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General Information
The Xerox PhaserTM 4400 Laser Printer Service Manual is the primary document used for repairing, maintaining and troubleshooting. To ensure complete understanding of the product, participation in Xerox Phaser 4400 Service Training is recommended.

Section Contents
Phaser 4400 Laser Printer Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Printer Memory Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Monitoring Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Repackaging Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Parts of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Base Configuration Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Front Panel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Image Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Machine Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 Menu Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13 Printer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Media and Tray Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

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Phaser 4400 Laser Printer Overview
The Phaser 4400 Laser Printer combines a monochrome print engine with an image processor supporting PostScript 3 and PCL5e/6. The Phaser 4400 is a high performance, 26 ppm desktop laser printer with a resolution up to 1200 x 1200 dpi.

Configurations
The Phaser 4400 is available in four configurations. A replaceable "Configuration Upgrade Chip" holds configuration information that enables or disables built-in features as described here. Phaser 4400B The Phaser 4400B is the base configuration laser printer. The printer comes standard with 32 Mbytes of memory, 600 x 600 dpi resolution, USB and Parallel support, a built in Multi-Purpose Tray, and a 550-sheet universal paper tray. Note: The Phaser 4400B reports 32 Mbytes of memory even though it has a 64-Mbyte DIMM installed. In order to get the full 64 Mbytes of memory to be reported as well as activate other features, users need to upgrade to the N-configuration with a Configuration Upgrade Kit, part number 098S04703.

Phaser 4400N The Phaser 4400N is the networking configuration. This configuration includes all the features of the 4400B, but comes with 64 Mbytes of memory, built-in 10/100 Ethernet networking capabilities, and a resolution up to 1200 x 1200 dpi. Phaser 4400DT The Phaser 4400DT includes all the features of the 4400N but comes standard with built in auto-duplexing, and one added 550-sheet feeder. Phaser 4400DXThe Phaser 4400DX includes all the features of the 4400DT, along with a 20-Gbyte hard drive and a Stacker with offset.

Page Description Languages (PDL)
I I I

PCL5e/6 Adobe PostScript 3 PDF 39 PostScript Roman fonts available on all models, plus an additional 97 Roman fonts available with the optional Hard Drive. 81 PCL fonts (more fonts are available with the optional internal Hard Drive.)

Resident Fonts
I I

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Phaser 4400 Laser Printer Service Manual

Printer Memory Configuration
The printer features two slots which accept 32-, 64-, and 128-Mbyte SDRAM DIMMs. All combinations except 32 Mbytes alone are allowed to a maximum of 256 Mbytes. The Phaser 4400B reports 32 Mbytes of memory, even though it has a 64-Mbyte DIMM installed. In order to get the full 64 Mbytes of memory to be reported as well as activate other features, users must upgrade to the N-model with a Configuration Upgrade Kit, part number 098S04703. The Startup page and the Configuration pages list the amount of RAM installed in the printer. If the memory does not meet the following specifications, it is ignored by the printer.
I I I I

PC133 DRAM Standard 144-Pin SODIMM Serial Presence Detect 3.3 Volt

Monitoring Consumables
The status of printer consumables is available through the Supplies Info Menu.
Replaceable Items
Print Cartridge (rated at 5% image coverage of letter-size paper)

Print Life
High-Capacity 15,000 Toner wt. 620 g (1.36 lbs.) Standard-Capacity 10,000 Toner wt. 420 g. (.9 lbs.) up to 200,000

Maintenance Kit (includes Fuser, Transfer Roller, and nine rollers for Feed, Retard, and Nudger Roller assemblies).

Repackaging Information
If the printer must be returned to Xerox and the customer has not saved the shipping box and all internal packaging, a repackaging kit is available for order from the local Customer Support Center. Repackaging Kit: part number 065-0606-00

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Parts of the Printer
The parts of the printer are covered here in three groups:
I I I

Base configuration components Internal components Printer options

Base Configuration Components
3 4 2 1

5 6 7 8
Front view of base configuration No.
1. 2. 3. 4. 5. 6. 7. 8. 9.

9

Description
Paper exit slot Standard Output Tray Front panel Front cover (shown closed) Multi-Purpose Tray (MPT) Multi-Purpose Tray extension Power switch Tray 1 Paper level gauge

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Phaser 4400 Laser Printer Service Manual

1 2 3 4 5 6 7
Rear view of base configuration No.
1. 2. 3. 4. 5. 6. 7. 8. 9.

9

8

Description
Option Cover Rear cover release Rear cover (shown closed) Parallel connector USB connector Ethernet connector Power cord receptacle Left cover Ventilation slots

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Internal Components
1 2 3 4

Front and rear views with covers open No.
1. 2. 3. 4.

Description
Print Cartridge Front cover (shown open) Fuser Rear door (shown open)

Printer Options
The following customer-installed options are available for the Phaser 4400 printer.
Option
32-Mbyte DIMM 64-Mbyte DIMM 128-Mbyte DIMM 4400 Network Upgrade Kit

Customer Description Order Number
97S02923 97S02912 97S02913 98S04703 32-Mbyte Memory 64-Mbyte Memory 128-Mbyte Memory 16-Mbyte Flash ROM for storage of fonts, forms, etc. Configuration Upgrade Chip upgrades a Base printer to a Network printer. Adds hard disk capability to the printer:
I I I

16-Mbyte Flash DIMM 97S02914

20+ Gbyte Hard Drive 97S02917

Stores fonts, forms, etc. Enables collation, proof, secure and save jobs. Provides user documentation, setup and care videos, and printer drivers.

550-Sheet Feeder

97S02878

Provides 550-sheet additional input capacity when used in conjunction with the 550-sheet Paper Tray. You can install one or two 550-Sheet Feeders. Used with the 550-Sheet Feeder. The Tray holds 550 sheets of paper. Provides duplex (two sided) printing capability. Adds 500 sheet output capacity with offset capability. Provides dedicated envelope feed.

550-Sheet Paper Tray 109R00448 Duplex Unit Stacker Envelope Feeder 97S02880 97S02881 97S02879

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1

2 5

3 4
s4400-346

Printer options No.
1. 2. 3. 4. 5.

Description
500-Sheet Stacker Envelope feeder 550-sheet feeder with tray 2 550-sheet feeder with tray 3 Automatic duplex unit

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Front Panel Configuration
The Front Panel consists of one tricolor LED, a display window and six functional keys. These keys navigate the menu system, perform functions and select modes of operation for the printer. The LED (light emitting diode) above the Graphics Display can be green, yellow or red, and can be off, blinking or steady.

LED indications:
Green -- Ready to Print Flashing Green -- Receiving, Processing Data or Printing Flashing Yellow -- Warning Flashing Red -- Error (blinks in unison with Image Processor Health LED)
1

2

3
4

5

7

8

6
s4400_006

Phaser 4400 Front Panel Configuration Front Panel Key Descriptions
1 2 3 4
Status LED Graphic front panel display Cancel Key Back Key

5 6 7 8

Up Arrow Key - scrolls up the menu system Down Arrow Key - scrolls down the menu system OK (select) Key INFO Key - for additional explanation or help

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Phaser 4400 Laser Printer Service Manual

Front Panel Shortcuts Mode
Skip execution of POST diagnostics Print Service Menu Map Reset PostScript NVRAM

Press this selection at power-on
OK INFO BACK+OK When "Password" appears, press UP + DOWN keys within 2 seconds

Enter Service Diagnostics

BACK+INFO

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Image Processor Board
The following components must be transferred from the old board when installing a new Image Processor Board in the printer:
I I I I

SDRAM DIMMs (Slot 1 on the left, slot 2 on the right) NVRAM Configuration Upgrade Chip Flash DIMM

See RRP 9.2 Image Processor Board on page 6-88 for information on replacing the Image Processor Board.

Inside the printer on the Image Processor board are four LEDs shown in the figure. DS210 illuminates when the e-net rate is set to 10 Mbits/sec (off indicates 100 Mbits/sec). DS211 illuminates when a link is established. DS380 is the HEALTH LED. The CPU flashes this LED to indicate that it is "alive", or in the case of a failure, the CPU flashes this LED (and the Front Panel LED, also) with a code to help diagnose the problem. DS390 is the CHECK STOP indicator, which illuminates when various fatal errors occur in the CPU.

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Phaser 4400 Laser Printer Service Manual

Rear Panel Configuration Interfaces
I I I

IEEE 1284 parallel Ethernet 10/100BaseTx USB

On the Ethernet port, the green LED is a RECEIVE DATA indicator and the yellow LED is a TRANSMIT DATA indicator.

Rear Panel DIP Switch Settings
Note: The DIP switch setting information presented here is meant to provide a means of returning to as-shipped status in case the switches have been inadvertently changed. Except in extreme circumstances, the DIP switches should be left in the Normal operating mode.

The DIP switches are defined as follows:
I

Switches 1-2 select the modes of operation, as follows:
SW1
Open Open Closed Closed

DIP Switch Settings Mode of Operation
Normal (or Customer) Manufacturing Developer (no POST) Disaster Recovery (vxWorks only)
I

SW2
Open Closed Closed Open

SW3
Open Open Open Open

SW4
Open Open Open Open

Switch 3 selects whether the rear panel serial port presents PostScript or vxWorks backchannel messages. OPEN presents PostScript; Closed presents vxWorks. Switch 4 is an IP board Reset switch (normally OPEN).

I

Processor Information
The processor used on the Image Processor board is a 266 MHz PowerPC processor.

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Machine Orientation
For servicing the Phaser 4400 Laser Printer, all references to machine orientation are as illustrated below.

Machine Orientation

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Phaser 4400 Laser Printer Service Manual

Menu Map
The menu map shown here lists the choices available when you select Menus, and is printed when you select Print Menu Map from the top level of Menus. The order of menus, items, and values found in the Menu Map is the order in which the menus, items, and values are displayed when scrolling through the menu items. Menus and items in this map marked with a numbered footnote do not appear on the front panel display unless the associated option is installed in the printer. Items in this map marked with an asterisk (*) do not appear on the base configuration 4400B.

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Printer Specifications
Physical Specifications
Physical Dimensions - Printer Dimensions
Size and weight (not including the Print Cartridge, Image Processor Board or any options)

Value
Width: 422 mm x Depth 439 mm x Height 413 mm (16.5 in. x 17.25 in. x 16.25 in.) Weight: 25 Kg (55 lbs.) Packaged Weight: 32.7 kg (72 lbs.)

Printer clearances Clearances
Top (to closest overhead object): Left: Right: Front: Rear: Mounting surface flatness:

Value
With Stacker 102 mm (4.0") Without Stacker 292 mm (11.5") Minimum 12" or 300 mm 300 mm (12 in.) Minimum 600 mm (24 in.) Minimum 600 mm (24 in.) Horizontal bias within 5 of level

Media and Tray Specifications
Refer to the "Paper Tips" pages shown beginning on page 1-15. You can print the Paper Tips pages from the Front Panel by selecting Menus | Supplies Info Menu | Print Paper Tips Page. The following table lists the total paper capacities available with the three paper deck combinations:

Maximum Paper Stack Capacity
Combination
1 2 3

MBF (standard)
100 sheets 100 sheets 100 sheets

1st deck (standard)
550 sheets 550 sheets 550 sheets

2nd deck (option)
-- 550 sheets 550 sheets

3rd deck (option)
-- -- 550 sheets

Total Capacity
650 sheets 1200 sheets 1750 sheets

Note:

Paper stack capacity applies to baseline paper: Xerox 4200/4024 20 lb. Letter and RX 80 A4 (3R91720).

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Phaser 4400 Laser Printer Service Manual

The Paper Tips Pages shown here list the supported paper and paper sizes, and provide the paper specifications for the printer.
Refer to the following tables to ensure the best print-quality and to avoid paper jams. For best results, use Xerox-branded paper as it is guaranteed to produce excellent results on your Xerox PhaserTM 4400 Laser Printer. Print-quality and paper handling performance may vary depending on vendor and type of paper used. Note: If you change the type of paper or transparencies, you must specify the type on the front panel of the printer. For the Multi-Purpose Tray or envelope feeder only: if you change the size of paper, also specify the size on the front panel.

Supported paper and paper sizes
Input
Paper Type
A4 (210 x 297 mm) A5 (148 x 210 mm) A6 (105 x 148 mm)
ISO B5 (176 x 250 mm)
(1) (1) (1) (1) (1) (1)

Output
Envelope Feeder ----(1)

550-Sheet Tray

Multi-Purpose Tray

Standard Tray

500-Sheet Stacker

custom custom

-----

B5 JIS (182 x 257 mm)

Index Card (3 x 5 in.)

--custom
(1)

(1) (1)

-------------

---

Statement (5.5 x 8.5 in.) Executive (7.25 x 10.5 in.) Letter (8.5 x 11 in.) US Folio (8.5 x 13 in.) Legal (8.5 x 14 in.)
Envelopes #10 Commercial (4.12 x 9.5 in.) Monarch (3.87 x 7.5 in.) DL (110 x 220 mm) C5 (162 x 229 mm) B5 (176 x 250 mm) Transparencies A4 (210 x 297 mm) Letter (8.5 x 11 in.) Labels A4 (210 x 297 mm) Letter (8.5 x 11 in.) Capacity(2)
= Short-edge feed (1) Simplex (one-sided) printing only.

custom custom custom custom custom

(1) (1) (1) (1) (1)

(1) (1) (1) (1) (1)

(1) (1) (1) (1) (1)

custom

(1) (1)

(1) (1)

-----

(1) (1)

(1) (1)

-----

550
2

100

75

500

500

(2) Maximum capacity at 75 g/m (20 lb.) paper stock. Capacity is reduced for heavier/thicker stock.

s4400_351

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Custom paper sizes
Input
550-Sheet Tray Simplex (one-sided) Width 98 - 216 mm 3.87 - 8.5 in. 148 - 356 mm 5.83 - 14.0 in. 76 - 216 mm 3.0 - 8.5 in. 127 - 356 mm 5.0 - 14.0 in. 98 - 178 mm 3.87 - 7.0 in. 76 - 216 mm 3.0 - 8.5 in. 127 - 356 mm 5.0 - 14.0 in. 98 - 216 mm 3.87 - 8.5 in. 148 - 356 mm 5.83 - 14.0 in. Multi-Purpose Tray Envelope Feeder Standard Tray

Output
500-Sheet Stacker

Length

148 - 254 mm 5.83 - 10.0 in.

Duplex (two-sided)
182 - 216 mm 7.16 - 8.5 in. 257 - 356 mm 10.12 - 14.0 in. 182 - 216 mm 7.16 - 8.5 in. 257 - 356 mm 10.12 - 14.0 in. Same as Input Same as Input

Width Length

-----

Paper weights
The PhaserTM 4400 Laser Printer supports paper weights as follows: 16 - 130 lbs. (60 - 216 g/m 2) simplex/one-sided 16 - 28 lbs. (60 - 105 g/m2 ) duplex/two-sided Plain Paper: (60 - 120 g/m2) (16 - 32 lb.) Card Stock: (120 - 216 g/m2) (32 - 130 lb.)

Paper tips
If excessive jams occur, flip the paper in the tray or install fresh paper from a newly opened ream. Transparencies should be fanned prior to loading. Other size envelopes may be printed as custom paper sizes. Use only paper envelopes. Do not use envelopes with windows or metal clasps. Label media should be fanned prior to loading. Do not print to label stock once a label has been removed.
s4400_352

Paper Tips Page 2 of 3

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Phaser 4400 Laser Printer Service Manual

Ordering supplies
See

www.xerox.com/officeprinting/4400supplies

for information on ordering supplies.

Xerox Branded Paper
Item Plain Paper Xerox Premier 80 Xerox Premier 80 Xerox 4024 DP statement Xerox 4024 DP Xerox 4024 DP folio Xerox 4024 DP legal Transparencies Xerox 3M Type L transparencies Xerox Clear transparencies Labels Xerox A4 24-up label Xerox Multi-purpose 30-up label A4 (210 x 297 mm) Letter (8.5 x 11 in.) 3R96178 3R12051 A4 (210 x 297 mm) Letter (8.5 x 11 in.) 3R91334 3R4446 A4 (210 x 297 mm) A5 (148 x 210 mm) Statement (5.5 x 8.5 in.) Letter (8.5 x 11 in.) Folio (8.5 x 13 in.) Legal (8.5 x 14 in.) 3R91720 3R91832 3R2072 3R721 3R725 3R727 Paper Size Part Number

Replaceable Items
Item Standard-Capacity Print Cartridge High-Capacity Print Cartridge Maintenance Kit
Contains: a Fuser Cartridge, 1 Transfer Roll, and 9 Feed Rollers.
s4400_353

Part Number 113R00627 113R00628 108R00497 for 110 V (60 Hz) 108R00498 for 220 V (50 Hz)

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Functional Specifications
Characteristic
Printing process

Specification
Recording System - Electro-photographic system (roller charging, single component magnetic toner development) Exposure System - Infrared Laser Diode Beam Scanning Class 1 Laser Product Class 3B Laser, rated at 5 mW output @ 780 nm Fusing System - Heat and pressure

Resolution / Addressability Operating Modes

600/1200 dots per inch (dpi), switchable at full engine speed. Ready Mode: Ready to receive data. Power Saver Mode: entered after a user-specified period of Print Engine inactivity since completion of the last print to minimize energy consumption.

Continuous Operating Printing Speed

Paper Size Low Letter SEF A4 SEF Legal 14" SEF Legal 13" SEF Executive B5 (JIS) SEF 18 18 18 18 18 18

Fuser Medium 26 25 21.5 21.5 26 26

Setting High Extra High 22 22 18 18 22 22 8 8 7.5 7.5 8 8

Duplex (ipm) 19 18 16 16 19 19

Fuser Configuration Temperature

Low - Medium setting Range: 194-209C/ 381-408F

High - Extra High setting Range: 197-212C/ 387-414F Tray 3 (sec) MPT (sec) Simp Dup 9.2 15.5/ 16.3 9.3 15.7/ 17.1 Simp Dup 7.7 7.8 14.0/ 14.8 15.9/ 17.3

First Print Out (Engine speed only)

Tray 1 (t sec) Tray 2 (sec) Paper Size Simp Dup Letter A4 7.5 7.6 13.8/ 14.6 14.0/ 15.4 Simp Dup 8.3 8.4 14.6/ 15.4 14.8/ 16.2

Warm-up time

From a cold start (22 C / 71.6 F ambient temperature) to READY TO PRINT within 70 seconds.

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Phaser 4400 Laser Printer Service Manual

Electrical Specifications
Characteristic
Power supply

Specification
120 VAC (98140 VAC) 50/60 Hz (47 Hz 63 Hz) 220/240 VAC (198264 VAC) 50/60 Hz (47 Hz 63 Hz)

Power consumption

Maximum - 600 Watts Printing - 525 Watts/hour or 1792 Btus/hour Standby - 110 Watts/hour or 375 Btus/hour Power Saver - 20 Watts/hour or 68 Btus/hour Note: No electrical power is supplied to the Fuser assembly in Power Saver Mode.

Environmental Specifications
Characteristic
Operating environment

Specification
535 C / 4195 F @ 15% to 85% Relative Humidity (operating) 0 - 3100 meter (10171 ft.) above sea level

Storage environment with a packed Print Cartridge

Normal condition:12 months maximum at 035 C/3295 F @ 1580% Relative Humidity with no condensation present Severe condition: 1 month maximum at -20 to 0 C / -4 to 32 F or 35 to 40 C / 95 to104 F @ 515 or 8095% Relative Humidity with no condensation present

Storage environment without a packed Print Cartridge

Normal condition: 12 months maximum at -20 to -50 C / -4 to -58 F @ 5-85% Relative Humidity with no condensation present Severe condition: 48 hours maximum at 5060 C / 122140 F @ 85-95% Relative Humidity with no condensation present

Heat Emission Acoustic Noise (MPT closed; options are Duplex Unit, two additional feeders, Envelope Feeder, Stacker) Dust Emission Ozone Emission

Maximum - 2730 BTU; Average - 1603; 102 (sleep mode) Standby: 4.9 B (35.0 dB(A)) Power Saver: 0 dB above background noise Printing (without options): 6.8 B (52.0 dB(A)) Printing (with options): 7.1 B (55.5 dB(A)) No more than 0.075 mg/m3 concentration. No more than 0.02 mg/m3 concentration, measured in accordance with BAM Standard.

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Phaser 4400 Laser Printer Service Manual