parts of the Printer Front Panel Image Processor Board Consumables and Routine Maintenance Items Printer Specifications Chapter...

  • Page 23: Printer Introduction And Overview

    Printer Introduction and Overview The Xerox Phaser 4500 Laser Printer Service Manual is the primary document used for repairing, maintaining, and troubleshooting the printer. To ensure complete understanding of this product, participation in Xerox Phaser 4500 Service Training is strongly recommended. To service this product, Xerox certification for this product is required.

  • Page 24: Printer Configurations

    Printer Configurations A replaceable Configuration Card holds configuration information that enables or disables the network features shown in the following table. Printer Configuration Features 4500B 4500N 4500DT 4500DX Maximum Print Speed (Letter-size 36 ppm 36 ppm 36 ppm 36 ppm Paper) Memory 48 MB...

  • Page 25: Parts Of The Printer

    1 - 4. 1. Parallel cable connector 2. Ethernet 10/100 Base-T connector 3. USB connector 4. Configuration card 5. Power receptacle 6. Optional Duplex Unit 7. Rear cover 8. Stacker rear cover 4500-073 9. Stacker extension Phaser 4500 Service Manual...

  • Page 26: Front Panel

    Front Panel The Front Panel consists of one tricolor LED, a display window, and six functional buttons. P h a s e r 4 5 0 0 s4500-003 1. LED 5. Up Arrow button - scrolls up the menu system 2.

  • Page 27: Image Processor Board

    Configuration Card 1. Memory (RAM) DIMM 1 and DIMM 2 6. Parallel connector 2. Flash Memory (optional) 7. Ethernet connector 3. Hard Drive (optional) 8. USB connector 4. NVRAM connector 9. Health LED 5. Configuration Card Phaser 4500 Service Manual...

  • Page 28: Consumables And Routine Maintenance Items

    Consumables and Routine Maintenance Items Print Cartridge Transfer Roller Feed Rollers 3 per paper tray s4500-267 Fuser s4500-268 General Information...

  • Page 29: Supply Life Counters

    Print life ratings are based on 5% coverage and an average job length of 4 pages. Supply Print Life (Number of Images) Consumables Print Cartridge, standard-capacity 10,000 Print Cartridge, high-capacity 18,000 Routine Maintenance Items Maintenance Kit (consists of Fuser, 200,000 Transfer Roller, and 12 Feed Rollers) Phaser 4500 Service Manual...

  • Page 30: Printer Specifications

    Printer Specifications Physical Dimensions and Clearances Print Engine Dimensions Value Height 404 mm (15.9 in.) Width 422 mm (16.6 in.) Depth 465 mm (18.3 in.) Depth with Paper Cassette extended 524 mm (20.7 in.) Weight (with 10-K Print Cartridge) 20.5 kg (45.2 lbs.) Clearances Value 400 mm (16 in.)

  • Page 31: Functional Specifications

    Tray 4 from Sleep Mode Letter Simplex 24.0 24.0 24.0 24.2 (in seconds); Duplex 27.8 27.8 27.8 28.1 Short Edge Feed Simplex 24.0 24.0 24.0 24.3 Duplex 28.0 28.0 28.0 28.3 Warm-Up Time 17 seconds 1-10 Phaser 4500 Service Manual...

  • Page 32: Electrical Specifications

    Electrical Specifications Characteristic Specification Primary Line Voltages 120 VAC nominal, min. 98 V, max. 140 V 220/240 VAC nominal, min. 198 V, max. 264 V Primary Line Voltage 50/60 Hz ± 3 Hz Frequency Range Power Consumption 985 W @ 120 V 985 W @ 220/240 V Environmental Specifications Characteristic...

  • Page 33: Media And Tray Specifications

    (16-58 lb.) Media Types Labels and Weights Transparency Greeting Cards 190 g/m (70 lb. Cover) Index Card Stock 60-216 g/m (33-120 lb.) Tag Card Stock 60-216 g/m (37-133 lb.) Cover Card Stock 60-216 g/m (37-133 lb.) 1-12 Phaser 4500 Service Manual...

  • Page 34: Memory Requirements

    Output Trays (Continued) Trays Specifications Supported Both #10 Commercial (4.12 x 9.5 in.) Envelopes Monarch (3.87 x 7.5 in.) DL (110 x 220 mm) C5 (162 x 229 mm) B5 (176 x 250 mm) Tray Capacity Standard Stacker Duplex Unit Media Specifications Input Tray Specifications Width Tray 1...
  • Page 35 1-14 Phaser 4500 Service Manual...

  • Page 36: Theory Of Operation

    Theory of Operation In this chapter... Overview of the Phaser 4500 Laser Printer Paper Path of the Printer Sensors Major Assemblies and Functions Printer Options Chapter...

  • Page 37: Overview Of The Phaser 4500 Laser Printer

    Switches located in the left tray guides detect the position of four tabs located on the paper tray. The Phaser 4500 uses a three- roller system to pick paper. Two springs raise the tray's lift plate, along with the paper stack, against the pick roller of the paper feeder assembly.
  • Page 38 Duplex Unit rollers and back to the registration roller. A sensor in the Duplex Unit detects the presence of paper. The block diagram of the Phaser 4500 print cycle shows the sequence of events for the xerographic process (dashed lines) and the paper flow (solid lines) into and out of the printer.
  • Page 39 This cut-away side view of the Phaser 4500 printer shows the location of individual components within the printer, and the major components that are directly related to the print cycle and to the paper path. Pressure Heat Roller Roller Fuser Assembly 8.

  • Page 40: Paper Path Of The Printer

    Paper Path of the Printer Paper is supplied from Trays 1 and 2 or the optional Trays 3 and 4, and is transported into the printer along the paper path shown below. Optional 550-Sheet Feeder Optional 550-Sheet Feeder (Tray 4) (Tray 3) 550-Sheet Tray 550-Sheet Tray...

  • Page 41: Layout Of Paper Transport Path

    Layout of Paper Transport Path This cross section of the Phaser 4500 printer shows the main components directly associated with the paper path and transport in the engine only. s4500-018 1. Exit Roller 8. Rubber Registration Roller 2. Exit Pinch Roller 9.
  • Page 42 This cross section shows the additional components associated with paper transport when the 550-Sheet Feeders, the Duplex Unit, and the Stacker are installed. 4500-019 1. Stacker Pinch Roller 8. Pinch Rollers 2. Lower Stacker Roller 9. Turn Pinch Rollers 3. Upper Stacker Roller 10.Turn Roller Assemblies 4.

  • Page 43: Sensors

    List of Sensors and Interlocks Name Type Function Reference Paper low Mechanically Detects low paper condition in page 2-11 actuated photo 550-Sheet trays 2, 3, and 4 page 2-17 sensor (there is no low-paper sensing in tray 1). Phaser 4500 Service Manual...
  • Page 44 List of Sensors and Interlocks Name Type Function Reference No paper Mechanically Detects no paper condition in Page 2-17 actuated photo all trays. sensor Paper size Microswitch bank Detects the presence of a tray Page 2-17 switches and the paper size setting of Page 2-44 the tray.
  • Page 45 Optional Feeder Microswitch bank Detects the presence of a tray Page 2-44 Paper Size Switch and the paper size setting of Assembly the tray. CRUM antenna Inductive magnetic Communicates with the Print code reader Cartridge CRUM. 2-10 Phaser 4500 Service Manual...
  • Page 46 Sensors in the Paper Path s4500-270 1. Registration Sensor 8. Tray 2 No Paper Sensor 2. Fuser Exit Sensor 9. Tray 2 Low Paper Sensor 3. Output Tray Full 10.Tray 3 No Paper Sensor 4. Stacker Sensor 11.Tray 3 Low Paper Sensor 5.

  • Page 47: Major Assemblies And Functions

    Major Assemblies and Functions The functions of the main components of the Phaser 4500 printer are described in the following sections: Paper Tray Paper Feeder Print Cartridge Transfer Roller Assembly Laser Assembly Fuser 500-sheet Paper Exit Drive Electrical Paper Tray Paper Trays include the 150-sheet tray and 550-sheet tray.
  • Page 48 Paper Tray Functional Assemblies s4500-021 1. Left-side Paper Guide Assembly 5. Right-side Paper Guide Assembly 2. Bottom Plate Assembly 6. Extension Lock 3. Bottom Lock Lever 7. End Guide 4. Gear Stopper Left- and Right-Side Paper Guide Assemblies The left and right Paper Guides adjust to fit different paper widths.
  • Page 49 Guide is converted to up and down combinations of the three Size Switch Links on the side of the tray. The links, when in contact with the Paper Size Switches in the Left Tray Guide, turn the switches on or off in combinations that correspond to the paper size. 2-14 Phaser 4500 Service Manual...

  • Page 50: Paper Lift Mechanism

    A5 SEF Paper Lift Mechanism The Phaser 4500 printer paper trays utilize a unique mechanical paper lift mechanism that eliminates the need for paper lift motors. The mechanism consists of a spring- loaded Bottom Plate Assembly that lifts the paper stack upward to the Paper Feeder Assembly.

  • Page 51: Paper Feeder

    Feeders, which includes Tray 2 and if installed, Trays 3, and 4. Low Paper Sensor This photo sensor remains in an OFF state until the paper level in the tray drops sufficiently to move the Low Paper Actuator flag out of the sensor. 2-16 Phaser 4500 Service Manual...
  • Page 52 4500-022 1. Paper Size Switch Assembly 7. Metal Registration Roller 2. Feed Clutch Assembly 8. No Paper Sensor 3. Registration Clutch 9. No Paper Actuator 4. Rubber Registration Roller 10.Low Paper Sensor 5. Feed Roller 11.Low Paper Actuator 6. Registration Sensor 12.Nudger Roller Theory of Operation 2-17...

  • Page 53: Control Of Paper Size

    The switches in the Paper Size Switch Assembly are denoted by “SW1”, “SW2”, “SW3”, and “SW4”, respectively, from the front side. Paper Size Switch Assembly Paper size No cassette Executive SEF B5(JIS) SEF A5 SEF Legal14”SEF Letter SEF A4 SEF Legal13”SEF 2-18 Phaser 4500 Service Manual...

  • Page 54: Xerographics

    Xerographics Print Cartridge The Print Cartridge is a customer-replaceable item that consists of the following components: Drum The Drum is an aluminum cylinder coated with a layer of photoconductive material that retains electrical charges on its surface until exposed to light, when electrical conduction occurs.
  • Page 55 1. Print Cartridge 2. Transfer Roller 2-20 Phaser 4500 Service Manual...

  • Page 56: Laser Assembly

    Laser Assembly The Laser Assembly scans the surface of the drum with a laser beam. The Laser Assembly consists of three components: the Laser Diode (LD) Assembly, the Scanner Assembly, and the Start of Scan (SOS) board. Laser Diode (LD) Assembly The LD Assembly produces a laser beam that is turned on and off according to the print data signal.
  • Page 57 Conceptual Diagram of Image Creation by Scanning s4500-011 Laser Assembly Functional Parts s4500-012 1. Start of Scan PWB 3. Laser Diode Assembly 2. Scanner Assembly 2-22 Phaser 4500 Service Manual...

  • Page 58: Laser Control

    Laser Control The scanner motor turns on when it receives a signal from the Controller, and turns off after printing ends. The motor remains off in the standby and power-saving states. There are two faults associated with the scanner motor speed: U2-1 Laser Fails at warm-up, and U2-2, Laser Fails Motor Speed.

  • Page 59: Fuser

    This sensor detects the arrival of the paper at a detection point in the exit area positioned behind the Fuser. This sensor also detects the discharge of the paper from this point. When the sensor receives light (i.e., paper is present), the signal /EXIT is Low. 2-24 Phaser 4500 Service Manual...
  • Page 60 s4500-023 1. Exit Motor Assembly 5. Pressure Roller 2. Exit Sensor 6. Heat Roller 3. Actuator 7. Thermostats 4. Temperature Sensors Theory of Operation 2-25...

  • Page 61: Fuser Control

    .25° C per page Thick Paper 1 Lamp ON 210° C Lamp OFF 211° C Thick Paper 2 Lamp ON 215° C Lamp OFF 216° C Transparency Lamp ON 185° C Lamp OFF 186° C 2-26 Phaser 4500 Service Manual...
  • Page 62 Temperature Stabilization The Fuser automatically enters a stabilization process under two circumstances: When the printer is processing thick paper. After 50 sheets of continuous printing on thick paper (Thick Paper 1 mode), the Fuser lamp turns off, the Main Motor stops, and the fans rotate at full speed until the temperature of both Temperature Sensors drops to 190°...
  • Page 63 Cover Open — Top, Rear, Duplex Unit, Stacker Laser Assembly (ROS) abnormality (U2) CPU or NVRAM abnormality (U6) Main Motor Assembly abnormality (U1) Fan abnormality (U5) Fuser Pause command issued Xerographics failure Duplex Unit failure Stacker failure Option Tray Unit failure 2-28 Phaser 4500 Service Manual...

  • Page 64: Paper Exit Assembly

    Paper Exit Assembly The Paper Exit Assembly discharges the printed paper out of the printer, sending it either to the standard output tray or to the optional Stacker. Exit Motor Assembly This motor drives the Exit Roller that conveys paper to each output tray.

  • Page 65: Drive

    Assembly. As the Link Lever moves up and down, Gear 4 in the Gear Assembly Plate moves right and left via Gear Link 3, and drive to the Print Cartridge Drum is connected or disconnected. s4500-025 1. Main Motor 3. Gear Assembly Housing 2. Gear Assembly Plate 4. Link Lever 2-30 Phaser 4500 Service Manual...

  • Page 66: Electrical

    Electrical 24 V Interlock This safety switch interrupts 24 VDC from the LVPS to the HVPS/ Engine Logic Board and Main Motor when the Top Cover is open. This switch operates in series with the Rear Cover Switch. See “Schematic Diagram of Power Distribution and Interlocks”...
  • Page 67 7. 5 V Interlock 2. Exit Motor PWBA 8. 24 V Interlock 3. Rear Cover Switch 9. Image Processor Board 4. Laser Interlock 10.HVPS/Engine Logic Board 5. Top Cover Switch 11.Sub Fan 6. Main Fan 12.DC-DC Converter 2-32 Phaser 4500 Service Manual...
  • Page 68 Main Fan Sub Fan Opt. 550-Sheet Feeder Rear Cover Image Duplex Cover Open Switch Open Switch PWBA Processor Front Panel Feeder 550 Optional Optional Duplex Unit Stacker Opt. 550-Sheet Scanner Feeder Motor Laser DC-DC Duplex Stacker PWBA Unit PWBA PWBA Feeder 550 Converter Interlock...

  • Page 69: Printer Options

    Printer Options Three options are available for the Phaser 4500 printer: Duplex Unit Stacker 550-Sheet Feeder Paper transport information for the options is discussed earlier in this chapter. Duplex Unit Drive Transmission Path The rotating force of the Duplex Unit Motor is transmitted by various gears to components requiring mechanical drive as shown in this flow chart and the gear layout that follows.
  • Page 70 Gear Layout s4500-029 1. Roller Gears 4. Idle Gear 49 2. Idle Gear 29 5. Duplex Unit Motor 3. Idle Gear 39 6. Idle Gear 67/29 Functional Components Two-sided printing is enabled by mounting the Duplex Unit on the rear side of the base engine.
  • Page 71 This motor drives the three duplex rollers, which transport the paper through the Duplex Unit. s4500-030 1. Duplex Unit Rollers 4. Duplex Unit PWBA 2. Duplex Unit Sensor 5. Duplex Unit Switch 3. Duplex Unit Fan 6. Duplex Unit Motor 2-36 Phaser 4500 Service Manual...

  • Page 72: Stacker

    Stacker Drive Transmission Path The rotating force of the Stacker Motor Assembly is transmitted by various gears to components requiring mechanical driving force as shown in this flow chart and the gear layout that follows. MOTOR ASSY OCT MOTOR ASSY OFFSET GEAR 19/37 GEAR CAM GEAR 45...
  • Page 73 Stacker paper output trays. When the Gate Solenoid Assembly activates, the solenoid armature pushes the Stacker Gate Link to operate the Stacker Exit Gate, which reroutes the paper to the Stacker paper output tray. 2-38 Phaser 4500 Service Manual...
  • Page 74 Stacker PWBA The CPU on the Stacker PWBA receives instructions from the HVPS/Engine Logic Board and information from sensors and switches, and controls paper transport through the Stacker. Stacker Rear Cover Switch This switch detects when the Stacker Rear Cover is open.
  • Page 75 7. Offset Motor Assembly 2. Upper Stacker Roller 8. Gate Solenoid Assembly 3. Rear Cover Switch 9. Offset Chute Assembly 4. Full Stack Sensor 10.Stacker Sensor 5. Offset Sensor 11.Lower Stacker Roller 6. Stacker PWBA 2-40 Phaser 4500 Service Manual...
  • Page 76 Optional 550-Sheet Feeder Drive Transmission Path The rotating force of the Feeder Motor is transmitted by various gears to components requiring mechanical driving force as shown in this flow chart and the gear layout that follows. Feeder Motor Optional Feeder Gear 2 Optional Feeder Gear 3 Optional Feeder Gear 4 Optional Feeder Gear 5...
  • Page 77 Paper Actuator is pushed up by the Bottom Plate Assembly, moving the actuator flag out of the sensor. Low Paper SensorThis photo sensor remains in an OFF state until the paper level in the tray drops sufficiently to move the Low Paper Actuator flag out of the sensor. 2-42 Phaser 4500 Service Manual...
  • Page 78 Optional 550-Sheet Feeder This is a mechanism for supplying paper from the paper tray into the printer. The driving force from the Feeder Motor is transmitted via the Feed Clutch Assembly to the Feed Roller and Nudger Roller, transporting paper from the tray into the printer.

  • Page 79: Optional 550-Sheet Feeder

    1. Optional 550-Sheet Feeder 5. Low Paper Sensor 2. Turn Roller 6. Low Paper Actuator 3. No Paper Actuator 7. 550-Sheet Feeder PWBA 4. No Paper Sensor 8. Option Paper Size Switch Assembly 2-44 Phaser 4500 Service Manual...

  • Page 80: Error Messages And Codes

    Error Messages and Codes In this chapter... Introduction Servicing Instructions Entry Level Fault Isolation Procedure Service Diagnostics System Start-Up and POST Operating System and Application Problems Error Messages and Codes Troubleshooting Procedures Inoperable Printer Chapter...

  • Page 81: Introduction

    Introduction This chapter covers troubleshooting procedures for problems in the Phaser 4500 that generate error messages or fault codes or both that appear on the Front Panel or in the Service Usage Profile report, and serves as the entry point into the troubleshooting process.
  • Page 82 Step 2: Inspect and Clean the Printer: 1. Switch OFF printer power. 2. Disconnect the AC power cord from the wall outlet. 3. Verify the power cord is free from damage or short circuit and is connected properly. 4. Remove the Print Cartridge and protect it from light. 5.

  • Page 83: Using The Troubleshooting Procedures

    All voltage values given in the troubleshooting procedures are approximate values. The main purpose of voltage readings is to determine whether or not a component is receiving the correct voltage value from the power supply and if Phaser 4500 Service Manual...
  • Page 84 gating (a voltage drop) occurs during component actuation. Gating signals may be nothing more than a pulse, resulting in a momentary drop in voltage that may be difficult or impossible to read on the average multi-meter. Unless otherwise specified, the following voltage tolerances are used within this section: Stated Measured...

  • Page 85: Accessing Fault Histories

    Code Error Fan Failure (U5) Laser Failure (U2) Fuser Failure (U4) Tray 3 Failure (E11-1) Motor Failure (U1) Tray 3 or 4 Failure (E11-2) IOT NVM Failure (U6) Duplex Failure (E9-1) Stacker Failure (E9) — — Phaser 4500 Service Manual...
  • Page 86 On the Front Panel, the Jam History lists a series of entries separated by semi-colons. Each entry is made up of two values separated by a comma: the first value is the numeric Fault History Code for the Jam Location, and the second value is the engine page count.

  • Page 87: Entry Level Fault Isolation Procedure

    Request the customer to send a print job Problem solved; Go to “Operating from their application. return to Final System and Did the job print successfully? Checkout in the Application Service Flowchart. Problems” on page 3-20 Phaser 4500 Service Manual...

  • Page 88: Service Diagnostics

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

  • Page 89: Service Diagnostic Front Panel Button Descriptions

    Lists the configurations set for the Engine. This report is of very limited use to the service technician; it is mainly intended for manufacturing use. Print Resolution Reports the printer’s maximum resolution capability. Determined at the time of manufacture. 3-10 Phaser 4500 Service Manual...
  • Page 90 Read Fuser Temperature Shows the current fuser temperature in degrees C. Reports the fuser temperature only in the Standby mode. Engine Test Print You can use Engine Test Print (see “Engine Test Print” on page 6-4) to identify, repair, and validate the operability of printer Xerographics and paper handling from all paper sources, options, and output destinations.
  • Page 91 Top Cover. The Print Cartridge must be installed and the Rear Cover closed for this test to be effective. Toggle the switch by opening and closing the Top Cover. “Open” or “Closed” indications appear on the front panel. 3-12 Phaser 4500 Service Manual...
  • Page 92 Rear Cover Switch Tests the circuit (not just a single switch) affected by opening the Rear Cover. The Print Cartridge must be installed and the Top Cover closed for this test to be effective. Toggle the switch by opening and closing the Rear Cover. “Open”...
  • Page 93 Tray 1/2/3/4 Feed Tests the clutch that couples drive power to the Feed Roller for the selected tray. Tray 3/4 Turn Roller Tests the clutch that couples drive power to the Turn Roller for the selected tray. 3-14 Phaser 4500 Service Manual...
  • Page 94 Controller NVRAM Access This menu allows you to reset the PostScript NVRAM locations to factory defaults. Reset PostScript NVRAM Resets the PS NVRAM. You are prompted to confirm your decision to perform a reset operation. Factory Reset NVRAM Allows you to reset the PS NVRAM locations to factory defaults.

  • Page 95: System Start-Up And Post

    If any tests fail, the front panel screen freezes with the name of the test displayed and the line posted is “Call Customer Service”. After the POST tests have finished running, the Xerox ‘splash screen’ is posted to the front panel and PostScript begins initialization.

  • Page 96: Post Faults

    POST Faults There are two kinds of faults: soft and hard. A soft fault is any fault that is discovered by POST, but does not prevent the operating system from initializing and becoming available as a tool for troubleshooting. These POST faults do not stop execution and are reported on the Start Page in a gray box after the system is running.

  • Page 97: Post Diagnostic Test Descriptions

    (Hard) Checks communication between the Image Command Processor Board and the HVPS/Engine Logic Board Real Time (Soft) Checks to ensure that the seconds count in the Real Clock Time Clock chip is incrementing at one-second intervals +/-2%. 3-18 Phaser 4500 Service Manual...
  • Page 98 POST Error Code Table LED Blink Front Panel Code Message Comment RAM ERROR No RAM present, or faulty RAM. Continuous 1/2 second interval LED blink. 1+1+1 3: I/O ASIC Image Processor Board ASIC failure. Go to “Image Processor Isolation” on page 4-37. 1+1+1+1 4: MEMORY Checks installed memory: walking ones address, walking...

  • Page 99: Operating System And Application Problems

    PostScript error occurred in the printer. Power cycle the printer and try printing again. Make sure that the correct Phaser 4500 printer icon was selected in the Chooser. Try printing the job again. In the Chooser or the print dialog, switch background printing to off. Try printing the job again.

  • Page 100: Network Problems

    Network Problems The Phaser 4500 printer maintains six logs in memory detailing network functions. The logs contain TCP/IP, NetWare and AppleTalk initialization events. The logs can also be accessed remotely via CentreWare. The logs list events chronologically. The log is limited in length; when the log is full the printer stops recording data to the log.

  • Page 101: Error Messages And Codes Troubleshooting Procedures

    3-28 “Fuser Failure\ Press i” Fuser Low Temp — Go to U4-2: Fuser Fail/Power Off page 3-28. “Fuser Failure\ Press i” Fuser Overheat in — Go to Stand-by page 3-28. U4-3: Fuser Fail/Power Off 3-22 Phaser 4500 Service Manual...
  • Page 102 Error Message Summary Engine Procedure Front Panel Message Diagnostic Message Errors Errors to Use “Fuser Failure\Press i” Fuser Fails at warm-up — Go to U4-4: Fuser Fail/ Power page 3-28. “Fuser Failure\Press i” Fuser Thermistor Failure — Go to U4-5: Fuser Fail/ Power page 3-28.
  • Page 103 Go to page 3-61. “No Paper in Tray 2\ Press i” Tray 2 empty — — Go to page 3-61. “No Paper in Tray 3\ Press i” Tray 3 empty — — Go to page 3-63. 3-24 Phaser 4500 Service Manual...
  • Page 104 Error Message Summary Engine Procedure Front Panel Message Diagnostic Message Errors Errors to Use “No Paper in Tray 4\ Press i” Tray 4 empty — — Go to page 3-63. “Maintenance Kit is Near End — — — of Life\ Press i” “Replace Maintenance Kit”...

  • Page 105: Main Motor Failure

    Does the Main Motor rotate, and each gear rotate normally? Rotate and check each gear of the Gear Go to Main Motor Replace the parts Assembly Housing and Plate Gear (page 4-11). causing the Assembly. obstruction. Does each gear rotate normally? 3-26 Phaser 4500 Service Manual...

  • Page 106: Laser Unit Failure

    Laser Unit Failure Error Codes Laser Fails at warm-up; U2-1 Laser Fail / Power Off Laser Fails Motor Speed; U2-2 Laser Fail/ Power Off LD Power is high; U2-3 Laser Fail/ Power Off LD Power is low; U2-4 Laser Fail/ Power Off Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References...

  • Page 107: Fuser Failure

    Turn the printer ON and notice how much Replace the Fuser Go to “Fuser time elapses before the error occurs. Assembly. Assembly” on Does the error occur soon after the (page 8-54) page 4-16. power is turned ON? 3-28 Phaser 4500 Service Manual...

  • Page 108: Fan Failure

    Fan Failure Error Code U-5: Fan Fail Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Main Fan “150-Sheet Feeder, 550-Sheet Feeder, Main Fan” on page 10-22 Sub Fan “24 V Interlock, Rear Cover Switch, Main Motor, Sub LVPS Fan, Exit Motor Assembly” on page 10-18 HVPS/Engine Logic Board “Print Engine General Wiring Diagram”...
  • Page 109 Problem solved. Does the fan error occur when the power is turned ON? Replace the LVPS. Replace the Problem solved. Does the fan error occur when the power HVPS/Engine is turned ON? Logic Board (page 8-89). 3-30 Phaser 4500 Service Manual...

  • Page 110: Engine Logic Board Nvram Failure

    Engine Logic Board NVRAM Failure Error Code U6: NVM Fail Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References HVPS/Engine Logic Board “24 V Interlock, Rear Cover Switch, Main Motor, Sub Fan, Exit Motor Assembly” on page 10-18 “Print Engine General Wiring Diagram” on page 10-17 “Print Engine Plug/Jack Locator”...

  • Page 111: Jam At Tray N

    Tray 1/No Paper in Tray 2” on page 3-61. Check the condition of the paper in the tray. Replace the Go to step 3. Is the paper crumpled, damaged, damp, paper. or out of specification? 3-32 Phaser 4500 Service Manual...

  • Page 112: Go To

    Troubleshooting Procedure (Continued) Steps Actions and Questions Compare the size of the paper in use with Go to step 4. Replace the the tray’s End Guide settings and the paper paper, or set up size selected by the print driver. the paper size Does the paper size in use match the correctly.
  • Page 113 Does the Turn Roller Clutch operate on page 4-52. normally? Manually rotate the Turn Roller. Replace the Replace the “550- Does the Turn Roller rotate smoothly? HVPS/Engine Sheet Feeder” on Logic Board page 8-104. (page 8-89). 3-34 Phaser 4500 Service Manual...

  • Page 114: Jam At Tray N

    Jam at Tray N Paper arrives late at the Registration Sensor. Error Codes E2-11: Feed Jam at Tray 1 E2-12: Feed Jam at Tray 2 E2-13: Feed Jam at Tray 3 E2-14: Feed Jam at Tray 4 Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References 150-Sheet Feeder Assembly “150-Sheet Feeder, 550-Sheet Feeder, Main Fan”...

  • Page 115: Go To

    Enter Service Diagnostics, and from the Go to step 14. Go to “Optional Clutch Tests menu select the appropriate 550-Sheet feed clutch test. Feeder Feed Does the Feed Clutch Assembly operate Clutch Assembly” normally? on page 4-50. 3-36 Phaser 4500 Service Manual...
  • Page 116 Troubleshooting Procedure (Continued) Steps Actions and Questions Manually rotate each gear and roller of the Go to step 15. Replace the “550- Optional 550-Sheet Feeder. Sheet Feeder” on Does each gear and roller of the page 8-104. Optional 550-Sheet Feeder rotate smoothly? Enter Service Diagnostics, and from the Go to step 16.

  • Page 117: Jam At Top; Open Top Cover To Clear

    Go to step 15. Go to step 6. through Transfer Roller Assembly? Does the leading edge of the paper go Go to step 14. Go to step 19. between metal Registration Roller and rubber Registration Roller? 3-38 Phaser 4500 Service Manual...
  • Page 118 Troubleshooting Procedure (Continued) Steps Actions and Questions At the exit of the Fuser Assembly, manually Go to step 8. Replace the move the exit actuator up and down. Fuser Assembly Does the Exit Actuator move smoothly? (page 8-54). Enter Service Diagnostics, and from the Replace the Go to step 9.

  • Page 119: Go To

    Contact Xerox for Replace the Gear (page 8-71) to check gear operation. technical support. Assembly See “Technical Housing 2. Manually rotate the gears. Support (page 8-71). Does each gear rotate smoothly? Information” on page 1-2 3-40 Phaser 4500 Service Manual...

  • Page 120: Jam At Exit; Open Rear/Top Cover To Clear

    Jam At Exit; Open Rear/Top Cover To Clear Error Codes E4-0 E4-2 E4-3 Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Fuser Assembly “Fuser Assembly, Power Switch” on page 10-20 HVPS/Engine Logic Board “24 V Interlock, Rear Cover Switch, Main Motor, Sub Fan, Exit Motor Assembly”...
  • Page 121 Replace the LVPS Replace the LVPS Logic Board. (page 8-78). Harness Assembly 2. Disconnect P/J41 on the LVPS. (page 8-44). 3. Check the LVPS Harness Assembly for continuity between J11-10 and J41-7. Is it continuous? 3-42 Phaser 4500 Service Manual...

  • Page 122: Jam At Rear; Open Rear Cover To Clear

    Jam At Rear; Open Rear Cover To Clear Error Code E6-1: Stacker Jam Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References HVPS/Engine Logic Board “Stacker General Wiring Diagram” on page 10-31 Stacker Sensor “Stacker Signal Diagram” on page 10-32 Stacker Actuator “Stacker Plug/Jack Locator”...
  • Page 123 Replace the Go to “Stacker Motors/Fan Tests menu select the HVPS/Engine Motor Assembly” Stacker Motor test. Logic Board on page 4-60. (page 8-89). 2. Check the Stacker Motor Assembly Does Stacker Motor Assembly rotate normally? 3-44 Phaser 4500 Service Manual...

  • Page 124: Jam At Stacker; Open Rear Stacker Cover To Clear

    Jam At Stacker; Open Rear Stacker Cover To Clear Error Code E6-2: Stacker Jam Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References HVPS/Engine Logic Board “Stacker General Wiring Diagram” on page 10-31 Stacker Sensor “Stacker Signal Diagram” on page 10-32 Stacker Actuator “Stacker Plug/Jack Locator”...

  • Page 125: Go To

    Replace the Go to “Stacker Enter Service Diagnostics, and from the HVPS/Engine Motor Assembly” Motors/Fan Tests menu select the Logic Board on page 4-60. Stacker Motor test. (page 8-89). Does the Stacker Motor Assembly rotate normally? 3-46 Phaser 4500 Service Manual...

  • Page 126: Jam At Rear; Open Duplex And Rear Cover To Clear

    Jam At Rear; Open Duplex And Rear Cover To Clear Error Codes E7-1: Jam at Rear E7-2: Jam at Duplex E7-3: Jam at Duplex Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References HVPS/Engine Logic Board “Duplex Unit Signal Diagram” on page 10-30 Duplex Unit Sensor “Duplex Unit General Wiring Diagram”...
  • Page 127 Does the Duplex Unit Motor rotate normally? Enter Service Diagnostics, and from the Replace the Motors/Fan Tests menu select the Duplex HVPS/Engine Motor Low test. Logic Board Does the Duplex Unit Motor rotate (page 8-89). normally? 3-48 Phaser 4500 Service Manual...

  • Page 128: Jam At Duplex; Open Duplex To Clear

    Jam At Duplex; Open Duplex To Clear Error Code E7-0: Duplex jam Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References HVPS/Engine Logic Board “Duplex Unit Plug/Jack Locator” on page 10-12 FDR1 AS SUB 150 A4 “Duplex Unit General Wiring Diagram” on page 10-29 Duplex Unit Sensor “Duplex Unit Signal Diagram”...

  • Page 129: Duplex Unit Error

    “Duplex Unit Signal Diagram” on page 10-30 Troubleshooting Procedure Steps Actions and Questions Remove the Duplex Unit, re-install it, and Go to “Duplex Unit Problem solved. turn the power ON. PWBA” on Does the error still occur? page 4-54. 3-50 Phaser 4500 Service Manual...

  • Page 130: Stacker Error

    Stacker Error Error Code E9-2: Stacker Unit failure Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Stacker Assembly Harness 1 “Stacker General Wiring Diagram” on page 10-31 HVPS/Engine Logic Board “Stacker Signal Diagram” on page 10-32 Stacker PWBA “Stacker Plug/Jack Locator” on page 10-14 Stacker Assembly Harness 2 Troubleshooting Procedure Steps...

  • Page 131: Tray 3 Failure\ Tray 3 Or 4 Failure

    2 if 2. Disconnect P/J2083. Tray 4 is not 3. Check the following for continuity: recognized. J2083-1 <=> J83-10 J2083-2 <=> J83-9 J2083-3 <=> J83-8 J2083-4 <=> J83-7 J2083-5 <=> J83-6 Is each continuous? 3-52 Phaser 4500 Service Manual...
  • Page 132 Troubleshooting Procedure (Continued) Steps Actions and Questions Check Feeder Harness 5 of the Tray 3 Go to step 3. Replace Feeder Feeder: Harness 5. 1. Remove Optional 550-Sheet Paper Feeder. 2. Disconnect P/J84 from the 550-Sheet Feeder PWBA. 3. Check the following for continuity: J84-1 <=>...

  • Page 133: Paper Size Jam

    Go to “Left Tray Replace the Are these End Guide Assembly, Sector Guide” on paper cassette. Gear, Size Rack, Size Switch Links 1/2/3 page 4-34. of the Paper Cassette in Tray 1 or Tray 2 installed correctly? 3-54 Phaser 4500 Service Manual...
  • Page 134 Troubleshooting Procedure (Continued) Steps Actions and Questions Check the paper tray. Go to step 6. Replace the Is the paper supplied from either Tray 3 HVPS/Engine or Tray 4 when the error occurs? Logic Board. (page 8-89) Check Paper Cassette (2). Go to “Optional Replace the Are the End Guide Assembly, Sector...

  • Page 135: Close Top Cover/Close Rear Cover

    Logic Board. following: Switch test. (page 8-89) “24 V Interlock” Is the position of the Rear Cover on page 4-26. accurately reported when the Rear “Rear Cover Switch” on Cover is opened and closed? page 4-28. 3-56 Phaser 4500 Service Manual...

  • Page 136: Close Duplex Unit Cover

    Close Duplex Unit Cover Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References HVPS/Engine Logic Board “Duplex Unit Signal Diagram” on page 10-30 LVPS “Duplex Unit General Wiring Diagram” on page 10-29 Duplex Unit Lower Housing “Duplex Unit Plug/Jack Locator” on page 10-12 Duplex Unit Housing Cover Duplex Unit Switch Duplex Unit PWBA...

  • Page 137: Close Stacker Cover

    Enter Service Diagnostics, and from the HVPS/Engine Rear Cover Sensor Tests menu select the Stacker Logic Board Switch” on Cover Switch test. (page 8-89). page 4-63. Is the position correctly reported when the Stacker Cover is opened and closed? 3-58 Phaser 4500 Service Manual...

  • Page 138: Install Or Reseat Print Cartridge

    Install or Reseat Print Cartridge Error Indication Install or Reseat Print Cartridge Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References HVPS/Engine Logic Board “Print Cartridge, Transfer Roller Assembly” on page 10-21 Print Cartridge “Print Engine General Wiring Diagram” on Print Cartridge Right Guide page 10-17 Assembly...

  • Page 139: Replace Print Cartridge

    Replace the Print HVPS/Engine Cartridge Right 2. Remove the Print Cartridge Right Guide Logic Board Guide Assembly. Assembly (page 8-58). (page 8-89). (page 8-58). 3. Test each harness for continuity. Is each cable of each harness continuous? 3-60 Phaser 4500 Service Manual...

  • Page 140: No Paper In Tray 1/No Paper In Tray

    No Paper in Tray 1/No Paper in Tray 2 Error Indications No Paper in Tray 1 No Paper in Tray 2 Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References No Paper Sensor “150-Sheet Feeder, 550-Sheet Feeder, Main Fan” on page 10-22 No Paper Actuator “Print Engine General Wiring Diagram”...

  • Page 141: Tray 2 Paper Is Low

    Go to “Low Paper Sensor Tests menu select the Tray 2 Low HVPS/Engine Sensor” on Paper test. Logic Board page 4-22. Is the correct state reported when the (page 8-89). Low Paper Actuator is manually actuated? 3-62 Phaser 4500 Service Manual...

  • Page 142: No Paper In Tray 3/No Paper In Tray 4

    No Paper in Tray 3/No Paper in Tray 4 Error Indications No Paper in Tray 3 No Paper in Tray 4 Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References HVPS/Engine Logic Board “550-Sheet Feeder General Wiring Diagram” on page 10-27 LVPS “550-Sheet Feeder Signal Diagram”...

  • Page 143: Tray 3 Paper Is Low/Tray 4 Paper Is Low

    Tray 3 HVPS/Engine 550-Sheet Tray 4 Low Paper test. Logic Board Feeder Low Is the correct state reported when the (page 8-89). Paper Sensor” on Low Paper Actuator is manually page 4-47. actuated? 3-64 Phaser 4500 Service Manual...

  • Page 144: Insert Tray 1/Insert Tray 2

    Insert Tray 1/Insert Tray 2 Error Indications Insert Tray 1 Insert Tray 2 Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Left Tray Guide “150-Sheet Feeder, 550-Sheet Feeder, Main Fan” on page 10-22 150-Sheet Paper Cassette “Print Engine General Wiring Diagram” on HVPS/Engine Logic Board page 10-17 550-Sheet Paper Cassette...

  • Page 145: Insert Tray 3/Insert Tray 4

    Check the following Tray 3 or Tray 4 Paper Go to “Optional Re-install the Casette parts: Feeder Paper Size Paper Cassette. Switch Assembly” End Guide Assembly on page 4-49. Sector Gear Size Rack Size Switch Link 1/2/3 Are the parts installed correctly? 3-66 Phaser 4500 Service Manual...

  • Page 146: Stacker Is Full, Unload Paper

    Stacker Is Full, Unload Paper Error Indication Stacker Is Full, Unload Paper Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Stack Full Sensor (0n Stacker “Stacker Signal Diagram” on page 10-32 PWBA) “Stacker General Wiring Diagram” on page 10-31 HVPS/Engine Logic Board “Stacker Plug/Jack Locator”...

  • Page 147: Standard Output Tray Is Full, Unload Paper

    Sensor Tests menu select the Output HVPS/Engine Tray Stack Full Tray Full Sensor test. Logic Board Sensor” on Is the position of the sensor actuator (page 8-89). page 4-25. correctly reported when it is manually actuated? 3-68 Phaser 4500 Service Manual...

  • Page 148: Replace Maintenance Kit

    Replace Maintenance Kit Error Indication Replace Maintenance Kit Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Fuser Assembly “Fuser Assembly, Power Switch” on page 10-20 Fuser Assembly Harness “Print Engine General Wiring Diagram” on page 10-17 HVPS/Engine Logic Board “Print Engine Plug/Jack Locator”...

  • Page 149: Inoperable Printer

    Does the problem still occur? Replace the Image Processor Board Let the customer Problem solved. (page 8-91). know that the Does the problem still occur? cause may be in the host computer. 3-70 Phaser 4500 Service Manual...

  • Page 150: No Recognition Of Duplex Unit

    No Recognition of Duplex Unit Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References HVPS/Engine Logic Board “Duplex Unit Signal Diagram” on page 10-30 LVPS Harness Assembly “Duplex Unit General Wiring Diagram” on page 10-29 Duplex Unit PWBA “Duplex Unit Plug/Jack Locator” on page 10-12 Duplex Unit Assembly Harness Troubleshooting Procedure Steps...
  • Page 151 Duplex Unit 1. Disconnect connectors of Duplex Unit PWBA Assembly Assembly Harness. (page 8-123). Harness. 2. Check the following for continuity: J2750-3 <=> J50-8 J2750-4 <=> J50-7 J2750-5 <=> J50-6 J2750-6 <=> J50-5 Is each continuous? 3-72 Phaser 4500 Service Manual...

  • Page 152: No Recognition Of Stacker

    No Recognition of Stacker Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References HVPS/Engine Logic Board “Stacker Signal Diagram” on page 10-32 Stacker Assembly Harness 1 “Stacker General Wiring Diagram” on page 10-31 Stacker PWBA “Stacker Plug/Jack Locator” on page 10-14 Stacker Assembly Harness 2 Troubleshooting Procedure Steps...
  • Page 153 3-74 Phaser 4500 Service Manual...

  • Page 154: General Troubleshooting

    General Troubleshooting In this chapter... Introduction Front Panel Troubleshooting DC Power Supply Troubleshooting AC Power Supply Troubleshooting Print Engine Troubleshooting Chapter...

  • Page 155: Introduction

    “Error Messages and Codes” on page 3-1. Print quality problems are covered in “Print-Quality Troubleshooting” on page 5-1. Phaser 4500 Service Manual...

  • Page 156: Front Panel Troubleshooting

    Front Panel Troubleshooting LCD/LED Display Error/Inoperable Buttons Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Front Panel “Image Processor Board, DC-DC Converter, Front Panel” on page 10-26 Front Panel Harness “Print Engine General Wiring Diagram” on HVPS/Engine Logic Board page 10-17 LVPS “Print Engine Plug/Jack Locator”...

  • Page 157: Dc Power Supply Troubleshooting

    1. Turn the power OFF. Assembly 2. Disconnect P/J11 from the HVPS/ (page 8-78). Engine Logic Board. 3. Disconnect P/J41 from the LVPS. 4. Check each conductor in the harness for continuity. Is each conductor of J11 <=> J41 continuous? Phaser 4500 Service Manual...

  • Page 158: Dc-Dc Converter

    Troubleshooting Procedure (Continued) Steps Actions and Questions Is the AC power supply outlet correctly Replace the Inform the wired and grounded? HVPS/Engine customer or the Logic Board. electrician. (page 8-89) DC-DC Converter Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References DC-DC Converter PWBA “Image Processor Board, DC-DC Converter, Front Panel”...
  • Page 159 DC-DC Converter Harness C. (page 8-80). 1. Turn the power OFF. 2. Disconnect P/J402 on the DC-DC Converter and P/J130 on the I/P Board. 3. Check for continuity between P/J402 and P/J130 Are all conductors continuous Phaser 4500 Service Manual...

  • Page 160: Ac Power Supply Troubleshooting

    AC Power Supply Troubleshooting No AC Power Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Power Cord “Print Engine General Wiring Diagram” on page 10-17 LVPS “Fuser Assembly, Power Switch” on page 10-20 HVPS/Engine Logic Board “24 V Interlock, Rear Cover Switch, Main Motor, Sub Front Panel Fan, Exit Motor Assembly”...
  • Page 161 Feeder Assembly removal (page 8-18). “Registration Clutch” on 2. Disconnect P/J243 (see the Registration page 4-32. Clutch removal on page 8-26). 3. Remove the Print Cartridge. Does the Main Fan rotate when the power is turned ON? Phaser 4500 Service Manual...
  • Page 162 Troubleshooting Procedure (Continued) Steps Actions and Questions 1. Disconnect the Front Panel harness Go to step 9. Go to step 10. from the Image Processor Board (J110). 2. Remove the Print Cartridge. 3. Turn the power ON and check for air blowing from the exhaust on back of the printer.
  • Page 163 ON? 1. Replace the Sub Fan. (page 8-44) Problem solved. Replace the HVPS/Engine 2. Remove the Print Cartridge. Logic Board. Does the Sub Fan rotate when the (page 8-89) power is turned ON? 4-10 Phaser 4500 Service Manual...

  • Page 164: Print Engine Troubleshooting

    Print Engine Troubleshooting Main Motor Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Main Motor “24 V Interlock, Rear Cover Switch, Main Motor, Sub Fan, Exit Motor Assembly” on page 10-18 LVPS Harness Assembly “Print Engine General Wiring Diagram” on LVPS page 10-17 HVPS/Engine Logic Board...
  • Page 165 Problem solved. Replace the Does the Main Motor rotate? HVPS/Engine Logic Board (page 8-89), then go to step 6. Turn ON the printer. Problem solved. Replace the Main Does the Main Motor rotate? Motor (page 8-69). 4-12 Phaser 4500 Service Manual...

  • Page 166: Laser Unit Assembly

    Laser Unit Assembly Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Laser Unit Assembly “Laser Unit, 5 V Interlock, Interlock Switch Assembly” on page 10-24 Laser Unit Harness Assembly “24 V Interlock, Rear Cover Switch, Main Motor, Sub 5 V Interlock Fan, Exit Motor Assembly”...
  • Page 167 Test for continuity between P/J14-1 <=> P/J11-13. Is there continuity? 1. Disconnect P/J11 from the HVPS/ Go to step 9. Replace the Engine Logic Board. LVPS Harness Assembly (1). 2. Test for continuity between P/J11-13 <=> P/J41-4. Is there continuity? 4-14 Phaser 4500 Service Manual...
  • Page 168 Troubleshooting Procedure (Continued) Steps Actions and Questions Check the /ROSMOT ON signal of the Go to step 11. Go to step 10. Scanner Motor: 1. Install the Print Cartridge. 2. Close the Top Cover. 3. Measure the voltage across P/J13-3 <=> P/J13-2 on the HVPS/Engine Logic Board.

  • Page 169: Fuser Assembly

    Go to step 5. Go to step 4. 1. Disconnect P/J48 from the LVPS. 2. Remove the Print Cartridge. 3. Turn the power ON. 4. Measure the voltage across P/J48-1 <=> P/J48-3 Does it measure at line voltage? 4-16 Phaser 4500 Service Manual...
  • Page 170 Troubleshooting Procedure (Continued) Steps Actions and Questions Check the AC line voltage. Replace the AC Inform the Is the AC line voltage correct? Power Harness customer or the Assembly electrician. (RRP12.4) Check the Heater Rod ON signal voltages: Go to step 7. Go to step 6.

  • Page 171: Registration Sensor

    Check the power to Registration Sensor: Go to step 4. Go to step 6. 1. Remove the Print Cartridge. 2. Measure the voltage across P/J24-9 <=> P/J24-10 on the HVPS/Engine Logic Board. Is the voltage about 3.3 VDC? 4-18 Phaser 4500 Service Manual...
  • Page 172 Troubleshooting Procedure (Continued) Steps Actions and Questions Check the Chute Assembly Harness: Go to step 5. Replace the Chute Assembly 1. Disconnect P/J24 from the HVPS/ Harness. Engine Logic Board. 2. Disconnect P/J245. 3. Test the following for continuity: J24-9 <=> J245-10 J24-10 <=>...

  • Page 173: No Paper Sensor

    Actuator. 3. Measure the voltages across P/J24-8 <=> P/J24-7 and P/J24-3 <=> P/J24-2 while moving the actuator. Do the voltages measure 0VDC when the No Paper Actuator is moved up, and 3.3 VDC when down? 4-20 Phaser 4500 Service Manual...
  • Page 174 Troubleshooting Procedure (Continued) Steps Actions and Questions Check the power to No Paper Sensor: Go to step 5. Go to step 6. 1. Remove the Print Cartridge. 2. Measure the voltages across P/J24-6 <=> P/J24-7 and P/J24-1 <=> P/J24-2 on the HVPS/Engine Logic Board. Do the voltages measure 3.3 VDC? Check the Chute Assembly Harness: Go to step 7.

  • Page 175: Low Paper Sensor

    Assembly. 2. Test for continuity across J260 <=> J26. Is it continuous? Replace the Low Paper Sensor Replace the Problem solved. (page 8-42). HVPS/Engine Does the problem still occur after Logic Board replacement? (page 8-89). 4-22 Phaser 4500 Service Manual...

  • Page 176: Toner Sensor

    Toner Sensor Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Toner Sensor “150-Sheet Feeder, 550-Sheet Feeder, Main Fan” on page 10-22 Toner Sensor Assembly “Print Engine General Wiring Diagram” on Toner Harness Assembly 1 page 10-17 Toner Harness Assembly 2 “Print Engine Plug/Jack Locator”...
  • Page 177 Assembly 2. 2. Test for continuity across J22 <=> J221. Is it continuous? Replace the Toner Sensor (page 8-30). Replace the Problem solved. Does the problem still occur after HVPS/Engine replacement? Logic Board (page 8-89). 4-24 Phaser 4500 Service Manual...

  • Page 178: Output Tray Stack Full Sensor

    Output Tray Stack Full Sensor Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Stack Full Sensor “Paper Exit” on page 10-25 Stack Full Actuator “Fuser Assembly, Power Switch” on page 10-20 Exit Sensor Assembly Harness “Print Engine General Wiring Diagram” on page 10-17 HVPS/Engine Logic Board “Print Engine Plug/Jack Locator”...

  • Page 179: 24 V Interlock

    “Laser Unit, 5 V Interlock, Interlock Switch Assembly” on page 10-24 Interlock Switch Assembly “Print Engine General Wiring Diagram” on Laser Unit Harness Assembly page 10-17 LVPS Harness Assembly “Print Engine Plug/Jack Locator” on page 10-3 LVPS HVPS/Engine Logic Board 4-26 Phaser 4500 Service Manual...
  • Page 180 Troubleshooting Procedure Steps Actions and Questions Check the 5 V Interlock: Go to step 2. Replace the 5 V Interlock 1. Disconnect P/J142. (page 8-49). 2. Test for continuity across P/J142-1 <=> P/J142-2 while manually operating the switch. Is the switch continuous when pushed and open when released? Check the Interlock Switch Assembly Go to step 3.

  • Page 181: Rear Cover Switch

    1. Disconnect P/J44 from the LVPS. Supply)” on (page 8-83). 2. Test for continuity across P/J44-1 <=> P/ page 4-4. J44-3 while manually operating the switch. Is the switch continuous when pushed and open when released? 4-28 Phaser 4500 Service Manual...

  • Page 182: Interlock Switch Assembly

    Interlock Switch Assembly Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Interlock Switch Assembly “Laser Unit, 5 V Interlock, Interlock Switch Assembly” on page 10-24 LVPS “Print Engine General Wiring Diagram” on HVPS/Engine Logic Board page 10-17 “Print Engine Plug/Jack Locator” on page 10-3 Troubleshooting Procedure Steps Actions and Questions...

  • Page 183: Exit Motor Pwba

    2. Measure the voltage across J101-2 <=> J101-1. Is the voltage +24 VDC? Replace the Exit Motor PWBA (page 8-76). Problem solved. Replace the Is the problem cleared, after HVPS/Engine replacement? Logic Board (page 8-89). 4-30 Phaser 4500 Service Manual...

  • Page 184: Exit Motor Assembly

    Exit Motor Assembly Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Exit Motor Assembly “24 V Interlock, Rear Cover Switch, Main Motor, Sub Fan, Exit Motor Assembly” on page 10-18 Exit Motor PWBA “Print Engine General Wiring Diagram” on LVPS Harness Assembly page 10-17 LVPS...

  • Page 185: Registration Clutch

    Go to “LVPS (Low Replace the Voltage Power HVPS/Engine 1. Disconnect P/J24 and P/J10 from the Supply)” on Logic Board HVPS/Engine Logic Board. page 4-4. (page 8-89). 2. Test for continuity across J24-14 <=> J10-1 Is it continuous? 4-32 Phaser 4500 Service Manual...

  • Page 186: Feed Clutches

    Feed Clutches Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Feed Clutch “150-Sheet Feeder, 550-Sheet Feeder, Main Fan” on page 10-22 Tray 1 Harness “Print Engine General Wiring Diagram” on Tray 2 Harness page 10-17 Chute Harness “Print Engine Plug/Jack Locator” on page 10-3 HVPS/Engine Logic Board LVPS Troubleshooting Procedure...

  • Page 187: Left Tray Guide

    Check Left Tray Guide: Go to “HVPS/ Replace the Left Test each cable between: Engine Logic Tray Guide Board” on (page 8-41). Tray1 Size Switch <=> J1821 page 4-35. Tray2 Size Switch <=> J1821 Are all continuous? 4-34 Phaser 4500 Service Manual...

  • Page 188: Hvps/Engine Logic Board

    HVPS/Engine Logic Board Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References HVPS/Engine Logic Board “Print Cartridge, Transfer Roller Assembly” on page 10-21 Print Cartridge Right Guide Assembly “24 V Interlock, Rear Cover Switch, Main Motor, Sub Fan, Exit Motor Assembly” on page 10-18 Print Cartridge “Print Engine General Wiring Diagram”...
  • Page 189 Check the ANT Harness Assembly: Replace the Replace the ANT HVPS/Engine Harness 1. Disconnect P/J15 from the HVPS/ Logic Board Assembly. Engine Logic Board. (page 8-89). 2. Test each cable between J15 <=> J150 for continuity. Are all continuous? 4-36 Phaser 4500 Service Manual...

  • Page 190: Image Processor Isolation

    Image Processor Isolation Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Image Processor Board “Image Processor Board, DC-DC Converter, Front Panel” on page 10-26 DC-DC Converter “Print Engine General Wiring Diagram” on DC-DC Converter Harness page 10-17 LVPS “Print Engine Plug/Jack Locator” on page 10-3 LVPS Harness Troubleshooting Procedure Step Actions and Questions...

  • Page 191: Image Processor Board

    Does the voltage measure +3.3 VDC? Check the DC-DC Converter Harness: Replace the I/P Replace the Board DC-DC Converter 1. Disconnect P/J402 and J130. (page 8-91). Harness. 2. Test each cable between J402 <=> J130 for continuity. Are all continuous? 4-38 Phaser 4500 Service Manual...

  • Page 192: Ram Dimm Fault Isolation

    A minimum of 64 MB of RAM must be installed for proper printer operation. The Phaser 4500 Laser Printer supports PC133 SDRAM in 144-pin SO-DIMM form. The printer accepts modules of 32, 64, 128, or 256 MB in combinations to a total of 512 MB.
  • Page 193 2. Power on the printer. Does the DIMM fail in the new location? Install all of the DIMMs and power on the Replace the I/P Problem Solved printer. board Is a memory fault message displayed? (page 8-92) 4-40 Phaser 4500 Service Manual...

  • Page 194: Electrical Noise

    Electrical Noise Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References HVPS/Engine Logic Board “Print Engine Plug/Jack Locator” on page 10-3 Print Cartridge Right Guide “Print Engine General Wiring Diagram” on Assembly page 10-17 Fuser Assembly “Print Cartridge, Transfer Roller Assembly” on page 10-21 Print Cartridge “Fuser Assembly, Power Switch”...
  • Page 195 Are the screws of the Stacker PWBA firmly tightened? Warning: Allow the Fuser Assembly to Go to step 11. Problem solved. cool down before removing. Replace the Fuser Assembly (page 4-16). Does the problem still occur after replacement? 4-42 Phaser 4500 Service Manual...

  • Page 196: Optional 550-Sheet Feeder Pwba (Tray 3)

    Troubleshooting Procedure (Continued) Steps Actions and Questions Replace the HVPS/Engine Logic Board Replace all related Problem solved. (page 8-89). parts. Does the problem still occur after replacement? Optional 550-Sheet Feeder PWBA (Tray 3) Note Use this procedure when the Optional 550-Sheet Paper Feeder is installed as Tray 3.

  • Page 197: Optional 550-Sheet Feeder Pwba (Tray 4)

    Harness 5. Remove Feeder Harness 5. Is J84 <=> J8483 continuous? Replace the 550-Sheet Feeder PWBA Problem solved. Replace the (page 8-102). HVPS/Engine Does the problem still occur after Logic Board replacement? (page 8-89). 4-44 Phaser 4500 Service Manual...

  • Page 198: Optional 550-Sheet Feeder No Paper Sensor

    Optional 550-Sheet Feeder No Paper Sensor Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References No Paper Sensor “550-Sheet Feeder Signal Diagram” on page 10-28 No Paper Actuator “550-Sheet Feeder General Wiring Diagram” on page 10-27 Clutch/Sensor Harness 1 “550-Sheet Feeder Plug/Jack Locator” on Clutch/Sensor Harness 2 page 10-10 Optional 550-Sheet Paper...
  • Page 199 (page 8-89). 2. Test P11-16 <=> P20-5 for continuity. Is it continuous? Replace the No Paper Sensor (page 8-28). Replace the Problem solved. Does the problem still occur after HVPS/Engine replacement? Logic Board (page 8-89). 4-46 Phaser 4500 Service Manual...

  • Page 200: Optional 550-Sheet Feeder Low Paper Sensor

    Optional 550-Sheet Feeder Low Paper Sensor Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Low Paper Sensor “550-Sheet Feeder Signal Diagram” on page 10-28 Low Paper Actuator “550-Sheet Feeder General Wiring Diagram” on page 10-27 Low Paper Sensor Harness “550-Sheet Feeder Plug/Jack Locator”...
  • Page 201 HVPS/Engine Logic Board. (page 8-89). 2. Test P11-16 <=> P20-5 for continuity. Is it continuous? Replace Low Paper Sensor (page 8-42). Replace the Problem solved. Does the problem still occur after HVPS/Engine replacement? Logic Board (page 8-89). 4-48 Phaser 4500 Service Manual...

  • Page 202: Optional Feeder Paper Size Switch Assembly

    Optional Feeder Paper Size Switch Assembly Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Option Paper Size Switch “550-Sheet Feeder Signal Diagram” on page 10-28 Assembly “550-Sheet Feeder General Wiring Diagram” on Feeder Size Assembly Harness page 10-27 “550-Sheet Feeder Plug/Jack Locator” on Feeder Size Assembly Harness page 10-10 Optional 550-Sheet Paper...

  • Page 203: Optional 550-Sheet Feeder Feed Clutch Assembly

    Go to step 5. Replace the 550- Sheet Feeder 1. Disconnect P/J83 from the 550-Sheet PWBA Feeder PWBA. (page 8-102). 2. Test the following points for continuity: P83-1 <=> P85-1 P83-2 <=> P85-2 Are both continuous? 4-50 Phaser 4500 Service Manual...
  • Page 204 Troubleshooting Procedure (Continued) Steps Actions and Questions Check Feeder Harness 2: Go to step 6. Replace Feeder Harness 2. 1. Remove Feeder Harness 2. 2. Test for continuity across J2083 <=> J83. Is it continuous? Check Feeder Harness 1: Go to step 7. Replace Feeder Harness 1.

  • Page 205: Optional 550-Sheet Feeder Turn Roller Clutch

    Check the resistance of the Turn Roller Go to step 4. Replace the Turn Clutch: Roller Clutch Measure the resistance of the clutch (page 8-112). between P/J854-1 <=> P/J854-2. Does the resistance measure 172 ohm +/-10% (at 20° C)? 4-52 Phaser 4500 Service Manual...
  • Page 206 Troubleshooting Procedure (Continued) Steps Actions and Questions Check the 550-Sheet Feeder PWBA: Go to step 5. Replace the 550- Sheet Feeder 1. Disconnect P/J83 from the 550-Sheet PWBA Feeder PWBA. (page 8-102). 2. Test for continuity at these points: P83-3 <=> P85-3 P83-4 <=>...

  • Page 207: Duplex Unit Pwba

    2. Test each cable between J27 <=> J2750 for continuity. Is each cable continuous? Replace the Duplex Unit PWBA Problem solved. Replace the (page 8-123). HVPS/Engine Is the problem cleared after Logic Board replacement? (page 8-89). 4-54 Phaser 4500 Service Manual...

  • Page 208: Duplex Unit Motor

    Duplex Unit Motor Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Duplex Unit Motor “Duplex Unit Signal Diagram” on page 10-30 Duplex Unit PWBA “Duplex Unit General Wiring Diagram” on page 10-29 Duplex Unit Assembly Harness “24 V Interlock, Rear Cover Switch, Main Motor, Sub HVPS/Engine Logic Board Fan, Exit Motor Assembly”...

  • Page 209: Duplex Unit Sensor

    Replace the Go to step 4. HVPS/Engine 1. Enter Service Diagnostics, and from the Logic Board Sensor Tests menu select Duplex (page 8-89). Sensor test. Does the sensor correctly report the position of the actuator? 4-56 Phaser 4500 Service Manual...
  • Page 210 Troubleshooting Procedure (Continued) Steps Actions and Questions Check the Duplex Unit Sensor (2): Replace the Go to step 4. HVPS/Engine 1. Open the Duplex Unit Housing Cover Logic Board and keep open. (page 8-89). 2. Measure the voltage across P/J53-3 <=> P/J53-2 while manually operating the Duplex Unit Actuator.

  • Page 211: Duplex Unit Switch

    Go to “Duplex Unit Go to step 6. PWBA” on 1. Remove the Print Cartridge. page 4-54. 2. Measure the voltage across P/J27-4 <=> P/J27-3 on the HVPS/Engine Logic Board. Does the voltage measure 3.3 VDC? 4-58 Phaser 4500 Service Manual...

  • Page 212: Stacker Pwba

    Troubleshooting Procedure (Continued) Steps Actions and Questions Check the HVPS/Engine Logic Board: Go to “LVPS (Low Replace the Voltage Power HVPS/Engine 1. Disconnect P/J27 from the HVPS/ Supply)” on Logic Board Engine Logic Board. page 4-4. (page 8-89). 2. Test P27-4 <=> P11-16 on the HVPS/ Engine Logic Board for continuity.

  • Page 213: Stacker Motor Assembly

    Replace the Stacker Motor (page 8-154 Problem solved. Go to step 6. Is the problem cleared? Replace the Stacker PWBA (page 8-142). Problem solved. Replace the Is the problem cleared? HVPS/Engine Logic Board (page 8-89). 4-60 Phaser 4500 Service Manual...

  • Page 214: Offset Motor Assembly

    Offset Motor Assembly Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Offset Motor Assembly “Stacker Signal Diagram” on page 10-32 Stacker Motor Assembly “Stacker General Wiring Diagram” on page 10-31 Stacker PWBA “24 V Interlock, Rear Cover Switch, Main Motor, Sub Fan, Exit Motor Assembly”...

  • Page 215: Gate Solenoid Assembly

    Replace the Gate Solenoid Assembly Problem solved. Go to step 5. (page 8-145). Is the problem cleared? Replace the Stacker PWBA (page 8-142). Problem solved. Replace the Is the problem cleared? HVPS/Engine Logic Board (page 8-89). 4-62 Phaser 4500 Service Manual...

  • Page 216: Stacker Rear Cover Switch

    Stacker Rear Cover Switch Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Rear Cover Switch “Stacker Signal Diagram” on page 10-32 Rear Cover Assembly Harness “Stacker General Wiring Diagram” on page 10-31 Stacker PWBA “24 V Interlock, Rear Cover Switch, Main Motor, Sub Fan, Exit Motor Assembly”...
  • Page 217 Replace the Go to “LVPS (Low HVPS/Engine Voltage Power 1. Disconnect P/J30 from the HVPS/ Logic Board Supply)” on Engine Logic Board. (page 8-89). page 4-4. 2. Test P30-4 <=> P11-16 for continuity. Is is continuous? 4-64 Phaser 4500 Service Manual...

  • Page 218: Stacker Sensor

    Stacker Sensor Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Stacker Sensor “Stacker Plug/Jack Locator” on page 10-14 Stacker Actuator “Stacker General Wiring Diagram” on page 10-31 Stacker Sensor Harness “Stacker Signal Diagram” on page 10-32 Stacker PWBA “24 V Interlock, Rear Cover Switch, Main Motor, Sub Fan, Exit Motor Assembly”...
  • Page 219 1. Remove Stacker Harness 1. 2. Test J30 <=> J3070 for continuity Is the harness continuous? Replace the Stacker Sensor (page 8-146). Problem solved. Go to “Stacker Is the problem cleared? PWBA” on page 4-59. 4-66 Phaser 4500 Service Manual...

  • Page 220: Stack Full Sensor (On Stacker Pwba)

    Stack Full Sensor (On Stacker PWBA) Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Stack Full Sensor (Mounted on “Stacker Plug/Jack Locator” on page 10-14 Stacker PWBA) “Stacker General Wiring Diagram” on page 10-31 Stack Full Actuator “Stacker Signal Diagram” on page 10-32 Stacker PWBA “24 V Interlock, Rear Cover Switch, Main Motor, Sub Stacker Assembly Harness 2...
  • Page 221 1. Remove Stacker Harness 1. 2. Test J30 <=> J3070 for continuity. Is the harness continuous? Replace the Stacker PWBA (page 8-142). Problem solved. Replace the Is the problem cleared? HVPS/Engine Logic Board (page 8-89). 4-68 Phaser 4500 Service Manual...

  • Page 222: Offset Sensor (On Stacker Pwba)

    Offset Sensor (On Stacker PWBA) Troubleshooting Reference Applicable Parts Wiring and Plug/Jack Map References Offset Sensor (Mounted on “Stacker Plug/Jack Locator” on page 10-14 Stacker PWBA) “Stacker General Wiring Diagram” on page 10-31 Offset Assembly Chute “Stacker Signal Diagram” on page 10-32 Stacker PWBA “24 V Interlock, Rear Cover Switch, Main Motor, Sub Stacker Assembly Harness 2...
  • Page 223 4-70 Phaser 4500 Service Manual...

  • Page 224: Print-Quality Troubleshooting

    Print-Quality Troubleshooting In this chapter... Print-Quality Problems Overview Analyzing Test Prints Print-Quality Troubleshooting Chapter...

  • Page 225: Print-Quality Problems Overview

    See “Xerox Printing Media” on page 9-45 for supported paper and specialty media that has been tested and approved for use in the Phaser 4500 printer. If the print- quality defect is still present when printing on approved media from an unopened ream of paper, then media, software applications, and environmental conditions need to be researched.

  • Page 226: Analyzing Test Prints

    Analyzing Test Prints The test print shown on page 5-5 is used to evaluate and ensure that the printed image meets the printer specifications. To make the test print: From the main menu, scroll to Troubleshooting, then press the OK button. Print Quality Problems, then press the OK button.
  • Page 227 SKIPS / SMEARS: Skip-Loss or stretching of the image in bands across the page 5-49 process direction. Smear-The distortion of the image in bands across the process direction that cause it to appear to be blurred or compressed. Phaser 4500 Service Manual...

  • Page 228: Test Print

    Test Print Test Print est Print Phaser4500-030129-2-S Phaser4500-030129-2-S 8.5x1 8.5x11 (SEF) 1 (SEF) s4500-256 Print-Quality Troubleshooting...

  • Page 229: Deletions (Line, Band, Spots)

    Are there Horizontal (in direction of scanning) Go to Go to step 4. Line/Band Deletions present? Horizontal Deletions on page 5-23. Are there Spot Deletions present? Go to “Spot Go to Deletions” on “Fusing” on page 5-37. page 5-7. Phaser 4500 Service Manual...

  • Page 230: Fusing

    Fusing Test Print Phaser4500-030129-2-S 8.5x11 (SEF) s4500-258 Print-Quality Troubleshooting...
  • Page 231 Go to soft cloth or tissue. the image should not lift off of the surface “Resolution” “Unfused of the print. on page 5-9. Image” on Does the fusing quality of the image appear acceptable? page 5-32. Phaser 4500 Service Manual...

  • Page 232: Resolution

    Resolution Test Print Phaser4500-030129-2-S 8.5x11 (SEF) s4500-263 Actions and Questions Observe the three resolution check points on several Test Prints. The printed Go to Check the resolution of the images in each of the following test patterns “Resolution” areas: meet the Resolution page 5-36.

  • Page 233: Registration (Side-To-Side)

    5-47. target. Side Is the fold within +/- 2.5 mm of the target cross hairs Registration (each line on the target is 1 mm). Specification. Go to “Registration (Lead Edge- to-Trail Edge)” on page 5-11. 5-10 Phaser 4500 Service Manual...

  • Page 234: Registration (Lead Edge-To-Trail Edge)

    Registration (Lead Edge-to-Trail Edge) Actions and Questions Measure the registration on two consecutive test prints: The printed Go to test patterns “Registration” 1. Fold the paper in half (Lead Edge-to-Trail Edge). meet the on page 5-47. 2. Observe the fold line of the paper with reference to the Lead Edge- cross hairs of the target.

  • Page 235: Skips/Smears

    Actions and Questions Inspect the ladder chart test pattern as shown in the figure. Go to “Spots” Go to “Skips Is the pattern free from skips and smears? on page 5-13. and Smears” on page 5-49. 5-12 Phaser 4500 Service Manual...

  • Page 236: Spots

    Spots Actions and Questions 1. From the Main Menu, select Information, then press the Go to “Light Go to “Spots” button. (Undertoned) on page 5-30. Print” on 2. Scroll to Information Pages, then press the OK button. page 5-16. 3. Scroll to Configuration Page, then press the OK button.

  • Page 237: Skew

    Skew page 5-44. 3. Measure the dimensions ‘A’ and ‘B’ on two consecutive specifications. test patterns. Go to “Skips Is the difference between ‘A’ and ‘B’ 1.2 mm or less? and Smears” on page 5-49. 5-14 Phaser 4500 Service Manual...

  • Page 238: Other Print Defects

    Other Print Defects Step Actions and Questions Inspect the Test Patterns for other Print Defects. Return to Go to step 2. Are the test prints free of defects? “Analyzing Test Prints” on page 5-3. Are there dark streaks present on the test prints? Go to Go to step 3.

  • Page 239: Print-Quality Troubleshooting

    Contact, so it makes Contacts on the Print Cartridge better contact with the Right Side Guide. drum shaft, or replace Is the Metal Grounding Contact the Print Cartridge intact and free of contamination? Right Side Guide (page 8-58). 5-16 Phaser 4500 Service Manual...
  • Page 240 Light Prints Troubleshooting Procedure (Continued) Step Actions and Questions Check for continuity between the Go to step 5. Replace the Print Metal Grounding Contact and the Cartridge Right Guide printer body frame. (page 8-58). Is there continuity between the Metal Grounding Contact and the printer frame? Inspect the Laser Beam path Go to step 6.

  • Page 241: Blank Print (No Print)

    3. Scroll to Information Pages, then replace the Image Image Processor press the OK button. Processor Board Board (page 8-91). 4. Scroll to Configuration Page, (page 8-91). then press the OK button. Are the pages blank? 5-18 Phaser 4500 Service Manual...
  • Page 242 Blank Prints Troubleshooting Procedure (Continued) Step Actions and Questions 1. Install a new Print Cartridge. Problem solved. Go to step 4. 2. Print a test print as in Step 1. Is there a normal image on the paper? 1. Remove the Print Cartridge. Go to step 5.

  • Page 243: Black Prints

    Go to Laser Go to HVPS/ Print a test print. Assembly on Engine Logic Is the print half white and half black? “Laser Unit Board on Assembly” on “HVPS/Engine page 8-46. Logic Board” on page 4-35. 5-20 Phaser 4500 Service Manual...

  • Page 244: Vertical Deletions

    Vertical Deletions A vertical band in the process direction (direction of paper travel) where the image is missing or extremely light. Initial Actions Check that the paper supply is dry and fresh. Inspect the printer paper path for foreign items, such as staples, paper clips, and paper scraps.
  • Page 245 Are the Heat Roller and Pressure Roller free of surface defects and contamination? Replace in order until the problem is solved. Transfer Roller Assembly (page 8-55) Laser Assembly (page 8-46) Fuser Assembly page 8-54) Engine Logic Board (page 8-89) 5-22 Phaser 4500 Service Manual...

  • Page 246: Horizontal Deletions

    Horizontal Deletions A deletion is an area of the print where the image is missing or extremely light. Horizontal deletions extend across the page. Initial Actions Check that the paper supply is dry and fresh. Inspect the printer paper path for foreign items, such as staples, paper clips, and paper scraps.
  • Page 247 Gear and inspect the Heat Roller. 3. Open the Fuser Jam Access cover. 4. Manually rotate the Fuser Drive Gear and inspect the Pressure Roller. Are the Heat Roller and the Pressure Roller free of surface defects and contamination? 5-24 Phaser 4500 Service Manual...

  • Page 248: Vertical Streaks

    Horizontal Deletions Troubleshooting Procedure (Continued) Step Actions and Questions Replace in order until the problem is solved: HVPS/Eng Logic PWB (page 8-89) Print Cartridge Right Side Guide (page 8-58) Transfer Roller Assembly (page 8-55) Laser Assembly (page 8-46) Fuser Assembly (page 8-54) Registration Clutch (page 8-112) Main Motor Assembly (page 8-69 Gear Assembly Housing...
  • Page 249 Are the vertical streaks gone? Inspect the Transfer Roller Assembly Go to step 5. Replace the Transfer for contamination and wear. Roller Assembly Is the Transfer Roller free of (“Transfer Roller contamination and wear? Assembly” on page 8-55). 5-26 Phaser 4500 Service Manual...
  • Page 250 Vertical Streaks Troubleshooting Procedure (Continued) Step Actions and Questions Warning: Allow the Fuser Assembly Go to Electrical Replace the Fuser to cool before removing. Noise (page 4-41). Assembly (page 8-54). 1. Open the Rear Cover and remove the Fuser Assembly. 2.

  • Page 251: Horizontal Streaks

    3. Scroll to Information Pages, then Processor Board Image Processor press the OK button. (page 8-91). Board (page 8-91). 4. Scroll to Configuration Page, then press the OK button. Do the prints have horizontal streaks? 5-28 Phaser 4500 Service Manual...
  • Page 252 Horizontal Streaks Troubleshooting Procedure (Continued) Step Actions and Questions 1. Install a new Print Cartridge. Problem solved. Go to step 4. 2. Print a test print. Do the prints have horizontal streaks? Verify that the connectors on the Go to step 5. Reconnect the Laser Assembly are firmly connectors and/or re-...

  • Page 253: Spots

    (on the right side of the Print Cartridge and in the Print Cartridge Right Side Guide in the printer) are clean. s4500-045 Check that rollers and other components in the paper path are clean and unobstructed. 5-30 Phaser 4500 Service Manual...
  • Page 254 Spots Troubleshooting Procedure Step Actions and Questions 1. Install a new Print Cartridge. Problem solved. Go to step 2. 2. Print a test print. Are the spots gone? Inspect the Transfer Roller Assembly Go to step 3. Replace the Transfer for contamination and wear.

  • Page 255: Unfused Image

    Is the problem still present? 1. Check that the levers on both Go to step 3. Problem solved. sides of the Fuser Assembly are pushed down. s4500-265 2. Reprint the problem image. Does the problem still occur? 5-32 Phaser 4500 Service Manual...
  • Page 256 Unfused Image Troubleshooting Procedure (Continued) Step Actions and Questions 1. From the main menu, select Go to step 4. Problem solved. Printer Setup, then press the OK button. 2. Scroll to Paper Handling Setup, then press the OK button. 3. Scroll to Fuser Configuration, then press the OK button.
  • Page 257 HVPS/Engine Logic Board (page 8-89) LVPS PWB (page 8-78) Fuser Configuration Defaults Paper Type Default Fuser Temperature Setting Plain Medium Letterhead Medium Transparency Labels High Colored Paper Medium Card Stock High Envelope High Special Medium 5-34 Phaser 4500 Service Manual...

  • Page 258: Damaged Print

    Damaged Print The printed page comes out of the printer either wrinkled, creased, or torn. Initial Actions Check that the paper supply is dry and fresh. Check that rollers and other components in the paper path are clean and unobstructed. Ensure that paper is within specification.

  • Page 259: Resolution

    Go to step 2. 2. Print a test print. Is the test print output resolution good? Replace the following, in order until the defective component is found: Laser Assembly (page 8-46) HVPS/Engic Logic PWBA (page 8-89) 5-36 Phaser 4500 Service Manual...

  • Page 260: Spot Deletions

    Spot Deletions Solid areas are marked with irregular white areas. Initial Actions Check that the paper supply is dry and fresh. Inspect the printer paper path for foreign items, such as staples, paper clips, and paper scraps. Check the installation of the Print Cartridge. Check that the Print Cartridge ground contacts (on the right side of the Print Cartridge and in the Print Cartridge Right Side Guide in the...
  • Page 261 Roller Drive. Are the Heat Roller and the Pressure Roller free of surface defects and contamination? Replace the following, in order, until the defective component is found: Transfer Roller Assembly (page 8-55) Laser Assembly (page 8-46) 5-38 Phaser 4500 Service Manual...

  • Page 262: Repeating Defects

    Repeating Defects Recurring marks, spots, lines, or voids. Initial Actions Check that the paper supply is dry and fresh. Inspect the printer paper path for foreign items, such as staples, paper clips, and paper scraps. Check installation of the Print Cartridge. Check that the Print Cartridge ground contacts (on the right side of the Print Cartridge and in the Print Cartridge Right Side Guide in the printer) are clean.

  • Page 263: Residual Image

    Do the residual images still appear? Inspect the Transfer Roller Assembly Go to step 4. Replace the Transfer for contamination and wear. Roller Assembly Is the Transfer Roller free of (page 8-55). contamination and wear? 5-40 Phaser 4500 Service Manual...
  • Page 264 Residual Image Troubleshooting Procedure (Continued) Step Actions and Questions Warning: Allow the Fuser Assembly Go to step 5. Clean or replace the to cool before removing. Fuser Assembly 1. Open the Rear Cover and remove (page 8-54). the Fuser Assembly. 2.

  • Page 265: Background

    Feeder Assembly and install again for the 2. Remove the Print Cartridge. correct ground. 3. Check the connection between the 150-Feeder Assembly metal part and printer frame metal part. Is the 150-Feeder Assembly grounded? 5-42 Phaser 4500 Service Manual...

  • Page 266: Uneven Density

    Background Troubleshooting Procedure (Continued) Step Actions and Questions 1. Check the Fuser Assembly Go to step 5. Remove the Fuser ground. Assembly and install again. 2. Open Rear Cover. 3. Check the connection between the printer frame and the screw on the back of Fuser Assembly.

  • Page 267: Skewed Image

    Load fresh, dry paper. Paper meets specifications. Check the paper path for any obstructions or debris that might hamper the passage of the paper. Ensure the Print Cartridge is properly installed. s4500-048 5-44 Phaser 4500 Service Manual...
  • Page 268 Skewed Image Troubleshooting Procedure Step Actions and Questions Yes Run 5 Test Prints, single Check the Fuser Assembly. Check for worn parts or rollers. sided, from each paper tray. Check for obstructions or If the printer has a Duplex contamination. Clean or replace Unit, run five duplexed as necessary.
  • Page 269 Tray 3 and Tray 2. Check for obstructions or Check the feed contamination. Clean as chute between Tray 4 necessary. and Tray 3. Check for obstructions or Check condition of paper tray. contamination. Clean Replace if necessary. as necessary. 5-46 Phaser 4500 Service Manual...

  • Page 270: Registration

    Go to step 4. Go to step 5. Is the image registration correct? Have the customer run a print job. Problem solved. Problem may be Are the customer’s prints application related. correctly registered? Have the customer contact Xerox customer support. Print-Quality Troubleshooting 5-47...
  • Page 271 Turn Roller Clutch (Trays 3 and 4 only) (page 8-112) Feeder Assembly (page 8-104) HVPS/Engine Logic PWBA (page 8-89) If misregistaition occurs in the scan direction, replace in sequence as necessary: Laser Assembly (page 8-46) I/P PWBA (page 8-91) 5-48 Phaser 4500 Service Manual...

  • Page 272: Skips And Smears

    Skips and Smears Initial Actions: Check to ensure that the paper is within specification. Check that the paper supply is dry, fresh, and loaded correctly. Check the paper path for any XEROX XEROX obstructions or debris. XEROX s4500-261 Skips/Smears Troubleshooting Procedure Step Actions and Questions Replace the Print Cartridge.
  • Page 273 5-50 Phaser 4500 Service Manual...

  • Page 274: Adjustments And Calibrations

    Adjustments and Calibrations In this chapter... Service Test Prints Adjustments Resetting Fuser Life Resetting Printer Values to the Factory Default Values Chapter...

  • Page 275: Service Test Prints

    In other cases, you press the OK button to toggle the setting between and Off. Exit When you have finished setting all the parameters, select and press the OK button to return the printer to the Ready state. Phaser 4500 Service Manual...
  • Page 276 Test Print Phaser4500-030129-2-S 8.5x11 (SEF) s4500-256 Adjustments and Calibrations...

  • Page 277: Engine Test Print

    The Engine Test Print is used for checking the functionality of various print engine components and for making the registration adjustment. It is accessed through Service Diagnostics. To print the Engine Test Print: Enter Service Diagnostics. Engine Test Print, then press the OK button. Select Phaser 4500 Service Manual...

  • Page 278: Adjustments

    Adjustments Adjusting Laser Power (Image Density) This adjustment procedure increases or decreases the output of the laser to lighten or darken the printable image. This adjustment allows you to “tune” the image density to accommodate a customer’s special application. Note Adjusting laser power from the default value impacts other print-quality parameters, such as background, halftone/fine line production, fuser fix, and toner consumption.
  • Page 279 If Duplex is Off, press the Down Arrow button to change it to On. Repeat steps 7 and 8. Check the registration for the duplexed prints. If a registration measurement does not meet the specification, perform the duplex adjustment procedure on page 6-8. Phaser 4500 Service Manual...

  • Page 280: Adjusting Simplex Registration

    Adjusting Simplex Registration Enter Service Diagnostics. Engine NVRAM Adjustments, then press the OK button. Select Select either the process adjustment (Tray [#] Proc Dir) or scan adjustment (Tray [#] Scan Dir) for the desired tray, then press the OK button. Use the Up Arrow and Down Arrow buttons to set the new value.

  • Page 281: Adjusting Duplex Registration

    Repeat steps 1 through 9 until correct measurements are achieved. Perform the Registration (Side-To-Side) test on page 5-10 and the Registration (Lead Edge-to-Trail Edge) test on page 5-11. Repeat this adjustment procedure if the results are incorrect. Phaser 4500 Service Manual...

  • Page 282: Adjusting Fuser Temperature

    Adjusting Fuser Temperature Four temperature settings, listed in the following Fuser Temperatures table, are available for each paper type supported by the printer. The default fuser temperature setting for each paper type is listed in the following Fuser Configuration Defaults table.

  • Page 283: Resetting Fuser Life

    From the Main Menu, select Information, then press the OK button. Select Supplies Info, then press the OK button. Select Reset Fuser Life, then press the OK button. Reset Fuser Life NOW, then press the OK button to reset the fuser life. Select 6-10 Phaser 4500 Service Manual...

  • Page 284: Resetting Printer Values To The Factory Default Values

    Resetting Printer Values to the Factory Default Values You can reset printer values on the following menus to the factory default settings: Connection Setup Paper Handling Setup PostScript Setup PCL Setup General Setup Front Panel Setup Printer Controls File Security (available if the printer has a hard drive) You can reset all of the Image Processor Board NVRAM-stored parameters to their factory default values by resetting the PostScript NVRAM.

  • Page 285: Resetting Paper Handling Setup Values

    Print with Low Toner settings. From the Main Menu, select General Setup, then press the OK button. Reset General Setup, then press the OK button. Select Select Reset General Setup NOW, then press the OK button. 6-12 Phaser 4500 Service Manual...

  • Page 286: Resetting Front Panel Setup Values

    Resetting Front Panel Setup Values Resetting the Front Panel values resets the Front Panel Language, Front Panel Brightness, Front Panel Contrast, and Accessible Front Panel settings. From the Main Menu, select Front Panel Setup, then press the OK button. Reset Front Panel Setup, then press the OK button.

  • Page 287: Resetting All Printer Default Settings (Postscript Nvram)

    The printer then exits Service Diagnostics and reboots. While booting, NVRAM is reset. Using the Front Panel Shortcut At power-on, press the Back + OK buttons together. When Password appears, press and hold the Up Arrow + Down Arrow buttons together within 2 seconds. 6-14 Phaser 4500 Service Manual...

  • Page 288: Cleaning And Maintenance

    Cleaning and Maintenance In this chapter... Service Preventive Maintenance Procedure Recommended Tools Cleaning Chapter...

  • Page 289: Service Preventive Maintenance Procedure

    Laser Unit Assembly, and paper path. Vacuum out any loose toner from the interior of the printer with a Type II toner vacuum only. Remove and clean the paper trays. Clean feed rollers with a lint-free cloth lightly dampened with water. Phaser 4500 Service Manual...

  • Page 290: Fru Disassembly

    Disassembly In this chapter... Overview General Notes on Disassembly Print Engine: Covers Print Engine: 150- or 550-Sheet Paper Cassette Print Engine: 150-Sheet Feeder Print Engine: 550-Sheet Paper Feeder Print Engine: Xerographics Print Engine: Paper Exit Print Engine: Frame and Drive Print Engine: Electrical Options: 550-Sheet Paper Feeder Options: Duplex Unit...

  • Page 291: Overview

    When needed the orientation of the printer is called out in the procedure for locating printer parts, refer to the printer orientation graphic for locating the right, left, front and back sides of the printer. s4500-247 1. Front 3. Right 2. Left 4. Rear or Back Phaser 4500 Service Manual...

  • Page 292: General Notes On Disassembly

    General Notes on Disassembly Preparation Before you begin any Removal and Replacement Procedure: Switch OFF the printer power and disconnect the power cord from the wall outlet. Remove the Print Cartridge and protect it from exposure to light by covering it with a light proof bag or by placing it in a light-tight container.

  • Page 293: Print Engine: Covers

    Unscrew the thumbscrews at the right and left rear sides of the Paper Exit Cover. Lift the rear of the Paper Exit Cover, then pull back to release the tabs at the front of the cover. Phaser 4500 Service Manual...

  • Page 294: Paper Exit Rear Door

    Paper Exit Rear Door (PL10.2.21) s4500-135 1. Paper Exit Rear Door 2. Hinge Retainer Remove the Duplex Unit if one is installed (page 8-115). Lift the lever to release the lock, and open the Paper Exit Rear Door. Pry out the hinge retainer on the right side. Release the hook of the left side hinge, and shift the Paper Exit Rear Door in the direction of the arrow to remove from the printer.

  • Page 295: Rear Cover

    Swing out the left end of the door, then disengage the three hooks on the right side and move the door away from the printer as indicated in the illustration. Replacement Note: Two screw types are used; be sure to install them in the correct locations. Phaser 4500 Service Manual...

  • Page 296: Right Cover

    Right Cover (PL1.1.4) s4500-058 1. Thumbscrew 2. Bottom Hooks FRU Disassembly...
  • Page 297 (two at the bottom edge, one in front, and one on rear), then swing out the bottom edge. Move the Right Cover downward to release the three tabs along the top edge, and lift away from the printer. Phaser 4500 Service Manual...

  • Page 298: Left Cover

    Left Cover (PL1.1.6) s4500-059 Remove the Rear Cover (page 8-6). Shift the Left Cover towards the rear of the printer to release the five hooks (one at the front, two at the bottom, two on the rear), then swing out the bottom edge. Move the Left Cover downward to release the three tabs along the top edge, and lift away from the printer.

  • Page 299: Top Cover Assembly, Front Panel

    Front Panel. Remove the Print Cartridge. Remove the Paper Exit Cover (page 8-4) or Stacker, if installed (page 8-132). Remove the Right Cover (page 8-7). Remove the Left Cover (page 8-9). 8-10 Phaser 4500 Service Manual...

  • Page 300: Replacement Notes

    Remove the Paper Exit Assembly (page 8-61). Disconnect the connectors (P/J144 and P/J411) of the Interlock Switch Assembly from the frame connectors. Remove the two screws (silver with flange, 8 mm) that secure the Top Cover Assembly to the printer. Open the Top Cover and slide the Link Lever off the boss.

  • Page 301: Front Cover

    Remove the Top Cover Assembly (page 8-10). Release the two upper hooks that secure the Front Cover to the printer by pressing down on the hooks. Tilt the cover out and lift to release the lower hooks from the frame. 8-12 Phaser 4500 Service Manual...

  • Page 302: Interlock Switch Assembly

    Interlock Switch Assembly (PL1.1.11) s4500-062 1. Top Cover Assembly 3. Cable Clamps 2. Hole FRU Disassembly 8-13...
  • Page 303 Remove the two screws (gold tapping, 8 mm) that attach the Interlock Switch Assembly. Lift the Interlock Switch Assembly from the Top Cover Assembly, release the harnesses from the cable restraints, and draw the Interlock Switch harness out of the hole in the Top Cover Assembly. 8-14 Phaser 4500 Service Manual...

  • Page 304: Print Engine: 150- Or 550-Sheet Paper Cassette

    Print Engine: 150- or 550-Sheet Paper Cassette Retard Roller and Holder (PL2.1.2 and 2.1.51 for 150-sheet, PL 4.1.2 and 4.1.51 for 550-sheet); the roller is also part of the Maintenance Kit. s4500-064 1. Retard Roller 2. Retard Holder FRU Disassembly 8-15...

  • Page 305: Replacement Note

    While installing the Retard Holder, ensure that both ends of the coil spring under the holder are properly engaged with two boss pins. Check that it springs back to its normal position when depressed and released. 8-16 Phaser 4500 Service Manual...
  • Page 306 s4500-063 1. Retard Roller 4. Retard Holder 2. Friction Clutch 5. Retard Spring 3. Hooks 6. 150- or 550-Sheet Paper Cassette FRU Disassembly 8-17...

  • Page 307: Print Engine: 150-Sheet Feeder

    Disconnect the two harnesses, P/J 245 and P/J 221. Swing the roller holder assembly up firmly until it latches in the detent. Remove the five screws (gold, flanged, 8 mm) that attach the 150-Sheet Feeder Assembly to the printer. 8-18 Phaser 4500 Service Manual...
  • Page 308 Shift the 150-Sheet Feeder Assembly backward to disengage the right boss from the frame. Lift the 150-Sheet Feeder Assembly to disengage the left boss. Remove the 150-Sheet Feeder Assembly from the printer. FRU Disassembly 8-19...

  • Page 309: Nudger Roller, Feed Roller

    Nudger Roller, Feed Roller (PL5.1.11) (PL5.1.44); the rollers are also part of Maintenance Kit s4500-091 1. Feed Roller 2. Nudger Roller Note When handling the Nudger Roller and Feed Roller Assemblies, avoid touching the rubber roller surfaces. 8-20 Phaser 4500 Service Manual...
  • Page 310 Open the Top Cover. Remove the Print Cartridge, and protect it from light exposure. Release the hook retaining the Nudger Roller, and slide the Nudger Roller off the Nudger Shaft. Release the hook retaining the Feed Roller, and slide the Feed Roller off the Feed Shaft.

  • Page 311: Nudger One-Way Clutch

    Nudger One-way Clutch (PL5.1.42) s4500-092 1. Nudger One-way Clutch 3. Feed Roller 2. Feed One-way Clutch 8-22 Phaser 4500 Service Manual...
  • Page 312 Open the Top Cover. Remove the Feed Roller (page 8-20). Slide the Feed One-way Clutch off the Feed Shaft. Remove the E-ring retaining the Nudger One-way Clutch on the Feed Shaft. Slide the Nudger One-way Clutch off the Feed Shaft. FRU Disassembly 8-23...

  • Page 313: Nudger Gear

    Nudger Gear (PL5.1.10) s4500-163 1. Nudger Gear 5. Boss (Lift Up) 2. Nudger Roller 6. Left Holder 3. Nudger Support 7. Hooks 4. No Paper Actuator 8-24 Phaser 4500 Service Manual...
  • Page 314 Remove the 150-Sheet Feeder Assembly (page 8-18). Press down the boss of the Left Holder at the back of the 150-Sheet Feeder Assembly, then shift the Left Holder in the direction of the arrow to release the three hooks. Remove the Left Holder and No Paper Actuator from the Nudger Support. Release the hook of the Nudger Roller, and pull the Nudger Roller out from the Nudger Shaft.

  • Page 315: Feed Clutch, Registration Clutch

    Assembly from the Feed Shaft. Disconnect the connector (P/J 243) of the Registration Clutch from the Tray 1 Harness Assembly. Remove the E-ring retaining the Registration Clutch, and slide the Registration Clutch from the Metal Registration Roller. 8-26 Phaser 4500 Service Manual...

  • Page 316: Registration Sensor

    Registration Sensor (PL5.1.30) P/J 241 s4500-097 1. Registration Sensor 2. Sensor Cover Remove the Main Fan (page 8-84). Release the hooks that secure the Sensor Cover, and remove the Sensor Cover from the Registration Chute Assembly. Release the hooks that secure the Registration Sensor, and remove it from the Sensor Cover.

  • Page 317: No Paper Sensor

    No Paper Sensor (PL5.1.38) P/J 240 s4500-098 1. No Paper Sensor Holder 3. 150-Sheet Feeder Assembly 2. No Paper Sensor 8-28 Phaser 4500 Service Manual...
  • Page 318 Remove the 150-Sheet Paper Cassette (Tray 1). Remove the Print Cartridge, and protect it from light exposure. Remove the Paper Exit Rear Door (PL10.2.21/PL9.1.12) (page 8-5). Remove the Fuser Assembly (page 8-54). Lift the 150-Sheet Feeder roller holder assembly upward until it latches into the lifted position detent.

  • Page 319: Toner Sensor Assembly

    When removing the Toner Sensor Assembly, be careful not to lose the holder tension spring. Replacement Note: When installing the Toner Sensor Assembly, put the Toner Sensor Spring on the boss of the D-Holder, and then install the Toner Sensor on it. 8-30 Phaser 4500 Service Manual...

  • Page 320: Print Engine: 550-Sheet Paper Feeder

    Print Engine: 550-Sheet Paper Feeder 550-Sheet Feeder Assembly (PL7.1.10) J248 P248 s4500-101 1. Out Chute 2. Tie Plate Remove the 150-Sheet Feeder Assembly (page 8-18). Remove the 550-Sheet Paper Cassette (Tray 2). Unplug the connector (P/J248) and release the cables from the two cable restraints on the Tie Plate.

  • Page 321: Nudger Roller, Feed Roller

    Reach through the Paper Cassette openings and release the hook retaining the Nudger Roller. Slide the Nudger Roller off the Nudger Shaft. Release the hook retaining the Feed Roller as in step 4. Slide the Feed Roller off the Feed Shaft. 8-32 Phaser 4500 Service Manual...

  • Page 322: Nudger One-Way Clutch

    Nudger One-way Clutch (PL7.1.27) s4500-104 1. Nudger One-way Clutch 3. Feed Roller 2. Feed One-way Clutch 4. 150-Sheet Feeder Assembly Remove the Print Cartridge and leave the cover open so that the removal can be checked visually. Remove the Tray 1 and Tray 2 Paper Cassettes. Lift up the 150-Sheet Feeder Assembly until it locks into the raised detent position.

  • Page 323: Nudger Gear

    Nudger Gear (PL7.1.18) s4500-105 1. Nudger Support 5. Nudger Roller 2. No Paper Actuator 6. Pick Gear 3. Boss (Lift Tab) 7. Metal pivot plate 4. Left Holder 8. Hook 8-34 Phaser 4500 Service Manual...
  • Page 324 Remove the Stacker if installed. Remove the Print Cartridge and leave the Top Cover open. Remove both paper cassettes (Trays 1 and 2). Remove any optional 500-Sheet Feeder(s) (page 8-93). Remove the Paper Exit Rear Door (page 8-5). Remove the Fuser Assembly (page 8-54). Lay the printer on its left side.

  • Page 325: Feed Clutch

    Feed Clutch (PL7.1.20) P/J 247 s4500-106 1. Out Chute 3. Feed Clutch 2. Tie Plate 8-36 Phaser 4500 Service Manual...
  • Page 326 Remove the 150-Sheet Feeder Assembly (page 8-18). Remove the 550-Sheet Feeder Assembly (page 8-31). Remove the six screws (gold tapping, 8 mm) that attach the Tie Plate to the Out Chute, and remove the Tie Plate from the Out Chute. Unplug the connector (P/J247) of the Feed Clutch from the Tray 2 Harness Assembly.

  • Page 327: No Paper Sensor

    Remove the No Paper Sensor Holder from the 550-Sheet Feeder Assembly. Release the hooks that secure the No Paper Sensor to the No Paper Sensor Holder, and remove the No Paper Sensor. Unplug the cable connector (P/J246) from the No Paper Sensor. 8-38 Phaser 4500 Service Manual...

  • Page 328: Right Tray Guide

    Right Tray Guide (PL7.1.3) P/J260 s4500-108 1. Low Paper Sensor Harness 3. Latch 2. Right Tray Guide 4. Cassette Lock Plate Remove the Print Cartridge and Paper Cassettes. Remove any optional 550-Sheet Feeder(s) (page 8-93). Lay the printer on its right side. Remove the screw (silver, 6 mm) that attaches the Right Tray Guide to the frame.
  • Page 329 After re-connecting P/J260, make sure the Low-Paper Sensor Harness is properly looped through the two harness retainers. When installing the Right Tray Guide, be sure to position the Cassette Lock Plates as shown in the figure. 8-40 Phaser 4500 Service Manual...

  • Page 330: Left Tray Guide

    Left Tray Guide (PL7.1.7) P/J1821 s4500-109 1. Silver machine screw (6 mm) 3. Gold tapping screw 2. Gold machine screw (6 mm) 4. Left Tray Guide Remove the Print Cartridge and Paper Cassettes. Remove any optional 550-Sheet Paper Feeder(s) (page 8-93). Remove the Front Cover (page 8-12).

  • Page 331: Low Paper Sensor/Actuator

    Low Paper Sensor/Actuator (PL7.1.4) P/J 260 s4500-110 1. Low 1 Harness Assembly 3. Latch hooks 2. Low Paper Sensor 4. Actuator 8-42 Phaser 4500 Service Manual...
  • Page 332 Remove the Print Cartridge and Paper Cassettes. Remove any optional 550-Sheet Paper Feeder(s) (page 8-93). Lay the printer on its right side. Note Take care not to scratch or mar the printer covers. Squeeze the actuator latch hooks together and lift the actuator off the pivot shaft. Release the sensor harness wires from the restraints.

  • Page 333: Print Engine: Xerographics

    Front Duct, Sub Fan (PL8.1.4) (PL8.1.5) J270 P270 s4500-112 1. Front Duct 2. Front Tie Plate Remove the Front Cover (page 8-12). Removing the Front Cover requires removing all other printer covers and the Paper Exit Assembly. 8-44 Phaser 4500 Service Manual...
  • Page 334 Remove the three screws (one silver tapping with flange, 8 mm; two gold tapping, 8 mm) that attach the Front Duct. Unplug the Sub Fan harness from the LVPS Harness Assembly at connector P/J270. Release the gray wires from the Cable Slot. Remove the Front Duct (with the Sub Fan attached) from the frame by moving it in the direction of the arrow.

  • Page 335: Laser Unit Assembly

    Working on a rough or inclined surface can result in mis-alignment of the Laser Unit Assembly. P/J140, 160, 170 P/J131 s4500-111 1. Laser Unit Assembly 3. Front Tie Plate 2. Cable Clamps 4. Upper Duct 8-46 Phaser 4500 Service Manual...
  • Page 336 Remove the Front Duct (page 8-44), but do not remove the Sub Fan from the duct. Remove the three screws (silver machine with flange, 8 mm) that attach the Upper Duct. Tilt out the left side of the Upper Duct to clear the connector, and remove the duct.

  • Page 337: Laser Unit Shield Plate

    Remove the Laser Unit Assembly (page 8-46). Remove the two screws (black with flange, 8 mm) that attach the Laser Unit Shield Plate to the frame. Lift the Laser Unit Shield Plate out of the frame as indicated by the arrow. 8-48 Phaser 4500 Service Manual...

  • Page 338: Print Cartridge Left Guide

    Print Cartridge Left Guide (PL8.1.15) 2 (P/J 4647) P/J 142 s4500-115 1. Print Cartridge Left Guide Assembly 4. Gear 3 Link 2. Fuser Connector (P/J 4647) 5. LVPS 3. Link Lever 6. Fuser Harness Clamp Remove the Laser Unit Shield Plate (page 8-48). Remove the Fuser Harness Clamp that secures the Fuser Harness to the frame.

  • Page 339: Fuser Harness Assembly

    1. Fuser Harness Assembly 4. Claws 2. Print Cartridge Guide Cover 5. Hooks 3. Print Cartridge Left Guide Remove the Fuser Assembly (page 8-54). Remove the Transfer Roller Assembly (page 8-55). Remove the Left Tray Guide (page 8-41). 8-50 Phaser 4500 Service Manual...
  • Page 340 Remove the Motor Cover (page 8-67). Remove the LVPS Shield Plate (page 8-75). Remove the Print Cartridge Left Guide (page 8-49). Spread the loops on the Print Cartridge Guide Cover to release the hooks in the Print Cartridge Left Guide, Then remove the Print Cartridge Guide Cover together with the Fuser Harness Assembly.

  • Page 341: Link Lever, Gear 3 Link

    Remove the Transfer Roller Assembly (page 8-55). Remove the Laser Unit Shield Plate (page 8-48). Remove the LVPS Shield Plate (page 8-75). Remove the Left Tray Guide (page 8-41). Remove the Motor Cover (page 8-67). 8-52 Phaser 4500 Service Manual...
  • Page 342 Remove the Print Cartridge Left Guide (page 8-49). Remove the Print Cartridge Guide Cover and Fuser Harness Assembly from the Print Cartridge Left Guide (page 8-50). Remove the Link Lever and Gear 3 Link. FRU Disassembly 8-53...

  • Page 343: Fuser Assembly

    Push down the Left and Right Fuser Levers in the direction of the arrow to release the Fuser Assembly locks. Pull the Fuser Assembly out the back of the printer as indicated by the arrow. 8-54 Phaser 4500 Service Manual...

  • Page 344: Transfer Roller Assembly

    Transfer Roller Assembly (PL8.1.21) s4500-121 1. Transfer Roller Assembly Remove the Print Cartridge and leave the Top Cover open. Protect the Print Cartridge from light exposure. Pinch the hooks of both ends of the Transfer Roller Assembly, and remove it from the printer.

  • Page 345: Transfer Chute

    Transfer Chute (PL8.1.22) s4500-122 1. Transfer Chute 2. Latch tab 8-56 Phaser 4500 Service Manual...
  • Page 346 Remove the Transfer Roller Assembly (page 8-55). Remove the Fuser Assembly (page 8-54). Remove the Main Fan (page 8-84) Lift the Latch Tab on the Transfer Chute and shift the Transfer Chute toward the printer’s left side. Shift the Transfer Chute in the direction of the arrow, and remove it from the frame.

  • Page 347: Print Cartridge Right Guide Assembly

    Print Cartridge Right Guide Assembly (PL8.1.25) J15 J31 S4500-124 1. Image Processor Shield Assembly 3. HVPS/Engine Logic Board 2. HVPS Shield Plate 4. Print Cartridge Right Guide Assembly 8-58 Phaser 4500 Service Manual...
  • Page 348 Remove the Fuser Assembly (page 8-54). Remove the Transfer Roller Assembly (page 8-55). Remove the Front Duct (page 8-44). Remove the Image Processor Shield Assembly (page 8-86). Remove the HVPS Shield Plate (page 8-88). Unplug the HV connector, J31 from P31 on the HVPS/Engine Logic Board. Unplug J15 from P15 on the HVPS/Engine Logic Board.

  • Page 349: Duplex Unit Opening Cover

    Duplex Unit Opening Cover (PL9.1.13) s4500-126 1. Duplex Unit Opening Cover 2. Latch hooks Release the latch hooks of the Duplex Unit Opening Cover, and remove it from the Paper Exit Rear Door. 8-60 Phaser 4500 Service Manual...

  • Page 350: Print Engine: Paper Exit

    Print Engine: Paper Exit Paper Exit Assembly (PL10.1.2) J103 s4500-128 1. Image Processor Shield Assembly 3. Exit Motor PWBA 2. Paper Exit Assembly Remove the Paper Exit Cover (page 8-4) or Stacker (page 8-132) if installed. Remove the Right Cover (page 8-7 Remove the Left Cover (page 8-9).
  • Page 351 Exit Assembly to the top of the printer, and the one screw (silver flanged machine, 8 mm) that attaches the Paper Exit Assembly to the left side of the printer. Remove the Paper Exit Assembly. 8-62 Phaser 4500 Service Manual...

  • Page 352: Upper Exit Chute, Lower Exit Chute

    Upper Exit Chute, Lower Exit Chute (PL10.1.4) (PL10.1.21) s4500-129 1. Stacker Gate Link 3. Lower Exit Chute 2. Upper Exit Chute Remove the Paper Exit Assembly (page 8-61). Remove the two screws (gold tapping, 8 mm) that attach the Upper Exit Chute to the Lower Exit Chute.

  • Page 353: Exit Motor Assembly

    Remove the Paper Exit Assembly (page 8-61). Remove the Upper Exit Chute (page 8-63). Remove the two screws (silver machine, 6 mm) that attach the Exit Motor Assembly to the Exit Motor Bracket. Remove the Exit Motor Assembly. 8-64 Phaser 4500 Service Manual...

  • Page 354: Stack Full Sensor

    Stack Full Sensor (PL10.1.26) P290 J290 s4500-133 1. Stack Full Sensor 2. Lower Exit Chute Remove the Paper Exit Assembly (page 8-61). Remove the Upper Exit Chute (page 8-63). Unplug J290 from P290 on the Stack Full Sensor. Release the hooks of the Stack Full Sensor, and remove the Stack Full Sensor from the Lower Exit Chute.

  • Page 355: Stack Full Actuator

    Remove the Stack Full Actuator from the Upper Exit Chute: Snap the flag end out of the retainer. Shift to the left (as shown in the drawing) to pull the shaft end from the bearing hole. 8-66 Phaser 4500 Service Manual...

  • Page 356: Print Engine: Frame And Drive

    Print Engine: Frame and Drive Motor Cover (PL11.1.1) s4500-137 1. Motor Cover FRU Disassembly 8-67...
  • Page 357 Swing the 150-Sheet Feeder roller assembly upward to lock it into its raised detent position. Remove the screw (silver machine, 6 mm) that attaches the Motor Cover to the frame. Lift the Motor Cover out of the printer as shown. 8-68 Phaser 4500 Service Manual...

  • Page 358: Main Motor

    Main Motor (PL11.1.2) s4500-138 1. Main Motor 3. LVPS 2. LVPS Shield Plate FRU Disassembly 8-69...
  • Page 359 The screws that attach the Main Motor to the frame are accessed through the cutouts at the edge of the Main Motor PWBA; they are not the screws that attach the Main Motor PWBA to the motor. Remove the Main Motor. 8-70 Phaser 4500 Service Manual...

  • Page 360: Gear Assembly Housing

    Gear Assembly Housing (PL11.1.3) s4500-139 1. Gear Assembly Housing 2. Screw (A) Remove the Left Cover (page 8-9). Remove the LVPS Shield Plate (page 8-75). Unplug J44 (Rear Cover Switch cable) from P44 on the LVPS. Release the wiring harnesses from the cable restraints on the Gear Assembly Housing.
  • Page 361 Main Motor by hand to check the engagement of the gears. Be sure that the gold 6 mm screw (called out as Screw A on the previous page) is returned to its proper hole. 8-72 Phaser 4500 Service Manual...

  • Page 362: Gear Assembly Plate

    Gear Assembly Plate (PL11.1.10) s4500-141 1. Gear 9 4. Gear 2. Gear Assembly Plate 5. Spring 3. Locking Tab FRU Disassembly 8-73...
  • Page 363 Remove Gear 9 from the shaft on the frame. Replacement Note: When installing, engage the gears of the Gear Assembly Housing, Main Motor, and Gear Assembly Plate. After assembling, rotate the Main Motor by hand to check the engagement of the gears. 8-74 Phaser 4500 Service Manual...

  • Page 364: Print Engine: Electrical

    Print Engine: Electrical LVPS Shield Plate (PL12.1.3) s4500-142 1. LVPS Shield Plate Remove the Front Cover (page 8-12). Remove the five screws (silver, 6 mm) that attach the LVPS Shield Plate to the frame. Remove the LVPS Shield Plate. FRU Disassembly 8-75...

  • Page 365: Exit Motor Pwba

    Exit Motor PWBA (PL12.1.4) s4500-143 1. Exit Motor PWBA 3. P/J 101 2. P/J 102 4. P/J 103 8-76 Phaser 4500 Service Manual...
  • Page 366 Remove the Paper Exit Rear Door (page 8-5). Remove the Rear Cover (page 8-6). Remove the Left Cover (page 8-9). Disconnect the harnesses from the connectors (P/J101, P/J102 and P/J103) on the Exit Motor PWBA. Remove the two screws (silver, 6 mm) that attach the Exit Motor PWBA to the frame.

  • Page 367: Low Voltage Power Supply (Lvps)

    Low Voltage Power Supply (LVPS) (PL12.1.5) P/J 42 4140 s4500-144 1. Exit Motor PWBA 3. P101 2. LVPS 4. P/J404 8-78 Phaser 4500 Service Manual...
  • Page 368 Remove the Front Cover (page 8-12). Remove the LVPS Shield Plate (page 8-75). Caution Do not attempt to unplug the cables from J101 or J104 on the LVPS. These are soldered connections and attempts to disconnect the wires will damage the circuit board.

  • Page 369: Dc-Dc Converter

    P402 P401 P403 s4500-262 1. DC-DC Converter Remove the Front Cover (page 8-12). Unplug the cable connectors at P401, P402, and P403. Remove the two screws (silver machine, 6 mm) and lift out the board. 8-80 Phaser 4500 Service Manual...

  • Page 370: Power Switch, Ac Power Harness Assembly

    Power Switch, AC Power Harness Assembly (PL12.1.6), (PL12.1.8) s4500-145 1. LVPS 5. Power Switch 2. P/J 48 6. AC Inlet 3. Cable tie clamp 7. Ground Wire 4. P/J 480 8. Cable Retainer Hooks FRU Disassembly 8-81...
  • Page 371 Remove the screw (silver with toothed washer, 6 mm) that attaches the ground terminal of the AC Power Harness Assembly to the frame. Pull out the AC Power Harness Assembly from the hole at the rear of the frame. Remove the Power Switch from the frame. 8-82 Phaser 4500 Service Manual...

  • Page 372: Rear Cover Switch

    Rear Cover Switch (PL12.1.7) s4500-146 1. Rear Cover Switch Removal Remove the LVPS Shield Plate (page 8-75). Disconnect the connector (P/J44) of the Rear Cover Switch from the LVPS. Release the Harness Assembly of the Rear Cover Switch from the clamps on the Gear Assembly Housing.

  • Page 373: Main Fan

    Main Fan (PL12.1.10) s4500-147 1. Main Fan 2. Label 8-84 Phaser 4500 Service Manual...
  • Page 374 Remove the Paper Exit Rear Door (page 8-5). Remove the Rear Cover (page 8-6). Disconnect the connector (P/J244) of the Main Fan from the Tray 1 Harness Assembly. Remove the two screws (tapping, 30 mm) that attach the Main Fan to the frame. Replacement Note: When installing, make sure the harness wires are not pinched between the Main Fan and the frame, and make sure the label faces the outside.

  • Page 375: Image Processor Shield Assembly

    1. Image Processor Shield Assembly Remove the Right Cover (page 8-7). Remove the twelve screws (silver, 6 mm) that attach the Image Processor Shield Assembly to the frame. Remove the Image Processor Shield Assembly. 8-86 Phaser 4500 Service Manual...

  • Page 376: I/P Shield Window

    I/P Shield Window (PL12.1.15) s4500-149 1. Shield Window Remove the Right Cover (page 8-7). Remove the two screws that secure the Shield Window to the IP Shield Assembly. Remove the Shield Window. FRU Disassembly 8-87...

  • Page 377: Hvps Shield Plate

    Remove the Right Cover (page 8-7). Remove the Image Processor Shield Assembly (page 8-86). Remove the 10 screws (silver, 6 mm) that attach the HVPS Shield Plate to the frame. Remove the HVPS Shield Plate. 8-88 Phaser 4500 Service Manual...

  • Page 378: Hvps/Engine Logic Board

    HVPS/Engine Logic Board (PL12.1.19) 1716 20 192226 24 s4500-151 1. Hook 3. HVPS Shield Bracket 2. HVPS/Engine Logic Board 4. Right Handle Bracket Remove the Right Cover (page 8-7). Remove the HVPS Shield Plate (page 8-88). FRU Disassembly 8-89...
  • Page 379 When installing the HVPS/Engine Logic Board, install the board under the hook of the frame. When tightening the screws, be careful not to pinch the harness between the board and frame. Note that connectors P19 and P32 are not used (no connection). 8-90 Phaser 4500 Service Manual...

  • Page 380: Image Processor (I/P) Board

    Image Processor (I/P) Board (PL 12.1.13) J130 J110 J800 s4500-255 1. Memory DIMMs 4. NVRAM (U660) 2. Flash Memory (Optional) 5. Rear Panel 3. Hard Disk Drive (Optional) Caution Observe electrostatic precautions when handling the I/P board and its components. Remove the Right Cover (page 8-7).
  • Page 381 USB connector to the Rear Panel Separate the Rear Panel from the I/P Board. Replacement Note: The Configuration Card, memory DIMM(s), Flash Memory (if present), NVRAM, and Hard Drive (if present) must be transferred to the replacement I/P Board. 8-92 Phaser 4500 Service Manual...

  • Page 382: Options: 550-Sheet Paper Feeder

    Options: 550-Sheet Paper Feeder 550-Sheet Paper Feeder Removal s4500-152 1. 550-Sheet Paper Feeder 2. Latch Clip FRU Disassembly 8-93...
  • Page 383 Lift and remove the printer from the optional 550-Sheet Paper Feeder, and put it aside. Replacement Note: When installing, align the holes and the bosses of the printer and optional 550-Sheet Paper Feeder, and secure using the four Latch Clips. 8-94 Phaser 4500 Service Manual...

  • Page 384: Right Cover Plate

    Right Cover Plate (PL20.1.1) s4500-153 1. Right Cover Plate 3. Boss 2. 550 Right Cover Frame FRU Disassembly 8-95...
  • Page 385 Shift the Right Cover Plate in the direction of the arrow to release the four hooks of the 550 Right Cover Frame, and remove the Right Cover Plate from the optional 550-Sheet Paper Feeder. Replacement Note: When re-installing the Right Cover Plate, ensure all four hooks are properly engaged. 8-96 Phaser 4500 Service Manual...

  • Page 386: Left Cover Plate

    Left Cover Plate (PL20.1.3) s4500-154 1. Grounding Plate 3. 550 Left Cover Frame 2. Left Cover Plate FRU Disassembly 8-97...
  • Page 387 When installing the Grounding Plate, be sure to install the tip of the Grounding Plate under the Left Cover Plate. Ensure all four hooks on the Left Cover Plate are properly engaged by pressing down on each while sliding it toward the front. 8-98 Phaser 4500 Service Manual...

  • Page 388: Option Paper Size Switch Assembly

    Option Paper Size Switch Assembly (PL20.1.18) P/J802 1. Hooks 3. Bosses 2. Option Paper Size Switch Assembly Release the Feeder Size 1 Assembly Harness from the hooks of the 550 Left Cover Frame. Remove the two screws (gold tapping, 8 mm) that attach the Option Paper Size Switch Assembly to the 550 Left Cover Frame.

  • Page 389: Optional Feeder Drive Assembly

    Optional Feeder Drive Assembly (PL20.1.8) J820 s4500-156 1. Optional Feeder Drive Assembly 2. Screw A Remove the optional 550-Sheet Paper Feeder (page 8-93). Remove the Left Cover Plate (page 8-97). 8-100 Phaser 4500 Service Manual...
  • Page 390 Remove the Rear Cover (steps 1 and 2 in “550-Sheet Feeder” on page 8-104). Disconnect the Feeder Motor Harness (J820) from P820 (located at the rear of the 550-Sheet Feeder Assembly). Remove the three screws at the left end of the 550-Sheet Feeder (page 8-104). Remove the three screws (two gold tapping, 8 mm;...

  • Page 391: 550-Sheet Feeder Pwba

    550-Sheet Feeder PWBA (PL20.1.34) P/J82 s4500-159 1. 550-Sheet Feeder PWBA 2. Boss 8-102 Phaser 4500 Service Manual...
  • Page 392 Remove the Right Cover Plate (page 8-95). Disconnect the harness connectors from the connectors (P/J80, P/J81, P/J82, P/J83, P/J84 and P/J85) on the 550-Sheet Feeder PWBA. Remove the two screws (gold tapping, 8 mm) that attach the 550-Sheet Feeder PWBA to the frame. Remove the 550-Sheet Feeder PWBA.

  • Page 393: 550-Sheet Feeder

    550-Sheet Feeder (PL20.2.1) s4500-160 1. Feeder Rear Cover 3. Lower Chute 2. Optional 550-Sheet Feeder 4. Harness Clamps 8-104 Phaser 4500 Service Manual...
  • Page 394 Remove the five screws (gold tapping, 8 mm) that attach the Feeder Rear Cover to the frame. Remove the Feeder Rear Cover. Note The three connectors in the following step have gender adapters that could stay with either side of the harness. Disconnect the three wiring harness connectors (P/J801, P/J820, and P/J855) exposed behind the Rear Cover.

  • Page 395: Nudger Roller, Feed Roller

    Shaft. Release the hook that retains the Feed Roller and pull the roller off the Feed Shaft. Replacement Note: The same roller (same part number) is used for the Feed Roller and Nudger Roller Assemblies. 8-106 Phaser 4500 Service Manual...

  • Page 396: Nudger One-Way Clutch

    Nudger One-way Clutch (PL20.2.15) s4500-162 1. Nudger One-way Clutch 3. Feed Roller 2. One-way Feed clutch Remove the Feed Roller (page 8-106). Pull out the One-way Feed Clutch from the Feed Shaft. Remove the E-ring that secures the Nudger One-way Clutch to the Feed Shaft. Pull out the Nudger One-way Clutch from the Feed Shaft.

  • Page 397: Nudger Gear

    Nudger Gear (PL20.2.10) s4500-163 1. Nudger Gear 5. Boss (Lift Up) 2. Nudger Roller 6. Left Holder 3. Nudger Support 7. Hooks 4. No Paper Actuator 8-108 Phaser 4500 Service Manual...
  • Page 398 Note When handling the Nudger Roller or Nudger Gear, avoid touching the rubber surfaces of the rollers. Remove the optional 550-Sheet Paper Feeder (page 8-93). Note The following steps are more easily performed by turning the 550-Sheet Paper Feeder upside-down. While lifting up the boss of the Left Holder at the back of the optional 550-Sheet Paper Feeder, shift the Left Holder in the direction of the arrow to remove the 3 hooks.

  • Page 399: Feed Clutch Assembly

    (PL20.2.21) s4500-165 1. Out Chute 3. Tie Plate 2. Feed Clutch Assembly 4. Connector Remove the optional 550-Sheet Paper Feeder (page 8-93). Remove the six screws (gold taping, 8 mm) that attach the Tie Plate. 8-110 Phaser 4500 Service Manual...
  • Page 400 Remove the Tie Plate from the Out Chute. Note The connector in the following step has a gender adapter that could stay with either side of the harness. Disconnect the connector (P/J853) of the Feed Clutch Assembly from the Clutch Sensor 1 Assembly Harness.

  • Page 401: Turn Roller Clutch

    Disconnect the connector (P/J854) of the Turn Roller Clutch from the Clutch Sensor 1 Assembly Harness. Remove the E-ring that secures the Turn Roller Clutch, and remove the Turn Roller Clutch from the Turn Roller. 8-112 Phaser 4500 Service Manual...

  • Page 402: Retard Roller

    Retard Roller (PL20.3.2) s4500-168 1. Retard Roller 3. Hooks 2. Friction Clutch 4. Retard Spring FRU Disassembly 8-113...
  • Page 403 550-Sheet Paper Cassette. Note After installing, make sure the Retard Holder comes back to the former position with the spring force of the Retard Spring. Install the 550-Sheet Paper Cassette to the optional 550-Sheet Paper Feeder. 8-114 Phaser 4500 Service Manual...

  • Page 404: Options: Duplex Unit

    Options: Duplex Unit Duplex Unit Removal (PL 21.1) s4500-184 1. Thumbscrew 3. Bottom Hook 2. Right Latch Lever 4. Duplex Unit FRU Disassembly 8-115...
  • Page 405 Push up the Right Latch Lever to release the Duplex Unit from the printer. Tilt the Duplex Unit back, then lift away from the printer. Replacement Note: When installing, be sure to insert the bottom hooks of the Duplex Unit into the holes of the printer. 8-116 Phaser 4500 Service Manual...

  • Page 406: Left Cover

    Left Cover (PL21.1.25) s4500-193 1. Duplex Unit Housing Cover 2. Left Cover Remove the three screws (gold tapping, 8 mm) that attach the Left Cover. Remove the Left Cover from the Duplex Unit Housing Cover. FRU Disassembly 8-117...

  • Page 407: Right Cover

    Right Cover (PL21.1.41) s4500-194 1. Right Cover 2. Duplex Unit Housing Cover Remove the two screws (gold tapping, 8 mm) that attach the Right Cover. Remove the Right Cover from the Duplex Unit Housing Cover. 8-118 Phaser 4500 Service Manual...

  • Page 408: Top Cover

    Top Cover (PL21.1.12) s4500-188 1. Top Cover 2. Duplex Unit Housing Cover Remove the Right Cover (page 8-118). Remove the screw (gold tapping, 8 mm) that attaches the Top Cover to the Duplex Unit Housing Cover. Shift the Top Cover in the direction of the arrow to release the four hooks, and remove the Top Cover from the Duplex Unit Housing Cover.

  • Page 409: Upper Assembly Housing

    1. Upper Assembly Housing 2. Duplex Unit Housing Cover Remove the four screws (gold tapping, 8 mm) that attach the Upper Assembly Housing to the Duplex Unit. Remove the Upper Assembly Housing from the Duplex Unit Housing Cover. 8-120 Phaser 4500 Service Manual...

  • Page 410: Duplex Unit Lower Housing

    Duplex Unit Lower Housing (PL21.1.6) s4500-186 1. Duplex Unit Harness 5. Hinge Screw 2. Duplex Unit Ground Wire 6. Damper Spring 3. Duplex Unit PWBA 7. Duplex Unit Lower Housing 4. Shoulder Screw 8. Duplex Unit Housing Cover FRU Disassembly 8-121...
  • Page 411 Release the Duplex Unit Harness from the harness clamp. Remove the Shoulder Screw that attaches the Damper Spring. Remove the two Hinge Screws that secure the Duplex Unit Lower Housing, and remove the Duplex Unit Lower Housing from the Duplex Unit Housing Cover. 8-122 Phaser 4500 Service Manual...

  • Page 412: Duplex Unit Pwba

    Duplex Unit PWBA (PL21.1.32) s4500-189 1. Duplex Unit PWBA 3. Duplex Unit Housing cover. 2. Cable Retainer Slot Remove the Left Cover (page 8-117). Remove the Right Cover (page 8-118). Remove the Top Cover (page 8-119). Unplug the harness connectors from P50, P51, P52, P53 and P54) on the Duplex Unit PWBA.

  • Page 413: Duplex Unit Fan

    Duplex Unit Fan (PL21.1.33) s4500-190 1. Duplex Unit PWBA 3. Duplex Unit Fan 2. Duplex Unit Housing Cover 4. Label 8-124 Phaser 4500 Service Manual...
  • Page 414 Remove the Right Cover (page 8-118). Remove the Top Cover (page 8-119). Unplug the fan cable connector, J54, from P54) on the Duplex Unit PWBA. Release the fan cable from the hook on the Duplex Unit Housing Cover. Remove the two screws (gold tapping, 22 mm) that attach the Duplex Unit Fan to the Duplex Unit Housing Cover.

  • Page 415: Duplex Unit Sensor

    Remove the Top Cover (page 8-119). Release the hooks of the Duplex Unit Sensor, and remove it from the Duplex Unit Housing Cover. Disconnect the connector (P/J530) of the Duplex Unit Assembly Harness SNR form the Duplex Unit Sensor. 8-126 Phaser 4500 Service Manual...

  • Page 416: Duplex Unit Roller

    Duplex Unit Roller (PL21.1.17) s4500-192 1. Shoulder Screw (tapping) 5. Roller Gear 2. Damper Cover 6. Duplex Unit Rollers 3. Damper Spring 7. Duplex Unit Housing Cover 4. Duplex Unit Bearings Remove the Left Cover (page 8-117). Remove the Right Cover (page 8-118). Remove the Top Cover (page 8-119).
  • Page 417 Release the hooks of three Duplex Unit Bearings on the other side of the Roller Gear from the inside, and remove three Duplex Unit Bearings from the Duplex Unit Housing Cover. Remove three Duplex Unit Rollers by moving them in the direction of the arrow. 8-128 Phaser 4500 Service Manual...

  • Page 418: Duplex Unit Motor

    Duplex Unit Motor (PL21.1.29) s4500-195 1. Duplex Unit Motor 4. Latch Spring 2. Ground wire 5. Duplex Unit Housing Cover 3. Motor Bracket FRU Disassembly 8-129...
  • Page 419 When removing the Motor Bracket, be careful not to lose the gears attached to the Duplex Unit Housing Cover. Remove the two screws (silver, 6 mm) that attach the Duplex Unit Motor to the Motor Bracket. Remove the Duplex Unit Motor. 8-130 Phaser 4500 Service Manual...

  • Page 420: Duplex Unit Switch

    Duplex Unit Switch (PL21.1.27) s4500-196 1. Duplex Unit Cover Harness 4. Motor Bracket 2. Duplex Unit Switch 5. Latch Spring 3. Duplex Unit Ground Wire 6. Duplex Unit Housing Cover Remove the Left Cover (page 8-117). Remove the Top Cover (page 8-119). Remove the Duplex Unit Motor bracket as described in the Duplex Unit Motor procedure (page 8-129).

  • Page 421: Options: Stacker

    3. Hook 2. Stacker Loosen the two thumb screws that secure the Stacker to the printer. Tilt the Stacker forward to release connector P/J3070 and the front hooks, then lift the Stacker off the printer. 8-132 Phaser 4500 Service Manual...

  • Page 422: Stacker Rear Cover

    Stacker Rear Cover (PL23.1.4) s4500-199 1. Rear Cover 2. Boss Open the rear cover about 1in. (2cm). While pressing the door either to the left or right, lift the opposite end upward to clear the boss from the hinge in the Stacker Cover. FRU Disassembly 8-133...

  • Page 423: Stacker Cover

    Stacker Cover (PL23.1.1) s4500-201 1. Stacker Cover 8-134 Phaser 4500 Service Manual...
  • Page 424 s4500-202 1. Weight 4. Link 2. Left Flapper 5. Stack Full Shaft 3. Hinge 6. Stack Full Actuator Removal Remove the Stacker Rear Cover (page 8-133). Remove the Weight. Disengage both Left Flapper hinges from the Stacker Cover. Disengage the Link attached to the Left Flapper from the Stack Full Shaft. Disengage both Right Flapper hinges from the Stacker Cover.
  • Page 425 Install the Right Flapper in a similar manner. Install the Weight. Install the Stacker Rear Cover (page 8-133). Note After installation, manually move the Left Flapper and verify that the Stack Full Actuator moves together with the Left Flapper. 8-136 Phaser 4500 Service Manual...

  • Page 426: Stacker Front Cover

    Stacker Front Cover (PL23.1.45) s4500-204 1. Front Cover 2. Cam Gear Remove the Stacker Rear Cover (page 8-133). Remove the Stacker Cover (page 8-134). Remove the three screws (gold tapping, 8 mm) that attach the Stacker Front Cover to the Stacker. Release the hooks on both sides of the Stacker Front Cover, and remove the Stacker Front Cover.

  • Page 427: Stacker Tray Assembly

    Remove the Stacker Rear Cover (page 8-133). Remove the Stacker Cover (page 8-134). Remove the four screws (gold tapping, 8 mm) that attach the Stacker Tray Assembly to the Stacker Cover, and remove the Stacker Tray Assembly from the Stacker Cover. 8-138 Phaser 4500 Service Manual...

  • Page 428: Stack Full Actuator

    Stack Full Actuator (PL23.1.15) s4500-206 1. Flap 3. Hook 2. Stack Full Actuator FRU Disassembly 8-139...
  • Page 429 Move the Stack Full Actuator in the opposite direction of the arrow (2) to install. Note When installing the Stack Full Actuator to the Stacker, engage the actuator with the Stack Full Shaft as shown in the figure. 8-140 Phaser 4500 Service Manual...
  • Page 430 Install the Stacker Cover (page 8-134). Install the Stacker Rear Cover (page 8-133). Note After installation, manually move the Left Flapper and verify that the Stack Full Actuator moves together with the Left Flapper. FRU Disassembly 8-141...

  • Page 431: Stacker Pwba

    Stacker PWBA (PL23.1.22) s4500-208 1. Stacker PWBA 3. Guide Slots 2. Stacker Right Support 8-142 Phaser 4500 Service Manual...
  • Page 432 Remove the Stacker Rear Cover (page 8-133). Remove the Stacker Cover (page 8-134). Remove the Stacker Front Cover (page 8-137). Unplug the harness connectors at P70, P71, P72, P73, P74 and P75 on the Stacker PWBA. Remove the two screws (gold tapping, 8 mm) that attach the Right Stacker Support to the Stacker Housing.

  • Page 433: Offset Motor Assembly

    Remove the Stacker Front Cover (page 8-137). Remove the Stacker PWBA (page 8-142). Remove the two screws (gold tapping, 8 mm) that attach the Offset Motor Assembly to the Stacker. Remove the Offset Motor Assembly. 8-144 Phaser 4500 Service Manual...

  • Page 434: Gate Solenoid Assembly

    Gate Solenoid Assembly (PL23.1.27) s4500-210 1. Gate Solenoid 3. Stacker Housing 2. Hook Remove the Stacker Rear Cover (page 8-133). Remove the Stacker Cover (page 8-134). Remove the Stacker Front Cover (page 8-137). Remove the Stacker PWBA (page 8-142). Remove the Offset Motor Assembly (page 8-144). Remove the two screws (silver with washer, 6 mm) that attach the Gate Solenoid Assembly to the Stacker.

  • Page 435: Stacker Sensor And Actuator

    Stacker Sensor and Actuator (PL23.1.30) J730 s4500-211 1. Stacker Actuator 4. Stacker Housing 2. Pivot Hooks 5. Actuator Spring 3. Stacker Sensor 8-146 Phaser 4500 Service Manual...
  • Page 436 Remove the Stacker Rear Cover (page 8-133). Remove the Stacker Cover (page 8-134). Remove the Stacker Front Cover (page 8-137). Shift the Stacker Actuator in the direction of the arrows to release the pivots from the hooks on both sides. Note Carefully observe the orientation of the actuator spring for reference when reassembling.

  • Page 437: Stacker Rear Cover Interlock Switch

    Remove the Stacker Rear Cover (page 8-133). Remove the Stacker Cover (page 8-134). Disconnect the wire harness from the Interlock Switch. Compress the hooks on the top and bottom of the switch and slide it out of the housing. 8-148 Phaser 4500 Service Manual...

  • Page 438: Lower Stacker Roller

    Lower Stacker Roller (PL23.1.16) s4500-214 1. Stacker Left Support 5. Gear 19 2. Stacker Motor Bracket 6. Roller Bearing 3. Gear 45 7. Lower Stacker Roller 4. Gear 19/37 8. Stacker Housing FRU Disassembly 8-149...
  • Page 439 Shift the Lower Stacker Roller in the direction of the arrow to remove. Replacement Note: When installing Gears 19 and 19/37, be sure the gears are correctly oriented on their shafts. 8-150 Phaser 4500 Service Manual...
  • Page 440 Upper Stacker Roller (PL23.1.36) s4500-215 1. Offset Chute 6. Gear 19/37 2. Stacker Housing 7. Gear 19 3. Offset Bearing 8. Left Stacker Support 4. Hook 9. Stacker Motor Bracket 5. Gear 45 FRU Disassembly 8-151...
  • Page 441 Remove the Offset Bearing from the Stacker Housing. Remove the Offset Chute Assembly by raising the free end high enough to clear the chassis while sliding in the direction of the arrow. (continues on the next page) 8-152 Phaser 4500 Service Manual...

  • Page 442: Upper Stacker Roller

    s4500-216 1. Upper Stacker Roller 3. Offset Chute Assembly 2. Roller Bearing Release the hook of the Roller Bearing at the end of the roller with the flatted shaft, rotate the bearing 90 degrees CW, and remove the bearing. Remove the Upper Stacker Roller from the Offset Chute Assembly. Replacement Note: When installing Gears 19 and 19/37, make sure the gears are correctly oriented on their shafts.

  • Page 443: Stacker Motor Assembly

    Remove the Stacker Front Cover (page 8-137). Disconnect the connector of the Stacker Motor Assembly from the Stacker Motor Harness Assembly. Remove the two screws (silver machine, 8 mm) that attach the Stacker Motor Assembly, and remove the Stacker Motor Assembly. 8-154 Phaser 4500 Service Manual...

  • Page 444: Parts Lists

    Parts Lists In this chapter... Serial Number Format Using the Parts List Print Engine Parts Options Xerox Supplies and Accessories Chapter...

  • Page 445: Serial Number Format

    Serial Number Format Changes to Xerox products are made to accommodate improved components as they become available. It is important when ordering parts to include the following information: Component's part number Product type or model number Serial number of the printer The serial number is found on a label located on the frame of the printer just inside the Tray 2 opening.

  • Page 446: Using The Parts List

    Using the Parts List No.: The callout number from the exploded part diagram. Name/Description: The name of the part to be ordered and the number of parts supplied per order. Part Number: The material part number used to order that specific part. Parts identified throughout this manual are referenced PL#.#.#;...

  • Page 447: Print Engine Parts

    Print Engine Parts Parts List 1.1 Covers [Ref PL10.1] s4500-218 JG5014AA Phaser 4500 Service Manual...
  • Page 448 FRU Parts List 1.1 Covers Name/Description Part Number OPERATION PANEL (Front Panel) 802K60111 COVER OPEN (Top Cover) 802E47284 COVER REAR 604K16460 COVER RIGHT 802E49522 COVER FRONT 802E63801 COVER LEFT 802E49491 COVER TOP ASSY COVER STOPPER 802E61862 STOPPER OPEN HARNESS ASSY PANEL 962K22731 SWITCH I/L ASSY (J144, J411) 110K11894...

  • Page 449: Parts List 2.1 150-Sheet Paper Cassette

    Parts List 2.1 150-Sheet Paper Cassette 50 (with 1-13,15-39) 51 (with 2-5) 21 22 26 25 S4500-219 JG5002AA Phaser 4500 Service Manual...
  • Page 450 FRU Parts List 2.1 150-Sheet Paper Cassette Name/Description Part Number COVER CST 802E47191 ROLL ASSY RETARD (p/o Item 99) FRICTION CLUTCH SHAFT RETARD HOLDER RETARD SPRING RETARD 809E37500 GEAR PB L GEAR BTM ONEWAY SHAFT PB PLATE ASSY BTM (with 14) GUIDE ASSY SD L150 GEAR PINION GUIDE ASSY SD R150...
  • Page 451 HOUSING EXTENSION 150 GUIDE END 150 HOUSING BASE 150 LINK SW SIZE1-150 LINK SW SIZE2-150 LINK SW SIZE3-150 150 PAPER CASSETTE (with 1-13, 15-39) 084K15350 HOLDER ASSY RETARD (with 2-5) 019K98186 Roller Kit (Item 2, Qty. 3) 604K11192 Phaser 4500 Service Manual...

  • Page 452: Parts List 4.1 550-Sheet Paper Cassette

    Parts List 4.1 550-Sheet Paper Cassette 50 (with 1-13,15-32,34-48,52,53) 51 (with 2-5) 27 26 s4500-220 JG5004AB Parts Lists...
  • Page 453 RACK BTM LOCK 550 COVER BTM UP 550 GEAR LOCK PINION SPRING BTM LOCK GEAR BTM LOCK GEAR LEVER LOCK LEVER BTM LOCK SPRING STOPPER GEAR STOPPER GEAR PLATE SUPPORT COVER EXTENSION SUPPORT GUIDE IND GUIDE INDICATOR 1 9-10 Phaser 4500 Service Manual...
  • Page 454 FRU Parts List 4.1 550-Sheet Paper Cassette (Continued) Name/Description Part Number GUIDE INDICATOR 2 GUIDE INDICATOR 3 LOW INDICATOR LOW IND FRONT GEAR SECTOR RACK SIZE HANDLE EXTENSION 550 HOUSING EXTENSION 550 GUIDE END 550 HOUSING BASE 550 LINK SW SIZE1-550 LINK SW SIZE2-550 LINK SW SIZE3-550 LINK SW SIZE LOW...

  • Page 455: Parts List 5.1 150-Sheet Paper Feeder

    Parts List 5.1 150-Sheet Paper Feeder 1 (with 4-12,14-23,25-35, 37-44,46-51) 2 (with 4-10,12,14-20,22,25-28 31-35,40-42,46-50) 3 (Reference Only) 18 17 45 (with 46-50) 16 15 33 32 51 32 27 26 s4500-221 JG5019AA 9-12 Phaser 4500 Service Manual...
  • Page 456 FRU Parts List 5.1 150-Sheet Paper Feeder Name/Description Part Number 150 FEEDER ASSY (with 4-12, 14-23, 25-35, 37-44, 46-51) 604K16682 FDR1 AS SUB 150 A4 (with 4-10, 12, 14-20, 22, 25-28, 31-35, 40-42, 46-50) CHUTE ASSY FDR 1 (Reference Only) (with 4-10,14-20,40-42) SUPPORT NUDGER HOLDER LEFT ACTUATOR NO PAPER...
  • Page 457 SPRING TONER (part of item 46) SPRING (part of item 46) HARNESS ASSY TONER 1 (J220-P221) GEAR REGI METAL (WHITE) Roller Kit (with 11 or 44, Qty. 3) 604K11192 KIT CHUTE REGI (with 25-28) KIT CHUTE BTM (with 14-19) 9-14 Phaser 4500 Service Manual...

  • Page 458: Parts List 7.1 550-Sheet Paper Feeder

    Parts List 7.1 550-Sheet Paper Feeder 10 (with 12-20,22-31,33-39) 7 (with 8,9) s4500-222 JG5015AA Parts Lists 9-15...
  • Page 459 CHUTE BTM CHUTE TOP ASSY SHAFT FEED CLUTCH ONEWAY NUDGER 005E16951 CLUTCH ONEWAY FEED 005E16941 ROLL ASSY FEED (Part of item 99) HOLDER PIVOT LEFT EARTH PLATE CHUTE 550 LOWER CHUTE OUT HOLDER PIVOT RIGHT 9-16 Phaser 4500 Service Manual...
  • Page 460 FRU Parts List 7.1 550-Sheet Paper Feeder (Continued) Name/Description Part Number PLATE TIE HARNESS ASSY TRAY2 (J248-J246, P247) COVER HARNESS R SENSOR NO PAPER (P246) 130E81970* CLAMP-10V0 STOPPER TRAY R STOPPER TRAY L FEED ROLLER KIT (with 19 or 29, qty. 3) 604K11192 Parts Lists 9-17...

  • Page 461: Parts List 8.1 Xerographics

    Parts List 8.1 Xerographics PRINT CARTRIDGE * (with 7-15) 10 11 25 (with 23,24) s4500-223 JG5016AB 9-18 Phaser 4500 Service Manual...
  • Page 462 FRU Parts List 8.1 Xerographics No. Name/Description Part Number ROS ASSY (Laser Unit) (J131,J140,J160,J170) 084K13151 HARNESS ASSY ROS (J13, J14, J16, J17-P131, P140, P141, P160, P170) SHIELD PLATE ROS DUCT FRONT FAN SUB (J270) 127K39390 GUIDE ASSY CRU L (with 7-15) 032K97110 GUIDE SL (part of item 6) SPACER SS (part of item 6)

  • Page 463: Parts List 10.1 Paper Exit (1/2)

    Parts List 10.1 Paper Exit (1/2) 2 (with 4-7, 10-13, 15-24, 26-28, 30) 30 23 22 22 S4500-224 JG5017AB 9-20 Phaser 4500 Service Manual...
  • Page 464 FRU Parts List 10.1 Paper Exit (1/2) Name/Description Part Number COVER EXIT 500 604K16590 500 EXIT ASSY (with 4-7, 10-13, 15-24, 26-28, 30) 084K18470 CHUTE UP EXIT ELIMINATOR EXIT EARTH PLATE EXIT LINK GATE OCT (Stacker Gate Link) ACTUATOR FULL STACK 604K15560 BEARING EXIT ROLL EXIT...

  • Page 465: Parts List 10.2 Paper Exit (2/2)

    Parts List 10.2 Paper Exit (2/2) s4500-225 JG5702AB 9-22 Phaser 4500 Service Manual...
  • Page 466 FRU Parts List 10.2 Paper Exit (2/2) Name/Description Part Number CHUTE UP FU GATE FU CHUTE LOW FU LEVER LATCH LEFT PIPE LATCH LEFT SPRING LATCH FU LEVER LATCH RIGHT LEVER GATE HOLDER EARTH PLATE FU COVER REAR 500 COVER DUP 802E48402 STOPPER FSR COVER REAR 500 (with 2-22)

  • Page 467: Parts List 11.1 Frame And Drive

    Parts List 11.1 Frame and Drive s4500-226 JG5020AA 9-24 Phaser 4500 Service Manual...
  • Page 468 PL11.1 Frame and Drive Name/Description Part Number MOTOR COVER MAIN MOTOR (J43) 127K36822 GEAR ASSY HOUSING (with 4) 604K16670 SPRING RELEASE (part of item 3) CLAMP EDGE CLAMP-5 V0 CLAMP-10V0 CLAMP-EDGE GEAR 9 807E02560 GEAR ASSY PLATE 007K87753 FOOT 550 GUIDE HARNESS R CLAMP-RWSH Parts Lists...

  • Page 469: Parts List 12.1 Electrical

    Parts List 12.1 Electrical s4500-227 JG5018AA 9-26 Phaser 4500 Service Manual...
  • Page 470 PL12.1 Electrical Name/Description Part Number HARNESS ASSY LVPS (J10, J11, J18, J27, CNPOW, J141-J42, J41, J1821, P270, J102, P2750, J40, P142, P144, J411, J400) PLATE TIE FRONT SHIELD PLATE LVPS PWBA EXIT MOTOR 160K91991 LVPS 110 V 105K20392 LVPS 220 V 105K20401 POWER SWITCH 110K11570...
  • Page 471 64 MB RAM DIMM 156-4838-00 128 MB RAM DIMM 156-4837-00 256 MB RAM DIMM 156-4663-00 FLASH DIMM 671-5325-0A HARD DRIVE ASSY 650-4309-00 CONFIG CARD B TO N 163-1505-00 CONFIG CARD BASE 163-1513-00 NVRAM DEVICE 163-1459-00 9-28 Phaser 4500 Service Manual...

  • Page 472: Options

    Options Parts List 20.1 550-Sheet Paper Feeder (1/2) 29 (with 30-33) 8 (with 9-17) [Ref PL20.2.1] s4500-228 JG5501AB Parts Lists 9-29...
  • Page 473 HARNESS ASSY FDR5 (J84-PD8483) (Feeder Harness 5) PLATE CST LOCK FRAME CVR R550 HLD LOW PAPER ASSY (P810) (with 30-33) 019K98503 SENSOR LOW PAPER (P810) ACTUATOR LOW PAPER HOLDER LOW PAPER HARNESS LOW PAPER (J81-J810) 9-30 Phaser 4500 Service Manual...
  • Page 474 Parts List 20.1 550-Sheet Paper Feeder (1/2) (Continued) Name/Description Part Number PWBA FEEDER 550 160K86723 HARNESS ASSY SIZE FDR2 (J80-J801) HARNESS ASSY CLSNR2 (J85-P855) HARNESS ASSY FDR MOT (J82-P820) JOINT FEEDER 113E36900 LOCK CST L 003E59231 HARNESS ASSYSIZE FDR3 (J802-J800) STOPPER TRAY L STOPPER TRAY R 550 DECK ASSY (ENTIRE)

  • Page 475: Parts List 20.2 550-Sheet Paper Feeder (2/2)

    Parts List 20.2 550-Sheet Paper Feeder (2/2) 1 (with 4-23,25-34) 12 13 32 33 s4500-229 JG5502AA 9-32 Phaser 4500 Service Manual...
  • Page 476 Parts List 20.2 550-Sheet Paper Feeder (2/2) Name/Description Part Number 550 FEEDER OPTION (with 4-23, 25-34) 022K66124 SUPPORT NUDGER HOLDER LEFT ACTUATOR NO PAPER GEAR IDLER NUDGER HOLDER RIGHT SHAFT NUDGER GEAR NUDGER 059K25270 ROLL ASSY NUDGER (part of 99) ROLL ASSY FEED (part of 99) CLUTCH ONEWAY FEED 005E16941...

  • Page 477: Parts List 20.3 Optional 550-Sheet Paper Cassette

    Parts List 20.3 Optional 550-Sheet Paper Cassette 50 (with 1-13,15-32,34-48,52,53) 51 (with 2-5) 27 26 s4500-220 JG5004AB 9-34 Phaser 4500 Service Manual...
  • Page 478 Parts List 20.3 Optional 550-Sheet Paper Cassette Name/Description Part Number COVER CST 802E47191 ROLL ASSY RETARD (part of 99) FRICTION CLUTCH SHAFT RETARD HOLDER RETARD SPRING RETARD 809E37500 GEAR PB L GEAR BTM ONEWAY SHAFT PB PLATE ASSY BTM GUIDE ASSY SD L550 GEAR PINION GUIDE ASSY SD R550 GEAR LOCK ONEWAY...
  • Page 479 LINK SW SIZE3-550 LINK SW SIZE LOW 550 PAPER CASSETTE (with 1-13, 15-32, 34-48, 51-53) 084K15411 HLDER ASSY RETARD (with 2-5) 019K98186 STOPPER BASE R STOPPER BASE L Roller Kit (with 2, qty. 3) 604K11192 9-36 Phaser 4500 Service Manual...

  • Page 480: Parts List 21.1 Duplex Unit

    Parts List 21.1 Duplex Unit 1 (with 2-4) 19 20 s4500-231 JG5602AB Parts Lists 9-37...
  • Page 481 GEAR IDLE77 GEAR IDLE57/37 COVER LEFT BRACKET MOTOR SWITCH DUPLEX (P520) 110E10200 HARNESS ASSY DUP EARTH (J56-JD560) MOTOR DUPLEX (J51) 127E83201 CLAMP EDGE HARNESS ASSY DUP COVER (J52-J520) PWBA DUPLEX 160K86756 FAN DUPLEX (J54) 127E83210 9-38 Phaser 4500 Service Manual...
  • Page 482 Parts List 21.1 Duplex Unit (Continued) Name/Description Part Number SENSOR DUP (P530) 130E82740 HARNESS ASSY DUP SNR (J53-J530) SPRING ACTUATOR 809E50961 ACTUATOR DUP 604K16750 COVER DAMPER SPRING DAMPER SCREW TAPPING COVER RIGHT SPRING Frame Ground DUP DUPLEX ASSY (ENTIRE UNIT) 084K18292 Parts Lists 9-39...

  • Page 483: Parts List 23.1 Stacker

    Parts List 23.1 Stacker 11 12 11 13 (with 41-44, 35 (with 13,36-39) s4500-232 JG5801AB 9-40 Phaser 4500 Service Manual...
  • Page 484 Parts List 23.1 Stacker Name/Description Part Number COVER OCT (with 3) (Stacker Cover) WEIGHT 036E91551 ELIMINATOR ASSY COVER REAR SCREW THUMB MOTOR ASSY OCT (J71) (Stacker Motor Assembly) 127K36291 GEAR 45 007E74830 GEAR 19/37 007E74840 BRACKET MOTOR OCT (Stacker Motor Bracket) SUPPORT OCT LEFT (Left Stacker Support) GEAR 19 007E74821...
  • Page 485 HARNESS ASSY OCT MOT (J71-P710) (Stacker Motor Harness) LINK SHAFT FULL STACK 006E79380 FLAPPER ASSY L (with 47) 036K91582 FLAPPER ASSY R (with 47) 036K91592 SPRING DAMPER ASSY TRAY L 004K02070 STOPPER DAMPER ASSY TRAY R 004K02080 STACKER ASSY (ENTIRE UNIT) 084K18114 9-42 Phaser 4500 Service Manual...

  • Page 486: Xerox Supplies And Accessories

    Xerox Supplies and Accessories Repair Kits, World Kits and Repacking Kits Description Part Number World Kit 061-4495-00 Phaser 4500 Getting Started Pack 061-4496-00 Setup Guide (Poster) 001-1552-00 QRG (E,FIGS,BP) 001-1549-00 QRG (E, DU, SV, DA, FI, NO) 001-1550-00 QRG (E, PO, HU, RU, CZ, EL)
  • Page 487 B TO N Upgrade Option 097S03146 Consumables Description Part Number Standard-Capacity Print Cartridge (10K) 113R00656 High-Capacity Print Cartridge (18K) 113R00657 Routine Maintenance Items Description Part Number Maintenance Kit, 110 V 108R00600 Maintenance Kit, 220 V 108R00601 9-44 Phaser 4500 Service Manual...
  • Page 488 A4 210 x 297 mm 3R91720 Xerox Business Paper A4 210 x 297 mm 3R91820 Xerox Cover and Index Stock Xerox Premium Multipurpose 4024, Cover Stock Letter 8.5 x 11 in. 3R3041 Xerox Premium Multipurpose 4024, Index Stock Letter 8.5 x 11 in. 3R3004...
  • Page 489 Xerox Printing Media (Continued) Part Description Size Number Xerox Pre-Punched Paper Xerox Premium Multipurpose 4024 - 3Hole Letter 8.5 x 11 in. 3R2193 Xerox Premium Multipurpose 4024 - 3Hole Letter 8.5 x 11 in. 3R3317 Xerox Business Paper - 4Hole...

  • Page 490: Wiring Diagrams

    Wiring Diagrams In this chapter... Print Engine Plug/Jack Locator 550-Sheet Feeder Plug/Jack Locator Duplex Unit Plug/Jack Locator Stacker Plug/Jack Locator Notations Used in Wiring Diagrams Print Engine Wiring Diagrams Optional 550-Sheet Feeder Duplex Unit Stacker Chapter...

  • Page 491: Introduction

    The Print Engine P/J Locator diagrams show the print engine in four views. The first two views depict the front and right sides of the printer, while the last two views cover the rear and left sides of the printer. 10-2 Phaser 4500 Service Manual...

  • Page 492: Print Engine Plug/Jack Locator

    Print Engine Plug/Jack Locator P/J Locator Table P/J Coordinates Remarks G-108 Connects the LVPS Harness Assembly and HVPS/Engine Logic Board G-108 Connects the LVPS Harness Assembly and HVPS/Engine Logic Board G-109 Connects the Laser Unit Harness and HVPS/Engine Logic Board G-109 Connects the Laser Unit Harness and HVPS/Engine Logic Board G-109...
  • Page 493 Connects 24 V from the LVPS to the DC-DC Converter at P403 J-106 Connects the Top Cover Switch and LVPS Harness V-124 Connects the AC Harness to the Power Switch H-109 Connects the I/P Board to the HVPS/Engine Logic Board 10-4 Phaser 4500 Service Manual...
  • Page 494 P/J Coordinates Remarks E-107 Connects the Front Panel and Front Panel Harness Assembly I-109 Plug on the I/P Board for the Hard Drive. 1821 B-108 Connects the Left Tray Guide Assembly and LVPS Harness Assembly 2083 G-110 Connects the Feeder Harness 1 and Feeder Harness 2 2750 R-124 Connects the LVPS Harness Assembly and Duplex Unit Assembly...
  • Page 495 P/J Locator Diagrams 1821 s4500-233 Printer Front 10-6 Phaser 4500 Service Manual...
  • Page 496 J310 2083 s4500-252 Printer Right Side Wiring Diagrams 10-7...
  • Page 497 4647 3070 260 241 2750 s4500-234 Printer Rear 10-8 Phaser 4500 Service Manual...
  • Page 498 s4500-253 Printer Left Side Wiring Diagrams 10-9...

  • Page 499: 550-Sheet Feeder Plug/Jack Locator

    Connects the Turn Roller Clutch and Clutch/Sensor Harness 1 J-204 Connects Clutch/Sensor Harness 1 and Clutch/Sensor Harness 2 2083 G-205 Connects Feeder Harness 1 and Feeder Harness 2 8483 G-206 Connects Feeder Harness 5 and Feeder Harness 5 10-10 Phaser 4500 Service Manual...
  • Page 500 8483 2083 s4500-272 Wiring Diagrams 10-11...

  • Page 501: Duplex Unit Plug/Jack Locator

    Connects the Duplex Unit Switch and Duplex Unit Harness C-303 Connects the Duplex Unit Sensor and Duplex Unit Sensor Harness H-307 Connects the Duplex Unit Harness Ground and Ground Plate Assembly 2750 I-304 Connects the Duplex Unit Harness and LVPS Harness Assembly 10-12 Phaser 4500 Service Manual...
  • Page 502 2750 s4500-271 Wiring Diagrams 10-13...

  • Page 503: Stacker Plug/Jack Locator

    Connects the Stacker Motor Harness and Stacker Motor F-404 Connects the Stacker Sensor and Stacker Sensor Harness I-403 Connects the Stacker Rear Cover Switch and Stacker Rear Cover Harness 3070 J-406 Connects Stacker Harness 2 and Stacker Harness 1 3070 s4500-273 10-14 Phaser 4500 Service Manual...

  • Page 504: Notations Used In Wiring Diagrams

    Notations Used in Wiring Diagrams The symbols in the interconnection wiring diagram are described below. Note that the description of general symbols is omitted. Symbol Description Represents an interconnection between parts using wiring harness or wire, and indicates its signal name/ contents.
  • Page 505 “PL X.Y.Z” indicates the item “Z” of the plate (PL) “X.Y” described in Chapter 5 “Parts List.” Represents a functional part within a part, and indicates the name of the functional part. Indicates a reference item associated with the section. 10-16 Phaser 4500 Service Manual...

  • Page 506: Print Engine Wiring Diagrams

    Print Engine Wiring Diagrams Print Engine General Wiring Diagram See page 10-25 HVPS/ Engine Logic Stack Full P/J290 P/J29 Sensor Image Front Panel J110 J810 J800 P/J28 Processor See page 10-24 P/J401 P/J142 P/J141 P/J14 DC-DC P/J130 P/J402 Interlock Converter P/J403 See page 10-26 Interlock Switch Assembly...

  • Page 507: Interlock, Rear Cover Switch, Main Motor, Sub Fan, Exit Motor Assembly

    Signal indicating that the rear cover is open. This signal goes High when the top or rear cover is open. INTERLOCK BEF Signal indicating that the top cover is open. This signal goes High when the top cover is open. 10-18 Phaser 4500 Service Manual...
  • Page 508 Signal line Description name FAN ALARM Sub Fan monitor signal. If a trouble occurs, this signal goes High. EXIT /INB Excitation signal for Exit Motor. Phase /B. EXIT /INA Excitation signal for Exit Motor. Phase /A. EXIT INB Excitation signal for Exit Motor. Phase B. EXIT INA Excitation signal for Exit Motor.

  • Page 509: Fuser Assembly, Power Switch

    Signal from Exit Sensor. This signal goes Low when the flag moves out of the sensor. Temperature monitor signal (analog signal) from Temperature Sensor (Thermistor). It detects the temperature on the surface of Heat Roller. Output from HVPS which applies a high voltage to Pressure Roller. 10-20 Phaser 4500 Service Manual...

  • Page 510: Print Cartridge, Transfer Roller Assembly

    Print Cartridge, Transfer Roller Assembly HVPS/ R. PRINT CARTRIDGE PRINT CARTRIDGE ENGINE LOGIC GUIDE PWBA Mag Roller Drum Detack P/J 310 P/J 31 Transfer Roller TRANSFER ROLLER HVPS ASSEMBLY ENGINE LOGIC CRUM P/J15 P/J150 ANTENNA ANT IN CRUM ANT OUT ANTENNA HARNESS s4500-237 Signal line...

  • Page 511: 150-Sheet Feeder, 550-Sheet Feeder, Main Fan

    24V DC Registration CLUTCH-REGI ON Clutch P/J244 FAN ALARM 24V RTN Main Fan 24V DC Toner Toner P/J220 P/J221 P/J22 Harness 2 Harness 1 24V DC Toner A OUT Sensor N.C. 24V RTN D OUT s4500-238 10-22 Phaser 4500 Service Manual...
  • Page 512 Signal line name Description /LOW-PAPER2 SNR ON Signal from Low Paper Sensor. This signal goes Low when the flag moves out of the sensor. /NO-PAPER2 SNR ON Signal from the No Paper Sensor of Tray2. This signal goes Low when the flag moves out of the sensor. CLUTCH-TRAY2 ON Control signal for Tray 2 Feed Clutch.

  • Page 513: Laser Unit, 5 V Interlock, Interlock Switch Assembly

    /PCONT 1 /SOS Scan Vref Sensor MO/DET-OUT /PCONT2 /LDENB P/J17 P/J170 XPDATA 2+ XPDATA 2- P/J16 P/J160 XPDATA 1+ XPDATA 1- P/J13 P/J131 P/J130 24V DC 24V RTN/SG Scanner /ROSMOT ON Motor /ROSMOT CLK s4500-239 10-24 Phaser 4500 Service Manual...

  • Page 514: Paper Exit

    Signal line name Description /SOS Synchronization signal generated by SOS Sensor. This signal commands start of each scan. /PCONT Sample / Hold circuit Low: Sampled (LD is forcibly lit up); High: Held Vref Laser output control signal for determining or adjusting the current flowing through Laser Diode.

  • Page 515: Image Processor Board, Dc-Dc Converter, Front Panel

    DC-DC Converter Harness C Ribbon Cable Image HVPS Processor Engine Logic J110 Front Panel Harness Ground <-Rx Data (command) Ground (Status) Tx Data -> Ground Front Panel Status N Ground Reset N 5VDC 5VDC s4500-266 10-26 Phaser 4500 Service Manual...

  • Page 516: Optional 550-Sheet Feeder

    Optional 550-Sheet Feeder 550-Sheet Feeder General Wiring Diagram 550-Sheet Feeder HVPS/ PWBA Engine Logic Paper Size PWBA P/J20 P/J2083 P/J83 P/J80 P/J801 P/J802 Switch Assembly Low Paper P/J81 P/J810 Sensor Feeder Motor P/J82 P/J820 Feed Clutch P/J85 P/J855 P/J853 Turn Roller P/J854 P/J84 Clutch...

  • Page 517: 550-Sheet Feeder Signal Diagram

    Signal detecting an optional 550-Sheet Paper Feeder. ID is recognized by the number of falling edges. /LOW-PAPER FEED SNR ON Signal from Low Paper Sensor. This signal goes Low when the flag moves out of the sensor. 10-28 Phaser 4500 Service Manual...

  • Page 518: Duplex Unit

    Signal line name Description A and B Excitation signal for Feeder Motor. Phases A and B. /A and /B Excitation signal for Feeder Motor. Phases /A and /B. CLUTCH-FEED ON Control signal for Feed Clutch. Low: ON / High: OFF CLUTCH-TURN ON Control signal for Turn Roller Clutch.

  • Page 519: Duplex Unit Signal Diagram

    Signal from Duplex Unit Switch. This signal goes Low when the cover of Duplex (Duplex Unit Housing Cover) is closed. A and B Excitation signal for Duplex Unit Motor. Phases A and B. /A and /B Excitation signal for Duplex Unit Motor. Phases /A and /B. 10-30 Phaser 4500 Service Manual...

  • Page 520: Stacker

    Stacker Stacker General Wiring Diagram STACKER HVPS PWBA ENGINE LOGIC PWBA STACKER P/J71 P/J710 MOTOR P/J30 P/J3070 P/J70 OFFSET P/J72 MOTOR GATE P/J75 SOLENOID STACKER P/J73 P/J730 SENSOR STACKER REAR P/J74 P/J740 COVER SWITCH s4500-245 Wiring Diagrams 10-31...

  • Page 521: Stacker Signal Diagram

    Signal from Duplex Unit Sensor. This signal goes Low when the flag moves out of the sensor. /REAR Top Cover Signal from Rear Cover Switch. This signal goes Low when the rear cover of Stacker (Rear Cover) is closed. 10-32 Phaser 4500 Service Manual...

  • Page 522: A Appendix

    Appendix Contents... Menu Map Service Diagnostics Menu Map Appendix...
  • Page 523 Networked printer Duplex Unit Page Description Language † Hard Drive NetWare †† Lower Tray(s) IPX Frame Type ‡ Networked printer or Hard Drive with stored jobs present ‡‡ Flash Memory Page 1 of 2 § Stacker Phaser 4500 Service Manual...
  • Page 524 Paper Source 2-Sided Printing** Tray 1 Setup Tray 2 Setup † Tray 3 Setup PostScript Error Info † Tray 4 Setup Image Smoothing Load Paper Timeout Edge-to-Edge Printing Tray Sequence Reset PostScript Setup Tray Prompt Custom Units § Paper Destination Font Number §...

  • Page 525: Service Diagnostics Menu Map

    Main Motor + Tray 1 Feed Main Motor + Tray 2 Feed Main Motor + Tray 3 Feed Main Motor + Tray 4 Feed Main Motor + Tray 3 Turn Roll Main Motor + Tray 4 Turn Roll Phaser 4500 Service Manual...
  • Page 526 Factory Reset NVRAM Exit: Reboots Printer out of Diagnostics. For Service Use Only The Service menu functions are to be used by Xerox service personnel and authorized service providers. The printer can be damaged by improper use of the built-in service tests.
  • Page 527 Phaser 4500 Service Manual...
  • Page 528 Index Numerics 24 V interlock 2-31 4-26 DC-DC converter 2-32 5 V interlock 2-31 4-26 Default 550-sheet feeder PWBA 2-43 duplex registration factory values reset 6-11 fuser temperature setting 5-34 job, changing AC power supply troubleshooting laser power Actuator simplex registration low paper 2-16 2-42...
  • Page 529 Error message summary 3-22 heater assembly 2-24 Event log 3-21 pressure roller 2-24 Exit gate, stacker 2-29 problems (U4 error code) 2-27 Exit motor assembly 2-29 4-31 temperature adjusting Exit motor PWBA 2-31 4-30 Index – 2 Phaser 4500 Laser Printer...
  • Page 530 temperature cycling 2-26 registration, lead edge-to-trail edge temperature defaults 5-34 5-11 temperature sensors 2-24 resolution temperature stabilization 2-27 side-to-side registration 5-10 theory 2-24 2-28 skew 5-14 thermostats 2-24 skips/smears 5-12 troubleshooting 4-16 spots 5-13 warm-up 2-26 test print Inoperable front panel buttons Interlock 24 V 2-31...
  • Page 531 2-43 diagnostic tests 3-12 turn roller clutch 4-52 duplex unit 2-36 4-55 Optional hard drive exit 2-29 4-31 power source 2-32 feeder 2-43 Output tray stack full sensor 4-25 stacker 2-37 2-38 4-60 Index – 4 Phaser 4500 Laser Printer...
  • Page 532 Print engine troubleshooting 4-11 4-41 Paper exit theory 2-29 Printer configurations Paper feeder theory 2-16 Printer controls setup values 6-13 Paper lift theory 2-15 Printer options Paper path theory 2-34 2-44 print engine Printer orientation, standard stacker 2-38 Printer specifications Paper size control 2-18 clearances...
  • Page 533 NVRAM access 3-15 PWBA 2-39 entering rear cover switch 2-39 fans 3-12 sensor 2-39 front panel button descriptions 3-10 theory 2-37 2-40 general status tests 3-10 upper roller 2-39 hidden menu Stacker error 3-51 Index – 6 Phaser 4500 Laser Printer...
  • Page 534 Stacker gate duplex unit sensor 4-56 solenoid 3-14 duplex unit switch 4-58 Stacker motor assembly 4-60 electrical noise 4-41 Stacker PWBA 4-59 exit motor 4-31 Stacker rear cover switch 4-63 exit motor PWBA 4-30 Stacker sensor 4-65 feed clutch, optional feeder 4-50 Standard printer orientation feed clutches...
  • Page 535 Windows printing problems 3-20 uneven density 5-43 unfused image 5-32 vertical deletions 5-21 vertical streaks 5-25 Xerographics 2-19 2-23 Troubleshooting print quality page laser assembly 2-21 Turn roller 2-43 transfer roller assembly 2-23 Index – 8 Phaser 4500 Laser Printer...
  • Page 537 071-0867-00 A...

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