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Error Messages and Codes
Section Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Service Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Service Technician Cautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Voltage Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Using Fault History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Entering Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Service Diagnostics Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Using the Front Panel with Service Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . 2-9 Engine Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Engine NVRAM Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Printer Error Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
Index of Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Error Message Summaries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Image Processor POST Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58
Fault Reporting Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

Introduction
This section covers troubleshooting procedures for the Phaser 4400 Laser Printer's front panel error messages. Only jams and fatal errors will produce an associated numeric code. Error messages and codes are usually specific, making it important that service personnel and users record errors exactly when reporting problems with the printer. Any error code associated with an error message or jam can be viewed by pressing the INFO key. Jam error are displayed at the beginning of the info menu, while engine errors are display at the end. Some procedures require running Service Diagnostics tests to verify a specific printer assembly is operating correctly. Refer to Service Diagnostics on page 2-7. To troubleshoot problems not associated with a front panel error message or code such as ac power, or problems related to print-quality, refer to the section Troubleshooting on page 3-1.

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Service Flowchart
The Service Flowchart outlines one possible approach to troubleshooting and repair of the printer. The Service Flowchart is an overview of the path a service technician could take, using this technical manual, to service the printer and options. If you choose not to use the Service Flowchart, it is recommended that you start at the appropriate troubleshooting table and proceed from there.
Step 1: Identify the Problem: 1. Verify the reported problem does exist. 2. Check for any error codes and write them down. 3. Print Test Prints. 4. Make note of any print-quality problems in the Test Prints. 5. Make note of any mechanical or electrical abnormalities present. 6. Make note of any unusual noise or smell coming from the printer. 7. Print a Usage Profile Report, if the printer is able to print. 8. View the fault history under the Service Tools Menu 9. Verify the AC input power supply is within proper specifications. Step 2: Inspect and Clean the Printer: 1. Switch OFF printer power. 2. Disconnect the AC power cord from the wall outlet. 3. Verify the power cord is free from damage or short circuit and is connected properly. 4. Remove the Print Cartridge and protect it from light. 5. Inspect the printer interior and remove any foreign matter such as paper clips, staples, pieces of paper, dust or toner. 6. Clean the printer interior with a lint-free cloth, dampened slightly with cold water and mild detergent. I Do not use solvents or chemical cleaners to clean the printer interior. I Do not use any type of oil or lubricant on printer parts. I Use only an approved toner vacuum. 7. Clean all rubber rollers with a lint-free cloth, dampened slightly with cold water and mild detergent. 8. Inspect the interior of the printer for damaged wires, loose connections, toner leakage, and damaged or obviously worn parts. 9. If a Print Cartridge appears obviously damaged, replace with a new one. Step 3: Find the Cause of the Problem: 1. Use the Print Engine Error Messages table (page 2-11) or POST Error Code table (page 2-58) to find the cause of the problem. 2. Use Diagnostics to check printer and optional components. 3. Use the Wiring Diagrams and Plug/Jack Locator to locate test points. 4. Take voltage readings at various test points as instructed in the appropriate troubleshooting procedure. 5. Use the Engine Logic Board Test Print on page 3-49, to isolate print capability problems between the print engine the Image Processor Board. Step 4: Correct the Problem: 1. Use the Parts List to locate a part number 2. Use the Removal and Replacement Procedures to replace the part. Step 5: Final Checkout: 1. Test the printer to be sure you have corrected the initial problem and there are no additional problems present.

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Phaser 4400 Laser Printer Service Manual

Service Technician Cautionary Statements
I

Always turn off the printer and remove the AC power cord, unless instructed to do otherwise in a procedure. This is particularly important when checking continuity between wiring. If the printer is kept ON, never touch the conductive parts. Wear an electrostatic discharge wrist strap to help prevent damage to the sensitive electronics on the printer circuit boards. Wait at least 5 minutes after you have switched OFF the printer power for the Fuser to cool before you work on or around the Fuser. If checking a specific part with the covers removed and the interlocks, safety and power switches ON, laser beams may be irradiated from the Laser Unit causing a health hazard. Observe proper precautions at all times. When using service diagnostics to turn motors, drives and/or gears, never touch or interrupt the moving parts as damage to the printer will result.

I I I I

I

Procedures
Using the Troubleshooting Procedures
1. Each Step in a Troubleshooting Procedure instructs you to perform a certain action or procedure. The steps are to be followed sequentially in the order given until the problem is fixed or resolved. 2. The Actions and Questions box contains additional information and/or additional procedures you must follow to isolate the problem. 3. When a procedure instructs you test a component using service diagnostics, see Service Diagnostics on page 2-7 for the detailed steps and functions for testing parts of the printer. 4. The action is followed by a question. If your response to the question is "Yes", then follow the instructions for a "Yes" reply. If your response to the question is "No", then follow the instructions for a "No" reply. 5. Troubleshooting Procedures may ask you to take voltage readings or test for continuity at certain test points within the printer. For detailed diagrams, refer to the section Wiring Data on page 9-1 for complete information on test point locations and signal names. 6. Troubleshooting Procedures often ask you to replace a printer component. The section FRU Disassembly on page 6-1 provides detailed steps for removing and replacing all major parts of the printer. The section Parts Lists on page 7-1 details the location, quantity and part number for all spared parts of the printer.

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General Notes on Troubleshooting
1. Unless indicated otherwise, the instruction "switch ON printer main power" means for you to switch ON printer power and let the printer proceed through POST. 2. When instructed to take voltage, continuity or resistance readings on wiring harness, proceed as follows: check P/J 2321 to P/J 2105 by placing the red probe (+) of your meter on pin 1 of P/J 232, and place the black probe () of your meter on pin 5 of P/J 210. 3. When you are instructed to take voltage readings between "P/J 232 P/J 210" (without specified pin numbers), check all pins. Refer to the section Wiring Data on page 9-1 for the location of all wiring harnesses and pins. 4. When you are instructed to take a voltage reading, the black probe () is generally connected to a pin that is either RTN (Return) or SG (Signal Ground). You can substitute any RTN pin or test point in the printer, and you can use FG (frame ground) in place of any SG pin or test point. 5. Unless a troubleshooting procedure instructs otherwise; before measuring voltages make sure the printer is switched ON, the Imaging Unit and the paper trays are in place, and the interlock switches are actuated. 6. All voltage values given in the troubleshooting procedures are approximate values. The main purpose of voltage readings is to determine whether or not a component is receiving the correct voltage value from the power supply and if gating (a voltage drop) occurs during component actuation. Gating signals may be nothing more than a pulse, resulting in a momentary drop in voltage that may be difficult or impossible to read on the average multi-meter. 7. When a Troubleshooting Procedure instructs you to replace a non-spared component and that component is part of a parent assembly, you should replace the entire parent assembly.

Voltage Measurements
Power and signal grounds are connected to frame ground. You can perform all circuit troubleshooting using the metal frame (chassis) as the grounding point. If you need more information to locate connectors or test points, refer to Wiring Data on page 9-1. Unless otherwise specified, the following voltage tolerances are used within this section.
Voltage Measurements Stated
+3.3 VDC +5.0 VDC

Measured
+3.0 to 3.6 VDC +4.8 to +5.2 VDC

Stated
0.0 VDC

Measured
Less than +0.5 VDC

+24.0 VDC +21.6 to +26.4 VDC

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Phaser 4400 Laser Printer Service Manual

Using Fault History
The printer keeps a record of engine errors and jams. You can access Fault History for either engine errors or jams in one of three ways:
I I I

View the Fault History at the Front Panel. Print the printer's Usage Profile. View or print the Usage Profile from the printer's web page, if the printer is connected to a network.

The errors are presented as a series of one- or two-digit numeric codes. Use the tables in "Interpreting Fault History" to decipher the codes. When an error first occurs, record the error message and code, then cycle power to the printer to see if the error recurs.

Accessing Fault History
1. View the printer's fault history on the front panel. a. Enter Menus, then select Support Menu | Service Tools Menu | Fault History. b. Select Engine Errors or Jam Errors to display the errors. 2. Print (if possible) the Usage Profile from the printer's front panel Support Menu. Fault history information for Engine Errors and Jams is detailed in this report log. 3. If the printer is connected to a network and has a TCP/IP address, view the printer's web page using a web browser. a. Open a web browser. b. Enter the printer's IP address as the URL. c. Select the "Jobs" tab and click the Usage Profile link. You can then click a link to view or to print the Usage Profile.

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Interpreting Fault History Error Codes
The following tables provide a cross-reference of the numeric fault history codes to the Diagnostic Message and code found in Printer Error Messages on page 2-11. These numeric codes are displayed on the Front Panel for both Engine Errors and Jams; in the Usage Profile, the numeric codes are used only in the Engine Error Log (Item 262).
Fault History Codes for Engine Errors Fault History Code
0 1 2 3 4 5

Error

Fault History Code
6 7 8 9 10 --

Error

Fan Failure (U5) Fuser Failure (U4) Motor Failure (U1) IOT NVM Failure (U6) Stacker Failure (E9) Laser failure (U2)

Tray 2/3 Failure (E11) Tray 1 Failure (C3) Tray 2 Failure (C3) Tray 3 Failure (C3) Tray 2 Failure (E11) --

Fault History Codes for Jams Fault History Code
1 2 3 4 5 6 7 8 9 10 11

Jam Code

Fault History Code
12 13 14 15 16 17 18 19 20 21 22

Jam Code

E7-1 E7-2 E7-3 E4-0 E4-2 E4-3 E2-0M E2-1M E2-01 E2-11 E2-02

E2-12 E2-03 E2-13 E2-0E E2-1E E6-1 E6-2 PSE-1 E3-1 E3-2 E7-0

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Phaser 4400 Laser Printer Service Manual

Service Diagnostics
The printer's Service Diagnostics provide the ability to:
I I I I I I I I I

Print the Service Diagnostics Menu Map. Check the current print engine status. Start the Engine Test Print after selecting the print quantity, the source tray, output tray, and simplex or duplex printing. Test the functionality of printer motors and fans, solenoids, and clutches. Test some portions of drive trains by engaging combinations of motors and clutches or solenoids. Test the functionality of sensors, switches, and options by manually toggling each sensor or installing an option. Perform NVRAM adjustments essential to the performance of the printer. Check eight different print engine components. Reset the PS NVRAM locations to factory defaults (see Resetting NVRAM on page 4-7).

Entering Service Diagnostics
To enter Service Diagnostics: While turning on power, press and hold Back + Info until the message "Entering Service Diagnostics" appears on the display, then release the keys. The Service Diagnostics Menu appears. The Service Diagnostic menu has the following selections:
General Status -- Provides current print engine status. Engine Test Print -- Starts the test print. Motors/Fans Tests -- Tests the functionality of the printer Motors/Fan. Main Motor + Clutches/Sol Tests -- Tests the functionality of the main motor plus clutches or Solenoid at the same time. Sensor Tests -- Tests the functionality of sensors, switches, or the presence of options by manually toggling each sensor or installing an option. Some of the sensor tests require cheating the front and/or rear door interlocks.

Note:

The Service Diagnostics Sensor Tests do not include a check of the Tray Stack Height Sensor. Refer to the Stack Height Sensor Checkout on page 3-23.

Solenoid Tests -- Tests the functionality of printer solenoids. Clutch Tests -- Tests the functionality of printer clutches. Engine NVRAM Adjustments -- Perform NVRAM adjustments essential to the performance of the printer.

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Component Checks -- Tests print engine component functions. NVRAM Access -- Lets you reset the PS NVRAM locations to factory defaults. Exit -- Reboots the Printer out of Diagnostics.

Service Diagnostics Menu Map
The Service Diagnostics Menu Map lists the tests available for testing print engine parts and functions while diagnosing printer problems. When you enter Service Diagnostics, the menu items shown in bold type appear on the front panel. When you select one of these items, the list of individual tests appear.

Print Service Menu Map: Prints this page General Status: Provides current print engine status. Engine ROM Version Engine Print Counter Engine Configuration Print Resolution Read Fuser Temperature Read Fuser Set Temperature Engine Test Print: Starts the test print. Print Test pattern Input tray Output tray Duplex Print Quantity

Solenoid Tests:Test the functionality of printer solenoids *MPT Solenoid Stacker Direction Solenoid Clutch tests:Test the functionality of printer clutches. *Registration Clutch *Tray 1 Feed Clutch *Tray 2 Feed Clutch *Tray 3 Feed Clutch *Tray 1 Turn Roll Clutch *Tray 2 Turn Roll Clutch *Tray 3 Turn Roll Clutch *Envelope Feeder Clutch

Engine NVRAM Adjustments: Perform NVRAM adjustments essential to the performance of the printer. Laser Power Setting Motors/Fan Test: Test the functionality for motors/fan. MPT Paper Size Adjustment Duplex Motor High Envelope Paper Size Adjustment Duplex Motor Low Tray 1 Process Direction Exit Motor Forward Tray 2 Process Direction Exit Motor Reverse High Tray 3 Process Direction Exit Motor Reverse Low Envelope Feeder Process Direction Main Motor MPT Process Direction Fan Motor High Speed Tray 1 Scan Direction Laser Scan Motor Tray 2 Scan Direction Stacker Motor Tray 3 Scan Direction Stacker Offset Motor Envelope Feeder Scan Direction Main Motor + Clutch/Sol Tests: * Runs main drive motor with each MPT Scan Direction Duplex Process Direction individual clutch and MPT solenoid. Duplex Scan Direction Tests the functionality of sensors/switches/options by Sensor Tests: Component Checks: manually toggling each sensor or installing an option. Laser Diode Front Cover Switch Detack Saw Output Rear Cover Switch Transfer Roll + Paper Tray Size Read (display paper size, for trays) Transfer Roll Print Cartridge Switch Developer Bias AC Toner Sensor Developer Bias DC Registration Sensor Charge Roll AC Exit Sensor (Fuser) Charge Roll DC Duplex Sensor Stacker Sensor NVRAM Access: This menu lets you reset the PS NVRAM locations to Stacker Full Sensor factory defaults. Output Tray Full Sensor (Printer) PostScript NVRAM Reset Tray 1 Low Paper Sensor Tray 2 Low Paper Sensor Exit: Reboots Printer out of Diagnostics. Tray 3 Low Paper Sensor Tray 1 No Paper Sensor For Service Use Only: Tray 2 No Paper Sensor The Service menu functions are to be used by Xerox service personnel Tray 3 No Paper Sensor and authorized service providers. The printer can be damaged by MPT No Paper Sensor improper use of the built-in service tests. Envelope Feeder No Paper Sensor Envelope Feeder Presence Duplex Unit Presence Stacker Unit Presence

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Phaser 4400 Laser Printer Service Manual

Using the Front Panel with Service Diagnostics
The keys on the Front Panel provide the user interface for Service Diagnostics. The keys and their functions are shown in Front Panel Configuration on page 1-8. After you enter Service Diagnostics, the Up and Down keys allow you to move or scroll the highlight up and down through a menu. When you have highlighted the item you want to select, press OK to enter the selection. When you are selecting a page quantity in the Engine Test Print menu use the OK key to move the highlight to the right. then use the Up or Down key to change the value of the selected digit. when you have entered the desired quantity, use the Back key to enter the selection. Note: If you moved past the digit you want to change, keep pressing the OK key until the highlight wraps to the desired digit.

In most of the Service Diagnostics menus, use the Back key to exit a menu to the level just above. In most cases, scrolling to the end of a menu and selecting Exit takes you back to the Service Diagnostics Main Menu. When you select Read Fuser Temperature from the General Status menu, the temperature is presented in hex values. The following table lists the temperatures that correspond to the hex values displayed.
Fuser Temperature Cross Reference Table Hex value
EE FE FD FC FB F9 F7 F4 F0 EC E7 E1 DA D3

Temperature (C / F)
0C / 32F 10C / 50F 20C / 68F 30C / 86F 40C / 104F 50C / 122F 60C / 140F 70C / 158F 80C / 176F 90C / 194F 100C / 212F 110C / 230F 120C / 248F 130C / 266F

Hex value
CA C6 C1 BD B8 B3 AE A9 A4 99 8F 85 7C 72

Temperature (C / F)
140C / 284F 145C / 293F 150C / 302F 155C / 311F 160C / 320F 165C / 329F 170C / 338F 175C / 347F 180C / 356F 190C / 374F 200C / 392F 210C / 410F 220C / 428F 230C / 446F

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Engine Test Print
The Engine Test Print test pattern (shown on page 4-4) is stored in the Engine Logic Board and is accessible through Service Diagnostics. You can use the Engine Test Print to identify, repair, and validate the operability of printer xerographics and paper handling from all paper sources, options, and output destinations. When you select Engine Test Print from the main Service Diagnostics menu, the following selections are available:
Print Test Pattern -- Starts the print Input Tray -- Allows you to select the paper source Output Tray -- Allows you to select the test print destination Duplex -- Turns duplexing on or off if the Duplex Unit is installed Print Quantity -- Allows you to select the number of test prints to run

Error and Jam Recovery
If the printer encounters a problem while printing the Engine Test Print, it halts printing and displays an error message on the Front Panel. Refer to the Diagnostic Messages in the Print Engine Error Messages table that follows. (The Diagnostic Messages also appear as secondary headings in the Troubleshooting Procedures.) Printing resumes after the problem has been fixed.

Engine NVRAM Default Settings
The following table lists the defaults for each of the Engine NVRAM Adjustments except the paper size adjustments, which have no default settings.
NVRAM Default Table Engine NVRAM Adjustment
Laser Power Tray 1 Process Direction Tray 2 Process Direction Tray 3 Process Direction Envelope Process Direction MPT Process Direction Tray 1 Scan Direction

Default Value
10 8 8 8 8 8 4

Range
0 - 15 0 - 15 0 - 15 0 - 15 0 - 15 0 - 15 0-8

Engine NVRAM Adjustments
Tray 2 Scan Direction Tray 3 Scan Direction Envelope Scan Direction MPT Scan Direction Duplex Process Direction Duplex Scan Direction

Default Value
3 2 4 6 8 4

Range
0-8 0-8 0-8 0-8 0 - 15 0-8

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Phaser 4400 Laser Printer Service Manual

Printer Error Messages
Index of Errors
Front Panel Message Page
Code: Jam E2-## 2-18 2-21 2-22 2-23 2-25

Jam Errors
Jam at Tray [#]. Open Tray [#] and Front Cover. Jam at Envelope Feeder; Remove Feeder and Open Front Cover. Code: Jam E2-#E Jam at MPT; Open Front Cover to Clear. Jam at Front; Open Front Cover to Clear. Jam At Exit; Open Rear Cover To Clear. Code: Jam E2-0M Code: Jam E2-1M Code: Jam E3-# Code: Jam E4-0 Code: Jam E4-2 Code: Jam E4-3 Code: Jam E6-# Code: Jam E7-1 Code: Jam E7-2 Code: Jam E7-3

Jam at Stacker; Open Both Rear Covers to Clear. Jam at Front/Rear; Open Front/Rear Cover to Clear.

2-27 2-29

Paper Size Jam; Check Size and Open Rear Cover to Clear. (PSE-1) Code: Jam PSE-1

2-30

Door and Cover Errors
Close Front Cover/Close Rear Cover. 2-31 2-33 2-34 2-35 2-36 Code: E9-1 Code: E9-2 Code: E9-E 2-36 2-37 2-37 2-38 C3-[#]E 2-43 2-39 2-40 2-51 2-41 2-42 Code: E11 Code: U1 Code: U2 Code: U4 2-52 2-45 2-48 2-49

Consumable Errors
Install or Reseat Print Cartridge. Replace Print Cartridge. Toner is Low. Maintenance Kit is Near End of Life.

Printer Option Errors
Install or Reseat the Duplex Unit. Stacker Failure. Install or Reseat the Envelope Feeder.

Tray and Media Errors
Standard Output Tray is Full. Unload Paper. Tray [#] Failure. Open and Close Tray [#]. Tray [#] Paper is Low. Tray 2 (or Tray 3) Paper is Low. Load MPT with [paper size] [paper type]. No Paper in Tray [#].

Media Mismatch Errors
Load Tray [#] with [paper size] [paper type].

Front Panel Fatal Error Messages and Codes
Tray 2 or 3 Failure. Main Motor Failure. Laser Unit Failure. Fuser Failure.

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Index of Errors (cont'd.)
Front Panel Message
Fan Failure; Power Off Now. Engine Logic Board NVRAM Failure. Code: U5 Code: U6

Page
2-49 2-50

Image Processor POST Error Codes

2-58

Error Message Summaries
Note: The messages listed in the "Diagnostic Message" column appear only in Service Diagnostics while printing Engine Test Prints. The code numbers in these messages also appear as part of the Help information displayed when you press i.
Diagnostic Message
E2-01: Feed Jam E2-02 E2-03 E2-11: Feed Jam E2-12 E2-13

Front Panel Message
Jam At Tray [#]; Open Tray [#] and Front Cover to Clear. Press i.

Error Description
Paper arrives at Registration Sensor too early. Paper does not arrive at Registration Sensor position within the specified time. Paper arrives at Registration Sensor too early. Paper does not arrive at Registration Sensor position within the specified time. Paper arrives at Registration Sensor too early. Paper does not arrive at REG Sensor position within the specified time.

Troubleshooting Procedure
Open Tray [#]. Open Front Cover. Clear Paper Path. Go to Jam at Tray [#]. Open Tray [#] and Front Cover. on page 2-18.

Jam At Envelope Feeder; Remove Feeder and Open Front Cover to Clear. Press i. Jam At MPT; Open Front Cover To Clear. Press i.

E2-0E: Feed Jam

Remove Envelope Feeder. Open Front Cover. Clear Paper Path. Go to Jam at Envelope Feeder; Remove Feeder and Open Front Cover. on page 2-21. Open Front Cover and remove paper. Go to Jam at MPT; Open Front Cover to Clear. on page 2-22.

E2-1E: Feed Jam

E2-0M: Feed Jam

E2-1M: Feed Jam

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Phaser 4400 Laser Printer Service Manual

Error Message Summaries (cont'd.)
Note: The messages listed in the "Diagnostic Message" column appear only in Service Diagnostics while printing Engine Test Prints. The code numbers in these messages also appear as part of the Help information displayed when you press i.
Diagnostic Message
E3-1: Registration Jam

Front Panel Message
Jam at Front; Open Front Cover to Clear. Press i.

Error Description
Paper Late to Fuser sensor after arrival at Registration Sensor. Exit Sensor did not actuate within time after the Registration clutch is actuated.

Troubleshooting Procedure
Open Front Cover. Remove Print Cartridge. Clear Paper Path. Go to Jam at Front; Open Front Cover to Clear. on page 2-23.

E3-2: Registration Jam

1. Registration Sensor did not deactuate within time after actuation of Registration sensor. 2. Registration Sensor is actuated at power-on.

Jam At Exit; Open Rear Cover To Clear. Press i.

E4-0: Exit Jam E4-2: Exit Jam

Paper leaves Exit Sensor early. 1. Paper late off Exit Sensor. 2. Exit Sensor on at power-on.

Open Rear Cover. Clear Paper Path. Go to Jam At Exit; Open Rear Cover To Clear. on page 2-25. Open Rear Cover. Clear Paper Path. Change Paper Setting in Custom Mode to correct size. Go to Jam At Exit; Open Rear Cover To Clear. on page 2-25.

E4-3: Exit Jam

Custom Paper late off Exit Sensor, exceeding the specified time from Registration Sensor.

Jam At Stacker; Open Both Rear Covers to Clear. Press i.

E6-1: Stacker Jam E6-2: Stacker Jam

1. Paper late to Stacker Sensor. 1. Paper late off Stacker Sensor. 2. Stacker Sensor on at power-on.

Open Stacker Rear Door. Clear Paper Path. Open Printer Rear Cover. Clear Paper Path. Go to Jam at Stacker; Open Both Rear Covers to Clear. on page 2-27.

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Error Message Summaries (cont'd.)
Note: The messages listed in the "Diagnostic Message" column appear only in Service Diagnostics while printing Engine Test Prints. The code numbers in these messages also appear as part of the Help information displayed when you press i.
Diagnostic Message
E7-0: Duplex Jam

Front Panel Message
Jam At Front; Open Front Cover To Clear Press i.

Error Description
Paper arrives at Registration Sensor early from Duplex Sensor.

Troubleshooting Procedure
Open front cover. Remove print cartridge. Clear paper path. Go to Jam at Front/Rear; Open Front/Rear Cover to Clear. on page 2-29.

Jam At Rear; Open Rear Cover To Clear. Press i.

E7-1: Duplex Jam E7-2: Duplex Jam

Paper late to Duplex Sensor. 1. Paper late off Duplex Sensor. 2. Duplex Sensor on at power-up.

Open Rear Cover. Remove Duplex Unit. Clear paper path. Go to Jam at Front/Rear; Open Front/Rear Cover to Clear. on page 2-29.

E7-3: Duplex Jam

Paper late to Registration Sensor from Duplex Sensor. Tray [#] is not detected I Tray motor failure I Harness problem I Stack height sensor failure
I

Tray [#] Failure. Open and Close Tray [#]. Press i. No (Load) Paper In Envelope Feeder Press i. Load MPT

C3-#E Tray [#] Not In

Inspect and repair Tray [#]. Tray [#] Failure. Open and Close Tray [#]. on page 2-43. Load Paper into Envelope Feeder. Go to Load Envelope Feeder with [paper size] [paper type]. on page 2-55.

Envelope Feeder Empty

Envelope Feeder is out of paper.

MPT Paper Empty

MPT is out of paper.

Load paper into MPT. Go to Load MPT with [paper size] [paper type]. on page 2-51.

Stacker Is Full, Unload Paper. Press i.

Stacker Output Tray Full

Several prints are delivered to the top tray after the Stacker Full Stack Sensor is actuated. Top Tray is declared full when several prints are delivered to the top tray after the Full Stack Sensor is actuated.

Empty Stacker Tray. Go to Stacker is Full, Unload Paper. on page 2-54. Empty Top Tray. Go to Standard Output Tray is Full. Unload Paper. on page 2-38.

Standard Output Tray is Full, Unload Paper. Press i.

Output Tray Full

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Phaser 4400 Laser Printer Service Manual

Error Message Summaries (cont'd.)
Note: The messages listed in the "Diagnostic Message" column appear only in Service Diagnostics while printing Engine Test Prints. The code numbers in these messages also appear as part of the Help information displayed when you press i.
Diagnostic Message
Tray [#] Empty

Front Panel Message
No Paper In Tray [#] Press i. Load Tray [#] with [paper size] [paper type].

Error Description
Tray [#] is out of paper.

Troubleshooting Procedure
Load paper into Tray [#]. Go to No Paper in Tray [#]. on page 2-41. Load correct size paper in tray. Go to Load Tray [#] with [paper size] [paper type]. on page 2-42

PSE-1: Paper Size Error

Paper Size Error.

Close Front Cover Close Rear Cover. Press i. Install or Reseat The Duplex Unit. Press i. Stacker Failure. Press i. Install or Reseat the Envelope Feeder Press i. Tray 2 or 3 Failure Press i. or Tray 2 Failure Press i.

Close Front Cover/Close Rear Cover

1. Front cover interlock is open. 2. Rear cover interlock is open.

Close Front Cover. Close Rear Cover. Go to Close Front Cover/Close Rear Cover. on page 2-31. Reinstall Duplex Module. Go to Install or Reseat the Duplex Unit. on page 2-36. Reinstall Stacker. Go to Stacker Failure. on page 2-37. Reinstall Envelope Feeder. Go to Install or Reseat the Envelope Feeder. on page 2-37. Reinstall Feeder 2/3. Go to Tray 2 or 3 Failure. on page 2-52.

E9-1: Duplex Unit Fail.

Duplex module removed while power is on.

E9-2: Stacker Unit Fail

Stacker removed while power is on.

E9-E: Envelope Feeder Fail/Reinstall

Envelope feeder module removed while power-on.

E11: Tray 2/3 Fail

Either Tray 2 or Tray 3 was disconnected after power-on.

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2-15

Error Message Summaries (cont'd.)
Note: The messages listed in the "Diagnostic Message" column appear only in Service Diagnostics while printing Engine Test Prints. The code numbers in these messages also appear as part of the Help information displayed when you press i.
Diagnostic Message
PSE-1: Paper Size Error

Front Panel Message
Paper Size Jam; Check Size and Open Rear Cover To Clear. Press i.

Error Description
There is a conflict between the size of the paper, which is detected by the Size Switches, and the length of paper the printer detects by the length of time the Registration Sensor is actuated. 1. Print Cartridge is not installed. 2. The installed Print Cartridge is not the correct one.

Troubleshooting Procedure
Correct the mismatch. Open Rear Cover. Go to Paper Size Jam; Check Size and Open Rear Cover to Clear. (PSE-1) on page 2-30.

Install Or Reseat Print Cartridge Press i. Toner Is Low. Press i.

J3 Missing Print Cartridge.

Install the Print Cartridge, or replace with the correct Print Cartridge. Go to Install or Reseat Print Cartridge. on page 2-33. Go to Toner is Low. on page 2-35.

J5 Toner Low.

Toner Low is detected after 10 prints while Toner Sensor is on. Main Motor speed is less than specified RPM after 1.3 seconds. 1.Transmitting /BD signal is longer than specified value for 10 sec. + t1. 2. The laser power does not reach the specified value. 3. Laser signal intervals become longer than the Fail time interval after Laser warm-up is completed.

Main Motor Failure Press i. Laser Unit Failure Press i.

U1 Motor Fail/Power Off

Power Off and On. Go to Main Motor Failure. on page 2-45. Power Off and On. Go to Laser Unit Failure. on page 2-48.

U2 Laser Fail/Power Off

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Phaser 4400 Laser Printer Service Manual

Error Message Summaries (cont'd.)
Note: The messages listed in the "Diagnostic Message" column appear only in Service Diagnostics while printing Engine Test Prints. The code numbers in these messages also appear as part of the Help information displayed when you press i.
Diagnostic Message
U4 Fuser Fail/Power Off

Front Panel Message
Fuser Failure Press i.

Error Description
Low temperature trouble/Power off (Fuser temperature drops below the set temperature after the Fuser warm-up is complete). I Warm-up fail/Power off (Fuser warm-up does not complete within 110 seconds). I STS Disconnection fail/Power off (Thermistor circuit is detected to be open). I High Temperature trouble/Power off (Fuser temperature rises above the set temperature). I Continuous heat on/Power off (Heat rod is on for 10 seconds when the Main Drive Motor is stopped, after the Fuser warm-up is completed).
I

Troubleshooting Procedure
Go to Fuser Failure. on page 2-49.

Fan Failure Power Off Now Press i. Engine Logic Board NVRAM Failure. Press i.

U5 Fan Fail/Power Off

Main Fan has failed.

Check the Main Fan. Power Off and On. Go to Fan Failure; Power Off Now. on page 2-49.

U6 NVM Fail/Power Off

1. Read error detected during power-on. 2. Write Error detected.

Power Off and On. Go to Engine Logic Board NVRAM Failure. on page 2-50).

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2-17

Jam at Tray [#]. Open Tray [#] and Front Cover.
(E2-##: Feed Jam)
E2-0#: Paper arrives early to the Registration Sensor or is on the sensor at power-on. E2-1#: Paper arrives late to the Registration Sensor.
Paper Jam/Misfeed Troubleshooting Procedure Step Actions and Questions
1 Check the paper in all trays. Check for curled, damaged, or damp paper and for paper that is out of specification.

Yes
Go to step 2.

No
Replace with fresh dry paper that is within specifications. Remove contamination or obstructions.

Is the paper in good condition and does it meet specification?
2 Check all paper paths for contamination, paper, or other obstructions. Go to step 3.

Are all paper paths clean and free of obstructions?
3 1. Enter Service Diagnostics and select Test Print. 2. Run five prints from every paper tray. Go to step 9.

Go to step 4.

Does the problem appear when printing from Tray 2 or 3?
4 1. Remove Tray 1 from the printer. 2. Check the Nudger Roller, Feed Roller, and Retard Roller for contamination and wear. Go to step 5. Clean or replace the Nudger, Feed or Retard Roller as necessary (RRP 3.8 on page 6-36/ RRP 2.1 on page 6-18). Go to Tray Motor Assembly Checkout on page 3-26. Go to Tray 1 Feed Clutch on page 3-29. Replace the Retard, Nudger, and Feed Rollers (RRP 2.1 on page 6-18 and RRP 3.8 on page 6-36).

Are all rolls clean and in good condition?

5

1. Reinsert Tray 1 into the printer. 2. From the rear of the printer, watch the Tray 1 Bottom Plate.

Go to step 6.

Is the Bottom Plate raised fully and evenly?
6 From the rear of the printer, watch the paper feed as you print a test print from Tray 1. Go to step 7.

Do the Nudger Roller and Feed Roller rotate?
7

Is paper fed from the tray to the Turn Roller Assembly?

Go to step 8.

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Phaser 4400 Laser Printer Service Manual

Paper Jam/Misfeed Troubleshooting Procedure (cont'd.) Step Actions and Questions
8

Yes
Go to Registration Sensor on page 3-20. Go to step 10.

No
Go to Turn Roller Clutch Assembly on page 3-28. Remove obstructions and clean chute. Replace paper tray if necessary (PL 2.1 on page 7-6). Go to step 11. Go to step 12.

Does the Turn Roller Assembly move the paper to the Registration Sensor?

9

1. Remove Tray 1. 2. Check the paper chute at the front of the tray (the chute guides paper from Tray 2 to the Tray 1 turn rollers). Check for contamination, paper, or other obstructions.

Is the chute clean and free of obstructions?

10 11

Do the jams occur when feeding from Tray 3.
1. Remove Tray 2 and place the tray in Feeder 1. 2. Place Tray 1 in Feeder 2. 3. Enter Service Diagnostics and select Test Print. 4. Run 20 to 25 test prints from Tray 2.

Go to step 14. The paper tray currently in Feeder 1 appears to be defective. Go to step 18. Go to step 13.

Did all prints complete successfully?

12

1. Remove the tray currently in Feeder 2. 2. Check the Nudger and Feed Rollers in Feeder 2 for contamination and wear.

Are the Feed Rollers clean and in good condition?
13 Check the Tray 2 Turn Roller Assembly for obstructions, contamination, or wear. Replace the Feeder PWB (RRP 11.9 on page 6-128). If the problem persists, replace the Size PWB (RRP 11.19 on page 6-139), then the Engine Logic Board (RRP 9.3 on page 6-89). Go to step 15.

Replace the Feed Rollers (RRP 11.11 on page 6-130). Remove the obstruction; clean, or replace the Turn Roller Assembly (RRP 11.8 on page 6-127).

Are the Turn Rolls clean and in good condition?

14

Remove Tray 1 and Tray 2. Check the paper chute at the front of both trays (the chute guides paper from Tray 3 to the Tray 2 turn rolls and from Tray 2 to the Tray 1 turn rollers). Check for contamination, paper, or other obstructions.

Is the chute clean and free of obstructions?

Remove obstructions and clean chute. Replace paper tray if necessary (PL 2.1 on page 7-6).

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2-19

Paper Jam/Misfeed Troubleshooting Procedure (cont'd.) Step Actions and Questions
15 1. Replace Tray 2. 2. Remove Tray 3 and place the tray in Feeder 1. 3. Place Tray 1 in Feeder 3. 4. Enter Service Diagnostics and select Test Print. 5. Run 20 to 25 test prints from tray 3.

Yes
The paper tray currently in Feeder 1 appears to be defective. Go to step 19. Go to step 17.

No
Go to step 16.

Did all prints complete successfully?

16

1. Remove the tray currently in Feeder 3. 2. Check the Nudger and Feed Rolls in Feeder 3 for contamination and wear.

Are the Feed Rolls clean and in good condition?
17 Check the Tray 3 Turn Roller Assembly for obstructions, contamination, or wear. Go to step 20.

Replace the Feed Rolls (RRP 11.11 on page 6-130). Remove the obstruction, clean, or replace the Turn Roller Assembly (RRP 11.8 on page 6-127). Follow the repair advice in the checkout procedure.

Are the Turn Rolls clean and in good condition?

18

Perform Tray Motor Assembly Checkout on page 3-26 to check the tray motor.

Does it operate correctly?

Check the paper tray for contamination, obstructions, broken or deformed parts. Replace the paper tray if necessary (PL 2.1 on page 7-6). Check the paper tray for contamination, obstructions, broken or deformed parts. Replace the paper tray if necessary (PL 2.1 on page 7-6).

19

Perform Tray Motor Assembly Checkout on page 3-26 to check the tray motor.

Does it operate correctly?

Follow the repair advice in the checkout procedure.

20

Replace the Feeder PWB (RRP 11.9 on page 6-128). If the problem persists, replace in this order:
I I

Size PWB (RRP 11.19 on page 6-139) Engine Logic Board (RRP 9.3 on page 6-89)

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Phaser 4400 Laser Printer Service Manual

Jam at Envelope Feeder; Remove Feeder and Open Front Cover.
(E2-#E: Feed Jam)
E2-0E: Paper arrives at Registration Sensor too early. E2-1E: Paper does not arrive at Registration Sensor position within a specified time.
Envelope Feeder Jam Troubleshooting Procedure Step Actions and Questions
1 1. Remove all envelopes. 2. Check the Envelope Feeder and Printer for contamination, paper scraps, or other obstructions.

Yes
Go to step 2.

No
Clean feeder and remove all obstructions. Replace the Feed Belts (RRP 13.17 on page 6-176). Go to Envelope Feed Clutch on page 3-38. Go to step 5.

Is the printer and Envelope Feeder clean and free of obstructions?
2 Check the Feed Belts. Check for dirt or contamination on the top side and the under side of the belt. Go to step 3.

Are both sides of the belt clean?
3 1. Enter Service Diagnostics and select Clutch Tests. 2. Scroll to Envelope Feeder and press OK. Go to step 4.

Can you hear the clutch energize?

4

1. Press Back. 2. Scroll to Main Motor+Clutch/Sol Tests and press OK. 3. Scroll to Motor+Envelope Feeder. 4. Press OK and watch the Feed Belts and Feed Rollers.

Go to step 7.

Do all the Feed Belts and Feed Rollers rotate?
5 Ensure the Envelope Feeder is installed properly and is contacting the printer drive gear. Go to step 6. Reinstall the Envelope Feeder correctly. Replace the gears as necessary (PL 12.2 on page 7-32).

Is the Envelope Feeder installed correctly?
6 Remove the Envelope Feeder and check the feeder drive gears. Replace the Envelope Feed Clutch (RRP 13.12 on page 6-168). If the problem persists, Replace the Envelope Feeder PWB (RRP 13.3 on page 6-159).

Are all gears in good condition and operating properly?

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2-21

Envelope Feeder Jam Troubleshooting Procedure (cont'd.) Step Actions and Questions
7 Perform Registration Sensor on page 3-20 to check the Registration Sensor.

Yes
Replace the Engine Logic Board (RRP 9.3 on page 6-89).

No
Replace the Registration Sensor (RRP 5.4 on page 6-61).

Is the Registration Sensor operating correctly?

Jam at MPT; Open Front Cover to Clear.
(E2-#M: Feed Jam)
E2-0M: Paper arrives at REG sensor early. E2-1M: Paper arrives at REG sensor late.
Feed Jam Procedure Step Actions and Questions
1 1. Switch the printer power OFF. 2. Open the Front Cover. 3. Check the MPT Chute for contamination or obstructions.

Yes
Go to step 2.

No
Clean the MPT and remove the paper or obstruction. Replace the MPT Feed Roller (RRP 4.3 on page 6-47). Go to MPT Pick Up Solenoid on page 3-30. Check, repair, or replace the Drive Gear (PL 5.1 on page 7-14), Main Drive Gear Assembly (RRP 8.2 on page 6-85), or Main Motor Assembly (RRP 8.1 on page 6-84) as necessary.

Is the MPT free of contamination, paper, or other obstructions?
2 Check the MPT Feed Roller for contamination and wear. Go to step 3.

Is the feed roller clean and in good condition?
3 1. Enter Service Diagnostics and select Solenoid Tests. 2. Scroll to MPT and press OK. Go to step 4.

Can you hear the solenoid energize?
4 1. Open the Front Cover and cheat the Front Cover Interlock. 2. From the Service Diagnostics menu select Motors/Fans Tests and press OK. 3. Scroll to Main Motor and press OK. Go to step 5.

Do the MPT drive gears rotate smoothly?

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Phaser 4400 Laser Printer Service Manual

Feed Jam Procedure (cont'd.) Step Actions and Questions
5 1. Scroll to Main Motor + Clutch/Sol Tests and press OK. 2. Select Main Motor + MPT Sol and press OK.

Yes
Check the Registration Sensor (Registration Sensor on page 3-20).

No
Remove the MPT Chute Assembly (RRP 4.1 on page 6-44) and repair or replace components as necessary. Follow the repair advice in the Registration Sensor check.

Do all of the following occur?
The Feed Roller Shaft rotates? The Pick-up Cams move and allow the Bottom Plate to contact the Feed Roller? I The Feed Roller Shaft stops after one complete revolution?
I I

6

1. Check the Registration Sensor (Registration Sensor on page 3-20).

Is the Registration Sensor good?

If the problem persists, replace the Engine Logic Board (RRP 9.3 on page 6-89).

Jam at Front; Open Front Cover to Clear.
(E3-#: Registration Jam)
E3-1: Paper is late to the Exit Sensor or paper is late off the Registration Sensor. E3-2: Registration Sensor is actuated at power-on.
Registration Jam Troubleshooting Procedure Step Actions and Questions
1 1. Switch the printer power OFF. 2. Open the Front Cover and remove the Print Cartridge. 3. Check the printer for contamination, paper scraps, or other obstructions.

Yes
Go to step 2.

No
Clean components and remove all obstructions.

Is the paper path clean and free of obstructions?
2 1. Open the Rear Cover. 2. Remove the Duplex unit if installed. 3. Open the Fuser Access Cover. 4. Check for contamination, paper scraps, or other obstructions. Go to step 3. Clean components and remove all obstructions.

Is the paper path clean and free of obstructions?
3 1. Remove Fuser. 2. Rotate the Fuser Gear. Go to step 4. Replace the Fuser Assembly (RRP 6.2 on page 6-66). Go to step 5.

Does the Fuser Idler Gear rotate smoothly?

4

Check the paper in all trays.

Is the paper loaded in the paper trays damp, wrinkled, or damaged?

Replace with fresh, dry paper.

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2-23

Registration Jam Troubleshooting Procedure (cont'd.) Step Actions and Questions
5

Yes
Go to step 6.

No
Replace with paper meeting size specifications. Go to Registration Clutch on page 3-27.

Is the paper size used within specifications?

6

1. Reinstall the Fuser. 2. Close the Rear Cover. 3. Cheat the Front Cover Interlock. 4. Enter Service Diagnostics, select Clutch Tests, and press OK. 5. Select Registration and press OK.

Go to step 7.

Can you hear the Registration Clutch energize?
7 1. Press Back to return to the top Diagnostics menu, then select Main Motor+Clutch/Sol tests and press OK. 2. Select Motor+Registration and press OK. Go to step 9. Go to step 8.

Do the Registration Rolls rotate smoothly?
8 Repair or replace as necessary:
I I I I

Registration Rolls (RRP 5.6 on page 6-62) Registration Clutch (RRP 5.5 on page 6-62) Main Drive Gear Assembly (RRP 8.2 on page 6-85) Main Motor Assembly (RRP 8.1 on page 6-84). Go to step 10. Repair or replace the Registration Sensor as necessary (RRP 5.4 on page 6-61). Replace the Fuser Assembly (RRP 6.2 on page 6-66). Clean the Registration Rollers.

9

Perform Registration Sensor on page 3-20 to test the Registration Sensor.

Is the Registration Sensor working correctly?

10

Perform Exit Sensor on page 3-34 to test the Exit Sensor.

Go to step 11.

Is the Exit Sensor working correctly?
11 1. Enter Service Diagnostics (if necessary). 2. Select Engine Test Print and press OK. 3. Run test prints. 4. When the error code appears, inspect the position of lead edge of the paper. Go to step 12.

Does the lead edge of the paper pass between the Transfer Roller and the Print Cartridge Drum?
12

Is the Detack Saw clean and free of contamination?

Go to step 13.

Clean the Detack Saw or Replace the Transport Chute Assembly (RRP 6.1 on page 6-65).

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Phaser 4400 Laser Printer Service Manual

Registration Jam Troubleshooting Procedure (cont'd.) Step Actions and Questions
13 Inspect paper path between Transport Chute Assembly and the Fuser Assembly.

Yes
Replace the Engine Logic Board (RRP 9.3 on page 6-89).

No
Replace the Fuser Assembly (RRP 6.2 on page 6-66).

Does the paper pass through the Fuser Assembly.

Jam At Exit; Open Rear Cover To Clear.
(E4-#: Exit Jam)
E4-0: Paper leaves the Exit Sensor early. E4-2: Paper leaves the Exit Sensor late. The Exit Sensor is on at power-on. E4-3: Custom paper late off the Exit Sensor within a specified time from the Registration Sensor.
Exit Jam Troubleshooting Procedure Step Actions and Questions
1 Check the paper in the paper trays. Ensure that: The paper is installed correctly and the end guide touches the rear of the paper stack. I The paper is within specification. I If Custom Mode is used, the settings are correct.
I

Yes
Go to step 2.

No
Install fresh paper that is within specification or correct settings.

Are all settings correct and is the paper within specification?
2 Check the paper path for contamination, paper, or other obstructions. Go to step 3.

Is the paper path clean and free of obstructions?

Remove obstructions and clean components as necessary. Go to step 4.

3

1. Enter Service Diagnostics and select Engine Test Print. 2. Print 25 prints from Tray 1.

Go to step 6.

When the error code is displayed, is there paper on the Exit Sensor?
4 1. Open the Rear Cover and the Fuser Access Cover. 2. Check the Exit Sensor Actuator. Go to step 5. Repair actuator or replace the Fuser Assembly (RRP 6.2 on page 6-66).

Does the actuator move freely and return to the home position when released?

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2-25

Exit Jam Troubleshooting Procedure (cont'd.) Step Actions and Questions
5 1. Enter Service Diagnostics and select Sensor Tests. 2. Scroll to Exit Sensor (Fuser) and press OK. 3. Open the Fuser Access Cover and use a piece of paper to block and unblock the Exit Sensor.

Yes
Replace Engine Logic Board (RRP 9.3 on page 6-89).

No
Go to Exit Sensor on page 3-34.

Does the message on the display alternate between "With Paper" and "Without Paper" as you block and unblock the sensor?
6 Open the Rear Cover and check the Face Up Chute Assembly for contamination or obstructions.

Go to step 7.

Is the chute assembly clean and free of obstructions?

Clean or replace the Face Up Chute Assembly as necessary (PL 1.2 on page 7-4). Go to Exit Motor on page 3-35. Replace the Exit Rollers or Exit Chute Assembly as necessary (PL 7.1 on page 7-18). Clean or replace the Fuser Assembly (RRP 6.2 on page 6-66), as necessary. Clean or replace the Transport Chute as necessary (RRP 6.1 on page 6-65).

7

1. Scroll to Motors/Fans Tests and press OK. 2. Scroll to Exit Motor Forward and press OK.

Go to step 8.

Does the Exit Motor rotate?
8

Do the Exit Rollers and Pinch Rollers (on the Rear Cover) rotate smoothly?

Go to step 9.

9

Check the Fuser Assembly for obstructions or contamination.

Go to step 10.

Is the Fuser clean and free of obstructions?

10

Check the Transport Chute for contamination or obstructions.

Is the Transport Chute clean and free of obstructions?

Replace the Engine Logic Board (RRP 9.3 on page 6-89).

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Phaser 4400 Laser Printer Service Manual

Jam at Stacker; Open Both Rear Covers to Clear.
(E6-#: Stacker Jam)
E6-1: Paper late to Stacker Sensor. E6-2: Paper late off Stacker Sensor.
Stacker Jam Troubleshooting Procedure Step Actions and Questions
1 1. Open the printer Rear Cover and the Stacker Rear Cover. 2. Check for paper or other obstructions in the paper path.

Yes
Go to step 2.

No
Clear all jammed paper, paper scraps, and obstructions from the printer and the Stacker. Problem solved.

Is the printer free of jammed paper, paper scraps, or other obstructions?

2

1. Enter Service Diagnostics. 2. Select Engine Test Print and press OK 3. Scroll to Print Quantity and press OK. 4. Set the quantity 15 and press Back. 5. Scroll to Output Tray and press OK. 6. Press Down to select Stacker and press OK. 7. Scroll to Print Test Pattern and press OK.

Go to step 3.

Does the error code reappear?
3 1. Enter Service Diagnostics and select Sensor Tests. 2. Scroll to Stacker Sensor test and press OK. 3. Open the Stacker Rear Cover. 4. Press and release the Stacker Exit Sensor Actuator. Go to step 5. Go to step 4.

Does the message on the display alternate between "With Paper" and "Without Paper" as you press and release the actuator?
4 1. Remove the Left Interface Cover (RRP 1.1 on page 6-6), Left Cover (RRP 1.2 on page 6-7), and the Left Plate (RRP 1.11 on page 6-16). 2. On the Engine Logic Board, check the voltage between P/J35 pin 7 and frame ground as you actuate and deactuate the Stacker Exit Sensor Actuator. Replace the Engine Logic Board (RRP 9.3 on page 6-89). Replace the Stacker Exit Sensor (RRP 10.11 on page 6-111). If the problem persists, replace the Stacker PWB (RRP 10.7 on page 6-107). Go to step 6.

Is the voltage +3.3 VDC when deactuated and 0.0 VDC when actuated?

5

1. Exit Sensor Tests and scroll to Motors/Fans Tests. 2. Scroll to Stacker Motor and press OK. The motor should run for about three seconds.

Go to step 8.

Does the Stacker Motor run?

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2-27

Stacker Jam Troubleshooting Procedure (cont'd.) Step Actions and Questions
6 1. Remove the Left Interface Cover (RRP 1.1 on page 6-6), Left Cover (RRP 1.2 on page 6-7), and the Left Plate (RRP 1.11 on page 6-16). 2. Enter Service Diagnostics and select Motors/Fans Tests. 3. Scroll to Stacker Motor. 4. On the Engine Logic Board, measure the voltage between P/J35 pin 6 and frame ground as you press OK.

Yes
Go to step 7.

No
Replace the Engine Logic Board (RRP 9.3 on page 6-89).

Does the voltage drop from +3.3 VDC to +0.5 VDC when OK is pressed?
7 1. Switch the printer power OFF. 2. Remove the Stacker from the printer (RRP 10.1 on page 6-101) and turn the Stacker upside down. 3. Disconnect P/J210 from the Stacker PWB. 4. Check the resistance between pins 1 and 4, pins 1 and 6, pins 2 and 3, and pins 2 and 5 on the disconnected plug. Replace the Stacker PWB (RRP 10.7 on page 6-107). Replace the Stacker Motor (RRP 10.8 on page 6-108).

Are all readings 70 10 ohms?
8 1. Open the Stacker Rear Cover. 2. Press OK to run the Stacker Motor. 3. Check the Stacker rollers. Go to step 9. Repair or replace the Stacker Rollers as necessary (RRP 10.14 on page 6-114/ RRP 10.15 on page 6-115). Repair or replace the Exit Gate as necessary (RRP 6.4 on page 6-69). Replace the Direction Solenoid (RRP 10.10 on page 6-110). If the problem persists, replace the Stacker PWB (RRP 10.7 on page 6-107).

Are the Stacker Rollers rotating smoothly?

9

1. Switch the printer power OFF. 2. Remove the Stacker (RRP 10.1 on page 6-101). 3. Open the printer rear cover and check the movement of the Exit Gate.

Go to step 10.

Does the Exit Gate move freely in both directions when pressed and released?
10 1. Reinstall the Stacker. Note: Each time the printer's rear cover or front cover is opened and closed with power applied, the printer performs a reset. At the completion of the reset, the Exit Gate toggles between fully open and fully closed positions. 2. Open the printer rear cover. Remove the Duplex Unit if installed. 3. Switch the printer power-on. 4. Cheat the Rear Cover Interlock and watch the Exit Gate at the end of reset. 5. Remove then replace the Rear Cover Interlock cheater. Replace the Stacker PWB (RRP 10.7 on page 6-107). If the problem persists, replace the Engine Logic Board (RRP 9.3 on page 6-89).

Does the Exit Gate toggle at the completion of each reset?

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Phaser 4400 Laser Printer Service Manual

Jam at Front/Rear; Open Front/Rear Cover to Clear.
(E7-#: Duplex Jam)
E7-0: Paper arrives at the Registration Sensor early from the Duplex Sensor. E7-1: Paper is late to the Duplex Sensor. E7-2: Paper is late off the Duplex Sensor. The Duplex Sensor is on at power-on. E7-3: Paper is late to the Registration Sensor from the Duplex Sensor.
Duplex Jam Troubleshooting Procedure Step Actions and Questions
1 1. Open the printer and check for paper or other obstructions in the paper path. 2. Remove the Duplex Unit and check the rear entrance chute to the Paper Handler.

Yes
Go to step 2.

No
Clear all jammed paper, paper scraps, and obstructions from the printer. Replace components or Duplex Unit as necessary (RRP 12.1 on page 6-141). Problem solved.

Is the printer free of jammed paper, paper scraps, or other obstructions?
2 Check the Duplex Belt, Rollers, and gears. Check for contamination, wear, and obstructions. Go to step 3.

Are the Duplex rollers, gears, and belt clean and in good condition?

3

1. Reinstall the Duplex Unit and enter Service Diagnostics. 2. Select Engine Test Print and press OK 3. Scroll to Print Quantity and press OK. 4. Set the quantity to 15 and press Back. 5. Scroll to Duplex and press OK. Set duplex to ON. 6. Scroll to Print Test Pattern and press OK.

Clear the jam and press Back. Go to step 4.

Does the error code reappear?
4 1. Select Motors/Fans Tests. 2. Scroll to Duplex Motor High and press OK. The motor should run for about three seconds. 3. Scroll to Duplex Motor Low and press OK. The motor should run for about three seconds. Go to step 5. Go to step 6.

Can you hear the Duplex Motor run at both speeds?

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2-29

Duplex Jam Troubleshooting Procedure (cont'd.) Step Actions and Questions
5 1. Select Sensor Tests. 2. Select Duplex Sensor. 3. Open the Rear Cover and use a narrow strip of paper (approximately 1 inch wide) to actuate and deactuate the Duplex Sensor.

Yes
Perform Registration Sensor on page 3-20 to test the Registration Sensor.

No
Replace the Duplex Sensor (RRP 12.13 on page 6-155). If the problem persists, replace the Engine Logic Board (RRP 9.3 on page 6-89). Replace the Duplex Motor Assembly (RRP 12.8 on page 6-149).

Does the message on the display alternate between "With Paper" and "Without Paper" as you press and release the actuator?

6

1. Remove the Duplex Unit, then remove the Duplex Cover (RRP 12.3 on page 6-143). 2. Disconnect P/J38 from the Duplex PWB. 3. Measure the resistance on the disconnected plug between pin 1 and pin 2; between pin 1 and pin 3; between pin 1 and pin 4; and between pin 1 and pin 5.

Are all four readings between 30 and 37 ohms?

Replace the Duplex PWB (RRP 12.4 on page 6-144). If the problem persists, replace the Engine Logic Board (RRP 9.3 on page 6-89).

Paper Size Jam; Check Size and Open Rear Cover to Clear. (PSE-1)
(PSE-1: Paper size error)
There is a conflict between the size of the paper detected by the printer, and the length of time the Registration Sensor is actuated.
Paper Size Error Troubleshooting Procedure Step Actions and Questions
1 2

Yes
Go to step 3. Replace the Engine Logic Board (RRP 9.3 on page 6-89).

No
Go to step 2. Set MPT size to the size of paper actually installed, then press OK.

Does the problem appear when using Tray 1, 2, or 3?
1. Verify the size of paper currently in the MPT Tray. 2. Select Menus and press OK, then 3. Select Printer Setup Menu and press OK. 4. Select Tray Setup Menu and press OK. 5. Select MPT Setup Menu and press OK. 6. Select Change Paper Size and press OK.

Does the paper size checked in the MPT Setup Menu match the size actually in the MPT?

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Phaser 4400 Laser Printer Service Manual

Paper Size Error Troubleshooting Procedure (cont'd.) Step Actions and Questions
3

Yes
Go to step 4.

No
Replace with paper that meets specifications. Properly set the guides.

Is the paper size in the problem tray within printer specifications?

4

Check the side guides and the Paper Stack End Guide in the problem tray.

Go to step 5.

Are all guides properly set for the size of paper installed?
5 Check the size cam on the left side of the paper tray (see the Paper Size Actuators table below). Go to step 6. Replace the paper tray (PL 2.1 on page 7-6/PL 11.1 on page 7-26). Replace the Tray Size PWB (RRP 3.13 on page 6-42/ RRP 11.19 on page 6-139).

Are the cams in good condition (not broken) and do they move freely as the paper tray end guide is moved.
6 1. Reinstall the paper tray. 2. Enter Service Diagnostics and select Sensor Tests. 3. Scroll to Paper Tray Size Read and press OK. 4. Select "Tray 1 Size" and press OK. 5. Press "Back" and select another tray size until all installed trays are tested. Replace the Engine Logic Board (RRP 9.3 on page 6-89).

Does the paper size displayed on the Front Panel display match the size of the paper actually loaded in the tray?

Close Front Cover/Close Rear Cover.
(Close Front Cover/Close Rear Cover)
Close Front/Rear Cover Troubleshooting Procedure Step Actions and Questions
1 1. Open and close the Front Cover. 2. Inspect the movement of the Interlock Switch.

Yes
Go to step 2.

No
Replace the Front Cover Assembly (PL 1.1 on page 7-2). Replace the Rear Cover Assembly (PL 1.2 on page 7-4). Go to step 4.

Does the actuator tab on the Front Cover press down on the Interlock Switch lever?
2 1. Open and close the Rear Cover. 2. Inspect the movement of the Interlock Switch. Go to step 3.

Does the actuator tab on the Rear Cover press down on the Interlock Switch lever?
3 1. Enter Service Diagnostics and select Sensor Tests. 2. Scroll to Rear Cover Switch test and press OK. 3. Open and close the Rear Cover. Go to step 5.

Does the message on the display alternate between "Closed" and "Open" as you open and close the Rear Cover?

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Close Front/Rear Cover Troubleshooting Procedure (cont'd.) Step Actions and Questions
4 1. Switch the printer power OFF. 2. Remove the Left Interface Cover (RRP 1.1 on page 6-6), Left Cover (RRP 1.2 on page 6-7), and the Left Plate (RRP 1.11 on page 6-16). 3. Disconnect P/J30 from the Engine Logic Board. 4. Measure the resistance between pins 1 and 2 on the disconnected plug as you open and close the Rear Cover.

Yes
Replace the Engine Logic Board (RRP 9.3 on page 6-89).

No
Check the wiring between P/J30 and the Rear Cover Interlock Switch. Repair or replace the wiring or interlock switch (RRP 9.10 on page 6-97) as required. Go to step 6.

Is there continuity when the Rear Cover is closed and infinity when the Rear Cover is open?

5

Open and close the Front Cover.

Does the message on the display alternate between "Closed" and "Open" as you open and close the Front Cover?
6 1. Switch the printer power OFF. 2. Remove the Left Interface Cover (RRP 1.1 on page 6-6), Left Cover (RRP 1.2 on page 6-7), and the Left Plate (RRP 1.11 on page 6-16). 3. Disconnect P/J284 from the LVPS PWB. 4. Measure the resistance between pins 1 and 2 on the disconnected plug as you open and close the Front Cover.

Replace the Engine Logic Board (RRP 9.3 on page 6-89). Go to step 7.

Is there continuity when the Front Cover is closed and infinity when the Front Cover is open?

Check the wiring between P/J284 and the Front Cover Interlock Switch. Repair or replace the wiring or interlock switch (RRP 9.9 on page 6-96) as required. Replace the LVPS (RRP 9.5 on page 6-91).

7

1. Connect P/J284 to the LVPS. 2. Switch the printer power-on. 3. On the Engine Logic Board, check the voltage between P/J28 pin 1 and frame ground.

Is the voltage +24 VDC?

Replace the Engine Logic Board (RRP 9.3 on page 6-89).

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Phaser 4400 Laser Printer Service Manual

Install or Reseat Print Cartridge.
(J3: Missing Print Cartridge)
1. Print Cartridge is not installed or seated correctly. 2. The installed Print Cartridge is not the correct one.
Print Cartridge Installation Troubleshooting Procedure Step Actions and Questions
1 1. Open the Front Cover and remove the Print Cartridge. 2. Inspect the tab on the top center of the Print Cartridge that actuates the Print Cartridge Sensor Assembly.

Yes
Go to step 2.

No
Replace the Print Cartridge (PL 8.1 on page 7-20). Replace the Print Cartridge Sensor Assembly (RRP 7.3 on page 6-81). Go to step 4.

Is the tab on the Print Cartridge intact?
2 Press and release the Print Cartridge Sensor Assembly Actuator. Go to step 3.

Does the Print Cartridge Sensor Assembly Actuator move smoothly?

3

1. Enter Service Diagnostics and select Sensor Tests. 2. Scroll to Print Cartridge Sensor test and press OK. 3. Insert and remove the Print Cartridge a few times.

Does the display alternate between "Not Installed" and "Installed" as you remove and replace the Print Cartridge?
4 1. Switch the printer power OFF. 2. Remove the Left Interface Cover (RRP 1.1 on page 6-6), the Left Cover (RRP 1.2 on page 6-7), and the Left Plate (RRP 1.11 on page 6-16). 3. Install the Print Cartridge. Leave the Front Cover open. 4. Disconnect P/J25 from the Engine Logic Board. 5. On the Engine Logic Board, check for continuity between J21-4 and J25-3, and J25-2 and J25-1 as you insert and remove the Print Cartridge.

Replace the Engine Logic Board (RRP 9.3 on page 6-89). Replace the Engine Logic Board (RRP 9.3 on page 6-89).

Go to step 5.

Is there continuity between J25-4 and J25-3, and J25-2 and J25-1 when you insert the cartridge and no continuity when you remove the cartridge?
5

Is the Print Cartridge a Xerox Phaser 4400 Print Cartridge?

Replace the Print Cartridge Sensor Assembly together with the harness (RRP 7.4 on page 6-81).

Replace Print Cartridge with a Xerox Phaser 4400 Print Cartridge (PL 8.1 on page 7-20).

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Replace Print Cartridge.
(J5: Toner Low)
The Print Cartridge is in a low toner condition.
Print Cartridge Low Toner Troubleshooting Procedure Step Actions and Questions
1 Install a new Print Cartridge.

Yes
Go to step 2.

No
Problem solved.

Does the Replace Print Cartridge message still appear?
2 1. Remove the Front Cover (RRP 1.6 on page 6-11) and the Left Front Cover (RRP 1.7 on page 6-12). 2. Cheat the Front Cover Interlock Switch. 3. On the Connector PWB, check the voltage between P/J42 pin 4 and frame ground. Go to step 5.

Go to step 3.

Is the voltage 0.0 VDC with the print cartridge installed and +3.3 VDC with the print cartridge removed?
3 Check the voltage between P/J42 pin 3 and pin 1.

Is the voltage +24 VDC?
4 On the Connector PWB, check the voltage between P/J231 pin 11 and pin 12.

Replace the Toner Sensor (RRP 5.2 on page 6-59). Replace the Connector PWB (RRP 9.7 on page 6-94).

Go to step 4.

Is the voltage +24 VDC?

Check the Connector Harness Assembly. If OK, replace the Engine Logic Board (RRP 9.3 on page 6-89). Replace the Connector PWB (RRP 9.7 on page 6-94).

5

On the connector PWB, check the voltage between P/J231 pin 9 and frame ground.

Is the voltage 0.0 VDC with the print cartridge installed and +3.3 VDC with the print cartridge removed?

Check th