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5/2011

8-1

Phaser 4600/4620 Printer Service Manual

Principles of Operation

Revision - Xerox Internal Use Only

8 Principles of Operation

Phaser 4600/4620 Operational Overview .......................................................................

8-3

Media Handling ...............................................................................................................

8-4

Sensors ...........................................................................................................................

8-5

Xerographics ...................................................................................................................

8-7

Major IOT Assemblies.....................................................................................................

8-11

Phaser 4600/4620 Options .............................................................................................

8-20

520-Sheet Feeder ...........................................................................................................

8-20

2000-Sheet Feeder .........................................................................................................

8-23

Mailbox............................................................................................................................

8-24

Finisher ...........................................................................................................................

8-27

Summary of Contents for Phaser 4620

Page 1: ...Phaser 4600 4620 Laser Printer Phaser 4600 4620 Service Manual Xerox Internal Use Only ...

Page 2: ... not for resale These materials may not be distributed copied or otherwise reproduced without prior written consent from Xerox Corporation 2010 Xerox Corporation All rights reserved XEROX and XEROX and design Phaser PhaserSMART DocuCard DocuSP FreeFlow CentreWare infoSMART Made For Each Other PagePack ColorCube ProfitAccelertor and Walk Up are trademarks of Xerox Corporation in the United States a...

Page 3: ...o Use This Manual iii Service Safety Summary iv Symbols Used On The Product v Voltage Measurement and Specifications vi Health and Safety Incident reporting vi Regulatory Specifications vii Translation of Warnings viii Phaser 4600 4620 Overview x Printer Options xi Control Panel Layout xiii Routine Maintenance Items xiv Consumables xiv ...

Page 4: ...5 2011 ii Phaser 4600 4620 Printer Service Manual Revision Xerox Internal Use Only Introduction ...

Page 5: ... is spared or that must be removed to access a spared part is illustrated Section 6 General Procedures Information This section contains all other procedures product specifications and general information Section 7 Wiring Data This section contains the wiring diagrams Section 8 Accessories This section contains details of any accessories that the machine may have Publication Comments Sheet A Publi...

Page 6: ...perational Safety The printer and supplies were designed and tested to meet strict safety requirements These include safety agency examination approval and compliance with established environmental standards Pay attention to these safety guidelines to ensure the continued safe operation of the printer Use the supplies specifically designed for your system The use of unsuitable materials may cause ...

Page 7: ...Earth symbol Figure 2 Protective Ground Earth Symbol This symbol indicates hot surface Use caution to avoid personal injury Figure 3 Hot Surface Symbol The surface is hot while the printer is running After turning off the power wait 30 minutes Figure 4 Wait 30 Minutes Symbol Avoid pinching fingers in the printer Use caution to avoid personal injury Figure 5 Pinch Injury Symbol Use caution or draws...

Page 8: ...ccurring in a customer account that has resulted in injury illness or property damage Examples of incidents include machine fires smoke generation physical injury to an operator or service representative Alleged events and product conditions are included in this definition V Requirements Initial Report 1 Xerox organizations shall establish a process for individuals to report product incidents to X...

Page 9: ... A digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a commercial installation This equipment generates uses and can radiate radio frequency energy If it is not installed and used in accordance with these instructions it may cause harmful interference to radio communications Operation of Class A equipment ...

Page 10: ...n Bewegliche Teile können zu Verletzungen führen AVISO Apague la electricidad de la máquina Desconecte el cable de alimentación eléc trica de la toma de pared mientras esté realizando tareas que no necesiten corriente La electricidad puede causar daños o la muerte Las partes móviles pueden causar daños WARNING Do not work in a confined space 1 m 39 inches space is needed for safe working DANGER Ne...

Page 11: ...ont of the machine in hallway and exit routes DANGER États Unis et Canada Si cette machine est installée dans un couloir ou une voie de sortie 1 12 m 44 pouces d espace supplémentaire à l espace normal doit être disponible devant la machine conformément aux normes de sécurité d incendie AVVERTENZA N A VORSICHT N A AVISO Estados Unidos y Canadá No instale esta máquina en un corredor o ruta de sal i...

Page 12: ...and the high capacity 2000 sheet feeder On the output side 500 sheet sta pler stacker or 4 bin 400 sheet Mailbox are available Figure 1 Front View Figure 1 Front View Rear View Figure 2 shows features located at the rear of the system Figure 2 Rear view Table 1 Front View 1 Finisher Stacker Stapler 10 Tray 2 2 Mailbox 11 Front Door 3 Staple Cartridge Door 12 Top Door 4 IP Board Cover 13 Control Pa...

Page 13: ... for a 512 MB DDR2 DIMM Figure 1 Memory must meet these characteristics 200 Pin DDR2 SODIMM Unbuffered Non parity The printer s Configuration page lists the amount of RAM installed in the printer Figure 1 Optional memory 520 Sheet Feeder The 520 sheet Feeder increases the input capacity of the printer and is attached to the printer underneath Tray 2 These additional tray combinations are supported...

Page 14: ...e input capacity of the printer and is attached to the printer underneath Tray 2 or installed 520 sheet Feeders These additional tray combinations are sup ported One 2000 Sheet Feeder Tray 3 Up to 2 520 Sheet Feeders Trays 3 4 and 1 2000 Sheet Feeder Tray 5 Figure 3 2000 Sheet Feeder Mailbox The Mailbox provides four 100 sheet output trays Figure 4 Optional Mailbox ...

Page 15: ...lists the function of each control Figure 1 Control Panel Table 1 Control Panel Features 1 Display Displays printer settings status messages and menus 2 Menu Enters Menu Mode and scrolls through the available menus 3 Back Sends you back one level in the menu 4 Status LED Green Printer is ready to print Yellow Startup sequence or error condition Flashing Yellow Error Condition Green Warming up or R...

Page 16: ...ger Rollers 200 000 pages 2 Separator Roller 100 000 pages 3 Transfer Roller 100 000 images 4 Fuser 200 000 images 5 Feed Roller 100 000 pages Table 1 Consumable Life Expectancy Item Description Print Life 1 Standard Toner Cartridge 20 000 cycles High Capacity Toner Cartridge 30 000 cycles Starter Toner Cartridge 10 000 cycles 2 Drum Cartridge 60 000 cycles 3 Waste Toner Cartridge Provided with ne...

Page 17: ...on Xerox Internal Use Only 1 Service Call Procedures Service Call Procedures 1 3 SCP 1 Initial Actions 1 4 SCP 2 First Call Actions 1 4 SCP 3 Normal Call Actions 1 5 SCP 4 Fault Analysis 1 5 SCP 5 Subsystem Maintenance 1 6 SCP 6 Final Actions 1 7 SCP 7 Configurations and Options 1 8 ...

Page 18: ...5 2011 1 2 Phaser 4600 4620 Printer Service Manual Revision Xerox Internal Use Only Service Call Procedures ...

Page 19: ...cal abnormalities present Make note of any unusual noise or smell coming from the printer Print a Usage Profile if the printer is able to print View the Engine Error and Jam Histories under the Tools menu Verify the AC input from the wall outlet is within specifications 2 Inspect and clean the printer Follow the cleaning instructions Verify that the power cord is in serviceable condition Restart t...

Page 20: ... 3 Make sure that a The power cord is connected to the wall outlet and to the machine b Paper is loaded correctly and all paper trays and covers are closed c If installed the USB cable or network connection is installed correctly 4 If available check the machine service log book for any previous actions that may be rel evant to the call 5 If this is the first service call to this machine perform S...

Page 21: ...mined In the instance of finding more than one fault or failure cor rect one fault before going to the next fault If no fault is found go to SCP 5 Subsystem Mainte nance Fault Codes If a fault code is displayed go to the relevant RAP UI Faults If the machine is on but the UI is blank test the UI with dC330 Stapler Faults If the machine has a stapler fault test the Stapler with dC330 Image Quality ...

Page 22: ...ut of roundness Cracked rubber Loss of traction tackiness causing pick or feed failures Gears Replace Gears that show any signs of wear or damage Look for these problems Thinned gear teeth Bent or missing gear teeth check especially where a metal gear drives a plastic gear Fractured or cracked Gears oil or incorrect grease on a plastic Gear can cause the Gear to crack Belts There are rubber belts ...

Page 23: ...Refer to GP 4 System Administration Tools At the first service and at any subsequent service where changes are made or options are added print the configuration report and store it with machine log book Discard any pre vious versions of the configuration report Remove and destroy any copies of test patterns Ensure the machine and service area are clean before leaving the customer premises Provide ...

Page 24: ...hernet Interface 10 100 Base TX 10 100 Base TX 10 100 Base TX 10 100 Base TX 10 100 Base TX Tray 1 100 sheet Standard Standard Standard Standard Standard Tray 2 520 sheet Standard Standard Standard Standard Standard Tray 3 520 sheet Optional Standard Standard Optional Standard Tray 4 520 sheet Optional Optional Optional Optional Optional Tray 5 2000 520 sheet Optional Optional Optional Optional Op...

Page 25: ... 5 2 28 07 420 00 Tray 5 is Open RAP 2 29 07 430 00 07 431 00 Jam in Tray 5 RAP 2 29 07 500 00 Paper Empty in Tray 1 RAP 2 30 07 510 00 07 700 00 Paper Empty at Tray 6 2 31 07 520 00 Tray 6 is Open RAP 2 31 07 530 00 Jam 0 in Tray 1 RAP 2 32 07 531 00 07 630 00 Jam in Tray 6 RAP 2 32 07 710 00 HCF Out of Paper 2 33 07 720 00 HCF Door is Open RAP 2 34 07 730 00 07 731 00 Jam in HCF RAP 2 35 08 100 ...

Page 26: ...12 942 00 Mailbox Bin Jam 2 65 12 913 00 12 923 00 12 933 00 12 943 00 Mailbox Bin Jam 2 66 12 915 00 Diverter Fault RAP 2 66 12 925 00 12 935 00 Upper Diverter Fault Home RAP 2 67 12 945 00 12 955 00 Lower Diverter Fault Home RAP 2 67 15 110 00 Email Send Failed RAP 2 68 15 120 00 Invalid Recipient Email Address RAP 2 68 15 300 00 Network Connection Failure RAP 2 69 15 310 00 15 600 00 Authentica...

Page 27: ... are secure Y N Secure the connections Replace these components in order until the error is corrected 1 Top Door Interlock Switch PL 28 15 Item 2 2 MCU Board PL 3 10 Item 3 01 102 00 Rear Door Open RAP 01 102 00 The Rear Door is not latched BSD Reference WD 1 Initial Actions Close the Rear Door Check for obstructions or bent pins in P J61 Procedure WARNING Switch off the electricity to the machine...

Page 28: ...5 Item 14 2 Finisher Control Board PL 12 15 Item 2 3 IOT Upper Option Harness PL 10 30 Item 24 4 MCU Board PL 3 10 Item 3 01 700 00 Stapler Door Open RAP 01 700 00 The Staple Cartridge Door is not latched securely BSD Reference WD 17 Initial Actions Close and latch the Staple Cartridge Door Check for obstructions blocking the interlock switch Procedure WARNING Switch off the electricity to the mac...

Page 29: ... right cover The harness is undamaged Y N Repair or replace the Mailbox option harness PL 11 15 Item 4 Replace these components in order until the error is corrected 1 Mailbox Rear Door Interlock Switch PL 11 30 Item 4 2 Mailbox Control Board PL 11 15 Item 1 3 IOT Upper Option Harness PL 10 30 Item 24 4 MCU Board PL 3 10 Item 3 03 100 00 03 110 00 Finisher Interface Error RAP 03 100 00 Communicati...

Page 30: ...corrected 1 Mailbox Control Board PL 11 15 Item 1 2 MCU Board PL 3 10 Item 3 03 120 00 03 940 00 Tray 3 Communications Fault RAP 03 120 00 A communication error has occurred between the MCU Board and Tray 3 03 940 00 A communication error has occurred between the MCU Board and Tray 3 BSD Reference WD 15 Initial Actions Lock the feeder to the IOT Reseat the IOT on the Feeder Check for obstructions ...

Page 31: ...d Y N Replace the Lower Option Harness REP 10 5 Replace these components in order until the error is corrected 1 Feeder Board PL 8 30 Item 7 2 MCU Board PL 3 10 Item 3 03 140 00 03 960 00 Tray 5 Communications Fault RAP 03 140 00 A communication error has occurred between the MCU Board and Tray 5 03 960 00 A communication error has occurred between the MCU Board and Tray 5 BSD Reference WD 15 Init...

Page 32: ...10 5 Replace these components in order until the error is corrected 1 Feeder Board PL 8 30 Item 7 2 MCU Board PL 3 10 Item 3 03 160 00 03 990 00 HCF Communications Fault RAP 03 160 00 A communication error has occurred between the MCU Board and the HCF 03 990 00 A communication error has occurred between the MCU Board and the HCF BSD Reference WD 16 Initial Actions Lock the feeder to the HCF Resea...

Page 33: ...lder The holder is secure Y N Secure the holder to the IP Board Install the card Replace these components in order until the error is corrected 1 Configuration Card PL 3 10 Item 6 2 IP Board PL 3 10 Item 2 03 315 00 03 325 00 Manufacturer ID RAP 03 315 00 The Configuration Card is invalid for this system 03 325 00 The Configuration Card is invalid for this system BSD Reference WD 1 Initial Actions...

Page 34: ...Mismatch RAP 03 410 00 Media size setting for Tray 2 differs from the media size reported by the Tray 2 Size Switch BSD Reference WD 3 Initial Actions Check media size settings for the tray from the Control Panel Reset the tray side and rear guides Check for obstructions blocking the Size Switch Procedure WARNING Switch off the electricity to the machine Disconnect the power cord from the customer...

Page 35: ...witch PL 3 10 Item 9 2 Tray PL 7 10 Item 23 3 Feeder Board PL 8 30 Item 7 4 MCU Board PL 3 10 Item 3 03 430 00 Tray 4 Paper Mismatch RAP 03 430 00 Media size setting for Tray 4 differ from those reported by the Size Switch BSD Reference WD 13 Initial Actions Check media size settings for the tray from the Control Panel Reset the tray side and rear guides Check for obstructions blocking the Size Sw...

Page 36: ...e Upper Option Harness REP 7 31 Check option harness continuity through all trays The harnesses are undamaged Y N Replace damaged harnesses Check the IOT Lower Option Harness The harness is undamaged Y N Replace the Lower Option Harness REP 10 5 Replace these components in order until the error is corrected 1 Size Switch PL 3 10 Item 9 2 Tray PL 7 10 Item 23 3 Feeder Board PL 8 30 Item 7 4 MCU Boa...

Page 37: ...ay PL 7 10 Item 23 3 Feeder Board PL 8 30 Item 7 4 MCU Board PL 3 10 Item 3 03 480 00 HCF Paper Mismatch RAP 03 480 00 Media size setting for the HCF differs from those reported by the Size Switch NOTE Optional Tray numbering varies by configuration When testing HCF components use the dC330 codes appropriate for the HCF s position For example if the configuration is 5 trays and the 5th tray is the...

Page 38: ... Actions Cycle system power Reseat or remove optional memory Procedure WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury Cycle system power The error message is displayed Y N Complete Remove optional memory if installed and retes...

Page 39: ...message is displayed Y N Complete Replace the Hard Drive using the instructions provided The error message is displayed Y N Complete Replace the IP Board REP 3 6 03 970 00 Software Lock Up RAP 03 970 00 A problem has been detected with software running on the MCU Board Initial Actions Cycle system power Reseat MCU Board connections Procedure WARNING Switch off the electricity to the machine Discon...

Page 40: ...d perform SCP 6 Final Actions Replace these components in order until the error is corrected 1 Tray 2 Tray 2 Level Sensor PL 8 50 Item 25 3 MCU Board REP 3 4 04 110 00 Tray 6 Lift Error RAP 04 110 00 Tray 6 Level Sensor did not change state within 13 seconds of Lift Motor activation BSD Reference WD 13 Initial Actions Remove and replace Tray 6 Check for obstructions blocking bottom plate movement ...

Page 41: ...e Tray 3 Check for obstructions blocking bottom plate movement Procedure WARNING Use safe handling procedures when removing the module Refer to GP 15 The module is heavy WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury Cycle sys...

Page 42: ...r to GP 15 The module is heavy WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury Cycle system power The error message is displayed Y N Complete Check Tray 4 bottom plate linkage and sector gear condition Use an alternate Tray to ...

Page 43: ...r position to isolate the problem Procedure WARNING Use safe handling procedures when removing the module Refer to GP 15 The module is heavy WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury Cycle system power The error message i...

Page 44: ...cedure WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury CAUTION Cover the Drum Cartridge to prevent light exposure Cycle system power The error message is displayed Y N Perform SCP 6 Final Actions Select dC330 code 04 100 All mo...

Page 45: ...ower lift plate moves up and down smoothly Y N Repair or replace damaged components Check Pick Assembly PL 8 25 motion Pick assembly motion is good Y N Repair improper Pick Assembly motion Select dC330 code for the HCF position The sensor is operational high low Y N Repair or replace the Level Sensor REP 8 50 Check the Lift Gear PL 8 35 Item 4 The gear is undamaged and properly installed Y N Repla...

Page 46: ...onnections Replace these components in order until the error is corrected 1 Rear Door PL 28 25 Item 1 2 Joint Board PL 9 15 Item 7 3 Exit Assembly PL 10 30 Item 25 Reassemble and perform SCP 6 Final Actions Reassemble and perform SCP 6 Final Actions 04 930 00 Main Fan Failure RAP 04 930 00 The SMPS Fan has failed BSD Reference WD 8 Initial Actions Check for obstructions blocking fan rotation Proce...

Page 47: ...inal Actions Reassemble and perform SCP 6 Final Actions 07 110 00 Paper Empty at Tray 2 RAP 07 110 00 The Tray 2 No Paper indicates the Tray is empty BSD Reference WD 3 Initial Actions 1 Add media to the Tray 2 Check the No Paper Sensor Actuator 3 Check for obstruction of the Pick mechanism Procedure WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supp...

Page 48: ...ke Away Sensor BSD Reference WD 3 Initial Actions 1 Check media condition 2 Check for obstructions in the media path Procedure WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury Check the Nudger Feed and Separator Rollers for exce...

Page 49: ...s REP 10 5 Replace the Tray 3 No Paper Sensor REP 7 35 then retest The sensor signal changes Y N Remove the Right Cover REP 28 2 and reseat CN3 on the Feeder Board then retest The sensor signal changes Y N Replace the MCU Board REP 3 4 Reassemble and perform SCP 6 Final Actions Reassemble and perform SCP 6 Final Actions Replace the MCU Board REP 3 4 07 220 00 Tray 3 is Open RAP 07 220 00 The Size ...

Page 50: ...otates Y N Replace the Feed Drive Assembly REP 8 42 Reassemble and perform SCP 6 Final Actions Replace these components in order until the error is corrected 1 Feed Assembly PL 8 40 Item 10 2 Pick Assembly PL 8 20 Item 17 07 310 00 Paper Empty at Tray 4 07 310 00 The Tray 4 No Paper Sensor indicates Tray 4 is empty BSD Reference WD 13 Initial Actions 1 Check the No Paper Sensor Actuator 2 Check fo...

Page 51: ...ssembly 07 331 00 Check Tray 4 Feed Area Media remains at the Tray 4 Take Away Sensor BSD Reference WD 13 Initial Actions 1 Check for obstructions in the media path Procedure WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury Chec...

Page 52: ... Paper Sensor Actuator The actuator is undamaged and motion is good Y N Repair or replace the Tray 5 No Paper Sensor Actuator Select dC330 code 07 510 to test the sensor The sensor signal changes high low Y N Remove the IOT Tray 3 and Tray 4 Check the option harness connections The har ness connectors are undamaged Y N Replace any damaged harnesses Reassemble the system to exchange Feeder position...

Page 53: ...ck up Assembly 07 431 00 Check Tray 5 Feed Area Media remains at the Tray 5 Take Away Sensor BSD Reference WD 13 Initial Actions 1 Check for obstructions in the media path Procedure WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause inju...

Page 54: ... performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury Check the Tray 1 No Paper Sensor Actuator The actuator is undamaged and motion is good Y N Repair or replace the Tray 1 No Paper Sensor Actuator Select dC330 code 07 110 to test the sensor The sensor signal changes high low Y N Replace the Tray 1 No Paper Sensor REP 7 15 then retest T...

Page 55: ...tion Harness REP 10 5 Replace the MCU Board REP 3 4 Replace the No Paper Sensor REP 7 35 then retest The signal changes Y N Remove the Right Cover REP 28 2 and reseat CN3 on the Feeder Board then retest The sensor signal changes Y N Replace the Feeder Board REP 7 28 Reassemble and perform SCP 6 Final Actions Reassemble and perform SCP 6 Final Actions Replace the MCU Board REP 3 4 07 520 00 Tray 6 ...

Page 56: ...lace the MCU Board REP 3 4 07 531 00 07 630 00 Jam in Tray 6 RAP 07 531 00 Check Tray 6 Feed Area Media remains in the Tray 6 Take Away Sensor 07 630 00 Jam 0 in Tray 6 Media remains at the Tray 6 Pick up Assembly BSD Reference WD 13 Initial Actions 1 Check for obstructions in the media path Procedure WARNING Switch off the electricity to the machine Disconnect the power cord from the customer sup...

Page 57: ...the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury Cycle system power The error message is displayed Y N Complete Check the No Paper Sensor Actuator The actuator is undamaged and motion is good Y N Repair or replace the No Paper Sensor Actuator Select dC330 code for the No Paper Sensor base...

Page 58: ...ING Use safe handling procedures when removing the module Refer to GP 15 The module is heavy WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury Cycle system power The error message is displayed Y N Complete Check the HCF Front Doo...

Page 59: ...Actions 1 Check for obstructions in the media path Procedure WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury Check the Nudger Feed and Separator Rollers for excessive wear or contamination The rollers are undamaged and clean Y ...

Page 60: ...ollers for excessive wear poor spring tension or contamination The rollers are undamaged and clean Y N Clean or replace the Registration Roller Assembly REP 8 27 Check for obstructions or debris in the media path The media path is clear Y N Clear the media path of obstructions or debris Select dC330 code 08 850 to test the Registration Clutch The clutch is engaged on off Y N Remove the Right Cover...

Page 61: ...emains in the Tray 2 Pick up Assembly BSD Reference WD 3 Initial Actions 1 Check media condition 2 Check for obstructions in the media path Procedure WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury Check the Nudger Feed and Sep...

Page 62: ...ollers are undamaged and clean Y N Clean or replace the rollers Check for obstructions or debris in the media path The media path is clear Y N Clear the media path of obstructions or debris Check Tray 3 Pick Assembly PL 8 20 Item 17 motion Pick assembly motion is good Y N Repair improper Pick up Assembly motion Select dC330 code 08 300 to test the Take Away Sensor The sensor signal changes high lo...

Page 63: ... death or injury Moving parts can cause injury Check the Nudger Feed and Separator Rollers for excessive wear or contamination The rollers are undamaged and clean Y N Clean or replace the rollers Check for obstructions or debris in the media path The media path is clear Y N Clear the media path of obstructions or debris Check Tray 3 Pick Assembly PL 8 20 Item 17 motion Pick assembly motion is good...

Page 64: ... death or injury Moving parts can cause injury Check the Nudger Feed and Separator Rollers for excessive wear or contamination The rollers are undamaged and clean Y N Clean or replace the rollers Check for obstructions or debris in the media path The media path is clear Y N Clear the media path of obstructions or debris Check the Pick Assembly PL 8 20 Item 17 motion Pick assembly motion is good Y ...

Page 65: ...r injury Moving parts can cause injury WARNING Do not touch the Fuser while it is hot Check the Fuser Gear for damage The gear is undamaged Y N Replace the Fuser Gear REP 10 14 Check the Fuser Heat and Pressure rollers The rollers rotate freely and are clean Y N Replace Fuser components as needed to restore proper operation Heat Roller and Bearings PL 10 11 Item 12 Pressure Roller and Bearings PL ...

Page 66: ...asks that do not need electricity Electricity can cause death or injury Moving parts can cause injury Check the Duplex Unit transport components for damage or excessive wear The rollers are undamaged and clean Y N Clean or replace the Duplex Unit PL 10 25 Item 26 Check for obstructions or debris in the media path The media path is clear Y N Clear the media path of obstructions or debris Check the ...

Page 67: ...code 04 230 to test the Duplex Drive Assembly The Duplex Drive Assembly rotates in both directions Y N Remove the Right Cover REP 28 2 and reseat CN11 on the MCU Board then retest The Duplex Drive Assembly rotates Y N Replace the Duplex Drive Assembly REP 10 9 Reassemble and perform SCP 6 Final Actions Replace the MCU Board REP 3 4 08 650 00 Duplex Unit Not Installed RAP 08 650 00 Duplex Unit Dete...

Page 68: ...Assembly PL 8 20 Item 17 motion Pick assembly motion is good Y N Repair improper pick assembly motion Select dC330 code 08 650 to test the Take Away Sensor The sensor signal changes high low Y N Remove the Right Cover REP 7 25 and reseat CN3 on the Feeder Board then retest The sensor signal changes Y N Replace the sensor REP 8 44 Reassemble and perform SCP 6 Final Actions Select dC330 code 08 856 ...

Page 69: ...ions or debris Check HCF Pick Assembly PL 8 25 Item 16 motion Pick assembly motion is good Y N Repair improper pick assembly motion Select dC330 code 08 300 08 400 or 08 550 based on HCF position to test the Take Away Sensor The sensor signal changes high low Y N Remove the Right Cover REP 7 25 and reseat CN3 on the Feeder Board then retest The sensor signal changes Y N Replace the sensor REP 8 44...

Page 70: ...ver REP 28 2 and reseat CN5 on the MCU Board then retest The motor rotates Y N Replace the Main Drive Assembly REP 4 1 Reassemble and perform SCP 6 Final Actions Replace these components in order until the error is corrected 1 Drum Cartridge PL 9 10 Item 1 2 Main Drive Assembly PL 4 10 Item 1 3 MCU Board PL 3 10 Item 3 09 100 00 Toner Low RAP 09 100 00 Toner is almost empty Possible low Toner or t...

Page 71: ...ilure BSD Reference WD 6 Initial Actions Cycle system power Check for obstructions debris or accumulations of toner blocking the ADC Sensor and shutter Check Toner Cartridge life count Check Drum Cartridge life count Procedure WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can caus...

Page 72: ... is con nected and undamaged Y N Repair or reconnect the harness Replace these components in order until the error is corrected 1 Joint Board PL 9 15 Item 7 2 MCU Board PL 3 10 Item 3 09 240 00 Toner Cartridge Communications Error RAP 09 240 00 Fail to communicate with the Toner Cartridge CRUM NOTE Messages are different based on the Toner Fault Count BSD Reference WD 7 Initial Actions Cycle syste...

Page 73: ...isplayed Y N Reassemble and perform SCP 6 Final Actions Follow procedures in 09 210 00 09 270 00 to correct the ADC Sensor error 09 290 00 Adjusting Image Quality RAP 09 290 00 Automated image quality routine in progress The printer idles and adjusts process parameters until they fall within established setpoints Listed are situations where the status message is displayed Toner density adjustments...

Page 74: ...P 28 2 and reseat CN16 on the MCU Board The error message is displayed Y N Reassemble and perform SCP 6 Final Actions Replace the MCU Board REP 9 8 Replace the Drum Cartridge 09 400 00 Replace Drum Cartridge RAP 09 400 00 The Drum Cartridge has reached end of life BSD Reference WD 6 Initial Actions Check Drum Cartridge life count Replace if at or near end of life Procedure WARNING Switch off the e...

Page 75: ...oner Cartridge The error message is displayed Y N Reassemble and perform SCP 6 Final Actions Remove the Right Cover REP 28 2 and reseat CN2 on the MCU Board The error message is displayed Y N Reassemble and perform SCP 6 Final Actions Replace the MCU Board REP 9 8 Remove the Left Cover REP 28 3 and check the CRUM harness The harness is con nected and undamaged Y N Repair or reconnect the harness R...

Page 76: ... Item 5 2 Joint Board PL 9 15 Item 7 3 MCU Board PL 3 10 Item 3 09 590 00 Waste Toner Cartridge Not Installed RAP 09 590 00 The Waste Toner Cartridge Detect Sensor indicates the Waste Toner Cartridge is not installed BSD Reference WD 7 Initial Actions Check the actuator on the Waste Toner Cartridge Door Procedure WARNING Switch off the electricity to the machine Disconnect the power cord from the ...

Page 77: ...in order until the error is corrected 1 Waste Toner Full Sensor PL 9 15 Item 5 2 Joint Board PL 9 15 Item 7 3 MCU Board PL 3 10 Item 3 09 600 00 Drum Cartridge Not Installed RAP 09 600 00 The Drum Cartridge is not installed or the CRUM did not properly connect BSD Reference WD 6 Initial Actions Reseat the DRUM Cartridge Cycle system power Procedure WARNING Switch off the electricity to the machine...

Page 78: ... connections between the MCU Board and Main Drive Assembly The harnesses are connected and undamaged Y N Repair or reconnect the harness Replace these components in order until the error is corrected 1 Toner Cartridge 2 Main Drive Assembly PL 4 10 Item 1 3 MCU Board PL 3 10 Item 3 09 800 00 09 810 00 Invalid Toner Cartridge RAP 09 800 00 Invalid Toner Cartridge detected Unmatched area code or CRU ...

Page 79: ...Reassemble and perform SCP 6 Final Actions Replace these components in order until the error is corrected 1 Drum Cartridge 2 MCU Board PL 3 10 Item 3 09 920 00 Transfer Unit Error RAP 09 910 00 The Transfer Roller high voltage contact point is not connected or is dirty BSD Reference WD 11 Initial Actions Reseat the Transfer Roller Clean the high voltage contact Procedure WARNING Switch off the ele...

Page 80: ...Replace the Fuser REP 10 10 Remove the Right Cover REP 28 2 and bottom fuser bracket Figure 1 Check the Fuser Drive Board MCU Board CN10 and HVPS connections The harnesses are connected and undamaged Y N Repair or connect the harness Replace these components in order until the error is corrected 1 Fuser PL 10 10 Item 1 2 Fuser Drive Board PL 1 15 Item 2 3 MCU Board PL 3 10 Item 3 10 308 00 Fuser M...

Page 81: ...e MCU Board REP 3 4 Replace the Fuser REP 10 10 The error message is displayed Y N Reassemble and perform SCP 6 Final Actions Replace the MCU Board REP 3 4 10 700 00 10 710 00 Fuser Initial Fuse Error RAP 10 700 00 The fuse on the replacement Fuser did not open after installation 10 710 00 The status of the initialization fuse is unknown after installation BSD Reference WD 11 Initial Actions Check...

Page 82: ...the Finisher option harness in the Finisher right cover The harness is undamaged Y N Repair the harness Replace these components in order until the error is corrected 1 IOT Upper Option Harness PL 10 30 Item 24 2 MCU Board PL 3 10 Item 3 12 200 00 Jam 1 in Finisher RAP 08 500 00 Media did not reach the exit sensor and remains inside the Finisher BSD Reference WD 17 Initial Actions Check the Finish...

Page 83: ...he Transport Motor connection and harness Repair or reconnect as necessary Check the Finisher option harness in the Finisher Right Cover The harness is undamaged Y N Repair the harness Replace these components in order until the error is corrected 1 IOT Upper Option Harness PL 10 30 Item 24 2 MCU Board PL 3 10 Item 3 12 500 00 Full Stack RAP 12 500 00 The Stack Full Sensor indicates the Finisher S...

Page 84: ...se components in order until the error is corrected 1 IOT Upper Option Harness PL 10 30 Item 24 2 MCU Board PL 3 10 Item 3 12 610 00 12 855 00 Out of Staples RAP 12 610 00 The Stapler Cartridge is empty as indicated by the Stapler self priming sensor 12 855 00 The Stapler is not properly primed with staples as reported by the self priming sen sor BSD Reference WD 17 Initial Actions Reseat the Stap...

Page 85: ...ged Y N Repair the harness Replace these components in order until the error is corrected 1 IOT Upper Option Harness PL 10 30 Item 24 2 MCU Board PL 3 10 Item 3 12 725 00 12 726 00 Rear Jogger Home Fault RAP 12 725 00 The right tamper did not move from home position as indicated by the Right Tamper Home Position Sensor 12 726 00 The right tamper did not move to home position as indicated by the Ri...

Page 86: ... Finisher option harness in the Finisher Right Cover The harness is undamaged Y N Repair the harness Replace these components in order until the error is corrected 1 IOT Upper Option Harness PL 10 30 Item 24 2 MCU Board PL 3 10 Item 3 12 750 00 12 755 00 Stapler Fault RAP 12 750 00 The Stapler failed 12 750 00 The Stapler jaw did not move to home position as indicated by the staple home sen sor BS...

Page 87: ...he error message is displayed Y N Reassembly and perform SCP 6 Final Actions Replace the Finisher Control Board REP 12 2 Replace these components in order until the error is corrected 1 IOT Upper Option Harness PL 10 30 Item 24 2 MCU Board PL 3 10 Item 3 12 870 00 Stapler Safety Not Detected RAP 12 870 00 The Stapler Interlock Switch is open BSD Reference WD 17 Initial Actions Check the Staple Car...

Page 88: ...r PL 11 20 Item 1 The motor rotates Y N Check the Transport Motor connection and harness REP 11 14 Repair or reconnect as necessary Replace these components in order until the error is corrected 1 IOT Upper Option Harness PL 10 30 Item 24 2 MCU Board PL 3 10 Item 3 12 910 00 12 920 00 12 930 00 12 940 00 Mailbox Bin Full 12 910 00 Mailbox Bin 1 is full 12 920 00 Mailbox Bin 2 is full 12 930 00 Mai...

Page 89: ...lace the Mailbox Control Board REP 11 5 Replace these components in order until the error is corrected 1 IOT Upper Option Harness PL 10 30 Item 24 2 MCU Board PL 3 10 Item 3 12 912 00 12 922 00 12 932 00 12 942 00 Mailbox Bin Jam 12 912 00 Mailbox Bin 1 jam from exit 12 922 00 Mailbox Bin 2 jam from exit 12 932 00 Mailbox Bin 3 jam from exit 12 942 00 Mailbox Bin 4 jam from exit BSD Reference WD 1...

Page 90: ...he Mailbox Control Board The error message is displayed Y N Reassembly and perform SCP 6 Final Actions Replace the Mailbox Control Board REP 11 5 Replace these components in order until the error is corrected 1 IOT Upper Option Harness PL 10 30 Item 24 2 MCU Board PL 3 10 Item 3 12 915 00 Diverter Fault RAP 12 915 00 The Finisher IOT exit gate diverter could not find home position as indicated by ...

Page 91: ...ss REP 11 7 Repair or reconnect as necessary Replace these components in order until the error is corrected 1 IOT Upper Option Harness PL 10 30 Item 24 2 MCU Board PL 3 10 Item 3 12 945 00 12 955 00 Lower Diverter Fault Home RAP 12 945 00 The Mailbox lower diverter did not move from home position 12 955 00 The Mailbox lower diverter did not move to home position BSD Reference WD 18 Initial Actions...

Page 92: ...s Resend the email Check network configuration Procedure The SMTP server authentication may be supported but not enabled on the device or any 500 code is returned from the mail server Resend the email 15 120 00 Invalid Recipient Email Address RAP 15 120 00 Email address has either been restricted or is in an improper format Initial Actions Resend the email Check network configuration Procedure Ent...

Page 93: ...or LDAP operations Initial Actions Check the network connection Check network configuration Procedure Cycle system power 15 310 00 15 600 00 Authentication Failure RAP 15 310 00 An authentication failure for invalid account or password was entered by the user 15 600 00 Account authentication is required by the mail server Initial Actions Check account configuration parameters Check network configu...

Page 94: ...r 15 330 00 The printer can not contact a DNS server to resolve the SMTP host name Initial Actions Check the SMTP IP address or host name Check network configuration Procedure Check that the SMTP port is open and working correctly 15 700 00 DNS Error RAP 15 700 00 A DNS resolution failure or the DNS server is not reachable Initial Actions Check DNS server configuration Check network configuration ...

Page 95: ...nflict RAP 17 100 00 Two devices are trying to use the same IP address Initial Actions Check DHCP settings Check network configuration Procedure Cycle system power 17 110 00 Connection Error RAP 17 110 00 A connection error occurred while establishing a connection to the server Initial Actions Check network configuration Procedure Cycle system power ...

Page 96: ...al Actions Check network configuration Procedure Cycle system power 17 200 00 Network Cable Disconnected RAP 17 200 00 Network cable is not connected Initial Actions Check the network connection NOTE The network connection has two LEDs The green LED on indicates that the net work connection is ready The amber LED flashing indicates that the network is good Procedure Reseat the network cable to the...

Page 97: ... 00 BOOTP and auto IP is not working 17 710 00 BOOTP and auto IP is not working Initial Actions Check BOOTP configuration Check network configuration Procedure Cycle system power 17 800 00 17 810 00 DHCP Server Error RAP 17 800 00 DHCP and auto IP is not working 17 810 00 DHCP and auto IP is not working Initial Actions Check DHCP settings Check network configuration Procedure Cycle system power ...

Page 98: ...al Actions Close the Rear Door Check for obstructions blocking the latch Procedure Ensure that the 802 1X EAP type user name and password for the machine authentication switch and authentication server match 17 910 00 Firmware Upgrade Fault RAP 17 910 00 Upgrade aborted invalid file Initial Actions Download a new firmware file Check the USB connection Procedure Cycle system power and repeat the up...

Page 99: ...oned Print 3 8 IQ7 Spots 3 9 IQ8 Blank Print 3 10 IQ9 Black Print 3 11 IQ10 Process Streaks 3 12 IQ11 Scan Streaks 3 13 IQ12 Damaged Print 3 14 IQ13 Repeating Defects 3 15 IQ14 Residual Image 3 16 IQ15 Background 3 17 IQ16 Uneven Density 3 18 IQ17 Stains on Print Back 3 19 IQ18 Registration 3 20 IQ19 Curved Vertical Lines 3 20 Test Prints 3 21 IQS 1 Solid Area Density 3 21 IQS 2 Skew 3 22 IQS 3 Re...

Page 100: ...5 2011 3 2 Phaser 4600 4620 Printer Service Manual Revision Xerox Internal Use Only Image Quality ...

Page 101: ...ersists begin to isolate the defect by attempting to identify the component responsible 9 Check stored tray settings for media size and type 10 Check image adjustment and print mode settings being used Defects Associated with Specific Components To aid with defect diagnosis listed below are defects associated with specific components Laser Unit image defects Black Print Vertical white lines Curved...

Page 102: ...eletions are visible Y N Perform SCP 6 Final Actions Check the media The media is clean of the approved type and free of defects Y N Replace the media with approved media from a freshly opened package Check the media path for dirt debris or toner residue The media path is clean Y N Clean the media path Replace the Drum Cartridge and reprint the test print The image contains spots Y N Perform SCP 6...

Page 103: ...k the printing environment A location that s too cold or humid reduces fusing perfor mance Inspect the media path for debris such as staples paper clips and paper scraps Verify that the media type is set correctly Procedure WARNING Do not touch the Fuser while it is hot Rub the image with a soft cloth or tissue The image smears when rubbed Y N Perform SCP 6 Final Actions Replace the media with new...

Page 104: ...ese ares Arrow 1 The vertical horizontal and diagonal lines should be clear and continuous The diagonal lines might appear to be narrower than the others Arrow 2 The text paragraphs should be roughly equal in density Arrow 3 The half tone patches adjacent to the solid blocks in the corners should be uni form in appearance The check points arrows 1 2 and 3 meet specification Y N Replace the followi...

Page 105: ...m SCP 6 Final actions Check the installation The printer is on a level surface Y N Correct the installation No more than a 10 mm difference side to side or front to back is required Reload the tray with new previously unopened media and reprint the test print The image is skewed Y N Instruct the customer on proper media storage and perform SCP 6 Final Actions Print test prints from a different sou...

Page 106: ... is too light Y N Perform SCP 6 Final Actions Replace the Drum Cartridge and reprint the test print The image is too light Y N Perform SCP 6 Final Actions Remove the Transfer Roller and check for surface contamination or excessive wear The Transfer Roller is good Y N Replace the Transfer Roller REP 9 1 Remove the Drum Cartridge clean the electrical contacts then print a test print The image is too...

Page 107: ...eck the media The media is clean of the approved type and free of defects Y N Replace the media with approved media from a freshly opened package Check the media path for dirt debris or toner residue The media path is clean Y N Clean the media path Replace the Drum Cartridge and reprint the test print The image contains spots Y N Perform SCP 6 Final Actions Remove the Transfer Roller and check for...

Page 108: ...nt the test print The image is blank Y N Perform SCP 6 Final Actions Install a new Drum Cartridge and reprint the test print The image is blank Y N Perform SCP 6 Final Actions Remove the Transfer Roller and check for surface contamination or excessive wear The Transfer Roller is good Y N Replace the Transfer Roller REP 9 1 Check for obstructions between the Laser Unit and Drum Cartridge The laser ...

Page 109: ... the printer Figure 1 Black print example Procedure Print a test print The test print is completely black Y N Check the customer s print settings Remove the Drum Cartridge and clean the electrical contacts Replace the Drum Cartridge and reprint the test print The image is black Y N Perform SCP 6 Final Actions Install a new Drum Cartridge and reprint the test print The image is black Y N Perform SC...

Page 110: ...ruction Figure 1 Process streak example Procedure Check the media The media is clean of the approved type and free of defects Y N Replace the media with approved media from a freshly opened package Check the media path for dirt debris or toner residue The media path is clean Y N Clean the media path Replace the Drum Cartridge and reprint the test print The image contains vertical streaks Y N Perfo...

Page 111: ...clean Y N Clean the media path Remove the Drum Cartridge and clean the electrical contacts Replace the Drum Cartridge and reprint the test print The image has horizontal streaks Y N Perform SCP 6 Final Actions Install a new Drum Cartridge and reprint the test print The image has horizontal streaks Y N Perform SCP 6 Final Actions Remove the Transfer Roller and check for surface contamination or exc...

Page 112: ...ucted Procedure Check that the printer is level has its feet and has adaquate airflow The installation loca tion is within specification Y N Correct the installation Check the media The media is clean of the approved type and free of defects Y N Replace the media with approved media from a freshly opened package Check the media path for dirt debris or toner residue The media path is clean Y N Clea...

Page 113: ...edia is clean of the approved type and free of defects Y N Replace the media with approved media from a freshly opened package Check the media path for dirt debris or toner residue The media path is clean Y N Clean the media path Print a test print and compare the defect to the values listed in Table 1 Replace the defective component Xerographic Component Dimensions The following table lists measu...

Page 114: ...esidual toner from the rollers Measure the defect frequency on the prints No defect pattern is visible Y N Refer to IQ13 Repeating Defects to determine the deffective component Remove the Drum Cartridge and clean the electrical contacts Replace the Drum Cartridge and reprint the test print The residual image defect is still visible Y N Perform SCP 6 Final Actions Install a new Drum Cartridge and r...

Page 115: ... test print The image includes background defects Y N Perform SCP 6 Final Actions Remove the Drum Cartridge clean the electrical contacts then print a test print The image includes background defects Y N Perform SCP 6 Final Actions Replace the Drum Cartridge and reprint the test print The image includes background defects Y N Perform SCP 6 Final Actions Remove the Transfer Roller and check for sur...

Page 116: ...s Y N Perform SCP 6 Final Actions Remove the Drum Cartridge clean the electrical contacts then print a test print The image has density defects Y N Perform SCP 6 Final Actions Replace the Drum Cartridge and reprint the test print The image has density defects Y N Perform SCP 6 Final Actions Remove the Transfer Roller and check for surface contamination or excessive wear The Transfer Roller is good...

Page 117: ...ifications Ensure that the printer is level Remove the Drum Cartridge and check for contamination or obstructions Figure 1 Toner on the back of prints Procedure Print 10 test prints A staining appears on all copies Y N Print an additional 10 prints to clean residual toner from the rollers Remove the Transfer Roller and check for surface contamination or excessive wear The Transfer Roller is good Y...

Page 118: ... necessary Laser Unit IP Board Drum Cartridge Tray To make registration and margin adjustments use dC131 to adjust NVRAM values Procedure Measure the registration on two consecutive test prints Registration is within specification refer to IQS 3 Y N Print test prints from all input sources to isolate the defective component Perform IQ5 Skew IQ19 Curved Vertical Lines When printing vertical lines a...

Page 119: ...ugh to pass taping test Using a 500g weight after rubbing the test pattern 5 times calculate the ratio of pre and post test data density After taping test the image density of black area of test pattern should be higher than 80 of its original density in standard paper under N N environmental condition Specification Make a copy of the test pattern Compare the copy with the solid area density scale...

Page 120: ...cifications Refer to Table 1 Corrective Action Go to the IQ19 Poor Registration RAP Table 1 Margin Specifications Mode Tray Margin Specification mm Magnification Error Leading Edge Side Edge Simplex Tray 1 and 2 12 7 1 0 12 7 1 5 Horizontal 177 8 1 5mm Vertical 241 3 1 5mm Optional Trays 12 7 1 5 12 7 2 0 Duplex Tray 1 and 2 12 7 1 5 12 7 2 0 Optional Trays 12 7 2 0 12 7 2 5 Table 1 Registration m...

Page 121: ...ndard Transparency media A4 Letter designed exclusively for Xerox 3R9023 Separate each page after printing Specifications Refer to Table 1 IQS 5 Image Area Specifications Refer to Figure 1 Figure 1 Image area specifications Table 1 Registration measurement Registration Specification Shearing Angle 4 degrees Thickness 0 114 0 01mm Weight 138 146g m2 Curl 5 mm ...

Page 122: ...5 2011 3 24 Phaser 4600 4620 Printer Service Manual IQS 4 IQS 5 Revision Xerox Internal Use Only Image Quality ...

Page 123: ...CF Left Cover 4 54 REP 7 41 HCF Caster 4 55 REP 7 42 HCF Reduction Gear Assembly 4 55 REP 7 43 HCF Front Door Interlock Switch 4 56 REP 7 44 HCF Control Board 4 56 REP 7 45 HCF Lift Motor Assembly 4 57 REP 7 46 HCF Feed Clutch 4 57 REP 7 47 HCF Feed Drive Assembly 4 58 REP 7 48 HCF Feed Motor 4 58 REP 7 49 HCF Top Plate 4 59 REP 8 11 Registration Sensor 4 60 REP 8 12 Feed Sensor 4 61 REP 8 16 Shaf...

Page 124: ...ker Full Sensor 4 129 REP 12 5 Finisher Transport Drive Assembly 4 130 REP 12 6 Finisher Exit Gate Sensor 4 132 REP 12 7 Finisher Exit Gate Actuator 4 133 REP 12 8 Finisher Entrance Drive Belt 4 134 REP 12 9 Finisher Exit Gate Cam Shaft 4 135 REP 12 10 Left Tamper Home Position Sensor 4 136 REP 12 11 Finisher Right Cover 4 137 REP 12 12 Right Tamper Home Position Sensor 4 138 REP 12 13 Staple Cart...

Page 125: ...t secure the cover to the assembly 7 Disconnect the board from the harness to remove Figure 1 Figure 1 Remove the Fuser Drive Board REP 1 3 Fuser Drive Board Assembly Parts List on PL 1 15 Item 8 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Movin...

Page 126: ... WARNING Do not touch the Fuser while it is hot 1 Remove the Duplex Unit REP 10 1 2 Remove the Waste Toner Cartridge 3 Remove the Left Cover REP 28 3 4 Remove the IP Board Cover REP 28 1 5 Remove the Right Cover REP 28 2 6 Remove the IP Board Cage REP 3 5 7 Remove the Rear Door REP 28 6 8 Remove the Fuser REP 10 10 9 Remove 5 screws 2 plastic 3 metal that secure the bottom fuser bracket to the cha...

Page 127: ...o the chas sis Figure 3 Figure 3 Remove the right side power supply tray screws 13 Remove 2 screws metal that secure the left side of the power supply tray to the chassis Figure 4 Figure 4 Remove the left side power supply tray screws 14 Remove 2 screws shank metal that secure the Fuser connector to the power supply tray Figure 5 15 Disconnect CN3 from the HVPS and move the Fuser harness to the si...

Page 128: ...N2 from the HVPS using a small screwdriver to release the connector hook Figure 6 Figure 6 Disconnect the drum bias voltage connector 18 Disconnect CON1 from the SMPS and raise the harness over the SMPS heat sink to release the power supply tray from the chassis Figure 7 Figure 7 Slide the power supply tray out of the chassis 19 Disconnect CN1 and remove 5 screws metal that secure the HVPS to the ...

Page 129: ...ove the Left Cover REP 28 3 4 Remove the IP Board Cover REP 28 1 5 Remove the Right Cover REP 28 2 6 Remove the IP Board Cage REP 3 5 7 Remove the Rear Door REP 28 5 8 Remove the Fuser REP 10 10 9 Remove 5 screws 2 plastic 3 metal that secure the bottom fuser bracket to the chassis Figure 1 Figure 1 Remove the bottom fuser bracket 10 Disconnect CN6 from the MCU Board Figure 2 11 Release the ribbon...

Page 130: ...4 Remove 2 screws shank metal that secure the Fuser connector to the power supply tray Figure 5 15 Disconnect CN3 from the HVPS and move the Fuser harness to the side Figure 5 Figure 5 Remove the Fuser connector 16 Pull the power supply tray out of the chassis to access CN2 through the SMPS Fan duct Figure 6 17 Disconnect CN2 from the HVPS using a small screwdriver to release the connector hook Fi...

Page 131: ...e SMPS and raise the harness over the SMPS heat sink to release the power supply tray from the chassis Figure 7 Figure 7 Slide the power supply tray out of the chassis 19 Disconnect CON3 release the harness from the clamp and remove 4 screws metal that secure the SMPS to the power supply tray Figure 8 Figure 8 Remove the SMPS ...

Page 132: ... Board Cover REP 28 1 5 Remove the Right Cover REP 28 2 6 Remove the Top Cover REP 28 5 7 Turn the cover over and release 4 hooks that secure the switches to the cover Figure 1 Figure 1 Remove the Interlock Switch REP 1 7 SMPS Fan Parts List on PL 1 15 Item 6 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do ...

Page 133: ...ectricity can cause death or injury Moving parts can cause injury 1 Remove the Duplex Unit REP 10 1 2 Remove the Waste Toner Cartridge 3 Remove the Left Cover REP 28 3 4 Remove the Right Cover REP 28 2 5 Remove the Top Cover REP 28 5 6 Release the Control Panel harness from the hooks Figure 1 Figure 1 Release the Control Panel harness 7 Remove 2 screws plastic that secure the Top Door hinges to th...

Page 134: ...at secure the harness cover to the Top Door Figure 4 Figure 4 Remove the Control Panel harness cover 10 Release the Control Panel harness from 2 hooks on the harness cover 11 Remove 2 screws plastic that secure the Control Panel to the Top Door and feed the harness through the hole in the Top Door Figure 5 Figure 5 Remove the Control Panel from the Top Door ...

Page 135: ...rts List on PL 2 10 Item 8 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury CAUTION Control Panel buttons are not captive to the Control Panel Board During disassembly use care to avoid dropping buttons into the printer ...

Page 136: ...anel Board 4 Release 2 hooks that secure the LCD screen to the Control Panel Board 5 Disconnect CN1 and CN3 from the Control Panel Board to remove the LCD screen Figure 3 Remove the LCD screen Replacement Install the LCD screen on the new board and reconnect the Control Panel harness before securing the new board to the top cover ...

Page 137: ...e MCU Board move the MSOK board located in CN4 at Red arrow in Figure 1 to the new board 1 Remove Tray 2 2 Remove the Duplex Unit REP 10 1 3 Remove the IP Board Cover REP 28 1 4 Remove the Right Cover REP 28 2 5 Disconnect all harness connections to the MCU Board 6 Release the harnesses from 1 harness clamp 7 Remove 3 screws metal that secure the bracket to the chassis 8 Lift the assembly up to re...

Page 138: ...o not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove Tray 2 2 Remove the Duplex Unit REP 10 1 3 Remove the IP Board Cover REP 28 1 4 Remove the Right Cover REP 28 2 5 Disconnect 5 connections CN8 CN10 CN12 CN13 and CN14 to the IP Board and feed the harnesses out the holes provided Figure 1 Figure 1 Disconnect the IP Board 6 Remove 2 screws metal and s...

Page 139: ...hile performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury NOTE After removal of the IP Board from the cage move the Configuration Card Configura tion Card holder and if installed optional memory and Hard Drive to the new board 1 Remove Tray 2 2 Remove the Duplex Unit REP 10 1 3 Remove the IP Board Cover REP 28 1 4 Disconnect 5 connection...

Page 140: ...he IP Board 5 Remove 5 screws metal and swing the front edge out to release the connectors from the rear panel Figure 2 Figure 2 Remove the IP Board Replacement After removal of the IP Board from the cage move the Configuration Card Configuration Card holder and if installed optional Memory and Hard Drive to the new board ...

Page 141: ...ry 1 Remove Tray 2 2 Remove the Duplex Unit REP 10 1 3 Remove the IP Board Cover REP 28 1 4 Remove the Right Cover REP 28 2 5 Disconnect 4 connections from the Main Drive Assembly Figure 1 6 Release the harnesses from 4 harness clamps Figure 1 Figure 1 Disconnect the Main Drive Assembly 7 Disconnect the USB cable from the Front Cover 8 Raise the Top Door 9 Release the top door linkage from the Mai...

Page 142: ...achine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove the Duplex Unit REP 10 1 2 Remove the IP Board Cover REP 28 1 3 Remove the Right Cover REP 28 2 4 Disconnect the Registration Clutch P J36 from the harness 5 Disconnect P J37 from the Main Drive Assembly 6 Disconn...

Page 143: ...oard bracket to release the tabs and move the board out and right to access the clutch Figure 2 Figure 2 Loosen the MCU Board and bracket to access the clutch 10 Disconnect P J52 from the Tray 2 Feed Clutch 11 Remove 2 screws Gold metal that secure the clutch bracket to the Feed Drive 12 Remove the E ring that secures the clutch to the shaft Figure 3 ...

Page 144: ...rom the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove the Duplex Unit REP 10 1 2 Remove the IP Board Cover REP 28 1 3 Remove the Right Cover REP 28 2 4 Disconnect the Registration Clutch P J36 from the harness 5 Remove 2 screws Gold metal that secure the clutch bracket to the Feed Drive Figure 1 6 Re...

Page 145: ...erforming tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove the Duplex Unit REP 10 1 2 Remove the IP Board Cover REP 28 1 3 Remove the Right Cover REP 28 2 4 Remove the MCU Board REP 3 4 5 Remove the Registration Clutch REP 4 3 6 Remove the Feed Clutch REP 4 2 7 Disconnect P J53 from the Feed Drive Assembly 8 Remove 5 screws Gold metal ...

Page 146: ...res the fan in the duct 6 Pull the fan from the duct to remove Figure 1 Remove the Right Side Chassis Fan REP 6 1 Laser Unit Parts List on PL 6 10 Item 1 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury NOTE Laser Unit p...

Page 147: ...re 1 Remove Tray 2 2 Open the Top Door 3 Remove the Toner Cartridge 4 Remove the Drum Cartridge 5 Remove the Duplex Unit REP 10 1 6 Remove the Right Cover REP 28 1 7 Remove the Front Cover REP 28 4 8 Disconnect CN13 from the MCU Board and feed the harness through the hole into the chassis Figure 1 Figure 1 Disconnect the Tray 1 Feeder harness from the MCU Board 9 Remove 4 screws metal that secure ...

Page 148: ...do not need electricity Electricity can cause death or injury Moving parts can cause injury CAUTION Cover the Drum Cartridge to prevent light exposure 1 Remove Tray 2 2 Open the Top Door 3 Remove the Toner Cartridge 4 Remove the Drum Cartridge 5 Remove the Duplex Unit REP 10 1 6 Remove the IP Board Cover REP 28 1 7 Remove the Right Cover REP 28 2 8 Remove the Front Cover REP 28 4 9 Remove the Tray...

Page 149: ...l Use Only Figure 1 Remove the Feeder Assembly top screws 12 Remove the Pick Assembly from the Feeder Assembly Figure 2 Figure 2 Remove the Tray 1 Pick up Assembly Replacement Check No Paper Sensor actuator operation and position before securing the Tray 1 Feeder Assembly top cover Figure 3 ...

Page 150: ...tch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Open Tray 1 2 Release the Tray 1 guide PL 28 20 Item 4 pins from the Tray 1 cover Figure 1 Figure 1 Release the Tray 1 guide from the cover 3 Rotate the Tray 1 cover to horizontal to relea...

Page 151: ...e the guide from the Front Cover Fig ure 3 Figure 3 Remove the Tray 1 guide 5 Remove the screw that secures the Separator Roller Assembly to the feeder Figure 4 Figure 4 Remove the Tray 1 Separator Roller Assembly screw Replacement Hold the No Paper Sensor Actuator in while during Separator Roller Assembly installation The actuator should rest behind the Separator Roller Assembly Figure 5 ...

Page 152: ...nt light exposure NOTE To service or replace the Tray 2 Feeder Assembly requires separation of the left side chassis With the left side chassis separated the chassis is prone to collapse As you release the left side chassis use a prop placed in the Tray 2 cavity to maintain as best as possible chassis alignment 1 Remove Tray 2 2 Open the Top Door 3 Remove the Toner Cartridge 4 Remove the Drum Cart...

Page 153: ...d and bracket REP 3 4 15 Remove the Tray 2 Feed Clutch REP 4 2 16 Remove the Registration Clutch REP 4 3 17 Remove the Feed Drive Assembly REP 4 4 18 Remove 4 screws metal that secure the front support bracket Figure 2 Figure 2 Remove the front support bracket 19 Remove 3 plastic screws disconnect the Duplex Unit Detect Sensor P J24 depress 1 tab and slide the guide to the rear to release the hook...

Page 154: ...e ground strap then slide the guide forward to release the hooks and remove the left lower tray guide from the chassis Figure 4 Figure 4 Remove the left lower tray guide 21 Remove 2 plastic screws that secure the left side of the middle frame assembly Figure 5 Figure 5 Remove the left side middle frame assembly screws 22 Remove the Joint Board REP 9 8 23 Remove 3 2 plastic 1 metal screws that secu...

Page 155: ...sembly screws 24 Remove 4 metal screws that secure the Tray 2 baseplate Figure 8 25 Remove the bearing from the Pick up Assembly shaft Figure 8 26 Release the feeder harness from the clamp and feed the harness into the Tray 2 cavity Figure 7 Figure 7 Release the Tray 2 Feeder harness 27 Remove the spring from the Pick up Assembly Figure 8 ...

Page 156: ... screws bearing and spring 28 Remove 2 metal screws that secure the left side of the power supply tray Figure 9 Figure 9 Remove the left side power supply tray screws 29 Remove 3 metal screws that secure the left side of the lower LSU frame Figure 10 30 Remove 3 metal screws that secure the left side chassis to the bottom plate Figure 10 ...

Page 157: ...left side chassis and release the Tray 2 baseplate from the chassis to remove the Tray 2 Feeder Assembly from the chassis Figure 11 Figure 11 Remove the Tray 2 Feeder Assembly and baseplate Replacement Perform the removal steps in reverse order Pay particular attention to chassis alignment fea tures bosses and pins as you install each component Do not overtighten fasteners in plastic ...

Page 158: ...EP 3 4 6 Disconnect P J49 from the Tray 2 Lift Motor 7 Remove 3 screws long metal that secure the assembly to the chassis Figure 1 Figure 1 Remove the Tray 2 Lift Motor REP 7 8 Tray 2 Lift Gear Parts List on PL 4 10 Item 12 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can...

Page 159: ...dge to prevent light exposure 1 Remove Tray 2 2 Open the Top Door 3 Remove the Duplex Unit REP 10 1 4 Remove the IP Board Cover REP 28 1 5 Remove the Right Cover REP 28 2 6 Remove the Front Cover REP 28 4 7 Remove the Tray 1 Feeder Assembly REP 7 0 8 Remove 4 screws plastic that secure the top of the Feeder Assembly Figure 1 Figure 1 Remove the Feeder Assembly top screws 9 Disconnect the spring fr...

Page 160: ...ight exposure 1 Remove Tray 2 2 Open the Top Door 3 Remove the Duplex Unit REP 10 1 4 Remove the IP Board Cover REP 28 1 5 Remove the Right Cover REP 28 2 6 Remove the Front Cover REP 28 4 7 Remove the Tray 1 Feeder Assembly REP 7 0 8 Disconnect P J58 from the feeder harness 9 Remove the fibre retainer that secures the clutch to the shaft Figure 1 Figure 1 Remove the Feeder Assembly top screws REP...

Page 161: ...r 3 Remove the Separator Roller REP 7 20 4 Remove the E clip that secures the clutch to the shaft and slide the clutch off the shaft Figure 1 Figure 1 Remove the Separator Clutch REP 7 22 Tray Front Cover Parts List on PL 7 10 Item 1 Removal 1 Remove the Tray 2 Remove 2 screws plastic and release 4 hooks that secure the cover to the tray 3 Release the media level indicator from the opening and rem...

Page 162: ... Repairs Figure 1 Remove the Tray 3 Front Cover REP 7 23 Tray Media Level Indicator Parts List on PL 7 10 Item 22 Removal 1 Remove the Tray 2 Remove the Tray Front Cover REP 7 22 3 Remove the indicator from the tray by releasing the hooks from the tray Figure 1 Figure 1 Remove the Media Level Indicator ...

Page 163: ... Separate the option feeder from the printer GP XX 2 Remove 4 screws and lift to release 2 hooks that secure the Front Cover Figure 1 Figure 1 Remove the Front Cover REP 7 25 Feeder Right Cover Parts List on PL 7 15 Item 7 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can ...

Page 164: ... cover Figure 1 Figure 1 Remove the Left Cover Replacement To install the Left Cover on a 550 Sheet Feeder removed from the system lower the safety hook into the feeder chassis and with the slider completely forward replace the cover REP 7 27 Feeder Rear Cover Parts List on PL 7 15 Item 5 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply w...

Page 165: ... 2 Remove the Right Cover REP 7 25 3 Disconnect 8 connections and remove 3 screws metal that secure the Feeder Board Figure 1 Figure 1 Remove the Feeder Board REP 7 29 Feeder Lift Motor Parts List on PL 8 35 Item 1 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause de...

Page 166: ...on PL 8 30 Item 9 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove the Tray 2 Release the upper hook that secures the switch in the tray cavity 3 Disconnect P J86 and remove the switch Figure 1 ...

Page 167: ...h off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Separate the option feeder from the printer GP 15 2 Remove the Tray 3 Remove the Right Cover REP 7 25 4 Disconnect CN6 from the Feeder Board Figure 1 Figure 1 Disconnect the Upper Feeder Har...

Page 168: ...witch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Separate the option feeder from the printer GP 15 2 Remove the Tray 3 Remove the Right Cover REP 7 25 4 Disconnect CN14 from the Feeder Board Figure 1 Figure 1 Disconnect the Upper Feede...

Page 169: ... off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Separate the option feeder from the printer GP 15 2 Remove the Tray 3 Remove the Front Cover REP 7 24 4 Remove the Right Cover REP 7 25 5 Remove the Rear Cover REP 7 27 6 Remove the safety la...

Page 170: ...d from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Separate the option feeder from the printer GP 15 2 Remove the Tray 3 Remove the Front Cover REP 7 24 4 Remove the Right Cover REP 7 25 5 Remove the Rear Cover REP 7 27 6 Disconnect CN6 and CN14 from the Feeder Board Figure 1 Disconnect the Upper and ...

Page 171: ...ry 1 Separate the option feeder from the printer GP 15 2 Remove the Tray 3 Remove the Front Cover REP 7 24 4 Remove the Right Cover REP 7 25 5 Remove the Rear Cover REP 7 27 6 Remove the right side frame REP 7 34 7 Remove the Take Away Clutch REP 8 40 8 Remove the Feed Clutch REP 8 41 9 Remove the Feed Drive Assembly REP 8 42 10 Remove the 2 screws that secure front frame rail to the chassis Figur...

Page 172: ...performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Separate the option feeder from the printer GP 15 2 Remove the Tray 3 Remove the Front Cover REP 7 24 4 Remove the Right Cover REP 7 25 5 Remove the Rear Cover REP 7 27 6 Remove the right side frame REP 7 34 7 Remove the Take Away Clutch REP 8 40 8 Remove the Feed Clutch REP 8 41 9 R...

Page 173: ...l REP 7 36 Repairs Revision Xerox Internal Use Only Figure 2 Remove the top cover 12 Remove the Feed Assembly REP 8 46 13 Turn the assembly over and release the actuator shaft from the Feed Assembly Figure 3 Figure 3 Remove the No Paper Sensor Actuator ...

Page 174: ... 1 Separate the option feeder from the printer GP 15 2 Remove the Tray 3 Remove the Front Cover REP 7 24 4 Remove the Right Cover REP 7 25 5 Remove the Rear Cover REP 7 27 6 Remove the right side frame REP 7 34 7 Remove the Take Away Clutch REP 8 40 8 Remove the Feed Clutch REP 8 41 9 Remove the Feed Drive Assembly REP 8 42 10 Remove the 2 screws that secure front frame rail to the chassis Figure ...

Page 175: ...l WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury NOTE Cover removal is possible without removing the feeder from the printer 1 Remove 2 screws metal that secure the rear cover to the chassis Figure 1 Figure 1 Remove the rear c...

Page 176: ...elease the hooks that secure the cover to the chassis Figure 1 Figure 1 Remove the right cover REP 7 40 HCF Left Cover Parts List on PL 7 20 Item 5 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury CAUTION The Front Door ...

Page 177: ... the IOT GP 14 2 Separate the HCF feeder from the printer GP 15 3 Pull the affected caster from the base unit Figure 1 Figure 1 Remove the Caster REP 7 42 HCF Reduction Gear Assembly Parts List on PL 7 25 Item 7 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death...

Page 178: ...door 3 Remove the HCF left cover REP 7 40 4 Disconnect CN2 and remove 2 screws metal that secure the switch to the chassis Fig ure 1 Figure 1 Remove the Front Door Interlock Switch REP 7 44 HCF Control Board Parts List on PL 7 25 Item 18 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity E...

Page 179: ... Release the spring from the lift linkage 4 Disconnect the motor and remove 4 screws metal that secure the assembly to the chas sis Figure 1 Figure 1 Remove the Lift Motor Assembly REP 7 46 HCF Feed Clutch Parts List on PL 7 25 Item 24 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Ele...

Page 180: ...e the HCF Feed Clutch REP 7 46 4 Disconnect CN1 from the feed motor and remove 5 screws metal that secure the assembly to the chassis Figure 1 Figure 1 Remove the Feed Drive Assembly REP 7 48 HCF Feed Motor Parts List on PL 7 25 Item 20 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity El...

Page 181: ...n cause injury 1 Remove any installed finishing options from the IOT GP 14 2 Separate the HCF feeder from the printer GP 15 3 Remove the HCF rear cover REP 7 38 4 Remove the HCF right cover REP 7 39 5 Remove the HCF left cover REP 7 40 6 Disconnect CN2 CN3 CN4 and CN6 from the HCF Control Board Figure 1 Figure 1 Disconnect the harnesses from the HCF Control Board 7 Disconnect CN2 from the Jumper B...

Page 182: ...exposure NOTE To service or replace the Registration Sensor requires separation of the left side chas sis With the left side chassis separated the chassis is prone to collapse As you release the left side chassis use a prop placed in the Tray 2 cavity to maintain as best as possible chas sis alignment The Registration Sensor is located on the underside of the middle frame assembly Access the Regis...

Page 183: ...sembly Access the Regis tration Sensor by removing the Tray 2 Feeder Assembly 1 Remove the Tray 2 Feeder Assembly REP 7 6 2 Reach into the Tray 2 cavity to release 3 hooks that secure the sensor to the assembly 3 Disconnect P J64 from the Feed Sensor Figure 1 Figure 1 Remove the Feed Sensor REP 8 16 Shaft Frame Assembly Parts List on PL 8 50 Item 15 Removal WARNING Switch off the electricity to th...

Page 184: ...ion Xerox Internal Use Only Repairs Figure 2 Remove the Shaft Frame Assembly screw 9 Slide the assembly to the left to release the shaft from the Fuser Drive Assembly 10 Raise the assembly to remove it from the printer Figure 3 Figure 3 Remove the Shaft Frame Assembly ...

Page 185: ...lapse As you release the left side chassis use a prop placed in the Tray 2 cavity to maintain as best as pos sible chassis alignment The Drum Cartridge CRUM harness connection is located on the underside of the middle frame assembly Access the harness and connection by removing the Tray 2 Feeder Assem bly 1 Remove Tray 2 Feeder Assembly REP 7 6 2 Reach into the Tray 2 cavity to locate the harness ...

Page 186: ...ry CAUTION Cover the Drum Cartridge to prevent light exposure 1 Remove Tray 2 2 Open the Top Door 3 Remove the Toner Cartridge 4 Remove the Drum Cartridge 5 Remove the Duplex Unit REP 10 1 6 Remove the IP Board Cover REP 28 1 7 Remove the Right Cover REP 28 2 8 Remove the Registration Clutch REP 4 3 9 Remove 4 screws plastic that secure the assembly to the frame Figure 1 Figure 1 Remove the Regist...

Page 187: ... Moving parts can cause injury CAUTION Cover the Drum Cartridge to prevent light exposure 1 Remove Tray 2 2 Remove the Toner Cartridge 3 Remove the Drum Cartridge 4 Remove the Duplex Unit REP 10 1 5 Remove the IP Board Cover REP 28 1 6 Remove the Right Cover REP 28 2 7 Remove the Registration Clutch REP 4 3 8 Remove the Registration Roller Assembly REP 8 27 9 Remove 2 screws plastic that secure th...

Page 188: ...e machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury CAUTION Cover the Drum Cartridge to prevent light exposure 1 Remove Tray 2 2 Remove the Toner Cartridge 3 Remove the Drum Cartridge 4 Remove the Duplex Unit REP 10 1 5 Remove the IP Board Cover REP 28 1 6 Remove the Rig...

Page 189: ...e Only Figure 1 Remove the envelope guide screws 10 Release 2 clips that secure the actuator cap to the frame and remove the cap Figure 2 Figure 2 Remove the actuator cap 11 Release the actuator and spring from the tabs in the frame to remove the actuator Figure 3 Remove the Feed Sensor Actuator ...

Page 190: ... from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Separate the option feeder from the printer GP 15 2 Remove the Tray 3 Remove the Front Cover REP 7 24 4 Remove the Right Cover REP 7 25 5 Remove the Rear Cover REP 7 27 6 Remove the right side frame REP 7 34 7 Remove 2 screws metal that secure the clut...

Page 191: ...t holds the bracket to the clutch 9 Disconnect P J89 to remove the clutch from the shaft Figure 1 Figure 1 Remove the Feed Clutch REP 8 42 Feeder Feed Drive Assembly Parts List on PL 8 30 Item 1 Removal WARNING Use safe handling procedures when removing the module Refer to GP 15 The module is heavy WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply...

Page 192: ...ving the module Refer to GP XX The module is heavy WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Separate the option feeder from the printer GP XX 2 Remove the Tray 3 Remove the Front Cover REP 7 24 4 Release the actuator f...

Page 193: ... injury Moving parts can cause injury 1 Separate the option feeder from the printer GP 15 2 Remove the Tray 3 Remove the Front Cover REP 7 24 4 Remove the Right Cover REP 7 25 5 Remove the Rear Cover REP 7 27 6 Remove the right side frame REP 7 34 7 Remove the Take Away Clutch REP 8 40 8 Remove the Feed Clutch REP 8 41 9 Remove the Feed Drive Assembly REP 8 42 10 Remove the 2 screws that secure fr...

Page 194: ...orming tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Separate the option feeder from the printer GP 15 2 Remove the Tray 3 Remove the Front Cover REP 7 24 4 Remove the Right Cover REP 7 25 5 Remove the Rear Cover REP 7 27 6 Remove the right side frame REP 7 34 7 Remove the Take Away Clutch REP 8 40 8 Remove the Feed Clutch REP 8 41 9 Remov...

Page 195: ...inter Service Manual REP 8 45 Repairs Revision Xerox Internal Use Only Figure 2 Remove the top cover 12 Remove 2 E clips and 2 bearings then move the shaft to release it from the chassis Fig ure 3 Figure 3 Remove the Take Away Roller ...

Page 196: ...ving parts can cause injury 1 Separate the option feeder from the printer GP 15 2 Remove the Tray 3 Remove the Front Cover REP 7 24 4 Remove the Right Cover REP 7 25 5 Remove the Rear Cover REP 7 27 6 Remove the right side frame REP 7 34 7 Remove the Take Away Clutch REP 8 40 8 Remove the Feed Clutch REP 8 41 9 Remove the Feed Drive Assembly REP 8 42 10 Remove the 2 screws that secure front frame ...

Page 197: ...Disconnect the Feed Assembly 13 Remove the spring from the pick assembly 14 Remove 2 screws Black plastic and release 4 bosses that secure the Feed Assembly to the chassis Figure 4 Remove the Feed Assembly screws 15 Lift the left side and lower the right side to remove the Feed Assembly from the chassis Figure 5 ...

Page 198: ...ine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove any installed finishing options from the IOT GP 14 2 Separate the HCF feeder from the printer GP 15 3 Remove the HCF rear cover REP 7 38 4 Remove the HCF right cover REP 7 39 5 Remove the HCF left cover REP 7 40 6 Re...

Page 199: ...9 7 Disconnect P J93 and release 2 hooks that secure the switch to the HCF Feed Assembly Figure 1 Figure 1 Remove the Lift Limit Switch REP 8 49 HCF Take Away Sensor Parts List on PL 8 25 Item 2 Removal WARNING Use safe handling procedures when removing the module Refer to GP 15 The module is heavy WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply...

Page 200: ... Feed Assembly REP 8 47 8 Disconnect P J94 and release 2 hooks that secure the sensor to the HCF Feed Assembly Figure 1 Figure 1 Remove the HCF No Paper Sensor REP 8 51 HCF Level Sensor Parts List on PL 8 25 Item 2 Removal WARNING Use safe handling procedures when removing the module Refer to GP 15 The module is heavy WARNING Switch off the electricity to the machine Disconnect the power cord from...

Page 201: ...dge 4 Release 2 clips that secure the Transfer Roller and remove the roller Figure 1 Figure 1 Removing the Transfer Roller REP 9 2 ADC Sensor Parts List on PL 8 50 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury CAUTION...

Page 202: ...e Detect Sensor Parts List on PL 9 15 Item 6 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove the Duplex Unit REP 10 1 2 Remove the Waste Toner Cartridge 3 Remove the Left Cover REP 28 3 4 Release 3 hooks that s...

Page 203: ...over REP 28 3 4 Release 1 screw that secures the fan to the duct 5 Disconnect P J33 to remove the fan Figure 1 Figure 1 Remove the Left Side Chassis Fan REP 9 5 Environmental Sensor Parts List on PL 9 15 Item 8 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death ...

Page 204: ...ury 1 Remove the Duplex Unit REP 10 1 2 Remove the Waste Toner Cartridge 3 Remove the Left Cover REP 28 3 4 Disconnect P J29 from the bias contact cover 5 Remove 5 screws metal that secure the bias contact cover to the chassis Figure 1 Figure 1 Remove the bias contact cover 6 Remove the Waste Toner Cartridge Detect Sensor REP 9 3 7 Remove 1 screw that secures the Waste Toner Full Sensor to the bia...

Page 205: ...d electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove the Duplex Unit REP 10 1 2 Remove the Waste Toner Cartridge 3 Remove the Left Cover REP 28 3 4 Disconnect P J29 from the bias contact cover 5 Remove 5 screws metal that secure the bias contact cover to the chassis Figure 1 Figure 1 Remove the bias contact cover 6 Remove 2 screws Gold metal that secure the Pi...

Page 206: ...ot need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove the Duplex Unit REP 10 1 2 Remove the Waste Toner Cartridge 3 Remove the Left Cover REP 28 3 4 Disconnect all connections to the Joint Board 5 Remove 4 screws metal that secure the Joint Board to the chassis Fgiure 1 Figure 1 Remove the Interconnect Board screws REP 10 1 Duplex Unit Parts List on PL 10...

Page 207: ...erforming tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove the Duplex Unit REP 10 1 2 Remove the Waste Toner Cartridge 3 Remove the Left Cover REP 28 3 4 Remove the Right Cover REP 28 2 5 Remove the Top Cover REP 28 5 6 Disconnect CN14 from the MCU Board Figure 1 Figure 1 Disconnect CN14 from the MCU Board 7 Remove 2 screws plastic tha...

Page 208: ...ord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove the IOT from Tray 3 if installed 2 Remove the Duplex Unit REP 10 1 3 Remove the Right Cover REP 28 2 4 Disconnect CN15 from the MCU Board Figure 1 Figure 1 Disconnect CN15 from the MCU Board 5 Move the printer so the right side overhangs the ...

Page 209: ...REP 28 1 3 Remove the Right Cover REP 28 2 4 Remove the Waste Toner Cartridge 5 Remove the Left Cover REP 28 3 6 Remove the IP Board Cage REP 3 5 7 Remove the Top Cover REP 28 5 8 Remove 2 screws that secure the Upper Option Connector to the chassis Figure 1 Figure 1 Remove the Upper Option Connector screws 9 Remove 5 screws 2 plastic 3 metal that secure the rear support bracket to the chassis 10 ...

Page 210: ...10 6 Revision Xerox Internal Use Only Repairs Figure 3 Remove the Joint Board screws 13 Disconnect P J40 from the Exit Assembly Figure 4 Figure 4 Disconnect the Exit Assembly 14 Remove 2 screws metal from the left side that secure the Exit Assembly Figure 5 ...

Page 211: ... Revision Xerox Internal Use Only Figure 5 Remove the left side Exit Assembly screws 15 Remove 2 screws metal from the right side that secure the Exit Assembly Figure 6 Figure 6 Remove the right side Exit Assembly screws 16 Raise the Exit Assembly up to remove Figure 7 ...

Page 212: ... need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove the Duplex Unit REP 10 1 2 Remove the IP Board Cover REP 28 1 3 Remove the Right Cover REP 28 2 4 Remove the Waste Toner Cartridge 5 Remove the Left Cover REP 28 3 6 Remove the Top Cover REP 28 5 7 Remove 5 screws 2 plastic 3 metal that secure the rear support bracket to the chassis 8 Lift the bracket an...

Page 213: ...ision Xerox Internal Use Only 10 Lift the chute and rest on the support bracket Figure 2 Figure 2 Remove the Exit Chute 11 Disconnect P J27 from the Stack Full Sensor 12 Release 3 hooks that secure the sensor to the Exit Chute Figure 3 Figure 3 Remove the Stack Full Sensor ...

Page 214: ...move the Right Cover REP 28 2 4 Remove the Rear Door REP 28 6 5 Remove the Fuser REP 10 10 6 Remove the IP Board Cage REP 3 5 7 Remove the Main Drive Assembly REP 4 1 8 Disconnect CN9 CN12 CN13 CN16 from the MCU Board and CN37 from the developer motor Release the harnesses from the upper clamps Figure 1 Figure 1 Remove the MCU Board bracket screws 9 Disconnect P J52 Feed Clutch and P J36 Registrat...

Page 215: ...Figure 3 Position the MCU Board bracket to access the center harness guide 12 Remove 3 screws metal that secure the center harness guide to the chassis and move the guide away from the Fuser Drive Assembly Figure 4 Figure 4 Remove the center harness guide screws 13 Remove the Fuser Drive spring Figure 5 ...

Page 216: ...rnal Use Only Repairs Figure 5 Remove the Fuser Drive spring 14 Disconnect P J39 from the Fuser Drive Assembly 15 Remove 4 screws metal that secure the Fuser Drive Assembly Figure 6 Figure 6 Remove the Fuser Drive screws 16 Pull the assembly through the hole in the chassis Figure 7 ...

Page 217: ...nnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove the Duplex Unit REP 10 1 2 Remove the IP Board Cover REP 28 1 3 Remove the Right Cover REP 28 2 4 Remove the MCU Board REP 3 4 5 Disconnect P J37 from the Duplex Dive Assembly 6 Remove 4 screws Gold metal that secure the asse...

Page 218: ...in the chassis 3 Hold the handles and slide the Fuser from the chassis Figure 1 Figure 1 Remove the Fuser REP 10 11 Fuser Thermistor Assembly Parts List on PL 10 15 Item 3 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury...

Page 219: ...do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Do not touch the Fuser while it is hot CAUTION Fuser plastic is easily over stressed or broken Use care when releasing hooks that secure Fuser covers and guides CAUTION Two small bushings washers are located under the Thermostat Use care removing the Ther mostat 1 Remove the Rear Door REP 28 6 2 Rem...

Page 220: ...chine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Do not touch the Fuser while it is hot CAUTION Fuser plastic is easily over stressed or broken Use care when releasing hooks that secure Fuser covers and guides 1 Remove the Rear Door REP 28 6 2 Remove the Fuser REP...

Page 221: ...Service Manual REP 10 13 Repairs Revision Xerox Internal Use Only Figure 2 Remove the duplex cover 5 Open the lower exit guide Figure 3 Figure 3 Open the lower exit guide 6 Remove 2 screws silver metal that secure the right cover Figure 4 ...

Page 222: ...erox Internal Use Only Repairs Figure 4 Remove the Fuser Right Cover 7 Disconnect T2 from the Thermostat Figure 5 Figure 5 Disconnect the Thermostat 8 Remove 1 screw Black plastic that secures the lamp bracket to the Fuser Figure 6 Figure 6 Remove the right side lamp bracket ...

Page 223: ...city to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury WARNING Do not touch the Fuser while it is hot CAUTION Fuser plastic is easily over stressed or broken Use care when releasing hooks that secure Fuser covers and guides 1 Remove the Rear Door REP 28 6 2 Remove...

Page 224: ... Service Manual REP 10 14 Revision Xerox Internal Use Only Repairs Figure 2 Remove the duplex cover 5 Open the lower exit guide Figure 3 Figure 3 Open the lower exit guide 6 Remove 2 screws silver metal that secure the right cover Figure 4 ...

Page 225: ...Xerox Internal Use Only Figure 4 Remove the Fuser Right Cover 7 Disconnect 1 terminal from the Thermostat Figure 5 Figure 5 Disconnect the Thermostat 8 Remove 1 screw Black plastic that secures the right lamp bracket to the Fuser Figure 6 Figure 6 Remove the right side lamp bracket ...

Page 226: ...re the Fuser left cover Figure 7 Figure 7 Remove the Fuser left cover 10 Remove the spring the secures the Fuser Gear to the Heat Roller Figure 8 Remove the Fuser Gear Spring 11 Remove 1 screw silver metal that secures the thermostat holder to the upper fuser bracket 12 Shift the thermostat holder right to release the hooks and lift the holder ...

Page 227: ...105 Phaser 4600 4620 Printer Service Manual REP 10 14 Repairs Revision Xerox Internal Use Only Figure 9 Release the thermostat holder 13 Remove the Fuser Gear from the Heat Roller Figure 10 Remove the Fuser Gear ...

Page 228: ... electricity Electricity can cause death or injury Moving parts can cause injury WARNING Do not touch the Fuser while it is hot CAUTION Fuser plastic and metal components are easily over stressed bent or broken Use care when releasing hooks that secure Fuser covers and guides 1 Remove the Rear Door REP 28 6 2 Remove the Fuser REP 10 10 3 Remove 3 screws 2 metal and 1 plastic that secure the Fuser ...

Page 229: ...al REP 10 15 Repairs Revision Xerox Internal Use Only Figure 3 Open the lower exit guide 6 Remove 2 screws silver metal that secure the right cover Figure 4 Figure 4 Remove the Fuser Right Cover 7 Disconnect 2 terminals T1 T2 to the Thermostat Figure 5 ...

Page 230: ... screw Black plastic that secures the lamp bracket to the Fuser Figure 6 Figure 6 Remove the right side lamp bracket 9 Remove 2 screws silver metal that secure the Fuser left cover Figure 7 Figure 7 Remove the Fuser left cover 10 Disconnect the Heat roller thermistors P J67 and P J68 and release the wiring from the thermostat holder guides Figure 8 ...

Page 231: ...erox Internal Use Only Figure 8 Disconnect Heat Roller thermistors 11 Remove 1 screw that secures the Thermostat holder to the Fuser and move the holder right to release the hooks Figure 9 Figure 9 Remove the thermostat holder 12 Remove the Fuser Gear from the Heat Roller Figure 10 ...

Page 232: ...ure 10 Remove the Fuser Gear 13 Remove 3 screws silver metal with washers and release 3 hooks that secure the upper exit guide to the Fuser Open the lower exit guide if closed earlier Figure 11 Figure 11 Remove the upper exit guide 14 Remove 5 screws silver metal that secure the upper fuser bracket Figure 12 ...

Page 233: ...620 Printer Service Manual REP 10 15 Repairs Revision Xerox Internal Use Only Figure 12 Remove the upper fuser bracket 15 Remove the Heat Roller and Bearings from the Fuser Figure 13 Figure 13 Remove the Heat Roller and Bearings ...

Page 234: ...ile it is hot CAUTION Fuser plastic and metal components are easily over stressed bent or broken Use care when releasing hooks that secure Fuser covers and guides 1 Remove the Rear Door REP 28 6 2 Remove the Fuser REP 10 10 3 Remove the Fuser Heat Roller and Bearings REP 10 15 4 Release the right cam follower spring 5 Remove 2 screws with washers 1 metal 1 plastic that secure the cam follower to t...

Page 235: ...e machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove the Duplex Unit REP 10 1 2 Remove the Waste Toner Cartridge 3 Remove the Left Cover REP 28 3 4 Disconnect P J23 from the Fuser Release Drive Assembly 5 Remove 3 screws Gold metal that secure the Release Drive A...

Page 236: ...y 1 Remove the Duplex Unit REP 10 1 2 Remove the Waste Toner Cartridge 3 Remove the Left Cover REP 28 3 4 Release 3 hooks that secure the sensor to the left side tray guide 5 Disconnect P J25 to remove the sensor Figure 1 Figure 1 Remove the Duplex Unit Detect Sensor REP 10 19 Duplex Unit Timing Belt Parts List on PL 10 25 Item 11 Removal 1 Remove the Duplex Unit REP 10 1 2 Remove 6 screws plastic...

Page 237: ...forming tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove the Duplex Unit REP 10 1 2 Remove the IP Board Cover REP 28 1 3 Remove the Right Cover REP 28 2 4 Remove the Waste Toner Cartridge 5 Remove the Left Cover REP 28 3 6 Remove the IP Board Cage REP 3 5 7 Remove the Top Cover REP 28 5 8 Remove 5 screws 2 plastic 3 metal that secure t...

Page 238: ...plastic that secure the Exit Chute to the chassis 11 Lift the chute and rest on the support bracket Figure 2 Figure 2 Remove the Exit Chute screws 12 Remove 4 screws metal that secure the Exit Drive Assembly to the chassis 13 Disconnect P J40 to remove the Exit Drive Assembly Figure 3 Figure 3 Remove the Exit Drive Assembly ...

Page 239: ...beginning with the lowest tray REP 11 2 Mailbox Left Cover Parts List on PL 11 10 Item 1 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove the Mailbox Output Trays REP 11 1 2 Separate the Mailbox from the printer...

Page 240: ...cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove the Mailbox Output Trays REP 11 1 2 Separate the Mailbox from the printer GP 14 3 Remove 1 screw and release 1 hook that secures the cover to the Mailbox Figure 1 Figure 1 Remove the right cover 4 Disconnect P J 1 on the Mailbox Control Boar...

Page 241: ...nd loosen the side covers 4 Open the rear door 90 degrees to release the hinges for the side covers Figure 1 Figure 1 Remove the rear door REP 11 5 Mailbox Control Board Parts List on PL 11 15 Item 1 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury M...

Page 242: ...se death or injury Moving parts can cause injury 1 Remove the Mailbox Output Trays REP 11 1 2 Separate the Mailbox from the printer GP 14 3 Remove the right cover REP 11 3 4 Remove the Control Board REP 11 5 5 Remove 3 plastic screws that secure the mounting bracket Figure 1 Figure 1 Remove the mounting bracket 6 Remove 2 screws plastic that secure the Control Board bracket to the Mailbox Figure 2...

Page 243: ... to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove the Mailbox Output Trays REP 11 1 2 Separate the Mailbox from the printer GP 14 3 Remove the left cover REP 11 2 4 Release the harness from the clamp 5 Disconnect the Diverter Home Position Sensor and aff...

Page 244: ...er REP 11 2 4 Remove but do not disconnect the affected Diverter Drive Assembly 5 Release 3 hooks that secure the sensor to the Diverter Drive Assembly Figure 1 Figure 1 Remove the Diverter Home Position Sensor REP 11 9 Mailbox Exit Gate Actuator Parts List on PL 11 25 Item 6 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performi...

Page 245: ...t the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove the Mailbox Output Trays REP 11 1 2 Separate the Mailbox from the printer GP 14 3 Remove the left cover REP 11 2 4 Remove the lower Diverter Drive Assembly REP 11 7 5 Remove 1 screw plastic that secures the cam gear Figure 1 Figu...

Page 246: ...em 4 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove the Mailbox Output Trays REP 11 1 2 Separate the Mailbox from the printer GP 14 3 Remove the right cover REP 11 3 4 Disconnect P J1 from the Control Board 5 ...

Page 247: ... Electricity can cause death or injury Moving parts can cause injury NOTE Mailbox output trays are numbered 1 through 4 with 4 being the top tray 1 Remove the Mailbox Output Trays REP 11 1 2 Separate the Mailbox from the printer GP 14 3 Remove the right cover REP 11 3 4 Remove the left cover REP 11 2 5 Remove 4 screws plastic that secure the Top Cover to the Mailbox Figure 1 Figure 1 Remove the to...

Page 248: ...an cause death or injury Moving parts can cause injury 1 Remove the Mailbox Output Trays REP 11 1 2 Separate the Mailbox from the printer GP 14 3 Remove the right cover REP 11 3 4 Remove the left cover REP 11 2 5 Remove 4 screws plastic that secure the Top Cover to the Mailbox Figure 1 Figure 1 Remove the top cover 6 Lift the hook and slide the switch to release the switch 7 Slide the insulation o...

Page 249: ...captive to the motor 1 Remove the Mailbox Output Trays REP 11 1 2 Separate the Mailbox from the printer GP 14 3 Remove the right cover REP 11 3 4 Remove 2 screws metal and disconnect P J127 remove the motor Figure 1 Figure 1 Remove the Transport Motor REP 12 1 Finisher Left Cover Parts List on PL 12 10 Item 1 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from ...

Page 250: ...lectricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Separate the Finisher from the printer GP 14 2 Remove the left cover REP 12 1 3 Disconnect all connections to the Control Board 4 Remove 5 screws metal that secure the board to the bracket Figure 1 Fig...

Page 251: ...ectricity Electricity can cause death or injury Moving parts can cause injury 1 Separate the Finisher from the printer GP 14 2 Remove the left cover REP 12 1 3 Remove 4 screws 2 metal 2 plastic that secure the Control Board bracket to the Fin isher Figure 1 Figure 1 Remove the Control Board bracket screw 4 Release the harness clamp and lift the front of the bracket Figure 2 Figure 2 Position the C...

Page 252: ...machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Separate the Finisher from the printer GP 14 2 Remove the left cover REP 12 1 3 Remove 4 screws 2 metal 2 plastic that secure the Control Board bracket to the Fin isher Figure 1 Figure 1 Remove the Control Board bracket...

Page 253: ...osition the Control Board bracket 5 Remove the Transport Drive Belt from the motor Figure 3 Figure 3 Remove the drive belt 6 Mark the position of the bracket in relation to the frame 7 Remove 2 screws metal that secure the motor bracket to the frame 8 Disconnect P J108 from the motor and remove the motor Figure 4 ...

Page 254: ...val WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Separate the Finisher from the printer GP 14 2 Remove the left cover REP 12 1 3 Disconnect P J116 and release 3 hooks that secure the sensor to the bracket Figure 1 Figure 1...

Page 255: ... the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Separate the Finisher from the printer GP 14 2 Remove the left cover REP 12 1 3 Remove 2 metal screws that secure the actuator bearing to the bracket 4 Turn the cam lobe to provide clearance to remove the actuator from the bracket Figure...

Page 256: ...oving parts can cause injury 1 Separate the Finisher from the printer GP 14 2 Remove the left cover REP 12 1 3 Remove the exit gate actuator REP 12 7 4 Remove but do not disconnect the Exit Gate Sensor REP 12 6 5 Compress the spring and remove the E clip that secures the outer bearing in the bracket Figure 1 Figure 1 Release the bearing from the bracket 6 Move the shaft outwards to release the sha...

Page 257: ...rming tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Separate the Finisher from the printer GP 14 2 Remove the left cover REP 12 1 3 Remove the exit gate actuator REP 12 7 4 Remove but do not disconnect the Exit Gate Sensor REP 12 6 5 Compress the spring and remove the E clip that secures the outer bearing in the bracket Figure 1 Figure 1 R...

Page 258: ...Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Separate the Finisher from the printer GP 14 2 Remove the Left Cover REP 12 1 3 Release the hook and disconnect P J118 to remove the sensor Figure 1 Figure 1 Remove the ...

Page 259: ...chine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Separate the Finisher from the printer GP 14 2 Remove 3 screws 1 metal 2 plastic that secure the cover Figure 1 Figure 1 Remove the right cover screws 3 Release 2 hooks that secure the option connector cover to the Right ...

Page 260: ...e the hook and disconnect P J119 to remove the sensor Figure 1 Figure 1 Remove the Right Tamper Home Position Sensor REP 12 13 Staple Cartridge Door Interlock Switch Parts List on PL 12 45 Item 4 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Movin...

Page 261: ...2 14 Stapler Assembly Parts List on PL 12 45 Item 1 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Separate the Finisher from the printer GP 14 2 Remove the right cover REP 12 11 3 Disconnect P J122 and P J123 from t...

Page 262: ...r supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Separate the Finisher from the printer GP 14 2 Remove the right cover REP 12 11 3 Remove 2 screws metal that secure the Stacker Drive Assembly to the Finisher 4 Disconnect P J124 from the motor to remove the assembly Figure 1 Figure 1 Disconnect and remove the Stacker ...

Page 263: ...r Interlock Switch 4 Slide the insulation off the switch terminals and using a small screwdriver release the har ness connectors from the switch Figure 2 Figure 2 Remove the switch from the harness REP 12 17 Finisher Rear Door Parts List on PL 12 10 Item 4 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not...

Page 264: ...s plastic that secure the top cover to the Finisher Figure 1 Figure 1 Remove the top cover REP 12 19 Tamper Motor Parts List on PL 12 35 Item 19 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Separate the Finisher fr...

Page 265: ...Remove the top cover REP 12 18 5 Release 1 hook that secures the sensor 6 Disconnect P J121 to remove the sensor Figure 1 Figure 1 Remove the Rear Door Open Sensor REP 12 21 Finisher Exit Sensor Parts List on PL 12 35 Item 10 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity c...

Page 266: ...then left to remove the actuator Figure 1 Figure 1 Remove the Finisher exit sensor actuator REP 12 23 Compile Tray Assembly Parts List on PL 12 35 Item 1 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Separate the Fi...

Page 267: ...y while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Separate the Finisher from the printer GP 14 2 Remove the right cover REP 12 11 3 Remove the left cover REP 12 1 4 Retract the eject assembly into the Finisher 5 Remove 4 screws plastic that secure the assembly to the Control Board bracket and Finisher chassis Figure 1 Figure...

Page 268: ...nual REP 12 24 Revision Xerox Internal Use Only Repairs Figure 2 Remove but do not disconnect the Stapler Assembly 7 Remove 3 screws plastic that secure the Stacker Shield Assembly to the Finisher Fig ure 3 Figure 3 Remove the Stacker Shield Assembly ...

Page 269: ...he rear to release the hooks that secure the cover Figure 1 Figure 1 Remove the IP Board Cover REP 28 2 Right Cover Parts List on PL 28 10 Item 4 Removal WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove the Duplex Unit ...

Page 270: ...e Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove the Duplex Unit REP 10 1 2 Remove the Waste Toner Cartridge 3 Remove 2 screws metal that secure the cover to the chassis 4 Slide the cover to the rear to release 6 hooks to remove the cover Figure 1 Figure 1 Remove the...

Page 271: ...rom the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 Remove Tray 2 2 Raise the Top Door 3 Remove 2 screws that secure the front of the Top Cover 4 Position the front of the printer at the edge of the work surface and tilt the cover outward at the bottom then lower the cover to release the bosses at the top...

Page 272: ...eath or injury Moving parts can cause injury 1 Remove the Duplex Unit REP 10 1 2 Remove the Waste Toner Cartridge 3 Remove the Left Cover REP 28 3 4 Remove the Right Cover REP 28 2 5 Release the Top Door linkage from the Main Drive Assembly 6 Disconnect CN8 from the IP Board and P J45 from the harness Figure 1 Figure 1 Disconnect the Control Panel and Top Door linkage 7 Remove the option panel and...

Page 273: ...e boss from the slot and rotate the door away from the printer Figure 1 Figure 1 Remove the Rear Door REP 28 7 Rear Door Fan Parts List on PL 28 25 Item 13 Removal 1 Remove the Rear Door REP 28 6 2 Flex the diverter gate at the center and remove 3 Flex the duplex chute to release the bosses from the door Figure 1 Figure 1 Remove the duplex chute 4 Disconnect P J28 and release 4 hooks that secure t...

Page 274: ...vision Xerox Internal Use Only Repairs Figure 2 Remove the Rear Door fan REP 28 8 Right Seal Filter Parts List on PL 28 10 Item 10 Removal 1 Release the hook that secures the filter cover to the Right Cover and remove the filter Figure 1 Figure 1 Remove the Right Seal Filter ...

Page 275: ...n cause death or injury Moving parts can cause injury 1 Remove Tray 2 2 Raise the Top Door 3 Remove the Front Cover REP 28 4 4 Remove 2 screws plastic that secure the holder to the Front Cover 5 Remove 2 screws plastic that secure the USB Host Board to the holder Figure 1 Figure 1 Remove the USB Host Board REP 28 10 Rear Seal Filter Parts List on PL 28 25 Item 12 Removal 1 Remove the Rear Door REP...

Page 276: ...5 2011 4 154 Phaser 4600 4620 Printer Service Manual REP 28 9 REP 28 10 Revision Xerox Internal Use Only Repairs ...

Page 277: ...m Cartridge 5 23 PL 9 15 Waste Toner 5 24 PL 10 Copy Transportation and Fusing PL 10 10 Fuser Assembly 1 of 2 5 25 PL 10 11 Fuser Assembly 2 of 2 5 26 PL 10 15 Upper Fuser Bracket Assembly 5 27 PL 10 20 Lower Fuser Exit Guide Assembly 5 28 PL 10 25 Duplex Unit Assembly 5 29 PL 10 30 Exit Assembly 5 30 PL 11 Sorting PL 11 10 Mailbox Covers 5 31 PL 11 15 Mailbox Control Board 5 32 PL 11 20 Mailbox D...

Page 278: ...r 4620 220 VAC Table 1 Option and Accessory Part Numbers Iten Service Part Number Sales Part Number 520 Sheet Feeder 050K74180 097N01874 2000 Sheet Feeder 059K77920 097N01875 Finisher 500 Sheet 059K77910 097N01876 Mailbox 400 Sheet 050K74190 097N01877 Duplex Unit 022N02484 097N01923 Memory Upgrade 128K01770 097N01878 160MB Hard Disk 007N01651 097N01879 Wireless Network Adaptor 120K03640 097N01880 ...

Page 279: ...e Only PL 1 10 HVPS Item Part Description 1 105N02193 HVPS REP 1 4 2 105N02157 SMPS 110V REP 1 5 105N02158 SMPS 220V REP 1 5 3 HVPS shield P O PL 1 10 Item 6 4 HVPS insulation sheet P O PL 1 10 Item 6 5 Fuser connector P O PL 1 10 Item 6 6 HVPS assembly Not Spared 7 Bottom fuser bracket Not Spared ...

Page 280: ... 1 15 Item 8 2 140N63472 Fuser drive board 110V REP 1 2 140N63473 Fuser drive board 220V REP 1 2 3 Back cover P O PL 1 15 Item 8 4 Main power switch P O PL 1 15 Item 8 5 Main power socket P O PL 1 15 Item 8 6 127N07668 SMPS fan MOT09 500 REP 1 7 7 Fan duct Not Spared 8 001N00525 Fuser drive board assembly 110V REP 1 3 140N63538 Fuser drive board assembly 220V REP 1 3 9 127N07584 Fan DC ...

Page 281: ...1 2 Decoration cover P O PL 2 10 Item 1 3 Top cover housing P O PL 2 10 Item 1 4 UI top cover P O PL 2 10 Item 1 5 Help key P O PL 2 10 Item 1 6 Power key P O PL 2 10 Item 1 7 Stop key P O PL 2 10 Item 1 8 140N63466 Main board REP 2 2 9 Lower cover P O PL 2 10 Item 1 10 LCD screen housing P O PL 2 10 Item 1 11 LCD ground P O PL 2 10 Item 1 12 LCD screen P O PL 2 10 Item 1 13 Rubber stop P O PL 2 1...

Page 282: ...6 3 140N63467 MCU board REP 3 4 4 MCU board bracket Not Spared REP 3 4 5 Lower option connector Not Spared REP 10 5 6 Configuration card Not Spared 7 113N01312 Configuration card holder 8 128K01770 Memory card 512 Mb 9 007N01651 160Gb Hard disk 10 see note Tray 2 size switch Not Spared 11 117N01902 Ribbon cable 120K03640 Wireless I F option not shown NOTE Tray 2 size switch is not spared but avail...

Page 283: ...bly REP 10 17 4 007N01659 Fuser drive assembly REP 10 8 5 007N01661 Duplex drive assembly REP 10 9 6 007N01662 Feed drive assembly REP 4 4 7 005N01128 Registration clutch CL08 850 REP 4 3 Tray 2 feed clutch CL08 820 REP 4 2 Not Spared 8 Registration clutch bracket Not Spared 9 Not Used 10 Feed clutch bracket Not Spared 11 127N07488 Tray 2 lift motor REP 7 7 12 007N01665 Tray 2 lift gear REP 7 8 13...

Page 284: ... 5 8 Phaser 4600 4620 Printer Service Manual PL 6 10 Revision Xerox Internal Use Only Parts Lists PL 6 10 Laser Unit Item Part Description 1 122N00292 Laser unit 4600 REP 6 1 122N00293 Laser unit 4620 REP 6 1 ...

Page 285: ...perator clutch P O PL 7 10 Item 23 REP 7 21 8 Roller P O PL 7 10 Item 23 9 Shaft P O PL 7 10 Item 23 10 Bearing P O PL 7 10 Item 23 11 Idle shaft P O PL 7 10 Item 23 12 Lift plate shaft P O PL 7 10 Item 23 13 Lift shaft plate P O PL 7 10 Item 23 14 Pad P O PL 7 10 Item 23 15 Pick up mounting bracket P O PL 7 10 Item 23 16 Rack guide P O PL 7 10 Item 23 17 Rack drive gear P O PL 7 10 Item 23 18 Sec...

Page 286: ...eft cover Not Spared REP 7 26 2 Left side frame Not Spared REP 7 33 3 Front cover Not Spared REP 7 24 4 Rear tray cover Not Spared 5 Rear cover Not Spared REP 7 27 6 Right side frame Not Spared REP 7 34 7 Right cover Not Spared REP 7 25 8 Clutch cover Not Spared NOTE Order the entire 520 Sheet Feeder using Service part number 050K74180 or Sales part number 097N01874 ...

Page 287: ...cription 1 Paper feed assembly Not Spared 2 Rear cover Not Spared REP 7 38 3 Right cover Not Spared REP 7 39 4 Front cover assembly Not Spared 5 Left cover Not Spared REP 7 40 6 002N02988 Front cover dummy 7 Retard cover Not Spared NOTE Order the entire 2000 Sheet Feeder using Service part number 059K77920 or Sales part number 097N01875 ...

Page 288: ...6 13 Top plate P O PL 7 25 Item 26 REP 7 49 14 Harness mount P O PL 7 25 Item 26 15 Harness P O PL 7 25 Item 26 16 Rear plate P O PL 7 25 Item 26 17 Right side plate P O PL 7 25 Item 26 18 140N63469 HCF control board REP 7 44 19 127N07669 Lift motor REP 7 45 see NOTE 20 127N07588 Feed motor REP 7 48 see NOTE 21 Feed motor gear bracket P O PL 7 25 Item 28 22 Clutch bracket assembly P O PL 7 25 Item...

Page 289: ...assembly REP 7 3 4 022N02479 Seperator roller assembly REP 7 5 5 Envelope guide P O PL 8 10 Item 14 6 Release guide P O PL 8 10 Item 14 7 Top ground P O PL 8 10 Item 14 8 Ground P O PL 8 10 Item 14 9 Release ground P O PL 8 10 Item 14 10 130N01628 No paper sensor Q07 110 REP 7 15 11 Feed clutch CL08 810 P O PL 8 10 Item 14 REP 7 16 12 Bearing P O PL 8 10 Item 14 13 Actuator arm P O PL 8 10 Item 14...

Page 290: ...PL 8 15 Item 21 7 Paper guide P O PL 8 15 Item 21 8 Shaft P O PL 8 15 Item 21 9 Static eliminator P O PL 8 15 Item 21 10 022N02232 Feed roller 11 Idle forward roller P O PL 8 15 Item 21 12 One way gear P O PL 8 15 Item 21 13 Feed idle gear P O PL 8 15 Item 21 14 Feed joint gear P O PL 8 15 Item 21 15 Spring P O PL 8 15 Item 21 16 Bearing P O PL 8 15 Item 21 17 Bearing P O PL 8 15 Item 21 18 Tray u...

Page 291: ...sor actuator P O PL 8 20 Item 17 REP 7 36 4 022N02232 Feed roller 1 each 5 Idle gear P O PL 8 20 Item 17 6 One way gear P O PL 8 20 Item 17 7 Bearing P O PL 8 20 Item 17 8 Feed roll shaft P O PL 8 20 Item 17 9 Static eliminator P O PL 8 20 Item 17 10 Ground strip P O PL 8 20 Item 17 11 Feed joint gear P O PL 8 20 Item 17 12 Idle gear P O PL 8 20 Item 17 13 Not used 14 Housing P O PL 8 20 Item 17 1...

Page 292: ...4 022N02232 Feed roller 5 Idle gear P O PL 8 25 Item 16 6 One way gear P O PL 8 25 Item 16 7 Bearing P O PL 8 25 Item 16 8 Feed roll shaft P O PL 8 25 Item 16 9 Static eliminator P O PL 8 25 Item 16 10 Ground strip P O PL 8 25 Item 16 11 Feed joint gear P O PL 8 25 Item 16 12 Idle gear P O PL 8 25 Item 16 13 Housing P O PL 8 25 Item 16 14 Tray up limit switch P O PL 8 25 Item 16 see NOTE 15 Bearin...

Page 293: ... 840 Tray 5 feed clutch CL08 855 Tray 6 feed clutch CL08 856 REP 8 41 see NOTE 3 Bracket Not Spared 4 Bearing Not Spared 5 005N01085 Take away clutch REP 8 40 see NOTE 6 Bracket Not Spared 7 140N63468 Feeder board REP 7 28 8 Take away roller Not Spared REP 8 45 9 Size switch Not Spared REP 7 30 see NOTE 10 Upper option harness Not Spared REP 7 31 11 Lower option harness Not Spared REP 7 32 NOTE Th...

Page 294: ...al Use Only Parts Lists PL 8 35 Optional Feeder Lift Assembly Item Part Description 1 120N00537 Lift motor REP 7 29 see NOTE 2 Lift motor bracket Not Spared 3 Swing housing Not Spared 4 Lift gear Not Spared NOTE The component control codes are dependent on the machine configuration ...

Page 295: ... plate P O PL 8 40 Item 10 5 Mylar guide P O PL 8 40 Item 10 6 Ground strip P O PL 8 40 Item 10 7 130N01628 Tray 3 take away sensor Q08 300 Tray 4 take away sensor Q08 400 Tray 5 take away sensor Q08 550 Tray 6 take away sensor REP 8 44 see NOTE 8 Spring P O PL 8 40 Item 10 9 Take away sensor actuator P O PL 8 40 Item 10 REP 8 43 10 Feed assembly Not Spared REP 8 46 NOTE The component control code...

Page 296: ...ve roller P O PL 8 45 Item 12 2 Registration idle roller P O PL 8 45 Item 12 3 Not Used 4 Right registration bracket P O PL 8 45 Item 12 5 Left registration bracket P O PL 8 45 Item 12 6 Spring P O PL 8 45 Item 12 7 Not Used 8 Not Used 9 Spring P O PL 8 45 Item 12 10 Bearing P O PL 8 45 Item 12 11 Bearing bronze P O PL 8 45 Item 12 12 105N02192 Registration roller assembly REP 8 27 ...

Page 297: ... PL 8 50 Item 28 13 Exit gear P O PL 8 50 Item 28 14 Rear transfer guide P O PL 8 50 Item 28 15 001N00526 Shaft frame assembly REP 8 16 16 Feed sheet P O PL 8 50 Item 28 17 Registration ground P O PL 8 50 Item 28 18 Take away roller P O PL 8 50 Item 28 19 Bearing P O PL 8 50 Item 28 20 Feed frame assembly P O PL 8 50 Item 28 21 Feed gear P O PL 8 50 Item 28 22 Drum cartridge CRUM connector P O PL ...

Page 298: ...tem Part Description 1 Lower LSU frame 2 Upper fuser frame P O PL 8 55 Item 9 3 Left registration bracket P O PL 8 55 Item 9 4 Right registration bracket P O PL 8 55 Item 9 5 LED holder P O PL 8 55 Item 9 6 Eraser board P O PL 8 55 Item 9 7 Slide B roller P O PL 8 55 Item 9 8 Spring P O PL 8 55 Item 9 9 Upper frame assembly Not Spared ...

Page 299: ...ion 1 113R00762 Drum cartridge 2 022N02478 Transfer roller REP 9 1 3 Holder Not Spared 4 Spring Not Spared 5 Retaining clip Not Spared 6 106R01533 NA XE std toner cartridge 13K 106R01534 DMO std toner cartridge 13K 106R01535 NA XE Hi Cap toner cartridge 30K 106R01536 DMO Hi Cap toner cartridge 30K 106R01532 Metered PagePack Hi Cap toner cartridge ...

Page 300: ...Bias contact cover Not Spared 2 001N00528 Pipe assembly REP 9 7 3 127N07668 Left side chassis fan MOT04 120 REP 9 4 4 093N01732 Waste toner cartridge 5 Waste toner full sensor Not Spared REP 9 6 6 130N01628 Waste toner cartridge detect sensor REP 9 3 7 140N63465 Joint board REP 9 8 8 Environmental sensor Not Spared REP 9 5 9 Sensor holder Not Spared ...

Page 301: ...inter Service Manual PL 10 10 Parts Lists Revision Xerox Internal Use Only PL 10 10 Fuser Assembly 1 of 2 Item Part Description 1 126N00339 Fuser assembly 110V REP 10 10 126N00340 Fuser assembly 220V REP 10 10 2 Thumbscrew Not Spared ...

Page 302: ...Heat roller REP 10 15 13 013N13929 Heat roller bearing REP 10 15 14 007N01657 Fuser gear REP 10 14 15 Spring clamp P O PL 10 10 Item 1 16 Upper fuser bracket assembly REF PL 10 15 17 122N00290 Heat lamp 110V REP 10 13 122N00291 Heat lamp 220V 18 Lamp bracket P O PL 10 10 Item 1 19 Gear bracket P O PL 10 10 Item 1 20 Upper exit guide P O PL 10 10 Item 1 21 AC harness holder P O PL 10 10 Item 1 22 S...

Page 303: ...on Xerox Internal Use Only PL 10 15 Upper Fuser Bracket Assembly Item Part Description 1 Upper bracket Not Spared 2 Thermostat holder Not Spared 3 130N01531 Thermistor NTC REP 10 11 4 Thermostat Not Spared REP 10 12 5 130N01615 Thermistor NTC side 6 130N01614 Thermistor NTC center ...

Page 304: ...20 Lower Fuser Exit Guide Assembly Item Part Description 1 Lower exit guide Not Spared 2 Clip Not Spared 3 Spring Not Spared 4 Rear lever Not Spared 5 Actuator holder Not Spared 6 Fuser exit sensor actuator Not Spared 7 Actuator spring Not Spared 8 Upper fuser exit roller Not Spared 9 Duplex exit gear Not Spared ...

Page 305: ... cover P O PL 10 25 Item 26 10 Tension spring P O PL 10 25 Item 18 11 023N01051 Timing belt REP 10 19 12 M feed bush P O PL 10 25 Item 26 13 Conductive gasket P O PL 10 25 Item 26 14 P terminal ground P O PL 10 25 Item 26 15 Exit F gear P O PL 10 25 Item 26 16 Idle roll shaft P O PL 10 25 Item 26 17 Pulley 18 P O PL 10 25 Item 26 18 Pulley M 18 dummy P O PL 10 25 Item 26 19 Idle roller P O PL 10 2...

Page 306: ...9 130N01628 Stack full sensor Q08 720 REP 10 7 10 Spring P O PL 10 30 Item 25 11 Bearing P O PL 10 30 Item 25 12 Bearing P O PL 10 30 Item 25 13 Bearing P O PL 10 30 Item 25 14 Rear bracket P O PL 10 30 Item 25 15 Damper pad P O PL 10 30 Item 25 16 Duplex exit gear P O PL 10 30 Item 25 17 Upper exit gear P O PL 10 30 Item 25 18 Lower exit gear P O PL 10 30 Item 25 19 Static eliminator P O PL 10 30...

Page 307: ...em Part Description 1 Left cover Not Spared REP 11 2 2 Right cover Not Spared REP 11 3 3 Top cover Not Spared 4 Output tray assembly Not Spared REP 11 1 5 Rear door Not Spared REP 11 4 6 Connector cover Not Spared 7 Base plate Not Spared NOTE Order the entire Mailbox using Service part number 050K74190 or Sales part number 097N01877 ...

Page 308: ... PL 11 15 Revision Xerox Internal Use Only Parts Lists PL 11 15 Mailbox Control Board Item Part Description 1 140N63470 Control board REP 11 5 2 Control board bracket Not Spared 3 Mounting bracket Not Spared 4 Mailbox option harness Not Spared REP 11 11 ...

Page 309: ...s Lists Revision Xerox Internal Use Only PL 11 20 Mailbox Drive Belts Item Part Description 1 127N07670 Transport motor MOT12 120 REP 11 14 2 Grounding strip Not Spared 3 Motor bracket Not Spared 4 023N01282 Primary drive belt REP 11 6 5 023N01281 Drive belt REP 11 6 ...

Page 310: ...r drive assembly MOT12 935 Lower diverter drive assembly MOT12 955 REP 11 7 2 Upper diverter home position sensor Q12 925 Lower diverter home position sensor Q12 945 Not Spared REP 11 8 3 Not used 4 Cam gear Not Spared 5 Exit gate cam follower Not Spared REP 11 10 6 Exit gate actuator Not Spared REP 11 9 7 Mounting bracket Not Spared 8 Bearing Not Spared 9 Cam follower spring Not Spared ...

Page 311: ...t Spared 3 Magnet Not Spared 4 Rear door interlock switch S12 915 Not Spared REP 11 13 5 Top stacker shield Not Spared 6 Static eliminator Not Spared 7 Stacker full actuator Not Spared 8 Idle feed roll assembly Not Spared 9 Idle feed roll Not Spared 10 Pin Not Spared 11 Spring Not Spared 12 Stack full sensor assembly Not Spared 13 Output tray 1 stack full sensor Q12 910 Not Spared REP 11 12 14 Sen...

Page 312: ...r Q12 941 Tray 2 stacker full sensor Q12 920 Tray 3 stacker full sensor Q12 930 Tray 4 stacker full sensor Q12 940 Not Spared 3 Actuator shaft Not Spared 4 Spring Not Spared 5 Stacker empty actuator Not Spared 6 Exit feed actuator Not Spared 7 Spring Not Spared 8 Stacker sensor bracket Not Spared 9 Idle feed roll assembly Not Spared 10 Idle feed shaft Not Spared 11 Idle feed roll Not Spared 12 Spr...

Page 313: ...ty sensor Q12 910 Not Spared 3 Entrance actuator assembly Not Spared 4 Shaft Not Spared 5 Entrance feed actuator Not Spared 6 Spring Not Spared 7 Stacker actuator shaft Not Spared 8 Spring tray empty Not Spared 9 Stacker empty actuator Not Spared 10 Exit feed actuator Not Spared 11 Spring paper path Not Spared 12 Harness Not Spared NOTE Order the entire Mailbox using Service part number 050K74190 ...

Page 314: ...her Covers Item Part Description 1 Left cover Not Spared REP 12 1 2 Right cover Not Spared REP 12 11 3 Option connector cover Not Spared 4 Rear door Not Spared REP 12 17 5 Bearing Not Spared 6 Top cover Not Spared REP 12 18 NOTE Order the entire Finisher using Service part number 059K77910 or Sales part number 097N01876 ...

Page 315: ...e Manual PL 12 15 Parts Lists Revision Xerox Internal Use Only PL 12 15 Finisher Control Board Item Part Description 1 Control board bracket Not Spared REP 12 3 2 140N63471 Control board REP 12 2 3 Stacker full sensor Q12 845 Not Spared REP 12 3 ...

Page 316: ...ion 1 050N00559 Stacker shield assembly REP 12 24 2 Stacker tray P O PL 12 20 Item 1 3 Left guide P O PL 12 20 Item 1 4 Right guide P O PL 12 20 Item 1 5 Bearing P O PL 12 20 Item 1 6 Gear P O PL 12 20 Item 1 7 Shaft P O PL 12 20 Item 1 8 Guide roll P O PL 12 20 Item 1 NOTE Order the entire Finisher using Service part number 059K77910 or Sales part number 097N01876 ...

Page 317: ... P O PL 12 25 Item 1 3 Collar P O PL 12 25 Item 1 4 Shaft P O PL 12 25 Item 1 5 Mounting bracket P O PL 12 25 Item 1 6 Idle shaft P O PL 12 25 Item 1 7 Idle gear P O PL 12 25 Item 1 8 Transport motor P O PL 12 25 Item 1 9 Drive gear P O PL 12 25 Item 1 10 Drive belt P O PL 12 25 Item 1 11 Securing bracket P O PL 12 25 Item 1 NOTE Order the entire Finisher using Service part number 059K77910 or Sal...

Page 318: ...tem 1 5 Roller P O PL 12 30 Item 1 6 Link arm P O PL 12 30 Item 1 7 Idle gear P O PL 12 30 Item 1 8 Drive belt P O PL 12 30 Item 1 9 Drive gear P O PL 12 30 Item 1 10 Actuator P O PL 12 30 Item 1 11 Mounting plate P O PL 12 30 Item 1 12 Drive motor MOT12 400 P O PL 12 30 Item 1 13 Left bracket P O PL 12 30 Item 1 14 Support finger home sensor Q12 825 Stacker top sensor Q12 840 P O PL 12 30 Item 1 ...

Page 319: ...em 1 9 Idle roll P O PL 12 35 Item 1 10 Left tamper home position sensor Q12 820 REP 12 10 Rear door open sensor Q12 895 REP 12 20 Right tamper home position sensor Q12 815 REP 12 12 Exit sensor Q12 805 REP 12 21 11 Exit sensor actuator P O PL 12 35 Item 1 REP 12 22 12 Spring P O PL 12 35 Item 1 13 Drive gear P O PL 12 35 Item 1 14 Not used 15 Tamper link arm P O PL 12 35 Item 1 16 Shaft P O PL 12...

Page 320: ...e pulley P O PL 12 40 Item 1 14 Idle gear P O PL 12 40 Item 1 15 Motor bracket P O PL 12 40 Item 1 16 023N01283 Entrance drive belt REP 12 8 17 Transport drive belt P O PL 12 40 Item 1 REP 12 5 18 Exit gate sensor Q12 900 Finisher entrance sensor Q12 800 REP 12 21 Not Spared 19 Exit gate sensor actuator P O PL 12 40 Item 1 REP 12 7 20 Actuator bearing P O PL 12 40 Item 1 21 Plastic washer P O PL 1...

Page 321: ... Use Only PL 12 45 Finisher Stapler Assembly Item Part Description 1 029N00417 Stapler assembly REP 12 14 2 Stapler bracket P O PL 12 45 Item 1 3 Stapler P O PL 12 45 Item 1 4 Staple cartridge door interlock switch S12 870 Not Spared REP 12 13 5 Staple interlock switch S12 890 Not Spared REP 12 16 ...

Page 322: ...EP 28 3 2 002N03024 Waste toner box cover 3 002N02996 Rear door assembly REP 28 1 4 002N02986 Right cover REP 28 2 5 002N02995 Front cover assembly REF PL 28 20 Item 2 REP 28 4 6 002N02985 IP board cover REP 28 1 7 Top cover REF PL 28 15 Item 9 REP 28 5 8 Right fan cover Not Spared 9 Option cover Not Spared 10 035N00428 Right seal filter 11 Rear support bracket Not Spared ...

Page 323: ...t Description 1 002N02981 Top cover 2 130N01399 Top door interlock switch Q01 100 REP 1 6 3 Hinge stopper P O PL 28 15 Item 9 4 Harness cover P O PL 28 15 Item 9 5 Control panel assembly REF PL 2 10 Item 1 6 Top door P O PL 28 15 Item 9 7 Exit gate actuator P O PL 28 15 Item 9 8 Stacker guide P O PL 28 15 Item 9 9 002N02982 Top cover assembly ...

Page 324: ...t Cover Assembly Item Part Description 1 Front cover assembly REF REP 28 4 2 Front cover P O 3 Tray 1 cover P O PL 28 20 Item 1 4 Tray 1 paper guide asembly P O PL 28 20 Item 1 5 002N02991 Tray 1 stacker 6 Tray 1 extension tray P O PL 28 20 Item 1 7 USB host holder P O PL 28 20 Item 1 8 140N63464 USB host board REP 28 9 ...

Page 325: ...15 Item 1 6 Rear right locker P O PL 28 15 Item 1 7 Spring P O PL 28 15 Item 1 8 Handle bracket P O PL 28 15 Item 1 9 Rear cover handle P O PL 28 15 Item 1 10 Handle sponge P O PL 28 15 Item 1 11 Locker handle P O PL 28 15 Item 1 12 Not used 13 127N07668 Rear door fan MOT10 500 REP 28 7 14 Tension spring P O PL 28 15 Item 1 15 Roller P O PL 28 15 Item 1 16 Idle shaft P O PL 28 15 Item 1 17 Damper ...

Page 326: ... Rollers 115R00063 110V 115R00070 220V Staple Cartridge 008R12941 Table 1 Options and Accessories Iten Service Part Number Sales Part Number 520 Sheet Feeder 050K74180 097N01874 2000 Sheet Feeder 059K77920 097N01875 Finisher 500 Sheet 059K77910 097N01876 Mailbox 400 Sheet 050K74190 097N01877 Duplex Unit 022N02484 097N01923 Memory Upgrade 128K01770 097N01878 160MB Hard Disk 007N01651 097N01879 Wire...

Page 327: ...ap 6 9 GP 10 How to Check a Motor 6 12 GP 11 How to Check a Sensor 6 13 GP 12 How to Check a Solenoid or Clutch 6 13 GP 13 How to Check a Switch 6 14 GP 14 Separate System Modules 6 14 GP 15 How to Safely Lift or Move Heavy Modules 6 15 GP 16 Machine Lubrication 6 15 GP 17 Installation Space Requirements 6 16 GP 18 Glossary of Terms Acronyms and Abbreviations 6 17 GP 19 Restriction of Hazardous Su...

Page 328: ...5 2011 6 2 Phaser 4600 4620 Printer Service Manual Revision Xerox Internal Use Only General Procedures Information ...

Page 329: ... the Control Panel refer to GP 1 and GP 9 For information on fault codes refer to Table 1 Function and Fault Codes Refer to Table 1 for a list of Fault code prefixes These prefixes are also commonly referred to as chain codes Machine Status and Fault History View error messages at the Control Panel or print the last 40 messages by printing the Error Message report from the Control Panel 1 Enter di...

Page 330: ...5 2011 6 4 Phaser 4600 4620 Printer Service Manual GP 3 Revision Xerox Internal Use Only General Procedures Information GP 3 System Administration Tools Figure 1 Customer menu map 1 of 2 ...

Page 331: ...5 2011 6 5 Phaser 4600 4620 Printer Service Manual GP 3 General Procedures Information Revision Xerox Internal Use Only Figure 2 Customer menu map 2 of 2 ...

Page 332: ...only be used by the System Administrator Use this procedure to upgrade system firmware from CWIS 1 Open Microsoft Internet Explorer Enter the machines IP address 2 Enter the machines IP address Press return The CentreWare Internet Services window will open 3 Click on the Properties tab 4 In the Properties window click on Maintenance then Firmware Upgrade 5 Enter the customers username and password...

Page 333: ...e package until you are ready to install it Immediately before removing the protective material from the leads of a replacement device touch the protective material to the chassis or circuit assembly into which the device will be installed Minimize body motions when handling unpacked replacement devices Motion such as your clothes brushing together or lifting a foot from a carpeted floor can gener...

Page 334: ...e removing any component from the machine note the cable routing that will be affected Whenever servicing the machine perform the following 1 Check to verify that jobs are not stored in memory 2 Unplug the power cord 3 Use a flat and clean surface 4 Only install authorized components 5 Do not forcibly remove plastic components 6 Ensure all components are in their correct position 7 When replacing ...

Page 335: ...5 2011 6 9 Phaser 4600 4620 Printer Service Manual GP 9 General Procedures Information Revision Xerox Internal Use Only GP 9 Service Menu Map Figure 1 Service menu map 1 3 ...

Page 336: ...5 2011 6 10 Phaser 4600 4620 Printer Service Manual GP 9 Revision Xerox Internal Use Only General Procedures Information Figure 2 Service menu map 2 3 ...

Page 337: ...5 2011 6 11 Phaser 4600 4620 Printer Service Manual GP 9 General Procedures Information Revision Xerox Internal Use Only Figure 3 Service menu map 3 3 ...

Page 338: ...der A pulses lead the encoder B pulses In the other direction encoder B pulses lead encoder A pulses In this way the control ler can detect that the motor is running in the correct direction Check the operation of the motor as follows 1 Check the drive voltage when the component control code for the motor is entered If the drive voltage is present at the motor install a new motor If the drive volt...

Page 339: ... How to Check a Solenoid or Clutch Use this procedure to check a clutch or solenoid Initial Actions WARNING Switch off the electricity to the machine Disconnect the power cord from the customer supply while performing tasks that do not need electricity Electricity can cause death or injury Moving parts can cause injury 1 For a clutch check that the shafts gears rolls etc associated with the clutch...

Page 340: ...pin 1 and pin 2 on the wiring side of the connector 4 5V is available at PJ5 between pins 3 and 4 on the PWB 5 Check the supply voltage If 5V is available install a new PWB 6 Check the wiring between PJ5 and T072 Repair or install new parts as necessary 7 Install a new switch Figure 1 Example Switch Wiring Diagram GP 14 Separate System Modules Use this procedure to remove the Mailbox or Finisher m...

Page 341: ...the following 1 Ensure that a suitable stable surface to support the module after removal is located in close proximity to the machine 2 Ensure the support surface height is between 750mm and 1000mm 30 inches and 39 inches 3 Ensure there are no hazards or obstacles between the machine and the support surface 4 Two people are required if the module is to be lifted on to the floor or lifted from the...

Page 342: ...dditional 1 12 m 44 inches of space is needed in front of the machine in hallway and exit route Space Requirements Figure 1 shows the required amounts of space needed to properly operate and service the machine 1 In order to function properly the printer must be placed on a flat surface with the following minimum clearances Figure 1 Figure 1 Minimum Clearances 2 Mounting surface flatness must be w...

Page 343: ...n Bodies CCA Cenelec Certification Agreement CCA Customer Call Assistance CCD Charged Coupled Device CCITT Comite Consultatif International Telegraphique et Telephonique CCR Change Control Request CD Copy Darker A copy density setting CD ROM Compact Disk Read Only Memory CDDU Controller and Drivers Delivery Unit CDDUW Controller and Drivers Delivery Unit West Coast CDS Charge deficient spot A phot...

Page 344: ...DST Daylight Saving Time DT Dial Tone DTC Digital Transmit Command DTMF Dual Tone Multiple Frequency DU Density Units Dust Off Routine to return machine to pre install state Table 1 Glossary Term Description EAA Electron Auditron Administrator EBS Electronic Billing Service EC European Community ECE External Customer Engagement ECM Error Correction Mode Electronic Counter Measure EEC European Econ...

Page 345: ...are high level design HTTP Hyper Text Transfer Protocol HUI Hybrid User Interface HVPS High Voltage Power Supply Table 1 Glossary Term Description Hz Hertz IB InBoard I2C bus Inter Integrated Circuit bus This provides a simple bidirectional 2 wire bus for efficient inter IC control All I2C bus compatible devices incorpo rate an interface which allows them to communicate directly with each other vi...

Page 346: ...tor Hardware unit that converts the one and zero binary values from the computer to two frequencies for transmission over the public telephone network modulation It also converts the two fre quencies received from the telephone network to the binary values for the computer demodulation Moire Image quality defect caused by interference between patterned originals and the digital imaging process Moi...

Page 347: ...rinter Description A PPD file is a simple formatted text file that contains a description of the printers features and the corresponding PostScipt code needed to activate each feature Apple LaserWrite driv ers and application programs such as Adobe PageMaker can use PPD files With a OOD file many of the printing features of a network printer can be made available to users However advanced features...

Page 348: ...s SAP Service Advertising Protocol SAR Semi Active Retard feeder SCD Software Compatibility Database SCF Second Cassette Feeder SCM Software Configuration Management Table 1 Glossary Term Description SCN Specification Change Notice SCR Software Change Request SCSI Small computer Systems Interface SCT Simple Catch Tray S D Shut Down SDK Software Development Kit SDP Software Development Plan SDR Shu...

Page 349: ...gd UART Universal Asynchronous Receiver Transmitter UDP User Datagram Protocol UI User Interface display screen UK United Kingdom UM Unscheduled Maintenance UMR Unscheduled Maintenance Rate URL Universal Resource Locator USB Universal Serial Bus High speed successor to parallel port for local device communications Operates at 12 Mbits s See FireWire and RS 232 USCO United States Customer Operation...

Page 350: ...rcury Hg Cadmium Cd Hexavalent Chromium Cr 6 Cr VI Polybrominated Diphenyl Ethers PBDE s Polybrominated Biphenyls PBB s Identification of a RoHS Compliant Machine Xerox will maintain a central list of RoHS compliant machines This general procedure is for information only All Phaser machines are RoHS compliant GP 20 First Print Output Time Purpose First Print Output Time FPOT is defined as the time...

Page 351: ...educed as much as possible Maintain constant temperatures and relative humidity Avoid light heat and dampness Avoid attics kitchens garages and basements for storing paper Inside walls are drier than outside walls where moisture can collect Store paper flat Paper should be stored on pallets cartons shelves or in cabinets Avoid having food or drinks in the area where paper is stored or handled Do n...

Page 352: ... parameters Table 1 NVM chain 7 Table 2 NVM chain 8 Table 3 NVM chain 9 Table 4 NVM chain 10 8 When the values of an editable NVM have been changed switch off the machine the switch on the machine to check and evaluate the changes made to the NVM Table 1 Environmental Specifications Characteristic Specifications Operating Storage Temperature 15º to 32º C 59º to 86º F 20º to 40º C 4º to 104º F Humi...

Page 353: ...4 Dup_long 2nd side The changed dimension of Tray 4 side registration of 2nd side in duplex long 0 60 0 5mm 13 steps 30 Table 1 NVM Chain 7 Location NVM Name NVM Description Value Default 07 440 Top Registration Tray 4 Duplex 1st side The changed dimension of Tray 4 top registration of 1st side in duplex long and short 0 60 0 5mm 13 steps 30 07 450 Side Registra tion Tray 4 Duplex 1st side The cha...

Page 354: ... Table 4 NVM Chain 10 Location NVM Name NVM Description Value Default 10 100 StandBy Temper ature Offset Target temperature during standby mode 0 15 4 steps 5 degree intervals 10 Table 2 NVM Chain 8 Location NVM Name NVM Description Value Default 10 105 Run Tempera ture Offset Target temperature during run mode 0 15 3 steps 5 degree intervals 5 10 115 101 185 mm Temperature Off set Offset temperat...

Page 355: ... the DC132 NVRAM Initialization 3 Confirm Yes to reset NVRAM to factory defaults dC305 UI Test Purpose To test Control panel display function 1 Enter diagnostics refer to GP 1 2 Select Printer Routines the DC305 NVRAM Initialization 3 Select from LDCD test or a complete UI test The display turns black as data is written to the display buffer For the complete test following the LCD test the test co...

Page 356: ...mal speed Low abnormal speed Table 3 Input Codes 06 Code Display Name Description General 06 110 LSU Motor Ready Laser Unit scan motor High normal speed Low abnormal speed Table 4 Input Codes 07 Code Display Name Description General 07 110 T1 Paper Empty Sensor Tray 1 No Paper Sensor High Low 07 200 Tray 2 Home Position Tray 2 Size Switch SW1 Open Closed 07 210 T2 Paper Empty Sensor Tray 2 No Pape...

Page 357: ...gh Low 12 815 Front Jog Home Sensor Right Tamper Home Position High Low 12 820 Rear Jog Home Sensor Left Tamper Home Position High Low 12 825 Support Finger Home Sensor Support Finger Home Position High Low 12 840 Stacker Top Sensor Stacker Top Sensor High Low 12 845 Stacker Bottom Switch Stacker Full Sensor High Low 12 850 Staple Home Sensor Staple Home Position High Low 12 855 Staple Ready Senso...

Page 358: ...tor Run the toner dispense motor in the Main Drive Assembly On Off 09 950 Erase lamp Toggle the Erase lamp On Off Table 13 Output Codes 10 Code Display Name Description General 10 100 Fuser Power On Main Raises Fuser temperature to 180 degree setpoint On Off 10 110 Fuser Power On Side Raises Fuser temperature to 180 degree setpoint On Off 10 400 Fuser Motor Forward Run Fuser Drive Assembly On Off ...

Page 359: ...on Xerox Internal Use Only dC612 Print Test Pattern Purpose To print embedded test prints useful for troubleshooting print quality problems 1 Enter diagnostics refer to GP 1 2 Select Printer Routines the DC612 Print Test pattern 3 Select the test pattern to print from those listed on the display ...

Page 360: ...5 2011 6 34 Phaser 4600 4620 Printer Service Manual dC612 Revision Xerox Internal Use Only General Procedures Information ...

Page 361: ...4 WD 4 MCU Board 2 4 7 5 WD 5 MCU Board 3 4 7 5 WD 6 MCU Board 4 4 7 6 WD 7 Joint Board 1 2 7 6 WD 8 Joint Board 2 2 7 7 WD 9 IP Board 1 2 7 7 WD 10 Laser Unit 7 8 WD 11 HVPS 7 8 WD 12 SMPS 7 9 WD 13 500 Sheet Feeder 7 9 WD 14 500 Sheet Feeder Board 1 2 7 10 WD 15 500 Sheet Feeder Board 2 2 7 10 WD 16 2000 Sheet Feeder 7 11 WD 17 Finisher 7 12 WD 18 Mailbox 7 14 ...

Page 362: ...5 2011 7 2 Phaser 4600 4620 Printer Service Manual Revision Xerox Internal Use Only Wiring ...

Page 363: ...5 2011 7 3 Phaser 4600 4620 Printer Service Manual WD 1 Wiring Revision Xerox Internal Use Only WD 1 IOT Figure 1 IOT system diagram ...

Page 364: ...5 2011 7 4 Phaser 4600 4620 Printer Service Manual WD 2 WD 3 Revision Xerox Internal Use Only Wiring WD 2 IP Board Interface Figure 1 IP Board interface WD 3 MCU Board 1 4 Figure 1 MCU Board 1 4 ...

Page 365: ...5 2011 7 5 Phaser 4600 4620 Printer Service Manual WD 4 WD 5 Wiring Revision Xerox Internal Use Only WD 4 MCU Board 2 4 Figure 1 MCU Board 2 4 WD 5 MCU Board 3 4 Figure 1 MCU Board 3 4 ...

Page 366: ...5 2011 7 6 Phaser 4600 4620 Printer Service Manual WD 6 WD 7 Revision Xerox Internal Use Only Wiring WD 6 MCU Board 4 4 Figure 1 MCU Board 4 4 WD 7 Joint Board 1 2 Figure 1 Joint Board 1 2 ...

Page 367: ...5 2011 7 7 Phaser 4600 4620 Printer Service Manual WD 8 WD 9 Wiring Revision Xerox Internal Use Only WD 8 Joint Board 2 2 Figure 1 Joint Board 2 2 WD 9 IP Board 1 2 Figure 1 IP Board 1 2 ...

Page 368: ...5 2011 7 8 Phaser 4600 4620 Printer Service Manual WD 10 WD 11 Revision Xerox Internal Use Only Wiring WD 10 Laser Unit Figure 1 Laser Unit connections WD 11 HVPS Figure 1 HVPS connections ...

Page 369: ... 2011 7 9 Phaser 4600 4620 Printer Service Manual WD 12 WD 13 Wiring Revision Xerox Internal Use Only WD 12 SMPS Figure 1 SMPS connections WD 13 500 Sheet Feeder Figure 1 500 sheet Feeder system diagram ...

Page 370: ...er 4600 4620 Printer Service Manual WD 14 WD 15 Revision Xerox Internal Use Only Wiring WD 14 500 Sheet Feeder Board 1 2 Figure 1 Feeder Board connections WD 15 500 Sheet Feeder Board 2 2 Figure 1 500 sheet Feeder 2 2 ...

Page 371: ...5 2011 7 11 Phaser 4600 4620 Printer Service Manual WD 16 Wiring Revision Xerox Internal Use Only WD 16 2000 Sheet Feeder Figure 1 2000 sheet Feeder system diagram Figure 2 HCF Feeder Board 1 2 ...

Page 372: ...5 2011 7 12 Phaser 4600 4620 Printer Service Manual WD 16 WD 17 Revision Xerox Internal Use Only Wiring Figure 3 HCF Feeder Board 2 2 WD 17 Finisher Figure 1 Finisher system diagram ...

Page 373: ...5 2011 7 13 Phaser 4600 4620 Printer Service Manual WD 17 Wiring Revision Xerox Internal Use Only Figure 2 Finisher Control Board 1 3 Figure 3 Finisher Control Board 2 3 ...

Page 374: ...5 2011 7 14 Phaser 4600 4620 Printer Service Manual WD 17 WD 18 Revision Xerox Internal Use Only Wiring Figure 4 Finisher Control Board 3 3 WD 18 Mailbox Figure 1 Mailbox system diagram ...

Page 375: ...5 2011 7 15 Phaser 4600 4620 Printer Service Manual WD 18 Wiring Revision Xerox Internal Use Only Figure 2 Mailbox Control Board 1 2 Figure 3 Mailbox Control Board 2 2 ...

Page 376: ...5 2011 7 16 Phaser 4600 4620 Printer Service Manual WD 18 Revision Xerox Internal Use Only Wiring ...

Page 377: ...Revision Xerox Internal Use Only 8 Principles of Operation Phaser 4600 4620 Operational Overview 8 3 Media Handling 8 4 Sensors 8 5 Xerographics 8 7 Major IOT Assemblies 8 11 Phaser 4600 4620 Options 8 20 520 Sheet Feeder 8 20 2000 Sheet Feeder 8 23 Mailbox 8 24 Finisher 8 27 ...

Page 378: ...5 2011 8 2 Phaser 4600 4620 Printer Service Manual Revision Xerox Internal Use Only Principles of Operation ...

Page 379: ...ea coverage 4 Development A magnetic roller in the Drum Cartridge carries a thin layer of developer and toner supplied by an agitator in the cartridge s toner compartment The charging and metering blade inside the cartridge applies a negative charge to the toner and spreads the toner onto the Magnetic Roller The negatively charged toner is transferred to the Areas of the drum surface that have bee...

Page 380: ...e Feed Roller and the Pinch Rollers Tray 2 When the control logic calls for media feed the Nudger Roller moves the sheet to the Feed Roller The Feed Roller moves a single sheet out of the tray and toward the tray s Take Away Roller The Separator Roller ensures only one sheet is fed The media then moves past the Pick Sensor and up the vertical path driven by the Take Away Roller The media continues...

Page 381: ... and light receiver aligned on a single surface Output of the photo receptor is High 4 5 V when light is being reflected back and Low 3 V when it is not Photo receptive sensors consist of a LED in one arm of a U shaped holder and a photo transistor in the other arm When the sensing area is vacant nothing is between the arms of the sensor light falls on the photo receptor sending the signal High If...

Page 382: ...the Level Sensor signaling the control logic to raise the tray bottom plate with the Lift Motor Raising the tray bottom plate pushes media up to achieve optimum force against the Nudger Roller and blocks the Level Sensor resuming paper feed This loop contin ues until the No Paper sensor is activated Paper level sensing operates the same way for Trays 2 through 6 Tray 1 uses No Paper sensing only F...

Page 383: ...negatively charged toners are attracted to the latent image Toner on the OPC drum moves to the media by the positive bias charge applied to the media by the Transfer Roller To better understand how the Drum Car tridge operates the name and function for each Drum Cartridge component is listed below Figure 2 Drum Cartridge components Table 1 Drum Cartridge Components Component Function Drum The Drum...

Page 384: ...e media The negatively charged developed image on the drum is attracted by the media s positive charge and is transferred from the drum to the media Figure 3 Transfer Roller Toner Cartridge The main Drive Assembly drives the Toner Cartridge to deliver toner to the Drum Cartridge Figure 4 Toner Cartridge Waste Toner Cartridge Excess toner is collected through a series of augers and deposited into t...

Page 385: ...ent image The resolution of the dual beam laser is either 600 dpi or 1200 dpi and is determined by the customer setting Both beams are always on For 600 dpi both beams receive the same data For 1200 dpi the beams receive different data resulting in a smaller pixel size The scanner motor turns On when it receives a signal and turns Off after printing ends The motor remains Off in the standby and po...

Page 386: ...essure Roller is pressed against the Heat Roller to melt the toner and bond the image to the media Table 2 Laser Assembly Components Component Function Laser Diode Assembly Produces two laser beams that are turned on and off according to the print data signal Scanner Assembly Consists of a faceted polygonal mirror mounted on the shaft of the scanner motor that reflects the beams to the drum surfac...

Page 387: ...es the Feed Drive Assembly to the Feed Roller No Paper Sensor that detects whether paper is in Tray 1 Figure 1 Tray 1 Feeder Table 4 Fuser Components Component Function Heat Roller The Heat Roller is a metal tube with a coated surface and a Heat Lamp inside As media passes between the Heat Roller and Pres sure Roller the heat fuses the toner to the media Pressure Roller The Pressure Roller maintai...

Page 388: ...ift gear on the Lift Motor shaft to raise the bottom plate Bottom Plate The Lift Motor through the lift gear and tray sector gear turn the lift shaft raising the bottom plate which causes the media to contact the Nudger Roller This activity is monitored by the Lift Sensor The bottom plate also actuates the media level indicator Figure 2 Tray Components Tray 2 and the optional trays are functionall...

Page 389: ... Figure 3 Duplex Unit Exit Assembly The Exit discharges the printed paper out of the printer sending it either to the Output Tray or when installed the optional Mailbox or Finisher Figure 4 Exit Assembly Exit Assembly components include Exit Rollers These rollers eject paper to the Output Tray or feed an installed option Exit Gate The exit gate switches the media path between the Output Tray and i...

Page 390: ... includes 3 motors One drives media transport one drives the Toner Cartridge auger and a third drives the Drum Cartridge The assembly gets 24 VDC power from the SMPS Motor control signals come from the MCU Board Figure 5 Main Drive Assembly Feed Drive Assembly The Feed Drive Assembly drives the Tray 2 feeder and Registration Roller Assembly Figure 6 Feed Drive Assembly Fuser Drive Assembly The Fus...

Page 391: ...Fuser Pressure Roller Figure 8 Fuser Release Drive Assembly Duplex Drive Assembly If 2 sided printing is selected paper is directed through the duplex path The Duplex Drive Assembly reverses direction and loads the paper into the Duplex Unit The paper pauses briefly then continues through the Duplex Unit to the Registration Roller for printing on the opposite side Rollers and solenoid activated ga...

Page 392: ... Board The function of the IP Board is to receive host data through one of the following available ports USB or Ethernet The received host data is buffered and stored and sent to the print engine in a rasterized format The secondary function of the I P Board is to provide print control Con trol Panel control configuration setup error reporting and job recovery The IP Board connects to the MCU Boar...

Page 393: ...ording to information obtained through communications with the IP Board and from sensors and switches located throughout the printer The MCU Board performs these functions Communicates with the Image Processor Controls the print sequence Distributes low DC voltages to various printer components Monitors printer status Maintains a running print count Writes the NVRAM settings Controls printer optio...

Page 394: ...ly Principles of Operation Joint Board The Joint Board provides for intermediary connections on the chassis left side Figure 13 Interconnect Board HVPS Located behind the Rear Door the High Voltage Power Supply HVPS provides high voltage to the OPC drum magnetic roller and Transfer Roller Figure 14 HVPS ...

Page 395: ...e Only SMPS The Switched Mode Power Supply SMPS generates low voltages 5 V and 3 3 V for logic circuits 5 V for laser diodes and 24 V for motors clutches from AC power provided by the Fuser Drive Board Figure 15 SMPS Fuser Drive Board The Fuser Drive Board provides AC power for the Fuser and HVPS Figure 16 Fuser Drive Board ...

Page 396: ...ese options 520 Sheet Feeder 2000 Sheet Feeder Mailbox Finisher Memory Hard Drive and Wireless options are documented in their respective installation instructions 520 Sheet Feeder When one or more optional 520 Sheet Feeders is installed under the printer additional 520 sheet universal trays are available extending the media path These trays are identical to the 520 sheet tray standard with the pr...

Page 397: ... plate also actuates the media level indicator 520 Sheet Feeder Feed Assembly Optional trays are functionally equivalent in terms of the feeder mechanism that moves media from the tray into the printer The driving force from each feeder s Feed Motor is transmitted via a gear assembly to the Feed and Nudger Rollers moving paper from the tray into the printer Figure 2 Feeder Assembly 520 Sheet Feede...

Page 398: ...m the MCU Board Feeder power is provided by the SMPS Figure 5 Feeder Board Size Switch The Size Switch reports the position of the tray end and side guides to the MCU Board The end and side guides adjust to different media sizes by moving them to contact the media edges and hold it in position Size Switch actuators located on the tray are set by the position of the end guide to indicate loaded med...

Page 399: ...e Control Board Level Sensor This sensor located on the Feeder uses an actuator to determine whether paper in the tray is lifted When the flag of the actuator leaves the sensing area the sensor detects that the paper has been lifted Take Away Sensor This sensor located on the upper chute in front of the Feeder uses an actuator to deter mine whether the paper has moved into the media path from the ...

Page 400: ... 2 2000 sheet Feeder drive and electrical Mailbox The Mailbox provides 4 individually assigned 100 sheet output trays This allows for job colla tion or specific output tray assignment The Mailbox Control Board communicates with the MCU Board to receive instructions to activate the IOT exit gate using the Lower Diverter Drive Assembly cam follower and exit gate actuator to divert media into the Mai...

Page 401: ...er the top cover this microswitch monitors the Mailbox rear door position When the rear door is opened power to the drive assemblies is cut off and the firmware enters a reinitiation state Figure 2 Mailbox component locator Mailbox Drive and Electrical The Mailbox uses these components to drive media transport and activate the IOT exit gate and diverters that route media into and out of the Mailbo...

Page 402: ...ation Figure 4 Mailbox Diverter Drive Assemblies Mailbox Control Board Figure 5 The Mailbox Control Board is responsible for all functions within the Mailbox Signals from the MCU Board reach the Mailbox Control Board through the option interface connector located in the right cover Figure 5 Mailbox Control Board ...

Page 403: ...detected by the Entrance Sensor activating the entrance roller driven by the Fin isher Transport Motor The Top Exit Roller is also driven by the Finisher Transport Motor and ejects media into the Stacker Tray Figure 1 Stapled or aligned sets on the Compile Tray are held between the Eject Clamp and the Eject Roller Shaft The clamp paddles attached to the Eject Roller Shaft transfer the compiled set...

Page 404: ... is ejected to the Stacker Tray to avoid ejection jams due to the stacking of multiple stapled sets Offset occurs for these staple positions Offset is not executed for small paper Compile Tray Sensors Motors Left Tamper Home Sensor A photo interrupter to detect the left tamper home position When the left tamper comes to the home position it enters the sensor s sensing area which turns the Left Tam...

Page 405: ...usts position according to the state of the Stack Full and Limit Sensors When media actuates the Stack Full Sensor the Elevator Motor is activated to move the Stacker Tray down until the sensor s signal returns to a Low state If the Limit Sensor is low indicating the Stacker Tray is at its limit of travel a stack full message is displayed on the Con trol Panel If an obstacle blocks the tray from l...

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