Lexmark XM91x5 Service Manual Download Page 1

Page: 1 / 89

MS911, MX91x, and XM91x5

4021-230, 7421-03x, -23x, -43x

Finisher Service Manual

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Start diagnostics

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Maintenance

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Safety and notices

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August 27, 2015

www

MK-Electronic

Summary of Contents for XM91x5

Page 1: ...91x and XM91x5 4021 230 7421 03x 23x 43x Finisher Service Manual Start diagnostics Maintenance Safety and notices Trademarks Index August 27 2015 www lexmark com P N 12G3392 w w w M K E l e c t r o n...

Page 2: ...mber of units in an option Units FRU Refers to the number of units in a FRU Description A brief description of the part The following abbreviations are used in the parts catalog NS not shown in the As...

Page 3: ...Assembly 1 Staple nisher Frame 4021 7421 Parts catalog 543 w w w M K E l e c t r o n i c d e...

Page 4: ...Frame Asm index P N Units opt Units FRU Description Removal procedure 1 40X9810 6 1 Staple nisher side guide wheel 2 40X9334 4 1 Staple nisher bottom guide wheel 4021 7421 Parts catalog 544 w w w M K...

Page 5: ...Assembly 2 Staple nisher Covers 4021 7421 Parts catalog 545 w w w M K E l e c t r o n i c d e...

Page 6: ...1 Staple nisher upper guide cover 3 40X9336 1 1 Staple nisher right cover Staple nisher right cover removal on page 234 4 40X9335 1 1 Staple nisher front cover Staple nisher front cover removal on pag...

Page 7: ...Assembly 3 Staple nisher Transport section 1 4021 7421 Parts catalog 547 w w w M K E l e c t r o n i c d e...

Page 8: ...de Staple nisher upper guide removal on page 291 3 40X9898 4 1 Staple nisher paper feed idler holder Staple nisher upper guide removal on page 291 4 40X9349 4 1 Staple nisher paper feed idler roller S...

Page 9: ...Assembly 4 Staple nisher Transport section 2 4021 7421 Parts catalog 549 w w w M K E l e c t r o n i c d e...

Page 10: ...ansport jam removal gears removal on page 244 5 40X9816 2 1 Staple nisher jam removal gear 1 Staple nisher transport jam removal gears removal on page 244 6 40X9371 1 1 Staple nisher jam removal gear...

Page 11: ...Assembly 5 Staple nisher Compiler feed roller assembly 4021 7421 Parts catalog 551 w w w M K E l e c t r o n i c d e...

Page 12: ...1 Staple nisher aligner roller belt Staple nisher compiler feed rollers and gears removal on page 302 4 40X9910 1 1 Staple nisher front aligner roller Staple nisher aligner roller removal on page 299...

Page 13: ...Assembly 6 Staple nisher Compiler section 1 4021 7421 Parts catalog 553 w w w M K E l e c t r o n i c d e...

Page 14: ...mper gear Staple nisher tamper drive gears removal on page 317 4 40X9380 1 1 Motor staple nisher front tamper Motor staple nisher tamper removal on page 242 5 40X9380 1 1 Motor staple nisher rear tamp...

Page 15: ...Assembly 7 Staple nisher Compiler section 2 4021 7421 Parts catalog 555 w w w M K E l e c t r o n i c d e...

Page 16: ...removal on page 319 4 40X9642 2 1 Staple nisher front and rear aligners Staple nisher tamper racks removal on page 319 5 40X9643 1 1 Staple nisher middle aligner Staple nisher tamper racks removal on...

Page 17: ...Assembly 8 Staple nisher Aligner section 4021 7421 Parts catalog 557 w w w M K E l e c t r o n i c d e...

Page 18: ...lt and gears removal on page 259 5 40X9380 1 1 Motor staple nisher aligner Motor staple nisher aligner removal on page 258 6 40X9383 1 1 Staple nisher aligner section cables 7 40X9382 1 1 Staple nishe...

Page 19: ...Assembly 9 Staple nisher Staple section 4021 7421 Parts catalog 559 w w w M K E l e c t r o n i c d e...

Page 20: ...taple unit removal on page 264 6 40X9608 1 1 Staple nisher staple unit carriage drive gear Staple nisher staple unit carriage gears removal on page 268 7 40X9406 1 1 Staple nisher staple unit rail Sta...

Page 21: ...Assembly 10 Staple nisher Exit section 1 4021 7421 Parts catalog 561 w w w M K E l e c t r o n i c d e...

Page 22: ...nisher upper exit roller belts and gear removal on page 313 5 40X9291 2 1 Staple nisher upper exit roller Staple nisher upper exit roller removal on page 312 6 40X9813 1 1 Staple nisher upper exit ro...

Page 23: ...Assembly 11 Staple nisher Exit section 2 4021 7421 Parts catalog 563 w w w M K E l e c t r o n i c d e...

Page 24: ...r drive gear Staple nisher exit roller drive belts and gears removal on page 287 9 40X9824 1 1 Staple nisher exit guide lift cam gear Staple nisher exit guide lift cam removal on page 283 10 40X9377 4...

Page 25: ...Assembly 12 Staple nisher Exit section 3 4021 7421 Parts catalog 565 w w w M K E l e c t r o n i c d e...

Page 26: ...roller solenoid Staple nisher exit roller solenoid removal on page 288 5 40X9343 1 1 Sensor staple nisher bin stack height Staple nisher bin stack height assembly sensors removal on page 238 6 40X9343...

Page 27: ...Assembly 13 Staple nisher Bin section 1 4021 7421 Parts catalog 567 w w w M K E l e c t r o n i c d e...

Page 28: ...or staple nisher elevator home Sensor staple nisher elevator home removal on page 261 6 40X9341 2 1 Staple nisher elevator belt Staple nisher elevator belts removal on page 276 7 40X9812 2 1 Staple ni...

Page 29: ...Assembly 14 Staple nisher Bin section 2 4021 7421 Parts catalog 569 w w w M K E l e c t r o n i c d e...

Page 30: ...age 275 5 40X9419 1 1 Staple nisher rear lock Staple nisher locks removal on page 245 6 40X9835 1 1 Staple nisher elevator idler gear 1 Staple nisher elevator drive gears removal on page 275 7 40X9830...

Page 31: ...Assembly 15 Staple nisher Electronics 4021 7421 Parts catalog 571 w w w M K E l e c t r o n i c d e...

Page 32: ...iption Removal procedure 1 40X9421 1 1 Staple nisher controller board Staple nisher controller board removal on page 248 2 40X9422 1 1 Staple nisher interface cable Staple nisher interface cable remov...

Page 33: ...Assembly 16 Horizontal paper transport Covers 1 7 1 2 2 2 4 2 4 2 2 5 5 6 6 3 3 4021 7421 Parts catalog 573 w w w M K E l e c t r o n i c d e...

Page 34: ...removal on page 328 2 40X9462 6 1 HPT transport idler roller 3 40X9333 2 1 HPT transport idler holder 1 4 40X8996 2 1 HPT transport idler holder bracket 1 5 40X9428 2 1 HPT transport idler holder 2 6...

Page 35: ...Assembly 17 Horizontal paper transport Covers 2 2 3 2 1 7 4 5 6 4021 7421 Parts catalog 575 w w w M K E l e c t r o n i c d e...

Page 36: ...on page 329 2 40X9322 2 1 HPT door locks HPT door locks removal on page 325 3 40X9313 1 1 Sensor HPT door Sensor HPT door removal on page 327 4 41X0972 1 1 Front HPT mounting plate 5 41X0971 1 1 Front...

Page 37: ...Assembly 18 Horizontal paper transport Drive section 4021 7421 Parts catalog 577 w w w M K E l e c t r o n i c d e...

Page 38: ...ransport roller ball bearing HPT transport rollers removal on page 333 8 40X9326 1 1 HPT paper feed sensor actuator HPT feed sensor actuator removal on page 327 9 40X9313 1 1 Sensor HPT feed Sensor HP...

Page 39: ...Assembly 19 SHPF Covers 4021 7421 Parts catalog 579 w w w M K E l e c t r o n i c d e...

Page 40: ...or 4 40X9512 1 1 SHPF front door SHPF front door removal on page 340 5 40X9514 1 1 SHPF post cover SHPF post cover removal on page 342 6 40X9515 1 1 SHPF lower cover SHPF lower cover removal on page 3...

Page 41: ...Assembly 20 SHPF Frame 4021 7421 Parts catalog 581 w w w M K E l e c t r o n i c d e...

Page 42: ...oor spring SHPF top jam access door and SHPF diverter removal on page 399 5 40X8869 1 1 Sensor SHPF top door Sensor SHPF top door removal on page 391 6 40X9527 1 1 SHPF front door switch SHPF front do...

Page 43: ...Assembly 21 SHPF Transport section 1 4021 7421 Parts catalog 583 w w w M K E l e c t r o n i c d e...

Page 44: ...n page 423 9 40X9843 1 1 SHPF aligner shaft SHPF aligner shaft removal on page 423 10 40X9845 1 1 SHPF rear aligner SHPF aligner shaft removal on page 423 11 40X9844 1 1 SHPF rear aligner holder SHPF...

Page 45: ...Assembly 22 SHPF Transport section 2 4021 7421 Parts catalog 585 w w w M K E l e c t r o n i c d e...

Page 46: ...in exit paper guide removal on page 403 10 40X9574 1 1 SHPF diverter feed roller gear 11 40X9221 1 1 SHPF entrance roller belt SHPF entrance and diverter feed roller gears removal on page 398 12 40X92...

Page 47: ...gear 22 40X9574 1 1 SHPF booklet maker pre feed roller gear 23 40X9567 1 1 SHPF top bin exit belt 24 40X9533 1 1 Motor SHPF transport Motor SHPF transport removal on page 361 25 40X9533 1 1 Motor SHPF...

Page 48: ...Assembly 23 SHPF Transport section 3 4021 7421 Parts catalog 589 w w w M K E l e c t r o n i c d e...

Page 49: ...n page 443 9 40X9585 1 1 SHPF top bin exit roller SHPF top bin exit roller removal on page 439 10 40X9584 1 1 SHPF booklet maker pre feed roller SHPF booklet maker pre feed roller removal on page 426...

Page 50: ...Assembly 24 SHPF Transport section 4 1 9 3 2 4 5 6 8 6 7 10 4021 7421 Parts catalog 591 w w w M K E l e c t r o n i c d e...

Page 51: ...on page 451 5 40X9574 1 1 SHPF entrance roller gear SHPF entrance idler and roller removal on page 452 6 40X9589 2 1 Ball bearing SHPF entrance idler and roller removal on page 452 7 40X9588 1 1 SHPF...

Page 52: ...Assembly 25 SHPF Elevator bin section 1 2 2 16 15 13 7 4 1 10 6 5 12 11 14 9 8 3 20 18 17 19 4021 7421 Parts catalog 593 w w w M K E l e c t r o n i c d e...

Page 53: ...pper left cover sensors removal on page 353 10 40X9540 1 1 Sensor SHPF elevator bin stack height transmit SHPF upper left cover sensors removal on page 353 11 40X9477 1 1 SHPF elevator bin rear stack...

Page 54: ...al procedure 19 40X9488 1 1 SHPF lower left cover Lower left cover removals on page 348 20 40X9877 1 1 SHPF elevator bin full sensor cable Sensor SHPF elevator bin full removal on page 347 4021 7421 P...

Page 55: ...Assembly 26 SHPF Elevator bin section 2 10 11 3 7 14 5 15 16 9 12 17 18 3 6 5 2 7 2 4 3 1 8 13 4 19 4021 7421 Parts catalog 597 w w w M K E l e c t r o n i c d e...

Page 56: ...elevator bin removal on page 335 10 40X9168 1 1 SHPF elevator motor encoder 11 40X9601 1 1 SHPF elevator motor encoder belt 12 40X9849 1 1 SHPF elevator bin clutch gear SHPF elevator drive assembly re...

Page 57: ...Assembly 27 SHPF Staple unit assembly 4021 7421 Parts catalog 599 w w w M K E l e c t r o n i c d e...

Page 58: ...and gear removal on page 374 7 40X8869 1 1 Sensor SHPF staple unit carriage center SHPF staple unit position sensors removal on page 373 8 40X9616 1 1 SHPF staple unit carriage rail 9 40X9535 1 1 Moto...

Page 59: ...Assembly 28 SHPF Compiler section 1 4021 7421 Parts catalog 601 w w w M K E l e c t r o n i c d e...

Page 60: ...and eject motor encoder 9 40X9537 1 1 Motor SHPF compiler eject Motor SHPF compiler eject removal on page 404 10 40X8869 1 1 Sensor SHPF compiler eject SHPF compiler eject sensors removal on page 406...

Page 61: ...Assembly 29 SHPF Compiler section 2 4021 7421 Parts catalog 603 w w w M K E l e c t r o n i c d e...

Page 62: ...n page 390 6 40X9853 1 1 SHPF paddle drive encoder SHPF paddle drive gears removal on page 389 7 40X9440 2 1 Ball bearing 8 40X9543 1 1 SHPF elevator bin stack limit switch SHPF elevator bin stack lim...

Page 63: ...Assembly 30 SHPF Compiler section 3 4021 7421 Parts catalog 605 w w w M K E l e c t r o n i c d e...

Page 64: ...SHPF tamper belts and gears removal on page 417 6 40X9485 2 1 SHPF tamper drive gear SHPF tamper belts and gears removal on page 417 7 40X9530 1 1 Motor SHPF front tamper Motor SHPF front tamper remo...

Page 65: ...Assembly 31 SHPF Punch unit 1 4021 7421 Parts catalog 607 w w w M K E l e c t r o n i c d e...

Page 66: ...Assembly 31 SHPF Punch unit 1 Asm index P N Units opt Units FRU Description Removal procedure 1 40X9550 1 1 Hole punch box 4021 7421 Parts catalog 608 w w w M K E l e c t r o n i c d e...

Page 67: ...Assembly 32 SHPF Punch unit 2 2 6 5 4 3 1 4021 7421 Parts catalog 609 w w w M K E l e c t r o n i c d e...

Page 68: ...t removal on page 369 2 40X9549 1 1 Punch unit cable 3 40X9547 1 1 Sensor hole punch box full transmit Sensor hole punch box full removal on page 370 4 40X9546 1 1 Hole punch box full sensor actuator...

Page 69: ...Assembly 33 Booklet maker Covers 4021 7421 Parts catalog 611 w w w M K E l e c t r o n i c d e...

Page 70: ...s FRU Description Removal procedure 1 40X9423 1 1 Booklet maker front cover Booklet maker front cover removal on page 461 2 40X9424 1 1 Booklet maker support Booklet maker support removal on page 462...

Page 71: ...Assembly 34 Booklet maker Electronics 4021 7421 Parts catalog 613 w w w M K E l e c t r o n i c d e...

Page 72: ...tronics Asm index P N Units opt Units FRU Description Removal procedure 1 40X9429 1 1 Booklet maker controller board Booklet maker controller board removal on page 466 4021 7421 Parts catalog 614 w w...

Page 73: ...Assembly 35 Booklet maker Fold section 1 4021 7421 Parts catalog 615 w w w M K E l e c t r o n i c d e...

Page 74: ...ary drive gears Bifold knife secondary drive gears removal on page 526 6 40X9430 2 1 Bifold knife static brush Bifold knife removal on page 527 7 40X9913 1 1 Bifold knife Bifold knife removal on page...

Page 75: ...Assembly 36 Booklet maker Fold section 2 4021 7421 Parts catalog 617 w w w M K E l e c t r o n i c d e...

Page 76: ...e drive gears removal on page 530 9 40X8869 1 1 Sensor bifold guide home Sensor bifold guide home removal on page 492 10 40X9446 1 1 Motor trifold guide Motor trifold guide removal on page 493 11 40X8...

Page 77: ...Assembly 37 Booklet maker Fold section 3 4021 7421 Parts catalog 619 w w w M K E l e c t r o n i c d e...

Page 78: ...Trifold roller gear Trifold gears removal on page 478 7 40X8955 2 1 Booklet maker exit roller springs Booklet maker exit roller springs removal on page 460 8 40X9864 1 1 Bifold exit roller Trifold ro...

Page 79: ...Assembly 38 Booklet maker Transport section 4021 7421 Parts catalog 621 w w w M K E l e c t r o n i c d e...

Page 80: ...r transport gear and belt removal on page 485 9 40X8869 1 1 Sensor booklet maker decurl Sensor booklet maker decurl removal on page 488 10 40X9474 1 1 Booklet maker transport section cable 11 40X9470...

Page 81: ...Assembly 39 Booklet maker Staple section 4021 7421 Parts catalog 623 w w w M K E l e c t r o n i c d e...

Page 82: ...460 1 1 Static brush 4 40X9466 1 1 Plastic lm 5 40X9450 1 1 Plastic lm 6 40X8976 1 1 Plastic lm 7 40X9303 1 1 Plastic lm 8 40X9476 2 1 Booklet maker staple cartridge 9 40X9478 1 1 Booklet maker staple...

Page 83: ...Assembly 40 Booklet maker Compiler section 4021 7421 Parts catalog 625 w w w M K E l e c t r o n i c d e...

Page 84: ...e gears removal on page 479 9 40X9493 1 1 Booklet maker paddle tensioner pulley Booklet maker paddle gears removal on page 479 10 40X9481 1 1 Motor booklet maker paddle Motor booklet maker paddle remo...

Page 85: ...Assembly 41 Booklet maker Aligner assembly 4021 7421 Parts catalog 627 w w w M K E l e c t r o n i c d e...

Page 86: ...on page 505 7 40X8869 1 1 Sensor booklet maker aligner home Sensor booklet maker aligner home removal on page 499 8 40X8964 1 1 Booklet maker compiler stack front guide Booklet maker aligner jam acce...

Page 87: ...Assembly 42 Booklet maker Exit section 4021 7421 Parts catalog 629 w w w M K E l e c t r o n i c d e...

Page 88: ...removals on page 351 5 40X9508 1 1 HPBF lower left cover Lower left cover removals on page 348 6 40X9499 1 1 HPBF bin Lower left cover removals on page 348 7 40X9540 1 1 Sensor HPBF bin empty receive...

Page 89: ...NS 40X9006 1 1 SHPF J9 cable harness NS 40X9412 1 1 SHPF ejector cable harness NS 40X8918 1 1 SHPF upper left cover cable harness NS 40X9509 1 1 Booklet maker J8 and J9 cable harness NS 40X9878 1 1 Bo...

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