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Lexmark W850n and W850dn Finisher 4024

1.
2. sensor Punch waste H e oS Stacker Bin Level SNR1 Clock y 2011 SIG GND 5 7 Sensor Kaes D L Stacker B
3. 5 Remove the sensor punch waste box set A 4 52 Finisher Service Manual 4024 110 Sensor punch waste box full removal Open the finisher front door assembly Remove the punch waste box A from the finisher Disconnect the connector from the sensor punch waste box full B Release the hooks securing the sensor punch waste box full B to the finisher e Connector 5 Remove the sensor punch waste box full B Repair information 4 53 4024 110 Stapler unit frame removal Remove the finisher front door assembly See Finisher front door assembly removal on page 4 27 Remove the staple cartridge Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the rear lower cover See Rear lower cover removal on page 4 23 Loosen the four screws securing the plate A to the finisher Move the plate A toward the right and out in the direction shown oe eS 7 Remove the plate 4 54 Finisher Service Manual 4024 110 8 Disconnect the connector P8308 from the finisher controller card assembly B 9 Remove the screw securing the ground wire C to
4. 7 5 Bridge unit cable assembly eee eee ee 7 5 Top cover 2 22 22 e ee eee eee eee eee eee eee eee 7 7 Upper media bin vertical cover 2 eee eee eee eee eee eee 7 7 Upper media bin assembly 4 7 4 1 7 7 Right eject cover ee ee 7 7 Stacker media bin mm eL 7 7 Right lower LVPS cover 7 7 Caster n nnn nnn nn nn eee eee 7 7 Rear lower cover 2 mL ee 7 7 Bridge unit hookup cover me TI Rear upper cover ee mem ee ee em mm a em a mm am emma mm ame ame mm eee eee ee ee TT Upper media bin front cover eee eee eee 7 9 Switch finisher front door interlock 7 9 Finisher front door assembly eee ee eee eee eee eee 7 9 Finisher docking latch kit 7 9 Finisher docking bracket kit eee 7 9 Left lower cover me ee 7 9 Left upper cover ee ee ee ee mm a me 7 9 Carriage lift belt kit eee ee eee 7 11 Sensor stacker bin level
5. Step Check Yes No 8 Check the drive motor buffer transport connection Replace the drive Replace the Is the above motor properly connected fabs ce to connection Drive motor buffer transport and belt buffer transport removal on page 4 115 9 Perform a test print Replace the Problem solved finisher controller Does the error still occur card assembly Go to Finisher controller card assembly removal on page 4 118 287 04 Sensor upper media exit off jam B Step Check Yes No 1 Check the media path Go to step 2 Clean or replace 1 Open the upper pinch guide assembly to the right EE 2 Check four upper pinch guide pinch roll on the the media path upper pinch guide assembly and two upper media transport roll assemblies by turning them with your fingers Are the upper pinch guide pinch roll and upper media transport roll assemblies installed correctly and do they rotate smoothly 2 Are the four upper pinch guide pinch rolls on the upper Go to step 3 Clean or replace pinch guide assembly and two upper media transport the appropriate roll assemblies free of damage roller and clean the media path 3 Check the sensor upper media exit for correct Replace the Go to step 4 operation finisher controller Perform the sensor upper media exit test CAC 1 Enter Diagnostics mode controller card 2 Select FINISHER TESTS Leger A 3 Select Sensor Tests page 4 118 4 Select Media
6. 2 22 eee eee eee eee eee ee 7 23 Buffer upper guide assembly 5 5 0 r rrr rrr rrr rrr rere errr rere eee 7 23 Buffer roll assembly eee errr eee ee eee eee ee 7 23 Buffer pinch guide assembly this comes assembled 0 r rr rrr ree 7 23 Media entrance pinch guide assembly this comes assembled 7 23 Sensor finisher media entrance ee ee ee ee ee ee ee cecs 7 23 Sensor upper media bin full 7 25 Media entrance roll assembly 20 02 ee ee ee ee ee ee ee ee me ee ee ee ee ee em ee 7 23 Drive motor buffer transport ee ee eee er eee ee eee 7 25 Drive motor entrance paddle ee ee eee eee ee 7 23 Drive motor exit ee ee emet eee eee eee eee ee 7 25 L Finisher Service Manual 40X0911 40X0912 40X0912 40X0913 40X0913 40X0914 40X0915 40X0916 40X0917 40X0918 40X0919 40X0920 40X0921 40X0922 40X0923 40X0924 40X0925 40X0926 40X0927 40X0928 40X0929 40X0930 40X0931 40X0932 40X0933 40X0934 40X0935 40X0936 40X0937 40X0938 40X0939 40X0940 40X0941 40X0942 40X0943 40X0944 40X0945 40X0946 40X0947 40X0950 40X1388 4024 110 Belt entrance paddle 31 6 cm Ve ee ee ee ee ee ee ee rrr rrr rr mea ee ee ee ee ee m
7. 2 emet ee eee eee 7 19 Media eject clutch kit eee eee eee ee 7 19 Media eject motor assembly e eee ree eee eee eee eee 7 19 Sensor lower media exit assembly 7 29 Sensor lower media exit with bracket 7 21 Sensor buffer path eee ee rere ee eee eee 7 23 Sensor lower media exit ee ee ee ee ee eee eee 7 21 Sensor upper media exit ee eee eee rere eee 7 25 Static eliminator brush es5s s05es5 5s sesh se sce se se ences esse as esses 7 21 Lower media exit roll assembly eee 7 21 Main paddle shaft kit 7 21 Belt idler pulley 77 7 21 7 23 7 25 Lower exit roll pulley kit 2 2 ee ae ea een mea emma menes 7 21 Main paddle idler gear kit ee ee ee 7 21 Main paddle drive pulley gear 44 20T rere reer eee 7 21 Lower pinch guide assembly this comes assembled 7 23 Media diverter gate s s lt ses shesncn EE cere cee eee ee eee eee eee E 7 23 Buffer diverter gate
8. Step Check Yes No 9 Check the sensor diverter gate for correct operation Go to step 11 Go to step 10 Perform the sensor diverter gate test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path2 5 Select Diverter gate Open the finisher front door 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 10 Check the sensor diverter gate connection Replace the Replace the Are the connectors of the diverter gate sensor cable can ner connecuon assembly correctly connected Sensor diverter gate removal on page 4 110 11 Check the drive motor entrance paddle for correct Go to step 13 Go to step 12 operation Check the above motor by opening the finisher front door assembly and then closing it Does the motor entrance paddle rotate normally 12 Check the drive motor entrance paddle connection Replace the drive Replace the Are the connections of the main drive cable assembly ais S ENEE correctly connected Drive motor entrance paddle and belt entrance paddle removal on page 4 100 13 Perform a test print Replace the Problem solved Does the error still occur en Go to Finisher controller card ass
9. eee eee enn ene ee eee 7 11 10 mm ball bearing am a eee ee eee ee eee eee ee 7 11 Stacker slip clutch pulley kit 7 11 Sensor front tamper HP e eee ee eee eee 7 19 Sensor punch cam front 22 een nner ee eee 7 13 Sensor punch carriage shift HP 713 Sensor punch hole select 7 13 Sensor punch unit HP ee TAS Sensor punch unit motor encoder 7 13 Sensor rear tamper HP mm ee eee 7 19 Sensor stacker bin level encoder 7 11 Sensor stacker bin no media 7 11 Sensor stacker bin upper limit 741 Sensor stapler carriage HP me eL 7 15 Stacker bin lift motor assembly eee 7 11 Part number index l 7 4024 110 40X0853 40X0854 40X0855 40X0856 40X0857 40X0858 40X0859 40X0860 40X0861 40X0862 40X0864 40X0865 40X0866 40X0867 40X0868 40X0869 40X0870 40X0871 40X0872 40X0873 40X0874 40X0875 40X0876 40X0877 40X0879 40X0881 40X0882 40X0883 40X0886 40X0887 4
10. 7 2 Bridge unit pinch roll kit 7 3 Bridge unit top cover assembly 3 3 Bridge unit rear cover a ne eee eee eee 7 5 Bridge unit drive belt eee eee 7 5 Bridge unit drive pulley eee nee eee eee 7 5 Bridge unit drive motor ee eee eee eee eee 7 5 Bridge unit entrance guide kit 7 5 Ball bearing 4mm tt em ee 7 5 Transport belts 7 5 Idler roll kit ee eee ee eee eee ee eee eee 7 5 Bridge unit right shaft kit 7 5 Bridge unit left shaft assembly eee 7 5 Magnetic catch 7 5 7 23 7 25 Sensor bridge unit top cover interlock 7 5 Sensor compiler media in ee eL 7 19 Sensor media eject shaft HP 7 17 7 19 Sensor bridge unit media exit 7 5 Sensor bridge unit media entrance
11. 2 2 err ee ee ee eee ee eee eee ee ee 7 15 Stapler carriage kit 2 ee ee eee eee eee ee eee 7 15 Stapler unit cable assembly eee ee ee eee 7 15 7 31 Stapler carriage motor assembly ee ee ee errr rere ee 7 15 Stapler carriage rack gear eee rere ee ee eee eee eee 7 15 Media eject unit assembly this comes assembled 7 17 Sub paddle 22 ere eee ee ee ee ee eee eee eee ee 7 17 Sub paddle drive shaft kit ee ee ee ee eee 7 17 Media eject clamp motor ee ee ee ee ee ee ee reer eee 7 17 Eject clamp lever assembly ee ee ee ee ee ee rere eee 7 17 Sub paddle entrance drive gear 23T 7 17 7 23 Eject clamp gear kit eee rere eee eee eee ee 7 17 Switch eject cover interlock ee eee eee eee eee 7 17 Media compiler unit assembly this comes assembled 7 19 Media eject shaft assembly 2 2 rere rere errr ee eee 7 19 Clamp paddle eee rr eee ee eee eee eee eee 7 19 Bushing 6 mm ee eee eee ee 7 17 7 19 7 21 7 23 7 25 Media eject shaft gear 39T
12. assembly removal on page 4 118 985 00 Sensor punch carriage shift HP on failure Step Check Yes No 1 Check the punch carriage for correct operation Go to step 2 Remove Does the punch carriage move back and forth SES smoothly Check this item by moving it with your fingers 2 Check the sensor punch carriage shift HP for correct Go to step 4 Go to step 3 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 change every time the sensing area of the above sensor is blocked 3 Check the sensor punch carriage shift HP Replace the Replace the connection sensor punch connection I carriage EE shit HP Go to y y Sensor punch carriage shift HP removal on page 4 51 4 Open the finisher front door assembly Go to step 6 Go to step 9 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 carriage shift motor assembly rotate and does the punch shift carriage move back and forth Diagnostic information 2 75 4024 110 Step Check Y
13. 2 84 Finisher Service Manual 989 00 Stapler unit failure 4024 110 Step Check Yes No 1 Check the stapler unit assembly for correct operation Check for staples Go to step 2 Perform the staple test and staple jam erform the staple test Problem 1 Enter Diagnostics mode resolved 2 Select FINISHER TESTS 3 Select Staple Test Does the motor in the stapler unit assembly rotate normally and staple the media 2 Is the stapler unit assembly connected properly Replace the Replace the stapler unit connection assembly Go to Stapler unit assembly removal on page 4 56 3 Perform a test print stapled document Replace the Problem solved printer engine Does the error still occur2 card assembly Refer to the Printer Service Manual 990 00 Sensor stapler carriage HP on failure Step Check Yes No 1 Check the stapler by moving it with your fingers Go to step 2 Remove Does the Stapler carriage move smoothly obstructions 2 Check the sensor stapler carriage HP for correct Go to step 4 Go to step 3 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
14. C EST ES es La o SS ays BE SS Se EL CH D ARA DEU P AA C Lock 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 Repair information 4 71 4024 110 Sensor front tamper HP and sensor rear tamper HP removals 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 Remove the rear lower cover See Rear lower cover removal on page 4 23 4 Remove the upper media bin assembly See Upper media bin assembly removal on page 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 assembly See Media eject motor assembly removal on page 4 78 10 Remove the media compiler unit assembly See Media compiler unit assembly removal on page 4 69 11 Disconnect the connector from the sensor front tamper HP A or the sensor rear tamper HP B 12 Release the hooks securing the sensor front ta
15. Diagnostic aids 3 3 4024 110 Theory Media transport This section describes transfer of media from the printer to a specified bin The following figures illustrate layouts side 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 To finisher From printer Transport i Sensor bridge unit media entrance pe p PA unit Finisher media path Upper media bin Punch unit Stacker media bin From bridge unit Compiler media Stapler unit unit assembly 3 4 Finisher Service Manual Finisher roll assemblies Upper media transport roll assembly driven 4024 110 Upper media exit roll assembly driven by drive motor exit by drive motor buffer transport Finisher media entrance roll assembly driven by drive motor entrance paddle _ Buffer roll assembly driven by drive motor buffer transport Buffer diverter gate Main paddle Finisher diverter gate a Sub paddle driven by drive motor entrance paddle Eject clamp driven by media eject clamp motor Media eject shaft assembly driven by media eject motor assembly Lower media exit roll assembly driven by drive motor exit driven by drive motor entrance paddle Finisher media path sensors Sensor diverter gate Sensor finisher media entrance From
16. 8 9 Open the finisher front door assembly Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the left lower cover See Left lower cover removal on page 4 28 Remove the left upper cover See Left upper cover removal on page 4 29 Remove the screw securing the cover A to the media entrance pinch guide assembly B Remove the cover A Disconnect the connector from the sensor finisher media entrance C Release the harness from the clamps Remove the three screws securing the media entrance pinch guide assembly B Ce re 08 Ee Rear 10 Remove the entrance pinch guide assembly B from the finisher Repair information 4 97 4024 110 Sensor finisher media entrance removal Open the front door assembly Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the top cover See Top cover removal on page 4 19 Remove the left lower cover See Left lower cover removal on page 4 28 Remove the left upper cover See Left upper cover removal on page 4 29 Disconnect the connector from the sensor finisher media entrance A Release the harness from the clamp Remove the screw securing the bracket B to the media entrance pinch guide assembly C SNS Lo Connector 9 Release the hooks securing the sensor finisher media entrance A to the bracket B 10 Remove the senso
17. 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 Tools required for service Flat blade screwdriver 1 Phillips screwdriver magnetic 2 Phillips screwdriver magnetic 2 Phillips screwdriver magnetic short blade Needlenose pliers Diagonal side cutters Spring hook Analog or digital multimeter Features Media processing requested Destination of media No post processing Upper media bin or stacker media bin Punching Upper media bin or stacker media bin Stapling Stacker media bin Punching and stapling Stacker media bin 1 4 Finisher Service Manual 4024 110 Acronyms 2TM 2 Tray Module AC Alternate Current ASIC Application Specific Intergrated Circuit CRU Customer Replaceable Unit CSU Customer Setup DC Direct Current DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory EDO Enhanced Data Out EP Electrophotographic Process EPROM Erasable Programmable Read only Memory ESD Electrostatic Discharge FRU Field Replaceable Unit GB Gigabyte GFI Ground Fault Interrupter HCF High Capacity Feeder HVPS High Voltage Power Supply LASER Light Amplification by Stimulated Emission of Radiation LCD Liquid Crystal Display LD Laser Diode LED Light Emitting
18. Every type has the same construction except for the sensor punch hole select that is provided for the 2 hole type and 3 hole type only Adjusting punching positions The punching positions from the media edge in the direction of feed are determined by gently pressing the media against the three punch media stopper assemblies While the three punching positions from the media edge in the direction of media width are determined by the following method e Activate the punch carriage shift motor assembly and move the punch to the front side until the sensor punch carriage shift HP turns L e Rotate reversely the motor and move the punch to the rear side until the sensor turns H to determine the home position e The punch carriage shift motor assembly is activated to move the punch to the front until the sensor punch unit side registration 1 and the sensor punch unit side registration 2 detects the media edge and then the punch is further moved to the front according to the pulse number determined by the media size The punch carriage shift motor assembly stops at this position Sensor punch carriage shift HP Punch carriage shift motor assembly Sensor punch cam front Sensor Ge Sensor punch unit HP S K Sensor punch unit motor encoder Punch unit motor 3 12 Finisher Service Manual 4024 110 Punching After punching positions are determined the punch unit motor is activated to move the ca
19. Go to Finisher controller card assembly removal on page 4 118 2 58 Finisher Service Manual 288 03 Sensor diverter gate static jam to top bin C 4024 110 Step Check Yes No 1 Check the sensor diverter gate for correct operation Go to step 3 Go to step 2 Perform the sensor diverter gate test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path2 5 Select Diverter gate Open the finisher front door 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 2 Check the sensor diverter gate connection Replace the Replace the Is the above senor connected properly occa KC conmecuon Sensor diverter gate removal on page 4 110 3 Chech the drive motor entrance paddle by opening Go to step 5 Go to step 4 the finisher front door assembly and then closing it Does the motor entrance paddle rotate normally 4 Is the drive motor entrance paddle connected Replace the drive Replace the properly motor entrance connection paddle Go to Drive motor entrance paddle and belt entrance paddle removal on page 4 100 5 Perform a test print Replace the Problem solved Does the error still occur e
20. Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the punch carriage assembly See Punch carriage assembly removal on page 4 41 Remove the two screws securing the cover A to the punch carriage assembly B Remove the cover A Remove the two screws securing the punch carriage shift motor assembly C to the punch unit assembly B D ORON A 7 Remove the punch carriage shift motor assembly C Repair information 4 43 4024 110 Sensor punch unit side registration pair with bracket removal Open the finisher front door assembly Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the punch carriage assembly See Punch carriage assembly removal on page 4 41 Remove the screw securing the cover A to the punch unit assembly B Remove the cover 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 OO P GAMM ch Turn the paper guide C upside down Remove the two screws securing the bracket D to the paper guide C Remove the bracket D Remove the two connectors from the sensor punch unit side registration pair E Release the hooks securing the sensors punch unit side registration pair E to the bracket D ee al ia zech l Connectors 12 Remove the sensor punch unit side registration pair E Note
21. 1 40X0901 1 1 Lower pinch guide assembly this comes assembled 2 40X0902 1 1 Media diverter gate 3 40X0903 1 1 Buffer diverter gate 4 40X0824 8 1 Magnetic catch 5 40X0888 15 1 Bushing 6 mm 6 40X0904 1 1 Buffer upper guide assembly 7 40X0893 1 1 Sensor buffer path 8 40X0905 1 1 Buffer roll assembly 9 40X0906 1 1 Buffer pinch guide assembly this comes assembled 10 40X0909 1 1 Media entrance roll assembly 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 Rit includes e Belt idler pulley e Spring e 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 1 1 Media entrance roll drive pulley 20T 19 40X0913 4 1 Ball bearing 6 mm 20 40X0915 1 1 Buffer roll drive gear 46T 21 40X0916 1 2 Media diverter solenoid kit includes e Media diverter solenoid e Media diverter solenoid link 22 40X0917 1 2 Buffer diverter solenoid kit includes e Buffer diverter solenoid e Buffer diverter solenoid link Parts catalog 7 23 4024 110 Assembly 13 Buffer transport and upper drive 7 24 Finisher Service Manual ei 1 Se Assembly 13 Transport and upper drive 4024 110 Asm Part Units Units Description Index number option FRU 13 1 4
22. 4024 110 Step Check Yes No 3 Check the drive motor exit for correct operation Go to step 5 Go to step 4 Check the above motor by opening the finisher front door assembly and then closing it Does the motor exit rotate normally 4 Check the drive motor exit connection Replace the drive Replace the Is the above motor connected properly TE eo connection exit assembly and belt exit removal on page 4 113 5 Perform a teat print Replace the Problem solved Does the error still occur e Go to Finisher controller card assembly removal on page 4 118 285 00 Finisher eject set jam Step Check Yes No 1 Check the media path Go to step 2 Clean or replace Check the media eject shaft by turning it with your ae fingers and clean the Is the media eject shaft assembly installed correctly media path meaning does it rotate smoothly 2 Check the media eject clamp motor by opening the Go to step 4 Go to step 3 finisher front door assembly and then closing it Does the media eject clamp motor rotate normally 3 Check the media eject motor connection Disconnect then Replace the Is the above motor connected properly EE E cannecion on the finisher controller card assembly Perform a test print if the error still occurs replace the media eject motor assembly 4 Check the compiler media in actuator for correct Go to step 5 Reinstall the operation compiler media in Is the actuato
23. 4024 110 Assembly 9 Media eject 7 16 Finisher Service Manual Assembly 9 Media eject 4024 110 Asm Part Units Units Description Index number option FRU 9 1 40X0873 1 1 Media eject unit assembly this comes assembled 2 40X0874 2 Sub paddle 3 40X0875 1 2 Sub paddle drive shaft kit includes e Sub paddle drive shaft assembly e 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 hit includes e Eject clamp gear 70T e Eject clamp gear 23T e Eject clamp gear 68 20T 11 40X0876 1 1 Media eject clamp motor Parts catalog 7 17 4024 110 Assembly 10 Eject and compiler unit 7 18 Finisher Service Manual De Assembly 10 Eject and compiler unit 4024 110 Weg dE de Gi Description 10 1 40X0883 1 1 Media compiler unit assembly this comes assembled 2 40X0850 1 1 Sensor rear tamper HP 3 40X0850 1 1 Sensor front tamper HP 4 40X0825 1 1 Sensor compiler media 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 e Media eject clutch e Media eject clutch actuator
24. 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 e Sensor low staple in the stapler unit assembly A photo interrupter to detect near end of staples Itturns H 5 V dc when 20 staples are left e Sensor self priming in the stapler unit assembly Aphoto interrupter to detect that staples are at the stapler unit assembly end and also to detect failure in stapling T 0 V light blocking when stapling is ready e Sensor staple home in the stapler unit assembly A photo interrupter to detect the stapler unit assembly home position and also to detect failure in stapling This sensor also functions as a trigger to stop the staple motor Itturns L 0 V dc light blocking while the stapler unit assembly stays at the home position 3 24 Finisher Service Manual 4024 110 e Stapler unit motor in the stapler unit assembly ADC motor to activate the stapler unit assembly for stapling Clockwise rotation of this motor enables stapling while counterclockwise rotation returns the stapler unit assembly Stapler rack gear Sensor stapler carriage HP Upper media bin Operation The upper media bin contains the sensor upper media bin full to detect the media stack volume in the upper media bin Once the sensor detects full stack 500 sheets of the upper media bin eject
25. Connector Remove the sensor compiler media present A Repair information 4 73 4024 110 Media eject shaft assembly removal Remove the finisher front door assembly See Finisher front door assembly removal on page 4 27 Remove the rear upper cover See Rear upper cover removal on page 4 24 Move the slip clutch gear 24T A toward the rear as shown to disengage the stacker bin B Move the stacker bin down as shown to its lowest position after being disengaged Note Make sure the stacker bin is at its lowest position before continuing RON ch Remove the upper media bin assembly See Stacker media bin assembly removal on page 4 22 Remove the four screws securing the right panel C to the finisher ao 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 F 11 Remove the e clip with a prying tool securing the media eject shaft assembly E to the rear of the finisher 12 Remove the 8 mm bushing G 13 Remove the two e clips securing the media eject shaft assembly E to the front of the finisher 14 Remove the 6 mm bushing E and the 8 mm bushing G 4 74 Finisher Service Manual 4024 110 15 Move the media eject shaft assembly toward the re
26. ME Mj ahoo Eik iv Ol Ha Ho c gt d H H la EI e e Ge P RA T A position m 2 hole B ea eae position m qu ta El oO IW Ee Sie c I Diagnostic aids 3 13 4024 110 Detecting punch waste full Punch waste is stored in the punch waste box A sensor is provided to detect punch waste full When punch waste full is detected it is notified to the operator only once Even if punch waste is not removed the finisher can still punch media However it can spread punch waste inside the machine Detecting punch waste box The sensor punch waste box set detects whether the punch waste box is properly set When the sensor punch waste box set does not detect that the punch waste box is properly set for four seconds the punch waste box count is reset Functions of punch sensors motors Sensor punch unit side registration 1 A reflective photo sensor to detect the side edge of large media Media side edge is detected by On Off of this sensor while shifting the punch containing this sensor in the direction of media width The sensor remains at H 5 v dc while media is present and turns L when media side edge is detected Sensor punch unit side registration 2 A reflective photo sensor to detect the side edge of small media This sensor has the same function as the sensor punch unit side registration 1 Sensor punch carriage shift HP A photo interrupter to detect the home p
27. References in this publication to products programs or services do not imply that the manufacturer intends to make these available in all countries in which it operates Any reference to a product program or service is not intended to state or imply that only that product program or service may be used Any functionally equivalent product program or service that does not infringe any existing intellectual property right may be used instead Evaluation and verification of operation in conjunction with other products programs or services except those expressly designated by the manufacturer are the user s responsibility Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries All other trademarks are the property of their respective owners 2009 Lexmark International Inc All rights reserved UNITED STATES GOVERNMENT RIGHTS This software and any accompanying documentation provided under this agreement are commercial computer software and documentation developed exclusively at private expense P N 12G9604 4024 110 Table of contents Notices and safety information 20 c eee ix CC i ee ee re ee re ere ee ere eee ee eee ee ix See el EE xiii Profa EE EE xvi Definitions 98 dae cea hee NS RR EE RR aud ae E RRE Hee rae a xvi General MONON EE 1 1 reet eee bisa ee aa a aaa aare hae ER 1 1 Lee e E naa dE nal ha hel one eh GE RRA
28. buffer path connection Replace the Replace the Is the above sensor connected properly in Gon conmecuon Sensor buffer path removal on page 4 93 3 Check the drive motor buffer transport for correct Go to step 5 Go to step 4 operation Check the above motor by opening the finisher front door assembly and then closing it Does the drive motor buffer transport rotate normally 4 Check the drive motor buffer transport connection Replace the drive Replace the motor buffer connection Is the above motor connect properly transport Go to Drive motor buffer transport and belt buffer transport removal on page 4 115 5 Perform a test print Replace the Problem solved Does the error still occur Gg Go to Finisher controller card assembly removal on page 4 118 Diagnostic information 2 29 4024 110 283 04 Sensor buffer path static jam C Step Check Yes No 1 Check the sensor buffer path for correct operation Go to step 3 Go to step 2 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 media into the buffer path and around the buffer roll assembly in a clockwise direction Does the display on the operator panel change every time the actuator of the sensor buffer pat
29. clamp as assembly removal on page 4 66 3 Check the sensor compiler media in for correct Go to step 5 Go to step 4 operation Perform the sensor compiler media in test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path1 5 Select Compiler media in Does the display on the operator panel change every time the actuator of the sensor compiler media in is operated Diagnostic information 2 43 4024 110 Does the error still occur finisher controller card assembly Go to Finisher controller card assembly removal on page 4 118 Step Check Yes No 4 Check the sensor compiler media in connection Replace the Replace the Is the ab ted y sensor compiler connection s the above sensor connected properly media in Go to Sensor compiler media in removal on page 4 73 5 Check the media eject motor assembly by opening the Go to step 7 Go to step 6 finisher front door assembly and then closing it Does the media eject motor assembly rotate normally 6 Check the media eject motor assembly connection Replace the Replace the p PE media eject connection Se SE the main drive cable assembly motor assembly y Go to Media eject motor assembly removal on page 4 78 7 Perform a test print Replace the Problem solved 2 44 Finisher Service Manual 287 00 Sensor upper media exit on jam A 4024
30. finisher controller card assembly Go to Finisher controller card Problem solved assembly removal on page 4 118 Stacker media bin full mix size Step Check Yes No 1 Check the stacker bin for obstructions Remove the Go to step 2 Are there any obstructions on the upper and lower obstructions parts of the stacker bin 2 Check the sensor stacker bin level 1 for correct Go to step 4 Go to step 3 operation Perform the sensor stacker bin level 1 test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Bin Level 5 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 3 Is the sensor stacker bin level 1 connected properly Replace the Replace the sensor stacker connection bin level 1 Go to Sensor stacker bin level 1 removal on page 4 34 4 Check the sensor stacker bin level 2 for correct Go to step 6 Go to step 5 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 rear is blocked by a multi page document or your finger 2 94 Finisher Service Manua
31. on page 4 118 282 01 Sensor finisher media entrance static jam A Step Check Yes No 1 Check the sensor finisher media entrance for correct Go to step 3 Go to step 2 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 finisher media entrance 2 Check the sensor finisher media entrance Replace the Replace the connection sensor finisher connector Is the above sensor connected correctly deli IS finisher media entrance removal on page 4 98 2 22 Finisher Service Manual 4024 110 Step Check Yes No 3 Check the drive motor entrance paddle for correct Go to step 5 Go to step 4 operation Check the above motor by opening the finisher front door assembly and then closing it Does the motor entrance paddle rotate normally 4 Check the drive motor entrance paddle connection Replace the drive Replace the Are the connections of the main drive cable assembly EE connecion correctly connected paddle Go to y i Drive motor entrance paddle and belt entrance paddle removal on page 4 100 5 Perform a test print Replace th
32. shaft HP off failure The sensor media eject shaft HP is not turned off within the specified time after the set clamp ends operating Go to 987 01 Sensor media eject shaft HP off failure on page 2 80 988 00 Service finisher error Sensor punch unit side reg1 on failure Sensor punch unit side reg2 on failure The sensor punch unit side reg1 or sensor punch unit side reg2 did not detect the media correctly or is defective Go to 988 00 Sensor punch unit side reg on failure on page 2 82 988 01 Service finisher error Sensor punch unit side reg1 off failure Sensor punch unit side reg2 off failure The sensor punch unit side reg1 or sensor punch unit side reg2 did not detect the media correctly or is defective Go to 988 01 Sensor punch unit side reg off failure on page 2 83 2 8 Finisher Service Manual 4024 110 989 00 Service finisher error Stapler unit failure The off on status of the sensor stapler unit motor HP is not detected within the specified time after the stapler unit motor forward operation Or the sensor stapler unit motor HP is not turned on within the specified timer after the stapler unit motor is on reverse operation Go to 989 00 Stapler unit failure on page 2 85 990 00 Service finisher error Sensor stapler carriage HP on failure The sensor stapler carriage HP is not turned on within two s
33. the appropriate roller and clean the media path 5 Check the sensor buffer path for correct operation Go to step 7 Go to step 6 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 media into the buffer path and around the buffer roll assembly in a clockwise direction Does the display on the operator panel change every time the actuator of the sensor buffer path is operated 6 Check the sensor buffer path connection Replace the Replace the Is the above sensor connected properly coe connecNon Sensor buffer path removal on page 4 93 7 Check the drive motor buffer transport by opening the Go to step 9 Go to step 8 finisher front door assembly and then closing it Does the drive motor buffer transport rotate normally 2 38 Finisher Service Manual 4024 110 Step Check Yes No 8 Check the drive motor buffer transport connection Replace the drive Replace the Is the above motor connected properly e to connection Drive motor buffer transport and belt buffer transport removal on page 4 115 9 Check the sensor diverter gate for correct operation Go to step 11 Go to step 10 Perform the sensor diverter gate test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sens
34. the sensor diverter gate is turned on Go to 283 01 Sensor buffer path on jam B on page 2 25 283 02 Sensor buffer path Paper remains on the sensor finisher buffer path Paper jam Static jam A At this time both sensor diverter gate and sensor Check areas G2 G3 finisher media exit are turned on Go to 283 02 Sensor buffer path static jam A on page 2 28 283 03 Sensor buffer path Paper remains on the sensor finisher buffer path Paper jam Static jam B At this time the sensor diverter gate is on state but Check area G2 the sensor finisher media entrance is turned off Go to 283 03 Sensor buffer path static jam B on page 2 29 283 04 Sensor buffer path Paper remains on the sensor finisher buffer path Paper jam Static jam C At this time the sensor diverter gate is turned off Check area G4 Go to 283 04 Sensor buffer path static jam C on page 2 30 284 00 Sensor lower media Sensor lower media exit is not turned off within the Paper jam exit off jam A specified time after the finisher sensor lower media Check area F exit is turned on At this time the sensor bridge unit media exit is turned on Go to 284 00 Sensor lower media exit off jam A on page 2 31 284 01 Paper jam Check area F Sensor lower media exit on jam A Sensor buffer path is not turned on within the specified time after the sensor finisher media entrance is turned o
35. 19 4 Remove the left lower cover 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 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 to the bracket A gt a Connector B A d d Left 11 Remove the sensor diverter gate B 4 110 Finisher Service Manual 4024 110 Upper media transport roll assembly removal Open the finisher front door assembly Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the top cover See Top cover removal on page 4 19 Remove the left lower cover See Left lower cover removal on page 4 28 Remove the left upper cover See Left upper cover removal on page 4 29 Remove the punch carriage assembly See Punch carriage assembly removal on page 4 41 Open the upper pinch guide assembly A toward the right Remove the two screws securing the bracket B on the rear of the finisher CN dl ais ED 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 should only be slightly moved to provide better acces
36. 2 3 punch unit assembly this comes assembled 4 40X0858 1 1 2 4 punch unit assembly this comes assembled 5 40X0859 3 1 Punch media stopper assembly 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 Sensor punch unit HP 16 40X0853 1 1 Punch unit cable assembly 17 40X0850 1 1 Sensor punch carriage shift HP Note Assembly index items 11 13 14 15 and 17 are identical sensors with different functions therefore they are the same part number with different descriptions Parts catalog 7 13 4024 110 Assembly 8 Stapler 7 14 Finisher Service Manual Assembly 8 Stapler 4024 110 Asm Part Units Units Description Index number option FRU 8 1 40X0870 1 1 Stapler unit cable assembly 2 40X0869 1 2 Stapler carriage kit includes e Stapler carriage wire guide e 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 Parts catalog 7 15
37. 38 Finisher Service Manual 4024 110 6 Move the slip clutch gear 24T B toward the rear to disengage the stacker bin C 7 Move the stacker 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 OTI EI O Repair information 4 39 4024 110 11 Remove the screw securing the bracket F to the stacker bin lift motor assembly G 12 Remove the bracket F Connector 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 g 16 Remove the stacker bin lift motor assembly G 4 40 Finisher Service Manual 4024 110 Punch carriage assembly removal Open the finisher front door assembly Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the connector from the sensor punch carriage shift HP A Remove the top cover See Top cover removal on page 4 19 Release the harness from the punch carriage assembly B Remove the connector from the punch carriage shi
38. 4 lle 145 SIG GND ES Sensor 26 rans TERA E S SS Diverter Gate SNR L 5VDC Stacker No Media SNR L 5VDC i G W 2 lt 25 Vf 9 S 4 5 16 1 n Stacker Bin ULL VL 24VDC 2 GK El Sensor _ O O SS SIGGND 347 i 5vDC SE No Medi 1 he Al rec MOST A a a Ja Diverter Gate ES 5VDC zuel SIG GND co o Media H DN 3 ML szavoc 23 Toke Fin Media Entrance SNR L 5VDC 2119 4 Stacker Bin Upper Limit SNR L 5VDC Pre N S 122 Eject Motor B gt 5VDC Sensor Stacker SH 21 OO Sol SIG GND 1 20 p gt a Bin Upper Limit d le Media eject clutch ON L 424VDC lt gt Sensor Finisher Media AB ee PP BS Sensor Front Tamper Media Let Eject Motor B x Near A Entrance T 2 Media In Motor Eject Clutch leer Neutral Ge ba el bal ES 6 17 gt Eject Motor A we P2 P505 qt a o wla DI 16 gt lL 24VDC AC IN a a SlO Stacker Bin a EE Sensor Front val z ee Eject Motor A D ial D 3 From Engine Tat 8 8 25 Lift Motor W Tamper HP Nee 2 B T Motor A 14 pe WL 24VDC o Finisher LVPS 3 g SE i H 82 Sege me EE eee To Metal Card ASM o a HO BeN qu RE Sensor Rear SE 2 BT Motora Pie dida le Finisher A A Si S De Tamper HP 6 o DI Motor B otorB a11 Z dele fe Frame J S El 5 o gt gt VL 24VDC VL 24VDC 10 o Q Q Q E El 2 El li DE 5g 5 Bit Motor B B T Motor A o REPERE A g S g ig Ja O 5 6 VL 24VDC 3 BS 3 35 LI 8 S 3 i 3 allo o a B T Motor A a Joad Mal El As H o 8 lt xola el lz on A 1 Exit Mo
39. 75 985 01 sensor punch carriage shift HP off failure 2 76 986 00 sensor media eject clamp HP on failure 2 77 986 01 sensor media eject clamp HP off failure 2 78 987 00 sensor media eject shaft HP on failure 2 79 988 00 sensor punch unit side reg on failure 2 82 988 01 sensor media eject shaft HP off failure 2 80 988 01sensor 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 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 size 2 94 stacker media bin full no mix 2 96 stacker set over count failure 2 99 staple cartridge empty 2 99 ESD sensitive parts 4 1 F finisher removal 4 4 finisher controller card assembly 4 118 FINISHER TESTS l 2 Finisher Service Manual Feed Tests 3 2 Hole Punch Test 3 2 Sensor Test 3 2 Bin Level Fin upper bin full 3 3 Stacker bin level encod 3 3 Stacker bin level1 3 3 Stacker bin level2 3 3 Stacker bin no media 3 3 Stacker bin upper limit 3 3 Cover and Door Cover F bridge top 3 3 Doo
40. 91 Buffer diverter gate removal 0 0 cece eee eee eee eee eee eee eee eeee 4 92 Sensor buffer path removal ssc se A ama mas ma Ras EA eens NE REE ee RE ee OEE RR RS 4 93 Buffer roll assembly removal sas EELER dee ds iraun eee peewee sie kin EES 4 94 Buffer pinch guide assembly removal 2 0 c cece eee n ee eee eee eee eee ene 4 96 Media entrance pinch guide assembly removal 4 97 Vi Finisher Service Manual 4024 110 Sensor finisher media entrance removal eee 4 98 Media entrance roll assembly removal 0 0 0 c eee eee eee eee 4 99 Drive motor entrance paddle and belt entrance paddle removal 4 100 Media diverter gate solenoid removal 0000 c eee e eee eee eee eee 4 102 Buffer diverter gate solenoid removal 0 00 csc eee eee eee 4 103 Sensor upper media exit removal 0c e eee eee eee eee eee eens 4 104 Upper media exit pinch roll assembly removal 00 0c cece eee eee eee 4 105 Upper media exit roll assembly removal 000 00 cee eee eee eee 4 106 Sensor upper media bin full removal 4 108 Upper pinch guide assembly removal 0000 see e cece eee eee eee 4 109 Sensor divennet Gate KEREN ica gg ene Ster Et wan naka ngewe EE ED ua 4 110 Upper media transport roll assembly removal 0200 0 cee eee eee eee 4 111 Drive motor exit assembly and belt exit removal 00 cece eee eee eee 4 113 Drive motor buffer transpo
41. A Replacement note Make sure to put the power cord B into the notch on the right lower LVPS cover A 4 22 Finisher Service Manual 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 e 3 Remove the rear lower cover A Repair information 4 23 4024 110 Rear upper 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 4 24 Finisher Service Manual 4024 110 Upper media bin front cover removal 1 Remove the 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 cag GE 4 Remove the upper media bin front cover A Repair information 4 25 4024 110 Switch finisher front door interlock removal Open the finisher front door assembly Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the punch waste box A Remove the
42. Check the sensor upper media exit for correct Go to step 3 Go to step 2 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 2 Check the sensor upper media exit and main sensor Replace the Replace the cable assembly connection sensor upper connection Is the above sensor connected properly eeh media exit removal on page 4 104 3 Check the drive motor buffer transport by opening the Go to step 5 Go to step 4 finisher front door assembly and then closing it Does the drive motor buffer transport rotate normally Diagnostic information 2 53 4024 110 Step Check Yes No 4 Check the drive motor buffer transport connection Replace the drive Replace the Is the above motor connected properly fabs ce to connection Drive motor buffer transport and belt buffer transport removal on page 4 115 5 Perform a test print Replace the Problem solved finisher controller Does the error still occur card assembly Go to Finisher controller card assembly removal on page 4 118 288 00 Sensor diverter gate on jam Step Check Yes No 1 Check the media path Go to step 2 Clean or replace 1 Open the bridge u
43. DIAGNOSTICS 2 Select Staple Test from FINISHER TESTS 3 Select the output bin and press While the test runs the power indicator blinks and the message Staple Test Running displays Select Stop to exit the test before it completes Hole Punch Test This test is used to verify whether or not media can be fed to a finisher output bin and punched Eight sheets of blank paper are fed from the default paper source and fed to the finisher output bins Letter size paper is used for the 3 hole test and A4 media is used for the 4 hole test Media is selected from the default tray To run the Feed Test 1 Select FINISHER TESTS from DIAGNOSTICS 2 Select Feed Tests from 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 output bins Note This test can be run using any of the paper sizes supported by the printer To run the Feed Test 1 Select FINISHER TESTS from DIAGNOSTICS 2 Select Feed Tests from 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 u
44. Disconnect the connector from the bridge unit drive motor A Release the harness from the clamp Open the bridge unit top cover assembly Remove the two screws securing the cover B from the bridge unit assembly C Remove the cover B Remove the two screws securing the bridge unit drive motor A to the bridge unit assembly C C ONDUR 9 Remove the bridge unit drive motor A Repair information 4 13 4024 110 Bridge unit entrance guide removal 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 4 14 Finisher Service Manual 4024 110 Sensor bridge unit top cover interlock removal Remove the bridge unit assembly See Bridge unit assembly removal on page 4 2 Place the bridge unit assembly upside down Remove the screw securing the bracket A to the bridge unit assembly B Disconnect the cable from the sensor bridge unit top cover interlock C RONA Connector 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 Repair information 4 15 4024 110 Sensor bridge unit media entrance removal Remove the bridge unit assembly See Brid
45. Does the front tamper drive motor rotate and does the tamper move back and forth 5 Check the compiler unit cable assembly connection Replace the Replace the Are the connections of the compiler unit cable o SE assembly correctly connected to Media y compiler unit assembly removal on page 4 69 6 Perform a test print Replace the Problem solved Does the error still occur LA ie U Go to Finisher controller card assembly removal on page 4 118 983 00 Sensor rear tamper HP on failure Step Check Yes No 1 Check the tamper mechanism by moving it with your Go to step 2 Replace the fingers Does the tamper mechanism operate smoothly media compiler unit assembly Go to Media compiler unit assembly removal on page 4 69 2 70 Finisher Service Manual 4024 110 Step Check Yes No 2 Check the sensor rear tamper HP for correct Go to step 4 Go to step 3 operation Perform the sensor rear tamper HP test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media path2 5 Select Rear tamper HP Does the display on the operator panel change every time the sensing area of the sensor rear tamper HP is blocked 3 Is the sensor rear tamper HP connected properly Replace the Replace the sensor rear connection tamper HP Sensor front tamper HP and sensor rear tamper HP removals on page 4
46. E 3 10 EUR dte a cus EES EES 3 11 TT EE 3 12 Adjusting PUNCHING POSMIONS sacra ates Shoes eek gsnamesaisgsats meee aa Ree wae ES 3 12 PUNCHING sc5024 oe2eeesee4un0s4 5444 99345 62455 EE 3 13 Detscting PUNCH WAST e cke deen reg EE EE ERR 3 14 Detecting punch Waste POX hs ccccccsrereeead ee EELER EE 3 14 Functions Of PUNCH SENSOFS INGIONS e SEA citereewe radot Unine per an deseo iT eE 3 14 COMPUGEUNIVASSEMINY est ee rieee sites dates ESE RES 3 15 OMNES Gi OS Arer Soe eee eke reso Seege 3 15 Capacny Of compiler unit ASSOMDY ae cater cases Seas AE AE conde EAR 3 16 Compiler unit assembly operation with multiple media sizes eee eee 3 16 MTEL Oe oe Ae a ett Eine Sak SA EE 3 16 Send EE 3 17 Meal AMG EE 3 18 Center len DEER 3 19 Determining tamper home position 3 19 JEE 6520 ce tet RES ES Sek GES DGE CG EES Q RL EERE ERLE DE CEER ERE EE 3 19 OUSSUING tar eden teii onde EE salva did eeh ger Ee dE 3 20 Functions of compiler unit assembly sensors motors 3 20 DIODIET eee ee ee EE ee ee ee eT ee ee ee rr 3 21 Stabling OPCHAUCH Eres Ree HRASAEAPED SELLS EASE ROARS HED OR ADORE RRR 3 21 ET Aler cicc coded oest adhd nee e ested rere aguas set Ome P oe ade Saas 3 21 Media sizes that allow stapling 3 22 SAPS ONE SHC 246 4 b ceddonadidgusecedodeeediegeutiede ie eiedbendseee tities 3 22 E Lee EE EE 3 22 Media limits tor Stapling ue Ach Are arr condo steed oon 4054 kde ies EE 3 23 SEELEN oben piece wetland 3 23 Sta
47. Go to Finisher controller card assembly removal on page 4 118 Diagnostic information 2 59 4024 110 288 04 Sensor diverter gate static jam to stacker bin A Step Check Yes No 1 Check the sensor diverter gate for correct operation Go to step 3 Go to step 2 Perform the sensor diverter gate test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path2 5 Select Diverter gate Open the finisher front door 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 2 Is the sensor diverter gate connected properly Replace the Replace the sensor diverter connection gate Go to Sensor diverter gate removal on page 4 110 3 Check the drive motor entrance paddle by opening Go to step 5 Go to step 4 the finisher front door assembly and then closing it Does the motor entrance paddle rotate normally 4 Check the main drive cable assembly connection Replace the drive Replace the Are the connections of the main drive cable assembly E Be e cone cuan correctly connected Drive motor entrance paddle and belt entrance paddle removal on page 4 100 5 Perform a test print Replace
48. Go to step 11 Go to step 10 operation Check the above motor 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 10 Is the stacker bin lift motor assembly connected Replace the Replace the properly stacker bin lift connection motor assembly Go to Stacker bin lift motor assembly removal on page 4 38 11 Perform a test print Replace the Problem solved 8 finisher controller Does the error still occur card assembly Go to Finisher controller card assembly removal on page 4 118 Stacker lower safety failure Step Check Yes No 1 Check the vertical transport mechanism of the stacker Remove Go to step 2 bin for obstructions and deformation obstructions Are there any obstructions in the vertical transport mechanism of the stacker bin 2 Is there any deformation in the vertical transport Replace Go to step 3 mechanism of the stacker bin deformed part Diagnostic information 2 97 4024 110 Step Check Yes No 3 Check the sensor stacker bin level 1 for correct Go to step 5 Go to step 4 operation Perform the sensor stacker bin level 1 test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Bin Level 5 Select Stacker bin level1 Does the display on the operator panel change every time the sensing area
49. 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 4 Check the sensor upper media exit and main sensor Replace the Replace the cable assembly connections sensor upper connection media exit Go to Is the above sensor connected properly Sensor upper media exit removal on page 4 104 2 50 Finisher Service Manual 4024 110 Step Check Yes No 5 Check the drive motor buffer transport for rotation Go to step 7 Go to step 6 Check the above motor by opening the finisher front door assembly and then closing it Does the drive motor buffer transport rotate properly 6 Check the drive motor buffer transport connection Replace drive Replace the I motor buffer connection s the above motor connected properly transport Go to Drive motor buffer transport and belt buffer transport removal on page 4 115 7 Check the drive motor exit for correct operation Go to step 9 Go to step 8 Check the above motor by opening the finisher front door assembly and then closing it Does the motor exit rotate normally 8 Check the drive motor exit connection Replace the drive Replace the Is the above motor connected properly CS connection exit assembly and belt exit removal on page 4 113 9 Perform a test print Replace the Problem solved Does the
50. Rear upper cover removal on page 4 24 2 3 Move the bracket slightly Remove the two screws securing the bracket A on the rear of the finisher 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 Loosen the two screws securing the belt tensioner bracket C to the finisher and move it down as shown Remove the belt buffer transport D from the drive motor buffer transport Connector Second _ Repair information 4 115 4024 110 Disconnect the connector from the drive motor buffer transport Remove the two screws securing the bracket E to the finisher Remove the bracket Remove the two screws securing the drive motor buffer transport to the bracket Remove the drive motor buffer transport Remove the belt buffer transport D SODN 1 1 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 Connector 4 116 Finisher Service Manual 4024 110 Bridge unit interface card assembly removal 1 Remove the rear upper cover See Rear upper cover removal on page 4 24 2 Disconnect all the connectors from the bridge unit interface card assembl
51. Replace the Is the above sensor connected properly GE to BEES Sensor lower media exit removal on page 4 80 5 Check the drive motor exit by opening the finisher Go to step 7 Go to step 6 front door assembly and then closing it Does the motor exit rotate normally 6 Check the drive motor exit connection Replace the drive Replace the Is the above motor connected properly Ee Se SES exit assembly and belt exit removal on page 4 113 7 Perform a test print Replace the Problem solved Does the error still occur eg Go to Finisher controller card assembly removal on page 4 118 284 05 Sensor lower media exit static jam Step Check Yes No 1 Check the sensor lower media exit for correct Go to step 3 Go to step 2 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 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 2 Check the sensor lower media exit assembly Replace the Replace the connection sensor lower connection Is the above sensor connected properly ee Se media exit removal on page 4 80 Diagnostic information 2 41
52. Replace the Problem solved i finisher controller Does the error still occur card assembly Go to Finisher controller card assembly removal on page 4 118 982 00 Sensor front tamper HP on failure Step Check Yes No 1 Check the tamper mechanism by moving it with your Go to step 2 Replace the fingers Does the tamper mechanism operate smoothly media compiler unit assembly Go to Media compiler unit assembly removal on page 4 69 2 68 Finisher Service Manual 4024 110 Step Check Yes No 2 Check the sensor front tamper HP for correct Go to step 4 Go to step 3 operation Perform the sensor front tamper HP test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media path2 5 Select Front tamper HP Does the display on the operator panel change every time the sensing area of the sensor front tamper HP is blocked 3 Is the sensor front tamper HP connected properly Replace the Replace the sensor front connection tamper HP Go to Sensor front tamper HP and sensor rear tamper HP removals on page 4 72 4 Check the front tamper drive motor by opening the Go to step 6 Go to step 5 finisher front door assembly and then closing it Does the front tamper drive motor rotate and does the tamper move back and forth 5 Check the compiler unit cable assembly connection Replace the Replace t
53. S E O 9 0 Sl Z Q k r Er o o o 5 00 22 8 2 o5 Q I I i i Z Shift Motor ASM x o 9 l oo o 2 i 1 1 i E g g2 5825 aoz gog i I od AUVs S52 54 5 GEE go Y bof i ot a E S Beer d vy i SIS SOS SOS SS SS CCE a k a Sensor Punch sen BA Sensor a WE HJEL S ao o0 JN ales elo I i hi za 12 1 T 1 OX oe ESE Hole Select 3 w Punch Hole Select SNR L 5VDC Jr 2 T Punch Waste Box Set L 5VDC 2 El ra d Sensor Punch S SIG GND_ 7973 SIGGND SI Sensor Punch Sto ta le LU EB 225 2285215 o Cam Front a Anode 4 g 4 i L35VDC di Carriage a GO 2 o 2 2 ES i i H Punch Cam Front SNR L 5VDC SIS Punch Carriage Shift L 5VDC 42 Shift HP Sensor Punch Unit IM Z lolk ale O zk P E i e 3 si 2 2 2915 i 1 eee 3 Side REG2 o Zee ue a eg 1 ef Anode qe 771 5vDC Ji g E SIS Sensor Punch Fig Punch Unit HP SNR L 5VDC J is ig Punch Unit side REG 2 SNR L 45VDC 42 HOO po it HP SIG GND SIG GND o Unit HP 11 419 3 d s Punch gt i SIGGND J 3401 p 5VDC Beni Unit Motor E er l e l PunchUnit Encoder SNR L 5VDC 2 Tal Punch Unit Side REG1 SNR L 5VDC Jan OO i I nit Motor Encoder 5VDC SIG GND CAREE d El qui 12 sigs 3 Sensor Punch Unit fe ees ep a ge i Side REG1
54. Sensor bridge unit top cover interlock removal on page 4 15 6 Check the sensor bridge unit top cover interlock for Go to step 7 Go to step 6 proper operation Perform the sensor bridge unit top cover interlock test 1 Enter the Diagnostics 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 7 Is the sensor bridge unit top cover interlock Replace the Replace the connected properly sensor bridge connection unit top cover interlock Go to Sensor bridge unit top cover interlock removal on page 4 15 8 Does the error still occur when the power is turned on Go to step 8 Problem solved 9 Replace the finisher controller card assembly Replace the Problem solved Diagnostic information 2 89 4024 110 Finisher front door open Step Check Yes No 1 Open and close the finisher front door assembly Go to step 2 Check the D it thiy finisher front door oes it open or close smoothly assembly for installation correct deformations or replace it Go to Finisher front door assembly removal on page 4 27 2 Check the switch finisher front door interlock Go to step 3 Reinstall the installation switch finisher F Sg 3 front door Is me SC finisher front door interlock installed i
55. The two sensors are identical 4 44 Finisher Service Manual 4024 110 Punch unit assembly removal Open the finisher front door assembly Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the punch carriage assembly See Punch carriage assembly removal on page 4 41 Remove the screw securing the cover A to the punch unit assembly B Remove the cover A Remove the two screws securing the bracket C to the punch carriage assembly D Remove the bracket C Remove the three screws securing the punch carriage assembly D to the punch unit assembly B Ee 9 Remove the punch unit assembly B Repair information 4 45 4024 110 Punch media stop assembly removal Open the finisher front door assembly Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the punch carriage assembly See Punch carriage assembly removal on page 4 41 Remove the punch unit assembly See Punch unit assembly removal on page 4 45 Remove the three screws securing the three punch media stop assemblies A to the punch unit assembly B dl am il 6 Remove the three punch media stop assemblies D 4 46 Finisher Service Manual 4024 110 Punch unit motor assembly removal Open the finisher front door assembly Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the punch carriage assembly See Punch carriage
56. Units Units Description Index number option FRU P 1 1 40X0811 1 1 Bridge unit assembly 2 40X0810 1 2 Bridge unit assembly docking screw 2 each 7 2 Finisher Service Manual 4024 110 Assembly 2 Bridge unit top cover assembly Asm Part Units Units Description Index number option FRU p 2 1 40X0813 1 1 Bridge unit top cover assembly 2 40X0812 6 2 Bridge unit pinch roll kit includes e Bridge unit pinch roll 6 each e Spring 6 each Parts catalog 7 3 4024 110 Assembly 3 Bridge unit lower assembly 7 4 Finisher Service Manual Assembly 3 Bridge unit lower assembly 4024 110 Asm Part Units Units Description Index number option FRU 3 1 40X0814 1 1 Bridge unit rear cover 2 40X0822 1 3 Bridge unit right shaft kit includes e Bushing 6 mm front e Bridge unit right shaft assembly e Bushing 6 mm rear 3 40X0820 1 2 Transport belts 2 each 4 40X0821 1 6 Idler roll kit includes Idler roll 2 each e 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 e Bridge unit entrance guide e Lower guides 2 each 11 40X0817 1 1 Bridge unit drive motor 12 40X0819 2 1 Ball bearing 4 mm 13 40X0823 1 1 Brid
57. a test print Replace the Problem solved f finisher controller Does the error still occur card assembly Go to Finisher controller card assembly removal on page 4 118 987 01 Sensor media eject shaft HP off failure Step Check Yes No 1 Check the media eject shaft assembly by moving it with Go to step 2 Remove your fingers obstructions Does the media eject shaft assembly mechanism move smoothly 2 80 Finisher Service Manual 4024 110 Step Check Yes No 2 Check the sensor media eject shaft HP for correct Go to step 4 Go to step 3 operation Perform the sensor media eject shaft HP test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path2 5 Select Media eject shaft HP Rotate the media clutch actuator manually by hand Does the display on the operator panel change every time the sensing area of the sensor media eject shaft HP 3 Check the sensor media eject shaft HP connection Replace the Replace the Are the connections of the main sensor cable assembly Sue connection correctly connected Go to Sensor media eject shaft HP removal on page 4 79 4 Check the for correct operation Go to step 6 Go to step 5 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 5 Is the media eject motor assembly co
58. arseneto de pot ssio de 5 milliwatts operando numa faixa de comprimento de onda entre 770 e 795 nan metros O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radia o laser superior a um nivel de Classe durante a opera o normal a manuten o feita pelo utilizador ou condi es de assist ncia prescritas Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J voor andere landen in IEC 60825 1 Laserprodukten van klasse worden niet als ongevaarlijk aangemerkt De printer is voorzien van een laser van klasse lllb 3b dat wil zeggen een gallium arsenide laser van 5 milliwatt met een golflengte van 770 795 nanometer Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal gebruik bij onderhoud of reparatie conform de voorschriften nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals voorgeschreven is voor klasse 1 Lasermeddelelse Printeren er godkendt som et Klasse I laserprodukt i overenstemmelse med kravene i IEC 60825 1 Klasse l laserprodunter betragtes ikke som farlige Printeren indeholder internt en Klasse IIIB 3b laser der nominelt er en 5 milliwatt galliumarsenid laser som arbejder p bglgeleengdeomr det 770 795 nanometer Lasersystemet og printeren er udformet s ledes at mennesker aldrig udseett
59. assembly H through the inside of the finisher Note When removing the media entrance roll assembly H do not touch the rubber surface Replacement notes e Make sure the flat spot on the media entrance roll assembly H is installed to the rear e When replacing the media entrance roll assembly H do not touch the rubber surface e The tension of the belt entrance paddle E is automatically adjusted to the force of the spring attached to the belt tensioner bracket D e Tighten the two screws in the order shown Drive motor entrance paddle and belt entrance paddle removal Remove the rear upper cover See Rear upper cover removal on page 4 24 Loosen the two screws securing the belt tensioner bracket A to the finisher and move upward as shown Remove the belt entrance paddle B from the drive motor entrance paddle C Disconnect the connector from the drive motor entrance paddle C PONHA 4 100 Finisher Service Manual 4024 110 5 Remove the two screws securing the bracket D to the finisher Connector Remove the bracket D Remove the two screws securing the bracket D to the drive motor entrance paddle C Remove the drive motor entrance paddle C Remove the belt entrance paddle B eo up Replacement notes e The tension of the belt entrance paddle B is automatically adjusted by the force of the spring att
60. assembly removal on page 4 41 Disconnect the connector from the punch unit motor assembly A Disconnect the connector from the sensor punch unit motor encoder B Remove the harness from the clamp Remove the two screws securing the punch unit motor assembly A to the punch unit assembly C SE Connector 8 Remove the punch unit motor assembly Repair information 4 47 4024 110 Sensor punch unit motor encoder removal Open the finisher front door assembly Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the punch carriage assembly See Punch carriage assembly removal on page 4 41 Disconnect the connector from the punch unit motor assembly A Disconnect the connector from the sensor punch unit motor encoder B Remove the harness from the clamp Remove the two screws securing the bracket C to the punch unit assembly D Se Connector 8 Release the hooks securing the sensor punch unit motor encoder B to the bracket C 9 Remove the sensor punch unit motor encoder B 4 48 Finisher Service Manual 4024 110 Sensor punch hole select sensor punch cam front and sensor punch unit HP removal Open the finisher front door assembly Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the punch carriage assembly See Punch carriage assembly removal on page 4 41 Remove the
61. assistance Diagnostic information 2 1 4024 110 Confirm the installation status Be sure to check the following items before starting the troubleshooting procedures With the power cord removed from the printer check that it is free from breakage short circuit disconnected wire or incorrect connection in the power cord The printer is properly grounded Check the power cord ground terminal The printer is not installed at a place subjected to extreme temperature or extreme 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 surface Media meets specifications and is installed properly Customer maintenance parts have been replaced at the specified intervals Check all attached options for proper attachment and electrical connection Refer to the User s Guide for proper installation 2 2 Finisher Service Manual Error code messages 4024 110 Error code or message Error contents Description action 280 00 Sensor bridge unit Sensor bridge unit media entrance is not turned on Banas iari media entrance on jam within the specified time after the sensor fuser
62. bridge unit Sensor buffer path Sensor upper media exit Sensor upper media bin full a Sensor lower media exit Sensor compiler media in Diagnostic aids 3 5 4024 110 Finisher motors Drive motor exit Drive motor buffer transport ES Media eject motor asm Finisher diverter gate solenoid Buffer diverter solenoid le Stacker bin lift lt motor assembly Bridge unit assembly Drive motor entrance paddle When the finisher is designated by the command of printer the media diverter gate in the printer activates and media is fed from the printer into the bridge unit assembly The bridge unit drive motor is activated by the trigger of printer s registration clutch on to drive the transport belts in the bridge unit assembly 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 Bridge unit drive motor EE Ee shaft assembly Bridge unit aa pinch roll Bridge unit left shaft assembly 3 6 Finisher Service Manual 4024 110 From bridge unit assembly to punch The media fed from the bridge unit assembly is fed into the finisher by the media entrance roll assembly located on the entrance section of the finisher that is driven b
63. compiler Media eject motor asm POP AU lt Cola aa Sensor media Sensor rear eject shaft HP tamper HP Rear tamper motor OE e SE sr Sensor Front tamper motor compiler media in 4024 110 Sensor front tamper HP Component locations 5 5 4024 110 Buffer upper exit lower exit and drive motors Sensor upper media exit Sensor upper media bin full Drive motor exit Drive motor buffer transp Sensor finishe media entrance I Sensor buffer path Drive motor eritrance paddle Finisher controller card assembly Finisher controller Bridge unit interface card assembly card assembly P8304 P8308 P8389 XP P8306 i P8307 A P8309 S 0 8300 P8305 E j Ie P8301 P8376 l SY paaga P8310 lt P8316 P8311 sft by P8314 wee J P8317 P8315 P8313 Finisher low voltage power supply 5 6 Finisher Service Manual 4024 110 Cabling Finisher media entrance sensor cable assembly Upper media exit sensor cable assembly Upper media bin full cable assembly Lower media exit sensor cable sssembly Compiler unit cable assembly Buffer path sensor cable assembly Main sensor cable assembly LVPS cable assembly SS AC power cord assembly Component locations 5 7 4024 110 Diverter gat
64. cover A VN lt e S es Se a ae e O O CH gt a Rear 3 Remove the finisher from the printer See Finisher removal on page 4 4 4 Remove the two screws securing the bridge unit assembly B to the printer 4 2 Finisher Service Manual 4024 110 5 Remove the bridge unit assembly B from the printer Repair information 4 3 4024 110 Finisher removal 1 Disconnect the 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 Right 3 Remove the bridge unit hookup cover A EY o bo a gt 4 Disconnect the bridge unit connection from the finisher 4 4 Finisher Service Manual 4024 110 5 Open 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 Repair information 4 5 4024 110 8 Remove the two screws securing the finisher docking bracket D to the printer 9 Remove the finisher docking bracket D Replacement note When docking the finisher to the printer make sure the boss on the finisher docking bracket D is
65. exit in per J the printer is turned on Check area A Go to 280 00 Sensor bridge unit media entrance on Jam on page 2 11 280 01 Sensor bridge unit Paper remains on the sensor bridge unit media Paper jam media entrance Static entrance Check area A jam A Go to 280 01 Sensor bridge unit media entrance static jam A on page 2 12 280 02 Paper Jam Check area F Sensor bridge unit media entrance Static jam B Paper remains on the sensor bridge unit media entrance Go to 280 02 Sensor bridge unit media entrance static jam B on page 2 13 281 00 Paper jam Check area A Sensor bridge unit media exit on jam A 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 fuser exit in the printer is turned on Go to 281 00 Sensor bridge unit media exit On Jam A on 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 jam C Sensor bridge unit media exit is not turned on within the specified
66. fo o 9 Staple 8 E 4 5 Staple Move A gt 2 O PE 3 2 4 D 5 1 VL 24VDC E 3 Unit A A a E g I 4 Staple Move A 440 ski fl E e E i i Staple Move B ZS Ed x a A I 2 5 5 2 u lt lt a a g a El FA E i 1 Staple Move B Stapler Carriage MOT A sl 1 GH 5 S SI lslslsSiSlolo 2E a z S a o g I IL 24VDC gt d SE gi 383383808 Ag gt a 59 3 D A Stapler Carriage MOT A 3 5i38101886388383838383 3 EE EE O CH Stapler Carriage MOTB 4 SE SE 895 Sais He Swuw sass CO P8308 VL 24VDC F5 vA va y 1 A Stapler Carriage MOT B 6 I I Q I oN a 1 Stapler E eloo 3 olol SJ N 2 st No Carriage aj L d I I M z h otor ASM S Bridge Unit gdekelssldaaelsiekiele dd ss D EI NH El Le LL 5 0 1 LL LU ESC git als FO oo BIH I 615 ole A A ps lei eil 5 Ei elals _l I 2 ol ol SE Interface Card ASM Ee SEER SP SS aigle del E GIL SS Eng KIR 1 i IG SO S O st IEF EZIN 5 L 58828908 I CB ol o 5 91818 5 3 S J8371 daune GONE BE Si 9292 Ji 5 66 gsz2 22 SIE N O SS 8 8 95 o i i go S S S I i I OO JO IN jo Lo XU gis eee aes easier d 3 I I i i i PJ416 SE dogage EF ae ce EE l l de BEER See tee To Printer Engine 8833383 i Card AS Sei suse I ee b E DB Saa S a d i i vv LB AE o po La a a co to o Cle CIS c ss I i I x gcSlgteag2sisz Zeie amp 3 5 5 2 5 5lala d EE so po o S Punch Carriage EE S L
67. home position Go to 983 00 Sensor rear tamper HP on failure on page 2 70 983 01 Service finisher error Sensor rear tamper HP off failure The sensor rear tamper HP is not turned off within the specified time after the rear tamper starts leaving from the rear tamper home position Or the sensor rear tamper HP is turned on again after the sensor rear tamper HP is turned off and the rear tamper stopped its moving Go to 983 01 Sensor rear tamper HP off failure on page 2 71 984 00 Service finisher error Sensor punch unit HP on failure The sensor punch unit HP is not turned on even when the specified time passed after the punch unit motor is turned on Go to 984 00 Sensor punch unit HP on failure on page 2 72 Diagnostic information 2 7 4024 110 984 01 Service finisher error Sensor punch unit HP off failure The sensor punch unit HP is not turned off even when the specified time passed after the punch unit motor is turned on Go to 984 01 Sensor punch unit HP off failure on page 2 74 985 00 Service finisher error Sensor punch carriage shift HP on failure The sensor punch carriage shift HP is not turned on even when the specified time passed after the punch carriage shift motor assembly is turned on Or the sensor punch carriage shift HP is turned off again after the sensor punch carriage shift HP is turned on and
68. la impressora han sigut concebuts de manera que mai hi hagi exposici a la radiaci laser per sobre d un nivell de classe durant una operaci normal durant les tasques de manteniment d usuari ni durant els serveis que satisfacin les condicions prescrites Notices and safety information Xi 4024 110 LF CBS a eM Se COoTJrs t RETRDHHS 21 CFRUZfFeZ3 J DOP IRXI 1 OR MK LEV V HMCHSS CE MAEWS ACTUA Fo KKKBUATAIEC 82508 BtmK LEFF ALOV YV WMECHSCEMEWSNTTOET FIFALOV VP WRE MERE UR OE SR GHTWETF Co TYYBI 5 2O0b 3b OL F EL ARU TU EF Co LH RR T TO T9I5t JA FY OMRAC BH 5307y bhOAVDAULWMERHITSLU P CF COL YAFLESP VY H BORE 2A VPOAYFIHYVAL D ES TBBMC BO TH ARR IFATOVANVE LOL P ik HIM NZCLOBWEABHAaANTHEF A H EN HL 32 EI UGE 473 DHHS 21 CFR Subchapter I XJA 1 1 BFK d HJ ii HE ME Hi eK RUE A FP IEC 825 A tr HE DEL RMIT A RUA ERE X FT EL OLA H amp AI Ib 3b WIE RR Eet EEGEN SS HK WE 4 770 795 nm Z RH RR RITE ARI CPI Ir EAEE A HE AU EE ME P AR SS ARE ih DET DE EY BEES 152 adlolgd d s CHSt DHHS 21 CFR Subchapter 32 PHS Escola Uee Dol ClB QFom 2 9 ejl E IEC 825 TAS Etste 158g 4H SORA ISS HS ICL 158 AOA ASSES HNE dos dE Ec BIAS 5 PASE HE ole lolc OIX EA 770 795 LOES IHHL Siss Class III 3b aous cyto Za Veit S WolA Mata zgage BA 45 SOL HA goe BLE PAE MHA SERA Sol Class SEY dora HZ Ao SO 422 MSs AAS oeh Xii Finisher Service Manual 4024 110 Safety in
69. media bin full connected properly Replace the sensor upper media bin full Go to Sensor upper media bin full removal on page 4 108 Replace the connection Perform a test print Does the error still occur Replace the finisher controller card assembly Go to Finisher controller card Problem solved assembly removal on page 4 118 No punch waste box Step Check Yes No 1 Check the sensor punch waste box present for Go to step 2 Reinstall the correct operation sensor punch waste box set Is the sensor installed properly Go to Sensor punch waste box set removal on page 4 52 2 Check the sensor punch waste box set Go to step 4 Go to step 3 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 operator panel change every time the sensing area of the sensor punch waste box set is blocked 3 Is the sensor punch waste box set properly Replace the Replace the connected sensor punch connection waste box set Go to Sensor punch waste box set removal on page 4 52 2 92 Finisher Service Manual 4024 110 Step Check Yes No 4 Perform a test print Replace the Problem solved brid
70. media path upper pinch guide assembly and two upper media transport roll assemblies by turning them with your fingers Are the upper pinch guide pinch roll and upper media transport roll assemblies installed correctly and do they rotate smoothly 2 Are the four upper pinch guide pinch rolls on the upper Go to step 3 Clean or replace pinch guide assembly and two upper media transport the appropriate roll assemblies free of damage roller and clean the media path 3 Check the sensor upper media exit for correct Replace the Go to step 4 operation finisher controller Perform the sensor upper media exit test CAC 1 Enter Diagnostics mode controller card 2 Select FINISHER TESTS Leger A 3 Select Sensor Tests page 4 118 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 4 Check the sensor upper media exit and main sensor Replace the Replace the cable assembly connections sensor upper connection media exit Go to Is the above sensor connected properly Sensor upper media exit removal on page 4 104 2 46 Finisher Service Manual 4024 110 Step Check Yes No 5 Check the drive motor buffer transport for rotation Go to step 7 Go to step 6 Check the above motor by opening the finisher front door assembly and then closing it Does th
71. of this motor moves the rear tamper to the front side Counterclockwise rotation of this motor moves the tamper to the rear side Rear tamper A Front tamper Sensor rear tamper HP Rear tamper motor Sensor compiler Sensor front tamper HP media in Front tamper motor Stapler This section describes the operation of the stapler Stapling operation Sheets of media fed from the punch are tamped on the compiler unit assembly and then stapled at specified positions by the command of the printer Staple positions There are four stapling modes e Front staple corner Front Corner The stapler staples a set of media obliquely 45 degrees after the rear tamper Rear aligns the media to the front side Process direction Front e Rear staple corner rear corner This type of stapling is applied for media with a width of 216 mm or more 4 Rear The stapler moves to the rear corner and staples a set of media obliquely 45 degrees after the front tamper aligns the media to the rear side Process direction Front Diagnostic aids 3 21 4024 110 e Rear Staple Straight rear Straight This type of stapling is applied for media with a width of less than 216 mm l Rear The Stapler staples a set of media in parallel with the media edge after the front tamper aligns the media to the rear side Process direction Front e Dual Staple Dual The Stapler staples a set of media at
72. on the media eject clutch is placed in the notch of the bracket Repair information 4 77 4024 110 Media eject motor assembly removal Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the media eject clutch See Media eject clutch removal on page 4 77 Disconnect the connector from the media eject motor assembly A Disconnect the connector from the sensor media bin level 2 B Remove the three screws securing the media eject motor assembly A dl al eg Connector 6 Remove the media eject motor assembly A 7 Remove any remaining harnesses from the clamps 4 78 Finisher Service Manual 4024 110 Sensor media eject shaft HP removal Remove the rear upper cover See Rear upper cover removal on page 4 24 Disconnect the connector from the sensor media eject shaft HP A Rotate the media eject clutch actuator B by hand so it clears the sensor media eject shaft HP A Release the hooks securing the sensor media eject shaft HP A to the bracket C Leet eg c Connector 5 Remove the sensor media eject shaft HP A Repair information 4 79 4024 110 Sensor lower media exit removal Open the finisher front door assembly Remove the upper media bin assembly See Upper media bin assembly removal on page 4 20 Disconnect the connector from the sensor lower media exit A Remove the harness from the clamps Re
73. on the operator panel change every time the actuator of the sensor bridge unit media exit is operated 2 Check the sensor bridge unit media exit connection Replace the Replace the Is the above sensor connected properly Sie Gil connection Go to Sensor bridge unit media exit removal on page 4 17 3 Check the bridge unit drive motor by opening the Go to step 5 Go to step 4 finisher front door assembly and then closing it Open the bridge unit top cover assembly Does the bridge unit drive motor rotate normally Diagnostic information 2 19 4024 110 Step Check Yes No 4 Check the bridge unit drive motor connection Replace the Replace the Are the connectors of the bridge unit cable assembly bridge ane connection connected to the bridge unit drive motor and bridge Bridge unit unit interface card assembly of the finisher correctly drive motor connected assembly removal on page 4 13 5 Perform a test print Replace the Problem solved i bridge unit Does the error still occur2 interface card assembly Go to Bridge unit interface card assembly removal on page 4 117 6 Perform a test print Replace the Problem solved finisher controller Does the error still occur card assembly Go to Finisher controller card assembly removal on page 4 118 282 00 Sensor finisher media entrance on jam Step Check Yes No 1 Check the media path Go to step 2 Cl
74. pulley 17T G inside the finisher Remove the main paddle shaft drive pulley 17T G Note The belt H will become attached Tighten first Remove the 6 mm bushing I Release the hook of the main paddle drive pulley gear 44 20T F from the shaft J Remove the main paddle drive pulley gear 44 20T F Remove the 6 mm bushing K Remove the main paddle idler gear 23T right L Remove the two front and the two rear screws securing the main paddle shaft assembly M Move the main paddle shaft assembly M forward and then downward and outward Repair information 4 87 4024 110 25 Remove the main paddle shaft assembly 4 88 Finisher Service Manual 4024 110 Replacement notes e The tension 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 e Tighten the two screws in the order shown y Tighten first Right J RS Tighten second Tighten third Front view Repair information 4 89 4024 110 Lower pinch guide assembly removal 1 Open 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 p
75. removal on page 4 104 7 Check the drive motor buffer transport by opening the Go to step 9 Go to step 8 finisher front door assembly and then closing it Does the drive motor buffer transport rotate properly 8 Check the drive motor buffer transport connection Replace the drive Replace the Is the above motor properly connected de to connection Drive motor buffer transport and belt buffer transport removal on page 4 115 9 Perform a test print Replace the Problem solved Does the error still occur ie aa Go to Finisher controller card assembly removal on page 4 118 2 48 Finisher Service Manual 287 03 Sensor upper media exit on jam C 4024 110 Step Check Yes No 1 Check the media path Go to step 2 Clean or replace 1 es the finisher front door assembly of the ee SEA the media path 2 Remove the top cover and left upper cover 3 Open the entrance pinch guide assembly upward 4 Check four media entrance pinch guide pinch rolls of the entrance pinch guide assembly and media entrance roll assembly by turning them with your fingers Are the media entrance pinch guide pinch rolls installed correctly and do they rotate smoothly 2 Are the four media entrance pinch guide pinch rolls of Go to step 3 Clean or replace the entrance pinch guide assembly and media the appropriate entrance roll assembly free of damage roller and clean the media path 3
76. removal on page 4 117 Go to step 8 Problem solved 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 Diagnostic information 2 17 4024 110 281 02 Sensor bridge unit media exit On Jam C Step Check Yes No 1 Check the media path Go to step 2 Clean or replace 1 Open the bridge unit top cover assembly of the GE bridge unit assembly unit pinch rolls 2 Check the transport belts and the six bridge unit and clean the pinch rolls attached on the bridge unit top cover media path assembly by turning them with your fingers Are the transport belts and the bridge unit pinch rolls installed correctly 2 Are two transport belts and the six bridge unit pinch roll Go to step 3 Clean or replace free of damage the transport belts and bridge unit pinch roll and clean the media path 3 Check the sensor bridge unit media exit for correct Go to step 5 Go to step 4 operation Perform the 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 4 Check the sensor bri
77. required The power switch and inlet of the low voltage power supply card LVPS card assembly is live even while the power supply is cut off Never touch the live parts Warning When operating the driving units using the diagnostics or other tools be sure to keep them covered unless otherwise specified 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 their body while working See Handling ESD sensitive parts on page 4 1 Using service checks It is assumed in the finisher service checks that the printer controller RIP card assembly is normally functioning If any trouble cannot be corrected by troubleshooting refer to the Printer Service Manual To determine the corrective action necessary to repair a finisher look for the following information e Verify Confirm the installation status on page 2 2 e Go to the Error code messages on page 2 3 e Additional information can be found at Service checks on page 2 11 Theory on page 3 4 Note There may be printer error messages that are not contained in this service manual Call your next level support for
78. 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 2 Are the media entrance roll assembly and the media Go to step 3 Clean or replace entrance pinch guide pinch rolls free of damage and the appropriate rotate smoothly rolls and clean the paper path Diagnostic information 2 25 4024 110 Step Check Yes No Check the media path 1 Open the finisher front door assembly of the finisher 2 Open the lower pinch guide assembly to the right 3 Check the buffer roll assembly by turning it with your fingers Is the buffer roll assembly installed correctly and is it free of damage and contamination Go to step 4 Clean or replace the appropriate rolls and clean the media path Are the four buffer pinch guide pinch rolls attached on the lower pinch guide assembly installed correctly Go to step 5 Clean or replace the appropriate rolls and clean the media path Check the sensor diverter gate for correct operation Perform the sensor diverter gate test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path2 5 Select Diverter gate Open the finisher front door Move the lower media guide assembly to the right Insert a sheet of white media beneath the media diverter gate Then pu
79. the finisher 10 Release the harness from the clamp a On O we o 000 o 11 Remove the media stacker bin lift motor assembly See Stacker media bin assembly removal on page 4 22 12 Disconnect the white connector and the yellow connector from the sensor stacker bin upper limit and the sensor stacker bin no media 13 Remove the four screws securing the stapler unit frame D to the finisher 14 Move the stapler unit frame upward and outward in the direction of the arrow as shown White connector 0 Q Yellow connector Es Q La Sa kill D Rear 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 e Do not force the stapler unit frame into the finisher e Be sure to hold the stapler unit frame firmly to avoid dropping it e Maker sure no harnesses are pinched when replacing the stapler unit frame e Be sure to replace the grounding wire e Ensure that the white connector and the yellow connector are properly replaced Repair information 4 55 4024 110 Stapler unit assembly removal 1 Remove the finisher front door assembly See Finisher front door assembly re
80. the media path 5 Check the sensor bridge unit media exit for correct Go to step 7 Go to step 6 operation Perform the 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 6 Check the sensor bridge unit media exit connection Replace the Replace the Is the above sensor connected properly oe an connection Go to Sensor bridge unit media exit removal on page 4 17 7 Check the sensor finisher media entrance for correct Go to step 9 Go to step 8 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 finisher media entrance 8 Check the sensor finisher media entrance Replace the Replace the connection sensor finisher connection Is the above sensor connected properly media entrance Go to Sensor finisher media entrance removal on page 4 98 Diagnostic information 2 55 4024 110
81. the punch carriage shift motor assembly stopped its rotation Go to 985 00 Sensor punch carriage shift HP on failure on page 2 75 985 01 Service finisher error Sensor punch carriage shift HP off failure The sensor punch carriage shift HP is not turned off even when the specified time passed after the punch carriage shift motor assembly is turned on Or the sensor punch carriage shift HP is turned on again after the sensor punch carriage shift HP is turned off and the punch carriage shift motor assembly stopped its rotation Go to 985 01 Sensor punch carriage shift HP off failure on page 2 76 986 00 Service finisher error Sensor media eject 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 78 987 00 Service finisher error Sensor media eject shaft HP on failure The sensor media eject shaft HP is not turned on within 200 ms after the set clamp starts operating Go to 987 00 Sensor media eject shaft HP on failure on page 2 79 987 01 Service finisher error Sensor media eject
82. the stacker bin lift motor assembly by blocking Go to step 9 Go to step 8 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 8 Is the stacker bin lift motor assembly connected Replace the Replace the properly stacker bin lift connection motor assembly Go to Stacker bin lift motor assembly removal on page 4 38 9 Perform a test print Replace the Problem solved finisher controller Does the error still occur2 card assembly Go to Finisher controller card assembly removal on page 4 118 2 64 Finisher Service Manual 981 01 Stacker bin upper limit failure 4024 110 Step Check Yes No 1 Check the sensor stacker bin level 1 for correct Go to step 3 Go to step 2 operation Perform the sensor stacker bin level 1 test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Bin Level 5 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 putting a piece of media or your finger over the sensor area 2 Check the sensor stacker bin level 1 connection Replace the Replace the Are the connections of the main sensor cable assembly Bin Every Gots connection properly connected Sensor stacker bin level 1 removal on page 4 34 3
83. the stapler carriage by hand 3 Is the sensor stapler carriage HP connected Replace the Replace the properly sensor stapler connection carriage HP Go to Sensor stapler carriage HP removal on page 4 58 Diagnostic information 2 85 4024 110 Step Check Yes No 4 Check the stapler carriage motor assembly by opening Go to step 6 Go to step 5 the finisher front door assembly then pushing the stapler carriage towards the back Then closing the finisher front door assembly the stapler carriage should move Does the stapler carriage motor assembly rotate normally 5 Is the stapler carriage motor assembly connected Replace the Replace the properly stapler carriage connection motor assembly 6 Perform a test print stapled document Replace the Problem solved 8 printer engine Does the error still occur card assembly Refer to the Printer Service Manual 990 01 Sensor stapler carriage HP off failure Step Check Yes No 1 Check the stapler by moving it with your fingers Go to step 2 Remove Does the Stapler carriage move smoothly obstructions 2 Check the sensor stapler carriage HP for correct Go to step 4 Go to step 3 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 chan
84. three main paddles are rotated by the main paddle shaft assembly to feed the media so that the media trailing edge butts against the rear wall of the compiler unit assembly The sub paddle solenoid of the media eject unit assembly is activated to lower the sub paddle so that the media can be fed to the compiler unit assembly Media eject clamp motor _ Ca Drive motor exit iy Ma Q z LB S Drive motor G buffer transport Media eject motor assembly Sensor lower media exit Eject clamp Media eject shaft assembly Buffer diverter solenoid Lower media exit roll assembly Compiler unit assembly Drive motor entrance paddle Buffer diverter gate Buffer roll assembly 3 8 Finisher Service Manual 4024 110 va Sensor lower media exit Sub paddie driven by drive motor entrance paddle Eject clamp driven Buffer roll assembly by else clamp motoi driven by drive motor buffer transport LS Media eject shaft assembly driven by media eject motor asm Buffer diverter Compiler unit assembly Main paddle motor driven by motor entrance paddle Lower media exit roll assembly driven by motor exit When printing multiple sets while stapling the first set on the compiler unit assembly or ejecting it to the stacker media bin the first media of the second set will not be fed to the compiler unit assembly When the first media of the second set reach
85. three screws in the front securing the punch waste chute B Gently pull down the punch waste chute B to gain better access to the switch finisher front door interlock C Disconnect the connector from the switch finisher front door interlock C oo PaaS Connector 7 Release the hooks securing the switch finisher front door interlock C to the finisher 8 Remove the switch finisher front door interlock C 4 26 Finisher Service Manual 4024 110 Finisher front door assembly removal 1 Open the finisher front door assembly A 2 Remove 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 Actuator Repair information 4 27 4024 110 Left lower cover removal 1 Open the finisher front door assembly 2 Remove the two screws securing the left lower cover A i S J e N m d AL b HE A 3 Remov
86. time after the sensor bridge unit media entrance is turned on Go to 281 02 Sensor bridge unit media exit On Jam C on page 2 18 281 03 Paper jam Check area F Sensor bridge unit media exit Static jam A Paper remains on the sensor bridge unit media exit Go to 281 03 Sensor bridge unit media exit static jam A on page 2 19 282 00 Paper jam Check area F Sensor finisher media entrance on jam Sensor finisher media entrance is not turned on with the specified time after the sensor bridge unit media exit is turned on Go to 282 00 Sensor finisher media entrance on jam on page 2 20 282 01 Paper jam Check area F Sensor finisher media entrance Static jam A Paper remains on the sensor finisher media entrance At this time the sensor bridge unit media exit is turned on Go to 282 01 Sensor finisher media entrance static jam A on page 2 22 Diagnostic information 2 3 4024 110 283 00 Paper jam Check areas G G4 Sensor buffer path on jam A Sensor buffer path is not turned on within the specified time after the sensor finisher media entrance is turned on Go to 283 00 Sensor buffer path on jam A on page 2 23 283 01 Sensor buffer path on Sensor buffer path is not turned on within the jam B specified time after the sensor finisher media entrance Paper jam is turned on Check area G2 At this time
87. une tension dangereuse dans la partie du produit sur laquelle vous travaillez D branchez le produit avant de commencer ou faites preuve de vigilance si l ex cution de la tache exige que le produit reste sous tension Norme di sicurezza e La sicurezza del prodotto si basa sui test e sull approvazione del progetto originale e dei componenti specifici Il produttore non responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti e Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato e Durante lo smontaggio e la manutenzione di questo prodotto il rischio di subire scosse elettriche e danni alla persona pi elevato Il personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie e ATTENZIONE Questo simbolo indica la presenza di tensione pericolosa nell area del prodotto Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per eseguire l intervento Safety information Xiii 4024 110 Sicherheitshinweise Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des urspr nglichen Modells und bestimmter Bauteile Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung f r die Sicherheit bernommen Die Wartungsinformationen f r dieses Produkt sind ausschlie lich f r die Verwendung durch einen Wartungsfachmann bestimm
88. upper cover Go to Rear upper cover removal on page 4 24 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Punch and Staple 5 Select Punch unit HP Move the rack gear in the punch unit assembly manually by hand Does the display on the operator panel change every time the sensing area of the sensor punch unit HP is blocked 3 Is the sensor punch unit HP and punch sensor cable Replace the Replace the assembly connected properly sensor punch connection unit HP Go to Sensor punch hole select sensor punch cam front and sensor punch unit HP removal on page 4 49 4 Check the punch unit motor for correct operation Go to step 6 Go to step 5 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 rotate normally and punch holes in the media 5 Is the punch unit motor and punch drive cable Replace the Replace the assembly connected properly punch unit motor connection Go to Punch unit motor assembly removal on page 4 47 2 74 Finisher Service Manual 4024 110 Step Check Yes No Perform a test print Does the error still occur Replace the finisher controller card assembly Go to Finisher controller card Problem solved
89. vertical transport Replace Go to step 3 mechanism of the stacker bin deformed part 3 Check the sensor stacker bin level 1 for correct Go to step 5 Go to step 4 operation Perform the sensor stacker bin level 1 test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Bin Level 5 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 Diagnostic information 2 63 4024 110 Step Check Yes No 4 Is the sensor stacker bin level 1 connected properly Replace the Replace the sensor stacker connection bin level 1 Go to Sensor stacker bin level 1 removal on page 4 34 5 Check the sensor stacker bin level 2 for correct Go to step 7 Go to step 6 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 putting a piece of media or your finger 6 Is the sensor stacker bin level 2 connected properly Replace the Replace the sensor stacker connection bin level 2 Go to Sensor stacker bin level 2 removal on page 4 34 7 Check
90. 0X0888 40X0889 40X0890 40X0891 40X0892 40X0892 40X0893 40X0893 40X0893 40X0894 40X0895 40X0896 40X0897 40X0898 40X0899 40X0900 40X0901 40X0902 40X0903 40X0904 40X0905 40X0906 40X0907 40X0908 40X0908 40X0909 40X0910 40X0910 40X0910 Punch unit cable assembly 22222 ee ee ee ee emma ee rrr me ee ee ee ee ee rere 7 13 Punch carriage shift motor assembly 7 13 Punch carriage assembly ee ee ee ee ee ee ee cecs 7 13 Sensor punch unit side reg assembly re err eee eee 7 13 2 3 punch unit assembly this comes assembled 7 13 2 4 punch unit assembly this comes assembled 7 13 Punch media stopper assembly 22 ee ee reer eee ee 7 13 Punch unit motor assembly eee errr eee ere eee 7 13 Sensor punch waste box set eee ee ere ee ee eee cecs 7 13 Punch waste box ee ee ee re ee er eee eee eee eee 7 13 Sensor punch waste box full ee ee ee rere eee 7 13 Punch waste box set cable assembly 7 13 7 30 Staple cartridge ee ee ee ee ee eee eee ee eee 7 15 Stapler unit assembly ee ere ee eee eee eee eee 7 15 Stapler unit cover
91. 0X0918 4 1 Upper media exit pinch roll assembly 2 40X0893 1 1 Sensor upper media exit 3 40X0919 1 1 Upper media exit roll assembly 4 40X0908 1 1 Sensor upper media bin full 5 40X0824 8 1 Magnetic catch 6 40X0888 15 1 Bushing 6 mm 7 40X0920 1 1 Upper pinch guide assembly this comes assembled 8 40X0921 1 1 Sensor diverter gate 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 e Belt idler pulley e Spring e 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 Belt buffer transport 19 8 cm 17 40X0929 1 1 Belt exit 27 7 cm 18 40X0926 1 1 Upper media exit roll drive pulley gear 20T 20T 19 40X0927 1 1 Upper media exit roll drive gear 20T 20 40X0910 1 1 Drive motor buffer transport 21 40X0910 1 1 Drive motor exit Parts catalog 7 25 4024 110 Assembly 14 Electronics 7 26 Finisher Service Manual Assembly 14 Electronics 4024 110 Asm Part Units Units Description Index number option FRU 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 4
92. 0X0935 1 1 AC power cord assembly 6 40X0936 1 1 Finisher LVPS card assembly Parts catalog 7 27 4024 110 Assembly 15 Cables 1 Ss 7 28 Finisher Service Manual Assembly 15 Cables 1 4024 110 Asm Part Units Units Description Index number option FRU P 15 1 40X0942 1 1 Upper media exit sensor cable assembly 2 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 e Sensor lower media exit e Lower media exit sensor cable assembly e Bracket 7 40X0943 1 1 Upper media bin full sensor cable assembly Parts catalog 7 29 4024 110 Assembly 16 Cables 2 Asm Part Units Units Index number option FRU Description 16 1 40X0922 Diverter gate sensor upper cable assembly 1 1 2 40X0944 1 1 Punch main drive cable assembly 3 40X0950 1 1 Diverter gate sensor lovver 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 7 30 Finisher Service Manual Assembly 17 Cables 3 4024 110 Asm Part Units Units Description Index number option FRU 17 1 40X0938 1 1 Main drive cable assembly 2 40X0930 1 1 Punch waste box
93. 10 Sensor stacker bin upper limit or sensor stacker bin no media removal Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the stacker media bin assembly See Stacker media bin assembly removal on page 4 22 Remove the stacker bin lift motor assembly See Stacker bin lift motor assembly removal on page 4 38 Remove the four screws securing the metal cover A to the finisher Remove the metal cover A ap Ono Te e mi wae mi i H Geld Lo GO ui ae gs Qo i oe Y Que X Right 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 8 Remove the sensor 4 36 Finisher Service Manual 4024 110 Replacement note Make sure that the yellow connector is plugged into the sensor stacker bin no media C White connector JE Yellow connector y Repair information 4 37 4024 110 Stacker bin lift motor assembly removal Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the rear lower cover See Rear lower cover removal on page 4 23 Loosen the four screws securing the plate A Move the plate A toward the right as shown Lo Es par Hl P VAS 5 Remove the plate A 4
94. 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 sensors with different functions therefore they are the same part number with different descriptions Parts catalog 7 19 4024 110 Assembly 11 Lower exit drive OOT e 2 lf GE of 6 yt 7 20 Finisher Service Manual Assembly 11 Lower drive 4024 110 Asm Part Units Units Description Index number option FRU 11 1 40X0892 1 1 Sensor lower media exit with bracket 2 40X0893 1 1 Sensor lower media exit 3 40X0894 1 1 Static eliminator brush 4 40X0895 1 1 Lovver media exit roll assembly 5 40X0896 1 2 Main paddle shaft kit includes this comes assembled e Main paddle shaft assembly e 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 hit includes e Main paddle idler gear 23TR e Main paddle idler gear 23TL 9 40X0898 1 2 Lower exit roll drive pulley kit includes e Lower exit roll drive pulley 20T e Idler pulley 20T 10 40X0913 4 1 Ball bearing 6 mm 11 40X0897 3 1 Belt idler pulley Parts catalog 7 21 4024 110 Assembly 12 Buffer and entrance drive 7 22 Finisher Service Manual 4024 110 Assembly 12 Buffer and entrance drive Asm Part Units Units Description Index number option FRU 12
95. 110 Step Check Yes No 1 Check the media path Go to step 2 Clean or replace 1 es the finisher front door assembly of the ee SEA the media path 2 Remove the top cover and left upper cover 3 Open the entrance pinch guide assembly upward 4 Check four media entrance pinch guide pinch rolls of the entrance pinch guide assembly and media entrance roll assembly by turning them with your fingers Are the media entrance pinch guide pinch rolls installed correctly and do they rotate smoothly 2 Are the four media entrance pinch guide pinch rolls of Go to step 3 Clean or replace the entrance pinch guide assembly and media the appropriate entrance roll assembly free of damage roller and clean the media path 3 Check the media path Go to step 4 Clean or replace 1 Open the upper pinch guide assembly to the right ea te 2 Check these items by turning them with your the media path fingers Are the four upper pinch guide pinch rolls of the upper pinch guide assembly and two upper media transport roll assemblies installed correctly meaning do they rotate smoothly 4 Are the four upper pinch guide pinch rolls of the upper Go to step 5 Clean or replace pinch guide assembly and two upper media transport the appropriate roll assemblies free of damage roller and clean the media path 5 Check the sensor upper media exit for correct Go to step 7 Go to step 6 operation Perform the sensor upper media e
96. 110 Bridge unit idler rolls removal Open the bridge unit top cover assembly Remove the bridge unit left shaft assembly See Bridge unit left shaft assembly removal on page 4 10 Move the two transport belts A away from the two bridge unit idler rolls B Lift the two bridge unit idler rolls upward to release them from the bridge unit assembly C Remove the bushings D from the bridge unit idler rolls Cee a DE Replacement note When replacing the bridge unit idler rolls make sure the bushings are installed as shown A Repair information 4 11 4024 110 Bridge unit transport belt removals Remove the bridge unit idler rolls See Bridge unit idler rolls removal on page 4 11 Remove the transport belts A from the bridge unit assembly B 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 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 6 4 12 Finisher Service Manual 4024 110 Bridge unit drive motor assembly removal 1 Remove the bridge unit rear cover See Bridge unit rear cover removal on page 4 6 2 Remove the bridge unit drive belt See Bridge unit drive belt and bridge unit drive pulley removal on page 4 8 3
97. 24 110 right eject cover 4 21 right lower LVPS cover 4 22 top cover 4 19 upper media bin front cover 4 25 D diagnostics exit 3 3 diagnostics mode accessing 3 1 available tests 3 1 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 sensor bridge unit media exit on jam A 2 14 281 01 sensor bridge unit media exit on jam B 2 16 281 02 sensor bridge unit media exit on jam C 2 18 281 03 sensor bridge unit media exit static jam 2 19 282 00 sensor finisher media entrance on jam 2 20 282 01 sensor finisher media entrance static jam 2 22 283 00 sensor finisher buffer path on jam A 2 23 283 01 sensor finisher 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 on jam A 2 32 on jam B 2 35 284 01 sensor lower media exit 284 02 sensor lower media exit 284 03 sensor lower media exit on jam C 2 38 284 04 sensor lower media exit off jam B 2 40 284 05 sensor lower media exit static jam 2 41 28
98. 5 00 finisher eject set jam 2 42 286 00 sensor compiler media present static jam 2 43 287 00 sensor upper media exit on jam A 2 45 287 01 sensor upper media exit off jam A 2 46 287 02 sensor upper media exit on jam B 2 47 287 03 sensor upper media exit on jam C 2 49 287 04 sensor upper media exit off jam B 2 50 orl aS ae Se ee Index l 1 4024 110 287 05 sensor upper media exit static jam A 2 51 287 06 sensor upper media exit static jam B 2 52 287 07sensor upper media exit static jam C 2 53 288 00 sensor diverter gate on jam 2 54 288 01 sensor diverter gate static jam to top bin A 2 57 288 02 sensor diverter gate static jam to top bin B 2 58 288 03 sensor diverter gate static jam to top bin C 2 59 288 04 sensor diverter gate static jam to stacker bin A 2 60 288 05 sensor diverter gate static jam to stacker bin B 2 61 288 06 sensor diverter gate static jam to stacker bin C 2 62 980 02 finisher communication failure 2 63 981 00 stacker bin fail 2 63 981 01 stacker bin upper limit failure 2 65 981 02 stacker bin lower limit failure 2 66 982 00 sensor front tamper HP on failure 2 68 982 01 sensor front tamper HP off failure 2 69 983 00 sensor rear tamper HP on failure 2 70 983 01 sensor rear tamper HP off failure 2 71 984 00 sensor punch unit HP on failure 2 72 984 01 sensor punch unit HP off failure 2 74 985 00 sensor punch carriage shift HP on failure 2
99. 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 LA Finisher Service Manual punch waste box set 5 3 rear tamper HP 4 72 stacker bin level 1 4 34 5 2 stacker bin level 2 4 34 5 2 stacker bin level encoder 4 35 stacker bin no media 4 36 stacker bin upper limit 4 36 5 2 stapler carriage HP 4 58 5 2 upper media bin full 4 108 upper media exit 4 104 service checks 2 11 service checks using 2 1 stacker unit locations 5 2 media bin assembly 4 22 stacker bin lift motor assembly 4 38 staple unit locations 5 2 parts catalog 7 14 stapler carriage motor assembly 5 2 stapler unit assembly 4 56 stapler unit frame 4 54 sub paddle removals 4 63 sub paddle drive shaft assembly 4 64 switches eject cover interlock 4 68 5 4 finisher front door interlock 4 26 5 2 T tests Bridge media ent 3 3 Bridge media exit 3 3 Buffer path 3 3 Compiler media in 3 3 Cover F bridge top 3 3 Diverter gate 3 3 Door G fin front 3 3 Eject clamp hp 3 3 Feed Tests 3 2 Fin media enter 3 3 Fin upper bin full 3 3 Front tamper hp 3 3 Fuser exit 3 3 Hole Punch Test 3 2 Low staple 3 3 Lower media exit 3 3 Media eject shaft hp 3 3 Punch box set 3 3 Punch cam front 3 3 Punch carriage shift hp 3 3 Punch hole select 3 3 Punch side reg1 3 3 Punch side reg2 3 3 Punch unit hp 3 3 Punch was
100. 56 Sensor stapler carriage HP removal 0 00 eee eee eee 4 58 Media eject unit assembly removal 2 c cece eee eens 4 59 SUD DEES TEMOVEl e Zeg e ee Ee EE Retina bh SS wos eee 4 63 Sub paddle drive shaft assembly removal 0 000 ee eee eee eee 4 64 Media eject clamp motor assembly removal 4 66 Sensor media eject clamp HP removal 0 0 e eee e eee eee 4 67 Switch eject cover interlock removal 205 0 00 cece eee eee 4 68 Media compiler unit assembly removal eee 4 69 Sensor front tamper HP and sensor rear tamper HP removals 4 72 Sensor compiler media in removal 000 cee eee ee eee eee 4 73 Media eject shaft assembly removal 2 0 00 cece cee eee eee eee eee eee eens 4 74 Clamp paddle removal qelciuriiimeiesmssostssmsgessmeciosamms ts mesi estes eo oa beeen 4 76 Media Sek CIUICH Femme Aa EELER vessa ms ena niesi ma Rew EE RE ME EES a EE Ed 4 77 Media eject motor assembly removal 0 ccc cece eee eee eee eee eee eee 4 78 Sensor media eject shaft HP removal 4 79 Sensor lower media exit removal 00 cece eee ee eee eee eee 4 80 Lower media exit roll assembly removal 0 0 00 e eee eee eee eee eee 4 82 Paddle and roll exit assembly removal ssrin EE ARTE eee EE ee end eas 4 86 Lower pinch guide assembly removal 00 0c cece eee eee eee eee eee eee 4 90 Media diverter gate removal en isan ENEE dade saa dans aa Oe EELER EELER REENEN 4
101. 72 4 Check the rear tamper drive motor by opening the Go to step 6 Go to step 5 finisher front door assembly and then closing it Does the rear tamper drive motor rotate and does the tamper move back and forth 5 Check the compiler unit cable assembly connection Replace the Replace the Are the connections of the compiler unit cable Geh E connection assembly correctly connected y 6 Perform a test print Replace the Problem solved Does the error still occur pe eee rad Go to Finisher controller card assembly removal on page 4 118 983 01 Sensor rear tamper HP off failure Step Check Yes No 1 Check the tamper mechanism by moving it with your Go to step 2 Replace the fingers Does the tamper mechanism operate smoothly media compiler unit assembly Go to Media compiler unit assembly removal on page 4 69 Diagnostic information 2 71 4024 110 Step Check Yes No 2 Check the sensor rear tamper HP for correct Go to step 4 Go to step 3 operation Perform the sensor rear tamper HP test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media path2 5 Select Rear tamper HP Does the display on the operator panel change every time the sensing area of the sensor rear tamper HP is blocked 3 Is the sensor rear tamper HP connected properly Replace the Replace the sensor rear connection tamper HP
102. AVAilADIETINISNENIENS maia ra RT eee PERI HORA OORT RHA ME DES WORT RGE OO Rade Rw 3 1 FINISHER TESTS caca RE EEN maia EERSTEN aed acai Seal i alae RE SERIES E ENEE Mes 3 2 Sepe 1eSt esc gaicogies ooo steed ee G4 eee bsese ers OF cen OS ee es ee eta eee tes enes 3 2 MOMS PUNCH Tel s 52654 44566 AH SARS SU READS Shee Bote EE costes GEnases 3 2 Feed TeS icccecseeesdeenrse EE EE EE EERE WELT EO Oe ER OSeE AEE TES 3 2 SONS NES DEE sien Riese EE EE COREE Rode E EL 3 2 EXIT DIAGNOSTICS eet Beer orina neda seer sGeOs sade Ei eres ama Beie beeen 3 3 TARDOR ses dane DE EE RAE PS RAE ORM SEARO RADARS Ao ee hae ema E aa eas 3 4 Media Tans pon ii cae stedearsanciedunige btewaadewa NN TS 3 4 Bidde unit assembly Paper pali csi25 5 58656 os dete ree ates KORE PORE EE Chee Sched ee 3 4 eg Cl WEE 3 4 ele Ee EE 3 5 FInBher Neda Pan sensos a ara ce a sare EE RSE PDR ERO EE EN 3 5 eil MOONS 3 5 5 44064 q0265499599055699545 00405084 G54 90 IF Ewe SE SESE EEE 3 6 EE ERUN 2625544 E Soe Rha c ee Sui ed toes obs ghee Ee Saas 3 6 From bridge unit assembly fo PUNCH REENEN SEELEN erect REEL EELER EEE 3 7 Finisher Service Manual 4024 110 From punch to compiler unit assembly cccccicscahwscagendepataobeagasasaonagegud ad 3 8 From compiler unit assembly to stacker media bn 3 10 From puncto upper Media DIN ctccdine I I 3 10 Functions of sensors along the media path 00 cece eee eee eee 3 10 Bridge unltaSsembly ssa2se0ses4 oitengss05G45005 See g eb ques EE EE
103. Check the media path Go to step 4 Clean or replace 1 Open the upper pinch guide assembly to the right ea te 2 Check these items by turning them with your the media path fingers Are the four upper pinch guide pinch rolls of the upper pinch guide assembly and two upper media transport roll assemblies installed correctly meaning do they rotate smoothly 4 Are the four upper pinch guide pinch rolls of the upper Go to step 5 Clean or replace pinch guide assembly and two upper media transport the appropriate roll assemblies free of damage roller and clean the media path 5 Check the sensor upper media exit for correct Go to step 7 Go to step 6 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 6 Check the sensor upper media exit and main sensor Replace the Replace the cable assembly connections sensor upper connection Is the above sensor connected properly media exit propery Sensor upper media exit removal on page 4 104 7 Check the drive motor buffer transport by opening the Go to step 9 Go to step 8 finisher front door assembly and then closing it Does the drive motor buffer transport rotate properly Diagnostic information 2 49 4024 110
104. Check the sensor stacker bin level 2 for correct Go to step 5 Go to step 4 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 document or your finger 4 Check the sensor stacker bin level 2 connection Replace the Replace the Are the connections of the main sensor cable assembly eee cote connection correctly connected Sensor stacker bin level 2 removal on page 4 34 5 Check the media stacker bin actuator for correct Go to step 6 Repair the media operation stacker bin Is the media stacker bin actuator installed correctly acuan Does it enter the sensing area of the sensor stacker bin upper limit Diagnostic information 2 65 4024 110 Step Check Yes No 6 Check the sensor stacker bin upper limit for correct Go to step 8 Go to step 7 operation Perform the sensor stacker bin upper limit test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Bin Level 5 Select Stacker bin upper limit Does the display on the operator panel change every time the sensing area of the sensor stacker bin upper limit is blocked 7 Check the sensor stacker bin uppe
105. 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 Device PWM Pulse Width Modulation RFID Radio Frequency Identification RIP Raster Imaging Processor ROM Read only Memory RPM Parallel Synchronous Communications SDRAM Synchronous Dual Random Access Memory SEF Short Edge Fed SIMM Single Inline Memory Module SOS Start of scan SRAM Static Random Access Memory TTM Tandem Tray Module UPR Used Parts Return V Volts Vac Volts alternating current V de Volts direct current General information 1 5 4024 110 1 6 Finisher Service Manual 4024 110 2 Diagnostic information Start CAUTION Unplug power cord from the printer or electrical outlet before you connect or disconnect any Disconnect any connections between the printer and PCs peripherals The printer and the finisher are cable or electronic board or assembly for personal safety and to prevent damage to the printer heavy and require at least two people to lift it safely Make sure your fingers are not under the printer when you lift or set the printer down CAUTION If the printer is kept on never touch the conductive parts while it is not specifically
106. EE MD Reta dal 4 29 Catnage lift DAVIS removal cain 55208 ceed tndedinweainkednnwed a 4 30 Carriage lift belt rig t removal sic ccte cies ieee Sad duke sea ed wed eee ee mie Dea 4 32 Sensor stacker bin level 1 removal 22 222 221e enaeeeee 4 34 Sensor stacker bin level 2 removal 000 cee eee eee eee eee 4 34 Sensor stacker bin level encoder removal 0c cece eee eee ee eee eee 4 35 Sensor stacker bin upper limit or sensor stacker bin no media removal 4 36 Stacker bin lift motor assembly removal 4 38 Puneh carnage assembly EE 4 41 Punch carriage shift motor assembly removal 4 43 Sensor punch unit side registration pair with bracket removal 4 44 PURER nit ASSEMDIY TEMOVAl RER 4 45 Punch media stop assembly removal 0 00 cece eee eee eee eee eee eee ei 4 46 Punch unit motor assembly removal 4 47 Sensor punch unit motor encoder removal 2002 0 0c ee eee eee ee eee 4 48 Sensor punch hole select sensor punch cam front and sensor punch unit HP removal 4 49 Sensor punch carriage shift HP removal 00 cece eee eee eee eee eee 4 51 Sensor punch waste box set removal 4 52 Sensor punch waste box full removal 4 53 Stapler unit frame rOemoval e AEN eee eee ee eee ee eee eee dees 4 54 Stapler unit assembly removal aiicccacanecsians cae REENEN ede eee na En KEIER KEIER e 4
107. Edition October 6 2009 Lexmark W850n and W850dn Finisher Service Manual FETT e Table of contents e Start diagnostics e Safety and notices e Trademarks e Index 4024 110 Edition October 6 2009 The following paragraph does not apply to any country where such provisions are inconsistent with local law LEXMARK INTERNATIONAL INC PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND EITHER EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow disclaimer of express or implied warranties in certain transactions therefore this statement may not apply to you This publication could include technical inaccuracies or typographical errors Changes are periodically made to the information herein these changes will be incorporated in later editions Improvements or changes in the products or the programs described may be made at any time Comments may be addressed to Lexmark International Inc Department D22X 002 1 740 West New Circle Road Lexington Kentucky 40550 U S A or e mail at ServicelnfoAndTraining Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any 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
108. Go to Sensor front tamper HP and sensor rear tamper HP removals on page 4 72 4 Check the rear tamper drive motor by opening the Go to step 6 Go to step 5 finisher front door assembly and then closing it Does the rear tamper drive motor rotate and does the tamper move back and forth 5 Check the compiler unit cable assembly connection Replace the Replace the Are the connections of the compiler unit cable eps SE assembly correctly connected to Media y compiler unit assembly removal on page 4 69 6 Perform a test print Replace the Problem solved Does the error still occur LA ie U Go to Finisher controller card assembly removal on page 4 118 984 00 Sensor punch unit HP on failure Step Check Yes No 1 Check the punch unit by moving it with your fingers Go to step 2 Remove obstacles Does the punch unit move smoothly 2 72 Finisher Service Manual 4024 110 Step Check Yes No 2 Check the sensor punch unit HP for correct operation Go to step 4 Go to step 3 Perform the sensor punch unit HP test Remove the rear upper cover Go to Rear upper cover removal on page 4 24 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Punch and Staple 5 Select Punch unit HP Move the rack gear in the punch unit assembly manually by hand Does the display on the operator panel change every time the sensing area of t
109. Grew RN Ged ER 1 1 Media Size Gnd WEG si ccecicaw sid dated hao wanes ie Ron an mmm ai ein Grim ainye Riana 1 2 Media size orientation and applicable functions 1 2 ool Ro eee cee ee ee ee Ter eT eee ee eee Tee eee eee eee ee a 1 4 TOGIS TEQUIFED ION SEIVICE csc 80 8 ciara career PE EQ eA RA ARR ARIA E Rak A Rew bo Raw eed 1 4 EE ger ee Ee be wid patie RODES EE E 1 4 ER 1 5 Diagnostic information E 2 1 SIO ana id eels pete aaae oana e eaa a dale aad pea a EE a anal de EO dt 2 1 Using Service EE 2 1 Confirm the installation status neu KEREN cede KEREN rennara ee nenas 2 2 Error code MGSSAQES a da crani mia sical EE REES edad deen oes ewe EEN SEAN 2 3 Service CHECKS 2 2898 nee oeni ba ard ache ERT NEE E ER ao ek Bi ada A erg ee er 2 11 280 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 Sensor bridge unit media exit On Jam A 2 14 281 01 Sensor bridge unit media exit On Jam B 42444244244224244 2 16 281 02 Sensor bridge unit media exit On Jam C 2 18 281 03 Sensor bridge unit media exit static jam A 4 4 4 44 4 2 19 282 00 Sensor finisher media entrance on jam 2 20 282 01 Sensor finisher media entrance static jam A 2 22 283 00 Se
110. J N gt Rear tamper offset position Determining tamper home position When the sensor lower media exit turns H 5 V dc light receiving the front and rear tamper motors on the compiler unit assembly are activated and the front and rear tampers start moving The front tamper home position is determined when the front tamper enters the sensor front tamper HP sensing area In the same 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 Diagnostic aids 3 19 4024 110 Offsetting Offsetting is an operation to shift the position of media to be ejected to the stacker media bin so that boundaries between media units sets of media job unit etc can be easily recognized Offsetting is executed for staple positions e During front stapling corner Shifts stapled sheets using the front tamper by 20 mm to the rear side before ejecting them to the stacker media bin e During rear stapling corner straight For media with a width of 216 mm or more rear staple corner l Shifts stapled sheets using the rear tamper by 20 mm to the front side before ejecting them to the stacker media bin For media with a width of less than 216 mm rear staple straight shifts stapl
111. R 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 rear is blocked by blocked by a multi page document or your finger 5 Is the sensor stacker bin level 2 connected properly Replace the Replace the sensor stacker connection bin level 2 Go to Sensor stacker bin level 2 removal on page 4 34 6 Check the encoder of the sensor stacker bin level Go to step 7 After reinstalling encoder installation go to step 7 Is the encoder installed correctly Does it enter the detection point of the sensor stacker bin level encoder 2 96 Finisher Service Manual 4024 110 Step Check Yes No 7 Check the sensor stacker bin level encoder for correct Go to step 9 Go to step 8 operation Perform the sensor stacker bin level encoder test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Bin Level 5 Select Stacker level encod Does the operator panel display change when the belt of the stacker bin lift motor assembly is moved by hand 8 Is the sensor stacker bin level encoder connected Replace the Replace the properly sensor stacker connection bin level encoder Go to Sensor stacker bin level encoder removal on page 4 35 9 Check the stacker bin lift motor assembly for correct
112. Replace the Is the above sensor connected properly coe connection Sensor buffer path removal on page 4 93 3 Check the drive motor buffer transport for correct Go to step 5 Go to step 4 operation Check the above motor by opening the finisher front door assembly and then closing it Does the drive motor buffer transport rotate normally 4 Check the drive motor buffer transport connection Replace the drive Replace the motor buffer connection Is the above motor connect properly transport Go to Drive motor buffer transport and belt buffer transport removal on page 4 115 5 Perform a test print Replace the Problem solved Does the error still occur eg Go to Finisher controller card assembly removal on page 4 118 2 28 Finisher Service Manual 283 03 Sensor buffer path static jam B 4024 110 Step Check Yes No 1 Check the sensor buffer path for correct operation Go to step 3 Go to step 2 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 media into the buffer path and around the buffer roll assembly in a clockwise direction Does the display on the operator panel change every time the actuator of the sensor buffer path is operated 2 Check the sensor
113. a exit removal on page 4 17 5 Check the bridge unit drive motor by opening the Go to step 7 Go to step 6 finisher front door assembly and then closing it Open the bridge unit top cover assembly Does the bridge unit drive motor rotate normally 6 Check the bridge unit drive motor connection Replace the Replace the Is the above motor properly connected n aoe connection Bridge unit drive motor assembly removal on page 4 13 7 Perform a test print Replace the Problem solved bridge unit Does the error still occur2 interface Card assembly Go to Bridge unit interface card assembly removal on page 4 117 Go to step 8 8 Perform a test print Replace the Problem solved Does the error still occur finisher controller card assembly Go to Finisher controller card assembly removal on page 4 118 Diagnostic information 2 15 4024 110 281 01 Sensor bridge unit media exit On Jam B Step Check Yes No 1 Check the media path Go to step 2 Clean or replace 1 Open the bridge unit top cover assembly of the GE bridge unit assembly unit pinch rolls 2 Check the transport belts and the six bridge unit and clean the pinch rolls attached on the bridge unit top cover media path assembly by turning them with your fingers Are the transport belts and the bridge unit pinch rolls installed correctly 2 Are two transport belts and the six bridge unit pinch roll G
114. ace facing outside 4 8 Finisher Service Manual 4024 110 Bridge unit right shaft assembly removal Remove the bridge unit rear cover See Bridge unit rear cover removal on page 4 6 Remove the bridge unit transport belt and bridge unit drive pulley See Bridge unit drive belt and bridge unit drive pulley removal on page 4 8 Remove the 6 mm bushing A from the bridge unit right shaft assembly B Open the bridge unit top cover assembly C ee OM Use a prying tool to remove the e clip securing the 6 mm bushing D to the bridge unit assembly Remove the 6 mm bushing D Move the bridge unit right shaft assembly B toward the right as shown Remove the bridge unit right shaft assembly B from the two transport belts E Remove the bridge unit right shaft assembly B eee AA AD Repair information 4 9 4024 110 Bridge unit left shaft assembly removal 1 Open the bridge unit top cover assembly 2 Use a prying tool to remove the front e clip securing the 4 mm ball bearing A to the bridge unit left shaft B Move the bridge unit left shaft B rearward as shown Remove the bridge unit left shaft B from the two transport belts C Remove the bridge unit left shaft B Remove the other e clip securing the 4 mm ball bearing A on the other end of the shaft Remove the second 4 mm ball bearing A from the bridge unit left shaft e EE pa a 4 10 Finisher Service Manual 4024
115. ached to the belt tensioner bracket A e Tighten the two screws in the order shown Repair information 4 101 4024 110 Media diverter gate solenoid removal Open the finisher front door assembly Remove the rear upper cover See Rear upper cover removal on page 4 24 Disconnect the connector from the media diverter gate solenoid A Release the harness from the clamp Remove the two screws securing the 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 OD P GAMM ch Remove the two screws securing the media diverter gate solenoid to the finisher Remove the media diverter gate solenoid Note The link C may remain inserted into the finisher NO Connector Clamp A Wi C 8 Remove the link Note When the link is removed the media diverter gate may become detached See Media diverter gate removal on page 4 91 4 102 Finisher Service Manual 4024 110 Buffer diverter gate solenoid removal Open the finisher front door assembly Remove the rear upper cover See Upper media bin front cover removal on page 4 25 Disconnect the connector from the buffer diverter gate solenoid A Release the harness from the clamp Remove the two screws securing the buffer diverter gate solenoid to the finisher Remove the buffer div
116. age 4 20 Remove the four screws securing the top cover A to the finisher Lef al si 5 Remove the top cover A Repair information 4 19 4024 110 Upper media bin assembly removal 1 Loosen the two screws securing the upper media bin assembly A to the finisher QP SE 2 Lift the upper media bin assembly A upward in the direction of the arrow 3 Remove the upper media bin assembly A 4 20 Finisher Service Manual 4024 110 Right eject cover 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 Remove the two screws securing the right eject cover A to the finisher Right Ee ee 4 Remove the right eject cover A Repair information 4 21 4024 110 Stacker media bin assembly removal 1 Release the two hooks securing the stacker media bin assembly A to the finisher 2 Lift 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
117. ain paddle shaft assembly See Paddle and roll exit assembly removal on page 4 86 12 Loosen the two screws securing the belt tensioner bracket A to the finisher and move it down in the direction of the arrow 13 Remove the belt exit B from the lower exit roll drive pulley 20T C ON OO P GAMM ch Tighten second 4 82 Finisher Service Manual 4024 110 D il G I J AWS 2 IN Sech e VI 4 e S 9 lt DN a Li DOS IN 075 S L we Ek d Front view Rear view 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 Repair information 4 83 4024 110 16 Remove the 6 mm ball bearing G o S SES a fa Ja SEN SE N Sy omen Ei ll GS aoa Ss dh SS AE 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 4 84 Finisher Service Manual 4024 110 18 Remove the 6 mm bushing H Front 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 Repair information 4 85 4024 110 Paddle and roll exit assembly removal Remove the finisher front door assembly See Finisher front door assembly removal on page 4 27 Remove the re
118. al 4024 110 The stacker media bin lowers according to the volume of media it contains If any obstacle under the tray hinders the tray from lowering Stacker Lower Safety Warning is detected and the stacker media bin is stopped Eject clamp motor Sensor stacker bin level 1 Sensor media eject clamp HP Media eject motor assembly Sensor media eject shaft HP Stacker media bin Sensor stacker bin level 2 Stacker bin Sensor stacker bin lift motor assembly evel encoder Sensor stacker bin upper limit Sensor stacker bin no media Actuator Diagnostic aids 3 27 4024 110 Full stack detection Full stack is detected when media in the stacker media bin becomes full to prevent media jam or falling of media to the floor The stacker media bin can stack up to approximately 3000 sheets The media volume in the stacker media bin is detected at every 10 approximately 300 sheets and notified to the Controller Furthermore the stacker media bin can stack up to 200 sets default of stapled media The stacker media bin can continue to stack media until media volume reaches either of the limits above In the mix stacking mode all the sizes are allowed until media volume of approximately 300 sheets in the stacker media bin is detected The mix stacking means one of the following cases e A larger any size of media sheet of media is stacked on a smaller shee
119. ar and outward as shown Bear Front 16 Remove the media eject shaft assembly E RN 5 k N e NF 5 d E o ND CS Rear vil Repair information 4 75 4024 110 Clamp paddle removal Remove the finisher front door assembly See Finisher front door assembly removal on page 4 27 Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the media eject shaft assembly See Media eject shaft assembly removal on page 4 74 Remove the three clamp paddles A by sliding them out of the media eject shaft assembly B EE Replacement note Replacement is easier if you lightly moisten the rubber surface of the paddles with water 4 76 Finisher Service Manual 4024 110 Media eject clutch removal Remove the rear upper cover See Rear upper cover removal on page 4 24 Disconnect the connector from the sensor media eject shaft HP A Release the harness from the clamp Disconnect the connector from the media eject clutch B Release the harness from the clamp Release the hook securing the media eject clutch actuator C to the media eject clutch B Remove the screw securing the spring clamp D to the finisher NOORONo Clamp ISA Connector Ka Connector 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
120. ar upper cover See Rear upper cover removal on page 4 24 Remove the rear lower cover See Rear lower cover removal on page 4 23 Remove the upper media bin assembly See Upper media bin assembly removal on page 4 20 Remove the upper media bin vertical cover See Right eject cover removal on page 4 21 Remove the stapler unit frame See Stapler unit frame removal on page 4 54 Remove the media eject clamp motor assembly See Media eject clamp motor assembly removal on page 4 66 Remove the media eject unit assembly See Media eject unit assembly removal on page 4 59 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 removal on page 4 78 11 Remove the media eject shaft assembly See Media eject shaft assembly removal on page 4 74 12 Loosen the two screws securing the belt tensioner bracket A to the finisher and move it down as shown 13 Remove the belt exit B from the lower exit roll drive pulley 20T C o pa OR Capa te Tighten second 4 86 Finisher Service Manual Tighten second 4024 110 Loosen the two screws securing the belt tensioner bracket D to the finisher and move it downward as shown Remove the belt paddle entrance E from the main paddle drive pulley gear 44 20T F Release the hook from the main paddle shaft drive
121. area of the sensor media eject clamp HP is blocked Diagnostic information 2 77 4024 110 Step Check Yes No 3 Check the sensor media eject clamp HP connection Replace the Replace the Is the above sensor connected properly Se AE HP connection Go to Sensor media eject clamp HP removal on page 4 67 4 Check the media eject clamp motor by opening the Go to step 6 Go to step 5 finisher front door assembly and then closing it Does the eject clamp motor rotate normally 5 Is the media eject clamp motor connected properly Replace the Replace the media eject connection clamp motor Go to Media eject clamp motor assembly removal on page 4 66 6 Perform a test print Replace the Problem solved S finisher controller Does the error still occur card assembly Go to Finisher controller card assembly removal on page 4 118 986 01 Sensor media eject clamp HP off failure Step Check Yes No 1 Check the media eject clamp by opening the finisher Go to step 2 Remove front door assembly and then closing it obstacles Does the eject clamp mechanism move smoothly 2 Check the sensor media eject clamp HP for correct Go to step 4 Go to step 3 operation Perform the sensor media eject clamp HP 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 Se
122. assembly removal on page 4 118 287 06 Sensor upper media exit static jam B Step Check Yes No 1 Check the sensor upper media exit for correct Go to step 3 Go to step 2 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 2 Check the sensor upper media exit and main sensor Replace the Replace the cable assembly connection sensor upper connection Is the above sensor connected properly ere media exit removal on page 4 104 2 5B2 Finisher Service Manual 4024 110 Step Check Yes No 3 Check the drive motor buffer transport by opening the Go to step 5 Go to step 4 finisher front door assembly and then closing it Does the drive motor buffer transport rotate normally 4 Check the drive motor buffer transport connection Replace the drive Replace the Is the above motor connected properly ere to connecion Drive motor buffer transport and belt buffer transport removal on page 4 115 5 Perform a test print Replace the Problem solved Does the error still occur H Go to Finisher controller card assembly removal on page 4 118 287 07 Sensor upper media exit static jam C Step Check Yes No 1
123. clamp motor assembly removal Noo P Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the upper media bin assembly See Upper media bin assembly removal on page 4 20 Remove the two media eject unit springs A attached to the media eject unit assembly B by pushing them downward Aste NN Teen of Disconnect the connector from the media eject clamp motor C Disconnect the connector from the sensor media eject clamp HP D Remove the three screws securing the bracket E to the finisher 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 Connector 8 Remove the two screws securing the media eject clamp motor to the bracket E 9 Remove the media eject clamp motor C Replacement note When replacing the bracket turn the media eject clamp gear 70T F so that it interacts with the sensor media eject clamp HP 4 66 Finisher Service Manual 4024 110 Sensor media eject clamp HP removal 1 Remove the rear upper cover See Rear upper cover removal on page 4 24 2 Remove the upper media bin assembly See Upper 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 Springs 4 Remove the
124. correct Go to step 5 Go to step 4 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 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 4 Check the sensor lower media exit connection Replace the Replace the sensor lower connection Is the above sensor connected properly media exit Go to Sensor lower media exit removal on page 4 80 5 Check the drive motor exit by opening the finisher Go to step 7 Go to step 6 front door assembly and then closing it Does the motor exit rotate normally 6 Check the drive motor exit connection Replace the drive Replace the motor exit Go connection Is the above motor connected properly to Drive motor exit assembly and belt exit removal on page 4 113 7 Perform a test print Replace the Problem solved finisher controller Does the error still occur card assembly Go to Finisher controller card assembly removal on page 4 118 Diagnostic information 2 31 4024 110 284 01 Sensor lower media exit on jam A Step Check Yes No 1 Check the media path Go t
125. cted Replace the Replace the properly stacker bin lift connection motor assembly Go to Stacker bin lift motor assembly removal on page 4 38 11 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 Diagnostic information 2 95 4024 110 Stacker media bin full no mix Step Check Yes No 1 Check the stacker bin for obstructions Remove the Go to step 2 Are there any obstructions on the upper and lower SERIES parts of the stacker bin 2 Check the sensor stacker bin level 1 for correct Go to step 4 Go to step 3 operation Perform the sensor stacker bin level 1 test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Bin Level 5 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 3 Is the sensor stacker bin level 1 installed correctly Replace the Replace the sensor stacker connection bin level 1 Go to Sensor stacker bin level 1 removal on page 4 34 4 Check the sensor stacker bin level 2 for correct Go to step 5 Go to step 6 operation Perform the sensor stacker bin level 2 test 1 Select Diagnostics mode 2 Select FINISHE
126. d based on the levels of these sensors This sensor information is used to control the elevator motor The motor is activated to move the stacker media bin while the sensor stacker bin level turns from the light blocking state to the light receiving state Sensor stacker bin level 1 gE Bin height Bin proper Bin low moves moves upward downward 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 the sensor stacker bin no media for protection against abnormal operation If an operator removes media from the stacker media bin during printing it is detected by the sensor stacker bin level 2 and the ejection of media to the stacker media bin is inhibited Then the elevator motor is activated to move the stacker media bin to the sensor stacker bin level 1 sensing area Thus the ejection of media to the stacker media bin is restored If an operator removes media from the stacker media bin while printing is stopped it is detected by the sensor stacker bin level 2 After three seconds have passed the elevator motor is activated to move the stacker media bin to the sensor stacker bin level 1 sensing area Thus the ejection of media to the stacker media bin is restored 3 26 Finisher Service Manu
127. d on within the specified time after the media eject motor is turned on Go to 285 00 Finisher eject set jam on page 2 42 286 00 Paper jam Check area H Sensor compiler media in Static jam Paper remains on the sensor compiler media in Go to 286 00 Sensor compiler media in static jam on page 2 43 287 00 Paper Jam Check area F Sensor upper media exit on jam A Sensor upper media exit is not turned on within the specified time after the sensor finisher media entrance is turned on At this time the 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 46 287 02 Paper jam Check areas G1 G3 Sensor upper media exit on jam B Sensor upper media exit is not turned on within the specified time after the sensor finisher media entrance is turned on At this time the sensor bridge unit media exit is turned on Go to 287 02 Sensor upper media exit on jam B on page 2 47 287 03 Sensor upper media Sensor upper media exit is not turned on within the Pap riam exit on
128. de 2 Select FINISHER TESTS 3 Select Punch and Staple 4 Select Low Staple Does the display on the operator panel change every time an undamaged and filled staple cartridge is removed and reinserted into the stapler unit assembly Diagnostic information 2 99 4024 110 Step Check Yes No Check the stapler unit cable assembly connection Are all the connections of the stapler unit cable assembly connected properly Replace the stapler unit assembly Go to Stapler unit assembly removal on page 4 56 Replace the connection 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 Perform a stapled print test Replace the printer engine card assembly Refer to Printer Service Manual Problem solved 2 100 Finisher Service Manual 4024 110 3 Diagnostic aids This chapter explains the finisher tests and procedures and information to identify finisher failures and verify repairs have corrected the problem Refer to the Printer Service Manual for the entire Diagnostics mode and Configuration menus Also descriptive information in Theory on page 3 4 explains the processes and is helpful in understanding the finisher Diagnostics are built into the printer RIP card assembly and can be accessed from the
129. dge unit media exit connection Replace the Replace the Is the above sensor connected properly GE connection Go to Sensor bridge unit media exit removal on page 4 17 5 Check the bridge unit drive motor by opening the Go to step 7 Go to step 6 finisher front door assembly and then closing it Open the bridge unit top cover assembly Does the bridge unit drive motor rotate normally 6 Check the bridge unit drive motor connection Replace the Replace the bridge unit drive connection Is the above motor properly connected tee Go to Bridge unit drive motor assembly removal on page 4 13 2 18 Finisher Service Manual 4024 110 Step Check Yes No 7 Perform a test print Replace the Problem solved Does the error still occur pe ee assembly Go to Bridge unit interface card assembly removal on page 4 117 Go to step 8 8 Perform a test print Replace the Problem solved Does the error still occur re Go to Finisher controller card assembly removal on page 4 118 281 03 Sensor bridge unit media exit static jam A Step Check Yes No 1 Check the sensor bridge unit media exit for correct Go to step 4 Go to step 2 operation Perform the 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
130. 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 sensor stacker bin level 1 A so L 3 J AY KA Gi K Front Connector A 4 Remove the screw 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 e Connector A 4 Remove the screw securing the sensor stacker bin level 2 A 5 Remove the sensor stacker bin level 2 A 4 34 Finisher Service Manual 4024 110 Sensor stacker bin level encoder removal Remove the rear upper cover See Rear upper cover removal on page 4 24 Disconnect the connector from the sensor stacker bin level encoder A Release the harness from the clamp Remove the screw securing the bracket B from the stacker bin lift motor assembly C AONA Connector Rear 5 Release the hooks securing the sensor to the bracket B 6 Remove the sensor stacker bin level encoder A Repair information 4 35 4024 1
131. dsomr det 770 795 nanometer Lasersystemet och skrivaren r utformade s att det aldrig finns risk f r att n gon person uts tts f r laserstr lning ver Klass l niv vid normal anv ndning underh ll som utf rs av anv ndaren eller annan f reskriven service tg rd Laser melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR underkapittel J for klasse 1 laserprodukter og er i andre land godkjent som et Klasse l laserprodukt i samsvar med kravene i IEC 60825 1 Klasse l laserprodukter er ikke betrakte som farlige Skriveren inneholder internt en klasse IIIb 3b laser som best r av en gallium arsenlaserenhet som avgir str ling i b lgelengdeomr det 770 795 nanometer Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstr ling ut over klasse l niv under vanlig bruk vedlikehold som utf res av brukeren eller foreskrevne serviceoperasjoner Av s sobre el L ser Segons ha estat certificat als Estats Units aquesta impressora compleix els requisits de DHHS 21 CFR apartat J pels productes l ser de classe 1 i segons ha estat certificat en altres llocs s un producte l ser de classe que compleix els requisits d IEC 60825 1 Els productes laser de classe no es consideren perillosos Aquesta impressora cont un l ser de classe IIIb 3b d arseni r de gal li nominalment de 5 mil livvats i funciona a la regi de longitud d ona de 770 795 nan metres El sistema l ser i
132. e Stapler carriage motor asm Media handling direction Sensor stapler carriage HP a Li Diagnostic aids 3 23 4024 110 Stapler unit assembly Stapling operation is executed by closing the stapler unit assembly The stapler unit assembly containing the staple motor the sensor staple home the sensor self priming and the sensor low staple is activated by the staple motor Forward clockwise rotation of the motor drives the stapler to staple a set of sheets and returns the stapling unit to the home position If stapling fails the motor rotates reversely counterclockwise to return the stapler unit assembly to the home position When staples become low the low staple sensor detects it and stapling stops automatically displaying an alarm message The message is also displayed when the staple cartridge is not installed Sensor staple home Sensor self priming Stapler unit assembly Sensor low staple Stapler unit motor Functions of stapler sensors motors e Sensor stapler carriage HP A photo interrupter to detect the stapler home position rear staple corner position and rear staple straight position Itturns H 5 V dc light blocking when the stapler comes to the specified position e Stapler carriage motor assembly A stepping motor to move the stapler unit assembly
133. e Problem solved Does the error still occur Ee Go to Finisher controller card assembly removal on page 4 118 283 00 Sensor buffer path on jam A Step Check Yes No 1 Check the media path Go to step 2 Clean or replace N the appropriate is la finisher front door assembly of the tolls and clean the media path 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 2 Are the media entrance roll assembly and the media Go to step 3 Clean or replace entrance pinch guide pinch rolls free of damage and the appropriate rotate smoothly rolls and clean the paper path 3 Check the media path Go to step 4 Clean or replace 2 the appropriate a finisher front door assembly of the rolls and clean I I the media path 2 Open the lovver pinch guide assembly to the right 3 Check the buffer roll assembly by turning it with your fingers Is the buffer roll assembly installed correctly and is it free of damage and contamination Diagnostic information 2 23 4024 110 finisher front door assembly and then closing it Does the drive motor buffer transport rotate no
134. e drive motor buffer transport rotate properly 6 Check the drive motor buffer transport connection Replace drive Replace the motor buffer connection Is the above motor connected properly transport Go to Drive motor buffer transport and belt buffer transport removal on page 4 115 7 Check the drive motor exit for correct operation Go to step 9 Go to step 8 Check the above motor by opening the finisher front door assembly and then closing it Does the motor exit rotate normally 8 Check the drive motor exit connection Replace the drive Replace the Is the above motor connected properly CS ENEE exit assembly and belt exit removal on page 4 113 9 Perform a test print Replace the Problem solved Does the error still occur e Go to Finisher controller card assembly removal on page 4 118 287 02 Sensor upper media exit on jam B Step Check Yes No 1 Check the media path Go to step 2 Clean or replace 1 Open the finisher front door assembly of the db tea int ce finisher the media path 2 Remove the top cover and left upper cover 3 Open the entrance pinch guide assembly upward 4 Check four media entrance pinch guide pinch rolls of the entrance pinch guide assembly and media entrance roll assembly by turning them with your fingers Are the media entrance pinch guide pinch rolls installed correctly and do they rotate smoothly 2 Are the four media entrance pinch guide pinch rolls of Go
135. e flat spot on the upper media transport roll assembly C is installed to the rear Note When replacing the upper media transport roll assembly C do not touch the rubber surface Note The tension of the belt buffer transport G is automatically adjusted by the force of the spring attached to the belt tensioner bracket F Note Tighten the two screws in the order shown 4 112 Finisher Service Manual 4024 110 Drive motor exit assembly and belt exit removal ee Remove the rear upper cover See Rear upper cover removal on page 4 24 Loosen the two screws securing the belt tensioner bracket A to the finisher and move it down as shown Remove the belt exit B from the drive motor exit assembly C Disconnect the connector from the drive motor exit assembly Second_ Repair information 4 113 4024 110 5 Remove the two screws securing the bracket D to the finisher 6 Remove the bracket D 7 Remove the two screws securing the drive motor exit assembly to the bracket D Connector 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 4 114 Finisher Service Manual 4024 110 Drive motor buffer transport and belt buffer transport removal 1 Remove the rear upper cover See
136. e properly installed as shown in the figure The paddles must not come in contact with the media eject unit assembly C Repair information 4 63 4024 110 Sub paddle drive shaft assembly removal Open the finisher front door assembly Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the media eject unit assembly See Media eject unit assembly removal on page 4 59 Loosen the screw securing the knob A to the sub paddle drive shaft assembly B on the front of the finisher Remove the knob A Remove the one e clip securing the sub paddle drive shaft assembly B Remove the bushing C N OI RON ch 4 64 Finisher Service Manual 4024 110 8 Loosen the two screws securing the belt tensioner bracket D to the rear of the finisher 9 Release the hook of the sub paddle drive gear 23T E from the sub paddle drive shaft assembly B 10 Remove the sub paddle 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 e The tension of the belt exit F is automatically adjusted by the force of the spring attached to the belt tensioner bracket D e Tighten the two screws in the order shown Tighten second Tighten first Repair information 4 65 4024 110 Media eject
137. e sensor bridge unit media entrance is operated 4 Check the sensor bridge unit media entrance Replace the Replace the connection sensor bridge connection Is the above sensor connected properly ae Go to Sensor bridge unit media entrance removal on page 4 16 5 Check the bridge unit drive motor by opening the Go to step 7 Go to step 6 finisher front door assembly and then closing it Open the bridge unit top cover assembly Does the bridge unit drive motor rotate normally 6 Check the bridge unit drive motor connection Replace the Replace the Is the above motor properly connected ae Bridge connecNon unit drive motor assembly removal on page 4 13 Diagnostic information 2 11 4024 110 Step Check Yes No 7 Perform a test print Replace the Problem solved Does the error still occur E assembly Go to Bridge unit interface card assembly removal on page 4 117 Go to step 8 8 Perform a test print Replace the Problem solved Does the error still occur erg Go to Finisher controller card assembly removal on page 4 118 280 01 Sensor bridge unit media entrance static jam A Step Check Yes No 1 Check the sensor bridge unit media entrance for Go to step 3 Go to step 2 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 B
138. e sensor upper cable assembly Punch main drive cable assembly Diverter gate sensor lower cable assembly Punch waste box set cable assembly Interlock switch cable assembly 5 8 Finisher Service Manual 4024 110 Main drive cable assembly Punch waste box full cable assembly Bridge unit connect cable assembly Stapler unit cable assembly Bridge unit interface card cable assembly Finisher interface cable assembly Component locations 5 9 4024 110 5 10 Finisher Service Manual 4024 110 6 Preventive maintenance This chapter describes procedures for printer preventive maintenance Follow these recommendations to help prevent problems and maintain optimum performance Safety inspection guide The purpose of this inspection guide is to aid you in identifying unsafe conditions If any unsafe conditions exist find out how serious the hazard could be and if you can continue before you correct the hazard Check the following items e Damaged missing or altered parts especially in the area of the on off switch and the power supply e Damaged missing or altered covers especially in the area of the top cover and the power supply cover e 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 Ma
139. e the left lower cover A 4 28 Finisher Service Manual 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 Repair information 4 29 4024 110 Carriage lift belt left removal Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the finisher front door assembly See Finisher front door assembly removal on page 4 27 Move the slip clutch gear 24T A toward the rear to disengage the stacker bin B 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 RON ch 4 30 Finisher Service Manual 4024 110 Remove the two screws securing the bin bracket C to the left carriage bracket D Remove the spring E from the left carriage lift assembly Remove the screw securing the upper belt clamp F to the left carriage bracket D Remove the upper belt clamp F Remove the left carriage bracket with the carriage lift belt G from the finisher Release the hook securing the carriage lift belt G to the lower belt clamp H Remove the carriage lift belt G im ee 1 1 Replacement notes e Make sure the carriage lift belt G is inserted in
140. e you are working Unplug the product before you begin or use caution if the product CAUTION When you see this symbol there is a danger from hazardous voltage in the area of the must receive power in order to perform the task Xvi Finisher Service Manual 1 General information 4024 110 The optional finisher performs staples punches and stacks media transferred from the Lexmark W850n and W850dn printer Output is stacked in the upper media bin or separately collated in the stacker media bin Bridge unit assembly ee aD a R Bo Finisher Finisher weight Packaged 42 kg Unpackaged 30 kg Components The finisher is composed of the following five components e Bridge unit assembly block to feed media from the printer to the finisher e Punch block to punch media e Compiler tray block to align media e Stapler block to staple a set of media at specified positions General information 1 1 4024 110 e Stacker media bin block to stack media i 8 I Bridge unit asm Punch unit bL Stacker media bin Compiler tray Stapler Media size and weight The following shows media sizes and weight that the finisher can handle as well as applicable functions for each media size The printer and the finisher handle different media sizes and weights For this reason if the printer has printed media that the fi
141. ean or replace 1 Open the bridge unit top cover assembly of the E e bridge unit assembly unit pinch aie 2 Check two transport belts and the six bridge unit and clean the pinch rolls attached on the bridge unit top cover media path assembly by turning them with your fingers Are transport belts and the bridge unit pinch rolls installed correctly 2 Are two transport belts and the six bridge unit pinch roll Go to step 3 Clean or replace free of damage the transport belts and bridge unit pinch rolls and clean the media path 2 20 Finisher Service Manual 4024 110 Step Check Yes No 3 Check the sensor bridge unit media exit for correct Go to step 6 Go to step 4 operation Perform the 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 4 Check the sensor bridge unit media exit connection Replace the After sensor bridge reconnecting go Is the above senor connected properly unit media exit to step 5 Go to Sensor bridge unit media exit removal on page 4 17 5 Check the sensor finisher media entrance for correct Go to step 7 Go to step 6 operation Perform the sensor finisher media entrance te
142. econds after the stapler starts moving toward the staple position and also the sensor stapler carriage HP is off Or the sensor stapler carriage HP is not turned on after the stapler was moved to the staple position Or the sensor stapler carriage HP is turned off again after the sensor stapler carriage HP is turned on and the stapler stopped its moving Go to 990 00 Sensor stapler carriage HP on failure on page 2 85 990 01 Service finisher error Sensor stapler carriage HP off failure The sensor stapler carriage HP is not turned off within 500 ms after stapler starts moving to the staple position and sensor stapler carriage HP is off Or the sensor stapler carriage HP is not turned off after 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 Finisher NVRAM R W failure on page 2 87 996 00 Service wrong finisher Finisher type failure An incorrect type of finisher is connected Go to 996 00 Finisher type failure on page 2 87 999 00 Service finisher error Finisher engine RIP functional failure The en
143. ect on the right side opens shutting off the Interlock 24 V dc line in the finisher HL Ee I J Switch eject cover interlock E ee Switch finisher front door interlock 7 Na CN Finisher controller card asm s Switch Finisher LVPS Switch finisher card asm eject cove front door interlock interlock AC ON OFF 24 Vdc Printer 3 30 Finisher Service Manual 4024 110 4 Repair information Warning Read the following before handling electronic parts Handling ESD sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge ESD To prevent damage to ESD sensitive parts use the following instructions in addition to all the usual precautions such as turning off power before removing logic boards Keep the ESD sensitive part in its original shipping container a special ESD bag until you are ready to install the part into the machine Make the least possible movements with your body to prevent an increase of static electricity from clothing fibers carpets and furniture Put the ESD wrist strap on your wrist Connect the wrist band to the system ground point This discharges any static electricity 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
144. ed Such different width sheets are forcibly ejected to the stacker media bin Media limits for stapling The number of sheets to be stapled is limited to prevent damage to the stapler e If the number of sheets of one set to be stapled exceeds the limit of the compiler unit assembly the exceeding sheets are not stacked on the compiler unit assembly and are forcibly ejected to the stacker media bin without being stapled e After the forcible ejection of media if the number of following sheets of one set to be stapled exceeds the limit of the compiler unit assembly the exceeding sheets are also ejected forcibly to the stacker media bin without being stapled e 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 volatile memory Stapler operation The stapler stays at the front home position that is at the front staple corner position when the power is turned on The stapler starts stapling when a set of sheets to be stapled is stacked on the compiler unit assembly The stapler does not move during stapling in the front staple mode In any mode other than the front staple mode the stapler moves to the specified position and then perform stapling e N 4 N R gt 7 NN vi K
145. ed sheets using the front tamper by 9 mm to the rear side before ejecting them to the stacker media bin During dual stapling e Shifts stapled sheets using the front tamper by 9 mm to the rear side before ejecting them to the stacker media bin e Offsetting is not executed 0 mm for small media Functions of compiler unit assembly sensors motors e 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 light receiving e Sensor front tamper HP A photo interrupter to detect the front tamper home position When the front tamper comes to the home position it enters the sensor s sensing area which turns the sensor to H 5 V dc light blocking e Sensor rear tamper HP Aphoto interrupter to detect the rear tamper home position When the rear tamper comes to the home position it enters the sensor s sensing area which turns the sensor to H 5 V dc light blocking e Front tamper motor A stepping motor to move the front tamper for tamping Clockwise rotation of this motor moves the front tamper to the rear side Counterclockwise rotation of this motor moves the tamper to the front side 3 20 Finisher Service Manual 4024 110 e Rear tamper motor A stepping motor to move the rear tamper for tamping Clockwise rotation
146. embly Finish assembly properly connected er controller card assembly removal on page 4 118 996 00 Finisher type failure Step Check Yes No 1 Check the printer and finisher installation Go to step 2 Reinstall the Is the finisher installed to the printer correctly ens 2 Turn the power on and off Go to step 3 Problem solved Does the error still occur when the power is back on 3 Check the finisher controller card assembly Replace the Replace the connection finisher controller connection Are the connections of the finisher controller card assembly correctly connected card assembly Go to Finisher controller card assembly removal on page 4 118 Diagnostic information 2 87 4024 110 999 00 Finisher engine RIP functional failure connection Are the connections of the finisher controller card assembly properly connected finisher controller card assembly Go to Finisher controller card Step Check Yes No 1 Turn the printer off and on several times Go to step 2 Problem solved Does the error still occur when the power is on 2 Check the finisher controller card assembly Replace the Problem solved assembly removal on page 4 118 Bridge unit top cover open Step Check Yes No 1 Check the bridge unit cable assembly for proper Go to step 2 Replace the connection connection Is the bridge unit cable assembly properly connected to the rear of
147. embly removal on page 4 118 2 56 Finisher Service Manual 288 01 Sensor diverter gate static jam to top bin A 4024 110 Step Check Yes No 1 Check the sensor diverter gate for correct operation Go to step 3 Go to step 2 Perform the sensor diverter gate test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path2 5 Select Diverter gate Open the finisher front door 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 2 Check the sensor diverter gate connection Replace the Replace the Is the above senor connected properly occa KC conmecuon Sensor diverter gate removal on page 4 110 3 Chech the drive motor entrance paddle by opening Go to step 5 Go to step 4 the finisher front door assembly and then closing it Does the motor entrance paddle rotate normally 4 Is the drive motor entrance paddle connected Replace the drive Replace the properly motor entrance connection paddle Go to Drive motor entrance paddle and belt entrance paddle removal on page 4 100 5 Perform a test print Replace the Problem solved Does the error still occur e Go to Finisher controller card as
148. embly free of damage Go to step 3 Clean or replace the appropriate roll and clean the media path 3 Are the buffer pinch guide pinch rolls attached to the Go to step 4 Clean or replace buffer pinch guide assembly correctly the appropriate roller and clean the media path 4 Are the buffer pinch 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 Go to step 7 Go to step 6 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 media into the buffer path and around the buffer roll assembly in a clockwise direction Does the display on the operator panel change every time the actuator of the sensor buffer path is operated 6 Check the sensor buffer path connection Replace the Replace the Is the above sensor connected properly on oe connection Sensor buffer path removal on page 4 93 7 Check the drive motor buffer transport by opening the Go to step 9 Go to step 8 finisher front door assembly and then closing it Does the drive motor buffer transport rotate normally Diagnostic information 2 35 4024 110 diverter gate removal on page 4 110 Step Check Yes No 8 Check the dr
149. enes 7 23 Belt tensioner bracket kit 2 2 eer rere eee eee ee 7 25 Belt tensioner pulley kit ee ee ee eee ee 7 23 6mm ball bearing ee ee ee ee eee ee ee eee eee eee 7 21 Ball bearing 6mm eer eee er ee ee ee eee eee 7 23 7 25 Media entrance roll drive pulley 20T eee 7 23 Buffer roll drive gear 46T 7 23 Media diverter solenoid kit e ee ee ee ee e ee 7 23 Buffer diverter solenoid kit ee ee ee ee ee cecs 7 23 Upper media exit pinch roll assembly 7 25 Upper media exit roll assembly 2 ee eee reer e ee 7 25 Upper pinch guide assembly this comes assembled 7 25 Sensor diverter gate r eee err eee ee eee eee eee ee 7 25 Diverter gate sensor upper cable assembly 7 25 7 30 Upper media transport roll assembly 7 25 Buffer roll drive pulley gear 53 23T e ee ee ee cecs 7 25 Upper media transport roll drive pulley 20T 7 25 Upp
150. ensor stacker bin level 2 connected properly Replace the Replace the sensor stacker connection bin level 2 Go to Sensor stacker bin level 2 removal on page 4 34 Diagnostic information 2 67 4024 110 Step Check Yes No 8 Check the sensor stacker bin level encoder for correct Go to step 10 Go to step 9 operation Perform the sensor stacker bin level encoder test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Bin Level 5 Select Stacker bin level encod Does the display on the operator panel change when the belt of the stacker bin lift motor assembly is moved by hand 9 Is the sensor stacker bin level encoder connected Replace the Replace the properly sensor stacker connection bin level encoder Go to Sensor stacker bin level encoder removal on page 4 35 10 Check the stacker bin lift motor assembly by blocking Go to step 12 Go to step 11 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 11 Check the stacker bin lift motor assembly connection Replace the Replace the Is the connector of the stacker bin lift motor assembly SEN connecuon correctly connected to the finisher controller card Go to Re assembly sa bin lift motor assembly removal on page 4 38 12 Perform a test print
151. ents iii 4024 110 288 02 Sensor diverter gate static jam to top bin B e 2 58 288 03 Sensor diverter gate static jam to top bin C 4 44244 4 2a 2 59 288 04 Sensor diverter gate static jam to stacker bin A 2 60 288 05 Sensor diverter gate static jam to stacker bin B 2 61 288 06 Sensor diverter gate static jam to stacker bin C 2 62 980 02 Finisher communication failure 0 0 c cee eee ees 2 63 931 00 Stacker bin failure ss ea sas sasaairanianamsiaaasssienssaaiseasiasasaaassuaaaa 2 63 981 01 Stacker bin upper limit failure 2 65 981 02 Stacker bin lower limit failure 0 00 cece eee eee eee eee 2 66 982 00 Sensor front tamper HP on failure 2 68 982 01 Sensor front tamper HP off failure 1 2 0 0 cece eee 2 69 983 00 Sensor rear tamper HP on failure 2 70 983 01 Sensor rear tamper HP off failure 0 cece eee 2 71 984 00 Sensor punch unit HP on failure 0 cece eee eee 2 72 984 01 Sensor punch unit HP off failure 2 cee eee eee eens 2 74 985 00 Sensor punch carriage shift HP on failure 2 75 985 01 Sensor punch carriage shift HP off failure 0 cee 2 76 986 00 Sensor media eject clamp HP on failure 2 77 986 01 Sensor media eject clamp HP off failure 2 78 987 00 Senso
152. ep 11 Go to step 10 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 step 12 Problem solved 12 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 Diagnostic information 2 27 4024 110 283 02 Sensor buffer path static jam A Step Check Yes No 1 Check the sensor buffer path for correct operation Go to step 3 Go to step 2 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 media into the buffer path and around the buffer roll assembly in a clockwise direction Does the display on the operator panel change every time the actuator of the sensor buffer path is operated 2 Check the sensor buffer path connection Replace the
153. er media bin full removal Open the finisher front door assembly Remove the screw securing the bracket A to the upper media bin vertical cover B Move the bracket frontward and downward to gain access to the harness and connector Release the harness from the clamp Move the bracket B frontward again and remove the screw securing the sensor upper media bin full C to the bracket akan ch Front 6 Remove the sensor upper media bin full C 7 Disconnect the connector from the sensor upper media bin full C 4 108 Finisher Service Manual 4024 110 Upper pinch guide assembly removal Oa EB Who Open the finisher front door assembly Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the drive motor buffer transport See Drive motor buffer transport and belt butter transport removal on page 4 115 Remove the three screws securing the hinge of the upper pinch guide assembly A on the rear of the finisher Move the upper pinch guide assembly hinge from the rear of the finisher Remove the upper pinch guide assembly A from inside of the finisher in the direction of the arrow i Repair information 4 109 4024 110 Sensor diverter gate removal 1 Open the finisher front door 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
154. er media exit roll drive pulley gear 20T 20T 7 25 Upper media exit roll drive gear 20T eee eee eee eee 7 25 Belt buffer transport 19 8 cm 2 2 errr eee eee eee 7 25 Belt exit 27 7 cm 7 25 Punch waste box full cable assembly 7 13 7 31 Bridge unit interface card assembly 7 27 7 31 Bridge unit connect cable assembly 7 27 7 31 Bridge unit interface card cable assembly 7 27 Finisher controller card assembly me ee ee ee ee ee eee ee 7 27 AC power cord assembly errr eee ee ee eee eee eee ee 7 27 Finisher LVPS card assembly r rrr ree ere e ee 7 27 Main sensor cable assembly errr rere errr ee eee eee 7 29 Main drive cable assembly rr errr ee ere eee eee 7 31 Finisher interface cable assembly eee errr ree eee eee 7 31 Finisher media entrance sensor cable assembly 7 29 Buffer path sensor cable assembly ee ee ee ee eee eee 7 29 Upper media exit sens
155. error still occur e Go to Finisher controller card assembly removal on page 4 118 287 05 Sensor upper media exit static jam A Step Check Yes No 1 Check the sensor upper media exit for correct Go to step 3 Go to step 2 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 Diagnostic information 2 51 4024 110 Step Check Yes No 2 Check the sensor upper media exit and main sensor Replace the Replace the cable assembly connection sensor upper connection kee zb ted y media exit Go to s the above sensor connected properly Sensor upper media exit removal on page 4 104 3 Check the drive motor buffer transport by opening the Go to step 5 Go to step 4 finisher front door assembly and then closing it Does the drive motor buffer transport rotate normally 4 Check the drive motor buffer transport connection Replace the drive Replace the Is the above motor connected properly EC to SERGE Drive motor buffer transport and belt buffer transport removal on page 4 115 5 Perform a test print Replace the Problem solved Does the error still occur Ce Go to Finisher controller card
156. erter gate solenoid Note The link B may remain inserted into the finisher Ou bo yy 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 Repair information 4 103 4024 110 Sensor upper media exit removal Open the finisher front door assembly Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the top cover See Top cover removal on page 4 19 Disconnect the connector from the sensor upper media exit A E 8 g KE PONH Y Connector WD o D Left 5 Release the hooks securing the sensor upper media exit A to the finisher 6 Remove the sensor upper media exit A 4 104 Finisher Service Manual 4024 110 Upper media exit pinch roll assembly removal Open the finisher front door assembly Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the top cover See Top cover removal on page 4 19 Remove the four screws securing the four upper media exit pinch roll assemblies A to the finisher Ee E el NS 2 YX ZK VA aA AS 5 Remove the four upper media exit pinch roll assembly A Repair information 4 105 4024 110 Upper media exit roll assembly removal 1 Open the finisher front door assembly 2 Remove the rear upper cover See Rear up
157. es No 5 Is the punch carriage shift motor assembly connected Replace the Replace the properly punch carriage connection shift motor assembly Go to Punch carriage shift motor assembly removal on page 4 43 6 Perform a test print Replace the Problem solved printer engine Does the error still occur card assembly Refer to the Printer Service Manual 985 01 Sensor punch carriage shift HP off failure Step Check Yes No 1 Check the punch carriage by moving it with your Go to step 2 Remove fingers obstructions Does the punch carriage move back and forth smoothly 2 Check the sensor punch carriage shift HP for correct Go to step 4 Go to step 3 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 change every time the sensing area of the above sensor is blocked 3 Check the sensor punch carriage shift HP Replace the Replace the connection sensor punch connection Are the connections of the punch sensor cable carriage shift assembly properly connected MP Go to y property i Sensor punch carriage shift HP removal on page 4 51 2 76 Finisher Service Manual 4024 110 Step Check Ye
158. es for en laserstraling over Klasse I niveau ved normal drift brugervedligeholdelse eller obligatoriske servicebetingelser X Finisher Service Manual 4024 110 Huomautus laserlaitteesta Tama kirjoitin on Yhdysvalloissa luokan 1 laserlaitteiden DHHS 21 CFR Subchapter J m rityksen mukainen ja muualla luokan laserlaitteiden IEC 60825 1 maarityksen mukainen Luokan laserlaitteiden ei katsota olevan vaarallisia k ytt j lle Kirjoittimessa on sis inen luokan IIIb 8b 5 milliwatin galliumarsenidilaser joka toimii aaltoalueella 770 795 nanometria Laserjarjestelma ja kirjoitin on suunniteltu siten ett k ytt j ei altistu luokan m rityksi voimakkaammalle s teilylle kirjoittimen normaalin toiminnan k ytt j n tekemien huoltotoimien tai muiden huoltotoimien yhteydess VARO Avattaessa ja suojalukitus ohitettaessa olet alttiina n kym tt m lle lasers teilylle l katso s teeseen VARNING Osynlig laserstralning n r denna del r ppnad och sp rren ar urkopplad Betrakta ej str len Laser notis Denna skrivare r i USA certifierad att motsvara kraven i DHHS 21 CFR underparagraf J f r laserprodukter av Klass 1 andra l nder uppfyller skrivaren kraven f r laserprodukter av Klass enligt kraven i IEC 60825 1 Laserprodukter i Klass anses ej h lsov dliga Skrivaren har en inbyggd laser av Klass IIIb 3b som best r av en laserenhet av gallium arsenid p 5 milliwatt som arbetar i v gl ng
159. es the finisher the buffer diverter solenoid is activated by the printer command and by the sensor finisher media entrance to switch the buffer diverter gate Thus the media route is switched into the buffer roll assembly s circumferential direction This operation is called buffer path The first media of the second setis aligned vvith the second media and then they are fed together to the compiler unit assembly Even for one sheet of media the buffer path operation is executed 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 avoid the second media from colliding with the first one ils Media Sensor J buffer path Buffer roll assembly driven by drive motor buffer transport Buffer Compiler unit diverter gate assembly Diagnostic aids 3 9 4024 110 From compiler unit assembly to stacker media bin Stapled media on the compiler unit assembly stapling mode or aligned media non stapling mode are held between the media eject clamp and the media eject shaft assembly The media eject shaft assembly is driven by the media eject m
160. fixed positions front rear sides in parallel Rear with the media edge after the front tamper aligns the media to the specified position for each media size Process direction Front Media sizes that allow stapling Media size that allows stapling depends on stapling positions The following table shows media sizes and the applicability of stapling for each staple position Front Rear Rear corner corner straight Dual A3 SEF Yes Yes No Yes A4 LEF Yes Yes No Yes 11 x 17 in SEF Yes Yes No Yes 8 5 x 11 in LEF Yes Yes No Yes 8K SEF GCO 16K LEF GCO Yes Yes No Yes B4 SEF B5 LEF Yes Yes No Yes 8 x 10 in LEF Yes Yes No Yes 8 5 x 14 in SEF 8 5 x 13 in SEF Yes No Yes Yes 8 5 x 11 in SEF A4 SEF Yes No Yes Yes 8 x 10 in SEF Yes No Yes Yes Yes Applicable No Not applicable 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 stacker media bin 3 22 Finisher Service Manual 4024 110 While if sheets with different widths are present on the compiler unit assembly stapling is stopped when a different width is detect
161. formation e The safety of this product is based on testing and approvals of the original design and specific components The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts e The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others e There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product Professional service personnel should understand this and take necessary precautions CAUTION When you see this symbol there is a danger from hazardous voltage in the area of the A product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task Consignes de s curit e La s curit de ce produit repose sur des tests et des agr ations portant sur sa conception d origine et sur des composants particuliers Le fabricant n assume aucune responsabilit concernant la s curit en cas d utilisation de pieces de rechange non agr es e Les consignes d entretien et de r paration de ce produit s adressent uniquement a un personnel de maintenance qualifi e Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires ATTENTION Ce symbole indique la pr sence d
162. ft motor assembly C Release the two punch unit assembly harnesses from the three clamps on the rear of the finisher Disconnect the two punch unit assembly harnesses from the main harness Remove the screw securing the grounding wire D to the punch unit carriage assembly B Remove the two screws on the rear securing the punch carriage assembly B to the finisher Serene din al E Connector 7 SZ IE LT z EES Re 3 Er T iy SGA S Repair information 4 41 4024 110 11 Remove the two screws on the front securing the punch carriage assembly B to the finisher Front 12 While moving the belt buffer transport E to the left as shown pull the punch carriage assembly B gently out of the rear of the finisher Warning Do not force the punch carriage assembly B out of the finisher Be sure to hold the unit firmly to avoid dropping it Replacement notes e Do not force the punch unit into the finisher e Be sure to hold the punch carriage assembly firmly to avoid dropping it e Make sure all harnesses are properly clamped e Make sure the punch carriage assembly is able to shift back and forth completely without binding the harnesses e Make sure the harnesses do not come into contact with any rotating mechanisms 4 42 Finisher Service Manual 4024 110 Punch carriage shift motor assembly removal Open the finisher front door assembly
163. 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 Parts catalog 7 31 4024 110 7 32 Finisher Service Manual Index A acronyms 1 5 B belts buffer transport 4 115 entrance paddle 4 100 exit 4 113 bridge unit bridge unit interface card assembly 4 117 drive belt 4 8 drive motor 5 1 drive pulley 4 8 drive unit motor assembly 4 13 entrance guide 4 14 idler rolls 4 11 left shaft assembly 4 10 locations 5 1 parts catalog 7 2 pinch roller 4 18 rear cover 4 6 removal 4 2 right shaft assembly 4 9 sensor bridge unit media entrance 4 16 sensor bridge unit media exit 4 17 sensor bridge unit top cover interlock 4 15 top cover assembly 4 7 transport belts 4 12 bridge unit top cover assembly parts catalog 7 3 buffer diverter gate 4 92 buffer diverter gate solenoid 4 103 buffer pinch guide assembly 4 96 buffer roll assembly 4 94 C cables locations 5 7 parts catalog 7 28 7 30 7 31 carriage lift belt left 4 30 carriage lift belt right 4 32 clamp paddle 4 76 compiler unit parts catalog 7 18 covers bridge unit rear cover 4 6 bridge unit top cover 4 7 bridge unit top cover assembly 7 3 finisher 7 6 finisher front door assembly 4 27 left lower cover 4 28 left upper cover 4 29 parts catalog 7 8 rear lower cover 4 23 rear upper cover 4 24 40
164. ge assembly See Punch carriage assembly removal on page 4 41 Disconnect the connector from the sensor buffer path A Remove the screw securing the bracket B to the finisher SNe dl ai a D A 9 Remove the bracket B 10 Release the hooks securing the sensor buffer path A to the bracket B 11 Remove the sensor buffer path A Repair information 4 93 4024 110 Buffer roll assembly removal Remove the rear upper cover See Rear upper cover removal on page 4 24 Open the finisher front door assembly Remove the stapler unit cartridge Move the stapler unit assembly by hand as far to the rear as it will go Lower the buffer pinch guide assembly A Move the lower pinch guide assembly to the right Position the buffer diverter gate B using your finger to its upper most position OS See 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 diverter gate removal on page 4 91 4 94 Finisher Service Manual 4024 110 11 Loosen the two screws securing the belt tensioner bracket E to the finisher and move it downward as shown 12 Remove the belt buffer transport E from the buffer roll drive gear 46T G First 13 Use a prying tool to remove the e clip securing the buffer roll drive gear 23 53T G 14 Remove
165. ge 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 by hand 3 Is the sensor stapler carriage HP connected Replace the Replace the properly sensor stapler connection carriage HP Go to Sensor stapler carriage HP removal on page 4 58 4 Check the stapler carriage motor assembly by opening Go to step 6 Go to step 5 the finisher front door assembly then pushing the stapler carriage towards the back Then closing the finisher front door assembly the stapler carriage should move Does the stapler carriage motor assembly rotate normally 5 Is the stapler carriage motor assembly connected Replace the Replace the properly stapler carriage connection motor assembly 2 86 Finisher Service Manual 4024 110 Step Check Yes No Perform a test print stapled document Does the error still occur Replace the printer engine card assembly Refer to the Problem solved Printer Service Manual 995 00 Finisher NVRAM R W failure Step Check Yes No 1 Turn the finisher off and on several times Go to step 2 Problem solved Does the error still occur when the power is on 2 Checking the finisher controller card assembly for Replace the Problem connection finisher controller resolved Are the connections of the finisher controller card oe s
166. ge interface Does the error still occur card assembly Go to Bridge unit interface card assembly removal on page 4 117 Go to step 5 5 Perform a test print Replace the Problem solved i finisher controller Does the error still occur2 card assembly Go to Finisher controller card assembly removal on page 4 118 Punch waste box full Step Check Yes No 1 Check the sensor punch waste box full for correct Go to step 2 Reinstall the installation sensor punch i waste box full Is the sensor installed properly Go to Sensor punch waste box full removal on page 4 53 2 Check the sensor punch waste box full Go to step 4 Go to step 3 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 sensor punch waste box Does the display on the operator panel change every time the sensing area of the sensor punch waste box full is blocked 3 Perform a test print Replace the Replace the sensor punch connection Does the error still occur waste box full Go to Sensor punch waste box full removal on page 4 53 Diagnostic information 2 93 4024 110 Step Check Yes No Perform a test print Does the error still occur Replace the
167. ge unit assembly removal on page 4 2 Place the bridge unit assembly upside down Remove the screw securing the bracket A to the bridge unit assembly B Disconnect the connector from the sensor bridge unit media entrance C RODE Connector 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 4 16 Finisher Service Manual 4024 110 Sensor bridge unit media exit removal 1 Remove the bridge unit assembly See Bridge unit assembly 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 Repair information 4 17 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 4 18 Finisher Service Manual 4024 110 Top cover removal Open the finisher front door assembly Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the upper media bin assembly See Upper media bin assembly removal on p
168. ge unit left shaft assembly 14 40X0816 1 1 Bridge unit drive pulley 15 40X0815 1 1 Bridge unit drive belt Parts catalog 7 5 4024 110 Assembly 4 Covers 7 6 Finisher Service Manual Assembly 4 Covers 4024 110 Asm Part Units Units Description Index number option FRU 4 1 40X0829 1 1 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 Parts catalog 7 7 4024 110 Assembly 5 Covers and front door 7 8 Finisher Service Manual Assembly 5 Covers and front door 4024 110 Asm Part Units Units Description Index number option FRU 5 1 40X0839 1 1 Upper media bin front cover 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 e Finisher docking latch assembly e Spring 5 40X0843 1 3 Finisher docking bracket kit includes e Finisher docking bracket e Screw 2 each 40X0844 1 1 Left lower cover 7 40X0845 1 1 Left upper cover Parts catalog 7 9 4024 110 Assembly 6 Stac
169. gine reported a finisher failure that the RIP card assembly did not recognize Go to 999 00 Finisher engine RIP functional failure on page 2 88 Close cover F Bridge unit top cover is open Bridge unit top cover is open Go to Bridge unit top cover open on page 2 88 Close door G Finisher front door open The finisher front cover is open Go to Finisher front door open on page 2 90 Close surface H Eject cover is open The finisher eject cover is open Go to Finisher eject cover open on page 2 91 Empty hole punch box Punch waste box full The punch waste box is filled Go to Punch waste box full on page 2 93 Insert hole punch box Punch waste box missing No punch waste box Go to No punch waste box on page 2 92 Load staples Staple cartridge empty Go to Staple cartridge empty on page 2 99 Diagnostic information 2 9 4024 110 Remove paper from Bin 1 Finisher upper media bin full The upper media bin has reached maximum capacity Go to Finisher upper media bin full on page 2 91 Remove paper from bin 2 Stacker set over count When the stapled media 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 s
170. h is operated 2 Check the sensor buffer path connection Replace the Replace the Is the above sensor connected properly coe connection Sensor buffer path removal on page 4 93 3 Check the drive motor buffer transport for correct Go to step 5 Go to step 4 operation Check the above motor by opening the finisher front door assembly and then closing it Does the drive motor buffer transport rotate normally 4 Check the drive motor buffer transport connection Replace the drive Replace the motor buffer connection Is the above motor connect properly transport Go to Drive motor buffer transport and belt buffer transport removal on page 4 115 5 Perform a test print Replace the Problem solved Does the error still occur eg Go to Finisher controller card assembly removal on page 4 118 2 30 Finisher Service Manual 284 00 Sensor lower media exit off jam A 4024 110 Step Check Yes No 1 Check the media path Go to step 2 Clean or replace Open the finisher front door assembly of the finisher Si GE Check lower media exit roll assembly by turning it with and clean the WW your fingers media path Is the lower media exit roll assembly installed correctly 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
171. he Are the connections of the compiler unit cable fencers A connection assembly correctly connected to Media y compiler unit assembly removal on page 4 69 6 Perform a test print Replace the Problem solved Does the error still occur SE Go to Finisher controller card assembly removal on page 4 118 982 01 Sensor front tamper HP off failure Step Check Yes No 1 Check the tamper mechanism by moving it with your Go to step 2 Replace the fingers Does the tamper mechanism operate smoothly media compiler unit assembly Go to Media compiler unit assembly removal on page 4 69 Diagnostic information 2 69 4024 110 Step Check Yes No 2 Check the sensor front tamper HP for correct Go to step 4 Go to step 3 operation Perform the sensor front tamper HP test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media path2 5 Select Front tamper HP Does the display on the operator panel change every time the sensing area of the sensor front tamper HP is blocked 3 Is the sensor front tamper HP connected properly Replace the Replace the sensor front connection tamper HP Go to Sensor front tamper HP and sensor rear tamper HP removals on page 4 72 4 Check the front tamper drive motor by opening the Go to step 6 Go to step 5 finisher front door assembly and then closing it
172. he sensor punch unit HP is blocked 3 Is the sensor punch unit HP and punch sensor cable Replace the Replace the assembly connected properly sensor punch connection unit HP Go to Sensor punch hole select sensor punch cam front and sensor punch unit HP removal on page 4 49 4 Check the punch unit motor for correct operation Go to step 6 Go to step 5 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 rotate normally and punch holes in the media 5 Is the punch unit motor and punch drive cable Replace the Replace the assembly connected properly punch unit motor connection Go to Punch unit motor assembly removal on page 4 47 6 Perform a test print Replace the Problem solved Does the error still occur finisher controller card assembly Go to Finisher controller card assembly removal on page 4 118 Diagnostic information 2 73 4024 110 984 01 Sensor punch unit HP off failure Step Check Yes No 1 Check the punch unit by moving it with your fingers Go to step 2 Remove Does the punch unit move smoothly ROS ones 2 Check the sensor punch unit HP for correct operation Go to step 4 Go to step 3 Perform the sensor punch unit HP test Remove the rear
173. he waste box is properly set When the punch waste box is properly set the actuator of the box blocks the light transmission of the sensor which turns the sensor to H 5 V dc e Sensor punch waste box full A photo interrupter to detect the punch waste box is filled with punch waste Sensor punch carriage shift HP Punch carriage shift motor Sensor punch cam front Sensor punch hole select KN Si Sensor punch unit side registration 2 Sensor punch unit side registration 1 Sensor punch unit HP motor encoder Compiler unit assembly This section describes the operation of the compiler unit assembly that aligns the media edge transferred from the punch unit Outline of operation When media is fed onto the compiler unit assembly tamping operation is performed 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 staple position between sets of media Rear tamper Front tamper Sensor rear tamper HP Rear tamper motor Sensor compiler Sensor front tamper HP media in Front tamper motor Diagnostic aids 3 15 4024 110 Capacity of compile
174. hin the specified period after the stacker bin starts rising Go to 981 00 Stacker bin failure on page 2 63 981 01 Service finisher error Stacker bin upper limit failure The stacker bin abnormally rises beyond the specified upper limit position stacker bin level Go to 981 01 Stacker bin upper limit failure on page 2 65 981 02 Service finisher error Stacker bin lower limit failure The stacker bin abnormally lowers beyond the specified lower limit position full stack Go to 981 02 Stacker bin lower limit failure on page 2 66 982 00 Service finisher error Sensor front tamper HP 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 the sensor front tamper HP is turned on again after the sensor front tamper HP is turned off and the front tamper stopped its moving Go to 982 01 Sensor front tamper HP off failure on page 2 69 983 00 Service finisher error Sensor rear tamper HP on failure The sensor rear tamper HP is not turned on after the rear tamper starts moving to the rear tamper
175. in Level SNR2 Clock J 19 2 k Stacker Bin Level SNR1 L 5VDC 4 Buffer Diverter o ge 48VDC Jl rees La J3 Stacker Bin Level 1 Solenoid ss Stacker Bin Level SNR2 L 5VDC 8 F Stacker Bin Level SNR1 Clock oleno SS S 2 o a gt 17 4 S 2 8 f3 e Buffer div solenoid pull L 24VDC 436 On CAIS SIG GND Stacker Bin Level SNR2 Clock HA S P Sensor 215 svoc 114815 sic GND ia J 7 CN Buffer div solenoid push L 24VDG 2435 273 Al o i j i N Stacker Bin Level 2 Sensor SL Buffer Path SNR L 5VDC_ Eject Clamp UP L 5VDC E Sensor Media Eject Eject Clamp 1 lt EE Ste SC 34 e S Buffer Path SIG GND 5VDC Clamp HP Motor 12 he ject Cramp Motor H 433 5 Le o D L upe 13 8 Fa GND Lb weg Transport Gate Solenoid pull L 24VDC Jas E 12 9 SEN co E d Eject Clamp Motor CW ON H 24VDC Sensor Upper SN Upper Media Bin Full SNR L 5VDC 14 101 Media Eject SNR L 45VDC Be Sensor Media Eject H 1 lt Media Di a ee ae ms 31 SERENE Media Bin Full Old Z sp nD laang d Shaft HP edia Diverter SE EE SS Els am HOH Psie ano SS Solenoid 3 le Media div solenoid pull L 24VDC Heger E do all oe s U RSE 8131 h Stacker Bin Level Encode SNR L 5VDC lt n Sensor Stacker Bin Level Encoder Sub Paddle ES 2 lei 24VDC lt 4 28 Ee 5 S 5 5 a 3 ensor Upper _ Ki SIG GND T4 p 5VDC sa Solenoid dee EE Media div solenoid push L 24VDC A 27 5 5595 2 T 1 lt Sub Paddle Solenoid ON L 24VDC Media Exit al 5VDC
176. in paddles 3 Inspect Clean with water or alcohol Sub paddles 2 Inspect Clean with water or alcohol Clamp paddles 3 Inspect Clean with water or alcohol Punch waste box Clean Clean Stapler cartridge Inspect for correct operation Inspect for correct operation Preventive maintenance 6 1 4024 110 6 2 Finisher Service Manual 7 Parts catalog How to use this parts catalog 4024 110 This parts catalog lists information for the finisher only Refer to the Printer Service Manual for the base unit information The following legend is used in the parts catalog Asm Index Part number Units option Units FRU Description e Asm index Identifies the assembly and the item in the diagram For example 3 1 indicates Assembly 3 and item number 1 in the table e Part number Identifies the unique number that identifies this FRU e Units option Refers to the number of units in a particular option It does not include the rest of the base machine e Units FRU Refers to the number of units packaged together and identified by the part number e NS Not shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration e PP Parts Packet in the parts description column indicates the part is contained in a parts packet Parts catalog 7 1 4024 110 Assembly 1 Bridge unit Asm Part
177. inch guide assembly A 4 90 Finisher Service Manual 4024 110 Media diverter gate removal Open the finisher front door assembly Remove the rear upper cover See Rear upper cover removal on page 4 24 Open the lower pinch guide assembly A to the right Open the upper pinch guide assembly B to the right Remove the media diverter gate solenoid See Media diverter gate removal on page 4 91 Remove the link C Move the media diverter gate D toward the rear to the right and forward as shown e TEON 8 Remove the media diverter gate Repair information 4 91 4024 110 Buffer diverter gate removal Open the finisher front door assembly Move the lower pinch guide assembly A to the right Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the buffer diverter gate solenoid See Media diverter gate solenoid removal on page 4 102 Remove the link D akan ch 7 Remove the buffer diverter gate C 4 92 Finisher Service Manual 4024 110 Sensor buffer path removal Open the finisher front door assembly Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the top cover See Top cover removal on page 4 19 Remove the left lower cover See Left lower cover removal on page 4 28 Remove the left upper cover See Left upper cover removal on page 4 29 Remove the punch carria
178. inserted into the hole on the finisher docking latch assembly C The finisher should be firmly locked into position jz 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 cover A 4 6 Finisher Service Manual 4024 110 Bridge unit top cover assembly removal 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 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 Repair information 4 7 4024 110 Bridge unit drive belt and bridge unit drive pulley removal 1 Remove the bridge unit rear cover See Bridge unit rear cover removal on page 4 6 2 Remove 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 Recessed key Install this surf
179. ion of media to the upper media bin is inhibited until full stack is reset Functions of upper media bin sensors e Sensor upper media exit Aphoto 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 the sensor to H 5 V dc e Sensor upper media bin full A reflective photo sensor to detect the media stack volume in the upper media bin Itturns H 5 V dc when it detects full stack Diagnostic aids 3 25 4024 110 Stacker media bin The stacker media bin goes up and down to an appropriate position according to the volume of media fed from the compiler unit assembly so as to properly stack media to full stack Operation The stacker media bin moves to an appropriate position according to the volume of media fed from the compiler unit assembly The sensor stacker bin level 1 and the sensor stacker bin level 2 detect the height of media in the stacker media bin and the sensor stacker bin level encoder determines the volume of media in the tray When media or the stacker media bin comes between the light emitter and the photo receiver of the sensor stacker bin level 1 and sensor stacker bin level 2 the emitted light is blocked and the sensors turn H The height of media or the stacker media bin is detecte
180. ive motor buffer transport connection Replace the drive Replace the Is the above motor connected properly ele to S IER Drive motor buffer transport and belt buffer transport removal on page 4 115 9 Check the sensor diverter gate for correct operation Go to step 11 Go to step 10 Perform the sensor diverter gate test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path2 5 Select Diverter gate Open the finisher front door 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 10 Check the sensor diverter gate for connection Replace the Replace the sensor diverter connection Is the above sensor connected properly gate Go to Sensor 11 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 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 lowe
181. iverter gate when the Paper jam Static jam to stacker finisher is in the stacker bin exit mode Check area F bin A At this time the sensor bridge unit media exit is turned on Go to 288 04 Sensor diverter gate static jam to stacker bin A on page 2 60 288 05 Paper jam Check areas G2 G3 Sensor diverter gate Static jam to stacker bin B Paper remains on the sensor diverter gate when the finisher is in the stacker 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 05 Sensor diverter gate static jam to stacker bin B on page 2 61 2 6 Finisher Service Manual 4024 110 288 06 Sensor diverter gate Paper remains on the sensor diverter gate when the gt Static jam to stacker finisher is in the stacker bin exit mode Paper jam bin C ah D Check area G2 At this time both sensor finisher media entrance and sensor bridge unit media exit are turned off Go to 288 06 Sensor diverter gate static jam to stacker bin C on page 2 62 980 02 Finisher communication A communication error occurred between the printer Service finisher comm failure engine card assembly and the finisher Go to 980 02 Finisher communication failure on page 2 63 981 00 Service finisher error Stacker bin failure The sensor stacker bin level is not turned on wit
182. ize 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 media size Go to Stacker media bin full mix size on page 2 94 2 10 Finisher Service Manual Service checks 280 00 Sensor bridge unit media entrance on Jam 4024 110 Step Check Yes No 1 Check the media path Go to step 2 Clean or replace I I z the transport Open the bridge unit top cover assembly of the bridge belts and bridge unit assembly unit pinch rolls Check the two transport belts and the six bridge unit and clean the pinch rolls attached on the bridge unit top cover media path assembly by turning them with your fingers Are the transport belts and the bridge unit pinch rolls installed correctly 2 Are the two transport belts and the six bridge unit pinch Go to step 3 Clean or replace rolls free of damage the transport belts and bridge unit pinch roll and clean the media path 3 Check the sensor bridge unit media entrance for Go to step 5 Go to step 4 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 operator panel change every time the actuator of th
183. jam C specified time after the sensor finisher media per entrance is turned on Check area G1 At this time the sensor bridge unit media exit is turned on Go to 287 03 Sensor upper media exit on jam C on page 2 49 287 04 Sensor upper media Sensor upper media exit is not turned off within the I exit off jam B specified time after the sensor upper media exit is Paper jam turned on Check area G At this time the sensor bridge unit media exit is turned off Go to 287 04 Sensor upper media exit off jam B on page 2 50 Diagnostic information 2 5 4024 110 287 05 Paper jam Check area F Sensor upper media exit Static jam A Paper remains on the sensor upper media exit At this time the sensor bridge unit media exit is turned on Go to 287 05 Sensor upper media exit static jam A on page 2 51 287 06 Paper jam Check areas G1 G3 Sensor upper media exit Static jam B Paper remains on the sensor upper media exit At this time the sensor bridge unit media exit is off state but the finisher sensor finisher media entrance is turned on Go to 287 06 Sensor upper media exit static jam B on page 2 52 287 07 Sensor upper media Paper remains on the sensor upper media exit Paper jam exit Static jam At this time both sensor bridge unit media exit and Check area G1 sensor finisher media entrance are turned off Go to 287 07 Se
184. ker bin lift 7 10 Finisher Service Manual Assembly 6 Stacker bin lift 4024 110 Asm Part Units Units SA Index number option FRU Description 6 1 40X0846 2 6 Carriage lift belt kit includes e Carriage lift belt e Belt clamp 2 each e Spring e Roll 2 each 2 40X0847 2 1 Sensor stacker bin level 3 40X0849 1 7 Stacker slip clutch pulley kit includes e Pulley 18T 3 each e Slip clutch pulley 18T e Slip clutch gear 24T e Spring e 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 e Bracket with sensor e Encoder e Stacker bin lift motor Note Assembly index items 4 5 and 6 are identical sensors with different functions therefore they are the same part number with different descriptions Parts catalog 7 11 4024 110 Assembly 7 Punch 7 12 Finisher Service Manual Assembly 7 Punch 4024 110 Asm Part Units Units Description Index number option FRU 7 1 40X0854 1 1 Punch carriage shift motor assembly 2 40X0855 1 1 Punch carriage assembly 3 40X0856 1 1 Sensor punch unit side reg assembly e Sensor punch unit side reg1 e Sensor punch unit side reg2 e Bracket 4 40X0857 1 1
185. l 4024 110 Step Check Yes No 5 Is the sensor stacker bin level 2 connected properly Replace the Replace the sensor stacker connection bin level 2 Go to Sensor stacker bin level 2 removal on page 4 34 6 Check the encoder of the sensor stacker bin level Go to step 7 After reinstalling encoder installation go to step 7 Is the encoder installed correctly Does it enter the detection point of the sensor stacker bin level encoder 7 Check the sensor stacker bin level encoder for correct Go to step 9 Go to step 8 operation Perform the sensor stacker bin level encoder test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Bin Level 5 Select Stacker level encod Does the operator panel display change when the belt of the stacker bin lift motor assembly is moved by hand 8 Is the sensor stacker bin level encoder connected Replace the Replace the properly sensor stacker connection bin level encoder Go to Sensor stacker bin level encoder removal on page 4 35 9 Check the stacker bin lift motor assembly by blocking Replace the Go to step 10 the lower hole in either of the sensor stacker bin level finisher controller The stacker bin should lower slightly card assembly SE Go to Finisher G a bin lift motor assembly rotate controller card y assembly removal on page 4 118 10 Is the stacker bin lift motor assembly conne
186. l change every time the actuator of the sensor buffer path is operated 8 Check the sensor buffer path connection Replace the After Is the above sensor connect properly fo oe 90 Sensor buffer path removal on page 4 93 9 Check the drive motor buffer transport by opening the Go to step 11 Go to step 10 2 24 Finisher Service Manual 4024 110 Step Check Yes No 10 Check the drive motor buffer transport connection Replace the drive Problem solved ist eab t tere motor buffer s the above motor connected properly transport Go to Drive motor buffer transport and belt buffer transport removal on page 4 115 11 Perform a test print Replace the Problem solved bridge unit Does the error still occur interface card assembly Go to Bridge unit interface card assembly removal on page 4 117 Go to step 12 12 Perform a test print Replace the Problem solved finisher controller Does the error still occur card assembly Go to Finisher controller card assembly removal on page 4 118 283 01 Sensor buffer path on jam B Step Check Yes No 1 Check the media path Go to step 2 Clean or replace 1 Open the finisher front door assembly of the ee finisher the media path 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
187. m plate With the movement of the cam plate the pins descend along the guide holes to punch the media This operation 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 Sensor punch hole select Sensor punch cam front Pin Cam plate Sensor punch unit HP Home p D os position JV EN Punch unit motor
188. m 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 fragment of a sheet of white media under the sensor punch unit side reg2 Does the display on the operator panel change every time a piece of white media is placed over the sensing area of the sensor punch unit side reg2 4 Check the appropriate sensor punch unit side reg Replace the Replace the connection appropriate connection sensor punch Is the above sensor connected properly unit side reg Go to Sensor punch unit side registration pair with bracket removal on page 4 44 5 Open the finisher front door assembly Go to step 7 Go to step 6 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 carriage shift motor assembly rotate and does the punch shift carriage move back and forth 6 Is the punch carriage shift motor assembly connected Replace the Replace the properly punch carriage connection shift motor assembly Go to Punch carriage shift motor assembly removal on page 4 43 7 Perform a test print Replace the Problem solved Does the error still occur printer engine card assembly Refer to the Printer Service Manual
189. mbly 4 97 media entrance roll assembly 4 99 models 1 1 P paddle and roll exit assembly 4 86 parts catalog bridge unit 7 2 bridge unit lower assembly 7 4 bridge unit top cover assembly 7 3 buffer 7 22 7 24 cables 7 28 7 30 7 31 covers 7 6 covers and front door 7 8 eject and compiler unit 7 18 electronics 7 26 entrance drive 7 22 lower exit drive 7 20 media eject 7 16 punch 7 12 stacker bin lift 7 10 stapler 7 14 transport 7 24 upper drive 7 24 punch unit parts catalog 7 12 punch carriage assembly 4 41 punch carriage shift motor assembly 4 43 punch media stop assembly 4 46 punch unit assembly 4 45 punch unit motor assembly 4 47 R rear upper cover 4 24 removals belt buffer transport 4 115 belt entrance paddle 4 100 belt exit 4 113 bridge unit assembly 4 2 4024 110 bridge unit drive belt 4 8 bridge unit drive motor assembly 4 13 bridge unit drive pulley 4 8 bridge unit entrance guide 4 14 bridge unit idler rolls 4 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 76 drive motor buffer transport 4 115 drive motor entrance paddle 4 100 drive mo
190. mbly E Be e cone cuan correctly connected Drive motor entrance paddle and belt entrance paddle removal on page 4 100 5 Perform a test print Replace the Problem solved I finisher controller Does the error still occur2 card assembly Go to Finisher controller card assembly removal on page 4 118 2 62 Finisher Service Manual 980 02 Finisher communication failure 4024 110 Step Check Yes No 1 Check the printer and finisher installation Go to step 2 Remove the we I finisher Go to Is the finisher installed to the printer correctly Finisher removal on page 4 4 2 Turn the power on and off Go to step 3 Problem solved Does the error still occur when the power is on 3 Check the finisher controller card assembly Replace the Replace the connection finisher controller connection Are the connections of the finisher controller card E assembly correctly connected controller card assembly removal on page 4 118 Go to step 4 4 Perform a test print Replace the Problem solved printer engine Does the problem remain card assembly Refer to the Printer Service Manual 981 00 Stacker bin failure Step Check Yes No 1 Check the vertical transport mechanism of the stacker Remove Go to step 2 bin for obstacles and deformation obstacles Are the any obstacles in the vertical transport mechanism of the stacker bin 2 Is there any deformation in the
191. 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 Repair information 4 67 4024 110 Switch eject cover interlock removal Remove the upper media bin assembly See Upper media bin assembly removal on page 4 20 Disconnect the connector from the switch eject cover interlock A Release the harness from the two clamps Remove the screw securing the bracket B to the finisher Remove the bracket B from the square hole in the finisher Remove the two screws securing the switch eject cover interlock A from the bracket B oe ml Connector Clamps 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 binding A Xa 4 68 Finisher Service Manual 4024 110 Media compiler unit assembly removal b TOL OTEO N T Remove the finisher front door assembly See Finisher front door assembly removal on page 4 27 Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the rear lower cover See Rear lower cover removal on page 4 23 Remove the upper media bin assembly See Upper media bin assembly removal on page 4 20 Remove the upper media bin ver
192. moval 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 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 carriage assembly D 10 Remove the stapler carriage motor assembly C C i gt aN 6 Kas CEB LVS A i Ni E N 4 p GN E 4 56 Finisher Service Manual 4024 110 11 Remove the screw securing the stapler cover E to the stapler unit assembly F 12 Remove the stapler cover E 13 Disconnect the two connectors from the stapler unit assembly F 14 Disconnect the connector from the sensor stapler carriage HP G 15 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 Ground wire Connectors 18 Remove the stapler unit assembly F Replacement notes e When replacing the stapler unit assembly F make sure the ground wire is reconnected e Make sure the stapler ca
193. move the two screws securing the bracket B to the finisher Li a a CUA X 4 80 Finisher Service Manual 4024 110 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 Repair information 4 81 4024 110 Lower media exit roll assembly removal Remove the finisher front door assembly See Finisher front door assembly removal on page 4 27 Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the upper media bin assembly See Upper media bin assembly removal on page 4 20 Remove upper media bin vertical cover See Right eject cover removal on page 4 21 Remove the stapler unit frame See Stapler unit frame removal on page 4 54 Remove the media eject clamp motor assembly See Media eject clamp motor assembly removal on page 4 66 Remove the media eject unit assembly See Media eject unit assembly removal on page 4 59 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 removal on page 4 74 11 Remove the m
194. mper HP A or the sensor rear tamper HP B from the media compiler unit assembly C 13 Remove the sensor s Note The sensors are identical N Connector 4 72 Finisher Service Manual 4024 110 Sensor compiler media in removal zech ch Qn ch 14 ere Ae te Se Remove the finisher front door assembly See Finisher front door assembly removal on page 4 27 Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the rear lower cover See Rear lower cover removal on page 4 23 Remove the upper media bin assembly See Upper media bin assembly removal on page 4 20 Remove the upper media bin vertical cover See Right eject cover removal on page 4 21 Remove the stapler unit frame See Stapler unit frame removal on page 4 54 Remove the media eject clamp motor assembly See Media eject clamp motor assembly removal on page 4 66 Remove the media eject unit assembly See Media eject unit assembly removal on page 4 59 Remove the media eject motor assembly See Media eject motor assembly removal on page 4 78 Remove the media compiler unit assembly See Media compiler unit assembly removal on page 4 69 Disconnect the connector from the sensor compiler media in A Release the hooks securing the sensor compiler media in A to the compiler unit assembly B Move the compiler media present actuator C downward as shown
195. n At this time the sensor bridge unit media exit is turned on Go to 284 01 Sensor lower media exit on jam A on page 2 32 284 02 Paper jam Check areas Q2 G3 Sensor lower media exit on jam B Sensor buffer path is not turned on within the specified time after the sensor bridge unit media entrance is turned on At this time the sensor finisher media entrance is turned on Go to 284 02 Sensor lower media exit on jam B on page 2 35 284 03 Paper jam Check area G2 Sensor lower media exit on jam C Finisher sensor lower media exit not turned on within the specified time after the sensor buffer path is turned on Go to 284 03 Sensor lower media exit on jam C on page 2 38 2 4 Finisher Service Manual 4024 110 284 04 Paper jam Check area H Sensor lower media exit off jam B Finisher sensor lower media exit not turned off within the specified time after the finisher sensor lower media exit on At this time the sensor finisher media entrance is turned on Go to 284 04 Sensor lower media exit off jam B on page 2 40 284 05 Paper jam Check areas H G3 Sensor lower media exit Static jam Paper remains on the sensor lower media exit Go to 284 05 Sensor lower media exit static jam on page 2 41 285 00 Paper jam Check area H Finisher eject set jam Finisher sensor compiler media in is not turne
196. nd belt entrance paddle removal on page 4 100 5 Perform a test print Replace the Problem solved finisher controller Does the error still occur card assembly Go to Finisher controller card assembly removal on page 4 118 Diagnostic information 2 61 4024 110 288 06 Sensor diverter gate static jam to stacker bin C Step Check Yes No 1 Check the sensor diverter gate for correct operation Go to step 3 Go to step 2 Perform the sensor diverter gate test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path2 5 Select Diverter gate Open the finisher front door 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 2 Is the sensor diverter gate connected properly Replace the Replace the sensor diverter connection gate Go to Sensor diverter gate removal on page 4 110 3 Check the drive motor entrance paddle by opening Go to step 5 Go to step 4 the finisher front door assembly and then closing it Does the motor entrance paddle rotate normally 4 Check the main drive cable assembly connection Replace the drive Replace the Are the connections of the main drive cable asse
197. nection 13 Perform a test print Does the error still occur Replace the finisher controller card assembly Go to Finisher controller card Problem solved assembly removal on page 4 118 284 04 Sensor lower media exit off jam B Step Check Yes No 1 Check the media path Go to step 2 Clean or replace Open the finisher front door assembly of the finisher i Gre Check lower media exit roll assembly by turning it with and clean the WW our fingers gt y media path Is the lower media exit roll assembly installed correctly 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 Go to step 5 Go to step 4 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 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 2 40 Finisher Service Manual 4024 110 Step Check Yes No 4 Check the sensor lower media exit connection Replace the
198. nisher cannot handle the exit 1 diverter gate in the printer is switched to eject the media from Exit 2 onto the bridge unit assembly Refer to the Printer Service Manual for additional information on the printer Media size orientation and applicable functions Short edge TOP Stacker Media I first SEF Hat description Size Long edge Offset first LEF Stack Stack Stack Punch Staple B5 SEF Yes No No No No JOE eamm LEF Yes Yes Yes Yesa 2 Yes Executive 7 25 x 10 5 in SEF Yes No No No No Dc a Omm LEF Yes Yes Yes Vesa 234 No Letter 8 5 x 11 in SEF Yes Yes Yes Yesa Yes SE EN LEF Yes Yes Yes Yes 234 wes A4 SEF Yes Yes Yes veel Yes del LEF Yes Yes Yes Yes23 34 Yes Folio foolscap 8 5 x 13 in SEF Yes Yes Yes Yes Yes Legal 8 5 x 14 in SEF Yes Yes Yes veel Yes B4 SEF Yes Yes Yes Yes Yes 257 x 364 mm 1 2 Finisher Service Manual 4024 110 A3 SEF Yes Yes Yes Yes amp 234 Yes 297 x 420 mm Ledger 11x 17 in SEF Yes Yes Yes Yes 234 wes Custom size Same width with Yes Yes Yes Yes Yes standard size Custom size Besides above Yes Yes Yes No No a Numters 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 General information 1 3 4024 110 Media weight
199. nit top cover assembly 44 444 4a La LL La 7 3 Assembly 3 Bridge unit lower assembIy 4 4 Lu rices nises ereti 7 4 ASSEMDIV AC COVES oc emaiiosos ss ian eaaa dores EEES DC Ge eee dr ED da sae iacaeiedegaasnea 7 6 Assembly 5 Covers and front GOOF e NEE E ririt erra Ersa pissarra tes ada dens EELER EE 7 8 Assembly 6 Stacker DIU 26 scicekiekeeiceheidaserceher dee sie eeei dee sareeteeeeke 7 10 Assembly 75 PUNCH es 2i045 00046 04946 00606005060040 907500000 genet 00460 SE NEE d 7 12 ASSOMDIY Gs Stale A EE 7 14 Assembly 9 Media eject 0 0 eee ete eee eens 7 16 Assembly 10 Eject and compiler unn 7 18 Assembly 11 Lower exit drive 0 00 cee ttt eet ees 7 20 Assembly 12 Buffer and entrance drive 7 22 Assembly 13 Buffer transport and upper drive 7 24 Assembly 14 ElGCWONICS 65 00 coit en coset eee eee ees obs dg Oe RSA Peres Meee 7 26 Assembly AS Cables EE EE EEN 7 28 ASSEMDIY 1G CAMlES 2 sincere doseececerRGeesecdieeketeis esse eiero dori resi ss nieens 7 30 Assembly 17 Cables 3 2 sis cen eceins cheed dee hese es Gar sees ee pe ake dSeseseekerares 7 31 io errr ee heer eT CI EER Li Table of contents vii 4024 110 viii Finisher Service Manual 4024 110 Notices and safety information Laser notice The printer is certified in the U S to conform to the requirements of DHHS 21 CFR Subchapter J for Class 1 laser p
200. nit top cover assembly of the oe bridge unit assembly and Fridge unit 2 Check the six bridge unit pinch rolls on the bridge pinch roll and unit top cover assembly and the two transport belts clean the media by turning them with your fingers path Are the bridge unit pinch rolls and transport belts installed correctly 2 Are the six bridge unit pinch rolls on the bridge unit top Go to step 3 Clean or replace cover assembly and two transport belts free of the appropriate damage transport belts and bridge unit pinch roll and clean the media path 3 Check the media path Go to step 4 Clean or replace 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 to upward 4 Check the media entrance pinch guide pinch roll on the entrance pinch guide assembly and media entrance roll assembly by turning them with your fingers Are the media entrance pinch guide pinch roll and media entrance roll assembly installed correctly the appropriate transport belts and bridge unit pinch roll and clean the media path 2 54 Finisher Service Manual 4024 110 Step Check Yes No 4 Are the media entrance pinch guide pinch roll on the Go to step 5 Clean or replace entrance pinch guide assembly and media entrance the appropriate roll assembly free of damage transport belts and bridge unit pinch roll and clean
201. nnected Replace the Replace the properly media eject connection motor assembly Go to Media eject motor assembly removal on page 4 78 6 Check the media eject clutch assembly by opening the Go to step 8 Go to step 7 finisher front door assembly and then closing it The three clamp paddles should rotate Does the media eject clutch assembly operate 7 Is the media eject clutch assembly connected Replace the Replace the properly media eject connection clutch assembly Go to Media eject clutch removal on page 4 77 8 Perform a test print Replace the Problem solved Does the error still occur finisher controller card assembly Go to Finisher controller card assembly removal on page 4 118 Diagnostic information 2 81 4024 110 988 00 Sensor punch unit side reg on failure Note This procedure pertains to sensor punch unit reg1 and reg2 Step Check Yes No 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 Check the sensor punch unit side reg1 for correct operation Perform the sensor punch unit side reg1 test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Punch and Staple 5 Select Punch side reg1 Open the finisher front door Insert a fragment of a sheet of white media under the sensor punch unit side
202. nsor buffer path on jam A eee eee eee 2 23 283 01 Sensor buffer path on jam B nee KEREN KEIER KEES KLEER cane ee are de KEES ra dua 2 25 283 02 Sensor buffer path static jam A 2 28 283 03 Sensor buffer path static jam BR eee eee 2 29 283 04 Sensor buffer path static jam C A 2 30 284 00 Sensor lower media exit off jam A 2 31 284 01 Sensor lower media exit on jam A eens 2 32 284 02 Sensor lower media exit on jam BR 2 35 284 03 Sensor lower media exit on jam C A 2 38 284 04 Sensor lower media exit off jam B 2 1 cece eee eee 2 40 284 05 Sensor lower media exit Static jam cee 2 41 285 00 Finisher ject SET AN 8 pb a ma EE a PE ES DD P RE eee El El bok dd EE 2 42 286 00 Sensor compiler media in static jam ccc eee 2 43 287 00 Sensor upper media exit on jam A eee eee 2 45 287 01 Sensor upper media exit Off jam A 2 46 287 02 Sensor upper media exit on jam B eee 2 47 287 03 Sensor upper media exit on jam eee eee 2 49 287 04 Sensor upper media exit Off jam B ce eee 2 50 287 05 Sensor upper media exit static jam A 2 51 287 06 Sensor upper media exit static jam B 2 52 287 07 Sensor upper media exit static jam C A 2 53 288 00 Sensor diverter gate on jam E eee 2 54 288 01 Sensor diverter gate static jam to top bin A 2 57 Table of cont
203. nsor upper media exit static jam C on page 2 53 288 00 Sensor diverter gate Sensor diverter gate is not turned on within the P I on jam specified time after the sensor bridge unit media exit aper jam is turned on Check area F Go to 288 00 Sensor diverter gate on jam on page 2 54 288 01 Paper jam Check area F Sensor diverter gate Static jam to top bin A Paper remains on the sensor diverter gate when the finisher is in the upper bin exit mode At this time the sensor 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 02 Sensor diverter gate static jam to top bin B on page 2 58 288 03 Sensor diverter gate Paper remains on the sensor diverter gate when the P Static jam to top bin C finisher is in the upper bin exit mode aper jam At this time both sensor finisher media entrance and Check area G1 sensor bridge unit media exit are turned off Go to 288 03 Sensor diverter gate static jam to top bin C on page 2 59 288 04 Sensor diverter gate Paper remains on the sensor d
204. nsor Test 4 Select Media Path 2 5 Select Eject clamp HP Rotate the eject gears manually by hand Does the display on the operator panel change every time the sensing area of the sensor media eject clamp HP is blocked 2 78 Finisher Service Manual 4024 110 Step Check Yes No 3 Is the sensor media eject clamp HP connected Replace the Replace the properly sensor media connection eject clamp HP Go to Sensor media eject clamp HP removal on page 4 67 4 Check the media eject clamp by opening the finisher Go to step 6 Go to step 5 front door assembly and then closing it Does the eject clamp motor rotate normally 5 Is the media eject clamp motor connected properly Replace the Replace the media eject connection clamp motor Go to Media eject clamp motor assembly removal on page 4 66 6 Perform a test print Replace the Problem solved finisher controller Does the error still occur card assembly Go to Finisher controller card assembly removal on page 4 118 987 00 Sensor media eject shaft HP on failure Step Check Yes No 1 Check the media eject shaft assembly by moving it with Go to step 2 Remove your fingers obstructions Does the media eject shaft assembly mechanism move smoothly 2 Check the sensor media eject shaft HP for correct Go to step 4 Go to step 3 operation Perform the sensor media eject shaft HP te
205. nterlock Go to correctly Switch finisher front door interlock removal on page 4 26 3 Check the switch finisher front door interlock for Go to step 5 Go to step 4 correct operation Perform the switch finisher front door interlock 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 4 Is the switch finisher front door interlock connected Replace the Replace the properly switch finisher connection front door interlock Go to Switch finisher front door interlock removal on page 4 26 5 Does the error still occur when the power is turned off Go to step 6 Problem solved and back on 6 Replace the finisher controller card assembly Go to Replace the Problem solved Finisher controller card assembly removal on printer engine page 4 118 card assembly Refer to the Does the error still occur when the power is turned off Printer Service and back on Manual 2 90 Finisher Service Manual Finisher eject cover open 4024 110 Step Check Yes No 1 Check the switch eject cover interlock installation Go to step 2 Reinstall the Is the switch eject cover interlock installed correctly switch media J y eject co
206. ntil the test is completed Sensor Test finisher This test can be used to verify whether or not the finisher sensors are working correctly To run the finisher Sensor Test 1 Select FINISHER TESTS from DIAGNOSTICS 2 Select Sensor Test from FINISHER TESTS 3 Select one of the test categories e Cover and Door e Bin Level e Media Path1 e Media Path2 e Punch and Staple 3 2 Finisher Service Manual 4024 110 4 Select the actual test to perform Each of the tests categories includes the individual sensors that can be manually actuated and the display shows Open or Closed e Cover and Door Cover F bridge top Door G fin front Surface H fin eject e Bin Level Fin upper bin full Stacker bin level1 Stacker bin level2 Stacker bin upper limit Stacker bin no media Stacker bin level encod e Media Path1 Fuser exit Bridge media ent Bridge media exit Fin media ent Buffer path Upper media exit Lower media exit Compiler media in e Media Path2 Diverter gate Front tamper hp Rear tamper hp Eject clamp hp Media eject shaft hp e 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 Punch hole select Press Back or Stop GB to exit the test EXIT DIAGNOSTICS This selection exits Diagnostics mode and Resetting the Printer displays The printer performs a POR and the printer returns to normal mode
207. o step 2 Clean or replace i Set the finisher front door assembly of the a loc Snel I media path 2 Open the lovver pinch guide assembly to the right 3 Open the buffer pinch guide assembly downward 4 Check the buffer roll assembly by turning the rolls with your fingers Is the buffer roll assembly installed correctly 2 Is the buffer roll assembly free of damage Go to step 3 Clean or replace the appropriate roll and clean the media path 3 Are the buffer pinch guide pinch rolls attached to the Go to step 4 Clean or replace buffer pinch guide assembly correctly the appropriate roller and clean the media path 4 Are the buffer pinch 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 Go to step 7 Go to step 6 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 media into the buffer path and around the buffer roll assembly in a clockwise direction Does the display on the operator panel change every time the actuator of the sensor buffer path is operated 6 Check the sensor buffer path connection Replace the Replace the Is the above sensor connected properly coe connecNon Sensor buffer path removal
208. o to step 3 Clean or replace free of damage the transport belts and bridge unit pinch roll and clean the media path 3 Check the sensor bridge unit media exit for correct Go to step 5 Go to step 4 operation Perform the 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 4 Check the sensor bridge unit media exit connection Replace the Replace the sensor bridge connection Is the above sensor connected properly unit media exit Go to Sensor bridge unit media exit removal on page 4 17 5 Check the bridge unit drive motor by opening the Go to step 7 Go to step 6 finisher front door assembly and then closing it Open the bridge unit top cover assembly Does the bridge unit drive motor rotate normally 6 Check the bridge unit drive motor connection Replace the Replace the bridge unit drive connection Is the above motor properly connected tee Go to Bridge unit drive motor assembly removal on page 4 13 2 16 Finisher Service Manual 4024 110 Step Check Yes No Perform a test print Does the error still occur Replace the bridge unit interface card assembly Go to Bridge unit interface card assembly
209. occur card assembly Go to Finisher controller card assembly removal on page 4 118 281 00 Sensor bridge unit media exit On Jam A Step Check Yes No 1 Check the media path Go to step 2 Clean or replace 1 Open the bridge unit top cover assembly of the Boe Te bridge unit assembly unit pinch rolls 2 Check the transport belts and the six bridge unit and clean the pinch rolls attached on the bridge unit top cover media path assembly by turning them with your fingers Are the transport belts and the bridge unit pinch rolls installed correctly 2 Are two transport belts and the six bridge unit pinch roll Go to step 3 Clean or replace free of damage the transport belts and bridge unit pinch roll and clean the media path 2 14 Finisher Service Manual 4024 110 Step Check Yes No 3 Check the sensor bridge unit media exit for correct Go to step 5 Go to step 4 operation Perform the 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 4 Check the sensor bridge unit media exit connection Replace the Replace the Is the above sensor connected properly Arad oh connection Go to Sensor bridge unit medi
210. of the sensor stacker bin level 1 is blocked by a multi page document 4 Is the sensor stacker bin level 1 connected properly Replace the Replace the sensor stacker connection bin level 1 Go to Sensor stacker bin level 1 removal on page 4 34 5 Check the sensor stacker bin level 2 for correct Go to step 7 Go to step 6 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 document 6 Check the sensor stacker bin level 2 connection Replace the Replace the Are the connections of the main sensor cable assembly ain ively Cate connection correctly connected Sensor stacker bin level 2 removal on page 4 34 7 Check the stacker bin lift motor assembly by blocking Go to step 9 Go to step 8 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 8 Is the stacker bin lift motor assembly connected Replace the Replace the properly stacker bin lift connection motor assembly Go to Stacker bin lift motor assembly removal on page 4 38 2 98 Finisher Service Manual 4024 110 Step Check Yes No Perf
211. on page 4 93 7 Check the drive motor buffer transport by opening the Go to step 9 Go to step 8 finisher front door assembly and then closing it Does the drive motor buffer transport rotate normally 2 32 Finisher Service Manual 4024 110 Step Check Yes No 8 Check the drive motor buffer transport connection Replace the drive Replace the Is the above motor connected properly eeh to connection Drive motor buffer transport and belt buffer transport removal on page 4 115 9 Check the sensor diverter gate for correct operation Go to step 11 Go to step 10 Perform the sensor diverter gate test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path2 5 Select Diverter gate Open the finisher front door 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 10 Check the sensor diverter gate for connection Replace the Replace the sensor diverter connection Is the above sensor connected properly gate Go to Sensor diverter gate removal on page 4 110 11 Check the sensor lower media exit for correct operation Perform the sensor lower media exit test 1 Enter Diagnostics mode 2 Selec
212. or Tests 4 Select Media Path2 5 Select Diverter gate Open the finisher front door 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 10 Check the sensor diverter gate for connection Replace the Replace the sensor diverter connection Is the above sensor connected properly gate Go to Sensor diverter gate removal on page 4 110 11 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 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 13 Go to step 12 Diagnostic information 2 39 4024 110 Step Check Yes No 12 Check the sensor lower media exit connection Is the above sensor connected properly Replace the sensor lower media exit Go to Sensor lower media exit removal on page 4 80 Replace the con
213. or cable assembly 7 29 Upper media bin full sensor cable assembly 7 29 Punch main drive cable assembly 7 30 Punch main sensor cable assembly 7 30 Finisher LVPS cable assembly ee ee ee eee errr eee rere 7 29 Interlock switch cable assembly eee eee e eee 7 30 Diverter gate sensor lower cable assembly ee ee rr mem emeses 7 30 Bushing 8 mm rrr eee ee er ree ee eee ee eee ee 7 17 7 19 Part number index l 9 4024 110 I 10 Finisher Service Manual 4024 Finisher Service Manual
214. orm a test print Does the error still occur Replace the finisher controller card assembly Go to Finisher controller card Problem solved assembly removal on page 4 118 Stacker set over count failure Step Check Yes No 1 Check connectors of the finisher controller card Go to step 3 After assembly connection reconnecting go Are all the connectors connected to the finisher EES controller card assembly correctly connected 2 Does the error still occur when the power is turned on Go to step 3 Problem solved 3 Replace the finisher controller card assembly Replace the Problem solved Does the error still occur when the power is turned on printer engine S i card assembly Refer to the Printer Service Manual Staple cartridge empty Step Check Yes No 1 Check the staple cartridge for new and unused staples Go to step 2 Refill the S cartridge with Does the staple cartridge have a sufficient amount of new and unused new and unused staples staples 2 Check the staple cartridge for correct installation Go to step 3 Install the staple cartridge Is the staple cartridge installed properly correctly 3 Check the staple cartridge for damage Go to step 4 Replace the Is the staple cartridge damaged staple cartridge 4 Check the sensor low staple for correct operation Go to step 6 Go to step 5 Perform the sensor low staple test 1 Enter Diagnostics mo
215. ormation 4 59 4024 110 8 Remove the screw securing 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 Screw 4 60 Finisher Service Manual 4024 110 12 Remove the e clip securing the shaft F to the front of the finisher 13 Remove the 8 mm bushing E on the front side Front 14 Gently 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 Repair information 4 61 4024 110 Replacement notes e Do not force the media eject unit assembly into the finisher Insert the right side before the left side e Make sure the media eject unit assembly properly actuates the switch eject cover interlock H without binding Actuator De 4 62 Finisher Service Manual 4024 110 Sub paddle removal 1 Remove the upper media bin assembly 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 ar
216. osition of the moving punch Itturns 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 Itturns H 5 V dc when the home position is detected Sensor punch hole select A photo interrupter to detect the rear position of the cam plate Itturns H 5 V dc when the rear position is detected This sensor also detects the Cam position to switch punch holes 2 hole 3 hole Sensor punch cam front A photo interrupter to detect the front position of the cam plate ltturns H 5 V dc when the front position is detected This sensor is used to determine to which side front or rear the cam plate should be moved Sensor punch unit motor encoder Aphoto interrupter to detect pulse generated by the encoder attached to the punch unit motor It counts punch unit motor revolutions and becomes a trigger to stop the motor by shutting off the current Punch carriage shift motor assembly A stepping motor to move the punch in the media width direction Punch unit motor ADC motor to move the cam plate that lowers the punching pins Forward rotation of the motor moves the cam plate to the front side and reverse rotation moves it to the rear side 3 14 Finisher Service Manual 4024 110 e Sensor punch waste box set A photo interrupter to detect whether t
217. otor assembly to transfer media to the stacker media bin After media is transferred to the stacker media bin it is held by the clamp paddle attached to the media eject shaft assembly From punch to upper media bin The media to be ejected to the upper media bin is switched in the media path by the media diverter gate located behind the punch and fed in the upper media transport roll assembly direction The media diverter gate is switched by the media diverter gate solenoid While the solenoid is activated media is fed in the upper media transport roll assembly direction The two upper media transport roll assembly driven by the motor buffer 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 unit media entrance A photo interrupter to detect whether media is fed from the printer to the bridge unit assembly Itturns H 5 V dc light receiving when media enters the bridge unit assembly e Sensor bridge unit media exit A photo interrupter to detect whether media passes through the bridge unit assembly Itturns H 5 V dc light receiving when media reaches thi
218. ounterclockwise rotation lowers the tray e 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 e Media eject clamp motor A DC motor to elevate or lower the media eject clamp when feeding media from the punch to the compiler unit assembly or from the compiler unit assembly to the stacker media bin e Sensor media eject clamp HP A photo interrupter to detect the set clamp home position This sensor functions as a trigger to control On Off of the set clamp clutch e Media eject clutch When this clutch is activated it transmits the media eject motor assembly rotating power to the media eject shaft assembly Sensor stacker bin level 1 Eject clamp motor Sensor media eject clamp HP Media eject motor assembly Sensor media eject shaft HP Sensor stacker bin level encoder Stacker bin lift motor assembly Sensor stacker bin no media Diagnostic aids 3 29 4024 110 Power supply and interlock The finisher is equipped with the following interlock switches Switch finisher front door interlock Turns off when the cover assembly front opens shutting off the Interlock 24 V dc line in the finisher Switch eject cover interlock Turns off when the cover ej
219. 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 electrical grounds They increase the risk of damage because they make a discharge path from your body through the ESD sensitive part Large metal objects can be discharge paths without being grounded Prevent ESD sensitive parts from being accidentally touched by other personnel Install machine covers when you are not working on the machine and do not put unprotected ESD sensitive parts on a table If possible keep all ESD sensitive parts in a grounded metal cabinet case Be extra careful in working with ESD sensitive parts when cold weather heating is used because low humidity increases static electricity Repair information 4 1 4024 110 Removal procedures CAUTION Remove the power cord from the printer or electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer Disconnect any connections between the printer and PCs 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
220. pecific information for the 2 Tray Module Tandem Tray Module Duplex High Capacity Feeder and Exit 2 options and a list of error codes and tests Finisher Service Manual Contains specific information for the Finisher option list of error codes and tests These manuals contain maintenance procedures for service personnel They are divided into the following chapters 1 N em BY N General information contains a general description of the printer and the maintenance approach used to repair it Special tools and test equipment are as well as general environmental and safety instructions Diagnostic information contains an error code messages table and service checks used to isolate failing field replaceable units FRUs Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer problems Repair information provides instructions for making printer adjustments and removing and installing FRUs Component locations uses illustrations to identify the connector locations and test points on the printer Preventive maintenance contains the lubrication specifications and recommendations to prevent problems Parts catalog contains illustrations and part numbers for individual FRUs Definitions Note A note provides additional information Warning A warning identifies something that might damage the product hardware or software CAUTION A caution identifies something that might cause a servicer harm product wher
221. per cover removal on page 4 24 3 Remove the top cover See Top cover removal on page 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 to the finisher 4 106 Finisher Service Manual 4024 110 10 Remove the bracket C 11 Release the hook from the upper media exit roll drive gear 20T D 12 Remove the upper media exit roll drive gear 20T 13 Remove the 6 mm bushing 14 Remove the e clip with a prying tool securing the upper media exit roll assembly F to the front 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 EE GP E 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 e Maker sure the flat spot of the upper media exit roll assembly F is installed to the rear e When replacing the upper media exit roll assembly F do not touch the rubber surface Repair information 4 107 4024 110 Sensor upp
222. pler UNIPASSEMDIY 223402346 6c200 be eens ekeeereagerd ete devedlowee o EO 3 24 Functions of stapler SensOrs MOIOS 2 5 cd pete Pee Bees we eee ERR demes 3 24 Upper medis Diletta keel DS RR TU IE a AT 3 25 OOM Eet DI 3 25 Functions of upper Media Dim Spee ciscccce creed cadee EE ERR EELER e 3 25 Slacker MEJIA D Ne sia aa ama del emma IES i EE Es EES bena 3 26 EHNEN EE o io mecis Ee AE 3 26 ENEE EE Ser prac Mico Mas EE Qe toe POAT n 3 28 Functions of stacker media bin sensors motors 3 28 Power supply and interlock a mama sacs SACHER Ba amena dada vi mes ERR REEL bees 3 30 Repair IE CRC sat Si ies EFE ae case ia sal see S see gt em s 4 1 Handling ESD sensitive Pane cosina sin mad osiip se dceue is tied teed rai RQ ue aa Mes aa 4 1 Removal procedures dama mones dus ics eeru n En RE ca EE 4 2 Bridge unit assembly removal sic sic EEEIN EELER cee cee eee ee ee 4 2 Finisnerremoval seua sosa gece tances 9009639 3 89 ERS 34 588 468 Ed deed debe ame elas 4 4 Bridge unit rear cover removal ii issiceccscecssnae dance nee edna EELER ee aa rasa EENS 4 6 Bridge unit top cover assembly removal 4 7 Bridge unit drive belt and bridge unit drive pulley removal 00 00 cee eee eee eee 4 8 Bridge unit right shaft assembly removal 0 0 cece eee eee eee eee eee 4 9 Bridge unit left shaft assembly removal 0 0 eee eee eee eee ees 4 10 Bridge unit idler rolls removal 1 2 2 0 00 c cece eee eee eee eee eee eee eee eee 4 11 Bridge unit t
223. printer operator panel Accessing Diagnostics mode There are different test menus that can be accessed during POR to identify problems with the printer Diagnostics mode 1 Turn off the printer The Diagnostics mode group contains the settings 2 Press and hold V and gt and operations used while manufacturing and servicing the printer and finisher See Available finisher tests on page 3 1 for A more information 3 Turn on the printer 4 Release the buttons when the clock face appears To run the printer diagnostic tests 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 Finisher tests from Diagnostics mode FINISHER TESTS Staple Test See Staple Test on page 3 2 Hole Punch Test See Hole Punch Test on page 3 2 Feed Tests See Feed Tests on page 3 2 Sensor Test See Sensor Test finisher on page 3 2 Cover and Door Bin Level Media Path1 Media Path2 Punch and Staple Diagnostic aids 3 1 4024 110 FINISHER TESTS Staple Test This test verifies the staple mechanism by sending eight sheets of media from the printers default paper source and stapling the sheets To run the Staple Test 1 Select FINISHER TESTS from
224. r finisher media entrance A 4 98 Finisher Service Manual 4024 110 Media entrance roll assembly removal EN e ek cl 10 Remove the entrance drive gear 23T G 12 13 14 15 SN e Remove the finisher front door assembly See Finisher front door assembly removal on page 4 27 Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the left upper cover See Left upper cover removal on page 4 29 Remove the punch waste box A from the finisher Remove the screw securing the cover B to the media entrance pinch guide assembly Remove the cover B Lift the media entrance pinch guide assembly C Loosen the two screws securing the belt tensioner bracket D to the finisher and move it upward in the direction of the arrow Remove the belt entrance paddle E from the entrance drive pulley 20T F Ri pla 5 j g SS 4 o N Le Second Se Release the hook securing the entrance drive gear 23T G to the media entrance roll assembly H Remove the entrance drive pulley 20T F Remove the bushing I Remove the e clip securing the media entrance roll assembly H to the front of the finisher Remove the bushing J Repair information 4 99 4024 110 16 Move the media entrance roll assembly H toward the rear downward and then forward 17 Remove the media entrance roll
225. r media eject shaft 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 Un TAUTE asics AER ERR E a Ge ae Sl aia ee EE Gla ta Soman NE it 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 RAW fail r mia ii aa KSE E BERN ieee dee eee ERR eee da 2 87 996 00 Finisher type TallUre saciia dein satmedeaw LEE RENE da RSE RE dame NEE ERR ER 2 87 999 00 Finisher engine RIP functional failure 2 88 Bridge unit top cover Open 8 caine cae sea ER seein na EX a RE RR KEEN EEN RER a 2 88 Finisher fromt doof open EE EE 2 90 Finisher eject Goeres as 9 e ena e RER REEL daska RECKEN sew ON E 2 91 Finisher upper media bin full ee ec eee eee eee eee a 2 91 No punch waste DOX ua g sinew aa ma taba m win Es RR sea RN ERR aan dow KOR na 2 92 Pinch Waste DOs rte ase Eh eee owes e ar Gai mee geg 2 93 Stacker media bin Tull MIX SIZE ea maia ARC tesco RED eke I es Oe RO RE ERR ge 2 94 Stacker media bin TA DOMO esiaoniansa na iene aR wa RE EE EES sacar dd Ss arta en wv ne ga 2 96 Stacker lower Salety tare sia EE E 2 97 Slacker s r over COUNT IAINNG ciaci med E ARERR RRR RRR ELAS Rae 2 99 Staple Carnage NEE EE ER 2 99 BEE 3 1 Accessing Diagnostics mode icici deeds sine sa ens Se ee PR eed a eee wee KEES ms 3 1
226. r G fin front 3 3 Surface H fin eject 3 3 Media Path Bridge media ent 3 3 Bridge media exit 3 3 Buffer path 3 3 Compiler media in 3 3 Fin media enter 3 3 Fuser exit 3 3 Lower media exit 3 3 Upper media exit 3 3 Media Path2 Diverter gate 3 3 Eject clamp hp 3 3 Front tamper hp 3 3 Media eject shaft hp 3 3 Rear tamper hp 3 3 Punch and Staple Low staple 3 3 Punch box set 3 3 Punch cam front 3 3 Punch carriage shift hp 3 3 Punch hole select 3 3 Punch side reg1 3 3 Punch side reg2 3 3 Punch unit hp 3 3 Punch waste full 3 3 Stapler carriage shift hp 3 3 Staple Test 3 2 front door parts catalog 7 8 H handling ESD sensitive parts 4 1 installation confirm status 2 2 L left lower cover 4 28 left upper cover 4 29 locations bridge unit assembly 5 1 buffer upper exit lower exit and drive motors 5 6 cables 5 7 diverter and media eject 5 4 finisher control card assembly 5 6 media eject and media compiler 5 5 punch unit 5 3 stacker lift and staple 5 2 low voltage power supply LVPS removal 4 119 lower exit drive parts catalog 7 20 lower media exit roll assembly 4 82 lower pinch guide assembly 4 90 media compiler unit assembly 4 69 media diverter gate 4 91 media diverter gate solenoid 4 102 media eject parts catalog 7 16 media eject clamp motor assembly 4 66 media eject clutch 4 77 media eject motor assembly 4 78 media eject shaft assembly 4 74 media eject unit assembly removal 4 59 media entrance pinch guide asse
227. r assembly rotate and does the punch shift carriage move back and forth 6 Is the punch carriage shift motor assembly connected Replace the Replace the properly punch carriage connection shift motor assembly Go to Punch carriage shift motor assembly removal on page 4 43 7 Perform a test print Replace the Problem solved printer engine Does the error still occur card assembly Refer to the Printer Service Manual 988 01 Sensor punch unit side reg off failure Note This procedure pertains to sensor punch unit reg1 and reg2 Step Check Yes No 1 Check the punch carriage by moving it with your Go to step 2 Remove fingers obstructions Does the punch carriage move back and forth smoothly 2 Check the sensor punch unit side reg1 for correct Go to step 3 Go to step 4 operation Perform the sensor punch unit side reg1 test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Punch and Staple 5 Select Punch side reg1 Open the finisher front door Insert a fragment of a sheet of white media under the sensor punch unit side reg1 Does the display on the operator panel change every time a piece of white media is placed over the sensing area of the sensor punch unit side reg1 Diagnostic information 2 83 4024 110 Step Check Yes No 3 Check the sensor punch unit side reg2 for correct Go to step 5 Go to step 4 operation Perfor
228. r limit connection Replace the Replace the Are the connections of the main sensor cable assembly Ge connection correctly connected Go to Sensor stacker bin upper limit or sensor stacker bin no media removal on page 4 36 8 Check the stacker bin lift motor assembly by blocking Go to step 10 Go to step 9 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 9 Check the stacker bin lift motor assembly connection Replace the Replace the Is the connection of the stacker bin lift motor assembly E connection connected to the finisher controller card assembly Go to etal securely bin lift motor assembly removal on page 4 38 10 Perform a test print Replace the Problem solved gt printer engine Does the error still occur card assembly Refer to the Printer Service Manual 981 02 Stacker bin lower limit failure Step Check Yes No 1 Check the media stacker bin actuator for correct Go to step 2 Repair the media operation Is the media stacker bin actuator installed correctly Does it enter the sensing area of the sensor stacker bin upper limit stacker bin actuator 2 66 Finisher Service Manual 4024 110 Step Check Yes No 2 Check the sensor stacker bin no media for correct Go to step 4 Go to step 3 operation Perform the sensor stacker bin no media te
229. r media exit is operated Go to step 13 Go to step 12 2 36 Finisher Service Manual 4024 110 Step Check Yes No 12 Check the sensor lower media exit connection Replace the Replace the sensor lower connection media exit Go to Sensor lower media exit removal on page 4 80 Is the above sensor connected properly 13 Perform a test print Replace the Problem solved p finisher controller Does the error still occur card assembly Go to Finisher controller card assembly removal on page 4 118 Diagnostic information 2 37 4024 110 284 03 Sensor lower media exit on jam C Step Check Yes No 1 Check the media path Go to step 2 Clean or replace i Set the finisher front door assembly of the a loc Snel I media path 2 Open the lovver pinch guide assembly to the right 3 Open the buffer pinch guide assembly downward 4 Check the buffer roll assembly by turning the rolls with your fingers Is the buffer roll assembly installed correctly 2 Is the buffer roll assembly free of damage Go to step 3 Clean or replace the appropriate roll and clean the media path 3 Are the buffer pinch guide pinch rolls attached to the Go to step 4 Clean or replace buffer pinch guide assembly correctly the appropriate roller and clean the media path 4 Are the buffer pinch guide pinch rolls free of damage Go to step 5 Clean or replace
230. r operating correctly SS Go to compiler media in removal on page 4 73 2 42 Finisher Service Manual 4024 110 Step Check Yes No 5 Check the sensor compiler media in for correct Go to step 7 Go to step 6 operation Perform the sensor compiler media in in test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path1 5 Select Compiler media in Does the display on the operator panel change every time the compiler media in actuator of the sensor compiler media in is operated 6 Check the sensor compiler media in connection Replace the Replace the Are the connections of the compiler unit cable Rein Gee connection assembly properly connected Sensor compiler media in removal on page 4 73 7 Perform a test print Does the error still occur Replace the Problem solved finisher controller card assembly Go to Finisher controller card assembly removal on page 4 118 286 00 Sensor compiler media in static jam Step Check Yes No 1 Check the eject clamp motor for correct operation Go to step 3 Go to step 2 Check the above motor by opening the finisher front door assembly and then closing it Does the eject clamp motor rotate normally 2 Check the eject clamp motor connection Replace the eject Replace the Are the connections of the main drive cable assembly e A connector correctly connected
231. r unit assembly Media volume that can be stacked on the compiler unit assembly is limited as shown in the table below The number of sheets depends on whether media is stapled or not as well as on media size If the number of sheets of one set to be stapled exceeds the limit the exceeding sheets are not stacked on the compiler unit assembly and are forcibly ejected to the stacker media bin without being stapled This forcible ejection is performed to prevent damage to the staple assembly When feeding large media in the non staple mode there may be a misalignment depending on media characteristics For this reason the default media capacity is set to a smaller value Compiler unit assembly media capacity Condition Min Default Max Staple mode 2 50 75 For small media less than 216 mm in the feed direction in 10 50 100 non staple mode For large media 216 mm or more in the feed direction in 10 25 100 non staple mode Compiler unit assembly operation with multiple media sizes When two or more media sizes are used and their widths are same example A4L and A3S all the sheets are compiled and stapled as a set on the compiler unit assembly and then ejected to the stacker media bin While if two or more media sizes with different media width 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
232. ransport belt removals 0 0 00 ccc ee eee eee eee eee 4 12 Bridge unit drive motor assembly removal 00 c cece eee eee eee 4 13 Bridge unit entrance guide removal 4 14 Sensor bridge unit top cover interlock removal cee ee eee eee eee 4 15 Sensor bridge unit media entrance removal 4 16 Table of contents V 4024 110 Sensor bridge unit media exit removal 000 cece eee ee 4 17 Bridge unit pinch roller removal 0 00 e eee ec eee eee eee eee eee eee eneeee 4 18 TOP COVElIEMOVAl 654 0244 Es PA tara PEE DS MES ede ed RAT TRATED Ra eT bett 4 19 Upper media bin assembly removal 0 cece eee eee eee eee eee eee e eee 4 20 Right eject cover removal cs ccsciacesvidaden dessa Sede een deeds IEEE I weed ee bed ses 4 21 Stacker media bin assembly removal 0c cece cece ee eee ee eee eee eens 4 22 Right lower low voltage power supply LVPS cover removal 20 00 e eee e een eee 4 22 Rear lower cover removal isisiiicdcw a cad sas an dain na XXX eee na DR Ra cde ae RR ma 4 23 Real upper cover Kette ciment ACHEN ECH d EIERE ee ieee 4 24 Upper media bin front cover removal 0 0 cece eee eee eee eee 4 25 Switch finisher front door interlock removal 0 00 cece eee eens 4 26 Finisher front door assembly removal 0 000 cece eee eee eee eee eee 4 27 Lent lower cover removal sea see OS PIS EEN 4 28 Left upper Cover FEMOVAl e Ae na BE RER ede eal EE RO EEES SS VD RA P
233. reg1 Does the display on the operator panel change 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 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 fragment of a sheet of white media under the sensor punch unit side reg2 Does the display on the operator panel change every time a piece of white media is placed over the sensing area of the sensor punch unit side reg2 Go to step 5 Go to step 4 Check the appropriate sensor punch unit side reg connection Is the above sensor connected properly Replace the appropriate sensor punch unit side reg Go to Sensor punch unit side registration pair with bracket removal on page 4 44 Replace the connection 2 82 Finisher Service Manual 4024 110 Step Check Yes No 5 Open the finisher front door assembly Go to step 7 Go to step 6 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 carriage shift moto
234. ridge 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 2 Check the sensor bridge unit media entrance Replace the Replace the connection sensor bridge connection Is the above sensor connected properly nee Go to Sensor bridge unit media entrance removal on page 4 16 3 Check the bridge unit drive motor by opening the Go to step 5 Go to step 4 finisher front door assembly and then closing it Open the bridge unit top cover assembly Does the bridge unit drive motor rotate normally 2 12 Finisher Service Manual 4024 110 Step Check Yes No 4 Check the bridge unit drive motor connection Replace the Replace the Is the above motor connected properly puede ae connection Bridge unit drive motor assembly removal on page 4 13 5 Perform a test print Replace the Problem solved bridge unit Does the error still occur interface catd assembly Go to Bridge unit interface card assembly removal on page 4 117 6 Perform a test print Replace the Problem solved finisher controller Does the error still occur card assembly Go to Finisher controller card assembly removal on page 4 118 280 02 Sensor bridge unit media entrance static jam B Step Check Yes No 1 Check the sensor bridge unit media entrance for Go to s
235. rmally Step Check Yes No 4 Are the four buffer pinch guide pinch rolls attached on Go to step 5 Clean or replace the lower pinch guide assembly installed correctly the appropriate rolls and clean the media path 5 Check the sensor diverter gate for correct operation Go to step 7 Go to step 6 Perform the sensor diverter gate test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path2 5 Select Diverter gate Open the finisher front door 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 6 Check the sensor diverter gate connection Replace the After sensor diverter reconnecting go Is the above sensor connected properly gate Go to to step 7 Sensor diverter gate removal on page 4 110 7 Check the sensor buffer path for correct operation Go to step 9 Go to step 8 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 media into the buffer path and around the buffer roll assembly in a clockwise direction Does the display on the operator pane
236. roducts and elsewhere is certified as a Class laser product conforming to the requirements of IEC 60825 1 Class laser products are not considered to be hazardous The printer contains internally a Class IIIb 3b laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770 795 nanometers The laser system and printer are designed so there is never any human access to laser radiation above a Class level during normal operation user maintenance or prescribed service condition Laser Der Drucker erf llt gem amtlicher Best tigung der USA die Anforderungen der Bestimmung DHHS Department of Health and Human Services 21 CFR Teil J f r Laserprodukte der Klasse 1 In anderen L ndern gilt der Drucker als Laserprodukt der Klasse der die Anforderungen der IEC International Electrotechnical Commission 60825 1 gem amtlicher Best tigung erf llt Laserprodukte der Klasse gelten als unsch dlich Im Inneren des Druckers befindet sich ein Laser der Klasse ID 3b bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt der Wellen der L nge 770 795 Nanometer ausstrahlt Das Lasersystem und der Drucker sind so konzipiert da im Normalbetrieb bei der Wartung durch den Benutzer oder bei ordnungsgemaBer Wartung durch den Kundendienst Laserbestrahlung die Klasse bersteigen w rde Menschen keinesfalls erreicht Avis relatif a l utilisation de laser Pour les Etats Unis ce
237. roll assembly entrance paddle Upper media transport roll assembly driven by drive motor buffer transport Punch unit Sensor finisher media entrance Media From bridge unit assembly Finisher diverter gate Finisher media entrance roll assembly driven by drive motor entrance paddle Buffer roll assembly driven by drive motor buffer transport Diagnostic aids 3 7 4024 110 From punch to compiler unit assembly The media is transferred to the compiler unit assembly by the buffer roll assembly driven by the motor buffer transport and by the lower media exit roll assembly driven by the drive motor exit When the first media reaches the compiler unit assembly the media eject clamp motor is activated to lower the media eject clamp so that the media eject clamp and the media eject shaft assembly can clamp the media Thus the media transferred from the punch unit is held by the media eject shaft assembly and the media eject clamp driven by the media eject motor assembly and is fed to the exit When the media trailing edge passes through the sensor lower media exit the media eject 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
238. rriage assembly D and the stapler carriage motor assembly C move freely without binding Repair information 4 57 4024 110 Sensor stapler carriage HP removal Remove the finisher front door assembly See Finisher front door assembly removal on page 4 27 Remove the staple cartridge Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the rear lower cover See Rear lower cover removal on page 4 23 Remove the stapler unit frame See Stapler unit frame removal on page 4 54 Remove the stapler unit assembly See Stapler unit assembly removal on page 4 56 Release the hooks securing the sensor stapler carriage HP A to the stapler carriage assembly B De Capa Lo a T 8 Remove the sensor stapler carriage HP A 4 58 Finisher Service Manual 4024 110 Media eject unit assembly removal NOORONo Remove the finisher front door assembly See Finisher front door assembly removal on page 4 27 Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the upper media bin assembly See Upper media bin assembly removal on page 4 20 Remove the upper media bin vertical cover See Right eject cover removal on page 4 21 Remove the two media eject unit springs A by pushing them downward Disconnect the connector from the eject unit solenoid B Release the harness from the two clamps Harness clamp Repair inf
239. rt and belt buffer transport removal 4 115 Bridge unit interface card assembly removal 0 000 cece eee eee eee eee 4 117 Finisher controller card assembly removal 000 cece eee eee eee 4 118 Finisher low voltage power supply LVPS removal 0 cece eee eee eee eee 4 119 Component locations ccc rccesinuseixccserehssntdinrdersntagsscesabiaas seein eehemiaes ex 5 1 LOCAUGCHS Le 8 464544 eRe REL RA TL 5 1 Bridge unit ASSEMBLY 1988 EELER danesa asma eo Kaa ee a ea a 5 1 Stacker lit and Stapler A8 ERNEIEREN ented ERR E AARTE RER A do RaSh ERR A 5 2 BQ ee ee ee ee eT ee ee ere eT ere ee eee 5 3 Diverter and Media eject camisa minsa sana ssessasmisaaissaneseass mens eh Enare aa kins 5 4 Media eject and media compiler cece eee eee eee eee eee eee Etien ini 5 5 Buffer upper exit lower exit and drive motors 0 200s 5 6 Sil cece et er eer eer ete Te Te eae ee a er a rea ee eee ee Ed 5 7 Preventive malmtenanco ciicesiiessoionsitsssomst s sis RER EEN semi peces EA 6 1 Safety inspection BIREN EAR ERNEIEREN sinus AIR EE REI eels 6 1 Maintenance recommendationS da A RN KEE RR REENERT KEEN KEREN KEEN beeen dea dele ae ee 6 1 eg Le PREA ee ee cet ee hs eee een er eet egy NENS DRETS EE OTe DRET wy EPA NE ry ET 7 1 How to Se Mis pants Catalo ea oa a a EE DR DE RE EIER ERR DOR EE be Rank a ROAR 7 1 Assembly i Bdge mb cick cece Rebs decees Datos Er EiT R tes es ds seues ROG Sede es 7 2 Assembly 2 Bridge u
240. s espec ficos O fabricante n o respons vel pela segunran a no caso de uso de pe as de substitui o n o autorizadas As informa es de seguran a relativas a este produto destinam se a profissionais destes servi os e n o devem ser utilizadas por outras pessoas Risco de choques el ctricos e ferimentos graves durante a desmontagem e manuten o deste produto Os profissionais destes servi os devem estar avisados deste facto e tomar os cuidados necess rios CUIDADO Quando vir este s mbolo existe a poss vel presen a de uma potencial tens o perigosa na zona do produto em que est a trabalhar Antes de come ar desligue o produto da tomada el ctrica ou seja cuidadoso caso o produto tenha de estar ligado corrente el ctrica para realizar a tarefa necess ria Finisher Service Manual Informaci de Seguretat A 4024 110 La seguretat d aquest producte es basa en l avaluaci i aprovaci del disseny original i els components espec fics El fabricant no es fa responsable de les q estions de seguretat si s utilitzen peces de recanvi no autoritzades La informaci pel manteniment d aquest producte est orientada exclusivament a professionals i no esta destinada a ning que no ho sigui El risc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients
241. s No 4 Open the finisher front door assembly Go to step 6 Go to step 5 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 carriage shift motor assembly rotate and does the punch shift carriage move back and forth 5 Is the punch carriage shift motor assembly connected Replace the Replace the properly punch carriage connection shift motor assembly Go to Punch carriage shift motor assembly removal on page 4 43 6 Perform a test print Replace the Problem solved printer engine Does the error still occur card assembly Refer to the Printer Service Manual 986 00 Sensor media eject clamp HP on failure Step Check Yes No 1 Check the media eject clamp by opening the finisher Go to step 2 Remove front door assembly and then closing it obstacles Does the eject clamp mechanism move smoothly 2 Check the sensor media eject clamp HP for correct Go to step 4 Go to step 3 operation Perform the sensor media eject clamp HP 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 Sensor Test 4 Select Media Path 2 5 Select Eject clamp HP Rotate the eject gears manually by hand Does the display on the operator panel change every time the sensing
242. s sensor and turns L 0 V dc when media exits from the bridge unit assembly e Sensor bridge unit top cover interlock A photo interrupter to detect open close of the bridge top cover assembly of the bridge unit assembly Itturns H 5 V dc light receiving when the bridge top cover assembly opens Sensor bridge unit media exit s j Sensor bridge unit top cover interlock Sensor bridge unit media entrance 3 10 Finisher Service Manual 4024 110 Finisher Sensor finisher media entrance A reflective photo sensor to detect whether media is fed from the bridge unit assembly to the finisher Itturns H 5 V dc while media is present within the sensing area When the level turns H due to the first media of the second set during multi set printing activates the buffer diverter solenoid to switch the buffer diverter gate so that the media goes in the buffer roll assembly s circumferential direction Sensor diverter gate A reflective photo sensor to detect the media leading edge Itturns L 0 V when the front end reaches the sensing area Sensor lower media exit A photo interrupter to detect whether media passes through the sensor lower media exit It turns H 5 V light receiving when the actuator is driven out of the sensing area by the media When the level tunes H activates the front tamper motor and the rear tamper motor on the compiler unit as
243. s to the two upper media transport roll assembly C for removal Repair information 4 111 4024 110 10 11 12 13 14 15 16 Remove the two screws securing the bracket D Note It is not necessary to remove the bracket from the finisher it should only be slightly moved to provide better access to the two upper media transport roll drive pulley 20T E Loosen the two screws securing the belt tensioner bracket F to the finisher and move it downward as shown Remove the belt buffer transport G from the two upper media transport roll drive pulley 20T E Release the hook securing the appropriate upper media transport roll drive pulley 20T E to the appropriate upper media transport roll assembly C Remove the appropriate upper media transport roll drive pulley 20T E Remove the appropriate bushing H With a prying tool remove the e clip securing the appropriate upper media transport roll assembly C to the front of the finisher C C 12 9 E clip e 8 2 Front Bag fa oe E clip E KE S S Rear C C 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 transport roll assembly C do not touch the rubber surface Replacement notes Note Make sure th
244. screw securing the bracket A to the punch unit assembly B ae DO 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 Repair information 4 49 4024 110 Replacement note Make sure the color coded connectors are connected to the proper sensors as shown C 4 50 Finisher Service Manual 4024 110 Sensor punch carriage shift HP removal Open the finisher front door assembly Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the punch carriage assembly See Punch carriage assembly removal on page 4 41 Remove the one screw securing the bracket A to the punch carriage unit B Release the hooks securing the sensor punch carriage shift HP C to the bracket A e XS ech Qe SEET C 6 Remove the sensor punch carriage shift HP C Repair information 4 51 4024 110 Sensor punch waste box set removal Open the finisher front door assembly Pull the punch waste box Disconnect the connector from the sensor punch waste box set A Release the hooks securing the sensor punch waste box set A to the finisher AONA
245. sembly 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 whether media is fed toward the buffer roll assembly While media is present the actuator is outside the sensing area and the sensor turns at H 5 V light receiving Sensor upper media exit Aphoto interrupter to detect whether media is fed to the upper media exit roll assembly Top at the exit side of the upper media bin When the media is fed the actuator leaves from the sensing area and the sensor tunes H 5 V Sensor upper media bin full A reflective photo sensor to detect the stack volume of media in the upper media bin Sensor upper media exit Sensor diverter gate Sensor upper media bin full Sensor finisher media entrance Sensor lower media exit From bridge unit Sensor buffer path Sensor compiler media in Diagnostic aids 3 11 4024 110 Punch unit This section describes the media punching operation of the punch Two types of punch are provided the 2 3 hole type and the 2 4 hole type The following explains the 2 3 hole type 2 hole 3 hole auto switching
246. sembly removal on page 4 118 Diagnostic information 2 57 4024 110 288 02 Sensor diverter gate static jam to top bin B Step Check Yes No 1 Check the sensor diverter gate for correct operation Go to step 3 Go to step 2 Perform the sensor diverter gate test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path2 5 Select Diverter gate Open the finisher front door 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 2 Check the sensor diverter gate connection Replace the Replace the Is the above senor connected properly econ rier connection Sensor diverter gate removal on page 4 110 3 Check the drive motor entrance paddle by opening Go to step 5 Go to step 4 the finisher front door assembly and then closing it Does the motor entrance paddle rotate normally 4 Is the drive motor entrance paddle connected Replace the drive Replace the properly motor entrance connection paddle Go to Drive motor entrance paddle and belt entrance paddle removal on page 4 100 5 Perform a test print Replace the Problem solved finisher controller Does the error still occur card assembly
247. sh 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 Check the sensor diverter gate connection Is the above sensor connected properly Replace the sensor diverter gate Go to Sensor diverter gate removal on page 4 110 After reconnecting go to step 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 Push a sheet of media into the buffer path and around the buffer roll assembly in a clockwise direction Does the display on the operator panel change every time the actuator of the sensor buffer path is operated Go to step 9 Go to step 8 2 26 Finisher Service Manual 4024 110 Step Check Yes No Check the sensor buffer path connection Is the above sensor connect properly Replace the sensor buffer path Go to Sensor buffer path removal on page 4 93 After reconnecting go to step 9 Check the drive motor buffer transport by opening the finisher front door assembly and then closing it Does the drive motor buffer transport rotate normally Go to st
248. sition Rear tamper tamping position NI OO oO BJ oO Pp Rear tamper offset position 4024 110 Diagnostic aids 3 17 4024 110 Rear tamping Rear tamping is used in the following cases e When executing rear stapling corner e When executing dual stapling The tamper positions during rear tamping are shown below Sensor front tamper HP Sensor rear tamper HP Front LA iN Front tamper motor Front tamper Reartamper Rear tamper motor Position Description Front tamper home position sensor front tamper HP Front tamper tamping position Front tamper offset position Rear tamper home position sensor rear tamper HP Rear tamper size position oO Olio pm Rear tamper offset position 3 18 Finisher Service Manual Center tamping Center tamping is used when executing rear stapling straight The tamper positions during center tamping are shown below Sensor front tamper HP 4024 110 Sensor rear tamper HP Front tamper motor Front tamper Reartamper Rear tamper motor Position Description Front tamper home position sensor front tamper HP Front tamper standby position Front tamper tamping position Front tamper offset position Rear tamper home position sensor rear tamper HP Rear tamper standby position Rear tamper size position CO NJ OO oO AJO
249. st 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Bin Level 5 Select Stacker bin no media Does the display on the operator panel change every time the sensing area of the sensor stacker bin no media is blocked 3 Is the sensor stacker bin no media connected Replace the Replace the properly sensor stacker connection bin no media 4 Check the sensor stacker bin level 1 for correct Go to step 6 Go to step 5 operation Perform the sensor stacker bin level 1 test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Bin Level 5 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 5 Is the sensor stacker bin level 1 connected properly Replace the Replace the sensor stacker connection bin level 1 Go to Sensor stacker bin level 1 removal on page 4 34 6 Check the sensor stacker bin level 2 for correct Go to step 8 Go to step 7 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 rear is blocked by a multi page document or your finger 7 Is the s
250. st 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path2 5 Select Media eject shaft HP Rotate the media clutch actuator manually by hand Does the display on the operator panel change every time the sensing area of the sensor media eject shaft HP Diagnostic information 2 79 4024 110 Step Check Yes No 3 Check the sensor media eject shaft HP connection Replace the Replace the Are the connections of the main sensor cable assembly SBS connection correctly connected Go to Sensor media eject shaft HP removal on page 4 79 4 Check the media eject motor assembly by opening the Go to step 6 Go to step 5 finisher front door assembly and then closing it Does the media eject motor assembly rotate normally 5 Is the media eject motor assembly connected Replace the Replace the properly media eject connection motor assembly Go to Media eject motor assembly removal on page 4 78 6 Check the media eject clutch assembly by opening the Go to step 8 Go to step 7 finisher front door assembly and then closing it The three clamp paddles should rotate Does the media eject clutch assembly operate 7 Check the media eject clutch assembly connection Replace the Replace the media eject connection Is the above component connected properly clutch assembly Go to Media eject clutch removal on page 4 77 8 Perform
251. st 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 finisher media entrance 9 Check the sensor finisher media entrance Replace the Replace the connection sensor finisher connection Is the above sensor connected properly ee Me bridge unit media entrance removal on page 4 16 7 Check the bridge unit drive motor by opening the Go to step 9 Go to step 8 finisher front door assembly and then closing it Open the bridge unit top cover assembly Does the bridge unit drive motor rotate normally Diagnostic information 2 21 4024 110 Step Check Yes No 8 Is the bridge unit drive motor connected properly Replace the Replace the bridge unit drive connection motor Go to Bridge unit drive motor assembly removal on page 4 13 9 Perform a test print Replace the Problem solved i bridge unit Does the error still occur2 interface card assembly Go to Bridge unit interface card assembly removal on page 4 117 Go to step 10 10 Perform a test print Replace the Problem solved S finisher controller Does the error still occur card assembly Go to Finisher controller card assembly removal
252. stenza tecnica non ricevano radiazioni laser superiori al livello della classe 1 Notices and safety information ix 4024 110 Avisos sobre el laser Se certifica que en los EE UU esta impresora cumple los requisitos para los productos laser de Clase 1 establecidos en el subcap tulo J de la norma CFR 21 del DHHS Departamento de Sanidad y Servicios y en los demas paises reune todas las condiciones expuestas en la norma IEC 60825 1 para productos laser de Clase 1 Los productos laser de Clase no se consideran peligrosos La impresora contiene en su interior un laser de Clase Illb 3b de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nan metros El sistema l ser y la impresora estan disefiados de forma que ninguna persona pueda verse afectada por ningun tipo de radiaci n l ser superior al nivel de la Clase durante su uso normal el mantenimiento realizado por el usuario o cualquier otra situaci n de servicio t cnico Declara o sobre Laser A impressora esta certificada nos E UA em conformidade com os requisitos da regulamenta o DHHS 21 CFR Subcapitulo J para a Classe 1 de produtos laser Em outros locais esta certificada como um produto laser da Classe I em conformidade com os requisitos da norma IEC 60825 1 Os produtos laser da Classe nao sao considerados perigosos Internamente a impressora cont m um produto laser da Classe IIIb 3b designado laser de
253. t For example A4LEF 297x210 media is stacked on A4SEF 210x297 media Note When B5LEF 257x182 media is stacked on A4LEF 297x210 media this is not mix stacking e Asheet of media of less than 11 inches is stacked in the stacker media bin with the Staple Mode changed Top view of finisher tray Rear i staple m Front staple e An operator put a sheet or sheets when no media is remaining in the stacker media bin The size and condition of media stacked in the tray are not identified e 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 e The finisher entered the Sleep Mode with mix stacking and then has exited the Sleep Mode e The post processing mode has changed Functions of stacker media bin sensors motors e sensor stacker bin level 1 A pair of light emitter and photo receiver to detect the height of media in the stacker media bin This sensor is used to control the elevator motor When blocked by media or the tray this sensor turns H deciding that the stacker media bin is above the reference level To the contrary when receiving light this sensor turns L deciding that the stacker media bin is below the reference level The H to L turning point of the sensor is defined as the reference level e sensor stacker bin level 2 A pair of light emi
254. t W hrend des Auseinandernehmens und der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schlags und R rperlicher Verletzung Das zustandige Fachpersonal sollte entsprechende VorsichtsmaBnahmen treffen ACHTUNG Dieses Symbol weist auf eine gefahrliche elektrische Spannung hin die in diesem Bereich des Produkts auftreten kann Ziehen Sie vor den Arbeiten am Ger t den Netzstecker des Ger ts bzw arbeiten Sie mit groBer Vorsicht wenn das Produkt f r die Ausf hrung der Arbeiten an den Strom angeschlossen sein muB Pautas de Seguridad La seguridad de este producto se basa en pruebas y aprobaciones del disefio original y componentes espec ficos El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas La informaci n sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga el ctrica y de da os personales durante el desmontaje y la reparaci n de la maquina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias PRECAUCION este simbolo indica que el voltaje de la parte del equipo con la que esta trabajando es peligroso Antes de empezar desenchufe el equipo o tenga cuidado si para trabajar con l debe conectarlo Informa es de Seguran a xiv A seguran a deste produto baseia se em testes e aprova es do modelo original e de componente
255. t FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path1 5 Select Lower media exit Open the finisher front door Move 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 13 Go to step 12 Diagnostic information 2 33 4024 110 Step Check Yes No 12 Check the sensor lower media exit connection Is the above sensor connected 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 2 34 Finisher Service Manual 284 02 Sensor lower media exit on jam B 4024 110 Step Check Yes No 1 Check the media path Go to step 2 Clean or replace 1 Ser the finisher front door assembly of the ee Sen media path 2 Open the lovver pinch guide assembly to the right 3 Open the buffer pinch guide assembly downward 4 Check the buffer roll assembly by turning the rolls with your fingers Is the buffer roll assembly installed correctly 2 Is the buffer roll ass
256. te full 3 3 Rear tamper hp 3 3 Stacker bin level encod 3 3 Stacker bin level1 3 3 Stacker bin level2 3 3 4024 110 Stacker bin no media 3 3 Stacker bin upper limit 3 3 Staple Test 3 2 Stapler carriage shift hp 3 3 Surface H fin eject 3 3 Upper media exit 3 3 theory compiler unit assembly 3 15 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 Index l 5 4024 110 L Finisher Service Manual 4024 110 Part number index P N 40X0810 40X0811 40X0812 40X0813 40X0814 40X0815 40X0816 40X0817 40X0818 40X0819 40X0820 40X0821 40X0822 40X0823 40X0824 40X0825 40X0825 40X0825 40X0826 40X0827 40X0828 40X0829 40X0830 40X0831 40X0832 40X0833 40X0834 40X0835 40X0836 40X0837 40X0838 40X0839 40X0840 40X0841 40X0842 40X0843 40X0844 40X0845 40X0846 40X0847 40X0848 40X0849 40X0850 40X0850 40X0850 40X0850 40X0850 40X0850 40X0850 40X0850 40X0850 40X0850 40X0850 40X0851 Description Page Bridge unit assembly docking screw 7 2 Bridge unit assembly
257. tep 3 Go to step 2 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 operator panel change every time the actuator of the sensor bridge unit media entrance is operated 2 Check the sensor bridge unit media entrance Replace the Replace the connection sensor bridge connection Is the above sensor connected properly ee Go to Sensor bridge unit media entrance removal on page 4 16 Diagnostic information 2 13 4024 110 Step Check Yes No 3 Check the bridge unit drive motor by opening the Go to step 5 Go to step 4 finisher front door assembly and then closing it Open the bridge unit top cover assembly Does the bridge unit drive motor rotate normally 4 Check the bridge unit drive motor connection Replace the Replace the bridge unit drive connection Is the above motor connected properly motor Go to Bridge unit drive motor assembly removal on page 4 13 5 Perform a test print Replace the Problem solved F bridge unit Does the error still occur interface card assembly Go to Bridge unit interface card assembly removal on page 4 117 6 Perform a test print Replace the Problem solved gt finisher controller Does the error still
258. the Problem solved I finisher controller Does the error still occur2 card assembly Go to Finisher controller card assembly removal on page 4 118 2 60 Finisher Service Manual 288 05 Sensor diverter gate static jam to stacker bin B 4024 110 Step Check Yes No 1 Check the sensor diverter gate for correct operation Go to step 3 Go to step 2 Perform the sensor diverter gate test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Media Path2 5 Select Diverter gate Open the finisher front door 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 2 Is the sensor diverter gate connected properly Replace the Replace the sensor diverter connection gate Go to Sensor diverter gate removal on page 4 110 3 Check the drive motor entrance paddle by opening Go to step 5 Go to step 4 the finisher front door assembly and then closing it Does the motor entrance paddle rotate normally 4 Check the main drive cable assembly connection Replace the drive Replace the Are the connections of the main drive cable assembly EES Sonnecuon paddle Go to correctly connected Drive motor entrance paddle a
259. the buffer roll drive gear 53 23T G 15 Release the hook of the buffer roll drive gear 46T H from the buffer roll 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 e Make sure the flat spot on the end of the buffer roll assembly C is installed to the rear E AN b 1 Ei Lar Front e When replacing the buffer roll assembly do not touch the rubber surface e The tension of the belt buffer transport F is automatically adjusted by the force of the spring attached to the belt tensioner bracket E e Tighten the two screws in the order shown Repair information 4 95 4024 110 Buffer pinch guide assembly removal Remove the finisher front door assembly See Finisher front door assembly removal on page 4 27 Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the stapler unit frame See Stapler unit frame removal on page 4 54 Lower the buffer pinch guide assembly A as far as it will go Move the buffer pinch guide assembly A to the right to remove the two bosses from the holes in the finisher GEET 4 96 Finisher Service Manual 4024 110 Media entrance pinch guide assembly removal 1 2 3 4 5 6 T
260. the finisher 2 Open and close the bridge unit top cover assembly on Go to step 2 Check that the the bridge unit assembly bridge unit top Does it open or close smoothly Gelee 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 removal on page 4 7 3 Check the bridge unit top cover assembly on the bridge Reshape the Go to step 3 unit assembly for shape and operation actuator so it fits Is the actuator of the bridge unit top cover assembly petals mes that enters the sensor bridge unit top cover interlock does not correct bent or damaged the problem replace the bridge unit top cover assembly Go to Bridge unit top cover assembly removal on page 4 7 2 88 Finisher Service Manual 4024 110 Go to Finisher controller card assembly removal on page 4 118 Does the error still occur when the power is turned on printer engine card assembly Refer to the Printer Service Manual Step Check Yes No 4 Check the bridge unit assembly top cover actuator Go to step 4 Problem solved Paint both faces of the actuator with a black permanent marker Does the error continue 5 Check the sensor bridge unit top cover interlock Go to step 5 Reinstall the installation sensor bridge Is the sensor bridge unit top cover interlock installed EE properly Go to
261. 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 to the specified position on the compiler unit assembly using the front tamper or rear tamper by moving them to the end of media by the respective motors Tamping is executed each time when a sheet of media reaches the compiler unit assembly Additional tamping is executed after tamping the last sheet There are three types of tamping e Front tamping tamping by the rear tamper with the front tamper fixed at the home position e Rear tamping tamping by the front tamper with the rear tamper fixed at the home position e Center tamping tamping by the front and rear tampers to align media to the almost center 3 16 Finisher Service Manual Front tamping Front tamping is used in the following cases e Inthe non staple mode e When executing front stapling corner The tamper positions during front tamping are shown below Sensor front tamper HP Sensor rear tamper HP Rear isi Front tamper motor Front tamper Rear tamper Rear tamper motor Position Description Front tamper home position sensor front tamper HP Front tamper size position Front tamper offset position Rear tamper home position sensor rear tamper HP Rear tamper standby po
262. tical cover See Right eject cover removal on page 4 21 Remove the stapler unit frame See Stapler unit frame removal on page 4 54 Remove the media eject clamp motor assembly See Media eject clamp motor assembly removal on page 4 66 Remove the media eject unit assembly See Media eject unit assembly removal on page 4 59 Remove the media eject motor assembly See Media eject motor assembly removal on page 4 78 Loosen the four screws securing the plate A to the finisher Move the plate to the right and outward Hl B VAS Rear 12 Remove the plate Repair information 4 69 4024 110 13 Disconnect the connector P8309 from the finisher controller card assembly B 14 Release the harness from the clamps Clamp cae ge SS OI I O Pel P8309 ol I o o o Rear Y O U co Le B 15 Remove the screw securing the media compiler unit assembly C to the finisher This screw is found inside the finisher Tn LM ni lit mM j I mm III u Inside view 4 70 Finisher Service Manual 4024 110 16 Release the media compiler assembly C by pushing the front lock and the rear lock inward to release the front boss and the rear boss from the finisher
263. to step 3 Clean or replace the entrance pinch guide assembly and media the appropriate entrance roll assembly free of damage roller and clean the media path Diagnostic information 2 47 4024 110 Step Check Yes No 3 Check the media path Go to step 4 Clean or replace 1 Open the upper pinch guide assembly to the right E 2 Check these items by turning them with your the media path fingers Are the four upper pinch guide pinch rolls of the upper pinch guide assembly and two upper media transport roll assemblies installed correctly meaning do they rotate smoothly 4 Are the four upper pinch guide pinch rolls of the upper Go to step 5 Clean or replace pinch guide assembly and two upper media transport the appropriate roll assemblies free of damage roller and clean the media path 5 Check the sensor upper media exit for correct Go to step 7 Go to step 6 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 6 Check the sensor upper media exit and main sensor Replace the Replace the cable assembly connections sensor upper connection Is the above sensor connected properly media exit propery Sensor upper media exit
264. to the upper belt clamp F as shown e Make sure the bin bracket C is level to prevent binding Repair information 4 31 4024 110 Carriage lift belt right removal Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the finisher front door assembly See Finisher front door assembly removal on page 4 27 Move the slip clutch gear 24T A toward the rear to disengage the stacker bin B Move the stacker bin B to its lowest position Note Make sure the stacker bin is at the lowest position before continuing RON ch 4 32 Finisher Service Manual 4024 110 5 Remove the two screws securing the bin bracket C to the right carriage bracket D 6 Remove the spring E from the right carriage bracket D 7 Remove the screw securing the upper belt clamp F to the 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 e Make sure the carriage lift belt G is inserted into the upper belt clamp F as shown e Make sure the bin bracket C is level to prevent binding Repair information 4 33 4024 110 Sensor stacker bin level 1 removal 1 Remove the finisher front
265. tor exit assembly 4 113 finisher 4 4 finisher controller card assembly 4 118 finisher front door assembly 4 27 finisher LVPS 4 119 left lower cover 4 28 left upper cover 4 29 lower media exit roll assembly 4 82 lower pinch guide assembly 4 90 media compiler unit assembly 4 69 media diverter gate 4 91 media diverter gate solenoid 4 102 media eject assembly 4 59 media eject clamp motor assembly 4 66 media eject clutch 4 77 media eject motor assembly 4 78 media eject shaft assembly 4 74 media entrance pinch guide assembly 4 97 media entrance roll assembly 4 99 paddle and roll exit assembly 4 86 pinch guide assembly 4 96 punch carriage assembly 4 41 punch carriage shift motor assembly 4 43 punch media stop assembly 4 46 punch unit assembly 4 45 punch unit motor assembly 4 47 rear lower cover 4 23 rear upper cover 4 24 right eject cover 4 21 right lower LVPS cover 4 22 sensor bridge unit media entrance 4 16 sensor bridge unit media exit 4 17 sensor bridge unit top cover interlock 4 15 sensor buffer path 4 93 sensor compiler media in 4 73 sensor diverter gate 4 110 sensor finisher media entrance 4 98 sensor front tamper HP 4 72 sensor lower media exit 4 80 es dees ee een GEES a ee Index 1 3 4024 110 sensor media eject clamp HP 4 67 sensor media eject shaft HP 4 79 sensor punch cam front 4 49 sensor punch carriage shift HP 4 51 sensor punch hole select 4 49 sensor punch
266. tor A 6 343332 z T Y A e o IS ES SE SS R o 7 W L 24VDC D 8 EE 5 5 5 8 3838 8868 ear os 3 Exit Motor A 5 cla P 5 ss ds sals Tamper 2 4 lt Exit Motor B 4 ejajn tjo o E SS El ZS g see 888 Motor ow VL 24VDC 9 238 g g eg RG RSS SS SS org a sie 2 933 ds SE SU St gi C SEI E 6 je Ext Motor B i 2 Q g 2 2 os o 5 gt 9 gt 15 2515 5 sales s So Z 30 SS ae ae Vag EA CEE X X Efa SE d EN ds Ds a a Ds A e e el P8304 Ek 5 i ii So o 8 Ja A oy DC Lu SS El w me o SS H o ee Ek 33 oo KE nS Ay E x 20 E i 6 Os os RTN os S 3 RTN 5 Fo E 2 e 02 31211 424VDC 4 ES gorj Bridge Unit save IA le XD i U See Drive Motor de Sensor Stapler SE 3 i i Carriage HP 2 o Q 3 l i Switch Eject Cover Interlock 424VDC ae ae j El 8 RAVE 4 Do vi e T Le l L 24VDC V L 24VDC d 7 18 Staple Carriage Position Sensed L 5VDC Bros 8 9 2 Eject Cover H H NM 16 8 SE 2 Stapler unit a 1 8 se on Finisher Controller 18 Low Staple Sensed L 5VDC 2 ASM oO alain Switch Finisher al Front door interlock SW Card ASM Ai 184 Staple Ready Sensed L 5VDC a 3 F Sensor gt FI 5 T d o d alolal Front Door Interlock 1 Ja SIG GND 12 Staple Head Home Sensedi L 5VDC a 4 Staple Ready L S 5 5 S 5 nk TE e ll Se o x CEE 10 gt Staple Motor Sensor Staple ke Dl 49 01419 Staple Motor Kc osoos o 9 w HP ra 9 g 2 8 Staple Motor I gt Staple Motor Sg 7 e 9 El VL 24VDC 1
267. treballant s perill s Abans PRECAUCI aquest s mbol indica que el voltatge de la part de l equip amb la qual esteu de comen ar desendolleu l equip o extremeu les precaucions si per treballar amb l equip l heu de connectar qr Are eee AAAY A TE UA SIS ESE A ele ce YULU eA et H Sres ds ic LAE AA I NE NM UE HE ed le Wee eT st Pee de VINE EST AF Ai EI Woes H AE AT Sol A OAL Cf 1 o L A 3 LE IC of T WH eq AE 8 A AT dE So UA GN EU Ke fc Soe te Ve eee Ste tee aA ef Sat Oe eae ale SE EE Pa EAE ae S ae Re AA EA YHE NEE EE eL kg 7948 18177101 eA mo Sere e ASP i A ZEAE VE DL JR RT RES ve ER aK EEA VE Wy HE fie D AEA ARE VE NS RI TER NOT EE AE e AP RES IE OES WARE AEA SPAT th 7 Ha e ARENE nt ME RA REIS ICS EAIA ES ENV ARIS A RIZ RUA PE T ic WARTS JP REU BE AY PV TE DE o Int WER LES m DX I A HIC ELE ii EA UR PEE AIRES im DS UE R RAE m UNS ME A o UE RA TES A AH Safety information XV 4024 110 Preface The service information for the Lexmark W850n and W850dn is contained within three service manuals Printer Service Manual Contains the base printer service information including the options and finisher error codes and tests Options Service Manual Contains s
268. tte imprimante est certifi e conforme aux provisions DHHS 21 CFR alin a J concernant les produits laser de Classe 1 Pour les autres pays cette imprimante r pond aux normes IEC 60825 1 relatives aux produits laser de Classe I Les produits laser de Classe sont consid r s comme des produits non dangereux Cette imprimante est quip e d un laser de Classe Illb 3b ars niure de gallium d une puissance nominale de 5 milliwatts mettant sur des longueurs d onde comprises entre 770 et 795 nanom tres Limprimante et son syst me laser sont con us pour impossible dans des conditions normales d utilisation d entretien par l utilisateur ou de r vision l exposition a des rayonnements laser sup rieurs a des rayonnements de Classe Avvertenze sui prodotti laser Questa stampante certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825 1 prodotti laser di classe non sono considerati pericolosi La stampante contiene al suo interno un laser di classe ID 3b all arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d onda compresa tra 770 e 795 nanometri Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante durante il normale funzionamento le operazioni di servizio o quelle di assi
269. tter and photo receiver to detect the height of media in the stacker media bin same function as sensor stacker bin level 1 This sensor is also used to control the elevator motor When blocked by media or the tray this sensor turns H deciding that the stacker media bin is above the reference level To the contrary when receiving light this sensor turns L deciding that the stacker media bin is below the reference level 3 28 Finisher Service Manual 4024 110 e Sensor stacker bin no media A photo interrupter to detect that the stacker media bin is at the highest position and also to detect no media When the actuator attached to the carriage assembly right enters the sensing area the emitted light is blocked which turns the sensor to H 5 V e Sensor stacker bin upper limit A photo interrupter to detect the stacker media bin s abnormal elevation above the top position sensor stacker bin no media position When the actuator attached to the carriage assembly right enters the sensing area the emitted light is blocked which turns the sensor to H 5 V e Sensor stacker bin level encoder A photo interrupter to count the pulse of the Encoder attached to the Shaft Elevator The media volume in the stacker media bin is detected based on this count e Stacker bin lift motor ADC motor to elevate or lower the stacker media bin Clockwise rotation elevates the tray and c
270. unit HP 4 49 sensor punch unit motor encoder 4 48 sensor punch unit side registration pair 4 44 sensor punch waste box full 4 53 sensor punch waste box set 4 52 sensor rear tamper HP 4 72 sensor stacker bin level 1 4 34 sensor stacker bin level 2 4 34 sensor stacker bin level encoder 4 35 sensor stacker bin no media 4 36 sensor stacker bin upper limit 4 36 sensor stapler carriage HP 4 58 sensor upper media bin full 4 108 sensor upper media exit 4 104 stacker bin lift motor assembly 4 38 stacker media bin assembly 4 22 stapler unit assembly 4 56 stapler unit frame 4 54 sub paddle 4 63 sub paddle drive shaft assembly 4 64 switch eject cover interlock 4 68 switch finisher front door interlock 4 26 top cover 4 19 upper media bin assembly 4 20 upper media bin front cover 4 25 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 S safety information Xiii safety inspection guide 6 1 sensors bridge unit media entrance 4 16 5 1 bridge unit media exit 4 17 5 1 bridge unit top cover interlock 4 15 5 1 buffer path 4 93 compiler media in 4 73 diverter gate 4 110 finisher media entrance 4 98 front tamper HP 4 72 lower media exit 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
271. ver 2 Check the operation of the switch eject cover Go to step 4 Go to step 3 interlock Perform the switch eject cover interlock test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Cover and Door 5 Select Surface H fin eject Does the display on the operator panel change every time the actuator of the switch is activated 3 Is the switch media cover interlock connected Replace the Replace the properly switch eject connection cover interlock Go to Switch eject cover interlock removal on page 4 68 4 Perform a test print Replace the Problem solved finisher controller Does the error still occur card assembly Go to Finisher controller card assembly removal on page 4 118 Finisher upper media bin full Step Check Yes No 1 Check the sensor upper media bin full for correct Replace the Go to step 2 operation Perform the sensor upper media bin full test 1 Enter Diagnostics mode 2 Select FINISHER TESTS 3 Select Sensor Tests 4 Select Bin Level 5 Select Fin upper bin full Does the display of the operator panel change every time a piece of white media is placed over the sensing area of the sensor upper media bin full finisher controller card assembly Go to Finisher controller card assembly removal on page 4 118 Diagnostic information 2 91 4024 110 Step Check Yes No Is the sensor upper
272. ws securing the finisher LVPS A to the finisher Sei 4 Remove the finisher LVPS A Repair information 4 119 4024 110 4 120 Finisher Service Manual 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 Component locations 5 1 4024 110 Stacker lift and stapler Sensor stacker bin upper limit Sensor stacker bin no media door interlock Sensor stacker bin level 2 es Sensor stacker Switch finisher mf oe bin level 1 Stapler carriage motor assembly A GEE SS Ne Sensor stapler carriage HP 5 2 Finisher Service Manual Punch unit Sensor punch unit HP lt q Sensor punch hole select Sensor punch cam front Punch unit motor asm Sensor punch waste box set Sensor punch waste box full 4024 110 Punch carriage shift motor asm Sensor punch carriage shift HP Sensor punch unit side reg 2 Sensor punch unit side reg 1 Component locations 5 3 4024 110 Diverter and media eject 5 4 Finisher Service Manual Sensor media eject clamp HP Media eject clamp motor Sensor Ll media exit Switch eject cover interlock Media eject and media
273. xit 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 6 Check the sensor upper media exit and main sensor Replace the Replace the cable assembly connections sensor upper connection Is the above sensor connected properly media exit propery Sensor upper media exit removal on page 4 104 7 Check the drive motor buffer transport by opening the Go to step 9 Go to step 8 finisher front door assembly and then closing it Does the drive motor buffer transport rotate properly Diagnostic information 2 45 4024 110 Step Check Yes No 8 Check the drive motor buffer transport connection Replace the drive Replace the Is the above motor properly connected bo ce to connection Drive motor buffer transport and belt buffer transport removal on page 4 115 9 Perform a test print Replace the Problem solved finisher controller Does the error still occur card assembly Go to Finisher controller card assembly removal on page 4 118 287 01 Sensor upper media exit off jam A Step Check Yes No 1 Check the media path Go to step 2 Clean or replace 1 Open the upper pinch guide assembly to the right EE 2 Check four upper pinch guide pinch roll on the the
274. y A 3 Remove the two screws securing the bridge unit interface card assembly A to the finisher Connector Connectors O 4 Remove the bridge unit interface card assembly A Repair information 4 117 4024 110 Finisher controller card assembly removal Lo Es eg Move the plate A to the right and outward 8 I Re CH qe eof Wa jO SI 5 Remove the plate A Remove the rear upper cover See Rear upper cover removal on page 4 24 Remove the rear lower cover See Rear lower cover removal on page 4 23 Loosen the four screws securing the plate A to the finisher gt 3 6 Disconnect the connectors from the finisher controller card assembly B V Ut A P8304 P8308 P8389 kaTa e P8306 P8309 ei e P8307 P8305 e 8 U a P8300 P8302 a P8301 P8311 ei be P8310 O ER OD P8317 P8315 P8313 P8314 P8316 7 Remove the six screws securing the finisher controller card assembly B 8 Remove the finisher controller card assembly B 4 118 Finisher Service Manual 4024 110 Finisher low voltage power 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 scre
275. y the motor entrance paddle The media route inside the finisher is determined by the media diverter gate The media diverter gate is activated by the media diverter gate solenoid controlled by the printer The media is further fed in the finisher by the two upper media transport roll or the buffer roll assembles that are driven by the motor buffer transport and passes through the punch unit The sensor finisher media entrance becomes LOW upon detecting media After a certain time has passed from the level transition to H the motor buffer transport that drives the upper media transport roll assembly or the buffer roll assembly starts reverse rotation The media is returned 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 while the motor buffer transport is rotating reversely to stop the media Thus punch hole positions in the media feed direction are determined Drive motor buffer transport Upper media transport roll assembly Finisher diverter gate soleno Ki 8 Finisher diverter gate Drive motor Sensor finisher media entrance Finisher media entrance

Lexmark W850n and W850dn Finisher 4024

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