Docuprint n4525 Service Book1

DOCUPRINT® N4525
NETWORK LASER PRINTER

Ser vice Quick Refe rence Gu ide
Volu me 1 — Pr int E ng ine
Warning
The following servicing instructions are for
use by qualified service personnel only. To
avoid 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
Copyright 2001 Xerox Corporation. Printed in the United States of America. All
rights reserved.
Contents 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
Users safety summary
Terms in manual: Various terms are used throughout this manual to either
provide additional information on a specific topic or to warn of possible danger
that might be present during a procedure or action. Be aware of all symbols and
terms when they are used, and always read NOTE, CAUTION and WARNING
messages.
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 on the results achieved
through a previous action.
CAUTION: A CAUTION indicates an operating or maintenance
procedure, practice or condition that, if not strictly
observed, could result in damage to, or destruction of,
equipment.
WARNING: A WARNING indicates an operating, or maintenance
procedure, practice or condition that, if not strictly
observed, could result in injury or loss of life.
Terms on product:
CAUTION: A personal injury hazard exists that may not be apparent.

For example, a panel may cover the hazardous area.
DANGER: A personal injury hazard exists in the area where you see
the sign.
Power source: For 110 VAC printers, Do not apply more than 130 volts RMS
between the supply conductors or between either supply conductor and ground.
Use only the specified power cord and connector. For 220 VAC printers, do not
apply more than 250 volts RMS between the supply conductors or between
either supply conductor and ground. Use only the specified power cord and
connector. Refer to a qualified service technician for 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.
Power Supply and Electrical Components: Before starting any service
procedure, switch off the printer power and unplug the power cord from the
wall outlet. If you must service the printer with power applied, be aware of the
potential for electrical shock.
Do not touch any electrical component unless you are instructed to do so by a
service procedure.
S4525-01
Mechanical components: Manually rotate drive assemblies to inspect

sprockets and gears.
Do not try to manually rotate or manually stop the drive assemblies while any
printer motor is running
S4525-02
Laser Components
WARNING: This printer generates a laser beam as part of the printing process.
The laser beam is a concentrated narrow beam of light that
produces extreme heat at its focal point. 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.
Do not disassemble the Raster Output Scanner Assembly (laser
scanner) or any laser component that displays a Laser Warning Sticker.
Use caution when you are working around the Raster Output Scanner
Assembly or when you are performing laser related troubleshooting or
repair procedures.
Never place a mirror or a reflective tool or object in the laser beam path.
Do not disassemble the printer in such a way that the laser beam can
exit the print engine during a print cycle.
Fuser Components
WARNING: This printer uses heat to fuse the toner image to a sheet of paper.
The Fuser Assembly is very hot. Switch off printer power and wait at least 30
minutes for the Fuser to cool before you attempt to service the Fuser Assembly or
adjacent components.
Safety Components: Make sure covers and panel are in place and that all
interlock switches are all functioning correctly after you have completed a printer
service call. If you bypass, or cheat, an interlock switch during a service call, use
extreme caution when working on or around the printer.
Warning Labels: Throughout the printer, warning labels are displayed on

potentially dangerous components. When you service the printer, check to make
certain that all warning labels are in place.
Most importantly, read 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 product: Disconnect the power plug by pulling the plug, not the cord.
Disconnect the power plug if the power cord or plug is frayed or otherwise
damaged,
Or if any liquid or foreign material is spilled into the case,
Or if the printer is exposed to any excess moisture,
Or if the printer is dropped or damaged,
Or if you suspect that the product needs servicing or repair,
And whenever you clean the product.
Ground the product: Plug the three-wire power cord (with grounding prong)
into grounded AC outlets only. If necessary, contact a licensed electrician to
install a properly grounded outlet.
Service Safety Summary
For qualified service personnel only: Refer also to the preceding Users Safety
Summary.
Do not service alone: Do not perform internal service or adjustment of this

product unless another person capable of rendering first aid or resuscitation is
present.
Use care when servicing with power: Dangerous voltages may exist at several
points in this product. To avoid personal injury, do not touch exposed
connections and components while power is on.
Disconnect power before removing the power supply shield, soldering or

replacing components.
Do not wear jewelry: Remove jewelry prior to servicing. Rings, necklaces and
other metallic objects could come into contact with dangerous voltages and
currents.
Power source: This product is intended to operate from a power source that will
not apply more then 250 volts rms between the supply conductors or between
wither supply conductor and ground. A protective ground 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 a class of
laser product that does not emit hazardous laser radiation; this is possible only
because the laser beam is totally enclosed during all modes of customer
operation.
The laser and output of the laser scanner unit produces a beam that, if looked
into, could cause eye damage. Service procedures must be followed exactly as
written without change.
When servicing the machine or laser module, follow the procedures specified in
the manual and there will be no hazards from the laser.
Laser (FDA): Any laser label visible to service must be reproduced in the service
manual with location shown or indicated. Safe working procedures and clear
warnings concerning precautions to avoid possible exposure must also be
included.
The Laser contained in the DocuPrint® N4525 Network 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

Federal Communications Commission Compliance
This equipment has been tested and found to comply with the limits set for a
Class B digital device, as stated in Part 15 of the FCC rules. These limits are
designed to provide reasonable protection against harmful interference in a
commercial installation. This equipment generates, uses, and may radiate radio
frequency energy. If not installed and used in accordance with the instructions
provided, this equipment may cause disruptive interference to nearby radio and
television communications. Even if the equipment is installed according to the
instructions, there is no guarantee that interference will not occur in a particular
installation. If this equipment does cause disruptive interference to nearby radio
and television reception, switch the equipment 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 antenna.
Increase the separation between the equipment and the radio/television

receiver.
Connect the equipment to an AC outlet that is not on the same circuit as the
radio/television receiver.
If the previous solutions fail to bring results, you should consult either your
equipment dealer or an experienced radio/television technician.
For more information on interference, refer to the Federal Communications
Commission’s booklet “How to Identify and Resolve Radio-TV Interference
Problems”. This booklet is available from the U.S. Government Printing Office,
Washington D.C. 20402, Stock No. 004-000-00345-4.
Canadian Notice
This digital apparatus does not exceed the Class B limits for radio noise
emissions from digital apparatus as described in the radio interference
regulations of the Canadian Department of Communications.
NOTE: Installation of the Finisher and/or the Token Ring Interface results in a
classification change to Class A.
Avis Canadien
Cet appareil numerique est conforme aux limites 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 104ß 984 funkenstört ist. Der Deutschen
Bundespost wurde das Inverkehrbringen dieses Gertëes angqeigt und die
Berechtigung zur berprufung der Serie auf Einhaltung der Bestimmungen
eingeräumt.
Manual Organization
This Service Quick Reference Guide (QRG) is divided into two volumes.
Book I
Book I of the QRG contains technical information for the N4525 Print Engine
(Volume 1), as well as complete Error Code and Repair Analysis Procedures
(RAPs) for the Print Engine and all options for the printer. Information specific to
each option is repeated in that option’s volume.
NOTE: All pages, figures, tables, RAPs, RRPs (Remove and Replace Procedures)
and Parts List numbers are preceded by a “dash” number, indicating the volume
number for that module according to the following legend
Volume Module
1 Print Engine
2 High Capacity Feeder
3 Duplex Unit
4 Envelope Feeder
5 Face Up Bin
6 Finisher
Volume 1 - Print Engine

Frontis - Introductory, Safety and Regulatory Information
This is the section you are reading at this moment. It contains important safety
information regarding technical components, regulatory agency requirements
and information about this manual, 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 Error Codes and Messages for conditions the user
may not be aware of, or conditions that exist which may not yet be made
apparent by printer performance or by image quality. Also contained in this
section is a vital error table which references Repair Analysis Procedures (RAPs)
for the Printer and all options, and referring the reader to appropriate sections in
each option manual supplement. In addition, there is additional, but valuable,
information on how to use the Repair Analysis Procedures for the Print Engine
and the options.
Section 3 - Troubleshooting
This section specifically discusses the most common problems (using additional
Repair Analysis Procedures) encountered in the following areas:
Printer Performance Problems
Image Quality Problems
Electrical Interference Problems.
Section 4 - Diagnostics, Test Prints, Service Tests & NVRAM Adjustments

This section provides a wide variety of test prints to assist in evaluating and/or
troubleshooting the printer and options. Also provided are many accessed
diagnostic tests and adjustments to assist in analyzing, adjusting registration and
fine tuning the printer and options performance.
Section 5 - Cleaning and Maintenance

A quick guide to routine cleaning and maintenance for the printer and options.
Section 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 7 - FRU List

This is the parts list for the Field Replaceable Units. This section contains
exploded views of the FRUs as well as part numbers for items available as FRUs.
Section 8 - Plug/Jack Connector Locations

This section contains a connector table and several locator illustrations to aid in
identifying all electrical connections within the printer and options.
Section 9 - Wiring Diagram

The Master Wiring Diagram is contained in this section. Please refer to the CD
version of the service manual for additional diagrams.
Book II
Book II contains technical information for all options for the N4525 Network
Laser Printer. Information for each option is contained in a separate volume as
see below.
Volume 2 - High Capacity Feeder (HCF)
This section contains information specific to the HCF 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 “2-”.
Volume 3 - Duplex Unit (DUP)
This section contains information specific to the DUP with General Information,
Error Codes, RAPs, RRPs, Parts Lists, Plug/Jack Locators and Wiring information.
Volume 4 - Envelope Feeder (ENV)
This section contains information specific to the ENV with General Information,
Volume 5 - Face Up Bin (FUB)
This section contains information specific to the FUT with General Information,
Volume 6 - Finisher (FIN)
This section contains information specific to the FIN with General Information,
Table of Contents
Table of Contents .................................................................................................................. 1 - i
List of Figures........................................................................................................................ 1 - iii
List of Tables ........................................................................................................................ 1 - vii
General Information 1-1
DocuPrint® N4525 Network Laser Printer Overview ............................................... 1 - 2
Parts of the Printer ............................................................................................................... 1 - 3
Control Panel......................................................................................................................... 1 - 5
Rear Panel .............................................................................................................................. 1 - 7
Print Engine Assemblies..................................................................................................... 1 - 8
Paper Path ........................................................................................................................... 1 - 12
About This Manual............................................................................................................ 1 - 13
General Specifications ..................................................................................................... 1 - 14
RAM and printer capabilities.......................................................................................... 1 - 14
Physical Dimensions......................................................................................................... 1 - 15
Electrical Specifications ................................................................................................... 1 - 16
Environmental Specifications ........................................................................................ 1 - 16
Regulatory Specifications ................................................................................................ 1 - 16
Functional Specifications ................................................................................................ 1 - 17
Printing Speeds: First Sheet Out................................................................................... 1 - 18
Printing Speeds: Continuous Printing After the First Sheet Out ......................... 1 - 18
Paper Input Devices.......................................................................................................... 1 - 19
Paper Output Devices ...................................................................................................... 1 - 21
Printing Media Specifications ........................................................................................ 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: ............................... 1 - 34
Repair Analysis Procedures (RAP)................................................................................ 1 - 34
System Controller Error Codes ...................................................................................... 1 - 44
Troubleshooting 1 - 103
Printer Performance Problems Repair Analysis Procedure (RAP) Table ........ 1 - 103
Image Quality Problems Repair Analysis Procedure (RAP) Table.................... 1 - 104
Electrical Interference Repair Analysis Procedure (RAP) Table......................... 1 - 104
Printer Performance Problems.................................................................................... 1 - 105
Image Quality Problems................................................................................................ 1 - 113
Electrical Interference Problems ................................................................................. 1 - 147
Diagnostics, Test Prints, Service Tests and NVRAM Adjustments 1 - 149
Maintenance Reset Procedure .................................................................................... 1 - 151
Table of Contents i
Test Prints .......................................................................................................................... 1 - 152
System Controller Test Prints ...................................................................................... 1 - 152
Print Engine Controller Board Test Prints................................................................ 1 - 154
Print Engine Controller Test Prints............................................................................. 1 - 155
Analyzing the Test Print................................................................................................. 1 - 157
NVRAM Counters Menu ................................................................................................ 1 - 158
NVRAM Adjustment Procedures................................................................................. 1 - 159
Tray Size Test .................................................................................................................... 1 - 162
Checking Lead Edge Registration............................................................................... 1 - 163
Service Tests ..................................................................................................................... 1 - 166
Scheduled Maintenance ............................................................................................... 1 - 177
Recommended Tools..................................................................................................... 1 - 177
Maintenance and Cleaning 1 - 177
Cleaning (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 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
Master Wiring Diagram 1 - 355
Wiring Diagrams, Signal Information ........................................................................ 1 - 355
Master Connection and Wiring Diagram.................................................................. 1 - 356
Master Connection and Wiring Diagram, continued............................................ 1 - 357
ii DocuPrint N4525 Network Laser Printer - Service Guide

List of Figures
Fig 1-1 Print Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
Fig 1-2 Parts of the Printer (Left/Front View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Fig 1-3 Parts of the Printer (Right/Rear View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Fig 1-4 Console Configuration with Options: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
Fig 1-5 Optional Finisher Components (Stapler/Hole Puncher): . . . . . . . . . . . . . . . 1 - 4
Fig 1-6 Control Panel with Icons and Text. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Fig 1-7 Control Panel with Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Fig 1-8 Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
Fig 1-9 Print Engine Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
Fig 1-10 Print Engine Assemblies, continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9
Fig 1-11 Print Engine Assemblies, continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
Fig 1-12 Print Engine Assemblies, continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
Fig 1-13 Print Engine Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12
Fig 1-14 Service Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 30
Fig 1-15 Light (Undertoned) Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 113
Fig 1-16 Blank Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Fig 1-29 Unfused Image or Image Easily Rubs Off of Page . . . . . . . . . . . . . . . . . . 1 - 141
Fig 1-30 Repetitive Marks on Each Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 142
Fig 1-31 Lead Edge Registration Is Not Correct . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 143
Fig 1-32 Side-to-Side Registration Is Not Correct . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 145
Fig 1-33 Lead Edge Registration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 163
Fig 1-34 Side Edge Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 164
Fig 1-35 Fuser Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 185
Fig 1-36 Top Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 186
Fig 1-37 Front Cover Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 187
Fig 1-38 Front Inner Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 188
Fig 1-39 Rear Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 189
Fig 1-40 Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 190
Service Guide iii

Fig 1-41 Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 191
Fig 1-42 Rear Lower Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 192
Fig 1-43 Tray 1 Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 193
Fig 1-44 Tray 1 Feed Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 194
Fig 1-45 Feeder, Pick and Retard Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 196
Fig 1-46 Tray 1 Take-Away Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 198
Fig 1-47 Tray 1 Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 200
Fig 1-48 Tray 1 Retard Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 202
Fig 1-49 Tray 1 & Tray 2 Front chute Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 203
Fig 1-50 Tray 1 & Tray 2 Paper Size Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 204
Fig 1-51 Tray 2 Feed Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 205
Fig 1-52 Tray 2 Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 206
Fig 1-53 Tray 2 Take-Away Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 208
Fig 1-54 Tray 2 Retard Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 210
Fig 1-55 Mult-Sheet Bypass Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 211
Fig 1-56 Multi-sheet Bypass Feeder Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . 1 - 212
Fig 1-57 Multi-sheet Bypass Feeder Support Assembly . . . . . . . . . . . . . . . . . . . . . 1 - 214
Fig 1-58 Multi-sheet Bypass Feeder Size Sensor Assembly . . . . . . . . . . . . . . . . . . 1 - 216
Fig 1-59 Multi-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 Cover Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 228
Fig 1-67 Registration Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 230
Fig 1-68 Left Upper Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 232
Fig 1-69 Left Chute Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 234
Fig 1-70 Registration Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 235
Fig 1-71 Registration Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 236
Fig 1-72 Laser Scanner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 237
Fig 1-73 Toner Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 238
Fig 1-74 Laser Print Cartridge Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 239
Fig 1-75 Fuser Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 240
Fig 1-76 Offset/Exit Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 242
Fig 1-77 Exit Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 243
Fig 1-78 Exit Gate Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 244
Fig 1-79 Offset Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 245
Fig 1-80 Full Stack Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 246
Fig 1-81 Offset Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 247
Fig 1-82 Lower Chute Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 248
Fig 1-83 Upper Chute Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 249
iv DocuPrint N4525 Network Laser Printer

Fig 1-84 Exit Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 250
Fig 1-85 Face Up Exit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 251
Fig 1-86 Inverter Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 252
Fig 1-87 Flywheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 253
Fig 1-88 Main Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 254
Fig 1-89 Low Voltage Power Supply Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 256
Fig 1-90 AC Driver Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 258
Fig 1-91 High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 259
Fig 1-92 Input/Output Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 260
Fig 1-93 Left Cover Interlock Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 261
Fig 1-94 Print Engine Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 262
Fig 1-95 System Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 264
Fig 1-96 Legend: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 265
Fig 1-97 Top Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 266
Fig 1-98 Font Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 268
Fig 1-99 Rear, Left, and Right Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 270
Fig 1-100 Tray Unit - Paper Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 272
Fig 1-101 Tray Unit - End Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 274
Fig 1-102 Tray Unit - Paper Stack (Custom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 276
Fig 1-103 Tray Unit - End Guide (Custom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 - 296
Fig 1-113 Upper Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 298
Fig 1-114 Multi-sheet Bypass Feeder Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . 1 - 300
Fig 1-115 Tray 1 Frame and Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 302
Fig 1-116 Tray 2 Frame and Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 304
Fig 1-117 Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 306
Fig 1-118 Left Upper Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 308
Fig 1-119 Transport Chute Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 310
Fig 1-120 Laser Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 312
Fig 1-121 Xerography and Development. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 314
Fig 1-122 Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 316
Fig 1-123 Lower Exit Chute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 318
Fig 1-124 Offset Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 320
Fig 1-125 Upper Exit Chute Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 322
Fig 1-126 Exit Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 324
Service Guide v
Fig 1-127 Main Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 326
Fig 1-128 Fuser Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 328
Fig 1-129 Power Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 330
Fig 1-130 High Voltage Power Supply and Input/Output Board . . . . . . . . . . . . . 1 - 332
Fig 1-131 System Controller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 334
Fig 1-132 Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 336
Fig 1-133 P/J Location Map 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 347
Fig 1-141 Master Connection and Wiring Diagram 1 of 2 . . . . . . . . . . . . . . . . . . . 1 - 356
Fig 1-142 Master Connection and Wiring Diagram 2 of 2 . . . . . . . . . . . . . . . . . . . 1 - 357
vi DocuPrint N4525 Network Laser Printer

List of Tables
Table 1-1 Memory Expansion Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 14
Table 1-2 Physical Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 15
Table 1-3 Printer Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 15
Table 1-4 Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 16
Table 1-5 Environmental Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 16
Table 1-6 Regulatory Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 16
Table 1-7 Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 17
Table 1-8 Printing Speeds: First Sheet Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 18
Table 1-9 Printing Speeds: Continuous Printing After the First Sheet Out . . . . . . . 1 - 18
Table 1-10 Tray 1 and 2 Paper Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 19
Table 1-11 Multi-sheet Bypass Feeder Paper Sizes . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 19
Table 1-12 High Capacity Feeder Tray 3 Paper Sizes . . . . . . . . . . . . . . . . . . . . . . . . 1 - 20
Table 1-13 High Capacity Feeder Tray 4 and Tray 5 Paper Sizes . . . . . . . . . . . . . . 1 - 20
Table 1-14 Envelope Feeder Envelope Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 20
Table 1-15 Offset Unit Paper Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 21
Table 1-16 Special Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 22
Table 1-17 Paper Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 23
Table 1-18 Capacities of Input Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 23
Table 1-19 Supported Media and Media Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 24
Table 1-20 Custom Paper Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 25
Table 1-21 Xerox Professional Printing Papers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 26
Table 1-22 Xerox Transparency Film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 26
Table 1-23 Xerox Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 26
Table 1-24 Printer Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 1-36 Error Code U4-1 Fuser Failure Power Off/On . . . . . . . . . . . . . . . . . . . . 1 - 54
Table 1-41 Error Code U4-9 Fan Failure Power Off/On. . . . . . . . . . . . . . . . . . . . . . 1 - 59
Table 1-42 Error Code U6-2 IOT Memory Fail Power Off/On . . . . . . . . . . . . . . . . . 1 - 60
Table 1-43 Error Code U6-3 IOT NVM Fail Power Off/On . . . . . . . . . . . . . . . . . . . . 1 - 61
Table 1-44 Error Code U6-4 IOT NVM Fail Power Off/On . . . . . . . . . . . . . . . . . . . . 1 - 62
Table 1-45 Error Code U6-5 IOT ASIC Fail Power Off/On . . . . . . . . . . . . . . . . . . . . 1 - 63
Table 1-46 Error Code E1-1 Paper Jam Clear Area A . . . . . . . . . . . . . . . . . . . . . . . . 1 - 64
Service Guide vii

Table 1-56 Error Code E5-1 Close Door A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 79
Table 1-57 Error Code E5-2 Close Door B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 80
Table 1-58 Error Code C1-3 Clear Area A Reset Tray 1 . . . . . . . . . . . . . . . . . . . . . . 1 - 81
Table 1-59 Error Code C2-2 Clear Area A,B Reset Tray 2. . . . . . . . . . . . . . . . . . . . . 1 - 83
Table 1-60 Error Code C2-3 Paper Jam Clear Area A . . . . . . . . . . . . . . . . . . . . . . . . 1 - 85
Table 1-61 Error Code C8-2 Paper Jam Clear Areas A,B . . . . . . . . . . . . . . . . . . . . . 1 - 86
Table 1-62 Error Code C9-2 Paper Jam Reset ENV/Bypass . . . . . . . . . . . . . . . . . . . 1 - 87
Table 1-63 Error Code C9-3 Paper Jam Reset ENV/Bypass . . . . . . . . . . . . . . . . . . . 1 - 89
Table 1-64 Error Code H1-1 Insert Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 91
Table 1-65 Error Code H1-2 Insert Tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 92
Table 1-66 Error Code H2-7 Duplex Unit Fail Power Off/On . . . . . . . . . . . . . . . . . 1 - 93
Table 1-67 Error Code H4-1 Load Tray 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 94
Table 1-68 Error 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 J8-5 CRUM Failure Replace CRU . . . . . . . . . . . . . . . . . . . . 1 - 102
Table 1-76 Print Performance Problems RAP Table . . . . . . . . . . . . . . . . . . . . . . . . 1 - 103
Table 1-77 Image Quality Problems RAP Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 104
Table 1-78 Electrical Interference RAP Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 104
Table 1-79 3.1 Inoperative Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 105
Table 1-80 Erratic Printer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 107
Table 1-81 Blank, Erratic, or Inoperative Control Panel . . . . . . . . . . . . . . . . . . . . . 1 - 109
Table 1-82 Printer Does Not Display and Error Code When Out of Toner. . . . . . 1 - 110
Table 1-83 Printer Does Not Offset Paper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 111
Table 1-84 Light (Undertoned) Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 113
Table 1-85 Blank Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 115
Table 1-86 Black Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 117
Table 1-87 Vertical Band Deletions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 119
Table 1-88 Horizontal Band Deletions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 121
Table 1-89 Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 123
Table 1-90 Horizontal Streaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 125
Table 1-91 Spot Deletions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 127
Table 1-92 Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 129
Table 1-93 Residual Image or Ghosting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 131
Table 1-94 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 133
Table 1-95 Toner on Back of Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 135
Table 1-96 Skewed Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 137
Table 1-97 Damaged Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 139
1-viii DocuPrint N4525 Network Laser Printer

Table 1-98 Unfused Image or Image Easily Rubs Off of Page. . . . . . . . . . . . . . . . 1 - 141
Table 1-99 Repetitive Marks on Each Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 142
Table 1-100 Lead Edge Registration Is Not Correct . . . . . . . . . . . . . . . . . . . . . . . . 1 - 143
Table 1-101 Side-to-Side Registration Is Not Correct. . . . . . . . . . . . . . . . . . . . . . . 1 - 145
Table 1-102 Electrical Interference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 147
Table 1-103 Print Engine Controller Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 155
Table 1-104 NVRAM Adjustment Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 159
Table 1-105 Tray Size Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 162
Table 1-106 Component Control Input Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 166
Table 1-107 Component Control Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 172
Table 1-108 PL 1.1 Top Cover Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 267
Table 1-109 PL 1.2 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 269
Table 1-110 PL 1.3 Rear, Left and Right Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 271
Table 1-111 PL 2.1 Tray Unit - Paper Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 273
Table 1-112 PL 2.2 Tray Unit - End Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 275
Table 1-113 PL 2.3 Tray Unit - Paper Stack (Custom) . . . . . . . . . . . . . . . . . . . . . . 1 - 277
Table 1-114 PL 2.4 Tray Unit - End Guide (Custom) . . . . . . . . . . . . . . . . . . . . . . . 1 - 279
Table 1-115 PL 3.1 Tray Interface - Tray 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 281
Table 1-116 PL 3.2 Paper Pick Up - Tray 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 283
Table 1-117 PL 3.3 Retard and Take Away Assembly - Tray 1 . . . . . . . . . . . . . . . 1 - 285
Table 1-118 PL 3.4 Tray Interface - Tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 287
Table 1-119 PL 3.5 Paper Pick Up Assembly - Tray 2. . . . . . . . . . . . . . . . . . . . . . . 1 - 289
Table 1-120 PL 3.6 Retard and Take Away Assembly - Tray 2 . . . . . . . . . . . . . . . 1 - 291
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 . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 305
Table 1-128 PL 6.1 Registration section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 307
Table 1-129 PL 6.2 Upper Left Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 309
Table 1-130 PL 6.3 Transport Chute Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 311
Table 1-131 PL 7.1 Laser Scanner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 313
Table 1-132 PL 7.2 Xerography and Development section . . . . . . . . . . . . . . . . . . 1 - 315
Table 1-133 PL 8.1 Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 317
Table 1-134 PL 9.1 Lower Exit Chute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 319
Table 1-135 PL 9.2 Offset Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 321
Table 1-136 PL 9.3 Upper Exit Chute Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 323
Table 1-137 PL 9.4 Exit Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 325
Table 1-138 PL 10.1 Main Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 327
Table 1-139 PL 10.2 Fuser Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 329
Table 1-140 PL 11.1 Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 331
Table 1-141 PL 11. 2 High Voltage Power Supply and I/O Board . . . . . . . . . . . . 1 - 333
Table 1-142 PL 11.3 System Controller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 335
Table 1-143 PL 11.4 Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 337
Table 1-144 Customer-Replaceable Consumables . . . . . . . . . . . . . . . . . . . . . . . . 1 - 338
Table 1-145 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 338
Table 1-146 Xerox Professional Printing Paper. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 339
Table 1-147 Xerox Transparency Film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 339
Service Guide ix
Table 1-148 Xerox Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 339
Table 1-149 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 340
Table 1-150 Plug/Jack Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 342
1-x DocuPrint N4525 Network Laser Printer

General Information
The DocuPrint 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.
S4525-00
Fig 1-1 Print Engine
Volume 1 / Print Engine - General Information 1-1

DocuPrint® N4525 Network Laser Printer Overview
The DocuPrint® N4525 Network Laser Printer is a 45 page per minute
monochrome, 600 dots per inch laser printer that uses a data- modulated laser
beam, standard dry-ink xerographic imaging processes, and heat and pressure
fusing to place a computer generated image onto the surface of a sheet of plain
paper.
The printer uses a semiconductor laser in the Laser Scanner to generate a 5
milliwatt infrared laser beam. Image data sent from the host computer
modulates the beam, creating a latent image on the surface of the electrically
charged xerographic drum.
The printer requires 110VAC @ 60HZ (or, optionally, 220VAC @
50HZ~60HZ) using approximately 900 watts during an average print cycle.
Two power supplies within the printer convert AC line voltage to the various
AC and DC voltages that are needed for printer operation.
Safety circuits within the printer remove power to the printer whenever 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 Printer comes standard with two 500
sheet paper feeders, a 50 sheet Multi-sheet Bypass Feeder, and an offset output
unit. Optional paper feeders are available.
The DocuPrint® N4525 Network Laser has one Customer Replaceable
Consumable (CRC), the Laser Print (EP) Cartridge that must be replaced when
depleted. The printer displays a warning message (“Replace Toner Cartridge”)
when it detects the toner getting low. When the printer detects the toner level is
empty, stops printing until the Laser Print (EP) Cartridge is replaced.
The printer will advise when it is time to install a Maintenance Kit:
At 280,000 page count the printer will display a message informing users of the
impending need to install the Maintenance Kit.
At 300,000 page count the printer will instruct the user to “Install Maintenance
Kit.”
1-2 DocuPrint N4525 Network Laser Printer - Service Guide

Parts of the Printer
The printer contains the following major components:
Front view Rear view
1. Door A 10. Ground-Fault-Interrupt switch
2. Multi-sheet Bypass Feeder 11. Finisher power connection
3. Door B 12. Hand grips
4. Face-down output bin 13. Controller board with host/network interface
5. Power switch ports
6. Control panel 14. Power cord receptacle
7. Front cover 15. Connectors for optional 2,500-Sheet
8. Tray 1 Feeder, Finisher, and Duplex Module
9. Tray 2
4
5
6
1
7
8
2
9
3
4525-01
Fig 1-2 Parts of the Printer (Left/Front View)
13
10
14
11
15
12 4525-02
Fig 1-3 Parts of the Printer (Right/Rear View)

1. Face-up output bin
2. Duplex Module
3. Envelope Feeder 1
4. High Capacity Feeder (with
Trays 3, 4, and 5)
2
4525-03
Fig 1-4 Console Configuration with Options:
1. Transport cover
2. Paper transport
3. Finisher access door
4. Finisher output bin 1
5. Punch bin
2 4
4525-49
Fig 1-5 Optional Finisher Components (Stapler/Hole Puncher):

Control Panel
The Xerox DocuPrint N4525 control panel:
Displays printer status and job in process.
Provides the means to change printer settings.
Allows you to print 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 3
2 4525-111/eng
Fig 1-6 Control Panel with Icons and Text

1. Four indicator lights
2. A two-line display screen (16 characters per line)
3. Eight control panel keys
1 3
2 4525-112/symb
Fig 1-7 Control Panel with Icons

Display Screen
The Control Panel’s display screen:
Provides access to a hierarchy of menus to configure and control the printer.
Access the menus by pressing the Menu keys (labeled 1 or 5). For more
information on the menu structure, refer to the Advanced Features and
Troubleshooting 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:
Ready
The printer is processing data:
Processing...
The printer is waiting for more data:
Waiting...
The printer is low on a supply (in this case, the toner is low and needs to be
replaced soon):
Toner Low
A tray is empty (in this case, Tray 2 is empty and no longer being used to print):
Tray 2 Empty
There is a problem (in this case, a paper jam in area A):
Paper Jam
Clear Area A

Rear Panel
Connectors
The rear panel of the printer features the host interface connectors:
Bi-directional parallel (high density connector).
Twisted Pair 10base2 Ethernet connector.
Standard USB Port.
Serial Port
Ethernet Port USB Port Parallel Port

LED Windows Network Card S4525-006
Fig 1-8 Rear Panel

Print Engine Assemblies
Print Engine Controller Board AC Driver Board
Main Switch System Controller Board
Noise Filter
Main Drive Unit
Laser
Scanner
Ground Fault Input/Output
Interrupter (I/O) Board
Low Voltage Option Connectors

Power Supply
Boards High Voltage High Voltage
Power Supply Power Supply
AC Plug Connector (HVPS) R2 (HVPS) Board
Low Voltage Transformer
Power Supply Fan (220V Printer Only) S4525-002
Fig 1-9 Print Engine Assemblies

Host Computer Parallel
Interface Cable
System Controller Board
Network Cable
Print Engine
Controller Board
Fuser
Laser Print (EP) Cartridge
Offset Exit Assembly S4525-003
Fig 1-10 Print Engine Assemblies, continued

Full Stack Sensor
Face Up Exit Sensor
Main Drive Assembly
Front Cover Interlock Offset Motor
Lazer Print (EP)

Cartridge Interlock Lift Motor Tray 1
Lift Motor Tray 2
Tray 1 Size Sensor S4525-004

Tray 2 Size Sensor
Tray 2 No Paper Sensor
Tray 2 Level Sensor
Tray 3 Take Away Sensor

Options Connector Panel Tray 2 LH Interlock
Tray 1 Level
Sensor
Tray 1 No Paper
Sensor
Registration
Sensor
Multi-sheet Bypass Feeder No Paper Sensor

Tray 2 Take Away Sensor
S4525-005

Paper Path
Offset Unit
Face Up Exit Sensor Exit Gate Stack Full Sensor
Exit Roller
Offset Roller Output Tray
Fuser Exit Sensor

Fuser
Pressure Roller Heat Roller
Laser Print
Bias Transfer Roller BTR Drum (EP) Cartridge
Pinch Roller Registration Roller

Registration Sensor
Feed Roller Tray 1 Feed

Pick Roller
Multi-sheet
Bypass Feeder Pinch Roller
(MBF) Retard Roller
Feed Roller
Take Away 2 Sensor
Pick Roller
Take Away Roller, Tray 2
Feed Roller Tray 2 Feed

Pick Roller
Retard Pad
Retard Roller
S4525-306
Fig 1-13 Print Engine Paper Path

About This Manual
The material contained in the QRG is extensive requiring two separate volumns to
facilitate binding. There are a total of six books contained in the two volumes.
Book I — Print Engine
1-Print Engine comprises the Service Quick Reference Guide for the
DocuPrint N4525 Network Laser Printer. This manual covers the Print Engine,
Safety Information, as well as the entirety of Error Codes and Messages, and
Diagnostics for the Print Engine and the options below.
Book II — Printer Options provides sections in the Service Quick Reference Guide for
the N4525 options:
2-High Capacity Feeder
3-Duplex Module
4-Envelope Feeder
5-Face-Up Bin
6-Finisher
There are many 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 “XXX”
is the page, RAP or RRP number being referenced.
3-XXX where the “3” indicates Book II, Volume 3 - Duplex Unit and the “XXX” is the
4-XXX where the “4” indicates Book II, Volume 4 - Envelope Feeder and the “XXX” is
the page, RAP or RRP number being referenced.
5-XXX where the “5” indicates Book II, Volume 5 - Face Up Bin and the “XXX” is the
6-XXX where the “6” indicates Book II, Volume 6 - Finisher and the “XXX” is the page,
RAP or RRP number being referenced.

General Specifications
RAM and printer capabilities
The DocuPrint® N4525 Network Laser Printer is equipped with 32 MB of RAM and is
expandable as shown below. Adding additional RAM:
Improves system performance
Improves processing of complex jobs
Enables increased graphics at higher resolutions.
Also, adding Flash Memory (non-volatile memory) in the Flash DIMM slot enables
downloading and storing fonts, forms, and macros.
Memory Expansion
The base printer contains 32 MB of DRAM installed as a standard. Three option slots are
provided on the System Controller Board to accommodate DIMMs per the Memory
Expansion Options table below. The maximum DRAM memory, both on-board and added
via DIMMs is 192 MB. Memory added 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 the printer or create resident macros by
installing Flash DIMMs and downloading resources permanently to this memory.
The printer features three DIMM slots (J4, J5, and J6) for memory expansion. DRAM
DIMMs can be installed in any of these slots. Refer to the instructions packed with the
DIMMs.
If flash memory is to be used, this 8-Mbyte Flash DIMM should be installed in the slot
labeled J6 (Bootable RAM).
Table 1-1 Memory Expansion Options
Memory Upgrades: Part Number
16-Mbyte DIMM 097S02356
8-Mbyte Flash DIMM 097S02360

Physical Dimensions
Table 1-2 Physical Dimensions

Dimensions Specification
Height 486 mm / 19.1 inches +/- 1%
Width 645 mm / 25.4 inches +/- 1%
Depth 540 mm / 21.3 inches +/- 1%
Weight (110 V model) 48.5 Kg / 106.92 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)
Note Above measurements taken with the Multi-sheet Bypass Feeder

(MBF) retracted.
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 Duplex Unit installed.
Top Typically 762 mm / 30 inches
Bottom No obstruction under printer that could block cooling vents
Mounting surface flatness Within 2 degrees of horizontal with all four feet in contact with the
table surface
Note Above minimum space requirements are measured from the

printer covers to the wall or neighboring object.

Electrical Specifications
Table 1-4 Electrical Specifications
Category Specification
Power supply requirements 110 V printer: 100/115 VAC (+/- 10%) @ 50/60 Hz (+/-
3 Hz)
Power supplied to the Electronic 5 VDC
Sub-System board
Power consumption of the print engine 110 VAC: 900 watts / 7.8 A
during an average print cycle. 220 VAC: 900 watts / 4.3 A
Environmental Specifications
Table 1-5 Environmental Specifications
Characteristic Specification
Normal operating environment:
Temperature 5 - 30o C
Humidity 15 - 85% Relative Humidity (no condensation)
Altitude 0 - 8200 feet above sea level
Exposure to sun No direct sunlight (less than 3,000 LUX)
Regulatory Specifications
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-chapter J,
Sections 1010 & 1040 for CDRH Class 1 Laser
Product.
220 V printer: IEC 825 Class 1 Laser Product.
Electro-Magnetic Interference 110 V printer: VCCI Information Processing
standards observed Equipment, Class II.
FCC Part 15, subpart B, class B (ANSI C63.4/11.4D)
220 V printer: EN55022 (CISPR Publication 22) Class
B
Ozone generation Less than 0.02 ppm in Time Weighted Average (TWA).
Measured according to ECMA 129.

Functional Specifications
Table 1-7 Functional Specifications
Characteristic Specification
Printing process Electro-photographic (Xerography) monochrome
transfer printing
Resolution of printed image 600 dpi (dots per inch)
Exposure method Data modulated (off/on) laser beam
Development method Dry toner and carrier mixture
Fusing method Heat and pressure
Laser specifications Class 3B, 5 milliwatt semiconductor laser diode
Warm-up time From either a cold start or from sleep mode (with an
ambient temperature of 22 C) to Ready to Print within 1
minute.
Maximum noise generated (excluding Standby: 58.0 db
impulse noise) Printing: 70.0 db
Laser Print (EP) Cartridge life 30,000 prints, assuming 5% image coverage and 4 mm
expectancy white borders
Key component life expectancy:
Engine 1.5 million simplex sheets 8.5 x 11 in. (A4)
Paper Feeder 1.5 million simplex sheets
Fuser Unit 300,000 prints
Bias Transfer Roller 300,000 prints
Feed Rollers (3) 300,000 prints
Usable Paper
Input Paper tray capacity
MBF (Multi-sheet Bypass Feeder) 50 sheets standard 20 lb. paper
Tray 1 500 sheets standard 20 lb. paper
Tray 2 500 sheets standard 20 lb. paper
HCF3 (High Capacity Feeder) 500 sheets standard 20 lb. paper
HCF4 1000 sheets standard 20 lb. paper
HCF5 1000 sheets standard 20 lb. paper
Output tray capacity (face down tray) 500 sheets standard 20 lb. paper

Printing Speeds: First Sheet Out
Table 1-8 Printing Speeds: First Sheet Out
Paper Size Mode Tray 1 Tray 2 Tray 3 HCF 4 HCF 5
A4 LEF Simplex 4.0 sec 4.7 sec 5.1 sec 6.0 sec 7.2 sec
8.5 x 11 LEF Simplex 4.0 sec 4.7 sec 5.1 sec 6.0 sec 7.2 sec
A4 LEF Duplex 8.6 sec 9.3 sec 9.7 sec 10.6 sec 11.8 sec
8.5 x 11 LEF Duplex 8.6 sec 9.3 sec 9.7 sec 10.6 sec 11.8 sec
Printing Speeds: Continuous Printing After the

First Sheet Out
Table 1-9 Printing Speeds: Continuous Printing After the First Sheet
Out
Paper Size Mode Trays 1 & 2 HCF 3 HCF 4 & 5 MBF
pages per pages per pages per pages per
minute minute minute 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 17 ppm -- --
Legal 13” SEF Simplex 28/27 ppm 27 ppm -- 25 ppm
Legal 13” SEF Duplex 17 ppm 17 ppm -- --
Legal 14” SEF Simplex 28/27 ppm 27 ppm -- 25 ppm
Legal 14” SEF Duplex 17ppm 17 ppm -- --
A3 SEF Simplex 24 ppm 24 ppm -- 22 ppm
A3 SEF Duplex 16 ppm 16 ppm -- --
Ledger SEF Simplex 24 ppm 24 ppm -- 22 ppm
Ledger SEF Duplex 16 ppm 16 ppm -- --

Paper Input Devices
Trays 1 and 2 for the 500 Sheet Feeder (standard)
Standard feeder for the DocuPrint® N4525 Network Laser Printer. Each tray has paper
size automatic sensing. Trays 1 and 2 can each hold up to 500 sheets (54 mm (2.126 in.)
stack height of 20 lb. paper) of the following paper:
Table 1-10 Tray 1 and 2 Paper Sizes
Factory set Option 1 Factory set Option 2
Ledger SEF - 279.4 mm x 431.8 mm (11 x Ledger SEF - 279.4 mm x 431.8 mm (11 x 17 in.)
17 in.)
A3 SEF - 297 mm x 420 mm (11.71 x 16.55 A3 SEF - 297 mm x 420 mm (11.71 x 16.55 in.)
in.)
B4 SEF - 257 mm x 364 mm (10.13 x 14.34) Legal 14" SEF - 215.9 mm x 355.6 mm (8.5 x 14
in.)
Letter SEF LEF - 215.9 mm x 279.4 mm (8.5 Letter SEF LEF - 215.9 mm x 279.4 mm (8.5 x 11
x 11 in.) in.)
Legal 13" SEF - 215.9 mm x 330.2 mm (8.5 x Legal 13" SEF - 215.9 mm x 330.2 mm (8.5 x 13
13 in.) in.)
A4 SEF LEF - 210 mm x 297 mm (8.27 x A4 SEF LEF - 210 mm x 297 mm (8.27 x 11.71
11.71 in.) in.)
Executive LEF - 184.2 mm x 266.7 mm (7.26 B5 LEF - 182 mm x 257 mm (7.17 x 10.13)
x 10.51 in.)
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 STATEMENT - 139.9 mm x 215.9 mm (5.51 x 8.5
x 8.5 in.) in.)
MBF (Multi-sheet Bypass Feeder - standard)

Standard feeder for the printer. The MBF attaches to the left side of the printer. The MBF
holds up to 50 sheets (5 mm stack height of 64~105 g/m2 (17~28 Lb.) paper or 190 g/m2
postcard) of the following paper:
Table 1-11 Multi-sheet Bypass Feeder Paper Sizes
Ledger SEF - 279.4mm x 431.8 mm (11 x 17 Ledger SEF - 279.4 mm x 431.8 mm (11 x 17
in.) in.)
A3 SEF - 297 mm x 420 mm (11.71 x 16.55 in.) A3 SEF - 297 mm x 420 mm (11.71 x 16.55
in.)
B4 SEF - 257 mm x 364 mm (10.13 x 14.34) Legal 14" SEF - 215.9 mm x 355.6 mm (8.5 x
14 in.)
Letter SEF LEF - 215.9 mm x 279.4 mm (8.5 x Letter SEF LEF - 215.9 mm x 279.4 mm (8.5 x
11 in.) 11 in.)
Legal 13" SEF - 215.9 mm x 330.2 mm (8.5 x Legal 13" SEF - 215.9 mm x 330.2 mm (8.5 x
13 in.) 13 in.)
A4 SEF LEF - 210 mm x 297 mm (8.27 x 11.71 A4 SEF LEF - 210 mm x 297 mm (8.27 x 11.71
in.) in.)
Executive LEF - 184.2 mm x 266.7 mm (7.26 x B5 LEF - 182 mm x 257 mm (7.17 x 10.13 in.)
10.51 in.)
Postcard - 100 mm x 148 mm (3.94 x 5.83 in.) Postcard - 100 mm x 148 mm (3.94 x 5.83 in.)

High Capacity Feeder (HCF - option)
Table 1-12 High Capacity Feeder Tray 3 Paper Sizes
Ledger SEF - 279.4 mm x 431.8 mm (11 x 17 Ledger SEF - 279.4 mm x 431.8 mm (11 x 17
in.) in.)
A3 SEF - 297 mm x 420 mm (11.71 x 16.55 in.) A3 SEF - 297 mm x 420 mm (11.71 x 16.55
in.)
B4 SEF - 257 mm x 364 mm (10.13 x 14.34) Legal 14" SEF - 215.9 mm x 355.6 mm (8.5 x
14 in.)
11 in.) 11 in.)
Legal 13" SEF - 215.9 mm x 330.2 mm (8.5 x Legal 13" SEF - 215.9 mm x 330.2 mm (8.5 x
13 in.) 13 in.)
in.) in.)
Executive LEF - 184.2 mm x 266.7 mm (7.26 x B5 LEF - 182 mm x 257 mm (7.17 x 10.13)
10.51 in.)
Note Tray 3 is the top tray of the High Capacity Feeder option. It
senses paper size and can hold up to 500 sheets of the above
paper.
Table 1-13 High Capacity Feeder Tray 4 and Tray 5 Paper Sizes
11 in.) 11 in.)
in.) in.)
Executive LEF - 184.2 mm x 266.7 mm (7.26 x B5 LEF - 182 mm x 257 mm (7.17 x 10.13)
10.51 in.)
Note Trays 4 and 5 can each hold up to 1000 sheets of the above paper.
Table 1-14 Envelope Feeder Envelope Sizes
Envelope type (100 maximum)
COM #10 (Monroe Brand) - 104.8 mm x 241.3 mm (4.13 x 9.5 in.)
Monarch (Monroe Brand) - 98.4 mm x 190.5 mm (3.88 x 7.5 in.)
C5 SEF (River series #02067/Gummed) - 162 mm x 229 mm (6.38 x 9 in.)
DL (River series #01029/Gummed) - 110 mm x 220 mm (4.33 x 8.67 in.)
Note The optional Envelope Feeder replaces the MBF. It has a No

Paper Sensor and can hold up to 100 of the above envelopes.

Paper Output Devices
The printer uses the following paper output/paper size combinations:
Face Down Tray (standard)

The Face Down Tray is the standard output tray for the printer. Paper is transported out of
the printer face down onto the printer Top Cover. This tray holds up to 500 sheets of 20 lb.
paper, and comes equipped with Full Stack detection. When the optional Finisher is
installed on the printer, the maximum paper stack in the Face Down Tray is reduced to
300.
Offset Unit (standard)

The Offset Unit is attached above the Fuser on the print engine. Each print job is offset 10
mm from the last, then placed in the Face Down Tray.
Paper size supported by the Offset Unit:

Table 1-15 Offset Unit Paper Sizes
Paper
Letter SEF (20lb) - 216 mm x 279 mm (8.5 x 11 in.)
Legal 13" SEF (20lb) - 216 mm x 330 mm (8.5 x 13 in.)
Legal 14" SEF (20lb) - 216 mm x 356 mm (8.5 x 14 in.)
A4 SEF (RX80) - 210 mm x 297 mm (8.27 x 11.71 in.)
Ledger - 297 mm x 432 mm (11.71 x 17 in.)
A3 - 297 mm x 420 mm (11.71 x 16.55 in.)
Duplex Unit (option)

The optional Duplex Unit for the 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 Tray holds up to 200 sheets of 20 lb.
paper. There is no Full Stack detection for this tray.
Finisher
The optional Finisher provides for hole punching (3-hole or 4-hole), compiling, stapling
and stacking of finished print jobs. The stacker will hold up to 3,000 sheets of 20 lb.
paper.

Printing Media Specifications
Standard Paper:
FX L A4 (LEF)
RX80 A4 (LEF)
XEROX 4024 DP 20 lb. Letter (LEF)
Special Media:
Table 1-16 Special Media
Type Size Media Name MBF Tray 1 HCF Env
Tray 2
Transparency Letter - 8.5" x 11" Xerox R2780 (US) Y Y Tray 3 N
only
Transparency A4 - 210 mm x 297 Xerox 3R9600 Y Y Tray 3 N
mm (EU) only
Transparency A4 - 210 mm x 297 Xerox E001 Y Y Tray 3 N
mm (Japan) only
Labels Letter - 8.5" x 11" Xerox 3R4469 Y Tray 2 Trays N
(US) only 3&4
only
Labels A4 - 210 mm x 297 Xerox 3R97406 Y Tray 2 Trays N
mm (EU) only 3&4
only
Labels A4 - 210 mm x 297 Xerox V860 Y Tray 2 Trays N
mm (Japan) only 3&4
only
Envelope 4 1/8" x 9 1/2" Monroe Brand Y N N Y
COM #10
Envelope 3 7/8" x 7 1/2" Monroe Brand Y N N Y
Monarch
Envelope 162 mm x 229 mm C5 (Rivers series Y N N Y
#02067/ Gummed
Envelope 110 mm x 220 mm DL (Rivers series Y N N Y
#01029/Gummed
Postcard A6 - 100 mm x 148 Japanese Official Y N N N
mm Postcard
Note Please refer to the FRU (Field Replaceable Unit) section for more
details and part numbers.

Print Media
Storing paper
Store the paper on a flat surface, in a relatively low-humidity environment.
Avoid storing paper in such a way as to cause wrinkling, bending, curling, etc.
Do not unwrap paper until you are ready to use it, and rewrap any paper you are
not using.
Do not expose paper to direct sunlight or high humidity for extended periods.
Table 1-17 Paper Weights

Acceptable 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*
Custom Paper Tray (optional) 500*
Multi-sheet Bypass Feeder 50*
Envelope Feeder (optional) 100 Envelopes
* Maximum capacity using 80 g/m2 (20 Lbs.) stock. Do not load paper above the indicated mark
located on the back or side of the tray.

Print Media, continued
Table 1-19 Supported Media and Media Sizes
Media Media Size Tray 1 Tray 2 Tray 4 Custom Multi- Envelope
Tray 3 Tray 5 Paper sheet Feeder
Tray Bypass
Feeder
A3 (2) 297 x 420 mm • • • •
A4 (1) 210 x 297 mm • • • • •
A5 (1) 148 x 210 mm • (6) •
A6 (1) 105 x 148 mm •
Statement (1) 5.5 x 8.5 in. • (6) •
B5-JIS (1) 182 x 257 mm • • • • •
B4-JIS (2) 257 x 364 mm • • • •
Executive (1) 7.25 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) 4.1 x 9.5 in. • •
Monarch (1) (4) 3.8 x 7.5 in. • •
DL (1) (4) 110 x 220 mm • •
C5 (1) (4) 162 x 229 mm • •
Transparencies
A4 (1) (4) 210 x 297 mm • • • •
Letter (1) (4) 8.5 x 11 in. • • • •
Labels
A4 (1) (4) 210 x 297 mm • (5)
• •
Letter (1) (4) 8.5 x 11 in. • (5)
• •
Custom Sizes(3) • •
(1) Use long-edge feed.
(2) Use short-edge feed.
(3) Custom Sizes — see the following page for the range of acceptable sizes.
(4) Envelopes, transparencies, labels, and custom sizes cannot be printed in duplex mode.
(5) Tray 4 only
(6) Not available if Custom Paper Tray is used in Tray 2 or 3 position.

Custom paper sizes
Table 1-20 Custom Paper Sizes
Acceptable sizes Custom paper tray Multi-sheet Bypass Feeder
Width 181 - 298.5 mm 76.2 - 297 mm
(7.13 - 11.75 in.) (3 - 11.69 in.)
Length up to 431.8 mm 98.4 - 431.8 mm
Tray 1 (up to 17 in.) (3.875 - 17 in.)
Trays 2 & 3 148 mm (5.83 in.) minimum
182 mm (7.16 in.) minimum
Unacceptable media
The following media are unacceptable for use in the printer. Their use may cause high
rates of jamming and other paper-handling problems:
Excessively thick or thin paper
Heavily textured paper
Paper that has already been printed on (pre-printed letterhead is allowed)
Wrinkled, torn, or bent paper
Moist 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.

Xerox Supplies and Accessories
Table 1-21 Xerox Professional Printing Papers
Item Size Description Part Number
Xerox 4024 DP Letter (U. S.) 20 lbs. 003R00721
8.5 x 11 in. (75 g/m2)
Xerox 4024 DP Legal 20 lbs. 003R00727
8.5 x 14 in. (75 g/m2)
Xerox 4024 DP Statement 20 lbs. 003R02072
5.5 x 8.5 in. (75 g/m2)
Rank Xerox Business A4 (Metric Letter) 80 g/m2 003R901820
210 x 297 mm
Rank Xerox Business A3 80 g/m2 003R91821
297 x 420 mm
Rank Xerox Printer A5 80 g/m2 003R91832
148.5 x 210 mm
Xerox Image Series Smooth Letter (U. S.) 20 lbs. 003R00054
8.5 x 11 in. (75 g/m2)
Xerox Image Series Smooth Legal 20 lbs. 003R00083
8.5 x 14 in. (75 g/m2)
Rank Xerox Legal 80 g/m2 003R901741
215 x 356 mm
LaserPrint 80 A4 (Metric Letter) 80 g/m2 003R91922
210 x 297 mm
Xerox Recycled Letter (U. S.) 20 lbs. 003R06296
8.5 x 11 in. (75 g/m2)
Steinbeis Recycled A4 (Metric Letter) 80 g/m2 003R91165
210 x 297 mm
80 DP Planet Plus A4 (Metric Letter) 80 g/m2 003R900652
210 x 297 mm
Table 1-22 Xerox Transparency Film

Item Size Part Number
Xerox Clear Letter (U. S.) 8.5 x 11 in. 003R02780
Rank Xerox Clear A4 (Metric Letter) 210 x 297 mm 003R96002
Table 1-23 Xerox Labels

Size Description Part Number
Letter (U. S.) 8.5 x 11 in. 30 labels per sheet 003R04469
A4 (Metric Letter) 210 x 297 mm 24 labels per sheet 003R97406

Printer Options
Table 1-24 Printer Options
Item Part Number
Custom Paper Tray 097S02562
Handles continuously variable paper sizes
Holds up to 500 sheets of 80 g/m2 (20 lbs.) stock
High Capacity Feeder - 2,500-Sheet Feeder 097S02560
Three additional trays
Increased paper-printing capacity
Increased printing versatility and convenience
Envelope Feeder 097S02567
Holds 100 standard-weight envelopes 097K24870 (Alt.)
Duplex Module 097S02561
Automatic duplex capability
Face-up Bin 097S02564
Holds up to 200 sheets
Provides face-up output stacking
Finisher with stapler and hole puncher 450S02180
Increased paper-output capacity 3-hole positions
Holds up to 3,000 sheets of 80 g/m2 (20 lbs.) stock (Letter, A4 450S02181
4-hole positions
paper)
Stapling capability
Hole-punching capability
Hard disk drive 097S02364
5+ Gbyte hard drive
Store resources, fonts, forms, and macros; enables uninterrupted
large-job collation
Memory upgrades 097S02356
Improved system performance (16 Mbyte DIMM)
Improved processing of complex jobs 097S02357
(32 Mbyte DIMM)
097S02358
(64 Mbyte DIMM)
8 Mbyte Flash DIMM 097S02360
Non-volative memory for downloading and storing fonts, forms,
and macros
Token Ring interface card 097S02363
Enables Token Ring connectivity
Ethernet 10Base2 Interface Card 097S02362
Enables Ethernet 10Base2 connectivity
RS232-C serial interface card 097S02361
Enables Serial connectivity

Blank Page

Error Codes and
Messages
Error messages
The Control Panel displays error codes when it encounters certain system failures or
anomalies otherwise undetected by the user. These error codes are discussed in this
section. When an error code first occurs, cycle power on the printer to see if the error
recurs.
For Printer Performance problems, start in the Error Codes and/or
Troubleshooting Sections of Book I, Volume 1 of the QRG.
For Image Quality problems, go to the Troubleshooting Section of Book I,
Volume 1 of this QRG.
For High Capacity Feeder problems, go to the Error Codes and
Troubleshooting sections of Book II, Volume 2 in this QRG.
For Duplex Unit problems, go to the Error Codes and Troubleshooting
sections of Book II, Volume 3 of this QRG.
For Envelope Feeder problems, go to the Error Codes and Troubleshooting
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 technical manual, to service the printer
engine and options.
To use the Service Flowchart, start at Block 1 to identify the problem. After you have
identified the problem, return to the Service Flowchart and proceed to Block 2 where you
inspect and clean the printer (a through cleaning frequently solves many printer
problems). You continue down the Flowchart in this manner, always returning to the next
block in the Service Flowchart after you have completed the tasks outlined in the current
block.
If you choose not to use the Service Flowchart, it is recommended that you start at the
appropriate Repair Analysis Procedure (RAP) Table and proceed from there.
Volume 1 / Print Engine - Error Codes & Messages 1-29

Service Flowchart, continued
Identify the Problem

1. Verify that the reported problem does exist.
2. Check for any error codes and write them down.
1 3. Print three test prints.
4. Make note of any print quality problems in the test prints.
5. Make note of any mechanical or electrical abnormalities present.
6. Make note of any unusual noise or smell coming from the printer.
7. Print a Fault History (if the printer is able to print).
Inspect and Clean the Printer

1. Switch OFF printer power.
2. Disconnect the AC power cord from the 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.
2 Do not use solvents or chemical cleaners to clean the printer interior.
Do not use any type of oil or lubricant on printer parts.
6. Clean all rubber rollers with a lint-free cloth that is dampened slightly with cold water.
Use a clean, dry, lint-free cloth to dry the rollers.
Do not use solvents or chemical cleaners to clean rubber rollers.
7. While you are cleaning, inspect the interior of the printer for damaged wires, loose
connections, toner leakage, and damaged or obviously worn parts.
8. If the Print (EP) Cartridge appears obviously damaged, replace it with a new one.
Find the Cause of the Problem

3 Use the Repair Analysis Procedure (RAP) Tables to find the cause of the problem.
Use Diagnostics to check printer and option components.
Use the Wiring Diagrams to locate Plugs/Jacks (P/Js) and test points.
Take voltage readings at various test points.
Correct the Problem

4 Use the Parts List to locate a part number.
Use the Removal and Replacement Procedures (RRPs) to replace a part.
Final Checkout
5 Test the printer to be sure you corrected the initial problem and there are no additional
problems present.
S4525-03
Fig 1-14 Service Flowchart

The Repair Analysis Procedure Table
If you used the Service Flowchart, it may have directed you to this section. Follow the
Repair Analysis Procedure Table located in this section to help you analyze your printer
problem.
How to Use a Repair Analysis Procedure Table

1. If you have an error code or error message displayed, refer to the Repair
Analysis Procedure in this section and locate the ERROR CODE in the “Error
Code” column or the “Error Message” in the “Displayed Error Message”
column, then go to the Repair Analysis Procedure indicated in the “Go To...”
cell to the right of the ERROR CODE.
2. If you have a printer operation problem; go to the PRINTER PERFORMANCE
area in the Troubleshooting Section of this manual.
3. If you have an print image problem; go to the IMAGE QUALITY area in the
Troubleshooting section of this manual.
4. Follow the Repair Analysis Procedure Table leading from the “Problem” cell to
the individual Primary Repair Analysis Procedure that corresponds to your
error code, printer operation problem, or print image problem.
5. Follow the instructions presented in the Repair Analysis Procedure.
6. If the Repair Analysis Procedure instructs you to perform a diagnostic test,
refer to Diagnostics area in the Tests and Adjustments Section of this manual.
7. Voltage and resistance values presented in the Repair 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 and Questions box may contain additional information and
numbered procedure steps you must follow to perform the action.
3. The action is followed by a question.
4. If your response to the question is Yes, then follow the instructions for a Yes
reply.
5. If your response to the question is No, then follow the instructions for a No
reply.
6. Repair Analysis Procedures may ask you to take voltage readings at certain
test points within the printer. The Plug/Jack Connector Locations and Master
Wiring Diagram sections of this manual contain information on test point
locations and signal names.
7. Repair Analysis Procedures may ask you to run a specific diagnostic routine in
order to test a component or circuit. The Tests /Adjustments and Resetting
NVRAM sections of this manual contain information on printer diagnostics.
8. Repair Analysis Procedures often ask you to replace a printer component. The
Key FRU (Field Replaceable Unit) section of this manual provides detailed
steps for removing and replacing all major parts of the printer. If the
component is not part of the base engine, the Repair Analysis Procedure
indicates which technical manual contains the procedure.

Table 1-25 RAP Table Example
Step Actions and Questions Yes No
2 NO PAPER SENSOR TEST Go to step 3 Replace the No
1. Enter Diagnostics. Paper Sensor
2. From the Main Menu, select Comp Output Assembly
Test / HCF Unit / Tray 3 Paper Sen.
3. Slide Tray 3 out of the printer.
4. Press [4] to start, [0] to stop.
5. Manually actuate and deactuate Tray 3
No Paper Sensor.
Does the Control Panel display “With
Paper” and “Without Paper” when
the actuator is toggled to its limits?
General Notes on Using Repair Analysis

Procedures
1. Unless indicated otherwise, the instruction “switch ON printer main power”
means for you to switch ON printer power and let the printer proceed through
power-on diagnostics and warm-up until it is on-line and ready to print.
2. Conventions used to represent connectors:
P/J XX means a Plug and its corresponding Jack are connected.
PXX means a Plug is disconnected. (Unless this plug is soldered to a board).
JXX means a Jack is disconnected. (Unless this jack is soldered to a board).
3. When you are instructed to take a voltage reading between “P/J A–B and P/J
X–Y”, place the red probe (+) of your meter on pin B of P/J A, and place the
black probe (–) of your meter on pin Y of P/J X.
4. When you are instructed to take voltage readings between “P/J X and P/J Y”
(without specified pin numbers), check all voltage carrying pins. Refer to the
Wiring Diagrams for signals and pin numbers.
5. When you are instructed to take a voltage reading, the black probe (–) is
generally connected to a pin that is either RTN (Return) or SG (Signal Ground).
You can substitute any RTN pin or test point in the printer, and you can use
frame ground (frame ground) in place of any SG pin or test point.
6. Unless a Repair Analysis Procedure instructs you otherwise; before measuring
voltages make sure the 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 Procedures is to determine whether or
not a component is receiving the correct voltage value from the power supply
and if gating (a voltage drop) occurs during component actuation. Gating
signals may be nothing more than a pulse, resulting in a momentary drop in
voltage that may be difficult or impossible to read on the average multi-meter.
8. Repair Analysis Procedures may instruct you to remove or replace a
component. Refer to the Key FRU Removal and Replacement Procedures
section for information on how to remove and reinstall a component.
9. When a Repair Analysis Procedure instructs you to replace a non-spared
component, and that component is part of a larger assembly, you should
replace the entire assembly.

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
replace the System Controller board. In some instances, the
Control Panel Display may not be sufficiently functional to
accurately show error codes and/or messages. 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 access and run the various diagnostic routines that are presented in
this manual. Refer to the Diagnostics, Test Prints, Service Tests and NVRAM
Adjustments section of this manual, on page 1-149 for details.

Before Starting the Error Code Repair
Analysis Procedures:
1. Is the AC power provided at the wall outlet within specifications for this printer;
either 110VAC or 220VAC?
2. Is the AC power cord in good condition (e.g. frayed or broken)?
3. Is one end of the AC power cord connected to the printer?
4. Is the other end of the AC power cord plugged into a grounded three-prong AC
wall outlet?
5. Is the printer located in an area where the temperature and humidity are
moderate and stable as recommended in the General Information section.
6. Is the printer located in an area that is free of dust?
7. Is the printer located away from water outlets, steamers, electric heaters,
volatile gases, or open flames?
8. Is the printer shielded from the direct rays of the sun?
9. Does the printer have the correct ventilation space around all sides as
recommended in the General Information section.
10.Is the printer sitting on a level and stable surface?
11.Is the paper stock used in the printer as recommended in the User Manual?
12.Does the customer use the printer as instructed in the User Manual?
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 System Controller Error Codes on page 1-44. If all else
fails, replace the System Controller board.
Repair Analysis Procedures (RAP)

Depending on the level of firmware on your Print Engine Controller Board some codes
listed in this table may be invalid, some codes generated may not appear in this table, and
Error and Message Code text presented in this table may differ slightly from the Error and
Message Code text appearing on the Control Panel display. In some cases, where no RAP
is indicated, follow the displayed message to clear the problem
Table 1-26 Legend

Term Definition Comment
PE Print Engine Sometimes referred to as “IOT” (Image Output
Terminal) and appears in the display on the Control
Panel as a result of programming.
HCF High Capacity Feeder Option
DUP Duplex Module Option
ENV Envelope Feeder Option
FIN Finisher Option
SE Sensor Abbreviated sensor callout identifier
SW Switch Abbreviated switch callout identifier

Table 1-27 Repair Analysis Procedure (RAP) Table
Displayed Error Fault Description Go To Unit/
Error Code RAP Page
Message No.
Clear Area A C1-3 There is a paper jam between Paper Tray 1 and RAP 1-81
Reset Tray 1 the Registration Sensor. 1-30
Logic Control on the print Engine Controller Board
sensed that the Registration Sensor did not actuate
within the specified time after the Tray 1 Feed Clutch
was actuated.
Clear Area A, B C2-2 There is a paper jam between Paper Tray 2 and RAP 1-83
Reset Tray 2 Take Away Roller 2 Sensor. 1-31
Logic Control on the Print Engine Contoller Board
sensed that the Take Away Roller 2 Sensor did not
actuate within the specified time after the Tray 2 Feed
Clutch was actuated.
Paper Jam C2-3 There is a paper jam between Paper Tray 2 and RAP 1-85
Clear Area A the Registration Sensor. 1-32
Logic Control on the Print Engine Controller Board
sensed that the Registration Sensor did not actuate
within the specified time after the Tray 2 Feed Clutch
was actuated.
Paper Jam C3-2 There is a paper jam between Tray 3 and Tray 2 RAP 2-373
Clear Areas A,B Take Away Sensor. 2-1
sensed that the Tray 2 Take Away Sensor did not
actuate within the specified time after the Tray 3 Feed
Paper Jam C3-3 There is a paper jam between Tray 3 and the RAP 2-375
Clear Area A, B Registration Sensor. 2-2
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
actuated.
Clear Area C C4-0 There is a paper jam between Paper Tray 4 and RAP 2-407
Reset Tray 4 the Tray 3 Take Away Sensor. 2-20
Tray 3 Take Away Sensor did not actuate within the
specified time after the Tray 4 Feed Clutch was
actuated.
Clear Areas B,C the Tray 3 Take Away Sensor. 2-3
actuated.
Paper Jam C4-2 There is a paper jam between Tray 2 Take Away RAP 2-379
Clear Areas A, Sensor and Tray 3 Take Away Sensor. 2-4
B, C Logic Control on the Print Engine Controller Board
specified time after the Tray 3 Take Away Sensor was
actuated.

Table 1-27 Repair Analysis Procedure (RAP) Table (cont'd.)
Error Code RAP Page
Message No.
Clear Area A, B the Registration Sensor. 2-5
Registration Sensor did not actuate within then
actuated.
Clear Area C C5-0 There is a paper jam between paper Tray 5 and RAP 2-383
actuated.
Paper Jam C5-1 There is a paper jam between paper Tray 5 and RAP 2-385
Clear Areas B,C the Tray 3 take Away Sensor. 2-7
actuated.
Paper Jam C5-2 There is a paper jam between Tray 2 Take Away RAP 2-387
Clear Areas A, Sensor and Tray 3 Take Away Sensor. 2-8
B, C Logic Control on the Print Engine Controller Board
Tray 2 Take Away Sensor signal did not actuate
within the specified time after the Tray 3 Take Away
Sensor was actuated.
Paper Jam C5-3 There is a paper jam between paper Tray 5 and RAP 2-389
Clear Area A, B the Registration Sensor. 2-9
Registration Sensor did not actuate within then
actuated.
Clear Area C C5-4 There is a paper jam between Paper Tray 5 and RAP 2-409
Paper fed from Tray 5 did not reach the Take-Away
Roller 5 Sensor within the specified time.
Paper Jam C6-1 There is a paper jam between the Duplex Wait RAP 3-518
Clear Duplx Unit Sensor and the Registration Sensor. 3-6
Paper fed from the Duplex Module did not reach the
Registration Sensor within specified time.
Paper Jam C8-1 There is a problem with the Envelope Feed RAP 4-565
Reset Sensor. 4-1
ENV/Bypass Remaining paper detected by the Envelope
Feeder/MBF Exit Sensor.
Paper Jam C8-2 There is a problem with the Tray Take Away RAP 1-86
Clear Areas A,B Sensor. 1-33
sensed the Tray 2 Take Away Sensor was on while
the printer was in standby.

Error Code RAP Page
Message No.
Paper Jam C8-3 There is a problem with the Tray 3 Take Away RAP 2-391
Clear Areas B,C Sensor. 2-10
Paper Jam C8-4 There is a problem with the Tray 4 Take Away RAP 2-392
Clear Area C Sensor. 2-11
Clear Area C C8-5 Logic Control on the Print Engine Controller Board RAP 2-411
Reset Tray 5 sensed paper remaining at the Take-Away Roller 5 2-22
Sensor.
Paper Jam C8-6 There is a paper jam at the Duplex Exit Sensor. RAP 3-520
Clear Duplx Unit Remaining paper detected in the Duplex Module. 3-7
Paper Jam C9-1 There is a paper jam between the Envelope Tray RAP 4-566
Reset and the Envelope Feed Sensor. 4-2
ENV/Bypass Paper fed from the MBF or the Envelope Feeder did
not reach the MBF/Envelope Feeder Exit Sensor
within specified time.
Paper Jam C9-2 There a paper jam between the Multi-sheet RAP 1-87
Reset Bypass Feeder (MBF) and Tray 2 Take Away 1-34 4-566
ENV/Bypass Sensor. RAP
Logic Control on the Print Engine Controller Board 4-3
sensed that when paper was fed from the Multi-sheet
Bypeas Feeder, Tray 2 Take Away Sensor did not
actuate within the specified time after the MBF Feed
Clutch was acuated.
Paper Jam C9-3 There is a paper jam between the Multi-sheet RAP 1-89
Reset Bypass Feeder (MBF) and the Registration 1-35 4-571
ENV/Bypass Sensor. RAP
sensed that when paper was fed from the Multi-sheet
Bypass Feeder, the Registration Sensor did not
actuate within the specified time after the MBF Feed
Paper Jam E1-1 There is a paper jam at the Registration Sensor. RAP 1-64
Clear Area A Logic Control on the Print Engine Controller Board 1-18
sensed the paper did not leave the Registration
Sensor within the specified time since paper feed.
Paper Jam E1-2 There is a paper jam between the Registration RAP 1-66
Clear Area A Sensor and the Fuser Exit Sensor. 1-19
sensed the Fuser Exit Sensor was not actuated
within the specified time since the Registration
Paper Jam E1-3 There is a paper jam between the Fuser Exit RAP 1-69
Clear Area A Sensor and the Face Up Exit Sensor. 1-20
sensed the Face Up Exit Sensor was not actuated
within the specified time since the Fuser Exit Sensor
was actuated.

Error Code RAP Page
Message No.
Paper Jam E1-6 There is a problem at the Registration Sensor. RAP 1-71
Clear Area A Paper is detected on the Registration Sensor. 1-21
Paper Jam E3-1 There is a paper jam at the Fuser Exit Sensor. RAP 1-72
sensed the Fuser Exit Sensor did not de-actuate
within the specified time after actuating.
Paper Jam E3-6 The Fuser Exit Sensor is actuated at printer RAP 1-74
Clear Area A power on. 1-23
sensed the Fuser Exit Sensor was on while the
printer was in standby.
Paper Jam E4-1 There is a paper jam at the Face Up Exit Sensor. RAP 1-75
sensed that during Face-Up-Mode the Face Up Exit
Sensor did not de-actuate within the specified time
after actuating.
Paper Jam E4-2 There is a paper jam at the Duplex Exit Sensor. RAP 3-509
Clear Duplx Unit Paper outputted to the Face Up Tray did not reach 3-1
the Duplex Exit Sensor within specified time.
Paper Jam E4-3 There is a paper jam at the Face Up Exit Sensor. RAP 1-76
sensed that during Duplex Mode the Face up Exit
Sensor did not de-actuate within the specified time
after actuating.
Paper Jam E4-5 There is a problem near the Fuser Exit Sensor. RAP 1-77
Clear Duplx Unit The inverted page to be stationed in the Duplex 1-26
Module did not reach the Face Up Exit Sensor within
the specified time.
Paper Jam E4-6 There a paper jam at the Face Up Exit Sensor. RAP 1-78
sensed the Face Up Exit Sensor was on while the
printer was in standby.
Close Door A E5-1 The Left Door (A) is open. RAP 1-79
The Left Door (A) is closed, but Logic Control on the 1-28
Print Engine Controller Board sensed the Left Door
(A) Interlock Switch indicates the door is open.
Close Door B E5-2 The Left Door (B) is open. RAP 1-80
The Left Door (B) is closed, but Logic Control on the 1-29
Print Engine Controller Board sensed the Left Door
(A) Interlock Switch is open.
Close Door C E6-1 Door C is sensed to be open. RAP 2-393
sensed that Door C is open.
Close Duplx Unit E7-3 Duplex Unit is sensed to be open. RAP 3-511
The Duplex Unit is closed, but Logic control on the 3-2
Print Engine controller board sensed that the Duplex
Interlock Switch is open.
Paper Jam E8-1 There is a paper jam at the Duplex Exit Sensor. RAP 3-512
Clear Duplx Unit Inverted Printed Page to be outputted to the Face Up 3-3
Tray did not leave the Duplex Module Exit Sensor
within the specified time.

Error Code RAP Page
Message No.
Paper Jam E8-2 There is a paper jam between the Face Up Exit RAP 3-514
Clear Duplx Unit sensor and the duplex Wait Sensor. 3-4
Inverted Printed Page to be stationed in the Duplex
Unit did not reach the Duplex Unit Wait Sensor within
specified time.
Paper Jam E8-6 There is a problem with the Duplex Exit Sensor. RAP 3-516
Clear Duplx Unit Paper detected on the Duplex Module’s Exit Sensor. 3-5
Paper Jam F4-11 The Trail Edge of paper does not leave the Finisher RAP 6-655
Clear Area E Transport Entrance Sensor within the specified time. 6-1
(SE 31)
Paper Jam F4-12 After leaving the Fuser Exit Sensor, the Lead Edge of RAP 6-657
Clear Area E paper does not reach the Finisher Transport 6-2
Entrance Sensor within specified time. (SE 31)
Paper Jam F4-16 Remaining paper detected by the Finisher RAP 6-659
Clear Area E Transport Entrance Sensor. (SE 31) 6-3
Paper was detected by the Finisher Transport
Entrance Sensor during the initialization of the
Finisher. (SE 31)
Paper Jam F4-21 Paper does not leave the Finisher Transport Exit RAP 6-661
Clear Area F Sensor within specified time. (SE 32) 6-4
Paper Jam F4-22 After leaving the Finisher Transport Entrance Sensor, RAP 6-663
Clear Area F the Lead Edge of paper does not reach the Finisher 6-5
Transport Exit Sensor within specified time. (SE 32)
Paper Jam F4-26 Remaining paper detected by the Finisher RAP 6-665
Clear Area F Transport Exit Sensor. (SE 32) 6-6
Paper was detected by the Finisher Transport
Exit Sensor when the Finisher was initialized.
(SE 32)
Paper Jam F4-31 Paper does not leave the Finisher Input Path Sensor RAP 6-667
Clear Area F after the paper has reached the Finisher Input Path 6-7
Sensor. (SE 1)
Paper Jam F4-32 After leaving the Finisher Transport Exit Sensor, the RAP 6-669
Clear Areas F Lead Edge of paper does not reach the Finisher 6-8
Input Path Sensor within specified time. (SE 1)
Paper Jam F4-36 Remaining paper detected by the Finisher Input Path RAP 6-671
Clear Areas G Sensor. (SE 1) 6-9
Paper Jam F4-41 Paper does not leave the Finisher Path Sensor after RAP 6-673
Clear Area G the paper has reached the Finisher Path Sensor. 6-10
(SE 2)
Paper Jam F4-42 Paper does not reach the Finisher Path Sensor for RAP 6-675
Clear Area G prescribed period of time, after the Lead Edge of 6-11
paper has reached the Finisher Input Path Sensor.
(SE 2)
Paper Jam F4-46 Remaining paper detected by the Finisher Path RAP 6-677
Clear Area G Sensor. (SE 2) 6-12
Paper Jam F4-51 Paper does not leave the Finisher Exit Path Sensor RAP 6-678
Clear Area G after paper has reached the Finisher Exit Path 6-13
Sensor. (SE 3)

Error Code RAP Page
Message No.
Paper Jam F4-52 After the Lead Edge of paper has reached the RAP 6-680
Clear Area G Finisher Path Sensor, the paper does not reach the 6-14
Finisher Exit Path Sensor within specified time.
(SE 3)
Paper Jam F4-56 Paper was detected by the Finisher Exit Path Sensor RAP 6-682
Clear Area G when the Finisher was initialized. (SE 3) 6-15
Paper Jam F4-61 1. In Staple Mode, the Compiler Tray Exit Path RAP 6-684
Clear Area H Sensor does not turn OFF within a prescribed period 6-16
of time from the time the set was to be ejected.
2. In Unstaple Mode, the Compiler Tray Exit Path
Sensor does not turn OFF within a prescribed period
of time from the time the Compiler Tray Exit Path
Sensor turned ON. (SE 4)
Paper Jam F4-66 Remaining paper detected by the Compiler Tray Exit RAP 6-686
Clear Area H Path Sensor. (SE 4) 6-17
Close Cover E F6-1 Finisher IN Gate Cover is sensed to be open. (SE RAP 6-688
29) 6-18
Close Door F F6-2 Finisher Transport Door F is sensed to be open. (SE RAP 6-690
30) 6-19
Close Stapler F7-1 Finisher Stapler Door is sensed to be open. (SW 27) RAP 6-691
Door 6-20
Close Exit Roller F7-3 Exit Roller Unit Interlock is Open. RAP 6-692
Unit (SW 26) 6-21
Slide In Finisher F8-1 Finisher Interlock Switch is sensed to be open. (SW RAP 6-694
24) 6-22
Insert Tray 1 H1-1 There is a Lift Up problem with Tray 1. RAP 1-91
sensed that Tray 1 was not raising into position in
Feeder 1.
Insert Tray 2 H1-2 There is a Lift Up problem with Tray 2. RAP 1-92
sensed that Tray 2 was not raising into position in
Feeder 2.
Insert Tray 3 H1-3 There is a problem with Tray 3. RAP 2-395
sensed that the Tray 3 Paper Level Sensor did not
actuate within the specified time after the Tray 3 Lift
Motor was actuated.
actuate within the specified time after the Tray 4 Lift
Motor was actuated.
actuate within the specified after the Tray 5 Lift Motor
was actuated.

Error Code RAP Page
Message No.
Duplex Unit Fail H2-7 There is a communication problem between the RAP 1-93
Power Off/On printer and the Duplex Unit. 1-38
could not initialize the Duplex Unit within the
specified time.
Install Correct H2-8 Incorrect Duplex Unit detected as being installed.
Duplex Unit (N24/N32/N40 Duplexer Installed instead of N4525
Duplexer.). No RAP required.
Load Tray 1 H4-1 Tray 1 out of paper or size/type incorrect for printed RAP 1-94
<size>, <type> job. 1-39
Finisher Failure H5-11 Failure of Finisher Bin. (SE21) RAP 6-696
Power Off/On 6-23
Finisher Failure H5-21 Failure of Finisher Front Jogger. (SE 8) RAP 6-698
Power Off/On 6-24
Finisher Failure H5-22 Failure of Finisher Rear Jogger. (SE 9) RAP 6-699
Power Off/On 6-25
Finisher Failure H5-81 Failure of Exit Roller Open/Close. RAP 6-700
Power Off/On (SE 5) 6-26
Finisher Failure H5-83 Failure of Roller Shift. (SE 6) RAP 6-702
Power Off/On 6-27
Finisher Failure H5-91 Failure of Stapler. (SE 16) RAP 6-704
Power Off/On 6-28
Finisher Failure H5-92 Failure of Stapler Head Home Sensor. (SE 16) RAP 6-705
Power Off/On 6-29
Finisher Failure H5-93 Failure of Stapler Front Staple Position. (SE 10) RAP 6-707
Power Off/On 6-30
Finisher Failure H5-96 Failure of Stapler Swing. (SE 11/12) RAP 6-709
Power Off/On 6-31
Finisher Failure H6-7 Communication Error between Print Engine RAP 6-710
Power Off/On Controller and Finisher Board. 6-32
HCF NVM Fail H7-3 There is a communication problem between the RAP 2-406
Power Off/On H7-4 Print Engine controller and the High Capacity 2-19
Feeder or a problem with NVM on the HCF.
H7-7
NVM on the High capacity feeder control Board
cannot execute a READ/WRITE, is non-functional, or
there is a communication error between the HCF and
the Print Engine Controller Board.
Replace Print J1-2 The Laser Print (EP) Cartridge is low on toner RAP 1-96
Cartridge and should be replaced. 1-41
sensed that at Main Motor start-up, the Toner Sensor
was off for longer than the specified time.

Error Code RAP Page
Message No.
Install Print J3-1 The Laser Print (EP) Cartridge is not installed or RAP 1-97
Cartridge is not installed correctly. 1-42
sensed that the Laser Print (EP) Cartridge Interlock
Switch was not actuated.
Replace Print J6-1 The Laser Print (EP) Cartridge has reached end RAP 1-98
Cartridge of life. 1-43
Logic Control on the Print Engine controller Board
sensed that the Laser Print (EP) Cartridge has
printed a specified number of prints and should be
replaced with a new one.
Print Cartridge J8-1 The wrong Laser Print (EP) Cartridge is installed RAP 1-99
OEM ID in the printer. 1-44
Mismatch Logic Control on the Print Engine Controller Board
sensed that the Laser Print (EP) Cartridge installed
is not compatible with the printer.
Install Print J8-3 A laser Print (EP) Cartridge Memory error RAP 1-100
Cartridge occurred. 1-45
could not read Laser Print (EP) Cartridge Memory
data.
CRUM Failure J8-4 A laser Print (EP) Cartridge memory RAP 1-101
Power Off/On communication error occurred. 1-46
could not access Laser Print (EP) Cartridge Memory
data.
CRUM Failure J8-5 A Laser Print (EP) Cartridge memory RAP 1-102
Replace CRU communication error occurred. 1-47
sensed a wrong or a counterfeit Laser Print (EP)
Cartridge.
Motor Failure U1-1 There is a problem with the Main Motor. RAP 1-46
Power Off/On Logic Control on the Print Engine Controller Board 1-1
detected a problem with the Main Motor.
LVPS Fan U1-3 There is a problem with the Low Voltage Power RAP 1-48
Failure Supply Fan. 1-2
detected a problem with the Low Voltage Power
Supply Fan.
Drum Mtr Fail U1-4 There is a problem with the Drum Motor. RAP 1-49
detected a problem with the Drum Motor.
Laser Failure U3-1 There is a problem with the Laser Scanner. RAP 1-50
received a constant HIGH signal from the Start Of
Scan (SOS) Sensor.
Laser Failure U3-3 There is a problem with the Start Of Scan (SOS) RAP 1-51
Power Off/On Sensor. 1-5
detected the time between signals from the Start of
Scan Sensor was longer than specified.

Error Code RAP Page
Message No.
Laser Failure U3-4 There is a problem with the Start Of Scan (SOS) RAP 1-52
Power Off/On Sensor. 1-6
detected the time between signals from the Start Of
Scan Sensor was shorter than specified.
Laser Failure U3-5 There is a problem with the Laser Scanner. RAP 1-53
detected that the Laser Scanner Motor has not come
up to full speed within the specified time.
Fuser Failure U4-1 There is a problem with the Fuser. RAP 1-54
detected that the thermistor remained on for longer
than the specified time.
detected that the Fuser temperature exceeded the
temperature set for Fuser overheat.
sensed that the Fuser thermostat opened.
sensed that the Fuser thermostat opened.
detected a fuser temperature above the upper limit.
Fan Failure U4-9 There is a problem with the Fuser Fan. RAP 1-59
received a Fan Alarm signal from Fuser Fan.
IOT Memory Fail U6-2 There is a problem reading information from RAP 1-60
Power Off/On RAM. 1-14
had a problem reading information from RAM.
IOT NVM Fail U6-3 There is an unnamed problem with Non-Volatile RAP 1-61
Power Off/On Memory. 1-15
had a problem with NVRAM.
IOT NVM Fail U6-4 There is a problem reading information from RAP 1-62
Power Off/On Non-Volatile Memory. 1-16
had a problem reading information from NVRAM.
IOT ASIC Fail U6-5 There is a problem with ASIC-CRUM. RAP 1-63
detected an ASIC-CRUM control circuit error.

System Controller Error Codes
The following error codes are considered to be Power-On Boot Codes.
Most Repair Analysis Procedures assume there is no malfunction in the System Controller
Board. If you are unable to correct a problem using the previous error code table, it is
recommended that you now check the System Controller Error Blink Codes per the table
below. In some instances, the Control Panel Display may not be sufficiently functional to
accurately show error codes/messages. Before replacing the System Controller, please
refer to this table for additional help in troubleshooting.
The System Controller Board is programmed to display simple error codes by means of a
single red LED (CR 1) near the connecter edge of the board. The LED blinking pattern
will indicate various detected failures connected with the board and/or accessories
installed on the board. The System Controller Error Code Table below will help you
pinpoint the fault. If all else fails, replace the System Controller Board.
Table 1-28 System Controller Error Code Table
LED # Blinks,
Followed by 1
Control Panel Message 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
0001 - BASE ROM 3 System Controller Board boot ROM. Replace
0001 - ASIC 4 System Controller Board ASIC failure. Replace
0001 - TIMER 4 System Controller Board Timer failure. Replace
0001 - PWPM 5 System Controller Board PWPM failure. Replace
0001 - DMA 5 System Controller Board DMA failure. Replace
0001 - COMM or 6 System Controller Board parallel or USB port failure.
0001 - USB Replace System Controller Board. Go to RRP 1-73.
1000 - IOT 8 System Controller - IOT (Print Engine)
handshake failure. Remove and reinstall the
System Controller Board (RRP 1-73)
Replace the System Controller Board (RRP
1-73)
Replace the Print Engine Controller Board
(RRP 1-72)
0010 - DISK 9 Hard disk failure.
Format Hard Disk (Call Technical Support for
assistance)
Replace the Hard Disk (Instructions supplied
with the replacement hard disk)
(RRP 1-73)

Table 1-28 System Controller Error Code Table (cont'd.)
LED # Blinks,
Followed by 1
Control Panel Message sec. Off Comment
0101 - DIMM1 10 DIMM 1 failure. Replace DIMM 1.
2000 - XIE RAM 15 System Controller Xerox Image Enhanced PWPM
failure. Replace System Controller Board. Go to
RRP 1-73.
2010 - XIE PWPM 15 System Controller Xerox Image Enhanced PWPM
RRP 1-73.
2020 - XIE VDMA 15 System Controller Xerox Image Enhanced VDMA
RRP 1-73.
3000 - Token Ring 16 Replace the appropriate network card.
3000 - Serial Replace System Controller Board. Go to RRP 1-73.
3000 - E-Net (10 Base 2)
5000 - Memory None Memory size not large enough to load the system
software Download Data.
Replace System Controller Board. Go to RRP 1-73.

RAP 1-1
Error Code U1-1 Motor Failure
Power Off/On
There is a problem with the Main Motor.
Logic Control on the Print Engine Controller Board detected a problem with the Main
Motor.
Table 1-29 Error Code U1-1 Motor Failure Power Off/On
1 DRIVE ASSEMBLY INSPECTION Go to step 8 Go to step 2
1. Remove the Rear Cover (RRP 1-5) so you can
observe the Main Motor and Drive Assembly.
2. Hand rotate (counter clockwise) the Main Motor.
Can you easily rotate the Main Motor and do all
of the gears on the Main Drive Assembly rotate
freely and without binding?
2 DRIVE ASSEMBLY INSPECTION Replace the Go to step 3
1. Remove the Laser Print (EP) Cartridge. Laser Print
2. Hand rotate (counter clockwise) the Main Motor. Cartridge with
a new one.
3 SUBSYSTEM ISOLATION Go to step 4 Replace the
1. Open the Left Cover A. Left Upper
2. Touching only the drive gear at the end of the Roller, Cover (A)
hand rotate the Bias Transfer Roller. Assembly
Can you easily rotate the Bias Transfer Roller? (RRP 1-42)
4 SUBSYSTEM ISOLATION Replace the Go to step 5

1. Remove the Fuser Assembly. Fuser
2. Hand rotate (counter clockwise) the Main Motor. Assembly
1. Remove the Offset Unit (RRP 1-54). Offset Unit
2. Hand rotate (counter clockwise) the Main Motor. (RRP 1-54)
1. Remove the Tray 1 Feed Clutch (RRP 1-10). Tray 1 Feed
2. Hand rotate (counter clockwise) the Main Motor. Clutch (RRP
1-10)

Table 1-29 Error Code U1-1 Motor Failure Power Off/On (cont'd.)
7 SUBSYSTEM ISOLATION Replace the Replace the
1. Remove the Multi-sheet Bypass Feeder Feed Clutch Multi-sheet Main Drive
(RRP 1-29). Bypass Asembly
2. Hand rotate (counter clockwise) the Main Motor. Feeder Feed (RRP 1-66)
Can you easily rotate the Main Motor and do all Clutch (RRP
of the gears on the Main Drive Assembly rotate 1-29
8 MAIN MOTOR TEST Go to step 9 Replace the
1. Enter Diagnostics Mode Main Drive
2. From the Main Menu, select Comp Output Test / IOT Assembly
Unit / Main Motor On to check the Main Motor function. (RRP 1-66)
Does the Main Motor run when you start Main
Motor Output Test?
9 PRINT ENGINE CONTROLLER BOARD Go to step 10 Problem
REPLACEMENT solved
Replace the Print Engine Controller Board (RRP 1-72).
Does the error code appear?
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
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
Low Voltage Power Supply (RRP 1-67)
Input/Output Board (RRP 1-70).

RAP 1-2
Error Code U1-3 LVPS Fan
Failure
There is a problem with the Low Voltage Power Supply Fan.
Logic Control on the Print Engine Controller Board detected a problem with the Low
Voltage Power Supply Fan.
Table 1-30 Error Code U1-3 LVPSFan Failure
1 LOW VOLTAGE POWER SUPPLY FAN TEST Replace the Replace the
1. Enter Diagnostics Mode. Print Engine Low Voltage
2. From the Main Menu, select Comp Output Test / LVPS Controller Power Supply
Fan High to check the Low Voltage Power Supply Fan Board (RRP cooling fan
function. 1-72) (RRP 1-67)
Does Fan rotate when you start theLVPS Fan
Output Test?

RAP 1-3
Error Code U1-4 Drum Mtr Fail
Power Off/On
There is a problem with the Drum Motor.
Logic Control on the Print Engine Controller Board detected a problem with the Drum
Motor.
Table 1-31 Error Code U1-4 Drum Mtr Fail Power Off/On
1 DRUM MOTOR TEST Replace the Go to step 2
1. Enter Diagnostics Mode. Print Engine
2. From the Main Menu, select Comp Output Test / IOT Controller
Unit / Drum Motor On to check the Drum Motor Board (RRP
function. 1-72)
Does Drum Motor rotate when you start Output
Test?
2 DRUM MOTOR TEST Replace the Replace the
1. Remove the Laser Print (EP) Cartridge from the Laser Print Main Drive
printer. (EP) Assembly
2. From the Main Menu, select Comp Output Test / IOT Cartridge with (RRP 1-66)
Unit / Drum Motor On to check the Drum Motor a new one
function.
Does Drum Motor rotate when you start the
test?

RAP 1-4
Error Code U3-1 Laser Failure
Power Off/On
There is a problem with the Laser Scanner.
Logic Control on the Print Engine Controller Board received a constant HIGH signal
from the Start of Scan (SOS) Sensor.
Table 1-32 Error Code U3-1 Laser Failure Power Off/On
1 RESET Go to step 2 Suspect an
Switch off printer main power. intermittent
problem with
Wait one minute.
the Print
Switch on printer main power. Engine
Controller
Board, the
Laser Diode
board, the
SOS Sensor,
or the
connectors
and wiring
linking these
Does the error code appear? components.
REPLACEMENT solved
3 LASER SCANNER REPLACEMENT Go to step 4 Problem
Replace the Laser Scanner Assembly (RRP 1-47). solved
Interlock switches and circuits

RAP 1-5
Power Off/On
There is a problem with the Start of Scan (SOS) Sensor.
Logic Control on the Print Engine Controller Board detected that the time between signals
from the Start of Scan Sensor was longer than specified.
Switch off printer main power. intermittent
problem with
Wait one minute.
the Print
Switch on printer main power. Engine
Controller
Board, the
Laser Diode
board, the
SOS Sensor,
or the
connectors
and wiring
linking these
Does the U3-3 error code appear? components.
2 LOW VOLTAGE POWER SUPPLY +5VDC Go to step 3 Replace the
CHECK Low Voltage
Measure the voltage between J400, pins 1, 2 & 3 (on the Power Supply
Print Engine Controller Board) and frame ground. Assembly
(RRP 1-67)
Is there +5VDC between J400, pins 1,2 & 3 and
frame ground?
REPLACEMENT solved

RAP 1-6
Power Off/On
There is a problem with the Start of Scan (SOS) Sensor.
Logic Control on the Print Engine Controller Board detected that the time between signals
from the Start of Scan Sensor was shorter than specified.
1. Switch off printer main power. intermittent
2. Wait one minute. problem with
3. Switch on printer main power. the Print
Engine
Controller
Board, the
Laser Diode
board, the
SOS Sensor,
or the
connectors
and wiring
linking these
CHECK Low Voltage
(RRP 1-67)
frame ground?
REPLACEMENT solved


RAP 1-7
Power Off/On
There is a problem with the Laser Scanner.
Logic Control on the Print Engine Controller Board detected that the Laser Scanner
Motor has not come up to full speed within the specified time.
Engine
Controller
Board, the
Laser
Scanner
Motor, the
SOS Sensor,
or the
connectors
and wiring
Does the U3-5 error code appear? linking these
components.
2 LASER SCANNER MOTOR TEST Go to step 4 Go to step 3
1. Enter Diagnostics Mode.
2. From the Main Menu, select Comp Output Test / IOT
Unit / ROS Motor On to check the Laser Scanner
Motor function.
Does the Laser Scanner Motor run when you
start the test?
3 LOW VOLTAGE POWER SUPPLY +24VDC Replace the Replace the
CHECK Laser Low Voltage
Measure the voltage between J400-8 (on the Print Scanner Power Supply
Engine Controller Board) and frame ground. Assembly Assembly
(RRP 1-47) (RRP 1-67)
Is there +24VDC between J400-8 and frame
ground?
REPLACEMENT solved

RAP 1-8
Error Code U4-1 Fuser Failure
Power Off/On
There is a problem with the Fuser.
Logic Control on the Print Engine Controller Board detected that the Thermistor remained
on for longer than the specified time.
Table 1-36 Error Code U4-1 Fuser Failure Power Off/On
1 FUSER WARM-UP Go to step 4 Go to step 2
1. Switch off printer main power.
2. Remove the Fuser Cover (RRP 1-1) so you can
observe the Heat Rods.
3. Switch on printer main power and observe the ends of
the Fuser Assembly.
Do the Heat Rods glow?
2 FUSER AC POWER Go to step 3 Replace the
1. Switch on printer main power. AC Driver
2. Measure the AC voltage between P/J31-1 (common) board (RRP
to P/J32-1 and P/J33-1 on the AC Driver board. 1-69)
Is there line voltage (110/220 VAC) between
P/J32-1 or P/J33-1 and P/J31-1 (common)?
REPLACEMENT solved
4 FUSER REPLACEMENT Go to step 5 Problem
Replace the Fuser Assembly. solved

RAP 1-9
Power Off/On
Logic Control on the Print Engine Controller Board detected the Fuser temperature
exceeded the temperature set for Fuser overheat.
REPLACEMENT solved
3 AC DRIVER BOARD REPLACEMENT Go to step 4 Problem
Replace the AC Driver board (RRP 1-68). solved

RAP 1-10
Power Off/On
Logic Control on the Print Engine Controller Board sensed that the Fuser Thermostat
opened.
REPLACEMENT solved

RAP 1-11
Power Off/On
Logic Control on the Print Engine Controller Board sensed that the Fuser Thermostat
opened.
REPLACEMENT solved

RAP 1-12
Power Off/On
Logic Control on the Print Engine Controller Board detected a fuser temperature above the
upper limit..
REPLACEMENT solved

RAP 1-13
Error Code U4-9 Fan Failure
Power Off/On
There is a problem with the Fuser Fan.
Logic control on the Print Engine Controller Board received a Fan Alarm signal from the
Fuser Fan.
Table 1-41 Error Code U4-9 Fan Failure Power Off/On
1 FUSER FAN TEST Replace the Go to step 2
1. Enter Diagnostics Mode. Print Engine
2. From the Main Menu, select Comp Output Test / IOT Controller
Unit / Fuser Fan High to check the Fuser Fan function. Board (RRP
3. Press [4] to start, [0] to stop. 1-72)
Does the Fuser Fan run when you start the
test?
2 LOW VOLTAGE POWER SUPPLY +24VDC Replace the Go to step 3
CHECK Fuser Fan
Measure the voltage between P/J204-1 and P/J204-4 (PL 8.1)
(on the Fuser Fan).
Is there +24VDC between P/J204-1 and
P/J204-4 on the fuser fan connector?
3 LOW VOLTAGE POWER SUPPLY Go to step 4 Problem
REPLACEMENT solved
Replace the Low Voltage Power Supply Assembly (RRP
1-67).

RAP 1-14
Error Code U6-2 IOT Memory Fail
Power Off/On
There is a problem reading information from RAM.
Logic control on the Print Engine Controller Board had a problem reading
information from RAM.
Table 1-42 Error Code U6-2 IOT Memory Fail Power Off/On
Engine
Controller
Board, the
Low Voltage
Power Supply,
or the
connectors
and wiring
linking these
CHECK Low Voltage
(RRP 1-67)
frame ground?
REPLACEMENT solved
4 SYSTEM CONTROLLER BOARD Go to step 5 Problem
REPLACEMENT solved
Replace the System Controller Board (RRP 1-73).

RAP 1-15
Error Code U6-3 IOT NVM Fail
Power Off/On
There is an unnamed problem with non-volatile memory.
Logic Control on the Print Engine Controller Board had a problem with NVRAM.
Table 1-43 Error Code U6-3 IOT NVM Fail Power Off/On
Engine
Controller
Board, the
Low Voltage
Power Supply,
or the
connectors
and wiring
linking these
CHECK Low Voltage
(RRP 1-67)
frame ground?
REPLACEMENT solved
REPLACEMENT solved
Wiring and connectors linking the components.

RAP 1-16
Error Code U6-4 IOT NVM Fail
Power Off/On
There is a problem reading information from non-volatile memory.
Logic control on the Print Engine Controller Board had a problem reading
information from NVRAM
Table 1-44 Error Code U6-4 IOT NVM Fail Power Off/On
Engine
Controller
Board, the
Low Voltage
Power Supply,
or the
connectors
and wiring
linking these
CHECK Low Voltage
(RRP 1-67)
frame ground?
REPLACEMENT solved
Replace the Print Engine Controller Board (RRP 1-72.
REPLACEMENT solved
Wiring and connectors linking the components.

RAP 1-17
Error Code U6-5 IOT ASIC Fail
Power Off/On
There is a problem with ASIC-CRUM.
Logic control on the Print Engine Controller Board detect an ASIC-CRUM control
circuit error.
Table 1-45 Error Code U6-5 IOT ASIC Fail Power Off/On
3. Switch on printer main power. the
Input/Output
Board, the
Print Engine
Controller
Board, the
Low Voltage
Power Supply,
or the
connectors
and wiring
Does the U6-5 error code appear? linking these
components.
CHECK Low Voltage
(RRP 1-67)
frame ground?
3 INPUT/OUTPUT BOARD REPLACEMENT Go to step 4 Problem
Replace the Input/Output Board (RRP 1-70). solved
REPLACEMENT solved
Laser Print (EP) Cartridge.

RAP 1-18
Error Code E1-1 Paper Jam
Clear Area A
There is a paper jam at the Registration Sensor.
Logic Control on the Print Engine Controller Board sensed that paper did not leave
the Registration Sensor within the specified time.
Table 1-46 Error Code E1-1 Paper Jam Clear Area A
1 PAPER PATH INSPECTION Go to step 2 Clear the
Inspect the paper path for paper scraps that may cause a paper path
paper jam.
Is the paper path free of paper scraps?
2 PAPER INSPECTION Replace with Go to step 3
Inspect the paper that is loaded in the paper tray. new paper
Is the paper loaded in the cassette wrinkled or
damaged?
3 PAPER SIZE INSPECTION Go to step 4 Adjust the
Inspect the cassette paper guides. guides
Are the guides set to the size of paper loaded
in the cassette?
4 PAPER TRAVEL INSPECTION Replace the Go to step 5
Open the Left Upper Cover and observe the position of Feed, Pick,
the jammed paper. and Retard
Rolls (RRP
Is the sheet of paper skewed? 1-11)
5 REGISTRATION SENSOR TEST Go to step 6 Replace the
1. Enter Diagnostics Mode. Registration
2. From the Main Menu, select Comp Input Test / IOT Sensor.
Unit / Reg. Sensor.
3. Press [4] to start.
4. Open the Left Upper Cover (A).
5. Insert, then remove, a sheet of paper into the
Registration Sensor.
6. Press [0] to stop.
Does the Control Panel Display show “"with
paper"” when you insert the paper into the
Registration Sensor, and does it show “without
paper” when you remove the paper?
REPLACEMENT solved

Table 1-46 Error Code E1-1 Paper Jam Clear Area A (cont'd.)

RAP 1-19
Clear Area A
There is a paper jam between the Registration Sensor and the Fuser Exit Switch.
Logic Control on the Print Engine Controller Board sensed the Fuser Exit Sensor was
not actuated within the specified time since the Registration Clutch was actuated.
Inspect the paper path for paper scraps that may cause a paper path
paper jam.
Is the paper path free of paper scraps?
2 PAPER INSPECTION Replace the Go to step 3
Inspect the paper that is loaded in the paper tray. paper with
new paper
damaged?
3 PAPER TRAVEL INSPECTION Go to step 4 Go to step 5
Open the Left Upper Cover (A) and observe the position
of the jammed paper.
Did the sheet of paper stop at the Registration
Rolls?
4 REGISTRATION CLUTCH TEST Clean the Replace the
1. Enter Diagnostics Mode. Registration Registration
2. From the Main Menu, select Comp Output Test / IOT Rollers or Clutch (RRP
Unit / Reg. Clutch On to check the Registration Clutch replace the 1-41)
function. Left Upper
3. Press [4] to start, the Registration Clutch will actuate Cover (A)
for 2 seconds and release. Assembly
Does the Registration Roller clutch Actuate (RRP 1-42)
when you start the test?
2. From the Main Menu, select Comp Input Test / IOT Sensor
Unit / Reg. Sensor.
4. Open Left Upper Cover (A) and 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?
Open the Left Upper Cover (A) and observe the position
of the jammed paper.
Did the sheet of paper stop on the Drum?

7 DRUM INSPECTION Replace the Go to step 8
Open the Left Upper Cover (A) and open the Drum Laser Print
Shutter. (EP)
Cartridge
Are the stripper fingers damaged or is there
paper stuck under the fingers or stuck between
the Drum and Laser Print (EP) Cartridge
frame?
8 DRUM ROTATION TEST Go to step 9 Replace the
1. Open the Left Upper Cover and open the Drum Laser Print
Shutter. (EP)
2. Hand rotate (counter clockwise) the Drum Drive Motor. Cartridge
Does the Drum rotate smoothly and without
binding?
Open the Left Upper Cover, and observe the position of
the jammed paper.
Did the sheet of paper stop while exiting the
Fuser?
10 FUSER INSPECTION Go to step 11 Replace the
1. Remove the three screws securing the Fuser Left Fuser
Cover and remove the Cover so you can observe the Assembly
Fuser Rolls.
2. Hand rotate (counter clockwise) the Main Drive Motor.
Does the Pressure Roller rotate smoothly and
are the Fuser Stripper Fingers undamaged?
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?
12 OFFSET UNIT INSPECTION Go to step 13 Clean or
Check the Offset Unit for lodged scraps of paper or replace the
damage. Offset Unit
Assembly
Is the Offset Unit clean and undamaged? (RRP 1-54)
13 FUSER EXIT SENSOR TEST Go to step 14 Replace the
1. Enter Diagnostic Mode. Fuser Exit
2. From the Main Menu, select Comp Input Test / IOT Sensor (PL
Unit / Fuser Exit Sen. 9.1)
4. Insert, then remove, a sheet of paper into the Fuser
Exit Sensor.
when you insert the paper into the Fuser Exit
REPLACEMENT solved


RAP 1-20
Clear Area A
There is a paper jam between the Fuser Exit Sensor and the Face Up Exit Sensor.
Logic Control on the Print Engine Controller Board sensed the Face Up Exit Sensor
was not actuated within the specified time since the Fuser Exit Sensor was actuated
1 OFFSET UNIT INSPECTION Go to step 2 Clean or
1. Remove the Fuser Cover (RRP 1-1). replace the
2. Check the Offset Unit for lodged scraps paper or Offset Unit
damage. Assembly
Is the Offset Unit clean and undamaged? (RRP 1-54)
2 FACE UP CLUTCH TEST Go to step 3 Replace the

NOTE: The Duplex Unit must be installed for this test. Offset Unit
Assembly
1. Enter Diagnostics Mode. (RRP 1-54)
2. From the Main Menu, select Comp Output Test /
Duplex Unit / Invert Clut. CCW.
3. Press [4] to start, clutch will actuate for 2 seconds,
then release.
Do the Offset Rollers rotate?
3 FACE UP EXIT SENSOR TEST Go to step 4 Replace the
1. Enter Diagnostics Mode. Face Up Exit
2. From the Main Menu, select Comp Input Test / IOT Sensor (RRP
Unit / FaceUp Exit Sen. 1-63)
4. Insert, then remove, a sheet of paper into the Face Up
Exit Sensor actuator.
Does the Control Panel display "with paper"
when you insert the paper into the Face Up Exit
Sensor, and "without paper" when you remove
the it?
4 DUPLEX EXIT GATE SOLENOID TEST Go to step 5 Replace the
1. Enter Diagnostics Mode. Exit Gate
2. From the Main Menu, select Comp Output Test / Solenoid
Duplex Unit / Exit Gate Sol. (RRP 1-56)
3. Press [4] to test the Duplex Exit Gate Solenoid
function. The Duplex Exit Gate Solenoid will actuate
for two seconds, then release.
Does the Exit Gate Solenoid actuate when you
run the Output Test?
REPLACEMENT solved


RAP 1-21
Clear Area A
There is a problem at the Registration Sensor.
Paper is detected on the Registration Sensor.
1 SENSOR INSPECTION Go to step 2 Clean or clear
Inspect the Registration Sensor for contamination or paper from
paper scraps that may have actuated the Sensor. the Sensor
Is the Registration Sensor clean and free of
paper scraps?
2. From the Main Menu, select Comp Input Test / IOT Sensor, then
Unit / Reg. Sensor. repeat this
3. Press [4] to start, [0] to stop. step.
REPLACEMENT solved

RAP 1-22
Clear Area A
There is a paper jam at the Fuser Exit Sensor.
Logic Control on the Print Engine Controller Board sensed the Fuser Exit Sensor did
not de-actuate within the specified time after actuating.
1. Remove the Fuser Cover (RRP 1-1).
2. Observe the position of the sheet of paper.
Did the sheet of paper stop on the Fuser Exit
Switch?
1. Enter Diagnostics Mode. Fuser Exit
2. From the Main Menu, select Comp Input Test / IOT Sensor (PL
Unit / Fuser Exit Sen. 9.1)
Exit Sensor.
you remove the it?
Observe the position of the sheet of paper.
Is the trail edge of the paper still in the Fuser?
1. Remove the three screws securing the Fuser Left Fuser
Cover and remove the Cover so you can observe the Assembly
Fuser Rollers.
Does the Pressure Roller rotate smoothly and
are the Fuser Stripper Fingers undamaged?
1. Enter Diagnostics Mode. Offset Unit
2. From the Main Menu, select Comp Output Test / Assembly
Duplex Unit / Invert Clut. CCW to check the Invert (RRP 1-54)
Clutch CCW function.
3. Press [4] to start, clutch will actuate for two seconds,
then release.
REPLACEMENT solved
Replace the Print Engine Controller Board (RRP 1-72)


RAP 1-23
Clear Area A
The Fuser Exit Sensor is actuated at printer power on.
Logic Control on the Print Engine Controller Board sensed the Fuser Exit Sensor was
on while the printer was in standby.
1 SENSOR INSPECTION Go to step 2 Clear paper
Inspect the Fuser Exit Sensor for paper scraps that may from the
have actuated the Sensor or may have caused it to stick. Sensor
Is the Fuser Exit Sensor free of paper scraps?
1. Remove the Fuser Cover (RRP 1-1) Fuser Exit
2. Enter Diagnostics Mode. Sensor (PL
3. From the Main Menu, select Comp Input Test / IOT 9.1)
Unit / Fuser Exit Sen.
Exit Sensor.
REPLACEMENT solved

RAP 1-24
Clear Area A
There is a paper jam at the Face Up Exit Sensor.
Logic Control on the Print Engine Controller Board sensed that during
Face-Up-Mode, the Face Up Exit Sensor did not de-actuate within the specified time
after actuating.
Did the sheet of paper stop on the Face Up Exit
Sensor?
2 FACE UP EXIT SENSOR TEST Replace the Replace the
1. Enter Diagnostics Mode. Print Engine Face Up Exit
2. From the Main Menu, select Comp Input Test / IOT Controller Sensor (RRP
Unit / FaceUp Exit Sen. Board (RRP 1-63)
4. Manually actuate and deactuate the Face Up Exit
Sensor.
Duplex Unit / Invert Clut. CCW. (RRP 1-54)
then release.

RAP 1-25
Clear Clear A
Logic Control on the Print Engine Controller Board sensed that during Duplex Mode
the Face Up Exit Sensor did not de-actuate within the specified time after actuating.
Did the sheet of paper stop on the Face Up Exit
Sensor?
1. Enter Diagnostics Mode. Print Engine Face Up Exit
2. From the Main Menu, select Comp Input Test / IOT Controller Sensor (RRP
Unit / FaceUp Exit Sen. Board (RRP 1-63)
4. Manually actuate and deactuate the Face Up Exit
Sensor.
2. From the Main Menu, select Comp Output / Duplex Assembly
Unit / Invert Clut. CCW. (RRP 1-54)
then release.
4 DUPLEX UNIT INSPECTION Treat problem Go to the
Examine the Duplex Unit operation. as an Duplex Unit
intermittent or section of this
Is the Duplex Unit functioning correctly, and go to step 5 manual and
the rollers are feeding paper from the Offset troubleshoot
Unit into the Duplex Unit? the problem

RAP 1-26
Clear Clear A
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.
1 DUPLEX UNIT INSPECTION Go to step 2 Go to the
Examine the Duplex Unit operation. Duplex Unit
section of this
Is the Duplex Unit functioning correctly, and manual and
the rollers are feeding paper from the Offset troubleshoot
Unit into the Duplex Unit? the problem
1. Enter Diagnostic Mode - Input Face Up Exit Sensor. Print Engine Face Up Exit
2. Manually actuate and deactuate the Face Up Exit Controller Sensor (RRP
Sensor. Board (RRP 1-63)
Does the Control Panel display “with paper” 1-72)
Duplex Unit / Invert Clut. CCW to check the Invert (RRP 1-54)
Clutch counter clockwise.
4 OFFSET CATCH Tray REVERSE CLUTCH TEST Go to step 5 Replace the
1. Enter Diagnostics Mode. Inverter
2. From the Main Menu, select Comp Output Test / Clutches
Duplex Unit / Invert Clut. CW to check the Invert (RRP 1-64)
Clutch clockwise.
then release.
5 DUPLEX BOARD REPLACEMENT Go to step 6 Problem
Replace the Duplex BOARD (RRP 3-5). solved

RAP 1-27
Clear Area A
Logic Control on the Print Engine Controller Board sensed the Face Up Exit Sensor
was on while the printer was in standby.
1 FACE UP EXIT SENSOR INSPECTION Go to step 2 Clear paper
1. Remove the Fuser Cover (RRP 1-1). from the
2. Inspect the Face Up Exit Sensor for paper scraps that Sensor
may be actuating the sensor.
Is the Face Up Exit Sensor actuator free of
paper scraps?
2 FACE UP EXIT SENSOR INSPECTION Go to step 3 Replace the
Inspect the Face Up Exit Sensor for damage. Face Up Exit
Sensor (RRP
Is the sensor undamaged? 1-63)
3 FACE UP EXIT SENSOR TEST Go to step 4 Replace the
1. Enter Diagnostics Mode. Face Up Exit
2. From the Main Menu, select Comp Input Test / IOT Sensor (RRP
Unit / FaceUp Exit Sen. 1-58)
4. Insert, then remove, a sheet of paper into the Face Up
Exit Sensor.
REPLACEMENT solved

RAP 1-28
Error Code E5-1 Close Door A
The Left Door (A) is open.
The Left Door (A) is closed, but Logic Control on the Print Engine Controller Board
sensed the Left Door (A) Interlock Switch indicates the door is open
Table 1-56 Error Code E5-1 Close Door A
1 LEFT DOOR CHECK Tighten the Go to step 2
Open and close the Left Door (A). Switch
Bracket screw
Does the error code appear? (RRP 1-71)
2 LEFT DOOR INTERLOCK SWITCH Go to step 3 Replace the
INSPECTION Left Cover
1. Remove the Rear Cover (RRP 1-5). Interlock
2. Inspect the Left Door (A) Interlock Switch for damage, Switch (RRP
such as a broken or missing spring or a broken switch 1-71)
button.
Is the switch undamaged?
3 LEFT DOOR INTERLOCK ACTUATOR Go to step 4 Replace the
INSPECTION Left Upper
Open and close the Left Door (A) while observing the Cover (RRP
action of the Left Door (A) Actuator against the Interlock 1-42)
Switch Spring.
Is the Left Cover Interlock Actuator pressing
against the Interlock Switch Spring?
4 LEFT DOOR INTERLOCK SWITCH TEST Go to step 5 Replace the
1. Enter Diagnostics Mode. Left Cover
2. From the Main Menu, select Comp Input Test / IOT Interlock
Unit / L/H Cover A. Switch (RRP
4. Actuate and deactuate the Left Door Interlock Switch.
Does the display indicate Open/Closed when
you actuate and deactuate the Left Cover
Interlock Switch?
REPLACEMENT solved
Replace the Print Engine Controller Board (RRP 1-72.

RAP 1-29
Error Code E5-2 Close Door B
The Left Lower Cover (B) is open.
The Left Lower Cover (B) is closed, but Logic Control on the Print Engine Controller
Board sensed the Left Lower Cover Interlock Switch is open.
Table 1-57 Error Code E5-2 Close Door B
1 LEFT LOWER COVER CHECK Problem Go to step 2
Open and close the Left Lower Cover (B). solved
Is the error code cleared?
2 LEFT LOWER COVER INTERLOCK SWITCH Replace the Go to step 3
INSPECTION Left Lower
Inspect the Left Lower Cover Interlock Switch for Cover
damage. Interlock
Switch
Is the switch damaged?
3 LEFT LOWER COVER INTERLOCK ACTUATOR Replace the Go to step 4
INSPECTION Left Lower
Inspect the Left Lower Cover (B) Interlock Actuator for Cover
damage that may prevent the Cover from actuating the
Interlock when the Cover is closed.
Is the Interlock Actuator damaged?
4 LEFT LOWER COVER INTERLOCK SWITCH Replace the Go to step 5
TEST Left Lower
1. Enter Diagnostics Mode. Cover
2. From the Main Menu, select Comp Input Test / Tray 1 Interlock
Cover (B). Switch
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?
REPLACEMENT solved

RAP 1-30
Error Code C1-3 Clear Area A
Reset Tray 1
There is a paper jam between Paper Tray 1 and the Registration Sensor.
Logic Control on the Print Engine Controller Board sensed that the Registration
Sensor did not actuate within the specified time after the Tray 1 Feed Clutch was
actuated.
Table 1-58 Error Code C1-3 Clear Area A Reset Tray 1
new paper
damaged?
Inspect the paper path for paper scraps or foreign objects paper path
that could cause a paper jam.
Is the paper path clear?
3 Tray 1 LIFT MOTOR TEST Go to step 4 Replace Tray
1. Enter Diagnostics Mode. 1 Lift Motor
2. From the Main Menu, select Comp Output Test / IOT (RRP 1-9)
Unit / Tray 1 Lift Mot to test the Tray 1 Lift Motor
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?
4 Tray 1 FEED CLUTCH TEST Go to step 5 Replace the
1. Enter Diagnostics Mode. Tray 1 Feed
2. From the Main Menu, select Comp Output Test / IOT Clutch (RRP
Unit / Tray 1 Feed Clut to check the Tray 1 Feed Clutch 1-10)
function.
3. Press [4] to start, the clutch should actuate for two
seconds, then release.
Does the Tray 1 Feed Clutch actuate when you
start the Output Test?
Unit / Reg. Sensor.
REPLACEMENT solved

Table 1-58 Error Code C1-3 Clear Area A Reset Tray 1

RAP 1-31
Error Code C2-2 Clear Area A,B
Reset Tray 2
There is a paper jam between Paper Tray 2 and the Take AwayRoller 2 Sensor.
Logic Control on the Print Engine Controller Board sensed that the Take Away Roller
2 Sensor did not actuate within the specified time after the Tray 2 Feed Clutch was
actuated.
Table 1-59 Error Code C2-2 Clear Area A,B Reset Tray 2
new paper
damaged?
3 Tray 2 LIFT MOTOR OPERATION Go to step 4 Check wiring
1. Enter Diagnostics Mode. between
2. From the Main Menu, select Comp Output Test / IOT P/J467 to
Unit / Tray 2 Lift Mot. P/J241. If
3. Press [4] to start, Tray 2 Lift Motor should actuate for OK, replace
two seconds, then stop. Tray 2 Lift
Does the Lift Motor lift the Bin? Motor (PL
3.4)
4 Tray 2 FEED CLUTCH OPERATION Go to step 5 Check wiring
2. From the Main Menu, select Comp Output Test / IOT P/J467 to
Unit / Tray 2 Feed Clut to test the Tray 2 Feed Clutch. P/J240. If
3. Press [4] to start, the clutch should actuate for two OK, replace
seconds, then release. the Tray 2
Does the clutch energize? Feed Clutch
(RRP 1-21).
5 PAPER TRAVEL INSPECTION Go to step 6 Replace Tray
Generate a test print from Tray 2. 2 Feed
Rollers (RRP
Does a sheet of paper feed out Tray 2 and into 1-11)
the Take-Away Roller area?
6 TAKE-AWAY ROLLER CHECK Go to step 7 Replace Tray
1. Enter Diagnostics Mode. 2 Take-Away
2. From the Main Menu, select Comp Output Test / IOT Rollers (RRP
Unit / Main Motor On to Start the Main Motor. 1-23).
4. Open Tray 1 and observe the Take Away Rollers.
Does the Take-Away Roller rotate when you run
the Main Motor?

Table 1-59 Error Code C2-2 Clear Area A,B Reset Tray 2 (cont'd.)
7 Tray 2 TAKE AWAY SENSOR TEST Go to step 8 Check wiring
2. From the Main Menu, select Comp Input Test / IOT P/J467 and
Unit / T/A Roll2 Sensor to test Tray 2 Take Away P/J101. If
Sensor. OK, replace
3. Press [4] to start, [0] to stop. the Tray 2
4. Alternately insert, then remove a sheet of paper over Take Away
the Tray 2 Take Away Sensor. Sensor
when you insert the paper into the Tray 2 Take
Away Sensor, and is “without paper” displayed
when you remove the paper?
REPLACEMENT solved
(RRP 1-72)

RAP 1-32
Error Code C2-3 Paper Jam
Clear Area A
There is a paper jam between Paper Tray 2 and the Registration Sensor.
Logic Control on the Print Engine Controller Board sensed that the Registration
Sensor did not actuate within the specified time after the Tray 2 Feed Clutch was
actuated.
Table 1-60 Error Code C2-3 Paper Jam Clear Area A
new paper
damaged?
3 TAKE-AWAY ROLLER CHECK Go to step 4 Replace Tray
1. Enter Diagnostics Mode. 2 Feeder
Unit / Main Motor On to start the Main Motor.
4. Open Tray 2 and observe the Take Away Roller.
Does the Take Away Roller rotate when you run
the Main Motor?
Unit / Reg. Sensor.
REPLACEMENT solved

RAP 1-33
Clear Areas A,B
There is problem with the Tray 2 Take Away Sensor.
Logic Control on the Print Engine Controller Board sensed the Tray 2 Take Away
Sensor was on while the printer was in standby.
Table 1-61 Error Code C8-2 Paper Jam Clear Areas A,B
1 Tray 2 TAKE AWAY SENSOR INSPECTION Go to step 2 Clean or clear
Inspect the Tray 2 Take Away Sensor for contamination or paper scraps
paper scraps that may have actuated the sensor. from the
Sensor
Is the Sensor clean and free of paper scraps?
2 Tray 2 TAKE AWAY SENSOR TEST Go to step 3 Replace the
1. Enter Diagnostics Mode. Tray 2 Take
2. From the Main Menu, select Comp Input Test / IOT Away Sensor
Unit / T/A Roll2 Sensor to test Take-Away Roller 2
Sensor.
5. Insert, then remove, a sheet of paper into the Tray 2
Take Away Sensor.
REPLACEMENT solved

RAP 1-34
Reset
ENV/Bypass
There is a paper jam between the Multi-sheet Bypass Feeder and Tray 2 Take Away
Sensor.
Logic Control on the Print Engine Controller Board sensed that when paper was fed
from the Multi-sheet Bypass Feeder, Tray 2 Take Away Sensor did not actuate within
the specified time after the Multi-sheet Bypass Feeder Feed Clutch was actuated.
Table 1-62 Error Code C9-2 Paper Jam Reset ENV/Bypass
Inspect the paper that is loaded in the Multi-sheet Bypass paper with
Feeder. new paper
Is the paper loaded in the Multi-sheet Bypass
Feeder wrinkled or damaged?
3 MULTI-SHEET BYPASS FEEDER FEED Replace the Go to step 4
ROLLER INSPECTION Multi-sheet
1. Run a Test Print, feeding from the Multi-sheet Bypass Bypass
Feeder. Feeder Feed
2. Observe the paper in the Multi-sheet Bypass Feeder Roller (RRP
Bin. 1-30), Pick
Roller (RRP
1-31), and
Multi-sheet
Bypass
Is the paper partially fed out of the Multi-sheet Feeder Pad
Bypass Feeder Bin? (RRP 1-33)
4 MULTI-SHEET BYPASS FEEDER DRIVE TEST Go to step 5 Replace the
Remove the Rear Cover (RRP 1-5) so you can observe Multi-sheet
the Main Drive Assembly and the Multi-sheet Bypass Bypass
Feeder Multi-sheet Bypass Feeder Drive Gear Feeder
Assembly. Assembly
(RRP 1-25)
1. Place a sheet of paper in the Multi-sheet Bypass
Feeder.
MBF/ENV Unit / MBF Feed Clutch to check the
Multi-sheet Bypass Feeder Drive Assembly.
4. Press [4] to start, clutch should actuate for two
5. Rotate the Main Drive Motor counter clockwise and
observe the paper in the MBF.
Does the paper begin to feed into the paper
path, indicating the Main Drive Assembly
rotated the Multi-sheet Bypass Feeder Drive
Gear Assembly?

Table 1-62 Error Code C9-2 Paper Jam Reset ENV/Bypass (cont'd.)
5 MULTI-SHEET BYPASS FEEDER CLUTCH Go to step 6 Replace the
TEST Multi-sheet
1. Enter Diagnostics Mode. Bypass
2. From the Main Menu, select Comp Output Test / Feeder Feed
MBF/ENV Unit / MBF Feed Clutch to check the Clutch (RRP
Multi-sheet Bypass Feeder Feed Clutch. 1-29)
3. Press [4] to start, clutch should actuate for two
Did the Multi-sheet Bypass Feeder Feed
Clutch actuate?
6 Tray 2 TAKE AWAY SENSOR TEST Go to step 7 Replace the
1. Enter Diagnostics Mode. Tray 2 Take
2. From the Main Menu, select Comp Input Test / IOT Away Sensor
Unit / T/A Roll2 Sensor to test the Tray 2 Take-Away
Roller Sensor.
4. Insert, then remove, a sheet of paper into the Tray 2
Take Away Sensor.
REPLACEMENT solved

RAP 1-35
Reset
ENV/Bypass
There is a paper jam between the Multi-sheet Bypass Feeder 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 Sensor did not actuate within
the specified time after the Multi-sheet Bypass Feeder Feed Clutch was actuated.
Table 1-63 Error Code C9-3 Paper Jam Reset ENV/Bypass
Inspect the paper that is loaded in the Multi-sheet Bypass paper with
Feeder. new paper
Is the paper loaded in the Multi-sheet Bypass
Feeder wrinkled or damaged?
3 MULTI-SHEET BYPASS FEEDER FEED Replace the Go to step 4
ROLLER INSPECTION Multi-sheet
1. Run a Test Print, feeding from the Multi-sheet Bypass Bypass
Feeder. Feeder Feed
2. Observe the paper in the Multi-sheet Bypass Feeder Roller (RRP
Bin. 1-30), Pick
Roller (RRP
1-31), and
Multi-sheet
Bypass
Is the paper partially fed out of the Multi-sheet Feeder Pad
Bypass Feeder Bin? (RRP 1-33)
4 MULTI-SHEET BYPASS FEEDER DRIVE TEST Go to step 5 Replace the
1. Remove the Rear Cover (RRP 1-5) so you can Multi-sheet
observe the Main Drive Assembly and the Multi-sheet Bypass
Bypass Feeder Drive Gear Assembly. Feeder
2. Enter Diagnostics Mode. Assembly
Unit / Main Motor On to actuate the Main Motor to
check the Multi-sheet Bypass Feeder Drive Assembly.
Does the Main Drive Assembly rotate the
Multi-sheet Bypass Feeder Drive Gear
Assembly?
5 MULTI-SHEET BYPASS FEEDER CLUTCH TEST Go to step 6 Replace the
Run Diagnostic Mode - Output Multi-sheet Bypass Multi-sheet
Feeder Feed Clutch. Bypass
Feeder Feed
Did the Multi-sheet Bypass Feeder Feed Clutch (RRP
Clutch actuate? 1-29)

Table 1-63 Error Code C9-3 Paper Jam Reset ENV/Bypass (cont'd.)
Unit / Reg. Sensor.
REPLACEMENT solved

RAP 1-36
Error Code H1-1 Insert Tray 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.
Table 1-64 Error Code H1-1 Insert Tray 1
1. Remove the Rear Cover (RRP 1-5). 1 Lift Motor
2. Load paper into Tray 1 and install Tray 1 into Feeder 1. (RRP 1-9)
Unit / Tray 1 Lift Mot to check the Tray 1 Lift Motor.
5. Press [4] to start, Tray 1 Lift Motor should run two
seconds, then stop.
Does the Tray 1 Lift Motor run when you start
the test?
2 Tray 1 CHECK Go to step 2 Replace Tray
Slowly side Tray 1 out of Feeder 1. 1 with a new
one
Can you hear the Tray 1 bottom plate drop as
you slide the Tray out of the Feeder?
3 Tray 1 LEVEL SENSOR TEST Go to step 4 Replace the
1. Enter Diagnostics Mode. Tray 1 Level
Unit / Tray 1 Level to check the Tray 1 Level Sensor.
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?
REPLACEMENT solved

RAP 1-37
Error Code H1-2 Insert Tray 2
There is a Lift Up problem with Tray 2.
Logic Control on the Print Engine Controller Board sensed that Tray 2 was not raising
into position in Feeder 2.
Table 1-65 Error Code H1-2 Insert Tray 2
1. Remove the Rear Cover (RRP 1-5). 2 Lift Motor
2. Load paper into Tray 2 and install Tray 2 into Feeder 2. (RRP 1-9)
Unit / Tray 2 Lift Mot to check the Tray 2 Lift Motor.
5. Press [4] to start, Tray 2 Lift Motor should actuate for
two seconds, then stop.
Does the Tray 2 Lift Motor run when you start
the test?
2 Tray 2 CHECK Go to step 2 Replace Tray
Slowly side Tray 2 out of Feeder 2. 2 with a new
one
Can you hear the Tray 2 bottom plate drop as
you slide the Tray out of the Feeder?
3 Tray 2 LEVEL SENSOR TEST Go to step 4 Replace the
1. Enter Diagnostics Mode. Tray 2 Level
Unit / Tray 2 Level to check the Tray 2 Level Sensor.
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?
REPLACEMENT solved

RAP 1-38
Error Code H2-7 Duplex Unit Fail
Power Off/On
There is a communication problem between the printer and the Duplex Unit.
Logic Control on the Print Engine Controller Board could not initialize the Duplex
Unit within the specified time.
Table 1-66 Error Code H2-7 Duplex Unit Fail Power Off/On
CHECK Low Voltage
(RRP 1-67)
frame ground?
2 DUPLEX BOARD REPLACEMENT Go to step 3 Problem
Replace the Duplex Module Board (RRP 3-5). solved
REPLACEMENT solved

RAP 1-39
Error Code H4-1 Load Tray 1
There is a problem with paper fed from Tray 1.
Tray 1 out of paper or size/type incorrect for printed job..
Table 1-67 Error Code H4-1 Load Tray 1
1 Tray 1 PAPER GUIDE CHECK Go to step 2 Adjust the
Remove Tray 1 and inspect the Paper Guides. Paper Guides
Are the Paper Guides adjusted so they rest
against the stack of paper?
2 Tray 1 SIZE SWITCH ACTUATOR Replace the Go to step 3
With Tray 1 removed, inspect the Size Switch Actuator Actuator
located on the rear of the Bin. Assembly
Is the Actuator broken or chipped?
3 Tray 1 PAPER SIZE SENSOR TEST Go to step 4 Replace the
1. Enter Diagnostics Mode. Tray 1 Paper
2. From the Main Menu, select Tray Size Test / Tray 1 Size Sensor
Size.
4. Take note of the displayed result.
Does the paper size displayed match the size
set in the Bin?
Unit / Reg. Sensor.
REPLACEMENT solved

RAP 1-40
Error Code H4-2 Load Tray 2
There is a problem with paper fed from Tray 2.
Tray 2 out of paper or size/type incorrect for printed job.
Table 1-68 Error Code H4-2 Load Tray 2
1 Tray 2 PAPER GUIDE CHECK Go to step 2 Adjust the
Remove Tray 2 and inspect the Paper Guides. Paper Guides
Are the Paper Guides adjusted so they rest
against the stack of paper?
2 Tray 2 SIZE SWITCH ACTUATOR Replace the Go to step 3
With Tray 2 removed, inspect the Size Switch Actuator Actuator
located on the rear of the Bin. Assembly
Is the Actuator broken or chipped?
3 Tray 2 PAPER SIZE SENSOR TEST Go to step 4 Replace the
1. Enter Diagnostics Mode. Tray 2 Paper
2. From the Main Menu, select Tray Size Test / Tray 2 Size Sensor
Size.
4. Take note of the displayed result.
Does the paper size displayed match the size
set in the Bin?
Unit / Reg. Sensor.
REPLACEMENT solved

RAP 1-41
Error Code J1-2 Replace Print
Cartridge
The Laser Print (EP) Cartridge is low on toner and should be replaced.
Logic Control on the Print Engine Controller Board sensed that at Main Motor
start-up the Toner Sensor was on for longer than the specified time.
Table 1-69 Error Code J1-2 Replace Print Cartridge
1 LASER PRINT (EP) CARTRIDGE Go to step 2 Problem
REPLACEMENT solved
Replace the Laser Print (EP) Cartridge with a new one.
Does the error code still appear?
2 TONER SENSOR TEST Go to step 3 Replace the
1. Enter Diagnostics Mode. Toner Sensor
2. From the Main Menu, select Comp Input Test / IOT (RRP 1-50)
Unit / Toner Empty.
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?
REPLACEMENT solved

RAP 1-42
Error Code J3-1 Install Print
Cartridge
The Laser Print (EP) Cartridge is not installed or is not installed correctly.
Logic Control on the Print Engine Controller Board sensed that the Laser Print (EP)
Cartridge Interlock Switch was not actuated.
Table 1-70 Error Code J3-1 Install Print Cartridge
1 LASER PRINT (EP) CARTRIDGE CHECK Go to step 2 Problem
1. Open the Upper Left Cover (A) and the Front Cover. solved
2. Alternately, remove, then reinstall the Laser Print (EP)
Cartridge.
2 LASER PRINT (EP) CARTRIDGE INTERLOCK Go to step 3 Replace the
SWITCH TEST Laser Print
1. Enter Diagnostics Mode. (EP)
2. From the Main Menu, select Comp Input Test / IOT Cartridge
Unit / CRU Installed. Interlock
3. Open the Upper Left Door (A) and the Front Door. Switch (RRP
4. Press [4] to start, then [0] to stop. 1-51)
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?
REPLACEMENT solved

RAP 1-43
Error Code J6-1 Replace Print
Cartridge
The Laser Print (EP) Cartridge has reached end of life.
Cartridge has printed a specified number of prints and should be replaced with a new
one.
Table 1-71 Error Code J6-1 Replace Print Cartridge
REPLACEMENT solved
Replace the Laser Print (EP) Cartridge with a new one.
REPLACEMENT solved

RAP 1-44
Error Code J8-1 Print Cartridge
OEM ID
Mismatch
The wrong Laser Print (EP) Cartridge is installed in the printer.
Cartridge installed is not compatible with the printer.
Table 1-72 Error Code J8-1 Print Cartridge OEM ID Mismatch
REPLACEMENT solved
Replace the Laser Print (EP) Cartridge with a different
one.
REPLACEMENT solved

RAP 1-45
Error Code J8-3 Install Print
Cartridge
A Laser Print (EP) Cartridge Memory error occurred.
Logic Control on the Print Engine Controller Board could not read Laser Print (EP)
Cartridge Memory data.
Table 1-73 Error Code J8-3 Install Print Cartridge
CHECK Low Voltage
(RRP 1-67)
frame ground?
REPLACEMENT solved
one.
REPLACEMENT solved

RAP 1-46
Error Code J8-4 CRUM Failure
Power Off/On
A Laser Print (EP) Cartridge memory communication error occurred.
Logic Control on the Print Engine Controller Board could not access Laser Print (EP)
Cartridge Memory data.
Table 1-74 Error Code J8-4 CRUM Failure Power Off/On
CHECK Low Voltage
(RRP 1-67)
frame ground?
REPLACEMENT solved
one.
REPLACEMENT solved

RAP 1-47
Error Code J8-5 CRUM Failure
Replace CRU
A Laser Print (EP) Cartridge memory communication error occurred.
Logic Control on the Print Engine Controller Board sensed a wrong or a counterfeit
Table 1-75 Error Code J8-5 CRUM Failure Replace CRU
REPLACEMENT solved
one.
REPLACEMENT solved

Troubleshooting
This topic discusses troubleshooting the printer. Troubleshooting is discussed in the
following areas:
Printer Performance Problems: Refer to the Printer Performance Problems
Repair Analysis Procedure (RAP) Table on page, 1-105.
Image Quality Problems: Refer to the Image Quality Problems Repair
Analysis Procedure (RAP) Table on 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 Inoperative Control Panel RAP 1-52 on page, 1-109
The Printer Does Not Display An Error Code When Out RAP 1-53 on page, 1-110
Of Toner
The Printer Does Not Offset Paper RAP 1-54 on page, 1-111
Volume 1 / Print Engine - Troubleshooting 1-103

Image Quality Problems Repair Analysis
Procedure (RAP) Table
Table 1-77 Image Quality Problems RAP Table
Problem Go To RAP No. Page
Light (Undertoned) Prints RAP 1-60 on page, 1-113
Blank Prints RAP 1-61 on page, 1-115
Black Prints RAP 1-62 on page, 1-117
Vertical Band Deletions RAP 1-63 on page, 1-119
Horizontal Band Deletions RAP 1-64 on page, 1-121
Vertical Streaks RAP 1-65 on page, 1-123
Horizontal Streaks RAP 1-66 on page, 1-125
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 Edge Registration Is Not Correct RAP 1-76 on page, 1-143
Side-To-Side Registration Is Not Correct RAP 1-77 on page, 1-145
Electrical Interference Repair Analysis

Procedure (RAP) Table
Table 1-78 Electrical Interference RAP Table
Problem Go To RAP No. Page
Electrical Interference - Something is generating RAP 1-80 on page, 1-147
electrical noise that may be interfering with the normal
operation of the printer.

Printer Performance Problems
RAP 1-50
Inoperative Printer
The printer appears to be dead. When you switch on the printer, the Control Panel LEDs
do not light, the display remains blank, the Fuser Fan does not rotate, and the printer does
not warm-up.
Table 1-79 3.1 Inoperative Printer
1 AC POWER CORD INSPECTION Go to step 2 Plug the AC
Inspect the AC Power Cord. Power Cord
into the
Is the AC Power Cord in good condition, and is printer and
it plugged into the printer and is the other end into an AC
plugged into an AC wall outlet? wall outlet
2 AC POWER CHECK Go to step 3 Troubleshoot
Measure the voltage at the AC wall outlet. the AC power
at the wall
Is there approximately 110VAC (or 220VAC if outlet
the printer is the 220VAC model) at the AC wall
outlet?
3 AC INPUT CHECK Go to step 4 Replace the
1. Remove the Rear Cover so you can access the AC power
Ground Fault Interrupter (RRP 1-5). cord
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?
4 AC OUTPUT CHECK Go to step 5 Replace the
Measure the voltage between P/J7-1 and P/J7-2 on the Low Voltage
Ground Fault Interrupter. Power Supply
(RRP 1-67)
Is there approximately 110VAC (or 220VAC if
the printer is the 220VAC model) between
P/J7-1 and P/J7-2?
CHECK Low Voltage
(RRP 1-67)
frame ground?
CHECK Low Voltage
Measure the voltage between J400-8 (on the Print Power Supply
Engine Controller Board) and frame ground. Assembly
(RRP 1-67)
Is there +24VDC between J400-8 and frame
ground?

Table 1-79 3.1 Inoperative Printer (cont'd.)
7 SYSTEM CONTROLLER Board CHECK Replace the Go to step 8
1. Switch off the Main Switch. System
2. Remove the System Controller Board (RRP 1-73). Controller
3. Switch on the Main Switch. Board (RRP
Does the printer go into warm-up? 1-73) with a
new one
8 PRINT ENGINE CONTROLLER BOARD Problem Go to step 9
REPLACEMENT solved
Does the printer go into warm-up?
9 Input/Output Board REPLACEMENT Problem Go to step 10
Does the printer go into warm-up?
10 OPTION ISOLATION Replace the Go to step 11
Remove all options, such as the Duplex Unit or the High options one
Capacity Feeder, from the base printer. by one until
the printer
Do the Control Panel LEDs light up and does becomes
the printer go into warm-up? inoperative
again.
Troubleshoot
or replace the
problem
option.
steps in this Fault Isolation Procedure, replace each
Interlock switches and circuits.

RAP 1-51
Erratic Printer Operation
The printer has a variety of problems that are not identified by displayed error codes or
messages. Problems may range from incomplete or garbled display text to intermittent
power shutdowns.
Table 1-80 Erratic Printer Operation
1 PRINTER OPERATING ENVIRONMENT CHECK Go to step 2 Move the
Compare the printer room environment, such as printer to an
temperature, humidity, and space requirements, with the environment
specifications listed in General Information section of this that meets
manual. printer
specifications
Does the printer room environment meet
printer specifications as listed in the General
Information Section?
2 AC POWER CHECK Go to step 3 Have an
1. Unplug the printer AC power cord from the AC wall electrician
outlet. troubleshoot
2. Use a digital multimeter to monitor the voltage at the the AC line
AC wall outlet.
3. Monitor the AC voltage 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?
3 NVRAM SETTINGS CHECK Go to step 4 Return all
If applicable to your printer configuration, check the settings to
NVRAM settings to make sure they are all set to the factory default
recommended factory default values. values
Are the NVRAM settings set to the factory
default values?
4 SOFTWARE RELOAD Go to step 5 Problem
1. Reload print driver software in the host computer. solved
(Refer to the Printer Driver CD.)
2. Monitor printer operation.
Does the printer display erratic operation?
5 AC POWER CORD REPLACEMENT Go to step 6 Problem
1. Replace the AC Power Cord. solved
6 SYSTEM CONTROLLER Board REPLACEMENT Go to step 7 Problem
1. Replace the System Controller Board with a new one solved
(RRP 1-73).

Table 1-80 Erratic Printer Operation (cont'd.)
REPLACEMENT solved
1. Reinstall the System Controller Board (RRP 1-73)
2. Replace the Low Voltage Power Supply (RRP 1-67).
8 PRINT ENGINE CONTROLLER Board Go to step 9 Problem
REPLACEMENT solved
1. Replace the Print Engine Controller Board (RRP
1-72).
9 Input/Output Board REPLACEMENT Go to step 10 Problem
1. Replace the Input/Output Board (RRP 1-70). solved
10 ELECTRICAL NOISE CHECK Go to step 11 Problem
1. Go to RAP 1-80 (Electrical Interference) and solved
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.
Interlock switches and circuits
Xerographic components and High Voltage
Power Supply (RRP 1-69)
Computer Interface Cable
Control Panel (RRP 1-7)
AC Driver Board (RRP 1-68).

RAP 1-52
Blank, Erratic, or Inoperative Control Panel
The Control Panel Display is blank or displays garbled text, or the Control Panel does not
respond to user input.
Table 1-81 Blank, Erratic, or Inoperative Control Panel
1 PRINTER STATUS TEST Go to step 2 Go to RAP
1. Switch on printer power and wait 2 minutes for 1-50 and
warm-up to complete. troubleshoot
2. Use any application on the host computer to generate an inoperative
a few prints. printer
Does the printer generate prints?

2 CONTROL PANEL TEST Go to step 3 Go to step 4
Power on printer while simultaneously pressing [0],
[5], & [7].
Do the Control Panel LEDs light up and does
the display show Chn-00 Fun-00?
3 SYSTEM CONTROLLER BOARD Replace the Problem
REPLACEMENT Print Engine solved
1. Replace the System Controller Board (RRP 1-73). Controller
Board (RRP
1-70)
Is the problem still present?
4 LOW VOLTAGE POWER SUPPLY +5VDC Replace the Go to step 5
CHECK Control Panel
Measure the voltage between J400, pins 1, 2 & 3 (on the (RRP 1-7)
Print Engine Controller Board) and frame ground.
frame ground?
REPLACEMENT solved
Replace the Low Voltage Power Supply (RRP 1-67).

RAP 1-53
The Printer Does Not Display an Error Code When Out of Toner
The Control Panel Display does not display the appropriate Error Code when the Laser
Print Cartridge runs out of toner.
Table 1-82 Printer Does Not Display and Error Code When Out of Toner
1 TONER SENSOR TEST Go to step 2 Replace the
1. Enter Diagnostics Mode. Toner Sensor
2. From the Main Menu, select Comp Input Test / IOT (RRP 1-50)
Unit / Toner Empty.
4. Alternately insert/remove a new Laser Print (EP)
Cartrdge into the printer.
5. Observe display.
Does the control panel display “not empty”
when the Laser Print (EP) Cartridge is in place,
and does the display show “Empty” when the
Cartridge is removed?
2 PRINT ENGINE CONTROLLER Board Go to step 3 Problem
REPLACEMENT solved
3 Input/Output Board REPLACEMENT Go to step 4 Problem
4 SYSTEM CONTROLLER Board REPLACEMENT Go to step 5 Problem
Replace the System Controller Board (RRP 1-73). solved
REPLACEMENT solved
Replace the Low Voltage Power Supply (RRP 1-67).

RAP 1-54
The Printer Does Not Offset Paper
The offset function does not work or does not work correctly.
Table 1-83 Printer Does Not Offset Paper
1 MAIN DRIVE ASSEMBLY INSPECTION Go to step 2 Replace the
1. Remove the Rear Cover Assembly (RRP 1-5) Main Drive
Unit / Main Motor On to check the Main Motor and
Main Drive Assembly.
Does the Main Motor run and do the gears of
the Drive Assembly rotate normally?
2 EXIT DRIVE TEST Go to step 3 Replace the
1. Remove the Fuser Cover (RRP 1-1). defective
2. Enter Diagnostics Mode. clutch
Duplex Unit / Invert Clutch CW.
4. While rotating the Main Drive Motor CCW by hand,
press [4] to start, the Invert Clutch CW should actuate
for two seconds, then release.
5. Observe the rotation of the exit gears.
6. Press [7] or [3] to display Invert Clutch CCW.
7. While rotating 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?
3 OFFSET TEST Go to step 4 Replace the
1. Remove the Fuser Cover (RRP 1-1). Offset Motor
Unit / Offset Motor Fnt.
4. Press [4] to start, Offset Motor should rotate and move
the offset roller toward the front of the printer.
5. Press [7] or [3] to display Offset Motor Rev.
6. Press [4] to start, Offset Motor should rotate the
opposite direction as in step 4 above and the offset
roller should move toward the rear of the printer.
Does the Offset Roller shift away from the
Offset Motor and toward the Motor?
REPLACEMENT solved
Does Offset work correctly?
5 Input/Output Board REPLACEMENT Problem Go to step 6
Replace the Input/Output Board (RRP 1-70) solved
Does Offset work correctly?

Table 1-83 Printer Does Not Offset Paper
Low Voltage Power Supply (RRP 1-67).

Image Quality Problems
RAP 1-60
Light (Undertoned) Prints
PROBLEM
The overall image density is too light. The image may also be
unfused due to insufficient image density.
THE PRINTER DISPLAYS NO ERROR CODE.
S4525-06
Fig 1-15 Light (Undertoned) Prints
Table 1-84 Light (Undertoned) Prints

Inspect the paper that is loaded in the paper Bins. dry, newly
opened paper
Is the paper wrinkled, dimpled, or show any
sign of having a high moisture content?
2 LASER PRINT (EP) CARTRIDGE Problem Go to step 3
REPLACEMENT solved
Install a new Laser Print (EP) Cartridge.
Is the image density normal?
3 IMAGE DEVELOPMENT INSPECTION Go to step 4 Replace the
1. Remove the Rear Cover (RRP 1-5). High Voltage
2. Generate a Grid Pattern Test Print and switch OFF Power Supply
printer power halfway through the print cycle. Assembly
3. Open the Left Upper Cover. (RRP 1-69)
4. Open the Drum Shutter by pressing in the interlock
plunger to the rear of the Laser Print Cartridge.
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
developed; with sharp, black, easily read
areas?

Table 1-84 Light (Undertoned) Prints (cont'd.)
4 IMAGE TRANSFER INSPECTION Go to step 5 Replace the
1. Carefully remove the Test Print generated in step 3. Bias Transfer
2. Inspect the print. Roller
Assembly. If
the problem
persists,
replace the
High Voltage
Was the toner image on the drum transferred Power Supply
completely to the paper and are the grid lines Assembly.
black and unbroken?
5 FUSER INSPECTION Replace the Go to step 6
1. Generate another Grid Pattern Test Print and switch Fuser
OFF printer power when the print is halfway through Assembly
the Fuser.
2. Open the Left Upper 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?
component or troubleshoot each area listed below until
you isolate and solve the problem.
Laser Scanner Assembly (RRP 1-47)
Print Engine Controller Board (RRP 1-72)

RAP 1-61
Blank Prints
PROBLEM
The entire image area is blank.
S4525-07
Fig 1-16 Blank Prints

.
Table 1-85 Blank Prints
1 CONTROLLER OR HOST SOFTWARE Troubleshoot Go to step 2
ISOLATION or replace the
Generate a Grid Test Print. System
Controller
Board (RRP
1-73) or
reload the
Is the test print image normal? print driver
software
REPLACEMENT solved
Is there a normal image on the paper?
1. Remove the Rear Cover (RRP 1-5). Laser
2. Generate a Grid Test Print and switch OFF printer Scanner
power halfway through the print cycle. Assembly
4. Open the Drum Shutter.
reached Transfer.
developed; with sharp, black, easily read
areas?

Table 1-85 Blank Prints (cont'd.)
4 IMAGE TRANSFER INSPECTION Suspect an Go to step 5
1. Carefully remove the Test Print generated in step 3. intermittent
2. Inspect the print. problem and
go to step 7
Was the toner image on the drum transferred
completely to the paper. And are the grid lines
black and unbroken?
5 BIAS TRANSFER ROLLER REPLACEMENT Go to step 6 Problem
Replace the Bias Transfer Roller Assembly. solved
Is the image still blank?
6 HIGH VOLTAGE POWER SUPPLY Go to step 7 Problem
REPLACEMENT solved
Replace the High Voltage Power Supply (RRP 1-69).
Is the image still blank?
Laser Print (EP) Cartridge Connector and
Contract Springs (PL 7.2)
Replace the Print Engine Controller Board (RRP
1-72)
Input/Output Board (RRP 1-70)
Refer to the wiring diagrams Section 14 and
check for a broken wire or loose connection
between components in the Xerographic sections
of the printer.

RAP 1-62
Black Prints
PROBLEM
The entire image area is black. There is no image visible on
the page.
S4525-08
Fig 1-17 Black Prints

.
Table 1-86 Black Prints
1 CONTROLLER OR HOST SOFTWARE Replace the Go to step 2
ISOLATION System
1. Generate a Grid Test Print. Controller
Board (RRP
1-73) or
reload the
Is the test print image normal? host software
REPLACEMENT solved
Is there a normal image on the paper?
3 IMAGE DEVELOPMENT INSPECTION Replace the Go to step 4
1. Remove the Rear Cover (RRP 1-5). Bias Transfer
2. Generate a Grid Test Print and switch OFF printer Roller
reached Transfer.
developed; with sharp, black, easily read areas
and clear, white areas?

Table 1-86 Black Prints (cont'd.)
4 SYSTEM CONTROLLER BOARD MOTHER Problem Go to step 5
Board REPLACEMENT solved
1. Replace the System Controller Board Mother Board
(RRP 1-73)
2. Generate a Grid Test Print.
Is the printed Test Pattern normal?
REPLACEMENT solved
1. Replace the Print Engine Controller Board (RRP 1-72)
6 Laser Scanner REPLACEMENT Problem Go to step 7
1. Replace the Laser Scanner Assembly (RRP 1-47) solved
Low Voltage Power Supply (RRP 1-67)
of the printer.

RAP 1-63
Vertical Band Deletions
PROBLEM
There are areas of the image that are extremely light or are
missing entirely. These missing areas form lines or bands
that run vertically along the page in the direction of paper
travel.
S4525-09
Fig 1-18 Vertical Band Deletions

.
Table 1-87 Vertical Band Deletions
1 Laser Scanner Window Inspection Go to step 2 Remove the
1. Remove the Laser Print (EP) Cartridge. paper scrap
2. Inspect the Laser Scanner Window for a scrap of or clean the
paper or other contamination that may have lodged in Laser
front of it and could be blocking part of the laser beam Scanner
from reach the Drum. window.
Is the Laser Scanner Window free of paper or
other contamination?
opened paper
REPLACEMENT solved
Are the vertical band deletions gone?

Table 1-87 Vertical Band Deletions (cont'd.)
4 IMAGE TRANSFER INSPECTION Replace the Go to step 5
2. Generate a Solid Black Test Print and switch OFF Roller
printer power halfway through the print cycle. Assembly
3. Open the Left Upper Door.
reached Transfer.
Before Transfer was the toner image on the
drum normal and without vertical band
deletions, but there were deletions after
transfer?
1. Generate another Solid Black Test Print and switch Fuser
OFF printer power when the print is halfway through Assembly
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?
Refer to the wiring diagrams, See “Master
Connection and Wiring Diagram” on page 356.
and check for a broken wire or loose connection
of the printer.

RAP 1-64
Horizontal Band Deletions
PROBLEM
missing entirely. These missing areas form lines or bands
that run horizontally across the page perpendicular to the
direction of paper travel.
S4525-10
Fig 1-19 Horizontal Band Deletions

.
Table 1-88 Horizontal Band Deletions
opened paper
REPLACEMENT solved
Install a new Laser Print (EP) Cartridge .
Are the horizontal band deletions gone?
3 IMAGE TRANSFER INSPECTION Go to step 4 Go to step 5
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.
flywheel to advance the drum far enough so you can
reached Transfer.
drum normal and without horizontal band
deletions, but there are deletions on the paper
after Transfer?
4 BIAS TRANSFER ROLLER REPLACEMENT Problem Go to step 5
1. Replace the Bias Transfer Roller Assembly. solved
2. Generate a Solid Black Test Print.
Is the Test Print normal, with no horizontal
band deletions?

Table 1-88 Horizontal Band Deletions (cont'd.)
5 HIGH VOLTAGE POWER SUPPLY Problem Go to step 6
REPLACEMENT solved
Replace the High Voltage Power Supply Assembly (RRP
1-69).
Are the horizontal band deletions gone?
Contact Springs (PL 7.2)
Fuser Assembly.

RAP 1-65
Vertical Streaks
PROBLEM
There are black lines running vertically along the page in the
direction of paper travel.
S4525-11
Fig 1-20 Vertical Streaks

.
Table 1-89 Vertical Streaks
1 PAPER PATH INSPECTION Go to step 2 Remove
Inspect the paper path, between feed and exit, for contamination
contamination or obstructions. and
obstructions
Is the paper path free of contamination or from the
obstructions? paper path.
REPLACEMENT solved
Are the vertical streaks gone?
2. Generate a Grid Test Print and switch OFF printer Roller
flywheel to advance the drum far enough so you can
reached Transfer.
drum normal and without vertical streaks, but
there are vertical streaks on the paper after
Transfer?

Table 1-89 Vertical Streaks (cont'd.)
1. Generate another Grid Test Print and switch OFF Laser
printer power when the print is halfway through the Scanner
Fuser. Assembly
2. Open the Left Upper Door. (RRP 1-47)
enters the Fuser, but there are vertical streaks
visible when it exits the Fuser?
5 FUSER ASSEMBLY REPLACEMENT Problem Go to step 6
1. Replace the Fuser Assembly. solved
2. Run a half dozen Grid Test Prints.
Are the vertical streaks gone?
of the printer

RAP 1-66
Horizontal Streaks
PROBLEM
There are black lines running horizontally across the paper
perpendicular to the direction of paper movement.
S4525-12
Fig 1-21 Horizontal Streask

.
Table 1-90 Horizontal Streaks
REPLACEMENT solved
Are the horizontal streaks gone?
2. Generate a Blank Test Print and switch OFF printer Scanner
reached Transfer.
Is the image on the drum completely white;
without any horizontal streaks visible?
Inspect the Blank Test Print you generated in step 2. Bias Transfer
Roller
Are horizontal streaks visible on the paper Assembly
after Transfer?

Table 1-90 Horizontal Streaks (cont'd.)
1. Generate another Blank Test Print and switch OFF Fuser
printer power when the print is halfway through the Assembly
Fuser.
enters the Fuser, but there are horizontal
streaks visible when it exits the Fuser?
5 SYSTEM CONTROLLER BOARD MOTHER Problem Go to step 6
REPLACEMENT solved
Replace the System Controller Board Mother (RRP
1-73).
6 HIGH VOLTAGE POWER SUPPLY Problem Go to step 7
REPLACEMENT solved
1-69).
Contact Springs (PL 7.2).

RAP 1-67
Spot Deletions
PROBLEM
missing entirely. These missing areas form non-uniform spots
that are localized to small areas of the page.
S4525-13
Fig 1-22 Spot Deletions

.
Table 1-91 Spot Deletions
opened paper
REPLACEMENT solved
Are the spot deletions gone?
2. Generate a Black Test Print and switch OFF printer Roller
reached Transfer.
drum normal and without spot deletions, but
there are spot deletions on the paper after
Transfer?

Table 1-91 Spot Deletions (cont'd.)
4 FUSER INSPECTION Replace the Replace the
1. Generate another Black Test Print and switch OFF Fuser paper with
printer power when the print is halfway through the Assembly fresh, dry
Fuser. paper and
2. Open the Left Upper Door. thoroughly
3. Examine the paper areas before the image enters the clean the
Fuser and after the image exits the Fuser. inside of the
Is the image on the paper normal before it printer.
enters the Fuser, but there are spot deletions
visible when it exits the Fuser?

RAP 1-68
Spots
PROBLEM
There are spots of toner scattered randomly across the page.
S4525-14
Fig 1-23 Spots

.
Table 1-92 Spots
1 LASER PRINT (EP) CARTRIDGE INSPECTION Replace the Go to step 2
1. Remove the Laser Print (EP) Cartridge. Laser Print
2. Inspect the outside of the Cartridge. (EP)
3. Open the Shutter and inspect the Drum. Cartridge
Is the Laser Print (EP) Cartridge dirty and is it
leaking toner?
2 INTERIOR INSPECTION AND CLEANING Problem Go to step 3
1. With the Laser Print (EP) Cartridge removed, inspect solved
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?
2. Generate a Blank Test Print and switch OFF printer Roller
reached Transfer.
Is the paper clean before Transfer, but there are
spots on the paper after Transfer?

Table 1-92 Spots (cont'd.)
4 FUSER INSPECTION Replace the Clean or
1. Generate another Blank Test Print and switch OFF Fuser replace the
printer power when the print is halfway through the Assembly Offset/Exit
Fuser. Assembly
2. Open the Left Upper Door. (RRP 1-54)
Is paper clean before it enters the Fuser, but
there are spots on the paper when it exits the
Fuser?

RAP 1-69
Residual Image or Ghosting
PROBLEM
There are faint, ghostly image appearing randomly on the
page. The images may be images from a previous page.
S4525-15
Fig 1-24 Residual Image or Ghosting

.
Table 1-93 Residual Image or Ghosting
1 CUSTOMER USAGE INSPECTION Go to step 2 Go to step 3
Inspect the residual images.
Was the customer printing numerous copies of
the same image?
2 Generate a print run of 30 pages of varying Go to step 3 Problem
images. solved. Avoid
printing
numerous
copies of the
Do residual images still appear? same image.
REPLACEMENT solved
Are the ghost images gone?
4 FUSER INSPECTION Replace the Replace the
1. Generate ten Grid Pattern Test Prints and switch OFF Fuser Bias Transfer
printer power when the last print is halfway through the Assembly Roller
Fuser. Assembly
2. Carefully remove the Laser Print (EP) Cartridge and
inspect the toner image on the print before it enters the
Fuser and immediately after it exits the Fuser.
enters the Fuser, but there are ghost images on
the paper when it exits the Fuser?

Table 1-93 Residual Image or Ghosting (cont'd.)
Print Engine Controller Board (RRP 1-72).

RAP 1-70
Background
PROBLEM
There is a light gray dusting of toner on all or most of the
printer page.
S4525-16
Fig 1-25 Background

.
Table 1-94 Background
REPLACEMENT solved
Is the background gone?
2. Generate a Blank Test Print and switch OFF printer Scanner
Flywheel to advance the Drum far enough so you can
reached Transfer.
Is the image on the drum completely clean and
without any noticeable background toner?

Table 1-94 Background (cont'd.)
2. Generate a Blank Test Print and switch OFF printer Roller
reached Transfer.
Before Transfer was the drum clean and
without noticeable background toner, but there
was background visible on the paper after
Transfer?
1. Generate another Blank Test Print and switch OFF Fuser
printer power when the print is halfway through the Assembly
Fuser.
3. Examine the paper before it enters the Fuser and after
it exits the Fuser.
there is background on the paper when it exits
the Fuser?
Replace the paper with another brand of paper
High Voltage Power Supply Assembly (RRP
1-69)

RAP 1-71
Toner on Back of Print
PROBLEM
There is toner contamination on the back of the fused sheet of
paper.
S4525-17
Fig 1-26 Toner on Back of Print

.
Table 1-95 Toner on Back of Print
1 PAPER JAM HISTORY Run 30 Test Go to step 2
Frequently a paper jam or clearing a paper jam may Prints to clear
result in some minor toner contamination of the paper the paper
path. path of
residual toner
Did you just clear a paper jam?
2 PAPER Tray INSPECTION Clean the Go to step 3
Inspect all of the paper Bins for loose toner on top of and Bins and
under the paper stack. replace all of
the paper with
Is there toner in any of the paper Bins? new paper
3 PAPER PATH INSPECTION Go to step 4 Thoroughly
1. Remove the paper Bins. clean the
2. Remove the Laser Print (EP) Cartridge. paper path,
3. Use a flashlight to inspect the entire paper path, from from Feeders
Feeder to Output Bin, for any loose toner. to the Output
Bin, including
Is the paper path free of loose toner? all rubber
feed Rollers
4 BIAS TRANSFER ROLLER INSPECTION Go to step 5 Clean or
Rotate and inspect the Bias Transfer Roller. replace the
Bias Transfer
Is the Bias Transfer Roller clean and free of Roller
toner?

Table 1-95 Toner on Back of Print (cont'd.)
5 FUSER INSPECTION Go to step 6 Clean or
1. Generate a Blank Test Print and switch OFF printer replace the
power when the print is halfway through the Fuser. Fuser
2. Open the Left Upper Cover. Assembly
3. Examine the paper before it enters the Fuser and after
it exits the Fuser.
there is background on the paper when it exits
the Fuser?
6 CLEAN PRINTER Go to step 7 Problem
1. Thoroughly clean the interior of the printer. solved
2. Replace the Laser Print (EP) Cartridge.
3. Generate 20 Test Prints.
Does the toner still appear on the back of
paper?
High Voltage Power Supply (RRP 1-69)

RAP 1-72
Skewed Image
PROBLEM
The image is either twisted on the page or is not parallel to the
sides of the page.
S4525-18
Fig 1-27 Skewed Image

.
Table 1-96 Skewed Image
1 PAPER FEED INSPECTION Go to step 2 Reload the
paper and
reinstall the
Are the paper trays installed correctly, and is cassettes.
the paper correctly loaded into each cassette?
2 PAPER PATH INSPECTION Go to step 3 Remove
Inspect the paper path, between the feed Tray and the obstructions
exit Bin, for contamination or obstructions. from the
paper path.
Is the paper path free of obstructions?
3 FEED, PICK, AND RETARD ROLLER Go to step 4 Problem
REPLACEMENT solved
Replace the Feed Roller, Pick Roller, and Retard Roller
for the Feeder having the skew problem.
Is the image still skewed?
4 REGISTRATION ROLLER REPLACEMENT Go to step 5 Problem
Replace the Registration Roller (RRP 1-45). solved
REPLACEMENT solved

Table 1-96 Skewed Image (cont'd.)
Bias Transfer Roller Assembly.

RAP 1-73
Damaged Prints
PROBLEM
The printed page exits the printer either wrinkled, creased,
folded or torn.
S4525-19
Fig 1-28 Damaged Prints

.
Table 1-97 Damaged Prints
1 PRINTER INTERIOR INSPECTION Go to step 2 Clean the
1. Remove the paper Bins and the Laser Print (EP) printer interior
Cartridge. or replace the
2. Thoroughly inspect the interior of the printer, looking broken printer
for bits of paper, paper clips, staples, broken printer parts
parts such as sensor actuators, 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?
2 FEEDER ISOLATION Go to step 3 Go to step 4
Feed paper out of each of the available paper feeders.
Is the paper damaged when fed out of only one
Bin?
3 PAPER STACK INSPECTION Go to step 4 Replace the
Inspect the paper that is loaded in the paper Tray that paper if it is
feeds the damaged prints. damaged or
reload the
Is the paper undamaged and is it loaded paper
correctly in the paper Tray with the paper
guides correctly positioned?

Table 1-97 Damaged Prints (cont'd.)
4 PAPER PATH INSPECTION - FEED TO Replace the Go to step 5
REGISTRATION Feed, Pick,
1. Generate a Test Print and Retard
2. Open the Left Upper Door just before the lead edge of Rollers (RRP
the sheet of paper reaches the Registration Rollers. 1-11)
3. Carefully remove the Laser Print (EP) Cartridge from
the printer.
4. Inspect the sheet of paper.
Is the sheet damaged as it arrives at the
Registration Rollers?
5 PAPER PATH INSPECTION - REGISTRATION Replace the Go to step 6
1. Generate a Test Print Registration
2. Open the Left Upper Door just after the lead edge of Roller (RRP
the sheet of paper has passed the Registration 1-45)
Rollers.
the printer.
Is the sheet damaged as it leaves the
Registration Rollers?
6 PAPER PATH INSPECTION - DRUM & BIAS Replace the Go to step 7
TRANSFER ROLLER Laser Print
1. Generate a Test Print (EP)
2. Open the Left Upper Door just after the lead edge of Cartridge and
the sheet of paper has passed the Bias Transfer the Bias
Roller. Transfer
3. Carefully remove the Laser Print (EP) Cartridge from Roller
the printer. Assembly
Is the sheet damaged as it leaves the Bias
Transfer Roller area?
7 PAPER PATH INSPECTION - FUSER Replace the Clean or
1. Generate a Test Print Fuser replace the
2. Open the Left Upper Cover just after the lead edge of Assembly Offset/Exit
the sheet of paper has exited the Fuser. Assembly
3. Inspect the sheet of paper. (RRP 1-54)
Is the sheet damaged as it leaves the Fuser?

RAP 1-74
Unfused Image or Image Easily Rubs Off of Page
PROBLEM
The toner image is not completely fused to the paper.
S4525-20
Fig 1-29 Unfused Image or Image Easily Rubs Off of Page

.
Table 1-98 Unfused Image or Image Easily Rubs Off of Page
opened paper
2 IMAGE DENSITY INSPECTION Go to step 3 Go to RAP
Run a Black Test Print. 1-60 Light
(Undertoned)
Prints
Is the Test Print black?
3 FUSER ASSEMBLY REPLACEMENT Go to step 4 Problem
1. Replace the Fuser Assembly. solved
2. Run a half dozen Grid Test Prints.
Does the image rub off?
AC Driver Board (RRP 1-68)

RAP 1-75
Repetitive Marks on Each Page
PROBLEM
Identical image defects appear on each or on every other
printed sheet.
S4525-21
Fig 1-30 Repetitive Marks on Each Page

.
Table 1-99 Repetitive Marks on Each Page
1 DRUM IMAGE INSPECTION Replace the Go to step 2
1. Generate a single Test Print. Laser Print
2. Open the Upper Left Cover when the sheet of paper is (EP)
approximately half-way through the transfer process. Cartridge
the printer.
4. Inspect the surface of the Drum.
Does the mark appear on the Drum before
image transfer?
2 TRANSFER IMAGE INSPECTION Replace the Go to step 3
Inspect the Test Print generated in step 1. Bias Transfer
Roller
Does the mark appear on the paper after image Assembly
transfer?
3 FUSED IMAGE INSPECTION Replace the
1. Generate a single Test Print. Fuser
2. Open the Upper Left Cover when the sheet of paper is Assembly
approximately half-way through the Fuser.
3. Inspect the Test Print.
Does the mark appear on the paper after
Fusing?

RAP 1-76
Lead Edge Registration Is Not Correct
PROBLEM
The printed image is not centered on the page. The lead
edge margin of the printed image is either too narrow or too
wide, and either cuts off the lead edge of the printer image or
starts the lead edge of the printed image too far into the page.
S4525-22
Fig 1-31 Lead Edge Registration Is Not Correct

.
Table 1-100 Lead Edge Registration Is Not Correct
1 PAPER Tray INSPECTION Go to step 2 Reload the
Inspect the paper that is loaded in the paper Bin. paper and
adjust the
Is the paper loaded correctly and are the paper paper guides
guides adjusted correctly?
2 LEAD EDGE REGISTRATION Problem Go to step 3
Refer to the Diagnostics, Test Prints, Service Tests & solved
NVRAM Adjustments section of this manual and use
NVRAM to adjust Lead Edge Registration.
Can you adjust lead edge registration using
NVRAM?
3 1. Reload print driver software. Problem Go to step 4
2. Generate 5 Test Prints. solved
Is the lead edge registration correct?
4 1. Replace the Print Engine Controller Board (RRP 1-72) Problem Go to step 5
5 1. Replace the Laser Scanner (RRP 1-47) Problem Go to step 6

Table 1-100 Lead Edge Registration Is Not Correct
Registration Sensor (PL 6.1.7)
Registration Clutch (RRP 1-41)

RAP 1-77
Side-to-Side Registration Is Not Correct
PROBLEM
The printed image is not centered on the page. The side
margins are not equal and the image may be cut off on either
the left or right side.
S4525-23
Fig 1-32 Side-to-Side Registration Is Not Correct

.
Table 1-101 Side-to-Side Registration Is Not Correct
1 PAPER Tray INSPECTION Go to step 2 Reload the
Inspect the paper that is loaded in the paper Bin. paper and
adjust the
Is the paper loaded correctly and are the paper paper guides
guides adjusted correctly?
2 SIDE-TO-SIDE REGISTRATION Problem Go to step 3
Refer to the Diagnostics, Test Prints, Service Tests & solved
NVRAM Adjustments section of this manual and use
NVRAM to adjust Side Edge Registration.
Can you adjust side-to-side registration using
NVRAM?
3 1. Reload print driver software. Problem Go to step 4
Is the side-to-side registration correct?
4 1. Replace the Print Engine Controller Board (RRP Problem Go to step 5
1-72). solved
2. Generate 5 Test Prints.
5 1. Replace the Laser Scanner (RRP 1-47) Problem Go to step 6

Table 1-101 Side-to-Side Registration Is Not Correct
Registration Chute Assembly (RRP 1-44)
Laser Print (EP) Cartridge

Electrical Interference Problems
RAP 1-80
Electrical Interference
Something is generating electrical noise that may be interfering with the normal operation
of the printer. The interference generator may be either external or internal to the printer.
Table 1-102 Electrical Interference
1 EXTERNAL NOISE Go to step 2 Permanently
1. Check if there is other electrical equipment, such as relocate
electrical generators, radio transmitters, or devices either the
using electrical motors, within ten feet of the printer. printer or the
2. Shut off the other electrical equipment or relocate the problem
printer at least twenty feet away from the other device.
devices.
Is the Electrical Noise problem still present?
2 OPTION ISOLATION Go to the Go to step 3
If the printer has options installed, such as Duplex Unit or option manual
the High Capacity Feeder, remove each option one at a and
time, and see how the printer operations without that troubleshoot
option installed. for arcing
solenoids and
motors, or
Does the Electrical Noise problem go away faulty boards
when you remove a specific option? or wiring.
3 AC GROUND Go to step 4 Repair the AC
Check the AC wall outlet. wall outlet
Is the AC wall outlet correctly wired and
grounded?
NOTE: Steps 4 through 11 attempt to find a faulty printer
component that may be generating electrical noise. If
replacing a component does not solve the problem,
reinstall the old component before moving on to the next
step.
REPLACEMENT solved
Replace the Laser Print (EP) Cartridge.
5 HIGH VOLTAGE POWER SUPPLY Go to step 6 Problem
REPLACEMENT solved
1-69)
6 AC DRIVER REPLACEMENT Go to step 7 Problem
Replace the AC Driver Board (RRP 1-68) solved

Table 1-102 Electrical Interference (cont'd.)
7 LOW VOLTAGE POWER SUPPLY ASSEMBLY Go to step 8 Problem
REPLACEMENT solved
Replace the Low Voltage Power Supply Assembly (RRP
1-67)
9 PRINT ENGINE CONTROLLER BOARD Board Go to step 10 Problem
REPLACEMENT solved.
10 MAIN DRIVE ASSEMBLY REPLACEMENT Go to step 11 Problem
Replace the Main Drive Assembly (RRP 1-66) 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
problem disappears.
Lift Motors
Feed Clutches
Offset Unit (RRP 1-54)

Diagnostics, Test
Prints, Service Tests
and NVRAM
Adjustments
The printer has four modes of operation:
On-Line Mode
Power Saver Mode
Diagnostic Mode
Menu Mode.
On-Line Mode
On-Line is the printer’s normal operating mode. In this mode, the printer is On-Line,
under the control of the System Controller Board, and ready to generate output. The
On-Line Mode occurs automatically when the printer is powered ON.
If the printer goes out of the On-Line Mode during operation, it may be restored to
On-Line by pressing the On-Line button [0] on the Control Panel.
When 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
performed, within a period of time (either printer default or set by the user) the printer
enters the power saving state.
The Power Saver Mode interval can be set from the System Menu (in Menu Mode) and
can be preset to Off, 15, 30, 60, 90, 120 or 180 minutes.
When the printer is in the power saving state, it takes longer to start printing the first page
because it takes some time to raise the fuser temperature.
Volume 1 / Print Engine - Diagnostics, Tests & NVRAM 1-149

Diagnostics
Diagnostics available to the technician are built into the System Controller Board.
However, test prints are available from both the System Controller and the Print Engine
Controller as described below.
You can use Diagnostics to:

Test the operation of printer switches and sensors.
Test the operation of printer motors, solenoids, and electric clutches.
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 Mode also enables the operator
to set, change or adjust various features/options available int he DocuPrint N4525
Network laser Printer. If an option is not installed, the menu items for that option will not
be displayed.

Maintenance Reset Procedure
The Maintenance Kit is a user installable kit which replaces the paper feed rollers, bias
transfer roller, cleaning cloth, gloves and a fuser. The printer’s control panel display
informs the user when it is time to install a Maintenance Kit.
Upon completing the Maintenance Kit installation, it is necessary to reset the Maintenance
Kit Counter. Although wordless instructions are included with the kit, the procedure
below is provided for when those instructions are not available to you.
Note The Maintenance Kit Counter should only be reset when a
complete 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] and [6]
and press [0] and [5]. Hold [0] and [5] until “Reset Complete Please Reboot” is
displayed. This message confirms the counter has been reset.
4. Reboot the printer by powering OFF, waiting 20 - 30 seconds and powering
ON.
The Maintenance Kit is a customer purchased / customer replaced unit (CRU). The
interval for replacement is 300K prints.
For Maintenance Kit part numbers, see Xerox Supplies and Accessories in the FRU Parts
Lists on page 1-338.

Test Prints
A variety of test prints are available to aid in determining the quality of output from the
printer and to assist in troubleshooting problems. Some test prints are available from the
System Controller Board and others from the Print Engine Controller Board This section
shows how to select and produce all test prints available.
Note For assistance in analyzing print quality problems, please refer to
the Troubleshooting section of this manual, Image Quality
Problems on page 1-113.
System Controller Test Prints

The test prints available from the System Controller Board consist of a “Test Print” for
helping to evaluate print quality and alignment/registration. Other available prints provide
a printer configuration sheet, fault history, menu map, PS and PCL font lists, and a PCL
Demo page. Some of these test prints serve a twofold purpose by providing information
germaine to the printer and an indicator of measurable print quality.
Note If multiple test prints are desired, enter the System Menu and
change “Print Quantity” value from 1 to the desired number.
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 with myriad of pertinent information regarding the printer’s
configuration. It is a good idea to print a configuration 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 “Config Sheet” is displayed.
3. Press [4] and a printer configuration sheet will be printed.
System Controller Test Print:
The “Test Print” is a multi-purpose print displaying a wide
variety of objects including text, multi-positional thin/thick
lines, black painted areas, gray scale, fine alignment
graduations to facilitate checking registration, lead edge and
side edge alignment, etc. Normally, running this test print
delivers two identical pages.
1. While in the menu mode, press [1] or [5] until “PRINT
MENU” is displayed.
2. Press [2] or [6] until “Test Print” is displayed.
3. Press [4] and the System Controller test page will be
printed.

Fault History:
The fault history provides two columns of figures to help track faults. A Page Count,
which refers to the actual page count of the printer where a problem occurred. The Fault
Description column lists the Fault (Error) Codes pertaining to the problem. In many
cases, these codes can be found in the Error Codes section of this manual as an aid to
troubleshooting. Not every code is listed in this manual. This fault history can become
helpful in troubleshooting difficult problems by providing the page count/fault description
code to Technical Support, if needed.
1. While in the menu mode, press [1] or [2] until “PRINT MENU” is displayed.
2. Press [2] or [6] until “Fault History” is displayed.
3. Press [4] and the fault history will be printed.
Note It is advisable to print a fault history and have it ready when
contacting Technical Support.
Menu Map:
The menu map helps the user/technician navigate the multitudes of menus and sub-menus
available. It is a good idea to print a configuration sheet and keep it close to the printer for
reference by users, technicians, and/or system administrators.
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 which to help determine print quality.
2. Press [2] or [6] until “PS Font List” is displayed.
3. Press [4] and the PS font list will be printed.
PCL® Font List:
Three pages of internal PCL fonts is provided with this test. This is another useful print
quality test print.
2. Press [2] until “PCL Font List” is displayed.
3. Press [4] and the PCL font list will be printed.
PCL® Demo Test Print:
The internal PCL Demo test page provides an additional print quality test for the printer.
The page is rich in graphics, black and grayscale painting and text.variations.
1. While in the menu mode, press [1] until “PRINT MENU” is displayed.
2. Press [2] until “PCL Demo” is displayed.
3. Press [4] and the PCL Demo test page will be printed.

Print Engine Controller Board Test Prints
Various test print images are stored in ROM on the Print Engine Controller Board. Use
this Test Print Diagnostic routine to bypass the System Controller Board and print a
variety of test prints directly from the Print Engine Controller Board. Running the Test
Print Diagnostic routine is an excellent tool for isolating and diagnosing printer feed,
paper path, and image quality problems. Refer to the NVRAM section of this manual for
information on using test prints to help adjust print image registration.
Note You must enter Diagnostic Mode to 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).
S4525-25
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 [4]. Hold [4] until “Main Menu Test Print” is display. You are now in
Diagnostics Mode.
S4525-25A
Note If you miss the 10-second window, the printer will reenter its
normal boot sequence. To try again, power down the printer, wait
20 - 30 seconds, and begin at step 1 above again.
4. When requested for password, sequentially press [0], [7], [3], [4] to gain entry.
Note To exit Diagnostics, you must power OFF the printer, wait 20 - 30
seconds and power ON the printer.

Print Engine Controller Test Prints
The Print Engine Controller Board Test Prints require entering Diagnostics Mode. Refer
to page 1-154 for instructions on how to enter Diagnostics Mode.
The Control Panel Test Legend to the right will aid in
S4525-25B
navigating through the variety of test prints available. Stop Menu Up Item Up Value Up
Start Menu Item Value

Down Down Down
Table 1-103 Print Engine Controller Test Prints

Press [1] or [5] to display: Þ Main Menu
Print Menu
Press [2] or [6] to display: ß Press [3] or [7] to display: ß Comment
Test Print Press [4] to start the test print
Start Print selected. Press [0] to stop.
Test Print Print Quantity Press [3] or [7] until desired
Print Quantity 1* quantity is selected (1~999),
then press [4].
Test Print Input Tray Press [4] to select the paper
Input Tray Tray 1* feed tray desired.
Input Tray Press [4] to select the paper
Tray 2 feed tray desired.
Tray 3(1) feed tray desired.
Input Tray Multi-sheet Bypass Feeder or
MBF/ENV(4) Envelope Feeder
Test Print Output Tray Press [4] to select the output
Output Tray Face Down* Tray desired.
This selection outputs to the
Face Down output Tray using
no offset.
Output Tray Outputs to the Face Down
Face Dw F Offset output Tray using front offset
Output Tray Outputs to the Face Down
Face Dw R Offset output Tray using rear offset
Output Tray Outputs to the Face up tray
Face up(2)
Output Tray Outputs to the Finisher
Finisher(3)
Test Print Duplex Single side printing
Duplex Off*
Duplex Both sides of page printed
On
Test Print Staple Selection
Staple Selection No Staple*(3)
Staple Selection 45o relative to the front
Front Staple(3) (Control Panel side) of the
printer

Table 1-103 Print Engine Controller Test Prints (cont'd.)
Print Menu
Press [2] or [6] to display: ß Press [3] or [7] to display: ß Comment
Staple Selection 45o relative to the rear of the
Rear Staple(3) printer
Staple Selection Two in-line staples and
Dual Staple(3) parallel to the long edge
(near the center)
Pages Per Set Pages Per Set Selects the number of pages
2* per print/staple set (2~50).
Test Print Punch Selection
Punch Selection On*
Punch Selection
Off
Test Print Select Pattern Wide, fine line grid pattern
Select Pattern Grid* suitable for checking and
adjusting registration.
Select Pattern Paints the printable area dark
Dark Dusting gray.
Select Pattern H pattern covering the entire
H Pattern printable area.
Select Pattern Blank page - suitable for
Blank inspecting for unwanted
shading, pattern or objects.
(1) If the High Capacity Feeder is installed.
(2) If the Face Up Tray is installed.
(3) If the Finisher is installed.
(4) If the Multi-sheet Bypass Feeder or Envelope Feeder is desired.
* = Default

Analyzing the Test Print
Test prints provide several uses in troubleshooting printer problems.
Isolating problems to either the print engine or to the System Controller Board
and host software.
Locating feed and paper transport problems.
Detecting print quality and image registration problems.
Using Test Prints to Isolate a Problem to the Print Engine or to the

You can use test prints to determine if a problem is caused by a faulty print engine or by a
faulty System Controller Board or host software.
Note This procedure presumes you have investigated any displayed
error code or message. If not, please do so now.
1. Print a sample image from the host computer.
2. Enter Printer Diagnostics and generate a test print.
3. Compare both prints.
4. If the problem occurs when you print from the host 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 print engine, system
controller board or host software. If the print quality problem is
an image registration problem, refer to the NVRAM section of this
manual for instructions on adjusting image registration.
Using Test Prints to Locate a Feed or Paper Transport Problem

You can use test prints to locate a problem with paper feed or with paper transportation
along the paper path.
Note This procedure presumes you have investigated any displayed
error code or message pertaining to paper feed or transport
problems. If not, please do so now.
1. Enter Printer Diagnostics and generate a test print.
2. Follow the paper along the paper path to locate the cause of the problem.

NVRAM Counters Menu
The Non-Volatile RAM counters provide page counts, ROM versions and/or other
information for selected items. Information displayed here requires entering Diagnostics
Mode. Refer to page 1-154 for instructions on entering Diagnostics Mode.
S4525-25B
navigating through the variety of counters available. Press [4] Stop Menu Up Item Up Value Up
to start the counter selected, press [0] to stop or wait

approximately 5 seconds and it will stop automatically. Start Menu
Down
Item
Down
Value
Down
Note Some displayed acronyms are parenthically clarified.

NVRAM Counters
NVM Counters
Range
Then, press [2] or (6) to display: ß Minimum Maximum
Note When 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 - 0 999999
Press [4]
Drum Rotate Time - Press [4] 0 999999
Tray 1 Feed - Press [4] 0 999999
Toner Rest Value - Press [4] 0 100000
MCU {Print Engine Controller} ROM Version - 0 99
Press [4]
MCU {Print Engine Controller} ROM Release - 0 99
Press [4]
DM {Duplex Module} ROM Version - Press [4] 0 99
DM {Duplex Module} ROM Release - Press [4] 0 99
Finisher ROM Version - Press [4] 0 99
Finisher ROM Release - Press [4] 0 99
HCF {High Capacity Feeder} ROM Release - Press [4] 0 99
HCF {High Capacity Feeder} ROM Release - Press [4] 0 99

NVRAM Adjustment Procedures
The NVRAM Adjustment Procedures instruct you in adjusting registration globally, as
well as for each individual tray and for simplex and duplex operations. In addition, the
adjustments in the table below enable you to adjust a variety of fuser temperatures and to
toggle Trail Force Erase on and off.
Information displayed here requires entering Diagnostics Mode. Refer to page 1-154 for
instructions on entering Diagnostics Mode.
S4525-25B
navigating through the variety of adjustments available. Press Stop Menu Up Item Up Value Up
[4] to start the adjustment selected, press [0] to stop. For

additional information on checking registration, refer to the Start Menu
Down
Item
Down
Value
Down
registration information beginning on page 1-163
Table 1-104 NVRAM Adjustment Table

Press (3) or (7) to display
“value”. Value Up (3) / Value
Continue pressing [3] or Down (7)
[7] to adjust “value”. Adjustment Range
Line Press [1] or [5] Press [2] or [6] Press [4] to write to Min Def Max
No. to display: ß to display: ß NVRAM, [0] to exit.
1 Main Menu NVM Side Edge SPX All Trays {Simplex} 1 50 99
NVM Side Edge SPX All Trays Each value step = .252 mm
2 NVM Side Edge SPX Tray 1 1 50 99
SPX Tray 1 Each value step = .252 mm
7 NVM Side Edge MBF {Multi-sheet Bypass 1 50 99
MBF Feeder}
Each value step = .252 mm
8 NVM Side Edge Envelope 1 50 99
Envelope Each value step = .252 mm
9 NVM Side Edge DPX All Trays 1 50 99
DPX All Trays Each value step = .252 mm
10 NVM Side Edge DPX Tray 1 1 50 99
DPX Tray 1 Each value step = .252 mm

Table 1-104 NVRAM Adjustment Table (cont'd.)
15 NVM Side Edge DPX MBF 1 50 99
DPX MBF Each value step = .252 mm
16 Main Menu NVM Lead Edge All Trays Reg. 10 27 50
NVM Lead Edge All Trays Reg. Each value step = .41 mm
17 NVM Lead Edge Duplex All Trays 0 9 16
Duplex All Trays Each value step = .41 mm
18 NVM Lead Edge Tray 1 Reg. 0 8 16
Tray 1 Reg. Each value step = .41 mm
19 NVM Lead Edge Tray 2~5 Reg. 0 8 16
Tray 2~5 Reg. Each value step = .41 mm
20 NVM Lead Edge MBF Reg. 0 7 16
MBF Reg. Each value step = .41 mm
21 NVM Lead Edge Envelope Reg. 0 10 16
Envelope Reg. Each value step = .41 mm
22 Main Menu NVM Fuser Adj. Ready Temp 16 38 51
NVM Fuser Adj. Ready Temp Each value step = .85o C (145oc) (165oc) (175oc)
23 NVM Fuser Adj. Standby Temp 19 42 55
Standby Temp Each value step = .82o C (150oc) (170oc) (180oc)
24 NVM Fuser Adj. Standby 2 Temp 21 46 59
Standby 2 Temp Each value step = .78o C (160oc) (180oc) (190oc)
25 NVM Fuser Adj. OHP Temp 0 50 68
OHP Temp Each value step = .82o C (160oc) (190oc) (205oc)
26 NVM Fuser Adj. TR1 Temp 11 49 61
TR1 Temp Each value stepe = .84o C (180oc) (200oc) (210oc)
27 NVM Fuser Adj. TR2 Temp 11 49 55
TR2 Temp Each value step = .80o C (165oc) (195oc) (200oc)
28 NVM Fuser Adj. TM1 Temp 11 49 61
TM1 Temp Each value step = .83o C (180oc) (200oc) (210oc)
29 NVM Fuser Adj. TM2 Temp 11 49 55
TM2 Temp Each value step = .80o C (165oc) (195oc) (200oc)
30 NVM Fuser Adj. TE1 Temp 12 50 62
TE1 Temp Each value step = .80o C (170oc) (200oc) (210oc)

Table 1-104 NVRAM Adjustment Table (cont'd.)
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. Trail Force Ers 0 54 97
NVM Others Adj. Trail Force Ers Each step value = .41 mm

Tray Size Test
The tray size test provides a convenient method of checking the paper feed tray sizes from
the Control Panel. This is a tray size test only. No adjustments can be made.
Information displayed here requires entering Diagnostics Mode. Refer to page 1-154 for
instructions on entering Diagnostics Mode.
S4525-25B
navigating through the variety of tests available. Press [4] to Stop Menu Up Item Up Value Up
start the test selected, press [0] to stop.

Down Down Down
Table 1-105 Tray Size Test

Press (3) or (7) to display “value”.
Continue pressing [3] or [7] to adjust
Press [1] or [5] Press [2] or [6] “value”.
to display: ß to display: ß Press [4] to write to NVRAM, [0] to exit.
Main Menu Tray Size Test Press [4] start, [0] stop
Tray Size Test Tray 1 Size Tray 1 paper size is displayed
Tray Size Test Press [4] start, [0] stop
Tray 2 Size Tray 2 paper size is displayed
MBF Tray Size MBF Tray paper size is displayed
Env Tray Size ENV Tray envelope size is displayed

Checking Lead Edge Registration
Note NVM (Non-Volatile Memory) and NVRAM (Non-Volatile Random
Access Memory) are synonymous. NVM is displayed by the
Control Panel. NVRAM appears in documented text.
Note Use only A4 paper or 8.5” x 11” paper and make certain the tray
being tested is the only tray installed when generating the test
print.
Checking Lead Edge Registration

1. Generate a Registration Grid Pattern Test Print, see page 1-155 to set up and page
1-156 for specifics on Grid Pattern test print launch.
Note The Grid Pattern test print on your printer may, or may not,
display edge lines. If no edge lines appear in your test print,
simply measure to the end of any line perpendicular to the Lead
Edge.
2. Using a metric scale, measure the distance from the lead edge of the test 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.
S4525-72
Fig 1-33 Lead Edge Registration
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 registration, it is recommended to run test prints
from all available trays and compare individual results before
making any adjustments. Doing this will help you determine
where any adjustments are required.
Adjusting Lead Edge Registration

1. Enter Diagnostics Mode, see page 1-154.
2. Press [1] or [5] until “NVM Lead Edge” appears in the bottom line of the display.
3. Press [2] or [6] until the tray you wish to adjust appears in the bottom line of the
display.
4. When prompted for a password, sequentially press [0], [7],[3], [4] to gain entry.
5. Press [3] or [7] once to display the current numerical registration setting.

Note The larger the value, the closer the print will move toward the
lead edge. Each incremental change of the NVM value is equal to
.41 mm when adjusting the lead edge registration.
6. Continue to press [3] or [7] to change the lead edge registration value.
7. Press [4] to write the new value into NVRAM.
8. Recheck the new lead edge registration by repeating the Checking Lead Edge
Registration test above.
Checking Feed Tray Side Edge Registration

1. Generate a Registration Grid Pattern Test Print from the tray you wish to check, see
page 1-154 for information on running a test print.
Note The Grid Pattern test print on your printer may, or may not,
display edge lines. If no edge lines appear in your test print,
simply measure to the end of any line perpendicular to the Side
Edge.
2. Using a metric scale, measure the 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.
S4525-73
Fig 1-34 Side Edge Registration
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 NVRAM
Adjustment Table above for adjustment information.
Adjusting Side Edge Registration

1. Enter Diagnostics Mode, see page 1-154.
2. Press [1] or [5] until “NVM Side Edge” appears in the bottom line of the display.
3. Press [2] or [6] until the tray you wish to adjust appears in the bottom line of the
display.
4. When prompted for a password, sequentially press [0], [7],[3], [4] to gain entry.
5. Press [3] or [7] once to display the current numerical registration setting.
Note The larger the value, the closer the print will move toward the side
edge. Each incremental change of the NVM value is equal to .252
mm when adjusting the side edge registration.

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.

Service Tests
The printer utilizes an extensive variety of Component Control Input and Output tests to
aid in diagnosing funtional problems. The following Diagnostic Service Tests are
provided by the System Controller Board.
Component Control Input

Component Control Input tests are used to aid in verifying proper component operation
and identifying problems and isolating faulty components. To access the following tests,
you must enter Diagnostics Mode:
1. Enter Diagnostics Mode - press and hold [2] and [6] while powering up the printer.
Continue holding [2] and [6] until *IOT?* is displayed.
2. Release [2] and [6], then press and hold [4] until “Main Menu” appears in the top line
of the display. You are now in Diagnostics Mode.
3. Use the Legend below to help navigate throught the various items in the Component
Control Input Tests table.
4. Press [1] or [5] until “Main Menu Comp Input Test” 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 options.
S4525-25B
Menu Up Item Up Value Up

Stop
HCF : High Capacity Feeder Option
MBF (or MSI): Multi-sheet Bypass Feeder
Down Down Down ENV: Envelope Feeder Option
Fin: Finisher Option
ROS: Laser Scanner
Table 1-106 Component Control Input Tests

Press [1] or [5] until to display: Main Menu
Comp Input Test
Press [2] or [6] to Press [3] or [7] to
display: ß display: ß Action To Take Displayed Result
Comp Input Test IOT Unit 1. Press [4] to begin test. Close
IOT Unit L/H Cover A 2. Open L/H Cover A. Open
3. Press [0] to end test.
IOT Unit 1. Press [4] to begin test. Close
Tray 1 Cover B 2. Open Tray 1 Cover B. Open
IOT Unit 1. Press [4] to begin test. Close
Front Cover 2. Open Front Cover. Open

Comp Input Test (cont'd.)
IOT Unit 1. Remove Tray 1. With paper
Tray 1 Paper Sen 2. Press [4] to start test. Without Paper
3. Manually actuate/deactuate
the Tray 1 No Paper Sensor
and observe display.
IOT Unit 1. Remove Tray 2. With Paper
IOT Unit 1. Press [4] to begin test. Up
Tray 1 Level 2. Pull Tray 1 part way out/push Down
in.
IOT Unit 1. Press [4] to begin test. Up
Tray 2 Level 2. Pull Tray 2 part way out/push Down
in.
IOT Unit 1. Press [4] to begin test. Without Paper
FaceDn Tray Full 2. Move Full Stack Senor lever With Paper
up.
Reg. Sensor 2. Open L/H Door A/Place With Paper
paper over registration
sensor.
T/A Roll2 Sensor 2. Open L/H Door A/insert thin With Paper
strip of paper over Take
Away Roller 2 Sensor.
IOT Unit 1. Press [4] to begin test. Installed
CRU Installed 2. Open Front Cover & L/H Not Installed
Door A/ Remove Laser
Print Cartridge.
IOT Unit 1. Press [4] to begin test. Not Empty
Toner Empty 2. Open Front Door & L/H Door Empty
A/ Alternately remove and
insert Laser Print Cartridge.
3. Observe display.
IOT Unit 1. Press [4] to begin test. 20 - 250 C
Fuser Ctr. Main 2. Press [0] to end test (Reads Fuser Temp.)
IOT Unit 1. Press [4] to begin test. 20 - 250 C
Fuser Ctr. Sub 2. Press [0] to end test. (Reads Fuser Temp.)
Fuser Exit Sen. 2. Open L/H Door A/Actuate With Paper
Fuser Exit Sensor.
FaceUp Exit Sen. 2. Open L/H Door A/Actuate With Paper
Face Up Exit Sensor.

Comp Input Test HCF Unit 1. Press [4] to begin test. Close
HCF Unit HCF Cab. Cover C 2. Open L/H Door C. Open
HCF Unit 1. Remove Tray 3. With Paper
HCF Unit 1. Press [4] to begin test. Down
Tray 3 Level 2. Pull Tray 3 part way out/push Up
in.
in.
in.
HCF Unit 1. Press [4] to begin test. Without Paper
T/A Roll3 Sensor 2. Open L/H Door B/Place With Paper
paper over Take Away
Roller 3 Sensor.
3. Press [0] to end test
T/A Roll4 Sensor 2. Open L/H Door C/Place With Paper
paper over Take Roller 4
Sensor.
T/A Roll5 Sensor 2. Open L/H Door C/Slide With Paper
paper into Tray 5 exit
transport.
Comp Input Test Duplex Unit 1. Press [4] to begin test. Close
Duplex Unit Interlock 2. Open Duplex Unit. Open
Duplex Unit 1. Press [4] to begin test. Without Paper
Exit Sensor 2. Actuate Duplex Exit Sensor. With Paper
Duplex Unit 1. Press [4] to begin test. Without Paper
Wait Sensor 2. Open Duplex Unit/Actuate With Paper
Wait Sensor at bottom.

Comp Input Test MBF/ENV Unit 1. Press [4] to begin test. Without Paper
MBF/ENV Unit MBF Paper Sensor 2. Insert a sheet of paper into With Paper
the MBF.
MBF/ENV Unit 1. Press [4] to begin test. Without Paper
Env Paper Sensor 2. Insert an envelope into the With Paper
Envelope Feeder.
MBF/ENV Unit 1. Press [4] to begin test. Without Paper
Env Feed Out Sen 2. Insert a folded paper into the With Paper
right side of the paper path.
Comp Input Test Finisher Unit 1. Press [4] to begin test. Without Paper
Finisher Unit Input Path Sen. 2. Actuate Input Path Sensor. With Paper
Finisher Unit 1. Press [4] to begin test. Without Paper
Path Sensor 2. Actuate Path Sensor. With Paper
Exit Path Sen. 2. Actuate Exit Path Sensor. With Paper
Compile Exit 2. Actuate Compile Exit With Paper
Sensor.
Finisher Unit 1. Press [4] to begin test. Not Home
Exit Rol Open HP 2. Actuate Exit Roller Open HP Home
Sensor.
Sht Rol HP Front 2. Actuate Sheet Roller Home Home
Position Front Sensor.
Jogger HP Front 2. Actuate Jogger Home Home
Position Front Sensor.
Jogger HP Rear 2. Actuate Jogger Home Home
Position Rear Sensor.
Stpl Traverse HP 2. Actuate Staple Traverse Home
Home Position Sensor.
2. Actuate Staple Swing Home
Stpl Swing Sen 1 Sensor 1.
Stpl Swing Sen 2 2. Actuate Staple Swing Home
Sensor 2.
Compile Tr Paper 2. Actuate Compile Tr Paper With Paper
Sensor.

Finisher Unit 1. Press [4] to begin test. With Pin
Low Stpl Switch 2. Actuate Low Staple Switch Without Pin
Sensor.
Finisher Unit 1. Press [4] to begin test. With Cartridge
Stpl Cart Switch 2. Actuate Staple Cartridge Without Cartridge
Switch Sensor.
Stpl Cam HP 2. Actuate Staple Cam Home Home
Position Sensor.
Finisher Unit 1. Press [4] to begin test. Without Pin Pos
Stpl Ready Sen. 2. Actuate Staple Ready With Pin Pos
Sensor.
Finisher Unit 1. Press [4] to begin test. With Paper
Stker Tray Paper 2. Actuate Stacker Bin Paper
Sensor.
Stk Hight Sen Lw 2. Actuate Stacker Height Low With Paper
Sensor.
Stk Hight Sen Up 2. Actuate Stacker Height Up With Paper
Sensor.
Finisher Unit 1. Press [4] to begin test. Off Position
Stker Upper Limit 2. Actuate Stacker Upper Limit On Position
Sensor.
Finisher Unit 1. Press [4] to begin test. Off Position
Stker Lower Lmt 2. Actuate Stacker Lower Limit On Position
Sensor.
Finisher Unit 1. Press [4] to begin test. Not Pass Slit
Stker Position 2. Actuate Stacker Position Pass Slit
Sensor.
Finisher Unit 1. Press [4] to begin test. Docked
Docking Lock 2. Actuate Docking Lock Not Docked
Sensor.
Finisher Unit 1. Press [4] to begin test. Out of Range
Exit Roller Lock 2. Actuate Exit Roller Lock In Range
Sensor.
Finisher Unit 1. Press [4] to begin test. Close
Front Cover Lock 2. Actuate Front Cover Lock Open
Sensor.
Finisher Unit 1. Press [4] to begin test. Without Box
Punch Dust Box 2. Remove Punch Dust Box/ With Box
Reinstall.

H Trans Gate 2. Activate Horizontal Transport Open
In-Gate Sensor.
H Trans Cover 2. Open Horizontal Transport Open
Cover.
H Trans Input P 2. Actuate Horizontal Transport With Paper
Input Path Sensor.
H Trans Exit P 2. Actuate Horizontal Transport With Paper
Exit Path Sensor.
Finisher Unit 1. Press [4] to begin test. Not Full
Face Dn Full Sen 2. Actuate Face Down Bin Full Full
Sensor.
Finisher Unit 1. Press [4] to begin test. Not Full
Punch Dust Full 2. Actuate Punch Dust Full Full
Sensor.

Component Control Output Tests
Component Control Output tests are used to aid in verifying proper component operation
and identifying problems and isolating faulty components. To access the following tests,
you must enter Diagnostics Mode:
1. Enter Diagnostics Mode - press and hold [2] and [6] while powering up the printer.
Continue holding [2] and [6] until *IOT?* is displayed.
2. Release [2] and [6], then press and hold [4] until “Main Menu” appears in the top line
of the display. You are now in Diagnostics Mode.
3. Use the Control Panel Test Legend below to help navigate throught the various items in
the Component Control Output table.
4. Press [1] or [5] until “Main Menu Comp Output Test” 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 output
devices performing work inside the printer.
Control Panel Test Legend: Nomenclature Legend:
IOT: Print Engine - the printer not including the
System Controller Board or options.
S4525-25B
Stop Menu Up Item Up Value Up

HCF: High Capacity Feeder Option
MBF (or MSI): Multi-sheet Bypass Feeder
Down Down Down 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 Press [3] or [7] to Turn -On
display: ß display: ß Duration Comment
Comp Output Test Main Motor On 2 min. Press [4] to start test.
IOT Unit Actuate Main Drive Motor for duration or
Press [0] to stop.
Fuser Fan High 2 min. Press [4] to start test.
Actuate Fuser Fan for duration or
Press [0] to stop.
LVPS Fan High 2 min. Press [4] to start test.
Actuate Low Voltage Power Supply fan for
duration or Press [0] to stop.
ROS Motor On 2 min. Press [4] to start test.
Actuate Laser Scanner Motor for duration or
Press [0] to stop.
ROS Motor Stadby 2 min. Press [4] to start test.
Places Laser Scanner Motor in standby for
Tray 1 Lift Mot 2 sec. Press [4] to start test.
Actuate Tray 1 Lift Motor for duration or
Press [0] to stop.

Comp Output Test
Tray 2 Lift Mot 2 sec. 1. Press [4] to start test.
2. Actuate Tray 2 Lift Motor for duration or
Press [0] to stop.
Drum Motor On 2 min. 1. Press [4] to start test.
2. Actuate Drum Motor for duration or
Press [0] to stop.
Reg. Clutch On 2 sec. 1. Press [4] to start test.
2. Actuate Registration Clutch for duration or
Press [0] to stop.
Tray 1 Feed Clut 2 sec. 1. Press [4] to start test.
2. Actuate Tray 1 Feed Clutch for duration or
Press [0] to stop.
Press [0] to stop.
Dev. Bias 2 sec. 1. Press [4] to start test.
2. Turns on Developer Bias output for duration
or Press [0] to stop.
DB AC Clock 2 sec. 1. Press [4] to start test.
2. Turns on DB AC Clock output for duration or
Press [0] to stop.
BCR/AC 2 sec. 1. Press [4] to start test.
2. Turns on Bias Charge Roller AC output for
BCR/DC 2 sec. 1. Press [4] to start test.
2. Turns on Bias Charge Roller DC output for
BTR Sel. 2 sec. 1. Press [4] to start test.
2. Turns on Bias Transfer Roller Sel. output for
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 stop.
Fuser Bias 2 sec. 1. Press [4] to start test.
2. Turns on Fuser Bias output for duration or
Press [0] to stop.
Fuser Bias Sel. 2 sec. 1. Press [4] to start test.
2. Turns on Fuser Bias Sel. output for duration
Offset Motor Fnt 1 sec. 1. Press [4] to start test.
2. Actuate Offset Motor front
Offset Motor Rev 1 sec. 1. Press [4] to start test.
2. Actuate Offset Motor reverse
CompOutput Test Tray 3 Lift 2 sec. 1. Press [4] to start test.
HCF Unit 2. Actuate Tray 3 Lift Motor for duration or
Press [0] to stop.
Tray 4 Lift 2 sec. 1. Press [4] to start test.
Press [0] to stop.
Tray 5 Lift 2 sec. 1. Press [4] to start test.
Press [0] to stop.

Comp Output Test
TTM Feed Motor 2 min. 1. Press [4] to start test.
2. Actuate TTM Feed Motor for duration or
Press [0] to stop.
Press [0] to stop.
Press [0] to stop.
Press [0] to stop.
Comp Output Test Motor Slow 2 min. 1. Press [4] to start test.
Duplex Unit 2. Actuate Exit Motor slow for duration or
Press [0] to stop.
Motor Fast 2 min. 1. Press [4] to start test.
2. Actuate Exit Motor fast for duration or
Press [0] to stop.
Exit Gate Sol. 2 sec. 1. Press [4] to start test.
2. Actuate the Exit Gate for duration or Press
[0] to stop.
Wait Clutch 2 sec. 1. Press [4] to start test.
2. Actuate Wait Clutch for duration or Press
[0] to stop.
Invert Clut CW 2 sec. 1. Press [4] to start test.
2. ActuateClockwise Invert Clutch for duration
Invert 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 Feed Clutch 2 sec. 1. Press [4] to start test.
MBF/ENV Unit 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
Env Clutch On 2 sec. 1. Press [4] to start test.
2. Actuate Envelope Feeder feed clutch for
Comp Output Test Finisher Unit 2 min. 1. Press [4] to start test.
Finisher Unit Fin Main Motor 2. Actuates Finisher Main Motor for duration
Finisher Unit 2 min. 1. Press [4] to start test.
Compile Tray Mot 2. Actuate Compile Tray Motor for duration or
Press [0] to stop.
Exit Motor CW 1. Actuates Exit Motor clockwise for duration
Exit Motor CCW 2. Actuates Exit Motor counter clockwise for
Finisher Unit 2 sec. 1. Press [4] to start test.
Exit Motor Open 2. Actuates Exit Motor Open function.
Exit Motor Close 2. Actuates Exit Motor Close function.

Comp Output Test
Shift Motor Rear 2. Actuates Shift Motor moving Shift Roller
toward the Rear.
Shift Motor Frnt 2. Actuates Shift Motor moving Shift Roller
toward the Front.
Jogging Motor F 2. Actuates the Jogging Motor Front for
Jogging Motor R 2. Actuates the Jogging Motor Rear for
Sheet Clamp Mot 2. Actuates the Sheet Clamp Motor in the
Stacker Bin.
Finisher Unit 2 sec. 1. Extend Compiler Tray (tongue) to facilitate
Trav Mot Front45 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.
Trav Mot Rear stapler movement.
Trav Mot Rear45 stapler movement.
Trav Mot Front stapler movement.
Swing Mot Frnt45 stapler movement.
2. Gently pull the Stapler to the front of the
Finisher.
4. Actuates Stapler Swing Motor to swing
Stapler 45o to the front.

Comp Output Test
Swing Mot Rear45 stapler movement.
2. Gently push the Stapler to the rear of the
Finisher.
4. Actuates the Stapler Swing Motor to swing
the Stapler 45o to the rear.
Swing Mot Flat 2. Actuates the Stapler Swing Motor to swing
the Stapler to the flat position to facilitate
traverse movement.
Stapler Motor stapler movement.
2. Place paper into the Compiler Tray and
“jog” to the front of the Finisher.
4. Actuates the Stapler.
Note: Staple head must be in the staple position
and paper must be in the Compiler Tray.
Stacker Mot down 2. Actuates the Stacker Motor for duration to
drive the Stacker Bin down.
Stacker Mot Up 2. Actuates the Stacker Motor for duration to
drive the Stacker Bin up.
Punch Clutch 2. Momentarily actuates the Punch Clutch.
Listen for click.
Punch Mot & Clut 2. Actuates the Punch Motor and Clutch for
duration.
H Tran Gate Pull 2. Opens the Horizontal Transport In-Gate.
H Tran Gate Push 2. Closes the Horizontal Transport In-Gate.

Maintenance and
Cleaning
Scheduled Maintenance
The DocuPrint N4525 is designed and tested to require little maintenance. A User
Maintenance Kit (P/N 109R00048 for 110 volt printer and 109R00049 for 220 volt
printers) contains:
Replacement Fuser
Bias Transfer Roller
Feed Rollers (15 ea. - three for each paper input Bin)
Rubber gloves for handling Feed and Bias Transfer rollers
Cleaning cloth.
The printer will tell the user when to install the User Maintenance Kit (300,000 prints).
Normally, it is not 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 vacuum to clean up a toner spill.
Suction bulb to use as an air puff blower
Toner rags (specially treat fibrous paper cleaning “rags” that attract and pick up
toner and dust particles
Cotton swabs (for those hard to get at places)
Cleaning cloth
Isopropyl alcohol
Simple Green or equivalent cleaner
Volume 1 / Print Engine - Maintenance & Cleaning 1-177

Inspect While Servicing
The above represents all the schedule maintenance for this printer. However, it is
important for all qualified service technicians to always inspect and clean “on-the-fly”
whenever repairing or other wise servicing the printer.
Areas to inspect and clean while in the printer:
Feed rollers for wear, dirt/grime/dust
Paper Bins for dust, lint, debris
Paper paths for debris
Laser print cartridge area for spilled toner
Cabinet interior
Multi-sheet Bypass Feeder roler and retard pad
Duplex Unit rollers and paper path
Envelope Feeder rollers (if installed)
All exit rollers
General overall appearance for signs of sbuse, wear, unfriendly envorinment
damage, etc.
Clean as necessary.
Cleaning (general - if needed)

Whenever you check, service, or repair a printer, you should perform the following
procedures. Cleaning the 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 should thoroughly
inspect and clean these printers.
Ask each printer customer about the type of paper he or she uses so that you can be sure to
clean the parts of the printer that particular paper may affect. If a customer is printing on
the more unusual or dustier papers, then you should pay particular attention to these
printer parts:
1. Turn off the printer.
2. Remove the Laser Print (EP) Cartridge and immediately cover it to protect the
drum from the light.
3. Remove the fuser.
4. Remove the paper Bins.
5. Slide out the Finisher (if installed).
6. Clean all printer rollers, except the Bias Transfer Roller, with alcohol-dampaned
wipes only. Never apply alcohol to the Bias Transfer Roller.

7. Clean the laser window with puffs of 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.
Volume 1 / Print Engine - Maintenance & Cleaning 1-179

Blank Page

Key FRU Removal /
Replacement
Procedures (RRPs)
Contents - Removal and Replacement Procedures
Preparation 1-183
Work Notes 1-183
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
Volume 1 / Print Engine - FRU RRPs 1-181

RRP 1-55 Exit Drive Assembly (PL 9.4). 1-242
RRP 1-56 Exit Gate Solenoid (PL 9.1) 1-244
RRP 1-57 Offset Motor (PL 9.1) 1-245
RRP 1-58 Full Stack Sensor (PL 9.1) 1-246
RRP 1-59 Offset Roller Assembly (PL 9.2) 1-247
RRP 1-60 Lower Chute Assembly (PL 9.1) 1-248
RRP 1-61 Upper Chute Assembly (PL 9.3) 1-249
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 1-71 Left Cover Interlock Switch Assembly (PL 11.2) 1-261
RRP 1-72 Print Engine Controller Board (PL 11.3) 1-262
RRP 1-73 System Controller (PL 11.3) 1-264

Removal and Replacement Procedures
(RRPs)
This section contains the removal and replacement procedures for selected parts of the
printer. Not all Replacement Procedures are included in this Quick Reference Guide. In
most cases, to reinstall a part, simply reverse the Removal Procedure shown. In some
instances, the Replacement Procedure is included because it may contain special steps.
Preparation
Before you begin any Removal and Replacement Procedure:
1. Switch OFF the printer power and disconnect the power cord from the AC wall
outlet.
2. Remove the Laser Print (EP) Cartridge and protect it from exposure to light by
covering it with a piece of opaque plastic sheeting or by placing it in a light-tight
container. See RRP 48 for 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 the
same as the names appear in the Section 12 Parts List. For
example; a part called the Metal Registration Roller in an RRP
may appear on the Parts List as Registration Metal Roller. When
working on an RRP, ignore any prerequisite RRP if you have
already performed that removal procedure.
Caution Always use the correct type and size screw. Using the wrong screw
can damage tapped holes. Do not use excessive force to either
remove or install either a screw or a printer part.
Warning Unplug the AC power cord from the AC wall outlet before
removing any printer part.

Notations in the RRP text
Locations, such as R or right, given in the RRPs assume you are facing the
printer control panel.
The notation "rear" of a component, in place or removed, refers to the surface
of the component that is, when installed, facing the rear of the print engine.
The notation "front" of a component refers to the surface of the component that
is, if installed, facing the front of 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 or
replacing a component.
Note For more detailed instructions and for RRPs not listed in the
QRG, refer to the CD-ROM (on-line) version of the N4525 Service
Manual and/or to Xerox Service and Support Resources “On-Line
Service Files” for this printer.

RRP 1-1 Fuser Cover
(PL 1.1)
S4525-74
Fig 1-35 Fuser Cover
Removal
1. Remove the Finisher, if installed.
2. Open the Duplex Module, if installed.
3. Pull 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.

RRP 1-2 Top Cover Assembly (PL 1.1)
(P/J204)
(P/J417)
S4525-75
Fig 1-36 Top Cover Assembly
Removal
1. Unplug the AC Power Cord from the rear of the printer.
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.

RRP 1-3 Front Cover Assembly (PL 1.1)
Right hinge
Strap
Metal hinge
Tab
S4525-76
Front Cover Assembly
Fig 1-37 Front Cover Assembly
Removal
1. Open the Front Cover.
2. Remove the black self-tapping screw securing the plastic strap 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.

RRP 1-4 Front Inner Cover (PL 2.3)
Front Inner Cover
(P/J237)
Front Cover
Interlock Switch
S4525-77
Fig 1-38 Front Inner Cover
Removal
1. Unplug the AC Power Cord from the rear of the printer.
2. Remove the Front Cover (RRP 1-3).
3. Remove the black machine screw securing the Front Inner Cover to the printer
frame and carefully pull the 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 the Cover.

RRP 1-5 Rear Cover Assembly (PL 3.3)
S4525-78
Fig 1-39 Rear Cover Assembly
Removal
1. Remove the AC power 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.

RRP 1-6 Right Cover (PL 3.2)
S4525-79
Fig 1-40 Right Cover
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.

RRP 1-7 Control Panel (PL 1.1)
S4525-80
Fig 1-41 Control Panel
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.

RRP 1-8 Rear Lower Cover (PL 3.4)
S4525-81
Fig 1-42 Rear Lower Cover
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.

RRP 1-9 Tray 1 Lift Motor (PL 3.1)
(P/J203)
S4525-82
Fig 1-43 Tray 1 Lift Motor
Removal
1. Slide Tray 1 halfway out of the printer.
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.

RRP 1-10 Tray 1 Feed Clutch (PL 3.2)
S4525-83
Fig 1-44 Tray 1 Feed Clutch

Removal
2. Open the Duplex Module, if installed.
4. Disconnect the Tray 1 Feed Clutch (P/J202).
5. Remove the E-ring that is securing the Feed Clutch to the shaft.
6. Slide the Feed Clutch away from the printer frame, then rotate the Clutch until
you have enough clearance from the Support Spring to slide the Clutch
completely 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 engages and the clutch bottoms,
and make sure the key on the frame is in the slot in the Clutch.
4. Use an E-ring to secure the Clutch to the shaft.
5. Reconnect J202 to the Feed Clutch.
6. Reinstall the Rear Cover (RRP 1-5).

RRP 1-11 Feeder, Pick and Retard Rollers (PL
3.2~PL 3.3~PL 3.5 and PL 3.6)
Chute
Roller Latch
S4525-84
Fig 1-45 Feeder, Pick and Retard Rollers

Note Use this procedure for Feeders 1 and 2. Replace the Feeder, Pick
and Retard rollers at the same time.

Removal
1. Remove the paper Tray from the appropriate feeder.
2. Swing the Chute down so it clears the Rollers.
3. Pull out on the Roller latch and slide 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.

RRP 1-12 Tray 1 Take-Away Roller Assembly
(PL 3.3)
Retaining Clip
Option Connector Bracket

Figure 1
S4525-8
Fi 2
Fig 1-46 Tray 1 Take-Away Roller Assembly

Removal
1. Remove the Duplex Module, if installed.
2. Remove the Laser Print (EP) Cartridge.
Caution Store the Laser Print (EP) Cartridge in a light proof storage bag
or in a dark place to prevent light damage to the drum.
3. Remove Bins 1 and 2.
Caution Do not place paper Bins flat on carpet. Place on a smooth
surface that cannot grab and dislodge the springs underneath the
Bin. Alternatively, remove any paper from the Tray and lean
against a wall or object.
4. Remove the Left Upper Cover Assembly (RRP 1-42).
5. Remove the Rear Cover Assembly (RRP 1-5).
6. Remove the Multi-sheet Bypass Feeder Support Assembly (RRP 1-27).
7. Remove the Left Middle Cover Assembly (RRP 1-36).
Caution Exercise caution in removing the Left Middle Cover after removing
the four screws. The Pinch Roller Assembly is loose and can drop
and be damaged.
8. Remove the retaining KL-clip from the docking stud that is located at the lower
right of Tray 1 and remove the stud.
9. Remove the machine screw securing the retaining clip that is located above the
Option Connector Bracket and remove the clip (see magnified detail in Figure
1).
10.Disconnect J463, J464, J466, and J467 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 the printer, with the right side down, on a level and stable work surface.
15.Remove the Support Assembly Spring.
Caution Remove the outer bushing, which floats in the Support Assembly
Spring arm as a precaution against losing it or dropping it into
the printer and causing damage.
16.Remove the Tray 1 Feed Clutch, along with the gear and bearing, (RRP 1-10).
17.Remove the three machine screws securing the Tray 1 Take-Away Roller
Assembly to the rear of the frame (see Figure 2).
18.Remove the two machine screws securing Tray 1 Take-Away Roller Assembly
to the front of the frame (see Figure 2).
19.Locate the two plastic mounting pins, located at each end of the Assembly, that
secure the top of the Assembly to the bottom of the printer frame.
20.Angle the front of the assembly down to release the front locating pin from the
frame. Then pull Tray 1 Take Away Assembly away from the printer,
disengaging the rear locating pin from the frame as you remove the assembly.

RRP 1-13 Tray 1 Feeder Assembly (PL 3.2)
Figure 1
S4525-86
Figure 2
Fig 1-47 Tray 1 Feeder Assembly

Removal
1. Tray 1 from the printer.
Caution Do not place paper Bins flat on carpet. Place on a smooth
surface that cannot grab and dislodge the springs underneath the
Bin. Alternatively, remove any paper from the Tray and lean
against a wall or object.
3. Remove the Front Chute (RRP 1-16).
4. Remove Tray 1 Feed Clutch (RRP 1-10) along with the Feed Gear and Bearing.
(Refer to the figure).
5. Remove the Feed, Pick and Retard Rollers (RRP 1-11).
6. Remove the E-ring that is securing the Feed Gear (located behind the Feed
Clutch) to the shaft, and remove the Feed Gear and Bearing.
7. Hold down the Stopper Link while pulling the Feeder Assembly to the front of
the printer frame.
Caution Take care not to break or dislodge the No Paper Actuator when
removing or replacing the Tray 1 Feeder Assembly.
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 should rest on top of the Stopper Link, and the Link
should secure the Feeder Assembly in place on the frame.
5. Make sure the Paper Level Actuator tab on the Feeder is positioned in the
center of the arms of the Paper Level Sensor.
6. Slide the Feed Bearing onto the Feed Shaft and press the Bearing into the
cutout in the frame.
7. Reinstall the Feed Gear onto the Feed Shaft, and use an E-ring to secure it to
the Shaft.
8. Reinstall the Feed, Pick and Retard Rollers (RRP 1-11).
9. Reinstall Tray 1 Feed Clutch (RRP 1-10) along with the Feed Gear and
Bearing.
10.Reinstall the Front Chute (RRP 1-16).
11.Reinstall the Rear Cover (RRP 1-5).
12.Reinstall Tray 1.

RRP 1-15 Tray 1 Retard Assembly (PL 3.3)
NT
FRO
1 2 3
S4525-88
Fig 1-48 Tray 1 Retard Assembly
Removal
1. Remove the Tray 1 Take-Away Roller Assembly (RRP 1-12).
2. Remove the machine screw securing the Feed In Chute (19) to the Assembly
and slide the Chute to the front of the Assembly to remove it.
3. Remove the plastic Feed Chute (18) from the Take-Away Roller.
4. Unhook the spring 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
Take-Away Roller Shaft.
9. Remove the Center Bearing on the Take-Away Roller Shaft, and slide the
Roller out of the Retard Support.

RRP 1-16 Tray 1 & Tray 2 Front Chute Assemblies
(PL 3.1~PL 3.4)
S4525-89
Fig 1-49 Tray 1 & Tray 2 Front chute Assemblies
Removal
1. Remove either Paper Tray 1 or Paper Tray 2.
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. 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 the Paper Bin.

RRP 1-20 Tray 1 & Tray 2 Paper Size Sensors
(PL 3.1~PL 3.4)
Paper Size Sensor Board
S4525-93
Fig 1-50 Tray 1 & Tray 2 Paper Size Sensors

Note Use this procedure to remove and replace the Paper Size Sensors
for Bins 1 and 2.
Removal
1. Remove either Paper Tray 1 or Paper Tray 2 from the printer.
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.

RRP 1-21 Tray 2 Feed Clutch (PL 3.5)
S4525-94
Fig 1-51 Tray 2 Feed Clutch
Removal
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.

RRP 1-22 Tray 2 Feeder Assembly (PL 3.5)
Figure 1
Figure 2 S4525-95
Fig 1-52 Tray 2 Feeder Assembly

Caution Take care not to break or dislodge the No Paper Actuator when
removing or replacing the Tray 2 Feeder Assembly.

Removal
1. Remove Tray 2 from the printer.
3. Remove the Front Chute (RRP 1-16).
4. Remove Tray 2 Feed Clutch (RRP 1-21) along with the Feed Gear and Bearing.
(Refer to the figure).
5. Remove the E-ring that is securing the Feed Gear (located behind the Feed
Clutch) to the shaft, and remove the Feed Gear and Bearing.
6. Hold down the Stopper Link while you pull the Feeder Assembly to the front of
the printer frame.
7. Remove the Feeder Assembly from Feeder 2.
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 should rest on top of the Stopper Link, and the Link
should secure the Feeder Assembly in place on the frame.
5. Make sure the Paper Level Actuator tab on the Feeder is positioned in the
center of the arms of the Paper Level Sensor.
6. Slide the Feed Bearing onto the Feed Shaft and press the Bearing into the
cutout in the frame.
7. Reinstall the Feed Gear onto the Feed Shaft, and use the E-ring (removed in
Step 5 above) to secure it to the Shaft.
8. Reinstall Tray 2 Feed Clutch (RRP 1-21).
9. Reinstall the Front Chute (RRP 1-16).
10.Reinstall the Rear Cover (RRP 1-5).
11.Reinstall Tray 2.

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

Front Bearing
Gear 22T
S4525-96
Fig 1-53 Tray 2 Take-Away Roller Assembly

Removal
1. Open the Left Lower Cover.
2. Remove Rear Cover (RRP 5)
3. Remove the machine screw securing the Feed In Chute to the Assembly, and
slide the Chute to the front of the Assembly to remove it.
4. Remove the plastic Feed Chute from the Take-Away Roller.
Caution Use extreme caution when removing the Feed Chute. It is easily
broken.
5. Unhook and remove the spring from the Retard Support.
6. Remove the machine screw securing the Bracket, then remove the Bracket.
7. Remove the machine screw securing the Gear Stopper to the assembly.
8. Remove the E-ring securing the Gear Stopper, 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 rear as possible, then swinging the
front end of the shaft to the right to clear the printer frame. Remove the
Take-Away Roller Assembly by sliding it out toward the front of the printer.
Note When removing the Take-Away Roller Assembly, it may be
necessary to hold down the Stopper Link (see RRP 22, Figure 2)
while gently moving the assembly in various directions to find the
best position to get it out easily.

RRP 1-24 Tray 2 Retard Assembly (PL 3.6)
S4525-97
Fig 1-54 Tray 2 Retard Assembly
Removal
1. Remove the Take-Away Roller Assembly (RRP 1-21).
2. Remove the E-ring securing the rear bearing on the Take-Away Roller and
remove the bearing.
3. Slide the Take-Away Roller Shaft 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 the Take-Away Roller Assembly (RRP 1-21).

RRP 1-25 Multi-sheet Bypass Feeder Assembly
(PL 4.2)
S4525-98
Fig 1-55 Mult-Sheet Bypass Feeder Assembly
Removal
1. Face the left side of the printer.
2. Hold both sides of the Multi-sheet Bypass Feeder Assembly and firmly pull the
Assembly toward you and out of 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.

RRP 1-26 Multi-sheet Bypass Feeder Tray Assembly
(PL 4.2)
Multi-sheet Bypass Feeder Top Cover
Figure 1
(P/J107)
Figure 2 S4525-99
Fig 1-56 Multi-sheet Bypass Feeder Tray Assembly

Removal
2. Remove the Multi-sheet Bypass Feeder Assembly (RRP 1-25).
3. Remove the two machine screws (one at each end) securing the Multi-sheet
Bypass Feeder Top Cover to the Multi-sheet Bypass Feeder Assembly, 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 metal shaft on the Front
Support.
7. Remove the Multi-sheet Bypass Feeder Tray Assembly.

RRP 1-27 Multi-sheet Bypass Feeder Support
Assembly (PL 4.1).
(P/J 603)
S4525-100
Fig 1-57 Multi-sheet Bypass Feeder Support Assembly

Removal
3. Disconnect P/J603 and free the harness from the wire retaining wrap to
facilitate removal of the support assembly without risk to the wires.
4. Remove the four machine screws securing the Multi-sheet Bypass Feeder
Support Assembly to the printer frame, and remove the Assembly.
Note It is not necessary to remove the two end covers to remove the
MBF Support Assembly. 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 positioning pins that are located at both ends of the Support
Assembly into the holes in the frame.
4. Use the four machine screws (removed in Step 4 above) to secure the
Assembly to the frame.
5. Reconnect J603.
6. Reinstall the Rear Cover Assembly (RRP 1-5).
7. Reinstall the Multi-sheet Bypass Feeder Assembly (RRP 1-25).

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

Side Guide
S4525-101
Fig 1-58 Multi-sheet Bypass Feeder Size Sensor Assembly

Removal
2. Place the Multi-sheet Bypass Feeder upside down, with the Tray facing you.
3. Remove the two self-tapping screws securing the Lower Cover to the Upper
Cover.
4. Locate the three latches on the right side of the Bin.
5. Press the first latch while you pry the edge of the Lower Cover out and over the
latch of the Upper Cover.
6. Repeat step 5 for the remaining two latches located on the right side of the Bin.
7. Repeat step 5 for the two latches that are located on the left side of the Bin,
and remove the Lower Cover from the Upper Cover.
8. Remove the Multi-sheet Bypass Feeder Bin.
9. Squeeze together the latches holding the Multi-sheet Bypass Feeder Size
Sensor to the Multi-sheet Bypass Feeder Side Guide, and pry the Sensor off
and away from the Upper Cover.
10.Disconnect P/J107 and remove the Sensor Assembly.
Replacement
1. Reinstall the Multi-sheet Bypass Feeder Side Guide, making sure the two latch
tabs at 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 track.
6. Slide the Sensor Assembly to the left to make sure it moves smoothly and the
spring-loaded arm lowers as you move the Sensor to the left, and raises when
you move the Sensor to the right.
7. Route the Sensor wire harness along the molded channel and through the
cutout on the right side of the Upper Cover.
8. Reconnect P/J107.
9. Reinstall the Multi-sheet Bypass Feeder Bin, with the arrow side down.
10.Slide the three tabs on the upper edge of the Upper Cover into the three
cutouts in Lower Cover, and press the Upper Cover onto the Lower Cover.
11.Press at the five latch locations to make sure the latches have locked the
Lower Cover in place.
12.Use the two self-tapping screws (removed in Step 3 above) to secure the
Lower Cover to the Upper Cover.
13.Reinstall the Multi-sheet Bypass Feeder Assembly (RRP 1-25).

RRP 1-29 Multi-sheet Bypass Feeder Feed Clutch
(PL 4.3)
Multi-sheet Bypass Feeder Tray Support
Figure 1
Figure 2
Figure 4
Figure 3 S4525-102
Fig 1-59 Multi-sheet Bypass Feeder Feed Clutch

Removal
1. Remove the Multi-sheet Bypass Feeder Tray Assembly (RRP 1-26).
2. Remove the machine screw securing the Multi-sheet Bypass Feeder Tray
Support to the Feeder Assembly, and pull the Support away from the Assembly
(Figure 1).
3. Disconnect the P/J208 running to the Multi-sheet Bypass Feeder Feed Clutch.
4. Remove the machine screw securing the Rear Hook Bracket to the Feeder
Assembly and remove the Bracket (Figure 2).
5. Unhook either end of the torsion spring to release tension BEFORE removing
the E-ring securing the MBF Link Gear in step (6).
Warning For safety, it is important to release the torsion spring to prevent
it from flying and causing injury. Also, take note of its orientation
so as to enable proper reinstallation.
6. Remove the E-ring securing the Multi-sheet Bypass Feeder Link Gear to the
idler shaft, and slide the Gear, along with the Multi-sheet Bypass Feeder Drive
Gear Assembly, and spring, off of the shaft (Figure 3).
7. Remove the E-ring securing the Multi-sheet Bypass Feeder Feed Clutch to the
Feed Shaft and slide the Clutch off of the Feed Shaft (Figure 4).
Replacement
1. Position 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 Link Spring onto the Rear Latch (Figure 3).
6. Slide the Multi-sheet Bypass Feeder Link Gear, along with the Multi-sheet
Bypass Feeder Drive Gear Assembly and torsion spring, onto the idler shaft.
7. Use the E-ring (removed in Step 6 above) to secure the Multi-sheet Bypass
Feeder Link Gear to the idler shaft.
8. Reinstall the Rear Hook Bracket to the Feeder Assembly, and use the machine
screw (removed in Step 4 above) to secure the Bracket.
9. Reconnect J208.
10.Reinstall the Multi-sheet Bypass Feeder Tray Support and use the machine
screw (removed in Step 2 above) to secure it to the Feeder Assembly.
11.Reinstall the Multi-sheet Bypass Feeder Tray Assembly (RRP 1-26).
12.Re-hook the ends of the torsion spring as they were prior to unhooking same
in step (5) of the Remove Procedure above.
13.Check for free rotation of the Link, Idler and Clutch gears, and for free
movement of the Link Gear arm and return to proper rest position by the spring.

RRP 1-30 Multi-sheet Bypass Feeder Feed Roller
(PL 4.3)
Feed Roller
KL Clip
Loosen screw
(P/J108)

No-Paper Sensor Assembly
S4525-103
Fig 1-60 Multi-sheet Bypass Feeder Feed Roller
Removal
2. Remove the Multi-sheet Bypass Feeder Top Cover per Step 3 of RRP 1-26.
3. Disconnect P/J108 from the 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.

RRP 1-31 Multi-sheet Bypass Feeder Pick Roller
(PL 4.3)
Pick Roller
S4525-104
Multi-sheet Bypass Feeder Gate
Fig 1-61 Multi-sheet Bypass Feeeder Pick Roller
Removal
1. Remove Multi-sheet Bypass 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.

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

Rear Bearing
Multi-sheet Bypass Feeder Front Bearing

S4525-105
Fig 1-62 Multi-sheet Bypass Feeder Pick Roller Assembly

Removal
1. Remove the Multi-sheet Bypass Feeder Feed Clutch (RRP 1-29).
2. Remove Multi-sheet Bypass Feeder Feed Roller (RRP 1-30).
3. Remove the E-ring securing the Multi-sheet Bypass Feeder Front Feed
Bearing to the Feed Shaft, and remove the Bearing.
Warning Before performing Step (4) below, take note of the Feed Spring
and its positioning before sliding out the Feed Shaft. Take care to
prevent the spring from releasing suddenly, which could result in
it flying and causing injury.
4. Slide the Feed Shaft out of the Pick Roller Assembly, and remove the Assembly
from the Multi-sheet Bypass Feeder frame.
5. Remove the Front and Rear Feed Bearings from the Pick Roller Assembly.
Replacement
1. Reinstall the Front and Rear Feed Bearings onto the Pick Roller Assembly (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 Spring, through the Front
Multi-sheet Bypass Feeder Bearing, and out through the cutout for the Front
Feed Bearing.
6. Slip the Front Feed Bearing over the end of the Feed Shaft, and slide the
Bearing into the cutout in the frame.
7. Continue sliding the Feed Shaft as far as it will go.
8. Use the E-ring (removed in Step 3 above) to secure the Shaft to the Front Feed
Bearing.
9. Hook the free end of the Feed Spring through the opening at the rear of the
Assembly frame.
10.Reinstall the Multi-sheet Bypass Feeder Feed Roller (RRP 1-30).
11.Reinstall the Multi-sheet Bypass Feeder Feed Clutch (RRP 1-29).

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

Feeder Paper Guide
Multi-sheet Bypass
Feeder Pad
S4525-106
Fig 1-63 Multi-sheet Bypass Feeder Pad

Removal
1. Remove the Multi-sheet Bypass Feeder (RRP 1-25).
2. Remove the Multi-sheet Bypass Feeder Top Cover per Step 3 of RRP 1-26.
3. Remove the Multi-sheet Bypass Feeder Feed Roller (RRP 1-30).
4. Remove the Multi-sheet Bypass Feeder Pick Roller (RRP 1-31).
5. Turn the Multi-sheet Bypass Feeder upside down.
6. Remove the KL-clip securing the Multi-sheet Bypass Feeder Pad Pin to the
Feeder, and slide the Pin out of the Multi-sheet Bypass Feeder Pad.
7. Turn the Multi-sheet Bypass Feeder right side up.
8. Flex back the Multi-sheet Bypass Feeder Paper Guide, push the Pad up, then
slide the Pad to the right and 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 Feeder.
4. Use the KL-clip (removed in Step 4 above) to secure the Multi-sheet Bypass
Feeder Pad Pin to the Feeder.
5. Make certain the two spring arms are resting on the back side of the Pad.
6. Press down on the Multi-sheet Bypass Feeder Pad to make sure it moves
smoothly and has a spring-action return.RRP 1-31
7. Reinstall the Multi-sheet Bypass Feeder Pick Roller (RRP 1-30).
8. Reinstall the Multi-sheet Bypass Feeder Feed Roller (RRP 1-30).

RRP 1-34 Multi-sheet Bypass Feeder Friction
Clutch (PL 4.3)
S4525-107
Fig 1-64 Multi-sheet Bypass Feeder Friction Clutch
Removal
2. Remove the E-ring securing the Clutch to the shaft.
3. Rotate the Clutch clockwise as you pull it off of the shaft.
Replacement
1. Make sure the Spacer is in place on the Clutch shaft.
2. Rotate the Spacer so 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 above) to secure the Clutch to the shaft.
6. Reinstall the Top Cover.
7. Reinstall the Multi-sheet Bypass Feeder Tray Assembly (RRP 1-26).

RRP 1-35 Multi-sheet Bypass Feeder No-Paper
Sensor Assembly (PL 4.3)
(P/J108)
S4525-108
Fig 1-65 Multi-sheet Bypass Feeder No-Paper Sensor Assembly
Removal
2. 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.

RRP 1-36 Left Middle Cover Assembly (PL 5.1)
Pinch Roller Bracket
Figure 1
Pinch Roller
Figure 2 S4525-109
Fig 1-66 Left Middle Cover Assembly

Removal
1. Remove the Multi-sheet Bypass Feeder Support Assembly (RRP 1-27).
Caution Exercise caution in removing the Left Middle Cover after
removing the four screws. The Pinch Roller Assembly is loose and
can be damaged from dropping.
2. Remove the four self-tapping screws securing the Left Middle Cover to the
printer frame, and remove the Cover.
3. LIft the Pinch Roller Bracket off of the Left Middle Cover.
4. Remove the two Holding Springs, and lift the Pinch Roller out of the Bracket.
5. Remove the two Center Bearings, the two Shaft Springs, and the two End
Brackets from the Shaft.
Replacement
1. Reinstall the two End Bearings onto the Shaft.
2. Reinstall the 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 hook the other end of each Spring into the
spring hole on the opposite side of the Bracket.
7. Slide a Center Bearing under each Holding Spring, as shown in the figure.
8. Reinstall the Pinch Roller Bracket onto the Left Middle Cover, as shown in the
figure.
9. Reinstall the Left Middle Cover onto the printer frame.
10.Use the four self-tapping screws (removed in Step 2 above) to secure the Left
Middle Cover to the printer frame.
11.Reinstall the Multi-sheet Bypass Feeder Support Assembly (RRP 1-27).

RRP 1-41 Registration Clutch (PL 6.1)
S4525-113
Fig 1-67 Registration Clutch

Removal
2. Remove the Flywheel Assembly (RRP 1-65)
3. Disconnect P/J200 from the Registration Clutch.
4. Remove the E-ring securing the Registration Clutch to the Registration 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).

RRP 1-42 Left Upper Cover Assembly (PL 6.2)
Front Shaft Hinge Pin
Rear Shaft Hinge Pin
S4535-114
Fig 1-68 Left Upper Cover Assembly

Removal
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
Transfer Roller will affect print quality.
4. Use a small screwdriver blade to release the latch securing the Front Shaft
Hinge Pin, and slide it out of the Cover Assembly.
Caution Remove this smaller Hinge Pin to prevent it from falling into the
printer and causing damage, or to prevent it from falling out and
getting lost.
5. Use a small screwdriver blade to release the latch securing the Rear Shaft
Hinge Pin, and slide it out of the Cover Assembly.
6. Pull the Left Upper 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
Transfer Roller will effect print quality.
2. Reinstall the Left Upper Cover Assembly so the hinge openings in the Cover
arms line up with the hinge holes in the printer frame.
3. Slide the Rear Shaft Hinge into the hinge opening in the Rear Cover arm, until
the latch locks the Hinge onto the shaft.
4. Slide the Front Shaft Hinge into the hinge opening in the Front Cover arm, until
the latch locks the Hinge onto the shaft.
5. Use the two black self-tapping screws to secure the two Cover Supports to the
frame.
7. Open and close the Cover to make sure it opens and latches correctly.

RRP 1-43 Left Chute Assembly (PL 6.2)
Registration Roller
S4525-115
Fig 1-69 Left Chute Assembly
Removal
2. Remove the Bias Transfer Roller Assembly.
3. Push down on the rear of the Chute 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.

RRP 1-44 Registration Chute (PL 6.1)
Registration Sensor
S4525-116
Fig 1-70 Registration Chute
Removal
1. Remove the Left Upper Cover Assembly (RRP 1-42).
2. Remove the Registration Clutch (RRP 1-41).
3. Open the Front Cover.
4. Remove the black machine screw securing the Inner Cover to the printer frame,
and remove the Inner Cover.
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 P/J200 from the rear of the Registration Sensor.

RRP 1-45 Registration Roller Assembly (PL 6.2)
S4525-117
Fig 1-71 Registration Roller Assembly
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.

RRP 1-47 Laser Scanner Assembly (PL 7.1)
S4525-118
Fig 1-72 Laser Scanner Assembly
Removal
1. Remove the Low Voltage Power Supply (RRP 1-67).
2. Disconnect the J106, J207, J407, and J430 from the Laser Scanner.
3. Remove the three 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.

RRP 1-50 Toner Sensor (PL 7.2)
(P/J127)
S4525-121
Fig 1-73 Toner Sensor
Removal
2. Disconnect P/J127 from the Input/Output Board.
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.

RRP 1-51 Laser Print Cartridge Interlock Switch (PL
7.2)
(P/J233)
(P/J232)
(P/J234)
S4525-122
Fig 1-74 Laser Print Cartridge Interlock Switch
Removal
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.

RRP 1-53 Fuser Drive Assembly (PL 10.2)
S4525-124
Fig 1-75 Fuser Drive Assembly

Removal
1. Remove the Fuser Assembly.
3. Remove the Offset Exit Unit Assembly (RRP 1-54).
4. Disconnect J31, J32, and J33 from the AC Driver Board and free the wire
harness from the harness clips.
5. Disconnect J802 from High Voltage Power Supply-R2 and free the wire
harness from the harness clips.
6. Remove P204 wire harness from the Fuser Drive Assembly.
7. Disconnect J104, J456 (on the Input/Output Board), J600, and J602.
8. Remove the two screws (one black self-tapping and one black machine screw)
securing the Fuser Drive Assembly to the printer frame, and lift the Assembly
off of the frame.
9. Remove the Input/Output Board and chassis sufficiently to swing out of the way
and access the High Voltage Power Supply (RRP 1-70).
10.Remove the High Voltage Power Supply sufficiently to access the machine
screw attaching the green wire (ground) 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 two screws to secure the Assembly to the frame.
4. Reinstall the green ground wire to the printer frame using the machine screw
(removed in Step 11 above) to secure the wire.
5. Reinstall the High Voltage Power Supply.
6. Reinstall the Input/Output Board and chassis.
7. Reconnect J104, J456, J600, and J602.
8. Reinstall P204 wire harness to the Fuser Drive Assembly.
9. Reconnect J802 to High Voltage Power Supply-R2 and secure the wire
harness under the harness clips.
10.Reconnect J31, J32, and J33 to the AC Driver Board and secure the wire
harness under the harness clips.
11.Reinstall the Offset Unit Assembly (RRP 1-51).
12.Reinstall the Laser Print (EP) Cartridge (RRP 1-45).
13.Reinstall the Fuser Assembly (RRP1- 49).

RRP 1-54 Offset/Exit Assembly (PL 9.1~PL 9.4)
S4525-125
Fig 1-76 Offset/Exit Assembly
Removal
3. Open 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.

RRP 1-55 Exit Drive Assembly (PL 9.4)
(P/J602)
S4525-126
Fig 1-77 Exit Drive Assembly
Removal
1. Disconnect P/J602.
2. Remove the three black machine screws securing the Exit Drive Assembly to
the Offset Assembly.
3. Carefully pull the Exit Drive Assembly straight out and away from the Offset
Unit.
Replacement
1. Align the Exit Drive Assembly with the Offset Assembly so the white drive gear
and shaft fit through the corresponding opening in the Exit Drive Assembly.
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 Offset Assembly.
3. Use the three black machine screws (removed in Step 2 above) to secure the
Exit Drive Assembly to the Offset Assembly.

RRP 1-56 Exit Gate Solenoid (PL 9.1)
S4525-127
Fig 1-78 Exit Gate Solenoid
Removal
2. Disconnect the Exit Gate Solenoid J210 from the wire harness.
3. Remove the wire harness from the harness clips.
4. Remove the two black machine screws securing the 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 to the harness clips.
6. Reinstall the Fuser Cover (RRP 1-1).

RRP 1-57 Offset Motor (PL 9.1)
Offset Roller Rack
S4525-128
Fig 1-79 Offset Motor
Removal
2. Remove the two 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.

RRP 1-58 Full Stack Sensor (PL 9.1)
(P/J133)
Full Stack Sensor Assembly
S4525-129
Fig 1-80 Full Stack Sensor
Removal
2. Disconnect P/J133.
3. Remove the two screws securing the Full Stack Sensor Switch Assembly
Bracket and remove the Assembly.

RRP 1-59 Offset Roller Assembly (PL 9.2)
S4525-130
Fig 1-81 Offset Roller Assembly
Removal
1. Remove the Exit Drive Assembly (RRP 1-55)
2. Remove the Offset Motor (RRP 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.

RRP 1-60 Lower Chute Assembly (PL 9.1)
S4525-131
Fig 1-82 Lower Chute Assembly
Removal
1. Remove the Offset Roller Assembly (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.

RRP 1-61 Upper Chute Assembly (PL 9.3)
S4525-132
Fig 1-83 Upper Chute Assembly
Removal
1. Remove the Offset Roller Assembly (RRP 1-59).
2. Disconnect P/J133 and free the wire harness from the harness clips.
3. Disconnect P/J210 and free the wire harness from the harness 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 Upper
Chute Assembly.

RRP 1-62 Exit Roller Assembly (PL 9.2)
Exit Roller
S4525-133
Fig 1-84 Exit Roller Assembly
Removal
1. Remove the Exit Drive Assembly (RRP 1-55).
2. Remove the two black machine screws securing the Face Up Lower 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.

RRP 1-63 Face Up Exit Sensor (PL 9.3)
(P/J109)
Face Up Exit Sensor
S4525-134
Fig 1-85 Face Up Exit Sensor
Removal
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.

RRP 1-64 Inverter Clutches (PL 9.4)
Clockwise Clutch
Counter-Clockwise Clutch
S4525-135
Fig 1-86 Inverter Clutches
Removal
1. Remove the Exit Drive Assembly (RRP 1-55).
2. Remove the four black machine screws securing the Drive Support to the
Inverter Bracket, and lift the Support 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.

RRP 1-65 Flywheel Assembly (PL 10.1)
Flywheel S4525-136
Fig 1-87 Flywheel Assembly
Removal
2. Remove the black machine screw securing the Flywheel to the Drive Assembly
shaft and pull the Flywheel off of the shaft.

RRP 1-66 Main Drive Assembly (PL 10.1)
Figure 1
Exit Gear
Remove Self-Tapping Screws
Remove Machine Screw

Figure 2
S4525-137
Fig 1-88 Main Drive Assembly

Removal
Caution Do not attempt to remove the Main Drive Assembly without first
removing the Laser Print (EP) Cartridge.
4. Remove the Flywheel Assembly (RRP 1-65).
5. Remove the Left Cover Interlock Switch Assembly (RRP 1-71).
6. Remove the screw securing the Inner Cover (next to the flywheel) to the printer
frame, and remove the Inner Cover.
7. Disconnect J205 from the Main Motor Board.
8. Release the wire harness that is located just above the Main Motor Board from
the wire clip and move the harness out of the way.
9. Remove the E-ring securing the Tray 1 Feed Clutch and slide the Feed Clutch
out just enough to rotate the keyslot away from the Main Drive Frame.
10.Disconnect 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 right screw also secures a ground wire (with attached
resistor) to the printer frame.
14.Remove the bottom machine screw securing a ground strap to the printer
frame at the bottom left of the Main Drive Assembly.
15.Lift the Exit Gear out of the way, and pull the Main Drive Assembly straight
back and out of the printer frame.
Note If you are having difficulty removing the Main Drive Assembly,
check to make sure there are no wire harnesses in the way, the
Registration Clutch location notch is not in the way, and that the
drive pin on the Drive Assembly is in the center of the cutout in the
printer frame.

RRP 1-67 Low Voltage Power Supply Assembly
(PL 11.1)
LVPS Cover
System Controller Assembly
Figure 1 Figure 2
Figure 3 S4525-138
Fig 1-89 Low Voltage Power Supply Assembly

Removal
1. Remove the Fuser cover (RRP 1-1).
2. Remove the Top Cover Assembly (RRP 1-2).
3. Remove the Front Inner Cover (RRP 1-4)
4. Remove the Right Cover (RRP 1-6).
5. Remove the four machine screws securing the System Controller Assembly to
the Low Voltage Power Supply, and tilt the System Controller 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 screws securing the Low Voltage Power Supply to
the printer frame (Figure 3).
10.Remove the Low Voltage Power Supply Assembly.

RRP 1-68 AC Driver Board (PL 11.2)
Bracket AC Driver PWB 20A 120V
Plate
Figure 1
AC Driver PWB 230V FLK
Figure 2 S4525-139
Fig 1-90 AC Driver Board
Removal
1. Remove the Input/Output Board (RRP 1-70).
2. Remove the five P/Js (J30, J31, J32, J33 and, 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.

RRP 1-69 High Voltage Power Supply (PL 11.2)
S4525-140
Fig 1-91 High Voltage Power Supply
Removal
1. Remove the Input/Output Board (RRP 1-70).
2. Disconnect J500, P701, P702 and BTR (Bias Transfer Roller) from the High
Voltage Power Supply Board.
Caution The board is easily broken. Use care when removing the P/Js from
the High Voltage Power Supply Board. 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 Supply to the printer frame.
5. Remove the High Voltage Power Supply Assembly from the frame.

RRP 1-70 Input/Output Board (PL 11.2)
(P452) (P453)
(P457) (P460) (P456)
(P458)
(P454)
(P127)
(P462)
(P461)
(P459)
(P465)
(P451)
(P450) (P467) (P464)
Bracket I/O Board
(P463) (P466)
S4525-141
Fig 1-92 Input/Output Board
Removal
2. Disconnect the eighteen P/Js (see Illustration) from 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.

RRP 1-71 Left Cover Interlock Switch Assembly
(PL 11.2)
(J232)
(J233)
S4525-142
Fig 1-93 Left Cover Interlock Switch Assembly
Removal
2. Disconnect J232 and J233 from the Interlock 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.

RRP 1-72 Print Engine Controller Board
(PL 11.3)
Remove Screws
(P409)
(J406) U9
Remove Pin Guides

S4525-143
Fig 1-94 Print Engine Controller Board
Removal
Caution Wear an electrostatic wrist strap and use caution when working
with the Print Engine Controller Board. Static electricity can
damage the sensitive electronics of the Print Engine Controller
Board.
1. Remove Fuser Cover (RRP 1-1).
2. Remove Top Cover (RRP 1-2).
3. Remove the System Controller Board (RRP 1-73).
4. Remove the System Controller Assembly Cover by removing the 14 machine
screws 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 of the System Controller Assembly.
9. Remove the U9 EEPROM from the Print Engine Controller Board and retain.
Replacement
1. Install the U9 EEPROM from the “old” Print Engine Controller Board onto the
“new” board.

2. Reinstall the Print Engine Controller Board onto the System Controller
Assembly. Align the board such that J406 faces the System Controller Board
location.
3. Reinstall the two 7mm nuts onto J406 and the six mounting screws (removed in
step 6 above) loosely. When all screws have been started, 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 Top Cover (RRP 1-2).
9. Resintall the Fuser Cover (RRP 1-1).
Note After Replacement, verify Lead and Side Edge Registration for all
Bins.

RRP 1-73 System Controller (PL 11.3)
Panel

S4525-144
Fig 1-95 System Controller
Removal
1. Turn OFF the printer.
Caution Wear an electrostatic wrist strap and use caution when working
with the System Controller Board. Static electricity can damage
the sensitive 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 mat.

FRU Parts List
This topic provides a list of Field Replaceable Units for the DocuPrint® N4525 Network
Laser Printer.
Changes to the printer may be made to accommodate improved components as they
become available. When ordering parts and/or supplies, it is important to include the
following information:
Component’s part number,
Printer type or model number,
Printer serial number, and
Modification number, if any.
Using the Parts List

1. The callout numbers shown in each parts exploded illustration correspond to
the parts list numbers for that illustration.
2. Throughout this manual, parts are identified by the prefix “PL”, followed by a
number, a decimal point, and another number. For example, 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 part 2, part 3, and part 4.
5. An asterisk (*) following a part name indicates the page contains a note about
this part.
6. The notation “J1<>J2 and P2” is attached to a wire harness. It indicates that
connector Jack 1 is attached to one end of the wire harness and connector J2
is attached to the other end that is plugged into P2.
Note Only parts showing part numbers are available for support.
Parts not showing part numbers are available on the parent
assembly.
Fig 1-96 Legend:

Identifier Meaning
C C-ring
E E-ring
KL E-clip
S Screw
Volume 1 / Print Engine - FRU Parts Lists 1-265

PL 1.1 Top Cover Assembly
6
(J204)
PL11.4.13
2
S
3
S
5
S 8
S
(NJ417) 4
PL11.3.16
S4525-157
Fig 1-97 Top Cover Assembly

Table 1-108 PL 1.1 Top Cover Assembly.
ID No. Part Number Qty Name / Description
1 802E25441 1 Cover, Top
2 003E52030 1 Stopper
3 802E08700 1 Cover, 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 1 Assembly, Fuser Fan
(Alt.) 127K21470
7 004K01730 1 Damper Assembly, Paper
8 892E38280 1 Overlay, Control Panel, English
892E38290 1 Overlay, Control Panel, Spanish, Portuguese, Chinese
892E38310 1 Overlay, Control Panel, Symbols Only

PL 1.2 Front Cover
S4525-158
Fig 1-98 Font Cover

Table 1-109 PL 1.2 Front Cover
1 802K25941 1 Assembly, Front Cover
2 830E44250 1 Hinge
3 802E08421 1 Cover, 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)

PL 1.3 Rear, Left, and Right Covers
S4525-159
Fig 1-99 Rear, Left, and Right Covers

Table 1-110 PL 1.3 Rear, Left and Right Covers
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

PL 2.1 Tray Unit - Paper Stack
S4525-160
Fig 1-100 Tray Unit - Paper Stack

Table 1-111 PL 2.1 Tray Unit - Paper Stack
1 109R00504 1 Tray Assembly (with 2~19 & PL 2.2)
2 1 Plate, Bottom (part of 1)
3 1 Pad, Bottom (part of 1)
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)
19 1 Cap, Tray (part of 1)

PL 2.2 Tray Unit - End Guide
Fig 1-101 Tray Unit - End Guide

Table 1-112 PL 2.2 Tray Unit - End Guide
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

PL 2.3 Tray Unit - Paper Stack (Custom)
PL2.4.1
PL 2.4.6
S4525-162
Fig 1-102 Tray Unit - Paper Stack (Custom)

Table 1-113 PL 2.3 Tray Unit - Paper Stack (Custom)
1 097S02562 1 Tray Assembly (Custom - with 2~21 & PL 2.4)
2 1 Plate, Bottom (part of 1)
3 1 Pad, Bottom (part of 1)
4 1 Plate, Tongue (part of 1)
5 1 Shaft Assembly, Tongue (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)
18 1 Washer, Side Guide (part of 1)
19 1 Cap, Tray (part of 1)
20 2 Roller, Tray (part of 1)
21 1 Spring, Tray (Custom) (part of 1)

PL 2.4 Tray Unit - End Guide (Custom)
S4525-163
Fig 1-103 Tray Unit - End Guide (Custom)

Table 1-114 PL 2.4 Tray Unit - End Guide (Custom)
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)

PL 3.1 Tray Interface - Tray 1
S4525-164
Fig 1-104 Tray Interface - Tray 1

Table 1-115 PL 3.1 Tray Interface - Tray 1
1 110K07740 1 Switch Assembly, Paper Size
2 127K20662 1 Motor Assembly
3 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)

PL 3.2 Paper Pick Up - Tray 1
98 (with 6, Qty 6)
99 (1~4)
S4525-165A
Fig 1-105 Paper Pick Up - Tray 1

Table 1-116 PL 3.2 Paper Pick Up - Tray 1
1 1 Gear, 46T (part of 99)
2 1 Clutch Assembly (part of 99)
3 1 Gear, 28T (part of 99) [for Tray 1 only]
4 1 Clutch, One-Way (part of 99) [for Tray 1 only]
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)
10 1 Shaft, Feed (part of 5)
13 1 Support Assembly, Pick (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 Roller (with item 6, Qty. 6)
99 600K85080 1 Kit, Tray 1 Clutch (with 1~4)

PL 3.3 Retard and Take Away - Tray 1
S4525-166
Fig 1-106 Retard and Take Away - Tray 1

Table 1-117 PL 3.3 Retard and Take Away Assembly - Tray 1
1 1 Retard Assembly, (with 2~8) {part of 98}
2 1 Spacer, Retard {part of 1}
3 1 Shaft Assembly, Retard (part of item 1)
4 1 Bearing (part of item 1)
5 1 Roller Assembly (part of item 1)
6 1 Spacer (part of item 1)
7 1 Clutch Assembly, Friction
8 1 Support, Retard (part 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}
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 Assembly, Spring {part of 98}
22 809E27440 1 Spring {part of 98}
23 1 Retard Frame {part of 98}
98 604K01160 1 Retard Assembly, Tray 1 High (with 1~23)
99 604K01860 1 Kit, Take Away Gear, Tray 1 (with 10 & 20)

PL 3.4 Tray Interface - Tray 2
S4525-167
Fig 1-107 Tray Interface - Tray 2

Table 1-118 PL 3.4 Tray Interface - Tray 2
1 110K07740 1 Switch Assembly, Paper Size
2 127K20662 1 Motor 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)

PL 3.5 Paper Pick Up - Tray 2
S4525-168
Fig 1-108 Paper Pick Up - Tray 2

Table 1-119 PL 3.5 Paper Pick Up Assembly - Tray 2
1 1 Gear, 46T {part of 97}
2 1 Clutch Assembly {part of 97}
3 1 Gear, 28T (for Tray 2 only) {part of 97}
4 013E86260 1 Bearing, Feeder (for Tray 2 and High Capacity Feeder
only) {part of 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}
13 1 Support Assembly, Pick {part of item 5}
15 1 Support, Brush
16 1 Web, Feed
17 1 Brush Assembly, Feed (with items 15 & 16)
97 600K65470 1 Kit, Tray 2 Clutch (with 1-4)
98 604K01130 1 Kit, Feed Roller (with 6, Qty. 6)

PL 3.6 Retard and Take Away - Tray 2
1 (with 2~8)
98 (1, 9~15, & 17)
S4525-169
99 (9, 16)
Fig 1-109 Retard and Take Away - Tray 2

Table 1-120 PL 3.6 Retard and Take Away Assembly - Tray 2
1 1 Retard Assembly, (with 2~8), {part of item 98}
2 1 Gear, 22T {part of item 1}, {part of item 99}
3 1 Shaft Assembly, Retard {part of item 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}
11 1 Gear Stopper {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
18 1 Bracket, Stopper
98 600K85160 1 Retard Assembly, Tray 2 High (with 1, 9~15 & 17)
99 600K85090 1 Kit, Take Away Gear, Tray 2 (with 9 & 16)

PL 3.7 Feed Drive Transmission
S4525-170
Fig 1-110 Feed Drive Transmission

Table 1-121 PL 3.7 Feed Drive Transmission
1 -- --
3 -- --
4 1 Support Assembly {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)

PL 4.1 Multi-sheet Bypass Feeder and Duplex
Support
S4525-171
Fig 1-111 Multi-sheet Bypass Feeder and Duplex Support

Table 1-122 PL 4.1 Multi-sheet Bypass Feeder and Duplex Module
Support
1 048E37370 1 Cover, Front
2 048K58760 1 Cover, Rear 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}
12 1 Clamp, Cable {part of item 7}

PL 4.2 Multi-sheet Bypass Feeder Assembly (MBF)
D4525-172
Fig 1-112 Multi-sheet Bypass Feeder Assembly (MBF)

Table 1-123 PL 4.2 Multi-sheet Bypass Feeder Assembly
1 1 Feeder Assembly, Multi-sheet Bypass (with 2 - 17 &
PL 4.3) {part of PL 4.1}
2 1 Gear, 16/22 {part of item 1 & PL 4.1}
3 1 Link Assembly {part of item 1 & PL 4.1}
4 1 Spring, Torsion {part of item 1 & PL 4.1}
5 1 Plate, Tie {part of item 1 & PL 4.1}
6 019K92810 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 item 1 & PL 4.1}
14 1 Latch, Front {part of item 1 & PL 4.1}
15 2 Spring, Latch {part of item 1 & PL 4.1}
16 1 Support, Retard {part of item 1 & PL 4.1}
17 1 Latch, Rear {part of item 1 & PL 4.1}

PL 4.3 Upper Feeder Assembly
S4525-173
Fig 1-113 Upper Feeder Assembly

Table 1-124 PL 4.3 Upper Feeder Assembly
1 1 Feeder Assembly, Upper (with 2~26) {part of PL 4.2,
item 1}
2 121K82880 1 Clutch Assembly {part of item 1}
4 1 Shaft Assembly, Feed {part of item 1}
5 1 Gear, Spur, 40T {part of item 1}
9 022K57020 1 Roller, Feed, Multi-sheet Bypass Feeder {part of item
1}
10 107E08680 1 Interrupter, Photo {part of item 1}
11 1 Bracket Assembly {part of item 1}
12 2 Gate, Reset {part 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 {part of item 1} {part
of item 14}
20 20 Bearing {part of item 1} {part of item 14}
21 1 Shaft Assembly, Pick Roller {part of item 1} {part of
item 14}
22 059K14560 1 Roller, Pick {part of item 1} {part of item 14}
23 005K80880 1 Clutch, Friction {part of item 1} {part of item 14}
24 1 Spacer {part of item 1} {part of item 14}
25 1 Gear, Spur {part of item 1} {part of item 14}
26 1 Chute Assembly, Upper {part of item 1}

PL 4.4 Multi-sheet Bypass Feeder Tray Assembly
S4525-174
Fig 1-114 Multi-sheet Bypass Feeder Tray Assembly

Table 1-125 PL 4.4 Multi-sheet Bypass Feeder Tray Assembly
1 050K42631 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}

PL 5.1 Tray 1 Frame and Left Cover
S4525-175
Fig 1-115 Tray 1 Frame and Left Cover

Table 1-126 PL 5.1 Tray 1 Frame and Left Cover
1 068K79283 1 Bracket Assembly, Pinch (with 2 - 7)
2 2 Spring, Exit {part of item 1}
3 2 Spring, Compression {part of item 1}
4 2 Bearing, In {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-Magnetic Emission

PL 5.2 Tray 2 Frame and Left Cover
S4525-176.ai
Fig 1-116 Tray 2 Frame and Left Cover

Table 1-127 PL 5.2 Tray 2 Frame and Left Cover
1 048K55751 1 Cover Assembly, Left Hand (with 2, 3, 9~11, 14 and 23)
2 1 Cover, Left Hand {part of item 1}
3 068K83512 1 Bracket Assembly, Pinch (with 4~8 and 21) {part of
item 1}
4 2 Bearing, Out {part of item 3}
5 2 Bearing, In {part of item 3}
6 1 Roller Assembly, Pinch {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 Emission
18 1 Cap
19 130E81311 1 Sensor‘, Take Away 3
20 1 Support, Rear
21 2 Washer, Nylon {part of item 3}
22 1 Harness Assembly, Left Hand (J607<>J143/J144)
23 1 Pad {part of item 1}

PL 6.1 Registration
S4525-177
Fig 1-117 Registration

Table 1-128 PL 6.1 Registration section
1 121K83190 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)

PL 6.2 Left Upper Cover Assembly
S4525-178
Fig 1-118 Left Upper Cover Assembly

Table 1-129 PL 6.2 Upper Left Cover Assembly
1 1 Shaft, Hinge
2 1 Shaft, Hinge Rear
3 802K10631 1 Cover Assembly, Left Hand (with 4~14 and PL 6.3)
4 1 Chute, Lower {part of item 3}
5 1 Guide, Paper {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
item 10}
13 2 Pulley {part of item 3} {part of item 7}
14 074E91101 2 Support, Left Hand Cover {part of item 3}

PL 6.3 Transport Chute Assembly
S4525-179
Fig 1-119 Transport Chute Assembly

Table 1-130 PL 6.3 Transport Chute Assembly
1 1 Spring, Bias Transfer Roller, In {part of item 18}
2 1 Chute, Transport {part of item 18}
3 1 Plate, Eliminator {part of item 18}
4 2 Sleeve, Bias Transfer Roller {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 {part of item 18}
18 1 Chute Assembly, Transport (with 1~7, 16 and 17) {part
of PL 6.2}

PL 7.1 Laser Scanner Assembly
S4525-180
Fig 1-120 Laser Scanner

Table 1-131 PL 7.1 Laser Scanner Assembly
ID No. Sub-ID Part Number Qty Name / Description
1 062K09874 1 Laser Scanner Assembly

PL 7.2 Xerography and Development
S4525-181
Fig 1-121 Xerography and Development

Table 1-132 PL 7.2 Xerography and Development section
1 022K57070 1 Roller Assembly, Bias Transfer (with 2 - 6)
(Alt. 022K61720)
2 1 Lever, Bias Transfer Roller, OUT {part of item 1}
3 2 Roller, Tracking, Bias Transfer Roller {part of item 1}
4 1 Roller, Bias Transfer Roller {part of item 1}
5 1 Spacer, Bias Transfer Roller {part of item 1}
6 1 Lever, Bias Transfer Roller, IN {part of item 1}
7 038K81662 1 Guide, Assembly, IN (with 8 - 10)
8 1 Guide, Bias Transfer Roller, IN {part of item 7}
9 12 Plate, Bias {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}
19 2 Stud, Screw {part of item 15}
20 1 Guide, Bias Transfer Roller, OUT
21 019K93342 1 Holder Assembly, Charge Bias
22 110K98770 1 Switch Assembly, Interlock (with 23 and 24)
23 1 Bracket, Interlock Switch {part of item 22}
24 1 Switch Assembly, Interlock {part of item 22}
25 1 Clamp Guide, Bias Transfer Roller
26 015E50040 1 Plate, Contact
27 015E50050 1 Plate, Contact
28 113R00195 1 Laser Print (EP) Cartridge,

PL 8.1 Fuser Assembly
S4525-182
Fig 1-122 Fuser Assembly

Table 1-133 PL 8.1 Fuser Assembly
1 126K10638 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)

PL 9.1Lower Exit Chute
24 (with 16~19) S4525-183
Fig 1-123 Lower Exit Chute

Table 1-134 PL 9.1 Lower Exit Chute
1 022K61824 1 Offset/Exit Assembly (with 2~22, PL 9.2, PL 9.3 and PL
9.4)
2 121K82870 1 Solenoid Assembly {part of item 1}
3 1 Link, Solenoid {part of item 1}
4 1 Spring {part of item 1}
5 127K18861 1 Motor Assembly, Offset {part of item 1}
6 1 Lower Assembly, Chute, Offset (with 7 - 15) {part of
item 1}
7 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}
16 -- --
17 -- --
18 -- --
19 -- --
20 1 Frame Assembly, Front {part of item 1}
21 1 Chute, Lower {part of item 1}
22 1 Bracket Assembly, Drive {part of item 1}
23 1 Harness Assembly, Face Up Tray
(J601<>P109/P110/P133/P210)
99 600K87660 1 Switch Assembly, Stack Full Sensor

PL 9.2 Offset Roller Assembly
S4525-184.ai
Fig 1-124 Offset Roller Assembly

Table 1-135 PL 9.2 Offset Roller Assembly
1 4 Bearing {part of PL 9.1, item 1}
2 022K35430 1 Roller Assembly, Face Up Tray Exit {part of PL 9.1,
item 1}
3 1 Gear, 19T {part of PL 9.1, item 1}
4 022K57200 1 Roller Assembly, Offset (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 of PL 9.1, item 1}
12 1 Pin {part of item 4} {part of PL 9.1, item 1}
13 1 Gear, 19T {part of PL 9.1, item 1}

PL 9.3 Upper Exit Chute Assembly
S4525-185
Fig 1-125 Upper Exit Chute Assembly

Table 1-136 PL 9.3 Upper Exit Chute Assembly
1 054K08504 1 Chute Assembly, Upper (with 2~16) {part of PL 9.1,
item 1}
2 110K94651 1 Switch Assembly, Face Up Exit Sensor {part of item 1}
3 1 Plate, Tie {part of item 1}
4 1 Spring, Plate {part of item 1}
5 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}
12 1 Chute, Middle {part of item 1}
13 1 Gate, Exit {part of item 1}

PL 9.4 Exit Drive Assembly
S4525-186
Fig 1-126 Exit Drive Assembly

Table 1-137 PL 9.4 Exit Drive Assembly
1 068K20660 1 Bracket Assembly, Drive (with 2 - 17) {part of PL 9.1,
item 1}
2 1 Support, Exit Drive {part of item 1}
3 1 Pulley, Exit Drive Idler {part of item 1}
4 1 Gear, Exit 1 {part of 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}
10 121K84520. 2 Gear/Clutch Assembly, Electric {part of item 1}
11 2 Shaft, Clutch {part of item 1}
14 1 Gear/Clutch Assembly, Friction {part of item 1}
16 1 Bracket, Inverter {part of item 1}
17 1 Harness Assembly {part of item 1} (J602<>J218/J219)

PL 10.1 Main Drive Assembly
S4525-187
Fig 1-127 Main Drive Assembly

Table 1-138 PL 10.1 Main Drive Assembly
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

PL 10.2 Fuser Drive Assembly
1 (with 2~9, 14 & 15)
S4525-188
Fig 1-128 Fuser Drive Assembly

Table 1-139 PL 10.2 Fuser Drive Assembly
1 068K18272 1 Frame Assembly, Rear Exit (with 2- 9, 14 & 15)
3 1 Spring {part of item 1}
4 1 Bracket Assembly {part of item 1}
5 1 Bracket {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
13 162K53843 1 Connector, Fuser (P12<>J31/J32/J33/J600)
14 1 Connector (P104)
15 1 Connector (P602)

PL 11.1 Power Unit
S4525-189
Fig 1-129 Power Unit

Table 1-140 PL 11.1 Power Unit
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

PL 11.2 High Voltage Power Supply and
Input/Output Board
S4525-190
Fig 1-130 High Voltage Power Supply and Input/Output Board

Table 1-141 PL 11. 2 High Voltage Power Supply and I/O Board
1 160K62830 1 Board, AC, Driver, 220 VAC
160K62400 1 Board, AC, Driver, 110 VAC
2 1 Bracket, System Controller, Rear
3 105K15631 1 High Voltage Power Supply, R1
4 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, Exit
19 105E09921 1 Transformer (220 VAC version only)
20 105E09290 1 High Voltage Power Supply, R2

PL 11.3 System Controller Assembly
S4525-191
Fig 1-131 System Controller Assembly

Table 1-142 PL 11.3 System Controller Assembly
1 101K37191 1 Assembly, System Controller (with 2 - 9, 11, 12, and
17)
2 1 Bracket Assembly, Board {part of item 1}
3 160K74034 1 Board Assembly, Print Engine Controller 110 VAC
or {part of item 1}
160K74044 1 Board Assembly, Print Engine Controller 220 VAC
{part of item 1}
4 1 Saddle, Bush {part of item 1}
5 1 Guide {part of item 1}
6 127K20030 1 Fan Assembly {part of item 1}
7 1 Bracket, Fan {part of item 1}
8 1 Box Assembly, System Controller {part of item 1}
9 1 Panel, 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 Option, Hard Disk Drive, 6+ Gbyte (not shown)
121K25970 (Alt.)
121K29430 (Alt.)
733W14695 Option, Memory Upgrade, 16 MB DIMM (not shown)
160K71940 Option, Flash DIMM, 8 Mbyte (not shown)
160K71530 Option, Interface Card, Ethernet 10Base2 (not shown)
160K71520 Option, Interface Card, RS232-C, Serial (not shown)
160K71540 Option, Interface Card, Token Ring (not shown)
14 1 Panel, System Controller Drawer {part of item 13}
15 1 Harness Assembly, Laser Scanner (J409<>P430)
16 162K52990 1 Harness Assembly, Console (NJ417<>J401)
17 1 Clamp {part of item 1}

PL 11.4 Wiring Harness
S4525-192
Fig 1-132 Wiring Harness

Table 1-143 PL 11.4 Wiring Harness
1 1 Harness Assembly, DC Main
Low Voltage Power Supply:
(J400/J450<>J502/J504/J505/J506/
System Controller Board: J452/J453<>J402/J403
Laser Scanner:
J411<>P220/P237?J106/J207/P234/J407/P499/ J510
2 1 Harness Assembly, 1TM, Rear
(J467<>J140/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/P602)
11 1 Harness Assembly, Motor (J460<>J205)
12 1 Harness Assembly, High Voltage Power Supply
(J457<>J500)
13 1 Harness Assembly, Fuser Fan (J456<>J204)

Xerox Supplies and Accessories
Table 1-144 Customer-Replaceable Consumables
Item Average Life Part Number
Laser Print Cartridge 30,000 prints* 113R00195
Staple Cartridge Refills 3 cartridges 108R00158
5,000 staples per
cartridge
Maintenance Kit 300,000 prints 109R00048
Contains: a Fuser Cartridge, Bias Transfer for 110 V (60 Hz)
Roller, 15 Feed Rolls (three for each paper 109R00049
input tray), gloves, cleaning cloth, and for 220 V (50 Hz)
instructions
*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.
Table 1-145 Miscellaneous

Item Part Number
Power Cord, 110 VAC 117E15940
Repackaging Kit 600K86720
Screw Kit 600K65640

Table 1-146 Xerox Professional Printing Paper
Item Size Description Part Number
Xerox 4024 DP Letter (U. S.) 20 lbs. 003R00721
8.5 x 11 in. (75 g/m2)
Xerox 4024 DP Legal 20 lbs. 003R00727
8.5 x 14 in. (75 g/m2)
Xerox 4024 DP Statement 20 lbs. 003R02072
5.5 x 8.5 in. (75 g/m2)
Rank Xerox Business A4 (Metric Letter) 80 g/m2 003R901820
210 x 297 mm
Rank Xerox Business A3 80 g/m2 003R91821
297 x 420 mm
Rank Xerox Printer A5 80 g/m2 003R91832
148.5 x 210 mm
Xerox Image Series Letter (U. S.) 20 lbs. 003R00054
Smooth 8.5 x 11 in. (75 g/m2)
Xerox Image Series Legal 20 lbs. 003R00083
Smooth 8.5 x 14 in. (75 g/m2)
Rank Xerox Legal 80 g/m2 003R901741
215 x 356 mm
LaserPrint 80 A4 (Metric Letter) 80 g/m2 003R91922
210 x 297 mm
Xerox Recycled Letter (U. S.) 20 lbs. 003R06296
8.5 x 11 in. (75 g/m2)
Steinbeis Recycled A4 (Metric Letter) 80 g/m2 003R91165
210 x 297 mm
80 DP Planet Plus A4 (Metric Letter) 80 g/m2 003R900652
210 x 297 mm
Table 1-147 Xerox Transparency Film

Item Size Part Number
Xerox Clear Letter (U. S.) 8.5 x 11 in. 003R02780
Rank Xerox Clear A4 (Metric Letter) 210 x 297 mm 003R96002
Table 1-148 Xerox Labels

Size Description Part Number
A4 (Metric Letter) 24 labels per sheet 003R97406
210 x 297 mm

Table 1-149 Options
Option and Features Part Number
Custom Paper Tray 097S02562
Handles continuously variable paper sizes
Holds up to 500 sheets of 80 g/m2 (20 lbs.) stock
2,500-Sheet Feeder 097S02560
Three additional trays
Increased paper-printing capacity
Increased printing versatility and convenience
Envelope Feeder 097S02567
Holds 100 standard-weight envelopes 097K24870 (Alt.)
Duplex Module 097S02561
Automatic duplex capability
Face-up Bin 097S02564
Holds up to 200 sheets
Provides face-up output stacking
Finisher with stapler and hole puncher 450S02180
3 hole positions
Increased paper-output capacity
450S02181
Holds up to 3,000 sheets of 80 g/m2 (20 lbs.) stock (Letter, 4 hole positions
A4 paper)
Stapling capability
Hole-punching capability
Hard disk drive 097S02364
5+ Gbyte hard drive
Store resources, fonts, forms, and macros; enables
uninterrupted large-job collation
Memory upgrades 097S02356
Improved system performance (16-Mbyte DIMM)
Improved processing of complex jobs 097S02357
(32-Mbyte DIMM)
097S02358
(64-Mbyte DIMM)
8-Mbyte Flash DIMM 097S02360
Non-volative memory for downloading and storing fonts,
forms, and macros
Ethernet 10Base2 Interface Card 097S02362
Enables Ethernet 10Base2 connectivity
Token Ring interface card 097S02363
Enables Token Ring connectivity
RS232-C serial interface card 097S02361
Enables Serial connectivity

Plug/Jack Connector
Locations
Locating Plug/Jack Connectors
Contents
P/J Location Table 1 - 342
P/J Location Map 1 1 - 347
Volume 1 / Print Engine - P/J Connector Locations 1-341

P/J Location
Use the table and maps in this section to locate specific plug/jack (P/J) connectors within
the printer.
To find the location of a P/J within the printer;
1. Locate the P/J connector number in the first column of the P/J Location table.
2. Locate the corresponding map and location number, such as M2-5, in the
second column.
3. With this information, go to the appropriate map (in this case, Map 2) and
locate item number 5.
Table 1-150 Plug/Jack Location
Map &
P/J Number Connected to... Other end connected to...
1 M8-16 AC Distribution Board P/J13 Finisher Option

2 M8-1 AC Distribution Board Low Voltage Power Supply
3 M8-17 AC Distribution Board P/J30 AC Driver Board
4 M8-14 Low Voltage Power Supply - P/J1 AC Distribution Board
B3
5 M8-15 AC Distribution Board --
7 M8-2 AC Distribution Board Main Power Switch
8 M8-3 AC 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
34 M8-11 AC Driver Board 220VAC Transformer
100 M2-6 Registration Sensor P/J459 Input/Output Board
101 M2-8 Take Away 2 Sensor P/J465 Input/Output Board
102 M2-7 Tray 1 No Paper Sensor P/J459 Input/Output Board
103 M2-5 Tray 1 Level Sensor P/J459 Input/Output Board
104 M4-11 Fuser Exit Sensor P/J462 Input/Output Board
105 M3-28 Tray 1 Size Sensor P/J461 Input/Output Board
106 M1-4 Start of Scan Sensor P/J411 Print Engine Controller Board
107 M2-1 Multi-sheet Bypass Feeder P/J465 Input/Output Board
Size Sensor
No Paper Sensor
109 M4-3 Face Up Exit Sensor P/J462 Input/Output Board
127 M3-13 Input/Output Board Toner Empty Sensor

Table 1-150 Plug/Jack Location (cont'd.)
Map &
133 M4-1 Full Stack Sensor P/J462 Input/Output Board

140 M5-5 Tray 2 No Paper Sensor P/J467 Input/Output Board
141 M5-4 Tray 2 Level Sensor P/J467 Input/Output Board
142 M5-1 Tray 2 Size Sensor P/J467 Input/Output Board
143 M5-6 Take-Away Roller 2 Sensor P/J467 Input/Output Board
144 M5-7 Interlock Switch P/J467 Input/Output Board
200 M3-14 Registration Clutch P/J462 Input/Output Board
202 M3-17 Tray 1 Feed Clutch P/J462 Input/Output Board
203 M3-18 Tray 1 Lift Motor P/J465 Input/Output Board
204 M4-4 Fuser Fan P/J456 Input/Output Board
205 M3-15 Main Motor Assembly P/J460 Input/Output Board
207 M1-9 Laser Scanner Motor P/J411 Print Engine Controller Board
Feed Clutch
209 M4-6 Offset Motor P/J462 Input/Output Board
210 M4-2 Exit Gate Solenoid P/J462 Input/Output Board
218 M4-7 Inverter Clockwise Clutch P/J462 Input/Output Board
219 M4-8 Inverter Counter Clockwise P/J462 Input/Output Board
Clutch
220 M8-7 Low Voltage Power Supply P/J411 Print Engine Controller Board
Fan
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 P/J411 Print Engine Controller Board
Interlock Switch & 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/J467 Input/Output Board
241 M5-10 Tray 2 Lift Motor P/J467 Input/Output Board
400 M6-9 Print Engine Controller Board P/J502 & P/J504 Low Voltage Power
Supply
401 M6-4 Print Engine Controller Board
402 M6-7 Print Engine Controller Board P/J452 Input/Output Board
403 M6-8 Print Engine Controller Board P/J453 Input/Output Board
404 M6-5 Print Engine Controller Board P/J417 Control Panel
405 M6-13 Print Engine Controller Board - -
406 M6-11 Print Engine Controller Board System Controller Board
407 M1-5 Laser Scanner LD P/J411 Print Engine Controller Board
408 M6-12 Print Engine Controller Board System Controller Board Fan
409 M6-2 Print Engine Controller Board P/J430 Video Data Laser Scanner LD
410 M6-10 Print Engine Controller Board - -

Map &
411 M6-1 Print Engine Controller Board P/J106 SOS

P/J207 Laser Scanner Motor
P/J220 Low Voltage Power Supply Fan
P/J237 Front Cover Interlock Switch
P/J407 Laser Print (EP) Cartridge
Interlock Switch
P/J499 Test Connector
P/J506 AC Distribution Board
P/J510 AC Distribution BoardAC
Distribution Board
417 M6-3 Control Panel P/J404 Print Engine Controller Board
430 M1-6 Laser Scanner LD P/J409 Print Engine Controller Board
450 M3-2 Input/Output Board P/J502, P/J504, P/J505 Low Voltage
Power Supply
451 M3-27 Input/Output Board MFD Card
452 M3-4 Input/Output Board P/J402 Print Engine Controller Board
453 M3-11 Input/Output Board P/J403 Print Engine Controller Board
454 M3-16 Input/Output Board P/J606 Laser Print (EP) Cartridge
456 M3-12 Input/Output Board P/J204 Fuser 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/Output Board P/J104 Fuser Exit Sensor
P/J109 Face Up Exit Sensor
P/J133 Full Stack Sensor
P/J200 Registration Clutch
P/J202 Tray 1 Feed Clutch
P/J209 OCT Motor
P/J210 Exit Gate Solenoid
P/J218 Inverter Clockwise Clutch
P/J219 Inverter Counter Clockwise
Clutch
463 M3-25 Input/Output Board P/J473 Duplex Board
464 M3-23 Input/Output Board P/J612 Finisher
465 M3-22 Input/Output Board P/J101 Take Away Sensor
P/J203 Tray 1 Lift Motor
P/J604Multi-sheet Bypass Feeder or
Envelope Feeder
466 M3-24 Input/Output Board P/J480 High Capacity Feeder

Map &
467 M3-26 Input/Output Board P/J140 Tray 2 No Paper Sensor

P/J141 Tray 2 Level Sensor
P/J142 Tray 2 Size Sensor
P/J143 Take Away Sensor 2
P/J144 L/H Interlock Switch
P/J240 Tray 2 Feed Clutch
P/J241 Tray 2 Lift Motor
468 M3-29 Input/Output Board P/J515 High Voltage Power Supply-FB
499 M1-7 Test Connector P/J411 Print Engine Controller Board
500 M3-1 High Voltage Power Supply P/J457 Input/Output Board
P/J450 Input/Output Board
P/J450 Input/Output Board
505 M8-4 Low Voltage Power Supply P/J450 Input/Output Board
510 M8-8 AC Driver Board P/J411 Print Engine Controller Board
515 M3-31 High Voltage Power P/J468 Input/Output Board
Supply-R2
600 M4-9 P/J12 Fuser P/J462 Input/Output Board
601 M4-10 P/J109 Face Up Exit Sensor P/J462 Input/Output Board
P/J133 Full Stack Sensor
P/J210 Exit Gate Solenoid
602 M4-12 P/J218 Inverter Clockwise P/J462 Input/Output Board
Clutch
P/J219 Inverter Counter
Clockwise Clutch
603 M2-4 P/J604 Multi-sheet Bypass P/J465 Input/Output Board
Feeder
604 M2-3 P/J603 P/J107Multi-sheet Bypass FeederSize
Sensor
P/J108Multi-sheet Bypass FeederNo
Paper Sensor
P/J208Multi-sheet Bypass FeederFeed
Clutch
606 M3-9 Laser Print (EP) Cartridge P/J454 Input/Output Board
607 M5-8 P/J143 Tray 2 Take Away P/J604
Sensor
P/J144 Tray 2 L/H Interlock
Switch
611 M7-6 P/J473 Duplex Board P/J463 Input/Output Board
612 M7-5 P/J830 Finisher P/J464 Input/Output Board
613 M7-7 P/J480 High Capacity Feeder P/J466 Input/Output Board
615 M6-6 P/J417 Control Panel P/J401 Print Engine Controller Board

Map &
802 M3-30 High Voltage Power Fuser

Supply-R2
Bias Transfer M7-4 Bias Transfer Roller High Voltage Power Supply
Roller
CB M7-3 Charge 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

P/J Location Map 1
S4525-148
Fig 1-133 P/J Location Map 1

P/J Location Map 2
S4525-149

P/J Location Map 3
S4535-150.ai

P/J Location Map 4
S4525-151

P/J Location Map 5
S4525-152

P/J Location Map 6
S4525-153A

P/J Location Map 7
S4525-154

P/J Location Map 8
S4525-155

Master Wiring
Diagram
Wiring Diagrams, Signal Information
Wiring Diagram Notations
This section of the manual contains a Master Wiring Diagram for the printer. The
Master Wiring Diagram shows the interconnections of the major subsystems. More
detailed wiring diagrams are contained in the CD Service Manual.
For more detailed information, refer to the On-Line CD version which contains
complete wiring information.
The following circuit notations are used to describe components and signal paths
throughout the Master Wiring Diagram.
P/J XX Plug/Jack XX
1
is a male connector (plug) of P/J xx
2
is a female connector (jack) of P/J xx
FUSER ASSY Component name
Relay Component or sub-assembly within a larger assembly
Wire connection
Frame ground wire fastened with a screw to

the printer frame
Wire with signal name and direction of signal flow.

/HEAT In some cases, such as a signal name of 5VDC,
the signal is a steady flow of approximately 5VDC.
In other cases, such as a signal name
/HEAT, the signal is near 5VDC when off and
near 0VDC when on. Or in the case of the signal
name HEAT, the signal is near 5VDC when on and
near 0VDC when off.
FG or Frame ground
SG Signal ground
RTN Signal return
Diagram simplification; connector, component, or

BD3, BD7 PWB is continued on the indicated Block Diagrams
S4525-193
Service Guide 355

Master Connection and Wiring Diagram
SYSTEM P/J
CONTROLLER P/J
FUSER FAN
FAN 408 204
P/J456
MASTER DRIVE
P/J ASSEMBLY
CONTROL
PANEL 417
P/J404
P/J MOT
205
P/J460
MOT
P/J
FAN ELECTRIC
220
TONER EMPTY SNR
P/J127
FRONT P/J
INTERLOCK 237
P/J606 XERO CRU
P/J454
START OF P/J
SCAN SENSOR 106
P/J233
INTLK SW1
LASER SCAN P/J P/J
M P/J232
MOTOR 240 207
P/J458
P/J231
LASER
FRONT INTLK INTLK SW2
LASER SCANNER P/J230
CARTRIDGE SW1
INPUT/OUTPUT BOARD
DRIVE P/J
234 P/J
P/J234
P/J411
SW2 FEED CL1
PRINT ENGINE CONTROLLER BOARD

P/J 202
407
P/J462
P/J430 P/J409 P/J REGI GATE
200 CL
S4525-305A
Fig 1-141 Master Connection and Wiring Diagram 1 of 2
Legend:
CCW Counter-Clockwise NOP No Paper

CL Clutch NUT Neutral - associated with electrical power to the
printer
CONN Connector OCT Offset
CW Clockwise REGI Registration
GFI Ground Fault Interrupt SNR Sensor
HVPS High Voltage Power Supply SOL Solenoid
INTLK Interlock SOS Start Of Scan - associated with the Laser Scanner
timing
LVPS Low Voltage Power Supply SW Switch
MBF Multi-sheet Bypass Feeder TA Take Away
MOT Motor
356 DocuPrint N4525 Network Laser Printer

Master Connection and Wiring Diagram, continued
P/J104 FUSER EXIT

P/J600 SNR
P/J P/J
462 P/J218 INVERTER CW CL
FUSER 31
P/J P/J
32 AC. P/J 602
DRIVE 510
POWER UNIT P/J
BOARD P/J219 INVERTER CCW CL
33
HOT-2
P/J462
P/J P/J
P/J411
P/J
12 NUT-2 3 30
P/J P/J P/J209 M OFFSET MOTOR

506 616
BIAS
FG FACE UP EXIT
P/J109
T3 SNR
HOT-2 P/J P/J133 FULL STACK

FINISHER P/J 601 SNR
NUT-2
AC CONN 13 CUPS
P/J P/J P/J
LVPS-B3 HOT-2 -TOP EXIT
8 504 400
510 P/J210 GATE
P/J NUT-2
P/J P/J SOLENOID
4 20 1 HOT-2
INPUT/OUTPUT BOARD
NUT-2
HOT-2
NUT-2 P/J105 SNR SIZE1
P/J461
HOT-1
NUT-1 HOT-SQ
P/J 120V
SSR
4 HOT-1 220V
PRINT ENGINE CONTROLLER BOARD

NUT-1 P/J CHOKE
P/J 9 COIL P/J100 REGI SNR
9
P/J102 NOP1 SNR

P/J459
P/J
P/J
450
502
HOT-SQ
P/J CUPS P/J103 LEVEL1 SNR
NUT-1 2 OP1C
P/J
505 NOP 2
P/J140
SNR
HOT-G NOISE HOT-1 HOT-2 EP CARTRIDGE HVPS

NUT-G FILTER NUT-1 NUT-2 LEVEL 2
Magnet Roller DB P/J141
SNR
GFI Bias Transfer Roller BTR
P/J P/J SIZE 2

P/J142
P/J457
Detack Saw
P/J500
7 8 DTS SNR
Bias Carge Roller BCR

P/J467
TA ROLLER 3
P/J P/J143
HVPS SNR
P/J457
500
P/J
607
2 L/H
P/J P/J P/J144
HVPS-FB INTLK
802 515
P/J468
FEED2
P/J240
CL
MBF
SIZE P/J107
SNR LIFTUP2
P/J241 M
MOT
P/J P/J
MBF 604 603
NOP P/J108
SNR
MBF MFD-CARD
P/J790
P/J451
FEED P/J208
P/J465
CL LIFTUP1 P/J
M 203
MOT
TA ROLLER 2 P/J
SNR 101
S4525-305B
Fig 1-142 Master Connection and Wiring Diagram 2 of 2
Service Guide 357

Blank Page
358 DocuPrint N4525 Network Laser Printer

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DOCUPRINT® N4525

NETWORK LASER PRINTER

This printing: April 5, 2001

Contents of this publication may not be reproduced in any form without

Other marks are trademarks or registered trademarks of the companies with

NOTE: A NOTE may indicate an operating or maintenance

CAUTION: A personal injury hazard exists that may not be apparent.

Mechanical components: Manually rotate drive assemblies to inspect

Warning Labels: Throughout the printer, warning labels are displayed on

Or if the printer is exposed to any excess moisture,

Or if the printer is dropped or damaged,

Or if you suspect that the product needs servicing or repair,

And whenever you clean the product.

Do not service alone: Do not perform internal service or adjustment of this

Disconnect power before removing the power supply shield, soldering or

This product is certified under IEC 825 as a Class 1 Laser Product.

CLASS 1 LASER PRODUCT

KLASS 1 LASER APPARAT

Either re–orient or relocate the radio/television receiving antenna.

Increase the separation between the equipment and the radio/television

Cet appareil numerique est conforme aux limites émission de bruits

This equipment was tested and is determined to be compliant with VDE

Hiermit wird bescheinigt, dass der Babe Laserdrucker, in bereinstimmung mit

Volume 1 - Print Engine

Section 1 - General Information

Section 2 - Error Codes and Messages

Section 4 - Diagnostics, Test Prints, Service Tests & NVRAM Adjustments

Section 5 - Cleaning and Maintenance

Section 6 - Key FRU Removal and Replacement Procedures

Section 7 - FRU List

Section 8 - Plug/Jack Connector Locations

Section 9 - Wiring Diagram

Volume 2 - High Capacity Feeder (HCF)

Volume 3 - Duplex Unit (DUP)

Volume 4 - Envelope Feeder (ENV)

Volume 5 - Face Up Bin (FUB)

Volume 6 - Finisher (FIN)

ii DocuPrint N4525 Network Laser Printer - Service Guide

Service Guide iii

iv DocuPrint N4525 Network Laser Printer

vi DocuPrint N4525 Network Laser Printer

Service Guide vii

1-viii DocuPrint N4525 Network Laser Printer

1-x DocuPrint N4525 Network Laser Printer

Fig 1-1 Print Engine

Volume 1 / Print Engine - General Information 1-1

1-2 DocuPrint N4525 Network Laser Printer - Service Guide

Fig 1-2 Parts of the Printer (Left/Front View)

Fig 1-3 Parts of the Printer (Right/Rear View)

Volume 1 / Print Engine - General Information 1-3

Fig 1-4 Console Configuration with Options:

Fig 1-5 Optional Finisher Components (Stapler/Hole Puncher):

1-4 DocuPrint N4525 Network Laser Printer - Service Guide

Fig 1-6 Control Panel with Icons and Text

Fig 1-7 Control Panel with Icons

Volume 1 / Print Engine - General Information 1-5

The printer is processing data:

The printer is waiting for more data:

There is a problem (in this case, a paper jam in area A):

1-6 DocuPrint N4525 Network Laser Printer - Service Guide