Lexmark MS911 User manual

MS911
4021-230
Service Manual
•Start diagnostics
•Maintenance
•Safety and notices
•Trademarks
•Index
June 18, 2014 www.lexmark.com
P/N 12G3390

Product information
Product name:
Lexmark MS911
Machine type:
4021
Model(s):
230
Edition notice
June 18, 2014
The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL,
INC., PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED
TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. 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.
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.
Trademarks
Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other
countries.
PCL® is a registered trademark of the Hewlett-Packard Company.
All other trademarks are the property of their respective owners.
© 2014 Lexmark International, Inc.
All rights reserved.
P/N 12G3390
4021

Table of contents
Product information.....................................................................................2
Edition notice...............................................................................................2
Notices and safety information..................................................................19
Laser notices............................................................................................................................................19
Safety information...................................................................................................................................22
Preface.......................................................................................................25
Service manual conventions....................................................................................................................25
General information...................................................................................27
Paper and specialty media guide.............................................................................................................27
Using specialty media .......................................................................................................................................27
Paper guidelines ...............................................................................................................................................29
Supported paper sizes, types, and weights ......................................................................................................33
Data security notice.................................................................................................................................37
Tools required for service........................................................................................................................38
Diagnostic information...............................................................................39
Troubleshooting overview.......................................................................................................................39
Performing the initial troubleshooting check ...................................................................................................39
Fixing print quality issues........................................................................................................................39
Initial print quality check ..................................................................................................................................40
Gray background check ....................................................................................................................................40
Blank pages check .............................................................................................................................................43
Solid black pages check.....................................................................................................................................44
Shadow images check .......................................................................................................................................46
Skewed print check...........................................................................................................................................48
Streaked horizontal or vertical lines check ....................................................................................................... 49
Toner smear check............................................................................................................................................51
Toner specks check ...........................................................................................................................................52
Paper jams...............................................................................................................................................53
Avoiding jams....................................................................................................................................................53
Understanding jam messages and locations.....................................................................................................54
200 paper jams .................................................................................................................................................56
202 paper jams .................................................................................................................................................63
23y paper jams .................................................................................................................................................71
241–242 paper jams .........................................................................................................................................74
4021
Table of contents
3

243–245 paper jams .........................................................................................................................................85
Understanding the printer messages......................................................................................................99
Cartridge low [88.xy].........................................................................................................................................99
Cartridge nearly low [88.xy]..............................................................................................................................99
Cartridge very low [88.xy].................................................................................................................................99
Change [paper source] to [custom string] load [orientation].........................................................................100
Change [paper source] to [custom type name] load [orientation]................................................................. 100
Change [paper source] to [paper size] load [orientation] ..............................................................................100
Change [paper source] to [paper type] [paper size] load [orientation]..........................................................100
Close door [x]..................................................................................................................................................100
Complex page, some data may not have printed [39]....................................................................................100
Configuration change, some held jobs were not restored [57] ......................................................................101
Defective flash detected [51]..........................................................................................................................101
Disk full [62] ....................................................................................................................................................101
Disk must be formatted for use in this device ................................................................................................101
Disk near full. Securely clearing disk space.....................................................................................................101
Empty the hole punch box ..............................................................................................................................102
Error reading USB drive. Remove USB. ...........................................................................................................102
Error reading USB hub. Remove hub. .............................................................................................................102
Incorrect paper size, open [paper source] [34] ..............................................................................................102
Insert hole punch box .....................................................................................................................................102
Insert Tray [x]..................................................................................................................................................102
Insufficient memory for Flash Memory Defragment operation [37] .............................................................. 102
Insufficient memory to collate job [37] ..........................................................................................................103
Insufficient memory to support Resource Save feature [35].......................................................................... 103
Insufficient memory, some Held Jobs were deleted [37] ...............................................................................103
Insufficient memory, some held jobs will not be restored [37]......................................................................103
Insufficient space between paper stacks in Tray 3 .........................................................................................103
Load [paper source] with [custom string] [paper orientation] .......................................................................103
Load [paper source] with [custom type name] [paper orientation] ...............................................................103
Load [paper source] with [paper size] [paper orientation].............................................................................104
Load [paper source] with [paper type] [paper size] [paper orientation]........................................................104
Load Multipurpose Feeder with [custom string] [paper orientation].............................................................104
Load Multipurpose Feeder with [custom type name] [paper orientation] ....................................................104
Load Multipurpose Feeder with [paper size] [paper orientation] ..................................................................104
Load Multipurpose Feeder with [paper type] [paper size] [paper orientation] .............................................105
Load staples ....................................................................................................................................................105
Load staples [G11, G12]..................................................................................................................................105
[x] maintenance kit very low [80.xy]...............................................................................................................105
Memory full [38] .............................................................................................................................................105
Network [x] software error [54] .....................................................................................................................106
Not enough free space in flash memory for resources [52] ...........................................................................106
Open door H and remove paper from beneath area H10 ..............................................................................106
Paper changes needed....................................................................................................................................106
Parallel port [x] disabled [56]..........................................................................................................................106
4021
Table of contents
4

Photoconductor low [84.xy] ...........................................................................................................................106
Photoconductor very low [84.xy]....................................................................................................................106
Printer had to restart. Last job may be incomplete........................................................................................107
Reinstall missing or unresponsive cartridge [31.xy] .......................................................................................107
Reinstall missing or unresponsive photoconductor [31.xy]............................................................................107
Remove defective disk [61].............................................................................................................................107
Remove packaging material, [area name] ......................................................................................................107
Remove packaging material, open door C, remove metal clips......................................................................107
Remove paper from all bins............................................................................................................................107
Remove paper from bin [x] .............................................................................................................................108
Remove paper from [linked set bin name] .....................................................................................................108
Remove paper from standard output bin.......................................................................................................108
Replace cartridge, 0 estimated pages remain [88.xy].....................................................................................108
Replace cartridge, printer region mismatch [42.xy] .......................................................................................108
Replace [x] maintenance kit, 0 estimated pages remain [80.xy] ....................................................................109
Replace missing photoconductor [31.xy]........................................................................................................109
Replace missing waste toner bottle [82.xy]....................................................................................................109
Replace missing cartridge [31.xy] ...................................................................................................................109
Replace paper pick rollers in [paper source], use parts and instructions in tray 1 or tray 2
compartment [80] ......................................................................................................................................109
Replace photoconductor, 0 pages remain [84.xy] ..........................................................................................109
Replace unsupported cartridge [32.xy] ..........................................................................................................109
Replace unsupported photoconductor [32.xy]...............................................................................................109
Replace waste toner bottle [82.xy].................................................................................................................109
Restore held jobs? ..........................................................................................................................................110
Serial port [x] disabled [56].............................................................................................................................110
Some held jobs were not restored .................................................................................................................110
SMTP server not set up. Contact system administrator. ................................................................................110
Standard network software error [54]............................................................................................................110
Standard USB port disabled [56].....................................................................................................................110
Supply needed to complete job......................................................................................................................111
The device is operating in Safe Mode. Some print options may be disabled or provide unexpected
results.........................................................................................................................................................111
Too many flash options installed [58].............................................................................................................111
Too many trays attached [58].........................................................................................................................111
Tray [x] paper size unsupported .....................................................................................................................111
Unformatted flash detected [53]....................................................................................................................111
Unsupported disk............................................................................................................................................112
Unsupported option in slot [x] [55] ................................................................................................................112
Waste toner bottle nearly full [82.xy].............................................................................................................112
Weblink server not set up. Contact system administrator. ............................................................................112
User attendance messages....................................................................................................................112
User attendance messages (0‑99) ..................................................................................................................112
Cartridge or photoconductor error service check ..........................................................................................113
Mismatched paper size service check.............................................................................................................114
4021
Table of contents
5

Insufficient memory service check .................................................................................................................115
Complex page service check ...........................................................................................................................115
PPDS font error service check.........................................................................................................................116
Flash memory failure service check................................................................................................................116
Insufficient flash memory service check.........................................................................................................117
Network service check.................................................................................................................................... 118
Unsupported internal option service check....................................................................................................120
Disabled port service check ............................................................................................................................121
Unrestored held jobs service check ................................................................................................................121
Excess options service check ..........................................................................................................................122
Incompatible hardware option service check.................................................................................................123
Hard disk failure service check .......................................................................................................................123
Maintenance kit service check........................................................................................................................124
Printer hardware errors........................................................................................................................124
111 errors .......................................................................................................................................................125
12y errors........................................................................................................................................................126
13y errors........................................................................................................................................................131
153 errors .......................................................................................................................................................134
16y errors........................................................................................................................................................135
171–182 errors ............................................................................................................................................... 141
189 errors .......................................................................................................................................................142
19y errors........................................................................................................................................................144
600 errors .......................................................................................................................................................158
Steps before starting the 9yy service checks ..................................................................................................159
900 errors .......................................................................................................................................................161
911–963 errors ............................................................................................................................................... 166
Symptoms..............................................................................................................................................168
3000‑sheet tray tray set failure service check ................................................................................................168
Service menus..........................................................................................171
Understanding the printer control panel..............................................................................................171
Using the control panel...................................................................................................................................171
Understanding the colors of the Sleep button and indicator lights................................................................ 171
Understanding the home screen .................................................................................................................... 172
Using the touch-screen buttons .....................................................................................................................173
Menus list..............................................................................................................................................175
Diagnostics menu..................................................................................................................................175
Entering the Diagnostics menu.......................................................................................................................175
Reset Separator Roll and Pick Assembly Counter ...........................................................................................175
Reset Maintenance Counter ...........................................................................................................................176
Reset Fuser Counter ....................................................................................................................................... 176
REGISTRATION ................................................................................................................................................ 176
PRINT TESTS ....................................................................................................................................................176
4021
Table of contents
6

Print Quality Pages..........................................................................................................................................177
HARDWARE TESTS ..........................................................................................................................................177
DUPLEX TESTS .................................................................................................................................................179
INPUT TRAY TESTS ..........................................................................................................................................179
OUTPUT BIN TESTS .........................................................................................................................................180
SENSOR TESTS.................................................................................................................................................180
Motor Tests.....................................................................................................................................................182
DEVICE TESTS ..................................................................................................................................................183
PRINTER SETUP ...............................................................................................................................................184
REPORTS .........................................................................................................................................................186
EVENT LOG......................................................................................................................................................187
Exit Diags.........................................................................................................................................................187
Configuration menu..............................................................................................................................188
Entering the Configuration menu ...................................................................................................................188
Hole Punch Configuration...............................................................................................................................188
Reset Maintenance Counter ...........................................................................................................................188
USB Scan to Local............................................................................................................................................188
Print Quality Pages..........................................................................................................................................188
Reports ........................................................................................................................................................... 189
SIZE SENSING ..................................................................................................................................................189
Tray Linking.....................................................................................................................................................189
Panel Menus ................................................................................................................................................... 189
PPDS Emulation ..............................................................................................................................................190
Download Emuls .............................................................................................................................................190
Safe Mode.......................................................................................................................................................190
Energy Conserve .............................................................................................................................................190
Min Copy Memory ..........................................................................................................................................190
NumPad Job Assist..........................................................................................................................................191
Paper Prompts ................................................................................................................................................191
Envelope Prompts........................................................................................................................................... 191
Action for Prompts..........................................................................................................................................191
Jobs on Disk ....................................................................................................................................................191
Disk Encryption ...............................................................................................................................................192
Font Sharpening..............................................................................................................................................192
Require Standby..............................................................................................................................................192
UI Automation ................................................................................................................................................192
LES Applications ..............................................................................................................................................192
Key Repeat Initial Delay ..................................................................................................................................193
Key Repeat Rate..............................................................................................................................................193
Clear Supply Usage History .............................................................................................................................193
Clear Custom Status........................................................................................................................................193
USB Speed.......................................................................................................................................................193
Automatically Display Error Screens ............................................................................................................... 193
Restore factory defaults .................................................................................................................................194
Exit Config .......................................................................................................................................................194
4021
Table of contents
7

Entering Invalid engine mode................................................................................................................195
Entering Recovery Mode.......................................................................................................................195
Entering Safe Mode (EverReady Mode)................................................................................................195
Accessing the Network SE Menu...........................................................................................................195
Service Engineer menu..........................................................................................................................195
Accessing the Service Engineer (SE) Menu .....................................................................................................195
Service Engineer (SE) Menu ............................................................................................................................195
Repair information...................................................................................197
Removal precautions.............................................................................................................................197
Data security notice ........................................................................................................................................197
Handling ESD‑sensitive parts ..........................................................................................................................197
Restoring the printer configuration after replacing the controller board ......................................................198
Restoring solutions, licenses, and configuration settings ...............................................................................201
Updating the printer firmware ......................................................................................................................202
Backing up eSF solutions and settings ............................................................................................................203
Understanding the marked or colored screws ...............................................................................................204
Ribbon cable connectors ................................................................................................................................ 204
Zero Insertion Force (ZIF) connectors ........................................................................................................204
Horizontal top contact connector ..............................................................................................................205
Horizontal bottom contact connector........................................................................................................207
Vertical mount contact connector ............................................................................................................. 209
Horizontal sliding contact connector .........................................................................................................211
Low Insertion Force (LIF) connector...........................................................................................................213
Adjustments..........................................................................................................................................214
Fuser alignment adjustment ...........................................................................................................................214
Pick roller pressure adjustment ...................................................................................................................... 215
MPF separator roller pressure adjustment.....................................................................................................217
3000‑sheet tray pick roller pressure adjustment ...........................................................................................219
2500‑sheet tray transfer guide belt adjustment.............................................................................................221
Removal procedures.............................................................................................................................222
Left side removals.................................................................................................................................223
Left cover removal ..........................................................................................................................................223
Rear left cover removal ..................................................................................................................................224
Main power supply shield removal.................................................................................................................224
Main power supply fan removal .....................................................................................................................225
Main power supply removal ........................................................................................................................... 226
Printhead removal ..........................................................................................................................................226
Right side removals...............................................................................................................................228
Port access door removal ...............................................................................................................................228
Fuser connector cover removal ......................................................................................................................229
Fuser removal .................................................................................................................................................230
4021
Table of contents
8

Induction heater removal ...............................................................................................................................230
Registration transport assembly.....................................................................................................................231
Top side cover removal...................................................................................................................................232
Upper right cover removal..............................................................................................................................233
Redrive belt cover removal.............................................................................................................................233
Redrive belt removal.......................................................................................................................................234
Transfer roller removal ...................................................................................................................................234
Duplex transport assembly removal ...............................................................................................................235
Duplex transport jam removal knob removal.................................................................................................236
Duplex transport diverter assembly removal .................................................................................................237
Sensor (fuser exit) removal.............................................................................................................................238
Fuser exit sensor actuator removal ................................................................................................................238
Sensor (duplex pass through 1) removal ........................................................................................................239
Duplex pass through 1 actuator removal........................................................................................................240
Duplex transport belt removal........................................................................................................................242
Duplex transport gears removal .....................................................................................................................242
Motor (duplex transport) removal..................................................................................................................243
Right door lock removal..................................................................................................................................245
Tray 2 transport guide ....................................................................................................................................246
MPF removal...................................................................................................................................................247
MPF tray removal ...........................................................................................................................................248
Sensor (MPF paper length) removal ...............................................................................................................249
MPF feed clutch removal ................................................................................................................................250
MPF lift plate solenoid removal......................................................................................................................251
MPF gears removal .........................................................................................................................................252
Sensor (MPF lift plate) removal ......................................................................................................................253
Sensor (MPF empty) removal .........................................................................................................................255
MPF feed/separator assembly........................................................................................................................256
MPF lift plate assembly removal.....................................................................................................................258
MPF empty actuator removal......................................................................................................................... 259
Duplex transport guide removal .....................................................................................................................260
Registration unit latch assembly removal....................................................................................................... 260
Right door switch actuator removal ...............................................................................................................262
Right door removal .........................................................................................................................................262
Registration unit assembly removal ...............................................................................................................263
Registration unit sub-assembly removal ........................................................................................................265
Sensor (fusing speed) removal........................................................................................................................267
Fusing speed actuator removal.......................................................................................................................267
Sensor (duplex pass through 2) removal ........................................................................................................268
Registration unit belt removal ........................................................................................................................ 269
Registration unit gears removal......................................................................................................................270
Registration unit lock removal........................................................................................................................271
Front side removals...............................................................................................................................273
Top front door removal .................................................................................................................................. 273
Bottom front door removal ............................................................................................................................274
4021
Table of contents
9

Front inner cover removal ..............................................................................................................................274
Waste toner door mount removal..................................................................................................................275
Image controller board removal .....................................................................................................................275
Door switch removal.......................................................................................................................................276
Main power switch removal ...........................................................................................................................277
Sensor (top front door) removal.....................................................................................................................278
Motor (toner supply) removal ........................................................................................................................279
Waste toner drive removal .............................................................................................................................280
Sensor (toner cartridge present) removal ......................................................................................................281
Toner agitator removal ...................................................................................................................................282
Developer unit removal ..................................................................................................................................283
Right door switch removal.............................................................................................................................. 284
Speaker cover removal ................................................................................................................................... 284
Rear side removals................................................................................................................................286
Scanner interface cable cover removal ..........................................................................................................286
Controller board access cover removal ..........................................................................................................287
Input options interface cover removal ...........................................................................................................288
Engine board cover removal ...........................................................................................................................289
Upper rear cover removal...............................................................................................................................289
IHPS shield removal ........................................................................................................................................290
Induction heater magnetic erase board (IHMEB) removal .............................................................................291
Induction heater power supply (IHPS) removal..............................................................................................293
Noise filter board removal..............................................................................................................................293
Expansion controller board removal ..............................................................................................................294
Power‑saving board removal..........................................................................................................................295
Engine controller board removal ....................................................................................................................296
Hard drive removal .........................................................................................................................................297
Controller board removal ...............................................................................................................................298
Motor (fuser pressure) removal .....................................................................................................................298
Paper exit fan duct removal............................................................................................................................299
Paper exit fan removal....................................................................................................................................300
IHPS frame removal ........................................................................................................................................300
Fuser power supply fan removal ....................................................................................................................301
Motor (toner cartridge) removal ....................................................................................................................302
Motor (redrive) removal .................................................................................................................................304
Controller board frame removal.....................................................................................................................305
Controller board fan removal .........................................................................................................................306
Motor (transport) removal ............................................................................................................................. 307
Motor (developer) removal ............................................................................................................................308
High voltage board removal ...........................................................................................................................309
Motor (registration) removal..........................................................................................................................310
Motor (feed) removal .....................................................................................................................................312
Tray 2 transport drive removal .......................................................................................................................313
Motor (tray 2 transport) removal ...................................................................................................................314
Feed drive assembly removal .........................................................................................................................315
4021
Table of contents
10

Sensor (tray 1 and 2 paper temperature) removal.........................................................................................316
Ozone fan removal..........................................................................................................................................316
Ozone fan duct removal .................................................................................................................................318
Main drive assembly removal.........................................................................................................................319
Center cable guide bracket removal...............................................................................................................321
Toner cartridge drive assembly removal ........................................................................................................322
Duplex transport clutch removal ....................................................................................................................323
Motor (fuser) removal ....................................................................................................................................324
Fuser drive gearbox removal ..........................................................................................................................325
Toner suction fan removal..............................................................................................................................327
Top side removals.................................................................................................................................329
Standard bin base removal .............................................................................................................................329
Transfer belt fan removal ...............................................................................................................................329
Bin side cover removal....................................................................................................................................330
2500-sheet tray removals......................................................................................................................331
2500-sheet tray caster wheel removal ........................................................................................................... 331
2500-sheet tray controller board removal .....................................................................................................332
2500-sheet tray LED cover removal................................................................................................................332
2500-sheet tray front right cover removal .....................................................................................................333
2500-sheet tray left cover removal ................................................................................................................333
2500-sheet tray lower right cover removal ....................................................................................................334
2500-sheet tray empty LED removal ..............................................................................................................334
2500-sheet tray rear cover removal ...............................................................................................................335
2500-sheet tray rear right cover removal.......................................................................................................335
2500‑sheet tray division board removal.........................................................................................................336
2500‑sheet tray empty sensor actuator removal ...........................................................................................337
2500‑sheet tray elevator home sensor actuator removal ..............................................................................338
2500‑sheet tray transfer guide stop removal .................................................................................................339
2500‑sheet reserve tray paper limit sensor actuator removal .......................................................................340
2500‑sheet tray vertical media transport guide assembly removal ...............................................................340
2500‑sheet tray transport roller removal .......................................................................................................341
2500-sheet tray jam access cover removal.....................................................................................................343
2500-sheet tray jam access door strap removal.............................................................................................344
2500-sheet tray paper feed assembly removal .............................................................................................. 344
2500-sheet tray pick assembly removal .........................................................................................................345
2500-sheet tray paper stack transfer guide removal......................................................................................346
2500-sheet reserve tray empty sensor actuator removal ..............................................................................347
2500‑sheet tray stopper removal ...................................................................................................................348
Motor (2500‑sheet tray elevator) removal.....................................................................................................349
Motor (2500‑sheet tray feed) removal...........................................................................................................349
Motor (2500‑sheet tray transfer guide) removal ...........................................................................................350
Motor (2500‑sheet tray transport) removal...................................................................................................351
Sensor (2500‑sheet tray jam access door) removal........................................................................................352
Sensor (2500‑sheet paper stack transfer) removal ........................................................................................353
4021
Table of contents
11

Sensor (2500‑sheet tray elevator home) removal..........................................................................................353
Sensor (2500‑sheet tray main tray empty, bottom) removal.........................................................................354
Sensor (2500‑sheet tray main tray near empty) removal...............................................................................355
Sensor (2500‑sheet tray main tray paper empty, top) removal .....................................................................355
Sensor (2500‑sheet tray main tray elevator limit) removal............................................................................356
Sensor (2500‑sheet tray feed) removal ..........................................................................................................356
Sensor (2500‑sheet tray reserve tray empty) removal...................................................................................357
Sensor (2500‑sheet tray reserve tray paper limit) removal............................................................................358
Sensor (2500‑sheet tray transport) removal .................................................................................................. 359
2 x 500-sheet tray removals..................................................................................................................360
Sensor (2 x 500-sheet tray jam access door) removal ....................................................................................360
2 x 500-sheet tray caster wheel removal........................................................................................................361
Printer rubber stopper removal......................................................................................................................361
Tray insert paper length guide removal..........................................................................................................362
Tray lock removal............................................................................................................................................364
2 x 500-sheet tray rollers removal..................................................................................................................366
Sensor (2 x 500-sheet tray paper length) removal .........................................................................................366
2 x 500-sheet tray left cover removal.............................................................................................................368
2 x 500-sheet tray empty LED cover removal .................................................................................................368
2 x 500-sheet tray empty LED removal...........................................................................................................369
2 x 500-sheet tray empty LED mount removal ...............................................................................................369
2 x 500-sheet tray rear cover removal............................................................................................................370
Motor (2 x 500-sheet tray lift) removal ..........................................................................................................370
Sensor (2 x 500-sheet tray near empty) removal ...........................................................................................371
Sensor (2 x 500-sheet tray paper width) removal ..........................................................................................372
2 x 500-sheet tray feed and transport motors removal .................................................................................373
2 x 500-sheet tray controller board removal..................................................................................................374
2 x 500-sheet tray jam access door removal ..................................................................................................375
2 x 500-sheet tray rear right cover removal ...................................................................................................376
2 x 500-sheet tray bottom right cover removal..............................................................................................377
2 x 500-sheet tray 3 transport assembly removal ..........................................................................................377
2 x 500-sheet tray 4 transport assembly removal ..........................................................................................378
2 x 500-sheet tray transport assembly sensors removal ................................................................................379
2 x 500‑sheet tray tray set actuator removal .................................................................................................380
Sensor (2 x 500-sheet tray transport) removal...............................................................................................381
2 x 500-sheet tray 3 transport belts and gears removal.................................................................................382
2 x 500-sheet tray 4 transport belts and gears removal.................................................................................383
3000-sheet tray removals......................................................................................................................385
3000-sheet tray rollers removal .....................................................................................................................385
3000-sheet tray feed and pick belt removal ...................................................................................................387
3000-sheet tray caster wheel removal ........................................................................................................... 389
3000-sheet tray release handle removal ........................................................................................................390
3000-sheet tray left cover removal ................................................................................................................391
3000-sheet tray right cover removal ..............................................................................................................392
4021
Table of contents
12

3000-sheet tray front cover removal..............................................................................................................392
3000-sheet tray rear cover removal ...............................................................................................................393
3000-sheet tray door removal ........................................................................................................................394
3000-sheet tray left top cover removal ..........................................................................................................395
Dehumidifier removal .....................................................................................................................................396
3000-sheet tray empty LED removal ..............................................................................................................397
Sensor (3000-sheet tray empty) removal .......................................................................................................397
Sensor (3000-sheet tray elevator level) removal............................................................................................398
Sensor (3000-sheet tray feed) removal ..........................................................................................................399
3000-sheet tray elevator spring removal........................................................................................................400
3000-sheet tray controller board removal .....................................................................................................400
3000-sheet tray door switch removal.............................................................................................................401
Motor (3000-sheet tray elevator) removal.....................................................................................................402
3000-sheet tray set sensor actuator removal.................................................................................................402
Sensor (3000-sheet tray set) removal.............................................................................................................403
Sensor (3000-sheet tray near empty) removal...............................................................................................404
Motor bracket removal................................................................................................................................... 406
3000-sheet tray feed and transport motors removal .....................................................................................406
3000-sheet tray feed roller assembly removal ...............................................................................................407
3000-sheet tray pick roller assembly removal................................................................................................410
Component locations...............................................................................415
Exterior locations..................................................................................................................................415
Front view .......................................................................................................................................................415
Rear view ........................................................................................................................................................417
Maintenance............................................................................................419
Inspection guide....................................................................................................................................419
Scheduled maintenance........................................................................................................................420
Maintenance kits ............................................................................................................................................420
Resetting the maintenance counter ...............................................................................................................421
Lubrication specification.......................................................................................................................421
Cleaning printer parts............................................................................................................................421
Cleaning the printer ........................................................................................................................................421
Cleaning the charger and the printhead lens .................................................................................................422
Emptying the hole punch box .........................................................................................................................424
Parts catalog............................................................................................426
Legend...................................................................................................................................................426
Assembly 1: Covers 1.............................................................................................................................427
Assembly 2: Covers 2.............................................................................................................................429
Assembly 3: Covers 3.............................................................................................................................431
4021
Table of contents
13

Assembly 4: Inner covers.......................................................................................................................433
Assembly 5: Control panel.....................................................................................................................435
Assembly 6: Printhead...........................................................................................................................437
Assembly 7: Toner supply 1...................................................................................................................439
Assembly 8: Toner supply 2...................................................................................................................441
Assembly 9: Waste toner......................................................................................................................443
Assembly 10: Developer........................................................................................................................445
Assembly 11: Photoconductor lock.......................................................................................................447
Assembly 12: Transfer belt....................................................................................................................449
Assembly 13: Tray 1 and 2 transport.....................................................................................................451
Assembly 14: Tray 1 feed......................................................................................................................453
Assembly 15: Tray 1 separator..............................................................................................................455
Assembly 16: Tray 2 feed......................................................................................................................457
Assembly 17: Tray 2 separator..............................................................................................................459
Assembly 18: Tray rail...........................................................................................................................461
Assembly 19: Tray paper detection.......................................................................................................463
Assembly 20: Tray insert 1....................................................................................................................465
Assembly 21: Tray insert 2....................................................................................................................467
Assembly 22: Tray insert 3....................................................................................................................469
Assembly 23: Registration transport.....................................................................................................471
Assembly 24: Transfer...........................................................................................................................473
Assembly 25: Registration unit..............................................................................................................475
Assembly 26: Right door transport........................................................................................................477
Assembly 27: MPF 1..............................................................................................................................479
Assembly 28: MPF 2..............................................................................................................................481
Assembly 29: Duplex 1..........................................................................................................................483
Assembly 30: Duplex 2..........................................................................................................................485
Assembly 31: Fuser................................................................................................................................487
Assembly 32: Exit 1................................................................................................................................489
Assembly 33: Exit 2................................................................................................................................491
Assembly 34: Main and feed drive........................................................................................................493
Assembly 35: Toner cartridge drive.......................................................................................................495
Assembly 36: Fuser drive 1....................................................................................................................497
Assembly 37: Fuser drive 2....................................................................................................................499
Assembly 38: Ozone duct......................................................................................................................501
Assembly 39: High voltage....................................................................................................................503
Assembly 40: Main power supply.........................................................................................................505
4021
Table of contents
14

Assembly 41: Electrical 1.......................................................................................................................507
Assembly 42: Electrical 2.......................................................................................................................509
Assembly 43: 2 x 500‑sheet tray—Covers.............................................................................................511
Assembly 44: 2 x 500‑sheet tray—Frame..............................................................................................513
Assembly 45: 2 x 500‑sheet tray—Paper feed......................................................................................515
Assembly 46: 2 x 500‑sheet tray—Paper size detection.......................................................................517
Assembly 47: 2 x 500‑sheet tray—Paper transport..............................................................................519
Assembly 48: 2 x 500‑sheet tray—Paper pick 1....................................................................................521
Assembly 49: 2 x 500‑sheet tray—Paper pick 2....................................................................................523
Assembly 50: 2 x 500‑sheet tray—Paper pick 3....................................................................................525
Assembly 51: 2 x 500‑sheet tray—Tray 3..............................................................................................527
Assembly 52: 2 x 500‑sheet tray—Tray 4..............................................................................................529
Assembly 53: 2 x 500‑sheet tray—Tray 3 or Tray 4 frame....................................................................531
Assembly 54: 3000‑sheet tray—Covers................................................................................................533
Assembly 55: 3000‑sheet tray—Frame 1..............................................................................................535
Assembly 56: 3000‑sheet tray—Frame 2..............................................................................................537
Assembly 57: 3000‑sheet tray—Elevator front section.........................................................................539
Assembly 58: 3000‑sheet tray—Paper feed 1.......................................................................................541
Assembly 59: 3000‑sheet tray—Paper feed 2.......................................................................................543
Assembly 60: 3000‑sheet tray—Paper transport..................................................................................545
Assembly 61: 3000‑sheet tray—Elevator rear section..........................................................................547
Assembly 62: 3000‑sheet tray—Drive section......................................................................................549
Assembly 63: 3000‑sheet tray—Wiring.................................................................................................551
Assembly 64: 2500-sheet tray covers....................................................................................................553
Assembly 65: 2500-sheet tray frame....................................................................................................555
Assembly 66: 2500-sheet tray paper feed.............................................................................................557
Assembly 67: 2500-sheet tray paper transport.....................................................................................559
Assembly 68: 2500-sheet tray paper pick 1..........................................................................................561
Assembly 69: 2500-sheet tray paper pick 2..........................................................................................563
Assembly 70: 2500-sheet tray paper pick 3..........................................................................................565
Assembly 71: 2500-sheet tray insert 1..................................................................................................567
Assembly 72: 2500-sheet tray insert 2..................................................................................................569
Assembly 73: 2500-sheet tray insert 3..................................................................................................571
Assembly 74: 2500-sheet tray insert 4..................................................................................................573
Assembly 75: Maintenance kits.............................................................................................................575
Assembly 76: Miscellaneous.................................................................................................................577
4021
Table of contents
15

Appendix A: Printer specifications............................................................579
Power consumption..............................................................................................................................579
Product power consumption ..........................................................................................................................579
Sleep Mode .....................................................................................................................................................579
Hibernate Mode..............................................................................................................................................579
Off mode.........................................................................................................................................................580
Total energy usage..........................................................................................................................................580
Operating clearances.............................................................................................................................580
Noise emission levels............................................................................................................................581
Temperature information.....................................................................................................................581
Appendix B: Options and features............................................................583
Available internal options.....................................................................................................................583
Media handling options.........................................................................................................................583
Appendix C: Theory of operation..............................................................585
POR sequence.......................................................................................................................................585
Printer control.......................................................................................................................................585
Print cycle operation.............................................................................................................................585
Flowchart ........................................................................................................................................................585
Charge.............................................................................................................................................................586
Expose.............................................................................................................................................................586
Develop...........................................................................................................................................................586
First transfer ...................................................................................................................................................587
Clean (photoconductor)..................................................................................................................................588
Second transfer...............................................................................................................................................589
Clean (transfer belt)........................................................................................................................................589
Fuse.................................................................................................................................................................590
Printer operation...................................................................................................................................592
Printer paper path ..........................................................................................................................................592
Tray section..................................................................................................................................................... 592
MPF section ....................................................................................................................................................595
2500‑sheet tray section ..................................................................................................................................597
3000‑sheet tray section ..................................................................................................................................600
Registration section ........................................................................................................................................603
Print section....................................................................................................................................................604
Exit section......................................................................................................................................................605
Duplex section ................................................................................................................................................607
Appendix D: Acronyms.............................................................................611
Acronyms...............................................................................................................................................611
4021
Table of contents
16

Index........................................................................................................613
Part number index...................................................................................623
Part name index.......................................................................................639
4021
Table of contents
17

4021
Table of contents
18

Notices and safety information
Laser notices
Laser notice
The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR, Chapter I, Subchapter J for Class I
(1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.
Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (3b) laser that is
nominally a 15‑milliwatt laser operating in the wavelength of 787–800 nanometers. The laser system and printer are
designed so there is never any human access to laser radiation above a Class I level during normal operation, user
maintenance, or prescribed service condition.
Laser-Hinweis
Der Drucker wurde in den USA zertifiziert und entspricht den DHHS-Vorschriften 21 CFR, Kapitel I, Unterkapitel J für
Laserprodukte der Klasse I (1); andernorts ist er als Laserprodukt der Klasse I zertifiziert, das den IEC 60825-1-
Anforderungen entspricht.
Laserprodukte der Klasse I werden nicht als gefährlich eingestuft. Der Drucker enthält im Inneren einen Laser der
Klasse IIIb (3b), und zwar einen 15-Milliwatt-Laser, der im Wellenlängenbereich von 787 bis 800 Nanometern arbeitet.
Das Lasersystem und der Drucker sind so konstruiert, dass unter normalen Betriebsbedingungen, bei der Wartung durch
den Benutzer oder bei den vorgeschriebenen Wartungsbedingungen Menschen keiner Laserstrahlung ausgesetzt sind,
die die Werte für Klasse I überschreitet.
Avis relatif à l'utilisation du laser
L'imprimante est certifiée conforme aux exigences de la réglementation des Etats-Unis relative aux produits laser (DHHS
21 CFR, Chapter I, Subchapter J for Class I (1)). Pour les autres pays, elle est certifiée conforme aux exigences des normes
IEC 60825-1 relatives aux produits laser de classe I.
Les produits laser de Classe I ne sont pas considérés comme dangereux. L'imprimante contient un laser de classe IIIb
(3b), laser 15 milliwatts opérant sur une longueur d'onde de l'ordre de 787 à 800 nanomètres. Le système laser ainsi
que l'imprimante ont été conçus de manière à ce que personne ne soit exposé à des rayonnements laser dépassant le
niveau de classe I dans le cadre d'un fonctionnement normal, de l'entretien par l'utilisateur ou de la maintenance.
Avvertenze sui prodotti laser
La stampante è certificata negli Stati Uniti come stampante conforme ai requisiti DHHS 21 CFR, Capitolo I, Sottocapitolo
J per i prodotti laser di Classe I (1), mentre in altri paesi è certificata come prodotto laser di Classe I conforme ai requisiti
IEC 60825-1.
I prodotti laser di Classe I non sono considerati pericolosi. La stampante contiene un laser di Classe IIIb (3b), che è
nominalmente un laser a 15 milliwatt funzionante a una lunghezza d'onda di 787–800 nanometri. Il sistema laser e la
stampante sono stati progettati in modo da impedire l'esposizione a radiazioni laser superiori al livello previsto dalla
Classe I durante le normali operazioni di stampa, manutenzione o assistenza.
4021
Notices and safety information
19

Aviso de láser
Esta impresora se ha certificado en EE. UU. de conformidad con los requisitos de DHHS 21 CFR, capítulo I, subcapítulo
J, para los productos láser de Clase I (1), y en otros países está certificada como un producto láser de Clase I de acuerdo
con los requisitos de IEC 60825-1.
Los productos láser de Clase I no se consideran peligrosos. La impresora contiene un láser interno de Clase IIIb (3b) que
nominalmente es un láser de 15 milivatios que funciona en una longitud de onda de 787–800 nanómetros. El sistema
láser y la impresora se han diseñado para que ningún individuo acceda nunca a las radiaciones láser por encima del
nivel de Clase I durante su uso normal, ni en tareas de mantenimiento o intervenciones de servicio técnico prescritas.
Aviso sobre laser
A impressora foi certificada nos EUA por estar em conformidade com os requisitos do DHHS 21 CFR, capítulo I,
subcapítulo J, para produtos a laser de Classe I (1) e, nos demais países, foi certificada como produto a laser de Classe
I em conformidade com os requisitos da IEC 60825-1.
Os produtos a laser de Classe I não são considerados perigosos. A impressora contém, internamente, um laser de Classe
IIIb (3b) que é um laser de 15 miliwatts operando no comprimento de onda de 787–800 nanômetros. O sistema do
laser e a impressora foram projetados para que jamais haja acesso humano à radiação do laser acima do nível da Classe
I durante a operação normal ou a manutenção pelo usuário ou sob as condições de manutenção prescritas.
Laserinformatie
Deze printer is in de Verenigde Staten gecertificeerd als een product dat voldoet aan de vereisten van DHHS 21 CFR,
hoofdstuk 1, paragraaf J voor laserproducten van klasse I (1). Elders is de printer gecertificeerd als een laserproduct
van klasse I dat voldoet aan de vereisten van IEC 60825-1.
Laserproducten van klasse I worden geacht geen gevaar op te leveren. De printer bevat intern een laser van klasse IIIb
(3b), met een nominaal vermogen van 15 milliwatt en een golflengtebereik van 787–800 nanometer. Het lasersysteem
en de printer zijn zodanig ontworpen dat gebruikers nooit blootstaan aan laserstraling die hoger is dan het toegestane
niveau voor klasse I-apparaten, tijdens normaal gebruik, onderhoudswerkzaamheden door de gebruiker of
voorgeschreven servicewerkzaamheden.
Lasererklæring
Denne printer er certificeret i USA i henhold til kravene i DHHS 21 CFR, afsnit I, underafsnit J, for Klasse I-laserprodukter
(1) og certificeret andetsteds som et Klasse I-laserprodukt i henhold til kravene i IEC 60825-1.
Klasse I-laserprodukter anses ikke for at være farlige. Printeren indeholder internt en klasse IIIb (3b)-laser, der nominelt
er en 15 milliwatt laser, som fungerer i bølgelængdeområdet 787–800 nanometer. Lasersystemet og printeren er
udviklet på en sådan måde, at der ikke er en direkte laserstråling, der overskrider Klasse I-niveauet under normal brug,
brugers vedligeholdelse eller de foreskrevne servicebetingelser.
Laserilmoitus
Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR, Chapter I, Subchapter J -standardin mukaiseksi luokan I (1) -
lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi.
Luokan I lasertuotteita ei pidetä haitallisina. Tulostimen sisällä on luokan IIIb (3b) laser, joka on nimellisteholtaan 15
mW:n laser ja toimii 787–800 nanometrin aallonpituuksilla. Laserjärjestelmä ja tulostin ovat rakenteeltaan sellaisia,
että käyttäjä ei joudu alttiiksi luokkaa 1 suuremmalle säteilylle normaalin käytön, ylläpidon tai huollon aikana.
4021
Notices and safety information
20