Xerox DocuPrint N4525 User manual

Warning
The following servicing instructions are for
use by qualified service personnel only. To
avoid personal injury, do not perform any
servicing other than that contained in
operating instructions unless you are qualified
to do so.
This printing: April 5, 2001
Rev. NEW
721P58090
DOCUPRINT®N4525
NETWORK LASER PRINTER
Service Quick Reference Guide
Book II — Options

Copyright 2001 Xerox Corporation. Printed in the United States of America. All
rights reserved.
Contents of this publication may not be reproduced in any form without
permission of Xerox, Inc.
Xerox, and all product names and product numbers mentioned in this
publication are trademarks.
Other marks are trademarks or registered trademarks of the companies with
which they are associated.
RJ/MP
sn/ck

Users safety summary
Terms in manual: Various terms are used throughout this manual to either
provide additional information on a specific topic or to warn of possible danger
that might be present during a procedure or action. Be aware of all symbols and
terms when they are used, and always read NOTE, CAUTION and WARNING
messages.
Terms on product:
Power source: For 110 VAC printers, Do not apply more than 130 volts RMS
between the supply conductors or between either supply conductor and ground.
Use only the specified power cord and connector. For 220 VAC printers, do not
apply more than 250 volts RMS between the supply conductors or between
either supply conductor and ground. Use only the specified power cord and
connector. Refer to a qualified service technician for changes to the cord or
connector.
WARNING: If the product loses the ground connection, usage of knobs and
controls (and other conductive parts) can cause an electrical shock.
NOTE:A NOTE may indicate an operating or maintenance
procedure, practice or condition that is necessary to
efficiently accomplish a task.
A NOTE may also provide additional information related to
a specific subject or add a comment on the results achieved
through a previous action.
CAUTION:A CAUTION indicates an operating or maintenance
procedure, practice or condition that, if not strictly
observed, could result in damage to, or destruction of,
equipment.
WARNING:A WARNING indicates an operating, or maintenance
procedure, practice or condition that, if not strictly
observed, could result in injury or loss of life.
CAUTION: A personal injury hazard exists that may not be apparent.
For example, a panel may cover the hazardous area.
DANGER: A personal injury hazard exists in the area where you see
the sign.

Power Supply and Electrical Components: Before starting any service
procedure, switch off the printer power and unplug the power cord from the
wall outlet. If you must service the printer with power applied, be aware of the
potential for electrical shock.
Do not touch any electrical component unless you are instructed to do so by a
service procedure.
Mechanical components: Manually rotate drive assemblies to inspect
sprockets and gears.
Do not try to manually rotate or manually stop the drive assemblies while any
printer motor is running
Laser Components
WARNING:This printer generates a laser beam as part of the printing process.
The laser beam is a concentrated narrow beam of light that
produces extreme heat at its focal point. The laser beam in this
printer is invisible. Although you cannot see the beam, it can still
cause severe damage. Direct eye exposure to the laser beam may
cause eye injury or blindness.
To avoid permanent eye damage, follow these directions:
 Before starting any service procedure, switch off the printer power and
unplug the power cord from the AC wall outlet.
 Do not disassemble the Raster Output Scanner Assembly (laser
scanner) or any laser component that displays a Laser Warning Sticker.
 Use caution when you are working around the Raster Output Scanner
Assembly or when you are performing laser related troubleshooting or
repair procedures.
 Never place a mirror or a reflective tool or object in the laser beam path.
 Do not disassemble the printer in such a way that the laser beam can
exit the print engine during a print cycle.
S4525-01
S4525-02

Fuser Components
WARNING:This printer uses heat to fuse the toner image to a sheet of paper.
The Fuser Assembly is very hot. Switch off printer power and wait at least 30
minutes for the Fuser to cool before you attempt to service the Fuser Assembly or
adjacent components.
Safety Components: Make sure covers and panel are in place and that all
interlock switches are all functioning correctly after you have completed a printer
service call. If you bypass, or cheat, an interlock switch during a service call, use
extreme caution when working on or around the printer.
Warning Labels: Throughout the printer, warning labels are displayed on
potentially dangerous components. When you service the printer, check to make
certain that all warning labels are in place.
Most importantly, read and obey all posted warning labels.
WARNING:Turning the power off using the On/Off switch does not de-energize
the printer. You must remove the power cord to disconnect the
printer from the main power source. Keep the power cord accessible
for removal in case of an emergency.
Safety instructions: Read all installation instructions carefully before you plug
the product into a power source.
Care of product: Disconnect the power plug by pulling the plug, not the cord.
 Disconnect the power plug if the power cord or plug is frayed or otherwise
damaged,
 Or if any liquid or foreign material is spilled into the case,
 Or if the printer is exposed to any excess moisture,
 Or if the printer is dropped or damaged,
 Or if you suspect that the product needs servicing or repair,
 And whenever you clean the product.
Ground the product: Plug the three-wire power cord (with grounding prong)
into grounded AC outlets only. If necessary, contact a licensed electrician to
install a properly grounded outlet.

Service Safety Summary
For qualified service personnel only: Refer also to the preceding Users Safety
Summary.
Do not service alone: Do not perform internal service or adjustment of this
product unless another person capable of rendering first aid or resuscitation is
present.
Use care when servicing with power: Dangerous voltages may exist at several
points in this product. To avoid personal injury, do not touch exposed
connections and components while power is on.
Disconnect power before removing the power supply shield, soldering or
replacing components.
Do not wear jewelry: Remove jewelry prior to servicing. Rings, necklaces and
other metallic objects could come into contact with dangerous voltages and
currents.
Power source: This product is intended to operate from a power source that will
not apply more then 250 volts rms between the supply conductors or between
wither supply conductor and ground. A protective ground connection by way of
the grounding conductor in the power cord is essential for safe operation.
This product is certified under IEC 825 as a Class 1 Laser Product.
CLASS 1 LASER PRODUCT
The DocuPrint®N4525 Network Laser Printer is certified to comply with Laser
Product Performance Standards set by the U.S. Department of Health and
Human Services as a Class 1 Laser Product. This means that this is a class of
laser product that does not emit hazardous laser radiation; this is possible only
because the laser beam is totally enclosed during all modes of customer
operation.
The laser and output of the laser scanner unit produces a beam that, if looked
into, could cause eye damage. Service procedures must be followed exactly as
written without change.
When servicing the machine or laser module, follow the procedures specified in
the manual and there will be no hazards from the laser.
Laser (FDA): Any laser label visible to service must be reproduced in the service
manual with location shown or indicated. Safe working procedures and clear
warnings concerning precautions to avoid possible exposure must also be
included.
The Laser contained in the DocuPrint®N4525 Network Laser Printer meets the
following standard: Laser class 3B, maximum 5mW, wavelength 780nm.
The following LASER symbol will be displayed at the start of any procedure

where possible exposure to the laser beam exists.
LUOKAN 1 LASERLAITE
KLASS 1 LASER APPARAT

Federal Communications Commission Compliance
This equipment has been tested and found to comply with the limits set for a
Class B digital device, as stated in Part 15 of the FCC rules. These limits are
designed to provide reasonable protection against harmful interference in a
commercial installation. This equipment generates, uses, and may radiate radio
frequency energy. If not installed and used in accordance with the instructions
provided, this equipment may cause disruptive interference to nearby radio and
television communications. Even if the equipment is installed according to the
instructions, there is no guarantee that interference will not occur in a particular
installation. If this equipment does cause disruptive interference to nearby radio
and television reception, switch the equipment off to determine if it is the true
cause of the interference. If the equipment is the cause of the interference, the
user should try to minimize the interference by taking one or more of the
following courses of action:
NOTE: Installation of the Finisher and/or the Token Ring Interface results in an
FCC classification change to Class A.
 Either re–orient or relocate the radio/television receiving antenna.
 Increase the separation between the equipment and the radio/television
receiver.
 Connect the equipment to an AC outlet that is not on the same circuit as the
radio/television receiver.
 If the previous solutions fail to bring results, you should consult either your
equipment dealer or an experienced radio/television technician.
For more information on interference, refer to the Federal Communications
Commission’s booklet “How to Identify and Resolve Radio-TV Interference
Problems”. This booklet is available from the U.S. Government Printing Office,
Washington D.C. 20402, Stock No. 004-000-00345-4.

Canadian Notice
This digital apparatus does not exceed the Class B limits for radio noise
emissions from digital apparatus as described in the radio interference
regulations of the Canadian Department of Communications.
NOTE: Installation of the Finisher and/or the Token Ring Interface results in a
classification change to Class A.
Avis Canadien
Cet appareil numerique est conforme aux limites émission de bruits
radioélectriques pour les appareils de classe B stipulés das le réglement sur le
brouillage radioéletrique du Ministére des Communcations du Canada.
European Notice
This equipment was tested and is determined to be compliant with VDE
requirements for a Class B device.
Hinweis
Hiermit wird bescheinigt, dass der Babe Laserdrucker, in bereinstimmung mit
den Betimmunngen der Vfg 104ß 984 funkenstört ist. Der Deutschen
Bundespost wurde das Inverkehrbringen dieses Gertëes angqeigt und die
Berechtigung zur berprufung der Serie auf Einhaltung der Bestimmungen
eingeräumt.

Manual Organization
This Service Quick Reference Guide (QRG) is divided into two volumes.
Book I
Book I of the QRG contains technical information for the N4525 Print Engine
(Volume 1), as well as complete Error Code and Repair Analysis Procedures
(RAPs) for the Print Engine and all options for the printer. Information specific to
each option is repeated in that option’s volume.
NOTE: All pages, figures, tables, RAPs, RRPs (Remove and Replace Procedures)
and Parts List numbers are preceded by a “dash” number, indicating the volume
number for that module according to the following legend
Volume 1 - Print Engine
Frontis - Introductory, Safety and Regulatory Information
This is the section you are reading at this moment. It contains important safety
information regarding technical components, regulatory agency requirements
and information about this manual, which is applicable to both Books I and II.
Section 1 - General Information
This section contains a general overview of the printer and basic information
regarding RAM, print engine illustrations (major assembly locations, sensor
locations, general views, etc.), printer specifications and vital information
regarding service call procedures.
Section 2 - Error Codes and Messages
Information regarding certain Error Codes and Messages for conditions the user
may not be aware of, or conditions that exist which may not yet be made
apparent by printer performance or by image quality. Also contained in this
section is a vital error table which references Repair Analysis Procedures (RAPs)
for the Printer and all options, and referring the reader to appropriate sections in
each option manual supplement. In addition, there is additional, but valuable,
information on how to use the Repair Analysis Procedures for the Print Engine
and the options.
Volume Module
1Print Engine
2High Capacity Feeder
3Duplex Unit
4Envelope Feeder
5Face Up Bin
6Finisher

Section 3 - Troubleshooting
This section specifically discusses the most common problems (using additional
Repair Analysis Procedures) encountered in the following areas:
 Printer Performance Problems
 Image Quality Problems
 Electrical Interference Problems.
Section 4 - Diagnostics, Test Prints, Service Tests & NVRAM Adjustments
This section provides a wide variety of test prints to assist in evaluating and/or
troubleshooting the printer and options. Also provided are many accessed
diagnostic tests and adjustments to assist in analyzing, adjusting registration and
fine tuning the printer and options performance.
Section 5 - Cleaning and Maintenance
A quick guide to routine cleaning and maintenance for the printer and options.
Section 6 - Key FRU Removal and Replacement Procedures
This large section provides many procedures and illustrations for removing and
replacing key Field Replaceable Units (FRUs) within the print engine. Option
specific Removal and Replacement Procedures (RRPs) appear in the Volume 2
manual supplement for each option. For more detailed procedures, please refer
to the CD version of the service manual.
Section 7 - FRU List
This is the parts list for the Field Replaceable Units. This section contains
exploded views of the FRUs as well as part numbers for items available as FRUs.
Section 8 - Plug/Jack Connector Locations
This section contains a connector table and several locator illustrations to aid in
identifying all electrical connections within the printer and options.
Section 9 - Wiring Diagram
The Master Wiring Diagram is contained in this section. Please refer to the CD
version of the service manual for additional diagrams.

Book II
Book II contains technical information for all options for the N4525 Network
Laser Printer. Information for each option is contained in a separate volume as
see below.
Volume 2 - High Capacity Feeder (HCF)
This section contains information specific to the HCF with General Information,
Error Codes, RAPs, RRPs, Parts Lists, Plug/Jack Locators and wiring information.
NOTE: All page, figure, table, RAP, RRP and Parts List numbers for this section are
preceded by a “2-”.
Volume 3 - Duplex Unit (DUP)
This section contains information specific to the DUP with General Information,
Error Codes, RAPs, RRPs, Parts Lists, Plug/Jack Locators and Wiring information.
NOTE: All page, figure, table, RAP, RRP and Parts List numbers for this
section are preceded by a “3-”.
Volume 4 - Envelope Feeder (ENV)
This section contains information specific to the ENV with General Information,
Error Codes, RAPs, RRPs, Parts Lists, Plug/Jack Locators and Wiring information.
NOTE: All page, figure, table, RAP, RRP and Parts List numbers for this
section are preceded by a “4-”.
Volume 5 - Face Up Bin (FUB)
This section contains information specific to the FUT with General Information,
Error Codes, RAPs, RRPs, Parts Lists, Plug/Jack Locators and Wiring information.
NOTE: All page, figure, table, RAP, RRP and Parts List numbers for this
section are preceded by a “5-”.
Volume 6 - Finisher (FIN)
This section contains information specific to the Finisher with General
Information, Error Codes, RAPs, RRPs, Parts Lists, Plug/Jack Locators and Wiring
information.
NOTE: All page, figure, table, RAP, RRP and Parts List numbers for this
section are preceded by a “6-”.

Service Guide i
Table of Contents
Table of Contents ......................................................................................................... 0 - i
List of Figures.................................................................................................................0 - v
List of Tables ................................................................................................................ 1 - xi
High Capacity Feeder
High Capacity Feeder Overview .........................................................................2 - 360
General Information ..............................................................................................2 - 361
The High Capacity Feeder Paper Path..............................................................2 - 362
Error Codes and Messages....................................................2 - 369
Error messages ........................................................................................................2 - 369
High Capacity Feeder Error Code Table...........................................................2 - 370
Troubleshooting........................................................................2 - 413
FRU Removal and Replacement Procedures (RRPs) ....2 - 415
Preparation ...............................................................................................................2 - 415
FRU Parts List.............................................................................2 - 457
PL12 & PL13 High Capacity Feeder Parts List................................................2 - 457
Using the Parts List.................................................................................................2 - 457
Plug/Jack Connectors..............................................................2 - 487
P/J Location Table ..................................................................................................2 - 488
P/J Location Map 1 ................................................................................................2 - 490
P/J Location Map 2 ................................................................................................2 - 491
Wiring Diagrams and Signal Information..........................2 - 493
High Capacity Feeder Master Wiring Diagram...............................................2 - 493
BD1 High Capacity Feeder Board´Tray 5 Components ......................2 - 494
BD2 HCF Board - HCF Tray 3 and Tray 4 Components......................2 - 496
Duplex Unit
General Information ..............................................................................................3 - 500
Continuous Printing Speed..................................................................................3 - 501
Paper Path ................................................................................................................3 - 502
Duplexer Unit Assemblies and Sensors...........................................................3 - 506
Error Codes and Messages....................................................3 - 507
Error messages ........................................................................................................3 - 507
Duplex Unit Error Code Table.............................................................................3 - 508

ii DocuPrint N4525 Network Laser Printer
Troubleshooting....................................................................... 3 - 523
Inoperative Duplex Unit ....................................................................................... 3 - 523
Removal and Replacement Procedures (RRPs)............. 3 - 525
Notations in the RRP text..................................................................................... 3 - 525
FRU Parts List ............................................................................ 3 - 541
FRU PL 14 Duplex Unit Parts List ...................................................................... 3 - 541
Usint the Parts List ................................................................................................. 3 - 541
Plug/Jack Connectors............................................................. 3 - 553
Wiring Diagrams and Signal Information......................... 3 - 555
Duplex Unit Master Wiring Diagram ........................................................ 3 - 556
Envelope Feeder
Envelope Feeder Overview.................................................................................. 4 - 559
General Information .............................................................................................. 4 - 560
The Envelope Feeder Paper Path ............................................................. 4 - 561
Error Codes and Messages ................................................... 4 - 563
Error messages........................................................................................................ 4 - 563
Envelope Feeder Error Code Table ................................................................... 4 - 564
Troubleshooting....................................................................... 4 - 573
Envelope Feeder Performance Problems ....................................................... 4 - 573
Inoperative Envelope Feeder.............................................................................. 4 - 573
Removal and Replacement Procedures (RRPs)............. 4 - 577
FRU Parts List ............................................................................ 4 - 601
FRU PL 16 Envelope Feeder Parts List ............................................................. 4 - 601
Using the Parts List ................................................................................................ 4 - 601
Wiring Diagrams and Signal Information......................... 4 - 613
Envelope Feeder Master Wiring Diagram ....................................................... 4 - 613
Plug/Jack Connectors............................................................. 4 - 609
Locating Plug/Jack Connectors Map ................................................................ 4 - 609
Plug/Jack Location Table ..................................................................................... 4 - 610
Plug/Jack Location Map 1.................................................................................... 4 - 611
Face-Up Bin............................................................................... 5 - 615
General Information .............................................................................................. 5 - 616
Removal and Replacement Procedures (RRPs)............. 5 - 617

Service Guide iii
Finisher
Finisher Overview ...................................................................................................2 - 624
General Information ..............................................................................................2 - 625
The Finisher Paper Path........................................................................................2 - 626
Finisher Paper Path ................................................................................................ 2 - 626
Horizontal Transport (H-Tra) Section.......................................................2 - 627
Punch Section ................................................................................................. 2 - 629
Shift Section.....................................................................................................2 - 631
Compiler and Jogger Section .....................................................................2 - 634
Staple Section .................................................................................................2 - 636
Exit Section ......................................................................................................2 - 637
Paper Stack Section.......................................................................................2 - 639
FRU, Sensor & Interlock Locations.....................................................................2 - 642
FRU, Sensor & Interlock Locator Map 1 ...........................................................2 - 642
FRU, Sensor & Interlock Locator Map 2 ..................................................2 - 644
FRUs, Sensors and Interlocks Locator......................................................2 - 646
FRU, Sensor & Interlock Locator Map 4 ..................................................2 - 648
Error Codes and Messages....................................................6 - 651
Error messages ........................................................................................................6 - 651
Service Flowchart....................................................................................................6 - 651
Repair Analysis Procedure Table........................................................................6 - 653
FRU Removal and Replacement Procedures (RRPs) ....6 - 711
Removal and Replacement Procedures (RRP)..............................................6 - 713
Preparation ...............................................................................................................6 - 713
Notations in the RRP text.....................................................................................6 - 714
Puncher Assembly, cont’d...........................................................................6 - 751
Finisher FRU Parts List.............................................................6 - 809
Using the Parts List.................................................................................................6 - 809
......................................................................................................................................6 - 811
Plug / Jack Connectors...........................................................6 - 845
P/J Location Map 1 ................................................................................................6 - 851
P/J Location Map 2 ................................................................................................6 - 852
P/J Location Map 3 ................................................................................................6 - 853
P/J Location Map 4 ................................................................................................6 - 854
P/J Location Map 5 ................................................................................................6 - 855
Master Wiring Diagram...........................................................6 - 857
Master Wiring Diagram .........................................................................................6 - 858

iv DocuPrint N4525 Network Laser Printer
Blank Page

Service Guide v
List of Figures
Fig 2-1 DocuPrint N4525 Network Laser Printer with the High Capacity
Feeder Highlighted.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 359
Fig 2-2 Feed From Tray 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 362
Fig 2-3 Feed From Tray 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 364
Fig 2-4 Feed From Tray 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 366
Fig 2-6 High Capacity Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 418
Fig 2-7 High Capacity Feeder Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 420
Fig 2-8 High Capacity Feeder Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 421
Fig 2-9 Door C Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 422
Fig 2-10 Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 423
Fig 2-11 Bottom Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 424
Fig 2-12 High Capacity Feeder Feed Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 425
Fig 2-13 High Capacity Feeder Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 426
Fig 2-14 High Capacity Feeder Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 427
Fig 2-15 Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 428
Fig 2-16 Tray 3 Paper Size Sensor Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 429
Fig 2-17 Tray 4 and Tray 5 Paper Size Sensor Boards . . . . . . . . . . . . . . . . . . . . . .2 - 430
Fig 2-18 Trays 3, 4, and 5 Feed Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 431
Fig 2-19 Trays 3, 4, and 5 No Paper Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 432
Fig 2-20 Trays 3, 4, and 5 No Paper Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 433
Fig 2-21 Trays 3, 4, and 5 Paper Level Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 434
Fig 2-22 Left Door C Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 435
Fig 2-23 Tray 4 Take Away Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 436
Fig 2-24 Tray 3 Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 437
Fig 2-25 Tray 3 Retard Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 439
Fig 2-26 Tray 3 (cont’d). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 440
Fig 2-27 Tray 3 Pick, Feeder, and Retard Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 442
Fig 2-28 High Capacity Feeder Tray 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 443
Fig 2-29 Tray 4 Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 444
Fig 2-30 Tray 5 Take Away Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 445
Fig 2-31 Tray 4 Take Away Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 446
Fig 2-32 Tray 4 (cont’d). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 447
Fig 2-33 Tray 4 Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 448
Fig 2-34 Tray 4 Retard Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 449
Fig 2-35 Tray 4 Feed, Pick and Retard Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 450
Fig 2-36 High Capacity Feeder Tray 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 451
Fig 2-37 Tray 5 Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 452
Fig 2-38 Tray 5 Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 453
Fig 2-39 Tray 5 Retard Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 454
Fig 2-40 Tray 5 Feed, Pick and Retard Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 455
Fig 2-40 PL12.1 Covers and Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 458

vi DocuPrint N4525 Network Laser Printer
Fig 2-41 PL 12.2 High Capacity Feeder Board, Harness, and Drive . . . . . . . . . . .2 - 460
Fig 2-42 Tray Interface 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 462
Fig 2-43 Tray Interface 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 464
Fig 2-44 Paper Pick-Up Tray 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 466
Fig 2-45 Retard and Take Away Roller - Tray 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 468
Fig 2-46 Paper Pick-Up Tray 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 470
Fig 2-47 Retard and Take Away Roller - Tray 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 472
Fig 2-48 Paper Pick-Up Tray 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 474
Fig 2-49 Retard and Take Away Roller - Tray 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 476
Fig 2-50 Left Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 478
Fig 2-51 High Capacity Tray 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 480
Fig 2-52 High Capacity Tray 5 - Paper Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 482
Fig 2-53 High Capacity Tray 5 - Paper Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 484
Fig 2-54 Map 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 490
Fig 2-55 Map 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 491
Fig 2-56 HCF Master Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 493
Fig 2-57 HCF Board - Tray 5 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 494
Fig 2-58 HCF Board - HCF Tray 3 and Tray 4 Components . . . . . . . . . . . . . . . . . . 2 - 496
Fig 3-1 Docuprint 4525 Printer shown with the Duplex Unit Highlighted. . . . . .3 - 499
Fig 3-2 Duplex Unit option highlighted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 500
Fig 3-3 Duplex Paper Path - Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 502
Fig 3-4 Duplex Paper Path - Step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 503
Fig 3-5 Duplex Paper Path - Step 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 504
Fig 3-6 Duplex Unit Assemblies and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 506
Fig 3-7 Duplex Unit Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 526
Fig 3-8 Duplex Unit Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 527
Fig 3-9 Duplex Unit Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 528
Fig 3-10 Duplex Unit Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 529
Fig 3-11 Duplex Board and Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 530
Fig 3-12 Duplex Wait Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 531
Fig 3-13 Duplex Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 532
Fig 3-14 Duplex Exit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 533
Fig 3-15 Duplex Exit Gate Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 534
Fig 3-16 Exit Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 535
Fig 3-17 Duplex Wait Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 536
Fig 3-18 Duplex Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 537
Fig 3-19 Exit Roller Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 538
Fig 3-20 Duplex Pinch Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 539
Fig 3-21 Inner Chute Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 540
Fig 3-22 PL 14.1 Duplex Covers and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 542
Fig 3-23 PL 14.2 Duplex Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 544
Fig 3-24 PL 14.3 Duplex Upper Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 546
Fig 3-25 PL 14.4 Duplex Paper Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 548

Service Guide vii
Fig 3-26 PL 14.5 Duplex Inner Chute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 550
Fig 3-27 Plug/Jack Location Map 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 554
Fig 3-28 Duplex Unit Master Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 556
Fig 3-29 BD1 Input/Output Board´Duplex Board´Duplex Components. . . . . . . .3 - 557
Fig 4-1 The DocuPrint N4525 Network Laser Printer shown with Envelope
Feeder highlighted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 559
Fig 4-2 Envelope Feeder highlighted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 560
Fig 4-3 Envelope Feeder Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 561
Fig 4-4 Envelope Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 579
Fig 4-5 Envelope Feeder Bottom Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 580
Fig 4-6 Envelope Feeder Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 581
Fig 4-7 Envelope Feeder Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 582
Fig 4-8 Envelope Feeder Rear Cover ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 583
Fig 4-9 Envelope Feeder Center Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . .4 - 584
Fig 4-10 Envelope Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 585
Fig 4-11 Envelope Feeder Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 586
Fig 4-12 Feed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 588
Fig 4-13 Envelope Feeder Retard Roller Assembly ) . . . . . . . . . . . . . . . . . . . . . . .4 - 590
Fig 4-14 No Paper Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 592
Fig 4-15 No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 593
Fig 4-16 Envelope Size Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 594
Fig 4-17 Envelope Feed Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 596
Fig 4-18 Upper Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 598
Fig 4-19 Feed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 600
Fig 4-20 Pl 16.1 Envelope Feeder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 602
Fig 4-21 PL 16.2 Envelope Feeder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 604
Fig 4-22 PL 16.3 Envelope Feeder 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 606
Fig 4-24 Envelope Feeder Master Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . .4 - 613
Fig 4-25 BD1 Print Engine Controller Board to Envelope Feeder Components. .4 - 614
Fig 4-23 Plug/Jack Location Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 611
Fig 5-1 The DocuPrint N4525 Network Laser Printer Face-Up Bin. . . . . . . . . . . .5 - 615
Fig 5-2 The DocuPrint N4525 Network Laser Printer Face-Up Bin with the
Duplex Unit highlighted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 615
Fig 5-3 Envelope Feeder highlighted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 616
Fig 5-4 Face-Up Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 618
Fig 5-5 Face-Up Bin attached to the Optional Duplex Unit . . . . . . . . . . . . . . . . . .5 - 619
Fig 5-6 Face-Up Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 620
Fig 2-1 DocuPrint N4525 Network Laser Printer with the Finisher Highlighted. .2 - 623
Fig 2-2 Finisher Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 626
Fig 2-3 Horizontal Transport Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 627
Fig 2-4 Punch Section Paper Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 629
Fig 2-5 Shift Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 631
Fig 2-6 Fixing Paper on the Stacker Bin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 633

viii DocuPrint N4525 Network Laser Printer
Fig 2-7 Compiler and Jogger Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 634
Fig 2-8 Compiler and Jogger Section, continued . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 635
Fig 2-9 Staple Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 636
Fig 2-10 Non-Stapling Job. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 637
Fig 2-11 Stapling Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 637
Fig 2-12 Paper Stack Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 639
Fig 2-13 Stacker Height Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 640
Fig 2-14 FRU, Sensor & Interlock Locator Map 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 642
Fig 2-15 FRU, Sensor & Interlock Locator Map 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 644
Fig 2-16 FRU, Sensor & Interlock Locator Map 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 646
Fig 2-17 FRU, Sensor & Interlock Locator Map 4 . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 648
Fig 6-1 Service Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 652
Fig 6-1 Notations in the RRP text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 714
Fig 6-2 Pulley 2, Tension Spring, Sensor and Ground Wire . . . . . . . . . . . . . . . . . .6 - 715
Fig 6-3 Sync-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 716
Fig 6-4 Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 717
Fig 6-5 Transport Gear Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 718
Fig 6-6 In-Gate Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 720
Fig 6-7 Cover Top, Horizontal Transport Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 6 - 721
Fig 6-8 Transport Roller and Aligner Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 722
Fig 6-9 H-Tra Input Path & Face Up Bin Full Sensors . . . . . . . . . . . . . . . . . . . . . . . 6 - 724
Fig 6-10 Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 725
Fig 6-11 Jogging Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 726
Fig 6-12 Top Cover, Front and Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 727
Fig 6-13 Front Cover-Open Front Cover and Kit Stud Cover . . . . . . . . . . . . . . . . .6 - 728
Fig 6-14 Switch Cover Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 730
Fig 6-15 Latch Assembly and Switch Docking. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 731
Fig 6-16 Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 732
Fig 6-17 Top Cover-Left. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 733
Fig 6-18 Top Center Cover Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 734
Fig 6-19 Kit Bracket Assembly and Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 735
Fig 6-20 Caster Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 736
Fig 6-21 Finisher Input Paper Path Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 737
Fig 6-22 Finisher Exit Path Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 738
Fig 6-23 Registration Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 739
Fig 6-24 Transport Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 740
Fig 6-25 Drive Assembly Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 742
Fig 6-26 Inlet Chute Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 744
Fig 6-27 Invert Guide Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 745
Fig 6-28 Buffer Chute Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 747
Fig 6-29 Transport (Main Feed) Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 749
Fig 6-30 Puncher Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 750
Fig 6-31 Puncher Position Adjustment Dimensions. . . . . . . . . . . . . . . . . . . . . . . .6 - 751