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Phaser® 4600/4620 Laser Printer

Phaser 4600/4620 Service Manual
®

Xerox Internal-Use Only

Phaser 4600/4620 Printer Service Manual Service Documentation Phaser 4600/4620 Printer Service Manual 705P01287 Revision - Xerox Internal Use Only 5/2011 Xerox Corporation Customer and Service Training and Information 26600 Parkway - Bldg. 60 P.O. Box 1000, M/S 7060-776 Wilsonville, OR 97070-1000 NOTICE: All service documentation is supplied to Xerox external customers for informational purposes only. Xerox service documentation is intended for use by certified, product trained service personnel only. Xerox does not warrant or represent that such documentation is complete, nor does Xerox represent or warrant that it will notify or provide to such customer any future changes to this documentation. Customer performed service of equipment, or modules, components or parts of such equipment may affect the warranty offered by Xerox with respect to such equipment. You should consult the applicable warranty for its terms regarding customer or third party provided service. If the customer services such equipment, modules, components or parts thereof, the customer releases Xerox from any and all liability for the customer actions, and the customer agrees to indemnify, defend and hold Xerox harmless from any third party claims which arise directly or indirectly from such service. Unpublished rights reserved under the copyright laws of the United States. Contents of this publication may not be reproduced in any form without permission of Xerox Corporation. Copyright protection claimed includes all forms of matters of copyrightable materials and information now allowed by statutory or judicial law or hereinafter granted, including without limitation, material generated from the software programs which are displayed on the screen such as styles, templates, icons, screen displays, looks, etc. Xerox technical training materials and service manuals are intended for use by authorized Xerox service technicians and service partners only and are 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®, PagePackTM, ColorCube®, ProfitAccelertorTM, and Walk-UpTM are trademarks of Xerox Corporation in the United States and/or other countries.

Acrobat®, Adobe® Reader®, Adobe Type Manager®, ATMTM, Illustrator® PageMaker®, Photoshop®, PostScript®, Adobe Brilliant® Screens, Adobe Garamond®, Adobe JensonTM, Birch®, Carta®, IntelliSelect®, Mythos®, Quake®, and Tekton® are trademarks of Adobe Systems Incorporated in the United States and/or other countries. Apple®, AppleTalk®, Bonjour®, EtherTalk®, LaserWriter®, LocalTalk®, Macintosh®, Mac OS®, TrueType®, Apple Chancery®, Chicago®, Geneva®, Monaco®, New York® , and QuickDraw® are trademarks of Apple Computer, Inc. in the United States and/or other countries. HP-GL®, HP-UX®, and PCL® are trademarks of Hewlett-Packard Corporation in the United States and/or other countries. IBM® and AIX® are trademarks of International Business Machines Corporation in the United States and/or other countries. Windows®, VistaTM, Windows ServerTM, and Wingdings® are trademarks of Microsoft Corporation in the United States and/or other countries. Novell®, NetWare®, NDPS®, NDS®, Novell Directory Services®, IPXTM, and Novell Distributed Print ServicesTM are trademarks of Novell, Incorporated in the United States and/or other countries. SunSM, Sun MicrosystemsTM, and SolarisTM are trademarks of Sun Microsystems, Incorporated in the United States and/or other countries. SWOP® is a trademark of SWOP, Inc. UNIX® is a trademark in the United States and other countries, licensed exclusively through X/ Open Company Limited. As an ENERGY STAR® partner, Xerox Corporation has determined that this product meets the ENERGY STAR guidelines for energy efficiency. The ENERGY STAR name and logo are registered U.S. marks. PANTONE® Colors generated may not match PANTONE-identified standards. Consult current PANTONE Publications for accurate color. PANTONE® and other Pantone, Inc. trademarks are the property of Pantone, Inc. © Pantone, Inc., 2000.

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

Revision - Xerox Internal Use Only Phaser 4600/4620 Printer Service Manual

5/2011 i

Introduction

Introduction

5/2011 ii

Revision - Xerox Internal Use Only Phaser 4600/4620 Printer Service Manual

About This Manual
The Phaser 4600/4620 Printer Service Manual is part of a multinational service documentation system organized in the standard Xerox EDOC service manual format. This manual is the primary document used for diagnosing, repairing, maintaining, and troubleshooting these systems. The Service Manual is the controlling publication for a service call. Information on using this document is found in the Introduction section. To ensure understanding of this product, complete the Xerox Service Training Program for this particular printer.

How To Use This Manual
Always start with the Service Call Procedures, Section 1. Perform Initial Actions and verify the problem, then follow the directions given.

How to Differentiate Between Machine Variants
The machine will be identified in this manual by the model identifier 4600/4620. When a procedure, parts list description or other reference is unique amongst different models of machine, the appropriate model designator is indicated. Any artwork is also specific. NOTE: This manual services all configurations of the machine. Ignore references to options not installed on the machine.

Organization
Section titles and the information contained in each is presented in the following paragraphs: Section 1 Service Call Procedures This section is used to start and complete a service call. The procedures in this section will either direct you to a Repair Analysis Procedure (RAP), or identify a faulty component or subassembly. Section 2 Status Indicator Repair Analysis Procedures This section contains the Repair Analysis Procedures (RAPs) and checkouts necessary to diagnose, isolate and repair faults other than image quality faults. Section 3 Image Quality This section contains the Image Quality Repair Analysis Procedures (IQ RAPs), checkouts and setup procedures necessary to diagnose, isolate and repair image quality faults. Section 4 Repairs/Adjustments This section contains the instructions for removal, replacement, and adjustment of parts within the machine. Section 5 Parts List This section contains the detailed and illustrated spare parts list. Any part that 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 Publication Comment Sheet is provided at the rear of the hardcopy manual.

Warnings, Cautions and Notes WARNING
A warning is used whenever an operating or maintenance procedure, practice, condition or statement, if not strictly observed, could result in personal injury. A translated version of all warnings is in Translation of Warnings. CAUTION A caution is used whenever an operation or maintenance procedure, practice, condition or statement, if not strictly observed, could result in damage to the equipment. NOTE: A note is used where it is essential to highlight a procedure, practice, condition or statement.

Component Names
Names of parts that appear in the disassembly procedures may not be exactly the same as the names that appear on the part or listed in the Parts List. For example; a part called the Registration Chute Assembly may appear on the Parts List as Assembly, Chute REGI.

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Introduction

About This Manual, How To Use This Manual

Service Safety Summary
General Guidelines
For qualified service personnel only: Refer also to the preceding Electrical Safety. Avoid servicing alone: Do not perform internal service or adjustment of this product unless another person capable of rendering first aid or resuscitation is present. Use care when servicing with power applied: Dangerous voltages may exist at several points in this product. To avoid personal injury, do not touch exposed connections and components while power is on. Disconnect power before removing the power supply shield or replacing components. Do not wear jewelry: Remove jewelry prior to servicing. Rings, necklaces and other metallic objects could come into contact with dangerous voltages and currents.

Warning Labels
Read and obey all posted warning labels. Throughout the printer, warning labels are displayed on potentially dangerous components. As you service the printer, check to make certain that all warning labels remain in place.

Safety Interlocks
Make sure all covers are in place and all interlock switches are functioning correctly after you have completed a printer service call. If you bypass an interlock switch during a service call, use extreme caution when working on or around the printer.

Warning: Any sub component level repair attempt on all circuit boards and fuser is prohibited."

Electrical Safety
· · · · · · · · Use the Power Cord supplied with the printer. Plug the Power Cord directly into a properly grounded electrical outlet. Do not use a ground adapter plug to connect the printer to an electrical outlet that does not have a ground connection terminal. Do not use an extension cord or power strip. Do not place the system in an area where people might step on the power cord. Do not place objects on the power cord. Do not block the ventilation openings. These openings are provided to prevent overheating of the printer. Do not drop paper clips or staples into the printer.

Operational 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 poor performance and a possible safety hazard. Follow all warnings and instructions marked on, or supplied with, the system, options and supplies.

NOTE: The Total Satisfaction Guarantee is available in the United States and Canada. Coverage may vary outside these areas; please contact your local representative for details.

Maintenance Safety
· · · Do not attempt any maintenance procedure that is not specifically described in the documentation supplied with the printer. Do not use aerosol cleaners. The use of supplies that are not approved may cause poor performance and could create a hazardous condition. Do not burn any consumables or routine maintenance items. For information on Xerox supplies recycling programs, go to www.xerox.com/gwa.

Introduction

Service Safety Summary

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Revision - Xerox Internal Use Only Phaser 4600/4620 Printer Service Manual

Symbols Used On The Product
The following precautionary symbols may appear on the machine. This symbol indicates Danger High Voltage.

Avoid pinching fingers in the printer. Use caution to avoid personal injury.

Figure 5 Pinch Injury Symbol Use caution (or draws attention to a particular component). Refer to the manual(s) for information.

Figure 1 High Voltage Symbol Protective Ground (Earth) symbol.

Figure 6 Use Caution 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

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Introduction

Symbols Used On The Product

Voltage Measurement and Specifications
Measurements of DC voltage must be made with reference to the specified DC Common, unless some other point is referenced in a diagnostic procedure. All measurements of AC voltage should be made with respect to the adjacent return or ACN wire. Table 1 Voltage Measurement and Specifications Voltage Input Power 220 V Input Power 100 V Input Power 120 V +5 VDC +24 VDC Specification 198 VAC TO 254 VAC 90 VAC TO 135 VAC 90 VAC TO 135 VAC +4.75 VDC TO +5.25 VDC +23.37 VDC TO +27.06 VDC

Health and Safety Incident reporting
I. Summary
This section defines requirements for notification of health and safety incidents involving Xerox products (equipment and materials) at customer locations.

II. Scope
Xerox Corporation and subsidiaries worldwide.

III. Objective
To enable prompt resolution of health and safety incidents involving Xerox products and to ensure Xerox regulatory compliance.

IV. Definitions
Incident: An event or condition occurring 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.

Logic Voltage Levels
Measurements of logic levels must be made with reference to the specified DC Common, unless some other point is referenced in a diagnostic procedure. Table 2 Logic Levels Voltage +5 VDC +3.3V H/L Specification H = +3.00 V or greater L = below 0.8 V H = +2 V or greater L =below 0.8 V

V. Requirements
Initial Report: 1. 2. Xerox organizations shall establish a process for individuals to report product incidents to Xerox Environment Health & Safety within 24 hours of becoming aware of the event. The information to be provided at the time of reporting is contained in Appendix A (Health and Safety Incident Report involving a Xerox product). The initial notification may be made by any of the following methods: · For incidents in North America and Developing Markets West (Brazil, Mexico, Latin American North and Latin American South): ­ ­ ­ · Phone* Xerox EH&S at: 1-800-828-6571. Electronic mail Xerox EH&S at: [email protected]. Fax Xerox EH&S at: 1-585-422-6449 [intelnet 8*222 6449].

DC Voltage Measurement in RAPs
The RAPs have been designed so that when it is required to use the DMM to measure a DC voltage, the first test point listed is the location for the red (+) meter lead and the second test point is the location for the black meter lead. For example, the following statement may be found in a RAP. There is +5 VDC from P/J7 to P/J68. In this example, the red meter lead would be placed on P/J7 and the black lead on P/J68. If a second test point is not given, it is assumed that the black meter lead may be attached to chassis ground.

3.

For incidents in Europe and Developing Markets East (Middle East, Africa, India, China and Hong Kong): ­ ­ ­ Phone* Xerox EH&S at: +44 (0) 1707 353434. Electronic mail Xerox EH&S at: [email protected]. Fax Xerox EH&S at: +44 (0) 1707 353914 [intelnet 8*668 3914].

*Initial notification made by phone must be followed within 24 hours by a completed incident report and sent to the indicated electronic mail address or fax number. NOTE: If sending a fax, please also send the original via internal mail.

Introduction

Voltage Measurement and Specifications, Health and

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Responsibilities for resolution: 1. Business Groups/Product Design Teams responsible for the product involved in the incident shall: a. b. 2. a. b. c. 3. a. b. c. d. Manage field bulletins, customer correspondence, product recalls, safety retrofits. Fund all field retrofits.

Regulatory Specifications
Xerox has tested this product to electromagnetic emission and immunity standards. These standards are designed to mitigate interference caused or received by this product in a typical office environment.

Field Service Operations shall: Preserve the Xerox product involved and the scene of the incident inclusive of any associated equipment located in the vicinity of the incident. Return any affected equipment/part(s) to the location designated by Xerox EH&S and/or the Business Division. Implement all safety retrofits. Manage and report all incident investigation activities. Review and approve proposed product corrective actions and retrofits, if necessary. Manage all communications and correspondence with government agencies. Define actions to correct confirmed incidents.

United States (FCC Regulations)
The Phaser 4600/4620 has been tested and found to comply with the limits for a Class 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 in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his/her own expense. There is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment Off and On, the user is encouraged to try to correct the interference by one or more of the following measures: · · · · Reorient or relocate the receiver. Increase the separation between the equipment and receiver. Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. Consult the dealer or an experienced radio/television technician for help.

Xerox EH&S shall:

Any changes or modifications not expressly approved by Xerox could void the user's authority to operate the equipment. To ensure compliance with Part 15 of the FCC rules, use shielded interface cables.

Canada (Regulations)
This Class A digital apparatus (4600/4620) complies with Canadian ICES-003. Cet appareil numérique (4600/4620) de la classe A est conforme à la norme NMB-003 du Canada.

Revision - Xerox Internal Use Only Phaser 4600/4620 Printer Service Manual

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Introduction

Health and Safety Incident reporting, Regulatory

European Union
CE Mark

Translation of Warnings
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. DANGER : Mettez la machine hors tension. Déconnectez le cordon d'alimentation de l'alimentation du client lorsque vous réalisez des tâches qui ne nécessitent pas d'électricité. L'électricité peut être à l'origine de blessures, voire d'un accident mortel. Les pièces amovibles peuvent être à l'origine de blessures. AVVERTENZA: Spegnere la macchina. Scollegare il cavo di alimentazione dall'alimentatore quando si eseguono attività che non richiedono elettricità. L'elettricità può causare morte o lesioni personali. Le parti in movimento possono causare lesioni personali. VORSICHT: Schalten Sie die Stromversorgung der Maschine ab. Ziehen Sie das Stromkabel ab, wenn Sie Aufgaben ausführen, für die keine Stromversorgung benötigt wird. Stromschläge können Todesfällen oder Verletzungen verursachen. Bewegliche Teile können zu Verletzungen führen. AVISO: Apague la electricidad de la máquina. Desconecte el cable de alimentación eléctrica 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.

The CE mark applied to this product symbolizes Xerox's declaration of conformity with the following applicable Directives of the European Union as of the dates indicated: Figure 1 CE Symbol December 12, 2006: Low Voltage Directive 2006/95/EC December 15, 2004: Electromagnetic Compatibility Directive 2004/108/EC This product, if used properly in accordance with the user's instructions, is neither dangerous for the consumer nor for the environment. To ensure compliance with European Union regulations, use shielded interface cables. A signed copy of the Declaration of Conformity for this product can be obtained from Xerox.

WARNING
Do not work in a confined space. 1 m (39 inches) space is needed for safe working. DANGER : Ne pas travailler dans un espace restreint. 1 mètre d'espace est nécessaire pour un dépannage en toute sécurité. AVVERTENZA: Non lavorare in uno spazio limitato; è necessario uno spazio di almeno un metro attorno alla macchina per la sicurezza dell'operatore. VORSICHT: Nur mit ausreichendem Bewegungsspielraum (1 m) arbeiten. AVISO: No trabaje en un espacio reducido. Se necesita 1 metro de espacio para trabajar con seguridad.

WARNING
Use safe handling procedures when removing the module. Refer to GP 16. The module is heavy. DANGER: Conformez-vous aux procédures de manipulation de sécurité pour le retrait du module. Reportez-vous à GP 16. Le module est lourd. AVVERTENZA: Utilizzare procedure di gestione sicure durante la rimozione del modulo. Vedere GP 16. Il modulo è pesante. VORSICHT: Verwenden Sie sichere Vorgehensweisen zum Entfernen des Moduls. Siehe auch GP 16. Das Modul ist sehr schwer. AVISO: Utilice los procedimientos de seguridad cuando elimine el módulo. Consulte el GP 16. El módulo es pesado.

Introduction

Regulatory Specifications, Translation of Warnings

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Revision - Xerox Internal Use Only Phaser 4600/4620 Printer Service Manual

WARNING
Follow the service procedure exactly as written. Use of controls or adjustments other than those specified in this manual, may result in an exposure to invisible laser radiation. During servicing, the invisible laser radiation can cause eye damage if looked at directly. DANGER : Les procédures de dépannage doivent être suivies à la lettre. Si les réglages ou vérifications ne sont pas effectués suivant les instructions de ce manuel, il peut y avoir un risque d'exposition dangereuse au faisceau laser. Celui-ci peut provoquer des lésions oculaires s'il est observé directement. AVVERTENZA: Eseguire le procedure di servizio esattamente come descritto. L'utilizzo di dispositivi di controllo o di registrazione diversi da quelli riportati in questo manuale potrebbe comportare un'esposizione a radiazioni laser invisibili. Tali radiazioni possono danneggiare gli occhi se si guarda direttamente il fascio laser durante gli interventi di servizio. VORSICHT: Die Wartungsarbeiten genau den Anweisungen entsprechend durchführen. Der Umgang mit Steuer- oder Bedienelementen, deren Verwendung nicht ausdrücklich in diesem Handbuch angewiesen wurde, kann dazu führen, dass unsichtbare Laserstrahlung frei gesetzt wird. Direkter Blickkontakt mit dem Laserstrahl kann bleibende Augenschäden verursachen. AVISO: Siga los procedimientos de mantenimiento tal como están descritos. El uso de controles o ajustes no especificados en este manual puede tener como resultado la exposición a radiación láser invisible. Durante las operaciones de mantenimiento, la radiación de láser invisible puede causar daños en los ojos si se mira directamente a ella.

WARNING
Use only Xerox materials and components. This product is safety certified using Xerox materials and components. The use of non Xerox materials and components may invalidate the safety certificate. DANGER : N'utilisez que des matières premières et des composants Xerox. La sécurité du produit est assurée dans le cadre de son utilisation avec des matières premières et des composants Xerox. L'utilisation de matières premières et de composants autres que ceux de Xerox risque d'invalider le certificat de sécurité. AVVERTENZA: Utilizzare solo materiali e componenti Xerox per avvalersi della certificazione di protezione. L'utilizzo di materiali e componenti non Xerox può rendere nulla la certificazione di protezione. VORSICHT: Verwenden Sie nur Materialien und Komponenten von Xerox. Dieses Produkt besitzt die Sicherheitszertifizierung bei Verwendung von Xerox-Materialien und -Komponenten. Die Verwendung von Materialien und Komponenten anderer Hersteller setzt möglicherweise das Sicherheitszertifikat außer Kraft. AVISO: Utilice solo los materiales y componentes Xerox. Este producto dispone de un certificado de seguridad si se utilizan los materiales y componentes Xerox. Este certificado de seguridad no será válido si se utilizan materiales y componentes que no sean de Xerox.

WARNING
Do not touch the fuser while it is hot. DANGER : Ne pas toucher au four pendant qu'il est encore chaud. AVVERTENZA: Non toccare il fonditore quando è caldo. VORSICHT: Fixierbereich erst berühren, wenn dieser abgekühlt ist. AVISO: No toque el fusor mientras está caliente.

WARNING
USA and Canada. Do not install this machine in a hallway or exit route that does not have 1.12 m (44 inches) of space additional to the normal space requirements in front of the machine. To conform with fire regulations this additional 1.12 m (44 inches) of space is needed in front 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 salida que no tenga 1.12 m (44 pulgadas) de ancho delante de la máquina, sin incluir el espacio que ocupe la máquina. Este espacio adicional de 1.12 m (44 pulgadas) delante de la máquina en corredores y rutas de salida es necesario para cumplir los requisitos de las normas sobre incendios.

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Introduction

Translation of Warnings

Phaser 4600/4620 Overview
The Phaser 4600/4620 combines a monochrome laser print engine with a multi-purpose Tray 1 (bypass) and universal media tray, Tray 2. The Output Tray holds 500 20lb. sheets facedown. Phaser 4600/4620 options add memory, media capacity, and functionality. For models not originally equipped, a 160 GB Hard Drive is available. A memory upgrade raises the installed RAM to the 768 MB maximum. Configurations of up to four 520-Sheet Feeders, or an additional 2 520-sheet feeders and the high-capacity 2000-sheet feeder. On the output side, 500 sheet stapler/stacker or 4-bin, 400-sheet Mailbox are available, Figure 1.

Rear View
Figure 2 shows features located at the rear of the system.

Front View

Figure 2 Rear view Table 2 Rear View Figure 1 Front View Table 1 Front View 1. 2. 3. 4. 5. 6. 7. 8. 9. Finisher (Stacker & Stapler) Mailbox Staple Cartridge Door IP Board Cover Filter Cover Printer Stand 2000-Sheet Feeder Media level Indicator 520-Sheet Feeder(s) 10. 11. 12. 13. 14. 15. 16. 17. 18. Tray 2 Front Door Top Door Control Panel Top Cover Toner Cartridge Drum Cartridge Tray 1 (bypass) Tray 1 Media Extension Revision - Xerox Internal Use Only Phaser 4600/4620 Printer Service Manual 1. 2. 3. 4. 5. Finisher Rear Door Rear Door Mailbox Rear Door Waste Toner Cartridge Door AC Input 6. 7. 8. 9. 10. Power Switch Ethernet Connection Configuration Card Slot USB Port Wireless Network Adaptor Slot

Introduction

Phaser 4600/4620 Overview

5/2011 x

Printer Options
Phaser 4600/4620 options include: · · · · · · · · Additional Memory (512 MB) Hard Disk Wireless network adaptor Printer stand 520-sheet Feeder 2000-sheet Feeder with casters Finisher with stapler, 500-sheet stacker. Mailbox, 4-bin, 400-sheets 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: · · One 520-Sheet Feeder (Tray 3) Up to 4, 520-Sheet Feeders (Trays 3, 4, 5, and 6)

Table 1 lists both Service and Sales part numbers for available options and accessories. Table 1 Option and Accessory Part Numbers Item 520-Sheet Feeder 2000-Sheet Feeder Finisher (500-sheet) Mailbox (400-sheet) Duplex Unit Memory Upgrade 160MB Hard Disk Wireless Network Adaptor Stand Service Part Number 050K74180 059K77920 059K77910 050K74190 022N02484 128K01770 007N01651 120K03640 078K00870 Sales Part Number 097N01874 097N01875 097N01876 097N01877 097N01923 097N01878 097N01879 097N01880 097N01916

Hard Disk Drive
The Phaser 4600/4620 supports an internal 160 GB Hard Disk Drive mounted to the IP Board. Features enabled by Hard Drive installation include: · · · · Secure Print Proof Print Save Print Disk Collation

Additional Memory
The Phaser 4600/4620 IP Board includes 1 slot for a 512 MB DDR2 DIMM, Figure 1. Memory must meet these characteristics: · · 200 Pin DDR2 SODIMM Unbuffered, Non-parity

Figure 2 520-Sheet Feeder

The printer's Configuration page lists the amount of RAM installed in the printer.

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Introduction

Printer Options

2000-Sheet Feeder
The 2000-sheet Feeder increases the input capacity of the printer and is attached to the printer underneath Tray 2 or installed 520-sheet Feeders. These additional tray combinations are supported: · · One 2000-Sheet Feeder (Tray 3) Up to 2 520-Sheet Feeders (Trays 3, 4) and 1 2000-Sheet Feeder (Tray 5).

Mailbox
The Mailbox provides four 100-sheet output trays.

Figure 4 Optional Mailbox

Figure 3 2000-Sheet Feeder

Introduction

Printer Options

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Finisher
The finisher provides a 500-sheet, offset Stacker Tray and includes a fixed-head stapler.

Control Panel Layout
The Control Panel consists of one LED, a display window, a keypad, and several buttons. These buttons are used to navigate the menu system, perform functions, and select modes of operation for the printer. Table 1 lists the function of each control.

Figure 1 Control Panel Table 1 Control Panel Features 1. 2. Figure 5 Finisher 3. 4. Back Status LED Display Menu Displays printer settings, status, messages and menus. Enters Menu Mode and scrolls through the available menus. Sends you back one level in the menu. · · · Green: Printer is ready to print. Yellow: Startup sequence or error condition. Flashing: ­ ­ 5. 6. 7. 8. 9. OK Keypad Help (?) Energy Saver Stop Yellow: Error Condition Green: Warming up or Receiving data

Accepts the selected settings. Use to enter alphanumeric characters. Additional information. Illuminates when the printer is in Power Saver mode. Press to enter or exit from Power Saver mode. Press to cancel the current activity.

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Introduction

Printer Options, Control Panel Layout

Routine Maintenance Items
Table 1 Routine Maintenance Items Item Description 1. 2. 3. 4. 5. Pick and nudger Rollers Separator Roller Transfer Roller Fuser Feed Roller Print Life 200,000 pages 100,000 pages 100,000 images 200,000 images 100,000 pages

Consumables
The rated life expectancy of 4600/4620 consumables is listed in Table 1. Table 1 Consumable Life Expectancy Item Description 1. Standard Toner Cartridge High Capacity Toner Cartridge Starter Toner Cartridge 2. 3. 4. 5. Drum Cartridge Waste Toner Cartridge Staple Cartridge Print Life 20,000 cycles 30,000 cycles 10,000 cycles 60,000 cycles Provided with new Toner Cartridge 15,000

Maintenance Kit (Fuser, Feed Rollers, Transfer 200,000 cycles Roller)

Introduction

Routine Maintenance Items

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Revision - Xerox Internal Use Only Phaser 4600/4620 Printer Service Manual

1 Service Call Procedures
Service Call Procedures.................................................................................................. SCP 1 Initial Actions........................................................................................................ SCP 2 First Call Actions .................................................................................................. SCP 3 Normal Call Actions ............................................................................................. SCP 4 Fault Analysis ...................................................................................................... SCP 5 Subsystem Maintenance ..................................................................................... SCP 6 Final Actions ........................................................................................................ SCP 7 Configurations and Options ................................................................................. 1-3 1-4 1-4 1-5 1-5 1-6 1-7 1-8

Revision - Xerox Internal Use Only Phaser 4600/4620 Printer Service Manual

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Service Call Procedures

Service Call Procedures

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Revision - Xerox Internal Use Only Phaser 4600/4620 Printer Service Manual

Service Call Procedures
This section provides an overview of the steps a service technician should take to service the printer and attached options. The printer's diagnostic routines report problems using error messages and fault codes displayed on the Control Panel, logged in the Service Usage Profile, or by flashing LEDs. These error indications serve as the entry point into the troubleshooting process. System problems not directly indicated by or associated with an error message or fault code are covered in Section 6, General Procedures. Print-quality problems are covered in Section 3, Image Quality. The steps listed here are a guide for performing any service on this printer. If you choose not to use these steps, it is recommended that you start at the appropriate troubleshooting procedure and proceed from there. When servicing the printer, follow the safety measures detailed in the Service Safety Summary section. 1. Identify the problem. · · · · · · · · · 2. · · · 3. · · · · 4. · · 5. · Verify the reported problem does exist. Check for any error codes and write them down. Print normal customer prints and service test prints. Make note of any print-quality problems in the test prints. Make note of any mechanical or electrical 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. Follow the cleaning instructions. Verify that the power cord is in serviceable condition. Restart the printer to check if the error reoccurs. Use the troubleshooting procedures to find the root cause of the problem. Use Service Diagnostics to check the printer and optional components. Use the Wiring Diagrams and Plug/Jack Locator to locate test points. Take voltage readings as instructed in the troubleshooting procedure. Use the Parts List to locate a part number. Use the Repair procedures to replace the part. Test the printer to verify the problem is corrected and no new problems arose.

Accessing Engine Fault History
Listed below are three ways in which you can access fault history records. 1. Print (if possible) the Error Message report from the Troubleshooting menu. The error history is listed on the report. NOTE: Error and fault code definitions of the codes appear in Section 2. 2. 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. b. c. Open a web browser. Enter the printer's IP address as the URL. Select Support --> Troubleshooting --> Diagnostics Logs and the fault history displays.

Inspect and clean the printer.

Find the cause of the problem.

Correct the problem.

Final Checkout

Revision - Xerox Internal Use Only Phaser 4600/4620 Printer Service Manual

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Service Call Procedures

Service Call Procedures

SCP 1 Initial Actions
Initial Actions are used to gather information on the machine performance Start a service call with SCP 1 and end with SCP6 Final Actions. Also refer to SCP 7 Configurations and Options.

SCP 2 First Call Actions
First Call Actions are used for the first service call.

Procedure
1. Check the machine configuration with the customer, refer to SCP 7 Machine Configurations and Options. Check that all required hardware and software is installed and/or enabled. Check that all the relevant machine settings are correctly entered, refer to GP 4 System Administration Tools. If a fault is present, go to SCP 3 Normal Call Actions. If there is no fault present, go to SCP 6 Final Actions. Enter the machine details and the customer details in the service log.

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.

2. 3. 4.

WARNING
Do not work in a confined space. 1m (39 inches) space is needed for safe working. NOTE: Ignore any references in this manual to options not installed on the machine. 1. 2. 3. Take note of symptoms or error messages. Ask the operator to describe or demonstrate the problem. Make sure that: a. b. c. 4. 5. The power cord is connected to the wall outlet and to the machine. Paper is loaded correctly and all paper trays and covers are closed If installed, the USB cable or network connection is installed correctly.

If available, check the machine service log book for any previous actions that may be relevant to the call. If this is the first service call to this machine perform SCP 2 First Call Actions, otherwise go to SCP 3 Normal Call Actions.

Service Call Procedures

SCP 1, SCP 2

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Revision - Xerox Internal Use Only Phaser 4600/4620 Printer Service Manual

SCP 3 Normal Call Actions
Normal Call Actions are used to determine the reason for the service call.

SCP 4 Fault Analysis
Fault Analysis is used to identify a fault.

Procedure
NOTE: If a fault message appears at any time. Refer directly to the RAP for the fault message and perform the procedure. If possible, perform the following: 1. 2. 3. 4. 5. Review any defective print samples. Determine that the user accessible settings are correct. If necessary refer to the user documentation. Check all job queues and verify with the customer any requirement to print the documents in memory, before switching off the power or clearing memory. Print the Customer Assistance Report (Call for Assistance), then record the total print count. Go to SCP 4 Fault Analysis.

Procedure
When diagnosing or repairing a fault in a particular subsystem, exercise the machine in all modes until the fault is determined. In the instance of finding more than one fault or failure, correct one fault before going to the next fault. If no fault is found, go to SCP 5 Subsystem Maintenance.

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 Defects
If the image quality is defective, go to the IQ1 Image Quality Entry RAP. For image quality specifications, refer to the following: · · · IQS 1 Solid Area Density. IQS 2 Skew. IQS 3 Registration.

Additional Information
If necessary, refer to the following general procedures and information: · · · · · · · · · · · · · · · · · GP 1 Diagnostics Entry GP 2 Fault Codes and History Files GP 3 System Administration Tools GP 4 Reports GP 5 Firmware Upgrade GP 6 Electrostatic Discharge Prevention GP 7 Machine Specifications GP 8 General Disassembly Precautions GP 9 Service Menu Map GP 10 How to Check a Motor GP 11 How to Check a Sensor GP 12 How to Check a Solenoid or Clutch GP 13 How to Check a Switch GP 14 Separate System Modules GP 15 How to Safely Move heavy Modules GP 16 Machine Lubrication GP 17 Installation Space Requirements

Revision - Xerox Internal Use Only Phaser 4600/4620 Printer Service Manual

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Service Call Procedures

SCP 3, SCP 4

· · · · ·

GP 18 Glossary of Terms GP 19 Restriction of Hazardous Substances (RoHS) GP 20 First Print Output Time GP 21 Media Specifications GP 22 Environmental Data

SCP 5 Subsystem Maintenance
Subsystem Maintenance contains information regarding the component life of the machine.

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. 1. 2. 3. 4. Clean the Pick Rollers on every call. Use the Control Panel to check maintenance item counters. Compare the counter values to those listed in Consumables. Advise the customer of any routine maintenance items that are approaching or over the service limit.

Inspection
Rollers Replace the Rollers when you see any of the following defects: · · · · Flat spots Out 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 in the printer. Inspect the belts for wear. Look for these problems: · · · Loose rubber particles below the belts indicate a worn belt. Missing teeth in the belts. Cracking or moderate fraying; a small amount of fraying is inevitable, so look for other signs of wear before replacing the belt.

Lubrication
The printer is lubricated during assembly at the factory and does not require periodic lubrication. Some parts require lubrication following replacement. These parts are identified in the replacement procedures. When lubricating during replacement, use the grease approved for all Phaser printers. CAUTION Plastic parts will deteriorate when unspecified grease and chemicals are used. To avoid damage to the printer, use only Rheolube 768 grease. · Rheolube 768 Grease: Part Number 070E00890

Service Call Procedures

SCP 4, SCP 5

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Revision - Xerox Internal Use Only Phaser 4600/4620 Printer Service Manual

Component Life
The design life of the major components are shown in Table 1. Environmental conditions and actual use will vary these factors. The component life shown in Table 1 is for reference only. Table 1 Component Life Expectancies Item Description 1. 2. 3. 4. 5. Pick and nudger Rollers Separator Roller Transfer Roller Fuser Feed Roller Print Life 200,000 pages 100,000 pages 100,000 images 200,000 images 100,000 pages

SCP 6 Final Actions
Final Actions are used to evaluate the total operation of the system and to identify the actions required to complete the service call.

Procedure
Complete the following, if a fault is identified, return to SCP 4 Fault Analysis: · · · · · Perform the end of call subsystem maintenance actions, SCP 5 Subsystem Maintenance. Exercise the machine in all modes, printing from all trays. If a fault message is displayed or some other problem is evident, go to SCP 4 Fault Analysis. Make a print of a customer document. If any of the customers selections were changed, return them to the customers preferred settings. 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 previous 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 customer training if required.

HFSI
The High Frequency Service Items are shown in Table 2. Table 2 High frequency service items Item Drum Cartridge Tray 1 Pick Roller Description Recommended life Reference PL 9.10 Item 1 PL 8.10 Item 3 PL 8.15 Item 10 PL 9.10 Item 2 PL 10.10 Item 1 · · ·

The total sides of copies and prints 10k impressions after the last HFSI reset. Sheets fed from Tray 1 after last HFSI reset. 150k feeds 200k feeds 100k impressions 200k impressions

Tray 2 Pick Rollers Sheets fed from Tray 2 after last HFSI reset. Transfer Roller Fuser Total prints after the last HFSI reset. Total prints after the last HFSI reset.

Revision - Xerox Internal Use Only Phaser 4600/4620 Printer Service Manual

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Service Call Procedures

SCP 5, SCP 6

SCP 7 Configurations and Options
Configurations and Options
Refer to Table 1 for basic configurations and options. This service manual covers all configurations. Within this manual ignore any references to options that are not installed. Table 1 Phaser 4600/4620 Configurations Features Processor Speed Memory* Print Speed PS3 Fonts (136) PCL6 Fonts (80 Scalable, 9 Bitmap) USB 2.0 Ethernet Interface Tray 1 (100 sheet) Tray 2 (520 sheet) Tray 3 (520 sheet) Tray 4 (520 sheet) Tray 5 (2000 / 520-sheet) Tray 6 (520-sheet) Duplex Mailbox (4-bin) Finisher Hard Disk Drive Printer Stand Wireless LAN Printer Resolution 4600N 700 MHz 256 MB 55 ppm, Letter 52 ppm A4 Standard Standard Standard 10/100 Base-TX Standard Standard Optional Optional Optional Optional Not available Optional Optional Optional Optional Optional 600 x 600 dpi 1200 Class 4600DN 700 MHz 256 MB 55 ppm, Letter 52 ppm, A4 Standard Standard Standard 10/100 Base-TX Standard Standard Standard Optional Optional Optional Standard Optional Optional Optional Optional Optional 600 x 600 dpi 1200 Class 4600DT 700 MHz 256 MB 55 ppm, Letter 52 ppm, A4 Standard Standard Standard 10/100 Base-TX Standard Standard Standard Optional Optional Optional Standard Optional Optional Optional Optional Optional 600 x 600 dpi 1200 Class 4620DN 700 MHz 256 MB 65 ppm, Letter 62 ppm, A4 Standard Standard Standard 10/100 Base-TX Standard Standard Optional Optional Optional Optional Standard Optional Optional Optional Optional Optional 600 x 600 dpi 1200 Class 4620DT 700 MHz 256 MB 65 ppm, Letter 62 ppm, A4 Standard Standard Standard 10/100 Base-TX Standard Standard Standard Optional Optional Optional Standard Optional Optional Optional Optional Optional 600 x 600 dpi 1200 Class

* All configurations have one memory slot supporting a 512 MB DDR2 DIMM, to a maximum 768 MB total.

Service Call Procedures

SCP 7

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Revision - Xerox Internal Use Only Phaser 4600/4620 Printer Service Manual

2 Status Indicator RAPS
01-100-00 Top Door Open RAP...................................................................................... 01-102-00 Rear Door Open RAP .................................................................................... 01-500-00 Finisher Door Open RAP ............................................................................... 01-700-00 Stapler Door Open RAP ................................................................................ 01-900-00 Mailbox Rear Door Open RAP....................................................................... 03-100-00, 03-110-00 Finisher Interface Error RAP ....................................................... 03-115-00 Mailbox Interface Error RAP .......................................................................... 03-120-00, 03-940-00 Tray 3 Communications Fault RAP ............................................. 03-130-00, 03-950-00 Tray 4 Communications Fault RAP ............................................. 03-140-00, 03-960-00 Tray 5 Communications Fault RAP ............................................. 03-150-00, 03-965-00 Tray 6 Communications Fault RAP ............................................. 03-160-00, 03-990-00 HCF Communications Fault RAP ................................................ 03-305-00 Configuration Card Not Present RAP ............................................................ 03-315-00, 03-325-00 Manufacturer ID RAP .................................................................. 03-335-00 Configuration Card Not Configured RAP ....................................................... 03-410-00 Tray 2 Paper Mismatch RAP ......................................................................... 03-420-00 Tray 3 Paper Mismatch RAP ......................................................................... 03-430-00 Tray 4 Paper Mismatch RAP ......................................................................... 03-440-00 Tray 5 Paper Mismatch RAP ......................................................................... 03-450-00 Tray 1 Paper Mismatch RAP ......................................................................... 03-470-00 Tray 6 Paper Mismatch RAP ......................................................................... 03-480-00 HCF Paper Mismatch RAP ............................................................................ 03-600-00 Memory Failure RAP ..................................................................................... 03-800-00 Hard Disk Drive Failure RAP ......................................................................... 03-970-00 Software Lock Up RAP .................................................................................. 04-100-00 Tray 2 Lift Error RAP ..................................................................................... 04-110-00 Tray 6 Lift Error RAP ..................................................................................... 04-200-00 Tray 3 Lift Error RAP ..................................................................................... 04-300-00 Tray 4 Lift Error RAP ..................................................................................... 04-400-00 Tray 5 Lift Error RAP ..................................................................................... 04-500-00 Main Motor Failure RAP ................................................................................ 04-730-00 HCF Lift Error RAP ........................................................................................ 04-810-00 Rear Fan Failure RAP ................................................................................... 04-930-00 Main Fan Failure RAP ................................................................................... 06-100-00, 06-200-00 LSU Error RAP ............................................................................ 07-110-00 Paper Empty at Tray 2 RAP .......................................................................... 07-120-00 Tray 2 is Open RAP ....................................................................................... 07-130-00 Jam 0 in Tray 2 RAP...................................................................................... 07-210-00 Paper Empty at Tray 3 RAP .......................................................................... 07-220-00 Tray 3 is Open RAP ....................................................................................... 07-230-00, 07-231-00 Jam in Tray 3 RAP ...................................................................... 07-310-00 Paper Empty at Tray 4................................................................................... 07-320-00 Tray 4 is Open RAP ....................................................................................... 07-330-00, 07-331-00 Jam in Tray 4 RAP ...................................................................... 07-410-00 Paper Empty at Tray 5................................................................................... 07-420-00 Tray 5 is Open RAP ....................................................................................... 07-430-00, 07-431-00 Jam in Tray 5 RAP ...................................................................... 07-500-00 Paper Empty in Tray 1 RAP........................................................................... Revision - Xerox Internal Use Only Phaser 4600/4620 Printer Service Manual 2-3 2-3 2-4 2-4 2-5 2-5 2-6 2-6 2-7 2-7 2-8 2-8 2-9 2-9 2-10 2-10 2-11 2-11 2-12 2-12 2-13 2-13 2-14 2-15 2-15 2-16 2-16 2-17 2-18 2-19 2-20 2-21 2-22 2-22 2-23 2-23 2-24 2-24 2-25 2-25 2-26 2-26 2-27 2-27 2-28 2-29 2-29 2-30 07-510-00, 07-700-00 Paper Empty at Tray 6................................................................. 07-520-00 Tray 6 is Open RAP ....................................................................................... 07-530-00 Jam 0 in Tray 1 RAP...................................................................................... 07-531-00, 07-630-00 Jam in Tray 6 RAP ...................................................................... 07-710-00 HCF Out of Paper .......................................................................................... 07-720-00 HCF Door is Open RAP ................................................................................. 07-730-00, 07-731-00 Jam in HCF RAP ......................................................................... 08-100-00 Jam 1 in Registration RAP............................................................................. 08-110-00 Feed Motor Failure RAP ................................................................................ 08-200-00 Jam in Tray 2 RAP......................................................................................... 08-300-00 Jam in Tray 3 RAP......................................................................................... 08-400-00 Jam in Tray 4 RAP......................................................................................... 08-450-00 Jam in Tray 5 RAP......................................................................................... 08-500-00 Jam 2 in Fuser Exit RAP................................................................................ 08-600-00 Jam 0 in Duplex Unit RAP ............................................................................. 08-610-00 Jam 1 in Duplex Unit RAP ............................................................................. 08-650-00 Duplex Unit Not Installed RAP ....................................................................... 08-800-00 Jam in Tray 6 RAP......................................................................................... 08-850-00 Jam in HCF RAP............................................................................................ 09-003-00 Developer Motor Failure RAP ........................................................................ 09-100-00 Toner Low RAP.............................................................................................. 09-200-00, 09-220-00 Toner Empty RAP........................................................................ 09-210-00, 09-270-00 Toner (ADC) Sensor Error RAP .................................................. 09-230-00, 09-250-00 Toner Cartridge CRUM Write/Read Error RAP ........................... 09-240-00 Toner Cartridge Communications Error RAP................................................. 09-271-00 Clean ID (ADC) Sensor RAP ......................................................................... 09-290-00 Adjusting Image Quality RAP......................................................................... 09-300-00 Drum Warning RAP ....................................................................................... 09-400-00 Replace Drum Cartridge RAP........................................................................ 09-500-00 Toner Cartridge Not Installed RAP ................................................................ 09-508-00 Waste Toner Cartridge Near Full RAP........................................................... 09-589-00 Waste Toner Cartridge Full RAP ................................................................... 09-590-00 Waste Toner Cartridge Not Installed RAP ..................................................... 09-591-00 Waste Toner Full Sensor Error RAP.............................................................. 09-600-00 Drum Cartridge Not Installed RAP ................................................................. 09-700-00 Toner Supply Error RAP ................................................................................ 09-800-00, 09-810-00 Invalid Toner Cartridge RAP........................................................ 09-900-00, 09-910-00 Invalid Drum Cartridge RAP ........................................................ 09-920-00 Transfer Unit Error RAP................................................................................. 10-100-00, 10-200-00, 10-300-00 Fuser Thermal Errors RAP........................................ 10-308-00 Fuser Motor Error RAP .................................................................................. 10-500-00, 10-510-00 Fuser End of Life RAP................................................................. 10-700-00, 10-710-00 Fuser Initial Fuse Error RAP........................................................ 12-100-00, 12-487-00 Jam at Finisher Entrance RAP .................................................... 12-200-00 Jam 1 in Finisher RAP ................................................................................... 12-300-00, 12-488-00, 12-489-00 Jam in Finisher Exit RAP .......................................... 12-500-00 Full Stack RAP............................................................................................... 12-605-00 Staples Low RAP ........................................................................................... 2-31 2-31 2-32 2-32 2-33 2-34 2-35 2-36 2-37 2-37 2-38 2-39 2-40 2-41 2-42 2-43 2-43 2-44 2-45 2-46 2-46 2-47 2-47 2-48 2-48 2-49 2-49 2-50 2-50 2-51 2-51 2-52 2-52 2-53 2-53 2-54 2-54 2-55 2-55 2-56 2-56 2-57 2-57 2-58 2-58 2-59 2-59 2-60

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Status Indicator RAPS

12-610-00, 12-855-00 Out of Staples RAP ..................................................................... 12-715-00, 12-716-00 Front Jogger Home Fault RAP .................................................... 12-725-00, 12-726-00 Rear Jogger Home Fault RAP..................................................... 12-735-00, 12-736-00 Support Finger Home Fault RAP................................................. 12-750-00, 12-755-00 Stapler Fault RAP........................................................................ 12-760-00, 12-770-00 Stacker Fault RAP ....................................................................... 12-870-00 Stapler Safety Not Detected RAP .................................................................. 12-906-00, 12-907-00 Jam in Mailbox Entrance RAP..................................................... 12-910-00, 12-920-00, 12-930-00, 12-940-00 Mailbox Bin Full ...................................... 12-911-00, 12-921-00, 12-931-00, 12-941-00 Mailbox Bin Jam ..................................... 12-912-00, 12-922-00, 12-932-00, 12-942-00 Mailbox Bin Jam ..................................... 12-913-00, 12-923-00, 12-933-00, 12-943-00 Mailbox Bin Jam ..................................... 12-915-00 Diverter Fault RAP ......................................................................................... 12-925-00, 12-935-00 Upper Diverter Fault Home RAP ................................................. 12-945-00, 12-955-00 Lower Diverter Fault Home RAP ................................................. 15-110-00 Email Send Failed RAP ................................................................................. 15-120-00 Invalid Recipient Email Address RAP ............................................................ 15-300-00 Network Connection Failure RAP .................................................................. 15-310-00, 15-600-00 Authentication Failure RAP ......................................................... 15-320-00, 15-330-00 Mail Server Connection Failure RAP........................................... 15-700-00 DNS Error RAP .............................................................................................. 17-100-00 IP Address Conflict RAP................................................................................ 17-110-00 Connection Error RAP ................................................................................... 17-120-00 Server Not Found RAP .................................................................................. 17-200-00 Network Cable Disconnected RAP ................................................................ 17-700-00, 17-710-00 BOOTP Server Error RAP ........................................................... 17-800-00, 17-810-00 DHCP Server Error RAP ............................................................. 17-900-00 802.1X Authentication Error RAP .................................................................. 17-910-00 Firmware Upgrade Fault RAP........................................................................

2-60 2-61 2-61 2-62 2-62 2-63 2-63 2-64 2-64 2-65 2-65 2-66 2-66 2-67 2-67 2-68 2-68 2-69 2-69 2-70 2-70 2-71 2-71 2-72 2-72 2-73 2-73 2-74 2-74

Status Indicator RAPS

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Revision - Xerox Internal Use Only Phaser 4600/4620 Printer Service Manual

01-100-00 Top Door Open RAP
01-100-00 The Top Door is not latched. BSD-Reference: WD 1

01-102-00 Rear Door Open RAP
01-102-00 The Rear Door is not latched. BSD-Reference: WD 1

Initial Actions
· · Close the Top Door. Check for obstructions blocking the latch.

Initial Actions
· · Close the Rear Door. Check for obstructions or bent pins in P/J61.

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. Reseat the Toner Cartridge and close the Top Door. The error message is displayed. Y N Complete. Check the Top Door interlock actuators. The interlock actuators are undamaged. Y N Replace the Top Door, REP 28.5. Select dC330 code 01-100. The switch is operational (open/closed). Y N Replace the Top Door Interlock Switch, REP 1.6. Remove the Left Cover (REP 28.3) and check P/J45 and CN9 on the MCU Board. The nections 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 con-

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. Close the Rear Door. The error message is displayed. Y N Complete. Check the Rear Door connection P/J63. The connector is undamaged. Y N Repair or replace the Rear Door, REP 28.6. Select dC330 code 01-300. The connection is operational (open/closed). Y N Repair or replace the Rear Door, REP 28.6. Remove the Right Cover (REP 28.2) and check CN4 on the Joint Board. The connection is secure. Y N Secure the connections. Replace these components in order until the error is corrected. 1. Rear Door, PL 28.25 Item 1 2. 3. Joint Board, PL 9.15 Item 7 Exit Assembly, PL 10.30 Item 25

Revision - Xerox Internal Use Only Phaser 4600/4620 Printer Service Manual

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Status Indicator RAPS

01-100-00, 01-102-00

01-500-00 Finisher Door Open RAP
01-500-00 The Finisher Rear Door is not latched. BSD-Reference: WD 17

01-700