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  • Brand:   Xerox
  • Models included:
    • Xerox Phaser 4400

File Information:

  • Type:   Factory Service Manual (FSM)
  • Language:   English
  • Number of pages:   503
  • File size:  ∼ 15.52  MB
  • File Format:   PDF only
  • SME Watermarks:   None
  • Password lock:   No
  • Edit/copy/modify:   Yes
  • SKU:   BMXX-1019

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Service
Manual
Phaser
Laser Printer 4400
Phaser 4400 Laser Printer Service Manual˙xiii
Contents
General Information˙1-1
Section Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙1-1
Phaser 4400 Laser Printer Overview˙ . . . . . . . . . . . . . . . . . . . . ˙1-2
Parts of the Printer˙ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙1-4
Machine Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙1-12
Menu Map˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙1-13
Printer Specifications˙ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙1-14
Error Messages and Codes˙2-1
Section Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙2-1
Introduction˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙2-1
Service Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙2-7
Printer Error Messages˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙2-11
Image Processor POST Error Codes . . . . . . . . . . . . . . . . . . . ˙2-58
Troubleshooting˙3-1
Section Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙3-1
Introduction˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙3-1
Measurements˙ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙3-1
Troubleshooting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . ˙3-2
Image-Quality Checkout Procedures˙ . . . . . . . . . . . . . . . . . . . ˙3-41
Image-Quality Troubleshooting Procedures . . . . . . . . . . . . . . ˙3-53
Tests Prints, Adjustments, and NVRAM Reset˙4-1
Section Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙4-1
Service Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙4-1
Adjustments˙ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙4-5
Resetting NVRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙4-7
xiv˙Phaser 4400 Laser Printer Service Manual
Cleaning and Maintenance˙5-1
Service Preventive Maintenance Procedure˙. . . . . . . . . . . . . . . 5-1
FRU Disassembly˙6-1
List of Procedures˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Covers and Trays˙ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Tray 1˙ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Paper Feed (Tray 1)˙ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Paper Feed (MPT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
Paper Transportation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
Exit Assembly and Fuser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
Xerographics˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79
Main Drive˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87
Stacker˙ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-101
Optional Paper Feeder˙ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-120
Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-141
Envelope Feeder˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-157
Parts Lists˙7-1
Parts List Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Using the Parts Lists˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Theory of Operation˙8-1
Section Contents˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Print Process Overview˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Print Process Description˙ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
The Paper Path˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Drive Flow˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Engine Logic Board and Front Panel Functions . . . . . . . . . . . 8-22
Image Processor Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Power Supplies˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Interlocks˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Phaser 4400 Laser Printer Service Manual ˙xv
Laser Control˙ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙8-25
Fuser Control˙ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙8-26
Erase Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙8-28
Fan Control˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙8-28
Duplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙8-29
Envelope Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙8-33
Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙8-37
Option Feeder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙8-42
Wiring Data˙9-1
Section Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙9-1
Introduction˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙9-2
Base Engine Wiring Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙9-4
550-Sheet Feeder˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙9-22
Duplex Unit˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙9-26
Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙9-31
Envelope Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ˙9-37
Phaser 4400 Laser Printer Service Manual˙3-1
Troubleshooting
Introduction
This section covers two types of troubleshooting procedures:
Troubleshooting procedures for problems not directly associated with error
messages or codes
Troubleshooting Procedures for Image-quality (IQ) problems
Troubleshooting procedures will normally isolate a problem to a specific component
or subassembly, in some cases including the wire harnesses.
In the Yes/No steps of the procedures, a Yes/No response will either lead you to the
next step or will indicate a corrective action. When you complete the indicated
corrective action, restart the System Check to verify that the problem has been
corrected.
Measurements
Power and signal grounds are connected to frame ground. You can perform all circuit
troubleshooting using the metal frame (chassis) as the grounding point. If you need
more information to locate connectors or test points, refer to Wiring Data on page˙9-1.
Unless otherwise specified, the following voltage tolerances are used within this
section:
Section Contents
Introduction˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Measurements˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Troubleshooting Procedures˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Index of Troubleshooting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Image-Quality Checkout Procedures˙ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41
Index of Image-Quality Checkout Procedures . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Image-Quality Troubleshooting Procedures˙ . . . . . . . . . . . . . . . . . . . . . . . .3-53
Index of Image-Quality Troubleshooting Procedures˙. . . . . . . . . . . . . . . . . . . 3-53
Voltage Measurements
Stated Measured Stated Measured
+3.3 VDC +3.0 to 3.6 VDC +24.0 VDC +21.6 to +26.4 VDC
+5.0 VDC +4.8 to +5.2 VDC 0.0 VDC Less than +0.5 VDC
3-2˙Phaser 4400 Laser Printer Service Manual
Troubleshooting Procedures
Verifying AC Power
There is a possible problem with AC power.
Warning:˙Improper connection of the grounding conductor can
result in the risk of electrical shock.
The following must be observed:
Never use a ground adapter plug to connect the machine to a power source.
Never attempt any maintenance function that is not specifically called out in
the service procedures.
Never remove any covers that are fastened with screws, unless so instructed
in the service procedures.
Caution:˙If any of the voltage measurements are not as specified in
the following steps, the cause must be corrected. Caution
the customer NOT to connect the machine to the wall
outlet. Advise the customer that a licensed electrician must
correct the wiring. Do not attempt to correct the wiring
yourself. If you later find the condition has not been
corrected, inform your manager in writing of the improper
wiring.
Index of Troubleshooting Procedures
Verifying AC Power˙ . . . . . . . . . . . . . . . . .3-2 Print Cartridge Sensor Assembly˙ . . . . . 3-24
DC Power (LVPS). . . . . . . . . . . . . . . . . . .3-4 Tray Motor Assembly Checkout˙ . . . . . . 3-26
DC Power Loading˙. . . . . . . . . . . . . . . . . .3-6 Registration Clutch˙ . . . . . . . . . . . . . . . . 3-27
Toner Sensor Failure . . . . . . . . . . . . . . . .3-8 Turn Roller Clutch Assembly. . . . . . . . . 3-28
Inoperative Printer . . . . . . . . . . . . . . . . . .3-9 Tray 1 Feed Clutch . . . . . . . . . . . . . . . . 3-29
Malfunctioning Front Panel. . . . . . . . . . .3-11 MPT Pick Up Solenoid˙ . . . . . . . . . . . . . 3-30
Inoperative Front Panel . . . . . . . . . . . . .3-13 Image Processor Isolation. . . . . . . . . . . 3-31
Erratic Printer Operation. . . . . . . . . . . . .3-13 High-Voltage Power Supply (HVPS)
Assembly. . . . . . . . . . . . . . . . . . . . . . . . 3-31
Power Supply˙. . . . . . . . . . . . . . . . . . . . .3-14 Electrical Noise . . . . . . . . . . . . . . . . . . . 3-33
Main Motor Assembly. . . . . . . . . . . . . . .3-15 Exit Sensor˙ . . . . . . . . . . . . . . . . . . . . . . 3-34
Laser Assembly . . . . . . . . . . . . . . . . . . .3-17 Exit Motor˙ . . . . . . . . . . . . . . . . . . . . . . . 3-35
Fuser Assembly . . . . . . . . . . . . . . . . . . .3-18 550-Sheet Feeder Feed Clutch. . . . . . . 3-36
Registration Sensor . . . . . . . . . . . . . . . .3-20 Stacker Full Sensor˙. . . . . . . . . . . . . . . . 3-37
MPT No Paper Sensor˙. . . . . . . . . . . . . .3-21 Stacker Offset Operation Not Performed3-38
Tray 1 No Paper Sensor. . . . . . . . . . . . .3-22 Envelope Feed Clutch. . . . . . . . . . . . . . 3-38
Output Tray Full Sensor˙. . . . . . . . . . . . .3-22 Envelope No Paper Sensor. . . . . . . . . . 3-39
Stack Height Sensor Checkout. . . . . . . .3-23
Phaser 4400 Laser Printer Service Manual˙6-1
FRU Disassembly
This section contains step-by-step removal procedures for a specific component or
assembly. Numbers in the illustrations refer to steps in the procedure. For example: if
step 3 in a procedure instructs you to remove a screw, the screw in the illustration is
labeled 3. Unless a specific Replacement procedure is included, reassembly is the
reverse of disassembly.
Illustrations are used to assist you with the procedures. You should refer to the
specific Parts List illustration (listed under the repair title) for locating most
components within a procedure.
Caution:˙Always reinstall the correct type and size screws. Using the
wrong screw can damage tapped holes.
Caution:˙Do not use excessive force to either remove or install a part.
Locations, such as left, right, front, or rear, given in the repairs assume you are facing
the printer front panel.
The Print Cartridge should be removed and stored in a dark, safe place when
performing any procedure where screws or components may damage the cartridge
and where exposure to light could degrade performance.
List of Procedures
Covers and Trays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
RRP 1.1 Left Interface Cover˙ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
RRP 1.2 Left Cover˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
RRP 1.3 Option Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
RRP 1.4 Top Cover Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
RRP 1.5 Right Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
RRP 1.6 Front Cover Assembly˙ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
RRP 1.7 Left Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
RRP 1.8 Rear Cover Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
RRP 1.9 Front Panel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
RRP 1.10 Interlock Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
RRP 1.11 Left Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
RRP 1.12 Plate Handle˙. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
Tray 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
RRP 2.1 Retard Roller Assembly˙ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
RRP 2.2 Friction Clutch Assembly˙ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
RRP 2.3 Retard Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
RRP 2.4 Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24
RRP 2.5 Paper Feeder Connector and Socket Guide. . . . . . . . . . . . . . . . . . .6-26


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