1. DL manuals
  2. Xerox
  3. Printer
  4. Phaser 4500
  5. Service Manual

Xerox Phaser 4500 Service Manual

Summary of Phaser 4500

  • Page 1

    Service manual phaser ® 4500/4510 701p45760 laser printers.

  • Page 3: Service Manual

    Service manual 701p45760 phaser 4500/4510 laser printers warning the following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing other than that contained in the operating instructions, unless you are qualified to do so..

  • Page 4

    Ii phaser 4500/4510 service manual prepared by: xerox corporation xog worldwide product training and information 26600 sw parkway wilsonville, or 97070 copyright © 2007 xerox corporation. All rights reserved. Unpublished rights reserved under the copyright laws of the united states. Contents of this...

  • Page 5: 1 General Information

    Phaser 4500/4510 laser printer service manual iii contents contents service terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Xi product terms . . . . . . . . . . . . . . . . . . . . ....

  • Page 6: 3 Error Messages And Codes

    Iv phaser 4500/4510 service manual contents 3 error messages and codes introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 servicing instructions . . . . . . . . . . . . . ....

  • Page 7: 4 General Troubleshooting

    Phaser 4500/4510 laser printer service manual v contents 4 general troubleshooting introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 control panel troubleshooting . . . . ...

  • Page 8

    Vi phaser 4500/4510 service manual contents 5 print-quality troubleshooting print-quality problems overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 analyzing test prints . . . . . . . . . . . . . . . . . . ...

  • Page 9: 8 Fru Disassembly

    Phaser 4500/4510 laser printer service manual vii contents 7 cleaning and maintenance service preventive maintenance procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 recommended tools . . . . . . . . . . . . . . . . . . ....

  • Page 10

    Viii phaser 4500/4510 service manual contents print engine: paper exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49 paper exit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 11: 9 Parts Lists

    Phaser 4500/4510 laser printer service manual ix contents options: stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-111 stacker removal . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 12: A Appendix

    X phaser 4500/4510 service manual contents print engine wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19 p4500: general wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 13: Service Terms

    Phaser 4500/4510 laser printer service manual xi 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 u...

  • Page 14: Product Terms

    Xii phaser 4500/4510 service manual 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 hot surface on or in the p...

  • Page 15: Power Safety Precautions

    Phaser 4500/4510 laser printer service manual xiii power safety precautions power source for 110 vac printers, do not apply more than 135 volts rms between the supply conductors or between either supply conductor and ground. Use only the specified power cord and connector. For 220 vac printers, do n...

  • Page 16

    Xiv phaser 4500/4510 service manual 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 circ...

  • Page 17: Service Safety Summary

    Phaser 4500/4510 laser printer service manual xv 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 capa...

  • Page 18

    Xvi phaser 4500/4510 service manual 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 ...

  • Page 19: Regulatory Specifications

    Phaser 4500/4510 laser printer service manual xvii regulatory specifications united states (federal communications commision the equipment described in this manual generates and uses radio frequency energy. If it is not installed properly in strict accordance with xerox instructions, it may cause in...

  • Page 20

    Xviii phaser 4500/4510 service manual european union the ce mark applied to this product symbolizes xerox’s declaration of conformity with the following applicable directives of the european union as of the dates indicated: january 1, 1995: low voltage directive 73/23/eec as amended by 98/68/ eec ja...

  • Page 21: In This Chapter...

    1 chapter general information in this chapter... ■ printer introduction and overview ■ printer configurations ■ parts of the printer ■ control panel ■ image processor board (phaser 4500) ■ image processor board (phaser 4510) ■ consumables and routine maintenance items ■ printer specifications.

  • Page 22

    1-2 phaser 4500/4510 service manual general information printer introduction and overview the xerox phaser 4500/4510 laser printer service manual is the primary document used for repairing, maintaining, and troubleshooting the printer. To ensure complete understanding of this product, participation ...

  • Page 23: Printer Configurations

    Phaser 4500/4510 service manual 1-3 general information printer configurations a replaceable configuration card holds configuration information that enables or disables the network features shown in the following table. Printer configurations features printer configuration b n dt dx maximum print sp...

  • Page 24: Parts of The Printer

    1-4 phaser 4500/4510 service manual general information parts of the printer front view rear view 1. Paper stop 2. Control 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 items 1 ...

  • Page 25: Control Panel

    Phaser 4500/4510 service manual 1-5 general information control panel the control panel consists of one tricolor led, a display window, and six functional buttons. Led states 1. Status indicator led 5. Up arrow button - scrolls up the menu system 2. Graphic control panel display 6. Down arrow button...

  • Page 26

    1-6 phaser 4500/4510 service manual general information control panel shortcuts mode buttons pressed at power on skip execution of post diagnostics ok print service diagnostics map information reset postscript nvram back + ok password bypass up arrow + down arrow enter service diagnostics back + inf...

  • Page 27

    Phaser 4500/4510 service manual 1-7 general information image processor board (phaser 4500) when installing a new image processor board in the printer, you must transfer the following parts from the old board: ■ memory dimms ■ hard drive (if installed) ■ nvram ■ configuration card 1. Memory (ram) di...

  • Page 28

    1-8 phaser 4500/4510 service manual general information image processor board (phaser 4510) when installing a new image processor board in the phaser 4510 printer, you must transfer the following parts from the old board: ■ memory dimms ■ configuration card ■ nvram ■ hard drive (if installed) ■ flas...

  • Page 29

    Phaser 4500/4510 service manual 1-9 general information consumables and routine maintenance items print cartridge transfer roller feed rollers 3 per paper tray s4510-267 fuser s4510-268.

  • Page 30

    1-10 phaser 4500/4510 service manual general information supply life counters internal counters track the usage of the consumables and routine maintenance items and store the values in nvram. The image processor board monitors these counters in order to display the near end-of-life and end- of-life ...

  • Page 31: Printer Specifications

    Phaser 4500/4510 service manual 1-11 general information 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 cartr...

  • Page 32

    1-12 phaser 4500/4510 service manual general information functional specifications characteristic specification printing process: recording system: electrophotography (roller charging, magnetic monocomponent toner development) exposure system: semiconductor laser beam scanning transfer system: rolle...

  • Page 33

    Phaser 4500/4510 service manual 1-13 general information 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 f...

  • Page 34

    1-14 phaser 4500/4510 service manual general information media and tray specifications 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 stacker width: 76.2 mm (3.0 in.) ~ 215.9 mm (8...

  • Page 35

    Phaser 4500/4510 service manual 1-15 general information memory requirements phaser 4500 characteristic specification minimum required 64 mb – the phaser 4500 b configuration reports 48 mb maximum supported 256 mb – accepts modules of 64 or 128 mb in combinations to a total of 256 mb supported type ...

  • Page 36

    1-16 phaser 4500/4510 service manual general information.

  • Page 37: In This Chapter...

    2 chapter theory of operation in this chapter... ■ overview of the phaser 4500/4510 laser printer ■ paper path of the printer ■ sensors ■ major assemblies and functions ■ printer options.

  • Page 38

    2-2 phaser 4500/4510 service manual theory of operation overview of the phaser 4500/4510 laser printer summary of the printing process the phaser 4500/4510 print process consists of the following steps: 1. Charge – the print cartridge contains a bias charge roller that uniformly distributes a negati...

  • Page 39

    Phaser 4500/4510 service manual 2-3 theory of operation 10. Two-sided printing reverses the direction of the exit rollers to route the paper through the duplex unit rollers and back to the registration roller. A sensor in the duplex unit detects the presence of paper. Block diagram of the print cycl...

  • Page 40: Paper Path of The Printer

    2-4 phaser 4500/4510 service manual theory of operation 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 ...

  • Page 41

    Phaser 4500/4510 service manual 2-5 theory of operation layout of paper transport path this cross section of the printer shows the main components directly associated with the paper path and transport in the engine only. 1. Exit roller 8. Rubber registration roller 2. Exit pinch roller 9. Metal regi...

  • Page 42

    2-6 phaser 4500/4510 service manual theory of operation this cross section shows the additional components associated with paper transport when the 550-sheet feeders, the duplex unit, and the stacker are installed. 1. Stacker pinch roller 8. Duplex pinch rollers 2. Lower stacker roller 9. Turn pinch...

  • Page 43: Sensors

    Phaser 4500/4510 service manual 2-7 theory of operation 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 presenc...

  • Page 44

    2-8 phaser 4500/4510 service manual theory of operation registration sensor mechanically actuated photo sensor detects the paper as it reaches the registration rollers. Page 2-10 page 2-16 toner sensor magnetic sensor detects the presence of toner in the print cartridge. Page 2-16 exit sensor mechan...

  • Page 45

    Phaser 4500/4510 service manual 2-9 theory of operation stacker offset sensor mechanically actuated photo sensor senses the position of the stacker offset chute. Page 2-38 duplex unit switch microswitch signals the hvps/engine logic board that the duplex unit rear cover is open. Page 2-35 duplex uni...

  • Page 46

    2-10 phaser 4500/4510 service manual theory of operation 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 ...

  • Page 47

    Phaser 4500/4510 service manual 2-11 theory of operation major assemblies and functions the functions of the main components of the phaser 4500/4510 printer are described in the following sections: ■ paper tray ■ paper feeder ■ print cartridge ■ transfer roller assembly ■ laser assembly ■ fuser ■ 50...

  • Page 48

    2-12 phaser 4500/4510 service manual theory of operation 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 assemb...

  • Page 49

    Phaser 4500/4510 service manual 2-13 theory of operation extension lock the 150-sheet tray extends to accommodate different paper lengths. The extension lock holds the extension in position. End guide the end guide can be adjusted to different paper sizes by making a forward or backward adjustment. ...

  • Page 50

    2-14 phaser 4500/4510 service manual theory of operation the paper sizes that can be automatically detected are as follows: paper lift mechanism the phaser 4500/4510 printer paper trays utilize a unique mechanical paper lift mechanism that eliminates the need for paper lift motors. The mechanism con...

  • Page 51

    Phaser 4500/4510 service manual 2-15 theory of operation 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 pape...

  • Page 52

    2-16 phaser 4500/4510 service manual theory of operation 1. Paper size switch assembly 7. Metal registration roller 2. Feed clutch assembly 8. No paper sensor 3. Registration clutch 9. No paper actuator 4. Rubber registration roller 10.Low paper sensor 5. Feed roller 11.Low paper actuator 6. Registr...

  • Page 53

    Phaser 4500/4510 service manual 2-17 theory of operation control of paper size paper size switch assembly the switches in this assembly send signals that indicates the paper size setting of the tray. Cams in the bottom of the tray are positioned by the tray’s end guide. At pre-defined paper lengths,...

  • Page 54

    2-18 phaser 4500/4510 service manual theory of operation xerographics print cartridge the print cartridge is a customer-replaceable item that consists of the following components: drum the drum is an aluminum cylinder coated with a layer of photoconductive material that retains electrical charges on...

  • Page 55

    Phaser 4500/4510 service manual 2-19 theory of operation 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) assemb...

  • Page 56

    2-20 phaser 4500/4510 service manual theory of operation laser assembly functional parts laser control the scanner motor turns on when it receives a signal from the controller, and turns off after printing ends. The motor remains off in the standby and power- saving states. There are two faults asso...

  • Page 57

    Phaser 4500/4510 service manual 2-21 theory of operation 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....

  • Page 58

    2-22 phaser 4500/4510 service manual theory of operation 1. Exit motor assembly 5. Pressure roller 2. Exit sensor 6. Heat roller 3. Actuator 7. Thermostats (p4510 uses only one) 4. Temperature sensors s4500-023 1 2 3 4 5 6 7.

  • Page 59

    Phaser 4500/4510 service manual 2-23 theory of operation 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 read...

  • Page 60

    2-24 phaser 4500/4510 service manual theory of operation fuser warm-up the halogen lamp is turned on when the fuser warm-up begins. When the surface temperature of the heat roller (detected by the thermistor) reaches the fuser control temperature (standby temperature), the fuser warm-up is ended. Fu...

  • Page 61

    Phaser 4500/4510 service manual 2-25 theory of operation temperature stabilization the fuser automatically enters a stabilization process under two circumstances: ■ when the printer is processing thick paper. After 50 impressions of continuous printing on thick paper (thick paper 1 mode), the fuser ...

  • Page 62

    2-26 phaser 4500/4510 service manual theory of operation power shutoff to the fuser the printer shuts off power to the fuser for the following reasons: ■ fuser abnormality (u4) ■ paper jam ■ cover open — top, rear, duplex unit, stacker ■ laser assembly (ros) abnormality (u2) ■ cpu or nvram abnormali...

  • Page 63

    Phaser 4500/4510 service manual 2-27 theory of operation 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 ...

  • Page 64

    2-28 phaser 4500/4510 service manual theory of operation drive gear assembly housing the gears in this housing transmit power from the main motor to various parts of the printer. Gear assembly plate this transmits power from the main motor to the print cartridge. Link lever this connects and disconn...

  • Page 65

    Phaser 4500/4510 service manual 2-29 theory of operation 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 phaser ...

  • Page 66

    2-30 phaser 4500/4510 service manual theory of operation 1. Lvps (includes dc-dc converter in p4510) 7. 5 v interlock 2. Exit motor pwba 8. 24 v interlock 3. Rear cover switch 9. Image processor board 4. Laser interlock (p4500 only) 10.Hvps/engine logic board 5. Top cover switch (p4500 only) 11.Sub ...

  • Page 67

    Phaser 4500/4510 service manual 2-31 theory of operation schematic diagram of phaser 4500 power distribution and interlocks opt. 550-sheet opt. 550-sheet feeder feeder opt. 550-sheet feeder optional duplex unit pwba feeder 550 duplex pwba optional stacker stacker pwba ldd laser unit 5v interlock rea...

  • Page 68

    2-32 phaser 4500/4510 service manual theory of operation schematic diagram of phaser 4510 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 circ...

  • Page 69: Printer Options

    Phaser 4500/4510 service manual 2-33 theory of operation printer options three options are available for the phaser 4500/4510 printer: ■ duplex unit ■ stacker ■ 550-sheet feeder paper transport information for the options is discussed earlier in this chapter. Duplex unit the duplex unit used on the ...

  • Page 70

    2-34 phaser 4500/4510 service manual theory of operation 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...

  • Page 71

    Phaser 4500/4510 service manual 2-35 theory of operation phaser 4500 and 4510 duplex units 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 p4500 s4510-030 4 5 2 6 1 3 p4510

  • Page 72

    2-36 phaser 4500/4510 service manual theory of operation stacker drive transmission path the rotating force of the stacker motor assembly is transmitted by various gears to components requiring mechanical driving force as shown in this flow chart and the gear layout that follows. Gear layout 1. Gear...

  • Page 73

    Phaser 4500/4510 service manual 2-37 theory of operation paper transport path when the stacker is installed on the printer, the paper is transported as shown in the illustration on page 2-6. The main components that transport paper through the stacker are shown in the diagram on page 2-4 functional ...

  • Page 74

    2-38 phaser 4500/4510 service manual theory of operation 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 ...

  • Page 75

    Phaser 4500/4510 service manual 2-39 theory of operation 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. Gear layout...

  • Page 76

    2-40 phaser 4500/4510 service manual theory of operation functional components the paper tray used in the optional feeder is identical to the 550-sheet paper tray used by the base engine, so the description of the paper tray is omitted here. Option paper size switch assembly a bank of switches for s...

  • Page 77

    Phaser 4500/4510 service manual 2-41 theory of operation 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 78

    2-42 phaser 4500/4510 service manual theory of operation.

  • Page 79: 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 ■ troubleshooting procedures for error messages and codes ■ inoperable pr...

  • Page 80: Introduction

    3-2 phaser 4500/4510 service manual error messages and codes introduction this chapter covers troubleshooting procedures for problems in the phaser 4500/4510 that generate error messages or fault codes or both that appear on the control panel or in the service usage profile report, and serves as the...

  • Page 81

    Phaser 4500/4510 service manual 3-3 error messages and codes step 2: inspect and clean the printer: 1. Switch off printer power. 2. Disconnect the ac power cord from the wall outlet. 3. Verify the power cord is free from damage or short circuit and is connected properly. 4. Remove the print cartridg...

  • Page 82

    3-4 phaser 4500/4510 service manual error messages and codes using the troubleshooting procedures 1. Each step in a troubleshooting procedure instructs you to perform a certain action or procedure. Follow the steps sequentially in the order given until the problem is fixed or resolved. 2. The action...

  • Page 83

    Phaser 4500/4510 service manual 3-5 error messages and codes unless otherwise specified, the following voltage tolerances are used within this section: 7. When a troubleshooting procedure instructs you to replace a non-spared component and that component is part of a parent assembly, you should repl...

  • Page 84

    3-6 phaser 4500/4510 service manual error messages and codes entry level fault isolation procedure use this procedure to quickly determine the general area of the printer in which the problem is located. Troubleshooting procedure steps actions and questions yes no 1 switch the printer off then on. D...

  • Page 85: Service Diagnostics

    Phaser 4500/4510 service manual 3-7 error messages and codes service diagnostics the phaser 4500/4510 laser printer has built-in diagnostics to aid in troubleshooting problems with the printer. The service diagnostics menu provides a means to test sensors, motors, switches, clutches, fans and soleno...

  • Page 86

    3-8 phaser 4500/4510 service manual error messages and codes 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 pri...

  • Page 87

    Phaser 4500/4510 service manual 3-9 error messages and codes service diagnostic control 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 achie...

  • Page 88

    3-10 phaser 4500/4510 service manual error messages and codes engine test print you can use engine test print (see “engine test print” on page 6-4) to identify, repair, and validate the operability of printer xerographics and paper handling from all paper sources, options, and output destinations. P...

  • Page 89

    Phaser 4500/4510 service manual 3-11 error messages and codes exit motor (all tests) the test runs the motor about three seconds, then stops it. Print engine top and rear covers must be closed and print cartridge must be installed for the motor to run. Main motor the test runs the motor for one minu...

  • Page 90

    3-12 phaser 4500/4510 service manual error messages and codes print cartridge switch checks for the presence of the print cartridge. Toggle the switch by partially removing the print cartridge. Displays “installed” or “not installed” toner sensor checks that there is toner in the print cartridge. Di...

  • Page 91

    Phaser 4500/4510 service manual 3-13 error messages and codes sensor locations 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...

  • Page 92

    3-14 phaser 4500/4510 service manual error messages and codes solenoid test tests the functionality of the printer’s only solenoid. Stacker gate solenoid this test is available at all times, but runs only when a stacker is installed. Attempting to run the test without a stacker results in the “optio...

  • Page 93: System Start-Up and Post

    Phaser 4500/4510 service manual 3-15 error messages and codes 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 p...

  • Page 94

    3-16 phaser 4500/4510 service manual error messages and codes post faults there are two kinds of faults: soft and hard. A soft fault is any fault that is discovered by post, but does not prevent the operating system from initializing and becoming available as a tool for troubleshooting. These post f...

  • Page 95

    Phaser 4500/4510 service manual 3-17 error messages and codes 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 control panel and blinks the control pane...

  • Page 96

    3-18 phaser 4500/4510 service manual error messages and codes post error code table led blink code control 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...

  • Page 97

    Phaser 4500/4510 service manual 3-19 error messages and codes 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 rec...

  • Page 98

    3-20 phaser 4500/4510 service manual error messages and codes network problems the printer maintains four (p4510) or six (p4500) logs in memory detailing network functions. The logs contain tcp/ip, netware (p4500 only) and appletalk initialization events. The logs can also be accessed remotely via c...

  • Page 99

    Phaser 4500/4510 service manual 3-21 error messages and codes troubleshooting procedures for error messages and codes the error message summary tables that follow are the lead-ins to the procedures that follow in subsequent pages. There are two tables because the engine error and jam error codes are...

  • Page 100

    3-22 phaser 4500/4510 service manual error messages and codes “fuser failure\ press i” fuser low temp u4-2: fuser fail/power off 1 — go to page 3-30. “fuser failure\ press i” fuser overheat in stand-by u4-3: fuser fail/power off 1 — go to page 3-30. “fuser failure\press i” fuser fails at warm-up u4-...

  • Page 101

    Phaser 4500/4510 service manual 3-23 error messages and codes “jam at duplex; open duplex to clear\ press i “ e7-0 duplex jam — 7 go to page 3-51. “jam at rear; open duplex and rear cover to clear\ press i “ e7-1 duplex jam — 7 go to page 3-49. “jam at duplex; open duplex to clear\ press i “ e7-2 du...

  • Page 102

    3-24 phaser 4500/4510 service manual error messages and codes “maintenance kit is near end of life\ press i” n/a — — — “replace maintenance kit” n/a — — go to page 3-71. “stacker is full, unload paper\ press i” stacker output tray full — — go to page 3-69 “standard output tray is full, unload paper\...

  • Page 103

    Phaser 4500/4510 service manual 3-25 error messages and codes phaser 4510 error message summary control panel message diagnostic message engine errors jam errors procedure to use “engine logic board nvram failure\ press ?” u6 nvm fail/ power off 59 — go to page 3-33. “main motor failure\ press ?” u1...

  • Page 104

    3-26 phaser 4500/4510 service manual error messages and codes “close top cover\ press ?” top cover open — 65 go to page 3-58. “close rear cover\ press ?” rear cover open — 66 go to page 3-58. “jam at tray n; remove trays and open top cover to clear\ press ?“ e2-01 feed jam e2-02 feed jam e2-03 feed ...

  • Page 105

    Phaser 4500/4510 service manual 3-27 error messages and codes “insert tray 4\ press ?” tray 4 out — 23 go to page 3-68 “tray 2 paper is low\ press ?” n/a — — go to page 3-64 “tray 3 paper is low\ press ?” n/a — — go to page 3-66 “tray 4 paper is low\ press ?” n/a — — go to page 3-66 “no paper in tra...

  • Page 106

    3-28 phaser 4500/4510 service manual error messages and codes main motor failure diagnostic 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 boa...

  • Page 107

    Phaser 4500/4510 service manual 3-29 error messages and codes laser unit failure diagnostic 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 tro...

  • Page 108

    3-30 phaser 4500/4510 service manual error messages and codes fuser failure diagnostic 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 m...

  • Page 109

    Phaser 4500/4510 service manual 3-31 error messages and codes fan failure diagnostic 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 ...

  • Page 110

    3-32 phaser 4500/4510 service manual error messages and codes 8 turn the power on. Does fan error occur? Replace the hvps/engine logic board (page 8-73). 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 th...

  • Page 111

    Phaser 4500/4510 service manual 3-33 error messages and codes engine logic board nvram failure diagnostic error code u6: nvm fail troubleshooting reference applicable parts wiring and plug/jack map references ■ hvps/engine logic board ■ “p4500: 24 v interlock, rear cover switch, main motor, sub fan,...

  • Page 112

    3-34 phaser 4500/4510 service manual error messages and codes jam at tray n paper arrives early at the registration sensor diagnostic error codes e2-01: feed jam 1 at tray 1 e2-02: feed jam 1 at tray 2 e2-03: feed jam 1 at tray 3 e2-04: feed jam 1 at tray 4 troubleshooting reference applicable parts...

  • Page 113

    Phaser 4500/4510 service manual 3-35 error messages and codes 4 1. Remove the paper cassette. 2. Check if the bottom plate assembly lifts while installing paper cassette. 3. Push the bottom plate assembly down and release; check the movement. 4. Check visually if the bottom plate assembly is incline...

  • Page 114

    3-36 phaser 4500/4510 service manual error messages and codes 13 enter service diagnostics, and from the clutch tests menu select the appropriate feed clutch test. Does the feed clutch assembly operate normally? Go to step 14. Go to “optional 550-sheet feeder feed clutch assembly” on page 4-46. 14 m...

  • Page 115

    Phaser 4500/4510 service manual 3-37 error messages and codes jam at tray n paper arrives late at the registration sensor. Diagnostic error codes e2-11: feed jam 2 at tray 1 e2-12: feed jam 2 at tray 2 e2-13: feed jam 2 at tray 3 e2-14: feed jam 2 at tray 4 troubleshooting reference applicable parts...

  • Page 116

    3-38 phaser 4500/4510 service manual error messages and codes 5 does the error occur when the power is turned on? Go to “registration sensor” on page 4-17. 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 ...

  • Page 117

    Phaser 4500/4510 service manual 3-39 error messages and codes 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 8-86. 15 enter service diagnostics...

  • Page 118

    3-40 phaser 4500/4510 service manual error messages and codes jam at top; open top cover to clear diagnostic error codes e3-1 registration jam 1 e3-2 registration jam 2 troubleshooting reference applicable parts wiring and plug/jack map references ■ fuser assembly ■ hvps/engine logic board ■ registr...

  • Page 119

    Phaser 4500/4510 service manual 3-41 error messages and codes 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 8-44). 8 enter service diagnostics, and from the sensor tests menu sele...

  • Page 120

    3-42 phaser 4500/4510 service manual error messages and codes 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 8-47). Go to step 16. 16 remove the print cartridge right g...

  • Page 121

    Phaser 4500/4510 service manual 3-43 error messages and codes jam at exit; open rear/top cover to clear diagnostic error codes e4-0 exit jam 3 e4-2 exit jam 1 e4-3 exit jam 2 troubleshooting reference applicable parts wiring and plug/jack map references ■ fuser assembly ■ hvps/engine logic board ■ f...

  • Page 122

    3-44 phaser 4500/4510 service manual error messages and codes 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 th...

  • Page 123

    Phaser 4500/4510 service manual 3-45 error messages and codes jam at rear; open rear cover to clear diagnostic 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 rol...

  • Page 124

    3-46 phaser 4500/4510 service manual error messages and codes 6 1. Remove the stacker cover (page 8-113). 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 pa...

  • Page 125

    Phaser 4500/4510 service manual 3-47 error messages and codes jam at stacker; open rear stacker cover to clear diagnostic 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 ...

  • Page 126

    3-48 phaser 4500/4510 service manual error messages and codes 6 remove the stacker cover (page 8-113), 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 ...

  • Page 127

    Phaser 4500/4510 service manual 3-49 error messages and codes jam at rear; open duplex and rear cover to clear diagnostic 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 ■ d...

  • Page 128

    3-50 phaser 4500/4510 service manual error messages and codes 6 1. Remove the duplex unit left cover (page 8-96). 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,...

  • Page 129

    Phaser 4500/4510 service manual 3-51 error messages and codes jam at duplex; open duplex to clear diagnostic 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 ac...

  • Page 130

    3-52 phaser 4500/4510 service manual error messages and codes duplex unit error diagnostic error code e9-1: duplex unit failure 6 enter service diagnostics, and from the motors/fan tests menu select the duplex motor low test. Does duplex unit motor rotate normally? Replace the hvps/engine logic boar...

  • Page 131

    Phaser 4500/4510 service manual 3-53 error messages and codes stacker error diagnostic 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...

  • Page 132

    3-54 phaser 4500/4510 service manual error messages and codes tray 3 failure/tray 3 or 4 failure no recognition of the optional 550-sheet feeder. Diagnostic error codes e11-1: tray 3 failure e11-2: tray 3 or 4 failure note this procedure assumes that optional 550-sheet paper feeders are installed as...

  • Page 133

    Phaser 4500/4510 service manual 3-55 error messages and codes 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...

  • Page 134

    3-56 phaser 4500/4510 service manual error messages and codes paper size jam diagnostic error code pse-1: paper size mismatch note this procedure assumes that optional 550-sheet paper feeders are installed as tray 3 and tray 4. P4500: if tray 3 or tray 4 is reporting “executive” when the tray is set...

  • Page 135

    Phaser 4500/4510 service manual 3-57 error messages and codes 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 8-73) 6 check paper cassette (2). Are the end guide assembly, sector gear, size rac...

  • Page 136

    3-58 phaser 4500/4510 service manual error messages and codes close top cover/close rear cover error indication close top cover close rear cover note p4500: refer to service bulletin 632 for more troubleshooting information. Troubleshooting reference applicable parts wiring and plug/jack map referen...

  • Page 137

    Phaser 4500/4510 service manual 3-59 error messages and codes close duplex unit cover 3 check the rear cover switch enter service diagnostics, and from the sensor tests menu select the rear cover switch test. Is the position of the rear cover accurately reported when the rear cover is opened and clo...

  • Page 138

    3-60 phaser 4500/4510 service manual error messages and codes close stacker cover troubleshooting reference applicable parts wiring and plug/jack map references ■ hvps/engine logic board ■ lvps ■ stacker pwba ■ rear cover ■ stacker cover ■ rear cover switch ■ rear cover assembly harness ■ “stacker s...

  • Page 139

    Phaser 4500/4510 service manual 3-61 error messages and codes 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 ...

  • Page 140

    3-62 phaser 4500/4510 service manual error messages and codes replace print cartridge error indication replace print cartridge note p4500: refer to sb 651 rev. 1. Before replacing the print cartridge, be sure that ps firmware version v.1.26 or later is installed in the printer. If it is not, downloa...

  • Page 141

    Phaser 4500/4510 service manual 3-63 error messages and codes 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 ■...

  • Page 142

    3-64 phaser 4500/4510 service manual error messages and codes 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 ...

  • Page 143

    Phaser 4500/4510 service manual 3-65 error messages and codes 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 act...

  • Page 144

    3-66 phaser 4500/4510 service manual error messages and codes 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 actua...

  • Page 145

    Phaser 4500/4510 service manual 3-67 error messages and codes 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 pa...

  • Page 146

    3-68 phaser 4500/4510 service manual error messages and codes 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 150-sheet pa...

  • Page 147

    Phaser 4500/4510 service manual 3-69 error messages and codes stacker is full, unload paper error indication stacker is full, unload paper troubleshooting reference applicable parts wiring and plug/jack map references ■ stacker full sensor (0n stacker pwba) ■ hvps/engine logic board ■ stacker pwba ■...

  • Page 148

    3-70 phaser 4500/4510 service manual error messages and codes 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 ■ output tray full sensor ■ stack full actuator ■ hvps/e...

  • Page 149

    Phaser 4500/4510 service manual 3-71 error messages and codes 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 s...

  • Page 150

    3-72 phaser 4500/4510 service manual error messages and codes 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 ■...

  • Page 151

    Phaser 4500/4510 service manual 3-73 error messages and codes 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...

  • Page 152

    3-74 phaser 4500/4510 service manual error messages and codes 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 dup...

  • Page 153

    Phaser 4500/4510 service manual 3-75 error messages and codes 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...

  • Page 154

    3-76 phaser 4500/4510 service manual error messages and codes.

  • Page 155: In This Chapter...

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

  • Page 156: Introduction

    4-2 phaser 4500/4510 service manual general troubleshooting introduction the procedures in this chapter troubleshoot problems that are not associated with an error code or control panel error message. For troubleshooting problems associated with an error code or control panel error message, notes on...

  • Page 157

    Phaser 4500/4510 service manual 4-3 general troubleshooting control panel troubleshooting lcd/led display error/inoperable buttons troubleshooting reference applicable parts wiring and plug/jack map references ■ control panel ■ control panel harness ■ image processor board ■ lvps ■ “image processor ...

  • Page 158

    4-4 phaser 4500/4510 service manual general troubleshooting 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 ■ “p4500: 24 v interlock, rear cover swi...

  • Page 159

    Phaser 4500/4510 service manual 4-5 general troubleshooting dc-dc converter (p4500 only) note the dc-dc converter is an integral part of the lvps in the p4510. This procedure applies only to the stand-alone board used in the p4500. 3 check the output of the dc-dc converter (p4510 only): 1. Disconnec...

  • Page 160

    4-6 phaser 4500/4510 service manual general troubleshooting troubleshooting procedure steps actions and questions yes no 1 check the 24 v input: 1. Remove the lvps shield plate (page 8-60). 2. Disconnect j404a from p404 (in-line connector). 3. Turn the power on. 4. Measure the voltage across j404a-3...

  • Page 161

    Phaser 4500/4510 service manual 4-7 general troubleshooting ac power supply troubleshooting no ac power troubleshooting reference applicable parts wiring and plug/jack map references ■ power cord ■ lvps ■ hvps/engine logic board ■ control panel ■ control panel harness ■ 24 v interlock ■ 5 v interloc...

  • Page 162

    4-8 phaser 4500/4510 service manual general troubleshooting 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 4-39, “optional 550-sheet feeder pwba (tray 4)” on page ...

  • Page 163

    Phaser 4500/4510 service manual 4-9 general troubleshooting 8 1. Disconnect the control 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 ...

  • Page 164

    4-10 phaser 4500/4510 service manual general troubleshooting 14 1. Disconnect p/j242 and p/j247 from the tray 1/2 harness assembly. 2. Remove the print cartridge. Does the main fan rotate when the power is turned on? Go to “feed clutches” on page 4-30. Go to step 15. 15 1. Disconnect p/j43 from the ...

  • Page 165

    Phaser 4500/4510 service manual 4-11 general troubleshooting 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 ■ “p4500: 24 v interlock, rear cover switch, main ...

  • Page 166

    4-12 phaser 4500/4510 service manual general troubleshooting laser unit assembly 5 turn on the printer. Does the main motor rotate? Problem solved. Replace the hvps/engine logic board (page 8-73), then go to step 6. 6 turn on the printer. Does the main motor rotate? Problem solved. Replace the main ...

  • Page 167

    Phaser 4500/4510 service manual 4-13 general troubleshooting 2 check the 5 v interlock. 1. Disconnect the 5 v interlock at p/j142 (clamped to the side of the gear housing near the exit motor pwba). 2. Test for continuity between p/j142-1 p/j142-3 while opening and closing the top cover. Is there con...

  • Page 168

    4-14 phaser 4500/4510 service manual general troubleshooting 7 check the hvps/engine logic board for continuity: disconnect p/j14 and p/j11 from the hvps/engine logic board. Test for continuity between p/j14-1 p/j11-13. Is there continuity? Go to step 8. Go to step 13. 8 1. Disconnect p/j11 from the...

  • Page 169

    Phaser 4500/4510 service manual 4-15 general troubleshooting fuser assembly 13 replace the hvps/engine logic board (page 8-73). Does the problem still occur after replacement? Go to step 14. Problem solved. 14 replace the laser unit assembly (page 8-38 does the problem still occur after replacement?...

  • Page 170

    4-16 phaser 4500/4510 service manual general troubleshooting 3 check the fuser power source voltage: 1. Disconnect p/j48 from the lvps. 2. Remove the print cartridge. 3. Turn the power on. 4. Measure the voltage across p/j48-1 p/j48-3 does it measure at line voltage? Go to step 5. Go to step 4. 4 ch...

  • Page 171

    Phaser 4500/4510 service manual 4-17 general troubleshooting registration sensor 9 replace the lvps (page 8-62). Does the problem still occur after replacement? Replace the fuser assembly (page 8-44). Problem solved. Troubleshooting reference applicable parts wiring and plug/jack map references ■ re...

  • Page 172

    4-18 phaser 4500/4510 service manual general troubleshooting 3 check the power to registration sensor: 1. Remove the print cartridge. 2. Measure the voltage across p/j24-9 p/j24-10 on the hvps/engine logic board. Is the voltage about 3.3 vdc? Go to step 4. Go to step 6. 4 check the chute assembly ha...

  • Page 173

    Phaser 4500/4510 service manual 4-19 general troubleshooting 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 ■...

  • Page 174

    4-20 phaser 4500/4510 service manual general troubleshooting 5 check the chute assembly harness: 1. Disconnect p/j24 from the hvps/engine logic board. 2. Disconnect p/j245 and p/j248. 3. Test the harness for continuity at these points: ■ j24-6 j245-13 ■ j24-7 j245-12 ■ j24-8 j245-11 ■ j24-1 j248-5 ■...

  • Page 175

    Phaser 4500/4510 service manual 4-21 general troubleshooting 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 fe...

  • Page 176

    4-22 phaser 4500/4510 service manual general troubleshooting toner sensor note p4500: refer to sb651 rev. 1. In the case of premature “toner low” or “replace print cartridge” messages, verify that ps firmware v.1.26 or later is installed in the printer before replacing the print cartridge. If it is ...

  • Page 177

    Phaser 4500/4510 service manual 4-23 general troubleshooting output tray full sensor 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 178

    4-24 phaser 4500/4510 service manual general troubleshooting 24 v interlock 3 check the exit sensor assembly harness: 1. Remove the paper exit assembly (page 8-49) 2. Remove exit sensor assembly harness. 3. Check the following for continuity: ■ j29-1 j290-3 ■ j29-2 j290-2 ■ j29-3 j290-1 are all cont...

  • Page 179

    Phaser 4500/4510 service manual 4-25 general troubleshooting 5 v interlock, interlock switch assembly troubleshooting reference applicable parts wiring and plug/jack map references ■ 5 v interlock ■ interlock switch assembly ■ laser unit harness assembly ■ lvps harness assembly ■ lvps ■ hvps/engine ...

  • Page 180

    4-26 phaser 4500/4510 service manual general troubleshooting rear cover switch interlock switch assembly (p4500 only) troubleshooting reference applicable parts wiring and plug/jack map references ■ rear cover switch ■ lvps ■ hvps/engine logic board ■ “p4500: 24 v interlock, rear cover switch, main ...

  • Page 181

    Phaser 4500/4510 service manual 4-27 general troubleshooting exit motor pwba 2 check the lvps harness assembly: 1. Disconnect p/j11, p/j41, and p/j411. 2. Test for continuity across the following points: ■ p411-3 j41-5 ■ p411-1 j11-12 are both continuous? Go to “lvps (low voltage power supply)” on p...

  • Page 182

    4-28 phaser 4500/4510 service manual general troubleshooting 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 ■ “p4500: 24 v interlock, rear cover switch...

  • Page 183

    Phaser 4500/4510 service manual 4-29 general troubleshooting 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 fee...

  • Page 184

    4-30 phaser 4500/4510 service manual general troubleshooting 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” ...

  • Page 185

    Phaser 4500/4510 service manual 4-31 general troubleshooting 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 volt...

  • Page 186

    4-32 phaser 4500/4510 service manual general troubleshooting 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 ■ “pri...

  • Page 187

    Phaser 4500/4510 service manual 4-33 general troubleshooting image processor isolation 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 (l...

  • Page 188

    4-34 phaser 4500/4510 service manual general troubleshooting image processor board 3 1. Switch the printer power off. 2. Re-install one of the removed options or cables. 3. Switch the printer power on. Does the printer boot up correctly and is ready to print displayed on the control panel? Repeat th...

  • Page 189

    Phaser 4500/4510 service manual 4-35 general troubleshooting ram dimm fault isolation initial actions: ■ power off printer. Remove and re-install ram dimms after verifying that they meet the xerox specifications. Note p4500: a minimum of 64 mb of ram must be installed for proper printer operation. T...

  • Page 190

    4-36 phaser 4500/4510 service manual general troubleshooting troubleshooting procedures step actions and questions yes no 1 power on the printer. Is ram error displayed on the control panel? Go to step 5 go to step 2 2 is power on self test error 4: memory displayed on the control panel? Go to step ...

  • Page 191

    Phaser 4500/4510 service manual 4-37 general troubleshooting 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 a...

  • Page 192

    4-38 phaser 4500/4510 service manual general troubleshooting 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 193

    Phaser 4500/4510 service manual 4-39 general troubleshooting 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-...

  • Page 194

    4-40 phaser 4500/4510 service manual general troubleshooting 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-...

  • Page 195

    Phaser 4500/4510 service manual 4-41 general troubleshooting 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 150-sheet paper f...

  • Page 196

    4-42 phaser 4500/4510 service manual general troubleshooting 3 check the no paper sensor (2) 1. Install the optional 550-sheet feeder (page 8-86). 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 o...

  • Page 197

    Phaser 4500/4510 service manual 4-43 general troubleshooting 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 150-sheet paper feed...

  • Page 198

    4-44 phaser 4500/4510 service manual general troubleshooting 3 check the low paper sensor (2) 1. Install the optional 550-sheet feeder (page 8-86). 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....

  • Page 199

    Phaser 4500/4510 service manual 4-45 general troubleshooting 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 150-...

  • Page 200

    4-46 phaser 4500/4510 service manual general troubleshooting optional 550-sheet feeder feed clutch assembly troubleshooting reference applicable parts wiring and plug/jack map references ■ feed clutch assembly ■ optional 150-sheet paper feeder ■ 550-sheet paper cassette ■ 550-sheet feeder pwba ■ clu...

  • Page 201

    Phaser 4500/4510 service manual 4-47 general troubleshooting 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 j2...

  • Page 202

    4-48 phaser 4500/4510 service manual general troubleshooting 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 ■...

  • Page 203

    Phaser 4500/4510 service manual 4-49 general troubleshooting duplex unit pwba 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 con...

  • Page 204

    4-50 phaser 4500/4510 service manual general troubleshooting duplex unit motor 2 check the lvps harness assembly: 1. Disconnect p/j27 from the hvps/engine logic board. 2. Test each cable between j27 j2750 for continuity. Is each cable continuous? Go to step 3. Replace the lvps harness assembly. 3 re...

  • Page 205

    Phaser 4500/4510 service manual 4-51 general troubleshooting duplex unit sensor 3 check the duplex unit motor for rotation: 1. Enter service diagnostics, and from the motors/fan test menu select duplex motor high and duplex motor low tests. Does the motor rotate? Replace the hvps/engine logic board ...

  • Page 206

    4-52 phaser 4500/4510 service manual general troubleshooting 2 check the duplex unit sensor (1): 1. Enter service diagnostics, and from the sensor tests menu select duplex sensor test. Does the sensor correctly report the position of the actuator? Replace the hvps/engine logic board (page 8-73). Go ...

  • Page 207

    Phaser 4500/4510 service manual 4-53 general troubleshooting 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/en...

  • Page 208

    4-54 phaser 4500/4510 service manual general troubleshooting 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 ...

  • Page 209

    Phaser 4500/4510 service manual 4-55 general troubleshooting 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 signa...

  • Page 210

    4-56 phaser 4500/4510 service manual general troubleshooting 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 ■ “stack...

  • Page 211

    Phaser 4500/4510 service manual 4-57 general troubleshooting 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 diag...

  • Page 212

    4-58 phaser 4500/4510 service manual general troubleshooting 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 harnes...

  • Page 213

    Phaser 4500/4510 service manual 4-59 general troubleshooting 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 ■ “...

  • Page 214

    4-60 phaser 4500/4510 service manual general troubleshooting stacker full sensor (on stacker pwba) 5 check stacker harness 1: 1. Remove stacker harness 1. 2. Test j30 j3070 for continuity is the harness continuous? Go to step 6. Replace stacker harness 1. 6 replace the stacker sensor (page 8-122). I...

  • Page 215

    Phaser 4500/4510 service manual 4-61 general troubleshooting offset sensor (on stacker pwba) 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 sta...

  • Page 216

    4-62 phaser 4500/4510 service manual general troubleshooting 3 check stacker harness 1: 1. Remove stacker harness 1. 2. Test j30 j3070 for continuity is the harness continuous? Go to step 4. Replace stacker harness 1. 4 replace the stacker pwba (page 8-119). Is the problem cleared? Problem solved. R...

  • Page 217: In This Chapter...

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

  • Page 218

    5-2 phaser 4500/4510 service manual print-quality troubleshooting 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-qua...

  • Page 219: Analyzing Test Prints

    Phaser 4500/4510 service manual 5-3 print-quality troubleshooting 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 o...

  • Page 220

    5-4 phaser 4500/4510 service manual print-quality troubleshooting resolution: at 600 dpi, the two pixel lines and halftone patches cannot be reproduced clearly on the print. Page 5-8 spot deletions: solid areas are marked with irregular white areas. Page 5-36 repeating defects: recurring marks, spot...

  • Page 221

    Phaser 4500/4510 service manual 5-5 print-quality troubleshooting test print note the test print for the phaser 4510 is identical to the test print for the phaser 4500 except for the model number shown on the page. S4510-256 test print test print phaser4500-030129-2-s phaser4500-030129-2-s 8.5x11 (s...

  • Page 222

    5-6 phaser 4500/4510 service manual print-quality troubleshooting 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 visi...

  • Page 223

    Phaser 4500/4510 service manual 5-7 print-quality troubleshooting fusing 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 en...

  • Page 224

    5-8 phaser 4500/4510 service manual print-quality troubleshooting 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 l...

  • Page 225

    Phaser 4500/4510 service manual 5-9 print-quality troubleshooting 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...

  • Page 226

    5-10 phaser 4500/4510 service manual print-quality troubleshooting 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...

  • Page 227

    Phaser 4500/4510 service manual 5-11 print-quality troubleshooting 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 5-12. Go to “skips and smears” on page 5-48. Test print test pri...

  • Page 228

    5-12 phaser 4500/4510 service manual print-quality troubleshooting 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. Inspe...

  • Page 229

    Phaser 4500/4510 service manual 5-13 print-quality troubleshooting 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...

  • Page 230

    5-14 phaser 4500/4510 service manual print-quality troubleshooting 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 pre...

  • Page 231

    Phaser 4500/4510 service manual 5-15 print-quality troubleshooting 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 installati...

  • Page 232

    5-16 phaser 4500/4510 service manual print-quality troubleshooting 4 1. Reform or clean the metal contacts so they make better contact with the print cartridge. Ensure that they are pressed firmly into their plastic mounting pins, and bent outward (not flat). 2. Print a test print. Does the image de...

  • Page 233

    Phaser 4500/4510 service manual 5-17 print-quality troubleshooting 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 p...

  • Page 234

    5-18 phaser 4500/4510 service manual print-quality troubleshooting 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 cartridg...

  • Page 235

    Phaser 4500/4510 service manual 5-19 print-quality troubleshooting 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...

  • Page 236

    5-20 phaser 4500/4510 service manual print-quality troubleshooting 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 f...

  • Page 237

    Phaser 4500/4510 service manual 5-21 print-quality troubleshooting 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 r...

  • Page 238

    5-22 phaser 4500/4510 service manual print-quality troubleshooting 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...

  • Page 239

    Phaser 4500/4510 service manual 5-23 print-quality troubleshooting 2 1. Exit service diagnostics. 2. When the printer has restarted, select information , then press the ok button. 3. Scroll to information pages , then press the ok button. 4. Scroll to configuration page , then press the ok button. D...

  • Page 240

    5-24 phaser 4500/4510 service manual print-quality troubleshooting 8 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 r...

  • Page 241

    Phaser 4500/4510 service manual 5-25 print-quality troubleshooting 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 sta...

  • Page 242

    5-26 phaser 4500/4510 service manual print-quality troubleshooting 2 1. Exit service diagnostics. 2. When the printer is ready, scroll to information , then press the ok button. 3. Scroll to information pages menu, then press the ok button. 4. Scroll to configuration page , then press the ok button....

  • Page 243

    Phaser 4500/4510 service manual 5-27 print-quality troubleshooting 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 pr...

  • Page 244

    5-28 phaser 4500/4510 service manual print-quality troubleshooting 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 i...

  • Page 245

    Phaser 4500/4510 service manual 5-29 print-quality troubleshooting 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 staple...

  • Page 246

    5-30 phaser 4500/4510 service manual print-quality troubleshooting 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 a...

  • Page 247

    Phaser 4500/4510 service manual 5-31 print-quality troubleshooting 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 y...

  • Page 248

    5-32 phaser 4500/4510 service manual print-quality troubleshooting 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 us...

  • Page 249

    Phaser 4500/4510 service manual 5-33 print-quality troubleshooting fuser configuration defaults 8 replace the following in order, until the defective component is found: ■ fuser assembly (page 8-44) ■ hvps/engine logic board (page 8-73) ■ lvps pwb (page 8-62) paper type default fuser temperature set...

  • Page 250

    5-34 phaser 4500/4510 service manual print-quality troubleshooting 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 unob...

  • Page 251

    Phaser 4500/4510 service manual 5-35 print-quality troubleshooting 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 pa...

  • Page 252

    5-36 phaser 4500/4510 service manual print-quality troubleshooting 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. ■ c...

  • Page 253

    Phaser 4500/4510 service manual 5-37 print-quality troubleshooting 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 r...

  • Page 254

    5-38 phaser 4500/4510 service manual print-quality troubleshooting 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 in...

  • Page 255

    Phaser 4500/4510 service manual 5-39 print-quality troubleshooting 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 cl...

  • Page 256

    5-40 phaser 4500/4510 service manual print-quality troubleshooting 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 r...

  • Page 257

    Phaser 4500/4510 service manual 5-41 print-quality troubleshooting 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. ■...

  • Page 258

    5-42 phaser 4500/4510 service manual print-quality troubleshooting 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 l...

  • Page 259

    Phaser 4500/4510 service manual 5-43 print-quality troubleshooting skewed image the image is not parallel to the edges of the print sheet. Note refer to “skew” on page 5-13 for specification information. Initial actions ■ check the paper tray(s) installation and the paper in the tray(s). ■ load fres...

  • Page 260

    5-44 phaser 4500/4510 service manual print-quality troubleshooting 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...

  • Page 261

    Phaser 4500/4510 service manual 5-45 print-quality troubleshooting 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...

  • Page 262

    5-46 phaser 4500/4510 service manual print-quality troubleshooting registration the image is not positioned correctly on the paper. It may be off in either the process direction or in the scan direction. Note refer to “registration (side-to-side)” on page 5-9 and “registration (lead edge-to-trail ed...

  • Page 263

    Phaser 4500/4510 service manual 5-47 print-quality troubleshooting 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 th...

  • Page 264

    5-48 phaser 4500/4510 service manual print-quality troubleshooting 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 troubl...

  • Page 265: 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 266: Service Test Prints

    6-2 phaser 4500/4510 service manual adjustments and calibrations 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 t...

  • Page 267

    Phaser 4500/4510 service manual 6-3 adjustments and calibrations note the test print for the phaser 4510 is identical to the test print for the phaser 4500 except for the model number shown on the page. S4510-256 test print test print phaser4500-030129-2-s phaser4500-030129-2-s 8.5x11 (sef) 8.5x11 (...

  • Page 268

    6-4 phaser 4500/4510 service manual adjustments and calibrations 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...

  • Page 269: Adjustments

    Phaser 4500/4510 service manual 6-5 adjustments and calibrations 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 ...

  • Page 270

    6-6 phaser 4500/4510 service manual adjustments and calibrations 8. Check the following measurements on two consecutive test patterns of the five made from the tray in step 6. If a registration measurement does not meet the specification, perform the simplex adjustment procedure on page 6-7. 9. Repe...

  • Page 271

    Phaser 4500/4510 service manual 6-7 adjustments and calibrations adjusting simplex registration (margins) 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 ...

  • Page 272

    6-8 phaser 4500/4510 service manual adjustments and calibrations adjusting duplex registration (margins) 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 di...

  • Page 273: Resetting Fuser Life

    Phaser 4500/4510 service manual 6-9 adjustments and calibrations to change the fuser setting for a particular paper type: 1. From the main menu, select printer setup , then press the ok button. 2. Select paper handling setup , then press the ok button. 3. Select fuser configuration , then press the ...

  • Page 274

    6-10 phaser 4500/4510 service manual adjustments and calibrations 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 ■ con...

  • Page 275

    Phaser 4500/4510 service manual 6-11 adjustments and calibrations 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 pape...

  • Page 276

    6-12 phaser 4500/4510 service manual adjustments and calibrations resetting control panel setup values resetting the control panel values resets the control panel language, control panel brightness, control panel contrast, and accessible control panel settings. 1. From the main menu, select control ...

  • Page 277

    Phaser 4500/4510 service manual 6-13 adjustments and calibrations 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 ...

  • Page 278

    6-14 phaser 4500/4510 service manual adjustments and calibrations.

  • Page 279: In This Chapter...

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

  • Page 280: Recommended Tools

    7-2 phaser 4500/4510 service manual cleaning and maintenance 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 p...

  • Page 281: 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 282: Overview

    8-2 phaser 4500/4510 service manual fru disassembly 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, ...

  • Page 283

    Phaser 4500/4510 service manual 8-3 fru disassembly 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...

  • Page 284: Print Engine: Covers

    8-4 phaser 4500/4510 service manual fru disassembly print engine: covers paper exit cover (pl10.1.1) procedure: 1. Open the duplex unit if one is installed (page 8-95). 2. Open the paper exit rear door. 3. Unscrew the thumbscrews at the right and left rear sides of the paper exit cover. 4. Lift the ...

  • Page 285

    Phaser 4500/4510 service manual 8-5 fru disassembly paper exit rear door (pl10.2.21) procedure: 1. Open the duplex unit if one is installed (page 8-95). 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 t...

  • Page 286

    8-6 phaser 4500/4510 service manual fru disassembly rear cover (pl 1.1.3) procedure: 1. Remove the paper exit rear door (page 8-5). 2. Remove the duplex unit if one is installed (page 8-95). 3. Phaser 4500: remove the three screws (two flanged machine, 8 mm; one tapping, 8 mm) that attach the rear c...

  • Page 287

    Phaser 4500/4510 service manual 8-7 fru disassembly right cover (pl1.1.4) procedure: 1. Loosen the thumbscrew at the rear of the printer that secures the right cover. 2. Shift the cover towards the rear of the printer to release the four hooks (two at the bottom edge, one in front, and one on rear),...

  • Page 288

    8-8 phaser 4500/4510 service manual fru disassembly left cover (pl1.1.6) procedure: 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 t...

  • Page 289

    Phaser 4500/4510 service manual 8-9 fru disassembly top cover assembly, control panel (pl1.1.7) (pl1.1.1) procedure: note the control panel can be removed without removing the top cover assembly by prying up carefully on the right edge of the control panel and disconnecting the harness. 1. Remove th...

  • Page 290

    8-10 phaser 4500/4510 service manual fru disassembly 5. Open the top cover and slide the link lever off the boss (item 1 in the figure). 6. Remove the top cover assembly. A. Lift the rear of the top cover assembly and slide the cover forward enough to release the hooks at the front. B. Tilt up the f...

  • Page 291

    Phaser 4500/4510 service manual 8-11 fru disassembly front cover (pl1.1.5) procedure: 1. Remove the top cover assembly (page 8-9). 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 t...

  • Page 292

    8-12 phaser 4500/4510 service manual fru disassembly interlock switch assembly (p4500 only) (pl1.1.11) procedure: 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 t...

  • Page 293

    Phaser 4500/4510 service manual 8-13 fru disassembly 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. Procedure: 1. Pull the paper cassette from the printer. ...

  • Page 294

    8-14 phaser 4500/4510 service manual fru disassembly replacement note: ■ while installing the retard holder, ensure that both ends of the coil spring under the holder are properly engaged with two boss pins. Check that it springs back to its normal position when depressed and released. 1. Retard rol...

  • Page 295

    Phaser 4500/4510 service manual 8-15 fru disassembly print engine: 150-sheet feeder 150-sheet feeder assembly (pl5.1.1) procedure: 1. Remove the 150-sheet paper cassette (tray 1). 2. Remove the transfer chute (page 8-46). 3. P4510: disconnect connectors p/j242 and p/j243 near the center of the feede...

  • Page 296

    8-16 phaser 4500/4510 service manual fru disassembly nudger roller, feed roller (pl5.1.11) (pl5.1.44); the rollers are also part of maintenance kit procedure: note when handling the nudger roller and feed roller assemblies, avoid touching the rubber roller surfaces. 1. Remove the 150-sheet paper cas...

  • Page 297

    Phaser 4500/4510 service manual 8-17 fru disassembly nudger one-way clutch (pl5.1.42) procedure: 1. Remove the 150-sheet paper cassette (tray 1). 2. Open the top cover. 3. Remove the print cartridge, and protect it from light exposure. 4. Remove the feed roller (page 8-16). 5. Slide the feed one-way...

  • Page 298

    8-18 phaser 4500/4510 service manual fru disassembly nudger gear (pl5.1.10) procedure: 1. Remove the 150-sheet feeder assembly (page 8-15). 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 ...

  • Page 299

    Phaser 4500/4510 service manual 8-19 fru disassembly 4. Release the hook of the nudger roller, and pull the nudger roller out from the nudger shaft. 5. Release the hook of the nudger gear, and pull the nudger gear out from the nudger shaft. Replacement note: ■ after the no paper actuator is replaced...

  • Page 300

    8-20 phaser 4500/4510 service manual fru disassembly registration sensor (pl5.1.30) procedure: 1. P4500: remove the main fan (page 8-68). P4510: remove the rear cover (page 8-6) 2. Release the hooks that secure the sensor cover, and remove the sensor cover from the registration chute assembly. 3. Re...

  • Page 301

    Phaser 4500/4510 service manual 8-21 fru disassembly no paper sensor (pl5.1.38) procedure: 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 assem...

  • Page 302

    8-22 phaser 4500/4510 service manual fru disassembly 6. Remove the 8 mm screw that attaches the no paper sensor holder. 7. Remove the no paper sensor holder from the 150-sheet feeder assembly. 8. Release the hooks that secure the no paper sensor to the no paper sensor holder, and remove the no paper...

  • Page 303

    Phaser 4500/4510 service manual 8-23 fru disassembly toner sensor assembly (pl5.1.45) procedure: 1. Remove the print cartridge and leave the top cover open. Protect the print cartridge from light exposure. Note before proceeding, remove the 150-sheet paper cassette and feed a sheet of paper partiall...

  • Page 304

    8-24 phaser 4500/4510 service manual fru disassembly print engine: 550-sheet paper feeder 550-sheet feeder assembly (pl7.1.10) procedure: 1. Remove the 150- and 550-sheet paper cassettes (trays 1 and 2). 2. Unplug the connector (p/j248) and release the cables from the two cable restraints on the tie...

  • Page 305

    Phaser 4500/4510 service manual 8-25 fru disassembly nudger roller, feed roller (pl7.1.19) (pl7.1.29) procedure: 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 a...

  • Page 306

    8-26 phaser 4500/4510 service manual fru disassembly nudger one-way clutch (pl7.1.27) procedure: 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 lock...

  • Page 307

    Phaser 4500/4510 service manual 8-27 fru disassembly nudger gear (pl7.1.18) procedure: 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 8-78). 5. Lay the pr...

  • Page 308

    8-28 phaser 4500/4510 service manual fru disassembly 6. Lift the boss of the left holder at the back of the 550-sheet feeder assembly, then shift the left holder in the direction of the arrow to release the three hooks. 7. Remove the left holder and no paper actuator from the nudger support. 8. Rele...

  • Page 309

    Phaser 4500/4510 service manual 8-29 fru disassembly feed clutch (pl7.1.20) procedure: 1. Remove the 150-sheet feeder assembly (page 8-15). 2. Remove the 550-sheet feeder assembly (page 8-24). 3. Remove the six 8 mm tapping screws that attach the tie plate to the out chute, and remove the tie plate ...

  • Page 310

    8-30 phaser 4500/4510 service manual fru disassembly no paper sensor (pl7.1.38) procedure: 1. Remove the 150-sheet feeder assembly (page 8-15). 2. Remove the 6 mm screw that attaches the no paper sensor holder. 3. Remove the no paper sensor holder from the 550-sheet feeder assembly. 4. Release the h...

  • Page 311

    Phaser 4500/4510 service manual 8-31 fru disassembly right tray guide (pl7.1.3) procedure: 1. Remove the print cartridge and paper cassettes. 2. Remove any optional 550-sheet feeder(s) (page 8-78). 3. Lay the printer on its right side. 4. Remove the 6 mm screw that attaches the right tray guide to t...

  • Page 312

    8-32 phaser 4500/4510 service manual fru disassembly replacement notes: ■ after re-connecting p/j260, make sure the low-paper sensor harness is properly looped through the two harness retainers. ■ when installing the right tray guide, be sure to position the cassette lock plates as shown in the figu...

  • Page 313

    Phaser 4500/4510 service manual 8-33 fru disassembly left tray guide (pl7.1.7) procedure: 1. Remove the print cartridge and paper cassettes. 2. Remove any optional 550-sheet paper feeder(s) (page 8-78). 3. Remove the front cover (page 8-11). Note removing the left tray guide might be easier with the...

  • Page 314

    8-34 phaser 4500/4510 service manual fru disassembly low paper sensor/actuator (pl7.1.4) procedure: 1. Remove the print cartridge and paper cassettes. 2. Remove the right tray guide (page 8-31) 3. Squeeze the actuator latch hooks together and lift the actuator off the pivot shaft. 4. Release the sen...

  • Page 315: Print Engine: Xerographics

    Phaser 4500/4510 service manual 8-35 fru disassembly print engine: xerographics vacuum duct (p4510) (pl8.1.31) procedure: 1. Remove the front cover (page 8-11). Removing the front cover requires removing all other printer covers and the paper exit assembly. 2. Remove the flanged screw that attaches ...

  • Page 316

    8-36 phaser 4500/4510 service manual fru disassembly front duct, sub fan (pl8.1.4) (pl8.1.5) procedure: 1. Remove the front cover (page 8-11). Removing the front cover requires removing all other printer covers and the paper exit assembly. 2. P4510: remove the vacuum duct (page 8-35). 3. Remove the ...

  • Page 317

    Phaser 4500/4510 service manual 8-37 fru disassembly 7. Release the latch that secures the sub fan to the front duct, and remove the sub fan. 1. Sub fan 3. Latch 2. Front duct 4. Cable slot s4510-113 1 4 2 p/j270 3.

  • Page 318

    8-38 phaser 4500/4510 service manual fru disassembly 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 assembl...

  • Page 319

    Phaser 4500/4510 service manual 8-39 fru disassembly 6. If a phillips screwdriver with a long shaft (min. 6.5 in (16.5 cm)) is available, skip this step. Otherwise, remove the eight 6 mm machine screws attaching the front tie plate to the frame, and remove the front tie plate. 7. Release the cable c...

  • Page 320

    8-40 phaser 4500/4510 service manual fru disassembly print cartridge left guide (pl8.1.15) procedure: 1. Remove the fuser assembly (page 8-44). 2. Remove the laser unit shield plate (page 8-39). 3. Remove the fuser harness clamp that secures the fuser harness to the frame. 4. Remove the rear cover (...

  • Page 321

    Phaser 4500/4510 service manual 8-41 fru disassembly 9. Unplug j46 (fuser status and sensor connections) and j47 (fuser ac connection) from p46 and p47 on the lvps 10. Remove the three 6 mm machine screws that attach the print cartridge left guide to the frame. Caution the loops on the print cartrid...

  • Page 322

    8-42 phaser 4500/4510 service manual fru disassembly fuser harness assembly (pl8.1.17) procedure: 1. Remove the print cartridge left guide (page 8-40). Caution the latch posts on the fuser connector are brittle and break very easily during removal. Use extreme caution in the next step when squeezing...

  • Page 323

    Phaser 4500/4510 service manual 8-43 fru disassembly link lever, gear 3 link (pl8.1.29) (pl8.1.30) procedure: 1. Remove the print cartridge left guide (page 8-40). 2. Remove the link lever and gear 3 link. 1. Gear 3 link 3. Print cartridge left guide 2. Link lever 1 2 s4500-125 3.

  • Page 324

    8-44 phaser 4500/4510 service manual fru disassembly fuser assembly note the fuser used in the phaser 4510 is different than the fuser used in the phaser 4500. The fusers are not interchangeable. (pl8.1.20) procedure: warning the fuser assembly is very hot immediately after the printer is turned off...

  • Page 325

    Phaser 4500/4510 service manual 8-45 fru disassembly transfer roller assembly (pl8.1.21) procedure: 1. Remove the print cartridge and leave the top cover open. Protect the print cartridge from light exposure. 2. Squeeze the latches of both ends of the transfer roller assembly, and remove it from the...

  • Page 326

    8-46 phaser 4500/4510 service manual fru disassembly transfer chute (pl8.1.22) procedure: 1. Remove the transfer roller assembly (page 8-45). 2. Remove the fuser assembly (page 8-44). 3. P4500: remove the main fan (page 8-68) p4510: remove the rear cover (page 8-6). 4. Lift the latch tab on the tran...

  • Page 327

    Phaser 4500/4510 service manual 8-47 fru disassembly print cartridge right guide assembly (pl8.1.25) procedure: 1. Remove the fuser assembly (page 8-44). 2. Remove the transfer roller assembly (page 8-45). 3. Remove the front duct (page 8-36). 4. Remove the image processor shield assembly (page 8-70...

  • Page 328

    8-48 phaser 4500/4510 service manual fru disassembly 7. Unplug j15 from p15 on the hvps/engine logic board. 8. Remove the three 6 mm machine screws that attach the print cartridge right guide assembly to the frame. 9. Pull the wiring harness of the print cartridge right guide assembly from the frame...

  • Page 329: Print Engine: Paper Exit

    Phaser 4500/4510 service manual 8-49 fru disassembly print engine: paper exit paper exit assembly (pl10.1.2) procedure: 1. Remove the paper exit cover (page 8-4) or stacker (page 8-111) if installed. 2. Remove the right cover (page 8-7 3. Remove the left cover (page 8-8). 4. Remove the image process...

  • Page 330

    8-50 phaser 4500/4510 service manual fru disassembly 7. Remove the four 8 mm machine screws (w/ washers) that attach the paper exit assembly to the top of the printer, and the one flanged 8 mm machine screw that attaches the paper exit assembly to the left side of the printer. 8. Remove the paper ex...

  • Page 331

    Phaser 4500/4510 service manual 8-51 fru disassembly replacement note: be sure that the stacker gate link is pivoted to the front of the upper exit chute when reassembling the paper exit assembly. Following assembly, verify that pressing the link actuates the stacker gate. Exit motor assembly (pl10....

  • Page 332

    8-52 phaser 4500/4510 service manual fru disassembly output tray full sensor (pl10.1.26) procedure: 1. Remove the paper exit assembly (page 8-49). 2. Remove the upper exit chute (page 8-50). 3. Unplug j290 from p290 on the output tray full sensor. 4. Release the hooks of the output tray full sensor,...

  • Page 333

    Phaser 4500/4510 service manual 8-53 fru disassembly stack full actuator (pl10.1.10) procedure: 1. Remove the paper exit assembly (page 8-49). 2. Remove the upper exit chute (page 8-50). 3. Remove the stack full actuator from the upper exit chute: a. Snap the flag end out of the retainer. B. Shift t...

  • Page 334

    8-54 phaser 4500/4510 service manual fru disassembly print engine: frame and drive motor cover (pl11.1.1) procedure: 1. Remove the laser unit shield plate (page 8-39). 2. Remove the left tray guide (page 8-33). 3. Swing the 150-sheet feeder roller assembly upward to lock it into its raised detent po...

  • Page 335

    Phaser 4500/4510 service manual 8-55 fru disassembly main motor (pl11.1.2) procedure: 1. Remove the print cartridge and paper cassettes. 2. Remove the lvps shield plate (page 8-60). 3. Unplug the main motor cable (j43) from p43 on the lvps. 4. P4510: disconnect secondary motor cable at inline connec...

  • Page 336

    8-56 phaser 4500/4510 service manual fru disassembly 6. Remove the three 6 mm machine screws that attach the main motor to the frame. Note the screws that attach the main motor to the frame are accessed through cutouts at the edge and in the center of the main motor pwba; they are not the screws tha...

  • Page 337

    Phaser 4500/4510 service manual 8-57 fru disassembly 5. Remove the six 6 mm machine screws 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 careful not to drop ...

  • Page 338

    8-58 phaser 4500/4510 service manual fru disassembly gear assembly plate (pl11.1.10) procedure: 1. Remove the fuser assembly (page 8-44). 2. Remove the gear assembly housing (page 8-56). Note when removing the gear assembly plate, one of the gears installed on the gear assembly plate is not secured ...

  • Page 339

    Phaser 4500/4510 service manual 8-59 fru disassembly 3. Remove the four 6 mm machine screws that attach the gear assembly plate to the frame. 4. Remove the gear assembly plate. 5. Release the locking tab of the bottom side of the connector of the fuser harness assembly from the frame. 6. Remove gear...

  • Page 340: Print Engine: Electrical

    8-60 phaser 4500/4510 service manual fru disassembly print engine: electrical lvps shield plate (pl12.1.3) procedure: 1. Remove the front cover (page 8-11). 2. Remove the five (p4500) or eight (p4510) 6 mm screws that attach the lvps shield plate to the frame. 3. Remove the lvps shield plate. 1. Lvp...

  • Page 341

    Phaser 4500/4510 service manual 8-61 fru disassembly exit motor pwba (pl12.1.4) procedure: 1. Remove the left cover (page 8-8). 2. Disconnect the harnesses from the connectors (p/j101, p/j102 and p/ j103) on the exit motor pwba. 3. Remove the two 6 mm screws that attach the exit motor pwba to the fr...

  • Page 342

    8-62 phaser 4500/4510 service manual fru disassembly low voltage power supply (lvps) (p4500) (pl12.1.5) procedure: 1. Remove the front cover (page 8-11). 2. Remove the lvps shield plate (page 8-60). Caution do not attempt to unplug the cables from j101 or j104 on the lvps. These are soldered connect...

  • Page 343

    Phaser 4500/4510 service manual 8-63 fru disassembly 3. Disconnect the harness connector from p101 on the exit motor pwba. 4. Unplug the inline harness connector at p/j 404. 5. Disconnect the harness connectors from the connectors (p/j40, 41, 42, 43, 44, 45, 46, 47 and 48) on the lvps. 6. Remove the...

  • Page 344

    8-64 phaser 4500/4510 service manual fru disassembly low voltage power supply (lvps) (p4510) (pl12.1.5) procedure: 1. Remove the front cover (page 8-11). 2. Remove the lvps shield plate (page 8-60). Caution do not attempt to unplug the cable from j101 on the lvps. This is a soldered connection and a...

  • Page 345

    Phaser 4500/4510 service manual 8-65 fru disassembly 3. Disconnect the harness connector from p101 on the exit motor pwba. 4. Disconnect the harness connectors from the connectors (p/j40, 41, 42, 43, 44, 45, 46, 47 and 48) on the lvps. 5. Remove the six 6 mm screws that attach the lvps to the frame....

  • Page 346

    8-66 phaser 4500/4510 service manual fru disassembly procedure: 1. Remove the front cover (page 8-11). 2. Remove the lvps shield plate (page 8-60). 3. Release the wires of the ac power harness assembly from the cable retainer hooks on the gear assembly housing. 4. Disconnect connector p/j480 from th...

  • Page 347

    Phaser 4500/4510 service manual 8-67 fru disassembly rear cover switch (pl12.1.7) procedure: 1. Remove the lvps shield plate (page 8-60). 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 a...

  • Page 348

    8-68 phaser 4500/4510 service manual fru disassembly main fan (p4500) (pl12.1.10) procedure: 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, 3...

  • Page 349

    Phaser 4500/4510 service manual 8-69 fru disassembly main fan (p4510) (pl1.1.14) procedure: 1. Remove the paper exit rear door (page 8-5). 2. Remove the rear cover (page 8-6). 3. Release the fan cable from the cable clamp on the rear cover. 4. Remove the two screws (tapping, 8 mm) that attach the ma...

  • Page 350

    8-70 phaser 4500/4510 service manual fru disassembly image processor shield assembly (pl12.1.14) procedure: 1. Remove the right cover (page 8-7). 2. Remove the twelve 6 mm screws that attach the image processor shield assembly to the frame. 3. Remove the image processor shield assembly. 1. Image pro...

  • Page 351

    Phaser 4500/4510 service manual 8-71 fru disassembly i/p shield window (pl12.1.15) procedure: 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 352

    8-72 phaser 4500/4510 service manual fru disassembly hvps shield plate (pl12.1.18) procedure: 1. Remove the right cover (page 8-7). 2. Remove the image processor shield assembly (page 8-70). 3. Remove the ten 6 mm screws that attach the hvps shield plate to the frame. 4. Remove the hvps shield plate...

  • Page 353

    Phaser 4500/4510 service manual 8-73 fru disassembly hvps/engine logic board (pl12.1.19) procedure: caution observe electrostatic precautions when handling the hvps/engine logic board and its components. 1. Remove the right cover (page 8-7). 2. Remove the hvps shield plate (page 8-72). 3. Remove the...

  • Page 354

    8-74 phaser 4500/4510 service manual fru disassembly 4. Remove the right handle bracket from the frame by sliding it toward the rear of the printer far enough to release the tabs at the ends, then lifting it out. Note it might be necessary to unplug the connectors 22, 24, and 26 and release the wire...

  • Page 355

    Phaser 4500/4510 service manual 8-75 fru disassembly image processor (i/p) board (pl 12.1.13) procedure: caution observe electrostatic precautions when handling the i/p board and its components. Do not attempt to slide the i/p board out from the rear of the printer due to the potential for damage to...

  • Page 356

    8-76 phaser 4500/4510 service manual fru disassembly 4. Unplug the cables at j110 and j130 (p4500) or j120 and 200 (p4510) near the top of the board. 5. Remove the four screws that attach the rear panel to the printer frame. 6. Remove the five 6 mm machine screws that mount the board and lift out th...

  • Page 357

    Phaser 4500/4510 service manual 8-77 fru disassembly 10. Remove the socketed nvram (p4500: u660; p4510: u520). 11. Remove the configuration card screw and unplug the configuration card. 12. Remove the two 10 mm machine screws that attach the parallel connector to the rear panel, and the 6 mm machine...

  • Page 358

    8-78 phaser 4500/4510 service manual fru disassembly options: 550-sheet paper feeder 550-sheet paper feeder removal procedure: 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 ...

  • Page 359

    Phaser 4500/4510 service manual 8-79 fru disassembly 4. Remove two latch clips at the rear of the printer and the two latch clips inside the tray insertion space that secure the printer and the optional 550-sheet paper feeder. 5. Lift and remove the printer from the optional 550-sheet paper feeder, ...

  • Page 360

    8-80 phaser 4500/4510 service manual fru disassembly procedure: 1. Remove the 8 mm tapping screw 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 t...

  • Page 361

    Phaser 4500/4510 service manual 8-81 fru disassembly left cover plate (pl20.1.3) procedure: 1. Remove the two 8 mm tapping screws 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 r...

  • Page 362

    8-82 phaser 4500/4510 service manual fru disassembly replacement notes: ■ when installing the grounding plate, be sure to install the tip of the grounding plate under the left cover plate. ■ ensure all four hooks on the left cover plate are properly engaged by pressing down on each while sliding it ...

  • Page 363

    Phaser 4500/4510 service manual 8-83 fru disassembly replacement note: ■ it is important to ensure the two holes in the bottom of the switch assembly properly engage the two bosses in the feeder housing before tightening screws. Optional feeder drive assembly (pl20.1.8) procedure: 1. Remove the opti...

  • Page 364

    8-84 phaser 4500/4510 service manual fru disassembly replacement notes: caution be careful to not pinch wires during re-assembly. ■ be sure to return the machine 6 mm screw to the location shown at “screw (a)” in the figure. ■ when installing the left cover plate, be sure to install the tip of the g...

  • Page 365

    Phaser 4500/4510 service manual 8-85 fru disassembly 550-sheet feeder pwba (pl20.1.34) procedure: 1. Remove the right cover plate (page 8-79). 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 8 mm ...

  • Page 366

    8-86 phaser 4500/4510 service manual fru disassembly 550-sheet feeder (pl20.2.1) procedure: 1. Remove the five 8 mm tapping screws 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 wit...

  • Page 367

    Phaser 4500/4510 service manual 8-87 fru disassembly 3. Disconnect the three wiring harness connectors (p/j801, p/j820, and p/ j855) exposed behind the rear cover. 4. Release release the wiring harnesses from the four harness clamps. 5. Remove the six 8 mm tapping screws that attach the optional 550...

  • Page 368

    8-88 phaser 4500/4510 service manual fru disassembly nudger one-way clutch (pl20.2.15) procedure: 1. Remove the feed roller (page 8-87). 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-...

  • Page 369

    Phaser 4500/4510 service manual 8-89 fru disassembly nudger gear (pl20.2.10) procedure: 1. Remove the optional 550-sheet paper feeder (page 8-78). Note the following steps are more easily performed by turning the 550- sheet paper feeder upside-down. 2. While lifting up the boss (or depressing the bo...

  • Page 370

    8-90 phaser 4500/4510 service manual fru disassembly 3. Remove the left holder from the nudger support. At the same time, the no paper actuator is removed. Note when handling the nudger roller or nudger gear, avoid touching the rubber surfaces of the rollers. 4. Release the hook of the nudger roller...

  • Page 371

    Phaser 4500/4510 service manual 8-91 fru disassembly feed clutch assembly (pl20.2.21) procedure: 1. Remove the optional 550-sheet paper feeder (page 8-78). 2. Remove the six screws (tapping, 8 mm) that attach the tie plate. 3. Remove the tie plate from the out chute. Note the connector in the follow...

  • Page 372

    8-92 phaser 4500/4510 service manual fru disassembly turn roller clutch (pl20.2.22) procedure: 1. Remove the optional 550-sheet paper feeder (page 8-78). 2. Remove the six screws (taping, 8 mm) that attach the tie plate. 3. Remove the tie plate from the out chute. Note the connector in the following...

  • Page 373

    Phaser 4500/4510 service manual 8-93 fru disassembly retard roller (pl20.3.2) note when handling the retard roller, avoid touching the rubber surfaces of the roller. 1. Retard roller 3. Hooks 2. Friction clutch 4. Retard spring s4500-168 2 3 4.

  • Page 374

    8-94 phaser 4500/4510 service manual fru disassembly procedure: 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 a screwdriver or similar tool. 3. Lift the retard holder up in t...

  • Page 375: Options: Duplex Unit

    Phaser 4500/4510 service manual 8-95 fru disassembly options: duplex unit duplex unit removal (pl 21.1) note be careful not to drop the duplex unit when removing it. Procedure: 1. Loosen the 2 thumb screws that secure the duplex unit to the printer. 2. Push up the right latch lever to release the du...

  • Page 376

    8-96 phaser 4500/4510 service manual fru disassembly left cover (pl21.1.25) procedure: 1. Remove the three 8 mm tapping screws that attach the left cover. 2. Remove the left cover from the duplex unit housing cover. 1. Duplex unit housing cover 2. Left cover s4510-193 1 2.

  • Page 377

    Phaser 4500/4510 service manual 8-97 fru disassembly right cover (pl21.1.41) procedure: 1. Remove the two 8 mm tapping screws that attach the right cover. 2. Remove the right cover from the duplex unit housing cover. 1. Right cover 2. Duplex unit housing cover 1 s4510-194 2.

  • Page 378

    8-98 phaser 4500/4510 service manual fru disassembly top cover (pl21.1.12) procedure: 1. Remove the right cover (page 8-97). A. Remove the 8 mm tapping screw that attaches the top cover to the duplex unit housing cover. 2. Shift the top cover in the direction of the arrow to release the four hooks, ...

  • Page 379

    Phaser 4500/4510 service manual 8-99 fru disassembly upper assembly housing (pl21.1.1) procedure: 1. Remove the four 8 mm tapping screws 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. Du...

  • Page 380

    8-100 phaser 4500/4510 service manual fru disassembly 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 7 5 8 s4510-186 5 4 6 2 1 3 p50...

  • Page 381

    Phaser 4500/4510 service manual 8-101 fru disassembly procedure: 1. Remove the left cover (page 8-96). 2. Remove the right cover (page 8-97). 3. Unplug j50, the duplex unit harness, from p50 on the duplex unit pwba. 4. Remove the 6 mm machine screw to disconnect the duplex unit ground wire. 5. Relea...

  • Page 382

    8-102 phaser 4500/4510 service manual fru disassembly duplex unit pwba (pl21.1.32) 1. Duplex unit pwba 3. Duplex unit housing cover. 2. Cable retainer slot s4510-189 p50 p53 p54 2 3 p51 p52 1 3 p/j50 51 52 53 54 2 p4500 p4510 1.

  • Page 383

    Phaser 4500/4510 service manual 8-103 fru disassembly procedure: 1. Remove the left cover (page 8-96). 2. Remove the right cover (page 8-97). 3. Remove the top cover (page 8-98). 4. Unplug the harness connectors from p50, p51, p52, p53 and p54) on the duplex unit pwba. Note the p55 connector is unus...

  • Page 384

    8-104 phaser 4500/4510 service manual fru disassembly duplex unit fan (p4500) (pl21.1.33) procedure: 1. Remove the right cover (page 8-97). 2. Remove the top cover (page 8-98). 3. Unplug the fan cable connector, j54, from p54 on the duplex unit pwba. 4. Release the fan cable from the hook on the dup...

  • Page 385

    Phaser 4500/4510 service manual 8-105 fru disassembly duplex unit fan (p4510) (pl21.1.33) procedure: 1. Remove the right cover (page 8-97). 2. Remove the top cover (page 8-98). 3. Remove the upper assembly housing (page 8-99). 4. Unplug the fan cable connector, j54, from p54 on the duplex unit pwba....

  • Page 386

    8-106 phaser 4500/4510 service manual fru disassembly 6. Remove the four screws (tapping, 22 mm) that attach the duplex unit rear cover to the duplex unit housing and remove the cover. The two screws near the bottom of the unit are accessible through holes in the duplex unit lower housing. 7. Remove...

  • Page 387

    Phaser 4500/4510 service manual 8-107 fru disassembly duplex unit roller (pl21.1.17) procedure: 1. Remove the left cover (page 8-96). 2. Remove the right cover (page 8-97). 3. Remove the upper assembly housing (page 8-99). 4. Remove the duplex unit lower housing (page 8-100). 5. Remove the two 8 mm ...

  • Page 388

    8-108 phaser 4500/4510 service manual fru disassembly 6. Remove the damper cover and damper spring from the duplex unit housing cover. Note some of the gears do not have retainers, and could fall off. Be careful not to lose any of the gears. 7. Release the hooks of three roller gears, and remove the...

  • Page 389

    Phaser 4500/4510 service manual 8-109 fru disassembly duplex unit motor (pl21.1.29) procedure: 1. Remove the left cover (page 8-96). 2. Remove the 6 mm screw that attaches the duplex unit assembly harness ground 3. Remove the three 8 mm tapping screws that attach the motor bracket to the duplex unit...

  • Page 390

    8-110 phaser 4500/4510 service manual fru disassembly 6. Remove the motor bracket together with the duplex unit motor and duplex unit switch. Note when removing the motor bracket, be careful not to lose the gears attached to the duplex unit housing cover. 7. Remove the two 6 mm screws that attach th...

  • Page 391: Options: Stacker

    Phaser 4500/4510 service manual 8-111 fru disassembly options: stacker stacker removal procedure: 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 ...

  • Page 392

    8-112 phaser 4500/4510 service manual fru disassembly stacker rear cover (pl23.1.4) procedure: 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 s4...

  • Page 393

    Phaser 4500/4510 service manual 8-113 fru disassembly stacker cover (pl23.1.1) procedure: 1. Remove the stacker from the printer (page 8-111) 2. Remove the stacker rear cover (page 8-112). 3. Remove the weight. 4. Disengage both left flapper hinges from the stacker cover. 5. Disengage the link attac...

  • Page 394

    8-114 phaser 4500/4510 service manual fru disassembly 10. 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 assem...

  • Page 395

    Phaser 4500/4510 service manual 8-115 fru disassembly 5. Lay the stacker cover on its back side. 6. Rotate the stacker tray up until it contacts the top of the stacker cover. 7. Snap the link from the right flapper to the crank arm on the stack full actuator. 8. Fit the hinge pins at both ends of th...

  • Page 396

    8-116 phaser 4500/4510 service manual fru disassembly stacker tray assembly (pl23.1.40) procedure: 1. Remove the stacker cover (page 8-113). 2. Remove the four 8 mm tapping screws that attach the stacker tray assembly to the stacker cover, and remove the stacker tray assembly from the stacker cover....

  • Page 397

    Phaser 4500/4510 service manual 8-117 fru disassembly stack full actuator (pl23.1.15) procedure: 1. Remove the stacker cover (page 8-113). 2. 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 ...

  • Page 398

    8-118 phaser 4500/4510 service manual fru disassembly replacement: 1. Lift up the stack full actuator in the direction of the arrow (1), and insert it to the hook. Move the stack full actuator in the opposite direction of the arrow (2) to install. Note when installing the stack full actuator to the ...

  • Page 399

    Phaser 4500/4510 service manual 8-119 fru disassembly stacker pwba (pl23.1.22) procedure: 1. Remove the stacker front cover (page 8-115). 2. Unplug the harness connectors at p70, p71, p72, p73, p74 and p75 on the stacker pwba. 3. Remove the two 8 mm tapping screws that attach the right stacker suppo...

  • Page 400

    8-120 phaser 4500/4510 service manual fru disassembly replacement notes: ■ be sure to install the stacker pwba into the two guide slots of the stacker. ■ be sure that the flag on the stack full actuator is in the gap in the sensor on the stacker pwba. Offset motor assembly (pl23.1.20) procedure: 1. ...

  • Page 401

    Phaser 4500/4510 service manual 8-121 fru disassembly gate solenoid assembly (pl23.1.27) procedure: 1. Remove the offset motor assembly (page 8-120). 2. Remove the two screws (with washer, 6 mm) that attach the gate solenoid assembly to the stacker. 3. Release the hook that secures the gate solenoid...

  • Page 402

    8-122 phaser 4500/4510 service manual fru disassembly stacker sensor and actuator (pl23.1.30) procedure: 1. Remove the stacker front cover (page 8-115). 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 403

    Phaser 4500/4510 service manual 8-123 fru disassembly 2. Shift the stacker actuator in the direction of the arrows to release the pivots from the hooks on both sides. Note carefully observe the orientation of the actuator spring for reference when reassembling. 3. Unplug stacker sensor harness (j730...

  • Page 404

    8-124 phaser 4500/4510 service manual fru disassembly lower stacker roller (pl23.1.16) procedure: 1. Remove the stacker cover (page 8-113). 2. Remove the screws (one tapping, 8 mm; one machine, 6 mm) that attach the left stacker support. 3. Remove the two 8 mm tapping screws that attach the stacker ...

  • Page 405

    Phaser 4500/4510 service manual 8-125 fru disassembly 4. Remove gears 45, 19/37, and two gears 19, in that order. 5. Rotate the roller bearing on the right end about 90 degrees cw to align the lock tabs with the keyway slot in the chassis, and remove the bearing from the stacker housing. Note be car...

  • Page 406

    8-126 phaser 4500/4510 service manual fru disassembly upper stacker roller (pl23.1.36) procedure: 1. Remove the stacker front cover (page 8-115). 2. Slide the cam gear off its shaft (page 8-115). 1. Offset chute 6. Gear 19/37 2. Stacker housing 7. Gear 19 3. Offset bearing 8. Left stacker support 4....

  • Page 407

    Phaser 4500/4510 service manual 8-127 fru disassembly 3. Release the hook of the offset bearing, and turn it 90 degrees ccw to align the lock tabs with the keyway slots in the chassis. Remove the offset bearing from the stacker housing. 4. Remove the offset chute assembly by raising the free end hig...

  • Page 408

    8-128 phaser 4500/4510 service manual fru disassembly stacker motor assembly (pl23.1.6) procedure: 1. Remove the stacker front cover (page 8-115). 2. Disconnect the connector of the stacker motor assembly from the stacker motor harness assembly. 3. Remove the two screws (machine, 8 mm) that attach t...

  • Page 409: 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 410: Serial Number Format

    9-2 phaser 4500/4510 service manual parts lists serial number format changes to xerox products are made to accommodate improved components as they become available. As improvements are made, part numbers may change from those appearing in this section. To get the latest part, provide the following i...

  • Page 411: Using The Parts List

    Phaser 4500/4510 service manual 9-3 parts lists using the parts list the following list explains the conventions and symbols used in the parts lists and parts diagrams. ■ no.: the callout number from the exploded part diagram. ■ name/description: the name of the part to be ordered and the number of ...

  • Page 412: Print Engine Parts

    9-4 phaser 4500/4510 service manual parts lists print engine parts parts list 1.1 covers s 11 front 2 [ref pl10.1] 1 7 8 9 9 13 14 15 3 4 6 5 s4510-218 j25016aa 10 16 (j244).

  • Page 413

    Phaser 4500/4510 service manual 9-5 parts lists fru parts list 1.1 covers no. Name/description part number 1 operation panel (control panel) p4500: 848k06471 p4510: 848e17860 2 cover open (top cover) 802e47286 3 cover rear p4500: 604k16463 p4510: 604k37141 4 cover right 802e49524 5 cover front p4500...

  • Page 414

    9-6 phaser 4500/4510 service manual parts lists parts list 2.1 150-sheet paper cassette s4510-219 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) front.

  • Page 415

    Phaser 4500/4510 service manual 9-7 parts lists 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 p4500: 809e37500 p4510: 809e74400 7 gear pb l 8 gear bt...

  • Page 416

    9-8 phaser 4500/4510 service manual parts lists 37 link sw size1-150 38 link sw size2-150 39 link sw size3-150 50 150 paper cassette (with 1-13, 15-39) a p4500: 084k15355 p4510: 050k58090 51 holder assy retard (with 2-5) 019k98186 99 roller kit (item 2, qty. 3) 604k19890 a the phaser 4510 paper cass...

  • Page 417

    Phaser 4500/4510 service manual 9-9 parts lists parts list 4.1 550-sheet paper cassette s4510-220 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 418

    9-10 phaser 4500/4510 service manual parts lists 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 p4500: 809e37500 p4510: 809e74400 7 gear pb l 8 gear b...

  • Page 419

    Phaser 4500/4510 service manual 9-11 parts lists 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 paper cassette a (with 1-13, 1...

  • Page 420

    9-12 phaser 4500/4510 service manual parts lists 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 j25019aa s4510-221 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 31-3...

  • Page 421

    Phaser 4500/4510 service manual 9-13 parts lists 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) p4500: 604k16683 p4510: 604k37313 2 fdr1 as sub 150 a4 (with 4-10, 12, 14-20, 22, 25- 28, 31-35, 40-42, 46-50) 3 chute...

  • Page 422

    9-14 phaser 4500/4510 service manual parts lists 37 harness assy tray1 (j245- j240,j241,j242,j243,j244) 38 sensor no paper (p240) 930w00113 39 cover harness r 40 chute top assy 41 shaft feed 42 clutch oneway nudger 005e16951 43 clutch oneway feed 005e16941 44 roll assy feed (part of item 97) 45 sens...

  • Page 423

    Phaser 4500/4510 service manual 9-15 parts lists 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 424

    9-16 phaser 4500/4510 service manual parts lists fru parts list 7.1 550-sheet paper feeder no. Name/description part number 1 — 2 harness assy low1 (j26-j260) 3 guide tray right 032e18795 4 sensor low paper (p260) 930w00113 5 actuator 120e21311 6 plate cst lock 7 guide tray left (with 8,9) 032k96837...

  • Page 425

    Phaser 4500/4510 service manual 9-17 parts lists 32 chute 550 lower 33 chute out 34 holder pivot right 35 plate tie 36 harness assy tray2 (j248-j246, p247) 37 cover harness r 38 sensor no paper (p246) 930w00113 39 clamp-10v0 40 stopper tray r 003e59510 41 stopper tray l 003e59501 99 feed roller kit ...

  • Page 426

    9-18 phaser 4500/4510 service manual parts lists parts list 8.1 xerographics jg25016aa s4510-223 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 31 32 front.

  • Page 427

    Phaser 4500/4510 service manual 9-19 parts lists fru parts list 8.1 xerographics no. Name/description part number 1 ros assy (laser unit) (j131,p140,p160,p170) p4500: 084k13156 p4510: 062k18170 2 harness assy ros (j13, j14, j16, j17-p131, j140, p141, j160, j170) 3 shield plate ros 4 duct front 5 fan...

  • Page 428

    9-20 phaser 4500/4510 service manual parts lists 31 vacuum duct r p4510 only: 054e27470 32 vacuum duct l p4510 only: 054e27460 fru parts list 8.1 xerographics (continued) no. Name/description part number.

  • Page 429

    Phaser 4500/4510 service manual 9-21 parts lists 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 s4510-224 27 30 23 30 23 22 22 22 22 28 2 (with 4-7, 10-13, 15-24, 26-28, 30).

  • Page 430

    9-22 phaser 4500/4510 service manual parts lists fru parts list 10.1 paper exit (1/2) no. Name/description part number 1 cover exit 500 p4500: 802e47345 p4510: 848e05030 2 500 exit assy (with 4-7, 10-13, 15-24, 26-28, 30) p4500: 084k18472 p4510: 054k33661 4 chute up exit 5 eliminator exit 6 earth pl...

  • Page 431

    Phaser 4500/4510 service manual 9-23 parts lists parts list 10.2 paper exit (2/2) 11 8 9 7 22 23 20 21 10 6 2 15 jg5702ab s4510-225.

  • Page 432

    9-24 phaser 4500/4510 service manual parts lists 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...

  • Page 433

    Phaser 4500/4510 service manual 9-25 parts lists parts list 11.1 frame and drive 3 2 1 4 j25020aa s4510-226 1 1 9 6 7 7 7 10 1 1 7 7 7 7 12 7 7 13 13 13 5 5 (j43) (j43) (j271) p4510 p4500

  • Page 434

    9-26 phaser 4500/4510 service manual parts lists pl11.1 frame and drive no. Name/description part number 1 motor cover 2 main motor (j43) p4500: 127k36824 p4510: 127k46132 3 gear assy housing (with 4) p4500: 604k16670 p4510: 604k38610 4 spring release (part of item 3) 5 clamp edge 6 clamp-5 v0 7 cla...

  • Page 435

    Phaser 4500/4510 service manual 9-27 parts lists parts list 12.1 electrical (p4500) 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 13.

  • Page 436

    9-28 phaser 4500/4510 service manual parts lists parts list 12.1 electrical (p4510) s4510-227 15 18 14 19 25 2 30 5 3 7 6 20 1 21 12 8 j25018aa 23 27 16 17 28 4 26 (j44) (j48) (j480) (j20) (j30) (j22) (j10) (j11) (j27) (j18) (j400) (p270) (pd2750a) (p271) (j1821a) (j102) (j40) (j41) (j42) (j24) (p20...

  • Page 437

    Phaser 4500/4510 service manual 9-29 parts lists 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 160k91992 5 lvps 110 v p45...

  • Page 438

    9-30 phaser 4500/4510 service manual parts lists pl12.1 electrical (continued) no. Name/description part number 23 power cord, na 125v, 15a 117e29520 power cord, euro 117e29500 power cord, australia 117e29490 power cord, swiss 117e35050 power cord, denmark 117e29460 power cord, china 117e35030 power...

  • Page 439: Options

    Phaser 4500/4510 service manual 9-31 parts lists 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 1 1 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 j25501aa 39 40 8 (with 9-17) 29 (with 30-33) (jd2083) (j83) (j80) (p855...

  • Page 440

    9-32 phaser 4500/4510 service manual parts lists 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 f...

  • Page 441

    Phaser 4500/4510 service manual 9-33 parts lists 31 actuator low paper 32 holder low paper 33 harness low paper (j81-j810) 34 pwba feeder 550 p4500: 160k86724 p4510: 960k26411 35 harness assy size fdr2 (j80-j801) 36 harness assy clsnr2 (j85-p855) 37 harness assy fdr mot (j82-p820) 38 joint feeder 11...

  • Page 442

    9-34 phaser 4500/4510 service manual parts lists parts list 20.2 550-sheet paper feeder (2/2) 1 (with 4-23,25-34) s4510-229 j25502aa 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 443

    Phaser 4500/4510 service manual 9-35 parts lists parts list 20.2 550-sheet paper feeder (2/2) no. Name/description part number 1 550 feeder option (with 4-23, 25-34) p4500: 022k66125 p4510: 022k74442 4 support nudger 5 holder left 6 actuator no paper 7 gear idler nudger 8 holder right 9 shaft nudger...

  • Page 444

    9-36 phaser 4500/4510 service manual parts lists parts list 20.3 optional 550-sheet paper cassette s4510-220 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...

  • Page 445

    Phaser 4500/4510 service manual 9-37 parts lists 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 p4500: 809e37500 p4510: 809e74400 7 gear pb l 8 g...

  • Page 446

    9-38 phaser 4500/4510 service manual parts lists 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 paper cassette a (with 1-13, 1...

  • Page 447

    Phaser 4500/4510 service manual 9-39 parts lists parts list 21.1 duplex unit (p4500) 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 front.

  • Page 448

    9-40 phaser 4500/4510 service manual parts lists parts list 21.1 duplex unit (p4510) 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 j25602aa 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 34 33 44 45 35 36 37 29 19 1 (with 2-4) 43 (jd2750) (j50) ...

  • Page 449

    Phaser 4500/4510 service manual 9-41 parts lists parts list 21.1 duplex unit no. Name/description part number 1 hsg upper assy (with2-4) 802k46802 2 hsg upper dup 3 spring pinch 809e37140 4 roll pinch 059e97500 6 hsg lower dup p4500: 802e50613 p4510: 848e06510 7 harness assy dup (j50-jd2750) 8 earth...

  • Page 450

    9-42 phaser 4500/4510 service manual parts lists 31 harness assy dup cover (j52-j520) 32 pwba duplex p4500: 160k86757 p4510: 960k28791 33 fan duplex (j54) p4500: 127e83210 p4510: 127e85210 34 sensor dup (p530) 130e87090 35 harness assy dup snr (j53-j530) 36 spring actuator 809e50961 37 actuator dup ...

  • Page 451

    Phaser 4500/4510 service manual 9-43 parts lists 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 j25801aa s4510-232 39 37 36 16 17 13 44 54 45 44 52 53 43 41 42 35 (with 13,36-39) 40 (with 41-44, ...

  • Page 452

    9-44 phaser 4500/4510 service manual parts lists parts list 23.1 stacker no. Name/description part number 1 cover oct (with 3) (stacker cover) 604k15645 2 weight 036e91551 3 eliminator assy 4 cover rear 5 screw thumb 6 motor assy oct (j71) (stacker motor assembly) 127k39351 7 gear 45 007e74830 8 gea...

  • Page 453

    Phaser 4500/4510 service manual 9-45 parts lists 37 roll pinch oct (stacker pinch roller) 38 chute offset 39 spring pinch exit 40 tray assy oct (with41-44, 53) (stacker tray assembly) 050k49267 41 tray extension 42 tray exit 43 tray base 44 spring tray 45 cover front 46 harness assy oct mot (j71-p71...

  • Page 454

    9-46 phaser 4500/4510 service manual parts lists xerox supplies and accessories repair kits, world kits and repacking kits description part number world kit installation guide quick user guides (qty. 4) software and documentation cd- rom and pocket registration cards (qty. 2) warranty booklet p4500:...

  • Page 455

    Phaser 4500/4510 service manual 9-47 parts lists base model configuration card ns p4500: 069e00440 p4510: 069e00540 550-sheet feeder a p4500: 097s03715 p4510: 097s03624 p4500: 084k24570 p4510: 084k25804 duplex unit p4500: 097s03713 p4510: 097s03625 p4500: 084k18297 p4510: 084k25791 500-sheet stacker...

  • Page 456

    9-48 phaser 4500/4510 service manual parts lists.

  • Page 457: 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 458: Introduction

    10-2 phaser 4500/4510 service manual wiring diagrams 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...

  • Page 459

    Phaser 4500/4510 service manual 10-3 wiring diagrams 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 un...

  • Page 460

    10-4 phaser 4500/4510 service manual wiring diagrams 48 u-124 connects the ac harness assembly and lvps 101 t-122 connects the lvps and exit motor pwba note j101 on the lvps is permanently wired and is not a plug. Do not attempt to unplug. 102 t-122 connects the lvps harness assembly and exit motor ...

  • Page 461

    Phaser 4500/4510 service manual 10-5 wiring diagrams 246 o-124 connects the no paper sensor and tray 2 harness assembly 247 p-125 connects the tray 2 feed clutch and tray 2 harness assembly 248 n-124 connects the tray 2 harness assembly and chute harness assembly 260 o-124 connects the tray 2 low pa...

  • Page 462

    10-6 phaser 4500/4510 service manual wiring diagrams p/j locator diagrams printer front a 104 105 106 107 108 109 110 111 b c d e 170 1821 160 140 141 810 180 210 s4510-233.

  • Page 463

    Phaser 4500/4510 service manual 10-7 wiring diagrams phaser 4500 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 464

    10-8 phaser 4500/4510 service manual wiring diagrams phaser 4510 right side f g h i j k l s4510-252 104 105 106 107 108 109 110 111 17 16 20 22 26 24 28 30 29 800 200 650 850 120 2083 10 11 27 13 14 15 18 31 131.

  • Page 465

    Phaser 4500/4510 service manual 10-9 wiring diagrams printer rear 290 150 4647 310 240 246 244 221 245 248 260 241 243 247 242 220 2750 3070 m 120 121 122 123 124 125 126 n o p q r s4510-234.

  • Page 466

    10-10 phaser 4500/4510 service manual wiring diagrams phaser 4500 left side 142 103 270 102 404 42 41 40 43 44 401 402 403 45 46 47 480 48 101 120 121 122 123 124 125 126 s t u v w x s4500-253.

  • Page 467

    Phaser 4500/4510 service manual 10-11 wiring diagrams phaser 4510 left side 141 103 270 102 101 271 42 40 46 43 44 45 41 47 4647 2750 48 480 120 121 122 123 124 125 126 s t u v w x s4510-253.

  • Page 468

    10-12 phaser 4500/4510 service manual wiring diagrams 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 connec...

  • Page 469

    Phaser 4500/4510 service manual 10-13 wiring diagrams 550-sheet feeder option note the plug/jack locations are the same for both the phaser 4500 and phaser 4510 optional feeders. 855 80 83 84 81 85 82 8483 2083 810 852 854 801 820 853 802 a 202 203 204 205 206 207 208 209 201 b c d e f g h i j k l s...

  • Page 470

    10-14 phaser 4500/4510 service manual wiring diagrams 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 an...

  • Page 471

    Phaser 4500/4510 service manual 10-15 wiring diagrams phaser 4500 duplex unit phaser 4510 duplex unit 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 a 302 303 304 305 306 307 308 309 301 b c d e f g h i j k 2750 51 52 50 54 560 53 530 56 520 s4...

  • Page 472: Stacker Plug/jack Locator

    10-16 phaser 4500/4510 service manual wiring diagrams 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 connect...

  • Page 473

    Phaser 4500/4510 service manual 10-17 wiring diagrams notations used in wiring diagrams the symbols in the interconnection wiring diagram are described below. Note that the description of general symbols is omitted. Symbol description represents an interconnection between parts using wiring harness ...

  • Page 474

    10-18 phaser 4500/4510 service manual wiring diagrams 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 plate ...

  • Page 475

    Phaser 4500/4510 service manual 10-19 wiring diagrams print engine wiring diagrams p4500: 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...

  • Page 476

    10-20 phaser 4500/4510 service manual wiring diagrams p4510: general wiring diagram j200 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 registration...

  • Page 477

    Phaser 4500/4510 service manual 10-21 wiring diagrams p4500: 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 si...

  • Page 478

    10-22 phaser 4500/4510 service manual wiring diagrams interlock bef signal indicating that the top cover is open. This signal goes high when the top cover is open. Fan alarm sub fan monitor signal. If a trouble occurs, this signal goes high. Exit /inb excitation signal for exit motor. Phase /b. Exit...

  • Page 479

    Phaser 4500/4510 service manual 10-23 wiring diagrams p4510: 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 si...

  • Page 480

    10-24 phaser 4500/4510 service manual wiring diagrams interlock bef signal indicating that the top cover is open. This signal goes high when the top cover is open. Fan alarm sub fan monitor signal. If a trouble occurs, this signal goes high. Exit /inb excitation signal for exit motor. Phase /b. Exit...

  • Page 481

    Phaser 4500/4510 service manual 10-25 wiring diagrams 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 t...

  • Page 482

    10-26 phaser 4500/4510 service manual wiring diagrams 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....

  • Page 483

    Phaser 4500/4510 service manual 10-27 wiring diagrams 150-sheet feeder, 550-sheet feeder, main fan note the diagram in the boxed area is for the p4500. See the p4510 differences diagram on the next page. P/j22 hvps/ engine logic pwba lvps harness (6/6) low paper sensor harness toner harness 1 toner ...

  • Page 484

    10-28 phaser 4500/4510 service manual wiring diagrams p4510: wiring difference 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 wh...

  • Page 485

    Phaser 4500/4510 service manual 10-29 wiring diagrams laser unit, 5 v interlock, interlock switch assembly 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); hig...

  • Page 486

    10-30 phaser 4500/4510 service manual wiring diagrams paper exit mo/det-out laser output monitor signal for providing feedback of laser output beam from laser diode (analog signal). /ldenb control signal permitting emission of laser diode. High: laser diode off. Xp data+ print image data. Data+ > da...

  • Page 487

    Phaser 4500/4510 service manual 10-31 wiring diagrams image processor board, dc-dc converter (p4500), control panel lvps lvps dc-dc converter image processor image processor hvps engine logic p/j40 p/j40 p/104 p/j404 p/j402 control panel s4510-266 3 4 2 2 3 3 1 2 3 1 1 3 2 1 4 n/c 24v n/c n/c j404-a...

  • Page 488: Optional 550-Sheet Feeder

    10-32 phaser 4500/4510 service manual wiring diagrams optional 550-sheet feeder 550-sheet feeder general wiring diagram note the printer can have up to two optional 150-sheet paper feeders installed. Paper size switch assembly 550-sheet feeder pwba hvps/ engine logic pwba feeder motor feed clutch tu...

  • Page 489

    Phaser 4500/4510 service manual 10-33 wiring diagrams 550-sheet feeder signal diagram signal line name description tray sns signal detecting an optional 150-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 ...

  • Page 490: Duplex Unit

    10-34 phaser 4500/4510 service manual wiring diagrams duplex unit duplex unit general wiring diagram /a and /b excitation signal for feeder motor. Phases /a and /b. Clutch-feed on control signal for feed clutch. Low: on / high: off clutch-turn on control signal for turn roller clutch. Low: on / high...

  • Page 491

    Phaser 4500/4510 service manual 10-35 wiring diagrams 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 th...

  • Page 492: Stacker

    10-36 phaser 4500/4510 service manual wiring diagrams 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 s4510-245.

  • Page 493

    Phaser 4500/4510 service manual 10-37 wiring diagrams stacker signal diagram signal line name description a and b excitation signal for stacker motor assembly and offset motor assembly. Phases a and b. /a and /b excitation signal for stacker motor assembly and offset motor assembly. Phases /a and /b...

  • Page 494

    10-38 phaser 4500/4510 service manual wiring diagrams.

  • Page 495: Contents...

    A appendix appendix contents... ■ phaser 4500 menu map ■ phaser 4510 menu map ■ service code table.

  • Page 496: Phaser 4500 Menu Map

    A-2 phaser 4500/4510 service manual appendix phaser 4500 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-...

  • Page 497

    Phaser 4500/4510 service manual a-3 appendix 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: ne...

  • Page 498: Phaser 4510 Menu Map

    A-4 phaser 4500/4510 service manual appendix phaser 4510 menu map control panel buttons: main menu: up arrow ok help back cancel down arrow walk-up features information paper tray setup printer setup walk-up features information paper tray setup printer setup ready to print press ? For help ready to...

  • Page 499

    Phaser 4500/4510 service manual a-5 appendix troubleshooting paper jams print quality problems network problems* service tools page 2 of 2 requires: networked printer duplex unit hard drive flash memory stacker * ** ‡ ‡‡ § printer setup configuration page connection setup paper handling setup postsc...

  • Page 500: Service Code Table

    A-6 phaser 4500/4510 service manual appendix service code table service codes that appear in the phaser 4510’s service usage profile at line 237 and line 262, on the printer status page, and are output by the diagnostic fault history utility are defined in the following table. Refer to the error mes...

  • Page 501

    Phaser 4500/4510 service manual a-7 appendix 27 out of paper: load tray 4 28 error: load tray 1 - wrong size 29 error: load tray 2 - wrong size 30 error: load tray 3 - wrong size 31 error: load tray 4 - wrong size 32 paper not available: load tray 1 33 paper not available: load tray 2 34 paper not a...

  • Page 502

    A-8 phaser 4500/4510 service manual appendix 62 error: toner cartridge - bad crum id 63 error: toner cartridge - bad crum id (pp) 64 metered toner disabled phaser 4510 service codes code error description.

  • Page 503: Index

    Phaser 4500/4510 service manual i – 1 index numerics 24 v interlock , 2-29 , 4-24 5 v interlock , 2-29 , 4-25 550-sheet feeder pwba , 2-40 a ac power supply troubleshooting , 4-7 actuator low paper , 2-15 , 2-40 , 3-64 , 3-66 , 4-21 , 4-43 no paper , 2-15 , 2-40 , 3-63 , 3-65 , 4-19 , 4-41 , 8-18 , ...

  • Page 504

    I – 2 phaser 4500/4510 service manual e electrical specifications , 1-13 theory , 2-29 electrical noise, troubleshooting , 4-37 engine error history , 3-5 engine logic board , 2-29 engine nvram adjustments , 3-10 environmental specifications , 1-13 error code e2-01 – e2-04 , 3-34 e2-11 – e2-14 , 3-3...

  • Page 505

    Phaser 4500/4510 service manual i – 3 side-to-side registration , 5-9 skew , 5-13 skips/smears , 5-11 spots , 5-12 test print , 5-5 inoperable control panel buttons , 4-3 interlock 24 v , 2-29 , 4-24 5 v , 2-29 , 4-25 diagnostic tests , 3-11 duplex unit switch , 2-34 , 4-53 interlock switch assembly...

  • Page 506

    I – 4 phaser 4500/4510 service manual no paper actuator , 2-40 no paper sensor , 4-41 nudger roller , 2-40 paper feeder assembly , 2-40 paper size switch , 2-40 , 4-45 theory , 2-39 to 2-41 turn roller , 2-40 turn roller clutch , 4-48 optional hard drive power source , 2-29 output tray full sensor ,...

  • Page 507

    Phaser 4500/4510 service manual i – 5 s scanner assembly , 2-19 sensor diagnostic tests , 3-11 duplex unit , 2-34 , 4-51 exit , 2-21 low paper , 2-15 , 2-40 , 4-21 low paper, optional feeder , 4-43 no paper , 2-15 , 2-40 , 4-19 no paper, optional feeder , 4-41 offset (in stacker) , 4-61 output tray ...

  • Page 508

    I – 6 phaser 4500/4510 service manual electrical noise , 4-37 exit motor , 4-28 exit motor pwba , 4-27 feed clutch, optional feeder , 4-46 feed clutches , 4-30 fuser , 4-15 gate assembly solenoid , 4-57 general notes , 3-4 horizontal deletions , 5-22 horizontal streaks , 5-27 hvps/engine logic , 4-3...

  • Page 510

    701p45760