Lexmark W820 Service Manual

• Table of Contents

• Start Diagnostics

• Safety and Notices

LexmarkTM W820 Finisher

4025-XXX

• Trademarksmarks

•Index

• Manuals Menu

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

Edition: May 2001

©

j

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 [e-mail]. Lexmark may use or distribute any
of the information you supply in any way it believes appropriate without incurring any obligation to you. You can purchase
additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of
purchase.

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.

PostScript is a registered trademark of Adobe Systems Incorporated.

Other trademarks are the property of their respective owners.

Copyright Lexmark International, Inc. 2001.

All rights reserved.

UNITED STATES GOVERNMENT RESTRICTED RIGHTS

This software and documentation are provided with RESTRICTED RIGHTS. Use, duplication or disclosure by the
Government is sub

ect to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer

U.S.A. P/N 12G3781

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Table of Contents

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Tools Required For Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Symbols Used in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Safety Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Printer Power Supply and Electrical Components . . . . . . . . . . . . . . . . . . . . . . . 1-2

Mechanical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Printer Laser Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Printer Fuser Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Safety Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Caution Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Finisher Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Finisher Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Mechanical Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Drive for Jogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Finisher Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

H-Tra Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

Punch Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

Shift Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

Compiler & Jogger Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33

Stapler Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

Exit Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37

Paper Stack Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39

Top Tray Exit Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43

Glossary of Terms, Acronyms, and Abbreviations . . . . . . . . . . . . . . . . . . . . . . 1-44

Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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

Operator Panel Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Accessing Additional Debug Information for Service Errors . . . . . . . . . . . . . . . 2-3

Service Error Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Attendance Message Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Service Checks Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

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How to Use the Service Checks Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

How to Follow a Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

General Notes on Using Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Attendance Message Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Service Error Code Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Diagnostic Aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Entering Diagnostic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Exiting Diagnostic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Analyzing the Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Using Test Print to Locate a Feed or Paper Transport Problem . . . . . . . . . . . . 3-1

Finisher Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Staple Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Finisher Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Removal and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Notations in the text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Cover, Rear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Spring Tension 80, Sensor and Harness Earth Removal . . . . . . . . . . . . . . . . . 4-3

Belt-Sync Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Bracket Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Tray Harness Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Transport Gear Kit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Solenoid Assembly-Gate In Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Cover Top H-Tra Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Roll Transport and Aligner Roll Kit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Entrance Roll Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Sensor and Sensor Full Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Sensors Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Shaft Transport Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Cover-Jogging Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Tray-Lower Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Cover-Top, Front and Rear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Cover-Open, Cover-Front and Kit Stud Cover Removal . . . . . . . . . . . . . . . . . 4-26

Switch Cover Front Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Latch Assembly and Switch Docking Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Kit H-Tra Bracket and Screw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

Cover-Rear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Cover-Top Left Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

Top Center Cover Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

Kit Bracket Assembly and Screw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

Frame Post Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

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Cap-End Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

Caster Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

Lever Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

Sensor, Input Path Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

Sensor, Exit Path Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

Roll Assembly-REGI Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

Roll Transport Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Kit Drive Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

Chute Assembly-Inlet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

Kit Invert Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49

Kit Buffer Chute Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51

Knob, Regi Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53

Transport Motor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54

Puncher Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

Kit Roll Pinch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57

Sensor, Path Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58

Guide Assembly-Dust Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59

Bottle Assembly-Dust Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60

Sensor Dust-Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61

Inner Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62

Sensor Bottle Kit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

Kit Motor Jogging Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

Sensor, Jogger Home Position Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

Plate-Jogger Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70

Kit Shift Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71

Knob, Shift Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75

Kit Shift Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76

Motor Assembly-MP2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77

Sensor, Exit Path Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79

Compiler Roll and Roll Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80

Sensor, Exit Roller Open/Close Home Position Removal . . . . . . . . . . . . . . . . 4-81

Exit Roll Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82

Kit Gear Front Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83

Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84

Kit Gear Rear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85

Motor Assembly-MP4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87

Staple Stage Assembly, Stack Roll Shaft, No Paper Sensor Stapler Removal 4-88

Stack Arm Assembly, No Paper Sensor Tray Lower Removal . . . . . . . . . . . . . 4-90

Stapler I Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92

Stapler II Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97

Stapler Harness Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-98

Cartridge Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-101

Traverse Motor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-102

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Motor Assembly-Swing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104

Sensor Assembly Swing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-106

Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-110

Cable, Flat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-111

Sensor, Stapler Home Position Traverse Removal . . . . . . . . . . . . . . . . . . . . 4-113

Kit Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-114

Holder Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-116

Blade Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-118

Sensor Tray Height Front Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-119

Shaft Assembly ELEV U Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-120

Shaft Assembly ELEV L Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-121

Drive Assembly-ELEV, Motor Assembly-MD11 Removal . . . . . . . . . . . . . . . 4-124

Right Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-126

Encorder Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-128

Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-130

PWB Assembly-Main Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-132

Port Harness Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-135

No Paper Sensor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-136

Face Up Tray Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-138

Top Cover Interlock Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-139

Gate Solenoid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-140

Full Stack Sensor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-141

Pinch Roll Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-142

Exit Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-143

Exit Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-145

Upper Roll and Roll Transport Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-147

Stepping Motor, Upper Tray Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-149

Gear Kit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-150

Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Location Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Location Map 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Location Map 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Location Map 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Location Map 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Location Map 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Location Map 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Wiring Diagram Notations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Master Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

vi

4025-Finisher

Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

How to Use This Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Assembly 1: Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Assembly 2: Frame Transport, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Assembly 3: Frame Transport, Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Assembly 4: Docking Parts, Front Cover, Top Tray . . . . . . . . . . . . . . . . . . . . . 7-8

Assembly 5: Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Assembly 6: Chute 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Assembly 7: Chute 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Assembly 8: Top Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

Assembly 9: Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Assembly 10: Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Assembly 11: Puncher Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Assembly 12: Jogging Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

Assembly 13: Shift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

Assembly 14: Stacker Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

Assembly 15: Stacker Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

Assembly 16: Stapler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

Assembly 17: Elevator Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

Assembly 18: Finisher Main PWB, Power Supply . . . . . . . . . . . . . . . . . . . . . . 7-36

Assembly 19: Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

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

vii

4025-Finisher

viii

Preface

4025-Finisher

This manual describes the Lexmark TM W820 4025-XXX Finisher and contains
maintenance procedures for service personnel only. 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 are listed
in this chapter, as well as general environmental and safety instructions.

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 - There are no preventative maintenance procedures for

the Lexmark W820 (4025) Finisher.

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

Preface ix

Safety Information

• This product is designed, tested and approved to meet strict global safety standards

with the use of specific Lexmark components. The safety features of some parts may
not always be obvious. Lexmark is not responsible for the use of other 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.

Consignes de Sécurité

• Ce produit a été conçu, testé et approuvé pour respecter les normes strictes de

sécurité globale lors de l'utilisation de composants Lexmark spécifiques. Les
caractéristiques de sécurité de certains éléments ne sont pas toujours évidentes.
Lexmark ne peut être tenu responsable de l'utilisation d'autres pièces de rechange.

• 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.

4025-Finisher

Norme di sicurezza

• Il prodotto è stato progettato, testato e approvato in conformità a severi standard di

sicurezza e per l’utilizzo con componenti Lexmark specifici. Le caratteristiche di
sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark
non è responsabile per l’utilizzo di parti di ricambio di altri produttori.

• 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.

x Safety Information

Sicherheitshinweise

• Dieses Produkt und die zugehörigen Komponenten wurden entworfen und getestet,

um beim Einsatz die weltweit gültigen Sicherheitsanforderungen zu erfüllen. Die
sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer
offensichtlich. Sofern Teile eingesetzt werden, die nicht von Lexmark sind, wird von
Lexmark keinerlei Verantwortung oder Haftung für dieses Produkt 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.

•

Pautas de Seguridad

• Este producto se ha diseñado, verificado y aprobado para cumplir los más estrictos

estándares de seguridad global usando los componentes específicos de Lexmark.
Puede que las características de seguridad de algunas piezas no sean siempre
evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio.

• 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.

4025-Finisher

Informações de Segurança

• Este produto foi concebido, testado e aprovado para satisfazer os padrões globais

de segurança na utilização de componentes específicos da Lexmark. As funções de
segurança de alguns dos componentes podem não ser sempre óbvias. A Lexmark
não é responsável pela utilização de outros componentes de substituição.

• 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.

Safety Information xi

Informació de Seguretat

• Aquest producte està dissenyat, comprovat i aprovat per tal d'acomplir les estrictes

normes de seguretat globals amb la utililització de components específics de
Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre
siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi.

• 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.

4025-Finisher

xii Safety Information

1. Introduction

Maintenance Approach

The diagnostic information in this manual leads you to the correct field replaceable unit
(FRU) or part for the Finisher. Use the error code table, attendance message table, error
code service checks and attendance message service checks to determine the corrective
action necessary to repair the failing option. After you complete the repair, perform tests
as needed to verify the repair.

Tools Required For Service

The removal and replacement procedures described in this manual require the following
tools and equipment:

• Magnetic tip Phillips screwdrivers, large and small

• Flat-blade screwdrivers

• Analog volt ohmmeter (a digital volt ohmmeter may also be used)

4025-Finisher

Symbols Used in this Manual

Various symbols are used throughout this manual to either provide additional information
on a specific topic or to warn of possible danger that might be present during a procedure
or action. Be aware of all symbols when they are used, and always read NOTE,
CAUTION, and WARNING messages.

Note: A NOTE may indicate an operating or maintenance procedure, practice, or
condition that is necessary to efficiently accomplish a task. A NOTE may also provide
additional information related to a specific subject or add a comment on the results
achieved through a previous action.

WARNING: A WARNING indicates an operating or maintenance procedure, practice, or
condition that, if not strictly observed, could result in damage to, or destruction of,
equipment.

CAUTION: A CAUTION indicates an operating or maintenance procedure, practice, or
condition that, if not strictly observed, could result in injury.

Safety Details

Follow all safety instructions to prevent accidents while servicing the printer and attached
options. Always be aware of the potential dangers that are present when you are working
with electrical or mechanical equipment.

Introduction 1-1

4025-Finisher

Printer Power Supply and Electrical Components

Before starting any service procedure, switch off the printer power and unplug the power
cord from the wall outlet. If you must service the options with the printer power applied, be
aware of the potential for electrical shock.

CAUTION: Do not touch any electrical component unless you are instructed to do so by
a service procedure.

Mechanical Components

Manually rotate drive assemblies to inspect sprockets and gears.

CAUTION: Do not try to manually rotate or manually stop the drive assemblies while any
printer or option motor is running.

Printer Laser Components

CAUTION: The printer generates a laser beam as part of the printing process. The laser

beam is a concentrated narrow beam of light that produces extreme heat at its focal point.
The laser beam in this printer is invisible. Although you cannot see the beam, it can still
cause severe damage. Direct eye exposure to the laser beam may cause eye injury or
blindness.

1-2 Service Manual

4025-Finisher

To avoid permanent eye damage, follow these directions:

• Before starting any service procedure, switch off the printer power and unplug the

power cord from the AC wall outlet.

• Do not disassemble the printer Printhead Assembly or any laser component that

displays a Laser Warning sticker.

• Use caution when you are working around the printer Printhead Assembly or when

you are performing laser related troubleshooting or repair procedures.

• Never place a mirror or a reflective tool or object in the laser beam path.

• Do not disassemble the printer in such a way that the laser beam can exit the print

engine during a print cycle.

Printer Fuser Components

CAUTION: This printer uses heat to fuse the toner image to a sheet paper. The printer

Fuser Assembly is very hot. Switch off printer power and wait at least 45 minutes for the
fuser to cool before you attempt to service the printer Fuser Assembly or adjacent
components.

Safety Components

Make sure covers and panel are in place and that all interlock switches are all functioning
correctly after you have completed a printer or option service call. If you bypass, or cheat,
an interlock switch during a service call, use extreme caution when working on or around
the printer or options.

Caution Labels

Throughout the equipment, warning labels are displayed on potentially dangerous
components. When you service the printer and options, check to make sure that all
caution labels are in place.

Most importantly, read and obey all posted caution labels.

Introduction 1-3

Principles of Operation

Finisher Power

The Base Engine supplies 120VAC to the Finisher, and the Finisher Power Supply
converts it into 24VDC and 5VDC that are necessary for the Finisher to function, and
sends these voltages to it.

The printer AC power cord plugs into a grounded AC electrical outlet. The cord carries AC
line voltage to the Noise Filter PWB. The Noise Filter smooths the AC voltage and sends
it to the Main Power Switch. Switching on the Main Power Switch applies AC voltage to
the Finisher Power Supply. The Finisher Power Supply converts the 120 V ac to regulated
+5 V dc and +24 V dc voltages. The Finisher Power Supply sends these voltages to the
Finisher PWB. The Finisher PWB uses these voltages to run internal logic, sensors,
clutches, and motors within the Finisher.

4025-Finisher

1-4 Service Manual

4025-Finisher

Finisher Control

Finisher Control describes the printer resources that monitor and control the actions and
operations of the printer and the Finisher; from paper feed to error detection.

The center of Finisher control is the Finisher PWB. The MCU PWB provides the logic and
information processing that is necessary for the printer to function, and the Finisher PWB
provides the logic and information processing that is necessary for the Finisher to
function. Every electrical component within the Finisher is connected to the Finisher
PWB. Sensors in the Finisher send paper feed status information to the Finisher PWB.
The Finisher PWB processes that information, shares it with the MCU PWB, and
compares it to timing tables stored in ROM. Acting on the results of the processing, the
Finisher PWB sends commands to the various Finisher components; turning on a motor.

Finisher Control Components

• The Finisher PWB controls all Finisher functions, executes commands sent from the

MCU PWB, and sends information back to the MCU PWB. All Finisher components
are connected directly to the Finisher PWB.

• The Finisher Power Supply takes filtered AC voltage and converts it into regulated

+24 V dc and +5 V dc.

• The Punch Dust Full Sensor detects that the Punch Dust Box becomes full with

punched dust.

• The Punch Dust Box Sensor detects the presence of the Punch Dust Box.

• The Exit Roller Interlock Switch detects whether the Exit Roller: Upper is open

excessively, and cuts off the power supply if excessively open.

• The Front Cover Interlock Switch detects whether the Front Cover is open. It cuts off

the power supply to each electrical component when the Front Cover is open.

• The Docking Interlock Switch detects whether the Finisher is docked to the printer

correctly.

• The Top Cover Interlock Switch detects whether the Top Cover is open. It cuts off the

power supply to each electrical component when the Top Cover is open.

Introduction 1-5

4025-Finisher

1-6 Service Manual

4025-Finisher

Mechanical Drive

Mechanical Drive describes both the rotation of the Motor and the action of the gears,
belts, and clutches that are used to transmit and control motor drive to the various
components throughout the Finisher.

Finisher is to provide the mechanical energy needed to drive

Drive for H-Tra

The driving force generated by the Main Feed Motor in the Finisher is transmitted from
the H-Tra Gear Idle R to the Pulley One-way 1.2.3 via the Belt-SYNC, to rotate the H-Tra
Feed Roller 1.2.3.

The primary purpose of Mechanical Drive within the

.

Mechanical Drive H-Tra Components

• The Gear Idle R transmits the driving force transmitted from the Finisher to the Gear

Idle L.

• The Gear Idle L transmits the driving force transmitted from the Gear Idle R to the

Gear Pulley 32/26.

• The Gear Pulley 32/26 transmits the driving force transmitted from the Gear Idle L to

the Pulley One way 1.2.3 via the Belt SYNC.

• The Belt SYNC transmits the driving force transmitted from the Gear Pulley 32/26 to

the Pulley One way 1.2.3.

• The Pulley One way 1 transmits the driving force transmitted from the Belt SYNC to

the H-Tra Feed Roller 1.

• The Pulley One way 2 transmits the driving force transmitted from the Belt SYNC to

the H-Tra Feed Roller 2.

• The Pulley One way 3 transmits the driving force transmitted from the Belt SYNC to

the H-Tra Feed Roller 3.

Introduction 1-7

4025-Finisher

Drive for Fin Input Roller & Regi Roller

The rotation of the Main Feed Motor drives the Main Drive Belt to transmit a driving force
to the Main Drive Gear. The rotation of the Main Drive Gear transmits a driving force to
the Feed Gear 1.

In the transmission of a driving force to the Regi Roller, the rotation of the Feed Gear 1
drives the Timing Belt 1, and the driving force from the Timing Belt 1 rotates the Regi Roll
Gear to rotate the Regi Roller.

In the transmission of a driving force to the Fin Input Roller and the H-Tra Drive, the
rotation of the Feed Gear 1 transmits a driving force to the Drive Gear 2. And the rotation
of the Drive Gear 2 is transmitted to the Drive Gear 3, and driving the Timing Belt 2
transmits a driving force to the Transport Gear, and then the Transport Gear transmits a
driving force to the entire H-Tra Drive. Drive Gear 3 rotates the Drive Gear 4. Then, the
rotation of the Drive Gear 4 transmits a driving force to the Fin Input Gear, to rotate the
Fin Input Roller. The Drive Gear 4 also transmits a driving force to the Transport Gear,
and then the Transport Gear transmits a driving force to the entire H-Tra Drive.

1-8 Service Manual

4025-Finisher

Mechanical Drive Fin Input Roller & Regi Roller Components

• The Main Feed Motor supplies a driving force to the Punch Clutch, Fin input Roller

and Regi Roller. It also supplies a driving force to the entire H-Tra via the Transport
Gear 1.

• The Main Drive Gear transmits the driving force transmitted from the Main Feed

Motor to the Feed Gear 1 via the Main Drive Belt.

• The Feed Gear 1 transmits the driving force transmitted from the Main Drive Gear to

the Timing Belt 1. It also transmits the driving force to the Drive Gear 2.

• The Drive Gear 2 transmits the driving force transmitted from the Feed Gear 1 to the

Timing Belt 1.

• The Drive Gear 3 transmits the driving force transmitted from the Drive Gear 2 to the

Timing Belt 2.

• The Drive Gear 4 transmits the driving force transmitted from the Timing Belt 2 to the

Fin Input Gear and Transport Gear 1.

• The Fin Input Gear rotates the Fin Input Roller.

• The Regi Roll Gear rotates the Regi Roller. It also transmits the driving force

transmitted from the Timing Belt 1 to the Punch Drive Belt.

• The Transport Gear 1 transmits the driving force transmitted from the Drive Gear 4 to

the H-Tra Gear Idle R.

• The Timing Belt 1 transmits the driving force transmitted from the Feed Gear 1 to the

Regi Roll Gear.

• The Timing Belt 2 transmits the driving force transmitted from the Drive Gear 3 to the

Fin Input Roll Gear.

Introduction 1-9

4025-Finisher

Drive for Punch Unit

The rotation of the Main Feed Motor drives the Main Drive Belt to transmit a driving force
to the Main Drive Gear. The rotation of the Main Drive Gear transmits a driving force to
the Feed Gear 1. The rotation of the Feed Gear 1 drives the Timing Belt 1, and driving the
Timing Belt 1 rotates the Regi Roll Gear. The driving force from the Regi Roll Gear is
transmitted to the Punch Gear 1 via the Punch Drive Belt. Then, the rotation of the Punch
Gear 1 transmits a driving force to the Punch Clutch via the Punch Gear 2. The rotation of
the Punch Clutch moves up and down the Punch Shaft in the Punch Unit to perform the
punching operation. The counterclockwise rotation of the Punch Motor moves up the
Punch Shaft, while the clockwise rotation moves down the shaft.

1-10 Service Manual

4025-Finisher

Mechanical Drive Punch Unit Components

• The Main Feed Motor supplies a driving force to the Punch Clutch, Fin input Roller

and Regi Roller. It also transmits a driving force to the entire H-Tra via the Transport
Gear 1.

• The Punch Clutch transmits the driving force transmitted from the Punch Gear2 to

the Punch Shaft on the Punch Unit.

• The Regi Roll Gear rotates the Regi Roller. It also transmits the driving force

transmitted from the Timing Belt 1 to the Punch Drive Belt.

• The Punch Gear 1 transmits the driving force transmitted from the Punch Drive Belt

to the Punch Gear 2.

• The Punch Gear 2 transmits the driving force transmitted from the Punch Drive 1 to

the Punch Clutch.

• The Punch Drive Belt transmits the driving force transmitted from the Regi Roll Gear

to the Punch Gear 1.

Introduction 1-11

4025-Finisher

Drive for Shift Roller Unit & Main Paddle & Sub Paddle

• The driving force transmitted by the Compiler Tray Feed Motor

In the transmission of a driving force to the Shift Roller, the rotation of the Compiler Tray
Feed Motor transmits a driving force to the Shift Roll Gear 1, to rotate the Shift Roller. At
the same time, the rotation of the Shift Roll Gear 1 rotates the Shift Roll Gear 2 via the
Shift Roller. The rotation of the Shift Roll Gear 2 transmits a driving force to the Shift
Transmit Pulley. The Paddle Drive Belt on the Shift Transmit Pulley transmits a driving
force to the Sub Paddle Pulley, and the rotation of the Sub Transmit Pulley rotates the Sub
Paddle.

In the shift of the Shift Roller Unit, the clockwise or counterclockwise rotation of the Shift
Motor moves up or down the unit.

In the transmission of a driving force to the Main Paddle, the rotation of the Compiler Tray
Feed Motor transmits a driving force to the Main Paddle Gear via the Transmit Gear.
Then, the rotation of the Main Paddle Gear rotates the Main Paddle.

• The driving force transmitted by the Shift Handle

The Shift Handle is manually rotated to rotate the Shift Handle Gear. The rotation of the
Shift Handle Gear transmits a driving force to the Shift Roll Gear, to rotate the Shift Roller.
And the rotation of the Shift Roll Gear also transmits a driving force to the Shift Transmit
Pulley. The Paddle Drive Belt on the Shift Transmit Pulley transmits a driving force to the
Sub Paddle Pulley, and the rotation of the Sub Transmit Pulley rotates the Sub Paddle.

1-12 Service Manual

4025-Finisher

Introduction 1-13

4025-Finisher

Mechanical Shift Roller Unit & Main Paddle & Sub Paddle
Components

• The Compiler Tray Feed Motor supplies a driving force to the Shift Roller and Main

Paddle.

• The Shift Motor supplies a driving force to the Shift Roller to perform the shifting job.

• The Shift Roll Gear 1 transmits the driving force transmitted from the Compiler Tray

Feed Motor to the Shift Roller, and the Shift Roller rotates.

• The Transmit Gear transmits the driving force transmitted from the Compiler Tray

Feed Motor to the Main Paddle Gear, and the Main Paddle Gear rotates.

• The Main Paddle Gear rotates the Main Paddle.

• The Shift Roll Gear 2 transmits the driving force generated from the rotation of the

Shift Roller to the Shift Transmit Gear. And it also transmits the driving force
transmitted from the Shift Handle Gear to the Shift Transmit Pulley, when rotating the
Shift Handle manually.

• The Shift Transmit Pulley transmits the driving force transmitted from the Shift Roll

Gear 2 to the Paddle Drive Belt via the Shift Transmit Pulley.

• The Paddle Drive Belt transmits the driving force generated from the rotation of the

Shift Transmit Pulley to the Sub Paddle Pulley.

• Driving the Sub Paddle Pulley rotates the Shift Transmit Pulley, and the Sub Paddle

is rotated.

1-14 Service Manual

4025-Finisher

Drive for Exit 1: Exit Pinch Roll Guide

The rotation of the Exit Roller Open/Close Motor transmits a driving force to the Open/
Close Gear 1 and Open/Close Gear 2. Then, the rotation of the Open/Close Gear 2
moves up the Sector Gear. By means of the convex portion on the side surface of the
Sector Gear, the lever at the end of the Exit Pinch Roll Shaft is raised, and the Exit Pinch
Roll Guide is opened upward.

Mechanical Drive Exit 1: Exit Pinch Roll Guide Components

•

The Exit Roller Open/Close Motor transmits a driving force to the Sector Gear via
each gear, to open/close the Exit Pinch Roll Guide.

• The Open/Close Gear 1 transmits the driving force transmitted from the Exit Roller

Open/Close Motor to the Open/Close Gear 2.

• The Open/Close Gear 2 transmits the driving force transmitted from the Open/Close

Gear 1 to the Sector Gear.

• Receiving the driving force transmitted from the Open/Close Gear 2, the Sector

Gear moves up and down the Exit Pinch Roll Guide by means of the convex portion
on the side surface of the Sector Gear.

Introduction 1-15

4025-Finisher

Drive for Exit 2: Exit Roller & Compiler Tray

• The driving force transmitted to the Exit Roller

The rotation of the Exit Motor transmits a driving force to the Exit Roll Gear. The rotation
of the Exit Roll Gear rotates the Exit Roller. Also, the Exit Motor rotates counterclockwise
when drawing the paper into the Compiler Tray.

• The driving force transmitted to the Compiler Move Tray

The counterclockwise rotation of the Exit Motor rotates the Exit Roller via the Exit Roll
Gear. The Compiler Drive Pulley on the Exit Roller transmits the driving force generated
from the rotation of the Exit Roller to the Move Tray Belt. The Move Tray Belt transmits a
driving force to the Com Drive Gear 1 on the Compiler Drive Shaft, to rotate the Compiler
Drive Shaft. The rotation of the Compiler Drive Shaft transmits a driving force to the Com
Transmit Gear via the Com Drive Gear 2, to rotate the Compiler Transmit Shaft. Then, the
rotation of the Compiler Transmit Shaft transmits a driving force to the gear on the back of
the Compiler Move Tray, via the Com Transmit Gear on the shaft. The Compiler Move Tray
is pushed out toward the paper delivery direction by the transmitted driving force.

1-16 Service Manual

4025-Finisher

Introduction 1-17

4025-Finisher

Mechanical Drive Exit 2: Exit Roller & Compiler Move Tray
Components

• The Exit Motor supplies a driving force to the Exit Roller.

• The Exit Roll Gear transmits a driving force transmitted from the Exit Motor to the

Exit Roller, to rotate the Exit Roller.

• The Compiler Drive Pulley rotates by the rotation of the Exit Roller to transmit a

driving force to the Move Tray Belt.

• The Move Tray Belt transmits the driving force transmitted from the Compiler Drive

Pulley to the Com Drive Gear 1.

• The Com Drive Gear 1 rotates the Compiler Drive Shaft.

• The rotation of the Compiler Drive Shaft transmits a driving force to the Com

Transmit Gear via the Com Drive Gear 2.
The Com Transmit Gear transmits the driving force transmitted from the Compiler

Drive Shaft to the gear on the back of the Compiler Move Tray, to move the Compiler
Move Tray forward or backward.

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4025-Finisher

Drive for Jogging

The Jogging Motor transmits a driving force to the Jogging Gear. The rotation of the
Jogger Gear rotates the Spiral Shaft. Then, the Jogger Flap moves on the Spiral Shaft.

Mechanical Drive Jogging Components

The Jogging Motor F/R supplies a driving force to the Jogging Gear, to move the

•

Jogger Flap.

• The Jogging Gear F/R transmits the driving force transmitted from the Jogging Motor

to the gear on the Spiral Shaft, to rotate the Spiral Shaft.

• The Spiral Shaft F/R moves the Jogger Flap by the rotation of the Spiral Shaft.

• The Jogger Flap aligns the paper in the Compiler.

• The Jogger HP Sensor detects the Jogger home position to confirm the Jogger Flap

position.

Introduction 1-19

4025-Finisher

Drive for Staple

The Stapler Traverse Motor transmits a driving force to the Stapler Drive Pulley. The
rotation of the Stapler Drive Pulley drives the Stapler Timing Belt to move the Stapler Unit
to the left and right.

The Stapler Swing Motor transmits a driving force to the Stapler Swing Gear 1. The
rotation of the Stapler Swing Gear 1 transmits a driving force to the Stapler Swing Gear 2.
Then, the Stapler Swing Gear 2 transmits a driving force to the Sector Gear in the Stapler
Unit, and the Sector Gear swings the Stapler Unit toward +45° or -45° direction.

1-20 Service Manual

4025-Finisher

Introduction 1-21

4025-Finisher

Mechanical Drive Stapler Components

• The Stapler Traverse Motor supplies a driving force to the Stapler Drive Pulley.

• The Stapler Drive Pulley transmits the driving force from the Stapler Traverse Motor

to the Stapler Timing Belt.

• The Stapler Timing Belt moves the Stapler Unit to the left and right by the belt drive.

• The Stapler Swing Motor supplies a driving force to the Stapler Swing Gear 1.

• The Stapler Swing Motor transmits the driving force transmitted from the Stapler

Swing Motor to the Stapler Swing Gear 2.

• The Stapler Swing Gear 2 transmits the driving force transmitted from the Stapler

Swing Gear 1 to the Sector Gear in the Stapler Unit, to swing the unit.

• The Stapler Swing HP Sensor detects the Stapler tilt angle when the Stapler Unit

performs the stapling.

Drive for Stacker Tray

The rotation of the worm gear in the Lift Up Motor supplies a driving force to each gear on
the Elevator Drive Unit via the Lift Up Gear 1. Then, the rotation of the Lift Up Gear 2
transmits a driving force to the Elevator Drive Gear. The driving force transmitted to the
Elevator Drive Gear rotates the Elevator Shaft. The rotation of the Elevator shaft transmits
a driving force to the Elevator Belt to elevate the Stacker Tray.

The rotation of the worm gear in the Lift Up Motor transmits a driving force to the Lift Up
Gear 3 via each gear on the Elevator Drive Unit. The rotation of the Lift Up Gear 3 rotates
the Liner Encoder.

1-22 Service Manual

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Introduction 1-23

4025-Finisher

Mechanical Stacker Tray Components

• The Lift Up Motor supplies a driving force to the Elevator Shaft via each gear on the

Elevator Drive Unit.

• The Elevator Drive Unit supplies the driving force generated by the Lift Up Motor to

the Elevator Drive Gear and Liner Encoder.

• The Elevator Drive Gear rotates the Elevator Shaft by the driving force transmitted

from the Elevator Drive Unit.

• The Elevator Belt elevates the Stacker Tray by the rotation of the Elevator Shaft.

• The Lift Up Gear 3 rotates the Liner Encoder by the driving force transmitted from

the Lift Up Motor.

Drive for Top Tray Exit

The rotation of the Exit Top Motor transmits a driving force to the Exit Top Belt. Driving the
Exit Top Belt transmits a driving force to the Exit Top Gear (Lower, Middle and Upper), to
rotate them. Then, the rotation of each gear rotates the Exit Top Roller.

1-24 Service Manual

4025-Finisher

Mechanical Top Tray Exit Components

• The Exit Top Motor supplies a driving force to the Exit Top Gear.

• The Exit Top Gear: Upper rotates the Exit Top Roller: Upper by the driving force

transmitted from the Exit Top Belt.

• The Exit Top Gear: Middle transmits the driving force transmitted from the Exit Top

Motor to the Exit Top Belt. And it also rotates the Exit Top Roller: Middle by the
rotation of the Exit Top Gear.

• The Exit Top Gear: Lower rotates the Exit Top Roller: Lower by the driving force

transmitted from the Exit Top Belt.

• The Exit Top Belt transmits the driving force transmitted from the Exit Top Motor to

each gear.

Introduction 1-25

4025-Finisher

Finisher Paper Path

Main mechanisms in the Finisher are described by paper transfer path, as follows:

• H-Tra: Mechanism to transfer paper from the printer to the Finisher.

• Punch section: Mechanism to punch paper.

• Shift section: Mechanism to shift paper toward the front or rear.

• Compile & Jogging section: Mechanism to draw the paper into the Compiler Tray by

the paddle and to jog a bundle of paper in a jogging job (only when stapling is
performed).

• Stapler section: Mechanism to compile a bundle of paper on the Compiler Tray (only

when stapling is performed).

• Exit section: Mechanism to deliver paper, or to transfer paper to the Compiler Tray.

• Paper Stack section: Mechanism to stack up the delivered paper on the tray and to

move up or down the Stacker Tray according to the stacking volume.

• Top Tray Exit section: Mechanism to deliver paper to the Top Tray.

1-26 Service Manual

4025-Finisher

H-Tra Section

The paper delivered from the printer passes the H-Tra Gate and is transferred into the
H-Tra. Then, the rotation of the H-Tra Feed Roller in the H-Tra transfers the paper toward
the Finisher. Also, during the paper transfer, the rotation of the H-Tra Feed Roller shifts
the paper to the front side, to adjust the skew and registered position.

H-Tra Components

The H-Tra Gate Solenoid changes over the H-Tra Gate.

•

• Changed over by the H-Tra Gate Solenoid, the H-Tra Gate transfers the paper

toward the H-Tra.

• Gate opens: When paper is transferred to the H-Tra.

• Gate closes: When paper is delivered on the printer Face Down Tray (in Duplex

mode)

• The H-Tra Input Path Sensor monitors paper being transferred from the printer into

the H-Tra.

• The H-Tra Exit Path Sensor monitors paper passing the H-Tra paper exit.

• The H-Tra Feed Roller feeds the paper transferred into the H-Tra toward the Finisher.

• The H-Tra Gate Interlock SW detects H-Tra Gate excessive open state, and cuts off

the power supply.

• The H-Tra Cover Interlock Sensor detects H-Tra Cover open state.

• The printer FD Tray Full Sensor detects when the printer Face Down Tray located at

the bottom of H-Tra is full with paper.

Introduction 1-27

4025-Finisher

Punch Section

• Route for paper delivery to the Stacker Tray

The paper transferred from the H-Tra to the Finisher passes the Fin Input Path Sensor in
the Finisher, and it is transferred toward the Shift Roller by the rotation of the Fin Input
Roller and Regi Roller. After the trailing edge of the paper passes the Fin Input Path
Sensor, the rotation speed of the Shift Roller decreases to reduce the paper transfer
speed of the Shift Roller toward the Exit Roller. Due to the reduced paper transfer speed
of the Shift Roller, a part of the paper located near the Chute Guide starts to deflect.
Paper deflection is caused by the Regi Roller rotation faster than the Shift Roller rotation.
The paper deflects successively by the Regi Roller, and after the specified pulses, the
Punch Unit punches the paper. After the punching operation is finished, the Shift Roller
rotation speed returns to normal speed to restart the paper transfer.

• Route for paper delivery to the Top Tray

Punching operation at the Top Tray Exit

The paper transferred from the H-Tra to the Finisher passes the Fin Input Path Sensor in
the Finisher, and it is transferred toward the Exit Top Gate by the rotation of the Fin Input
Roller and Regi Roller. After the trailing edge of the paper passes the Fin Input Path
Sensor, the rotation speed of the Exit Top Roller: Lower decreases to reduce the paper
transfer speed of the Exit Top Roller: Lower toward the Exit Roller. Due to the reduced
paper transfer speed of the Exit Top Roller: Lower, a part of the paper located near the
Chute Guide starts to deflect. Paper deflection is caused by the Regi Roller rotation faster
than the Exit Top Roller: Lower rotation. The paper deflects successively by the Regi
Roller, and after the specified pulses, the Punch Unit punches the paper. After the
punching operation is finished, the Exit Top Roller: Lower rotation speed returns to
normal speed to restart the paper transfer.

1-28 Service Manual

4025-Finisher

Introduction 1-29

4025-Finisher

1-30 Service Manual

4025-Finisher

Punch Components

• The Fin Input Path Sensor monitors paper being transferred from the H-Tra into the

Finisher.

• At the specified pulses after this sensor detects the trailing edge of the paper, the

Shift Roller rotation speed decreases to start the punching operation.

• The Fin Path Sensor monitors the paper passing condition between the Fin Input

Roller and the Regi Roller.

• The Punch Unit punches paper.

Introduction 1-31

4025-Finisher

Shift Section

After the trailing edge of paper passes the Fin Path Roller, the Exit Pinch Roll Guide
opens upward. Then, the Shift Roller Unit is moved forward or backward to perform an
offset job, and, at the same time, the Shift Roller rotates to transfer the paper toward the
Exit Roller. Also, each time a sheet of paper is moved forward or backward, the Exit Pinch
Roll Guide closes and the Exit Roller rotates to deliver the paper. Then, at the specified
pulses after the Fin Exit Path Sensor detects the trailing edge of the paper, the Shift
Roller Unit returns to the home position. The operation is repeated if the shift job is
executed.

Note: The shift job cannot be executed if the stapling job is performed.

Shift Components

The Fin Path Sensor monitors the paper passing condition between the Fin Input

•

Roller and the Regi Roller.

• The Fin Exit Path Sensor monitors paper passing condition before the Shift Roller.

• The Shift Roller transfers paper toward the Exit Roller.

• The Shift Roller HP Sensor detects the home position of the Shift Roller Unit.

1-32 Service Manual

4025-Finisher

Compiler & Jogger Section& Jogger Section

The paper transferred toward the Shift Roller by the Regi Roller starts to be drawn into
the Compiler Tray by the clockwise rotation of the Sub Paddle at the specified pulses after
the Fin Exit Path Sensor before the Shift Roller detects the trailing edge of the paper.
Also, the trailing edge passes the Fin Exit Path Sensor, the Exit Roller rotates
counterclockwise to draw out the Compiler Move Tray. The drawn-out Compiler Move Tray
assists the paper to be easily drawn into the Compiler Tray. Further, the rotation of the
Main Paddle near the Compiler Tray pushes the trailing edge of the paper against the end
wall in the Compiler Tray to ensure the paper alignment.

The bundle of paper transferred into the Compiler Tray is jogged by the Jogger Flap. The
Jogger Flap moves rapidly to the position 10 mm before the paper edge with respect to
the Jogger HP Sensor. Then, the Jogger Flap decelerates and jogs the bundle of paper.

Note: The stapling job cannot be executed if the Shift job is performed.

Introduction 1-33

4025-Finisher

1-34 Service Manual

4025-Finisher

Compiler & Jogger Components

• The Exit Roller delivers paper to the Stacker Tray, and transfers paper to the

Compiler Tray.

• The Sub Paddle assists the paper to be drawn into the Compiler Tray.

• The Main Paddle draws the paper into the Compiler Tray, and then pushes the

trailing edge of the paper against the end wall in the Compiler Tray.

• The Compiler Tray Paper Sensor detects the presence of paper in the Compiler.

• The Compiler Move Tray extends to assist the paper to be drawn easily into the

Compiler Tray.

• The Jogger HP Sensor detects the Jogger home position to confirm the Jogger Flap

position.

Introduction 1-35

4025-Finisher

Stapler Section

The Stapler staples a bundle of paper in the Compiler Tray. When performing the stapling,
the Stapler Unit starts moving along rails to the paper stapler position. The Stapler Unit
moves to the front side when the right side of paper is stapled, or to the rear side when
the left side of paper is stapled. When the Stapler Unit moves, the Stapler Traverse HP
Sensor detects the absolute position of the Stapler Unit from the presence of a notch on
the guide. After the Stapler Unit moves to the paper stapler position, the bundle of paper
is stapled immediately in the Dual Stapling mode, but in the Corner Stapling mode the
Stapler Unit tilts 45 degrees before the bundle of paper is stapled. As for the Stapler tilt
angle in the Corner Stapling mode, the Stapler tilts +45 degrees when the Stapler Unit
moves to the front side, but -45 degrees when it moves to the rear side. After the Stapler
staples the bundle of paper, the Exit Roller rotates together with the Main Paddle to
deliver the bundle of paper to the Stacker Tray via the Exit section.

Note: For the Letter and A4 size paper, the stapler positions are specified.

Stapler Components

1-36 Service Manual

• The Stapler Unit staples a bundle of paper.

• The Stapler Traverse HP Sensor detects the absolute position of the Stapler Unit

from the presence of a notch on the guide rail.

4025-Finisher

Exit Sections

• When the stapler job is not performed

At the specified pulses after the Fin Exit Path Sensor detects the leading edge of the
paper, the Exit Pinch Roll Guide lowers to nip the paper with the Exit Roller. Then the
rotation of the Exit Roller delivers the paper on the Stacker Tray. After the trailing edge of
the paper passes the Paper Exit Sensor, the Exit Pinch Roll Guide opens upward

.

• When the stapler job is performed

After the stapling operation is finished, the bundle of paper stacked on the Compiler Tray
is delivered on the Stacker Tray by the rotation of the Main Paddle and Exit Roller.

Introduction 1-37

4025-Finisher

Exit Components

• The Exit Roller delivers paper to the Stacker Tray, and transfers paper to the

Compiler Tray.

• The Exit Pinch Roll Guide nips the paper with the Exit Roller to assist the paper to be

delivered.

• The Paper Exit Sensor monitors the paper passing condition on the Exit Pinch Roll

Guide.

• The Exit Roller Open/Close HP Sensor detects whether the Exit Pinch Roll Guide is

in the home position.

1-38 Service Manual

4025-Finisher

Paper Stack Sections

From the Finisher Exit section, the paper or a bundle of paper is delivered on the Stacker
Tray. The Stacker Height Sensor detects the stack amount of bundles of paper, and
moves up or down the Stacker Tray according to the stack amount. At the initialization,
the absolute position of the Stacker Tray is recognized by the rotation of the Liner
Encoder. The Stacker Tray absolute position is defined to three positions, 25%, 50%, and
100%, according to the stack amount. The slits differently spaced on the Liner Encoder
correspond to respective positions. The absolute position is recognized when the Stacker
Tray Position Sensor detects a slit on the Liner Encoder for the first time. The Stacker Tray
moves up to the position where the Sensor B of the Stacker Height Sensor turns off.

Introduction 1-39

4025-Finisher

1-40 Service Manual

4025-Finisher

Paper Stack Components

• The Stack Tray Paper Sensor detects the presence of paper on the Stacker Tray.

• The Stacker Tray Position Sensor detects the current position of the Stacker Tray

from the Liner Encoder. The Liner Encoder has three slits differently spaced along
the edge, and according to these differently spaced slits, the Stacker Tray positions
on the Finisher are classified into 25%, 50% and 100% positions.

• The two sensors on the side of the Stacker Height Sensor detect the top surface of

the bundle of paper on the Stacker Tray.

• Once the Stacker Tray moves down where the top surface of paper is below the

Sensor B, it moves up again. After the Sensor B detects that the top surface of paper
passed the Sensor B, the Stacker Tray moves up further by the specified level, and
then stops. This position is the Home Position (HP).

• When the Sensor A detects the bundle of paper stacked on the Stacker Tray, the

Stacker Tray moves down where the top surface of paper is below the Sensor B, and
then moves up again to the home position.

• When the bundle of paper on the Stacker Tray is removed and the Sensor B detects

no paper, the Stacker Tray moves up and down to the home position.

Introduction 1-41

4025-Finisher

1-42 Service Manual

4025-Finisher

Top Tray Exit Sections

After the trailing edge of the paper passes the Regi Roller, the paper moves toward Exit
Top Gate via the Exit Top Gate. The paper is transferred toward the Top Exit by the
rotation of the Exit Top Roller: Lower and Exit Top Roller: Middle on the Top Exit Chute.
The paper transferred to the Top Exit section is delivered on the Top Tray by the rotation
of the Exit Top Roller: Upper.

Top Tray Exit Components

The Exit Top Gate Solenoid changes over the Exit Top Gate.

•

• Changed over by the Exit Top Gate Solenoid, the Exit Top Gate transfers the paper

toward the Top Tray Exit.

– Gate opens: When paper is transferred toward the H-Tra.
– Gate closes: When paper is delivered toward the Stacker Tray.

• The Exit Top Full Stack Sensor detects that the Top Tray is full with paper.

• The Exit Top Path Sensor monitors paper passing the paper exit.

• The Paper Empty Sensor detects that there is no paper on the Top Tray.

Introduction 1-43

4025-Finisher

Glossary of Terms, Acronyms, and Abbreviations

A-

AC Alternating Current
AC Line Voltage The AC voltage level at the AC wall outlet, such as 110VAC or

220VAC
Actuated A device, such as a switch or motor, that is switched on
Actuator Mechanical device used to toggle a switch or a sensor
Aux Auxiliary

B-

Base Engine The printer without options or Controller PWB installed
BCR Bias Charge Roll
BTR Bias Transfer Roll

C-

°C Degrees Celsius. °C = 0.55 (°F - 32)
CCW Counterclockwise
Charge The negative voltage that the High Voltage Power Supply

applies to the surface of the drum
Continuity A resistance reading of approximately 0 ohms
Controller PWB The electrical interface between the printer MCU and the host

computer. See ESS
CL Close
CRU Customer Replaceable Unit, such as an EP Cartridge
CW Clockwise

D-

DC Direct Current
DB Signal name for the Developer Bias voltage
Deactuated A device, such as a switch or a motor, that is switched off
Develop The part of the print cycle where toner adheres to the latent

image on the drum
Developed image The visible image on the drum after going through

development
Diagnostics The mode of operation that lets you check various

components, such as sensors, solenoids, and motors
DPI Dots Per Inch. The measure of image resolution
DRAM Dynamic Random Access Memory
Drum The Xerographic photoreceptor
DTS Signal name for the Detack Saw voltage
Duplex Printing on both sides of a single sheet of paper

E-

Earth Electrical ground

1-44 Service Manual

4025-Finisher

Earth Plate Electrical ground plate or ground strap
EP Cartridge A sealed assembly that houses the xerographic drum, major

xerographic components, and a finite supply of dry ink. The
EP Cartridge is a CRU.

Error Code A unique set of letters and numbers that the printer control

system displays to indicate that a problem exists in a specific

area of the printer
ESS Electronic Subsystem. Synonym for the Controller PWB
Exposure The action of the laser beam striking and discharging select

areas of the electrically charged surface of the drum

F-

°F Degrees Fahrenheit. °F = (°C x 1.8) + 32
Face Down Tray Standard output tray for the printer. Delivers paper face down.
Factory default An operational value or parameter that is set at the time of

equipment manufacture
FG Frame Ground
FRU Field Replaceable Unit
Fuser The printer subsystem that uses heat and pressure to

permanently adhere, or fuse, a transferred toner image to a

sheet of paper

G-

Ground Electrical ground

H-

Harness A bundle of wires that form a single unit and generally

terminated with connectors at both ends
HCF High Capacity Feeder
High (signal) A signal voltage that is equal to or almost equal to the base

voltage; such as +5VDC or +24VDC.
HS High Speed
HVPS High Voltage Power Supply

I-

Image density The relative darkness of the toner image on a sheet of paper
Image development Toner turning the latent image into a visible image.
Image fusing Using heat and pressure to permanently adhere the toner

image to a sheet of paper
Image transfer Moving the developed image from the surface of the drum to

the surface of a sheet of paper
Input test Diagnostic routine that is used to test switches and sensors
Interlock Interlock switch or circuit. Used as a safety measure to

remove voltage from circuits whenever the printer covers are

open or printer assemblies are not in position
IOT Image Output Terminal. Acronym that is sometimes used in

schematic diagrams to describe the base print engine

Introduction 1-45

4025-Finisher

J-

J Jack. A female electrical connector

L-

Laser Refers to either the Laser Diode Assembly or to the laser

beam

Laser beam path The path the laser beam takes, through lenses and mirrors,

from the Laser Diode to the surface of the drum

Laser Diode Semiconductor device that generates the laser beam used in

the Printhead

Latent image The invisible, electrical image remaining on the surface of the

drum after exposure
LCD Liquid Crystal Display
LD Laser Diode
LED Light Emitting Diode
L/H Left Hand
Low (signal) A signal voltage that is significantly lower than the base

voltage
LS Low Speed
LVPS Low Voltage Power Supply

M-

MCU Machine Control Unit. The PWB that controls the operation of

the printer
MBX Mailbox
MOT Motor

N-

NC No Connection
NVRAM Non-Volatile Random Access Memory

O-

OHP Transparency print media
OP Open
Output test Diagnostic routine used to switch on motors, solenoids, and

clutches

P-

P Plug. A male electrical connector
Paper jam A sheet of paper stops at a point along the paper path
Paper path The path a sheet of paper takes from the paper feeder to the

output tray
P/H Paper Handling
P/J Plug and Jack. Electrical connectors as a unit
PL Parts List
PPM Pages Per Minute or Prints Per Minute

1-46 Service Manual

4025-Finisher

Pre-Reg Pre-Registration
Print cycle The printer creating and delivering one finished print
Print surface The side of a sheet of paper that receives the printed image
PS Power Supply
PWB Printed Wiring Board (sometimes referred to as PCB or

Printed Circuit Board)

R

R Right
Reg or Regi Registration
R/H Right Hand
ROM Read Only Memory
RTN Return

S

Sensor A device used to monitor a function or operation, such as

paper travel along the paper path
SG Signal Ground
Signal name A name assigned to a wire, indicating the purpose of the wire

and/or the voltage carried by that wire
SNR Sensor
SOL Solenoid
SOS Start Of Scan
STA Status
STS Soft Touch Sensor
SW Switch

T

Te mp Tem p er a tu re
Test Print A grid pattern print that is generated by the MCU
Test Print Mode The mode of operation that lets you generate a test print
Toggle To switch between two states, such as on and off or up and

down
Toner The dry ink that is used to create the visible image. Toner is

stored in the EP Cartridge
Transfer Moving the toner image from the surface of the drum to the

surface of a sheet of paper

V-

VVolts
VAC Volts - Alternating Current
VDC Volts - Direct Current

W-

Warm-up The time it takes the printer to go from main power ON to

Ready to Print

Introduction 1-47

4025-Finisher

Wire Harness A bundle of wires that form a single unit and are generally

terminated with connectors at both ends

1-48 Service Manual

2. Diagnostic Information

Start

CAUTION: Remove the power cord from the printer or wall outlet before you connect or

disconnect any cable or electronic board or assembly for personal safety and to prevent
damage to the printer or Finisher. Make sure your fingers are not under the printer when
you lift or set the printer down.

Use the service error code table, attendance message table, attendance message
service checks, and service error code service checks to determine the corrective action
necessary to repair the Finisher. Verify the repair upon completion of service.

• “Service Error Code Table” on page 2-4

• “Attendance Message Table” on page 2-5

• “Attendance Message Service Checks” on page 2-12

• “Service Error Code Service Checks” on page 2-29

4025-Finisher

Operator Panel Messages

The operator panel messages are divided into four types: Status Screens, Status Messages, Attendance
Messages, and Service Messages. The characteristics of each type is described in this chapter. The

messages are displayed in the following priority order:

1. Status screens (lowest priority)

2. Status messages

3. Service messages (highest priority)

4. Attendance messages

The printer prioritizes the operator panel messages within each type, if they occur simultaneously.

Status Screens

Each of these message screens provide the operator with information on the current state of the printer. Each
screen of information provides various status information.

Each status screen includes the capability to display a warning message.

Ready

Ready

<warning>

Ready Screen Ready/Fax Screen

Ready <fax status>

<warning>

The above is a representation of the operator panel when the printer is in the Ready state. The printer is ready
to receive and process data from a host system.

Diagnostic Information 2-1

4025-Finisher

Status Messages

These messages provide the operator with information on the current state of the printer. Generally, no user
intervention is required.

Service Messages

These messages are displayed whenever the printer is in the Operator Intervention state, and the printer needs
servicing. In general, service errors are non-recoverable. However, it may be possible to power the printer off
and back on to temporarily recover from the error condition if it is intermittent in nature.

When a Service Message occurs, the printer stops printing. The only recovery is to power off the printer.

Attendance Messages

These messages are displayed when the printer is in the Operator Intervention state. The operator is provided
with a description of the operator intervention condition.

When an operator intervention condition occurs, all host links will be notified about the intervention required
condition.

All timeouts will be stopped while the printer is in an operator intervention state. The only exception is the
PostScript
manual source.

TM

Feed Timeout. This timeout will be started when the Load Paper message is displayed for the

2-2 Service Manual

4025-Finisher

Close Door Messages

Close Door K Close Door or check Front Cover K Switch

Close Cover J Close Top Cover or check Top Cover J Sensor

Close Cover H Close Horizontal Transport Cover or check H-TRA Cover H Sensor

Release Surface L Check Exit Roll Sensor

Accessing Additional Debug Information for Service Errors

Additional debug information may be available for the specific service error being displayed. This information
may help the Customer Support Center, customer engineer, and support engine resolve the problem.

To access this information:

1. Press and hold Return and then press and release Select. The first screen of debug

information is displayed. Write this information down.

2. Continue pressing Return+Select until each screen of debug data is obtained. Once

the end of the debug data is reached, the original service message is displayed.

Diagnostic Information 2-3

Service Error Code Table

9xx

Second Line

Code

Message

980 Finisher Comm. Finisher communication. Go to “980 - Error Code

981 Fin Non-Stapling Mechanical failure in stacker tray 1. Go to “981 -

982 Fin Non-Stapling Jogger (L) failure. Go to “982 - Error Code

983 Fin Non-Stapling Jogger (R) failure. Go to “983 - Error Code

984 Fin Non-Stapling Finisher mechanical failure. Go to “984 - Error

985 Fin Non-Stapling Finisher mechanical failure. Go to “985 - Error

986 Fin Non-Stapling Finisher mechanical failure. Go to “986 - Error

987 Fin Stapling Mechanical failure in stapling part. Go to “987 -

988 Fin Stapling Mechanical failure in stapling part. Go to “988 -

989 Fin Stapling Mechanical failure in stapling part. Go to “989 -

990 Fin Stapling Mechanical failure in stapling part. Go to “990 -

991 Fin Stapling Mechanical failure in stapling part. Go to “991 -

992 Fin Stapling Mechanical failure in stapling part. Go to “992 -

995 Wrong Finisher Incorrect finisher option. Go to “995 - Error Code

999 Finisher Error The engine has reported a Finisher failure that the

4025-Finisher

Description

Service Check” on page 2-29.

Stacker Tray Service Check” on page 2-29.

Service Check” on page 2-30.

Service Check” on page 2-31.

Code Service Check” on page 2-32.

Code Service Check” on page 2-34.

Code Service Check” on page 2-35.

Error Code Service Check” on page 2-36.

Error Code Service Check” on page 2-37.

Error Code Service Check” on page 2-38.

Error Code Service Check” on page 2-40.

Error Code Service Check” on page 2-41.

Error Code Service Check” on page 2-42.

Service Check” on page 2-43.

RIP code does not recognize.

2xx Paper Jam

Second Line Msg

2-4 Service Manual

Flip Flop 1

Flip Flop 2

Primary Message Secondary Message

Attendance Message Table

4025-Finisher

2XX

200 Open Door A Leave Staple Job in Finisher Register Area

201 Open Door A Leave Staple Job in Finisher Register Area

202 Open Door A Leave Staple Job in Finisher Register Area

204 Open Door A Leave Staple Job in Finisher Fuser Area

206 Open Door A Leave Staple Job in Finisher Print Exit Area

207 Open Door E Leave Staple Job in Finisher Print Exit Area

208 Open Door A Leave Staple Job in Finisher Print Exit Area

209 Open Door A Leave Staple Job in Finisher Print Exit Area

210 Open Door E Leave Staple Job in Finisher Print Exit Area

211 Open Door A Leave Staple Job in Finisher Print Exit Area

231 Open Door E Leave Staple Job in Finisher Duplex Area

232 Open Door E Leave Staple Job in Finisher Duplex Area

233 Open Door E Leave Staple Job in Finisher Duplex Area

234 Open Door E Leave Staple Job in Finisher Duplex Area

241 Open Door A Leave Staple Job in Finisher Input Area

241 Open Tray 1 Leave Staple Job in Finisher Input Area

242 Open Door B Leave Staple Job in Finisher Input Area

242 Open Tray 2 Leave Staple Job in Finisher Input Area

243 Open Door A Leave Staple Job in Finisher Input Area

244 Open Door B Leave Staple Job in Finisher Input Area

244 Open Tray 3 Leave Staple Job in Finisher Input Area

245 Open Doors A,B Leave Staple Job in Finisher Input Area

246 Open Door B Leave Staple Job in Finisher Input Area

247 Open Door C Leave Staple Job in Finisher Input Area

247 Open Tray 4 Leave Staple Job in Finisher Input Area

248 Open Doors B,C Leave Staple Job in Finisher Input Area

249 Open Door C Leave Staple Job in Finisher Input Area

250 Open Door B Leave Staple Job in Finisher Input Area

251 Open Door C Leave Staple Job in Finisher Input Area

251 Open Tray 5 Leave Staple Job in Finisher Input Area

Second Line
Message

Flip Flop 1 Flip Flop 2 Description

(no duplex
installed)

(duplex installed)

(second message)

(second message)

(second message)

(second message)

(second message)

Diagnostic Information 2-5

Attendance Message Table

4025-Finisher

2XX

252 Open Doors B,C Leave Staple Job in Finisher Input Area

253 Open Doors A,B,C Leave Staple Job in Finisher Input Area

254 Open Door C Leave Staple Job in Finisher Input Area

254 Open Tray 5 Leave Staple Job in Finisher Input Area

255 Open Door A Leave Staple Job in Finisher Input Area

255 Remove MP Feeder Leave Staple Job in Finisher Input Area (second

255 Remove Envelope Leave Staple Job in Finisher Input Area (second

256 Open Doors A,B Leave Staple Job in Finisher Input Area

257 Open Door B Leave Staple Job in Finisher Input Area

258 Open Door C Leave Staple Job in Finisher Input Area

259 Open Door C Leave Staple Job in Finisher Input Area

259 Open Tray 5 Leave Staple Job in Finisher Input Area

260 Open Door E Leave Staple Job in Finisher Input Area

261 Open Doors B,C Leave Staple Job in Finisher Input Area

271 Remove Envelope

272 Remove Envelope

273 Remove Envelope Leave Staple Job in Finisher Input Area

273 Remove MP Paper Leave Staple Job in Finisher Input Area

280 Open Door D Leave Staple Job in Finisher Mailbox Input Area

281 Open Door D Leave Staple Job in Finisher Mailbox Input Area

282 Open Door D Leave Staple Job in Finisher Mailbox Input Area

284 Open Door D Leave Staple Job in Finisher Mailbox Area

285 Open Door D Leave Staple Job in Finisher Mailbox Area

280 Open Cover H Leave Staple Job in Finisher Horizontal

Second Line
Message

Feeder

Feeder

Flip Flop 1 Flip Flop 2 Description

(second message)

message if MP
Feeder is installed)

message if
Envelope Feeder is
installed)

(second message)

Leave Staple Job in Finisher Input Area

Leave Staple Job in Finisher Input Area

(Envelope Feeder
installed)

(MP Feeder
installed)

Tra n sp o r t Ar e a ­Go to “280 -

Attendance
Message” on
page 2-12.

2-6 Service Manual

Attendance Message Table

4025-Finisher

2XX

281 Open Cover H Leave Staple Job in Finisher Horizontal

282 Open Cover H Leave Staple Job in Finisher Horizontal

283 Open Cover H Leave Staple Job in Finisher Horizontal

284 Open Cover H Leave Staple Job in Finisher Horizontal

285 Open Cover H Leave Staple Job in Finisher Horizontal

286 Open Cover H Leave Staple Job in Finisher Horizontal

287 Open Deflector G Leave Staple Job in Finisher Finisher Deflector -

288 Open Door K Leave Staple Job in Finisher Finisher Area - Go

Second Line
Message

Flip Flop 1 Flip Flop 2 Description

Tra n sp o r t Ar e a ­Go to “281 -

Attendance
Message” on
page 2-13.

Tra n sp o r t Ar e a ­Go to “282 -

Attendance
Message” on
page 2-14.

Tra n sp o r t Ar e a ­Go to “283 -

Attendance
Message” on
page 2-15.

Tra n sp o r t Ar e a ­Go to “284 -

Attendance
Message” on
page 2-16.

Tra n sp o r t Ar e a ­Go to “285 -

Attendance
Message” on
page 2-17.

Tra n sp o r t Ar e a ­Go to “286 -

Attendance
Message” on
page 2-19.

Go to “287 -

Attendance
Message” on
page 2-20.

to “288 -

Attendance
Message” on
page 2-21.

Diagnostic Information 2-7

Attendance Message Table

4025-Finisher

2XX

289 Open Door K Leave Staple Job in Finisher Finisher Area - Go

290 Open Door K Leave Staple Job in Finisher Finisher Area - Go

291 Open Door K Leave Staple Job in Finisher Finisher Area - Go

292 Open Cover J Leave Staple Job in Finisher Finisher Top Cover

293 Open Cover J Leave Staple Job in Finisher Finisher Top Cover

294 Open Cover J Leave Staple Job in Finisher Finisher Top Cover

295 in Finisher Clear Staple Job from Finisher Finisher

Second Line
Message

Flip Flop 1 Flip Flop 2 Description

to “289 -

Attendance
Message” on
page 2-23.

to “290 -

Attendance
Message” on
page 2-24.

to “291 -

Attendance
Message” on
page 2-25.

- Go to “292 -

Attendance
Message” on
page 2-26.

Accumulator - Go
to “295 -

Attendance
Message” on
page 2-27.

2-8 Service Manual

4025-Finisher

Service Checks Flowchart

How to Use the Service Checks Flowchart

• Follow your problem to the individual Primary Service Check that corresponds to

your error code, printer operation problem, or print image problem.

• Follow the instructions presented in the Service Check.

• Voltage and resistance values presented in the Service Checks are an

approximation. Actual readings may vary from the stated values.

• Primary Service Checks may direct you to a Secondary Service Check.

How to Follow a Service Check

(See the sample service check step below).

1. Each numbered step in a service check instructs you to perform a certain action or

procedure.

2. The Actions and Questions box may contain additional information and numbered

procedure steps you must follow to perform the action.

3. The action is followed by a question.

4. If your response to the question is Yes, then follow the instructions for a Yes reply.

5. If your response to the question is No, then follow the instructions for a No reply.

6. Service Checks may ask you to take voltage readings at certain test points within the

printer.

7. Service Checks may ask you to run a specific diagnostic routine in order to test a

FRU or circuit.

8. Service Checks often ask you to replace a printer FRU. Removal and Replacement

Procedures provide you detailed steps for removing and replacing major parts of the

printer.

Step Actions and Questions Yes No

1 NO PAPER SENSOR TEST

1. Enter Diagnostics and test Tray 3 No Paper
Sensor.

2. Slide Tray 3 out of the printer.

3. Manually actuate and deactuate Tray 3 No
Paper Sensor.

Does the last number in the Diagnostics
Status Window toggle between OP and
CL?

Go to following step Replace the No Paper

Sensor

Diagnostic Information 2-9

4025-Finisher

General Notes on Using Service Checks

• Unless indicated otherwise, the instruction “switch ON printer main power” means for

you to switch ON printer power and let the printer proceed through power-on
diagnostics and warm-up until it is online and ready to print.

• Conventions used to represent connectors:

• P/J XX means a Plug and its corresponding Jack are connected.

• PXX means a Plug is disconnected. (Unless this plug is soldered to a board).

• JXX means a Jack is disconnected. (Unless this jack is soldered to a board).

• When you are instructed to take a voltage reading between “P/J A–B and P/J

X–Y, ” place the red probe (+) of your meter on pin B of P/J A, and place the
black probe
(–) of your meter on pin Y of P/J X.

• When you are instructed to take voltage readings between “P/J X and P/J Y”

(without specified pin numbers), check all voltage carrying pins. Refer to the
Wiring Diagrams for signals and pin numbers.

• When you are instructed to take a voltage reading, the black probe (–) is

generally connected to a pin that is either RTN (Return) or SG (Signal Ground).
You can substitute any RTN pin or test point in the printer, and you can use FG
(Frame Ground) in place of any SG pin or test point.

• Unless a Service Check instructs you otherwise; before measuring voltages,

make sure the printer is switched ON, the Print Cartridge and the Paper
Cassettes are in place, and all of the interlock switches are actuated.

• All voltage values given in the Service Checks are approximate values. Actual

measured voltages may vary more than 25% from the values stated in the
Service Checks. The main purpose of most voltage readings taken in the
Service Checks is to determine whether or not a FRU is receiving the correct
voltage value from the power supply and if gating (a voltage drop) occurs during
FRU actuation. Gating signals may be nothing more than a pulse, resulting in a
momentary drop in voltage that may be difficult or impossible to read on the
average multimeter.

• Service Checks may instruct you to remove or replace a FRU. See "Removal

and Replacement Procedures" for information on how to remove and reinstall a
FRU.

• When a Service Check instructs you to replace a FRU, and that FRU is part of a

larger assembly, you should replace the entire assembly.

2-10 Service Manual

Service Checks

Before entering the service checks:

1. Is the AC power provided at the electrical outlet within specifications for this printer;

either 110 V ac or 220 V ac?

2. Is the AC power cord in good condition; neither frayed nor broken?

3. Is one end of the AC power cord connected to the printer?

4. Is the other end of the AC power cord plugged into a grounded three-prong AC

electrical outlet?

5. Is the printer located in an area where the temperature and humidity are moderate

and stable?

6. Is the printer located in an area free of dust?

7. Is the printer located away from water outlets, steamers, electric heaters, volatile

gases, or open flames?

8. Is the printer shielded from the direct rays of the sun?

9. Does the printer have adequate ventilation space around all sides?

10. Is the printer sitting on a level and stable surface?

11. Is the paper stock used in the printer as recommended in the User Manual?

12. Does the customer use the printer as instructed in the User Manual?

13. Are consumables replaced at the recommended intervals?

14. Do you have access to Printer Diagnostics and do you know how to use them?

15. Are all of the printer assemblies in place and are all printer covers and doors firmly

closed?

4025-Finisher

Diagnostic Information 2-11

4025-Finisher

Attendance Message Service Checks

280 - Attendance Message

Logic Control sensed that the H-Tra Input Sensor was not deactuated within a specified time after it was
actuated.

Step Actions and Questions Yes No

1 PATH LOCATION INSPECTION

Inspect the position of the sheet of paper in the H-Tra.

Has the trail edge of the sheet of paper cleared the H-Tra
Input Sensor?

2 SENSOR TEST

Enter Diagnostics and check the H-Tra Input Sensor function.
Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

3 H-TRA INPUT SENSOR

Replace the H-Tra Input Sensor. Go to “Sensors Removal”

on page 4-20. Enter Diagnostics and check the H-Tra Input

Sensor function. Insert then remove a sheet of paper into the
sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

4 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Enter Diagnostics and check

the H-Tra Input Sensor function. Insert then remove a sheet of
paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

Go to step 2 Go to step 5

Go to step 4 Go to step 3

Problem
solved

Problem
solved

Go to step 4

Replace the
MCU Board

5 PATH PAPER INSPECTION

Inspect the Drive Rolls in the entire H-Tra Assembly.

Are all of the Drive Rolls in the H-Tra Assembly clean and
free of obvious wear and damage?

6 DRIVE TRAIN TEST

Enter Diagnostics and select Output Bin Tests. Select Feed
Test, Output Bin 2 to run the Finisher Main Feed Motor.

Does the Finisher Main Feed Motor run smoothly?

7 DRIVE TRAIN INSPECTION

Inspect the drive train, including belts, pulleys, and gears, of
the entire H-Tra Assembly from the Finisher Main Feed Motor
to Feed Roller 1.

Does the entire drive train of the H-Tra Assembly appear
to be in good condition, with no damaged or slipping belts
and no chipped or broken pulleys or gears?

2-12 Service Manual

Go to step 6 Replace the

suspect Drive
Rolls

Go to step 7 Replace the

Finisher Main
Feed Motor

Go to step 8 Replace the

suspect belts,
pulleys, and
gears

4025-Finisher

Step Actions and Questions Yes No

8 The following Finisher FRUs and areas are associated with

this specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using these steps, replace each FRU or troubleshoot
each area listed below, one at a time, until you isolate and
solve the problem.

Wiring and connectors linking the components
Finisher Main Board
MCU Board

281 - Attendance Message

Logic Control sensed that the H-Tra Input Sensor was actuated during Finisher initialization.

Step Actions and Questions Yes No

1 SENSOR INSPECTION

Inspect the H-Tra Input Sensor for a piece of paper or
something else actuating the Sensor.

Is there a piece of paper or something else actuating the
Sensor?

2 SENSOR TEST

Enter Diagnostics and check the H-Tra Input Sensor function.
Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

3 H-TRA INPUT SENSOR

Replace the H-Tra Input Sensor. Go to “Sensors Removal”

on page 4-20. Enter Diagnostics and check the H-Tra Input

Sensor function. Insert then remove a sheet of paper into the
sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

4 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Enter Diagnostics and check

the H-Tra Input Sensor function. Insert then remove a sheet of
paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

Remove
whatever is
actuating the
Sensor

Go to step 4 Go to step 3

Problem
solved

Problem
solved

Go to step 2

Go to step 4

Go to step 5

Diagnostic Information 2-13

4025-Finisher

Step Actions and Questions Yes No

5 MCU BOARD

Replace the MCU Board. Refer to the Printer Service Manual.
Enter Diagnostics and check the H-Tra Input Sensor function.
Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

6 The following Finisher FRUs and areas are associated with

this specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using these steps, replace each FRU or troubleshoot
each area listed below, one at a time, until you isolate and
solve the problem.

• Wiring and connectors linking the FRUs

Problem
solved

Go to step 6

282 - Attendance Message

Logic Control sensed that the H-Tra Exit Sensor was not deactuated within a specified time after it was
actuated.

Step Actions and Questions Yes No

1 PATH LOCATION INSPECTION

Inspect the position of the sheet of paper exiting the H-Tra Exit
Sensor.

Has the trail edge of the sheet of paper cleared the H-Tra
Exit Sensor?

Go to step 2 Go to step 5

2 SENSOR TEST

Enter Diagnostics and check the H-Tra Exit Sensor function.
Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

3 H-TRA EXIT SENSOR

Replace the H-Tra Exit Sensor. Go to “Sensors Removal” on

page 4-20. Enter Diagnostics and check the H-Tra Exit Sensor

function. Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

4 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Enter Diagnostics and check

the H-Tra Exit Sensor function. Insert then remove a sheet of
paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

2-14 Service Manual

Go to step 4 Go to step 3

Problem
solved

Problem
solved

Go to step 4

Replace the
MCU Board

4025-Finisher

Step Actions and Questions Yes No

5 PATH PAPER INSPECTION

Inspect the Drive Rolls in the Finisher, especially the Input
Rolls and the Registration Rolls.

Are all of the Drive Rolls in the Finisher clean and free of
obvious wear and damage?

6 DRIVE TRAIN TEST

Enter Diagnostics and select Output Bin Tests. Select Feed
Test, Output Bin 2 to run the Finisher Main Feed Motor.

Does the Finisher Main Feed Motor run smoothly?

7 DRIVE TRAIN INSPECTION

Inspect the drive train, including belts, pulleys, and gears, of
the entire Finisher Assembly from the Finisher Main Feed
Motor to the Registration Rolls.

Does the entire drive train of the Finisher Assembly
appear to be in good condition, with no damaged or
slipping belts and no chipped or broken pulleys or gears?

8 The following Finisher FRUs and areas are associated with

this specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using these steps, replace each FRU or troubleshoot
each area listed below, one at a time, until you isolate and
solve the problem.

Go to step 6 Replace the

suspect Drive
Rolls

Go to step 7 Replace the

Finisher Main
Feed Motor

Go to step 8 Replace the

suspect belts,
pulleys, and
gears

• H-Tra drive train FRUs, including gear, belts, and rolls.

283 - Attendance Message

Logic Control sensed that the H-Tra Exit sensor was not actuated within a specified time after the H-Tra Input
Sensor was deactuated.

Step Actions and Questions Yes No

1 PATH LOCATION INSPECTION

Inspect the position of the sheet of paper on the H-Tra.

Has the lead edge of the sheet of paper actuated the H-Tra
Exit Sensor?

2 SENSOR TEST

Enter Diagnostics and check the H-Tra Exit Sensor function.

Does the H-Tra Exit Sensor test ok?

3 H-TRA EXIT SENSOR

Replace the H-Tra Exit Sensor. Go to “Sensors Removal” on

page 4-20. Enter Diagnostics and check the H-Tra Exit Sensor

function.

Does the H-Tra Exit Sensor test ok?

Go to step 2 Go to step 5

Go to step 4 Go to step 3

Problem
solved

Go to step 4

Diagnostic Information 2-15

4025-Finisher

Step Actions and Questions Yes No

4 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Enter Diagnostics and check

the H-Tra Exit Sensor function. Insert then remove a sheet of
paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

5 PATH PAPER INSPECTION

Inspect the Drive Rolls in the entire H-Tra Assembly.

Are all of the Drive Rolls in the H-Tra Assembly clean and
free of obvious wear and damage?

6 DRIVE TRAIN TEST

Enter Diagnostics and select Output Bin Tests. Select Feed
Test, Output Bin 2 to run the Finisher Main Feed Motor.

Does the Finisher Main Feed Motor run smoothly?

7 DRIVE TRAIN INSPECTION

Inspect the drive train, including belts, pulleys, and gears, of
the entire H-Tra Assembly from the Finisher Main Feed Motor
to Feed Roller 1.

Does the entire drive train of the H-Tra Assembly appear
to be in good condition, with no damaged or slipping belts
and no chipped or broken pulleys or gears?

Problem
solved

Go to step 6 Replace the

Go to step 7 Replace the

Go to step 8 Replace the

Replace the
MCU Board

suspect Drive
Rolls

Finisher Main
Feed Motor

suspect belts,
pulleys, and
gears

8 The following Finisher FRUs and areas are associated with

this specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using these steps, replace each FRU or troubleshoot
each area listed below, one at a time, until you isolate and
solve the problem.

• Wiring and connectors linking the FRUs

284 - Attendance Message

Logic Control sensed that the H-Tra Exit Sensor was actuated during Finisher initialization.

Step Actions and Questions Yes No

1 SENSOR INSPECTION

Inspect the H-Tra Exit Sensor for a piece of paper or something
else actuating the Sensor.

Is there a piece of paper or something else actuating the
Sensor?

Remove
whatever is
actuating the
Sensor

Go to step 2

2-16 Service Manual

4025-Finisher

Step Actions and Questions Yes No

2 SENSOR TEST

Enter Diagnostics and check the H-Tra Exit Sensor function.
Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

3 H-TRA EXIT SENSOR

Replace the H-Tra Exit Sensor. Go to “Sensors Removal” on

page 4-20. Enter Diagnostics and check the H-Tra Exit Sensor

function. Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

4 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Enter Diagnostics and check

the H-Tra Exit Sensor function. Insert then remove a sheet of
paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

5 MCU BOARD

Replace the MCU Board. Refer to the Printer Service Manual.
Enter Diagnostics and check the H-Tra Exit Sensor function.
Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

Go to step 4 Go to step 3

Problem
solved

Problem
solved

Problem
solved

Go to step 4

Go to step 5

Go to step 6

6 The following Finisher FRUs and areas are associated with

this specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using these steps, replace each FRU or troubleshoot
each area listed below, one at a time, until you isolate and
solve the problem.

• Wiring and connectors linking the FRUs

285 - Attendance Message

Logic Control sensed that the Finisher Input Path Sensor was not deactuated within a specified time after the
Finisher Input Path Sensor was actuated.

Step Actions and Questions Yes No

1 PATH LOCATION INSPECTION

Inspect the position of the sheet of paper exiting the Finisher
Input Path Sensor.

Has the trail edge of the sheet of paper cleared the
Finisher Input Path Sensor?

Go to step 2 Go to step 5

Diagnostic Information 2-17

4025-Finisher

Step Actions and Questions Yes No

2 SENSOR TEST

Enter Diagnostics and check the Finisher Input Path Sensor
function.

Does the Finisher Input Path Sensor test ok?

3 FINISHER INPUT PATH SENSOR

Replace the Finisher Input Path Sensor. Go to “Sensor, Input

Path Removal” on page 4-41. Enter Diagnostics and check

the Finisher Input Path Sensor function. Insert then remove a
sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

4 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Enter Diagnostics and check

the Finisher Input Path Sensor function. Insert then remove a
sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

5 PATH PAPER INSPECTION

Inspect the Drive Rolls in the Finisher, especially the Input
Rolls and the Registration Rolls.

Are all of the Drive Rolls in the Finisher clean and free of
obvious wear and damage?

Go to step 4 Go to step 3

Problem
solved

Problem
solved

Go to step 6 Replace the

Go to step 4

Replace the
MCU Board

suspect Drive
Rolls

6 DRIVE TRAIN TEST

Enter Diagnostics and select Output Bin Tests. Select Feed
Test, Output Bin 2 to run the Finisher Main Feed Motor.

Does the Finisher Main Feed Motor run smoothly?

7 DRIVE TRAIN INSPECTION

Inspect the drive train, including belts, pulleys, and gears, of
the entire Finisher Assembly from the Finisher Main Feed
Motor to the Registration Rolls.

Does the entire drive train of the Finisher Assembly
appear to be in good condition, with no damaged or
slipping belts and no chipped or broken pulleys or gears?

8 The following Finisher FRUs and areas are associated with

this specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using these steps, replace each FRU or troubleshoot
each area listed below, one at a time, until you isolate and
solve the problem.

• Wiring and connectors linking the FRUs

• H-Tra drive train FRUs, including gear, belts, and rolls.

Go to step 7 Replace the

Finisher Main
Feed Motor

Go to step 8 Replace the

suspect belts,
pulleys, and
gears

2-18 Service Manual

4025-Finisher

286 - Attendance Message

Logic Control sensed that the Finisher Input Path Sensor was not actuated within the specified time after the H­Tra Exit Sensor was deactuated.

Step Actions and Questions Yes No

1 PATH LOCATION INSPECTION

Inspect the position of the sheet of paper on the H-Tra.

Has the lead edge of the sheet of paper actuated the
Finisher Input Path Sensor?

2 SENSOR TEST

Enter Diagnostics and check the Finisher Input Path Sensor
function. Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

3 FINISHER INPUT PATH SENSOR

Replace the Finisher Input Path Sensor. Go to “Sensor, Input

Path Removal” on page 4-41. Enter Diagnostics and check

the Finisher Input Path Sensor function.Insert then remove a
sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

4 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Enter Diagnostics and check

the Finisher Input Path Sensor function. Insert then remove a
sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

Go to step 2 Go to step 5

Go to step 4 Go to step 3

Problem
solved

Problem
solved

Go to step 4

Replace the
MCU Board

5 PATH PAPER INSPECTION

Inspect the Drive Rolls in the Finisher, especially the Input
Rolls and the Registration Rolls.

Are all of the Drive Rolls in the Finisher clean and free of
obvious wear and damage?

6 DRIVE TRAIN TEST

Enter Diagnostics and select Output Bin Tests. Select Feed
Test, Output Bin 2 to run the Finisher Main Feed Motor.

Does the Finisher Main Feed Motor run smoothly?

7 DRIVE TRAIN INSPECTION

Inspect the drive train, including belts, pulleys, and gears, of
the entire Finisher Assembly from the Finisher Main Feed
Motor to the Registration Rolls.

Does the entire drive train of the Finisher Assembly
appear to be in good condition, with no damaged or
slipping belts and no chipped or broken pulleys or gears?

Go to step 6 Replace the

suspect Drive
Rolls

Go to step 7 Replace the

Finisher Main
Feed Motor

Go to step 8 Replace the

suspect belts,
pulleys, and
gears

Diagnostic Information 2-19

4025-Finisher

Step Actions and Questions Yes No

8 The following Finisher FRUs and areas are associated with

this specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using these steps, replace each FRU or troubleshoot
each area listed below, one at a time, until you isolate and
solve the problem.

• Wiring and connectors linking the FRUs

• H-Tra drive train FRUs, including gear, belts, and rolls.

287 - Attendance Message

Logic Control sensed that the H-Tra Input Sensor was not actuated within a specified time after the Fuser Exit
Sensor was deactuated.

Step Actions and Questions Yes No

1 PATH LOCATION INSPECTION

Inspect the position of the sheet of paper entering the H-Tra.

Has the lead edge of the sheet of paper actuated the H-Tra
Input Sensor?

2 H-TRA GATE SOLENOID TEST

Enter Diagnostics and check the H-Tra Gate Solenoid function.
Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

3 H-TRA GATE INSPECTION

Inspect the H-Tra Gate for damage.

Is the H-Tra Gate in good condition and does the H-Tra
Gate move when you actuate the H-Tra Gate Solenoid?

4 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Enter Diagnostics and check

the H-Tra Gate Solenoid function.Insert then remove a sheet of
paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

5 SENSOR TEST

Enter Diagnostics and check the H-Tra Input Sensor function.
Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

Go to step 5 Go to step 2

Go to step 3 Go to step 7

Go to step 4 Replace the

H-Tra Gate

Problem
solved

Go to step 8 Go to step 6

Replace the
MCU Board

2-20 Service Manual

4025-Finisher

Step Actions and Questions Yes No

6 H-TRA INPUT SENSOR

Replace the H-Tra Input Sensor. Go to “Sensors Removal”

on page 4-20. Enter Diagnostics and check the H-Tra Input

Sensor function. Insert then remove a sheet of paper into the
sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

7 H-TRA GATE SOLENOID

Replace the H-Tra Gate Solenoid. Enter Diagnostics and
check the H-Tra Gate Solenoid function. Insert then remove a
sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

8 FINISHER MAIN BOARD

Replace the Finisher Main Board. Enter Diagnostics and check
the H-Tra Input Sensor function. Insert then remove a sheet of
paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

9 MCU BOARD

Replace the MCU Board. Refer to the Printer Service Manual.
Enter Diagnostics and check the H-Tra Input Sensor function.

Does the H-Tra Input Sensor test ok?

Problem
solved

Problem
solved

Problem
solved

Problem
solved

Go to step 8

Go to step 8

Go to step 9

288 - Attendance Message

Logic Control sensed that the Finisher Path Sensor did not deactuate within the specified time after it was
actuated.

Step Actions and Questions Yes No

1 PATH LOCATION INSPECTION

Inspect the position of the sheet of paper in the Finisher.

Has the trail edge of the sheet of paper cleared the
Finisher Path Sensor?

2 SENSOR TEST

Enter Diagnostics and check the Finisher Path Sensor
function. Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

Go to step 2 Go to step 5

Go to step 4 Go to step 3

Diagnostic Information 2-21

4025-Finisher

Step Actions and Questions Yes No

3 FINISHER PATH SENSOR

Replace the Finisher Path Sensor. Go to “Sensor, Input Path

Removal” on page 4-41. Enter Diagnostics and check the

Finisher Path Sensor function. Insert then remove a sheet of
paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

4 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Enter Diagnostics and check

the Finisher Path Sensor function. Insert then remove a sheet
of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

5 PATH PAPER INSPECTION

Inspect the Drive Rolls in the Finisher, especially the Input
Rolls and the Registration Rolls.

Are all of the Drive Rolls in the Finisher clean and free of
obvious wear and damage?

6 DRIVE TRAIN TEST

Enter Diagnostics and select Output Bin Tests. Select Feed
Test, Output Bin 2 to run the Finisher Main Feed Motor.

Does the Finisher Main Feed Motor run smoothly?

Problem
solved

Problem
solved

Go to step 6 Replace the

Go to step 7 Replace the

Go to step 4

Replace the
MCU Board

suspect Drive
Rolls

Finisher Main
Feed Motor

7 DRIVE TRAIN INSPECTION

Inspect the drive train, including belts, pulleys, and gears, of
the entire Finisher Assembly from the Finisher Main Feed
Motor to the Registration Rolls.

Does the entire drive train of the Finisher Assembly
appear to be in good condition, with no damaged or
slipping belts and no chipped or broken pulleys or gears?

8 The following Finisher FRUs and areas are associated with

this specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using these steps, replace each FRU or troubleshoot
each area listed below, one at a time, until you isolate and
solve the problem.

• Wiring and connectors linking the FRUs

Go to step 8 Replace the

suspect belts,
pulleys, and
gears

2-22 Service Manual

4025-Finisher

289 - Attendance Message

Logic control sensed that the Finisher Path Sensor was not actuated within the specified time after the Finisher
Input Sensor was actuated.

Step Actions and Questions Yes No

1 PATH LOCATION INSPECTION

Inspect the position of the sheet of paper in the Finisher.

Has the lead edge of the sheet of paper actuated the
Finisher Path Sensor?

2 SENSOR TEST

Enter Diagnostics and check the Finisher Path Sensor
function. Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

3 FINISHER PATH SENSOR

Replace the Finisher Path Sensor. Go to “Sensor, Input Path

Removal” on page 4-41. Enter Diagnostics and check the

Finisher Path Sensor function.Insert then remove a sheet of
paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

4 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Enter Diagnostics and check

the Finisher Path Sensor function. Insert then remove a sheet
of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

Go to step 2 Go to step 5

Go to step 4 Go to step 3

Problem
solved

Problem
solved

Go to step 4

Replace the
MCU Board

5 PATH PAPER INSPECTION

Inspect the Drive Rolls in the Finisher, especially the Input
Rolls and the Registration Rolls.

Are all of the Drive Rolls in the Finisher clean and free of
obvious wear and damage?

6 DRIVE TRAIN TEST

Enter Diagnostics and select Output Bin Tests. Select Feed
Test, Output Bin 2 to run the Finisher Main Feed Motor.

Does the Finisher Main Feed Motor run smoothly?

7 DRIVE TRAIN INSPECTION

Inspect the drive train, including belts, pulleys, and gears, of
the entire Finisher Assembly from the Finisher Main Feed
Motor to the Registration Rolls.

Does the entire drive train of the Finisher Assembly
appear to be in good condition, with no damaged or
slipping belts and no chipped or broken pulleys or gears?

Go to step 6 Replace the

suspect Drive
Rolls

Go to step 7 Replace the

Finisher Main
Feed Motor

Go to step 8 Replace the

suspect belts,
pulleys, and
gears

Diagnostic Information 2-23

4025-Finisher

Step Actions and Questions Yes No

8 The following Finisher FRUs and areas are associated with

this specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using these steps, replace each FRU or troubleshoot
each area listed below, one at a time, until you isolate and
solve the problem.

• Wiring and connectors linking the FRUs

290 - Attendance Message

Logic Control sensed that the Finisher Exit Path Sensor did not deactuate within the specified time after it was
actuated.

Step Actions and Questions Yes No

1 PATH LOCATION INSPECTION

Inspect the position of the sheet of paper in the Finisher.

Has the trail edge of the sheet of paper cleared the
Finisher Exit Path Sensor?

2 SENSOR TEST

Enter Diagnostics and check the Finisher Exit Path Sensor
function. Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

3 FINISHER EXIT PATH SENSOR

Replace the Finisher Exit Path Sensor. Go to “Sensor, Input

Path Removal” on page 4-41. Enter Diagnostics and check

the Finisher Exit Path Sensor function. Insert then remove a
sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

4 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Enter Diagnostics and check

the Finisher Exit Path Sensor function.Insert then remove a
sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

Go to step 2 Go to step 5

Go to step 4 Go to step 3

Problem
solved

Problem
solved

Go to step 4

Replace the
MCU Board

5 PATH PAPER INSPECTION

Inspect the Drive Rolls in the Finisher, especially the
Registration Rolls, Shift Rolls, and Exit Rolls.

Are all of the Drive Rolls in the Finisher clean and free of
obvious wear and damage?

2-24 Service Manual

Go to step 6 Replace the

suspect Drive
Rolls

4025-Finisher

Step Actions and Questions Yes No

6 DRIVE TRAIN TEST

Enter Diagnostics and select Output Bin Tests. Select Feed
Test, Output Bin 2 to run the Finisher Main Feed Motor.

Does the Finisher Main Feed Motor run smoothly?

7 DRIVE TRAIN INSPECTION

Inspect the drive train, including belts, pulleys, and gears, of
the entire Finisher Assembly from the Finisher Main Feed
Motor, through the Shift Rolls, and on to the Exit Rolls.

Does the entire drive train of the Finisher Assembly
appear to be in good condition, with no damaged or
slipping belts and no chipped or broken pulleys or gears?

8 The following Finisher FRUs and areas are associated with

this specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using these steps, replace each FRU or troubleshoot
each area listed below, one at a time, until you isolate and
solve the problem.

• Shift Roll Unit

• Wiring and connectors linking the FRUs

291 - Attendance Message

Go to step 7 Replace the

Finisher Main
Feed Motor

Go to step 8 Replace the

suspect belts,
pulleys, and
gears

Logic Control sensed that the Finisher Exit Path Sensor was not actuated within the specified time after the
Finisher Path Sensor was actuated.

Step Actions and Questions Yes No

1 PATH LOCATION INSPECTION

Inspect the position of the sheet of paper in the Finisher.

Has the leading edge of the sheet of paper actuated the
Finisher Exit Path Sensor?

2 SENSOR TEST

Enter Diagnostics and check the Finisher Exit Path Sensor
function. Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

3 FINISHER EXIT PATH SENSOR

Replace the Finisher Exit Path Sensor. Enter Diagnostics and
check the Finisher Exit Path Sensor function. Insert then
remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

Go to step 2 Go to step 5

Go to step 4 Go to step 3

Problem
solved

Go to step 4

Diagnostic Information 2-25

4025-Finisher

Step Actions and Questions Yes No

4 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Enter Diagnostics and check

the Finisher Exit Path Sensor function. Insert then remove a
sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

5 PATH PAPER INSPECTION

Inspect the Drive Rolls in the Finisher, especially the Input
Rolls and the Registration Rolls.

Are all of the Drive Rolls in the Finisher clean and free of
obvious wear and damage?

6 DRIVE TRAIN TEST

Enter Diagnostics and select Output Bin Tests. Select Feed
Test, Output Bin 2 to run the Finisher Main Feed Motor.

Does the Finisher Main Feed Motor run smoothly?

7 DRIVE TRAIN INSPECTION

Inspect the drive train, including belts, pulleys, and gears, of
the entire Finisher Assembly from the Finisher Main Feed
Motor to the Registration Rolls.

Does the entire drive train of the Finisher Assembly
appear to be in good condition, with no damaged or
slipping belts and no chipped or broken pulleys or gears?

Problem
solved

Go to step 6 Replace the

Go to step 7 Replace the

Go to step 8 Replace the

Replace the
MCU Board

suspect Drive
Rolls

Finisher Main
Feed Motor

suspect belts,
pulleys, and
gears

8 The following Finisher FRUs and areas are associated with

this specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using these steps, replace each FRU or troubleshoot
each area listed below, one at a time, until you isolate and
solve the problem.

• Wiring and connectors linking the FRUs

292 - Attendance Message

Logic Control sensed that the Exit Roll Interlock Switch is actuated.

Step Actions and Questions Yes No

1 EXIT ROLL INTERLOCK INSPECTION

Remove the Top Covers and inspect the Exit Roll Unit and the
area around the Exit Roll Interlock Switch.

Is the Exit Roll Unit in good condition and is the area clear
of obvious damage?

Go to step 2 Replace the

suspect FRUs

2-26 Service Manual

4025-Finisher

Step Actions and Questions Yes No

2 INTERLOCK TEST

Enter Diagnostics and check the Exit Roll Interlock Switch
function. Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

3 EXIT ROLL INTERLOCK SWITCH

Replace the Exit Roll Interlock Switch. Go to “Exit Assembly

Removal” on page 4-145. Enter Diagnostics and check the

Exit Roll Interlock Switch function. Insert then remove a sheet
of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

4 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Enter Diagnostics and check

the Exit Roll Interlock Switch function. Insert then remove a
sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

5 MCU BOARD

Replace the MCU Board. Refer to the Printer Service Manual.
Enter Diagnostics and check the Exit Roll Interlock Switch
function.

Does the Exit Roll Interlock Switch test ok?

Go to step 4 Go to step 3

Problem
solved

Problem
solved

Problem
solved

Go to step 4

Go to step 5

Go to step 6

6 The following Finisher FRUs and areas are associated with

this specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using these steps, replace each FRU or troubleshoot
each area listed below, one at a time, until you isolate and
solve the problem.

• Wiring and connectors linking the FRUs

295 - Attendance Message

Logic control sensed that either the Compiler Tray Paper Sensor did not deactuate within the specified time
after the set started to output, or the Compiler Tray Paper Sensor did not deactuate within the specified time
after the Sensor was actuated.

Step Actions and Questions Yes No

1 PATH LOCATION INSPECTION

Inspect the position of the sheet of paper exiting the Complier
Tr ay.

Has the trail edge of the sheet of paper cleared the Compiler
Tray Paper Sensor?

Go to step 2 Go to step 5

Diagnostic Information 2-27

4025-Finisher

Step Actions and Questions Yes No

2 SENSOR TEST

Enter Diagnostics and check the Compiler Tray Paper Sensor
function. Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL as
you insert then remove the paper?

3 COMPILER TRAY PAPER SENSOR

Replace the Compiler Tray Paper Sensor. Go to “Compiler Roll

and Roll Shaft Removal” on page 4-80. Enter Diagnostics and

check the Compiler Tray Paper Sensor function. Insert then
remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL as
you insert then remove the paper?

4 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-Main

Removal” on page 4-132. Enter Diagnostics and check the

Compiler Tray Paper Sensor function. Insert then remove a sheet
of paper into the sensor.

Does the Operator Panel LCD change between OP and CL as
you insert then remove the paper?

5 PATH PAPER INSPECTION

Inspect the Exit Rolls in the Compiler.

Are all of the Exit Rolls in the Compiler clean and free of
obvious wear and damage?

Go to step 4 Go to step 3

Problem
solved

Problem
solved

Go to step 6 Replace the

Go to step 4

Replace the
MCU Board

suspect Rolls

6 DRIVE TRAIN TEST

Enter Diagnostics and select Output Bin Tests. Select Feed Test,
Output Bin 2 to run the Finisher Main Feed Motor.

Does the Finisher Main Feed Motor run smoothly?

7 DRIVE TRAIN INSPECTION

Inspect the drive train, including belts, pulleys, and gears, of the
entire Finisher Assembly from the Finisher Main Feed Motor to the
Compiler Exit Rolls.

Does the entire drive train of the Finisher Assembly appear to
be in good condition, with no damaged or slipping belts and
no chipped or broken pulleys or gears?

8 The following Finisher FRUs and areas are associated with this

specific problem. One or more of these FRUs or areas may have
failed partially or completely. If you cannot isolate this problem
using these steps, replace each FRU or troubleshoot each area
listed below, one at a time, until you isolate and solve the problem.

• Wiring and connectors linking the FRUs

• Compiler Tray and Compiler Move Tray

Go to step 7 Replace the

Finisher Main
Feed Motor

Go to step 8 Replace the

suspect belts,
pulleys, and
gears

2-28 Service Manual

4025-Finisher

Service Error Code Service Checks

980 - Error Code Service Check

Logic control sensed that there is a communication problem between the printer and the Finisher.

Step Actions and Questions Yes No

1 RESET

Switch off the printer and the Finisher. Wait one minute, then
switch on the printer and the Finisher

Is the error code gone?

2 RESEAT

Disconnect then reconnect the Finisher from the printer.

Is the error code gone?

3 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Check the Stapler function.

Does the Stapler function correctly?

4 MCU BOARD

Replace the MCU Board. Refer to the Printer Service Manual.
Check the Stapler function.

Does the Stapler function correctly?

5 The following Finisher FRUs and areas are associated with

this specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using these steps, replace each FRU or troubleshoot
each area listed below, one at a time, until you isolate and
solve the problem.

Problem
solved

Problem
solved

Problem
solved

Problem
solved

Go to step 2

Go to step 3

Go to step 4

Go to step 5

• Wiring and connectors linking the FRUs

981 - Stacker Tray Service Check

Logic control sensed that there is a problem with the Stacker Tray.

Step Actions and Questions Yes No

1 STACKER TRAY INSPECTION

Inspect the position of the Stacker Tray.

Has the Tray actuated the Stacker Height Sensor?

2 SENSOR TEST

Enter Diagnostics and check the Stacker Tray Position Sensor
function. Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

Go to step 3 Go to step 2

Go to step 4 Go to step 3

Diagnostic Information 2-29

4025-Finisher

Step Actions and Questions Yes No

3 ENCODER ASSEMBLY

Replace the Encoder Assembly. Enter Diagnostics and check
the Stacker Tray Position Sensor function. Insert then remove
a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

4 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Enter Diagnostics and check

the Docking Interlock Switch function.

Does the Interlock Switch test ok?

5 MCU BOARD

Replace the MCU Board. Refer to the Printer Service Manual.
Enter Diagnostics and check the Docking Interlock Switch
function.

Does the Interlock Switch test ok?

6 The following Finisher FRUs and areas are associated with

this specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using these steps, replace each FRU or troubleshoot
each area listed below, one at a time, until you isolate and
solve the problem.

Problem
solved

Problem
solved

Problem
solved

Go to step 4

Go to step 5

Go to step 6

• Wiring and connectors linking the FRUs

• Elevator Drive Unit

• Elevator Belt

• Stacker Tray

• Stacker Tray Paper Sensor

982 - Error Code Service Check

Logic control sensed that there is a problem at the Jogger Home F Sensor.

Step Actions and Questions Yes No

1 SENSOR TEST

Enter Diagnostics and check the Jogger Home F Sensor
function. Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

Go to step 3 Go to step 2

2-30 Service Manual

4025-Finisher

Step Actions and Questions Yes No

2 JOGGER HOME POSITION SENSOR

Replace the Jogger Home Position Sensor. Go to “Sensor,

Jogger Home Position Removal” on page 4-68. Enter

Diagnostics and check the Jogger Home F Sensor function.
Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

3 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Enter Diagnostics and check

the Jogger Home F Sensor function. Insert then remove a
sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

4 MCU BOARD

Replace the MCU Board. Refer to the Printer Service Manual.
Enter Diagnostics and check the Jogger Home F Sensor
function. Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

5 The following Finisher FRUs and areas are associated with

this specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using these steps, replace each FRU or troubleshoot
each area listed below, one at a time, until you isolate and
solve the problem.

Problem
solved

Problem
solved

Problem
solved

Go to step 3

Go to step 4

Go to step 5

• Wiring and connectors linking the FRUs

• FRUs within the Jogger Assembly

983 - Error Code Service Check

Logic control sensed that there is a problem at the Jogger Home R Sensor.

Step Actions and Questions Yes No

1 SENSOR TEST

Enter Diagnostics and check the Jogger Home R Sensor
function. Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

Go to step 3 Go to step 2

Diagnostic Information 2-31

4025-Finisher

Step Actions and Questions Yes No

2 JOGGER HOME POSITION SENSOR

Replace the Jogger Home Position Sensor. Go to “Sensor,

Jogger Home Position Removal” on page 4-68. Enter

Diagnostics and check the Jogger Home R Sensor function.
Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

3 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Enter Diagnostics and check

the Jogger Home R Sensor function. Insert then remove a
sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

4 MCU BOARD

Replace the MCU Board. Refer to the Printer Service Manual.
Enter Diagnostics and check the Jogger Home R Sensor
function. Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

5 The following Finisher FRUs and areas are associated with

this specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using these steps, replace each FRU or troubleshoot
each area listed below, one at a time, until you isolate and
solve the problem.

Problem
solved

Problem
solved

Problem
solved

Go to step 3

Go to step 4

Go to step 5

• Wiring and connectors linking the FRUs

• FRUs within the Jogger Assembly

984 - Error Code Service Check

Logic control sensed that there is a problem at the Exit Roll.

Step Actions and Questions Yes No

1 SENSOR TEST

Enter Diagnostics and check the Exit Roll Open/Close HP
Sensor. Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

Go to step 3 Go to step 2

2-32 Service Manual

4025-Finisher

Step Actions and Questions Yes No

2 EXIT ROLL OPEN/CLOSE HP SENSOR

Replace the Exit Roll Open/Close HP Sensor. Go to “Motor

Removal” on page 4-84. Enter Diagnostics and check the

Exit Roll Open/Close HP Sensor. Insert then remove a sheet of
paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

3 MOTOR TEST

Enter Diagnostics and select Output Bin Tests. Select Feed
Test, Output Bin 2 to feed paper through the Finisher.

Does the Exit Roll Open/Close Motor test ok?

4 EXIT ROLL OPEN/CLOSE MOTOR

Replace the Exit Roll Open/Close Motor. Go to “Motor

Removal” on page 4-84. Exit Roll Open/Close Motor function.

Does the Exit Roll Open/Close Motor test ok?

5 DRIVE TRAIN INSPECTION

Inspect the drive train, including belts, gears, and levers of the
entire Exit Roll Assembly.

Does the entire drive train of the Exit Roll Assembly
appear to be in good condition, with no damaged or
slipping gears and no broken levers?

6 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Enter Diagnostics and check

the Exit Roll Open/Close HP Sensor. Insert then remove a
sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

Problem
solved

Go to step 5 Go to step 4

Problem
solved

Go to step 6 Replace the

Problem
solved

Go to step 6

Go to step 6

damaged
FRUs

Go to step 7

7 MCU BOARD

Replace the MCU Board. Refer to the Printer Service Manual.
Enter Diagnostics and check the Exit Roll Open/Close HP
Sensor.

Does the Exit Roll Open/Close HP Sensor test ok?

8 The following Finisher FRUs and areas are associated with

this specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using these steps, replace each FRU or troubleshoot
each area listed below, one at a time, until you isolate and
solve the problem.

• Wiring and connectors linking the FRUs

• Broken or damaged FRUs within the Exit Roll area.

Problem
solved

Diagnostic Information 2-33

Go to step 8

4025-Finisher

985 - Error Code Service Check

Logic control sensed that the Shift Roller failed.

Step Actions and Questions Yes No

1 SENSOR TEST

Enter Diagnostics and check the Shift Roller HP Sensor
function. Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

2 SHIFT ROLLER HP SENSOR

Replace the Shift Roller HP Sensor. Go to “No Paper Sensor

Assembly Removal” on page 4-136. Enter Diagnostics and

check the Shift Roller HP Sensor function. Insert then remove
a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

3 MOTOR TEST

Enter Diagnostics and select Output Bin Tests. Select Feed
Test, Output Bin 2 to feed paper through the Finisher.

Does the Shift Motor test ok?

4 SHIFT MOTOR

Replace the Shift Motor. Go to “Motor Assembly-MP2

Removal” on page 4-77. Enter Diagnostics and check the

Shift Motor function.

Does the Shift Motor test ok?

5 DRIVE TRAIN INSPECTION

Inspect the drive train, including belts, gears, and levers of the
entire Shift Roller Assembly.

Does the entire drive train of the Shift Roller assembly
appear to be in good condition, with no damaged or
slipping gears and no broken levers?

Go to step 3 Go to step 2

Problem
solved

Go to step 5 Go to step 4

Problem
solved

Go to step 6 Replace the

Go to step 6

Go to step 6

damaged
FRUs

6 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Enter Diagnostics and select

Output Bin Tests. Select Feed Test, Output Bin 2 to feed paper
through the Finisher.

Does the Sensor and/or Motor test ok?

7 MCU BOARD

Replace the MCU Board. Refer to the Printer Service Manual.
Enter Diagnostics and check the Shift Roller HP Sensor and/or
Shift Motor function.

Does the Sensor and/or Motor test ok?

2-34 Service Manual

Problem
solved

Problem
solved

Go to step 7

Go to step 8

4025-Finisher

Step Actions and Questions Yes No

8 The following Finisher FRUs and areas are associated with

this specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using these steps, replace each FRU or troubleshoot
each area listed below, one at a time, until you isolate and
solve the problem.

• Wiring and connectors linking the FRUs.

• Broken or damaged FRUs within the Shift Roll area.

986 - Error Code Service Check

Logic control sensed that the Punch failed.

Step Actions and Questions Yes No

1 SENSOR TEST

Enter Diagnostics and check the Finisher Path Sensor
function. Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

2 FINISHER PATH SENSOR

Replace the Finisher Path Sensor. Enter Diagnostics and
check the Finisher Path Sensor function. Insert then remove a
sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

3 SENSOR TEST

Enter Diagnostics and check the Finisher Exit Path Sensor
function. Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

4 FINISHER EXIT PATH SENSOR

Replace the Finisher Exit Path Sensor. Go to “Sensor, Exit

Path Removal” on page 4-42. Enter Diagnostics and check

the Finisher Exit Path Sensor function. Insert then remove a
sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

Go to step 3 Go to step 2

Problem
solved

Go to step 5 Go to step 4

Problem
solved

Go to step 6

Go to step 6

5 PUNCH ASSEMBLY TEST

From the Finishing Menu, select Hole Punch On. From the
Utilities Menu, select Quick Demo.

Does the Punch Assembly test ok?

Go to step 6 Replace the

Punch
Assembly

Diagnostic Information 2-35

4025-Finisher

Step Actions and Questions Yes No

6 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Enter Diagnostics and check

the Sensor and/or Punch Assembly function. Insert then
remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

7 MCU BOARD

Replace the MCU Board. Refer to the Printer Service Manual.
Enter Diagnostics and check the Sensor and/or Punch
Assembly function.

Does the Sensor and/or Punch Assembly test ok?

8 The following Finisher FRUs and areas are associated with

this specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using these steps, replace each FRU or troubleshoot
each area listed below, one at a time, until you isolate and
solve the problem.

• Wiring and connectors linking the FRUs.

• Broken or damaged FRUs within the Punch Assembly area or

along the paper path.

Problem
solved

Problem
solved

Go to step 7

Go to step 8

987 - Error Code Service Check

Logic control sensed that the Stapler failed.

Step Actions and Questions Yes No

1 STAPLER INSPECTION

Inspect the Stapler for broken parts, jammed staples, or
obvious signs of damage.

Does the Stapler appear to be in good condition, with no
jammed staples or obvious signs of damage?

2 STAPLER CARTRIDGE

Replace the Stapler Cartridge. Go to “Cartridge Removal”

on page 4-101.

Does the Stapler function correctly?

3 STAPLER ASSEMBLY

Replace the Stapler Assembly. Go to “Stapler I Assembly

Removal” on page 4-92.

Does the Stapler function correctly?

Go to step 2 Clear the

Problem
solved

Problem
solved

staples or
replace the
damaged
FRUs

Go to step 3

Go to step 4

2-36 Service Manual

4025-Finisher

Step Actions and Questions Yes No

4 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Check the Stapler function.

Does the Stapler function correctly?

5 MCU BOARD

Replace the MCU Board. Refer to the Printer Service Manual.
Check the Stapler function.

Does the Stapler function correctly?

6 The following Finisher FRUs and areas are associated with

this specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using these steps, replace each FRU or troubleshoot
each area listed below, one at a time, until you isolate and
solve the problem.

• Wiring and connectors linking the FRUs

• Broken or damaged FRUs within the Stapler area, Compiler

area, or along the paper path.

Problem
solved

Problem
solved

988 - Error Code Service Check

Logic control sensed that there is a problem at the Stapler Head Home Sensor.

Go to step 5

Go to step 6

Step Actions and Questions Yes No

1 SENSOR TEST

Enter Diagnostics and check the Stapler Head Home Sensor
function. Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

2 STAPLER HEAD HOME SENSOR

Replace the Stapler Head Home Sensor. Go to “Sensor,

Stapler Home Position Traverse Removal” on page 4-113.

Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

3 TRAVERSE MOTOR TEST

From the Finishing Menu, select the following:
Copies 5, Staple ON, Staple Dual

Does the Stapler Traverse Motor test ok?

4 STAPLER BASE INSPECTION

Does the Stapler Base move freely back and forth?

Go to step 3 Go to step 2

Problem
solved

Go to step 4 Go to step 6

Go to step 7 Go to step 5

Go to step 7

Diagnostic Information 2-37

4025-Finisher

Step Actions and Questions Yes No

5 STAPLER ASSEMBLY

Replace the Stapler Assembly. Go to “Stapler I Assembly

Removal” on page 4-92. From the Finishing Menu, select the

following: Copies 5, Staple ON, Staple Dual

Does the Stapler Base move freely back and forth?

6 STAPLER TRAVERSE MOTOR

Replace the Stapler Traverse Motor. Go to “Traverse Motor

Assembly Removal” on page 4-102. From the Finishing

Menu, select the following: Copies 5, Staple ON, Staple Dual

Does the Stapler Traverse Motor test ok?

7 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Check the Stapler function.

Does the Stapler function correctly?

8 MCU BOARD

Replace the MCU Board. Refer to the Printer Service Manual.
Check the Stapler function.

Does the Stapler function correctly?

9 The following Finisher FRUs and areas are associated with

this specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using these steps, replace each FRU or troubleshoot
each area listed below, one at a time, until you isolate and
solve the problem.

Problem
solved

Problem
solved

Problem
solved

Problem
solved

Go to step 9

Go to step 7

Go to step 8

Go to step 9

• Wiring and connectors linking the FRUs.

• Broken or damaged FRUs within the Stapler area, Compiler

area, or along the paper path.

989 - Error Code Service Check

Logic control sensed that there is a problem with the Stapler Front Position Sensor.

Step Actions and Questions Yes No

1 SENSOR TEST

Enter Diagnostics and check the Stapler Front Sensor function.
Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

2 STAPLER FRONT SENSOR

Replace the Stapler Front Sensor. Insert then remove a sheet
of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

Go to step 3 Go to step 2

Problem
solved

Go to step 7

2-38 Service Manual

4025-Finisher

Step Actions and Questions Yes No

3 TRAVERSE MOTOR TEST

From the Finishing Menu, select the following:
Copies 5, Staple ON, Staple Dual

Does the Stapler Traverse Motor test ok?

4 STAPLER BASE INSPECTION

From the Finishing Menu, select the following:
Copies 5, Staple ON, Staple Dual

Does the Stapler Base move freely back and forth?

5 STAPLER ASSEMBLY

Replace the Stapler Assembly. Go to “Stapler I Assembly

Removal” on page 4-92. From the Finishing Menu, select the

following: Copies 5, Staple ON, Staple Dual

Does the Stapler Base move freely back and forth?

6 STAPLER TRAVERSE MOTOR

Replace the Stapler Traverse Motor. Go to “Traverse Motor

Assembly Removal” on page 4-102. From the Finishing

Menu, select the following: Copies 5, Staple ON, Staple Dual

Does the Stapler Traverse Motor test ok?

7 FINISHER MAIN BOARD

Replace the Finisher Main Board. Go to “PWB Assembly-

Main Removal” on page 4-132. Check the Stapler function.

Does the Stapler function correctly?

Go to step 4 Go to step 6

Go to step 7 Go to step 5

Problem
solved

Problem
solved

Problem
solved

Go to step 9

Go to step 7

Go to step 8

8 MCU BOARD

Replace the MCU Board. Refer to the Printer Service Manual.
Check the Stapler function.

Does the Stapler function correctly?

9 The following Finisher FRUs and areas are associated with

this specific problem. One or more of these FRUs or areas may
have failed partially or completely. If you cannot isolate this
problem using these steps, replace each FRU or troubleshoot
each area listed below, one at a time, until you isolate and
solve the problem.

• Wiring and connectors linking the FRUs.

• Broken or damaged FRUs within the Stapler area, Compiler

area, or along the paper path.

Problem
solved

Go to step 9

Diagnostic Information 2-39

4025-Finisher

990 - Error Code Service Check

Logic control sensed that there is a problem with the Stapler Dual Position function.

Step Actions and Questions Yes No

1 SENSOR TEST

Enter Diagnostics and check the Stapler Front Sensor function.
Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

2 STAPLER FRONT SENSOR

Replace the Stapler Front Sensor. Insert then remove a sheet
of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

3 SENSOR TEST

Enter Diagnostics and check the Stapler Head Home Sensor
function. Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

4 STAPLER HEAD HOME SENSOR

Replace the Stapler Head Home Sensor. Go to “Sensor,

Stapler Home Position Traverse Removal” on page 4-113.

Insert then remove a sheet of paper into the sensor.

Does the Operator Panel LCD change between OP and CL
as you insert then remove the paper?

5 TRAVERSE MOTOR TEST

From the Finishing Menu, select the following:
Copies 5, Staple ON, Staple Dual

Does the Stapler Traverse Motor test ok?

Go to step 3 Go to step 2

Problem
solved

Go to step 5 Go to step 4

Problem
solved

Go to step 6 Go to step 8

Go to step 9

Go to step 9

6 STAPLER BASE INSPECTION

From the Finishing Menu, select the following:
Copies 5, Staple ON, Staple Dual

Does the Stapler Base move freely back and forth?

7 STAPLER ASSEMBLY

Replace the Stapler Assembly. Go to “Stapler I Assembly

Removal” on page 4-92. From the Finishing Menu, select the

following: Copies 5, Staple ON, Staple Dual

Does the Stapler Base move freely back and forth?

8 STAPLER TRAVERSE MOTOR

Replace the Stapler Traverse Motor. Go to “Traverse Motor

Assembly Removal” on page 4-102. From the Finishing

Menu, select the following: Copies 5, Staple ON, Staple Dual

Does the Stapler Traverse Motor test ok?

2-40 Service Manual

Go to step 10 Go to step 7

Problem
solved

Problem
solved

Go to step 10

Go to step 9