Xerox Phaser 4500 Phaser 4510 Service Manual and Parts List Manual


Accurate, clear and concise text, combined with detailed illustrations, lists of error code, instruction and diagrams, guide you through procedure of repair, remediate, maintenance and adjustments your copier, printer or scanner.
Present manual Xerox Phaser 4500 Phaser 4510 contain clear instructions and procedures on how to fix the problems occurring in your equipment.
The information contained in this repair manual is necessary for the repair, but also prevention, resulting in a longer life of your equipment.
Format of the manual: PDF, makes it easy to navigate, instant download and print. English language.
To see what contain, please read table of contents:

SERVICE TERMS
PRODUCT TERMS
POWER SAFETY PRECAUTIONS
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
SERVICE SAFETY SUMMARY
REGULATORY SPECIFICATIONS
1. GENERAL INFORMATION
PRINTER INTRODUCTION AND OVERVIEW
TECHNICAL SUPPORT INFORMATION
PRINTER CONFIGURATIONS
PARTS OF THE PRINTER
CONTROL PANEL
IMAGE PROCESSOR BOARD (PHASER 4500)
IMAGE PROCESSOR BOARD (PHASER 4510)
CONSUMABLES AND ROUTINE MAINTENANCE ITEMS
SUPPLY LIFE COUNTERS
PRINTER SPECIFICATIONS
PHYSICAL DIMENSIONS AND CLEARANCES
FUNCTIONAL SPECIFICATIONS
ELECTRICAL SPECIFICATIONS
ENVIRONMENTAL SPECIFICATIONS
MEDIA AND TRAY SPECIFICATIONS
MEMORY REQUIREMENTS
2. THEORY OF OPERATION
OVERVIEW OF THE PHASER 4500/4510 LASER PRINTER
SUMMARY OF THE PRINTING PROCESS
PAPER PATH OF THE PRINTER
LAYOUT OF PAPER TRANSPORT PATH
SENSORS
MAJOR ASSEMBLIES AND FUNCTIONS
PAPER TRAY
PAPER FEEDER
CONTROL OF PAPER SIZE
XEROGRAPHICS
FUSER
FUSER CONTROL
PAPER EXIT ASSEMBLY
DRIVE
ELECTRICAL
PRINTER OPTIONS
DUPLEX UNIT
STACKER
OPTIONAL 550-SHEET FEEDER
3. ERROR MESSAGES AND CODES
INTRODUCTION
SERVICING INSTRUCTIONS
USING THE TROUBLESHOOTING PROCEDURES
GENERAL NOTES ON TROUBLESHOOTING
ACCESSING FAULT HISTORIES
ENTRY LEVEL FAULT ISOLATION PROCEDURE
SERVICE DIAGNOSTICS
SERVICE DIAGNOSTICS MENU MAP
SERVICE DIAGNOSTIC CONTROL PANEL BUTTON DESCRIPTIONS
USING SERVICE DIAGNOSTICS
SYSTEM START-UP AND POST
POWER ON SELF TEST (POST)
POST FAULTS
LED BLINK PATTERNS
POST DIAGNOSTIC TEST DESCRIPTIONS
OPERATING SYSTEM AND APPLICATION PROBLEMS
MACINTOSH PRINTING PROBLEMS
WINDOWS PRINTING PROBLEMS
NETWORK PROBLEMS
TROUBLESHOOTING PROCEDURES FOR ERROR MESSAGES AND CODES
MAIN MOTOR FAILURE
LASER UNIT FAILURE
FUSER FAILURE
FAN FAILURE
ENGINE LOGIC BOARD NVRAM FAILURE
JAM AT TRAY N
JAM AT TRAY N
JAM AT TOP; OPEN TOP COVER TO CLEAR
JAM AT EXIT; OPEN REAR/TOP COVER TO CLEAR
JAM AT REAR; OPEN REAR COVER TO CLEAR
JAM AT STACKER; OPEN REAR STACKER COVER TO CLEAR
JAM AT REAR; OPEN DUPLEX AND REAR COVER TO CLEAR
JAM AT DUPLEX; OPEN DUPLEX TO CLEAR
DUPLEX UNIT ERROR
STACKER ERROR
TRAY 3 FAILURE/TRAY 3 OR 4 FAILURE
PAPER SIZE JAM
CLOSE TOP COVER/CLOSE REAR COVER
CLOSE DUPLEX UNIT COVER
CLOSE STACKER COVER
INSTALL OR RESEAT PRINT CARTRIDGE
REPLACE PRINT CARTRIDGE
NO PAPER IN TRAY 1/NO PAPER IN TRAY 2
TRAY 2 PAPER IS LOW
NO PAPER IN TRAY 3/NO PAPER IN TRAY 4
TRAY 3 PAPER IS LOW/TRAY 4 PAPER IS LOW
INSERT TRAY 1/INSERT TRAY 2
INSERT TRAY 3/INSERT TRAY 4
STACKER IS FULL, UNLOAD PAPER
STANDARD OUTPUT TRAY IS FULL, UNLOAD PAPER
REPLACE MAINTENANCE KIT
INOPERABLE PRINTER
NO RECOGNITION OF DUPLEX UNIT
4. GENERAL TROUBLESHOOTING
INTRODUCTION
CONTROL PANEL TROUBLESHOOTING
LCD/LED DISPLAY ERROR/INOPERABLE BUTTONS
DC POWER SUPPLY TROUBLESHOOTING
LVPS (LOW VOLTAGE POWER SUPPLY)
DC-DC CONVERTER (P4500 ONLY)
AC POWER SUPPLY TROUBLESHOOTING
NO AC POWER
PRINT ENGINE TROUBLESHOOTING
MAIN MOTOR
LASER UNIT ASSEMBLY
FUSER ASSEMBLY
REGISTRATION SENSOR
NO PAPER SENSOR
LOW PAPER SENSOR
TONER SENSOR
OUTPUT TRAY FULL SENSOR
24 V INTERLOCK
5 V INTERLOCK, INTERLOCK SWITCH ASSEMBLY
REAR COVER SWITCH
INTERLOCK SWITCH ASSEMBLY (P4500 ONLY)
EXIT MOTOR PWBA
EXIT MOTOR ASSEMBLY
REGISTRATION CLUTCH
FEED CLUTCHES
LEFT TRAY GUIDE
HVPS/ENGINE LOGIC BOARD
IMAGE PROCESSOR ISOLATION
IMAGE PROCESSOR BOARD
RAM DIMM FAULT ISOLATION
ELECTRICAL NOISE
OPTIONAL 550-SHEET FEEDER PWBA (TRAY 3)
OPTIONAL 550-SHEET FEEDER PWBA (TRAY 4)
OPTIONAL 550-SHEET FEEDER NO PAPER SENSOR
OPTIONAL 550-SHEET FEEDER LOW PAPER SENSOR
OPTIONAL FEEDER PAPER SIZE SWITCH ASSEMBLY
OPTIONAL 550-SHEET FEEDER FEED CLUTCH ASSEMBLY
OPTIONAL 550-SHEET FEEDER TURN ROLLER CLUTCH
DUPLEX UNIT PWBA
DUPLEX UNIT MOTOR
DUPLEX UNIT SENSOR
DUPLEX UNIT SWITCH
STACKER PWBA
STACKER MOTOR ASSEMBLY
OFFSET MOTOR ASSEMBLY
GATE SOLENOID ASSEMBLY
STACKER REAR COVER SWITCH
STACKER SENSOR
STACKER FULL SENSOR (ON STACKER PWBA)
OFFSET SENSOR (ON STACKER PWBA)
5. PRINT-QUALITY TROUBLESHOOTING
PRINT-QUALITY PROBLEMS OVERVIEW
ANALYZING TEST PRINTS
DELETIONS (LINE, BAND, SPOTS)
FUSING
RESOLUTION
REGISTRATION (SIDE-TO-SIDE)
REGISTRATION (LEAD EDGE-TO-TRAIL EDGE)
SKIPS/SMEARS
SPOTS
SKEW
OTHER PRINT DEFECTS
PRINT-QUALITY TROUBLESHOOTING
LIGHT (UNDERTONED) PRINT
BLANK PRINT (NO PRINT)
BLACK PRINTS
VERTICAL DELETIONS
HORIZONTAL DELETIONS
VERTICAL STREAKS
HORIZONTAL STREAKS
SPOTS
UNFUSED IMAGE
DAMAGED PRINT
RESOLUTION
SPOT DELETIONS
REPEATING DEFECTS
RESIDUAL IMAGE
BACKGROUND
UNEVEN DENSITY
SKEWED IMAGE
REGISTRATION
SKIPS AND SMEARS
6. ADJUSTMENTS AND CALIBRATIONS
SERVICE TEST PRINTS
TEST PRINTS
ENGINE TEST PRINT
ADJUSTMENTS
ADJUSTING LASER POWER (IMAGE DENSITY)
CHECKING REGISTRATION (MARGINS)
ADJUSTING SIMPLEX REGISTRATION (MARGINS)
ADJUSTING DUPLEX REGISTRATION (MARGINS)
ADJUSTING FUSER TEMPERATURE
RESETTING FUSER LIFE
RESETTING PRINTER VALUES TO THE FACTORY DEFAULT VALUES
RESETTING CONNECTION SETUP VALUES
RESETTING PAPER HANDLING SETUP VALUES
RESETTING POSTSCRIPT SETUP VALUES
RESETTING PCL SETUP VALUES
RESETTING GENERAL SETUP VALUES
RESETTING CONTROL PANEL SETUP VALUES
RESETTING PRINTER CONTROLS SETUP VALUES
RESETTING FILE SECURITY SETUP VALUES
RESETTING ALL PRINTER DEFAULT SETTINGS (POSTSCRIPT NVRAM)
7. CLEANING AND MAINTENANCE
SERVICE PREVENTIVE MAINTENANCE PROCEDURE
RECOMMENDED TOOLS
CLEANING
8. FRU DISASSEMBLY
OVERVIEW
STANDARD ORIENTATION OF THE PRINTER
GENERAL NOTES ON DISASSEMBLY
PREPARATION
NOTATIONS IN THE DISASSEMBLY TEXT
PRINT ENGINE: COVERS
PAPER EXIT COVER
PAPER EXIT REAR DOOR
REAR COVER
RIGHT COVER
LEFT COVER
TOP COVER ASSEMBLY, CONTROL PANEL
FRONT COVER
INTERLOCK SWITCH ASSEMBLY (P4500 ONLY)
PRINT ENGINE: 150- OR 550-SHEET PAPER CASSETTE
RETARD ROLLER AND HOLDER
PRINT ENGINE: 150-SHEET FEEDER
150-SHEET FEEDER ASSEMBLY
NUDGER ROLLER, FEED ROLLER
NUDGER ONE-WAY CLUTCH
NUDGER GEAR
FEED CLUTCH, REGISTRATION CLUTCH
REGISTRATION SENSOR
NO PAPER SENSOR
TONER SENSOR ASSEMBLY
PRINT ENGINE: 550-SHEET PAPER FEEDER
550-SHEET FEEDER ASSEMBLY
NUDGER ROLLER, FEED ROLLER
NUDGER ONE-WAY CLUTCH
NUDGER GEAR
FEED CLUTCH
NO PAPER SENSOR
RIGHT TRAY GUIDE
LEFT TRAY GUIDE
LOW PAPER SENSOR/ACTUATOR
PRINT ENGINE: XEROGRAPHICS
VACUUM DUCT (P4510)
FRONT DUCT, SUB FAN
LASER UNIT ASSEMBLY
LASER UNIT SHIELD PLATE
PRINT CARTRIDGE LEFT GUIDE
FUSER HARNESS ASSEMBLY
LINK LEVER, GEAR 3 LINK
FUSER ASSEMBLY
TRANSFER ROLLER ASSEMBLY
TRANSFER CHUTE
PRINT CARTRIDGE RIGHT GUIDE ASSEMBLY
DUPLEX UNIT OPENING COVER
PRINT ENGINE: PAPER EXIT
PAPER EXIT ASSEMBLY
UPPER EXIT CHUTE, LOWER EXIT CHUTE
EXIT MOTOR ASSEMBLY
OUTPUT TRAY FULL SENSOR
STACK FULL ACTUATOR
PRINT ENGINE: FRAME AND DRIVE
MOTOR COVER
MAIN MOTOR
GEAR ASSEMBLY HOUSING
GEAR ASSEMBLY PLATE
PRINT ENGINE: ELECTRICAL
LVPS SHIELD PLATE
EXIT MOTOR PWBA
LOW VOLTAGE POWER SUPPLY (LVPS) (P4500)
DC-DC CONVERTER (P4500)
LOW VOLTAGE POWER SUPPLY (LVPS) (P4510)
POWER SWITCH, AC POWER HARNESS ASSEMBLY
REAR COVER SWITCH
MAIN FAN (P4500)
MAIN FAN (P4510)
IMAGE PROCESSOR SHIELD ASSEMBLY
I/P SHIELD WINDOW
HVPS SHIELD PLATE
HVPS/ENGINE LOGIC BOARD
IMAGE PROCESSOR (I/P) BOARD
OPTIONS: 550-SHEET PAPER FEEDER
550-SHEET PAPER FEEDER REMOVAL
RIGHT COVER PLATE
LEFT COVER PLATE
OPTION PAPER SIZE SWITCH ASSEMBLY
OPTIONAL FEEDER DRIVE ASSEMBLY
550-SHEET FEEDER PWBA
550-SHEET FEEDER
NUDGER ROLLER, FEED ROLLER
NUDGER ONE-WAY CLUTCH
NUDGER GEAR
FEED CLUTCH ASSEMBLY
TURN ROLLER CLUTCH
RETARD ROLLER
OPTIONS: DUPLEX UNIT
DUPLEX UNIT REMOVAL
LEFT COVER
RIGHT COVER
TOP COVER
UPPER ASSEMBLY HOUSING
DUPLEX UNIT LOWER HOUSING
DUPLEX UNIT PWBA
DUPLEX UNIT FAN (P4500)
DUPLEX UNIT FAN (P4510)
DUPLEX UNIT SENSOR
DUPLEX UNIT ROLLER
DUPLEX UNIT MOTOR
DUPLEX UNIT SWITCH
OPTIONS: STACKER
STACKER REMOVAL
STACKER REAR COVER
STACKER COVER
STACKER FRONT COVER
STACKER TRAY ASSEMBLY
STACK FULL ACTUATOR
STACKER PWBA
OFFSET MOTOR ASSEMBLY
GATE SOLENOID ASSEMBLY
STACKER SENSOR AND ACTUATOR
STACKER REAR COVER INTERLOCK SWITCH
LOWER STACKER ROLLER
UPPER STACKER ROLLER
STACKER MOTOR ASSEMBLY
9. PARTS LISTS
SERIAL NUMBER FORMAT
USING THE PARTS LIST
PRINT ENGINE PARTS
PARTS LIST 1.1 COVERS
PARTS LIST 2.1 150-SHEET PAPER CASSETTE
PARTS LIST 4.1 550-SHEET PAPER CASSETTE
PARTS LIST 5.1 150-SHEET PAPER FEEDER
PARTS LIST 7.1 550-SHEET PAPER FEEDER
PARTS LIST 8.1 XEROGRAPHICS
PARTS LIST 10.1 PAPER EXIT (1/2)
PARTS LIST 10.2 PAPER EXIT (2/2)
PARTS LIST 11.1 FRAME AND DRIVE
PARTS LIST 12.1 ELECTRICAL (P4500)
PARTS LIST 12.1 ELECTRICAL (P4510)
OPTIONS
PARTS LIST 20.1 550-SHEET PAPER FEEDER (1/2)
PARTS LIST 20.2 550-SHEET PAPER FEEDER (2/2)
PARTS LIST 20.3 OPTIONAL 550-SHEET PAPER CASSETTE
PARTS LIST 21.1 DUPLEX UNIT (P4500)
PARTS LIST 21.1 DUPLEX UNIT (P4510)
PARTS LIST 23.1 STACKER
XEROX SUPPLIES AND ACCESSORIES
10. WIRING DIAGRAMS
INTRODUCTION
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
P4500: GENERAL WIRING DIAGRAM
P4510: GENERAL WIRING DIAGRAM
P4500: 24 V INTERLOCK, REAR COVER SWITCH, MAIN MOTOR, SUB FAN, EXIT MOTOR ASSEMBLY
P4510: 24 V INTERLOCK, REAR COVER SWITCH, MAIN MOTOR, SUB FAN, EXIT MOTOR ASSEMBLY
FUSER ASSEMBLY, POWER SWITCH
PRINT CARTRIDGE, TRANSFER ROLLER ASSEMBLY
150-SHEET FEEDER, 550-SHEET FEEDER, MAIN FAN
LASER UNIT, 5 V INTERLOCK, INTERLOCK SWITCH ASSEMBLY
PAPER EXIT
IMAGE PROCESSOR BOARD, DC-DC CONVERTER (P4500), CONTROL PANEL
OPTIONAL 550-SHEET FEEDER
550-SHEET FEEDER GENERAL WIRING DIAGRAM
550-SHEET FEEDER SIGNAL DIAGRAM
DUPLEX UNIT
DUPLEX UNIT GENERAL WIRING DIAGRAM
DUPLEX UNIT SIGNAL DIAGRAM
STACKER
STACKER GENERAL WIRING DIAGRAM
STACKER SIGNAL DIAGRAM
A APPENDIX
PHASER 4500 MENU MAP
PHASER 4510 MENU MAP
SERVICE CODE TABLE

Number of pages: 506.