Lexmark W820 Service Manual
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Lexmark W820 Service Manual

Lexmark W820 Service Manual

4025 series
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TM
Lexmark
W820 Options
4025-XXX
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Tradem m a a r r k k s s
• Index
Lexmark and Lexmark with diamond design are
trademarks of Lexmark International, Inc., registered
in the United States and/or other countries.

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Summary of Contents for Lexmark W820

  • Page 1 • Start Diagnostics • Safety and Notices • Tradem m a a r r k k s s • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 1-800-553-9727. In other countries, contact your point of purchase. Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. PostScript is a registered trademark of Adobe Systems Incorporated.

  • Page 3: Table Of Contents

    4025 Options Contents Preface ................ix Safety Information .
  • Page 4 4025 Options Duplex General Specifications ........1-21 Mailbox .
  • Page 5 4025 Options Feed from Tray 3 ..........1-56 Tray 3 Paper Path Components .
  • Page 6 4025 Options Duplex Tests ............3-2 Feed Test .
  • Page 7 4025 Options Mailbox Exit Roll and Bin Gate ........4-38 Mailbox Entrance Sensor .
  • Page 8 4025 Options Tray 5 Retard Assembly ........4-102 Tray 5 Feed, Nudger, and Retard Rolls .

  • Page 9: Preface

    4025 Options Preface This manual describes the options for the Lexmark W820 printer: Envelope Feeder, Duplex Unit, Mailbox, and High Capacity Feeder. It contains maintenance procedures for service personnel only and is divided into the following chapters: General Information contains a general description of the printer options and the maintenance approach used to repair them.

  • Page 10: Safety Information

    This product is designed, tested and approved to meet strict global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts.
  • Page 11 Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio. • La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento.
  • Page 12 Aquest producte està dissenyat, comprovat i aprovat per tal d'acomplir les estrictes normes de seguretat globals amb la utililització de components específics de Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi.

  • Page 13: General Information

    4025 Options 1. General Information Maintenance Approach The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part for the Envelope Feeder, Duplex, Mailbox, and High Capacity Feeder options. Use the appropriate error code table, symptom table, error code service checks and symptom service checks to determine the corrective action necessary to repair the failing option.

  • Page 14: Printer Power Supply And Electrical Components

    4025 Options Printer Power Supply and Electrical Components Before starting any service procedure, switch off the printer power and unplug the power cord from the wall outlet. If you must service the options with the printer power applied, be aware of the potential for electrical shock. CAUTION: Do not touch any electrical component unless you are instructed to do so by a service procedure.

  • Page 15: Printer Fuser Components

    4025 Options To avoid permanent eye damage, follow these directions: • Before starting any service procedure, switch off the printer power and unplug the power cord from the AC wall outlet. • Do not disassemble the printer Printhead Assembly or any laser component that displays a Laser Warning sticker.

  • Page 16: Envelope Feeder

    4025 Options Envelope Feeder Envelope Feeder Overview • The Envelope Feeder is a customer installed option that feeds envelopes into the printer. • The Envelope Feeder is easily installed in place of the printer MP Feeder. • The printer base engine LVPS provides all of the DC voltages required by the Envelope Feeder.

  • Page 17: Schematic Diagram Of The Envelope Feeder Operation

    4025 Options Schematic Diagram of the Envelope Feeder Operation The following illustration is a simplified schematic of printer Envelope Feeder components, subsystems, and paper paths. General Information...

  • Page 18: Envelope Feeder Power And Control

    4025 Options Envelope Feeder Power and Control All active components within the Envelope Feeder are electrically connected to the Envelope PWB. The Base Engine Low Voltage Power Supply supplies +5VDC and +24VDC to the I/O PWB, and the I/O PWB supplies +5VDC and +24VDC to the Envelope PWB.

  • Page 19: Envelope Feeder Control

    4025 Options Envelope Feeder Control Envelope Feeder Control is a broad term used to describe the printer resources that monitor and control the actions and operations of the printer and the Envelope Feeder; from envelope feed to Envelope Feeder error detection. The center of Envelope Feeder control is the Envelope PWB.

  • Page 20: Envelope Feeder Control Components

    4025 Options Envelope Feeder Control Components Envelope Feeder Control is made up of four major components. Envelope Feeder PWB The Envelope Feeder PWB controls all Envelope Feeder functions, executes commands sent by the MCU PWB, and sends information back to the MCU PWB. No Paper Sensor Monitors the envelope level in the Envelope tray.
  • Page 21 4025 Options Envelope Feeder Mechanical Drive Components The Mechanical Drive for the Envelope Feeder is made up of one motor, two clutches, and a number of gears. Envelope Motor A +24VDC motor that provides the mechanical drive for the Envelope Feeder. Feed Clutch An electric clutch controlled by the Envelope PWB.

  • Page 22: Envelope Feeder Paper Path

    4025 Options Envelope Feeder Paper Path The Envelope Feeder Paper Path is the physical route that an envelope takes through the Envelope Feeder during a print cycle. The Feed Belt and Retard Roll feed a single envelope out of the stack and into the Take Away Roll. The Take Away Roll drives the envelope into the Transport Roll.

  • Page 23: Envelope Feeder General Specifications

    4025 Options Envelope Feeder General Specifications Category Specification Configuration Customer installed option. The Envelope Feeder replaces the MP Feeder. The Envelope Feeder attaches to the MP Feeder Support. Paper fed from the Envelope Feeder cannot be duplexed. Envelope stack capacity Maximum 100 envelope.

  • Page 24: Duplex

    4025 Options Duplex Duplex Overview • The Duplex Unit is a customer installed option that enables the printer to run duplex, or double-sided, print jobs. • The Duplex Unit is easily installed on the left side of the printer, just above the MP Feeder.

  • Page 25: Schematic Diagram Of The Duplex Operation

    4025 Options Schematic Diagram of the Duplex Operation The following illustration is a simplified schematic of the Duplex Unit components, subsystems, and paper paths. Duplex Power and Control All active components within the Duplex Unit are electrically connected to the Duplex PWB.

  • Page 26: Duplex Power

    4025 Options Duplex Power The base engine Low Voltage Power Supply and the I/O PWB provide the +5VDC and +24VDC that the Duplex Unit requires to operate. The Duplex PWB, located inside the Duplex Unit, plugs into the I/O PWB. The Base Engine LVPS supplies +5VDC and +24VDC to the I/O PWB.

  • Page 27: Duplex Control Components

    4025 Options Duplex Control Components Duplex Control is made up of four major components. Duplex PWB The Duplex PWB controls all Duplex functions, executes commands sent from the MCU PWB, and sends information back to the MCU PWB. Duplex Interlock Switch Monitors whether the Duplex Unit is closed (operating position) or open (not operating position).

  • Page 28: Duplex Drive Components

    4025 Options Duplex Drive Components Duplex Motor A +24VDC motor that provides mechanical drive for the Duplex Unit. Wait Clutch An electric clutch that controls Duplex Motor drive to the Transport Roll. Friction Clutch A mechanical clutch that transmits Duplex Motor drive to the Exit Roll and #1 Transport Roll.

  • Page 29: Duplex Paper Path

    4025 Options Duplex Paper Path The Duplex Unit Paper Path is the physical route that a sheet of paper takes through the printer and through the Duplex Unit during a duplex print cycle. Rubber rollers and solenoid activated gates drive and direct the paper along the Paper Path. The primary purpose of the Duplex Unit Paper Path is to accept a printed sheet of paper from the Fuser exit area, drive that sheet down through the Duplex Unit, effectively flipping over the sheet, and feeding the sheet back into the printer registration area so the printer can...
  • Page 30 4025 Options Step 2 The Inverter CCW Clutch switches on and rotates the Offset Roll backward, driving the sheet of paper back into the Exit Unit. The Exit Gate Solenoid toggles the Exit Gate so the paper path runs to the Exit Roll. The Exit Roll drives the sheet of paper into the Duplex Unit.
  • Page 31 4025 Options Step 3 The Drum and BTR place an image onto the second side of the sheet of paper. The Drum/BTR drive the paper into the Heat and Pressure Rolls. The Heat and Pressure Rolls drive the sheet into the Exit Unit. 1-19 General Information...

  • Page 32: Duplex Paper Path Components

    4025 Options Duplex Paper Path Components The Duplex Unit Paper Path is made up of a number of transport rolls and paper sensors. Exit Gate and Exit Gate Solenoid Diverts paper to either the Duplex Transport Roll #1. Transport Roll #1 and Pinch Roll Drives paper down through the Duplex Unit and into the lower Transport Roll.

  • Page 33: Duplex General Specifications

    4025 Options Duplex General Specifications Category Specification Configuration Customer installed option. Attaches to the left side of the printer, above the MP Feeder. Paper feed The Duplex Unit provides duplex printing for paper fed from all available paper trays except the MP Feeder and the Envelope Feeder.

  • Page 34: Mailbox

    4025 Options Mailbox Mailbox Overview • The Mailbox (or Sorter) is a customer installed option that distributes printed sheets to any one of ten Mailbox bins. • The Mailbox is easily installed on top of the printer. • The base engine LVPS provides all of the DC voltages required by the Mailbox. •...

  • Page 35: Schematic Diagram Of The Mailbox Operation

    4025 Options Schematic Diagram of the Mailbox Operation The following illustration is a simplified schematic of Mailbox components, subsystems, and paper paths. 1-23 General Information...

  • Page 36: Mailbox Power And Control

    4025 Options Mailbox Power and Control All active components within the Mailbox are electrically connected to the Mailbox Control PWB. The Base Engine Low Voltage Power Supply supplies +5VDC and +24VDC to the I/O PWB, and the I/O PWB supplies +5VDC and +24VDC to the Mailbox Control PWB.
  • Page 37 4025 Options 1-25 General Information...

  • Page 38: Mailbox Control Components

    4025 Options Mailbox Control Components Mailbox Control is made up of the following components: Mailbox Control PWB The Mailbox Control PWB controls all Mailbox functions, executes commands sent from the MCU PWB, and sends information back to the MCU PWB. All Mailbox components are connected directly to the Mailbox Control PWB.

  • Page 39: Mechanical Drive

    4025 Options Full Stack Sensor There are ten Full Stack Sensors within the Mailbox. Each Sensor monitors the paper level of the associated bin. The Full Stack Sensors are mounted on the Mailbox Control PWB. No Paper Sensor There are ten No Paper Sensors within the Mailbox. Each Sensor monitors the paper presence of the associated bin.

  • Page 40: Drive For The Mailbox

    4025 Options Drive for the Mailbox The Mailbox Control PWB controls the Mailbox Motor. The Motor rotates the Drive Gear. The Drive Belt wraps around the Drive Gear and the ten Drive Pulleys. Six Tension Rollers along the path press the Drive Belt against the Drive Pulleys. When the Mailbox Control PWB switches on the Mailbox Motor, the Motor rotates the Drive Gear, the Drive Gear drives the Belt which in turn rotates the ten Drive Pulleys.

  • Page 41: Mailbox Mechanical Drive Components

    4025 Options Mailbox Mechanical Drive Components The Mechanical Drive for the Mailbox is made up of one motor, a drive belt, and a number of pulleys. Mailbox Drive Motor Provides the mechanical drive for the Mailbox. Drive Gear A two part gear. One side of the gear rides on the Motor gear. The other side of the gear drives the Mailbox Drive Belt.

  • Page 42: Mailbox Paper Path

    4025 Options Mailbox Paper Path The Mailbox Paper Path is the physical route that a sheet of paper takes from the printer exit area to a specific Mailbox bin. Rubber rollers drive the paper along the Paper Path. Paper Path 1: Bypass the Mailbox and Feed Paper to the Bypass the Mailbox and Feed Paper to the Output Tray If the Controller signals the MCU PWB not to use Mailbox mode, the MCU PWB does not...

  • Page 43: Paper Path 1 Components

    4025 Options Paper Path 1 Components The Mailbox paper path when the Mailbox is bypassed is made up of two components. In Gate Solenoid Toggles the In Gate. In this case, the Gate Solenoid does not actuate. In Gate Switches the paper path from the Output Tray to the Mailbox. In this case, the In Gate remains up, and the paper is delivered to the printer Output Tray.

  • Page 44: Paper Path 2: Feed Paper To Bin 10

    4025 Options Paper Path 2: Feed Paper to Bin 10 If the Controller signals the MCU PWB to send the output to Bin 10, the Mailbox Control PWB actuates the In Gate Solenoid, the Solenoid drops the In Gate, and the paper path switches to the Mailbox.

  • Page 45: Paper Path 2 Components

    4025 Options Paper Path 2 Components The Mailbox paper path when the paper destination is Bin 10 is made up of a number of components. In Gate Solenoid Toggles the In Gate. In Gate Switches the paper path from the Output Tray to the Mailbox. Entrance Sensor Monitors paper arriving at the Mailbox.
  • Page 46 4025 Options Bin 10 Full Stack Sensor Monitors the paper level in Bin 10. Bin 10 No Paper Sensor Monitors the presence of paper in Bin 10. Vertical LED and Sensor Monitors paper travel into Bins 1 through 9. 1-34 Service Manual...

  • Page 47: Paper Path 3: Feed Paper To Bins 2 Through 10

    4025 Options Paper Path 3: Feed Paper to Bins 2 through 10 If the Controller signals the MCU PWB to send the output to any Mailbox Bin between 1 through 9, the MCU PWB actuates the In Gate Solenoid, the Solenoid drops the In Gate and the paper path continues into the Mailbox.

  • Page 48: Paper Path 3 Components

    4025 Options Paper Path 3 Components The Mailbox paper path when the paper destination is Bin 1 through Bin 9 is made up of a number of components. In Gate Solenoid Toggles the In Gate. In Gate Switches the paper path from the Output Tray to the Mailbox. Entrance Sensor Monitors paper arriving at the Mailbox.

  • Page 49: Mailbox Modes

    4025 Options Mailbox Modes Mode Specification Sort A maximum of 10 sets of 100 sheets per set, with one set delivered to each of the ten bins. Delivered face down in Simplex Mode. Delivered first sheet on the bottom and first printed side face down in Duplex Mode.

  • Page 50: Paper Size Recommendations

    4025 Options Paper Size Recommendations Use with one Paper Type Use with Simplex sheet batch Duplex Ledger (SEF) A3 (SEF) B4 (SEF) Legal 14” (SEF) Legal 13” (SEF) A4 (SEF) Letter (SEF) B5 (SEF) Letter (LEF) A4 (LEF) B5 (LEF) A5 (SEF) Print Speeds While Using the Mailbox Trays 1 &...

  • Page 51: Mailbox General Specifications

    4025 Options Mailbox General Specifications Category Specification Configuration Customer installed option. Attaches on top of the base printer. The basic Mailbox sorts printer output into 10 individual bins, with a maximum capacity of 100 sheets of standard 20 lb paper per bin. Duty cycle Maximum 150,000 sheets of paper per month, with an average of 25,000 sheets of paper per month.

  • Page 52: High Capacity Feeder

    4025 Options Category Specification Size and weight Height: 465mm / 18.3 inches Width: 539mm / 21.2 inches Depth: 590mm / 23.2 inches Weight: 16kg / 35.2 lbs High Capacity Feeder High Capacity Feeder Overview • The High Capacity Feeder is a customer installed option that adds three additional paper feeders to the existing two paper feeders that are standard with the print engine.

  • Page 53: Schematic Diagram Of The High Capacity Feeder Operation

    4025 Options Schematic Diagram of the High Capacity Feeder Operation The following illustration is a simplified schematic of High Capacity Feeder components, subsystems, and paper paths. 1-41 General Information...

  • Page 54: High Capacity Feeder Power And Control

    4025 Options High Capacity Feeder Power and Control All active components within the High Capacity Feeder are electrically connected to the HCF PWB. The Base Engine Low Voltage Power Supply supplies +5VDC and +24VDC to the I/O PWB, and the I/O PWB supplies +5VDC and +24VDC to the HCF PWB. The MCU PWB provides most of the High Capacity Feeder logic, while the HCF PWB executes the MCU commands.

  • Page 55: High Capacity Feeder Control

    4025 Options High Capacity Feeder Control High Capacity Feeder Control is a broad term used to describe the printer resources that monitor and control the actions and operations of the printer and the HCF; from paper feed to error detection. The center of HCF control is the HCF PWB.

  • Page 56: High Capacity Feeder Control Components

    4025 Options High Capacity Feeder Control Components The HCF Control is made up of one several major components. HCF PWB The HCF PWB controls all HCF functions, executes commands sent from the MCU PWB, and sends information back to the MCU PWB. All HCF components are connected directly to the HCF PWB.

  • Page 57: Mechanical Drive

    4025 Options Paper Level Sensors 3, 4, and 5 Monitors whether or not a Paper Tray is installed. Installing the Tray pushes the Link Stopper out, which in turn lowers the Feed Roll and moves the Level Sensor Actuator tab away from the Sensor window. Mechanical Drive Mechanical Drive is a term used to describe both the rotation of the HCF Feed Motor and the action of the gears and rollers used to transmit motor rotation to the drive rolls within...

  • Page 58: Drive For Tray 3

    4025 Options Drive for Tray 3 The HCF PWB switches on the Feed Motor. The HCF Drive Belt transmits drive from the Feed Motor to HCF Drive Transmission Gear 1. Gear 1 transmits drive to Tray 3 Drive Gear, which in turn transmits drive to Tray 3 Feed Clutch. When the HCF PWB actuates Tray 3 Feed Clutch, the Clutch transmits drive to the Tray 3 Feed Rolls, to the Retard Rolls, and to the Tray 3 Take Away Rolls.

  • Page 59: Mechanical Drive Tray 3 Components

    4025 Options Mechanical Drive Tray 3 Components The Mechanical Drive for Tray 3 of the HCF is made up of two motors along with associated gears that transmit the drive to the various Tray 3 paper transport rolls. Feed Motor Provides the mechanical drive for Tray 3 paper feed.
  • Page 60 4025 Options 1-48 Service Manual...

  • Page 61: Drive For Tray 4

    4025 Options Drive for Tray 4 The HCF PWB switches on the Feed Motor. The HCF Drive Belt transmits drive from the Feed Motor to Tray 4 Drive Gear 1. Gear 1 transmits drive to Tray 4 Drive Gear 2, which in turn transmits drive to Tray 4 Take Away Gear and Tray 4 Feed Clutch.

  • Page 62: Lift Motor Operation For Tray 4

    4025 Options Lift Motor Operation for Tray 4 The Tray 4 Lift Motor rotates the Bottom Plate Lift Pulley. Two cables are attached to each end of the Pulley. The other ends of the cables are attached to the four corners of the bottom plate.
  • Page 63 4025 Options Tray 4 Feed Clutch When actuated by the HCF PWB, the Clutch transmits drive to the Tray 4 Feed Roll and to the Tray 4 Retard Gear. Tray 4 Retard Gear Rotates Tray 4 Retard Roll. Tray 4 Take Away Gear Rotates Tray 4 Take Away Roll.

  • Page 64: Drive For Tray 5

    4025 Options Drive for Tray 5 The HCF PWB switches on the Feed Motor. The HCF Drive Belt transmits drive from the Feed Motor to HCF Drive Transmission Gear 1. Gear 1 transmits drive to HCF Drive Transmission Gear 2. HCF Drive Transmission Gear 1 also transmits drive to Tray 5 Drive Gear, which transmits drive to Tray 5 Take Away Gear.

  • Page 65: Lift Motor Operation For Tray 5

    4025 Options Lift Motor Operation for Tray 5 The Tray 5 Lift Motor rotates the Bottom Plate Lift Pulley. Two cables are attached to each end of the Pulley. The other ends of the cables are attached to the four corners of the bottom plate.

  • Page 66: Mechanical Drive Tray 5 Components

    4025 Options Mechanical Drive Tray 5 Components The Mechanical Drive for Tray 5 of the HCF is made up of two motors along with associated gears that transmit the motor drive to the various Tray 5 paper transport rolls. Feed Motor Provides the mechanical drive for Tray 5 paper feed.

  • Page 67: High Capacity Feeder Paper Path

    4025 Options High Capacity Feeder Paper Path The High Capacity Feeder Paper Path is the physical route that a sheet of paper takes from an HCF paper tray to the printer during a single print cycle. Rubber rollers drive the paper along the Paper Path.

  • Page 68: Feed From Tray 3

    4025 Options Feed from Tray 3 At the start of a print cycle the Tray 3 Nudger Roll moves a sheet of paper into Tray 3 Feed Roll. The Feed Roll moves a single sheet of paper out of Tray 3 and toward the Tray 2 Take Away Roll in the base engine.

  • Page 69: Feed From Tray 3

    4025 Options Tray 3 Paper Path Components The HCF Tray 3 Paper Path is made up of a number of transport rolls and paper sensors. Tray 3 Assembly Holds plain paper of various sizes. Slides into the top feeder, Feeder 3, of the High Capacity Feeder.
  • Page 70 4025 Options 1-58 Service Manual...

  • Page 71: Tray 4 Paper Path Components

    4025 Options Tray 4 Paper Path Components The HCF Tray 4 Paper Path is made up of a number of transport rolls and paper sensors. Tray 4 Assembly Holds plain paper of various sizes. Slides into the bottom left feeder, Feeder 4, of the High Capacity Feeder.
  • Page 72 4025 Options 1-60 Service Manual...

  • Page 73: Feed From Tray 5

    4025 Options Feed from Tray 5 At the start of a print cycle the Tray 5 Nudger Roll moves a sheet of paper into Tray 5 Feed Roll. The Feed Roll moves a single sheet of paper out of Tray 5 and toward the Tray 5 Take Away Roll.

  • Page 74: Tray 5 Paper Path Components

    4025 Options Tray 5 Paper Path Components The HCF Tray 5 Paper Path is made up of a number of transport rolls and paper sensors. Tray 5 Assembly Holds plain paper of various sizes. Slides into the bottom right feeder, Feeder 5, of the High Capacity Feeder.
  • Page 75 4025 Options Tray 2 Take Away Sensor Monitors paper travel from the HCF into the base engine. Tray 2 Take Away Roll Drives the sheet of paper into the printer Registration Rolls. Tray 1 Take Away Roll Part of the base engine. Drives the sheet of paper into the printer Registration Rolls. 1-63 General Information...

  • Page 76: High Capacity Feeder General Specifications

    4025 Options High Capacity Feeder General Specifications Category Specification Configuration Customer installed option. The base engine sits on top of the High Capacity Feeder. The HCF has three paper trays: Tray 3 - upper tray. Tray 4 - lower left tray. Tray 5 - lower right tray Paper feed The HCF feeds Letter (LEF), A4 (LEF), Executive (LEF), and...

  • Page 77: Glossary Of Terms, Acronyms, And Abbreviations

    4025 Options Glossary of Terms, Acronyms, and Abbreviations Acronyms, and Abbreviations Alternating Current AC Line Voltage The AC voltage level at the AC wall outlet, such as 110VAC or 220VAC Actuated A device, such as a switch or motor, that is switched on Actuator Mechanical device used to toggle a switch or a sensor Auxiliary...
  • Page 78 4025 Options Earth Electrical ground Earth Plate Electrical ground plate or ground strap Engine Board The board that controls the operation of the printer, synonym for MCU and MCU PWB EP Cartridge A sealed assembly that houses the xerographic drum, major xerographic components, and a finite supply of dry ink.
  • Page 79 4025 Options Interlock Interlock switch or circuit. Used as a safety measure to remove voltage from circuits whenever the printer covers are open or printer assemblies are not in position Image Output Terminal. Acronym that is sometimes used in schematic diagrams to describe the base print engine Jack.
  • Page 80 4025 Options Paper jam A sheet of paper stops at a point along the paper path Paper path The path a sheet of paper takes from the paper feeder to the output tray Paper Handling Plug and Jack. Electrical connectors as a unit Parts List Pages Per Minute or Prints Per Minute Pre-Reg...
  • Page 81 4025 Options Volts - Direct Current Warm-up The time it takes the printer to go from main power ON to Ready to Print Wire Harness A bundle of wires that form a single unit and are generally terminated with connectors at both ends 1-69 General Information...
  • Page 82 4025 Options 1-70 Service Manual...

  • Page 83: Diagnostic Information

    4025 Options 2. Diagnostic Information Start CAUTION: Remove the power cord from the printer and option or wall outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer or option. Make sure your fingers are not under the printer when you lift or set the printer down.

  • Page 84: Envelope Feeder

    4025 Options Envelope Feeder Envelope Feeder Error Code Table This table lists all of the Envelope Unit related Error Codes that are generated by the printer Engine Board (MCU PWB). Note: Depending on the level of firmware on your printer Engine Board (MCU PWB) some codes listed may be invalid, some codes generated by the MCU may not appear in this table, and Error and Message Code text presented may differ slightly from the Error and Message Code text that is actually generated by your MCU.

  • Page 85: Envelope Feeder Error Code Service Checks

    4025 Options Envelope Feeder Error Code Service Checks Error Code 271 There is a paper jam between the Envelope Tray and the Envelope Feed Sensor. Logic Control on the MCU PWB sensed that the Envelope Feed Sensor did not actuate within the specified time after the Envelope Feed Clutch was actuated.

  • Page 86: Error Code

    4025 Options Error Code 272 There is a problem with the Envelope Feed Sensor. Logic Control on the MCU PWB sensed the Envelope Feed Sensor was actuated while the printer was in standby. Step Actions and Questions ENVELOPE FEED SENSOR INSPECTION Go to step 2 Remove the paper scraps...
  • Page 87 4025 Options Step Actions and Questions PAPER INSPECTION Replace the Go to step 3 envelopes Inspect the envelopes that are loaded in the Envelope Tray. with new Are the envelopes that are loaded in the Envelope Tray envelopes wrinkled or damaged? ENVELOPE FEED TEST Problem Go to step 4...

  • Page 88: Registration Sensor

    4025 Options Error Code 255 There is a paper jam between the Envelope Feeder and the Registration Sensor. Logic Control on the MCU PWB sensed that the Registration Sensor did not actuate within the specified time after the Envelope Feed Clutch was actuated. Step Actions and Questions PAPER PATH INSPECTION...

  • Page 89: Envelope Feeder Symptom Service Checks

    4025 Options Step Actions and Questions The following printer FRUs and areas are associated with this specific problem. One or more of these FRUs or areas may have failed partially or completely. If you cannot isolate this problem using the steps in this chart, replace each FRU or troubleshoot each area, one at a time, until you isolate and solve the problem.

  • Page 90: Duplex

    4025 Options Step Actions and Questions The following printer FRUs and areas are associated with this specific problem. One or more of these FRUs or areas may have failed partially or completely. If you cannot isolate this problem using the steps in this chart, replace each FRU or troubleshoot each area, one at a time, until you isolate and solve the problem.

  • Page 91: Duplex Symptom Table

    4025 Options Duplex Symptom Table Symptom Action Inoperative Duplex Unit Go to “Inoperative Duplex Unit” on page 2-18 Duplex Printing Modes Mode Specification One Sheet Batch 1. The printer prints on one side of a sheet of paper. 2. The Duplex Unit returns the printed sheet to the printer. Page2 - Page1 3.
  • Page 92 4025 Options Step Actions and Questions PAPER INSPECTION Replace the Go to step 2 paper with Inspect the paper that is loaded in the paper cassette. new paper Is the paper that is loaded in the cassette wrinkled or damaged? PAPER PATH INSPECTION Go to step 3 Clear the...
  • Page 93 4025 Options Step Actions and Questions DUPLEX EXIT GATE INSPECTION Go to step 8 Reinstall the Exit Gate and 1. Open the Inner Chute. 2. Check the Duplex Exit Gate and Gate Spring. Spring or replace the Is the Duplex Exit Gate in place on the Inner Chute, is the Exit Gate and Gate unbroken, does it pivot freely on the Inner Chute, and Spring.

  • Page 94: Error Code 997

    4025 Options Error Code 231 There is a paper jam at the Duplex Exit Sensor. Logic Control on the MCU PWB sensed that the Duplex Exit Sensor did not actuate within the specified time after the Face Up Exit Sensor was actuated. Step Actions and Questions PAPER INSPECTION...
  • Page 95 4025 Options Error Code 232 There is a paper jam between the Face Up Exit Sensor and the Duplex Wait Sensor. Logic Control on the MCU PWB sensed that the Duplex Wait Sensor did not actuate within the specified time after the Face Up Exit Sensor was actuated. Step Actions and Questions PAPER INSPECTION...
  • Page 96 4025 Options Error Code 233 There is a problem with the Duplex Exit Sensor. Logic Control on the MCU PWB sensed that the Duplex Exit Sensor was on while the printer was in standby. Step Actions and Questions DUPLEX EXIT SENSOR INSPECTION Go to step 2 Clean or clear paper scraps...
  • Page 97 4025 Options Error Code 234 There is a paper jam between the Duplex Wait Sensor and the Registration Sensor. Logic Control on the MCU PWB sensed that the Registration Sensor did not actuate within the specified time after the Duplex Wait Clutch was actuated. Step Actions and Questions PAPER INSPECTION...
  • Page 98 4025 Options Step Actions and Questions The following printer FRUs and areas are associated with this specific problem. One or more of these FRUs or areas may have failed partially or completely. If you cannot isolate this problem using the steps in this service check, replace each FRU or troubleshoot each area, one at a time, until you isolate and solve the problem.
  • Page 99 4025 Options Step Actions and Questions I/O PWB REPLACEMENT Go to step 7 Problem solved Replace the I/O PWB. Go to the printer service manual for the Removal and Replacement Procedure. Does the error code appear? The following printer FRUs and areas are associated with this specific problem.

  • Page 100: Duplex Symptom Service Checks

    4025 Options Step Actions and Questions The following Duplex FRUs and areas are associated with this specific problem. One or more of these FRUs or areas may have failed partially or completely. If you cannot isolate this problem these steps, replace each FRU or troubleshoot each area listed below, one at a time, until you isolate and solve the problem.

  • Page 101: Mailbox

    4025 Options Step Actions and Questions DRIVE BELT INSPECTION Replace the Go to step 6 problem belt 1. Remove the Duplex Cover and reinstall the coverless Unit onto the printer. or gear 2. Reconnect the Duplex Interface Cable to the P/J at the rear of the printer.

  • Page 102: Mailbox Symptom Table

    4025 Options Error Code Description Logic Control on the MCU PWB sensed that the Mailbox Entrance Sensor was actuated when the printer was not in Mailbox mode. Go to “Error Code 282” on page 2-24. Logic Control on the MCU PWB sensed that either the Mailbox Vertical Sensor did not actuate within the specified time after the Mailbox Entrance Sensor was actuated, or that BIN 1 Jam Sensor did not deactuate within the specified time after the Mailbox Entrance Sensor was actuated.
  • Page 103 4025 Options Step Actions and Questions MAILBOX INPUT SENSOR TEST Go to step 4 Replace the “Mailbox Enter Diagnostic Mode - MBX Input Sensor Entrance Insert, then remove, a sheet of paper into the Sensor. Sensor” on Does the Control Panel LCD change between OP and CL page 4-39 as you insert then remove the paper? MAILBOX CONTROL PWB REPLACEMENT...

  • Page 104: Error Code 996

    4025 Options Step Actions and Questions OFFSET EXIT ASSEMBLY TEST Clean the Go to step 10 Offset Roll Enter Diagnostics - Output Bin Tests, Single. The MCU PWB actuates the CW Clutch which drives the Exit troubleshoot Roll and the Offset Roll. the printer Does the Offset Roll rotate? Fuser and...
  • Page 105 4025 Options Step Actions and Questions MAILBOX CONTROL PWB REPLACEMENT Replace the Problem printer Engine solved Replace the “Mailbox Control PWB” on page 4-44. Board (MCU Does the error code appear? PWB). Go to the printer service manual for the Removal and Replacement Procedure.
  • Page 106 4025 Options Step Actions and Questions BIN GATE SOLENOID TEST Replace the Go to step 11 “Mailbox Enter Diagnostic Mode - Output Bin Feed Test. Control Select Feed to all bins. PWB” on Paper should feed into each Mailbox Bin. page 4-44.
  • Page 107 4025 Options Step Actions and Questions MAILBOX ENTRANCE SENSOR TEST Go to step 3 Replace the “Mailbox Enter Diagnostic Mode - MBX Input Sensor. Entrance Insert, then remove, a sheet of paper into the Sensor. Sensor” on Does the Control Panel LCD change between OP and CL page 4-39 as you insert then remove the paper? IN GATE TEST...
  • Page 108 4025 Options Step Actions and Questions VERTICAL SENSOR TEST Go to step 3 Replace the “Vertical Enter Diagnostic Mode - Output Bin, Sensor Test. LED/Sensor” Select Vertical Sensor. Insert, then remove, a sheet of paper on page 4-42 into the Sensor. Does the Control Panel LCD change between OP and CL as you insert then remove the paper? BIN 10 JAM SENSOR TEST...
  • Page 109 4025 Options Step Actions and Questions MCU PWB REPLACEMENT Go to step 11 Problem solved Replace the printer Engine Board (MCU PWB). Go to the printer service manual for the Removal and Replacement Procedure. Does the error code appear? The following printer FRUs and areas are associated with this specific problem.
  • Page 110 4025 Options Step Actions and Questions MAILBOX MOTOR TEST Go to step 5 Go to step 9 Enter Diagnostic Mode - Output Bin Feed Test. Select single bin to feed one sheet of paper to one bin. Does the Mailbox Motor run? DRIVE BELT INSPECTION Go to step 6 Replace the...
  • Page 111 4025 Options Error Code 996 Logic control sensed that the installed Mailbox is not compatible with the printer. Step Actions and Questions MAILBOX INSPECTION Go to step 2 Replace the Mailbox with a Inspect the Mailbox to make sure it is the correct manufacture correct one and model for the printer.

  • Page 112: Mailbox Symptom Service Checks

    4025 Options Mailbox Symptom Service Checks Inoperative Mailbox The Mailbox does not function, the Mailbox Drive Motor does not switch on, and the problem is not identified by a displayed Error Code. Step Actions and Questions INTERFACE CABLE INSPECTION Go to step 2 Reconnect the Mailbox Check the Mailbox Interface Cable.
  • Page 113 4025 Options Step Actions and Questions MAILBOX VOLTAGE CHECK Replace the Go to step 7 “Mailbox Remove the Rear Cover. Control Switch on the printer power. PWB” on Measure the voltage between J800-8 and FG (frame ground), page 4-44 the voltage between J800-10 and FG, and the voltage between J800-12 and FG on the Mailbox Control PWB.

  • Page 114: High Capacity Feeder

    4025 Options High Capacity Feeder High Capacity Feeder Error Code Table This table lists all of the High Capacity Feeder Error Codes that are generated by the printer Engine Board (MCU PWB). Depending on the level of firmware on your printer Engine Board (MCU PWB) some codes listed may be invalid, some codes generated by the MCU may not appear in this table, and Error and Message Code text presented may differ slightly from the Error and Message Code text that is actually generated by your MCU.

  • Page 115: High Capacity Feeder Symptom Table

    4025 Options Error Code Description Logic Control on the MCU PWB sensed the Tray 3 Take Away Sensor was on while the printer was in standby. Go to “Error Code 257” on page 2-45 Logic Control on the MCU PWB sensed the Tray 4 Take Away Sensor was on while the printer was in standby.
  • Page 116 4025 Options Step Actions and Questions PAPER PATH INSPECTION Go to step 4 Clear the paper path Inspect the paper path for paper scraps or foreign objects that could cause a paper jam. Is the paper path clear? TRAY 3 LIFT MOTOR QUICK TEST Go to step 5 Replace the “Lift Motor”...
  • Page 117 4025 Options Step Actions and Questions The following printer FRUs and areas are associated with this specific problem. One or more of these FRUs or areas may have failed partially or completely. If you cannot isolate this problem using the steps in this service check, replace each FRU or troubleshoot each area, one at a time, until you isolate and solve the problem.
  • Page 118 4025 Options Step Actions and Questions TRAY 2 TAKE AWAY SENSOR TEST Go to step 6 Replace the Tray 2 Take Enter Diagnostic Mode, Base Sensors - Tray 2 Take Away Away Sensor. Sensor. Insert, then remove, a sheet of paper into the Sensor. Go to the Does the Control Panel LCD change between OP and CL printer service...
  • Page 119 4025 Options Step Actions and Questions PAPER INSPECTION Replace the Go to step 3 paper with Inspect the paper that is loaded in the paper cassette. new paper Is the paper loaded in the cassette wrinkled or damaged? PAPER PATH INSPECTION Go to step 4 Clear the paper path...
  • Page 120 4025 Options Step Actions and Questions The following printer FRUs and areas are associated with this specific problem. One or more of these FRUs or areas may have failed partially or completely. If you cannot isolate this problem using the steps in the service check, replace each FRU or troubleshoot each area, one at a time, until you isolate and solve the problem.
  • Page 121 4025 Options Step Actions and Questions TRAY 2 TAKE AWAY SENSOR TEST Go to step 7 Replace the Tray 2 Take Enter Diagnostic Mode, Base Sensors - Tray 2 Take Away Away Sensor. Sensor. Insert, then remove, a sheet of paper into the Sensor. Go to the Does the Control Panel LCD change between OP and CL printer service...
  • Page 122 4025 Options Step Actions and Questions PAPER INSPECTION Replace the Go to step 3 paper with Inspect the paper that is loaded in the paper cassette. new paper Is the paper loaded in the cassette wrinkled or damaged? PAPER PATH INSPECTION Go to step 4 Clear the paper path...
  • Page 123 4025 Options Step Actions and Questions The following printer FRUs and areas are associated with this specific problem. One or more of these FRUs or areas may have failed partially or completely. If you cannot isolate this problem using the steps in this service check, replace each FRU or troubleshoot each area, one at a time, until you isolate and solve the problem.
  • Page 124 4025 Options Step Actions and Questions FEED, NUDGER, AND RETARD ROLL CHECK Go to step 7 Replace the “Tray 5 After performing step 4, carefully open tray 5. Feeder Was a sheet of paper fed out of Tray 5? Assembly” page 4-100 TRAY 4 TAKE AWAY SENSOR TEST Go to step 8...
  • Page 125 4025 Options Step Actions and Questions PAPER INSPECTION Replace the Go to step 3 paper with Inspect the paper that is loaded in the paper cassette. new paper Is the paper loaded in the cassette wrinkled or damaged? PAPER PATH INSPECTION Go to step 4 Clear the paper path...
  • Page 126 4025 Options Error Code 253 There is a paper jam between Paper Tray 5 and the Registration Sensor. Logic Control on the MCU PWB sensed that when paper was fed from Tray 5, the Registration Sensor did not actuate within the specified time after the Tray 2 Take Away Sensor was actuated.
  • Page 127 4025 Options Step Actions and Questions I/O PWB REPLACEMENT Go to step 9 Problem solved Replace the I/O PWB. Does the error code appear? MCU PWB REPLACEMENT Go to step 10 Problem solved Replace the printer Engine Board (MCU PWB). Go to the printer service manual for the Removal and Replacement Procedure Does the error code appear?
  • Page 128 4025 Options Step Actions and Questions MCU PWB REPLACEMENT Go to step 6 Problem solved Replace the printer Engine Board (MCU PWB). Go to the printer service manual for the Removal and Replacement Procedure. Does the error code appear? The following printer FRUs and areas are associated with this specific problem.
  • Page 129 4025 Options Step Actions and Questions The following printer FRUs and areas are associated with this specific problem. One or more of these FRUs or areas may have failed partially or completely. If you cannot isolate this problem using the steps in this service check, replace each FRU or troubleshoot each area, one at a time, until you isolate and solve the problem.
  • Page 130 4025 Options Step Actions and Questions TRAY 3 TAKE AWAY ROLL CHECK Go to step 7 Troubleshoot the drive 1. Enter Diagnostic Mode - Input Tray Test 2. Select Tray 3, Single transmission, from the HCF Does the Take Away rotate when the HCF Motor runs? Motor to the Take Away Gear...
  • Page 131 4025 Options Step Actions and Questions TRAY 3 NO PAPER SENSOR TEST Go to step 4 Replace the “Trays 3, 4, Enter Diagnostic Mode, Base Sensors - Tray 3 Take Away and 5 No Sensor. Insert, then remove, a sheet of paper into the Sensor. Paper Does the Control Panel LCD change between OP and CL Sensors”...
  • Page 132 4025 Options Step Actions and Questions TRAY 4 NO PAPER SENSOR TEST Go to step 4 Replace “Trays 3, 4, Enter Diagnostic Mode, Base Sensors - Tray 4 Empty. and 5 No Push the sensor flag up and then release. Paper Does the Control Panel LCD change between OP and CL Sensors”...

  • Page 133: Error Code 993 And 994

    4025 Options Step Actions and Questions TRAY 5 NO PAPER SENSOR TEST Go to step 4 Replace the Tray 5 No Enter Diagnostic Mode, Base Sensors - Tray 5 Empty. Paper Sensor. Push the sensor flag up and then release. Go to “Trays Does the Control Panel LCD change between OP and CL...

  • Page 134: High Capacity Feeder Symptom Service Checks

    4025 Options Step Actions and Questions RESEAT Problem Go to step 4 solved Disconnect then reconnect the High Capacity Feeder from the printer. Is the error code gone? HIGH CAPACITY FEEDER PWB Problem Go to step 5 solved Replace the “HCF PWB”...
  • Page 135 4025 Options Step Actions and Questions HCF INTERFACE CABLE INSPECTION Go to step 4 Reconnect the interface Check the HCF to printer interface cable. cable Is the cable firmly connected to the P/J at the rear of the printer? APPLICATION SOFTWARE Reload Go to step 5 application...
  • Page 136 4025 Options 2-54 Service Manual...

  • Page 137: Diagnostic Aids

    4025 Options 3. Diagnostic Aids Envelope Feeder Tests Feed Test The Feed Test operation within the INPUT TRAY TESTS menu determines whether or not the sensors and switches are working correctly. No information is printed on the feed test pages since the laser isn’t engaged during this test. Note: The feed test can be run using any of the paper and envelope sizes supported by the printer.

  • Page 138: Duplex Tests

    4025 Options Duplex Tests Feed Test Use the Duplex Quick Test to feed paper and to verify that the duplex Top Margin is set correctly. This test prints a duplexed version of the Quick Test page that can be used to adjust the Top Margin for the backside of the page.

  • Page 139: Mailbox Tests

    4025 Options Once this screen is displayed, you can manually actuate each of the duplex sensors tests. When the sensor is closed, is displayed. Likewise, when the sensor is open, is displayed. if the wrong message is displayed, then the sensor is malfunctioning. To exit the sensor test, press Return.

  • Page 140: Sensor Test

    4025 Options Standard Bin, Bin #1, Bin #2, Bin #3, Bin #4, Bin #5, Bin #6, Bin #7, Bin #8, Bin #9, Bin #10, Bin #10, Bin #9, Bin #8, Bin #7, Bin #6, Bin #5, Bin #4, Bin #3, Bin #2, Bin #1, Standard Bin, Standard Bin, Bin #1, Bin #2,...

  • Page 141: High Capacity Feeder Tests

    4025 Options High Capacity Feeder Tests Feed Test Use the Feed Test operation within the INPUT TRAY TESTS to verify that media can be fed from a specific input source. No information is printed on the feed test pages since the laser isn’t engaged during this test.

  • Page 142: Sensor Test

    4025 Options Sensor Test Use this test to determine whether or not the High Capacity sensors and switches are working correctly. To test the High Capacity sensors, select Base Sensor Tests from the top level menu in diagnostics. The following High Capacity Sensor test is displayed in the bottom level menu: •...

  • Page 143: Repair Information

    4025 Options 4. Repair Information This section contains the removal and replacement procedures for select parts of the printer Envelope Feeder, Duplex Unit, Mailbox, and High Capacity Feeder. Preparation Before you begin any Removal and Replacement Procedure: Switch OFF the printer power and disconnect the power cord from the AC wall outlet. Wear an electrostatic discharge wrist strap to help prevent damage to the sensitive electronics of the printer PWBs.

  • Page 144: Removal And Replacement Procedures

    4025 Options Removal and Replacement Procedures Envelope Feeder Removal Pull the Envelope Feeder out and remove it from the MP Feeder Support. Replacement If the MP Feeder is installed, pull the MP Feeder Assembly out of the MP Feeder Support. Align the two pins on the Envelope Feeder with the corresponding openings in the MP Feeder Support, and slide the Feeder into the Support.

  • Page 145: Duplex Unit Assembly

    4025 Options Duplex Unit Assembly Removal Disconnect the Duplex Unit interface cable from the rear of the printer. Tilt the Duplex Unit back so it is open half way. Unhook the Support Cable from the printer frame. Support the Duplex Unit with your left hand. Close the Unit just enough so you can release the metal arm that runs from the Unit to the metal stud on the Front MP Feeder Support (see the inset in the illustration).

  • Page 146: Duplex Cover

    4025 Options Duplex Cover Removal Remove the Duplex Unit Assembly and place it on a flat and stable surface. Remove the four screws securing the Duplex Cover to the Assembly, and remove the Cover. Replacement Place the Assembly, feed wheels up, on a flat and stable surface. Reinstall the Duplex Cover over the Duplex Assembly using four screws to fasten it to the Assembly.

  • Page 147: Duplex Rear Cover

    4025 Options Duplex Rear Cover Removal Remove the Duplex Cover. Position the Duplex Assembly so the Inner Chute faces up. Remove the two screws, shown in the figure, securing the Rear Cover to the Duplex Assembly, and remove the Cover. Replacement Position the Rear Cover over the Duplex Assembly.

  • Page 148: Duplex Front Cover

    4025 Options Duplex Front Cover Removal Remove the Duplex Cover. Position the Duplex Assembly so the Inner Chute faces up. Remove the two screws, shown in the figure, securing the Front Cover to the Duplex Assembly, and remove the Cover. Replacement Seat the Front Cover on the Duplex Assembly, and use two screws to secure the Cover.

  • Page 149: Duplex Pwb And Bracket

    4025 Options Duplex PWB and Bracket Removal Remove the Duplex Rear Cover. Disconnect the six P/Js connected to the Duplex PWB. Remove the four screws securing the Duplex PWB to the Duplex PWB Bracket, and remove the PWB. WARNING: Wear an electrostatic wrist strap and use caution when working with the Duplex PWB.

  • Page 150: Duplex Wait Clutch

    4025 Options Duplex Wait Clutch Removal Remove the Duplex Rear Cover. Disconnect P/J224 (Wait Clutch) from the Duplex PWB. Remove the E-ring from the end of the Wait Clutch shaft. Push up on the shaft latch as you slide the Clutch off of the shaft. Replacement Position the Wait Clutch so the notch in the Clutch lines up with the tab on the Duplex frame.

  • Page 151: Duplex Drive Assembly

    4025 Options Duplex Drive Assembly Removal Remove the Duplex Rear Cover. Remove the Duplex PWB and Bracket. Remove the four screws securing the Duplex Drive Assembly to the Duplex frame, and remove the Assembly. Replacement Reinstall the Drive Assembly onto the Duplex frame. Slip the Drive Belt onto the Motor Gear.

  • Page 152: Duplex Exit Sensor

    4025 Options Duplex Exit Sensor Removal Remove the Duplex Cover. Squeeze the four latches securing the Sensor to the bracket on the Upper Chute and remove the Duplex Exit Sensor. Disconnect P/J 124 from the Sensor. Replacement Remove the Duplex Cover. Position the Duplex Exit Sensor so the P/J faces the wire harness.

  • Page 153: Duplex Exit Gate Solenoid

    4025 Options Duplex Exit Gate Solenoid Removal Remove the Duplex Cover. Remove the Duplex Rear Cover. Disconnect P/J 222 from the Duplex PWB. Remove the wire harnesses from the wire clip that is mounted on the Solenoid Bracket. Remove the two screws securing the Duplex Exit Gate Solenoid Bracket to the Duplex frame, and remove the Bracket and attached Solenoid.

  • Page 154: Exit Roll

    4025 Options Exit Roll 4-12 Service Manual...
  • Page 155 4025 Options Removal Remove the Duplex Cover. Remove the E-ring securing the Rear end of the Exit Roll shaft to the Duplex frame. Remove the E-ring securing the Front end of the Exit Roll shaft to the Duplex frame. Slide both bearings toward the center of the shaft, and lift the Exit Roll shaft out of the Duplex frame.

  • Page 156: Duplex Wait Sensor

    4025 Options Duplex Wait Sensor Removal Remove the Duplex Cover. Remove the screw securing the Wait Sensor Bracket to the Duplex frame. Remove the Bracket and the attached Wait Sensor. Disconnect P/J 123 from the Sensor. Squeeze the four latches securing the Sensor to the bracket and remove the Sensor. Replacement Position the Sensor on the Bracket so the Sensor latches match the openings in the Bracket.

  • Page 157: Duplex Interlock Switch

    4025 Options Duplex Interlock Switch Removal Remove the Duplex Cover. Remove the Duplex Front Cover. Disconnect P/J 125 from the Interlock Switch. Squeeze the sides of the Switch together to release the two latches securing the Duplex Interlock Switch to the Duplex frame, and remove the Switch. Replacement Position the Interlock Switch as shown.

  • Page 158: Exit Roll Belt

    4025 Options Exit Roll Belt Removal Remove the Duplex PWB Bracket. Remove the Duplex Drive Assembly. Remove the two screws securing the Exit Gate Solenoid Bracket to the frame and remove the Bracket and Solenoid. Remove the E-ring from the #1 Transport Roll Drive Gear, and slide the Gear off of the shaft.

  • Page 159: Duplex Pinch Roll

    4025 Options Duplex Pinch Roll Removal Remove the Duplex Unit Assembly. Open the Inner Chute. Working from the front of the Chute, use the flat blade of a screwdriver to carefully free the arms of the roll latch from the Inner Chute (see the figure), while pressing out on the rubber roll.

  • Page 160: Inner Chute Assembly

    4025 Options Inner Chute Assembly Removal Remove the Duplex Unit Assembly. Open the Inner Chute. Use the flat blade of a screwdriver to pry (arrow in the figure) the rear hinge of the Inner Chute out of the hole in the Duplex frame. Remove the Inner Chute.

  • Page 161: Mailbox

    4025 Options Mailbox 4-19 Repair Information...
  • Page 162 4025 Options Removal Disconnect P612 from the jack that is located at the rear of the printer. Unhook and remove the Stopper. Lift the Mailbox off of the Rack, and place the Mailbox on a level and stable surface. Press in on the latches securing the Rack to the Left and Right Brackets and lift the Rack up and off of the Brackets.

  • Page 163: Mailbox Left Cover Assembly

    4025 Options Mailbox Left Cover Assembly Removal Remove the screw securing the Left Cover Strap to the Mailbox Top Cover. Unhook the Left Cover Hook from the Mailbox Frame Assembly. Remove the KL clip from the Mailbox Left Cover Assembly. Lift the Cover up and off of the Mailbox.

  • Page 164: Mailbox Front Cover

    4025 Options Mailbox Front Cover 4-22 Service Manual...
  • Page 165 4025 Options Removal Open the Mailbox Left Cover Assembly. Push down on the Handle and remove it from the Mailbox frame. Remove the two screws securing the Mailbox Front Cover to the Mailbox, and remove the Front Cover. Replacement Reinstall the Front Cover onto the Mailbox frame. Use two screws to secure the Front Cover to the frame.

  • Page 166: Mailbox Rear Cover

    4025 Options Mailbox Rear Cover Removal Remove the screw securing the Rear Cover to the Mailbox frame. Remove the Rear Cover from the Mailbox frame. Replacement Reinstall the Rear Cover onto the Mailbox frame. Use one screw to secure the Rear Cover to the Mailbox frame. 4-24 Service Manual...

  • Page 167: Mailbox Top Cover

    4025 Options Mailbox Top Cover 4-25 Repair Information...
  • Page 168 4025 Options Removal Remove Mailbox Left Cover Assembly. Remove the Mailbox Front Cover Assembly. Remove the Mailbox Rear Cover Assembly. Loosen the three screws securing the Top Cover to the Mailbox frame, and remove the Top Cover. Replacement Reinstall the Mailbox Top Cover to the Mailbox frame, making sure you line up the slots in the Cover with the screws in the frame.

  • Page 169: Actuator Cover Assembly

    4025 Options Actuator Cover Assembly 4-27 Repair Information...
  • Page 170 4025 Options Removal Remove the Mailbox Top Cover Assembly. Disconnect P/J 820 from the Bin 10 Jam Sensor. Disconnect P/J 823 running to the Vertical Sensor. Pull all of the wires free of the wire clips at the top of the Actuator cover. Remove the three screws securing the Actuator Cover Assembly to the frame, lift the Cover free of the wire harness and remove it from the Mailbox.

  • Page 171: Bin 10 Jam Sensor

    4025 Options Bin 10 Jam Sensor Removal Remove the Mailbox Top Cover Assembly. Disconnect P/J 820 from the Bin 10 Jam Sensor. Remove the screw securing the Bin 10 Jam Sensor to the Actuator Cover. Remove Bin 10 Jam Sensor from the Actuator Cover. Replacement Reinstall Bin 10 Jam Sensor to the Actuator Cover.

  • Page 172: Bin 10 Tray Assembly

    4025 Options BIN 10 Tray Assembly 4-30 Service Manual...
  • Page 173 4025 Options Removal Remove the Paper Stopper. Remove the Actuator Cover Assembly. Remove the screw securing the LED and the LED Cover to the BIN 10 Tray Assembly, and remove the LED and LED Cover (Inset 1). Slip the Drive Belt off of BIN 10 Drive Pulley. Remove the three screws securing BIN 10 Tray to the Mailbox frame.

  • Page 174: Mailbox Drive Belt

    4025 Options Mailbox Drive Belt 4-32 Service Manual...
  • Page 175 4025 Options Removal Remove Mailbox Left Cover Assembly. Remove the Mailbox Rear Cover Assembly. Remove the Mailbox Drive Motor Assembly. Slide the Mailbox Drive Gear off of the shaft. Slip the Mailbox Drive Belt off of the Drive Pulleys. Replacement Position the Mailbox Belt as shown, and reinstall the Belt onto the Drive Pulleys.

  • Page 176: Bin Trays 1 - 9 Assemblies

    4025 Options BIN Trays 1 - 9 Assemblies 4-34 Service Manual...
  • Page 177 4025 Options Note: This Removal and Replacement procedure describes the removal and replacement of a single BIN Tray, from BIN 9 through BIN 1. When removing a BIN Tray start by removing BIN Tray 10, then remove BIN Tray 9. Remove the BIN Trays sequentially, 9 through 1, by repeating the steps in this procedure for each remaining Tray.

  • Page 178: Gate Solenoids

    4025 Options Gate Solenoids 1 - 9 4-36 Service Manual...
  • Page 179 4025 Options Removal Remove the Paper Stopper. Remove the Mailbox Top Cover Assembly. Remove BIN Tray 10. Disconnect P/J 803 (Solenoid 9) from the Mailbox PWB. Loosen, do not remove, the screw securing Solenoid 9 to the Mailbox frame. Release the Solenoid plunger from the end of Gate 9, and remove Solenoid 9. Remove BIN Tray 9.

  • Page 180: Mailbox Exit Roll And Bin Gate

    4025 Options Mailbox Exit Roll and Bin Gate Note: This procedure covers the removal and replacement of a BIN 1 Gate and Exit Roll. Start with BIN 10 and move sequentially to BIN 1. Remove Exit Rolls 9 through 1 by repeating the steps in this procedure for each Roll in the Mailbox.

  • Page 181: Mailbox Entrance Sensor

    4025 Options Mailbox Entrance Sensor Removal Open the Left Cover Assembly. Remove the screw securing the Mailbox Entrance Sensor to the Mailbox frame, and remove the Sensor. Disconnect the P/J from the Mailbox Entrance Sensor. Replacement Reconnect the Mailbox Entrance Sensor P/J. Reinstall the Mailbox Entrance Sensor, and use one screw to secure it to the Mailbox frame.

  • Page 182: In Gate Solenoid

    4025 Options IN Gate Solenoid 4-40 Service Manual...
  • Page 183 4025 Options Removal Remove the Mailbox Rear Cover. Lift the Mailbox off of the printer and set it down on the Front Cover. Disconnect P/J 812 (In Solenoid) from the Mailbox Control PWB. Remove the two screws securing the Tie Plate to the frame, and remove the Tie Plate.

  • Page 184: Vertical Led/Sensor

    4025 Options Vertical LED/Sensor 4-42 Service Manual...
  • Page 185 4025 Options Removal Remove the Actuator Cover Assembly. Disconnect P/J 823. Remove the screw securing the LED Cover and LED to the Bin 10 Tray Assembly, and remove the LED Cover and LED (inset in illustration). Remove the Lower Chute. Remove the screw securing the Vertical Sensor to the Lower Chute and remove the Sensor, the wire harness, and the LED.

  • Page 186: Mailbox Control Pwb

    4025 Options Mailbox Control PWB 4-44 Service Manual...
  • Page 187 4025 Options Removal Remove Mailbox Left Cover Assembly. Remove the Mailbox Rear Cover. Disconnect the thirteen P/Js from the Mailbox Control PWB. Remove the four screws securing the Mailbox Control PWB to the Mailbox frame, and remove the PWB. WARNING: Wear a grounded, electrostatic wrist strap and use caution when working with the Mailbox Control PWB.

  • Page 188: Mailbox Drive Motor

    4025 Options Mailbox Drive Motor 4-46 Service Manual...
  • Page 189 4025 Options Removal Remove Mailbox Left Cover Assembly. Remove the Mailbox Rear Cover. Disconnect P/J 802 (Drive Motor) from the Mailbox Control PWB. Remove the two screws securing the Mailbox Drive Motor Assembly to the frame, and remove the Motor Assembly (Figure 1). Remove the screw securing the Mailbox Drive Cover to the Mailbox Drive Bracket, and remove the Cover (Figure 2).

  • Page 190: Full Stack Actuator

    4025 Options Full Stack Actuator Removal Remove the Actuator Cover Assembly. Turn the Actuator Cover upside down. Hold the center of Full Stack Actuator 2 between your fingers and bow the Actuator just enough to free one end of it from the Actuator Cover, and remove the Actuator. Pull the outside end of Full Stack Actuator 1 free of the Actuator Cover, and remove the Actuator.

  • Page 191: Rear Lower Cover

    4025 Options Rear Lower Cover Removal Remove the IN Gate. Disconnect P/J 812 (IN Gate Solenoid) from the Mailbox Control PWB. Remove the two screws securing the Rear Lower Cover to the Mailbox frame, and remove the Rear Lower Cover, along with the attached IN Gate Solenoid. Remove the two brass screws securing the IN Gate Solenoid to the Rear Lower Cover, and remove the Solenoid along with the Solenoid Spring and Link.

  • Page 192: In Gate

    4025 Options IN Gate 4-50 Service Manual...
  • Page 193 4025 Options Removal Remove the Lower Chute. Remove the Mailbox Rear Cover Assembly. Lift the Mailbox off of the printer and set it down on the front frame. Remove the screw securing the Gate IN Arm Bracket to the Mailbox frame, and remove the Bracket along with the attached IN Gate Arm and Arm Spring.

  • Page 194: Lower Chute

    4025 Options Lower Chute Removal Remove the Mailbox Left Cover Assembly. Remove the Mailbox Front Cover. Remove the two screws securing the Lower Chute to the Mailbox frame. Push the Lower Chute out through the front of the Mailbox. Remove the screw securing the Vertical Sensor PWB to the Lower Chute and remove the PWB.

  • Page 195: Mailbox Interlock Switch

    4025 Options Mailbox Interlock Switch Removal Remove the Mailbox Front Cover. Open the Left Cover. Disconnect P/J 822. Remove the two screws securing the Mailbox Interlock Switch to the Mailbox frame, and remove the Switch. Replacement Position the Mailbox Interlock Switch as shown, and reinstall the Switch onto the Mailbox frame.

  • Page 196: Transport Guide Assembly

    4025 Options Transport Guide Assembly Removal Remove the screw securing the left cover strap to the mailbox top cover Lift the transport guide assembly up and away from the two hinges. Rotate the transport guide assembly enough to unhook the KL clip. Replacement Rotate the transport guide assembly to hook the KL clip to the transport assembly.

  • Page 197: High Capacity Feeder

    4025 Options High Capacity Feeder gh Capacity Feeder 4-55 Repair Information...
  • Page 198 4025 Options Removal Lock the two front HCF casters. Disconnect the HCF interface cable from P613 located at the rear of the base printer. Remove Tray 2 from the base printer. Open Tray 3 and remove the two screws securing the Left and Right Docking Brackets to the HCF frame, and remove the Brackets.

  • Page 199: Hcf Rear Cover

    4025 Options HCF Rear Cover Removal Remove the two screws securing the Rear Cover to the HCF frame. Pull up on the Rear cover and remove it from the frame. Replacement Slip the two tabs that are located at the bottom of the Rear Cover into the openings at the bottom of the HCF frame.

  • Page 200: Hcf Left Cover

    4025 Options HCF Left Cover Removal Slide Trays 3 and 4 a few inches out of the HCF. Open the Left Cover door. Remove two screws securing the Left Cover to the HCF frame. Lift up the Left Cover to free the four latching tabs from the HCF frame, and remove the Cover.

  • Page 201: Left Cover Assembly

    4025 Options Left Cover Assembly Removal Remove the HCF Left Cover. Open the Left Cover Assembly. Remove the two screws securing the Left Cover Assembly to the Left Cover. Remove the ends of the two Straps from the Left Cover Assembly. Remove the E-ring from the rear of the Cover Assembly shaft.

  • Page 202: Right Cover

    4025 Options Right Cover Removal Remove the two screws securing the Right Cover to the HCF frame. Lift up the Right Cover to free the two latching tabs from the HCF frame, and remove the Cover. Replacement Hook the two latching tabs that are located at the bottom edge of the Right Cover into the openings at the bottom of the HCF frame.

  • Page 203: Front Cover Btm

    4025 Options Front Cover BTM Removal Slide Trays 4 and 5 out of the HCF far enough so you can access the two screws securing the Front Cover BTM to the HCF frame. Remove the two screws securing the Front Cover BTM to the HCF frame , and remove the Cover.

  • Page 204: Hcf Feed Motor

    4025 Options HCF Feed Motor 4-62 Service Manual...
  • Page 205 4025 Options Removal Remove the HCF Rear Cover. Disconnect P/J217 from the HCF PWB. Hold on to the rear of the Feed Motor while you remove the two screws securing the Motor Bracket to the frame (Figure 1). Slide the Feed Motor out of the HCF Drive Belt and remove the Motor from the frame.

  • Page 206: Hcf Drive Belt

    4025 Options HCF Drive Belt 4-64 Service Manual...
  • Page 207 4025 Options Removal Remove the HCF Rear Cover. Remove the HCF Feed Motor. Remove two screws securing the Take Away Bracket to the frame and remove the Bracket (Figure 1). Remove the E-ring securing HCF Drive Gear 1 and the E-ring securing Tray 4 Drive Gear 1 and slide both Gears off of the shafts (Figure 2).

  • Page 208: Hcf Pwb

    4025 Options HCF PWB Removal Remove the HCF Rear Cover. Disconnect all seven P/Js from the HCF PWB. Press in and release the latches on the four plastic standoffs securing the PWB to the HCF frame, and remove the PWB. Replacement Position the HCF PWB so P/Js 484 and 480 are at the top.

  • Page 209: Lift Motor

    4025 Options Lift Motor Note: Use this procedure for removal of Tray 3, Tray 4, and Tray 5 Lift Motors. Removal Remove the Paper Tray (3 ~ 5) from the Paper Feeder (3 ~ 5). Remove the HCF Rear Cover. Disconnect the P/J that is attached to the Lift Motor.

  • Page 210: Tray 3 Paper Size Sensor Pwb

    4025 Options Tray 3 Paper Size Sensor PWB Removal Slide Paper Tray 3 out of the HCF. Disconnect the P/J 110 from the Size Sensor PWB. Remove the screw securing the Tray 3 Paper Size Sensor PWB to the HCF frame and remove the Sensor.

  • Page 211: Tray 4 And Tray 5 Paper Size Sensor Pwbs

    4025 Options Tray 4 and Tray 5 Paper Size Sensor PWBs Removal Remove Tray 4 and Paper Tray 5 from the HCF. Disconnect the P/J from the Size Sensor PWB. Remove the screw securing the Size Sensor PWB to the HCF frame, pull the PWB straight out and remove it from the frame.

  • Page 212: Trays 3, 4, And 5 Feed Clutches

    4025 Options Trays 3, 4, and 5 Feed Clutches Note: Removal and replacement of the three Feed Clutches are almost identical. Removal Remove the Rear Cover. Remove the Paper Tray associated with the Feed Clutch you are going to remove. Disconnect the P/J from the Feed Clutch.

  • Page 213: Trays 3, 4, And 5 No Paper Actuators

    4025 Options Trays 3, 4, and 5 No Paper Actuators 4-71 Repair Information...
  • Page 214 4025 Options Note: Use this procedure for removing and replacing the No Paper Actuator for Trays 3, 4, and 5. Removal Remove the Paper Tray associated with the No Paper Actuator you are going to remove. Remove the No Paper Sensor associated with the No Paper Actuator you are going to remove.

  • Page 215: Trays 3, 4, And 5 No Paper Sensors

    4025 Options Trays 3, 4, and 5 No Paper Sensors 4-73 Repair Information...
  • Page 216 4025 Options Note: Use this procedure for removing and replacing the No Paper Sensors for Trays 3, 4, and 5. Removal Remove the Paper Tray associated with the No Paper Sensor you are going to remove. Squeeze the Sensor latches and remove the No Paper Sensor from the frame. Disconnect the P/J from the Sensor.

  • Page 217: Trays 3, 4, And 5 Paper Level Sensors

    4025 Options Trays 3, 4, and 5 Paper Level Sensors 4-75 Repair Information...
  • Page 218 4025 Options Note: Use this procedure for removing and replacing the Paper Level Sensors for Trays 3, 4, and 5. Removal Remove the Paper Tray associated with the Paper Level Sensor you are going to remove. Squeeze the Sensor latches and remove the Paper Level Sensor from the frame. Disconnect the P/J from the Sensor.

  • Page 219: Left Cover Interlock Switch

    4025 Options Left Cover Interlock Switch Removal Open the Left Cover Assembly. Squeeze together the top and bottom of the Interlock Switch to release the Switch latches, and pull the Switch away from the HCF frame. Disconnect P/J 114 from the Switch. Replacement Reconnect P/J 114 to the Left Cover Interlock Switch.

  • Page 220: Tray 3 Take Away Sensor

    4025 Options Tray 3 Take Away Sensor Removal Open the Left Cover Assembly. Remove the Spring that is located on the left side of the Inner Chute. Remove the two screws securing the Inner Chute to the HCF frame, and remove the Inner Chute.

  • Page 221: Tray 3 Feeder Assembly

    4025 Options Tray 3 Feeder Assembly WARNING: Take care not to break or dislodge the No Paper Actuator when removing or replacing the Tray 3 Feeder Assembly. Removal Remove Tray 3 from the HCF. Remove the Rear Cover. Open the Left Cover Assembly. Remove the Spring that is located on the left side of the Inner Chute.
  • Page 222 4025 Options Replacement Hold down the Stopper Link while you insert the end of the Feed Shaft into the opening in the rear of the HCF frame. Slide the Bearing into the Bearing cutout (refer to the figure). When both the Bearing is in place and the end of the Feed Shaft is through the opening in the rear of the frame, release the Stopper Link.

  • Page 223: Tray 3 Retard Assembly

    4025 Options Tray 3 Retard Assembly 4-81 Repair Information...
  • Page 224 4025 Options Removal Remove Tray 3 from the HCF. Remove the Rear Cover. Remove the HCF Left Cover. Open the Left Cover Assembly. Remove the Spring that is located on the left side of the Inner Chute (Figure 1). Remove the two screws securing the Inner Chute to the HCF frame, and remove the Inner Chute.
  • Page 225 4025 Options Replacement Insert the Retard Assembly into the HCF as shown. Insert the bearing end of the Shaft into the bearing cutout at the front of the HCF frame. Slide the Shaft far enough to the front so you can insert the rear of the Shaft into the cutout at the rear of the HCF frame.

  • Page 226: Tray 3 Nudger, Feeder, And Retard Rolls

    4025 Options Tray 3 Nudger, Feeder, and Retard Rolls 4-84 Service Manual...
  • Page 227 4025 Options Note: Replace the Feeder, Nudger, and Retard Rolls as a unit. Removal Remove the Tray 3. Swing the Chute down so it clears the Rolls. Pull out on the Retard Roll latch and slide the Retard Roll off of the shaft. Repeat step 3 for the Nudger and Feeder Rolls.

  • Page 228: Hcf Tray 4

    4025 Options HCF Tray 4 Removal Pull Tray 4 out until it stops. Press and hold the tray release button while you slide Tray 4 out of the HCF. Replacement Align the guide rails on both sides of Tray 4 with the guide rails on the HCF frame. Push Tray 4 all the way into the HCF.

  • Page 229: Tray 4 Front Cover

    4025 Options Tray 4 Front Cover Removal Slide Tray 4 a few inches out of the HCF. Remove the screw securing the Tray 4 Front Cover to the Tray frame. Lift up and out to remove the Front Cover. Replacement Insert the two latches located on the inside of the Front Cover into the two slots in the Tray frame.

  • Page 230: Tray 4 Take Away Sensor

    4025 Options Tray 4 Take Away Sensor Removal Remove Tray 3, Tray 4, and Tray 5 from the HCF. Squeeze together the four latches that are located at the four corners of the Tray 4 Take Away Sensor, while pulling the Sensor up and out of the cutout in the HCF frame.

  • Page 231: Tray 4 Take Away Roll

    4025 Options Tray 4 Take Away Roll 4-89 Repair Information...
  • Page 232 4025 Options Removal Slide out Tray 5. Remove the Rear Cover. Remove the HCF Left Cover. Open the Left Cover Assembly. Remove the Spring that is located on the left side of the Inner Chute (Figure 1). Remove the two screws securing the Inner Chute to the HCF frame, and remove the Inner Chute.
  • Page 233 4025 Options Replacement Slide the captured bearing end of the Take Away Roll shaft into the bearing hole at the front of the HCF frame (Figure 3). Reinstall the Bearing into the bearing hole at the rear of the HCF. Place Gear 22 over the Bearing and hold it there while you reinstall the Take Away Roll shaft.

  • Page 234: Tray 4 Feeder Assembly

    4025 Options Tray 4 Feeder Assembly 4-92 Service Manual...
  • Page 235 4025 Options Removal Remove Tray 4 from the HCF. Remove the HCF Rear Cover. Open the Left Cover Assembly. Remove Tray 4 Feed Clutch. Remove the E-ring securing the Feed Shaft Bearing to the HCF frame, and slide the Bearing off of the shaft. Hold down the Stopper Link while you pull the Feeder Assembly to the front of the HCF frame.

  • Page 236: Tray 4 Retard Assembly

    4025 Options Tray 4 Retard Assembly 4-94 Service Manual...
  • Page 237 4025 Options Removal Remove Tray 4 from the HCF. Remove the HCF Rear Cover. Open the Left Cover Assembly. Remove the screw securing the Left Cover Left Strap to the HCF frame, and move the Strap out of the way. Unhook one arm of the Retard Spring from the hole in the HCF frame, and release the Spring.

  • Page 238: Tray 4 Feed, Nudger, And Retard Rolls

    4025 Options Tray 4 Feed, Nudger, and Retard Rolls 4-96 Service Manual...
  • Page 239 4025 Options Removal Note: Replace the Feeder, Nudger, and Retard Rolls as a unit. Remove the Tray 4. Swing the Chute down so it clears the Rolls. Pull out on the Retard Roll latch and slide the Retard Roll off of the shaft. Repeat step 3 for the Nudger and Feeder Rolls.

  • Page 240: Hcf Tray 5

    4025 Options HCF Tray 5 Removal Remove Tray 3. Slide Tray 5 out unit it stops. Use a flat screwdriver blade to press down on the latch spring that is located on the left Tray 5 guide rail, while you slide free the left side of the Tray. Press and hold the two release buttons, that are located behind Tray 5, while you slide Tray 5 out of the HCF.

  • Page 241: Tray 5 Front Cover

    4025 Options Tray 5 Front Cover Removal Slide Tray 5 out unit it stops. Open Tray 5 Upper Chute. Remove the two screws securing the Tray 5 Front Cover to the Tray frame. Lift up and out to remove the Front Cover. Replacement Insert the two latches located on the inside bottom of the Front Cover into the two slots in the Tray frame.

  • Page 242: Tray 5 Feeder Assembly

    4025 Options Tray 5 Feeder Assembly 4-100 Service Manual...
  • Page 243 4025 Options Removal Remove Tray 3 from the HCF. Remove Tray 5 from the HCF. Remove the HCF Rear Cover. Remove Tray 5 Feed Clutch. Remove the E-ring securing the Feed Shaft Bearing to the HCF frame, and slide the Bearing off of the shaft.

  • Page 244: Tray 5 Retard Assembly

    4025 Options Tray 5 Retard Assembly 4-102 Service Manual...
  • Page 245 4025 Options Removal Remove Tray 3 from the HCF. Remove Tray 5 from the HCF. Remove the HCF Rear Cover. Remove the screw securing the Fixed Gear to the HCF frame, and remove the Gear. Slide the Retard Gear off of the Retard Shaft. Slide the Retard Assembly to the rear of the HCF to release the front of the Retard Support Shaft from the cutout in the HCF frame.

  • Page 246: Tray 5 Feed, Nudger, And Retard Rolls

    4025 Options Tray 5 Feed, Nudger, and Retard Rolls 4-104 Service Manual...
  • Page 247 4025 Options Note: Replace the Feeder, Nudger, and Retard Rolls as a unit. Removal Remove Tray 4 and slide out Tray 5. Slide the Chute forward so it clears the Rolls. Pull out on the Retard Roll latch and slide the Retard Roll off of the shaft. Repeat step 3 for the Nudger and Feeder Rolls.
  • Page 248 4025 Options 4-106 Service Manual...

  • Page 249: Connector Locations

    4025 Options 5. Connector Locations Use the tables and maps in this section to locate specific P/J connectors within the Envelope Feeder, Duplex Unit, Mailbox, and High Capacity Feeder. Locate the P/J connector number in the first column of the table. Locate the corresponding map and location number, such as M1-5, in the second column.

  • Page 250: Envelope Feeder P/J Location Map 1

    4025 Options Envelope Feeder P/J Location Map 1 Envelope Feeder Wiring Diagrams This section contains a Master Wiring Diagram for the printer Envelope Feeder option. The Master Wiring Diagram shows the interconnections of the major subsystems within the Envelope Feeder. The remainder of this section presents an individual block diagram (BD) to better illustrate the electrical relationships between components and assemblies within the Envelope Feeder.
  • Page 251 4025 Options Connector Locations...
  • Page 252 4025 Options Envelope Feeder Master Wiring Diagram BD1 MCU PWB↔Envelope PWB↔Envelope Feeder Components Service Manual...
  • Page 253 4025 Options BD1 MCU PWB↔Envelope PWB↔Envelope Feeder Components The following table shows the signal names for this BD: Signal Name Description SNR#SIZE Analog signal from the Envelope Size Sensor. Voltage levels 0VDC~5VDC SNR#FEED Monitors paper between Envelope Feeder and base engine. High=Paper present. Low=No paper present SNR#NOP Signal from No Paper Sensor...

  • Page 254: Duplex X

    4025 Options Duplex x Duplex P/J Location Table Map & Connected to... Other end connected to... Number M1-10 Wait Sensor P475 Duplex PWB M1-2 Exit Sensor P474 Duplex PWB M1-1 Duplex Interlock Switch P474 Duplex PWB M1-3 Duplex PWB Exit Sensor M1-5 Duplex PWB Duplex Motor...

  • Page 255: Duplex P/J Location Map 1

    4025 Options Duplex P/J Location Map 1 Connector Locations...

  • Page 256: Duplex Wiring Diagrams

    4025 Options Duplex Wiring Diagrams Service Manual...
  • Page 257 4025 Options BD1 I/O PWB↔DUPLEX PWB↔DUPLEX COMPONENTS Connector Locations...
  • Page 258 4025 Options BD1 I/O PWB↔DUPLEX PWB↔DUPLEX COMPONENTS The following table shows the signal names for this BD: Signal Name Description OPT$TX+ Status of Duplex Unit sent to MCU. High=Mark. Low=No mark OPT#RX+ Status of MCU sent to the Duplex Unit. High=Mark. Low=No mark DUP#DET Monitors presence of a Duplex Unit.

  • Page 259: Mailbox

    4025 Options Mailbox Mailbox P/J Location Table Map & Connected to... Other end connected to... Number M1-9 P/J405 MCU PWB P/J800 Mailbox Control PWB M1-8 Mailbox Control PWB P405 MCU PWB M1-2 Mailbox Control PWB P/J815 Entrance Sensor P/J818 Vertical Jam Sensor P/J820 Bin 10 Jam Sensor P/J822 Interlock Switch M1-1...

  • Page 260: Mailbox P/J Location Map 1

    4025 Options Mailbox P/J Location Map 1 5-12 Service Manual...

  • Page 261: Mailbox Wiring Diagrams

    4025 Options Mailbox Wiring Diagrams 5-13 Connector Locations...
  • Page 262 4025 Options BD1 MCU PWB↔Mailbox Control PWB↔Mailbox Components 5-14 Service Manual...
  • Page 263 4025 Options BD1 MCU PWB↔Mailbox Control PWB↔Mailbox/Mailbox Components The following table shows the signal names for this BD: Signal Name Description MBX IN Monitors the presence of paper at the Entrance Sensor. High=No paper present. Low=Paper paper present INTLK ON Monitors the condition of the Mailbox Left Cover.
  • Page 264 4025 Options BD2 Mailbox Control PWB↔Solenoids 5-16 Service Manual...

  • Page 265: High Capacity Feeder

    4025 Options BD2 Mailbox Control PWB↔Solenoids The following table shows the signal names for this BD: Signal Name Description GATE SOL9 ON Controls Bin 9 Gate Solenoid. High=On. Low=Off GATE SOL8 ON Controls Bin 8 Gate Solenoid. High=On. Low=Off GATE SOL7 ON Controls Bin 7 Gate Solenoid.
  • Page 266 4025 Options Map & Connected to... Other end connected to... Number M1-6 Tray 3 Take Away Sensor P482 HCF PWB M1-5 Tray 4 Take Away Sensor P486 HCF PWB M2-3 Tray 3 Feed Clutch P482 HCF PWB M2-4 Tray 3 Lift Motor P482 HCF PWB M2-6 Tray 4 Feed Clutch...

  • Page 267: High Capacity Feeder P/J Location Map 1

    4025 Options High Capacity Feeder P/J Location Map 1 5-19 Connector Locations...

  • Page 268: High Capacity Feeder P/J Location Map 2

    4025 Options High Capacity Feeder P/J Location Map 2 5-20 Service Manual...

  • Page 269: High Capacity Feeder Wiring Diagrams

    4025 Options High Capacity Feeder Wiring Diagrams This section of the manual contains a Master Wiring Diagram for the High Capacity Feeder option. The Master Wiring Diagram shows the interconnections of the major subsystems within the High Capacity Feeder. The remainder of this section presents individual block diagrams (BD) to better illustrate the electrical relationships between components and assemblies within the High Capacity Feeder.
  • Page 270 4025 Options BD1 HCF PWB↔Tray 5 Components 5-22 Service Manual...
  • Page 271 4025 Options BD1 HCF PWB↔Tray 5 Components The following table shows the signal names for this BD: Signal Name Description CABI TEST Test point CAB#DET Monitors presence of the HCF. High=Not attached. Low=Attached SNR#TA4 Monitors paper travel between Tray 4 and Tray 3. High=Paper present. Low=Paper not present SNR#TA5 Monitors paper travel between Tray 5 and Tray 4.
  • Page 272 4025 Options BD2 HCF PWB↔HCF Trays 3 and 4 Components 5-24 Service Manual...
  • Page 273 4025 Options BD2 HCF PWB↔HCF Trays 3 and 4 Components The following table shows the signal names for this BD: Signal Name Description SNR#TAROL4 Monitors paper travel between Tray 4 and Tray 3. High=Paper present. Low=Paper not present L/H#INTLK Monitors the HCF Cover Interlock Switch. High=Cover closed. Low=Cover open CL$FEED2 Controls Tray 3 Feed Clutch.
  • Page 274 4025 Options 5-26 Service Manual...

  • Page 275: Preventative Maintenance

    Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover • Possible safety exposure from any non-Lexmark attachments Scheduled Maintenance There is no scheduled maintenance on the Mailbox, Duplex, Envelope Feeder, or High Capacity Feeder.
  • Page 276 4025 Options Service Manual...

  • Page 277: Parts Catalog

    4025 Options 7. Parts Catalog How to Use the Parts Catalog • The callout numbers shown in each parts illustration correspond to the parts list numbers for that illustration. • The capital letters “C,” “E,” "KL," and “S” shown in an illustration stand for C-ring, E- ring, Clamp, and Screw, respectively.

  • Page 278: Assembly 1: Envelope Feeder

    4025 Options Assembly 1: Envelope Feeder Service Manual...

  • Page 279: Index

    4025 Options Assembly 1: Envelope Feeder Asm- Part Units Description Index Number 12G4181 FEEDER ASM, ENVELOPE Parts Catalog...

  • Page 280: Assembly 2: Duplex

    4025 Options Assembly 2: Duplex Service Manual...
  • Page 281 4025 Options Assembly 2: Duplex Asm- Part Units Description Index Number 12G4152 COVER, DUPLEX 12G4153 COVER, DUPLEX R 12G4154 COVER, DUPLEX F 12G4155 TRANSPORT, DUPLEX ASSEMBLY 12G4156 CABLE ASM, DUPLEX 12G4158 COVER, DUPLEX TRAY Parts Catalog...
  • Page 282 4025 Options Assembly 2.1: Duplex Service Manual...
  • Page 283 4025 Options Assembly 2.1: Duplex Asm- Part Units Description Index Number 12G4162 SUPPORT ASM, DUPLEX 12G4163 STRAP ASM, SUPPORT 12G4159 CARD ASM, DUPLEX 12G4161 MOTOR ASM, DUPLEX 12G4160 CLUTCH ASM, DUPLEX Parts Catalog...
  • Page 284 4025 Options Assembly 2.2: Duplex Service Manual...
  • Page 285 4025 Options Assembly 2.2: Duplex Asm- Part Units Description Index Number 12G4165 LATCH ASM, DUPLEX 12G4164 SENSOR, PHOTO Parts Catalog...
  • Page 286 4025 Options Assembly 2.3: Duplex 7-10 Service Manual...
  • Page 287 4025 Options Assembly 2.3: Duplex Asm- Part Units Description Index Number 12G4167 ROLLER ASM, DUPLEX EXIT 12G4172 ROLLER ASM, TRANSPORT 12G4166 BEARING TRANSPORT, EXIT 12G4176 ROLLER ASM EXIT, TRANSPORT WAIT 12G4177 CLUTCH DUPLEX, ONE-WAY 12G4179 BEARING 12G4174 PULLEY, 20 12G4175 BELT, SYNCHRONOUS 12G4173 GEAR, 18...
  • Page 288 4025 Options Assembly 2.4: Duplex 7-12 Service Manual...
  • Page 289 4025 Options Assembly 2.4: Duplex Asm- Part Units Description Index Number 12G4180 GUIDE ASM, DUPLEX 7-13 Parts Catalog...

  • Page 290: Assembly 3: Mailbox

    4025 Options Assembly 3: Mailbox 7-14 Service Manual...
  • Page 291 4025 Options Assembly 3: Mailbox Asm- Part Units Description Index Number 12G4188 ASSEMBLY, MAILBOX 12G4189 STOP, PAPER 12G4190 BRACKET, MAILBOX 12G4191 SCREW 7-15 Parts Catalog...
  • Page 292 4025 Options Assembly 3.1: Mailbox 7-16 Service Manual...
  • Page 293 4025 Options Assembly 3.1: Mailbox Asm- Part Units Description Index Number 12G4195 COVER, TOP 12G4192 PANEL, MAILBOX 12G4193 LABEL, MAILBOX 12G4194 COVER, FRONT 12G4196 COVER, LEFT 12G4199 STRAP, LEFT COVER 12G4198 HANDLE, MAILBOX 12G4197 COVER, REAR 7-17 Parts Catalog...
  • Page 294 4025 Options Assembly 3.2: Mailbox 7-18 Service Manual...
  • Page 295 4025 Options Assembly 3.2: Mailbox Asm- Part Units Description Index Number 12G4200 COVER ASM, ACTUATOR 12G4201 SENSOR JAM, BIN 10 12G4202 ACTUATOR, 1 FULL STACK 12G4203 ACTUATOR, 2 FULL STACK 12G4204 TRANSPORT, GUIDE ASM 7-19 Parts Catalog...
  • Page 296 4025 Options Assembly 3.3: Mailbox 7-20 Service Manual...
  • Page 297 4025 Options Assembly 3.3: Mailbox Asm- Part Units Description Index Number 12G4205 ASSEMBLY, TRAY 1 12G4206 ROLLER ASM, EXIT 1 12G4207 BELT, DRIVE 7-21 Parts Catalog...
  • Page 298 4025 Options Assembly 3.4: Mailbox 7-22 Service Manual...
  • Page 299 4025 Options Assembly 3.4: Mailbox Asm- Part Units Description Index Number 12G4210 ASSEMBLY, TRAY ODD 12G4211 SOLENOID, GATE 1-9 12G4209 ASSEMBLY, TRAY 1 12G4208 ASSEMBLY, TRAY EVEN 7-23 Parts Catalog...
  • Page 300 4025 Options Assembly 3.5: Mailbox 7-24 Service Manual...
  • Page 301 4025 Options Assembly 3.5: Mailbox Asm- Part Units Description Index Number 12G4219 SWITCH ASM, INTERLOCK 12G4220 PINCH ROLL ASSEMBLY 12G4218 SENSOR, LED 12G4217 GUIDE PAPER, LOWER 12G4215 SENSOR 12G4216 GUIDE, PAPER 12G4222 COVER, LOWER 12G4214 SPRING, GATE IN 12G4221 ASSEMBLY, BRACKET 12G4213 SPRING, SOLENOID 12G4212...
  • Page 302 4025 Options Assembly 3.6: Mailbox 7-26 Service Manual...
  • Page 303 4025 Options Assembly 3.6: Mailbox Asm- Part Units Description Index Number 12G4226 HARNESS, DRIVE MOTOR 12G4225 HARNESS, SENSOR 12G4223 CARD ASM, MAILBOX 12G4227 MOTOR, DRIVE 12G4224 HARNESS, BASE ENGINE 7-27 Parts Catalog...
  • Page 304 4025 Options Assembly 3.7: Mailbox 7-28 Service Manual...
  • Page 305 4025 Options Assembly 3.7: Mailbox Asm- Part Units Description Index Number 12G4228 BRACKET, MAILBOX 12G4229 BRACKET, RIGHT 12G4231 SCREW, BRACKET 12G4230 BRACKET, LEFT 7-29 Parts Catalog...

  • Page 306: Assembly 4: High Capacity Feeder

    4025 Options Assembly 4: High Capacity Feeder 7-30 Service Manual...
  • Page 307 4025 Options Assembly 4: High Capacity Feeder Asm- Part Units Description Index Number 12G4118 KIT, HCF MOUNTING 12G4110 COVER, FRONT BOTTOM 12G4109 COVER, LEFT HCF 12G4113 CASTER, S 12G4117 COVER, FOOT 12G4116 FOOT ASM, AJUSTER 12G4115 BRACKET, FOOT 12G4114 CASTER 12G4112 COVER, REAR 12G4111...
  • Page 308 4025 Options Assembly 4.1: High Capacity Feeder 7-32 Service Manual...
  • Page 309 4025 Options Assembly 4.1: High Capacity Feeder Asm- Part Units Description Index Number 12G4123 KIT, HCF DRIVE GEAR 12G4122 CABLE, ASSEMBLY HCF 12G4121 CARD ASM, HCF 12G4119 MOTOR, FEED ASSEMBLY 12G4120 BELT, SYNCHRONOUS 7-33 Parts Catalog...
  • Page 310 4025 Options Assembly 4.2: High Capacity Feeder 7-34 Service Manual...
  • Page 311 4025 Options Assembly 4.2: High Capacity Feeder Asm- Part Units Description Index Number 12G4125 SWITCH ASM, PAPER SIZE TR 3 12G4126 SWITCH ASM, PAPER SIZE TR4, 5 12G4124 GUIDE ASM, FRONT TR4 12G4127 MOTOR ASM, TRAY 4, 5 7-35 Parts Catalog...
  • Page 312 4025 Options Assembly 4.3: High Capacity Feeder 7-36 Service Manual...
  • Page 313 4025 Options Assembly 4.3: High Capacity Feeder Asm- Part Units Description Index Number 12G4128 STOP, LINK TRAY 4 12G4129 GUIDE, FRONT RT 7-37 Parts Catalog...
  • Page 314 4025 Options Assembly 4.4: High Capacity Feeder 7-38 Service Manual...
  • Page 315 4025 Options Assembly 4.4: High Capacity Feeder Asm- Part Units Description Index Number 12G4130 KIT, TRAY 3 CLUTCH 7-39 Parts Catalog...
  • Page 316 4025 Options Assembly 4.5: High Capacity Feeder 7-40 Service Manual...
  • Page 317 4025 Options Assembly 4.5: High Capacity Feeder Asm- Part Units Description Index Number 12G4131 KIT, GEAR TAKE AWAY 3 12G4132 KIT, RETARD TAKE AWAY 3 7-41 Parts Catalog...
  • Page 318 4025 Options Assembly 4.6: High Capacity Feeder 7-42 Service Manual...
  • Page 319 4025 Options Assembly 4.6: High Capacity Feeder Asm- Part Units Description Index Number 12G4134 KIT, PAPER PICKUP 12G4133 FEEDER, HCF ASSEMBLY 7-43 Parts Catalog...
  • Page 320 4025 Options Assembly 4.7: High Capacity Feeder 7-44 Service Manual...
  • Page 321 4025 Options Assembly 4.7: High Capacity Feeder Asm- Part Units Description Index Number 12G4135 KIT, RETARD TAKE AWAY TR4 7-45 Parts Catalog...
  • Page 322 4025 Options Assembly 4.8: High Capacity Feeder 7-46 Service Manual...
  • Page 323 4025 Options Assembly 4.8: High Capacity Feeder Asm- Part Units Description Index Number 12G4136 GUIDE, PAPER 7-47 Parts Catalog...
  • Page 324 4025 Options Assembly 4.9: High Capacity Feeder 7-48 Service Manual...
  • Page 325 4025 Options Assembly 4.9: High Capacity Feeder Asm- Part Units Description Index Number 12G4137 KIT, TAKE AWAY TR 5 12G4138 KIT, RETARD TAKE AWAY TR 5 7-49 Parts Catalog...
  • Page 326 4025 Options Assembly 4.10: High Capacity Feeder 7-50 Service Manual...
  • Page 327 4025 Options Assembly 4.10: High Capacity Feeder Asm- Part Units Description Index Number 12G4139 COVER ASM, LH 12G4140 SUPPORT, COVER LH 7-51 Parts Catalog...
  • Page 328 4025 Options Assembly 4.11: High Capacity Feeder 7-52 Service Manual...
  • Page 329 4025 Options Assembly 4.11: High Capacity Feeder Asm- Part Units Description Index Number 12G4141 TRAY ASSEMBLY 12G4144 KIT, TRAY 4 CABLES 12G4142 BRAKE BRACKET ASSEMBLY 12G4143 COVER ASSEMBLY 7-53 Parts Catalog...
  • Page 330 4025 Options Assembly 4.12: High Capacity Feeder 7-54 Service Manual...
  • Page 331 4025 Options Assembly 4.12: High Capacity Feeder Asm- Part Units Description Index Number 12G4145 TRAY ASSEMBLY 12G4147 KIT, TRAY 5 CABLES 12G4146 BRAKE BRACKET ASSEMBLY 7-55 Parts Catalog...
  • Page 332 4025 Options Assembly 4.13: High Capacity Feeder 7-56 Service Manual...
  • Page 333 4025 Options Assembly 4.13: High Capacity Feeder Asm- Part Units Description Index Number 12G4148 TRANSPORT ASSEMBLY 12G4149 SCREW M3 12G4150 COVER ASSEMBLY 12G4151 KIT, SLIDE BAR 7-57 Parts Catalog...
  • Page 334 4025 Options 7-58 Service Manual...
  • Page 335 4025 Options Index Symptom Service Checks Symptom Table Caution Labels High Capacity Feeder Caution Notice 2-32 Error Code Table Connector Locations Service Checks Duplex 2-33 Error Code Service Checks P/J Location Map 2-52 Symptom Service Checks P/J Location Table 2-33 Symptom Table Wiring Diagrams Mailbox...
  • Page 336 4025 Options 1-24 Envelope Feeder Power 1-24 Control Power and Control 1-15 1-38 Control Components Print Speeds 1-23 Drive Generation and Distribution Schematic Diagram Feeder Control Components Safety Details 1-11 General Specifications Caution Labels Mechanical Drive Fuser Components Overview Laser Components 1-10 Paper Path Mechanical Components...
  • Page 337 4025 Options 4-18 Rear Cover Inner Chute Assembly 4-53 Wait Clutch Interlock Switch 4-14 4-21 Wait Sensor Left Cover Assembly 4-52 Envelope Feeder Lower Chute 4-55 4-24 High Capacity Feeder Rear Cover 4-64 4-49 Drive Belt Rear Lower Cover 4-61 4-25 Front Cover BTM Top Cover...

  • Page 338: Index

    4025 Options 7-35 12G4124 12G4181 7-35 7-15 12G4125 12G4188 7-35 7-15 12G4126 12G4189 7-35 7-15 12G4127 12G4190 7-37 7-15 12G4128 12G4191 7-37 7-17 12G4129 12G4192 7-39 7-17 12G4130 12G4193 7-41 7-17 12G4131 12G4194 7-41 7-17 12G4132 12G4195 7-43 7-17 12G4133 12G4196 7-43 7-17...

Table of Contents