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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.
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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.
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.
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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...
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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.
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.
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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.
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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.
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.
• 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.
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.
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.
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.
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.
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...
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.
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 °...
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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.
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).
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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.
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.
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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...
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.
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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.
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.
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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.
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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.
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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.
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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.
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.
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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.
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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.
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.
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.
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.
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°...
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.
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.
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.
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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.
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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.
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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.
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.
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.
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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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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;...
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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.
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.
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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.
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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.
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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.
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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.
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.
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.
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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.
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.
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...
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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.
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.
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)
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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...
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)
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.
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...
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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.
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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.
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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...
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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...
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.
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>...
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.
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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”...
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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.
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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.
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.
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”...
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 •...
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.
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...
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...
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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...
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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...
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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...
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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...
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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...
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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...
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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.
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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.
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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”...
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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.
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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...
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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...
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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.
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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.
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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...
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...
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...
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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...
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.
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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...
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...
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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...
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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...
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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...
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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...
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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...
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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)”...
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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...
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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...
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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...
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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.
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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.
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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.
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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.
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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”...
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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.
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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.
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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...
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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...
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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...
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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...
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?
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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...
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?
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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.
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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”...
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...
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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.
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.
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...
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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...
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...
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.
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.
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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.
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...
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.
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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.
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.
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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.
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...
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...
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.
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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.
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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.
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.
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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...
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.
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.
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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.
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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.
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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.
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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.
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: •...
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.
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.
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.
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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.
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.
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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 •...
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.
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.
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.
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.
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: •...
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.
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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 •...
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: •...
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.
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.
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.
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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...
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.
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.
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).
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.
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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.
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.
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.
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.
4025-XXX Removal and Replacement Procedures Fuser Full Cover Service Manual...
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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).
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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.
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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.
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.
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.
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.
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.
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.
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.
4025-XXX Tray 1 Feed Clutch 4-14 Service Manual...
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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.
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.
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...
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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.
4025-XXX Tray 1 Take Away Roll Assembly 4-19 Repair Information...
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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.
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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.
4025-XXX Tray 1 Feeder Assembly 4-22 Service Manual...
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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.
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.
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.
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 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 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.
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.
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.
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.
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.
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.
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.
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.
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 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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 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 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 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.
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).
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.
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.
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.
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 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.
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.
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.
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 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.
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.
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.
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.
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.
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 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.
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.
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.
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.
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.
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.
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.
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).
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.
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.
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...
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 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$ON Switches the Main Motor.
Page 333
4025-XXX BD8 Tray 1 Feeder↔I/O PWB↔ Offset Motor↔MCU PWB The following table shows the signal names for this BD: Signal Name Description CL$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...
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.
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.
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...
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...
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...
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...
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...
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...
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...
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...
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...
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...
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...
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...
4025-XXX Assembly 22: Power Unit 7-44 Service Manual...
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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...
4025-XXX Assembly 23: HVPS and I/O PWB 7-46 Service Manual...
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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...
4025-XXX Assembly 24: ESS Assembly 7-48 Service Manual...
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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)
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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...
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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...
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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...
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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...