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Lexmark W850dn, Manual

The Lexmark W850dn is a high-performance laser printer designed for professional environments. With its user-friendly interface and advanced features, this manual provides detailed instructions on how to optimize your printing experience. Download the free manual at manualshive.com, and unleash the true potential of your Lexmark W850dn printer.

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Table of contents

v

4024-110

From punch to compiler unit assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-8
From compiler unit assembly to stacker media bin  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-10
From punch to upper media bin   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-10

Functions of sensors along the media path  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-10

Bridge unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-10
Finisher  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-11

Punch unit   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-12

Adjusting punching positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-12
Punching  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-13
Detecting punch waste full   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-14
Detecting punch waste box  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-14
Functions of punch sensors/motors   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-14

Compiler unit assembly   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-15

Outline of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-15
Capacity of compiler unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-16
Compiler unit assembly operation with multiple media sizes   . . . . . . . . . . . . . . . . . . . . . . . . . .  3-16
Tamping   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-16
Front tamping   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-17
Rear tamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-18
Center tamping  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-19
Determining tamper home position  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-19
Tamping   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-19
Offsetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-20
Functions of compiler unit assembly sensors/motors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-20

Stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-21

Stapling operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-21
Staple positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-21
Media sizes that allow stapling  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-22
Stapling one sheet   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-22
Stapling multiple size media  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-22
Media limits for stapling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-23
Stapler operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-23
Stapler unit assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-24
Functions of stapler sensors/motors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-24

Upper media bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-25

Operation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-25
Functions of upper media bin sensors   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-25

Stacker media bin   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-26

Operation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-26
Full stack detection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-28
Functions of stacker media bin sensors/motors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-28

Power supply and interlock   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-30

Repair information

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  

4-1

Handling ESD-sensitive parts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1
Removal procedures   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-2

Bridge unit assembly removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-2
Finisher removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-4
Bridge unit rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-6
Bridge unit top cover assembly removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Bridge unit drive belt and bridge unit drive pulley removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-8
Bridge unit right shaft assembly removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Bridge unit left shaft assembly removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Bridge unit idler rolls removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-11
Bridge unit transport belt removals  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-12
Bridge unit drive motor assembly removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-13
Bridge unit entrance guide removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-14
Sensor (bridge unit top cover interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-15
Sensor (bridge unit media entrance) removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-16

Summary of Contents for W850dn

Page 1: ...4 110 Table of contents Start diagnostics Safety and notices Trademarks Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries Edition October 6 2009 ...

Page 2: ...obligation to you You can purchase additional copies of publications related to this product by calling 1 800 553 9727 In other countries contact your point of purchase References in this publication to products programs or services do not imply that the manufacturer intends to make these available in all countries in which it operates Any reference to a product program or service is not intended ...

Page 3: ...ntrance on jam 2 20 282 01 Sensor finisher media entrance static jam A 2 22 283 00 Sensor buffer path on jam A 2 23 283 01 Sensor buffer path on jam B 2 25 283 02 Sensor buffer path static jam A 2 28 283 03 Sensor buffer path static jam B 2 29 283 04 Sensor buffer path static jam C 2 30 284 00 Sensor lower media exit off jam A 2 31 284 01 Sensor lower media exit on jam A 2 32 284 02 Sensor lower m...

Page 4: ...ft HP on failure 2 79 987 01 Sensor media eject shaft HP off failure 2 80 988 00 Sensor punch unit side reg on failure 2 82 988 01 Sensor punch unit side reg off failure 2 83 989 00 Stapler unit failure 2 85 990 00 Sensor stapler carriage HP on failure 2 85 990 01 Sensor stapler carriage HP off failure 2 86 995 00 Finisher NVRAM R W failure 2 87 996 00 Finisher type failure 2 87 999 00 Finisher en...

Page 5: ...stapling 3 22 Stapling one sheet 3 22 Stapling multiple size media 3 22 Media limits for stapling 3 23 Stapler operation 3 23 Stapler unit assembly 3 24 Functions of stapler sensors motors 3 24 Upper media bin 3 25 Operation 3 25 Functions of upper media bin sensors 3 25 Stacker media bin 3 26 Operation 3 26 Full stack detection 3 28 Functions of stacker media bin sensors motors 3 28 Power supply ...

Page 6: ...ssembly removal 4 47 Sensor punch unit motor encoder removal 4 48 Sensor punch hole select sensor punch cam front and sensor punch unit HP removal 4 49 Sensor punch carriage shift HP removal 4 51 Sensor punch waste box set removal 4 52 Sensor punch waste box full removal 4 53 Stapler unit frame removal 4 54 Stapler unit assembly removal 4 56 Sensor stapler carriage HP removal 4 58 Media eject unit...

Page 7: ... low voltage power supply LVPS removal 4 119 Component locations 5 1 Locations 5 1 Bridge unit assembly 5 1 Stacker lift and stapler 5 2 Punch unit 5 3 Diverter and media eject 5 4 Media eject and media compiler 5 5 Buffer upper exit lower exit and drive motors 5 6 Cabling 5 7 Preventive maintenance 6 1 Safety inspection guide 6 1 Maintenance recommendations 6 1 Parts catalog 7 1 How to use this p...

Page 8: ...viii Finisher Service Manual 4024 110 ...

Page 9: ...h den Kundendienst Laserbestrahlung die Klasse I übersteigen würde Menschen keinesfalls erreicht Avis relatif à l utilisation de laser Pour les Etats Unis cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant les produits laser de Classe I 1 Pour les autres pays cette imprimante répond aux normes IEC 60825 1 relatives aux produits laser de Classe I Les produits las...

Page 10: ... de potássio de 5 milliwatts operando numa faixa de comprimento de onda entre 770 e 795 nanómetros O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radiação laser superior a um nível de Classe I durante a operação normal a manutenção feita pelo utilizador ou condições de assistência prescritas Laserinformatie De printer voldoet aan d...

Page 11: ...s risk för att någon person utsätts för laserstrålning över Klass I nivå vid normal användning underhåll som utförs av användaren eller annan föreskriven serviceåtgärd Laser melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR underkapittel J for klasse I 1 laserprodukter og er i andre land godkjent som et Klasse I laserprodukt i samsvar med kravene i IEC 60825 1 Klasse I laserprodukter...

Page 12: ...xii Finisher Service Manual 4024 110 ...

Page 13: ...signes d entretien et de réparation de ce produit s adressent uniquement à un personnel de maintenance qualifié Le démontage et l entretien de ce produit pouvant présenter certains risques électriques le personnel d entretien qualifié devra prendre toutes les précautions nécessaires ATTENTION Ce symbole indique la présence d une tension dangereuse dans la partie du produit sur laquelle vous travai...

Page 14: ... sobre el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de la máquina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias PRECAUCIÓN este símbolo indica que el voltaje de la parte del equipo con la q...

Page 15: ...roducte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients PRECAUCIÓ aquest símbol indica que el voltatge de la part de l equip amb la qual esteu treballant ...

Page 16: ...iagnostic information contains an error code messages table and service checks used to isolate failing field replaceable units FRUs 3 Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer problems 4 Repair information provides instructions for making printer adjustments and removing and installing FRUs 5 Component locations uses illustrations to identify the connec...

Page 17: ...r media bin or separately collated in the stacker media bin Finisher weight Packaged 42 kg Unpackaged 30 kg Components The finisher is composed of the following five components Bridge unit assembly block to feed media from the printer to the finisher Punch block to punch media Compiler tray block to align media Stapler block to staple a set of media at specified positions Bridge unit assembly Fini...

Page 18: ...itional information on the printer Media size orientation and applicable functions Media description Size Short edge first SEF Long edge first LEF Top tray Stacker Stack Stack Offset stack Punch1 Staple B5 182 x 257 mm SEF Yes No No No No LEF Yes Yes Yes Yesa 2 Yes Executive 7 25 x 10 5 in 184 2 x 27 0 mm SEF Yes No No No No LEF Yes Yes Yes Yesa 2 3 4 No Letter 8 5 x 11 in 215 9 x 279 4 mm SEF Yes...

Page 19: ... in SEF Yes Yes Yes Yesa 2 3 4 Yes Custom size Same width with standard size Yes Yes Yes Yes Yes Custom size Besides above Yes Yesb Yesb No No a Numbers 2 3 4 mean 2 holes 3 holes and 4 holes respectively b Applicable within the following range Media width 203 2 297 mm Media length 182 431 8 mm ...

Page 20: ...res Description Maximum weight For punching 52 176 gsm For stapling 52 226 gsm For ejecting in the stacker media bin 52 226 gsm For ejecting in the upper media bin 52 226 gsm The amount of media capable of being stapled will be less than 50 if media weight is greater than 90 gsm Media processing requested Destination of media No post processing Upper media bin or stacker media bin Punching Upper m...

Page 21: ...de LED Light Emitting Diode LEF Long Edge Fed LVPS Low Voltage Power Supply MPF Multi Purpose Feeder MS Microswitch NVM Nonvolatile Memory NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer OPT Optical Sensor PC Photoconductor pel Picture element POR Power on Reset POST Power on Self Test PPM Pages Per Minute PSC Parallel Synchronous Communications PSD Position Sensing Devi...

Page 22: ...1 6 Finisher Service Manual 4024 110 ...

Page 23: ... Warning When operating the driving units using the diagnostics or other tools never touch the driving units When operating the driving units using diagnostics or other tools be sure to follow the procedures in this manual CAUTION Be careful to avoid burns by safely handling hot parts Warning Servicers should wear a wrist band or the like to remove static electricity from their body grounding thei...

Page 24: ...eme humidity or rapid changes in temperature The printer is not installed close to water service humidifier heat generating unit fire in a very dusty place or a place exposed to air flow from the air conditioning system The printer is not installed in a place where volatile gas or inflammable gas is generated The printer is not installed in direct sun The printer is installed on a stout and stable...

Page 25: ...n page 2 14 281 01 Paper jam Check area F Sensor bridge unit media exit on jam B Sensor bridge unit media exit is not turned on within the specified time after the sensor bridge unit media entrance turned on At this time the sensor bridge unit media entrance is turned on Go to 281 01 Sensor bridge unit media exit On Jam B on page 2 16 281 02 Paper jam Check area F Sensor Bridge unit media exit on ...

Page 26: ...path Static jam C Paper remains on the sensor finisher buffer path At this time the sensor diverter gate is turned off Go to 283 04 Sensor buffer path static jam C on page 2 30 284 00 Paper jam Check area F Sensor lower media exit off jam A Sensor lower media exit is not turned off within the specified time after the finisher sensor lower media exit is turned on At this time the sensor bridge unit...

Page 27: ...sensor bridge unit media exit is turned on Go to 287 00 Sensor upper media exit on jam A on page 2 45 287 01 Paper Jam Check area F Sensor upper media exit off jam A Sensor upper media exit is not turned off within the specified time after the sensor upper media exit is turned on At this time the sensor bridge unit media exit is turned on Go to 287 01 Sensor upper media exit off jam A on page 2 46...

Page 28: ...r bridge unit media exit is turned on Go to 288 01 Sensor diverter gate static jam to top bin A on page 2 57 288 02 Paper jam Check areas G1 G3 Sensor diverter gate Static jam to top bin B Paper remains on the sensor diverter gate when the finisher is in the upper bin exit mode At this time the sensor finisher media entrance is on state but the sensor bridge unit media exit is turned off Go to 288...

Page 29: ...P on failure The sensor front tamper HP is not turned on after the front tamper starts moving to the front tamper home position Go to 982 00 Sensor front tamper HP on failure on page 2 68 982 01 Service finisher error Sensor front tamper HP off failure The sensor front tamper HP is not turned off within the specified time after the front tamper starts leaving from the front tamper home position Or...

Page 30: ... clamp HP on failure The sensor eject clamp HP is not turned on within 500 ms after the eject clamp up starts Go to 986 00 Sensor media eject clamp HP on failure on page 2 77 986 01 Service finisher error Sensor media eject clamp HP off failure The sensor eject clamp HP is not turned off within 200 ms after the eject clamp down starts Go to 986 01 Sensor media eject clamp HP off failure on page 2 ...

Page 31: ...the stapler was moved to the staple position Or the sensor stapler carriage HP is turned on again after the sensor stapler carriage HP is turned off and the stapler stopped its moving Go to 990 01 Sensor stapler carriage HP off failure on page 2 86 995 00 Service finisher NV Finisher NVM R W failure A read write error occurred on the NVM of the finisher controller card assembly Go to 995 00 Finish...

Page 32: ...a exceeds the specified value be able to stack on the stacker bin Go to Stacker set over count failure on page 2 99 Remove paper from Bin 2 Stacker media bin full no mix The stacker media bin has reached maximum capacity same media size Go to Stacker media bin full no mix on page 2 96 Remove paper from Bin 2 Stacker media bin full mix size The stacker media bin has reached maximum capacity mixed m...

Page 33: ...orm the sensor bridge unit media entrance test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path1 5 Select Bridge media ent Open the bridge unit top cover assembly Does the display on the operator panel change every time the actuator of the sensor bridge unit media entrance is operated Go to step 5 Go to step 4 4 Check the sensor bridge unit media entrance ...

Page 34: ...entrance test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path1 5 Select Bridge media ent Open the bridge unit top cover assembly Does the display on the operator panel change every time the actuator of the sensor bridge unit media entrance is operated Go to step 3 Go to step 2 2 Check the sensor bridge unit media entrance connection Is the above sensor co...

Page 35: ...ly Go to Finisher controller card assembly removal on page 4 118 Problem solved Step Check Yes No 1 Check the sensor bridge unit media entrance for correct operation Perform the sensor bridge unit media entrance test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path1 5 Select Bridge media ent Open the bridge unit top cover assembly Does the display on the o...

Page 36: ...y removal on page 4 117 Problem solved 6 Perform a test print Does the error still occur Replace the finisher controller card assembly Go to Finisher controller card assembly removal on page 4 118 Problem solved Step Check Yes No 1 Check the media path 1 Open the bridge unit top cover assembly of the bridge unit assembly 2 Check the transport belts and the six bridge unit pinch rolls attached on t...

Page 37: ... page 4 17 Replace the connection 5 Check the bridge unit drive motor by opening the finisher front door assembly and then closing it Open the bridge unit top cover assembly Does the bridge unit drive motor rotate normally Go to step 7 Go to step 6 6 Check the bridge unit drive motor connection Is the above motor properly connected Replace the bridge unit drive motor Go to Bridge unit drive motor ...

Page 38: ...e sensor bridge unit media exit test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path1 5 Select Bridge media exit Open the bridge unit top cover assembly Does the display on the operator panel change every time the actuator of the sensor bridge unit media exit is operated Go to step 5 Go to step 4 4 Check the sensor bridge unit media exit connection Is the...

Page 39: ...it interface card assembly Go to Bridge unit interface card assembly removal on page 4 117 Go to step 8 Problem solved 8 Perform a test print Does the error still occur Replace the finisher controller card assembly Go to Finisher controller card assembly removal on page 4 118 Problem solved Step Check Yes No ...

Page 40: ...e sensor bridge unit media exit test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path1 5 Select Bridge media exit Open the bridge unit top cover assembly Does the display on the operator panel change every time the actuator of the sensor bridge unit media exit is operated Go to step 5 Go to step 4 4 Check the sensor bridge unit media exit connection Is the...

Page 41: ...edia exit test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path1 5 Select Bridge media exit Open the bridge unit top cover assembly Does the display on the operator panel change every time the actuator of the sensor bridge unit media exit is operated Go to step 4 Go to step 2 2 Check the sensor bridge unit media exit connection Is the above sensor connecte...

Page 42: ... Perform a test print Does the error still occur Replace the finisher controller card assembly Go to Finisher controller card assembly removal on page 4 118 Problem solved Step Check Yes No 1 Check the media path 1 Open the bridge unit top cover assembly of the bridge unit assembly 2 Check two transport belts and the six bridge unit pinch rolls attached on the bridge unit top cover assembly by tur...

Page 43: ...isher media entrance for correct operation Perform the sensor finisher media entrance test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path1 5 Select Fin media ent Detach the finisher from the printer Insert a sheet of white media into the finisher media path entrance Does the display change every time a piece of white media is placed over the sensor finis...

Page 44: ...er card assembly removal on page 4 118 Problem solved Step Check Yes No 1 Check the sensor finisher media entrance for correct operation Perform the sensor finisher media entrance test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path1 5 Select Fin media ent Detach the finisher from the printer Insert a sheet of white media into the finisher media path entr...

Page 45: ...sher 2 Remove the top cover and left upper cover 3 Open the entrance pinch guide assembly upward 4 Check the media entrance roll assembly and the media entrance pinch guide pinch roll attached on the media entrance pinch guide assembly by turning them with your fingers Is the media entrance roll assembly and the media entrance pinch guide pinch rolls operating correctly Go to step 2 Clean or repla...

Page 46: ...nnected properly Replace the sensor diverter gate Go to Sensor diverter gate removal on page 4 110 After reconnecting go to step 7 7 Check the sensor buffer path for correct operation Perform the sensor buffer path test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path1 5 Select Buffer path Open the finisher front door Lower the buffer pinch guide assembly ...

Page 47: ...ller card assembly removal on page 4 118 Problem solved Step Check Yes No 1 Check the media path 1 Open the finisher front door assembly of the finisher 2 Remove the top cover and left upper cover 3 Open the entrance pinch guide assembly upward 4 Check the media entrance roll assembly and the media entrance pinch guide pinch roll attached on the media entrance pinch guide assembly by turning them ...

Page 48: ... Move the lower media guide assembly to the right Insert a sheet of white media beneath the media diverter gate Then push the media to the sensor diverter gate Does the operator panel display change each time a piece of media is placed at the front of the sensor diverter gate Go to step 7 Go to step 6 6 Check the sensor diverter gate connection Is the above sensor connected properly Replace the se...

Page 49: ...10 Check the drive motor buffer transport connection Is the above motor connected properly Replace the drive motor buffer transport Go to Drive motor buffer transport and belt buffer transport removal on page 4 115 Problem solved 11 Perform a test print Does the error still occur Replace the bridge unit interface card assembly Go to Bridge unit interface card assembly removal on page 4 117 Go to s...

Page 50: ... the sensor buffer path connection Is the above sensor connected properly Replace the sensor buffer path Go to Sensor buffer path removal on page 4 93 Replace the connection 3 Check the drive motor buffer transport for correct operation Check the above motor by opening the finisher front door assembly and then closing it Does the drive motor buffer transport rotate normally Go to step 5 Go to step...

Page 51: ... the sensor buffer path connection Is the above sensor connected properly Replace the sensor buffer path Go to Sensor buffer path removal on page 4 93 Replace the connection 3 Check the drive motor buffer transport for correct operation Check the above motor by opening the finisher front door assembly and then closing it Does the drive motor buffer transport rotate normally Go to step 5 Go to step...

Page 52: ... the sensor buffer path connection Is the above sensor connected properly Replace the sensor buffer path Go to Sensor buffer path removal on page 4 93 Replace the connection 3 Check the drive motor buffer transport for correct operation Check the above motor by opening the finisher front door assembly and then closing it Does the drive motor buffer transport rotate normally Go to step 5 Go to step...

Page 53: ...ve the lower media guide assembly to the right Push a sheet of media into the paper path toward the sensor lower media exit Does the display on the operator panel change every time the actuator of the sensor lower media exit is operated Go to step 5 Go to step 4 4 Check the sensor lower media exit connection Is the above sensor connected properly Replace the sensor lower media exit Go to Sensor lo...

Page 54: ...ch guide pinch rolls free of damage Go to step 5 Clean or replace the appropriate roller and clean the media path 5 Check the sensor buffer path for correct operation Perform the sensor buffer path test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path1 5 Select Buffer path Open the finisher front door Lower the buffer pinch guide assembly Push a sheet of m...

Page 55: ... Does the operator panel display change each time a piece of media is placed at the front of the sensor diverter gate Go to step 11 Go to step 10 10 Check the sensor diverter gate for connection Is the above sensor connected properly Replace the sensor diverter gate Go to Sensor diverter gate removal on page 4 110 Replace the connection 11 Check the sensor lower media exit for correct operation Pe...

Page 56: ...ted properly Replace the sensor lower media exit Go to Sensor lower media exit removal on page 4 80 Replace the connection 13 Perform a test print Does the error still occur Replace the finisher controller card assembly Go to Finisher controller card assembly removal on page 4 118 Problem solved Step Check Yes No ...

Page 57: ...h guide pinch rolls free of damage Go to step 5 Clean or replace the appropriate roller and clean the media path 5 Check the sensor buffer path for correct operation Perform the sensor buffer path test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path1 5 Select Buffer path Open the finisher front door Lower the buffer pinch guide assembly Push a sheet of me...

Page 58: ...e Does the operator panel display change each time a piece of media is placed at the front of the sensor diverter gate Go to step 11 Go to step 10 10 Check the sensor diverter gate for connection Is the above sensor connected properly Replace the sensor diverter gate Go to Sensor diverter gate removal on page 4 110 Replace the connection 11 Check the sensor lower media exit for correct operation P...

Page 59: ...ed properly Replace the sensor lower media exit Go to Sensor lower media exit removal on page 4 80 Replace the connection 13 Perform a test print Does the error still occur Replace the finisher controller card assembly Go to Finisher controller card assembly removal on page 4 118 Problem solved Step Check Yes No ...

Page 60: ...ch guide pinch rolls free of damage Go to step 5 Clean or replace the appropriate roller and clean the media path 5 Check the sensor buffer path for correct operation Perform the sensor buffer path test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path1 5 Select Buffer path Open the finisher front door Lower the buffer pinch guide assembly Push a sheet of m...

Page 61: ... Does the operator panel display change each time a piece of media is placed at the front of the sensor diverter gate Go to step 11 Go to step 10 10 Check the sensor diverter gate for connection Is the above sensor connected properly Replace the sensor diverter gate Go to Sensor diverter gate removal on page 4 110 Replace the connection 11 Check the sensor lower media exit for correct operation Pe...

Page 62: ...the lower media exit roll assembly installed correctly Go to step 2 Clean or replace the lower media exit roll assembly and clean the media path 2 Is the lower media exit roll assembly free of damage Go to step 3 Clean or replace the lower media exit roll assembly and clean the media path 3 Check the sensor lower media exit for correct operation Perform the sensor lower media exit test 1 Enter Dia...

Page 63: ...ur Replace the finisher controller card assembly Go to Finisher controller card assembly removal on page 4 118 Problem solved Step Check Yes No 1 Check the sensor lower media exit for correct operation Perform the sensor lower media exit test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path1 5 Select Lower media exit Open the finisher front door Move the l...

Page 64: ...edia eject shaft by turning it with your fingers Is the media eject shaft assembly installed correctly meaning does it rotate smoothly Go to step 2 Clean or replace the media eject shaft assembly and clean the media path 2 Check the media eject clamp motor by opening the finisher front door assembly and then closing it Does the media eject clamp motor rotate normally Go to step 4 Go to step 3 3 Ch...

Page 65: ...place the finisher controller card assembly Go to Finisher controller card assembly removal on page 4 118 Problem solved Step Check Yes No 1 Check the eject clamp motor for correct operation Check the above motor by opening the finisher front door assembly and then closing it Does the eject clamp motor rotate normally Go to step 3 Go to step 2 2 Check the eject clamp motor connection Are the conne...

Page 66: ... then closing it Does the media eject motor assembly rotate normally Go to step 7 Go to step 6 6 Check the media eject motor assembly connection Are the connections of the main drive cable assembly correctly connected Replace the media eject motor assembly Go to Media eject motor assembly removal on page 4 78 Replace the connection 7 Perform a test print Does the error still occur Replace the fini...

Page 67: ...the upper pinch guide assembly and two upper media transport roll assemblies installed correctly meaning do they rotate smoothly Go to step 4 Clean or replace the appropriate roller and clean the media path 4 Are the four upper pinch guide pinch rolls of the upper pinch guide assembly and two upper media transport roll assemblies free of damage Go to step 5 Clean or replace the appropriate roller ...

Page 68: ...rrectly and do they rotate smoothly Go to step 2 Clean or replace the appropriate roller and clean the media path 2 Are the four upper pinch guide pinch rolls on the upper pinch guide assembly and two upper media transport roll assemblies free of damage Go to step 3 Clean or replace the appropriate roller and clean the media path 3 Check the sensor upper media exit for correct operation Perform th...

Page 69: ...motor exit Go to Drive motor exit assembly and belt exit removal on page 4 113 Replace the connection 9 Perform a test print Does the error still occur Replace the finisher controller card assembly Go to Finisher controller card assembly removal on page 4 118 Problem solved Step Check Yes No 1 Check the media path 1 Open the finisher front door assembly of the finisher 2 Remove the top cover and l...

Page 70: ...ct Media Path1 5 Select Upper media exit Does the display on the operator panel change every time the actuator of the sensor upper media exit is operated Go to step 7 Go to step 6 6 Check the sensor upper media exit and main sensor cable assembly connections Is the above sensor connected properly Replace the sensor upper media exit Sensor upper media exit removal on page 4 104 Replace the connecti...

Page 71: ...the upper pinch guide assembly and two upper media transport roll assemblies installed correctly meaning do they rotate smoothly Go to step 4 Clean or replace the appropriate roller and clean the media path 4 Are the four upper pinch guide pinch rolls of the upper pinch guide assembly and two upper media transport roll assemblies free of damage Go to step 5 Clean or replace the appropriate roller ...

Page 72: ...rrectly and do they rotate smoothly Go to step 2 Clean or replace the appropriate roller and clean the media path 2 Are the four upper pinch guide pinch rolls on the upper pinch guide assembly and two upper media transport roll assemblies free of damage Go to step 3 Clean or replace the appropriate roller and clean the media path 3 Check the sensor upper media exit for correct operation Perform th...

Page 73: ...bly and then closing it Does the motor exit rotate normally Go to step 9 Go to step 8 8 Check the drive motor exit connection Is the above motor connected properly Replace the drive motor exit Go to Drive motor exit assembly and belt exit removal on page 4 113 Replace the connection 9 Perform a test print Does the error still occur Replace the finisher controller card assembly Go to Finisher contr...

Page 74: ...and belt buffer transport removal on page 4 115 Replace the connection 5 Perform a test print Does the error still occur Replace the finisher controller card assembly Go to Finisher controller card assembly removal on page 4 118 Problem solved Step Check Yes No 1 Check the sensor upper media exit for correct operation Perform the sensor upper media exit test 1 Enter Diagnostics mode 2 Select FINIS...

Page 75: ...removal on page 4 118 Problem solved Step Check Yes No 1 Check the sensor upper media exit for correct operation Perform the sensor upper media exit test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path1 5 Select Upper media exit Does the display on the operator panel change every time the actuator of the sensor upper media exit is operated Go to step 3 Go...

Page 76: ... pinch rolls and transport belts installed correctly Go to step 2 Clean or replace the appropriate transport belts and bridge unit pinch roll and clean the media path 2 Are the six bridge unit pinch rolls on the bridge unit top cover assembly and two transport belts free of damage Go to step 3 Clean or replace the appropriate transport belts and bridge unit pinch roll and clean the media path 3 Ch...

Page 77: ... the sensor bridge unit media exit connection Is the above sensor connected properly Replace the sensor bridge unit media exit Go to Sensor bridge unit media exit removal on page 4 17 Replace the connection 7 Check the sensor finisher media entrance for correct operation Perform the sensor finisher media entrance test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select ...

Page 78: ...he diverter gate sensor cable assembly correctly connected Replace the sensor diverter gate Go to Sensor diverter gate removal on page 4 110 Replace the connection 11 Check the drive motor entrance paddle for correct operation Check the above motor by opening the finisher front door assembly and then closing it Does the motor entrance paddle rotate normally Go to step 13 Go to step 12 12 Check the...

Page 79: ...t of the sensor diverter gate Go to step 3 Go to step 2 2 Check the sensor diverter gate connection Is the above senor connected properly Replace the sensor diverter gate Go to Sensor diverter gate removal on page 4 110 Replace the connection 3 Check the drive motor entrance paddle by opening the finisher front door assembly and then closing it Does the motor entrance paddle rotate normally Go to ...

Page 80: ...t of the sensor diverter gate Go to step 3 Go to step 2 2 Check the sensor diverter gate connection Is the above senor connected properly Replace the sensor diverter gate Go to Sensor diverter gate removal on page 4 110 Replace the connection 3 Check the drive motor entrance paddle by opening the finisher front door assembly and then closing it Does the motor entrance paddle rotate normally Go to ...

Page 81: ...t of the sensor diverter gate Go to step 3 Go to step 2 2 Check the sensor diverter gate connection Is the above senor connected properly Replace the sensor diverter gate Go to Sensor diverter gate removal on page 4 110 Replace the connection 3 Check the drive motor entrance paddle by opening the finisher front door assembly and then closing it Does the motor entrance paddle rotate normally Go to ...

Page 82: ...r diverter gate Go to step 3 Go to step 2 2 Is the sensor diverter gate connected properly Replace the sensor diverter gate Go to Sensor diverter gate removal on page 4 110 Replace the connection 3 Check the drive motor entrance paddle by opening the finisher front door assembly and then closing it Does the motor entrance paddle rotate normally Go to step 5 Go to step 4 4 Check the main drive cabl...

Page 83: ... diverter gate Go to step 3 Go to step 2 2 Is the sensor diverter gate connected properly Replace the sensor diverter gate Go to Sensor diverter gate removal on page 4 110 Replace the connection 3 Check the drive motor entrance paddle by opening the finisher front door assembly and then closing it Does the motor entrance paddle rotate normally Go to step 5 Go to step 4 4 Check the main drive cable...

Page 84: ...r diverter gate Go to step 3 Go to step 2 2 Is the sensor diverter gate connected properly Replace the sensor diverter gate Go to Sensor diverter gate removal on page 4 110 Replace the connection 3 Check the drive motor entrance paddle by opening the finisher front door assembly and then closing it Does the motor entrance paddle rotate normally Go to step 5 Go to step 4 4 Check the main drive cabl...

Page 85: ...erform a test print Does the problem remain Replace the printer engine card assembly Refer to the Printer Service Manual Problem solved Step Check Yes No 1 Check the vertical transport mechanism of the stacker bin for obstacles and deformation Are the any obstacles in the vertical transport mechanism of the stacker bin Remove obstacles Go to step 2 2 Is there any deformation in the vertical transp...

Page 86: ...step 7 Go to step 6 6 Is the sensor stacker bin level 2 connected properly Replace the sensor stacker bin level 2 Go to Sensor stacker bin level 2 removal on page 4 34 Replace the connection 7 Check the stacker bin lift motor assembly by blocking the lower hole in either of the sensor stacker bin level The stacker bin should lower slightly Does the stacker bin lift motor assembly rotate normally G...

Page 87: ...moval on page 4 34 Replace the connection 3 Check the sensor stacker bin level 2 for correct operation Perform the sensor stacker bin level 2 test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Bin Level 5 Select Stacker bin level2 Does the display on the operator panel change every time the sensing area of the sensor stacker bin level 2 is blocked by a multi page ...

Page 88: ...8 Check the stacker bin lift motor assembly by blocking the lower hole in either of the sensors stacker bin level The stacker bin should lower slightly Does the stacker bin lift motor assembly rotate normally Go to step 10 Go to step 9 9 Check the stacker bin lift motor assembly connection Is the connection of the stacker bin lift motor assembly connected to the finisher controller card assembly s...

Page 89: ...oes the display on the operator panel change every time the sensing area of the sensor stacker bin level 1 is blocked by a multi page document or your finger Go to step 6 Go to step 5 5 Is the sensor stacker bin level 1 connected properly Replace the sensor stacker bin level 1 Go to Sensor stacker bin level 1 removal on page 4 34 Replace the connection 6 Check the sensor stacker bin level 2 for co...

Page 90: ...ing the lower hole in either of the sensor stacker bin level The stacker bin should lower slightly Does the stacker bin lift motor assembly rotate normally Go to step 12 Go to step 11 11 Check the stacker bin lift motor assembly connection Is the connector of the stacker bin lift motor assembly correctly connected to the finisher controller card assembly Replace the stacker bin lift motor assembly...

Page 91: ...ve motor by opening the finisher front door assembly and then closing it Does the front tamper drive motor rotate and does the tamper move back and forth Go to step 6 Go to step 5 5 Check the compiler unit cable assembly connection Are the connections of the compiler unit cable assembly correctly connected Replace the media compiler unit assembly Go to Media compiler unit assembly removal on page ...

Page 92: ...ve motor by opening the finisher front door assembly and then closing it Does the front tamper drive motor rotate and does the tamper move back and forth Go to step 6 Go to step 5 5 Check the compiler unit cable assembly connection Are the connections of the compiler unit cable assembly correctly connected Replace the media compiler unit assembly Go to Media compiler unit assembly removal on page ...

Page 93: ...Check the rear tamper drive motor by opening the finisher front door assembly and then closing it Does the rear tamper drive motor rotate and does the tamper move back and forth Go to step 6 Go to step 5 5 Check the compiler unit cable assembly connection Are the connections of the compiler unit cable assembly correctly connected Replace the compiler unit assembly Replace the connection 6 Perform ...

Page 94: ...e the connection 4 Check the rear tamper drive motor by opening the finisher front door assembly and then closing it Does the rear tamper drive motor rotate and does the tamper move back and forth Go to step 6 Go to step 5 5 Check the compiler unit cable assembly connection Are the connections of the compiler unit cable assembly correctly connected Replace the media compiler unit assembly Go to Me...

Page 95: ... Go to Sensor punch hole select sensor punch cam front and sensor punch unit HP removal on page 4 49 Replace the connection 4 Check the punch unit motor for correct operation Perform the 2 punch test Remove the rear upper cover Go to Rear upper cover removal on page 4 24 1 Enter the Diagnostic mode 2 Select FINISHER TESTS 3 Select Hole Punch Test 4 Select 2 Punch test Does the punch unit motor rot...

Page 96: ...g area of the sensor punch unit HP is blocked Go to step 4 Go to step 3 3 Is the sensor punch unit HP and punch sensor cable assembly connected properly Replace the sensor punch unit HP Go to Sensor punch hole select sensor punch cam front and sensor punch unit HP removal on page 4 49 Replace the connection 4 Check the punch unit motor for correct operation Perform the 2 punch test Remove the rear...

Page 97: ...t Punch carriage shift HP Open the finisher front door assembly Move the punch carriage assembly back and forth Does the operator panel display change every time the sensing area of the above sensor is blocked Go to step 4 Go to step 3 3 Check the sensor punch carriage shift HP connection Are the connections of the punch sensor cable assembly correctly connected Replace the sensor punch carriage s...

Page 98: ... Go to step 2 Remove obstructions 2 Check the sensor punch carriage shift HP for correct operation Perform the sensor punch carriage shift HP test 1 Enter the Diagnostic mode 2 Select FINISHER TESTS 3 Select Sensor Test 4 Select Punch and Staple 5 Select Punch carriage shift HP Open the finisher front door assembly Move the punch carriage assembly back and forth Does the operator panel display cha...

Page 99: ...connection 6 Perform a test print Does the error still occur Replace the printer engine card assembly Refer to the Printer Service Manual Problem solved Step Check Yes No 1 Check the media eject clamp by opening the finisher front door assembly and then closing it Does the eject clamp mechanism move smoothly Go to step 2 Remove obstacles 2 Check the sensor media eject clamp HP for correct operatio...

Page 100: ...est print Does the error still occur Replace the finisher controller card assembly Go to Finisher controller card assembly removal on page 4 118 Problem solved Step Check Yes No 1 Check the media eject clamp by opening the finisher front door assembly and then closing it Does the eject clamp mechanism move smoothly Go to step 2 Remove obstacles 2 Check the sensor media eject clamp HP for correct o...

Page 101: ...ion 6 Perform a test print Does the error still occur Replace the finisher controller card assembly Go to Finisher controller card assembly removal on page 4 118 Problem solved Step Check Yes No 1 Check the media eject shaft assembly by moving it with your fingers Does the media eject shaft assembly mechanism move smoothly Go to step 2 Remove obstructions 2 Check the sensor media eject shaft HP fo...

Page 102: ...bly removal on page 4 78 Replace the connection 6 Check the media eject clutch assembly by opening the finisher front door assembly and then closing it The three clamp paddles should rotate Does the media eject clutch assembly operate Go to step 8 Go to step 7 7 Check the media eject clutch assembly connection Is the above component connected properly Replace the media eject clutch assembly Go to ...

Page 103: ...ation Check the media eject motor assembly by opening the finisher front door assembly and then closing it Does the media eject motor assembly rotate normally Go to step 6 Go to step 5 5 Is the media eject motor assembly connected properly Replace the media eject motor assembly Go to Media eject motor assembly removal on page 4 78 Replace the connection 6 Check the media eject clutch assembly by o...

Page 104: ... every time a piece of white media is placed over the sensing area of the sensor punch unit side reg1 Go to step 3 Go to step 4 3 Check the sensor punch unit side reg2 for correct operation Perform the sensor punch unit side reg2 test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Punch and Staple 5 Select Punch side reg2 Open the finisher front door Insert a fragm...

Page 105: ...oval on page 4 43 Replace the connection 7 Perform a test print Does the error still occur Replace the printer engine card assembly Refer to the Printer Service Manual Problem solved Step Check Yes No 1 Check the punch carriage by moving it with your fingers Does the punch carriage move back and forth smoothly Go to step 2 Remove obstructions 2 Check the sensor punch unit side reg1 for correct ope...

Page 106: ...propriate sensor punch unit side reg Go to Sensor punch unit side registration pair with bracket removal on page 4 44 Replace the connection 5 Open the finisher front door assembly Manually push the punch carriage toward the rear of the finisher Check the punch carriage shift motor assembly by opening and closing the finisher front door The punch carriage should move slightly Does the punch carria...

Page 107: ...printer engine card assembly Refer to the Printer Service Manual Problem solved Step Check Yes No 1 Check the stapler by moving it with your fingers Does the Stapler carriage move smoothly Go to step 2 Remove obstructions 2 Check the sensor stapler carriage HP for correct operation Perform the sensor stapler carriage HP test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 ...

Page 108: ...e HP for correct operation Perform the sensor stapler carriage HP test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Punch and Staple 5 Select Stapler carriage shift HP Does the display on the operator panel change every time the sensing area of the sensor stapler carriage HP is placed to the interrupt flag of the stapler rack gear by moving the stapler carriage b...

Page 109: ...oller card assembly properly connected Replace the finisher controller card assembly Finish er controller card assembly removal on page 4 118 Problem resolved Step Check Yes No 1 Check the printer and finisher installation Is the finisher installed to the printer correctly Go to step 2 Reinstall the finisher 2 Turn the power on and off Does the error still occur when the power is back on Go to ste...

Page 110: ...o the rear of the finisher Go to step 2 Replace the connection 2 Open and close the bridge unit top cover assembly on the bridge unit assembly Does it open or close smoothly Go to step 2 Check that the bridge unit top cover assembly is installed properly and correct any deformations If this does not correct the problem replace the bridge unit top cover assembly Go to Bridge unit top cover assembly...

Page 111: ... Menu 2 Touch FINISHER TESTS 3 Touch Sensor Test 4 Touch Cover and Door 5 Touch Door F bridge top Does the operator panel display change every time the detection point of the sensor bridge unit top cover interlock is blocked Go to step 7 Go to step 6 7 Is the sensor bridge unit top cover interlock connected properly Replace the sensor bridge unit top cover interlock Go to Sensor bridge unit top co...

Page 112: ...terlock test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Cover and Door 5 Select Door G fin front Does the display on the operator panel change every time the detection point of the switch finisher front door interlock is pressed by the tip of the screwdriver Go to step 5 Go to step 4 4 Is the switch finisher front door interlock connected properly Replace the s...

Page 113: ...edia cover interlock connected properly Replace the switch eject cover interlock Go to Switch eject cover interlock removal on page 4 68 Replace the connection 4 Perform a test print Does the error still occur Replace the finisher controller card assembly Go to Finisher controller card assembly removal on page 4 118 Problem solved Step Check Yes No 1 Check the sensor upper media bin full for corre...

Page 114: ...led properly Go to step 2 Reinstall the sensor punch waste box set Go to Sensor punch waste box set removal on page 4 52 2 Check the sensor punch waste box set Perform sensor punch waste box set test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Punch and Staple 5 Select Punch box set Open the finisher front door Remove the punch waste box Does the display on the ...

Page 115: ...all the sensor punch waste box full Go to Sensor punch waste box full removal on page 4 53 2 Check the sensor punch waste box full Perform the sensor punch waste box full test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Punch and Staple 5 Select Punch waste box full Open the finisher front door Remove the punch waste box Insert a sheet of white media into the se...

Page 116: ... Select Stacker bin level1 Does the display on the operator panel change every time the sensing area of the sensor stacker bin level 1 is blocked by a multi page document or your finger Go to step 4 Go to step 3 3 Is the sensor stacker bin level 1 connected properly Replace the sensor stacker bin level 1 Go to Sensor stacker bin level 1 removal on page 4 34 Replace the connection 4 Check the senso...

Page 117: ...or assembly is moved by hand Go to step 9 Go to step 8 8 Is the sensor stacker bin level encoder connected properly Replace the sensor stacker bin level encoder Go to Sensor stacker bin level encoder removal on page 4 35 Replace the connection 9 Check the stacker bin lift motor assembly by blocking the lower hole in either of the sensor stacker bin level The stacker bin should lower slightly Does ...

Page 118: ...or stacker bin level 1 Go to Sensor stacker bin level 1 removal on page 4 34 Replace the connection 4 Check the sensor stacker bin level 2 for correct operation Perform the sensor stacker bin level 2 test 1 Select Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Bin Level 5 Select Stacker bin level2 Does the display on the operator panel change every time the sensing area of...

Page 119: ... by blocking the lower hole in either of the sensors stacker bin level The stacker bin should lower slightly Does the stacker bin lift motor assembly rotate normally Go to step 11 Go to step 10 10 Is the stacker bin lift motor assembly connected properly Replace the stacker bin lift motor assembly Go to Stacker bin lift motor assembly removal on page 4 38 Replace the connection 11 Perform a test p...

Page 120: ...elect FINISHER TESTS 3 Select Sensor Tests 4 Select Bin Level 5 Select Stacker bin level2 Does the display on the operator panel change every time the sensing area of the sensor stacker bin level 2 is blocked by a multi page document Go to step 7 Go to step 6 6 Check the sensor stacker bin level 2 connection Are the connections of the main sensor cable assembly correctly connected Replace the sens...

Page 121: ...ssembly Refer to the Printer Service Manual Problem solved Step Check Yes No 1 Check the staple cartridge for new and unused staples Does the staple cartridge have a sufficient amount of new and unused staples Go to step 2 Refill the cartridge with new and unused staples 2 Check the staple cartridge for correct installation Is the staple cartridge installed properly Go to step 3 Install the staple...

Page 122: ...sembly Go to Stapler unit assembly removal on page 4 56 Replace the connection 6 Perform a stapled print test Does the error still occur Replace the finisher controller card assembly Go to Finisher controller card assembly removal on page 4 118 Problem solved 7 Perform a stapled print test Replace the printer engine card assembly Refer to Printer Service Manual Problem solved Step Check Yes No ...

Page 123: ...ests described in this chapter you must put the printer in Diagnostics mode Available finisher tests This is a partial list of the tests available to the printer Details below are for the finisher only The tests display on the operator panel in the order shown Diagnostics mode 1 Turn off the printer 2 Press and hold and 3 Turn on the printer 4 Release the buttons when the clock face appears The Di...

Page 124: ...om FINISHER TESTS While the feed test runs the power indicator blinks and the message Feed Test Running displays During the test no buttons are active and the test cannot be stopped until the test is completed Feed Tests This test is used to verify whether or not media can be fed to a finisher output bin Eight sheets of blank paper are fed from the default paper source and fed to the finisher outp...

Page 125: ...a Path1 Fuser exit Bridge media ent Bridge media exit Fin media ent Buffer path Upper media exit Lower media exit Compiler media in Media Path2 Diverter gate Front tamper hp Rear tamper hp Eject clamp hp Media eject shaft hp Punch and Staple Punch side reg1 Punch side reg2 Punch box set Punch waste full Low staple Punch carriage shift hp Punch unit hp Stapler carriage shift hp Punch cam front Punc...

Page 126: ...e view viewing from the front side of sensors rollers and main blocks as well as a layout rear view of the main components Bridge unit assembly paper path Finisher media path To finisher From printer Transport belt Sensor bridge unit media exit Sensor bridge unit media entrance Compiler media unit assembly Stapler unit Punch unit From bridge unit Upper media bin Stacker media bin ...

Page 127: ...otor exit Main paddle driven by drive motor entrance paddle Buffer diverter gate Buffer roll assembly driven by drive motor buffer transport Finisher media entrance roll assembly driven by drive motor entrance paddle Upper media transport roll assembly driven by drive motor buffer transport Eject clamp driven by media eject clamp motor From bridge unit Sensor upper media exit Sensor upper media bi...

Page 128: ...y The motor power is transmitted to the two belts between bridge unit right shaft assembly and bridge unit left shaft assembly The media fed to the bridge unit assembly is securely held between the transport belts and the pinch rolls and fed to the finisher Drive motor exit Drive motor buffer transport Finisher diverter gate solenoid Buffer diverter solenoid Drive motor entrance paddle Stacker bin...

Page 129: ...d to the punch unit by the upper media transport roll assembly or the buffer roll assembly assembly and is stopped with its end gently pressed against the three punch media stopper assemblies The three punch media stopper assemblies in the punch unit drop to let media pass through when feeding media to the exit while the motor buffer transport is rotating forward but rises when media is returned w...

Page 130: ...ect motor assembly starts reverse rotation to return the media to the compiler unit assembly When the following media reaches the compiler unit assembly the media eject clamp is raised and the media that has passed through the lower media exit roll assembly falls on the compiler unit assembly At this time the three main paddles are rotated by the main paddle shaft assembly to feed the media so tha...

Page 131: ...ted in the same way The media is stacked temporarily on the compiler unit assembly and then ejected in the stacker media bin After buffer path is executed for the first media if the second media of a different size comes the first media is fed to the compiler unit assembly but the second one is fed to the compiler unit assembly without buffer path At this time a certain delay time is provided to a...

Page 132: ...uffer transport feed media to the upper media exit roll assembly top at the top of the finisher The upper media exit roll assembly top driven by the drive motor exit to eject the media to the upper media bin The upper media exit roll assembly decelerates after a specified period of time from the following trigger events Functions of sensors along the media path Bridge unit assembly Sensor bridge u...

Page 133: ...tor on the compiler unit assembly This sensor is also used to control on off of the media eject motor assembly Sensor compiler media present A photo interrupter to detect whether media is present or not on the compiler unit assembly While media is present the actuator is outside the sensing area and the sensor turns at H 5 V dc light receiving Sensor buffer path A photo interrupter to detect wheth...

Page 134: ...he following method Activate the punch carriage shift motor assembly and move the punch to the front side until the sensor punch carriage shift HP turns L Rotate reversely the motor and move the punch to the rear side until the sensor turns H to determine the home position The punch carriage shift motor assembly is activated to move the punch to the front until the sensor punch unit side registrat...

Page 135: ...on is performed for each sheet of media The cam plate can lower the pins even while it is moving to the front or rear side The punch unit motor is rotated forward or reversely for each sheet of media which is triggered by the sensor punch cam front on off Pin position Home position Sensor punch hole select Sensor punch cam front Sensor punch unit HP Punch unit motor Pin Cam plate 3 hole position H...

Page 136: ...t side registration 1 Sensor punch carriage shift HP A photo interrupter to detect the home position of the moving punch It turns H 5 v dc light blocking when the home position is detected Sensor punch unit HP A photo interrupter to detect the home position of the cam plate that lowers the punching pins It turns H 5 V dc when the home position is detected Sensor punch hole select A photo interrupt...

Page 137: ...ormed to align the media edge in the media width direction When ejecting stapled sets of media to the stacker media bin if they are stacked in the stacker media bin with the same staple position the height of the stapled portion will increase This will cause improper compiling of media due to butting of the following media To prevent such improper compiling offsetting is required by shifting the s...

Page 138: ... are used stapling media on the compiler unit assembly is stopped when a different size is detected Such different size sheets of media are forcibly ejected to the stacker media bin Tamping When media is fed from the punch to the compiler unit assembly tamping operation is performed to align the media in the media width direction on the compiler unit assembly Tamping is an operation to align media...

Page 139: ...n below Position Description 1 Front tamper home position sensor front tamper HP 2 Front tamper size position 3 Front tamper offset position 4 Rear tamper home position sensor rear tamper HP 5 Rear tamper standby position 6 Rear tamper tamping position 7 Rear tamper offset position Sensor front tamper HP Front Sensor rear tamper HP Rear Rear tamper motor Rear tamper Front tamper Front tamper motor...

Page 140: ...rear tamping are shown below Position Description 1 Front tamper home position sensor front tamper HP 2 Front tamper tamping position 3 Front tamper offset position 4 Rear tamper home position sensor rear tamper HP 5 Rear tamper size position 6 Rear tamper offset position Sensor front tamper HP Front Sensor rear tamper HP Rear Front tamper motor Front tamper Rear tamper motor Rear tamper ...

Page 141: ...e way the rear tamper home position is determined when the rear tamper enters the sensor rear tamper HP sensing area Tamping Tamping is executed after a preset time has passed after the sensor compiler media present turns H 5 V dc when media is detected on the compiler unit assembly Position Description 1 Front tamper home position sensor front tamper HP 2 Front tamper standby position 3 Front tam...

Page 142: ... the front tamper by 9 mm to the rear side before ejecting them to the stacker media bin Offsetting is not executed 0 mm for small media Functions of compiler unit assembly sensors motors Sensor compiler media in A photo interrupter to detect whether media is present or not on the compiler unit assembly When media is detected the actuator leaves the sensing area which turns the sensor to H 5 V dc ...

Page 143: ...command of the printer Staple positions There are four stapling modes Front staple corner Front Corner The stapler staples a set of media obliquely 45 degrees after the rear tamper aligns the media to the front side Rear staple corner rear corner This type of stapling is applied for media with a width of 216 mm or more The stapler moves to the rear corner and staples a set of media obliquely 45 de...

Page 144: ...ition Stapling one sheet Upon receiving the stapling command from the printer with one sheet remaining on the compiler unit assembly the finisher ejects the media to the stacker media bin without stapling it Stapling multiple size media When sheets with different sizes and same width example A4L and A3S are present on the compiler unit assembly all the sheets are stapled and then ejected to the st...

Page 145: ...nit assembly the exceeding sheets are also ejected forcibly to the stacker media bin without being stapled After that even if the number of following sheets of one set to be stapled falls within the limit the sheets are also ejected forcibly to the stacker media bin without being stapled Upper limit of compiler unit assembly media capacity when stapling default 50 variable 10 to 100 by the non vol...

Page 146: ...ght position It turns H 5 V dc light blocking when the stapler comes to the specified position Stapler carriage motor assembly A stepping motor to move the stapler unit assembly Clockwise rotation of this motor moves the stapler unit assembly to the rear side while counterclockwise rotation moves the stapler unit assembly to the front side Sensor low staple in the stapler unit assembly A photo int...

Page 147: ...of the upper media bin ejection of media to the upper media bin is inhibited until full stack is reset Functions of upper media bin sensors Sensor upper media exit A photo interrupter to detect that media has come to the upper media exit roll assembly top at the exit of the upper media bin When media reaches the upper media exit roll assembly top the actuator leaves the sensing area which turns th...

Page 148: ...stacker media bin while the sensor stacker bin level turns from the light blocking state to the light receiving state The sensor stacker bin no media is turned On or Off by the actuator attached to the carriage assembly right on the rear side of the finisher In case the stacker media bin abnormally goes up above the sensor stacker bin no media the sensor stacker bin upper limit is installed above ...

Page 149: ...Lower Safety Warning is detected and the stacker media bin is stopped Actuator Stacker bin lift motor assembly Sensor stacker bin level encoder Sensor media eject shaft HP Media eject motor assembly Sensor media eject clamp HP Eject clamp motor Sensor stacker bin level 1 Stacker media bin Sensor stacker bin level 2 Sensor stacker bin upper limit Sensor stacker bin no media ...

Page 150: ...d condition of media stacked in the tray are not identified Media was present in the stacker media bin when power was turned on The size and condition of media stacked in the tray are not identified The finisher entered the Sleep Mode with mix stacking and then has exited the Sleep Mode The post processing mode has changed Functions of stacker media bin sensors motors sensor stacker bin level 1 A ...

Page 151: ...nd counterclockwise rotation lowers the tray Media eject motor assembly A stepper motor to eject stapled or non stapled media to the stacker media bin Clockwise rotation ejects media to the stacker media bin and counterclockwise rotation reverses the eject roll to feed the media from the punch to the compiler unit assembly Media eject clamp motor A DC motor to elevate or lower the media eject clam...

Page 152: ...he Interlock 24 V dc line in the finisher Switch eject cover interlock Turns off when the cover eject on the right side opens shutting off the Interlock 24 V dc line in the finisher Switch eject cover interlock Switch finisher front door interlock AC Printer Finisher LVPS card asm 24 Vdc ON OFF Finisher controller card asm 5 Vdc 24 Vdc Interlock 24 Vdc Sensor Switch eject cover interlock Switch fi...

Page 153: ...ectricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the ESD sensitive part on the machine cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tables are electric...

Page 154: ...s peripherals Note Some removal procedures require removing cable ties You must replace cable ties during reassembly to avoid pinching wires obstructing the paper path or restricting mechanical movement Bridge unit assembly removal 1 Release the hook securing the bridge unit hookup cover A to the finisher 2 Remove the bridge unit hookup cover A 3 Remove the finisher from the printer See Finisher r...

Page 155: ...Repair information 4 3 4024 110 5 Remove the bridge unit assembly B from the printer B ...

Page 156: ...finisher power cord and the finisher connection cable from the rear of the printer 2 Release the hook securing the bridge unit hookup cover A to the finisher 3 Remove the bridge unit hookup cover A 4 Disconnect the bridge unit connection from the finisher Right Rear A Hook ...

Page 157: ...en the finisher front door assembly B on the front of the finisher 6 Pull the finisher docking latch assembly C outward in the direction of the arrow and pull the finisher away from the printer 7 Close the finisher front door assembly C B ...

Page 158: ... sure the boss on the finisher docking bracket D is inserted into the hole on the finisher docking latch assembly C The finisher should be firmly locked into position Bridge unit rear cover removal 1 Remove the bridge unit assembly See Bridge unit assembly removal on page 4 2 2 Remove the two screws securing the bridge unit rear cover A to the bridge unit assembly B 3 Remove the bridge unit rear c...

Page 159: ...idge unit rear cover removal on page 4 6 2 Open the bridge unit top cover assembly A 3 Remove the six screws securing the bridge unit top cover assembly A to the bridge unit assembly B 4 Lift the bridge unit top cover assembly A upward in the direction of the arrow 5 Remove the bridge unit top cover assembly A A B ...

Page 160: ...emove the e clip with a prying tool securing the bridge unit drive pulley A to the bridge unit assembly B 3 Remove the bridge unit drive pulley A and the bridge unit drive belt C from the bridge unit assembly B Replacement note Make sure to install the bridge unit drive pulley A to the bridge unit assembly in the direction shown B A C Install this surface facing outside Recessed key ...

Page 161: ...removal on page 4 8 3 Remove the 6 mm bushing A from the bridge unit right shaft assembly B 4 Open the bridge unit top cover assembly C 5 Use a prying tool to remove the e clip securing the 6 mm bushing D to the bridge unit assembly 6 Remove the 6 mm bushing D 7 Move the bridge unit right shaft assembly B toward the right as shown 8 Remove the bridge unit right shaft assembly B from the two transp...

Page 162: ...mm ball bearing A to the bridge unit left shaft B 3 Move the bridge unit left shaft B rearward as shown 4 Remove the bridge unit left shaft B from the two transport belts C 5 Remove the bridge unit left shaft B 6 Remove the other e clip securing the 4 mm ball bearing A on the other end of the shaft 7 Remove the second 4 mm ball bearing A from the bridge unit left shaft C A B Front ...

Page 163: ... assembly removal on page 4 10 3 Move the two transport belts A away from the two bridge unit idler rolls B 4 Lift the two bridge unit idler rolls upward to release them from the bridge unit assembly C 5 Remove the bushings D from the bridge unit idler rolls Replacement note When replacing the bridge unit idler rolls make sure the bushings are installed as shown B A D D Flat C ...

Page 164: ...it top cover assembly 3 Remove the bridge unit right shaft assembly See Bridge unit right shaft assembly removal on page 4 9 4 Remove the bridge unit left shaft assembly See Bridge unit left shaft assembly removal on page 4 10 5 Remove the bridge unit idler rolls See Bridge unit idler rolls removal on page 4 11 6 Remove the transport belts A from the bridge unit assembly B A B ...

Page 165: ...it drive pulley removal on page 4 8 3 Disconnect the connector from the bridge unit drive motor A 4 Release the harness from the clamp 5 Open the bridge unit top cover assembly 6 Remove the two screws securing the cover B from the bridge unit assembly C 7 Remove the cover B 8 Remove the two screws securing the bridge unit drive motor A to the bridge unit assembly C 9 Remove the bridge unit drive m...

Page 166: ...val 1 Remove the bridge unit rear cover See Bridge unit rear cover removal on page 4 6 2 Open the bridge unit top cover assembly 3 Remove the two screws securing the bridge unit entrance guide A to the bridge unit assembly B 4 Remove the bridge unit entrance guide A A B ...

Page 167: ... 4 2 2 Place the bridge unit assembly upside down 3 Remove the screw securing the bracket A to the bridge unit assembly B 4 Disconnect the cable from the sensor bridge unit top cover interlock C 5 Release the hooks securing the sensor bridge unit top cover interlock C to the bracket A 6 Remove the sensor bridge unit top cover interlock C C B A Connector ...

Page 168: ...n page 4 2 2 Place the bridge unit assembly upside down 3 Remove the screw securing the bracket A to the bridge unit assembly B 4 Disconnect the connector from the sensor bridge unit media entrance C 5 Release the hooks securing the sensor bridge unit media entrance C to the bracket A 6 Remove the sensor bridge unit media entrance C C A B Connector ...

Page 169: ... removal on page 4 2 2 Place the bridge unit upside down 3 Remove the screw securing the bracket A to the bridge unit B 4 Disconnect the connector from the sensor bridge unit media exit C 5 Release the hooks securing the sensor bridge unit media exit C to the bracket A 6 Remove the sensor bridge unit media exit C A C B Connector ...

Page 170: ... 4024 110 Bridge unit pinch roller removal 1 Open the bridge unit top cover assembly A 2 Remove the six bridge unit pinch rollers B by gently pulling them out of the bridge unit top cover assembly 3 Remove the six springs C A C B ...

Page 171: ...front door assembly 2 Remove the rear upper cover See Rear upper cover removal on page 4 24 3 Remove the upper media bin assembly See Upper media bin assembly removal on page 4 20 4 Remove the four screws securing the top cover A to the finisher 5 Remove the top cover A A ...

Page 172: ...0 Upper media bin assembly removal 1 Loosen the two screws securing the upper media bin assembly A to the finisher 2 Lift the upper media bin assembly A upward in the direction of the arrow 3 Remove the upper media bin assembly A A Right ...

Page 173: ...he finisher front door assembly See Finisher front door assembly removal on page 4 27 2 Remove the rear upper cover See Rear upper cover removal on page 4 24 3 Remove the two screws securing the right eject cover A to the finisher 4 Remove the right eject cover A A Right ...

Page 174: ...the stacker media bin assembly A upward 3 Remove the stacker media bin assembly A Right lower low voltage power supply LVPS cover removal 1 Remove the two screws securing the right lower LVPS cover A to the finisher 2 Remove the right lower LVPS cover A Replacement note Make sure to put the power cord B into the notch on the right lower LVPS cover A A B Notch A ...

Page 175: ...n 4 23 4024 110 Rear lower cover removal 1 Remove the rear upper cover See Rear upper cover removal on page 4 24 2 Remove the four screws securing the rear lower cover A to the finisher 3 Remove the rear lower cover A A ...

Page 176: ...cover removal 1 Release the hook of the bridge unit hookup cover A to the finisher 2 Disconnect the bridge unit harness from the finisher 3 Remove the four screws securing the rear upper cover B to the finisher 4 Remove the rear upper cover B A B Hook ...

Page 177: ... finisher front door assembly See Finisher front door assembly removal on page 4 27 2 Remove the upper media bin assembly See Upper media bin assembly removal on page 4 20 3 Remove the two screws securing the upper media bin front cover A 4 Remove the upper media bin front cover A A ...

Page 178: ... box A 4 Remove the three screws in the front securing the punch waste chute B 5 Gently pull down the punch waste chute B to gain better access to the switch finisher front door interlock C 6 Disconnect the connector from the switch finisher front door interlock C 7 Release the hooks securing the switch finisher front door interlock C to the finisher 8 Remove the switch finisher front door interlo...

Page 179: ...the three screws securing the finisher front door assembly 3 Remove the finisher front door assembly Replacement note Make sure the actuator molded in the finisher front door assembly properly engages the switch finisher front door interlock B The two magnetic catches C should properly engage the finisher A C Actuator C B ...

Page 180: ...4 28 Finisher Service Manual 4024 110 Left lower cover removal 1 Open the finisher front door assembly 2 Remove the two screws securing the left lower cover A 3 Remove the left lower cover A A ...

Page 181: ...Repair information 4 29 4024 110 Left upper cover removal 1 Open the finisher front door assembly 2 Remove the two screws securing the left upper cover A 3 Remove the left upper cover A A ...

Page 182: ... 24 2 Remove the finisher front door assembly See Finisher front door assembly removal on page 4 27 3 Move the slip clutch gear 24T A toward the rear to disengage the stacker bin B 4 Move the stacker bin B down to its lowest position after being disengaged Note Make sure the stacker bin is at its lowest position before continuing Rear A B ...

Page 183: ...e left carriage bracket D 8 Remove the upper belt clamp F 9 Remove the left carriage bracket with the carriage lift belt G from the finisher 10 Release the hook securing the carriage lift belt G to the lower belt clamp H 11 Remove the carriage lift belt G Replacement notes Make sure the carriage lift belt G is inserted into the upper belt clamp F as shown Make sure the bin bracket C is level to pr...

Page 184: ...oval on page 4 24 2 Remove the finisher front door assembly See Finisher front door assembly removal on page 4 27 3 Move the slip clutch gear 24T A toward the rear to disengage the stacker bin B 4 Move the stacker bin B to its lowest position Note Make sure the stacker bin is at the lowest position before continuing Rear A B ...

Page 185: ...right carriage bracket D 8 Remove the upper belt clamp F 9 Remove the right carriage bracket D with the carriage lift belt G from the finisher 10 Release the hook securing the carriage lift belt G to the lower belt clamp H 11 Remove the carriage lift belt G Replacement notes Make sure the carriage lift belt G is inserted into the upper belt clamp F as shown Make sure the bin bracket C is level to ...

Page 186: ...w securing the sensor stacker bin level 1 A to the finisher 5 Remove the sensor stacker bin level 1 A Sensor stacker bin level 2 removal 1 Remove the finisher front door assembly See Finisher front door assembly removal on page 4 27 2 Remove the rear upper cover See Rear upper cover removal on page 4 24 3 Disconnect the connector from the lift tray height sensor stacker bin level 2 A 4 Remove the ...

Page 187: ...age 4 24 2 Disconnect the connector from the sensor stacker bin level encoder A 3 Release the harness from the clamp 4 Remove the screw securing the bracket B from the stacker bin lift motor assembly C 5 Release the hooks securing the sensor to the bracket B 6 Remove the sensor stacker bin level encoder A A B C Rear Clamp Clamp Connector ...

Page 188: ...y See Stacker media bin assembly removal on page 4 22 3 Remove the stacker bin lift motor assembly See Stacker bin lift motor assembly removal on page 4 38 4 Remove the four screws securing the metal cover A to the finisher 5 Remove the metal cover A 6 Disconnect the connector from the sensor stacker bin upper limit B or the sensor stacker bin no media C 7 Release the hooks of the selected sensor ...

Page 189: ...Repair information 4 37 4024 110 Replacement note Make sure that the yellow connector is plugged into the sensor stacker bin no media C C B Rear Yellow connector B White connector C ...

Page 190: ... removal 1 Remove the rear upper cover See Rear upper cover removal on page 4 24 2 Remove the rear lower cover See Rear lower cover removal on page 4 23 3 Loosen the four screws securing the plate A 4 Move the plate A toward the right as shown 5 Remove the plate A A Rear ...

Page 191: ...cker bin C to the lowest position Note Make sure the stacker bin C is at the lowest position before continuing 8 Disconnect the connector from the sensor stacker bin level encoder D 9 Release the harness from the clamps 10 Disconnect the connector P8305 from the finisher controller card assembly E C B Rear Clamp Clamp D P8305 E ...

Page 192: ...otor assembly G 12 Remove the bracket F 13 Release the hook securing the encoder H to the stacker bin lift motor assembly G 14 Remove the encoder 15 Remove the three screws securing the stacker bin lift motor assembly G to the finisher 16 Remove the stacker bin lift motor assembly G G F Clamp Connector G H ...

Page 193: ...ss from the punch carriage assembly B 6 Remove the connector from the punch carriage shift motor assembly C 7 Release the two punch unit assembly harnesses from the three clamps on the rear of the finisher 8 Disconnect the two punch unit assembly harnesses from the main harness 9 Remove the screw securing the grounding wire D to the punch unit carriage assembly B 10 Remove the two screws on the re...

Page 194: ...not force the punch carriage assembly B out of the finisher Be sure to hold the unit firmly to avoid dropping it Replacement notes Do not force the punch unit into the finisher Be sure to hold the punch carriage assembly firmly to avoid dropping it Make sure all harnesses are properly clamped Make sure the punch carriage assembly is able to shift back and forth completely without binding the harne...

Page 195: ...r removal on page 4 24 3 Remove the punch carriage assembly See Punch carriage assembly removal on page 4 41 4 Remove the two screws securing the cover A to the punch carriage assembly B 5 Remove the cover A 6 Remove the two screws securing the punch carriage shift motor assembly C to the punch unit assembly B 7 Remove the punch carriage shift motor assembly C A C B ...

Page 196: ...e cover 6 Remove the two screws securing the paper guide C to the punch unit assembly B Note Do not remove the harness attached to the paper guide C 7 Turn the paper guide C upside down 8 Remove the two screws securing the bracket D to the paper guide C 9 Remove the bracket D 10 Remove the two connectors from the sensor punch unit side registration pair E 11 Release the hooks securing the sensors ...

Page 197: ...arriage assembly See Punch carriage assembly removal on page 4 41 4 Remove the screw securing the cover A to the punch unit assembly B 5 Remove the cover A 6 Remove the two screws securing the bracket C to the punch carriage assembly D 7 Remove the bracket C 8 Remove the three screws securing the punch carriage assembly D to the punch unit assembly B 9 Remove the punch unit assembly B D B A C ...

Page 198: ...r upper cover removal on page 4 24 3 Remove the punch carriage assembly See Punch carriage assembly removal on page 4 41 4 Remove the punch unit assembly See Punch unit assembly removal on page 4 45 5 Remove the three screws securing the three punch media stop assemblies A to the punch unit assembly B 6 Remove the three punch media stop assemblies D ...

Page 199: ...nch carriage assembly See Punch carriage assembly removal on page 4 41 4 Disconnect the connector from the punch unit motor assembly A 5 Disconnect the connector from the sensor punch unit motor encoder B 6 Remove the harness from the clamp 7 Remove the two screws securing the punch unit motor assembly A to the punch unit assembly C 8 Remove the punch unit motor assembly B A Clamp C Connector ...

Page 200: ...arriage assembly removal on page 4 41 4 Disconnect the connector from the punch unit motor assembly A 5 Disconnect the connector from the sensor punch unit motor encoder B 6 Remove the harness from the clamp 7 Remove the two screws securing the bracket C to the punch unit assembly D 8 Release the hooks securing the sensor punch unit motor encoder B to the bracket C 9 Remove the sensor punch unit m...

Page 201: ...upper cover removal on page 4 24 3 Remove the punch carriage assembly See Punch carriage assembly removal on page 4 41 4 Remove the screw securing the bracket A to the punch unit assembly B 5 Disconnect the connector from the sensor punch hole select C the sensor punch cam front D or the sensor punch unit HP E 6 Release the hooks securing the sensor s to the bracket 7 Remove the sensor s A B ...

Page 202: ...4 50 Finisher Service Manual 4024 110 Replacement note Make sure the color coded connectors are connected to the proper sensors as shown C D A E White Black Blue ...

Page 203: ...er See Rear upper cover removal on page 4 24 3 Remove the punch carriage assembly See Punch carriage assembly removal on page 4 41 4 Remove the one screw securing the bracket A to the punch carriage unit B 5 Release the hooks securing the sensor punch carriage shift HP C to the bracket A 6 Remove the sensor punch carriage shift HP C A B C ...

Page 204: ...moval 1 Open the finisher front door assembly 2 Pull the punch waste box 3 Disconnect the connector from the sensor punch waste box set A 4 Release the hooks securing the sensor punch waste box set A to the finisher 5 Remove the sensor punch waste box set A A Connector ...

Page 205: ... finisher front door assembly 2 Remove the punch waste box A from the finisher 3 Disconnect the connector from the sensor punch waste box full B 4 Release the hooks securing the sensor punch waste box full B to the finisher 5 Remove the sensor punch waste box full B A B Connector ...

Page 206: ...val on page 4 27 2 Remove the staple cartridge 3 Remove the rear upper cover See Rear upper cover removal on page 4 24 4 Remove the rear lower cover See Rear lower cover removal on page 4 23 5 Loosen the four screws securing the plate A to the finisher 6 Move the plate A toward the right and out in the direction shown 7 Remove the plate A Rear ...

Page 207: ...pler unit frame D to the finisher 14 Move the stapler unit frame upward and outward in the direction of the arrow as shown 15 Remove the stapler unit frame Warning Do not force the stapler unit frame out of the finisher Warning Be sure to hold the stapler unit frame firmly to avoid dropping it Replacement notes Do not force the stapler unit frame into the finisher Be sure to hold the stapler unit ...

Page 208: ...rear lower cover See Rear lower cover removal on page 4 23 5 Remove the stapler unit frame See Stapler unit frame removal on page 4 54 6 Remove the five screws securing the stapler unit frame A to the plate B 7 Remove the stapler unit frame A 8 Release the harness from the three clamps on the stapler unit frame A 9 Remove the two screws securing the stapler carriage motor assembly C to the stapler...

Page 209: ...5 Remove the two screws securing the bracket H to the stapler carriage assembly D 16 Remove the bracket H 17 Remove the two screws securing the bracket H to the stapler unit assembly F 18 Remove the stapler unit assembly F Replacement notes When replacing the stapler unit assembly F make sure the ground wire is reconnected Make sure the stapler carriage assembly D and the stapler carriage motor as...

Page 210: ...r cover See Rear upper cover removal on page 4 24 4 Remove the rear lower cover See Rear lower cover removal on page 4 23 5 Remove the stapler unit frame See Stapler unit frame removal on page 4 54 6 Remove the stapler unit assembly See Stapler unit assembly removal on page 4 56 7 Release the hooks securing the sensor stapler carriage HP A to the stapler carriage assembly B 8 Remove the sensor sta...

Page 211: ...r cover removal on page 4 24 3 Remove the upper media bin assembly See Upper media bin assembly removal on page 4 20 4 Remove the upper media bin vertical cover See Right eject cover removal on page 4 21 5 Remove the two media eject unit springs A by pushing them downward 6 Disconnect the connector from the eject unit solenoid B 7 Release the harness from the two clamps Harness clamp Right B A A C...

Page 212: ...ing the eject clamp lever assembly C from the shaft D on the rear of the finisher 9 Remove the eject clamp lever assembly C 10 Remove the e clip securing the shaft D to the rear of the finisher 11 Remove the 8 mm bushing E on the rear side Rear C Screw E clip E D ...

Page 213: ...ly move the left side of the media eject unit assembly G out of the finisher followed by the right side Note Do not force the media eject unit assembly out of the finisher Remove the left side before the right side Note Tilting the media eject unit assembly slightly may make the removal easier 15 Remove the media eject unit assembly Front E clip E F Right G ...

Page 214: ...cement notes Do not force the media eject unit assembly into the finisher Insert the right side before the left side Make sure the media eject unit assembly properly actuates the switch eject cover interlock H without binding Right Actuator G H ...

Page 215: ...embly See Upper media bin assembly removal on page 4 20 2 Gently remove the two sub paddles A from the two shafts B Replacement notes Make sure the sub paddles are properly installed as shown in the figure The paddles must not come in contact with the media eject unit assembly C B C A ...

Page 216: ...cover removal on page 4 24 3 Remove the media eject unit assembly See Media eject unit assembly removal on page 4 59 4 Loosen the screw securing the knob A to the sub paddle drive shaft assembly B on the front of the finisher 5 Remove the knob A 6 Remove the one e clip securing the sub paddle drive shaft assembly B 7 Remove the bushing C B C A E clip Screw Front ...

Page 217: ...addle drive gear 23T E 11 Remove the e clip and the 6 mm bushing C 12 Move the sub paddle drive shaft assembly B toward the rear of the finisher and outward 13 Remove the sub paddle drive shaft assembly B Replacement notes The tension of the belt exit F is automatically adjusted by the force of the spring attached to the belt tensioner bracket D Tighten the two screws in the order shown Rear B C E...

Page 218: ...ect clamp motor C 5 Disconnect the connector from the sensor media eject clamp HP D 6 Remove the three screws securing the bracket E to the finisher 7 Remove the bracket E Note When removing the bracket turn the media eject clamp gear 70T F so that it does not interact with the sensor media eject clamp HP D 8 Remove the two screws securing the media eject clamp motor to the bracket E 9 Remove the ...

Page 219: ...media bin assembly removal on page 4 20 3 Remove the two media eject unit springs attached to the media eject unit assembly by pushing them downward 4 Remove the media eject clamp motor assembly See Media eject clamp motor assembly removal on page 4 66 5 Release the hooks of the sensor media eject clamp HP A from the bracket B 6 Remove the sensor media eject clamp HP A Right Springs B A B ...

Page 220: ...e harness from the two clamps 4 Remove the screw securing the bracket B to the finisher 5 Remove the bracket B from the square hole in the finisher 6 Remove the two screws securing the switch eject cover interlock A from the bracket B 7 Remove the switch eject cover interlock A Replacement note Make sure the media eject unit assembly C properly actuates the switch media eject interlock A without b...

Page 221: ...age 4 20 5 Remove the upper media bin vertical cover See Right eject cover removal on page 4 21 6 Remove the stapler unit frame See Stapler unit frame removal on page 4 54 7 Remove the media eject clamp motor assembly See Media eject clamp motor assembly removal on page 4 66 8 Remove the media eject unit assembly See Media eject unit assembly removal on page 4 59 9 Remove the media eject motor ass...

Page 222: ...the connector P8309 from the finisher controller card assembly B 14 Release the harness from the clamps 15 Remove the screw securing the media compiler unit assembly C to the finisher This screw is found inside the finisher B Rear P8309 Clamp Inside view ...

Page 223: ...he front lock and the rear lock inward to release the front boss and the rear boss from the finisher 17 Remove the harness from any additional parts 18 Remove the media compiler unit assembly through the inside of the finisher and out the front Right C Rear view Front view C Lock Lock C ...

Page 224: ...unit frame See Stapler unit frame removal on page 4 54 7 Remove the media eject clamp motor assembly See Media eject clamp motor assembly removal on page 4 66 8 Remove the media eject unit assembly See Media eject unit assembly removal on page 4 59 9 Remove the media eject motor assembly See Media eject motor assembly removal on page 4 78 10 Remove the media compiler unit assembly See Media compil...

Page 225: ...e See Stapler unit frame removal on page 4 54 7 Remove the media eject clamp motor assembly See Media eject clamp motor assembly removal on page 4 66 8 Remove the media eject unit assembly See Media eject unit assembly removal on page 4 59 9 Remove the media eject motor assembly See Media eject motor assembly removal on page 4 78 10 Remove the media compiler unit assembly See Media compiler unit a...

Page 226: ...e upper media bin assembly See Stacker media bin assembly removal on page 4 22 6 Remove the four screws securing the right panel C to the finisher 7 Remove the media eject motor assembly See Media eject motor assembly removal on page 4 78 8 Release the hook of the media eject shaft gear 39T D from the media eject shaft assembly E 9 Remove the media eject shaft gear 39T D 10 Remove the 6 mm bushing...

Page 227: ...Repair information 4 75 4024 110 15 Move the media eject shaft assembly toward the rear and outward as shown 16 Remove the media eject shaft assembly E F D Rear E clip G E C E G F Front E clips E Rear ...

Page 228: ...ear upper cover See Rear upper cover removal on page 4 24 3 Remove the media eject shaft assembly See Media eject shaft assembly removal on page 4 74 4 Remove the three clamp paddles A by sliding them out of the media eject shaft assembly B Replacement note Replacement is easier if you lightly moisten the rubber surface of the paddles with water A Narrow Wide B Right A ...

Page 229: ...om the media eject clutch B 5 Release the harness from the clamp 6 Release the hook securing the media eject clutch actuator C to the media eject clutch B 7 Remove the screw securing the spring clamp D to the finisher 8 Remove the spring clamp D 9 Remove the media eject clutch actuator C 10 Remove the media eject clutch B Installation note Make sure the hook on the media eject clutch is placed in ...

Page 230: ...ia eject clutch See Media eject clutch removal on page 4 77 3 Disconnect the connector from the media eject motor assembly A 4 Disconnect the connector from the sensor media bin level 2 B 5 Remove the three screws securing the media eject motor assembly A 6 Remove the media eject motor assembly A 7 Remove any remaining harnesses from the clamps A Rear Connector ...

Page 231: ...oval on page 4 24 2 Disconnect the connector from the sensor media eject shaft HP A 3 Rotate the media eject clutch actuator B by hand so it clears the sensor media eject shaft HP A 4 Release the hooks securing the sensor media eject shaft HP A to the bracket C 5 Remove the sensor media eject shaft HP A Rear B A C Connector ...

Page 232: ...ont door assembly 2 Remove the upper media bin assembly See Upper media bin assembly removal on page 4 20 3 Disconnect the connector from the sensor lower media exit A 4 Remove the harness from the clamps 5 Remove the two screws securing the bracket B to the finisher A B Front Clamp Connector ...

Page 233: ...Note The upper media bin vertical cover C has slots that make access to the screws easier as shown 6 Remove the bracket B 7 Release the hooks securing the sensor lower media exit A to the bracket 8 Remove the sensor lower media exit A ...

Page 234: ...ject clamp motor assembly removal on page 4 66 7 Remove the media eject unit assembly See Media eject unit assembly removal on page 4 59 8 Remove the media compiler unit assembly See Media compiler unit assembly removal on page 4 69 9 Remove the media eject motor assembly See Media eject motor assembly removal on page 4 78 10 Remove the media eject shaft assembly See Media eject shaft assembly rem...

Page 235: ...ir information 4 83 4024 110 14 Release the hook of the lower exit roll drive pulley 20T C from the lower media exit roll assembly F 15 Remove the lower exit roll drive pulley 20T C D E Front view Rear view ...

Page 236: ...4 Finisher Service Manual 4024 110 16 Remove the 6 mm ball bearing G 17 Remove the e clip on the front of the finisher with a prying tool securing the lower media exit roll assembly F to the finisher F G C ...

Page 237: ...information 4 85 4024 110 18 Remove the 6 mm bushing H 19 Move the lower media exit roll assembly F towards the rear and outward as shown 20 Remove the lower media exit roll assembly F Front E clip H G G Rear ...

Page 238: ...pler unit frame removal on page 4 54 7 Remove the media eject clamp motor assembly See Media eject clamp motor assembly removal on page 4 66 8 Remove the media eject unit assembly See Media eject unit assembly removal on page 4 59 9 Remove the media compiler unit assembly See Media compiler unit assembly removal on page 4 69 10 Remove the media eject motor assembly See Media eject motor assembly r...

Page 239: ...main paddle shaft drive pulley 17T G Note The belt H will become attached 18 Remove the 6 mm bushing I 19 Release the hook of the main paddle drive pulley gear 44 20T F from the shaft J 20 Remove the main paddle drive pulley gear 44 20T F 21 Remove the 6 mm bushing K 22 Remove the main paddle idler gear 23T right L 23 Remove the two front and the two rear screws securing the main paddle shaft asse...

Page 240: ...4 88 Finisher Service Manual 4024 110 25 Remove the main paddle shaft assembly Rear J F K L ...

Page 241: ...nsion of the belt exit A and the belt paddle entrance E is automatically adjusted by the force of the spring attached to the belt tensioner bracket A an D Tighten the two screws in the order shown M Front view Tighten second Tighten first Tighten third Right ...

Page 242: ... the finisher front door assembly 2 Open the lower pinch guide assembly A by lifting it upward 3 Remove the screw securing the lower pinch guide assembly A to the finisher 4 Move the lower pinch guide assembly A upward and outward 5 Remove the lower pinch guide assembly A A Front ...

Page 243: ...on page 4 24 3 Open the lower pinch guide assembly A to the right 4 Open the upper pinch guide assembly B to the right 5 Remove the media diverter gate solenoid See Media diverter gate removal on page 4 91 6 Remove the link C 7 Move the media diverter gate D toward the rear to the right and forward as shown 8 Remove the media diverter gate B D Front A Rear C D ...

Page 244: ...e right 3 Remove the rear upper cover See Rear upper cover removal on page 4 24 4 Remove the buffer diverter gate solenoid See Media diverter gate solenoid removal on page 4 102 5 Remove the link D 6 Move the buffer diverter gate C toward the rear the left and then forward as shown 7 Remove the buffer diverter gate C Buffer diverter gate A B Rear C C A ...

Page 245: ...ee Left lower cover removal on page 4 28 5 Remove the left upper cover See Left upper cover removal on page 4 29 6 Remove the punch carriage assembly See Punch carriage assembly removal on page 4 41 7 Disconnect the connector from the sensor buffer path A 8 Remove the screw securing the bracket B to the finisher 9 Remove the bracket B 10 Release the hooks securing the sensor buffer path A to the b...

Page 246: ...s far to the rear as it will go 5 Lower the buffer pinch guide assembly A 6 Move the lower pinch guide assembly to the right 7 Position the buffer diverter gate B using your finger to its upper most position 8 Use a prying tool to remove the e clip securing the buffer roll assembly C to the front of the finisher 9 Remove the 6 mm bushing D 10 Remove the media diverter gate solenoid See Media diver...

Page 247: ...oll assembly C 16 Remove the buffer roll drive gear 46T H 17 Remove the 6 mm bushing D 18 Remove the buffer roll assembly C from inside the finisher Note When remove the buffer roll assembly C do not touch the rubber surface Replacement notes Make sure the flat spot on the end of the buffer roll assembly C is installed to the rear When replacing the buffer roll assembly do not touch the rubber sur...

Page 248: ...on page 4 27 2 Remove the rear upper cover See Rear upper cover removal on page 4 24 3 Remove the stapler unit frame See Stapler unit frame removal on page 4 54 4 Lower the buffer pinch guide assembly A as far as it will go 5 Move the buffer pinch guide assembly A to the right to remove the two bosses from the holes in the finisher Hole in rear frame Boss A ...

Page 249: ... Remove the left upper cover See Left upper cover removal on page 4 29 5 Remove the screw securing the cover A to the media entrance pinch guide assembly B 6 Remove the cover A 7 Disconnect the connector from the sensor finisher media entrance C 8 Release the harness from the clamps 9 Remove the three screws securing the media entrance pinch guide assembly B 10 Remove the entrance pinch guide asse...

Page 250: ...er See Left lower cover removal on page 4 28 5 Remove the left upper cover See Left upper cover removal on page 4 29 6 Disconnect the connector from the sensor finisher media entrance A 7 Release the harness from the clamp 8 Remove the screw securing the bracket B to the media entrance pinch guide assembly C 9 Release the hooks securing the sensor finisher media entrance A to the bracket B 10 Remo...

Page 251: ...move the cover B 7 Lift the media entrance pinch guide assembly C 8 Loosen the two screws securing the belt tensioner bracket D to the finisher and move it upward in the direction of the arrow 9 Remove the belt entrance paddle E from the entrance drive pulley 20T F 10 Release the hook securing the entrance drive gear 23T G to the media entrance roll assembly H 11 Remove the entrance drive gear 23T...

Page 252: ...nce roll assembly H do not touch the rubber surface The tension of the belt entrance paddle E is automatically adjusted to the force of the spring attached to the belt tensioner bracket D Tighten the two screws in the order shown Drive motor entrance paddle and belt entrance paddle removal 1 Remove the rear upper cover See Rear upper cover removal on page 4 24 2 Loosen the two screws securing the ...

Page 253: ...ecuring the bracket D to the drive motor entrance paddle C 8 Remove the drive motor entrance paddle C 9 Remove the belt entrance paddle B Replacement notes The tension of the belt entrance paddle B is automatically adjusted by the force of the spring attached to the belt tensioner bracket A Tighten the two screws in the order shown D C Connector ...

Page 254: ...bracket B to the finisher Note The bracket should not be removed from the finisher it should be gently moved to provide better access to the media diverter gate solenoid mounting screws 6 Remove the two screws securing the media diverter gate solenoid to the finisher 7 Remove the media diverter gate solenoid Note The link C may remain inserted into the finisher 8 Remove the link Note When the link...

Page 255: ...from the buffer diverter gate solenoid A 4 Release the harness from the clamp 5 Remove the two screws securing the buffer diverter gate solenoid to the finisher 6 Remove the buffer diverter gate solenoid Note The link B may remain inserted into the finisher 7 Remove the link Note When the link is removed the buffer diverter gate may become detached See Buffer diverter gate removal on page 4 92 Con...

Page 256: ...e the rear upper cover See Rear upper cover removal on page 4 24 3 Remove the top cover See Top cover removal on page 4 19 4 Disconnect the connector from the sensor upper media exit A 5 Release the hooks securing the sensor upper media exit A to the finisher 6 Remove the sensor upper media exit A Rear Left A Connector ...

Page 257: ...r assembly 2 Remove the rear upper cover See Rear upper cover removal on page 4 24 3 Remove the top cover See Top cover removal on page 4 19 4 Remove the four screws securing the four upper media exit pinch roll assemblies A to the finisher 5 Remove the four upper media exit pinch roll assembly A Rear A Left ...

Page 258: ...4 19 4 Remove the drive motor exit See Drive motor exit assembly and belt exit removal on page 4 113 5 Disconnect the connector from the sensor upper media exit A 6 Release the harness from the clamps 7 Remove the two front and two rear screws securing the upper exit guide assembly B 8 Remove the upper exit guide assembly 9 Remove the two front screws and the two rear screws securing the bracket C...

Page 259: ...nt of the finisher 15 Remove the 6 mm bushing E 16 Move the upper media exit roll assembly frontward and outward in the direction of the arrow 17 Remove the upper media exit roll assembly F Note When removing the upper media exit roll assembly F do not touch the rubber surface Replacement notes Maker sure the flat spot of the upper media exit roll assembly F is installed to the rear When replacing...

Page 260: ... cover B 3 Move the bracket frontward and downward to gain access to the harness and connector 4 Release the harness from the clamp 5 Move the bracket B frontward again and remove the screw securing the sensor upper media bin full C to the bracket 6 Remove the sensor upper media bin full C 7 Disconnect the connector from the sensor upper media bin full C Front C Harness clamp A Front B A ...

Page 261: ...motor buffer transport See Drive motor buffer transport and belt buffer transport removal on page 4 115 4 Remove the three screws securing the hinge of the upper pinch guide assembly A on the rear of the finisher 5 Move the upper pinch guide assembly hinge from the rear of the finisher 6 Remove the upper pinch guide assembly A from inside of the finisher in the direction of the arrow A Rear A Fron...

Page 262: ...e Left lower cover removal on page 4 28 5 Remove the left upper cover See Left upper cover removal on page 4 29 6 Remove the punch carriage assembly See Punch carriage assembly removal on page 4 41 7 Remove the two screws securing the bracket A to the finisher 8 Remove the bracket A 9 Disconnect the connector from the sensor diverter gate B 10 Remove the screw securing the sensor diverter gate B t...

Page 263: ...r See Left upper cover removal on page 4 29 6 Remove the punch carriage assembly See Punch carriage assembly removal on page 4 41 7 Open the upper pinch guide assembly A toward the right 8 Remove the two screws securing the bracket B on the rear of the finisher 9 Move the bracket B slightly toward the exit side of the finisher Note It is not necessary to remove the bracket from the finisher it sho...

Page 264: ...5 Remove the appropriate bushing H 16 With a prying tool remove the e clip securing the appropriate upper media transport roll assembly C to the front of the finisher 17 Remove the appropriate 6 mm bushing I 18 Move the appropriate upper media transport roll assembly C toward the front and outward 19 Remove the appropriate upper media transport roll assembly C Note When removing the upper media tr...

Page 265: ...ver See Rear upper cover removal on page 4 24 2 Loosen the two screws securing the belt tensioner bracket A to the finisher and move it down as shown 3 Remove the belt exit B from the drive motor exit assembly C 4 Disconnect the connector from the drive motor exit assembly A B C A Rear Second First Connector ...

Page 266: ... Remove the two screws securing the drive motor exit assembly to the bracket D 8 Remove the drive motor exit assembly C Replacement notes Note The tension of the belt exit B is automatically adjusted by the force of the spring attached to the belt tensioner bracket A Note Tighten the two screws in the order shown D C Connector ...

Page 267: ...r of the finisher 3 Move the bracket slightly Note It is not necessary to remove the bracket from the finisher It should only be slightly moved to provide better access to the drive motor buffer transport B for removal 4 Loosen the two screws securing the belt tensioner bracket C to the finisher and move it down as shown 5 Remove the belt buffer transport D from the drive motor buffer transport A ...

Page 268: ...ket 9 Remove the two screws securing the drive motor buffer transport to the bracket 10 Remove the drive motor buffer transport 11 Remove the belt buffer transport D Replacement notes Note The tension of the belt buffer transport D is automatically adjusted by the force of the spring attached to the belt tensioner bracket C Note Tighten the two screws in the order shown E B Connector ...

Page 269: ...per cover See Rear upper cover removal on page 4 24 2 Disconnect all the connectors from the bridge unit interface card assembly A 3 Remove the two screws securing the bridge unit interface card assembly A to the finisher 4 Remove the bridge unit interface card assembly A A Connectors Rear Connector ...

Page 270: ...sen the four screws securing the plate A to the finisher 4 Move the plate A to the right and outward 5 Remove the plate A 6 Disconnect the connectors from the finisher controller card assembly B 7 Remove the six screws securing the finisher controller card assembly B 8 Remove the finisher controller card assembly B A Rear P8304 P8308 P8389 P8306 P8307 P8300 P8301 P8310 P8316 P8314 P8313 P8315 P831...

Page 271: ...wer supply LVPS removal 1 Remove the right lower cover See Rear lower cover removal on page 4 23 2 Disconnect all the connectors from the finisher LVPS A 3 Remove the two screws securing the finisher LVPS A to the finisher 4 Remove the finisher LVPS A Rear A ...

Page 272: ...4 120 Finisher Service Manual 4024 110 ...

Page 273: ...nent locations 5 1 4024 110 5 Component locations Locations Bridge unit assembly Sensor bridge unit media entrance Bridge unit drive motor Sensor bridge unit media exit Sensor bridge unit top cover interlock ...

Page 274: ...cker lift and stapler Sensor stacker bin no media Sensor stacker bin upper limit Sensor stacker bin level 2 Sensor stacker bin level 1 Switch finisher front door interlock Bottom view Stapler carriage motor assembly Sensor stapler carriage HP ...

Page 275: ...nch hole select Sensor punch cam front Sensor punch unit HP Punch unit motor asm Sensor punch unit side reg 2 Sensor punch unit side reg 1 Punch carriage shift motor asm Sensor punch carriage shift HP Sensor punch waste box set Sensor punch waste box full ...

Page 276: ...isher Service Manual 4024 110 Diverter and media eject Media eject clamp motor Sensor media eject clamp HP Switch eject cover interlock Sensor lower media exit Media diverter solenoid Buffer diverter solenoid ...

Page 277: ... locations 5 5 4024 110 Media eject and media compiler Media eject motor asm Sensor compiler media in Sensor media eject shaft HP Rear tamper motor Sensor rear tamper HP Front tamper motor Sensor front tamper HP ...

Page 278: ...a exit Drive motor entrance paddle Sensor buffer path Drive motor exit Drive motor buffer transport Sensor finisher media entrance Sensor diverter gate P8304 P8308 P8389 P8306 P8307 P8300 P8301 P8316 P8314 P8313 P8315 P8317 P8311 P8302 P8376 P8305 P8309 P8310 Finisher low voltage power supply Finisher controller card assembly Bridge unit interface card assembly ...

Page 279: ...y LVPS cable assembly Lower media exit sensor cable sssembly Upper media bin full cable assembly Upper media exit sensor cable assembly Finisher media entrance sensor cable assembly AC power cord assembly Compiler unit cable assembly Buffer path sensor cable assembly ...

Page 280: ...her Service Manual 4024 110 Diverter gate sensor lower cable assembly Diverter gate sensor upper cable assembly Interlock switch cable assembly Punch waste box set cable assembly Punch main drive cable assembly ...

Page 281: ...ons 5 9 4024 110 Stapler unit cable assembly Bridge unit interface card cable assembly Bridge unit connect cable assembly Punch waste box full cable assembly Finisher interface cable assembly Main drive cable assembly ...

Page 282: ...5 10 Finisher Service Manual 4024 110 ...

Page 283: ... the following items Damaged missing or altered parts especially in the area of the on off switch and the power supply Damaged missing or altered covers especially in the area of the top cover and the power supply cover Possible safety exposure from any non Lexmark attachments Maintenance recommendations Every service call Every 300 000 pages Bridge unit belts Inspect Clean with water or alcohol M...

Page 284: ...6 2 Finisher Service Manual 4024 110 ...

Page 285: ...ber 1 in the table Part number Identifies the unique number that identifies this FRU Units option Refers to the number of units in a particular option It does not include the rest of the base machine Units FRU Refers to the number of units packaged together and identified by the part number NS Not shown in the Asm Index column indicates that the part is procurable but is not pictured in the illust...

Page 286: ...nisher Service Manual 4024 110 Assembly 1 Bridge unit Asm Index Part number Units option Units FRU Description 1 1 40X0811 1 1 Bridge unit assembly 2 40X0810 1 2 Bridge unit assembly docking screw 2 each 2 1 ...

Page 287: ...ridge unit top cover assembly Asm Index Part number Units option Units FRU Description 2 1 40X0813 1 1 Bridge unit top cover assembly 2 40X0812 6 2 Bridge unit pinch roll kit includes Bridge unit pinch roll 6 each Spring 6 each 2 1 2 2 2 2 2 ...

Page 288: ...7 4 Finisher Service Manual 4024 110 Assembly 3 Bridge unit lower assembly 3 12 7 14 5 2 11 6 4 13 9 1 3 2 2 8 15 10 5 12 ...

Page 289: ...ludes Idler roll 2 each Bushing 4 each 5 40X0824 8 1 Magnetic catch 6 40X0825 1 1 Sensor bridge unit top cover interlock 7 40X0826 1 1 Sensor bridge unit media exit 8 40X0828 1 1 Bridge unit cable assembly 9 40X0827 1 1 Sensor bridge unit media entrance 10 40X0818 1 3 Bridge unit entrance guide kit includes Bridge unit entrance guide Lower guides 2 each 11 40X0817 1 1 Bridge unit drive motor 12 40...

Page 290: ...7 6 Finisher Service Manual 4024 110 Assembly 4 Covers 3 7 5 9 2 10 6 4 8 1 ...

Page 291: ... Top cover 2 40X0831 1 1 Upper media bin assembly 3 40X0830 1 1 Upper media bin vertical cover 4 40X0832 1 1 Right eject cover 5 40X0833 1 1 Stacker media bin 6 40X0834 1 1 Right lower LVPS cover 7 40X0835 4 1 Caster 8 40X0836 1 1 Rear lower cover 9 40X0837 1 1 Bridge unit hookup cover 10 40X0838 1 1 Rear upper cover ...

Page 292: ...7 8 Finisher Service Manual 4024 110 Assembly 5 Covers and front door 3 7 5 2 6 4 1 ...

Page 293: ...ver 2 40X0841 1 1 Finisher front door assembly this comes assembled 3 40X0840 1 1 Switch finisher front door interlock 4 40X0842 1 2 Finisher docking latch kit includes Finisher docking latch assembly Spring 5 40X0843 1 3 Finisher docking bracket kit includes Finisher docking bracket Screw 2 each 6 40X0844 1 1 Left lower cover 7 40X0845 1 1 Left upper cover ...

Page 294: ...7 10 Finisher Service Manual 4024 110 Assembly 6 Stacker bin lift 5 4 6 3 1 2 8 2 3 3 3 1 7 7 ...

Page 295: ...t includes Pulley 18T 3 each Slip clutch pulley 18T Slip clutch gear 24T Spring Washer 4 40X0850 1 1 Sensor stacker bin no media 5 40X0850 1 1 Sensor stacker bin upper limit 6 40X0850 1 1 Sensor stacker bin level encoder 7 40X0848 2 1 Ball bearing 10 mm 8 40X0851 1 3 Stacker bin lift motor assembly Bracket with sensor Encoder Stacker bin lift motor Note Assembly index items 4 5 and 6 are identical...

Page 296: ...7 12 Finisher Service Manual 4024 110 Assembly 7 Punch 3 9 16 6 2 8 4 14 1 13 5 7 10 11 12 17 15 5 5 ...

Page 297: ...bly 6 40X0862 1 1 Punch waste box 7 40X0930 1 1 Punch waste box full cable assembly 8 40X0864 1 1 Sensor punch waste box full 9 40X0865 1 1 Punch waste box set cable assembly 10 40X0861 1 1 Sensor punch waste box set 11 40X0850 1 1 Sensor punch unit motor encoder 12 40X0860 1 1 Punch unit motor assembly 13 40X0850 1 1 Sensor punch hole select 14 40X0850 1 1 Sensor punch cam front 15 40X0850 1 1 Se...

Page 298: ...7 14 Finisher Service Manual 4024 110 Assembly 8 Stapler 3 7 5 2 6 4 8 1 ...

Page 299: ...le assembly 2 40X0869 1 2 Stapler carriage kit includes Stapler carriage wire guide Stapler carriage assembly 3 40X0871 1 1 Stapler carriage motor assembly 4 40X0872 1 1 Stapler carriage rack gear 5 40X0868 1 1 Stapler unit cover 6 40X0850 1 1 Sensor stapler carriage HP 7 40X0866 1 1 Staple cartridge 8 40X0867 1 1 Stapler unit assembly ...

Page 300: ...7 16 Finisher Service Manual 4024 110 Assembly 9 Media eject 8 4 9 6 2 7 5 1 3 11 2 3 6 5 10 ...

Page 301: ...ft kit includes Sub paddle drive shaft assembly Knob 4 40X0882 1 1 Switch eject cover interlock 5 40X1388 4 1 Bushing 8 mm 6 40X0888 15 1 Bushing 6 mm 7 40X0879 2 2 Sub paddle entrance drive gear 23T 8 40X0877 1 1 Eject clamp lever assembly 9 40X0825 1 1 Sensor media eject clamp HP 10 40X0881 1 3 Eject clamp gear kit includes Eject clamp gear 70T Eject clamp gear 23T Eject clamp gear 68 20T 11 40X...

Page 302: ...7 18 Finisher Service Manual 4024 110 Assembly 10 Eject and compiler unit 7 5 2 6 4 1 10 11 3 8 9 12 6 6 8 7 ...

Page 303: ...a in 5 40X0886 1 1 Media eject shaft assembly 6 40X0887 3 1 Clamp paddle 7 40X0888 15 1 Bushing 6 mm 8 40X1388 4 1 Bushing 8 mm 9 40X0889 2 1 Media eject shaft gear 39T 10 40X0890 1 2 Media eject clutch kit includes Media eject clutch Media eject clutch actuator 11 40X0825 1 1 Sensor media eject shaft HP 12 40X0891 1 1 Media eject motor assembly Note Assembly index items 2 and 3 are identical sens...

Page 304: ...7 20 Finisher Service Manual 4024 110 Assembly 11 Lower exit drive 3 9 5 2 6 4 1 7 8 11 10 6 6 6 8 ...

Page 305: ... 5 40X0896 1 2 Main paddle shaft kit includes this comes assembled Main paddle shaft assembly Main paddle shaft drive pulley 17T 6 40X0888 15 1 Bushing 6 mm 7 40X0900 1 1 Main paddle drive pulley gear 44 20T 8 40X0899 1 2 Main paddle idler gear kit includes Main paddle idler gear 23TR Main paddle idler gear 23TL 9 40X0898 1 2 Lower exit roll drive pulley kit includes Lower exit roll drive pulley 2...

Page 306: ...7 22 Finisher Service Manual 4024 110 Assembly 12 Buffer and entrance drive 3 15 17 18 7 2 14 9 16 19 1 20 5 6 8 11 10 12 13 21 22 4 4 4 5 5 ...

Page 307: ...bly 11 40X0907 1 1 Media entrance pinch guide assembly this comes assembled 12 40X0908 1 1 Sensor finisher media entrance 13 40X0910 1 1 Drive motor entrance paddle 14 40X0912 3 3 Belt tensioner pulley kit includes Belt idler pulley Spring Belt tensioner bracket 15 40X0897 3 1 Belt idler pulley 16 40X0911 1 1 Belt entrance paddle 31 6 cm 17 40X0879 2 1 Sub paddle entrance drive gear 23T 18 40X0914...

Page 308: ...7 24 Finisher Service Manual 4024 110 Assembly 13 Buffer transport and upper drive 3 14 7 19 5 20 9 17 2 10 6 4 18 8 16 1 11 12 13 15 15 21 1 1 1 6 6 10 6 13 12 ...

Page 309: ...te 9 40X0922 1 1 Diverter gate sensor upper cable assembly 10 40X0923 2 1 Upper media transport roll assembly 11 40X0924 1 1 Buffer roll drive pulley gear 53 23T 12 40X0912 3 3 Belt tensioner bracket kit includes Belt idler pulley Spring Belt tensioner bracket 13 40X0925 2 1 Upper media transport roll drive pulley 20T 14 40X0897 3 1 Belt idler pulley 15 40X0913 4 1 Ball bearing 6 mm 16 40X0928 1 1...

Page 310: ...7 26 Finisher Service Manual 4024 110 Assembly 14 Electronics 3 5 2 6 4 1 ...

Page 311: ... Description 14 1 40X0931 1 1 Bridge unit interface card assembly 2 40X0932 1 1 Bridge unit connect cable assembly 3 40X0933 1 1 Bridge unit interface card cable assembly 4 40X0934 1 1 Finisher controller card assembly 5 40X0935 1 1 AC power cord assembly 6 40X0936 1 1 Finisher LVPS card assembly ...

Page 312: ...7 28 Finisher Service Manual 4024 110 Assembly 15 Cables 1 3 7 5 2 6 4 1 ...

Page 313: ... 40X0940 1 1 Finisher media entrance sensor cable assembly 3 40X0941 1 1 Buffer path sensor cable assembly 4 40X0937 1 1 Main sensor cable assembly 5 40X0946 1 1 Finisher LVPS cable assembly 6 40X0892 1 3 Sensor lower media exit assembly Sensor lower media exit Lower media exit sensor cable assembly Bracket 7 40X0943 1 1 Upper media bin full sensor cable assembly ...

Page 314: ...n 16 1 40X0922 1 1 Diverter gate sensor upper cable assembly 2 40X0944 1 1 Punch main drive cable assembly 3 40X0950 1 1 Diverter gate sensor lower cable assembly 4 40X0865 1 1 Punch waste box set cable assembly 5 40X0947 1 1 Interlock switch cable assembly 6 40X0945 1 1 Punch main sensor cable assembly 3 5 2 4 1 6 ...

Page 315: ...iption 17 1 40X0938 1 1 Main drive cable assembly 2 40X0930 1 1 Punch waste box full cable assembly 3 40X0932 1 1 Bridge unit connect cable assembly 4 40X0931 1 1 Bridge unit interface card assembly 5 40X0939 1 1 Finisher interface cable assembly 6 40X0870 1 1 Stapler unit cable assembly 3 5 2 6 4 1 ...

Page 316: ...7 32 Finisher Service Manual 4024 110 ...

Page 317: ...drive motors bridge unit 5 1 buffer transport 4 115 entrance paddle 4 100 exit 4 113 E eject unit parts catalog 7 18 electronics parts catalog 7 26 entrance drive parts catalog 7 22 error code messages 2 3 error codes 280 00 sensor bridge unit media entrance on jam 2 11 280 01 sensor bridge unit media entrance static jam A 2 12 280 02 sensor bridge unit media entrance static jam B 2 13 281 00 sens...

Page 318: ...nisher NVRAM R W failure 2 87 996 00 finisher type failure 2 87 999 00 finisher engine RIP functional failure 2 88 error messages bridge unit top cover open 2 88 bridge unit top door open 2 91 finisher eject cover open 2 91 finisher front door open 2 90 finisher upper media bin full 2 91 no punch waste box 2 92 punch waste box full 2 93 stacker lower safety failure 2 97 stacker media bin full mix ...

Page 319: ...11 bridge unit interface card assembly 4 117 bridge unit left shaft assembly 4 10 bridge unit pinch roller 4 18 bridge unit rear cover 4 6 bridge unit right shaft assembly 4 9 bridge unit top cover assembly 4 7 bridge unit transport belts 4 12 buffer diverter gate 4 92 buffer diverter gate solenoid 4 103 buffer roll assembly 4 94 carriage lift belt left 4 30 carriage lift right 4 32 clamp paddle 4...

Page 320: ...t 4 80 5 4 media eject clamp HP 4 67 5 4 media eject shaft HP 4 79 punch cam front 4 49 5 3 punch carriage shift HP 4 51 5 3 punch hole select 4 49 5 3 punch unit HP 4 49 5 3 punch unit motor encoder 4 48 punch unit side reg 1 5 3 punch unit side reg 2 5 3 punch unit side registration pair with bracket 4 44 punch waste box full 4 53 5 3 punch waste box set 4 52 punch waste box set 5 3 rear tamper ...

Page 321: ...functions of sensor along the media path 3 10 media transport 3 4 power supply and interlock 3 30 punch unit 3 12 stacker media bin 3 26 stapler 3 21 upper media bin 3 25 tools required 1 4 top cover removal 4 19 U upper media bin assembly 4 20 upper media exit pinch roll assembly 4 105 upper media exit roll assembly 4 106 upper media transport roll assembly 4 111 upper pinch guide assembly 4 109 ...

Page 322: ...I 6 Finisher Service Manual 4024 110 ...

Page 323: ... 7 40X0831 Upper media bin assembly 7 7 40X0832 Right eject cover 7 7 40X0833 Stacker media bin 7 7 40X0834 Right lower LVPS cover 7 7 40X0835 Caster 7 7 40X0836 Rear lower cover 7 7 40X0837 Bridge unit hookup cover 7 7 40X0838 Rear upper cover 7 7 40X0839 Upper media bin front cover 7 9 40X0840 Switch finisher front door interlock 7 9 40X0841 Finisher front door assembly 7 9 40X0842 Finisher dock...

Page 324: ...7 17 40X0883 Media compiler unit assembly this comes assembled 7 19 40X0886 Media eject shaft assembly 7 19 40X0887 Clamp paddle 7 19 40X0888 Bushing 6 mm 7 17 7 19 7 21 7 23 7 25 40X0889 Media eject shaft gear 39T 7 19 40X0890 Media eject clutch kit 7 19 40X0891 Media eject motor assembly 7 19 40X0892 Sensor lower media exit assembly 7 29 40X0892 Sensor lower media exit with bracket 7 21 40X0893 ...

Page 325: ...927 Upper media exit roll drive gear 20T 7 25 40X0928 Belt buffer transport 19 8 cm 7 25 40X0929 Belt exit 27 7 cm 7 25 40X0930 Punch waste box full cable assembly 7 13 7 31 40X0931 Bridge unit interface card assembly 7 27 7 31 40X0932 Bridge unit connect cable assembly 7 27 7 31 40X0933 Bridge unit interface card cable assembly 7 27 40X0934 Finisher controller card assembly 7 27 40X0935 AC power ...

Page 326: ...I 10 Finisher Service Manual 4024 110 ...

Page 327: ... 3 3 3 3 3 1 1 1 1 1 1 5VDC 5VDC 5VDC 5VDC 5VDC SIG GND SIG GND SIG GND SIG GND SIG GND 2 3 1 5VDC 5VDC Diverter Gate SNR L 5VDC SIG GND SIG GND Sensor Diverter Gate Sensor Finisher Media Entrance 2 3 1 Fin Media Entrance SNR L 5VDC A B A Stacker No Media SNR L 5VDC 2 3 1 5VDC SIG GND Sensor Stacker Bin Level Encoder Stacker Bin Level Encode SNR L 5VDC 2 3 1 5VDC SIG GND Sensor Media Eject Shaft H...

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