Xerox DocuPrint N4525 Service Quick Reference Manual Download Page 203

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Volume 1 / Print Engine - FRU RRPs

181

Key FRU Removal /

Replacement

Procedures (RRPs)

Contents - Removal and Replacement Procedures

Notations in the RRP text

1-184

RRP 1-1 Fuser Cover (PL 1.1)

1-185

RRP 1-2 Top Cover Assembly (PL 1.1).

1-186

RRP 1-3 Front Cover Assembly (PL 1.1)

1-187

RRP 1-4 Front Inner Cover (PL 2.3)

1-188

RRP 1-5 Rear Cover Assembly (PL 3.3)

1-189

RRP 1-6 Right Cover (PL 3.2)

1-190

RRP 1-7 Control Panel (PL 1.1)

1-191

RRP 1-8 Rear Lower Cover (PL 3.4)

1-192

RRP 1-9 Tray 1 Lift Motor (PL 3.1)

1-193

RRP 1-10 Tray 1 Feed Clutch (PL 3.2)

1-194

RRP 1-11 Feeder, Pick and Retard Rollers (PL 3.2~PL 3.3~PL 3.5 and PL 3.6)1-196

RRP 1-12 Tray 1 Take-Away Roller Assembly (PL 3.3)

1-198

RRP 1-13 Tray 1 Feeder Assembly (PL 3.2).

1-200

RRP 1-15 Tray 1 Retard Assembly (PL 3.3)

1-202

RRP 1-16 Tray 1 & Tray 2 Front Chute Assemblies (PL 3.1~PL 3.4)

1-203

RRP 1-20 Tray 1 & Tray 2 Paper Size Sensors (PL 3.1~PL 3.4)

1-204

RRP 1-21 Tray 2 Feed Clutch (PL 3.5)

1-205

RRP 1-22 Tray 2 Feeder Assembly (PL 3.5).

1-206

RRP 1-23 Tray 2 Take-Away Roller Assembly (PL 3.6)

1-208

RRP 1-24 Tray 2 Retard Assembly (PL 3.6).

1-210

RRP 1-25 Multi-sheet Bypass Feeder Assembly (PL 4.2)

1-211

RRP 1-26 Multi-sheet Bypass Feeder Tray Assembly (PL 4.2)

1-212

RRP 1-27 Multi-sheet Bypass Feeder Support Assembly (PL 4.1).

1-214

RRP 1-28 Multi-sheet Bypass Feeder Size Sensor Assembly (PL 4.4)

1-216

RRP 1-29 Multi-sheet Bypass Feeder Feed Clutch (PL 4.3)

1-218

RRP 1-30 Multi-sheet Bypass Feeder Feed Roller (PL 4.3)

1-220

RRP 1-31 Multi-sheet Bypass Feeder Pick Roller (PL 4.3).

1-221

RRP 1-32 Multi-sheet Bypass Feeder Pick Roller Assembly (PL 4.3)

1-222

RRP 1-33 Multi-sheet Bypass Feeder Pad (PL 4.2)

1-224

RRP 1-34 Multi-sheet Bypass Feeder Friction Clutch (PL 4.3).

1-226

RRP 1-35 Multi-sheet Bypass Feeder No-Paper Sensor Assembly (PL 4.3)

1-227

RRP 1-36 Left Middle Cover Assembly (PL 5.1)

1-228

RRP 1-41 Registration Clutch (PL 6.1)

1-230

RRP 1-42 Left Upper Cover Assembly (PL 6.2)

1-232

RRP 1-43 Left Chute Assembly (PL 6.2)

1-234

RRP 1-44 Registration Chute (PL 6.1)

1-235

RRP 1-45 Registration Roller Assembly (PL 6.2)

1-236

RRP 1-47 Laser Scanner Assembly (PL 7.1)

1-237

RRP 1-50 Toner Sensor (PL 7.2)

1-238

RRP 1-51 Laser Print Cartridge Interlock Switch (PL 7.2)

1-239

RRP 1-54 Offset/Exit Assembly (PL 9.1~PL 9.4)

1-242

Summary of Contents for DocuPrint N4525

Page 1: ...void personal injury do not perform any servicing other than that contained in operating instructions unless you are qualified to do so This printing April 5 2001 Rev NEW 721P58090 D O C U P R I N T N 4 5 2 5 N E T W O R K L A S E R P R I N T E R Service Quick Reference Guide Volume 1 Print Engine ...

Page 2: ...ntents of this publication may not be reproduced in any form without permission of Xerox Inc Xerox and all product names and product numbers mentioned in this publication are trademarks Other marks are trademarks or registered trademarks of the companies with which they are associated RJ MP sn ck ...

Page 3: ... changes to the cord or connector WARNING If the product loses the ground connection usage of knobs and controls and other conductive parts can cause an electrical shock NOTE A NOTE may indicate an operating or maintenance procedure practice or condition that is necessary to efficiently accomplish a task A NOTE may also provide additional information related to a specific subject or add a comment ...

Page 4: ...that produces extreme heat at its focal point The laser beam in this printer is invisible Although you cannot see the beam it can still cause severe damage Direct eye exposure to the laser beam may cause eye injury or blindness To avoid permanent eye damage follow these directions Before starting any service procedure switch off the printer power and unplug the power cord from the AC wall outlet D...

Page 5: ...and obey all posted warning labels WARNING Turning the power off using the On Off switch does not de energize the printer You must remove the power cord to disconnect the printer from the main power source Keep the power cord accessible for removal in case of an emergency Safety instructions Read all installation instructions carefully before you plug the product into a power source Care of produc...

Page 6: ...ound connection by way of the grounding conductor in the power cord is essential for safe operation This product is certified under IEC 825 as a Class 1 Laser Product CLASS 1 LASER PRODUCT The DocuPrint N4525 Network Laser Printer is certified to comply with Laser Product Performance Standards set by the U S Department of Health and Human Services as a Class 1 Laser Product This means that this is...

Page 7: ...Laser Printer meets the following standard Laser class 3B maximum 5mW wavelength 780nm The following LASER symbol will be displayed at the start of any procedure where possible exposure to the laser beam exists LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT ...

Page 8: ...ment off to determine if it is the true cause of the interference If the equipment is the cause of the interference the user should try to minimize the interference by taking one or more of the following courses of action NOTE Installation of the Finisher and or the Token Ring Interface results in an FCC classification change to Class A Either re orient or relocate the radio television receiving a...

Page 9: ...mites émission de bruits radioélectriques pour les appareils de classe B stipulés das le réglement sur le brouillage radioéletrique du Ministére des Communcations du Canada European Notice This equipment was tested and is determined to be compliant with VDE requirements for a Class B device Hinweis Hiermit wird bescheinigt dass der Babe Laserdrucker in bereinstimmung mit den Betimmunngen der Vfg 1...

Page 10: ...ual which is applicable to both Books I and II Section 1 General Information This section contains a general overview of the printer and basic information regarding RAM print engine illustrations major assembly locations sensor locations general views etc printer specifications and vital information regarding service call procedures Section 2 Error Codes and Messages Information regarding certain ...

Page 11: ...ection 6 Key FRU Removal and Replacement Procedures This large section provides many procedures and illustrations for removing and replacing key Field Replaceable Units FRUs within the print engine Option specific Removal and Replacement Procedures RRPs appear in the Volume 2 manual supplement for each option For more detailed procedures please refer to the CD version of the service manual Section...

Page 12: ...arts List numbers for this section are preceded by a 3 Volume 4 Envelope Feeder ENV This section contains information specific to the ENV with General Information Error Codes RAPs RRPs Parts Lists Plug Jack Locators and Wiring information NOTE All page figure table RAP RRP and Parts List numbers for this section are preceded by a 4 Volume 5 Face Up Bin FUB This section contains information specifi...

Page 13: ...1 22 Special Media 1 22 Print Media 1 23 Xerox Supplies and Accessories 1 26 Error Codes and Messages 1 29 Error messages 1 29 Service Flowchart 1 29 The Repair Analysis Procedure Table 1 31 How to Use a Repair Analysis Procedure Table 1 31 How to Follow a Repair Analysis Procedure 1 31 General Notes on Using Repair Analysis Procedures 1 32 Before Starting the Error Code Repair Analysis Procedures...

Page 14: ...eaning general if needed 1 178 Key FRU Removal Replacement Procedures RRPs 1 181 Removal and Replacement Procedures RRPs 1 183 FRU Parts List 1 265 Xerox Supplies and Accessories 1 338 Locating Plug Jack Connectors 1 341 Contents 1 341 Plug Jack Connector Locations 1 341 P J Location 1 342 P J Location Map 1 1 347 P J Location Map 2 1 348 P J Location Map 3 1 349 P J Location Map 4 1 350 P J Locat...

Page 15: ...ts 1 115 Fig 1 17 Black Prints 1 117 Fig 1 18 Vertical Band Deletions 1 119 Fig 1 19 Horizontal Band Deletions 1 121 Fig 1 20 Vertical Streaks 1 123 Fig 1 21 Horizontal Streask 1 125 Fig 1 22 Spot Deletions 1 127 Fig 1 23 Spots 1 129 Fig 1 24 Residual Image or Ghosting 1 131 Fig 1 25 Background 1 133 Fig 1 26 Toner on Back of Print 1 135 Fig 1 27 Skewed Image 1 137 Fig 1 28 Damaged Prints 1 139 Fi...

Page 16: ...sheet Bypass Feeder Feed Clutch 1 218 Fig 1 60 Multi sheet Bypass Feeder Feed Roller 1 220 Fig 1 61 Multi sheet Bypass Feeeder Pick Roller 1 221 Fig 1 62 Multi sheet Bypass Feeder Pick Roller Assembly 1 222 Fig 1 63 Multi sheet Bypass Feeder Pad 1 224 Fig 1 64 Multi sheet Bypass Feeder Friction Clutch 1 226 Fig 1 65 Multi sheet Bypass Feeder No Paper Sensor Assembly 1 227 Fig 1 66 Left Middle Cove...

Page 17: ...tom 1 278 Fig 1 104 Tray Interface Tray 1 1 280 Fig 1 105 Paper Pick Up Tray 1 1 282 Fig 1 106 Retard and Take Away Tray 1 1 284 Fig 1 107 Tray Interface Tray 2 1 286 Fig 1 108 Paper Pick Up Tray 2 1 288 Fig 1 109 Retard and Take Away Tray 2 1 290 Fig 1 110 Feed Drive Transmission 1 292 Fig 1 111 Multi sheet Bypass Feeder and Duplex Support 1 294 Fig 1 112 Multi sheet Bypass Feeder Assembly MBF 1 ...

Page 18: ...bly 1 334 Fig 1 132 Wiring Harness 1 336 Fig 1 133 P J Location Map 1 1 347 Fig 1 134 P J Location Map 2 1 348 Fig 1 135 P J Location Map 3 1 349 Fig 1 136 P J Location Map 4 1 350 Fig 1 137 P J Location Map 5 1 351 Fig 1 138 P J Location Map 6 1 352 Fig 1 139 P J Location Map 7 1 353 Fig 1 140 P J Location Map 8 1 354 Fig 1 141 Master Connection and Wiring Diagram 1 of 2 1 356 Fig 1 142 Master Co...

Page 19: ...ions 1 27 Table 1 25 RAP Table Example 1 32 Table 1 26 Legend 1 34 Table 1 27 Repair Analysis Procedure RAP Table 1 35 Table 1 28 System Controller Error Code Table 1 44 Table 1 29 Error Code U1 1 Motor Failure Power Off On 1 46 Table 1 30 Error Code U1 3 LVPSFan Failure 1 48 Table 1 31 Error Code U1 4 Drum Mtr Fail Power Off On 1 49 Table 1 32 Error Code U3 1 Laser Failure Power Off On 1 50 Table...

Page 20: ...r Code H4 2 Load Tray 2 1 95 Table 1 69 Error Code J1 2 Replace Print Cartridge 1 96 Table 1 70 Error Code J3 1 Install Print Cartridge 1 97 Table 1 71 Error Code J6 1 Replace Print Cartridge 1 98 Table 1 72 Error Code J8 1 Print Cartridge OEM ID Mismatch 1 99 Table 1 73 Error Code J8 3 Install Print Cartridge 1 100 Table 1 74 Error Code J8 4 CRUM Failure Power Off On 1 101 Table 1 75 Error Code J...

Page 21: ...1 Table 1 121 PL 3 7 Feed Drive Transmission 1 293 Table 1 122 PL 4 1 Multi sheet Bypass Feeder and Duplex Module Support 1 295 Table 1 123 PL 4 2 Multi sheet Bypass Feeder Assembly 1 297 Table 1 124 PL 4 3 Upper Feeder Assembly 1 299 Table 1 125 PL 4 4 Multi sheet Bypass Feeder Tray Assembly 1 301 Table 1 126 PL 5 1 Tray 1 Frame and Left Cover 1 303 Table 1 127 PL 5 2 Tray 2 Frame and Left Cover ...

Page 22: ...1 x DocuPrint N4525 Network Laser Printer Table 1 148 Xerox Labels 1 339 Table 1 149 Options 1 340 Table 1 150 Plug Jack Location 1 342 ...

Page 23: ...Print N4525 Service Manual is the primary document used for repairing and maintaining the DocuPrint N4525 Network Laser Printer To ensure complete understanding of the product participation in Xerox DocuPrint N4525 service training is recommended Fig 1 1 Print Engine S4525 00 ...

Page 24: ...the Cover A Cover B or the Front Cover is opened or the Laser Print EP Cartridge is removed The Print Engine Controller Board controls all printer functions houses printer diagnostics and supporting test prints stores operating parameters and signals printer errors The System Controller board interfaces a host computer with the Print Engine Controller Board The DocuPrint N4525 Network Laser Printe...

Page 25: ...1 Door A 2 Multi sheet Bypass Feeder 3 Door B 4 Face down output bin 5 Power switch 6 Control panel 7 Front cover 8 Tray 1 9 Tray 2 Rear view 10 Ground Fault Interrupt switch 11 Finisher power connection 12 Hand grips 13 Controller board with host network interface ports 14 Power cord receptacle 15 Connectors for optional 2 500 Sheet Feeder Finisher and Duplex Module 4525 01 4 5 6 7 9 8 1 2 3 4525...

Page 26: ...le 3 Envelope Feeder 4 High Capacity Feeder with Trays 3 4 and 5 Fig 1 4 Console Configuration with Options 1 Transport cover 2 Paper transport 3 Finisher access door 4 Finisher output bin 5 Punch bin Fig 1 5 Optional Finisher Components Stapler Hole Puncher 4525 03 1 4 2 3 1 4 2 3 4525 49 5 ...

Page 27: ...rint reports such as the configuration report which lists the printer s current settings As shown in the following figure the printer s control panel has either icons and text or icons only 1 Four indicator lights 2 A two line display screen 16 characters per line 3 Eight control panel keys Fig 1 6 Control Panel with Icons and Text Fig 1 7 Control Panel with Icons 4525 111 eng 1 2 3 4525 112 symb ...

Page 28: ...roubleshooting Manual Displays information about the status of the printer or the job in process Examples The printer is online and ready to accept print jobs The printer is processing data The printer is waiting for more data The printer is low on a supply in this case the toner is low and needs to be replaced soon A tray is empty in this case Tray 2 is empty and no longer being used to print The...

Page 29: ... rear panel of the printer features the host interface connectors Bi directional parallel high density connector Twisted Pair 10base2 Ethernet connector Standard USB Port Fig 1 8 Rear Panel S4525 006 Ethernet Port Serial Port USB Port Parallel Port LED Windows Network Card ...

Page 30: ...rrupter S4525 002 Low Voltage Power Supply Boards Low Voltage Power Supply Fan High Voltage Power Supply HVPS R2 High Voltage Power Supply HVPS Board Noise Filter AC Plug Connector Transformer 220V Printer Only Option Connectors Input Output I O Board Laser Scanner AC Driver Board System Controller Board Print Engine Controller Board Main Switch ...

Page 31: ...l Information 1 9 Fig 1 10 Print Engine Assemblies continued Host Computer Parallel Interface Cable Fuser Offset Exit Assembly Laser Print EP Cartridge Print Engine Controller Board System Controller Board Network Cable S4525 003 ...

Page 32: ...rvice Guide Fig 1 11 Print Engine Assemblies continued Front Cover Interlock Lift Motor Tray 1 Offset Motor Lift Motor Tray 2 Main Drive Assembly Face Up Exit Sensor Full Stack Sensor S4525 004 Tray 1 Size Sensor Lazer Print EP Cartridge Interlock ...

Page 33: ...s continued Tray 2 Level Sensor S4525 005 Tray 2 No Paper Sensor Tray 2 LH Interlock Tray 3 Take Away Sensor Options Connector Panel Tray 2 Size Sensor Tray 1 Level Sensor Tray 1 No Paper Sensor Registration Sensor Multi sheet Bypass Feeder No Paper Sensor Tray 2 Take Away Sensor ...

Page 34: ... Exit Sensor Registration Sensor Take Away 2 Sensor Retard Roller Retard Roller Retard Pad Pick Roller Pick Roller Feed Roller Feed Roller Feed Roller Pick Roller Pinch Roller Take Away Roller Tray 2 Pinch Roller Registration Roller Heat Roller Pressure Roller Exit Roller Offset Roller Bias Transfer Roller Laser Print EP Cartridge Drum Tray 1 Feed Tray 2 Feed Output Tray Fuser Offset Unit BTR ...

Page 35: ...y cross references to ease navigation between related topics You will find many referrals to page numbers in the six different books The page numbers and cross references will normally appear in numeric form 1 XXX where the 1 indicates Book I Volume 1 Print Engine and the XXX is the page RAP or RRP number being referenced 2 XXX where the 2 indicates Book II Volume 2 High Capacity Feeder and the XX...

Page 36: ...dded beyond this limit is ignored Additional memory provides the following enhanced printer capabilities Additional font cache Additional download space for fonts macros and images Increased throughput for complex pages duplex pages and larger paper sizes A3 Ledger Increased PostScript VM volatile memory Collated sets without the Hard Disk Drive You can essentially increase the resident fonts of t...

Page 37: ...Lbs 1 65 0 Kg 143 3 Lbs packaged for shipment Weight 220 V model 53 0 Kg 116 85 Lbs 1 69 5 Kg 153 22 Lbs packaged for shipment Table 1 3 Printer Clearances Clearances Specification Front 460 mm 18 1 inches Back 200 mm 7 9 inches for ventilation Right 200 mm 7 9 inches without Finisher 1000 mm 39 4 inches with Finisher Left 364 mm 14 3 inches without Duplex Unit installed 640 mm 25 2 inches with Du...

Page 38: ...idity no condensation 0 8200 feet above sea level No direct sunlight less than 3 000 LUX Table 1 6 Regulatory Specifications Category Specification General safety standards observed The packaged product meets ASTM D4169 86 and 110 V printer UL 1950 2nd edition 220 V printer IEC 950 2nd edition with amendment 1 1995 CE directive Laser safety standards observed 110 V printer FDA 21 CFR Chapter 1 Sub...

Page 39: ...1 minute Maximum noise generated excluding impulse noise Standby 58 0 db Printing 70 0 db Laser Print EP Cartridge life expectancy 30 000 prints assuming 5 image coverage and 4 mm white borders Key component life expectancy Engine Paper Feeder Fuser Unit Bias Transfer Roller Feed Rollers 3 1 5 million simplex sheets 8 5 x 11 in A4 1 5 million simplex sheets 300 000 prints 300 000 prints 300 000 pr...

Page 40: ...peeds Continuous Printing After the First Sheet Out Paper Size Mode Trays 1 2 pages per minute HCF 3 pages per minute HCF 4 5 pages per minute MBF pages per minute A4 LEF Simplex 45 ppm 44 ppm 43 41 ppm 36 ppm A4 LEF Duplex 38 37 ppm 36 ppm 39 ppm LETTER LEF Simplex 45 ppm 44 ppm 43 41 ppm 36 ppm LETTER LEF Duplex 38 37 ppm 36 ppm 39 ppm B4 SEF Simplex 28 27 ppm 27ppm 25 ppm B4 SEF Duplex 17 ppm 1...

Page 41: ...l 13 SEF 215 9 mm x 330 2 mm 8 5 x 13 in Legal 13 SEF 215 9 mm x 330 2 mm 8 5 x 13 in A4 SEF LEF 210 mm x 297 mm 8 27 x 11 71 in A4 SEF LEF 210 mm x 297 mm 8 27 x 11 71 in Executive LEF 184 2 mm x 266 7 mm 7 26 x 10 51 in B5 LEF 182 mm x 257 mm 7 17 x 10 13 A5 LEF 149 mm x 210 mm 5 87 x 8 27 in A5 LEF 149 mm x 210 mm 5 87 x 8 27 in STATEMENT 139 9 mm x 215 9 mm 5 51 x 8 5 in STATEMENT 139 9 mm x 2...

Page 42: ... 8 5 x 11 in Letter SEF LEF 215 9 mm x 279 4 mm 8 5 x 11 in Legal 13 SEF 215 9 mm x 330 2 mm 8 5 x 13 in Legal 13 SEF 215 9 mm x 330 2 mm 8 5 x 13 in A4 SEF LEF 210 mm x 297 mm 8 27 x 11 71 in A4 SEF LEF 210 mm x 297 mm 8 27 x 11 71 in Executive LEF 184 2 mm x 266 7 mm 7 26 x 10 51 in B5 LEF 182 mm x 257 mm 7 17 x 10 13 Table 1 13 High Capacity Feeder Tray 4 and Tray 5 Paper Sizes Factory set Opti...

Page 43: ...e printer provides duplex printing for 64 gsm 105 gsm paper fed from Trays 1 through 5 The minimum paper size recommended for Duplex feed is B5 LEF or Executive The maximum paper size recommended for Duplex feed is A3 SEF or 11 x 17 SEF Face Up Tray option The optional Face Up Tray attaches to the left side of the printer Paper is transported out of the printer face up onto the Face Up Tray The Tr...

Page 44: ...m x 297 mm Xerox 3R9600 EU Y Y Tray 3 only N Transparency A4 210 mm x 297 mm Xerox E001 Japan Y Y Tray 3 only N Labels Letter 8 5 x 11 Xerox 3R4469 US Y Tray 2 only Trays 3 4 only N Labels A4 210 mm x 297 mm Xerox 3R97406 EU Y Tray 2 only Trays 3 4 only N Labels A4 210 mm x 297 mm Xerox V860 Japan Y Tray 2 only Trays 3 4 only N Envelope 4 1 8 x 9 1 2 Monroe Brand COM 10 Y N N Y Envelope 3 7 8 x 7 ...

Page 45: ...able Weight Input Source 64 105 g m2 17 28 Lbs Trays 1 5 64 200 g m2 17 53 Lbs Trays 2 3 4 64 200 g m2 17 53 Lbs Multi sheet Bypass Feeder 64 105 g m2 17 28 Lbs Duplex Module 64 105 g m2 17 28 Lbs Finisher Table 1 18 Capacities of Input Sources Input Source Capacity Trays 1 2 500 tray Tray 3 part of the optional 2 500 Sheet Feeder 500 Trays 4 5 part of the optional 2 500 Sheet Feeder 1000 tray Cus...

Page 46: ...x 10 5 in Letter 1 8 5 x 11 in Folio 2 8 5 x 13 in Legal 2 8 5 x 14 in Ledger 2 11 x 17 in Envelopes COM 10 1 4 Monarch 1 4 DL 1 4 C5 1 4 4 1 x 9 5 in 3 8 x 7 5 in 110 x 220 mm 162 x 229 mm Transparencies A4 1 4 Letter 1 4 210 x 297 mm 8 5 x 11 in Labels A4 1 4 Letter 1 4 210 x 297 mm 8 5 x 11 in 5 5 Custom Sizes 3 1 Use long edge feed 2 Use short edge feed 3 Custom Sizes see the following page fo...

Page 47: ...st or wet paper Curled paper Paper with an electrostatic charge Glued paper Paper with special coating Paper unable to withstand a temperature of 150o C 302o F Thermal paper Carbon paper Universal transparencies Paper with paper fasteners ribbons staples tape etc attached Label stock with exposed backing sheet Table 1 20 Custom Paper Sizes Acceptable sizes Custom paper tray Multi sheet Bypass Feed...

Page 48: ...0 lbs 75 g m2 003R00054 Xerox Image Series Smooth Legal 8 5 x 14 in 20 lbs 75 g m2 003R00083 Rank Xerox Legal 215 x 356 mm 80 g m2 003R901741 LaserPrint 80 A4 Metric Letter 210 x 297 mm 80 g m2 003R91922 Xerox Recycled Letter U S 8 5 x 11 in 20 lbs 75 g m2 003R06296 Steinbeis Recycled A4 Metric Letter 210 x 297 mm 80 g m2 003R91165 80 DP Planet Plus A4 Metric Letter 210 x 297 mm 80 g m2 003R900652...

Page 49: ... and hole puncher Increased paper output capacity Holds up to 3 000 sheets of 80 g m2 20 lbs stock Letter A4 paper Stapling capability Hole punching capability 450S02180 3 hole positions 450S02181 4 hole positions Hard disk drive 5 Gbyte hard drive Store resources fonts forms and macros enables uninterrupted large job collation 097S02364 Memory upgrades Improved system performance Improved process...

Page 50: ...1 28 DocuPrint N4525 Network Laser Printer Service Guide Blank Page ...

Page 51: ...roubleshooting sections of Book II Volume 4 of this QRG For Finisher problems go to the Error Codes and Troubleshooting sections of Book II Volume 6 of this QRG Service Flowchart Note A Service Flowchart that outlines one possible approach to troubleshooting and repair of the printer has been provided The Service Flowchart is an overview of the path a service technician could take using this techn...

Page 52: ...wall outlet 3 Remove the Laser Print EP Cartridge and shield it from strong light 4 Inspect the printer interior and remove any foreign matter such as paper clips staples pieces of paper paper dust or toner 5 Clean the printer interior with a lint free cloth dampened slightly with cold water Do not use solvents or chemical cleaners to clean the printer interior Do not use any type of oil or lubric...

Page 53: ...ir Analysis Procedures are an approximation Actual readings may vary from the stated values 8 Primary Repair Analysis Procedures may direct you to a Secondary Repair Analysis Procedure How to Follow a Repair Analysis Procedure See the sample Repair Analysis Procedure step below 1 Each numbered step in a Repair Analysis Procedure instructs you to perform a certain action or procedure 2 The Actions ...

Page 54: ...he printer is switched ON the Xerographic Cartridge and the paper trays are in place and all of the interlock switches are actuated 7 All voltage values given in the Repair Analysis Procedures are approximate values Actual measured voltages may vary more than 25 from the values stated in the Repair Analysis Procedures The main purpose of most voltage readings taken in the Repair Analysis Procedure...

Page 55: ...s Before replacing the System Controller please refer to the System Controller Error Code Table on page 1 44 to check the LED blink codes for additional help in troubleshooting Using Printer Diagnostics Repair Analysis Procedures often ask you to enter Diagnostics and perform a specific output test or input test Diagnostics are built into the Print Engine Controller Board Use the Control Panel to ...

Page 56: ...ual 13 Are consumables replaced at the intervals recommended in the General Information section 14 Are all of the printer assemblies in place and are all printer covers and doors firmly closed Note Repair Analysis Procedures assume there is no malfunction in the System Controller Board If you are unable to fix a problem using the Repair Analysis Procedures it is recommended that you refer to the S...

Page 57: ...Away Sensor did not actuate within the specified time after the Tray 3 Feed Clutch was actuated RAP 2 1 2 373 Paper Jam Clear Area A B C3 3 There is a paper jam between Tray 3 and the Registration Sensor Logic Control on the Print Engine Controller Board sensed that when paper was fed from Tray 3 the Registration Sensor did not actuate within the specified time after the Tray 2 Take Away Sensor ac...

Page 58: ...r was fed from Tray 5 the Tray 2 Take Away Sensor signal did not actuate within the specified time after the Tray 3 Take Away Sensor was actuated RAP 2 8 2 387 Paper Jam Clear Area A B C5 3 There is a paper jam between paper Tray 5 and the Registration Sensor Logic Control on the Print Engine Controller Board sensed that when paper was fed from Tray 5 the Registration Sensor did not actuate within...

Page 59: ... Feeder Tray 2 Take Away Sensor did not actuate within the specified time after the MBF Feed Clutch was acuated RAP 1 34 RAP 4 3 1 87 4 566 Paper Jam Reset ENV Bypass C9 3 There is a paper jam between the Multi sheet Bypass Feeder MBF and the Registration Sensor Logic Control on the Print Engine Controller Board sensed that when paper was fed from the Multi sheet Bypass Feeder the Registration Sen...

Page 60: ...tuating RAP 1 25 1 76 Paper Jam Clear Duplx Unit E4 5 There is a problem near the Fuser Exit Sensor The inverted page to be stationed in the Duplex Module did not reach the Face Up Exit Sensor within the specified time RAP 1 26 1 77 Paper Jam Clear Area A E4 6 There a paper jam at the Face Up Exit Sensor Logic Control on the Print Engine Controller Board sensed the Face Up Exit Sensor was on while...

Page 61: ... Transport Exit Sensor within specified time SE 32 RAP 6 5 6 663 Paper Jam Clear Area F F4 26 Remaining paper detected by the Finisher Transport Exit Sensor SE 32 Paper was detected by the Finisher Transport Exit Sensor when the Finisher was initialized SE 32 RAP 6 6 6 665 Paper Jam Clear Area F F4 31 Paper does not leave the Finisher Input Path Sensor after the paper has reached the Finisher Inpu...

Page 62: ...er Unit Interlock is Open SW 26 RAP 6 21 6 692 Slide In Finisher F8 1 Finisher Interlock Switch is sensed to be open SW 24 RAP 6 22 6 694 Insert Tray 1 H1 1 There is a Lift Up problem with Tray 1 Logic Control on the Print Engine Controller Board sensed that Tray 1 was not raising into position in Feeder 1 RAP 1 36 1 91 Insert Tray 2 H1 2 There is a Lift Up problem with Tray 2 Logic Control on the...

Page 63: ...99 Finisher Failure Power Off On H5 81 Failure of Exit Roller Open Close SE 5 RAP 6 26 6 700 Finisher Failure Power Off On H5 83 Failure of Roller Shift SE 6 RAP 6 27 6 702 Finisher Failure Power Off On H5 91 Failure of Stapler SE 16 RAP 6 28 6 704 Finisher Failure Power Off On H5 92 Failure of Stapler Head Home Sensor SE 16 RAP 6 29 6 705 Finisher Failure Power Off On H5 93 Failure of Stapler Fro...

Page 64: ...r Print EP Cartridge Memory data RAP 1 46 1 101 CRUM Failure Replace CRU J8 5 A Laser Print EP Cartridge memory communication error occurred Logic Control on the Print Engine Controller Board sensed a wrong or a counterfeit Laser Print EP Cartridge RAP 1 47 1 102 Motor Failure Power Off On U1 1 There is a problem with the Main Motor Logic Control on the Print Engine Controller Board detected a pro...

Page 65: ...oblem with the Fuser Logic Control on the Print Engine Controller Board sensed that the Fuser thermostat opened RAP 1 11 1 57 Fuser Failure Power Off On U4 5 There is a problem with the Fuser Logic Control on the Print Engine Controller Board detected a fuser temperature above the upper limit RAP 1 12 1 58 Fan Failure Power Off On U4 9 There is a problem with the Fuser Fan Logic Control on the Pri...

Page 66: ...ble Control Panel Message LED Blinks Followed by 1 sec Off Comment 0001 ESS 1 System Controller Board major failure Replace System Controller Board Go to RRP 1 73 0001 BASE RAM 2 System Controller Board RAM failure Replace System Controller Board Go to RRP 1 73 0001 BASE ROM 3 System Controller Board boot ROM Replace System Controller Board Go to RRP 1 73 0001 ASIC 4 System Controller Board ASIC f...

Page 67: ...3 2010 XIE PWPM 15 System Controller Xerox Image Enhanced PWPM failure Replace System Controller Board Go to RRP 1 73 2020 XIE VDMA 15 System Controller Xerox Image Enhanced VDMA failure Replace System Controller Board Go to RRP 1 73 3000 Token Ring 3000 Serial 3000 E Net 10 Base 2 16 Replace the appropriate network card Replace System Controller Board Go to RRP 1 73 5000 Memory None Memory size n...

Page 68: ...tridge with a new one Go to step 3 3 SUBSYSTEM ISOLATION 1 Open the Left Cover A 2 Touching only the drive gear at the end of the Roller hand rotate the Bias Transfer Roller Can you easily rotate the Bias Transfer Roller Go to step 4 Replace the Left Upper Cover A Assembly RRP 1 42 4 SUBSYSTEM ISOLATION 1 Remove the Fuser Assembly 2 Hand rotate counter clockwise the Main Motor Can you easily rotat...

Page 69: ...start Main Motor Output Test Go to step 9 Replace the Main Drive Assembly RRP 1 66 9 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Does the error code appear Go to step 10 Problem solved 10 The following printer components and areas are associated with this specific problem One or more of these components or areas may have failed partially or complete...

Page 70: ... Supply Fan Table 1 30 Error Code U1 3 LVPSFan Failure Step Actions and Questions Yes No 1 LOW VOLTAGE POWER SUPPLY FAN TEST 1 Enter Diagnostics Mode 2 From the Main Menu select Comp Output Test LVPS Fan High to check the Low Voltage Power Supply Fan function 3 Press 4 to start 0 to stop Does Fan rotate when you start theLVPS Fan Output Test Replace the Print Engine Controller Board RRP 1 72 Repla...

Page 71: ...in Menu select Comp Output Test IOT Unit Drum Motor On to check the Drum Motor function 3 Press 4 to start 0 to stop Does Drum Motor rotate when you start Output Test Replace the Print Engine Controller Board RRP 1 72 Go to step 2 2 DRUM MOTOR TEST 1 Remove the Laser Print EP Cartridge from the printer 2 From the Main Menu select Comp Output Test IOT Unit Drum Motor On to check the Drum Motor func...

Page 72: ...onnectors and wiring linking these components 2 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Does the error code appear Go to step 3 Problem solved 3 LASER SCANNER REPLACEMENT Replace the Laser Scanner Assembly RRP 1 47 Does the error code appear Go to step 4 Problem solved 4 The following printer components and areas are associated with this specifi...

Page 73: ...voltage between J400 pins 1 2 3 on the Print Engine Controller Board and frame ground Is there 5VDC between J400 pins 1 2 3 and frame ground Go to step 3 Replace the Low Voltage Power Supply Assembly RRP 1 67 3 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Does the error code appear Go to step 4 Problem solved 4 LASER SCANNER REPLACEMENT Replace the L...

Page 74: ...ure the voltage between J400 pins 1 2 3 on the Print Engine Controller Board and frame ground Is there 5VDC between J400 pins 1 2 3 and frame ground Go to step 3 Replace the Low Voltage Power Supply Assembly RRP 1 67 3 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Does the error code appear Go to step 4 Problem solved 4 LASER SCANNER REPLACEMENT Repla...

Page 75: ...Laser Scanner Motor function 3 Press 4 to start 0 to stop Does the Laser Scanner Motor run when you start the test Go to step 4 Go to step 3 3 LOW VOLTAGE POWER SUPPLY 24VDC CHECK Measure the voltage between J400 8 on the Print Engine Controller Board and frame ground Is there 24VDC between J400 8 and frame ground Replace the Laser Scanner Assembly RRP 1 47 Replace the Low Voltage Power Supply Ass...

Page 76: ...1 1 common to P J32 1 and P J33 1 on the AC Driver board Is there line voltage 110 220 VAC between P J32 1 or P J33 1 and P J31 1 common Go to step 3 Replace the AC Driver board RRP 1 69 3 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Does the error code appear Go to step 4 Problem solved 4 FUSER REPLACEMENT Replace the Fuser Assembly Does the error c...

Page 77: ...RD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Does the error code appear Go to step 3 Problem solved 3 AC DRIVER BOARD REPLACEMENT Replace the AC Driver board RRP 1 68 Does the error code appear Go to step 4 Problem solved 4 The following printer components and areas are associated with this specific problem One or more of these components or areas may have failed partially or ...

Page 78: ...2 Problem solved 2 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Does the error code appear Go to step 3 Problem solved 3 The following printer components and areas are associated with this specific problem One or more of these components or areas may have failed partially or completely If you cannot isolate this problem using the steps in this Repair...

Page 79: ...oblem solved 2 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Does the error code appear Go to step 3 Problem solved 3 The following printer components and areas are associated with this specific problem One or more of these components or areas may have failed partially or completely If you cannot isolate this problem using the steps in this Repair Ana...

Page 80: ... step 2 Problem solved 2 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Does the error code appear Go to step 3 Problem solved 3 The following printer components and areas are associated with this specific problem One or more of these components or areas may have failed partially or completely If you cannot isolate this problem using the steps in this ...

Page 81: ...OW VOLTAGE POWER SUPPLY 24VDC CHECK Measure the voltage between P J204 1 and P J204 4 on the Fuser Fan Is there 24VDC between P J204 1 and P J204 4 on the fuser fan connector Replace the Fuser Fan PL 8 1 Go to step 3 3 LOW VOLTAGE POWER SUPPLY REPLACEMENT Replace the Low Voltage Power Supply Assembly RRP 1 67 Does the error code appear Go to step 4 Problem solved 4 The following printer components...

Page 82: ...2 3 on the Print Engine Controller Board and frame ground Is there 5VDC between J400 pins 1 2 3 and frame ground Go to step 3 Replace the Low Voltage Power Supply Assembly RRP 1 67 3 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Does the error code appear Go to step 4 Problem solved 4 SYSTEM CONTROLLER BOARD REPLACEMENT Replace the System Controller B...

Page 83: ...2 3 on the Print Engine Controller Board and frame ground Is there 5VDC between J400 pins 1 2 3 and frame ground Go to step 3 Replace the Low Voltage Power Supply Assembly RRP 1 67 3 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Does the error code appear Go to step 4 Problem solved 4 SYSTEM CONTROLLER BOARD REPLACEMENT Replace the System Controller B...

Page 84: ...between J400 pins 1 2 3 on the Print Engine Controller Board and frame ground Is there 5VDC between J400 pins 1 2 3 and frame ground Go to step 3 Replace the Low Voltage Power Supply Assembly RRP 1 67 3 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Does the error code appear Go to step 4 Problem solved 4 SYSTEM CONTROLLER BOARD REPLACEMENT Replace the...

Page 85: ...int Engine Controller Board and frame ground Is there 5VDC between J400 pins 1 2 3 and frame ground Go to step 3 Replace the Low Voltage Power Supply Assembly RRP 1 67 3 INPUT OUTPUT BOARD REPLACEMENT Replace the Input Output Board RRP 1 70 Does the error code appear Go to step 4 Problem solved 4 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Does the ...

Page 86: ...N Inspect the cassette paper guides Are the guides set to the size of paper loaded in the cassette Go to step 4 Adjust the guides 4 PAPER TRAVEL INSPECTION Open the Left Upper Cover and observe the position of the jammed paper Is the sheet of paper skewed Replace the Feed Pick and Retard Rolls RRP 1 11 Go to step 5 5 REGISTRATION SENSOR TEST 1 Enter Diagnostics Mode 2 From the Main Menu select Com...

Page 87: ...ed partially or completely If you cannot isolate this problem using the steps in this Repair Analysis Procedure replace each component or troubleshoot each area listed below one at a time until you isolate and solve the problem Wiring and connectors linking the components Input Output Board RRP 1 70 Table 1 46 Error Code E1 1 Paper Jam Clear Area A cont d Step Actions and Questions Yes No ...

Page 88: ...top at the Registration Rolls Go to step 4 Go to step 5 4 REGISTRATION CLUTCH TEST 1 Enter Diagnostics Mode 2 From the Main Menu select Comp Output Test IOT Unit Reg Clutch On to check the Registration Clutch function 3 Press 4 to start the Registration Clutch will actuate for 2 seconds and release Does the Registration Roller clutch Actuate when you start the test Clean the Registration Rollers o...

Page 89: ...tate smoothly and are the Fuser Stripper Fingers undamaged Go to step 11 Replace the Fuser Assembly 11 PAPER TRAVEL INSPECTION Remove the Fuser Cover RRP 1 1 and observe the position of the jammed paper Did the sheet of paper stop in the Offset Unit Go to step 12 Go to step 13 12 OFFSET UNIT INSPECTION Check the Offset Unit for lodged scraps of paper or damage Is the Offset Unit clean and undamage...

Page 90: ... failed partially or completely If you cannot isolate this problem using the steps in this Repair Analysis Procedure replace each component or troubleshoot each area listed below one at a time until you isolate and solve the problem Wiring and connectors linking the components Input Output Board RRP 1 70 Table 1 47 Error Code E1 2 Paper Jam Clear Area A cont d Step Actions and Questions Yes No ...

Page 91: ...ease 4 Hand rotate counter clockwise the Main Motor Do the Offset Rollers rotate Go to step 3 Replace the Offset Unit Assembly RRP 1 54 3 FACE UP EXIT SENSOR TEST 1 Enter Diagnostics Mode 2 From the Main Menu select Comp Input Test IOT Unit FaceUp Exit Sen 3 Press 4 to start 0 to stop 4 Insert then remove a sheet of paper into the Face Up Exit Sensor actuator Does the Control Panel display with pa...

Page 92: ...failed partially or completely If you cannot isolate this problem using the steps in this Repair Analysis Procedure replace each component or troubleshoot each area listed below one at a time until you isolate and solve the problem Wiring and connectors linking the components Input Output Board RRP 1 70 Table 1 48 Error Code E1 3 Paper Jam Clear Area A cont d Step Actions and Questions Yes No ...

Page 93: ...Insert then remove a sheet of paper into the Registration Sensor Does the Control Panel display with paper when you insert the paper into the Registration Sensor and is without paper displayed when you remove the paper Go to step 3 Replace the Registration Sensor then repeat this step 3 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Does the error code...

Page 94: ...is without paper displayed when you remove the it Go to step 3 Replace the Fuser Exit Sensor PL 9 1 3 PAPER TRAVEL INSPECTION Observe the position of the sheet of paper Is the trail edge of the paper still in the Fuser Go to step 4 Go to step 5 4 FUSER INSPECTION 1 Remove the three screws securing the Fuser Left Cover and remove the Cover so you can observe the Fuser Rollers 2 Hand rotate counter ...

Page 95: ...ailed partially or completely If you cannot isolate this problem using the steps in this Repair Analysis Procedure replace each component or troubleshoot each area listed below one at a time until you isolate and solve the problem Wiring and connectors linking the components Input Output Board RRP 1 70 Table 1 50 Error Code E3 1 Paper Jam Clear Area A Step Actions and Questions Yes No ...

Page 96: ...IOT Unit Fuser Exit Sen 4 Press 4 to start 0 to stop 5 Insert then remove a sheet of paper into the Fuser Exit Sensor Does the Control Panel display with paper when you insert the paper into the Fuser Exit Sensor and is without paper displayed when you remove the paper Go to step 3 Replace the Fuser Exit Sensor PL 9 1 3 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller ...

Page 97: ... Control Panel display with paper when you insert the paper into the Face Up Exit Sensor and is without paper displayed when you remove the paper Replace the Print Engine Controller Board RRP 1 72 Replace the Face Up Exit Sensor RRP 1 63 3 FACE UP CLUTCH TEST 1 Enter Diagnostics Mode 2 From the Main Menu select Comp Output Test Duplex Unit Invert Clut CCW 3 Press 4 to start clutch will actuate for...

Page 98: ...er Replace the Print Engine Controller Board RRP 1 72 Replace the Face Up Exit Sensor RRP 1 63 3 FACE UP CLUTCH TEST 1 Enter Diagnostics Mode 2 From the Main Menu select Comp Output Duplex Unit Invert Clut CCW 3 Press 4 to start clutch will actuate for two seconds then release 4 Hand rotate counter clockwise the Main Motor Do the Offset Rollers rotate Go to step 4 Replace the Offset Unit Assembly ...

Page 99: ... TEST 1 Enter Diagnostics Mode 2 From the Main Menu select Comp Output Test Duplex Unit Invert Clut CCW to check the Invert Clutch counter clockwise 3 Hand rotate counter clockwise the Main Motor Do the Offset Rollers rotate Go to step 4 Replace the Offset Unit Assembly RRP 1 54 4 OFFSET CATCH Tray REVERSE CLUTCH TEST 1 Enter Diagnostics Mode 2 From the Main Menu select Comp Output Test Duplex Uni...

Page 100: ...1 Enter Diagnostics Mode 2 From the Main Menu select Comp Input Test IOT Unit FaceUp Exit Sen 3 Press 4 to start 0 to stop 4 Insert then remove a sheet of paper into the Face Up Exit Sensor Does the Control Panel display with paper when you insert the paper into the Face Up Exit Sensor and is without paper displayed when you remove the paper Go to step 4 Replace the Face Up Exit Sensor RRP 1 58 4 ...

Page 101: ...ng Is the Left Cover Interlock Actuator pressing against the Interlock Switch Spring Go to step 4 Replace the Left Upper Cover RRP 1 42 4 LEFT DOOR INTERLOCK SWITCH TEST 1 Enter Diagnostics Mode 2 From the Main Menu select Comp Input Test IOT Unit L H Cover A 3 Press 4 to start 0 to stop 4 Actuate and deactuate the Left Door Interlock Switch Does the display indicate Open Closed when you actuate a...

Page 102: ...closed Is the Interlock Actuator damaged Replace the Left Lower Cover Go to step 4 4 LEFT LOWER COVER INTERLOCK SWITCH TEST 1 Enter Diagnostics Mode 2 From the Main Menu select Comp Input Test Tray 1 Cover B 3 Actuate and deactuate the Left Lower Cover B Interlock Switch Does the display indicate Open Closed when you actuate and deactuate the Lower Left Cover Interlock Switch Replace the Left Lowe...

Page 103: ...otor function 3 Press 4 to start the Tray 1 Lift Motor should actuate for two seconds then stop Does the Motor switch on when you start the Output Test Go to step 4 Replace Tray 1 Lift Motor RRP 1 9 4 Tray 1 FEED CLUTCH TEST 1 Enter Diagnostics Mode 2 From the Main Menu select Comp Output Test IOT Unit Tray 1 Feed Clut to check the Tray 1 Feed Clutch function 3 Press 4 to start the clutch should a...

Page 104: ...e failed partially or completely If you cannot isolate this problem using the steps in this Repair Analysis Procedure replace each component or troubleshoot each area listed below one at a time until you isolate and solve the problem Wiring and connectors linking the components Input Output Board RRP 1 70 Table 1 58 Error Code C1 3 Clear Area A Reset Tray 1 Step Actions and Questions Yes No ...

Page 105: ...it Tray 2 Lift Mot 3 Press 4 to start Tray 2 Lift Motor should actuate for two seconds then stop Does the Lift Motor lift the Bin Go to step 4 Check wiring between P J467 to P J241 If OK replace Tray 2 Lift Motor PL 3 4 4 Tray 2 FEED CLUTCH OPERATION 1 Enter Diagnostics Mode 2 From the Main Menu select Comp Output Test IOT Unit Tray 2 Feed Clut to test the Tray 2 Feed Clutch 3 Press 4 to start the...

Page 106: ...P J467 and P J101 If OK replace the Tray 2 Take Away Sensor 8 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Go to step 9 Problem solved 9 The following printer components and areas are associated with this specific problem One or more of these components or areas may have failed partially or completely If you cannot isolate this problem using the step...

Page 107: ...ay 2 and observe the Take Away Roller Does the Take Away Roller rotate when you run the Main Motor Go to step 4 Replace Tray 2 Feeder RRP 1 22 4 REGISTRATION SENSOR TEST 1 Enter Diagnostics Mode 2 From the Main Menu select Comp Input Test IOT Unit Reg Sensor 3 Press 4 to start 0 to stop 4 Insert then remove a sheet of paper into the Registration Sensor Does the Control Panel display with paper whe...

Page 108: ...ke Away Roller 2 Sensor 3 Press 4 to start 0 to stop 4 Open the Left Upper Cover A 5 Insert then remove a sheet of paper into the Tray 2 Take Away Sensor Does the Control Panel display with paper when you insert the paper into the Tray 2 Take Away Sensor and is without paper displayed when you remove the paper Go to step 3 Replace the Tray 2 Take Away Sensor 3 PRINT ENGINE CONTROLLER BOARD REPLACE...

Page 109: ...EEDER FEED ROLLER INSPECTION 1 Run a Test Print feeding from the Multi sheet Bypass Feeder 2 Observe the paper in the Multi sheet Bypass Feeder Bin Is the paper partially fed out of the Multi sheet Bypass Feeder Bin Replace the Multi sheet Bypass Feeder Feed Roller RRP 1 30 Pick Roller RRP 1 31 and Multi sheet Bypass Feeder Pad RRP 1 33 Go to step 4 4 MULTI SHEET BYPASS FEEDER DRIVE TEST Remove th...

Page 110: ...ay Sensor Does the Control Panel display with paper when you insert the paper into the Tray 2 Take Away Sensor and is without paper displayed when you remove the paper Go to step 7 Replace the Tray 2 Take Away Sensor 7 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Does the error code appear Go to step 8 Problem solved 8 The following printer component...

Page 111: ...ASS FEEDER FEED ROLLER INSPECTION 1 Run a Test Print feeding from the Multi sheet Bypass Feeder 2 Observe the paper in the Multi sheet Bypass Feeder Bin Is the paper partially fed out of the Multi sheet Bypass Feeder Bin Replace the Multi sheet Bypass Feeder Feed Roller RRP 1 30 Pick Roller RRP 1 31 and Multi sheet Bypass Feeder Pad RRP 1 33 Go to step 4 4 MULTI SHEET BYPASS FEEDER DRIVE TEST 1 Re...

Page 112: ...ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Does the error code appear Go to step 8 Problem solved 8 The following printer components and areas are associated with this specific problem One or more of these components or areas may have failed partially or completely If you cannot isolate this problem using the steps in this Repair Analysis Procedure repla...

Page 113: ...s you slide the Tray out of the Feeder Go to step 2 Replace Tray 1 with a new one 3 Tray 1 LEVEL SENSOR TEST 1 Enter Diagnostics Mode 2 From the Main Menu select Comp Input Test IOT Unit Tray 1 Level to check the Tray 1 Level Sensor 3 Press 4 to start 0 to stop 4 Repeatedly open and close Tray 1 Does the Control Panel display Up when you open the Bin and Down when you close the Bin Go to step 4 Re...

Page 114: ...e drop as you slide the Tray out of the Feeder Go to step 2 Replace Tray 2 with a new one 3 Tray 2 LEVEL SENSOR TEST 1 Enter Diagnostics Mode 2 From the Main Menu select Comp Input Test IOT Unit Tray 2 Level to check the Tray 2 Level Sensor 3 Press 4 to start 0 to stop 4 Repeatedly open and close Tray 2 Does the Control Panel display Up when you open the Bin and Down when you close the Bin Go to s...

Page 115: ...o step 2 Replace the Low Voltage Power Supply Assembly RRP 1 67 2 DUPLEX BOARD REPLACEMENT Replace the Duplex Module Board RRP 3 5 Does the error code appear Go to step 3 Problem solved 3 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Does the error code appear Go to step 4 Problem solved 4 The following printer components and areas are associated with...

Page 116: ...t in the Bin Go to step 4 Replace the Tray 1 Paper Size Sensor 4 REGISTRATION SENSOR TEST 1 Enter Diagnostics Mode 2 From the Main Menu select Comp Input Test IOT Unit Reg Sensor 3 Press 4 to start 0 to stop 4 Insert then remove a sheet of paper into the Registration Sensor Does the Control Panel display with paper when you insert the paper into the Registration Sensor and is without paper display...

Page 117: ... the Bin Go to step 4 Replace the Tray 2 Paper Size Sensor 4 REGISTRATION SENSOR TEST 1 Enter Diagnostics Mode 2 From the Main Menu select Comp Input Test IOT Unit Reg Sensor 3 Press 4 to start 0 to stop 4 Insert then remove a sheet of paper into the Registration Sensor Does the Control Panel display with paper when you insert the paper into the Registration Sensor and is without paper displayed w...

Page 118: ...4 Open the Upper Left Cover A and the Front Cover 5 Alternately remove and install a new Laser Print EP Cartridge Does the Control Panel display not empty when you insert the cartridge into the Printer and empty when you remove the cartridge from the printer Go to step 3 Replace the Toner Sensor RRP 1 50 3 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72...

Page 119: ...3 Open the Upper Left Door A and the Front Door 4 Press 4 to start then 0 to stop 5 Alternately remove then reinstall the Laser Print EP Cartridge Does the Control Panel display installed when you install the Laser Print Cartridge and not installed when you remove it Go to step 3 Replace the Laser Print EP Cartridge Interlock Switch RRP 1 51 3 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the ...

Page 120: ...EP Cartridge with a new one Does the error code still appear Go to step 2 Problem solved 2 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Does the error code appear Go to step 3 Problem solved 3 The following printer components and areas are associated with this specific problem One or more of these components or areas may have failed partially or comp...

Page 121: ... with a different one Does the error code still appear Go to step 2 Problem solved 2 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Does the error code appear Go to step 3 Problem solved 3 The following printer components and areas are associated with this specific problem One or more of these components or areas may have failed partially or completely...

Page 122: ...er Supply Assembly RRP 1 67 2 LASER PRINT EP CARTRIDGE REPLACEMENT Replace the Laser Print EP Cartridge with a different one Does the error code still appear Go to step 3 Problem solved 3 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Does the error code appear Go to step 4 Problem solved 4 The following printer components and areas are associated with...

Page 123: ...e Power Supply Assembly RRP 1 67 2 LASER PRINT EP CARTRIDGE REPLACEMENT Replace the Laser Print EP Cartridge with a different one Does the error code still appear Go to step 3 Problem solved 3 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Does the error code appear Go to step 4 Problem solved 4 The following printer components and areas are associated...

Page 124: ...t one Does the error code still appear Go to step 2 Problem solved 2 PRINT ENGINE CONTROLLER BOARD REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Does the error code appear Go to step 3 Problem solved 3 The following printer components and areas are associated with this specific problem One or more of these components or areas may have failed partially or completely If you cannot i...

Page 125: ...page 1 113 Electrical Interference Problems Refer to the Electrical Interference Problems Repair Analysis Procedure RAP Table on page 1 147 Printer Performance Problems Repair Analysis Procedure RAP Table Table 1 76 Print Performance Problems RAP Table Problem Go To RAP No Unit Page Inoperative Printer RAP 1 50 on page 1 105 Erratic Printer Operation RAP 1 51 on page 1 107 Blank Erratic or Inopera...

Page 126: ... 125 Spot Deletions RAP 1 67 on page 1 127 Spots RAP 1 68 on page 1 129 Residual Image Ghosting RAP 1 69 on page 1 131 Background RAP 1 70 on page 1 133 Toner On Back Of Print RAP 1 71 on page 1 135 Skewed Image RAP 1 72 on page 1 137 Damaged Prints RAP 1 73 on page 1 139 Unfused Image Or Image Easily Rubs Off Page RAP 1 74 on page 1 141 Repetitive Marks On Each Page RAP 1 75 on page 1 142 Lead Ed...

Page 127: ...emove the Rear Cover so you can access the Ground Fault Interrupter RRP 1 5 2 Measure the voltage between P J8 1 and P J8 3 on the Ground Fault Interrupter Is there approximately 110VAC or 220VAC if the printer is the 220VAC model between P J8 1 and P J8 3 Go to step 4 Replace the AC power cord 4 AC OUTPUT CHECK Measure the voltage between P J7 1 and P J7 2 on the Ground Fault Interrupter Is there...

Page 128: ...ve all options such as the Duplex Unit or the High Capacity Feeder from the base printer Do the Control Panel LEDs light up and does the printer go into warm up Replace the options one by one until the printer becomes inoperative again Troubleshoot or replace the problem option Go to step 11 11 The following printer components and areas are associated with this specific problem One or more of thes...

Page 129: ...age for 30 minutes or longer Does the voltage at the AC wall outlet meet printer specifications as listed in the General Information Section and does the voltage remain relatively stable without wide fluctuations Go to step 3 Have an electrician troubleshoot the AC line 3 NVRAM SETTINGS CHECK If applicable to your printer configuration check the NVRAM settings to make sure they are all set to the ...

Page 130: ...lectrical Interference and troubleshoot for a possible internal or external interference problem 2 After you finish with RAP 1 80 return to this step and monitor printer operation Does the printer display erratic operation Go to step 11 Problem solved 11 The following printer components and areas are associated with this specific problem One or more of these components or areas may have failed par...

Page 131: ...NT 1 Replace the System Controller Board RRP 1 73 Is the problem still present Replace the Print Engine Controller Board RRP 1 70 Problem solved 4 LOW VOLTAGE POWER SUPPLY 5VDC CHECK Measure the voltage between J400 pins 1 2 3 on the Print Engine Controller Board and frame ground Is there 5VDC between J400 pins 1 2 3 and frame ground Replace the Control Panel RRP 1 7 Go to step 5 5 LOW VOLTAGE POW...

Page 132: ...INE CONTROLLER Board REPLACEMENT Replace the Print Engine Controller Board RRP 1 72 Is the problem still present Go to step 3 Problem solved 3 Input Output Board REPLACEMENT Replace the Input Output Board RRP 1 70 Is the problem still present Go to step 4 Problem solved 4 SYSTEM CONTROLLER Board REPLACEMENT Replace the System Controller Board RRP 1 73 Is the problem still present Go to step 5 Prob...

Page 133: ...the Main Drive Motor CCW by hand press 4 to start the Invert Clutch CCW should actuate for two seconds then release 8 Observe the rotation of the exit gears they should rotate the opposite direction as observed in step 5 above Do the clutches function properly Go to step 3 Replace the defective clutch 3 OFFSET TEST 1 Remove the Fuser Cover RRP 1 1 2 Enter Diagnostics Mode 3 From the Main Menu sele...

Page 134: ... have failed partially or completely If you cannot isolate this problem using the steps in this Fault Isolation Procedure replace each component or troubleshoot each area listed below one at a time until you isolate and solve the problem Wiring and connectors linking the components Low Voltage Power Supply RRP 1 67 Table 1 83 Printer Does Not Offset Paper Step Actions and Questions Yes No ...

Page 135: ...ASER PRINT EP CARTRIDGE REPLACEMENT Install a new Laser Print EP Cartridge Is the image density normal Problem solved Go to step 3 3 IMAGE DEVELOPMENT INSPECTION 1 Remove the Rear Cover RRP 1 5 2 Generate a Grid Pattern Test Print and switch OFF printer power halfway through the print cycle 3 Open the Left Upper Cover 4 Open the Drum Shutter by pressing in the interlock plunger to the rear of the ...

Page 136: ... Cover 3 Examine the paper areas before the image enters the Fuser and after the image exits the Fuser Is the image normal before it enters the Fuser but light when it exits the Fuser Replace the Fuser Assembly Go to step 6 6 The following printer components and areas are associated with this specific problem One or more of these components or areas may have failed partially or completely If you c...

Page 137: ...ARTRIDGE REPLACEMENT Install a new Laser Print EP Cartridge Is there a normal image on the paper Problem solved Go to step 3 3 IMAGE DEVELOPMENT INSPECTION 1 Remove the Rear Cover RRP 1 5 2 Generate a Grid Test Print and switch OFF printer power halfway through the print cycle 3 Open the Left Upper Cover 4 Open the Drum Shutter 5 Hand rotate counter clockwise the Drum Drive Motor flywheel to advan...

Page 138: ...till blank Go to step 7 Problem solved 7 The following printer components and areas are associated with this specific problem One or more of these components or areas may have failed partially or completely If you cannot isolate this problem using the steps in this Fault Isolation Procedure replace each component or troubleshoot each area listed below one at a time until you isolate and solve the ...

Page 139: ...TRIDGE REPLACEMENT Install a new Laser Print EP Cartridge Is there a normal image on the paper Problem solved Go to step 3 3 IMAGE DEVELOPMENT INSPECTION 1 Remove the Rear Cover RRP 1 5 2 Generate a Grid Test Print and switch OFF printer power halfway through the print cycle 3 Open the Left Upper Cover 4 Open the Drum Shutter 5 Hand rotate counter clockwise the Drum Drive Motor flywheel to advance...

Page 140: ...rate a Grid Test Print Is the printed Test Pattern normal Problem solved Go to step 7 7 The following printer components and areas are associated with this specific problem One or more of these components or areas may have failed partially or completely If you cannot isolate this problem using the steps in this Fault Isolation Procedure replace each component or troubleshoot each area listed below...

Page 141: ...rtridge 2 Inspect the Laser Scanner Window for a scrap of paper or other contamination that may have lodged in front of it and could be blocking part of the laser beam from reach the Drum Is the Laser Scanner Window free of paper or other contamination Go to step 2 Remove the paper scrap or clean the Laser Scanner window 2 PAPER INSPECTION Inspect the paper that is loaded in the paper Bins Is the ...

Page 142: ...ough the Fuser 2 Open the Left Upper Door 3 Examine the paper areas before the image enters the Fuser and after the image exits the Fuser Is the image on the paper normal before it enters the Fuser but there are vertical band deletions visible when it exits the Fuser Replace the Fuser Assembly Go to step 6 6 The following printer components and areas are associated with this specific problem One o...

Page 143: ...T Install a new Laser Print EP Cartridge Are the horizontal band deletions gone Problem solved Go to step 3 3 IMAGE TRANSFER INSPECTION 1 Remove the Rear Cover RRP 1 5 2 Generate a Solid Black Test Print and switch OFF printer power halfway through the print cycle 3 Open the Left Upper Cover 4 Open the Drum Shutter 5 Hand rotate counter clockwise the Drum Drive Motor flywheel to advance the drum f...

Page 144: ...em One or more of these components or areas may have failed partially or completely If you cannot isolate this problem using the steps in this Fault Isolation Procedure replace each component or troubleshoot each area listed below one at a time until you isolate and solve the problem Laser Print EP Cartridge Connector and Contact Springs PL 7 2 Print Engine Controller Board RRP 1 72 Input Output B...

Page 145: ...th 2 LASER PRINT EP CARTRIDGE REPLACEMENT Install a new Laser Print EP Cartridge Are the vertical streaks gone Problem solved Go to step 3 3 IMAGE TRANSFER INSPECTION 1 Remove the Rear Cover RRP 1 5 2 Generate a Grid Test Print and switch OFF printer power halfway through the print cycle 3 Open the Left Upper Door 4 Open the Drum Shutter 5 Hand rotate counter clockwise the Drum Drive Motor flywhee...

Page 146: ...the Fuser Assembly 2 Run a half dozen Grid Test Prints Are the vertical streaks gone Problem solved Go to step 6 6 The following printer components and areas are associated with this specific problem One or more of these components or areas may have failed partially or completely If you cannot isolate this problem using the steps in this Fault Isolation Procedure replace each component or troubles...

Page 147: ... Remove the Rear Cover RRP 1 5 2 Generate a Blank Test Print and switch OFF printer power halfway through the print cycle 3 Open the Left Upper Cover 4 Open the Drum Shutter 5 Hand rotate counter clockwise the Drum Drive Motor flywheel to advance the Drum far enough so you can see the developed image area on the Drum before it reached Transfer Is the image on the drum completely white without any ...

Page 148: ...he horizontal streaks gone Problem solved Go to step 6 6 HIGH VOLTAGE POWER SUPPLY REPLACEMENT Replace the High Voltage Power Supply Assembly RRP 1 69 Are the horizontal streaks gone Problem solved Go to step 7 7 The following printer components and areas are associated with this specific problem One or more of these components or areas may have failed partially or completely If you cannot isolate...

Page 149: ... opened paper Go to step 2 2 LASER PRINT EP CARTRIDGE REPLACEMENT Install a new Laser Print EP Cartridge Are the spot deletions gone Problem solved Go to step 3 3 IMAGE TRANSFER INSPECTION 1 Remove the Rear Cover RRP 1 5 2 Generate a Black Test Print and switch OFF printer power halfway through the print cycle 3 Open the Left Upper Door 4 Open the Drum Shutter 5 Hand rotate counter clockwise the D...

Page 150: ...per Door 3 Examine the paper areas before the image enters the Fuser and after the image exits the Fuser Is the image on the paper normal before it enters the Fuser but there are spot deletions visible when it exits the Fuser Replace the Fuser Assembly Replace the paper with fresh dry paper and thoroughly clean the inside of the printer Table 1 91 Spot Deletions cont d Step Actions and Questions Y...

Page 151: ...inspect the interior of the printer for toner contamination 2 Vacuum or wipe all interior surfaces including Feed Rollers 3 Generate 30 Blank Test Prints to clean out the printer 4 Examine the last print out Are the spots gone Problem solved Go to step 3 3 IMAGE TRANSFER INSPECTION 1 Remove the Rear Cover RRP 1 5 2 Generate a Blank Test Print and switch OFF printer power halfway through the print ...

Page 152: ...ough the Fuser 2 Open the Left Upper Door 3 Examine the paper areas before the image enters the Fuser and after the image exits the Fuser Is paper clean before it enters the Fuser but there are spots on the paper when it exits the Fuser Replace the Fuser Assembly Clean or replace the Offset Exit Assembly RRP 1 54 Table 1 92 Spots cont d Step Actions and Questions Yes No ...

Page 153: ...o residual images still appear Go to step 3 Problem solved Avoid printing numerous copies of the same image 3 LASER PRINT EP CARTRIDGE REPLACEMENT Install a new Laser Print EP Cartridge Are the ghost images gone Problem solved Go to step 4 4 FUSER INSPECTION 1 Generate ten Grid Pattern Test Prints and switch OFF printer power when the last print is halfway through the Fuser 2 Carefully remove the ...

Page 154: ...nents or areas may have failed partially or completely If you cannot isolate this problem using the steps in this Fault Isolation Procedure replace each component or troubleshoot each area listed below one at a time until you isolate and solve the problem Print Engine Controller Board RRP 1 72 Table 1 93 Residual Image or Ghosting cont d Step Actions and Questions Yes No ...

Page 155: ... Problem solved Go to step 2 2 IMAGE DEVELOPMENT INSPECTION 1 Remove the Rear Cover RRP 1 5 2 Generate a Blank Test Print and switch OFF printer power halfway through the print cycle 3 Open the Left Upper Cover 4 Open the Drum Shutter 5 Hand rotate counter clockwise the Drum Drive Motor Flywheel to advance the Drum far enough so you can see the developed image area on the Drum before it reached Tr...

Page 156: ... printer power when the print is halfway through the Fuser 2 Open the Left Upper Door 3 Examine the paper before it enters the Fuser and after it exits the Fuser Is paper clean before it enters the Fuser but there is background on the paper when it exits the Fuser Replace the Fuser Assembly Go to step 5 5 The following printer components and areas are associated with this specific problem One or m...

Page 157: ...ray INSPECTION Inspect all of the paper Bins for loose toner on top of and under the paper stack Is there toner in any of the paper Bins Clean the Bins and replace all of the paper with new paper Go to step 3 3 PAPER PATH INSPECTION 1 Remove the paper Bins 2 Remove the Laser Print EP Cartridge 3 Use a flashlight to inspect the entire paper path from Feeder to Output Bin for any loose toner Is the ...

Page 158: ...rinter 2 Replace the Laser Print EP Cartridge 3 Generate 20 Test Prints Does the toner still appear on the back of paper Go to step 7 Problem solved 7 The following printer components and areas are associated with this specific problem One or more of these components or areas may have failed partially or completely If you cannot isolate this problem using the steps in this Fault Isolation Procedur...

Page 159: ...TH INSPECTION Inspect the paper path between the feed Tray and the exit Bin for contamination or obstructions Is the paper path free of obstructions Go to step 3 Remove obstructions from the paper path 3 FEED PICK AND RETARD ROLLER REPLACEMENT Replace the Feed Roller Pick Roller and Retard Roller for the Feeder having the skew problem Is the image still skewed Go to step 4 Problem solved 4 REGISTR...

Page 160: ... or areas may have failed partially or completely If you cannot isolate this problem using the steps in this Fault Isolation Procedure replace each component or troubleshoot each area listed below one at a time until you isolate and solve the problem Laser Scanner Assembly RRP 1 47 Bias Transfer Roller Assembly Table 1 96 Skewed Image cont d Step Actions and Questions Yes No ...

Page 161: ...ctuators or anything that might be rubbing against or catching on the paper as it moves along the paper path Is the interior of the printer clear of debris or broken parts Go to step 2 Clean the printer interior or replace the broken printer parts 2 FEEDER ISOLATION Feed paper out of each of the available paper feeders Is the paper damaged when fed out of only one Bin Go to step 3 Go to step 4 3 P...

Page 162: ...paper Is the sheet damaged as it leaves the Registration Rollers Replace the Registration Roller RRP 1 45 Go to step 6 6 PAPER PATH INSPECTION DRUM BIAS TRANSFER ROLLER 1 Generate a Test Print 2 Open the Left Upper Door just after the lead edge of the sheet of paper has passed the Bias Transfer Roller 3 Carefully remove the Laser Print EP Cartridge from the printer 4 Inspect the sheet of paper Is ...

Page 163: ... 2 2 IMAGE DENSITY INSPECTION Run a Black Test Print Is the Test Print black Go to step 3 Go to RAP 1 60 Light Undertoned Prints 3 FUSER ASSEMBLY REPLACEMENT 1 Replace the Fuser Assembly 2 Run a half dozen Grid Test Prints Does the image rub off Go to step 4 Problem solved 4 The following printer components and areas are associated with this specific problem One or more of these components or area...

Page 164: ... the transfer process 3 Carefully remove the Laser Print EP Cartridge from the printer 4 Inspect the surface of the Drum Does the mark appear on the Drum before image transfer Replace the Laser Print EP Cartridge Go to step 2 2 TRANSFER IMAGE INSPECTION Inspect the Test Print generated in step 1 Does the mark appear on the paper after image transfer Replace the Bias Transfer Roller Assembly Go to ...

Page 165: ... Is the paper loaded correctly and are the paper guides adjusted correctly Go to step 2 Reload the paper and adjust the paper guides 2 LEAD EDGE REGISTRATION Refer to the Diagnostics Test Prints Service Tests NVRAM Adjustments section of this manual and use NVRAM to adjust Lead Edge Registration Can you adjust lead edge registration using NVRAM Problem solved Go to step 3 3 1 Reload print driver s...

Page 166: ... completely If you cannot isolate this problem using the steps in this Fault Isolation Procedure replace each component or troubleshoot each area listed below one at a time until you isolate and solve the problem Registration Sensor PL 6 1 7 Registration Clutch RRP 1 41 System Controller Board RRP 1 73 Input Output Board RRP 1 70 Table 1 100 Lead Edge Registration Is Not Correct Step Actions and Q...

Page 167: ... adjusted correctly Go to step 2 Reload the paper and adjust the paper guides 2 SIDE TO SIDE REGISTRATION Refer to the Diagnostics Test Prints Service Tests NVRAM Adjustments section of this manual and use NVRAM to adjust Side Edge Registration Can you adjust side to side registration using NVRAM Problem solved Go to step 3 3 1 Reload print driver software 2 Generate 5 Test Prints Is the side to s...

Page 168: ...mpletely If you cannot isolate this problem using the steps in this Fault Isolation Procedure replace each component or troubleshoot each area listed below one at a time until you isolate and solve the problem Registration Chute Assembly RRP 1 44 Laser Print EP Cartridge System Controller Board RRP 1 73 Input Output Board RRP 1 70 Table 1 101 Side to Side Registration Is Not Correct Step Actions a...

Page 169: ...move each option one at a time and see how the printer operations without that option installed Does the Electrical Noise problem go away when you remove a specific option Go to the optionmanual and troubleshoot for arcing solenoids and motors or faulty boards or wiring Go to step 3 3 AC GROUND Check the AC wall outlet Is the AC wall outlet correctly wired and grounded Go to step 4 Repair the AC w...

Page 170: ...REPLACEMENT Replace the Main Drive Assembly RRP 1 66 Is the Electrical Noise problem still present Go to step 11 Problem solved 11 The following components are associated with this specific problem One or more of these components may have failed partially or completely If you cannot isolate the problem using this Fault Isolation Procedure replace each component listed below one at a time until the...

Page 171: ...the printer is On Line the On Line LED is illuminated steadily indicating data reception transmission analysis and printing are allowed When the On Line LED is blinking the printer is receiving or processing data or printing Power Saver The printer employs a Power Saver Mode to reduce power consumption by lowering the temperature of the fuser If no data is received or no Control Panel operation is...

Page 172: ...es Generate a variety of test patterns to check printer operation and xerographic functions Print fault history Read component usage logs Read and change operational parameters Analyze and adjust registration both overall and for each paper feed tray Menu Mode Menu Mode utilizes the Control Panel to select various printer operations print configuration sheets and print test demo prints The Menu Mo...

Page 173: ...lete kit has been installed Maintenance Kit Counter Reset Procedure 1 Make certain the printer is OFF 2 Press and hold buttons 2 and 6 on the Control Panel while you switch ON printer main power Continue holding until IOT appears in the display approximately 20 seconds 3 When the Control Display shows IOT release buttons 2 and 6 then press and hold button 0 and 5 You have 10 seconds to release 2 a...

Page 174: ...ber Remember to reset the value back to 1 after checking adjusting registration Note It is not necessary to take the printer Off Line to run the following test prints The 0 key takes the printer Off Line if needed and returns all modes except Diagnostics to Ready Configuration Sheet A printer configuration sheet can be used as an indicator of print quality as well as providing the user technician ...

Page 175: ...uration sheet and keep it close to the printer for reference by users technicians and or system administrators 1 While in the menu mode press 1 or 5 until PRINT MENU is displayed 2 Press 2 or 6 until Menu Map is displayed 3 Press 4 and the menu map will be printed PS Font List The PS Font List produces a list of internally available PostScript fonts This single test page is an excellent tool with ...

Page 176: ...generate the following test prints To Enter Diagnostic Mode 1 Make certain the printer is OFF 2 Press and hold buttons 2 and 6 on the Control Panel while you switch ON printer main power Continue holding until IOT appears in the display approximately 20 seconds 3 When the Control Display shows IOT release buttons 2 and 6 then press and hold button 4 You have 10 seconds to release 2 and 6 and press...

Page 177: ...paper feed tray desired Input Tray Tray 3 1 Press 4 to select the paper feed tray desired Input Tray Tray 4 1 Press 4 to select the paper feed tray desired Input Tray Tray 5 1 Press 4 to select the paper feed tray desired Input Tray MBF ENV 4 Multi sheet Bypass Feeder or Envelope Feeder Test Print Output Tray Output Tray Face Down Press 4 to select the output Tray desired This selection outputs to...

Page 178: ...election Punch Selection On Punch Selection Off Test Print Select Pattern Select Pattern Grid Wide fine line grid pattern suitable for checking and adjusting registration Select Pattern Dark Dusting Paints the printable area dark gray Select Pattern H Pattern H pattern covering the entire printable area Select Pattern Blank Blank page suitable for inspecting for unwanted shading pattern or objects...

Page 179: ...computer but does not occur when you print from Diagnostics the problem may be in the System Controller Board in the print driver software or in the application software on the host computer 5 If the problem occurs when you print a test print then the problem is in the print engine Note You can also use the above procedure to assist in determining if a print quallty problem is caused by a faulty p...

Page 180: ...en password is requested sequentially press 0 7 3 4 to gain entry System Type Press 4 00 99 Face Up Install Press 4 Not Installed Installed Total Print Press 4 0 1500000 BTR Bias Transfer Roller Total Press 4 0 999999 Total CRU Laser Print Cartridge Print Press 4 0 999999 Drum Rotate Time Press 4 0 999999 Tray 1 Feed Press 4 0 999999 Tray 2 Feed Press 4 0 999999 Tray 3 Feed Press 4 0 999999 Tray 4...

Page 181: ...ine No Press 1 or 5 to display ß Press 2 or 6 to display ß Press 4 to write to NVRAM 0 to exit Min Def Max 1 Main Menu NVM Side Edge NVM Side Edge SPX All Trays SPX All Trays Simplex Each value step 252 mm 1 50 99 2 NVM Side Edge SPX Tray 1 SPX Tray 1 Each value step 252 mm 1 50 99 3 NVM Side Edge SPX Tray 2 SPX Tray 2 Each value step 252 mm 1 50 99 4 NVM Side Edge SPX Tray 3 SPX Tray 3 Each value...

Page 182: ... value step 41 mm 0 7 16 21 NVM Lead Edge Envelope Reg Envelope Reg Each value step 41 mm 0 10 16 22 Main Menu NVM Fuser Adj NVM Fuser Adj Ready Temp Ready Temp Each value step 85o C 16 145o c 38 165o c 51 175o c 23 NVM Fuser Adj Standby Temp Standby Temp Each value step 82o C 19 150o c 42 170o c 55 180o c 24 NVM Fuser Adj Standby 2 Temp Standby 2 Temp Each value step 78o C 21 160o c 46 180o c 59 ...

Page 183: ...x 31 NOTE The following papers are applicable for the temperature settings TR1 TM1 11 x 17 SEF A3 SEF A4 LEF or SEF 8 5 x 11 LEF or SEF B4 SEF B5 LEF 7 25 x 10 5 Executive LEF 5 5 x 8 5 Statement LEF 8 5 x 14 Legal SEF TR2 B5 SEF TM2 B5 SEF C6 SEF A5 SEF 5 5 x 8 5 SEF A6 Postcard SEF TE1 TE2 10 SEF Monarch LEF DL LEF C5 LEF 32 Main Menu NVM Others Adj NVM Others Adj Trail Force Ers Trail Force Ers...

Page 184: ... 7 to display value Continue pressing 3 or 7 to adjust value to display ß to display ß Press 4 to write to NVRAM 0 to exit Main Menu Tray Size Test Tray Size Test Tray 1 Size Press 4 start 0 stop Tray 1 paper size is displayed Tray Size Test Tray 2 Size Press 4 start 0 stop Tray 2 paper size is displayed Tray Size Test Tray 3 Size Press 4 start 0 stop Tray 3 paper size is displayed Tray Size Test ...

Page 185: ...sheet to the end of any line or the edge line The distance should be 4 0 mm 1 5 mm in Simplex 1 9 mm in Duplex see illustration 3 If the line is within 1 5 mm from the Lead Edge the printer is within specification If it is greater than 1 5 mm refer to line 16 in Table 1 104 NVRAM Adjustment Table beginning on page 159 Lead Edge Registration for adjustment information Note When checking registratio...

Page 186: ...distance from the side edge of the test sheet to the end of any line or the edge line The distance should be 4 0 mm 2 0 mm in Simplex 2 4 mm in Duplex see illustration 3 If the line is within 4 0 mm from the Side Edge the printer is within specification If it is greater than 1 5 mm refer to Line 1 in Table 1 104 NVRAM Adjustment Table beginning on page 159 Side Edge Registration All Trays in the N...

Page 187: ...ts NVRAM 1 165 6 Continue to press 3 or 7 to change the side edge registration value 7 Press 4 to write the new value into NVRAM 8 Recheck the new side edge registration by repeating the Checking Feed Tray Side Edge Registration test above ...

Page 188: ...st is displayed 5 Follow the table headings and the Control Panel Test Legend below to navigate to the desired test The tests in the table below enable the technician to test the many input sensors and switches providing vital information to the Print Engine Controller Board Control Panel Test Legend Nomenclature Legend IOT Print Engine the printer not including the System Controller Board or opti...

Page 189: ...gistration sensor 3 Press 0 to end test Without Paper With Paper IOT Unit T A Roll2 Sensor 1 Press 4 to begin test 2 Open L H Door A insert thin strip of paper over Take Away Roller 2 Sensor 3 Press 0 to end test Without Paper With Paper IOT Unit CRU Installed 1 Press 4 to begin test 2 Open Front Cover L H Door A Remove Laser Print Cartridge 3 Press 0 to end test Installed Not Installed IOT Unit T...

Page 190: ...el 1 Press 4 to begin test 2 Pull Tray 4 part way out push in 3 Press 0 to end test Down Up HCF Unit Tray 5 Level 1 Press 4 to begin test 2 Pull Tray 5 part way out push in 3 Press 0 to end test Down Up HCF Unit T A Roll3 Sensor 1 Press 4 to begin test 2 Open L H Door B Place paper over Take Away Roller 3 Sensor 3 Press 0 to end test Without Paper With Paper HCF Unit T A Roll4 Sensor 1 Press 4 to ...

Page 191: ... 4 to begin test 2 Actuate Compile Exit Sensor 3 Press 0 to end test Without Paper With Paper Finisher Unit Exit Rol Open HP 1 Press 4 to begin test 2 Actuate Exit Roller Open HP Sensor 3 Press 0 to end test Not Home Home Finisher Unit Sht Rol HP Front 1 Press 4 to begin test 2 Actuate Sheet Roller Home Position Front Sensor 3 Press 0 to end test Not Home Home Finisher Unit Jogger HP Front 1 Press...

Page 192: ...sher Unit Stk Hight Sen Up 1 Press 4 to begin test 2 Actuate Stacker Height Up Sensor 3 Press 0 to end test Without Paper With Paper Finisher Unit Stker Upper Limit 1 Press 4 to begin test 2 Actuate Stacker Upper Limit Sensor 3 Press 0 to end test Off Position On Position Finisher Unit Stker Lower Lmt 1 Press 4 to begin test 2 Actuate Stacker Lower Limit Sensor 3 Press 0 to end test Off Position O...

Page 193: ...Press 4 to begin test 2 Actuate Horizontal Transport Input Path Sensor 3 Press 0 to end test Without Paper With Paper Finisher Unit H Trans Exit P 1 Press 4 to begin test 2 Actuate Horizontal Transport Exit Path Sensor 3 Press 0 to end test Without Paper With Paper Finisher Unit Face Dn Full Sen 1 Press 4 to begin test 2 Actuate Face Down Bin Full Sensor 3 Press 0 to end test Not Full Full Finishe...

Page 194: ...e printer Control Panel Test Legend Nomenclature Legend IOT Print Engine the printer not including the System Controller Board or options HCF High Capacity Feeder Option MBF or MSI Multi sheet Bypass Feeder ENV Envelope Feeder Option Fin Finisher Option Table 1 107 Component Control Output Press 1 or 5 to display Main Menu Comp Output Test Press 2 or 6 to display ß Press 3 or 7 to display ß Turn O...

Page 195: ...ess 4 to start test 2 Turns on Bias Charge Roller DC output for duration or Press 0 to stop BTR Sel 2 sec 1 Press 4 to start test 2 Turns on Bias Transfer Roller Sel output for duration or Press 0 to stop BTR RMT 2 sec 1 Press 4 to start test 2 Turns on Bias Transfer Roller RMT output for duration or Press 0 to stop DTS 2 sec 1 Press 4 to start test 2 Turns on DTS output for duration or Press 0 to...

Page 196: ...t Clut CCW 2 sec 1 Press 4 to start test 2 Actuate Counter Clockwise INvert Clutch for duration or Press 0 to stop Comp Output Test MBF ENV Unit MBF Feed Clutch 2 sec 1 Press 4 to start test 2 Actuate Multi sheet Bypass Feeder feed clutch for duration or Press 0 to stop Env Feed Motor 2 min 1 Press 4 to start test 2 Actuate Envelope Feed Motor for duration or Press 0 to stop Env Clutch On 2 sec 1 ...

Page 197: ...her Unit Trav Mot Rear 2 sec 1 Extend Compiler Tray tongue to facilitate stapler movement 2 Press 4 to start test 3 Actuates the Traverse Motor moving the Stapler to the front of the Finisher Note All four Traverse Motor Tests result in similar movement bringing the Stapler to the front of the Finisher Finisher Unit Trav Mot Rear45 2 sec 1 Extend Compiler Tray tongue to facilitate stapler movement...

Page 198: ...sher 3 Press 4 to start test 4 Actuates the Stapler Note Staple head must be in the staple position and paper must be in the Compiler Tray Finisher Unit Stacker Mot down 2 sec 1 Press 4 to start test 2 Actuates the Stacker Motor for duration to drive the Stacker Bin down Finisher Unit Stacker Mot Up 2 sec 1 Press 4 to start test 2 Actuates the Stacker Motor for duration to drive the Stacker Bin up...

Page 199: ...ot necessary for a trained technician to install the kit Following installation it is necessary to reset the maintenance counter Note See NVRAM Adjusments in the Diagnostics Test Prints Serivces Tests and NVRAM Adjustments section of this manual for this procedure Recommended Tools Standard service tools used in printer repair Toner vacuum such as the 3M Toner Vac Caution Do NOT use a standad vacu...

Page 200: ...he printer as outlined in the following steps assures proper operation of the printer and reduces the probability of having to service the printer in the future The frequency of use and the type of paper a customer prints on determines how critical cleaning the machine is Users of ordinary Bond paper copier paper should have very few problems since this paper is smooth and relatively dust free You...

Page 201: ...f air from the suction bulb Alternately you can vacuum the window clean 8 Vacuum out the interior of the printer 9 Carefully clean the area around the bias transfer roller for impacted toner a Remove the bias transfer roller b Vacuum any toner visible c Reinstall the Bias Transfer Roller ...

Page 202: ...1 180 DocuPrint N4525 Network Laser Printer Service Guide Blank Page ...

Page 203: ...Away Roller Assembly PL 3 6 1 208 RRP 1 24 Tray 2 Retard Assembly PL 3 6 1 210 RRP 1 25 Multi sheet Bypass Feeder Assembly PL 4 2 1 211 RRP 1 26 Multi sheet Bypass Feeder Tray Assembly PL 4 2 1 212 RRP 1 27 Multi sheet Bypass Feeder Support Assembly PL 4 1 1 214 RRP 1 28 Multi sheet Bypass Feeder Size Sensor Assembly PL 4 4 1 216 RRP 1 29 Multi sheet Bypass Feeder Feed Clutch PL 4 3 1 218 RRP 1 30...

Page 204: ...RRP 1 62 Exit Roller Assembly PL 9 2 1 250 RRP 1 63 Face Up Exit Sensor PL 9 3 1 251 RRP 1 64 Inverter Clutches PL 9 4 1 252 RRP 1 65 Flywheel Assembly PL 10 1 1 253 RRP 1 66 Main Drive Assembly PL 10 1 1 254 RRP 1 67 Low Voltage Power Supply Assembly PL 11 1 1 256 RRP 1 68 AC Driver Board PL 11 2 1 258 RRP 1 69 High Voltage Power Supply PL 11 2 1 259 RRP 1 70 Input Output Board PL 11 2 1 260 RRP ...

Page 205: ...details 3 Disconnect all computer interface cables from the printer 4 Wear an electrostatic discharge wrist strap to help prevent damage to the sensitive electronics of the printer circuit boards 5 Wait at least 30 minutes after you have switched OFF printer power for the Fuser to cool before you work on or around the Fuser Work Notes Note Names of parts that appear in the RRPs may not be exactly ...

Page 206: ...f the print engine The notation RRP X Y in an RRP step directs you to another RRP for information on how to perform a related or prerequisite procedure The notation Figure X points to the illustration that corresponds to the RRP you are performing The notation PLX indicates that this component is listed in the PLX parts list Bold arrows in an illustration show direction of movement when removing o...

Page 207: ... back and remove the Paper Assembly Damper PL 1 1 7 4 Open the Left Upper Cover Assembly A and remove the machine screw securing the Fuser Cover to the frame see figure 5 Open the Front Cover and remove the machine screw securing the Fuser Cover to the frame see figure 6 Lift the Fuser Cover off of the Top Cover Assembly Fig 1 35 Fuser Cover S4525 74 ...

Page 208: ...3 Disconnect the Fuser Fan P J204 4 Remove the two machine screws securing the right side of the Top Cover Assembly and the Right Cover see figure to the printer frame 5 Carefully lift the Top Cover a few inches off of the printer frame 6 Disconnect the P J417 from the Control Panel and lift the Top Cover Assembly off of the printer frame Fig 1 36 Top Cover Assembly S4525 75 P J417 P J204 ...

Page 209: ...trap to the printer frame and free the strap 3 Remove the black machine screw securing the metal hinge to the printer frame 4 Slide the Front Cover to the left to free the Front Cover right hinge from the frame and the metal hinge from the frame and remove the Front Cover Fig 1 37 Front Cover Assembly Front Cover Assembly Strap Right hinge Tab Metal hinge S4525 76 ...

Page 210: ... Cover away from the printer 4 Disconnect the two wires attached to the Interlock Switch and remove the Cover Note The two wires attached to the Interlock Switch are not polarized It is not necessary to reconnect them to the same terminal on the Interlock Switch 5 If you are replacing the Interlock Switch squeeze the latches securing the Interlock Switch to the Cover and slide the Switch out of th...

Page 211: ...ower cord from the rear of the printer 2 Remove the two machine screws securing the Rear Cover Assembly to the printer frame 3 Lift the Rear Cover 1 4 6 mm then pull the bottom of the Rear Cover away from the printer frame and slide the cover down to remove it Fig 1 39 Rear Cover Assembly S4525 78 ...

Page 212: ... Cover PL 3 2 Removal 1 Remove the two machine screws securing the Top Cover and the Right Cover to the printer frame 2 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 Fig 1 40 Right Cover S4525 79 ...

Page 213: ... Panel PL 1 1 Removal 1 Remove the Top Cover RRP 1 2 2 Disconnect the P J417 from the Control Panel 3 Push in on the four tabs securing the Control Panel to the Top Cover while you press the Control Panel out of the Cover Fig 1 41 Control Panel S4525 80 ...

Page 214: ...r Cover PL 3 4 Removal 1 Disconnect all option plugs from the Plug Jack located at the rear of the printer 2 Remove the two screws securing the Rear Lower Cover to the printer frame 3 Lift up on the Cover and remove it from the printer frame Fig 1 42 Rear Lower Cover S4525 81 ...

Page 215: ... Slide Tray 1 halfway out of the printer 2 Remove the Rear Cover RRP 1 5 3 Disconnect the P J203 from the rear of Tray 1 Lift Motor 4 Remove the three long screws securing the Motor to the printer frame 5 Slide the Motor out to remove it Fig 1 43 Tray 1 Lift Motor S4525 82 P J203 ...

Page 216: ...1 194 DocuPrint N4525 Network Laser Printer Service Guide RRP 1 10 Tray 1 Feed Clutch PL 3 2 Fig 1 44 Tray 1 Feed Clutch S4525 83 ...

Page 217: ...y off of the shaft Caution Carefully work J202 around the spring arm to avoid damage to the wires and or the spring arm Replacement 1 Position the Feed Clutch over the end of the Feed Shaft Rotate the rear bearing of the clutch until it engages the flat on the shaft 2 Rotate the Clutch until the slot in the Clutch lines up with the key on the frame 3 Press the Clutch onto the shaft until the gear ...

Page 218: ...e Guide RRP 1 11 Feeder Pick and Retard Rollers PL 3 2 PL 3 3 PL 3 5 and PL 3 6 Note Use this procedure for Feeders 1 and 2 Replace the Feeder Pick and Retard rollers at the same time Fig 1 45 Feeder Pick and Retard Rollers Roller Latch Chute S4525 84 ...

Page 219: ...the Roller off of the shaft 4 Repeat step 3 for the remaining two Rollers Replacement 1 Swing the Chute down so it clears the Rollers 2 Position the Roller with the latch end facing out and slide the Roller onto the shaft 3 Rotate and push the Roller down the shaft until the latch locks the Roller into place 4 Repeat steps 2 and 3 for the remaining two Rollers 5 Reinstall the paper Bin ...

Page 220: ...8 DocuPrint N4525 Network Laser Printer Service Guide RRP 1 12 Tray 1 Take Away Roller Assembly PL 3 3 Fig 1 46 Tray 1 Take Away Roller Assembly Fi 2 S4525 8 Option Connector Bracket Retaining Clip Figure 1 ...

Page 221: ...467 from the Input Output Board 11 Remove the self tapping screw securing the retaining clip that is located at the upper left corner of Tray 2 and remove the clip 12 Remove Tray 1 Lift Motor RRP 1 9 Warning The following step has you lift the printer The printer is very heavy and requires two people to lift it Do not attempt to lift the printer by yourself 13 Lift the printer off of Tray 2 14 Set...

Page 222: ...1 200 DocuPrint N4525 Network Laser Printer Service Guide RRP 1 13 Tray 1 Feeder Assembly PL 3 2 Fig 1 47 Tray 1 Feeder Assembly Figure 1 Figure 2 S4525 86 ...

Page 223: ...mbly 8 Remove theTray 1 Feeder Assembly Replacement 1 Hold down the Stopper Link while you insert the end of the Feed Shaft into the opening in the rear of the printer frame 2 Slide the Bearing into the Bearing cutout refer to the figure 3 When both the Bearing is in place and the end of the Feed Shaft is through the opening in the rear of the frame release the Stopper Link 4 The Pick Roller Shaft...

Page 224: ...from the Retard Support 5 Remove Tray 1 Support Assembly Spring 21 RRP 1 15 6 Remove the screw securing the Gear Stopper 12 to the Assembly and move the Stopper out of the way 7 Remove the plastic bearing securing the Take Away Roller Shaft to the front of the Retard Frame and remove the Retard Assembly and Take Away Roller 8 Remove the E rings and Gears PL 3 3 10 12 attached to the rear of the Ta...

Page 225: ...en lifted the spring may pop off rendering the paper Tray useless 2 Use a flat blade screwdriver to unhook the front of the Chute and remove the Chute Replacement 1 Remove either Paper Tray 1 or Paper Tray 2 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 3 Reinstall...

Page 226: ...2 from the printer Caution Do not lay paper Bins flat on carpeted floors The carpet can grab the spring on the bottom of the Tray and when lifted the spring may pop off rendering the paper Tray useless 2 Disconnect the P J from the Size Sensor Board 3 Remove the screw securing the Size Sensor Board to the printer frame pull the board straight out and remove it from the frame Fig 1 50 Tray 1 Tray 2...

Page 227: ... 21 Tray 2 Feed Clutch PL 3 5 Removal 1 Remove the Rear Cover RRP 1 6 2 Disconnect the Feed Clutch connector P J240 3 Remove the E ring securing the Clutch to the shaft and slide the Clutch off of the shaft Fig 1 51 Tray 2 Feed Clutch S4525 94 ...

Page 228: ...Printer Service Guide RRP 1 22 Tray 2 Feeder Assembly PL 3 5 Caution Take care not to break or dislodge the No Paper Actuator when removing or replacing the Tray 2 Feeder Assembly Fig 1 52 Tray 2 Feeder Assembly Figure 1 Figure 2 S4525 95 ...

Page 229: ...down the Stopper Link while you insert the end of the Feed Shaft into the opening in the rear of the printer frame 2 Slide the Bearing into the Bearing cutout refer to the figure 3 When both the Bearing is in place and the end of the Feed Shaft is through the opening in the rear of the frame release the Stopper Link 4 The Pick Roller Shaft should rest on top of the Stopper Link and the Link should...

Page 230: ...uPrint N4525 Network Laser Printer Service Guide RRP 1 23 Tray 2 Take Away Roller Assembly PL 3 6 Fig 1 53 Tray 2 Take Away Roller Assembly S4525 96 Take Away Roller Gear 22T Take Away Roller Front Bearing FRONT ...

Page 231: ...topper then remove the Gear Stopper from the shaft 9 Remove the E ring securing Gear 22 20T to the shaft and remove the gear 10 Remove the E ring securing Gear 22T to the shaft and remove the gear 11 Remove E ring securing the plastic bearing and the Take Away Roller Shaft to the front of the printer frame Then remove the Retard Assembly and attached Take Away Roller by moving it as far to the rea...

Page 232: ...t out of the Retard Assembly 4 Remove the E ring securing the center bearing on the Take Away Roller shaft and remove the bearing Replacement 1 Reinstall the center bearing on the Take Away Roller shaft and secure with the E ring removed in Step 4 above 2 Slide the Take Away Roller Shaft into the Retard Assembly 3 Reinstall the bearing and secure with the E ring removed in Step 2 above 4 Reinstall...

Page 233: ...the printer Replacement 1 Face the left side of the printer 2 Position the Multi sheet Bypass Feeder against the Multi sheet Bypass Feeder Support 3 Tilt the Multi sheet Bypass Feeder so the Feed Gear slides through the cutout in the printer cover 4 Hold the Multi sheet Bypass Feeder Assembly level and push the Assembly against the printer making certain the top cover hides the metal frame Fig 1 5...

Page 234: ... N4525 Network Laser Printer Service Guide RRP 1 26 Multi sheet Bypass Feeder Tray Assembly PL 4 2 Fig 1 56 Multi sheet Bypass Feeder Tray Assembly Multi sheet Bypass Feeder Top Cover Figure 1 Figure 2 S4525 99 P J107 ...

Page 235: ... and remove the Top Cover by sliding it slightly toward the Bin 4 Disconnect the P J107 that runs from the Tray Assembly to the Feeder Assembly the three wire connector residing adjacent to the Tray Spring 5 Remove the screw securing the Tray Spring and free the Spring 6 Push out on the Front Support as you slightly bow the Bin and release the pivot hole on the right side of the Tray from the meta...

Page 236: ...1 214 DocuPrint N4525 Network Laser Printer Service Guide RRP 1 27 Multi sheet Bypass Feeder Support Assembly PL 4 1 Fig 1 57 Multi sheet Bypass Feeder Support Assembly S4525 100 P J 603 ...

Page 237: ...bly If you do remove the end covers take note of the different length of the two machine screws securing same The four screws securing the support assembly are longer than the two screws securing the end covers Replacement 1 Position the Multi sheet Bypass Feeder Support Assembly a few inches from the printer frame 2 Insert the wire harness into the cutout in the printer frame 3 Slide the two posi...

Page 238: ...ork Laser Printer Service Guide RRP 1 28 Multi sheet Bypass Feeder Size Sensor Assembly PL 4 4 Fig 1 58 Multi sheet Bypass Feeder Size Sensor Assembly S4525 101 Multi sheet Bypass Feeder Tray Multi sheet Bypass Feeder Side Guide ...

Page 239: ...the bottom of the Guide fit through the cutout in the Upper Cover 2 Slide the Side Guide all the way to the right toward the Multi sheet Bypass Feeder Tray Spring 3 Hold the Side Guide in place while you press the two holes in the Size Sensor onto the two latch tabs 4 Press hard enough so the Size Sensor locks snaps into place 5 Make sure the spring loaded arm of the Sensor is under the molded tra...

Page 240: ... Network Laser Printer Service Guide RRP 1 29 Multi sheet Bypass Feeder Feed Clutch PL 4 3 Fig 1 59 Multi sheet Bypass Feeder Feed Clutch Figure 1 Figure 2 Figure 3 Figure 4 Multi sheet Bypass Feeder Tray Support S4525 102 ...

Page 241: ...on the Multi sheet Bypass Feeder Feed Clutch with the gear facing out and slide the Clutch onto the Feed Shaft 2 Thread the Clutch wire harness through the cutout in the Support frame 3 Rotate the Clutch so the notch in the Clutch fits into the key in the Assembly Figure 4 4 Use the E ring removed in Step 7 above to secure the Multi sheet Bypass Feeder Feed Clutch to the Feed Shaft 5 Reinstall the...

Page 242: ... Multi sheet Bypass Feeder No Paper Sensor Assembly 4 Loosen the machine screw securing the Multi sheet Bypass Feeder No Paper Sensor Assembly to the Feeder Assembly and move the Assembly out of the way 5 Remove the KL clip securing the Multi sheet Bypass Feeder Feed Roller to the Feed Shaft and slide the Feed Roller off of the shaft Fig 1 60 Multi sheet Bypass Feeder Feed Roller Multi sheet Bypas...

Page 243: ... Feeder Feed Roller RRP 1 30 2 Remove the E ring securing the Multi sheet Bypass Feeder Gate to the shaft and remove the Gate 3 Remove the E ring securing the Pick Roller to the shaft and slide the Pick Roller off of the shaft Fig 1 61 Multi sheet Bypass Feeeder Pick Roller Multi sheet Bypass Feeder Gate Pick Roller S4525 104 ...

Page 244: ...ser Printer Service Guide RRP 1 32 Multi sheet Bypass Feeder Pick Roller Assembly PL 4 3 Fig 1 62 Multi sheet Bypass Feeder Pick Roller Assembly S4525 105 Multi sheet Bypass Feeder Front Bearing Multi sheet Bypass Feeder Rear Bearing ...

Page 245: ...bly see the figure for correct placement 2 Hook one end of the Feed Spring over the Pick Roller Assembly frame 3 Reinstall the Pick Roller Assembly into the Multi sheet Bypass Feeder Assembly 4 Hold the Feed Gear in place with the flat side against the Pick Roller Assembly 5 Slide the Feed Shaft through the Feed Gear through the Rear Feed Bearing through the Pick Roller Assembly through the Feed S...

Page 246: ...nt N4525 Network Laser Printer Service Guide RRP 1 33 Multi sheet Bypass Feeder Pad PL 4 2 Fig 1 63 Multi sheet Bypass Feeder Pad Multi sheet Bypass Feeder Pad Spring S4525 106 Multi sheet Bypass Feeder Paper Guide ...

Page 247: ... out of the Feeder Replacement 1 Flex back the Multi sheet Bypass Feeder Paper Guide and slide the Multi sheet Bypass Feeder Pad between the Guide and the Pad Spring 2 Turn the Multi sheet Bypass Feeder upside down 3 Slide the Multi sheet Bypass Feeder Pad Pin into the hole in the Feeder through the holes in the three legs of the Multi sheet Bypass Feeder Pad and out through the other hole in the ...

Page 248: ...o the tabs on the Spacer mesh with the notches on the Clutch Gear Caution When performing step 3 below push only on the rear of the Clutch Never press the sides of the Clutch Pressing the sides of the Clutch may break the Clutch 3 Slide the Friction Clutch onto the shaft rotating the Clutch as you slide it toward the Spacer 4 Make sure the Clutch and Spacer mesh 5 Use the E ring removed in Step 2 ...

Page 249: ...Loosen the machine screw securing the Multi sheet Bypass Feeder No Paper Sensor Bracket to the Feeder Assembly and lift the Sensor Bracket off of the Feeder 3 Disconnect P J108 from the Multi sheet Bypass Feeder No Paper Sensor 4 Squeeze the Sensor latches and remove the Sensor from the Bracket Fig 1 65 Multi sheet Bypass Feeder No Paper Sensor Assembly S4525 108 P J108 ...

Page 250: ...1 228 DocuPrint N4525 Network Laser Printer Service Guide RRP 1 36 Left Middle Cover Assembly PL 5 1 Fig 1 66 Left Middle Cover Assembly Figure 1 Figure 2 Pinch Roller Pinch Roller Bracket S4525 109 ...

Page 251: ...e two Shaft Springs over the End Bearings 3 Compress the Shaft Springs and reinstall the Shaft into the Bracket 4 Make sure that the lip of each Bearing is trapped behind the tabs in the Bracket and that each Pinch Roller lines up with the corresponding cutout in the Bracket 5 Hook one end of each Holding Spring into a spring hole in one side of the Bracket 6 Bring the Springs over the Shaft and h...

Page 252: ...1 230 DocuPrint N4525 Network Laser Printer Service Guide RRP 1 41 Registration Clutch PL 6 1 Fig 1 67 Registration Clutch S4525 113 ...

Page 253: ...gistration Shaft 5 Push out on the shaft latch as you slide the Clutch off of the shaft Replacement 1 Slide the Registration Clutch onto the shaft The shaft latch snaps the Clutch into place on the shaft 2 Use the E clip removed in Step 4 above to secure the Registration Clutch to the Registration Shaft 3 Reconnect P J200 from the Registration Clutch 4 Reinstall the Flywheel Assembly RRP 1 65 5 Re...

Page 254: ...1 232 DocuPrint N4525 Network Laser Printer Service Guide RRP 1 42 Left Upper Cover Assembly PL 6 2 Fig 1 68 Left Upper Cover Assembly S4535 114 Rear Shaft Hinge Pin Front Shaft Hinge Pin ...

Page 255: ...Cover Assembly away from the printer frame 7 Remove the two black self tapping screws securing the two Cover Supports to the frame and remove the Cover See illustration Replacement 1 Open the Duplex Module Caution When the Left Upper Cover is open the Bias Transfer Roller is exposed Do not touch the Bias Transfer Roller Grease and dirt on the Bias Transfer Roller or physical damage to the Bias Tra...

Page 256: ...ute Assembly and use the blade of a small screwdriver to free the rear latches from the Cover 4 Push down on the front of the Chute Assembly and use the blade of a small screwdriver to free the front latches from the Cover 5 Remove the Left Chute Assembly 6 Release the two springs and remove the Registration Roller Assembly from the Chute Assembly Fig 1 69 Left Chute Assembly Registration Roller S...

Page 257: ...ove the Laser Print EP Cartridge 6 Remove the black machine screw securing the Magnet Plate to the printer frame and remove the Plate 7 Remove the two screws under the Magnet Plate securing the front of the Registration Chute to the printer frame 8 Remove the two screws under the Registration Clutch securing the rear of the Registration Chute to the printer frame and remove the Chute 9 Disconnect ...

Page 258: ... PL 6 2 Removal 1 Remove the Registration Chute RRP 1 44 2 Remove the E ring from the rear of the Registration Roller Shaft 3 Slide the Shaft to the rear to free the front of the Shaft from the front bearing 4 Remove the Registration Roller Assembly Fig 1 71 Registration Roller Assembly S4525 117 ...

Page 259: ...ree screws that secure the Laser Scanner to the printer frame 4 Lift the Laser Scanner Assembly off of the printer frame 5 Place the Laser Scanner Assembly on a flat and stable surface Warning Do not remove Laser Scanner covers or disassemble the Laser Scanner Assembly There are no replaceable parts or field adjustable points located inside the Laser Scanner Assembly Fig 1 72 Laser Scanner Assembl...

Page 260: ...over 4 Remove the Laser Print EP Cartridge 5 Remove the Flywheel Assembly RRP 1 65 6 Remove the Left Cover Interlock Switch RRP 1 71 7 Remove the Main Drive Assembly RRP 1 66 8 Use the flat blade of a screwdriver to pry up the front end of the Toner Sensor refer to the figure 9 When the front end is freed remove the Sensor along with the attached wire harness Fig 1 73 Toner Sensor S4525 121 P J127...

Page 261: ...the Rear Cover RRP 1 5 3 Disconnect J232 and J233 from the Laser Print Cartridge Interlock Switch 4 Disconnect P J234 from the Interlock Switch wire harness 5 Remove the screw securing the Laser Print Cartridge Interlock Switch to the printer frame and remove the Switch Fig 1 74 Laser Print Cartridge Interlock Switch S4525 122 P J233 P J232 P J234 ...

Page 262: ...1 240 DocuPrint N4525 Network Laser Printer Service Guide RRP 1 53 Fuser Drive Assembly PL 10 2 Fig 1 75 Fuser Drive Assembly S4525 124 ...

Page 263: ...nd termination 11 Remove the machine screw securing the green ground wire to the printer frame 12 Pull up and remove the Fuser Drive Assembly Replacement 1 Reinstall the Fuser Drive Assembly onto the printer frame Refer to the figure for correct positioning 2 Align the Assembly so the screw holes and locating holes in the Assembly line up with the screw holes and locating tabs on the frame 3 Use t...

Page 264: ...the Duplex Module 4 Open the Upper Left Cover 5 Remove J104 J209 J601 and J602 from the Offset Unit Assembly 6 Remove the three black machine 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 7 Lift the Offset Unit up and off of the printer frame Fig 1 76 Offset Exit Assembly S4525 125 ...

Page 265: ...shaft fit through the corresponding opening in the Exit Drive Assembly 2 Press the Exit Drive Assembly onto the Offset Assembly slightly repositioning the Exit Drive Assembly so the positioning pin on the upper right side of the Offset Assembly fits through the corresponding hole in the Exit Drive Assembly Caution Make certain not to trap any wire harnesses between the Exit Drive Assembly and the ...

Page 266: ...he Exit Gate Solenoid to the Offset Assembly and remove the Solenoid Replacement 1 Position the Exit Gate Solenoid so the wire harness faces up 2 Reinstall the Solenoid onto the Offset Assembly making sure the crossbar of the solenoid plunger latches onto the Solenoid Link 3 Use the two screws removed in Step 4 above to secure the Solenoid to the Assembly 4 Reconnect J210 5 Secure the wire harness...

Page 267: ...wo black machine screws securing the Motor to the Offset Assembly Caution Do not remove the brass colored screws when removing the Offset Motor 3 Lift the Motor off of the Assembly and free the Motor arm from the Offset Roller Rack 4 Disconnect J209 from the Offset Motor Fig 1 79 Offset Motor S4525 128 Offset Roller Rack ...

Page 268: ...1 58 Full Stack Sensor PL 9 1 Removal 1 Remove the Fuser Cover RRP 1 1 2 Disconnect P J133 3 Remove the two screws securing the Full Stack Sensor Switch Assembly Bracket and remove the Assembly Fig 1 80 Full Stack Sensor S4525 129 P J133 Full Stack Sensor Assembly ...

Page 269: ... 1 57 3 Remove the Face Up Exit Sensor RRP 1 58 4 Remove the gear located at the end of the Roller Assembly 5 Remove the KL clip securing the Roller shaft to the rear bearing 6 Slide the bearing out of the Offset Assembly frame 7 Slide the front bearing out the Assembly frame and remove the Offset Roller Assembly Fig 1 81 Offset Roller Assembly S4525 130 ...

Page 270: ...bly RRP 1 59 2 Remove the five black machine screws securing the Lower Chute to the Exit Assembly frame and separate the Lower Chute from the frame 3 Release P J104 wire harness from the harness clips 4 Squeeze the latches to unlock the Fuser Exit Sensor and remove the Sensor from the Lower Chute Fig 1 82 Lower Chute Assembly S4525 131 ...

Page 271: ...ness clips 4 Open the Upper Chute Assembly and loosen do not remove the rear black machine screw securing the Face Up Lower Chute to the frame 5 Remove the three rear black machine screws that secure the Lower Chute to the frame 6 Carefully pull the frame far enough to the rear to free the rear hinge of the Upper Chute 7 Pull the Upper Chute to the rear and free the front hinge and remove the Uppe...

Page 272: ...er Chute to the Assembly frame and remove the Chute 3 Remove the KL clip securing the Gear located at the rear of the Exit Roller shaft and remove the Gear and rear bearing 4 Remove the E ring securing the front of the Exit Roller shaft to the Assembly frame and remove the front bearing 5 Slide the shaft to the rear and remove the shaft from the Assembly Fig 1 84 Exit Roller Assembly Exit Roller S...

Page 273: ...oval 1 Remove the Fuser Cover RRP 1 1 2 Disconnect P J109 and remove the wire harness from the harness clips 3 Squeeze the latches to unlock the Face Up Exit Sensor and remove the Sensor from the Offset Assembly Fig 1 85 Face Up Exit Sensor S4525 134 P J109 Face Up Exit Sensor ...

Page 274: ...rt off of the Bracket 3 Disconnect P J218 and P J219 and free the wire harness from the harness clips 4 Slide the Counter Clockwise Gear off of the Counter Clockwise Clutch 5 Slide the Clockwise Gear off of the Clockwise Clutch 6 Lift the Counter Clockwise Clutch off of the bearing and remove the Clutch 7 Lift the Clockwise Clutch off of the bearing and remove the Clutch Fig 1 86 Inverter Clutches...

Page 275: ...P 1 65 Flywheel Assembly PL 10 1 Removal 1 Remove the Rear Cover RRP 1 5 2 Remove the black machine screw securing the Flywheel to the Drive Assembly shaft and pull the Flywheel off of the shaft Fig 1 87 Flywheel Assembly Flywheel S4525 136 ...

Page 276: ...4 DocuPrint N4525 Network Laser Printer Service Guide RRP 1 66 Main Drive Assembly PL 10 1 Fig 1 88 Main Drive Assembly Figure 2 S4525 137 Remove Machine Screw Remove Self Tapping Screws Figure 1 Exit Gear ...

Page 277: ...t P J462 from the Input Output Board 11 Disconnect P J202 J209 J600 and J601 from the Harness Support Bracket 12 Remove the two black machine screws securing the Harness Support to the Main Drive Assembly and move the Harness Support and attached harness out of the way 13 Remove the four black self tapping screws securing the Main Drive Assembly to the printer frame see figure 2 Note The bottom ri...

Page 278: ...int N4525 Network Laser Printer Service Guide RRP 1 67 Low Voltage Power Supply Assembly PL 11 1 Fig 1 89 Low Voltage Power Supply Assembly LVPS Cover Figure 2 Figure 3 S4525 138 System Controller Assembly Figure 1 ...

Page 279: ...ntroller Assembly back and out of the way Figure 1 6 Remove the machine screws securing the Low Voltage Power Supply Cover to the Low Voltage Power Supply and remove the Cover Figure 2 7 Disconnect J1 J3 J220 J502 J504 J505 and J506 from the Low Voltage Power Supply Figure 3 8 Remove the wire harnesses from the harness clips at the rear of the Low Voltage Power Supply 9 Remove the five machine scr...

Page 280: ... J510 from the AC Driver Board 3 Remove the two machine screws securing the Plate Bracket and AC Drive Board to the frame and remove the Bracket and the Plate 4 Press in on the two latches securing the top of the AC Driver Board to the printer frame and remove the board Fig 1 90 AC Driver Board AC Driver PWB 230V FLK Bracket Plate AC Driver PWB 20A 120V Figure 1 Figure 2 S4525 139 ...

Page 281: ...oard Use your fingers to hold down the board while you carefully disconnect each P J 3 Remove the two machine screws one on the left side and one on the right side that secure the High Voltage Power Supply Assembly to the printer frame 4 Pull out on the High Voltage Power Supply Assembly while you release the two clips one at the top and one on the right side that secure the High Voltage Power Sup...

Page 282: ...m the Input Output Board 3 Remove the four machine screws securing the Input Output Board Bracket to the printer frame and remove the Bracket 4 Remove the six machine screws securing the Input Output Board to the Bracket and remove the board Fig 1 92 Input Output Board I O Board Bracket P450 P451 P467 P463 P464 P466 P127 P462 P461 P459 P465 P457 P452 P453 P460 P456 P458 P454 S4525 141 ...

Page 283: ...nterlock Switch 3 Remove the screw that secures the Interlock Switch Bracket to the printer frame and pull the Assembly out of the printer 4 Rotate the Switch Lever so it is straight up and slide it off of the Bracket 5 Press the two clips securing the Switch to the Bracket and push the Switch out of the Bracket Fig 1 93 Left Cover Interlock Switch Assembly J232 J233 S4525 142 ...

Page 284: ... securing the cover to the assembly then lifting the cover off of the assembly 5 Disconnect the six P Js J400 J402 J403 J404 J408 and J411 and the video plug P409 that are connected to the Print Engine Controller Board 6 Remove the six screws securing the Print Engine Controller Board to the System Controller Assembly 7 Remove the two 7mm nuts from J406 8 Lift the Print Engine Controller Board out...

Page 285: ...d tighten them 4 Reconnect J400 J402 J403 J404 J408 J411 and the video plug P409 into their respective connectors on the Print Engine Controller Board 5 Reinstall the System Controller Board mating with J406 on the Print Engine Controller Board 6 Reconnect J400 J402 J403 J404 J408 J409 and J411 to the Print Engine Controller Board 7 Reinstall the System Controller Assembly Cover 8 Reinstall the To...

Page 286: ...ve electronics of the System Controller 2 Disconnect all input cables from the connectors on the System Controller Board Panel 3 Loosen the two thumbscrews that secure the System Controller Assembly Panel to the System Controller Box 4 Slide the System Controller Board out of the System Controller Box 5 Place the System Controller Board and the attached Drawer Panel on a grounded anti static work ...

Page 287: ...xample PL9 3 3 means the part is item 3 of Parts List 9 3 3 A black triangle preceding a number followed by a parenthetical statement in an illustration means the item is an assembly made up of the individual parts called out in parentheses 4 The notation with X Y following a part name indicates an assembly that is made up of components X through Y For example 1 with 2 4 means part 1 consists of p...

Page 288: ...1 266 DocuPrint N4525 Network Laser Printer Service Guide PL 1 1 Top Cover Assembly Fig 1 97 Top Cover Assembly S4525 157 4 NJ417 PL11 3 16 8 S 3 S 2 1 6 J204 PL11 4 13 5 S S S 7 ...

Page 289: ...r Connector 4 802K18182 1 Assembly Control Panel NOTE When ordering this part be certain to order the appropriate item 8 also 5 802E08760 1 Cover Fuser 6 127K19110 Alt 127K21470 1 Assembly Fuser Fan 7 004K01730 1 Damper Assembly Paper 8 892E38280 892E38290 892E38310 1 1 1 Overlay Control Panel English Overlay Control Panel Spanish Portuguese Chinese Overlay Control Panel Symbols Only ...

Page 290: ...1 268 DocuPrint N4525 Network Laser Printer Service Guide PL 1 2 Front Cover Fig 1 98 Font Cover S4525 158 ...

Page 291: ...Inner Front 4 054K15471 1 Assembly Duct 5 1 Plate Cover 6 1 Stud Docking part of 99 7 1 Bracket Left Docking part of 99 8 1 Bracket Rear Docking part of 99 9 1 Switch Front Cover Interlock part of 11 10 1 Harness Assembly Front Interlock part of 11 FS237 FS235 FS236 11 110K10630 1 Switch Assembly Interlock with 9 10 12 830E44240 1 Support Cover 99 600K85070 1 Kit Tray 2 Mounting with 6 8 ...

Page 292: ...1 270 DocuPrint N4525 Network Laser Printer Service Guide PL 1 3 Rear Left and Right Covers Fig 1 99 Rear Left and Right Covers S4525 159 ...

Page 293: ...s Lists 1 271 Table 1 110 PL 1 3 Rear Left and Right Covers ID No Part Number Qty Name Description 1 802E08370 1 Cover Inner Left Hand 2 802E08581 1 Cover Right Hand 3 802K10221 1 Cover Assembly Rear 4 048E37410 1 Cover Rear Bottom ...

Page 294: ...1 272 DocuPrint N4525 Network Laser Printer Service Guide PL 2 1 Tray Unit Paper Stack Fig 1 100 Tray Unit Paper Stack S4525 160 ...

Page 295: ... 4 1 Plate Tongue part of 1 5 1 Shaft Assembly Tongue part of 1 6 1 Bearing part of 1 7 1 Guide Assembly Side part of 1 8 1 Lever part of 1 9 1 Shaft part of 1 10 1 Spring Compression part of 1 11 1 Plate Side part of 1 12 1 Actuator part of 1 13 1 Link part of 1 14 1 Spring Torsion part of 1 15 1 Stopper Left Hand part of 1 16 1 Housing Tray part of 1 17 2 Washer part of 1 18 1 Washer part of 1 1...

Page 296: ...1 274 DocuPrint N4525 Network Laser Printer Service Guide PL 2 2 Tray Unit End Guide Fig 1 101 Tray Unit End Guide ...

Page 297: ...n 1 1 Guide Assembly End part of PL 2 1 item 1 2 1 Plate Assembly End part of PL 2 1 item 1 3 1 Assembly Actuator part of PL 2 1 item 1 4 2 Assembly Cable part of PL2 1 item 1 5 2 Spring Tension part of PL 2 1 item 1 6 2 Pulley part of PL 2 1 item 1 7 1 Actuator Guide part of PL 2 1 item 1 99 600K61610 1 Kit Tray Cables ...

Page 298: ...1 276 DocuPrint N4525 Network Laser Printer Service Guide PL 2 3 Tray Unit Paper Stack Custom Fig 1 102 Tray Unit Paper Stack Custom S4525 162 PL2 4 1 PL 2 4 6 ...

Page 299: ...haft Assembly Tongue part of 1 6 1 Bearing part of 1 7 1 Guide Assembly Side Custom part of 1 8 1 Lever part of 1 9 1 Shaft part of 1 10 1 Spring Compression part of 1 11 1 Plate Side part of 1 12 1 Actuator part of 1 13 1 Link part of 1 14 1 Spring Torsion part of 1 15 1 Stopper Left Hand part of 1 16 1 Housing Tray part of 1 17 2 Washer part of 1 18 1 Washer Side Guide part of 1 19 1 Cap Tray pa...

Page 300: ...1 278 DocuPrint N4525 Network Laser Printer Service Guide PL 2 4 Tray Unit End Guide Custom Fig 1 103 Tray Unit End Guide Custom S4525 163 ...

Page 301: ...ty Name Description 1 1 Guide Paper End part of PL 2 3 item 1 2 1 Label End Guide part of PL 2 3 item 1 3 1 Washer Nylon part of PL 2 3 item 1 4 1 Pinslide Custom part of PL 2 3 item 1 5 1 Spring Torsion part of PL 2 3 item 1 6 1 Plate Assembly End part of PL 2 3 item 1 7 1 Guide Actuator part of PL 2 3 item 1 ...

Page 302: ...1 280 DocuPrint N4525 Network Laser Printer Service Guide PL 3 1 Tray Interface Tray 1 Fig 1 104 Tray Interface Tray 1 S4525 164 ...

Page 303: ... 1 Actuator Sensor part of 99 4 1 Support Actuator part of 99 5 107E08680 2 Sensor Photo Interrupter J103 Lift Up Sensor J102 No Paper Sensor 6 054K09020 1 Chute Assembly Front for Tray 1 only 7 003E23672 1 Stopper Tray Front 8 003E23690 1 Stopper Tray Rear 9 1 Spacer Left 10 023E13230 1 Link Stopper Tray 1 only 11 809E05870 1 Spring Torsion 99 600K56730 1 Kit Actuator Sensor Assembly with 3 4 ...

Page 304: ...1 282 DocuPrint N4525 Network Laser Printer Service Guide PL 3 2 Paper Pick Up Tray 1 Fig 1 105 Paper Pick Up Tray 1 S4525 165A 99 1 4 98 with 6 Qty 6 ...

Page 305: ...ly 5 050K43520 1 Feeder Assembly with 6 14 6 2 Roller Assembly part of 5 7 1 Clutch Assembly One Way part of 5 8 1 Clutch Gear 25T part of 5 9 1 Bearing part of 5 10 1 Shaft Feed part of 5 11 1 Gear 31T part of 5 12 1 Gear 25T part of 5 13 1 Support Assembly Pick part of 5 14 1 Bearing part of 5 15 1 Support Brush 16 1 Web Feed 17 1 Brush Assembly Feed with items 15 16 98 604K01130 1 Kit Feed Roll...

Page 306: ...1 284 DocuPrint N4525 Network Laser Printer Service Guide PL 3 3 Retard and Take Away Tray 1 Fig 1 106 Retard and Take Away Tray 1 S4525 166 ...

Page 307: ...rt of item 1 9 2 Bearing part of 98 10 1 Gear 22T part of 98 part of 99 11 1 Spacer part of 98 12 1 Gear Stopper part of 98 13 1 Bearing part of 98 14 1 Bearing part of 98 15 1 Roller Assembly part of 98 16 1 Bearing part of 98 17 1 Bearing part of 98 18 054K88590 1 Chute Assembly Feed Out part of 98 19 1 Chute Feed In part of 98 20 1 Gear 22 20T part of 98 part of 99 21 074K92500 1 Support Assemb...

Page 308: ...1 286 DocuPrint N4525 Network Laser Printer Service Guide PL 3 4 Tray Interface Tray 2 Fig 1 107 Tray Interface Tray 2 S4525 167 ...

Page 309: ...tor Assembly 3 1 Actuator Sensor part of item 99 4 1 Support Actuator part of item 99 5 107E08680 2 Photo Interrupter No Paper Sensor Lift Up Sensor 6 054K09030 1 Chute Assembly Front for Tray 2 only 7 003E23672 1 Stopper Tray Front 8 003E23690 1 Stopper Tray Rear 9 1 Spacer Left 10 023E08660 1 Link Stopper 11 809E05870 1 Spring Torsion 99 600K56730 1 Kit Actuator Sensor with 3 4 ...

Page 310: ...1 288 DocuPrint N4525 Network Laser Printer Service Guide PL 3 5 Paper Pick Up Tray 2 Fig 1 108 Paper Pick Up Tray 2 S4525 168 ...

Page 311: ...f 97 5 050K43520 1 Feeder Assembly with 6 14 6 2 Roller Assembly part of item 5 7 1 Clutch Assembly One Way part of item 5 8 1 Clutch Gear 25T part of item 5 9 1 Bearing part of item 5 10 1 Shaft Feed part of item 5 11 1 Gear 31T part of item 5 12 1 Gear 25T part of item 5 13 1 Support Assembly Pick part of item 5 14 1 Bearing part of item 5 15 1 Support Brush 16 1 Web Feed 17 1 Brush Assembly Fee...

Page 312: ...1 290 DocuPrint N4525 Network Laser Printer Service Guide PL 3 6 Retard and Take Away Tray 2 Fig 1 109 Retard and Take Away Tray 2 S4525 169 98 1 9 15 17 1 with 2 8 99 9 16 ...

Page 313: ... 1 6 1 Spacer part of item 1 7 1 Clutch Assembly Friction part of item 1 8 1 Support Retard part of item 1 9 1 Gear 22T part of item 98 part of item 99 10 3 Bearing part of item 98 11 1 Gear Stopper part of item 98 12 1 Roller Assembly part of item 98 13 1 Bearing part of item 98 14 054E08680 1 Chute Feed Out part of item 98 15 1 Chute Feed In 16 1 Gear 22 20 part of item 99 17 809E27440 1 Spring ...

Page 314: ...1 292 DocuPrint N4525 Network Laser Printer Service Guide PL 3 7 Feed Drive Transmission Fig 1 110 Feed Drive Transmission S4525 170 ...

Page 315: ... of item 99 3 4 1 Support Assembly part of item 99 5 1 Gear 31T part of item 99 6 1 Gear 33T part of item 99 7 1 Gear 16 22T part of item 99 8 1 Link Assembly part of item 99 9 1 Spring Torsion part of item 99 10 1 Bearing part of item 99 11 1 Harness Clamp part of item 99 12 1 Shaft Gear 16T Assembly 99 600K85100 1 Kit Feed Drive Repair 2 4 12 ...

Page 316: ...1 294 DocuPrint N4525 Network Laser Printer Service Guide PL 4 1 Multi sheet Bypass Feeder and Duplex Support Fig 1 111 Multi sheet Bypass Feeder and Duplex Support S4525 171 ...

Page 317: ... Assembly 3 068K11630 1 Support Assembly Multi Sheet Bypass Feeder Duplex Module 4 162K20380 1 Harness Assembly Drawer J603 J604 5 1 Spring Front Damper 6 1 Spring Rear Damper 7 059K14753 1 Feeder Assembly Multi sheet Bypass with 8 12 PL 4 2 8 048E37401 1 Cover Top part of item 7 9 1 Bracket Spring part of item 7 10 1 Stud part of item 7 11 1 Spring Torsion part of item 7 12 1 Clamp Cable part of ...

Page 318: ...1 296 DocuPrint N4525 Network Laser Printer Service Guide PL 4 2 Multi sheet Bypass Feeder Assembly MBF Fig 1 112 Multi sheet Bypass Feeder Assembly MBF D4525 172 ...

Page 319: ...92810 1 Pad Assembly Multi sheet Bypass Feeder part of item 1 PL 4 1 7 1 Pin Retard part of item 1 PL 4 1 8 1 Shaft Multi sheet Bypass Feeder Pad part of item 1 PL 4 1 9 1 Spring Multi sheet Bypass Feeder Pad part of item 1 PL 4 1 10 1 Guide Paper part of item 1 PL 4 1 11 1 Bracket Frame Front part of item 1 PL 4 1 12 1 Latch Assembly Front part of item 1 PL 4 1 13 1 Latch Assembly Rear part of it...

Page 320: ...1 298 DocuPrint N4525 Network Laser Printer Service Guide PL 4 3 Upper Feeder Assembly Fig 1 113 Upper Feeder Assembly S4525 173 ...

Page 321: ...t of item 1 13 1 Harness Assembly Multi sheet Bypass Feeder P604 J108 P107 P208 part of item 1 14 059K14760 1 Roller Assembly Pick with 15 25 part of item 1 15 1 Support Assembly Pick Roller part of item 1 part of item 14 16 1 Cover Gear part of item 1 part of item 14 17 1 Gear Spur 30T part of item 1 part of item 14 18 1 Bearing part of item 1 part of item 14 19 2 Gate Multi sheet Bypass Feeder p...

Page 322: ...1 300 DocuPrint N4525 Network Laser Printer Service Guide PL 4 4 Multi sheet Bypass Feeder Tray Assembly Fig 1 114 Multi sheet Bypass Feeder Tray Assembly S4525 174 ...

Page 323: ...1 1 Tray Assembly Multi sheet Bypass Feeder with 2 9 2 1 Pad part of item 1 3 1 Guide Side part of item 1 4 130K83360 1 Size Sensor Assembly Multi sheet Bypass Feeder part of item 1 5 1 Spring Sensor part of item 1 6 1 Link Sensor part of item 1 7 1 Tray Cover part of item 1 8 1 Tray Low part of item 1 9 1 Tray Multi sheet Bypass Feeder part of item 1 ...

Page 324: ...1 302 DocuPrint N4525 Network Laser Printer Service Guide PL 5 1 Tray 1 Frame and Left Cover Fig 1 115 Tray 1 Frame and Left Cover S4525 175 ...

Page 325: ...ing Compression part of item 1 4 2 Bearing In part of item 1 5 2 Bearing part of item 1 6 1 Roller Assembly Pinch part of item 1 7 1 Bracket Pinch part of item 1 8 802K18130 1 Cover Assembly Left Hand Low with 9 10 and 13 9 1 Spring Earth part of item 8 10 1 Cover Left Low part of item 8 11 1 Feeder Assembly 12 130E81311 1 Sensor Tray 2 Take Away 13 1 Pad part of item 8 14 1 Spring Front Electro M...

Page 326: ...1 304 DocuPrint N4525 Network Laser Printer Service Guide PL 5 2 Tray 2 Frame and Left Cover Fig 1 116 Tray 2 Frame and Left Cover S4525 176 ai ...

Page 327: ...Assembly Pinch part of item 3 7 2 Spring Exit part of item 3 8 1 Bracket Pinch part of item 3 9 1 Handle Assembly Left Hand part of item 1 10 1 Support Cover Outboard part of item 1 11 1 Support Cover Inboard part of item 1 12 1 Hinge Cover Outboard 13 1 Hinge Cover Inboard 14 1 Support Cover part of item 1 15 110E93440 1 Switch Interlock 16 1 Chute Assembly Upper 17 2 Spring Electro Magnetic Emis...

Page 328: ...1 306 DocuPrint N4525 Network Laser Printer Service Guide PL 6 1 Registration Fig 1 117 Registration S4525 177 ...

Page 329: ...90 1 Clutch Assembly Registration 2 2 Bearing 3 022K33900 1 Roller Assembly Registration 4 054K17501 1 Chute Assembly Registration with 5 6 5 1 Chute Registration part of item 4 6 1 Eliminator Static part of item 4 7 130E81311 1 Sensor Registration 8 103K80192 1 Assembly Resistor Capacitor R C 99 600K65500 1 Kit Bearing with 2 qty 2 ...

Page 330: ...1 308 DocuPrint N4525 Network Laser Printer Service Guide PL 6 2 Left Upper Cover Assembly Fig 1 118 Left Upper Cover Assembly S4525 178 ...

Page 331: ...ompression part of item 3 7 054K88605 1 Chute Assembly Left Hand with 8 13 part of item 3 8 2 Spring Extension part of item 3 part of item 7 9 1 Roller Assembly Registration Left Hand part of item 3 part of item 7 10 1 Chute Assembly Registration Left Hand with 12 part of item 3 part of item 7 11 1 Guide Paper part of item 3 part of item 7 12 1 Guide Paper part of item 3 part of item 7 part of ite...

Page 332: ...1 310 DocuPrint N4525 Network Laser Printer Service Guide PL 6 3 Transport Chute Assembly Fig 1 119 Transport Chute Assembly S4525 179 ...

Page 333: ...ller part of item 18 5 2 Spring Rod part of item 18 6 2 Rod part of item 18 7 1 Chute Assembly Inlet part of item 18 8 1 Cover Assembly Left Hand 9 1 Pad 10 1 Bracket Left Hand 11 1 Plate Contact Left Hand 12 1 Plate Contact Left Hand 13 1 Frame Left Hand Front 14 1 Frame Left Hand Rear 15 1 Handle Assembly Left Hand 16 1 Shield Bias Transfer Roller part of item 18 17 1 Shield Bias Transfer Roller...

Page 334: ...1 312 DocuPrint N4525 Network Laser Printer Service Guide PL 7 1 Laser Scanner Assembly Fig 1 120 Laser Scanner S4525 180 ...

Page 335: ...Volume 1 Print Engine FRU Parts Lists 1 313 Table 1 131 PL 7 1 Laser Scanner Assembly ID No Sub ID Part Number Qty Name Description 1 062K09874 1 Laser Scanner Assembly ...

Page 336: ...1 314 DocuPrint N4525 Network Laser Printer Service Guide PL 7 2 Xerography and Development Fig 1 121 Xerography and Development S4525 181 ...

Page 337: ... part of item 7 10 1 Plate Contact part of item 7 11 024K92312 1 Rod Assembly Exit 12 1 Spring Rod Exit 13 130K55770 1 Sensor Assembly Toner Empty 14 009E55260 2 Spring Sensor 15 162K55360 1 Harness Assembly with 16 19 16 1 Harness Laser Print Cartridge Memory J454 J606 part of item 15 17 1 Bracket Connector part of item 15 18 2 Spring Compression part of item 15 19 2 Stud Screw part of item 15 20...

Page 338: ...1 316 DocuPrint N4525 Network Laser Printer Service Guide PL 8 1 Fuser Assembly Fig 1 122 Fuser Assembly S4525 182 ...

Page 339: ...10638 1 Fuser Assembly 115 VAC Customer Replaceable Unit with 2 126K10648 1 Fuser Assembly 220 VAC Customer Replaceable Unit with 2 2 2 Holder Nip Clip Note Remove and discard the two Nip Clip Holders when installing a replacement Fuser Assembly 99A 109R00048 1 Kit Maintenance 110 VAC 99B 109R00049 1 Kit Maintenance 220 VAC ...

Page 340: ...1 318 DocuPrint N4525 Network Laser Printer Service Guide PL 9 1Lower Exit Chute Fig 1 123 Lower Exit Chute S4525 183 24 with 16 19 ...

Page 341: ... 1 Spring Pinch part of item 6 part of item 1 9 1 Spring Pinch part of item 6 part of item 1 10 1 Roller Pinch part of item 6 part of item 1 11 1 Roller Pinch part of item 6 part of item 1 12 110K94632 1 Switch Assembly Fuser Exit Sensor part of item 6 part of item 1 13 1 Chute Lower part of item 6 part of item 1 14 1 Eliminator Static part of item 6 part of item 1 15 1 Spring Pinch part of item 6...

Page 342: ...1 320 DocuPrint N4525 Network Laser Printer Service Guide PL 9 2 Offset Roller Assembly Fig 1 124 Offset Roller Assembly S4525 184 ai ...

Page 343: ...set with 5 12 part of PL 9 1 item 1 5 1 Rack Offset part of item 4 part of PL 9 1 item 1 6 1 Bracket Offset part of item 4 part of PL 9 1 item 1 7 1 Sleeve Offset part of item 4 part of PL 9 1 item 1 8 1 Roller Assembly part of item 4 part of PL 9 1 item 1 9 1 Bearing IN part of item 4 part of PL 9 1 item 1 10 1 Bearing OUT part of item 4 part of PL 9 1 item 1 11 1 Shaft Offset part of item 4 part...

Page 344: ...1 322 DocuPrint N4525 Network Laser Printer Service Guide PL 9 3 Upper Exit Chute Assembly Fig 1 125 Upper Exit Chute Assembly S4525 185 ...

Page 345: ... Tie part of item 1 4 1 Spring Plate part of item 1 5 1 Spring Assembly Pinch part of item 1 6 1 Spring Assembly Pinch part of item 1 7 1 Roller Pinch part of item 1 8 1 Roller Pinch part of item 1 9 1 Chute Upper part of item 1 10 1 Guide Paper part of item 1 11 1 Guide Paper part of item 1 12 1 Chute Middle part of item 1 13 1 Gate Exit part of item 1 14 1 Spring Exit part of item 1 15 1 Spring ...

Page 346: ...1 324 DocuPrint N4525 Network Laser Printer Service Guide PL 9 4 Exit Drive Assembly Fig 1 126 Exit Drive Assembly S4525 186 ...

Page 347: ... item 1 5 1 Gear Exit 2 part of item 1 6 1 Bracket Exit Gear 2 part of item 1 7 1 Gear Exit Idler part of item 1 8 1 Spring Exit Ratchet part of item 1 9 1 Gear 25T part of item 1 10 121K84520 2 Gear Clutch Assembly Electric part of item 1 11 2 Shaft Clutch part of item 1 12 2 Bearing part of item 1 13 1 Gear 42T part of item 1 14 1 Gear Clutch Assembly Friction part of item 1 15 1 Gear 42T part o...

Page 348: ...1 326 DocuPrint N4525 Network Laser Printer Service Guide PL 10 1 Main Drive Assembly Fig 1 127 Main Drive Assembly S4525 187 ...

Page 349: ...ble 1 138 PL 10 1 Main Drive Assembly ID No Part Number Qty Name Description 1 007K85362 1 Drive Assembly Main 2 1 Clamp Harness 3 020K98171 1 Flywheel Assembly 4 1 Flange Flywheel 5 1 Support Harness 6 1 Bracket 7 1 Clamp Harness 8 1 Clamp Harness ...

Page 350: ...1 328 DocuPrint N4525 Network Laser Printer Service Guide PL 10 2 Fuser Drive Assembly Fig 1 128 Fuser Drive Assembly S4525 188 1 with 2 9 14 15 ...

Page 351: ...2T part of item 1 3 1 Spring part of item 1 4 1 Bracket Assembly part of item 1 5 1 Bracket part of item 1 6 1 Spring Exit part of item 1 7 1 Bracket part of item 1 8 1 Frame Assembly Exit Rear part of item 1 9 1 Holder part of item 1 10 1 Clamp Harness 1 11 1 Clamp Harness 2 12 1 Clamp Harness 3 13 162K53843 1 Connector Fuser P12 J31 J32 J33 J600 14 1 Connector P104 15 1 Connector P602 ...

Page 352: ...1 330 DocuPrint N4525 Network Laser Printer Service Guide PL 11 1 Power Unit Fig 1 129 Power Unit S4525 189 ...

Page 353: ...Number Qty Name Description 1 105K15540 1 Power Unit 110 VAC with 6 105K15550 1 Power Unit 220 VAC with 6 2 1 Cover Assembly Low Voltage Power Supply 3 1 Harness Assembly AC Main J3 J1 J13 J30 P20 4 1 Connector Outlet 5 1 Bracket Finisher 6 127K21460 1 Fan Power Unit 7 3 Clamp 8 1 Clamp ...

Page 354: ...1 332 DocuPrint N4525 Network Laser Printer Service Guide PL 11 2 High Voltage Power Supply and Input Output Board Fig 1 130 High Voltage Power Supply and Input Output Board S4525 190 ...

Page 355: ... 101K35030 1 Chassis Assembly Input Output Input Output with 5 6 5 1 Board Input Output part of item 4 6 1 Bracket Board part of item 4 7 110E93460 1 Switch Interlock 8 1 Bracket Switch 9 1 Lever Switch 10 1 Support Harness 11 3 Support Board 12 1 Clamp Mini Saddle 13 1 Bracket Assembly AC Driver 14 1 Harness Tray 15 1 Harness Output 16 1 Harness Duplex 17 1 Bracket Connector 18 1 Harness Assembly...

Page 356: ...1 334 DocuPrint N4525 Network Laser Printer Service Guide PL 11 3 System Controller Assembly Fig 1 131 System Controller Assembly S4525 191 ...

Page 357: ...Rear part of item 1 10 1 Cover System Controller 11 1 Rail part of item 1 12 3 Clamp part of item 1 13 160K80181 1 Board System Controller with item 14 121K25530 121K25970 Alt 121K29430 Alt Option Hard Disk Drive 6 Gbyte not shown 733W14695 Option Memory Upgrade 16 MB DIMM not shown 733W14696 Option Memory Upgrade 32 MB DIMM not shown 733W14697 Option Memory Upgrade 64 MB DIMM not shown 160K71940 ...

Page 358: ...1 336 DocuPrint N4525 Network Laser Printer Service Guide PL 11 4 Wiring Harness Fig 1 132 Wiring Harness S4525 192 ...

Page 359: ...140 J141 J142 P607 P240 J241 3 1 Harness Assembly Tray J466 J613A B 4 1 Harness Assembly Bottom J465 J101 J203 J603 5 1 Harness Assembly Duplex J463 J611A B 6 1 Harness Assembly Output J464 J612A B 7 1 Harness Assembly J459 J100 J102 J103 8 1 Harness Assembly J461 J105 9 1 Harness Assembly Interlock Switch J458 J232 J233 FS230 FS231 10 1 Harness Assembly DC Rear J462 P104 P200 P202 P209 P600 P601 ...

Page 360: ...er Cartridge Bias Transfer Roller 15 Feed Rolls three for each paper input tray gloves cleaning cloth and instructions 300 000 prints 109R00048 for 110 V 60 Hz 109R00049 for 220 V 50 Hz Average life of Laser Print Cartridge based on page coverage of 5 Letter or A4 paper The printer displays a message on the control panel when the toner is low and when you need to replace the Laser Print Cartridge ...

Page 361: ... Xerox Image Series Smooth Legal 8 5 x 14 in 20 lbs 75 g m2 003R00083 Rank Xerox Legal 215 x 356 mm 80 g m2 003R901741 LaserPrint 80 A4 Metric Letter 210 x 297 mm 80 g m2 003R91922 Xerox Recycled Letter U S 8 5 x 11 in 20 lbs 75 g m2 003R06296 Steinbeis Recycled A4 Metric Letter 210 x 297 mm 80 g m2 003R91165 80 DP Planet Plus A4 Metric Letter 210 x 297 mm 80 g m2 003R900652 Table 1 147 Xerox Tran...

Page 362: ... puncher Increased paper output capacity Holds up to 3 000 sheets of 80 g m2 20 lbs stock Letter A4 paper Stapling capability Hole punching capability 450S02180 3 hole positions 450S02181 4 hole positions Hard disk drive 5 Gbyte hard drive Store resources fonts forms and macros enables uninterrupted large job collation 097S02364 Memory upgrades Improved system performance Improved processing of co...

Page 363: ...onnectors Contents P J Location Table 1 342 P J Location Map 1 1 347 P J Location Map 2 1 348 P J Location Map 3 1 349 P J Location Map 4 1 350 P J Location Map 5 1 351 P J Location Map 6 1 352 P J Location Map 7 1 353 P J Location Map 8 1 354 Plug Jack Connector Locations ...

Page 364: ... Power Inlet Main Power Switch 12 M4 5 Fuser P J31 P J32 P J33 AC Driver Board FS T3 High Voltage Power Supply P J600 13 M1 8 Finisher AC Connector P J1 AC Distribution Board 20 M7 8 P J4 P J1 AC Distribution Board 30 M8 10 AC Driver Board P J3 AC Distribution Board 31 M8 13 AC Driver Board P J12 Fuser 32 M8 9 AC Driver Board P J12 Fuser 33 M8 12 AC Driver Board P J12 Fuser 34 M8 11 AC Driver Boar...

Page 365: ... 220 M8 7 Low Voltage Power Supply Fan P J411 Print Engine Controller Board 232 M3 8 Interlock Switch 1 FS231 Interlock Switch 2 233 M3 7 Interlock Switch 1 P J458 Input Output Board 234 M3 6 Laser Print EP Cartridge Interlock Switch P J411 Print Engine Controller Board P J407 Laser Scanner LD 237 M1 3 Front Cover Interlock Switch P J411 Print Engine Controller Board 240 M5 9 Tray 2 Feed Clutch P ...

Page 366: ...user Fan 457 M3 3 Input Output Board P J500 High Voltage Power Supply 458 M3 5 Input Output Board P J233 Interlock Switch 1 FS230 Interlock Switch 2 459 M3 21 Input Output Board P J100 Registration Sensor P J102 Tray 1 No Paper Sensor P J103 Tray 1 Paper Level Sensor 460 M3 10 Input Output Board P J205 Main Motor Assembly 461 M3 20 Input Output Board P J105 Tray 1 Size Sensor 462 M3 19 Input Outpu...

Page 367: ...roller Board 515 M3 31 High Voltage Power Supply R2 P J468 Input Output Board 600 M4 9 P J12 Fuser P J462 Input Output Board 601 M4 10 P J109 Face Up Exit Sensor P J133 Full Stack Sensor P J210 Exit Gate Solenoid P J462 Input Output Board 602 M4 12 P J218 Inverter Clockwise Clutch P J219 Inverter Counter Clockwise Clutch P J462 Input Output Board 603 M2 4 P J604 Multi sheet Bypass Feeder P J465 In...

Page 368: ...e Roller High Voltage Power Supply DTS M7 1 Detach Saw High Voltage Power Supply FS230 M5 3 Interlock Switch 2 P J458 Input Output Board FS231 M5 2 Interlock Switch 2 P J232 Interlock Switch 1 FS235 M1 2 P J237 P J411 Print Engine Controller Board FS236 M1 1 P J237 P J411 Print Engine Controller Board Table 1 150 Plug Jack Location cont d P J Map Number Connected to Other end connected to ...

Page 369: ...Volume 1 Print Engine P J Connector Locations 1 347 P J Location Map 1 Fig 1 133 P J Location Map 1 S4525 148 ...

Page 370: ...1 348 DocuPrint N4525 Network Laser Printer Service Guide P J Location Map 2 Fig 1 134 P J Location Map 2 S4525 149 ...

Page 371: ...Volume 1 Print Engine P J Connector Locations 1 349 P J Location Map 3 Fig 1 135 P J Location Map 3 S4535 150 ai ...

Page 372: ...1 350 DocuPrint N4525 Network Laser Printer Service Guide P J Location Map 4 Fig 1 136 P J Location Map 4 S4525 151 ...

Page 373: ...Volume 1 Print Engine P J Connector Locations 1 351 P J Location Map 5 Fig 1 137 P J Location Map 5 S4525 152 ...

Page 374: ...1 352 DocuPrint N4525 Network Laser Printer Service Guide P J Location Map 6 Fig 1 138 P J Location Map 6 S4525 153A ...

Page 375: ...Volume 1 Print Engine P J Connector Locations 1 353 P J Location Map 7 Fig 1 139 P J Location Map 7 S4525 154 ...

Page 376: ...1 354 DocuPrint N4525 Network Laser Printer Service Guide P J Location Map 8 Fig 1 140 P J Location Map 8 S4525 155 ...

Page 377: ...k XX is a male connector plug of P J xx is a female connector jack of P J xx Component name FUSER ASSY Relay Component or sub assembly within a larger assembly Wire connection Frame ground wire fastened with a screw to the printer frame FG or Frame ground Signal ground SG RTN Signal return HEAT Wire with signal name and direction of signal flow In some cases such as a signal name of 5VDC the signa...

Page 378: ...nner timing LVPS Low Voltage Power Supply SW Switch MBF Multi sheet Bypass Feeder TA Take Away MOT Motor CONTROL PANEL SYSTEM CONTROLLER FAN M LASER SCAN MOTOR START OF SCAN SENSOR LASER SCANNER DRIVE INTLK SW1 LASER FRONT CARTRIDGE SW2 FAN ELECTRIC FRONT INTERLOCK P J 220 P J404 P J411 P J 237 P J 106 P J 240 P J P J 207 408 P J 234 P J 407 P J234 P J430 P J409 P J 417 FUSER FAN XERO CRU TONER EM...

Page 379: ...LTER HOT 1 NUT 1 GFI HOT 2 NUT 2 P J 9 HOT SQ SSR HOT 2 NUT 2 HOT 1 NUT 1 HOT 1 NUT 1 P J 4 P J 1 P J 13 P J 20 LVPS B3 FINISHER AC CONN P J 4 P J 3 P J 504 P J 502 P J 450 P J 505 P J 400 P J451 BIAS FG FUSER P J 12 P J 462 P J 603 P J 604 P J 203 P J 101 M LIFTUP1 MOT TA ROLLER 2 SNR MBF FEED CL MBF SIZE SNR MBF NOP SNR PRINT ENGINE CONTROLLER BOARD INPUT OUTPUT BOARD P J465 P J208 P J107 P J108...

Page 380: ...358 DocuPrint N4525 Network Laser Printer Blank Page ...

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