Lexmark W840 Finisher User Manual

• Table of contents

• Start diagnostics

• Safety and notices

Lexmark™ W840 Finisher

4024-XXX

• Trademarks

•Index

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

4024-XXX

Edition: September 8, 2005
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 edi tions. 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.

References in this publication to products, programs, or services do not imply that the manufacturer intends to make these
available in all countries in which it operates. Any reference to a product, program, or service is not intended to state or
imply that only that product, program, or service may be used. Any functionally equivalent product, program, or service that
does not infringe any existing intellectual property right may be used instead. Evaluation and verification of operation in
conjunction with other products, programs, or services, except those expressly designated by the manufacturer, are the
user’s responsibility.

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

Other trademarks are the property of their respective owners.

© 2005 Lexmark International, Inc.

All rights reserved.

UNITED STAT ES GOVERNMENT RIGHTS

This software and any accompanying documentation provided under this agreement are commercial computer software
and documentation developed exclusively at private expense.

P/N 12G9604

4024-XXX

Table of contents

Notices and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ix

Laser notice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi

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

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

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

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

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

Media weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Tools required for service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

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

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

Using service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Confirm the installation status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

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

Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

280.00 Sensor (bridge unit media entrance) on Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

280.01 Sensor (bridge unit media entrance) static jam A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

280.02 Sensor (bridge unit media entrance) static jam B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

281.00 Sensor (bridge unit media exit) On Jam A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

281.01 Sensor (bridge unit media exit) On Jam B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

281.02 Sensor (bridge unit media exit) On Jam C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

281.03 Sensor (bridge unit media exit) static jam A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

282.00 Sensor (finisher media entrance) on jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

282.01 Sensor (finisher media entrance) static jam A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

283.00 Sensor (buffer path) on jam A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

283.01 Sensor (buffer path) on jam B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

283.02 Sensor (buffer path) static jam A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

283.03 Sensor (buffer path) static jam B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

283.04 Sensor (buffer path) static jam C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

284.00 Sensor (lower media exit) off jam A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

284.01 Sensor (lower media exit) on jam A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

284.02 Sensor (lower media exit) on jam B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

284.03 Sensor (lower media exit) on jam C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

284.04 Sensor (lower media exit) off jam B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

284.05 Sensor (lower media exit) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37

285.00 Finisher eject set jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37

286.00 Sensor (compiler media in) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

287.00 Sensor (upper media exit) on jam A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

287.01 Sensor (upper media exit) off jam A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

287.02 Sensor (upper media exit) on jam B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

287.03 Sensor (upper media exit) on jam C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

287.04 Sensor (upper media exit) off jam B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

287.05 Sensor (upper media exit) static jam A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

287.06 Sensor (upper media exit) static jam B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

287.07 Sensor (upper media exit) static jam C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

288.00 Sensor (diverter gate) on jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

288.01 Sensor (diverter gate) static jam (to top bin) A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

Table of contents iii

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288.02 Sensor (diverter gate) static jam (to top bin) B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52

288.03 Sensor (diverter gate) static jam (to top bin) C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53

288.04 Sensor (diverter gate) static jam (to stacker bin) A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54

288.05 Sensor (diverter gate) static jam (to stacker bin) B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

288.06 Sensor (diverter gate) static jam (to stacker bin) C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56

980.02 Finisher communication failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56

981.00 Stacker bin failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57

981.01 Stacker bin upper limit failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-59

981.02 Stacker bin lower limit failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 -60

982.00 Sensor (front tamper HP) on failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62

982.01 Sensor (front tamper HP) off failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-63

983.00 Sensor (rear tamper HP) on failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64

983.01 Sensor (rear tamper HP) off failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65

984.00 Sensor (punch unit HP) on failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66

984.01 Sensor (punch unit HP) off failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-67

985.00 Sensor (punch carriage shift HP) on failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68

985.01 Sensor (punch carriage shift HP) off failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-69

986.00 Sensor (media eject clamp HP) on failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70

986.01 Sensor (media eject clamp HP) off failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

987.00 Sensor (media eject shaft HP) on failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-72

987.01 Sensor (media eject shaft HP) off failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74

988.00 Sensor (punch unit side reg) on failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-75

988.01 Sensor (punch unit side reg) off failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-76

989.00 Stapler unit failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78

990.00 Sensor (stapler carriage HP) on failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78

990.01 Sensor (stapler carriage HP) off failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-79

995.00 Finisher NVRAM R/W failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-80

996.00 Finisher type failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-80

999.00 Finisher engine/RIP functional failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-81

Bridge unit top cover open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-81

Finisher front door open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-82

Finisher eject cover open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-83

Finisher upper media bin full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-84

No punch waste box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-85

Punch waste box full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-86

Stacker media bin full (mix size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-86

Stacker media bin full (no mix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-88

Stacker lower safety failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-90

Stacker set over count failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-92

Staple cartridge empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-92

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

Accessing Diagnostics mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Available finisher tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

FINISHER TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

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

Hole Punch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Feed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Sensor Test (finisher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

EXIT DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

iv Finisher Service Manual

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Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Media transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Bridge unit assembly paper path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Finisher media path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Finisher roll assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Finisher media path sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Finisher motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Bridge unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

From bridge unit assembly to punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

From punch to compiler unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

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

From punch to upper media bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

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

Bridge unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

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

Adjusting punching positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -12

Punching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Detecting punch waste full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Detecting punch waste box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Functions of punch sensors/motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

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

Outline of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Capacity of compiler unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Compiler unit assembly operation with multiple media sizes . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Tamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Front tamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Rear tamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Center tamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Determining tamper home position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Tamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Offsetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Functions of compiler unit assembly sensors/motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

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

Stapling operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Staple positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Media sizes that allow stapling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Stapling one sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Stapling multiple size media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Media limits for stapling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Stapler operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Stapler unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Functions of stapler sensors/motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

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

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

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

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

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Full stack detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Functions of stacker media bin sensors/motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

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

Table of contents v

4024-XXX

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

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

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

Bridge unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

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

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

Bridge unit top cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Bridge unit drive belt and bridge unit drive pulley removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Bridge unit right shaft assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

Bridge unit left shaft assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Bridge unit idler rolls removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Bridge unit transport belt removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Bridge unit drive motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 -13

Bridge unit entrance guide removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

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

Sensor (bridge unit media entrance) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

Sensor (bridge unit media exit) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

Bridge unit pinch roller removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

Top cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

Upper media bin assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

Right eject cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21

Stacker media bin assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

Right lower low voltage power supply (LVPS) cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

Rear lower cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23

Rear upper cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

Upper media bin front cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25

Switch (finisher front door interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

Finisher front door assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27

Left lower cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28

Left upper cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29

Carriage lift belt left removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30

Carriage lift belt right removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32

Sensor (stacker bin level 1) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34

Sensor (stacker bin level 2) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34

Sensor (stacker bin level encoder) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35

Sensor (stacker bin upper limit) or sensor (stacker bin no media) removal . . . . . . . . . . . . . . . .4-36

Stacker bin lift motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-38

Punch carriage assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 -41

Punch carriage shift motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43

Sensor (punch unit side registration pair) with bracket removal . . . . . . . . . . . . . . . . . . . . . . . . .4-44

Punch unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45

Punch media stop assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46

Punch unit motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47

Sensor (punch unit motor encoder) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48

Sensor (punch hole select), sensor (punch cam front), and sensor (punch unit HP) removal .4-49

Sensor (punch carriage shift HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-51

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

Sensor (punch waste box full) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-53

Stapler unit frame removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-54

Stapler unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-56

Sensor (stapler carriage HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-58

Media eject unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-59

Sub paddle removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-63

Sub paddle drive shaft assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-64

Media eject clamp motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-66

Sensor (media eject clamp HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-67

Switch (eject cover interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-68

Media compiler unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-69

Sensor (front tamper HP) and sensor (rear tamper HP) removals . . . . . . . . . . . . . . . . . . . . . . . .4-72

vi Finisher Service Manual

4024-XXX

Sensor (compiler media in) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73

Media eject shaft assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74

Clamp paddle removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76

Media eject clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77

Media eject motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78

Sensor (media eject shaft HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79

Sensor (lower media exit) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80

Lower media exit roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82

Paddle and roll exit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86

Lower pinch guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90

Media diverter gate removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91

Buffer diverter gate removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92

Sensor (buffer path) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93

Buffer roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94

Buffer pinch guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-96

Media entrance pinch guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97

Sensor (finisher media entrance) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-98

Media entrance roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-99

Drive motor (entrance/paddle) and belt (entrance/paddle) removal . . . . . . . . . . . . . . . . . . . . . 4-100

Media diverter gate solenoid removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-102

Buffer diverter gate solenoid removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-103

Sensor (upper media exit) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104

Upper media exit pinch roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-105

Upper media exit roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-106

Sensor (upper media bin full) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-108

Upper pinch guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-109

Sensor (diverter gate) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-110

Upper media transport roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-111

Drive motor (exit) assembly and belt (exit) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-113

Drive motor (buffer/transport) and belt (buffer/transport) removal . . . . . . . . . . . . . . . . . . . . . 4-115

Bridge unit interface card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-117

Finisher controller card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-118

Finisher low voltage power supply (LVPS) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-119

Component locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

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

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

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

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

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

Buffer, upper exit, lower exit, and drive motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Electronic component diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

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

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

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

Table of contents vii

4024-XXX

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

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

Assembly 1: Bridge unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Assembly 2: Bridge unit top cover assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Assembly 3: Bridge unit lower assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Assembly 4: Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Assembly 5: Covers and front door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Assembly 6: Stacker bin lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Assembly 7: Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Assembly 8: Stapler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Assembly 9: Media eject . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

Assembly 10: Eject and compiler unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Assembly 11: Lower exit drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Assembly 12: Buffer and entrance drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Assembly 13: Buffer, transport, and upper drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

Assembly 14: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

Assembly 15: Cables 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

Assembly 16: Cables 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

Assembly 17: Cables 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

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

Part number index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-7

viii Finisher Service Manual

Notices and safety information

Laser notice

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

Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (3b) laser
that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770-795 nanometers.
The laser system and printer are designed so there is never any human access to laser radiation above a Class
I level during normal operation, user maintenance, or prescribed service condition.

Laser

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

4024-XXX

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

Avis relatif à l’utilisation de laser

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

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

Avvertenze sui prodotti laser

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

I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un laser di classe
IIIb (3b) all’arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d’onda compresa tra 770 e 795
nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la
stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non
ricevano radiazioni laser superiori al livello della classe 1.

Notices and safety information ix

4024-XXX

Avisos sobre el láser

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

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

Declaração sobre Laser

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

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

Laserinformatie

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

Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van
klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met een golflengte van 770-795
nanometer. Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal gebruik, bij onderhoud of reparatie
conform de voorschriften, nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals
voorgeschreven is voor klasse 1.

Lasermeddelelse

Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825-1.
Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der

nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer.
Lasersystemet og printeren er udformet således, at mennesker aldrig udsættes for en laserstråling over Klasse
I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.

x Finisher Service Manual

Huomautus laserlaitteesta

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

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

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

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

Laser-notis

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

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

4024-XXX

Laser-melding

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

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

Avís sobre el Làser

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

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

Notices and safety information xi

4024-XXX

xii Finisher Service Manual

Safety information

• The safety of this product is based on testing and approvals of the original design and specific

components. The manufacturer is not responsible for safety in the event of use of unauthorized
replacement parts.

• The maintenance information for this product has been prepared for use by a professional service person

and is not intended to be used by others.

• There may be an increased risk of electric shock and personal injury during disassembly and servicing of

this product. Professional service personnel should understand this and take necessary precautions.

• CAUTION: When you see this symbol, there is a danger from hazardous voltage in the area of the

product where you are working. Unplug the product before you begin, or use caution if the product
must receive power in order to perform the task.

Consignes de sécurité

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

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

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

maintenance qualifié.

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

d'entretien qualifié devra prendre toutes les précautions nécessaires.

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

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

4024-XXX

Norme di sicurezza

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

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

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

assistenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto,

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

• ATTENZIONE: Questo simbolo indica la presenza di tensione pericolosa nell'area del prodotto.

Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per
eseguire l'intervento.

Safety information xiii

4024-XXX

Sicherheitshinweise

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

bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine
Verantwortung oder Haftung für die Sicherheit übernommen.

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

Wartungsfachmann bestimmt.

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

elektrischen Schlags und körperlicher Ve rletzung. Das zuständige Fachpersonal sollte entsprechende
Vorsichtsmaßnahmen treffen.

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

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

Pautas de Segur i dad

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

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

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

cualificado de mantenimiento.

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

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

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

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

Informações de Segurança

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

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

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

devem ser utilizadas por outras pessoas.

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

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

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

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

xiv Finisher Service Manual

Informació de Seguretat

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

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

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

destinada
a ningú que no ho sigui.

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

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

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

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

4024-XXX

Safety information xv

4024-XXX

Preface

The service information for the Lexmark W840 is contained within three service manuals:

• Printer Service Manual—Contains the base printer service information including the options and finisher

error codes and tests.

• Options Service Manual—Contains specific information for the 2 Tray Module, Tandem Tray Module,

Duplex, High Capacity Feeder and Exit 2 options and a list of error codes and tests.

• Finisher Service Manual—Contains specific information for the Finisher option list of error codes and tests.

These manuals contain maintenance procedures for service personnel. They are divided into the following
chapters:

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

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

2. Diagn ostic information contains an error code messages table and service checks used to isolate failing

field replaceable units (FRUs).

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

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

FRUs.

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

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

problems.

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

Definitions

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

CAUTION: A caution identifies something that might cause a servicer harm.

CAUTION: When you see this symbol, there is a danger from hazardous voltage in the area of the

product where you are working. Unplug the product before you begin, or use caution if the product
must receive power in order to perform the task.

xvi Finisher Service Manual

1. General information

The optional finisher performs staples, punches, and stacks media transferred from the Lexmark™ W840 printer.
Output is stacked in the upper media bin or separately collated in the stacker media bin.

Bridge unit assembly

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Finisher weight

Packaged: 42 kg
Unpackaged: 30 kg

Components

The finisher is composed of the following five components.

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

• Punch block to punch media

• Compiler tray block to align media

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

Finisher

General information 1-1

4024-XXX

n

• Stacker media bin block to stack media

Bridge unit asm

Media size and weight

The following shows media sizes and weight that the finisher can handle, as well as applicable functions for each
media size.

The printer and the finisher handle different media sizes and weights. For this reason, if the printer has printed
media that the finisher cannot handle, the exit 1 diverter gate in the printer is switched to eject the media from
Exit 2 onto the bridge unit assembly . Refer to the Printer Service Manual for additional information on the printer.

Punch unit

Stacker media bi

Compiler tray

Stapler

Media size/orientation and applicable functions

Short edge
Media
description

Size

B5

182 x 257 mm

Executive 7.25 x 10.5 in.

184.2 x 27 0 mm

Letter 8.5 x 11 in.

215.9 x 279.4 mm

A4

210 x 297

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

Legal 8.5 x 14 in. SEF Yes Yes Yes Yes

B4

257 x 364 mm

first (SEF)/

Long edge

first (LEF)

SEF Yes No No No No
LEF Yes Yes Yes Yes
SEF Yes No No No No
LEF Yes Yes Yes Yes
SEF Yes Yes Yes Yes
LEF Yes Yes Yes Yes
SEF Yes Yes Yes Yes
LEF Yes Yes Yes Yes2

SEF Yes Yes Yes Yes

Top
tray

Stacker

Stack Stack

Offset
stack

Punch

a(2,3,4)

a(2,3,4)

1

a(2)

Yes

a(2)

Yes

a(2)

Yes

,a(3,4)

a(2)

Yes

a(2)

Yes

a(2)

Yes

Staple

No

Yes

Yes

1-2 Finisher Service Manual

4024-XXX

A3

SEF Yes Yes Yes Yes

a(2,3,4)

Yes

297 x 420 mm

a(2,3,4)

Ledger 11 x 17 in. SEF Yes Yes Yes Yes

Custom size Same width with

Yes Yes Yes Yes Yes

Yes

standard size

Custom size Besides above Yes Yesb Yesb No No

a

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

b

Applicable within the following range:

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

General information 1-3

4024-XXX

Media weight

Description Maximum weight

For punching 52—176 gsm
For stapling 52—226 gsm*
For ejecting in the stacker media bin 52—226 gsm
For ejecting in the upper media bin 52—226 gsm
* The amount of media capable of being stapled will be less than 50 if media weight

is greater than 90 gsm.

Tools required for service

Flat-blade screwdriver
#1 Phillips screwdriver, magnetic
#2 Phillips screwdriver, magnetic
#2 Phillips screwdriver, magnetic short-blade
Needlenose pliers
Diagonal side cutters
Spring hook
Analog or digital multimeter

Features

Media processing requested Destination of media

No post-processing Upper media bin or stacker media bin
Punching Upper media bin or stacker media bin
Stapling Stacker media bin
Punching and stapling Stacker media bin

1-4 Finisher Service Manual

Acronyms

2TM 2 Tray Module
AC Alternate Current
ASIC Application Specific Intergrated Circuit
CRU Customer Replaceable Unit
CSU Customer Setup
DC Direct Current
DIMM Dual Inline Memory Module
DRAM Dynamic Random Access Memory
EDO Enhanced Data Out
EP Electrophotographic Process
EPROM Erasable Programmable Read-only Memory
ESD Electrostatic Discharge
FRU Field Replaceable Unit
GB Gigabyte
GFI Ground Fault Interrupter
HCF High-Capacity Feeder
HVPS High Voltage Power Supply
LASER Light Amplification by Stimulated Emission of Radiation
LCD Liquid Crystal Display
LD Laser Diode
LED Light-Emitting Diode
LEF Long Edge Fed
LVPS Low Voltage Power Supply
MPF Multi-Purpose Feeder
MS Microswitch
NVM Nonvolatile Memory
NVRAM Nonvolatile Random Access Memory
OEM Original Equipment Manufacturer
OPT Optical Sensor
PC Photoconductor
pel Picture element
POR Power-on Reset
POST Power-on Self Test
PPM Pages Per Minute
PSC Parallel Synchronous Communications
PSD Position Sensing Device
PWM Pulse Width Modulation
RFID Radio Frequency Identification
RIP Raster Imaging Processor
ROM Read only Memory
RPM Parallel Synchronous Communications
SDRAM Synchronous Dual Random Access Memory
SEF Short Edge Fed
SIMM Single Inline Memory Module
SOS Start of scan
SRAM Static Random Access Memory
TTM Tandem Tray Module
UPR Used Parts Return
VVolts
V ac Volts alternating current
V dc Volts direct current

4024-XXX

General information 1-5

4024-XXX

1-6 Finisher Service Manual

2. Diagnostic information

Start

CAUTION: Unplug power cord from the printer or electrical outlet before you connect or disconnect any

cable or electronic board or assembly for personal safety and to prevent damage to the printer.
Disconnect any connections between the printer and PCs/peripherals. The printer and the finisher are
heavy and require at least two people to lift it safely. Make sure your fingers are not under the printer
when you lift or set the printer down.

CAUTION: If the printer is kept on, never touch the conductive parts while it is not specifically required. The
power switch and inlet of the low voltage power supply card (LVPS card) assembly is live even while the power
supply is cut off. Never touch the live parts.

Warning: When operating the driving units using the diagnostics or other tools, be sure to keep them covered

unless otherwise specified.

Warning: When operating the driving units using the diagnostics or other tools, never touch the driving units.

When operating the driving units using diagnostics or other tools, be sure to follow the procedures
in this manual.

CAUTION: Be careful to avoid burns by safely handling hot parts.

4024-XXX

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

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

Using service checks

It is assumed in the finisher service checks that the printer controller RIP card assembly is normally functioning.
If any trouble cannot be corrected by troubleshooting, refer to the Printer Service Manual.

To determine the corrective action necessary to repair a finisher, look for the following information:

• Verify “Confirm the installation status” on page 2-2

• Go to the “Error code messages” on page 2-3.

• Additional information can be found at:
– “Service checks” on page 2-11.
– “Theory” on page 3-4

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

Diagnostic information 2-1

4024-XXX

Confirm the installation status

Be sure to check the following items before starting the troubleshooting procedures

• With the power cord removed from the printer, check that it is free from breakage, short-circuit,

disconnected wire, or incorrect connection in the power cord.

• The printer is properly grounded. Check the power cord ground terminal.

• The printer is not installed at a place subjected to extreme temperature, or extreme humidity, or rapid

changes in temperature.

• The printer is not installed close to water service, humidifier, heat generating unit, fire, in a very dusty

place, or a place exposed to air flow from the air conditioning system.

• The printer is not installed in a place where volatile gas or inflammable gas is generated.

• The printer is not installed in direct sun.

• The printer is installed on a stout and stable surface.

• Media meets specifications and is installed properly.

• Customer maintenance parts have been replaced at the specified inter vals.

• Check all attached options for proper attachment and electrical connection.

• Refer to the User’s Guide fo r proper installation.

2-2 Finisher Service Manual

Error code messages

Error code or message Error contents Description/action

4024-XXX

280.00
Paper jam
Check area A

280.01
Paper jam
Check area A

280.02
Check area F

281.00
Paper jam
Check area A

281.01
Paper jam
Check area F

Sensor (bridge unit
media entrance) on jam

Sensor (bridge unit
media entrance) Static
jam A

Sensor (bridge unit
media entrance) Static
jam B

Sensor (bridge unit
media exit) on jam A

Sensor (bridge unit
media exit) on jam B

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

Go to “280.00 Sensor (bridge unit media entrance)

on Jam” on page 2-11.

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

Go to “280.01 Sensor (bridge unit media entrance)

static jam A” on page 2-12.

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

Go to “280.02 Sensor (bridge unit media entrance)

static jam B” on page 2-13.

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

At this time, the sensor (fuser exit) in the printer is
turned on.

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

Jam A” on page 2-14.

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

At this time, the sensor (bridge unit media entrance) is
turned on.

Go to “281.01 Sensor (bridge unit media exit) On

Jam B” on page 2-15.

281.02
Paper jam
Check area F

281.03
Paper jam
Check area F

282.00
Paper jam
Check area F

282.01
Paper jam
Check area F

Sensor (Bridge unit
media exit) on jam C

Sensor (bridge unit
media exit) Static jam A

Sensor (finisher media
entrance) on jam

Sensor (finisher media
entrance) Static jam A

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

Go to “281.02 Sensor (bridge unit media exit) On

Jam C” on page 2-17.

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

jam A” on page 2-18.

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

Go to “282.00 Sensor (finisher media entrance) on

jam” on page 2-19.

Paper remains on the sensor (finisher media
entrance).

At this time, the sensor (bridge unit media exit) is
turned on.

Go to “282.01 Sensor (finisher media entrance)

static jam A” on page 2-21.

Diagnostic information 2-3

4024-XXX

283.00
Paper jam
Check areas G, G4

283.01
Paper jam
Check area G2

283.02
Paper jam
Check areas G2, G3

283.03
Paper jam
Check area G2

283.04
Paper jam
Check area G4

Sensor (buffer path) on
jam A

Sensor (buffer path) on
jam B

Sensor (buffer path)
Static jam A

Sensor (buffer path)
Static jam B

Sensor (buffer path)
Static jam C

Sensor (buffer path) is not turned on within the
specified time after the sensor (finisher media entrance
is turned on.

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

page 2-22.

Sensor (buffer path) is not turned on within the
specified time after the sensor (finisher media entrance
is turned on.

At this time, the sensor (diverter gate) is turned on.
Go to “283.01 Sensor (buffer path) on jam B” on

page 2-24.

Paper remains on the sensor (finisher buffer path).
At this time, both sensor (diverter gate) and sensor

(transport exit) are turned on.
Go to “283.02 Sensor (buffer path) static jam A” on

page 2-26.

Paper remains on the sensor (finisher buffer path).
At this time, the sensor (diverter gate) is on state, but

the sensor (finisher media entrance) is turned off.
Go to “283.03 Sensor (buffer path) static jam B” on

page 2-27.

Paper remains on the sensor (finisher buffer path).
At this time, the sensor (diverter gate) is turned off.
Go to “283.04 Sensor (buffer path) static jam C” on

page 2-28.

284.00
Paper jam
Check area F

284.01
Paper jam
Check area F

284.02
Paper jam
Check areas G2, G3

284.03
Paper jam
Check area G2

Sensor (lower media
exit) off jam A

Sensor (lower media
exit) on jam A

Sensor (lower media
exit) on jam B

Sensor (lower media
exit) on jam C

Sensor (lower media exit) is not turned off within the
specified time after the finisher sensor (lower media
exit) is on.

At this time, the sensor (bridge unit media exit) is
turned on.

Go to “284.00 Sensor (lower media exit) off jam A.”

on page 2-28.

Sensor (buffer path) is not turned on within the
specified time after the sensor (finisher media
entrance) is turned on.

At this time the sensor (bridge unit media exit) is turned
on.

Go to “284.01 Sensor (lower media exit) on jam A”

on page 2-30.

Sensor (buffer path) is not turned on within the
specified time after the sensor (bridge unit medi a
entrance) is turned on.

At this time, the sensor (finisher media entrance) is
turned on.

Go to “284.02 Sensor (lower media exit) on jam B”

on page 2-32.

Finisher sensor (lower media exit) not turned on within
the specified time after the sensor (buffer path) is
turned on.

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

on page 2-34.

2-4 Finisher Service Manual

4024-XXX

284.04
Paper jam
Check area H

284.05
Paper jam
Check areas H, G3

285.00
Paper jam
Check area H

286.00
Paper jam
Check area H

287.00
Check area F

Sensor (lower media
exit) off jam B

Sensor (lower media
exit) Static jam

Finisher eject set jam Finisher sensor (compiler media in) is not turned on

Sensor (compiler media
in) Static jam

Sensor (upper media
exit) on jam A

Finisher sensor (lower media exit) not turned off within
the specified time after the finisher sensor (lower
media exit) on.

At this time, the sensor (finisher media entrance) is
turned on.

Go to “284.04 Sensor (lower media exit) off jam B.”

on page 2-36.

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

on page 2-37.

within the specified time after the media eject motor is
turned on.

Go to “285.00 Finisher eject set jam” on page 2-37.
Paper remains on the sensor (compiler media in).

Go to “286.00 Sensor (compiler media in) static

jam” on page 2-38.

Sensor (upper media exit) is not turned on within the
specified time after the sensor (finisher media
entrance) is turned on.

At this time, the sensor (bridge unit media exit) is
turned on.

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

on page 2-40.

287.01
Check area F

287.02
Paper jam
Check areas G1, G3

287.03
Paper jam
Check area G1

287.04
Paper jam
Check area G

Sensor (upper media
exit) off jam A

Sensor (upper media
exit) on jam B

Sensor (upper media
exit) on jam C

Sensor (upper media
exit) off jam B

Sensor (upper media exit) is not turned off within the
specified time after the sensor (upper media exit) is
turned on.

At this time, the sensor (bridge unit media exit) is
turned on.

Go to “287.01 Sensor (upper media exit) off jam A.”

on page 2-41.

Sensor (upper media exit) is not turned on within the
specified time after the sensor (finisher media
entrance) is turned on.

At this time, the sensor (bridge unit media exit) is
turned on.

Go to “287.02 Sensor (upper media exit) on jam B”

on page 2-42.

Sensor (upper media exit) is not turned on within the
specified time after the sensor (finisher media
entrance) is turned on.

At this time, the sensor (bridge unit media exit) is
turned on.

Go to “287.03 Sensor (upper media exit) on jam C”

on page 2-44.

Sensor (upper media exit) is not turned off within the
specified time after the sensor (upper media exit) is
turned on.

At this time, the sensor (bridge unit media exit) is
turned off.

Go to “287.04 Sensor (upper media exit) off jam B.”

on page 2-45.

Diagnostic information 2-5

4024-XXX

287.05
Paper jam
Check area F

287.06
Paper jam
Check areas G1, G3

287.07
Paper jam
Check area G1

288.00
Paper jam
Check area F

288.01
Paper jam
Check area F

Sensor (upper media
exit) Static jam A

Sensor (upper media
exit) Static jam B

Sensor (upper media
exit) Static jam C

Sensor (diverter gate)
on jam

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

Paper remains on the sensor (upper media exit).
At this time, the sensor (bridge unit media exit) is

turned on.
Go to “287.05 Sensor (upper media exit) static jam

A” on page 2-46.

Paper remains on the sensor (upper media exit).
At this time, the sensor (bridge unit media exit) is off

state but the finisher sensor (finisher media entrance)
is turned on.

Go to “287.06 Sensor (upper media exit) static jam

B” on page 2-47.

Paper remains on the sensor (upper media exit).
At this time, both sensor (bridge unit media exit) and

sensor (finisher media entrance) are turned off.
Go to “287.07 Sensor (upper media exit) static jam

C” on page 2-48.

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

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

page 2-49.

Paper remains on the sensor (diverter gate) when the
finisher is in the upper bin exit mode.

At this time the sensor (bridge unit media exit) is turned
on.

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

top bin) A” on page 2-51.

288.02
Paper jam
Check areas G1, G3

288.03
Paper jam
Check area G1

288.04
Paper jam
Check area F

288.05
Paper jam
Check areas G2, G3

Sensor (diverter gate)
Static jam (to top bin) B

Sensor (diverter gate)
Static jam (to top bin) C

Sensor (diverter gate)
Static jam (to stacker
bin) A

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

Paper remains on the sensor (diverter gate) when the
finisher is in the upper bin exit mode.

At this time, the sensor (finisher media entrance) is on
state, but the sensor (bridge unit media exit) is turned
off.

Go to “288.02 Sensor (diverter gate) static jam (to

top bin) B” on page 2-52.

Paper remains on the sensor (diverter gate) when the
finisher is in the upper bin exit mode.

At this time, both sensor (finisher media entrance) and
sensor (bridge unit media exit) are turned off.

Go to “288.03 Sensor (diverter gate) static jam (to

top bin) C” on page 2-53.

Paper remains on the sensor (diverter gate) when the
finisher is in the stacker bin exit mode.

At this time, the sensor (bridge unit media exit) is
turned on.

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

stacker bin) A” on page 2-54.

Paper remains on the sensor (diverter gate) when the
finisher is in the stacker bin exit mode.

At this time, the sensor (finisher media entrance) is on
state, but the sensor (bridge unit media exit) is turned
off.

Go to “288.05 Sensor (diverter gate) static jam (to

stacker bin) B” on page 2-55.

2-6 Finisher Service Manual

4024-XXX

288.06
Paper jam
Check area G2

980.02
Service finisher comm.

981.00
Service finisher error

981.01
Service finisher error

981.02
Service finisher error

982.00
Service finisher error

Sensor (diverter gate)
Static jam (to stacker
bin) C

Finisher communication
failure

Stacker bin failure The sensor (stacker bin level) is not turned on within

Stacker bin upper limit
failure

Stacker bin lower limit
failure

Sensor (front tamper
HP) on failure

Paper remains on the sensor (diverter gate) when the
finisher is in the stacker bin exit mode.

At this time, both sensor (finisher media entrance) and
sensor (bridge unit media exit) are turned off.

Go to “288.06 Sensor (diverter gate) static jam (to

stacker bin) C” on page 2-56.

A communication error occurred between the printer
engine card assembly and the finisher.

Go to “980.02 Finisher communication failure” on

page 2-56.

the specified period after the stacker bin starts rising.
Go to “981.00 Stacker bin failure” on page 2-57.

The stacker bin abnormally rises beyond the specified
upper limit position (stacker bin level).

Go to “981.01 Stacker bin upper limit failure” on

page 2-59.

The stacker bin abnormally lowers beyond the
specified lower limit position (full stack).

Go to “981.02 Stacker bin lower limit failure” on

page 2-60.

The sensor (front tamper HP) is not turned on after the
front tamper starts moving to the front tamper home
position.

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

on page 2-62.

982.01
Service finisher error

983.00
Service finisher error

983.01
Service finisher error

984.00
Service finisher error

Sensor (front tamper
HP) off failure

Sensor (rear tamper HP)
on failure

Sensor (rear tamper HP)
off failure

Sensor (punch unit HP)
on failure

The sensor (front tamper HP) is not turned off within
the specified time after the front tamper starts leaving
from the front tamper home position.

Or the sensor (front tamper HP) is turned on again
after the sensor (front tamper HP) is turned off and the
front tamper stopped its moving.

Go to “982.01 Sensor (front tamper HP) off failure”

on page 2-63.

The sensor (rear tamper HP) is not turned on after the
rear tamper starts moving to the rear tamper home
position.

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

on page 2-64.

The sensor (rear tamper HP) is not turned off within the
specified time after the rear tamper starts leaving from
the rear tamper home position.

Or the sensor (rear tamper HP) is turned on again after
the sensor (rear tamper HP) is turned off and the rear
tamper stopped its moving.

Go to “983.01 Sensor (rear tamper HP) off failure”

on page 2-65.

The sensor (punch unit HP) is not turned on even
when the specified time passed after the punch unit
motor is turned on.

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

page 2-66.

Diagnostic information 2-7

4024-XXX

984.01
Service finisher error

985.00
Service finisher error

985.01
Service finisher error

986.00
Service finisher error

Sensor (punch unit HP)
off failure

Sensor (punch carriage
shift HP) on failure

Sensor (punch carriage
shift HP) off failure

Sensor (media eject
clamp HP) on failure

The sensor (punch unit HP) is not turned off even
when the specified time passed after the punch unit
motor is turned on.

Go to “984.01 Sensor (punch unit HP) off failure”

on page 2-67.

The sensor (punch carriage shift HP) is not turned on
even when the specified time passed after the punch
carriage shift motor assembly is turned on.

Or the sensor (punch carriage shift HP) is turned off
again after the sensor (punch carriage shift HP) is
turned on and the punch carriage shift motor assembly
stopped its rotation.

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

failure” on page 2-68.

The sensor (punch carriage shift HP) is not turned off
even when the specified time passed after the punch
carriage shift motor assembly is turned on.

Or the sensor (punch carriage shift HP) is turned on
again after the sensor (punch carriage shift HP) is
turned off and the punch carriage shift motor assembly
stopped its rotation.

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

failure” on page 2-69.

The sensor (eject clamp HP) is not turned on within
500 ms after the eject clamp up starts.

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

failure” on page 2-70.

986.01
Service finisher error

987.00
Service finisher error

987.01
Service finisher error

988.00
Service finisher error

988.01
Service finisher error

Sensor (media eject
clamp HP) off failure

Sensor (media eject
shaft HP) on failure

Sensor (media eject
shaft HP) off failure

Sensor (punch unit side
reg1) on failure

Sensor (punch unit side
reg2) on failure

Sensor (punch unit side
reg1) off failure

Sensor (punch unit side
reg2) off failure

The sensor (eject clamp HP) is not turned off within
200 ms after the eject clamp down starts.

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

failure” on page 2-71.

The sensor (media eject shaft HP) is not turned on
within 200 ms after the set clamp starts operating.

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

failure” on page 2-72.

The sensor (media eject shaft HP) is not turned off
within the specified time after the set clamp ends
operating.

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

failure” on page 2-74.

The sensor (punch unit side reg1) or sensor (punch
unit side reg2) did not detect the media correctly or is
defective.

Go to “988.00 Sensor (punch unit side reg) on

failure” on page 2-75.

The sensor (punch unit side reg1) or sensor (punch
unit side reg2) did not detect the media correctly or is
defective.

Go to “988.01 Sensor (punch unit side reg) off

failure” on page 2-76.

2-8 Finisher Service Manual

4024-XXX

989.00
Service finisher error

990.00
Service finisher error

990.01
Service finisher error

Stapler unit failure The off/on status of the sensor (stapler unit motor HP)

Sensor (stapler
carriage HP) on failure

Sensor (stapler
carriage HP) off failure

is not detected within the specified time after the
stapler unit motor (forward operation).

Or the sensor (stapler unit motor HP) is not turned on
within the specified timer after the stapler unit motor is
on (reverse operation).

Go to “989.00 Stapler unit failure” on page 2-78.
The sensor (stapler carriage HP) is not turned on

within two seconds after the stapler starts moving
toward the staple position and also the sensor (stapler
carriage HP) is off.

Or the sensor (stapler carriage HP) is not turned on
after the stapler was moved to the staple position.

Or the sensor (stapler carriage HP) is turned off again
after the sensor (stapler carriage HP) is turned on and
the stapler stopped its moving.

Go to “990.00 Sensor (stapler carriage HP) on

failure” on page 2-78.

The sensor (stapler carriage HP) is not turned off
within 500 ms after stapler starts moving to the staple
position and sensor (stapler carriage HP) is off.

Or the sensor (stapler carriage HP) is not turned off
after the stapler was moved to the staple position.

Or the sensor (stapler carriage HP) is turned on again
after the sensor (stapler carriage HP) is turned off and
the stapler stopped its moving.

Go to “990.01 Sensor (stapler carriage HP) off

failure” on page 2-79.

995.00
Service finisher NV

996.00
Service wrong finisher

999.00
Service finisher error

Close cover F Bridge unit cover is open Finisher bridge unit cover is open.

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

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

Empty hole punch box Punch waste box full The punch waste box is filled.

Insert hole punch box Punch waste box

Finisher NVM R/W
failure

Finisher type failure An incorrect type of finisher is connected.

Finisher engine/RIP
functional failure

missing

A read/write error occurred on the NVM of the finisher
controller card assembly.

Go to “995.00 Finisher NVRAM R/W failure” on

page 2-80.

Go to “996.00 Finisher type failure” on page 2-80.
The engine reported a finisher failure that the RIP card

assembly did not recognize.
Go to “999.00 Finisher engine/RIP functional

failure” on page 2-81.

Go to “999.00 Finisher engine/RIP functional

failure” on page 2-81.

Go to “Finisher front door open” on page 2-82.

Go to “Finisher eject cover open” on page 2-83.

Go to “Punch waste box full” on page 2-86.
No punch waste box.

Go to “No punch waste box.” on page 2-85.

Load staples Staple cartridge empty Go to “Staple cartridge empty” on page 2-92.

Diagnostic information 2-9

4024-XXX

Remove paper from
Bin 1

Remove paper from
bin 2

Remove paper from
Bin 2

Remove paper from
Bin 2

Finisher upper media
bin full

Stacker set over count When the sta pled media exceeds the specified value

Stacker media bin fu ll
(no mix)

Stacker media bin fu ll
(mix size)

The upper media bin has reached maximum capacity.
Go to “Finisher upper media bin full” on page 2-84.

be able to stack on the stacker bin.
Go to “Stacker set over count failure” on page 2-92.

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

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

page 2-88.

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

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

page 2-86.

2-10 Finisher Service Manual

Service checks

280.00 Sensor (bridge unit media entrance) on Jam

Step Check Yes No

4024-XXX

1 Check the media path.

Open the bridge unit top cover assembly of the bridge
unit assembly.

Check the two transport belts and the six bridge unit
pinch rolls attached on the bridge unit top cover
assembly by turning them with your fingers.

Are the transport belts and the br idge unit pinch rolls
installed correctly?

2 Are two transport belts and the six bridge unit pinch

rolls free of damage?

3 Check the sensor (bridge unit media entrance) for

correct operation.
Perf orm the Bridge media ent test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Bridge media ent.

Does the display on the operator panel change every
time the actuator of the sensor (bridge unit media
entrance) is operated?

4 Check the sensor (bridge unit media entrance)

connection.
Is the above sensor connected properly?

Go to step 2. Clean or replace

Go to step 3. Clean or replace

Go to step 5. Go to step 4.

Replace the
sensor (bridge
unit media
entrance). See

“Sensor (bridge
unit media
entrance)
removal” on
page 4-16.

the transport
belts and bridge
unit pinch rolls,
and clean the
media path.

the transport
belts and bridge
unit pinch roll,
and clean the
media path.

Replace the
connection.

5 Check the bridge unit drive motor f o r corre ct o pe ration

by opening the finisher front door assembly then
closing it.

Does the bridge unit drive motor rotate normally?

6 Check the bridge unit drive motor connection.

Is the above motor properly connected?

Go to step 7. Go to step 6.

Replace the
bridge unit drive
motor. “Bridge

unit drive motor
assembly
removal” on
page 4-13.

Diagnostic information 2-11

Replace the
connection.

4024-XXX

Step Check Yes No

7 Perform a test print.

Does the error still occur?

8 Perform a test print.

Does the error still occur?

280.01 Sensor (bridge unit media entrance) static jam A

Step Check Yes No

1 Check the sensor (bridge unit media entrance) for

correct operation.
Perf orm the Bridge media ent test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Bridge media ent.

Does the display on the operator panel change every
time the actuator of the sensor (bridge unit media
entrance) is operated?

Replace the
bridge unit
interface card
assembly. See

“Bridge unit
interface card
assembly
removal” on
page 4-117.

Go to step 8.
Replace the

finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 3. Go to step 2.

Problem solved.

Problem solved.

2 Check the sensor (bridge unit media entrance)

connection
Is the above sensor connected properly?

3 Check the bridge unit drive motor for correct operation.

Check the above motor by opening the finisher front
door assembly and then closing it.

Does the bridge unit drive motor rotate normally?

4 Check the bridge unit drive motor connection.

Is the above motor connected properly?

2-12 Finisher Service Manual

Replace the
sensor (bridge
unit media
entrance). See

“Sensor (bridge
unit media
entrance)
removal” on
page 4-16.

Go to step 5. Go to step 4.

Replace the
bridge unit drive
motor. See

“Bridge unit
drive motor
assembly
removal” on
page 4-13.

Replace the
connection.

Replace the
connection.

Step Check Yes No

4024-XXX

5 Perform a test print.

Does the error still occur?

6 Perform a test print.

Does the error still occur?

280.02 Sensor (bridge unit media entrance) static jam B

Step Check Yes No

1 Check the sensor (bridge unit media entrance) for

correct operation.
Perf orm the Bridge media ent test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Bridge media ent.

Does the display on the operator panel change every
time the actuator of the sensor (bridge unit media
entrance) is operated?

Replace the
bridge unit
interface card
assembly. See

“Bridge unit
interface card
assembly
removal” on
page 4-117.

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 3. Go to step 2.

Problem solved.

Problem solved.

2 Check the sensor (bridge unit media entrance)

connection
Is the above sensor connected properly?

3 Check the bridge unit drive motor f o r corre ct o pe ration.

Check the above motor by opening the finisher front
door assembly and then closing it.

Does the bridge unit drive motor rotate normally?

4 Check the bridge unit drive motor connection.

Is the above motor connected properly?

Replace the
sensor (bridge
unit media
entrance). See

“Sensor (bridge
unit media
entrance)
removal” on
page 4-16.

Go to step 5. Go to step 4.

Replace the
bridge unit drive
motor. See

“Bridge unit
drive motor
assembly
removal” on
page 4-13.

Diagnostic information 2-13

Replace the
connection.

Replace the
connection.

4024-XXX

Step Check Yes No

5 Perform a test print.

Does the error still occur?

6 Perform a test print.

Does the error still occur?

281.00 Sensor (bridge unit media exit) On Jam A

Step Check Yes No

1 Check the media path.

1.Open the bridge unit top cover assembly of the
bridge unit assembly.

2.Check the transport belts and the six bridge unit
pinch rolls attached on the bridge unit top cover
assembly by turning them with your fingers.

Are the transport belts and the br idge unit pinch rolls
installed correctly?

Replace the
bridge unit
interface card
assembly. See

“Bridge unit
interface card
assembly
removal” on
page 4-117.

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 2. Clean or replace

Problem solved.

Problem solved.

the transport
belts and bridge
unit pinch rolls,
and clean the
media path.

2 Are two transport belts and the six bridge unit pinch roll

free of damage?

3 Check the sensor (bridge unit media exit) for correct

operation.
Perform the Bridge media exit test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Bridge media exit.

Does the display on the operator panel change every
time the actuator of the sensor (bridge unit media exit)
is operated?

4 Check the sensor (bridge unit media exit) connection.

Is the above sensor connected properly?

Go to step 3. Clean or replace

Go to step 5. Go to step 4.

Replace the
sensor (bridge
unit media exit).
See “Sensor

(bridge unit
media exit)
removal” on
page 4-17.

the transport
belts and bridge
unit pinch roll,
and clean the
media path.

Replace the
connection.

2-14 Finisher Service Manual

Step Check Yes No

4024-XXX

5 Check the bridge unit drive motor by opening the

finisher front door assembly and then closing it.
Does the bridge unit drive motor rotate normally?

6 Check the bridge unit drive motor connection.

Is the above motor properly connected?

7 Perform a test print.

Does the error still occur?

8 Perform a test print.

Does the error still occur?

Go to step 7. Go to step 6.

Replace the
bridge unit drive
motor. See

“Bridge unit
drive motor
assembly
removal” on
page 4-13.

Replace the
bridge unit
interface card
assembly. See

“Bridge unit
interface card
assembly
removal” on
page 4-117.

Go to step 8.
Replace the

finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Replace the
connection.

Problem solved.

Problem solved.

281.01 Sensor (bridge unit media exit) On Jam B

Step Check Yes No

1 Check the media path.

1.Open the bridge unit top cover assembly of the
bridge unit assembly.

2.Check the transport belts and the six bridge unit
pinch rolls attached on the bridge unit top cover
assembly by turning them with your fingers.

Are the transport belts and the br idge unit pinch rolls
installed correctly?

2 Are two transport belts and the six bridge unit pinch roll

free of damage?

Go to step 2. Clean or replace

the transport
belts and bridge
unit pinch rolls,
and clean the
media path.

Go to step 3. Clean or replace

the transport
belts and bridge
unit pinch roll,
and clean the
media path.

Diagnostic information 2-15

4024-XXX

Step Check Yes No

3 Check the sensor (bridge unit media exit) for correct

operation.
Perform the Bridge media exit test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Bridge media exit.

Does the display on the operator panel change every
time the actuator of the sensor (bridge unit media exit)
is operated?

4 Check the sensor (bridge unit media exit) connection.

Is the above sensor connected properly?

5 Check the bridge unit drive motor by opening the

finisher front door assembly and then closing it.
Does the bridge unit drive motor rotate normally?

6 Check the bridge unit drive motor connection.

Is the above motor properly connected?

Go to step 5. Go to step 4.

Replace the
sensor (bridge
unit media exit).
See “Sensor

(bridge unit
media exit)
removal” on
page 4-17.

Go to step 7. Go to step 6.

Replace the
bridge unit drive
motor. See

“Bridge unit
drive motor
assembly
removal” on
page 4-13.

Replace the
connection.

Replace the
connection.

7 Perform a test print.

Does the error still occur?

8 Perform a test print.

Does the error still occur?

Replace the
bridge unit
interface card
assembly. See

“Bridge unit
interface card
assembly
removal” on
page 4-117.

Go to step 8.
Replace the

finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Problem solved.

Problem solved.

2-16 Finisher Service Manual

281.02 Sensor (bridge unit media exit) On Jam C

Step Check Yes No

4024-XXX

1 Check the media path.

1.Open the bridge unit top cover assembly of the
bridge unit assembly.

2.Check the transport belts and the six bridge unit
pinch rolls attached on the bridge unit top cover
assembly by turning them with your fingers.

Are the transport belts and the br idge unit pinch rolls
installed correctly?

2 Are two transport belts and the six bridge unit pinch roll

free of damage?

3 Check the sensor (bridge unit media exit) for correct

operation.
Perform the Bridge media exit test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Bridge media exit.

Does the display on the operator panel change every
time the actuator of the sensor (bridge unit media exit)
is operated?

4 Check the sensor (bridge unit media exit) connection.

Is the above sensor connected properly?

Go to step 2. Clean or replace

Go to step 3. Clean or replace

Go to step 5. Go to step 4.

Replace the
sensor (bridge
unit media exit).
See “Sensor

(bridge unit
media exit)
removal” on
page 4-17.

the transport
belts and bridge
unit pinch rolls,
and clean the
media path.

the transport
belts and bridge
unit pinch roll,
and clean the
media path.

Replace the
connection.

5 Check the bridge unit drive motor by opening the

finisher front door assembly and then closing it.
Does the bridge unit drive motor rotate normally?

6 Check the bridge unit drive motor connection.

Is the above motor properly connected?

7 Perform a test print.

Does the error still occur?

Go to step 7. Go to step 6.

Replace the
bridge unit drive
motor. See

“Bridge unit
drive motor
assembly
removal” on
page 4-13.

Replace the
bridge unit
interface card
assembly. See

“Bridge unit
interface card
assembly
removal” on
page 4-117.

Go to step 8.

Diagnostic information 2-17

Replace the
connection.

Problem solved.

4024-XXX

Step Check Yes No

8 Perform a test print.

Does the error still occur?

281.03 Sensor (bridge unit media exit) static jam A

Step Check Yes No

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

operation.
Perform the Bridge media exit test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Bridge media exit.

Does the display on the operator panel change every
time the actuator of the sensor (bridge unit media exit)
is operated?

2 Check the sensor (bridge unit media exit) connection.

Is the above sensor connected properly?

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 4. Go to step 2.

Replace the
sensor (bridge
unit media exit).
See “Sensor

(bridge unit
media exit)
removal” on
page 4-17.

Problem solved.

Replace the
connection.

3 Check the bridge unit drive motor for correct operation.

Check the above motor by opening the finisher front
door assembly and then closing it.

Does the bridge unit drive motor rotate normally?

4 Check the bridge unit drive motor connection.

Are the connectors of the bridge unit cable assembly
connected to the bridge unit drive motor and bridge
unit interface card assembly of the finisher correctly
connected?

5 Perform a test print.

Does the error still occur?

2-18 Finisher Service Manual

Go to step 5. Go to step 4.

Replace the
bridge unit drive
motor. See

“Bridge unit
drive motor
assembly
removal” on
page 4-13.

Replace the
bridge unit
interface card
assembly. See

“Bridge unit
interface card
assembly
removal” on
page 4-117.

Replace the
connection.

Problem solved.

Step Check Yes No

4024-XXX

6 Perform a test print.

Does the error still occur?

282.00 Sensor (finisher media entrance) on jam

Step Check Yes No

1 Check the media path.

1.Open the bridge unit top cover assembly of the
bridge unit assembly.

2.Check two transport bel ts and the six bridge unit
pinch rolls attached on the bridge unit top cover
assembly by turning them with your fingers.

Are transport belts and the bridge uni t pinch rolls
installed correctly?

2 Are two transport belts and the six bridge unit pinch roll

free of damage?

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 2. Clean or replace

Go to step 3. Clean or replace

Problem solved.

the transport
belts and bridge
unit pinch rolls,
and clean the
media path.

the transport
belts and bridge
unit pinch rolls,
and clean the
media path.

3 Check sensor (bridge unit media exit) for correct

operation.
Perform the Bridge media exit test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Bridge media exit.

Does the display on the operator panel change every
time the actuator of the sensor (bridge unit media exit)
is operated?

4 Check the sensor (bridge unit media exit) connection.

Is the above senor connected properly?

Go to step 6. Go to step 4.

Replace the
sensor (bridge
unit media exit).
See “Sensor

(bridge unit
media exit)
removal” on
page 4-17.

After
reconnecting, go
to step 5.

Diagnostic information 2-19

4024-XXX

Step Check Yes No

5 Check the sensor (finisher media entra n ce) for correct

operation.
Perf orm the Bridge media ent test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Bridge media ent.

Does the display on the operator panel change every
time a piece of white media is placed over the sensing
area of the sensor (finisher media entrance)?

9 Check the sensor (finisher media ent rance)

connection.
Is the above sensor connected properly?

7 Check the bridge unit drive motor by opening the

finisher front door assembly and then closing it.
Does the bridge unit drive motor rotate normally?

8 Is the bridge unit drive motor connected properly? Replace the

Go to step 7. Go to step 6.

Replace the
sensor (finisher
media entrance).
See “Sensor

(bridge unit
media entrance)
removal” on
page 4-16.

Go to step 9. Go to step 8.

bridge unit drive
motor. See

“Bridge unit
drive motor
assembly
removal” on
page 4-13.

Replace the
connection.

Replace the
connection.

9 Perform a test print.

Does the error still occur?

10 Perf orm a test print.

Does the error still occur?

Replace the
bridge unit
interface card
assembly. See

“Bridge unit
interface card
assembly
removal” on
page 4-117.

Go to step 10.
Replace the

finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Problem solved.

Problem solved.

2-20 Finisher Service Manual

282.01 Sensor (finisher media entrance) static jam A

Step Check Yes No

4024-XXX

1 Check the sensor (finisher media entrance) for correct

operation.
Perf orm the Fin media ent test.

1.Enter Diagnostics mode

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Fin media ent.

Does the display change, every time a piece of white
media is placed over the sensor (finisher media
entrance)?

2 Check the sensor (finisher media entr a n c e)

connection,
Is the above sensor connected correctly?

3 Check the drive motor (entrance/paddle) for correct

operation.
Check the above motor by opening the finisher front

door assembly and then closing it.
Does the motor (entrance/paddle) rotate normally?

4 Check the drive motor (entrance/paddle) connection.

Are the connections of the main drive cable assembly
correctly connected?

Go to step 3. Go to step 2.

Replace the
sensor (finisher
media entrance).
See “Sensor

(finisher media
entrance)
removal” on
page 4-98.

Go to step 5. Go to step 4.

Replace the drive
motor (entrance/
paddle). See

“Drive motor
(entrance/
paddle) and belt
(entrance/
paddle)
removal” on
page 4-100.

Replace the
connector.

Replace the
connection.

5 Perform a test print.

Does the error still occur?

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Diagnostic information 2-21

Problem solved.

4024-XXX

283.00 Sensor (buffer path) on jam A

Step Check Yes No

1 Check the media path.

1.Open the finisher front door asse mbly of the
finisher.

2.Remove the top cover and left upper cover.

3.Open the entrance pinch guide assembly upward.

4.Check the media entrance roll assembly and the
media entrance pinch guide pinch roll attached on
the media entrance pinch guide assembly by
turning them with your fingers.

Are the media entrance roll assembly and the media
entrance pinch guide pinch rolls operating correctly?

2 Are the media entrance roll assembly and the media

entrance pinch guide pinch rolls free of damage, and
rotate smoothly?

3 Check the media path.

1.Open the finisher front door asse mbly of the
finisher.

2.Remove the top cover and left upper cover.

3.Open the lower pinch guide assembly to the right.

4.Check the buffer roll assembly by turning it with
your fingers.

Is the buffer roll assembly installed correctly, and is it
free of damage and contamination?

4 Are the four buffer pinch guide pinch rolls attached on

the lower pinch guide assembly installed correctly?

Go to step 2. Clean or replace

the appropriate
rolls and clean
the media path.

Go to step 3. Clean or replace

the appropriate
rolls and clean
the paper path.

Go to step 4. Clean or replace

the appropriate
rolls, and clean
the media path.

Go to step 5. Clean or replace

the appropriate
rolls and clean
the media path.

5 Check the sensor (diverter gate) for correct operation.

Perf orm the Diverter gate test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path2.

5.Select Diverter gate.

Does the display on the operator panel change every
time a piece of white media is placed over the sensing
area of the sensor (diverter gate)?

6 Check the sensor (diverter gate) connection.

Is the above sensor connected properly?

Go to step 7. Go to step 6.

Replace the
sensor (diverter
gate). See

“Sensor
(diverter gate)
removal” on
page 4-110.

After
reconnecting, go
to step 7.

2-22 Finisher Service Manual

Step Check Yes No

4024-XXX

7 Check the sensor (buff e r pa th ) for correct operation.

Perform the Buffer path test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Buffer path.

Does the display on the operator panel change every
time the actuator of the sensor (buffer path) is
operated?

8 Check the sensor (buffer path) connection.

Is the above sensor connect properly?

9 Check the drive motor (buffer/transport) by opening the

finisher front door assembly and then closing it.
Does the drive motor (buffer/transport) rotate

normally?

10 Check the drive motor (buffer/transport) connection.

Is the above motor connected properly?

Go to step 9. Go to step 8.

Replace the
sensor (buffer
path). See

“Sensor (buffer
path) removal”
on page 4-93.

Go to step 11. Go to step 10.

Replace the drive
motor (buffer/
transport). See

“Drive motor
(buffer/
transport) and
belt (buffer/
transport)
removal” on
page 4-115.

After
reconnecting, go
to step 9.

Problem solved.

11 Perf orm a test print.

Does the error still occur?

12 Perf orm a test print.

Does the error still occur?

Replace the
bridge unit
interface card
assembly. See

“Bridge unit
interface card
assembly
removal” on
page 4-117.

Go to step 12.
Replace the

finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Problem solved.

Problem solved.

Diagnostic information 2-23

4024-XXX

283.01 Sensor (buffer path) on jam B

Step Check Yes No

1 Check the media path.

1.Open the finisher front door asse mbly of the
finisher.

2.Remove the top cover and left upper cover.

3.Open the entrance pinch guide assembly upward.

4.Check the media entrance roll assembly and the
media entrance pinch guide pinch roll attached on
the media entrance pinch guide assembly by
turning them with your fingers.

Are the media entrance roll assembly and the media
entrance pinch guide pinch rolls operating correctly?

2 Are the media entrance roll assembly and the media

entrance pinch guide pinch rolls free of damage, and
rotate smoothly?

3 Check the media path.

1.Open the finisher front door asse mbly of the
finisher.

2.Remove the top cover and left upper cover.

3.Open the lower pinch guide assembly to the right.

4.Check the buffer roll assembly by turning it with
your fingers.

Is the buffer roll assembly installed correctly, and is it
free of damage and contamination?

4 Are the four buffer pinch guide pinch rolls attached on

the lower pinch guide assembly installed correctly?

Go to step 2. Clean or replace

the appropriate
rolls and clean
the media path.

Go to step 3. Clean or replace

the appropriate
rolls and clean
the paper path.

Go to step 4. Clean or replace

the appropriate
rolls, and clean
the media path.

Go to step 5. Clean or replace

the appropriate
rolls and clean
the media path.

5 Check the sensor (diverter gate) for correct operation.

Perf orm the Diverter gate test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path2.

5.Select Diverter gate.

Does the display on the operator panel change every
time a piece of white media is placed over the sensing
area of the sensor (diverter gate)?

6 Check the sensor (diverter gate) connection.

Is the above sensor connected properly?

Go to step 7. Go to step 6.

Replace the
sensor (diverter
gate). See

“Sensor
(diverter gate)
removal” on
page 4-110.

After
reconnecting, go
to step 7.

2-24 Finisher Service Manual

Step Check Yes No

4024-XXX

7 Check the sensor (buff e r pa th ) for correct operation.

Perform the Buffer path test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Buffer path.

Does the display on the operator panel change every
time the actuator of the sensor (buffer path) is
operated?

8 Check the sensor (buffer path) connection.

Is the above sensor connect properly?

9 Check the drive motor (buffer/transport) by opening the

finisher front door assembly and then closing it.
Does the drive motor (buffer/transport) rotate

normally?

10 Check the drive motor (buffer/transport) connection.

Is the above motor connected properly?

Go to step 9. Go to step 8.

Replace the
sensor (buffer
path). See

“Sensor (buffer
path) removal”
on page 4-93.

Go to step 11. Go to step 10.

Replace the drive
motor (buffer/
transport). See

“Drive motor
(buffer/
transport) and
belt (buffer/
transport)
removal” on
page 4-115.

After
reconnecting, go
to step 9.

Problem solved.

11 Perf orm a test print.

Does the error still occur?

12 Perf orm a test print.

Does the error still occur?

Replace the
bridge unit
interface card
assembly. See

“Bridge unit
interface card
assembly
removal” on
page 4-117.

Go to step 12.
Replace the

finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Problem solved.

Problem solved.

Diagnostic information 2-25

4024-XXX

283.02 Sensor (buffer path) static jam A

Step Check Yes No

1 Check the sensor (buffer path) for correct operation.

Perform the Buffer path test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Buffer path.

Does the display on the operator panel change every
time the actuator of the sensor (buffer path) is
operated?

2 Check the sensor (buffer path) connection.

Is the above sensor connected properly?

3 Check the drive motor (buffer/transport) for correct

operation.
Check the above motor by opening the finisher front

door assembly and then closing it.
Does the drive motor (buffer/transport) rotate

normally?

4 Check the drive motor (buffer/transport) connection.

Is the above motor connect properly?

Go to step 3. Go to step 2.

Replace the
sensor (buffer
path). See

“Sensor (buffer
path) removal”
on page 4-93.

Go to step 5. Go to step 4.

Replace the drive
motor (buffer/
transport). See

“Drive motor
(buffer/
transport) and
belt (buffer/
transport)
removal” on
page 4-115.

Replace the
connection.

Replace the
connection.

5 Perform a test print.

Does the error still occur?

2-26 Finisher Service Manual

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Problem solved.

283.03 Sensor (buffer path) static jam B

Step Check Yes No

4024-XXX

1 Check the sensor (buffer path) for correct operation.

Perform the Buffer path test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Buffer path.

Does the display on the operator panel change every
time the actuator of the sensor (buffer path) is
operated?

2 Check the sensor (buffer path) connection.

Is the above sensor connected properly?

3 Check the drive motor (buffer/transport) for correct

operation.
Check the above motor by opening the finisher front

door assembly and then closing it.
Does the drive motor (buffer/transport) rotate

normally?

4 Check the drive motor (buffer/transport) connection.

Is the above motor connect properly?

Go to step 3. Go to step 2.

Replace the
sensor (buffer
path). See

“Sensor (buffer
path) removal”
on page 4-93.

Go to step 5. Go to step 4.

Replace the drive
motor (buffer/
transport). See

“Drive motor
(buffer/
transport) and
belt (buffer/
transport)
removal” on
page 4-115.

Replace the
connection.

Replace the
connection.

5 Perform a test print.

Does the error still occur?

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Diagnostic information 2-27

Problem solved.

4024-XXX

283.04 Sensor (buffer path) static jam C

Step Check Yes No

1 Check the sensor (buffer path) for correct operation.

Perform the Buffer path test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Buffer path.

Does the display on the operator panel change every
time the actuator of the sensor (buffer path) is
operated?

2 Check the sensor (buffer path) connection.

Is the above sensor connected properly?

3 Check the drive motor (buffer/transport) for correct

operation.
Check the above motor by opening the finisher front

door assembly and then closing it.
Does the drive motor (buffer/transport) rotate

normally?

4 Check the drive motor (buffer/transport) connection.

Is the above motor connect properly?

Go to step 3. Go to step 2.

Replace the
sensor (buffer
path). See

“Sensor (buffer
path) removal”
on page 4-93.

Go to step 5. Go to step 4.

Replace the drive
motor (buffer/
transport). See

“Drive motor
(buffer/
transport) and
belt (buffer/
transport)
removal” on
page 4-115.

Replace the
connection.

Replace the
connection.

5 Perform a test print.

Does the error still occur?

284.00 Sensor (lower media exit) off jam A.

Step Check Yes No

1 Check the media path.

Open the finisher front door assembly of the finisher.
Check lower media exit roll assembly by turning it with
your fingers.

Is the lower media exit roll assembly installed
correctly?

2-28 Finisher Service Manual

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 2. Clean or replace

Problem solved.

the lower media
exit roll assembly ,
and clean the
media path.

Step Check Yes No

4024-XXX

2 Is the lower media exit roll assembly free of damage? Go to step 3. Clean or replace

3 Check the sensor (lower media exit) for correct

operation.
Perform the Lower media exit test.

1.In Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Lower media exit.

Does the display on the operator panel change every
time the actuator of the sensor (lower media exit) is
operated?

4 Check the sensor (lower media exit) connection.

Is the above sensor connected properly?

5 Check the drive motor (exit) by opening the finisher

front door assembly and then closing it.
Does the motor (exit) rotate normally?

Go to step 5. Go to step 4.

Replace the
sensor (lower
media exit). See

“Sensor (lower
media exit)
removal” on
page 4-80.

Go to step 7. Go to step 6.

the lower media
exit roll assembly ,
and clean the
media path.

Replace the
connection.

6 Check the drive motor (exit) connection.

Is the above motor connected properly?

7 Perform a test print.

Does the error still occur?

Replace the drive
motor (exit). See

“Drive motor
(exit) assembly
and belt (exit)
removal” on
page 4-113

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Replace the
connection.

Problem solved.

Diagnostic information 2-29

4024-XXX

284.01 Sensor (lower media exit) on jam A

Step Check Yes No

1 Check the media path.

1.Open the finisher front door asse mbly of the
finisher.

2.Open the lower pinch guide assembly to the right.

3.Open the buffer pinch guide assembly downward.

4.Check the buffer roll assembly by turning the rolls
with your fingers.

Is the buffer roll assembly installed correctly?

2 Is the buffer roll assembly free of damage? Go to step 3. Clean or replace

3 Are the buffer pinch guide pinch rolls attached to the

buffer pinch guide assembly correctly?

4 Are the buffer pinch guide pinch rolls free of damage? Go to step 5. Clean or replace

5 Check the sensor (buff e r pa th ) for correct operation.

Perform the Buffer path test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Buffer path.

Does the display on the operator panel change every
time the actuator of the sensor (buffer path) is
operated?

Go to step 2. Clean or replace

the appropriate
roll, and clean the
media path.

the appropriate
roll, and clean the
media path.

Go to step 4. Clean or replace

the appropriate
roller, and clean
the media path.

the appropriate
roller, and clean
the media path.

Go to step 7. Go to step 6.

6 Check the sensor (buffer path) connection.

Is the above sensor connected properly?

7 Check the drive motor (buffer/transport) by opening the

finisher front door assembly and then closing it.
Does the drive motor (buffer/transport) rotate

normally?

8 Check the drive motor (buffer/transport) connection.

Is the above motor connected properly?

2-30 Finisher Service Manual

Replace the
sensor (buffer
path). See

“Sensor (buffer
path) removal”
on page 4-93.

Go to step 9. Go to step 8.

Replace the drive
motor (buffer/
transport). See

“Drive motor
(buffer/
transport) and
belt (buffer/
transport)
removal” on
page 4-115.

Replace the
connection.

Replace the
connection.

Step Check Yes No

4024-XXX

9 Check the sensor (diverter gate) for correct operation.

Perf orm the Diverter gate test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path2.

5.Select Diverter gate.

Does the operator panel display change each time a
piece of media is placed at the front of the sensor
(diverter gate)?

10 Check the sensor (diverter gate) for connection.

Is the above sensor connected properly?

11 Check the sensor (lower media exit) for correct

operation.
Perform the Lower media exit test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Lower media exit.

Does the display on the operator panel change every
time the actuator of the sensor (lower media exit) is
operated?

Go to step 11. Go to step 10.

Replace the
sensor (diverter
gate). See

“Sensor
(diverter gate)
removal” on
page 4-110.

Go to step 13. Go to step 12.

Replace the
connection.

12 Check the sensor (lower media exit) connection.

Is the above sensor connected properly?

13 Perf orm a test print.

Does the error still occur?

Replace the
sensor (lower
media exit). See

“Sensor (lower
media exit)
removal” on
page 4-80.

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Replace the
connection.

Problem solved.

Diagnostic information 2-31

4024-XXX

284.02 Sensor (lower media exit) on jam B

Step Check Yes No

1 Check the media path.

1.Open the finisher front door asse mbly of the
finisher.

2.Open the lower pinch guide assembly to the right.

3.Open the buffer pinch guide assembly downward.

4.Check the buffer roll assembly by turning the rolls
with your fingers.

Is the buffer roll assembly installed correctly?

2 Is the buffer roll assembly free of damage? Go to step 3. Clean or replace

3 Are the buffer pinch guide pinch rolls attached to the

buffer pinch guide assembly correctly?

4 Are the buffer pinch guide pinch rolls free of damage? Go to step 5. Clean or replace

5 Check the sensor (buff e r pa th ) for correct operation.

Perform the Buffer path test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Buffer path.

Does the display on the operator panel change every
time the actuator of the sensor (buffer path) is
operated?

Go to step 2. Clean or replace

the appropriate
roll, and clean the
media path.

the appropriate
roll, and clean the
media path.

Go to step 4. Clean or replace

the appropriate
roller, and clean
the media path.

the appropriate
roller, and clean
the media path.

Go to step 7. Go to step 6.

6 Check the sensor (buffer path) connection.

Is the above sensor connected properly?

7 Check the drive motor (buffer/transport) by opening the

finisher front door assembly and then closing it.
Does the drive motor (buffer/transport) rotate

normally?

8 Check the drive motor (buffer/transport) connection.

Is the above motor connected properly?

2-32 Finisher Service Manual

Replace the
sensor (buffer
path). See

“Sensor (buffer
path) removal”
on page 4-93.

Go to step 9. Go to step 8.

Replace the drive
motor (buffer/
transport). See

“Drive motor
(buffer/
transport) and
belt (buffer/
transport)
removal” on
page 4-115.

Replace the
connection.

Replace the
connection.

Step Check Yes No

4024-XXX

9 Check the sensor (diverter gate) for correct operation.

Perf orm the Diverter gate test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path2.

5.Select Diverter gate.

Does the operator panel display change each time a
piece of media is placed at the front of the sensor
(diverter gate)?

10 Check the sensor (diverter gate) for connection.

Is the above sensor connected properly?

11 Check the sensor (lower media exit) for correct

operation.
Perform the Lower media exit test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Lower media exit.

Does the display on the operator panel change every
time the actuator of the sensor (lower media exit) is
operated?

Go to step 11. Go to step 10.

Replace the
sensor (diverter
gate). See

“Sensor
(diverter gate)
removal” on
page 4-110.

Go to step 13. Go to step 12.

Replace the
connection.

12 Check the sensor (lower media exit) connection.

Is the above sensor connected properly?

13 Perf orm a test print.

Does the error still occur?

Replace the
sensor (lower
media exit). See

“Sensor (lower
media exit)
removal” on
page 4-80.

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Replace the
connection.

Problem solved.

Diagnostic information 2-33

4024-XXX

284.03 Sensor (lower media exit) on jam C

Step Check Yes No

1 Check the media path.

1.Open the finisher front door asse mbly of the
finisher.

2.Open the lower pinch guide assembly to the right.

3.Open the buffer pinch guide assembly downward.

4.Check the buffer roll assembly by turning the rolls
with your fingers.

Is the buffer roll assembly installed correctly?

2 Is the buffer roll assembly free of damage? Go to step 3. Clean or replace

3 Are the buffer pinch guide pinch rolls attached to the

buffer pinch guide assembly correctly?

4 Are the buffer pinch guide pinch rolls free of damage? Go to step 5. Clean or replace

5 Check the sensor (buff e r pa th ) for correct operation.

Perform the Buffer path test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Buffer path.

Does the display on the operator panel change every
time the actuator of the sensor (buffer path) is
operated?

Go to step 2. Clean or replace

the appropriate
roll, and clean the
media path.

the appropriate
roll, and clean the
media path.

Go to step 4. Clean or replace

the appropriate
roller, and clean
the media path.

the appropriate
roller, and clean
the media path.

Go to step 7. Go to step 6.

6 Check the sensor (buffer path) connection.

Is the above sensor connected properly?

7 Check the drive motor (buffer/transport) by opening the

finisher front door assembly and then closing it.
Does the drive motor (buffer/transport) rotate

normally?

8 Check the drive motor (buffer/transport) connection.

Is the above motor connected properly?

2-34 Finisher Service Manual

Replace the
sensor (buffer
path). See

“Sensor (buffer
path) removal”
on page 4-93.

Go to step 9. Go to step 8.

Replace the drive
motor (buffer/
transport). See

“Drive motor
(buffer/
transport) and
belt (buffer/
transport)
removal” on
page 4-115.

Replace the
connection.

Replace the
connection.

Step Check Yes No

4024-XXX

9 Check the sensor (diverter gate) for correct operation.

Perf orm the Diverter gate test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path2.

5.Select Diverter gate.

Does the operator panel display change each time a
piece of media is placed at the front of the sensor
(diverter gate)?

10 Check the sensor (diverter gate) for connection.

Is the above sensor connected properly?

11 Check the sensor (lower media exit) for correct

operation.
Perform the Lower media exit test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Lower media exit.

Does the display on the operator panel change every
time the actuator of the sensor (lower media exit) is
operated?

Go to step 11. Go to step 10.

Replace the
sensor (diverter
gate). See

“Sensor
(diverter gate)
removal” on
page 4-110.

Go to step 13. Go to step 12.

Replace the
connection.

12 Check the sensor (lower media exit) connection.

Is the above sensor connected properly?

13 Perf orm a test print.

Does the error still occur?

Replace the
sensor (lower
media exit). See

“Sensor (lower
media exit)
removal” on
page 4-80.

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Replace the
connection.

Problem solved.

Diagnostic information 2-35

4024-XXX

284.04 Sensor (lower media exit) off jam B.

Step Check Yes No

1 Check the media path.

Open the finisher front door assembly of the finisher.
Check lower media exit roll assembly by turning it with
your fingers.

Is the lower media exit roll assembly installed
correctly?

2 Is the lower media exit roll assembly free of damage? Go to step 3. Clean or replace

3 Check the sensor (lower media exit) for correct

operation.
Perform the Lower media exit test.

1.In Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Lower media exit.

Does the display on the operator panel change every
time the actuator of the sensor (lower media exit) is
operated?

4 Check the sensor (lower media exit) connection.

Is the above sensor connected properly?

Go to step 2. Clean or replace

Go to step 5. Go to step 4.

Replace the
sensor (lower
media exit). See

“Sensor (lower
media exit)
removal” on
page 4-80.

the lower media
exit roll assembly ,
and clean the
media path.

the lower media
exit roll assembly ,
and clean the
media path.

Replace the
connection.

5 Check the drive motor (exit) by opening the finisher

front door assembly and then closing it.
Does the motor (exit) rotate normally?

6 Check the drive motor (exit) connection.

Is the above motor connected properly?

7 Perform a test print.

Does the error still occur?

2-36 Finisher Service Manual

Go to step 7. Go to step 6.

Replace the drive
motor (exit). See

“Drive motor
(exit) assembly
and belt (exit)
removal” on
page 4-113

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Replace the
connection.

Problem solved.

284.05 Sensor (lower media exit) static jam

Step Check Yes No

4024-XXX

1 Check the sensor (lower media exit) for correct

operation.
Perform the Lower media exit test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Lower media exit.

Does the display on the operator panel change every
time the actuator of the sensor (lower media exit) is
operated?

2 Check the sensor (lower media exit) assembly

connection.
Is the above sensor connected properly?

3 Check the drive motor (exi t) for correct operation.

Check the above motor by opening the finisher front
door assembly and then closing it.

Does the motor (exit) rotate normally?

4 Check the drive motor (exit) connection.

Is the above motor connected properly?

Go to step 3. Go to step 2.

Replace the
sensor (lower
media exit). See

“Sensor (lower
media exit)
removal” on
page 4-80.

Go to step 5. Go to step 4.

Replace the drive
motor (exit). See

“Drive motor
(exit) assembly
and belt (exit)
removal” on
page 4-113.

Replace the
connection.

Replace the
connection.

5 Perform a teat print.

Does the error still occur?

285.00 Finisher eject set jam

Step Check Yes No

1 Check the media path.

Check the media eject shaft by turning it with your
fingers.

Is the media eject shaft assembly installed correctly,
meaning does it rotate smoothly?

2 Check the media eject clamp motor by opening the

finisher front door assembly, and then closing it.
Does the media eject clamp motor rotate normally?

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 2. Clean or replace

Go to step 4. Go to step 3.

Diagnostic information 2-37

Problem solved.

the media eject
shaft assembly
and clean the
media path.

4024-XXX

Step Check Yes No

3 Check the media eject motor connection.

Is the above motor connected properly?

4 Check the compiler media in actuator for correct

operation.
Is the actuator operating correctl y ?

5 Check the sensor (compiler media in) f o r correct

operation.
Perform the Compiler media in test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Compiler media in.

Does the display on the operator panel change every
time the compiler media in actuator of the sensor
(compiler media in) is operated?

Disconnect then
reconnect the
connector P8304
on the finisher
controller card
assembly.
Perform a test
print, if the error
still occurs
replace the
media eject
motor assembly.

Go to step 5. Reinstall the

Go to step 7. Go to step 6.

Replace the
connection.

compiler media in
actuator. See

“Sensor
(compiler media
in) removal” on
page 4-73.

6 Check the sensor (compiler media in) connection.

Are the connections of the compiler unit cable
assembly properly connected?

7 Perform a test print. Does the error still occur? Replace the

286.00 Sensor (compiler media in) static jam

Step Check Yes No

1 Check the eject clamp motor for correct operation.

Check the above motor by opening the finisher front
door assembly and then closing it.

Does the eject clamp motor rotate normally?

Replace the
sensor (compiler
media in). See

“Sensor
(compiler media
in) removal” on
page 4-73.

finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 3. Go to step 2.

Replace the
connection.

Problem solved

2-38 Finisher Service Manual

Step Check Yes No

4024-XXX

2 Check the eject clamp motor connection.

Are the connections of the main drive cable assembly
correctly connected?

3 Check the sensor (compiler media in) f o r correct

operation.
Perform the Compiler media in test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Compiler media in.

Does the display on the operator panel change every
time the actuator of the sensor (compiler media in) is
operated?

4 Check the sensor (compiler media in) connection.

Is the above sensor connected properly?

5 Check the media eject motor assembly by opening the

finisher front door assembly and then closing it.
Does the media eject motor assembly rot at e no rmally?

Replace the eject
clamp motor. See

“Media eject
clamp motor
assembly
removal” on
page 4-66.

Go to step 5. Go to step 4.

Replace the
sensor (compiler
media in). See

“Sensor
(compiler media
in) removal” on
page 4-73.

Go to step 7. Go to step 6.

Replace the
connector.

Replace the
connection.

6 Check the media eject motor assembly connection.

Are the connections of the main drive cable assembly
correctly connected?

7 Perform a test print.

Does the error still occur?

Replace the
media eject
motor assembly.
See “Media

eject motor
assembly
removal” on
page 4-78.

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Replace the
connection.

Problem solved.

Diagnostic information 2-39

4024-XXX

287.00 Sensor (upper media exit) on jam A

Step Check Yes No

1 Check the media path.

1.Open the finisher front door asse mbly of the
finisher.

2.Remove the top cover and left upper cover.

3.Open the entrance pinch guide assembly upward.

4.Check four media entrance pinch guide pinch rolls
of the entrance pinch guide assembly and media
entrance roll assembly by turning them with your
fingers.

Are the media entrance pinch guide pinch rolls
installed correctly and do they rotate smoothly?

2 Are the four media entrance pinch guide pinch rolls of

the entrance pinch guide assembly and media
entrance roll assembly free of damage?

3 Check the media path.

1.Open the upper pinch guide assembly to the right.

2.Check these items by turning them with your
fingers.

Are the four upper pinch guide pinch rolls of the upper
pinch guide assembly and two upper media transport
roll assemblies installed correctly, meaning do they
rotate smoothly?

4 Are the four upper pinch guide pinch rolls of the upper

pinch guide assembly and two upper media transport
roll assemblies free of damage?

Go to step 2. Clean or replace

the appropriate
roller, and clean
the media path.

Go to step 3. Clean or replace

the appropriate
roller and clean
the media path.

Go to step 4. Clean or replace

the appropriate
roller and clean
the media path.

Go to step 5. Clean or replace

the appropriate
roller and clean
the media path.

5 Check the sensor (upper media exit) for correct

operation.
Perf orm the Upper media exit test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Upper media exit.

Does the display on the operator panel change every
time the actuator of the sensor (upper media exit) is
operated?

6 Check the sensor (upper media exit) and main sensor

cable assembly connections
Is the above sensor connected properly?

7 Check the drive motor (buffer/transport) by opening the

finisher front door assembly and then closing it.
Does the drive motor (buffer/transport) rotate properly?

Go to step 7. Go to step 6.

Replace the
sensor (upper
media exit).

“Sensor (upper
media exit)
removal” on
page 4-104.

Go to step 9. Go to step 8.

Replace the
connection.

2-40 Finisher Service Manual

Step Check Yes No

4024-XXX

8 Check the drive motor (buffer/transport/connection.

Is the above motor properly connected?

9 Perform a test print.

Does the error still occur?

287.01 Sensor (upper media exit) off jam A.

Step Check Yes No

1 Check the media path.

1.Open the upper pinch guide assembly to the right.

2.Check four upper pinch guide pinch roll on the
upper pinch guide assembly and two upper media
transport roll assemblies by turning them with your
fingers.

Are the upper pinch guide pinch roll and upper media
transport roll assemblies installed correctly and do they
rotate smoothly?

Replace the drive
motor (buffer/
transport). See

“Drive motor
(buffer/
transport) and
belt (buffer/
transport)
removal” on
page 4-115.

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 2. Clean or replace

Replace the
connection.

Problem solved.

the appropriate
roller and clean
the media path.

2 Are the four upper pinch guide pinch rolls on the upper

pinch guide assembly and two upper media transport
roll assemblies free of damage?

3 Check the sensor (upper media exit) for correct

operation.
Perf orm the Upper media exit test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Upper media exit.

Does the display on the operator panel change every
time the actuator of the sensor (upper media exit) is
operated?

4 Check the sensor (upper media exit) and main sensor

cable assembly connections.
Is the above sensor connected properly?

Go to step 3. Clean or replace

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Replace the
sensor (upper
media exit). See

“Sensor (upper
media exit)
removal” on
page 4-104.

Diagnostic information 2-41

the appropriate
roller and clean
the media path.

Go to step 4.

Replace the
connection.

4024-XXX

Step Check Yes No

5 Check the drive motor (buffer/transport) for rotation.

Check the above motor by opening the finisher front
door assembly and then closing it.

Does the drive motor (buffer/transport) rotate properly?

6 Check the drive motor (buffer/transport) connection.

Is the above motor connected properly?

7 Check the drive motor (exit) for correct operation.

Check the above motor by opening the finisher front
door assembly and then closing it.

Does the motor (exit) rotate normally?

8 Check the drive motor (exit) connection.

Is the above motor connected properly?

9 Perform a test print.

Does the error still occur?

Go to step 7. Go to step 6.

Replace drive
motor (buffer/
transport). See

“Drive motor
(buffer/
transport) and
belt (buffer/
transport)
removal” on
page 4-115.

Go to step 9. Go to step 8.

Replace the drive
motor (exit). See

“Drive motor
(exit) assembly
and belt (exit)
removal” on
page 4-113.

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Replace the
connection.

Replace the
connection.

Problem solved.

287.02 Sensor (upper media exit) on jam B

Step Check Yes No

1 Check the media path.

1.Open the finisher front door asse mbly of the
finisher.

2.Remove the top cover and left upper cover.

3.Open the entrance pinch guide assembly upward.

4.Check four media entrance pinch guide pinch rolls
of the entrance pinch guide assembly and media
entrance roll assembly by turning them with your
fingers.

Are the media entrance pinch guide pinch rolls
installed correctly and do they rotate smoothly?

2 Are the four media entrance pinch guide pinch rolls of

the entrance pinch guide assembly and media
entrance roll assembly free of damage?

2-42 Finisher Service Manual

Go to step 2. Clean or replace

the appropriate
roller, and clean
the media path.

Go to step 3. Clean or replace

the appropriate
roller and clean
the media path.

Step Check Yes No

4024-XXX

3 Check the media path.

1.Open the upper pinch guide assembly to the right.

2.Check these items by turning them with your
fingers.

Are the four upper pinch guide pinch rolls of the upper
pinch guide assembly and two upper media transport
roll assemblies installed correctly, meaning do they
rotate smoothly?

4 Are the four upper pinch guide pinch rolls of the upper

pinch guide assembly and two upper media transport
roll assemblies free of damage?

5 Check the sensor (upper media exit) for correct

operation.
Perf orm the Upper media exit test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Upper media exit.

Does the display on the operator panel change every
time the actuator of the sensor (upper media exit) is
operated?

6 Check the sensor (upper media exit) and main sensor

cable assembly connections
Is the above sensor connected properly?

Go to step 4. Clean or replace

Go to step 5. Clean or replace

Go to step 7. Go to step 6.

Replace the
sensor (upper
media exit).

“Sensor (upper
media exit)
removal” on
page 4-104.

the appropriate
roller and clean
the media path.

the appropriate
roller and clean
the media path.

Replace the
connection.

7 Check the drive motor (buffer/transport) by opening the

finisher front door assembly and then closing it.
Does the drive motor (buffer/transport) rotate properly?

8 Check the drive motor (buffer/transport/connection.

Is the above motor properly connected?

9 Perform a test print.

Does the error still occur?

Go to step 9. Go to step 8.

Replace the drive
motor (buffer/
transport). See

“Drive motor
(buffer/
transport) and
belt (buffer/
transport)
removal” on
page 4-115.

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Replace the
connection.

Problem solved.

Diagnostic information 2-43

4024-XXX

287.03 Sensor (upper media exit) on jam C

Step Check Yes No

1 Check the media path.

1.Open the finisher front door asse mbly of the
finisher.

2.Remove the top cover and left upper cover.

3.Open the entrance pinch guide assembly upward.

4.Check four media entrance pinch guide pinch rolls
of the entrance pinch guide assembly and media
entrance roll assembly by turning them with your
fingers.

Are the media entrance pinch guide pinch rolls
installed correctly and do they rotate smoothly?

2 Are the four media entrance pinch guide pinch rolls of

the entrance pinch guide assembly and media
entrance roll assembly free of damage?

3 Check the media path.

1.Open the upper pinch guide assembly to the right.

2.Check these items by turning them with your
fingers.

Are the four upper pinch guide pinch rolls of the upper
pinch guide assembly and two upper media transport
roll assemblies installed correctly, meaning do they
rotate smoothly?

4 Are the four upper pinch guide pinch rolls of the upper

pinch guide assembly and two upper media transport
roll assemblies free of damage?

Go to step 2. Clean or replace

the appropriate
roller, and clean
the media path.

Go to step 3. Clean or replace

the appropriate
roller and clean
the media path.

Go to step 4. Clean or replace

the appropriate
roller and clean
the media path.

Go to step 5. Clean or replace

the appropriate
roller and clean
the media path.

5 Check the sensor (upper media exit) for correct

operation.
Perf orm the Upper media exit test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Upper media exit.

Does the display on the operator panel change every
time the actuator of the sensor (upper media exit) is
operated?

6 Check the sensor (upper media exit) and main sensor

cable assembly connections
Is the above sensor connected properly?

7 Check the drive motor (buffer/transport) by opening the

finisher front door assembly and then closing it.
Does the drive motor (buffer/transport) rotate properly?

Go to step 7. Go to step 6.

Replace the
sensor (upper
media exit).

“Sensor (upper
media exit)
removal” on
page 4-104.

Go to step 9. Go to step 8.

Replace the
connection.

2-44 Finisher Service Manual

Step Check Yes No

4024-XXX

8 Check the drive motor (buffer/transport/connection.

Is the above motor properly connected?

9 Perform a test print.

Does the error still occur?

287.04 Sensor (upper media exit) off jam B.

Step Check Yes No

1 Check the media path.

1.Open the upper pinch guide assembly to the right.

2.Check four upper pinch guide pinch roll on the
upper pinch guide assembly and two upper media
transport roll assemblies by turning them with your
fingers.

Are the upper pinch guide pinch roll and upper media
transport roll assemblies installed correctly and do they
rotate smoothly?

Replace the drive
motor (buffer/
transport). See

“Drive motor
(buffer/
transport) and
belt (buffer/
transport)
removal” on
page 4-115.

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 2. Clean or replace

Replace the
connection.

Problem solved.

the appropriate
roller and clean
the media path.

2 Are the four upper pinch guide pinch rolls on the upper

pinch guide assembly and two upper media transport
roll assemblies free of damage?

3 Check the sensor (upper media exit) for correct

operation.
Perf orm the Upper media exit test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Upper media exit.

Does the display on the operator panel change every
time the actuator of the sensor (upper media exit) is
operated?

4 Check the sensor (upper media exit) and main sensor

cable assembly connections.
Is the above sensor connected properly?

Go to step 3. Clean or replace

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Replace the
sensor (upper
media exit). See

“Sensor (upper
media exit)
removal” on
page 4-104.

Diagnostic information 2-45

the appropriate
roller and clean
the media path.

Go to step 4.

Replace the
connection.

4024-XXX

Step Check Yes No

5 Check the drive motor (buffer/transport) for rotation.

Check the above motor by opening the finisher front
door assembly and then closing it.

Does the drive motor (buffer/transport) rotate properly?

6 Check the drive motor (buffer/transport) connection.

Is the above motor connected properly?

7 Check the drive motor (exit) for correct operation.

Check the above motor by opening the finisher front
door assembly and then closing it.

Does the motor (exit) rotate normally?

8 Check the drive motor (exit) connection.

Is the above motor connected properly?

9 Perform a test print.

Does the error still occur?

Go to step 7. Go to step 6.

Replace drive
motor (buffer/
transport). See

“Drive motor
(buffer/
transport) and
belt (buffer/
transport)
removal” on
page 4-115.

Go to step 9. Go to step 8.

Replace the drive
motor (exit). See

“Drive motor
(exit) assembly
and belt (exit)
removal” on
page 4-113.

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Replace the
connection.

Replace the
connection.

Problem solved.

287.05 Sensor (upper media exit) static jam A

Step Check Yes No

1 Check the sensor (upper media exit) f or correct

operation.
Perf orm the Upper media exit test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Upper media exit.

Does the display on the operator panel change every
time the actuator of the sensor (upper media exit) is
operated?

2-46 Finisher Service Manual

Go to step 3. Go to step 2.

Step Check Yes No

4024-XXX

2 Check the sensor (upper media exit) and main sensor

cable assembly connection.
Is the above sensor connected properly?

3 Check the drive motor (buffer/transport) by opening the

finisher front door assembly and then closing it.
Does the drive motor (buffer/transport) rotate

normally?

4 Check the drive motor (buffer/transport) connection.

Is the above motor connected properly?

5 Perform a test print.

Does the error still occur?

Replace the
sensor (upper
media exit). See

“Sensor (upper
media exit)
removal” on
page 4-104.

Go to step 5. Go to step 4.

Replace the drive
motor (buffer/
transport). See

“Drive motor
(buffer/
transport) and
belt (buffer/
transport)
removal” on
page 4-115.

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Replace the
connection.

Replace the
connection.

Problem solved.

287.06 Sensor (upper media exit) static jam B

Step Check Yes No

1 Check the sensor (upper media exit) for correct

operation.
Perf orm the Upper media exit test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Upper media exit.

Does the display on the operator panel change every
time the actuator of the sensor (upper media exit) is
operated?

2 Check the sensor (upper media exit) and main sensor

cable assembly connection.
Is the above sensor connected properly?

Go to step 3. Go to step 2.

Replace the
sensor (upper
media exit). See

“Sensor (upper
media exit)
removal” on
page 4-104.

Replace the
connection.

Diagnostic information 2-47

4024-XXX

Step Check Yes No

3 Check the drive motor (buffer/transport) by opening the

finisher front door assembly and then closing it.
Does the drive motor (buffer/transport) rotate

normally?

4 Check the drive motor (buffer/transport) connection.

Is the above motor connected properly?

5 Perform a test print.

Does the error still occur?

287.07 Sensor (upper media exit) static jam C

Step Check Yes No

Go to step 5. Go to step 4.

Replace the drive
motor (buffer/
transport). See

“Drive motor
(buffer/
transport) and
belt (buffer/
transport)
removal” on
page 4-115.

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Replace the
connection.

Problem solved.

1 Check the sensor (upper media exit) f or correct

operation.
Perf orm the Upper media exit test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Upper media exit.

Does the display on the operator panel change every
time the actuator of the sensor (upper media exit) is
operated?

2 Check the sensor (upper media exit) and main sensor

cable assembly connection.
Is the above sensor connected properly?

3 Check the drive motor (buffer/transport) by opening the

finisher front door assembly and then closing it.
Does the drive motor (buffer/transport) rotate

normally?

Go to step 3. Go to step 2.

Replace the
sensor (upper
media exit). See

“Sensor (upper
media exit)
removal” on
page 4-104.

Go to step 5. Go to step 4.

Replace the
connection.

2-48 Finisher Service Manual

Step Check Yes No

4024-XXX

4 Check the drive motor (buffer/transport) connection.

Is the above motor connected properly?

5 Perform a test print.

Does the error still occur?

288.00 Sensor (diverter gate) on jam

Step Check Yes No

1 Check the media path.

1.Open the bridge unit top cover assembly of the
bridge unit assembly.

2.Check the six bridge unit pinch rolls on the bridge
unit top cover assembly and the two transport belts
by turning them with your fingers.

Are the bridge unit pinch rolls and transport belts
installed correctly?

Replace the drive
motor (buffer/
transport). See

“Drive motor
(buffer/
transport) and
belt (buffer/
transport)
removal” on
page 4-115.

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 2. Clean or replace

Replace the
connection.

Problem solved.

the appropriate
transport belts
and bridge unit
pinch roll, and
clean the media
path.

2 Are the six bridge unit pinch rolls on the bridge unit top

cover assembly and two transport belts free of
damage.

3 Check the media path.

1.Open the finisher front door assembly of the
finisher.

2.Remove the top cover and left upper cover.

3.Open the entrance pinch guide assembly to
upward.

4.Check the media entrance pinch guide pinch roll on
the entrance pinch guide assembly and media
entrance roll assembly by turning them with your
fingers.

Are the media entrance pinch guide pinch roll and
media entrance roll assembly installed correctly?

Go to step 3. Clean or replace

the appropriate
transport belts
and bridge unit
pinch roll, and
clean the media
path.

Go to step 4. Clean or replace

the appropriate
transport belts
and bridge unit
pinch roll, and
clean the media
path.

Diagnostic information 2-49

4024-XXX

Step Check Yes No

4 Are the media entrance pinch guide pinch roll on the

entrance pinch guide assembly and media entrance
roll assembly free of damage?

5 Check the sensor (bridge unit media exit) for correct

operation.
Perform the Bridge media exit test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Bridge media exit.

Does the display on the operator panel change every
time the actuator of the sensor (bridge unit media exit)
is operated?

6 Check the sensor (bridge unit media exit) connection.

Is the above sensor connected properly?

7 Check the sensor (finisher media entra n ce) for correct

operation.
Perform the Fin media ent test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path1.

5.Select Fin media ent.

Does the display change, every time a piece of white
media is placed over the sensor (finisher media
entrance)?

Go to step 5. Clean or replace

Go to step 7. Go to step 6

Replace the
sensor (bridge
unit media exit).
See “Sensor

(bridge unit
media exit)
removal” on
page 4-17.

Go to step 9. Go to step 8.

the appropriate
transport belts
and bridge unit
pinch roll, and
clean the media
path.

Replace the
connection.

8 Check the sensor (finisher media ent rance)

connection.
Is the above sensor connected properly?

9 Check the sensor (diverter gate) for correct operation.

Perf orm the Diverter gate test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path2.

5.Select Diverter gate.

Does the display on the operator panel change every
time a piece of white media is placed over the sensing
area of the sensor (diverter gate)?

2-50 Finisher Service Manual

Replace the
sensor (finisher
media entrance).
See “Sensor

(finisher media
entrance)
removal” on
page 4-98.

Go to step 11. Go to step 10.

Replace the
connection.

Step Check Yes No

4024-XXX

10 Check the sensor (diverter gate) connection.

Are the connectors of the diverter gate sensor cable
assembly correctly connected?

11 Check the drive motor (entrance/paddle) for correct

operation.
Check the above motor by opening the finisher front

door assembly and then closing it. Does the motor
(entrance/paddle) rotate normally?

12 Check the drive motor (entrance/paddle) connection.

Are the connections of the main drive cable assembly
correctly connected?

13 Perf orm a test print.

Does the error still occur?

Replace the
sensor (diverter
gate). See

“Sensor
(diverter gate)
removal” on
page 4-110.

Go to step 13. Go to step 12.

Replace the drive
motor (entrance/
paddle). See

“Drive motor
(entrance/
paddle) and belt
(entrance/
paddle)
removal” on
page 4-100.

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Replace the
connection.

Replace the
connection.

Problem solved.

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

Step Check Yes No

1 Check the sensor (diverter gate) for correct operation.

Perf orm the Diverter gate test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path2.

5.Select Diverter gate.

Does the display on the operator panel change every
time a piece of white media is placed over the sensing
area of the sensor (diverter gate)?

2 Check the sensor (diverter gate) connection.

Is the above senor connected properly?

Go to step 3. Go to step 2.

Replace the
sensor (diverter
gate). See

“Sensor
(diverter gate)
removal” on
page 4-110.

Replace the
connection.

Diagnostic information 2-51

4024-XXX

Step Check Yes No

3 Check the drive motor (entrance/paddle) by opening

the finisher front door assembly and then closing it.
Does the motor (entrance/paddle) rotate normally?

4 Is the drive motor (entrance/paddle) connected

properly?

5 Perform a test print.

Does the error still occur?

288.02 Sensor (diverter gate) static jam (to top bin) B

Step Check Yes No

Go to step 5. Go to step 4.

Replace the drive
motor (entrance/
paddle). See

“Drive motor
(entrance/
paddle) and belt
(entrance/
paddle)
removal” on
page 4-100.

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Replace the
connection.

Problem solved.

1 Check the sensor (diverter gate) for correct operation.

Perf orm the Diverter gate test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path2.

5.Select Diverter gate.

Does the display on the operator panel change every
time a piece of white media is placed over the sensing
area of the sensor (diverter gate)?

2 Check the sensor (diverter gate) connection.

Is the above senor connected properly?

3 Check the drive motor (entrance/paddle) by opening

the finisher front door assembly and then closing it.
Does the motor (entrance/paddle) rotate normally?

Go to step 3. Go to step 2.

Replace the
sensor (diverter
gate). See

“Sensor
(diverter gate)
removal” on
page 4-110.

Go to step 5. Go to step 4.

Replace the
connection.

2-52 Finisher Service Manual

Step Check Yes No

4024-XXX

4 Is the drive motor (entrance/paddle) connected

properly?

5 Perform a test print.

Does the error still occur?

288.03 Sensor (diverter gate) static jam (to top bin) C

Step Check Yes No

1 Check the sensor (diverter gate) for correct operation.

Perf orm the Diverter gate test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path2.

5.Select Diverter gate.

Does the display on the operator panel change every
time a piece of white media is placed over the sensing
area of the sensor (diverter gate)?

Replace the drive
motor (entrance/
paddle). See

“Drive motor
(entrance/
paddle) and belt
(entrance/
paddle)
removal” on
page 4-100.

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 3. Go to step 2.

Replace the
connection.

Problem solved.

2 Check the sensor (diverter gate) connection.

Is the above senor connected properly?

3 Check the drive motor (entrance/paddle) by opening

the finisher front door assembly and then closing it.
Does the motor (entrance/paddle) rotate normally?

4 Is the drive motor (entrance/paddle) connected

properly?

Replace the
sensor (diverter
gate). See

“Sensor
(diverter gate)
removal” on
page 4-110.

Go to step 5. Go to step 4.

Replace the drive
motor (entrance/
paddle). See

“Drive motor
(entrance/
paddle) and belt
(entrance/
paddle)
removal” on
page 4-100.

Diagnostic information 2-53

Replace the
connection.

Replace the
connection.

4024-XXX

Step Check Yes No

5 Perform a test print.

Does the error still occur?

288.04 Sensor (diverter gate) static jam (to stacker bin) A

Step Check Yes No

1 Check the sensor (diverter gate) for correct operation.

Perform the Diverter gate test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path2.

5.Select Diverter gate.

Does the display on the operator panel change every
time a piece of white media is placed over the sensing
area of the sensor (diverter gate)?

2 Is the sensor (diverter gate) connected properly? Replace the

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 3. Go to step 2.

sensor (diverter
gate). See

“Sensor
(diverter gate)
removal” on
page 4-110.

Problem solved.

Replace the
connection.

3 Check the drive motor (entrance/paddle) by opening

the finisher front door assembly and then closing it.
Does the motor (entrance/paddle) rotate normally?

4 Check the main drive cable asse mbly connection.

Are the connections of the main drive cable assembly
correctly connected?

5 Perform a test print.

Does the error still occur?

2-54 Finisher Service Manual

Go to step 5. Go to step 4.

Replace the drive
motor (entrance/
paddle). See

“Drive motor
(entrance/
paddle) and belt
(entrance/
paddle)
removal” on
page 4-100.

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Replace the
connection.

Problem solved.

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

Step Check Yes No

4024-XXX

1 Check the sensor (diverter gate) for correct operation.

Perform the Diverter gate test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path2.

5.Select Diverter gate.

Does the display on the operator panel change every
time a piece of white media is placed over the sensing
area of the sensor (diverter gate)?

2 Is the sensor (diverter gate) connected properly? Replace the

3 Check the drive motor (entrance/paddle) by opening

the finisher front door assembly and then closing it.
Does the motor (entrance/paddle) rotate normally?

4 Check the main drive cable asse mbly connection.

Are the connections of the main drive cable assembly
correctly connected?

Go to step 3. Go to step 2.

sensor (diverter
gate). See

“Sensor
(diverter gate)
removal” on
page 4-110.

Go to step 5. Go to step 4.

Replace the drive
motor (entrance/
paddle). See

“Drive motor
(entrance/
paddle) and belt
(entrance/
paddle)
removal” on
page 4-100.

Replace the
connection.

Replace the
connection.

5 Perform a test print.

Does the error still occur?

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Diagnostic information 2-55

Problem solved.

4024-XXX

288.06 Sensor (diverter gate) static jam (to stacker bin) C

Step Check Yes No

1 Check the sensor (diverter gate) for correct operation.

Perform the Diverter gate test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path2.

5.Select Diverter gate.

Does the display on the operator panel change every
time a piece of white media is placed over the sensing
area of the sensor (diverter gate)?

2 Is the sensor (diverter gate) connected properly? Replace the

3 Check the drive motor (entrance/paddle) by opening

the finisher front door assembly and then closing it.
Does the motor (entrance/paddle) rotate normally?

4 Check the main drive cable asse mbly connection.

Are the connections of the main drive cable assembly
correctly connected?

Go to step 3. Go to step 2.

sensor (diverter
gate). See

“Sensor
(diverter gate)
removal” on
page 4-110.

Go to step 5. Go to step 4.

Replace the drive
motor (entrance/
paddle). See

“Drive motor
(entrance/
paddle) and belt
(entrance/
paddle)
removal” on
page 4-100.

Replace the
connection.

Replace the
connection.

5 Perform a test print.

Does the error still occur?

980.02 Finisher communication failure

Step Check Yes No

1 Check the printer and finisher installation.

Is the finisher installed to the printer correctly?

2 Turn the power on and off.

Does the error still occur when the power is on?

2-56 Finisher Service Manual

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 2. After reinstalling,

Go to step 3. Problem solved.

Problem solved.

go to step 2.

Step Check Yes No

4024-XXX

3 Check the finisher controller card assembly

connection.
Are the connections of the finisher controller card

assembly correctly connected?

4 Perform a test print.

Does the problem remain .

981.00 Stacker bin failure

Step Check Yes No

1 Check the vertical transport mechanism of the stacker

bin for obstacles and deformation.
Are the any obstacles in the vertical transport

mechanism of the stacker bin?

2 Is there any deformation in the vertical transport

mechanism of the stacker bin?

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 4.
Replace the

printer engine
card assembly.
Refer to the

Printer Service
Manual.

Remove
obstacles.

Replace
deformed part.

Replace the
connection.

Problem solved.

Go to step 2.

Go to step 3

3 Check the sensor (stacker bi n l evel 1) f o r correct

operation.
Perform the Stacker bin level1 test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Bin Level.

5.Select Stacker bin level1.

Does the display on the operator panel change every
time the sensing area of the sensor (stacker bin level 1)
is blocked by a multi page document or your finger?

4 Is the sensor (stacker bin level 1) connected properly? Replace the

Go to step 5. Go to step 4.

sensor (stacker
bin level 1). See

“Sensor
(stacker bin
level 1)
removal” on
page 4-34.

Replace the
connection.

Diagnostic information 2-57

4024-XXX

Step Check Yes No

5 Check the sensor (stacke r bin l evel 2) for correct

operation.
Perform the Stacker bin level 2 test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Bin Level.

5.Select Stacker bin level2.

Does the display on the operator panel change every
time the sensing area of the sensor (stacker bin level 2)
is blocked by putting a piece of media or your finger?

6 Is the sensor (stacker bin level 2) connected properly Replace the

7 Check the stacker bin lift motor assembly by blocking

the lower hole in either of the sensor (stacker bin level).
The stacker bin should lower slightly.

Does the stacker bin lift motor assembly rotate
normally?

8 Is the stacker bin lift motor assembly connected

properly?

Go to step 7. Go to step 6.

sensor (stacker
bin level 2). See

“Sensor
(stacker bin
level 2)
removal” on
page 4-34.

Go to step 9. Go to step 8.

Replace the
stacker bin lift
motor assembly.
See “Stacker

bin lift motor
assembly
removal” on
page 4-38.

Replace the
connection.

Replace the
connection.

9 Perform a test print.

Does the error still occur?

2-58 Finisher Service Manual

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Problem solved.

981.01 Stacker bin upper limit failure

Step Check Yes No

4024-XXX

1 Check the sensor (stacker bi n l evel 1) f o r correct

operation.
Perform the Stacker bin level 2 test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Bin Level.

5.Select Stacker bin level1.

Does the display on the operator panel change every
time the sensing area of the sensor (stacker bin level 1)
is blocked by putting a piece of media or your finger
over the sensor ar ea ?

2 Check the sensor (stacker bin level 1) connection.

Are the connections of the main sensor cable assembly
properly connected?

3 Check the sensor (stacker bi n l evel 2) f o r correct

operation.
Perform the Stacker bin level 2 test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Bin Level.

5.Select Stacker bin level2.

Does the display on the operator panel change every
time the sensing area of the sensor (stacker bin level 2)
is blocked by a multi page document or your finger?

Go to step 3. Go to step 2.

Replace the
sensor (stacker
bin level 1). See

“Sensor
(stacker bin
level 1)
removal” on
page 4-34.

Go to step 5. Go to step 4.

Replace the
connection.

4 Check the sensor (stacker bin level 2) connection.

Are the connections of the main sensor cable assembly
correctly connected?

5 Check the media stacker bin actuator for correct

operation.
Is the media stacker bin actuator installed correctly?
Does it enter the sensing area of the sensor (stacker

bin upper limit)?

Replace the
sensor (stacker
bin level 2). See

“Sensor
(stacker bin
level 2)
removal” on
page 4-34.

Go to step 6. Repair the media

Diagnostic information 2-59

Replace the
connection.

stacker bin
actuator.

4024-XXX

Step Check Yes No

6 Check the sensor (stacker bin upper limit) for correct

operation.
Perform the Stacker bin upper limit test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Bin Level.

5.Select Stacker bin upper limit.

Does the display on the operator panel change every
time the sensing area of the sensor (stacker bin upper
limit) is blocked?

7 Check the sensor (stacker bin upper limit) connection.

Are the connections of the main sensor cable assembly
correctly connected?

8 Check the stacker bin lift motor assembly by blocking

the lower hole in either of the sensors (stacker bin
level). The stacker bin should lower slightly.

Does the stacker bin lift motor assembly rotate
normally?

9 Check the stacker bin lift motor assembly connection.

Is the connection of the stacker bin lift motor assembly
connected to the finisher controller card assembly
securely?

Go to step 8. Go to step 7.

Replace the
sensor (stacker
bin upper limit).
See “Sensor

(stacker bin
upper limit) or
sensor (stacker
bin no media)
removal” on
page 4-36.

Go to step 10. Go to step 9.

Replace the
stacker bin lift
motor assembly.
Go to “Stacker

bin lift motor
assembly
removal” on
page 4-38.

Replace the
connection.

Replace the
connection.

10 Perf orm a test print.

Does the error still occur?

981.02 Stacker bin lower limit failure

Step Check Yes No

1 Check the media stack er bin actuator for correct

operation.
Is the media stacker bin actuator installed correctly?
Does it enter the sensing area of the sensor (stacker

bin upper limit)?

2-60 Finisher Service Manual

Replace the
printer engine
card assembly.
Refer to the

Printer Service
Manual.

Go to step 2. Repair the media

Problem solved.

stacker bin
actuator.

Step Check Yes No

4024-XXX

2 Check the sensor (stacker bin no media) for correct

operation.
Perform the Stacker bin no media test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Bin Level.

5.Select Stacker bin no media.

Does the display on the operator panel change every
time the sensing area of the sensor (stacker bin no
media) is blocked?

3 Is the sensor (stacker bin no media) connected

properly?

4 Check the sensor (stacker bi n l evel 1) f o r correct

operation.
Perform the Stacker bin level1 test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Bin Level.

5.Select Stacker bin level1.

Does the display on the operator panel change every
time the sensing area of the sensor (stacker bin level 1)
is blocked by a multi page document or your finger?

Go to step 4. Go to step 3.

Replace the
sensor (stacker
bin no media).

Go to step 6. Go to step 5.

Replace the
connection.

5 Is the sensor (stacker bin level 1) connected properly? Replace the

6 Check the sensor (stacker bi n l evel 2) f o r correct

operation.
Perform the Stacker bin level2 test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Bin Level.

5.Select Stacker bin level2.

Does the display on the operator panel change every
time the sensing area of the sensor (stacker bin level
rear) is blocked by a multi page document or your
finger?

7 Is the sensor (stacker bin level 2) connected properly? Replace the

sensor (stacker
bin level 1). See

“Sensor
(stacker bin
level 1)
removal” on
page 4-34.

Go to step 8. Go to step 7.

sensor (stacker
bin level 2). See

“Sensor
(stacker bin
level 2)
removal” on
page 4-34.

Replace the
connection.

Replace the
connection.

Diagnostic information 2-61

4024-XXX

Step Check Yes No

8 Check the sensor (stacker bin level encoder) for correct

operation.
Perform the Stacker bin level encod test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Bin Level.

5.Select Stacker bin level encod.

Does the display on the operator panel change when
the belt of the stacker bin lift motor assembly is moved
by hand?

9 Is the sensor (stacker bin level encoder) connected

properly?

10 Check the stacker bin lift motor assembly by blocking

the lower hole in either of the sensor (stacker bin level).
The stacker bin should lower slightly.

Does the stacker bin lift motor assembly rotate
normally?

11 Check the stacker bin lift motor assembly connection.

Is the connector of the stacker bin lift motor assembly
correctly connected to the finisher controller card
assembly?

Go to step 10. Go to step 9.

Replace the
sensor (stacker
bin level
encoder). See

“Sensor
(stacker bin
level encoder)
removal” on
page 4-35.

Go to step 12. Go to step 11.

Replace the
stacker bin lift
motor assembly.
See “Stacker

bin lift motor
assembly
removal” on
page 4-38.

Replace the
connection.

Replace the
connection.

12 Perf orm a test print.

Does the error still occur?

982.00 Sensor (front tamper HP) on failure

Step Check Yes No

1 Check the tamper mechanism by moving it with your

fingers.
Does the tamper mechanism operate smoothly?

2-62 Finisher Service Manual

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 2. Replace the

Problem solved.

media compiler
unit assembly.
See “Media

compiler unit
assembly
removal” on
page 4-69.

Step Check Yes No

4024-XXX

2 Check the sensor (front tamper HP) for correct

operation.
Perf orm the F ront tamper HP test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media path2.

5.Select Front tamper HP.

Does the display on the operator panel change every
time the sensing area of the sensor (front tamper HP)
is blocked?

3 Is the sensor (front tamper HP) connected properly? Replace the

4 Check the front tamper drive motor by opening the

finisher front door assembly and then closing it.
Does the front tamper drive motor rotate, and does the

tamper move back and forth?

5 Check the compiler unit cable assembly connection.

Are the connections of the compiler unit cable
assembly correctly connected?

Go to step 4. Go to step 3.

sensor (front
tamper HP). See

“Sensor (front
tamper HP) and
sensor (rear
tamper HP)
removals” on
page 4-72.

Go to step 6. Go to step 5.

Replace the
media compiler
unit assembly.
See “Media

compiler unit
assembly
removal” on
page 4-69.

Replace the
connection.

Replace the
connection.

6 Perform a test print.

Does the error still occur?

982.01 Sensor (front tamper HP) off failure

Step Check Yes No

1 Check the tamper mechanism by moving it with your

fingers.
Does the tamper mechanism operate smoothly?

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 2. Replace the

Diagnostic information 2-63

Problem solved.

media compiler
unit assembly.
See “Media

compiler unit
assembly
removal” on
page 4-69.

4024-XXX

Step Check Yes No

2 Check the sensor (front tamper HP) for correct

operation.
Perform the front tamper HP test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media path2.

5.Select Front tamper HP.

Does the display on the operator panel change every
time the sensing area of the sensor (front tamper HP)
is blocked?

3 Is the sensor (front tamper HP) connected properly? Replace the

4 Check the front tamper drive motor by opening the

finisher front door assembly and then closing it.
Does the front tamper drive motor rotate, and does the

tamper move back and forth?

5 Check the compiler unit cable assembly connection.

Are the connections of the compiler unit cable
assembly correctly connected?

Go to step 4. Go to step 3.

sensor (front
tamper HP). See

“Sensor (front
tamper HP) and
sensor (rear
tamper HP)
removals” on
page 4-72.

Go to step 6. Go to step 5.

Replace the
media compiler
unit assembly.
See “Media

compiler unit
assembly
removal” on
page 4-69.

Replace the
connection.

Replace the
connection.

6 Perform a test print.

Does the error still occur?

983.00 Sensor (rear tamper HP) on failure

Step Check Yes No

1 Check the tamper mechanism by moving it with your

fingers.
Does the tamper mechanism operate smoothly?

2-64 Finisher Service Manual

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 2. Replace the

Problem solved.

media compiler
unit assembly.
See “Media

compiler unit
assembly
removal” on
page 4-69.

Step Check Yes No

4024-XXX

2 Check the sensor (rear tamper HP) for correct

operation.
Perf orm the Rear tamper HP test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media path2.

5.Select Rear tamper HP.

Does the display on the operator panel change every
time the sensing area of the sensor (rear tamper HP) is
blocked?

3 Is the sensor (rear tamper HP) connected properly? Replace the

4 Check the rear tamper drive motor by opening the

finisher front door assembly and then closing it.
Does the rear tamper drive motor rotate, and does the

tamper move back and forth?

5 Check the compiler unit cable assembly connection.

Are the connections of the compiler unit cable
assembly correctly connected?

Go to step 4. Go to step 3.

sensor (rear
tamper HP).

“Sensor (front
tamper HP) and
sensor (rear
tamper HP)
removals” on
page 4-72.

Go to step 6. Go to step 5.

Replace the
compiler unit
assembly.

Replace the
connection.

Replace the
connection.

6 Perform a test print.

Does the error still occur?

983.01 Sensor (rear tamper HP) off failure

Step Check Yes No

1 Check the tamper mechanism by moving it with your

fingers.
Does the tamper mechanism operate smoothly?

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 2. Replace the

Problem solved.

media compiler
unit assembly.
See “Media

compiler unit
assembly
removal” on
page 4-69.

Diagnostic information 2-65

4024-XXX

Step Check Yes No

2 Check the sensor (rear tamper HP) for correct

operation.
Perform the rear tamper HP test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media path2.

5.Select Rear tamper HP.

Does the display on the operator panel change every
time the sensing area of the sensor (rear tamper HP) is
blocked?

3 Is the sensor (rear tamper HP) connected properly? Replace the

4 Check the rear tamper drive motor by opening the

finisher front door assembly and then closing it.
Does the rear tamper drive motor rotate, and does the

tamper move back and forth?

5 Check the compiler unit cable assembly connection.

Are the connections of the compiler unit cable
assembly correctly connected?

Go to step 4. Go to step 3.

sensor (rear
tamper HP). See

“Sensor (front
tamper HP) and
sensor (rear
tamper HP)
removals” on
page 4-72.

Go to step 6. Go to step 5.

Replace the
media compiler
unit assembly.
See “Media

compiler unit
assembly
removal” on
page 4-69.

Replace the
connection.

Replace the
connection.

6 Perform a test print.

Does the error still occur?

984.00 Sensor (punch unit HP) on failure

Step Check Yes No

1 Check the punch unit by moving it with your fingers.

Does the punch unit move smoothly?

2-66 Finisher Service Manual

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 2. Remove

Problem solved.

obstacles.

Step Check Yes No

4024-XXX

2 Check the sensor (punch unit HP) for correct operation.

Perf orm the Punch unit HP test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Punch and Staple.

5.Select Punch unit HP.

Does the display on the operator panel change every
time the sensing area of the sensor (punch unit HP) is
blocked?

3 Is the sensor (punch unit HP) and punch sensor cable

assembly connected properly?

4 Check the punch unit motor for correct operation.

Perform the 2 punch test.

1.Enter the Diagnostic mode.

2.Select FINISHER TESTS.

3.Select Hole Punch Test.

4.Select 2 Punch test.

Does the punch unit motor rotate normally and punch
holes in the media?

Go to step 4. Go to step 3.

Replace the
sensor (punch
unit HP). See

“Sensor (punch
hole select),
sensor (punch
cam front), and
sensor (punch
unit HP)
removal” on
page 4-49.

Go to step 6. Go to step 5.

Replace the
connection.

5 Is the punch unit motor and punch drive cable

assembly connected properly?

6 Perform a test print.

Does the error still occur?

984.01 Sensor (punch unit HP) off failure

Step Check Yes No

1 Check the punch unit by moving it with your fingers.

Does the punch unit move smoothly?

Replace the
punch unit motor.
See “Punch un it

motor assembly
removal” on
page 4-47.

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 2. Remove

Replace the
connection.

Problem solved.

obstructions.

Diagnostic information 2-67

4024-XXX

Step Check Yes No

2 Check the sensor (punch unit HP) for correct operation.

Perf orm the Punch unit HP test.

1.Enter the Diagnostic mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Punch and Staple.

5.Select Punch unit HP.

Does the display on the operator panel change every
time the sensing area of the sensor (punch unit HP) is
blocked?

3 Is the sensor (punch unit HP) and punch sensor cable

assembly connected properly?

4 Check the punch unit motor for correct operation.

Perform the 2 punch test.

1.Enter the Diagnostic mode.

2.Select FINISHER TESTS.

3.Select Hole Punch Test.

4.Select 2 Punch test.

Does the punch unit motor rotate normally and punch
holes in the media?

Go to step 4. Go to step 3.

Replace the
sensor (punch
unit HP). See

“Sensor (punch
hole select),
sensor (punch
cam front), and
sensor (punch
unit HP)
removal” on
page 4-49.

Go to step 6. Go to step 5.

Replace the
connection.

5 Is the punch unit motor and punch drive cable

assembly connected properly?

6 Perform a test print.

Does the error still occur?

985.00 Sensor (punch carriage shift HP) on failure

Step Check Yes No

1 Check the punch carriage for correct operation.

Does the punch carriage move back and forth
smoothly?

Check this item by moving it with your fingers.

Replace the
punch unit motor.
See “Punch un it

motor assembly
removal” on
page 4-47.

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 2. Remove

Replace the
connection.

Problem solved.

obstacles.

2-68 Finisher Service Manual

Step Check Yes No

4024-XXX

2 Check the sensor (punch carriage shift HP) for correct

operation.
Perf orm the Punch carriage shift HP test.

1.Enter the Diagnostic mode.

2.Select FINISHER TESTS.

3.Select Sensor Test.

4.Select Punch and Staple.

5.Select Punch carriage shift HP.

Is the above sensor connected properly?

3 Check the sensor (punch carriage shift HP)

connection.
Are the connections of the punch sensor cable

assembly correctly connected?

4 Check the punch carriage shift motor assembly by

opening and then closing the finisher front door. The
punch carriage should move slightly.

Does the punch carriage shift motor assembly rotate,
and does the punch shift carriage move back and
forth?

5 Is the punch carriage shift motor assembly connected

properly?

Go to step 4. Go to step 3.

Replace the
sensor (punch
carriage
shift HP). See

“Sensor (punch
carriage shift
HP) removal” on
page 4-51.

Go to step 6. Go to step 9.

Replace the
punch carriage
shift motor
assembly. See

“Punch carriage
shift motor
assembly
removal” on
page 4-43.

Replace the
connection.

Replace the
connection.

6 Perform a test print.

Does the error still occur.

985.01 Sensor (punch carriage shift HP) off failure

Step Check Yes No

1 Check the punch carriage by moving it with your

fingers.
Does the punch carriage move back and forth

smoothly?

Replace the
printer engine
card assembly.
Refer to the

Printer Service
Manual.

Go to step 2. Remove

Diagnostic information 2-69

Problem solved.

obstructions.

4024-XXX

Step Check Yes No

2 Check the sensor (punch carriage shift HP) for correct

operation.
Perf orm the Punch carriage shift HP test.

1.Enter the Diagnostic mode.

2.Select FINISHER TESTS.

3.Select Sensor Test.

4.Select Punch and Staple.

5.Select Punch carriage shift HP.

Is the above sensor connected properly?

3 Check the sensor (punch carriage shift HP)

connection.
Are the connections of the punch sensor cable

assembly properly connected?

4 Check the punch carriage shift motor assembly by

opening and closing the finisher front door. The punch
carriage should move slightly.

Does the punch carriage shift motor assembly rotate,
and does the punch shift carriage move back and
forth?

5 Is the punch carriage shift motor assembly connected

properly?

Go to step 4. Go to step 3.

Replace the
sensor (punch
carriage shift
HP). See

“Sensor (punch
carriage shift
HP) removal” on
page 4-51.

Go to step 6. Go to step 5.

Replace the
punch carriage
shift motor
assembly. See

“Punch carriage
shift motor
assembly
removal” on
page 4-43.

Replace the
connection.

Replace the
connection.

6 Perform a test print.

Does the error still occur.

986.00 Sensor (media eject clamp HP) on failure

Step Check Yes No

1 Check the media eject clamp by opening the finisher

front door assembly and then closing it.
Does the eject clamp mechanism move smoothly?

2-70 Finisher Service Manual

Replace the
printer engine
card assembly.
Refer to the

Printer Service
Manual.

Go to step 2. Remove

Problem solved.

obstacles.

Step Check Yes No

4024-XXX

2 Check the sensor (media eject clamp HP) for correct

operation.
Perform the Eject clamp HP test.

1.Enter the Diagnostic mode.

2.Select FINISHER TESTS.

3.Select Sensor Test.

4.Select Media Path 2.

5.Select Eject clamp HP.

Does the display on the operator panel change every
time the sensing area of the sensor (media eject
clamp HP) is blocked?

3 Check the sensor (media eject clamp HP) connection.

Is the above sensor connected properly?

4 Check the media eject clamp motor by opening the

finisher front door assembly and then closing it.
Does the eject clamp motor rotate normally?

5 Is the media eject clamp motor connected properly? Replace the

Go to step 4. Go to step 3.

Replace the
sensor (media
eject clamp HP).
See “Sensor

(media eject
clamp HP)
removal” on
page 4-67.

Go to step 6. Go to step 5.

media eject
clamp motor. See

“Media eject
clamp motor
assembly
removal” on
page 4-66.

Replace the
connection.

Replace the
connection.

6 Perform a test print.

Does the error still occur?

986.01 Sensor (media eject clamp HP) off failure

Step Check Yes No

1 Check the media eject clamp by opening the finisher

front door assembly and then closing it.
Does the eject clamp mechanism move smoothly?

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 2. Remove

Problem solved.

obstacles.

Diagnostic information 2-71

4024-XXX

Step Check Yes No

2 Check the sensor (media eject clamp HP) for correct

operation.
Perform the Eject clamp HP test.

1.Enter Diagnostics.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path2.

5.Select Eject clamp HP.

Does the display on the operator panel change every
time the sensing area of the sensor (media eject
clamp HP) is blocked?

3 Is the sensor (media eject clamp HP) connected

properly?

4 Check the media eject clamp by opening the finisher

front door assembly and then closing it.
Does the eject clamp motor rotate normally?

5 Is the media eject clamp motor connected properly? Replace the

Go to step 4. Go to step 3.

Replace the
sensor (media
eject clamp HP).
See “Sensor

(media eject
clamp HP)
removal” on
page 4-67.

Go to step 6. Go to step 5.

media eject
clamp motor. See

“Media eject
clamp motor
assembly
removal” on
page 4-66.

Replace the
connection.

Replace the
connection.

6 Perform a test print.

Does the error still occur?

987.00 Sensor (media eject shaft HP) on failure

Step Check Yes No

1 Check the media eject shaft assembly by moving it with

your fingers.
Does the media eject shaft assembly mechanism move

smoothly?

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 2. Remove

Problem solved.

obstructions.

2-72 Finisher Service Manual

Step Check Yes No

4024-XXX

2 Check the sensor (media eject shaft HP) for corre ct

operation.
Perform the Media eject shaft HP test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path2.

5.Select Media eject shaft HP.

Does the display on the operator panel change every
time the sensing area of the sensor (media eject
shaft HP)?

3 Check the sensor (media eject shaft HP) connection.

Are the connections of the main sensor cable assembly
correctly connected?

4 Check the media eject motor assembly by opening the

finisher front door assembly and then closing it.
Does the media eject motor assembly rot at e no rmally?

5 Is the media eject motor assembly connected

properly?

Go to step 4. Go to step 3.

Replace the
sensor (media
eject shaft HP).
See “Sensor

(media eject
shaft HP)
removal” on
page 4-79.

Go to step 6. Go to step 5.

Replace the
media eject
motor assembly.
See “Media

eject motor
assembly
removal” on
page 4-78.

Replace the
connection.

Replace the
connection.

6 Check the media eject clutch assembly by opening the

finisher front door assembly and then closing it. The
three clamp paddles should rotate.

Does the media eject clutch assembly operate?

7 Check the media eject clutch assembly connection.

Is the above component connected properly?

8 Perform a test print.

Does the error still occur?

Go to step 8. Go to step 7.

Replace the
media eject
clutch assembly.
See “Media

eject clutch
removal” on
page 4-77.

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Replace the
connection.

Problem solved.

Diagnostic information 2-73

4024-XXX

987.01 Sensor (media eject shaft HP) off failure

Step Check Yes No

1 Check the media eject shaft assembly by moving it with

your fingers.
Does the media eject shaft assembly mechanism move

smoothly?

2 Check the sensor (media eject shaft HP) for corre ct

operation.
Perform the Media eject shaft HP test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Media Path2.

5.Select Media eject shaft HP.

Does the display on the operator panel change every
time the sensing area of the sensor (media eject
shaft HP)?

3 Check the sensor (media eject shaft HP) connection.

Are the connections of the main sensor cable assembly
correctly connected?

4 Check the for correct operation.

Check the media eject motor assembly by opening the
finisher front door assembly and then closing it.

Does the media eject motor assembly rot at e no rmally?

Go to step 2. Remove

Go to step 4. Go to step 3.

Replace the
sensor (media
eject shaft HP).
See “Sensor

(media eject
shaft HP)
removal” on
page 4-79.

Go to step 6. Go to step 5.

obstructions.

Replace the
connection.

5 Is the media eject motor assembly connected

properly?

6 Check the media eject clutch assembly by opening the

finisher front door assembly and then closing it. The
three clamp paddles should rotate.

Does the media eject clutch assembly operate?

7 Is the media eject clutch assembly connected

properly?

Replace the
media eject
motor assembly.
See “Media

eject motor
assembly
removal” on
page 4-78.

Go to step 8. Go to step 7.

Replace the
media eject
clutch assembly.
See “Media

eject clutch
removal” on
page 4-77.

Replace the
connection.

Replace the
connection.

2-74 Finisher Service Manual

Step Check Yes No

4024-XXX

8 Perform a test print.

Does the error still occur?

988.00 Sensor (punch unit side reg) on failure

Note: This procedure pert ains to sensor punch unit reg1 and reg2.

Step Check Yes No

1 Check the punch carriage by moving it with your

fingers.
Does the punch carriage move back and forth

smoothly?

2 Check the sensor (punch unit side reg1) for correct

operation.
Perf orm the Punch side reg1 test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Punch and Staple.

5.Select Punch side re g1.

Does the display on the operator panel change every
time a piece of white media is placed over the sensing
area of the sensor (punch unit side reg1)?

Replace the
finisher controller
card assembly.
See “Finisher

controller card
assembly
removal” on
page 4-118.

Go to step 2. Remove

Go to step 3. Go to step 4.

Problem solved.

obstructions.

3 Check the sensor (punch unit side reg2) for correct

operation.
Perf orm the Punch side reg2 test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Punch and Staple.

5.Select Punch side re g2.

Does the display on the operator panel change every
time a piece of white media is placed over the sensing
area of the sensor (punch unit side reg2)?

4 Check the appropriate sensor (punch unit side reg)

connection.
Is the above sensor connected properly?

Go to step 5. Go to step 4.

Replace the
appropriate
sensor (punch
unit side reg).
See “Sensor

(punch unit side
registration
pair) with
bracket
removal” on
page 4-44.

Diagnostic information 2-75

Replace the
connection.

4024-XXX

Step Check Yes No

5 Check the punch carriage shift motor assembly by

moving the punch carriage forward, then opening the
finisher front door; the punch carriage should move
slightly.

Does the punch carriage shift motor assembly rotate,
and does the punch shift carriage move back and
forth?

6 Is the punch carriage shift motor assembly connected

properly?

7 Perform a test print.

Does the error still occur?

988.01 Sensor (punch unit side reg) off failure

Note: This procedure pertains to sensor punch unit reg1 and reg2.

Go to step 7. Go to step 6.

Replace the
punch carriage
shift motor
assembly. See

“Punch carriage
shift motor
assembly
removal” on
page 4-43.

Replace the
printer engine
card assembly.
Refer to the

Printer Service
Manual.

Replace the
connection.

Problem solved.

Step Check Yes No

1 Check the punch carriage by moving it with your

fingers.
Does the punch carriage move back and forth

smoothly?

2 Check the sensor (punch unit side reg1) for correct

operation.
Perf orm the Punch side reg1 test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Punch and Staple.

5.Select Punch side r eg1.

Does the display on the operator panel change every
time a piece of white media is placed over the sensing
area of the sensor (punch unit side reg1)?

Go to step 2. Remove

obstructions.

Go to step 3. Go to step 4.

2-76 Finisher Service Manual

Step Check Yes No

4024-XXX

3 Check the sensor (punch unit side reg2) for correct

operation.
Perf orm the Punch side reg2 test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Punch and Staple.

5.Select Punch side re g2.

Does the display on the operator panel change every
time a piece of white media is placed over the sensing
area of the sensor (punch unit side reg2)?

4 Check the appropriate sensor (punch unit side reg)

connection.
Is the above sensor connected properly?

5 Check the punch carriage shift motor assembly by

moving the punch carriage forward, then opening the
finisher front door; the punch carriage should move
slightly.

Does the punch carriage shift motor assembly rotate,
and does the punch shift carriage move back and
forth?

Go to step 5. Go to step 4.

Replace the
appropriate
sensor (punch
unit side reg).
See “Sensor

(punch unit side
registration
pair) with
bracket
removal” on
page 4-44.

Go to step 7. Go to step 6.

Replace the
connection.

6 Is the punch carriage shift motor assembly connected

properly?

7 Perform a test print.

Does the error still occur?

Replace the
punch carriage
shift motor
assembly. See

“Punch carriage
shift motor
assembly
removal” on
page 4-43.

Replace the
printer engine
card assembly.
Refer to the

Printer Service
Manual.

Replace the
connection.

Problem solved.

Diagnostic information 2-77

4024-XXX

989.00 Stapler unit failure

Step Check Yes No

1 Check the stapler unit assembly for correct operation.

Perform the Staple test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Staple Test.

Does the motor in the stapler unit assembly rotate
normally and staple the media?

2 Is the stapler unit assembly connected properly? Replace the

3 Perform a test print stapled document.

Does the error still occur?

990.00 Sensor (stapler carriage HP) on failure

Step Check Yes No

Check for staples
and staple jam.
Problem
resolved.

stapler unit
assembly. See

“Stapler unit
assembly
removal” on
page 4-56.

Replace the
printer engine
card assembly.
Refer to the

Printer Service
Manual.

Go to step 2.

Replace the
connection.

Problem solved.

1 Check the stapler by moving it with your fingers .

Does the Stapler carriage move smoothly?

2 Check the sensor (stapler carriage HP) for correct

operation.
Perf orm the Stapler carriage shift HP test.

1.Enter Diagnostics mode.

2.Select FINISHER TESTS.

3.Select Sensor Tests.

4.Select Punch and Staple.

5.Select Stapler carriage shift HP.

Does the display on the operator panel change every
time the sensing area of the sensor (stapler carriage
HP) is placed to the interrupt flag of the stapler rack
gear by moving the stapler carriage by hand

3 Is the sensor (stapler carriage HP) connected

properly?

Go to step 2. Remove

Go to step 4. Go to step 3.

Replace the
sensor (stapler
carriage HP).
See “Sensor

(stapler carriage
HP) removal” on
page 4-58.

obstructions.

Replace the
connection.

2-78 Finisher Service Manual