Page 1 MS911 4021-230 Service Manual • Start diagnostics • Maintenance • Safety and notices • Trademarks • Index June 18, 2014 www.lexmark.com P/N 12G3390...
Page 2: Product Information
June 18, 2014 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.
Page 3: Table Of Contents
4021 Table of contents Product information..................2 Edition notice....................2 Notices and safety information..............19 Laser notices............................19 Safety information...........................22 Preface.......................25 Service manual conventions........................25 General information...................27 Paper and specialty media guide......................27 Using specialty media ............................27 Paper guidelines ...............................29 Supported paper sizes, types, and weights ......................33 Data security notice..........................37 Tools required for service........................38 Diagnostic information................39...
Page 4 4021 243–245 paper jams ............................85 Understanding the printer messages......................99 Cartridge low [88.xy]............................99 Cartridge nearly low [88.xy]..........................99 Cartridge very low [88.xy]..........................99 Change [paper source] to [custom string] load [orientation] .................100 Change [paper source] to [custom type name] load [orientation]..............100 Change [paper source] to [paper size] load [orientation] ................100 Change [paper source] to [paper type] [paper size] load [orientation]............100 Close door [x]..............................100 Complex page, some data may not have printed [39]..................100...
Page 5 4021 Photoconductor low [84.xy] ...........................106 Photoconductor very low [84.xy]........................106 Printer had to restart. Last job may be incomplete..................107 Reinstall missing or unresponsive cartridge [31.xy] ..................107 Reinstall missing or unresponsive photoconductor [31.xy]................107 Remove defective disk [61]..........................107 Remove packaging material, [area name] ......................107 Remove packaging material, open door C, remove metal clips..............107 Remove paper from all bins..........................107 Remove paper from bin [x]..........................108...
Page 6 4021 Insufficient memory service check .........................115 Complex page service check ...........................115 PPDS font error service check.........................116 Flash memory failure service check........................116 Insufficient flash memory service check......................117 Network service check............................118 Unsupported internal option service check....................120 Disabled port service check ..........................121 Unrestored held jobs service check ........................121 Excess options service check ..........................122 Incompatible hardware option service check....................123 Hard disk failure service check ........................123...
Page 7 4021 Print Quality Pages............................177 HARDWARE TESTS ............................177 DUPLEX TESTS ..............................179 INPUT TRAY TESTS ............................179 OUTPUT BIN TESTS ............................180 SENSOR TESTS..............................180 Motor Tests..............................182 DEVICE TESTS ..............................183 PRINTER SETUP ...............................184 REPORTS .................................186 EVENT LOG..............................187 Exit Diags.................................187 Configuration menu..........................188 Entering the Configuration menu ........................188 Hole Punch Configuration..........................188 Reset Maintenance Counter ...........................188 USB Scan to Local............................188...
Page 8 4021 Entering Invalid engine mode........................195 Entering Recovery Mode........................195 Entering Safe Mode (EverReady Mode)....................195 Accessing the Network SE Menu......................195 Service Engineer menu..........................195 Accessing the Service Engineer (SE) Menu .....................195 Service Engineer (SE) Menu ..........................195 Repair information...................197 Removal precautions..........................197 Data security notice ............................197 Handling ESD‑sensitive parts ..........................197 Restoring the printer configuration after replacing the controller board ............198 Restoring solutions, licenses, and configuration settings................201...
Page 9 4021 Induction heater removal ..........................230 Registration transport assembly........................231 Top side cover removal...........................232 Upper right cover removal..........................233 Redrive belt cover removal..........................233 Redrive belt removal............................234 Transfer roller removal ...........................234 Duplex transport assembly removal .......................235 Duplex transport jam removal knob removal....................236 Duplex transport diverter assembly removal ....................237 Sensor (fuser exit) removal..........................238 Fuser exit sensor actuator removal ........................238 Sensor (duplex pass through 1) removal ......................239...
Page 10 4021 Front inner cover removal ..........................274 Waste toner door mount removal........................275 Image controller board removal........................275 Door switch removal............................276 Main power switch removal ...........................277 Sensor (top front door) removal........................278 Motor (toner supply) removal ........................279 Waste toner drive removal ..........................280 Sensor (toner cartridge present) removal ......................281 Toner agitator removal...........................282 Developer unit removal ..........................283 Right door switch removal..........................284...
Page 11 4021 Sensor (tray 1 and 2 paper temperature) removal..................316 Ozone fan removal............................316 Ozone fan duct removal ..........................318 Main drive assembly removal.........................319 Center cable guide bracket removal.......................321 Toner cartridge drive assembly removal ......................322 Duplex transport clutch removal ........................323 Motor (fuser) removal ............................324 Fuser drive gearbox removal ..........................325 Toner suction fan removal..........................327 Top side removals..........................329...
Page 12 4021 Sensor (2500‑sheet tray elevator home) removal..................353 Sensor (2500‑sheet tray main tray empty, bottom) removal.................354 Sensor (2500‑sheet tray main tray near empty) removal................355 Sensor (2500‑sheet tray main tray paper empty, top) removal ..............355 Sensor (2500‑sheet tray main tray elevator limit) removal................356 Sensor (2500‑sheet tray feed) removal ......................356 Sensor (2500‑sheet tray reserve tray empty) removal...................357 Sensor (2500‑sheet tray reserve tray paper limit) removal................358...
Page 13 4021 3000-sheet tray front cover removal......................392 3000-sheet tray rear cover removal .......................393 3000-sheet tray door removal ........................394 3000-sheet tray left top cover removal ......................395 Dehumidifier removal.............................396 3000-sheet tray empty LED removal ......................397 Sensor (3000-sheet tray empty) removal .......................397 Sensor (3000-sheet tray elevator level) removal....................398 Sensor (3000-sheet tray feed) removal ......................399 3000-sheet tray elevator spring removal......................400 3000-sheet tray controller board removal .....................400...
Page 14 4021 Assembly 4: Inner covers........................433 Assembly 5: Control panel........................435 Assembly 6: Printhead...........................437 Assembly 7: Toner supply 1........................439 Assembly 8: Toner supply 2........................441 Assembly 9: Waste toner........................443 Assembly 10: Developer........................445 Assembly 11: Photoconductor lock.......................447 Assembly 12: Transfer belt........................449 Assembly 13: Tray 1 and 2 transport.....................451 Assembly 14: Tray 1 feed........................453 Assembly 15: Tray 1 separator......................455 Assembly 16: Tray 2 feed........................457...
Page 15 4021 Assembly 41: Electrical 1........................507 Assembly 42: Electrical 2........................509 Assembly 43: 2 x 500‑sheet tray—Covers.....................511 Assembly 44: 2 x 500‑sheet tray—Frame....................513 Assembly 45: 2 x 500‑sheet tray—Paper feed..................515 Assembly 46: 2 x 500‑sheet tray—Paper size detection...............517 Assembly 47: 2 x 500‑sheet tray—Paper transport................519 Assembly 48: 2 x 500‑sheet tray—Paper pick 1..................521 Assembly 49: 2 x 500‑sheet tray—Paper pick 2..................523 Assembly 50: 2 x 500‑sheet tray—Paper pick 3..................525...
Page 16 4021 Appendix A: Printer specifications............579 Power consumption..........................579 Product power consumption ..........................579 Sleep Mode ..............................579 Hibernate Mode..............................579 Off mode.................................580 Total energy usage............................580 Operating clearances..........................580 Noise emission levels..........................581 Temperature information........................581 Appendix B: Options and features............583 Available internal options........................583 Media handling options.........................583 Appendix C: Theory of operation..............585 POR sequence............................585 Printer control............................585 Print cycle operation..........................585...
Page 17 4021 Index......................613 Part number index...................623 Part name index..................639 Table of contents...
Page 18 4021 Table of contents...
Page 19: Notices And Safety Information
4021 Notices and safety information Laser notices Laser notice The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR, Chapter I, Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1. Class I laser products are not considered to be hazardous.
Page 20 4021 Aviso de láser Esta impresora se ha certificado en EE. UU. de conformidad con los requisitos de DHHS 21 CFR, capítulo I, subcapítulo J, para los productos láser de Clase I (1), y en otros países está certificada como un producto láser de Clase I de acuerdo con los requisitos de IEC 60825-1.
Page 21 4021 Lasermeddelande Skrivaren är certifierad i USA enligt kraven i DHHS 21 CFR, avsnitt I, underavsnitt J för laserprodukter av klass I (1) och i andra länder är den certifierad som en laserprodukt av klass I som uppfyller kraven i IEC 60825-1. Laserprodukter av klass I anses inte vara skadliga.
Page 22: Safety Information
4021 一般认为分类 I 激光产品不具有危险性。本打印机内部含有分类 IIIb（3b）的激光，在操作过程中会产生额定 15 毫瓦的激光，其波长范围在 787–800nm 之间。本激光系统及打印机的设计，在一般操作、使用者维护或规定内的维修情况下，不会使人体接触分类 I 以上等级的辐射。雷射聲明本印表機係經過美國核可，符合 DHHS 21 CFR，Chapter I，Subchapter J 規定的 I (1) 級雷射產品激光注意事项；在美國以外的地區，為符合 IEC 60825-1 規定的 I 級雷射產品。根據 I 級雷射產品的規定，這類產品不會對人體造成傷害。本機所採用之 IIIb (3b) 級雷射只會產生 15 百萬分之一瓦特 (milliwatt)、波長 787 至 800 億分之一米 (nanometer) 的放射線。使用者只要以正確的方法操作及維護保養，並依照先前所述之維修方式進行修護，此印表機與其雷射系統絕不會產生...
Page 23 4021 Norme di sicurezza • La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti. • Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato.
Page 24 4021 • 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. ATENÇÃO — RISCO DE FERIMENTO A bateria de lítio neste produto não deve ser substituída. Existe o risco de explosão se uma bateria de lítio for substituída incorretamente.
Page 25: Preface
4021 Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: • General information contains a general description of the printer. Special tools and test equipment are discussed. • Diagnostic information contains diagnostic aids you can use to isolate failing FRUs. These diagnostic aids include error code tables, symptom tables, and service checks.
Page 26 4021...
Page 27: General Information
The printer may print at a reduced speed to prevent damage to the fuser. • For more information on card stock and labels, see the Card Stock & Label Guide on the Lexmark support Web site at http://support.lexmark.com. Using specialty media Tips on using card stock Card stock is heavy, single‑ply specialty media.
Page 28 • Print samples on labels being considered for use before buying large quantities. • For more information on label printing, characteristics, and design, see the Card Stock & Label Guide on the Lexmark Web site at http://support.lexmark.com. • Use labels designed specifically for laser printers.
Page 29: Paper Guidelines
4021 Source Printing Side with the Paper orientation letterhead Trays One‑sided Faceup Load the sheet with the top edge toward the back of the tray. Two‑sided Facedown Load the sheet with the top edge toward the front of the tray. Multipurpose feeder One‑sided Facedown...
Page 30: Moisture Content
4021 Smoothness Paper smoothness directly affects print quality. If paper is too rough, toner cannot fuse to it properly. If paper is too smooth, it can cause paper feeding or print quality issues. Always use paper between 100 and 200 Sheffield points. Moisture content The amount of moisture in paper affects both print quality and the ability of the printer to feed the paper correctly.
Page 31 Lexmark concerns itself with the responsible use of paper in general based on life cycle assessments of its products. To gain a better understanding of the impact of printers on the environment, the company commissioned a number of life cycle assessments and found that paper was identified as the primary contributor (up to 80%) of carbon emissions caused throughout the entire life of a device (from design to end-of-life).
Page 32: Storing Paper
(16 lb) • Multiple part forms or documents For more information about Lexmark, visit www.lexmark.com. General sustainability-related information can be found at the Environmental Sustainability link. Storing paper Use these paper storage guidelines to help avoid jams and uneven print quality: •...
Page 33: Supported Paper Sizes, Types, And Weights
4021 Supported paper sizes, types, and weights The following tables provide information on standard and optional paper sources and the sizes, types, and weights of paper they support. Note: For an unlisted paper size, select the closest larger listed size. Paper sizes supported by the printer Paper size Dimensions...
Page 34 4021 Paper size Dimensions Standard Standard 2 x 500‑ 2500‑sheet 3000‑sheet Multipurpose Two‑sided 500‑sheet 500‑sheet sheet tray tray printing feeder tray (Tray tray (Tray tray Oficio 216 x 340 mm (8.5 x 13.4 in.) Folio 216 x 330 mm (8.5 x 13 in.) Statement 140 x 216 mm (5.5 x 8.5 in.)
Page 35 4021 Paper type Standard Standard 2 x 500‑sheet 2500‑sheet 3000‑sheet Multipurpose 500‑sheet tray 500‑sheet tray tray tray tray feeder (Tray 1) (Tray 2) Plain Paper Card Stock Transparencies Recycled Glossy Heavy Glossy Labels Bond Envelope Rough Envelope Letterhead Preprinted Colored Paper Light Paper Heavy Paper Rough Cotton...
Page 36 4021 Supported paper sizes Paper size Staple finisher Staple, hole punch Staple, hole punch Booklet finisher finisher bin 1 finisher bin 2 JIS B5 JIS B4 Executive Letter Legal 12 x 18 11 x 17 SRA3 Oficio Folio Statement Universal Paper is supported only if the finisher stacks the paper but does not staple or punch holes in it.
Page 37: Data Security Notice
4021 Paper type Staple finisher Staple, hole punch finisher Booklet finisher Card Stock Transparency Recycled Glossy Heavy Glossy Labels Bond Envelope Rough Envelope Letterhead Preprinted Colored Paper Light Paper Heavy Paper Rough Cotton Custom Type Print on transparencies by batches of only up to 20 to prevent them from sticking together. For more information, see “Tips on using transparencies”...
Page 38: Tools Required For Service
4021 • Hard disk memory—The printer hard disk is designed for device-specific functionality and cannot be used for the long‑term storage of data that is not print-related. The hard disk can retain buffered user data from complex print jobs, form data, and font data. To erase volatile memory, turn off the printer.
Page 39: Diagnostic Information
4021 Diagnostic information CAUTION—SHOCK HAZARD: For personal safety and to prevent damage to the printer, remove the power cord from the electrical outlet before you connect or disconnect any cable, electronic board, or assembly. Disconnect any connections between the printer and the computer or peripherals. CAUTION—POTENTIAL INJURY: The printer weight is greater than 18 kg (40 lb) and requires two or more trained personnel to lift it safely.
Page 40: Initial Print Quality Check
4021 • “Toner smear check” on page 51 • “Toner specks check” on page 52 The symptoms described in this chapter might require replacement of one or more CRUs (Customer Replaceable Units) designated as supplies or maintenance items, which are the responsibility of the customer. With the customer's permission, you might need to install a toner cartridge.
Page 41 4021 Actions Step 2 Go to step 3. The problem is solved. Navigate to Settings > Print Settings > Quality Menu > Adjust Print Quality to perform print quality calibration. Does the problem remain? Step 3 Go to step 4. The problem is solved.
Page 42 4021 Actions Step 10 Go to step 11. The problem is solved. Check the following parts for damage or contamination, and replace if necessary. • Pick roller • Feed roller • Separator roller • Imaging unit • Developer unit Does the problem remain? Step 11 Go to step 12.
Page 43: Blank Pages Check
4021 Blank pages check Actions Step 1 Go to step 2. The problem is solved. Navigate to Settings > Allow Background Removal. Make sure that the value is set to On. Navigate to Settings > Print Settings > Quality Menu. Decrease the toner darkness (8 is the default value).
Page 44: Solid Black Pages Check
4021 Actions Step 6 Go to step 7. The problem is solved. Maker sure that the erase LED is properly installed. Check the LED for damage, and replace if necessary. Does the problem remain? Step 7 Go to step 8. The problem is solved.
Page 45 4021 Actions Step 1 Go to step 2. The problem is solved. Navigate to Settings > Allow Background Removal. Make sure that the value is set to On. Navigate to Settings > Print Settings > Quality Menu. Decrease the toner darkness (8 is the default value). Does the problem remain? Step 2 Go to step 3.
Page 46: Shadow Images Check
4021 Actions Step 7 Go to step 8. The problem is solved. CAUTION—SHOCK HAZARD: Do not perform this step if the printer is on. Make sure that the following cables are properly connected: • High voltage charge cable • High voltage transfer cable •...
Page 47 4021 Actions Step 1 Go to step 2. The problem is solved. Make sure that the paper type and weight are supported. Does the problem remain? Step 2 Go to step 3. The problem is solved. Check the exit roller for wear, damage, or contamination, and replace if necessary.
Page 48: Skewed Print Check
4021 Actions Step 9 Go to step 10. The problem is solved. Replace the sensor (fusing speed). See “Sensor (fusing speed) removal” on page 267. Does the problem remain? Step 10 Contact the next level The problem is solved. of support. Make sure that the fuser and its cable are properly connected.
Page 49: Streaked Horizontal Or Vertical Lines Check
4021 Actions Step 4 Go to step 5. The problem is solved. Check the registration belt for proper tension, and then adjust if necessary. Check the registration gear and belt for wear or damage, and replace if necessary. See “Registration unit belt removal” on page 269 “Registration unit gears removal”...
Page 50 4021 Actions Step 2 Go to step 3. The problem is solved. Make sure that the toner cartridge supply is not low. Check the photoconductor for contamination or damage, and replace if necessary. Does the problem remain? Step 3 Go to step 4. Go to step 5.
Page 51: Toner Smear Check
4021 Actions Step 7 Go to step 8. The problem is solved. CAUTION—SHOCK HAZARD: Do not perform this step if the printer is on. Make sure that the cables are properly connected. Check the high voltage board for damage, and replace if necessary. Does the problem remain? Step 8 Contact the next level...
Page 52: Toner Specks Check
4021 Actions Step 4 Go to step 5. The problem is solved. Make sure that the induction heater is properly installed. Reseat the induction heater cable. Check the induction heater and its cable for damage, and replace if necessary. See “Induction heater removal”...
Page 53: Paper Jams
4021 Actions Step 3 Go to step 4. Go to step 5. Enter the Diagnostics menu, and then navigate to: PRINTER SETUP > Printed Page Count Does the page count reach 300K or 600K? Step 4 Go to step 5. The problem is solved.
Page 54: Understanding Jam Messages And Locations
4021 • Do not slide the paper into the tray. Load paper as shown in the illustration. • Make sure the guides in the tray or the multipurpose feeder are properly positioned and are not pressing tightly against the paper or envelopes. •...
Page 55 4021 Area G Door C Door D Door F Trays Door H Finisher bins Door J Area name Control panel message What to do Multipurpose feeder [x]‑page jam, clear jammed paper from Remove the jammed paper from the multipurpose feeder. [200.xx] feeder.
Page 56: 200 Paper Jams
4021 Area name Control panel message What to do Doors C and G, finisher bin [x]‑page jam, press latch to access area G. Slide the staple finisher to the left, and then Leave paper in bin. [40y.xx] remove the jammed paper. Area G, doors C, J, and H, finisher [x]‑page jam, open door H and rotate knob Open door H, and then remove the jammed...
Page 57 4021 Error code Description Action 200.16 The sensor (registration) did not detect the paper fed “Registration jam service check” on page from tray 1. 200.19 While feeding from tray 1, skew correction did not complete at the registration roller. 200.91 Paper remains detected at the sensor (registration) after the printer turned on.
Page 58 4021 Action Step 6 Go to step 7. The problem is solved. Reseat the registration sensor cable. Check the sensor cable for damage, and replace if necessary. Does the problem remain? Step 7 Go to step 8. The problem is solved. Replace the sensor (registration).
Page 59 4021 Action Step 14 Go to step 15. The problem is solved. Replace the motor (registration). See “Motor (registration) removal” on page 310. Does the problem remain? Step 15 Go to step 16. The problem is solved. Check the feed belts for proper tension, and then adjust if necessary. Check the feed gears and belts for wear or damage, and replace if necessary.
Page 60 4021 Action Step 21 Go to step 22. The problem is solved. Check the expansion controller board pins for damage, and replace if necessary. See “Expansion controller board removal” on page 294. Does the problem remain? Step 22 Contact the next level The problem is solved.
Page 61 4021 Action Step 7 Go to step 8. The problem is solved. Replace the sensor (MPF empty). Does the problem remain? Step 8 Go to step 9. The problem is solved. Make sure that the MPF lift plate, including the cam and gears, are properly installed.
Page 62 4021 Action Step 15 Go to step 16. Go to step 18. Check the sensor (MPF lift plate). Is it free of damage? Step 16 Go to step 19. Go to step 17. Enter the Diagnostics menu, and then navigate to: SENSOR TESTS >...
Page 63: Paper Jams
4021 Action Step 23 Go to step 24. The problem is solved. Make sure that the MPF is properly installed. Check the MPF for damage, and replace if necessary. See “MPF removal” on page 247. Does the problem remain? Step 24 Contact the next level The problem is solved.
Page 64 4021 • Below the fuser area • Duplex area • Above the duplex area Open the standard trays, and then locate the jammed paper. Remove the jammed paper. Note: Make sure that all paper fragments are removed. Diagnostic information...
Page 65 4021 Close the trays and door C. [x]‑page jam, slide the 3000‑sheet tray and open door C. [2yy.xx] Slide the 3000‑sheet tray. Open door C. Make sure that it does not hit any cable attached to the printer. Remove the jammed paper from any of the following locations: Note: Make sure that all paper fragments are removed.
Page 66 4021 • Fuser area • Below the fuser area • Duplex area • Above the duplex area Diagnostic information...
Page 67 4021 Open the standard trays, and then locate the jammed paper. Remove the jammed paper. Note: Make sure that all paper fragments are removed. Close the trays and door C. Slide the 3000‑sheet tray back into place. 202 paper jam messages Error code Description Action 202.91...
Page 68 4021 Action Step 3 Go to step 4. The problem is solved. Check the exit sensor actuator for damage, and replace if necessary. See “Fuser exit sensor actuator removal” on page 238. Does the problem remain? Step 4 Go to step 5. Go to step 7.
Page 69 4021 Action Step 11 Go to step 12. The problem is solved. Make sure that the registration transport assembly is properly installed. Make sure that the registration transport assembly is clear of obstructions. Check the registration transport assembly for damage, and replace if necessary.
Page 70 4021 Action Step 18 Go to step 19. The problem is solved. Make sure that the exit guide assembly is properly installed. Make sure that the exit guide assembly is clear of obstructions. Does the problem remain? Step 19 Go to step 20. The problem is solved.
Page 71: 23Y Paper Jams
4021 Action Step 26 Go to step 27. The problem is solved. Check the expansion controller board pins for damage, and replace if necessary. See “Expansion controller board removal” on page 294. Does the problem remain? Step 27 Contact the next level The problem is solved.
Page 72 4021 Action Step 3 Go to step 4. The problem is solved. Check the duplex pass through 1 and duplex pass through 2 sensor actuator for damage, and replace if necessary. See “Duplex pass through 1 actuator removal” on page 240.
Page 73 4021 Action Step 10 Go to step 13. Go to step 11. Enter the Diagnostics menu, and then navigate to: MOTOR TESTS > PRINTER MOTOR TESTS > Duplex transport tray Does the motor run? Step 11 Go to step 12. The problem is solved.
Page 74: Paper Jams
4021 Action Step 17 Go to step 18. The problem is solved. Replace the motor (transport). See “Motor (transport) removal” on page 307. Does the problem remain? Step 18 Go to step 19. The problem is solved. Check the expansion controller board pins for damage, and replace if necessary.
Page 75 4021 Note: Make sure that all paper fragments are removed. Close the tray and door D. 241–242 paper jam messages Error code Description Action 241.11 Paper remains detected at the sensor (tray 1 “Tray 1 feed jam service check” on page feed) after the printer turned on.
Page 76 4021 Action Step 3 Go to step 4. Go to step 6. Check the sensor (tray 1 paper feed). Is it free of damage? Step 4 Go to step 7. Go to step 5. Enter the Diagnostics menu, and then navigate to: SENSOR TESTS >...
Page 77 4021 Action Step 11 Go to step 12. The problem is solved. Check the paper feed belt for proper tension, and then adjust if necessary. Check the paper feed gear and belt for wear or damage, and replace if necessary. Does the problem remain? Step 12 Go to step 13.
Page 78 4021 Action Step 18 Go to step 19. The problem is solved. Make sure that the registration unit is properly installed. Make sure that the registration unit is clear of obstructions. Check the registration unit for damage, and replace if necessary. See “Registration unit assembly removal”...
Page 79 4021 Tray 2 feed jam service check Action Step 1 Go to step 2. Go to step 7. Enter the Diagnostics menu, and then navigate to: EVENT LOG > Display Log Do most of the recent error codes end with a 1? (Example: 241.11, 200.91) Step 2 Go to step 3.
Page 80 4021 Action Step 9 Go to step 10. The problem is solved. Check the tray 2 feed, pick, and separator rollers for damage, and replace if necessary. Note: If the page count is over 50K, then clean the rollers. Does the problem remain? Step 10 Go to step 14.
Page 81 4021 Action Step 16 Go to step 17. The problem is solved. Reseat the tray 2 transport motor cable. Check the tray 2 transport motor cable for damage, and replace if necessary. Does the problem remain? Step 17 Go to step 18. The problem is solved.
Page 82 4021 Action Step 24 Contact the next level The problem is solved. of support. Check the engine controller board pins for damage, and replace if necessary. See “Engine controller board removal” on page 296. Does the problem remain? 2 x 500‑sheet tray 3 transport jam service check Action Step 1 Go to step 2.
Page 83 4021 Action Step 8 Go to step 12. Go to step 9. Enter the Diagnostics menu, and then navigate to: MOTOR TESTS > 2 x 500-Sheet Tray Motor Tests > Tray 3 transport Does the motor run? Step 9 Go to step 10. The problem is solved.
Page 84 4021 Action Step 2 Go to step 3. Go to step 4. Remove the rear cover. Make sure that the sensor (3000-sheet tray set) is properly installed. Make sure that the sensor is free of debris or dust. Reseat the cable on the sensor and the cable CN5 on the controller board.
Page 85: 243-245 Paper Jams
4021 243–245 paper jams [x]‑page jam, slide the 3000‑sheet tray and open door D. [24y.xx] Slide the 3000‑sheet tray. Open door D, and then remove the jammed paper. Note: Make sure that all paper fragments are removed. Open the optional tray, and then locate the jammed paper. Remove the jammed paper.
Page 86 4021 Close the tray and door D. Slide the 3000‑sheet tray back into place. 243 paper jam messages Error code Description Action 243.31 2 x 500‑sheet tray: Paper remains detected “2 x 500‑sheet tray 3 jam service check” on page at the sensor (tray 3 feed) after printer is turned on.
Page 87 4021 244 paper jam messages Error code Description Action 244.41 Paper remains detected at the sensor (tray 4 “2 x 500‑sheet tray 4 jam service check” on page feed) after the printer turned on. 244.46 The sensor (tray 4 transport) did not detect “2 x 500‑sheet tray 4 jam service check”...
Page 88 4021 Actions Step 4 Go to step 13. Go to step 5. Enter the Diagnostics Menu, and then navigate to: SENSOR TESTS > 2500-Sheet Tray Sensor Tests Does the sensor status change while toggling the sensor? Step 5 Go to step 6. The problem is solved.
Page 89 4021 Actions Step 11 Go to step 12. The problem is solved. Check the 2500-sheet tray feed and transport motor belt for proper tension, and adjust if necessary. Check the 2500-sheet tray feed and transport motor belt and gears for wear or damage, and replace if necessary. Does the problem remain? Step 12 Go to step 13.
Page 90 4021 2 x 500‑sheet tray 3 jam service check Action Step 1 Go to step 2. Go to step 7. Enter the Diagnostics menu, and then navigate to: EVENT LOG > Display Log Do most of the recent error codes end with a 1? (Example: 241.11, 200.91) Step 2 Go to step 3.
Page 91 4021 Action Step 9 Go to step 17. Go to step 10. Enter the Diagnostics menu, and then navigate to: MOTOR TESTS > 2 x 500-Sheet Tray Motor Tests > Tray 3 feed Does the motor run? Step 10 Go to step 11. The problem is solved.
Page 92 4021 Action Step 17 Contact the next level The problem is solved. of support. Check the 2 x 500‑sheet tray controller board pins for damage, and replace if necessary. See “2 x 500-sheet tray controller board removal” on page 374. Does the problem remain? 2 x 500‑sheet tray 4 jam service check Action...
Page 93 4021 Action Step 7 Go to step 13. Go to step 8. Enter the Diagnostics menu, and then navigate to: INPUT TRAY TESTS > Feed Tests > Tray 4 Does the leading edge of the paper reach the sensor (2 x 500‑sheet tray 4 paper feed)? Step 8 Go to step 9.
Page 94 4021 Action Step 15 Go to step 16. The problem is solved. Reseat the sensor cable. Check the cable for damage, and replace if necessary. Does the problem remain? Step 16 Go to step 17. The problem is solved. Replace the sensor (2 x 500‑sheet tray 4 transport). See “2 x 500-sheet tray transport assembly sensors removal”...
Page 95 4021 Action Step 5 Go to step 6. The problem is solved. Reseat the sensor cable. Check the cable for damage, and replace if necessary. Does the problem remain? Step 6 Go to step 7. The problem is solved. Replace the sensor (tray 3 transport). See “2 x 500-sheet tray transport assembly sensors removal”...
Page 96 4021 Action Step 12 Contact the next level The problem is solved. of support. Check the 2 x 500‑sheet tray controller board pins for damage, and replace if necessary. See “2 x 500-sheet tray controller board removal” on page 374. Does the problem remain? 3000‑sheet tray feed jam service check Action...
Page 97 4021 Action Step 4 Go to step 5. Go to step 6. Make sure that the following sensors are properly installed: • Sensor (3000-sheet tray elevator level) • Sensor (3000-sheet tray empty) • Sensor (3000-sheet tray feed) Make sure that the sensors are free of debris or dust. Reseat the cable on the sensors and the cable CN5 on the controller board.
Page 98 4021 Action Step 10 Go to step 11. The problem is solved. Reseat the cable on the rest of the sensors. Reseat the cable CN5 on the controller board. If necessary, reseat all the junction connectors on the cables. Make sure that the cables do not block the path of moving parts. Check the cables for damage, and replace if necessary.
Page 99: Understanding The Printer Messages
4021 Action Step 4 Go to step 5. The problem is solved. Replace the sensor. See “Sensor (3000-sheet tray feed) removal” on page 399. Does the problem remain? Step 5 Go to step 6. The problem is solved. Reseat the cable on all of the sensors. Reseat the cable CN5 on the controller board.
Page 100: Change [Paper Source] To [Custom String] Load [Orientation]
4021 Change [paper source] to [custom string] load [orientation] Try one or more of the following: • Load the correct size and type of paper in the tray, specify the paper size and type in the Paper menu on the control panel, and then touch Finished changing paper.
Page 101: Configuration Change, Some Held Jobs Were Not Restored [57]
4021 • Cancel the print job. • Install additional printer memory. Configuration change, some held jobs were not restored [57] Held jobs are invalidated because of the following possible changes in the printer: • The printer firmware has been updated. •...
Page 102: Empty The Hole Punch Box
4021 Empty the hole punch box Try one or more of the following: • Empty the hole punch box. • Select Continue on the printer control panel to clear the message and continue printing. • Cancel the print job. Error reading USB drive. Remove USB. An unsupported USB device is inserted.
Page 103: Insufficient Memory To Collate Job [37]
4021 Insufficient memory to collate job [37] Try one or more of the following: • From the printer control panel, touch Continue to print the part of the job already stored and begin collating the rest of the print job. •...
Page 104: Load [Paper Source] With [Paper Size] [Paper Orientation]
4021 Load [paper source] with [paper size] [paper orientation] Try one or more of the following: • Load the tray or feeder with the correct size of paper, and then touch Finished loading paper on the control panel. • Touch Reset active bin to reset the active bin for a linked set of bins. •...
Page 105: Load Multipurpose Feeder With [Paper Type] [Paper Size] [Paper Orientation]
Cancel the print job. [x] maintenance kit very low [80.xy] You may need to replace the maintenance kit very soon. For more information, go to the Lexmark support Web site at http://support.lexmark.com or contact customer support, and then report the message.
Page 106: Network [X] Software Error [54]
Turn off the printer, wait for about 10 seconds, and then turn the printer back on. • Update the network firmware in the printer or print server. For more information, visit the Lexmark support Web site at http://support.lexmark.com. Not enough free space in flash memory for resources [52] Try one or more of the following: •...
Page 107: Printer Had To Restart. Last Job May Be Incomplete
Printer had to restart. Last job may be incomplete. From the printer control panel, touch Continue to clear the message and continue printing. For more information, visit http://support.lexmark.com or contact customer support. Reinstall missing or unresponsive cartridge [31.xy] Try one or more of the following: •...
Page 108: Remove Paper From Bin [X]
“Replacing supplies” section of the User’s Guide. Note: If you do not have a replacement cartridge, then see the “Ordering supplies” section of the User’s Guide or visit www.lexmark.com. Replace cartridge, printer region mismatch [42.xy] Install a toner cartridge that matches the region number of the printer.
Page 109: Replace [X] Maintenance Kit, 0 Estimated Pages Remain [80.Xy]
4021 Replace [x] maintenance kit, 0 estimated pages remain [80.xy] The printer is scheduled for maintenance. For more information, go to the Lexmark support Web site at http://support.lexmark.com or contact your service representative, and then report the message. Replace missing photoconductor [31.xy] Install the missing photoconductor unit to clear the message.
Page 110: Restore Held Jobs
• Turn off the printer, and then turn it back on. • Update the network firmware in the printer or print server. For more information, visit the Lexmark support Web site at http://support.lexmark.com or contact customer support, and then report the message.
Page 111: Supply Needed To Complete Job
4021 Supply needed to complete job Do either of the following: • Install the missing supply to complete the job. • Cancel the current job. The device is operating in Safe Mode. Some print options may be disabled or provide unexpected results. Touch Continue on the control panel to clear the message and continue printing.
Page 112: Unsupported Disk
4021 Unsupported disk Remove the unsupported printer hard disk, and then insert a supported one. Unsupported option in slot [x] [55] Turn off the printer. Unplug the power cord from the electrical outlet. Remove the unsupported option card from the printer controller board, and then replace it with a supported card. Connect the power cord to a properly grounded electrical outlet.
Page 113: Cartridge Or Photoconductor Error Service Check
4021 Error code Description Action The cartridge is incompatible due to printer region “Cartridge or photoconductor error service mismatch. check” on page 113. PPDS encountered a font error. “PPDS font error service check” on page 116. The flash memory is defective. “Flash memory failure service check”...
Page 114: Mismatched Paper Size Service Check
4021 Action Step 2 Go to step 3. The problem is solved. Make sure that the cartridge or photoconductor is properly installed. Make sure that the cartridge or photoconductor cables are properly connected. Does the problem remain? Step 3 Go to step 4. The problem is solved.
Page 115: Insufficient Memory Service Check
4021 Action Step 5 Contact the next level The problem is solved. of support. Check the controller board pins for damage, and replace if necessary. See “Controller board removal” on page 298. Does the problem remain? Insufficient memory service check Action Step 1 Go to step 2.
Page 116: Ppds Font Error Service Check
4021 Action Step 3 Go to step 4. The problem is solved. If applicable, install extra memory card. If applicable, make sure that the additional memory card is properly installed. Does the problem remain? Step 4 Contact the next level The problem is solved.
Page 117: Insufficient Flash Memory Service Check
4021 Action Step 3 Go to step 4. The problem is solved. Check the controller board pins for damage, and replace if necessary. See “Controller board removal” on page 298. Does the problem remain? Step 4 Contact the next level The problem is solved.
Page 118: Network Service Check
Verify if there is no electronic interference in the wireless network. Have the network administrator verify that the device is using the correct SSID, and wireless security protocols. For more network troubleshooting information, consult the Lexmark Network Setup Guide.
Page 119 4021 Actions Step 8 Go to step 9. The problem is solved. Reset the address on the printer to match the IP address on the driver. Does the problem remain? Step 9 Go to step 11. Go to step 10. Have the network administrator verify that the printer and computer IP address have identical subnet addresses.
Page 120: Unsupported Internal Option Service Check
4021 Actions Step 18 Go to step 19. The problem is solved. Make sure that the wireless card on the controller board is properly installed. Does the problem remain? Step 19 Go to step 20. The problem is solved. If there is an attached antenna, check it for damage, and replace if necessary.
Page 121: Disabled Port Service Check
4021 Disabled port service check Action Step 1 Go to step 2. The problem is solved. Make sure that the cables connected to ports are properly installed. Check the cables for damage, and replace if necessary. Does the problem remain? Step 2 Go to step 3.
Page 122: Excess Options Service Check
4021 Action Step 3 Go to step 4. The problem is solved. If applicable, remove all internal options. Reset the printer, and then resend the print job. Does the problem remain? Step 4 Contact the next level The problem is solved. of support.
Page 123: Incompatible Hardware Option Service Check
Go to step 3. The problem is solved. Make sure that the firmware version is the latest. Note: The latest firmware versions are available on the Technical service bulletins at support.lexmark.com. Does the problem remain? Step 3 Go to step 4.
Page 124: Maintenance Kit Service Check
4021 Action Step 4 Go to step 5. The problem is solved. Make sure that the hard disk is properly installed. Check the hard disk for damage, and replace if necessary. Does the problem remain? Step 5 Contact the next level The problem is solved.
Page 125: 111 Errors
4021 111 errors 111 error messages Error code Description Action 111.01 The printhead motor malfunctioned. “Printhead failure service check” on page 125. 111.06 The printhead laser malfunctioned. Printhead failure service check Action Step 1 Go to step 2. The problem is solved. Enter the Diagnostics menu, and then navigate to: PRINTER SETUP >...
Page 126: 12Y Errors
4021 12y errors 12y error messages Error code Description Action 120.00 The motor (fuser) did not run. “Motor (fuser) failure service check” on page 126. 120.06 The motor (fuser) did not run at the correct timing. 121.02 The fuser temperature did not reach the required “Fuser temperature failure service check”...
Page 127 4021 Action Step 3 Go to step 7. Go to step 4. Enter the Diagnostics menu, and then navigate to: MOTOR TESTS > PRINTER MOTOR TESTS > Fusing tray Does the motor run? Step 4 Go to step 5. The problem is solved. Reseat the fuser motor cable.
Page 128 4021 Action Step 11 Go to step 12. The problem is solved. Replace the sensor (fusing speed). See “Sensor (fusing speed) removal” on page 267. Does the problem remain? Step 12 Contact the next level The problem is solved. of support. Check the controller board pins for damage, and replace if necessary.
Page 129 4021 Action Step 6 Go to step 7. The problem is solved. Make sure that the paper exit fan cable is properly connected. Check the paper exit fan for damage, and replace if necessary. See “Paper exit fan removal” on page 300.
Page 130 4021 Fuser roller pressure failure service check Action Step 1 Go to step 2. The problem is solved. Enter the Diagnostics menu, and then navigate to: PRINTER SETUP > Reset Engine Service Error Does the problem remain? Step 2 Go to step 3. The problem is solved.
Page 131: 13Y Errors
4021 Action Step 9 Contact the next level The problem is solved. of support. Check the engine controller board pins for damage, and replace if necessary. See “Engine controller board removal” on page 296. Does the problem remain? 13y errors 13y error messages Error code Description...
Page 132 4021 Action Step 5 Go to step 6. The problem is solved. Make sure that the toner is properly installed. Make sure that the toner is supported. Does the problem remain? Step 6 Go to step 7. The problem is solved. Make sure that the sensor (toner density) is free of dust or debris.
Page 133 4021 Action Step 12 Go to step 13. The problem is solved. Make sure that the toner cartridge motor cable is properly connected. Check the motor (toner cartridge) and its cable for damage, and replace if necessary. See “Motor (toner cartridge) removal” on page 302.
Page 134: 153 Errors
4021 Action Step 5 Go to step 6. The problem is solved. Replace the motor (developer). See “Motor (developer) removal” on page 308. Does the problem remain? Step 6 Go to step 9. Go to step 7. Check the developer for proper operation. Is it working properly? Step 7 Go to step 8.
Page 135: 16Y Errors
4021 Motor (transport) failure service check Action Step 1 Go to step 2. The problem is solved. Enter the Diagnostics menu, and then navigate to: PRINTER SETUP > Reset Engine Service Error Does the problem remain? Step 2 Go to step 6. Go to step 3.
Page 136 4021 Error code Description Action 164.04 The motor (tray 4 feed) did not reach the required “2 x 500-sheet tray 4 feed failure service speed. check” on page 138. 167.04 The motor (tray 3 transport) did not reach the “2 x 500-sheet tray 3 transport failure service required speed.
Page 137 4021 2500-sheet tray feed failure service check Actions Step 1 Go to step 2. The problem is solved. Enter the Diagnostics Menu, and then navigate to: PRINTER SETUP > Reset engine Service Error Note: Do this every time a service error would occur to clear the error and restore the engine settings.
Page 138 4021 2 x 500-sheet tray 4 feed failure service check Actions Step 1 Go to step 2. The problem is solved. Enter the Diagnostics menu, and then navigate to: PRINTER SETUP > Reset Engine Service Error Does the problem remain? Step 2 Go to step 3.
Page 139 4021 2 x 500-sheet tray 3 transport failure service check Actions Step 1 Go to step 2. The problem is solved. Enter the Diagnostics menu, and then navigate to: PRINTER SETUP > Reset Engine Service Error Does the problem remain? Step 2 Go to step 3.
Page 140 4021 2500-sheet tray transport failure service check Actions Step 1 Go to step 2. The problem is solved. Enter the Diagnostics Menu, and then navigate to: PRINTER SETUP > Reset engine Service Error Note: Do this step every time a service error would occur to clear the error and restore the engine settings.
Page 141: 171-182 Errors
4021 2 x 500-sheet tray 4 transport failure service check Actions Step 1 Go to step 2. The problem is solved. Enter the Diagnostics menu, and then navigate to: PRINTER SETUP > Reset Engine Service Error Does the problem remain? Step 2 Go to step 3.
Page 142: 189 Errors
4021 Fan failure service check Action Step 1 Go to step 2. The problem is solved. Enter the Diagnostics menu, and then navigate to: PRINTER SETUP > Reset Engine Service Error Does the problem remain? Step 2 Go to step 3. The problem is solved.
Page 143 4021 2 x 500-sheet tray communication error service check Actions Step 1 Go to step 2. The problem is solved. Enter the Diagnostics menu, and then navigate to: PRINTER SETUP > Reset Engine Service Error Does the problem remain? Step 2 Go to step 3.
Page 144: 19Y Errors
4021 2500-sheet tray communication error service check Actions Step 1 Go to step 2. The problem is solved. Enter the Diagnostics Menu, and then navigate to: PRINTER SETUP > Reset Engine Service Error Note: Do this step every time a service error would occur to clear the error and restore the engine settings.
Page 145 4021 196–197 error messages Error code Description Action 196.10 The 2500-sheet tray lift plate did not move to the “2500-sheet tray lift plate failure service check” correct position. on page 155. 196.11 The 2500-sheet tray transfer guide did not move to the “2500-sheet tray transfer guide motor failure correct position.
Page 146 4021 Action Step 5 Go to step 6. The problem is solved. Check the MPF lift plate solenoid, including the actuator for wear or damage, and replace if necessary. See “MPF lift plate solenoid removal” on page 251. Does the problem remain? Step 6 Go to step 8.
Page 147 4021 Action Step 13 Go to step 17. Go to step 14. Enter the Diagnostics menu, and then navigate to: MOTOR TESTS > PRINTER MOTOR TESTS > Paper feed Does the motor run? Step 14 Go to step 15. The problem is solved. Reseat the feed motor cable.
Page 148 4021 Tray 1 lift plate failure service check Action Step 1 Go to step 2. The problem is solved. Enter the Diagnostics menu, and then navigate to: PRINTER SETUP > Reset Engine Service Error Does the problem remain? Step 2 Go to step 5.
Page 149 4021 Action Step 9 Go to step 10. The problem is solved. Replace the sensor. Does the problem remain? Step 10 Contact the next level The problem is solved. of support. Check the engine controller board pins for damage, and replace if necessary.
Page 150 4021 Action Step 7 Go to step 10. Go to step 8. Enter the Diagnostics menu, and then navigate to: SENSOR TESTS > PRINTER SENSOR TESTS > Tray 2 lift plate limit Does the sensor status change while toggling the sensor? Step 8 Go to step 9.
Page 151 4021 Action Step 5 Go to step 6. The problem is solved. Make sure that the tray 3 tray set actuator is properly installed. Check the actuator for damage, and replace if necessary. “2 x 500‑sheet tray tray set actuator removal” on page 380.
Page 152 4021 2 x 500‑sheet tray 4 lift plate failure service check Action Step 1 Go to step 2. The problem is solved. Enter the Diagnostics menu, and then navigate to: PRINTER SETUP > Reset Engine Service Error Does the problem remain? Step 2 Go to step 5.
Page 153 4021 Action Step 9 Go to step 10. The problem is solved. Replace the sensor (2 x 500-sheet tray 4 lift plate level). See “2 x 500-sheet tray transport assembly sensors removal” on page 379. Does the problem remain? Step 10 Contact the next level The problem is solved.
Page 154 4021 Action Step 5 Contact the next level The problem is solved. of support. Reseat the cable on the rest of the motors and on the top door switch. Reseat the cables CN3 and CN4 on the controller board. If necessary, reseat all of the junction connectors on the cables. Make sure that the cables do not block the path of moving parts.
Page 155 4021 Action Step 5 Go to step 6. The problem is solved. Make sure that the fuser is properly installed. Make sure that the fuser cable is properly connected. Check the fuser for damage, and replace if necessary. See “Fuser removal”...
Page 156 4021 Actions Step 4 Go to step 5. The problem is solved. Check the coupling for wear or damage, and replace if necessary. Check the motor gears, rollers, and belts for wear or damage, and replace if necessary. Does the problem remain? Step 5 Go to step 6.
Page 157 4021 2500-sheet tray transfer guide motor failure service check Actions Step 1 Go to step 2. The problem is solved. Enter the Diagnostics Menu, and then navigate to: PRINTER SETUP > Reset engine Service Error Note: Do this step every time a service error would occur to clear the error and restore the engine settings.
Page 158: 600 Errors
4021 Actions Step 7 Go to step 9. Go to step 8. Enter the Diagnostics Menu, and then navigate to: SENSOR TESTS > 2500-Sheet Tray Sensor Tests Does the sensor status change while toggling the sensor? Step 8 Go to step 9. The problem is solved.
Page 159: Steps Before Starting The 9Yy Service Checks
4021 Unready image service check Action Step 1 Go to step 2. The problem is solved. Make sure that the Page description language (PDL) of the print job is supported. Install the supporting option card if necessary. Does the problem remain? Step 2 Go to step 3.
Page 160 4021 A. Collecting the history information from the SE menu Note: Make sure your printer is connected to a network or to a print server. From a Web browser, type http://printer_IP_address/se, and then press Enter. Notes: • printer_IP_address is the TCP/IP address of the printer •...
Page 161: 900 Errors
159. Determine the operating system used when the error occurred. If possible determine whether a PostScript or PCL file was sent to the device when the error occurred. Ask the customer which Lexmark Solutions applications are installed on the device.
Page 162 4021 Action Step 1 Go to step 2. The problem is solved. POR the printer. Does the error remain? Step 2 Go to step 3. Go to step 6. Write down the exact 900.xx error code displayed on the device. Turn off the printer.
Page 163 4021 Action Step 7 Go to step 8. Go to step 10. Note: Before performing this step, write down the following information about the file being sent to the printer: • Application used • Operating system • Driver type • File type (PCL, PostScript, XPS, etc.) Reattach the communications cable.
Page 164 4021 Action Step 15 Go to step 31. The problem is solved. Install a Lexmark recommended memory option. Send a print job to the printer. Does the error remain? Step 16 Go to step 17. Go to step 21. Is there a modem installed? Step 17 Go to step 18.
Page 165 4021 Action Step 24 Go to step 25. The problem is solved. Upgrade the firmware if it was not upgraded in a previous step. Note: Contact your next level of support for the correct firmware level to use. POR the printer. Send the printer a print job.
Page 166: 911-963 Errors
4021 Action Step 31 Contact your next level of support. You will need the following information: • Exact 900.xx error digits and complete error message • Printed menu settings page • Printed network settings page • Device error log • A sample print file if the error appears to be isolated to a single file •...
Page 167 4021 Engine and controller board error service check Action Step 1 Go to step 2. The problem is solved. Reset the printer. Make sure that the cables are properly connected to the engine controller board and controller board. Does the problem remain? Step 2 Go to step 3.
Page 168: Symptoms
4021 Action Step 4 Contact the next level The problem is solved. of support. Make sure that the firmware version is the latest. Does the problem remain? Symptoms 3000‑sheet tray tray set failure service check Action Step 1 Go to step 2. The problem is solved.
Page 169 4021 Action Step 6 Go to step 7. The problem is solved. Reseat the cable on the rest of the sensors. Reseat the cable CN5 on the controller board. If necessary, reseat all the junction connectors on the cables. Make sure that the cables do not block the path of moving parts. Check the cables for damage, and replace if necessary.
Page 170 4021...
Page 171: Service Menus
4021 Service menus Understanding the printer control panel Using the control panel Use the Display • Show the status of the printer. • Set up and operate the printer. Home button Go to the home screen. Sleep button Enable Sleep mode or Hibernate mode. The following actions wake the printer from Sleep mode: •...
Page 172: Understanding The Home Screen
4021 Indicator light Printer status The printer is off or in Hibernate mode. Blinking green The printer is warming up, processing data, or printing. Solid green The printer is on, but idle. Blinking red The printer requires user intervention. Sleep button light Printer status The printer is off, idle or in Ready state.
Page 173: Using The Touch-Screen Buttons
4021 Touch View, select, or print photos and documents from a flash drive. Note: This icon appears only when you return to the home screen while a memory card or flash drive is connected to the printer. Menus Access printer menus. Note: These menus are available only when the printer is in Ready state.
Page 174 4021 Touch the Radio button Select or clear an item. Up arrow Scroll up. Down arrow Scroll down. Accept button Save a setting. Cancel button • Cancel an action or a selection. • Return to the previous screen. Touch Return to the home screen. Open a context-sensitive Help dialog on the printer control panel.
Page 175: Menus List
4021 Menus list Paper Menu Reports Network/Ports Option Card Menu Default Source Menu Settings Page Active NIC A list of installed DLEs (Download Emulators) Paper Size/Type Device Statistics Standard Network appears. Configure MP Stapler Test Standard USB Substitute Size Network Setup Page Parallel [x] Paper Texture Profiles List...
Page 176: Reset Maintenance Counter
4021 Reset Maintenance Counter This setting resets the value of the counter that tracks the usage of the multipurpose feeder maintenance roller kit. Enter the Diagnostics Menu, and then select Reset Maintenance Counter. Select the kit to reset. Reset Fuser Counter This setting resets the fuser counter to zero.
Page 177: Print Quality Pages
4021 Select any of the following: • Single—This option prints a single Print Test page (no buttons are active while the test page is printing). • Continuous—This option continuously prints the Print Test page until X is pressed. Print Quality Pages This setting lets you view the values of a broad range of the printer settings and test the printer ability to generate an acceptable printed output.
Page 178 4021 After the printer resets, the results of the test appear: DRAM Test [x] P:###### F:######. • [x] represents the size of the installed DRAM. • P:###### represents the number of times the memory test passed and finished successfully. The maximum pass count is 999,999. •...
Page 179: Duplex Tests
4021 DUPLEX TESTS Quick Test This test determines if the top margin at the back of a duplexed page is set correctly. Enter the Diagnostics Menu, and then navigate to: DUPLEX TESTS > Quick Test Select any of the following: •...
Page 180: Output Bin Tests
4021 OUTPUT BIN TESTS Feed Tests This test verifies if paper can be fed to a specific output bin. No information is printed on the paper. Enter the Diagnostics Menu, and then navigate to: OUTPUT BIN TESTS > Feed Tests Select the output bin.
Page 181 4021 Select a sensor. Manually toggle the sensor. Note: The sensor status on the screen toggles between Open and Close when the sensor is working properly. 3000‑Sheet Tray Sensor Tests These tests verify that the 3000-sheet tray sensors are working properly. Remove the tray inserts from tray 1 and tray 2.
Page 182: Motor Tests
4021 Staple Finisher Sensor Tests These tests verify that the staple finisher sensors are working properly. Remove the tray inserts from tray 1 and tray 2. Enter the Diagnostics Menu, and then navigate to: SENSOR TESTS > Staple Finisher Sensor Tests Select a sensor.
Page 183: Device Tests
4021 3000‑Sheet Tray Motor Tests These tests verify that the 3000‑sheet tray motors are working properly. Enter the Diagnostics Menu, and then navigate to: Motor Tests > 3000‑Sheet Tray Motor Tests Select a motor. Check if the motor runs. Staple Finisher Motor Tests These tests verify that the staple finisher motors are working properly.
Page 184: Printer Setup
4021 Disk Test/Clean Warning—Potential Damage: This test destroys all data on the printer hard disk. This test may run for approximately 1.5 hours depending on the disk size. Enter the Diagnostics Menu, and then navigate to: DEVICE TESTS > Disk Test/Clean You cannot cancel the test once it has started.
Page 185 4021 Printed Page Count This setting gauges the amount of usage on the printer. The value of the Printed Page Count setting equals the value of the Picked Sides meter. After all print tests are completed, the value resets to zero. Enter the Diagnostics Menu, and then navigate to: PRINTER SETUP >...
Page 186: Reports
4021 Reset Engine Service Error This setting restores the engine to normal functioning mode after a fatal error occurs that places the engine into lockdown mode. Enter the Diagnostics Menu, and then navigate to: PRINTER SETUP > Reset Engine Service Error Restore Backup Data This setting transfers the settings from the engine controller board to the printer controller board and vice versa.
Page 187: Event Log
4021 EVENT LOG Display Log This setting displays the panel text that appears when the event occurs. Enter the Diagnostics Menu, and then navigate to: EVENT LOG > Display Log Print Log This setting prints the various printer events. Note: The events that appear in the report vary depending on the operational history of the printer. Enter the Diagnostics Menu, and then navigate to: EVENT LOG >...
Page 188: Configuration Menu
4021 Configuration menu The Configuration menu group consists of menus, settings, and operations that are used to configure a printer for operation. Entering the Configuration menu Turn off the printer. Press and hold 2 and 6 while turning on the printer. Release the buttons when the splash screen appears.
Page 189: Reports
4021 Reports Menu Settings Page This report lists of the Configuration Menu settings and the value of each setting. Enter the Configuration Menu, and then navigate to: Reports > Menu Settings Page Return to the Configuration Menu screen. Event Log This setting prints a report of the detailed events in the print log.
Page 190: Ppds Emulation
4021 Apply the changes. PPDS Emulation This setting determines if the printer can recognize and use the PPDS data stream. Enter the Configuration Menu, and then select PPDS Emulation. Select a setting. Apply the changes. Download Emuls This menu appears only if at least one download emulator (DLE) is installed. The default setting is Disable. All download emulators are automatically re‑enabled after two PORs.
Page 191: Numpad Job Assist
4021 NumPad Job Assist This setting determines if you can configure and initiate a job using the hard buttons of the control panel. Enter the Configuration Menu, and then select NumPad Job Assist. Select a setting. Apply the changes. Paper Prompts This setting determines the input source to which the printer directs a paper change prompt.
Page 192: Disk Encryption
Enter the Configuration Menu, and then select UI Automation. Select a setting. Apply the changes. LES Applications This setting allows you to enable the Lexmark Embedded Solutions (LES) applications. Enter the Configuration Menu, and then select LES Applications. Select a setting. Apply the changes.
Page 193: Key Repeat Initial Delay
4021 Key Repeat Initial Delay This setting determines the length of delay before a repeating key starts repeating. Enter the Configuration Menu, and then select Key Repeat Initial Delay. Select a setting. Apply the changes. Key Repeat Rate This setting indicates the number of presses per second for a repeating key. Enter the Configuration Menu, and then select Key Repeat Rate.
Page 194: Restore Factory Defaults
4021 Restore factory defaults Restore Settings This setting restores the printer to its network or base settings Enter the Configuration Menu, and then navigate to: Restore Factory Defaults > Restore Settings Select a setting. Apply the changes. Erase Printer Memory This setting makes any sensitive information on the volatile or non-volatile storage of the printer completely indecipherable.
Page 195: Entering Invalid Engine Mode
4021 Entering Invalid engine mode This mode allows the printer to load the correct firmware code. Turn off the printer. Press and hold 3, 4, and 6 while turning on the printer. Release the buttons after 10 seconds. Entering Recovery Mode This mode allows the printer to receive firmware updates using a USB connection.
Page 196 4021 Top level menu Intermediate menu ‑‑ Print SE Menus General Copyright Code Revision Info • Network Code Level • Network Compile Info • Printer Code Level • Printer Compile Info History • Print History • Mark History • History Mode •...
Page 197: Repair Information
4021 Repair information Removal precautions CAUTION—SHOCK HAZARD: For personal safety and to prevent damage to the printer, remove the power cord from the electrical outlet before you connect or disconnect any cable, electronic board, or assembly. Disconnect any connections between the printer and the computer or peripherals. Data security notice The printer contains various types of memory that store device and network settings, information from embedded solutions, and user data.
Page 198: Restoring The Printer Configuration After Replacing The Controller Board
Note: The software bundle contains the latest version of the firmware, applications, and software licenses from the Lexmark Virtual Solutions Center (VSC). The printer firmware may be at a different level from what was used before replacing the controller board.
Page 199 4021 Save the zip file. Note: Make sure that the serial number in the zip file matches the serial number of the printer being restored. Extract the contents of the zip file, open the Readme file, and then follow the instructions in the file. Notes: •...
Page 200 4021 After performing the installation instructions in the Readme file, confirm from the customer if all the eSF apps have been installed. Notes: • If you are unable to access the administrative menus to verify that the printer is restored, then ask the customer for access rights.
Page 201: Restoring Solutions, Licenses, And Configuration Settings
4021 Restoring solutions, licenses, and configuration settings To load the zip files that are extracted from the Service Restore Tool, do the following: Open a Web browser, and then type the printer IP address. Navigate to Settings > Configuration Files. From the Configuration File History tab, navigate to Import >...
Page 202: Updating The Printer Firmware
4021 Click Import. Repeat steps 3 to 5 for the other zip files that are included in the expanded zip file. Updating the printer firmware Warning—Potential Damage: Before updating the printer firmware, ask the next level of support for the correct code.
Page 203: Backing Up Esf Solutions And Settings
4021 Using a network computer Using the File Transfer Protocol (FTP) Make sure that the printer is in ready state before flashing the printer. Turn on the printer. Obtain the IP address: • From the home screen • From the TCP/IP section of the Network/Ports menu From the command prompt of a network computer, open an FTP session to the printer IP address.
Page 204: Understanding The Marked Or Colored Screws
4021 Importing eSF solutions and settings file After replacing the controller board, import back to the printer the eSF solutions and settings that were exported. POR the printer into Invalid engine mode. See “Entering Invalid engine mode” on page 195. Open a Web browser, and then type the printer IP address.
Page 205: Horizontal Top Contact Connector
4021 Horizontal top contact connector This connector uses a back flip locking actuator to lock the ribbon cable into the ZIF connector. Warning—Potential Damage: When opening or closing this type of actuator, lift or close the two tabs located on each end of the actuator.
Page 206 4021 Rotate the locking actuator to the locked position. Notes: • Do not move the cable while locking the actuator. • If the cable moves, open the actuator, reposition the cable, and then close the actuator. Repair information...
Page 207: Horizontal Bottom Contact Connector
4021 Horizontal bottom contact connector This connector uses a flip locking actuator to lock the ribbon cable into the ZIF connector. Warning—Potential Damage: When opening or closing this type of actuator, gently lift the center of the actuator using your finger. Do not use a fingernail or screwdriver to open the actuator to avoid damaging the ribbon cable. Do not close the actuator from its ends.
Page 208 4021 Inserting the cable Make sure that the actuator is in the open position. Insert the cable below the actuator with the contacts facing downward and away from the locking actuator. Note: Make sure that the cable is installed squarely into the connector to avoid intermittent failures. Repair information...
Page 209: Vertical Mount Contact Connector
4021 Rotate the locking actuator to the locked position. Vertical mount contact connector This connector uses a back flip locking actuator to lock the ribbon cable into the ZIF connector. Warning—Potential Damage: When opening or closing this type of actuator, gently lift the center of the actuator using your finger.
Page 210 4021 Inserting the cable Make sure that the locking actuator is in the open position. Insert the cable on top of the actuator with the contacts facing away from the locking actuator. Note: Make sure that the cable is installed squarely into the connector to avoid intermittent failures. Rotate the locking actuator to the locked position.
Page 211: Horizontal Sliding Contact Connector
4021 Horizontal sliding contact connector This connector uses a slide locking actuator to lock the ribbon cable into the ZIF connector. Warning—Potential Damage: When opening or closing this type of actuator, gently push or pull the two tabs located on each end of the actuator. Do not close the actuator from the center of the actuator. Do not use a screwdriver to open or close the actuator to avoid damage to the cable or connector.
Page 212 4021 Inserting the cable Make sure that the locking actuator is in the open position. If you are opening the connector, then pull back the end tabs using equal force to avoid breaking the connector. Insert the cable on top of the actuator with the contacts facing away from the locking actuator. Slide the locking actuator toward the connector to lock the cable.
Page 213: Low Insertion Force (Lif) Connector
4021 Low Insertion Force (LIF) connector Warning—Potential Damage: When installing a cable into an LIF connector, avoid bending the edges of the cables and damaging the contacts on the cables. Inserting the cable Make sure that the contacts of the controller board and connectors are on the same side. Insert the cable.
Page 214: Adjustments
4021 Adjustments Fuser alignment adjustment Fuser misalignment may cause wrinkles on the paper. Perform this step to align the fuser with the registration unit assembly. Remove the fuser. See “Fuser removal” on page 230. Remove the two screws (A), and then remove the fuser mount. Add or decrease the number of plates to adjust the position of the fuser.
Page 215: Pick Roller Pressure Adjustment
4021 Notes: • A single plate (B) has a thickness of 0.6 mm. • The default number of plates is 1. Perform a print job to verify the adjustment. Pick roller pressure adjustment Jams may occur if the improper level of pressure is applied in picking thin paper. Perform this step to increase or decrease the pick roller pressure.
Page 216 4021 Release the clips (B), and then remove the pick tire, bushing, and shaft. Repair information...
Page 217: Mpf Separator Roller Pressure Adjustment
4021 Press the lever, and then remove the spring (C). Install the replacement spring from step 2. Perform a print job to verify the adjustment. MPF separator roller pressure adjustment Jams may occur if the improper level of pressure is applied in picking thick paper from the MPF tray. Perform this step to increase or decrease the separator roller pressure.
Page 218 4021 Release the hook (B). Attach the hook to the hole (C). Note: The correct position is shown in the following illustration. Repair information...
Page 219: 3000-Sheet Tray Pick Roller Pressure Adjustment
4021 Perform a print job to verify the adjustment. 3000‑sheet tray pick roller pressure adjustment Jams may occur if the improper level of pressure is applied in picking thin paper. Perform this step to increase the pick roller pressure. Remove the screw (A), and then remove the plates. Installation note: Replace this screw with an M3 x 10 mm screw.
Page 220 4021 Remove the screw (B), and then remove the handle. Add one or more plates. Note: A total of four plates can be installed. Perform a print job to verify the adjustment. Repair information...
Page 221: 2500-Sheet Tray Transfer Guide Belt Adjustment
4021 2500‑sheet tray transfer guide belt adjustment Loose transfer guide belt may cause paper stack transfer failure. Perform this step to correct the transfer guide belt tension. Remove the tray insert. Raise the main tray. Remove the two screws (A), and then remove the belt cover (B). Move the paper stack transfer guide.
Page 222: Removal Procedures
4021 Loosen the tension screw (C) and then move the belt (D) to adjust. Retighten the tension screw. Removal procedures Keep the following tips in mind as you replace parts: • Some removal procedures require removing cable ties. You must replace cable ties during reassembly to avoid pinching wires, obstructing the paper path, or restricting mechanical movement.
Page 223: Left Side Removals
4021 Left side removals Left cover removal Remove the three screws (A). Remove the cover. Repair information...
Page 224: Rear Left Cover Removal
4021 Rear left cover removal Remove the left cover. See “Left cover removal” on page 223. Remove the three screws (A), and then remove the cover. Main power supply shield removal Note: This part is not a FRU. Remove the left cover. See “Left cover removal”...
Page 225: Main Power Supply Fan Removal
4021 Remove the six screws (A), and then remove the shield. Main power supply fan removal Remove the left cover. See “Left cover removal” on page 223. Remove the rear left cover. See “Rear left cover removal” on page 224. Remove the main power supply shield.
Page 226: Main Power Supply Removal
4021 Main power supply removal CAUTION—SHOCK HAZARD: The main power supply capacitors may have residual voltage. Do not touch the parts under the insulated area. The printer must be turned off for four hours to dissipate the charge. CAUTION—FIRE HAZARD: To prevent fire, do not replace fuse with the incorrect type and rating. Remove the left cover.
Page 227 4021 Disconnect the two cables (A), and then remove the eight screws (B) from the cover. From the front, disconnect the two cables (C), and then remove the two screws (D). Remove the cover and printhead. Repair information...
Page 228: Right Side Removals
4021 Right side removals Port access door removal Open the door, and then remove the four screws (A). Remove the door. Repair information...
Page 229: Fuser Connector Cover Removal
4021 Fuser connector cover removal Note: This part is not a FRU. Open the right door, and then remove the screw (A). Remove the cover. Repair information...
Page 230: Fuser Removal
4021 Fuser removal Open the right door. Remove the three screws (A). Remove the fuser connector cover, and then disconnect the three fuser cables (B). Remove the fuser. Note: If the fuser rollers are not retracted, the fuser may be hard to remove. To retract the fuser roller, turn on the printer to initiate warm‑up, and then turn off the printer.
Page 231: Registration Transport Assembly
4021 From the rear side, disconnect the four cables (A), and then remove the two screws (B). Remove the two screws (B) and then remove the heater. Registration transport assembly Remove the fuser connector cover. See “Fuser connector cover removal” on page 229.
Page 232: Top Side Cover Removal
4021 Remove the clip (A), and then remove the gear. Remove the four screws (B), and then remove the assembly. Top side cover removal Remove the three screws (A). Remove the cover. Repair information...
Page 233: Upper Right Cover Removal
4021 Upper right cover removal Note: This part is not a FRU. Remove the top side cover. See “Top side cover removal” on page 232. Remove the two screws (A), and then remove the cover. Redrive belt cover removal Note: This part is not a FRU. Open the right door.
Page 234: Redrive Belt Removal
4021 Redrive belt removal Remove the motor (redrive). See “Motor (redrive) removal” on page 304. Remove the redrive belt cover. See “Redrive belt cover removal” on page 233. Remove the redrive belt. Transfer roller removal Open the right door. Release the latches (A). Remove the transfer roller.
Page 235: Duplex Transport Assembly Removal
4021 Duplex transport assembly removal Open the right door. Remove the two screws (A), and then remove the cover. Disconnect the cable (B), and then remove the three screws (C). Repair information...
Page 236: Duplex Transport Jam Removal Knob Removal
4021 Remove the five screws (D), and then remove the assembly. Duplex transport jam removal knob removal Open the right door. Remove the screw (A), and then remove the knob. Repair information...
Page 237: Duplex Transport Diverter Assembly Removal
4021 Duplex transport diverter assembly removal Note: This part is not a FRU. Remove the duplex transport assembly. See “Duplex transport assembly removal” on page 235. Remove the two screws (A), and then remove the bracket. Remove the three screws (B), and then lift the diverter assembly. Repair information...
Page 238: Sensor (Fuser Exit) Removal
4021 Disconnect the cable (C), and then remove the assembly. Sensor (fuser exit) removal Remove the duplex transport assembly. See “Duplex transport assembly removal” on page 235. Remove the duplex transport diverter assembly. See “Duplex transport diverter assembly removal” on page 237.
Page 239: Sensor (Duplex Pass Through 1) Removal
4021 Remove the six screws (A), remove the diverter bracket, and then remove the sensor actuator (B). Installation note: Make sure that the ground retainers (A) are correctly installed. Sensor (duplex pass through 1) removal Remove the duplex transport assembly. See “Duplex transport assembly removal”...
Page 240: Duplex Pass Through 1 Actuator Removal
4021 Disconnect the cable (A), and then remove the sensor. Duplex pass through 1 actuator removal Remove the duplex transport assembly. See “Duplex transport assembly removal” on page 235. Remove the duplex transport diverter assembly. See “Duplex transport diverter assembly removal” on page 237.
Page 241 4021 Release the retainers (B), and then remove the bracket. Remove the actuator (C). Repair information...
Page 242: Duplex Transport Belt Removal
4021 Duplex transport belt removal Remove the duplex transport assembly. See “Duplex transport assembly removal” on page 235. Release the clip (A), and then remove the gear. Remove the belt. Duplex transport gears removal Remove the duplex transport assembly. See “Duplex transport assembly removal”...
Page 243: Motor (Duplex Transport) Removal
4021 Motor (duplex transport) removal Remove the duplex transport assembly. See “Duplex transport assembly removal” on page 235. Remove the five screws (A). Note: Take note of the original position of the retainer (B). Repair information...
Page 244 4021 Disconnect the cable (C). Move away the bracket, and then remove the two screws (D). Remove the motor. Repair information...
Page 245: Right Door Lock Removal
4021 Right door lock removal Open the right door. Remove the six screws (A). Release the spring (B), and then remove the lock. Installation note: Make sure that the bottom spring (B) is correctly installed. Repair information...
Page 246: Tray 2 Transport Guide
4021 Tray 2 transport guide Open the right door. Remove the 11 screws (A), and then remove the guide. Repair information...
Page 247: Mpf Removal
4021 MPF removal Remove the tray 2 transport guide. See “Tray 2 transport guide” on page 246. Remove the screw (A), and then remove the cover. Disconnect the three cables (B), and then remove the ground screw (C). Repair information...
Page 248: Mpf Tray Removal
4021 Remove the 10 screws (D), and then remove the assembly. Installation note: Secure the cables to their clips. MPF tray removal Note: This part is not a FRU. Remove the tray 2 transport guide. See “Tray 2 transport guide” on page 246.
Page 249: Sensor (Mpf Paper Length) Removal
4021 Sensor (MPF paper length) removal Remove the tray 2 transport guide. See “Tray 2 transport guide” on page 246. Remove the MPF. See “MPF removal” on page 247. Remove the MPF tray. See “MPF tray removal” on page 248. Remove the five screws (A), and then lift the cover.
Page 250: Mpf Feed Clutch Removal
4021 MPF feed clutch removal Remove the tray 2 transport guide. See “Tray 2 transport guide” on page 246. Remove the MPF. See “MPF removal” on page 247. Remove the screw (A), and then remove the cover. Disconnect the cable (B), and then release the clip (C). Remove the clutch.
Page 251: Mpf Lift Plate Solenoid Removal
4021 MPF lift plate solenoid removal Remove the tray 2 transport guide. See “Tray 2 transport guide” on page 246. Remove the MPF. See “MPF removal” on page 247. Remove the MPF feed clutch. See “MPF feed clutch removal” on page 250.
Page 252: Mpf Gears Removal
4021 Disconnect the cable (E), and then remove the solenoid. MPF gears removal Remove the tray 2 transport guide. See “Tray 2 transport guide” on page 246. Remove the MPF. See “MPF removal” on page 247. Remove the MPF feed clutch. See “MPF feed clutch removal”...
Page 253: Sensor (Mpf Lift Plate) Removal
4021 Release the clip (B), and then remove the bushing. Remove the screw (C), remove the bracket, and then remove the gear (D). Note: The MPF gears include the gears, bushing, clips, cam, and actuator. Sensor (MPF lift plate) removal Remove the tray 2 transport guide.
Page 254 4021 Remove the screw (A), and then remove the cover. Disconnect the cable (B), and then remove the screw (C). Repair information...
Page 255: Sensor (Mpf Empty) Removal
4021 Lift the bracket, and then disconnect the cable (D). Remove the sensor. Sensor (MPF empty) removal Remove the tray 2 transport guide. See “Tray 2 transport guide” on page 246. Remove the MPF. See “MPF removal” on page 247. Remove the screw (A), and then disconnect the cable (B).
Page 256: Mpf Feed/Separator Assembly
4021 MPF feed/separator assembly Remove the tray 2 transport guide. See “Tray 2 transport guide” on page 246. Remove the MPF. See “MPF removal” on page 247. Remove the screw (A), remove the bracket, and then remove the separator spring. Remove the two screws (B), and then remove the cover and bracket.
Page 257 4021 Installation notes: • Make sure that the separator roller slot (A) aligns with the pin (B) on the shaft. Repair information...
Page 258: Mpf Lift Plate Assembly Removal
4021 • Make sure that the bushing (C) is correctly positioned onto the shaft. MPF lift plate assembly removal Note: This part is not a FRU. Remove the tray 2 transport guide. See “Tray 2 transport guide” on page 246. Remove the MPF.
Page 259: Mpf Empty Actuator Removal
4021 Disconnect the cable (B), and then release it from the cable clips. Remove the assembly. MPF empty actuator removal Note: This part is not a FRU. Remove the tray 2 transport guide. See “Tray 2 transport guide” on page 246.
Page 260: Duplex Transport Guide Removal
4021 Duplex transport guide removal Note: This part is not a FRU. Remove the tray 2 transport guide. See “Tray 2 transport guide” on page 246. Remove the MPF. See “MPF removal” on page 247. Remove the seven screws (A), and then remove the guide. Registration unit latch assembly removal Note: This part is not a FRU.
Page 261 4021 Remove the screw (A), and then remove the latch and spring. On the rear side of the printer, remove the two screws (B), and then remove the latch. Repair information...
Page 262: Right Door Switch Actuator Removal
4021 Right door switch actuator removal Open the right door. Remove the four screws (A), and then remove the actuator. Right door removal Note: This part is not a FRU. Open the right door. Installation note: Before removing the door, take note of the alignment of the door hinge. Repair information...
Page 263: Registration Unit Assembly Removal
4021 Remove the two screws (A), and then remove the upper hinge. Remove the door. Registration unit assembly removal Open the right door. Installation note: Before removing the assembly, take note of the alignment position of the door hinge. Repair information...
Page 264 4021 Disconnect the cable (A), and then remove the two screws (B). Lift the registration unit to release, and then remove. Repair information...
Page 265: Registration Unit Sub-Assembly Removal
4021 Registration unit sub-assembly removal Note: This part is not a FRU. Remove the registration unit assembly. See “Registration unit assembly removal” on page 263. Remove the screw (A) from the right bracket. Remove the screw (B) from the left bracket. Repair information...
Page 266 4021 Disconnect the cable (C), and then remove the sub-assembly. CAUTION—POTENTIAL INJURY: This part has sharp points. Installation note: Align the two springs while pushing down the assembly, and then move the assembly to the left to lock. Repair information...
Page 267: Sensor (Fusing Speed) Removal
4021 Sensor (fusing speed) removal Remove the registration unit assembly. See “Registration unit assembly removal” on page 263. Remove the registration unit sub-assembly. See “Registration unit sub-assembly removal” on page 265. Disconnect the cable (A), and then remove the sensor. Fusing speed actuator removal Note: This part is not a FRU.
Page 268: Sensor (Duplex Pass Through 2) Removal
4021 Installation note: Make sure that the spring (A) is correctly positioned on the actuator base. Sensor (duplex pass through 2) removal Remove the registration unit assembly. See “Registration unit assembly removal” on page 263. Remove the registration unit sub-assembly. See “Registration unit sub-assembly removal”...
Page 269: Registration Unit Belt Removal
4021 Registration unit belt removal Remove the registration unit assembly. See “Registration unit assembly removal” on page 263. Remove the registration unit sub-assembly. See “Registration unit sub-assembly removal” on page 265. Remove the 11 screws (A), and then remove the plate. Release the clip (B), and then remove the gear.
Page 270: Registration Unit Gears Removal
4021 Registration unit gears removal Remove the registration unit assembly. See “Registration unit assembly removal” on page 263. Remove the registration unit sub-assembly. See “Registration unit sub-assembly removal” on page 265. Remove the 11 screws (A), and then remove the plate. Remove the screw (B), remove the bracket, and then remove the gear.
Page 271: Registration Unit Lock Removal
4021 Release the two clips (C), and then remove the gears. Note: The registration gear pack includes the gears, bushings, and clips. Registration unit lock removal Remove the registration unit assembly. See “Registration unit assembly removal” on page 263. Remove the registration unit sub-assembly. See “Registration unit sub-assembly removal”...
Page 272 4021 Remove the 11 screws (A), and then remove the plate. Remove the two screws (A), and then remove the lock. Repair information...
Page 273: Front Side Removals
4021 Front side removals Top front door removal Open the door, and then remove the two clips (A). Slightly move the door to the right to release, and then remove. Repair information...
Page 274: Bottom Front Door Removal
4021 Bottom front door removal Open the door, and then remove the clip (A). Slightly move the door to the right to release, and then remove. Front inner cover removal Remove the top front door. See “Top front door removal” on page 273.
Page 275: Waste Toner Door Mount Removal
4021 Waste toner door mount removal Remove the top front door. See “Top front door removal” on page 273. Remove the bottom front door. See “Bottom front door removal” on page 274. Remove the 11 screws (A), and then remove the door mount. Image controller board removal Remove the top front door.
Page 276: Door Switch Removal
4021 Disconnect the cables, and then remove the six screws (A). Remove the board. Door switch removal Remove the top front door. See “Top front door removal” on page 273. Remove the bottom front door. See “Bottom front door removal” on page 274.
Page 277: Main Power Switch Removal
4021 Disconnect the two cables (B), and then remove the screw (C). Release the retainer, and then remove the switch. Main power switch removal Remove the top front door. See “Top front door removal” on page 273. Remove the bottom front door. See “Bottom front door removal”...
Page 278: Sensor (Top Front Door) Removal
4021 Installation note: Red connectors are on top, while white connectors are at the bottom. Black cables are on the right, while white cables are on the left. Sensor (top front door) removal Remove the top front door. See “Top front door removal” on page 273.
Page 279: Motor (Toner Supply) Removal
4021 Disconnect the cable, and then remove the sensor (B). Motor (toner supply) removal Remove the top front door. See “Top front door removal” on page 273. Remove the bottom front door. See “Bottom front door removal” on page 274. Remove the waste toner door mount.
Page 280: Waste Toner Drive Removal
4021 Waste toner drive removal Remove the top front door. See “Top front door removal” on page 273. Remove the bottom front door. See “Bottom front door removal” on page 274. Remove the waste toner door mount. See “Waste toner door mount removal” on page 275.
Page 281: Sensor (Toner Cartridge Present) Removal
4021 Sensor (toner cartridge present) removal Remove the top front door. See “Top front door removal” on page 273. Remove the bottom front door. See “Bottom front door removal” on page 274. Remove the waste toner door mount. See “Waste toner door mount removal” on page 275.
Page 282: Toner Agitator Removal
4021 Toner agitator removal Remove the standard bin base. See “Standard bin base removal” on page 329. Remove the top front door. See “Top front door removal” on page 273. Remove the bottom front door. See “Bottom front door removal” on page 274.
Page 283: Developer Unit Removal
4021 Developer unit removal Remove the standard bin base. See “Standard bin base removal” on page 329. Remove the top front door. See “Top front door removal” on page 273. Remove the bottom front door. See “Bottom front door removal” on page 274.
Page 284: Right Door Switch Removal
4021 Right door switch removal Remove the speaker cover. Disconnect the two cables (A), and then remove the screw (B). Remove the switch. Speaker cover removal Remove the four screws (A) securing the cover. Repair information...
Page 285 4021 Remove the two screws (B) securing the metal frame, and then remove the metal frame. Remove the two screws (C) to disengage the USB cover. Note: Do not remove the USB cable from the cover. Open the cartridge door. Repair information...
Page 286: Rear Side Removals
4021 Remove the speaker cover. Rear side removals Scanner interface cable cover removal Remove the screw (A). Remove the cover. Repair information...
Page 287: Controller Board Access Cover Removal
4021 Controller board access cover removal Remove the seven screws (A). Remove the input options cover, and then remove the controller board cover. Repair information...
Page 288: Input Options Interface Cover Removal
4021 Input options interface cover removal Note: This part is not a FRU. Remove the screw (A). Remove the cover. Repair information...
Page 289: Engine Board Cover Removal
4021 Engine board cover removal Remove the controller board access cover. See “Controller board access cover removal” on page 287. Remove the two filters (A), and then remove the six screws (B). Remove the cover. Upper rear cover removal Remove the scanner interface cable cover. See “Scanner interface cable cover removal”...
Page 290: Ihps Shield Removal
4021 Disconnect the four cables (A), and then remove the two screws (B). Remove the cover. IHPS shield removal Note: This part is not a FRU. Remove the scanner interface cable cover. See “Scanner interface cable cover removal” on page 286.
Page 291: Induction Heater Magnetic Erase Board (Ihmeb) Removal
4021 Remove the seven screws (A), and then remove the shield. Induction heater magnetic erase board (IHMEB) removal Remove the scanner interface cable cover. See “Scanner interface cable cover removal” on page 286. Remove the controller board access cover. See “Controller board access cover removal”...
Page 292 4021 Installation note: Follow the arrangement of the colored symbols to install the cables to their correct positions. Release the four latches (B), and then remove the board. Release the four latches still attached on the board. Repair information...
Page 293: Induction Heater Power Supply (Ihps) Removal
4021 Induction heater power supply (IHPS) removal Remove the scanner interface cable cover. See “Scanner interface cable cover removal” on page 286. Remove the controller board access cover. See “Controller board access cover removal” on page 287. Remove the engine board cover. See “Engine board cover removal”...
Page 294: Expansion Controller Board Removal
4021 Disconnect the cables, and then remove the four screws (A). Remove the board. Expansion controller board removal Remove the scanner interface cable cover. See “Scanner interface cable cover removal” on page 286. Remove the controller board access cover. See “Controller board access cover removal”...
Page 295: Power-Saving Board Removal
4021 Disconnect the cables, and then remove the four screws (A). Remove the board. Power‑saving board removal Remove the scanner interface cable cover. See “Scanner interface cable cover removal” on page 286. Remove the controller board access cover. See “Controller board access cover removal” on page 287.
Page 296: Engine Controller Board Removal
4021 Disconnect the cables, and then remove the two screws (A). Remove the board. Engine controller board removal Warning—Potential Damage: Do not replace the engine controller board and controller board at the same time. Before removing the engine controller board, copy its settings to the controller board to avoid losing its original settings.
Page 297: Hard Drive Removal
4021 Disconnect the cables, and then remove the eight screws (A). Remove the board. Hard drive removal Note: This part is not a FRU. Remove the controller board cover. See “Controller board access cover removal” on page 287. Disconnect the cable (A), and then remove the two screws (B). Remove the hard drive.
Page 298: Controller Board Removal
4021 Controller board removal Warning—Potential Damage: Do not replace the engine controller board and controller board at the same time. Before removing the controller board, copy its settings to the engine board to avoid losing its original settings. See “Restore Backup Data” on page 186.
Page 299: Paper Exit Fan Duct Removal
4021 Disconnect the cable (A), and then remove the two screws (B). Remove the motor. Paper exit fan duct removal Remove the scanner interface cable cover. See “Scanner interface cable cover removal” on page 286. Remove the controller board access cover. See “Controller board access cover removal”...
Page 300: Paper Exit Fan Removal
4021 Paper exit fan removal Remove the scanner interface cable cover. See “Scanner interface cable cover removal” on page 286. Remove the controller board access cover. See “Controller board access cover removal” on page 287. Remove the engine board cover. See “Engine board cover removal”...
Page 301: Fuser Power Supply Fan Removal
4021 Remove the seven screws (A). Disconnect the cables within the frame, and then release them from the guides. Remove the frame. Fuser power supply fan removal Remove the scanner interface cable cover. See “Scanner interface cable cover removal” on page 286.
Page 302: Motor (Toner Cartridge) Removal
4021 Disconnect the cable (A). Remove the IHPS frame. See “IHPS frame removal” on page 300. Remove the two screws (B), and then remove the fan. Motor (toner cartridge) removal Remove the scanner interface cable cover. See “Scanner interface cable cover removal” on page 286.
Page 303 4021 Remove the IHPS shield. See “IHPS shield removal” on page 290. Disconnect the cable (A) and then remove the motor screw (B). Release the cable from the guides, and then remove the motor. Repair information...
Page 304: Motor (Redrive) Removal
4021 Motor (redrive) removal Remove the port access door. See “Port access door removal” on page 228. Remove the three screws (A), and then remove the bracket. From the rear, disconnect the cable (B), and then remove the two screws (C). Remove the motor.
Page 305: Controller Board Frame Removal
4021 Controller board frame removal Note: This part is not a FRU. Remove the port access door. See “Port access door removal” on page 228. Remove the controller board access cover. See “Controller board access cover removal” on page 287. Remove the engine board cover.
Page 306: Controller Board Fan Removal
4021 From the rear, remove the two screws (B). Disconnect the four cables (C), and then open the frame. Controller board fan removal Remove the port access door. See “Port access door removal” on page 228. Remove the controller board access cover. See “Controller board access cover removal”...
Page 307: Motor (Transport) Removal
4021 Open the controller board frame. See “Controller board frame removal” on page 305. Disconnect the cable (A), and then remove the two screws (B). Remove the fan. Motor (transport) removal Remove the port access door. See “Port access door removal” on page 228.
Page 308: Motor (Developer) Removal
4021 Disconnect the cable (A), and then remove the four screws (B). Motor (developer) removal Remove the port access door. See “Port access door removal” on page 228. Remove the controller board access cover. See “Controller board access cover removal” on page 287.
Page 309: High Voltage Board Removal
4021 Disconnect the cable (A), and then remove the four screws (B). High voltage board removal Remove the port access door. See “Port access door removal” on page 228. Remove the controller board access cover. See “Controller board access cover removal” on page 287.
Page 310: Motor (Registration) Removal
4021 Disconnect the cables, remove the four screws (A), and then release the latch (B). Remove the board. Motor (registration) removal Remove the port access door. See “Port access door removal” on page 228. Remove the controller board access cover. See “Controller board access cover removal”...
Page 311 4021 Disconnect the cable (A), and then remove the two screws (B). Remove the bracket, remove the two screws (C), and then remove the motor. Repair information...
Page 312: Motor (Feed) Removal
4021 Motor (feed) removal Remove the port access door. See “Port access door removal” on page 228. Remove the controller board access cover. See “Controller board access cover removal” on page 287. Remove the engine board cover. See “Engine board cover removal” on page 289.
Page 313: Tray 2 Transport Drive Removal
4021 Remove the two screws (C), and then remove the motor. Tray 2 transport drive removal Remove the port access door. See “Port access door removal” on page 228. Remove the controller board access cover. See “Controller board access cover removal” on page 287.
Page 314: Motor (Tray 2 Transport) Removal
4021 From the right, remove the three screws (A), and then remove the bracket. From the rear, disconnect the cable (B), and then remove the three screws (C). Remove the assembly. Motor (tray 2 transport) removal Remove the port access door. See “Port access door removal”...
Page 315: Feed Drive Assembly Removal
4021 Remove the scanner interface cable cover. See “Scanner interface cable cover removal” on page 286. Remove the upper rear cover. See “Upper rear cover removal” on page 289. Open the controller board frame. See “Controller board frame removal” on page 305.
Page 316: Sensor (Tray 1 And 2 Paper Temperature) Removal
4021 Sensor (tray 1 and 2 paper temperature) removal Remove the port access door. See “Port access door removal” on page 228. Remove the controller board access cover. See “Controller board access cover removal” on page 287. Remove the engine board cover. See “Engine board cover removal”...
Page 317 4021 Repair information...
Page 318: Ozone Fan Duct Removal
4021 Disconnect the cable (D), and then remove the two screws (E). Remove the fan. Ozone fan duct removal Remove the port access door. See “Port access door removal” on page 228. Remove the controller board access cover. See “Controller board access cover removal” on page 287.
Page 319: Main Drive Assembly Removal
4021 Main drive assembly removal Remove the port access door. See “Port access door removal” on page 228. Remove the controller board access cover. See “Controller board access cover removal” on page 287. Remove the engine board cover. See “Engine board cover removal” on page 289.
Page 320 4021 Disconnect the two cables (E), and then release the cables from the assembly cable clips. Repair information...
Page 321: Center Cable Guide Bracket Removal
4021 Remove the nine screws (F), and then remove the ground screw (G). Open the right door, and then remove the screw (H). Remove the assembly. Center cable guide bracket removal Note: This part is not a FRU. Remove the port access door. See “Port access door removal”...
Page 322: Toner Cartridge Drive Assembly Removal
4021 Remove the scanner interface cable cover. See “Scanner interface cable cover removal” on page 286. Remove the upper rear cover. See “Upper rear cover removal” on page 289. Open the controller board frame. See “Controller board frame removal” on page 305.
Page 323: Duplex Transport Clutch Removal
4021 Remove the screw (A), and then remove the guide. Remove the three screws (B), and then release the cables from the guides. Remove the assembly. Duplex transport clutch removal Remove the port access door. See “Port access door removal” on page 228.
Page 324: Motor (Fuser) Removal
4021 Remove the two screws (A), remove the bracket, and then remove the clip (B). Remove the clutch. Motor (fuser) removal Remove the port access door. See “Port access door removal” on page 228. Remove the scanner interface cable cover. See “Scanner interface cable cover removal”...
Page 325: Fuser Drive Gearbox Removal
4021 Remove the screw (A), and then remove the guide. Disconnect the cable (B), and then remove the four screws (C). Slightly lift the motor to release, and then remove it. Fuser drive gearbox removal Remove the port access door. See “Port access door removal”...
Page 326 4021 Remove the upper rear cover. See “Upper rear cover removal” on page 289. Remove the IHPS shield. See “IHPS shield removal” on page 290. From the right, release the two clips (A), remove the two gears, and then release the belt. From the rear, disconnect the four cables (B), and then remove the six screws (C).
Page 327: Toner Suction Fan Removal
4021 Toner suction fan removal Remove the left cover. See “Left cover removal” on page 223. Remove the rear left cover. See “Rear left cover removal” on page 224. Remove the port access door. See “Port access door removal” on page 228.
Page 328 4021 Remove the three screws (C), and then remove the fan duct. Remove the screw (D), and then remove the bracket. Repair information...
Page 329: Top Side Removals
4021 Remove the two screws (E), and then remove the fan. Top side removals Standard bin base removal Remove the left cover. See “Left cover removal” on page 223. Remove the standard bin base. Transfer belt fan removal Remove the left cover. See “Left cover removal”...
Page 330: Bin Side Cover Removal
4021 Remove the screw (A), and then remove the cover. Disconnect the cable (B), and then remove the two screws (C). Release the latches (D), and then open the case. Remove the fan. Bin side cover removal Remove the left cover. See “Left cover removal”...
Page 331: 2500-Sheet Tray Removals
4021 Remove the two screws (A), and then remove the cover. 2500-sheet tray removals 2500-sheet tray caster wheel removal Position the tray on its side. Select a caster. Remove the two screws (A), and then remove the caster. Repair information...
Page 332: 2500-Sheet Tray Controller Board Removal
4021 2500-sheet tray controller board removal Remove the tray rear cover. See “2500-sheet tray rear cover removal” on page 335. Disconnect the cables, and then remove the four screws (A). Remove the controller board. 2500-sheet tray LED cover removal Open the tray. Remove the four screws (A), and then remove the cover.
Page 333: 2500-Sheet Tray Front Right Cover Removal
4021 2500-sheet tray front right cover removal Remove the 2500-sheet tray LED cover. See “2500-sheet tray LED cover removal” on page 332. Remove the two screws (A), and then remove the cover. 2500-sheet tray left cover removal Remove the five screws (A). Remove the cover.
Page 334: 2500-Sheet Tray Lower Right Cover Removal
4021 2500-sheet tray lower right cover removal Remove the two screws (A). Remove the cover. 2500-sheet tray empty LED removal Remove the 2500-sheet tray LED cover. See “2500-sheet tray LED cover removal” on page 332. Disconnect the cable (A), and then remove the screw (B). Remove the LED.
Page 335: 2500-Sheet Tray Rear Cover Removal
4021 2500-sheet tray rear cover removal Remove the five screws (A). Remove the cover. 2500-sheet tray rear right cover removal Remove the two screws (A). Remove the cover. Repair information...
Page 336: 2500-Sheet Tray Division Board Removal
4021 2500‑sheet tray division board removal Remove the tray insert. Disconnect the two cables (A), and then remove the two screws (B). Remove the division board, and then remove the sensors (C). Installation note: Install the sensors on the new division board. Repair information...
Page 337: 2500-Sheet Tray Empty Sensor Actuator Removal
4021 2500‑sheet tray empty sensor actuator removal Remove the tray insert. Slightly raise the main tray. Remove the actuator (C). Repair information...
Page 338: 2500-Sheet Tray Elevator Home Sensor Actuator Removal
4021 2500‑sheet tray elevator home sensor actuator removal Remove the tray insert. Slightly raise the main tray. Rotate the actuator (C) until it is in the upright position, and then slide out to remove. Note: Take note of the position of the spring on the actuator. Repair information...
Page 339: 2500-Sheet Tray Transfer Guide Stop Removal
4021 2500‑sheet tray transfer guide stop removal Remove the tray insert. Slightly raise the main tray. Remove the actuator (C). Note: Do not lose the spring on the actuator. Repair information...
Page 340: 2500-Sheet Reserve Tray Paper Limit Sensor Actuator Removal
4021 2500‑sheet reserve tray paper limit sensor actuator removal Remove the tray insert . Disconnect the two cables (A), and then remove the two screws (B). Remove the division board, and then remove the actuator (C). 2500‑sheet tray vertical media transport guide assembly removal Remove the rear right cover.
Page 341: 2500-Sheet Tray Transport Roller Removal
4021 Remove the roller (A), and then remove the two screws (B). Remove the two clips (C), and then remove the two shafts from the bracket. Remove the vertical media transport guide assembly (D) from the shafts. 2500‑sheet tray transport roller removal Remove the rear right cover.
Page 342 4021 Remove the two clips (A), washer (B), and two gears (C) on the right side of the paper feed assembly. Remove the clip on the left side (D), and then remove the five screws (E). Remove the roller. Repair information...
Page 343: 2500-Sheet Tray Jam Access Cover Removal
4021 2500-sheet tray jam access cover removal Open the jam access cover. Remove the screw (A). Pry the right hinge to release, and then remove the cover. Repair information...
Page 344: 2500-Sheet Tray Jam Access Door Strap Removal
4021 2500-sheet tray jam access door strap removal Open the jam access cover. Remove the two screws (A), and then remove the strap. 2500-sheet tray paper feed assembly removal Open the rear right cover. See “2500-sheet tray rear right cover removal” on page 335.
Page 345: 2500-Sheet Tray Pick Assembly Removal
4021 Remove the four screws (B), and then remove the paper feed assembly. 2500-sheet tray pick assembly removal Remove the 2500-Sheet Tray rear right cover. See “2500-sheet tray rear right cover removal” on page 335. Remove the 2500-Sheet Tray paper feed assembly. See “2500-sheet tray paper feed assembly removal”...
Page 346: 2500-Sheet Tray Paper Stack Transfer Guide Removal
4021 2500-sheet tray paper stack transfer guide removal Remove the tray insert. Remove the two screws (A), and then remove the paper stack transfer guide (B). Raise the main tray, and then remove the two screws (C). Remove the sub-tray plate (D). Repair information...
Page 347: 2500-Sheet Reserve Tray Empty Sensor Actuator Removal
4021 Move the paper stack transfer guide base (E), and then remove the two screws (F). Remove the bracket, and then remove the guide base. 2500-sheet reserve tray empty sensor actuator removal Remove the tray insert. Remove the screw (A). Repair information...
Page 348: 2500-Sheet Tray Stopper Removal
4021 Swing open the sensor cover, and then remove the actuator (B). 2500‑sheet tray stopper removal Position the tray on its side. Select a stopper. Remove the two screws (A), and then remove the stopper. Repair information...
Page 349: Motor (2500-Sheet Tray Elevator) Removal
4021 Motor (2500‑sheet tray elevator) removal Remove the rear cover. See “2500-sheet tray rear cover removal” on page 335. Disconnect the cable (A), and then remove the three screws (B). Remove the motor. Motor (2500‑sheet tray feed) removal Remove the rear cover. See “2500-sheet tray rear cover removal”...
Page 350: Motor (2500-Sheet Tray Transfer Guide) Removal
4021 Note: Make sure that the feed motor belt (C) remains attached to the gear. Installation note: Make sure that the feed motor belt is installed properly before installing the feed motor. Motor (2500‑sheet tray transfer guide) removal Remove the rear cover. See “2500-sheet tray rear cover removal”...
Page 351: Motor (2500-Sheet Tray Transport) Removal
4021 Motor (2500‑sheet tray transport) removal Remove the rear cover. See “2500-sheet tray rear cover removal” on page 335. Disconnect the cable (A), and then remove the three screws (B). Remove the motor. Note: Make sure that the belt (C) remains on the gear. Installation note: Make sure that the belt is installed properly before reinstalling the transport motor.
Page 352: Sensor (2500-Sheet Tray Jam Access Door) Removal
4021 Sensor (2500‑sheet tray jam access door) removal Remove the screw (A), and then remove the sensor mount. Disconnect the sensor (B) from the cable. Repair information...
Page 353: Sensor (2500-Sheet Paper Stack Transfer) Removal
4021 Sensor (2500‑sheet paper stack transfer) removal Remove the tray insert. Disconnect the cable (A), and then remove the two screws (B). Remove the sensor from its housing on the division board. Sensor (2500‑sheet tray elevator home) removal Remove the tray insert. Remove the 2500-sheet tray elevator home sensor actuator.
Page 354: Sensor (2500-Sheet Tray Main Tray Empty, Bottom) Removal
4021 Disconnect the cable (A), and then remove the sensor (B). Sensor (2500‑sheet tray main tray empty, bottom) removal Remove the tray insert. Remove the 2500‑sheet tray empty sensor actuator. See “2500‑sheet tray empty sensor actuator removal” on page 337. Disconnect the cable (A), and then remove the sensor (B).
Page 355: Sensor (2500-Sheet Tray Main Tray Near Empty) Removal
4021 Sensor (2500‑sheet tray main tray near empty) removal Remove the tray insert. Disconnect the cable (A), and then remove the sensor (B). Sensor (2500‑sheet tray main tray paper empty, top) removal Disconnect the cable (A). Remove the sensor. Repair information...
Page 356: Sensor (2500-Sheet Tray Main Tray Elevator Limit) Removal
4021 Sensor (2500‑sheet tray main tray elevator limit) removal Disconnect the cable (A). Remove the sensor. Sensor (2500‑sheet tray feed) removal Remove the five screws (A). Repair information...
Page 357: Sensor (2500-Sheet Tray Reserve Tray Empty) Removal
4021 Disconnect the cable (B), and then remove the sensor. Sensor (2500‑sheet tray reserve tray empty) removal Remove the tray insert. Remove the screw (A). Repair information...
Page 358: Sensor (2500-Sheet Tray Reserve Tray Paper Limit) Removal
4021 Swing open the cover, and then disconnect the cable (B). Remove the sensor. Sensor (2500‑sheet tray reserve tray paper limit) removal Remove the tray insert. Disconnect the cable (A), and then remove the two screws (B). Remove the sensor. Repair information...
Page 359: Sensor (2500-Sheet Tray Transport) Removal
4021 Sensor (2500‑sheet tray transport) removal Remove the five screws (A). Disconnect the cable (B), and then remove the sensor. Repair information...
Page 360: X 500-Sheet Tray Removals
4021 2 x 500-sheet tray removals Sensor (2 x 500-sheet tray jam access door) removal Remove the screw (A), and then remove the sensor bracket. Disconnect the cable (B), and then remove the sensor. Remove the sensor from the bracket. Repair information...
Page 361: X 500-Sheet Tray Caster Wheel Removal
4021 2 x 500-sheet tray caster wheel removal Position the tray on its side. Select a caster. Remove the two screws (A), and then remove the caster. Printer rubber stopper removal Position the tray on its side. Select a stopper. Repair information...
Page 362: Tray Insert Paper Length Guide Removal
4021 Remove the two screws (A), and then remove the stopper. Tray insert paper length guide removal Remove the tray insert. Move the guide to the shortest paper length setting. Repair information...
Page 363 4021 From under the tray, remove the screw (A). Raise the lift plate, move the length guide slightly under the lift plate, and then remove the length guide. Repair information...
Page 364: Tray Lock Removal
4021 Tray lock removal Remove the tray insert. Remove the two screws (A). Remove the tray cover. Repair information...
Page 365 4021 Disconnect the spring (B) from the tray, and then remove the shaft. Remove the two screws (C), and then remove the plate. Repair information...
Page 366: X 500-Sheet Tray Rollers Removal
4021 Align the notches on the link and cover, and then remove the link. 2 x 500-sheet tray rollers removal Remove the tray inserts. Open the jam access door. Release the three clips (A), and then remove the rollers. Sensor (2 x 500-sheet tray paper length) removal Remove the tray inserts.
Page 367 4021 Remove the screw, press the latch, and then remove the sensor holder. Part Sensor (2 x 500 sheet tray 3 paper length) Sensor (2 x 500 sheet tray 4 paper length) Remove the screw (A), and then remove the sensor. Repair information...
Page 368: X 500-Sheet Tray Left Cover Removal
4021 2 x 500-sheet tray left cover removal Remove the five screws (A). Remove the cover. 2 x 500-sheet tray empty LED cover removal Remove the four screws (A). Repair information...
Page 369: X 500-Sheet Tray Empty Led Removal
4021 Remove the cover. 2 x 500-sheet tray empty LED removal Remove the tray empty LED cover. See “2 x 500-sheet tray empty LED cover removal” on page 368. Disconnect the cable. Remove the screw, and then remove the LED. Part Tray 3 tray empty LED Tray 4 tray empty LED...
Page 370: X 500-Sheet Tray Rear Cover Removal
4021 Remove the two screws (A), and then remove the cover. Remove all of the cable holders from the cover. 2 x 500-sheet tray rear cover removal Remove the five screws (A). Remove the cover. Motor (2 x 500-sheet tray lift) removal Remove the rear cover.
Page 371: Sensor (2 X 500-Sheet Tray Near Empty) Removal
4021 Remove the three screws, and then remove the motor. Part Motor (2 x 500-sheet tray 3 lift) Motor (2 x 500-sheet tray 4 lift) Sensor (2 x 500-sheet tray near empty) removal Remove the tray inserts. Disconnect the cable from the sensor, and then remove the sensor. Repair information...
Page 372: Sensor (2 X 500-Sheet Tray Paper Width) Removal
4021 Part Sensor (2 x 500-sheet tray 3 near empty) Sensor (2 x 500-sheet tray 4 near empty) Sensor (2 x 500-sheet tray paper width) removal Remove the rear cover. See “2 x 500-sheet tray rear cover removal” on page 370.
Page 373: X 500-Sheet Tray Feed And Transport Motors Removal
4021 Remove the screw (A), and then remove the sensor. Installation note: Toggle the sensor to make sure that it bounces back. 2 x 500-sheet tray feed and transport motors removal Remove the rear cover. See “2 x 500-sheet tray rear cover removal” on page 370.
Page 374: X 500-Sheet Tray Controller Board Removal
4021 Remove the three screws, and then remove the motor. Part Motor (2 x 500‑sheet tray 3 feed) Motor (2 x 500‑sheet tray 4 feed) Motor (2 x 500‑sheet tray 4 transport) Motor (2 x 500‑sheet tray 3 transport) 2 x 500-sheet tray controller board removal Remove the rear cover.
Page 375: X 500-Sheet Tray Jam Access Door Removal
4021 Remove the four screws (A), and then remove the board. 2 x 500-sheet tray jam access door removal Open the door, and then remove the screw (A). Repair information...
Page 376: X 500-Sheet Tray Rear Right Cover Removal
4021 Pry to release the hinge, and then remove the cover. 2 x 500-sheet tray rear right cover removal Remove the two screws (A). Remove the cover. Repair information...
Page 377: X 500-Sheet Tray Bottom Right Cover Removal
4021 2 x 500-sheet tray bottom right cover removal Remove the two screws (A). Remove the cover. 2 x 500-sheet tray 3 transport assembly removal Remove the rear right cover. See “2 x 500-sheet tray rear right cover removal” on page 376.
Page 378: X 500-Sheet Tray 4 Transport Assembly Removal
4021 Remove the assembly. 2 x 500-sheet tray 4 transport assembly removal Remove the rear right cover. See “2 x 500-sheet tray rear right cover removal” on page 376. Remove the jam access door. See “2 x 500-sheet tray jam access door removal” on page 375.
Page 379: X 500-Sheet Tray Transport Assembly Sensors Removal
4021 2 x 500-sheet tray transport assembly sensors removal Note: The following procedure begins with the tray 4 transport assembly sensors. If you are removing the tray 3 transport assembly sensors, then proceed directly to step 5. Remove the rear right cover. See “2 x 500-sheet tray rear right cover removal”...
Page 380: X 500-Sheet Tray Tray Set Actuator Removal
4021 Part 2 x 500-sheet tray empty sensor actuator Sensor (2 x 500-sheet tray empty) Sensor (2 x 500-sheet tray lift plate level) Sensor (2 x 500-sheet tray feed) Note: Remove the screw, remove the sensor bracket, and then remove the sensor. 2 x 500‑sheet tray tray set actuator removal Remove the rear right cover.
Page 381: Sensor (2 X 500-Sheet Tray Transport) Removal
4021 Remove the clip (B). Remove the shaft, and then remove the actuator. Sensor (2 x 500-sheet tray transport) removal Note: The following procedure begins with the tray 4 sensor. If you are removing the tray 3 sensor, then proceed directly to step 5.
Page 382: X 500-Sheet Tray 3 Transport Belts And Gears Removal
4021 Remove the five screws (A). Disconnect the cable (B), and then remove the sensor. 2 x 500-sheet tray 3 transport belts and gears removal Remove the rear right cover. See “2 x 500-sheet tray rear right cover removal” on page 376.
Page 383: X 500-Sheet Tray 4 Transport Belts And Gears Removal
4021 Remove the three screws (A), and then remove the bracket. Remove the three gears and two belts. 2 x 500-sheet tray 4 transport belts and gears removal Remove the rear right cover. See “2 x 500-sheet tray rear right cover removal” on page 376.
Page 384 4021 Remove the three screws (A), and then remove the bracket. Remove the three gears and two belts. Repair information...
Page 385: 3000-Sheet Tray Removals
4021 3000-sheet tray removals 3000-sheet tray rollers removal Remove the two clips (A), and then remove the bushings. Remove the two clips (B), and then remove the actuator (C). Repair information...
Page 386 4021 Remove the two clips (D), and then remove the feed and pick rollers. Remove the four screws (E), and then remove the cover. Repair information...
Page 387: 3000-Sheet Tray Feed And Pick Belt Removal
4021 Remove the clip (F), and then remove the roller. 3000-sheet tray feed and pick belt removal Remove the feed and pick rollers. See “3000-sheet tray rollers removal” on page 385. Remove the two clips (A), and then remove the bushings. Repair information...
Page 388 4021 Remove the two clips (B), and then remove the two bushings. Remove the clip (C). Repair information...
Page 389: 3000-Sheet Tray Caster Wheel Removal
4021 Remove the clip (D). Remove the pin (E). Pull out the shaft (F), and then remove the belt. 3000-sheet tray caster wheel removal Remove the right cover. See “3000-sheet tray right cover removal” on page 392. Depending on the caster to remove, remove the front cover or the rear cover. See “3000-sheet tray front cover removal”...
Page 390: 3000-Sheet Tray Release Handle Removal
4021 Remove the nut (A), and then remove the caster. 3000-sheet tray release handle removal Remove the right cover. See “3000-sheet tray right cover removal” on page 392. Remove the front cover. See “3000-sheet tray front cover removal” on page 392.
Page 391: 3000-Sheet Tray Left Cover Removal
4021 Remove the two screws (C), and then remove the handle. 3000-sheet tray left cover removal Remove the four screws (A). Remove the cover. Repair information...
Page 392: 3000-Sheet Tray Right Cover Removal
4021 3000-sheet tray right cover removal Remove the four screws (A). Remove the cover. 3000-sheet tray front cover removal Remove the right cover. See “3000-sheet tray right cover removal” on page 392. Disconnect the cable (A), and then remove it from the cable clips. Remove the three screws (B).
Page 393: 3000-Sheet Tray Rear Cover Removal
4021 Remove the two screws (C), and then remove the cover. 3000-sheet tray rear cover removal Remove the right cover. See “3000-sheet tray right cover removal” on page 392. Remove the three screws (A). Repair information...
Page 394: 3000-Sheet Tray Door Removal
4021 Remove the two screws (B). Remove the two screws (C). Remove the plate, and then remove the cover. 3000-sheet tray door removal Remove the right cover. See “3000-sheet tray right cover removal” on page 392. Remove the rear cover. See “3000-sheet tray rear cover removal”...
Page 395: 3000-Sheet Tray Left Top Cover Removal
4021 Remove the two screws (B), and then remove the bracket. Remove the door. 3000-sheet tray left top cover removal Remove the right cover. See “3000-sheet tray right cover removal” on page 392. Remove the front cover. See “3000-sheet tray front cover removal” on page 392.
Page 396: Dehumidifier Removal
4021 Remove the two screws (A), and then remove the cover. Dehumidifier removal Remove the right cover. See “3000-sheet tray right cover removal” on page 392. Disconnect the cable (A). Remove the four screws (B), and then remove the dehumidifier. Repair information...
Page 397: 3000-Sheet Tray Empty Led Removal
4021 3000-sheet tray empty LED removal Remove the right cover. See “3000-sheet tray right cover removal” on page 392. Remove the front cover. See “3000-sheet tray front cover removal” on page 392. Remove the screw (A), and then remove the LED. Sensor (3000-sheet tray empty) removal Remove the right cover.
Page 398: Sensor (3000-Sheet Tray Elevator Level) Removal
4021 Disconnect the cable (A), and then remove the sensor. Sensor (3000-sheet tray elevator level) removal Remove the right cover. See “3000-sheet tray right cover removal” on page 392. Remove the rear cover. See “3000-sheet tray rear cover removal” on page 393.
Page 399: Sensor (3000-Sheet Tray Feed) Removal
4021 Sensor (3000-sheet tray feed) removal Remove the right cover. See “3000-sheet tray right cover removal” on page 392. Remove the rear cover. See “3000-sheet tray rear cover removal” on page 393. Remove the front cover. See “3000-sheet tray front cover removal” on page 392.
Page 400: 3000-Sheet Tray Elevator Spring Removal
4021 3000-sheet tray elevator spring removal Remove the right cover. See “3000-sheet tray right cover removal” on page 392. Remove the front cover. See “3000-sheet tray front cover removal” on page 392. Remove the spring (A). 3000-sheet tray controller board removal Remove the right cover.
Page 401: 3000-Sheet Tray Door Switch Removal
4021 Remove the four screws (A), and then remove the board. 3000-sheet tray door switch removal Remove the right cover. See “3000-sheet tray right cover removal” on page 392. Remove the rear cover. See “3000-sheet tray rear cover removal” on page 393.
Page 402: Motor (3000-Sheet Tray Elevator) Removal
4021 Motor (3000-sheet tray elevator) removal Remove the right cover. See “3000-sheet tray right cover removal” on page 392. Remove the rear cover. See “3000-sheet tray rear cover removal” on page 393. Disconnect the cable (A). Remove the three screws (B), and then remove the motor. 3000-sheet tray set sensor actuator removal Remove the right cover.
Page 403: Sensor (3000-Sheet Tray Set) Removal
4021 Remove the screw (A), and then remove the bracket. Remove the clip (B). Remove the shaft, and then remove the actuator. Sensor (3000-sheet tray set) removal Remove the right cover. See “3000-sheet tray right cover removal” on page 392. Remove the rear cover.
Page 404: Sensor (3000-Sheet Tray Near Empty) Removal
4021 Disconnect the cable (A), and then remove the sensor. Sensor (3000-sheet tray near empty) removal Remove the right cover. See “3000-sheet tray right cover removal” on page 392. Remove the rear cover. See “3000-sheet tray rear cover removal” on page 393.
Page 405 4021 Remove the six screws (B), and then remove the bracket. Disconnect the cable, and then remove the sensor. Repair information...
Page 406: Motor Bracket Removal
4021 Part Sensor (3000-sheet tray near empty 1) Sensor (3000-sheet tray near empty 2) Motor bracket removal Note: This part is not a FRU. Remove the right cover. See “3000-sheet tray right cover removal” on page 392. Remove the rear cover. See “3000-sheet tray rear cover removal”...
Page 407: 3000-Sheet Tray Feed Roller Assembly Removal
4021 Remove the two screws, and then remove the motor. Part Motor (3000-sheet tray transport) Motor (3000-sheet tray feed) 3000-sheet tray feed roller assembly removal Remove the left cover. See “3000-sheet tray left cover removal” on page 391. Remove the right cover. See “3000-sheet tray right cover removal”...
Page 408 4021 Remove the clip (A), and then remove the gear. Remove the clip (B), and then remove the bushing. Repair information...
Page 409 4021 From the other end of the shaft, remove the clip (C), and then remove the bushing. Remove the screw (D), remove the sensor bracket, and then remove the roller. Repair information...
Page 410: 3000-Sheet Tray Pick Roller Assembly Removal
4021 From under the assembly, remove the two springs (E), and then remove the roller. 3000-sheet tray pick roller assembly removal Remove the left cover. See “3000-sheet tray left cover removal” on page 391. Remove the right cover. See “3000-sheet tray right cover removal” on page 392.
Page 411 4021 Remove the three clips (B), and then remove the three gears. Remove the three clips (C), and then remove the three bushings. Remove the two screws (D). Repair information...
Page 412 4021 Remove the two screws (E), and then dislodge the bracket. Remove the three screws (F), and then remove the assembly. Disconnect the spring (G). Repair information...
Page 413 4021 Remove the clip (H), and then remove the bushing. Remove the pick roller assembly from the bracket. Remove the clip (J), and then remove the roller and the gear. Repair information...
Page 414 4021 Remove the clip (K), and then remove the bushing. Remove the shaft (L), and then remove the separator belt (M). Repair information...
Page 415: Component Locations
4021 Component locations Exterior locations Front view Basic model Control panel Multipurpose feeder Standard 2 x 500‑sheet tray Standard bin Component locations...
Page 416 4021 Configured model Staple finisher Note: The staple finisher is not supported if another finisher is installed. 3000‑sheet tray Note: The 3000‑sheet tray is supported only if the option 2 x 500‑ or 2500‑sheet tray is installed. 2 x 500‑sheet tray 2500‑sheet tray Finisher •...
Page 417: Rear View
4021 Rear view Part name Printer power cord socket Internal Solutions Port (ISP) or printer hard disk slot Ethernet port USB ports USB printer port Component locations...
Page 418 4021...
Page 419: Maintenance
• Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover • Possible safety exposure from any non-Lexmark attachments Use the following table to determine when specified parts should be inspected: PART...
Page 420: Scheduled Maintenance
4021 PART EVERY 50K EVERY 300K EVERY 600K EVERY 720K ‑‑ ‑‑ ‑‑ Developer unit Replace FUSER ‑‑ ‑‑ ‑‑ Fuser Replace ‑‑ ‑‑ ‑‑ Induction heater Clean DUPLEX TRANSPORT ‑‑ ‑‑ ‑‑ Transport rollers Clean For 500‑sheet trays, if jams still occur after 80K, replace using the spare rollers in the tray compartment. Clean with damp cloth.
Page 421: Resetting The Maintenance Counter
4021 Resetting the maintenance counter Always reset the maintenance counter after installing the maintenance kit. Note: Once initiated, the operation cannot be canceled. Page count Enter the Navigate to 200K Diagnostics menu Reset Separator Roll and Pick Assembly Counter > Reset Separator Roll and Pick Assembly Counter 200K Diagnostics menu...
Page 422: Cleaning The Charger And The Printhead Lens
4021 Cleaning the charger and the printhead lens Open the bottom front door. Remove the waste toner bottle. Locate the white tab. Maintenance...
Page 423 4021 Gently pull the tab until it stops, and then slowly slide it back into place. Repeat three times. Remove the printhead wiper. Insert the wiper into the hole until it stops, and then slide it out. Repeat three times. Put the wiper back to its holder.
Page 424: Emptying The Hole Punch Box
4021 Reinstall the waste toner bottle. Close the bottom front door. Emptying the hole punch box Open door H. Remove and empty the hole punch box. Maintenance...
Page 425 4021 Reinstall the hole punch box. Close door H. Maintenance...
Page 426: Parts Catalog
4021 Parts catalog Legend The following column headings are used in the parts catalog: • Asm‑index—Identifies the item in the illustration. • P/N—Identifies the unique part number that correlates with the part. • Units/mach—Refers to the number of units used in the printer. •...
Page 427: Assembly 1: Covers 1
4021 Assembly 1: Covers 1 Parts catalog...
Page 428 4021 Assembly 1: Covers 1 Asm-index Units/mach Units/FRU Description Removal procedure ‑‑ 40X9924 Standard bin ‑‑ 40X8901 Tray empty board cable ‑‑ 40X9758 Tray empty board mount ‑‑ 40X8903 Tray 1 empty indicator ‑‑ 40X8902 Tray empty board cover ‑‑ 40X8903 Tray 2 empty indicator ‑‑...
Page 429: Assembly 2: Covers 2
4021 Assembly 2: Covers 2 Parts catalog...
Page 430 4021 Assembly 2: Covers 2 Asm-index Units/mach Units/FRU Description Removal procedure 40X8914 Bin side cover “Bin side cover removal” on page 330 ‑‑ 40X9591 Finisher interface cable 40X8908 Upper rear cover “Upper rear cover removal” on page 289 40X9762 Scanner interface cable “Scanner interface cable cover removal”...
Page 431: Assembly 3: Covers 3
4021 Assembly 3: Covers 3 Parts catalog...
Page 432 4021 Assembly 3: Covers 3 Asm-index Units/mach Units/FRU Description Removal procedure ‑‑ 40X9018 Top cover 40X8967 Top side cover “Top side cover removal” on page 232 ‑‑ 40X9157 Top cover base ‑‑ 40X9038 Hole plug Parts catalog...
Page 433: Assembly 4: Inner Covers
4021 Assembly 4: Inner covers Parts catalog...
Page 434 4021 Assembly 4: Inner covers Asm-index Units/mach Units/FRU Description Removal procedure 40X8915 Waste toner bottle latch -- 40X8916 Front inner cover “Front inner cover removal” on page 274 40X9764 Waste toner door mount “Waste toner door mount removal” on page 275 40X8919 Lower front door strap 40X8917...
Page 435: Assembly 5: Control Panel
4021 Assembly 5: Control panel Parts catalog...
Page 436 4021 Assembly 5: Control panel Asm-index Units/mach Units/FRU Description Removal procedure ‑‑ 40X9662 Control panel 40X9965 USB port cover 40X9970 USB extension cable 40X9966 Speaker cover “Speaker cover removal” on page 284 40X9967 Control panel cable guide lower cover -- 40X9969 Control panel cable guide upper cover -- 40X9968...
Page 437: Assembly 6: Printhead
4021 Assembly 6: Printhead Parts catalog...
Page 438 4021 Assembly 6: Printhead Asm-index Units/mach Units/FRU Description Removal procedure 40X8944 Transfer belt fan duct 40X8945 Transfer belt fan “Transfer belt fan removal” on page 329 40X8946 Image controller board “Image controller board removal” on page 275 40X9188 Ozone filter duct 40X8949 Printhead (MFP) “Printhead removal”...
Page 439: Assembly 7: Toner Supply 1
4021 Assembly 7: Toner supply 1 Parts catalog...
Page 440 4021 Assembly 7: Toner supply 1 Asm-index Units/mach Units/FRU Description Removal procedure 40X9313 Sensor (top front door) “Sensor (top front door) removal” on page 278 40X9750 Toner cartridge relay “Toner agitator removal” on page 282 contact cable 40X8962 Toner cartridge contact “Toner agitator removal”...
Page 441: Assembly 8: Toner Supply 2
4021 Assembly 8: Toner supply 2 Parts catalog...
Page 442 4021 Assembly 8: Toner supply 2 Asm-index Units/mach Units/FRU Description Removal procedure 40X8957 Toner supply motor cable 40X8956 Motor (toner supply) “Motor (toner supply) removal” on page 279 40X9751 Toner cartridge present sensor cable 40X8869 Sensor (toner cartridge present) “Sensor (toner cartridge present) removal”...
Page 443: Assembly 9: Waste Toner
4021 Assembly 9: Waste toner Parts catalog...
Page 444 4021 Assembly 9: Waste toner Asm-index Units/mach Units/FRU Description Removal procedure 40X8958 Waste toner drive “Waste toner drive removal” on page 280 40X8959 Waste toner duct Parts catalog...
Page 445: Assembly 10: Developer
4021 Assembly 10: Developer Parts catalog...
Page 446 4021 Assembly 10: Developer Asm-index Units/mach Units/FRU Description Removal procedure 40X8960 Erase LED 40X9977 Erase LED cable 40X9936 Developer unit “Developer unit removal” on page 283 Parts catalog...
Page 447: Assembly 11: Photoconductor Lock
4021 Assembly 11: Photoconductor lock Parts catalog...
Page 448 4021 Assembly 11: Photoconductor lock Asm-index Units/mach Units/FRU Description Removal procedure 40X8962 Photoconductor relay contact 40X9978 Photoconductor release lever 40X8961 Photoconductor cable Parts catalog...
Page 449: Assembly 12: Transfer Belt
4021 Assembly 12: Transfer belt Parts catalog...
Page 450 4021 Assembly 12: Transfer belt Asm-index Units/mach Units/FRU Description Removal procedure 40X8963 Transfer belt cable 40X9704 Imaging unit maintenance kit 40X9979 Transfer belt paper guide Parts catalog...
Page 451: Assembly 13: Tray 1 And 2 Transport
4021 Assembly 13: Tray 1 and 2 transport Parts catalog...
Page 452 4021 Assembly 13: Tray 1 and 2 transport Asm-index Units/mach Units/FRU Description Removal procedure 40X9980 Tray 2 transport drive gear 40X8966 Tray 1 and 2 paper feed unit Parts catalog...
Page 453: Assembly 14: Tray 1 Feed
4021 Assembly 14: Tray 1 feed Parts catalog...
Page 454 4021 Assembly 14: Tray 1 feed Asm-index Units/mach Units/FRU Description Removal procedure 40X8971 Tray 1 paper feed clutch 40X8972 Tray 1 sensor cables 40X8869 Sensor (tray 1 lift plate level) 40X9899 Tray empty sensor actuator 40X8968 Sensor (tray 1 paper feed) 40X8869 Sensor (tray 1 empty) 40X8970...
Page 455: Assembly 15: Tray 1 Separator
4021 Assembly 15: Tray 1 separator Parts catalog...
Page 456 4021 Assembly 15: Tray 1 separator Asm-index Units/mach Units/FRU Description Removal procedure 40X9455 Roller clutch 40X8970 Separator roller 40X9927 Separator roller assembly Parts catalog...
Page 457: Assembly 16: Tray 2 Feed
4021 Assembly 16: Tray 2 feed Parts catalog...
Page 458 4021 Assembly 16: Tray 2 feed Asm-index Units/mach Units/FRU Description Removal procedure 40X9983 Tray 2 transport roller 40X9984 Tray 2 transport sensor cable 40X8968 Sensor (tray 2 transport) 40X8968 Sensor (tray 2 paper feed) 40X9899 Tray 2 empty sensor actuator 40X8970 Feed roller 40X9981...
Page 459: Assembly 17: Tray 2 Separator
4021 Assembly 17: Tray 2 separator Parts catalog...
Page 460 4021 Assembly 17: Tray 2 separator Asm-index Units/mach Units/FRU Description Removal procedure 40X9455 Roller clutch 40X8970 Separator roller 40X9927 Separator roller assembly Parts catalog...
Page 461: Assembly 18: Tray Rail
4021 Assembly 18: Tray rail Parts catalog...
Page 462 4021 Assembly 18: Tray rail Asm-index Units/mach Units/FRU Description Removal procedure 40X8978 Rear right lift handle 40X8977 Front right lift handle 40X8982 Tray 1 insert rail 40X8982 Tray 2 insert rail 40X9305 Tray left rail guide wheel 40X8981 Tray right rail guide wheel 40X9989 Tray stopper 40X8979...
Page 463: Assembly 19: Tray Paper Detection
4021 Assembly 19: Tray paper detection Parts catalog...
Page 464 4021 Assembly 19: Tray paper detection Asm-index Units/mach Units/FRU Description Removal procedure 40X8988 Tray size sensing assembly 40X8984 Tray 1 feed cable 40X8987 Motor (tray 1 lift) 40X8869 Sensor (tray 1 near empty) 40X8989 Sensor (tray 1 paper width) 40X8987 Motor (tray 2 lift) 40X8869 Sensor (tray 2 near empty)
Page 465: Assembly 20: Tray Insert 1
4021 Assembly 20: Tray insert 1 Parts catalog...
Page 466 4021 Assembly 20: Tray insert 1 Asm-index Units/mach Units/FRU Description Removal procedure 40X9305 Tray insert guide wheel 40X8990 Tray 1 insert 40X9925 Pick roller 40X8970 Feed/separator roller Parts catalog...
Page 467: Assembly 21: Tray Insert 2
4021 Assembly 21: Tray insert 2 Parts catalog...
Page 468 4021 Assembly 21: Tray insert 2 Asm-index Units/mach Units/FRU Description Removal procedure 40X9308 Tray near empty sensor actuator 40X9306 Tray paper length guide Parts catalog...
Page 469: Assembly 22: Tray Insert 3
4021 Assembly 22: Tray insert 3 Parts catalog...
Page 470 4021 Assembly 22: Tray insert 3 Asm-index Units/mach Units/FRU Description Removal procedure 40X9305 Tray insert guide wheel 40X8992 Tray 2 insert 40X9925 Pick roller 40X8970 Feed/separator roller Parts catalog...
Page 471: Assembly 23: Registration Transport
4021 Assembly 23: Registration transport Parts catalog...
Page 472 4021 Assembly 23: Registration transport Asm-index Units/mach Units/FRU Description Removal procedure 40X8994 Registration transport assembly “Registration transport assembly” on page 231 40X9706 Registration primary gear 40X9707 Registration secondary gear 40X9009 Registration roller fixed power resistor -- 40X9007 Registration cable 40X8998 Toner density solenoid 40X8997 Sensor (registration humidity)
Page 473: Assembly 24: Transfer
4021 Assembly 24: Transfer Parts catalog...
Page 474 4021 Assembly 24: Transfer Asm-index Units/mach Units/FRU Description Removal procedure 40X9011 Registration unit assembly “Registration unit assembly removal” on page 263 40X9990 Fusing speed sensor cable -- 40X9009 Fuser fixed power resistor -- 40X8869 Sensor (fusing speed) “Sensor (fusing speed) removal” on page 40X9010 Transfer roller “Transfer roller removal”...
Page 475: Assembly 25: Registration Unit
4021 Assembly 25: Registration unit Parts catalog...
Page 476 4021 Assembly 25: Registration unit Asm-index Units/mach Units/FRU Description Removal procedure 40X9012 Registration unit gear “Registration unit gears removal” on page 270 40X9992 Registration unit lock “Registration unit lock removal” on page 40X9993 Registration unit lock shaft “Registration unit lock removal” on page 40X9994 Registration unit handle “Registration unit lock removal”...
Page 477: Assembly 26: Right Door Transport
4021 Assembly 26: Right door transport Parts catalog...
Page 478 4021 Assembly 26: Right door transport Asm-index Units/mach Units/FRU Description Removal procedure 40X9019 Right door upper lock “Right door lock removal” on page 245 40X9020 Right door switch actuator “Right door switch actuator removal” on page 262 40X9711 Right door handle 40X9713 Right door lower lock “Right door lock removal”...
Page 479: Assembly 27: Mpf 1
4021 Assembly 27: MPF 1 Parts catalog...
Page 480 4021 Assembly 27: MPF 1 Asm-index Units/mach Units/FRU Description Removal procedure 40X9027 “MPF removal” on page 247 40X9716 MPF lift plate sensor cable -- 40X9996 MPF lift plate cam 40X9995 MPF feed roller “MPF feed/separator assembly” on page 40X9719 MPF feed clutch gear “MPF gears removal”...
Page 481: Assembly 28: Mpf 2
4021 Assembly 28: MPF 2 Parts catalog...
Page 482 4021 Assembly 28: MPF 2 Asm-index Units/mach Units/FRU Description Removal procedure 40X8869 Sensor (MPF paper length 1) “Sensor (MPF paper length) removal” on page 249 40X9026 MPF paper length 1 sensor actuator -- 40X9026 MPF paper length 2 sensor actuator -- 40X8869 Sensor (MPF paper length 2) “Sensor (MPF paper length)
Page 483: Assembly 29: Duplex 1
4021 Assembly 29: Duplex 1 Parts catalog...
Page 484 4021 Assembly 29: Duplex 1 Asm-index Units/mach Units/FRU Description Removal procedure 40X9031 Duplex transport assembly “Duplex transport assembly removal” on page 235 40X9997 Right door cover 40X9998 Duplex transport jam “Duplex transport jam removal knob removal knob removal” on page 236 40X9012 Duplex transport gear “Duplex transport gears removal”...
Page 485: Assembly 30: Duplex 2
4021 Assembly 30: Duplex 2 Parts catalog...
Page 486 4021 Assembly 30: Duplex 2 Asm-index Units/mach Units/FRU Description Removal procedure 40X9723 Fuser exit sensor cable 40X8869 Sensor (fuser exit) “Sensor (fuser exit) removal” on page 40X9039 Fuser exit sensor actuator “Fuser exit sensor actuator removal” on page 238 40X9999 Redrive diverter gear 40X8869 Sensor (duplex pass through...
Page 487: Assembly 31: Fuser
4021 Assembly 31: Fuser Parts catalog...
Page 488 4021 Assembly 31: Fuser Asm-index Units/mach Units/FRU Description Removal procedure 40X9046 Fuser “Fuser removal” on page 230 40X9044 Induction heater (100 V) “Induction heater removal” on page 230 40X9045 Induction heater (230 V) “Induction heater removal” on page 230 40X9047 Sensor (fuser temperature) with cable 40X9041...
Page 489: Assembly 32: Exit 1
4021 Assembly 32: Exit 1 Parts catalog...
Page 490 4021 Assembly 32: Exit 1 Asm-index Units/mach Units/FRU Description Removal procedure 40X9167 Redrive exit guide 40X9313 Sensor (redrive exit) 40X9644 Redrive exit sensor cable 40X9714 Redrive exit sensor actuator -- 40X9042 HPT bin paper bail 40X9313 Sensor (exit) 40X9599 Exit sensor cable 40X9484 Exit sensor actuator 40X8974...
Page 491: Assembly 33: Exit 2
4021 Assembly 33: Exit 2 Parts catalog...
Page 492 4021 Assembly 33: Exit 2 Asm-index Units/mach Units/FRU Description Removal procedure 40X9159 Exit guide assembly 40X9161 Diverter solenoid Parts catalog...
Page 493: Assembly 34: Main And Feed Drive
4021 Assembly 34: Main and feed drive Parts catalog...
Page 494 4021 Assembly 34: Main and feed drive Asm-index Units/mach Units/FRU Description Removal procedure 40X9164 Main drive assembly “Main drive assembly removal” on page 319 40X9564 Motor (developer) “Motor (developer) removal” on page 40X9163 Motor (transport) “Motor (transport) removal” on page 40X9166 Duplex transport clutch “Duplex transport clutch removal”...
Page 495: Assembly 35: Toner Cartridge Drive
4021 Assembly 35: Toner cartridge drive Parts catalog...
Page 496 4021 Assembly 35: Toner cartridge drive Asm-index Units/mach Units/FRU Description Removal procedure 40X9223 Toner cartridge drive “Toner cartridge drive assembly removal” on assembly page 322 40X9179 Motor (toner cartridge) “Motor (toner cartridge) removal” on page 302 Parts catalog...
Page 497: Assembly 36: Fuser Drive 1
4021 Assembly 36: Fuser drive 1 Parts catalog...
Page 498 4021 Assembly 36: Fuser drive 1 Asm-index Units/mach Units/FRU Description Removal procedure 40X9177 Fuser drive gearbox “Fuser drive gearbox removal” on page 325 40X9729 Fuser pressure primary gear 40X9730 Fuser pressure secondary gear -- 40X9731 Fuser transport primary gear 40X9732 Fuser transport secondary gear -- Parts catalog...
Page 499: Assembly 37: Fuser Drive 2
4021 Assembly 37: Fuser drive 2 Parts catalog...
Page 500 4021 Assembly 37: Fuser drive 2 Asm-index Units/mach Units/FRU Description Removal procedure 40X9179 Motor (fuser pressure) “Motor (fuser pressure) removal” on page 298 40X9163 Motor (fuser) “Motor (fuser) removal” on page 324 40X9178 Fuser exit clutch Parts catalog...
Page 501: Assembly 38: Ozone Duct
4021 Assembly 38: Ozone duct Parts catalog...
Page 502 4021 Assembly 38: Ozone duct Asm-index Units/mach Units/FRU Description Removal procedure 40X9184 Exhaust filter 40X8859 Toner suction fan “Toner suction fan removal” on page 327 40X9183 Ozone filter 40X9185 Ozone fan “Ozone fan removal” on page 316 40X9182 Ozone fan with duct “Ozone fan removal”...
Page 503: Assembly 39: High Voltage
4021 Assembly 39: High voltage Parts catalog...
Page 504 4021 Assembly 39: High voltage Asm-index Units/mach Units/FRU Description Removal procedure 40X9189 Power‑saving board “Power‑saving board removal” on page 295 40X9198 Induction heater magnetic erase “Induction heater magnetic erase board board (IHMEB) removal” on page 291 40X8945 Fuser power supply fan “Fuser power supply fan removal”...
Page 505: Assembly 40: Main Power Supply
4021 Assembly 40: Main power supply Parts catalog...
Page 506 4021 Assembly 40: Main power supply Asm-index Units/mach Units/FRU Description Removal procedure 40X9203 Main power supply, 100 V “Main power supply removal” on page 40X9204 Main power supply, 230 V “Main power supply removal” on page 40X9205 Main power supply fan with “Main power supply fan removal”...
Page 507: Assembly 41: Electrical 1
4021 Assembly 41: Electrical 1 Parts catalog...
Page 508 4021 Assembly 41: Electrical 1 Asm-index Units/mach Units/FRU Description Removal procedure 40X9741 Power socket 40X9402 Power socket mount 40X9740 Power socket cable Parts catalog...
Page 509: Assembly 42: Electrical 2
4021 Assembly 42: Electrical 2 Parts catalog...
Page 510 4021 Assembly 42: Electrical 2 Asm-index Units/mach Units/FRU Description Removal procedure 40X9207 Engine controller board “Engine controller board removal” on page 296 40X9744 Engine controller board FFC -- 40X9664 Controller board (SFP) “Controller board removal” on page 298 40X9209 Controller board fan “Controller board fan removal”...
Page 511: Assembly 43: 2 X 500-Sheet Tray-Covers
4021 Assembly 43: 2 x 500‑sheet tray—Covers Parts catalog...
Page 512 4021 Assembly 43: 2 x 500‑sheet tray—Covers Asm-index Units/opt Units/FRU Description Removal procedure 40X9779 2 x 500-sheet tray rear right “2 x 500-sheet tray rear right cover cover removal” on page 376 40X9285 2 x 500-sheet tray bottom right “2 x 500-sheet tray bottom right cover cover removal”...
Page 513: Assembly 44: 2 X 500-Sheet Tray-Frame
4021 Assembly 44: 2 x 500‑sheet tray—Frame Parts catalog...
Page 514 4021 Assembly 44: 2 x 500‑sheet tray—Frame Asm-index Units/opt Units/FRU Description Removal procedure 40X8981 2 x 500-sheet tray right rail guide wheel -- ‑‑ 40X9014 2 x 500-sheet tray insert stopper 40X9305 2 x 500-sheet tray left rail guide wheel 40X9290 2 x 500-sheet tray controller board “2 x 500-sheet tray controller...
Page 515: Assembly 45: 2 X 500-Sheet Tray-Paper Feed
4021 Assembly 45: 2 x 500‑sheet tray—Paper feed Parts catalog...
Page 516 4021 Assembly 45: 2 x 500‑sheet tray—Paper feed Asm-index Units/opt Units/FRU Description Removal procedure 40X9294 2 x 500-sheet tray feed and “2 x 500-sheet tray 3 transport belts and gears transport motor belt removal” on page 382 “2 x 500-sheet tray 4 transport belts and gears removal”...
Page 517: Assembly 46: 2 X 500-Sheet Tray-Paper Size Detection
4021 Assembly 46: 2 x 500‑sheet tray—Paper size detection Parts catalog...
Page 518 4021 Assembly 46: 2 x 500‑sheet tray—Paper size detection Asm-index Units/opt Units/FRU Description Removal procedure 40X8987 Motor (2 x 500-sheet tray 3 lift) “Motor (2 x 500-sheet tray lift) removal” on page 370 40X8869 Sensor (2 x 500-sheet tray 3 near “Sensor (2 x 500-sheet tray near empty) empty) removal”...
Page 519: Assembly 47: 2 X 500-Sheet Tray-Paper Transport
4021 Assembly 47: 2 x 500‑sheet tray—Paper transport Parts catalog...
Page 520 4021 Assembly 47: 2 x 500‑sheet tray—Paper transport Asm-index Units/opt Units/FRU Description Removal procedure 40X9908 2 x 500-sheet tray jam access door strap 40X8973 Transport idler roller Parts catalog...
Page 521: Assembly 48: 2 X 500-Sheet Tray-Paper Pick 1
4021 Assembly 48: 2 x 500‑sheet tray—Paper pick 1 Parts catalog...
Page 522 4021 Assembly 48: 2 x 500‑sheet tray—Paper pick 1 Asm-index Units/opt Units/FRU Description Removal procedure 40X9313 Sensor (2 x 500-sheet tray jam access door) “Sensor (2 x 500-sheet tray jam access door) removal” on page 360 40X9892 2 x 500-sheet tray transport gear spring 40X9893 2 x 500-sheet tray transport gear bushing 40X9894...
Page 523: Assembly 49: 2 X 500-Sheet Tray-Paper Pick 2
4021 Assembly 49: 2 x 500‑sheet tray—Paper pick 2 Parts catalog...
Page 524 4021 Assembly 49: 2 x 500‑sheet tray—Paper pick 2 Asm-index Units/opt Units/FRU Description Removal procedure 40X8968 Sensor (2 x 500-sheet tray 3 or 4 “Sensor (2 x 500-sheet tray transport) transport) removal” on page 381 40X8968 Sensor (2 x 500-sheet tray 3 or 4 “2 x 500-sheet tray transport assembly feed) sensors removal”...
Page 525: Assembly 50: 2 X 500-Sheet Tray-Paper Pick 3
4021 Assembly 50: 2 x 500‑sheet tray—Paper pick 3 Parts catalog...
Page 526 4021 Assembly 50: 2 x 500‑sheet tray—Paper pick 3 Asm-index Units/opt Units/FRU Description Removal procedure 40X9455 Separator clutch 40X8970 Separator roller “2 x 500-sheet tray rollers removal” on page 366 Parts catalog...
Page 527: Assembly 51: 2 X 500-Sheet Tray-Tray 3
4021 Assembly 51: 2 x 500‑sheet tray—Tray 3 Parts catalog...
Page 528 4021 Assembly 51: 2 x 500‑sheet tray—Tray 3 Asm-index Units/opt Units/FRU Description Removal procedure ‑‑ 40X9635 2 x 500-sheet tray 3 insert 40X9304 2 x 500-sheet tray lock lever “Tray lock removal” on page 364 40X9017 2 x 500-sheet tray 3 right front cover 40X9034 2 x 500-sheet tray 3 handle cover 40X9186...
Page 529: Assembly 52: 2 X 500-Sheet Tray-Tray 4
4021 Assembly 52: 2 x 500‑sheet tray—Tray 4 Parts catalog...
Page 530 4021 Assembly 52: 2 x 500‑sheet tray—Tray 4 Asm-index Units/opt Units/FRU Description Removal procedure ‑‑ 40X9697 2 x 500‑sheet tray 4 insert 40X9304 2 x 500-sheet tray lock lever “Tray lock removal” on page 364 40X9033 2 x 500-sheet tray 4 right front cover 40X9320 2 x 500-sheet tray 4 handle cover 40X9186...
Page 531: Assembly 53: 2 X 500-Sheet Tray-Tray 3 Or Tray 4 Frame
4021 Assembly 53: 2 x 500‑sheet tray—Tray 3 or Tray 4 frame Parts catalog...
Page 532 4021 Assembly 53: 2 x 500‑sheet tray—Tray 3 or Tray 4 frame Asm-index Units/opt Units/FRU Description Removal procedure 40X9308 2 x 500-sheet tray near empty sensor actuator 40X9306 Tray insert paper length guide “Tray insert paper length guide removal” on page 362 40X9309 2 x 500-tray insert paper length sensor actuator...
Page 533: Assembly 54: 3000-Sheet Tray-Covers
4021 Assembly 54: 3000‑sheet tray—Covers Parts catalog...
Page 534 4021 Assembly 54: 3000‑sheet tray—Covers Asm-index Units/opt Units/FRU Description Removal procedure 40X9260 3000-sheet tray top door “3000-sheet tray door removal” on page 394 40X9255 3000-sheet tray right cover “3000-sheet tray right cover removal” on page 392 40X8903 3000-sheet tray empty LED “3000-sheet tray empty LED removal”...
Page 535: Assembly 55: 3000-Sheet Tray-Frame 1
4021 Assembly 55: 3000‑sheet tray—Frame 1 Parts catalog...
Page 536 4021 Assembly 55: 3000‑sheet tray—Frame 1 Asm-index Units/opt Units/FRU Description Removal procedure 40X9279 3000-sheet tray caster wheel “3000-sheet tray caster wheel removal” on page 389 Parts catalog...
Page 537: Assembly 56: 3000-Sheet Tray-Frame 2
4021 Assembly 56: 3000‑sheet tray—Frame 2 Parts catalog...
Page 538 4021 Assembly 56: 3000‑sheet tray—Frame 2 Asm-index Units/opt Units/FRU Description Removal procedure 40X9261 Dehumidifier “Dehumidifier removal” on page 396 Parts catalog...
Page 539: Assembly 57: 3000-Sheet Tray-Elevator Front Section
4021 Assembly 57: 3000‑sheet tray—Elevator front section Parts catalog...
Page 540 4021 Assembly 57: 3000‑sheet tray—Elevator front section Asm-index Units/opt Units/FRU Description Removal procedure 40X9275 3000-sheet tray release “3000-sheet tray release handle removal” on handle page 390 40X9276 3000-sheet tray elevator “3000-sheet tray elevator spring removal” on spring page 400 Parts catalog...
Page 541: Assembly 58: 3000-Sheet Tray-Paper Feed 1
4021 Assembly 58: 3000‑sheet tray—Paper feed 1 Parts catalog...
Page 542 4021 Assembly 58: 3000‑sheet tray—Paper feed 1 Asm-index Units/opt Units/FRU Description Removal procedure 40X9886 3000-sheet tray feed and “3000-sheet tray pick roller assembly pick drive gear removal” on page 410 40X9267 Feed and pick roller “3000-sheet tray rollers removal” on page 385 40X9881 3000-sheet tray empty...
Page 543: Assembly 59: 3000-Sheet Tray-Paper Feed 2
4021 Assembly 59: 3000‑sheet tray—Paper feed 2 Parts catalog...
Page 544 4021 Assembly 59: 3000‑sheet tray—Paper feed 2 Asm-index Units/opt Units/FRU Description Removal procedure 40X9880 Sensor (3000-sheet tray “Sensor (3000-sheet tray elevator level) elevator level) removal” on page 398 40X9880 Sensor (3000-sheet tray “Sensor (3000-sheet tray empty) removal” empty) on page 397 40X9267 3000-sheet tray separator “3000-sheet tray feed roller assembly...
Page 545: Assembly 60: 3000-Sheet Tray-Paper Transport
4021 Assembly 60: 3000‑sheet tray—Paper transport Parts catalog...
Page 546 4021 Assembly 60: 3000‑sheet tray—Paper transport Asm-index Units/opt Units/FRU Description Removal procedure 40X9273 3000-sheet tray transport “3000-sheet tray feed roller assembly roller removal” on page 407 40X9885 Sensor (3000-sheet tray “Sensor (3000-sheet tray feed) removal” on feed) page 399 40X9790 Spring “3000-sheet tray feed roller assembly removal”...
Page 547: Assembly 61: 3000-Sheet Tray-Elevator Rear Section
4021 Assembly 61: 3000‑sheet tray—Elevator rear section Parts catalog...
Page 548 4021 Assembly 61: 3000‑sheet tray—Elevator rear section Asm-index Units/opt Units/FRU Description Removal procedure 40X9277 3000-sheet tray elevator release spring Parts catalog...
Page 549: Assembly 62: 3000-Sheet Tray-Drive Section
4021 Assembly 62: 3000‑sheet tray—Drive section Parts catalog...
Page 550 4021 Assembly 62: 3000‑sheet tray—Drive section Asm-index Units/opt Units/FRU Description Removal procedure 40X9262 3000-sheet tray controller “3000-sheet tray controller board removal” board on page 400 40X9266 3000‑sheet tray door switch “3000-sheet tray door switch removal” on page 401 40X9880 Sensor (3000-sheet tray near “Sensor (3000-sheet tray near empty) empty 1) removal”...
Page 551: Assembly 63: 3000-Sheet Tray-Wiring
4021 Assembly 63: 3000‑sheet tray—Wiring Asm-index Units/opt Units/FRU Description Removal procedure 40X9202 3000-sheet tray controller board cable 40X9698 3000-sheet tray interface cable Parts catalog...
Page 552 4021 Parts catalog...
Page 553: Assembly 64: 2500-Sheet Tray Covers
4021 Assembly 64: 2500-sheet tray covers Parts catalog...
Page 554 4021 Assembly 64: 2500-sheet tray covers Asm-index Units/opt Units/FRU Description Removal procedure 40X9280 2500-sheet tray rear cover “2500-sheet tray rear cover removal” on page 335 40X9779 2500-sheet tray rear right “2500-sheet tray rear right cover removal” on cover page 335 40X9285 2500-sheet tray bottom “2500-sheet tray lower right cover removal”...
Page 555: Assembly 65: 2500-Sheet Tray Frame
4021 Assembly 65: 2500-sheet tray frame Parts catalog...
Page 556 4021 Assembly 65: 2500-sheet tray frame Asm-index Units/opt Units/FRU Description Removal procedure 40X8869 Sensor (2500-sheet tray set) 40X8981 Tray rail guide wheel 40X9784 Tray insert guide wheel 40X9785 2500-sheet tray controller board “2500-sheet tray controller board removal” on page 332 40X9783 2500-sheet tray interface cable Parts catalog...
Page 557: Assembly 66: 2500-Sheet Tray Paper Feed
4021 Assembly 66: 2500-sheet tray paper feed Parts catalog...
Page 558 4021 Assembly 66: 2500-sheet tray paper feed Asm-index Units/opt Units/FRU Description Removal procedure 40X9293 Motor (2500-sheet tray feed) “Motor (2500‑sheet tray feed) removal” on page 349 40X9293 Motor (2500-sheet tray transport) “Motor (2500‑sheet tray transport) removal” on page 351 40X9294 2500-sheet tray feed and transport motor belt 40X9891...
Page 559: Assembly 67: 2500-Sheet Tray Paper Transport
4021 Assembly 67: 2500-sheet tray paper transport Parts catalog...
Page 560 4021 Assembly 67: 2500-sheet tray paper transport Asm-index Units/opt Units/FRU Description Removal procedure 40X9908 2500-sheet tray jam access door “2500-sheet tray jam access door strap strap removal” on page 344 40X8973 Transport idler roller Parts catalog...
Page 561: Assembly 68: 2500-Sheet Tray Paper Pick 1
4021 Assembly 68: 2500-sheet tray paper pick 1 Parts catalog...
Page 562 4021 Assembly 68: 2500-sheet tray paper pick 1 Asm-index Units/opt Units/FRU Description Removal procedure 40X9298 2500-sheet tray transport gear 40X9892 2500-sheet tray transport gear spring 40X9893 2500-sheet tray transport gear bushing 40X9313 Sensor (2500-sheet tray jam access door) “Sensor (2500‑sheet tray jam access door) removal”...
Page 563: Assembly 69: 2500-Sheet Tray Paper Pick 2
4021 Assembly 69: 2500-sheet tray paper pick 2 Parts catalog...
Page 564 4021 Assembly 69: 2500-sheet tray paper pick 2 Asm-index Units/opt Units/FRU Description Removal procedure 40X9299 2500-sheet tray transport roller “2500‑sheet tray transport roller removal” on page 341 40X8968 Sensor (2500-sheet tray feed) “Sensor (2500‑sheet tray feed) removal” on page 356 40X8968 Sensor (2500-sheet tray transport) “Sensor (2500‑sheet tray transport)
Page 565: Assembly 70: 2500-Sheet Tray Paper Pick 3
4021 Assembly 70: 2500-sheet tray paper pick 3 Parts catalog...
Page 566 4021 Assembly 70: 2500-sheet tray paper pick 3 Asm-index Units/opt Units/FRU Description Removal procedure 40X9455 Separator clutch 40X8970 Separator roller Parts catalog...
Page 567: Assembly 71: 2500-Sheet Tray Insert 1
4021 Assembly 71: 2500-sheet tray insert 1 Parts catalog...
Page 568 4021 Assembly 71: 2500-sheet tray insert 1 Asm-index Units/opt Units/FRU Description Removal procedure 40X9602 2500-sheet tray insert (LTR) 40X9576 2500-sheet tray insert (A4) 40X9789 2500-sheet tray front cover 40X9339 2500-sheet tray right front cover 40X9320 2500-sheet tray handle cover 40X9186 2500-sheet tray handle 40X9788 2500-sheet tray lock lever...
Page 569: Assembly 72: 2500-Sheet Tray Insert 2
4021 Assembly 72: 2500-sheet tray insert 2 Parts catalog...
Page 570 4021 Assembly 72: 2500-sheet tray insert 2 Asm-index Units/opt Units/FRU Description Removal procedure 40X9794 Paper stack transfer sensor actuator spring 40X8869 Sensor (main tray near empty) “Sensor (2500‑sheet tray main tray near empty) removal” on page 355 40X9792 Paper stack transfer guide “2500-sheet tray paper stack transfer guide removal”...
Page 571: Assembly 73: 2500-Sheet Tray Insert 3
4021 Assembly 73: 2500-sheet tray insert 3 Parts catalog...
Page 572 4021 Assembly 73: 2500-sheet tray insert 3 Asm-index Units/opt Units/FRU Description Removal procedure 40X9796 Transfer guide primary gear 40X9798 Main tray elevator coupling 40X9901 Main tray elevator gear spring 40X9902 Main tray elevator gear 40X9797 Transfer guide primary gear spring 40X9795 Transfer guide secondary gear Parts catalog...
Page 573: Assembly 74: 2500-Sheet Tray Insert 4
4021 Assembly 74: 2500-sheet tray insert 4 Parts catalog...
Page 574 4021 Assembly 74: 2500-sheet tray insert 4 Asm-index Units/opt Units/FRU Description Removal procedure 40X9802 2500-sheet tray empty sensor “2500‑sheet tray empty sensor actuator actuator removal” on page 337 40X9801 2500-sheet tray elevator home “2500‑sheet tray elevator home sensor sensor actuator actuator removal”...
Page 575: Assembly 75: Maintenance Kits
4021 Assembly 75: Maintenance kits Asm-index Units/mach Units/FRU Description Removal procedure ‑‑ 40X9669 Maintenance kit, 300K—includes: • Pick roller • Feed/separator roller • Imaging unit maintenance kit ‑‑ 40X9673 Maintenance kit, 200K—MPF includes: • MPF feed roller • MPF separator roller Parts catalog...
Page 576 4021 Parts catalog...
Page 577: Assembly 76: Miscellaneous
4021 Assembly 76: Miscellaneous Asm-index Units/mach Units/FRU Description Removal procedure 41X0007 Forms and Bar code card 41X0009 IPDS card 41X0008 PRESCRIBE card 41X0030 Keyboard kit, English 41X0031 Keyboard kit, French 41X0032 Keyboard kit, Italian 41X0033 Keyboard kit, German 41X0034 Keyboard kit, Spanish Parts catalog...
Page 578 4021...
Page 579: Appendix A: Printer Specifications
The power consumption levels listed in the previous table represent time-averaged measurements. Instantaneous power draws may be substantially higher than the average. Values are subject to change. See www.lexmark.com for current values. Sleep Mode This product is designed with an energy-saving mode called Sleep Mode. The Sleep Mode saves energy by lowering power consumption during extended periods of inactivity.
Page 580: Off Mode
4021 The Hibernate mode can be entered in any of the following methods: • Using the Hibernate Timeout • Using the Schedule Power modes • Using the Sleep/Hibernate button Factory default Hibernate Timeout for this product in all countries or regions 3 days The amount of time the printer waits after a job is printed before it enters Hibernate mode can be modified between one hour and one month.
Page 581: Noise Emission Levels
1-meter average sound pressure, dBA Printing 54 (one-sided); 55 (two-sided) Scanning Copying Ready Values are subject to change. See www.lexmark.com for current values. Temperature information Ambient operating temperature 10 to 30°C (50 to 86°F) Shipping temperature -10 to 40°C (14 to 104°F) Storage temperature and relative humidity -10 to 40°C (14 to 104°F)
Page 582 4021...
Page 583: Appendix B: Options And Features
Forms and Bar Code – PRESCRIBE – IPDS • Printer hard disk • Lexmark Internal Solutions Ports (ISP) – Standard 10/100/1000 Ethernet – MarkNet N8350 802.11 b/g/n wireless print server – MarkNet N8352 802.11 b/g/n wireless print server Media handling options Some options may not be available for all models.
Page 584 4021...
Page 585: Appendix C: Theory Of Operation
4021 Appendix C: Theory of operation POR sequence At power on, the engine code goes through a series of tests to verify hardware integrity. If a hardware failure is detected, it will be reported to the printer. If the POR sequence cannot be completed successfully, the printer may post an error message identifying service may be needed.
Page 586: Charge
4021 Charge A uniform negative electrical charge is applied to the surface of the photoconductor roller. The photoconductive properties of the surface material allow it to hold the charge as long as it is not exposed to light. Part Photoconductor roller Charge source Expose The printhead emits the light that hits the surface of the photoconductor.
Page 587: First Transfer
4021 Part Photoconductor roller Developer First transfer The image transfers from the photoconductor roller to the transfer belt. Due to relative opposite polarities, the transfer belt pressed against the photoconductor roller attracts the toner onto its surface. Appendix C: Theory of operation...
Page 588: Clean (Photoconductor)
4021 Part Transfer belt Photoconductor roller Clean (photoconductor) The erase LED emits light that neutralizes the remaining charge on the photoconductor surface. As a result, the toner loosens or separates from the photoconductor. Then, a cleaning blade scrapes off the remaining toner. The cycle (charge, expose, develop, first transfer, clean) repeats until the whole image is transferred to the transfer belt.
Page 589: Second Transfer
4021 Part Erase LED Cleaning blade Photoconductor roller Second transfer The whole image from the transfer belt is transferred again, this time onto the paper. The paper, which is pressed between the transfer belt and transfer roller, attracts the toner to its surface. As the paper moves up, a separator guide prevents it from entering the top side of the transfer belt.
Page 590: Fuse
4021 Part Transfer belt Cleaning blade Fuse Even if the toner image is already on the paper, the toner particles are not yet permanently bonded to the surface. For the final part of printing, the paper is transported to the fuser where heat and pressure are applied to it. As a result, the toner particles melt and permanently fuse with the paper, completing the print process.
Page 591 4021 Part Pressure roller Transfer roller Transfer belt Heat roller Appendix C: Theory of operation...
Page 592: Printer Operation
4021 Printer operation Printer paper path Part Duplex section Registration section MPF section Tray section Print section Exit section Tray section Paper presence and size detection The sensor (tray empty) detects if there is no paper in the tray. The positions of the guides determine the dimensions of the paper.
Page 593 4021 Part Sensor (tray paper width) Sensor (tray paper length) Tray insert paper width guides Sensor (tray empty) Tray insert paper length guide Paper lift During feed, the lift plate raises the paper until the paper comes into contact with the pick roller. The sensor (lift plate level) detects if the pick roller is sufficiently engaged with the paper.
Page 594 4021 Part Motor (lift) Sensor (near empty) Actuator Sensor (lift plate level) Pick roller Lift plate Paper Paper feed The pick roller pushes the topmost sheet to the feed roller. The separator roller makes sure that only one sheet is fed at a time.
Page 595: Mpf Section
4021 Part Sensor (pass through) Sensor (paper feed) Feed roller Separator roller Pick roller MPF section Paper presence detection The sensor (MPF empty) detects if there is no paper in the tray. Paper lift During feed, the lift plate pushes up to engage the paper with the pick roller. The movement of the lift plate is controlled by the MPF pick solenoid and is detected by the sensor (MPF lift plate position).
Page 596 4021 Part MPF pick roller Lift plate MPF pick solenoid Sensor (MPF lift plate position) Paper feed The MPF pick assembly moves the paper from the MPF tray to the registration section. Part MPF pick assembly MPF tray Appendix C: Theory of operation...
Page 597: 2500-Sheet Tray Section
4021 2500‑sheet tray section Paper path Part Paper feed from main tray Main tray Paper transfer movement from reserve tray to main tray Reserve tray Paper feed mechanism When the drawer is inserted, the lever is triggered to lower the pick roller. The motor (2500-sheet tray elevator) drives and raises the main tray until the paper is engaged with the pick roller.
Page 598 4021 Part Shifter stop detection actuator Lower limit detection actuator Transfer guide stop lever Sensor (2500-sheet tray elevator home) Main tray Near empty detection actuator Motor (2500-sheet tray elevator) Sensor (2500-sheet tray main tray near empty) Appendix C: Theory of operation...
Page 599 4021 Part Paper feed section Motor (2500-sheet tray feed) Motor (2500-sheet tray transport) Sensor (2500-sheet tray main tray elevator limit) Pick roller Feed roller Transport roller Sensor (2500-sheet tray transport) Separator roller Sensor (2500-sheet tray main tray paper empty, top) Lever The main tray continues to move up as the amount of paper decreases.
Page 600: 3000-Sheet Tray Section
4021 If the reserve tray is empty when paper on the main tray runs out, then the main tray is not lowered. The main tray lowers only when the drawer is removed. Part Sensor (2500-sheet tray reserve tray paper limit) Motor (2500-sheet tray transfer guide) Sensor (2500-sheet tray elevator home) Sensor (2500-sheet tray transfer guide home)
Page 601 4021 Part Paper Sensor (tray empty) Actuator position (with paper) Actuator position (without paper) Paper lift During feed, the elevator plate raises the paper until the paper comes into contact with the pick roller. The sensor (elevator level) detects if the pick roller is sufficiently engaged with the paper. The motor (elevator) controls the movement of the elevator plate.
Page 602 4021 Part Sensor (elevator level) Pick roller Elevator plate Paper feed and transport The pick roller pushes the topmost sheet to the feed roller. The separator roller makes sure that only one sheet is fed at a time. The paper is fed from the pick assembly to the transport rollers before going to the registration section. For more information, see “Registration section”...
Page 603: Registration Section
4021 Part Tray 2 transport roller Registration section Registration section Depending on the print job, the registration section receives paper from the tray, MPF or duplex section. As paper enters the registration roller, the sensor (registration) detects its presence. Skew adjustments are made on the registration roller to align the leading edge of the paper.
Page 604: Print Section
4021 Print section Toner from the transfer belt is transferred to the paper. For more information, see “Second transfer” on page 589. The rotation of the transfer belt and transfer roller is controlled by the motor (developer). Part Motor (developer) Fuser Transfer roller Transfer belt...
Page 605: Exit Section
4021 Part Fuser Transfer roller Transfer belt Motor (fuser) Motor (fuser pressure) Exit section Exit roller path Paper moves from the fuser to the exit roller. The motor (fuser) drives the exit roller to push out the printed paper to the standard bin.
Page 606 4021 Part Motor (fuser) Fuser Exit roller Redrive roller path If a paper transport is on the printer during a standard print job, then paper exits on top of the paper transport. As paper moves up from the fuser, the diverter closes the path to the exit roller and opens the path to the redrive roller. The motor (redrive) controls the redrive roller, which exits the printed paper.
Page 607: Duplex Section
4021 Part Motor (redrive) Redrive roller Diverter Fuser Duplex section Upper duplex transport For a duplex print job, the paper is fed back to print on the other side. The redrive roller, which is driven by the motor (redrive), reverses rotation to feed the paper back to the printer. The path to the fuser section is closed by the diverter so that the paper moves along the duplex path.
Page 608 4021 Part Motor (redrive) Duplex entrance roller Sensor (duplex pass through 1) Upper duplex transport roller Diverter Lower duplex transport The paper continues to move down to the lower duplex transport roller and duplex exit roller. Appendix C: Theory of operation...
Page 609 4021 The sensor (duplex pass through 2) detects the position of the paper. The motor (transport) drives the lower duplex transport roller and duplex exit roller. The paper then travels to the registration section to print on the other side. For more information, see “Registration section”...
Page 610 4021...
Page 611: Appendix D: Acronyms
4021 Appendix D: Acronyms Acronyms ASIC Application-Specific Integrated Circuit BLDC Brushless DC Motor Black Only Retract Cyan Charge Coupled Device Carbonless Copy Paper Cyclic Redundancy Check Customer Setup CTLS Capacitance Toner Level Sensing DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory Enhanced Data Out Electrophotographic Process EPROM...
Page 612 4021 MROM Masked Read Only Memory Microswitch Nonvolatile Memory NVRAM Nonvolatile Random Access Memory Original Equipment Manufacturer Optical Sensor Photoconductor pel, pixel Picture element Power-On Reset POST Power-On Self Test Position Sensing Device Pulse Width Modulation Raster Imaging Processor Read Only Memory SDRAM Synchronous Dual Random Access Memory SIMM...
Page 613: Index
4021 Index buttons, touch screen Numerics using 173 163.04 error 2500-sheet tray paper feed failure service check 137 167.04 error cables 2500-sheet tray transport failure service check 140 Ethernet 417 189.xx errors USB 417 2500-sheet tray communication error service card stock check 144 tips 27 196.xx errors...
Page 614 4021 exit configuration 194 display log 187 font sharpening 192 DRAM test 177 hole punch configuration 188 duplex top margin 179 jobs on disk 191 edge to edge 185 key repeat initial delay 193 enable edge to edge copy 185 key repeat rate 193 exit diagnostics 187 LES applications 192...
Page 615 4021 Empty the hole punch box 102 print log 187 emptying the hole punch box 424 print log summary 187 envelopes expose 586 tips on using 28 exterior of the printer error codes cleaning 421 0‑99 112 111 error messages 125 120 error messages 126 fax ports 417 121 error messages 126...
Page 616 4021 Insufficient memory, some Held Jobs were deleted lubrication [37] 103 guidelines 421 Insufficient memory, some held jobs will not be restored [37] 103 Insufficient space between paper stacks in Tray 3 103 maintenance counter 421 internal options 583 maintenance kit invalid code, fixing 195 resetting the counter 421 invalid engine mode...
Page 617 4021 paper characteristics 29 [x]‑page jam, clear manual feeder. [200.xx] 56 paper jams [x]‑page jam, open door C and clear all jammed avoiding 53 media. [2yy.xx] 63 paper jams, clearing [x]‑page jam, open door D and clear all jammed door C 63, 65 media.
Page 618 4021 Load [paper source] with [paper type] [paper size] Restore held jobs? 110 [paper orientation] 104 Serial port [x] disabled [56] 110 Load Multipurpose Feeder with [custom string] SMTP server not set up. Contact system [paper orientation] 104 administrator. 110 Load Multipurpose Feeder with [custom type name] Some held jobs were not restored 110 [paper orientation] 104...
Page 619 4021 removal 3000-sheet tray left cover 391 2 x 500-sheet tray 3 transport assembly 377 3000-sheet tray left top cover 395 2 x 500-sheet tray 4 transport assembly 378 3000-sheet tray pick roller assembly 410 2 x 500-sheet tray 4 transport belts and gears 383 3000-sheet tray rear cover 393 2 x 500-sheet tray bottom right cover 377 3000-sheet tray release handle 390...
Page 620 4021 main power switch 277 registration unit sub-assembly 265 motor (2 x 500-sheet tray 3 feed) 373 right door 262 motor (2 x 500-sheet tray 3 lift) 370 right door lock 245 motor (2 x 500-sheet tray 3 transport) 373 right door switch 284 motor (2 x 500-sheet tray 4 feed) 373 right door switch actuator 262...
Page 621 4021 top front door 273 safety information 22 top side cover 232 scheduled maintenance 420 transfer belt fan 329 screw transfer roller 234 blue 204 tray 2 transport drive 313 green 204 tray 2 transport guide 246 red 204 tray insert paper length guide 362 second transfer 589 tray lock 364 security slot 417...
Page 622 4021 theory of operation POR sequence 585 vertical mount contact connector 209 printer control 585 theory, 3000‑sheet tray 600 theory, duplex section 607 Waste toner bottle nearly full [82.xy] 112 theory, exit section 605 Weblink server not set up. Contact system theory, MPF section 595 administrator.
Page 623: Part Number Index
4021 Part number index Part name Page 40X8859 Paper exit fan............................490 40X8859 Toner suction fan...........................502 40X8869 Sensor (2 x 500-sheet tray 3 near empty)....................518 40X8869 Sensor (2 x 500-sheet tray 3 or 4 tray empty)..................524 40X8869 Sensor (2 x 500-sheet tray 3 or 4 tray lift plate level)................524 40X8869 Sensor (2 x 500-sheet tray 4 near empty)....................518 40X8869 Sensor (2500-sheet tray elevator home)....................574 40X8869 Sensor (2500-sheet tray main tray elevator limit).................564...
Page 624 4021 Part name Page 40X8895 Exit sensor housing..........................490 40X8897 Standard bin base...........................428 40X8898 Left cover..............................428 40X8899 Rear left cover............................428 40X8900 Top front door............................428 40X8901 Tray empty board cable.........................428 40X8902 Tray empty board cover.........................428 40X8903 2 x 500-sheet tray empty LED........................512 40X8903 3000-sheet tray empty LED........................534 40X8903 Tray 1 empty indicator...........................428 40X8903 Tray 2 empty indicator...........................428...
Page 625 4021 Part name Page 40X8951 Toner agitator............................440 40X8956 Motor (toner supply)..........................442 40X8957 Toner supply motor cable........................442 40X8958 Waste toner drive..........................444 40X8959 Waste toner duct...........................444 40X8960 Erase LED..............................446 40X8961 Photoconductor cable..........................448 40X8962 Photoconductor relay contact........................448 40X8962 Toner cartridge contact..........................440 40X8963 Transfer belt cable..........................450 40X8966 Tray 1 and 2 paper feed unit........................452 40X8967 Top side cover............................432 40X8968 Sensor (2 x 500-sheet tray 3 or 4 feed) ....................524...
Page 626 4021 Part name Page 40X8977 Front right lift handle..........................462 40X8978 Rear right lift handle..........................462 40X8979 Front left lift handle..........................462 40X8980 Rear left lift handle..........................462 40X8981 2 x 500-sheet tray right rail guide wheel....................514 40X8981 Tray rail guide wheel..........................556 40X8981 Tray right rail guide wheel........................462 40X8982 Tray 1 insert rail.............................462 40X8982 Tray 2 insert rail.............................462 40X8984 Tray 1 feed cable............................464...
Page 627 4021 Part name Page 40X9010 Transfer roller............................474 40X9011 Registration unit assembly........................474 40X9012 Duplex transport gear..........................484 40X9012 Registration unit gear..........................476 40X9013 Registration unit belt..........................476 40X9014 2 x 500-sheet tray insert stopper......................514 40X9017 2 x 500-sheet tray 3 right front cover....................528 40X9018 Top cover..............................432 40X9019 Right door upper lock..........................478 40X9020 Right door switch actuator........................478 40X9022 MPF separator gear..........................480...
Page 628 4021 Part name Page 40X9156 Exit clutch belt............................490 40X9157 Top cover base............................432 40X9159 Exit guide assembly..........................492 40X9161 Diverter solenoid............................492 40X9163 Motor (fuser)............................500 40X9163 Motor (transport)...........................494 40X9164 Main drive assembly..........................494 40X9165 Transport motor gear..........................494 40X9166 Duplex transport clutch..........................494 40X9167 Redrive exit guide...........................490 40X9170 Motor (feed)............................494 40X9170 Motor (tray 2 transport).........................494 40X9171 Motor (registration)..........................494...
Page 629 4021 Part name Page 40X9197 Induction heater power supply ,230 V....................504 40X9198 Induction heater magnetic erase board....................504 40X9199 Expansion controller board........................504 40X9200 Noise filter board, 100 V........................504 40X9201 Noise filter board, 230 V........................504 40X9202 3000-sheet tray controller board cable....................551 40X9203 Main power supply, 100 V........................506 40X9204 Main power supply, 230 V........................506 40X9205 Main power supply fan with duct......................506 40X9207 Engine controller board..........................510...
Page 630 4021 Part name Page 40X9280 2500-sheet tray rear cover........................554 40X9281 2 x 500-sheet tray left cover........................512 40X9281 2500-sheet tray left cover........................554 40X9282 2 x 500-sheet tray caster wheel......................512 40X9282 Caster wheel............................554 40X9283 Printer rubber stopper...........................512 40X9283 Tray stopper............................554 40X9285 2 x 500-sheet tray bottom right cover....................512 40X9285 2500-sheet tray bottom right cover.......................554 40X9286 2 x 500-sheet tray empty LED mount.....................512 40X9286 2500-sheet tray LED mount........................554...
Page 631 4021 Part name Page 40X9305 2 x 500-sheet tray left rail guide wheel....................514 40X9305 Tray insert guide wheel..........................466 40X9305 Tray insert guide wheel..........................470 40X9305 Tray insert guide wheel..........................528 40X9305 Tray insert guide wheel..........................530 40X9305 Tray insert guide wheel..........................574 40X9305 Tray left rail guide wheel........................462 40X9306 Tray insert paper length guide.......................532 40X9306 Tray paper length guide.........................468 40X9308 2 x 500-sheet tray near empty sensor actuator..................532...
Page 632 4021 Part name Page 40X9615 MPF separator roller..........................482 40X9635 2 x 500-sheet tray 3 insert........................528 40X9639 Tray 2 transport drive belt........................494 40X9644 Redrive exit sensor cable........................490 40X9662 Control panel............................436 40X9664 Controller board (SFP)..........................510 40X9669 Maintenance kit, 300K...........................575 40X9673 Maintenance kit, 200K—MPF........................575 40X9697 2 x 500‑sheet tray 4 insert........................530 40X9698 3000-sheet tray interface cable......................551 40X9704 Imaging unit maintenance kit.........................450...
Page 633 4021 Part name Page 40X9731 Fuser transport primary gear.........................498 40X9732 Fuser transport secondary gear......................498 40X9733 High voltage transfer cable........................504 40X9734 High voltage toner charge cable......................504 40X9735 Induction heater magnetic erase board cable..................504 40X9736 Induction heater power supply cable.....................504 40X9737 Noise filter board cable..........................504 40X9740 Power socket cable..........................508 40X9741 Power socket............................508 40X9744 Engine controller board FFC........................510...
Page 634 4021 Part name Page 40X9785 2500-sheet tray controller board......................556 40X9786 2500-sheet tray cable harness.......................562 40X9787 2500-sheet tray pick assembly sensor cable..................564 40X9788 2500-sheet tray lock lever........................568 40X9789 2500-sheet tray front cover........................568 40X9790 Spring..............................546 40X9791 Paper stack transfer guide base......................570 40X9792 Paper stack transfer guide........................570 40X9793 Paper stack transfer sensor actuator.....................570 40X9794 Paper stack transfer sensor actuator spring..................570 40X9795 Transfer guide secondary gear.......................572...
Page 635 4021 Part name Page 40X9884 3000-sheet tray empty LED cover......................534 40X9885 Sensor (3000-sheet tray feed)........................546 40X9886 3000-sheet tray feed and pick drive gear....................542 40X9886 3000-sheet tray separator roller drive gear...................544 40X9887 3000-sheet tray separator roller secondary gear...................544 40X9888 3000-sheet tray separator roller clutch....................544 40X9889 2 x 500 sheet tray lift motor cable......................518 40X9890 2 x 500-sheet tray cable harness......................522 40X9891 2 x 500-sheet tray feed and transport primary gear................516...
Page 636 4021 Part name Page 40X9925 Pick roller..............................564 40X9925 Tray pick roller............................454 40X9927 Separator roller assembly......................456, 460 40X9936 Developer unit............................446 40X9962 Screwdriver............................428 40X9963 Waste toner door switch........................434 40X9965 USB port cover............................436 40X9966 Speaker cover............................436 40X9967 Control panel cable guide lower cover....................436 40X9968 Speaker..............................436 40X9969 Control panel cable guide upper cover....................436 40X9970 USB extension cable..........................436...
Page 637 4021 Part name Page 40X9999 Redrive diverter gear..........................486 41X0007 Forms and Bar code card........................577 41X0008 PRESCRIBE card............................577 41X0009 IPDS card..............................577 41X0030 Keyboard kit, English..........................577 41X0031 Keyboard kit, French..........................577 41X0032 Keyboard kit, Italian..........................577 41X0033 Keyboard kit, German..........................577 41X0034 Keyboard kit, Spanish..........................577 Part number index...
Page 638 4021 Part number index...
Page 639: Part Name Index
4021 Part name index Part name Page 40X9889 2 x 500 sheet tray lift motor cable......................518 40X9775 2 x 500 sheet tray paper length sensor cable..................518 40X9882 2 x 500-sheet tray 3 feed and transport motor cable................516 40X8871 2 x 500-sheet tray 3 front cover......................528 40X9034 2 x 500-sheet tray 3 handle cover......................528 40X9635 2 x 500-sheet tray 3 insert........................528 40X9299 2 x 500-sheet tray 3 or 4 transport roller....................524...
Page 640 4021 Part name Page 40X9281 2 x 500-sheet tray left cover........................512 40X9305 2 x 500-sheet tray left rail guide wheel....................514 40X9304 2 x 500-sheet tray lock lever......................528, 530 40X9308 2 x 500-sheet tray near empty sensor actuator..................532 40X9280 2 x 500-sheet tray rear cover.........................512 40X9779 2 x 500-sheet tray rear right cover......................512 40X8981 2 x 500-sheet tray right rail guide wheel....................514 40X9982 2 x 500-sheet tray set actuator......................524...
Page 641 4021 Part name Page 40X9286 2500-sheet tray LED mount........................554 40X9281 2500-sheet tray left cover........................554 40X9788 2500-sheet tray lock lever........................568 40X9899 2500-sheet tray main tray top paper empty actuator................564 40X9787 2500-sheet tray pick assembly sensor cable..................564 40X9280 2500-sheet tray rear cover........................554 40X9779 2500-sheet tray rear right cover......................554 40X9339 2500-sheet tray right front cover......................568 40X9803 2500-sheet tray transfer guide stop.......................574...
Page 642 4021 Part name Page 40X9765 3000-sheet tray left top cover........................534 40X9048 3000-sheet tray pick gear........................542 40X9258 3000-sheet tray rear cover........................534 40X9275 3000-sheet tray release handle......................540 40X9255 3000-sheet tray right cover........................534 40X9297 3000-sheet tray roller clutch........................542 40X9271 3000-sheet tray separator belt......................544 40X9267 3000-sheet tray separator roller......................544 40X9888 3000-sheet tray separator roller clutch....................544 40X9886 3000-sheet tray separator roller drive gear...................544...
Page 643 4021 Part name Page 40X9527 Door switch............................434 40X9031 Duplex transport assembly........................484 40X9036 Duplex transport belt..........................484 40X9166 Duplex transport clutch..........................494 40X9725 Duplex transport clutch gear........................494 40X9012 Duplex transport gear..........................484 40X9998 Duplex transport jam removal knob......................484 40X8909 Engine board cover..........................430 40X9207 Engine controller board..........................510 40X9744 Engine controller board FFC........................510 40X8960 Erase LED..............................446 40X9977 Erase LED cable............................446...
Page 644 4021 Part name Page 40X9178 Fuser exit clutch.............................500 40X9039 Fuser exit sensor actuator........................486 40X9723 Fuser exit sensor cable...........................486 40X9041 Fuser fan..............................488 40X9009 Fuser fixed power resistor........................474 40X8945 Fuser power supply fan..........................504 40X9729 Fuser pressure primary gear........................498 40X9730 Fuser pressure secondary gear......................498 40X9731 Fuser transport primary gear.........................498 40X9732 Fuser transport secondary gear......................498 40X9990 Fusing speed sensor cable........................474...
Page 645 4021 Part name Page 40X8898 Left cover..............................428 40X8919 Lower front door strap...........................434 40X9710 Lower registration gear..........................476 40X9164 Main drive assembly..........................494 40X8945 Main power supply fan...........................506 40X9205 Main power supply fan with duct......................506 40X9203 Main power supply, 100 V........................506 40X9204 Main power supply, 230 V........................506 40X8917 Main power switch..........................434 40X9798 Main tray elevator coupling........................572 40X9902 Main tray elevator gear..........................572...
Page 646 4021 Part name Page 40X9179 Motor (toner cartridge)..........................496 40X8956 Motor (toner supply)..........................442 40X9163 Motor (transport)...........................494 40X8987 Motor (tray 1 lift)...........................464 40X8987 Motor (tray 2 lift)...........................464 40X9170 Motor (tray 2 transport).........................494 40X9027 MPF................................480 40X9023 MPF feed clutch.............................480 40X9719 MPF feed clutch gear..........................480 40X9995 MPF feed roller............................480 40X9996 MPF lift plate cam ..........................480 40X9720 MPF lift plate clutch..........................480...
Page 647 4021 Part name Page 40X8961 Photoconductor cable..........................448 40X8905 Photoconductor cleaner.........................428 40X8962 Photoconductor relay contact........................448 40X9978 Photoconductor release lever........................448 40X9925 Pick roller........................458, 466, 470, 524, 564 40X9763 Port access door.............................430 40X8912 Port mount.............................430 40X9741 Power socket............................508 40X9740 Power socket cable..........................508 40X9402 Power socket mount..........................508 40X9189 Power‑saving board..........................504 41X0008 PRESCRIBE card............................577 40X9283 Printer rubber stopper...........................512...
Page 648 4021 Part name Page 40X9994 Registration unit handle.........................476 40X9992 Registration unit lock..........................476 40X9993 Registration unit lock shaft........................476 40X9900 Reserve tray empty sensor actuator......................574 40X9883 Reserve tray empty sensor actuator spring...................574 40X9900 Reserve tray paper limit sensor actuator....................570 40X9883 Reserve tray paper limit sensor actuator spring..................570 40X9997 Right door cover.............................484 40X9711 Right door handle...........................478 40X9715 Right door lock support..........................478...
Page 649 4021 Part name Page 40X8869 Sensor (2500-sheet tray main tray elevator limit).................564 40X8869 Sensor (2500-sheet tray main tray paper empty, top)................564 40X8869 Sensor (2500-sheet tray set)........................556 40X8968 Sensor (2500-sheet tray transport)......................564 40X9880 Sensor (3000-sheet tray elevator level)....................544 40X9880 Sensor (3000-sheet tray empty)......................544 40X9885 Sensor (3000-sheet tray feed)........................546 40X9880 Sensor (3000-sheet tray near empty 1)....................550 40X9880 Sensor (3000-sheet tray near empty 2)....................550...
Page 650 4021 Part name Page 40X8869 Sensor (tray 1 lift plate level).........................454 40X8869 Sensor (tray 1 near empty)........................464 40X8968 Sensor (tray 1 paper feed)........................454 40X8985 Sensor (tray 1 paper length)........................464 40X8989 Sensor (tray 1 paper width)........................464 40X8869 Sensor (tray 2 empty)..........................458 40X8869 Sensor (tray 2 lift plate level).........................458 40X8869 Sensor (tray 2 near empty)........................464 40X8968 Sensor (tray 2 paper feed)........................458...
Page 651 4021 Part name Page 40X8906 Top front door outer hinge........................428 40X8967 Top side cover............................432 40X8963 Transfer belt cable..........................450 40X8945 Transfer belt fan.............................438 40X8944 Transfer belt fan duct..........................438 40X9979 Transfer belt paper guide........................450 40X9808 Transfer guide belt..........................574 40X9796 Transfer guide primary gear........................572 40X9797 Transfer guide primary gear spring......................572 40X9795 Transfer guide secondary gear.......................572 40X9010 Transfer roller............................474...
Page 652 4021 Part name Page 40X8902 Tray empty board cover.........................428 40X9758 Tray empty board mount........................428 40X8903 Tray empty LED .............................554 40X9782 Tray empty LED cable..........................554 40X9899 Tray empty sensor actuator........................454 40X8970 Tray feed roller............................454 40X9805 Tray insert bottom left guide wheel.......................574 40X9799 Tray insert bottom right guide wheel....................574 40X9305 Tray insert guide wheel..................466, 470, 528, 530, 574 40X9784 Tray insert guide wheel........................556, 574...

Lexmark MS911 Service Manual

Product Information

Edition Notice

Notices and Safety Information

Preface

General Information

Diagnostic Information

Service Menus

Repair Information

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