Xerox WorkCentre 4150/4250/4260 Service Manual, 2008–2009 (P/N 708P89388)

Xerox’s April 2009 service manual (P/N 708P89388) covers the 2008–2009 WorkCentre 4150, 4250, and 4260 multifunction printers, including the base, s, x, and xf configurations of each model.

PDF Search, Bookmarks, and Page Count

Search and diagram detail: The service text and diagram titles are searchable. Embedded bookmarks open the main chapters and many individual procedures. Zooming helps with small connector, pin, and wire labels, which have limited text search support.

The download is one printable PDF with 484 pages. It contains 482 service-manual pages, including the cover and title page, plus a two-page health and safety incident report form.

Fault Codes, Print Defects, and Component Repairs

These selected service topics show the types of repairs and checks covered. Other examples include USB fault diagnosis and paper-tray lift troubleshooting.

• Fault-code diagnosis: Repair Analysis Procedures (RAPs) for tray and duplex jams, tray communication errors, and fuser heating faults.

• Image quality: Symptom-based checks for blank or black output, banding, unwanted background, ghosting, and poor fusing.

• Drive and power: Main-drive removal, power-supply replacement, and high-voltage power supply (HVPS) replacement procedures.

• Document feeder: Duplex Automatic Document Feeder (DADF) service covers feed rolls, pickup and registration clutches, document-path sensors, and scan and duplex motors.

• Scanner and laser: Scanner and laser scanner unit (LSU) replacement, shading adjustment, DADF side-edge registration, and print lead- and side-edge registration.

• Finisher: Service procedures cover front and rear joggers, support fingers, ejector and stacker drives, and jogger-belt tensioning.

Xerox specifies this manual for certified service technicians trained on these models.

Fault Isolation and Image Quality

Boot-failure checkouts distinguish the controller connections and assemblies to check on the 4150 and 4250/4260. The manual also covers memory and hard-disk faults and toner or drum cartridge communication errors. dC330 Component Control documents sensor-state checks and tests for motors, clutches, and solenoids.

The S600 and Ghosting internal test patterns help distinguish uneven density, image repetition, and fuser offset.

Fax coverage includes coded faults, failures without a code, and interpretation of the embedded fax protocol report. Network and scan-to-email troubleshooting covers connection and mail-server errors. The separate System Administration Guide covers enabling mail-server authentication.

Paper Path, Fuser, and Controller Service

Paper-path repairs cover tray feed assemblies, bypass feed and retard components, registration rolls, and the duplex gate. High-capacity feeder (HCF) procedures apply to the 4250 and 4260.

Fuser disassembly covers the heat roller and bearings, with a separate heat-lamp assembly procedure for the 4250/4260. The repair notes flag the exit-sensor actuator during fuser reinstallation and the thin clutch wires that can break during main-drive removal. The tool list identifies slim Phillips screwdriver 600T02299 for restricted LSU screw access.

Controller service covers main PWB replacement, dC131 NVM Read/Write, and NVM initialization. Local firmware upgrades use ControlCentre over USB on a Windows 2000 or XP PC for the 4150 and a USB flash drive for the 4250/4260. The 4250/4260 hard-disk formatting routine erases stored jobs, scan templates, and address books.

Internal service requires electrical isolation and attention to the manual’s laser and hot-fuser precautions.

Wiring, Parts, and Maintenance References

The 32 wiring diagrams include 4150 input power and distribution (WD 1), the 4250/4260 document feeder (WD 29), and the 4250-specific LSU circuit (WD 32). There are also diagrams for the finisher, extra trays, and high-capacity feeder. The RAPs, PWB connector views, and test-point references help trace a fault between assemblies.

Illustrated parts lists distinguish model-specific assemblies and metered/PagePack versus sold toner cartridges. The configuration chart distinguishes standard and optional fax and finishing equipment. The accessories section covers installation and checkout of the optional Foreign Device Interface.

Component-life tables separate reference design life from High Frequency Service Item (HFSI) replacement guidance for the xerographic module, fuser, transfer roll, and feed components. The manual covers counter resets and threshold settings. Actual component life varies with use and operating conditions. Service tables also list HVPS outputs and fuser operating temperatures.

Examples of Print Defect Spacing and Registration Tolerances

For all three models, the Periodic Printing Defects Check lists recurring black or white spots spaced 94 mm apart as a possible xerographic drum fault and spots spaced 126 mm apart as a possible fuser heat-roller fault.

For simplex and duplex registration checks on portrait A4 or Letter test prints, the manual specifies a lead-edge distance of 12.7 mm ± 0.3 mm and a side-edge distance of 12.7 mm ± 3 mm.