Service Manual
Page 8
... voltage power supply 5-10 Output expander control board 5-11 StapleSmart finisher 5-12 Preventive maintenance 6-1 Safety inspection guide 6-1 Lubrication specifications 6-1 Scheduled maintenance 6-1 Maintenance kit 6-1 Parts catalog 7-1 How to use this parts catalog 7-1 Assembly 1: Covers 7-2 Assembly 2: Frame 1 7-4 Assembly 3: Frame 2 7-6 Assembly 4: Frame 3 7-8 Assembly 5: Printhead 7-10 Assembly 6: Paper feed-autocompensator 7-12 Assembly 7: Paper feed-multipurpose feeder 7-14 Assembly...
... voltage power supply 5-10 Output expander control board 5-11 StapleSmart finisher 5-12 Preventive maintenance 6-1 Safety inspection guide 6-1 Lubrication specifications 6-1 Scheduled maintenance 6-1 Maintenance kit 6-1 Parts catalog 7-1 How to use this parts catalog 7-1 Assembly 1: Covers 7-2 Assembly 2: Frame 1 7-4 Assembly 3: Frame 2 7-6 Assembly 4: Frame 3 7-8 Assembly 5: Printhead 7-10 Assembly 6: Paper feed-autocompensator 7-12 Assembly 7: Paper feed-multipurpose feeder 7-14 Assembly...
Service Manual
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...failing field replaceable units (FRUs). 3. Diagnostic aids contains tests and checks used to perform the task. Parts catalog contains illustrations and part numbers for making printer adjustments and removing and installing FRUs. 5. Warning: A warning identifies something that might cause a servicer... symbol, there is divided into the following chapters: 1. xx Service Manual General information contains a general description of printer problems. 4. 4061-xx0 Preface This manual contains maintenance procedures for service personnel. Special tools and test equipment are ...
...failing field replaceable units (FRUs). 3. Diagnostic aids contains tests and checks used to perform the task. Parts catalog contains illustrations and part numbers for making printer adjustments and removing and installing FRUs. 5. Warning: A warning identifies something that might cause a servicer... symbol, there is divided into the following chapters: 1. xx Service Manual General information contains a general description of printer problems. 4. 4061-xx0 Preface This manual contains maintenance procedures for service personnel. Special tools and test equipment are ...
Service Manual
Page 41
...cases, five digits are indicated by a period and additional numbers in this chapter to determine the corrective action necessary to repair a malfunctioning printer. If a user error message displays, go to "User status displays" on page 2-31. • User attendance messages are shown....; "Understanding the printer operator panel" on page 2-2 • "Understanding the menus" on page 2-3 • "Diagnostics mode" on page 3-2 • "Configuration menu (CONFIG MENU)" on page 3-25 • "Theory" on page 3-31 • "Paper feed jams" on page 3-37 • "Parts catalog" on the current...
...cases, five digits are indicated by a period and additional numbers in this chapter to determine the corrective action necessary to repair a malfunctioning printer. If a user error message displays, go to "User status displays" on page 2-31. • User attendance messages are shown....; "Understanding the printer operator panel" on page 2-2 • "Understanding the menus" on page 2-3 • "Diagnostics mode" on page 3-2 • "Configuration menu (CONFIG MENU)" on page 3-25 • "Theory" on page 3-31 • "Paper feed jams" on page 3-37 • "Parts catalog" on the current...
Service Manual
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... that identifies this parts catalog The following legend is contained in the parts catalog. Model name Lexmark T640 Lexmark T640n Lexmark T642 Lexmark T642n Lexmark T644 Lexmark T644n Configuration Non-network Network Non-network Network Non-network Network Machine type 4061-000 4061-010 4061-200 4061-210 4061-400 4060-410 Parts catalog 000 010 200 210 400 410 Parts catalog 7-1 Parts catalog 4061-xx0 How...
... that identifies this parts catalog The following legend is contained in the parts catalog. Model name Lexmark T640 Lexmark T640n Lexmark T642 Lexmark T642n Lexmark T644 Lexmark T644n Configuration Non-network Network Non-network Network Non-network Network Machine type 4061-000 4061-010 4061-200 4061-210 4061-400 4060-410 Parts catalog 000 010 200 210 400 410 Parts catalog 7-1 Parts catalog 4061-xx0 How...
Service Manual
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... kit or pkg 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 10 Description Fuser wiper cover assembly Redrive cap cover assembly Laser cover assembly-250-sheet output, 000/010 Laser cover assembly-500-sheet output, 200/210/400/410 Counterbalance spring Paper support Upper front cover hinge assembly, includes: • USB cable... Functional rubber sheet (1) Operator panel outer bezel with Lexmark logo, T640 Operator panel outer bezel with Lexmark logo T642 Operator panel outer bezel with Lexmark logo T644 Clear LCD bezel Kit, upper front panel...Parts packet (cable ties) (PP 40X0174) Parts catalog 7-3
... kit or pkg 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 10 Description Fuser wiper cover assembly Redrive cap cover assembly Laser cover assembly-250-sheet output, 000/010 Laser cover assembly-500-sheet output, 200/210/400/410 Counterbalance spring Paper support Upper front cover hinge assembly, includes: • USB cable... Functional rubber sheet (1) Operator panel outer bezel with Lexmark logo, T640 Operator panel outer bezel with Lexmark logo T642 Operator panel outer bezel with Lexmark logo T644 Clear LCD bezel Kit, upper front panel...Parts packet (cable ties) (PP 40X0174) Parts catalog 7-3
Service Manual
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4061-xx0 Assembly 3: Frame 2 AsmIndex 3-1 2 3 3 4 5 6 7 8 9 10 10 11 12 13 14 15 16 16 17 18 18 19 Part number 40X0027 40X0028 40X0029 40X0030 40X0032 40X0044 40X0048 40X0046 40X0049 40X0053 40X0054 40X0212 40X0211 40X0052 40X0051 40X0264 40X0057 40X0058 40X0210 40X0056 40X0232 40X0059 Units/ mach 1 1 1 1 1 1 ..., 000/010 Redrive assembly-500-sheet in/500 out, 200/210/400/410 Transfer deflector Gear guard Parts packet (PP 40X0165) Paper switch activate spring Paper size sensing board assembly Gear release link Main fan... door assembly 500 sheet 200/210/400/410 Extension guide Parts catalog 7-7
4061-xx0 Assembly 3: Frame 2 AsmIndex 3-1 2 3 3 4 5 6 7 8 9 10 10 11 12 13 14 15 16 16 17 18 18 19 Part number 40X0027 40X0028 40X0029 40X0030 40X0032 40X0044 40X0048 40X0046 40X0049 40X0053 40X0054 40X0212 40X0211 40X0052 40X0051 40X0264 40X0057 40X0058 40X0210 40X0056 40X0232 40X0059 Units/ mach 1 1 1 1 1 1 ..., 000/010 Redrive assembly-500-sheet in/500 out, 200/210/400/410 Transfer deflector Gear guard Parts packet (PP 40X0165) Paper switch activate spring Paper size sensing board assembly Gear release link Main fan... door assembly 500 sheet 200/210/400/410 Extension guide Parts catalog 7-7
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Assembly 4: Frame 3 AsmIndex 4-1 2 3 3 4 5 6 7 8 9 10 11 12 13 13 14 15 16 17 18 Part number 40X0249 40X0208 40X0034 40X0035 40X0033 40X0223 40X0036 40X0306 40X0213 40X0021 40X0040 40X0041 40X0042 40X0039 40X0043 40X0209 40X0045 40X0207 Units/ mach 1 1 1 1 1 1 4 1 1 1 1 2 1 1 1... 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Description EP DC fan assembly, 200/210/400/410 Blower duct, 200/210/400/410 Parts packet (PP 40X0165) Parts packet (PP 40X0165) Signature button sensor assembly EP DC fan assembly, 000/010 Machine mounting pad HVPS/input sensor/toner sensor cable assembly Toner...Parts catalog 7-9
Assembly 4: Frame 3 AsmIndex 4-1 2 3 3 4 5 6 7 8 9 10 11 12 13 13 14 15 16 17 18 Part number 40X0249 40X0208 40X0034 40X0035 40X0033 40X0223 40X0036 40X0306 40X0213 40X0021 40X0040 40X0041 40X0042 40X0039 40X0043 40X0209 40X0045 40X0207 Units/ mach 1 1 1 1 1 1 4 1 1 1 1 2 1 1 1... 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Description EP DC fan assembly, 200/210/400/410 Blower duct, 200/210/400/410 Parts packet (PP 40X0165) Parts packet (PP 40X0165) Signature button sensor assembly EP DC fan assembly, 000/010 Machine mounting pad HVPS/input sensor/toner sensor cable assembly Toner...Parts catalog 7-9
Service Manual
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4061-xx0 Assembly 5: Printhead AsmIndex 4-1 2 3 Part number 40X0061 40X0062 Units/ mach 1 1 Units/ kit or pkg 1 1 Description Laser cable assembly Parts packet (printhead mounting screw) (PP 40X0165) Printhead assembly (includes all cables) CAUTION:The printhead is not a serviceable FRU. Do not disassemble the printhead. Parts catalog 7-11
4061-xx0 Assembly 5: Printhead AsmIndex 4-1 2 3 Part number 40X0061 40X0062 Units/ mach 1 1 Units/ kit or pkg 1 1 Description Laser cable assembly Parts packet (printhead mounting screw) (PP 40X0165) Printhead assembly (includes all cables) CAUTION:The printhead is not a serviceable FRU. Do not disassemble the printhead. Parts catalog 7-11
Service Manual
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4061-xx0 Assembly 7: Paper feed-multipurpose feeder AsmIndex 7-1 2 3 4 5 5 5 NS Part number 40X0079 40X0310 40X0076 40X0077 Units/ mach 1 1 1 1 Units/ kit or pkg 1 1 1 1 1 Description Multipurpose feeder lower deflector assembly Multipurpose feeder pick arm assembly with solenoid Pick roll assembly Multipurpose feeder paper out flag Parts packet (lower deflector mounting screw, 8 mm) (PP 40X0165) Parts packet (lower deflector mounting screw, 12 mm) (PP 40X0165) Parts packet (frame mounting screw) (PP 40X0165) Parts packet (pick roll shaft clip) (PP 40X0165) Parts catalog 7-15
4061-xx0 Assembly 7: Paper feed-multipurpose feeder AsmIndex 7-1 2 3 4 5 5 5 NS Part number 40X0079 40X0310 40X0076 40X0077 Units/ mach 1 1 1 1 Units/ kit or pkg 1 1 1 1 1 Description Multipurpose feeder lower deflector assembly Multipurpose feeder pick arm assembly with solenoid Pick roll assembly Multipurpose feeder paper out flag Parts packet (lower deflector mounting screw, 8 mm) (PP 40X0165) Parts packet (lower deflector mounting screw, 12 mm) (PP 40X0165) Parts packet (frame mounting screw) (PP 40X0165) Parts packet (pick roll shaft clip) (PP 40X0165) Parts catalog 7-15
Service Manual
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4061-xx0 Assembly 8: Paper feed-alignment AsmIndex 8-1 2 3 4 NS Part number 40X0084 40X0085 40X0086 Units/ mach 1 1 Units/ kit or pkg 1 1 Description Paper feed alignment assembly paper feed Parts packet (clip ref ground mounting screw) (PP 40X0165) Reference ground clip Parts packet (reference adjust) • Screw, paper reference adjust (1) • Washer, paper reference adjust (1) • Nut, paper reference adjust (1) Parts packet (alignment asm mounting screw) (PP 40X0165) Parts catalog 7-17
4061-xx0 Assembly 8: Paper feed-alignment AsmIndex 8-1 2 3 4 NS Part number 40X0084 40X0085 40X0086 Units/ mach 1 1 Units/ kit or pkg 1 1 Description Paper feed alignment assembly paper feed Parts packet (clip ref ground mounting screw) (PP 40X0165) Reference ground clip Parts packet (reference adjust) • Screw, paper reference adjust (1) • Washer, paper reference adjust (1) • Nut, paper reference adjust (1) Parts packet (alignment asm mounting screw) (PP 40X0165) Parts catalog 7-17
Service Manual
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Assembly 9: Integrated 250-sheet paper tray AsmIndex 9-1 2 3 4 5 6 7 Part number 40X0087 40X0092 40X0093 40X0263 40X0094 40X0105 40X0090 Units/ mach 1 1 4 1 1 2 1 Units/ kit or pkg 1 1 1 1 1 1 1 Description Integrated 250-sheet tray Side restraint-250-sheet tray Wear strips Pass thru plate-250-sheet tray Wear plate-250-sheet tray Restraint pad Back restraint-250-sheet tray 4061-xx0 Parts catalog 7-19
Assembly 9: Integrated 250-sheet paper tray AsmIndex 9-1 2 3 4 5 6 7 Part number 40X0087 40X0092 40X0093 40X0263 40X0094 40X0105 40X0090 Units/ mach 1 1 4 1 1 2 1 Units/ kit or pkg 1 1 1 1 1 1 1 Description Integrated 250-sheet tray Side restraint-250-sheet tray Wear strips Pass thru plate-250-sheet tray Wear plate-250-sheet tray Restraint pad Back restraint-250-sheet tray 4061-xx0 Parts catalog 7-19
Service Manual
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Assembly 10: Integrated 500-sheet paper tray AsmIndex 10-1 2 3 4 5 6 7 Part number 40X0098 40X0099 40X0182 40X0103 40X0183 40X0105 40X0106 Units/ mach 1 1 4 1 1 2 1 Units/ kit or pkg 1 1 1 1 1 1 1 Description Tray assembly-500-sheet tray Side restraint Wear strip Pass thru plate-500-sheet tray Wear plate-500-sheet tray Restraint pad Back restraint 4061-xx0 Parts catalog 7-21
Assembly 10: Integrated 500-sheet paper tray AsmIndex 10-1 2 3 4 5 6 7 Part number 40X0098 40X0099 40X0182 40X0103 40X0183 40X0105 40X0106 Units/ mach 1 1 4 1 1 2 1 Units/ kit or pkg 1 1 1 1 1 1 1 Description Tray assembly-500-sheet tray Side restraint Wear strip Pass thru plate-500-sheet tray Wear plate-500-sheet tray Restraint pad Back restraint 4061-xx0 Parts catalog 7-21
Service Manual
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4061-xx0 Assembly 11: Drives-Main drive and developer drive AsmIndex 11-1 2 2 3 4 5 6 7 NS Part number 40X0107 40X0110 40X0111 40X0112 40X0113 40X0114 40X0115 Units/ mach 1 1 1 1 1 1 Units/ kit or pkg 1 1 1 1 1 1 3 4 Description Gearbox with... packet and washer • Bevel gear (1) • Instruction sheet (1) • Grease packet (1) Developer drive assembly Parts packet, developer drive • Developer drive shaft (1) • shaft, coupler gear #55 (1) Parts packet (developer drive ground screw) (PP 40X0165) Parts packet (gearbox mounting screw) (PP 40X0165) Parts catalog 7-23
4061-xx0 Assembly 11: Drives-Main drive and developer drive AsmIndex 11-1 2 2 3 4 5 6 7 NS Part number 40X0107 40X0110 40X0111 40X0112 40X0113 40X0114 40X0115 Units/ mach 1 1 1 1 1 1 Units/ kit or pkg 1 1 1 1 1 1 3 4 Description Gearbox with... packet and washer • Bevel gear (1) • Instruction sheet (1) • Grease packet (1) Developer drive assembly Parts packet, developer drive • Developer drive shaft (1) • shaft, coupler gear #55 (1) Parts packet (developer drive ground screw) (PP 40X0165) Parts packet (gearbox mounting screw) (PP 40X0165) Parts catalog 7-23
Service Manual
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... 220V Fuser cover assembly kit, including: • Thermistor (1) • Thermostat (1) • Left and right fuser lamp contact assemblies (1) Parts packet (fuser mounting screw) (PP 40X0227) Exit sensor flag/spring kit, including: • Spring (1) • Flag (1) Exit/narrow media sensor cover... Parts packet (PP 40X0165) Exit sensor Exit sensor cable Narrow media flag/spring kit, including: • Spring • Flag Narrow media sensor Narrow media sensor cable Fuser AC to fuser lamp cable 4061-xx0 Parts catalog 7-25
... 220V Fuser cover assembly kit, including: • Thermistor (1) • Thermostat (1) • Left and right fuser lamp contact assemblies (1) Parts packet (fuser mounting screw) (PP 40X0227) Exit sensor flag/spring kit, including: • Spring (1) • Flag (1) Exit/narrow media sensor cover... Parts packet (PP 40X0165) Exit sensor Exit sensor cable Narrow media flag/spring kit, including: • Spring • Flag Narrow media sensor Narrow media sensor cable Fuser AC to fuser lamp cable 4061-xx0 Parts catalog 7-25
Service Manual
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Use the first eight numbers to identify the board with an board ID and barcode. 4061-xx0 Assembly 15: Electronics-card assemblies AsmIndex 15-1 2 3 3 3 4 4 4 5 5 5 5 Part number 40X0146 40X0147 56P4355 56P4357 56P4359 56P4356 56P4358 56P4360 40X0198 40X0248 40X0199 40X0265 Units/ mach 1 1 1 1 1 1 1 1 1 1 1 1 Units/ kit or pkg 1 1 1 1 1 1 1 1 1 1 1 1 Description Interconnect card assembly ...code card assembly IPDS and SC5/TNe card assembly PrintCryption card assembly PRESCRIBE card assembly Note: The system board has a label with the part number in the table above: Parts catalog 7-31
Use the first eight numbers to identify the board with an board ID and barcode. 4061-xx0 Assembly 15: Electronics-card assemblies AsmIndex 15-1 2 3 3 3 4 4 4 5 5 5 5 Part number 40X0146 40X0147 56P4355 56P4357 56P4359 56P4356 56P4358 56P4360 40X0198 40X0248 40X0199 40X0265 Units/ mach 1 1 1 1 1 1 1 1 1 1 1 1 Units/ kit or pkg 1 1 1 1 1 1 1 1 1 1 1 1 Description Interconnect card assembly ...code card assembly IPDS and SC5/TNe card assembly PrintCryption card assembly PRESCRIBE card assembly Note: The system board has a label with the part number in the table above: Parts catalog 7-31
Service Manual
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Assembly 16: Electronics-shields AsmIndex 16-1 2 2 2 3 4 5 6 7 Part number 40X0150 40X0149 40X0153 40X0152 40X0154 40X0222 Units/ mach 1 1 1 1 1 1 Units/ kit or pkg 1 1 1 1 1 1 Description Outer shield-2 slot, 200/210/400/410 Parts packet (INA cover mounting screw) (PP 40X0165) Parts packet (outer shield mounting screw) (PP 40X0165) Parts packet (inner shield mounting screw) (PP 40X0165) Inner shield assembly-2 slot, 200/210/400/410 INA flat cover (blank) Ethernet shield (blank), 000/200/400 Inner shield assembly-1 slot. 000/010 Outer shield-1 slot, 000/010 4061-xx0 Parts catalog 7-33
Assembly 16: Electronics-shields AsmIndex 16-1 2 2 2 3 4 5 6 7 Part number 40X0150 40X0149 40X0153 40X0152 40X0154 40X0222 Units/ mach 1 1 1 1 1 1 Units/ kit or pkg 1 1 1 1 1 1 Description Outer shield-2 slot, 200/210/400/410 Parts packet (INA cover mounting screw) (PP 40X0165) Parts packet (outer shield mounting screw) (PP 40X0165) Parts packet (inner shield mounting screw) (PP 40X0165) Inner shield assembly-2 slot, 200/210/400/410 INA flat cover (blank) Ethernet shield (blank), 000/200/400 Inner shield assembly-1 slot. 000/010 Outer shield-1 slot, 000/010 4061-xx0 Parts catalog 7-33
Service Manual
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Assembly 18: Cabling diagrams 2 4061-xx0 AsmIndex 18-1 2 3 Part number 40X0061 40X0074 40X0046 Units/ mach 1 1 1 Units/ kit or pkg 1 1 1 Description Laser printhead cable assembly Autocompensator motor cable Paper size sensing board/Tray 1 autocompensator paper out/low cable Parts catalog 7-35
Assembly 18: Cabling diagrams 2 4061-xx0 AsmIndex 18-1 2 3 Part number 40X0061 40X0074 40X0046 Units/ mach 1 1 1 Units/ kit or pkg 1 1 1 Description Laser printhead cable assembly Autocompensator motor cable Paper size sensing board/Tray 1 autocompensator paper out/low cable Parts catalog 7-35
Service Manual
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Assembly 19: Cabling diagrams 3 AsmIndex 19-1 2 3 4 5 Part number 40X0034 40X0156 40X0223 40X0157 40X0224 Units/ mach 1 1 1 1 1 Units/ kit or pkg 1 1 1 1 1 Description Signature button contact assembly with cable Bottom/front autoconnect cable assembly HVPS/input sensor/toner sensor cable assembly Top autoconnect cable assembly LVPS to system board cable assembly 4061-xx0 Parts catalog 7-37
Assembly 19: Cabling diagrams 3 AsmIndex 19-1 2 3 4 5 Part number 40X0034 40X0156 40X0223 40X0157 40X0224 Units/ mach 1 1 1 1 1 Units/ kit or pkg 1 1 1 1 1 Description Signature button contact assembly with cable Bottom/front autoconnect cable assembly HVPS/input sensor/toner sensor cable assembly Top autoconnect cable assembly LVPS to system board cable assembly 4061-xx0 Parts catalog 7-37
Service Manual
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Assembly 20: Cabling diagrams 4 AsmIndex 20-1 2 3 4 Part number 40X0006 40X0162 40X0163 40X0226 Units/ mach 1 1 1 1 Units/ kit or pkg 1 1 1 1 Description Upper front cover hinge assembly, includes: • USB cable (A) (1) • Operator panel cable (B) (1) • Cover open switch/cable (C) (1) System board to fuser board cable assembly Fuser AC lamp to LVPS cable assembly Fuser connector (fuser AC to fuser lamp) 4061-xx0 Parts catalog 7-39
Assembly 20: Cabling diagrams 4 AsmIndex 20-1 2 3 4 Part number 40X0006 40X0162 40X0163 40X0226 Units/ mach 1 1 1 1 Units/ kit or pkg 1 1 1 1 Description Upper front cover hinge assembly, includes: • USB cable (A) (1) • Operator panel cable (B) (1) • Cover open switch/cable (C) (1) System board to fuser board cable assembly Fuser AC lamp to LVPS cable assembly Fuser connector (fuser AC to fuser lamp) 4061-xx0 Parts catalog 7-39
Service Manual
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Assembly 21: Cabling diagrams 5 AsmIndex 21-1 2 3 3 4 4 Part number 40X0083 40X0159 40X0035 40X0249 40X0053 40X0054 Units/ mach 1 1 1 1 1 1 Units/ kit or pkg 1 1 1 1 1 1 Description Frame assembly with solenoid and cable Main drive motor cable assembly EP fan with cable-250 sheet, 000/010 EP fan with cable-500 sheet, 200/210/400/410 Main fan, 250 sheet Main fan, 500 sheet 4061-xx0 Parts catalog 7-41
Assembly 21: Cabling diagrams 5 AsmIndex 21-1 2 3 3 4 4 Part number 40X0083 40X0159 40X0035 40X0249 40X0053 40X0054 Units/ mach 1 1 1 1 1 1 Units/ kit or pkg 1 1 1 1 1 1 Description Frame assembly with solenoid and cable Main drive motor cable assembly EP fan with cable-250 sheet, 000/010 EP fan with cable-500 sheet, 200/210/400/410 Main fan, 250 sheet Main fan, 500 sheet 4061-xx0 Parts catalog 7-41