Thursday, August 12, 2010

Lexmark 241 Errors

A 241 error indicates that paper failed to leave Tray 1 and reach the registration sensor after a pickup cycle was executed. Following are some likely causes:

a) Worn early-style pickup rollers with insufficient traction. See this post for information on the new-style service replacement pickup rollers.

b) Toner/paper-dust fouling the pickup rollers. Scrubbing the rollers' tires with a tooth brush and methyl hydrate may clear it up, but when machines get that filthy, they're usually due for a proper overhaul in the shop.

If the rollers are ok but you're getting solid, not intermittent, 241 errors, there's likely an outright hardware failure causing it. We've seen two such in our shop:

1) Failure of the auto-compensator to lower down onto the paper stack.

On the upper right side ledge of Tray 1, about half way back, there's a vertical protrusion that causes the auto-compensator to drop when the tray is pushed in. If that protrusion gets snapped off, the auto-compensator will remain in its retracted 'up' position, spinning its wheels in the air to no effect. Replace the tray.

2) Failure of the one-way clutch in the pickup rollers' axle.

If you take the tray out and try to rotate the pickup rollers by hand, they're supposed to turn freely in the direction of paper feed, but lock up in the opposite direction. If they turn freely in either direction, the axle/clutch has a defect. Replace the auto-compensator assembly.

In closing, I should point out that whenever you're getting 241 errors, it can be helpful to get a look at what's happening as the machine is attempting to execute a pickup cycle. If you remove the redrive assembly from the rear of the machine, you're afforded quite a good view inside the tray. Both of the hardware failures described immediately above became obvious when I got a look inside that way. Unfortunately, the add-on trays don't permit such a view, short of sawing off their rear covering.
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