Lexmark W840 Service Manual
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Lexmark W840 Service Manual

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Lexmark
W840 Printer
4024-XXX
• 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.

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Summary of Contents for Lexmark W840

  • Page 1 ™ Lexmark W840 Printer 4024-XXX • 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. PostScript® is a registered trademark of Adobe Systems Incorporated.

  • Page 3: Table Of Contents

    4024-XXX Table of contents Notices ............. . . ix Laser notice .
  • Page 4 4024-XXX 921.00 Over heat temperature failure ..........2-48 922.00 Center thermistor failure .
  • Page 5 4024-XXX Diagnostic aids ............... . . Accessing service menus .
  • Page 6 4024-XXX Repair information ..............Handling ESD-sensitive parts .
  • Page 7 4024-XXX Printer left lower pinch roll assembly removal ........4-69 Left lower door handle assembly removal .
  • Page 8 4024-XXX Preventive maintenance ............. . . Safety inspection guide .

  • Page 9: Notices

    4024-XXX 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-XXX 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-XXX 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-XXX Printer Service Manual...

  • Page 13: Safety Information

    4024-XXX Safety information • The safety of this product is based on testing and approvals of the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. • The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others.
  • Page 14 4024-XXX 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-XXX 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-XXX Preface The service information for the Lexmark W840 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 •...

  • Page 17: General Information

    4024-XXX 1. General information About this manual This manual is a standard service manual containing information required for maintenance of the Lexmark ™ W840 (4024) laser printer. 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-XXX 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-XXX 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 EPROM Erasable Programmable Read-only Memory Electrostatic Discharge Field Replaceable Unit Gigabyte Ground Fault Interrupter...
  • Page 20 4024-XXX Printer Service Manual...

  • Page 21: Diagnostic Information

    4024-XXX 2. Diagnostic information Start CAUTION: Unplug the power cord from the printer or electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs peripherals. CAUTION: The printer weighs 47.7 kg (105 lb.) and requires at least two people to lift it safely.

  • Page 22: Confirm The Installation Status

    4024-XXX 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-XXX Printer operator panel The operator panel consists of the these items: • A 4-line, back-lit, 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. Display Menu Back...

  • Page 24: Error Code Messages

    4024-XXX 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 25 4024-XXX 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 26 4024-XXX 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 Check areas C, tray 3...
  • Page 27 4024-XXX Error code or Error contents Description/Action message 245.01 Sensor (tray 2 feed-out) on The sensor (tray 2 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 245.02...
  • Page 28 4024-XXX Error code or Error contents Description/Action message 282.00 Sensor (bridge unit media Sensor (finisher media entrance) is not turned on exit) 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 282.01...
  • Page 29 4024-XXX 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 30 4024-XXX 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 31 4024-XXX 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 32 4024-XXX 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 2-66. 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 33 4024-XXX 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 2-44. 913.00 Printhead assembly failure Rotation speed of the printhead motor is less than the specified value even when the specified time is...
  • Page 34 4024-XXX 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 35 4024-XXX 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 2-51. 930.00 Laser power failure Light intensity of the LD2 is less than the specified value.
  • Page 36 4024-XXX 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 950.00 EPROM mismatch failure This error code indicates a mismatch between the...
  • Page 37 4024-XXX Error code or Error contents Description/Action message 952.XX Interconnect card assembly A recoverable NVRAM Cyclic redundancy check NVRAM CRC failure (CRC) error occurred. Service NV failure Go to “952.XX Interconnect card assembly NVRAM CRC failure” on page 2-59. 953.XX Operator panel assembly NVRAM chip failure with operator panel assembly NVRAM failure...
  • Page 38 4024-XXX 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-XXX 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-XXX 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-XXX 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 2-69. Close door C 2TM/TTM left door assembly The 2TM/TTM door is open.

  • Page 42: Service Checks

    4024-XXX 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 2-70. standard output bin Remove Standard bin 2 full. Media in standard bin 2 is at maximum capacity.

  • Page 43: Sensor (Registration) Static On Jam

    4024-XXX Step Check Check the sensor (registration) connection. Replace the Replace the sensor connection. Is the sensor (registration) properly connected? (registration). Go to “Sensor (registration) removal” on page 4-79. Check the registration clutch for proper operation. Go to step 7. Go to step 6.

  • Page 44: Sensor (Fuser Exit) On Jam

    4024-XXX 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 4-120 201.00 Sensor (fuser exit) on jam Step Check Check the media position. Remove the media Go to step 2.

  • Page 45: Sensor (Fuser Exit) Off Jam

    4024-XXX Step Check Check the registration clutch connection. Replace the Replace the registration clutch. connection. Is the registration clutch properly connected? Go to “Registration clutch assembly removal” on page 4-78. Perform a print test. Replace the Problem solved. printer engine card Does the error continue? assembly.

  • Page 46: Sensor (Fuser Exit) Off (Too Short) Jam

    4024-XXX 202.01 Sensor (fuser exit) off (too short) jam Step Check Check the media position. Remove the media Go to step 2. 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 47: Sensor (Fuser Exit) Static Jam

    4024-XXX 202.02 Sensor (fuser exit) static jam Step Check Check the media position. Remove the media Go to step 2. Open the printer left door assembly and visually check it. Does the media touch the sensor (fuser exit). Open the printer left door assembly and visually check it.? Check the sensor (fuser exit) for operation.
  • Page 48 4024-XXX Step Check Check the sensor (fuser exit) for operation. Go to step 7. Go to step 6. 1. Enter Diagnostics mode. 2. Select BASE SENSOR TESTS. 3. Select Media Path. 4. Select Registration. Open the printer left door assembly and check it. Warning: The area around the actuator is very hot.

  • Page 49: Sensor (Exit 2) Off Jam

    4024-XXX 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 4-120. 203.01 Sensor (exit 2) off jam Step Check Check the media position. Remove the Go to step 2.

  • Page 50: Sensor (Pre-Feed) On Jam (Tray 1 Feed)

    4024-XXX Step Check Check the exit 2 motor for proper operation. Go to step 10. Go to step 9. 1. Enter Diagnostics mode. 2. Select MOTOR TESTS. 3. Select Tray2 drive mtr. Does the above motor rotate normally? Check the exit 2 motor connection. Replace the exit 2 Replace the unit assembly.

  • Page 51: Sensor (Registration) On Jam (Tray 1 Feed)

    4024-XXX Step Check Check the sensor (pre-feed) for proper operation in tray 1. Ensure the media Go to step 6. feed unit front 1. Enter Diagnostics mode. guide is installed 2. Select INPUT TRAY TESTS properly. 3. Select Sensor test Go to step 7.
  • Page 52 4024-XXX Step Check Check the media size setup. Go to step 3. Replace the media or change the Does the size of media in use match the size set for tray 1? media size setup. Check the rolls for tray 1. Go to step 4.

  • Page 53: Sensor (Pre-Feed) On Jam (Tray 2 Feed)

    4024-XXX 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 4-120. 242.00 Sensor (pre-feed) on jam (tray 2 feed) Step Check Check the media condition. Replace the media Go to step 2.

  • Page 54: Sensor (Tray 2 Feed-Out) On Jam (Tray 2 Feed)

    4024-XXX Step Check Check the media feed lift motor in tray 2 for proper Go to step 10. Go to step 8. operation. 1. Enter Diagnostics mode. 2. Select MOTOR TESTS. 3. Select Tray 2 feed mtr. Pull out tray 1, and check it. Does the media feed lift motor rotate normally.

  • Page 55: Sensor (Registration) On Jam (Tray 2 Feed)

    4024-XXX Step Check Check the media position. Remove the Go to step 5. media. Does the media touch the sensor (tray 2 feed-out) or the tray 2 media feed unit? Check the sensor (tray 2 feed-out) for proper operation. Go to step 7. Go to step 6.
  • Page 56 4024-XXX Step Check Check the roll 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, and pick roll free of excess wear and contamination? Go to “Feed roll...

  • Page 57: Sensor (Tray 2 Feed-Out) Static Jam

    4024-XXX 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 4-120. 242.03 Sensor (tray 2 feed-out) static jam Step Check Check the media position. Remove the Go to step 2.
  • Page 58 4024-XXX Step Check Check the media position. Remove the Go to step 4. media. Open the printer left door assembly, and visually check it. Does the media touch the sensor (registration)? Check the MPF media side guides for proper operation. Go to step 5.

  • Page 59: Rip Card Assembly Software Failure

    4024-XXX 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 4-120 900.XX RIP card assembly software failure Step Check Perform a POR. Go to step 2.

  • Page 60: Nvm Data Failure

    4024-XXX Step Check Perform a print test. Replace the Problem solved. printer engine card Does the error still occur? assembly. Go to “Printer engine card assembly removal” on page 4-120. 904.00 NVM data failure Step Check Perform a POR. Go to step 2. Perform several print tests.

  • Page 61: Cpu Power To Access Nvm Failure

    4024-XXX Step Check Perform a print test. Replace the Problem solved. printer engine card Does the error still occur? assembly. Go to “Printer engine card assembly removal” on page 4-120. 906.00 CPU power to access NVM failure Step Check Perform a POR. Go to step 2.

  • Page 62: Ppm Data Failure

    4024-XXX Step Check Check connector P419 on the printer engine card assembly. Replace the Replace the printer engine card connection. Is connector P419 on the printer engine card assembly assembly. properly connected? Go to “Printer engine card assembly removal” on page 4-120.

  • Page 63: Transport Motor Failure

    4024-XXX Step Check Check the dual drive motor assembly rotation operation. Go to step 4 Go to step 3. 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 connection.

  • Page 64: Pc Cartridge Unit Motor Failure

    4024-XXX 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 4-120. 912.00 PC cartridge unit motor failure Step Check Check the PC cartridge for installation. Go to step 2.

  • Page 65: Toner Add Motor Assembly Failure

    4024-XXX Step Check Check the printhead assembly connection. Replace the Replace the printhead. connection. Is the printhead assembly properly connected? Perform a print test. Replace the Problem solved. printer engine card Does the error continue? assembly. Go to “Printer engine card assembly removal”...

  • Page 66: Fuser Cooling Fan Failure

    4024-XXX 915.00 Fuser cooling fan failure Step Check Check the fuser cooling fan for installation. Go to step 2. Install the fuser cooling fan Is the fuser cooling fan installed securely? securely. Visually check the fuser cooling fan for rotation. Go to step 3.

  • Page 67: Sensor (Exit 1 Media Shift Hp) Failure

    4024-XXX 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 4-120. 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.

  • Page 68: Fuser Unit Assembly On Time Failure

    4024-XXX Step Check Perform a print test. Replace the Problem solved. printer engine card Does the error still occur? assembly Go to “Printer engine card assembly removal” on page 4-120. 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.

  • Page 69: Center Thermistor Failure

    4024-XXX Step Check Check the connection between the LVPS card assembly Replace the fuser Replace the P525 and the printer engine card assembly P401. unit assembly. connection. Are the cards connected properly? Perform a print test. Replace the Problem solved. printer engine card Does the error continue? assembly.

  • Page 70: Pressure Roll Thermistor Failure

    4024-XXX 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 71: Pc Cartridge Rfid Data Write Failure

    4024-XXX 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 72: Laser Power Failure

    4024-XXX 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 73: Toner Cartridge Rfid Communication Failure

    4024-XXX 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 4-120. 933.00 Toner cartridge RFID communication failure Step Check Check the toner cartridge installation. Go to step 2.

  • Page 74: Rip Card Assembly Communication Failure

    4024-XXX 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 75: Media Tray 2 Lift Up / No Media Tray Failure

    4024-XXX 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 tray 2 media tray 2 as it was.
  • Page 76 4024-XXX Step Check Check the tray 2 media feed lift motor connection. Go to step 6. Replace the connection. Is the tray 2 media feed lift motor properly connected? Check the tray 2 media feed lift motor for operation. • Reinstall the Go to step 7.

  • Page 77: Through 950.29 Eprom Mismatch Failure

    4024-XXX 950.00 through 950.29 EPROM mismatch failure Warning: When replacing any of the following components: • Operator panel assembly • RIP card assembly • Interconnect card assembly Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above.

  • Page 78: Through 950.60 Eprom Mismatch Failure

    4024-XXX 950.30 through 950.60 EPROM mismatch failure Warning: When replacing any of the following components: • Operator panel assembly • RIP card assembly • Interconnect card assembly Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above.

  • Page 79: Interconnect Card Assembly Nvram Crc Failure

    4024-XXX Step Check Perform a print test. Replace the Problem solved. printer engine card Does the error still occur? assembly. Go to “Printer engine card assembly removal” on page 4-120. 952.XX Interconnect card assembly NVRAM CRC failure Step Check Perform a POR. Go to step 2.

  • Page 80: Interconnect Card Assembly Nvram Failure

    4024-XXX Step Check Turn the printer off for 60 seconds. Replace the Problem solved. operator panel Does the error occur when the power is turned off/on again? assembly. Go to “Operator panel assembly removal” on page 4-6. Go to step 3. Perform a print test.

  • Page 81: Rip Card Assembly Nand Crc Failure

    4024-XXX Step Check Perform a print test. Replace the Problem solved. printer engine card Does the error still occur? assembly. Go to “Printer engine card assembly removal” on page 4-120. 955.XX RIP card assembly NAND CRC failure Step Check Perform a POR. Go to step 2.

  • Page 82: Rip Card Assembly Processor Over Temperature Failure

    4024-XXX Step Check Perform a print test. Printer engine Problem solved. card assembly Does the error still occur? Go to “Printer engine card assembly removal” on page 4-120. 956.01 RIP card assembly processor over temperature failure Step Check Perform a POR. Go to step 2.

  • Page 83: Exit Interface Card Assembly Communication Failure

    4024-XXX Step Check Perform a print test. Printer engine Problem solved. card Does the error still occur? assembly“Printer engine card assembly removal” on page 4-120. 980.03 Exit interface card assembly communication failure Step Check Check the exit interface card assembly for proper Go to step 2.

  • Page 84: No Media In The Select Media Tray

    4024-XXX Step Check Check the switch (media size) for installation. Go to step 4. Install the switch (media size) for Pull out the media tray to visually check it. each media tray correctly. Is the switch (media size) for media tray 1 and media tray 2 installed correctly? Check the switch (media size) connection for tray 1 and/or Replace the...

  • Page 85: Paper Is Installed (Short Edge) In The Media Paper Tray

    4024-XXX 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 4-120. 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...

  • Page 86: Pc Cartridge End Of Life

    4024-XXX 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 4-120. PC cartridge end of life Step Check Check the PC cartridge installation. Go to step 2.

  • Page 87: Pc Cartridge Set Failure

    4024-XXX 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 88: Printer Left Door Open

    4024-XXX 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 Perform a print test.

  • Page 89: Printer Left Lower Door Open

    4024-XXX 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 90: Standard Bin 1 Full

    4024-XXX 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 91: Toner Cartridge Empty

    4024-XXX Step Check Check the sensor (standard bin full exit 2) for operation. Go to step 5. Go to step 3. 1. Enter Diagnostics mode 2. Select BASE SENSOR TESTS 3. Select Exit level 4. Select Standard bin full 2 Does the display, on the operator panel, change every time the sensing area is blocked? Check the sensor (standard bin full exit 2) connection.

  • Page 92: Toner Cartridge Near Empty

    4024-XXX Step Check Check the sensor (RFID toner cartridge) for proper Replace the Replace the connection. sensor (RFID connection. toner cartridge). Go to “Toner cartridge guide assembly removal” on page 4-95 Check the toner add motor assembly for operation. Go to step 9. Go to step 8.

  • Page 93: Toner Cartridge Failure

    4024-XXX Step Check Check the toner add motor assembly for operation. Go to step 7. Go to step 6. Warning: Only perform this test in segments of three seconds or less or toner spill will occur. 1. Enter Diagnostics mode 2.

  • Page 94: Toner Cartridge Rfid Failure

    4024-XXX Toner cartridge RFID 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? cartridge)

  • Page 95: Tray 1 Media Size Failure

    4024-XXX Step Check Perform a print test. Replace the Problem solved. printer engine card Does the error still occur? assembly Go to “Printer engine card assembly removal” on page 4-120 Tray 1 media size failure Step Check Check the media. Go to step 2.

  • Page 96: Tray 1 Media Size Mismatch In Length

    4024-XXX Step Check Check the media. Go to step 3. Set the guides properly. Are the front media tray guide assembly, rear media tray guide, and media tray end guide of media tray 2 set correctly? Pull out media tray 2 to visually check it. Check the tray 2 switch (media size) 2 for proper Go to step 4.
  • Page 97 4024-XXX 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 guide assembly removal”...

  • Page 98: Tray 2 Media Size Mismatch In Length

    4024-XXX Tray 2 media size mismatch in length Step Check Check the media. Go to step 2. Load media properly. Pull out tray 2 to visually check it. Is media loaded in tray 2 properly? Check the media. Go to step 3. Set the guides properly.
  • Page 99 4024-XXX Step Check Check the sensor (registration) for operation. Go to step 11. Go to step 10. 1. Enter Diagnostics mode 2. Select BASE SENSOR TESTS 3. Select media path 4. Select Registration Open the printer left door assembly and check it. Does the display, on the operator panel, change every time the sensor actuator is operated? Check the sensor (registration) connection.

  • Page 100: Image Quality Trouble

    4024-XXX Image quality trouble Troubleshooting Note: First, get a printout as a base, follow the symptom table to identify the possible failing FRU’s. Image quality symptoms: • Faint print (low contrast) “Faint print (Low contrast) .” on page 2-81. • Blank print (no print) “Blank print (no print)”...

  • Page 101: Image Quality

    4024-XXX 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 print test.
  • Page 102 4024-XXX 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 103: Blank Print (No Print)

    4024-XXX Blank print (no print) 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 the transfer roll assembly.
  • Page 104 4024-XXX 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 105: Solid Black

    4024-XXX 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 the HVPS card assembly.
  • Page 106 4024-XXX Vertical blank lines (white stripes in media transport direction) 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? Is the media transfer route and the media path clear of Go to step 3.
  • Page 107 4024-XXX Step Check Check the heat roll and pressure roll. Replace the fuser Go to step 9. unit assembly. Remove the fuser unit assembly. Warning: Allow the fuser unit assembly to cool down. Is there contamination or cracks on the heat roll or pressure roll? Check the printer engine card assembly.

  • Page 108: Horizontal Band Printheads Out

    4024-XXX Horizontal band printheads out 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 109 4024-XXX 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. Problem solved.

  • Page 110: Vertical Stripes

    4024-XXX Vertical stripes 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. Remove debris contamination or debris? contamination.
  • Page 111 4024-XXX 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 112: Horizontal Stripes

    4024-XXX Horizontal stripes 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 113 4024-XXX 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. Problem solved.

  • Page 114: Partial Lack

    4024-XXX Partial lack 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 115 4024-XXX Spots 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 116: After Image

    4024-XXX After image 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. Re-print the defective image.

  • Page 117: Background (Fog)

    4024-XXX Background (fog) 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 118 4024-XXX Step Check Check the printer engine card assembly. Problem solved. Replace the RIP card assembly. Replace the printer engine card assembly. Go to “RIP card Perform a print test. assembly removal” on Does the error continue? page 4-127. 2-98 Printer Service Manual...
  • Page 119 4024-XXX Skew 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 120: Media Damage

    4024-XXX Media damage 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. Problem solved.

  • Page 121: No Fuse

    4024-XXX No fuse 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 122 4024-XXX Step Check Check the printer engine card assembly. Problem solved. Replace the RIP card assembly. Replace the printer engine card assembly. Go to “RIP card Perform a print test. assembly removal” on Does the error continue? page 4-127. 2-102 Printer Service Manual...

  • Page 123: Diagnostic Aids

    4024-XXX 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 124: Diagnostics Mode

    4024-XXX 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 Transport mtr Fuser cooling fan PC unit cooling fan...
  • Page 125 4024-XXX Diagnostics mode tests (continued) HARDWARE TESTS Panel Test “Panel Test” on page 3-6 Button Test “Button Test” on page 3-6 DRAM Test “DRAM Test” on page 3-7 CACHE Test Parallel Wrap “Parallel Wrap tests” on page 3-8 Parallel 1 Wrap (if installed) Parallel 2 Wrap (if installed) Serial 1 Wrap (if installed) “Serial Wrap tests”...

  • Page 126: Exiting Diagnostics Mode

    4024-XXX Diagnostics mode tests (continued) Par S Strobe Adj “Parallel strobe adjustment (Par x Strobe Adj)” on page 3-18 Par x Strobe Adj (if additional parallel options are installed) EVENT LOG Display Log “Display Log” on page 3-18 Print Log “Print Log”...

  • Page 127: Motor Tests

    4024-XXX 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 128: Hardware Tests

    4024-XXX 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 129: Dram Test

    4024-XXX 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 130: Parallel Wrap Tests

    4024-XXX Parallel Wrap tests This test is used with a wrap plug to check operation of the parallel port hardware. Each parallel signal is tested. Use Parallel Wrap for the standard parallel port or Parallel 1 Wrap if a parallel port is available by PCI slot 1. To run the Parallel Wrap tests: Disconnect the parallel interface cable, and install the wrap plug (P/N 1319128).

  • Page 131: Duplex Tests

    4024-XXX 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 132: Input Tray Tests

    4024-XXX 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 133: Output Bin Tests

    4024-XXX 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 134: Finisher Tests

    4024-XXX 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 135 4024-XXX 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 136: Base Sensor Test

    4024-XXX • 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 137: Device Tests

    4024-XXX 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 138: Printer Setup

    4024-XXX 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 139: Serial Number

    4024-XXX Serial Number The serial number can only be viewed and cannot be changed. To view the serial number: Select PRINTER SETUP from DIAGNOSTICS. Select Serial number from PRINTER SETUP. Press Back ( ) to return to PRINTER SETUP. Engine Setting 1 through 4 Warning: Do not change these settings unless requested to do so by your next level of support.

  • Page 140: 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. 3-18 Printer Service Manual...

  • Page 141: Exit Diagnostics

    4024-XXX 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 142: Configuration Menu (Config Menu)

    4024-XXX 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 143: Maintenance Page Count (Maint Cnt Value)

    4024-XXX Configuration Menu (continued) Tray Low Message “Tray Low Message” on page 3-26 Exit Config Menu “Exit Config Menu” on page 3-26 Some menus are not available, depending on the configuration of the printer. Maintenance page count (Maint Cnt Value) The current value for the maintenance page counter is displayed.

  • Page 144: Registration

    4024-XXX 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 145: Print Quality Pages (Prt Quality

    4024-XXX 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 146: Size Sensing

    4024-XXX 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) Tray 2 (integrated 500-sheet drawer) Tray 3 (optional 2TM 500-sheet drawer) Tray 4 (optional 2TM 500-sheet drawer) Tray 3 (optional TTM 850-sheet drawer)

  • Page 147: Ppds Emulation

    4024-XXX 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 148: Env Prompts

    4024-XXX 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 149: Analyzing The Print Test

    4024-XXX 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 150: Driving Force Transmission Path

    4024-XXX 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 151: Media Transport

    4024-XXX 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 Separation roll Separation roll Roll ASM-drive...
  • Page 152 4024-XXX 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 Option exit 2 Exit 2 media transport roll ASM Option duplex...

  • Page 153: Functions Of Main Components

    4024-XXX 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 154 4024-XXX 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 155 4024-XXX 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 156: Multi-Function Peripheral (Mpf)

    4024-XXX Multi-Function Peripheral (MPF) The MPF is a mechanical unit suppling media to the printer. The driving force from the transport motor of the dual drive motor assembly is transmitted to the MPF feed roll to feed media. MPF pick roll The MPF feed roll feeds media set on the MPF.

  • Page 157: Detecting Media Size

    4024-XXX 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 158: Transfer Roll Assembly

    4024-XXX 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 159 4024-XXX 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 CD card ASM Polygon mirror...

  • Page 160: Fuser

    4024-XXX Fuser Heat roll The heat roll is a hollow metal tube with a coated surface. This tube is heated by the inner heater rod. The heat is applied to the media passing between the heat roll and pressure roll, fusing the toner on the media. Pressure roll The pressure roll is a metal shaft coated with sponge rubber.
  • Page 161 4024-XXX 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 162: Exit

    4024-XXX 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 163: Drive

    4024-XXX 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 drum cartridge motor is a DC brushless motor that drives the drum cartridge, mag roll and transfer roll assembly.

  • Page 164: Electrical Components And Controller

    4024-XXX 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 165 4024-XXX Registration roll assembly The registration roll assembly feeds media from all trays to the PC cartridge or fuser. Switch (PC cartridge interlock) Switch (main power) Switch Switch (printer front (printer left door door interlock) interlock) Fuser cooling fan RIP card ASM Switch (printer left lower door interlock) Printer engine...

  • Page 166: Control

    4024-XXX 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 167: Printhead Control

    4024-XXX 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 168: Xerographic Process During A Print Cycle

    4024-XXX Xerographic Process During a Print Cycle Heat roll Pressure Fuser ASM roll Cleaning blade Charger roll Drum Laser beam Transfer roll PC cartridge Magnetic roll Paper 3-46 Printer Service Manual...
  • Page 169 4024-XXX 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. Charge roll HVPS (-VDC)
  • Page 170 4024-XXX 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 171 4024-XXX 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 172 4024-XXX 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 173 4024-XXX 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 174 4024-XXX 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 175: Safety System Diagram

    4024-XXX 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 176 4024-XXX 3-54 Printer Service Manual...

  • Page 177: Repair Information

    4024-XXX 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 178: Removal Procedures

    4024-XXX Removal procedures CAUTION: Remove the power cord from the printer or electrical outlet before connecting or disconnecting any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals. The printer weighs approximately 41 kg (90.2 lbs) and requires at least two people to lift it safely.

  • Page 179: Printer Front Left Cover Removal

    4024-XXX 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 one screw securing the front left cover (B) to the machine. Remove the front left cover (B).

  • Page 180: Top Rear Cover Removal

    4024-XXX Top rear cover removal Remove the cable hookup cover. “Cable hookup door removal” on page 4-14 Remove two screws securing the rear motor cover (A). Open and remove the rear motor cover (A). Remove one 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 181: Switch (Printer Front Door Interlock) Removal

    4024-XXX Switch (printer front door interlock) removal Note: First remove the bridge unit and finisher, if equipped. Refer to the Finisher Service Manual. Remove the top cover assembly. Go to“Top cover assembly removal” on page 4-8. Remove the printer front door assembly. Go to“Printer front door assembly removal”...

  • Page 182: Operator Panel Assembly Removal

    4024-XXX Operator panel assembly removal Warning: In the event of replacement of any one of the following components: • Operator panel assembly • RIP card assembly • Interconnect card assembly Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above.
  • Page 183 4024-XXX Hooks Repair information...

  • Page 184: Top Cover Assembly Removal

    4024-XXX Top cover assembly removal Note: First remove the bridge unit and 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 4-9.

  • Page 185: Printer Front Door Assembly Removal

    4024-XXX Printer front door assembly removal Open 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 186: Front Door Support Strap And Front Door Magnetic Catch Removal

    4024-XXX Front door support strap and front door magnetic catch removal Remove the printer front door assembly. See “Printer front door assembly removal” on page 4-9. Remove one screw securing the front door support strap (A) to the printer front door assembly (B). Remove the front door support strap (A).

  • Page 187: Front Inner Cover Removal

    4024-XXX Front inner cover removal Remove the top cover assembly. See “Top cover assembly removal” on page 4-8. Remove the printer front door assembly. See “Printer front door assembly removal” on page 4-9. Remove the front left cover. See “Printer front left cover removal” on page 4-3.

  • Page 188: Right Upper Cover Removal

    4024-XXX Right upper cover removal Note: First, remove the bridge unit, finisher and finisher docking bracket, if equipped. Remove 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 189: Right Lower Cover Removal

    4024-XXX Right lower cover removal Remove the right upper cover. See “Right upper cover removal” on page 4-12 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 4-13 Repair information...

  • Page 190: Cable Hookup Door Removal

    4024-XXX 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 191: Rear Motor Cover Removal

    4024-XXX Rear motor cover removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-127. 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 192: Rear Lower Cover Removal

    4024-XXX Rear lower cover removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-127. Remove the rear motor cover. See “Rear motor cover removal” on page 4-15. Remove the two screws securing the rear lower cover (A). Remove the rear lower cover (A).

  • Page 193: Option Hookup Cover Removal

    4024-XXX 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. 4-17 Repair information...

  • Page 194: Switch (Media Size) Removal

    4024-XXX 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 one screw securing the switch (media size) (A) to the bracket (B) inside the machine. Remove the connector from switch (media size) (A).

  • Page 195: Media Feed Unit Assembly 1 Removal

    4024-XXX Media feed unit assembly 1 removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-56. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-52. Remove printer left door assembly. See “Printer left door support strap removal”...
  • Page 196 4024-XXX 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 197 4024-XXX 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 4-21 Repair information...

  • Page 198: Media Feed Unit Assembly 2 Removal

    4024-XXX Media feed unit assembly 2 removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-56. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-52. Remove the printer left door assembly. See “Printer left door support strap removal”...
  • Page 199 4024-XXX Release the plastic bosses on both ends of the vertical turn guide (A). Remove the vertical turn guide (A). Left 4-23 Repair information...
  • Page 200 4024-XXX 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 201: Media Tray Side Guides Removal

    4024-XXX 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 202 4024-XXX 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 4-26 Printer Service Manual...
  • Page 203 4024-XXX Note: Before reinstalling the pinion gears (C), slide the front media tray guide assembly (D) and the rear media guide (E) to their outward most positions. Ensure the media side guides slide smoothly. Front 4-27 Repair information...

  • Page 204: Media Tray End Guide Removal

    4024-XXX Media tray end guide removal Remove the media tray. Remove the media tray side guides. See “Media tray side guides removal” on page 4-25. Remove the media side guide actuator (A). Front Hole Hook Lock lever Square hole 4-28 Printer Service Manual...
  • Page 205 4024-XXX Turn the media tray assembly upside down, and remove the screw and 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 206: Media Tray Lift Gear Group Removal

    4024-XXX 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 207: Media Feed Lift Motor Removal

    4024-XXX Media feed lift motor removal Remove the media feed unit. See “Media feed unit assembly 1 removal” on page 4-19 “Media feed unit assembly 2 removal” on page 4-22. 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 208: Tray Lift Coupling Assembly Removal

    4024-XXX Tray lift coupling assembly removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-56. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-52. Remove the printer left door. See “Printer left door support strap removal”...

  • Page 209: Tray Lift One Way Clutch / Gear Assembly Removal

    4024-XXX Tray lift one way clutch / gear assembly removal Remove the media feed unit assembly. Go to“Media feed unit assembly 1 removal” on page 4-19 “Media feed unit assembly 2 removal” on page 4-22. Remove the harness from the bracket (A). Remove the three screws securing the bracket (A) to the media feed unit assembly.
  • Page 210 4024-XXX 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). 4-34 Printer Service Manual...

  • Page 211: Media Feed Unit Drive Gear - 13 Tooth Removal

    4024-XXX Media feed unit drive gear - 13 tooth removal Remove the appropriate media feed unit assembly. See “Media feed unit assembly 1 removal” on page 4-19 “Media feed unit assembly 2 removal” on page 4-22. Remove the harness from the bracket (A). Remove the three screws securing the bracket (A) to the media feed unit assembly.

  • Page 212: Media Out Actuator Removal

    4024-XXX Media out actuator removal Remove the appropriate media feed unit assembly. See “Media feed unit assembly 1 removal” on page 4-19 “Media feed unit assembly 2 removal” on page 4-22. Remove the two bosses on the media out actuator (A) to the media feed unit assembly. Remove the media out actuator (A).

  • Page 213: Sensor (Media Level) Removal

    4024-XXX Sensor (media level) removal Remove the appropriate media feed unit assembly. See “Media feed unit assembly 1 removal” on page 4-19 “Media feed unit assembly 2 removal” on page 4-22. Disconnect the connector from the sensor (media level) (A). Release the hooks securing the sensor (media level) (A) to the media feed unit.

  • Page 214: Sensor (Media Out) Removal

    4024-XXX Sensor (media out) removal Remove the appropriate media feed unit assembly. See “Media feed unit assembly 1 removal” on page 4-19 “Media feed unit assembly 2 removal” on page 4-22. Remove the media out actuator. See “Media out actuator removal” on page 4-36.

  • Page 215: Sensor (Pre-Feed) Removal

    4024-XXX Sensor (pre-feed) removal Remove the appropriate media feed unit assembly. See “Media feed unit assembly 1 removal” on page 4-19 “Media feed unit assembly 2 removal” on page 4-22. 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 216: Media Feed Unit Drive Gear - 28 / 21 Tooth Removal

    4024-XXX 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 4-19 “Media feed unit assembly 2 removal” on page 4-22. Remove the harness from the bracket (A). Remove the three screws securing the bracket (A) to the media feed unit assembly.

  • Page 217: Media Feed Unit Drive Gear - 29 Tooth Removal

    4024-XXX Media feed unit drive gear - 29 tooth removal Remove the appropriate media feed unit assembly. See “Media feed unit assembly 1 removal” on page 4-19 “Media feed unit assembly 2 removal” on page 4-22. Remove the harness from the bracket (A). Remove the three screws securing the bracket (A) to the media feed unit assembly.
  • Page 218 4024-XXX 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). 4-42 Printer Service Manual...

  • Page 219: Feed Roll Removal

    4024-XXX 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). 4-43 Repair information...

  • Page 220: Feed Roll One Way Clutch Removal

    4024-XXX Feed roll one way clutch removal Remove the media tray. Remove the feed roll. See “Feed roll removal” on page 4-43. Remove the feed roll one way clutch (A) from the shaft (B). Front 4-44 Printer Service Manual...

  • Page 221: Feed Roll One Way Gear 22 Tooth Removal

    4024-XXX Feed roll one way gear 22 tooth removal Remove the media tray. Remove the feed roll. See “Feed roll removal” on page 4-43. Remove the feed roll one way clutch. See “Feed roll one way clutch removal” on page 4-44.

  • Page 222: Separation Roll One Way Friction Clutch Removal

    4024-XXX Separation roll one way friction clutch removal Remove the media tray. Remove the separation roll. See “Separation roll removal” on page 4-47. Remove the separation roll spacer (A) from the shaft (B). Remove the separation roll one-way friction clutch (C) from the shaft (B). Front 4-46 Printer Service Manual...

  • Page 223: Separation Roll Removal

    4024-XXX 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 224: Pick Roll Idler Gear 33 Tooth Removal

    4024-XXX Pick roll idler gear 33 tooth removal Remove the media tray. Release the pick roll. See “Pick roll removal” on page 4-49. Remove the pick roll drive gear - 25 tooth. See “Pick roll drive gear 25 tooth removal” on page 4-50.

  • Page 225: Pick Roll Removal

    4024-XXX 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 226: Pick Roll Drive Gear 25 Tooth Removal

    4024-XXX Pick roll drive gear 25 tooth removal Remove the media tray. Remove the pick roll. See “Pick roll removal” on page 4-49. Remove the pick roll drive gear 25 tooth (A) from the shaft (B). Front 4-50 Printer Service Manual...

  • Page 227: Feed Unit Drive Gear 27 Tooth Removal

    4024-XXX Feed unit drive gear 27 tooth removal Remove the media feed unit assembly. See “Media feed unit assembly 1 removal” on page 4-19 “Media feed unit assembly 2 removal” on page 4-22. Remove the harness from the bracket (A). Remove the three screws securing the bracket (A) to the media feed unit assembly.

  • Page 228: Mpf Feed Unit Assembly Removal

    4024-XXX MPF feed unit assembly removal Remove the MPF rear cover. “MPF rear cover removal” on page 4-56. 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 229: Mpf Media Out Actuator And Upper Frame Removal

    4024-XXX MPF media out actuator and upper frame removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-56. Remove the MPF feed unit assembly. “MPF feed unit assembly removal” on page 4-52. 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 230: Sensor (Mpf Media Out) Removal

    4024-XXX Sensor (MPF media out) removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-56. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-52. 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 231: Mpf Transport Pinch Roll Assembly Removal

    4024-XXX MPF transport pinch roll assembly removal Remove the MPF rear cover. Go to “MPF rear cover removal” on page 4-56. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-52. Remove the two end screws securing the upper bracket (A) to the MPF feed unit assembly. Remove the upper bracket (A).

  • Page 232: Mpf Rear Cover Removal

    4024-XXX MPF rear cover removal Remove the one screw securing the MPF rear cover (A). Remove the MPF rear cover (A). Connector Rear 4-56 Printer Service Manual...

  • Page 233: Mpf Feed Drive Gear Group Removal

    4024-XXX MPF feed drive gear group removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-56. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-52. 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 234: Mpf Pressure Pad Removal

    4024-XXX MPF pressure pad removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-56. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-52. Remove the MPF pick roll. See “MPF pick roll removal” on page 4-62.

  • Page 235: Mpf Transport Roll Assembly Removal

    4024-XXX MPF transport roll assembly removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-56. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-52. Remove the two end screws securing the upper bracket to the MPF feed unit assembly. Remove the upper bracket.

  • Page 236: Mpf Pick Solenoid / Pick Lever Removal

    4024-XXX MPF pick solenoid / pick lever removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-56. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-52. Remove the MPF feed drive gear group. See “MPF feed drive gear group removal”...

  • Page 237: Mpf Feed Shaft Assembly Removal

    4024-XXX MPF feed shaft assembly removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-56. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-52. Remove the MPF pick roll. See “MPF pick roll removal”...

  • Page 238: Mpf Pick Roll Removal

    4024-XXX MPF pick roll removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-56. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-52. Remove the two end screws securing the upper bracket (A) to the MPF feed unit assembly. Remove the upper bracket (A).

  • Page 239: Mpf Fold Down Tray Assembly Removal

    4024-XXX MPF fold down tray assembly removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-56. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-52. Remove the MPF upper frame. See “MPF media out actuator and upper frame removal”...
  • Page 240 4024-XXX 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. 4-64 Printer Service Manual...

  • Page 241: Vertical Drive Gear Assembly

    4024-XXX Vertical drive gear assembly Remove the MPF rear cover. See “MPF rear cover removal” on page 4-56. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-52. Remove the printer left door assembly. See “Printer left door support strap removal”...

  • Page 242: Switch (Left Lower Door Interlock)

    4024-XXX Switch (left lower door interlock) Remove the MPF rear cover. See “MPF rear cover removal” on page 4-56. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-52. Remove the printer left door assembly. See “Printer left door support strap removal”...

  • Page 243: Media Transport Roll Assembly / Gear Removal

    4024-XXX Media transport roll assembly / gear removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-56. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-52. Remove the printer left door assembly. See “Printer left door support strap removal”...

  • Page 244: Printer Left Lower Door Assembly Removal

    4024-XXX 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 245: Printer Left Lower Pinch Roll Assembly Removal

    4024-XXX 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 two hooks securing the left lower pinch roll assembly (A) to the printer left lower door assembly (B).

  • Page 246: Left Lower Door Handle Assembly Removal

    4024-XXX 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 4-72. Remove the left lower door handle (A). Remove the spring (B). 4-70 Printer Service Manual...

  • Page 247: Transfer Roll Assembly Removal

    4024-XXX 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 248: Printer Left Door Support Strap Removal

    4024-XXX Printer left door support strap removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-56. 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 249: Printer Left Door Assembly Removal

    4024-XXX 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. 4-73 Repair information...

  • Page 250: Switch (Printer Left Door Interlock) Removal

    4024-XXX Switch (printer left door interlock) removal Remove the rear motor cover. See “Rear motor cover removal” on page 4-15. Open the printer left door assembly. Remove the one screw securing the bracket (A) to the printer. Remove the bracket (A). Disconnect the connector from the switch (printer left door interlock) (B).

  • Page 251: Transfer Roll Guide Assembly Removal

    4024-XXX 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 4-72. Remove the transfer roll assembly. See “Transfer roll assembly removal” on page 4-71.

  • Page 252: Printer Left Door Assembly Handle Removal

    4024-XXX 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 4-72. Remove the transfer roll guide assembly. See “Transfer roll guide assembly removal” on page 4-75.

  • Page 253: Registration Roll Assembly Removal

    4024-XXX Registration roll assembly removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-56. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-52. Remove the printer left door assembly. See “Printer left door support strap removal”...

  • Page 254: Registration Clutch Assembly Removal

    4024-XXX Registration clutch assembly removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-56. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-52. Remove the printer left door assembly. See “Printer left door support strap removal”...

  • Page 255: Sensor (Registration) Removal

    4024-XXX Sensor (registration) removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-56. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-52. Remove the printer left door assembly. See “Printer left door support strap removal” on page 4-72.

  • Page 256: Transport Clutch Assembly Removal

    4024-XXX Transport clutch assembly removal Remove the rear RIP card cover. See “RIP card assembly removal” on page 4-127. Remove the rear motor cover. See “Rear motor cover removal” on page 4-15. Remove the two screws securing the bracket (A). Disconnect the connector leading to the transport clutch assembly (B).
  • Page 257 4024-XXX 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 258: Sensor (Tray 2 Feed-Out) Removal

    4024-XXX Sensor (tray 2 feed-out) removal Remove the MPF rear cover. See “MPF rear cover removal” on page 4-56. Remove the MPF feed unit assembly. See “MPF feed unit assembly removal” on page 4-52. Remove the printer left door assembly. See “Printer left door support strap removal”...

  • Page 259: Switch (Pc Cartridge Interlock) Removal

    4024-XXX 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 4-8. Remove the PC cartridge. Remove the toner cartridge. Remove the printer front door assembly.
  • Page 260 4024-XXX 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 4-84 Printer Service Manual...
  • Page 261 4024-XXX 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 Cover Left Harness assembly 4-85 Repair information...
  • Page 262 4024-XXX 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 263 4024-XXX Harness Left Clamps 4-87 Repair information...
  • Page 264 4024-XXX 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. 4-88 Printer Service Manual...

  • Page 265: Sensor (Humidity And Temperature) Removal

    4024-XXX 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 4-8. Remove the PC cartridge. Remove the toner cartridge. Remove the printer front door assembly.
  • Page 266 4024-XXX 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). Clamps Connector 4-90 Printer Service Manual...
  • Page 267 4024-XXX Remove the laser opening guide (B) by lifting it upward then outward in the direction of the arrow. Guide assembly Screws Left view Guide assembly Cover Left Harness assembly 4-91 Repair information...
  • Page 268 4024-XXX Remove the four screws securing the PC cartridge guide (D). 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). While pressing the PC cartridge drive coupler (G), lift the front side of the PC cartridge guide (C) upward.
  • Page 269 4024-XXX 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). Connector Left 4-93 Repair information...

  • Page 270: Sensor (Rfid Pc Cartridge) And Sensor (Rfid Toner Cartridge) Removal

    4024-XXX 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 4-8.

  • Page 271: Toner Cartridge Guide Assembly Removal

    4024-XXX 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 4-8. Remove the PC cartridge. Remove the toner cartridge. PC cartridge Front Toner cartridge...
  • Page 272 4024-XXX While moving the toner cartridge guide assembly (A) to the left, release the toner add chute (B) from the frame.Remove the toner cartridge guide assembly from the printer. Note: Remove all spilled toner from the printer. Note: Before reinstalling, ensure the shaft (C) on the toner cartridge guide assembly is inserted into the toner add motor assembly (D).

  • Page 273: Toner Add Motor Assembly Removal

    4024-XXX 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 4-8. Remove the PC cartridge. Remove the toner cartridge. Remove the printer front door assembly.

  • Page 274: Fuser Cooling Fan Removal

    4024-XXX Fuser cooling fan removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-127. Remove the rear motor cover. See “Rear motor cover removal” on page 4-15. 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-XXX Printhead assembly removal Remove the top cover assembly. See “Top cover assembly removal” on page 4-8. Open the printer front door assembly. See “Printer front door assembly removal” on page 4-9. Remove the PC cartridge. Remove the toner cartridge. Remove the printer front door assembly.
  • Page 276 4024-XXX Remove the printhead assembly (A) by lifting it upward. Rear Junction harness Front 4-100 Printer Service Manual...

  • Page 277: Pc Cartridge Cooling Fan Duct Removal

    4024-XXX PC cartridge cooling fan duct removal Remove the top cover assembly. See “Top cover assembly removal” on page 4-8. 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-XXX 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-XXX PC cartridge cooling fan removal Remove the top cover assembly. See “Top cover assembly removal” on page 4-8. Remove the PC cartridge cooling fan duct. See “PC cartridge cooling fan duct removal” on page 4-101. 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-XXX Sensor (fuser exit) removal Open the printer left door assembly. Remove the fuser unit. See “Fuser unit assembly removal” on page 4-105. 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-XXX 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 4-105 Repair information...

  • Page 282: Exit 1 Media Shift Assembly Removal

    4024-XXX Exit 1 media shift assembly removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-127. Remove the rear motor cover. See “Rear motor cover removal” on page 4-15. Remove the top rear cover. See “Top cover assembly removal”...
  • Page 283 4024-XXX Remove the exit 1 media shift assembly (B) by lifting it upward and outward in the direction of the arrow. Harness connectors Left Left Note: When reinstalling the bracket (A), first release the hooks securing the plastic guide (C) that is attached to the bracket (A).

  • Page 284: Media Shift Motor Removal

    4024-XXX Note: Make sure the standard bin 1 full shaft (E) operates smoothly without binding. Media shift motor removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-127. Remove the rear motor cover. See “Rear motor cover removal”...

  • Page 285: Sensor (Exit 1 Media Shift) Removal

    4024-XXX Sensor (exit 1 media shift) removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-127. 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 286: Sensor (Exit 1 Bin Full) Removal

    4024-XXX Sensor (exit 1 bin full) removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-127. Remove the rear motor cover. See “Rear motor cover removal” on page 4-15. Remove the top rear cover. See “Top rear cover removal”...

  • Page 287: Exit 1 Media Shift Gear Removal

    4024-XXX Exit 1 media shift gear removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-127. Remove the rear motor cover. See “Rear motor cover removal” on page 4-15. Remove the top rear cover. See “Top rear cover removal”...
  • Page 288 4024-XXX Remove the exit 1 media shift gear (D) by lifting it upward. Left 4-112 Printer Service Manual...
  • Page 289 4024-XXX Rear Right Boss 4-113 Repair information...

  • Page 290: Standard Exit 1 Top Cover Removal

    4024-XXX 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 Exit 1 drive belt removal Remove the rear RIP card cover. See “Rear RIP card cover removal”...
  • Page 291 4024-XXX Remove the exit 1 drive belt (B) from the exit 1 media shift assembly (D). Left side view Hook Rear Note: Press on the exit 1 drive belt (B) while slowly turning the motor (D) by hand. 4-115 Repair information...

  • Page 292: Dual Drive Motor Assembly Removal

    4024-XXX Dual drive motor assembly removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-127. Remove the rear motor cover. See “Rear motor cover removal” on page 4-15. Remove the exit 1 top cover. See “Standard exit 1 top cover removal”...

  • Page 293: High Voltage Power Supply (Hvps) Card Removal

    4024-XXX 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 4-8. Remove the PC cartridge. Remove the printer front door assembly. See “Printer front door assembly removal”...

  • Page 294: Switch (Main Power) Removal

    4024-XXX Switch (main power) removal Remove the top cover assembly. See “Top cover assembly removal” on page 4-8. Open the printer front door assembly. Remove the right upper cover. See “Right upper cover removal” on page 4-12. 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-XXX Exit interface card assembly removal Remove the top cover assembly. See “Top cover assembly removal” on page 4-8. 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: Printer Engine Card Assembly Removal

    4024-XXX Remove the exit 2 card assembly (A). P433 P434 P432 P430 P431 Printer engine card assembly removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-127. Remove the rear motor cover. See “Rear motor cover removal” on page 4-15.
  • Page 297 4024-XXX Remove the printer engine card assembly (A). Connector Rear 4-121 Repair information...

  • Page 298: Low Voltage Power Supply (Lvps) Card Assembly Removal

    4024-XXX Low voltage power supply (LVPS) card assembly removal Remove the right upper cover. See “Right upper cover removal” on page 4-12. 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-XXX 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 4-123 Repair information...

  • Page 300: Ac Power Input Socket Assembly Removal

    4024-XXX AC power input socket assembly removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-127. Remove the rear motor cover. See “Rear motor cover removal” on page 4-15. Remove the rear lower cover. See “Rear lower cover removal”...

  • Page 301: Ac Power Input Socket Removal

    4024-XXX AC power input socket removal Remove the rear RIP card cover. See “Rear RIP card cover removal” on page 4-127. Remove the rear motor cover. See “Rear motor cover removal” on page 4-15. Remove the rear lower cover. See “Rear lower cover removal”...

  • Page 302: Finisher Ac Output Removal

    4024-XXX Finisher AC output removal Remove the RIP card cover. See “Rear RIP card cover removal” on page 4-127. Remove the rear motor cover. See “Rear motor cover removal” on page 4-15. Remove the rear lower cover. See “Rear lower cover removal” on page 4-16.

  • Page 303: Rear Rip Card Cover Removal

    4024-XXX 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 RIP card assembly removal Warning: In the event of replacement of any one of the following components: •...

  • Page 304: Interconnect Card Assembly Removal

    4024-XXX Remove any screws securing the side of the RIP card assembly to the printer. Remove the RIP card assembly gently from the rear of the printer (A). Interconnect card assembly removal Warning: In the event of replacement of any one of the following components: •...
  • Page 305 4024-XXX 4-129 Repair information...
  • Page 306 4024-XXX 4-130 Printer Service Manual...

  • Page 307: Component Locations

    4024-XXX 5. Component locations Locations Printer boards HVPS LVPS Component locations...

  • Page 308: Printer Motors And Sensors

    4024-XXX Printer motors and sensors Printer Service Manual...
  • Page 309 4024-XXX 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 310 4024-XXX Sensor (RFID PC cartridge) Registration Sensor (humidity and clutch temperature) Sensor (registration) Printer Service Manual...
  • Page 311 4024-XXX Sensor (media level) Sensor (media out) Sensor (pre-feed) Switch (lower left door interlock) Sensor (tray 2 feed out) Component locations...
  • Page 312 4024-XXX 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 313: Printer Switches

    4024-XXX Printer switches Exit interface card assembly Switch (main power) HVPS card assembly Switch (printer front door interlock) Component locations...

  • Page 314: Cables

    4024-XXX Cables RFID Sensor Cable Main Power Switch Assembly Cable Assembly Fuser AC Cable Assembly Duplex Finisher Option Tray Printer Service Manual...
  • Page 315 4024-XXX 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: - HVPS...
  • Page 316 4024-XXX Multi Connect Cable Assembly 3 Connects the following: - LVPS - Toner add motor RIP Card - Exit interface card assembly Cable Assembly - Fuser cable assembly Media Cable MPF Hookup Media Feed Unit Cable Assembly Cable Assembly Main Finisher AC Main AC Cable Cable Assembly Assembly...

  • Page 317: Components Locations

    4024-XXX Printhead Multi Connect Cable Assembly Cable Assembly 2 Connects the following: - Fuser sensor cable assembly - Transport clutch Sensor (Tray 2 feed out) Exit Interface Cable Assembly 5-11 Component locations...
  • Page 318 4024-XXX Electronic component diagram Drum Sensor +3.3VDC Humidity & Temp) SIG-GND +5VDC Op Panel +5VDC PC Cartridge +3.3VDC SIG-GND Op-Panel Charge Transfer Transfer Roll Roll Roll JHAB3 USB +5VDC SIG-GND I/L +24VDC SIG-GND SIG-GND I/L +24VDC MAIN PWR ON Registration /XDATA 2 DTS ON Clutch...

  • Page 319: 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 320: Lubrication Specifications

    4024-XXX 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 Main Paddles (3) Inspect Sub Paddles (2) Inspect Clamp Paddles (3) Inspect...

  • Page 321: Parts Catalog

    4024-XXX 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 322: Assembly 1: Covers And Operator Panel (1 Of 2)

    4024-XXX Assembly 1: Covers and operator panel (1 of 2) Printer Service Manual...
  • Page 323 4024-XXX Assembly 1: Covers and operator panel Assembly Part Units/ Units/ kit Description - Index number mach or pkg 40X0557 USB connector cover 40X0556 USB connector 40X0554 Operator panel assembly 40X0555 Operator panel cable assembly 40X0553 Switch (printer front door interlock) 40X0558 Top cover assembly 40X0559...

  • Page 324: Assembly 2: Covers

    4024-XXX Assembly 2: Covers Assembly Part Units/ Units/ kit Description - Index number mach or pkg 2–1 40X0566 Rear motor cover 40X0565 Cable hookup door kit includes: • Cable hookup cover • Cable hookup door 40X0568 Option hookup cover 40X0567 Rear lower cover (110V) 40X0955 Rear lower cover (220V)

  • Page 325: Assembly 3: Media Feed Unit

    4024-XXX 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) 40X0572 Vertical turn guide 40X0571 Vertical turn mylar guide Parts catalog...

  • Page 326: Assembly 4: Media Feed Unit Exploded (Tray 1 And Tray 2)

    4024-XXX Assembly 4: Media feed unit exploded (tray 1 and tray 2) Printer Service Manual...
  • Page 327 4024-XXX 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 328: Assembly 5: Media Tray

    4024-XXX Assembly 5: Media tray Printer Service Manual...
  • Page 329 4024-XXX 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) 40X0578 Media tray end guide kit includes: •...

  • Page 330: Assembly 6: Mpf Unit

    4024-XXX Assembly 6: MPF unit 7-10 Printer Service Manual...
  • Page 331 4024-XXX 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 40X0595 MPF feed unit assembly 40X0608 Fold down tray assembly 40X0597 MPF unit cable assembly 40X0755 MPF pickup spring 40X0598...

  • Page 332: Assembly 7: Mpf Unit Feed

    4024-XXX Assembly 7: MPF unit feed 7-12 Printer Service Manual...
  • Page 333 4024-XXX 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 334: Assembly 8: Left Lower Door And Transport

    4024-XXX Assembly 8: Left lower door and transport 7-14 Printer Service Manual...
  • Page 335 4024-XXX 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 6 mm bushing (transport roll rear) 40X1387 Transport roll kit includes: •...

  • Page 336: Assembly 9: Left Door And Transfer Roll

    4024-XXX Assembly 9: Left door and transfer roll 7-16 Printer Service Manual...
  • Page 337 4024-XXX 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 338 4024-XXX Assembly 10: Printer left door 7-18 Printer Service Manual...

  • Page 339: Assembly 10: Printer Left Door

    4024-XXX 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 Left door support strap 40X0623 Left door duplex entrance guide 40X0621 Printer left door assembly handle kit includes: •...

  • Page 340: Assembly 11: Registration

    4024-XXX Assembly 11: Registration 7-20 Printer Service Manual...
  • Page 341 4024-XXX 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 342: Assembly 12: Printhead, Cartridge Guides, And Fans

    4024-XXX Assembly 12: Printhead, cartridge guides, and fans 7-22 Printer Service Manual...
  • Page 343 4024-XXX Assembly 12: Printhead, cartridge guide 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 40X1390 Switch (PC cartridge interlock) kit includes: •...

  • Page 344: Assembly 13: Fuser

    4024-XXX Assembly 13: Fuser 7-24 Printer Service Manual...
  • Page 345 4024-XXX Assembly 13: Fuser Assem Part Units/ Units/ kit bly- Description number mach or pkg Index 13-1 40X0588 Sensor (fuser exit) 40X0645 Fuser exit actuator kit includes: • Shaft • Fuser exit actuator • Spring • Bracket 40X0647 Fuser assembly 110V (this comes assembled) 40X0648 Fuser assembly 220V (this comes assembled) 40X0646...

  • Page 346: Assembly 14: Standard Exit 1

    4024-XXX Assembly 14: Standard Exit 1 7-26 Printer Service Manual...
  • Page 347 4024-XXX 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 Bin full actuator kit includes: •...

  • Page 348: Assembly 15: Dual Unit Drive Motor

    4024-XXX Assembly 15: Dual unit drive motor 7-28 Printer Service Manual...
  • Page 349 4024-XXX 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 350: Assembly 16: Electrical

    4024-XXX Assembly 16: Electrical 7-30 Printer Service Manual...
  • Page 351 4024-XXX Assembly 16: Electrical Assem Part Units/ Units/ kit bly- Description number mach or pkg Index 16–1 40X0664 Exit interface card assembly 40X0642 RIP card assembly 40X0964 Interconnect card assembly 40X0673 HCF hookup connector assembly 40X0672 Rear RIP card cover 40X0665 Printer engine card assembly 40X0670...

  • Page 352: Assembly 17: Electrical Cables

    4024-XXX 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 353: Assembly 18: Electrical Cables

    4024-XXX 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 354: Assembly 19: Electrical Cables

    4024-XXX 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 355: Assembly 20: Electrical Cables

    4024-XXX 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 356: Assembly 21: Electrical Cable

    4024-XXX 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 357: Assembly 22: Power Cords

    4024-XXX 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 40X0270 Power cord—Japan 8ft 15A straight 40X0274 Power cord—Switzerland 6ft straight 40X0275 Power cord—Israel 6ft straight 40X0276 Power cord—South Africa 6ft straight 40X0277...

  • Page 358: Assembly 23: Miscellaneous

    Part Units/ Units/ kit Description Index number mach or pkg 23–NS 7374474 W840 Repacking kit 40X0179 Nyogel 744 grease packet 40X0248 Cx/Tx card assembly 40X0250 9-pin to Twinax cable 40X0251 9-pin to Coax (BNC) cable 40X0252 9-pin to 9-pin cable assembly...
  • Page 359 4024-XXX Assembly 23 (continued): Miscellaneous Asm- Part Units/ Units/ kit Description Index number option or pkg 40X1564 32MB Flash card 40X1565 64MB Flash card 56P9982 Hard disk with adapter—20+GB 7-39 Parts catalog...
  • Page 360 4024-XXX 7-40 Printer Service Manual...
  • Page 361 4024-XXX Index 3-15 Numerics Disk Test/Clean 3-16 Flash Test 7-38 7374474sm W84 Repacking kit 3-15 Quick Disk Test DUPLEX TESTS Quick Test acronyms Sensor Test EVENT LOG button test 3-19 Clear Log 3-18 Display Log 3-18 Print Log CACHE Test exiting code update FINISHER TESTS...
  • Page 362 4024-XXX 956.01 RIP card assembly processor over temperature 2-62 failure error code messages 2-62 956.02 RIP card assembly cooling fan failure error codes 980.03 exit interface card assembly communication 2-22 200.00 sensor (registration) off jam (too long) 2-63 failure 2-23 200.01 sensor (registration) static on jam error messages 2-24...
  • Page 363 4024-XXX 3-10 input sensor tray tests input source tests 3-23 quality pages 3-10 input tray feed test 3-15 Quick Disk Test 3-23 Quick Test lubrication specification 3-22 registration removals maintenance scheduled 4-14 cable hookup door memory 4-116 dual drive motor assembly DRAM Test ESD-sensitive parts 3-17...
  • Page 364 4024-XXX printer front left cover 4-72 printer left door support strap wrap tests 4-68 printer left lower door assembly 4-99 printhead assembly 4-16 rear lower cover 4-15 rear motor cover 4-78 registration clutch assembly 4-77 registration roll assembly 4-13 right lower cover 4-12 right upper cover 4-127...

  • Page 365: Part Number Index

    4024-XXX Part number index Description Page 40X0179 Nyogel 744 grease packet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-38 40X0198 Bar code card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 366 4024-XXX 40X0574 Media tray front cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X0576 Media tray side guide kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X0577...
  • Page 367 4024-XXX 40X0636 Sensor (RFID PC cartridge) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23 40X0636 Sensor (RFID toner cartridge) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 368 4024-XXX 40X0968 Media tray lift one-way shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X0969 Pick roll idler gear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X0970...

  • Page 369: Printer Service Manual

    4024 Printer Service Manual Drum Sensor +3.3VDC Humidity & Temp) SIG-GND +5VDC Op Panel +5VDC PC Cartridge +3.3VDC SIG-GND Op-Panel Charge Transfer Transfer Roll Roll Roll JHAB3 USB +5VDC SIG-GND I/L +24VDC SIG-GND SIG-GND I/L +24VDC MAIN PWR ON Registration DTS ON /XDATA 2 Clutch...

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