Lexmark C930, C935 Service Manual

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Edition: May 22, 2007

Lexmark™ C930 and C935 Printer Finisher

• Table of contents

• Start diagnostics

5057-XXX

• Safety and notices

• Trademarks

•Index

A later version of this service manual will be

posted to the web on or before 6-15-07.

Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

5057-XXX

Edition: May 22, 2007

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 D22A/032-2, 740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at ServiceInfoAndTraining@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.

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.

PCL® is a registered trademark of the Hewlett-Packard Company. All other trademarks are the property of their respective owners.

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 12G9766

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Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Notices and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi

Laser notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi

Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx

Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Standard Finisher weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Booklet Finisher weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Media path overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Media size and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Media size/orientation and applicable functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Media weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Finisher theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Media transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Bridge unit assembly paper path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Finisher media path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Finisher roll assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Finisher media path sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Finisher motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Bridge unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

From bridge unit assembly to punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

From punch to compiler unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

From compiler unit assembly to stacker media bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

From punch to upper media bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Functions of sensors along the media path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Bridge unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Punch unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Adjusting punching positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Punching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Detecting punch waste full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Detecting punch waste box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Functions of punch sensors/motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Compiler unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Outline of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Capacity of compiler unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Compiler unit assembly operation with multiple media sizes . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Tamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Front tamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Rear tamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Center tamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

Determining tamper home position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

Tamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

Offsetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

Functions of compiler unit assembly sensors/motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

Table of contents iii

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Stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22

Stapling operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22

Staple positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22

Media sizes that allow stapling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23

Stapling one sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23

Stapling multiple size media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24

Media limits for stapling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24

Stapler operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24

Stapler unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25

Functions of stapler sensors/motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25

Booklet Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26

Functions of booklet sensors and motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-27

Upper media bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29

Functions of upper media bin sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29

Stacker media bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30

Full stack detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32

Functions of stacker media bin sensors/motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32

Booklet tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34

Power supply and interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34

Tools required for service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-36

Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-36

Diagnostic information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

POR (Power-On Reset) sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

To enter the diagnostic menu: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Error code messages - finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Service checks - finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

280.00 Sensor (bridge unit media entrance) late Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

280.01 Sensor (bridge unit media entrance) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

281.00 Sensor (bridge unit media exit) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

281.03 Sensor (bridge unit media exit) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

281.04 Sensor (bridge exit bin) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

281.05 Sensor (bridge exit bin) lag jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

281.06 Sensor (bridge exit bin) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19

282.00 Sensor (finisher media entrance) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

282.01 Sensor (finisher media entrance) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

283.00 Sensor (buffer path) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

283.03 Sensor (buffer path) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

284.00 Sensor (lower media exit) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

284.03 Sensor (lower media exit) lag jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29

284.05 Sensor (lower media exit) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

285.00 Sensor (media compiler in) lag jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

286.00 Sensor (compiler media in) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33

287.00 Sensor (upper media exit) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35

287.01 Sensor (upper media exit) lag jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

287.05 Sensor (upper media exit) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38

288.00 Sensor (diverter gate) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

288.01 Sensor (diverter gate) static jam A (to top bin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41

288.04 Sensor (diverter gate) static jam B (to stacker bin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42

289.00 sensor (booklet unit media entrance) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43

289.01 sensor (booklet unit media entrance) lag jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44

289.02 sensor (booklet unit media entrance) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46

289.03 sensor (booklet compiler media in) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47

289.04 Sensor (booklet unit media exit) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48

289.05 Sensor (booklet unit media exit) lag jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50

289.06 Sensor (booklet unit media exit) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51

iv Printer Finisher Service Manual

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981.00 Sensor (stacker bin level 1) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

981.01 Stacker bin upper limit error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

981.02 Stacker bin lower limit error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

982.00 Sensor (front tamper HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

982.01 Sensor (front tamper HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

983.00 Sensor (rear tamper HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

983.01 Sensor (rear tamper HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61

984.00 Sensor (punch unit HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

984.01 Sensor (punch unit HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

985.00 Sensor (punch carriage shift HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

985.01Sensor (punch carriage shift HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

986.00 Sensor (media eject clamp HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67

986.01 Sensor (media eject clamp HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

987.00 Sensor (media eject shaft HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70

987.01 Sensor (media eject shaft HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

988.01 Sensor (punch unit side reg1) or (sensor (punch unit side reg2) lag failure . . . . . . . . . 2-73

989.00 Stapler unit failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75

990.00 Sensor (stapler carriage HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75

990.01 Sensor (stapler carriage HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76

991.00 Sensor (booklet front temper HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78

991.01 Sensor (booklet front tamper HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79

991.02 Sensor (booklet rear tamper HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80

991.03 Sensor (booklet rear tamper HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82

991.04 Sensor (booklet end guide HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83

991.05 Sensor (booklet end guide HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85

991.06 Sensor (booklet unit interlock) error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86

991.07 Sensor (booklet compiler no media) no media detected . . . . . . . . . . . . . . . . . . . . . . . . . 2-87

991.08 Sensor (booklet knife HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88

991.09 Sensor (booklet knife HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90

991.10 Sensor (booklet knife folding) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92

991.11 Booklet stapler error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93

991.12 Communication error with booklet controller card assembly . . . . . . . . . . . . . . . . . . . . . 2-94

991.13 Booklet unit maker error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95

992.00 Sensor (de-curler cam HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95

992.01 Sensor (de-curler cam HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97

Bridge unit top cover open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98

Finisher front door open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100

Finisher eject cover open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101

Finisher upper media bin full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101

No punch waste box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102

Punch waste box full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103

Stacker media bin full (mix size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104

Stacker media bin full (no mix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106

Stacker lower safety failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108

Stacker set over count failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109

Staple cartridge empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110

Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Accessing service menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Diagnostics Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Entering Diagnostics Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Available tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

MOTOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

PRINT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Input Source Print Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Print Quality Test Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Table of contents v

5057-XXX

HARDWARE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

DRAM Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

CACHE Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

DUPLEX TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Sensor Test (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

INPUT TRAY TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Feed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Sensor Test (input tray) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

OUTPUT BIN TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Feed Tests (output bins) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Feed To All Bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Sensor Test (output bin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

FINISHER TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Staple Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Hole Punch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Feed Tests (Finisher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Sensor Test (Finisher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

BASE SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

PRINTER SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

PAGE COUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

Engine Setting 1 to 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

Model Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

Configuration ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

EVENT LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

Display the Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

Print the Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

Clear the Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

Trans Belt HP Fail Clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

Dev Unit Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

Fuser Temp Fail Clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

ATC SENSOR FAILURE CLEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

ENGINE ADJUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

Booklet Fold Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Finisher Config . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Exiting Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Entering Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

Available menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

Maintenance Counter Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

Reset Maintenance Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Black Only Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Print Quality Pages (Configuration Menu) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Color Trapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

SIZE SENSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

A5/Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B5/Executive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

Panel Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

PPDS Emulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

Energy Conserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

EVENT LOG (Configuration Menu) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

Paper Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

Envelope Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

Font Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

Require Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

. . . . . .3-26

vi Printer Finisher Service Manual

5057-XXX

Short Edge Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Tray Low Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Exiting Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Repair information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Before starting service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Finisher removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Bridge unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Bridge unit top cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Sensor (bridge unit top cover interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Bridge unit drive motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Bridge unit exit/de-curler drive belt removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

De-curler clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

sensor (de-curler cam HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Bridge unit motor cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Bridge unit right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Sensor (bridge unit media entrance) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Sensor (bridge unit media exit) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Sensor (bridge unit bin exit) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Bridge unit diverter gate solenoid removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Switch (bridge unit top cover interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Bridge unit diverter gate removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Bridge unit bin media exit solenoid removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Bridge unit left cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Top cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Upper media bin assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Right eject cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Stacker media bin assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Right lower low voltage power supply (LVPS) cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Rear lower cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Rear upper cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Upper media bin front cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Switch (finisher front door interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Finisher front door assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Left lower cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

Left upper cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Carriage lift belt left removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Carriage lift belt right removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

Sensor (stacker bin level 1) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

Sensor (stacker bin level 2) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

Sensor (stacker bin level encoder) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

Sensor (stacker bin upper limit) or sensor (stacker bin no media) removal . . . . . . . . . . . . . . . 4-35

Stacker bin lift motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

Punch carriage assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

Punch carriage shift motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

Sensor (punch unit side registration pair) with bracket removal . . . . . . . . . . . . . . . . . . . . . . . . 4-43

Punch unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Punch media stop assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45

Punch unit motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

Sensor (punch unit motor encoder) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47

Sensor (punch hole select), sensor (punch cam front), and sensor (punch unit HP) removal 4-48

Sensor (punch carriage shift HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

Sensor (punch waste box set) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51

Sensor (punch waste box full) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52

Stapler unit frame removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53

Stapler unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

Sensor (stapler carriage HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57

Table of contents vii

5057-XXX

Media eject unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-58

Sub paddle removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-62

Sub paddle drive shaft assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-63

Media eject clamp motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-65

Sensor (media eject clamp HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-66

Switch (eject cover interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67

Media compiler unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-68

Sensor (front tamper HP) and sensor (rear tamper HP) removals . . . . . . . . . . . . . . . . . . . . . . . .4-70

Sensor (compiler media in) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-71

Media eject shaft assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73

Clamp paddle removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-75

Media eject clutch assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-76

Media eject motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-77

Sensor (media eject shaft HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-78

Sensor (lower media exit) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79

Lower media exit roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-80

Paddle and roll exit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-84

Lower pinch guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-88

Finisher diverter gate removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-89

Buffer diverter gate removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-90

Sensor (buffer path) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-91

Finisher buffer roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-92

Buffer pinch guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-94

Media entrance pinch guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-95

Sensor (finisher media entrance) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-96

Finisher media entrance roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-97

Drive motor (entrance/paddle) and belt (entrance/paddle) removal . . . . . . . . . . . . . . . . . . . . . .4-98

Finisher diverter gate solenoid removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-100

Buffer diverter gate solenoid removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-101

Sensor (upper media exit) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-102

Upper media exit pinch roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-102

Upper media exit roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-103

Sensor (upper media bin full) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-105

Upper pinch guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-106

Sensor (diverter gate) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-107

Upper media transport roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-108

Drive motor (exit) assembly and belt (exit) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-110

Drive motor (buffer/transport) and belt (buffer/transport) removal . . . . . . . . . . . . . . . . . . . . . .4-112

Bridge unit interface card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-114

Finisher controller card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-115

Finisher low voltage power supply (LVPS) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-116

Booklet bin hookup cable assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-117

Booklet bin assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-118

Sensor (booklet unit interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-119

Booklet controller card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-119

Booklet unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-121

Booklet folding/exit drive motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-121

Booklet diverter gate solenoid removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-122

Booklet stapler unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-122

Booklet knife solenoid frame removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Booklet knife solenoid removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-124

Booklet knife sector drive gear 42T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-125

Booklet media entrance drive motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-126

Booklet unit gear train frame removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-127

Booklet unit assembly left cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-128

Booklet rear tamper assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-129

Booklet front tamper guide removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-130

Sensor (booklet front tamper HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-131

Sensor (booklet rear tamper HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-132

4-123

viii Printer Finisher Service Manual

5057-XXX

Booklet front tamper motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-133

Booklet rear tamper motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-134

Sensor (booklet knife HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-135

Sensor (booklet knife folding) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-136

Booklet unit front door assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-137

Sensor (booklet unit media entrance) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-137

Sensor (booklet media compiler in) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-138

Sensor (booklet unit media exit) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-138

Sensor (booklet end guide HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-139

Booklet media pinch roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-140

Booklet paddle motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-141

Booklet end guide drive motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-141

Connector locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Finisher components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Bridge unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Stacker lift and stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Punch unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Diverter and media eject . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Media eject and media compiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Buffer, upper exit, lower exit, and drive motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Booklet media bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Booklet maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Preventive maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Safety inspection guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Lubrication specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Maintenance recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Assembly 1: Finisher–bridge unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Assembly 2: Finisher–bridge unit covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Assembly 3: Finisher–media drive 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Assembly 4: Finisher–media drive 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Assembly 5: Finisher–covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Assembly 6: Finisher–covers and front door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Assembly 7: Finisher–stacker bin lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Assembly 8: Finisher–punch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Assembly 9: Finisher–stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

Assembly 10: Finisher–media eject . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Assembly 11: Finisher–eject and compiler unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Assembly 12: Finisher–lower exit drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Assembly 13: Finisher–buffer and entrance drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

Assembly 14: Finisher–buffer, transport, and upper drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

Assembly 15: Booklet maker 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

Assembly 16: Booklet maker 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

Assembly 17: Booklet maker 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

Assembly 18: Booklet maker 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

Assembly 19: Booklet maker 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33

Assembly 20: Booklet maker 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

Assembly 21: Booklet maker 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35

Assembly 22: Booklet maker 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

Assembly 23: Booklet maker 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

Assembly 24: Finisher–electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

Assembly 25: Finisher–cables 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

Assembly 26: Finisher–cables 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42

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Assembly 27: Finisher–cables 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-1

Part number index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-5

x Printer Finisher Service Manual

Notices and safety information

The following laser notice labels may be affixed to this printer.

Laser notice

The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.

Class I 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 I level during normal operation, user maintenance, or prescribed service condition.

Laser

Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die Anforderungen der Bestimmung DHHS (Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International Electrotechnical Commission) 60825-1 gemäß amtlicher Bestätigung erfüllt.

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Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen der Länge 770-795 Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, daß im Normalbetrieb, bei der Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laserbestrahlung, die Klasse I übersteigen würde, Menschen keinesfalls erreicht.

Avis relatif à l’utilisation de laser

Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant les produits laser de Classe I (1). Pour les autres pays : cette imprimante répond aux normes IEC 60825-1 relatives aux produits laser de Classe I.

Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette imprimante est équipée d’un laser de Classe IIIb (3b) (arséniure de gallium d’une puissance nominale de 5 milliwatts) émettant sur des longueurs d’onde comprises entre 770 et 795 nanomètres. L’imprimante et son système laser sont conçus pour impossible, dans des conditions normales d’utilisation, d’entretien par l’utilisateur ou de révision, l’exposition à des rayonnements laser supérieurs à des rayonnements de Classe I .

Avvertenze sui prodotti laser

Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825-1.

I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un laser di classe IIIb (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 assistenza tecnica, non ricevano radiazioni laser superiori al livello della classe 1.

Notices and safety information xi

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Avisos sobre el láser

Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de Clase I (1).

Los productos láser de Clase I no se consideran peligrosos. La impresora contiene en su interior un láser de Clase IIIb (3b) de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nanómetros. El sistema láser y la impresora están diseñados de forma que ninguna persona pueda verse afectada por ningún tipo de radiación láser superior al nivel de la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra situación de servicio técnico.

Declaração sobre Laser

A impressora está certificada nos E.U.A. em conformidade com os requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a Classe I (1) de produtos laser. Em outros locais, está certificada como um produto laser da Classe I, em conformidade com os requisitos da norma IEC 60825-1.

Os produtos laser da Classe I não são considerados perigosos. Internamente, a impressora contém um produto laser da Classe IIIb (3b), designado laser de arseneto de potássio, de 5 milliwatts ,operando numa faixa de comprimento de onda entre 770 e 795 nanómetros. O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radiação laser superior a um nível de Classe I durante a operação normal, a manutenção feita pelo utilizador ou condições de assistência prescritas.

Laserinformatie

De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1.

Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van klasse IIIb (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 I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer. Lasersystemet og printeren er udformet således, at mennesker aldrig udsættes for en laserstråling over Klasse I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.

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Laserilmoitus

Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi.

Luokan I lasertuotteita ei pidetä haitallisina. Tulostimen sisällä on luokan IIIb (3b) laser, joka on nimellisteholtaan 5 mW:n galliumarsenidilaser ja toimii 770 - 795 nanometrin aallonpituuksilla. Laserjärjestelmä ja tulostin ovat rakenteeltaan sellaisia, että käyttäjä ei joudu alttiiksi luokkaa 1 suuremmalle säteilylle normaalin käytön, ylläpidon tai huollon aikana.

Huomautus laserlaitteesta

Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen.

Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä. Laserjärjestelmä ja kirjoitin on suunniteltu siten, että käyttäjä ei altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen normaalin toiminnan, käyttäjän tekemien huoltotoimien tai muiden huoltotoimien yhteydessä.

VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso säteeseen.

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VARNING! Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad. Betrakta ej strålen.

Laser-notis

Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 60825-1.

Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770-795 nanometer. Lasersystemet och skrivaren är utformade så att det aldrig finns risk för att någon person utsätts för laserstrålning över Klass I-nivå vid normal användning, underhåll som utförs av användaren eller annan föreskriven serviceåtgärd.

Laser-melding

Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1.

Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer. Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstråling ut over klasse I-nivå under vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne serviceoperasjoner.

Notices and safety information xiii

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Avís sobre el Làser

Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe I que compleix els requisits d’IEC 60825-1.

Els productes làser de classe I no es consideren perillosos. Aquesta impressora conté un làser de classe IIIb (3b) d’arseniür de gal.li, nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona de 770-795 nanòmetres. El sistema làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la radiació làser per sobre d’un nivell de classe I durant una operació normal, durant les tasques de manteniment d’usuari ni durant els serveis que satisfacin les condicions prescrites.

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Notices and safety information xv

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xvi Printer Finisher Service Manual

Safety information

• 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.

• 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.

• 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

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 sécurité

• La sécurité de ce produit repose sur des tests et des

agréations portant sur sa conception d'origine et sur des composants particuliers. Le fabricant n'assume aucune responsabilité concernant la sécurité en cas d'utilisation de pièces de rechange non agréées.

• Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de

maintenance qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel

d'entretien qualifié devra prendre toutes les précautions nécessaires.

• ATTENTION : Ce symbole indique la présence d'une tension dangereuse dans la partie du

produit sur laquelle vous travaillez. Débranchez le produit avant de commencer ou faites preuve de vigilance si l'exécution de la tâche exige que le produit reste sous tension.

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Norme di sicurezza

• La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti

specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti.

• Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di

assistenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto,

il rischio di subire scosse elettriche e danni alla persona è più elevato. Il personale di assistenza autorizzato deve, quindi, adottare le precauzioni necessarie.

• 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 xvii

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Sicherheitshinweise

• Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und

bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine

Verantwortung oder Haftung für die Sicherheit übernommen.

• Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen

Wartungsfachmann bestimmt.

• Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusätzliches Risiko eines

elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende

Vorsichtsmaßnahmen treffen.

• ACHTUNG: Dieses Symbol weist auf eine gefährliche elektrische Spannung hin, die in diesem

Bereich des Produkts auftreten kann. Ziehen Sie vor den Arbeiten am Gerät den Netzstecker des Geräts, bzw. arbeiten Sie mit großer Vorsicht, wenn das Produkt für die Ausführung der Arbeiten an den Strom angeschlossen sein muß.

Pautas de Seguridad

• La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes

específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no

autorizadas.

• La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal

cualificado de mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de

la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones

necesarias.

• PRECAUCIÓN: este símbolo indica que el voltaje de la parte del equipo con la que está

trabajando es peligroso. Antes de empezar, desenchufe el equipo o tenga cuidado si, para trabajar con él, debe conectarlo.

Informações de Segurança

• A segurança deste produto baseia-se em testes e aprovações do modelo original e de componentes

específicos. O fabricante não é responsável pela segunrança, no caso de uso de peças de substituição

não autorizadas.

• As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não

devem ser utilizadas por outras pessoas.

• Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste produto.

Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários.

• CUIDADO: Quando vir este símbolo, existe a possível presença de uma potencial tensão

perigosa na zona do produto em que está a trabalhar. Antes de começar, desligue o produto da tomada eléctrica ou seja cuidadoso caso o produto tenha de estar ligado à corrente eléctrica para realizar a tarefa necessária.

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Informació de Seguretat

• La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components

específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades.

• La informació pel manteniment d’aquest producte està orientada exclusivament a professionals i no està

destinada a ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei

d’aquest producte. El personal professional ha d’estar-ne assabentat i prendre les mesures convenients.

• PRECAUCIÓ: aquest símbol indica que el voltatge de la part de l'equip amb la qual esteu

treballant és perillós. Abans de començar, desendolleu l'equip o extremeu les precaucions si, per treballar amb l'equip, l'heu de connectar.

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Safety information xix

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Preface

This manual contains maintenance procedures for service personnel. It is divided into the following chapters:

1. General information contains a general description of the printer and the maintenance approach used to

repair it. Special tools and test equipment, as well as general environmental and safety instructions, are discussed.

2. Diagnostic information contains an error indicator table, symptom tables, and service checks used to

isolate failing field replaceable units (FRUs).

3. Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer problems.

4. Repair information provides instructions for making printer adjustments and removing and installing FRUs.

5. Connector locations uses illustrations to identify the connector locations and test points on the printer.

6. Preventive maintenance contains the lubrication specifications and recommendations to prevent

problems.

7. Parts catalog contains illustrations and part numbers for individual FRUs.

Conventions

Note: A note provides additional information. Warning: A warning identifies something that might damage the product hardware or software.

There are several types of caution statements:

CAUTION

A caution identifies something that might cause a servicer harm.

CAUTION

This type of caution indicates there is a danger from hazardous voltage in the area of the 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.

CAUTION

This type of caution indicates a hot surface.

CAUTION

This type of caution indicates a tipping hazard.

xx Printer Finisher Service Manual

1. General information

Finisher

The optional finisher staples, punches, folding and stapling, and stacks media transferred from the Lexmark™ C930, C935, X940e and X945e. Output is stacked in the upper media bin or separately collated in the stacker media bin or folded and stapled in the booklet bin.

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Standard Finisher weight

Unpacked: 59 kg (130 lbs)

Booklet Finisher weight

Unpacked: 87.5 kg (193 lbs)

Components

The finisher is composed of the following components.

• Bridge unit assembly block to feed media from the printer to the finisher

• Punch block to punch media

• Compiler tray block to align media

• Stapler block to staple a set of media at specified positions

• Booklet unit and tray

General information 1-1

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Media path overview

Media size and weight

The following shows media sizes and weights 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 finisher 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 Media description

Size

first (SEF)/

Long edge

first (LEF)

182 x 257 mm

Executive 7.25 x 10.5 in.

184.2 x 27 0 mm

Letter 8.5 x 11 in.

215.9 x 279.4 mm

210 x 297

SEF Yes No No No No No No LEF Yes Yes Yes Yes SEF Yes No No No No No No LEF Yes Yes Yes Yes SE F Ye s Yes Ye s Yes LEF Yes Yes Yes Yes SE F Ye s Yes Ye s Yes LEF Yes Yes Yes Yes2

Folio (foolscap) 8,5 x 13 in. SEF Yes Yes Yes Yes

Top tray

Stacker

Stack Stack

Offset stack

Punch Staple Booklet Folding

a(2)

Yes No No

a(2,3,4)

No No No

a(2)

Yes Yes Yes

a(2,3,4)

Yes No No

a(2)

Yes Yes Yes

,a(3,4)

Yes No No

a(2)

Yes Yes Yes

Legal 8.5 x 14 in. SEF Yes Yes Yes Yes

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a(2)

Yes Yes Yes

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Ledger 11 x 17 in. SEF Yes Yes Yes Yes

Custom size Same width with

Custom size Besides above Yes Yesb Yesb No No No No

Numbers (2,3,4) mean 2 holes, 3 holes, and 4 holes, respectively.

Applicable within the following range:

Media width: 203.2—297 mm Media length: 182—431.8 mm

257 x 364 mm

297 x 420 mm

standard size

SE F Ye s Yes Ye s Yes

Yes Yes Yes Ye s Yes No No

a(2)

Yes Yes Yes

a(2,3,4)

Yes Yes Yes

a(2,3,4)

Yes Yes Yes

Media weight

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 For folding and stapling 52-226 gsm * The amount of media capable of being stapled will be less than 50 if the media

weight is greater than 90 g/m

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 Folding and stapling Booklet tray

Finisher theory

Media transport

This section describes the transfer of media from the printer to a specified bin.

The following figures illustrate layouts (front view) of sensors, rollers, and main blocks, as well as a layout (rear view) of the main components.

General information 1-3

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Bridge unit assembly paper path

Finisher media path

Upper Media Bin

Punch Unit

From Bridge Unit

Knife Folding

Booklet Stapler Unit

End Guide

Stapler Unit

Stacker Media Bin

Compiler Media Unit Assembly

Booklet Bin

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Finisher roll assemblies

Upper Media Transport Roll Assembly – driven by drive motor (buffer/transport)

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Upper Media Exit Roll Assemblydriven by motor (exit)

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 assembly driven by drive motor (entrance paddle)

Booklet entrance roll assembly media entrance drive motor

driven by booklet

Booklet fold roll assembly driven by booklet folding/exit drive motor assembly

Finisher Diverter Gate

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

Booklet media exit roll assembly driven by booklet folding/exit drive motor assembly

Booklet paddle shaft assembly

General information 1-5

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Finisher media path sensors

Sensor (diverter gate)

Sensor (upper media)

Sensor (upper media bin full)

Sensor (media entrance)

Sensor (buffer path)

Sensor (booklet media entrance)

Sensor (booklet compiler media in)

Sensor (lower media exit)

Sensor (booklet media exit)

Sensor (booklet bin media present)

1-6 Printer Finisher Service Manual

Finisher motors

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Drive motor (exit)

Media eject clamp motor

Media eject motor assembly

Stacker bin lift motor assembly

Bridge unit assembly

When the printer designates the finisher, 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 the printer’s registration clutch, which drives the transport belts in the bridge unit assembly. The motor power is transmitted to the two belts between the bridge unit right shaft assembly and the bridge unit left shaft assembly.

Drive motor (buffer/transport)

Finisher diverter gate solenoid

Buffer diverter solenoid

Drive motor (entrance paddle)

The media fed to the bridge unit assembly is securely held between the transport belts and the pinch rolls, and fed to the finisher.

Sensor (bridge unit

Bridge unit assembly

Bridge unit drive motor assembly

Bridge unit decurler clutch

Sensor (bridge unit media exit)

top cover interlock

Sensor (bridge unit bin media exit)

Bridge unit diverter gate solenoid

Sensor (bridge unit media entrance)

Bridge unit bin media exit solenoid

General information 1-7

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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 which is driven by the drive motor (entrance/paddle).

The media route inside the finisher is determined by the finisher diverter gate.

The finisher diverter gate is activated by the finisher diverter gate solenoid controlled by the printer.

The media is further fed in the finisher by the two upper media transport roll assemblies, or the buffer roll assemblies 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 amount of time has passed and the level has changed to high, 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, 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 media is fed to the exit (while the motor (buffer/transport) is rotating forward), but rise 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)

Punch unit

Finisher diverter gate solenoid

Drive motor (entrance paddle)

Sensor (finisher media entrance)

Upper media transport roll assembly—driven by drive motor (buffer/transport)

Punch unit

Sensor (finisher media entrance)

Media

From bridge unit assembly

Finisher media entrance roll assembly—driven by drive motor (entrance/paddle)

Upper media transport roll assembly

Punch unit

Finisher diverter gate

Buffer roll assembly

Finisher media entrance roll assembly

Finisher diverter gate

1-8 Printer Finisher Service Manual

Buffer roll assembly— driven by drive motor (buffer/transport)

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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 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

Drive motor (exit)

Drive motor (buffer/transport)

Buffer diverter solenoid

Drive motor (entrance/paddle)

Media eject motor assembly

Sensor (lower media exit)

Eject clamp

Buffer roll assembly

Buffer diverter gate

Media eject shaft assembly

Lower media exit roll assembly

Compiler unit assembly

General information 1-9

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Sensor (lower media exit)

Sub paddle—driven by drive motor (entrance/paddle)

Buffer roll assembly— driven by drive motor (buffer/transport)

Media eject shaft assembly—

Eject clamp—driven by eject clamp motor

driven by media eject motor asm

Buffer diverter

Main paddle motor—driven by motor (entrance/paddle)

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 reaches 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 the buffer path.)

The first media of the second set is aligned with 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 the buffer path is executed for the first media, if a 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 the buffer path. At this time, a certain delay time is provided to prevent the second media from colliding with the first one.

Compiler unit assembly

Lower media exit roll assembly—driven by motor (exit)

Media

Sensor (buffer path)

Buffer roll assembly driven by drive motor (buffer/transport)

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Buffer diverter gate

Compiler unit assembly

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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 motor 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 finisher diverter gate located behind the punch and fed in the upper media transport roll assembly direction.

The finisher diverter gate is switched by the finisher 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 assemblies 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) ejects 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 sensor that detects whether media is fed from the printer to the bridge unit assembly — It turns high (+5 V dc) (light receiving) when media enters the bridge unit assembly.

• Sensor (bridge unit media exit)

— A photo-interrupter sensor that detects whether media passes through the bridge unit assembly — It turns high (+5 V dc) (light receiving) when media reaches this sensor, and turns low (0 V dc) when

media exits from the bridge unit assembly.

• Sensor (bridge unit top cover interlock)

— A photo-interrupter sensor that detects open/close of the bridge top cover assembly of the bridge unit

assembly

— It turns high (+5 V dc) (light receiving) when the bridge top cover assembly opens.

Sensor (bridge unit

Bridge unit assembly

Bridge unit drive motor assembly

top cover interlock

Sensor (bridge unit bin media exit)

Bridge unit decurler clutch

Sensor (bridge unit media exit)

Bridge unit diverter gate solenoid

Sensor (bridge unit media entrance)

Bridge unit bin media exit solenoid

General information 1-11

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Finisher

• Sensor (finisher media entrance)

— A photo-reflective sensor detects whether media is fed from the bridge unit assembly to the finisher — It turns high (+5 V dc) while media is present within the sensing area. — When the level turns high due to the first media of the second set during multi-set printing, this sensor

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 photo-reflective sensor that detects the leading edge of the media — It turns low (0 V) when the front end reaches the sensing area.

• Sensor (lower media exit)

— A photo-interrupter sensor that detects whether media passes through the sensor (lower media exit) — It turns high (+5 V) (light receiving) when the actuator is driven out of the sensing area by the media. — When the level turns high, this sensor activates the front tamper motor and the rear tamper motor on the

compiler unit assembly.

— This sensor is also used to control on/off of the media eject motor assembly

• Sensor (compiler media present)

— A photo-interrupter sensor that detects 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 high (+5 V dc)

(light receiving).

• Sensor (buffer path)

— A photo-interrupter sensor that detects 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 high (+5 V dc)

(light receiving).

• Sensor (upper media exit)

— A photo-interrupter sensor that detects 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 turns high (+5 V dc).

• Sensor (upper media bin full) A photo-reflective sensor that detects the stack volume of media in the upper media bin

Sensor (diverter gate)

Sensor (finisher media entrance)

From bridge unit

Sensor (buffer path)

Sensor (upper media exit)

Sensor (upper media bin full)

Sensor (lower media exit)

Sensor (compiler media in)

1-12 Printer Finisher Service Manual

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).

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.

The three punching positions from the media edge in the direction of media width are determined by the following method.

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• Activate the punch carriage shift motor assembly, and move the punch to the front side until the sensor (punch carriage shift HP) turns low.

• Reversely rotate the motor, and move the punch to the rear side until the sensor turns high to determine the home position.

• The punch carriage shift motor assembly is activated to move the punch to the front until the sensor (punch unit side 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)

Sensor (punch cam front)

Sensor (punch hole select)

Sensor (punch unit HP)

Sensor (punch unit motor encoder)

Punch carriage shift motor assembly

Sensor (punch unit side registration 2)

Sensor (punch unit side registration 1)

Punch unit motor

General information 1-13

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Punching

After punching positions are determined, the punch unit motor is activated to move the cam 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) being turned on/off.

Pin position

Sensor (punch hole select)

Home position

Sensor (punch cam front)

Sensor (punch unit HP)

Punch unit motor

Cam plate

3 hole position

Home position

2 hole position

Home position

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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 photo-reflective sensor that detects 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 high (+5 V dc) while media is present, and turns low when media side edge is

detected.

• Sensor (punch unit side registration 2)

— A photo-reflective sensor that detects 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 sensor that detects the home position of the moving punch — It turns high (+5 V dc) (light blocking) when the home position is detected.

• Sensor (punch unit HP)

— A photo-interrupter sensor that detects the home position of the cam plate that lowers the punching pins — It turns high (+5 V dc) when the home position is detected.

• Sensor (punch hole select)

— A photo-interrupter sensor that detects the rear position of the cam plate — It turns high (+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 sensor that detects the front position of the cam plate — It turns high (+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)

— A photo-interrupter sensor that detects 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

— A DC 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.

General information 1-15

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• Sensor (punch waste box set)

— A photo-interrupter sensor that detects whether the 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 high (+5 V dc).

• Sensor (punch waste box full) A photo-interrupter sensor that detects whether the punch waste box is filled with punch waste.

Sensor (punch carriage shift HP)

Sensor (punch cam front)

Sensor (punch hole select)

Sensor (punch unit HP)

Sensor (punch unit motor encoder)

Compiler unit assembly

This section describes the operation of the compiler unit assembly which aligns the media edge transferred from the punch unit.

Outline of operation

When media is fed onto the compiler unit assembly, tamping is performed to align the media edge in the media width direction.

Punch carriage shift motor

Sensor (punch unit side registration 2)

Sensor (punch unit side registration 1)

Punch unit motor

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

Sensor (rear tamper HP)

Rear tamper motor

1-16 Printer Finisher Service Manual

Sensor (compiler media in)

Front tamper

Sensor (front tamper HP)

Front tamper motor

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Capacity of compiler 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

non-staple mode For large media (216 mm or more in the feed direction) in

non-staple mode

10 50 100

10 25 100

Compiler unit assembly operation with multiple media sizes

When two or more media sizes are used and their widths are the 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.

When 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 the stacker media bin.

Tamping

When media is fed from the punch to the compiler unit assembly, tamping 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. The front tamper or rear tamper is moved to the end of the media by its motor.

Tamping is executed each time when a sheet of media reaches the compiler unit assembly. Additional tamping is executed after the last sheet is tamped.

There are three types of tamping.

• Front tamping–Tamping by the rear tamper with the front tamper fixed at the home position

• Rear tamping–Tamping by the front tamper with the rear tamper fixed at the home position

• Center tamping–Tamping by the front and rear tampers to align media to the center

General information 1-17

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Front tamping

Front tamping is used in the following cases.

• In the non-staple mode

• When executing front stapling (corner)

The tamper positions during front tamping are shown below.

Sensor (front tamper HP)

Front

Sensor (rear tamper HP)

Rear

Front tamper motor

Position Description

1 Front tamper home position–sensor (front tamper HP) 2 Front tamper size position 3 Front tamper offset position 4 Rear tamper home position–sensor (rear tamper HP) 5 Rear tamper standby position 6 Rear tamper tamping position 7 Rear tamper offset position

Front tamper

Rear tamper

Rear tamper motor

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Rear tamping

Rear tamping is used in the following cases.

• When executing rear stapling (corner)

• When executing dual stapling

The tamper positions during rear tamping are shown below.

Sensor (front tamper HP)

Front

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Sensor (rear tamper HP)

Rear

Front tamper motor Front tamper

Position Description

1 Front tamper home position–sensor (front tamper HP) 2 Front tamper tamping position 3 Front tamper offset position 4 Rear tamper home position–sensor (rear tamper HP) 5 Rear tamper size position 6 Rear tamper offset position

Rear tamper

Rear tamper motor

General information 1-19

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Center tamping

Center tamping is used when executing rear stapling (straight).

The tamper positions during center tamping are shown below.

Sensor (front tamper HP)

Front

Sensor (rear tamper HP)

Rear

Front tamper motor Front tamper

Position Description

1 Front tamper home position–sensor (front tamper HP) 2 Front tamper standby position 3 Front tamper tamping position 4 Front tamper offset position 5 Rear tamper home position–sensor (rear tamper HP) 6 Rear tamper standby position 7 Rear tamper size position 8 Rear tamper offset position

Rear tamper

Rear tamper motor

Determining tamper home position

When the sensor (lower media exit) turns high (+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 high (+5 V dc) when media is detected on the compiler unit assembly.

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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 units, etc.) can be easily recognized.

Offsetting is executed for staple positions:

• 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

• During rear stapling (corner/straight)

— For media with a width of 216 mm or more [rear staple (corner)]–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 stapled sheets using the front

tamper by 9 mm to the rear side before ejecting them to the stacker media bin.

During dual stapling:

• Shifts stapled sheets using the front tamper by 9 mm to the rear side before ejecting them to the stacker media bin.

• Offsetting is not executed (0 mm) for small media.

Functions of compiler unit assembly sensors/motors

• Sensor (compiler media in)

— A photo-interrupter sensor that detects 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 high (+5 V dc)

(light receiving).

• Sensor (front tamper HP)

— A photo-interrupter sensor that detects 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 high (+5 V dc) (light blocking).

• Sensor (rear tamper HP)

— A photo-interrupter sensor that detects 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 high (+5 V dc) (light blocking).

• Front tamper motor

— A stepping motor that moves 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.

General information 1-21

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Stapler

• Rear tamper motor

— A stepping motor that moves the rear tamper for tamping — Clockwise rotation 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

Front tamper

Sensor (rear tamper HP)

Rear tamper motor

Sensor (compiler media in)

Front tamper motor

Sensor (front tamper HP)

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:

• Front staple (corner) [front corner] The stapler staples a set of media obliquely (45 degrees) after the rear tamper aligns the media to the front side.

• Rear staple (corner) [rear corner]

This type of stapling is applied for media with a width of 216 mm or more. The stapler moves to the rear corner and staples a set of media obliquely (45

degrees) after the front tamper aligns the media to the rear side.

Rear

Process direction

Front

Rear

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Process direction

Front

• Rear Staple (Straight) [rear straight] This type of stapling is applied for media with a width of less than 216 mm. The Stapler staples a set of media in parallel with the media edge after the front

tamper aligns the media to the rear side.

• Dual Staple [dual] The Stapler staples a set of media at fixed positions (front/rear sides) in parallel

with the media edge after the front tamper aligns the media to the specified position for each media size.

Media sizes that allow stapling

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Rear

Process direction

Front

Rear

Process direction

Front

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 corner

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 /

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

Yes N o Ye s Ye s

Rear corner

Rear straight

Dual

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.

General information 1-23

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Stapling multiple size media

When sheets with different sizes and the 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.

When sheets with different widths are present on the compiler unit assembly, stapling is stopped when a different width is detected. 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.

• 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.

• 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.

• 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.

The upper limit (and default) of the compiler unit assembly media capacity when stapling is 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 performs stapling.

Stapler carriage motor asm

Media handling direction

Sensor (stapler carriage HP)

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Stapler unit assembly

The 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)

Sensor (low staple)

Stapler unit assembly

Stapler unit motor

Functions of stapler sensors/motors

• Sensor (stapler carriage HP)

— A photo-interrupter sensor that detects the stapler home position, rear staple (corner) position, and rear

staple (straight) position

— It turns high (+5 V dc) (light blocking) when the stapler comes to the specified position.

• Stapler carriage motor assembly

— A stepping motor that moves the stapler unit assembly — Clockwise rotation of this motor moves the stapler unit assembly to the rear side, while counterclockwise

rotation moves the stapler unit assembly to the front side.

• Sensor (low staple) in the stapler unit assembly

— A photo-interrupter sensor that detects when the stapler unit assembly is nearly out of staples — It turns high (+5 V dc) when 20 staples are left.

• Sensor (self priming) in the stapler unit assembly

— A photo-interrupter sensor that detects that staples are at the stapler unit assembly end; it also detects

failure in stapling

— It turns low (0 V dc) (light blocking) when stapling is ready.

• Sensor (staple home) in the stapler unit assembly

— A photo-interrupter sensor that detects the stapler unit assembly home position; it also detects failure in

stapling

— This sensor also functions as a trigger to stop the staple motor. — It turns low (0 V dc) (light blocking) while the stapler unit assembly stays at the home position.

General information 1-25

5057-XXX

• Stapler unit motor (in the stapler unit assembly)

— A DC motor to activate the stapler unit assembly for stapling — Clockwise rotation of this motor enables stapling, while counterclockwise rotation returns the stapler unit

assembly.

Sensor (stapler carriage HP)

Booklet Operation

The booklet media entrance roll assembly driven by the booklet media entrance drive motor will deliver media from the finisher entrance and stack it against the booklet end guide in the booklet unit. When the booklet end guide is at the bottom of the booklet unit it will continue to accept media. Once the proper amount of media is reached, stapling will occur and booklets will be delivered in sets to the booklet media bin.

Stapler carriage motor asm

Stapler rack gear

The booklet media exit roll assembly is driven by booklet folding/exit drive motor assembly and delivers booklets to the booklet media bin. During printing, paper drawn to the booklet compiler is aligned by the booklet paddle shaft assembly which is driven by booklet paddle shaft drive Motor.

When a sheet of paper enters the booklet compiler, tamping operation is performed by two moving tampers moving towards the front and rear. The front tamper is driven by front booklet tamper drive motor; rear booklet tamper drive motor. Tamping operation will be performed a final time after the last sheet is received.

Documents in the compiler tray are assembled towards the front. For center stapling and folding positions, one set of document is assembled and moved to the center.

The booklet end guide is lifted to where the fold will divide the paper into two equal halves. When the printouts are stapled, the booklet end guide will be raised so that the stapled position is at the folding position. The stapling position is slightly lower than the folding position center line.

When the movement from the booklet folding/exit drive motor is transferred to the knife through the engagement of the sector gear, the knife will thrust forward and then return to the original position after one full rotation. At the folding position, the knife is thrust forward to fold the paper between booklet folding roll and booklet folding nip roll.

Paper is folded into two halves by the booklet folding roll driven by the booklet folding/exit drive motor and is delivered to the booklet media bin by the booklet media exit roll assembly. The booklet media bin belt will move at a fixed interval for every set of booklets that are created.

1-26 Printer Finisher Service Manual

Functions of booklet sensors and motors

5057-XXX

• Sensor (booklet media entrance)

— This photo sensor detects the media delivery to the booklet unit.

• Sensor (booklet media exit)

— This photo sensor detects paper delivery to booklet media bin.

• Booklet media entrance drive motor assembly

— This stepping motor drives the booklet media entrance roll assembly.

• Booklet folding/exit drive motor assembly

— This DC motor drives booklet folding roll, booklet media exit roll assembly, and knife.

General information 1-27

5057-XXX

• Booklet knife solenoid

— This solenoid transfers the booklet folding/exit drive motor assembly to the knife through the gear.

Booklet media entrance roll assembly

Booklet folding roll assembly

Booklet media exit roll assembly

Sensor (booklet media exit roll assembly)

• Sensor (booklet front tamper HP)

Booklet folding/exit motor assembly

Sensor (booklet media entrance)

Booklet media entrance drive motor

Booklet knife solenoid

— This photo sensor detects the home position of the booklet front tamper.

• Sensor (booklet rear tamper HP)

— This photo sensor detects the home position of the booklet Rear tamper.

• Sensor (booklet compile media in) This photo sensor detects paper present in the booklet compiler tray.

— Booklet front tamper motor

This stepping motor drives the booklet front tamper.

• Booklet rear tamper motor

— This stepping motor drives the booklet rear tamper.

• Sensor (booklet knife HP)

— This photo sensor detects the home position (stored condition) of knife.

• Sensor (knife folding)

— This photo sensor detects the fold position (protruded condition) of knife.

• Booklet staple assembly

— This booklet stapler consist of two stapler units (including stapler low switch) and booklet stapler head

motor.

• Booklet paddle motor

— This DC motor drives the paddle at the booklet section.

• Sensor (booklet end guide HP)

— This photo sensor detects the home position of the booklet end guide.

• Booklet end guide drive motor

— This stepping motor moves the booklet end guide up and down.

1-28 Printer Finisher Service Manual

• Sensor (booklet drawer interlock)

— This photo sensor detects when the booklet unit is set.

• Sensor (booklet bin media present)

— This photo sensor detects paper availability on the booklet media bin. If 15 sets of printouts are detected

in the booklet media bin, it will be considered as Full Stack.

Upper media bin

5057-XXX

Booklet bin drive motor

Sensor (booklet bin media present)

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 a full stack (500 sheets) in the upper media bin, ejection of media to the upper media bin is inhibited until a full stack is reset.

Functions of upper media bin sensors

• Sensor (upper media exit)

— A photo-interrupter sensor that detects 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 high (+5 V dc).

• Sensor (upper media bin full)

— A photo-reflective sensor that detects the media stack volume in the upper media bin — It turns high (+5 V dc) when it detects a full stack.

General information 1-29

5057-XXX

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 a 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 high. The height of media or the stacker media bin is detected 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)

Bin: height moves

Bin: proper

Bin: low moves upward

wnwar

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.

1-30 Printer Finisher Service Manual

5057-XXX

The stacker media bin lowers according to the volume of media it contains. If any obstacle under the tray hinders the tray from lowering, the 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)

Sensor (stacker bin upper limit)

Sensor (stacker bin no media)

Stacker bin lift motor assembly

Actuator

Sensor (stacker bin level encoder)

General information 1-31

5057-XXX

Full stack detection

A 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 a media volume of approximately 300 sheets in the stacker media bin is detected.

The mix stacking mode indicates one of the following cases:

• A larger (any size of media) sheet of media is stacked on a smaller sheet.

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.

• A sheet of media of less than 11 inches is stacked in the stacker media bin with the Staple Mode changed.

• 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.)

• Media was present in the stacker media bin when power was turned on.

(The size and condition of media stacked in the tray are not identified.)

• The finisher entered the Sleep Mode with mix stacking and then has exited the Sleep Mode.

• The post-processing mode has changed.

Top view of finisher tray

Functions of stacker media bin sensors/motors

• Sensor (stacker bin level 1)

— A light emitter and photo-receiver paired together 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 high, deciding that the stacker media bin is above

the reference level.

— To the contrary, when receiving light, this sensor turns low, deciding that the stacker media bin is below

the reference level.

— The high to low turning point of the sensor is defined as the reference level.

• Sensor (stacker bin level 2)

— A light emitter and photo-receiver paired together 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 high, deciding that the stacker media bin is above

the reference level.

— To the contrary, when receiving light, this sensor turns low, deciding that the stacker media bin is below

the reference level.

• Sensor (stacker bin no media)

Rear staple

Front staple

1-32 Printer Finisher Service Manual

— A photo-interrupter sensor that detects that the stacker media bin is at the highest position; it also

detects 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 high (+5 V).

• Sensor (stacker bin upper limit)

— A photo-interrupter sensor that detects 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 high (+5 V).

• Sensor (stacker bin level encoder)

— A photo-interrupter sensor that counts the pulse of the Encoder attached to the Shaft-Elevator. — The media volume in the stacker media bin is detected based on this count.

• Stacker bin lift motor

— A DC motor that elevates or lowers the stacker media bin — Clockwise rotation elevates the tray, and counterclockwise rotation lowers the tray.

• Media eject motor assembly

— A stepper motor that ejects stapled or non-stapled media to the stacker media bin — Clockwise rotation ejects media to the stacker media bin, and counterclockwise rotation reverses the

eject roll to feed the media from the punch to the compiler unit assembly.

• Media eject clamp motor A DC motor that elevates or lowers 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

• Sensor (media eject clamp HP)

— A photo-interrupter sensor that detects the set clamp home position — This sensor functions as a trigger to control On/Off of the set clamp clutch.

• 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

5057-XXX

Sensor (stacker bin level 2)

Media eject clutch

Sensor (stacker bin upper limit)

Sensor (stacker bin no media)

Stacker bin lift motor assembly

Sensor (media eject clamp HP)

Media eject motor assembly

Sensor (media eject shaft HP)

Sensor (stacker bin level encoder)

General information 1-33

5057-XXX

Booklet tray

Paper is folded into two by the booklet folding roll driven by the booklet Fold Roll Motor and booklet Eject Roll, and delivered to the booklet tray. Booklet tray is at a position lower than the paper delivery exit. Paper delivery belt will move at fixed interval for every set of output. When two sets or more is being delivered, one set at a time is being delivered.

When the front of the booklet tray is facing down, the printout will fall automatically below the tray. When removing paper, press booklet tray belt switch to move the paper delivery belt to the position for paper removal.

Booklet bin drive motor

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.

Sensor (booklet bin media present)

1-34 Printer Finisher Service Manual

5057-XXX

• Switch (eject cover interlock)–Turns off when the cover eject on the right side opens, shutting off the Interlock +24 V dc line in the finisher.

Switch (eject cover interlock)

Switch (finisher front door interlock)

Printer

Finisher LVPS card asm

+24Vdc

ON/OFF

Finisher controller card asm

+5Vdc

+24Vdc

Interlock +24Vdc

Sensor

Switch (eject cover interlock)

Switch (finisher front door interlock)

General information 1-35

5057-XXX

Tools required for service

Flat-blade screwdriver #1 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic short-blade Needle nose pliers Diagonal side cutters Spring hook

5.5 mm hex driver, magnetic Analog or digital multi-meter Parallel wrap plug 1319128 Twinax/serial debug cable 1381963 Coax/serial debug cable 1381964

Acronyms

3TM 3 Tray Module AC Alternating Current ADF Automatic Document Feeder APS Automatic Paper Size ASIC Application Specific Integrated Circuit BLDC Brushless DC Motor BOR Black Only Retract CCyan CRU Customer Replaceable Unit CSU Customer Setup CCW Counterclockwise CW Clockwise 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 HCIT High-Capacity Input Tray HCOF High-Capacity Output Finisher HVPS High Voltage Power Supply ITU Image Transfer Unit KBlack LASER Light Amplification by Stimulated Emission of Radiation LCD Liquid Crystal Display LD Laser Diode LED Light-Emitting Diode LEF Long Edge Feed LVPS Low Voltage Power Supply M Magenta

1-36 Printer Finisher Service Manual

MPF Multi-Purpose Feeder MROM Masked Read Only Memory 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 Revolutions Per Minute SDRAM Synchronous Dual Random Access Memory SEF Short Edge Feed SIMM Single Inline Memory Module SOS Start of scan SRAM Static Random Access Memory TTM Tandem Tray Module TVOC Total Volatile Organic Compound UPR Used Parts Return VVolts V ac Volts alternating current V dc Volts direct current VTB Vacuum Transport Belt Y Yellow

5057-XXX

General information 1-37

5057-XXX

1-38 Printer Finisher Service Manual

2. Diagnostic information

Start

CAUTION:

Unplug the power cord from the electrical outlet before you connect or disconnect any cabl electronic board or assembly.

CAUTION

If the printer is kept on, never touch the conductive parts if not specifically 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.

CAUTION

5057-XXX

Be careful to avoid burns by safely handling hot parts.

CAUTION

The standard finisher weight is 59 kg (130 lb.) and requires at least two people to lift it safely. The booklet finisher weight is 87.5 kg (193 lb.) and requires at least four people to lift it safely. Make sure your fingers are not under the finisher when you lift or set it down.

The MFP weighs approximately 173kg (383 lb.) and requires at least four people to lift it safely. Make sure your fingers are not under the MFP when you lift or set it down.

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.

Warning: Servicers should wear a wrist band or the like to remove static electricity from their body, grounding

their body while working. Go to “Handling ESD-sensitive parts” on page 4-1.

Note: There may be printer error messages that are not contained in this service manual. Call your next level support for assistance.

Diagnostic information 2-1

5057-XXX

POR (Power-On Reset) sequence

The following is an example of the events that occur during the POR sequence for the base machine with no paper handling options installed.

1. Turn the machine on.

2. +5V LED (Power ON) on the system board comes on.

3. Operator Panel LED comes on solid.

4. All diamonds appear on the LCD.

5. While loading code, dots scroll across the LCD.

6. The following is an example of the screen that displays after the code is loaded.

128MB 600Mhz 128MB = Amount of Memory 600Mhz = Processor Speed

7. Performing Self Test appears on the LCD.

8. Fuser drive motor turns on.

9. Fuser fan turns on.

10. RIP fan turns on.

11. Heartbeat LED on system boards turns on.

12. Fuser lamps turn on.

13. Vacuum transport belt fan turns on.

14. ITU Missing appears on the LCD, if the ITU is missing.

15. Fuser Missing appears on the LCD, if the fuser is missing.

16. Close Door appears on the LCD, if the front cover is open.

17. Busy appears on the LCD.

18. Operator panel LED blinks.

19. Redrive exit roller turns.

20. Any cartridge errors appear on the LCD such as a Defective Cartridge, Return Program Information, or Missing Cartridge.

21. Any applicable maintenance messages appear on the LCD such as 80 Fuser Maintenance or 83 ITU Maintenance.

22. One of the toner low messages appears when applicable: 88 Yellow Toner Low, 88 Magenta Toner Low, 88 Cyan Toner Low, or 88 Black Toner Low.

23. Color calibration may be initiated. This is appears if one of the following occurs:

• The printer detects at power on, or the front cover is closed, that a new or different toner cartridge has been

installed.

• The printer detects at power on when the cover is closed that a new or different ITU has been installed.

• The printer detects at power on that the fuser temperature is below 60° C.

• When coming out of power saver if power saver has been active for eight hours or longer.

• If the printer is turned on when a calibration cycle was in progress since the printer was last powered off.

24. Ready appears on the LCD.

To enter the diagnostic menu:

1. Turn off the printer.

2. Press and hold the and buttons simultaneously.

3. Turn on the printer.

4. Release the buttons after 10 seconds.

2-2 Printer Finisher Service Manual

Error code messages - finisher

5057-XXX

Error code or message

280.00 Paper jam

280.01 Paper jam

281.00 Paper jam

281.03 Paper jam

281.04 Paper jam

Error contents Description/action

Sensor (bridge unit media entrance) late jam

Sensor (bridge unit media entrance) static jam

Sensor (bridge unit media exit) late jam

Sensor (bridge unit media exit) static jam

Sensor (bridge exit bin) late jam.

The media is late reaching the sensor (bridge unit media entrance) within the specified time after reaching the sensor (fuser exit).

Go to “280.00 Sensor (bridge unit media entrance)

late Jam” on page 2-10.

Media remains on the sensor (bridge unit media entrance).

Go to “280.01 Sensor (bridge unit media entrance)

static jam” on page 2-11.

The media is late reaching the sensor (bridge unit media exit) within the specified time after reaching the sensor (bridge unit media entrance).

Go to “281.00 Sensor (bridge unit media exit) late

jam” on page 2-12.

Media remains on the sensor (bridge unit media exit). Go to “281.03 Sensor (bridge unit media exit) static

jam” on page 2-14.

Sensor (bridge unit exit bin) is not turned on within the specified time after the sensor (bridge unit media entrance) is turned on.

Go to “281.04 Sensor (bridge exit bin) late jam” on

page 2-15.

281.05 Paper jam

281.06 Paper jam

282.00 Paper jam

282.01 Paper jam

283.00 Paper jam

283.03 Paper jam

Sensor (bridge exit bin) lag jam.

Sensor (bridge exit bin) static jam.

Sensor (finisher media entrance) late jam

Sensor (finisher media entrance) static jam

Sensor (buffer path) late jam The media is late reaching the sensor (buffer path)

Sensor (buffer path) static jam Paper remains on the sensor (finisher buffer path).

Sensor (bridge unit exit bin) is not turned off within the specified time after the sensor (bridge unit exit bin) is turned on.

Go to “281.05 Sensor (bridge exit bin) lag jam” on

page 2-17.

Paper remains on the sensor (bridge exit bin). Go to “281.06 Sensor (bridge exit bin) static jam” on

page 2-19.

The media is late reaching the sensor (finisher media entrance) within the specified time after reaching the sensor (bridge unit media exit).

Go to “282.00 Sensor (finisher media entrance) late

jam” on page 2-20.

Paper remains on the sensor (finisher media entrance). Go to “282.01 Sensor (finisher media entrance) static

jam” on page 2-22.

within the specified time after reaching the sensor (finisher media entrance).

Go to “283.00 Sensor (buffer path) late jam” on

page 2-23.

Go to “283.03 Sensor (buffer path) static jam” on

page 2-26.

Diagnostic information 2-3

5057-XXX

Error code or message

284.00 Paper jam

284.03 Paper jam

284.05 Paper jam

285.00 Paper jam

286.00 Paper jam

287.00 Paper jam

Error contents Description/action

Sensor (lower media exit) late jam

Sensor (lower media exit) lag jam

Sensor (lower media exit) static jam

Sensor (compiler media in) lag jam

Sensor (compiler media in) static jam

Sensor (upper media exit) late jam

The media is late reaching the sensor (lower media exit) within the specified time after reaching the sensor (buffer path).

Go to “284.00 Sensor (lower media exit) late jam” on

page 2-27.

The media reached the sensor (lower media exit) but did not clear it within the specified time.

Go to “284.03 Sensor (lower media exit) lag jam” on

page 2-29.

Media remains on the sensor (lower media exit). Go to “284.05 Sensor (lower media exit) static jam”

on page 2-30.

The media reached the sensor (lower media exit) but did not clear it within the specified time.

Go to “285.00 Sensor (media compiler in) lag jam” on

page 2-32.

Media remains on the sensor (compiler media in). Go to “286.00 Sensor (compiler media in) static jam”

on page 2-33.

The media is late reaching the sensor (upper media exit) within the specified time after reaching the sensor (finisher media entrance).

Go to “287.00 Sensor (upper media exit) late jam” on

page 2-35.

287.01 Paper jam

287.05 Paper jam

288.00 Paper jam

288.01 Paper jam

288.04 Paper jam

289.00 Paper jam

Sensor (upper media exit) lag jam

Sensor (upper media exit) static jam

Sensor (diverter gate) late jam The media is late reaching the sensor (diverter gate)

Sensor (diverter gate) static jam A (to top bin)

Sensor (diverter gate) static jam B (to stacker bin)

sensor (booklet unit media entrance) late jam

The media reached the sensor (upper media exit) but did not clear it within the specified time.

Go to “287.01 Sensor (upper media exit) lag jam” on

page 2-36.

Media remains on the sensor (upper media exit). Go to “287.05 Sensor (upper media exit) static jam”

on page 2-38.

within the specified time after reaching the sensor (bridge unit media exit).

Go to “288.00 Sensor (diverter gate) late jam” on

page 2-39.

The media reached the sensor (diverter gate) but did not clear it within the specified time.

Go to “288.01 Sensor (diverter gate) static jam A (to

top bin)” on page 2-41.

The media reached the sensor (diverter gate) but did not clear it within the specified time.

Go to “288.04 Sensor (diverter gate) static jam B (to

stacker bin)” on page 2-42.

The media is late reaching the sensor (booklet unit media entrance) within the specified time after reaching the sensor (bridge unit media exit).

Go to “289.00 sensor (booklet unit media entrance)

late jam” on page 2-43.

2-4 Printer Finisher Service Manual

5057-XXX

Error code or message

289.01 Paper jam

289.02 Paper jam

289.03 Paper jam

289.04 Paper jam

289.05 Paper jam

289.06 Paper jam

Error contents Description/action

sensor (booklet unit media entrance) lag jam

sensor (booklet unit media entrance) static jam

sensor (booklet compiler media in) static jam

sensor (booklet unit media exit) late jam

sensor (booklet unit media exit) lag jam

sensor (booklet unit media exit) static jam

The media reached the sensor (booklet unit media entrance) but did not clear it within the specified time.

Go to “289.01 sensor (booklet unit media entrance)

lag jam” on page 2-44.

Media remains on the sensor (diverter gate). Go to “289.02 sensor (booklet unit media entrance)

static jam” on page 2-46.

Media remains on the sensor (booklet compiler media in).

Go to “289.03 sensor (booklet compiler media in)

static jam” on page 2-47.

The media is late reaching the sensor (booklet unit media exit) within the specified time after the booklet knife solenoid is turned on.

Go to “289.04 Sensor (booklet unit media exit) late

jam” on page 2-48.

The media reached the sensor (booklet unit media exit) but did not clear it within the specified time.

Go to “289.05 Sensor (booklet unit media exit) lag

jam” on page 2-50.

Media remains on the sensor (booklet unit media exit). Go to “289.06 Sensor (booklet unit media exit) static

jam” on page 2-51.

980.03 Service finisher

comm

981.00 Service finisher

error

981.01 Service finisher

error

981.02 Service finisher

error

982.00 Service finisher

error

Communication error with finisher controller card assembly

Sensor (stacker bin level 1) late error

Sensor (stacker bin level 2) late error

Stacker bin upper limit error The sensing area of the sensor (stacker bin upper limit)

Stacker bin lower limit error The stacker bin lowers beyond the specified lower limit

Sensor (front tamper HP) late error

A communication error has occurred with the upper printer engine card assembly and the finisher controller card assembly.

Refer to the MFP Service Manual.

The sensing area of the sensor (stacker bin level 1) or Sensor (stacker bin level 2) is not interrupted within the specified period after the stacker bin starts rising.

Go to “981.00 Sensor (stacker bin level 1) late error”

on page 2-52.

is not interrupted when the stacker bin raises to its upper most limit.

Go to “981.01 Stacker bin upper limit error” on

page 2-54.

within the specified time. Go to “981.02 Stacker bin lower limit error” on

page 2-56.

The sensing area of the sensor (front tamper HP) is not interrupted when the front tamper starts moving to the home position.

Go to “982.00 Sensor (front tamper HP) late error” on

page 2-58.

Diagnostic information 2-5

5057-XXX

Error code or message

982.01 Service finisher

error

983.00 Service finisher

error

983.01 Service finisher

error

984.00 Service finisher

error

984.01 Service finisher

error

Error contents Description/action

Sensor (front tamper HP) lag error

Sensor (rear tamper HP) late error

Sensor (rear tamper HP) lag error

Sensor (punch unit HP) late error

Sensor (punch unit HP) lag error

The sensing area of the sensor (front tamper HP) remains interrupted within the specified time after the front tamper starts moving from the home position.

Go to “982.01 Sensor (front tamper HP) lag error” on

page 2-59.

The sensing area of the sensor (rear tamper HP) is not interrupted when the rear tamper starts moving to the home position.

Go to “983.00 Sensor (rear tamper HP) late error” on

page 2-60.

The sensing area of the sensor (rear tamper HP) remains interrupted within the specified time after the rear tamper starts moving from the home position.

Go to “983.01 Sensor (rear tamper HP) lag error” on

page 2-61.

The sensing area of the sensor (punch unit HP) is not interrupted during the specified time after the punch unit starts moving to the home position.

Go to “984.00 Sensor (punch unit HP) late error” on

page 2-62.

The sensing area of the sensor (punch unit HP) remains interrupted within the specified time after the punch unit starts moving from the home position.

Go to “984.01 Sensor (punch unit HP) lag error” on

page 2-63.

985.00 Service finisher

error

985.01 Service finisher

error

986.00 Service finisher

error

986.01 Service finisher

error

987.00 Service finisher

error

Sensor (punch carriage shift HP) late error

Sensor (punch carriage shift HP) lag error

Sensor (media eject clamp HP) late error

Sensor (media eject clamp HP) lag error

Sensor (media eject shaft HP) late error

The sensing are of the sensor (punch carriage shift HP) is not interrupted within the specified time after the punch carriage starts moving to the home position.

Go to “985.00 Sensor (punch carriage shift HP) late

error” on page 2-65.

The sensor (punch carriage shift HP) remains interrupted within the specified time after the punch carriage starts moving from the home position.

Go to “985.01Sensor (punch carriage shift HP) lag

error” on page 2-66.

The sensing area of the sensor (media eject clamp HP) is not interrupted within the specified time after the eject clamp starts moving to the home position.

Go to “986.00 Sensor (media eject clamp HP) late

error” on page 2-67.

The sensing area of the sensor (media eject clamp HP) remains interrupted within the specified time after the eject clamp starts moving from the home position.

Go to “986.01 Sensor (media eject clamp HP) lag

error” on page 2-68.

The sensing area of the sensor (media eject shaft HP) is not interrupted within the specified time after the media eject shaft starts moving to the home position.

Go to “987.00 Sensor (media eject shaft HP) late

error” on page 2-70.

2-6 Printer Finisher Service Manual

5057-XXX

Error code or message

987.01 Service finisher

error

988.01 Service finisher

error

989.00 Service finisher

error

990.00 Service finisher

error

990.01 Service finisher

error

Error contents Description/action

Sensor (media eject shaft HP) lag error

Sensor (punch unit side reg 1) lag error

Sensor (punch unit side reg 2) lag error

Stapler unit error The sensing area of the sensor (stapler unit motor HP)

Sensor (stapler carriage HP) late error

Sensor (stapler carriage HP) lag error

The sensing area of the sensor (media eject shaft HP) remains interrupted within the specified time after the media eject shaft starts moving from the home position.

Go to “987.01 Sensor (media eject shaft HP) lag

error” on page 2-71.

The sensor (punch unit side reg 1) or sensor (punch unit side reg 2) did not detect any media correctly.

Go to “988.01 Sensor (punch unit side reg1) or

(sensor (punch unit side reg2) lag failure” on page 2-73.

inside the stapler unit assembly is not interrupted within the specified timer after the stapler unit motor starts moving to the home position.

Go to “989.00 Stapler unit failure” on page 2-75.

The sensing area of the sensor (stapler carriage HP) is not interrupted within the specified time after the stapler carriage starts moving to the home position.

Go to “990.00 Sensor (stapler carriage HP) late error”

on page 2-75.

The sensing area of the sensor (stapler carriage HP) remains interrupted within the specified time after the stapler carriage starts moving from the home position.

Go to “990.01 Sensor (stapler carriage HP) lag error”

on page 2-76.

991.00 Service finisher

error

991.01 Service finisher

error

991.02 Service finisher

error

991.03 Service finisher

error

991.04 Service finisher

error

Sensor (booklet front tamper HP) late error

Sensor (booklet front tamper HP) lag error

Sensor (booklet rear tamper HP) late error

Sensor (booklet rear tamper HP) lag error

Sensor (booklet end guide HP) late error

The sensing area of the sensor (booklet front tamper HP) is not interrupted within the specified time after the front booklet tamper starts moving to the home position.

Go to “991.00 Sensor (booklet front temper HP) late

error” on page 2-78.

The sensing area of the sensor (booklet front tamper HP) remains interrupted within the specified time after the front booklet tamper starts moving from the home position.

Go to “991.01 Sensor (booklet front tamper HP) lag

error” on page 2-79.

The sensing area of the sensor (booklet rear tamper HP) is not interrupted within the specified time after the rear booklet tamper starts moving to the home position.

Go to “991.02 Sensor (booklet rear tamper HP) late

error” on page 2-80.

The sensing area of the sensor (booklet rear tamper HP) remains interrupted within the specified time after the rear booklet tamper starts moving from the home position.

Go to “991.03 Sensor (booklet rear tamper HP) lag

error” on page 2-82.

The sensing area of the sensor (booklet end guide HP) is not interrupted within the specified time after the booklet end guide starts moving to the home position.

Go to “991.04 Sensor (booklet end guide HP) late

error” on page 2-83.

Diagnostic information 2-7

5057-XXX

Error code or message

991.05 Service finisher

error

991.06 Service finisher

error

991.07 Service finisher

error

991.08 Service finisher

error

991.09 Service finisher

error

Error contents Description/action

Sensor (booklet end guide HP) lag error

Sensor (booklet unit interlock) error

Sensor (booklet compiler no media) no media detected

Sensor (booklet knife HP) late error

Sensor (booklet knife HP) lag error

The sensing area of the sensor (booklet end guide HP) remains interrupted within the specified time after the booklet end guide starts moving from the home position.

Go to “991.05 Sensor (booklet end guide HP) lag

error” on page 2-85.

The sensor (booklet unit interlock) detected that the booklet maker was not completely inserted when the finisher front door assembly was closed.

Go to “991.06 Sensor (booklet unit interlock) error”

on page 2-86.

The sensing area of the sensor (booklet compiler no media) did not detect any media when the booklet stapler motor was activated.

Go to “991.07 Sensor (booklet compiler no media) no

media detected” on page 2-87.

The sensing area of the sensor (booklet knife HP) is not interrupted within the specified time after the booklet knife started moving to home position.

Go to “991.08 Sensor (booklet knife HP) late error”

on page 2-88.

The sensing area of the sensor (booklet knife HP) remains interrupted within the specified time after the booklet knife started moving from home position.

Go to “991.09 Sensor (booklet knife HP) lag error” on

page 2-90.

991.10 Service finisher

error

991.11 Service finisher

error

991.12 Service finisher

error

991.13 Service finisher

error

992.00 Service finisher

error

Sensor (booklet knife folding) late error

Booklet stapler error The booklet stapler unit has failed.

Communication error with booklet controller card assembly

Booklet unit maker error Booklet set recovery was detected too many times for

Sensor (de-curler cam HP) late error

The sensing area of the sensor (booklet knife folding) is not interrupted within the specified time after the booklet knife solenoid was activated.

Go to “991.10 Sensor (booklet knife folding) late

error” on page 2-92.

Go to “991.11 Booklet stapler error” on page 2-93.

A communication error has occurred with the booklet controller card assembly and the finisher controller card assembly.

Go to “991.12 Communication error with booklet

controller card assembly” on page 2-94.

the same job. Perform a POR. Go to “991.13 Booklet unit maker error” on

page 2-95.

The sensing area of the sensor (de-curler cam HP) is not interrupted within the specified time after the de-curler roll assembly (nip) starts moving to the home position.

Go to “992.00 Sensor (de-curler cam HP) late error”

on page 2-95.

2-8 Printer Finisher Service Manual

5057-XXX

Error code or message

992.01 Service finisher

error

Close cover F Bridge unit top cover is open. The bridge unit top cover is open.

Close door G Finisher front door open. The finisher front door is open.

Close surface H Eject cover open. The finisher eject cover is open.

Empty hole punch box

Insert hole punch box

Load staples Staple cartridge empty. Staple cartridge empty.

Error contents Description/action

Sensor (de-curler cam HP) lag error

Punch waste box full. The punch waste box is full.

Punch waste box missing. No punch waste box.

The sensing area of the sensor (de-curler cam HP) remains interrupted within the specified time after the de-curler roll assembly (nip) starts moving from the home position.

Go to “992.01 Sensor (de-curler cam HP) lag error”

on page 2-97.

Go to “Bridge unit top cover open” on page 2-98.

Go to “Finisher front door open” on page 2-100.

Go to “Finisher eject cover open” on page 2-101.

Go to “Punch waste box full” on page 2-103.

Go to “No punch waste box.” on page 2-102.

Go to “Staple cartridge empty” on page 2-110.

Load staples Booklet maker

Remove paper from bin 1

Remove paper from bin 2

Booklet unit staple cartridge empty

Finisher upper media bin full. Stacker set over count

Stacker media bin full (no mix) The stacker media bin has reached maximum capacity

Stacker media bin full (mix size)

Booklet unit staple cartridge empty. Go to ??.

The upper media bin has reached maximum capacity. Go to “Finisher upper media bin full” on page 2-101.

(no mix). Go to “Stacker media bin full (no mix)” on

page 2-106.

The stacker media bin has reached maximum capacity (mix size).

Go to “Stacker media bin full (mix size)” on

page 2-104.

Diagnostic information 2-9

5057-XXX

Service checks - finisher

280.00 Sensor (bridge unit media entrance) late Jam

Step Check Yes No

1 Check the bridge unit media transport rolls.

Are the bridge unit media transport rolls free of excess wear and contamination?

Check the sensor (bridge unit media entrance) for

proper operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 1.

5. Select Bridge media entrance

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (bridge unit media entrance)

connection. Is the above sensor properly connected?

Go to step 2. Clean or replace

Go to step 4. Go to step 3.

Replace the sensor (bridge unit media entrance).

Go to “Sensor

(bridge unit media entrance) removal” on page 4-11.

the bridge unit assembly.

Go to “Bridge

unit assembly removal” on page 4-5.

Replace the connection.

Check the bridge unit drive motor for proper operation.

Caution: When performing motor tests,

ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Bridge unit drive motor.

Does the above component operate properly?

Check the bridge unit drive motor connection.

Is the above motor properly connected?

2-10 Printer Finisher Service Manual

Go to step 6. Go to step 5.

Replace the bridge unit drive motor.

Go to “Bridge

unit drive motor removal” on page 4-8.

Go to step 6.

Replace the connection.

Step Check Yes No

5057-XXX

Perform a print test.

Does the error remain?

Perform a print test.

Does the error remain?

280.01 Sensor (bridge unit media entrance) static jam

Step Check Yes No

1 Check the sensor (bridge unit media entrance) for

proper operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 1.

5. Select Bridge media entrance

Replace the bridge unit interface card assembly.

Go to “Bridge

unit interface card assembly removal” on page 4-114.

Go to step 7.

Replace the finisher controller card assembly.

Go to “Finisher

controller card assembly removal” on page 4-115.

Go to step 3. Go to step 2.

Problem solved.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (bridge unit media entrance)

connection Is the above sensor properly connected?

Replace the sensor (bridge unit media entrance).

Go to “Sensor

(bridge unit media entrance) removal” on page 4-11.

Diagnostic information 2-11

Replace the connection.

5057-XXX

Step Check Yes No

Check the bridge unit drive motor for proper operation.

Caution: When performing motor tests,

ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Bridge unit drive motor.

Does the above component operate properly?

Check the bridge unit drive motor for proper

connection. Is the above component properly connected?

Perform a print test.

Does the error remain?

Go to step 5. Go to step 4.

Replace the bridge unit drive motor.

Go to “Bridge

unit drive motor removal” on page 4-8.

Go to step 5.

Replace the bridge unit interface card assembly.

Go to “Bridge

unit interface card assembly removal” on page 4-114.

Go to step 6.

Replace the connection.

Problem solved.

Perform a print test.

Does the error remain?

281.00 Sensor (bridge unit media exit) late jam

Step Check Yes No

1 Check the bridge unit media transport rolls.

Are the bridge unit media transport rolls free of excess wear and contamination?

2-12 Printer Finisher Service Manual

Replace the finisher controller card assembly.

Go to “Finisher

controller card assembly removal” on page 4-115.

Go to step 2. Clean or replace

Problem solved.

the bridge unit assembly.

Go to “Bridge

unit assembly removal” on page 4-5.

Step Check Yes No

5057-XXX

Check the sensor (bridge unit media exit) for proper

operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 1.

5. Select Bridge unit media exit.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (bridge unit media exit) connection.

Is the above sensor properly connected?

Check the bridge unit drive motor for proper operation.

Caution: When performing motor tests,

ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Bridge unit drive motor.

Go to step 4. Go to step 3.

Replace the sensor (bridge unit media exit).

Go to “Sensor

(bridge unit media exit) removal” on page 4-12.

Go to step 6. Go to step 5.

Replace the connection.

Does the above component operate properly?

Check the bridge unit drive motor connection.

Is the above component properly connected?

Perform a print test.

Does the error remain?

Replace the bridge unit drive motor.

Go to “Bridge

unit drive motor removal” on page 4-8.

Replace the bridge unit interface card assembly.

Go to “Bridge

unit interface card assembly removal” on page 4-114.

Go to step 7.

Diagnostic information 2-13

Replace the connection.

Problem solved.

5057-XXX

Step Check Yes No

Perform a print test.

Does the error remain?

281.03 Sensor (bridge unit media exit) static jam

Step Check Yes No

1 Check the sensor (bridge unit media exit) for proper

operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 1.

5. Select Bridge unit media exit.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (bridge unit media exit) connection.

Is the above sensor properly connected?

Replace the finisher controller card assembly.

Go to “Finisher

controller card assembly removal” on page 4-115.

Go to step 4. Go to step 2.

Replace the sensor (bridge unit media exit).

Go to “Sensor

(bridge unit media exit) removal” on page 4-12.

Problem solved.

Replace the connection.

Check the bridge unit drive motor for proper operation.

Caution: When performing motor tests,

ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Bridge unit drive motor.

Does the above component operate properly?

Check the bridge unit drive motor connection.

Is the above component properly connected?

2-14 Printer Finisher Service Manual

Go to step 5. Go to step 4.

Replace the bridge unit drive motor.

Go to “Bridge

unit drive motor removal” on page 4-8.

Replace the connection.

Step Check Yes No

5057-XXX

Perform a print test.

Does the error remain?

Perform a print test.

Does the error remain?

281.04 Sensor (bridge exit bin) late jam

Step Check Yes No

1 Check the media position.

Does the media Select the sensor (bridge unit bin exit)? Check the sensor (bridge unit media bin exit) for proper

operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor test

4. Select Media Path 1.

5. Select Bridge unit media bin exit.

Replace the bridge unit interface card assembly.

Go to “Bridge

unit interface card assembly removal” on page 4-114.

Go to step 6.

Replace the finisher controller card assembly.

Go to “Finisher

controller card assembly removal” on page 4-115.

Remove the media.

Go to step 4. Go to step 3.

Problem solved.

Go to step 2.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (bridge unit bin exit) for proper

connection. Is the above component properly connected?

Replace the sensor (bridge unit bin exit).

Go to “Sensor

(bridge unit bin exit) removal” on page 4-13.

Diagnostic information 2-15

Replace the connection.

5057-XXX

Step Check Yes No

Check the bridge unit diverter gate solenoid for proper

operation.

Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Test.

4. Select Bridge unit diverter gate solenoid.

Does the above component operate properly? Check the bridge unit diverter gate solenoid for proper

connection. Is the above component properly connected?

Check the bridge unit bin media exit solenoid for proper

operation.

Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden.

Go to step 6. Go to step 5

Replace the bridge unit diverter gate solenoid.

Go to “Bridge

unit diverter gate solenoid removal” on page 4-14.

Go to step 8. Go to step 7

Replace the connection.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Test.

4. Select Bridge unit bin media exit solenoid.

Does the above component operate properly? Check the bridge unit bin media exit solenoid for proper

connection. Is the above component properly connected?

Replace the bridge unit bin media exit solenoid.

Go to “Bridge

unit bin media exit solenoid removal” on page 4-16.

Replace the connection.

2-16 Printer Finisher Service Manual

Step Check Yes No

5057-XXX

Check the bridge unit drive motor for proper operation.

Caution: When performing motor tests,

ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Bridge unit drive motor.

Does the above component operate properly? Check the bridge unit drive motor for proper connection.

Is the above component properly connected?

Perform a print test.

Does the error continue?

Perform a print test.

Does the error continue?

Go to step 10. Go to step 9.

Replace the bridge unit drive motor.

Go to “Bridge

unit drive motor removal” on page 4-8.

Replace the bridge unit interface card assembly.

Go to “Bridge

unit interface card assembly removal” on page 4-114.

Go to step 11. Replace the

finisher controller card assembly.

Go to “Finisher

controller card assembly removal” on page 4-115.

Replace the connection.

Problem solved.

281.05 Sensor (bridge exit bin) lag jam

Step Check Yes No

1 Check the media position.

Does the media touch the sensor (bridge unit bin exit)? Check the sensor (bridge unit media bin exit) for proper

operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor test.

4. Select Media Path 1.

5. Select Bridge unit media bin exit.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Remove the media.

Go to step 4. Go to step 3.

Diagnostic information 2-17

Go to step 2.

5057-XXX

Step Check Yes No

Check the sensor (bridge unit bin exit) for proper

connection. Is the above component properly connected?

Check the bridge unit diverter gate solenoid for proper

operation.

Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Test.

4. Select Bridge unit diverter gate solenoid.

Does the above component operate properly? Check the bridge unit diverter gate solenoid for proper

connection. Is the above component properly connected?

Check the bridge unit bin media exit solenoid for proper

operation.

Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden.

Replace the sensor (bridge unit bin exit).

Go to “Sensor

(bridge unit bin exit) removal” on page 4-13.

Go to step 6. Go to step 5.

Replace the bridge unit diverter gate solenoid.

Go to “Bridge

unit diverter gate solenoid removal” on page 4-14.

Go to step 8. Go to step 7.

Replace the connection.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Test.

4. Select Bridge unit bin media exit solenoid.

Does the above component operate properly? Check the bridge unit bin media exit solenoid for proper

connection. Is the above component properly connected?

2-18 Printer Finisher Service Manual

Replace the bridge unit bin media exit solenoid.

Go to “Bridge

unit bin media exit solenoid removal” on page 4-16.

Replace the connection.

Step Check Yes No

5057-XXX

Perform a print test.

Does the error continue?

Perform a print test.

Does the error continue?

281.06 Sensor (bridge exit bin) static jam

Step Check Yes No

1 Check the sensor (bridge unit media bin exit) for proper

operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor test

4. Select Media Path 1.

5. Select Bridge unit media bin exit.

Replace the bridge unit interface card assembly.

Go to “Bridge

unit interface card assembly removal” on page 4-114.

Go to step 9. Replace the

finisher controller card assembly.

Go to “Finisher

controller card assembly removal” on page 4-115.

Go to step 4. Go to step 2.

Problem solved.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (bridge unit bin exit) for proper

connection. Is the above component properly connected?

Check the bridge unit drive motor for proper operation.

Caution: When performing motor tests,

ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Bridge unit drive motor.

Does the above component operate properly?

Replace the sensor (bridge unit bin exit).

Go to “Sensor

(bridge unit bin exit) removal” on page 4-13.

Go to step 10. Go to step 9.

Diagnostic information 2-19

Replace the connection.

5057-XXX

Step Check Yes No

Check the bridge unit drive motor for proper connection.

Is the above component properly connected?

Perform a print test.

Does the error remain?

Perform a print test.

Does the error remain?

282.00 Sensor (finisher media entrance) late jam

Replace the bridge unit drive motor.

Go to “Bridge

unit drive motor removal” on page 4-8.

Replace the bridge unit interface card assembly.

Go to “Bridge

unit interface card assembly removal” on page 4-114.

Go to step 6. Replace the

finisher controller card assembly.

Go to “Finisher

controller card assembly removal” on page 4-115.

Replace the connection.

Problem solved.

Step Check Yes No

1 Check the bridge unit media transport rolls.

Are the bridge unit media transport rolls free of excess wear and contamination?

Check sensor (bridge unit media exit) for proper

operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 1.

5. Select Bridge unit media exit.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (bridge unit media exit) connection.

Is the above component properly connected?

Go to step 2. Clean or replace

Go to step 4. Go to step 3.

Replace the sensor (bridge unit media exit).

Go to “Sensor

(bridge unit media exit) removal” on page 4-12.

the bridge unit assembly.

Go to “Bridge

unit assembly removal” on page 4-5.

Replace the connection.

2-20 Printer Finisher Service Manual

Step Check Yes No

5057-XXX

Check the sensor (finisher media entrance) for proper

operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 1.

5. Select Finisher media entrance.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (finisher media entrance) for proper

connection. Is the above component properly connected?

Check the bridge unit drive motor for proper operation.

Caution: When performing motor tests,

ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Bridge unit drive motor.

Go to step 6. Go to step 5.

Replace the sensor (finisher media entrance).

Go to “Sensor

(finisher media entrance) removal” on page 4-96.

Go to step 8. Go to step 7.

Replace the connection.

Does the above component operate properly?

Check the bridge unit drive motor for proper

connection. Is the above component properly connected?

Perform a print test.

Does the error remain?

Replace the bridge unit drive motor.

Go to “Bridge

unit drive motor removal” on page 4-8.

Replace the bridge unit interface card assembly.

Go to “Bridge

unit interface card assembly removal” on page 4-114.

Go to step 9.

Diagnostic information 2-21

Replace the connection.

Problem solved.

5057-XXX

Step Check Yes No

Perform a print test.

Does the error remain?

282.01 Sensor (finisher media entrance) static jam

Step Check Yes No

1 Check the sensor (finisher media entrance) for proper

operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 1.

5. Select Finisher media entrance.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (finisher media entrance) for proper

connection. Is the above component properly connected?

Replace the finisher controller card assembly.

Go to “Finisher

controller card assembly removal” on page 4-115.

Go to step 3. Go to step 2.

Replace the sensor (finisher media entrance).

Go to “Sensor

(finisher media entrance) removal” on page 4-96.

Problem solved.

Replace the connector.

Check the drive motor (entrance/paddle) for proper

operation.

Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Motor (entrance/paddle).

Does the above component operate properly?

2-22 Printer Finisher Service Manual

Go to step 5. Go to step 4.

Step Check Yes No

5057-XXX

Check the drive motor (entrance/paddle) for proper

connection. Is the above component properly connected?

Perform a print test.

Does the error remain?

283.00 Sensor (buffer path) late jam

Step Check Yes No

1 Check the finisher media entrance roll assembly.

Is the above component free of excess wear and contamination?

Replace the drive motor (entrance/ paddle).

Go to “Drive

motor (entrance/ paddle) and belt (entrance/ paddle) removal” on page 4-98.

Replace the finisher controller card assembly.

Go to “Finisher

controller card assembly removal” on page 4-115.

Go to step 2. Clean or replace

Replace the connection.

Problem solved.

the finisher media entrance roll assembly.

Go to “Finisher

media entrance roll assembly removal” on page 4-97.

Check the finisher buffer roll assembly.

Is the above component free of excess wear and contamination?

Check the sensor (diverter gate) for proper operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 2.

5. Select Diverter gate.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Go to step 3. Clean or replace

the finisher buffer roll assembly.

Go to “Finisher

buffer roll assembly removal” on page 4-92.

Go to step 5. Go to step 4.

Diagnostic information 2-23

5057-XXX

Step Check Yes No

Check the sensor (diverter gate) for proper connection.

Is the above component properly connected?

Check the buffer diverter gate solenoid for proper

operation.

Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Fin buffer solenoid.

5. Select Forward or reverse.

Does the above component operate properly?

Check the buffer diverter gate solenoid for proper

connection. Is the above component properly connected?

Replace the sensor (diverter gate).

Go to “Sensor

(diverter gate) removal” on page 4-107.

Go to step 7. Go to step 6.

Replace the buffer diverter gate solenoid.

Go to “Buffer

diverter gate solenoid removal” on page 4-101.

Replace the connection.

Problem solved.

Check the sensor (buffer path) for proper operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 1.

5. Select Buffer path.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (buffer path) for proper connection.

Is the above component properly connected?

Go to step 9. Go to step 8.

Replace the sensor (buffer path).

Go to “Sensor

(buffer path) removal” on page 4-91.

Replace the connection.

2-24 Printer Finisher Service Manual

Step Check Yes No

5057-XXX

Check the drive motor (buffer/transport) for proper operation.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Motor (buffer/transport).

Does the above component operate properly?

Check the drive motor (buffer/transport) for proper connection.

Is the above component properly connected?

Perform a print test. Does the error remain?

Go to step 11. Go to step 10.

Replace the drive motor (buffer/ transport).

Go to “Drive

motor (buffer/ transport) and belt (buffer/ transport) removal” on page 4-112.

Replace the bridge unit interface card assembly.

Go to “Bridge

unit interface card assembly removal” on page 4-114.

Go to step 12.

Problem solved.

Perform a print test. Does the error remain?

Replace the finisher controller card assembly.

Go to “Finisher

controller card assembly removal” on page 4-115.

Problem solved.

Diagnostic information 2-25

5057-XXX

283.03 Sensor (buffer path) static jam

Step Check Yes No

1 Check the sensor (buffer path) for proper operation.

Caution: When performing motor tests,

ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 1.

5. Select Buffer path.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (buffer path) for proper connection.

Is the above component properly connected?

Check the drive motor (buffer/transport) for proper

operation.

Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden.

Go to step 3. Go to step 2.

Replace the sensor (buffer path).

Go to “Sensor

(buffer path) removal” on page 4-91.

Go to step 5. Go to step 4.

Replace the connection.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Motor (buffer/transport).

Does the above component operate properly?

Check the drive motor (buffer/transport) for proper

connection. Is the above component properly connected?

2-26 Printer Finisher Service Manual

Replace the drive motor (buffer/ transport).

Go to “Drive

motor (buffer/ transport) and belt (buffer/ transport) removal” on page 4-112.

Replace the connection.

Step Check Yes No

5057-XXX

Perform a print test.

Does the error remain?

284.00 Sensor (lower media exit) late jam

Step Check Yes No

1 Check the finisher buffer roll assembly.

Is the above component free of excess wear and contamination?

Check the sensor (buffer path) for proper operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 1.

5. Select Buffer path.

Replace the finisher controller card assembly.

Go to “Finisher

controller card assembly removal” on page 4-115.

Go to step 2. Clean or replace

Go to step 4. Go to step 3.

Problem solved.

the finisher buffer roll assembly.

Go to “Finisher

buffer roll assembly removal” on page 4-92.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (buffer path) for proper connection.

Is the above component properly connected?

Check the drive motor (buffer/transport) for proper

operation.

Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Motor (buffer/transport).

Does the above component operate properly?

Replace the sensor (buffer path).

Go to “Sensor

(buffer path) removal” on page 4-91.

Go to step 6. Go to step 5.

Replace the connection.

Diagnostic information 2-27

5057-XXX

Step Check Yes No

Check the drive motor (buffer/transport) for proper

connection. Is the above component properly connected?

Check the sensor (diverter gate) for proper operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 2.

5. Select Diverter gate.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (diverter gate) for proper connection.

Is the above component properly connected?

Replace the drive motor (buffer/ transport).

Go to “Drive

motor (buffer/ transport) and belt (buffer/ transport) removal” on page 4-112.

Go to step 8. Go to step 7.

Replace the sensor (diverter gate).

Go to “Sensor

(diverter gate) removal” on page 4-107.

Replace the connection.

Check the sensor (lower media exit) for proper operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 1.

5. Select Lower media exit.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (lower media exit) for proper connection?

Is the above component properly connected?

Perform a print test. Does the error remain?

Go to step 10. Go to step 9.

Replace the sensor (lower media exit).

Go to “Sensor

(lower media exit) removal” on page 4-79.

Replace the finisher controller card assembly.

Go to “Finisher

controller card assembly removal” on page 4-115.

Replace the connection.

Problem solved.

2-28 Printer Finisher Service Manual

284.03 Sensor (lower media exit) lag jam

Step Check Yes No

5057-XXX

1 Check the lower media exit roll assembly.

Is the above component free of excess wear and contamination?

Check the sensor (lower media exit) for proper

operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 1.

5. Select Lower media exit.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (lower media exit) for proper

connection. Is the above component properly connected?

Go to step 2. Clean or replace

Go to step 4. Go to step 3.

Replace the sensor (lower media exit).

Go to “Sensor

(lower media exit) removal” on page 4-79.

the lower media exit roll assembly.

Go to “Lower

media exit roll assembly removal” on page 4-80.

Replace the connection.

Check the drive motor (exit) for proper operation.

Caution: When performing motor tests,

ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Motor (exit).

Does the above component operate properly?

Check the drive motor (exit) for proper connection.

Is the above component properly connected?

Go to step 6. Go to step 5.

Replace the drive motor (exit).

Go to “Drive

motor (exit) assembly and belt (exit) removal” on page 4-110.

Replace the connection.

Diagnostic information 2-29

5057-XXX

Step Check Yes No

Perform a print test.

Does the error remain?

284.05 Sensor (lower media exit) static jam

Step Check Yes No

1 Check the sensor (lower media exit) for proper

operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 1.

5. Select Lower media exit.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (lower media exit) for proper

connection. Is the above component properly connected?

Replace the finisher controller card assembly.

Go to “Finisher

controller card assembly removal” on page 4-115.

Go to step 3. Go to step 2.

Replace the sensor (lower media exit).

Go to “Sensor

(lower media exit) removal” on page 4-79.

Problem solved.

Replace the connection.

Check the buffer diverter gate solenoid for proper

operation.

Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Fin buffer solenoid.

5. Select Forward or reverse.

Does the above component operate properly?

2-30 Printer Finisher Service Manual

Go to step 5. Go to step 4.

Step Check Yes No

5057-XXX

Check the buffer diverter gate solenoid for proper

connection. Is the above component properly connected?

Check the drive motor (exit) for proper operation.

Caution: When performing motor tests,

ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Motor (exit).

Does the above component operate properly?

Check the drive motor (exit) for proper connection.

Is the above component properly connected?

Replace the buffer diverter gate solenoid.

Go to “Buffer

diverter gate solenoid removal” on page 4-101.

Go to step 7. Go to step 6.

Replace the drive motor (exit).

Go to “Drive

motor (exit) assembly and belt (exit) removal” on page 4-110.

Problem solved.

Replace the connection.

Check the finisher diverter gate solenoid for proper

operation.

Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Fin diverter solenoid.

5. Select Forward or reverse.

Does the above component operate properly?

Check the finisher diverter gate solenoid for proper

connection. Is the above component properly connected?

Go to step 9. Go to step 8.

Replace the finisher diverter gate solenoid.

Go to “Finisher

diverter gate solenoid removal” on page 4-100.

Problem solved.

Diagnostic information 2-31

5057-XXX

Step Check Yes No

Perform a print test.

Does the error remain?

285.00 Sensor (media compiler in) lag jam

Step Check Yes No

1 Check the media eject clamp motor for proper

operation.

Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Media eject clamp motor.

Replace the finisher controller card assembly.

Go to “Finisher

controller card assembly removal” on page 4-115.

Go to step 3. Go to step 2.

Problem solved.

Does the above component operate properly?

Check the media eject motor for proper connection.

Is the above component properly connected?

Check the compiler media in actuator for proper

operation. Is the actuator operating properly?

Replace the media eject motor.

Go to “Media

eject motor assembly removal” on page 4-77.

Go to step 4. Replace the

Replace the connection.

media compiler unit assembly.

Go to “Media

compiler unit assembly removal” on page 4-68.

2-32 Printer Finisher Service Manual

Step Check Yes No

5057-XXX

Check the sensor (compiler media in) for proper

operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 1.

5. Select Compiler media in.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (compiler media in) for proper

connection. Is the above component properly connected?

Perform a print test. Does the error remain? Replace the

Go to step 6. Go to step 5.

Replace the sensor (compiler media in).

Go to “Sensor

(compiler media in) removal” on page 4-71.

finisher controller card assembly.

Go to “Finisher

controller card assembly removal” on page 4-115.

Replace the connection.

Problem solved.

286.00 Sensor (compiler media in) static jam

Step Check Yes No

1 Check the media eject clamp motor for proper

operation.

Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Media eject clamp motor.

Does the above component operate properly?

Check the media eject clamp motor for proper

connection. Is the above component properly connected?

Go to step 3. Go to step 2.

Replace the media eject clamp motor.

Go to “Media

eject clamp motor assembly removal” on page 4-65.

Replace the connector.

Diagnostic information 2-33

5057-XXX

Step Check Yes No

Check the sensor (compiler media in) for proper

operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 1.

5. Select Compiler media in.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (compiler media in) for proper

connection. Is the above component properly connected?

Check the media eject motor assembly for proper

operation.

Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Media eject mtr.

Go to step 5. Go to step 4.

Replace the sensor (compiler media in).

Go to “Sensor

(compiler media in) removal” on page 4-71.

Go to step 7. Go to step 6.

Replace the connection.

Does the above component operate properly?

Check the media eject motor assembly for proper

connection. Is the above component properly connected?

Perform a print test.

Does the error remain?

2-34 Printer Finisher Service Manual

Replace the media eject motor assembly.

Go to “Media

eject motor assembly removal” on page 4-77.

Replace the finisher controller card assembly.

Go to “Finisher

controller card assembly removal” on page 4-115.

Replace the connection.

Problem solved.

287.00 Sensor (upper media exit) late jam

Step Check Yes No

5057-XXX

1 Check the two upper media transport roll assemblies.

Are the two upper media transport roll assemblies free of excess wear and contamination?

Check the sensor (upper media exit) for proper

operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 1.

5. Select Upper media exit.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (upper media exit) for proper

connection. Is the above component properly connected?

Go to step 2. Clean or replace

Go to step 4. Go to step 3.

Replace the sensor (upper media exit).

Go to “Sensor

(upper media exit) removal” on page 4-102.

the two upper media transport roll assemblies.

Go to “Upper

media transport roll assembly removal” on page 4-108.

Replace the connection.

Check the drive motor (buffer/transport) for proper

operation.

Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Motor (buffer/transport).

Does the above component operate properly?

Check the drive motor (buffer/transport) for proper

connection. Is the above component properly connected?

Go to step 6. Go to step 5.

Replace the drive motor (buffer/ transport).

Go to “Drive

motor (buffer/ transport) and belt (buffer/ transport) removal” on page 4-112.

Replace the connection.

Diagnostic information 2-35

5057-XXX

Step Check Yes No

Perform a print test.

Does the error remain?

287.01 Sensor (upper media exit) lag jam

Step Check Yes No

1 Check the two upper media transport roll assemblies.

Are the two upper media transport roll assemblies free of excess wear and contamination?

Check the sensor (upper media exit) for proper

operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 1.

5. Select Upper media exit.

Replace the finisher controller card assembly.

Go to “Finisher

controller card assembly removal” on page 4-115.

Go to step 2. Clean or replace

Go to step 3. Go to step 4.

Problem solved.

the two upper media transport roll assemblies.

Go to “Upper

media transport roll assembly removal” on page 4-108.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (upper media exit) for proper

connection. Is the above component properly connected?

2-36 Printer Finisher Service Manual

Replace the sensor (upper media exit).

Go to “Sensor

(upper media exit) removal” on page 4-102.

Replace the connection.

Step Check Yes No

5057-XXX

Check the drive motor (buffer/transport) for proper

operation.

Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Motor (buffer/transport).

Does the above component operate properly?

Check the drive motor (buffer/transport) for proper

connection. Is the above component properly connected?

Check the drive motor (exit) for proper operation.

Caution: When performing motor tests,

ensure that all cover and door interlock switches are overridden.

Go to step 6. Go to step 5.

Replace the drive motor (buffer/ transport).

Go to “Drive

motor (buffer/ transport) and belt (buffer/ transport) removal” on page 4-112.

Go to step 8. Go to step 7.

Replace the connection.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Motor (exit).

Does the above component operate properly?

Check the drive motor (exit) for proper connection.

Is the above component properly connected?

Perform a print test.

Does the error remain?

Replace the drive motor (exit).

Go to “Drive

motor (exit) assembly and belt (exit) removal” on page 4-110.

Replace the finisher controller card assembly.

Go to “Finisher

controller card assembly removal” on page 4-115.

Replace the connection.

Problem solved.

Diagnostic information 2-37

5057-XXX

287.05 Sensor (upper media exit) static jam

Step Check Yes No

1 Check the sensor (upper media exit) for proper

operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 1.

5. Select Upper media exit.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (upper media exit) for proper

connection. Is the above component properly connected?

Check the drive motor (buffer/transport) for proper

operation.

Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Motor (buffer/transport).

Go to step 3. Go to step 2.

Replace the sensor (upper media exit).

Go to “Sensor

(upper media exit) removal” on page 4-102.

Go to step 5. Go to step 4.

Replace the connection.

Does the above component operate properly?

Check the drive motor (buffer/transport) for proper

connection. Is the above component properly connected?

Perform a print test.

Does the error remain?

2-38 Printer Finisher Service Manual

Replace the drive motor (buffer/ transport).

Go to “Drive

motor (buffer/ transport) and belt (buffer/ transport) removal” on page 4-112.

Replace the finisher controller card assembly.

Go to “Finisher

controller card assembly removal” on page 4-115.

Replace the connection.

Problem solved.

288.00 Sensor (diverter gate) late jam

Step Check Yes No

5057-XXX

1 Check the finisher media entrance roll assembly.

Is the finisher media entrance roll assembly free of excess wear and contamination?

Check the sensor (bridge unit media exit) for proper

operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 1.

5. Select Bridge unit media exit.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (bridge unit media exit) for proper

connection. Is the above component properly connected?

Go to step 2. Clean or replace

Go to step 4. Go to step 3.

Replace the sensor (bridge unit media exit).

Go to “Sensor

(bridge unit media exit) removal” on page 4-12.

the finisher media entrance roll assembly.

Go to “Finisher

media entrance roll assembly removal” on page 4-97.

Replace the connection.

Check the sensor (finisher media entrance) for proper

operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 1.

5. Select Finisher media entrance.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (finisher media entrance) for proper

connection. Is the above component properly connected?

Go to step 6. Go to step 5.

Replace the sensor (finisher media entrance).

Go to “Sensor

(finisher media entrance) removal” on page 4-96.

Replace the connection.

Diagnostic information 2-39

5057-XXX

Step Check Yes No

Check the sensor (diverter gate) for proper operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 2.

5. Select Diverter gate.

Does the operator panel display change every time the actuator of the sensor (bridge unit media exit) is operated?

Check the sensor (diverter gate) for proper connection.

Is the above component properly connected?

Check the drive motor (entrance/paddle) for proper

operation.

Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Motor (entrance/paddle).

Go to step 8. Go to step 7.

Replace the sensor (diverter gate).

Go to “Sensor

(diverter gate) removal” on page 4-107.

Go to step 10. Go to step 9.

Replace the connection.

Does the above component operate properly?

Check the drive motor (entrance/paddle) for proper connection.

Is the above component properly connected.

Perform a print test. Does the error remain?

Replace the drive motor (entrance/ paddle).

Go to “Drive

motor (entrance/ paddle) and belt (entrance/ paddle) removal” on page 4-98.

Replace the finisher controller card assembly.

Go to “Finisher

controller card assembly removal” on page 4-115.

Replace the connection.

Problem solved.

2-40 Printer Finisher Service Manual

288.01 Sensor (diverter gate) static jam A (to top bin)

Step Check Yes No

5057-XXX

1 Check the sensor (diverter gate) for proper operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 2.

5. Select Diverter gate.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (diverter gate) for proper connection.

Is the above component properly connected?

Check the drive motor (entrance/paddle) for proper

operation.

Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Motor (entrance/paddle).

Go to step 3. Go to step 2.

Replace the sensor (diverter gate).

Go to “Sensor

(diverter gate) removal” on page 4-107.

Go to step 5. Go to step 4.

Replace the connection.

Does the above component operate properly?

Check the drive motor (entrance/paddle) for proper

connection. Is the above component properly connected?

Perform a print test.

Does the error remain?

Replace the drive motor (entrance/ paddle).

Go to “Drive

motor (entrance/ paddle) and belt (entrance/ paddle) removal” on page 4-98.

Replace the finisher controller card assembly.

Go to “Finisher

controller card assembly removal” on page 4-115.

Diagnostic information 2-41

Replace the connection.

Problem solved.

5057-XXX

288.04 Sensor (diverter gate) static jam B (to stacker bin)

Step Check Yes No

1 Check the sensor (diverter gate) for proper operation.

1. Enter the Diagnostics Menu.

2. Select FINISHER TESTS.

3. Select Sensor Test.

4. Select Media Path 2.

5. Select Diverter gate.

Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?

Check the sensor (diverter gate) for proper connection.

Is the above component properly connected?

Check the motor (entrance/paddle) for proper

operation.

Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden.

1. Enter the Diagnostics Menu.

2. Select MOTOR TESTS.

3. Select Finisher Motor Tests.

4. Select Motor (entrance/paddle).

Go to step 3. Go to step 2.

Replace the sensor (diverter gate).

Go to “Sensor

(diverter gate) removal” on page 4-107.

Go to step 5. Go to step 4.

Replace the connection.

Does the above component operate properly?

Check the motor (entrance/paddle) for proper

connection. Is the above component properly connected.

Perform a print test.

Does the error remain?

2-42 Printer Finisher Service Manual

Replace the drive motor (entrance/ paddle).

Go to “Drive

motor (entrance/ paddle) and belt (entrance/ paddle) removal” on page 4-98.

Replace the finisher controller card assembly.

Go to “Finisher

controller card assembly removal” on page 4-115.

Replace the connection.

Problem solved.

Lexmark C930, C935 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of contents

Notices and safety information

Laser notice

Laser

Avis relatif à l’utilisation de laser

Avvertenze sui prodotti laser

Avisos sobre el láser

Declaração sobre Laser

Laserinformatie

Lasermeddelelse

Laserilmoitus

Huomautus laserlaitteesta

Laser-notis

Laser-melding

Avís sobre el Làser

Consignes de sécurité

Norme di sicurezza

Sicherheitshinweise

Pautas de Seguridad

Informações de Segurança

Informació de Seguretat

Preface

1. General information

Finisher

Standard Finisher weight

Booklet Finisher weight

Components

Media path overview

Media size and weight

Media weight

Features

Finisher theory

Media transport

Functions of sensors along the media path

Punch unit

Compiler unit assembly

Stapler

Booklet Operation

Functions of booklet sensors and motors

Upper media bin

Stacker media bin

Booklet tray

Power supply and interlock

Tools required for service

Acronyms

2. Diagnostic information

Start

POR (Power-On Reset) sequence

To enter the diagnostic menu:

Error code messages - finisher

Service checks - finisher

280.00 Sensor (bridge unit media entrance) late Jam

280.01 Sensor (bridge unit media entrance) static jam

281.00 Sensor (bridge unit media exit) late jam

281.03 Sensor (bridge unit media exit) static jam

281.04 Sensor (bridge exit bin) late jam

281.05 Sensor (bridge exit bin) lag jam

281.06 Sensor (bridge exit bin) static jam

282.00 Sensor (finisher media entrance) late jam

282.01 Sensor (finisher media entrance) static jam

283.00 Sensor (buffer path) late jam

283.03 Sensor (buffer path) static jam

284.00 Sensor (lower media exit) late jam

284.03 Sensor (lower media exit) lag jam

284.05 Sensor (lower media exit) static jam

285.00 Sensor (media compiler in) lag jam

286.00 Sensor (compiler media in) static jam

287.00 Sensor (upper media exit) late jam

287.01 Sensor (upper media exit) lag jam

287.05 Sensor (upper media exit) static jam

288.00 Sensor (diverter gate) late jam

288.01 Sensor (diverter gate) static jam A (to top bin)

288.04 Sensor (diverter gate) static jam B (to stacker bin)