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W850 (4024-110) - LPT Home Page

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2. N Left view Guide assembly Connector Harness assembly LE Repair information 4 89 4024 110 18 Slide the PC cartridge guide D toward the left side and disconnect the connector from the PC cartridge sensor connector E 19 Remove the two hooks securing the transfer roll power contact F Gees oe Seen ran LS ee 4 90 Printer Service Manual 4024 110 20 While pressing the PC cartridge drive coupler G lift the front side of the PC cartridge guide C upward 21 Disconnect the connector from the sensor humidity and temperature H 22 Remove the screw securing the sensor humidity and temperature H to the PC cartridge guide C 23 Remove the sensor humidity and temperature H Kn Ss C i Se Sege Q eS CL A Repair information 4 91 4024 110 Sensor RFID PC cartridge and sensor RFID toner cartridge removal Note This removal applies to the sensor RFID PC cartridge A and the sensor RFID toner cartridge B Remove the top cover assembly See Top cover assembly removal on page 4 7 Remove the toner cartridge guide assembly See Toner cartridge guide assembly removal on page 4 93 Disconnect the connector from the sensor RFID P
3. TINI O LO OInN OMFM e 3 3VDC i JOPP1 else Drum Sensor SIG GND aen J Zil READY A Humidity amp Temp 5VDC JSFP P1 ESS READY Dt 3 3VDC ENGINE READY PCC i n 12C DATA OP artridge JUSBHF H doc dach dc Wher SRS ee ee a a On Op Panel 12C CLK OF elses ehar Mag AE ge Nelo SEIS ii Tope Jr PANEL INT R Wray J 2 We We Wa Be 2 529 2 E a ele SIG GND FWE Jal la OG dags MAD m MAIN PWR ON gt SCLOCK S S56 5 1L 24VDC n Lo oo 0 o k Command Ready o a a r s A 5 5 RTN a r Registration Su DTS ON JVIDEO 1 Clutch z BTR MONITOR ASM e a ees HVPS A Zi BTR SEL BTR REMOTE J160 pp BOR AC CLOCK Card ASM Print Head BCRACON ar XDATA2 IXDATA 2 Sensor BCR DC REMOTE XTATA2 J170 ASM Sensor Sensor Registration TATA RFID PC E tft DEVE BIAS DC REMOTE TATA artridge Cartridge d2 gt _ DEVE BIAS DC ON USB DIRECT J140 J130 S U Ua i f A A lf A A A l ETHERNET zilola ola soo olz 93 59 5 919 SES 8 24VAC AEAEE 3 5 z SIG GND USB 2 0 PORT SklWEIEEEES 6 SZ eislels ele Hoof 5 ls Fuser Fan ON H 24VDC Ses Be Se E i 55 23 2 H oo S o 3999 8E i Se ZS SS Q alz EE gt o da Ho gd a 6 6 gu 9 gt 65 S E a9 99 Jaq 9 9 Oe o x Did Did 2 HA GACEE Sa Sooo oO 52 ME 9 E a E E o g o D D D cy Baan sii x AJ Q p _ 2 so E d yyy 4 A M i E a OO Fuser Fan Fail J a e ZOS ml Joie SECEESEEE Fuser Fan ON j GLE gisele P403 Media Trans Motor ON
4. Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on print tests If the problem remains go to step 2 2 Turn the printer off for 60 seconds Go to step 3 Problem solved Does the error occur when the power is turned off on again 3 Check the RIP card cooling fan and heatsink for installation Replace the RIP Install the RIP Is the RIP card cooling fan and heatsink installed correctly card assembly eae on card correctly removal on page 4 126 Go to step 4 4 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 4 119 956 02 RIP card assembly cooling fan failure Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on prile tests If the problem remains go to step 2 2 Turn the printer off for 60 seconds Go to step 3 Problem solved Does the error occur when the power is turned off on again 3 Check the RIP card assembly cooling fan and heatsink Replace the RIP Reattach the RIP attachment card assembly card assembly Is the above fan attached properly Go to RIP card pee ian ang assembly i removal on page 4 126 4 Perform a print test Replace the Problem solved printer engine card Does the error still occur assembly Go to Printer
5. 7 38 W850 IPDS and SCS TNEcard 7 38 MPF pressure pad spring 2 2 2 eee reer reer 7 13 MPF feed shaft bushing 2 2 2 a n ee eee eee 7 13 MPF feed shaft kit eee ee eee eee eee ee 7 13 Bushing 6 mm transport roll rear 2 2 2 eee ce eres 7 15 Transport roll kit 2 eee eee ee eee eee eee 7 15 Bushing 8 mm rrr rr ree ee rr re er eee eee eee ee 7 15 PC cartridge interlock switch screw r rrr rrr rrr rrr rrr rrr rrr rene 7 23 PC cartridge interlock switch kit eee eee 7 23 Switch PC cartridge interlock kit 7 33 Exit 1 static eliminator eee e eee eee eee eee 7 27 Exit 1 media exit guide kit 225 errr errr errr rere ee 7 27 TVOC filter assembly eer eee eee eee ee eee eee ee 7 4 Output guide ee 7 27 RS 232C serial interface card 22 2 eee eee eee 7 38 Hard disk saskes See EE Ee Se et Sone ees 7 38 Parallel 1284 B interface card eee reer ee ere eee
6. 7 23 7 33 Toner cartridge guide kit 7 23 Toner add motor assembly eee ee eee nn ee eee 7 23 Fuser cooling fan 2 2 2 enn nn ne ene eee 7 23 Printhead assembly eee enn ne eee eee 7 23 PC cartridge cooling fan 2 2 2 2 2 2 2 2 2 e eee ee 7 23 PC cartridge sensor connector 7 23 Fuserassembly 100 V sei ae e ees cee bee an sek an pecan ee bee eee eee 7 25 Fuser assembly 110 V 7 25 Fuser assembly 220 V lt see sesceecsese de SIE ee SIE see chee SEET See See Sees 7 25 Exit 1 media shift assembly e e eee 7 27 Exit 1 sensor cable assembly eee teen eee eee ee 7 27 Media shift motor 2 22 eee eee eee eee eee eee eee 7 27 Exit 1 media shift gear eee ee eee eee 7 27 Media diverter gate kit 2 eee eee eee eee 7 27 Standard exit 1 top cover eee eee eee eee eee 7 27 Standard bin full exit 1 actuator kit 7 27 MPF amp transport roll idler gear kit
7. Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on print tests If the problem remains go to step 2 2 Turn the printer off for 60 seconds Go to step 3 Problem solved Does the error occur when the power is turned off on again 3 Check connector P419 on the printer engine card assembly Replace the Replace the Is connector P419 on the printer engine card assembly See SE connection properly connected y Go to Printer engine card assembly removal on page 4 119 Go to step 4 4 Perform a print test Replace the RIP Problem solved Does the error still occur card assembly Go to RIP card assembly removal on page 4 126 908 00 PPM data failure Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on print tests If the problem remains go to step 2 2 Turn the printer off for 60 seconds Replace the RIP Problem solved Does the error occur when the power is turned off on again card assembly Go to RIP card assembly removal on page 4 126 Go to step 3 3 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 4 119 2 44 Printer Service Manual 910 00 Transport motor stop failure 4024 110 Step Check Ye
8. 7 29 Exit 1 drive belt eee nee nn ee eee eee 7 29 Dual drive motor assembly eee ener eee eee 7 29 Drive belt flange 2220 eee ee ee eee eee e eee eee 7 29 HVPS EE 7 31 Switch main power 22 eee ee ee eee ee ee 7 31 Exit interface card assembly 7 7 31 Printer engine card assembly 2 0 2 r eee reer ee eee eee eeee 7 31 VPS400M10V saasha eia t ets eee es eee etek eee eke eee eee ees 7 31 IEN ES EEN e EE EE eee eset eee ee EE E eases ce EES 7 31 Choke coil 220 V 22 0 0 2 eee eee eee eee rere eee eee 7 31 AC power input socket kit e ee eer r ee eee 7 31 7 34 Rear RIP card cover 22 eee ee eee eee eee 7 31 HCF hookup connector assembly 7 31 7 33 Media feed unit cable assembly 7 34 L Printer Service Manual 40X0675 40X0676 40X0677 40X0678 40X0679 40X0680 40X0681 40X0682 40X0683 40X0684 40X0685 40X0686 40X0755 40X0880 40X0948 40X0949 40X0952 40X0955 40X0956 40X0957 40X0958 40X0960 40X0965 40X0966 40X0967 40X0968 40X0969 40X0970 40X0971 40X0973 40X0974 40X1373 40X1379 40X1380 40X1381 40X1382 40X1386 40X1387 40X1388 40X1389 40X1
9. Note Assembly index items 7 and 8 are identical sensors with different functions therefore are the same part number with different descriptions Parts catalog 7 27 4024 110 Assembly 15 Dual unit drive motor 7 28 Printer Service Manual Assembly 15 Dual unit drive motor 4024 110 Assem part Units Units kit di bly Description number mach _ or pkg Index 15 1 40X0660 1 1 Dual drive motor assembly 2 40X0659 1 1 Exit 1 drive belt 3 40X0661 1 1 Drive belt flange 4 40X0658 1 4 MPF amp transport roll idler gear kit includes e Transport roll idler gear 28T e MPF idler gear 18T e Flange e Transport MPF idler gear 21 21T Parts catalog 7 29 4024 110 Assembly 16 Electrical 7 30 Printer Service Manual Assembly 16 Electrical 4024 110 Assem bart Units Units kit d bly Description number mach or pkg Index 16 1 40X0664 1 1 Exit interface card assembly 2 40X5562 1 1 RIP card assembly 3 40X0673 1 1 HCF hookup connector assembly 4 40X0672 1 1 Rear RIP card cover 5 40X0665 1 1 Printer engine card assembly 6 40X0670 1 7 AC power input socket kit includes e Screws 4 mm 2 each e Bracket e AC power input socket e Ground wire e Main AC cable assembly e Finisher AC output 7 40X0666 1 1 LVPS 100 110 V 7 40X0667 1 1 LVPS 220 V 8 40X0668 1 1 Choke coil 220 V 220 V model only 9 40X0662 1 1 HVPS 10 40
10. Fuser AC Cable Assembly 5 8 Printer Service Manual RFID Sensor Cable Assembly 4024 110 PC Cartridge cooling fan Switch PC cartridge Interlock switch interlock cable assembly S Multi Connect Cable Assembly 3 Connects the following LVPS Toner add motor Exit interface card assembly Fuser cable assembly Koch E a ee 0 S D c lt H IG H 5 a wf gt AD 5 ca HCF Hookup connector Media Size Switch Cable Assembly Multi Connect Cable Assembly 1 Connects the following HVPS Registration clutch Sensor registration Sensor hum temp PC Cartridge sensor connector Component locations 5 9 4024 110 Multi Connect Cable Assembly 3 Connects the following LVPS Toner add motor Exit interface card assembly Fuser cable assembly GE Dual drive Cable Assembly MPF SH Cable Assembly Media Feed Unit Cable Assembly Main AC Cable Main Finisher AC Assembly Cable Assembly 5 10 Printer Service Manual 4024 110 Printhead Cable Assembly Multi Connect Cable Assembly 2 Connects the following Fuser sensor cable assembly Transport clutch Sensor Tray 2 feed out Switch Printer left lower door interlock Component locations 5 11 4024 110 Exit Interface Cable Assembly 5 12 Printer Service Manual 4024 110 6 Preventive maintenance This chapter describes procedures for
11. 44 mm 78 5 mm 1 73 in 3 09 in If the defect appears on the printed side of a single sided print job change the photoconductor kit If the defect appears on the back change the fuser 94 2 mm 3 71 in 4024 110 Repeating defects Roll Pitch Transfer roll 59 mm Registration roll 44mm Fuser pressure roll 94 mm Fuser heat roll 79mm Charge roll 44mm PC drum 94 mm Heat roll Pressure Fuser ASM roll Cleaning blade pS Se eS Be e Ze E e Charge roll lt E K Laser beam Transfer roll PC cartridge Magnetic roll Paper 3 54 Printer Service Manual 4024 110 4 Repair information Warning Read the following before handling electronic parts Handling ESD sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge ESD To prevent damage to ESD sensitive parts use the following instructions in addition to all the usual precautions such as turning off power before removing logic boards Keep the ESD sensitive part in its original shipping container a special ESD bag until you are ready to install the part into the machine Make the least possible movements with your body to prevent an increase of static electricity from clothing fibers carpets and furniture Put the ESD wrist strap on your wrist Connect the wrist band to the system ground point This discharges any static electricity i
12. Item Description Navigation Press the up or down arrow buttons to scroll through menus or menu items or to increase or decrease a value when entering numbers Ca Press the left or right arrow buttons to scroll through menu settings also called values or options or to scroll through text that rolls to another screen Stop Stops all printer activity Sal A list of options is offered once Stopped appears on the display Menu Opens the menu index o gt Note The menus are available only when the printer is in the Ready state Back Returns the display to the previous screen USB direct interface Insert a flash drive into the front of the printer to print saved files Note Only the front USB direct interface supports flash drives 2 4 Printer Service Manual Error code messages 4024 110 Error code or Error contents Description Action message 200 00 Sensor registration off The sensor registration is not turned off within the Paper jam jam too long SES time after the registration clutch is turned Check area A Go to 200 00 Sensor registration off jam too long on page 2 23 200 01 Sensor registration static Media remains on the sensor registration Paper jam Jam Go to 200 01 Sensor registration static on Check area A jane on pageza 201 00 Sensor fuser exit on jam The sensor fuser exit is not turned on within the Paper jam SE time after the registration clutch is turned Ch
13. 2 40X0603 1 2 3 40X1382 1 6 4 40X0974 1 2 5 40X1380 2 1 6 40X1381 2 7 40X0606 1 3 8 40X0971 1 2 9 40X0973 1 2 MPF transport roll kit includes e MPF transport shaft collar e MPF transport gear 18T MPF transport roll assembly e Bushing 8 mm 2 each MPF pick roll kit includes e MPF pressure pad e MPF pick roll assembly MPF feed shaft kit includes e MPF feed shaft e MPF feed shaft cam rear e MPF feed shaft cam front e MPF feed shaft roll core 2 each e MPF feed roll assembly MPF pressure pad kit includes e Shaft e MPF pressure pad MPF pressure pad spring MPF feed shaft bushing MFP pick solenoid kit includes e Pick lever e Pick solenoid e Spring MPF feed drive gear kit includes e MPF feed gear e MPF feed gear stopper MPF feed cam gear kit includes e MPF feed cam gear e Spring Parts catalog 7 13 4024 110 Assembly 8 Left lower door and transport 7 14 Printer Service Manual 4024 110 Assembly 8 Left lower door and transport Assem Part Units Units kit S bly Description number mach _ or pkg Index 8 1 40X0609 1 1 Vertical drive gear assembly 2 40X0610 1 1 Switch left lower door interlock 3 40X1386 1 1 Bushing 6 mm transport roll rear 4 40X1387 1 2 Transport roll kit includes e Transport roll assembly e Transport roll gear 18T 5 40X1388 1 1 Bushing 8 mm 6 40X0612 1 1 Printer left lower door assembly this comes ass
14. Pick roll idler gear 33 tooth removal Remove the media tray Release the pick roll See Pick roll removal on page 4 48 Remove the pick roll drive gear 25 tooth See Pick roll drive gear 25 tooth removal on page 4 49 Remove the pick roll idler gear 33 tooth A Soh Repair information 4 47 4024 110 Pick roll removal Remove the media tray Move the media feed unit front guide A in the direction of the arrow Release the hook securing the pick roll B to the shaft C Remove the pick roll B Note Do not touch the rubber surface of the feed roll B Pe Front Se Note Before reinstalling do not touch the rubber surface of the pick roll B 4 48 Printer Service Manual 4024 110 Pick roll drive gear 25 tooth removal 1 Remove the media tray 2 Remove the pick roll See Pick roll removal on page 4 48 3 Remove the pick roll drive gear 25 tooth A from the shaft B Repair information 4 49 4024 110 Feed unit drive gear 27 tooth removal 1 ARON a Remove the media feed unit assembly See Media feed unit assembly 1 removal on page 4 18 or Media feed unit assembly 2 removal on page 4 21 Remove the harness from the bracket A Remove the three screws securing the bracket A to the
15. Remove the bracket A Note The gears may become detached from the bracket A Remove the tray lift one way clutch See Tray lift one way clutch gear assembly removal on page 4 32 Remove the tray lift one way gear 24 tooth See Tray lift one way clutch gear assembly removal on page 4 32 Remove the media feed unit drive gear 13 tooth B as Q Q jc D e SS SS S o D Harness Washer Note Before reinstalling ensure all gears and washers are securely attached to the bracket A 4 34 Printer Service Manual 4024 110 Media out actuator removal 1 Remove the appropriate media feed unit assembly See Media feed unit assembly 1 removal on page 4 18 or Media feed unit assembly 2 removal on page 4 21 2 Remove the two bosses on the media out actuator A to the media feed unit assembly 3 Remove the media out actuator A Lower view Repair information 4 35 4024 110 Sensor media level removal 1 Remove the appropriate media feed unit assembly See Media feed unit assembly 1 removal on page 4 18 or Media feed unit assembly 2 removal on page 4 21 Disconnect the connector from the sensor media level A Release the hooks securing the sensor media level A to the media
16. SIG GND i 13 8 2 S 36826 8lsl 8 9 9 s s Tray 2 Size S5 on L 5VDC i 12 E eol RaleEid lSlsglsaEis S ozo t ol 2 l Choke 1 ae aa Coil 220 240 AC Outlet FIN SIG GND 5V0C_ P41 2 10 HS se Sosa me ce ete e tape eee ee age eater coeie Sine ee Soe mime a ee a a Sdt ee I 9 ALN Loon co wl ee eil el et fA 24VDC l P409 8 P409 ml eilelsalimlaireelg laien 2lg SS Se H AE GE ZC y 6 lt RAS a S Se tm ase FE ao SEEM GSS ea E SS ee 4 ag aaa Main Power 1121314 a DOG X Relay ON L 24DC 4 5 2 EE z z a o o D n rt P4 A Ea SIG GND Zeno cRoss BS 8 UU 2 2 A e S A _ b De Ss S EE Fan eme SIG GND o __ Sensor MPF Media Size 3 3 s EL 5 2 P1 P521 Main Pwr On 5VDC S p t5VDC 1 S 3 4 9 RIN HEI PAOD _ __ Css tase stsescnsenescnszsconscnsenenonseatsorsesestsausenenevaesssosossenescuseonsorscsentscusenensraessocuseseserocseotscrocsentsauscuousnaenssouauatseracaes SIG GND 613 318 _SIG GND Sr 12 E i HOT y aiT SIG GND 24VDC s MPF Media Size SNR Signal Be MPF Pj k HOT Toi Card ASM i 3 3VDC a H MPF Pic Solenoid ON L 24VDC Deg IC l j I d 6 P EVDO i 24vDC Bea Solenoid TEREP Neutral SIG GND p gt 5VDC 3 x Se Talose ees S edia Present 5 E 7 8 9 fot 112 1 2 3 4 5 61A mii 2 3 4 P414 P415 i P pai Sensor S A To Metal Fe HEED a1 2 at 4 11213 1 2 3 4 5 6 MPF Media Out of CH Jo HUA olaf Printer Frame TS zl sl SES Ee 1 es gt T
17. on page 4 93 9 Perform a print test Replace the Problem solved printer engine card Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 Diagnostic information 2 73 4024 110 Toner cartridge near empty Step Check Yes No 1 Does the toner cartridge contain toner Go to step 2 Replace the toner cartridge 2 Check the toner cartridge for proper installation Problem solved Go to step 3 Remove the toner cartridge and reinstall it Does it install properly 3 Check the gear rotation in the toner cartridge guide Go to step 4 Replace the toner assembly guide assembly Remove the toner cartridge guide assembly Does the gear located at the lower part of the toner cartridge guide assembly rotate smoothly 4 Check the toner cartridge guide assembly for pipe clogging Go to step 5 Clean the pipe Is the pipe located at the lower part of the toner cartridge guide assembly clogged 5 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 Select MOTOR TESTS 3 SelectToner add motor Does the motor rotate normally 6 Check the toner add motor assembly connection Replace the toner Replace the add motor connection Is the toner add motor assembly properly connected
18. 1381963 Coax serial debug cable 1381964 5 5 mm hexdriver magnetic 1 2 Printer Service Manual 4024 110 Acronyms 2TM 2 Tray Module AC Alternate Current ASIC Application Specific Integrated Circuit CRU Customer Replaceable Unit CSU Customer Setup DC Direct Current DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory EDO Enhanced Data Out EP Electrophotographic Process ESD Electrostatic Discharge FRU Field Replaceable Unit GB Gigabyte GFI Ground Fault Interrupter HCF High Capacity Feeder HVPS High Voltage Power Supply LASER Light Amplification by Stimulated Emission of Radiation LCD Liquid Crystal Display LD Laser Diode LED Light Emitting Diode LEF Long Edge Feed LVPS Low Voltage Power Supply MPF Multi Purpose Feeder MS Microswitch NVM Nonvolatile Memory NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer OPT Optical Sensor PC Photoconductor PEL Picture element POR Power on Reset POST Power on Self Test PPM Pages Per Minute PSC Parallel Synchronous Communications PSD Position Sensing Device PWM Pulse Width Modulation RFID Radio Frequency Identification RIP Raster Imaging Processor ROM Read only Memory RPM Revolutions Per Minute SDRAM Synchronous Dual Random Access Memory SEF Short Edge Feed SIMM Single Inline Memory Module SOS Start of scan SRAM Static Random Access Memory TVOC Total Volatile Organic Compound TTM Tandem Tray Module UPR Used Parts Return V Volts Vac Volts alter
19. 905 00 NVM read write cannot be executed failure 4024 110 Step Check Yes No Perform a POR Does the error occur when the power is turned off on Go to step 2 Perform several print tests If the problem remains go to step 2 Turn the printer off for 60 seconds Does the error occur when the power is turned off on again Replace the RIP card assembly Go to RIP card assembly removal on page 4 126 Go to step 3 Problem solved Perform a print test Does the error still occur Replace the printer engine card assembly Go to Printer engine card assembly removal on page 4 119 Problem solved 906 00 CPU power to access NVM failure Step Check Yes No Perform a POR Does the error occur when the power is turned off on Go to step 2 Perform several print tests If the problem remains go to step 2 Turn the printer off for 60 seconds Does the error occur when the power is turned off on again Replace the RIP card assembly Go to RIP card assembly removal on page 4 126 Go to step 3 Problem solved Perform a print test Does the error still occur Replace the printer engine card assembly Go to Printer engine card assembly removal on page 4 119 Problem solved Diagnostic information 2 43 4024 110 907 00 RFID ASIC failure
20. Spots Leading edge Replace the printer engine card assembly Perform a print test Does the error continue card assembly Go to RIP card assembly removal on page 4 126 Taiing edge Step Check Yes No 1 Check the media condition Go to step 2 Problem solved Load new dry recommended media Re print the defective image Does the error continue 2 Check the media transfer route Go to step 3 Remove debris E e or Is the media route free of contamination or debris contamination 3 Check the toner cartridge Problem solved Go to step 4 Install a new toner cartridge Re print the defective image Is the image density normal 4 Check the transfer roll assembly Go to step 5 Replace the transfer roll Remove the transfer roll assembly assembly Is the transfer roll assembly rotating and free of contamination and wear 5 Check the heat roll and the pressure roll Replace the Go to step 6 fuser unit Remove the fuser unit assembly assembly Is there contamination or cracking on the heat roll and or the pressure roll 6 Check the printer engine card assembly Replace the RIP Problem solved 2 96 Printer Service Manual After image CH Ber Tra iling edge 4024 110 The ghost appears on the media which may be the image from the previous page or part of the page currently printing Step Check Yes No 1 Check the media conditio
21. on page 4 51 Remove the printer left door assembly See Printer left door support strap removal on page 4 71 Remove the vertical drive gear assembly See Vertical drive gear assembly on page 4 64 Disconnect the harness from the switch left lower door interlock A Release the hooks securing the switch left lower door interlock A to the vertical drive gear assembly B Remove the lower switch left lower door interlock A Repair information 4 65 4024 110 Media transport roll assembly gear removal Remove the MPF rear cover See MPF rear cover removal on page 4 55 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 51 Remove the printer left door assembly See Printer left door support strap removal on page 4 71 Open the printer left lower door assembly Remove the two screws securing the tray 2 feed out sensor guide A Remove the tray 2 feed out sensor guide A while pulling on its center most point Remove the e clip with needle nose pliers on the front side securing the media transport roll B Remove the media transport roll assembly B by sliding it in the direction of the arrow and pulling out Note When removing the media transport roll assembly B do not touch the rubber surface SAS Sah Note When removing the media transport roll B the bushings and gear may become detached 9 Remove the media transport roll gear
22. 2 Check the fuser unit assembly connection Replace the fuser Replace the Is the fuser unit assembly properly connected unit assembly SEBES 3 Perform a print test Replace the Problem solved Does the error continue i i carg Go to Printer engine card assembly removal on page 4 119 2 52 Printer Service Manual 924 00 Pressure roll thermistor failure 4024 110 Step Check Yes No 1 Check the fuser unit assembly for installation Go to step 2 Install the fuser Open the printer left door assembly and check it unit assembly P p y securely Is the fuser unit assembly installed securely 2 Check the fuser unit assembly connection Replace the fuser Replace the Is the fuser unit assembly properly connected unit assembly connection 3 Perform a print test Replace the Problem solved Does the error continue AEDE N card Go to Printer engine card assembly removal on page 4 119 925 00 Fuser operating temperature failure Step Check Yes No 1 Check the fuser unit assembly for a media jam Go to step 2 Remove the Open the printer left door assembly and check it SES Is there a media jam in the fuser unit assembly 2 Leave the printer powered on with the error code displayed Go to step 3 Problem solved for 10 minutes then perform a POR Does the error still occur 3 Check the fuser unit assembly for installation Go to step 4 Install the fuser O
23. Go to step 11 10 Check the image transfer process Check the toner image formed on the drum after the transfer roll assembly Is the toner image completely transferred on the media Go to step 12 Go to step 11 11 Check the HVPS card assembly Replace the HVPS card assembly Perform a print test Does the error continue Go to step 12 Problem solved 12 Check the printer engine card assembly Replace the printer engine card assembly Perform a print test Does the error continue Replace the RIP card assembly Go to RIP card assembly removal on page 4 126 Problem solved Diagnostic information 2 85 4024 110 Solid black Check the media path for foreign objects such as staples clips scraps of media Step Check Yes No 1 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 2 Check connector JHAB1 on the RIP card assembly Go to step 3 Replace the Is the above connector connected properly connection 3 Check the HVPS card assembly Go to step 4 Problem solved Replace the HVPS card assembly Perform a print test Does the error continue 4 Check the printer engine card assembly Replace the RIP Problem solved Replace the printer engine card assembly card assembly e Go to RIP card Perform a print test assembly Does the err
24. INPUT TRAY TESTS Feed Tests See Feed Tests input tray on page 3 9 Sensor Test See Sensor Test input tray on page 3 9 OUTPUT BIN TESTS Feed Tests See Feed Tests output bins on page 3 10 Feed To All Bins See Feed To All Bins on page 3 10 Sensor Test See Sensor Test output bin on page 3 10 FINISHER TESTS if installed Staple Test See Staple Test on page 3 11 Feed Tests See Feed Tests on page 3 11 Sensor Test See Sensor Test finisher on page 3 12 BASE SENSOR TEST See BASE SENSOR TEST on page 3 13 Cover and Door Devices Exit Level Media Path DEVICE TESTS Quick Disk Test if installed See Quick Disk Test on page 3 14 Disk Test Clean if installed See Disk Test Clean on page 3 14 Flash Test if installed See Flash Test on page 3 15 PRINTER SETUP Defaults See Defaults on page 3 15 Page Count See Page Count on page 3 15 Perm Page Count See Perm Page Count permanent page count on page 3 15 Serial Number See Serial Number on page 3 16 Engine Setting 1 through 16 See Engine Setting 1 through 16 on page 3 16 Model Name See Model Name on page 3 16 Configuration ID See Configuration ID on page 3 16 Edge to Edge See Edge to Edge on
25. Paper jam Check areas G G4 Sensor buffer path on jam A Sensor buffer path is not turned on within the specified time after the sensor finisher media entrance is turned on Refer to Finisher Service Manual 283 01 Sensor buffer path on jam B Sensor buffer path is not turned on within the specified time after the sensor finisher media exit Paper jam is turned on eae area At this time the sensor diverter gate is turned on Refer to Finisher Service Manual 283 02 Sensor buffer path Static Paper remains on the sensor finisher buffer path Paper jam jam A At this time both sensor diverter gate and sensor Check areas transport exit are on state G2 G3 Refer to Finisher Service Manual 283 03 Sensor buffer path Static Paper remains on the sensor finisher buffer path Paper jam jam B At this time the sensor diverter gate is on state but Check areas G2 the sensor finisher media entrance is turned off Refer to Finisher Service Manual 283 04 Paper jam Check areas G4 Sensor buffer path Static jam C Paper remains on the sensor finisher buffer path At this time the sensor diverter gate is turned off Refer to Finisher Service Manual 284 00 Paper jam Check area F Sensor lower media exit off jam A Sensor lower media exit is not turned off within the specified time after the finisher sensor lower media exit is turned on At this time the sensor
26. See Top cover assembly removal on page 4 7 Remove the PC cartridge cooling fan duct See PC cartridge cooling fan duct removal on page 4 99 Disconnect the harness of the PC cartridge cooling fan A to the PC cartridge cooling fan duct B Release two hooks securing the PC cartridge cooling fan A to the PC cartridge cooling fan duct B Note Use care in handling the PC cartridge cooling fan duct hooks as they easily break RON ch 5 Release the harness of the PC cartridge cooling fan A from the slot in the PC cartridge cooling fan duct B 6 Remove the PC cartridge cooling fan A Connector Hooks Front Connector Note Before reinstalling the PC cartridge cooling fan A ensure the fan blade is facing toward the front of the machine Repair information 4 101 4024 110 Sensor fuser exit removal Open the printer left door assembly Remove the fuser unit See Fuser unit assembly removal on page 4 103 Disconnect the connector from the sensor fuser exit A Remove the screw securing the bracket B Remove the three hooks securing the sensor fuser exit A to the bracket B Remove the sensor fuser exit A OO P GAMM ch 4 102 Printer Service Manual 4024 110 Fuser unit assembly removal 1 Open the printer left cover assembly 2 Loosen the two colored knobs securing the fuser unit A 3 Pull on the two colored handles to remove the fu
27. e 7 34 Assembly 20 Electrical c DleS dure r dco edee cedceee 44 b 9S E AAR E SE AE Se bees 7 35 Assembly 21 Electrical cabl wecscicsccciacesisastisac set ee seeeciedeasiescadhbeadcass 7 36 ASSEMbly 22 POWES COMMS EE 7 37 Assembly 23 Miscellaneous 00 eee eee ete eee eee eee 7 38 ol rr er rr ree Li Pari TMOG INGE Ee ee Ke CN BEE ENEE l 5 viii Printer Service Manual 4024 110 Notices Laser notice The printer is certified in the U S to conform to the requirements of DHHS 21 CFR Subchapter J for Class 1 laser products and elsewhere is certified as a Class laser product conforming to the requirements of IEC 60825 1 Class laser products are not considered to be hazardous The printer contains internally a Class IIIb 3b laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770 795 nanometers The laser system and printer are designed so there is never any human access to laser radiation above a Class level during normal operation user maintenance or prescribed service condition Laser Der Drucker erf llt gem amtlicher Best tigung der USA die Anforderungen der Bestimmung DHHS Department of Health and Human Services 21 CFR Teil J f r Laserprodukte der Klasse 1 In anderen Landern gilt der Drucker als Laserprodukt der Klasse der die Anforderungen der IEC International Electrotechnical Commission 60825 1 gem amtlicher Best tigung
28. meda Does the media touch the sensor fuser exit 2 Check the sensor fuser exit for operation Go to step 4 Go to step 3 1 Enter Diagnostics mode 2 Select BASE SENSOR TEST 3 Select Media path 4 Select Fuser exit Open the printer left door assembly and check it A The area around the actuator is very hot Allow the fuser area to cool before proceeding Does the display on the operator panel change every time the sensor actuator is operated 3 Is the sensor fuser exit properly connected Replace the Replace the sensor fuser exit connection Go to Sensor fuser exit removal on page 4 102 4 Perform a print test Replace the Problem solved printer engine card Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 203 00 Sensor exit 2 on jam Step Check Yes No 1 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 2 Check the media position Remove the media Go to step 3 Open the exit 2 left door assembly and check it Does the media touch the sensor exit 2 3 Check the roll Go to step 4 Clean or replace the exit 1 media shift Open printer left door assembly assembly Is the exit 1 media exit roll assembly free of excess wear Go to Exit 1 media and contamination shift assembly removal on page 4 104 2 28 Printer Serv
29. on page 4 119 Diagnostic information 2 71 4024 110 Standard bin 2 full Step Check Yes No 1 Check the actuator for movement Go to step 2 Reinstall the i media weight Does the media weight assembly move up and down normally assembly 2 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 SelectExit level 4 Select Standard bin full exit2 Does the display on the operator panel change every time the sensing area is blocked 3 Check the sensor standard bin full exit 2 connection Replace the Replace the Is the sensor standard bin full exit 2 properly connected senor standard Connection bin full exit 2 Go to step 4 Refer to Options Service Manual 4 Check the exit interface card assembly connection P432 Replace the exit Replace the P433 and P434 interface card connection m assembly Is the exit interface card assembly properly connected P432 P433 and P434 Go to Exit interface card assembly removal on page 4 117 5 Perform a print test Replace the Problem solved f printer engine card Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 Toner cartridge empty Step Check Yes No 1 Check remaining toner Go to step 2 Replace the toner Does the toner cartridge contain toner cartridge 2 Check the toner cartridg
30. registration for proper operation Go to step 7 Go to step 6 1 Enter Diagnostics mode 2 Select BASE SENSOR TEST 3 Select Media path 4 Select Registration Open and check the printer left door assembly Does the display on the operator panel change every time the sensor actuator operates 6 Check the sensor registration connection Replace the Replace the Is the sensor registration properly connected ogetration connection Go to Sensor registration removal on page 4 78 7 Check the sensor pre feed for proper operation in tray 1 Ensure the media Replace the e feed unit front sensor pre feed 1 Enter Diagnostics mode guide is installed i 2 Select NPUT TRAY TESTS properly a d SES pre fee a See test Go to step 9 removal on i age 4 38 5 Select pre feed W s Remove the media tray assembly and check it Does the display on the operator panel change every time a white piece of paper is placed over the sensing area 8 Check the sensor pre feed connection Replace the Replace the Is the sensor pre feed properly connected sensor pre feed connection Go to Sensor pre feed removal on page 4 38 9 Perform a print test Replace the Problem solved Does the error continue AE SR Go to Printer engine card assembly removal on page 4 119 242 00 Sensor pre feed on jam tray 2 feed Step Check Yes No 1 Check the media condition Replace the media Go to step 2 Is the medi
31. 1 Check the media position Remove the Go to step 2 Open the printer left door assembly and visually check it media Does the media touch the sensor fuser exit 2 Check the fuser exit actuator Replace the fuser Go to step 3 8 E SA exit actuator Does the fuser exit actuator appear to be binding or sticking in its normal resting position and not allowing media to Go to Sensor pass fuser exit removal on page 4 102 3 Check the roll Go to step 4 Clean or replace Open the printer left door assembly and check it a roll Is the transport roll assembly free of excess wear and Go to Transfer contamination roll assembly removal on page 4 70 2 24 Printer Service Manual 4024 110 Step Check Yes No 4 Inspect the pinch roll on the transfer roll guide assembly Go to step 5 Replace the transfer roll guide Is the transfer roll guide assembly free of damage assembly Go to Transfer roll guide assembly removal on page 4 74 5 Check the sensor fuser exit for proper operation Go to step 7 Go to step 6 1 Enter Diagnostics mode 2 Select BASE SENSOR TESTS 3 Select MEDIA PATH 4 Select Fuser exit Open the printer left door assembly and check it The area around the actuator is very hot Allow the AN fuser area to cool before proceeding Does the display on the operator panel change every time the sensor actuator is operated 6 Check the sensor fuser exit conne
32. 18 tooth C 10 Remove the transport roll rear bushing D 11 Remove the transport roll front bushing E Note Before reinstalling the media transport roll assembly B do not touch the rubber surface 4 66 Printer Service Manual 4024 110 Printer left lower door assembly removal Open the printer left lower door assembly Remove the two screws securing the bracket A Remove the bracket A Pull the cap of the hinge pin B out with a prying tool to remove the hinge pin B from the bracket A Remove the hinge pin B Remove the printer left lower door assembly C from the bracket A DIRON Repair information 4 67 4024 110 Printer left lower pinch roll assembly removal 1 Open the printer left lower door assembly 2 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 3 Release the two hooks securing the left lower pinch roll assembly A to the printer left lower door assembly B 4 Remove the left lower pinch roll assembly A Screw driver C 4 68 Printer Service Manual 4024 110 Left lower door handle assembly removal Open the printer left lower door assembly Remove the left lower pinch roll assembly See Printer left door support strap removal on page 4 71 Remove the
33. 2 set correctly Pull out media tray 2 and visually check it 3 Check the tray 2 switch media size 2 for proper Go to step 4 Install the tray 2 installation switch media Pull out media tray 2 and visually check it size correctly Is the above switch installed properly 4 Check the tray 2 switch media size connection Replace the switch Replace the Is the tray 2 switch media size properly connected media size SEENEN Go to Switch media size removal on page 4 17 5 Perform a print test Replace the Problem solved Does the error continue EE card Go to Printer engine card assembly removal on page 4 119 Tray 1 media size mismatch in length Step Check Yes No 1 Check the media Go to step 2 Load media Pull out media tray 1 and visually check it properly Is media properly loaded in media tray 1 2 Check the media Go to step 3 Set the guides Pull out media tray 1 and check it properly Are the front media tray guide assembly rear media tray guide and media tray end guide of media tray 1 set correctly 3 Check the switch media size in media tray 1 for Go to step 4 Install the switch installation media size for e media tray 1 Pull out media tray 1 and check it correctly Is the switch media size in media tray 1 installed correctly 4 Check the switch media size in tray 1 connection Replace the switch Replace the Is the switch media size in tray 1 properly connected media
34. 4024 Printer Service Manual
35. 40X0560 1 1 Front door magnetic catch 9 40X0561 1 1 Front door support strap 10 40X0562 1 1 Front inner cover 11 40X0960 1 2 2TM TTM retaining screws 12 40X0551 1 1 Front left cover 13 40X0550 1 1 Left lower cover 14 40X0552 1 1 Top rear cover Warning In the event of replacement of any one of the following components e Operator panel assembly e RIP card assembly Replace only one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more of the components listed above without a POR after installing each one or the printer will be rendered inoperable Warning Never install and remove components listed above as a method of troubleshooting components Once a component has been installed in a machine it cannot be used in another machine It must be returned to the manufacturer Parts catalog 7 3 4024 110 Assembly 2 Covers Assembly Part Units Units kit Description Index number mach or pkg 2 1 40X0566 1 1 Rear motor cover 2 40X2382 1 1 TVOC filter assembly 3 40X0565 1 2 Cable hookup door kit includes e Cable hookup cover e Cable hookup door 4 40X0568 1 1 Option hookup cover 5 40X0567 1 1 Rear lower cover 110 V 5 40X0955 1 1 Rear lower cover 220 V 6 40X0564 1 1 Right lower cover 7 40X0563 1 1 Right upper cover 7 4 Printer
36. 69 4024 110 Error code or Error contents Description Action message Close door B Printer left lower door open The printer left lower door assembly is open Go to Printer left lower door open on page 2 70 Close door C 2TM TIM left door assembly The 2TM TTM door is open opem Refer to Options Service Manual Close door D Duplex left door open The duplex left cover is open Refer to Options Service Manual Close door E Exit 2 left door open The exit 2 left door is open Refer to Options Service Manual Close door G Finisher front door open The finisher front door is open Refer to Finisher Service Manual Close door J Printer front door open The printer front door assembly is open Go to Printer front door open on page 2 68 Close Eject cover open Finisher eject cover is open surface H Refer to Finisher Service Manual Empty hole Punch waste box full The punch waste box is full punch box d Refer to Finisher Service Manual Insert hole Punch waste box missing No punch waste box punch box Refer to Finisher Service Manual Load staples Staple cartridge empty Staple cartridge empty Refer to Finisher Service Manual Load tray 1 or tray 2 with lt media gt No media in the selected media tray Media is not loaded in the tray Go to No media in the select media tray on page 2 65 Load tray 3 or No media in the selected Media is not loaded
37. B inside the machine Remove the connector from switch media size A Remove the switch media size A Q Connector EE Front Repair information 4 17 4024 110 Media feed unit assembly 1 removal Remove the MPF rear cover See MPF rear cover removal on page 4 55 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 51 Remove printer left door assembly See Printer left door support strap removal on page 4 71 Remove the vertical drive gear assembly See Vertical drive gear assembly on page 4 64 Pull out the media Tray 1 Sey gt W W S Front 4 18 Printer Service Manual 4024 110 Release the plastic bosses on both ends of the vertical turn mylar guide A Remove the vertical turn mylar guide A Warning The vertical turn mylar guide will take extra force to remove Be careful not to damage it Release the harness from the plastic clamps on the machine Disconnect the connector Repair information 4 19 4024 110 10 Remove the two screws securing the media feed unit assembly B 11 Remove the media feed unit assembly B in the direction of the arrow Clamp 4 20 Printer Service Manual 4024 110 Media feed unit assembly 2 removal Remove the MPF rear cover See MPF rear cover removal on page 4 55 Remove the MPF feed unit assembly See MPF
38. Brush or blower brush MEDIA FEED UNIT HCF if equipped Feed Roll Inspect Replace Verify page count before replacing Pick Roll Inspect Replace Verify page count before replacing Separation Roll Inspect Replace Verify page count before replacing HCF Transport Roll Assembly Clean Water or alcohol Front Edge Guide Inspect Check for correct positioning Rear Edge Guide Inspect Check for correct positioning Long Edge Guide Inspect Check for correct positioning Separation Pad Inspect Clean Damp cloth TRANSFER ROLL Transfer Roll Inspect Replace FUSER UNIT Fuser Unit Inspect Replace Sensor fuser exit Clean Blower brush DUPLEX if equipped Duplex Transport Roll 2 Clean Water or alcohol Duplex Transport Roll Middle Clean Water or alcohol Preventive maintenance 6 1 4024 110 LEXMARK W8XX EVERY SERVICE CALL EVERY 300K NOTE EXIT 2 if equipped Exit 2 Transport Roll Clean Water or alcohol Exit 2 Media Exit Roll Clean Water or alcohol FINISHER if equipped Bridge Unit Transport Belts Clean Water or alcohol Main Paddles 3 Inspect Sub Paddles 2 Inspect Clamp Paddles 3 Inspect Punch Waste Box Clean Stapler Cartridge Inspect Inspect Check for correct operation Lubrication specifications Lubricate only when parts are replaced or as needed not on a scheduled basis Use of lubricants other than those specified can cause premature failure Some unautho
39. Check the transfer roll assembly for rotation contamination and wear 5 Check white band pitch Go to step 6 Go to step 9 Is the white band pitch approximately 78 mm heat roll circumference 6 Check the heat roll and pressure roll Replace the Go to step 7 F fuser unit Remove the fuser unit assembly assembly Is there contamination or cracking on the heat roll and or the pressure roll 7 Check the image development process Go to step 8 Go to step 9 Perform a print test Turn off the printer power while printing Carefully remove the PC cartridge and check the toner image formed on the drum before the transfer roll assembly Is the image completely formed on the drum and is the area clear black and easy to read Diagnostic information 2 89 4024 110 Step Check Yes No 8 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 9 Check the HVPS card assembly Go to step 10 Problem solved Replace the HVPS card assembly Perform a print test Does the problem continue 10 Check the printer engine card assembly Replace the RIP Problem solved Replace the printer engine card assembly Gard assembly Go to RIP card Perform a print test assembly Does the error continue removal on page 4 126 2 90 Printer Service Manual 402
40. Development The toner contained within the PC Cartridge has a magnetic property that causes it to adhere to the Magnetic Roll The Metering Blade spreads the toner into a very thin layer on the Magnetic Roll Friction between the Magnetic Roll and the CM Blade generates a small electrical charge that is transferred to the toner The surface of the Magnetic Roll is made up of a thin sheet of conductive material The HVPS supplies the Magnetic Roll with two voltages a DC voltage and an AC voltage The DC voltage is used to transfer toner from the Magnetic Roll to the surface of the drum The AC voltage agitates the toner on the Magnetic Roll making toner transfer easier The Magnetic Roll maintains a negative DC electrical potential Negative charged areas of the drum have a lower electrical potential or higher relative negative value than the Magnetic Roll Discharged areas of the drum have a higher electrical potential or lower relative negative value than the Magnetic Roll A discharged point on the surface of the drum now appears less negative in relation to the negative charge on the Magnetic Roll 3 48 Printer Service Manual 4024 110 The toner adhering to the Magnet Roll is always in contact with the drum surface When a less negative point on the drum a discharged area comes in contact with the more negative charged toner on the Magnet Roll toner transfers from the Magnet Roll to that point on the drum There is now a visible toner im
41. 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 3 Remove the nine screws securing the LVPS card assembly A to the printer 4 120 Printer Service Manual 4024 110 4 Remove the LVPS card assembly A Note Grasp the card by the edge avoid touching the bottom of the LVPS assembly A v E 3 q L E aal Q O L AR F002 Repair information 4 121 4024 110 AC power input socket assembly removal A Remove the rear RIP card cover See Rear RIP card cover removal on page 4 125 Remove the rear motor cover See Rear motor cover removal on page 4 14 Remove the rear lower cover See Rear lower cover removal on page 4 15 Remove the top cover assembly See Top cover assembly removal on page 4 7 Remove the right upper cover See Right upper cover removal on page 4 11 Remove the three screws securing the AC power input socket assembly A Release the harness from the clamp Remove the AC power bracket assembly A ONDARON KS Warning Before reinstalling ensure all connectors are plugged into their proper location to prevent damage 4 122 Printer Service Manual 4024 110 AC power input socket removal A Remove the rear
42. EVENT LOG on page 3 24 Paper Prompts See Paper Prompts on page 3 24 Env Prompts See Env Prompts on page 3 25 Jobs On Disk if hard disk is installed See Jobs On Disk on page 3 25 Disk Encryption only if hard disk is installed and feature is set up See Disk Encryption on page 3 25 Font Sharpening See Font Sharpening on page 3 25 Short edge Printing See Short Edge Printing on page 3 25 3 19 Diagnostic aids 4024 110 Configuration Menu continued Tray Low Message See Tray Low Message on page 3 25 Exit Config Menu See Exit Config Menu on page 3 25 Some menus are not available depending on the configuration of the printer Maintenance page count Maint Cnt Value The current value for the maintenance page counter is displayed This counter tracks printer usage A print job containing a single page increments the counter by one and a duplex page by two At 300 000 the customer is reminded that the printer requires scheduled maintenance This counter is reset by the servicer after a 80 Scheduled Maintenance message displays and a maintenance kit is installed See Scheduled maintenance on page 6 2 for maintenance kit part number To view the maintenance page count 1 Select Maint Cnt Value from CONFIG MENU 2 Press to view the value Press Back to return to the main Configuration me
43. Eeer SE connection Go to Sensor registration removal on page 4 78 11 Check the registration clutch for proper operation Go to step 13 Go to step 12 1 Enter Diagnostics mode 2 Select MOTOR TESTS 3 Select Regi strat clutch Does the above component operate normally 12 Check the registration clutch connection Replace the Replace the Is the registration clutch properly connected EE connection Go to Registration clutch assembly removal on page 4 77 2 78 Printer Service Manual 4024 110 Go to Printer Step Check Yes No 13 Perform a print test Replace the Problem solved printer engine card Does the error continue assembly engine card assembly removal on page 4 119 Tray 2 media size mismatch in length Step Check Yes No 1 Check the media Go to step 2 Load media Pull out tray 2 and visually check it properly Is media loaded in tray 2 properly 2 Check the media Go to step 3 Set the guides Pull out tray 2 and check it properly Are the front media tray guide assembly rear media tray guide and media tray end guide of tray 2 set correctly 3 Check the switch media size for tray 2 installation Go to step 4 Install the switch Is the switch media size for tray 2 installed correctly media size for l y y tray 2 correctly Pull out tray 2 and check it Go to Switch media size removal on page 4 17 4 Check the switch m
44. Go to step 2 Is the media in the MPF tray crumpled or damaged age ensure 2 Check the media size setup Go to step 3 Replace the Does the media size in use match the size set for MPF tray Pa eat a setup 3 Check the media position Remove the Go to step 4 Open the printer left door assembly and visually check it media Does the media touch the sensor registration 4 Check the MPF media side guides for proper operation Go to step 5 Adjust the MPF Do the MPF media side guides operate smoothly P guides 5 Check the MPF for installation Go to step 6 Problem solved Remove the MPF feed unit assembly and reinstall it Perform a print test Does an error occur during print test 6 Check the roll Go to step 7 Clean or replace Remove the MPF pick unit assembly AT ee pi Is the MPF feed roll assembly free of excess wear and Go to MPF feed contamination unit assembly removal on page 4 51 7 Check the roll Go to step 8 Clean or replace Remove the MPF feed unit assembly A a roll Is the MPF feed roll assembly free of excess wear and Go to MPF feed contamination unit assembly removal on page 4 51 8 Check the sensor registration for proper operation Go to step 10 Go to step 9 1 Enter Diagnostics mode 2 Select BASE SENSOR TESTS 3 Select Media path 4 Select Regi stration Open the printer left door assembly and check it Does the display on the operator panel change every time the sensor actuator is operated 9 Che
45. He 4545 468 004 ix Laser noei cost ccernAe E E EE ix Lithium WANG ssi okie his eee Ae eRe REE ee eee ER AEN A EES en EC xiii Safety informati n sri EEN EES coum einem seem ds Rae eda A a A xiii Prae E TEE EE xvi CONVENTIONS Sege geet mate tire daa ee EE RL ee RE ek ek Rad RO RAL DOE xvi General information 00 00 00 0 0 ccc ccc been n eben ene es 1 1 HOCUS MENUS E aces eke tes Sens ewereewetiGawtausecaeberaunsdagas 1 1 Printer OVEIVIOW EIERE ar cee aicae reese ewe eR SNE Ree eRe Caw ee ewe de ew eee ales 1 1 Basic MOdEl 59 895 d ERR eed nee eRe eRe eee eR Sd Oem Re SEET A RE 1 1 Contigured model i663 iiws i died Awades ease EE 1 2 TOMS TEQUITEHIOL SEVICE REEL tara ed eta et eee nates ROR RES NTR eae 1 2 ACTON MS ere eter rte eee cree Te eee ee Te Ee re rr eer ree erg 1 3 Diagnostic EVER AA ENEE dE EE EE E EE ER EE senses ieeesaseaser 2 1 J eeC te eter Tre ree eer eee EE 2 1 USING SENE E EE 2 1 Contitm the installation Status ae ge eed ewan de Giese sok oR leet ANER EES A 2 2 POR Sequence EE 2 2 Primer operator panel 5x seine smc AE mm es RE Ech 2 3 Biron Cove messages ebe Ee E E EE e ee 2 5 Service CHECKS iad ha Gani COE TeEN SLAG see aE a a c hes Caden awe ede 2 23 200 00 Sensor registration off jam too long 6 ee eee 2 23 200 01 Sensor registration static ON jam wk eee 2 24 201 00 Sensor fuser exit On jam 988 SERIES REES RRE EIER sage ree hees EE SEET 2 24 202 00 Sensor fuser exit Off jam 2 26 202 0
46. L 5VDC i ctl EL i ojolN co Lo st n K PC Cartridge Motor CW CCW QOS PC Cartridge Motor ON L 5VDC g g xl oldo Z 2Z 2 H e gt oo l 2 is 5 H Z SO Si SE EI PC Cartridge Motor REF Clock H Media Shift Mes o g8 5656 Sel kenrg i PC Cartridge Motor Fail H 5VDC 4 heed Fuser Cooling g ay g 5 Q Q S oO SD sl Media Trans Motor REF Clock Motor Fan Motor 1 lt EENS SE E i MIC Clock 4 Nea e lodlenlst lu 7 S S g 3 Oe S j 5VDC 7 Cartridge LNS pp 1 F a Motor e Ech 2 7 1 L 24VDC 1 VL 24VDC Kach lt a lt a l o O eg Ze Soe 5568 S SS e g A TS S 5 to ba lt gt Hl EXIT MED Shift SNR L SEKR PC Cartridge SE Als 28 d 3 PARERE N101 S 2 2E H Zz gt ui g8istagga ae SE EE Cooling Fan g sia a8 e S 1 gszi e SIG GND BEER Ek CB asi 33 EE a NNN NN BN i RR je Ia Dual Drive 2 oi 9 2 2 2 3 SI oe ao O o S S 1 SBZOREIE E Std Bin Full 1SNR L 2233 al a lo SS re Brel u e g E KE 05 olo ooz 3k Helo Bog tsb seal e5 3885 S s 5 2 2 2 2 3 2 x Sg Motor ASM e 3 Ahad tge sagsog sss 33 ogie g gs 8 1 KERRERREER SS otor o Sensor r BERRE PERELE PEFR EET BET EPERIRPFEnE S dE E S D bd E ba Std Bin Full Exit 1 E gala eee fo Ve ee EIERE 8 sea le yo Feseeeess teas l eg A CT Ad Se Ee CS RR SS KR RK j Switch Printer Left 2 KEE ERE S SES Door Interlock Biol 6 8 p zao eje w115 SIG GND E Wa ze a x e
47. MPF transport roll assembly C do not touch the rubber surface Note Before reinstalling the MPF transport roll assembly C do not touch the rubber surface 4 58 Printer Service Manual 4024 110 MPF pick solenoid pick lever removal oor eh o N Remove the MPF rear cover See MPF rear cover removal on page 4 55 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 51 Remove the MPF feed drive gear group See MPF feed drive gear group removal on page 4 56 Remove the screw securing the pick solenoid A Disconnect the connector from the pick solenoid A Remove the MPF pick solenoid A Note When removing the pick solenoid A lower the actuator B Remove the pick lever B Remove the spring C Actuator Repair information 4 59 4024 110 MPF feed shaft assembly removal Remove the MPF rear cover See MPF rear cover removal on page 4 55 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 51 Remove the MPF pick roll See MPF pick roll removal on page 4 61 Remove the MPF feed drive gear group See MPF feed drive gear group removal on page 4 56 Remove the two e rings with a prying tool that secures the feed shaft assembly A to the MPF feed unit assembly Remove the two bushings B Release the hooks securing the two feed shaft cams C and slide them inward towards the center of the MPF feed sha
48. Manual Diagnostic information 2 5 4024 110 Error code or Error contents Description Action Check area D message 230 00 Sensor duplex wait on jam The sensor duplex wait is not turned on within the P f specified time after the exit2 motor is turned on aper jam i Sherk areas Refer to Options Service Manual AE 230 01 sensor duplex wait static Media remains on the sensor duplex wait Paper jam Jam Refer to Options Service Manual Check areas 231 00 Sensor registration on jam Sensor registration is not turned on within the Paper jam duplex media feed specified time after the duplex motor is turned on Check areas Refer to Options Service Manual A D 231 01 Sensor registration on jam Sensor registration is not turned on within the duplex media feed specified time after the sensor duplex wait is Paper jam turned on Refer to Options Service Manual Check areas A D 241 00 Sensor pre feed on jam The sensor pre feed tray 1 is not turned on within Paper Jam tray 1 feed the specified time after the tray 1 media feed lift motor is turned on le alga Go to 241 00 Sensor pre feed on jam tray 1 ay feed on page 2 32 241 01 Sensor registration on The sensor registration is not turned on within the P S jam tray 1 feed specified time after the sensor pre feed media aperjam feed unit 1 is turned on Go to 241 01 Sensor registration on jam
49. No 1 Check the media Go to step 2 Load media Pull out media tray 1 and visually check it Is media loaded in tray 1 2 Check the media tray Go to step 3 Go to step 4 Replace media tray 1 with media tray 2 Is the replaced media tray lifted up 3 Check the media tray Replace the media Go to step 4 Are the tray lift sector gear 12T of media tray 1 or KE d Se gear surrounding parts damaged damaged components 4 Check the tray 1 media feed lift motor for operation Go to step 9 Go to step 5 Pull out the media tray and then push it back in Does the motor lift up the tray normally 5 Is the tray 1 media feed lift motor properly connected Go to step 6 Replace the connection Diagnostic information 2 57 4024 110 Step Check Yes No 6 Check the tray 1 media feed lift motor for operation Reinstall the Go to step 7 i f o media feed lift e the tray 1 media feed lift motor with the motor from motor for media tray 2 as it was Pull out the media tray and then push it back in Replace the motor Does the motor rotate normally for media tray 1 with a new motor 7 Check the tray 1 sensor media level for operation Go to step 9 Go to step 8 1 Enter Diagnostics mode 2 Select NPUT TRAY TESTS 3 Select Sensor test 4 SelectTray 1 5 Select Media level Remove the media tray assembly Move the pick roll with your finger up and down Note Avoid touching t
50. Open the rear motor cover and check it SCH Can the rotor be rotated by hand without excessive load 4 Check the dual drive motor assembly connection Replace the dual Replace the Is the dual dri t bl ted drive motor connection s the dual drive motor assembly properly connected assembly 5 Perform a print test Replace the Problem solved D th f c ntinue printer engine card oes the error continue assembly Go to Printer engine card assembly removal on page 4 119 912 00 PC cartridge unit motor failure Step Check Yes No 1 Check the PC cartridge for installation Go to step 2 Install the PC Is the PC cartridge installed securely cartridge sectrely 2 Check the dual drive motor assembly for 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 SelectDrum unit motor Does the motor rotate normally 3 Check the dual drive motor assembly for installation Go to step 4 Install the dual Open the rear motor cover and check it GC Is the dual drive motor assembly installed securely securely 4 Check the rotation of the rotor in the dual drive motor Go to step 5 Install the dual assembly drive motor i assembly Open the rear motor cover and check it securely Can the rotor be rotated by hand without excessive load 2 46 Printer Service Manual 4024 110 Step Check Yes No 5 Check the dual
51. P jam tray 4 media feed the specified time after the sensor tray 4 feed out aper jam is turned on Check areas Refer to Options Service Manual 244 03 Paper jam Check area B Sensor registration on jam tray 4 media feed The sensor registration is not turned on within the specified time after the sensor tray 4 feed out is turned on Refer to Options Service Manual 244 04 Sensor pre feed on jam The sensor pre feed is not turned on within the Paper jam tray 4 media feed specified time after the tray 4 feed lift motor is turned on e heck area Refer to Options Service Manual ray 4 244 05 Sensor tray 4 feed out static Media remains on the sensor tray 4 feed out Paper jam ER Refer to Options Service Manual Check areas C tray 4 245 00 Sensor tray 5 feed out on The sensor tray 5 feed out is not turned on with in jam the specified time after the HCF feed lift motor is Paper jam turned on Check area K tray 5 Refer to Options Service Manual Diagnostic information 2 7 4024 110 2 8 Printer Service Manual Error code or Error contents Description Action message 245 01 Sensor tray 5 feed out on The sensor tray 5 feed out on the printer is not Paper jar jam turned on within the specified time after the HCF per feed lift motor is turned on Check area K Refer to Options Service Manual 245 02 Paper jam Check area B Sensor r
52. RIP card cover See Rear RIP card cover removal on page 4 125 Remove the rear motor cover See Rear motor cover removal on page 4 14 Remove the rear lower cover See Rear lower cover removal on page 4 15 Remove the three screws securing the bracket A Disconnect the two connectors to the AC power input socket B Remove the two screws securing the AC power input socket B to the bracket A Remove the AC GFI breaker B IHN Mul ZN d s ol 6 ee a En ET oO oe eS Warning Before reinstalling ensure all connectors are plugged into their proper location to prevent damage Repair information 4 123 4024 110 Finisher AC output removal A Remove the RIP card cover See Rear RIP card cover removal on page 4 125 Remove the rear motor cover See Rear motor cover removal on page 4 14 Remove the rear lower cover See Rear lower cover removal on page 4 15 Remove the three screws securing the bracket A Disconnect the three connectors to the finisher AC output B Release the two hooks securing the finisher AC output B to the bracket A Remove the finisher AC output B E e gt y OS Warning Before reinstalling ensure all connectors are plugged into their proper location to prevent damage 4 124 Printer Service Manual 4024 110 Rear RIP card cover removal 1 Loosen the two screws securing the rear R
53. 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 See Maintenance page count Maint Cnt Value on page 3 20 Reset Maint Cnt See Maintenance page counter reset Reset Maint Cnt on page 3 20 REGISTRATION See REGISTRATION on page 3 21 Top Margin See Top Margin on page 3 21 Tray 1 Left Mar Tray 2 Left Mar Tray 3 Left Mar if installed Tray 4 Left Mar if installed Tray 5 Left Mar if installed See Tray 1 5 Left Margin on page 3 21 Quick Test See Quick Test on page 3 22 Prt Quality Pgs See Print quality pages Prt Quality Pgs on page 3 22 SIZE SENSING Tray 1 Sensing Tray 2 Sensing Tray 3 Sensing if installed Tray 4 Sensing if installed Tray 5 Sensing if installed See SIZE SENSING on page 3 23 Statement A5 See Statement A5 on page 3 23 Executive B5 See Executive B5 on page 3 23 Panel Menus See Panel Menus on page 3 23 PPDS Emulation See PPDS Emulation on page 3 24 Demo Mode See Demo Mode on page 3 24 Factory Defaults See Factory Defaults on page 3 24 Energy Conserve See Energy Conserve on page 3 24 EVENT LOG print log only See
54. Remove the five screws securing the metal frame A to the plastic cover B Remove the metal frame A by lifting it upward and sliding outward Remove the three screws securing the handle cover C Remove the handle cover C Remove the printer left door assembly handle D Remove the spring E Repair information 4 75 4024 110 Registration roll assembly removal ll ll ae San P Remove the MPF rear cover See MPF rear cover removal on page 4 55 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 51 Remove the printer left door assembly See Printer left door support strap removal on page 4 71 Remove the bosses on both ends of the vertical turn mylar guide A Remove the vertical turn mylar guide A Warning The vertical turn mylar guide A requires moderate force to remove Be careful not to damage it Remove the two screws securing the registration mylar guide assembly B to the registration roll assembly C Remove the registration mylar guide assembly B Remove the two screws securing registration roll assembly C Remove the registration roll assembly C by lifting it upward and outward in the direction of the arrow Note When removing the registration roll assembly C use care not to damage the two harnesses located on the backside of the assembly Release the harness from the clamp 11 Disconnect the two connectors from the registration roll
55. Remove the media tray 2 Remove the feed roll See Feed roll removal on page 4 42 3 Remove the feed roll one way clutch A from the shaft B Repair information 4 43 4024 110 Feed roll one way gear 22 tooth removal Remove the media tray Remove the feed roll See Feed roll removal on page 4 42 Remove the feed roll one way clutch See Feed roll one way clutch removal on page 4 43 Remove the feed roll one way gear 22 tooth A from the shaft B eh 4 44 Printer Service Manual 4024 110 Separation roll one way friction clutch removal Remove the media tray Remove the separation roll See Separation roll removal on page 4 46 Remove the separation roll spacer A from the shaft B Remove the separation roll one way friction clutch C from the shaft B GET Repair information 4 45 4024 110 Separation roll removal Remove the media tray Move the feed unit front guide A in the direction of the arrow Release the hook securing the separation roll B to the shaft C Remove the separation roll B Note Do not touch the rubber surface of the feed roll B Pen gt Note Before reinstalling do not touch the rubber surface of the separation roll B 4 46 Printer Service Manual 4024 110
56. See Front inner cover removal on page 4 10 Remove the toner cartridge guide assembly See Toner cartridge guide assembly removal on page 4 93 Coon Repair information 4 97 4024 110 8 Disconnect the three connectors from the printhead assembly A 9 Disconnect the connector from the junction harness 10 Remove the four screws securing the printhead assembly A 11 Remove the printhead assembly A by lifting it upward W A Fs a 4 98 Printer Service Manual 4024 110 PC cartridge cooling fan duct removal Remove the top cover assembly See Top cover assembly removal on page 4 7 Disconnect the harness from the duct connector Release the connector harness from the clamp on the PC cartridge cooling fan duct A Release the hook securing the PC cartridge cooling fan duct A to the toner cartridge guide assembly B Soh Front view Repair information 4 99 4024 110 5 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 6 Remove the PC cartridge cooling fan duct A Connector Connector Clamps Connector 4 100 Printer Service Manual 4024 110 PC cartridge cooling fan removal Remove the top cover assembly
57. To run the Print Quality Test Pages 1 Select PRINT TESTS from DIAGNOSTICS 2 Select Prt Quality Pgs from PRINT TESTS The message Printing Quality Test Pages is displayed Note The print quality test pages can also be printed from the Configuration menu CONFIG MENU however a cartridge must be installed with a machine class ID matching the machine class ID stored in NVRAM Additional diagnostic information may be printed on the pages when printing from DIAGNOSTICS The following is included in the DIAGNOSTICS version of the print quality pages e Values from EP SETUP in DIAGNOSTICS including Fuser temperature warm up time transfer print contrast and charge roll settings e Contents of the EVENT LOG from DIAGNOSTICS e Configuration information including printer serial number controller code level engine code level operator panel code level font versions and cartridge information e Default values for the QUALITY MENU settings used to print the pages HARDWARE TESTS Select the following Hardware Tests from this menu e Panel Test e Button Test e DRAM Test e CACHE Test Panel Test This test automatically toggles all pixels of the operator panel through every contrast level beginning with the darkest and on to the brightest This test continues until you press Stop Button Test The Button Test verifies the operation of the buttons on the operator panel When you select Button Test a diagram of the operator
58. Units kit aon bly Description number mach _ or pkg Index 22 NS_ 40X0269 1 1 Power cord USA ET AL 8ft right angle NS 40X0296 1 1 Power cord Australia 6ft straight NS 40X0297 1 1 Power cord USA ET AL 6ft straight Parts catalog 7 37 4024 110 Assembly 23 Miscellaneous Asm Part Units Units kit Description Index number mach or pkg p 23 NS 40X0956 1 14 Maintenance kit 110 V e Fuser unit assembly e Transfer roll assembly e Feed rolls 4 each e Pick rolls 4 each e Separation rolls 4 each NS 40X0957 1 14 Maintenance kit 220 V e Fuser unit assembly e Transfer roll assembly e Feed rolls 4 each e Pick rolls 4 each e Separation rolls 4 each NS 40X0958 1 14 Maintenance kit 100 V e Fuser unit assembly e Transfer roll assembly e Feed rolls 4 each e Pick rolls 4 each e Separation rolls 4 each W850 Forms and Bar code card W850 IPDS and SCS TNEcard RS 232C serial interface card Hard disk Parallel 1284 B interface card MarkNet N8120 Gigabit Ethernet MarkNet N8130 Fiber Ethernet 100BaseFX 10BaseFL 256MB DDR2 DRAM 512MB DDR2 DRAM 1024MB DDR2 DRAM 256MB Flash card Korean font card NS 40X1373 NS 40X1379 NS 40X4819 NS 40X4822 NS 40X4823 NS 40X4826 NS 40X4827 NS 40X5301 NS 40X5302 NS 40X5303 NS 40X5704 NS 40X5969 NS 40X5970 NS 40X5971 NS 40X5972 Japanese font card NS 40X0948 NA NA Assorted e clip packet NS 40X0949 NA NA Assorted screw packet Simplified font
59. and wear Diagnostic information 2 87 4024 110 Step Check Yes No 8 Check the heat roll and pressure roll Replace the fuser Go to step 9 unit assembly Remove the fuser unit assembly Is there contamination or cracking on the heat roll or pressure roll 9 Check the printer engine card assembly Go to step 10 Problem solved Replace the printer engine card assembly Perform a print test Does the error continue 10 Check the printhead for connection Replace the RIP Replace the Warning If too much force is applied to the board when card assembly connection checking it the printhead could become misaligned Go to RIP card assembly Is the component connected properly removal op page 4 126 2 88 Printer Service Manual Leading edge Horizontal band printheads out 4024 110 Trailing edge Step Check Yes No 1 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 2 Are the media transfer route and the media path free of Go to step 3 Remove debris contamination and debris or contamination 3 Check the toner cartridge Problem solved Go to step 4 Install a new toner cartridge Re print the defective image Is the image density normal 4 Check the transfer roll assembly Go to step 5 Replace the Remove the transfer roll assembly e
60. assembly Remove the bracket A Note The gears may become detached from the bracket A Remove the media feed unit drive gear 28 21 tooth B Harness Rear Note Before reinstalling ensure all gears and washers are securely attached to the bracket A Repair information 4 39 4024 110 Media feed unit drive gear 29 tooth removal 1 Remove the appropriate media feed unit assembly See Media feed unit assembly 1 removal on page 4 18 or Media feed unit assembly 2 removal on page 4 21 2 Remove the harness from the bracket A 3 Remove the three screws securing the bracket A to the media feed unit assembly 4 Remove the bracket A Note The gears may become detached from the bracket A 5 Remove the media feed unit drive gear 29 tooth B Harness 4 40 Printer Service Manual 4024 110 6 Remove the media feed unit drive gear 29 tooth B Harness Note Before reinstalling ensure all gears and washers are securely attached to the bracket A Repair information 4 41 4024 110 Feed roll removal Remove the media tray Move the feed unit front guide A in the direction of the arrow Release the hook securing the feed roll B to the shaft C Remove the feed roll B Le at eo Note Do not touch the rubber surface of the feed roll B 4 42 Printer Service Manual 4024 110 Feed roll one way clutch removal 1
61. assembly Go to Toner add motor assembly removal on page 4 95 7 Perform a print test Replace the Problem solved f printer engine card Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 Toner cartridge failure Step Check Yes No 1 Check the toner cartridge installation Go to step 2 Install the correct S toner cartridge Is the correct toner cartridge properly installed properly 9 2 Checking the sensor RFID toner cartridge for installation Go to step 3 Install the sensor Is the sensor RFID toner cartridge installed correctly aaa correctly 2 74 Printer Service Manual 4024 110 Step Check Yes No 3 Checking the sensor RFID toner cartridge connection Replace the Replace the sensor RFID connection Is the sensor RFID toner cartridge properly connected toner cartridge 4 Perform a print test Replace the Problem solved Does the error continue cee carg Go to Printer engine card assembly removal on page 4 119 Toner cartridge RFID failure Step Check Yes No 1 Check the toner cartridge installation Go to step 2 Install the toner Is the toner cartridge properly installed cartridge properly 2 Check the sensor RFID toner cartridge installation Go to step 3 Install the sensor Is the sensor RFID toner cartridge properly installed ee correctly 3 Check th
62. assembly P P y i securely Is the fuser unit assembly installed securely 2 Check the fuser unit assembly for proper connection Go to step 3 Replace the connection 3 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 AN 4 Perform a print test Replace the Problem solved f printer engine card Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 Diagnostic information 2 51 4024 110 922 00 Center thermistor failure Step Check Yes No 1 Check the fuser unit assembly for installation Go to step 2 Install the fuser Open the printer left door assembly and check it unit assembly H P y i securely Is the fuser unit assembly installed securely 2 Check the fuser unit assembly connection Replace the fuser Replace the Is the fuser unit assembly properly connected unit assembly SERIES 3 Perform a print test Replace the Problem solved Does the error continue Beene card Go to Printer engine card assembly removal on page 4 119 923 00 Rear thermistor failure Step Check Yes No 1 Check the fuser unit assembly for installation Go to step 2 Install the fuser Open the printer left door assembly and check it unit assembly p p y i securely Is the fuser unit assembly installed securely
63. content of the Print Test Page varies depending on the media installed in the selected input source Check each Test Page from each source to assist in print quality and paper feed problems To run the Print Test Page 1 Select PRINT TESTS from DIAGNOSTICS 2 Select the media source Tray 1 Tray 2 Tray 3 if installed Tray 4 if installed Tray 5 if installed Multipurpose Feeder 3 Select Single or Continuous e If Single is selected a single page is printed e If Continuous is selected printing continues until Stop is pressed to cancel the test If a source is selected that contains envelopes an envelope test pattern is printed If Continuous is selected the test pattern is printed only on the first envelope Note The Print Test Page always prints on one side of the paper regardless of the duplex setting or the presence of a duplex option Press Back to return to PRINT TESTS Diagnostic aids 3 5 4024 110 Print quality pages Prt Quality Pgs The purpose of this diagnostic function is to allow printing of the print quality test pages with the toner cartridge lockout function disabled The print quality pages consists of four pages Page one contains a mixture of graphics and text Page two is gray with black boxes Page three is solid black The last page is blank If duplex is turned on the pages are duplexed The Print Quality Test pages are printed in English and print on the media available in Tray 1
64. cover See Printer front left cover removal on page 4 3 Remove the top cover assembly See Top cover assembly removal on page 4 7 Remove the PC cartridge Remove the toner cartridge Remove the printer front door assembly See Printer front door assembly removal on page 4 8 Remove the front inner cover See Front inner cover removal on page 4 10 Remove the HVPS card See High voltage power supply HVPS card removal on page 4 115 Remove the toner cartridge guide assembly See Toner cartridge guide assembly removal on page 4 93 Remove the rear lower cover See Rear lower cover removal on page 4 15 Disconnect the two connectors P403 and P404 from the printer engine card assembly A Release the harnesses from the two clamps Remove the registration roll assembly See Registration roll assembly removal on page 4 76 Repair information 4 87 4024 110 13 Remove the two screws securing the laser opening guide B 14 Release the harness from the clamp on the laser opening guide B 15 Disconnect the connector from the laser opening guide B 16 Remove the laser opening guide B by lifting it upward then outward in the direction of the arrow 4 88 Printer Service Manual 4024 110 17 Remove the four screws securing the PC cartridge guide D I Sf EMAAR TTT
65. failure Step Check Yes No 1 Check the sensor exit 1 media shift HP for operation Go to step 3 Go to step 2 1 Enter Diagnostics mode 2 Select BASE SENSOR TESTS 3 Select Media Path 4 SelectExit shift HP Move the shift assembly with your finger in a side to side motion Does the display on the operator panel change every time the sensing area is blocked 2 Check the sensor exit 1 media shift HP for connection Replace the Replace the Is the sensor exit 1 media shift HP connected sada att HP epnnecion Go to Exit 1 media shift assembly removal on page 4 104 3 Check the media shift motor for operation Go to step 5 Go to step 4 1 Enter Diagnostics mode 2 Select MOTOR TESTS 3 SelectExit shift motor Note A continuous operation check is allowed up to twice for each direction Does the motor operate normally 4 Check the media shift motor for connection Replace the media Replace the Is the above motor connected properly Sr Sree connecten Go to Media shift motor removal on page 4 107 5 Check the printer engine card assembly for connection Replace the exit Replace the P421 and the exit interface card assembly connector P431 interface card connection Are the above cards connected properly assembly Go to Exit interface card assembly removal on page 4 117 6 Perform a print test Replace the Problem solved F printer engine card Does the error still oc
66. feed lift motor for operation Reinstall the Go to step 7 Replace the tray 2 media feed lift motor with media tray 1 media feed lift H y IT motor for tray 1 as Pull out the media tray and then push it back in it previously was Does the above motor rotate normally Go to Media feed lift motor removal on page 4 30 Replace the tray 2 motor with a new one Go to Media feed lift motor removal on page 4 30 7 Check the tray 2 sensor media level 2 for operation Go to step 9 Go to step 8 1 Enter Diagnostics mode 2 Select NPUT TRAY TESTS 3 Select Sensor test 4 SelectTray 2 5 Select Media level Remove the media tray assembly Move the pick roll with your finger up and down Note Avoid touching the rubber roll surface Does the display on the operator panel change every time the sensing area is blocked 8 Check the tray 2 sensor media level connection Replace the Replace the Is the tray 2 sensor media level properly connected Get media connection Go to Sensor media level removal on page 4 36 9 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 4 119 Diagnostic information 2 59 4024 110 951 XX RIP card assembly NVRAM failure Step Check Yes No Perform a POR Does the error occur when the power is turned off on Go to step 2 Per
67. feed rolls to feed media When the pick roll picks up media the remaining media decreases and the actuator of the sensor media level lowers accordingly When the sensor media level detects the lowering the media feed lift motor is activated to lift the lift up shaft and the bottom plate accordingly Thus the remaining media is ready to be fed Media feed lift motor This motor is activated to feed media and to lift the bottom plate When feeding media it rotates forward to drive the pick roll When lifting the bottom plate it rotates reversely to drive the tray module gears to lift the lift up shaft Switch media size This switch media size sets the size of media supplied from each media tray assembly A signal indicating the media size is transmitted as a voltage to the printer engine card assembly Sensor media out If media runs out in a media tray assembly the actuator lowers and the actuator flag unlocks the sensing area of the sensor media out The sensor light is transmitted When the sensing area is blocked media is present the signal is off Diagnostic aids 3 31 4024 110 Sensor media level This sensor detects by the actuator position whether media in the media tray assembly is lifted When the flag of the actuator unblocks the sensing area of the sensor media level the sensor detects that the media has been lifted Sensor pre feed This sensor detects a media jam in the media tray assembly
68. feed unit assembly removal on page 4 51 Remove the printer left door assembly See Printer left door support strap removal on page 4 71 Open the printer left lower door assembly See Printer left lower door assembly removal on page 4 67 Remove the vertical drive gear assembly See Vertical drive gear assembly on page 4 64 Pull out the media Tray 2 Sx of SONS TW E O NA WN Repair information 4 21 4024 110 7 Release the plastic bosses on both ends of the vertical turn guide A 8 Remove the vertical turn guide A 4 22 Printer Service Manual 4024 110 9 Release the harness from the plastic clamps on the machine 10 Disconnect the harness connector from the machine 11 Remove the two screws securing the media feed assembly B 12 Remove the media feed assembly B in the direction of the arrow Harness connector Repair information 4 23 4024 110 Media tray side guides removal Remove the media tray Remove the two e rings securing the metal bottom plate A to the media tray using a small prying tool Push the front hinge point B in the direction of the arrow to release the front boss from the metal bottom plate A Remove the metal bottom plate A by sliding it off the rear boss gt eS E ring Rear boss LO S quare hole 4 24 Printer Service Manual NOU 4024 110 Remove the two
69. heehee ees eRe ee ees de eee eee cena 7 1 Assembly 1 Covers and operator panel 1 of 2 0 eee eee 7 2 Assemb 27 COVERS sisiran onire enine cpasd padee denis darn ees cee SE RSE 7 4 Assembly 3 Mediafeed umit cic2 52 cscakesaadie dah be bse be cob A EELER wae 7 5 Assembly 4 Media feed unit exploded tray 1 and tray 2 0 0 eee eee eee 7 6 Assembly 5 Mediattay 2dic2 02005 Eeer eh i S48 EES ge EE Rae eR od 7 8 Assembly 6 MPF UNI ae AE EE NEE AE sate E EEN NEE EE EE 7 10 Assembly 7 MPF UN feed pc csccccad ceacdeetaad ss cube Seb EE UNE AER EE AER 2S 7 12 Assembly 8 Left lower door and transport 7 14 Table of contents vii 4024 110 Assembly 9 Left door and transfer roll 0 cece eee eee 7 16 Assembly 10 Printer left door 20icenccsieetesedisensise dicks hd ese beeassdee eyed ae ee 7 18 Assembly Ti REGISNaAllON WEE 7 20 Assembly 12 Printhead cartridge guides and fans 7 22 Assembly 13 Fueerg si6c0 3000556 EE 654 6 B49 ON CEO bis PARLE GEOL NEE EE ier 7 24 Assembly 14 Standard Exit 1 ccc ccc REEL RER A E EES pbe oe eee ated e acne aaan a 7 26 Assembly 15 Dual unit drive motor 0 0 tee ee 7 28 Assembly 16 Eet AAA see ness 3b bangs AE e ba cesGe oun dma Radda ARGS RSS 7 30 Assembly 17 Electrical cables 7 32 Assembly 18 Electrical Cables isco sccicccncdewes desc ds E Danser dE rer 7 33 Assembly 19 Electrical Cables e EELER EE EN dace dacaad ease d EE e e
70. idler gear bracket assembly B to the MPF feed unit assembly Remove the idler gear bracket assembly B Remove the green ground wire D from the idler gear bracket assembly B Remove the green D ground wire from the clamp on Sg 4 62 Printer Service Manual 4024 110 9 Disconnect the connector leading to the MPF fold down tray assembly E 10 Raise the MPF fold down tray assembly E to its upright position and slide it to the side 11 Remove the MPF fold down tray assembly E Note Before reinstalling the idler gear bracket assembly B ensure the wiring is not pinched Repair information 4 63 4024 110 Vertical drive gear assembly Remove the MPF rear cover See MPF rear cover removal on page 4 55 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 51 Remove the printer left door assembly See Printer left door support strap removal on page 4 71 Open the printer left lower door assembly Remove the three screws securing the vertical drive gear assembly A Release the harness from the clamp on the vertical drive gear assembly A Remove the vertical drive gear assembly A ao oe eS 4 64 Printer Service Manual 4024 110 Switch left lower door interlock oooh Remove the MPF rear cover See MPF rear cover removal on page 4 55 Remove the MPF feed unit assembly See MPF feed unit assembly removal
71. in the tray er a media tray Refer to Options Service Manual Load tray 5 No media in the selected Media is not loaded in the tray with lt media gt media tray Refer to Options Service Manual Remove Finisher upper media bin full Stacker set over count ei trom The upper media bin has reached maximum capacity Refer to Finisher Service Manual Remove Stacker media bin full no The stacker media bin has reached maximum paper from mix capacity no mix bin 2 Refer to Finisher Service Manual Remove Stacker media bin full mix The stacker media bin has reached maximum paper from size capacity mix size bin 2 Refer to Finisher Service Manual Diagnostic information 2 21 4024 110 2 22 Printer Service Manual Error code or Error contents Description Action message Remove Standard bin 1 full Media in standard bin 1 is at maximum capacity ae Go to Standard bin 1 full on page 2 71 output bin Remove Standard bin 2 full Media in standard bin 2 is at maximum capacity eae om Go to Standard bin 2 full on page 2 72 output bin Toner low Toner cartridge near empty The toner in the toner cartridge is low but can be used Go to Toner cartridge near empty on page 2 74 Toner Toner cartridge RFID failure A toner cartridge of a different specification is unsupported installed Go to Toner cartridge RFID failure on page 2 75 Tray 5 HCF unit
72. is a safety switch to cut off a 5 VDC power supply from the LVPS card assembly to the printhead while the PC cartridge is removed Switch printer left lower door interlock The switch left lower door interlock detects open or close of the printer left lower door assembly Fuser cooling fan The fuser cooling fan discharges air from the printer to prevent excessive temperature increase LVPS card assembly The LVPS card assembly generates low voltages 5 V and 3 3 V for logic circuits 5 V for laser diodes and 24 V for motors clutches from AC power It also contains the fuser relay to feed cut off AC power to the heater rod of the fuser assembly HVPS card assembly The HVPS card assembly generates AC power a high DC voltage and feeds them to the charge roll development magnet roll transfer roll assembly Printer engine card assembly The printer engine card assembly controls printing operation based on the communication with the RIP card assembly and on sensor switch information It also controls optional module boards RIP card assembly The RIP card assembly connected to the printer engine card assembly controls the entire system Transport roll assembly The transport roll assembly feeds media from tray 2 or an optional tray to the registration roll assembly and fuser Diagnostic aids 3 41 4024 110 Registration roll assembly The registration roll assembly feeds media from all trays to the PC cartridge and fuser S
73. it 2 Check the switch printer front door interlock for operation Go to step 4 Go to step 3 1 Enter Diagnostics mode 2 Select BASE SENSOR TESTS 3 Select Cover and Door 4 Select Door J printer front Open the printer front door assembly and check it Does the display on the operator panel change every time the switch actuator is operated 2 68 Printer Service Manual 4024 110 Step Check Yes No 3 Check the switch printer front door interlock connection Replace the switch Replace the Is the switch printer front door interlock properly eee door connecNon connected Go to Switch printer front door interlock removal on page 4 5 4 Perform a print test Replace the Problem solved Does the error continue Ge carg Go to Printer engine card assembly removal on page 4 119 Printer left door open Step Check Yes No 1 Is the printer left door assembly opening and closing Go to step 2 Check the printer properly left door assembly for deformation and reinstall it 2 Check the switch printer left door interlock for operation Go to step 4 Go to step 3 1 Enter Diagnostics mode 2 Select BASE SENSOR TESTS 3 Select Cover and Door 4 Select Door A left side Open the printer left door assembly and check it Does the display on the operator panel change every time the switch actuator is operated 3 Check the switch printer left doo
74. left lower door handle A Remove the spring B oh Repair information 4 69 4024 110 Transfer roll assembly removal 1 Open the printer left door assembly 2 Release the two plastic hooks on the transfer roll assembly A 3 Remove the transfer roll assembly A by lifting it upward Note When removing the transfer roll assembly A do not touch the roll surface e L o SK l d Note Before reinstalling the transfer roll assembly A do not touch the roll surface 4 70 Printer Service Manual 4024 110 Printer left door support strap removal oS er Remove the MPF rear cover See MPF rear cover removal on page 4 55 Open the printer left door assembly A Remove the screw securing the printer left door support strap B to the printer left door A Remove the e clip securing the shaft C to the printer Remove the shaft C Remove the printer left door support strap B Repair information 4 71 4024 110 Printer left door assembly removal Note First remove the duplex unit assembly if equipped 1 Open the printer left door assembly 2 Remove the screw securing the left door support strap A to the printer left door assembly B 3 Remove the printer left door assembly B by lowering it then lifting upward 4 72 Printer Service Manual 4024 110 Switch printer left door interlock removal oooh Remove the rear moto
75. media feed unit assembly Remove the bracket A Note The gears may become detached from the bracket A Remove the hook securing the feed unit drive gear 27 tooth B to the shaft C Remove the feed unit drive gear 27 tooth B Note Before reinstalling ensure all gears and washers are securely attached to the bracket A 4 50 Printer Service Manual 4024 110 MPF feed unit assembly removal Remove the MPF rear cover MPF rear cover removal on page 4 55 Disconnect the connector Release the harness from the clamp Remove the two screws securing the MPF feed unit assembly A Remove the MPF feed unit assembly A m ROND Note Before reinstalling place the harness along the slot on the left of the MPF feed unit assembly A so it does not pinch the harness between the feed unit Repair information 4 51 4024 110 MPF media out actuator and upper frame removal Remove the MPF rear cover See MPF rear cover removal on page 4 55 Remove the MPF feed unit assembly MPF feed unit assembly removal on page 4 51 Remove the two hooks securing the upper frame A Remove the upper frame A by moving it up and out in the direction of the arrow Remove the MPF media out actuator B by prying it outward with a flat tip screwdriver then slide it out in the direction of the arrow aS N b GC rn J cop GE PRONT Hook 4 52 Printer Service Manual 4024
76. of purchase References in this publication to products programs or services do not imply that the manufacturer intends to make these available in all countries in which it operates Any reference to a product program or service is not intended to state or imply that only that product program or service may be used Any functionally equivalent product program or service that does not infringe any existing intellectual property right may be used instead Evaluation and verification of operation in conjunction with other products programs or services except those expressly designated by the manufacturer are the user s responsibility Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries MarkNet is a trademark of Lexmark International Inc registered in the United States and or other countries PrintCryption is a trademark of Lexmark International Inc PCL is a registered trademark of the Hewlett Packard Company All other trademarks are the property of their respective owners 2009 Lexmark International Inc All rights reserved UNITED STATES GOVERNMENT RIGHTS This software and any accompanying documentation provided under this agreement are commercial computer software and documentation developed exclusively at private expense P N 12G0036 4024 110 Table of contents EE 4 6 4050S de 959 G40 tHE HSER 64s S644 FEED ONE eed o
77. of the RIP card assembly to the printer Remove the RIP card assembly gently from the rear of the printer A SES ee 4 126 Printer Service Manual 4024 110 5 Component locations Locations Printer boards HVPS LVPS 5 1 Component locations 4024 110 Printer motors and sensors Sensor fuser exit Sensor RFID toner cartridge Toner add motor Switch main power Switch printer front door interlock 5 2 Printer Service Manual 4024 110 Sensor exit 1 media shift HP Sensor standard bin full exit 1 Exit 1 media shift assembly Exit shift motor Component locations 5 3 Sensor registration Sensor humidity and temperature Sensor RFID PC cartridge Se Registration LT Wey sex EE MEF S SC e Rk CSS LY Be d WAN 4024 110 AV SINA 5 4 Printer Service Manual 4024 110 Switch printer left door interlock Fuser cooling fan ee ec JL i Transport clutch v ae A Ge PC cartridge motor Transport Drum unit motor motor N HCF hookup connector NEESwitch media size Printer engine card assembly 5 6 Printer Service Manual 4024 110 Printer switches Exit interface card assembly PGES a Switch printer front door interlock Component locations 5 7 4024 110 Cables Main Power Switch Cable Assembly
78. oy ese 1 SS er S29 S42 KEE E eee Hasa AHE AAs eels een ae TIR TEFA THR mo ek ere e ASP i A ZEAE PE VA OR Cb ARG ve A DEI E EAE Wy BE fie D A AREY E OY EE TER ANT SEE AE e AP mm INES OS WARE A REH SPAT Sih AE Ay e Ay nea E TASS Ae IE PES N e ENV ARIS A RIZ A AAT TT i WARS P FFARR BE AY YoU tia Bt o DI WER CHEI m DX I A Ai fe or ZR LE 4 EIERE IIET m A LD SE EC AEA o HY BUT ES I AH Safety information XV 4024 110 Preface The service information for the Lexmark W850 is contained within three service manuals e Printer Service Manual Contains the base printer service information including the options and finisher error codes and tests e Options Service Manuat Contains specific information for the 2X 500 Sheet Drawer 2TM 2000 Sheet Dual Input TTM Duplex High Capacity Feeder and Exit 2 options and a list of error codes and tests e Finisher Service Manuat Contains specific information for the Finisher option list of error codes and tests The printer service manual contains maintenance procedures for service personnel It is divided into the following chapters zech D General information contains a general description of the printer and the maintenance approach used to repair it Special tools and test equipment are required as well as general environ
79. page 3 16 EVENT LOG Display Log See Display Log on page 3 17 Print Log See Print Log on page 3 17 Clear Log See Clear Log on page 3 18 REPORTS Prints Menu Settings Page EXIT DIAGNOSTICS Diagnostic aids 3 3 4024 110 Exiting Diagnostics mode Select Exit Diagnostics to exit the Diagnostics mode Resetting the Printer displays the printer performs a POR and returns to normal mode 3 4 Printer Service Manual 4024 110 MOTOR TESTS The tests in this group allow you to test specific motors and on some motors run them forward or reverse To run the MOTOR TESTS 1 Select MOTOR TESTS from DIAGNOSTICS 2 Select the test to run The following tests are available es Transport mtr e MPF pick solenoid e Fuser cooling fan e Transport clutch e PC unit cooling fan e Duplex drv mtr e Toner add mtr e Diverter solenoid e Drum unit mtr e Ex cooling fan e Registrat clutch e Exit shift mtr e Tray 1 feed mtr e Exit2 shift mtr e Tray 2 feed mtr e Exit2 drive mtr e Tray 3 feed mtr e Tray 4 feed mir e Tray 5 feed mtr Once selected the name of the selected test appears on the operator panel 3 If available Forward and Reverse appear for selected tests To stop the test press Back or Stop PRINT TESTS Input source tests The purpose of the diagnostic Print Tests is to verify that the printer can print on media from each of the installed input options The
80. panel appears on the panel When you press a button on the operator panel the X appears on the corresponding diagram When you release the button the X disappears Pressing Back or Stop cancels the test 3 6 Printer Service Manual 4024 110 DRAM Test The purpose of this test is to check the validity of DRAM memory both standard and optional The test writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly To run the DRAM Test 1 2 Select HARDWARE TESTS from DIAGNOSTICS Select DRAM Test from HARDWARE TESTS The message DRAM Test Testing displays Then the message Resetting Printer appears and the power indicator light blinks red The printer automatically performs a Power On Reset POR While the DRAM test executes the power indicator blinks green The following type of message appears DRAM Test Xxx MB D HHHH F HHH e xxx represents the installed DRAM size es P represents the number of times the memory test has passed and finished successfully Initially 000000 displays with the maximum pass count being 999 999 es F represents the number of times the memory test has failed and finished with errors Initially 0000 displays with the maximum fail count being 99 999 Initially only four digits appear but additional digits appear as needed Each time a test is completed the number of passes and failures is incremented If the t
81. printer preventive maintenance Follow these recommendations to help prevent problems and maintain optimum performance AN Safety inspection guide The purpose of this inspection guide is to aid you in identifying unsafe conditions If any unsafe conditions exist find out how serious the hazard could be and if you can continue before you correct the hazard Check the following items e Damaged missing or altered parts especially in the area of the on off switch and the power supply e Damaged missing or altered covers especially in the area of the top cover and the power supply cover e Possible safety exposure from any non Lexmark attachments LEXMARK W8XX EVERY SERVICE CALL EVERY 300K NOTE MEDIA TRAY PRINTER 2TM TTM if equipped Media Side Guides Inspect Inspect Check for correct positioning Media End Guide Inspect Inspect Check for correct positioning Separation Pad Inspect Clean Damp cloth Tray Lift Gear Group Inspect MEDIA FEED UNIT PRINTER 2TM TTM if equipped Feed Roll Inspect Replace Verify page count before replacing Pick Roll Inspect Replace Verify page count before replacing Separation Roll Inspect Replace Verify page count before replacing MPF feed roll Inspect Clean Water or alcohol Transport Roll Assembly Clean Water or alcohol Sensor registration Clean Brush or blower brush Sensor tray 2 feed out Clean
82. registration roll assembly B Repair information 4 77 4024 110 Sensor registration removal Remove the MPF rear cover See MPF rear cover removal on page 4 55 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 51 Remove the printer left door assembly See Printer left door support strap removal on page 4 71 Remove the registration roll assembly See Registration roll assembly removal on page 4 76 Release the hooks securing the sensor registration A to the registration roll assembly B Remove the sensor registration A Disconnect the connector from the sensor registration oo e Care 4 78 Printer Service Manual 4024 110 Transport clutch assembly removal oooh Remove the rear RIP card cover See RIP card assembly removal on page 4 126 Remove the rear motor cover See Rear motor cover removal on page 4 14 Remove the two screws securing the bracket A Disconnect the connector leading to the transport clutch assembly B Remove the e ring with a prying tool securing the transport clutch assembly B Open the printer left door assembly Remove the transport clutch assembly B Warning When removing the transport clutch assembly B some gears will remain on the shaft C Remove any gears that remain on the shaft C Warning When removing the gears make sure not to drop them into the framework of the machine Remove th
83. reparatie conform de voorschriften nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals voorgeschreven is voor klasse 1 Lasermeddelelse Printeren er godkendt som et Klasse I laserprodukt i overenstemmelse med kravene i IEC 60825 1 Klasse I laserprodukter betragtes ikke som farlige Printeren indeholder internt en Klasse IIIB 3b laser der nominelt er en 5 milliwatt galliumarsenid laser som arbejder pa balgelaangdeomradet 770 795 nanometer Lasersystemet og printeren er udformet s ledes at mennesker aldrig uds ttes for en laserstraling over Klasse I niveau ved normal drift brugervedligeholdelse eller obligatoriske servicebetingelser X Printer Service Manual 4024 110 Huomautus laserlaitteesta Tama kirjoitin on Yhdysvalloissa luokan 1 laserlaitteiden DHHS 21 CFR Subchapter J maarityksen mukainen ja muualla luokan laserlaitteiden IEC 60825 1 m rityksen mukainen Luokan laserlaitteiden ei katsota olevan vaarallisia k ytt j lle Kirjoittimessa on sis inen luokan Illb 3b 5 milliwatin galliumarsenidilaser joka toimii aaltoalueella 770 795 nanometri Laserj rjestelm ja kirjoitin on suunniteltu siten ett k ytt j ei altistu luokan m rityksi voimakkaammalle s teilylle kirjoittimen normaalin toiminnan k ytt j n tekemien huoltotoimien tai muiden huoltotoimien yhteydess VARO Avattaessa ja suojalukitus ohitettaessa olet alttiina n kym tt m lle lasers teilylle l kat
84. 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 Repair information 4 25 4024 110 Note Before reinstalling the pinion gears C slide the front media tray guide assembly D and the rear media guide E to their outermost positions Ensure the media side guides slide smoothly E c 4 26 Printer Service Manual 4024 110 Media tray end guide removal 1 Remove the media tray 2 Remove the media tray side guides See Media tray side guides removal on page 4 24 3 Remove the media side guide actuator A Front A Repair information 4 27 4024 110 Turn the media tray assembly upside down and remove the screw and the two hooks securing the actuator link B to the media tray Release the boss on the media end guide actuator C from the hole in the actuator link B by moving the link in the direction of the arrow Remove the media end guide actuator C Turn the media tray assembly right side up and slide the media tray end guide D toward the center of the media tray assembly to remove NO FS 4 28 Printer Service Manual 4024 110 Media tray lift gear group removal Remove the media tray from the machine Remove the two screws securing bracket A Remove the bracket A Remove the tray li
85. sensor stapler carriage HP is turned off again after the sensor stapler carriage HP is turned on and the stapler stopped its moving Refer to Finisher Service Manual Diagnostic information 2 19 4024 110 2 20 Printer Service Manual Error code or Error contents Description Action message 990 01 Sensor stapler carriage HP The sensor stapler carriage HP is not turned off Seier off failure within 500 ms after stapler starts moving to the finisher error staple position and sensor stapler carriage HP is turned off Or the sensor stapler carriage HP is not turned off after the stapler was moved to the staple position Or the sensor stapler carriage HP is turned on again after the sensor stapler carriage HP is turned off and the stapler stopped its moving Refer to Finisher Service Manual 995 00 Finisher NVM R W failure A read write error occurred on the NVM of the Seri finisher controller card assembly ervice finisher NV Refer to Finisher Service Manual 996 00 Finisher type failure An incorrect type of finisher is connected Service wrong Refer to Finisher Service Manual finisher 997 00 Duplex controller card A duplex controller card assembly of a different Service wrong assembly type failure specification is installed duplex Refer to Options Service Manual 999 00 Finisher engine RIP The engine reported a finisher failure that the RIP Service functional failure card assemb
86. size EEN Diagnostic information 2 77 4024 110 Step Check Yes No 5 Check the roll for tray 1 Go to step 6 Clean or replace Pull out tray 1 and check it ee Is the feed roll separation roll and pick roll free of excess and pick roll wear and contamination 6 Check the media position Remove the Go to step 7 Open the printer left door assembly and check it media Does the media touch the sensor registration 7 Check the roll Go to step 8 Clean or replace e the transport roll Open the printer left door assembly and check it assembly Is Ae e roll assembly free of excess wear and Go to Transfer contamination roll guide assembly removal on page 4 74 8 Check the roll Go to step 9 Clean or replace the registration roll Open the printer left door assembly and check it assembly Is the registration roll assembly free of excess wear and Go to contamination Registration roll assembly removal on page 4 76 9 Check the sensor registration for operation Go to step 11 Go to step 9 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 registration actuator is operated 10 Check the sensor registration connection Replace the Replace the Is the sensor registration properly connected
87. the fuser unit assembly Is there contamination or cracking on the heat roll and or the pressure roll Replace the fuser unit assembly Go to step 4 Check the image development process Perform a print test Turn off the printer power while printing Carefully remove the PC cartridge and check the toner image formed on the drum before the transfer roll assembly Is the image completely formed on the drum and the area clear black and easily read Go to step 5 Go to step 7 Check the image transfer process Check the toner image formed on the drum after the transfer roll assembly is passed Is the toner image completely transferred on the media Go to step 7 Go to step 6 Check the HVPS card assembly Replace the HVPS card assembly Perform a print test Does the error continue Go to step 7 Problem solved 2 102 Printer Service Manual 4024 110 Step Check Yes No Check the printer engine card assembly Replace the printer engine card assembly Perform a print test Does the error continue Replace the RIP card assembly Go to RIP card assembly removal on page 4 126 Problem solved Diagnostic information 2 103 4024 110 2 104 Printer Service Manual 3 Diagnostic aids 4024 110 This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the proble
88. 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 Also turns off if a print command is not received within 30 seconds from the reception of the signal Sleep mode Always off Determination of printhead ready The printhead goes into ready state after the specified period passes since the reception of the printhead MPA start signal and the SOS cycle exceeds the reference value Printhead reference value Printhead reference value Description Ready reference value SOS signal interval equivalent to 98 or more of the rated RPM of the printhead motor Fail reference value SOS signal interval less than 98 of the rated rpm of the printhead motor Fuser control Fuser control method The on off control of the main sub heater lamps is performed based on the fuser control temperature The fuser transmits between the five states warm up ready standby print and low power depending on the heat roll surface temperature or printer conditions The fuser temperature control starts when the fuser ready in the LVPS card assembly is turned on after a preset time period has passed from power on If a failure occurs the heater lamps are turned off the fuser ready is turne
89. top cover removal on page 4 112 Open the printer front door assembly Remove the front left cover See Printer front left cover removal on page 4 3 Remove the exit 1 media shift assembly See Exit 1 media shift gear removal on page 4 110 Release the hooks securing the sensor exit 1 bin full A to the exit 1 media shift assembly B Remove the sensor exit 1 bin full A B Repair information 4 109 4024 110 Exit 1 media shift gear removal 1 Remove the rear RIP card cover See Rear RIP card cover removal on page 4 125 2 Remove the rear motor cover See Rear motor cover removal on page 4 14 3 Remove the top rear cover See Top rear cover removal on page 4 4 4 Open the printer left door assembly 5 Remove the exit 1 top cover See Standard exit 1 top cover removal on page 4 112 6 Open the printer front door assembly 7 Remove the front left cover See Printer front left cover removal on page 4 3 8 Remove the exit 1 media shift assembly See Exit 1 media shift assembly removal on page 4 104 9 Remove the exit 1 media shift motor See Media shift motor removal on page 4 107 10 Remove the two screws securing the bracket A to the exit 1 media shift assembly B 11 Remove the bracket A from the exit 1 media shift assembly B 4 110 Printer Service Manual 4024 110 12 Slide the shift assembly C in order to release the shift assem
90. tray 1 Check area B A tray 1 feed on page 2 33 242 00 Sensor pre feed on jam The sensor pre feed tray 2 is not turned on within tray 2 feed the specified time after the tray 2 media feed lift Paper jam motor is turned on SE ales Go to 242 00 Sensor pre feed on jam tray 2 ray feed on page 2 34 242 01 Sensor tray 2 feed out on The sensor tray 2 feed out is not turned on within P jam tray 2 feed the specified time after the sensor pre feed media aper jam feed unit 2 is turned on Go to 242 01 Sensor tray 2 feed out on jam Check area B tray 2 tray 2 feed on page 2 36 242 02 Sensor registration on The sensor registration is not turned on within the jam tray 2 feed specified time after the sensor tray 2 feed out is Paper jam turned on Go to 242 02 Sensor registration on jam tray 2 feed on page 2 38 242 03 Paper jam Check area B Sensor tray 2 feed out static jam Media remains on the sensor tray 2 feed out Go to 242 03 Sensor tray 2 feed out static jam on page 2 39 243 00 Paper jam Check area 3 Sensor pre feed on jam tray 3 media feed The sensor pre feed is not turned on within the specified time after the tray 3 feed lift motor is turned on Refer to Options Service Manual 2 6 Printer Service Manual 4024 110 Error code or Error contents Description Action message 2
91. until the top margin is adjusted Tray 1 5 Left Margin To set the left margin for an individual tray 1 Select REGISTRATION from CONFIG MENU 2 Select one of the following from the REGISTRATION menu The current setting is displayed e Tray 1 Left Margin e Tray 2 Left Margin e Tray 3 Left Margin if installed e Tray 4 Left Margin if installed e Tray 5 Left Margin if installed 3 Check the Quick Test and adjust the value The range of valid settings for each Left margin is 50 to 50 Each unit represents 1 300 of an inch Increasing the value by one moves the image on the page to the right by one pixel 1 300 inch widens the left margin and narrows the right margin Decreasing the value by one moves the image on the page to the left by one pixel 1 300 inch narrows the left margin and widens the right margin When you select a value the Quick Test prints so you can verify the value is correct 4 Continue until the Left Margin value is properly adjusted 5 If you need to adjust the Left Margin on another tray select that tray Note The printer attempts to print the Quick Test page from the media source for which the registration adjustments are currently being made Diagnostic aids 3 21 4024 110 Quick Test The Quick Test contains the following information e Print registration settings e Alignment diamonds at the top and bottom e Horizontal lines to check for skew e General printer information including current
92. will be lost Go or Stop displays to warn the user that all contents on the disk will be lost 3 To exit the test immediately and return to the Device Tests menu press Back or Stop To continue with the test press Gi If is selected the following screen displays and updates periodically indicating the percentage of test completed Formatting Disk 1 1 0 DO NOT POWER OFF The power indicator blinks during the test Note The test can NOT be canceled 4 Once the test is complete the power indicator turns on solid and either the message Disk Test Clean Test Passed or Disk Test Clean Failed appears If the message indicates failure the disk is unusable 3 14 Printer Service Manual 4024 110 Flash Test This test verifies the functioning of the flash device by writing and reading data on the flash to test the flash Warning This test destroys all data on the flash because the flash is unformatted at the end of the test To reformat the flash the servicer or the user must use FORMAT FLASH from the UTILITIES MENU To run the Flash Test 1 Select DEVICE TESTS from DIAGNOSTICS 2 Select Flash Test from DEVICE TESTS The message Files will be lost Go or Stop displays to warn the user that all contents on the flash device will be lost 3 To exit the test immediately and return to the Device Tests menu press Back or Stop To continue with the test press The power indicator blink
93. 0 cece eee eee eee e eee eee eee 4 81 Switch PC cartridge interlock removal cece eee eee eee eee eee 4 82 Sensor humidity and temperature removal 4 87 Sensor RFID PC cartridge and sensor RFID toner cartridge removal 5 4 92 Toner cartridge guide assembly removal 0 ccc cece eee eee eee eee eens 4 93 Toner add motor assembly removal 4 95 FUSEr COGING fan TEMOVEl asicccctarananna nae te arene AAP RE ERE ORR eed 4 96 Printhead assembly removal sic cstcaacied dedeanee Ee EE data mewn 4 97 PC cartridge cooling fan duct removal 4 99 PC cartridge cooling fan removal 4 101 Sensor User exit FEMOVGl ag RER ch ced re kaedees MOREE ER hHROR TORE eM 4 102 F seruntassempiy removal cississcetiacdindedinweaeneeaduain sed scams A 4 103 Exit 1 media shift assembly removal 0 0 cece eee eee eee eee eee eee eens 4 104 Media shift Motor removal ng cscaisind ceae eee ee eee ee eee eee eS eee 4 107 Sensor exit 1 media shift removal 0 00 cece eee eee eee 4 108 Sensor exit 1 bin full removal acs cccicenci viene e reese ness een ee eee ee Ree emer E RR 4 109 Exit 1 media shift gear removal seu scciee cece EEN saws bees nian scene eee KREE 4 110 Standard exit 1 top cover removal 0c e eee eee eee eee eee eee eee eens 4 112 Ext Eeer EE aed ak end acess Sege sea wees 4 113 Dual drive motor assembly removal 0c eee eee eee eee eee eee eee eens 4 114 High voltage power su
94. 1 Sensor fuser exit off too Short jam eee 2 27 202 02 Sensor fuser exit Static jam eee eee eee 2 28 203 00 Sensor EC RR JAM cacticantiana boca tees eaan canner mew talon eo 2 28 203 01 Sensor ext 2 OM aM EE EE 2 30 241 00 Sensor pre feed on jam tray 1 feed 2 32 241 01 Sensor registration on jam tray 1 feed 2 33 242 00 Sensor pre feed on jam tray 2 feed 2 34 242 01 Sensor tray 2 feed out on jam tray 2 feed 2 36 242 02 Sensor registration on jam tray 2 feed 1 cece eee 2 38 242 03 Sensor tray 2 feed out static fam kee eee 2 39 250 00 Sensor registration on jam MPF pick 2 40 900 XX RIP card assembly software failure 2 41 903 00 RAM read write check failure 2 42 904 00 NVM d ta failure AEN EIERE REES SC ee deeee Rese keene deed eam Ree RE 2 42 905 00 NVM read write cannot be executed failure 0 cece eee eee 2 43 906 00 CPU power to access NVM failure 2 43 S07 OO RFID ASIC TANIE eg SE EE ee EE 2 44 80800 PPM Gala failile e EE Eege EE dE dE eae wee 2 44 910 00 Transport motor stop failure 2 45 911 00 Transport Motor TAUTE eg sie tena cree ee ee TRE eee eee h oceania EES 2 46 912 00 PC cartridge unit motor failure 2 46 913 00 Printhead assembly failure 2 47 914 00 Toner add motor assembly failure 2 48 915 00 Fuser cooling fan failure gg ted ered ieee shee sa nee es dees ace ee amas 2 48 916 00 PC cartridge cooling fan failure 1 0 cc
95. 110 Sensor MPF media out removal NO oR OND ch Remove the MPF rear cover See MPF rear cover removal on page 4 55 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 51 Remove the two hooks securing the upper frame A to the MPF feed unit assembly Remove the upper frame A by moving it up and out in the direction of the arrow Disconnect the connector from the sensor MPF media out B Release the hooks securing the sensor MPF media out B in the upper frame A Remove the sensor MPF media out B Repair information 4 53 4024 110 MPF transport pinch roll assembly removal Remove the MPF rear cover Go to MPF rear cover removal on page 4 55 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 51 Remove the two end screws securing the upper bracket A to the MPF feed unit assembly Remove the upper bracket A Remove the center screw securing the MPF transport pinch roll assembly B to the upper bracket A Release the bosses securing the MPF transport pinch roll assembly B to the upper bracket Remove the MPF transport pinch roll assembly B by moving it in the direction of the arrow Note Do not touch the plastic surface of the MPF pinch roll ao oe eS Note The bushings and the springs may become detached Note Before reinstalling ensure you do not touch the plastic roll surface 4 54 Printer S
96. 112 4 Open the printer left door assembly 5 Remove the PC cartridge 6 Remove the exit 1 drive belt See Exit 1 drive belt removal on page 4 113 7 Disconnect the two harness connectors from the dual drive motor assembly A 8 Remove the two screws securing the bracket B Connector 9 Remove the four screws securing the dual drive motor assembly A to the printer 10 Remove the dual drive motor assembly A Note Depress the spring loaded gear C while removing the dual drive motor assembly A to prevent damage Warning Before reinstalling depress the spring loaded gear C while replacing the dual drive motor assembly A to prevent damage 4 114 Printer Service Manual 4024 110 High voltage power supply HVPS card removal A Remove the front left cover See Printer front left cover removal on page 4 3 Remove the top cover assembly See Top cover assembly removal on page 4 7 Remove the PC cartridge Remove the printer front door assembly See Printer front door assembly removal on page 4 8 Remove the front inner cover See Front inner cover removal on page 4 10 Disconnect the connector from the HVPS card assembly A Release the harness from the clamps Remove the two screws securing the HVPS card assembly A Remove the HVPS card assembly A by sliding it outward in the direction of the arrow d i d San d d e teg Connector Cl
97. 2 64 Media siz MISMAICHIN width accdew tides neaka EEN 2 64 No media in the select media tray 2 65 Paper is installed short edge in the media paper tray 2 66 Led E dE 2 66 PC Cartnidge Gnd ert E sssiackaiega views eek EE EAR Een 2 67 PC cartridge RFID failure 299 EELER EIERE care EELER EE rR ee eae 2 67 PC cartridge set CIE 2 68 Printer front door open e EIERE EIER sake NEES EERSTEN me 2 68 Printenisttdoor Open ici sncoe ERC ahs aces uw same ache wed bales ed ais bono 2 69 Printer left lower door Open csccicetisgedssxeweneeeiianss Kea Ree eae eR EE ag 2 70 Scheduled maintenance required 0 00 e eee eee eee eee eee eee 2 70 Standard bin 1 full sister sdastdeetaikeresReteemasaeK ewe a ee eee eee Ra a eR ee 2 71 SHEET ee DEE BEE EE Ee dae 2 72 TGHEr cando ENP snccc0ncccaneden tien ran ENEE 2 72 Toner camag Near emp e Ser RBE EE eg anes SE wean Gewese Cae as 2 74 TOREP e ET EE wha vbisas teehee Reece e nave se kt them waw eee e heed 2 74 Toner cartridge RFID failure 1 ccc eee eee ene e eee eee eeee 2 75 Toner CAMMAGE SEL FANUKE gg REEL Sd he hig eA ge 2 75 Tray 1 media size fat EE EE male 2 76 Tray 2 media size failure vasa ea aad dae Ss Fado EE 2 77 Tray 1 media size mismatch in length 2 77 Tray 2 media size mismatch in length eee 2 79 image quality trouble a ax EEN e KREE newer aed deed eRe eee ERROR ee ROR OE 2 81 Troubleshooting iss ins bsbdie EE 2 81 image QUAY a gab note news EE OEE CHEE CRETE DRE OR R
98. 2 feed out 4 81 separation roll 4 46 separation roll one way friction clutch 4 45 standard exit 1 top cover 4 112 switch left lower door interlock 4 65 switch main power 4 116 switch media size 4 17 switch PC cartridge interlock 4 82 switch printer front door interlock 4 5 switch printer left door interlock 4 73 toner add motor assembly 4 95 toner cartridge guide assembly 4 93 top cover assembly 4 7 top rear cover 4 4 transfer roll assembly 4 70 transfer roll guide assembly 4 74 transport clutch assembly 4 79 tray lift coupling assembly 4 31 tray lift one way clutch gear assembly 4 32 vertical drive gear assembly 4 64 ne eee Index l 3 4024 110 S safety information xiii safety inspection guide 6 1 scheduled maintenance 6 2 serial number 3 16 service checks 2 23 Symptom tables tray 1 media size mismatch in length 2 77 system code 3 1 T tools required 1 2 Top Margin simplex front side 3 21 LA Printer Service Manual 4024 110 Part number index P N 40X0269 40X0296 40X0297 40X0550 40X0551 40X0552 40X0553 40X0553 40X0558 40X0560 40X0561 40X0562 40X0563 40X0564 40X0565 40X0566 40X0567 40X0568 40X0569 40X0570 40X0571 40X0572 40X0573 40X0574 40X0576 40X0577 40X0578 40X0579 40X0580 40X0581 40X0582 40X0583 40X0585 40X0586 40X0587 40X0588 40X0588 40X0588 40X0588 40X0588 40X0588 40X0589 40X0589 40X0590 40X0591 40X0593 40X0594 40X0596 40X0597 40X0
99. 2 media size mismatch in length on page 2 79 34 Incorrect media check tray 3 guides Tray 3 media size mismatch in length Refer to Options Service Manual 34 Incorrect media check tray 4 guides Tray 4 media size mismatch in length Refer to Options Service Manual 80 Scheduled maintenance Scheduled maintenance required Service is required to maintain printer performance Go to Scheduled maintenance required on page 2 70 84 PC cartridge set failure The PC cartridge is not installed or is not installed Insert PC unit properly Go to PC cartridge set failure on page 2 68 84 PC cartridge RFID failure A PC cartridge of a incorrect specification is PC unit installed abnormal Go to PC cartridge RFID failure on page 2 67 4024 110 Error code or Error contents Description Action message 84 PC cartridge end of life The PC cartridge needs to be replaced Replace PC Go to PC cartridge end of life on page 2 67 unit 84 PC cartridge life near end The PC cartridge needs to be replaced soon PC unit life Go to PC cartridge end of life on page 2 66 warning 88 Toner cartridge near empty The toner cartridge needs to be replaced soon Toner low Go to Toner cartridge near empty on page 2 74 88 Toner cartridge empty All toner in the toner cartridge is consumed or toner Replace toner supply is clogged Go to Toner cart
100. 3 Part number index l 5 4024 110 40X0605 40X0606 40X0608 40X0609 40X0610 40X0612 40X0613 40X0614 40X0616 40X0617 40X0618 40X0619 40X0620 40X0621 40X0622 40X0624 40X0625 40X0627 40X0628 40X0629 40X0630 40X0631 40X0633 40X0634 40X0635 40X0636 40X0636 40X0637 40X0638 40X0639 40X0640 40X0641 40X0643 40X0644 40X0646 40X0647 40X0648 40X0649 40X0650 40X0651 40X0653 40X0654 40X0655 40X0657 40X0658 40X0659 40X0660 40X0661 40X0662 40X0663 40X0664 40X0665 40X0666 40X0667 40X0668 40X0670 40X0672 40X0673 40X0674 MPF transport roll kit 2202 rrr rrr rrr rrr rr rrr rrr ree 7 13 MFP pick solenoid kit 2 2 2 2 22 2202 reer reer e eee eee 7 13 MPF fold down tray assembly 7 11 Vertical drive gear assembly 7 15 Switch left lower door interlock 7 15 Printer left lower door assembly this comes assembled 7 15 Hinge pin 2 ee eee ee eee ee eee eee eee 7 15 Left lower door handle kit eee eee eee eee 7 15 Transfer roll assembly 7 17 7 19 Transfer roll power contact 22 eee ee ene nee eee eee 7 17 PC cartri
101. 390 40X1390 40X1391 40X1392 40X2382 40X2389 40X4819 40X4822 40X4823 40X4826 40X4827 40X5301 40X5302 40X5303 40X5561 40X5562 40X5563 40X5564 40X5565 4024 110 MPF hookup cable assembly e 7 34 Media size switch cable assembly 7 33 RIP card cable assembly 222 22 errr eee eee ee 7 34 Printhead cable assembly 25 555 reer 7 35 Exit interface cable assembly 7 36 Multi connector cable assembly 2 5 5 eee ee 7 35 Fuser AC cable assembly 2 2 2225 eee reer ee 7 32 Multi connector cable assembly 3 7 33 7 34 Interlock switch cable assembly 7 33 Main switch cable assembly 2 2 2 r reer rere ee 7 32 Dual drive motor cable assembly 7 34 RFID sensor cable assembly 2 22 r errr reer ree ee 7 32 MPF pickup spring 7 11 Bushing 6 mm 7 7 7 Assorted e clip packet 2522 e522 eee nec en eee eee en
102. 4 Option hookup cover een ne eee 7 4 Media tray catch kit 7 5 Switch media size 2 ee eee ee ee ee eee eee eee 7 5 Vertical turn mylar guide 7 5 Vertical turn guide 225 225 ee eee eee ee eee 7 5 Media tray assembly 2 22 rnnr 7 9 Media tray front cover 22 2 eee ee enn eee eee eee 7 9 Media tray side guide kit 7 9 Media tray side guide actuator kit 7 9 Media tray end guide kit 7 9 Media tray end guide actuatorkit 7 9 Media tray lift gear kit eee eee eee eee 7 9 Media feed unit assembly 7 7 Media feed lift motor eee ee eee eee eee eee 7 7 Tray lift coupling kit 7 7 Media feed drive gear kit eee ee eee eee ee eee eee 7 7 Media feed unit front guide kit 77
103. 4 110 Vertical stripes Leading edge Trailing edge Step Check Yes No 1 Check the media condition Go to step 2 Problem solved Load new dry recommended media Re print the defective image Does the error continue 2 Are the media transfer route and the media path free of Go to step 3 Remove debris contamination or debris or contamination 3 Check the toner cartridge Problem solved Go to step 4 Install a new toner cartridge Re print the defective image Is the image density normal 4 Check the transfer roll assembly Go to step 5 Replace the transfer roll Remove the transfer roll assembly assembly Is the transfer roll assembly rotating free of contamination and wear 5 Check the PC cartridge installation condition Go to step 6 Correct and i clean Remove the PC cartridge contaminated Check the PC cartridge connections pins or replace the PC cartridge Are the PC cartridge connections free of excess wear or connector and contamination 6 Check the PC cartridge ground Go to step 7 Correct and clean the drum Remove the PC cartridge grounding plate Check the drum grounding plate located behind rear or replace the motor cover This plate can be found behind the PC cartridge flywheel Is the drum grounding plate free of excess wear and contamination Diagnostic information 2 91 4024 110 Step Check Yes No 7 Check th
104. 406 connected properly Replace the RIP card assembly Go to RIP card assembly removal on page 4 126 Replace the connections 2 94 Printer Service Manual Partial lack Leading edge Trailing edge 4024 110 Step Check Yes No 1 Check the media condition Load new dry recommended media Re print the defective image Does the error continue Go to step 2 Problem solved 2 Check the media transfer route Is the media path free of contamination or debris Go to step 3 Remove debris or contamination Is there contamination or cracking on the heat roll and or the pressure roll 3 Check the toner cartridge Problem solved Go to step 4 Install a new toner cartridge Re print the defective image Is the image density normal 4 Check the transfer roll assembly Go to step 5 Replace the Remove the transfer roll assembl transfer roll y assembly Is the transfer roll assembly rotating and free of contamination and wear 5 Check the heat roll and the pressure roll Replace the Go to step 6 fuser unit Remove the fuser unit assembly assembly 6 Check the printer engine card assembly Replace the printer engine card assembly Perform a print test Does the error continue Replace the RIP card assembly Go to RIP card assembly removal on page 4 126 Problem solved Diagnostic information 2 95 4024 110
105. 43 01 Sensor tray 3 feed out on The sensor tray 3 feed out is not turned on within Paper jam jam tray 3 media feed the specified time after the pre feed sensor is on EE Refer to Options Service Manual C tray 3 243 02 Sensor tray 2 feed out on The sensor tray 2 feed out is not turned on within jam tray 3 media feed the specified time after the sensor tray 3 feed out Paper jam is turned on Check areas A B Refer to Options Service Manual 243 03 Paper jam Check area B Sensor registration on jam tray 3 media feed The sensor registration is not turned on within the specified time after the sensor tray 3 feed out is turned on Refer to Options Service Manual 243 04 Sensor tray 3 feed out static Media remains on the sensor tray 3 feed out Paper jam Jam Refer to Options Service Manual Check area C 244 00 Sensor tray 4 feed out on The sensor tray 4 feed out is not turned on within f jam tray 4 media feed the specified time after the sensor pre feed is Paper jam turned on Check areas Refer to Options Service Manual C tray 4 244 01 Sensor tray 3 feed out on The sensor tray 3 feed out is not turned on within P jam tray 4 media feed the specified time after the sensor tray 4 feed out aper jam is turned on Check areas Refer to Options Service Manual C tray 4 244 02 Sensor tray 2 feed out on The sensor tray 2 feed out is not turned on within
106. 55 XX RIP card assembly NAND CRC failure Step Check Yes No Perform a POR Does the error occur when the power is turned off on Go to step 2 Perform several print tests If the problem remains go to step 2 Turn the printer off for 60 seconds Does the error occur when the power is turned off on again Replace the RIP card assembly Go to RIP card assembly removal on page 4 126 Go to step 3 Problem solved Perform a print test Does the error still occur Replace the printer engine card assembly Go to Printer engine card assembly removal on page 4 119 Problem solved 956 00 RIP card assembly processor failure Step Check Yes No Perform a POR Does the error occur when the power is turned off on Go to step 2 Perform several print tests If the problem remains go to step 2 Turn the printer off for 60 seconds Does the error occur when the power is turned off on again Replace the RIP card assembly Go to RIP card assembly removal on page 4 126 Go to step 3 Problem solved Perform a print test Does the error still occur Replace the printer engine card assembly Go to Printer engine card assembly removal on page 4 119 Problem solved 2 62 Printer Service Manual 956 01 RIP card assembly processor over temperature failure 4024 110
107. 598 40X0599 40X0600 40X0601 40X0603 Description Page Power cord USA ET AL 8ft right angle 7 37 Power cord Australia 6ft straight 7 37 Power cord USA ET AL 6ft straight 7 37 Left lower cover 2 eee een ne ee eee eee 7 3 Front left cover 7 7 7 71 7 ee ee eee ee 7 3 Top rear cover 2 2 2222 e rere eee eee eee ee eee eee eee ee eee eee eee 7 3 Switch printer front door interlock 7 3 Switch printer left door interlock 7 17 Top cover assembly 7 3 Front door magnetic catch eee ee eee eee eee 73 Front door support strap 2 2 eee nn ee eee eee 7 3 Front inner cover eee ne eee eee eee ee 7 3 Right upper cover 2 2 eee een ee ee eee eee 7 4 Right lower cover 22 22 22 rere errr eee eee eee eee eee eee 7 4 Cable hookup door kit eee en nen eee eee 7 4 Rear motor cover 2 2 2222 e rere reer ee eee eee eee e eee 7 4 Rear lower cover 110 V nnn nn nnn ene eee eee 7
108. 910 00 transport motor stop failure 2 45 911 00 transport motor failure 2 46 912 00 PC cartridge unit motor failure 2 46 913 00 printhead assembly failure 2 47 914 00 toner add motor assembly failure 2 48 915 00 fuser cooling fan failure 2 48 916 00 PC cartridge cooling fan failure 2 49 918 00 exit 1 media shift HP failure 2 50 920 00 fuser unit assembly on time failure 2 51 921 00 over heat temperature failure 2 51 922 00 center thermistor failure 2 52 923 00 rear thermistor failure 2 52 924 00 pressure roll thermistor failure 2 53 925 00 fuser operating temperature failure 2 53 927 00 PC cartridge RFID data write failure 2 54 928 00 PC cartridge RFID communication failure 2 54 929 00 sensor ATC failure 2 54 930 00 laser power failure 2 55 932 00 toner cartridge RFID data write failure 2 56 933 00 toner cartridge RFID communication failure 2 56 939 00 RIP card assembly communication failure 2 57 941 00 media tray 1 lift up no media tray failure 2 57 942 00 media tray 2 lift up no media tray failure 2 58 951 XX RIP card assembly NVRAM failure 2 60 953 XX operator panel assembly NVRAM failure 2 61 955 XX RIP card assembly NAND CRC failure 2 62 956 00 RIP card assembly processor failure 2 62 956 01 RIP card assembly processor over temperature failure 2 63 956 02 RIP card assembly cooling fan failure 2 63 980 03 exit interface card assembly communication failure 2 64 error messages media size mismatch in wi
109. Be a oi oa ul a8 sea ys of Lt t 2 9z S J of ut i eaa a Aa PRELE GKEEERGSEEEET Bees ees ae Pa EEN eal tela Pa da jay gady eng b 88223588 SE zg aie Media SE a3 jaa Boe l gage ages a2 19 Z ae wm Q Zale b SEMELE EE SECER AJo jad zo a S ee pn Feed Lift 2 fa g 5 4 o ega 52 L 2S 8 Sg SE aga oc S IER APEE 6 F Size Switch 1 Signal H o o Motor 3 o NT MainLamp1 ON H AC HOT fa 3 F Q S ui S S fo Si D gt SNE 2 ol S it h M di S p Ka Center Thermistor Signal EI a N y fo Z i EE Gl gt a 2 ZS m z 3 WItC edia o ate Oo SIG GND 3 B 3 3 a 3 3 A s 3 i l 5VDC 1 l Size Switch 2 ON L 5VDC 4 H H dp Bet 8 Se 5 di Sublampi ON H AC HOT E z 2 E Z 5 Size Switch 1 Signal gt i S S Size 2 bal 5 6 2 Pressure Roll Thermistor Signal 4 A 5l YY fo Si g SIG GND 3 a Switch Media 3 wn oO Ee SIG GND 4 I ER S T Size Switch 1 ON L 5VDC J4 o ol Si bs nk SubLamp2 ON H AC HOT 4 AA Yhhabvvvvvvaiy 2 Ize E Rear Thermistor Signal KA A 2 SIG GND D SIE PF03 Relay ON L neutral Di To Finisher To TTM 2TM D ees Pi gt Ze eee tee
110. C E 5VDC j Ou st Le E o LU 3 5 2 RTN S Di E 5 pt Ee lt 2 24VDC G cx le E U et OO pt24VDC Saile o A Exit Gate Solenoid ON H 5VDC Le FS 8 vA Ze 2 REGI Clutch ON L 5VDC os JS gt 1 1 w ES D FULL STACK SENSED L 5VDCC SR _SIG GND SS Switch Printer Front K oO 7 Media FUSER EXIT PAPER SENSED H 5VDC BP SE 7 Rear Thermistor Signal 0 Door Interlock elaia 8 SIG GND c Dun x Poe ee te ee ee eee gt il SIG GND y D Feed Lift A i 3 X Pressure Roll Thermistor Signal wm EEN 24vDe SE SIG GND z Nje Motard i ee SIG GND Toner Add Motor ON L 24voc 2 P420 O nter_Thermistor Signal oe Sensor x l AR L a P410 EE 1 Fuser Exit d 2 Jo eg Pri nter Fuser Exit SNR L 5VDC S j SENDT i SIG GND B N 4 z Switch Printer Left CG O oO Engine To Exit i E n i n e Left Lower Door Interlock Open H 5VDC Brae Lower Door Interlock SSESESAEEES z S z Exit To Engine l g 5VDC Be SIG GND P421 i Taye Feed SNR L 5VDC lt 2 OJ Ol Sensor Tray 2 Feed Out Fuser Exit Paper Sensed H 5VDC a C a r d A SM SE LI 3 E o 2 I 24 1 o Ile S Full Stack Sensed L 5VDC l Fe irano ONSE ni EES Transport iz D Zo qg REGI Clutch ON L 5VDC I be po utc 2 DCH A E 2 S S S S H Clutch SE T Blk GI Exit Gate Solenoid ON H 5VDC J J aq 1S T e e Q Q Ka Ga P T R 5VDC l nn Z Ss 5 5 15 3 clo Finsher Tray 2 Size Switch Signal l 14 Jalsa 4 3 3 ele 3 3
111. C cartridge A or the sensor RFID toner cartridge B Release the hooks securing the sensor RFID PC cartridge A or the sensor RFID toner cartridge B Remove the sensor RFID PC cartridge A or sensor RFID toner cartridge B by sliding it out in the direction of the arrow bo PS Note The sensor RFID PC cartridge A and sensor RFID toner cartridge B require moderate force to remove Front 4 92 Printer Service Manual 4024 110 Toner cartridge guide assembly removal Remove the front left cover See Printer front left cover removal on page 4 3 Remove the top cover assembly See Top cover assembly removal on page 4 7 Remove the PC cartridge Remove the toner cartridge g p SSS Ge Ss Si rs Front Toner cartridge 5 Remove the printer front door assembly See Printer front door assembly removal on page 4 8 6 Remove the front inner cover See Front inner cover removal on page 4 10 Repair information 4 93 4024 110 7 Disconnect the two harnesses from the toner cartridge guide assembly A one on the right and one on the left 8 Remove the harnesses from the clamps 9 Remove the two screws on the front of the printer securing the toner cartridge guide assembly A 10 Open the printer left door assembly See Printer left door support strap removal on page 4 71 11 Remove the printer left door support strap See Printer left door support strap rem
112. C cartridge guide C ake PRAM T Guide assembly Connector Harness assembly 4 84 Printer Service Manual 18 19 20 21 22 4024 110 Slide the PC cartridge guide C toward the left side and disconnect the connector from the PC cartridge sensor connector Remove the two hooks securing the transfer roll power contact E While pressing the PC cartridge drive coupler F lift the front side of the PC cartridge guide assembly C upward Release the harness from the clamp on the rear side of the PC cartridge guide assembly C While pressing the PC cartridge drive coupler F lower the left side of the PC cartridge guide assembly C Clamps Repair information 4 85 4024 110 23 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 24 Remove the PC cartridge guide assembly C from the printer 4 86 Printer Service Manual 4024 110 Sensor humidity and temperature removal Neo tre Remove the front left
113. Do not change these settings unless requested to do so by your next level of support Model Name The model name can only be viewed and cannot be changed Configuration ID The two configuration IDs are used to communicate information about certain areas of the printer that cannot be determined using hardware sensors The configuration IDs are originally set at the factory when the printer is manufactured however the servicer may need to reset Configuration ID 1 or Configuration ID 2 whenever the system board is replaced The IDs consist of eight hexadecimal characters including 0 through 9 and A through F Note When the printer detects a Configuration ID that is not define or invalid the following occurs e The default standard model Configuration ID is used instead e Configuration ID is the only function available in DIAGNOSTICS e Unless the menu is in DIAGNOSTICS Check Config ID displays To set the configuration ID 1 Select PRINTER SETUP from DIAGNOSTICS 2 Select Configuration ID from PRINTER SETUP Submitting Selection displays followed by the value for Configuration ID 1 3 Enter the Configuration ID 1 e To select a digit or character to change press 4 or p until the digit or character is underlined e To change a digit or character press A to increase or w to decrease the value e When the last digit is changed press 7 to validate the Configuration ID 1 If Invalid ID appears the entry is discarded and the previous Con
114. ESTS 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 10 Check the sensor registration connection Replace the Replace the Is the sensor registration properly connected Seck connection Go to Sensor registration removal on page 4 78 11 Check the registration clutch for proper operation Go to step 13 Go to step 12 1 Enter Diagnostics mode 2 Select MOTOR TESTS 3 Select Regi strat clutch Does the component make an audible clicking sound when itis operated 12 Check the registration clutch connection Replace the Replace the Is the registration clutch properly connected registration clutch connection Go to Registration clutch assembly removal on page 4 77 13 Perform a print test Replace the Problem solved f printer engine card Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 2 80 Printer Service Manual 4024 110 Image quality trouble Troubleshooting Note First get a printout as a base follow the symptom table to identify the possible failing FRUs Image quality symptoms Faint print low contrast Faint print Low contrast on page 2 82 Blank print no print Blank print no print on page 2 84 Solid black Solid black on page 2 86 Vertical blank lines White stripes in m
115. Eet EEGEN SS HK WE 4 770 795 nm Z 3 RITE ARI RE fe HABE RE AWA AR SS ARE fh DET DE EY BEES 152 adlolgd d s CHSt DHHS 21 CFR Subchapter 32 PAYS Brau Ves Dol olzzatoton 122 Cato IEC 825 TAS T lke 158 alol dSoeu VISES BIOPSLict 158 AOA ASSES HNE AOS zeckt BAYS 5 UAVS WS ole lolc alol 2A 770 795 LELO E S IHHL SISStE Class Ill 3b aous cyto Za Veit S ao AAD eeler BA 45 Sol RA BS SHE PAS MHA AEWA Sol Class SEY Hlo HZ Ato SO 422 MSs MAS aleet Xii Printer Service Manual 4024 110 Lithium warning CAUTION POTENTIAL INJURY There is a danger of explosion if a lithium battery is incorrectly replaced Replace it only with the same or an equivalent type of lithium battery Do not recharge disassemble or incinerate a lithium battery Discard used batteries according to the manufacturer s instructions and local regulations 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 There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product Professional service personnel should understand this and take necessary precaut
116. IP card cover A 2 Remove the rear RIP card cover A by moving it in the direction of the arrow BEE WAY S aa 7 SW een H Li Hl ill D WS Repair information 4 125 4024 110 RIP card assembly removal Warning In the event of replacement of any one of the following components e Operator panel assembly e RIP card assembly Replace only one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more of the components listed above without a POR after installing each one or the printer will be rendered inoperable Warning Never install and remove components listed above as a method of troubleshooting components Once a component has been installed in a machine it cannot be used in another machine It must be returned to the manufacturer Remove the rear RIP card cover See Rear RIP card cover removal on page 4 125 Remove the rear motor cover See Rear motor cover removal on page 4 14 Remove the top rear cover See Top rear cover removal on page 4 4 Disconnect all the connectors excluding the cooling fan connector from the RIP card assembly A Remove the five screws securing the RIP card assembly A to the printer Remove any screws securing the side
117. Manual 288 05 Paper jam Check areas Sensor diverter gate Static jam to stacker bin B Paper remains on the sensor diverter gate when the finisher is in the stacker bin exit mode At this time the sensor finisher media entrance is turned on but the sensor bridge unit media exit is G2 G3 turned off Refer to Finisher Service Manual 288 06 Sensor diverter gate Static Paper remains on the sensor diverter gate when jam to stacker bin C the finisher is in the stacker bin exit mode Paper jam At this time both sensor finisher media entrance SES RIES and sensor bridge unit media exit are turned off Refer to Finisher Service Manual 32 Toner cartridge RFID failure A toner cartridge of a incorrect specification is Unsupported installed toner cartridge Go to Toner cartridge RFID failure on page 2 75 34 Incorrect media check tray 1 guides Tray 1 media size mismatch in length The media length detected by the sensor registration after the media is fed from media tray 1 does not match the length detected by media tray 1 switch media size Go to Tray 1 media size mismatch in length on page 2 77 34 Incorrect media check tray 2 guides Tray 2 media size mismatch in length The media length detected by the sensor registration after the media is fed from media tray 2 does not match the length detected by media tray 2 switch media size Go to Tray
118. Media out actuator e eee ee eee ee eee eee 7 7 Sensor exit 1 media shift HP 2 27 72 ee 7 27 Sensor fuser exit H 7 25 Sensor media level aa a ee 7 7 Sensor media out 2 e ene ee 7 7 Sensor MPF media out 7 11 Sensor standard bin full exit 1 7 27 Sensor pre feed 2 2 enn nn nee 7 7 Sensor tray 2 feed out H 7 21 Pick roll assembly spring 22 e ene nee 77 Feed roll one way clutch kit e eee eee eee 7 7 Separation roll friction clutch kit 737 Feed unit roll kit een eee eee eee ee 7 7 MPF media out actuator kit ee 7 11 MPF unit cable assembly 2 2 reer ern ee eee 7 11 MPF idler gear bracket assembly 7 11 MPF front cover 2 2 ene nnn ee eee 7 11 MPF rear cover 7 2 2200 r rere ee rrr 7 11 MPF transport pinch roll assembly 7 11 MPF pick roll Kit 2 2 eee enn en nnn eee eee 7 1
119. OE 2 82 Ee LE 3 1 ACCESSING service MENUS EE 3 1 Diagnosncs EE 3 2 Entering Diagnostics TEE 3 2 PVOUADIC EE co Dea RE ee RE RRR E EE wae DEN 3 2 Exiting Diagnostics EE es cites eGUaee ewe tense eee edewnaeaennas 3 4 MOTOR TESTS scccccidcctusecrcsdedesetse ates ee eteeed EE EE 3 5 PRINT EE 3 5 HARDWARE TESTS EE 3 6 DUPLEX TESTS ge Hoge g e Eer REES ee ea E EE RM A SE E 3 8 INPUT TRAY TESTS EE 3 9 iv Printer Service Manual 4024 110 OUTPUT BIN TESTS fe sete tach sick ices eee EE EES etree Ree EE ER 3 10 FINISHER TESTS Eer de r SNE EERSTEN ZE tale vie eae 3 11 BASE SENSOR TEST EE EES ccameassececesdecceanaeec eee dau ee eda eeemagen 3 13 DEVICE TESTS SES RE e ERR SEELEN EES OER SER SHER ERS REE 3 14 PRINTER SETUP tere See Eege EES EE SREL saws sexe tae mee 3 15 EVENT LOG 9a sie aber cia ieae et eewed tered eee nde dE REEE Re ee me seme RE 3 17 EXIT DIAGNOSTICS lt 6 ce ccc sedi csidadawedsadtgs EE bees cee EEEN NEEE Arbi 3 18 Configuration menu CONFIG MENU 0002 c eee ee 3 19 Entering Configuration Menu ak NUEEEKIEE ENTREE EC takit TREIER dean RIES 3 19 Aviale MENUS i 2205002000000 c eRe ede ee deed ROE RE HER OTR EE 3 19 Maintenance page count Maint Cnt Value 3 20 Maintenance page counter reset Reset Maint Cnt 00 2 0c e eee eee eee eee 3 20 MESSE HESE EE EE EE embed eer eiasssiaes 3 21 Print quality pages Prt Quality Pos 3 22 SIZE SENSING EE 3 23 Pattel MENUS isckicantetee cauno idara rE nnana sees d
120. Revision January 7 2010 Service Manual Lexmark W850n and W850dn Printer 4024 110 e Table of contents e Start diagnostics e Safety and notices e Trademarks e Index LEXMARK 4024 110 Edition January 7 2010 The following paragraph does not apply to any country where such provisions are inconsistent with local law LEXMARK INTERNATIONAL INC PROVIDES THIS PUBLICATIon AS IS WITHOUT WARRANTY OF ANY KIND EITHER EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow disclaimer of express or implied warranties in certain transactions therefore this statement may not apply to you This publication could include technical inaccuracies or typographical errors Changes are periodically made to the information herein these changes will be incorporated in later editions Improvements or changes in the products or the programs described may be made at any time Comments may be addressed to Lexmark International Inc Department D22X 002 1 740 West New Circle Road Lexington Kentucky 40550 USA or e mail at ServicelnfoAndTraining Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you You can purchase additional copies of publications related to this product by calling 1 800 553 9727 In other countries contact your point
121. Service Manual Assembly 3 Media feed unit 7 4024 110 Assembly Part Units Units kit Description Index number mach or pkg 3 1 40X0570 2 1 Switch media size 2 40X0569 2 3 Media tray catch kit includes e Media tray catch e Media tray slide 2 each 3 40X0572 1 1 Vertical turn guide 4 40X0571 1 1 Vertical turn mylar guide Parts catalog 7 5 4024 110 Assembly 4 Media feed unit exploded tray 1 and tray 2 Note Applies to tray 3 and tray 4 7 6 Printer Service Manual 4024 110 Assembly 4 Media feed unit exploded tray 1 and tray 2 Assembly Part Units Units kit Description Index number mach _ or pkg 4 1 40X0581 2 1 Media feed unit assembly 2 40X0582 2 1 Media feed lift motor 3 40X0585 2 6 Media feed drive gear kit includes e Media feed unit drive gear 13T e Media feed unit drive gear 28 21T e Media feed unit drive gear 29T e Media feed unit drive gear 27T e 2mm washer 2 each 4 40X0880 2 1 Bushing 6 mm 5 40X0967 2 2 Media tray lift one way clutch gear kit includes e Media tray lift one way clutch e Media tray lift one way gear 6 40X0968 2 1 Media tray lift one way shaft 7 40X0583 2 3 Tray lift coupling kit includes e Tray lift coupling e Tray lift coupling gear 31T e Spring 8 40X0590 2 1 Pick roll assembly spring 9 40X0593 2 2 Separation roll friction clutch kit includes e Separation roll one way friction clutch e Separation roll sp
122. X0663 1 1 Switch main power Warning In the event of replacement of any one of the following components e Operator panel assembly e RIP card assembly Replace only one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more of the components listed above without a POR after installing each one or the printer will be rendered inoperable Warning Never install and remove components listed above as a method of troubleshooting components Once a component has been installed in a machine it cannot be used in another machine It must be returned to the manufacturer Parts catalog 7 31 4024 110 Assembly 17 Electrical cables Option Tray assem Part Units Units kit WS bly Description number mach or pkg Index 17 1 40X0686 1 1 RFID sensor cable assembly 2 40X0681 1 1 Fuser AC cable assembly 3 40X0684 1 1 Main switch cable assembly 7 32 Printer Service Manual 4024 110 Assembly 18 Electrical cables gl RL A gt o SS Ld N gt e SECH i al sai K f g RH o a Assem bart Units Units kit _ bly Description number mach _ or pkg Index 18 1 40X0683 1 1 Interlock switch cable assembly 2 40X0673 1 1 HCF hookup connector assembly 3 40X0637 1 1 Multi connector cable assemb
123. a exit on Sensor upper media exit is not turned on within the Paper ari jam C specified time after the sensor finisher media BS entrance is turned on SES area At this time the sensor bridge unit media exit is turned on Refer to Finisher Service Manual 287 04 Sensor upper media exit off Sensor upper media exit is not turned off within the Papetiam jam B specified time after the sensor upper media exit is aper ja turned off Check area G At this time the sensor bridge unit media exit is turned off Refer to Finisher Service Manual 287 05 Sensor upper media exit Paper remains on the sensor upper media exit Paper jam static jam At this time the sensor bridge unit media exit is Check area F turned on Refer to Finisher Service Manual 287 06 Paper jam Check areas Sensor upper media exit Static jam B Paper remains on the sensor upper media exit At this time the sensor bridge unit media exit is off state but the finisher sensor finisher media entrance is turned on G1 G3 Refer to Finisher Service Manual 287 07 Sensor upper media exit Paper remains on the sensor upper media exit Paper jam Static jam C At this time both sensor bridge unit media exit and Checkared sensor finisher media entrance are turned off G1 Refer to Finisher Service Manual 288 00 Sensor diverter gate on jam Sensor diverter gate is not turned on within the Paper jam specified time after the sensor b
124. a in the tray crumpled or damaged We ae 2 Check the media size setup Go to step 3 Replace the Does the media size in use match the size set for tray 2 media or change the media size setup 2 34 Printer Service Manual 4024 110 Step Check Yes No 3 Check the rolls for tray 2 Go to step 4 Clean or replace the feed roll Remove tray 2 and check it separation roll Are the feed roll separation roll pick roll free of excess and pick roll wear and contamination Go to Feed roll removal on page 4 42 Separation roll removal on page 4 46 and Pick roll removal on page 4 48 4 Check the media position Remove the Go to step 5 Open the printer left lower door assembly and visually media check it Does the media touch the sensor pre feed in the tray 2 media feed unit 5 Check the sensor pre feed in tray 2 for proper operation Ensure the media Go to step 6 1 Select Diagnostics mode teed unit iret i g guide is installed 2 Select NPUT TRAY TESTS properly 3 Select Sensor test 4 Select Tray 2 SES 5 Select Pre fei Remove the media tray assembly and check it Does the display on the operator panel change every time a white piece of paper is placed over the sensing area 6 Check the sensor pre feed connection Replace the Replace the Is the sensor pre feed properly connected sensor prefed connection Go to Sensor Go to Sensor pre
125. a size setup Go to step 2 Replace the oe media or change Does the media size in use match the size set for tray 2 the media size setup 3 Check the rolls for tray 2 Go to step 4 Clean or replace the feed roll Pull out tray 2 and check it separation roll Open the printer left lower door assembly and visually and pick roll check it Go to Feed roll Are the feed roll separation roll and pick roll free of excess removal on wear and contamination page 4 42 Separation roll removal on page 4 46 and Pick roll removal on page 4 48 4 Check the media position Remove the Go to step 5 Does the media touch the sensor tray 2 feed out or the mena tray 2 media feed unit 2 36 Printer Service Manual 4024 110 Step Check Yes No 5 Check the sensor tray 2 feed out for proper operation Go to step 7 Go to step 6 1 Enter Diagnostics mode 2 Select NPUT TRAY TESTS 3 Select Sensor test 4 SelectTray 2 5 Select Media out Open the printer left lower door assembly and check it Does the display on the operator panel change every time a white piece of paper is placed over the sensing area 6 Check the sensor tray 2 feed out connection Replace the Replace the Is the sensor tray 2 feed out properly connected eae SE 2 connection Go to Sensor tray 2 feed out removal on page 4 81 7 Check the sensor pre feed in tray 2 for proper operation Ensu
126. acer 10 40X0594 1 6 Feed unit roll kit includes e Feed roll 2 e Pick roll 2 e Separation roll 2 11 40X0970 2 1 Pick roll drive gear 12 40X0969 2 1 Pick roll idler gear 13 40X0591 2 2 Feed roll one way clutch kit includes e Feed roll one way clutch e Feed roll one way gear 22T 14 40X0952 2 1 Bushing 6 mm 15 40X0586 2 2 Media feed unit front guide kit includes e Media feed unit front guide e Media feed unit front guide rail 16 40X0587 2 1 Media out actuator 17 40X0588 2 1 Sensor media out 18 40X0588 2 1 Sensor media level 19 40X0589 2 1 Sensor pre feed Note Assembly index items 17 and 18 are identical sensors with different functions therefore they are the same part number with different descriptions Parts catalog 7 7 4024 110 Assembly 5 Media tray 7 8 Printer Service Manual 4024 110 Assembly 5 Media tray Assembly Part Units Units kit Index number mach or pkg Description 5 1 40X0573 2 3 Media tray assembly includes this comes assembled e Media tray assembly e Labels 2 each 2 40X0578 2 2 Media tray end guide kit includes e Media tray end guide e Spring 3 40X0577 2 3 Media tray side guide actuator kit includes e Media tray side guide actuator e Media tray side guide slide e Spring 4 40X0576 2 5 Media tray side guide kit includes e Media max label e Front media tray guide assembly e Rear media tray guide e Pinion gear 2 each 5 40X0966 4 1 Media tray sep
127. age density normal 3 Check the transfer roll assembly Go to step 4 Replace the Remove the transfer roll assembly e Check the transfer roll assembly for contamination and wear Is the transfer roll assembly free of excess wear and contamination 4 Check the PC cartridge installation Go to step 5 Correct and i clean Remove the PC cartridge contaminated Check the PC cartridge connections pins or replace the PC cartridge Are the PC cartridge connections free of excess wear or connector and contamination 5 Check the drum grounding plate Go to step 6 Correct and A clean the drum Remove the PC cartridge grounding plate Check the drum grounding plate located behind the rear or replace the motor cover This plate can be found behind the flywheel PC cartridge Is the drum grounding plate free of excess wear and contamination 2 82 Printer Service Manual 4024 110 Step Check Yes No Check the image development process 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 Is the image completely formed on the drum and the area clear black and easy to read Go to step 7 Go to step 9 Check the image transfer process Check the toner image formed on the drum after the transfer roll assembly Is the toner image completely transferred on the med
128. age on the drum surface The image is called a developed image Z Ex HVPS Magnetic Metering Roll Blade Toner Q j VDC Ki A VDC Drum Surface Drum Surface Image Voltage A Toner at VDC Developer Bias value Discharge Level OV Visible Developed Image Diagnostic aids 3 49 4024 110 Transfer As the paper travels between the Transfer Roll and the drum surface the Transfer Roll applies a positive charge to the back of the printing paper This positive charge transfers the negative charged toner image from the drum surface to the top surface of the paper The toner image is now on the paper and the paper is now stuck to the drum surface due to the relative electrical differences between the negative electrical charge of the inner conductive layer of the drum and the positive electrical charge of the paper HVPS VDC kO Transfer roll Sheet of paper 3 50 Printer Service Manual 4024 110 Cleaning The Cleaning Blade removes any toner that remains on the drum after the transfer process The toner that the Cleaning Blade removes is collected inside the sealed PC Cartridge and reused Used Toner Cleaning Blade Charge roll 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 The AC voltage removes any residual DC charge tha
129. amp Note Before reinstalling ensure the HVPS A is inserted into the side slots properly Repair information 4 115 4024 110 Switch main power removal A Remove the top cover assembly See Top cover assembly removal on page 4 7 Open the printer front door assembly Remove the right upper cover See Right upper cover removal on page 4 11 Remove the screw securing the bracket A Slide the bracket A to the side and then upward in the direction of the arrow Remove the bracket A Disconnect the four connectors from the switch main power B Note Make note of the proper location of the four connectors PoP eh Release the hooks securing the switch main power B to the bracket A B Sb Hook Hook o Remove the switch main power B Connector Front Note Before reinstalling ensure the four connectors are plugged into their proper location to prevent damage 4 116 Printer Service Manual 4024 110 Exit interface card assembly removal Oa Pw Connector 1 Remove the top cover assembly See Top cover assembly removal on page 4 7 2 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 Release the plastic supports securing the exit interface card assembly A Remove the exit interface c
130. ansmitted to the pulley 25 tooth drives the exit 1 media exit roll assembly through the gears The driving force transmitted to the fuser assembly drives the heat roll PC cartridge motor The rotating force of the PC cartridge motor is transmitted through the gears to components that need a mechanical driving force as shown in the following diagram PC cartridge motor Drum Magnetic Roll Transfer roll The driving force transmitted to the PC cartridge drives the drum The driving force is then transmitted to the transfer roll assembly by direct contact with the drum Diagnostic aids 3 27 4024 110 Media transport Media transport path Media is supplied from the MPF tray 1 or tray 2 and is transported to the printer along the media transport path shown below MPF Tray 1 Tray 2 oo Te GC H CH MPF pick roll i 1 Pick roll i Pick roll i i i 1 J I I I I Ti d MPF Transport Roll ASM I Separation roll i Separation roll I I I i 1 Feed roll d Feed roll i i i 1 Hh d Seege I Ir Ir Media feed l MPFASM 4 unit ASM 1 unit ASM Heat roll Pressure roll Fuser unit ASM Exit 1 media exit roll ASM Duplex media transport roll ASM Duplex media Center transport roll ASM PRINT EXIT 3 28 Printer Service Manual Media transport path layout 4024 110 The following is a cross section of the laser p
131. aper is used for the 3 hole test and A4 media is used for the 4 hole test Media is selected from the default tray To run the Feed Test 1 Select FINISHER TESTS from DIAGNOSTICS 2 Select Feed Tests from FINISHER TESTS While the feed test runs the power indicator blinks and the message Feed Test Running displays During the test no buttons are active and the test cannot be stopped until the test is completed Feed Tests This test is used to verify whether or not media can be fed to a finisher output bin Eight sheets of blank paper are fed from the default paper source and fed to the finisher output bins Note This test can be run using any of the paper sizes supported by the printer To run the Feed Test 1 Select FINISHER TESTS from DIAGNOSTICS 2 Select Feed Tests from FINISHER TESTS While the feed test runs the power indicator blinks and the message Feed Test Running displays During the test no buttons are active and the test cannot be stopped until the test is completed Diagnostic aids 3 11 4024 110 Sensor Test finisher This test can be used to verify whether or not the finisher sensors are working correctly To run the finisher Sensor Test 1 Select FINISHER TESTS from DIAGNOSTICS 2 Select Sensor Test from FINISHER TESTS 3 Select one of the test categories e Cover and Door e Bin Level e Media Path1 e Media Path2 e Punch and Staple 4 Select the actual test to perform Each of the tests c
132. aration brush 6 40X0574 2 1 Media tray front cover includes e Media tray front cover e Labels 2 each 7 40X0579 2 2 Media tray end guide actuator kit includes e Media end guide actuator e Actuator link Note The graphic on the previous page shows two 7 callouts These callouts are the two items that make up the media tray end guide actuator kit 8 40X0580 2 3 Media tray lift gear kit includes e Tray lift coupling gear 13T e Tray lift gear 13 60T e Tray lift sector gear 12T 9 40X0965 2 1 Media tray separation pad Parts catalog 7 9 4024 110 Assembly 6 MPF unit 7 10 Printer Service Manual Assembly 6 MPF unit 4024 110 Assem bart Units Units kit bg bly Description number mach or pkg Index 6 1 40X0600 1 1 MPF rear cover 2 40X0599 1 1 MPF front cover 3 40X6000 1 1 MPF feed unit assembly 4 40X0608 1 1 MPF fold down tray assembly 5 40X0597 1 1 MPF unit cable assembly 6 40X0755 1 1 MPF pickup spring 7 40X0598 1 1 MPF idler gear bracket assembly 8 40X0601 1 1 MPF transport pinch roll assembly 9 40X0588 1 1 Sensor MPF media out 10 40X0596 1 2 MPF media out actuator kit includes e MPF media out actuator e Upper frame Parts catalog 7 11 4024 110 Assembly 7 MPF unit feed 7 12 Printer Service Manual Assembly 7 MPF unit feed 4024 110 Assem bly Index Part Units Units kit number mach _ or pkg Description 7 1 40X0605 1 5
133. ard assembly A along with the bracket B Remove the two screws securing the exit interface card assembly A to the bracket B Plastic support Connector Repair information 4 117 4024 110 7 Remove the exit 2 card assembly A P434 4 118 Printer Service Manual Printer engine card assembly removal Soh ou 4024 110 Remove the rear RIP card cover See Rear RIP card cover removal on page 4 125 Remove the rear motor cover See Rear motor cover removal on page 4 14 Remove the rear lower cover See Rear lower cover removal on page 4 15 Disconnect all the connectors from the engine controller card assembly A Note Connectors P405 P414 P416 and P400 have a hook that must be released Remove the six screws securing the printer engine card assembly A Remove the printer engine card assembly A P420 P421 P412 P401 P400 P419 P402 P404 P429 P413 P417 Connector P409 P411 P414 P415 Repair information 4 119 4024 110 Low voltage power supply LVPS card assembly removal AX 1 Remove the right upper cover See Right upper cover removal on page 4 11 2
134. ard bins e Bridge unit area if equipped e Finisher media bins 6 2 Printer Service Manual 7 Parts catalog 4024 110 How to use this parts catalog The following legend is used in the parts catalog Assem Part bly number Index Units mach Units kit or pkg Description e 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 es Part number Identifies the unique number that identifies this FRU e Units mach Refers to the number of units actually used in the base machine or product es Units kit or pkg Refers to the number of units packaged together and identified by the part number e NS Not shown in the assembly Index column indicates that the part is procurable but is not pictured in the illustration e PP Parts Packet in the parts description column indicates the part is contained in a parts packet Parts catalog 7 1 4024 110 Assembly 1 Covers and operator panel 1 of 2 7 2 Printer Service Manual Assembly 1 Covers and operator panel 1 of 2 4024 110 ee 1 1 40X5566 1 1 Operator panel assembly 2 40X5561 1 1 Operator panel controller card 3 40X5563 1 1 Operator panel cable 4 40X5564 1 1 Operator panel USB cable assembly 5 40X0553 1 1 Switch printer front door interlock 6 40X0558 1 1 Top cover assembly 7 40X5565 1 1 Printer front door cover assembly 8
135. assembly C BN Fatty x o A i Uy LU 3 ay Connector HH CHEC F ll ef Ge EFEFEF i Left view Note e Before reinstalling the registration roll assembly C fit the bosses on the rear center of the assembly into the holes e Before reinstalling the two harness connectors ensure they are plugged in properly 4 76 Printer Service Manual 4024 110 Registration clutch assembly removal D AROUND Note Remove the MPF rear cover See MPF rear cover removal on page 4 55 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 51 Remove the printer left door assembly See Printer left door support strap removal on page 4 71 Remove the registration roll assembly See Registration roll assembly removal on page 4 76 Remove the e ring with a prying tool securing the registration clutch assembly A to the registration roll assembly B Remove the registration clutch assembly A along with the harness A Before reinstalling the harness for the clutch must be placed through the hole on the registration roll assembly B e Before reinstalling the notch on the registration clutch assembly A must be placed over the boss of the
136. assembly printhead motor polygon mirror and start of scan card assembly 1 LD card assembly generates a laser beam with the two LDs of LD1 and LD2 The beam is turned on or off according to a print data signal 2 Printhead motor polygon mirror the polygon mirror is mounted to the shaft of the printhead motor and is rotated at a high speed by the printhead motor The mirror rotation shifts the incidence and reflection angles of a laser beam to scan the laser beam in the drum axial direction The laser beam reaches the polygon mirror as it passes through the lens L1 lens L2 and window The laser beam then arrives at the drum surface 3 SOS card assembly when a laser beam hits the SOS sensor on the SOS card assembly the beam is converted to an electrical signal SOS signal and detects the initial position where a scan starts on each line When a laser beam is scanned across the drum surface from one end to the other while turning on and off the beam one line of latent image is created If the scanning by the laser beam is repeated while rotating the drum a two dimensional image is created The resolution in the scanning direction from right to left is determined by the rotational speed of the printhead motor depending on how quickly the laser is adjusted The resolution in the Diagnostic aids 3 35 4024 110 process direction from top to bottom is determined by the rotational speed of the printhead motor The higher the
137. ate is lifted media is fed to the standard bin exit 1 When it is lowered media is fed to the standard bin exit 2 Sensor standard bin full exit 1 Media diverter gate Exit 1 media exit roll ASM Dual drive motor ASM Le Diagnostic aids 3 39 4024 110 Drive Media transport motor The media transport motor is a DC brushless motor that drives the exit 1 media exit shaft assembly fuser assembly registration roll assembly and transport roll assembly PC cartridge motor The PC cartridge motor is a DC brushless motor that drives the PC cartridge mag roll and transfer roll assembly Media transport motor PC cartridge motor p Dual drive motor ASM 3 40 Printer Service Manual 4024 110 Electrical components and controller Switch main power Turning on off the switch power supplies cuts off the main power of the printer Finisher AC output Supplies power to the finisher from the main LVPS low voltage power supply card assembly Switch printer front door interlock and switch printer left door interlock The switch is a safety switch to cut off a 24 VDC power supply from the LVPS card assembly to the high volt power supply HVPS card assembly printer engine card assembly and to the dual motor assembly while the printer front door assembly and the printer left door assembly are open Switch PC Cartridge interlock The switch PC interlock 5 V interlock
138. ategories includes the individual sensors that can be manually actuated and the display shows Open or Closed e Cover and Door Cover F bridge top Door G fin front Surface H fin eject e Bin Level Fin upper bin full Stacker bin level1 Stacker bin level2 Stacker bin upper limit Stacker bin no media Stacker bin level encod e Media Path1 Fuser exit Bridge media ent Bridge media exit Fin media enter Buffer path Upper media exit Lower media exit Compiler media in e Media Path2 Diverter gate Front tamper hp Rear tamper hp Eject clamp hp Media eject shaft hp 3 12 Printer Service Manual 4024 110 e 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 BASE SENSOR TEST This test is used to determine if the sensors located inside the printer are working correctly To run the Base Sensor Test 1 Select BASE SENSOR TEST from DIAGNOSTICS 2 Select one of the test categories e Cover and Door e Devices es Exit level e Media Path 3 Select the actual test to perform Each of the tests categories includes the individual sensors that can be manually actuated and the display shows Open or Closed e Cover and Door Door A left side Door B left lower Door C 2TM TTM Door D duplex left Door E exit2 left Door J front Door K hef top e Devi
139. bly boss from the exit 1 media shift gear D 13 Remove the exit 1 media shift gear D by lifting it upward Repair information 4 111 4024 110 Standard exit 1 top cover removal 1 Remove the standard exit 1 top cover A by moving it toward the rear then lifting it upward in the direction of the arrow 4 112 Printer Service Manual 4024 110 Exit 1 drive belt removal Remove the rear RIP card cover See Rear RIP card cover removal on page 4 125 Remove the rear motor cover See Rear motor cover removal on page 4 14 Remove the standard exit top cover See Standard exit 1 top cover removal on page 4 112 Release the hook on the drive belt flange A Remove the drive belt flange A Remove the exit 1 drive belt B from the drive pulley 25 tooth C Note The drive pulley 25 tooth C may become detached Vor eh 7 Remove the exit 1 drive belt B from the exit 1 media shift assembly D Note Press on the exit 1 drive belt B while slowly turning the motor E by hand Repair information 4 113 4024 110 Dual drive motor assembly removal 1 Remove the rear RIP card cover See Rear RIP card cover removal on page 4 125 2 Remove the rear motor cover See Rear motor cover removal on page 4 14 3 Remove the exit 1 top cover See Standard exit 1 top cover removal on page 4
140. bridge unit media exit is turned off Refer to Finisher Service Manual 284 01 Paper jam Check area F Sensor lower media exit on jam A Sensor buffer path is not turned on within the specified time after the sensor finisher media entrance is turned on At this time the sensor bridge unit media exit is turned on Refer to Finisher Service Manual Diagnostic information 2 9 4024 110 Error code or Error contents Description Action Check areas message 284 02 Sensor lower media exit on Sensor buffer path is not turned on within the Paper jam jam B specified time after the sensor bridge unit media entrance is turned on At this time the sensor finisher media entrance is Check area H G2 G3 turned on Refer to Finisher Service Manual 284 03 Sensor lower media exit on Finisher sensor lower media exit not turned on Paperjam jam C within the specified time after the sensor buffer per path is turned on as area Refer to Finisher Service Manual 284 04 Sensor lower media exit off Finisher sensor lower media exit not turned off Paper jam jam B within the specified time after the finisher sensor lower media exit on At this time the sensor finisher media entrance is turned on Refer to Finisher Service Manual 284 05 Paper jam Check area H Sensor lower media exit Static jam Paper remains on the sensor lower media exit Refer to Fi
141. by the media position and sensor on off time The sensor on off states can be monitored by media passing through the sensor pre feed sensing area Media feed lift motor Sensor pre feed Switch media size Media feed unit asm 3 32 Printer Service Manual 4024 110 Multi purpose feeder MPF The MPF is a mechanical unit suppling media to the printer The driving force from the transport motor of the dual drive motor assembly is transmitted to the MPF feed roll to feed media MPF pick roll The MPF pick roll feeds media set on the MPF MPF pick roll The MPF pick roll feeds media into the printer MPF pick solenoid The MPF pick solenoid transmits the driving force from the main motor to the MPF pick roll Sensor MPF media out The sensor MPF media out detects whether media is present on the MPF Sensor MPF media width The MPF side guides detects the width length in the main scanning direction of media on the MPF MPF media transport roll ASM Sensor MPF media out MPF pick solenoid Sensor MPF media width Diagnostic aids 3 33 4024 110 Detecting media size The size of media on the MPF is transmitted by moving the MPF side guide and is determined by the printer engine card assembly Media sizes that can be automatically detected are as follows Media size Wi
142. c eee eee eee 2 49 918 00 Sensor exit 1 media shift HP failure 2 50 Table of contents iii 4024 110 920 00 Fuser unit assembly on time failure eee 2 51 921 00 Over heat temperature failure 2 51 922 00 Center thermistor fail re ANEN EELER EEIEER eames EIERE ENEE RER EE EE ERR ms 2 52 923 00 Rear thermistor tailUr ass cacccandras dessa dnre Reece ees ss meari minii Reema ae 2 52 924 00 Pressure roll thermistor failure eee 2 53 925 00 Fuser operating temperature failure eee 2 53 927 00 PC cartridge RFID data write failure 2 54 928 00 PC cartridge RFID communication failure 2 54 929 00 Sensor ATG CIE EE 2 54 930 00 Laser Reger Tele ag BEER EE EE ER kideri A eee eRe e A 2 55 932 00 Toner cartridge RFID data write failure eee 2 56 933 00 Toner cartridge RFID communication failure 2 56 939 00 RIP card assembly communication failure nannan 2 57 941 00 Media tray 1 lift up no media tray failure 200s 2 57 942 00 Media tray 2 lift up no media tray failure 2 58 951 XX RIP card assembly NVRAM failure 2 60 953 XX Operator panel assembly NVRAM failure 2 61 955 XX RIP card assembly NAND CRC failure 2 62 956 00 RIP card assembly processor failure 2 62 956 01 RIP card assembly processor over temperature failure e eee nee 2 63 956 02 RIP card assembly cooling fan failure 2 63 980 03 Exit interface card assembly communication failure 00 0 cece eee eee
143. card Traditional Chinese font card Fa mko Cas Ce ree Ces Ces Cees Ces Cs Cs COs Cs Cee e Ca sch Ce Cs Ce Ces Ce Ces Cs Ces COs Ces Cree 7 38 Printer Service Manual Index A acronyms 1 3 B button test 3 6 C CACHE Test 3 7 code update 3 1 component locations 5 1 cables 5 8 HVPS 5 1 LVPS 5 1 printer boards 5 1 printer motors and sensors 5 2 printer switches 5 7 configuration menu accessing 3 1 3 19 available menus 3 19 Demo Mode 3 24 Disk Encryption 3 25 Energy Conserve 3 24 Env Prompts 3 25 EVENT LOG 3 24 Factory Defaults 3 24 Font Sharpening 3 25 Jobs On Disk 3 25 Maint Cnt Value 3 20 Panel Menus 3 23 Paper Prompts 3 24 PPDS Emulation 3 24 Prt Quality Pgs 3 22 Reset Maint Cnt 3 20 SIZE SENSING 3 23 D defaults factory defaults 3 24 US Non US defaults 3 15 diagnostic information 2 1 confirm the installation status 2 2 error code messages 2 5 POR sequence 2 2 service checks 2 23 start 2 1 using service checks 2 1 diagnostic mode 3 2 diagnostics mode accessing 3 1 available tests 3 2 BASE SENSOR TEST 3 13 DEVICE TESTS Disk Test Clean 3 14 Flash Test 3 15 Quick Disk Test 3 14 4024 110 DUPLEX TESTS Quick Test 3 8 Sensor Test 3 8 EVENT LOG Clear Log 3 18 Display Log 3 17 Print Log 3 17 exiting 3 4 FINISHER TESTS Sensor Test 3 12 Staple Test 3 11 HARDWARE TESTS Button Test 3 6 CACHE Test 3 7 DRAM Test 3 7 Panel Test 3 6 INPUT TRAY TESTS Feed Test 3 9 Senso
144. ces PC unit present Exit2 present e Exit level Std bin full exit1 Std bin full exit2 e Media Path Registration Fuser exit Exit1 shift hp Exit2 Exit2 shift hp Manually actuate the sensors to verify that each sensor switches from Open to Closed Press Back or Stop to exit the test Diagnostic aids 3 13 4024 110 DEVICE TESTS Quick Disk Test This test performs a non destructive read write on one block per track on the disk The test reads one block on each track saves the data and proceeds to write and read four test patterns to the bytes in the block If the block is good the saved data is written back to the disk To run the Quick Disk Test 1 Select DEVICE TESTS from DIAGNOSTICS 2 Select Quick Disk Test from DEVICE TESTS The power indicator blinks while the test is in progress and quick Disk Test Testing displays e Quick Disk Test Test Passed displays if the test passes and the power indicator turns on solid e Quick Disk Test Test Failed displays if the test failed and the power indicator turns on solid Press Back or Stop to return to the Device Tests menu Disk Test Clean Warning This test destroys all data on the disk and should not be attempted on a good disk Also note that this test may run approximately 11 2 hours depending on the disk size To run the Disk Test Clean Test 1 Select DEVICE TESTS from DIAGNOSTICS 2 Select Disk Test Clean from DEVICE TESTS Files
145. ck the sensor registration connection Replace the Replace the Is the sensor registration properly connected Ceo raii connection Go to Sensor registration removal on page 4 78 2 40 Printer Service Manual 4024 110 Step Check Yes No 10 Check the MPF pick solenoid for proper operation Go to step 12 Go to step 11 1 Enter Diagnostics mode 2 Select MOTOR TESTS 3 Select MPF pick solenoid Does the MPF pick solenoid make an audible clicking sound when activated 11 Check the MPF pick solenoid connection Replace the MPF Replace the Is the MPF pick solenoid properly connected pick solenoid connection Go to MPF pick solenoid pick lever removal on page 4 59 12 Perform a print test Replace the Problem solved printer engine card Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 900 XX RIP card assembly software failure Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on print tests If the problem remains go to step 2 2 Turn the printer off for 60 seconds Replace the RIP Problem solved Does the error occur when the power is turned off on again card assembly Go to RIP card assembly removal on page 4 126 Go to step 3 3 Perform a print test Replace the Problem solved Does the error still occur E card Go to Printer engi
146. clamps on the exit 1 media shift assembly B to prevent damage Repair information 4 107 4024 110 Sensor exit 1 media shift removal Peano ONT Remove the rear RIP card cover See Rear RIP card cover removal on page 4 125 Remove the rear motor cover Remove the top rear cover See Top rear cover removal on page 4 4 Open the printer left door assembly Remove the standard exit top cover See Standard exit 1 top cover removal on page 4 112 Open the printer front door assembly Remove the front left cover See Printer front left cover removal on page 4 3 Remove the exit 1 media shift assembly See Exit 1 media shift assembly removal on page 4 104 Remove the media shift motor See Media shift motor removal on page 4 107 Remove the two screws securing the bracket A to the exit 1 media shift assembly B Remove the bracket A Release the hooks securing the sensor exit 1 media shift C to the bracket A Remove the sensor exit 1media shift C 4 108 Printer Service Manual 4024 110 Sensor exit 1 bin full removal zech Le el rors Remove the rear RIP card cover See Rear RIP card cover removal on page 4 125 Remove the rear motor cover See Rear motor cover removal on page 4 14 Remove the top rear cover See Top rear cover removal on page 4 4 Open the printer left door assembly Remove the standard exit top cover See Standard exit 1
147. clutch assembly includes e Bushing 4 5 mm front e Bushing 4 5 mm rear e Shaft e Transport clutch gear 19T e Transport clutch 2 40X0628 1 1 Registration mylar guide assembly 3 40X0625 1 1 Registration roll assembly this comes assembled 4 40X0627 1 1 Sensor registration 5 40X0589 1 1 Sensor tray 2 feed out 6 40X0630 1 1 Tray 2 feed out sensor guide this comes assembled Parts catalog 7 21 4024 110 Assembly 12 Printhead cartridge guides and fans 7 22 Printer Service Manual 4024 110 Assembly 12 Printhead cartridge guides and fans Assem bly Part Units Units kit Description Index number mach or pkg 12 1 40X0639 1 1 Toner add motor assembly 2 40X0640 1 1 Fuser cooling fan 3 40X0636 1 1 Sensor RFID toner cartridge 4 40X0641 1 1 Printhead assembly 5 40X0631 1 1 PC cartridge stop 6 40X0644 1 1 PC cartridge sensor connector 7 40X1390 1 2 Switch PC cartridge interlock kit includes e Backup spring e Switch PC cartridge interlock 8 40X1389 1 1 PC cartridge interlock switch screw 9 40X0633 1 1 Sensor hum amp temp 10 40X0634 1 1 PC cartridge guide assembly 11 40X0635 1 1 Laser opening guide 12 40X0636 1 1 Sensor RFID PC cartridge 13 40X0643 1 1 PC cartridge cooling fan 14 40X0637 1 1 Multi connector cable assembly 1 15 40X0638 1 2 Toner cartridge guide kit includes e Toner cartridge guide assembly e PC cartridge cooling fan duct e PC cartridge cooling fan Parts catal
148. contains a mixture of graphics and text Pages two and three contain only graphics Page four is blank If duplex is turned on the pages are duplexed The Print Quality Test pages are printed in English and must always be printed on letter legal or A4 paper The value of the lt media width gt field is displayed once the printer narrow media sensor has determined whether the media used for the Quick Test is narrow or wide An N indicates the media sensed is narrow and a W indicates the media sensed is wide 3 22 Printer Service Manual 4024 110 SIZE SENSING This setting controls whether the printer automatically registers the size of paper installed in an input source with size sensing Size sensing Paper source Length Width Multipurpose feeder integrated MPF v 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 Tray 4 optional TTM 1150 sheet drawer Tray 5 optional HCF 2000 sheet drawer SINSINIS SISISINSINSINIS When the setting is Auto every input option equipped with size sensing hardware automatically registers what size media it contains When the setting is off the media size detected by hardware is ignored The media size can be set by the operator panel or the data stream To change the size sensing sett
149. ct Exit2 Does the display on the operator panel change every time the actuator on the above sensor operates 10 Check the sensor exit 2 for proper connection Replace the sensor Replace the exit 2 connection Is the above sensor connected properly Refer to Options Service Manual Diagnostic information 2 29 4024 110 Step Check Yes No 11 Check the media diverter solenoid for proper operation 1 Enter Diagnostics mode 2 Select MOTOR TESTS 3 Select Diverter solenoid Open the printer left door assembly Does the above component operate normally Go to step 13 Go to step 12 12 Check the media diverter solenoid for proper connection Is the above component connect properly Replace the media diverter solenoid Refer to Options Service Manual Replace the connection 13 Perform a print test Does the error still occur Replace the exit interface card assembly Go to Exit interface card assembly removal on page 4 117 Go to step 14 Problem solved 14 Perform a print test Does the error still occur Replace the printer engine card assembly Go to Printer engine card assembly removal on page 4 119 Problem solved 203 01 Sensor exit 2 off jam Step Check Yes No Check the media position Open the exit 2 left door assembly and visually check it Does the media touch
150. ction Replace the Replace the Is the sensor fuser exit properly connected SENSON MUSET EE Go to Sensor fuser exit removal on page 4 102 7 Check the registration clutch for proper operation Go to step 8 Go to step 9 1 Enter Diagnostics mode 2 Select MOTOR TESTS 3 Select Regi strat clutch Does the registration clutch make an audible clicking sound when activated 8 Check the registration clutch connection Replace the Replace the Is the registration clutch properly connected registr tion clutchi cannection Go to Registration clutch assembly removal on page 4 77 9 Perform a print test Replace the Problem solved printer engine card Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 Diagnostic information 2 25 4024 110 202 00 Sensor fuser exit off jam Step Check Yes No 1 Check the media position Remove the Go to step 3 Open the printer left door assembly and visually check it mena f Go to step 2 Does the media touch the sensor fuser exit 2 Check the roll Go to step 3 Clean or replace F the transport roll Open the printer left door assembly and check it assembly Is the transport roll assembly free of excess wear and contamination 3 Inspect the pinch roll on the transfer roll guide assembly Go to step 4 Replace the transfer roll guide Is the transfer roll guide assembly free o
151. cur assembly Go to Printer engine card assembly removal on page 4 119 2 50 Printer Service Manual 920 00 Fuser unit assembly on time failure 4024 110 Step Check Yes No 1 Check the fuser unit assembly for a media jam Remove the Go to step 2 Open the printer left door assembly and check it media Is there a media jam in the fuser unit assembly 2 Leave the printer powered on with the error code displayed Go to step 3 Problem solved for 10 minutes then perform a POR Does the error still occur 3 Check the fuser unit assembly for installation Go to step 4 Install the fuser Open the printer left door assembly and check it unit assembly H H y securely Is the fuser unit assembly installed securely 4 Check the fuser unit assembly connection Go to step 5 Replace the Is the fuser unit assembly properly connected connecuon 5 Check between the LVPS card assembly P525 and the Replace the fuser Replace the printer engine card assembly P401 for proper connection unit assembly connection Are the cards connected properly A 6 Perform a print test Replace the Problem solved Does the error continue A card Go to Printer engine card assembly removal on page 4 119 921 00 Over heat temperature failure Step Check Yes No 1 Check the fuser unit assembly for installation Go to step 2 Install the fuser Open the printer left door assembly and check it unit
152. d Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 Diagnostic information 2 67 4024 110 PC cartridge set failure Step Check Yes No 1 Check the PC cartridge installation Go to step 2 Install the PC Is the PC cartridge properly installed cartridge properly 2 Check the PC cartridge sensor connection Replace the PC Replace the cartridge connection Is the PC cartridge sensor properly connected connector 3 Check the switch PC cartridge interlock for operation Go to step 5 Go to step 4 1 Enter Diagnostics mode 2 Select BASE SENSOR TEST 3 Select Devices 4 Select PC unit present Open the printer left door assembly and the front door assembly and check them Does the display on the operator panel change every time the PC cartridge is removed and replaced 4 Check the switch PC cartridge interlock connection Replace the switch Replace the Is the switch PC cartridge interlock properly connected PG cartridge connection interlock 5 Perform a print test Replace the Problem solved Does the error continue SE bard Go to Printer engine card assembly removal on page 4 119 Printer front door open Step Check Yes No 1 Check the opening and closing of the printer front door Go to step 2 Check the printer assembly front door Is the KO front door assembly opening and closing Se re normally reinstall
153. d off and then the fuser temperature control is stopped Main sub heater lamps on off control The center and rear thermistors detect the heat roll surface temperature fuser temperature to regulate the temperature at the target control temperature by turning on or off the main sub heater lamps Fuser warm up The fuser warm up starts at the time of power on interlock open or close jam reset or return from the low power mode and ends when the ready temperature is attained when a failure occurs or when executing diagnosis 3 44 Printer Service Manual 4024 110 Xerographic Process During a Print Cycle Heat roll ressure roll al Fuser ASM REESEN Cleaning blade ch Sen ee Ss oe erh a Charge roll K Laser beam Transfer roll See e ee Ze e e Ee e i PC cartridge Magnetic roll Paper Diagnostic aids 3 45 4024 110 Charge The Charge Roll places a uniform negative electrostatic charge on the surface of the drum The drum surface is made of a photoconductive material that holds an electrical charge as long as the drum remains in darkness Light striking the drum discharges the surface charge Charge roll Ground Drum Surface Drum Surface Photoconductive Image Voltage Surface T VDC value Conductive Tube Ground 3 46 Printer Service Manual 4024 110 The charge roll is a conductive roll that is positioned slightly above the surface of the drum The HVPS supplies th
154. des come into contact with the media and hold it in position The rear media tray guide moves together with the front media tray guide assembly Media tray end guide The media tray assembly is designed so it can adapt to the media length in the media feed direction by moving the media tray end guide to the left or right Bottom plate The force pushing up the bottom plate is transmitted by the driving force of the motor on the media feed unit assembly to the lift up shaft through the gear 13 60 tooth and sector gear 12 tooth The bottom plate is pushed up by the rotation of the lift up shaft which causes the supplied media to come in contact with the pick roll 3 30 Printer Service Manual 4024 110 Media tray assembly Media end guide 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 Media feed unit assembly Since tray 1 and tray 2 are functionally equivalent in terms of the switch media size sensor media out sensor media level and sensor pre feed only the components of one tray are described here The media feed unit assembly is a mechanical unit supplying media from the media tray assembly to the printer The driving force from the media feed lift motor on the media feed unit assembly is transmitted to the three media
155. dge shutter link eee TA17 Transfer roll guide assembly 7 17 Printer left door assembly this comes assembled 7 19 Printer left door assembly handle kit 7 19 PC cartridge shutter actuator 7 19 Printer left door support strap eee eee eee 7 19 Registration roll assembly eee eee eee eee 7 21 Sensor registration 22 eee eee ee ee ee eee eee 7 21 Registration mylar guide assembly 7 21 Transport clutch assembly eee eee eee ee 7 21 Tray 2 feed out sensor guide 7 21 PC cartridge stop 2 2 ee ee nn ee eee eee eee 7 23 Sensor hum amp temp H 7 23 PC cartridge guide assembly 7 23 Laser opening guide 7 23 Sensor RFID PC cartridge nnn nn er nee eee 7 23 Sensor RFID toner cartridge 7 23 Multi connector cable assembly 1
156. docking failure or The tray 5 HCF unit is not properly docked with the missing HCF tray 5 set failure printer or the HCF tray 5 is not set Refer to Options Service Manual Service checks 200 00 Sensor registration off jam too long 4024 110 Step Check Yes No 1 Check the media position Remove the Go to step 2 Open the printer left door assembly and visually check it media Does the media touch the sensor registration 2 Check the roll Go to step 3 Clean or replace Open the printer left door assembly and check it AEN i roll Is the transport roll assembly free of excess wear and Go to Transfer contamination roll assembly removal on page 4 70 3 Check the sensor registration for proper operation Go to step 5 Go to step 4 1 Enter Diagnostics mode 2 SelectBASE 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 4 Check the sensor registration connection Replace the Replace the Is the sensor registration properly connected registration connection Go to Sensor registration removal on page 4 78 5 Check the registration clutch for proper operation Go to step 7 Go to step 6 1 Enter Diagnostics mode 2 Select MOTOR TESTS 3 Select Regi strat clutch Does the registration clutch make an audible clickin
157. drive gear 29 tooth 4 40 media out actuator 4 35 media shift motor 4 107 media transport roll assembly gear 4 66 media tray end guide 4 27 media tray lift gear group 4 29 media tray side guides 4 24 MPF feed drive gear group 4 56 4024 110 MPF feed shaft assembly 4 60 MPF feed unit assembly 4 51 MPF fold down tray assembly 4 62 MPF media out actuator and upper frame 4 52 MPF pick solenoid pick lever 4 59 MPF pressure pad 4 57 MPF rear cover 4 55 MPF transport pinch roll assembly 4 54 MPF transport roll assembly 4 58 operator panel assembly 4 6 option hookup cover 4 16 PC cartridge cooling fan 4 101 PC cartridge cooling fan duct 4 99 pick roll 4 48 4 61 pick roll drive gear 25 tooth 4 49 pick roll idler gear 33 tooth 4 47 printer front door assembly 4 8 printer front left cover 4 3 printer left door support strap 4 71 printer left lower door assembly 4 67 printhead assembly 4 97 rear lower cover 4 15 rear motor cover 4 14 registration clutch assembly 4 77 registration roll assembly 4 76 right lower cover 4 12 right upper cover 4 11 RIP card assembly 4 126 sensor exit 1 bin full 4 109 sensor exit 1 media shift 4 108 sensor fuser exit 4 102 sensor humidity and temperature 4 87 sensor media level 4 36 sensor media out 4 37 sensor MPF media out 4 53 sensor pre feed 4 38 sensor registration 4 78 sensor RFID PC cartridge and sensor RFID toner cartridge 4 92 sensor tray
158. drive motor assembly connection Replace the dual Replace the Is the dual drive motor assembly properly connected oo connection 6 Perform a print test Replace the Problem solved Does the error continue GE carg Go to Printer engine card assembly removal on page 4 119 913 00 Printhead assembly failure Step Check Yes No 1 Check the printhead assembly for installation Go to step 2 Install the Is the printhead assembly installed securely GE securely 2 Check the printhead assembly connection Replace the Replace the Is the printhead assembly properly connected printhead connection 3 Perform a print test Replace the Problem solved printer engine card Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 Diagnostic information 2 47 4024 110 914 00 Toner add motor assembly failure Step Check Yes No 1 Check the toner cartridge for installation Problem solved Go to step 2 Remove the toner cartridge and reinstall it Does it operate properly 2 Check the gear rotation for the toner cartridge guide Go to step 3 Replace the toner assembly cartridge guide Remove the toner guide assembly assembly Does the gear located at the lower part of the toner cartridge guide assembly rotate smoothly 3 Check the toner cartridge guide assembly for pipe clogging Go to step 4 Clean the pipe Is the pipe located at
159. dth mm Feed length mm Side guide stopper min 84 Media detection area min 88 3 5 x 8 5 SEF 89 216 Postcard SEF 102 152 5 5 x 8 5 SEF 140 216 Postcard LEF 148 100 A6 LEF 148 105 A5 SEF 148 210 Postcard LEF 152 102 B6 LEF 182 129 B5 SEF 182 257 Monarch LEF 191 98 A5 LEF 210 148 A4 SEF 210 297 5 5 x 8 5 LEF 216 140 5 5 x 11 SEF Letter 216 280 5 5 x 13 SEF Legal 216 330 5 5 x 14 SEF Legal 216 356 DL LEF 220 110 C5 LEF 229 162 C4 SEF 229 324 Rectangular LEF 235 120 Com10 LEF 241 105 B5 LEF 257 182 B4 SEF 257 364 Executive LEF 267 184 16K LEF TFX PRC 267 270 194 195 8K SEF TFX PRC 267 270 389 390 8 5 x 11 SEF Letter 279 216 11 x 17 LEF 279 432 A4 LEF 297 210 A3 SEF 297 420 Stopper max 303 3 34 Printer Service Manual 4024 110 Transfer roll assembly The transfer roll assembly is driven by direct contact with the drum of the PC cartridge The transfer roll assembly applies positive charges to the rear surface of the media when the media passes between the transfer roll assembly and the drum The negatively charged toner image is attracted by positive charges on the rear surface of the media Thus the toner image is transferred from the drum surface to the media surface PC cartridge Printhead assembly The printhead scans the drum surface with a laser beam It consists of four components laser diode LD card
160. dth 2 64 no media in the select media tray 2 65 paper is installed short edge in the media paper tray 2 66 PC cartridge end of life 2 66 2 67 PC cartridge RFID failure 2 67 PC cartridge set failure 2 68 printer front door open 2 68 printer left door open 2 69 printer left lower door open 2 70 scheduled maintenance required 2 70 standard bin 1 full 2 71 standard bin 2 full 2 72 l 2 Printer Service Manual toner cartridge empty 2 72 toner cartridge near empty 2 74 toner cartridge RFID failure 2 74 2 75 toner cartridge set failure 2 75 tray 1 media size failure 2 76 tray 1 media size mismatch in length 2 77 tray 2 media size failure 2 77 tray 2 media size mismatch in length 2 79 event log clear log diagnostics mode 3 18 display log diagnostics mode 3 17 print log configuration menu 3 24 print log diagnostics mode 3 17 F finisher tests Sensor Test 3 12 Flash Test 3 15 l image quality trouble 2 81 blank print no print 2 84 faint print low contrast 2 82 image quality 2 82 solid black 2 86 troubleshooting 2 81 vertical blank lines white stripes in media transport direction 2 87 image quality troubles after image 2 97 background fog 2 98 horizontal band printheads out 2 87 horizontal stripes 2 93 media damage 2 101 no fuse 2 102 partial lack 2 95 skew 2 100 spots 2 96 vertical stripes 2 89 input sensor tray tests 3 9 input source tests 3 5 input tray feed test 3 9 L lubr
161. dy appears on the screen 2 2 Printer Service Manual Printer operator panel 4024 110 The printer operator panel consists of these items e A four line backlit gray scale display that can show both graphics and test e Eight buttons e Indicator light e Numeric pad e USB direct interface The use of the buttons and the layout of the display panel is described in the following table T direct interface Indicator Display light Numeric keypad Gem at 0 0 0O Scheffe g p ee Back Menu Stop Navigation button Select button Item Description Display Shows messages that communicate the status of the printer Indicator light e Off tThe power is off e Blinking green The printer is warming up processing data or printing e Solid green The printer is on but idle e Solid red Operator intervention is needed Numeric keypad GG GG Enter numbers or symbols on the display e Opens a menu item and displays the available values or settings e Saves a displayed menu item as the new user default setting Notes e When a new setting is saved as the user default setting it remains in effect until a new setting is saved or until factory defaults are restored e Settings chosen from a software program can also change or override the user default settings selected from the printer control panel Diagnostic information 2 3 4024 110
162. e feeds one sheet of media from the selected source e Continuous media continues feeding from the selected source until Stop is pressed Sensor Test input tray This test is used to determine if the input tray sensors are working correctly To run the Input Tray Sensor Test 1 5 Select INPUT TRAY TESTS from DIAGNOSTICS 2 Select the Sensor Test from INPUT TRAY TESTS 3 4 Select the input source from the sources displayed on the Sensor Test menu All installed sources are listed Select the sensor to test Various menus have different listings of sensors depending on the input source or tray selected See the table below Tray sensors support by source Sensor Input source D S E S Ss gt N N 2 as P S a a i 3 5 H o S E S 98 8 5 5 Ta oO D Tray 1 v v v Tray 2 v v v v Tray 3 v v v v Tray 4 v v v v Tray 5 v v v v v v v v Multipurpose vd tray The servicer can manually actuate the selected sensor and Open or Closed displays Press Back or Stop to exit the test Diagnostic aids 3 9 4024 110 OUTPUT BIN TESTS Feed Tests output bins Use these tests to verify that media can be fed to a specific output bin Media is fed from the default input source to the selected output bin No information is printed on the media fed to the output bin because the printhead is not engaged during this test These t
163. e printer engine card assembly the transport motor does not stop when media is not transported Go to 910 00 Transport motor stop failure on page 2 45 911 00 Service motor error Transport motor failure The transport motor does not rotate at the specified speed Go to 911 00 Transport motor failure on page 2 46 Diagnostic information 2 13 4024 110 Error code or Error contents Description Action message 912 00 PC cartridge unit motor The PC cartridge motor does not rotate at the b failure specified speed Service motor error Go to 912 00 PC cartridge unit motor failure on page 2 46 913 00 Printhead assembly failure Rotation speed of the printhead motor is less than Seri t the specified value even when the specified time is SS motor passed after the motor starts rotating Light intensity of the LD1 is less than the specified value Go to 913 00 Printhead assembly failure on page 2 47 914 00 Toner add motor assembly The toner concentration in the PC cartridge does Service motor failure not increase when the toner add motor is turned on rror for more than the specified time Go to 914 00 Toner add motor assembly failure on page 2 48 915 00 Fuser cooling fan failure The fuser cooling fan has failed Service fan Go to 915 00 Fuser cooling fan failure on error page 2 48 916 00 PC cartridge cooling fan The PC cartridge cooling fan has
164. e 2 56 939 00 RIP card assembly A communication error occurred between the printer S communication failure engine card and the RIP card assembly Service RIP engine Go to 939 00 RIP card assembly communication Comm failure on page 2 57 941 00 Media tray 1 lift up no tray The media tray 1 sensor media level is not turned g failure on within the specified time after the tray 1 media SE tray 1 feed lift motor is turned on The media tray 1 switch media size detected no media tray Go to 941 00 Media tray 1 lift up no media tray failure on page 2 57 942 00 Media tray 2 lift up no tray The media tray 2 sensor media level is not turned e failure on within the specified time after the media tray 2 aa tray 2 media feed lift motor is turned on The media tray 2 switch media size detected no media tray Go to 942 00 Media tray 2 lift up no media tray failure on page 2 58 943 00 Media tray 3 lift up no tray The 2TM tray 3 sensor media level is not turned Sgr ays failure on within the specified time after the 2TM tray 3 See ray media feed lift motor is turned on The 2TM tray 3 switch media size detected no tray Refer to Options Service Manual 944 00 Media tray 4 lift up no tray The 2TM tray 4 sensor media level is not turned S rvice iraya failure on within the specified time after the 2TM tray 4 chte ray media feed lift motor is turned on The 2TM tray 4 switch media size detected no tray Refer to Opti
165. e amount of jitter or unevenness This is normal for Print Tests 1 2 3 Print a sample image from the host computer Enter Printer Diagnostics and generate a Print Test If the print quality problem occurs when you print from the host computer but does not occur when you print from Diagnostics the problem may be in the RIP card assembly in the print driver software or in the application software on the host computer If the print quality problem occurs on the Print Test then the problem is caused by the print engine If the print quality problem is an image registration problem go to Setting Printer Registration on page 3 31 3 26 Printer Service Manual 4024 110 Driving force transmission path Transport motor The rotating force of the transport motor is transmitted through the gear and the pulley 25 tooth to components that need mechanical driving force as shown in the following diagram Media transport motor Transport MPF idler gear 21T 21T j Pulley25T j Transport Clutch Gear exit Vertical gear drive ASM j Gear19T AA AA Gear18T MPF feed Registration Fuser unit Exit1 media roll ASM roll ASM ASM SIE Transport roll ASM The driving force transmitted to the gear drives the transport roll assembly multipurpose feeder MPF feed roll registration roll assembly fuser assembly and exit 1 media exit roll assembly through the clutch and gears The driving force tr
166. e band pitch Go to step 9 Go to step 6 Is the white band pitch approximately 78 mm heat roll circumference 6 Check the heat roll and pressure roll Replace the Go to step 7 fuser unit Remove the fuser unit assembly assembly Is there any contamination or crack on the heat roll and or pressure roll 7 Check the image development process Go to step 8 Go to step 9 Perform a print test Turn off the printer power while printing Carefully remove the toner cartridge and check the toner image formed on the drum before the transfer roll assembly Is the image completely formed on the drum and is the area clear black and easily read Diagnostic information 2 93 4024 110 Step Check Yes No Check the image transfer process Check the toner image formed on the drum after the transfer roll assembly passed Is the toner image completely transferred on the media Go to step 9 Go to step 10 Check the HVPS Replace the HVPS Perform a print test Does the error continue Go to step 10 Problem solved 10 Check the printer engine card assembly Replace the printer engine card assembly Perform a print test Does the error continue Go to step 11 Problem solved 11 Check the printhead assembly for connection Warning If too much force is applied to the board when checking it the printhead could become misaligned Are P J130 P J620 and P J
167. e 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 Clean Charge roll Ground Drum Surface Drum Surface Photoconductive Image Voltage SSES T VDC value Conductive Tube Exposure The Printhead generates a beam of laser light Image data received from the RIP card assembly modulates this beam turning it on and off according to image information that is received from the host computer and software Through the use of a series of rotating and stationary mirrors within the Printhead the beam scans the negative charged drum surface Whenever the print controller sends a command to print a black pixel the laser switches on long enough to shine onto the drum at a single pixel point That point is now discharged and slightly less negative than the surrounding negative charge The less negative areas are considered positive This discharge no discharge process creates an invisible electrostatic image on the surface of the drum This image is called a latent image Diagnostic aids 3 47 4024 110 The Printhead also helps to clean and prepare the drum by scanning the surface of the drum at the beginning of each individual printer cycle This action discharges a residual DC charge that may still remain on the Drum from the last print cycle Si Second First
168. e e clip with needle nose pliers on the front of the shaft C directly behind the printer left door assembly Remove the shaft C Connector Repair information 4 79 4024 110 11 Release the hooks securing the front bushing D to the frame 12 Remove the front bushing D 13 Release the hooks securing the rear bushing E from the bracket A 14 Remove the rear bushing E Ce SSAA Sees yi ep 0 Oi Note Before reinstalling the notch of the transport clutch assembly B must be placed over the boss of the bracket A 4 80 Printer Service Manual 4024 110 Sensor tray 2 feed out removal Sono Fons Remove the MPF rear cover See MPF rear cover removal on page 4 55 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 51 Remove the printer left door assembly See Printer left door support strap removal on page 4 71 Open the printer left lower door assembly See Printer left lower door assembly removal on page 4 67 Remove the two screws securing the tray 2 feed out sensor guide A Remove the tray 2 feed out sensor guide A while pulling on its center most point Disconnect the connector from the sensor tray 2 feed out B Release the hook securing the sensor tray 2 feed out B Remove the sensor tray 2 feed out B Connector Repair information 4 81 4024 110 Switch PC car
169. e for installation Problem solved Go to step 3 Remove the toner cartridge and reinstall it Does it operate properly 3 Check the toner cartridge guide assembly Go to step 4 Replace toner Remove the toner cartridge guide assembly GE E ald Does the gear located on the lower part of the toner cartridge guide assembly rotate smoothly 2 72 Printer Service Manual 4024 110 Step Check Yes No 4 Check the pipe located on the lower part of the toner Go to step 5 Clean the pipe cartridge for debris Is the pipe located on the lower part of the toner cartridge guide assembly clogged 5 Check the sensor RFID toner cartridge for proper Go to step 6 Install the sensor installation RFID toner cartridge correctly 6 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 93 7 Check the toner add motor assembly for operation Go to step 9 Go to step 8 Warning Only perform this test in segments of three seconds or less or toner spill will occur 1 Enter Diagnostics mode 2 Select MOTOR TESTS 3 SelectToner add motor Does the motor rotate normally 8 Check the toner add motor assembly connection Replace the toner Replace the Is the toner add motor assembly properly connected add moror Gonnacnon Go to Toner cartridge guide assembly removal
170. e gears may become detached from bracket A OND FPS 9 Remove the e ring with a prying tool securing the tray lift coupling B to bracket A 10 Remove the tray lift coupling gear 31 tooth C 11 Remove the spring D Note Before reinstalling ensure all gears and washers attached to bracket A are securely installed Repair information 4 31 4024 110 Tray lift one way clutch gear assembly removal 1 ARON Remove the media feed unit assembly Go to Media feed unit assembly 1 removal on page 4 18 or Media feed unit assembly 2 removal on page 4 21 Remove the harness from the bracket A Remove the three screws securing the bracket A to the media feed unit assembly Remove the bracket A Note The gears may become detached from the bracket A Remove the tray lift one way clutch B Harness 4 32 Printer Service Manual 4024 110 6 Remove the tray lift one way gear 24 tooth C Harness Note Before reinstalling ensure all gears and washers are securely attached to the bracket A Repair information 4 33 4024 110 Media feed unit drive gear 13 tooth removal 1 ARON L Remove the appropriate media feed unit assembly See Media feed unit assembly 1 removal on page 4 18 or Media feed unit assembly 2 removal on page 4 21 Remove the harness from the bracket A Remove the three screws securing the bracket A to the media feed unit assembly
171. e laser beam route Go to step 8 Remove debris Check for debris between the transfer roll assembly and oe a the PC drum assembly Check the printhead assembly window for window contamination Is there any debris in the laser beam route or the printhead assembly window 8 Check the heat roll and pressure roll Replace the Go to step 9 Remove the fuser unit assembl Sor unit emove the fuser unit assembly assembly Is there contamination or cracking on the heat roll and or pressure roll 9 Check the printer engine card assembly Replace the RIP Problem solved Replace the printer engine card assembly EE Perform a print test SC carg Does the error continue removal on page 4 126 2 92 Printer Service Manual Horizontal stripes 4024 110 Trailing edge Step Check Yes No 1 Check the media condition Go to step 2 Problem solved Load new dry recommended media Re print the defective image Does the error continue 2 Check the media transfer route Go to step 3 Remove ee obstacles or Check the media route for contamination or obstacles contamination 3 Check the toner cartridge Problem solved Go to step 4 Install a new toner cartridge Re print the defective image Is the image density normal 4 Check the transfer roll assembly Go to step 5 Replace the Remove the transfer roll assembly Meats Is the transfer roll assembly free of contamination and wear 5 Check whit
172. e sensor RFID toner cartridge connection Replace the Replace the Is the sensor RFID toner cartridge properly connected ae ae connection 4 Perform a print test Replace the Problem solved printer engine card Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 Toner cartridge set failure Step Check Yes No 1 Check the toner cartridge for correct installation Go to step 2 Reinstall the toner Open the printer front door assembly cartridge properly Go to Toner Is the toner cartridge installed properly cartridge guide assembly removal on page 4 93 2 Check the toner cartridge Replace the toner Go to step 3 Is the toner cartridge damaged cartridge Go to Toner cartridge guide assembly removal on page 4 93 Diagnostic information 2 75 4024 110 Step Check Yes No 3 Check the toner cartridge guide assembly Replace the toner Go to step 4 Remove the top cover assembly cartridge i Go to Toner Is the toner cartridge guide assembly damaged cartridge guide assembly removal on page 4 93 4 Check the sensor RFID toner cartridge Replace the Go to step 5 Is the above sensor attached and connected properly sensor RFID propery toner cartridge 5 Perform a print test Replace the Problem solved Does the error still occur T card Go to Printer engine card assembly removal o
173. eck area A Go to 201 00 Sensor fuser exit on jam on page 2 24 202 00 Sensor fuser exit off jam The sensor fuser exit is not turned off within the Paper jam SSES time after the sensor fuser exit is turned Check area A Go to 202 00 Sensor fuser exit off jam on page 2 26 202 01 Sensor fuser exit off too The sensor fuser exit is turned off earlier than the Paper jam short jam SES time after the sensor fuser exit is turned Check area A Go to 202 01 Sensor fuser exit off too short jam on page 2 27 202 02 Sensor fuser exit static jam Media remains on the sensor fuser exit Paper jam Go to 202 02 Sensor fuser exit static jam on Check area A page 2 28 203 00 Sensor exit 2 on jam The sensor exit 2 is not turned on within the Paper jam RE time after the sensor fuser exit is turned Check area A Go to 203 00 Sensor exit 2 on jam on page 2 28 203 01 Sensor exit 2 off jam The sensor exit 2 is not turned off within the Paper jam specified time after the sensor exit 2 is turned on Check areas Go to 203 01 Sensor exit 2 off jam on page 2 30 203 02 Sensor exit 2 is on the The sensor exit 2 was turned on when the media is iere SA standard bin or simplex delivered to the exit 1 standard bin or simplex am finisher finisher Refer to Options Service Manual 203 03 Sensor exit2 static jam Media remains on the sensor exit2 Jam in A E Refer to Options Service
174. ed off within the specified time after the set clamp ends operating Refer to Finisher Service Manual 988 00 Service finisher error Sensor punch unit side reg 1 on failure Sensor punch unit side reg 2 on failure The sensor punch unit side reg 1 or sensor punch unit side reg 2 did not detect the media correctly or is defective Refer to Finisher Service Manual 988 01 Service finisher error Sensor punch unit side reg 1 off failure Sensor punch unit side reg 2 off failure The sensor punch unit side reg 1 or sensor punch unit side reg 2 did not detect the media correctly or is defective Refer to Finisher Service Manual 989 00 Service finisher error Stapler unit failure The off on status of the sensor stapler unit motor HP is not detected within the specified time after the stapler unit motor forward operation Or the sensor stapler unit motor HP is not turned on within the specified timer after the stapler unit motor is on reverse operation Refer to Finisher Service Manual 990 00 Service finisher error Sensor stapler carriage HP on failure The sensor stapler carriage HP is not turned on within two seconds after the stapler starts moving toward the staple position and also the sensor stapler carriage HP is turned off Or the sensor stapler carriage HP is not turned on after the stapler was moved to the staple position Or the
175. edia size for tray 2 connection Replace the switch Replace the Is the switch media size for tray 2 properly connected media size connection Go to Switch media size removal on page 4 17 5 Check the roll for tray 2 Go to step 6 Clean or replace the feed roll Pull out tray 2 and check it separation roll Is the feed roll separation roll and pick roll free of excess and pick roll wear and contamination Go to Feed roll removal on page 4 42 Separation roll removal on page 4 46 and Pick roll removal on page 4 48 6 Open the printer left door assembly and check it Remove the Go to step 7 Check the media position media Does the media touch the sensor registration Diagnostic information 2 79 4024 110 Step Check Yes No 7 Check the roll Go to step 8 Clean or replace Open the printer left door assembly and check it D roll Is the transport roll assembly free of excess wear and contamination j Go to Transfer roll assembly removal on page 4 70 8 Check the roll Go to step 9 Clean or replace Open the printer left door assembly and check it a e Si Is the roll in the registration roll assembly free of excess Go to wear and contamination Registration roll assembly removal on page 4 76 9 Check the sensor registration for operation Go to step 11 Go to step 10 1 Enter Diagnostics mode 2 Select BASE SENSOR T
176. edia transport direction Vertical blank lines white stripes in media transport direction on page 2 87 Horizontal band Horizontal band printheads out on page 2 89 Printhead out 913 00 Printhead assembly failure on page 2 47 Vertical stripes Vertical stripes on page 2 91 Horizontal stripes Horizontal stripes on page 2 93 Partial lack Partial lack on page 2 95 Spots Spots on page 2 96 Afterimage After image on page 2 97 Background fog Background fog on page 2 98 Skew Skew on page 2 100 Media damage Media damage on page 2 101 No fix No fuse on page 2 102 Note When horizontal lines and or spots occur periodically it is possibly caused by a particular roll In this case measure the interval on the print test and check the relation to the roll in the printer The interval does not necessarily match circumference of the roll Diagnostic information 2 81 4024 110 Image Quality Faint print Low contrast Before starting check the media route for foreign objects such as staples clips and scraps in the media path Step Check Yes No 1 Check the media condition Problem solved Go to step 2 Load new dry recommended media and perform a print test Is the image density normal 2 Check the toner cartridge Problem solved Go to step 3 Install a new toner cartridge Re print the defective image Is the im
177. ee EELER a 4 11 Right lower cover removal sisi sisi eee eee ELEKTRESCHEN KLEK das 4 12 Cable hookup door removal cdcciiacsiianicseeesinetaee ene ee nana Eren eee ae 4 13 Rear motor cover removal a ia ca dee roenn papri ode ee eee ddd Mies Ea A 4 14 Rear lower cover removal 88 KRIER RIESEN scence ckeerknnt ser NEESS AE CEET SA EE AOE 4 15 Option hookup cover removal 00sec ee eee 4 16 SWHCH media SIZE rem val 6 64 5 0224400 EE REE RO Rae Re ES 4 17 Media feed unit assembly 1 removal 200 c cece eee eee eee eee eee eens 4 18 Media feed unit assembly 2 removal 2 0 0 00 ce eee eee eee eee eee 4 21 Media tray side guides removal 1 0 2 0c e eee eee eee ee eee eee 4 24 Media tray end guide removal 2 cece cece eee eee eee nena nena eens 4 27 Media tray lift gear group removal 0c cece eee eee eee eee anA 4 29 Media feed lift motor removal 4 30 Tray lift coupling assembly removal 00 ccc eee eee eee teen eee 4 31 Tray lift one way clutch gear assembly removal 2000 0c eee eee eee 4 32 Media feed unit drive gear 13 tooth removal 0c eee eee eee 4 34 Media OUT actuator removal coo 588 Ss bed ies eee essa eee eee nelee Chase ee cies 4 35 Sensor media level removal 9189 scans semester etenes tees EEN EES E 4 36 Sensor Media Out removal cota tices SE TEE E rg SE 4 37 Sensor pre Teed removal ebe REEL AE cae deem ace eer 4 38 Media feed unit drive gear 28 21 t
178. eee 7 38 MarkNet N8120 Gigabit Ethernet 2 22 errr errr ee 7 38 MarkNet N8130 Fiber Ethernet 100BaseFX 10BaseFL 7 38 256MB DDR2 DRAM 2 errr errr eee ren ener eee eee 7 38 512MB DDR2 DRANM 7 38 1024MB DDR2 DRAM 7 38 Operator panel card assembly 7 3 RIP card assembly e 7 31 Operator panel cable assembly 7 3 Operator panel USB cable assembly 7 3 Printer front door cover assembly 5 55 55 e eee ee 7 3 Part number index l 7 4024 110 40X5566 40X5704 40X5931 40X5969 40X5970 40X5971 40X5972 40X6000 Operator panel assembly 222 200 rrr rr rrr rrr rr rrr rrr 7 3 256MB Flash card e ree 7 38 Sensor fuser exit assembly with actuator 7 25 Korean font card ze neces eter eeese EE Ee E 7 38 Simplified font card 5 2 5 eee eee e ee ee errr ener eee 7 38 Traditional Chinese font card 25 225 e errr errr reer reer e eee 7 38 Japanese font card en 7 38 MPF feed unit assembly e 7 11 l 8 Printer Service Manual
179. eee eee eee eee eee eee 4 60 MPF pick roll removal jiicctancccckia diamine ene seem eae Red RW On eRe RS aR SEELEN R 4 61 MPF fold down tray assembly removal 000 eee eee eee eee eee eee 4 62 Vertical drive Gear assembly ccasicrcctacacds nana ee nated nates eaeee eee e EDOR 4 64 Swen left lower door inienock dE EE Ee ee e dae ee 4 65 Media transport roll assembly gear removal 000 cece eee eee eee 4 66 Printer left lower door assembly removal 4 67 Printer left lower pinch roll assembly removal 4 68 Left lower door handle assembly removal 0 0 c eee e eee eee eee eee eee 4 69 Transfer roll assembly removal age ear EEINIEIR cee sece wees setae eaweseneen nee EK E 4 70 Printer left door support strap removal 0 000 cece eee eee eee 4 71 Printer left door assembly removal 00 0c cece eee eee eee eee eee e eee 4 72 Switch printer left door interlock removal 2002 00 c cece eee eee eee 4 73 Transfer roll guide assembly removal 000 c cece eee eee eee eee 4 74 Printer left door assembly handle removal 4 75 Registration roll assembly removal 000 c eee eee eee eee eee eee e ene 4 76 vi Printer Service Manual 4024 110 Registration clutch assembly removal 2 ccs eee eee eee eee eee 4 77 Sensor registration removal Aa o are E BLESER eee eae heme EE oes eee EREKE SEEE 4 78 Transport clutch assembly removal 4 79 Sensor tray 2 feed out removal 0
180. ees REES 3 35 PUGH EE EE newest saned Rees soe EE E 3 37 ee ee ee ER ee eee ee ee 3 39 Drive tere tee rr rr ee ere ee eee ee ee rr ert reer 3 40 Electrical components and controller 3 41 i ter Eng ERR IER ENEE er RRE eT eee er eee ere ee ere er 3 43 M dia SIZE CONTIG EE 3 43 Printhead Control 2 a198 ccna ATERT EIERE NEEN sakes been see Rees eee eae Re ee EELER 3 44 Fuser GONG cccicceg icasiuawe die ase Med anaana E 3 44 Xerographic Process During a Print Cycle 3 45 DOW SVSICM Cala a EE E E ocean nieuwe Ee 3 52 Repealing le ccs EE EE REENEN E EES 3 54 Repair informatlOM AE EREECHEN ee 4 1 Handling ESD SenSitiVe parts 12 cca eee ad ca dE een eae ane wenn e eis EE Obauled ease 4 1 REMOVal PlOCEGUles EE 4 2 Before starting service work 4 2 Printer ffont left COVerremOVal cccccccccaccscscesceec EIERE inas te badbin a EE ERR 4 3 POD Tear COVElTeMOVal ticacctne EE EE 4 4 Switch printer front door interlock removal 000 2c eee e eee eee 4 5 Operator panel assembly removal 0 0 cece eee eee eee eee teen eee eeeee 4 6 Top cover assembly removal 2 00 c cece eee ete e eee eee eee eee eee eeeee 4 7 Table of contents V 4024 110 Printer front door assembly removal 00 e eee e eee eee eee eee eee eee eens 4 8 Front door support strap and front door magnetic catch removal 4 9 Front inn r GOERENS EE EE eek eta ew Rae Re 4 10 Right upper cover removal isisss NEIER EELER RE ERSTEN ta eee eee B
181. efer to Options Service Manual 8 Check the exit 2 drive motor for proper operation Go to step 10 Go to step 9 1 Enter Diagnostics mode 2 Select MOTOR TESTS 3 SelectExit 2 drive mtr 4 SelectForward or Reverse Does the above motor rotate normally 9 Check the exit 2 drive motor for proper connection Replace the exit 2 Replace the Is the above motor connected properly Une assembly connection Refer to Options Service Manual 10 Perform a print test Replace the exit Problem solved 11 Perform a print test Does the error still occur Replace the printer engine card assembly Go to Printer engine card assembly removal on page 4 119 Problem solved Diagnostic information 2 31 4024 110 241 00 Sensor pre feed on jam tray 1 feed Step Check Yes No 1 Check the media condition Replace the _ Go to step 2 Is the media in the tray crumpled or damaged omora media 2 Check the media size setup Go to step 3 Replace the Does the media size in use match the size set for tray 1 EES setup 3 Check the rolls for tray 1 Go to step 4 Clean or replace R t 1 cheek it the feed roll emove tray 1 check it over separating roll or Is the feed roll separation roll and pick roll free of excess pick roll wear and contamination Go to Feed roll removal on page 4 42 Separation roll removal on page 4 46 and Pick roll removal on pa
182. egistration on jam The sensor registration on the printer is not turned on within the specified time after the HCF feed lift motor is turned on Refer to Options Service Manual 245 03 Paper jam Check area K Sensor tray 5 feed out static jam Paper remains on the sensor tray 5 feed out Refer to Options Service Manual 250 00 Paper jam Check areas Sensor registration on jam MPF pick The sensor registration is not turned on within the specified time after the MPF pick solenoid is turned on Go to 250 00 Sensor registration on jam MPF A MPF pick on page 2 40 280 00 Sensor bridge unit media Sensor bridge unit media entrance is not turned on Paper jam entrance on jam within the specified time after the sensor fuser exit Check areas A in the printer is turned on Refer to Finisher Service Manual 280 01 Paper jam Check area A Sensor bridge unit media entrance Static jam A Paper remains on the sensor bridge unit media entrance Refer to Finisher Service Manual 280 02 Paper jam Check area F Sensor bridge unit media entrance Static jam B Paper remains on the sensor bridge unit media entrance Refer to Finisher Service Manual 281 00 Paper jam Check area A Sensor bridge unit media exit onjam A Sensor bridge unit media exit is not turned on within the specified time after the sensor bridge unit media entrance is turned on A
183. embled 7 40X0614 1 2 Left lower door handle kit includes e Left lower door handle e Spring 8 40X0613 1 1 Hinge pin Parts catalog 7 15 4024 110 Assembly 9 Left door and transfer roll fax A 7 16 Printer Service Manual 4024 110 Assembly 9 Left door and transfer roll Assem Part Units Units kit ner bly Description number mach _ or pkg Index 9 1 40X0553 1 1 Switch printer left door interlock 2 40X0618 1 1 PC cartridge shutter link 3 40X0617 1 1 Transfer roll power contact 4 40X0616 1 1 Transfer roll assembly 5 40X0619 1 1 Transfer roll guide assembly Parts catalog 7 17 4024 110 Assembly 10 Printer left door 7 18 Printer Service Manual 4024 110 Assembly 10 Printer left door Assem Part Units Units kit as bly Description number mach or pkg Index 10 1 40X0620 1 1 Printer left door assembly this comes assembled 2 40X0624 1 1 Printer left door support strap 3 40X0623 1 1 Left door duplex entrance guide 4 40X0621 1 2 Printer left door assembly handle kit includes e Printer left door assembly handle e Spring 5 40X0622 1 1 PC cartridge shutter actuator Parts catalog 7 19 4024 110 Assembly 11 Registration 7 20 Printer Service Manual Assembly 11 Registration 4024 110 Assem Part Units Units kit kes bly Description number mach or pkg Index 11 1 40X0629 1 5 Transport
184. engine card assembly removal on page 4 119 Diagnostic information 2 63 4024 110 980 03 Exit interface card assembly communication failure Step Check Yes No 1 Check the exit interface card assembly for proper Go to step 2 Replace the connection connection 2 Check the connection between the exit interface card Go to step 3 Replace the assembly P430 and the LVPS assembly P526 connection Are the cards connected properly 3 Perform a print test Replace the exit Problem solved f interface card Does the error continue assembly Go to Exit interface card assembly removal on page 4 117 4 Perform a print test Replace the Problem solved Does the error continue printer engine cord j assembly Go to Printer engine card assembly removal on page 4 119 Media size mismatch in width Step Check Yes No 1 Check the media Go to step 2 Load media f properly Pull out the tray and visually check it Is media properly loaded in the tray 2 Check the media Go to step 3 Set the guides F properly Pull out the tray and visually check it Are the front media tray guide assembly rear media tray guide and media tray end guide of tray 1 or tray 2 set correctly 3 Check the switch media size for installation Go to step 4 Install the switch Pull out the media tray and visually check it ee Are the switches media size for media tray 1 and media correct
185. ensor tray 2 feed out removal on page 4 81 Replace the sensor tray 2 feed out 10 Perform a print test Does the error continue Replace the printer engine card assembly Go to Printer Problem solved engine card assembly removal on page 4 119 242 03 Sensor tray 2 feed out static jam Step Check Yes No 1 Check the media position Remove the Go to step 2 Does the media touch the sensor tray 2 feed out nedia Open the printer left lower door assembly and visually check it 2 Check the sensor tray 2 feed out for proper operation Go to step 4 Go to step 3 1 Enter Diagnostics mode 2 Select NPUT TRAY TESTS 3 Select Sensor test 4 SelectTray 2 5 Select Feed out Open the printer left lower door assembly and check it Does the display on the operator panel change every time a white piece of paper is placed over the sensing area 3 Check the sensor tray 2 feed out connection Replace the Replace the Is the sensor tray 2 feed out properly connected oan 2 connection 4 Perform a print test Replace the Problem solved printer engine card Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 Diagnostic information 2 39 4024 110 250 00 Sensor registration on jam MPF pick Step Check Yes No 1 Check the media condition Replace the media
186. ept the value Short Edge Printing The default printing orientation is long edge This setting allows a user to enable or prohibit short edge fed paper If the setting Disabled default is selected letter and A4 paper can be fed only long edge If they are fed short edge a prompt will ask the user to use the correct paper size When the setting is Enabled the user can feed paper either long edge or short edge Tray Low Message Selecting Disabled turns off the tray low prompts The default is Enabled Exit Config Menu Press to exit the CONFIG MENU The message Resetting the Printer displays and the printer performs a POR and restarts in normal mode Diagnostic aids 3 25 4024 110 Analyzing the Print Test Print Tests provide several uses in troubleshooting the printer problems e Isolating problems to either the print engine printer engine card assembly or to the RIP card assembly and host software e Locating feed and media transport problems e Detecting print quality and image registration problems Using print test to locate a feed or media transport problem Use Print Tests to locate a problem with media feed or with media transportation along the media path 1 2 Enter Printer Diagnostics and generate a Print Test Follow the media along the media path until the problem occurs Using print test to analyze a print quality problem Due to the method used to generate Print Tests grid lines may display a noticeabl
187. erf llt Laserprodukte der Klasse gelten als unsch dlich Im Inneren des Druckers befindet sich ein Laser der Klasse IIIb 3b bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt der Wellen der Lange 770 795 Nanometer ausstrahlt Das Lasersystem und der Drucker sind so konzipiert da im Normalbetrieb bei der Wartung durch den Benutzer oder bei ordnungsgem er Wartung durch den Kundendienst Laserbestrahlung die Klasse bersteigen w rde Menschen keinesfalls erreicht Avis relatif a l utilisation de laser Pour les Etats Unis cette imprimante est certifi e conforme aux provisions DHHS 21 CFR alin a J concernant les produits laser de Classe 1 Pour les autres pays cette imprimante r pond aux normes IEC 60825 1 relatives aux produits laser de Classe Les produits laser de Classe sont consid r s comme des produits non dangereux Cette imprimante est quip e d un laser de Classe Illb 3b ars niure de gallium d une puissance nominale de 5 milliwatts mettant sur des longueurs d onde comprises entre 770 et 795 nanom tres L imprimante et son syst me laser sont con us pour impossible dans des conditions normales d utilisation d entretien par l utilisateur ou de r vision l exposition a des rayonnements laser sup rieurs a des rayonnements de Classe Avvertenze sui prodotti laser Questa stampante certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitol
188. erly grounded Check the power cord ground terminal The printer is not installed at a place subjected to extreme temperature extreme humidity or rapid changes in temperature The printer is not installed close to water service humidifier heat generating unit fire in a very dusty place or a place exposed to air flow from the air conditioning system The printer is not installed in a place where volatile gas or inflammable gas is generated The printer is not installed in direct sun The printer is installed on a level and stable surface Media meets specifications and is installed properly Customer maintenance parts have been replaced at the specified intervals Check all attached options for proper attachment and electrical connection Refer to the User s Guide for proper installation POR sequence The following is an example of the events that occur during the POR sequence for the base machine with no media handling options installed ONDARON oo Power the machine on The RIP card assembly cooling fan turns on Operator panel LED becomes solid While loading code a series of dots scroll across the screen The transport motor turns on The fuser unit assembly lamps turn on The fuser cooling fan turns on The following is an example of the screen that displays after the code is loaded 256 MB 800 Mhz 256 MB Amount of memory 800 Mhz Processor speed An animated stopwatch appears on the screen Rea
189. ervice Manual 983 00 Service finisher error Sensor rear tamper HP on failure The sensor rear tamper HP is not turned on after the rear tamper starts moving to the rear tamper home position Refer to Finisher Service Manual 983 01 Service finisher error Sensor compiler rear tamper HP off failure The sensor compiler rear tamper HP is not turned off within the specified time after the rear tamper starts leaving from the rear tamper home position Or the sensor compiler rear tamper HP is turned on again after the sensor compiler rear tamper HP is turned off and the rear tamper stopped its moving Refer to Finisher Service Manual 984 00 Service finisher error Sensor punch unit HP on failure The sensor punch unit HP is not turned on even when the specified time passed after the punch unit motor is turned on Refer to Finisher Service Manual 984 01 Service finisher error Sensor punch unit HP off failure The sensor punch unit HP is not turned off even when the specified time passed after the punch unit motor is turned on Refer to Finisher Service Manual 985 00 Service finisher error Sensor punch carriage shift HP on failure The sensor punch carriage shift HP is not turned on even when the specified time passed after the punch carriage shift motor assembly is turned on Or the sensor punch carriage shift HP is turned off again a
190. ervice Manual 4024 110 MPF rear cover removal 1 Remove the screw securing the MPF rear cover A 2 Remove the MPF rear cover A Repair information 4 55 4024 110 MPF feed drive gear group removal 1 Remove the MPF rear cover See MPF rear cover removal on page 4 55 2 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 51 3 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 Remove the three screws securing the idler gear bracket assembly B to the MPF feed unit assembly Remove the idler gear bracket assembly B Release the hooks securing the MPF feed drive gear pickup C to the shaft Remove the MPF feed drive gear pickup and pickup spring A and C NOUA Warning Depress the pick solenoid lever F and the pick lever G while performing step 8 or damage may occur 8 Remove the small spring D from the drive cam gear E 9 Remove the drive gear cam E and the drive stopper H Warning Before reinstalling depress the pick solenoid lever and the pick lever while replacing the drive gear cam E and the drive stopper H or damage may occur 4 56 Printer Service Manual 4024 110 MPF pressure pad removal Remove the MPF rear cover See MPF rear cover removal on page 4 55 Remove the MPF feed unit assembly See MPF
191. est fails the message Failure displays for approximately three seconds and the failure count increases by one The test continues until all standard and optional DRAM is tested Once the maximum pass count or fail count is reached the test is stopped the power indicator is turned on solid and the final results display To stop the test before completion turn the printer off CACHE Test This test is used to verify the printer processor cache To run the CACHE Test 1 2 3 Select HARDWARE TESTS from DIAGNOSTICS Select CACHE TEST from HARDWARE TESTS The message CACHE Test Testing displays Then the message Resetting Printer appears The printer automatically performs a Power On Reset POR While the CACHE test executes the power indicator blinks green The following type of message appears CACHE Test x100 P HHHH F At e P represents the number of times the cache has passed and finished successfully Initially 000000 displays with the maximum pass count being 999 999 es 6F represents the number of times the cache has failed and finished with errors Initially 0000 displays with the maximum fail count being 99 999 Initially only four digits appear but additional digits appear as needed Each time a test is completed the number of passes and failures is incremented If the test fails the message Failure displays for approximately three seconds and the failure count increases by one The tes
192. ests can use any media size or envelope supported by the printer To run the Feed Tests for the output bins 1 Select OUTPUT BIN TESTS from DIAGNOSTICS 2 Select Feed Tests from the OUTPUT BIN TESTS 3 Select the output bin you want the paper to exit into The standard bin as well as any output option bin installed on the printer is shown on the menu The output bins are displayed in the order installed on the printer e Standard Bin e Output Bin 1 e Output Bin 2 4 Select either Single or Continuous e Single feeds one sheet of media from the selected source Continuous media continues feeding from the selected source until Stop is pressed Press Back to return to OUTPUT BIN TESTS Feed To All Bins This test can be used to verify that the printer can feed media to the standard bin or any installed output options No information will be printed on the test pages as the printhead is not engaged during the feed test The media feeds from the default paper source To run the Feed To All Bins Test 1 Select OUTPUT BIN TESTS from DIAGNOSTICS 2 Select Feed To All Bins from OUTPUT BIN TESTS The printer feeds a separate piece of media to the standard bin first then it feeds a separate piece of media to each output bin installed The test is continuous until Stop is pressed Press Back to return to OUTPUT BIN TESTS Sensor Test output bin These tests are used to determine if the output tray se
193. f damage assembly Go to Transfer roll guide assembly removal on page 4 74 4 Check the sensor fuser exit for proper operation Go to step 6 Go to step 5 1 Enter Diagnostics mode 2 Select BASE SENSOR TESTS 3 Select Media path 4 Select Fuser exit Open the printer left door assembly and check it The area around the actuator is very hot Allow the A fuser area to cool before proceeding Does the display on the operator panel change every time the sensor actuator is operated 5 Check the sensor fuser exit connection Replace the Replace the Is the sensor fuser exit properly connected sensor EES connection Go to Sensor fuser exit removal on page 4 102 6 Perform a print test Replace the Problem solved Does the error continue i ER Go to Printer engine card assembly removal on page 4 119 2 26 Printer Service Manual 202 01 Sensor fuser exit off too short jam 4024 110 Step Check Yes No 1 Check the media position Remove the Go to step 2 Open the printer left door assembly and visually check it media Does the media touch the sensor fuser exit 2 Check the fuser unit assembly for a media jam Remove the Go to step 3 Open the printer left door assembly and check it meda Is there a media jam in the fuser unit assembly 3 Check the fuser unit assembly for installation Go to step 4 Install the fuser e unit assembly Open the printer lef
194. failed Service fan failure Go to 916 00 PC cartridge cooling fan failure error on page 2 49 918 00 Sensor exit 1 media shift The sensor exit 1 media shift HP is not turned on Seri td HP failure within the specified period after the exit 1 media SIVICE SIO shift motor is turned on bin 1 error Go to 918 00 Sensor exit 1 media shift HP failure on page 2 50 919 00 Sensor exit 2 media shift HP The sensor exit 2 media shift HP is not turned on Service std failure within the specified time after the exit 2 shift motor is turned on bin 2 error Refer to Options Service Manual 919 01 Exit 2 unit assembly failure Exit 2 unit assembly connection is missing or F damaged Service std bin 2 Refer to Options Service Manual 2 14 Printer Service Manual 4024 110 Error code or message Error contents Description Action 920 00 Service fuser error Fuser unit assembly on time failure During the warm up period the control thermistor does not detect the ready temperature even when the specified time is passed after the main lamp is turned on During the standby period the control thermistor does not detect the specified temperature even when the specified time is passed after the main lamp is on During the standby period the control thermistor does not detect the specified temperature even when the specified time is passed after the sub lamp in on During idling after power on the con
195. feed pre feed removal on removal on page 4 38 page 4 38 7 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 SelectTray 2 feed mtr Pull out tray 2 and check it Does the media feed lift motor rotate normally 8 Check the media feed lift motor connection Go to step 9 Replace the Is the media feed lift motor properly connected ponneton Go to Sensor pre feed removal on page 4 38 Diagnostic information 2 35 4024 110 Step Check Yes No 9 Check the media feed lift motor in tray 2 for proper Install the media Go to step 10 operation feed lift motor for Replace the media feed lift motor for tray 2 with the one tray 1 a it f p ee y previously was LOM May t and replace the 1 Enter Diagnostics mode motor for tray 2 2 Select MOTOR TESTS with a new motor 3 SelectTray 2 feed motor Go to Media feed lift motor removal on Does the media feed lift motor rotate normally page 4 30 10 Perform a print test Replace the Problem solved 8 printer engine card Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 242 01 Sensor tray 2 feed out on jam tray 2 feed Step Check Yes No 1 Check the media condition Replace the media Go to step 2 Is the media in the tray crumpled or damaged GE Merde 2 Check the medi
196. feed unit Remove the sensor media level A ARON 4 36 Printer Service Manual 4024 110 Sensor media out removal 1 Remove the appropriate media feed unit assembly See Media feed unit assembly 1 removal on page 4 18 or Media feed unit assembly 2 removal on page 4 21 Remove the media out actuator See Media out actuator removal on page 4 35 Disconnect the connector from the sensor media out A Release the hooks securing the sensor media out A to the media feed unit Remove the sensor media out A Gesell Lower view Repair information 4 37 4024 110 Sensor pre feed removal 1 Remove the appropriate media feed unit assembly See Media feed unit assembly 1 removal on page 4 18 or Media feed unit assembly 2 removal on page 4 21 Release the hook securing the sensor pre feed A Remove the sensor pre feed A from the feed unit front guide B Disconnect the connector from the sensor pre feed A Remove the sensor pre feed A IRON 4 38 Printer Service Manual 4024 110 Media feed unit drive gear 28 21 tooth removal 1 PON Remove the appropriate media feed unit assembly See Media feed unit assembly 1 removal on page 4 18 or Media feed unit assembly 2 removal on page 4 21 Remove the harness from the bracket A Remove the three screws securing the bracket A to the media feed unit
197. feed unit assembly removal on page 4 51 Remove the MPF pick roll See MPF pick roll removal on page 4 61 Remove the MPF feed shaft assembly See MPF feed shaft assembly removal on page 4 60 Remove the two springs A under the pressure pad B Turn the MPF upside down and pry the shaft out with a flat blade screwdriver Remove the separation pad B and the shaft C by moving it in the direction of the arrow from the backside NOOR ONS Front Note Before reinstalling ensure the two springs A remain in the proper position during reassembly of the feed shaft assembly and MPF feed roll Repair information 4 57 4024 110 MPF transport roll assembly removal 1 Remove the MPF rear cover See MPF rear cover removal on page 4 55 2 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 51 3 Remove the two end screws securing the upper bracket to the MPF feed unit assembly 4 Remove the upper bracket 5 Remove the MPF transport gear 18 tooth A Note The MPF transport gear 18 tooth will be tight and requires extra force to remove 6 Remove the transport shaft collar B 7 Remove the e clip with a prying tool securing the MPF transport roll assembly C to the MPF feed unit assembly 8 Remove the two bushings 8mm D 9 Remove the MPF transport roll assembly by moving it rightward then upward in the direction of the arrow Note When removing the
198. figuration ID 1 is displayed on the screen If the process is successful Submitting Selection appears on the display followed by the current value for Configuration ID 2 4 Repeat the steps for entering the Configuration ID and press If the Configuration ID 2 is validated Submitting Selection appears and a check w appears next to Printer Setup 5 Restart the printer Edge to Edge When this setting is On the text and graphics are shifted to the physical edges of the paper for all margins When the setting is Off the normal margins are restored 3 16 Printer Service Manual 4024 110 EVENT LOG Display Log The event log provides a history of printer errors It contains the 12 most recent errors that have occurred on the printer The most recent error displays in position 1 and the oldest error displays in position 12 if 12 errors have occurred If an error occurs after the log is full the oldest error is discarded Identical errors in consecutive positions in the log are entered so there may be repetitions All 2xx and 9xx error messages are stored in the event log To view the event log 1 Select EVENT LOG from DIAGNOSTICS 2 Select Display Log from EVENT LOG Up to three error codes display at atime Press a or w to view additional error codes 3 Press Back to return to the EVENT LOG menu Print Log Additional diagnostic information is available when you print the event log from DIAGNOSTICS rather t
199. form several print tests If the problem remains go to step 2 Turn the printer off for 60 seconds Does the error occur when the power is turned off on again Replace the RIP card assembly Go to RIP card assembly removal on page 4 126 Go to step 3 Problem solved Perform a print test Does the error still occur Replace the printer engine card assembly Go to Printer engine card assembly removal on page 4 119 Problem solved 2 60 Printer Service Manual 953 XX Operator panel assembly NVRAM failure 4024 110 Step Check Yes No Perform a POR Does the error occur when the power is turned off on Go to step 2 Perform several print tests If the problem remains go to step 2 Turn the printer off for 60 seconds Does the error occur when the power is turned off on again Replace the operator panel assembly Go to Operator panel assembly removal on page 4 6 Go to step 3 Problem solved Perform a print test Does the error still occur Replace the RIP card assembly Go to RIP card assembly removal on page 4 126 Go to step 4 Problem solved Perform a print test Does the error still occur Replace the printer engine card assembly Go to Printer engine card assembly removal on page 4 119 Problem solved Diagnostic information 2 61 4024 110 9
200. front left cover See Printer front left cover removal on page 4 3 Remove the PC cartridge Remove the three screws securing the front inner cover A Remove the front inner cover QURON T Ce Gan i EE run D 1 1 1 Hook Front S Note To reinstall the front inner cover A start with the four plastic hooks on the bottom of the front inner cover 4 10 Printer Service Manual 4024 110 Right upper cover removal Note First remove the bridge unit finisher and finisher docking bracket if equipped Remove the two screws securing the right upper cover A Move the upper edge of the right upper cover A downward and outward as shown by the arrow Move the lower edge of the right upper cover A downward to release the right upper cover A Remove the right upper cover A Note The right upper cover A may take some extra force to remove G ren Repair information 4 11 4024 110 Right lower cover removal 1 Remove the right upper cover See Right upper cover removal on page 4 11 2 Pull out media Tray 1 and media Tray 2 3 Remove the right lower cover A by lifting it upward then outward Note The right lower cover may take some force to remove 4 12 Printer Service Manual 4024 110 Cable hookup door removal Open the cable hookup door A Slightly lift the top rear cover B upward in the direction of
201. ft assembly A Remove the feed shaft assembly A by moving it to the side then upwards in the direction of the arrow NO Sen gt 4 60 Printer Service Manual 4024 110 MPF pick roll removal 1 Remove the MPF rear cover See MPF rear cover removal on page 4 55 2 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 51 3 Remove the two end screws securing the upper bracket A to the MPF feed unit assembly 4 Remove the upper bracket A 5 Release the two hooks securing the two feed shaft cores B and slide them both outward 6 Remove the MPF pick roll C from the feed shaft assembly D by sliding it to the right in the direction of the arrow and lifting upward Note When removing the MPF pick roll C do not touch the rubber surface eau A JOT SE RE 6 Note Before reinstalling the MPF pick roll assembly C do not touch the rubber surface Repair information 4 61 4024 110 MPF fold down tray assembly removal Remove the MPF rear cover See MPF rear cover removal on page 4 55 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 51 Remove the MPF upper frame See MPF media out actuator and upper frame removal 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 a eS Remove three screws securing the
202. ft coupling gear 13 tooth B from bracket A Remove the tray lift gear 13 60 tooth C from bracket A ROND 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 Repair information 4 29 4024 110 Media feed lift motor removal 1 Remove the media feed unit See Media feed unit assembly 1 removal on page 4 18 or Media feed unit assembly 2 removal on page 4 21 Disconnect the harness from the media feed lift motor A Remove the two screws securing the media feed lift motor A to the media feed unit assembly B Remove the media feed lift motor A RON Connector 4 30 Printer Service Manual 4024 110 Tray lift coupling assembly removal Remove the MPF rear cover See MPF rear cover removal on page 4 55 Remove the MPF feed unit assembly See MPF feed unit assembly removal on page 4 51 Remove the printer left door See Printer left door support strap removal on page 4 71 Remove the vertical drive gear assembly See Vertical drive gear assembly on page 4 64 Remove the media feed unit assembly See Media feed unit assembly 1 removal on page 4 18 or Media feed unit assembly 2 removal on page 4 21 Remove the harness from bracket A Remove the three screws securing bracket A to the media feed unit Remove the bracket A Note Th
203. fter the sensor punch carriage shift HP is turned on and the punch carriage shift motor assembly stopped its rotation Refer to Finisher Service Manual 4024 110 Error code or Error contents Description Action message 985 01 Sensor punch carriage shift The sensor punch carriage shift HP is not turned Swine HP off failure off even when the specified time passed after the finisher error punch carriage shift motor assembly is turned on Or the sensor punch carriage shift HP is turned on again after the sensor punch carriage shift HP is turned off and the punch carriage shift motor assembly stopped its rotation Refer to Finisher Service Manual 986 00 Service finisher error Sensor eject clamp HP on failure The sensor eject clamp HP is not turned on within 500 ms after the eject clamp up starts Refer to Finisher Service Manual 986 01 Service finisher error Sensor eject clamp HP off failure The sensor eject clamp HP is not turned off within 200 ms after the eject clamp down starts Refer to Finisher Service Manual 987 00 Service finisher error Sensor media eject shaft HP on failure The sensor media eject shaft HP is not turned on within 200 ms after the set clamp starts operating Refer to Finisher Service Manual 987 01 Service finisher error Sensor media eject shaft HP off failure The sensor media eject shaft HP is not turn
204. g sound when activated 6 Check the registration clutch connection Replace the Replace the Is the registration clutch properly connected registration clutch connection Go to Registration clutch assembly removal on page 4 77 7 Perform a print test Replace the Problem solved printer engine card Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 Diagnostic information 2 23 4024 110 200 01 Sensor registration static on jam Step Check Yes No 1 Check the media position Remove the Go to step 2 Open the printer left door assembly and visually check it media Does the media touch the sensor registration 2 Check the sensor registration for proper operation Go to step 4 Go to step 3 1 Enter Diagnostics mode 2 Select BASE SENSOR TESTS 3 Select Media path 4 Select Regi stration Open the printer left door assembly and check it Does the display on the operator panel change every time the sensor actuator is operated 3 Check the sensor registration connection Replace the Replace the Is the sensor registration properly connected Geh connection Go to Sensor registration removal on page 4 78 4 Perform a print test Replace the Problem solved Does the error continue AE carg Go to Printer engine card assembly removal on page 4 119 201 00 Sensor fuser exit on jam Step Check Yes No
205. ge 4 48 4 Check the media position Remove the Go to step 5 Open the printer left door assembly and visually check it media Does the media touch the sensor pre feed in tray 1 media feed unit assembly 5 Check the sensor pre feed for proper operation in tray 1 Ensure the media Go to step 6 1 Enter Di ti d feed unit front Enter Diagnostics mode guide is installed 2 Select INPUT TRAY TESTS properly 3 Select Sensor test 4 SelectTray 1 Goito step 7 5 Select Pre feed Remove the media tray assembly and check it Does the display on the operator panel change every time a white piece of paper is placed over the sensing area 6 Check the sensor pre feed connection Replace the Replace the Is the sensor pre feed connected properly sensor pre feed connection 7 Check the media feed lift motor in tray 1 for proper Go to step 10 Skip to step 9 operation 1 Enter Diagnostics mode 2 Select MOTOR TESTS 3 SelectTray 1 Feed mtr Pull out tray 1 and check over Does the media feed lift motor rotate normally 8 Check the media feed lift motor connection Go to step 9 Replace the Is the media feed lift motor connected properly connection 2 32 Printer Service Manual 4024 110 Step Check Yes No 9 Check the media feed lift motor for proper operation of Re install the Go to step 10 tray 1 media feed lift vee the media feed lift motor for tray 1 with one from Ee tra
206. han CONFIG MENU The Event Log printed from DIAGNOSTICS includes e Detailed printer information including code versions e Time and date stamps e Page counts for most errors e Additional debug information in some cases Model and Event Zog Serial number Printer information Panel display when error occurred _ Page count __ Earliest error code Next error code The printed event log can be faxed to Lexmark or your next level of support for verification or diagnosis Diagnostic aids 3 17 4024 110 To print the event log 1 Select EVENT LOG from DIAGNOSTICS 2 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 1 Select EVENT LOG from DIAGNOSTICS 1 Select Clear Log from EVENT LOG 2 Select YES to clear the Event Log or NO to exit the Clear Log menu If YES is selected Deleting EVENT LOG displays on the screen Press Back to return to EVENT LOG EXIT DIAGNOSTICS This selection exits Diagnostics mode and Resetting the Printer displays The printer performs a POR and the printer returns to normal mode 3 18 Printer Service Manual 4024 110 Configuration menu CONFIG MENU Entering Configuration Menu Turn off the printer Press and hold and gt Turn on the printer poh
207. he components listed above without a POR after installing each one or the printer will be rendered inoperable Warning Never install and remove components listed above as a method of troubleshooting components Once a component has been installed in a machine it cannot be used in another machine It must be returned to the manufacturer 1 Release the two front hooks of the operator panel assembly A by inserting a flat tip screwdriver into the two slots on the top cover assembly B While releasing the hooks lift the operator panel assembly A upward in the direction of the arrow Remove the USB connector C from the operator panel assembly A Detach the operator panel connector D from the panel ARON 4 6 Printer Service Manual 4024 110 Top cover assembly removal Note First remove the bridge unit and the finisher if equipped Pon gt Remove the operator panel assembly See Operator panel assembly removal on page 4 6 Remove the printer front door assembly See Printer front door assembly removal on page 4 8 Remove the front left cover See Printer front door assembly removal on page 4 8 Remove the two screws securing the top cover assembly A Remove the top cover assembly A by sliding it to the right and then forward in the direction of the arrow Repair information 4 7 4024 110 Printer front door assembly removal Open the printer front door assembly A Remove the f
208. he drum grounding plate located behind the or replace the rear motor cover This plate can be found behind the PC cartridge flywheel Is the drum grounding plate free of excess wear and contamination 5 Check the laser beam route Go to step 6 Remove debris or clean the Check for debris between the printhead assembly and printhead the PC drum assembly Check the printhead assembly window for window contamination Is the laser beam route free of debris and the glass window in the printhead assembly free of contamination 2 84 Printer Service Manual 4024 110 Step Check Yes No Check the printhead installation Is the printhead assembly installed securely with four screws Go to step 8 Go to step 7 Check the printhead assembly installation Install the printhead assembly securely and perform a print test Does the error continue Problem solved Go to step 8 Check the printhead for proper connection Warning If too much force is applied to the board when checking it the printhead could become misaligned Go to step 9 Replace the connection Check the image development process Perform a print test Turn off the printer power while printing Carefully remove the PC cartridge Check the toner image formed on the drum before the transfer roll assembly Is the image completely formed on the drum and the area clear black and easy to read Go to step 10
209. he duplex controller card assembly Refer to Options Service Manual Diagnostic information 2 17 4024 110 2 18 Printer Service Manual Error code or Error contents Description Action message 981 00 Stacker bin failure The sensor stacker bin level is not turned on within er the specified period after the stacker bin starts finisher error rising Refer to Finisher Service Manual 981 01 Service finisher error Stacker bin upper limit failure The stacker bin abnormally rises beyond the specified upper limit position stacker bin level Refer to Finisher Service Manual 981 02 Service finisher error Stacker bin lower limit failure The stacker bin abnormally lowers beyond the specified lower limit position full stack Refer to Finisher Service Manual 982 00 Service finisher error Sensor front tamper HP on failure The sensor front tamper HP is not turned on after the front tamper starts moving to the front tamper home position Refer to Finisher Service Manual 982 01 Service finisher error Sensor front tamper HP off failure The sensor front tamper HP is not turned off within the specified time after the front tamper starts leaving from the front tamper home position Or the sensor front tamper HP is turned on again after the sensor compiler front tamper HP is turned off and the front tamper stopped its moving Refer to Finisher S
210. he rubber roll surface Does the display on the operator panel change every time the sensing area is blocked 8 Check the tray 1 sensor media level connection Replace the Replace the Is the tray 1 sensor media level properly connected ek media connection Go to Sensor media level removal on page 4 36 9 Perform a print test Replace the Problem solved f printer engine card Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 942 00 Media tray 2 lift up no media tray failure Step Check Yes No 1 Check the media Go to step 2 Load media Is any media loaded in media tray 2 Pull out media tray 2 and visually check it 2 Check the media tray Go to step 3 Go to step 4 Replace media tray 2 with media tray 1 Is the replaced tray lifted up 3 Check the media tray Replace the tray Go to step 4 Are the tray lift sector gear 12T of media tray 2 or litt sector gear surrounding parts damaged 12T OF other gP ged damaged components 2 58 Printer Service Manual 4024 110 Step Check Yes No 4 Check the tray 2 media feed lift motor for operation Go to step 9 Go to step 5 Pull out the media tray and then push it back in Does the motor lift up the tray normally 5 Check the tray 2 media feed lift motor connection Go to step 6 Replace the Is the tray 2 media feed lift motor properly connected connector 6 Check the tray 2 media
211. ia Go to step 9 Go to step 8 Check the HVPS card assembly Replace the HVPS card assembly Perform a print test Does the error continue Go to step 9 Problem solved Check the printer engine card assembly Replace the printer engine card assembly Perform a print test Does the error continue Replace the RIP card assembly Go to RIP card assembly removal on page 4 126 Problem solved Diagnostic information 2 83 4024 110 Blank print no print Check the media path for foreign objects such as staples clips and scraps of media Step Check Yes No 1 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 2 Check the transfer roll assembly Go to step 3 Replace the R thet f ll bl transfer roll emove the transfer roll assembly assembly Check the transfer roll assembly rotation Is the transfer roll assembly free of excess wear and contamination 3 Check the PC cartridge installation condition Go to step 4 Correct and clean Remove the PC cartridge contaminated Check the PC cartridge connections pins or replace the PC cartridge Are the PC cartridge connections free of excess wear or connector and contamination 4 Check the PC cartridge ground Go to step 5 Correct and clean the drum Remove the PC cartridge grounding plate Check t
212. ia position Remove the Go to step 5 Open the printer left door assembly and visually check it media Does the media touch the sensor registration 5 Check the media position Remove the Go to step 6 Open the printer left lower door assembly and check it media Does the media touch the sensor tray 2 feed out 6 Check the sensor registration for proper operation Go to step 8 Go to step 7 1 Enter Diagnostics mode 2 Select BASE SENSOR TESTS 3 Select Media Path 4 Select 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 7 Check the sensor registration connection Replace the Replace the Is the sensor registration properly connected hragic tration connection Go to Sensor registration removal on page 4 78 8 Check the sensor tray 2 feed out for proper operation Go to step 10 Go to step 9 1 Enter Diagnostics mode 2 Select INPUT TRAY TESTS 3 Select Sensor Test 4 Select Tray 2 5 Select f eed out Open the printer left lower door assembly and check it Does the display on the operator panel change every time a white piece of paper is placed over the sensing area 2 38 Printer Service Manual 4024 110 Step Check Yes No Check the sensor tray 2 feed out connection Is the sensor tray 2 feed out properly connected Replace the sensor tray 2 Tee out Go to S
213. ication specification 6 2 maintenance scheduled 6 2 memory DRAM Test 3 7 model name 3 16 models 1 1 multi purpose feeder MPF 3 33 O operator panel 2 3 operator panel tests Button Test 3 6 Panel Test 3 6 options and features description 1 1 output bin sensor tests standard bin 3 10 P page count Page Count 3 15 permanent page count 3 15 panel test 3 6 POR sequence 2 2 preventive maintenance 6 1 print quality pages 3 6 3 22 print registration 3 21 printer overview 1 1 basic model 1 1 configured model 1 2 Q quality pages 3 6 3 22 Quick Disk Test 3 14 Quick Test 3 22 R registration 3 21 removals cable hookup door 4 13 dual drive motor assembly 4 114 ESD sensitive parts 4 1 exit 1 drive belt 4 113 exit 1 media shift assembly 4 104 exit 1 media shift gear 4 110 exit interface card assembly 4 117 feed roll 4 42 feed roll one way clutch 4 43 feed roll one way gear 22 tooth 4 44 feed unit drive gear 27 tooth 4 50 front door support strap and front door magnetic catch 4 9 front inner cover 4 10 fuser cooling fan 4 96 fuser unit assembly 4 103 high voltage power supply HVPS card 4 115 left door assembly 4 72 left door assembly handle 4 75 left lower door handle assembly 4 69 left lower pinch roll assembly 4 68 media feed lift motor 4 30 media feed unit assembly 1 4 18 media feed unit assembly 2 4 21 media feed unit drive gear 13 tooth 4 34 media feed unit drive gear 28 21 tooth 4 39 media feed unit
214. ice Manual 4024 110 Step Check Yes No 4 Check the drive power transmission Go to step 5 Replace damaged Does the exit 1 media exit roll assembly and the other Gel gears rotate smoothly Go to Exit 1 media shift assembly removal on page 4 104 5 Check the sensor fuser exit for proper operation Go to step 7 Go to step 6 1 Enter Diagnostics mode 2 Select BASE SENSOR TESTS 3 Select Media Path 4 SelectFuser exit Open the printer left door assembly and visually check it Does the display on the operator panel change every time the actuator on the above sensor operates 6 Check the sensor fuser exit Replace the sensor Replace the Is the above sensor connected properly fuser exit connection Go to Sensor fuser exit removal on page 4 102 7 Check the exit 2 drive motor for proper operation Go to step 9 Go to step 8 1 Enter Diagnostics mode 2 Select MOTOR TESTS 3 SelectExit 2 drive mtr 4 SelectForward or Reverse Does the above motor rotate normally 8 Check the exit 2 drive motor for proper operation Replace the exit 2 Replace the Is the above motor connected properly nit assembly connecHon Refer to Options Service Manual 9 Check the sensor exit 2 for proper operation Go to step 11 Go to step 10 Open the printer left door assembly and the exit 2 left door assembly 1 Enter Diagnostics mode 2 Select BASE SENSOR TESTS 3 Select Media Path 4 Sele
215. il you press Stop Sensor Test duplex This test is used to determine whether or not the duplex sensors and switches are working correctly The test allows you to actuate the duplex input sensor located in the back part of the duplex unit and the duplex exit sensor located in the return paper path 1 Select DUPLEX TESTS from DIAGNOSTICS 2 Select Sensor Test from DUPLEX TESTS The message Sensor Test Testing displays 3 Select Duplex wait from the Sensor Test menu 4 Manually actuate each of the duplex wait sensors When the sensor is closed Closed displays when the sensor is open Open displays Press Back or Stop to exit the test 3 8 Printer Service Manual 4024 110 INPUT TRAY TESTS Feed Tests input tray This test lets the servicer observe the paper path as media is feeding through the printer A blank sheet of paper feeds through the printer as the laser turns off during this test The only way to observe the paper path is to open the lower front door that is used to access the envelope or multipurpose feeder The paper is placed in the output bin To run the Input Tray Feed Tests 1 2 3 Select INPUT TRAY TESTS from DIAGNOSTICS Select Feed Tests from INPUT TRAY TESTS Select the input source from the sources displayed on the Feed Tests menu All installed sources are listed e Tray 1 e Tray 2 e Tray 3 e Tray 4 e Tray 5 e MP Feeder Select either Single or Continuous e Singl
216. ing 1 Select SIZE SENSING from CONFIG MENU 2 Select which tray to set e Tray 1 Sensing e Tray 2 Sensing e Tray 3 Sensing e Tray 4 Sensing e Tray 5 Sensing 3 Select Auto or Off and press Press Back to exit Statement A5 Trays 1 through 4 cannot simultaneously sense A5 and Statement sized paper Select either Sense Statement default or Sense A5 to determine which of the two paper sizes these trays sense automatically The MP Feeder can support these paper sizes regardless of the value of this setting Executive B5 Trays 1 through 4 cannot simultaneously sense Executive and JIS B5 sized paper Select either Sense Executive default or Sense JIS B5 to determine which of the two paper sizes these trays sense automatically The MP Feeder can support these paper sizes regardless of the value of this setting Panel Menus Selections are to Disable or Enable default operator panel menus Diagnostic aids 3 23 4024 110 PPDS Emulation This menu item allows the user to enable or disable PPDS emulation datastream When this setting is enabled the following settings are also changed e SmartSwitch settings for each port are turned off e The printer language is changed to PPDS Emulation Users can still switch languages on the operator panel and through the PJL datastream Demo Mode There is a built in demonstration mode The settings allow you to Deactivate to turn off the demo mode and Activate to turn i
217. ion of the arrow Repair information 4 105 4024 110 Reinstallation procedure for the bracket A Release the hooks securing the plastic guide C that is attached to the bracket A Remove the plastic guide C from the bracket A Install the bracket A Install the plastic guide C and the standard bin full exit 1 actuator shaft D at the same time Make sure the standard bin full exit 1 actuator shaft D operates smoothly without binding SP eh 4 106 Printer Service Manual 4024 110 Media shift motor removal Remove the rear RIP card cover See Rear RIP card cover removal on page 4 125 Remove the rear motor cover See Rear motor cover removal on page 4 14 Remove the top rear cover See Top rear cover removal on page 4 4 Open the printer left door assembly Remove the standard exit top cover See Standard exit 1 top cover removal on page 4 112 Open the printer front door assembly Remove the front left cover See Printer front left cover removal on page 4 3 Remove the exit 1 media shift assembly See Exit 1 media shift assembly removal on page 4 104 Disconnect the connector from the media shift motor A Remove the two screws securing the media shift motor A to the exit 1 media shift assembly B Remove the media shift motor A eg e E lt TS zech l S Connector Note Before reinstalling secure the media shift motor A harness to the
218. ions CAUTION When you see this symbol there is a danger from hazardous voltage in the area of the AN product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task Consignes de s curit La s curit de ce produit repose sur des tests et des agr ations portant sur sa conception d origine et sur des composants particuliers Le fabricant n assume aucune responsabilit concernant la s curit en cas d utilisation de pi ces de rechange non agr es Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires ATTENTION Ce symbole indique la pr sence d une tension dangereuse dans la partie du produit sur laquelle vous travaillez D branchez le produit avant de commencer ou faites preuve de vigilance si l ex cution de la t che exige que le produit reste sous tension Norme di sicurezza La sicurezza del prodotto si basa sui test e sull approvazione del progetto originale e dei componenti specifici Il produttore non responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza aut
219. llation Go to step 2 Install the PC Is the PC cartridge properly installed cartridge properly 2 Check the sensor RFID PC cartridge installation Go to step 3 Install the sensor Is the sensor RFID PC cartridge properly installed I correctly 3 Check the sensor RFID PC cartridge connection Replace the Replace the Is the sensor RFID PC cartridge properly connected SE EE EEEEERER A Perform a print test Replace the Problem solved Does the error continue een BER Go to Printer engine card assembly removal on page 4 119 929 00 Sensor ATC failure Step Check Yes No 1 Check the PC cartridge installation Go to step 2 Install the PC Is the PC cartridge properly installed cartridge properly 2 Check the PC cartridge sensor connector installation Replace the PC Replace the Is the PC cartridge sensor connector properly connected SE onnecuon 2 54 Printer Service Manual 4024 110 Step Check Yes No 3 Check the switch PC cartridge interlock connection Replace the PC Replace the Is the switch PC cartridge interlock properly connected cartridge Gonnecvon 4 Perform a print test Replace the Problem solved printer engine card Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 930 00 Laser power failure Step Check Yes No 1 Check the printhead assembly for installation Go to step 2 Install the Is
220. ly tray 2 installed correctly 4 Check the switch media size connection for tray 1 and or Replace the Replace the tray 2 required switch connection Is the switch media size properly connected for tray 1 media size d or tray 2 Go to Toner angor way e cartridge guide assembly removal on page 4 93 2 64 Printer Service Manual 4024 110 Step Check Yes No 5 Perform a print test Replace the Problem solved printer engine card Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 No media in the select media tray Step Check Yes No 1 Check the media Go to step 2 Load media Is media loaded in the selected tray 2 Check the sensor media out for operation Go to step 4 Go to step 3 1 Enter Diagnostics mode 2 Select NPUT TRAY TESTS 3 SelectSensor test 4 SelectTray 1 5 Select Media out 1 Enter Diagnostics mode 2 Select NPUT TRAY TESTS 3 SelectSensor test 4 SelectTray 2 5 Select Media out Remove the media tray assembly Does the display on the operator panel change every time the sensing area is blocked by the media out actuator 3 Check the sensor media out connection for tray 1 or Replace the Replace the tray 2 sensor media connection Is the sensor media out properly connected for tray 1 or out tray 2 Go to Sensor media out removal on page 4 37 4 Perform a print te
221. ly 1 4 40X0676 1 1 Media size switch cable assembly 5 40X0682 1 1 Multi connector cable assembly 3 6 40X1390 1 2 Switch PC cartridge interlock kit includes e Backup spring e Switch PC cartridge interlock Parts catalog 7 33 4024 110 Assembly 19 Electrical cables Assem part Units Units kit bly Description number mach _ or pkg Index 19 1 40X0677 1 1 RIP card cable assembly 2 40X0685 1 1 Dual drive motor cable assembly 3 40X0674 1 1 Media feed unit cable assembly 4 40X0675 1 1 MPF hookup cable assembly 5 40X0670 1 7 AC power input socket kit includes e Screws 4 mm 2 each e Bracket e AC power input socket e Ground wire e Main AC cable assembly e Finisher AC output 6 40X0682 1 1 Multi connector cable assembly 3 7 34 Printer Service Manual Assembly 20 Electrical cables 4024 110 Assem bart Units Units kit _ bly Description number mach _ or pkg Index 20 1 40X0680 1 1 Multi connector cable assembly 2 2 40X0678 1 1 Printhead cable assembly Parts catalog 7 35 4024 110 Assembly 21 Electrical cable Assem bart Units Units kit Si bly Description number mach _ or pkg Index 21 1 40X0679 1 1 Exit interface cable assembly 7 36 Printer Service Manual Assembly 22 Power cords 4024 110 Assem part Units
222. ly did not recognize finisher error Refer to Finisher Service Manual Check tray 1 guides Tray 1 media size failure Although tray 1 is in the printer the media size is not detected correctly Go to Tray 1 media size failure on page 2 76 Check tray 1 or 2 orientation or guides Paper is installed short edge in the media paper tray This error occurs when short edge printing is disabled and the paper in the tray is not installed long edge Letter A4 Go to Paper is installed short edge in the media paper tray on page 2 66 Check tray 1 or tray 2 orientation or guides Media size mismatch in width The media width is incorrect Go to Media size mismatch in width on page 2 64 Check tray 2 Tray 2 media size failure Although tray 2 is in the printer the media size is not guides detected correctly Go to Tray 2 media size failure on page 2 77 Check tray 3 Media size mismatch in The media width is incorrect or check tray 4 orientation or guides width Refer to Options Service Manual Close cover F Bridge unit cover is open The bridge unit assembly cover is open Refer to Finisher Service Manual Close cover K HCF top door open The tray 5 HCF top door is open Refer to Options Service Manual Close door A Printer left door open The printer left door assembly is open Go to Printer left door open on page 2
223. m 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 Diagnostics Mode D O O 1 Turn off the printer 2 Press and hold w and p SE 3 Turn on the printer 4 Release the buttons when Performing Self Test displays es The Diagnostics Mode group contains the settings and operations used while manufacturing and servicing the printer See Diagnostics mode on page 3 2 for more information Configuration Menu O O O 1 Turn off the printer 2 Press and hold Qand p d E 3 Turn on the printer 4 Release the buttons when Performing Self Test displays The Configuration Menu group contains a set of menus settings and operations which are infrequently required by a user Generally the options made available in this menu group are used to configure a printer for operation See Configuration menu CONFIG MENU on page 3 19 for more information Flash system code mode 1 Turn off the printer 2 Press and hold 4 and gt O9 3 Turn on the printer 4 Release the buttons when Performing Self Test displays D To run the printer diagnostic tests described in this chapter you must put the printer in Diagno
224. mental and safety instructions Diagnostic information contains an error indicator table symptom tables and service checks used to isolate failing field replaceable units FRUs Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer problems Repair information provides instructions for making printer adjustments and removing and installing FRUs Component locations uses illustrations to identify the component locations and test points on the printer Preventive maintenance contains the lubrication specifications and recommendations to prevent problems Parts catalog contains illustrations and part numbers for individual FRUs N pm BY N Conventions Note A note provides additional information Warning A warning identifies something that might damage the product hardware or software There are several types of caution statements CAUTION POTENTIAL INJURY A caution identifies something that might cause a servicer harm CAUTION SHOCK HAZARD This type of caution indicates there is a danger from hazardous voltage in the area of the product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task CAUTION HOT SURFACE This type of caution indicates a hot surface CAUTION TIPPING HAZARD This type of caution indicates a tipping hazard gt P Pe Xv Printer Service Ma
225. missing printer foot Is the setup surface normal 2 Properly load media into the media tray assembly Go to step 3 Problem solved Properly install the media tray assembly into the printer Re print the defective image Does the error continue 3 Are the media transfer route and the media route free of Go to step 4 Remove debris contamination or debris or contamination 4 Check the drive rolls on the media transfer route Go to step 5 Replace ati defective rolls Check all rolls on the transfer route for contamination Go to wear or damage applicable repair Check whether the pinch rolls rotate freely and spring procedures for pressure is applied evenly replacement Are all drive rolls free of contamination wear or damage 5 Check the printer engine card assembly Replace the RIP Problem solved card assembly Replace the printer engine card assembly Go to RIP card Perform a print test assembly Does the error continue removal on page 4 126 2 100 Printer Service Manual Media damage Leading edge Trailing edge 4024 110 Is there contamination or cracking on the heat roll and or the pressure roll Step Check Yes No 1 Check printer installation placement Go to step 2 Correct the Check the installation surface for irregularities de Check for missing printer foot Is the setup surface normal 2 Check the media feed Go to step 3 Problem solved Remove
226. mistor monitors the surface temperature at the rear side of the heat roll to switch the heater lamp to on Pressure roll thermistor The pressure roll thermistor monitors the temperature of the pressure roll to control the idling time for fuser warm up before printing Diagnostic aids 3 37 4024 110 Fuser exit sensor The fuser exit sensor detects the arrival of media at the detection point in the exit area of the fuser and also detects the ejection of media from this point Rear thermistor Center thermistor Pressure roll thermistor Pressure roll SS Sub heater lamp 2 KE Ge TA Heat roll 0 A Sub heater lamp 1 Front Es Main heater lamp Thermostat 3 38 Printer Service Manual Exit 4024 110 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 Exit 1 media exit roll assembly The exit 1 media exit roll assembly feeds printed media from the fuser to the standard bins Sensor standard bin full exit 1 The sensor standard bin 1 full detects whether the exit 1 face down tray is full by moving the actuator up and down Media diverter gate The media diverter gate switches the media transport path When the media diverter g
227. n Go to step 2 Problem solved Load new dry recommended media Re print the defective image Does the error continue 2 Check the toner cartridge Problem solved Go to step 3 Install a new toner cartridge Re print the defective image Is the image density normal 3 Check the heat roll and the pressure roll Replace the Go to step 4 Remove the fuser unit assembly E Is there contamination or cracking on the heat roll and or pressure roll 4 Check the printer engine card assembly Replace the RIP Problem solved Replace the printer engine card assembly card assembly Go to RIP card Perform a print test assembly Does the error continue removal on page 4 126 Diagnostic information 2 97 4024 110 Background fog Leading edge Trailing edge Step Check Yes No 1 Check the media condition Load new dry recommended media Re print the defective image Does the error continue Go to step 2 Problem solved 2 Check the media transfer route Is the media path free of contamination or debris Go to step 3 Remove debris or contamination 3 Check the toner cartridge Install a new toner cartridge Re print the defective image Is the image density normal Problem solved Go to step 4 4 Check the transfer roll assembly Remove the transfer roll assembly Is the transfer roll assembly rotating and free of contamination and wear Go to s
228. n page 4 119 Tray 1 media size failure Step Check Yes No 1 Check the media Go to step 2 Load media g properly Pull out media tray 1 and visually check it Is media loaded in media tray 1 properly 2 Check the media Go to step 3 Set the guides Pull out media tray 1 and visually check it properly Are the front media tray guide assembly rear media tray guide and media tray end guide of media tray 1 set correctly 3 Check the tray 1 switch media size for proper installation Go to step 4 Install switch Pull out media tray 1 and visually check it e for Is the above switch installed properly correctly 4 Check the tray 1 switch media size connection Replace the switch Replace the Is the tray 1 switch media size properly connected media size connection Go to Switch media size removal on page 4 17 5 Perform a print test Replace the Problem solved Does the error continue A cara Go to Printer engine card assembly removal on page 4 119 2 76 Printer Service Manual Tray 2 media size failure 4024 110 Step Check Yes No 1 Check the media Go to step 2 Load media Is media loaded in media tray 2 properly properly Pull out media tray 2 and visually check it 2 Check the media Go to step 3 Set the guides Are the front media tray guide assembly rear media tray properly guide and media tray end guide of media tray
229. n 7 38 Assorted screw packet 2 22 25 5 5 5 5 eee eee eee ee 7 38 Bushing 6 mm 7 7 Rear lower cover 220 V eee r rrr ree er eee ee ee ee eee 7 4 Maintenance kit 110 V 6 2 7 38 Maintenance kit 220 V 6 2 7 38 Maintenance kit 100 V 6 2 7 38 2TM TTM retaining screws reer rrr eee eer eee eee eee eee 7 3 Media tray separation pad eee e eee 7 9 Media tray separation brush 2 2 rere eee eee 7 9 Media tray lift one way clutch gear kit 7 7 Media tray lift one way shaft 2 52 e eee ee eee eens 7 7 Pick roll idler gear 2 2 errr ee er eee ee eee eee ee 7 7 Pick roll drive gear eer ere ee ee eee eee eee ee 7 7 MPF feed drive gear kit 2 eee ee eee eee eee ee 7 13 MPF feed cam gear kit e ee eee ee eee eee ee 7 13 MPF pressure pad kit 2 2 2222 2 eee ee eee 7 13 W850 Forms and Bar code card
230. n your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the ESD sensitive part on the machine cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tables are electrical grounds They increase the risk of damage because they make a discharge path from your body through the ESD sensitive part Large metal objects can be discharge paths without being grounded Prevent ESD sensitive parts from being accidentally touched by other personnel Install machine covers when you are not working on the machine and do not put unprotected ESD sensitive parts on a table If possible keep all ESD sensitive parts in a grounded metal cabinet case Be extra careful in working with ESD sensitive parts when cold weather heating is used because low humidity increases static electricity Repair information 4 1 4024 110 Removal procedures CAUTION SHOCK HAZARD Remove the power cord from the electrical outlet and then from the printer before connecting or disconnecting any cable assembly or electronic board This is a precaution for personal safety and to prevent damage to the printer Disconnect any connections between the printer and PCs peripherals CAUTION POTENTIAL INJURY The printer weighs approxima
231. na do produto em que est a trabalhar Antes de come ar desligue o produto da tomada el ctrica ou seja cuidadoso caso o produto tenha de estar ligado corrente el ctrica para realizar a tarefa necess ria Printer Service Manual Informacio de Seguretat A 4024 110 La seguretat d aquest producte es basa en l avaluaci i aprovaci del disseny original i els components espec fics El fabricant no es fa responsable de les q estions de seguretat si s utilitzen peces de recanvi no autoritzades La informaci pel manteniment d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui El risc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients treballant s perill s Abans PRECAUCI aquest s mbol indica que el voltatge de la part de l equip amb la qual esteu de comen ar desendolleu l equip o extremeu les precaucions si per treballar amb l equip l heu de connectar A y eee AAAY A 73 el a RAE u 74 See el E Een e ee ee g k ng Kack A ee de Ae A A S HE tc le Wee Te et KA e Ne 35 gt AF AI EI Woes H AE AT Sol A OAL Cf 10L A 3 LE IC ore T WH e ENEEIER HE id cs pe a a Ve pete Ve eee fete ee ao ee
232. nating current V dc Volts direct current General information 1 3 4024 110 1 4 Printer Service Manual 4024 110 2 Diagnostic information Start CAUTION SHOCK HAZARD disconnecting any cable assembly or electronic board This is a precaution for personal safety and to prevent damage to the printer Disconnect any connections between the printer and PCs peripherals A Remove the power cord from the electrical outlet and then from the printer before connecting or CAUTION POTENTIAL INJURY The printer weighs approximately 41 kg 90 2 lbs and requires two or more trained personnel to lift it safely Make sure your fingers are not under the printer when you lift or set the printer down CAUTION SHOCK HAZARD If the printer is kept on never touch the conductive parts while it is not specifically required The power switch and inlet of the low voltage power supply card LVPS card assembly is live even while the power supply is cut off Never touch the live parts gt amp P CAUTION HOT SURFACE The inside of the printer might be hot To reduce the risk of injury from a hot component allow the surface to cool before touching Warning Warning Warning When operating the driving units using the diagnostics or other tools be sure to keep them covered unless otherwise specified When operating the driving units using the diagnostics or other tools never to
233. ne card assembly removal on page 4 119 Diagnostic information 2 41 4024 110 903 00 RAM read write check failure Step Check Yes No Perform a POR Does the error occur when the power is turned off on Go to step 2 Perform several print tests If the problem remains go to step 2 Turn the printer off for 60 seconds Does the error occur when the power is turned off on again Replace the RIP card assembly Go to RIP card assembly removal on page 4 126 Go to step 3 Problem solved Perform a print test Does the error still occur Replace the printer engine card assembly Go to Printer engine card assembly removal on page 4 119 Problem solved 904 00 NVM data failure Step Check Yes No Perform a POR Does the error occur when the power is turned off on Go to step 2 Perform several print tests If the problem remains go to step 2 Turn the printer off for 60 seconds Does the error occur when the power is turned off on again Replace the RIP card assembly Go to RIP card assembly removal on page 4 126 Go to step 3 Problem solved Perform a print test Does the error still occur Replace the printer engine card assembly Go to Printer engine card assembly removal on page 4 119 Problem solved 2 42 Printer Service Manual
234. ner Av s sobre el L ser Segons ha estat certificat als Estats Units aquesta impressora compleix els requisits de DHHS 21 CFR apartat J pels productes laser de classe 1 i segons ha estat certificat en altres llocs s un producte laser de classe que compleix els requisits d IEC 60825 1 Els productes laser de classe no es consideren perillosos Aquesta impressora cont un l ser de classe IIIb 3b d d arseni r de gal li nominalment de 5 mil liwats i funciona a la regi de longitud d ona de 770 795 nan metres El sistema l ser i la impressora han sigut concebuts de manera que mai hi hagi exposici a la radiaci l ser per sobre d un nivell de classe durant una operaci normal durant les tasques de manteniment d usuari ni durant els serveis que satisfacin les condicions prescrites Notices Xi 4024 110 LFR T Seno LCO7 Yry is KBCADHHS 21 CFRYTFHTFF J ODIVFAI 1 ORBt MLL EV V HMCHSSCEMAEWS MEWS KKAKBUATAIEC 82508 BtmK LEFF ALOV VYV WMECHSCEMEWSNTTVET FPIFAILOV VP WHRE MERE EBA GCHTWEF CO PUvy wu7FIAMb 3b OL P AAMLTIET CO LH RBOT70 T9IO5t JA FY OHRAC BH SL UDybhOAVDAULWERHITSLU P CF Got YAFLEPV YA H BORE 2A VPOA YFIHYVAL D SESH EL BW Ta ARR FATOVANVE LOL P ik HIM NSZCLOBWEABHaANTHEF Ax FT EN OL ae Se EIU GEA 7 DHHS 21 CFR Subchapter I XJA 1 1 6 re RYH HE m H te e X m g A EA E IEC 825 WIRE DEL RMIT A RUARAERH FT EX OLA BS amp G2 Ib 3b HIE EC
235. nisher Service Manual 285 00 Paper jam Check area H Finisher set eject jam Finisher sensor compiler media in is not turned on within the specified time after the media eject motor is turned on Refer to Finisher Service Manual 286 00 Paper jam Check area H Sensor compiler media in Static jam Paper remains on the sensor compiler media in Refer to Finisher Service Manual 287 00 Check area F Sensor upper media exit on jam A Sensor upper media exit is not turned on within the specified time after the sensor finisher media entrance is turned on At this time the sensor bridge unit media exit is turned on Refer to Finisher Service Manual 287 01 Check area F Sensor upper media exit off jam A Sensor upper media exit is not turned off within the specified time after the sensor upper media exit is turned on At this time the sensor bridge unit media exit is turned on Refer to Finisher Service Manual 287 02 Paper jam Check areas G1 G3 Sensor upper media exit on jam B Sensor upper media exit is not turned on within the specified time after the sensor finisher media entrance is turned on At this time the sensor bridge unit media exit is on state Refer to Finisher Service Manual 2 10 Printer Service Manual 4024 110 Error code or Error contents Description Action message 287 03 Sensor upper medi
236. nostics mode 2 Select MOTOR TESTS 3 SelectFuser cooling fan Does the fuser cooling fan RPM increase 4 Check the fuser cooling fan for proper connection Replace the fuser Replace the Is CN102 on the dual drive motor assembly connected cooling tau connection properly 5 Perform a print test Replace the Problem solved Does the error continue GE card Go to Printer engine card assembly removal on page 4 119 916 00 PC cartridge cooling fan failure Step Check Yes No 1 Visually check the PC cartridge cooling fan rotation Go to step 3 Go to step 2 Is the PC cartridge cooling fan visually rotating 2 Check the PC cartridge cooling fan Remove the object Go to step 3 Is there an object blocking the PC cartridge cooling fan ee We rotation i 3 Check the PC cartridge cooling fan for operation Go to step 5 Go to step 4 1 Enter Diagnostics mode 2 Select MOTOR TESTS 3 SelectPC unit cooling fan Does the fan rotate normally 4 Check the PC cartridge cooling fan connection Replace the PC Replace the Is the PC cartridge cooling fan properly connected SE cooling connection Go to PC cartridge cooling fan removal on page 4 101 5 Perform a print test Replace the Problem solved printer engine card Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 Diagnostic information 2 49 4024 110 918 00 Sensor exit 1 media shift HP
237. nsors are working correctly To run the Output Bin Sensor Test 1 Select OUTPUT BIN TESTS from DIAGNOSTICS 2 Select the Sensor Test from OUTPUT BIN TESTS 3 Select the output bin from the bins displayed on the Sensor Test menu All installed bins are listed e Standard Bin es Output Bin 1 e Output Bin 2 3 10 Printer Service Manual 4024 110 4 Each of the tests categories includes the individual sensors that can be manually actuated and the display shows Open or Closed e Standard Bin Std bin full exit1 Std bin full exit2 Output Bin 1 Fin upper bin full e Output Bin 2 Stacker bin level1 Stacker bin level2 5 Manually actuate the selected sensor and Open or Closed displays Press Back or Stop to exit the test FINISHER TESTS Staple Test This test verifies the staple mechanism by sending eight sheets of media from the printer s default paper source and stapling the sheets To run the Staple Test 1 Select FINISHER TESTS from DIAGNOSTICS 2 Select Staple Test from FINISHER TESTS 3 Select the output bin and press While the test runs the power indicator blinks and the message Staple Test Running displays Select Stop to exit the test before it completes Hole Punch Test This test is used to verify whether or not media can be fed to a finisher output bin and punched Eight sheets of blank paper are fed from the default paper source and fed to the finisher output bins Letter size p
238. ntenimiento realizado por el usuario o cualquier otra situaci n de servicio t cnico Declara o sobre Laser A impressora esta certificada nos E U A em conformidade com os requisitos da regulamenta o DHHS 21 CFR Subcapitulo J para a Classe 1 de produtos laser Em outros locais esta certificada como um produto laser da Classe I em conformidade com os requisitos da norma IEC 60825 1 Os produtos laser da Classe nao sao considerados perigosos Internamente a impressora cont m um produto laser da Classe IIIb 3b designado laser de arseneto de pot ssio de 5 milliwatts operando numa faixa de comprimento de onda entre 770 e 795 nan metros O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radia o laser superior a um nivel de Classe durante a opera o normal a manuten o feita pelo utilizador ou condi es de assist ncia prescritas Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J voor andere landen in IEC 60825 1 Laserprodukten van klasse worden niet als ongevaarlijk aangemerkt De printer is voorzien van een laser van klasse lllb 3b dat wil zeggen een gallium arsenide laser van 5 milliwatt met een golflengte van 770 795 nanometer Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal gebruik bij onderhoud of
239. nu Maintenance page counter reset Reset Maint Cnt After scheduled maintenance the servicer needs to reset the page counter To reset the maintenance page count to zero 1 Select Reset Maint Cnt from CONFIG MENU The message e Reset displays 2 Press to confirm the selection Press Back to return to the main Configuration menu without resetting the page counter When the reset operation is complete the menu returns to the Printer Setup Reset Maintenance Count screen 3 20 Printer Service Manual 4024 110 REGISTRATION Print registration makes sure the printing is properly aligned on the page This setting allows separate Left Margin settings for each media tray The Top Margin setting is the same for all trays Incorrect Registration line Correct Top Margin To set the top margin for all trays 1 Select REGISTRATION from CONFIG MENU 2 Select Top Margin from REGISTRATION The current setting is displayed 3 Check the Quick Test and adjust the value The range of valid settings for the top margin is 0 to 50 Increasing the value by one increment moves the image on the page down by one pixel 1 300 inch and widens the top margin Decreasing the value by one increment moves the image up the page by one pixel 1 300 inch and narrows the top margin When you select a value the Quick Test prints so you can verify the value is correct 4 Continue
240. nual 4024 110 1 General information About this manual This manual is a standard service manual containing information required for maintenance of the Lexmark W850n and W850dn 4024 110 laser printers Printer overview CAUTION Do not set up this product or make any electrical or cabling connections such as the power cord or options and features during a lightning storm Basic model The following illustration shows a printer with its base features Standard output bin Operator panel Multipurpose feeder MPF Sg Lx Tray 1 and Tray 2 500 sheet trays General information 1 1 4024 110 Configured model The following illustration shows a fully configured printer Items denoted with an asterisk are options Bridge unit z on Used in conjunction au with finisher Used in conjunction with duplex unit Operator panel ee Finisher eo Tray 5 2000 sheet high capacity feeder HCF Tray 3 and Tray A 500 sheet trays or 850 and 1150 sheet dual input trays Tray 1 and Tray 2 500 sheet trays Tools required for service Flat blade screwdriver 1 Phillips screwdriver magnetic 2 Phillips screwdriver magnetic 2 Phillips screwdriver magnetic short blade Needle nose pliers Diagonal side cutters Spring hook Analog or digital multi meter Parallel wrap plug 1319128 Twinax serial debug cable
241. nue Replace the printer engine card assembly Go to Printer engine card assembly removal on page 4 119 Problem solved 2 66 Printer Service Manual 4024 110 PC cartridge end of life Step Check Yes No 1 Check the PC cartridge installation Go to step 2 Install the PC Is the PC cartridge properly installed cartridge properly 2 Check the sensor RFID PC cartridge installation Go to step 3 Install the sensor Is the sensor RFID PC cartridge properly installed Seely unit 3 Check the sensor RFID PC cartridge for proper Replace the Replace the connection sensor RFID PC connection Is the sensor RFID PC cartridge properly connected cartridge 4 Perform a print test Replace the Problem solved Does the error continue AE ara Go to Printer engine card assembly removal on page 4 119 PC cartridge RFID failure Step Check Yes No 1 Check the PC cartridge installation Go to step 2 Install the PC Is the PC cartridge properly installed cartridge properly 2 Check the sensor RFID PC cartridge installation Go to step 3 Install the sensor Is the sensor RFID PC cartridge properly installed E 3 Check the sensor RFID PC cartridge connection Replace the Replace the sensor RFID PC connection Is the sensor RFID PC cartridge properly connected cartridge 4 Perform a print test Replace the Problem solved f printer engine car
242. o J per i prodotti laser di classe 1 ed certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825 1 prodotti laser di classe non sono considerati pericolosi La stampante contiene al suo interno un laser di classe ID 3b all arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d onda compresa tra 770 e 795 nanometri Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante durante il normale funzionamento le operazioni di servizio o quelle di assistenza tecnica non ricevano radiazioni laser superiori al livello della classe 1 Notices ix 4024 110 Avisos sobre el laser Se certifica que en los EE UU esta impresora cumple los requisitos para los productos laser de Clase 1 establecidos en el subcapitulo J de la norma CFR 21 del DHHS Departamento de Sanidad y Servicios y en los demas paises reune todas las condiciones expuestas en la norma IEC 60825 1 para productos laser de Clase 1 Los productos laser de Clase no se consideran peligrosos La impresora contiene en su interior un laser de Clase IIIb 3b de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nan metros El sistema laser y la impresora estan dise ados de forma que ninguna persona pueda verse afectada por ningun tipo de radiaci n laser superior al nivel de la Clase durante su uso normal el ma
243. og 7 23 4024 110 Assembly 13 Fuser Ve E d 7 24 Printer Service Manual Assembly 13 Fuser 4024 110 Assem Part Units Units kit ke bly Description number mach or pkg Index 13 1 40X0588 1 1 Sensor fuser exit 2 40X5931 1 1 Sensor fuser exit assembly with actuator 3 40X0647 1 1 Fuser assembly 110 V this comes assembled 3 40X0648 1 1 Fuser assembly 220 V this comes assembled 3 40X0646 1 1 Fuser assembly 100 V this comes assembled Parts catalog 7 25 4024 110 Assembly 14 Standard Exit 1 7 26 Printer Service Manual Assembly 14 Standard Exit 1 4024 110 Assem Part Units Units kit kee bly Description number mach or pkg Index 14 1 40X0649 1 1 Exit 1 media shift assembly this comes assembled 2 40X0655 1 1 Standard exit 1 top cover 3 40X0657 1 3 Standard bin full exit 1 actuator kit includes e Standard bin full exit 1 actuator shaft e Standard bin full exit 1 actuator e Output guide 4 40X0650 1 1 Exit 1 sensor cable assembly 5 40X0651 1 1 Media shift motor 6 40X0653 1 1 Exit 1 media shift gear 7 40X0588 1 1 Sensor standard bin full exit 1 8 40X0588 1 1 Sensor exit 1 media shift HP 9 40X0654 1 2 Media diverter gate kit includes e Media diverter gate e Spring 10 40X1391 1 1 Exit 1 static eliminator 11 40X1392 1 2 Exit 1 media exit guide kit includes e Exit 1 media guide e Exit 1 media guide pad 12 40X2389 1 1 Output guide
244. onde leche thee ewe 3 23 PPDS EMUMON 3 seg tana EEN siete eke eR Ree ERE ORE Pee dee RE 3 24 DEMO Mod ed ERAN EE EE EINEN E RE dE 3 24 Factory Detauns sis stds AER daa AE dE REES ee dew EE EELER US 3 24 Energy CONSCIVG 5 640 REENERT ERR ENER REESEN ELE ECKER ERR Bie Eis 3 24 EVENT LOG s cic teed dea eke Reed eked taser eee Eee eee geb S 3 24 Paper From 2 inte cies fe geg emat sabes e e Ee 3 24 ESCH tees theese aban east A RR 3 25 JODS Oi Bist s citpocnceesdienoatwas EE EE EE 3 25 Disk ENChVPHOR E ET EE 3 25 Fant Snelpening icecitcansene st awieneo eo eodnceet seeded dane OAA AEE A 3 25 SHON Ede Printing enne es Crees EE Ee ee das amas ta kata d ed Re 3 25 Tray Low Me sSaGe iiss ccainitce sien EELER REES eae ee ewe RR aE 3 25 Exit Config Men A1 ce caecaca dices doses sede s Gee ACEN RE EELER eee bale anew 3 25 Analyzing the Print Test ac NEE cena cana ead ace Re eee EES EE Reem EEN Re aad 3 26 Driving force transmission path 2 0 cc eee eee eee 3 27 M dia transport tices ens EELER EELER REES eRe KE EE Sek Sea oR 3 28 Functions of main components 2 0 0 cece eee eee eee 3 30 Media tray assembly ax e EAER RL EATEN es cee RE AE eRe RETR REN Ree eee Ee ERR FRE 3 31 Multi purpose feeder MPF 0 c cece eer erence eee eee eee e eens 3 33 GLE CHING Media SEE ass cs pst Ay ww sli ko oe nk am ay we ek oat pea 3 34 RRE ENT si cdeitedanigdthiaanted cease cemed eee EE 3 35 Printhead ASSEMOlY cance cia takw vidoe hieeed Ee Ee ae
245. oner cartridge guide assembly See Toner cartridge guide assembly removal on page 4 93 8 Disconnect the connector from the toner add motor assembly A 9 Remove the four screws securing the toner add motor assembly A 10 Remove the toner add motor assembly A f Cx Connector YO Note Before reinstalling ensure the shaft on the toner cartridge guide assembly is inserted into the toner add motor assembly A Repair information 4 95 4024 110 Fuser cooling fan removal Remove the rear RIP card cover See Rear RIP card cover removal on page 4 125 Remove the rear motor cover See Rear motor cover removal on page 4 14 Disconnect the connector from the fuser cooling fan A from the dual drive motor assembly B Release the two hooks securing the fuser cooling fan A to the fan duct C Remove the fuser cooling fan A ORONT Note Before reinstalling the fuser cooling fan A must be installed with the center label facing outward 4 96 Printer Service Manual 4024 110 Printhead assembly removal Remove the top cover assembly See Top cover assembly removal on page 4 7 Open the printer front door assembly See Printer front door assembly removal on page 4 8 Remove the PC cartridge Remove the toner cartridge Remove the printer front door assembly See Printer front door assembly removal on page 4 8 Remove the front inner cover
246. ons Service Manual 945 00 Media tray 5 lift up no tray The sensor HCF media level is not turned on with z failure the specified time after the HCF feed lift motor is Service tray 5 turned on failure Refer to Options Service Manual 2 16 Printer Service Manual 4024 110 Error code or message Error contents Description Action 945 01 Service tray 5 failure Tray 5 HCF NVM R W failure A read write error has occurred on the NVM of the tray 5 HCF controller card assembly Refer to Options Service Manual 951 XX RIP card assembly NVRAM A failure has occurred in the RIP card asm NVRAM Service failure Go to 951 XX RIP card assembly NVRAM NVRAM failure on page 2 60 failure 953 XX Operator panel assembly NVRAM chip failure with operator panel assembly Servi NVRAM failure mirror ervice NVRAM Go to 953 XX Operator panel assembly NVRAM failure failure on page 2 61 955 XX RIP card assembly NAND The code ROM or NAND flash failed the cyclic Service Code CRC CRC failure redundancy check Go to 955 XX RIP card assembly NAND CRC failure on page 2 62 956 00 Service system board RIP card assembly processor failure The RIP card processor has failed Go to 956 00 RIP card assembly processor failure on page 2 62 956 01 Service system board RIP card assembly processor over temperature failure The RIP card assembly has exceeded safe operating
247. ooth removal 00 eee eee eee eee 4 39 Media feed unit drive gear 29 tooth removal 0 00 e eee eee eee ene 4 40 Feed TON TEMOVAl tege iton same spans actus E wares buat Gudea eam aku A 4 42 Feed roll one way CIUICH removal ex KREE eae dsc EUR AER cree eee EE EIERE new eae 4 43 Feed roll one way gear 22 tooth removal 2000 c eee e eee eee 4 44 Separation roll one way friction clutch removal 4 45 Separation roll removal aiiscaicsdecssneetens EELER EE EN ere em dese eae Re Aas 4 46 Pick roll idler gear 33 tooth removal 0 0 cece eee eee eee eee eee ee eee 4 47 Pick roll removal sic6icgeccaceeeeme dae weak wea eRe ENEE Rae ER ee eR de Kg 4 48 Pick roll drive gear 25 tooth removal 4 49 Feed unit drive gear 27 tooth removal cece eee eee eee eee e eee eee 4 50 MPF feed unit assembly removal 4 51 MPF media out actuator and upper frame removal 00 cee eee eee eee 4 52 Sensor MPFinedia out removal 22cscccchaceah scene ais K sse EE e aes 4 53 MPF transport pinch roll assembly removal 4 54 MPF tear cover lemoval ucciicsest es rch oe EE Eh EE 4 55 MPF feed drive gear group removal 20 c eee eee eee eee eee eee eee eee 4 56 MPF pressure pad removal be aEIE dada sedees see sake EEN te Ree Rea ee Rae EEN R 4 57 MPF transport roll assembly removal 0 0 0 cee eee eee eens 4 58 MPF pick solenoid pick lever removal 4 59 MPF feed shaft assembly removal 0 0 e eee
248. op rear cover B by sliding it left in the direction of the arrow then lift up Note The cable hookup door if still installed becomes detached Seah 4 4 Printer Service Manual 4024 110 Switch printer front door interlock removal Note First remove the bridge unit and the finisher if equipped Refer to the Finisher Service Manual ONDARON Remove the top cover assembly Go to Top cover assembly removal on page 4 7 Remove the printer front door assembly Go to Printer front door assembly removal on page 4 8 Remove the front left cover See Printer front door assembly removal on page 4 8 Remove the front inner cover See Front inner cover removal on page 4 10 Remove the screw securing the bracket A Disconnect the connector from the switch printer front door interlock B Release the hooks securing the switch printer front door interlock B to the bracket A Remove the switch printer front door interlock B Repair information 4 5 4024 110 Operator panel assembly removal Warning In the event of replacement of any one of the following components e Operator panel assembly e RIP card assembly Replace only one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more of t
249. operly 2 Check the sensor RFID toner cartridge installation Go to step 3 Install the sensor Is the sensor RFID toner cartridge properly installed ace correctly 3 Check the sensor RFID toner cartridge connection Replace the Replace the Is the sensor RFID toner cartridge properly connected eee Sonnacion 4 Perform a print test Replace the Problem solved Does the error continue et iad BER Go to Printer engine card assembly removal on page 4 119 2 56 Printer Service Manual 939 00 RIP card assembly communication failure 4024 110 Step Check Yes No 1 Perform a POR Go to step 2 Perform several Does the error occur when the power is turned off on print tests If the problem remains go to step 2 2 Turn the printer off for 60 seconds Go to step 3 Problem solved Does the error occur when the power is turned off on again 3 Check the RIP card assembly connection Replace the RIP Replace the Are the RIP card assembly connection JHAB2 and the Gardiassembly eannecnon printer engine card assembly connection P402 connected Go to RIP card properly assembly removal on page 4 126 Go to step 4 4 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 4 119 941 00 Media tray 1 lift up no media tray failure Step Check Yes
250. or continue removal on page 4 126 2 86 Printer Service Manual Vertical blank lines white stripes in media transport direction Leading edge 4024 110 Trailing edge Step Check Yes No 1 Check the media condition Go to step 2 Problem solved Load new dry recommended media Re print the defective image Does the error continue 2 Are the media transfer route and the media path clear of Go to step 3 Remove debris or debris contamination 3 Check laser beam route Go to step 4 Remove debris or clean the Check for debris between the transfer roll assembly and printhead the PC drum assembly window Check the printhead assembly window for contamination Is there any debris in the laser beam route and is the printhead assembly window free of debris and contamination 4 Check the printhead assembly installation Go to step 6 Go to step 5 Is the printhead assembly installed securely with four screws 5 Check the printhead assembly installation Problem solved Go to step 6 Install the printhead assembly securely and perform a print test Does the error continue 6 Check the toner cartridge Problem solved Go to step 7 Install a new toner cartridge Re print the defective image Is the image density normal 7 Check the transfer roll assembly Go to step 8 Replace the Remove the transfer roll assembly ET Is the transfer roll assembly rotating free of contamination
251. orizzato Durante lo smontaggio e la manutenzione di questo prodotto il rischio di subire scosse elettriche e danni alla persona pi elevato Il personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie ATTENZIONE Questo simbolo indica la presenza di tensione pericolosa nell area del prodotto Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per eseguire l intervento Lithium warning xiii 4024 110 Sicherheitshinweise Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des urspr nglichen Modells und bestimmter Bauteile Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung f r die Sicherheit bernommen Die Wartungsinformationen f r dieses Produkt sind ausschlie lich f r die Verwendung durch einen Wartungsfachmann bestimmt W hrend des Auseinandernehmens und der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zust ndige Fachpersonal sollte entsprechende VorsichtsmaBnahmen treffen ACHTUNG Dieses Symbol weist auf eine gef hrliche elektrische Spannung hin die in diesem Bereich des Produkts auftreten kann Ziehen Sie vor den Arbeiten am Ger t den Netzstecker des Ger ts bzw arbeiten Sie mit gro er Vorsicht wenn das Produkt f r die Ausf hrung der Arbeiten an den Strom angeschlossen sein mu Pautas de Seguridad La seguridad de e
252. oval on page 4 71 12 Remove the screw securing the toner add chute B to the frame 13 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 ek d TU it f ND duu EE Se es t s Ke a Fs h S lt see N a Ss Note Before reinstalling ensure the shaft C on the toner cartridge guide assembly A is inserted into the toner add motor assembly D VS 4 94 Printer Service Manual 4024 110 Toner add motor assembly removal 1 Remove the front left cover See Printer front left cover removal on page 4 3 2 Remove the top cover assembly See Top cover assembly removal on page 4 7 3 Remove the PC cartridge 4 Remove the toner cartridge 5 Remove the printer front door assembly See Printer front door assembly removal on page 4 8 6 Remove the front inner cover See Front inner cover removal on page 4 10 7 Remove the t
253. 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 1 Select REGISTRATION from CONFIG MENU 2 Select Quick Test from REGISTRATION The message Quick Test Printing appears on the display Once the Quick Test Page completes printing the Registration screen displays again Print quality pages Prt Quality Pgs The print quality test pages can be printed from either the Diagnostics mode or Configuration Menu CONFIG MENU When printed from the Diagnostic mode additional information is included and the print cartridge lockout is bypassed See Print quality pages Prt Quality Pgs on page 3 6 Additional configuration information may be included on the print quality pages which is not included on the print menu page To print the Print Quality Test Page select Prt Quality Pgs from CONFIG MENU The message Printing Quality Test Pages is displayed The following is printed e Settings from EP SETUP from DIAGNOSTICS Fuser temperature warm up time transfer print contrast and charge roll settings e Contents of the EVENT LOG from DIAGNOSTICS e Printer configuration information Printer serial number controller code level engine code level operator panel code level smart option code levels font versions and so on Values for the QUALITY MENU settings used to print the pages The print quality test consists of four pages Page one
254. pen the printer left door assembly and check it unit assembly P p y securely Is the fuser unit assembly installed securely 4 Check the fuser unit assembly connection Go to step 5 Replace the i connection Is the fuser unit assembly properly connected 5 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 A 6 Perform a print test Replace the Problem solved Does the error continue Ge card Go to Printer engine card assembly removal on page 4 119 Diagnostic information 2 53 4024 110 927 00 PC cartridge RFID data write failure Step Check Yes No 1 Check the PC cartridge installation Go to step 2 Install the PC Is the PC cartridge properly installed cartridge properly 2 Check the sensor RFID PC cartridge installation Go to step 3 Install the sensor Is the sensor RFID PC cartridge properly installed EN correctly 3 Check the sensor RFID PC cartridge connection Replace the Replace the Is the sensor RFID PC cartridge properly connected A SE SES A Perform a print test Replace the Problem solved Does the error continue A carg Go to Printer engine card assembly removal on page 4 119 928 00 PC cartridge RFID communication failure Step Check Yes No 1 Check the PC cartridge insta
255. pply HVPS card removal 2 00 c cece eee eee eee eens 4 115 Switch main power removal a ebe KEEN ices cece eeewn dese eee ead ew cde ea cae 4 116 Exit interface card assembly removal 00 cee e eee ee eee eee teen eee 4 117 Printer engine card assembly removal 4 119 Low voltage power supply LVPS card assembly removal 4 120 AC power input socket assembly removal 4 122 AC power input socket removal sang icant i nannes seed dere een ewe ede Ree ew ees 4 123 Finisher AC Output removal o5 seinen EERSTEN nat 4 124 Rear RIP card cover removal oi iiss cise cain dann aan rontet EES eee eee eam ean 4 125 RIP card assembly removal e ciao deena eee eed EELER REEL EELER EE ER 4 126 IR le 5 1 eh ol Meee eee ee ee eee ee ee eT eer ree ee ree eee re eT ee Nee ee eae ye ee ee ee 5 1 Printer boards ce idee SMS Adee E EEN 5 1 HVPS ccna ccna cainng i anir eeeat deen NEELA ROOTS ER ee REGO Rea aR meas naw Ras 5 1 IVES seosiiegsi sete die EE 5 1 Printer Motors and Sensors cccaeccceccaean tance esad ewan weed had eda Sed hawea cia Oe oA 5 2 PUDE SWICIES E E Kade nGeletana E AE a 5 7 RE 5 8 Preventive maintenance 0 2 6 0 c naarn rrera rreran errare 6 1 Safety inspection Guid va sce vaca denn cae a AR ENER ab eae E enina si eee eae beeen 6 1 L brication SPeCINCAIONS 255 j205 cee ben ieee tee Re ees SRS Cdedad ESNE AE EEEE EES 6 2 Ru len EE EE 6 2 Blt CAO EE 7 1 Howto USe his parts catalog sxsnsckas hhen deen
256. r Test 3 9 OUTPUT BIN TESTS Feed Test 3 10 Feed to All Bins 3 10 Sensor Tests 3 10 PRINT TESTS input source 3 5 Prt Quality Pgs 3 6 PRINTER SETUP Configuration ID 3 16 Defaults 3 15 Edge to Edge 3 16 Engine settings 3 16 Model Name 3 16 Page Count 3 15 Perm Page Count 3 15 Serial Number 3 16 REGISTRATION 3 21 DRAM memory test 3 7 duplex tests Quick Test 3 8 Sensor Test 3 8 E error code messages 2 5 error codes 200 00 sensor registration off jam too long 2 23 200 01 sensor registration static on jam 2 24 201 00 sensor fuser exit on jam 2 24 202 00 sensor fuser exit off jam 2 26 202 01 sensor fuser exit off too short jam 2 27 202 02 sensor fuser exit static jam 2 28 203 00 sensor exit 2 on jam 2 28 203 01 sensor exit 2 off jam 2 30 241 00 sensor pre feed on jam tray 1 feed 2 32 241 01 sensor registration on jam tray 1 feed 2 33 242 00 sensor pre feed on jam tray 2 feed 2 34 Index l 1 4024 110 242 01 sensor tray 2 feed out on jam tray 2 feed 2 36 242 02 sensor registration on jam tray 2 feed 2 38 242 03 sensor tray 2 feed out static jam 2 39 250 00 sensor registration on jam MPF pick 2 40 900 XX RIP card assembly software failure 2 41 903 00 RAM read write check failure 2 42 904 00 NVM data failure 2 42 905 00 NVM read write cannot be executed failure 2 43 906 00 CPU power to access NVM failure 2 43 907 00 RFID ASIC failure 2 44 908 00 PPM data failure 2 44
257. r cover See Rear motor cover removal on page 4 14 Open the printer left door assembly Remove the screw securing the bracket A to the printer Remove the bracket A Disconnect the connector from the switch printer left door interlock B Release the hooks securing the switch printer left door interlock B to the bracket A Remove the switch printer left door interlock B Connector L gt OER N MA Repair information 4 73 4024 110 Transfer roll guide assembly removal Open the printer left door assembly Remove the printer left door assembly See Printer left door support strap removal on page 4 71 Remove the transfer roll assembly See Transfer roll assembly removal on page 4 70 Release the two hooks securing the transfer roll guide assembly A to the printer left door assembly B Remove the transfer roll guide assembly A ORONT SG UTS BP EN EN ASS SN SNV RNS EE SS LSPA Ee we alin Hooks L LLP x eel ea 4 74 Printer Service Manual 4024 110 Printer left door assembly handle removal Sanyo eh S Open the printer left door assembly Remove the printer left door assembly See Printer left door support strap removal on page 4 71 Remove the transfer roll guide assembly See Transfer roll guide assembly removal on page 4 74
258. r interlock connection Replace the switch Replace the Is the switch printer left door interlock connected properly oie door conneclion Go to Switch printer left door interlock removal on page 4 73 4 Perform a print test Replace the Problem solved Does the error continue e Gad Go to Printer engine card assembly removal on page 4 119 Diagnostic information 2 69 4024 110 Printer left lower door open Step Check Yes No 1 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 2 Check the switch printer front door interlock for operation Go to step 4 Go to step 3 1 Enter Diagnostics mode 2 Select BASE SENSOR TESTS 3 Select Cover and Door 4 Select Door B left lower Open the printer front door assembly and check it Does the display on the operator panel change every time the switch actuator is operated 3 Check the switch printer left lower door interlock Replace the switch Replace the connection printer front door connection interlock Is the switch printer left lower door interlock properly connected Go to Switch printer front door interlock removal on page 4 5 4 Perform a print test Replace the Problem solved printer engine card Does the error continue assembly Go to Printer engine card assembly
259. re the media Replace the g i feed unit front sensor pre feed 1 Enter Diagnostics mode guide is installed 2 SelectI NPUT TRAY TESTS properly 3 Select Sensor test 4 Select Tray 2 G0 lo Step 9 5 Select Pre feed Remove the media tray assembly and check it Does the display on the operator panel change every time a white piece of paper is placed over the sensing area 8 Check the sensor pre feed connection Replace the Replace the Is the sensor pre feed properly connected sensor pre feed connection 9 Perform a print test Replace the Problem solved Does the error continue ae ER Go to Printer engine card assembly removal on page 4 119 Diagnostic information 2 37 4024 110 242 02 Sensor registration on jam tray 2 feed Step Check Yes No 1 Check the media condition Replace the media Go to step 2 Is the media in the tray crumpled or damaged age ensure 2 Check the media size setup Go to step 3 Replace the Does the media size in use match the size set for tray 2 eee ge setup 3 Check the roll for tray 2 Go to step 4 Clean or replace P the feed roll Remove tray 2 and check it separation roll Are the feed roll separation roll and pick roll free of excess and pick roll wear and contamination Go to Feed roll removal on page 4 42 Separation roll removal on page 4 46 and Pick roll removal on page 4 48 4 Check the med
260. removal on page 4 119 Scheduled maintenance required Step Check Yes No 1 Install the proper maintenance kit Reset the Problem solved Does the message still occur Ge E Go to Select Reset Maint Cnt from CONFIG MENU on page 6 2 2 70 Printer Service Manual Standard bin 1 full 4024 110 Step Check Yes No 1 Check the actuator for movement Go to step 2 Reinstall the Does the standard bin 1 full actuator move up and down ee SE normally i 2 Check the sensor standard bin full exit 1 for operation Go to step 5 Go to step 3 1 Enter Diagnostics mode 2 Select BASE SENSOR TESTS 3 SelectExit level 4 SelectStandard bin full exitl Does the display on the operator panel change every time the sensing area is blocked 3 Check the sensor standard bin full 1 connection Replace the Replace the Is the sensor standard bin full 1 properly connected iat PIERRE Go to step 4 Go to Sensor exit 1 bin full removal on page 4 109 4 Check the exit interface card assembly connection P432 Replace the exit Replace the P433 and P434 interface card connection a assembly Is the exit interface card assembly properly connected P432 P433 and P434 Go to Exit interface card assembly removal on page 4 117 5 Perform a print test Replace the Problem solved printer engine card Does the error continue assembly Go to Printer engine card assembly removal
261. ridge empty on page 2 72 900 XX RIP card assembly software A failure has occurred in the RIP card assembly Service RIP failure software software Go to 900 XX RIP card assembly software failure on page 2 41 903 00 RAM read write check failure Read write of RAM on the printer engine card Service assembly failed engine error Go to 903 00 RAM read write check failure on page 2 42 904 00 Service engine error NVM data failure A data error of NVM on the printer engine card assembly occurred Go to 904 00 NVM data failure on page 2 42 905 00 Service engine error NVM read write cannot be executed failure Read write of the NVM on the printer engine card assembly failed Go to 905 00 NVM read write cannot be executed failure on page 2 43 906 00 Service engine error CPU power to access NVM failure An internal process for data write of the NMVM on the printer engine card assembly failed Go to 906 00 CPU power to access NVM failure on page 2 43 907 00 Service engine error RFID ASIC failure The RFID control circuit failed Go to 907 00 RFID ASIC failure on page 2 44 908 00 Service engine error PPM data failure An incorrect NVM data is saved on the PPM Go to 908 00 PPM data failure on page 2 44 910 00 Service motor error Transport motor stop failure Due to the malfunction in the control system of th
262. ridge unit media Check area F exit is turned on Refer to Finisher Service Manual 288 01 Paper jam Check area F Sensor diverter gate Static jam to top bin A Paper remains on the sensor diverter gate when the finisher is in the upper bin exit mode At this time the sensor bridge unit media exit is turned on Refer to Finisher Service Manual 288 02 Paper jam Check areas Sensor diverter gate Static jam to top bin B Paper remains on the sensor diverter gate when the finisher is in the upper bin exit mode At this time the sensor finisher media entrance is turned on but the sensor bridge unit media exit is G2 G3 turned off Refer to Finisher Service Manual 288 03 Sensor diverter gate Static Paper remains on the sensor diverter gate when Paper jam jam to top bin C the finisher is in the upper bin exit mode At this time both sensor finisher media entrance SES arga and sensor bridge unit media exit are turned off Refer to Finisher Service Manual Diagnostic information 2 11 4024 110 2 12 Printer Service Manual Error code or Error contents Description Action message 288 04 Sensor diverter gate Static Paper remains on the sensor diverter gate when Paper jam jam to stacker bin A the finisher is in the stacker bin exit mode Check area F At this time the sensor bridge unit media exit is turned on Refer to Finisher Service
263. rinter showing main components directly associated with the media path and transport Main components associated with transport of media Exit 2 NI Duplex Duplex media transport roll ASM Duplex media Exit 2 media exit roll ASM Exit 2 media exit pinch rolls Exit 2 media transport roll ASM Exit 1 media exit roll ASM Exit 1 media exit pinch rolls Pressure roll Heat Roll center transport roll ASM KA Transfer roll ASM Duplex media Drum transport pinch roll Duplex media GC ER Ao pinch Vgl EE Registration roll ASM ASM MPF pick roll Q MPF p TRAY 1 Pick roll MPF Transport e z pinch roll m Z Feed roll MPF Transport Z roll ASM YP 5 ae y Media transport d L O La TTM pinch tol LA Tandem tray Transport CH TRAY 4 roll ASM See TRAY 3 Separation roll Tray 4 transport roll ASM 3 29 Diagnostic aids 4024 110 Functions of main components e Media tray assembly e Media feed unit assembly e MPF e Xerographics e Fuser e Drive e 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 Front media tray guide assembly and rear media guide The front media tray guide assembly can be adjusted to different media sizes by moving the guides to the front or rear These gui
264. rized lubricants may chemically attack polycarbonate parts Use IBM no 10 oil P N 1280443 Approved equivalents Mobil DTE27 Shell Tellus 100 Fuchs Renolin MR30 IBM no 23 grease Approved equivalent Shell Darina 1 and grease P N 99A0394 to lubricate appropriate areas Scheduled maintenance The operator panel displays the message 80 scheduled maintenance at each 300K page count interval It is necessary to replace the fuser assembly transfer roller and feed pick and separation rollers at this interval to maintain the print quality and reliability of the printer The parts are available as a maintenance kit with the following part numbers 40X0956 Maintenance Kit 110 V 40X0957 Maintenance Kit 220 V 40X0958 Maintenance Kit 100 V After replacing the kit the maintenance count must be reset to zero to clear the 80 scheduled maintenance message 1 Select Reset Maint Cnt from CONFIG MENU The message e Reset displays 2 Press to confirm the selection Press Back to return to the main Configuration menu without resetting the page counter When the reset operation is complete the menu returns to the Printer Setup Reset Maintenance Count screen When performing the 300K scheduled maintenance procedure the following areas should be cleaned of media dust and toner contamination e Media trays e PC cartridge area e Transfer roll area e Duplex area if equipped e Exit 2 area if equipped e Stand
265. ront 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 Slide the printer front door assembly A first to the right as shown by arrow 1 to remove the printer front door assembly A from the right hinge point Slide the printer front door assembly A to the left as shown by arrow 2 to remove the printer front door assembly A from the left hinge point Raise the printer front door assembly to its upright position and remove it _ of aA MS 4 8 Printer Service Manual 4024 110 Front door support strap and front door magnetic catch removal ROND Remove the printer front door assembly See Printer front door assembly removal on page 4 8 Remove the screw securing the front door support strap A to the printer front door assembly B Remove the front door support strap A Release the two hooks on the printer front door assembly securing the front door magnetic catch C Remove the front door magnetic catch C d Hooks Repair information 4 9 4024 110 Front inner cover removal Remove the top cover assembly See Top cover assembly removal on page 4 7 Remove the printer front door assembly See Printer front door assembly removal on page 4 8 Remove the
266. s No 1 Check the dual drive motor assembly installation Go to step 2 Install the PC Is the dual drive motor assembly properly installed cartridge properly Open the rear motor cover and check it 2 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 SelectTransport motor Does the motor rotate normally 3 Check the dual drive motor assembly connection Replace the dual Replace the i drive motor connection Is the dual drive motor assembly properly connected assembly 4 Perform a print test Replace the Problem solved printer engine card Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 Diagnostic information 2 45 4024 110 911 00 Transport motor failure Step Check Yes No 1 Check the dual drive motor assembly for operation Go to step 3 Go to step 2 Open the rear motor cover and check it 1 Enter Diagnostics mode 2 Select MOTOR TESTS 3 SelectTransport motor Does the motor rotate normally 2 Check the dual drive motor assembly for installation Go to step 3 Install the dual Remove the rear motor cover and check it See Is the dual drive motor assembly installed securely securely 3 Check the rotation of the rotor in the dual drive motor Go to step 4 Install the dual assembly drive motor
267. s while the test is running and the message Flash Test Testing displays Once the test is complete the power indicator turns on solid and either the message Flash Test Test Passed or Flash Test Test Failed displays Press Back or Stop to return to DEVICE TESTS PRINTER SETUP Defaults US Non US defaults changes whether the printer uses the US factory defaults or the non US factory defaults The settings affected include paper size envelope size PCL symbol set code pages and units of measure Warning Changing this setting resets the printer to factory defaults and data may be lost It cannot be undone Page Count The page count can only be viewed and cannot be changed To view the page count 1 Select PRINTER SETUP from DIAGNOSTICS 2 Select Page Count from PRINTER SETUP 3 Press Back to return to PRINTER SETUP Perm Page Count permanent page count The permanent page count can only be viewed and cannot be changed To view the permanent page count 1 Select PRINTER SETUP from DIAGNOSTICS 2 Select Perm Page Count from PRINTER SETUP 3 Press Back to return to PRINTER SETUP Diagnostic aids 3 15 4024 110 Serial Number The serial number can only be viewed and cannot be changed To view the serial number 1 Select PRINTER SETUP from DIAGNOSTICS 2 Select Serial number from PRINTER SETUP 3 Press Back to return to PRINTER SETUP Engine Setting 1 through 16 Warning
268. scanning speed becomes the sooner the scanning of the next row can be started Conceptual diagram of an image created by scanning Paper Path 600 dots inch SOS card ASM 600 sc LD card ASM 3 36 Printer Service Manual Printhead motor ans inch Polygon mirror Fuser 4024 110 Heat roll The heat roll is a hollow metal tube with a coated surface This tube is heated by the inner heater lamp The heat is applied to the media passing between the heat roll and pressure roll fusing the toner on the media Pressure roll The pressure roll is a metal shaft coated with sponge rubber Pressure is applied to the media between the pressure roll and heat roll pressing the melted toner against the media Heater lamp The heater rod of the lamp is compressed of a quartz glass tube containing a heater coil A terminal is mounted to the end of the heater rod via a harness Three heater lamps are provided the main heater rod to heat entire heat roll and the sub heater lamp 1 and 2 to heat the central portion of the heat roll Thermostat If the heat roll temperature exceeds the preset temperature the thermostat cuts off the circuits of the main heater rod and sub heater rods 1 and 2 Center thermistor The center thermistor monitors the surface temperature of the media feed portion of the heat roll to control on off of the main heater lamp and sub heater lamps 1 and 2 Rear thermistor The rear ther
269. ser unit A Repair information 4 103 4024 110 Exit 1 media shift assembly removal Remove the rear RIP card cover See Rear RIP card cover removal on page 4 125 Remove the rear motor cover See Rear motor cover removal on page 4 14 Remove the top rear cover See Top cover assembly removal on page 4 7 Open the printer left door assembly Remove the standard exit top cover See Standard exit 1 top cover removal on page 4 112 Open the printer front door assembly See Printer front door assembly removal on page 4 8 Remove the front left cover See Printer front left cover removal on page 4 3 Remove the two screws securing the bracket A Remove the bracket A by lifting it upward Remove the exit 1 drive belt See Exit 1 media shift assembly removal on page 4 104 Senor SSNS zech Note Disconnect the two connectors from the sensor exit 1 media shift and the sensor exit 1 bin full 4 104 Printer Service Manual 4024 110 Disconnect the two connectors from the exit 1 media shift assembly B Remove the two screws securing the exit 1 media shift assembly B to the printer Remove the exit 1 media shift assembly B by lifting it upward and outward in the direction of the arrow Remove the two screws securing the exit 1 media shift assembly B Remove the exit 1 media shift assembly B by lifting it upward and outward in the direct
270. so s teerefer ton VARNING Osynlig laserstralning n r denna del r ppnad och sp rren r urkopplad Betrakta ej str len Laser notis Denna skrivare r i USA certifierad att motsvara kraven i DHHS 21 CFR underparagraf J f r laserprodukter av Klass 1 andra l nder uppfyller skrivaren kraven f r laserprodukter av Klass enligt kraven i IEC 60825 1 Laserprodukter i Klass anses ej h lsov dliga Skrivaren har en inbyggd laser av Klass IIIb 3b som best r av en laserenhet av gallium arsenid p 5 milliwatt som arbetar i v gl ngdsomr det 770 795 nanometer Lasersystemet och skrivaren r utformade s att det aldrig finns risk f r att n gon person uts tts f r laserstr lning ver Klass l niv vid normal anv ndning underh ll som utf rs av anv ndaren eller annan f reskriven service tg rd Laser melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR underkapittel J for klasse 1 laserprodukter og er i andre land godkjent som et Klasse l laserprodukt i samsvar med kravene i IEC 60825 1 Klasse l laserprodukter er ikke betrakte som farlige Skriveren inneholder internt en klasse IIIb 3b laser som best r av en gallium arsenlaserenhet som avgir str ling i b lgelengdeomr det 770 795 nanometer Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstr ling ut over klasse l niv under vanlig bruk vedlikehold som utf res av brukeren eller foreskrevne serviceoperasjo
271. st Replace the Problem solved f printer engine card Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 Diagnostic information 2 65 4024 110 Paper is installed short edge in the media paper tray Step Check Yes No Is the media installed short edge orientation in the media tray assembly as opposed to long edge Turn media 90 degrees or enable short edge feeding which is found in the configuration menu press select and right arrow at power on and then find the menu item short edge printing Go to step 2 Perform a print test Does the error still occur Replace the printer engine card assembly Go to Printer engine card assembly removal on page 4 119 Problem solved PC cartridge end of life Step Check Yes No Check the PC cartridge for installation Is the PC cartridge installed securely Go to step 2 Install the PC cartridge securely Is the sensor RFID PC cartridge installed properly Go to step 4 Go to step 3 Check the sensor RFID PC cartridge connection Is the sensor RFID PC cartridge connected properly Replace the sensor RFID PC cartridge Go to Sensor RFID PC cartridge and sensor RFID toner cartridge removal on page 4 92 Connect P J126 and P J419 securely Perform a print test Does the error conti
272. ste producto se basa en pruebas y aprobaciones del dise o original y componentes espec ficos El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas La informaci n sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga el ctrica y de da os personales durante el desmontaje y la reparaci n de la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias PRECAUCI N este s mbolo indica que el voltaje de la parte del equipo con la que est trabajando es peligroso Antes de empezar desenchufe el equipo o tenga cuidado si para trabajar con l debe conectarlo Informa es de Seguran a xiv A seguran a deste produto baseia se em testes e aprova es do modelo original e de componentes espec ficos O fabricante n o respons vel pela segunran a no caso de uso de pe as de substitui o n o autorizadas As informa es de seguran a relativas a este produto destinam se a profissionais destes servi os e n o devem ser utilizadas por outras pessoas Risco de choques el ctricos e ferimentos graves durante a desmontagem e manuten o deste produto Os profissionais destes servi os devem estar avisados deste facto e tomar os cuidados necess rios CUIDADO Quando vir este s mbolo existe a poss vel presen a de uma potencial tens o perigosa na zo
273. stics Mode Diagnostic aids 3 1 4024 110 Diagnostics mode Entering Diagnostics mode 1 Press and hold w and gt 2 Turn on the printer 3 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 See MOTOR TESTS on page 3 5 Transport mtr Fuser cooling fan PC unit cooling fan Toner add mir Drum unit mtr Registrat clutch Tray 1 feed mtr Tray 2 feed mtr Tray 3 feed mtr Tray 4 feed mtr Tray 5 feed mtr MPF pick solenoid Transport clutch Duplex drv mtr Diverter solenoid Exit2 cooling fan Ev shift mtr Exit2 shift mtr Exit2 drive mtr PRINT TESTS Tray 1 See Input source tests on page 3 5 Tray 2 Tray 3 if installed Tray 4 if installed Tray 5 if installed MP Feeder Prt Quality Pgs See Print quality pages Prt Quality Pgs on page 3 6 3 2 Printer Service Manual 4024 110 Diagnostics mode tests continued HARDWARE TESTS Panel Test See Panel Test on page 3 6 Button Test See Button Test on page 3 6 DRAM Test See DRAM Test on page 3 7 CACHE Test DUPLEX TESTS if installed Quick Test See Quick Test duplex on page 3 8 Sensor Test See Sensor Test duplex on page 3 8
274. t continues until all of the printer processor s cache has been tested Once the maximum pass count or fail count is reached the test is stopped the power indicator is turned on solid and the final results display To stop this test before completion turn the printer off Diagnostic aids 3 7 4024 110 DUPLEX TESTS Only displayed if a duplex option is installed Quick Test duplex This test prints a duplex version of the Quick Test that can be used to verify that the correct placement of the top margin on the back side of a duplex page You can run one duplexed page Single or continue printing duplexed pages Continuous until Stop is pressed Make sure either Letter or A4 is loaded in the default paper source If the default source supports only envelopes then the Quick Test will be printed from Tray 1 To run the Quick Test duplex 1 Select DUPLEX TESTS from DIAGNOSTICS 2 Select Quick Test from DUPLEX TESTS 3 Select Single or Continuous e The single Duplex Quick test cannot be canceled es The printer attempts to print the Quick Test Page from the default paper source If the default paper source supports only envelopes then the page is printed from Tray 1 e Check the Quick Test Page for the correct offset between the placement of the first scan line on the front and back side of a duplexed sheet The single test stops automatically when a single duplex sheet is printed and the continuous test continues unt
275. t door assembly and check it securely Is the fuser unit assembly installed securely Go to Fuser unit assembly removal on page 4 103 4 Checking the roll Go to step 5 Clean or replace Open the printer left door assembly and check it See ia roll Is the transport roll assembly free of excess wear and G Fue o to Transfer contamination roll guide assembly removal on page 4 74 5 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 Fuser exit Open the printer left door assembly and check it A The area around the actuator is very hot Allow the fuser area to cool before proceeding Does the display on the operator panel change every time the sensor actuator is operated 6 Check the sensor fuser exit connection Replace the Replace the Is the sensor fuser exit properly connected sensor f ser exit connection Go to Sensor fuser exit removal on page 4 102 7 Perform a print test Replace the Problem solved printer engine card Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 Diagnostic information 2 27 4024 110 202 02 Sensor fuser exit static jam Step Check Yes No 1 Check the media position Remove the Go to step 2 Open the printer left door assembly and visually check it
276. t on While Demo Mode is set the printer will start in Demo Mode until you change the setting Warning While Demo Mode is set to Activate only demonstration files can print and files received across the network or from the host computer are ignored Factory Defaults This setting enables a user to restore all the printer settings to the original factory settings Selections are Restore Base and Restore Network Network does not appear unless you have a network printer The following settings are not changed e Display language e Settings in the NETWORK PORTS MENU group Warning Selecting to restore factory defaults may change personalized settings and some saved data may be lost Energy Conserve This menu controls what values appear on the Power Saver menu If Off is selected in Energy Conserve menu then Disabled appears in the Power Saver menu and Power Saver can be turned off If On is set in Energy Conserve the Power Saver feature cannot be disabled EVENT LOG The event log provides a history of printer errors The event log can only be printed in CONFIG MENU Additional options are available in DIAGNOSTICS See EVENT LOG on page 3 17 To print the event log 1 Select EVENT LOG from CONFIG MENU 2 Select Print Log from EVENT LOG Press Back or Stop to return to EVENT LOG Note An event log printed from the CONFIG MENU will not contain debug information or secondary codes for 900 service errors Ho
277. t this time the sensor fuser exit in the printer is in the on state Refer to Finisher Service Manual 281 01 Paper jam Check area F Sensor bridge unit media exit on jam B Sensor bridge unit media exit is not turned on within the specified time after the sensor bridge unit media entrance is turned on At this time the sensor bridge unit media entrance is in the on state Refer to Finisher Service Manual 281 02 Paper jam Check area F Sensor bridge unit media exit on jam C Sensor bridge unit media exit is not turned on within the specified time after the sensor bridge unit media entrance is turned on Refer to Finisher Service Manual 281 03 Paper jam Check area F Sensor bridge unit media exit Static jam A Paper remains on the sensor bridge unit media exit Refer to Finisher Service Manual 4024 110 Error code or Error contents Description Action message 282 00 Sensor finisher media Sensor finisher media entrance is not turned on Paper jam entrance on jam with the specified time after the sensor bridge unit Check area F media exit is turned on Refer to Finisher Service Manual 282 01 Paper jam Check areas F Sensor finisher media entrance Static jam A Paper remains on the sensor finisher media entrance At this time the sensor bridge unit media exit is turned on Refer to Finisher Service Manual 283 00
278. t was left from the previous print cycle At the beginning of each individual printer cycle the Printhead scans the surface of the drum further discharging any residual DC charge that may be left on the drum Charge roll Ground Diagnostic aids 3 51 4024 110 Safety system diagram Fuser cooling fan A Switch Switch Switch Printhead i PC Cartridge Printer front Printer left interlock door interlock door interlock SCANNER MOTOR ON SCANNER MOTOR CLOCK al Fuser j cooling fan control FUSER FAN ON FUSER FAN FAIL SVDC Fuser unit ASM e i l PC cartridge motor FUSER L Control Control L a 24VDC Switch main HENTER T Control L I Low Voltage c Generation 3 52 Printer Service Manual Print defects guide Match a set of repeating defects on a print job to the marks on one of the vertical lines The line that best matches the defects on the print job indicates which particular part is causing the defect Change the Change the photoconductor kit fuser For example the distance between these two marks represents a repeating defect that occurs every 44 mm 1 73 in which means the photoconductor kit needs replacing Change the transfer roller 58 7 mm 2 31 in
279. tely 41 kg 90 2 lbs and requires two or more trained personnel to lift it safely Make sure your fingers are not under the printer when you lift or set the printer down Parts removal and replacement procedures are described in this chapter Note Parts are controlled as spare parts When servicing parts for which no procedure is described observe the assembly before starting the service Note Though the optional parts are assumed to be removed they may not be removed if not required for the purpose of service Before starting service work CAUTION HOT SURFACE The inside of the printer might be hot To reduce the risk of injury from a hot component allow the surface to cool before touching Note A wide variety of screws are used make note of their positions during service 4 2 Printer Service Manual 4024 110 Printer front left cover removal Note First remove the exit 2 unit assembly if equipped Refer to the Options Service Manual 1 Open the printer front door assembly A 2 Remove the screw securing the front left cover B to the machine 3 Remove the front left cover B Repair information 4 3 4024 110 Top rear cover removal Remove the cable hookup cover Cable hookup door removal on page 4 13 Remove the two screws securing the rear motor cover A Open and remove the rear motor cover A Remove the screw securing the top rear cover B Remove the t
280. temperature Go to 956 01 RIP card assembly processor over temperature failure on page 2 63 956 02 Service system board RIP card assembly cooling fan failure The RIP card assembly cooling fan is not functioning properly Go to 956 02 RIP card assembly cooling fan failure on page 2 63 980 00 Service tray 3 comm Tray 3 4 communication failure A communication error occurred between the printer engine card assembly and the 2TM TTM controller card assembly Refer to Options Service Manual 980 01 Service tray 5 comm Tray 5 HCF communication failure A communication error occurred between the printer engine card assembly and the HCF controller card assembly Refer to Options Service Manual 980 02 Service finisher error Printer engine card finisher communication failure A communication error occurred between the printer engine card assembly and the finisher Refer to Finisher Service Manual 980 03 Service standard bin comm Exit interface card assembly communication failure A communication error occurred between the printer engine card assembly and the exit interface card assembly Go to 980 03 Exit interface card assembly communication failure on page 2 64 980 04 Service duplex comm Duplex controller card assembly communication failure A communication error occurred between the printer engine card assembly and t
281. tep 5 Replace the transfer roll assembly 5 Check the image development process Perform a print test Turn off the printer power while printing Carefully remove the PC cartridge and check the toner image formed on the drum before the transfer roll assembly Is the image completely formed on the drum and the area clear black and easily read Go to step 6 Go to step 7 6 Check the image transfer process Check the toner image formed on the drum after the transfer roll assembly passed Is the toner image completely transferred on the media Go to step 8 Go to step 7 7 Check the HVPS card assembly Replace the HVPS card assembly Perform a print test Does the error continue Go to step 8 Problem solved 2 98 Printer Service Manual 4024 110 Step Check Yes No Check the printer engine card assembly Replace the printer engine card assembly Perform a print test Does the error continue Replace the RIP card assembly Go to RIP card assembly removal on page 4 126 Problem solved Diagnostic information 2 99 4024 110 Skew Leading edge Trailing edge The printed image is not paralleled with both sides of the media Step Check Yes No 1 Check printer installation placement Go to step 2 Correct the Check the installation surface for irregularities dE Check for
282. 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 Remove the cable hookup door A aO N gt Boss Repair information 4 13 4024 110 Rear motor cover removal Remove the rear RIP card cover See Rear RIP card cover removal on page 4 125 Remove the two screws securing the rear motor cover A Open the rear motor cover A by swinging it outward in the direction of the arrow Remove the rear motor cover A Le gt 4 14 Printer Service Manual 4024 110 Rear lower cover removal 1 Remove the rear RIP card cover See Rear RIP card cover removal on page 4 125 2 Remove the rear motor cover See Rear motor cover removal on page 4 14 3 Remove the two screws securing the rear lower cover A 4 Remove the rear lower cover A Repair information 4 15 4024 110 Option hookup cover removal Remove the option hookup cover A from the rear lower cover B by moving it outward in the direction of the arrow 4 16 Printer Service Manual 4024 110 Switch media size removal Note This procedure can be applied to tray 1 or tray 2 switch media size Remove media Tray 1 and media Tray 2 Remove the screw securing the switch media size A to the bracket
283. the lower part of the toner cartridge guide assembly clogged 4 Check the toner add motor assembly for operation Go to step 6 Go to step 5 Warning Only perform this test in segments of three seconds or less or toner spill will occur Remove the top cover assembly and observe the toner add motor 1 Enter the Diagnostics Menu 2 Select MOTOR TESTS 3 Select Printer Motor Test 4 SelectToner add motor Note When performing this test the drum unit motor will also operate Does the motor rotate normally 5 Check the toner add motor assembly connection Replace the toner Replace the Is the toner add motor assembly properly connected ada motor connection Go to Toner cartridge guide assembly removal on page 4 93 6 Perform a print test Replace the Problem solved printer engine card Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 915 00 Fuser cooling fan failure Step Check Yes No 1 Check the fuser cooling fan for installation Go to step 2 Install the fuser f cooling fan Is the fuser cooling fan installed securely securely 2 Visually check the fuser cooling fan for rotation Go to step 5 Go to step 3 Is the fuser cooling fan visually rotating 2 48 Printer Service Manual 4024 110 Step Check Yes No 3 Check the fuser cooling fan for operation Go to step 5 Go to step 4 1 Enter Diag
284. the media tray assembly Properly load media in the media tray assembly Properly install the media tray assembly in the printer Re print the defective image Does the error continue 3 Check the media condition Go to step 4 Problem solved Load new dry recommended media Re print the defective image Does the error continue 4 Check the media transfer route Go to step 5 Remove debris r S d or Is the media path free of contamination or debris contamination 5 Check the drive rolls on the media transfer route Go to step 6 Replace PEE defective rolls Check all rolls on the transfer route for contamination Go to wear or damage applicable repair Are the pinch rolls rotating freely and spring pressure procedures for applied evenly replacement 6 Check the heat roll and the pressure roll Replace the Contact the i fuser unit technical Remove the fuser unit assembly assembly engineer Diagnostic information 2 101 4024 110 No fuse Trailing edge Step Check Yes No Check the fuser unit assembly installation Check that the levers on both sides of the fuser unit assembly are pushed down Re print the defective image Does the error continue Go to step 2 Problem solved Check the media condition Load new dry recommended media Re print the defective image Does the error continue Go to step 3 Problem solved Check the heat roll and the pressure roll Remove
285. the printhead assembly installed securely Ee securely 2 Check the printhead assembly connection Replace the Replace the Is the printhead assembly properly connected printhead connection 3 Perform a print test Replace the Problem solved Does the error continue E cae Go to Printer engine card assembly removal on page 4 119 4 Perform a print test Replace the RIP Problem solved Does the error continue card assembly Go to RIP card assembly removal on page 4 126 Diagnostic information 2 55 4024 110 932 00 Toner cartridge RFID data write failure Step Check Yes No 1 Check the toner cartridge installation Go to step 2 Install the toner Is the toner cartridge properly installed cartridge properly 2 Check the sensor RFID toner cartridge installation Go to step 3 Install the sensor Is the sensor RFID toner cartridge properly installed ee correctly 3 Check the sensor RFID toner cartridge connection Replace the Replace the Is the sensor RFID toner cartridge properly connected they earned Spnnecton 4 Perform a print test Replace the Problem solved Does the error continue Se card Go to Printer engine card assembly removal on page 4 119 933 00 Toner cartridge RFID communication failure Step Check Yes No 1 Check the toner cartridge installation Go to step 2 Install the toner Is the toner cartridge properly installed cartridge pr
286. the sensor exit 2 Remove the media Go to step 2 Do the exit 2 media exit roll assembly and the other gears rotate smoothly 2 Check the roll Go to step 3 Clean or replace the Open the exit 2 left door assembly iia i efer to Options i N Sei ede EEN roll assembly free of excess Service Manual 3 Check the drive power transmission Go to step 4 Replace damaged Do the exit 2 media transport roll assembly and the parts other gears rotate smoothly Refer to Options Service Manual 4 Check the roll Go to step 5 Clean or replace the Open exit 2 left door assembly SS S GE efer to Options aale a roll assembly free of excess wear Service Manual 5 Check the drive power transmission Go to step 6 Replace damaged parts Refer to Options Service Manual 2 30 Printer Service Manual 4024 110 Does the error still occur interface card assembly Go to Exit interface card assembly removal on page 4 117 Go to step 11 Step Check Yes No 6 Check the sensor exit 2 for proper operation Go to step 8 Go to step 7 1 Enter Diagnostics mode 2 Select BASE SENSOR TESTS 3 Select Media Path 4 Select Exit2 Does the display on the operator panel change every time the actuator on the above sensor operates 7 Check the sensor exit 2 for proper connection Replace the sensor Replace the Is the above sensor connected properly exit 2 ConnecHon R
287. tridge interlock removal zech of Noo care Remove the front left cover See Printer front left cover removal on page 4 3 Remove the top cover assembly See Top cover assembly removal on page 4 7 Remove the PC cartridge Remove the toner cartridge Remove the printer front door assembly See Printer front door assembly removal on page 4 8 Remove the front inner cover See Front inner cover removal on page 4 10 Remove the HVPS card assembly See High voltage power supply HVPS card removal on page 4 115 Remove the toner cartridge guide assembly See Toner cartridge guide assembly removal on page 4 93 Remove the rear lower cover See Rear lower cover removal on page 4 15 Disconnect the two connectors P403 and P404 from the printer engine card assembly A P404 Connectors A 11 Open the printer left door assembly 12 Remove the registration roll assembly See Registration roll assembly removal on page 4 76 4 82 Printer Service Manual 4024 110 13 Remove the two screws securing the laser opening guide B 14 Release the harness from the clamp on the laser opening guide B 15 Disconnect the connector from the laser opening guide B Repair information 4 83 4024 110 16 Remove the laser opening guide B by lifting it upward then outward in the direction of the arrow 17 Remove the four screws securing the P
288. trol thermistor does not detect the idling stop temperature even after the specified time is passed During print the control thermistor does not detect the specified temperature even when the specified time is passed after the main lamp is turned on During print the control thermistor does not detect the specified temperature even when the specified time is passed after the sub lamp is turned on Go to 920 00 Fuser unit assembly on time failure on page 2 51 921 00 Service fuser error Over heat temperature failure The control thermistor detects a temperature higher than the specified value The lamp change thermistor detects a temperature higher than the specified value Go to 921 00 Over heat temperature failure on page 2 51 922 00 Service fuser error Center thermistor failure The center thermistor has failed Go to 922 00 Center thermistor failure on page 2 52 923 00 Service fuser error Rear thermistor failure The rear thermistor has failed Go to 923 00 Rear thermistor failure on page 2 52 924 00 Service fuser error Pressure roll thermistor failure The pressure roll thermistor has failed Go to 924 00 Pressure roll thermistor failure on page 2 53 925 00 Service fuser error Fuser operating temperature failure Fuser temperature is not high enough during printing Go to 925 00 Fuser operating temperature fail
289. uch the driving units When operating the driving units using diagnostics or other tools be sure to follow the procedures in this manual Servicers should wear a wrist band or the like to remove static electricity from their body grounding their body while working Go to Handling ESD sensitive parts on page 4 1 Using service checks To determine the corrective action necessary to repair a printer look for the following information e Verify the installation status Go to Confirm the installation status on page 2 2 e Does POR power on reset stop Check the POR sequence Go to POR sequence on page 2 2 e Ifyou get an error code message go to Error code messages on page 2 5 eas For detailed information on specific error codes and error messages go to on page 2 22 e If you have an attendance messages refer to the User s Guide e Additional operator panel information go to Printer operator panel on page 2 3 Note There may be printer error messages that are not contained in this service manual Call your next level support for assistance Diagnostic information 2 1 4024 110 Confirm the installation status Be sure to check the following items before starting the troubleshooting procedures With the power cord unplugged from the wall outlet check that the cord is free from breakage short circuit disconnected wire or incorrect connection in the power cord The printer is prop
290. ure on page 2 53 927 00 PC cartridge RFID data write A data write error occurred on the PC cartridge Service PC failure RFID tag in the PC cartridge cartridge Go to 927 00 PC cartridge RFID data write failure on page 2 54 928 00 PC cartridge RFID A communication error occurred between the PC Service PC communication failure cartridge RFID tag in the PC cartridge and the RFID sartidae ASIC on the printer engine card assembly Go to 928 00 PC cartridge RFID communication failure on page 2 54 Diagnostic information 2 15 4024 110 Error code or Error contents Description Action message 929 00 Sensor ATC failure The sensor ATC failed Service PC Go to 929 00 Sensor ATC failure on cartridge page 2 54 930 00 Laser power failure Light intensity of the LD2 is less than the specified 8 value Service printhead Go to 930 00 Laser power failure on page 2 55 error 932 00 Toner cartridge RFID data A data write error occurred on the toner cartridge Taner write failure RFID tag in the toner cartridge cartridge Go to 932 00 Toner cartridge RFID data write failure on page 2 56 933 00 Toner cartridge RFID A communication error occurred between the toner Toner communication failure RFID tag in the toner cartridge and the RFID ASIC cartridge on the printer engine card assembly Go to 933 00 Toner cartridge RFID communication failure on pag
291. wever the event log printed from DIAGNOSTICS mode does include this information Paper Prompts When a tray is out of the indicated paper size a prompt is sent to the user to load paper in a tray This setting controls the tray the user is directed to fill Selections are Auto default MP Feeder and Manual Paper 3 24 Printer Service Manual 4024 110 Env Prompts This setting controls the tray the user is directed to refill when specific envelope size is out The selections are Auto default MP Feeder and Manual Env Jobs On Disk If the hard disk is installed Jobs On Disk allows the user to delete buffered jobs saved on the disk The values are Delete and Do Not Delete Disk Encryption If a hard disk is installed Disk Encryption selects whether the data on the disk is encrypted or not The values are Disable and Enable Warning Whenever this value is changed data on the hard disk is erased Font Sharpening This setting allows a user to set a text point size below which the high frequency screens are used when printing font data For example at the default 24 all text in font sizes 24 and less will use the high frequency screens The values for this setting range from 0 to 150 and the default value is 24 This setting affects PostScript PDF PCL and XL emulations To change the value 1 Select Font Sharpening from the CONFIG MENU 2 Use 4 to decrease the value and to increase the value 3 Select to acc
292. witch PC cartridge interlock Switch main power Switch printer front Switch door interlock printer left door interlock Fuser cooling fan RIP card ASM j D 1 switch printer left e i lower door interlock a Printer engine card ASM HVPS SY AC power input socket LVPS 3 42 Printer Service Manual Control Media size control Media tray assembly feeding 4024 110 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 Analog switch Digital Media size switch S W1 S W2 S W3 S W4 S W5 No media tray assembly off off off off off 5 5 x 8 5 SEF A5 SEF off off on off off B5 SEF off off on on on 8 5 x 13 SEF off on off on off 8 5 x 14 SEF off on off on on A4 SEF off on on off off 8 5 x 11 SEF off on on off on A4 LEF on off on off off A3 SEF on off on on off B5 LEF executive LEF on on off off on 8K SEF TFX GCO on on off on off B4 SEF on on off on on 8 5 x 11 LEF on on on off off 16K LEF TFX GCO on on on off on 11 x 17 LEF on on on on on Diagnostic aids 3 43 4024 110 Printhead control Rotation of printhead motor The on off control of
293. y 2 and replace the 1 Enter Diagnostics mode tray 1 motor with a 2 Select MOTOR TESTS MEMOS a 3 SelectTray 1 feed mtr Go to Media feed lift motor removal on Does the motor rotate normally page 4 30 10 Perform a print test Replace the printer Problem solved i engine card Does the error continue assembly Go to Printer engine card assembly removal on page 4 119 241 01 Sensor registration on jam tray 1 feed Step Check Yes No 1 Check the media condition Replace with new Go to step 2 Is the media in the tray crumpled or damaged a ernisure Itis 2 Check the media size setup Go to step 3 Replace the s SC media or change E ing size of media in use match the size set for the media size yrs setup 3 Check the rolls for tray 1 Go to step 4 Clean or replace the feed roll Remove and check tray 1 separation roll Are the feed roll separation roll and pick roll free of excess and pick roll wear and contamination Go to Feed roll removal on page 4 42 Separation roll removal on page 4 46 and Pick roll removal on page 4 48 4 Check the media position Remove the Go to step 5 Open the printer left door assembly and visually check it media Does the media touch the sensor registration or the sensor pre feed in tray 1 media feed unit assembly Diagnostic information 2 33 4024 110 Step Check Yes No 5 Check the sensor

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