Lexmark W820 Service Manual
Lexmark W820 Service Manual

Lexmark W820 Service Manual

Printers
Hide thumbs Also See for W820:
Table of Contents

Advertisement

TM
Lexmark
W820, X820e, X830e, X832e
Printers
4025-XXX
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
• Index
• Manuals Menu
Lexmark and Lexmark with diamond design are
trademarks of Lexmark International, Inc., registered
in the United States and/or other countries.

Advertisement

Table of Contents
loading

Summary of Contents for Lexmark W820

  • Page 1 Printers 4025-XXX • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index • Manuals Menu Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 Lexington, Kentucky 40550, U.S.A or e-mail at ServiceInfoAndTraining@Lexmark.com. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you. Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 3: Table Of Contents

    4025-XXX Table of Contents Notices and Safety Information ..........ix Laser Advisory and Caution Labels .
  • Page 4 4025-XXX Printhead ............1-46 Printhead Components .
  • Page 5 4025-XXX Service Checks Flowchart ......... . . 2-9 How to Use the Service Checks Flowchart .
  • Page 6 4025-XXX Finisher Tests ........... . 3-19 Staple Test .
  • Page 7 4025-XXX Tray 1 & 2 Level Sensors ......... 4-27 Tray 1 &...
  • Page 8 4025-XXX I/O PWB ............4-89 Left Cover Interlock Switch Assembly .
  • Page 9: Notices And Safety Information

    4025-XXX Notices and Safety Information Laser Advisory and Caution Labels Notices and Safety Information...
  • Page 10: Class 1 Laser Statement Label

    4025-XXX Class 1 Laser Statement Label Notices and Safety Information...
  • Page 11: Laser Notices

    4025-XXX Laser Notices The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825. Class I laser products are not considered to be hazardous.
  • Page 12 4025-XXX stampante sono stati progettati in modo tale che le persone a contatto con la stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non ricevano radiazioni laser superiori al livello della classe 1. Avisos sobre el láser Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las...
  • Page 13 4025-XXX Lasermeddelelse Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825. Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer.
  • Page 14: 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 15 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 16 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 17: Preface

    4025-XXX Preface This manual describes the Lexmark W820 (4025-XXX) and contains maintenance procedures for service personnel only. It is divided into the following chapters: General Information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions.
  • Page 18 4025-XXX xviii Preface...
  • Page 19: General Information

    • Finisher Service information for the Envelope Feeder, Duplex, Mailbox, and High Capacity Feeder is contained in the Lexmark W820 Options Service Manual. Service information for the Finisher is in the Lexmark W820 Finisher Service Manual. Maintenance Approach The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part for the printer.
  • Page 20: Serial Number Locations

    4025-XXX Serial Number Locations Printer serial number labels are on the rear of the printer and inside the front cover. Service Manual...
  • Page 21: Symbols Used In This Manual

    4025-XXX Symbols Used in this Manual Various symbols are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger that might be present during a procedure or action. Be aware of all symbols when they are used, and always read NOTE, CAUTION, and WARNING messages.
  • Page 22: Mechanical Components

    4025-XXX Mechanical Components Manually rotate drive assemblies to inspect sprockets and gears. CAUTION: Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running. Laser Components CAUTION: This printer generates a laser beam as part of the printing process. The laser beam is a concentrated narrow beam of light that produces extreme heat at its focal point.
  • Page 23: Caution Labels

    4025-XXX Caution Labels Throughout the printer, warning labels are displayed on potentially dangerous components. When you service the printer, check to make sure that all caution labels are in place. Most importantly, read and obey all posted caution labels. Service Flowchart Included is a Service Flowchart that outlines the approach to troubleshooting and repair of the printer.
  • Page 24: Printer Overview

    4025-XXX Find the Cause of the Problem Use the “Service Flowchart” on page 1-5 to find out how to use the Service Checks. Use the “Service Checks” on page 2-11 to check printer components. Use the “Connector Locations” on page 5-1 to locate P/Js and test points.
  • Page 25: Schematic Diagram Of Printer Operation

    4025-XXX Schematic Diagram of Printer Operation The following illustration is a simplified schematic of the printer components, subsystems, and paper paths. Refer to individual sections of the Principles of Operation for greater detail on specific areas. General Information...
  • Page 26: Power And Control

    4025-XXX Power and Control The printer power cord plugs into an AC wall outlet. The other end of the power cord plugs into the Noise Filter PWB, where the Filter removes fluctuations from the AC line voltage. A Ground Fault Interrupter in the AC line protects the printer from electrical shorts.
  • Page 27: Paper Exit

    4025-XXX Fusing After image transfer, the toner image is not permanently fixed to the sheet of paper - it is still dry power and can be easily rubbed off. The Fuser has two rotating rolls; the Hot Roll and the Pressure Roll. A Lamp inside each of the Rolls heats the Fuser Rolls to °...
  • Page 28 4025-XXX The PSHV-R2 converts the +24VDC received from the I/O PWB into the bias voltage required by the Fuser. Safety Interlocks for the printer are made up of two separate switches that are wired in series with the I/O PWB and one switch that is attached to the MCU PWB. When the Front Cover is open, the Front Cover Interlock Switch cuts +24VDC output from the MCU PWB.
  • Page 29: Power Supply Components

    4025-XXX Power Supply Components The printer Power Supply is made up of five major components and a number of subcomponents. Noise Filter PWB Smooths and removes any fluctuation or hum from the AC line voltage. Main Power Switch: Used to switch AC voltage on and off (switches the printer on and off).
  • Page 30 4025-XXX Low Voltage Power Supply (LVPS) Takes filtered AC voltage and converts it into regulated +24VDC and +5VDC. The LVPS contains overcurrent protection circuits. If an excessive current begins to flow through any of the components supplied by the LVPS, the LVPS immediately shuts down all low voltage output.
  • Page 31: Electrical Safety Circuits

    4025-XXX PSHV-R2 Takes the +24VDC received from the I/O PWB and converts it into the Fuser Bias voltage. Electrical Safety Circuits The printer contains three safety circuits that are controlled by three interlock switches and one Ground Fault Interrupter (GFI). Cutting power prevents a service technician or a printer user from being injured by high voltage, by moving parts, or by exposure to the laser beam.
  • Page 32 4025-XXX SW1 (CRU Interlock) EP Cartridge I/O PWB +24VDC SW2 (Left Cover Interlock) Left Cover MCU PWB Front Cover Interlock Front Cover +24VDC Ground Fault Interrupter Main Power Switch Ground Fault Interrupter (GFI) Left Front Cover Interlock Switch 1-14 Service Manual...
  • Page 33: Printer Control

    4025-XXX Printer Control Printer control is a broad term that is used to describe the printer resources that monitor and control the actions and operations of the print engine - from warm-up, through the print cycle, to machine error detection. The center of printer control for the base engine is the Machine Control Unit PWB, or MCU PWB.
  • Page 34 4025-XXX 1-16 Service Manual...
  • Page 35 4025-XXX Printer Control Components The printer control is made up of the MCU PWB, the I/O PWB, and numerous connected components. Machine Control Unit PWB (MCU PWB) The printer receives status and command information from the I/O PWB and from the ESS PWB and controls most printer operations.
  • Page 36: Components Attached To Or Associated With The Mcu Pwb

    4025-XXX Components attached to or associated with the MCU PWB: I/O PWB Interface between the MCU PWB and most of the printer components. Low Voltage Power Supply Converts AC line voltage to +5VDC and +24VDC. ESS PWB Connected to the MCU PWB. The interface between the print engine and the host computer.
  • Page 37 4025-XXX Fuser Exit Sensor Monitors paper travel out of the Fuser. Face Up Exit Sensor Monitors paper travel out of the Offset Unit. Full Stack Sensor Monitors the paper level in the Output Tray. Exit Gate Solenoid Toggles the Exit Gate. Inverter CW Clutch Transmits Main Motor drive, forward, to the Offset Rolls.
  • Page 38 4025-XXX Registration Sensor Monitors paper travel out of the paper tray. No Paper Sensor 1 Monitors the paper level in Feeder 1. When the Lift Motor raises the Bottom Plate, the Plate raises the paper stack, the stack pushes the No Paper Actuator up and away from the No Paper Sensor.
  • Page 39 4025-XXX 1-21 General Information...
  • Page 40 4025-XXX Level 1 Sensor Monitors whether or not Tray 1 is installed. Installing the Tray pushes the Link Stopper out, which in turn lowers the Feed Roll and moves the Level 1 Sensor Actuator tab away from the Sensor window. MP Feeder Size Sensor Monitors the size of paper that is loaded in the MP Feeder.
  • Page 41 4025-XXX Lift Motor 1 Raises the paper tray in Feeder 1. The MCU PWB switches on the Lift Motor. The Motor rotates a square, metal shaft that is located inside the Paper Tray. The Shaft raises the Tongue, which in turn raises the Bottom Plate, and the paper stack, up to the Feed Rolls.
  • Page 42: Control Functions Of The Machine Control Unit (Mcu)

    4025-XXX No Paper Sensor 2 Monitors the paper level in Feeder 2. Functions identical to No Paper Sensor 1. Level 2 Sensor Monitors whether or not Tray 2 is installed. Size Sensor 2 Monitors the size of the paper that is loaded in Feeder 2. Take Away Roll Sensor 2 Monitors the paper travel at the Take Away Roll 2.
  • Page 43 4025-XXX Processing input information Logic on the MCU compares the input information with the timing and reference values that are stored in ROM and NVRAM on the PWB. Example follows: The Fuser Thermistor monitors the temperature of the Fuser Hot Roll and sends the current temperature value to the I/O PWB.
  • Page 44 4025-XXX Output to motors, solenoids, and other components After comparing input values with timing and reference values, the MCU makes a decision on the current status of the printer and responds appropriately. The MCU may switch on or off motors, solenoids, or other components. The MCU may also signal that an error occurred.
  • Page 45 4025-XXX 1-27 General Information...
  • Page 46: Mechanical Drive

    4025-XXX Mechanical Drive Mechanical Drive is a term that is used to describe both the rotation of the printer motors and the action of the gear clusters and clutches that are used to transmit and control motor rotation to the various components throughout the printer. The primary purpose of Mechanical Drive within the base printer is to drive a sheet of paper out of a selected paper tray, through the printer synchronous with the photo conductor surface and into an output tray.
  • Page 47: Mechanical Drive Components

    4025-XXX Mechanical Drive Components The mechanical drive is made up of the four major components. Offset Motor A +24VDC motor. Main Drive Assembly Contains the +24VDC Main Drive Motor, the +24VDC Drum Motor, and the Main Drive Assembly gears. The Main Motor and Drum Motor are attached to the Main Drive Assembly.
  • Page 48: Offset Motor

    4025-XXX Offset Motor During Offset Mode, the MCU switches on the Offset Motor. The Offset Motor transmits drive to the Offset Bracket. The Motor drives the Bracket toward the front of the printer, pushing the Offset Roll along with it, until the Bracket reaches the end of travel, where it stops.
  • Page 49 4025-XXX 1-31 General Information...
  • Page 50: Printer Motor Control

    4025-XXX Printer Motor Control The I/O PWB provides power to the Main Motor, Drum Motor, the Lift Motors, and the Offset Motor. All motors run on +24VDC. The Main Motor and Drum Motor are stepper motors. The MCU controls all motor operation. MCU signals step the Main Motor and Drum Motor through a 360°...
  • Page 51: Paper Path

    4025-XXX Paper Path Paper Path is the physical route that a sheet of paper takes through the printer during a print cycle; from leaving the Paper Cassette to arriving at the Output Tray. Rubber rollers and other components drive the paper along the Paper Path. A sheet of paper may be fed from either Tray 1, Tray 2, or from the MP Feeder.
  • Page 52 4025-XXX 1-34 Service Manual...
  • Page 53: Paper Path Components

    4025-XXX Paper Path Components The paper path is made up of a number of major components and subcomponents. Tray Assembly Holds plain paper of various sizes. Slides into the Feeder. Feeder 1 and Feeder 2 Framework that is attached under the printer. A Tray Assembly slides into the Feeder.
  • Page 54: Paper Path Mechanical Drive

    4025-XXX Drum and BTR (Bias Transfer Roll) In addition to xerographic functions, the Drum and BTR drive the paper out of the Xerographic area and into the Fuser area. Hot Roll and Pressure Roll In addition to fusing functions, the Hot Roll and Pressure Roll drive the sheet of paper out of the Fuser and into the Offset Unit.
  • Page 55 4025-XXX Mechanical Drive for Paper Fed from the MP Feeder The Main Motor provides mechanical drive for the MP Feeder. The Drive Assembly transmits drive to the MP Feeder Feed Clutch. The MP Feeder Feed Roll and Nudger Roll are attached to the MP Feeder Clutch. At paper feed, the MCU switches on the MP Feeder Feed Clutch.
  • Page 56 4025-XXX Mechanical Drive for Paper Fed from Tray 1 The Main Motor provides mechanical drive for Tray 1 feed. The Drive Assembly transmits drive to Tray 1 Feed Clutch. Tray 1 Feed Roll and Nudger Roll are attached to the Feed Clutch.
  • Page 57 4025-XXX Mechanical Drive for Paper Fed from Tray 2 The Main Motor provides mechanical drive for Tray 2 feed. The Drive Assembly transmits drive to Tray 2 Feed Clutch. Tray 2 Feed Roll and Nudger Roll are attached to the Feed Clutch.
  • Page 58: Mechanical Drive For Registration

    4025-XXX Mechanical Drive for Registration The Main Motor provides mechanical drive for the Registration Roll. The Main Drive Assembly transmits drive to the Registration Clutch. At a specific time in the print cycle the MCU switches on the Registration Clutch to align the paper with the image on the PC drum.
  • Page 59: Mechanical Drive For The Drum And Btr

    4025-XXX Mechanical Drive for the Drum and BTR The Drum Motor provides mechanical drive for the Drum and BTR. The Main Drive Assembly transmits drive to the Drum. A shutter covers and protects the Drum surface. When the Left Cover is closed, a mechanical link opens the Shutter. When the Left Cover is open, the link closes the Shutter.
  • Page 60 4025-XXX Mechanical Drive for the Fuser The Main Motor provides mechanical drive for the Fuser Assembly. The Main Drive Assembly transmits drive to the Fuser Drive Assembly and on to the Fuser Hot Roll Gear. A gear at the end of the Hot Roll drives the Pressure Roll. The Heat and Pressure Rolls rotates continuously while the Main Motor is on and the Left Front Cover is closed.
  • Page 61: Mechanical Drive For Exit Drive

    4025-XXX Mechanical Drive for Exit Drive The Main Motor provides mechanical drive for the Offset and Exit Rolls. The Main Drive Assembly transmits drive to the Inverter CW Clutch and to the Inverter CCW Clutch. At a specific point in the print cycle the MCU switches on the CW Clutch. The CW Clutch transmits forward drive to the Offset Roll, which drives the sheet of paper into the Face Down Output Tray.
  • Page 62: Mechanical Drive For Offset

    4025-XXX Mechanical Drive for Offset The Offset Motor provides mechanical drive for the Offset Rolls. The Offset Motor transmits drive to the Offset Bracket. If the printer is running in Offset mode, the MCU switches on the Offset Motor. The Motor drives the Offset Bracket toward the front of the printer.
  • Page 63: Paper Path Component Control

    4025-XXX Paper Path Component Control The logic on the MCU PWB controls the Paper Path components. Sensors along the paper path monitor the movement of each sheet of paper and send information back to the MCU, through the I/O PWB. The MCU provides the timing and data processing necessary to actuate clutches and solenoids, switch motors on and off, and to identify paper jams.
  • Page 64: Printhead

    4025-XXX Printhead The Printhead is the mechanism that performs Step 2. Expose of the print cycle. A semiconductor within the Printhead Assembly generates a beam of laser light. Image data received from the print controller modulates this beam, turning it on and off according to image information that is received from the host computer.
  • Page 65: Printhead Components

    4025-XXX Printhead Components The Printhead Assembly is made up of one major component housing a number of sub- components. CAUTION: The Printhead generates a laser beam. The laser beam is a very powerful and narrow beam of light that produces extreme heat at its focal point. The laser beam in the printer is invisible.
  • Page 66: Printhead Operation

    4025-XXX Printhead Operation The MCU PWB supplies +5VDC to drive the Laser Diode semiconductor. The semiconductor uses the +5VDC to generate a 5 milliwatt beam of invisible laser light. As is characteristic of semiconductor devices, the Laser Diode can switch states very rapidly.
  • Page 67: Image Resolution

    4025-XXX Image Resolution The printer has an adjustable print image resolution of 600 dpi (dots per inch). Print image resolution is determined by the number of dots (or pixels) per inch of beam sweep and the number of sweeps per inch of paper travel. In the case of the 600 dpi image resolution, there is a total of 600x600, or 360,000, separate pixels per square inch of printed image.
  • Page 68: Printhead Control

    4025-XXX Printhead Control The Laser Diode PWB controls laser power monitoring and adjustment. The MCU PWB controls the rest of the Printhead Assembly functions. The ESS PWB processes video data sent from a host computer. The ESS PWB then passes that data on to the MCU PWB which controls the flow of video data to the Laser Diode PWB.
  • Page 69: Printhead Safeguards

    4025-XXX Laser Hazards Lasers generate a very powerful beam of light that produces extreme heat at its focal point. The laser beam that the Printhead generates is invisible. Although you cannot see the laser beam, direct eye contact with the beam will cause serious eye injury. CAUTION: Always follow the laser service safety rules and use good judgement when working on the printer.
  • Page 70: Xerographics

    4025-XXX Xerographics Xerographics and the Print Cycle The printer xerographics is represented by steps 1 through 5, and steps 7 and 8 of the print cycle. The seven Xerographic steps (Step 6 Fuse is not part of the Xerographic cycle) in the print cycle are: Charge Places a uniform negative electrostatic charge on the surface of the drum.
  • Page 71: Xerographics Overview

    4025-XXX Xerographics Overview Xerography is the process of using an electrically charged surface and a dry, powered ink to create an image on a sheet of plain paper. Xerography, in some form, is used in most of today’s copiers and laser printers. The printer uses a number of components and AC and DC voltages in its xerographic process.
  • Page 72: Xerographic Components

    4025-XXX Xerographic Components Xerographics in the printer is made up of ten major components. Six of those components are housed inside the EP Cartridge. The EP Cartridge is a sealed unit that contains no field replaceable parts. The EP Cartridge is a CRU (Customer Replaceable Unit) with an estimated life of 23,000 prints;...
  • Page 73 4025-XXX Cleaning Blade The Cleaning Blade rides the surface of the rotating drum, removing any residual toner left from the previous print cycle. Drum Shutter The Drum Shutter protects the drum from damage by light or contamination. When the EP Cartridge is in the printer and the Left Upper Cover is closed, the Drum Shutter opens to expose the drum surface.
  • Page 74: Xerographic Process During A Print Cycle

    4025-XXX Xerographic Process During a Print Cycle Charge The Bias Charge Roll (BCR) places a uniform negative electrostatic charge on the surface of the drum. The drum surface is made of a photoconductive material that holds an electrical charge as long as the drum remains in darkness. Light striking the drum discharges the surface charge.
  • Page 75 4025-XXX The Printhead also helps to clean and prepare the drum by scanning the surface of the drum at the beginning of each individual printer cycle. This action discharges an residual DC charge that may still remain on the Drum from the last print cycle. Develop The toner contained within the EP Cartridge has a magnetic property that causes it to adhere to the Magnetic Roll.
  • Page 76 4025-XXX The toner adhering to the Magnet Roll is always in contact with the drum surface. When a less negative point on the drum (a discharged area) comes in contact with the more negative charged toner on the Magnet Roll, toner transfers from the Magnet Roll to that point on the drum.
  • Page 77 4025-XXX Transfer As the paper travels between the BTR and the drum surface, the Bias Transfer Roll (BTR) applies a positive charge to the back of the printing paper. This positive charge transfers the negative charged toner image from the drum surface to the top surface of the paper.
  • Page 78 4025-XXX Detack After the toner image transfers to the surface of the paper, the Detack Saw (a thin strip of metal that resembles a saw blade) applies a low voltage negative charge to the back of the paper to neutralize the positive voltage that was applied to it by the BTR.
  • Page 79: Mechanical Drive For Xerographics

    4025-XXX Discharge At both the start and the end of each individual printer cycle the HVPS supplies the BCR with an AC voltage that is used to electrically clean the drum. The AC voltage removes any residual DC charge that was left from the previous print cycle. At the beginning of each individual printer cycle the Printhead scans the surface of the drum, further discharging any residual DC charge that may be left on the drum.
  • Page 80: Image Quality Control - The Toner Sensor

    4025-XXX Toner Sensor The Toner Sensor is electrically connected to the MCU PWB through the I/O PWB. The logic on the MCU PWB uses the NO TONER signal to monitor the level of unused toner inside the EP Cartridge. When the NO TONER signal goes low, the MCU PWB logic waits for ten additional print cycles to complete, then it generates a 88 Toner low message.
  • Page 81 4025-XXX Fusing Image fusing is the sixth step of the print cycle. When a sheet of paper leaves the transfer area, static electricity holds the unfused toner image to the surface of the paper. After transfer, the paper moves to the Fuser where it passes between the Hot Roll and the Pressure Roll.
  • Page 82: Fuser Components

    4025-XXX Fuser Components The Fuser Assembly is made up of seven major components: CAUTION: The Fuser can be extremely hot. Be careful when working with or around the Fuser Assembly. Switch off the printer and wait until the Fuser has cooled before attempting to remove or disassemble it.
  • Page 83: Mechanical Drive For The Fuser Assembly

    4025-XXX Mechanical Drive for the Fuser Assembly The Main Drive Motor, the Main Drive Assembly, and the Fuser Drive Assembly provide the mechanical drive for the Fuser Assembly. The Main Drive Assembly transmits drive to the Fuser Drive Gear. 1-65 General Information...
  • Page 84 4025-XXX When the Left Upper Cover is closed, the DTS Link Rod pushes the Fuser Drive Assembly into contact with the Fuser Drive Gear, which transmits drive to the Hot Roll Gear. The Hot Roll rotates and transmits drive through a Pressure Roll Gear to the Pressure Roll.
  • Page 85: Fuser Control

    4025-XXX Fuser Control Logic circuits on the MCU PWB and relays on the AC Drive PWB control all Fuser functions. 1-67 General Information...
  • Page 86: Fuser Fan

    4025-XXX Thermistor (STS) The Thermistor monitors the surface temperature of the Hot Roll and sends information back to the MCU PWB through the I/O PWB. According to the temperature information received, the MCU PWB commands the AC Driver PWB to either switch on or switch off the Heat Lamps.
  • Page 87: General Specifications

    4025-XXX General Specifications Category Specification for product Standard configuration Print Engine with Tray 1 (500 sheet), Tray 2 (500 sheet), MP Feeder (50 sheet), and the Offset Unit Printing method Xerography Exposure method Data modulated (off/on) laser beam Laser specifications Class 3B, 5 milliwatt semiconductor laser diode Resolution of printed image 600 dpi (dots per inch)
  • Page 88 4025-XXX Category Specification for product Maximum paper tray capacity MP Feeder:50 sheets standard paper Tray 1: 500 sheets standard paper Tray 2: 500 sheets standard paper HCF3: 500 sheets standard paper HCF4: 1000 sheets standard paper HCF5: 1000 sheets standard paper Maximum output tray capacity Face Down Tray: 500 sheets standard paper Maximum noise generated...
  • Page 89: Image Registration And Reproduction Tolerances

    4025-XXX Image Registration and Reproduction Tolerances Category Tolerance range Lead edge registration Simplex ±1.5 mm Duplex ±1.9 mm MP Feeder ±2.1 mm Side edge registration Simplex ±2.0 mm Duplex ±2.4 mm MP Feeder ±2.9 mm Skew (200 mm distance) Simplex ±1.54 mm Duplex ±2.0 mm MP Feeder ±1.5 mm Orthogonality (390 mm distance)
  • Page 90: Paper Handling Devices

    4025-XXX Paper Handling Devices The printer uses the following paper output/paper size combinations: Face Down Tray (standard) The standard output tray for the printer. Paper is transported out of the printer face down onto the printer Top Cover. This Tray holds up to 500 sheets of 20 lb. paper, and comes equipped with Full Stack detection.
  • Page 91: Glossary Of Terms, Acronyms, And Abbreviations

    4025-XXX Glossary of Terms, 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 Base Engine...
  • Page 92 4025-XXX 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 93 4025-XXX 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 94 4025-XXX 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 95 4025-XXX 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 1-77 General Information...
  • Page 96 4025-XXX 1-78 Service Manual...
  • Page 97: Diagnostic Information

    4025-XXX 2. Diagnostic Information Start CAUTION: Remove the power cord from the printer 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. Make sure your fingers are not under the printer when you lift or set the printer down.
  • Page 98: Status Screens

    4025-XXX Status Screens Each of these message screens provide the operator with information on the current state of the printer. Each screen of information provides various status information. Each status screen includes the capability to display a warning message. Ready Ready Ready <fax status>...
  • Page 99: Accessing Additional Debug Information For Service Errors

    4025-XXX Accessing Additional Debug Information for Service Errors Additional debug information may be available for the specific service error being displayed. This information may help the Customer Support Center, customer engineer, and support engine resolve the problem. To access this information: Press and hold Go, then press and release Select.
  • Page 100 4025-XXX Service Error Code Table Second Line Description/Action Code Message Fuser Error An error is detected in fuser on time. Go to “Error Code 920” on page 2-21. Fuser Error Fuser temperature reaches 250 degrees celsius or more. Go to “Error Code 921”...
  • Page 101 4025-XXX Service Error Code Table Second Line Description/Action Code Message NAND Failure Flash base or daughter card failure. Replace the “Controller Board (ESS PWB)” on page 4-94. ESS PWB Board RIP card failure: SRAM failure. Replace the “Controller Board (ESS PWB)” on page 4-94.
  • Page 102 4025-XXX Service Error Code Table Second Line Description/Action Code Message Fin Stapling Mechanical failure in stapling part - Go to the Finisher Service Manual. Fin Stapling Mechanical failure in stapling part - Go to the Finisher Service Manual. Fin Stapling Mechanical failure in stapling part - Go to the Finisher Service Manual.
  • Page 103: Symptom Service Check Table

    4025-XXX Symptom Service Check Table Symptom Action Inoperative printer Go to “Inoperative Printer” on page 2-54. Erratic printer operation Go to “Erratic Printer Operation” on page 2-56. Blank, erratic, or inoperative operator panel Go to “Blank, Erratic, or Inoperative Operator Panel” on page 2-58.
  • Page 104: Attendance Message Table

    4025-XXX Attendance Message Table Attendance Message Action Go to “Attendance Message 200” on page 2-33. Go to “Attendance Message 201” on page 2-34. Go to “Attendance Message 202” on page 2-36. Go to “Attendance Message 204” on page 2-37. Go to “Attendance Message 204”...
  • Page 105: Service Checks Flowchart

    4025-XXX Attendance Message Action Close Door A Go to “Attendance Message - Close Door A” on page 2-52. Close Door B Go to “Attendance Message - Close Door B” on page 2-53. Service Checks Flowchart How to Use the Service Checks Flowchart •...
  • Page 106: General Notes On Using Service Checks

    4025-XXX General Notes on Using Service Checks Unless indicated otherwise, the instruction “switch ON printer main power” means for you to switch ON printer power and let the printer proceed through power-on diagnostics and warm-up until it is on-line and ready to print. Conventions used to represent connectors: P/J XX means a Plug and its corresponding Jack are connected.
  • Page 107: Service Checks

    4025-XXX Service Checks Before entering the service checks: Is the AC power provided at the wall outlet within specifications for this printer; either 110VAC or 220VAC? Is the AC power cord in good condition; neither frayed nor broken? Is one end of the AC power cord connected to the printer? Is the other end of the AC power cord plugged into a grounded three-prong AC wall outlet? Is the printer located in an area where the temperature and humidity are moderate...
  • Page 108: Error Code

    4025-XXX Step Actions and Questions +24VDC CHECK Replace the Go to step 3 “Engine Measure the voltage between P/J207-1 and FG. Board (MCU Is there +24VDC between P/J207-1 and FG? PWB)” on page 4-92 +24VDC CHECK Go to step 4 Use the Block Diagrams in Measure the voltage between J400-8 and FG on the MCU...
  • Page 109 4025-XXX Step Actions and Questions +5VDC CHECK Go to step 3 Go to the “Printer Measure the voltage between J400-1 and FG and J400-2 and Wiring FG on the MCU PWB. Diagrams” Is there +5VDC between J400-1 and FG? on page 5-14 Is there +5VDC between J400-2 and FG? troubleshoot a loss of +5VDC...
  • Page 110 4025-XXX Step Actions and Questions LVPS +5VDC CHECK Go to step 3 Go to the “Printer Measure the voltage between J400-1 and FG, and between Wiring J400-2 and FG on the MCU PWB. Diagrams” Is there +5VDC between J400-1 and FG, and +5VDC on page 5-14 between J400-2 and FG? troubleshoot a...
  • Page 111 4025-XXX Step Actions and Questions LVPS +5VDC CHECK Go to step 3 Go to the “Printer Measure the voltage between J400-1 and FG, and between Wiring J400-2 and FG on the MCU PWB. Diagrams” Is there +5VDC between J400-1 and FG, and +5VDC on page 5-14 between J400-2 and FG? troubleshoot a...
  • Page 112 4025-XXX Step Actions and Questions LVPS +5VDC CHECK Go to step 3 Go to the “Printer Measure the voltage between J400-1 and FG, and between Wiring J400-2 and FG on the MCU PWB. Diagrams” Is there +5VDC between J400-1 and FG, and +5VDC on page 5-14 between J400-2 and FG? troubleshoot a...
  • Page 113 4025-XXX Step Actions and Questions DRIVE ASSEMBLY INSPECTION Replace the Go to step 3 EP Cartridge Remove the EP Cartridge. with a new Hand rotate (counterclockwise) the Main Motor. Can you easily rotate the Main Motor and do all of the gears on the Main Drive Assembly rotate freely and without binding? SUBSYSTEM ISOLATION...
  • Page 114 4025-XXX Step Actions and Questions +24VDC CHECK Replace the Use the Block “Engine Diagrams in Measure the voltage between J460-11 and FG on the I/O Board (MCU the printer PWB. PWB)” on service Is there +24VDC between J460-11 and FG? page 4-92 manual to troubleshoot a...
  • Page 115 4025-XXX Error Code 912 There is a problem with the Printhead. Logic Control on the MCU PWB detected that the Printhead Motor has not come up to full speed within the specified time. Step Actions and Questions RESET Go to step 2 Suspect an intermittent 1.
  • Page 116 4025-XXX Error Code 915 There is a problem with the Fuser Fan. Logic Control on the MCU PWB received a Fan Alarm signal from the Fuser Fan. Step Actions and Questions +24VDC CHECK Replace the Use the Block “Fuser Fan” Diagrams in Measure the voltage at P/J456-1 and FG on the I/O PWB.
  • Page 117 4025-XXX Error Code 917 There is a problem with the ESS Fan. Logic Control on the MCU PWB detected a problem with the ESS Fan. Step Actions and Questions +24VDC CHECK Replace the Go to Step 2 “Fan Measure the voltage between J408-1 and FGMCU PWB. Assembly”...
  • Page 118 4025-XXX 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 listed below, one at a time, until you isolate and solve the problem.
  • Page 119 4025-XXX Error Code 922 There is a problem with the Fuser. Logic Control on the MCU PWB sensed that the Fuser Thermostat opened. Step Actions and Questions FUSER REPLACEMENT Go to step 2 Problem solved Replace the “Fuser Assembly” on page 4-65 Does the error code appear? MCU PWB REPLACEMENT Go to step 3...
  • Page 120 4025-XXX Error Code 924 There is a problem with the Fuser. Logic Control on the MCU PWB detected high temperature at Fuser I/B. Step Actions and Questions FUSER REPLACEMENT Go to step 2 Problem solved Replace the “Fuser Assembly” on page 4-65 Does the error code appear? MCU PWB REPLACEMENT Go to step 3...
  • Page 121 4025-XXX 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 listed below, one at a time, until you isolate and solve the problem.
  • Page 122 4025-XXX Error Code 929 A CRU memory communication error occurred. Logic Control on the MCU PWB could not access CRU Memory data. Step Actions and Questions LVPS +5VDC CHECK Go to step 2 Go to the “Printer Measure the voltage between J400-1 and FG, and between Wiring J400-2 and FG on the MCU PWB.
  • Page 123 4025-XXX Error Code 930 There is a problem with the Start of Scan (SOS) Sensor. Logic Control on the MCU PWB detected that the time between signals from the Start of Scan Sensor was longer than specified. Step Actions and Questions RESET Go to step 2 Suspect an...
  • Page 124: Lvps +5Vdc Check Go To Step

    4025-XXX Error Code 931 There is a problem with the Start of Scan (SOS) Sensor. Logic Control on the MCU PWB detected that the time between signals from the Start of Scan Sensor was shorter than specified. Step Actions and Questions RESET Go to step 2 Suspect an...
  • Page 125: Mcu Pwb Replacement Replace The "Engine Board (Mcu Pwb)" On Page

    4025-XXX Error Code 941 There is a Lift Up problem with Tray 1. Logic Control on the MCU PWB sensed that Tray 1 was not raising into position in Feeder 1. Step Actions and Questions TRAY 1 LIFT MOTOR QUICK TEST Go to step 2 Replace the “Tray 1 Lift...
  • Page 126 4025-XXX Error Code 942 There is a Lift Up problem with Tray 2. Logic Control on the MCU PWB sensed that Tray 2 was not raising into position in Feeder 2. Step Actions and Questions TRAY 2 LIFT MOTOR QUICK TEST Go to step 2 Replace the “Tray 2 Lift...
  • Page 127: Go To The "Printer Wiring Diagrams

    4025-XXX Error Code 980 There is a communication problem between the printer and a failing option. Logic Control on the printer MCU PWB could not initialize the failing option within the specified time. Determine which option is failing by looking at the second line message of the 980 error code displayed.
  • Page 128 4025-XXX Error Code 200 There is a paper jam at the Registration Sensor. Logic Control on the MCU PWB sensed the Registration Sensor was not actuated within the specified time since paper feed. Step Actions and Questions PAPER PATH INSPECTION Go to step 2 Clear the paper path...
  • Page 129: Attendance Messages

    4025-XXX Attendance Messages Attendance Message 200 The Registration Sensor is actuated at printer power on. Logic Control on the MCU PWB sensed the Registration Sensor was on while the printer was in standby. Step Actions and Questions SENSOR INSPECTION Go to step 2 Clean or clear paper from Inspect the Registration Sensor for contamination or paper...
  • Page 130 4025-XXX Attendance Message 201 There is a paper jam between the Registration Sensor and the Fuser Exit Switch. Logic Control on the MCU PWB sensed the Fuser Exit Switch was not actuated within the specified time since the Registration Clutch was actuated. Step Actions and Questions PAPER PATH INSPECTION...
  • Page 131 4025-XXX Step Actions and Questions PAPER TRAVEL INSPECTION Go to step 10 Go to step 11 Open the Left Upper Cover, and observe the position of the jammed paper. Did the sheet of paper stop while exiting the Fuser? FUSER INSPECTION Go to step 11 Replace the “Fuser...
  • Page 132 4025-XXX Attendance Message 202 There is a paper jam between the Fuser Exit Switch and the Face Up Exit Sensor. Logic Control on the MCU PWB sensed the Face Up Exit Sensor was not actuated within the specified time since the Fuser Exit Switch was actuated. Step Actions and Questions OFFSET UNIT INSPECTION...
  • Page 133 4025-XXX Attendance Message 204 There is a paper jam at the Fuser Exit Switch. Logic Control on the MCU PWB sensed the Fuser Exit Switch did not deactuate within the specified time after the Switch actuated. Step Actions and Questions PAPER TRAVEL INSPECTION Go to step 2 Go to step 3...
  • Page 134 4025-XXX Attendance Message 204 The Fuser Exit Sensor is actuated at printer power on. Logic Control on the MCU PWB sensed the Fuser Exit Sensor was on while the printer was in standby. Step Actions and Questions SENSOR INSPECTION Go to step 2 Clear paper from the Inspect the Fuser Exit Sensor for paper scraps that may have...
  • Page 135 4025-XXX Step Actions and Questions FACE UP EXIT SENSOR TEST Replace the Replace the “Engine “Face Up Enter Diagnostic Mode and select Face Up Exit Sensor. Board (MCU Exit Sensor” Insert and then remove, a sheet of paper into the Face Up Exit PWB)”...
  • Page 136 4025-XXX Step Actions and Questions PAPER FEED TEST Go to step 4 Replace the “Offset/Exit Enter Diagnostic Mode and select Duplex Quick Test. Assembly” The Face Up Clutch and the Exit Gate Solenoid should on page 4-69 operate. Do the Offset Rollers rotate? Does the Exit Gate Solenoid actuate during the Quick Test? DUPLEX UNIT INSPECTION Treat problem...
  • Page 137 4025-XXX Step Actions and Questions PAPER FEED TEST Go to step 4 Replace the “Offset/Exit Enter Diagnostic Mode and select Duplex Quick Test. Assembly” The Face Up Clutch and the Exit Gate Solenoid should on page 4-69 operate. Do the Offset Rollers rotate? Does the Exit Gate Solenoid actuate during the Quick Test? REVERSE CLUTCH TEST Go to step 5...
  • Page 138 4025-XXX Step Actions and Questions FACE UP EXIT SENSOR TEST Go to step 4 Replace the “Face Up Enter Diagnostic Mode and select Face Up Exit Sensor. Exit Sensor” Insert and then remove, a sheet of paper into the Face Up Exit on page 4-77 Sensor Does the Operator Panel LCD change between OP and CL...
  • Page 139 4025-XXX Step Actions and Questions TRAY 1 FEED CLUTCH TEST Go to step 5 Replace the “Tray 1 Feed Remove the printer rear cover to observe the paper feed Clutch” on during a print cycle. Enter Diagnostic Mode - Input Tray Test, page 4-14 Tray 1, Single print.
  • Page 140 4025-XXX Step Actions and Questions TAKE AWAY ROLL CHECK Go to step 4 Replace the “Tray 2 Enter Diagnostic Mode - Input Tray Test, tray 2. Feeder Remove Tray 1 to observe Tray 2 Take Away Roll rotation. Assembly” There is a small cutout just above the tray 2 Take Away Roll on page 4-36 that can be used to observe roll rotation.
  • Page 141 4025-XXX Step Actions and Questions TAKE AWAY ROLL CHECK Go to step 4 Replace the “Tray 2 Enter Diagnostic Mode - Input Tray Test, tray 2. Feeder Remove Tray 1 to observe Tray 2 Take Away Roll rotation. Assembly” There is a small cutout just above the tray 2 Take Away Roll on page 4-36 that can be used to observe roll rotation.
  • Page 142 4025-XXX Step Actions and Questions TRAY 2 TAKE AWAY SENSOR TEST Go to step 3 Replace the “Tray 2 Take Enter Diagnostic Mode, Base Sensor Test Away Open the Left Upper Cover. Insert and then remove, a sheet of Sensor” on paper into the Tray 2 Take Away Sensor.
  • Page 143 4025-XXX Step Actions and Questions TRAY 2 TAKE AWAY SENSOR TEST Go to step 5 Replace the “Tray 2 Take Enter Diagnostic Mode, Base Sensor Test. Away Insert and then remove, a sheet of paper into the Tray 2 Take Sensor”...
  • Page 144 4025-XXX Step Actions and Questions REGISTRATION SENSOR TEST Go to step 5 Replace the “Registration Enter Diagnostic Mode and select Registration Sensor. Sensor” on Open the Left Upper Cover. page 4-56 Insert and then remove, a sheet of paper into the Registration Sensor.
  • Page 145 4025-XXX Step Actions and Questions REGISTRATION SENSOR TEST Go to step 5 Replace the “Registration Enter Diagnostic Mode and select Registration Sensor. Sensor” on Open the Left Upper Cover. page 4-56 Insert and then remove, a sheet of paper into the Registration Sensor.
  • Page 146 4025-XXX Attendance Message - Toner Low The EP Cartridge is low on toner and should be replaced. Logic Control on the MCU PWB sensed that at Main Motor start-up the Toner Sensor was on for longer than the specified time. Step Actions and Questions EP CARTRIDGE REPLACEMENT...
  • Page 147 4025-XXX Step Actions and Questions CRU INTERLOCK SWITCH TEST Go to step 3 Replace the “CRU Enter Diagnostic Mode, Base Sensor Test, Drum Detect. Interlock Open the Upper Left Cover. Switch” on Install, then remove, a new EP Cartridge. page 4-64 Does the Operator Panel LCD change between OP and CL as you install and then remove the cartridge? MCU PWB REPLACEMENT...
  • Page 148 4025-XXX Attendance Message - Close Door A The Left Cover is open. The Left Cover is closed, but Logic Control on the MCU PWB sensed the Left Cover Interlock Switch indicates the Cover is open. Step Actions and Questions LEFT COVER CHECK Tighten the Go to step 2 Switch...
  • Page 149 4025-XXX Attendance Message - Close Door B The Left Lower Cover is open. The Left Lower Cover is closed, but Logic Control on the MCU PWB sensed the Left Lower Cover Interlock Switch is open. Step Actions and Questions LEFT LOWER COVER CHECK Problem Go to step 2 solved...
  • Page 150: Inoperative Printer

    4025-XXX Symptom Service Checks Do the following before entering the Symptom Service Checks: Is the AC power provided at the wall outlet within specifications for this printer; either 110VAC or 220VAC? Is the AC power cord in good condition; neither frayed nor broken? Is one end of the AC power cord connected to the printer? Is the other end of the AC power cord plugged into a grounded three-prong AC wall outlet?
  • Page 151 4025-XXX Step Actions and Questions AC INPUT CHECK Go to step 4 Replace the AC power Remove the Rear Cover so you can access the GFI. cord Measure the voltage between P/J8-1 and P/J8-3 on the GFI. Is there approximately 110VAC (or 220VAC if the printer is the 220VAC model) between P/J8-1 and P/J8-3? AC OUTPUT CHECK Go to step 5...
  • Page 152: Erratic Printer Operation

    4025-XXX Step Actions and Questions OPTION ISOLATION Replace the Go to step 11 options one Remove all options, such as the Duplex Unit or the High by one until Capacity Feeder, from the base printer. the printer becomes inoperative again. Do the Operator Panel LEDs light up and does the printer Troubleshoot go into warm-up?
  • Page 153 4025-XXX Step Actions and Questions SOFTWARE RELOAD Go to step 5 Problem solved Reload print driver software. Monitor printer operation. Does the printer display erratic operation? AC POWER CORD REPLACEMENT Go to step 6 Problem solved Replace the AC Power Cord. Monitor printer operation.
  • Page 154 4025-XXX Blank, Erratic, or Inoperative Operator Panel The Operator Panel LCD is blank or displays garbled text, or the Operator Panel Keypad does not respond to user input. Step Actions and Questions PRINTER STATUS TEST Go to step 2 Go to “Inoperative Switch on printer power and wait 2 minutes for warm-up to Printer”...
  • Page 155: Print Quality Service Checks

    4025-XXX Step Actions and Questions PAPER FEED TEST Go to step 3 Replace the “Offset/Exit Enter Diagnostic Mode and select Duplex Quick Test. Assembly” The Face Up Clutch and the Exit Gate Solenoid should on page 4-69 operate. Do the Offset Rollers rotate? Does the Exit Gate Solenoid actuate during the Quick Test? MCU PWB REPLACEMENT Problem...
  • Page 156 4025-XXX Light (Undertoned) Prints The overall image density is too light. The image may also be unfused due to insufficient image density. THE PRINTER DISPLAYS NO ERROR CODE. Step Actions and Questions PAPER INSPECTION Replace with Go to step 2 dry, newly Inspect the paper loaded in the paper trays.
  • Page 157: Blank Prints

    4025-XXX 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 listed below until you isolate and solve the problem.
  • Page 158: Black Prints

    4025-XXX Step Actions and Questions IMAGE TRANSFER INSPECTION Suspect an Go to step 5 intermittent Carefully remove the Test Print generated in step 3. problem and Inspect the print. go to step 7 Was the toner image on the drum transferred completely to the paper? BTR REPLACEMENT Go to step 6...
  • Page 159 4025-XXX Step Actions and Questions CONTROLLER OR HOST SOFTWARE ISOLATION Replace the Go to step 3 “Controller Generate a Test Print. Board (ESS PWB)” on Is the test print image normal? page 4-94 reload the host software EP CARTRIDGE REPLACEMENT Problem Go to step 4 solved...
  • Page 160: Vertical Band Deletions

    4025-XXX Vertical Band Deletions There are areas of the image that are extremely light or are missing entirely. These missing areas form lines or bands that run vertically along the page in the direction of paper travel. THE PRINTER DISPLAYS NO ERROR CODE. Step Actions and Questions PRINTHEAD WINDOW INSPECTION...
  • Page 161: Horizontal Band Deletions

    4025-XXX 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 listed below, one at a time, until you isolate and solve the problem.
  • Page 162: Vertical Streaks

    4025-XXX Step Actions and Questions HVPS REPLACEMENT Problem Go to step 6 solved Replace the “High Voltage Power Supply (HVPS) Assembly” on page 4-88. Are the horizontal band deletions gone? The following printer FRUs and areas are associated with this specific problem.
  • Page 163 4025-XXX Step Actions and Questions IMAGE TRANSFER INSPECTION Go to step 5 Replace the “BTR Remove the Rear Cover. Assembly” Generate a Test Print and switch OFF printer power halfway on page 4-61 through the print cycle. Open the Left Upper Cover. Open the Drum Shutter.
  • Page 164: Horizontal Streaks

    4025-XXX Horizontal Streaks There are black lines running horizontally across the paper. THE PRINTER DISPLAYS NO ERROR CODE. Step Actions and Questions EP CARTRIDGE REPLACEMENT Problem Go to step 2 solved Install a new EP Cartridge. Are the horizontal streaks gone? IMAGE DEVELOPMENT INSPECTION Go to step 3 Replace the...
  • Page 165: Spot Deletions

    4025-XXX 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 listed below, one at a time, until you isolate and solve the problem.
  • Page 166 4025-XXX Step Actions and Questions FUSER INSPECTION Replace the Replace the “Fuser paper with Generate another Black Test Print and switch OFF printer Assembly” fresh, dry power when the print is halfway through the Fuser. on page 4-65 paper and Open the Left Upper Cover.
  • Page 167: Toner On Back Of Print

    4025-XXX Step Actions and Questions FUSER INSPECTION Replace the Go to step 5 “Fuser Generate another Test Print and switch OFF printer power Assembly” when the print is halfway through the Fuser. on page 4-65 Open the Left Upper Cover. Examine the paper before it enters the Fuser and after it exits the Fuser.
  • Page 168 4025-XXX Step Actions and Questions PAPER PATH INSPECTION Go to step 4 Thoroughly clean the Remove the paper trays. paper path, Remove the EP Cartridge. from Feeders Use a flashlight to inspect the entire paper path, from Feeder to the Output to Output Tray, for any loose toner.
  • Page 169: Skewed Image

    4025-XXX Skewed Image The image is either twisted on the page or is not parallel to the sides of the page. THE PRINTER DISPLAYS NO ERROR CODE. Step Actions and Questions PAPER FEED INSPECTION Go to step 2 Reload the paper and reinstall the Are the paper cassettes installed correctly, and is the...
  • Page 170: Damaged Prints

    4025-XXX Damaged Prints The printed page exits the printer either wrinkled, creased, or torn. THE PRINTER DISPLAYS NO ERROR CODE. Step Actions and Questions PRINTER INTERIOR INSPECTION Go to step 2 Clean the printer interior Remove the paper trays and the EP Cartridge. or replace the Thoroughly inspect the interior of the printer, looking for bits of broken printer...
  • Page 171: Unfused Image Or Image Easily Rubs Off Of Page

    4025-XXX Step Actions and Questions PAPER PATH INSPECTION - FUSER Replace the Clean or “Fuser replace the Generate a Test Print Assembly” “Offset/Exit Open the Left Upper Cover just after the lead edge of the sheet on page 4-65 Assembly” of paper has exited the Fuser.
  • Page 172 4025-XXX Repetitive Marks on Each Page Identical image defects appears on each or on every other printed sheet. THE PRINTER DISPLAYS NO ERROR CODE. Step Actions and Questions DRUM IMAGE INSPECTION Replace the Go to step 2 EP Cartridge Generate a single Test Print. Open the Upper Left Cover when the sheet of paper is approximately half-way through the transfer process.
  • Page 173 4025-XXX Step Actions and Questions Replace the “Engine Board (MCU PWB)” on page 4-92. Problem Go to step 5 solved Generate 5 Test Prints. Is the lead edge registration correct? Replace the “Printhead Assembly” on page 4-57. Problem Go to step 6 solved Generate 5 Test Prints.
  • Page 174: Electrical Interference

    4025-XXX Step Actions and Questions Replace the “Printhead Assembly” on page 4-57. Problem Go to step 6 solved Generate 5 Test Prints. Is the side-to-side registration correct? 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.
  • Page 175 4025-XXX Step Actions and Questions Steps 4 through 11 attempt to find a faulty printer FRU that may be generating electrical noise. If replacing a FRU does not solve the problem, reinstall the old FRU before moving on to the next step. EP CARTRIDGE REPLACEMENT Go to step 5 Problem...
  • Page 176 4025-XXX 2-80 Service Manual...
  • Page 177: Diagnostic Aids

    4025-XXX 3. Diagnostic Aids Diagnostics are built into the printer MCU PWB (Engine Card) and can be accessed from the printer Operator Panel. Diagnostics includes: Button Test, LCD Test, Error Log, Printer Setup, Configuration ID, Device Test, base Sensor Test, and a demo or print test page. Analyzing the Test Print Test Prints provide several uses in troubleshooting the printer problems.
  • Page 178: Using The Operator Panel Diagnostics Menu

    4025-XXX Using the Operator Panel Diagnostics Menu Entering Diagnostic Mode Press and hold Go and Return as you turn on the printer to access Diagnostic Mode. While the Diagnostic Menu is active, all host interfaces are offline. Exiting Diagnostic Mode To exit diagnostic mode and POR the printer into normal user mode, select EXIT DIAGNOSTICS.
  • Page 179 4025-XXX Intermediate Menu, Top-level Menu Printer Setting, or Value List Operation DRAM Memory Test Go to “DRAM Memory Test” on page 3-9. ROM Memory Test Go to “ROM Memory Test” on page 3-10. Parallel Wrap Go to “Parallel Wrap Test” on page 3-10.
  • Page 180 4025-XXX Intermediate Menu, Top-level Menu Printer Setting, or Value List Operation Feed Test Only installed paper sources are displayed. Tray 1 Tray 2 Tray 3 Tray 4 Tray 5 MP Feeder Envelope Single Continuous For additional information, go to “Input Tray Feed Test” on page 3-15.
  • Page 181 4025-XXX Intermediate Menu, Top-level Menu Printer Setting, or Value List Operation Sensor Test For additional information, go to “Finisher Sensor Test” on page 3-19. BASE SENSOR TEST For additional information, go to “Base Sensor Test” on page 3-21 DEVICE TESTS Only displayed if a flash or disk unit is installed.
  • Page 182 4025-XXX Intermediate Menu, Top-level Menu Printer Setting, or Value List Operation Par 3 Strobe Adj -4 to 6 (0) Only displayed if a parallel port is available using PCI slot 3. ERROR LOG Display Log Go to “Viewing the Error Log” on page 3-28.
  • Page 183: Print Tests

    4025-XXX Print Tests The Diagnostic Input Source PRINT TESTS may be used to verify that the printer can print on media from each of the installed input sources. Each of the installed sources is available as a selectable option within the PRINT TESTS menu. For each source, the user has 2 choices: •...
  • Page 184: Print Quality

    4025-XXX Print Quality Pages Execution of this diagnostic function causes the printer to print the Print Quality Test Pages. Since the printer is in diagnostics, the toner cartridge lockout functionality is disabled. These pages can also be printed using the Configuration Menu Group; however, when printed using this method the toner cartridge lockout functionality is enabled.
  • Page 185: Hardware Tests

    4025-XXX Hardware Tests LCD Hardware Test Selecting this test causes the printer to continually execute the LCD display test. To cancel the test, press Return or Stop. Button Test Use the Button Test to verify the operation of each button on the operator panel. When you select the Button Test the following screen is displayed.
  • Page 186: Dram Error

    4025-XXX DRAM Error Once the maximum pass count or fail count is reached, the test is stopped and the final test results are displayed. Press Return or Stop to exit the test. ROM Memory Test Use the ROM Memory Test to check the validity of the RIP code and fonts. When you select this test from the operator panel, the following screen is displayed and the printer begins testing ROM memory for the first time.
  • Page 187 4025-XXX The following screen is displayed and the printer begins testing the parallel hardware for the first time. Parallel Wrap P:###### F:##### Terminology: • P:###### represents the number of times the test has passed (finished successfully). Initially 000000 is displayed for ######. The maximum pass count is 999,999.
  • Page 188: Serial Wrap Test

    4025-XXX Serial Wrap Test Use the Serial Wrap Test to check the operation of the serial port hardware using a wrap plug. Each serial signal is tested. To perform the wrap test: Disconnect the serial interface cable, and install the serial wrap plug. Select HARDWARE TESTS from the Diagnostics Menu.
  • Page 189 4025-XXX • Receive Status Interrupt Error • Status Error • Receive Data Interrupt Error • Transmit Data Interrupt Error • Transmit Empty Error • Threshold Error • Receive Data Ready Error • Break Interrupt Error • Framing Error • Parity Error •...
  • Page 190: Duplex Tests

    4025-XXX Duplex Tests Duplex Quick Test Use the Duplex Quick Test 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 191: Input Tray Tests

    4025-XXX 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 must be malfunctioning.
  • Page 192: Input Tray Sensor Test

    4025-XXX Input Tray Sensor Test Use this test to determine whether or not the input tray sensors are working correctly. To run the test, select the Sensor Test operation from the INPUT TRAY TESTS menu. The Power indicator blinks while the page is being fed. If Single is selected, no buttons are active during the feed test.
  • Page 193: Feed All Bins Test

    4025-XXX Feed All Bins Test This test may be used to verify that the printer can feed media to all installed output destinations. No information is printed on the feed test pages since the laser is not engaged during this test. After this test is selected, media is fed from the User Default Paper Source.
  • Page 194: Output Bin Sensor Test

    4025-XXX Output Bin Sensor Test Use this test to determine whether or not the output bin sensors are working correctly. To run the test, select the Sensor Test operation from the OUTPUT BIN TESTS menu. The following sensors will be listed in the bottom level menu: •...
  • Page 195: Finisher Tests

    4025-XXX Finisher Tests Staple Test This test verifies the operation of the staple mechanism in the finisher. The media used in this test is fed from the default paper source. After selecting a destination bin, the printer feeds eight pieces of media and accumulates all eight pieces of media in the finisher accumulator.
  • Page 196 4025-XXX • Stk Hight Upper • Stk Hight Lower • Stk Tray Low Lmt • Stack Tray Pos • Dock Interlock • Top Cover J • Front Cover K • Punch Dust Box M • H-Tra Gate • H-Tra Cover H •...
  • Page 197: Base Sensor Test

    4025-XXX Base Sensor Test Use the Base Sensor Test to determine whether or not the sensors located inside the printer are working correctly. To run the test, select Base Sensor Tests from the top level menu in diagnostics. The following sensors are displayed in the bottom level menu: •...
  • Page 198: Storage Device Tests

    4025-XXX Storage Device Tests Quick Disk Test Selecting this test runs a disk test that performs a non-destructive read/write on one block per track on the disk. The following message is displayed while the test is running. The Power indicator also blinks while the test is in progress.
  • Page 199: Flash Test

    4025-XXX Once Go is selected, the following screen is displayed to indicate the operation has begun. Disk Test/Clean Testing... If the test passes, then the following message is displayed. Press Go, Return, or Stop to return to the DEVICE TESTS screen. Disk Test/Clean Test Passed If the test fails, then the following message is displayed.
  • Page 200: Printer Setup

    4025-XXX If the test fails, then the following message is displayed. Press Go, Return, or Stop to return to the DEVICE TESTS screen. Flash Test Test Failed Printer Setup Configuration ID The printer code uses the Configuration ID to determine the characteristics of certain areas of the printer that cannot be determined using hardware sensors.
  • Page 201 4025-XXX Digit Bit Position Printer Setting Values Bit 3 Standard output bin Near Full 0 = No (Most-significant hardware present 1 = Yes bit) Bit 2 Standard output bin capacity 0 = 250 sheets 1 = 500 sheets Bits 1-0 Maximum number of input trays 00 = 2 trays 01 = 3 trays...
  • Page 202: Setting The Page Count

    4025-XXX Digit Bit Position Printer Setting Values Bit 3 Operator Panel Configuration 0 = The panel character ROM supports the modified Code Page 850 and Katakana encodings. 1 = The panel character ROM supports the modified Code Page 850, ISO Cyrillic, ISO Latin 2 and ISO Latin 5 encodings.
  • Page 203: Viewing The Permanent Page Count

    4025-XXX When Select is pressed after the final digit (‘7’ in this example), the new page count is stored in NVRAM. Viewing the Permanent Page Count The permanent page count setting cannot be modified using the operator panel. It can only be viewed using the Diagnostics menus.
  • Page 204: Error Log

    4025-XXX Error Log Viewing the Error Log The Error Log aids the Customer Engineer by providing a history of printer errors. It contains the 12 most recent errors that have occurred. The most recent error is displayed in position 1, and the oldest error is displayed in position 12 (assuming 12 or more errors have occurred).
  • Page 205: Clearing The Error Log

    4025-XXX Clearing the Error Log To clear the error log, select the Clear Log operation from the ERROR LOG menu. The printer displays the following message. Clear Log =Yes Select Yes to confirm that you really want to clear the log. The error log is cleared and then the empty log is displayed as shown.
  • Page 206 4025-XXX Intermediate Menu, Printer Value List Setting or Printer Operation Top Margin Tray 1 Left Mar Tray 2 Left Mar Only displayed if Tray 2 is installed. Tray 3 Left Mar Only displayed if Tray 3 is installed. Tray 4 Left Mar Only displayed if Tray 4 is installed.
  • Page 207: Viewing And Resetting The Maintenance Page Count

    4025-XXX Viewing and Resetting the Maintenance Page Count The maintenance page counter is incremented when a page is printed and incremented by two when a duplex sheet is printed. The counter is used to track printer usage.When the counter reaches 300,000, the printer posts a maintenance intervention and a status indicator on the display.
  • Page 208: Setting Printer Registration

    4025-XXX Setting Printer Registration This setting is in the Configuration Menu to allow easier access for customers. This setting also allows separate Left Margin settings for each paper tray. (The Top Margin setting is the same for all trays.) The range of valid settings for the Top margin is 0 to +50. The range of valid settings for each Left margin is -50 to +50.
  • Page 209: Repair Information

    4025-XXX 4. Repair Information This chapter contains the Removal and Replacement Procedures for select parts of the printer. Do the following steps before you begin any Removal and Replacement Procedure: Switch OFF the printer power and disconnect the power cord from the AC wall outlet. Remove the EP Cartridge and protect it from exposure to light by covering it with a piece of opaque plastic sheeting or by placing it in a light-tight container.
  • Page 210: Removal And Replacement Procedures

    4025-XXX Removal and Replacement Procedures Fuser Full Cover Service Manual...
  • Page 211 4025-XXX Removal Remove the Mailbox or the Finisher if installed. Open the Duplex Unit if installed. Pull back and remove the Paper Assembly Damper. Open the Left Upper Cover Assembly and remove the screw securing the Fuser Cover to the frame (Figure 1). Open the Front Cover and remove the screw securing the Fuser Cover to the frame (Figure 1).
  • Page 212: Top Cover Assembly

    4025-XXX Top Cover Assembly Service Manual...
  • Page 213 4025-XXX Removal Unplug the AC Power Cord from the rear of the printer. Remove the Fuser Full Cover. Disconnect J204 from the Fuser Fan. Remove the two screws securing the right side of the Top Cover Assembly to the Right Cover (Figure 1). Carefully lift the Top Cover a few inches off of the printer frame.
  • Page 214: Front Cover Assembly

    4025-XXX Front Cover Assembly Service Manual...
  • Page 215 4025-XXX Removal Open the Front Cover. Remove the screw securing the plastic strap to the printer frame and free the strap. Remove the screw securing the metal hinge to the printer frame. Slide the Front Cover to the right to free the Front Cover right hinge from the frame and the metal hinge from the frame, and remove the Front Cover.
  • Page 216: Front Inner Cover

    4025-XXX Front Inner Cover Removal Unplug the AC Power Cord from the rear of the printer. Remove the Front Cover. Remove the screw securing the Front Inner Cover to the printer frame and pull the Cover away from the printer. Disconnect the two wires attached to the Interlock Switch and remove the Cover.
  • Page 217: Rear Cover Assembly

    4025-XXX Rear Cover Assembly Removal Remove the AC power cord from the rear of the printer. Remove the two screws securing the Rear Cover Assembly to the printer frame. Pull the bottom of the Rear Cover away from the printer frame and slide the Cover down to remove it.
  • Page 218: Right Cover

    4025-XXX Right Cover Removal Remove the two screws securing the Top Cover to the Right Cover. Carefully raise the right end of the Top Cover and at the same time lift the Right Cover up and away from the printer frame. Replacement Raise the right end of the Top Cover.
  • Page 219: Operator Panel

    4025-XXX Operator Panel Removal Remove the Top Cover. Disconnect the P/J417 from the Operator Panel. Push in on the four tabs securing the Operator Panel to the Top Cover, while you press the Operator Panel out of the Cover. Replacement Position the Operator Panel over the opening in the Top Cover Assembly, and press the Panel into the opening.
  • Page 220: Rear Cover 1Tm

    4025-XXX Rear Cover 1TM Removal Disconnect all option plugs from the Plug Jack located at the rear of the printer. Remove the two screws securing the Rear Cover 1TM to the printer frame. Lift up on the Cover and remove it from the printer frame. Replacement Reinstall the Rear Cover 1TM by first hooking the bottom edge of the Cover onto the frame, and then pressing the top of the Cover against the frame.
  • Page 221: Tray 1 Lift Motor

    4025-XXX Tray 1 Lift Motor Removal Slide Tray 1 halfway out of the printer. Remove the Rear Cover. Disconnect the J203 from the rear of Tray 1 Lift Motor. Remove the three long screws securing the Motor to the printer frame. Slide the Motor out to remove it.
  • Page 222: Tray 1 Feed Clutch

    4025-XXX Tray 1 Feed Clutch 4-14 Service Manual...
  • Page 223 4025-XXX Removal Remove the Rear Cover. Open the Duplex Unit. Open the Left Upper Cover. Disconnect J202 from the Tray 1 Feed Clutch. Remove the E ring that is securing the Feed Clutch to the shaft. Remove the E ring that is securing the neighboring drive gear to the shaft (see figure) - for ease of Clutch removal.
  • Page 224: Tray 1 Feed Rolls

    4025-XXX Tray 1 Feed Rolls Removals Remove the paper tray from the appropriate feeder. Swing the Chute down so it clears the Rolls. Pull out on the Roll latch and slide the Roll from the shaft. Repeat step 3 for the remaining two Rolls. Replacement Swing the Chute down so it clears the Rolls.
  • Page 225: Feeder, Nudger, And Retard Rolls

    4025-XXX Feeder, Nudger, and Retard Rolls Note: Use this procedure for Feeders 1 and 2. Replace the Feeder, Nudger, and Retard Rolls at the same time. 4-17 Repair Information...
  • Page 226 4025-XXX Removal Remove the paper tray from the appropriate feeder. Swing the Chute down so it clears the Rolls. Pull out on the Roll latch and slide the Roll off of the shaft. Repeat step 3 for the remaining two Rolls. Replacement Swing the Chute down so it clears the Rolls.
  • Page 227: Tray 1 Take Away Roll Assembly

    4025-XXX Tray 1 Take Away Roll Assembly 4-19 Repair Information...
  • Page 228 4025-XXX Removal Remove the Duplex Unit, if one is installed. Remove the EP Cartridge. Remove Tray 1 and Tray 2. Remove the Left Upper Cover Assembly. Remove the Rear Cover Assembly. Remove the MP Feeder Support Assembly. Remove the retaining clip from the docking stud that is located at the lower right of Feeder 1 and remove the stud.
  • Page 229 4025-XXX Replacement Reinstall Tray 1 Take Away Roll Assembly onto the bottom of the printer frame. Align the two plastic mounting pins, located on the top of the Assembly, with the two mounting holes located in the bottom of the printer frame. Press the Assembly into the frame so the mounting pins snap into the holes.
  • Page 230: Tray 1 Feeder Assembly

    4025-XXX Tray 1 Feeder Assembly 4-22 Service Manual...
  • Page 231 4025-XXX WARNING: Take care not to break or dislodge the No Paper Actuator when removing or replacing the Tray 1 Feeder Assembly. Removal Remove Tray 1 from the printer. Remove the Rear Cover. Remove the Front Chute. Remove Tray 1 Feed Clutch along with the Feed Gear and Bearing. (Figure 1). Remove the Feed, Nudger, and Retard Rolls.
  • Page 232: Support Assembly Spring

    4025-XXX Support Assembly Spring Removal Remove Tray 1 Lift Motor. Remove the screw securing the Support Assembly Spring to the printer frame, and remove the Spring. Replacement Reinstall the Support Assembly Spring. (See the figure for correct positioning). Make sure the front and rear arms of the Spring are positioned as shown. Use one screw to secure the Spring to the frame.
  • Page 233: Tray 1 Retard Assembly

    4025-XXX Tray 1 Retard Assembly Removal Remove Tray 1 Take Away Roll Assembly. Remove the Left Middle Cover. Remove the screw securing the Feed In Chute to the Assembly and slide the Chute to the front of the Assembly to remove it. Remove the plastic Feed Chute from the Take Away Roll.
  • Page 234: Tray 1 & Tray 2 Front Chute Assemblies

    4025-XXX Tray 1 & Tray 2 Front Chute Assemblies Removal Remove either Paper Tray 1 or Paper Tray 2. Use a flat blade screwdriver to unhook the front of the Chute, and remove the Chute. Replacement Remove either Paper Tray 1 or Paper Tray 2. Reinstall the Chute by sliding the opening in the rear of the Chute into the tab on the printer frame, then hooking the tab at the front of the Chute into the opening on the frame.
  • Page 235: Tray 1 & 2 Level Sensors

    4025-XXX Tray 1 & 2 Level Sensors 4-27 Repair Information...
  • Page 236 4025-XXX Use this procedure to remove and replace the Paper Level Sensors for Trays 1 and 2. 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 237: Tray 1 & Tray 2 Paper Size Sensors

    4025-XXX Tray 1 & Tray 2 Paper Size Sensors 4-29 Repair Information...
  • Page 238 4025-XXX Use this procedure to remove and replace the Paper Size Sensors for Trays 1 and 2. Removal Tray 1 Paper Size Sensor Remove the Rear Cover Assembly. Remove the I/O PWB. Remove the High Voltage Power Supply Assembly. Remove Paper Tray 1 from the printer. Disconnect the P/J from the Size Sensor PWB.
  • Page 239: Tray 1 & 2 No Paper Sensors

    4025-XXX Tray 1 & 2 No Paper Sensors 4-31 Repair Information...
  • Page 240 4025-XXX Removal Remove the Paper Tray associated with the No Paper Sensor you are removing. Squeeze the Sensor latches and remove the No Paper Sensor from the frame. Disconnect the P/J from the Sensor. Replacement Reconnect the P/J to the Sensor. Push the No Paper Actuator up and out of the way.
  • Page 241: Actuator Assembly

    4025-XXX Actuator Assembly Removal Remove the paper tray from the printer. Turn the tray upside down. Remove the two E rings securing the two cable pulleys to the Rear Bracket and carefully remove the pulleys from the tray. Remove the two screws securing the Rear Bracket to the paper tray and move the Bracket far enough so you can remove the Actuator Assembly.
  • Page 242: Tray 2 Lift Motor

    4025-XXX Tray 2 Lift Motor Removal Slide Tray 2 halfway out of the printer. Remove the Rear Cover. Disconnect the J241 from the rear of Tray 2 Lift Motor. Remove the three long screws securing the Motor to the printer frame. Slide the Motor out to remove it.
  • Page 243: Tray 2 Feed Clutch

    4025-XXX Tray 2 Feed Clutch Removal Remove the Rear Cover 1TM. Disconnect J240 from the Feed Clutch. Remove the E ring securing the Clutch to the shaft, and slide the Clutch off of the shaft. Remove the E ring securing the Gear to the shaft, and slide the Gear and Bearing off of the shaft.
  • Page 244: Tray 2 Feeder Assembly

    4025-XXX Tray 2 Feeder Assembly 4-36 Service Manual...
  • Page 245 4025-XXX WARNING: Take care not to break or dislodge the No Paper Actuator when removing or replacing the Tray 2 Feeder Assembly. Removal Remove Tray 2 from the printer. Remove the Rear Cover. Remove the Front Chute. Remove Tray 2 Feed Clutch along with the Feed Gear and Bearing. (Figure 1). Remove the Feeder, Nudger, and Retard Rolls.
  • Page 246: Tray 2 Take Away Roll Assembly

    4025-XXX Tray 2 Take Away Roll Assembly Removal Remove Tray 2 Retard Assembly. Remove the E rings and Gears attached to the rear of the Take Away Roll shaft. Remove the Center Bearing on the Take Away Roll Shaft, and slide the Roll out of the Retard Support.
  • Page 247: Tray 2 Retard Assembly

    4025-XXX Tray 2 Retard Assembly Removal Open the Left Lower Cover. Remove the screw securing the Feed In Chute to the Assembly, and slide the Chute to the front of the Assembly to remove it. Remove the plastic Feed Chute from the Take Away Roll. Unhook the spring from the Retard Support.
  • Page 248: Mp Feeder Assembly

    4025-XXX MP Feeder Assembly Removal Face the left side of the printer. Hold both sides of the MP Feeder Assembly and firmly pull the Assembly toward you and out of the printer. Replacement Face the left side of the printer. Position the MP Feeder against the MP Feeder Support.
  • Page 249: Mp Feeder Tray Assembly

    4025-XXX MP Feeder Tray Assembly 4-41 Repair Information...
  • Page 250 4025-XXX Removal Remove the MP Feeder Assembly. Remove the two screws securing the MP Feeder Top Cover to the MP Feeder Assembly, and remove the Top Cover. Disconnect the P/J that runs from the Tray Assembly to the Feeder Assembly. Remove the screw securing the Tray Spring and free the Spring.
  • Page 251: Mp Feeder Support Assembly

    4025-XXX MP Feeder Support Assembly Removal Remove the MP Feeder Assembly. Remove the one screw securing the Front Support Cover to the Support Assembly, and remove the Cover. Remove the one screw securing the Rear Support Cover to the Support Assembly, and remove the Cover.
  • Page 252: L/H Low Cover Assembly

    4025-XXX L/H Low Cover Assembly 4-44 Service Manual...
  • Page 253 4025-XXX Removal Remove the MP Feeder Support Assembly. Remove the four screws securing the Left Middle Cover to the printer frame, and remove the Cover. LIft the Pinch Roll Bracket off of the Left Middle Cover. Remove the two Holding Springs, and lift the Pinch Roll out of the Bracket. Remove the two Center Bearings, the two Shaft Springs, and the two End Brackets from the Shaft.
  • Page 254: Left Lower Cover Assembly

    4025-XXX Left Lower Cover Assembly Removal Open the Left Lower Cover. Remove the screw securing the Front Hinge to the printer frame. Pull the Left Lower Cover away from the printer frame. Replacement Reinstall the Front Hinge onto the pivot post on right side of the Left Lower Cover. Reinstall the Left Lower Cover by first sliding the left pivot post into the Rear Hinge.
  • Page 255: Left Lower Cover Pinch Roll Assembly

    4025-XXX Left Lower Cover Pinch Roll Assembly 4-47 Repair Information...
  • Page 256 4025-XXX Removal Remove the Left Lower Cover Assembly. Remove the three screws securing the Pinch Roll Bracket to the Assembly, and remove the Bracket. Unhook the two Pinch Roll Springs and lift the Pinch Roll out of the Bracket. Remove the two Center Bearings and the two End Bearings from the Roll. Replacement Reinstall an End Bearing to each end of the Pinch Roll.
  • Page 257: Left Lower Cover Interlock Switch

    4025-XXX Left Lower Cover Interlock Switch Removal Open the Left Lower Cover. Squeeze the sides of the Switch and pull it away from the printer frame. Disconnect J144. Replacement Reconnect J144. Squeeze the sides of the Switch while inserting the locating tab on the Switch into the opening in the frame.
  • Page 258: Tray 2 Take Away Sensor

    4025-XXX Tray 2 Take Away Sensor Removal Remove the Duplex Option and MP Feeder if equipped. See MP Feeder Assembly removal on page 4-40. Remove the MP Feeder Support Assembly. See MP Feeder Support Assembly removal on page 4-43. Remove the four screws securing the Left Middle Cover and Pinch Roll Bracket. Squeeze in all four sensor latches while you pull the sensor out of the frame.
  • Page 259: Registration Clutch

    4025-XXX Registration Clutch Removal Remove the Rear Cover. Remove the Flywheel Assembly. Disconnect P/J 200 from the Registration Clutch. Remove the E clip securing the Registration Clutch to the Registration Shaft. Push out on the shaft latch as you slide the Clutch off of the shaft. Replacement Slide the Registration Clutch onto the shaft.
  • Page 260: Left Upper Cover Assembly

    4025-XXX Left Upper Cover Assembly 4-52 Service Manual...
  • Page 261 4025-XXX Removal Remove the Rear Cover. Open the Duplex Unit. Open the Left Upper Cover. WARNING: When the Left Upper Cover is open, the BTR is exposed. Do not touch the BTR. Grease and dirt on the BTR, or physical damage to the BTR effects print quality. Use a screwdriver blade to open the latch securing the Front Shaft Hinge, and slide the Hinge out of the Cover Assembly.
  • Page 262: Registration Chute

    4025-XXX Registration Chute Removal Remove the Left Upper Cover Assembly. Remove the Registration Clutch. Remove the screw securing the Inner Cover to the printer frame, and remove the Inner Cover. Remove the EP Cartridge. Remove the screw securing the Magnet Plate to the printer frame, and remove the Plate.
  • Page 263: Registration Roll Assembly

    4025-XXX Registration Roll Assembly Removal Remove the Registration Chute. Remove the E ring from the rear of the Registration Roll Shaft. Slide the Shaft to the rear to free the front of the Shaft from the front bearing. Remove the Registration Roll Assembly. Replacement Make sure both the front and rear bearings are in place in the frame.
  • Page 264: Registration Sensor

    4025-XXX Registration Sensor Removal Open the Left Upper Cover. Squeeze in all four Sensor latches while you pull the Sensor out of the Registration Chute Assembly. Disconnect J100 from the rear of the Sensor. Replacement Reconnect J100 to the Registration Sensor. Insert the Sensor into the cutout in the Registration Chute Assembly.
  • Page 265: Printhead Assembly

    4025-XXX Printhead Assembly 4-57 Repair Information...
  • Page 266 4025-XXX Removal Remove the Low Voltage Power Supply. Disconnect J106, J207, J407, and J430 from the Printhead. Remove the three screws that secure the Printhead to the printer frame. Lift the Printhead Assembly off of the printer frame. Place the Printhead Assembly on a flat and stable surface. WARNING: Do not remove Printhead covers or disassemble the Printhead Assembly.
  • Page 267: Ep Cartridge

    4025-XXX EP Cartridge 4-59 Repair Information...
  • Page 268 4025-XXX Removal Open the Duplex Unit if one is installed. Open the Left Upper Cover. WARNING: Do not attempt to remove the EP Cartridge without first opening the Left Upper Cover. Open the Front Cover. Pull up on the handle and slide the EP Cartridge half way out of the printer. Hold on to the top handle and slide the EP Cartridge out of the printer.
  • Page 269: Btr Assembly

    4025-XXX BTR Assembly 4-61 Repair Information...
  • Page 270 4025-XXX Removal Open the Left Upper Cover. WARNING: If replacing the BTR Assembly with a new one, use the gloves that come with the kit. Touching the sponge roll surface of the BTR with your bare skin affects print quality. Grease and dirt on, or physical damage to, the BTR affects print quality. Face the left side of the printer.
  • Page 271: Toner Sensor

    4025-XXX Toner Sensor Removal Remove the Rear Cover. Disconnect P/J127 from the I/O PWB. Open the Left Upper Cover. Remove the EP Cartridge. Remove the Flywheel Assembly. Remove the Left Cover Interlock Switch. Remove the Main Drive Assembly. Use the flat blade of a screwdriver to pry up the front end of the Toner Sensor (see figure).
  • Page 272: Cru Interlock Switch

    4025-XXX CRU Interlock Switch Removal Remove the EP Cartridge. Remove the Rear Cover. Disconnect J232 and J233 from the CRU Interlock Switch. Disconnect J234 from the Interlock Switch wire harness. Remove the screw securing the CRU Interlock Switch to the printer frame, and remove the Switch.
  • Page 273: Fuser Assembly

    4025-XXX Fuser Assembly CAUTION: The Fuser is extremely hot. Switch off printer main power and wait at least thirty minutes for the Fuser to cool down before attempting to work on or to remove the Fuser Assembly. Removal Open the Left Upper Cover. Open the Front Cover.
  • Page 274: Fuser Drive Assembly

    4025-XXX Fuser Drive Assembly 4-66 Service Manual...
  • Page 275 4025-XXX Removal Remove the Fuser Assembly. Remove the EP Cartridge. Remove the Offset Unit Assembly. Remove the Flywheel Assembly. Remove the Main Drive Assembly. Disconnect J31, J32, and J33 from the AC Driver PWB and free the wire harness from the harness clips. Disconnect J802 from PSHV-R2 and free the wire harness from the harness clips.
  • Page 276: Fuser Fan

    4025-XXX Fuser Fan Removal Unplug the AC Power Cord from the rear of the printer. Remove the Fuser Full Cover. Disconnect J204 from the Fuser Fan. Remove the Fuser Fan. Replacement Unplug the AC Power Cord from the rear of the printer. Reconnect J204 to the Fuser Fan.
  • Page 277: Offset/Exit Assembly

    4025-XXX Offset/Exit Assembly 4-69 Repair Information...
  • Page 278 4025-XXX Removal Remove the Fuser Full Cover. Remove the Rear Cover Assembly. Open the Duplex Unit. Open the Upper Left Cover. Remove J104, J209, J601, and J602 from the Offset Unit Assembly. Remove the three screws (one screw at the front of the Assembly, next to the solenoid, and two screws at the rear of the Assembly) securing the Offset Unit to the printer frame.
  • Page 279: Exit Drive Assembly

    4025-XXX Exit Drive Assembly Removal Remove the Offset Assembly. Remove the three screws securing the Exit Drive Assembly to the Offset Assembly. Pull the Exit Drive Assembly straight out and away from the Offset Unit. Replacement Align the Exit Drive Assembly with the Offset Assembly so the white drive gear and shaft fit through the corresponding opening in the Exit Drive Assembly.
  • Page 280: Exit Gate Solenoid

    4025-XXX Exit Gate Solenoid Removal Remove the Fuser Full Cover. Disconnect J210 from the Exit Gate Solenoid. Remove the wire harness from the harness clips. Remove the two screws securing the Exit Gate Solenoid to the Offset Assembly, and remove the Solenoid. Replacement Position the Exit Gate Solenoid so the wire harness faces up.
  • Page 281: Offset Motor

    4025-XXX Offset Motor Removal Remove the Fuser Full Cover. Disconnect J209 and remove the wire harness from the harness clips. Squeeze the latches to unlock the Full Stack Sensor, and remove the Sensor from the Offset Assembly. Replacement Reinstall the Full Stack Sensor by pressing the Sensor latches into the cutouts in the Offset Assembly.
  • Page 282: Inverter Clutches

    4025-XXX Inverter Clutches 4-74 Service Manual...
  • Page 283 4025-XXX Removal Remove the Exit Drive Assembly. Remove the four screws securing the Drive Support to the Inverter Bracket and lift the Support from the Bracket. Disconnect P/J218 and P/J219, and free the wire harness from the harness clips. Slide the CCW Gear from the CCW Clutch. Slide the CW Gear fro the CW Clutch.
  • Page 284: Full Stack Sensor

    4025-XXX Full Stack Sensor Removal Remove the Fuser Full Cover. Disconnect J133 and remove the wire harness from the harness clips. Press the latches to unlock the Full Stack Sensor. Remove the Full Stack Sensor from the Offset Assembly. Replacement Reinstall the Full Stack Sensor by pressing the Sensor latches into the cutouts in the Offset Assembly.
  • Page 285: Face Up Exit Sensor

    4025-XXX Face Up Exit Sensor Removal Remove the Fuser Full Cover. Disconnect P/J109. Remove the two screws securing the Face Up Exit Sensor Assembly to the Exit Sensor Bracket and remove the Assembly. Replacement Reinstall the Face Up Exit Sensor Assembly onto the Bracket and use two screws to secure the Assembly.
  • Page 286: Flywheel Assembly

    4025-XXX Flywheel Assembly Removal Remove the Rear Cover. Remove the screw securing the Flywheel to the Drive Assembly shaft and pull the Flywheel off of the shaft. Replacement Position the Flywheel as shown, making sure the screw hole in the flange at the rear of the Flywheel lines up with the screw hole in the shaft.
  • Page 287: Main Drive Assembly

    4025-XXX Main Drive Assembly 4-79 Repair Information...
  • Page 288 4025-XXX Removal Remove the EP Cartridge. WARNING: Do not attempt to remove the Main Drive Assembly without first removing the EP Cartridge. Remove the Rear Cover. Open the Left Upper Cover. Remove the Flywheel Assembly. Remove the Left Cover Interlock Switch Assembly. Remove the screw securing the Inner Cover to the printer frame, and remove the Inner Cover.
  • Page 289 4025-XXX Replacement Push all of the wire harnesses out of the way. Rotate the Registration Clutch and the Feed Clutch so the location notches are not in the way of Main Drive installation. Lift the Exit Gear out of the way and slide the drive pin at the back of the Main Drive Assembly into the large opening in the printer frame.
  • Page 290: Low Voltage Power Supply (Lvps) Assembly

    4025-XXX Low Voltage Power Supply (LVPS) Assembly 4-82 Service Manual...
  • Page 291 4025-XXX Removal Remove the Top Cover Assembly. Remove the Front Inner Cover. Remove the Right Cover. Remove four screws securing the ESS Assembly to the LVPS, and tilt the ESS Assembly back and out of the way. Remove the eight screws securing the LVPS Cover to the LVPS and remove the Cover.
  • Page 292: Fan Assembly

    4025-XXX Fan Assembly 4-84 Service Manual...
  • Page 293 4025-XXX Removal Remove the Top Cover Assembly Remove the Front Inner Cover. Remove the Right Cover. Remove four screws securing the ESS Assembly to the LVPS, and tilt the ESS Assembly back and out of the way. Remove the eight screws securing the LVPS Cover to the LVPS and remove the Cover.
  • Page 294: Ac Driver Pwb 120/230 Vac

    4025-XXX AC Driver PWB 120/230 VAC 4-86 Service Manual...
  • Page 295 4025-XXX Removal Remove the I/O PWB. Remove the five P/Js from the AC Driver PWB. Refer to the appropriate Figure 1 or Figure 2 and remove the screws securing the Plate, Bracket, and AC Driver PWB to the frame and remove the Bracket and the Plate.
  • Page 296: High Voltage Power Supply (Hvps) Assembly

    4025-XXX High Voltage Power Supply (HVPS) Assembly Removal Remove the I/O PWB. Disconnect J500, J701, J702, and BTR from the HVPS PWB. WARNING: The PWB is easily broken. Use care when removing the P/Js from the HVPS PWB. Use your fingers to hold down the PWB while you carefully disconnect each P/J. Remove the two screws, one on the left side and one on the right side, that secure the HVPS Assembly to the printer frame.
  • Page 297: I/O Pwb

    4025-XXX I/O PWB Removal Remove the Rear Cover. Disconnect the seventeen P/Js from the I/O PWB. Remove the four screws securing the I/O PWB Bracket to the printer frame and remove the Bracket. Remove the six screws securing the I/O PWB to the Bracket and remove the PWB. Replacement Position the I/O PWB against the Bracket as shown in the illustration.
  • Page 298: Left Cover Interlock Switch Assembly

    4025-XXX Left Cover Interlock Switch Assembly 4-90 Service Manual...
  • Page 299 4025-XXX Removal Remove the Rear Cover Assembly. Disconnect J232 and J233 from the Interlock Switch. Remove the screw that secures the Interlock Switch Bracket to the printer frame, and pull the Assembly out of the printer. Rotate the Switch Lever so it is straight up, and slide it off of the Bracket. Press the two clips securing the Switch to the Bracket and push the Switch out of the Bracket.
  • Page 300: Engine Board (Mcu Pwb)

    4025-XXX Engine Board (MCU PWB) 4-92 Service Manual...
  • Page 301 4025-XXX Removal If you are able to access Diagnostics Mode, then enter Diagnostic to read the print engine usage logs. Write down the print count for each category. Remove the ESS Cover. Remove the ESS PWB. Disconnect J400, J401, J402, J403, J408, J409, and J411 from the MCU PWB. Remove the six screws securing the MCU PWB to the ESS Assembly.
  • Page 302: Controller Board (Ess Pwb)

    4025-XXX Controller Board (ESS PWB) 4-94 Service Manual...
  • Page 303 4025-XXX Removal Remove the interface cables from the connectors on the ESS Drawer Panel. Loosen the two thumbscrews that secure the ESS Drawer Panel to the ESS Box. Slide the ESS out of the ESS Box. WARNING: Wear an electrostatic wrist strap and use caution when working with the ESS PWB.
  • Page 304: Ess Cover

    4025-XXX ESS Cover Removal Remove the Top Cover Assembly. Remove the fourteen screws that secure the ESS Cover to the ESS Box. Lift the ESS Cover off of the ESS Box. Replacement Reinstall the ESS Cover onto the top of the ESS Box (see the figure for correct positioning).
  • Page 305: 220Vac Transformer

    4025-XXX 220VAC Transformer Removal Remove the Rear Cover. Disconnect P/J34 from the AC Driver PWB. Remove the four screws securing the 220 VAC Transformer to the printer frame and remove the Transformer. Replacement Position the 220 VAC Transformer against the printer frame as shown. Use four screws to secure the Transformer to the printer frame.
  • Page 306: Ess Assembly

    4025-XXX ESS Assembly Removal Remove the ESS Cover. Disconnect J400, J401, J402, J403, J404, J408, J409, and J411 from the MCU PWB. Release the wire harness from the wire clamps and pull the harnesses free of the ESS Assembly. Remove the four screws securing the ESS Assembly to the printer frame, and remove the Assembly.
  • Page 307: Connector Locations

    4025-XXX 5. Connector Locations P/J Location Table Use the table and maps in this section to locate specific P/J connectors within the printer: Locate the P/J connector number in the first column of the table. Locate the corresponding map and location number, such as M2-5, in the second column.
  • Page 308 4025-XXX Map & Number Connected to... Other end connected to... M1-4 Start of Scan Sensor P/J411 MCU PWB M2-1 MP Feeder Size Sensor P/J465 I/O PWB M2-9 MP Feeder No Paper Sensor P/J465 I/O PWB M4-3 Face Up Exit Switch P/J462 I/O PWB M3-13 I/O PWB...
  • Page 309 4025-XXX Map & Number Connected to... Other end connected to... M5-9 Tray 2 Feed Clutch P/J467 I/O PWB M5-10 Tray 2 Lift Motor P/J467 I/O PWB M6-9 MCU PWB P/J502 & P/J504 LVPS M6-4 MCU PWB P/J417 Operator Panel M6-7 MCU PWB P/J452 I/O PWB M6-8...
  • Page 310 4025-XXX Map & Number Connected to... Other end connected to... M3-10 I/O PWB P/J205 Main Motor Assembly M3-20 I/O PWB P/J105 Tray 1 Size Sensor M3-19 I/O PWB P/J104 Fuser Exit Sensor P/J109 Face Up Exit Sensor P/J133 Full Stack Sensor P/J200 Registration Clutch P/J202 Tray 1 Feed Clutch P/J209 Offset Motor...
  • Page 311 4025-XXX Map & Number Connected to... Other end connected to... M8-8 AC Driver PWB P/J411 MCU PWB M3-31 PSLV-R2 P/J468 I/O PWB M4-9 P/J12 Fuser P/J462 I/O PWB M4-10 P/J109 Face Up Exit Sensor P/J462 I/O PWB P/J133 Full Stack Sensor P/J210 Exit Gate Solenoid M4-12 P/J218 Inverter CW Clutch...
  • Page 312: P/J Location Maps

    4025-XXX Map & Number Connected to... Other end connected to... FS236 M1-1 P/J237 P/J411 MCU PWB P/J Location Maps P/J Location Map 1 Service Manual...
  • Page 313 4025-XXX P/J Location Map 2 Connector Locations...
  • Page 314 4025-XXX P/J Location Map 3 Service Manual...
  • Page 315 4025-XXX P/J Location Map 4 Connector Locations...
  • Page 316 4025-XXX P/J Location Map 5 5-10 Service Manual...
  • Page 317 4025-XXX P/J Location Map 6 5-11 Connector Locations...
  • Page 318 4025-XXX P/J Location Map 7 5-12 Service Manual...
  • Page 319 4025-XXX P/J Location Map 8 5-13 Connector Locations...
  • Page 320: Wiring Diagram Notations

    4025-XXX Printer Wiring Diagrams Wiring Diagram Notations This section contains a Master Wiring Diagram for the printer. The Master Wiring Diagram shows the interconnections of the major subsystems within the printer. The remainder of this section divides the Master Wiring Diagram into individual block diagrams (BD) to better illustrate the electrical relationships between components and assemblies.
  • Page 321 4025-XXX 5-15 Connector Locations...
  • Page 322: Master Wiring Diagram

    4025-XXX Master Wiring Diagram 5-16 Service Manual...
  • Page 323 4025-XXX BD1 AC in↔Noise Filter↔LVPS↔MCU PWB↔AC Drive 5-17 Connector Locations...
  • Page 324 4025-XXX BD1 AC in↔Noise Filter↔LVPS↔MCU PWB↔AC Drive The following table shows the signal names for this BD: Signal Name Description LVPS$ON Switches AC to the Finisher. 0VDC=AC on. +5VDC=AC off. BD2 Fuser↔AC Driver PWB↔I/O PWB↔MCU PWB BD2 Fuser↔AC Driver PWB↔I/O PWB↔MCU PWB The following table shows the signal names for this BD: Signal Name Description...
  • Page 325 4025-XXX Signal Name Description RLY$FUSER Switches AC to the AC Driver PWB FUSER$MAIN Switches AC to Heat Lamp 1 FUSER$SUB Switches AC to Heat Lamp 2 BD3 LVPS↔MCU PWB↔I/O PWB Signal Name Description There are no signals for this block diagram. BD4 Console↔MCU PWB 5-19 Connector Locations...
  • Page 326 4025-XXX BD4 Console↔MCU PWB The following table shows the signal names for this BD: Connector/Pin Number Signal Name P615 to P/J401 Pin 1 P615 to P/J401 Pin 2 +5VDC P615 to P/J401 Pin 3 P615 to P/J401 Pin 4 5VRTN P615 to P/J401 Pin 5 FPIRQ BD5 HVPS↔I/O PWB...
  • Page 327 4025-XXX BD5 HVPS↔I/O PWB The following table shows the signal names for this BD: Signal Name Description DBAC$CLK Controls AC to the Mag Roll DBAC$RMT Varies the DB AC voltage DBAC$ON Varies the DB AC voltage DBDC$RMT Varies the DB DC voltage BCRAC$CLK Controls AC to the BCR BCRAC$ON...
  • Page 328 4025-XXX BD6 Printhead↔MCU PWB 5-22 Service Manual...
  • Page 329 4025-XXX BD6 Printhead↔MCU PWB The following table shows the signal names for this BD: Signal Name Description FAN$HI Switches speed of LVPS Fan. 5V=Low speed. 0V=High speed FAN#FAIL Monitors LVPS Fan. 5V=Fan operation problem. 0V=Fan operation normal INTLK#FRONT Monitors the Front Cover Interlock Switch. 5V=Cover close. 0V=Cover open Printhead#SOS Monitors the Start of Scan RMOT$ON...
  • Page 330 4025-XXX BD7 Main Motor↔Interlocks SW1 & SW2↔I/O PWB 5-24 Service Manual...
  • Page 331 4025-XXX BD7 Main Motor↔Interlocks SW1 & SW2↔I/O PWB The following table shows the signal names for this BD: Signal Name Description FAN$LOW Switches speed of Fuser Fan. 5V=Low speed. 0V=High speed FAN$FAIL Monitors Fuser Fan. 5V=Fan operation problem. 0V=Fan operation normal MMOT$ON Switches the Main Motor.
  • Page 332 4025-XXX BD8 Tray 1 Feeder↔I/O PWB↔ Offset Motor↔MCU PWB 5-26 Service Manual...
  • Page 333 4025-XXX BD8 Tray 1 Feeder↔I/O PWB↔ Offset Motor↔MCU PWB The following table shows the signal names for this BD: Signal Name Description CL$FEED1 Switches Tray 1 Feed Clutch. 24V=Off. 0V=On CL$RGATE Switches Registration Roll Clutch. 24V=Off. 0V=On FSR##FEXIT Signal from the Fuser Exit Sensor. 5V=Not actuated. 0V=Actuated CL$ICW Switches the CW Inverter Clutch.
  • Page 334 4025-XXX BD9 Tray 2 Feeder↔I/O PWB BD9 Tray 2 Feeder↔I/O PWB The following table shows the signal names for this BD: Signal Name Description SNR#NOP2 Signal from the Tray 2 No Paper Sensor. 5V=Not actuated. 0V=Actuated SNR#LVL2 Signal from the Tray 2 Level Sensor. 5V=Not actuated. 0V=Actuated SNR#SIZE2 Analog signal from the Tray 2 Size Sensor.
  • Page 335 4025-XXX BD10 ESS Fan↔MCU PWB BD10 ESS Fan↔MCU PWB The following table shows the signal names for this BD: Signal Name Description FAN$SEL Switches the ESS Fan. 24V=Off. 0V=On FAN#FAIL Monitors ESS Fan. 5V=Fan operation problem. 0V=Fan operation normal 5-29 Connector Locations...
  • Page 336 4025-XXX BD11 MP Feeder↔I/O PWB 5-30 Service Manual...
  • Page 337 4025-XXX BD11 MP Feeder↔I/O PWB The following table shows the signal names for this BD: Signal Name Description SNR#SIZEM Analog signal from the MP Feeder Size Sensor. 0VDC ~ 5VDC SNR#NOPM Signal from the MP Feeder No Paper Sensor. 5V=Not actuated. 0V=Actuated MSI#DET Signal between the IOT and the MP Feeder connection.
  • Page 338 4025-XXX BD12 I/O PWB↔MCU PWB (1 of 7) The following table shows the signal names for this BD: Signal Name Description BTR##MON Monitors BTR current value BTR$RMT Controls voltage to the BTR BTR$ON Switches HVPS voltage to the BTR. 5V=Off. 0V=On BTR$SEL Reverses BTR polarity.
  • Page 339 4025-XXX BD13 I/O PWB↔MCU PWB (2 of 7) The following table shows the signal names for this BD: Signal Name Description MMOT$ON Switches Main Motor. 5V=Off. 0V=On DMOT$ON Switches Developer Motor. 5V=Off. 0V=On DMOT$REF Control signal for the Developer Motor. FAN$LOW Switches Fuser Fan speed.
  • Page 340 4025-XXX BD14 I/O PWB↔MCU PWB (3 of 7) The following table shows the signal names for this BD: Signal Name Description CRU$DATA Input the CRU Memory CRUM$PWR Switches on and off the CRU Memory STS##FSR1 Analog signal from the Fuser Thermistor SNR#FUT Signal from the Face Up Sensor.
  • Page 341 4025-XXX BD15 I/O PWB↔MCU PWB (4 of 7) PWBA MCU(4/7) PWBA I/O P/J403 P/J453 SNR##SIZEM SNR#NOPM SNR#FEED EMOT$ON CL$FEEDM MOT$LIFT1 SNR#TAROLL BD15 I/O PWB↔MCU PWB (4 of 7) The following table shows the signal names for this BD: Signal Name Description SNR##SIZEM Analog signal from the MP Feeder Paper Size Sensor.
  • Page 342 4025-XXX BD16 I/O PWB↔MCU PWB (5 of 7) The following table shows the signal names for this BD: Signal Name Description SNR#TA4 Signal from the Take Away Sensor 4. 5V=Astuated. 0V=Not actuated SNR#TA5 Signal from the Take Away Sensor 5. 5V=Astuated. 0V=Not actuated CL$FEEDA Switches Feed Clutch A.
  • Page 343 4025-XXX BD18 I/O PWB↔MCU PWB (7 of 7) PWBA MCU(7/7) PWBA I/O P/J402 P/J452 5VRTN 5VRTN 5VRTN 5VRTN P/J403 P/J453 CL#ICCW OPT$TX+ 5VRTN 5VRTN OPT#DET OPT$RX+ CL#ICW BD18 I/O PWB↔MCU PWB (7 of 7) The following table shows the signal names for this BD: Signal Name Description CL#ICCW...
  • Page 344 4025-XXX 5-38 Service Manual...
  • Page 345: 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 The operator panel displays the message “80 Scheduled Maintenance” at each 300K page count interval. It is necessary to replace the fuser assembly, transfer roller, and pick rollers at this interval to maintain the print quality and reliability of the printer.
  • Page 346 4025-XXX Service Manual...
  • Page 347: Parts Catalog

    4025-XXX 7. Parts Catalog How to Use This 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 348: Assembly 1: Top Cover Assembly

    4025-XXX Assembly 1: Top Cover Assembly Service Manual...
  • Page 349 4025-XXX Assembly 1: Top Cover Assembly Asm- Part Units Description Index Number 12G4000 COVER PRINTER, TOP 12G4001 STOP, PAPER 12G4002 COVER, CONNECTOR 12G4003 OP PANEL ASSEMBLY 12G4004 COVER, FUSER 12G4005 FAN, FUSER 12G4186 DAMPER ASM, PAPER Parts Catalog...
  • Page 350: Assembly 2: Front Cover

    4025-XXX Assembly 2: Front Cover Service Manual...
  • Page 351 Description Index Number 12G4009 DUCT, AIR 12G4012 KIT,TRAY 2 MOUNTING 12G4008 COVER, PRINTER INNER FRONT 12G4006 COVER, PRINTER, FRONT (W820, X820E) 56P2725 COVER, PRINTER, FRONT (X830E) 56P2726 COVER, PRINTER, FRONT (X832E) 12G4007 HINGE, COVER 12G4011 STRAP, COVER SUPPORT 12G4010 SWITCH, INTERLOCK ASSEMBLY...
  • Page 352: Assembly 3: Rear, Left, And Right Covers

    4025-XXX Assembly 3: Rear, Left, and Right Covers Service Manual...
  • Page 353 4025-XXX Assembly 3: Rear, Left, and Right Covers Asm- Part Units Description Index Number 12G4013 COVER, PRINTER INNER LH 12G4015 COVER ASM, PRINTER REAR UPPER 12G4016 COVER PRINTER, REAR LOWER 12G4014 COVER, PRINTER RH Parts Catalog...
  • Page 354: Assembly 4: Tray Unit - Paper Stack

    4025-XXX Assembly 4: Tray Unit - Paper Stack Service Manual...
  • Page 355 4025-XXX Assembly 4: Tray Unit - Paper Stack Asm- Part Units Description Index Number 12G4017 TRAY ASM, PAPER 12G4018 KIT, PAPER TRAY CABLES Parts Catalog...
  • Page 356: Assembly 5: Tray Interface

    4025-XXX Assembly 5: Tray Interface 7-10 Service Manual...
  • Page 357 4025-XXX Assembly 5: Tray Interface Asm- Part Units Description Index Number 12G4024 STOP, TRAY R 12G4027 SPRING, TORSION 12G4026 LINK STOP, TRAY 1 12G4036 LINK STOP, TRAY 2 12G4021 SENSOR, PHOTO 12G4023 STOP, TRAY F 12G4025 SPACER, L 12G4022 GUIDE, TRAY 1 12G4035 GUIDE, TRAY 2 12G4028...
  • Page 358: Assembly 6: Paper Pick Up

    4025-XXX Assembly 6: Paper Pick Up 7-12 Service Manual...
  • Page 359 4025-XXX Assembly 6: Paper Pick Up Asm- Part Units Description Index Number 12G4030 KIT, TRAY 1 CLUTCH 12G4037 KIT, TRAY 2 CLUTCH 12G4029 FEEDER ASM PAPER 12G4031 KIT, FEED ROLL (Qty 6) 7-13 Parts Catalog...
  • Page 360: Assembly 7: Retard And Take Away - Tray 1

    4025-XXX Assembly 7: Retard and Take Away - Tray 1 7-14 Service Manual...
  • Page 361 4025-XXX Assembly 7: Retard and Take Away - Tray 1 Asm- Part Units Description Index Number 12G4034 EXIT ASM, HIGH PAPER RETARD 12G4033 SPRING, EXTENSION 12G4032 GUIDE, PAPER FEED OUT 7-15 Parts Catalog...
  • Page 362: Assembly 8: Retard And Take Away - Tray 2

    4025-XXX Assembly 8: Retard and Take Away - Tray 2 7-16 Service Manual...
  • Page 363 4025-XXX Assembly 8: Retard and Take Away - Tray 2 Asm- Part Units Description Index Number 12G4040 KIT, TRAY 2 EXIT GEAR 12G4039 EXIT ASM, TRAY 2 PAPER 12G4033 SPRING 12G4038 GUIDE, PAPER EXIT 7-17 Parts Catalog...
  • Page 364: Assembly 9: Feed Drive Transmission

    4025-XXX Assembly 9: Feed Drive Transmission 7-18 Service Manual...
  • Page 365 4025-XXX Assembly 9: Feed Drive Transmission Asm- Part Units Description Index Number 12G4041 KIT, FEED DRIVE REPAIR 7-19 Parts Catalog...
  • Page 366: Assembly 10: Multi Purpose Feeder And Mpf/Duplex Support

    4025-XXX Assembly 10: Multi Purpose Feeder and MPF/Duplex Support 7-20 Service Manual...
  • Page 367 4025-XXX Assembly 10: Multi Purpose Feeder and MPF/Duplex Support Asm- Part Units Description Index Number 10-1 12G4043 COVER, MP FEEDER REAR 12G4042 COVER, MP FEEDER FRONT 12G4044 FEEDER, MP FEEDER 12G4046 TRAY ASM, MP FEEDER 12G4045 COVER, MP FEEDER TOP 7-21 Parts Catalog...
  • Page 368: Assembly 11: Tray 1 Frame And Left Cover

    4025-XXX Assembly 11: Tray 1 Frame and Left Cover 7-22 Service Manual...
  • Page 369 4025-XXX Assembly 11: Tray 1 Frame and Left Cover Asm- Part Units Description Index Number 11-1 12G4049 SENSOR, PHOTO 12G4047 ROLLER ASM, PINCH 12G4048 COVER ASM, PRINTER LOWER LEFT 7-23 Parts Catalog...
  • Page 370: Assembly 12: Tray 2 Frame And Left Cover

    4025-XXX Assembly 12: Tray 2 Frame and Left Cover 7-24 Service Manual...
  • Page 371 4025-XXX Assembly 12: Tray 2 Frame and Left Cover Asm- Part Units Description Index Number 12-1 12G4053 SWITCH, INTERLOCK 12G4049 SENSOR 12G4054 COVER, CAP 12G4050 COVER ASM, PRINTER LEFT 12G4051 HINGE, COVER RH 12G4052 HINGE, COVER LH 7-25 Parts Catalog...
  • Page 372: Assembly 13: Registration

    4025-XXX Assembly 13: Registration 7-26 Service Manual...
  • Page 373 4025-XXX Assembly 13: Registration Asm- Part Units Description Index Number 13-1 12G4057 GUIDE, REGISTRATION 12G4049 SENSOR 12G4059 KIT, BEARING 12G4056 ROLLER ASM, REGISTRATION 12G4055 CLUTCH ASM, REGISTRATION 12G4058 CABLE, REGISTRATION 7-27 Parts Catalog...
  • Page 374: Assembly 14: Left Upper Cover Assembly

    4025-XXX Assembly 14: Left Upper Cover Assembly 7-28 Service Manual...
  • Page 375 4025-XXX Assembly 14: Left Upper Cover Assembly Asm- Part Units Description Index Number 14-1 12G4060 COVER ASM, PRINTER UPPER LEFT 7-29 Parts Catalog...
  • Page 376: Assembly 15: Printhead Assembly

    4025-XXX Assembly 15: Printhead Assembly 7-30 Service Manual...
  • Page 377 4025-XXX Assembly 15: Printhead Assembly Asm- Part Units Description Index Number 15-1 12G4061 PRINTHEAD 7-31 Parts Catalog...
  • Page 378: Assembly 16: Xerography And Development

    4025-XXX Assembly 16: Xerography and Development 7-32 Service Manual...
  • Page 379 4025-XXX Assembly 16: Xerography and Development Asm- Part Units Description Index Number 16-1 12G4069 SWITCH ASM, INTERLOCK 12G4071 PLATE, CONTACT D 12G4070 PLATE, CONTACT C 12G4065 SENSOR ASM, TONER 12G4066 SPRING, SENSOR 12G4062 ROLLER, TRANSFER 12G4064 SLIDER, EXIT 12G4063 CONTACT ASM, TRANSFER ROLLER 12G4068 BRACKET, CABLE 12G4067...
  • Page 380: Assembly 17: Fuser Assembly

    4025-XXX Assembly 17: Fuser Assembly 7-34 Service Manual...
  • Page 381 4025-XXX Assembly 17: Fuser Assembly Asm- Part Units Description Index Number 17-1 12G4184 FUSER ASM, LV 12G4185 FUSER ASM, HV 7-35 Parts Catalog...
  • Page 382: Assembly 18: Exit Lower Chute

    4025-XXX Assembly 18: Exit Lower Chute 7-36 Service Manual...
  • Page 383 4025-XXX Assembly 18: Exit Lower Chute Asm- Part Units Description Index Number 18-1 12G4072 OFFSET / EXIT / TRANSPORT ASSEMBLY 12G4074 MOTOR ASM, OFFSET 12G4076 SENSOR ASM, EXIT LOWER 12G4073 SOLENOID ASM, EXIT LOWER 12G4075 SWITCH ASM, EXIT LOWER 7-37 Parts Catalog...
  • Page 384: Assembly 19: Exit Drive Assembly

    4025-XXX Assembly 19: Exit Drive Assembly 7-38 Service Manual...
  • Page 385 4025-XXX Assembly 19: Exit Drive Assembly Asm- Part Units Description Index Number 19-1 12G4077 DRIVE ASM, EXIT 7-39 Parts Catalog...
  • Page 386: Assembly 20: Main Drive Assembly

    4025-XXX Assembly 20: Main Drive Assembly 7-40 Service Manual...
  • Page 387 4025-XXX Assembly 20: Main Drive Assembly Asm- Part Units Description Index Number 20-1 12G4078 DRIVE ASM, MAIN 12G4079 FLYWHEEL, MAIN DRIVE ASM 7-41 Parts Catalog...
  • Page 388: Assembly 21: Fuser Drive Assembly

    4025-XXX Assembly 21: Fuser Drive Assembly 7-42 Service Manual...
  • Page 389 4025-XXX Assembly 21: Fuser Drive Assembly Asm- Part Units Description Index Number 21-1 12G4080 FRAME ASM, FUSER EXIT 12G4081 CONNECTOR, FUSER DRIVE 7-43 Parts Catalog...
  • Page 390: Assembly 22: Power Unit

    4025-XXX Assembly 22: Power Unit 7-44 Service Manual...
  • Page 391 4025-XXX Assembly 22: Power Unit Asm- Part Units Description Index Number 22-1 12G4082 PWR SUPPLY, 110V 12G4083 PWR SUPPLY, 220V 12G4084 FAN, POWER UNIT 11A9095 POWER CORD LV, U.S., Canada, Australia/New Zealand, Columbia, Costa Rica, Dominican Republic, Ecuador, El Salvador, Guatemala, Honduras, Mexico, Nicaragua, Panama, Peru, Venezuela, Puerto Rico, US Virgin Islands, Caribbean countries other than Dominican Republic 1339518...
  • Page 392: Assembly 23: Hvps And I/O Pwb

    4025-XXX Assembly 23: HVPS and I/O PWB 7-46 Service Manual...
  • Page 393 4025-XXX Assembly 23: HVPS and I/O PWB Asm- Part Units Description Index Number 23-1 12G4085 CARD ASM, AC DRIVER, 110V 12G4086 CARD ASM, AC DRIVER, 220V 12G4089 SWITCH, INTERLOCK 12G4088 CARD ASM, I/O 12G4087 HVPS 12G4090 TRANSFORMER, 220 V MACHINE ONLY 12G4376 PSLV-R2 POWER SUPPLY 7-47...
  • Page 394: Assembly 24: Ess Assembly

    4025-XXX Assembly 24: ESS Assembly 7-48 Service Manual...
  • Page 395 Note: Factory defaults must be reset after you replace the engine board (MCU PWB) contained in this B/M. Go to “PRINTER SETUP” on page 3-5 56P2711 BOARD ASM, CONTROLLER (ESS PWB), NETWORK (W820, X820E) 56P2710 BOARD ASM, CONTROLLER (ESS PWB), NON NETWORK (W820) 56P2723 BOARD ASM, CONTROLLER (ESS PWB), NETWORK (X830E)
  • Page 396: Assembly 25: Harness

    4025-XXX Assembly 25: Harness 7-50 Service Manual...
  • Page 397 4025-XXX Assembly 25: Harness Asm- Part Units Description Index Number 25-1 12G4108 CABLE ASM, HVPS 12G4107 CABLE ASM, MOTOR 12G4105 CABLE ASM, INTERLOCK 12G4104 CABLE ASM, PAPER SIZE 12G4103 CABLE ASM, REGISTRATION 12G4102 CABLE ASM, OUTPUT 12G4101 CABLE ASM, DUPLEX 12G4100 CABLE ASM, BOTTOM 12G4099...
  • Page 398: Assembly 26: Miscellaneous

    4025-XXX Assembly 26: Miscellaneous Asm- Part Units Description Index Number 12G4375 SCREW PARTS PACK 12G4368 KIT CLAMP 12G4369 KIT E CLIP 12G4370 KIT REPACK, PRINTER 12G4371 KIT REPACK, ENVELOPE FEEDER 12G4372 KIT REPACK, DUPLEX UNIT 12G4373 KIT REPACK, HCF 12G4374 KIT REPACK, FINISHER 99A1752 4 MB MEMORY...
  • Page 399 OPTRA FORMS 2MB FLASH DIMM 99A1684 OPTRA FORMS 4MB FLASH DIMM 99A1685 OPTRA FORMS 8MB FLASH DIMM 99A1686 OPTRA FORMS 16MB FLASH DIMM 56P3836 W820 / X83XE IPDS 56P3140 PRINT CRYPTION 56P3141 BAR CODE 56P3300 PRESCRIBE 56p3301 IMAGEQUICK™ 7-53 Parts Catalog...
  • Page 400 4025-XXX 7-54 Service Manual...
  • Page 401 4025-XXX Index 2-11 Service Checks 2-11 Error Code Service Checks Attendance Message Table 2-59 Print Quality Service Checks 2-33 Attendance Messages 2-54 Symptom Service Checks Service Checks Flowchart Service Error Code Table 3-21 Base Sensor Tests Symptom Service Check Table Button Test 3-22 Disk Test/Clean...
  • Page 402 4025-XXX 1-45 Paper Path Component Control 1-36 Paper Path Mechanical Drive Operator Panel Messages Power and Control 3-16 Output Bin Feed Test 1-11 Power Supply Components Output Bin Feed Tests 1-15 Printer Control 3-18 Sensor Test 1-24 Printer Control Functions 3-18 Output Bin Sensor Test 1-32...
  • Page 403 4025-XXX 4-54 Printer Setup Registration Chute 3-27 4-51 Setting Configuration ID Registration Clutch 3-26 4-55 Setting the Page Count Registration Roll Assembly 3-27 4-56 Viewing the Permanent Page Count Registration Sensor 5-14 4-10 Printer Wiring Diagrams Right Cover 1-46 4-24 Printhead Support 4-63...
  • Page 404 4025-XXX Storage Device Tests 12G4014 3-22 Disk Test/Clean 12G4015 3-23 Flash Test 12G4016 3-22 Quick Disk Test 12G4017 Symbols 12G4018 7-11 Symptom Service Check Table 12G4019 2-54 Symptom Service Checks 7-11 12G4020 7-11 12G4021 7-11 12G4022 Using the Operator Panel Diagnostics Menu 7-11 12G4023 7-11...
  • Page 405: Index

    4025-XXX 7-33 7-52 12G4063 12G4369 7-33 12G4064 7-33 7-52 12G4065 12G4370 7-33 7-52 12G4066 12G4371 7-33 7-52 12G4067 12G4372 7-33 7-52 12G4068 12G4373 7-33 7-52 12G4069 12G4374 7-52 12G4375 7-33 7-47 12G4070 12G4376 7-33 7-49 12G4071 12G4377 7-37 7-49 12G4072 12G4379 7-37 12G4073...
  • Page 406 4025-XXX 7-53 99A1683 7-53 99A1684 7-53 99A1685 7-53 99A1686 7-52 99A1752 7-52 99A1753 7-52 99A1754 7-52 99A1755 7-52 99A1756 7-52 99A1757 7-52 99A1758 7-52 99A1759 7-52 99A1773 7-52 99A1774 Index...

This manual is also suitable for:

X820eX830eX832e

Table of Contents