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Xerox Phaser 4500 Service Manual

Summary of Phaser 4500

  • Page 1

    Laser printer phaser ™ 4500 service manual.

  • Page 3: Phaser 4500 Laser Printer

    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. First printing: ja...

  • Page 4: 1 General Information

    Service manual iii contents service terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Xiii product terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Xiv power safety precautions . . . . . . . . . . . . . . ...

  • Page 5: 3 Error Messages and Codes

    Iv phaser 4500 laser printer printer options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 duplex unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 stacker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 6: 4 General Troubleshooting

    Service manual v replace print cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60 no paper in tray 1/no paper in tray 2 . . . . . . . . . . . . . . . . . . . . 3-61 tray 2 paper is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62 no paper in tray...

  • Page 7

    Vi phaser 4500 laser printer optional 550-sheet feeder pwba (tray 3) . . . . . . . . . . . . . . . . 4-43 optional 550-sheet feeder pwba (tray 4) . . . . . . . . . . . . . . . . 4-44 optional 550-sheet feeder no paper sensor . . . . . . . . . . . . . . . 4-45 optional 550-sheet feeder low paper sens...

  • Page 8: 7 Cleaning and Maintenance

    Service manual vii residual image. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42 uneven density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5...

  • Page 9

    Viii phaser 4500 laser printer left cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 top cover assembly, front panel . . . . . . . . . . . . . . . . . . . . . . . 8-10 front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 10

    Service manual ix print engine: frame and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-67 motor cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-67 main motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 11: 9 Parts Lists

    X phaser 4500 laser printer options: stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-132 stacker removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-132 stacker rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 12: A Appendix

    Service manual xi notations used in wiring diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15 print engine wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17 print engine general wiring diagram. . . . . . . . . . . . . . . . . . . . 10-17 24 v interl...

  • Page 13

    Xii phaser 4500 laser printer.

  • Page 14: Service Terms

    Service manual xiii 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, ca...

  • Page 15: Product Terms

    Xiv phaser 4500 laser printer product terms caution: a personal injury hazard exists that may not be apparent. For example, a panel may cover the hazardous area. Danger: a personal injury hazard exists in the area where you see the sign. Symbols marked on the product danger high voltage. Protective ...

  • Page 16: Power Safety Precautions

    Service manual xv power safety precautions power source for 110 vac printers, do not apply more than 140 volts rms between the supply conductors or between either supply conductor and ground. Use only the specified power cord and connector. For 220 vac printers, do not apply more than 264 volts rms ...

  • Page 17

    Xvi phaser 4500 laser printer electrostatic discharge (esd) precautions some semiconductor components, and the respective sub-assemblies that contain them, are vulnerable to damage by electrostatic discharge (esd). These components include integrated circuits (ics), large-scale integrated circuits (...

  • Page 18: Service Safety Summary

    Service manual xvii service safety summary general guidelines for xerox-certified service personnel only: refer also to the preceding power safety precautions. Avoid servicing alone: do not perform internal service or adjustment of this product unless another person capable of rendering first aid or...

  • Page 19: Servicing Fuser Components

    Xviii phaser 4500 laser printer servicing electrical components before starting any service procedure, switch off the printer power and unplug the power cord from the wall outlet. If you must service the printer with power applied, be aware of the potential for electrical shock. Warning turning the ...

  • Page 20: Regulatory Specifications

    Service manual xix regulatory specifications federal communications compliance the equipment described in this manual generates and uses radio frequency energy. If it is not installed properly in strict accordance with xerox instructions, it may cause interference with radio and television reception...

  • Page 21: Declaration of Conformity

    Xx phaser 4500 laser printer 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...

  • Page 22: In This Chapter...

    1 chapter 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.

  • Page 23

    1-2 phaser 4500 service manual 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 t...

  • Page 24: Printer Configurations

    General information 1-3 printer configurations a replaceable configuration card holds configuration information that enables or disables the network features shown in the following table. Features printer configuration 4500b 4500n 4500dt 4500dx maximum print speed (letter-size paper) 36 ppm 36 ppm 3...

  • Page 25: Parts of The Printer

    1-4 phaser 4500 service manual parts of the printer front view rear view 1. Paper stop 2. Front panel 3. Tray 1 4. On/off switch 5. Tray 2 6. Optional tray 3 7. Optional tray 4 8. Paper gauge 9. Print cartridge 10.Standard output tray 11.Optional 500-sheet stacker the image processor board contains ...

  • Page 26: Front Panel

    General information 1-5 front panel the front panel consists of one tricolor led, a display window, and six functional buttons. Led states front panel shortcuts 1. Led 5. Up arrow button - scrolls up the menu system 2. Graphic front panel display 6. Down arrow button - scrolls down the menu system 3...

  • Page 27: Image Processor Board

    1-6 phaser 4500 service manual image processor board when installing a new image processor board in the printer, you must transfer the following parts from the old board: ■ memory dimms ■ hard drive (if installed) ■ nvram ■ configuration card 1. Memory (ram) dimm 1 and dimm 2 6. Parallel connector 2...

  • Page 28

    General information 1-7 consumables and routine maintenance items print cartridge transfer roller feed rollers 3 per paper tray s4500-267 fuser s4500-268.

  • Page 29: Supply Life Counters

    1-8 phaser 4500 service manual supply life counters internal counters track the usage of the consumables and routine maintenance items and store the values in nvram. The image processor board monitors these counters in order to display the near end-of-life and end-of-life messages. Print life rating...

  • Page 30: Printer Specifications

    General information 1-9 printer specifications physical dimensions and clearances print engine dimensions value height 404 mm (15.9 in.) width 422 mm (16.6 in.) depth depth with paper cassette extended 465 mm (18.3 in.) 524 mm (20.7 in.) weight (with 10-k print cartridge) 20.5 kg (45.2 lbs.) clearan...

  • Page 31: Functional Specifications

    1-10 phaser 4500 service manual functional specifications stacker dimensions value height 226 mm (8.9 in.) width 418 mm (16.4 in.) depth depth with stacker tray extended 312.5 mm (12.3 in.) 382.5 mm (15.1 in.) weight 2.6 kg (5.7 lbs.) characteristic specification printing process: recording system: ...

  • Page 32: Electrical Specifications

    General information 1-11 electrical specifications environmental specifications e nergy s tar qualified printer 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 frequency range 50/60 hz ± 3 hz p...

  • Page 33

    1-12 phaser 4500 service manual media and tray specifications input trays trays specifications printable area all within 4 mm of paper edge guaranteed. Edge-to-edge printing supported. Supported media sizes tray 1 trays 2-4 tray 1 trays 2-4 width: 76.2 mm (3.0 in.) ~ 215.9 mm (8.5 in.) width: 98.4 m...

  • Page 34: Memory Requirements

    General information 1-13 memory requirements supported envelopes both #10 commercial (4.12 x 9.5 in.) monarch (3.87 x 7.5 in.) dl (110 x 220 mm) c5 (162 x 229 mm) b5 (176 x 250 mm) tray capacity standard stacker 500 500 duplex unit media specifications input tray specifications width tray 1 trays 2-...

  • Page 35

    1-14 phaser 4500 service manual.

  • Page 36: In This Chapter...

    2 chapter 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.

  • Page 37

    2-2 phaser 4500 service manual overview of the phaser 4500 laser printer summary of the printing process the phaser 4500 print process consists of the following steps: 1. Charge – the print cartridge contains a bias charge roller that uniformly distributes a negative electrical charge over the photo...

  • Page 38

    Theory of operation 2-3 8. Cleaning – a cleaning blade in the print cartridge scrapes off toner remaining on the drum surface after transfer has occurred. Then, the latent charge pattern remaining on the photoconductive drum is neutralized to prepare the drum for the next exposure cycle. 9. Paper ex...

  • Page 39

    2-4 phaser 4500 service manual 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. Components associated with the xerographic process fuser asse...

  • Page 40: Paper Path of The Printer

    Theory of operation 2-5 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. Nudger roller feed roller retard roller tray 2 tray 1 nudger roller feed roller retard roller turn roller turn p...

  • Page 41

    2-6 phaser 4500 service manual 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. 1. Exit roller 8. Rubber registration roller 2. Exit pinch roller 9. Metal registration roll...

  • Page 42

    Theory of operation 2-7 this cross section shows the additional components associated with paper transport when the 550-sheet feeders, the duplex unit, and the stacker are installed. 1. Stacker pinch roller 8. Pinch rollers 2. Lower stacker roller 9. Turn pinch rollers 3. Upper stacker roller 10.Tur...

  • Page 43: Sensors

    2-8 phaser 4500 service manual sensors the printer contains a number of sensors of various types that perform a variety of functions. One group of sensors track the progress of the paper along the paper path, and detect if a paper jam occurs. Other sensors detect the presence of the print cartridge,...

  • Page 44

    Theory of operation 2-9 no paper mechanically actuated photo sensor detects no paper condition in all trays. Page 2-17 paper size switches microswitch bank detects the presence of a tray and the paper size setting of the tray. Page 2-17 page 2-44 registration sensor mechanically actuated photo senso...

  • Page 45

    2-10 phaser 4500 service manual stacker rear cover switch microswitch signals the hvps/engine logic board that the stacker rear cover is open. Page 2-40 stacker sensor mechanically actuated photo sensor senses the presence of paper in the stacker. Page 2-40 stacker offset sensor mechanically actuate...

  • Page 46

    Theory of operation 2-11 sensors in the paper path 1. Registration sensor 8. Tray 2 no paper sensor 2. Fuser exit sensor 9. Tray 2 low paper sensor 3. Output tray full 10.Tray 3 no paper sensor 4. Stacker sensor 11.Tray 3 low paper sensor 5. Stacker full 12.Tray 4 no paper sensor 6. Duplex unit sens...

  • Page 47: Paper Tray

    2-12 phaser 4500 service manual 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 ■ e...

  • Page 48

    Theory of operation 2-13 paper tray functional assemblies left- and right-side paper guide assemblies the left and right paper guides adjust to fit different paper widths. The guides hold the paper in position in the tray. Bottom plate assembly the bottom plate assembly is pushed up by the bottom li...

  • Page 49

    2-14 phaser 4500 service manual end guide the end guide can be adjusted to different paper sizes by making a forward or backward adjustment. It makes contact with the rear end of the paper, and holds the paper in position front-to-back in the paper tray. Through the cam action of the sector gear and...

  • Page 50: Paper Lift Mechanism

    Theory of operation 2-15 the types of paper that can be automatically detected are as follows: 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 p...

  • Page 51: Paper Feeder

    2-16 phaser 4500 service manual paper feeder tray 1 and tray 2 are functionally equivalent in terms of the paper size switch assembly, no paper actuator, and no paper sensor. The component descriptions given here apply to both trays. Since the low paper actuator and low paper sensor are not part of ...

  • Page 52

    Theory of operation 2-17 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 45...

  • Page 53: Control of Paper Size

    2-18 phaser 4500 service manual control of paper size paper size switch assembly the switches in this assembly send a signal that indicates the paper size setting of the tray. Cams in the bottom of the tray are positioned by the tray’s end guide. At pre-defined paper lengths, actuators on the side o...

  • Page 54: Xerographics

    Theory of operation 2-19 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 li...

  • Page 55

    2-20 phaser 4500 service manual 1. Print cartridge 2. Transfer roller s4500-10 1 2.

  • Page 56: Laser Assembly

    Theory of operation 2-21 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 la...

  • Page 57

    2-22 phaser 4500 service manual conceptual diagram of image creation by scanning laser assembly functional parts 1. Start of scan pwb 3. Laser diode assembly 2. Scanner assembly s4500-011 s4500-012 1 2 3.

  • Page 58: Laser Control

    Theory of operation 2-23 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,...

  • Page 59: Fuser

    2-24 phaser 4500 service manual fuser heat roller the heat roller is a metal tube with a coated surface and a heater assembly inside. As paper passes between the heat roller and pressure roller, the heat that is applied to the paper melts the toner and fuses it to the paper. Pressure roller the pres...

  • Page 60

    Theory of operation 2-25 1. Exit motor assembly 5. Pressure roller 2. Exit sensor 6. Heat roller 3. Actuator 7. Thermostats 4. Temperature sensors s4500-023 1 2 3 4 5 6 7.

  • Page 61: Fuser Control

    2-26 phaser 4500 service manual fuser control the fuser heater control maintains the fuser at a pre-determined control temperature by turning the halogen lamp in the heat roller on and off. The control temperature varies depending on whether or not the printer is at the ready state, and whether the ...

  • Page 62: Temperature Stabilization

    Theory of operation 2-27 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,...

  • Page 63: Power Shutoff to The Fuser

    2-28 phaser 4500 service manual power shutoff to the fuser the printer shuts off power to the fuser for the following reasons: 1. Fuser abnormality (u4) 2. Paper jam 3. Cover open — top, rear, duplex unit, stacker 4. Laser assembly (ros) abnormality (u2) 5. Cpu or nvram abnormality (u6) 6. Main moto...

  • Page 64: Paper Exit Assembly

    Theory of operation 2-29 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. If the optiona...

  • Page 65: Drive

    2-30 phaser 4500 service manual drive gear assembly housing the gears in this housing transmit power from the main motor to various parts of the printer. Gear assembly plate this transmits power from the main motor to the print cartridge. Link lever this connects and disconnects the drive force from...

  • Page 66: Electrical

    Theory of operation 2-31 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” on ...

  • Page 67

    2-32 phaser 4500 service manual dc-dc converter the dc-dc converter uses 24 v and 3.3 v from the lvps to supply 5 v and 3.3 v to the image processor board. By using the 24 v, the dc-dc converter supplies additional power for the optional hard drive. 1. Lvps 7. 5 v interlock 2. Exit motor pwba 8. 24 ...

  • Page 68

    Theory of operation 2-33 schematic diagram of power distribution and interlocks opt. 550-sheet feeder optional duplex unit pwba feeder 550 duplex pwba optional stacker stacker pwba ldd laser unit 5v interlock rear cover switch (24v) 24v interlock hvps circuit fan control exit motor pwba exit motor m...

  • Page 69: Printer Options

    2-34 phaser 4500 service manual 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 u...

  • Page 70: Gear Layout

    Theory of operation 2-35 gear layout functional components two-sided printing is enabled by mounting the duplex unit on the rear side of the base engine. Duplex unit switch this switch detects that the duplex unit lower housing and duplex unit housing cover are closed. Duplex unit sensor this sensor...

  • Page 71

    2-36 phaser 4500 service manual duplex unit motor this motor drives the three duplex rollers, which transport the paper through the duplex unit. 1. Duplex unit rollers 4. Duplex unit pwba 2. Duplex unit sensor 5. Duplex unit switch 3. Duplex unit fan 6. Duplex unit motor s4500-030 1 2 3 4 5 6.

  • Page 72: Stacker

    Theory of operation 2-37 stacker drive transmission path the rotating force of the stacker motor assembly is transmitted by various gears to components requiring mechanical driving force as shown in this flow chart and the gear layout that follows. Gear 19/37 motor assy oct gear 45 gear 19 roll oct ...

  • Page 73: Gear Layout

    2-38 phaser 4500 service manual gear layout paper transport path when the stacker is installed on the printer, the paper is transported as shown in the illustration on page 2-7. The main components that transport paper through the stacker and shown in the diagram on page 2-5 functional components of...

  • Page 74

    Theory of operation 2-39 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. Sta...

  • Page 75

    2-40 phaser 4500 service manual 1. Stacker motor assembly 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 s4500-033 1 2 3 4 5 6 7 8...

  • Page 76: Optional 550-Sheet Feeder

    Theory of operation 2-41 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 optiona...

  • Page 77: Functional Components

    2-42 phaser 4500 service manual gear layout functional components the paper tray used in the optional feeder is identical to the 550-sheet paper tray used by the base engine, so the description of the paper tray is omitted here. Option paper size switch assembly a bank of switches for setting the si...

  • Page 78

    Theory of operation 2-43 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

    2-44 phaser 4500 service manual 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 s4500-036 8 1 2 3 4 5 6 7.

  • Page 80: In This Chapter...

    3 chapter 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 printe...

  • Page 81: Introduction

    3-2 phaser 4500 service manual 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...

  • Page 82

    Error messages and codes 3-3 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

    3-4 phaser 4500 service manual using the troubleshooting procedures 1. Each step in a troubleshooting procedure instructs you to perform a certain action or procedure. Follow the steps sequentially in the order given until the problem is fixed or resolved. 2. The actions and questions box contains a...

  • Page 84

    Error messages and codes 3-5 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 ...

  • Page 85: Accessing Fault Histories

    3-6 phaser 4500 service manual accessing fault histories ■ print (if possible) the service usage profile. A. At the printer’s front panel, go to the troubleshooting menu and select service tools . B. From the service tools menu select service usage profile. The fault histories are detailed in this r...

  • Page 86

    Error messages and codes 3-7 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. An ent...

  • Page 87

    3-8 phaser 4500 service manual entry level fault isolation procedure use this procedure to quickly determine the general area of the printer in which the problem is located. Troubleshooting procedure steps actions and questions yes no 1 switch the printer off then on. Does the printer display ready ...

  • Page 88: Service Diagnostics

    Error messages and codes 3-9 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-i...

  • Page 89: Using Service Diagnostics

    3-10 phaser 4500 service manual service diagnostic front panel button descriptions using service diagnostics most of the diagnostic tests are straightforward and require no additional explanation, but there are some that require that specific conditions be met to achieve meaningful results. These in...

  • Page 90: Engine Test Print

    Error messages and codes 3-11 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 pr...

  • Page 91: Motors/fan Test

    3-12 phaser 4500 service manual motors/fan test individually turns on each drive motor or fan. In each case except the stacker offset motor, the sound of the motor running is the indication that the item passed or failed the test. In the case of the stacker offset motor, the motion of the offset chu...

  • Page 92

    Error messages and codes 3-13 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” or “closed” i...

  • Page 93: Solenoid Test

    3-14 phaser 4500 service manual tray 2/3/4 low paper tests the operation of the low paper sensor in the 550-sheet feeders. Reports “not low” in the resting position, and “low” when lifted. You can test the sensor by removing all but three or four sheets of paper from the cassette in that tray and re...

  • Page 94: Controller Nvram Access

    Error messages and codes 3-15 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 n...

  • Page 95: System Start-Up and Post

    3-16 phaser 4500 service manual system start-up and post power on self test (post) the following tests are performed when the printer is powered on, after the boot loader runs, and before the operating system is loaded and initialized. Post diagnostics are intended to provide a quick means of isolat...

  • Page 96: Post Faults

    Error messages and codes 3-17 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 ...

  • Page 97

    3-18 phaser 4500 service manual post diagnostic test descriptions test fault code description sdram 1 (hard) this test fails if the boot loader finds no ram present or faulty ram. Boot loader posts the message “ram error” to the front panel and blinks the front panel led at an even rate. Real time c...

  • Page 98

    Error messages and codes 3-19 post error code table led blink code front panel message comment 1 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 ...

  • Page 99: Macintosh Printing Problems

    3-20 phaser 4500 service manual operating system and application problems troubleshooting tips and more information are also available on the xerox web site at: www.Xerox.Com/office/support . Macintosh printing problems image never prints 1. Printer acts as if it is receiving data, but nothing comes...

  • Page 100: Network Problems

    Error messages and codes 3-21 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 ...

  • Page 101: Procedures

    3-22 phaser 4500 service manual error messages and codes troubleshooting procedures the error message summary table that follows is the lead-in to the procedures that follow in subsequent pages. The front panel message column lists the error message that appears on the front panel when the error occ...

  • Page 102

    Error messages and codes 3-23 “fuser failure\press i” fuser fails at warm-up u4-4: fuser fail/ power off 1 — go to page 3-28. “fuser failure\press i” fuser thermistor failure u4-5: fuser fail/ power off 1 — go to page 3-28. “toner is low\ press i” j5: toner low — — go to “toner sensor” on page 23 “f...

  • Page 103

    3-24 phaser 4500 service manual “jam at rear; open duplex and rear cover to clear\ press i “ e7-1 duplex jam — 7 go to page 3-47. “jam at duplex; open duplex to clear\ press i “ e7-2 duplex jam — 7 go to page 3-47. “jam at duplex; open duplex to clear\ press i “ e7-3 duplex jam — 7 go to page 3-47. ...

  • Page 104

    Error messages and codes 3-25 “no paper in tray 4\ press i” tray 4 empty — — go to page 3-63. “maintenance kit is near end of life\ press i” n/a — — — “replace maintenance kit” n/a — — go to page 3-69. “stacker is full, unload paper\ press i” stacker output tray full — — go to page 3-67 “standard ou...

  • Page 105: Main Motor Failure

    3-26 phaser 4500 service manual main motor failure error code u1: main drive motor failure troubleshooting reference applicable parts wiring and plug/jack map references ■ main motor ■ gear assembly housing ■ plate gear assembly ■ lvps ■ hvps/engine logic board ■ “24 v interlock, rear cover switch, ...

  • Page 106: Laser Unit Failure

    Error messages and codes 3-27 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 wir...

  • Page 107: Fuser Failure

    3-28 phaser 4500 service manual fuser failure error codes u4-1: fuser high temp u4-2: fuser low temp u4-3: fuser overheat in stand-by u4-4: fuser fails at warm-up u4-5: fuser thermistor failure troubleshooting reference applicable parts wiring and plug/jack map references ■ fuser assembly ■ hvps/eng...

  • Page 108: Fan Failure

    Error messages and codes 3-29 fan failure error code u-5: fan fail troubleshooting reference applicable parts wiring and plug/jack map references ■ main fan ■ sub fan ■ lvps ■ hvps/engine logic board ■ “150-sheet feeder, 550-sheet feeder, main fan” on page 10-22 ■ “24 v interlock, rear cover switch,...

  • Page 109

    3-30 phaser 4500 service manual 8 turn the power on. Does fan error occur? Replace the hvps/engine logic board (page 8-89). Problem solved. 9 measure the voltage across p/j27-19 p/j27-18. Does the voltage measure 24 vdc? (12 vdc when low-speed) go to step 10. Replace the lvps (page 8-78) then go to ...

  • Page 110: Error Code

    Error messages and codes 3-31 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 engin...

  • Page 111: Jam At Tray N

    3-32 phaser 4500 service manual jam at tray n paper arrives early at the registration sensor error codes e2-01: feed jam at tray 1 e2-02: feed jam at tray 2 e2-03: feed jam at tray 3 e2-04: feed jam at tray 4 troubleshooting reference applicable parts wiring and plug/jack map references ■ 150-sheet ...

  • Page 112

    Error messages and codes 3-33 3 compare the size of the paper in use with the tray’s end guide settings and the paper size selected by the print driver. Does the paper size in use match the settings? Go to step 4. Replace the paper, or set up the paper size correctly. 4 1. Remove the paper cassette....

  • Page 113

    3-34 phaser 4500 service manual 11 manually rotate each gear and roller in the 150-sheet feeder. Does each gear and roller rotate smoothly? Go to step 12. Replace the 150-sheet feeder assembly (page 8-18). 12 check the paper feeding tray. Is the paper for test printing supplied from tray 3 or tray 4...

  • Page 114: Jam At Tray N

    Error messages and codes 3-35 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 fe...

  • Page 115

    3-36 phaser 4500 service manual 5 does the error occur when the power is turned on? Go to “registration sensor” on page 4-18. Go to step 6. 6 check the operation of the retard roller in each paper cassette. Is the retard roller undamaged, and installed correctly? Go to step 7. Replace the retard rol...

  • Page 116

    Error messages and codes 3-37 14 manually rotate each gear and roller of the optional 550-sheet feeder. Does each gear and roller of the optional 550-sheet feeder rotate smoothly? Go to step 15. Replace the “550- sheet feeder” on page 8-104. 15 enter service diagnostics, and from the clutch tests me...

  • Page 117: Error Codes

    3-38 phaser 4500 service manual jam at top; open top cover to clear error codes e3-1 reg. Jam e3-2 reg. Jam troubleshooting reference applicable parts wiring and plug/jack map references ■ fuser assembly ■ hvps/engine logic board ■ registration clutch ■ transfer roller assembly ■ print cartridge ■ g...

  • Page 118

    Error messages and codes 3-39 7 at the exit of the fuser assembly, manually move the exit actuator up and down. Does the exit actuator move smoothly? Go to step 8. Replace the fuser assembly (page 8-54). 8 enter service diagnostics, and from the sensor tests menu select the exit sensor (fuser) test....

  • Page 119

    3-40 phaser 4500 service manual 15 check the print cartridge right guide assembly is the print cartridge right guide assembly damaged or stained? Clean or replace the print cartridge right guide assembly (page 8-58). Go to step 16. 16 remove the print cartridge right guide assembly (page 8-58). Chec...

  • Page 120: Error Codes

    Error messages and codes 3-41 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 ■ hvps/engine logic board ■ fuser assembly harness ■ exit motor assembly ■ lvps ■ exit pinch roller ■ exi...

  • Page 121

    3-42 phaser 4500 service manual 7 1. Remove the paper exit cover (page 8-4) 2. Check the exit pinch roller by manually turning the exit roller. Is the exit pinch roller undamaged, and does it rotate smoothly? Are the exit pinch springs attached? Go to step 8. Replace the exit pinch roller. 8 1. Turn...

  • Page 122: Error Code

    Error messages and codes 3-43 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 sensor ■ stacker actuator ■ lower stacker roller ■ upper stacker roller ■ pinch roller ■...

  • Page 123

    3-44 phaser 4500 service manual 6 1. Remove the stacker cover (page 8-134). 2. Manually turn the lower stacker roller, upper stacker roller, and each gear. Do both rollers and all gears rotate smoothly? Go to step 7. Replace the parts preventing rotation. 7 check the paper transfer at the lower stac...

  • Page 124: Error Code

    Error messages and codes 3-45 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 sensor ■ stacker actuator ■ lower stacker roller ■ upper stacker roller ■ pin...

  • Page 125

    3-46 phaser 4500 service manual 6 remove the stacker cover (page 8-134), and manually turn the lower stacker roller, upper stacker roller, and each gear. Does the lower stacker roller, upper stacker roller, and all gears rotate smoothly? Go to step 7. Replace the parts preventing rotation. 7 check t...

  • Page 126: Error Codes

    Error messages and codes 3-47 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 sensor ■ duplex unit actuator ■ ...

  • Page 127

    3-48 phaser 4500 service manual 6 1. Remove the duplex unit left cover (page 8-117). 2. Manually rotate the gears. Do the duplex unit roller and all gears rotate smoothly? Go to step 7. Replace parts as necessary. 7 1. Open the duplex unit housing cover and insert paper, then close it. 2. Manually r...

  • Page 128: Error Code

    Error messages and codes 3-49 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 ■ fdr1 as sub 150 a4 ■ duplex unit sensor ■ duplex unit actuator ■ duplex unit roller ■ pinch roller ...

  • Page 129: Duplex Unit Error

    3-50 phaser 4500 service manual duplex unit error error code e9-1: duplex unit failure 5 enter service diagnostics, and from the motors/fan tests menu select the duplex motor high test. Does duplex unit motor rotate normally? Go to step 6. Go to “duplex unit motor” on page 4-55. 6 enter service diag...

  • Page 130: Stacker Error

    Error messages and codes 3-51 stacker error error code e9-2: stacker unit failure troubleshooting reference applicable parts wiring and plug/jack map references ■ stacker assembly harness 1 ■ hvps/engine logic board ■ stacker pwba ■ stacker assembly harness 2 ■ “stacker general wiring diagram” on pa...

  • Page 131: Error Code

    3-52 phaser 4500 service manual tray 3 failure\ tray 3 or 4 failure no recognition of the optional 550-sheet feeder. Error code e-11-1: tray 3 failure e-11-2: tray 3 or 4 failure note this procedure assumes that optional 550-sheet paper feeders are installed as tray 3 and tray 4. Troubleshooting ref...

  • Page 132

    Error messages and codes 3-53 2 check feeder harness 5 of the tray 3 feeder: 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 j8483-10 ■ j84-2 j8483-9 ■ j84-3 j8483-8 ■ j84-4 j8483-7 ■ j84-5 j8483-6 is each ...

  • Page 133: Paper Size Jam

    3-54 phaser 4500 service manual paper size jam error code pse-1: paper size jam note this procedure assumes that optional 550-sheet paper feeders are installed as tray 3 and tray 4. Troubleshooting reference applicable parts wiring and plug/jack map references ■ 150-sheet feeder assembly ■ 150-sheet...

  • Page 134

    Error messages and codes 3-55 5 check the paper tray. Is the paper supplied from either tray 3 or tray 4 when the error occurs? Go to step 6. Replace the hvps/engine logic board. (page 8-89) 6 check paper cassette (2). Are the end guide assembly, sector gear, size rack, size switch link 1/2/3 of pap...

  • Page 135: Error Indication

    3-56 phaser 4500 service manual close top cover/close rear cover error indication close top cover close rear cover troubleshooting reference applicable parts wiring and plug/jack map references ■ top cover switch ■ 5 v interlock ■ rear cover switch ■ interlock switch assembly ■ top cover ■ hvps/engi...

  • Page 136: Close Duplex Unit Cover

    Error messages and codes 3-57 close duplex unit cover troubleshooting reference applicable parts wiring and plug/jack map references ■ hvps/engine logic board ■ lvps ■ duplex unit lower housing ■ duplex unit housing cover ■ duplex unit switch ■ duplex unit pwba ■ “duplex unit signal diagram” on page...

  • Page 137: Close Stacker Cover

    3-58 phaser 4500 service manual close stacker cover troubleshooting reference applicable parts wiring and plug/jack map references ■ hvps/engine logic board ■ lvps ■ pwba stacker ■ rear cover ■ cover stacker ■ rear cover switch ■ rear cover assembly harness ■ “stacker signal diagram” on page 10-32 ■...

  • Page 138: Error Indication

    Error messages and codes 3-59 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 ■ print cartridge right guide assembly ■ “print cartridge, tra...

  • Page 139: Replace Print Cartridge

    3-60 phaser 4500 service manual replace print cartridge error indication replace print cartridge troubleshooting reference applicable parts wiring and plug/jack map references ■ print cartridge ■ print cartridge right guide assembly ■ hvps/engine logic board ■ “print cartridge, transfer roller assem...

  • Page 140: Error Indications

    Error messages and codes 3-61 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 ■ no paper actuator ■ hvps/engine logic board ■ lvps ■ “150-sheet feeder, 550-s...

  • Page 141: Tray 2 Paper Is Low

    3-62 phaser 4500 service manual tray 2 paper is low error indication tray 2 paper is low troubleshooting reference applicable parts wiring and plug/jack map references ■ low paper sensor ■ low paper actuator ■ bottom plate assembly ■ hvps/engine logic board ■ 550-sheet paper cassette ■ 550-sheet fee...

  • Page 142: Error Indications

    Error messages and codes 3-63 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 ■ lvps ■ no paper sensor ■ no paper actuator ■ optional 550-sheet paper...

  • Page 143: Error Indications

    3-64 phaser 4500 service manual tray 3 paper is low/tray 4 paper is low error indications tray 3 paper is low tray 4 paper is low troubleshooting reference applicable parts wiring and plug/jack map references hvps/engine logic board lvps low paper sensor low paper actuator bottom plate assembly opti...

  • Page 144: Insert Tray 1/insert Tray 2

    Error messages and codes 3-65 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 paper cassette ■ hvps/engine logic board ■ 550-sheet paper cassette ■ “150-sheet feeder...

  • Page 145: Insert Tray 3/insert Tray 4

    3-66 phaser 4500 service manual insert tray 3/insert tray 4 error indications insert tray 3 insert tray 4 troubleshooting reference applicable parts wiring and plug/jack map references ■ hvps/engine logic board ■ option paper size switch assembly ■ optional 550-sheet paper feeder ■ 550-sheet paper c...

  • Page 146: Error Indication

    Error messages and codes 3-67 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 pwba) ■ hvps/engine logic board ■ stacker pwba ■ stack full actuator ■ “stacker si...

  • Page 147: Error Indication

    3-68 phaser 4500 service manual standard output tray is full, unload paper error indication standard output tray is full, unload paper troubleshooting reference applicable parts wiring and plug/jack map references ■ stack full sensor ■ stack full actuator ■ hvps/engine logic board ■ “stacker signal ...

  • Page 148: Replace Maintenance Kit

    Error messages and codes 3-69 replace maintenance kit error indication replace maintenance kit troubleshooting reference applicable parts wiring and plug/jack map references ■ fuser assembly ■ fuser assembly harness ■ hvps/engine logic board ■ “fuser assembly, power switch” on page 10-20 ■ “print en...

  • Page 149: Inoperable Printer

    3-70 phaser 4500 service manual inoperable printer error indication will not print under the customer’s normal operating conditions. Troubleshooting reference applicable parts wiring and plug/jack map references ■ hvps/engine logic board ■ lvps ■ image processor board ■ “24 v interlock, rear cover s...

  • Page 150

    Error messages and codes 3-71 no recognition of duplex unit troubleshooting reference applicable parts wiring and plug/jack map references ■ hvps/engine logic board ■ lvps harness assembly ■ duplex unit pwba ■ duplex unit assembly harness ■ “duplex unit signal diagram” on page 10-30 ■ “duplex unit g...

  • Page 151

    3-72 phaser 4500 service manual 4 check the duplex unit assembly harness: 1. Disconnect connectors of duplex unit assembly 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? Replace the duplex unit pwba (page 8-123). Re...

  • Page 152: No Recognition of Stacker

    Error messages and codes 3-73 no recognition of stacker troubleshooting reference applicable parts wiring and plug/jack map references ■ hvps/engine logic board ■ stacker assembly harness 1 ■ stacker pwba ■ stacker assembly harness 2 ■ “stacker signal diagram” on page 10-32 ■ “stacker general wiring...

  • Page 153

    3-74 phaser 4500 service manual.

  • Page 154: In This Chapter...

    4 chapter general troubleshooting in this chapter... ■ introduction ■ front panel troubleshooting ■ dc power supply troubleshooting ■ ac power supply troubleshooting ■ print engine troubleshooting.

  • Page 155: Introduction

    4-2 phaser 4500 service manual introduction the procedures in this chapter troubleshoot problems that are not associated with an error code or front panel error message. For troubleshooting problems associated with an error code or front panel error message, notes on how to use the troubleshooting p...

  • Page 156: Front Panel Troubleshooting

    General troubleshooting 4-3 front panel troubleshooting lcd/led display error/inoperable buttons troubleshooting reference applicable parts wiring and plug/jack map references ■ front panel ■ front panel harness ■ hvps/engine logic board ■ lvps ■ “image processor board, dc-dc converter, front panel”...

  • Page 157

    4-4 phaser 4500 service manual dc power supply troubleshooting lvps (low voltage power supply) troubleshooting reference applicable parts wiring and plug/jack map references ■ lvps ■ hvps/engine logic board ■ lvps harness assembly ■ “24 v interlock, rear cover switch, main motor, sub fan, exit motor...

  • Page 158: Dc-Dc Converter

    General troubleshooting 4-5 dc-dc converter 4 is the ac power supply outlet correctly wired and grounded? Replace the hvps/engine logic board. (page 8-89) inform the customer or the electrician. Troubleshooting reference applicable parts wiring and plug/jack map references ■ dc-dc converter pwba ■ l...

  • Page 159

    4-6 phaser 4500 service manual 3 check harness a, 24 v input: 1. Turn the power off. 2. Disconnect j404b and j403. 3. Check each conductor in the harness for continuity. Is each conductor continuous? Go to step 4. Replace harness a from the lvps (page 8-78). 4 check harness b, 3.3 v input: 1. Turn t...

  • Page 160: No Ac Power

    General troubleshooting 4-7 ac power supply troubleshooting no ac power troubleshooting reference applicable parts wiring and plug/jack map references ■ power cord ■ lvps ■ hvps/engine logic board ■ front panel ■ front panel harness ■ 24 v interlock ■ 5 v interlock ■ rear cover switch ■ main fan ■ s...

  • Page 161

    4-8 phaser 4500 service manual 4 1. Remove the optional 550-sheet paper feeder. 2. Turn on the printer power. Do both fans rotate when the power is turned on? Go to “optional 550-sheet feeder pwba (tray 3)” on page 4-43, “optional 550-sheet feeder pwba (tray 4)” on page 4-44 “optional 550- sheet fee...

  • Page 162

    General troubleshooting 4-9 8 1. Disconnect the front panel harness 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. Does the main fan rotate when the power is turned on? Go to step 9. Go to ...

  • Page 163

    4-10 phaser 4500 service manual 13 check the top cover interlock: 1. Disconnect p/j411. 2. Test for continuity between p/j411-3 p/j411-1 while opening and closing the top cover. Is there continuity when the top cover is closed, and no continuity when the top cover is open? Go to step 14. Replace the...

  • Page 164: Print Engine Troubleshooting

    General troubleshooting 4-11 print engine troubleshooting main motor troubleshooting reference applicable parts wiring and plug/jack map references ■ main motor ■ lvps harness assembly ■ lvps ■ hvps/engine logic board ■ “24 v interlock, rear cover switch, main motor, sub fan, exit motor assembly” on...

  • Page 165

    4-12 phaser 4500 service manual 5 turn on the printer. Does the main motor rotate? Problem solved. Replace the hvps/engine logic board (page 8-89), then go to step 6. 6 turn on the printer. Does the main motor rotate? Problem solved. Replace the main motor (page 8-69). Troubleshooting procedure (con...

  • Page 166: Laser Unit Assembly

    General troubleshooting 4-13 laser unit assembly troubleshooting reference applicable parts wiring and plug/jack map references ■ laser unit assembly ■ laser unit harness assembly ■ 5 v interlock ■ lvps harness assembly ■ hvps/engine logic board ■ lvps ■ “laser unit, 5 v interlock, interlock switch ...

  • Page 167

    4-14 phaser 4500 service manual 4 check the lvps harness: 1. Disconnect p/j141 of the lvps harness (near the laser unit pwba). 2. Test for continuity between p/j141-1 p/j141-3 while opening and closing the top cover. Is there continuity when the top cover is closed, and no continuity when the top co...

  • Page 168

    General troubleshooting 4-15 9 check the /rosmot on signal of the 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. Does the voltage measure 0 v just after the power is turned on, and 5 vdc 10 seconds ...

  • Page 169: Fuser Assembly

    4-16 phaser 4500 service manual fuser assembly troubleshooting reference applicable parts wiring and plug/jack map references ■ fuser assembly ■ hvps/engine logic board ■ 24 v interlock ■ fuser assembly harness 110v/ 220v ■ ac power harness assembly ■ lvps ■ lvps harness assembly ■ “fuser assembly, ...

  • Page 170

    General troubleshooting 4-17 4 check the ac line voltage. Is the ac line voltage correct? Replace the ac power harness assembly (rrp12.4) inform the customer or the electrician. 5 check the heater rod on signal voltages: warning: allow the fuser assembly to cool down before beginning. 1. Make sure t...

  • Page 171: Registration Sensor

    4-18 phaser 4500 service manual registration sensor troubleshooting reference applicable parts wiring and plug/jack map references ■ registration sensor ■ registration sensor actuator ■ 150-sheet feeder assembly ■ tray 1 assembly harness ■ chute assembly harness ■ hvps/engine logic board ■ lvps ■ “1...

  • Page 172

    General troubleshooting 4-19 4 check the chute assembly harness: 1. Disconnect p/j24 from the hvps/ engine logic board. 2. Disconnect p/j245. 3. Test the following for continuity: ■ j24-9 j245-10 ■ j24-10 j245-9 ■ j24-11 j245-8 is each conductor continuous? Go to step 5. Replace the chute assembly h...

  • Page 173: No Paper Sensor

    4-20 phaser 4500 service manual no paper sensor troubleshooting reference applicable parts wiring and plug/jack map references ■ no paper sensor ■ no paper actuator ■ 150-sheet feeder assembly ■ tray 1 assembly harness ■ tray 2 assembly harness ■ chute assembly harness ■ hvps/engine logic board ■ bo...

  • Page 174

    General troubleshooting 4-21 4 check the power to no paper sensor: 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? Go to step 5. Go to step 6. 5 check the chute assembly harness: 1. Dis...

  • Page 175: Low Paper Sensor

    4-22 phaser 4500 service manual low paper sensor troubleshooting reference applicable parts wiring and plug/jack map references ■ low paper sensor ■ low paper actuator ■ bottom plate assembly ■ low paper 1 harness assembly ■ lvps ■ hvps/engine logic board ■ “150-sheet feeder, 550-sheet feeder, main ...

  • Page 176: Toner Sensor

    General troubleshooting 4-23 toner sensor troubleshooting reference applicable parts wiring and plug/jack map references ■ toner sensor ■ toner sensor assembly ■ toner harness assembly 1 ■ toner harness assembly 2 ■ print cartridge ■ hvps/engine logic board ■ “150-sheet feeder, 550-sheet feeder, mai...

  • Page 177

    4-24 phaser 4500 service manual 6 check the toner harness assembly 2: 1. Remove the toner harness assembly 2. 2. Test for continuity across j22 j221. Is it continuous? Go to step 7. Replace the toner harness assembly 2. 7 replace the toner sensor (page 8-30). Does the problem still occur after repla...

  • Page 178

    General troubleshooting 4-25 output tray stack full sensor troubleshooting reference applicable parts wiring and plug/jack map references ■ stack full sensor ■ stack full actuator ■ exit sensor assembly harness ■ hvps/engine logic board ■ “paper exit” on page 10-25 ■ “fuser assembly, power switch” o...

  • Page 179: 24 V Interlock

    4-26 phaser 4500 service manual 24 v interlock 5 v interlock, interlock switch assembly troubleshooting reference applicable parts wiring and plug/jack map references ■ 24 v interlock ■ lvps ■ hvps/engine logic board ■ “24 v interlock, rear cover switch, main motor, sub fan, exit motor assembly” on ...

  • Page 180

    General troubleshooting 4-27 troubleshooting procedure steps actions and questions yes no 1 check the 5 v interlock: 1. Disconnect p/j142. 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? Go to step 2. R...

  • Page 181: Rear Cover Switch

    4-28 phaser 4500 service manual rear cover switch troubleshooting reference applicable parts wiring and plug/jack map references ■ rear cover switch ■ lvps ■ hvps/engine logic board ■ “24 v interlock, rear cover switch, main motor, sub fan, exit motor assembly” on page 10-18 ■ “print engine general ...

  • Page 182: Interlock Switch Assembly

    General troubleshooting 4-29 interlock switch assembly troubleshooting reference applicable parts wiring and plug/jack map references ■ interlock switch assembly ■ lvps ■ hvps/engine logic board ■ “laser unit, 5 v interlock, interlock switch assembly” on page 10-24 ■ “print engine general wiring dia...

  • Page 183: Exit Motor Pwba

    4-30 phaser 4500 service manual exit motor pwba troubleshooting reference applicable parts wiring and plug/jack map references ■ exit motor pwba ■ lvps harness assembly ■ lvps ■ hvps/engine logic board ■ “24 v interlock, rear cover switch, main motor, sub fan, exit motor assembly” on page 10-18 ■ “p...

  • Page 184: Exit Motor Assembly

    General troubleshooting 4-31 exit motor assembly troubleshooting reference applicable parts wiring and plug/jack map references ■ exit motor assembly ■ exit motor pwba ■ lvps harness assembly ■ lvps ■ hvps/engine logic board ■ “24 v interlock, rear cover switch, main motor, sub fan, exit motor assem...

  • Page 185: Registration Clutch

    4-32 phaser 4500 service manual registration clutch troubleshooting reference applicable parts wiring and plug/jack map references ■ registration clutch ■ chute assembly harness ■ tray 1 assembly harness ■ hvps/engine logic board ■ lvps ■ “150-sheet feeder, 550-sheet feeder, main fan” on page 10-22 ...

  • Page 186: Feed Clutches

    General troubleshooting 4-33 feed clutches troubleshooting reference applicable parts wiring and plug/jack map references ■ feed clutch ■ tray 1 harness ■ tray 2 harness ■ chute harness ■ hvps/engine logic board ■ lvps ■ “150-sheet feeder, 550-sheet feeder, main fan” on page 10-22 ■ “print engine ge...

  • Page 187: Left Tray Guide

    4-34 phaser 4500 service manual left tray guide 4 check the hvps/engine logic board: 1. Disconnect p/j24 and p/j10 from the hvps/engine logic board. 2. Test for continuity across the following points: ■ j24-12 j10-1 ■ j24-4 j10-1 are both continuous go to “lvps (low voltage power supply)” on page 4-...

  • Page 188: Hvps/engine Logic Board

    General troubleshooting 4-35 hvps/engine logic board troubleshooting reference applicable parts wiring and plug/jack map references ■ hvps/engine logic board ■ print cartridge right guide assembly ■ print cartridge ■ ant harness assembly ■ lvps harness assembly ■ “print cartridge, transfer roller as...

  • Page 189

    4-36 phaser 4500 service manual 4 check the lvps harness assembly: 1. Disconnect p/j10 from the hvps/ engine logic board. 2. Disconnect p/j42 from the lvps. 3. Test each cable between p/j10 p/j42 for continuity. Are all continuous? Go to “lvps (low voltage power supply)” on page 4-4. Replace the lvp...

  • Page 190: Image Processor Isolation

    General troubleshooting 4-37 image processor isolation troubleshooting reference applicable parts wiring and plug/jack map references ■ image processor board ■ dc-dc converter ■ dc-dc converter harness ■ lvps ■ lvps harness ■ “image processor board, dc-dc converter, front panel” on page 10-26 ■ “pri...

  • Page 191: Image Processor Board

    4-38 phaser 4500 service manual image processor board troubleshooting reference applicable parts wiring and plug/jack map references ■ image processor board ■ dc-dc converter ■ dc-dc converter harness ■ lvps ■ lvps harness ■ “image processor board, dc-dc converter, front panel” on page 10-26 ■ “prin...

  • Page 192: Ram Dimm Fault Isolation

    General troubleshooting 4-39 ram dimm fault isolation initial actions: ■ power off printer. Remove and re-install ram dimms after verifying that they meet the xerox specifications. Note a minimum of 64 mb of ram must be installed for proper printer operation. The phaser 4500 laser printer supports p...

  • Page 193

    4-40 phaser 4500 service manual 7 1. Power off the printer and remove the first dimm. 2. Install the second dimm and power on the printer. Is a memory fault message displayed? Go to step 8 go to step 9 8 1. Power off the printer and move the suspected defective dimm to the other memory socket. 2. Po...

  • Page 194: Electrical Noise

    General troubleshooting 4-41 electrical noise troubleshooting reference applicable parts wiring and plug/jack map references ■ hvps/engine logic board ■ print cartridge right guide assembly ■ fuser assembly ■ print cartridge ■ ant harness assembly ■ ac power harness assembly ■ lvps harness assembly ...

  • Page 195

    4-42 phaser 4500 service manual 6 check the print cartridge right guide assembly (1) does the ground plate of the print cartridge right guide make proper contact with terminals on the hvps/ engine logic board? Go to step 7. Replace the print cartridge right guide assembly (page 8-58). 7 check the pr...

  • Page 196

    General troubleshooting 4-43 optional 550-sheet feeder pwba (tray 3) note use this procedure when the optional 550-sheet paper feeder is installed as tray 3. When it is installed as tray 4, see the procedure for the “optional 550-sheet feeder pwba (tray 4)” on page 4-44. 11 replace the hvps/engine l...

  • Page 197

    4-44 phaser 4500 service manual optional 550-sheet feeder pwba (tray 4) note use this procedure when the optional 550-sheet paper feeder is installed as tray 4. When it is installed as tray 3, see the procedure for the “optional 550-sheet feeder pwba (tray 3)” on page 4-43. Troubleshooting reference...

  • Page 198

    General troubleshooting 4-45 optional 550-sheet feeder no paper sensor troubleshooting reference applicable parts wiring and plug/jack map references ■ no paper sensor ■ no paper actuator ■ clutch/sensor harness 1 ■ clutch/sensor harness 2 ■ optional 550-sheet paper feeder ■ 550-sheet feeder pwba ■ ...

  • Page 199

    4-46 phaser 4500 service manual 3 check the no paper sensor (2) 1. Install the optional 550-sheet feeder (page 8-104). 2. Remove the print cartridge. 3. Close the top cover. 4. Remove 550-sheet paper cassette. 5. Measure the voltage across p/j85-7 p/j85-6 while manually operating the no paper actuat...

  • Page 200

    General troubleshooting 4-47 optional 550-sheet feeder low paper sensor troubleshooting reference applicable parts wiring and plug/jack map references ■ low paper sensor ■ low paper actuator ■ low paper sensor harness ■ feeder harness 2 ■ optional 550-sheet paper feeder ■ 550-sheet paper cassette ■ ...

  • Page 201

    4-48 phaser 4500 service manual 3 check the low paper sensor (2) 1. Install the optional 550-sheet feeder (page 8-104). 2. Remove the 550-sheet paper cassette. 3. Measure the voltage across p/j81-3 p/j81-2 while manually operating the low paper actuator. Is the voltage 3.3 vdc when the low paper act...

  • Page 202

    General troubleshooting 4-49 optional feeder paper size switch assembly troubleshooting reference applicable parts wiring and plug/jack map references ■ option paper size switch assembly ■ feeder size assembly harness 1 ■ feeder size assembly harness 2 ■ optional 550-sheet paper feeder ■ 550-sheet p...

  • Page 203

    4-50 phaser 4500 service manual optional 550-sheet feeder feed clutch assembly troubleshooting reference applicable parts wiring and plug/jack map references ■ feed clutch assembly ■ optional 550-sheet paper feeder ■ 550-sheet paper cassette ■ 550-sheet feeder pwba ■ clutch/sensor harness 1 ■ clutch...

  • Page 204

    General troubleshooting 4-51 5 check feeder harness 2: 1. Remove feeder harness 2. 2. Test for continuity across j2083 j83. Is it continuous? Go to step 6. Replace feeder harness 2. 6 check feeder harness 1: 1. Remove feeder harness 1. 2. Test for continuity across j20 j2083. Is it continuous? Go to...

  • Page 205

    4-52 phaser 4500 service manual optional 550-sheet feeder turn roller clutch troubleshooting reference applicable parts wiring and plug/jack map references ■ optional 550-sheet paper feeder turn roller clutch ■ optional 550-sheet paper feeder ■ 550-sheet paper cassette ■ 550-sheet feeder pwba ■ clut...

  • Page 206

    General troubleshooting 4-53 4 check the 550-sheet feeder pwba: 1. Disconnect p/j83 from the 550-sheet feeder pwba. 2. Test for continuity at these points: ■ p83-3 p85-3 ■ p83-4 p85-4 are both continuous go to step 5. Replace the 550- sheet feeder pwba (page 8-102). 5 check feeder harness 2: 1. Remo...

  • Page 207: Duplex Unit Pwba

    4-54 phaser 4500 service manual duplex unit pwba troubleshooting reference applicable parts wiring and plug/jack map references ■ duplex unit pwba ■ duplex unit assembly harness ■ hvps/engine logic board ■ lvps harness assembly ■ “duplex unit signal diagram” on page 10-30 ■ “duplex unit general wiri...

  • Page 208: Duplex Unit Motor

    General troubleshooting 4-55 duplex unit motor troubleshooting reference applicable parts wiring and plug/jack map references ■ duplex unit motor ■ duplex unit pwba ■ duplex unit assembly harness ■ hvps/engine logic board ■ lvps ■ lvps harness assembly ■ “duplex unit signal diagram” on page 10-30 ■ ...

  • Page 209: Duplex Unit Sensor

    4-56 phaser 4500 service manual duplex unit sensor 6 check the hvps/engine logic board: 1. Disconnect p/j10 from the hvps/ engine logic board. 2. Test for continuity across p10-1 p27-8. Is it continuous? Go to “lvps (low voltage power supply)” on page 4-4. Replace the hvps/engine logic board (page 8...

  • Page 210

    General troubleshooting 4-57 3 check the duplex unit sensor (2): 1. Open the duplex unit housing cover and keep open. 2. Measure the voltage across p/j53-3 p/j53-2 while manually operating the duplex unit actuator. Does the voltage measure 0 vdc when the actuator is pushed, and 3.3 vdc when released...

  • Page 211: Duplex Unit Switch

    4-58 phaser 4500 service manual duplex unit switch troubleshooting reference applicable parts wiring and plug/jack map references ■ duplex unit switch ■ lvps harness assembly ■ duplex unit cover assembly harness ■ duplex unit pwba ■ duplex unit assembly harness ■ hvps/engine logic board ■ lvps ■ “du...

  • Page 212: Stacker Pwba

    General troubleshooting 4-59 stacker pwba 6 check the hvps/engine logic board: 1. Disconnect p/j27 from the hvps/ engine logic board. 2. Test p27-4 p11-16 on the hvps/ engine logic board for continuity. Is it continuous? Go to “lvps (low voltage power supply)” on page 4-4. Replace the hvps/engine lo...

  • Page 213: Stacker Motor Assembly

    4-60 phaser 4500 service manual stacker motor assembly troubleshooting reference applicable parts wiring and plug/jack map references ■ stacker motor ■ stacker pwba ■ stacker motor harness ■ stacker harness 2 ■ hvps/engine logic board ■ stacker harness 1 ■ “stacker signal diagram” on page 10-32 ■ “s...

  • Page 214: Offset Motor Assembly

    General troubleshooting 4-61 offset motor assembly troubleshooting reference applicable parts wiring and plug/jack map references ■ offset motor assembly ■ stacker motor assembly ■ stacker pwba ■ stacker harness 2 ■ hvps/engine logic board ■ stacker harness 1 ■ “stacker signal diagram” on page 10-32...

  • Page 215: Gate Solenoid Assembly

    4-62 phaser 4500 service manual gate solenoid assembly troubleshooting reference applicable parts wiring and plug/jack map references ■ gate solenoid assembly ■ stacker pwba ■ stacker harness 2 ■ hvps/engine logic board ■ stacker assembly harness 1 ■ “stacker signal diagram” on page 10-32 ■ “stacker...

  • Page 216: Stacker Rear Cover Switch

    General troubleshooting 4-63 stacker rear cover switch troubleshooting reference applicable parts wiring and plug/jack map references ■ rear cover switch ■ rear cover assembly harness ■ stacker pwba ■ stacker harness 2 ■ hvps/engine logic board ■ lvps ■ stacker harness 1 ■ “stacker signal diagram” o...

  • Page 217

    4-64 phaser 4500 service manual 4 check stacker harness 1: 1. Remove stacker harness 1. 2. Test j30 j3070 for continuity is the harness continuous? Go to step 5. Replace stacker harness 1. 5 check the rear cover switch (2): measure the voltage across p/j30-4 p/j30-3 on the hvps/engine logic board. D...

  • Page 218: Stacker Sensor

    General troubleshooting 4-65 stacker sensor troubleshooting reference applicable parts wiring and plug/jack map references ■ stacker sensor ■ stacker actuator ■ stacker sensor harness ■ stacker pwba ■ stacker harness 2 ■ hvps/engine logic board ■ stacker harness 1 ■ “stacker plug/jack locator” on pa...

  • Page 219

    4-66 phaser 4500 service manual 4 check stacker harness 2: 1. Disconnect p/j70 from stacker pwba. 2. Remove stacker harness 2. 3. Test j70 j3070 for continuity is the harness continuous? Go to step 5. Replace stacker harness 2. 5 check stacker harness 1: 1. Remove stacker harness 1. 2. Test j30 j307...

  • Page 220

    General troubleshooting 4-67 stack full sensor (on stacker pwba) troubleshooting reference applicable parts wiring and plug/jack map references ■ stack full sensor (mounted on stacker pwba) ■ stack full actuator ■ stacker pwba ■ stacker assembly harness 2 ■ hvps/engine logic board ■ stacker assembly...

  • Page 221

    4-68 phaser 4500 service manual 3 check stacker harness 2: 1. Disconnect p/j70 from stacker pwba. 2. Remove stacker harness 2. 3. Test j70 j3070 for continuity is the harness continuous? Go to step 4. Replace stacker harness 2. 4 check stacker harness 1: 1. Remove stacker harness 1. 2. Test j30 j307...

  • Page 222

    General troubleshooting 4-69 offset sensor (on stacker pwba) troubleshooting reference applicable parts wiring and plug/jack map references ■ offset sensor (mounted on stacker pwba) ■ offset assembly chute ■ stacker pwba ■ stacker assembly harness 2 ■ hvps/engine logic board ■ stacker assembly harne...

  • Page 223

    4-70 phaser 4500 service manual.

  • Page 224: In This Chapter...

    5 chapter print-quality troubleshooting in this chapter... ■ print-quality problems overview ■ analyzing test prints ■ print-quality troubleshooting.

  • Page 225

    5-2 phaser 4500 service manual print-quality problems overview print-quality defects can be attributed to printer components, consumables, media, internal software, external software applications, and environmental conditions. To successfully troubleshoot print-quality problems, as many variables as...

  • Page 226: Analyzing Test Prints

    Print-quality troubleshooting 5-3 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: 1. From the main menu, scroll to troubleshooting , then press the ok button. 2. Scroll to print qua...

  • Page 227

    5-4 phaser 4500 service manual resolution: at 600 dpi, the two pixel lines and halftone patches cannot be reproduced clearly on the print. Page 5-9 spot deletions: solid areas are marked with irregular white areas. Page 5-37 repeating defects: recurring marks, spots, lines, or voids. Page 5-39 resid...

  • Page 228

    Print-quality troubleshooting 5-5 test print s4500-256 test print est print phaser4500-030129-2-s phaser4500-030129-2-s 8.5x1 8.5x11 (sef) 1 (sef).

  • Page 229

    5-6 phaser 4500 service manual deletions (line, band, spots) line, band, or spot deletions step actions and questions yes no 1 inspect the test print for the presence of deletions (missing image). There should be no deletions with a diameter larger than 0.5 mm visible on test prints. Are there delet...

  • Page 230: Fusing

    Print-quality troubleshooting 5-7 fusing test print phaser4500-030129-2-s 8.5x11 (sef) s4500-258.

  • Page 231

    5-8 phaser 4500 service manual note the operating environment of the printer is from 41 degrees f (5 degrees c) at 15% relative humidity to 95 degrees f (35 degrees c) at 85% relative humidity. The fusing performance of the printer varies according to the environment. ■ a cold environment affects th...

  • Page 232: Resolution

    Print-quality troubleshooting 5-9 resolution actions and questions yes no observe the three resolution check points on several test prints. Check the resolution of the images in each of the following areas: ■ arrow 1: the two pixel vertical, horizontal, and diagonal lines should be clear and continu...

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

    5-10 phaser 4500 service manual registration (side-to-side) actions and questions yes no measure the registration on two consecutive test prints. Fold the paper in half (side-edge to side-edge). Observe the fold line of the paper with reference to the cross hairs of the target. Is the fold within +/...

  • Page 234

    Print-quality troubleshooting 5-11 registration (lead edge-to-trail edge) actions and questions yes no measure the registration on two consecutive test prints: 1. Fold the paper in half (lead edge-to-trail edge). 2. Observe the fold line of the paper with reference to the cross hairs of the target. ...

  • Page 235: Skips/smears

    5-12 phaser 4500 service manual skips/smears actions and questions yes no inspect the ladder chart test pattern as shown in the figure. Is the pattern free from skips and smears? Go to “spots” on page 5-13. Go to “skips and smears” on page 5-49. Test print phaser4500-030129-2-s 8.5x11 (sef) s4500-27...

  • Page 236: Spots

    Print-quality troubleshooting 5-13 spots actions and questions yes no 1. From the main menu, select information , then press the ok button . 2. Scroll to information pages , then press the ok button. 3. Scroll to configuration page , then press the ok button. 4. Inspect the print for spots. Within a...

  • Page 237: Skew

    5-14 phaser 4500 service manual skew actions and questions yes no 1. Enter service diagnostics, select engine test print , then press the ok button. 2. Scroll to print test pattern , then press the ok button. 3. Measure the dimensions ‘a’ and ‘b’ on two consecutive test patterns. Is the difference b...

  • Page 238: Other Print Defects

    Print-quality troubleshooting 5-15 other print defects step actions and questions yes no 1 inspect the test patterns for other print defects. Are the test prints free of defects? Return to “analyzing test prints” on page 5-3. Go to step 2. 2 are there dark streaks present on the test prints? Go to “...

  • Page 239: Light (Undertoned) Print

    5-16 phaser 4500 service manual print-quality troubleshooting light (undertoned) print the overall image density is too light. Initial actions ■ inspect the printer paper path for foreign items, such as staples, paper clips, and paper scraps. ■ check the installation of the print cartridge. ■ check ...

  • Page 240

    Print-quality troubleshooting 5-17 4 check for continuity between the metal grounding contact and the printer body frame. Is there continuity between the metal grounding contact and the printer frame? Go to step 5. Replace the print cartridge right guide (page 8-58). 5 inspect the laser beam path be...

  • Page 241: Blank Print (No Print)

    5-18 phaser 4500 service manual blank print (no print) no visible image anywhere on the output print as shown here. Initial actions ■ 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 pr...

  • Page 242

    Print-quality troubleshooting 5-19 3 1. Install a new print cartridge. 2. Print a test print as in step 1. Is there a normal image on the paper? Problem solved. Go to step 4. 4 1. Remove the print cartridge. 2. Inspect the metal grounding contact on the print cartridge right side guide. Is the metal...

  • Page 243: Black Prints

    5-20 phaser 4500 service manual black prints a totally black output print. There is toner on the paper with no visible image. Initial actions ■ inspect the printer paper path for foreign items, such as staples, paper clips, and paper scraps. ■ check installation of the print cartridge. ■ check that ...

  • Page 244: Vertical Deletions

    Print-quality troubleshooting 5-21 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 staple...

  • Page 245

    5-22 phaser 4500 service manual 6 warning: allow the fuser assembly to cool before removing. 1. Open the rear cover and remove the fuser assembly. 2. Manually rotate the fuser drive gear and inspect the heat roller. 3. Open the fuser jam access cover. 4. Manually rotate the fuser drive gear and insp...

  • Page 246: Horizontal Deletions

    Print-quality troubleshooting 5-23 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, s...

  • Page 247

    5-24 phaser 4500 service manual 3 1. Load fresh, dry paper. 2. Print a test print. Is the problem still present? Go to step 4. Problem solved. 4 1. Install a new print cartridge. 2. Print a test print. Is the problem still present? Go to step 5. Problem solved. 5 inspect the transfer roller assembly...

  • Page 248: Vertical Streaks

    Print-quality troubleshooting 5-25 vertical streaks extraneous dark lines/bands in the process direction (in the direction of paper travel). 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 scr...

  • Page 249

    5-26 phaser 4500 service manual vertical streaks troubleshooting procedure step actions and questions yes no 1 1. Enter service diagnostics , then select engine test print . 2. Scroll to print quantity , then press the ok button. 3. Press the ok button to move the cursor over the last digit, then pr...

  • Page 250

    Print-quality troubleshooting 5-27 5 warning: allow the fuser assembly to cool before removing. 1. Open the rear cover and remove the fuser assembly. 2. Rotate the fuser drive gear manually and inspect the heat roller. 3. Open the fuser jam access cover. 4. Rotate the fuser drive fear manually and i...

  • Page 251: Horizontal Streaks

    5-28 phaser 4500 service manual horizontal streaks there are black lines running horizontally across the page in the scan direction (at a right angle to the direction of paper travel). Initial actions ■ check that the paper supply is dry and fresh. ■ inspect the printer paper path for items, such as...

  • Page 252

    Print-quality troubleshooting 5-29 3 1. Install a new print cartridge. 2. Print a test print. Do the prints have horizontal streaks? Problem solved. Go to step 4. 4 verify that the connectors on the laser assembly are firmly connected. Verify that the laser assembly is firmly connected to the frame....

  • Page 253: Spots

    5-30 phaser 4500 service manual spots there are spots of toner randomly scattered on the page. Initial actions ■ check that the paper supply is clean, dry, and fresh (recycled paper may have spots). ■ inspect the printer paper path for foreign items, such as staples, paper clips, and paper scraps. ■...

  • Page 254

    Print-quality troubleshooting 5-31 spots troubleshooting procedure step actions and questions yes no 1 1. Install a new print cartridge. 2. Print a test print. Are the spots gone? Problem solved. Go to step 2. 2 inspect the transfer roller assembly for contamination and wear. Is the transfer roller ...

  • Page 255: Unfused Image

    5-32 phaser 4500 service manual unfused image the printed image is not fully fused to the paper. The image rubs off easily. Initial actions check to ensure that the paper is within specifications. Unfused image troubleshooting procedure step actions and questions yes no 1 1. Replace the paper with f...

  • Page 256

    Print-quality troubleshooting 5-33 3 1. From the main menu, select 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. 4. Scroll to the media type being used and see the fuser configurati...

  • Page 257: Fuser Configuration Defaults

    5-34 phaser 4500 service manual fuser configuration defaults 8 replace the following in order, until the defective component is found: ■ fuser assembly (page 8-54) ■ hvps/engine logic board (page 8-89) ■ lvps pwb (page 8-78) paper type default fuser temperature setting plain medium letterhead medium...

  • Page 258: Damaged Print

    Print-quality troubleshooting 5-35 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...

  • Page 259: Resolution

    5-36 phaser 4500 service manual resolution the two pixel lines and halftone patches cannot be reproduced clearly on the print. Initial actions ensure the nvram laser power adjustment is set to the default, which is 4. 5 inspect all of the rollers along the paper path, between the feed tray and the e...

  • Page 260: Spot Deletions

    Print-quality troubleshooting 5-37 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 pri...

  • Page 261

    5-38 phaser 4500 service manual 4 warning: allow the fuser assembly to cool before removing. 1. Open the rear cover and remove the fuser assembly. 2. Manually rotate the fuser drive gear and inspect the heat roller. 3. Open the fuser jam access cover. 4. Manually rotate the fuser drive gear and insp...

  • Page 262: Repeating Defects

    Print-quality troubleshooting 5-39 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 cartridg...

  • Page 263: Residual Image

    5-40 phaser 4500 service manual residual image the image from a previous print, which was not removed during the cleaning process, has been developed on the current print. Initial actions ■ inspect the printer paper path for foreign items, such as staples, paper clips, and paper scraps. ■ check the ...

  • Page 264

    Print-quality troubleshooting 5-41 4 warning: allow the fuser assembly to cool before removing. 1. Open the rear cover and remove the fuser assembly. 2. Manually rotate the fuser drive gear and inspect the heat roller. 3. Open the fuser jam access cover. 4. Manually rotate the fuser drive gear and i...

  • Page 265: Background

    5-42 phaser 4500 service manual background there is toner contamination on all or part of the page. The contamination appears as a very light gray dusting. Initial actions ■ inspect the printer paper path for items, such as staples, paper clips, and paper scraps. ■ check the installation of the prin...

  • Page 266: Uneven Density

    Print-quality troubleshooting 5-43 uneven density image density varies within the page in either direction. Initial actions: ■ load fresh dry paper. ■ check that the correct print cartridge is properly installed and not empty. ■ ensure that the machine is reasonably level. ■ check to make sure the l...

  • Page 267: Skewed Image

    5-44 phaser 4500 service manual skewed image the image is not parallel to the edges of the print sheet. Initial actions ■ check the paper tray(s) installation and the paper in the tray(s). ■ load fresh, dry paper. ■ paper meets specifications. ■ check the paper path for any obstructions or debris th...

  • Page 268

    Print-quality troubleshooting 5-45 skewed image troubleshooting procedure step actions and questions yes no 1 run 5 test prints, single sided, from each paper tray. If the printer has a duplex unit, run five duplexed prints from each tray. Does the skewed image appear only on duplexed prints? ■ chec...

  • Page 269

    5-46 phaser 4500 service manual 4 the skewed image occurs on prints fed from tray 2. ■ check the tray 2 feed rollers. Clean or replace if necessary. ■ check the tray 2 retard pad/ retard roller. Clean or replace if necessary. ■ check the tray 2 nudger roller. Clean or replace if necessary. ■ check t...

  • Page 270: Registration

    Print-quality troubleshooting 5-47 registration the image is not positioned correctly on the paper. It may be off in either the process direction or in the scan direction. Initial actions: ■ check to ensure that the paper is within specification. ■ check that the paper supply is dry, fresh, and load...

  • Page 271

    5-48 phaser 4500 service manual 5 the following printer components and areas are associated with this problem. One or more of these components or areas may have partially or completely failed. If misregistration occurs only on two- sided prints, repair or replace the duplex unit. If misregistration ...

  • Page 272: Skips and Smears

    Print-quality troubleshooting 5-49 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 obstructions or debris. Skips/smears troubleshooting procedure step actions...

  • Page 273

    5-50 phaser 4500 service manual.

  • Page 274: In This Chapter...

    6 chapter adjustments and calibrations in this chapter... ■ service test prints ■ adjustments ■ resetting fuser life ■ resetting printer values to the factory default values.

  • Page 275: Service Test Prints

    6-2 phaser 4500 service manual service test prints there are two test prints stored in the printer that are primarily intended for service use: ■ the test prints ■ the engine test print test prints test prints contain blocks, lines, patterns, and text, as shown in the sample on the following page. T...

  • Page 276

    Adjustments and calibrations 6-3 s4500-256 test print phaser4500-030129-2-s 8.5x11 (sef).

  • Page 277: Engine Test Print

    6-4 phaser 4500 service manual 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: 1. Enter service diagnostics. 2. Se...

  • Page 278: Adjustments

    Adjustments and calibrations 6-5 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...

  • Page 279

    6-6 phaser 4500 service manual 6. Select a quantity of 5 , then press the back button to enter the selection. Note use the ok button to move the highlight over the digit you want to change. Use the up arrow and down arrow buttons to change the value of the digit. 7. Select print test pattern , then ...

  • Page 280

    Adjustments and calibrations 6-7 adjusting simplex registration 1. Enter service diagnostics. 2. Select engine nvram adjustments , then press the ok button. 3. Select either the process adjustment ( tray [#] proc dir ) or scan adjustment ( tray [#] scan dir ) for the desired tray, then press the ok ...

  • Page 281

    6-8 phaser 4500 service manual adjusting duplex registration 1. Enter service diagnostics. 2. Select engine nvram adjustments , then press the ok button. 3. Select either the duplex process adjustment ( duplex proc dir ) or scan adjustment ( duplex scan dir ), then press the ok button. 4. Use the up...

  • Page 282: Adjusting Fuser Temperature

    Adjustments and calibrations 6-9 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 configurati...

  • Page 283: Resetting Fuser Life

    6-10 phaser 4500 service manual resetting fuser life this procedure restarts the counter that tracks fuser life. Perform this procedure after you install a new maintenance kit. To reset the fuser: 1. From the main menu, select information , then press the ok button. 2. Select supplies info , then pr...

  • Page 284: Values

    Adjustments and calibrations 6-11 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 control...

  • Page 285: Resetting Pcl Setup Values

    6-12 phaser 4500 service manual resetting paper handling setup values resetting the paper handling setup values resets the default paper source, 2-sided printing, tray setup (default paper type/size), load paper timeout, tray sequence, tray prompt, custom size paper units, default paper destination,...

  • Page 286

    Adjustments and calibrations 6-13 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. 1. From the main menu, select front panel setup , then press the ok button. 2. Sel...

  • Page 287: Nvram)

    6-14 phaser 4500 service manual resetting all printer default settings (postscript nvram) resetting the postscript nvram restores all printer values stored in the image processor controller nvram (including network, printer setup, job defaults, and margin) to their factory default values. The print ...

  • Page 288: In This Chapter...

    7 chapter cleaning and maintenance in this chapter... ■ service preventive maintenance procedure ■ recommended tools ■ cleaning.

  • Page 289: Recommended Tools

    7-2 phaser 4500 service manual service preventive maintenance procedure perform the following procedures whenever you check, service, or repair a printer. Cleaning the printer, as outlined in the following steps, assures proper operation of the printer and reduces the probability of having to servic...

  • Page 290: In This Chapter...

    8 chapter fru 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 engin...

  • Page 291: Overview

    8-2 phaser 4500 service manual overview this section contains the removal and replacement procedures for selected parts of the printer according to the field replaceable units (frus) parts list. Replacement procedures are not provided for most of the frus because in most cases, re-installing a part ...

  • Page 292: General Notes On Disassembly

    Fru disassembly 8-3 general notes on disassembly preparation before you begin any removal and replacement procedure: 1. Switch off the printer power and disconnect the power cord from the wall outlet. 2. Remove the print cartridge and protect it from exposure to light by covering it with a light pro...

  • Page 293: Print Engine: Covers

    8-4 phaser 4500 service manual print engine: covers paper exit cover (pl10.1.1) 1. Open the paper exit rear door. 2. Unscrew the thumbscrews at the right and left rear sides of the paper exit cover. 3. Lift the rear of the paper exit cover, then pull back to release the tabs at the front of the cove...

  • Page 294: Paper Exit Rear Door

    Fru disassembly 8-5 paper exit rear door (pl10.2.21) 1. Remove the duplex unit if one is installed (page 8-115). 2. Lift the lever to release the lock, and open the paper exit rear door. 3. Pry out the hinge retainer on the right side. 4. Release the hook of the left side hinge, and shift the paper ...

  • Page 295: Rear Cover

    8-6 phaser 4500 service manual rear cover (pl 1.1.3) 1. Remove the paper exit rear door (page 8-5). 2. Remove the three screws (two silver with flange, 8 mm; one gold tapping, 8 mm) that attach the rear cover to the printer. 3. Swing out the left end of the door, then disengage the three hooks on th...

  • Page 296: Right Cover

    Fru disassembly 8-7 right cover (pl1.1.4) 1. Thumbscrew 2. Bottom hooks s4500-058 1 2.

  • Page 297

    8-8 phaser 4500 service manual 1. Loosen the thumbscrew at the rear of the printer that secures the right cover. 2. Shift the right cover towards the rear of the printer to release the four hooks (two at the bottom edge, one in front, and one on rear), then swing out the bottom edge. 3. Move the rig...

  • Page 298: Left Cover

    Fru disassembly 8-9 left cover (pl1.1.6) 1. Remove the rear cover (page 8-6). 2. 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. 3. Move the left cover downward to release the three...

  • Page 299

    8-10 phaser 4500 service manual top cover assembly, front panel (pl1.1.7) (pl1.1.1) note the front panel can be removed without removing the top cover assembly by prying up carefully on the right edge of the front panel. 1. Remove the print cartridge. 2. Remove the paper exit cover (page 8-4) or sta...

  • Page 300: Replacement Notes:

    Fru disassembly 8-11 5. Remove the paper exit assembly (page 8-61). 6. Disconnect the connectors (p/j144 and p/j411) of the interlock switch assembly from the frame connectors. 7. Remove the two screws (silver with flange, 8 mm) that secure the top cover assembly to the printer. 8. Open the top cove...

  • Page 301: Front Cover

    8-12 phaser 4500 service manual front cover (pl1.1.5) 1. Remove the top cover assembly (page 8-10). 2. Release the two upper hooks that secure the front cover to the printer by pressing down on the hooks. 3. Tilt the cover out and lift to release the lower hooks from the frame. S4500-061.

  • Page 302: Interlock Switch Assembly

    Fru disassembly 8-13 interlock switch assembly (pl1.1.11) 1. Top cover assembly 3. Cable clamps 2. Hole s4500-062 1 2 3.

  • Page 303

    8-14 phaser 4500 service manual 1. Remove the top cover assembly. Note the interlock switch assembly is attached to the underside of the top cover assembly on the right hand side near the top cover opening. 2. Remove the two screws (gold tapping, 8 mm) that attach the interlock switch assembly. 3. L...

  • Page 304: Cassette

    Fru disassembly 8-15 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. 1. Retard roller 2. Retard holder s4500-064 2 1.

  • Page 305: Replacement Note:

    8-16 phaser 4500 service manual 1. Pull the paper cassette from the printer. Note to remove just the retard roller, perform step 2. To remove the retard holder, perform steps 3 and 4. Avoid touching the rubber surfaces on the new roller as much as possible to avoid contamination. 2. Press down on th...

  • Page 306

    Fru disassembly 8-17 1. Retard roller 4. Retard holder 2. Friction clutch 5. Retard spring 3. Hooks 6. 150- or 550-sheet paper cassette s4500-063 1 4 2 3 5 6.

  • Page 307: 150-Sheet Feeder Assembly

    8-18 phaser 4500 service manual print engine: 150-sheet feeder 150-sheet feeder assembly (pl5.1.1) 1. Remove the 150-sheet paper cassette (tray 1). 2. Remove the fuser assembly (page 8-54). 3. Remove the main fan (page 8-84). 4. Remove the transfer chute (page 8-56). 5. Disconnect the two harnesses,...

  • Page 308

    Fru disassembly 8-19 8. Shift the 150-sheet feeder assembly backward to disengage the right boss from the frame. 9. Lift the 150-sheet feeder assembly to disengage the left boss. 10. Remove the 150-sheet feeder assembly from the printer..

  • Page 309: Nudger Roller, Feed Roller

    8-20 phaser 4500 service manual nudger roller, feed roller (pl5.1.11) (pl5.1.44); the rollers are also part of maintenance kit note when handling the nudger roller and feed roller assemblies, avoid touching the rubber roller surfaces. 1. Feed roller 2. Nudger roller s4500-091 1 2.

  • Page 310

    Fru disassembly 8-21 1. Open the top cover. 2. Remove the print cartridge, and protect it from light exposure. 3. Release the hook retaining the nudger roller, and slide the nudger roller off the nudger shaft. 4. Release the hook retaining the feed roller, and slide the feed roller off the feed shaf...

  • Page 311: Nudger One-Way Clutch

    8-22 phaser 4500 service manual nudger one-way clutch (pl5.1.42) 1. Nudger one-way clutch 3. Feed roller 2. Feed one-way clutch s4500-092 1 2 3.

  • Page 312

    Fru disassembly 8-23 1. Open the top cover. 2. Remove the feed roller (page 8-20). 3. Slide the feed one-way clutch off the feed shaft. 4. Remove the e-ring retaining the nudger one-way clutch on the feed shaft. 5. Slide the nudger one-way clutch off the feed shaft..

  • Page 313: Nudger Gear

    8-24 phaser 4500 service manual nudger gear (pl5.1.10) 1. Nudger gear 5. Boss (lift up) 2. Nudger roller 6. Left holder 3. Nudger support 7. Hooks 4. No paper actuator s4500-163 4 6 7 7 7 5 6 3 4 5 6 1 2.

  • Page 314: Replacement Note:

    Fru disassembly 8-25 1. Remove the 150-sheet feeder assembly (page 8-18). 2. 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. 3. Remove the left holder and no paper actuator from ...

  • Page 315

    8-26 phaser 4500 service manual feed clutch, registration clutch (pl5.1.21) (pl5.1.23) 1. Remove the 150-sheet feeder assembly (page 8-18). 2. Disconnect the connector (p/j 242) of the feed clutch from the tray 1 harness assembly. 3. Remove the e-ring retaining the feed clutch, and slide the feed cl...

  • Page 316: Registration Sensor

    Fru disassembly 8-27 registration sensor (pl5.1.30) 1. Remove the main fan (page 8-84). 2. Release the hooks that secure the sensor cover, and remove the sensor cover from the registration chute assembly. 3. Release the hooks that secure the registration sensor, and remove it from the sensor cover. ...

  • Page 317: No Paper Sensor

    8-28 phaser 4500 service manual no paper sensor (pl5.1.38) 1. No paper sensor holder 3. 150-sheet feeder assembly 2. No paper sensor s4500-098 1 2 3 p/j 240

  • Page 318: Replacement Note:

    Fru disassembly 8-29 1. Remove the 150-sheet paper cassette (tray 1). 2. Remove the print cartridge, and protect it from light exposure. 3. Remove the paper exit rear door (pl10.2.21/pl9.1.12) (page 8-5). 4. Remove the fuser assembly (page 8-54). 5. Lift the 150-sheet feeder roller holder assembly u...

  • Page 319: Toner Sensor Assembly

    8-30 phaser 4500 service manual toner sensor assembly (pl5.1.45) 1. Remove the print cartridge and leave the top cover open. Protect the print cartridge from light exposure. 2. Unplug the connector (p/j220) of the toner sensor from the toner harness assembly 1. 3. Release the wires from the cable re...

  • Page 320: 550-Sheet Feeder Assembly

    Fru disassembly 8-31 print engine: 550-sheet paper feeder 550-sheet feeder assembly (pl7.1.10) 1. Remove the 150-sheet feeder assembly (page 8-18). 2. Remove the 550-sheet paper cassette (tray 2). 3. Unplug the connector (p/j248) and release the cables from the two cable restraints on the tie plate....

  • Page 321: Nudger Roller, Feed Roller

    8-32 phaser 4500 service manual nudger roller, feed roller (pl7.1.19) (pl7.1.29) 1. Remove the print cartridge and leave the cover open so that the removal can be checked visually. 2. Remove the paper cassettes from tray 1 and tray 2. 3. Lift up the 150-sheet feeder assembly until it locks into the ...

  • Page 322: Nudger One-Way Clutch

    Fru disassembly 8-33 nudger one-way clutch (pl7.1.27) 1. Remove the print cartridge and leave the cover open so that the removal can be checked visually. 2. Remove the tray 1 and tray 2 paper cassettes. 3. Lift up the 150-sheet feeder assembly until it locks into the raised detent position. 4. Remov...

  • Page 323: Nudger Gear

    8-34 phaser 4500 service manual nudger gear (pl7.1.18) 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 s4500-105 1 2 3 4 5 6 7 8 7 3.

  • Page 324: Replacement Note:

    Fru disassembly 8-35 1. Remove the stacker if installed. 2. Remove the print cartridge and leave the top cover open. 3. Remove both paper cassettes (trays 1 and 2). 4. Remove any optional 500-sheet feeder(s) (page 8-93). 5. Remove the paper exit rear door (page 8-5). 6. Remove the fuser assembly (pa...

  • Page 325: Feed Clutch

    8-36 phaser 4500 service manual feed clutch (pl7.1.20) 1. Out chute 3. Feed clutch 2. Tie plate s4500-106 1 2 3 1 p/j 247.

  • Page 326

    Fru disassembly 8-37 1. Remove the 150-sheet feeder assembly (page 8-18). 2. Remove the 550-sheet feeder assembly (page 8-31). 3. 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. 4. Unplug the connector (p/j247) of th...

  • Page 327: No Paper Sensor

    8-38 phaser 4500 service manual no paper sensor (pl7.1.38) 1. Remove the 150-sheet feeder assembly (page 8-18). 2. Remove the screw (gold, 6 mm) that attach the no paper sensor holder. 3. Remove the no paper sensor holder from the 550-sheet feeder assembly. 4. Release the hooks that secure the no pa...

  • Page 328: Right Tray Guide

    Fru disassembly 8-39 right tray guide (pl7.1.3) 1. Remove the print cartridge and paper cassettes. 2. Remove any optional 550-sheet feeder(s) (page 8-93). 3. Lay the printer on its right side. 4. Remove the screw (silver, 6 mm) that attaches the right tray guide to the frame. 1. Low paper sensor har...

  • Page 329: Replacement Notes:

    8-40 phaser 4500 service manual 5. Lift the latch and shift the right tray guide back and up as indicated by the arrow in the figure. Separate the right tray guide from the frame. 6. Release the wire harness from the rear of the right tray guide. 7. Unplug the connector (p/j260) of the low-paper sen...

  • Page 330: Left Tray Guide

    Fru disassembly 8-41 left tray guide (pl7.1.7) 1. Remove the print cartridge and paper cassettes. 2. Remove any optional 550-sheet paper feeder(s) (page 8-93). 3. Remove the front cover (page 8-12). 4. Lay the printer on its left side. 5. Unplug the left tray guide harness at connector p/j1821. 6. R...

  • Page 331: Low Paper Sensor/actuator

    8-42 phaser 4500 service manual low paper sensor/actuator (pl7.1.4) 1. Low 1 harness assembly 3. Latch hooks 2. Low paper sensor 4. Actuator s4500-110 1 2 4 p/j 260 3.

  • Page 332

    Fru disassembly 8-43 1. Remove the print cartridge and paper cassettes. 2. Remove any optional 550-sheet paper feeder(s) (page 8-93). 3. Lay the printer on its right side. Note take care not to scratch or mar the printer covers. 4. Squeeze the actuator latch hooks together and lift the actuator off ...

  • Page 333: Print Engine: Xerographics

    8-44 phaser 4500 service manual print engine: xerographics front duct, sub fan (pl8.1.4) (pl8.1.5) 1. Remove the front cover (page 8-12). Removing the front cover requires removing all other printer covers and the paper exit assembly. 1. Front duct 2. Front tie plate p270 j270 s4500-112 1 2.

  • Page 334

    Fru disassembly 8-45 2. Remove the three screws (one silver tapping with flange, 8 mm; two gold tapping, 8 mm) that attach the front duct. 3. Unplug the sub fan harness from the lvps harness assembly at connector p/j270. 4. Release the gray wires from the cable slot. 5. Remove the front duct (with t...

  • Page 335: Laser Unit Assembly

    8-46 phaser 4500 service manual laser unit assembly (pl8.1.1) caution when removing or installing the laser unit assembly, set the printer on a smooth, level work surface such as a desk. Working on a rough or inclined surface can result in mis-alignment of the laser unit assembly. 1. Laser unit asse...

  • Page 336

    Fru disassembly 8-47 1. Remove the front duct (page 8-44), but do not remove the sub fan from the duct. 2. Remove the three screws (silver machine with flange, 8 mm) that attach the upper duct. 3. Tilt out the left side of the upper duct to clear the connector, and remove the duct. 4. Release the th...

  • Page 337: Laser Unit Shield Plate

    8-48 phaser 4500 service manual laser unit shield plate (pl8.1.3) 1. Remove the fuser assembly (page 8-54). 2. Remove the laser unit assembly (page 8-46). 3. Remove the two screws (black with flange, 8 mm) that attach the laser unit shield plate to the frame. 4. Lift the laser unit shield plate out ...

  • Page 338: Print Cartridge Left Guide

    Fru disassembly 8-49 print cartridge left guide (pl8.1.15) 1. Remove the laser unit shield plate (page 8-48). 2. Remove the fuser harness clamp that secures the fuser harness to the frame. 3. Release the latch posts and free the fuser connector (p/j4647) from the frame. 4. Disconnect p/j142, which c...

  • Page 339: Fuser Harness Assembly

    8-50 phaser 4500 service manual fuser harness assembly (pl8.1.17) 1. Remove the fuser assembly (page 8-54). 2. Remove the transfer roller assembly (page 8-55). 3. Remove the left tray guide (page 8-41). 1. Fuser harness assembly 4. Claws 2. Print cartridge guide cover 5. Hooks 3. Print cartridge lef...

  • Page 340

    Fru disassembly 8-51 4. Remove the motor cover (page 8-67). 5. Remove the lvps shield plate (page 8-75). 6. Remove the print cartridge left guide (page 8-49). 7. Spread the loops on the print cartridge guide cover to release the hooks in the print cartridge left guide, then remove the print cartridg...

  • Page 341: Link Lever, Gear 3 Link

    8-52 phaser 4500 service manual link lever, gear 3 link (pl8.1.29) (pl8.1.30) 1. Remove the transfer roller assembly (page 8-55). 2. Remove the laser unit shield plate (page 8-48). 3. Remove the lvps shield plate (page 8-75). 4. Remove the left tray guide (page 8-41). 5. Remove the motor cover (page...

  • Page 342

    Fru disassembly 8-53 6. Remove the print cartridge left guide (page 8-49). 7. Remove the print cartridge guide cover and fuser harness assembly from the print cartridge left guide (page 8-50). 8. Remove the link lever and gear 3 link..

  • Page 343: Fuser Assembly

    8-54 phaser 4500 service manual fuser assembly (pl8.1.20) warning the fuser assembly is very hot immediately after the printer is turned off. To avoid possible burns, wait to remove the fuser until it cools down sufficiently to be handled. 1. Open the paper exit rear door (page 8-5). 2. Push down th...

  • Page 344: Transfer Roller Assembly

    Fru disassembly 8-55 transfer roller assembly (pl8.1.21) 1. Remove the print cartridge and leave the top cover open. Protect the print cartridge from light exposure. 2. Pinch the hooks of both ends of the transfer roller assembly, and remove it from the printer. Note be careful to avoid damaging the...

  • Page 345: Transfer Chute

    8-56 phaser 4500 service manual transfer chute (pl8.1.22) 1. Transfer chute 2. Latch tab s4500-122 2 1.

  • Page 346

    Fru disassembly 8-57 1. Remove the transfer roller assembly (page 8-55). 2. Remove the fuser assembly (page 8-54). 3. Remove the main fan (page 8-84) 4. Lift the latch tab on the transfer chute and shift the transfer chute toward the printer’s left side. 5. Shift the transfer chute in the direction ...

  • Page 347

    8-58 phaser 4500 service manual print cartridge right guide assembly (pl8.1.25) 1. Image processor shield assembly 3. Hvps/engine logic board 2. Hvps shield plate 4. Print cartridge right guide assembly s4500-124 p31 p15 3 j15 j31 4 1 2.

  • Page 348

    Fru disassembly 8-59 1. Remove the fuser assembly (page 8-54). 2. Remove the transfer roller assembly (page 8-55). 3. Remove the front duct (page 8-44). 4. Remove the image processor shield assembly (page 8-86). 5. Remove the hvps shield plate (page 8-88). 6. Unplug the hv connector, j31 from p31 on...

  • Page 349: Duplex Unit Opening Cover

    8-60 phaser 4500 service manual duplex unit opening cover (pl9.1.13) 1. Release the latch hooks of the duplex unit opening cover, and remove it from the paper exit rear door. 1. Duplex unit opening cover 2. Latch hooks s4500-126 1 2.

  • Page 350: Print Engine: Paper Exit

    Fru disassembly 8-61 print engine: paper exit paper exit assembly (pl10.1.2) 1. Remove the paper exit cover (page 8-4) or stacker (page 8-132) if installed. 2. Remove the right cover (page 8-7 3. Remove the left cover (page 8-9). 4. Remove the image processor shield assembly (page 8-86). 5. Unplug j...

  • Page 351

    8-62 phaser 4500 service manual 6. Unplug j103 (the exit motor assembly) from p103 on the exit motor pwba. 7. Remove the four screws (gold machine w/ washers, 8 mm) that attach the paper exit assembly to the top of the printer, and the one screw (silver flanged machine, 8 mm) that attaches the paper...

  • Page 352: Replacement Note:

    Fru disassembly 8-63 upper exit chute, lower exit chute (pl10.1.4) (pl10.1.21) 1. Remove the paper exit assembly (page 8-61). 2. Remove the two screws (gold tapping, 8 mm) that attach the upper exit chute to the lower exit chute. 3. Separate the upper exit chute and lower exit chute. Replacement not...

  • Page 353: Exit Motor Assembly

    8-64 phaser 4500 service manual exit motor assembly (pl10.1.15) 1. Remove the paper exit assembly (page 8-61). 2. Remove the upper exit chute (page 8-63). 3. Remove the two screws (silver machine, 6 mm) that attach the exit motor assembly to the exit motor bracket. 4. Remove the exit motor assembly....

  • Page 354: Stack Full Sensor

    Fru disassembly 8-65 stack full sensor (pl10.1.26) 1. Remove the paper exit assembly (page 8-61). 2. Remove the upper exit chute (page 8-63). 3. Unplug j290 from p290 on the stack full sensor. 4. Release the hooks of the stack full sensor, and remove the stack full sensor from the lower exit chute. ...

  • Page 355: Stack Full Actuator

    8-66 phaser 4500 service manual stack full actuator (pl10.1.10) 1. Remove the paper exit assembly (page 8-61). 2. Remove the upper chute (page 8-63). 3. Remove the stack full actuator from the upper exit chute: a. Snap the flag end out of the retainer. B. Shift to the left (as shown in the drawing) ...

  • Page 356: Motor Cover

    Fru disassembly 8-67 print engine: frame and drive motor cover (pl11.1.1) 1. Motor cover s4500-137 1.

  • Page 357

    8-68 phaser 4500 service manual 1. Remove the print cartridge and paper cassettes. 2. Remove the transfer roller assembly (page 8-55). 3. Remove the fuser assembly (page 8-54). 4. Remove the laser unit shield plate (page 8-48). 5. Remove the left tray guide (page 8-41). 6. Swing the 150-sheet feeder...

  • Page 358: Main Motor

    Fru disassembly 8-69 main motor (pl11.1.2) 1. Main motor 3. Lvps 2. Lvps shield plate s4500-138 1 2 p43 3 j43.

  • Page 359

    8-70 phaser 4500 service manual 1. Remove the print cartridge and paper cassettes. 2. Remove the lvps shield plate (page 8-75). 3. Unplug the main motor cable (j43) from p43 on the lvps. 4. Remove the motor cover (page 8-67). 5. Remove the three screws (gold machine, 6 mm) that attach the main motor...

  • Page 360: Gear Assembly Housing

    Fru disassembly 8-71 gear assembly housing (pl11.1.3) 1. Remove the left cover (page 8-9). 2. Remove the lvps shield plate (page 8-75). 3. Unplug j44 (rear cover switch cable) from p44 on the lvps. 4. Release the wiring harnesses from the cable restraints on the gear assembly housing. 1. Gear assemb...

  • Page 361: Replacement Notes:

    8-72 phaser 4500 service manual 5. Remove the six screws (five silver machine, 6; one gold machine, 6 mm) that attach the gear assembly housing to the frame. Note the gears pointed out in this figure are not secured on their shafts and may come off when you remove the gear assembly housing. Be caref...

  • Page 362: Gear Assembly Plate

    Fru disassembly 8-73 gear assembly plate (pl11.1.10) 1. Gear 9 4. Gear 2. Gear assembly plate 5. Spring 3. Locking tab s4500-141 1 2 4 5 3.

  • Page 363: Replacement Note:

    8-74 phaser 4500 service manual 1. Remove the fuser assembly (page 8-54). 2. Remove the gear assembly housing (page 8-71). Note when removing the gear assembly plate, one of the gears installed on the gear assembly plate is not secured on its shaft and might come off. Also, there is a spring inside ...

  • Page 364: Print Engine: Electrical

    Fru disassembly 8-75 print engine: electrical lvps shield plate (pl12.1.3) 1. Remove the front cover (page 8-12). 2. Remove the five screws (silver, 6 mm) that attach the lvps shield plate to the frame. 3. Remove the lvps shield plate. 1. Lvps shield plate s4500-142 1.

  • Page 365: Exit Motor Pwba

    8-76 phaser 4500 service manual exit motor pwba (pl12.1.4) 1. Exit motor pwba 3. P/j 101 2. P/j 102 4. P/j 103 s4500-143 1 2 3 4.

  • Page 366

    Fru disassembly 8-77 1. Remove the paper exit rear door (page 8-5). 2. Remove the rear cover (page 8-6). 3. Remove the left cover (page 8-9). 4. Disconnect the harnesses from the connectors (p/j101, p/j102 and p/j103) on the exit motor pwba. 5. Remove the two screws (silver, 6 mm) that attach the ex...

  • Page 367

    8-78 phaser 4500 service manual low voltage power supply (lvps) (pl12.1.5) 1. Exit motor pwba 3. P101 2. Lvps 4. P/j404 46 47 45 p/j 42 4140 43 44 48 p/j s4500-144 1 2 3 4.

  • Page 368

    Fru disassembly 8-79 1. Remove the front cover (page 8-12). 2. 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. 3. Disconnect the har...

  • Page 369: Dc-Dc Converter

    8-80 phaser 4500 service manual dc-dc converter (pl 12.01.Aa) 1. Remove the front cover (page 8-12). 2. Unplug the cable connectors at p401, p402, and p403. 3. Remove the two screws (silver machine, 6 mm) and lift out the board. 1. Dc-dc converter s4500-262 p402 p401 p403 1.

  • Page 370

    Fru disassembly 8-81 power switch, ac power harness assembly (pl12.1.6), (pl12.1.8) 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 s4500-145 6 7 8 1 2 3 4 5.

  • Page 371

    8-82 phaser 4500 service manual 1. Remove the front cover (page 8-12). 2. Remove the lvps shield plate (page 8-75). 3. Release the clamp of the ac power harness assembly from the clamps on the gear assembly housing. 4. Disconnect the connector (p/j480) of the ac power harness assembly from the power...

  • Page 372: Rear Cover Switch

    Fru disassembly 8-83 rear cover switch (pl12.1.7) removal 1. Remove the lvps shield plate (page 8-75). 2. Disconnect the connector (p/j44) of the rear cover switch from the lvps. 3. Release the harness assembly of the rear cover switch from the clamps on the gear assembly housing. 4. Remove the scre...

  • Page 373: Main Fan

    8-84 phaser 4500 service manual main fan (pl12.1.10) 1. Main fan 2. Label 1 s4500-147 2.

  • Page 374: Replacement Note:

    Fru disassembly 8-85 1. Remove the paper exit rear door (page 8-5). 2. Remove the rear cover (page 8-6). 3. Disconnect the connector (p/j244) of the main fan from the tray 1 harness assembly. 4. Remove the two screws (tapping, 30 mm) that attach the main fan to the frame. Replacement note: ■ when in...

  • Page 375

    8-86 phaser 4500 service manual image processor shield assembly (pl12.1.14) 1. Remove the right cover (page 8-7). 2. Remove the twelve screws (silver, 6 mm) that attach the image processor shield assembly to the frame. 3. Remove the image processor shield assembly. 1. Image processor shield assembly...

  • Page 376: I/p Shield Window

    Fru disassembly 8-87 i/p shield window (pl12.1.15) 1. Remove the right cover (page 8-7). 2. Remove the two screws that secure the shield window to the ip shield assembly. 3. Remove the shield window. 1. Shield window s4500-149 1.

  • Page 377: Hvps Shield Plate

    8-88 phaser 4500 service manual hvps shield plate (pl12.1.18) 1. Remove the right cover (page 8-7). 2. Remove the image processor shield assembly (page 8-86). 3. Remove the 10 screws (silver, 6 mm) that attach the hvps shield plate to the frame. 4. Remove the hvps shield plate. 1. Hvps shield plate ...

  • Page 378: Hvps/engine Logic Board

    Fru disassembly 8-89 hvps/engine logic board (pl12.1.19) 1. Remove the right cover (page 8-7). 2. Remove the hvps shield plate (page 8-88). 1. Hook 3. Hvps shield bracket 2. Hvps/engine logic board 4. Right handle bracket s4500-151 10 11 27 13 14 15 18 1716 20 192226 24 28 30 29 31 p/j 4 1 2 3.

  • Page 379: Replacement Notes:

    8-90 phaser 4500 service manual 3. Remove the screw (silver, 6 mm) that attach the right handle bracket to the frame. 4. Remove the right handle bracket from the frame. 5. Remove the three screws (silver, 6 mm) that attach the hvps shield bracket to the frame. 6. Remove the hvps shield bracket. 7. U...

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

    Fru disassembly 8-91 image processor (i/p) board (pl 12.1.13) caution observe electrostatic precautions when handling the i/p board and its components. 1. Remove the right cover (page 8-7). 1. Memory dimms 4. Nvram (u660) 2. Flash memory (optional) 5. Rear panel 3. Hard disk drive (optional) s4500-2...

  • Page 381: Replacement Note:

    8-92 phaser 4500 service manual 2. Remove the image processor shield assembly (page 8-86). 3. Unplug the ribbon cable from j800 (the connector to the hvps/engine logic board). Be sure to note the orientation of the blue stripe on the ribbon. 4. Unplug the cables at j110 and j130 (at the top of the b...

  • Page 382

    Fru disassembly 8-93 options: 550-sheet paper feeder 550-sheet paper feeder removal 1. 550-sheet paper feeder 2. Latch clip s4500-152 1 2.

  • Page 383: Replacement Note:

    8-94 phaser 4500 service manual 1. Remove the print cartridge. 2. Pull out the 550-sheet paper cassette from the 2nd tray of the printer. 3. Remove the 550-sheet paper cassette from the optional 550-sheet paper feeder. 4. Remove two latch clips at the rear of the printer and the two latch clips insi...

  • Page 384: Right Cover Plate

    Fru disassembly 8-95 right cover plate (pl20.1.1) 1. Right cover plate 3. Boss 2. 550 right cover frame s4500-153 1 3 2.

  • Page 385: Replacement Note:

    8-96 phaser 4500 service manual 1. Remove the screw (gold tapping, 8 mm) that attaches the right cover plate to the frame. 2. Lift up the rear of the right cover plate just above the boss of the 550 right cover frame a little to release it. 3. Shift the right cover plate in the direction of the arro...

  • Page 386: Left Cover Plate

    Fru disassembly 8-97 left cover plate (pl20.1.3) 1. Grounding plate 3. 550 left cover frame 2. Left cover plate s4500-154 1 2 3.

  • Page 387: Replacement Notes:

    8-98 phaser 4500 service manual 1. Remove the two screws (gold tapping, 8 mm) that attach the grounding plate to the frame. 2. Remove the grounding plate. 3. Lift up the left cover plate just above the boss of the 550 left cover frame a little to release it. 4. Shift the left cover plate in the dire...

  • Page 388: Replacement Note:

    Fru disassembly 8-99 option paper size switch assembly (pl20.1.18) 1. Release the feeder size 1 assembly harness from the hooks of the 550 left cover frame. 2. Remove the two screws (gold tapping, 8 mm) that attach the option paper size switch assembly to the 550 left cover frame. These screws are a...

  • Page 389

    8-100 phaser 4500 service manual optional feeder drive assembly (pl20.1.8) 1. Remove the optional 550-sheet paper feeder (page 8-93). 2. Remove the left cover plate (page 8-97). 1. Optional feeder drive assembly 2. Screw a s4500-156 1 2 j820

  • Page 390: Replacement Notes:

    Fru disassembly 8-101 3. Remove the rear cover (steps 1 and 2 in “550-sheet feeder” on page 8-104). 4. Disconnect the feeder motor harness (j820) from p820 (located at the rear of the 550-sheet feeder assembly). 5. Remove the three screws at the left end of the 550-sheet feeder (page 8-104). 6. Remo...

  • Page 391: 550-Sheet Feeder Pwba

    8-102 phaser 4500 service manual 550-sheet feeder pwba (pl20.1.34) 1. 550-sheet feeder pwba 2. Boss s4500-159 p/j82 85 81 84 83 80 1 2.

  • Page 392

    Fru disassembly 8-103 1. Remove the right cover plate (page 8-95). 2. 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. 3. Remove the two screws (gold tapping, 8 mm) that attach the 550-sheet feeder pwba to the frame. 4....

  • Page 393: 550-Sheet Feeder

    8-104 phaser 4500 service manual 550-sheet feeder (pl20.2.1) 1. Feeder rear cover 3. Lower chute 2. Optional 550-sheet feeder 4. Harness clamps s4500-160 4 3 2 1.

  • Page 394

    Fru disassembly 8-105 1. Remove the five screws (gold tapping, 8 mm) that attach the feeder rear cover to the frame. 2. 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. 3. Disconnect the three wiring h...

  • Page 395: Nudger Roller, Feed Roller

    8-106 phaser 4500 service manual nudger roller, feed roller (pl20.2.11) (pl20.2.12) 1. Release the hook that retains the nudger roller and pull the roller off the nudger shaft. 2. Release the hook that retains the feed roller and pull the roller off the feed shaft. Replacement note: ■ the same rolle...

  • Page 396: Nudger One-Way Clutch

    Fru disassembly 8-107 nudger one-way clutch (pl20.2.15) 1. Remove the feed roller (page 8-106). 2. Pull out the one-way feed clutch from the feed shaft. 3. Remove the e-ring that secures the nudger one-way clutch to the feed shaft. 4. Pull out the nudger one-way clutch from the feed shaft. 1. Nudger...

  • Page 397: Nudger Gear

    8-108 phaser 4500 service manual nudger gear (pl20.2.10) 1. Nudger gear 5. Boss (lift up) 2. Nudger roller 6. Left holder 3. Nudger support 7. Hooks 4. No paper actuator s4500-163 4 6 7 7 7 5 6 3 4 5 6 1 2.

  • Page 398: Replacement Notes:

    Fru disassembly 8-109 note when handling the nudger roller or nudger gear, avoid touching the rubber surfaces of the rollers. 1. 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. 2. While lift...

  • Page 399: Feed Clutch Assembly

    8-110 phaser 4500 service manual feed clutch assembly (pl20.2.21) 1. Remove the optional 550-sheet paper feeder (page 8-93). 2. Remove the six screws (gold taping, 8 mm) that attach the tie plate. 1. Out chute 3. Tie plate 2. Feed clutch assembly 4. Connector s4500-165 1 2 3 4 1.

  • Page 400

    Fru disassembly 8-111 3. 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. 4. Disconnect the connector (p/j853) of the feed clutch assembly from the clutch sensor 1 assembly harness. 5. Remove the e...

  • Page 401: Turn Roller Clutch

    8-112 phaser 4500 service manual turn roller clutch (pl20.2.22) 1. Remove the optional 550-sheet paper feeder (page 8-93). 2. Remove the six screws (gold taping, 8 mm) that attach the tie plate. 3. Remove the tie plate from the out chute. Note the connector in the following step has a gender adapter...

  • Page 402: Retard Roller

    Fru disassembly 8-113 retard roller (pl20.3.2) 1. Retard roller 3. Hooks 2. Friction clutch 4. Retard spring s4500-168 1 2 3 4.

  • Page 403: Removal

    8-114 phaser 4500 service manual note when handling the retard roller, avoid touching the rubber surfaces of the roller. Removal 1. Pull out the 550-sheet paper cassette from the optional 550-sheet paper feeder. 2. Release the hooks that secure the retard holder to the 550-sheet paper cassette using...

  • Page 404: Options: Duplex Unit

    Fru disassembly 8-115 options: duplex unit duplex unit removal (pl 21.1) 1. Thumbscrew 3. Bottom hook 2. Right latch lever 4. Duplex unit s4500-184 2 4 1 3.

  • Page 405: Replacement Note:

    8-116 phaser 4500 service manual note be careful not to drop the duplex unit when removing it. 1. Loosen the 2 thumb screws that secure the duplex unit to the printer. 2. Push up the right latch lever to release the duplex unit from the printer. 3. Tilt the duplex unit back, then lift away from the ...

  • Page 406: Left Cover

    Fru disassembly 8-117 left cover (pl21.1.25) 1. Remove the three screws (gold tapping, 8 mm) that attach the left cover. 2. Remove the left cover from the duplex unit housing cover. 1. Duplex unit housing cover 2. Left cover s4500-193 1 2.

  • Page 407: Right Cover

    8-118 phaser 4500 service manual right cover (pl21.1.41) 1. Remove the two screws (gold tapping, 8 mm) that attach the right cover. 2. Remove the right cover from the duplex unit housing cover. 1. Right cover 2. Duplex unit housing cover s4500-194 1 2.

  • Page 408: Top Cover

    Fru disassembly 8-119 top cover (pl21.1.12) 1. Remove the right cover (page 8-118). 2. Remove the screw (gold tapping, 8 mm) that attaches the top cover to the duplex unit housing cover. 3. Shift the top cover in the direction of the arrow to release the four hooks, and remove the top cover from the...

  • Page 409: Upper Assembly Housing

    8-120 phaser 4500 service manual upper assembly housing (pl21.1.1) 1. Remove the four screws (gold tapping, 8 mm) that attach the upper assembly housing to the duplex unit. 2. Remove the upper assembly housing from the duplex unit housing cover. 1. Upper assembly housing 2. Duplex unit housing cover...

  • Page 410: Duplex Unit Lower Housing

    Fru disassembly 8-121 duplex unit lower housing (pl21.1.6) 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 s4500-186 4 5 7 8 3 5 1 2 p50 j50 6.

  • Page 411

    8-122 phaser 4500 service manual 1. Remove the left cover (page 8-117). 2. Remove the right cover (page 8-118). 3. Unplug j50, the duplex unit harness, from p50 on the duplex unit pwba. 4. Remove the screw (silver machine, 6 mm) to disconnect the duplex unit ground wire. 5. Release the duplex unit h...

  • Page 412: Duplex Unit Pwba

    Fru disassembly 8-123 duplex unit pwba (pl21.1.32) 1. Remove the left cover (page 8-117). 2. Remove the right cover (page 8-118). 3. Remove the top cover (page 8-119). 4. Unplug the harness connectors from p50, p51, p52, p53 and p54) on the duplex unit pwba. Note the p55 connector is unused. 5. Remo...

  • Page 413: Duplex Unit Fan

    8-124 phaser 4500 service manual duplex unit fan (pl21.1.33) 1. Duplex unit pwba 3. Duplex unit fan 2. Duplex unit housing cover 4. Label s4500-190 2 3 4 1 j54 p54.

  • Page 414

    Fru disassembly 8-125 1. Remove the right cover (page 8-118). 2. Remove the top cover (page 8-119). 3. Unplug the fan cable connector, j54, from p54) on the duplex unit pwba. 4. Release the fan cable from the hook on the duplex unit housing cover. 5. Remove the two screws (gold tapping, 22 mm) that ...

  • Page 415: Duplex Unit Sensor

    8-126 phaser 4500 service manual duplex unit sensor (pl21.1.34) 1. Remove the right cover (page 8-118). 2. Remove the top cover (page 8-119). 3. Release the hooks of the duplex unit sensor, and remove it from the duplex unit housing cover. 4. Disconnect the connector (p/j530) of the duplex unit asse...

  • Page 416: Duplex Unit Roller

    Fru disassembly 8-127 duplex unit roller (pl21.1.17) 1. Remove the left cover (page 8-117). 2. Remove the right cover (page 8-118). 3. Remove the top cover (page 8-119). 1. Shoulder screw (tapping) 5. Roller gear 2. Damper cover 6. Duplex unit rollers 3. Damper spring 7. Duplex unit housing cover 4....

  • Page 417

    8-128 phaser 4500 service manual 4. Remove the upper assembly housing (page 8-120). 5. Remove the duplex unit lower housing (page 8-121). 6. Remove the two screws (gold tapping, 8 mm) and the tapping screw that attach the damper cover to the duplex unit housing cover. 7. Remove the damper cover and ...

  • Page 418: Duplex Unit Motor

    Fru disassembly 8-129 duplex unit motor (pl21.1.29) 1. Duplex unit motor 4. Latch spring 2. Ground wire 5. Duplex unit housing cover 3. Motor bracket s4500-195 1 2 5 4 3.

  • Page 419

    8-130 phaser 4500 service manual 1. Remove the left cover (page 8-117). 2. Remove the top cover (page 8-119). 3. Remove the duplex unit pwba (page 8-123). 4. Remove the screw (silver, 6 mm) that attaches the duplex unit assembly harness ground 5. Remove the three screws (gold tapping, 8 mm) that att...

  • Page 420: Duplex Unit Switch

    Fru disassembly 8-131 duplex unit switch (pl21.1.27) 1. Remove the left cover (page 8-117). 2. Remove the top cover (page 8-119). 3. Remove the duplex unit motor bracket as described in the duplex unit motor procedure (page 8-129). 4. Disconnect the connector of the duplex unit cover assembly harnes...

  • Page 421: Options: Stacker

    8-132 phaser 4500 service manual options: stacker stacker removal 1. Loosen the two thumb screws that secure the stacker to the printer. 2. Tilt the stacker forward to release connector p/j3070 and the front hooks, then lift the stacker off the printer. 1. Thumbscrew 3. Hook 2. Stacker s4500-198 1 2...

  • Page 422: Stacker Rear Cover

    Fru disassembly 8-133 stacker rear cover (pl23.1.4) 1. Open the rear cover about 1in. (2cm). 2. 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. 1. Rear cover 2. Boss s4500-199 1 2.

  • Page 423: Stacker Cover

    8-134 phaser 4500 service manual stacker cover (pl23.1.1) 1. Stacker cover s4500-201 1.

  • Page 424: Removal

    Fru disassembly 8-135 removal 1. Remove the stacker rear cover (page 8-133). 2. Remove the weight. 3. Disengage both left flapper hinges from the stacker cover. 4. Disengage the link attached to the left flapper from the stack full shaft. 5. Disengage both right flapper hinges from the stacker cover...

  • Page 425: Replacement

    8-136 phaser 4500 service manual 8. Lift the stacker cover with the attached stacker tray assembly to remove it from the stacker. Replacement caution to avoid breaking the sensor flag off the right end of the stack full actuator, be very careful while sliding the stacker assembly back into the stack...

  • Page 426: Stacker Front Cover

    Fru disassembly 8-137 stacker front cover (pl23.1.45) 1. Remove the stacker rear cover (page 8-133). 2. Remove the stacker cover (page 8-134). 3. Remove the three screws (gold tapping, 8 mm) that attach the stacker front cover to the stacker. 4. Release the hooks on both sides of the stacker front c...

  • Page 427: Stacker Tray Assembly

    8-138 phaser 4500 service manual stacker tray assembly (pl23.1.40) 1. Remove the stacker rear cover (page 8-133). 2. Remove the stacker cover (page 8-134). 3. Remove the four screws (gold tapping, 8 mm) that attach the stacker tray assembly to the stacker cover, and remove the stacker tray assembly ...

  • Page 428: Stack Full Actuator

    Fru disassembly 8-139 stack full actuator (pl23.1.15) 1. Flap 3. Hook 2. Stack full actuator s4500-206 1 2 3.

  • Page 429: Removal

    8-140 phaser 4500 service manual removal 1. Remove the stacker rear cover (page 8-133). 2. Remove the stacker cover (page 8-134). 3. Lift the stack full actuator flap in the direction of the arrow (1). Release the actuator shaft from the hook, then move the actuator in the direction of the arrow (2)...

  • Page 430

    Fru disassembly 8-141 2. Install the stacker cover (page 8-134). 3. 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..

  • Page 431: Stacker Pwba

    8-142 phaser 4500 service manual stacker pwba (pl23.1.22) 1. Stacker pwba 3. Guide slots 2. Stacker right support s4500-208 p74 1 2 2 p70 p72 p71 p73 p75 3.

  • Page 432: Replacement Notes:

    Fru disassembly 8-143 1. Remove the stacker rear cover (page 8-133). 2. Remove the stacker cover (page 8-134). 3. Remove the stacker front cover (page 8-137). 4. Unplug the harness connectors at p70, p71, p72, p73, p74 and p75 on the stacker pwba. 5. Remove the two screws (gold tapping, 8 mm) that a...

  • Page 433: Offset Motor Assembly

    8-144 phaser 4500 service manual offset motor assembly (pl23.1.20) 1. Remove the stacker rear cover (page 8-133). 2. Remove the stacker cover (page 8-134). 3. Remove the stacker front cover (page 8-137). 4. Remove the stacker pwba (page 8-142). 5. Remove the two screws (gold tapping, 8 mm) that atta...

  • Page 434: Gate Solenoid Assembly

    Fru disassembly 8-145 gate solenoid assembly (pl23.1.27) 1. Remove the stacker rear cover (page 8-133). 2. Remove the stacker cover (page 8-134). 3. Remove the stacker front cover (page 8-137). 4. Remove the stacker pwba (page 8-142). 5. Remove the offset motor assembly (page 8-144). 6. Remove the t...

  • Page 435: Stacker Sensor and Actuator

    8-146 phaser 4500 service manual stacker sensor and actuator (pl23.1.30) 1. Stacker actuator 4. Stacker housing 2. Pivot hooks 5. Actuator spring 3. Stacker sensor s4500-211 j730 4 2 1 5 4 3.

  • Page 436

    Fru disassembly 8-147 1. Remove the stacker rear cover (page 8-133). 2. Remove the stacker cover (page 8-134). 3. Remove the stacker front cover (page 8-137). 4. Shift the stacker actuator in the direction of the arrows to release the pivots from the hooks on both sides. Note carefully observe the o...

  • Page 437

    8-148 phaser 4500 service manual stacker rear cover interlock switch (pl23.1.18) 1. Remove the stacker rear cover (page 8-133). 2. Remove the stacker cover (page 8-134). 3. Disconnect the wire harness from the interlock switch. 4. Compress the hooks on the top and bottom of the switch and slide it o...

  • Page 438: Lower Stacker Roller

    Fru disassembly 8-149 lower stacker roller (pl23.1.16) 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 s4500-214 1 4 5 2 5 3 6 7 8.

  • Page 439: Replacement Note:

    8-150 phaser 4500 service manual 1. Remove the stacker rear cover (page 8-133). 2. Remove the stacker cover (page 8-134). 3. Remove the screws (one gold tapping, 8 mm; one silver machine, 6 mm) that attach the left stacker support. 4. Remove the two screws (gold tapping, 8 mm) that attach the stacke...

  • Page 440: Upper Stacker Roller

    Fru disassembly 8-151 upper stacker roller (pl23.1.36) 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 s4500-215 3 4 8 6 7 9 5 7 1 2.

  • Page 441

    8-152 phaser 4500 service manual 1. Remove the stacker rear cover (page 8-133). 2. Remove the stacker cover (page 8-134). 3. Remove the stacker front cover (page 8-137). 4. Slide the cam gear off its shaft (page 8-137). 5. Remove the two screws (one gold tapping, 8 mm; one silver machine, 6 mm) that...

  • Page 442: Replacement Note:

    Fru disassembly 8-153 11. 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. 12. Remove the upper stacker roller from the offset chute assembly. Replacement note: ■ when installing gears 19 and 19/37, make...

  • Page 443: Stacker Motor Assembly

    8-154 phaser 4500 service manual stacker motor assembly (pl23.1.6) 1. Remove the stacker rear cover (page 8-133). 2. Remove the stacker cover (page 8-134). 3. Remove the stacker front cover (page 8-137). 4. Disconnect the connector of the stacker motor assembly from the stacker motor harness assembl...

  • Page 444: In This Chapter...

    9 chapter parts lists in this chapter... ■ serial number format ■ using the parts list ■ print engine parts ■ options ■ xerox supplies and accessories.

  • Page 445: Serial Number Format

    9-2 phaser 4500 service manual 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 th...

  • Page 446: Using The Parts List

    Parts lists 9-3 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 th...

  • Page 447: Print Engine Parts

    9-4 phaser 4500 service manual print engine parts parts list 1.1 covers 2 [ref pl10.1] 7 8 9 9 3 4 6 5 jg5014aa s4500-218 10 11 1.

  • Page 448

    Parts lists 9-5 fru parts list 1.1 covers no. Name/description part number 1 operation panel (front panel) 802k60111 2 cover open (top cover) 802e47284 3 cover rear 604k16460 4 cover right 802e49522 5 cover front 802e63801 6 cover left 802e49491 7 cover top assy 8 cover stopper 802e61862 9 stopper o...

  • Page 449

    9-6 phaser 4500 service manual parts list 2.1 150-sheet paper cassette s4500-219 jg5002aa 1 2 3 4 5 6 18 19 19 20 21 22 23 24 26 25 27 29 30 31 32 33 34 35 28 18 29 16 7 8 9 11 12 13 15 36 37 38 39 17 17 10 50 (with 1-13,15-39) 51 (with 2-5).

  • Page 450

    Parts lists 9-7 fru parts list 2.1 150-sheet paper cassette no. Name/description part number 1 cover cst 802e47191 2 roll assy retard (p/o item 99) 3 friction clutch 4 shaft retard 5 holder retard 6 spring retard 809e37500 7 gear pb l 8 gear btm oneway 9 shaft pb 10 plate assy btm (with 14) 11 guide...

  • Page 451

    9-8 phaser 4500 service manual 34 housing extension 150 35 guide end 150 36 housing base 150 37 link sw size1-150 38 link sw size2-150 39 link sw size3-150 50 150 paper cassette (with 1-13, 15-39) 084k15350 51 holder assy retard (with 2-5) 019k98186 99 roller kit (item 2, qty. 3) 604k11192 fru parts...

  • Page 452

    Parts lists 9-9 parts list 4.1 550-sheet paper cassette s4500-220 jg5004ab 1 2 3 4 5 6 18 19 19 20 21 22 23 24 27 26 25 28 30 31 39 40 41 42 43 29 18 30 34 36 38 37 35 32 16 7 8 9 11 12 13 15 44 45 46 47 48 17 17 10 50 (with 1-13,15-32,34-48,52,53) 51 (with 2-5) 52 53.

  • Page 453

    9-10 phaser 4500 service manual fru parts list 4.1 550-sheet paper cassette no. Name/description part number 1 cover cst 802e47191 2 roll assy retard (p/o item 99) 3 friction clutch 4 shaft retard 5 holder retard 6 spring retard 809e37500 7 gear pb l 8 gear btm oneway 9 shaft pb 10 plate assy btm 11...

  • Page 454

    Parts lists 9-11 35 guide indicator 2 36 guide indicator 3 37 low indicator 38 low ind front 39 gear sector 40 rack size 41 handle extension 550 42 housing extension 550 43 guide end 550 44 housing base 550 45 link sw size1-550 46 link sw size2-550 47 link sw size3-550 48 link sw size low 50 550 pap...

  • Page 455

    9-12 phaser 4500 service manual parts list 5.1 150-sheet paper feeder 33 32 51 32 31 30 28 25 22 31 21 20 14 18 17 16 15 38 40 34 35 37 44 43 42 41 20 11 10 9 8 7 6 5 12 4 39 19 jg5019aa s4500-221 27 26 22 23 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 ...

  • Page 456

    Parts lists 9-13 fru parts list 5.1 150-sheet paper feeder no. Name/description part number 1 150 feeder assy (with 4-12, 14-23, 25-35, 37-44, 46-51) 604k16682 2 fdr1 as sub 150 a4 (with 4-10, 12, 14-20, 22, 25-28, 31-35, 40-42, 46-50) 3 chute assy fdr 1 (reference only) (with 4-10,14-20,40-42) 4 su...

  • Page 457

    9-14 phaser 4500 service manual 34 roll regi metal 35 chute earth regi 37 harness assy tray1 (j245-j240,j241,j242,j243,j244) 38 sensor no paper (p240) 130e81970 39 cover harness r 40 chute top assy 41 shaft feed 42 clutch oneway nudger 43 clutch oneway feed 005e16941 44 roll assy feed (part of item ...

  • Page 458

    Parts lists 9-15 parts list 7.1 550-sheet paper feeder jg5015aa s4500-222 8 37 12 18 38 27 26 22 20 35 22 23 31 33 32 30 24 25 34 14 15 13 28 29 16 36 17 19 6 3 5 4 2 6 9 9 39 7 (with 8,9) 41 40 10 (with 12-20,22-31,33-39).

  • Page 459

    9-16 phaser 4500 service manual fru parts list 7.1 550-sheet paper feeder no. Name/description part number 1 — 2 harness assy low1 (j26-p260) 3 guide tray right 032e18795 4 sensor low paper (j260) 130e81970 5 actuator 120e21311 6 plate cst lock 7 guide tray left (with 8,9) 032k96836 8 cover harness ...

  • Page 460

    Parts lists 9-17 35 plate tie 36 harness assy tray2 (j248-j246, p247) 37 cover harness r 38 sensor no paper (p246) 130e81970* 39 clamp-10v0 40 stopper tray r 41 stopper tray l 99 feed roller kit (with 19 or 29, qty. 3) 604k11192 fru parts list 7.1 550-sheet paper feeder (continued) no. Name/descript...

  • Page 461: Parts List 8.1 Xerographics

    9-18 phaser 4500 service manual parts list 8.1 xerographics jg5016ab s4500-223 23 print cartridge* 17 18 22 21 20 8 10 11 12 13 7 9 2 15 1 24 14 3 19 25 (with 23,24) 6 (with 7-15) 30 29 16 4 5.

  • Page 462

    Parts lists 9-19 fru parts list 8.1 xerographics no. Name/description part number 1 ros assy (laser unit) (j131,j140,j160,j170) 084k13151 2 harness assy ros (j13, j14, j16, j17-p131, p140, p141, p160, p170) 3 shield plate ros 4 duct front 5 fan sub (j270) 127k39390 6 guide assy cru l (with 7-15) 032...

  • Page 463

    9-20 phaser 4500 service manual parts list 10.1 paper exit (1/2) 19 18 20 6 11 12 1 4 10 11 7 26 24 28 5 15 16 17 13 21 jg5017ab s4500-224 27 30 23 30 23 22 22 22 22 28 2 (with 4-7, 10-13, 15-24, 26-28, 30).

  • Page 464

    Parts lists 9-21 fru parts list 10.1 paper exit (1/2) no. Name/description part number 1 cover exit 500 604k16590 2 500 exit assy (with 4-7, 10-13, 15-24, 26-28, 30) 084k18470 4 chute up exit 5 eliminator exit 6 earth plate exit 7 link gate oct (stacker gate link) 10 actuator full stack 604k15560 11...

  • Page 465

    9-22 phaser 4500 service manual parts list 10.2 paper exit (2/2) 11 8 9 7 22 23 20 21 10 6 2 15 jg5702ab s4500-225.

  • Page 466

    Parts lists 9-23 fru parts list 10.2 paper exit (2/2) no. Name/description part number 2 chute up fu 6 gate fu 7 chute low fu 8 lever latch left 9 pipe latch left 10 spring latch fu 11 lever latch right 15 lever gate holder 20 earth plate fu 21 cover rear 500 22 cover dup 802e48402 23 stopper fsr 99...

  • Page 467

    9-24 phaser 4500 service manual parts list 11.1 frame and drive 3 2 1 4 jg5020aa s4500-226 11 9 6 7 8 10 11 7 7 7 12 7 7 13 13 5 5.

  • Page 468

    Parts lists 9-25 pl11.1 frame and drive no. Name/description part number 1 motor cover 2 main motor (j43) 127k36822 3 gear assy housing (with 4) 604k16670 4 spring release (part of item 3) 5 clamp edge 6 clamp-5 v0 7 clamp-10v0 8 clamp-edge 9 gear 9 807e02560 10 gear assy plate 007k87753 11 foot 550...

  • Page 469: Parts List 12.1 Electrical

    9-26 phaser 4500 service manual parts list 12.1 electrical 15 18 14 19 25 10 11 2 30 5 31 3 7 6 20 1 21 12 8 jg5018aa s4500-227 23 27 16 17 32 33 37 34 36 35 28 4 26.

  • Page 470

    Parts lists 9-27 pl12.1 electrical no. Name/description part number 1 harness assy lvps (j10, j11, j18, j27, cnpow, j141-j42, j41, j1821, p270, j102, p2750, j40, p142, p144, j411, j400) 2 plate tie front 3 shield plate lvps 4 pwba exit motor 160k91991 5 lvps 110 v 105k20392 lvps 220 v 105k20401 6 po...

  • Page 471

    9-28 phaser 4500 service manual 32 64 mb ram dimm 156-4838-00 128 mb ram dimm 156-4837-00 256 mb ram dimm 156-4663-00 33 flash dimm 671-5325-0a 34 hard drive assy 650-4309-00 35 config card b to n 163-1505-00 36 config card base 163-1513-00 37 nvram device 163-1459-00 pl12.1 electrical (continued) n...

  • Page 472: Options

    Parts lists 9-29 options parts list 20.1 550-sheet paper feeder (1/2) [ref pl20.2.1] 1 2 3 5 6 6 7 9 12 13 14 15 16 17 11 10 18 41 19 20 21 22 22 26 28 30 31 34 33 35 36 37 38 38 32 27 42 23 25 4 jg5501ab s4500-228 39 40 8 (with 9-17) 29 (with 30-33).

  • Page 473

    9-30 phaser 4500 service manual parts list 20.1 550-sheet paper feeder (1/2) no. Name/description part number 1 cover right plate 2 cover front 3 cover left plate 4 earth plate 5 harness assy fdr2 (j83-jd2083) (feeder harness 2) 6 spring earth top 7 frame top assy 8 drive assy opt fdr (with 9-17) 00...

  • Page 474

    Parts lists 9-31 34 pwba feeder 550 160k86723 35 harness assy size fdr2 (j80-j801) 36 harness assy clsnr2 (j85-p855) 37 harness assy fdr mot (j82-p820) 38 joint feeder 113e36900 39 lock cst l 003e59231 40 harness assysize fdr3 (j802-j800) 41 stopper tray l 42 stopper tray r 99 550 deck assy (entire)...

  • Page 475

    9-32 phaser 4500 service manual parts list 20.2 550-sheet paper feeder (2/2) 1 (with 4-23,25-34) s4500-229 jg5502aa 4 5 7 8 9 10 11 12 13 15 16 17 17 21 22 23 23 31 32 33 25 26 27 28 29 30 34 30 28 18 19 20 14 6.

  • Page 476

    Parts lists 9-33 parts list 20.2 550-sheet paper feeder (2/2) no. Name/description part number 1 550 feeder option (with 4-23, 25-34) 022k66124 4 support nudger 5 holder left 6 actuator no paper 7 gear idler nudger 8 holder right 9 shaft nudger 10 gear nudger 059k25270 11 roll assy nudger (part of 9...

  • Page 477

    9-34 phaser 4500 service manual parts list 20.3 optional 550-sheet paper cassette s4500-220 jg5004ab 1 2 3 4 5 6 18 19 19 20 21 22 23 24 27 26 25 28 30 31 39 40 41 42 43 29 18 30 34 36 38 37 35 32 16 7 8 9 11 12 13 15 44 45 46 47 48 17 17 10 50 (with 1-13,15-32,34-48,52,53) 51 (with 2-5) 52 53.

  • Page 478

    Parts lists 9-35 parts list 20.3 optional 550-sheet paper cassette no. Name/description part number 1 cover cst 802e47191 2 roll assy retard (part of 99) 3 friction clutch 4 shaft retard 5 holder retard 6 spring retard 809e37500 7 gear pb l 8 gear btm oneway 9 shaft pb 10 plate assy btm 11 guide ass...

  • Page 479

    9-36 phaser 4500 service manual 35 guide indicator 2 36 guide indicator 3 37 low indicator 38 low ind front 39 gear sector 40 rack size 41 handle extension 550 42 housing extension 550 43 guide end 550 44 housing base 550 45 link sw size1-550 46 link sw size2-550 47 link sw size3-550 48 link sw size...

  • Page 480: Parts List 21.1 Duplex Unit

    Parts lists 9-37 parts list 21.1 duplex unit 2 4 4 3 3 3 4 4 6 7 8 9 10 11 11 12 13 16 17 14 15 10 4 3 3 4 3 jg5602ab s4500-231 17 17 18 19 19 38 40 40 41 39 19 19 19 20 20 20 21 22 23 24 25 26 27 28 30 30 31 32 33 34 35 36 37 29 19 1 (with 2-4) 43.

  • Page 481

    9-38 phaser 4500 service manual parts list 21.1 duplex unit no. Name/description part number 1 hsg upper assy (with2-4) 802k46801 2 hsg upper dup 3 spring pinch 809e37140 4 roll pinch 059e97500 6 hsg lower dup 7 harness assy dup (j50-jd2750) 8 earth assy plate 9 cover harness 10 screw thumb 11 screw...

  • Page 482

    Parts lists 9-39 34 sensor dup (p530) 130e82740 35 harness assy dup snr (j53-j530) 36 spring actuator 809e50961 37 actuator dup 604k16750 38 cover damper 39 spring damper 40 screw tapping 41 cover right 43 spring frame ground dup 99 duplex assy (entire unit) 084k18292 parts list 21.1 duplex unit (co...

  • Page 483: Parts List 23.1 Stacker

    9-40 phaser 4500 service manual parts list 23.1 stacker 33 33 24 34 34 37 13 38 39 28 27 26 29 31 30 1 2 7 7 8 9 10 11 12 11 13 13 14 18 13 23 22 25 20 6 46 5 5 4 32 15 48 47 49 50 47 jg5801ab s4500-232 39 37 36 16 17 13 44 54 45 44 52 53 43 41 42 35 (with 13,36-39) 40 (with 41-44, 53).

  • Page 484

    Parts lists 9-41 parts list 23.1 stacker no. Name/description part number 1 cover oct (with 3) (stacker cover) 2 weight 036e91551 3 eliminator assy 4 cover rear 5 screw thumb 6 motor assy oct (j71) (stacker motor assembly) 127k36291 7 gear 45 007e74830 8 gear 19/37 007e74840 9 bracket motor oct (sta...

  • Page 485

    9-42 phaser 4500 service manual 35 chute offset assy (with 13, 36-39) 054k23313 36 roll oct upper (upper stacker roller) 37 roll pinch oct (stacker pinch roller) 38 chute offset 39 spring pinch exit 40 tray assy oct (with41-44, 53) (stacker tray assembly) 050k49264 41 tray extension 42 tray exit 43 ...

  • Page 486

    Parts lists 9-43 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, r...

  • Page 487

    9-44 phaser 4500 service manual cable pwr euro 220v, 99l 161-0066-09 cable pwr u.K. 240 v, 96l 161-0066-10 cable pwr aust 240 v, 96l 161-0066-11 cable assy swiss 220/240 v, 50hz 161-0154-00 cable assy pwr. Danish, 250 v 161-0240-00 cable assy pwr, prc 161-0304-00 power, 240v, argentina 161-0307-00 u...

  • Page 488

    Parts lists 9-45 printer options description part number 550-sheet feeder (includes tray) 097s03127 duplex unit 097s03128 500-sheet stacker with job offset 097s03129 150-sheet replacement paper tray 109r00734 550-sheet replacement paper tray 109r00721 software and documentation description part numb...

  • Page 489

    9-46 phaser 4500 service manual 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 a4 210 x 297 mm 3r91823 xerox labels xerox high speed labels letter 8.5 x 11 in. ...

  • Page 490: In This Chapter...

    10 chapter 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.

  • Page 491: Introduction

    10-2 phaser 4500 service manual introduction this chapter contains the plug/jack locators and the wiring diagrams for the print engine and all options. The plug/jack locators consist of the p/j locator tables and the p/j locator diagrams. The table lists the plug/jack numbers in numerical order. The...

  • Page 492: P/j Locator Table

    Wiring diagrams 10-3 print engine plug/jack locator p/j locator table p/j coordinates remarks 10 g-108 connects the lvps harness assembly and hvps/engine logic board 11 g-108 connects the lvps harness assembly and hvps/engine logic board 13 g-109 connects the laser unit harness and hvps/engine logic...

  • Page 493

    10-4 phaser 4500 service manual 130 i-107 connects the dc-dc converter harness to the i/p board 131 f-108 connects the laser unit assembly and laser unit harness assembly 140 c-107 connects the laser unit assembly and laser unit harness assembly 141 d-108 connects the laser unit harness assembly and...

  • Page 494

    Wiring diagrams 10-5 810 e-107 connects the front panel and front panel harness assembly 850 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 th...

  • Page 495: P/j Locator Diagrams

    10-6 phaser 4500 service manual p/j locator diagrams printer front s4500-233 170 1821 160 140 141 a 104 105 106 107 108 109 110 111 b c d e 810

  • Page 496

    Wiring diagrams 10-7 printer right side f g h i j k l s4500-252 104 105 106 107 108 109 110 111 17 16 20 22 26 24 28 30 29 411 144 800 110 j310 850 130 2083 10 11 27 13 14 15 18 31 131.

  • Page 497

    10-8 phaser 4500 service manual printer rear m 120 121 122 123 124 125 126 n o p q r s4500-234 290 150 4647 310 240 246 244 221 245 248 260 241 243 247 242 220 2750 3070

  • Page 498

    Wiring diagrams 10-9 printer left side 120 121 122 123 124 125 126 s t u v w x s4500-253 142 103 270 102 404 42 41 40 43 44 401 402 403 45 46 47 480 48 101.

  • Page 499: P/j Locator Table

    10-10 phaser 4500 service manual 550-sheet feeder plug/jack locator p/j locator table p/j coordinates remarks 80 i-205 connects feeder size switch harness 2 and the 550-sheet feeder pwba 81 h-205 connects the low paper sensor harness and the 550-sheet feeder pwba 82 h-205 connects the feeder motor h...

  • Page 500

    Wiring diagrams 10-11 a 202 203 204 205 206 207 208 209 201 b c d e f g h i j k l s4500-272 855 80 83 84 81 85 82 8483 2083 810 852 854 801 820 853 802.

  • Page 501: P/j Locator Table

    10-12 phaser 4500 service manual duplex unit plug/jack locator p/j locator table p/j coordinates remarks 50 g-304 connects the duplex unit harness and duplex unit pwba 51 g-304 connects the duplex unit motor and duplex unit pwba 52 g-304 connects the duplex unit harness cover and duplex unit pwba 53...

  • Page 502

    Wiring diagrams 10-13 a 302 303 304 305 306 307 308 309 301 b c d e f g h i j k s4500-271 2750 51 52 50 54 560 53 530 56 520

  • Page 503: Stacker Plug/jack Locator

    10-14 phaser 4500 service manual stacker plug/jack locator p/j locator table p/j coordinates remarks 70 j-403 connects stacker harness 2 and the stacker pwba 71 j-404 connects the stacker motor and stacker pwba 72 j-404 connects the offset motor and stacker pwba 73 j-404 connects the stacker sensor ...

  • Page 504

    Wiring diagrams 10-15 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 signa...

  • Page 505

    10-16 phaser 4500 service manual rtn indicates a return. Represents a connector. The connector and pin nos. Are shown at the upper and lower parts respectively. “p,-” indicates the plug side of the connector. “j,>” indicates the jack side of the connector. Represents a connection terminal with a pla...

  • Page 506: Print Engine Wiring Diagrams

    Wiring diagrams 10-17 print engine wiring diagrams print engine general wiring diagram j110 hvps/ engine logic image processor exit motor assembly 24 v interlock rear cover switch tray 1 size switch assy. Tray 2 size switch assy. 5 v interlock tray 2 low paper sensor tray 1 no paper sensor registrat...

  • Page 507: Fan, Exit Motor Assembly

    10-18 phaser 4500 service manual 24 v interlock, rear cover switch, main motor, sub fan, exit motor assembly signal line name description /heat on ac power-supply control signal for heater rod. Low: on/high: off motor on control signal for main motor. Motor alm monitor signal for main motor. Interlo...

  • Page 508

    Wiring diagrams 10-19 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 moto...

  • Page 509

    10-20 phaser 4500 service manual fuser assembly, power switch signal line name description /exit signal from exit sensor. This signal goes low when the flag moves out of the sensor. Sts temperature monitor signal (analog signal) from temperature sensor (thermistor). It detects the temperature on the...

  • Page 510

    Wiring diagrams 10-21 print cartridge, transfer roller assembly signal line name description db output from hvps to magnet roller (development bias) cr output from hvps to bcr dts output from hvps to detack saw tr output from hvps to transfer roller print cartridge r. Print cartridge guide hvps/ eng...

  • Page 511

    10-22 phaser 4500 service manual 150-sheet feeder, 550-sheet feeder, main fan p/j22 hvps/ engine logic pwba lvps harness (6/6) low paper sensor harness toner harness 1 toner harness 2 chute harness tray 2 harness tray 1 harness 2 3 4 5 1 7 8 9 10 6 p/j18 tray2 size switch 2 3 4 5 6 7 8 9 10 11 12 13...

  • Page 512

    Wiring diagrams 10-23 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 cont...

  • Page 513

    10-24 phaser 4500 service manual laser unit, 5 v interlock, interlock switch assembly p/j130 start of scan sensor hvps/ engine logic pwba lvps harness 5/6 laser unit harness 2 3 4 5 6 7 8 1 2 3 4 1 7 6 5 4 3 2 1 8 sg /sos n.C. N.C. /pcont 1 vref mo/det-out /pcont2 /ldenb xpdata 2+ xpdata 2- p/j14 p/...

  • Page 514: Paper Exit

    Wiring diagrams 10-25 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 ...

  • Page 515

    10-26 phaser 4500 service manual image processor board, dc-dc converter, front panel lvps dc-dc converter image processor hvps engine logic p/j40 p/104 p/j130 p/j404 p/j403 p/j402 j800 p28 p/j401 front panel s4500-266 3 4 2 2 2 2 3 3 1 1 1 2 3 1 1 3 2 1 4 n/c 24v n/c n/c j404-a j404-b p404 5v sg 3.3...

  • Page 516: Optional 550-Sheet Feeder

    Wiring diagrams 10-27 optional 550-sheet feeder 550-sheet feeder general wiring diagram note the printer can have up to two optional 550-sheet paper feeders installed. Paper size switch assembly 550-sheet feeder pwba hvps/ engine logic pwba feeder motor feed clutch turn roller clutch no paper sensor...

  • Page 517

    10-28 phaser 4500 service manual 550-sheet feeder signal diagram signal line name description tray sns 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 o...

  • Page 518: Duplex Unit

    Wiring diagrams 10-29 duplex unit duplex unit general wiring diagram 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 r...

  • Page 519: Duplex Unit Signal Diagram

    10-30 phaser 4500 service manual duplex unit signal diagram signal line name description fan alarm fan monitor signal. This signal goes high if there is a trouble with duplex unit fan. /dup snr on signal from duplex unit sensor. This signal goes low when the flag moves out of the sensor. /dup top co...

  • Page 520: Stacker

    Wiring diagrams 10-31 stacker stacker general wiring diagram stacker motor offset motor gate solenoid stacker sensor stacker rear cover switch stacker pwba hvps engine logic pwba p/j72 p/j71 p/j70 p/j30 p/j3070 p/j710 p/j75 p/j73 p/j74 p/j740 p/j730 s4500-245.

  • Page 521: Stacker Signal Diagram

    10-32 phaser 4500 service manual stacker signal diagram signal line name description a and b excitation signal for stacker motor assembly and motor assembly. Phases a and b. /a and /b excitation signal for motor assembly stacker and offset motor assembly. Phases /a and /b. Dir sol fukki dir sol kyui...

  • Page 522: Contents...

    A appendix appendix contents... ■ menu map ■ service diagnostics menu map.

  • Page 523: Menu Map

    A-2 phaser 4500 service manual menu map front panel buttons: main menu: up arrow ok information back cancel down arrow information walk-up features printer setup troubleshooting information walk-up features printer setup troubleshooting ready to print. Ready to print. Walk-up features‡ information p...

  • Page 524

    Appendix a-3 printer setup paper handling setup postscript setup pcl setup general setup front panel setup printer controls file security troubleshooting help guide paper jams print quality problems network log pages* service tools page 2 of 2 (continued) requires: networked printer duplex unit hard...

  • Page 525: Service Diagnostics Menu Map

    A-4 phaser 4500 service manual service diagnostics menu map print service menu map prints this page. General status: provides current print engine status: engine rom version engine print counter engine configuration print resolution read fuser temperature engine test print: starts the test print. Pr...

  • Page 526

    Appendix a-5 sensor tests: tests the functionality of sensors /switches/options by manually toggling each sensor or installing an option. Top cover switch rear cover switch duplex cover switch stacker cover switch paper tray size read (display paper size, for trays) print cartridge switch toner sens...

  • Page 527

    A-6 phaser 4500 service manual.

  • Page 528: Numerics

    Service manual index – 1 index numerics 24 v interlock , 2-31 , 4-26 5 v interlock , 2-31 , 4-26 550-sheet feeder pwba , 2-43 a ac power supply troubleshooting , 4-7 actuator low paper , 2-16 , 2-42 , 3-62 , 3-64 , 4-22 , 4-47 no paper , 2-16 , 2-42 , 3-61 , 3-63 , 4-20 , 4-45 , 8-24 , 8-34 , 8-108 ...

  • Page 529

    Index – 2 phaser 4500 laser printer duplex roller , 2-35 duplex unit drive transmission path , 2-34 failure troubleshooting , 3-50 fan , 2-35 functional components , 2-35 gear layout , 2-35 motor , 2-36 , 4-55 no recognition , 3-71 pwba , 2-35 , 4-54 sensor , 2-35 , 4-56 switch , 2-35 , 4-58 theory ...

  • Page 530

    Service manual index – 3 temperature cycling , 2-26 temperature defaults , 5-34 temperature sensors , 2-24 temperature stabilization , 2-27 theory , 2-24 to 2-28 thermostats , 2-24 troubleshooting , 4-16 warm-up , 2-26 g gate assembly solenoid , 4-62 gate solenoid assembly , 2-38 gear assembly housi...

  • Page 531

    Index – 4 phaser 4500 laser printer laser power adjusting , 6-5 default , 6-5 laser power adjustment , 3-11 laser unit failure troubleshooting , 3-27 laser unit assembly , 4-13 lcd/led display error , 4-3 led blink patterns , 3-17 left tray guide , 4-34 link lever , 2-30 low paper actuator , 2-16 , ...

  • Page 532

    Service manual index – 5 p paper exit theory , 2-29 paper feeder theory , 2-16 paper lift theory , 2-15 paper path print engine , 2-5 stacker , 2-38 paper size control , 2-18 paper size jam , 3-54 paper size switch optional 550-sheet feeder , 2-42 paper size switch assembly , 2-18 paper transport la...

  • Page 533

    Index – 6 phaser 4500 laser printer roller duplex , 2-35 exit , 2-29 feed (optional feeder) , 2-43 heat , 2-24 lower stacker , 2-39 magnet , 2-19 nudger (optional feeder) , 2-43 pressure , 2-24 transfer , 2-23 turn , 2-43 upper stacker , 2-39 routine maintenance items , 1-7 runtime log , 3-21 s scan...

  • Page 534

    Service manual index – 7 stacker gate solenoid , 3-14 stacker motor assembly , 4-60 stacker pwba , 4-59 stacker rear cover switch , 4-63 stacker sensor , 4-65 standard printer orientation , 8-2 start of scan (sos) board , 2-21 sub fan , 2-31 supply life counters , 1-8 t technical support , 1-2 tempe...

  • Page 535

    Index – 8 phaser 4500 laser printer spots , 5-30 stack full sensor, stacker , 4-67 stacker motor , 4-60 stacker pwba , 4-59 stacker rear cover switch , 4-63 stacker sensor , 4-65 toner sensor , 4-23 tray 3 , 4-43 tray 4 , 4-44 turn roller clutch, optional feeder , 4-52 uneven density , 5-43 unfused ...

  • Page 537

    071-0867-00 a.