Page 1 Lexmark™ W850n and W850dn Options 4024-110 • Table of contents • Start diagnostics • Safety and notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
Page 2 Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. Other trademarks are the property of their respective owners.
Page 3: Table Of Contents
4024-110 Table of contents Safety information..............xiii Preface .
Page 4 4024-110 High capacity feeder ..............1-18 Media feeding .
Page 5 4024-110 243.03 Sensor (registration) on jam (tray 3 media feed) ....... 2-10 243.04 Sensor (tray 3 feed-out) static jam .
Page 6 4024-110 980.04 Duplex controller card assembly communication failure ......2-89 997.00 Duplex controller card assembly type failure ........2-90 Duplex left door assembly open .
Page 7 4024-110 Edge to Edge ............. . 3-17 Parallel strobe adjustment (Par x Strobe Adj) .
Page 8 4024-110 MPF pick solenoid ............3-34 Sensor (MPF media out) .
Page 9 4024-110 2X 500-sheet drawer (2TM) removals ........... 4-3 2X 500-sheet drawer (2TM)—top cover removal .
Page 10 4024-110 2000-sheet dual input (TTM)—tray 4 media transport assembly removal ....4-68 2000-sheet dual input (TTM)—tray 4 rear cables removal ......4-69 2000-sheet dual input (TTM)—tray 4 front cables removal .
Page 11 4024-110 HCF sensor (media level) removal ..........4-139 HCF sensor (media out) removal .
Page 12 4024-110 Parts catalog ................How to use this parts catalog .
Page 13: Safety Information
4024-110 Safety information • The safety of this product is based on testing and approvals of the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. • The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others.
Page 14 4024-110 Sicherheitshinweise • Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen. • Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.
Page 15 4024-110 Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. •...
Page 16: Preface
4024-110 Preface The service information for the Lexmark W850n and W850dn is contained within three service manuals: • Printer Service Manual—Contains the base printer service information including the options and finisher error codes and tests. • Options Service Manual—Contains specific information for the 2 Tray Module, Tandem Tray Module, Duplex, High Capacity Feeder and Exit 2 options and a list of error codes and tests.
Page 17: General Information
4024-110 1. General information Options and features This chapter describes features for the tray 2, tandem tray, high capacity feeder, duplex, and exit 2 options for the Lexmark™ W850n and W850dn (4024-110) printer. Tray 2 General information...
Page 18: Driving Force Transmission Path
4024-110 Driving force transmission path The rotating force of the 2 tray/tandem tray drive motor is transmitted through the gears to components that need mechanical driving force as shown below. 2TM/TTM Drive motor 2TM drive gear (22T/40T) 2TM drive gear (60T) 2TM/TTM Clutch 2TM drive gear (32T) 2TM drive gear (38T)
Page 19: Media Transport
4024-110 Media transport Media transport path Media is supplied from tray 3 or tray 4, and is transported to the printer along the media transport path shown below. Tray 4 Tray 3 Pick roll Pick roll Separation roll Separation roll Feed roll Feed roll Upper pinch roll...
Page 20: Layout Of Media Transport Path
4024-110 Layout of media transport path The following is a cross section of the laser printer and the optional 2 tray module, showing main components directly associated with the media path and transport. Main components associated with the media transport Exit 2 media exit roll ASM Exit 2 media exit roll ASM Exit 2 media exit pinch rolls...
Page 21: Media Tray Assembly
4024-110 Media tray assembly It is necessary to adjust the front side guide, rear side guide and end guide on the media tray assembly to match the media size. Front media tray guide and rear media tray guide The front media tray guide can be adjusted to different media sizes by moving it to the front or rear. These guides come into contact with the front and rear edges of the media and hold it in position.
Page 22: Sensor (Pre-Feed)
4024-110 Sensor (pre-feed) This sensor detects a media jam in the media tray assembly by the media position and sensor on/off time. The sensor on/off state is monitored by media passing through the sensor (pre-feed) sensing area. Media feed lift motor Sensor (pre-feed) Sensor (media level) Sensor (media out)
Page 23: Main Components
4024-110 Main components Switch (2TM/TTM left door interlock) The left door interlock switch detects open/close of the left door assembly. Sensor (tray 3 feed-out) The sensor (tray 3 feed-out) detects media fed from tray 3 or tray 4. Sensor (tray 4 feed-out) The sensor (tray 4 feed-out) detects media fed from tray 4.
Page 24: Switch (Media Size)
4024-110 Switch (media size) The following table gives on/off states for the switch (media size), corresponding to the media sizes on the media tray assembly. Note: The switches (media size) are denoted by “S/W2”, “S/W4”, “S/W3”, “S/W5”, and “S/W1” respectively from the left side.
Page 25: Tandem Tray
4024-110 Tandem tray General information...
Page 26: Driving Force Transmission Path
4024-110 Driving force transmission path 2 tray / tandem tray drive motor assembly The rotating force of the 2 tray / tandem tray motor is transmitted through the gears to components that require mechanical driving force as shown below. 2TM/TTM drive motor TTM drive gear (22/40) 2TM/TTM clutch TTM drive gear (38T)
Page 27: Media Transport
4024-110 Media transport Media transport path Media is supplied from tray 3 or tray 4, and is transported to the printer along the media transport path shown below. Tray 4 Tray 3 Pick roll Pick roll Separation roll Separation roll Feed roll Feed roll Upper pinch roll...
Page 28: Media Transport Path
4024-110 Media transport path The following is a cross section of the printer and the optional tandem tray module, showing the main components directly associated with the media path and transport. Exit 2 media exit roll ASM Exit 2 media exit roll ASM Exit 2 media exit pinch rolls Exit 2 media exit pinch rolls Option exit 2...
Page 29: Media Tray Assembly
4024-110 Media tray assembly Media feed unit assembly It is necessary to adjust the front and rear side guides in the media tray assembly to match the media size. Front media guide / rear media guide The front media guide can be adjusted to different media sizes by moving it to the front or rear. These guides come into contact with the front and rear edges of the media and hold it in position.
Page 30: Media Feed Unit Assembly
4024-110 Tray 4 media tray assembly Rear lift cables Rear media guide Front media guide Bottom plate F/R lift cable F/L lift cable Media feed unit assembly Since the tray 3 and tray 4 are functionally equivalent in terms of the switch (TTM media size), sensor (media out), sensor (media level) and sensor (pre-feed), only the components of one tray are described here.
Page 31: Sensor (Media Level)
4024-110 Sensor (media level) This sensor detects by the actuator position whether media in the media tray assembly is lifted. When the flag of the actuator leaves the sensor (media level) sensing area, the sensor detects that the media has been lifted. Sensor (pre-feed) This sensor detects a media jam in the media tray assembly by the media position and sensor on/off time.
Page 32: Main Components
4024-110 Main components Switch (2TM/TTM left door interlock) The left door interlock switch detects open/close of the left door assembly. Sensor (tray 3 feed-out) The sensor (tray 3 feed-out) detects media fed from the tray 3 or tray 4. Sensor (tray 4 feed-out) The sensor (tray 4 feed-out) detects media fed from the tray 4.
Page 33: Switch (Tandem Tray Media Size)
4024-110 Switch (tandem tray media size) The following table gives on/off states of the switches on the switch (TTM media size), corresponding to the media sizes of the media tray assembly. Note: The switches (TTM media size) are denoted by “S/W1” and “S/W3” respectively from the left side. Analog switch Media Size S/W1...
Page 34: High Capacity Feeder
4024-110 High capacity feeder 1-18 Options Service Manual...
Page 35: Media Feeding
4024-110 Media feeding Outline The HCF feeds media from the tray to the printer through the HCF media feed unit assembly and the HCF media transport roll assembly. HCF media feed unit assembly The pick roll feeds media from the tray, the feed roll, and separation roll feed media from the pick roll to the HCF media transport roll assembly.
Page 36 4024-110 The sensor (tray 5 feed-out) detects the presence of media fed from the tray, and controls the media feed lift motor stop and the transport motor speed. It also detects media jams to identify media jam zone. Separation roll Feed roll Pick roll HCF media transport roll asm...
Page 37: Hcf Media Feed Unit Assembly Operation
4024-110 HCF media feed unit assembly operation Upon receiving the feed start signal from the controller, the HCF activates the pick solenoid after a preset time has passed to press the pick roll against the media in the tray. After a preset time has passed, after receiving the feed start signal, the HCF feed lift motor rotates forward to feed media from the tray to the feed roll side with the pick roll.
Page 38: Hcf Media Transport Roll Assembly Operation
4024-110 HCF media transport roll assembly operation Upon receiving the feed start signal, from the controller, the HCF activates the HCF transport motor at a high speed after a preset time has passed. This rotating power of the HCF transport motor is transmitted to the HCF media transport roll assembly, and the media from the HCF media feed unit assembly is transferred to the printer.
Page 39: Hcf Media Feed Unit Assembly Sensor/Motor Functions
4024-110 HCF media feed unit assembly sensor/motor functions Functions of the sensors and motors of the media feed unit assembly are outlined below. HCF media feed lift motor—is a stepping motor that rotates (forward) the pick roll and feed roll to send media from the tray to the HCF media transport roll assembly.
Page 40: Status Monitoring
4024-110 Status monitoring This function includes detection of static media jams, interlocking, and insertion of the HCF media tray assembly. Static media jam detection Checks the status of all relevant sensors on the media path to detect media jams. When media is present on the sensor, it is treated as a static jam.
Page 41: Tray Insertion Detection
4024-110 Tray insertion detection The sensor (HCF media tray set) checks whether the tray is properly set. This check is constant while the power is on. Printing operation is inhibited if the sensor (HCF media tray set) off (tray is not present) is detected before starting printing.
Page 42: Media Size Detection
4024-110 Media size detection Media size is automatically detected by loading media in the tray and by the rear media edge guide that is attached to the media tray assembly and aligned with the side of the media. The position of the rear media edge guide is detected by the sensor (HCF media size L) and the sensor (HCF media size R).
Page 43: Media Out Detection
4024-110 HCF feed lift motor Feed lift gear bracket asm Bottom plate Media out detection This function checks whether media is loaded in the HCF media tray. When media is present, the media out actuator in the middle of the HCF is raised by the lifting of media and leaves the sensing area of the sensor (media out), which makes the sensor light-receivable.
Page 44: Sensor (Media Out)
4024-110 If media out is detected during printing, print operation of the next media is stopped. However, when the printer is operating in the Auto Tray Select mode and there is media of the same size in another tray, media is automatically fed out of the tray.
Page 45 4024-110 While this sensor (media level) is off, lifting the tray is continued until the sensor (media level) turns on. HCF pick solenoid Sensor (media level) HCF feed lift motor Front 1-29 General information...
Page 46: Duplex
4024-110 Duplex Duplex drive motor The rotating force of the drive motor is transmitted through the gears to components that need mechanical driving force as shown below. Duplex drive motor Duplex drive gear 33/74T Duplex drive gear 33/74T Duplex drive gear 28T Duplex drive gear 28T Duplex drive gear 33T Duplex media transport roll asm...
Page 47: Media Transport
4024-110 Media transport Media transport path With the optional duplex installed, media is supplied from the MPF, tray 1 or tray 2, and is transported to the printer along the media transport path shown below. Tray 1 Tray 2 Pick roll Pick roll MPF pick roll MPF Transport Roll ASM...
Page 48: Layout Of Media Transport Path
4024-110 Layout of media transport path The main components associated with the media path and transport with the optional duplex installed. Exit 2 media exit roll ASM Exit 2 media exit roll ASM Exit 2 media exit pinch rolls Exit 2 media exit pinch rolls Option exit 2 Option exit 2 Exit 2 media transport roll ASM...
Page 49: Duplex Media Transport Roll Assembly
4024-110 Duplex media transport roll assembly The two duplex media transport roll assemblies and the duplex media center transport roll assembly re-feeds the media printed on the front side through the duplex to print on the rear side. Duplex controller card assembly The duplex controller card assembly that contains a CPU controls media feed in the duplex upon receiving a command from the printer engine card assembly and sensor/switch information.
Page 50: Exit 2
4024-110 Exit 2 Exit 2 drive motor The rotating force of the exit 2 drive motor is transmitted through the gears to components that need mechanical driving force as shown below. Exit 2 drive motor Exit 2 drive gear 19T Exit 2 drive gear 19T Exit 2 drive gear 19/44T Exit 2 media exit roll asm...
Page 51: Media Transport
4024-110 Media transport Media transport path With the optional exit 2 installed, media is supplied from the MPF, tray 1, or tray 2 and is transported to the printer along the media transport path shown below. Tray 1 Tray 2 MPF pick roll Pick roll Pick roll...
Page 52: Layout Of Media Transport Path
4024-110 Layout of media transport path The following figure illustrates the main components directly associated with the media path and transport with the optional exit 2 installed. Exit 2 media exit roll ASM Exit 2 media exit roll ASM Exit 2 media exit pinch rolls Exit 2 media exit pinch rolls Option exit 2 Option exit 2...
Page 53: Media Shift Motor
4024-110 Media shift motor The media shift motor is a stepping motor moving the media exit roll assembly frontward or rearward. Forward rotation of this motor moves the media exit roll assembly to the front side. Reverse rotation of this motor moves it to the rear side.
Page 54 4024-110 Sensor (exit 2 media shift HP) Sensor (standard bin full exit 2) Exit 2 media exit roll asm Exit interface Sensor (exit 2) card asm Switch (exit 2 left door interlock) Exit 2 media transport roll asm Media shift motor Rear Exit 2 drive motor 1-38...
Page 55: Tools Required For Service
4024-110 Tools required for service Flat-blade screwdriver #1 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic short-blade Needle nose pliers Diagonal side cutters Spring hook 5.5 mm hex driver, magnetic Analog or digital multi meter Parallel wrap plug 1319128 Twinax/serial debug cable 1381963 Coax/serial debug cable 1381964 Acronyms...
Page 56 4024-110 Position Sensing Device Pulse Width Modulation RFID Radio Frequency Identification Raster Imaging Processor Read only Memory Revolutions Per Minute SDRAM Synchronous Dual Random Access Memory Short Edge Fed SIMM Single Inline Memory Module Start of scan SRAM Static Random Access Memory Tandem Tray Module Used Parts Return Volts...
Page 57: Diagnostic Information
4024-110 2. Diagnostic information Start CAUTION: Unplug the power cord from the electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals. CAUTION: The printer weighs 47.7 kg (105 lb.) and requires at least two people to lift it safely.
Page 58: Confirm The Installation Status
4024-110 Confirm the installation status Be sure to check the following items before starting the troubleshooting procedures. • The power cord is free from breakage, short-circuit, disconnected wire, or incorrect connection in the power cord. • The printer is properly grounded. Check the power cord ground terminal. •...
Page 59: Error Code Messages - 2X 500-Sheet Drawer (2Tm)
4024-110 Error code messages - 2X 500-sheet drawer (2TM) Error code or Error contents Description/Action message 243.00 Sensor (pre-feed) on jam (tray The pre-feed sensor 3 is not turned on within the 3 media feed) specified time after the tray 3 feed lift motor is turned on. Paper jam Go to “243.00 Sensor (pre-feed) on jam (tray 3 media...
Page 60 4024-110 Error code or Error contents Description/Action message 244.05 Sensor (tray 4 feed-out) static Media remains on the sensor (tray 4 feed-out). Paper jam Go to “244.05 Sensor (tray 4 feed-out) static jam” on page 2-22. Check areas C, tray 4 Tray 3 media size mismatch in The media length detected by the sensor (registration) length...
Page 61: Service Checks - 2X 500-Sheet Drawer (2Tm)
4024-110 Service checks—2X 500-sheet drawer (2TM) 243.00 Sensor (pre-feed) on jam (tray 3 media feed) Step Check Check the media condition. Replace the media. Go to step 2. Is the media in the tray crumpled or damaged? Check the media size setup. Go to step 3.
Page 62: Sensor (Tray 3 Feed-Out) On Jam (Tray 3 Media Feed)
4024-110 Step Check Check the tray 3 media feed lift motor for proper Go to step 11. Go to step 9. operation. 1. Enter Diagnostics mode. 2. Select MOTOR TESTS. 3. Select Tray 3 feed mtr. Does the above media feed lift motor rotate normally? Check the tray 3 media feed lift motor for proper Replace the media Replace the...
Page 63 4024-110 Step Check Check the media size setup. Go to step 3. Replace the media or change the media Does the size of media in use match the size set for tray size setup. Check the tray 3 rolls. Go to step 4. Clean or replace the feed roll, separation Pull out tray 3, and check it.
Page 64: Sensor (Tray 2 Feed-Out) On Jam (Tray 3 Media Feed)
4024-110 Step Check Check the tray 3 sensor (pre-feed) for proper operation. Go to step 10. Go to step 9. 1. Enter Diagnostics mode. 2. Select INPUT TRAY TESTS. 3. Select Sensor Tests. 4. Select Tray 3. 5. Select Pre-feed. Remove the media tray assembly.
Page 65 4024-110 Step Check Check the tray 3 rolls. Go to step 4. Clean or replace the feed roll, separation Pull out tray 3, and check it. roll, and pick roll. Are the feed roll, separation roll, and pick roll for Go to “2X 500- transport free of excess wear and contamination?
Page 66: Sensor (Registration) On Jam (Tray 3 Media Feed)
4024-110 Step Check Check the sensor (tray 3 feed-out) for proper Replace the sensor Replace the connection. (tray 3 feed-out). connection. Is the above sensor connected properly? Go to “2X 500- sheet drawer (2TM)—sensor (tray 3 feed-out) removal” on page 4-37.
Page 67 4024-110 Step Check Check the media position. Remove the media. Go to step 5. Open the printer left door assembly, and visually check Does the media touch the sensor (registration)? Check the media position. Remove the media. Go to step 6. Open the 2TM/TTM left door assembly, and visually check it.
Page 68: Sensor (Tray 3 Feed-Out) Static Jam
4024-110 Step Check Perform a print test. Replace the 2TM/ Problem solved. TTM controller card Does the error still occur? assembly. Go to “2X 500- sheet drawer (2TM)—2TM/TTM controller card assembly removal” on page 4-43. Go to step 12. Perform a print test. Replace the printer Problem solved.
Page 69: Sensor (Tray 4 Feed-Out) On Jam (Tray 4 Media Feed)
4024-110 Step Check Perform a print test. Replace the printer Problem solved. engine card Does the error still occur? assembly. Refer to the Printer Service Manual. 244.00 Sensor (tray 4 feed-out) on jam (tray 4 media feed) Step Check Check the media condition. Replace the media.
Page 70: Sensor (Tray 3 Feed-Out) On Jam (Tray 4 Media Feed)
4024-110 Step Check Check the tray 4 pre-feed sensor for proper connection. Replace the sensor Replace the (pre-feed). connection. Is the above sensor connected properly? Go to “2X 500- sheet drawer (2TM)—sensor (pre-feed) removal” on page 4-25. Check the 2TM/TTM controller card assembly and the Go to step 8.
Page 71 4024-110 Step Check Check the media size setup. Go to step 3. Replace the media or change the media Does the media size in use match the size set for tray 4? size setup. Check the tray 4 rolls. Go to step 4. Clean or replace the feed roll, separation Pull out tray 4, and check it.
Page 72: Sensor (Tray 2 Feed-Out) On Jam (Tray 4 Media Feed)
4024-110 Step Check Check the sensor (tray 3 feed-out) for proper operation. Replace the sensor Go to step 9. (tray 3 feed-out). 1. Enter Diagnostics mode. Go to “2X 500- 2. Select INPUT TRAY TESTS. sheet drawer 3. Select Sensor Tests. (2TM)—sensor 4.
Page 73 4024-110 Step Check Check the tray 4 rolls. Go to step 4. Clean or replace the feed roll, separation Pull out tray 4, and check it. roll, and pick roll. Are the feed roll, separation roll, and pick roll for Go to “2X 500- transport free of excess wear and contamination?
Page 74: Sensor (Registration) On Jam (Tray 4 Media Feed)
4024-110 Step Check Check the sensor (tray 4 feed-out) for proper Replace the sensor Replace the connection. (tray 3 feed-out). connection. Is the above sensor connected properly? Go to “2X 500- sheet drawer (2TM)—sensor (tray 3 feed-out) removal” on page 4-37.
Page 75 4024-110 Step Check Check the media position. Remove the media. Go to step 5. Open the printer left door assembly, and visually check Does the media touch the sensor (registration)? Check the media position. Remove the media. Go to step 6. Open the 2TM/TTM left door assembly, and visually check it.
Page 76: Sensor (Pre-Feed) On Jam (Tray 4 Media Feed)
4024-110 Step Check Perform a print test. Replace the 2TM/ Problem solved. TTM controller card Does the error still occur? assembly. Go to “2X 500- sheet drawer (2TM)—2TM/TTM controller card assembly removal” on page 4-43. Go to step 12. Perform a print test. Replace the printer Problem solved.
Page 77 4024-110 Step Check Check the tray 4 pre-feed sensor for proper operation. Ensure the Feed unit Go to step 6. front guide is 1. Enter Diagnostics mode. properly installed. 2. Select INPUT TRAY TESTS. Go to step 7. 3. Select Sensor Tests. 4.
Page 78: Sensor (Tray 4 Feed-Out) Static Jam
4024-110 Step Check Perform a print test. Replace the 2TM/ Problem solved. TTM controller card Does the error still occur? assembly. Go to “2X 500- sheet drawer (2TM)—2TM/TTM controller card assembly removal” on page 4-43. Go to step 13. Perform a print test. Replace the printer Problem solved.
Page 79: Tray 3 Lift Up / No Tray Failure
4024-110 Step Check Perform a print test. Replace the printer Problem solved. engine card Does the error still occur? assembly. Refer to the Printer Service Manual. 943.00 Tray 3 lift up / no tray failure Step Check Check the media. Go to step 2.
Page 80: Tray 4 Lift Up / No Tray Failure
4024-110 Step Check Check the tray 3 sensor (media level) for proper Go to step 9. Go to step 8. operation. 1. Enter Diagnostics mode. 2. Select INPUT TRAY TESTS. 3. Select Sensor Tests. 4. Select Tray 3. 5. Select Media level. Remove the media tray assembly, and move the pick roll with your finger in an up and down motion.
Page 81 4024-110 Step Check Check the tray. Go to step 3. Replace the tray lift sector gear 12T or Are the tray lift sector gear 12T of tray 4 or the any other damaged surrounding parts of it damaged? components. Check the tray 4 media feed lift motor for proper Go to step 7.
Page 82: 2Tm/Ttm Controller Card Assembly Communication Failure
4024-110 Step Check Perform a print test. Replace the 2TM/ Problem solved. TTM controller card Does the error still occur? assembly. Go to “2X 500- sheet drawer (2TM)—2TM/TTM controller card assembly removal” on page 4-43. Go to step 11. Perform a print test. Replace the printer Problem solved.
Page 83: Tray 4 Media Size Failure
4024-110 Step Check Check the tray 3 switch (media size) for proper Go to step 4. Install the switch operation. (media size) for tray 3 correctly. Pull out tray 3, and visually check it. Go to “2X 500- Is the switch (media size) for tray 3 installed properly? sheet drawer (2TM)—switch (media size)
Page 84: 2Tm/Ttm Left Door Assembly Open
4024-110 Step Check Check the tray 4 switch (media size) for proper Go to step 4. Install the switch operation. (media size) for tray 4 correctly. Pull out tray 4, and visually check it. Go to “2X 500- Is the tray 4 switch (media size) installed properly? sheet drawer (2TM)—switch (media size)
Page 85: No Media In The Select Media Tray
4024-110 Step Check Check the switch (2TM/TTM left door interlock) for Go to step 4. Go to step 3. proper operation. 1. Enter Diagnostics mode. 2. Select BASE SENSOR TESTS. 3. Select Cover and Door. 4. Select Door C 2TM/TTM. Open the 2TM/TTM left door assembly, and visually check it.
Page 86: Media Size Mismatch In Width
4024-110 Step Check Check the sensor (media out) for proper operation. Go to step 4. Go to step 3. 1. Enter Diagnostics mode. 2. Select INPUT TRAY TESTS. 3. Select Sensor Tests. 4. Select Tray 3. 5. Select Media out. 1.
Page 87: Tray 3 Media Size Mismatch In Length
4024-110 Step Check Check the media. Go to step 3. Set the parts properly. Pull out each tray, and visually check it. Are the front media tray guide assembly and rear media tray guide on tray 3 and tray 4 set correctly? Check the switch (media size) for proper installation.
Page 88 4024-110 Step Check Check the tray 3 switch (media size) for proper Go to step 5. Install the switch installation. (media size) for tray 3 correctly. Pull out tray 3, and visually check it. Go to “2X 500- Is the switch (media size) for tray 3 installed properly? sheet drawer (2TM)—switch (media size)
Page 89: Tray 4 Media Size Mismatch In Length
4024-110 Step Check Check the sensor (registration) for proper operation. Go to step 12. Go to step 11. 1. Enter Diagnostics mode. 2. Select BASE SENSOR TESTS. 3. Select Media Path. 4. Select Registration. Open the printer left door assembly, and visually check Does the display on the operator panel change every time the actuator on the above sensor operates? Check the sensor (registration) for proper connection.
Page 90 4024-110 Step Check Check the tray 4 switch (media size) for proper Go to step 5. Install the switch installation. (media size) for tray 4 correctly. Pull out tray 4, and visually check it. Is the tray 4 switch (media size) installed properly? Check the tray 4 switch (media size) for proper Replace the switch Replace the...
Page 91 4024-110 Step Check Check the sensor (registration) for proper operation. Go to step 12. Go to step 11. 1. Enter Diagnostics mode. 2. Select BASE SENSOR TESTS. 3. Select Media Path. 4. Select Registration. Open the printer left door assembly, and visually check Does the display on the operator panel change every time the actuator on the above sensor operates? Check the sensor (registration) for proper connection.
Page 92: Error Code Messages - 2000-Sheet Dual Input (Ttm)
4024-110 Error code messages - 2000-sheet dual input (TTM) Error code or Error Contents Description\Action message 243.00 Sensor (pre-feed) on jam (tray The sensor (pre-feed) is not turned on within the 3 media feed) specified time after the tray 3 feed lift motor is turned on. Paper jam Go to “243.00 Sensor (pre-feed) on jam (tray 3 media...
Page 93 4024-110 Error code or Error Contents Description\Action message 244.05 Sensor (tray 4 feed-out) static Media remains on the sensor (tray 4 feed-out). Paper jam Go to “244.05 Sensor (tray 4 feed-out) static jam” on page 2-55. Check areas C, tray 4 Tray 3 media size mismatch in The media length detected by the sensor (registration) length...
Page 94: Service Checks - 2000-Sheet Dual Input (Ttm)
4024-110 Service checks - 2000-sheet dual input (TTM) 243.00 Sensor (pre-feed) on jam (tray 3 media feed) Step Check Check the media condition. Replace the media. Go to step 2. Is the media in the tray crumpled or damaged? Check the media size setup. Go to step 3.
Page 95: Sensor (Tray 3 Feed-Out) On Jam (Tray 3 Media Feed)
4024-110 Step Check Check the tray 3 media feed lift motor for proper Go to step 11. Go to step 9. operation. 1. Enter Diagnostics mode. 2. Select MOTOR TESTS. 3. Select Tray 3 feed mtr. Does the above motor rotate normally? Check the tray 3 media feed lift motor for proper Go to step 10.
Page 96 4024-110 Step Check Check the tray 3 rolls. Go to step 4. Clean or replace the feed roll, separation Pull out tray 3, and check it. roll, and pick roll. Are the feed roll, separation roll, and pick roll for Go to “2000-sheet transport free of excess wear and contamination?
Page 97: Sensor (Tray 2 Feed-Out) On Jam (Tray 3 Media Feed)
4024-110 Step Check Check the tray 3 sensor (pre-feed) for proper Replace the sensor Replace the connection. (pre-feed). connection. Is the above sensor connected properly? Go to “2000-sheet dual input (TTM)— sensor (media out) removal” on page 4-96. Perform a print test. Replace the 2TM/ Problem solved.
Page 98 4024-110 Step Check Check the media position. Remove the media. Go to step 6. Open the 2TM/TTM left door assembly, and visually check it. Does the media touch the sensor (tray 3 feed-out)? Check the sensor (tray 2 feed-out) for proper operation. Go to step 8.
Page 99: Sensor (Registration) On Jam (Tray 3 Media Feed)
4024-110 Step Check Perform a print test. Replace the printer Problem solved. engine card Does the error still occur? assembly. Refer to the Printer Service Manual. 243.03 Sensor (registration) on jam (tray 3 media feed) Step Check Check the media condition. Replace the media.
Page 100: Sensor (Tray 3 Feed-Out) Static Jam
4024-110 Step Check Check the sensor (tray 3 feed-out) for proper operation. Go to step 10. Go to step 9. 1. Enter Diagnostics mode. 2. Select INPUT TRAY TESTS. 3. Select Sensor Tests. 4. Select Tray 3. 5. Select Feed-out. Open the 2TM/TTM left door assembly, and visually check it.
Page 101: Sensor (Tray 4 Feed-Out) On Jam (Tray 4 Media Feed)
4024-110 Step Check Check the sensor (tray 3 feed-out) for proper operation. Go to step 4. Go to step 3. 1. Enter Diagnostics mode. 2. Select INPUT TRAY TESTS. 3. Select Sensor Tests. 4. Select Tray 3. 5. Select Feed-out. Open the 2TM/TTM left door assembly, and visually check it.
Page 102 4024-110 Step Check Check the tray 4 rolls. Go to step 4. Clean or replace the feed roll, separation Pull out tray 4, and check it. roll, and pick roll. Are the feed roll, separation roll, and pick roll for Go to “2000-sheet transport free of excess wear and contamination?
Page 103 4024-110 Step Check Check the sensor (tray 4 feed-out) for proper Replace the sensor Replace the connection. (tray 4 feed-out). connection. Is the above sensor connected properly? Go to “2000-sheet dual input (TTM)— sensor (tray 4 feed- out) removal” on page 4-82.
Page 104: Sensor (Tray 3 Feed-Out) On Jam (Tray 4 Media Feed)
4024-110 244.01 Sensor (tray 3 feed-out) on jam (tray 4 media feed) Step Check Check the media condition. Replace the media. Go to step 2. Is the media in the tray crumpled or damaged? Check the media size setup. Go to step 3. Replace the media or change the media Does the media size in use match the size set for tray...
Page 105 4024-110 Step Check Check the sensor (tray 3 feed-out) for proper operation. Go to step 10. Go to step 9. 1. Enter Diagnostics mode. 2. Select INPUT TRAY TESTS. 3. Select Sensor Tests. 4. Select Tray 3. 5. Select Feed-out. Open the 2TM/TTM left door assembly, and visually check it.
Page 106: Sensor (Tray 2 Feed-Out) On Jam (Tray 4 Media Feed)
4024-110 Step Check Perform a print test. Replace the printer Problem solved. engine card Does the error still occur? assembly. Refer to the Printer Service Manual. 244.02 Sensor (tray 2 feed-out) on jam (tray 4 media feed) Step Check Check the media condition. Replace the media.
Page 107: Sensor (Registration) On Jam (Tray 4 Media Feed)
4024-110 Step Check Check the sensor (tray 2 feed-out) for proper Replace the sensor Replace the connection. (tray 2 feed-out). connection. Is the above sensor connected properly? Refer to the Printer Service Manual. Check the sensor (tray 4 feed-out) for proper operation. Go to step 10.
Page 108 4024-110 Step Check Check the tray 4 rolls. Go to step 4. Clean or replace the feed roll, separation Pull out tray 4, and check it. roll, and pick roll. Are the feed roll, separation roll, and pick roll for Go to “2000-sheet transport free of excess wear and contamination?
Page 109: Sensor (Pre-Feed) On Jam (Tray 4 Media Feed)
4024-110 Step Check Check the sensor (tray 4 feed-out) for proper Replace the sensor Replace the connection. (tray 4 feed-out). connection. Is the above sensor connected properly? Go to “2000-sheet dual input (TTM)— sensor (tray 4 feed- out) removal” on page 4-82.
Page 110 4024-110 Step Check Check the tray 4 sensor (pre-feed) for proper operation. Go to step 7. Go to step 6. 1. Enter Diagnostics mode. 2. Select INPUT TRAY TESTS. 3. Select Sensor Tests. 4. Select Tray 4. 5. Select Pre-feed. Remove the media tray assembly.
Page 111: Sensor (Tray 4 Feed-Out) Static Jam
4024-110 Step Check Perform a print test. Replace the printer Problem solved. engine card Does the error still occur? assembly. Refer to the Printer Service Manual. 244.05 Sensor (tray 4 feed-out) static jam Step Check Check the media position. Remove the media. Go to step 2.
Page 112: Tray 3 Lift Up / No Tray Failure
4024-110 943.00 Tray 3 lift up / no tray failure Step Check Check the media. Go to step 2. Load media. Pull out tray 3, and visually check it. Is any media loaded in tray 3? Check the tray. Go to step 3. Replace the tray 3 lift gear assembly or Is the tray 3 lift gear assembly or the surrounding parts...
Page 113: Tray 4 Lift Up / No Tray Failure
4024-110 Step Check Check the sensor (media level) for proper connection. Replace the sensor Replace the (media level). connection. Is the above sensor connected properly? Go to “2000-sheet dual input (TTM)— sensor (media level) removal” on page 4-95. Check the switch (TTM media size) for proper Replace the switch Replace the connection.
Page 114 4024-110 Step Check Check the tray 4 media feed lift motor for proper Reinstall the media Go to step 6. operation. feed lift motor for tray 3 as it Replace the media feed lift motor for tray 4 with that for previously was, and tray 3.
Page 115: 2Tm/Ttm Controller Card Assembly Communication Failure
4024-110 Step Check Perform a print test. Replace the printer Problem solved. engine card Does the error still occur? assembly. Refer to the Printer Service Manual. 980.00 2TM/TTM controller card assembly communication failure Step Check Check the 2TM/TTM controller card assembly and the Problem solved.
Page 116: Tray 4 Media Size Failure
4024-110 Step Check Check the switch (TTM media size) for proper Replace the switch Replace the connection. (TTM media size). connection. Is the above switch installed correctly? Go to “2000-sheet dual input (TTM)— switch (TTM media size) removal” on page 4-83.
Page 117: 2Tm/Ttm Left Door Assembly Open
4024-110 Step Check Check the 2TM/TTM controller card assembly and the Go to step 6. Replace the printer engine card assembly for proper connection. connection. Are connectors P541 and P413 on the above cards connected properly? Perform a print test. Replace the 2TM/ Problem solved.
Page 118: No Media In The Select Media Tray
4024-110 Step Check Check the 2TM/TTM controller card assembly and the Go to step 5. Replace the printer engine card assembly for proper connection. connection. Are connectors P541 and P413 on the above cards connected properly? Perform a print test. Replace the 2TM/ Problem solved.
Page 119: Media Size Mismatch In Width
4024-110 Step Check Check the 2TM/TTM controller card assembly and the Go to step 5. Replace the printer engine card assembly for proper connection. connection. Are connectors P541 and P413 on the above cards connected properly? Perform a print test. Replace the 2TM/ Problem solved.
Page 120: Tray 3 Media Size Mismatch In Length
4024-110 Step Check Perform a print test. Replace the 2TM/ Problem solved. TTM controller card Does the error still occur? assembly. Go to “2000-sheet dual input (TTM)— 2TM/TTM controller card assembly removal” on page 4-115. Go to step 7. Perform a print test. Replace the printer Problem solved.
Page 121 4024-110 Step Check Check the tray 3 rolls. Go to step 7. Clean or replace the feed roll, separation Pull out tray 3, and check it. roll, and pick roll. Are the feed roll, separation roll, and pick roll for Go to “2000-sheet transport free of excess wear and contamination?
Page 122: Tray 4 Media Size Mismatch In Length
4024-110 Step Check Check the registration clutch for proper connection. Replace the Replace the registration clutch. connection. Is the above component connected properly? Refer to the Printer Service Manual. Perform a print test. Replace the 2TM/ Problem solved. TTM controller card Does the error still occur? assembly.
Page 123 4024-110 Step Check Check the tray 4 rolls. Go to step 7. Clean or replace the feed roll, separation Pull out tray 4, and check it. roll, and pick roll. Are the feed roll, separation roll, and pick roll for Go to “2000-sheet transport free of excess wear and contamination?
Page 124 4024-110 Step Check Check the registration clutch for proper connection. Replace the Replace the registration clutch. connection. Is the above component connected properly? Refer to the Printer Service Manual. Perform a print test. Replace the 2TM/ Problem solved. TTM controller card Does the error still occur? assembly.
Page 125: Error Code Messages - Hcf
4024-110 Error code messages - HCF Error code or Error Contents Description/Action message 245.00 Sensor (tray 5 feed-out) on jam The sensor (tray 5 feed-out) is not turned on within the specified time after the HCF feed lift motor is turned Paper jam Check areas K, Go to...
Page 126: Service Checks - Hcf
4024-110 Service checks - HCF 245.00 Sensor (tray 5 feed-out) on jam Step Check Check the paper path. Go to step 2. Clean or replace the appropriate roll, and Open the HCF top door assembly clean the paper path. Open the HCF media feed unit assembly. Go to “HCF pick Check these items by turning them with your fingers.
Page 127 4024-110 Step Check Check the sensor (pre-feed) for proper connection. Replace the sensor Replace the (pre-feed). connection. Is the above sensor connected properly? Go to “HCF sensor (pre-feed) removal” on page 4-137. Check the HCF feed unit cable assembly for proper Go to step 6.
Page 128: Sensor (Tray 2 Feed-Out) On Jam
4024-110 Step Check Perform a print test. Replace the printer Problem solved. engine card Does the error still occur? assembly. Refer to the Printer Service Manual. 245.01 Sensor (tray 2 feed-out) on jam Step Check Check the paper path. Go to step 2. Clean or replace the appropriate roll, and Open the HCF top door assembly...
Page 129: Sensor (Registration) On Jam
4024-110 Step Check Check the sensor (tray 2 feed-out) for proper Replace the sensor Replace the connection. (tray 2 feed-out). connection. Is the above sensor connected properly? Refer to the Printer Service Manual. Check the media transport motor for proper operation. Go to step 7.
Page 130 4024-110 Step Check Check the sensor (registration) in the printer for proper Go to step 5. Go to step 4. operation. 1. Enter Diagnostics mode. 2. Select BASE SENSOR TESTS. 3. Select Media Path. 4. Select Registration. Open the printer left door assembly. Does the display on the screen change every time the actuator on the above sensor operates? Check the sensor (registration) for proper connection.
Page 131: Sensor (Tray 5 Feed-Out) Static Jam
4024-110 245.03 Sensor (tray 5 feed-out) static jam Step Check Check the paper path. Go to step 2. Clean or replace the appropriate roll, and Open the HCF top door assembly clean the paper path. Open the HCF media feed unit assembly. Go to “HCF pick Check these items by turning them with your fingers.
Page 132 4024-110 Step Check Check the HCF feed lift motor for proper operation. Go to step 8. Go to step 7. 1. Enter Diagnostics mode. 2. Select MOTOR TESTS. 3. Select Tray 5 feed mtr. Does the above motor rotate normally? Check the HCF feed lift motor for proper connection.
Page 133: Hcf Unit Media Tray Lift Failure
4024-110 945.00 HCF unit media tray lift failure Step Check Check sensor (HCF media level) for proper operation. Go to step 9. Go to step 2. 1. Enter Diagnostics mode. 2. Select INPUT TRAY TESTS. 3. Select Sensor Tests. 4. Select Tray 5. 5.
Page 134: Hcf Unit Nvm R/W Failure
4024-110 Step Check Perform a print test. Replace the printer Problem solved. engine card Does the error still occur? assembly. Refer to the Printer Service Manual. 945.01 HCF unit NVM R/W failure Step Check Turn the main switch off and on several times. Go to step 2.
Page 135: Hcf Top Door Assembly Open
4024-110 Step Check Perform a print test. Replace the printer Problem solved. engine card Does the error still occur? assembly. Refer to the Printer Service Manual. HCF top door assembly open Step Check Check the HCF top door assembly for deformation. Go to step 2.
Page 136: Hcf Unit Docking Failure Or Tray 5 Set Failure
4024-110 HCF unit docking failure or tray 5 set failure Step Check Check the HCF unit for proper installation. Go to step 2. After reinstalling, go to step 2. Is the HCF unit installed to the printer correctly? Check the switch (HCF unit docking interlock) for Go to step 3.
Page 137: No Media In The Select Media Tray
4024-110 Step Check Perform a print test. Replace the HCF Problem solved. controller card Does the error still occur? assembly. Go to “HCF controller card assembly removal” on page 4-152. Go to step 8. Perform a print test. Replace the printer Problem solved.
Page 138 4024-110 Step Check Perform a print test. Replace the printer Problem solved. engine card Does the error still occur? assembly. Refer to the Printer Service Manual. 2-82 Options Service Manual...
Page 139: Error Code Messages - Dup
4024-110 Error code messages - DUP Error code or Error Contents Description/Action message 230.00 Sensor (duplex wait) on jam The sensor (duplex wait) is not turned on within the specified time after the exit 2 drive motor is turned on. Paper jam Go to “230.00 Sensor (duplex wait) on jam”...
Page 140: Service Checks - Dup
4024-110 Service checks - DUP 230.00 Sensor (duplex wait) on jam Step Check Check the paper position. Remove the paper. Go to step 2. Open the exit 2 left door assembly, and visually check it. Does the paper remain in the exit 2? Check the roll.
Page 141: Sensor (Duplex Wait) Static Jam
4024-110 Step Check Check the sensor (duplex wait) for proper operation. Go to step 11. Go to step 10. 1. Enter Diagnostics mode. 2. Select DUPLEX TESTS. 3. Select Sensor Tests. 4. Select Duplex wait. Open the duplex left door assembly. Does the display on the operator panel change every time the sensing area of the above sensor is blocked by the duplex wait actuator?
Page 142: Sensor (Registration) On Jam (Duplex Paper Feed)
4024-110 Step Check Check the sensor (duplex wait) for proper connection. Replace the sensor Replace the (duplex wait). connection. Is the above sensor connected properly? Go to “Duplex sensor (duplex wait) removal” on page 4-184. Perform a 2 sided print test. Replace the duplex Problem solved.
Page 143 4024-110 Step Check Check the roll. Go to step 6. Clean or replace the duplex media Open the duplex left door assembly. transport center roll assembly. Is the duplex media transport center roll assembly free of excess wear and contamination? Go to “Duplex media center...
Page 144 4024-110 Step Check Check the paper position. Remove the paper. Go to step 3. Open the duplex left door assembly and visually check Does the paper touch the duplex wait actuator? Check the duplex unit for proper installation. Go to step 4. Problem solved.
Page 145: Duplex Controller Card Assembly Communication Failure
4024-110 Step Check Check the duplex drive motor for proper operation. Go to step 12. Go to step 11. 1. Enter Diagnostics mode. 2. Select MOTOR TESTS. 3. Select Duplex drv mtr. Open the duplex left cover assembly. Does the above motor rotate properly? Check the duplex drive motor assembly for proper Replace the duplex Replace the...
Page 146: Duplex Controller Card Assembly Type Failure
4024-110 Step Check Perform a 2 sided print test. Replace the duplex Problem solved. controller card Does the error still occur? assembly. Go to “Duplex controller card assembly removal” on page 4-181. Go to step 4. Perform a 2 sided print test. Replace the printer Problem solved.
Page 147 4024-110 Step Check Check the switch (duplex left door interlock) for proper Reconnect the Go to step 3. operation. connector on the printer engine card 1. Enter Diagnostics mode. assembly. 2. Select DUPLEX TESTS. 3. Select Sensor Tests. 4. Select Door D duplex left. Open the duplex left door assembly, and visually check Does the operator panel change every time the actuator on the above switch operates?
Page 148: Error Code Messages - Ex2
4024-110 Error code messages - EX2 Error code or Error Contents Description/Action message 203.00 Sensor (exit 2) on jam The sensor (exit 2) is not turned on within the specified time after the sensor (fuser exit) is turned on. Paper jam Go to “203.00 Sensor (exit 2) on jam”...
Page 149: Service Checks - Ex2
4024-110 Service checks - EX2 203.00 Sensor (exit 2) on jam Step Check Check the media position. Remove the media. Go to step 2. Open the printer left door assembly, and visually check Does the media touch the sensor (fuser exit)? Check the media position.
Page 150: Sensor (Exit 2) Off Jam
4024-110 Step Check Check the sensor (exit 2) for proper operation. Go to step 11. Go to step 10. Open the printer left door assembly and the exit 2 left door assembly. 1. Enter Diagnostics mode. 2. Select BASE SENSOR TESTS. 3.
Page 151 4024-110 Step Check Check the roll. Go to step 3. Clean or replace the exit 2 unit assembly. Open the exit 2 left door assembly. Go to “Exit 2 unit Is the exit 2 media transport roll assembly free of excess assembly removal”...
Page 152: Sensor (Exit 2) On Jam In Standard Bin Or Finisher
4024-110 Step Check Perform a print test. Replace the printer Problem solved. engine card Does the error still occur? assembly. Refer to the Printer Service Manual. 203.02 Sensor (exit 2) on jam in standard bin or finisher Step Check Check the position of the media diverter solenoid. Go to step 2.
Page 153: Sensor (Exit 2) Static Jam
4024-110 Step Check Perform a print test. Replace the exit Problem solved. interface card Does the error still occur? assembly. Refer to the Printer Service Manual. Go to step 9. Perform a print test. Replace the printer Problem solved. engine card Does the error still occur? assembly.
Page 154: Sensor (Duplex Wait) On Jam
4024-110 230.00 Sensor (duplex wait) on jam Step Check Check the media position. Remove the media. Go to step 2. Does the media remain in the exit 2? Open the exit 2 left door assembly, and visually check it. Check the roll. Go to step 3.
Page 155: Sensor (Exit 2 Media Shift Hp) Failure
4024-110 Step Check Check the sensor (duplex wait) for proper connection. Replace the sensor Replace the (duplex wait). connection. Is the above sensor connected properly? Go to “Duplex sensor (duplex wait) removal” on page 4-184. Perform a print test. Replace the exit Problem solved.
Page 156: Exit 2 Unit Assembly Connection Failure
4024-110 Step Check Check the media shift motor for proper operation. Go to step 5. Go to step 4. 1. Enter Diagnostics mode. 2. Select MOTOR TESTS. 3. Select Exit2 shift mtr. Does the above motor rotate properly? Check the media shift motor for proper connection. Replace the media Replace the shift motor.
Page 157: Exit 2 Left Door Assembly Open
4024-110 Exit 2 left door assembly open Step Check Check the exit 2 left door assembly for opening and Go to step 2. Check the exit 2 left closing. door assembly for deformation, and Does the exit 2 left door assembly open or close then reinstall it.
Page 158 4024-110 2-102 Options Service Manual...
Page 159: Diagnostic Aids
4024-110 3. Diagnostic aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. Diagnostics are built into the printer RIP card assembly and can be accessed from the printer operator panel. Accessing service menus There are different test menus that can be accessed during POR to identify problems with the printer.
Page 160: Diagnostics Mode
4024-110 Diagnostics mode Entering Diagnostics mode: Press and hold Turn on the printer. Release the buttons when Performing Self Test displays. Available tests The tests display on the operator panel in the order shown: Diagnostics mode tests MOTOR TESTS “MOTOR TESTS” on page 3-5.
Page 161 4024-110 Diagnostics mode tests (continued) HARDWARE TESTS Panel Test “Panel Test” on page 3-6. Button Test “Button Test” on page 3-6. DRAM Test “DRAM Test” on page 3-7. CACHE Test Parallel Wrap “Parallel Wrap tests” on page 3-8. Parallel 1 Wrap (if installed) Parallel 2 Wrap (if installed) Serial 1 Wrap (if installed) “Serial Wrap tests”...
Page 162: Exiting Diagnostics Mode
4024-110 Diagnostics mode tests (continued) Par S Strobe Adj “Parallel strobe adjustment (Par x Strobe Adj)” on page 3-18. Par x Strobe Adj (if additional parallel options are installed) EVENT LOG Display Log “Display Log” on page 3-18. Print Log “Print Log”...
Page 163: Motor Tests
4024-110 MOTOR TESTS The tests in this group allow you to test specific motors, and on some motors run them forward or reverse. To run the MOTOR TESTS: Select MOTOR TESTS from DIAGNOSTICS. Select the test to run. The following tests are available: •...
Page 164: Print Quality Pages (Prt Quality
4024-110 Print quality pages (Prt Quality Pgs) The purpose of this diagnostic function is to allow printing of the print quality test pages with the toner cartridge lockout function disabled. The print quality pages consists of four pages. Page one contains a mixture of graphics and text.
Page 165: Dram Test
4024-110 DRAM Test The purpose of this test is to check the validity of DRAM memory, both standard and optional. The test writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly. To run the DRAM Test: Select HARDWARE TESTS from DIAGNOSTICS.
Page 166: Parallel Wrap Tests
4024-110 Parallel Wrap tests This test is used with a wrap plug to check operation of the parallel port hardware. Each parallel signal is tested. Use Parallel Wrap for the standard parallel port or Parallel 1 Wrap if a parallel port is available by PCI slot 1. To run the Parallel Wrap tests: Disconnect the parallel interface cable, and install the wrap plug (P/N 1319128).
Page 167: Duplex Tests
4024-110 DUPLEX TESTS Only displayed if a duplex option is installed. Quick Test (duplex) This test prints a duplex version of the Quick Test that can be used to verify that the correct placement of the top margin on the back side of a duplex page. You can run one duplexed page (Single), or continue printing duplexed pages (Continuous) until Stop ( ) is pressed.
Page 168: Input Tray Tests
4024-110 INPUT TRAY TESTS Feed Tests (input tray) This test lets the servicer observe the paper path as media is feeding through the printer. A blank sheet of paper feeds through the printer as the laser turns off during this test. The only way to observe the paper path is to open the lower front door that is used to access the envelope or multipurpose feeder.
Page 169: Output Bin Tests
4024-110 OUTPUT BIN TESTS Feed Tests (output bins) Use these tests to verify that media can be fed to a specific output bin. Media is fed from the default input source to the selected output bin. No information is printed on the media fed to the output bin because the printhead is not engaged during this test.
Page 170: Finisher Tests
4024-110 Each of the tests categories includes the individual sensors that can be manually actuated, and the display shows Open or Closed. • Standard Bin Std bin full exit1 Std bin full exit2 • Output Bin 1 Fin upper bin full •...
Page 171: Sensor Test (Finisher)
4024-110 Sensor Test (finisher) This test can be used to verify whether or not the finisher sensors are working correctly. To run the finisher Sensor Test: Select FINISHER TESTS from DIAGNOSTICS. Select Sensor Test from FINISHER TESTS. Select one of the test categories: •...
Page 172: Base Sensor Test
4024-110 • Punch and Staple Punch side reg1 Punch side reg2 Punch box set Punch waste full Low staple Punch carriage shift hp Punch unit hp Stapler carriage shift hp Punch cam front Punch hole select Press Back ( ) or Stop ( ) to exit the test.
Page 173: Device Tests
4024-110 DEVICE TESTS Quick Disk Test This test performs a non-destructive read/write on one block per track on the disk. The test reads one block on each track, saves the data, and proceeds to write and read four test patterns to the bytes in the block. If the block is good, the saved data is written back to the disk.
Page 174: Flash Test
4024-110 Flash Test This test verifies the functioning of the flash device by writing and reading data on the flash to test the flash. Warning: This test destroys all data on the flash, because the flash is unformatted at the end of the test. To reformat the flash, the servicer or the user must use FORMAT FLASH from the UTILITIES MENU.
Page 175: Serial Number
4024-110 Serial Number The serial number can only be viewed and cannot be changed. To view the serial number: Select PRINTER SETUP from DIAGNOSTICS. Select Serial number from PRINTER SETUP. Press Back ( ) to return to PRINTER SETUP. Engine Setting 1 through 4 Warning: Do not change these settings unless requested to do so by your next level of support.
Page 176: Parallel Strobe Adjustment (Par X Strobe Adj)
Time and date stamps • Page counts for most errors • Additional debug information in some cases The printed event log can be faxed to Lexmark or your next level of support for verification or diagnosis. 3-18 Options Service Manual...
Page 177: Clear Log
4024-110 To print the event log: Select EVENT LOG from DIAGNOSTICS. Select Print Log from EVENT LOG. Press Back ( ) to return to EVENT LOG. Clear Log Use Clear Log to remove the current information in the Event Log. This affects both the viewed log and the printed log information.
Page 178: Configuration Menu (Config Menu)
4024-110 Configuration menu (CONFIG MENU) Entering Configuration Menu Turn off the printer. Press and hold Turn on the printer. Release the buttons when Performing Self Test displays. The message CONFIG MENU displays on the top line of the operator panel. Available menus Configuration Menu Maint Cnt Value...
Page 179: Maintenance Page Count (Maint Cnt Value)
4024-110 Configuration Menu (continued) Tray Low Message “Tray Low Message” on page 3-26 Exit Config Menu “Exit Config Menu” on page 3-26 Some menus are not available, depending on the configuration of the printer. Maintenance page count (Maint Cnt Value) The current value for the maintenance page counter is displayed.
Page 180: Registration
4024-110 REGISTRATION Print registration makes sure the printing is properly aligned on the page. This setting allows separate Left Margin settings for each media tray. (The Top Margin setting is the same for all trays.) Incorrect Registration line Correct Top Margin To set the top margin for all trays: Select REGISTRATION from CONFIG MENU.
Page 181: Quick Test
4024-110 Quick Test The Quick Test contains the following information: • Print registration settings • Alignment diamonds at the top and bottom • Horizontal lines to check for skew • General printer information, including current page count, installed memory, serial number, and code level. To print the Quick Test page: Note: Print the Quick Test Page on letter or A4 paper.
Page 182: Size Sensing
4024-110 SIZE SENSING This setting controls whether the printer automatically registers the size of paper installed in an input source with size sensing. Size sensing Paper source Length Width ✓ Multipurpose feeder (integrated MPF) ✓ ✓ Tray 1 (integrated 500-sheet drawer) ✓...
Page 183: Ppds Emulation
4024-110 PPDS Emulation This menu item allows the user to enable or disable PPDS emulation datastream. When this setting is enabled, the following settings are also changed: • SmartSwitch settings for each port are turned off. • The printer language is changed to PPDS Emulation. Users can still switch languages on the operator panel and through the PJL datastream.
Page 184: Env Prompts
4024-110 Env Prompts This setting controls the tray the user is directed to refill when specific envelope size is out. The selections are Auto (default), MP Feeder, and Manual Env. Jobs On Disk If the hard disk is installed, Jobs On Disk allows the user to delete buffered jobs saved on the disk. The values are Delete and Do Not Delete.
Page 185: Analyzing The Print Test
4024-110 Analyzing the Print Test Print Tests provide several uses in troubleshooting the printer problems. • Isolating problems to either the print engine (printer engine card assembly) or to the RIP card assembly and host software. • Locating feed and media transport problems. •...
Page 186: Driving Force Transmission Path
4024-110 Driving force transmission path Transport motor The rotating force of the transport motor is transmitted through the gear and the pulley (25 tooth) to components that need mechanical driving force as shown in the following diagram. Media transport motor Transport/MPF idler gear 21T/21T Pulley25T Gear exit...
Page 187: Media Transport
4024-110 Media transport Media transport path Media is supplied from the MPF, tray 1 or tray 2, and is transported to the printer along the media transport path shown below. Tray 2 Tray 1 Pick roll Pick roll MPF pick roll MPF Transport Roll ASM Separation roll Separation roll...
Page 188: Media Transport Path Layout
4024-110 Media transport path layout The following is a cross section of the laser printer, showing main components directly associated with the media path and transport. Main components associated with transport of media Exit 2 media exit roll ASM Exit 2 media exit pinch rolls Exit 2 Exit 2 media transport roll ASM Exit 1 media exit roll ASM...
Page 189: Functions Of Main Components
4024-110 Functions of main components • Media tray assembly • Media feed unit assembly • • Xerographics • Fuser • Drive • Electrical components and rolls Media tray assembly It is necessary to adjust the front media tray guide assembly, rear media tray guide and media tray end guide of the media tray assembly to match the media size.
Page 190: Media Tray Assembly
4024-110 Media tray assembly Media end guide Rear media tray guide Bottom plate Front media tray guide assembly Detection of media size The media size set for the media tray assembly is transmitted to the switch (media size) by moving these guides. The media size is detected by the on/off information of these switches.
Page 191: Sensor (Media Level)
4024-110 Sensor (media level) This sensor detects by the actuator position whether media in the media tray assembly is lifted. When the flag of the actuator unblocks the sensing area of the sensor (media level), the sensor detects that the media has been lifted.
Page 192: Multi-Function Peripheral (Mpf)
4024-110 Multi-Function Peripheral (MPF) The MPF is a mechanical unit suppling media to the printer. The driving force from the transport motor of the dual drive motor assembly is transmitted to the MPF feed roll to feed media. MPF pick roll The MPF feed roll feeds media set on the MPF.
Page 193: Detecting Media Size
4024-110 Detecting media size The size of media on the MPF is transmitted by moving the MPF side guide, and is determined by the printer engine card assembly. Media sizes that can be automatically detected are as follows: Media size Width (mm) Feed length (mm) Side-guide stopper (min.)
Page 194: Transfer Roll Assembly
4024-110 Transfer roll assembly The transfer roll assembly is driven by direct contact with the drum of the PC cartridge. The transfer roll assembly applies positive charges to the rear surface of the media when the media passes between the transfer roll assembly and the drum. The negatively charged toner image is attracted by positive charges on the rear surface of the media.
Page 195 4024-110 process direction (from top to bottom) is determined by the rotational speed of the printhead motor. (The higher the scanning speed becomes, the sooner the scanning of the next row can be started.) Conceptual diagram of an image created by scanning SOS card ASM LD card ASM Polygon mirror...
Page 196: Fuser
4024-110 Fuser Heat roll The heat roll is a hollow metal tube with a coated surface. This tube is heated by the inner heater rod. The heat is applied to the media passing between the heat roll and pressure roll, fusing the toner on the media. Pressure roll The pressure roll is a metal shaft coated with sponge rubber.
Page 197: Fuser Exit Sensor
4024-110 Fuser exit sensor The fuser exit sensor detects the arrival of media at the detection point in the exit area of the fuser, and also detects the ejection of media from this point. Rear thermistor Center thermistor Pressure roll thermistor Pressure roll Sub heater lamp 2 Heat roll...
Page 198: Exit
4024-110 Exit Exit 1 ejects printed media from the printer to the standard bin 1. With the optional exit 2 installed, it is also possible to eject media to the standard bin 2 by changing the orientation of the diverter gate on the exit 1. Dual drive motor assembly Drives the exit 1 media exit roll assembly that feeds media to each bin.
Page 199: Drive
4024-110 Drive Media transport motor The media transport motor is a DC brushless motor that drives the exit 1 media exit shaft assembly, fuser assembly, registration roll assembly. PC cartridge motor The PC cartridge motor is a DC brushless motor that drives the PC cartridge, mag roll and transfer roll assembly.
Page 200: Electrical Components And Controller
4024-110 Electrical components and controller Switch (main power) Turning on/off the switch, power supplies/cuts off the main power of the printer. Finisher AC output Supplies power to the finisher from the main LVPS (low voltage power supply) card assembly. Switch (printer front door interlock) and switch (printer left door interlock) The switch is a safety switch to cut off a 24 VDC power supply from the LVPS card assembly to the high volt power supply (HVPS) card assembly, printer engine card assembly and to the dual motor assembly, while the printer front door assembly and the printer left door assembly are open.
Page 201: Registration Roll Assembly
4024-110 Registration roll assembly The registration roll assembly feeds media from all trays to the PC cartridge or fuser. Switch (PC cartridge interlock) Switch (main power) Switch Switch (printer front (printer left door door interlock) interlock) Fuser cooling fan RIP card ASM Switch (printer left lower door interlock) Printer engine...
Page 202: Control
4024-110 Control Media size control Media tray assembly feeding The following table gives the states (on/off) of the switches on the switch (media size), corresponding to the media sizes of the media tray assembly. Note: The switches on the switch (media size) are denoted by “S/W2”, “S/W4”, “S/W3”, “S/W5”, and “S/W1” respectively from the left side.
Page 203: Printhead Control
4024-110 Printhead control Rotation of printhead motor The on/off control of the printhead motor is performed according to the mode of operation as shown below. Operation mode PRINTHEAD motor on/off Standby mode Always off Print mode Turns on upon receiving the signal from the controller, and turns off after a preset time has passed from the end of printing.
Page 204: Xerographic Process During A Print Cycle
4024-110 Xerographic Process During a Print Cycle 3-46 Options Service Manual...
Page 205: Charge
4024-110 Charge The Charge Roll places a uniform negative electrostatic charge on the surface of the drum. The drum surface is made of a photoconductive material that holds an electrical charge as long as the drum remains in darkness. Light striking the drum discharges the surface charge. HVPS Charge roll (-VDC)
Page 206: Exposure
4024-110 The charge roll is a conductive roll that is positioned slightly above the surface of the drum. The HVPS supplies the charge roll with two voltages; a negative DC charge voltage and an AC discharge voltage that is used for electrically cleaning the drum (discussed in Step 6.
Page 207: Development
4024-110 The Printhead also helps to clean and prepare the drum by scanning the surface of the drum at the beginning of each individual printer cycle. This action discharges a residual DC charge that may still remain on the Drum from the last print cycle.
Page 208 4024-110 The toner adhering to the Magnet Roll is always in contact with the drum surface. When a less negative point on the drum (a discharged area) comes in contact with the more negative charged toner on the Magnet Roll, toner transfers from the Magnet Roll to that point on the drum.
Page 209: Transfer
4024-110 Transfer As the paper travels between the Transfer Roll and the drum surface, the Transfer Roll applies a positive charge to the back of the printing paper. This positive charge transfers the negative charged toner image from the drum surface to the top surface of the paper.
Page 210: Cleaning
4024-110 Cleaning The Cleaning Blade removes any toner that remains on the drum after the transfer process. The toner that the Cleaning Blade removes is collected inside the sealed PC Cartridge and reused. Discharge At both the start and the end of each individual printer cycle, the HVPS supplies the charge roll with an AC voltage that is used to electrically clean the drum.
Page 211: Safety System Diagram
4024-110 Safety system diagram Fuser cooling fan Switch Switch Switch Printhead (PC Cartridge (Printer front (Printer left Printhead interlock) door interlock) door interlock) Dual drive motor ASM motor PC cartridge Transport motor motor Printer engine card ASM Printhead motor Fuser cooling control Fuser unit ASM...
Page 212 4024-110 3-54 Options Service Manual...
Page 213: Repair Information
4024-110 4. Repair information Warning: Read the following before handling electronic parts. Handling ESD-sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, use the following instructions in addition to all the usual precautions, such as turning off power before removing logic boards: •...
Page 214: Removal Procedures
4024-110 Removal procedures CAUTION: Remove the power cord from the printer or electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals. CAUTION: The printer weighs approximately 47.7 kg (105 lb) and requires at least two people to lift it safely.
Page 215: 500-Sheet Drawer (2Tm) Removals
4024-110 2X 500-sheet drawer (2TM) removals Right Rear Front Left 2X 500-sheet drawer (2TM)—top cover removal Remove tray 3. Remove one screw securing the top cover (A). Remove the top cover (A). Front Repair information...
Page 216: 500-Sheet Drawer (2Tm)-Foot Cover Removal
4024-110 2X 500-sheet drawer (2TM)—foot cover removal Remove tray 4. Remove the right cover. See “2X 500-sheet drawer (2TM)—right cover removal” on page 4-4. Remove the two screws securing the foot cover (A). Remove the foot cover (A). Front 2X 500-sheet drawer (2TM)—right cover removal Remove the three screws securing the right cover (A).
Page 217: 500-Sheet Drawer (2Tm)-Left Cover Removal
4024-110 2X 500-sheet drawer (2TM)—left cover removal Remove the two screws securing the left cover (A). Remove the left cover (A). Left 2X 500-sheet drawer (2TM)—rear cover removal Remove the four screws securing the rear cover (A). Remove the rear cover (A). Rear Repair information...
Page 218: 500-Sheet Drawer (2Tm)-2Tm/Ttm Left Door Assembly Removal
4024-110 2X 500-sheet drawer (2TM)—2TM/TTM left door assembly removal Remove the left cover. See “2X 500-sheet drawer (2TM)—left cover removal” on page 4-5. Open the 2TM/TTM left door assembly. Remove the one screw securing the 2TM/TTM left door support strap (A) to the unit. Remove the screw securing the bracket (B) to the unit.
Page 219: 500-Sheet Drawer (2Tm)-Caster Removal
4024-110 2X 500-sheet drawer (2TM)—caster removal Remove tray 3. Remove tray 4. Place the right side down. Remove the three screws securing the caster (A). Remove the caster (A). Front Repair information...
Page 220: 500-Sheet Drawer (2Tm)-Switch (Media Size) Assembly Removal
4024-110 2X 500-sheet drawer (2TM)—switch (media size) assembly removal Note: This removal procedure applies to both tray 3 and tray 4. Remove tray 3. Remove tray 4. Disconnect the switch (media size) selector (A). Remove one screw securing the switch (media size) selector (A). Remove the switch (media size) selector (A).
Page 221: 500-Sheet Drawer (2Tm)-Media Feed Unit Assembly Removal (Tray 3)
4024-110 2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 3) Remove tray 3. Remove the left cover. See “2X 500-sheet drawer (2TM)—left cover removal” on page 4-5. Open the 2TM/TTM left door assembly (A). Remove one screw securing the 2TM/TTM left door support strap (B). Release the plastic bosses on both ends of the vertical turn guide (C).
Page 222 4024-110 Remove one screw securing the bracket (D). Remove the bracket (D). Release the harness from the clamp. Disconnect the connector from the machine. Remove the two screws securing the media feed unit assembly (E). Remove the media feed unit assembly (E) in the direction of the arrow. Clamp Harness Connector...
Page 223: 500-Sheet Drawer (2Tm)-Media Feed Unit Assembly Removal (Tray 4)
4024-110 2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 4) Remove tray 4. Open the 2TM/TTM left door assembly (A). Remove one screw securing the 2TM/TTM left door support strap (B). Remove the plastic bosses on both ends of the vertical turn guide (C). Remove the vertical turn guide (C).
Page 224: 500-Sheet Drawer (2Tm)-Media Tray Guides Removal
4024-110 2X 500-sheet drawer (2TM)—media tray guides removal Remove the media tray. Remove the two e-rings securing the metal bottom plate (A) to the media tray using a small prying tool. Push the front hinge point (B) in the direction of the arrow to release the front boss from the metal bottom plate (A).
Page 225 4024-110 Remove the two screws securing the two pinion gears (C) to the media tray. Remove the pinion gears (C). Remove the front media guide assembly (D) and the rear media guide (E). Front Note: Before re-installing the pinion gears (C), slide the front media tray guide (D) and the rear media tray guide (E) to their outward most positions.
Page 226: 500-Sheet Drawer (2Tm)-Media Tray End Guide Removal
4024-110 2X 500-sheet drawer (2TM)—media tray end guide removal Remove the media tray. Remove the media tray guides. See “2X 500-sheet drawer (2TM)—media tray guides removal” on page 4-12. Remove the media side guide actuator (A). Turn the media tray upside down, and remove the two hooks securing the actuator link (B) to the media tray.
Page 227 4024-110 Turn the media tray right side up, and slide the media end guides (D) toward the center of the media tray to remove. Hook End guide Front 4-15 Repair information...
Page 228: 500-Sheet Drawer (2Tm)-Tray Lift Gear Group Removal
4024-110 2X 500-sheet drawer (2TM)—tray lift gear group removal Remove the media tray from the machine. Remove the two screws securing bracket (A). Remove the tray lift sector gear 12 tooth (B). Remove the tray lift gear 13 tooth (C) from bracket (A). Remove the tray lift gear 13/60 tooth (D) from bracket (A).
Page 229: 500-Sheet Drawer (2Tm)-Media Feed Lift Motor Removal
4024-110 2X 500-sheet drawer (2TM)—media feed lift motor removal Remove the media feed unit assembly. See “2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 3)” on page 4-9 “2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 4)” on page 4-11.
Page 230: 500-Sheet Drawer (2Tm)-Lift Coupling Assembly Removal
4024-110 2X 500-sheet drawer (2TM)—lift coupling assembly removal Remove the media feed unit assembly. See “2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 3)” on page 4-9 “2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 4)” on page 4-11.
Page 231: 500-Sheet Drawer (2Tm)-Tray Lift One-Way Gear Clutch Assembly Removal
4024-110 2X 500-sheet drawer (2TM)—tray lift one-way gear clutch assembly removal Remove the media feed unit assembly. See “2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 3)” on page 4-9 “2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 4)” on page 4-11.
Page 232 4024-110 Remove the tray lift one-way gear 24 tooth (C). Harness Washer Rear Note: Before re-installing, ensure all gears and washers are securely attached to the bracket (A). 4-20 Options Service Manual...
Page 233: 500-Sheet Drawer (2Tm)-Media Feed Unit Drive Gear - 13 Tooth Removal
4024-110 2X 500-sheet drawer (2TM)—media feed unit drive gear - 13 tooth removal Remove the media feed unit assembly. See “2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 3)” on page 4-9 “2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 4)”...
Page 234: 500-Sheet Drawer (2Tm)-Media Out Actuator Removal
4024-110 2X 500-sheet drawer (2TM)—media out actuator removal Remove the media feed unit assembly. See “2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 3)” on page 4-9 “2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 4)” on page 4-11.
Page 235: 500-Sheet Drawer (2Tm)-Sensor (Media Level) Removal
4024-110 2X 500-sheet drawer (2TM)—sensor (media level) removal Remove the media feed unit assembly. See “2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 3)” on page 4-9 “2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 4)” on page 4-11.
Page 236: 500-Sheet Drawer (2Tm)-Sensor (Media Out) Removal
4024-110 2X 500-sheet drawer (2TM)—sensor (media out) removal Remove the media feed unit assembly. See “2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 3)” on page 4-9 “2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 4)” on page 4-11.
Page 237: 500-Sheet Drawer (2Tm)-Sensor (Pre-Feed) Removal
4024-110 2X 500-sheet drawer (2TM)—sensor (pre-feed) removal Remove the media feed unit assembly. See “2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 3)” on page 4-9 “2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 4)” on page 4-11. Remove the sensor (pre-feed) (A) from the feed unit front guide (B).
Page 238: 500-Sheet Drawer (2Tm)-Media Feed Unit Drive Gear - 28 / 21 Tooth Removal
4024-110 2X 500-sheet drawer (2TM)—media feed unit drive gear - 28 / 21 tooth removal Remove the media feed unit assembly. See “2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 3)” on page 4-9 “2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 4)”...
Page 239: 500-Sheet Drawer (2Tm)-Media Feed Unit Drive Gear - 29 Tooth Removal
4024-110 2X 500-sheet drawer (2TM)—media feed unit drive gear - 29 tooth removal Remove the media feed unit assembly. See “2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 3)” on page 4-9 “2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 4)”...
Page 240: 500-Sheet Drawer (2Tm)-Feed Roll Removal
4024-110 2X 500-sheet drawer (2TM)—feed roll removal Remove the media tray assembly. Move the feed unit front guide (A) in the direction of the arrow. Release the hook securing the feed roll (B) to the shaft (C). Remove the feed roll (B). Note: Do not touch the rubber surface of the feed roll (B).
Page 241: 500-Sheet Drawer (2Tm)-Feed Roll One-Way Clutch Removal
4024-110 2X 500-sheet drawer (2TM)—feed roll one-way clutch removal Remove the media tray assembly. Remove the feed roll. See “2X 500-sheet drawer (2TM)—feed roll removal” on page 4-28. Remove the feed roll one-way clutch (A) from the shaft (B). Front 4-29 Repair information...
Page 242: 500-Sheet Drawer (2Tm)-Feed Roll One-Way Gear 22 Tooth Removal
4024-110 2X 500-sheet drawer (2TM)—feed roll one-way gear 22 tooth removal Remove the media tray assembly. Remove the feed roll. See “2X 500-sheet drawer (2TM)—feed roll removal” on page 4-28. Remove the feed roll one-way clutch. See “2X 500-sheet drawer (2TM)—feed roll one-way clutch removal”...
Page 243: 500-Sheet Drawer (2Tm)-Separation Roll One-Way Friction Clutch Removal
4024-110 2X 500-sheet drawer (2TM)—separation roll one-way friction clutch removal Remove the media tray assembly. Remove the separation roll. See “2X 500-sheet drawer (2TM)—separation roll removal” on page 4-32. Remove the separation roll spacer (A) from the shaft (B). Remove the separation roll one-way friction clutch (C). Front 4-31 Repair information...
Page 244: 500-Sheet Drawer (2Tm)-Separation Roll Removal
4024-110 2X 500-sheet drawer (2TM)—separation roll removal Remove the media tray assembly. Move the feed unit front guide (A) in the direction of the arrow. Release the hook securing the separation roll (B) to the shaft (C). Front Remove the separation roll (B). Note: Do not touch the rubber surface of the feed roll (B).
Page 245: 500-Sheet Drawer (2Tm)-Pick Roll Idler Gear - 33 Tooth Removal
4024-110 2X 500-sheet drawer (2TM)—pick roll idler gear - 33 tooth removal Remove the media tray assembly. Remove the pick roll. See “2X 500-sheet drawer (2TM)—pick roll removal” on page 4-34. Remove the pick roll drive gear - 25 tooth. See “2X 500-sheet drawer (2TM)—pick roll drive gear 25 tooth removal”...
Page 246: 500-Sheet Drawer (2Tm)-Pick Roll Removal
4024-110 2X 500-sheet drawer (2TM)—pick roll removal Remove the media tray assembly. Move the front guide (A) in the direction of the arrow. Release the hook securing the pick roll (B) to the shaft (C). Remove the pick roll (B). Note: Do not touch the rubber surface of the feed roll (B).
Page 247: 500-Sheet Drawer (2Tm)-Pick Roll Drive Gear 25 Tooth Removal
4024-110 2X 500-sheet drawer (2TM)—pick roll drive gear 25 tooth removal Remove the media tray assembly. Remove the pick roll. See “2X 500-sheet drawer (2TM)—pick roll removal” on page 4-34. Remove the pick roll drive gear 25 tooth (A) from shaft (B). Front 4-35 Repair information...
Page 248: 500-Sheet Drawer (2Tm)-Feed Unit Drive Gear - 27 Tooth Removal
4024-110 2X 500-sheet drawer (2TM)—feed unit drive gear - 27 tooth removal Remove the media feed unit assembly. See “2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 3)” on page 4-9 “2X 500-sheet drawer (2TM)—media feed unit assembly removal (tray 4)”...
Page 249: 500-Sheet Drawer (2Tm)-Sensor (Tray 3 Feed-Out) Removal
4024-110 2X 500-sheet drawer (2TM)—sensor (tray 3 feed-out) removal Open the 2TM/TTM left door assembly. Remove the two screws securing the upper bracket (A). Disconnect the connector from the sensor (tray 3 feed-out) (B). Release the hooks securing the sensor (tray 3 feed-out) (B) to the upper bracket (A). Remove the sensor (tray 3 feed-out) (B).
Page 250: 500-Sheet Drawer (2Tm)-Sensor (Tray 4 Feed-Out) Removal
4024-110 2X 500-sheet drawer (2TM)—sensor (tray 4 feed-out) removal Open the 2TM/TTM left door assembly. Remove the screw securing the 2TM/TTM left door support strap (A). Remove the two screws securing the lower bracket (B). Disconnect the connector from the sensor (tray 4 feed-out) (C). Release the hooks securing the sensor (tray 3 feed-out) (C) to the lower bracket (B).
Page 251: 500-Sheet Drawer (2Tm)-Upper Media Transport Roll Removal
4024-110 2X 500-sheet drawer (2TM)—upper media transport roll removal Open the 2TM/TTM left door assembly. Remove the two screws securing the upper bracket (A). Disconnect the connector from the upper bracket (A). Remove the large e-clip securing the 2TM/TTM media transport roll assembly (B). Remove the bearing (C).
Page 252: 500-Sheet Drawer (2Tm)-Lower Media Transport Roll Assembly Removal
4024-110 2X 500-sheet drawer (2TM)—lower media transport roll assembly removal Open the 2TM/TTM left door assembly. Remove the two screws securing the lower bracket (A). Disconnect the connector from the lower bracket (A). Remove the large e-clip securing the 2TM/TTM media transport roll assembly (B). Remove the bearing (C).
Page 253: 500-Sheet Drawer (2Tm)-Left Door Pinch Roll Assembly Removal
4024-110 2X 500-sheet drawer (2TM)—left door pinch roll assembly removal Note: This procedure can be used for both the upper and left lower door pinch roll assembly (C). Open the 2TM/TTM left door assembly. Remove the four screws securing the bracket (A) to the left door assembly (A). Remove the bracket (A).
Page 254: 500-Sheet Drawer (2Tm)-Switch (2Tm/Ttm Left Door Interlock) Removal
4024-110 2X 500-sheet drawer (2TM)—switch (2TM/TTM left door interlock) removal Open the 2TM/TTM left door assembly. Remove the one screw securing the bracket (A). Disconnect the connector from the switch (2TM/TTM left door interlock) (B). Release the hooks securing the switch (2TM/TTM left door interlock) (B) to the bracket (A). Remove the switch (2TM/TTM left door interlock) (B).
Page 255: 500-Sheet Drawer (2Tm)-2Tm/Ttm Controller Card Assembly Removal
4024-110 2X 500-sheet drawer (2TM)—2TM/TTM controller card assembly removal Remove the rear cover. See “2X 500-sheet drawer (2TM)—rear cover removal” on page 4-5. Disconnect all the connectors from the 2TM/TTM controller card assembly (A). Remove the four screws securing the 2TM/TTM controller card assembly (A). Remove the 2TM/TTM controller card assembly (A).
Page 256: 500-Sheet Drawer (2Tm)-Transport Clutch Removal
4024-110 2X 500-sheet drawer (2TM)—transport clutch removal Remove the rear cover. See “2X 500-sheet drawer (2TM)—rear cover removal” on page 4-5. Disconnect the connector from the machine to the bracket (A). Remove the two screws securing the bracket (A) to the frame assembly. Rear Remove the bracket (A).
Page 257: 500-Sheet Drawer (2Tm)-Drive Motor Assembly Removal
4024-110 2X 500-sheet drawer (2TM)—drive motor assembly removal Remove the rear cover. See “2X 500-sheet drawer (2TM)—rear cover removal” on page 4-5. Disconnect the connector harness from the 2TM/TTM drive motor assembly (A). Remove two screws securing the 2TM/TTM drive motor assembly (A) to the machine. Remove the 2TM/TTM drive motor assembly (A).
Page 258: 2000-Sheet Dual Input (Ttm) Removals
4024-110 2000-sheet dual input (TTM) removals Rear Left Right Front 4-46 Options Service Manual...
Page 259: 2000-Sheet Dual Input (Ttm)-Top Cover Removal
4024-110 2000-sheet dual input (TTM)—top cover removal Pull out tray 3 (A) and tray 4 (B). Remove one screw securing the top cover (C). Remove the top cover (C). 4-47 Repair information...
Page 260: 2000-Sheet Dual Input (Ttm)-Foot Cover Removal
4024-110 2000-sheet dual input (TTM)—foot cover removal Remove tray 3 assembly. See “2000-sheet dual input (TTM)—tray 3 assembly removal” on page 4-55. Remove tray 4 assembly. See “2000-sheet dual input (TTM)—tray 4 assembly removal” on page 4-54. Remove the right cover. See “2000-sheet dual input (TTM)—right cover removal”...
Page 261: 2000-Sheet Dual Input (Ttm)-Right Cover Removal
4024-110 2000-sheet dual input (TTM)—right cover removal Remove two screws securing the right cover (A). Remove the right cover (A) by lifting upward and outward in the direction of the arrow. Front 4-49 Repair information...
Page 262: 2000-Sheet Dual Input (Ttm)-Left Cover Removal
4024-110 2000-sheet dual input (TTM)—left cover removal Remove two screws securing the left cover (A). Remove the left cover (A). 2000-sheet dual input (TTM)—rear cover removal Remove four screws securing the rear cover (A). Remove the rear cover (A). Rear 4-50 Options Service Manual...
Page 263: 2000-Sheet Dual Input (Ttm)-Caster Removal
4024-110 2000-sheet dual input (TTM)—caster removal Remove tray 3. Remove tray 4. Place the right side down. Remove three screws securing the caster (A). Remove the caster (A). 4-51 Repair information...
Page 264: 2000-Sheet Dual Input (Ttm)-Tray Support Roll Removal
4024-110 2000-sheet dual input (TTM)—tray support roll removal Remove tray 3 assembly. See “2000-sheet dual input (TTM)—tray 3 assembly removal” on page 4-55. Remove tray 4 assembly. See “2000-sheet dual input (TTM)—tray 4 assembly removal” on page 4-54. Remove the foot cover. See “2000-sheet dual input (TTM)—foot cover removal”...
Page 265 4024-110 Remove the shafts (D). Remove the tray support rolls (B). Front E-ring 4-53 Repair information...
Page 266: 2000-Sheet Dual Input (Ttm)-Tray 4 Assembly Removal
4024-110 2000-sheet dual input (TTM)—tray 4 assembly removal Pull out the tray 4 assembly. Remove two screws securing the tray 4 transport assembly (A). Push the tray 4 transport assembly (A) into the machine in the direction of the arrow. Remove two screws securing the tray 4 stopper (B) to the lower part of tray 4 assembly (C).
Page 267: 2000-Sheet Dual Input (Ttm)-Tray 3 Assembly Removal
4024-110 2000-sheet dual input (TTM)—tray 3 assembly removal Remove the left cover. See “2000-sheet dual input (TTM)—left cover removal” on page 4-50. Open the 2TM/TTM left door assembly. Loosen the screw securing the tray 3 stopper (A). Move the tray 3 stopper (A) outward in the direction of the arrow while pulling out the tray 3 assembly (B). Remove the tray 3 assembly (B).
Page 268: 2000-Sheet Dual Input (Ttm)-Tray 3 Front Cover Removal
4024-110 2000-sheet dual input (TTM)—tray 3 front cover removal Pull out the tray 3 assembly. Remove two screws securing the tray 3 front cover (A) to tray 3 assembly (B). Remove the tray 3 front cover (A). 4-56 Options Service Manual...
Page 269: 2000-Sheet Dual Input (Ttm)-Tray 3 Rear Cable Assembly Removal
4024-110 2000-sheet dual input (TTM)—tray 3 rear cable assembly removal Remove the left cover. See “2000-sheet dual input (TTM)—left cover removal” on page 4-50. Remove the tray 3 assembly. See “2000-sheet dual input (TTM)—tray 3 assembly removal” on page 4-55. Remove the tray 3 front cover.
Page 270 4024-110 Move the rear lift cable pulley (D) toward the rear of the tray to release the two tray 3 rear cables (E) from the tray lift shaft assembly (B). Remove the two tray 3 rear cables (E) from the tray lift shaft assembly (B). 4-58 Options Service Manual...
Page 271 4024-110 Remove two E-clips with a prying tool securing the two small pulleys (F) on the rear of the frame assembly. Remove the two small guides (G) and the two small pulleys (F). Remove the E-clip with a prying tool securing the large guide (H) and the large pulley (I) to the frame assembly.
Page 272: 2000-Sheet Dual Input (Ttm)-Tray 3 Front Cable Assembly Removal
4024-110 2000-sheet dual input (TTM)—tray 3 front cable assembly removal Remove the left cover. See “2000-sheet dual input (TTM)—left cover removal” on page 4-50. Remove the tray 3 assembly. See “2000-sheet dual input (TTM)—tray 3 assembly removal” on page 4-55. Remove the tray 3 front cover.
Page 273 4024-110 Remove two E-clips with a prying tool securing the two small pulleys (D) on the front of the frame assembly. Remove two small guides (E) and the two small pulleys (D). Remove the tray 3 front cables (C) from the bottom plate (F). Note: Before re-installing: –...
Page 274: 2000-Sheet Dual Input (Ttm)-Media Guide Rack And Pinion Removal
4024-110 2000-sheet dual input (TTM)—media guide rack and pinion removal Remove the tray 3 assembly. See “2000-sheet dual input (TTM)—tray 3 assembly removal” on page 4-55. Place the tray 3 assembly on its right side. Remove two e-clips securing the two pinion gears (A) to the frame assembly (B). Remove the two pinion gears (A).
Page 275 4024-110 Note: Before re-installing, move the two side guides (D) of the frame assembly (B) fully outward before installing the two pinion gears (A). 4-63 Repair information...
Page 276: 2000-Sheet Dual Input (Ttm)-Tray 3 Media Guide Lock Assembly Removal
4024-110 2000-sheet dual input (TTM)—tray 3 media guide lock assembly removal Remove the tray 3 assembly. See “2000-sheet dual input (TTM)—tray 3 assembly removal” on page 4-55. Remove the tray 3 front cover. See “2000-sheet dual input (TTM)—tray 3 front cover removal” on page 4-56.
Page 277: 2000-Sheet Dual Input (Ttm)-Tray 3 Mylar Actuator Removal
4024-110 2000-sheet dual input (TTM)—tray 3 mylar actuator removal Remove the tray 3 assembly. See “2000-sheet dual input (TTM)—tray 3 assembly removal” on page 4-55. Remove the tray 3 front cover. See “2000-sheet dual input (TTM)—tray 3 front cover removal” on page 4-56.
Page 278 4024-110 Remove the bottom plate (A) from the tray. Remove the two screws securing the bracket (B) to the tray. Remove the rear media guide (C). Remove the mylar actuator (D) by sliding it out of the tray in the direction of the arrow. Note: Before re-installing, ensure the bosses on the rear media guide (C) are fitted into the slots on the mylar actuator (D) as shown in the figure.
Page 279: 2000-Sheet Dual Input (Ttm)-Tray 4 Front Cover Removal
4024-110 2000-sheet dual input (TTM)—tray 4 front cover removal Remove the tray 4 assembly. See “2000-sheet dual input (TTM)—tray 4 assembly removal” on page 4-54. Remove two screws securing the tray 4 front cover (A). Remove the tray 4 front cover (A) by moving it upward in the direction of the arrow. Remove the four screws securing the bracket (B) to the tray.
Page 280: 2000-Sheet Dual Input (Ttm)-Tray 4 Media Transport Assembly Removal
4024-110 2000-sheet dual input (TTM)—tray 4 media transport assembly removal Remove the tray 4 assembly. See “2000-sheet dual input (TTM)—tray 4 assembly removal” on page 4-54. Remove the tray 4 transport assembly (A). Note: Before re-installing, insert the tray 4 transport assembly (A) into the rails of the frame assembly (B). 4-68 Options Service Manual...
Page 281: 2000-Sheet Dual Input (Ttm)-Tray 4 Rear Cables Removal
4024-110 2000-sheet dual input (TTM)—tray 4 rear cables removal Remove the tray 4 assembly. See “2000-sheet dual input (TTM)—tray 4 assembly removal” on page 4-54. Remove the tray 4 front cover. See “2000-sheet dual input (TTM)—tray 4 front cover removal” on page 4-67.
Page 282 4024-110 Place the tray 4 assembly back to its upright position. 4-70 Options Service Manual...
Page 283 4024-110 Remove two E-clips with a prying tool securing the two small pulleys (F) on the rear of the frame assembly. Remove two small guides (G) and two small pulleys (F). Remove the tray 4 rear cables (D) from the bottom plate (H). Note: Before re-installing: –...
Page 284 4024-110 2000-sheet dual input (TTM)—tray 4 front cables removal Remove the tray 4 assembly. See “2000-sheet dual input (TTM)—tray 4 assembly removal” on page 4-54. Remove the tray 4 front cover. See “2000-sheet dual input (TTM)—tray 4 front cover removal” on page 4-67.
Page 285 4024-110 Place the tray 4 assembly back in its upright position. Remove two E-clips with a prying tool securing the two small pulleys (D) on the front of the frame assembly. Remove the two small guides (E) and the two small pulleys (D). Remove the tray 4 front cables (C) from the bottom plates (F).
Page 286: 2000-Sheet Dual Input (Ttm)-Tray 4 Media Guide Rack And Pinion Removal
4024-110 2000-sheet dual input (TTM)—tray 4 media guide rack and pinion removal Remove the tray 4 assembly. See “2000-sheet dual input (TTM)—tray 4 assembly removal” on page 4-54. Place the tray 4 assembly on its right side, as shown in the figure. Remove two e-clips securing the two pinion gears (A) to the frame assembly (B).
Page 287 4024-110 Remove the rack gears (C). Note: Before re-installing, move the two side guides (D) of the frame assembly (B) fully outward before installing the two pinion gears (A). 4-75 Repair information...
Page 288: 2000-Sheet Dual Input (Ttm)-Tray 4 Media Guide Lock Assembly Removal
4024-110 2000-sheet dual input (TTM)—tray 4 media guide lock assembly removal Remove the tray 4 assembly. See “2000-sheet dual input (TTM)—tray 4 assembly removal” on page 4-54. Remove the tray 4 front cover. See “2000-sheet dual input (TTM)—tray 4 front cover removal” on page 4-67.
Page 289: 2000-Sheet Dual Input (Ttm)-Tray 4 Mylar Actuator Removal
4024-110 2000-sheet dual input (TTM)—tray 4 mylar actuator removal Remove the tray 4 assembly. See “2000-sheet dual input (TTM)—tray 4 assembly removal” on page 4-54. Remove the tray 4 front cover. See “2000-sheet dual input (TTM)—tray 4 front cover removal” on page 4-67.
Page 290 4024-110 Remove the mylar actuator (D) by sliding it out of the tray in the direction of the arrow. Note: Before re-installing, ensure the bosses on the rear media guide (C) are fitted into the slots on the mylar actuator (D) as shown in the figure. 4-78 Options Service Manual...
Page 291: 2000-Sheet Dual Input (Ttm)-Media Feed Unit Assembly Removal (Tray 4)
4024-110 2000-sheet dual input (TTM)—media feed unit assembly removal (tray 4) Remove the tray 3 assembly. See “2000-sheet dual input (TTM)—tray 3 assembly removal” on page 4-55. Remove the tray 4 assembly. See “2000-sheet dual input (TTM)—tray 4 assembly removal” on page 4-54.
Page 292 4024-110 Remove two screws securing the media feed unit assembly (A). Note: Removing the media tray 1 and media tray 2 in the printer makes removing the media feed unit assembly (A) rear screws easier. Connectors Front Remove one screw securing the front bracket (B). Remove the front bracket (B).
Page 293 4024-110 Remove the two screws securing the lower guide (C) to the media feed unit assembly (A). Remove the lower guide (C). Remove two screws securing the upper guide (D) to the media feed unit assembly (A). Remove the upper guide (D). Remove two screws securing the rear bracket (E) to the media feed unit assembly (A).
Page 294: 2000-Sheet Dual Input (Ttm)-Sensor (Tray 4 Feed-Out) Removal
4024-110 2000-sheet dual input (TTM)—sensor (tray 4 feed-out) removal Remove the tray 3 assembly. See “2000-sheet dual input (TTM)—tray 3 assembly removal” on page 4-55. Remove the tray 4 assembly. See “2000-sheet dual input (TTM)—tray 4 assembly removal” on page 4-54.
Page 295: 2000-Sheet Dual Input (Ttm)-Switch (Ttm Media Size) Removal
4024-110 2000-sheet dual input (TTM)—switch (TTM media size) removal Note: This removal procedure may be applied to tray 3 and tray 4. Remove the tray 3 assembly “2000-sheet dual input (TTM)—tray 3 assembly removal” on page 4-55 tray 4 assembly “2000-sheet dual input (TTM)—tray 4 assembly removal”...
Page 296: 2000-Sheet Dual Input (Ttm)-Media Feed Unit Assembly Removal (Tray 3)
4024-110 2000-sheet dual input (TTM)—media feed unit assembly removal (tray 3) Pull out the tray 3 assembly. Pull out the tray 4 assembly. Open the 2TM/TTM left door assembly. Remove one screw securing the 2TM/TTM left door support strap (A). Release the bosses on both sides securing the vertical turn guide (B).
Page 297 4024-110 Release the harness from the clamp. Disconnect the connector from the machine. Front Connector Clamps 4-85 Repair information...
Page 298 4024-110 Remove three screws securing the media feed unit assembly (D). Remove the media feed unit assembly (D) by pulling outward. Remove two screws securing the rear bracket (E) to the media feed unit assembly (D). Remove the rear bracket (E). Connector Clamps Front...
Page 299: 2000-Sheet Dual Input (Ttm)-2Tm/Ttm Media Transport Roll Assembly Removal
4024-110 2000-sheet dual input (TTM)—2TM/TTM media transport roll assembly removal Open the left door assembly. Remove two screws securing the bracket (A). Disconnect the connector to the sensor (tray 3 feed-out) (B). Remove the bracket (A). Remove the large e-clip on the left securing the 2TM/TTM media transport roll assembly (C). Slide the bushing (D) to the right.
Page 300: 2000-Sheet Dual Input (Ttm)-Sensor (Tray 3 Feed-Out) Removal
4024-110 2000-sheet dual input (TTM)—sensor (tray 3 feed-out) removal Open the left door assembly. Remove two screws securing the bracket (A). Disconnect the connector to the sensor (tray 3 feed-out) (B). Remove the bracket (A). Release the hooks securing the sensor (tray 3 feed-out) (B) to the bracket (A) Remove the sensor (tray 3 feed-out) (B).
Page 301: 2000-Sheet Dual Input (Ttm)-Media Feed Lift Motor Removal
4024-110 2000-sheet dual input (TTM)—media feed lift motor removal Remove the media feed unit assembly. See “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 3)” on page 4-84 “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 4)” on page 4-79.
Page 302: 2000-Sheet Dual Input (Ttm)-Lift Coupling Assembly Removal
4024-110 2000-sheet dual input (TTM)—lift coupling assembly removal Remove the media feed unit assembly. See “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 3)” on page 4-84 “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 4)” on page 4-79.
Page 303: 2000-Sheet Dual Input (Ttm)-One-Way Clutch / Gear Assembly Removal
4024-110 2000-sheet dual input (TTM)—one-way clutch / gear assembly removal Remove the media feed unit assembly. See “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 3)” on page 4-84 “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 4)” on page 4-79.
Page 304 4024-110 Remove the tray lift one-way gear 24 tooth (C). Harness Washer Rear Note: Before re-installing, ensure all gears and washers are securely attached to the bracket (A). 4-92 Options Service Manual...
Page 305: 2000-Sheet Dual Input (Ttm)-Media Feed Unit Drive Gear 13 Tooth Removal
4024-110 2000-sheet dual input (TTM)—media feed unit drive gear 13 tooth removal Remove the media feed unit assembly. See “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 3)” on page 4-84 “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 4)”...
Page 306: 2000-Sheet Dual Input (Ttm)-Media Out Actuator Removal
4024-110 2000-sheet dual input (TTM)—media out actuator removal Remove the media feed unit assembly. See “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 3)” on page 4-84 “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 4)” on page 4-79.
Page 307: 2000-Sheet Dual Input (Ttm)-Sensor (Media Level) Removal
4024-110 2000-sheet dual input (TTM)—sensor (media level) removal Remove the media feed unit assembly. See “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 3)” on page 4-84 “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 4)” on page 4-79.
Page 308: 2000-Sheet Dual Input (Ttm)-Sensor (Media Out) Removal
4024-110 2000-sheet dual input (TTM)—sensor (media out) removal Remove the media feed unit assembly. See “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 3)” on page 4-84 “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 4)” on page 4-79.
Page 309: 2000-Sheet Dual Input (Ttm)-Sensor (Pre-Feed) Removal
4024-110 2000-sheet dual input (TTM)—sensor (pre-feed) removal Remove the media feed unit assembly. See “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 3)” on page 4-84 “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 4)” on page 4-79. Remove the sensor (pre-feed) (A) from the feed unit front guide (B).
Page 310: 2000-Sheet Dual Input (Ttm)-Media Feed Unit Drive Gear 28 / 21 Tooth Removal
4024-110 2000-sheet dual input (TTM)—media feed unit drive gear 28 / 21 tooth removal Remove the media feed unit assembly. See “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 3)” on page 4-84 “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 4)”...
Page 311: 2000-Sheet Dual Input (Ttm)-Media Feed Unit Drive Gear 29 Tooth Removal
4024-110 2000-sheet dual input (TTM)—media feed unit drive gear 29 tooth removal Remove the media feed unit assembly. See “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 3)” on page 4-84 “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 4)”...
Page 312: 2000-Sheet Dual Input (Ttm)-Feed Roll Removal
4024-110 2000-sheet dual input (TTM)—feed roll removal Remove the media tray assembly. Move the feed unit front guide (A) in the direction of the arrow. Release the hook securing the feed roll (B) to the shaft (C). Remove the feed roll (B). Note: Do not touch the rubber surface of the feed roll (B).
Page 313: 2000-Sheet Dual Input (Ttm)-Feed Roll One-Way Clutch Removal
4024-110 2000-sheet dual input (TTM)—feed roll one-way clutch removal Remove the media tray assembly. Remove the feed roll. See “2000-sheet dual input (TTM)—feed roll removal” on page 4-100. Remove the feed roll one-way clutch (A) from the shaft (B). Front 4-101 Repair information...
Page 314: 2000-Sheet Dual Input (Ttm)-One-Way 22 Tooth Removal
4024-110 2000-sheet dual input (TTM)—one-way 22 tooth removal Remove the media tray assembly. Remove the feed roll. See “2000-sheet dual input (TTM)—feed roll removal” on page 4-100. Remove the feed roll one-way clutch. See “2000-sheet dual input (TTM)—feed roll one-way clutch removal”...
Page 315: 2000-Sheet Dual Input (Ttm)-Separation Roll One-Way Friction Clutch Removal
4024-110 2000-sheet dual input (TTM)—separation roll one-way friction clutch removal Remove the media tray assembly. Remove the separation roll. See “2000-sheet dual input (TTM)—separation roll removal” on page 4-104. Remove the separation roll spacer (A). Remove the separation roll one-way friction clutch (B). Front 4-103 Repair information...
Page 316: 2000-Sheet Dual Input (Ttm)-Separation Roll Removal
4024-110 2000-sheet dual input (TTM)—separation roll removal Remove the media tray assembly. Move the feed unit front guide (A) in the direction of the arrow. Release the hook securing the separation roll (B) to the shaft (C). Front 4-104 Options Service Manual...
Page 317 4024-110 Remove the separation roll (B). Note: Do not touch the rubber surface of the feed roll (B). Front Note: Before re-installing, do not touch the rubber surface of the separation roll (B). 4-105 Repair information...
Page 318: 2000-Sheet Dual Input (Ttm)-Pick Roll Idler Gear 33 Tooth Removal
4024-110 2000-sheet dual input (TTM)—pick roll idler gear 33 tooth removal Remove the media tray assembly. Remove the pick roll. See “2000-sheet dual input (TTM)—pick roll removal” on page 4-107. Remove the pick roll drive gear 25 tooth. See “2000-sheet dual input (TTM)—pick roll drive gear 25 tooth removal”...
Page 319: 2000-Sheet Dual Input (Ttm)-Pick Roll Removal
4024-110 2000-sheet dual input (TTM)—pick roll removal Remove the media tray assembly. Move the front guide (A) in the direction of the arrow. Release the hook securing the pick roll (B) to the shaft (C). Remove the pick roll (B). Note: Do not touch the rubber surface of the feed roll (B).
Page 320: 2000-Sheet Dual Input (Ttm)-Pick Roll Drive Gear 25 Tooth Removal
4024-110 2000-sheet dual input (TTM)—pick roll drive gear 25 tooth removal Remove the media tray assembly. Remove the pick roll. See “2000-sheet dual input (TTM)—pick roll removal” on page 4-107. Remove the pick roll drive gear 25 tooth (A). Front 4-108 Options Service Manual...
Page 321: 2000-Sheet Dual Input (Ttm)-Feed Unit Drive Gear 27 Tooth Removal
4024-110 2000-sheet dual input (TTM)—feed unit drive gear 27 tooth removal Remove the media feed unit assembly. See “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 3)” on page 4-84 “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 4)” on page 4-79.
Page 322: 2000-Sheet Dual Input (Ttm)-2Tm/Ttm Left Door Assembly Removal
4024-110 2000-sheet dual input (TTM)—2TM/TTM left door assembly removal Open the 2TM/TMM left door assembly. Remove one screw securing the 2TM/TTM left door support strap (A). Remove one screw securing the bracket (B). Remove the bracket (B). Move the 2TM/TTM left door assembly (C) toward the right and outward in the direction of the arrow. Remove the 2TM/TTM left door assembly (C).
Page 323: 2000-Sheet Dual Input (Ttm)-Switch (2Tm/Ttm Left Door Interlock) Removal
4024-110 2000-sheet dual input (TTM)—switch (2TM/TTM left door interlock) removal Open the left door assembly. Remove the screw securing the bracket (A). Remove the bracket (A). Disconnect the connector from the switch (2TM/TTM left door interlock) (B). Release the hooks securing the switch (2TM/TTM left door interlock) (B) to the bracket (A). Remove the switch (2TM/TTM left door interlock) (B).
Page 324: 2000-Sheet Dual Input (Ttm)-Tray 3 Lift Gear Assembly Removal
4024-110 2000-sheet dual input (TTM)—tray 3 lift gear assembly removal Remove the rear cover. See “2000-sheet dual input (TTM)—rear cover removal” on page 4-50. Remove the media feed unit 3 assembly. See “2000-sheet dual input (TTM)—media feed unit assembly removal (tray 3)” on page 4-84.
Page 325: 2000-Sheet Dual Input (Ttm)-Tray 4 Lift Gear Assembly Removal
4024-110 2000-sheet dual input (TTM)—tray 4 lift gear assembly removal Remove the rear cover. See “2000-sheet dual input (TTM)—rear cover removal” on page 4-50. Remove the controller card assembly. See “2000-sheet dual input (TTM)—2TM/TTM controller card assembly removal” on page 4-115.
Page 326: 2000-Sheet Dual Input (Ttm)-Drive Motor Assembly Removal
4024-110 2000-sheet dual input (TTM)—drive motor assembly removal Remove the rear cover. See “2000-sheet dual input (TTM)—rear cover removal” on page 4-50. Disconnect the connector from the 2TM/TTM drive motor (A). Remove two screws securing the 2TM/TTM drive motor (A). Remove the 2TM/TTM drive motor (A).
Page 327: 2000-Sheet Dual Input (Ttm)-2Tm/Ttm Controller Card Assembly Removal
4024-110 2000-sheet dual input (TTM)—2TM/TTM controller card assembly removal Remove the rear cover. See “2000-sheet dual input (TTM)—rear cover removal” on page 4-50. Disconnect all the connectors from the 2TM/TTM controller card assembly (A). Connector Connectors DIP switch Connectors Remove four screws securing the 2TM/TTM controller card assembly (A). 4-115 Repair information...
Page 328 4024-110 Remove the controller card assembly (A). P541 P554 P548 P552 switch DIP switch settings, TTM P649 Tray Module PWB 4-116 Options Service Manual...
Page 329: 2000-Sheet Dual Input (Ttm)-Clutch Removal
4024-110 2000-sheet dual input (TTM)—clutch removal Remove the rear cover. See “2000-sheet dual input (TTM)—rear cover removal” on page 4-50. Disconnect the connector from the machine to the bracket (A). Remove two screws securing the bracket (A) to the frame assembly. Remove the bracket (A).
Page 330: High Capacity Feeder (Hcf) Removals
4024-110 High capacity feeder (HCF) removals Right Rear Front Left 4-118 Options Service Manual...
Page 331: Hcf Top Cover Removal
4024-110 HCF top cover removal Pull out the HCF media tray. Remove the four screws securing the HCF top cover (B). Remove the HCF top cover (B). 4-119 Repair information...
Page 332: Hcf Right Cover Removal
4024-110 HCF right cover removal Pull out the HCF media tray. Remove the four screws securing the HCF right cover (A). Remove the HCF right cover (A). 4-120 Options Service Manual...
Page 333: Hcf Sensor (Hcf Media Tray Set) Removal
4024-110 HCF sensor (HCF media tray set) removal Pull out the HCF media tray. Remove the HCF left cover. See “HCF left cover removal” on page 4-124. Remove the HCF rear cover. See “HCF rear cover removal” on page 4-124. Disconnect the connector from the sensor (HCF media tray set) (A).
Page 334: Hcf Sensor (Hcf Media Size) Removal
4024-110 HCF sensor (HCF media size) removal Note: This procedure can be applied to HCF sensor (media size L) and the HCF sensor (media size R). Remove the HCF media tray. See “HCF media tray assembly removal” on page 4-127. Remove the HCF top cover.
Page 335: Hcf Caster Removal
4024-110 HCF caster removal Remove the HCF unit from the printer. Place the machine so the HCF left cover faces down. Remove the three screws securing the HCF caster (A) to the unit. Remove the HCF caster (A). 4-123 Repair information...
Page 336: Hcf Left Cover Removal
4024-110 HCF left cover removal Remove the five screws securing the HCF left cover (A) to the unit. Remove the HCF left cover (A). HCF rear cover removal Remove the four screws securing the HCF rear cover (A) to the unit. Remove the HCF rear cover (A).
Page 337: Hcf Media Tray Front Cover Removal
4024-110 HCF media tray front cover removal Pull out the HCF media tray. Remove the five screws securing the HCF media tray front cover (A) to the HCF media tray. Remove the HCF media tray front cover (A). Note: Ensure that the HCF media tray assembly contains no media when the bottom plate (B) is raised after replacing the HCF media tray front cover (A).
Page 338: Hcf Media Long Edge Guide Assembly Removal
4024-110 HCF media long edge guide assembly removal Pull out the HCF media tray. Remove the e-clip securing the media long edge guide assembly (A) to the HCF media tray. Lift the media long edge guide assembly (A) upward to release it from the hinges on the HCF media tray. Remove the media long edge guide assembly (A).
Page 339: Hcf Media Tray Assembly Removal
4024-110 HCF media tray assembly removal Pull out the HCF media tray assembly (A) from the unit. Release the two bearing slides (B) by inserting a prying tool into the two holes while pulling the HCF media tray (A) from the frame assembly (B). Remove the HCF media tray (A) from the frame assembly.
Page 340: Hcf Lift Cables Removal
4024-110 HCF lift cables removal Remove the HCF media tray assembly. See “HCF media tray assembly removal” on page 4-127. Remove the tray lift gear bracket. See “HCF tray lift gear bracket removal” on page 4-131. Remove the HCF media tray front cover. See “HCF media tray front cover removal”...
Page 341 4024-110 Remove the two rear cables (D) from the bottom plate (I). Rear side E-ring Remove the e-clip securing the bushing (J) to the tray lift shaft assembly (B). Move the bushing (J) inward in the direction of the arrow (4) to remove it from the tray. Move the tray lift shaft assembly (B) outward in the direction of the arrow (5) to remove it from the tray.
Page 342 4024-110 Move the tray lift shaft pulley (C) inward in the direction of arrow (6) to detach the front cables (K). Remove the two e-clips securing the small cable pulleys (E) on the top front of the HCF media tray. Remove the two small guides (F) and the two small pulleys (E).
Page 343: Hcf Tray Lift Gear Bracket Removal
4024-110 HCF tray lift gear bracket removal Remove the HCF media tray assembly. See “HCF media tray assembly removal” on page 4-127. Remove the two e-clips with a prying tool securing the plastic retainer (A). Remove the plastic retainer (A). Remove the media tray lift shaft gear 51T (B).
Page 344: Hcf Media Feed Unit Assembly Removal
4024-110 HCF media feed unit assembly removal Remove the HCF media tray assembly from the printer. See “HCF media tray assembly removal” on page 4-127. Remove the two screws securing the media feed unit assembly (A) on the front side. Pull the media feed unit assembly (A) out of the machine in the direction of the arrow.
Page 345: Hcf Feed Lift Gear Bracket Removal
4024-110 HCF feed lift gear bracket removal Remove the HCF media tray assembly from the printer. See “HCF media tray assembly removal” on page 4-127. Remove the HCF media feed unit assembly. See “HCF media feed unit assembly removal” on page 4-132.
Page 346: Hcf Separation Gear Group Removal
4024-110 HCF separation gear group removal Remove the HCF media tray assembly from the printer. See “HCF media tray assembly removal” on page 4-127. Remove the HCF media feed unit assembly. See “HCF media feed unit assembly removal” on page 4-132.
Page 347: Hcf Media Tray Lift Coupling Assembly Removal
4024-110 HCF media tray lift coupling assembly removal Remove the HCF media tray assembly from the printer. See “HCF media tray assembly removal” on page 4-127. Remove the HCF media feed unit assembly. See “HCF media feed unit assembly removal” on page 4-132.
Page 348: Hcf Pick Solenoid Assembly Removal
4024-110 HCF pick solenoid assembly removal Remove the HCF media tray assembly from the printer. See “HCF media tray assembly removal” on page 4-127. Remove the HCF media feed unit assembly. See “HCF media feed unit assembly removal” on page 4-132.
Page 349: Hcf Sensor (Pre-Feed) Removal
4024-110 HCF sensor (pre-feed) removal Open the HCF top door. Open the HCF feed unit assembly. Remove the three screws securing the upper guide (A) to the HCF feed unit assembly (B). Remove the upper guide (A). Remove the connector from the sensor (pre-feed) (C). Remove the one screw securing the sensor (pre-feed) (C) to the HCF feed unit assembly (B).
Page 350: Hcf Media Out Actuator Removal
4024-110 HCF media out actuator removal Open the HCF top door. Open the HCF feed unit assembly. Remove the e-clip securing the media out actuator (A) to the HCF media feed unit assembly (B). Remove the media out actuator (A). E-ring 4-138 Options Service Manual...
Page 351: Hcf Sensor (Media Level) Removal
4024-110 HCF sensor (media level) removal Open the HCF top door. Open the HCF feed unit assembly. Disconnect the connector from the sensor (HCF media level) (A). Release the hooks securing the sensor (HCF media level) (A) from the HCF feed unit assembly (B). Remove the sensor (HCF media level) (A).
Page 352: Hcf Sensor (Media Out) Removal
4024-110 HCF sensor (media out) removal Open the HCF top door. Open the HCF feed unit assembly. Remove the connector from the sensor (HCF media out) (A). Release the hooks securing the sensor (HCF media out) (A) to the HCF feed unit assembly (B). Remove the sensor (HCF media out) (A).
Page 353: Hcf Pick Roll Shaft Assembly Removal
4024-110 HCF pick roll shaft assembly removal Open the HCF top door. Open the HCF feed unit assembly. Remove the HCF pick roll assembly. See “HCF pick roll assembly removal” on page 4-142. Remove the e-clip with a prying tool securing the HCF pick roll shaft assembly (A) to the HCF media feed unit assembly (B).
Page 354: Hcf Pick Roll Assembly Removal
4024-110 HCF pick roll assembly removal Open the HCF top door. Open the HCF feed unit assembly. Push the two ends of the HCF pick roll assembly (A) inward, and move it upward in the direction of the arrow to release it from the HCF media feed unit assembly (B). Remove the HCF pick roll assembly (A).
Page 355: Hcf Feed Roll Assembly Removal
4024-110 HCF feed roll assembly removal Open the HCF top door. Open the HCF feed unit assembly. Push the two ends of the HCF feed roll assembly (A) inward, and move it upward in the direction of the arrow to release it from the HCF media feed unit assembly (B). Remove the HCF feed roll assembly (A).
Page 356: Hcf Separation Roll Shaft Assembly Removal
4024-110 HCF separation roll shaft assembly removal Remove the HCF media tray assembly. See “HCF media tray assembly removal” on page 4-127. Remove the HCF media feed unit assembly. See “HCF media feed unit assembly removal” on page 4-132. Remove the HCF feed lift motor. See “HCF feed lift motor removal”...
Page 357: Hcf Separation Roll Assembly Removal
4024-110 HCF separation roll assembly removal Open the HCF top door. Open the HCF feed unit assembly. Push the two ends of the HCF separation roll assembly (A) inward, and move it upward in the direction of the arrow to release it from the HCF media feed unit assembly (B). Remove the HCF separation roll assembly (A).
Page 358: Hcf Top Door Assembly Removal
4024-110 HCF top door assembly removal Remove the HCF unit from the printer. Remove the HCF top cover. See “HCF top cover removal” on page 4-119. Remove the HCF rear cover. See “HCF rear cover removal” on page 4-124. Open the HCF top door assembly. Remove the two screws securing the bracket (A) to the frame assembly (B).
Page 359: Hcf Switch (Top Door Interlock) Removal
4024-110 Lift the HCF top door (E) and remove the shaft (C) from the hole in the frame assembly (B). Remove the HCF top door spring L (F) from the slot in the frame assembly (B). Remove the HCF top door assembly. Remove the shaft (C).
Page 360: Hcf Sensor (Tray 5 Feed-Out) Removal
4024-110 HCF sensor (tray 5 feed-out) removal Remove the HCF unit from the printer. Remove the HCF right cover. See “HCF right cover removal” on page 4-120. Open the HCF top door assembly. Remove the two screws securing the bracket (B) to the unit. Remove the bracket (B).
Page 361: Hcf Media Transport Roll Assembly Removal
4024-110 HCF media transport roll assembly removal Remove the HCF unit from the printer. Remove the HCF right cover. See “HCF right cover removal” on page 4-120. Remove the e-clip with needle nose pliers on the front side securing the HCF media transport roll assembly (A) to the unit.
Page 362: Hcf Media Transport Motor Assembly Removal
4024-110 HCF media transport motor assembly removal Remove the HCF unit from the printer. Remove the HCF rear cover. See “HCF rear cover removal” on page 4-124. Disconnect the connector from the HCF transport motor (A). Release the harness from the clamp. Remove the three screws securing the HCF transport motor (A) to the unit.
Page 363: Hcf Switch (Unit Docking Interlock) Removal
4024-110 HCF switch (unit docking interlock) removal Remove the HCF right cover. See “HCF right cover removal” on page 4-120. Remove the HCF media tray. Disconnect the connector from the HCF switch (HCF unit docking interlock) (A). Release the hooks securing the HCF switch (HCF unit docking interlock) (A) to the unit. Remove the HCF switch (HCF unit docking interlock) (A).
Page 364: Hcf Controller Card Assembly Removal
4024-110 HCF controller card assembly removal Remove the HCF rear cover. See “HCF rear cover removal” on page 4-124. Disconnect all connectors from the HCF controller card assembly (A). Remove the four screws securing the HCF controller card assembly (A) to the unit. Remove the HCF controller card assembly (A).
Page 365: Duplex Unit Removals
4024-110 Duplex unit removals Right Rear Left Front 4-153 Repair information...
Page 366: Duplex Unit Assembly Removal
4024-110 Duplex unit assembly removal Pull the option hookup cover (A) outward in the direction of the arrow to remove. Disconnect the connector of the duplex unit assembly harness from the machine. Release the duplex unit assembly harness clamp from the machine. Open the duplex unit assembly.
Page 367 4024-110 Turn the two duplex docking locks (B) on the duplex unit assembly by 90 degrees counterclockwise to release the duplex unit assembly from the machine. Remove the duplex unit assembly. Release Hook Hook Hole Front Hole 4-155 Repair information...
Page 368: Duplex Docking Locks Removal
4024-110 Duplex docking locks removal Remove the duplex unit assembly. See “Duplex unit assembly removal” on page 4-154. Open the duplex unit assembly. Turn the two duplex docking locks (A) 45 degrees, and release the hooks with needle nose pliers on the back side securing them to the duplex.
Page 369: Duplex Support Strap Removal
4024-110 Duplex support strap removal Remove the duplex unit assembly. See “Duplex unit assembly removal” on page 4-154. Remove the two screws securing the duplex lower guide (A) to the duplex unit assembly. Remove the duplex lower guide (A). Right Open the duplex unit assembly.
Page 370 4024-110 Release the hook of the duplex left door support strap (B) securing the duplex left cover (C) to the duplex unit assembly. Left Remove the four screws securing the duplex left cover (C) to the duplex unit assembly. Remove the duplex left cover (C). 4-158 Options Service Manual...
Page 371 4024-110 Remove the duplex left door support strap (B) from the duplex unit assembly. Hook Left 4-159 Repair information...
Page 372: Duplex Drive Gear 28 Tooth Removal
4024-110 Duplex drive gear 28 tooth removal Remove the duplex unit assembly. See “Duplex unit assembly removal” on page 4-154. Remove the two screws securing the duplex lower guide (A) to the duplex unit assembly. Remove the duplex lower guide (A). Right 4-160 Options Service Manual...
Page 373 4024-110 Open the duplex unit assembly. Release the hook of the duplex left door support strap (B) securing the duplex left cover (C) to the duplex unit assembly. Remove the four screws securing the duplex left cover (C) to the duplex unit assembly. Remove the duplex left cover (C).
Page 374 4024-110 Disconnect the connector of the harness from duplex drive motor assembly (D) to the duplex main cable assembly. Release the harness from the clamps of the duplex unit assembly. Remove the three screws securing the bracket (E) to the duplex unit assembly. Remove the bracket (E).
Page 375: Duplex Drive Gear 33 / 74 Tooth Removal
4024-110 Duplex drive gear 33 / 74 tooth removal Remove the duplex unit assembly. See “Duplex unit assembly removal” on page 4-154. Remove the two screws securing the duplex lower guide (A) to the duplex unit assembly. Remove the duplex lower guide (A). Right 4-163 Repair information...
Page 376 4024-110 Open the duplex unit assembly. Release the hook of the duplex left door support strap (B) securing the duplex left cover (C) to the duplex unit assembly. Remove the four screws securing the duplex left cover (C) to the duplex unit assembly. Remove the duplex left cover (C).
Page 377 4024-110 Disconnect the connector of the harness from duplex drive motor assembly (D) to the duplex main cable assembly. Release the harness from the clamps of the duplex unit assembly. Remove the three screws securing the bracket (E) to the duplex unit assembly. Remove the bracket (E).
Page 378: Duplex Drive Gear 33 Tooth Removal
4024-110 Duplex drive gear 33 tooth removal Remove the duplex unit assembly. See “Duplex unit assembly removal” on page 4-154. Remove the two screws securing the duplex lower guide (A) to the duplex unit assembly. Remove the duplex lower guide (A). Right 4-166 Options Service Manual...
Page 379 4024-110 Open the duplex unit assembly. Release the hook of the duplex left door support strap (B) securing the duplex left cover (C) to the duplex unit assembly. Remove the four screws securing the duplex left cover (C) to the duplex unit assembly. Remove the duplex left cover (C).
Page 380 4024-110 Disconnect the connector of the harness from duplex drive motor assembly (D) to the duplex main cable assembly. Release the harness from the clamps of the duplex unit assembly. Remove the three screws securing the bracket (E) to the duplex unit assembly. Remove the bracket (E).
Page 381: Duplex Drive Gear 42 Tooth Removal
4024-110 Duplex drive gear 42 tooth removal Remove the duplex unit assembly. See “Duplex unit assembly removal” on page 4-154. Remove the two screws securing the duplex lower guide (A) to the duplex unit assembly. Remove the duplex lower guide (A). Right 4-169 Repair information...
Page 382 4024-110 Open the duplex unit assembly. Release the hook of the duplex left door support strap (B) securing the duplex left cover (C) to the duplex unit assembly. Remove the four screws securing the duplex left cover (C) to the duplex unit assembly. Remove the duplex left cover (C).
Page 383 4024-110 Disconnect the connector of the harness from duplex drive motor assembly (D) to the duplex main cable assembly. Release the harness from the clamps of the duplex unit assembly. Remove the three screws securing the bracket (E) to the duplex unit assembly. Remove the bracket (E).
Page 384: Duplex Switch (Left Cover Interlock) Removal
4024-110 Duplex switch (left cover interlock) removal Remove the duplex unit assembly. See “Duplex unit assembly removal” on page 4-154. Remove the two screws securing the duplex lower guide (A) to the duplex unit assembly. Remove the duplex lower guide (A). Right 4-172 Options Service Manual...
Page 385 4024-110 Open the duplex unit assembly. Release the hook of the duplex left door support strap (B) securing the duplex left cover (C) to the duplex unit assembly. Remove the four screws securing the duplex left cover (C) to the duplex unit assembly. Remove the duplex left cover (C).
Page 386 4024-110 Disconnect the connector from the switch (duplex left door interlock) (D). Release the hooks securing the switch (duplex cover interlock) (D) to the bracket (E). Remove the switch (duplex left door interlock) (D). Connector Hooks Rear 4-174 Options Service Manual...
Page 387: Duplex Media In Actuator Removal
4024-110 Duplex media in actuator removal Remove the duplex unit assembly. See “Duplex unit assembly removal” on page 4-154. Remove the two screws securing the duplex lower guide (A) to the duplex unit assembly. Remove the duplex lower guide (A). Right 4-175 Repair information...
Page 388 4024-110 Open the duplex unit assembly. Release the hook of the duplex left door support strap (B) securing the duplex left cover (C) to the duplex unit assembly. Remove the four screws securing the duplex left cover (C) to the duplex unit assembly. Remove the duplex left cover (C).
Page 389 4024-110 Remove the spring (D) from the duplex wait actuator (E). Turn the duplex wait in actuator (E) 180 degrees, and move it rightward and upward in the direction of the arrow. Remove the duplex wait actuator (E). Left 4-177 Repair information...
Page 390: Duplex Drive Motor Assembly Removal
4024-110 Duplex drive motor assembly removal Remove the duplex unit assembly. See “Duplex unit assembly removal” on page 4-154. Remove the two screws securing the duplex lower guide (A) to the duplex unit assembly. Remove the duplex lower guide (A). Right 4-178 Options Service Manual...
Page 391 4024-110 Open the duplex unit assembly. Release the hook of the duplex left door support strap (B) securing the duplex left cover (C) to the duplex unit assembly. Remove the four screws securing the duplex left cover (C) to the duplex unit assembly. Remove the duplex left cover (C).
Page 392 4024-110 Disconnect the connector of the harness from duplex motor assembly (D) to the duplex main cable assembly. Release the harness from the clamps of the duplex unit assembly. Remove the two screws securing the duplex drive motor assembly (E) to the duplex unit assembly. Remove the duplex drive motor assembly (E).
Page 393: Duplex Controller Card Assembly Removal
4024-110 Duplex controller card assembly removal Remove the duplex unit assembly. See “Duplex unit assembly removal” on page 4-154. Remove the two screws securing the duplex lower guide (A) to the duplex unit assembly. Remove the duplex lower guide (A). Right 4-181 Repair information...
Page 394 4024-110 Open the duplex unit assembly. Release the hook of the duplex left door support strap (B) securing the duplex left cover (C) to the duplex unit assembly. Remove the four screws securing the duplex left cover (C) to the duplex unit assembly. Remove the duplex left cover (C).
Page 395 4024-110 Disconnect all the connectors to the duplex controller card assembly (D). Remove the two screws securing the duplex controller card assembly (D) to the duplex unit assembly. Remove the duplex controller card assembly (D). Right Connectors 4-183 Repair information...
Page 396: Duplex Sensor (Duplex Wait) Removal
4024-110 Duplex sensor (duplex wait) removal Remove the duplex unit assembly. See “Duplex unit assembly removal” on page 4-154. Remove the two screws securing the duplex lower guide (A) to the duplex unit assembly. Remove the duplex lower guide (A). Right 4-184 Options Service Manual...
Page 397 4024-110 Open the duplex unit assembly. Release the hook of the duplex left door support strap (B) securing the duplex left cover (C) to the duplex unit assembly. Remove the four screws securing the duplex left cover (C) to the duplex unit assembly. Remove the duplex left cover (C).
Page 398 4024-110 Disconnect the connector of the harness from the sensor (duplex wait) (D). Release the hooks securing the sensor (duplex wait) (D) to the duplex unit assembly. Remove the sensor (duplex wait) (D). Hooks Connector Left 4-186 Options Service Manual...
Page 399: Duplex Access Handle Removal
4024-110 Duplex access handle removal Remove the duplex unit assembly. See “Duplex unit assembly removal” on page 4-154. Remove the two screws securing the duplex lower guide (A) to the duplex unit assembly. Remove the duplex lower guide (A). Right 4-187 Repair information...
Page 400 4024-110 Open the duplex unit assembly. Release the hook of the duplex left door support strap (B) securing the duplex left cover (C) to the duplex unit assembly. Remove the four screws securing the duplex left cover (C) to the duplex unit assembly. Remove the duplex left cover (C).
Page 401 4024-110 Remove the three screws securing the bracket (E) to the duplex unit assembly. Remove the bracket (E). Remove the spring (F). Rotate the duplex left door handle (G) upward, and move in the direction of the arrow. Note: The metal shaft (H) may become detached. Remove the duplex left door handle (G).
Page 402: Duplex Media Transport Rolls Removal
4024-110 Duplex media transport rolls removal Remove the duplex unit assembly. See “Duplex unit assembly removal” on page 4-154. Remove the duplex controller card assembly. See “HCF controller card assembly removal” on page 4-152. Remove the duplex drive gears 28T. See “Duplex drive gear 28 tooth removal”...
Page 403: Duplex Media Center Transport Roll Removal
4024-110 Duplex media center transport roll removal Remove the duplex unit assembly. See “Duplex unit assembly removal” on page 4-154. Remove the duplex controller card assembly. See “Duplex controller card assembly removal” on page 4-181. Remove the hooks of the two bushings (A) securing the duplex media transport center roll (B) to the duplex unit assembly.
Page 404: Exit 2 Removals
4024-110 Exit 2 removals Exit 2 unit assembly removal Open the printer left door assembly (A). Lift the two levers (B) while pulling the exit 2 unit (C) outward in the direction of the arrow. Remove the exit 2 unit (C). Note: The left side of the exit 2 unit (C) may require some force to disengage the electrical connector.
Page 405: Exit 2 Unit Docking Lever Removal
4024-110 Exit 2 unit docking lever removal Remove the exit 2 unit assembly. See “Exit 2 unit assembly removal” on page 4-192. Remove the two exit 2 unit docking levers (A) with a prying tool from the brackets (B). Note: When removing the two exit 2 docking levers, ensure the brackets (B) are not bent or deformed. Remove the springs (C) from the brackets (B).
Page 406: Exit 2 Left Door Handle Removal
4024-110 Exit 2 left door handle removal Remove the exit 2 unit assembly. See “Exit 2 unit assembly removal” on page 4-192. Open the exit 2 unit assembly. Remove two screws securing the upper guide assembly (A) to the exit 2 unit assembly. Remove the upper guide assembly (A).
Page 407: Exit 2 Diverter Gate Removal
4024-110 Exit 2 diverter gate removal Remove the exit 2 unit assembly. See “Exit 2 unit assembly removal” on page 4-192. Open the exit 2 unit assembly. Remove two screws securing the upper guide assembly (A) to the exit 2 unit assembly. Boss Front 4-195...
Page 408 4024-110 Remove the upper guide assembly (A). Note: The exit 2 access handle (B) may become detached. Remove the spring (C) connecting the exit 2 diverter gate (D) to the upper guide assembly (A). Gently flex the mounting points securing the exit 2 diverter gate (D) to the upper guide assembly (A). Remove the exit 2 diverter gate (D) Note: After reinstalling the upper guide assembly (A), ensure the exit 2 access handle (B) operates freely.
Page 409: Exit 2 Left Cover Removal
4024-110 Exit 2 left cover removal Remove the exit 2 unit assembly. See “Exit 2 unit assembly removal” on page 4-192. Open the exit 2 unit assembly. Release two hooks securing the exit 2 left cover (A) to the exit 2 unit assembly. Move the exit 2 left cover (A) downward and outward in the direction of the arrow.
Page 410: Exit 2 Right Cover Removal
4024-110 Exit 2 right cover removal Remove the exit 2 unit assembly. See “Exit 2 unit assembly removal” on page 4-192. Open the exit 2 unit assembly. Remove the exit 2 left cover. See “Exit 2 left cover removal” on page 4-197.
Page 411 4024-110 Gently pry apart, with a flat tip screwdriver, the boss on the right then the one on the left to separate the exit 2 unit assembly into two pieces. Note: The exit 2 unit assembly should be in two pieces. Remove the four screws securing the exit 2 right cover assembly (F) to the exit 2 unit assembly.
Page 412: Exit 2 Bin Full Actuator Removal
4024-110 Exit 2 bin full actuator removal Remove the exit 2 unit assembly. See “Exit 2 unit assembly removal” on page 4-192. Open the exit 2 unit assembly (A). Remove the exit 2 left cover. See “Exit 2 left cover removal” on page 4-197.
Page 413: Exit 2 Actuator Removal
4024-110 Exit 2 actuator removal Remove the exit 2 unit assembly. See “Exit 2 unit assembly removal” on page 4-192. Open the exit 2 unit assembly. Remove the exit 2 left cover. See “Exit 2 left cover removal” on page 4-197.
Page 414: Exit 2 Switch (Exit 2 Left Door Interlock) Removal
4024-110 Exit 2 switch (exit 2 left door interlock) removal Remove the exit 2 unit assembly. See “Exit 2 unit assembly removal” on page 4-192. Open the exit 2 unit assembly. Remove the exit 2 left cover. See “Exit 2 left cover removal” on page 4-197.
Page 415 4024-110 Remove the connector from the exit 2 switch (exit 2 left door interlock) (A). CONNECTOR FRONT Note: Before reinstalling the switch (exit 2 left door interlock) (A), ensure all the harnesses and connectors are properly installed. 4-203 Repair information...
Page 416: Exit 2 Media Shift Gear Removal
4024-110 Exit 2 media shift gear removal Remove the exit 2 unit assembly. See “Exit 2 unit assembly removal” on page 4-192. Open the exit 2 unit assembly. Remove the exit 2 left cover. See “Exit 2 left cover removal” on page 4-197.
Page 417: Exit 2 Media Diverter Solenoid Removal
4024-110 Exit 2 media diverter solenoid removal Remove the exit 2 unit assembly. See “Exit 2 unit assembly removal” on page 4-192. Open the exit 2 unit assembly. Remove the exit 2 left cover. See “Exit 2 left cover removal” on page 4-197.
Page 418: Exit 2 Sensor (Exit 2) Removal
4024-110 Exit 2 sensor (exit 2) removal Remove the exit 2 unit assembly. See “Exit 2 unit assembly removal” on page 4-192. Open the exit 2 unit assembly. Remove the exit 2 left cover. See “Exit 2 left cover removal” on page 4-197.
Page 419: Exit 2 Sensor (Exit 2 Media Shift Hp) Removal
4024-110 Exit 2 sensor (exit 2 media shift HP) removal Remove the exit 2 unit assembly. See “Exit 2 unit assembly removal” on page 4-192. Open the exit 2 unit assembly. Remove the exit 2 left cover. See “Exit 2 left cover removal” on page 4-197.
Page 420: Exit 2 Sensor (Standard Bin Full Exit 2) Removal
4024-110 Exit 2 sensor (standard bin full exit 2) removal Remove the exit 2 unit assembly. See “Exit 2 unit assembly removal” on page 4-192. Open the exit 2 unit assembly. Remove the exit 2 left cover. See “Exit 2 left cover removal” on page 4-197.
Page 421: Exit 2 Cooling Fan Removal
4024-110 Exit 2 cooling fan removal Remove the exit 2 unit assembly. See “Exit 2 unit assembly removal” on page 4-192. Open the exit 2 unit assembly. Remove the exit 2 left cover. See “Exit 2 left cover removal” on page 4-197.
Page 422 4024-110 4-210 Options Service Manual...
Page 423: Component Locations
4024-110 5. Component locations 2TM components 2TM/TTM clutch 2TM/TTM controller card assembly 2TM/TTM drive motor Component locations...
Page 424 4024-110 Sensor (media level) Sensor (media out) Sensor (pre-feed) Switch (2TM/TTM Switch (media size) left door interlock) Sensor (tray 3 feed out) Sensor (tray 4 feed out) Options Service Manual...
Page 425: Ttm Components
4024-110 TTM components 2TM/TTM clutch assembly 2TM/TTM controller 2TM/TTM drive motor card assembly Sensor (media level) Sensor (media out) Sensor (pre-feed) Sensor (tray 4 feed out) Switch (2TM/TTM left door interlock) Sensor (tray 3 feed out) Switch (TTM media size) Component locations...
Page 426: Hcf Components
4024-110 HCF components Switch (HCF top door interlock) Sensor (media Sensor (tray 5 level) feed out) HCF main connector Sensor (media out) Switch (HCF unit docking) Options Service Manual...
Page 427 4024-110 Sensor (HCF media size L) Sensor (HCF media size R) HCF transport motor HCF feed lift motor HCF controller card asm Sensor (HCF media tray set) Component locations...
Page 428: Duplex Components
4024-110 Duplex components Switch (duplex left door interlock) Sensor (duplex wait) Duplex controller card assembly Duplex drive motor Options Service Manual...
Page 429: Exit 2 Components
4024-110 Exit 2 components Switch (exit 2 left door interlock) Sensor (exit 2 media shift HP) Exit 2 drive motor Sensor (standard bin full exit 2) Sensor (exit 2) Not used Media shift motor Media diverter solenoid Component locations...
Page 430 4024-110 Options Service Manual...
Page 431: Preventive 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 Lubrication specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use of lubricants other than those specified can cause premature failure.
Page 432 4024-110 Options Service Manual...
Page 433: Parts Catalog
4024-110 7. Parts catalog How to use this parts catalog The following legend is used in the parts catalog: Asm- Part Units/ Units/ Description Index number option • Asm-index: Identifies the assembly and the item in the diagram. For example 3-1 indicates Assembly 3 and item number 1 in the table.
Page 434: Assembly 1: 2X 500-Sheet Drawer (2Tm)-Covers
4024-110 Assembly 1: 2X 500-sheet drawer (2TM)—covers Options Service Manual...
Page 435 4024-110 Assembly 1: 2X 500-sheet drawer (2TM)—covers Asm- Part Units/ Units/ Description Index number option 1—1 40X0689 Right cover 40X0687 Top cover 40X0688 Foot cover 40X0691 Locking caster 40X0690 Left cover Parts catalog...
Page 436: Assembly 2: 2X 500-Sheet Drawer (2Tm)-Media Tray And Media Feed Units
4024-110 Assembly 2: 2X 500-sheet drawer (2TM)—media tray and media feed units Options Service Manual...
Page 437 4024-110 Assembly 2: 2X 500-sheet drawer (2TM)—media tray and media feed units Asm- Part Units/ Units/ Description Index number option 2—1 40X0570 Switch (media size) 40X0569 Media tray catch kit includes: • Media tray catch • Media tray slide (2) 40X0581 Media feed unit assembly (this comes assembled) 40X0572...
Page 438: Assembly 3: 2X 500-Sheet Drawer (2Tm)-Media Tray
4024-110 Assembly 3: 2X 500-sheet drawer (2TM)—media tray Options Service Manual...
Page 439 4024-110 Assembly 3: 2X 500-sheet drawer (2TM)—media tray Asm- Part Units/ Units/ Description Index number option 3–1 40X0573 Media tray assembly (this comes assembled) • Media tray assembly • Labels (2) 40X0578 Media tray end guide kit includes: • Media tray end guide •...
Page 440: Assembly 4: 2X 500-Sheet Drawer (2Tm)-Media Feed Unit
4024-110 Assembly 4: 2X 500-sheet drawer (2TM)—media feed unit Options Service Manual...
Page 441 4024-110 Assembly 4: 2X 500-sheet drawer (2TM)—media feed unit Asm- Part Units/ Units/ Description Index number option 4–1 40X0581 Media feed unit assembly (this comes assembled) 40X0582 Media feed lift motor 40X0585 Media feed drive gear kit includes: • Media feed unit drive gear 13T •...
Page 442: Assembly 5: 2X 500-Sheet Drawer (2Tm)-Left Door
4024-110 Assembly 5: 2X 500-sheet drawer (2TM)—left door 7-10 Options Service Manual...
Page 443 4024-110 Assembly 5: 2X 500-sheet drawer (2TM)—left door Asm- Part Units/ Units/ Description Index number option 5—1 40X0692 Sensor (tray 3 feed-out) kit includes: • Sensor (tray 3 feed-out) • Sensor protector 40X0695 2TM/TTM media transport roll assembly includes: • 2TM/TTM media transport roll assembly •...
Page 444: Assembly 6: 2X 500-Sheet Drawer (2Tm)-Drive And Electrical
4024-110 Assembly 6: 2X 500-sheet drawer (2TM)—drive and electrical 7-12 Options Service Manual...
Page 445 4024-110 Assembly 6: 2X 500-sheet drawer (2TM)—drive and electrical Asm- Part Units/ Units/ Description Index number option 6—1 40X0701 2TM drive gear kit includes: • 2TM drive gear 22T/40T • 2TM drive gear 126T • 2TM drive gear 60T • 2TM drive gear 37T (2) •...
Page 446: Assembly 7: 2000-Sheet Dual Input (Ttm)-Covers
4024-110 Assembly 7: 2000-sheet dual input (TTM)—covers 7-14 Options Service Manual...
Page 447 4024-110 Assembly 7: 2000-sheet dual input (TTM)—covers Asm- Part Units/ Units/ Description Index number option 7—1 40X0687 Top cover 40X0688 Foot cover 40X0689 Right cover 40X0703 Tray support roll (4) 40X0691 Locking caster 40X0704 Tray 4 stopper 40X0690 Left cover 7-15 Parts catalog...
Page 448 4024-110 Assembly 8: 2000-sheet dual input (TTM)—tray 3 7-16 Options Service Manual...
Page 449: Assembly 8: 2000-Sheet Dual Input (Ttm)-Tray 3
4024-110 Assembly 8: 2000-sheet dual input (TTM)—tray 3 Asm- Part Units/ Units/ Description Index number option 8—1 40X0712 Tray 3 media guide lock kit includes: • Tray 3 media guide lock button • Tray 3 media guide lock shaft • Spring 40X0953 TTM tray lift pulley kit includes: •...
Page 450 4024-110 Assembly 9: 2000-sheet dual input (TTM)—tray 4 7-18 Options Service Manual...
Page 451: Assembly 9: 2000-Sheet Dual Input (Ttm)-Tray 4
4024-110 Assembly 9: 2000-sheet dual input (TTM)—tray 4 Asm- Part Units/ Units/ Description Index number option 9—1 40X0721 Tray 4 media guide lock kit includes: • Tray 4 media guide lock button • Tray 4 media guide lock shaft • Spring 40X0711 TTM tray separator kit includes: •...
Page 452: Assembly 10: 2000-Sheet Dual Input (Ttm)-Feed And Transport
4024-110 Assembly 10: 2000-sheet dual input (TTM)—feed and transport 7-20 Options Service Manual...
Page 453: Assembly 11: 2000-Sheet Dual Input (Ttm)-Feed And Transport
4024-110 Assembly 10: 2000-sheet dual input (TTM)—feed and transport Asm- Part Units/ Units/ Description Index number option 10—1 40X0729 Switch (TTM media size switch) 40X0581 Media feed unit assembly (this comes assembled) 40X0728 Tray 4 media guide kit includes: • Tray 4 upper media guide •...
Page 454 4024-110 Assembly 11: 2000-sheet dual input (TTM)—feed and transport 7-22 Options Service Manual...
Page 455 4024-110 Assembly 11: 2000-sheet dual input (TTM)—feed and transport Asm- Part Units/ Units/ Description Index number option 11—1 40X0692 Sensor (tray 3 feed-out) kit includes: • Sensor (tray 3 feed-out) • Sensor protector 40X0732 Upper vertical turn guide 40X0581 Media feed unit assembly (this comes assembled) 40X0572 Vertical turn guide 40X0695...
Page 456: Assembly 12: 2000-Sheet Dual Input (Ttm)-Media Feed Unit
4024-110 Assembly 12: 2000-sheet dual input (TTM)—media feed unit 7-24 Options Service Manual...
Page 457 4024-110 Assembly 12: 2000-sheet dual input (TTM)—media feed unit Asm- Part Units/ Units/ Description Index number option 12–1 40X0581 Media feed unit assembly (this comes assembled) 40X0582 Media feed lift motor 40X0585 Media feed drive gear kit includes: • Media feed unit drive gear 13T •...
Page 458: Assembly 13: 2000-Sheet Dual Input (Ttm)-Left Door
4024-110 Assembly 13: 2000-sheet dual input (TTM)—left door 7-26 Options Service Manual...
Page 459 4024-110 Assembly 13: 2000-sheet dual input (TTM)—left door Asm- Part Units/ Units/ Description Index number option 13—1 40X0733 2TM/TTM left door assembly (this comes assembled) 40X0696 2TM/TTM left door pinch assembly (this comes assembled) 40X0697 2TM/TTM left door support strap 40X0610 Switch (2TM/TTM left door interlock) 7-27...
Page 460: Assembly 14: 2000-Sheet Dual Input (Ttm)-Drive And Electrical
4024-110 Assembly 14: 2000-sheet dual input (TTM)—drive and electrical 7-28 Options Service Manual...
Page 461 4024-110 Assembly 14: 2000-sheet dual input (TTM)—drive and electrical Asm- Part Units/ Units/ Description Index number option 14—1 40X0736 TTM drive gear kit includes: • TTM drive gear 22/40T • TTM drive gear 37T (2) • TTM drive gear 32T •...
Page 462: Assembly 15: High Capacity Feed (Hcf)-Covers And Media Tray
4024-110 Assembly 15: High capacity feed (HCF)—covers and media tray 7-30 Options Service Manual...
Page 463 4024-110 Assembly 15: High capacity feed (HCF)—covers and media tray Asm- Part Units/ Units/ Description Index number option 15—1 40X0738 Top cover 40X0745 HCF docking bracket kit • HCF docking bracket • HCF docking bracket screw (2) 40X0746 Inner front cover 40X0740 HCF docking latch kit includes: •...
Page 464: Assembly 16: High Capacity Feed (Hcf)-Media Tray
4024-110 Assembly 16: High capacity feed (HCF)—media tray 7-32 Options Service Manual...
Page 465 4024-110 Assembly 16: High capacity feed (HCF)—media tray Asm- Part Units/ Units/ Description Index number option 16—1 40X0747 HCF media tray front cover assembly (this comes assembled) 40X0740 HCF docking latch kit includes: • HCF docking latch • Spring 40X0749 HCF media long edge guide kit includes: (this comes assembled) •...
Page 466: Assembly 17: High Capacity Feed (Hcf)-Media Tray Lift
4024-110 Assembly 17: High capacity feed (HCF)—media tray lift 7-34 Options Service Manual...
Page 467 4024-110 Assembly 17: High capacity feed (HCF)—media tray lift Asm- Part Units/ Units/ Description Index number option 17—1 40X0750 HCF rear media guide kit includes: • HCF rear media guide • Screw 40X0966 HCF media tray separation brush 40X0751 HCF front media guide kit includes: •...
Page 468: Assembly 18: High Capacity Feed (Hcf)-Media Feed Unit
4024-110 Assembly 18: High capacity feed (HCF)—media feed unit 7-36 Options Service Manual...
Page 469: Assembly 19: High Capacity Feed (Hcf)-Media Feed Unit
4024-110 Assembly 18: High capacity feed (HCF)—media feed unit Asm- Part Units/ Units/ Description Index number option 18—1 40X0758 HCF feed unit assembly (this comes assembled) 40X0759 HCF feed lift motor 40X0760 HCF feed lift gear bracket assembly 40X0913 Ball bearing 6 mm 40X0761 HCF separation drive gear kit includes: •...
Page 470 4024-110 Assembly 19: High capacity feed (HCF)—media feed unit Note: This assembly includes everything on pages 7-36 and 7-38. 7-38 Options Service Manual...
Page 471 4024-110 Assembly 19: High capacity feed (HCF)—media feed unit Asm- Part Units/ Units/ Description Index number option 19—1 40X0758 HCF feed unit assembly (this comes assembled) 40X0764 HCF feed unit latch kit includes: • HCF feed unit latch (2) • Spring •...
Page 472: Assembly 20: High Capacity Feed (Hcf)-Top Door And Transport
4024-110 Assembly 20: High capacity feed (HCF)—top door and transport 7-40 Options Service Manual...
Page 473 4024-110 Assembly 20: High capacity feed (HCF)—top door and transport Asm- Part Units/ Units/ Description Index number option 20—1 40X0773 HCF top door kit includes: • HCF top door • HCF top door shaft • HCF top door spring R •...
Page 474: Assembly 21: High Capacity Feed (Hcf)-Electrical
4024-110 Assembly 21: High capacity feed (HCF)—electrical 7-42 Options Service Manual...
Page 475 4024-110 Assembly 21: High capacity feed (HCF)—electrical Asm- Part Units/ Units/ Description Index number option 21—1 40X0779 HCF main cable assembly 40X0778 HCF controller card assembly 7-43 Parts catalog...
Page 476: Assembly 22: Duplex Outer
4024-110 Assembly 22: Duplex outer 7-44 Options Service Manual...
Page 477 4024-110 Assembly 22: Duplex outer Asm- Part Units/ Units/ Description Index number option 22—1 40X0780 Duplex unit assembly (this comes assembled) 40X0788 Duplex cable kit includes: • Duplex sensor cable assembly • Duplex motor cable assembly • Duplex main cable assembly 40X0782 Duplex left door handle kit includes: •...
Page 478: Assembly 23: Duplex Inner
4024-110 Assembly 23: Duplex inner 7-46 Options Service Manual...
Page 479 4024-110 Assembly 23: Duplex inner Asm- Part Units/ Units/ Description Index number option 23—1 40X0780 Duplex unit assembly (this comes assembled) 40X0792 Duplex media transport pinch roll kit includes: • Duplex media transport pinch roll (10) • Spring (10) 40X0790 Duplex docking lock (2) 40X0791 Hinge pin (2)
Page 480: Assembly 24: Exit 2 Outer
4024-110 Assembly 24: Exit 2 outer 7-48 Options Service Manual...
Page 481 4024-110 Assembly 24: Exit 2 outer Asm- Part Units/ Units/ Description Index number option 24—1 40X0794 Exit 2 unit assembly (this comes assembled) 40X0800 Rear cover 40X0797 Exit 2 left door support strap 40X0795 Exit 2 left door handle kit includes: •...
Page 482: Assembly 25: Exit 2 Inner
4024-110 Assembly 25: Exit 2 inner 7-50 Options Service Manual...
Page 483 4024-110 Assembly 25: Exit 2 inner Asm- Part Units/ Units/ Description Index number option 25—1 40X0794 Exit 2 unit assembly (this comes assembled) 40X0807 Exit 2 cooling fan 40X0802 Exit 2 docking latch kit includes: • Exit 2 docking latch (2) •...
Page 484 4024-110 7-52 Options Service Manual...
Page 485 4024-110 Index diagnostic mode diagnostics mode 1-39 acronyms accessing available tests 3-14 BASE SENSOR TEST button test DEVICE TESTS 3-15 Disk Test/Clean CACHE Test 3-16 Flash Test code update 3-15 Quick Disk Test component locations DUPLEX TESTS 2TM components Quick Test duplex components Sensor Test exit 2 components...
Page 486 4024-110 2-90 duplex left door assembly open 2-101 exit 2 left door assembly open 2-36 error code messages - 2000-sheet dual input (TTM) 2-79 HCF top door assembly open error code messages - 2X 500-sheet drawer (2TM) 2-80 HCF unit docking failure or tray 5 set failure 2-83 error code messages - DUP 2-30...
Page 487 4024-110 1-11 4-117 media transport clutch 1-13 4-114 media tray assembly drive motor assembly 4-100 tray 2 feed roll 4-101 driving force transmission path feed roll one-way clutch 4-109 main components feed unit drive gear 27T 4-48 media transport foot cover 4-60 media tray assembly front cable assembly...
Page 488 4024-110 4-208 left cover exit 2 sensor (standard bin full exit 2) 4-41 4-202 left door pinch roll assembly exit 2 switch (left door interlock) 4-18 4-192 lift coupling assembly exit 2 unit assembly 4-40 4-193 lower media transport roll assembly exit 2 unit docking lever 4-17 media feed lift motor...
Page 489: Index
4024-110 1-39 tools required Top Margin 3-22 simplex (front side) wrap tests Index...
Page 490 4024-110 Options Service Manual...
Page 491: Part Number Index
4024-110 Part number index Description Page 40X0553 Switch (HCF top door interlock) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41 40X0569 Media tray catch kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 492 4024-110 40X0708 Large idler pulley kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17 40X0709 Tray 3 rear cable (2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 493 4024-110 40X0769 HCF pick roll shaft kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39 40X0770 HCF feed unit roll kit (3) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 494 4024-110 Options Service Manual...
Page 495 4024 Options Service Manual Switch (HCF Unit SIG GND PF08 Sensor(Tray 5 Docking Switch Close(L)+5VDC Docking) Feed Out) SIG GND EXIT Interface Card HCF Tray5 Feed Out Paper SNR(H)+5VDC +5VDC HCF Pick SIG GND Sensor Solenoid HCF Tray Set(L)+5VDC Assembly (Media Tray Set) +5VDC PF01...

This manual is also suitable for:

W850dn

Lexmark W850n Service Manual

Safety Information

Preface

Definitions

General Information

Options and Features

Tray 2

Tandem Tray

High Capacity Feeder

Duplex

Exit 2

Tools Required for Service

Acronyms

Diagnostic Information

Start

Confirm the Installation Status

POR (Power-On Reset) Sequence

Error Code Messages - 2X 500-Sheet Drawer (2TM)

Service Checks - 2X 500-Sheet Drawer (2TM)

Error Code Messages - 2000-Sheet Dual Input (TTM)

Service Checks - 2000-Sheet Dual Input (TTM)

Error Code Messages - HCF

Service Checks - HCF

Error Code Messages - DUP

Service Checks - DUP

Error Code Messages - EX2

Service Checks - EX2

Diagnostic Aids

Accessing Service Menus

Diagnostics Mode

Configuration Menu (CONFIG MENU)

Analyzing the Print Test

Control

Safety System Diagram

Quick Links

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Summary of Contents for Lexmark W850n