Page 1 W850n and W850dn Printer 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. MarkNet is a trademark of Lexmark International, Inc., registered in the United States and/or other countries.
Page 3: Table Of Contents
4024-110 Table of contents Notices ............. . . ix Laser notice .
Page 4 4024-110 920.00 Fuser unit assembly on time failure ......... . 2-51 921.00 Over heat temperature failure .
Page 5 4024-110 OUTPUT BIN TESTS ............3-10 FINISHER TESTS .
Page 6 4024-110 Printer front door assembly removal ..........4-8 Front door support strap and front door magnetic catch removal .
Page 7 4024-110 Registration clutch assembly removal ..........4-77 Sensor (registration) removal .
Page 8 4024-110 Assembly 9: Left door and transfer roll ..........7-16 Assembly 10: Printer left door .
Page 9: Notices
4024-110 Notices Laser notice The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.
Page 10 4024-110 Avisos sobre el láser Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de Clase I (1).
Page 11 4024-110 Huomautus laserlaitteesta Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen. Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä.
Page 12 4024-110 Printer Service Manual...
Page 13: Lithium Warning
4024-110 Lithium warning CAUTION—POTENTIAL INJURY: There is a danger of explosion if a lithium battery is incorrectly replaced. Replace it only with the same or an equivalent type of lithium battery. Do not recharge, disassemble, or incinerate a lithium battery. Discard used batteries according to the manufacturer’s instructions and local regulations.
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 W850 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 2X 500-Sheet Drawer (2TM), 2000-Sheet Dual Input (TTM), 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 About this manual This manual is a standard service manual containing information required for maintenance of the Lexmark™ W850n and W850dn (4024-110) laser printers. Printer overview CAUTION: Do not set up this product or make any electrical or cabling connections, such as the power cord or options and features, during a lightning storm.
Page 18: Configured Model
4024-110 Configured model The following illustration shows a fully configured printer. Items denoted with an asterisk (*) are options. Bridge unit* (Used in conjunction Exit 2* with finisher) (Used in conjunction with duplex unit) Operator panel Duplex unit* Finisher* Multipurpose feeder (MPF) Tray 5*...
Page 19: Acronyms
4024-110 Acronyms 2 Tray Module Alternate Current ASIC Application Specific Integrated Circuit Customer Replaceable Unit Customer Setup Direct Current DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory Enhanced Data Out Electrophotographic Process Electrostatic Discharge Field Replaceable Unit Gigabyte Ground Fault Interrupter High-Capacity Feeder HVPS...
Page 20 4024-110 Printer Service Manual...
Page 21: Diagnostic Information
4024-110 2. Diagnostic information Start CAUTION—SHOCK HAZARD: Remove the power cord from the electrical outlet and then from the printer before connecting or disconnecting any cable, assembly, or electronic board. This is a precaution for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/ peripherals.
Page 22: Confirm The Installation Status
4024-110 Confirm the installation status Be sure to check the following items before starting the troubleshooting procedures. • With the power cord unplugged from the wall outlet, check that the cord is free from breakage, short-circuit, disconnected wire, or incorrect connection in the power cord. •...
Page 23: Printer Operator Panel
4024-110 Printer operator panel The printer operator panel consists of these items: • A four-line, backlit, gray-scale display that can show both graphics and test • Eight buttons • Indicator light • Numeric pad • USB direct interface The use of the buttons and the layout of the display panel is described in the following table. USB direct interface Indicator Display...
Page 24: Index
4024-110 Item Description Navigation Press the up or down arrow buttons to scroll through menus or menu items, or to increase or decrease a value when entering numbers. Press the left or right arrow buttons to scroll through menu settings (also called values or options), or to scroll through text that rolls to another screen.
Page 25: Error Code Messages
4024-110 Error code messages Error code or Error contents Description/Action message 200.00 Sensor (registration) off The sensor (registration) is not turned off within the jam (too long) specified time after the registration clutch is turned Paper jam Check area A Go to “200.00 Sensor (registration) off jam (too long)”...
Page 26 4024-110 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 exit2 motor is turned on. Paper jam Refer to Options Service Manual. Check areas A, E 230.01...
Page 27 4024-110 Error code or Error contents Description/Action message 243.01 Sensor (tray 3 feed-out) on The sensor (tray 3 feed-out) is not turned on within jam (tray 3 media feed) the specified time after the pre-feed sensor3 is on. Paper jam Refer to Options Service Manual.
Page 28 4024-110 Error code or Error contents Description/Action message 245.01 Sensor (tray 5 feed-out) on The sensor (tray 5 feed-out) on the printer is not turned on within the specified time after the HCF Paper jam feed lift motor is turned on. Check area K Refer to Options Service Manual.
Page 29 4024-110 Error code or Error contents Description/Action message 282.00 Sensor (finisher media Sensor (finisher media entrance) is not turned on entrance) on jam with the specified time after the sensor (bridge unit Paper jam media exit) is turned on. Check area F Refer to Finisher Service Manual.
Page 30 4024-110 Error code or Error contents Description/Action message 284.02 Sensor (lower media exit) on Sensor (buffer path) is not turned on within the jam B specified time after the sensor (bridge unit media Paper jam entrance) is turned on. Check areas At this time, the sensor (finisher media entrance) is G2, G3 turned on.
Page 31 4024-110 Error code or Error contents Description/Action message 287.03 Sensor (upper media exit) on Sensor (upper media exit) is not turned on within the jam C specified time after the sensor (finisher media Paper jam entrance) is turned on. Check area At this time, the sensor (bridge unit media exit) is turned on.
Page 32 4024-110 Error code or Error contents Description/Action message 288.04 Sensor (diverter gate) Static Paper remains on the sensor (diverter gate) when jam (to stacker bin) A the finisher is in the stacker bin exit mode. Paper jam At this time, the sensor (bridge unit media exit) is Check area F turned on.
Page 33 4024-110 Error code or Error contents Description/Action message PC cartridge end of life The PC cartridge needs to be replaced. Replace PC Go to “PC cartridge end of life” on page 2-67. unit PC cartridge life near end The PC cartridge needs to be replaced soon. PC unit life Go to “PC cartridge end of life”...
Page 34 4024-110 Error code or Error contents Description/Action message 912.00 PC cartridge unit motor The PC cartridge motor does not rotate at the failure specified speed. Service motor error Go to “912.00 PC cartridge unit motor failure” on page 2-46. 913.00 Printhead assembly failure Rotation speed of the printhead motor is less than the specified value even when the specified time is...
Page 35 4024-110 Error code or Error contents Description/Action message 920.00 Fuser unit assembly on time During the warm-up period, the control thermistor failure does not detect the ready temperature even when Service fuser the specified time is passed after the main lamp is error turned on.
Page 36 4024-110 Error code or Error contents Description/Action message 929.00 Sensor (ATC) failure The sensor (ATC) failed. Service PC Go to “929.00 Sensor (ATC) failure” on cartridge page 2-54. 930.00 Laser power failure Light intensity of the LD2 is less than the specified value.
Page 37 4024-110 Error code or Error contents Description/Action message 945.01 Tray 5 HCF NVM R/W failure A read/write error has occurred on the NVM of the tray 5 HCF controller card assembly. Service tray 5 failure Refer to Options Service Manual. 951.XX RIP card assembly NVRAM A failure has occurred in the RIP card asm NVRAM.
Page 38 4024-110 Error code or Error contents Description/Action message 981.00 Stacker bin failure The sensor (stacker bin level) is not turned on within the specified period after the stacker bin starts Service rising. finisher error Refer to Finisher Service Manual. 981.01 Stacker bin upper limit failure The stacker bin abnormally rises beyond the specified upper limit position (stacker bin level).
Page 39 4024-110 Error code or Error contents Description/Action message 985.01 Sensor (punch carriage shift The sensor (punch carriage shift HP) is not turned HP) off failure off even when the specified time passed after the Service punch carriage shift motor assembly is turned on. finisher error Or the sensor (punch carriage shift HP) is turned on again after the sensor (punch carriage shift HP) is...
Page 40 4024-110 Error code or Error contents Description/Action message 990.01 Sensor (stapler carriage HP) The sensor (stapler carriage HP) is not turned off off failure within 500 ms after stapler starts moving to the Service staple position, and sensor (stapler carriage HP) is finisher error turned off.
Page 41 4024-110 Error code or Error contents Description/Action message Close door B Printer left lower door open. The printer left lower door assembly is open. Go to “Printer left lower door open” on page 2-70. Close door C 2TM/TTM left door assembly The 2TM/TTM door is open.
Page 42 4024-110 Error code or Error contents Description/Action message Remove Standard bin 1 full. Media in standard bin 1 is at maximum capacity. paper from Go to “Standard bin 1 full” on page 2-71. standard output bin Remove Standard bin 2 full. Media in standard bin 2 is at maximum capacity.
Page 43: Service Checks
4024-110 Service checks 200.00 Sensor (registration) off jam (too long) Step Check Check the media position. Remove the Go to step 2. media. Open the printer left door assembly, and visually check it. Does the media touch the sensor (registration)? Check the roll.
Page 44: Sensor (Registration) Static On Jam
4024-110 200.01 Sensor (registration) static on jam Step Check Check the media position. Remove the Go to step 2. media. Open the printer left door assembly, and visually check it. Does the media touch the sensor (registration)? Check the sensor (registration) for proper operation. Go to step 4.
Page 45 4024-110 Step Check Inspect the pinch roll on the transfer roll guide assembly. Go to step 5. Replace the transfer roll guide Is the transfer roll guide assembly free of damage? assembly. Go to “Transfer roll guide assembly removal” on page 4-74.
Page 46: Sensor (Fuser Exit) Off Jam
4024-110 202.00 Sensor (fuser exit) off jam Step Check Check the media position. Remove the Go to step 3. media. Open the printer left door assembly, and visually check it. Go to step 2. Does the media touch the sensor (fuser exit)? Check the roll.
Page 47: Sensor (Fuser Exit) Off (Too Short) Jam
4024-110 202.01 Sensor (fuser exit) off (too short) jam Step Check Check the media position. Remove the Go to step 2. media. Open the printer left door assembly, and visually check it. Does the media touch the sensor (fuser exit)? Check the fuser unit assembly for a media jam.
Page 48: Sensor (Fuser Exit) Static Jam
4024-110 202.02 Sensor (fuser exit) static jam Step Check Check the media position. Remove the Go to step 2. media. Open the printer left door assembly, and visually check it. Does the media touch the sensor (fuser exit). Check the sensor (fuser exit) for operation. Go to step 4.
Page 49 4024-110 Step Check Check the drive power transmission. Go to step 5. Replace damaged components. Does the exit 1 media exit roll assembly and the other gears rotate smoothly? Go to “Exit 1 media shift assembly removal” on page 4-104. Check the sensor (fuser exit) for proper operation.
Page 50: Sensor (Exit 2) Off Jam
4024-110 Step Check Check the media diverter solenoid for proper operation. Go to step 13. Go to step 12. 1. Enter Diagnostics mode. 2. Select MOTOR TESTS. 3. Select Diverter solenoid. Open the printer left door assembly. Does the above component operate normally? Check the media diverter solenoid for proper Replace the media Replace the...
Page 51 4024-110 Step Check Check the sensor (exit 2) for proper operation. Go to step 8. Go to step 7. 1. Enter Diagnostics mode. 2. Select BASE SENSOR TESTS. 3. Select Media Path. 4. Select Exit2. Does the display on the operator panel change every time the actuator on the above sensor operates? Check the sensor (exit 2) for proper connection.
Page 52: Sensor (Pre-Feed) On Jam (Tray 1 Feed)
4024-110 241.00 Sensor (pre-feed) on jam (tray 1 feed) Step Check Replace the Go to step 2. Check the media condition. damaged media Is the media in the tray crumpled or damaged? with new. Check the media size setup. Go to step 3. Replace the media, or change Does the media size in use match the size set for tray 1?
Page 53: Sensor (Registration) On Jam (Tray 1 Feed)
4024-110 Step Check Check the media feed lift motor for proper operation of Re-install the Go to step 10. tray 1. media feed lift motor for tray 2 as Replace the media feed lift motor for tray 1 with one from it previously was, tray 2.
Page 54: Sensor (Pre-Feed) On Jam (Tray 2 Feed)
4024-110 Step Check Check the sensor (registration) for proper operation. Go to step 7. Go to step 6. 1. Enter Diagnostics mode. 2. Select BASE SENSOR TEST. 3. Select Media path. 4. Select Registration. Open and check the printer left door assembly. Does the display on the operator panel change every time the sensor actuator operates? Check the sensor (registration) connection.
Page 55 4024-110 Step Check Check the rolls for tray 2. Go to step 4. Clean or replace the feed roll, Remove tray 2, and check it. separation roll, and pick roll. Are the feed roll, separation roll, pick roll free of excess wear and contamination? Go to “Feed roll...
Page 56: Sensor (Tray 2 Feed-Out) On Jam (Tray 2 Feed)
4024-110 Step Check Check the media feed lift motor in tray 2 for proper Install the media Go to step 10. operation. feed lift motor for tray 1 as it Replace the media feed lift motor for tray 2 with the one previously was, from tray 1.
Page 57 4024-110 Step Check Check the sensor (tray 2 feed-out) for proper operation. Go to step 7. Go to step 6. 1. Enter Diagnostics mode. 2. Select INPUT TRAY TESTS. 3. Select Sensor test. 4. Select Tray 2. 5. Select Media out. Open the printer left lower door assembly and check it.
Page 58: Sensor (Registration) On Jam (Tray 2 Feed)
4024-110 242.02 Sensor (registration) on jam (tray 2 feed) Step Check Check the media condition. Replace the media Go to step 2. with new; ensure it Is the media in the tray, crumpled or damaged? is dry. Check the media size setup. Go to step 3.
Page 59: Sensor (Tray 2 Feed-Out) Static Jam
4024-110 Step Check Check the sensor (tray 2 feed-out) connection. Replace the Replace the sensor (tray 2 sensor (tray 2 Is the sensor (tray 2 feed-out) properly connected? feed-out). feed-out). Go to “Sensor (tray 2 feed-out) removal” on page 4-81. Perform a print test.
Page 60: Sensor (Registration) On Jam (Mpf Pick)
4024-110 250.00 Sensor (registration) on jam (MPF pick) Step Check Check the media condition. Replace the media Go to step 2. with new; ensure it Is the media in the MPF tray crumpled or damaged? is dry. Check the media size setup. Go to step 3.
Page 61: Rip Card Assembly Software Failure
4024-110 Step Check Check the MPF pick solenoid for proper operation. Go to step 12. Go to step 11. 1. Enter Diagnostics mode. 2. Select MOTOR TESTS. 3. Select MPF pick solenoid. Does the MPF pick solenoid make an audible clicking sound when activated? Check the MPF pick solenoid connection.
Page 62: Ram Read/Write Check Failure
4024-110 903.00 RAM read/write check failure Step Check Perform a POR. Go to step 2. Perform several print tests. Does the error occur when the power is turned off/on? If the problem remains, go to step 2. Turn the printer off for 60 seconds. Replace the RIP Problem solved.
Page 63: Nvm Read/Write Cannot Be Executed Failure
4024-110 905.00 NVM read/write cannot be executed failure Step Check Perform a POR. Go to step 2. Perform several print tests. Does the error occur when the power is turned off/on? If the problem remains, go to step 2. Turn the printer off for 60 seconds. Replace the RIP Problem solved.
Page 64: Rfid Asic Failure
4024-110 907.00 RFID ASIC failure Step Check Perform a POR. Go to step 2. Perform several print tests. Does the error occur when the power is turned off/on? If the problem remains, go to step 2. Turn the printer off for 60 seconds. Go to step 3.
Page 65: Transport Motor Stop Failure
4024-110 910.00 Transport motor stop failure Step Check Check the dual drive motor assembly installation. Go to step 2. Install the PC cartridge properly. Is the dual drive motor assembly properly installed? Open the rear motor cover, and check it. Check the dual drive motor assembly rotation operation.
Page 66: Transport Motor Failure
4024-110 911.00 Transport motor failure Step Check Check the dual drive motor assembly for operation. Go to step 3. Go to step 2. Open the rear motor cover, and check it. 1. Enter Diagnostics mode. 2. Select MOTOR TESTS. 3. Select Transport motor. Does the motor rotate normally? Check the dual drive motor assembly for installation Go to step 3.
Page 67: Printhead Assembly Failure
4024-110 Step Check Check the dual drive motor assembly connection. Replace the dual Replace the drive motor connection. Is the dual drive motor assembly properly connected? assembly. Perform a print test. Replace the Problem solved. printer engine card Does the error continue? assembly.
Page 68: Toner Add Motor Assembly Failure
4024-110 914.00 Toner add motor assembly failure Step Check Check the toner cartridge for installation. Problem solved Go to step 2. Remove the toner cartridge, and reinstall it. Does it operate properly? Check the gear rotation for the toner cartridge guide Go to step 3.
Page 69: Pc Cartridge Cooling Fan Failure
4024-110 Step Check Check the fuser cooling fan for operation. Go to step 5. Go to step 4. 1. Enter Diagnostics mode. 2. Select MOTOR TESTS. 3. Select Fuser cooling fan. Does the fuser cooling fan RPM increase? Check the fuser cooling fan for proper connection. Replace the fuser Replace the cooling fan.
Page 70: Sensor (Exit 1 Media Shift Hp) Failure
4024-110 918.00 Sensor (exit 1 media shift HP) failure Step Check Check the sensor (exit 1 media shift HP) for operation. Go to step 3. Go to step 2. 1. Enter Diagnostics mode. 2. Select BASE SENSOR TESTS. 3. Select Media Path. 4.
Page 71: Fuser Unit Assembly On Time Failure
4024-110 920.00 Fuser unit assembly on time failure Step Check Check the fuser unit assembly for a media jam. Remove the Go to step 2. media. Open the printer left door assembly, and check it. Is there a media jam in the fuser unit assembly? Leave the printer powered on with the error code displayed Go to step 3.
Page 72: Center Thermistor Failure
4024-110 922.00 Center thermistor failure Step Check Check the fuser unit assembly for installation. Go to step 2. Install the fuser unit assembly Open the printer left door assembly, and check it. securely. Is the fuser unit assembly installed securely? Check the fuser unit assembly connection.
Page 73: Pressure Roll Thermistor Failure
4024-110 924.00 Pressure roll thermistor failure Step Check Check the fuser unit assembly for installation. Go to step 2. Install the fuser unit assembly Open the printer left door assembly, and check it. securely. Is the fuser unit assembly installed securely? Check the fuser unit assembly connection.
Page 74: Pc Cartridge Rfid Data Write Failure
4024-110 927.00 PC cartridge RFID data write failure Step Check Check the PC cartridge installation. Go to step 2. Install the PC cartridge properly. Is the PC cartridge properly installed? Check the sensor (RFID PC cartridge) installation. Go to step 3. Install the sensor (RFID PC Is the sensor (RFID PC cartridge) properly installed?
Page 75: Laser Power Failure
4024-110 Step Check Check the switch (PC cartridge interlock) connection. Replace the PC Replace the cartridge. connection. Is the switch (PC cartridge interlock) properly connected? Perform a print test. Replace the Problem solved. printer engine card Does the error continue? assembly.
Page 76: Toner Cartridge Rfid Data Write Failure
4024-110 932.00 Toner cartridge RFID data write failure Step Check Check the toner cartridge installation. Go to step 2. Install the toner cartridge properly. Is the toner cartridge properly installed? Check the sensor (RFID toner cartridge) installation. Go to step 3. Install the sensor (RFID toner Is the sensor (RFID toner cartridge) properly installed?
Page 77: Rip Card Assembly Communication Failure
4024-110 939.00 RIP card assembly communication failure Step Check Perform a POR. Go to step 2. Perform several print tests. Does the error occur when the power is turned off/on? If the problem remains, go to step 2. Turn the printer off for 60 seconds. Go to step 3.
Page 78: Media Tray 2 Lift Up / No Media Tray Failure
4024-110 Step Check Check the tray 1 media feed lift motor for operation. Reinstall the Go to step 7. media feed lift Replace the tray 1 media feed lift motor with the motor from motor for media tray 2. tray 2 as it was. Pull out the media tray, and then push it back in.
Page 79 4024-110 Step Check Check the tray 2 media feed lift motor for operation. Go to step 9. Go to step 5. Pull out the media tray, and then push it back in. Does the motor lift up the tray normally? Check the tray 2 media feed lift motor connection.
Page 80: Rip Card Assembly Nvram Failure
4024-110 951.XX RIP card assembly NVRAM failure Step Check Perform a POR. Go to step 2. Perform several print tests. Does the error occur when the power is turned off/on? If the problem remains, go to step 2. Turn the printer off for 60 seconds. Replace the RIP Problem solved.
Page 81: Operator Panel Assembly Nvram Failure
4024-110 953.XX Operator panel assembly NVRAM failure Step Check Perform a POR. Go to step 2. Perform several print tests. Does the error occur when the power is turned off/on? If the problem remains, go to step 2. Turn the printer off for 60 seconds. Replace the Problem solved.
Page 82: Rip Card Assembly Nand Crc Failure
4024-110 955.XX RIP card assembly NAND CRC failure Step Check Perform a POR. Go to step 2. Perform several print tests. Does the error occur when the power is turned off/on? If the problem remains, go to step 2. Turn the printer off for 60 seconds. Replace the RIP Problem solved.
Page 83: Rip Card Assembly Processor Over Temperature Failure
4024-110 956.01 RIP card assembly processor over temperature failure Step Check Perform a POR. Go to step 2. Perform several print tests. Does the error occur when the power is turned off/on? If the problem remains, go to step 2. Turn the printer off for 60 seconds.
Page 84: Exit Interface Card Assembly Communication Failure
4024-110 980.03 Exit interface card assembly communication failure Step Check Check the exit interface card assembly for proper Go to step 2. Replace the connection. connection. Check the connection between the exit interface card Go to step 3. Replace the assembly P430 and the LVPS assembly P526.
Page 85: No Media In The Select Media Tray
4024-110 Step Check Perform a print test. Replace the Problem solved. printer engine card Does the error continue? assembly. Go to “Printer engine card assembly removal” on page 4-119. No media in the select media tray Step Check Check the media. Go to step 2.
Page 86: Paper Is Installed (Short Edge) In The Media Paper Tray
4024-110 Paper is installed (short edge) in the media paper tray Step Check Is the media installed (short edge) orientation in the media Turn media 90 Go to step 2. tray assembly as opposed to long edge? degrees, or enable short edge feeding which is found in the configuration...
Page 87: Pc Cartridge End Of Life
4024-110 PC cartridge end of life Step Check Check the PC cartridge installation. Go to step 2. Install the PC cartridge properly. Is the PC cartridge properly installed? Check the sensor (RFID PC cartridge) installation. Go to step 3. Install the sensor (RFID PC unit) Is the sensor (RFID PC cartridge) properly installed? correctly.
Page 88: Pc Cartridge Set Failure
4024-110 PC cartridge set failure Step Check Check the PC cartridge installation. Go to step 2. Install the PC cartridge properly. Is the PC cartridge properly installed? Check the PC cartridge sensor connection. Replace the PC Replace the cartridge connection. Is the PC cartridge sensor properly connected? connector.
Page 89: Printer Left Door Open
4024-110 Step Check Check the switch (printer front door interlock) connection. Replace the switch Replace the (printer front door connection. Is the switch (printer front door interlock) properly interlock). connected? Go to “Switch (printer front door interlock) removal” on page 4-5.
Page 90: Printer Left Lower Door Open
4024-110 Printer left lower door open Step Check Is the printer left lower door assembly opening and closing Go to step 2. Check the printer properly? front door assembly for deformation, and reinstall it. Check the switch (printer front door interlock) for operation. Go to step 4.
Page 91: Standard Bin 1 Full
4024-110 Standard bin 1 full Step Check Check the actuator for movement. Go to step 2. Reinstall the standard bin 1 full Does the standard bin 1 full actuator move up and down actuator. normally? Check the sensor (standard bin full exit 1) for operation. Go to step 5.
Page 92: Standard Bin 2 Full
4024-110 Standard bin 2 full Step Check Check the actuator for movement. Go to step 2. Reinstall the media weight Does the media weight assembly move up and down assembly. normally? Check the sensor (standard bin full exit 2) for operation. Go to step 5.
Page 93 4024-110 Step Check Check the pipe, located on the lower part of the toner Go to step 5. Clean the pipe. cartridge for debris. Is the pipe, located on the lower part of the toner cartridge guide assembly, clogged? Check the sensor (RFID toner cartridge) for proper Go to step 6.
Page 94: Toner Cartridge Near Empty
4024-110 Toner cartridge near empty Step Check Does the toner cartridge contain toner? Go to step 2. Replace the toner cartridge. Check the toner cartridge for proper installation. Problem solved. Go to step 3. Remove the toner cartridge, and reinstall it. Does it install properly? Check the gear rotation in the toner cartridge guide Go to step 4.
Page 95: Toner Cartridge Rfid Failure
4024-110 Step Check Checking the sensor (RFID toner cartridge) connection. Replace the Replace the sensor (RFID connection. Is the sensor (RFID toner cartridge) properly connected? toner cartridge). Perform a print test. Replace the Problem solved. printer engine card Does the error continue? assembly.
Page 96: Tray 1 Media Size Failure
4024-110 Step Check Check the toner cartridge guide assembly. Replace the toner Go to step 4. cartridge. Remove the top cover assembly. Go to “Toner Is the toner cartridge guide assembly damaged? cartridge guide assembly removal” on page 4-93. Check the sensor (RFID toner cartridge). Replace the Go to step 5.
Page 97: Tray 2 Media Size Failure
4024-110 Tray 2 media size failure Step Check Check the media. Go to step 2. Load media properly. Is media loaded, in media tray 2, properly? Pull out media tray 2, and visually check it. Check the media. Go to step 3. Set the guides properly.
Page 98 4024-110 Step Check Check the roll for tray 1 Go to step 6. Clean or replace the feed roll, Pull out tray 1, and check it. separation roll, and pick roll. Is the feed roll, separation roll, and pick roll free of excess wear and contamination? Check the media position Remove the...
Page 99: Tray 2 Media Size Mismatch In Length
4024-110 Step Check Perform a print test Replace the Problem solved. printer engine card Does the error continue? assembly. Go to “Printer engine card assembly removal” on page 4-119. Tray 2 media size mismatch in length Step Check Check the media. Go to step 2.
Page 100 4024-110 Step Check Check the roll. Go to step 8. Clean or replace the transport roll Open the printer left door assembly, and check it. assembly. Is the transport roll assembly free of excess wear and Go to “Transfer contamination? roll assembly removal”...
Page 101: Image Quality Trouble
4024-110 Image quality trouble Troubleshooting Note: First, get a printout as a base, follow the symptom table to identify the possible failing FRUs. Image quality symptoms: • Faint print (low contrast) “Faint print (Low contrast)” on page 2-82. • Blank print (no print) “Blank print (no print)”...
Page 102: Image Quality
4024-110 Image Quality Faint print (Low contrast) Before starting, check the media route for foreign objects, such as staples, clips, and scraps, in the media path. Step Check Check the media condition. Problem solved. Go to step 2. Load new, dry, recommended media, and perform a print test.
Page 103 4024-110 Step Check Check the image development process. Go to step 7. Go to step 9. Perform a print test. Turn off the printer power while printing. Carefully remove the PC cartridge, and check the developed image formed on the drum right before the transfer roll assembly.
Page 104: Blank Print (No Print)
4024-110 Blank print (no print) Check the media path for foreign objects such as staples, clips, and scraps of media. Step Check Check the toner cartridge. Problem solved. Go to step 2. Install a new toner cartridge. Re-print the defective image. Is the image density normal? Check the transfer roll assembly.
Page 105 4024-110 Step Check Check the printhead installation. Go to step 8. Go to step 7. Is the printhead assembly installed securely with four screws? Check the printhead assembly installation. Problem solved. Go to step 8. Install the printhead assembly securely and perform a print test.
Page 106: Solid Black
4024-110 Solid black Check the media path for foreign objects such as staples, clips, scraps of media. Step Check Check the toner cartridge. Problem solved. Go to step 2. Install a new toner cartridge. Re-print the defective image. Is the image density normal? Check connector JHAB1 on the RIP card assembly.
Page 107 4024-110 Vertical blank lines (white stripes in media transport direction) Leading edge Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Are the media transfer route and the media path clear of Go to step 3.
Page 108 4024-110 Step Check Check the heat roll and pressure roll. Replace the fuser Go to step 9. unit assembly. Remove the fuser unit assembly. Is there contamination or cracking on the heat roll or pressure roll? Check the printer engine card assembly. Go to step 10.
Page 109: Horizontal Band Printheads Out
4024-110 Horizontal band printheads out Leading edge Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, and recommended media. Re-print the defective image. Does the error continue? Are the media transfer route and the media path free of Go to step 3.
Page 110 4024-110 Step Check Check the image transfer process. Go to step 10. Go to step 9. Check the toner image formed on the drum after the transfer roll assembly passed. Is the toner image completely transferred on the media? Check the HVPS card assembly. Go to step 10.
Page 111: Vertical Stripes
4024-110 Vertical stripes Leading edge Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Are the media transfer route and the media path free of Go to step 3.
Page 112 4024-110 Step Check Check the laser beam route. Go to step 8. Remove debris, or clean the Check for debris between the transfer roll assembly and transfer roll the PC drum. assembly window. Check the printhead assembly window for contamination. Is there any debris in the laser beam route or the printhead assembly window? Check the heat roll and pressure roll.
Page 113: Horizontal Stripes
4024-110 Horizontal stripes Leading edge Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Check the media transfer route. Go to step 3. Remove obstacles or Check the media route for contamination or obstacles.
Page 114 4024-110 Step Check Check the image transfer process. Go to step 9. Go to step 10. Check the toner image formed on the drum after the transfer roll assembly passed. Is the toner image completely transferred on the media? Check the HVPS. Go to step 10.
Page 115: Partial Lack
4024-110 Partial lack Leading edge Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Check the media transfer route. Go to step 3. Remove debris Is the media path free of contamination or debris? contamination.
Page 116 4024-110 Spots Leading edge Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Check the media transfer route. Go to step 3. Remove debris Is the media route free of contamination or debris? contamination.
Page 117: After Image
4024-110 After image Leading edge Trailing edge The ghost appears on the media which may be the image from the previous page, or part of the page currently printing. Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media.
Page 118: Background (Fog)
4024-110 Background (fog) Leading edge Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Check the media transfer route. Go to step 3. Remove debris Is the media path free of contamination or debris? contamination.
Page 119 4024-110 Step Check Check the printer engine card assembly. Replace the RIP Problem solved. card assembly. Replace the printer engine card assembly. Go to “RIP card Perform a print test. assembly removal” on Does the error continue? page 4-126. 2-99 Diagnostic information...
Page 120 4024-110 Skew Leading edge Trailing edge The printed image is not paralleled with both sides of the media. Step Check Check printer installation placement. Go to step 2. Correct the installation Check the installation surface for irregularities. placement. Check for missing printer foot. Is the setup surface normal? Properly load media into the media tray assembly.
Page 121: Media Damage
4024-110 Media damage Leading edge Trailing edge Step Check Check printer installation placement. Go to step 2. Correct the installation Check the installation surface for irregularities. placement. Check for missing printer foot. Is the setup surface normal? Check the media feed. Go to step 3.
Page 122: No Fuse
4024-110 No fuse Leading edge Trailing edge Step Check Check the fuser unit assembly installation. Go to step 2. Problem solved. Check that the levers, on both sides of the fuser unit assembly, are pushed down. Re-print the defective image. Does the error continue? Check the media condition.
Page 123 4024-110 Step Check Check the printer engine card assembly. Replace the RIP Problem solved. card assembly. Replace the printer engine card assembly. Go to “RIP card Perform a print test. assembly removal” on Does the error continue? page 4-126. 2-103 Diagnostic information...
Page 124 4024-110 2-104 Printer Service Manual...
Page 125: 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 126: 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 127 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 DUPLEX TESTS (if installed) Quick Test “Quick Test (duplex)” on page 3-8.
Page 128: Exiting Diagnostics Mode
4024-110 Exiting Diagnostics mode Select Exit Diagnostics to exit the Diagnostics mode. Resetting the Printer displays, the printer performs a POR, and returns to normal mode. Printer Service Manual...
Page 129: 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 130: Hardware Tests
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 131: 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 132: 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 133: 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 134: 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 135: 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 136 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 137: 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 138: 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 139: Printer Setup
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 140: 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 16 Warning: Do not change these settings unless requested to do so by your next level of support.
Page 141: Event Log
• 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. 3-17 Diagnostic aids...
Page 142: Exit Diagnostics
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 143: 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 144: Maintenance Page Count (Maint Cnt Value)
4024-110 Configuration Menu (continued) Tray Low Message “Tray Low Message” on page 3-25. Exit Config Menu “Exit Config Menu” on page 3-25. 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 145: 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 146: Print Quality Pages (Prt Quality
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 147: 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 148: 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 149: 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 150: 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 151: 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 152: 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 153 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 154: 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 155 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 156 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 157: Multi-Purpose Feeder (Mpf)
4024-110 Multi-purpose feeder (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 pick roll feeds media set on the MPF.
Page 158: 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 159: 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 160 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 161: 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 lamp. 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 162 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 163: 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 164: 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, and transport 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 165: 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 166 4024-110 Registration roll assembly The registration roll assembly feeds media from all trays to the PC cartridge and 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 167: 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 168: 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 169: Xerographic Process During A Print Cycle
4024-110 Xerographic Process During a Print Cycle 3-45 Diagnostic aids...
Page 170 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 171 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 172 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 173 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 174 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 175 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 176: 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 177 Print defects guide Match a set of repeating defects on a print If the defect appears on the printed side of a single-sided print job to the marks on one of the vertical lines. job, change the photoconductor kit. The line that best matches the defects on If the defect appears on the back, change the fuser.
Page 178: Repeating Defects
4024-110 Repeating defects Roll Pitch Transfer roll 59 mm Registration roll 44 mm Fuser pressure roll 94 mm Fuser heat roll 79 mm Charge roll 44 mm PC drum 94 mm 3-54 Printer Service Manual...
Page 179: 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 180: Removal Procedures
4024-110 Removal procedures CAUTION—SHOCK HAZARD: Remove the power cord from the electrical outlet and then from the printer before connecting or disconnecting any cable, assembly, or electronic board. This is a precaution for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/ peripherals.
Page 181: Printer Front Left Cover Removal
4024-110 Printer front left cover removal Note: First, remove the exit 2 unit assembly, if equipped. Refer to the Options Service Manual. Open the printer front door assembly (A). Remove the screw securing the front left cover (B) to the machine. Remove the front left cover (B).
Page 182: Top Rear Cover Removal
4024-110 Top rear cover removal Remove the cable hookup cover. “Cable hookup door removal” on page 4-13. Remove the two screws securing the rear motor cover (A). Open and remove the rear motor cover (A). Remove the screw securing the top rear cover (B). Remove the top rear cover (B) by sliding it left in the direction of the arrow, then lift up.
Page 183: Switch (Printer Front Door Interlock) Removal
4024-110 Switch (printer front door interlock) removal Note: First, remove the bridge unit and the finisher, if equipped. Refer to the Finisher Service Manual. Remove the top cover assembly. Go to “Top cover assembly removal” on page 4-7. Remove the printer front door assembly. Go to “Printer front door assembly removal”...
Page 184: Operator Panel Assembly Removal
4024-110 Operator panel assembly removal Warning: In the event of replacement of any one of the following components: • Operator panel assembly • RIP card assembly Replace only one component at a time. Replace the required component, and perform a POR before replacing a second component listed above.
Page 185: Top Cover Assembly Removal
4024-110 Top cover assembly removal Note: First, remove the bridge unit and the finisher, if equipped. Remove the operator panel assembly. See “Operator panel assembly removal” on page 4-6. Remove the printer front door assembly. See “Printer front door assembly removal” on page 4-8.
Page 186: Printer Front Door Assembly Removal
4024-110 Printer front door assembly removal Open the printer front door assembly (A). Remove the front door support strap (B) securing the printer front door assembly (A) to the printer by releasing the plastic hook. With the front door support strap (B) disconnected, place the printer front door assembly (A) in the lower most position.
Page 187: Front Door Support Strap And Front Door Magnetic Catch Removal
4024-110 Front door support strap and front door magnetic catch removal Remove the printer front door assembly. See “Printer front door assembly removal” on page 4-8. Remove the screw securing the front door support strap (A) to the printer front door assembly (B). Remove the front door support strap (A).
Page 188: Front Inner Cover Removal
4024-110 Front inner cover removal Remove the top cover assembly. See “Top cover assembly removal” on page 4-7. Remove the printer front door assembly. See “Printer front door assembly removal” on page 4-8. Remove the front left cover. See “Printer front left cover removal” on page 4-3.
Page 189: Right Upper Cover Removal
4024-110 Right upper cover removal Note: First, remove the bridge unit, finisher and finisher docking bracket, if equipped. Remove the two screws securing the right upper cover (A). Move the upper edge of the right upper cover (A) downward and outward as shown by the arrow. Move the lower edge of the right upper cover (A) downward to release the right upper cover (A).
Page 190: Right Lower Cover Removal
4024-110 Right lower cover removal Remove the right upper cover. See “Right upper cover removal” on page 4-11. Pull out media Tray 1 and media Tray 2. Remove the right lower cover (A) by lifting it upward then outward. Note: The right lower cover may take some force to remove. Rear 4-12 Printer Service Manual...
Page 191: Cable Hookup Door Removal
4024-110 Cable hookup door removal Open the cable hookup door (A). Slightly lift the top rear cover (B) upward in the direction of the arrow on its outer edge to release the upper boss on the cable hookup door (A). Release the lower boss from the option hookup door (A).
Page 192: Rear Motor Cover Removal
4024-110 Rear motor cover removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-125. Remove the two screws securing the rear motor cover (A). Open the rear motor cover (A) by swinging it outward in the direction of the arrow. Remove the rear motor cover (A).
Page 193: Rear Lower Cover Removal
4024-110 Rear lower cover removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-125. Remove the rear motor cover. See “Rear motor cover removal” on page 4-14. Remove the two screws securing the rear lower cover (A). Remove the rear lower cover (A).
Page 194: Option Hookup Cover Removal
4024-110 Option hookup cover removal Remove the option hookup cover (A) from the rear lower cover (B) by moving it outward in the direction of the arrow. 4-16 Printer Service Manual...
Page 195: Switch (Media Size) Removal
4024-110 Switch (media size) removal Note: This procedure can be applied to tray 1 or tray 2 switch (media size). Remove media Tray 1 and media Tray 2. Remove the screw securing the switch (media size) (A) to the bracket (B) inside the machine. Remove the connector from switch (media size) (A).
Page 196: Media Feed Unit Assembly 1 Removal
4024-110 Media feed unit assembly 1 removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-55. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-51. Remove printer left door assembly. See “Printer left door support strap removal”...
Page 197 4024-110 Release the plastic bosses on both ends of the vertical turn mylar guide (A). Remove the vertical turn mylar guide (A). Warning: The vertical turn mylar guide will take extra force to remove. Be careful not to damage it. Release the harness from the plastic clamps on the machine.
Page 198 4024-110 Remove the two screws securing the media feed unit assembly (B). Remove the media feed unit assembly (B) in the direction of the arrow. Clamp Front 4-20 Printer Service Manual...
Page 199: Media Feed Unit Assembly 2 Removal
4024-110 Media feed unit assembly 2 removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-55. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-51. Remove the printer left door assembly. See “Printer left door support strap removal”...
Page 200 4024-110 Release the plastic bosses on both ends of the vertical turn guide (A). Remove the vertical turn guide (A). Left 4-22 Printer Service Manual...
Page 201 4024-110 Release the harness from the plastic clamps on the machine. Disconnect the harness connector from the machine. Remove the two screws securing the media feed assembly (B). Remove the media feed assembly (B) in the direction of the arrow. Clamp Harness connector...
Page 202: Media Tray Side Guides Removal
4024-110 Media tray side 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 203 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) by sliding them toward the center of the media tray assembly, and lifting up. Front 4-25 Repair information...
Page 204 4024-110 Note: Before reinstalling the pinion gears (C), slide the front media tray guide assembly (D) and the rear media guide (E) to their outermost positions. Ensure the media side guides slide smoothly. Front 4-26 Printer Service Manual...
Page 205: Media Tray End Guide Removal
4024-110 Media tray end guide removal Remove the media tray. Remove the media tray side guides. See “Media tray side guides removal” on page 4-24. Remove the media side guide actuator (A). Front Hole Hook Lock lever Square hole 4-27 Repair information...
Page 206 4024-110 Turn the media tray assembly upside down, and remove the screw and the two hooks securing the actuator link (B) to the media tray. Release the boss on the media end guide actuator (C) from the hole in the actuator link (B) by moving the link in the direction of the arrow.
Page 207: Media Tray Lift Gear Group Removal
4024-110 Media tray lift gear group removal Remove the media tray from the machine. Remove the two screws securing bracket (A). Remove the bracket (A). Remove the tray lift coupling gear 13 tooth (B) from bracket (A). Remove the tray lift gear 13/60 tooth (C) from bracket (A). Rear Note: Extra force is required to pull the tray lift coupling gear 13 tooth (B) and the tray lift gear 13/60 tooth (C) from bracket (A).
Page 208: Media Feed Lift Motor Removal
4024-110 Media feed lift motor removal Remove the media feed unit. See “Media feed unit assembly 1 removal” on page 4-18 “Media feed unit assembly 2 removal” on page 4-21. Disconnect the harness from the media feed lift motor (A). Remove the two screws securing the media feed lift motor (A) to the media feed unit assembly (B).
Page 209: Tray Lift Coupling Assembly Removal
4024-110 Tray lift coupling assembly removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-55. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-51. Remove the printer left door. See “Printer left door support strap removal”...
Page 210: Tray Lift One Way Clutch / Gear Assembly Removal
4024-110 Tray lift one way clutch / gear assembly removal Remove the media feed unit assembly. Go to “Media feed unit assembly 1 removal” on page 4-18 “Media feed unit assembly 2 removal” on page 4-21. Remove the harness from the bracket (A). Remove the three screws securing the bracket (A) to the media feed unit assembly.
Page 211 4024-110 Remove the tray lift one-way gear 24 tooth (C). Harness Washer Rear Note: Before reinstalling, ensure all gears and washers are securely attached to the bracket (A). 4-33 Repair information...
Page 212: Media Feed Unit Drive Gear - 13 Tooth Removal
4024-110 Media feed unit drive gear - 13 tooth removal Remove the appropriate media feed unit assembly. See “Media feed unit assembly 1 removal” on page 4-18 “Media feed unit assembly 2 removal” on page 4-21. Remove the harness from the bracket (A). Remove the three screws securing the bracket (A) to the media feed unit assembly.
Page 213: Media Out Actuator Removal
4024-110 Media out actuator removal Remove the appropriate media feed unit assembly. See “Media feed unit assembly 1 removal” on page 4-18 “Media feed unit assembly 2 removal” on page 4-21. Remove the two bosses on the media out actuator (A) to the media feed unit assembly. Remove the media out actuator (A).
Page 214: Sensor (Media Level) Removal
4024-110 Sensor (media level) removal Remove the appropriate media feed unit assembly. See “Media feed unit assembly 1 removal” on page 4-18 “Media feed unit assembly 2 removal” on page 4-21. Disconnect the connector from the sensor (media level) (A). Release the hooks securing the sensor (media level) (A) to the media feed unit.
Page 215: Sensor (Media Out) Removal
4024-110 Sensor (media out) removal Remove the appropriate media feed unit assembly. See “Media feed unit assembly 1 removal” on page 4-18 “Media feed unit assembly 2 removal” on page 4-21. Remove the media out actuator. See “Media out actuator removal” on page 4-35.
Page 216: Sensor (Pre-Feed) Removal
4024-110 Sensor (pre-feed) removal Remove the appropriate media feed unit assembly. See “Media feed unit assembly 1 removal” on page 4-18 “Media feed unit assembly 2 removal” on page 4-21. Release the hook securing the sensor (pre-feed) (A). Remove the sensor (pre-feed) (A) from the feed unit front guide (B). Disconnect the connector from the sensor (pre-feed) (A).
Page 217: Media Feed Unit Drive Gear - 28 / 21 Tooth Removal
4024-110 Media feed unit drive gear - 28 / 21 tooth removal Remove the appropriate media feed unit assembly. See “Media feed unit assembly 1 removal” on page 4-18 “Media feed unit assembly 2 removal” on page 4-21. Remove the harness from the bracket (A). Remove the three screws securing the bracket (A) to the media feed unit assembly.
Page 218: Media Feed Unit Drive Gear - 29 Tooth Removal
4024-110 Media feed unit drive gear - 29 tooth removal Remove the appropriate media feed unit assembly. See “Media feed unit assembly 1 removal” on page 4-18 “Media feed unit assembly 2 removal” on page 4-21. Remove the harness from the bracket (A). Remove the three screws securing the bracket (A) to the media feed unit assembly.
Page 219 4024-110 Remove the media feed unit drive gear - 29 tooth (B). Harness Clamp Washer Rear Rear Note: Before reinstalling, ensure all gears and washers are securely attached to the bracket (A). 4-41 Repair information...
Page 220: Feed Roll Removal
4024-110 Feed roll removal Remove the media tray. 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). Hook Front 4-42...
Page 221: Feed Roll One Way Clutch Removal
4024-110 Feed roll one way clutch removal Remove the media tray. Remove the feed roll. See “Feed roll removal” on page 4-42. Remove the feed roll one way clutch (A) from the shaft (B). Front 4-43 Repair information...
Page 222: Feed Roll One Way Gear 22 Tooth Removal
4024-110 Feed roll one way gear 22 tooth removal Remove the media tray. Remove the feed roll. See “Feed roll removal” on page 4-42. Remove the feed roll one way clutch. See “Feed roll one way clutch removal” on page 4-43.
Page 223: Separation Roll One Way Friction Clutch Removal
4024-110 Separation roll one way friction clutch removal Remove the media tray. Remove the separation roll. See “Separation roll removal” on page 4-46. Remove the separation roll spacer (A) from the shaft (B). Remove the separation roll one-way friction clutch (C) from the shaft (B). Front 4-45 Repair information...
Page 224: Separation Roll Removal
4024-110 Separation roll removal Remove the media tray. 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). Remove the separation roll (B). Note: Do not touch the rubber surface of the feed roll (B). Front Note: Before reinstalling, do not touch the rubber surface of the separation roll (B).
Page 225: Pick Roll Idler Gear 33 Tooth Removal
4024-110 Pick roll idler gear 33 tooth removal Remove the media tray. Release the pick roll. See “Pick roll removal” on page 4-48. Remove the pick roll drive gear - 25 tooth. See “Pick roll drive gear 25 tooth removal” on page 4-49.
Page 226: Pick Roll Removal
4024-110 Pick roll removal Remove the media tray. Move the media feed unit 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). Hook Front Note: Before reinstalling, do not touch the rubber surface of the pick roll (B).
Page 227: Pick Roll Drive Gear 25 Tooth Removal
4024-110 Pick roll drive gear 25 tooth removal Remove the media tray. Remove the pick roll. See “Pick roll removal” on page 4-48. Remove the pick roll drive gear 25 tooth (A) from the shaft (B). Front 4-49 Repair information...
Page 228: Feed Unit Drive Gear 27 Tooth Removal
4024-110 Feed unit drive gear 27 tooth removal Remove the media feed unit assembly. See “Media feed unit assembly 1 removal” on page 4-18 “Media feed unit assembly 2 removal” on page 4-21. Remove the harness from the bracket (A). Remove the three screws securing the bracket (A) to the media feed unit assembly.
Page 229: Mpf Feed Unit Assembly Removal
4024-110 MPF feed unit assembly removal Remove the MPF rear cover. “MPF rear cover removal” on page 4-55. Disconnect the connector. Release the harness from the clamp. Remove the two screws securing the MPF feed unit assembly (A). Remove the MPF feed unit assembly (A). Clamp Left Note: Before reinstalling, place the harness along the slot on the left of the MPF feed unit assembly (A) so it...
Page 230: Mpf Media Out Actuator And Upper Frame Removal
4024-110 MPF media out actuator and upper frame removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-55. Remove the MPF feed unit assembly. “MPF feed unit assembly removal” on page 4-51. Remove the two hooks securing the upper frame (A). Remove the upper frame (A) by moving it up and out in the direction of the arrow.
Page 231: Sensor (Mpf Media Out) Removal
4024-110 Sensor (MPF media out) removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-55. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-51. Remove the two hooks securing the upper frame (A) to the MPF feed unit assembly. Remove the upper frame (A) by moving it up and out in the direction of the arrow.
Page 232: Mpf Transport Pinch Roll Assembly Removal
4024-110 MPF transport pinch roll assembly removal Remove the MPF rear cover. Go to “MPF rear cover removal” on page 4-55. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-51. Remove the two end screws securing the upper bracket (A) to the MPF feed unit assembly. Remove the upper bracket (A).
Page 233: Mpf Rear Cover Removal
4024-110 MPF rear cover removal Remove the screw securing the MPF rear cover (A). Remove the MPF rear cover (A). Connector Rear 4-55 Repair information...
Page 234: Mpf Feed Drive Gear Group Removal
4024-110 MPF feed drive gear group removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-55. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-51. Remove the pickup spring (A) from the idler gear bracket assembly (B). Note: Leave the pickup spring (A) attached to the MPF feed drive gear pickup (C).
Page 235: Mpf Pressure Pad Removal
4024-110 MPF pressure pad removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-55. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-51. Remove the MPF pick roll. See “MPF pick roll removal” on page 4-61.
Page 236: Mpf Transport Roll Assembly Removal
4024-110 MPF transport roll assembly removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-55. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-51. Remove the two end screws securing the upper bracket to the MPF feed unit assembly. Remove the upper bracket.
Page 237: Mpf Pick Solenoid / Pick Lever Removal
4024-110 MPF pick solenoid / pick lever removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-55. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-51. Remove the MPF feed drive gear group. See “MPF feed drive gear group removal”...
Page 238: Mpf Feed Shaft Assembly Removal
4024-110 MPF feed shaft assembly removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-55. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-51. Remove the MPF pick roll. See “MPF pick roll removal”...
Page 239: Mpf Pick Roll Removal
4024-110 MPF pick roll removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-55. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-51. Remove the two end screws securing the upper bracket (A) to the MPF feed unit assembly. Remove the upper bracket (A).
Page 240: Mpf Fold Down Tray Assembly Removal
4024-110 MPF fold down tray assembly removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-55. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-51. Remove the MPF upper frame. See “MPF media out actuator and upper frame removal”...
Page 241 4024-110 Disconnect the connector leading to the MPF fold down tray assembly (E). Raise the MPF fold down tray assembly (E) to its upright position, and slide it to the side. Remove the MPF fold down tray assembly (E). Note: Before reinstalling the idler gear bracket assembly (B), ensure the wiring is not pinched. Front 4-63 Repair information...
Page 242: Vertical Drive Gear Assembly
4024-110 Vertical drive gear assembly Remove the MPF rear cover. See “MPF rear cover removal” on page 4-55. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-51. Remove the printer left door assembly. See “Printer left door support strap removal”...
Page 243: Switch (Left Lower Door Interlock)
4024-110 Switch (left lower door interlock) Remove the MPF rear cover. See “MPF rear cover removal” on page 4-55. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-51. Remove the printer left door assembly. See “Printer left door support strap removal”...
Page 244: Media Transport Roll Assembly / Gear Removal
4024-110 Media transport roll assembly / gear removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-55. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-51. Remove the printer left door assembly. See “Printer left door support strap removal”...
Page 245: Printer Left Lower Door Assembly Removal
4024-110 Printer left lower door assembly removal Open the printer left lower door assembly. Remove the two screws securing the bracket (A). Remove the bracket (A). Pull the cap of the hinge pin (B) out with a prying tool to remove the hinge pin (B) from the bracket (A). Remove the hinge pin (B).
Page 246: Printer Left Lower Pinch Roll Assembly Removal
4024-110 Printer left lower pinch roll assembly removal Open the printer left lower door assembly. Remove the two screws securing the left lower pinch roll assembly (A) to the printer left lower door assembly (B). Note: The media guide (C) can be slightly lifted to gain better access to the attaching screws. Release the two hooks securing the left lower pinch roll assembly (A) to the printer left lower door assembly (B).
Page 247: Left Lower Door Handle Assembly Removal
4024-110 Left lower door handle assembly removal Open the printer left lower door assembly. Remove the left lower pinch roll assembly. See “Printer left door support strap removal” on page 4-71. Remove the left lower door handle (A). Remove the spring (B). 4-69 Repair information...
Page 248: Transfer Roll Assembly Removal
4024-110 Transfer roll assembly removal Open the printer left door assembly. Release the two plastic hooks on the transfer roll assembly (A). Remove the transfer roll assembly (A) by lifting it upward. Note: When removing the transfer roll assembly (A), do not touch the roll surface. Hook Hook Left...
Page 249: Printer Left Door Support Strap Removal
4024-110 Printer left door support strap removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-55. Open the printer left door assembly (A). Remove the screw securing the printer left door support strap (B) to the printer left door (A). Remove the e-clip securing the shaft (C) to the printer.
Page 250: Printer Left Door Assembly Removal
4024-110 Printer left door assembly removal Note: First, remove the duplex unit assembly, if equipped. Open the printer left door assembly. Remove the screw securing the left door support strap (A) to the printer left door assembly (B). Remove the printer left door assembly (B) by lowering it then lifting upward. 4-72 Printer Service Manual...
Page 251: Switch (Printer Left Door Interlock) Removal
4024-110 Switch (printer left door interlock) removal Remove the rear motor cover. See “Rear motor cover removal” on page 4-14. Open the printer left door assembly. Remove the screw securing the bracket (A) to the printer. Remove the bracket (A). Disconnect the connector from the switch (printer left door interlock) (B).
Page 252: Transfer Roll Guide Assembly Removal
4024-110 Transfer roll guide assembly removal Open the printer left door assembly. Remove the printer left door assembly. See “Printer left door support strap removal” on page 4-71. Remove the transfer roll assembly. See “Transfer roll assembly removal” on page 4-70.
Page 253: Printer Left Door Assembly Handle Removal
4024-110 Printer left door assembly handle removal Open the printer left door assembly. Remove the printer left door assembly. See “Printer left door support strap removal” on page 4-71. Remove the transfer roll guide assembly. See “Transfer roll guide assembly removal” on page 4-74.
Page 254: Registration Roll Assembly Removal
4024-110 Registration roll assembly removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-55. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-51. Remove the printer left door assembly. See “Printer left door support strap removal”...
Page 255: Registration Clutch Assembly Removal
4024-110 Registration clutch assembly removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-55. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-51. Remove the printer left door assembly. See “Printer left door support strap removal”...
Page 256: Sensor (Registration) Removal
4024-110 Sensor (registration) removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-55. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-51. Remove the printer left door assembly. See “Printer left door support strap removal” on page 4-71.
Page 257: Transport Clutch Assembly Removal
4024-110 Transport clutch assembly removal Remove the rear RIP card cover. See “RIP card assembly removal” on page 4-126. Remove the rear motor cover. See “Rear motor cover removal” on page 4-14. Remove the two screws securing the bracket (A). Disconnect the connector leading to the transport clutch assembly (B).
Page 258 4024-110 Release the hooks securing the front bushing (D) to the frame. Remove the front bushing (D). Release the hooks securing the rear bushing (E) from the bracket (A). Remove the rear bushing (E). Left E-clip Note: Before reinstalling, the notch of the transport clutch assembly (B) must be placed over the boss of the bracket (A).
Page 259: Sensor (Tray 2 Feed-Out) Removal
4024-110 Sensor (tray 2 feed-out) removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-55. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-51. Remove the printer left door assembly. See “Printer left door support strap removal”...
Page 260: Switch (Pc Cartridge Interlock) Removal
4024-110 Switch (PC cartridge interlock) removal Remove the front left cover. See “Printer front left cover removal” on page 4-3. Remove the top cover assembly. See “Top cover assembly removal” on page 4-7. Remove the PC cartridge. Remove the toner cartridge. Remove the printer front door assembly.
Page 261 4024-110 Remove the two screws securing the laser opening guide (B). Release the harness from the clamp on the laser opening guide (B). Disconnect the connector from the laser opening guide (B). Front 4-83 Repair information...
Page 262 4024-110 Remove the laser opening guide (B) by lifting it upward then outward in the direction of the arrow. Remove the four screws securing the PC cartridge guide (C). Guide assembly Screws Left view Guide assembly Connector Cover Left Harness assembly 4-84 Printer Service Manual...
Page 263 4024-110 Slide the PC cartridge guide (C) toward the left side and disconnect the connector from the PC cartridge sensor connector. Remove the two hooks securing the transfer roll power contact (E). While pressing the PC cartridge drive coupler (F), lift the front side of the PC cartridge guide assembly (C) upward.
Page 264 4024-110 Lift the right side of the PC cartridge guide assembly (C). Remove the screw (G) securing the switch (PC cartridge interlock) (H) to the PC cartridge guide assembly (C). Remove the switch (PC cartridge interlock) (H). Connector Front Remove the PC cartridge guide assembly (C) from the printer. 4-86 Printer Service Manual...
Page 265: Sensor (Humidity And Temperature) Removal
4024-110 Sensor (humidity and temperature) removal Remove the front left cover. See “Printer front left cover removal” on page 4-3. Remove the top cover assembly. See “Top cover assembly removal” on page 4-7. Remove the PC cartridge. Remove the toner cartridge. Remove the printer front door assembly.
Page 266 4024-110 Remove the two screws securing the laser opening guide (B). Release the harness from the clamp on the laser opening guide (B). Disconnect the connector from the laser opening guide (B). Remove the laser opening guide (B) by lifting it upward then outward in the direction of the arrow. Clamps Connector 4-88...
Page 267 4024-110 Remove the four screws securing the PC cartridge guide (D). Guide assembly Screws Left view Guide assembly Connector Cover Left Harness assembly 4-89 Repair information...
Page 268 4024-110 Slide the PC cartridge guide (D) toward the left side, and disconnect the connector from the PC cartridge sensor connector (E). Remove the two hooks securing the transfer roll power contact (F). Hook Hook Left 4-90 Printer Service Manual...
Page 269 4024-110 While pressing the PC cartridge drive coupler (G), lift the front side of the PC cartridge guide (C) upward. Disconnect the connector from the sensor (humidity and temperature) (H). Remove the screw securing the sensor (humidity and temperature) (H) to the PC cartridge guide (C). Remove the sensor (humidity and temperature) (H).
Page 270: Sensor (Rfid Pc Cartridge) And Sensor (Rfid Toner Cartridge) Removal
4024-110 Sensor (RFID PC cartridge) and sensor (RFID toner cartridge) removal Note: This removal applies to the sensor (RFID PC cartridge) (A) and the sensor (RFID toner cartridge) (B). Remove the top cover assembly. See “Top cover assembly removal” on page 4-7.
Page 271: Toner Cartridge Guide Assembly Removal
4024-110 Toner cartridge guide assembly removal Remove the front left cover. See “Printer front left cover removal” on page 4-3. Remove the top cover assembly. See “Top cover assembly removal” on page 4-7. Remove the PC cartridge. Remove the toner cartridge. PC cartridge Front Toner cartridge...
Page 272 4024-110 Disconnect the two harnesses from the toner cartridge guide assembly (A), one on the right and one on the left. Remove the harnesses from the clamps. Remove the two screws on the front of the printer securing the toner cartridge guide assembly (A). Open the printer left door assembly.
Page 273: Toner Add Motor Assembly Removal
4024-110 Toner add motor assembly removal Remove the front left cover. See “Printer front left cover removal” on page 4-3. Remove the top cover assembly. See “Top cover assembly removal” on page 4-7. Remove the PC cartridge. Remove the toner cartridge. Remove the printer front door assembly.
Page 274: Fuser Cooling Fan Removal
4024-110 Fuser cooling fan removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-125. Remove the rear motor cover. See “Rear motor cover removal” on page 4-14. Disconnect the connector from the fuser cooling fan (A) from the dual drive motor assembly (B). Release the two hooks securing the fuser cooling fan (A) to the fan duct (C).
Page 275: Printhead Assembly Removal
4024-110 Printhead assembly removal Remove the top cover assembly. See “Top cover assembly removal” on page 4-7. Open the printer front door assembly. See “Printer front door assembly removal” on page 4-8. Remove the PC cartridge. Remove the toner cartridge. Remove the printer front door assembly.
Page 276 4024-110 Disconnect the three connectors from the printhead assembly (A). Disconnect the connector from the junction harness. Remove the four screws securing the printhead assembly (A). Remove the printhead assembly (A) by lifting it upward. Rear Connectors Junction harness Front 4-98 Printer Service Manual...
Page 277: Pc Cartridge Cooling Fan Duct Removal
4024-110 PC cartridge cooling fan duct removal Remove the top cover assembly. See “Top cover assembly removal” on page 4-7. Disconnect the harness from the duct connector. Release the connector harness from the clamp on the PC cartridge cooling fan duct (A). Release the hook securing the PC cartridge cooling fan duct (A) to the toner cartridge guide assembly (B).
Page 278 4024-110 Move the PC cartridge cooling fan duct (A) in the direction of the arrow while lifting the left side, to release the hook securing it to the toner cartridge guide assembly (B). Remove the PC cartridge cooling fan duct (A). Connector Hooks Connector...
Page 279: Pc Cartridge Cooling Fan Removal
4024-110 PC cartridge cooling fan removal Remove the top cover assembly. See “Top cover assembly removal” on page 4-7. Remove the PC cartridge cooling fan duct. See “PC cartridge cooling fan duct removal” on page 4-99. Disconnect the harness of the PC cartridge cooling fan (A) to the PC cartridge cooling fan duct (B). Release two hooks securing the PC cartridge cooling fan (A) to the PC cartridge cooling fan duct (B).
Page 280: Sensor (Fuser Exit) Removal
4024-110 Sensor (fuser exit) removal Open the printer left door assembly. Remove the fuser unit. See “Fuser unit assembly removal” on page 4-103. Disconnect the connector from the sensor (fuser exit) (A). Remove the screw securing the bracket (B). Remove the three hooks securing the sensor (fuser exit) (A) to the bracket (B). Remove the sensor (fuser exit) (A).
Page 281: Fuser Unit Assembly Removal
4024-110 Fuser unit assembly removal Open the printer left cover assembly. Loosen the two colored knobs securing the fuser unit (A). Pull on the two colored handles to remove the fuser unit (A). Left Handle Knob 4-103 Repair information...
Page 282: Exit 1 Media Shift Assembly Removal
4024-110 Exit 1 media shift assembly removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-125. Remove the rear motor cover. See “Rear motor cover removal” on page 4-14. Remove the top rear cover. See “Top cover assembly removal”...
Page 283 4024-110 Disconnect the two connectors from the exit 1 media shift assembly (B). Remove the two screws securing the exit 1 media shift assembly (B) to the printer. Remove the exit 1 media shift assembly (B) by lifting it upward and outward in the direction of the arrow. Remove the two screws securing the exit 1 media shift assembly (B).
Page 284 4024-110 Reinstallation procedure for the bracket (A): Release the hooks securing the plastic guide (C) that is attached to the bracket (A). Remove the plastic guide (C) from the bracket (A). Install the bracket (A). Install the plastic guide (C) and the standard bin full exit 1 actuator shaft (D) at the same time. Make sure the standard bin full exit 1 actuator shaft (D) operates smoothly without binding.
Page 285: Media Shift Motor Removal
4024-110 Media shift motor removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-125. Remove the rear motor cover. See “Rear motor cover removal” on page 4-14. Remove the top rear cover. See “Top rear cover removal” on page 4-4.
Page 286: Sensor (Exit 1 Media Shift) Removal
4024-110 Sensor (exit 1 media shift) removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-125. Remove the rear motor cover. Remove the top rear cover. See “Top rear cover removal” on page 4-4. Open the printer left door assembly.
Page 287: Sensor (Exit 1 Bin Full) Removal
4024-110 Sensor (exit 1 bin full) removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-125. Remove the rear motor cover. See “Rear motor cover removal” on page 4-14. Remove the top rear cover. See “Top rear cover removal”...
Page 288: Exit 1 Media Shift Gear Removal
4024-110 Exit 1 media shift gear removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-125. Remove the rear motor cover. See “Rear motor cover removal” on page 4-14. Remove the top rear cover. See “Top rear cover removal”...
Page 289 4024-110 Slide the shift assembly (C) in order to release the shift assembly boss from the exit 1 media shift gear (D). Remove the exit 1 media shift gear (D) by lifting it upward. Rear Right Boss 4-111 Repair information...
Page 290: Standard Exit 1 Top Cover Removal
4024-110 Standard exit 1 top cover removal Remove the standard exit 1 top cover (A) by moving it toward the rear, then lifting it upward in the direction of the arrow. Rear 4-112 Printer Service Manual...
Page 291: Exit 1 Drive Belt Removal
4024-110 Exit 1 drive belt removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-125. Remove the rear motor cover. See “Rear motor cover removal” on page 4-14. Remove the standard exit top cover. See “Standard exit 1 top cover removal”...
Page 292: Dual Drive Motor Assembly Removal
4024-110 Dual drive motor assembly removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-125. Remove the rear motor cover. See “Rear motor cover removal” on page 4-14. Remove the exit 1 top cover. See “Standard exit 1 top cover removal”...
Page 293: High Voltage Power Supply (Hvps) Card Removal
4024-110 High voltage power supply (HVPS) card removal Remove the front left cover. See “Printer front left cover removal” on page 4-3. Remove the top cover assembly. See “Top cover assembly removal” on page 4-7. Remove the PC cartridge. Remove the printer front door assembly. See “Printer front door assembly removal”...
Page 294: Switch (Main Power) Removal
4024-110 Switch (main power) removal Remove the top cover assembly. See “Top cover assembly removal” on page 4-7. Open the printer front door assembly. Remove the right upper cover. See “Right upper cover removal” on page 4-11. Remove the screw securing the bracket (A). Slide the bracket (A) to the side and then upward in the direction of the arrow.
Page 295: Exit Interface Card Assembly Removal
4024-110 Exit interface card assembly removal Remove the top cover assembly. See “Top cover assembly removal” on page 4-7. Disconnect all the connectors from the exit interface card assembly (A). Note: Connector P430 has a hook that must first be released. Remove the two screws securing the exit interface card assembly (A).
Page 296 4024-110 Remove the exit 2 card assembly (A). P433 P434 P432 P430 P431 4-118 Printer Service Manual...
Page 297: Printer Engine Card Assembly Removal
4024-110 Printer engine card assembly removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-125. Remove the rear motor cover. See “Rear motor cover removal” on page 4-14. Remove the rear lower cover. See “Rear lower cover removal”...
Page 298: Low Voltage Power Supply (Lvps) Card Assembly Removal
4024-110 Low voltage power supply (LVPS) card assembly removal Remove the right upper cover. See “Right upper cover removal” on page 4-11. Disconnect the connectors from the LVPS card assembly (A). Note: The connectors P1, P2, P4, P6, P521, and P526 have hooks that must first be released. Remove the nine screws securing the LVPS card assembly (A) to the printer.
Page 299 4024-110 Remove the LVPS card assembly (A). Note: Grasp the card by the edge; avoid touching the bottom of the LVPS assembly (A). P526 F401 P521 F001 P525 4-121 Repair information...
Page 300: Ac Power Input Socket Assembly Removal
4024-110 AC power input socket assembly removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-125. Remove the rear motor cover. See “Rear motor cover removal” on page 4-14. Remove the rear lower cover. See “Rear lower cover removal”...
Page 301: Ac Power Input Socket Removal
4024-110 AC power input socket removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-125. Remove the rear motor cover. See “Rear motor cover removal” on page 4-14. Remove the rear lower cover. See “Rear lower cover removal”...
Page 302: Finisher Ac Output Removal
4024-110 Finisher AC output removal Remove the RIP card cover. See “Rear RIP card cover removal” on page 4-125. Remove the rear motor cover. See “Rear motor cover removal” on page 4-14. Remove the rear lower cover. See “Rear lower cover removal” on page 4-15.
Page 303: Rear Rip Card Cover Removal
4024-110 Rear RIP card cover removal Loosen the two screws securing the rear RIP card cover (A). Remove the rear RIP card cover (A) by moving it in the direction of the arrow. Rear 4-125 Repair information...
Page 304: Rip Card Assembly Removal
4024-110 RIP card assembly removal Warning: In the event of replacement of any one of the following components: • Operator panel assembly • RIP card assembly Replace only one component at a time. Replace the required component, and perform a POR before replacing a second component listed above.
Page 305: Component Locations
4024-110 5. Component locations Locations Printer boards HVPS LVPS Component locations...
Page 306: Printer Motors And Sensors
4024-110 Printer motors and sensors Sensor (fuser exit) Sensor (RFID toner cartridge) Toner add motor PC cartridge cooling fan HVPS Switch (main power) Switch (printer front door interlock) Printer Service Manual...
Page 307 4024-110 Sensor (exit 1 media shift HP) Sensor (standard bin full exit 1) Exit 1 media shift assembly Exit shift motor Fuser unit assembly Component locations...
Page 308 4024-110 Sensor (RFID PC cartridge) Registration Sensor (humidity and clutch temperature) Sensor (registration) Printer Service Manual...
Page 309 4024-110 Sensor (media level) Sensor (media out) Sensor (pre-feed) Switch (lower left door interlock) Sensor (tray 2 feed out) Component locations...
Page 310 4024-110 Switch (printer left door interlock) Fuser cooling fan Transport clutch PC cartridge motor Transport (Drum unit motor) motor HCF hookup connector Printer engine Switch (media size) card assembly Printer Service Manual...
Page 311: Printer Switches
4024-110 Printer switches Exit interface card assembly Switch (main power) HVPS card assembly Switch (printer front door interlock) Component locations...
Page 312: Cables
4024-110 Cables RFID Sensor Cable Main Power Switch Assembly Cable Assembly Fuser AC Cable Assembly Duplex Finisher Option Tray Printer Service Manual...
Page 313 4024-110 PC Cartridge cooling fan Switch (PC cartridge Interlock switch interlock) cable assembly HCF Hookup connector Multi Connect Cable Assembly 3 Media Size Switch Connects the following: Cable Assembly - LVPS - Toner add motor Multi Connect - Exit interface card assembly Cable Assembly 1 - Fuser cable assembly Connects the following:...
Page 314 4024-110 Multi Connect Cable Assembly 3 Connects the following: - LVPS - Toner add motor - Exit interface card assembly RIP Card - Fuser cable assembly Cable Assembly Dual drive Cable Assembly MPF Hookup Media Feed Unit Cable Assembly Cable Assembly Main AC Cable Main Finisher AC Cable Assembly...
Page 315 4024-110 Printhead Multi Connect Cable Assembly Cable Assembly 2 Connects the following: - Fuser sensor cable assembly - Transport clutch - Sensor (Tray 2 feed-out) - Switch (Printer left lower door interlock) 5-11 Component locations...
Page 316 4024-110 Exit Interface Cable Assembly 5-12 Printer Service Manual...
Page 317: Preventive Maintenance
Damaged, missing, or altered parts, especially in the area of the on/off switch and the power supply • 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 LEXMARK W8XX EVERY SERVICE CALL EVERY 300K NOTE MEDIA TRAY—PRINTER...
Page 318: Lubrication Specifications
4024-110 LEXMARK W8XX EVERY SERVICE CALL EVERY 300K NOTE: EXIT 2 (if equipped) Exit 2 Transport Roll Clean Water or alcohol Exit 2 Media Exit Roll Clean Water or alcohol FINISHER (if equipped) Bridge Unit Transport Belts Clean Water or alcohol...
Page 319: Parts Catalog
4024-110 7. Parts catalog How to use this parts catalog The following legend is used in the parts catalog: Assem Units/ Part bly- Units/mach kit or Description number Index • Assembly-index: Identifies the assembly and the item in the diagram. For example, 3-1 indicates Assembly 3 and the item number 1 in the table.
Page 320: Assembly 1: Covers And Operator Panel (1 Of 2)
4024-110 Assembly 1: Covers and operator panel (1 of 2) Printer Service Manual...
Page 321 4024-110 Assembly 1: Covers and operator panel (1 of 2) Assembly Part Units/ Units/ kit Description - Index number mach or pkg 40X5566 Operator panel assembly 40X5561 Operator panel controller card 40X5563 Operator panel cable 40X5564 Operator panel USB cable assembly 40X0553 Switch (printer front door interlock) 40X0558...
Page 322: Assembly 2: Covers
4024-110 Assembly 2: Covers Assembly Part Units/ Units/ kit Description - Index number mach or pkg 2–1 40X0566 Rear motor cover 40X2382 TVOC filter assembly 40X0565 Cable hookup door kit includes: • Cable hookup cover • Cable hookup door 40X0568 Option hookup cover 40X0567 Rear lower cover (110 V)
Page 323: Assembly 3: Media Feed Unit
4024-110 Assembly 3: Media feed unit Assembly Part Units/ Units/ kit Description - Index number mach or pkg 40X0570 Switch (media size) 40X0569 Media tray catch kit includes: • Media tray catch • Media tray slide (2 each) 40X0572 Vertical turn guide 40X0571 Vertical turn mylar guide Parts catalog...
Page 324: Assembly 4: Media Feed Unit Exploded (Tray 1 And Tray 2)
4024-110 Assembly 4: Media feed unit exploded (tray 1 and tray 2) Printer Service Manual...
Page 325 4024-110 Assembly 4: Media feed unit exploded (tray 1 and tray 2) Assembly Part Units/ Units/ kit Description - Index number mach or pkg 4–1 40X0581 Media feed unit assembly 40X0582 Media feed lift motor 40X0585 Media feed drive gear kit includes: •...
Page 326: Assembly 5: Media Tray
4024-110 Assembly 5: Media tray Printer Service Manual...
Page 327 4024-110 Assembly 5: Media tray Assembly Part Units/ Units/ kit Description - Index number mach or pkg 5–1 40X0573 Media tray assembly includes: (this comes assembled) • Media tray assembly • Labels (2 each) 40X0578 Media tray end guide kit includes: •...
Page 328: Assembly 6: Mpf Unit
4024-110 Assembly 6: MPF unit 7-10 Printer Service Manual...
Page 329 4024-110 Assembly 6: MPF unit Assem Part Units/ Units/ kit bly- Description number mach or pkg Index 6–1 40X0600 MPF rear cover 40X0599 MPF front cover 40X6000 MPF feed unit assembly 40X0608 MPF fold down tray assembly 40X0597 MPF unit cable assembly 40X0755 MPF pickup spring 40X0598...
Page 330: Assembly 7: Mpf Unit Feed
4024-110 Assembly 7: MPF unit feed 7-12 Printer Service Manual...
Page 331 4024-110 Assembly 7: MPF unit feed Assem Part Units/ Units/ kit bly- Description number mach or pkg Index 7–1 40X0605 MPF transport roll kit includes: • MPF transport shaft collar • MPF transport gear 18T • MPF transport roll assembly •...
Page 332: Assembly 8: Left Lower Door And Transport
4024-110 Assembly 8: Left lower door and transport 7-14 Printer Service Manual...
Page 333 4024-110 Assembly 8: Left lower door and transport Assem Part Units/ Units/ kit bly- Description number mach or pkg Index 8–1 40X0609 Vertical drive gear assembly 40X0610 Switch (left lower door interlock) 40X1386 Bushing 6 mm (transport roll rear) 40X1387 Transport roll kit includes: •...
Page 334: Assembly 9: Left Door And Transfer Roll
4024-110 Assembly 9: Left door and transfer roll 7-16 Printer Service Manual...
Page 335 4024-110 Assembly 9: Left door and transfer roll Assem Part Units/ Units/ kit bly- Description number mach or pkg Index 9–1 40X0553 Switch (printer left door interlock) 40X0618 PC cartridge shutter link 40X0617 Transfer roll power contact 40X0616 Transfer roll assembly 40X0619 Transfer roll guide assembly 7-17...
Page 336: Assembly 10: Printer Left Door
4024-110 Assembly 10: Printer left door 7-18 Printer Service Manual...
Page 337 4024-110 Assembly 10: Printer left door Assem Part Units/ Units/ kit bly- Description number mach or pkg Index 10–1 40X0620 Printer left door assembly (this comes assembled) 40X0624 Printer left door support strap 40X0623 Left door duplex entrance guide 40X0621 Printer left door assembly handle kit includes: •...
Page 338: Assembly 11: Registration
4024-110 Assembly 11: Registration 7-20 Printer Service Manual...
Page 339 4024-110 Assembly 11: Registration Assem Part Units/ Units/ kit bly- Description number mach or pkg Index 11–1 40X0629 Transport clutch assembly includes: • Bushing 4.5 mm front • Bushing 4.5 mm rear • Shaft • Transport clutch gear 19T • Transport clutch 40X0628 Registration mylar guide assembly 40X0625...
Page 340: Assembly 12: Printhead, Cartridge Guides, And Fans
4024-110 Assembly 12: Printhead, cartridge guides, and fans 7-22 Printer Service Manual...
Page 341 4024-110 Assembly 12: Printhead, cartridge guides, and fans Assem Part Units/ Units/ kit bly- Description number mach or pkg Index 12-1 40X0639 Toner add motor assembly 40X0640 Fuser cooling fan 40X0636 Sensor (RFID toner cartridge) 40X0641 Printhead assembly 40X0631 PC cartridge stop 40X0644 PC cartridge sensor connector 40X1390...
Page 342: Assembly 13: Fuser
4024-110 Assembly 13: Fuser 7-24 Printer Service Manual...
Page 343 4024-110 Assembly 13: Fuser Assem Part Units/ Units/ kit bly- Description number mach or pkg Index 13-1 40X0588 Sensor (fuser exit) 40X5931 Sensor (fuser exit) assembly with actuator 40X0647 Fuser assembly 110 V (this comes assembled) 40X0648 Fuser assembly 220 V (this comes assembled) 40X0646 Fuser assembly 100 V (this comes assembled) 7-25...
Page 344: Assembly 14: Standard Exit 1
4024-110 Assembly 14: Standard Exit 1 7-26 Printer Service Manual...
Page 345 4024-110 Assembly 14: Standard Exit 1 Assem Part Units/ Units/ kit bly- Description number mach or pkg Index 14-1 40X0649 Exit 1 media shift assembly (this comes assembled) 40X0655 Standard exit 1 top cover 40X0657 Standard bin full exit 1 actuator kit includes: •...
Page 346: Assembly 15: Dual Unit Drive Motor
4024-110 Assembly 15: Dual unit drive motor 7-28 Printer Service Manual...
Page 347 4024-110 Assembly 15: Dual unit drive motor Assem Part Units/ Units/ kit bly- Description number mach or pkg Index 15–1 40X0660 Dual drive motor assembly 40X0659 Exit 1 drive belt 40X0661 Drive belt flange 40X0658 MPF & transport roll idler gear kit includes: •...
Page 348: Assembly 16: Electrical
4024-110 Assembly 16: Electrical 7-30 Printer Service Manual...
Page 349: Assembly 17: Electrical Cables
4024-110 Assembly 16: Electrical Assem Part Units/ Units/ kit bly- Description number mach or pkg Index 16–1 40X0664 Exit interface card assembly 40X5562 RIP card assembly 40X0673 HCF hookup connector assembly 40X0672 Rear RIP card cover 40X0665 Printer engine card assembly 40X0670 AC power input socket kit includes: •...
Page 350: Assembly 17: Electrical Cables
4024-110 Assembly 17: Electrical cables assem Part Units/ Units/ kit bly- Description number mach or pkg Index 17–1 40X0686 RFID sensor cable assembly 40X0681 Fuser AC cable assembly 40X0684 Main switch cable assembly 7-32 Printer Service Manual...
Page 351: Assembly 18: Electrical Cables
4024-110 Assembly 18: Electrical cables Assem Part Units/ Units/ kit bly- Description number mach or pkg Index 18–1 40X0683 Interlock switch cable assembly 40X0673 HCF hookup connector assembly 40X0637 Multi connector cable assembly 1 40X0676 Media size switch cable assembly 40X0682 Multi connector cable assembly 3 40X1390...
Page 352: Assembly 19: Electrical Cables
4024-110 Assembly 19: Electrical cables Assem Part Units/ Units/ kit bly- Description number mach or pkg Index 19–1 40X0677 RIP card cable assembly 40X0685 Dual drive motor cable assembly 40X0674 Media feed unit cable assembly 40X0675 MPF hookup cable assembly 40X0670 AC power input socket kit includes: •...
Page 353: Assembly 20: Electrical Cables
4024-110 Assembly 20: Electrical cables Assem Part Units/ Units/ kit bly- Description number mach or pkg Index 20–1 40X0680 Multi connector cable assembly 2 40X0678 Printhead cable assembly 7-35 Parts catalog...
Page 354: Assembly 21: Electrical Cable
4024-110 Assembly 21: Electrical cable Assem Part Units/ Units/ kit bly- Description number mach or pkg Index 21–1 40X0679 Exit interface cable assembly 7-36 Printer Service Manual...
Page 355: Assembly 22: Power Cords
4024-110 Assembly 22: Power cords Assem Part Units/ Units/ kit bly- Description number mach or pkg Index 22–NS 40X0269 Power cord—USA ET AL 8ft right angle 40X0296 Power cord—Australia 6ft straight 40X0297 Power cord—USA ET AL 6ft straight 7-37 Parts catalog...
Page 356: Assembly 23: Miscellaneous
4024-110 Assembly 23: Miscellaneous Asm- Part Units/ Units/ kit Description Index number mach or pkg 23-NS 40X0956 Maintenance kit (110 V) • Fuser unit assembly • Transfer roll assembly • Feed rolls (4 each) • Pick rolls (4 each) • Separation rolls (4 each) 40X0957 Maintenance kit (220 V) •...
Page 357 4024-110 Index DUPLEX TESTS Quick Test acronyms Sensor Test EVENT LOG 3-18 Clear Log button test 3-17 Display Log 3-17 Print Log CACHE Test exiting code update FINISHER TESTS component locations 3-12 Sensor Test cables 3-11 Staple Test HVPS HARDWARE TESTS LVPS Button Test printer boards...
Page 358 4024-110 2-72 242.01 sensor (tray 2 feed-out) on jam (tray 2 feed) toner cartridge empty 2-36 2-74 toner cartridge near empty 2-38 2-74 2-75 242.02 sensor (registration) on jam (tray 2 feed) toner cartridge RFID failure 2-39 2-75 242.03 sensor (tray 2 feed-out) static jam toner cartridge set failure 2-40 2-76...
Page 359 4024-110 4-60 options and features MPF feed shaft assembly 4-51 description MPF feed unit assembly 4-62 output bin sensor tests MPF fold down tray assembly 3-10 4-52 standard bin MPF media out actuator and upper frame 4-59 MPF pick solenoid/pick lever 4-57 MPF pressure pad page count...
Page 360 4024-110 xiii safety information safety inspection guide scheduled maintenance 3-16 serial number 2-23 service checks Symptom tables 2-77 tray 1 media size mismatch in length system code tools required Top Margin 3-21 simplex (front side) Printer Service Manual...
Page 361: Part Number Index
4024-110 Part number index Description Page 40X0269 Power cord—USA ET AL 8ft right angle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37 40X0296 Power cord—Australia 6ft straight - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 362 4024-110 40X0605 MPF transport roll kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13 40X0606 MFP pick solenoid kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 363 4024-110 40X0675 MPF hookup cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-34 40X0676 Media size switch cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 364 4024-110 40X5566 Operator panel assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X5704 256MB Flash card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-38...
Page 365: Printer Service Manual
4024 Printer Service Manual Drum Sensor +3.3VDC JOPP1 Humidity & Temp) SIG-GND READY JSFP P1 +5VDC ESS READY +3.3VDC ENGINE READY PC Cartridge 12C DATA OP JUSBHF PRED +5V FUSED START Op-Panel Charge Transfer Transfer 12C CLK OP Roll Roll Roll PANEL INT R +3.3V...

This manual is also suitable for:

W850dn

Lexmark W850n Service Manual

Notices

Laser Notice

Lithium Warning

Safety Information

Preface

Conventions

General Information

Printer Overview

Tools Required for Service

Acronyms

Diagnostic Information

Start

Confirm the Installation Status

POR Sequence

Printer Operator Panel

Error Code Messages

Service Checks

PC Cartridge End of Life

Image Quality Trouble

Diagnostic Aids

Accessing Service Menus

Diagnostics Mode

100 C

B

S

Configuration Menu (CONFIG MENU)

T

Analyzing the Print Test

Control

Safety System Diagram

Repeating Defects

Repair Information

Handling ESD-Sensitive Parts

Removal Procedures

Printer Front Door Assembly Removal

Front Door Support Strap and Front Door Magnetic Catch Removal

Front Inner Cover Removal

Right Upper Cover Removal

Right Lower Cover Removal

Cable Hookup Door Removal

Rear Motor Cover Removal

Rear Lower Cover Removal

Option Hookup Cover Removal

Switch (Media Size) Removal

Media Feed Unit Assembly 1 Removal

Media Feed Unit Assembly 1 Removal

Media Feed Unit Assembly 2 Removal

Media Tray Side Guides Removal

Media Tray End Guide Removal

Media Tray Lift Gear Group Removal

Media Feed Lift Motor Removal

Tray Lift Coupling Assembly Removal

Tray Lift One Way Clutch / Gear Assembly Removal

Media Feed Unit Drive Gear - 13 Tooth Removal

Media out Actuator Removal

Sensor (Media Level) Removal

Sensor (Media Out) Removal

Sensor (Pre-Feed) Removal

Media Feed Unit Drive Gear - 28 / 21 Tooth Removal

Media Feed Unit Drive Gear - 29 Tooth Removal

Feed Roll Removal

Feed Roll One Way Clutch Removal

Feed Roll One Way Gear 22 Tooth Removal

Separation Roll One Way Friction Clutch Removal

Separation Roll Removal

Pick Roll Idler Gear 33 Tooth Removal

Pick Roll Removal

Pick Roll Drive Gear 25 Tooth Removal

Feed Unit Drive Gear 27 Tooth Removal

MPF Feed Unit Assembly Removal

MPF Media out Actuator and Upper Frame Removal

Sensor (MPF Media Out) Removal

MPF Transport Pinch Roll Assembly Removal

MPF Rear Cover Removal

MPF Feed Drive Gear Group Removal

MPF Pressure Pad Removal

MPF Transport Roll Assembly Removal

MPF Pick Solenoid / Pick Lever Removal

MPF Feed Shaft Assembly Removal