Lexmark W820 Options Service Manual

• Table of Contents

• Start Diagnostics

• Safety and Notices

LexmarkTM W820 Options

4025-XXX

• Trademmaarrkkss

•Index

Lexmark and Lexmark with diamond design are
trademarks of Lexmark International, Inc., registered
in the United States and/or other countries.

Edition: May 2001

©

The following paragraph does not apply to any country where such provisions are inconsistent with local law:

LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND,
EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or
implied warranties in certain transactions; therefore, this statement may not apply to you.

This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the
information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the
programs described may be made at any time.

Comments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 West New Circle Road,
Lexington, Kentucky 40550, U.S.A or e-mail at [e-mail]. Lexmark may use or distribute any
of the information you supply in any way it believes appropriate without incurring any obligation to you. You can purchase
additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of
purchase.

Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States
and/or other countries.

PostScript is a registered trademark of Adobe Systems Incorporated.

Other trademarks are the property of their respective owners.

Copyright Lexmark International, Inc. 2001.

All rights reserved.

UNITED STATES GOVERNMENT RESTRICTED RIGHTS

This software and documentation are provided with RESTRICTED RIGHTS. Use, duplication or disclosure by the
Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer
Software clause at DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Lexington, KY

U.S.A. P/N 12G3782

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Contents

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Tools Required For Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Symbols Used in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Safety Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Printer Power Supply and Electrical Components . . . . . . . . . . . . . . . . . . . . . . . 1-2

Mechanical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Printer Laser Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Printer Fuser Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Safety Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Caution Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Envelope Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Envelope Feeder Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Schematic Diagram of the Envelope Feeder Operation . . . . . . . . . . . . . . . . . . 1-5

Envelope Feeder Power and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Envelope Feeder Drive Generation and Distribution . . . . . . . . . . . . . . . . . . . . . 1-6

Envelope Feeder Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Envelope Feeder Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Envelope Feeder Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Mechanical Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Envelope Feeder Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Envelope Feeder Paper Path Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Envelope Feeder General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Duplex Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Schematic Diagram of the Duplex Operation . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Duplex Power and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Duplex Drive Generation and Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Duplex Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Duplex Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Duplex Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Mechanical Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Duplex Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Duplex Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Duplex Paper Path Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

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Duplex General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

Mailbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

Mailbox Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

Schematic Diagram of the Mailbox Operation . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

Mailbox Power and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

Mailbox Drive Generation and Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

Mailbox Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

Mailbox Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

Mailbox Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

Mechanical Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

Drive for the Mailbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

Mailbox Mechanical Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

Mailbox Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30

Paper Path 1: Bypass the Mailbox and Feed Paper to the Output Tray . . . . . . 1-30

Paper Path 1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31

Paper Path 2: Feed Paper to Bin 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

Paper Path 2 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33

Paper Path 3: Feed Paper to Bins 2 through 10 . . . . . . . . . . . . . . . . . . . . . . . 1-35

Paper Path 3 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

Mailbox Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37

Paper Size Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

Print Speeds While Using the Mailbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

Mailbox General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39

High Capacity Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40

High Capacity Feeder Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40

Schematic Diagram of the High Capacity Feeder Operation . . . . . . . . . . . . . . 1-41

High Capacity Feeder Power and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42

High Capacity Feeder Drive Generation and Distribution . . . . . . . . . . . . . . . . 1-42

High Capacity Feeder Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42

High Capacity Feeder Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43

High Capacity Feeder Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44

Mechanical Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45

Drive for High Capacity Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45

Drive for Tray 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46

Mechanical Drive Tray 3 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47

Drive for Tray 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49

Lift Motor Operation for Tray 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50

Mechanical Drive Tray 4 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50

Drive for Tray 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52

Lift Motor Operation for Tray 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53

Mechanical Drive Tray 5 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54

High Capacity Feeder Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-55

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Feed from Tray 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-56

Tray 3 Paper Path Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57

Feed from Tray 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57

Tray 4 Paper Path Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-59

Feed from Tray 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61

Tray 5 Paper Path Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62

High Capacity Feeder General Specifications . . . . . . . . . . . . . . . . . . . . . . . . 1-64

Glossary of Terms, Acronyms, and Abbreviations . . . . . . . . . . . . . . . . . . . . . . 1-65

Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Envelope Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Envelope Feeder Error Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Envelope Feeder Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Envelope Feeder Error Code Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Envelope Feeder Symptom Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Duplex Error Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Duplex Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Duplex Error Code Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Error Code 997 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Duplex Symptom Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Mailbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Mailbox Error Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Mailbox Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Mailbox Error Code Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Error Code 996 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Mailbox Symptom Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

High Capacity Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

High Capacity Feeder Error Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

High Capacity Feeder Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

High Capacity Feeder Error Code Service Checks . . . . . . . . . . . . . . . . . . . . . 2-33

Error Code 993 and 994 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

High Capacity Feeder Symptom Service Checks . . . . . . . . . . . . . . . . . . . . . . 2-52

Diagnostic Aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Envelope Feeder Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Contents v

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Duplex Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Mailbox Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Feed All Bins Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

High Capacity Feeder Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Work Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Removal and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Envelope Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Duplex Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Duplex Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Duplex Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Duplex Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Duplex PWB and Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Duplex Wait Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Duplex Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Duplex Exit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Duplex Exit Gate Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Exit Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Duplex Wait Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Duplex Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Exit Roll Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Duplex Pinch Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Inner Chute Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Mailbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Mailbox Left Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Mailbox Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Mailbox Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Mailbox Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Actuator Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

Bin 10 Jam Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

BIN 10 Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

Mailbox Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

BIN Trays 1 - 9 Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

Gate Solenoids 1 - 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

vi Contents

4025 Options

Mailbox Exit Roll and Bin Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

Mailbox Entrance Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

IN Gate Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

Vertical LED/Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

Mailbox Control PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Mailbox Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

Full Stack Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

Rear Lower Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49

IN Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

Lower Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52

Mailbox Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53

Transport Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54

High Capacity Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

HCF Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57

HCF Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58

Left Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59

Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60

Front Cover BTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61

HCF Feed Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62

HCF Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

HCF PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67

Tray 3 Paper Size Sensor PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

Tray 4 and Tray 5 Paper Size Sensor PWBs . . . . . . . . . . . . . . . . . . . . . . . . . 4-69

Trays 3, 4, and 5 Feed Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70

Trays 3, 4, and 5 No Paper Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71

Trays 3, 4, and 5 No Paper Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73

Trays 3, 4, and 5 Paper Level Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75

Left Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77

Tray 3 Take Away Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78

Tray 3 Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79

Tray 3 Retard Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81

Tray 3 Nudger, Feeder, and Retard Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84

HCF Tray 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86

Tray 4 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87

Tray 4 Take Away Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88

Tray 4 Take Away Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89

Tray 4 Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92

Tray 4 Retard Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94

Tray 4 Feed, Nudger, and Retard Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-96

HCF Tray 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-98

Tray 5 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-99

Tray 5 Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-100

Contents vii

4025 Options

Tray 5 Retard Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-102

Tray 5 Feed, Nudger, and Retard Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104

Connector Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Envelope Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Envelope Feeder P/J Location Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Envelope Feeder P/J Location Map 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Envelope Feeder Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Duplex P/J Location Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Duplex P/J Location Map 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Duplex Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Mailbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Mailbox P/J Location Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Mailbox P/J Location Map 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Mailbox Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

High Capacity Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

High Capacity Feeder P/J Location Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

High Capacity Feeder P/J Location Map 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

High Capacity Feeder P/J Location Map 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

High Capacity Feeder Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Parts Catalog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

How to Use the Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Assembly 1: Envelope Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Assembly 2: Duplex. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Assembly 3: Mailbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Assembly 4: High Capacity Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

viii Contents

Preface

4025 Options

This manual describes the options for the LexmarkTM W820 printer: Envelope Feeder,
Duplex Unit, Mailbox, and High Capacity Feeder. It contains maintenance procedures for
service personnel only and is divided into the following chapters:

1. General Information contains a general description of the printer options and the

maintenance approach used to repair them. Special tools and test equipment are
listed, as well as general environmental and safety instructions.

2. Diagnostic Information contains an error indicator table, symptom tables, and

service checks used to isolate failing field replaceable units (FRUs).

3. Diagnostic Aids contains tests and checks used to locate or repeat symptoms of

printer option problems.

4. Repair Information provides instructions for removing and installing FRUs.

5. Connector Locations uses illustrations to identify the connector locations and test

points on the options.

6. Preventive Maintenance contains the lubrication specifications and

recommendations to prevent problems.

7. Parts Catalog contains illustrations and part numbers for individual FRUs.

Preface ix

Safety Information

• This product is designed, tested and approved to meet strict global safety standards

with the use of specific Lexmark components. The safety features of some parts may
not always be obvious. Lexmark is not responsible for the use of other replacement
parts.

• The maintenance information for this product has been prepared for use by a

professional service person and is not intended to be used by others.

• There may be an increased risk of electric shock and personal injury during

disassembly and servicing of this product. Professional service personnel should
understand this and take necessary precautions.

Consignes de Sécurité

• Ce produit a été conçu, testé et approuvé pour respecter les normes strictes de

sécurité globale lors de l'utilisation de composants Lexmark spécifiques. Les
caractéristiques de sécurité de certains éléments ne sont pas toujours évidentes.
Lexmark ne peut être tenu responsable de l'utilisation d'autres pièces de rechange.

• Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à

un personnel de maintenance qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter certains risques

électriques, le personnel d'entretien qualifié devra prendre toutes les précautions
nécessaires.

4025 Options

Norme di sicurezza

• Il prodotto è stato progettato, testato e approvato in conformità a severi standard di

sicurezza e per l’utilizzo con componenti Lexmark specifici. Le caratteristiche di
sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark
non è responsabile per l’utilizzo di parti di ricambio di altri produttori.

• Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate

soltanto al personale di assistenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto, il rischio di subire

scosse elettriche e danni alla persona è più elevato. Il personale di assistenza
autorizzato, deve, quindi, adottare le precauzioni necessarie.

x Safety Information

Sicherheitshinweise

• Dieses Produkt und die zugehörigen Komponenten wurden entworfen und getestet,

um beim Einsatz die weltweit gültigen Sicherheitsanforderungen zu erfüllen. Die
sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer
offensichtlich. Sofern Teile eingesetzt werden, die nicht von Lexmark sind, wird von
Lexmark keinerlei Verantwortung oder Haftung für dieses Produkt übernommen.

• Die Wartungsinformationen für dieses Produkt sind ausschließlich für die

Verwendung durch einen Wartungsfachmann bestimmt.

• Während des Auseinandernehmens und der Wartung des Geräts besteht ein

zusätzliches Risiko eines elektrischen Schlags und körperlicher Verletzung. Das
zuständige Fachpersonal sollte entsprechende Vorsichtsmaßnahmen treffen.

Pautas de Seguridad

• Este producto se ha diseñado, verificado y aprobado para cumplir los más estrictos

estándares de seguridad global usando los componentes específicos de Lexmark.
Puede que las características de seguridad de algunas piezas no sean siempre
evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio.

• La información sobre el mantenimiento de este producto está dirigida

exclusivamente al personal cualificado de mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños personales durante el

desmontaje y la reparación de la máquina. El personal cualificado debe ser
consciente de este peligro y tomar las precauciones necesarias.

4025 Options

Informações de Segurança

• Este produto foi concebido, testado e aprovado para satisfazer os padrões globais

de segurança na utilização de componentes específicos da Lexmark. As funções de
segurança de alguns dos componentes podem não ser sempre óbvias. A Lexmark
não é responsável pela utilização de outros componentes de substituição.

• As informações de segurança relativas a este produto destinam-se a profissionais

destes serviços e não devem ser utilizadas por outras pessoas.

• Risco de choques eléctricos e ferimentos graves durante a desmontagem e

manutenção deste produto. Os profissionais destes serviços devem estar avisados
deste facto e tomar os cuidados necessários.

Safety Information xi

Informació de Seguretat

• Aquest producte està dissenyat, comprovat i aprovat per tal d'acomplir les estrictes

normes de seguretat globals amb la utililització de components específics de
Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre
siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi.

• La informació pel manteniment d’aquest producte està orientada exclusivament a

professionals i no està destinada a ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augmentar durant el procés de

desmuntatge i de servei d’aquest producte. El personal professional ha d’estar-ne
assabentat i prendre les mesures convenients.

4025 Options

xii Safety Information

1. General Information

Maintenance Approach

The diagnostic information in this manual leads you to the correct field replaceable unit
(FRU) or part for the Envelope Feeder, Duplex, Mailbox, and High Capacity Feeder
options. Use the appropriate error code table, symptom table, error code service checks
and symptom service checks to determine the corrective action necessary to repair the
failing option. After you complete the repair, perform tests as needed to verify the repair.

Tools Required For Service

The removal and replacement procedures described in this manual require the following
tools and equipment:

• Magnetic tip Phillips screwdrivers, large and small

• Flat-blade screwdrivers

• Analog volt ohmmeter (a digital volt ohmmeter may also be used)

4025 Options

Symbols Used in this Manual

Various symbols are used throughout this manual to either provide additional information
on a specific topic or to warn of possible danger that might be present during a procedure
or action. Be aware of all symbols when they are used, and always read NOTE,
CAUTION, and WARNING messages.

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.

WARNING: A WARNING indicates an operating or maintenance procedure, practice, or
condition that, if not strictly observed, could result in damage to, or destruction of,
equipment.

CAUTION: A CAUTION indicates an operating or maintenance procedure, practice, or
condition that, if not strictly observed, could result in injury.

Safety Details

Follow all safety instructions to prevent accidents while servicing the printer and attached
options. Always be aware of the potential dangers that are present when you are working
with electrical or mechanical equipment.

General Information 1-1

4025 Options

Printer Power Supply and Electrical Components

Before starting any service procedure, switch off the printer power and unplug the power
cord from the wall outlet. If you must service the options with the printer power applied, be
aware of the potential for electrical shock.

CAUTION: Do not touch any electrical component unless you are instructed to do so by
a service procedure.

Mechanical Components

Manually rotate drive assemblies to inspect sprockets and gears.

CAUTION: Do not try to manually rotate or manually stop the drive assemblies while any
printer or option motor is running.

Printer Laser Components

CAUTION: The 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.

1-2 Service Manual

4025 Options

To avoid permanent eye damage, follow these directions:

• Before starting any service procedure, switch off the printer power and unplug the

power cord from the AC wall outlet.

• Do not disassemble the printer Printhead Assembly or any laser component that

displays a Laser Warning sticker.

• Use caution when you are working around the printer Printhead 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.

Printer Fuser Components

CAUTION: This printer uses heat to fuse the toner image to a sheet paper. The printer

Fuser Assembly is very hot. Switch off printer power and wait at least 45 minutes for the
fuser to cool before you attempt to service the printer 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 or option service call. If you bypass, or cheat,
an interlock switch during a service call, use extreme caution when working on or around
the printer or options.

Caution Labels

Throughout the equipment, warning labels are displayed on potentially dangerous
components. When you service the printer and options, check to make sure that all
caution labels are in place.

Most importantly, read and obey all posted caution labels.

General Information 1-3

Envelope Feeder

Envelope Feeder Overview

4025 Options

• The Envelope Feeder is a customer installed option that feeds envelopes into the

printer.

• The Envelope Feeder is easily installed in place of the printer MP Feeder.

• The printer base engine LVPS provides all of the DC voltages required by the

Envelope Feeder.

• One +24VDC motor inside the Envelope Feeder provides all of the mechanical drive

required for operation.

• One PWB and three sensors inside the Envelope Feeder provide all of the control

and paper path monitoring required for operation.

1-4 Service Manual

4025 Options

Schematic Diagram of the Envelope Feeder Operation

The following illustration is a simplified schematic of printer Envelope Feeder
components, subsystems, and paper paths.

General Information 1-5

4025 Options

Envelope Feeder Power and Control

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

Envelope Feeder Drive Generation and Distribution

The printer Envelope Feeder has one +24VDC motor, the Envelope Motor, that supplies
drive to the entire Envelope Feeder. A Gear Assembly and Feed Clutch controls and
transfers motor drive to Envelope Feeder components.

Envelope Feeder Power

The Envelope PWB, located inside the Envelope Feeder, plugs into the I/O PWB. The
Base Engine LVPS supplies +5VDC and +24VDC to the I/O PWB. The I/O PWB then
supplies +5VDC and +24VDC to the Envelope PWB. The +5VDC powers the Envelope
PWB and the Envelope Feeder Sensors, the +24VDC powers the Envelope Motor and
the Feed Clutch.

1-6 Service Manual

4025 Options

Envelope Feeder Control

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

The center of Envelope Feeder control is the Envelope PWB. The MCU PWB provides
the logic and information processing necessary for the printer to function, and the
Envelope PWB provides the logic and information processing necessary for the Envelope
Feeder to function. Every electrical component within the Envelope Feeder is connected
to the Envelope PWB. Sensors in the Envelope Feeder send status information to the
Envelope PWB. The Envelope PWB processes that information and shares it with the
MCU PWB. Acting on the results of the processing, the Envelope PWB sends commands
to the various Envelope Feeder components; switching off the motor or switching on the
Feed Clutch.

General Information 1-7

4025 Options

Envelope Feeder Control Components

Envelope Feeder Control is made up of four major components.

1. Envelope Feeder PWB

The Envelope Feeder PWB controls all Envelope Feeder functions, executes
commands sent by the MCU PWB, and sends information back to the MCU PWB.

2. No Paper Sensor

Monitors the envelope level in the Envelope tray.

3. Size Sensor

Monitors the envelope size loaded in the Envelope tray.

4. Feed Sensor

Monitors envelope travel out of the Envelope Feeder.
Monitors paper entering the Envelope Feeder from the printer.

Mechanical Drive

Mechanical Drive is a term used to describe both the rotation of the Envelope Motor and
the action of the gears and rollers used to transmit motor rotation to the drive rolls within
the Envelope Feeder. The purpose of Mechanical Drive within the Envelope Feeder is to
provide the mechanical energy needed to drive an envelope from the Envelope Feeder
tray and into the printer base engine.

Drive for the Envelope Feeder

The Envelope PWB controls the Envelope Motor. The Motor rotates the Drive Gears.
When the Envelope PWB switches on the Envelope Motor, the Motor rotates the Drive
Gears. When the Envelope PWB actuates the Feed Clutch, the Clutch transmits drive to
the Envelope Feed and Transport Roll. The Friction Clutch transmits drive to the Retard
Roll.

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Envelope Feeder Mechanical Drive Components

The Mechanical Drive for the Envelope Feeder is made up of one motor, two clutches,
and a number of gears.

1. Envelope Motor

A +24VDC motor that provides the mechanical drive for the Envelope Feeder.

2. Feed Clutch

An electric clutch controlled by the Envelope PWB. When actuated, the Feed Clutch
transmits Envelope Motor drive to the Envelope feed and transport assemblies.

3. Retard Roll Friction Clutch

Transmits motor drive to the Retard Roll.

General Information 1-9

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Envelope Feeder Paper Path

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

Envelope Feeder Paper Path Components

1. Weight Arm

Presses the stack of envelopes against the Feed Belt.

2. Feed Belt

Feeds an envelope off of the stack and into the Take Away Roll.

3. Retard Roll

Prevents multiple envelope feed.

4. Take Away Roll & Pinch Roll

Continues to drive the envelope out of the feed area and into the Transport Roll.

5. Transport Roll & Pinch Roll

Drives the envelope out of the Envelope Feeder and into the printer Registration Roll.

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Envelope Feeder General Specifications

Category Specification

Configuration Customer installed option. The Envelope Feeder replaces the

MP Feeder. The Envelope Feeder attaches to the MP Feeder
Support.

Paper fed from the Envelope Feeder cannot be duplexed.

Envelope stack capacity Maximum 100 envelope.

Envelope Feeder is equipped with a No Paper Sensor.

Recommended envelope sizes Monroe Brand COM #10 - 104.8mm x 241.3mm

Monroe Brand Monarch - 98.4mm x 190.5mm
C5 - 162mm x 220mm
DL - 110mm x 220mm

Power requirements The printer provides all of the Envelope Feeder power

requirements; +5VDC and +24VDC.

Size and weight Height: 133 mm / 5.2 inches

Width: 278 mm / 10.9 inches
Depth: 444 mm / 17.4 inches
Weight: 3.0kg / 6.6 lbs

General Information 1-11

Duplex

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Duplex Overview

• The Duplex Unit is a customer installed option that enables the printer to run duplex,

or double-sided, print jobs.

• The Duplex Unit is easily installed on the left side of the printer, just above the MP

Feeder.

• The base engine LVPS provides all of the DC voltages required by the Duplex Unit.

• One +24VDC motor inside the Duplex Unit provides all of the mechanical drive

required by the Duplex Unit.

• One PWB and two sensors inside the Duplex Unit provide all of the control and

paper path monitoring required by the Duplex Unit.

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Schematic Diagram of the Duplex Operation

The following illustration is a simplified schematic of the Duplex Unit components,
subsystems, and paper paths.

Duplex Power and Control

All active components within the Duplex Unit are electrically connected to the Duplex
PWB. The Base Engine Low Voltage Power Supply supplies +5VDC and +24VDC to the

I/O PWB, and the I/O PWB supplies +5VDC and +24VDC to the Duplex PWB. The MCU
PWB provides most of the Duplex Unit logic, while the Duplex PWB executes the MCU
commands.

Duplex Drive Generation and Distribution

The Duplex Unit has one +24VDC motor, the Duplex Motor, that supplies drive to the
entire Duplex Unit. A Gear Assembly and drive belts transfer motor drive to Duplex
components. An electrical Wait Clutch controls drive to the Transport Rolls and the
Duplex PWB controls the Duplex Motor and the Wait Clutch.

General Information 1-13

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Duplex Power

The base engine Low Voltage Power Supply and the I/O PWB provide the +5VDC and
+24VDC that the Duplex Unit requires to operate. The Duplex PWB, located inside the
Duplex Unit, plugs into the I/O PWB. The Base Engine LVPS supplies +5VDC and
+24VDC to the I/O PWB. The I/O PWB then supplies +5VDC and +24VDC to the Duplex
PWB. The +5VDC powers the Duplex PWB and the Duplex Sensors, the +24VDC powers
the Duplex Motor and the Wait Clutch and Exit Solenoid.

Duplex Control

Duplex Unit Control is a broad term used to describe the printer resources that monitor
and control the actions and operations of the Duplex Unit.

The center of the Duplex Unit control is the Duplex PWB. The Duplex PWB, along with
the MCU PWB, provide the logic and information processing necessary for the Duplex
Unit to function. Every electrical component within the Duplex Unit is connected to the
Duplex PWB. The Wait Sensor and Exit Sensor in the Duplex Unit send paper status
information to the Duplex PWB. The Duplex PWB processes that information and shares
it with the MCU PWB. The MCU compares the information to timing tables stored in ROM.
Acting on the results of the processing, the MCU PWB sends commands to various base
engine components and to the Duplex PWB. The Duplex PWB then switches the Duplex
components.

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Duplex Control Components

Duplex Control is made up of four major components.

1. Duplex PWB

The Duplex PWB controls all Duplex functions, executes commands sent from the
MCU PWB, and sends information back to the MCU PWB.

2. Duplex Interlock Switch

Monitors whether the Duplex Unit is closed (operating position) or open (not
operating position).

3. Exit Sensor

Monitors paper travel out of the Duplex Unit.

4. Wait Sensor

Monitors paper travel to the Wait Rolls.

Mechanical Drive

Mechanical Drive is a term used to describe both the rotation of the Duplex Motor and the
action of the gears, clutches, and belts that transmit motor drive to the components
throughout the Duplex Unit. The primary purpose of Mechanical Drive within the Duplex
Unit is to provide the mechanical energy needed to drive a sheet of paper into the Output
Tray, back through the Duplex Unit and into the base engine for a second side printing,
and then back out into the Output Tray.

Drive for the Duplex Unit

The Duplex Motor generates the mechanical drive for the entire Duplex Unit. One end of
the Duplex Motor Belt is attached to the Duplex Motor and the other end is attached to
Gear (24T/30T/22T). One end of the Exit Roll Belt is attached to Gear (24T/30T/22T)
and the other end is attached to the Friction Clutch. One end of the Transport Roll Belt
is attached to the Wait Clutch and the other end is attached to the Lower Drive Roll.
The Wait Clutch is always in contact with Gear (24T/30T/22T). When the Duplex PWB
switches on the Duplex Motor, Gear (24T/30T/22T) transmits drive, through belts,
clutches, and pulleys to the various drive rolls along the duplex paper-path.

General Information 1-15

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Duplex Drive Components

1. Duplex Motor

A +24VDC motor that provides mechanical drive for the Duplex Unit.

2. Wait Clutch

An electric clutch that controls Duplex Motor drive to the Transport Roll.

3. Friction Clutch

A mechanical clutch that transmits Duplex Motor drive to the Exit Roll and #1
Transport Roll.

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Duplex Paper Path

The Duplex Unit Paper Path is the physical route that a sheet of paper takes through the
printer and through the Duplex Unit during a duplex print cycle. Rubber rollers and
solenoid activated gates drive and direct the paper along the Paper Path. The primary
purpose of the Duplex Unit Paper Path is to accept a printed sheet of paper from the
Fuser exit area, drive that sheet down through the Duplex Unit, effectively flipping over
the sheet, and feeding the sheet back into the printer registration area so the printer can
begin to transfer an image onto the second side.

Note: The Duplex Unit provides duplex printing for paper fed from all available paper
trays except the MP Feeder and the Envelope Feeder. Paper fed from either the MP
Feeder or the Envelope Feeder cannot be duplexed.

Step 1

The Drum and BTR place an image on side one of a sheet of paper. The Drum/BTR drive
the paper into the Heat and Pressure Rolls. The Heat and Pressure Rolls drive the sheet
into the Exit Unit. The Exit Gate Solenoid toggles the Exit Gate so the paper path runs to
the Offset Roll. The Offset Roll drives the sheet partially into the Output Tray, then stops.

General Information 1-17

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Step 2

The Inverter CCW Clutch switches on and rotates the Offset Roll backward, driving the
sheet of paper back into the Exit Unit. The Exit Gate Solenoid toggles the Exit Gate so the
paper path runs to the Exit Roll. The Exit Roll drives the sheet of paper into the Duplex
Unit. The Duplex Exit Solenoid toggles the Duplex Exit Gate so the paper path runs to the
Duplex Transport Roll. Two sets of Transport Rolls drive the paper down to the Wait Roll.
The paper stops momentarily at the Wait Roll. When it is time to send the sheet of paper
back into the printer for printing on the second side, the Wait Clutch switches on and the
Wait Roll drives the paper out of the Duplex Unit and into the printer Registration Roll.
The paper stops at the Registration Roll so the image on the Drum can align with the
leading edge of the paper. When registration is complete, the Registration Roll drives the
paper into the Drum and BTR where the second side is printed.

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Step 3

The Drum and BTR place an image onto the second side of the sheet of paper. The
Drum/BTR drive the paper into the Heat and Pressure Rolls. The Heat and Pressure
Rolls drive the sheet into the Exit Unit.

General Information 1-19

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Duplex Paper Path Components

The Duplex Unit Paper Path is made up of a number of transport rolls and paper sensors.

1. Exit Gate and Exit Gate Solenoid

Diverts paper to either the Duplex Transport Roll #1.

2. Transport Roll #1 and Pinch Roll

Drives paper down through the Duplex Unit and into the lower Transport Roll.

3. Transport Roll and Pinch Roll

Drive paper into the Wait Roll area.

4. Wait Sensor

Monitors paper at the Wait Roll. Holds paper there until it is time to feed the sheet
into the printer.

5. Wait Roll and Pinch Roll

Note: When it is time to feed the sheet into the printer for the second side printing,

the Wait Roll drives the paper out of the Duplex Unit and back into the printer.

6. Exit Roll

Drives paper out of the Duplex Unit.

7. Exit Sensor

Monitors paper travel through the Exit Roll.

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Duplex General Specifications

Category Specification

Configuration Customer installed option. Attaches to the left side of the

printer, above the MP Feeder.

Paper feed The Duplex Unit provides duplex printing for paper fed from all

available paper trays except the MP Feeder and the Envelope
Feeder. Paper fed from the MP Feeder or from the Envelope
Feeder cannot be duplexed.

Power requirements The base printer provides all of the Duplex Unit power

requirements; +5VDC and +24VDC

Size and weight Height: 369 mm / 14.5 inches

Width: 92 mm / 3.6 inches
Depth: 484 mm / 19.0 inches
Weight: 5.5kg / 12.1 pounds

General Information 1-21

Mailbox

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Mailbox Overview

1-22 Service Manual

• The Mailbox (or Sorter) is a customer installed option that distributes printed sheets

to any one of ten Mailbox bins.

• The Mailbox is easily installed on top of the printer.

• The base engine LVPS provides all of the DC voltages required by the Mailbox.

• One +24VDC motor inside the Mailbox provides all of the mechanical drive required

for operation.

• One PWB and thirteen sensors inside the Mailbox provide all of the control and

paper path monitoring required for operation.

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Schematic Diagram of the Mailbox Operation

The following illustration is a simplified schematic of Mailbox components, subsystems,
and paper paths.

General Information 1-23

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Mailbox Power and Control

All active components within the Mailbox are electrically connected to the Mailbox
Control PWB. The Base Engine Low Voltage Power Supply supplies +5VDC and

+24VDC to the I/O PWB, and the I/O PWB supplies +5VDC and +24VDC to the Mailbox
Control PWB. The MCU PWB provides most of the Mailbox logic, while the Mailbox PWB
executes the MCU commands.

Mailbox Drive Generation and Distribution

The Mailbox has one +24VDC motor, the Mailbox Drive Motor, that supplies drive to the
entire Mailbox. A Gear Assembly and drive belt transfers motor drive to Mailbox
components.

Mailbox Power

The base engine Low Voltage Power Supply and I/O PWB provide the +5VDC and
+24VDC that the Mailbox requires to operate. The Mailbox Control PWB, located inside
the Mailbox, plugs into the I/O PWB. The Base Engine LVPS supplies +5VDC and
+24VDC to the I/O PWB. The I/O PWB then supplies +5VDC and +24VDC to the Mailbox
Control PWB. The +5VDC powers the Mailbox Control PWB and the Mailbox Sensors,
the +24VDC powers the Mailbox Motor and the Mailbox Solenoids.

Mailbox Control

Mailbox Control is a broad term used to describe the printer resources that monitor and
control the actions and operations of the printer and the Mailbox; from bin output to error
detection.

The center of Mailbox control is the Mailbox Control PWB. The MCU PWB provides the
logic and information processing necessary for the printer to function, and the Mailbox
Control PWB provides the logic and information processing necessary for the Mailbox to
function. Every electrical component within the Mailbox is connected to the Mailbox
Control PWB. Sensors in the Mailbox send paper travel status information to the Mailbox
Control PWB. The Mailbox Control PWB processes that information and shares it with the
MCU PWB. Acting on the results of the processing, the Mailbox Control PWB sends
commands to the various Mailbox components; switching on the motor or switching off a
bin solenoid.

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General Information 1-25

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Mailbox Control Components

Mailbox Control is made up of the following components:

1. Mailbox Control PWB

The Mailbox Control PWB controls all Mailbox functions, executes commands sent
from the MCU PWB, and sends information back to the MCU PWB. All Mailbox
components are connected directly to the Mailbox Control PWB.

2. Mailbox Interlock Switch

Monitors the Left Cover position. When the Cover is open, the Mailbox Control PWB
cuts power to the Mailbox components.

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3. Full Stack Sensor

There are ten Full Stack Sensors within the Mailbox. Each Sensor monitors the
paper level of the associated bin. The Full Stack Sensors are mounted on the
Mailbox Control PWB.

4. No Paper Sensor

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

5. Mailbox Entrance Sensor

Monitors paper entering the Mailbox from the printer.

6. Mailbox Drive Motor

A 24VDC motor. Provides mechanical drive for the Mailbox.

7. Gate Solenoid

There are nine Gate Solenoids within the Mailbox. Each Solenoid controls the paper
path Gate of the associated bin.

8. Vertical LED and Sensor

Monitors paper travel into Bins 2 through 10.

9. Bin 10 Jam Sensor

Monitors paper travel to Bin 10.

Mechanical Drive

Mechanical Drive is a term used to describe both the rotation of the Mailbox Drive Motor
and the action of the gear, belt, pulleys, and rollers used to transmit motor rotation to the
ten Mailbox Rolls within the Mailbox. The purpose of Mechanical Drive within the Mailbox
is to provide the mechanical energy needed to drive a sheet from the printer paper exit
and into a Mailbox bin.

General Information 1-27

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Drive for the Mailbox

The Mailbox Control PWB controls the Mailbox Motor. The Motor rotates the Drive
Gear. The Drive Belt wraps around the Drive Gear and the ten Drive Pulleys. Six

Tension Rollers along the path press the Drive Belt against the Drive Pulleys. When the
Mailbox Control PWB switches on the Mailbox Motor, the Motor rotates the Drive Gear,
the Drive Gear drives the Belt which in turn rotates the ten Drive Pulleys. The ten Drive
Pulleys rotate the ten Mailbox Exit Rolls.

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Mailbox Mechanical Drive Components

The Mechanical Drive for the Mailbox is made up of one motor, a drive belt, and a number
of pulleys.

1. Mailbox Drive Motor

Provides the mechanical drive for the Mailbox.

2. Drive Gear

A two part gear. One side of the gear rides on the Motor gear. The other side of the
gear drives the Mailbox Drive Belt.

3. Mailbox Drive Belt

Transmits Mailbox Motor drive to the ten Drive Pulleys.

4. Drive Pulleys

Ten pulleys.

5. Tension Rollers

Six rollers that press the Drive Belt against the Drive Pulleys.

General Information 1-29

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Mailbox Paper Path

The Mailbox Paper Path is the physical route that a sheet of paper takes from the printer
exit area to a specific Mailbox bin. Rubber rollers drive the paper along the Paper Path.

Paper Path 1: Bypass the Mailbox and Feed Paper to the Bypass the Mailbox and Feed Paper to the
Output Tray

If the Controller signals the MCU PWB not to use Mailbox mode, the MCU PWB does not
actuate the In Gate Solenoid, the Solenoid does not drop the In Gate, and the paper path
continues into the printer Face Down Output Tray.

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Paper Path 1 Components

The Mailbox paper path when the Mailbox is bypassed is made up of two components.

1. In Gate Solenoid

Toggles the In Gate. In this case, the Gate Solenoid does not actuate.

2. In Gate

Switches the paper path from the Output Tray to the Mailbox. In this case, the In
Gate remains up, and the paper is delivered to the printer Output Tray.

General Information 1-31

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Paper Path 2: Feed Paper to Bin 10

If the Controller signals the MCU PWB to send the output to Bin 10, the Mailbox Control
PWB actuates the In Gate Solenoid, the Solenoid drops the In Gate, and the paper path
switches to the Mailbox. The Entrance Sensor monitors paper arrival at the Mailbox
entrance. The Exit and Pinch Rolls drive the sheet of paper to the top of the Mailbox. All
of the Bin Gates remain closed, so the paper path moves past Bin 1 through 9. Bin 10,
located at the top of the Mailbox, is unique. Bin 10 has neither a Bin Gate Solenoid nor a
Bin Gate. There is a jam sensor in Bin 10 that detects when a sheet of paper arrives at
Bin 10.

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Paper Path 2 Components

The Mailbox paper path when the paper destination is Bin 10 is made up of a number of
components.

1. In Gate Solenoid

Toggles the In Gate.

2. In Gate

Switches the paper path from the Output Tray to the Mailbox.

3. Entrance Sensor

Monitors paper arriving at the Mailbox.

4. Bin Rolls and Pinch Rolls

Drives the sheet of paper up the Mailbox paper path.

5. Bin Gates 1 through 9

When closed, the paper moves over the top of the Gates. When open, the paper is
diverted into the Bin that the specific Gate controls. In this case, all of the Bin Gates
are closed. Bin 10 does not have a Bin Gate.

6. Bin 10 Jam Sensor

Monitors paper arriving at Bin 10.

General Information 1-33

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7. Bin 10 Full Stack Sensor

Monitors the paper level in Bin 10.

8. Bin 10 No Paper Sensor

Monitors the presence of paper in Bin 10.

9. Vertical LED and Sensor

Monitors paper travel into Bins 1 through 9.

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Paper Path 3: Feed Paper to Bins 2 through 10

If the Controller signals the MCU PWB to send the output to any Mailbox Bin between 1
through 9, the MCU PWB actuates the In Gate Solenoid, the Solenoid drops the In Gate
and the paper path continues into the Mailbox. The Entrance Sensor, located at the input
of the Mailbox paper path, monitors paper arrival into the Mailbox. The Exit Rolls and the
Pinch Rolls drive the sheet of paper to the top of the Mailbox. Along the way, all of the Bin
Gates remain closed except the Bin Gate of the designated Bin. (In the following
example, the output is destined for Bin 5.)

The paper path moves past Bins 1 through 4. Bin 5 Gate Solenoid opens Bin 5 Gate and
Bin 5 Roller drives the paper into Bin 5. The Vertical Sensor monitors paper travel into
Bins 1 through 9. An LED located at the top of the Bin Gates shines light down through
cutouts in each Gate and onto the Vertical Sensor located at the bottom of the Bin Gates.
When a sheet of paper enters any Bin, 1 through 9, the sheet breaks the light beam and
the Sensor signals the Mailbox Control PWB that a sheet of paper has entered a Bin. All
Bins have a Full Stack Sensor. The Full Stack Sensors monitor the paper level in each
Bin and signal the Mailbox Control PWB when a Bin is full. The No Paper Sensors
monitor the presence of paper in each Bin and signal the Mailbox PWB when paper is
present in a Bin.

General Information 1-35

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Paper Path 3 Components

The Mailbox paper path when the paper destination is Bin 1 through Bin 9 is made up of a
number of components.

1. In Gate Solenoid

Toggles the In Gate.

2. In Gate

Switches the paper path from the Output Tray to the Mailbox.

3. Entrance Sensor

Monitors paper arriving at the Mailbox.

4. Bin Rolls and Pinch Rolls

Drives the sheet of paper up the Mailbox paper path.

5. Bin Gates 1 through 9

When closed, the paper moves over the top of the Gates. When open, the paper is
diverted into the Bin that the Gate controls. In this example, Bin 5 is open.

6. Bin Gate Solenoids 1 through 9

Toggles the corresponding Bin Gate open and closed. Bin 10 does not have a Bin
Gate Solenoid.

7. Bin 10 Full Stack Sensor

Monitors the paper level in Bin 10.

8. Bin 10 No Paper Sensor

Monitors the presence of paper in Bin 10.

9. Vertical LED and Sensor

Monitors paper travel into Bins 1 through 9.

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Mailbox Modes

Mode Specification

Sort A maximum of 10 sets of 100 sheets per set, with one set delivered to each of the ten

bins. Delivered face down in Simplex Mode. Delivered first sheet on the bottom and first
printed side face down in Duplex Mode.

Stack A maximum of 100 sheets delivered to a designated bin. Delivered face down in

Simplex Mode. Delivered first printed side face down in Duplex Mode.

General Information 1-37

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Paper Size Recommendations

Paper Type Use with Simplex

Ledger (SEF) Y Y

A3 (SEF) Y Y

B4 (SEF) Y Y

Legal 14” (SEF) Y Y

Legal 13” (SEF) Y Y

A4 (SEF) Y Y

Letter (SEF) Y Y

B5 (SEF) Y Y

Letter (LEF) Y Y

Use with one
sheet batch
Duplex

A4 (LEF) Y Y

B5 (LEF) Y Y

A5 (SEF) Y N

Print Speeds While Using the Mailbox

Trays 1 & 2

Paper Type

(prints per
minute)

A4 LEF Simplex = 32

Duplex = 31

LETTER LEF Simplex = 32

Duplex = 31

Tray 3
(prints per
minute)

Simplex = 32
Duplex = 28

Simplex = 32
Duplex = 28

Trays 4 & 5
(prints per
minute)

Simplex = 32
Duplex = 23

Simplex = 32
Duplex = 23

MP Feeder
(prints per
minute)

Simplex = 26
Duplex = 19

Simplex = 26
Duplex = 19

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Mailbox General Specifications

Category Specification

Configuration Customer installed option. Attaches on top of the base printer.

The basic Mailbox sorts printer output into 10 individual bins,
with a maximum capacity of 100 sheets of standard 20 lb
paper per bin.

Duty cycle Maximum 150,000 sheets of paper per month, with an average

of 25,000 sheets of paper per month.

Mailbox noise levels Maximum of 64dB while running

Power requirements The printer provides all of the Mailbox power requirements;

+5VDC and +24VDC.

General Information 1-39

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Category Specification

Size and weight Height: 465mm / 18.3 inches

Width: 539mm / 21.2 inches
Depth: 590mm / 23.2 inches
Weight: 16kg / 35.2 lbs

High Capacity Feeder

High Capacity Feeder Overview

1-40 Service Manual

• The High Capacity Feeder is a customer installed option that adds three additional

paper feeders to the existing two paper feeders that are standard with the print
engine.

• The print engine sits on top of the High Capacity Feeder.

• The base engine LVPS provides all of the DC voltages required by the High Capacity

Feeder.

• Four +24VDC motors inside the High Capacity Feeder provide all of the mechanical

drive required for operation. Three electrical clutches control Feed Motor drive.

• One PWB, two sensors, and one interlock switch inside the High Capacity Feeder

provide all of the control and paper path monitoring required for operation.

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Schematic Diagram of the High Capacity Feeder Operation

The following illustration is a simplified schematic of High Capacity Feeder components,
subsystems, and paper paths.

General Information 1-41

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High Capacity Feeder Power and Control

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

High Capacity Feeder Drive Generation and Distribution

The High Capacity Feeder has one +24VDC motor, the HCF Motor, that supplies drive to
the entire High Capacity Feeder. A succession of gear assemblies and feed clutches
control and transfers motor drive to High Capacity Feeder components. The HCF also
contains three tray Lift Motors that raise each HCF Tray bottom plate so the paper stack
contains the Feed Rolls.

High Capacity Feeder Power

The HCF PWB, located inside the High Capacity Feeder, plugs into the I/O PWB. The
Base Engine LVPS supplies +5VDC and +24VDC to the I/O PWB. The I/O PWB then
supplies +5VDC and +24VDC to the HCF PWB. The +5VDC powers the HCF PWB and
the High Capacity Feeder Sensors. The +24VDC powers the HCF Feed Motor, the Lift
Motors, and the Feed Clutches.

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High Capacity Feeder Control

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

The center of HCF control is the HCF PWB. The MCU PWB provides the logic and
information processing necessary for the printer to function, and the HCF PWB provides
the logic and information processing necessary for the HCF to function. Every electrical
component within the HCF is connected to the HCF PWB. Sensors in the HCF send
paper feed status information to the HCF PWB. The HCF PWB processes that
information, shares it with the MCU PWB, and compares it to timing tables stored in
ROM. Acting on the results of the processing, the HCF PWB sends commands to the
various HCF components; switching on a motor or switching off a feed clutch.

General Information 1-43

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High Capacity Feeder Control Components

The HCF Control is made up of one several major components.

1. HCF PWB

The HCF PWB controls all HCF functions, executes commands sent from the MCU
PWB, and sends information back to the MCU PWB. All HCF components are
connected directly to the HCF PWB.

2. L/H Interlock Switch

Monitors the Left Cover position.

3. Feed Motor

Provides most of the mechanical drive for the HCF.

4. Lift Motor 3

Raises the paper tray in Feeder 3.

5. Lift Motor 4

Raises the paper tray in Feeder 4.

6. Lift Motor 5

Raises the paper tray in Feeder 5.

7. Feed Clutch 3

Transmits Feed Motor drive to Tray 3 Feed Rolls.

8. Feed Clutch 4

Transmits Feed Motor drive to Tray 4 Feed Rolls.

9. Feed Clutch 5

Transmits Feed Motor drive to Tray 5 Feed Rolls.

10. Tray 3 Take Away Sensor

Monitors paper travel arriving at the Take Away Rolls in Feeder 3.

11. Tray 4 Take Away Sensor

Monitors paper travel arriving at the Take Away Rolls in Feeder 4.

12. Size Sensors 3, 4, and 5

Monitors the size of the paper loaded in a Feeder. The Actuator Assembly located at
the rear of the Paper Tray has series of cams that face the Size Sensor PWB.
Pushing the Paper Guide against the paper stack slides the Actuator Assembly
along a track. When the Tray is inserted into the Feeder, the cams on the Actuator
press the switches on the Size Sensor PWB in a pattern unique to the position of the
Paper Guide. The MCU PWB interprets this pattern as a specific paper size.

13. No Paper Sensors 3, 4, and 5

Monitors the paper level in a Feeder. When the Lift Motor raises the Bottom Plate,
the Plate raises the paper stack, the stack pushes the No Paper Actuator up and
away from the No Paper Sensor. The Sensor sends a paper present signal to the
MCU PWB. When the last sheet of paper is fed out of the Paper Tray, the No Paper
Actuator drops through a cutout in the Bottom Plate. The Actuator then blocks the
Sensor, and the Sensor sends a no paper signal to the MCU PWB.

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14. Paper Level Sensors 3, 4, and 5

Monitors whether or not a Paper Tray is installed. Installing the Tray pushes the Link
Stopper out, which in turn lowers the Feed Roll and moves the Level Sensor
Actuator tab away from the Sensor window.

Mechanical Drive

Mechanical Drive is a term used to describe both the rotation of the HCF Feed Motor and
the action of the gears and rollers used to transmit motor rotation to the drive rolls within
the High Capacity Feeder. The purpose of Mechanical Drive within the High Capacity
Feeder is to provide the mechanical energy needed to drive a sheet of paper from a High
Capacity Feeder tray and into the registration area of the base engine. The three Lift
Motors provide a secondary mechanical drive for the HCF. Each Lift Motor raises the
Bottom Plate of the associated paper tray so the paper contains the Feed Rolls.

Drive for High Capacity Feeder

The HCF PWB controls the HCF Feed Motor. The Drive Belt connects the Motor to the
Drive Pulley. The Drive Pulley transmits HCF Feed Motor drive to the three HCF feeder

assemblies. Each feeder assembly has a unique drive path, with the same end goal of
driving a sheet of paper out of a paper tray.

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Drive for Tray 3

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

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Mechanical Drive Tray 3 Components

The Mechanical Drive for Tray 3 of the HCF is made up of two motors along with
associated gears that transmit the drive to the various Tray 3 paper transport rolls.

1. Feed Motor

Provides the mechanical drive for Tray 3 paper feed.

2. HCF Drive Belt

Transmits Feed Motor drive to the HCF Drive Pulley.

3. HCF Drive Pulley

Transmits Feed Motor drive to the HCF Drive Gear 1.

4. HCF Drive Gear 1

Transmits Feed Motor drive to Tray 3 Drive Gear.

5. Tray 3 Feed Clutch

When actuated by the HCF PWB, the Clutch transmits drive to the Tray 3 Feed Roll,
to the Tray 3 Retard Gear, and to the Drive Transmission Gear.

6. Tray 3 Retard Gear

Rotates Tray 3 Retard Roll.

7. Drive Transmission Gear

Transmits drive to the Tray 3 Take Away Gear.

8. Tray 3 Take Away Gear

Rotates Tray 3 Take Away Roll.

9. Lift Motor 3

Raises the paper tray in Feeder 3.

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Drive for Tray 4

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

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Lift Motor Operation for Tray 4

The Tray 4 Lift Motor rotates the Bottom Plate Lift Pulley. Two cables are attached to each
end of the Pulley. The other ends of the cables are attached to the four corners of the
bottom plate. When the Motor rotates the Pulley, the cables wrap around the Pulley and
raise the bottom plate.

Mechanical Drive Tray 4 Components

The Mechanical Drive for Tray 4 of the HCF is made up of two motors along with
associated gears that transmit the motor drive to the various Tray 4 paper transport rolls.

1. Feed Motor

Provides the mechanical drive for Tray 4 paper feed.

2. HCF Drive Belt

Transmits Feed Motor drive to the HCF Drive Pulley.

3. HCF Drive Pulley

Transmits Feed Motor drive to the Tray 4 Drive Gear 1.

4. Tray 4 Drive Gear 1

Transmits Feed Motor drive to the Tray 4 Drive Gear 2.

5. Tray 4 Drive Gear 2

Transmits Feed Motor drive to the Tray 4 Take Away Gear and to the Tray 4 Feed
Clutch.

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6. Tray 4 Feed Clutch

When actuated by the HCF PWB, the Clutch transmits drive to the Tray 4 Feed Roll
and to the Tray 4 Retard Gear.

7. Tray 4 Retard Gear

Rotates Tray 4 Retard Roll.

8. Tray 4 Take Away Gear

Rotates Tray 4 Take Away Roll.

9. Lift Motor 4

Raises the paper tray in Feeder 4.

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Drive for Tray 5

The HCF PWB switches on the Feed Motor. The HCF Drive Belt transmits drive from the
Feed Motor to HCF Drive Transmission Gear 1. Gear 1 transmits drive to HCF Drive
Transmission Gear 2. HCF Drive Transmission Gear 1 also transmits drive to Tray 5 Drive
Gear, which transmits drive to Tray 5 Take Away Gear. HCF Drive Transmission Gear 2
transmits drive to Tray 5 Feed Clutch. When the HCF PWB actuates Tray 5 Feed Clutch,
the Clutch transmits drive to the Tray 5 Feed Roll and to the Retard Roll.

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Lift Motor Operation for Tray 5

The Tray 5 Lift Motor rotates the Bottom Plate Lift Pulley. Two cables are attached to each
end of the Pulley. The other ends of the cables are attached to the four corners of the
bottom plate. When the Motor rotates the Pulley, the cables wrap around the Pulley and
raise the bottom plate.

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Mechanical Drive Tray 5 Components

The Mechanical Drive for Tray 5 of the HCF is made up of two motors along with
associated gears that transmit the motor drive to the various Tray 5 paper transport rolls.

1. Feed Motor

Provides the mechanical drive for Tray 5 paper feed.

2. HCF Drive Belt

Transmits Feed Motor drive to the HCF Drive Pulley.

3. HCF Drive Pulley

Transmits Feed Motor drive to the HCF Drive Transmission Gear 1.

4. HCF Drive Transmission Gear 1

Transmits Feed Motor drive to the HCF Drive Transmission Gear 2 and to the Tray 5
Drive Gear.

5. Tray 5 Drive Gear

Transmits Feed Motor drive to the Tray 5 Take Away Gear.

6. HCF Drive Transmission Gear 2

Transmits Feed Motor drive to the Tray 5 Feed Clutch.

7. Tray 5 Feed Clutch

When actuated by the HCF PWB, the Clutch transmits drive to the Tray 5 Feed Roll
and to the Tray 5 Retard Gear.

8. Tray 5 Retard Gear

Rotates Tray 5 Retard Roll.

9. Tray 5 Take Away Gear

Rotates Tray 5 Take Away Roll.

10. Lift Motor 5

Raises the paper tray in Feeder 5.

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High Capacity Feeder Paper Path

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

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Feed from Tray 3

At the start of a print cycle the Tray 3 Nudger Roll moves a sheet of paper into Tray 3
Feed Roll. The Feed Roll moves a single sheet of paper out of Tray 3 and toward the Tray
2 Take Away Roll in the base engine. The Tray 3 Retard Roll makes sure that only one
sheet of paper is fed. As the sheet of paper is driven to the Tray 2 Take Away Roll it
actuates the Tray 2 Take Away Sensor, notifying the MCU PWB logic that the paper has
arrived. The Tray 2 Take Away Roll drives the sheet into Tray 1 Take Away Rolls. Tray 1
Take Away Rolls drive the sheet of paper into the Registration Roll. After that, the sheet
continues along the printer paper path until the sheet of paper, complete with fused
image, is driven into an output tray.

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Tray 3 Paper Path Components

The HCF Tray 3 Paper Path is made up of a number of transport rolls and paper sensors.

1. Tray 3 Assembly

Holds plain paper of various sizes. Slides into the top feeder, Feeder 3, of the High
Capacity Feeder.

2. Tray 3 Lift Motor

Raises the tray bottom plate so the paper contacts the Feed Roll.

3. Tray 3 No Paper Sensor

Monitors the level of paper in Tray 3.

4. Tray 3 Paper Size Sensor

Monitors the size of paper loaded into Tray 3.

5. Tray 3 Feed Clutch

Transmits HCF Motor drive to the Tray 3 Feed Roll and Nudger Roll.

6. Tray 3 Nudger Roll

Drives the top sheet of paper into the Feed Roll.

7. Tray 3 Fe e d Roll

Drives the top sheet of paper out of Tray 3 and into the Tray 2 Take Away Roll area of
the base engine.

8. Tray 2 Take Away Sensor

Monitors paper travel from the HCF into the base engine.

9. Tray 2 Take Away Roll

Drives the sheet of paper into the base engine Tray 1 Take Away Rolls.

10. Tray 1 Take Away Roll

Part of the base engine. Drives the sheet of paper into the printer Registration Rolls.

Feed from Tray 4

At the start of a print cycle the Tray 4 Nudger Roll moves a sheet of paper into Tray 4
Feed Roll. The Feed Roll moves a single sheet of paper out of Tray 4 and toward the Tray
4 Take Away Roll. The Tray 4 Retard Roll makes sure that only one sheet of paper is fed.
Tray 4 Take Away Roll drives the paper into Tray 3 Take Away Roll. As the sheet of paper
is driven to the Tray 3 Take Away Roll it actuates the Tray 3 Take Away Sensor, notifying
the MCU PWB logic that the paper has arrived. The Tray 3 Take Away Roll drives the
sheet of paper to the Tray 2 Take Away Roll. As the sheet of paper is driven into the Take
2 Take Away Roll it actuates the Tray 2 Take Away Sensor, notifying the MCU PWB logic
that the paper has arrived. The Tray 2 Take Away Roll drives the sheet into Tray 1 Take
Away Rolls. Tray 1 Take Away Rolls drive the sheet of paper into the Registration Roll.
After that, the sheet continues along the printer paper path until the sheet of paper,
complete with fused image, is driven into an output tray.

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Tray 4 Paper Path Components

The HCF Tray 4 Paper Path is made up of a number of transport rolls and paper sensors.

1. Tray 4 Assembly

Holds plain paper of various sizes. Slides into the bottom left feeder, Feeder 4, of the
High Capacity Feeder.

2. Tray 4 Lift Motor

Raises the tray bottom plate so the paper contacts the Feed Roll.

3. Tray 4 No Paper Sensor

Monitors the level of paper in Tray 4.

4. Tray 4 Paper Size Sensor

Monitors the size of paper loaded into Tray 4.

5. Tray 4 Feed Clutch

Transmits HCF Motor drive to the Tray 4 Feed Roll and Nudger Roll.

6. Tray 4 Nudger Roll

Drives the top sheet of paper into the Feed Roll.

7. Tray 4 Fe e d Roll

Drives the top sheet of paper out of Tray 4 and into the Tray 4 Take Away Roll.

8. Tray 4 Take Away Roll

Drives the sheet of paper out of Feeder 4 and into Tray 3 Take Away Roll.

9. Tray 3 Take Away Sensor

Monitors paper travel from the Tray 4 to Tray 3 Take Away Roll.

10. Tray 3 Take Away Roll

Drives the sheet of paper into the Tray 2 Take Away Roll area of the base engine.

11. Tray 2 Take Away Sensor

Monitors paper travel from the HCF into the base engine.

12. Tray 2 Take Away Roll

Drives the sheet of paper into the printer Registration Rolls.

13. Tray 1 Take Away Roll

Part of the base engine. Drives the sheet of paper into the printer Registration Rolls.

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Feed from Tray 5

At the start of a print cycle the Tray 5 Nudger Roll moves a sheet of paper into Tray 5
Feed Roll. The Feed Roll moves a single sheet of paper out of Tray 5 and toward the Tray
5 Take Away Roll. The Tray 5 Retard Roll makes sure that only one sheet of paper is fed.
Tray 5 Take Away Roll drives the paper into Tray 4 Take Away Roll. As the sheet of paper
is driven to the Tray 4 Take Away Roll it actuates the Tray 4 Take Away Sensor, notifying
the MCU PWB logic that the paper has left Take Away Roll 5. Tray 4 Take Away Roll
drives the paper into Tray 3 Take Away Roll. As the sheet of paper is driven to the Tray 3
Take Away Roll it actuates the Tray 3 Take Away Sensor, notifying the MCU PWB logic
that the paper has arrived. The Tray 3 Take Away Roll drives the sheet of paper to the
Tray 2 Take Away Roll. As the sheet of paper is driven into the Take 2 Take Away Roll it
actuates the Tray 2 Take Away Sensor, notifying the MCU PWB logic that the paper has
arrived. The Tray 2 Take Away Roll drives the sheet into Tray 1 Take Away Rolls. Tray 1
Take Away Rolls drive the sheet of paper into the Registration Roll. After that, the sheet
continues along the printer paper path until the sheet of paper, complete with fused
image, is driven into an output tray.

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Tray 5 Paper Path Components

The HCF Tray 5 Paper Path is made up of a number of transport rolls and paper sensors.

1. Tray 5 Assembly

Holds plain paper of various sizes. Slides into the bottom right feeder, Feeder 5, of
the High Capacity Feeder.

2. Tray 5 Lift Motor

Raises the tray bottom plate so the paper contacts the Feed Roll.

3. Tray 5 No Paper Sensor

Monitors the level of paper in Tray 5.

4. Tray 5 Paper Size Sensor

Monitors the size of paper loaded into Tray 5.

5. Tray 5 Feed Clutch

Transmits HCF Motor drive to the Tray 5 Feed Roll and Nudger Roll.

6. Tray 5 Nudger Roll

Drives the top sheet of paper into the Feed Roll.

7. Tray 5 Fe e d Roll

Drives the top sheet of paper out of Tray 5 and into the Tray 5 Take Away Roll.

8. Tray 4 Take Away Sensor

Monitors paper travel from the Tray 5 Take Away Roll to Tray 3 Take Away Roll.

9. Tray 4 Take Away Roll

Drives the sheet of paper out of Feeder 4 and into Tray 3 Take Away Roll.

10. Tray 3 Take Away Sensor

Monitors paper travel from the Tray 4 Take Away Roll to Tray 3 Take Away Roll.

11. Tray 3 Take Away Roll

Drives the sheet of paper into the Tray 2 Take Away Roll area of the base engine.

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12. Tray 2 Take Away Sensor

Monitors paper travel from the HCF into the base engine.

13. Tray 2 Take Away Roll

Drives the sheet of paper into the printer Registration Rolls.

14. Tray 1 Take Away Roll

Part of the base engine. Drives the sheet of paper into the printer Registration Rolls.

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High Capacity Feeder General Specifications

Category Specification

Configuration Customer installed option. The base engine sits on top of the

High Capacity Feeder. The HCF has three paper trays:
Tray 3 - upper tray.
Tray 4 - lower left tray.
Tray 5 - lower right tray

Paper feed The HCF feeds Letter (LEF), A4 (LEF), Executive (LEF), and

B5 (LEF)

Power requirements The printer provides all of the High Capacity Feeder power

requirements; +5VDC and +24VDC.

HCF noise level Standby, with all trays closed: 58db

Printing: 70dB

Size and weight Height: 426 mm / 16.7 inches

Width: 520 mm / 20.4 inches
Depth: 490 mm / 19.2 inches
Weight: 35kg /77 lbs

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Glossary of Terms, Acronyms, and AbbreviationsAcronyms, and Abbreviations

A-

AC Alternating Current
AC Line Voltage The AC voltage level at the AC wall outlet, such as 110VAC or

220VAC
Actuated A device, such as a switch or motor, that is switched on
Actuator Mechanical device used to toggle a switch or a sensor
Aux Auxiliary

B-

Base Engine The IOT without options or Controller PWB installed
BCR Bias Charge Roll
BTR Bias Transfer Roll

C-

°C Degrees Celsius. °C = 0.55 (°F - 32)
CCW Counterclockwise
Charge The negative voltage that the High Voltage Power Supply

applies to the surface of the drum
Continuity A resistance reading of approximately 0 ohms
Controller PWB The electrical interface between the printer MCU and the host

computer. See ESS and Controller Board.
Controller Board Synonym for Controller PWB, ESS, and ESS PWB
CL Close
CRU Customer Replaceable Unit, such as an EP Cartridge
CW Clockwise

D-

DC Direct Current
DB Signal name for the Developer Bias voltage
Deactuated A device, such as a switch or a motor, that is switched off
Develop The part of the print cycle where toner adheres to the latent

image on the drum
Developed image The visible image on the drum after going through

development
Diagnostics The mode of operation that lets you check various

components, such as sensors, solenoids, and motors
DPI Dots Per Inch. The measure of image resolution
DRAM Dynamic Random Access Memory
Drum The Xerographic photoreceptor
DTS Signal name for the Detack Saw voltage
Duplex Printing on both sides of a single sheet of paper

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E-

Earth Electrical ground
Earth Plate Electrical ground plate or ground strap
Engine Board The board that controls the operation of the printer, synonym

for MCU and MCU PWB

EP Cartridge A sealed assembly that houses the xerographic drum, major

xerographic components, and a finite supply of dry ink. The
EP Cartridge is a CRU.

Error Code A unique set of letters and numbers that the printer control

system displays to indicate that a problem exists in a specific
area of the printer

ESS Electronic Subsystem. Synonym for the Controller PWB and

Controller Board

Exposure The action of the laser beam striking and discharging select

areas of the electrically charged surface of the drum

F-

°F Degrees Fahrenheit. °F = (°C x 1.8) + 32
Face Down Tray Standard output tray for the printer. Delivers paper face down.
Factory default An operational value or parameter that is set at the time of

equipment manufacture
FG Frame Ground
FRU Field Replaceable Unit
Fuser The printer subsystem that uses heat and pressure to

permanently adhere, or fuse, a transferred toner image to a

sheet of paper

G-

Ground Electrical ground

H-

Harness A bundle of wires that form a single unit and generally

terminated with connectors at both ends
HCF High Capacity Feeder
High (signal) A signal voltage that is equal to or almost equal to the base

voltage; such as +5VDC or +24VDC.
HS High Speed
HVPS High Voltage Power Supply

I-

Image density The relative darkness of the toner image on a sheet of paper
Image development Toner turning the latent image into a visible image.
Image fusing Using heat and pressure to permanently adhere the toner

image to a sheet of paper
Image transfer Moving the developed image from the surface of the drum to

the surface of a sheet of paper
Input test Diagnostic routine that is used to test switches and sensors

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Interlock Interlock switch or circuit. Used as a safety measure to

remove voltage from circuits whenever the printer covers are
open or printer assemblies are not in position

IOT Image Output Terminal. Acronym that is sometimes used in

schematic diagrams to describe the base print engine

J-

J Jack. A female electrical connector

L-

Laser Refers to either the Laser Diode Assembly or to the laser

beam

Laser beam path The path the laser beam takes, through lenses and mirrors,

from the Laser Diode to the surface of the drum

Laser Diode Semiconductor device that generates the laser beam used in

the Printhead

Latent image The invisible, electrical image remaining on the surface of the

drum after exposure
LD Laser Diode
LCD Liquid Crystal Display
LED Light Emitting Diode
L/H Left Hand
Low (signal) A signal voltage that is significantly lower than the base

voltage
LS Low Speed
LVPS Low Voltage Power Supply

M-

MCU Machine Control Unit. The board that controls the operation

of the printer, synonym for Engine Board and MCU PWB
MBX Mailbox
MOT Motor

N-

NC No Connection
NVRAM Non-Volatile Random Access Memory

O-

OHP Transparency print media
OP Open
Output test Diagnostic routine used to switch on motors, solenoids, and

clutches

P-

P Plug. A male electrical connector

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Paper jam A sheet of paper stops at a point along the paper path
Paper path The path a sheet of paper takes from the paper feeder to the

output tray
P/H Paper Handling
P/J Plug and Jack. Electrical connectors as a unit
PL Parts List
PPM Pages Per Minute or Prints Per Minute
Pre-Reg Pre-Registration
Print cycle The printer creating and delivering one finished print
Print surface The side of a sheet of paper that receives the printed image
PS Power Supply
PWB Printed Wiring Board (sometimes referred to as PCB or

Printed Circuit Board)

R

R Right
Reg or Regi Registration
R/H Right Hand
ROM Read Only Memory
RTN Return

S

Sensor A device used to monitor a function or operation, such as

paper travel along the paper path
SG Signal Ground
Signal name A name assigned to a wire, indicating the purpose of the wire

and/or the voltage carried by that wire
SNR Sensor
SOL Solenoid
SOS Start Of Scan
STA Status
STS Soft Touch Sensor
SW Switch

T

Te mp Tem pe ra tu re
Test Print A grid pattern print that is generated by the MCU
Test Print Mode The mode of operation that lets you generate a test print
Toggle To switch between two states, such as on and off or up and

down
Toner The dry ink that is used to create the visible image. Toner is

stored in the EP Cartridge
Transfer Moving the toner image from the surface of the drum to the

surface of a sheet of paper

V-

VVolts
VAC Volts - Alternating Current

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VDC Volts - Direct Current

W-

Warm-up The time it takes the printer to go from main power ON to

Ready to Print

Wire Harness A bundle of wires that form a single unit and are generally

terminated with connectors at both ends

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2. Diagnostic Information

Start

CAUTION: Remove the power cord from the printer and option or wall outlet before you

connect or disconnect any cable or electronic board or assembly for personal safety and
to prevent damage to the printer or option. Make sure your fingers are not under the
printer when you lift or set the printer down.

Use the appropriate error code table, symptom table, error code service checks and
symptom service checks in the following table to determine the corrective action
necessary to repair the failing option.

Option Tables and Service Checks

Envelope Feeder “Envelope Feeder Error Code Table” on page 2-2

“Envelope Feeder Symptom Table” on page 2-2

“Envelope Feeder Error Code Service Checks” on page 2-3

“Envelope Feeder Symptom Service Checks” on page 2-7

Duplex “Duplex Error Code Table” on page 2-8

“Duplex Symptom Table” on page 2-9

“Duplex Error Code Service Checks” on page 2-9

“Duplex Symptom Service Checks” on page 2-18

Mailbox “Mailbox Error Code Table” on page 2-19

“Mailbox Symptom Table” on page 2-20

“Mailbox Error Code Service Checks” on page 2-20

“Mailbox Symptom Service Checks” on page 2-30

High Capacity Feeder “High Capacity Feeder Error Code Table” on page 2-32

“High Capacity Feeder Symptom Table” on page 2-33

“High Capacity Feeder Error Code Service Checks” on page 2-33

“High Capacity Feeder Symptom Service Checks” on page 2-52

Diagnostic Information 2-1

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Envelope Feeder

Envelope Feeder Error Code Table

This table lists all of the Envelope Unit related Error Codes that are generated by the
printer Engine Board (MCU PWB).

Note: Depending on the level of firmware on your printer Engine Board (MCU PWB)
some codes listed may be invalid, some codes generated by the MCU may not appear in
this table, and Error and Message Code text presented may differ slightly from the Error
and Message Code text that is actually generated by your MCU.

Error Code Description

271 Logic Control on the MCU PWB sensed that the Envelope Feed Sensor did not

actuate within the specified time after the Envelope Feed Clutch was actuated.
Go to “Error Code 271” on page 2-3.

272 Logic Control on the MCU PWB sensed the Envelope Feed Sensor was

actuated while the printer was in standby. Go to “Error Code 272” on

page 2-4.

273 Logic Control on the MCU PWB sensed that the Tray 2 Take Away Sensor did

not actuate within the specified time after the Envelope Feed Clutch was
actuated. Go to “Error Code 273” on page 2-4.

255 Logic Control on the MCU PWB sensed that the Registration Sensor did not

actuate within the specified time after the Envelope Feed Clutch was actuated.
Go to “Error Code 255” on page 2-6.

Envelope Feeder Symptom Table

Symptom Action

Inoperative Envelope Feeder Go to “Inoperative Envelope Feeder” on page 2-7.

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Envelope Feeder Error Code Service Checks

Error Code 271

There is a paper jam between the Envelope Tray and the Envelope
Feed Sensor.

Logic Control on the MCU PWB sensed that the Envelope Feed Sensor did not actuate
within the specified time after the Envelope Feed Clutch was actuated.

Step Actions and Questions Yes No

1 PAPER PATH INSPECTION

Inspect the paper path for paper scraps that may cause a
paper jam.

Is the paper path free of paper scraps?

2 PAPER INSPECTION

Inspect the envelopes that are loaded in the Envelope Tray.

Are the envelopes that are loaded in the Envelope Tray
wrinkled or damaged?

3 ENVELOPE FEED TEST

Enter Diagnostic Mode, Input Tray Test, Envelope.
Load envelopes and select “Single.”
A single envelope should feed and exit into the standard bin.

Did a single envelope feed?

4 +24VDC CHECK

Measure the voltage between P/J700-7 and P/J700-12 on the
Envelope PWB.

Is there +24VDC between P/J700-7 and P/J700-12?

Go to step 2 Clean the

paper path

Replace the
envelopes
with new
envelopes

Problem
solved

Replace the
Envelope
Feeder Option

Go to step 3

Go to step 4

Use the Block
Diagrams in
the printer
service
manual to
troubleshoot a
loss of
+24VDC from
the MCU
PWB

5 The following printer FRUs and areas are associated with this

specific problem. One or more of these FRUs or areas may
have failed partially or completely. Replace each FRU or
troubleshoot each area, one at a time, until you isolate and
solve the problem.

• Envelope Feeder Option - Go to “Envelope Feeder” on

page 2-2.

• Printer MCU PWB - Go to the Printer Service Manual for the

Removal and Replacement Procedure.

• Wiring and connectors linking the FRUs

Diagnostic Information 2-3

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Error Code 272

There is a problem with the Envelope Feed Sensor.

Logic Control on the MCU PWB sensed the Envelope Feed Sensor was actuated while
the printer was in standby.

Step Actions and Questions Yes No

1 ENVELOPE FEED SENSOR INSPECTION

Inspect the Envelope Feed Sensor for paper scraps that may
be actuating the sensor.

Is the Sensor free of paper scraps?

2 ENVELOPE FEED TEST

Enter Diagnostic Mode, Input Tray Test, Envelope.
Load envelopes and select “Single.”
A single envelope should feed and exit into the standard bin.

Did a single envelope feed?

3 The following printer FRUs and areas are associated with this

specific problem. One or more of these FRUs or areas may
have failed partially or completely. Replace each FRU or
troubleshoot each area listed, one at a time, until you isolate
and solve the problem.

• Envelope Feeder Option - Go to “Envelope Feeder” on

page 4-2.

• Printer MCU PWB - Go to the Printer Service Manual for the

Removal and Replacement Procedure.

• Wiring and connectors linking the FRUs

Error Code 273

Go to step 2 Remove the

paper scraps

Go to step 3 Replace the

Envelope
Feeder Option

There is a paper jam between the Envelope Feeder and the
Tray 2 Ta ke Away Sensor.

Logic Control on the MCU PWB sensed that the Tray 2 Take Away Sensor did not actuate
within the specified time after the Envelope Feed Clutch was actuated.

Step Actions and Questions Yes No

1 PAPER PATH INSPECTION

Inspect the paper path for paper scraps that may cause a
paper jam.

Is the paper path free of paper scraps?

2-4 Service Manual

Go to step 2 Clean the

paper path

4025 Options

Step Actions and Questions Yes No

2 PAPER INSPECTION

Inspect the envelopes that are loaded in the Envelope Tray.

Are the envelopes that are loaded in the Envelope Tray
wrinkled or damaged?

3 ENVELOPE FEED TEST

Enter Diagnostic Mode, Input Tray Test, Envelope.
Load envelopes and select “Single.”
A single envelope should feed and exit into the standard bin.

Did a single envelope feed?

4 +24VDC CHECK

Measure the voltage between P/J700-7 and P/J700-12 on the
Envelope PWB.

Is there +24VDC between P/J700-7 and P/J700-12?

5 The following printer FRUs and areas are associated with this

specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using the steps in this service check, replace each
FRU or troubleshoot each area, one at a time, until you isolate
and solve the problem.

• Wiring and connectors linking the FRUs

• Envelope Feeder Option - Go to “Envelope Feeder” on

page 2-2.

• MCU PWB - Go to the Printer Service Manual for the

Removal and Replacement Procedure.

• I/O PWB - Go to the Printer Service Manual for the Removal

and Replacement Procedure.

Replace the
envelopes
with new
envelopes

Problem
solved

Go to step 5 Use the Block

Go to step 3

Go to step 4

Diagrams in
the printer
service
manual to
troubleshoot a
loss of
+24VDC from
the MCU
PWB.

Diagnostic Information 2-5

4025 Options

Error Code 255

There is a paper jam between the Envelope Feeder and the
Registration Sensor.

Logic Control on the MCU PWB sensed that the Registration Sensor did not actuate
within the specified time after the Envelope Feed Clutch was actuated.

Step Actions and Questions Yes No

1 PAPER PATH INSPECTION

Inspect the paper path for paper scraps that may cause a
paper jam.

Is the paper path free of paper scraps?

2 PAPER INSPECTION

Inspect the envelopes that are loaded in the Envelope Tray.

Are the envelopes that are loaded in the Envelope Tray
wrinkled or damaged?

3 REGISTRATION SENSOR TEST

Enter Diagnostic Mode and select Sensor Test- Registration
Sensor.

Open the Left Upper Cover and insert, then remove, a sheet of
paper into the Registration Sensor.

Does the Control Panel LCD change between OP and CL
as you insert then remove the paper?

4 TRAY 2 TAKE AWAY SENSOR TEST

1. Enter Diagnostic Mode.

2. Insert, then remove, a sheet of paper into the Tray 2 Take Away
Sensor.

Does the Control Panel LCD change between OP and CL
as you insert then remove the paper?

Go to step 2 Clean the

paper path

Replace the
envelopes
with new
envelopes

Go to step 4 Replace the

Go to step 5 Replace the

Go to step 3

Envelope
Feeder Option

Tray 2 Ta k e
Away Sensor.
Go to the
Printer
Service
Manual for the
Removal and
Replacement
Procedure.

5 +24VDC CHECK

Measure the voltage between P/J700-7 and P/J700-12 on the
Envelope PWB.

Is there +24VDC between P/J700-7 and P/J700-12?

2-6 Service Manual

Go to step 6 Use the Block

Diagrams in
the printer
service
Manual to
troubleshoot a
loss of
+24VDC from
the MCU
PWB

4025 Options

Step Actions and Questions Yes No

6 The following printer FRUs and areas are associated with this

specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using the steps in this chart, replace each FRU or
troubleshoot each area, one at a time, until you isolate and
solve the problem.

• Wiring and connectors linking the FRUs

• Envelope Feeder Option - Go to “Envelope Feeder” on

page 2-2.

• MCU PWB - Go to the Printer Service Manual for the

Removal and Replacement Procedure.

• I/O PWB - Go to the Printer Service Manual for the Removal

and Replacement Procedure.

Envelope Feeder Symptom Service Checks

Inoperative Envelope Feeder

The Envelope Feeder does not function, the Envelope Motor does not switch on, and the
problem is not identified by a displayed Error Code.

Step Actions and Questions Yes No

1 ENVELOPE FEEDER CONNECTION INSPECTION

Remove the Envelope Feeder from the Base Engine.
Inspect the P/J that connects the Feeder to the Base Engine.

Is the P/J free of damage, loose wires, and damaged or
missing pins?

2 ENVELOPE FEED TEST

Enter Diagnostic Mode, Input Tray Test, Envelope.
Load envelopes and select “Single.”
A single envelope should feed and exit into the standard bin.

Did a single envelope feed?

3 +24VDC CHECK

Measure the voltage between P/J700-7 and P/J700-12 on the
Envelope PWB.

Is there +24VDC between P/J700-7 and P/J700-12?

Go to step 2 Replace or

repair the
connector

Problem
solved

Replace the
Envelope
Feeder Option

Go to step 3

Use the Block
Diagrams in
the printer
service
Manual to
troubleshoot a
loss of
+24VDC from
the MCU
PWB

Diagnostic Information 2-7

4025 Options

Step Actions and Questions Yes No

4 The following printer FRUs and areas are associated with this

specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using the steps in this chart, replace each FRU or
troubleshoot each area, one at a time, until you isolate and
solve the problem.

• Wiring and connectors linking the FRUs

Duplex

Duplex Error Code Table

This table lists all of the Duplex Unit related Error Codes that are generated by the printer
Engine Board (MCU PWB).

Note: Depending on the level of firmware on your printer Engine Board (MCU PWB)
some codes listed may be invalid, some codes generated by the MCU may not appear in
this table, and Error and Message Code text presented may differ slightly from the Error
and Message Code text that is actually generated by your MCU.

Error Code Description

207 Logic control on the MCU PWB sensed that the Duplex Exit Sensor did not

actuate within the specified time after the Face Up Exit Sensor was actuated.
Go to “Error Code 207” on page 2-9.

231 Logic control on the MCU PWB sensed that the Duplex Exit Sensor did not

actuate within the specified time after the Face Up Exit Sensor was actuated.
Go to “Error Code 231” on page 2-12.

232 Logic control on the MCU PWB sensed that the Duplex Wait Sensor did not

actuate within the specified time after the Face Up Exit Sensor was actuated.
Go to “Error Code 232” on page 2-13.

233 Logic control on the MCU PWB sensed that the Duplex Exit Sensor was on

while the printer was in standby. Go to “Error Code 233” on page 2-14.

234 Logic control on the MCU PWB sensed that the Duplex Exit Sensor was on

while the printer was in standby. Go to “Error Code 234” on page 2-15.

260 Logic control on the MCU PWB sensed that the Registration Sensor did not

actuate within the specified time after the Duplex Wait Clutch was actuated. Go
to “Error Code 260” on page 2-16.

997 Logic control sensed that the installed Duplex is not compatible with the printer.

Go to “Error Code 997” on page 2-17.

2-8 Service Manual

4025 Options

Duplex Symptom Table

Symptom Action

Inoperative Duplex Unit Go to “Inoperative Duplex Unit” on page 2-18

Duplex Printing Modes

Mode Specification

One Sheet Batch

Page2 - Page1

Two Sheet Batch

Page2 - Page4- Page1­Page3

Three Sheet Batch

Page 2 - Page 4- Page 1­Page 6- Page 3- Page 5

1. The printer prints on one side of a sheet of paper.

2. The Duplex Unit returns the printed sheet to the printer.

3. The printer prints on the other side of the sheet of paper.

4. The printer transports the duplex printed sheet to the output tray.

5. The printer prints on one side of a sheet of paper.

6. The Duplex Unit holds that sheet, while the printer prints on one side of a
second sheet of paper.

7. The Duplex Unit returns the first sheet to the printer.

8. The printer prints on the second side of the first sheet.

9. The Duplex Unit then returns the second sheet to the printer.

10.The printer transports the duplex printed first sheet to the output tray.

11.The printer prints on the second side of the second sheet.

12.The printer transports the duplex printed second sheet to the output tray.

13.This process repeats for additional prints.

14.The printer prints on one side of a sheet of paper.

15.The Duplex Unit holds that sheet, while the printer prints on one side of a
second sheet of paper.

16.The Duplex Unit returns the first sheet to the printer.

17.The printer prints on the second side of the first sheet.

18.The printer prints on the second side of a third sheet.

19.The Duplex Unit holds the third sheet.

20.The Duplex Unit returns the second sheet to the printer.

21.The printer prints on the second side of the second sheet.

22.The Duplex Unit returns the third sheet to the printer.

23.The printer prints on the second side of the third sheet.

Duplex Error Code Service Checks

Error Code 207

There is a paper jam at the Duplex Exit Sensor.

Logic Control on the MCU PWB sensed that the Duplex Exit Sensor did not actuate within
the specified time after the Face Up Exit Sensor was actuated.

Diagnostic Information 2-9

4025 Options

Step Actions and Questions Yes No

1 PAPER INSPECTION

Inspect the paper that is loaded in the paper cassette.

Is the paper that is loaded in the cassette wrinkled or
damaged?

2 PAPER PATH INSPECTION

Open the Duplex Unit and inspect the paper path between the
Fuser and the Duplex for paper scraps or foreign objects that
could cause a paper jam.

Is the paper path clear?

3 FACE UP EXIT SENSOR TEST

Enter Diagnostic Mode and select Face Up Exit Sensor.
Insert, then remove, a sheet of paper into the Face Up Exit

Sensor

Does the Control Panel LCD change between OP and CL
as you insert then remove the paper?

4 DUPLEX UNIT EXIT SENSOR TEST

Enter Diagnostic Mode, select Duplex Exit Sensor.
Insert, then remove, a sheet of paper into the Duplex Exit

Sensor.

Does the Control Panel LCD change between OP and CL
as you insert then remove the paper?

Replace the
paper with
new paper

Go to step 3 Clear the

Go to step 4 Replace the

Go to step 5 Replace the

Go to step 2

paper path

Face Up Exit
Sensor. Go to
the printer
service
manual for the
Removal and
Replacement
Procedure.

“Duplex Exit
Sensor” on
page 4-10)

5 INVERTER CLUTCH TEST

Enter Diagnostic Mode, select Duplex Quick Test.
You can see and hear the clutch “pick” (energize). The Exit Roll

shaft rotates when the clutch engages.

Does the Wait Clutch actuate and does the Exit Roll rotate
during the Quick Test?

6 DUPLEX EXIT GATE SOLENOID TEST

Enter Diagnostic Mode, select Duplex Quick Test.
With the Duplex top cover removed, you can see the Exit Gate

solenoid “pick” (energize) during the Quick Test.

Does the Exit Gate Solenoid toggle the Exit Gate during
the Quick Test?

Go to step 6 Replace the

Exit Drive
Assembly. Go
to the printer
service
manual for the
Removal and
Replacement
Procedure.

Go to step 7 Replace the

“Duplex Exit
Gate
Solenoid” on
page 4-11

2-10 Service Manual

4025 Options

Step Actions and Questions Yes No

7 DUPLEX EXIT GATE INSPECTION

1. Open the Inner Chute.

2. Check the Duplex Exit Gate and Gate Spring.

Is the Duplex Exit Gate in place on the Inner Chute, is the
Gate unbroken, does it pivot freely on the Inner Chute, and
does it have a spring-action return?

8 DUPLEX PWB REPLACEMENT

Replace the “Duplex PWB and Bracket” on page 4-7.

Does the error code appear?

9 MCU PWB REPLACEMENT

Replace the printer Engine Board (MCU PWB). Go to the
Printer Service Manual for Removal and Replacement
Procedures

Does the error code appear?

10 I/O PWB REPLACEMENT

Replace the I/O PWB. Go to the printer service manual for the
Removal and Replacement Procedure.

Does the error code appear?

Go to step 8 Reinstall the

Exit Gate and
Spring or
replace the
Exit Gate and
Spring. Go to
the printer
service
manual for the
Removal and
Replacement
Procedure.

Go to step 9 Problem

solved

Go to step 10 Problem

solved

Go to step 11 Problem

solved

11 The following printer FRUs and areas are associated with this

specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using the steps in this service check, replace each
FRU or troubleshoot each area, one at a time, until you isolate
and solve the problem.

• Wiring and connectors linking the FRUs

• Fuser Drive Assembly - Go to the printer service manual for

the Removal and Replacement Procedure.

• Fuser Assembly - Go to the printer service manual for the

Removal and Replacement Procedure.

Diagnostic Information 2-11

4025 Options

Error Code 231

There is a paper jam at the Duplex Exit Sensor.

Logic Control on the MCU PWB sensed that the Duplex Exit Sensor did not actuate within
the specified time after the Face Up Exit Sensor was actuated.

Step Actions and Questions Yes No

1 PAPER INSPECTION

Inspect the paper that is loaded in the paper cassette.

Is the paper that is loaded in the cassette wrinkled or
damaged?

2 PAPER PATH INSPECTION

Observe the location of the last sheet of paper out of the
Duplex Unit.

Did the paper exit the Duplex Unit?

3 DUPLEX UNIT EXIT SENSOR TEST

Enter Diagnostic Mode, select Duplex Exit Sensor.
Insert, then remove, a sheet of paper into the Duplex Exit

Sensor.

Does the Control Panel LCD change between OP and CL
as you insert then remove the paper?

4 DUPLEX MOTOR TEST

Enter Diagnostic Mode, select Duplex Quick Test.

Does the Duplex Drive Motor run and do the gears of the
Drive Assembly rotate?

5 EXIT ROLL AND TRANSPORT ROLL CHECK

While running Diagnostic Mode - Duplex Quick Test observe
the Exit and Transport Rolls.

Do the Exit Roll and Transport Roll rotate?

Replace the
paper with
new paper

Go to step 3 Go to step 4

Replace the

“Duplex
PWB and
Bracket” on
page 4-7

Go to step 5 Replace the

Replace the

“Exit Roll
Belt” on
page 4-16

Go to step 2

Replace the

“Duplex Exit
Sensor” on
page 4-10

“Duplex
Drive
Assembly”
on page 4-9

Go to step 6

6 EXIT ROLL BELT REPLACEMENT

Replace the “Exit Roll Belt” on page 4-16.

Does the error code appear?

7 The following printer FRUs and areas are associated with this

specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using the steps in this service check, replace each
FRU or troubleshoot each area, one at a time, until you isolate
and solve the problem.

• Wiring and connectors linking the FRUs

• MCU PWB - Go to the Printer Service Manual for the

Removal and Replacement Procedure.

• I/O PWB - Go to the Printer Service Manual for the Removal

and Replacement Procedure.

2-12 Service Manual

Go to step 7 Problem

solved

4025 Options

Error Code 232

There is a paper jam between the Face Up Exit Sensor and
the Duplex Wait Sensor.

Logic Control on the MCU PWB sensed that the Duplex Wait Sensor did not actuate
within the specified time after the Face Up Exit Sensor was actuated.

Step Actions and Questions Yes No

1 PAPER INSPECTION

Inspect the paper that is loaded in the paper cassette.

Is the paper that is loaded in the cassette wrinkled or
damaged?

2 PAPER PATH INSPECTION

Open the Inner Chute and observe the location of the jammed
sheet of paper.

Did the paper actuate the Wait Sensor?

3 DUPLEX WAIT SENSOR TEST

Enter Diagnostic Mode, select Duplex Wait Sensor.
Insert, then remove, a sheet of paper into the Duplex Wait

Sensor.

Does the Control Panel LCD change between OP and CL
as you insert then remove the paper?

4 DUPLEX WAIT CLUTCH TEST

Enter Diagnostic Mode, select Duplex Quick Test.
You can hear and see the clutch “pick” (energize) and the Exit

Roll shaft rotate when the clutch engages.

Does the Wait Clutch actuate and does the Exit Roll rotate
during the Quick Test?

5 EXIT ROLL OBSERVATION

When performing step 4, does the Exit Roll drive the sheet
of paper into the Wait Sensor actuator?

Replace the
paper with
new paper

Go to step 3 Go to step 4

Replace the

“Duplex
PWB and
Bracket” on
page 4-7

Go to step 5 Replace the

Go to step 6 Replace the

Go to step 2

Replace the

“Duplex Wait
Sensor” on
page 4-14

“Duplex Wait
Clutch” on
page 4-8

“Exit Roll”
on page 4-12

6 MCU PWB REPLACEMENT

Replace the printer Engine Board (MCU PWB). Go to the
printer service manual for the Removal and Replacement
Procedure.

Does the error code appear?

7 The following printer FRUs and areas are associated with this

specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using the steps in this service check, replace each
FRU or troubleshoot each area, one at a time, until you isolate
and solve the problem.

• Wiring and connectors linking the FRUs

• I/O PWB - Go to the Printer Service Manual for the Removal

and Replacement Procedure.

Go to step 7 Problem

solved

Diagnostic Information 2-13

4025 Options

Error Code 233

There is a problem with the Duplex Exit Sensor.

Logic Control on the MCU PWB sensed that the Duplex Exit Sensor was on while the
printer was in standby.

Step Actions and Questions Yes No

1 DUPLEX EXIT SENSOR INSPECTION

Inspect the Duplex Exit Sensor for contamination or paper
scraps that may be actuating the sensor.

Is the Duplex Exit Sensor clean and free of paper scraps?

2 DUPLEX EXIT SENSOR INSPECTION

Inspect the Duplex Exit Sensor for damage, such as a broken
spring or actuator, that may have locked the Sensor in the on
position.

Is the sensor undamaged?

3 DUPLEX UNIT EXIT SENSOR TEST

Enter Diagnostic Mode, select Duplex Exit Sensor.
Insert, then remove, a sheet of paper into the Duplex Exit

Sensor.

Does the Control Panel LCD change between OP and CL
as you insert then remove the paper?

4 DUPLEX PWB REPLACEMENT

Replace the “Duplex PWB and Bracket” on page 4-7.

Does the error code appear?

5 MCU PWB REPLACEMENT

Replace the printer Engine Board (MCU PWB). Go to the
printer service manual for the Removal and Replacement
Procedure.

Does the error code appear?

Go to step 2 Clean or clear

paper scraps
from the
Sensor

Go to step 3 Replace the

“Duplex Exit
Sensor” on
page 4-10

Go to step 4 Replace the

“Duplex Exit
Sensor” on
page 4-10

Go to step 5 Problem

solved

Go to step 6 Problem

solved

6 I/O PWB REPLACEMENT

Replace the I/O PWB. Go to the printer service manual for the
Removal and Replacement Procedure.

Does the error code appear?

7 The following printer FRUs and areas are associated with this

specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using the steps in this service check, replace each
FRU or troubleshoot each area, one at a time, until you isolate
and solve the problem.

Wiring and connectors linking the FRUs

2-14 Service Manual

Go to step 7 Problem

solved

4025 Options

Error Code 234

There is a paper jam between the Duplex Wait Sensor and
the Registration Sensor.

Logic Control on the MCU PWB sensed that the Registration Sensor did not actuate
within the specified time after the Duplex Wait Clutch was actuated.

Step Actions and Questions Yes No

1 PAPER INSPECTION

Inspect the paper that is loaded in the paper cassette.

Is the paper that is loaded in the cassette wrinkled or
damaged?

2 PAPER PATH INSPECTION

Open the Duplex Unit and observe the location of the jammed
sheet of paper.

Is the paper sticking a few inches out of the bottom of the
Duplex Unit?

3 REGISTRATION SENSOR TEST

Enter Diagnostic Mode and select Sensor Test- Registration
Sensor.

Open the Left Upper Cover and insert, then remove, a sheet of
paper into the Registration Sensor.

Does the Control Panel LCD change between OP and CL
as you insert then remove the paper?

4 DUPLEX WAIT CLUTCH TEST

Enter Diagnostic Mode, select Duplex Quick Test.
You can hear and see the clutch “pick” (energize) and the Exit

Roll shaft rotate when the clutch engages.

Does the Wait Clutch actuate and does the Exit Roll rotate
during the Quick Test?

Replace the
paper with
new paper

Go to step 3 Go to step 4

Go to step 4 Replace the

Go to step 5 Replace the

Go to step 2

Registration
Sensor. Go to
the printer
service
manual for the
Removal and
Replacement
Procedure.

“Duplex
PWB and
Bracket” on
page 4-7

5 EXIT ROLL OBSERVATION

When performing step 4, does the Exit Roll drive the sheet
of paper into the Wait Sensor actuator?

6 MCU PWB REPLACEMENT

Replace the printer Engine Board (MCU PWB). Go to the
printer service manual for the Removal and Replacement
Procedure.

Does the error code appear?

Go to step 6 Replace the

“Exit Roll”
on page 4-12

Go to step 7 Problem

solved

Diagnostic Information 2-15

4025 Options

Step Actions and Questions Yes No

7 The following printer FRUs and areas are associated with this

specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using the steps in this service check, replace each
FRU or troubleshoot each area, one at a time, until you isolate
and solve the problem.

Wiring and connectors linking the FRUs

Error Code 260

There is a paper jam at the Duplex Exit Sensor.

Logic Control on the MCU PWB sensed that the Duplex Exit Sensor did not actuate within
the specified time after the Face Up Exit Sensor was actuated.

Step Actions and Questions Yes No

1 DUPLEX WAIT SENSOR INSPECTION

Inspect the Duplex Wait Sensor for contamination or paper
scraps that may be actuating the sensor.

Is the Duplex Wait Sensor clean and free of paper scraps?

2 DUPLEX WAIT SENSOR INSPECTION

Inspect the Duplex Wait Sensor for damage, such as a broken
spring or actuator, that may have locked the Sensor in the on
position.

Is the sensor undamaged?

3 DUPLEX WAIT SENSOR TEST

Enter Diagnostic Mode, select Duplex Wait Sensor.
Insert, then remove, a sheet of paper into the Duplex Wait

Sensor.

Does the Control Panel LCD change between OP and CL
as you insert then remove the paper?

4 DUPLEX PWB REPLACEMENT

Replace the “Duplex PWB and Bracket” on page 4-7.

Does the error code appear?

5 MCU PWB REPLACEMENT

Replace the printer Engine Board (MCU PWB). Go to the
printer service manual for the Removal and Replacement
Procedure.

Does the error code appear?

Go to step 2 Clean or clear

paper scraps
from the
Sensor

Go to step 3 Replace the

“Duplex Wait
Sensor” on
page 4-14

Go to step 4 Replace the

“Duplex Wait
Sensor” on
page 4-14

Go to step 5 Problem

solved

Go to step 6 Problem

solved

2-16 Service Manual

4025 Options

Step Actions and Questions Yes No

6 I/O PWB REPLACEMENT

Replace the I/O PWB. Go to the printer service manual for the
Removal and Replacement Procedure.

Does the error code appear?

7 The following printer FRUs and areas are associated with this

specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using the steps in this service check, replace each
FRU or troubleshoot each area, one at a time, until you isolate
and solve the problem.

Go to step 7 Problem

solved

• Wiring and connectors linking the FRUs

Error Code 997

Logic control sensed that the installed Duplex is not compatible with the printer.

Step Actions and Questions Yes No

1 DUPLEX INSPECTION

Inspect the Duplex Unit to make sure it is the correct
manufacture and model for the printer.

Is the Duplex Unit the correct manufacture and model for
this printer?

Go to step 2 Replace the

Duplex Unit
with a correct
one

2 RESET

Turn off the printer. Wait one minute, then turn on the printer.

Is the error code gone?

3 RESEAT

Disconnect then reconnect the Duplex from the printer.

Is the error code gone?

4 DUPLEX PWB

Replace the “Duplex PWB and Bracket” on page 4-7.

Is the error code gone?

5 MCU BOARD

Replace the printer Engine Board (MCU PWB). Go to the
Printer Service Manual for the Removal and Replacement
Procedure.

Is the error code gone?

Problem
solved

Problem
solved

Problem
solved

Problem
solved

Go to step 3

Go to step 4

Go to step 5

Go to step 6

Diagnostic Information 2-17

4025 Options

Step Actions and Questions Yes No

6 The following Duplex FRUs and areas are associated with this

specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem these steps, replace each FRU or troubleshoot each
area listed below, one at a time, until you isolate and solve the
problem.

• Wiring and connectors linking the FRUs.

Duplex Symptom Service Checks

Inoperative Duplex Unit

The Duplex Unit does not function, the Duplex Motor does not switch on, and the problem
is not identified by a displayed Error Code.

Step Actions and Questions Yes No

1 INTERFACE CABLE INSPECTION

Check the Duplex Interface Cable.

Is the cable firmly connected to the P/J at the rear of the
printer?

2 DUPLEX MODE TEST PRINT

Enter Diagnostic Mode, select Duplex Quick Test.
With the Duplex top cover removed, observe the paper feed

process.

Does the duplex unit process the duplex test print?

3 DUPLEX UNIT VOLTAGE CHECK

1. Remove the “Duplex Cover” on page 4-4 and reinstall the
coverless duplex unit onto the printer.

2. Reconnect the Duplex Interface Cable to the P/J at the rear of the
printer.

3. Switch on the printer power.

4. Measure the voltage between J473-13 and FG (frame ground), and
the voltage between J473-2 and FG on the Duplex PWB.

Is there +5VDC between J473-13 and FG, and is there
+24VDC between J473-2 and FG?

4 MCU PWB POWER OUT CHECK

1. Remove the printer Rear Cover.

2. Measure the voltage between J404-6 and FG, and the voltage
between J404-24 and FG on the MCU PWB.

Is there +5VDC between J404-6 and FG, and is there
+24VDC between J404-24 and FG?

Go to step 2 Reconnect

the Duplex
Interface
Cable

Problem
solved

Replace the

“Duplex
Drive
Assembly”
on page 4-9

Replace the
printer Engine
Board (MCU
PWB). Go to
the printer
service
manual for the
Removal and
Replacement
Procedure.

Go to step 3

Go to step 4

Use the Block
Diagrams in
the printer
service
manual to
troubleshoot a
loss of DC
voltage from
the MCU
PWB

2-18 Service Manual