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Lexmark X860de, X862de, X864de MFP Service Manual, Parts List, Options & Booklet Maker Finisher

Revision: September 20, 2013
Machine Type 7500-432, -632, and -832

Service Manual, Parts List, Options & Booklet Maker Finisher Lexmark X860de, X862de, X864de MF;
This service manual, is the full Lexmark X860de, X862de, X864de MF Service Repair Manual.
This manual, Lexmark X860de, X862de, X864de MF, is in the PDF format and have detailed Diagrams, pictures and full procedures to diagnose and repair your Lexmark X860de, X862de, X864de MF copier.
You can print, zoom or read any diagram, picture or page from this Service Manual. Every chapter on this manual is fully detailed and contain all the simulation codes, trouble codes, maintenance procedures, reset procedures, diagnose procedures of Lexmark X860de, X862de, X864de MF photocopier. You can find easily everything what do you need.
To see what contain, please read table of contents:


CONTENTS FOR SERVICE MANUAL & PARTS LIST:
Notices
Laser notice
Lithium warning
Safety information
Preface
Change history
Conventions
GENERAL INFORMATION
Models
Printer technology
Maximum resolution
Processor
Memory
Standard connectivity
Optional connectivity
Operating systems-printer driver
Emulation
Fonts
Paper capacity
Paper handling
Media types
Media weights
Size and weight-without finisher
Duty cycle
Printer overview
Basic model
Configured model
Printer theory
Driving force transmission path
Media transport
Functions of main components
Media tray assembly
Multi-purpose feeder (MPF)
Detecting media size
Registration
Transfer roll assembly
Printhead assembly
Fuser
Exit
Drive
Electrical components and controller
Control
Media size control
Printhead control
Fuser control
Xerographic Process During a Print Cycle
Safety system diagram
Document scanning
Document scanning at platen
Document scanning at ADF
Image data flow
Drive torque transfer scheme
ADF feed motor assembly
ADF registration motor
Names and functions of components
Scanner unit assembly
ADF
Control
Document size detection at scanner unit assembly
ADF document size detection
Document scanning steps
Tandem tray theory
Driving force transmission path
Media transport
Media tray assembly
Main components
Duplex
Duplex drive motor
Media transport
Exit 2
Exit 2 drive motor
Media transport
Tools required for service
Acronyms
Diagnostic information
Start
Using service checks
Confirm the installation status
Power-on Reset sequence
Understanding the printer operator panel
Understanding the home screen
Other buttons may appear on the home screen
Using the touch-screen buttons
Sample touch screen
Other touch-screen buttons
Features
Error code messages
Service checks
200.00 Sensor (registration) off jam (too long)
200.01 Sensor (registration) static on jam
201.00 Sensor (fuser exit) on jam
202.00 Sensor (fuser exit) off jam
202.01 Sensor (fuser exit) off (too short) jam
202.02 Sensor (fuser exit) static jam
203.00 Sensor (exit 2) on jam
203.01 Sensor (exit 2) off jam
203.02 Sensor (exit 2) on jam in standard bin or finisher
203.03 Sensor (exit 2) static jam
230.00 Sensor (duplex wait) on jam
230.00 Sensor (duplex wait) on jam
230.01 Sensor (duplex wait) static jam
231.00 Sensor (registration) on jam (duplex paper feed)
231.01 Sensor (registration) on jam (duplex paper feed)
241.00 Sensor (pre-feed) on jam (tray 1 feed)
241.01 Sensor (registration) on jam (tray 1 feed)
242.00 Sensor (pre-feed) on jam (tray 2 feed)
242.01 Sensor (tray 2 feed-out) on jam (tray 2 feed)
242.02 Sensor (registration) on jam (tray 2 feed)
242.03 Sensor (tray 2 feed-out) static jam
243.00 Sensor (pre-feed) on jam (tray 3 media feed)
243.01 Sensor (tray 3 feed-out) on jam (tray 3 media feed)
243.02 Sensor (tray 2 feed-out) on jam (tray 3 media feed)
243.03 Sensor (registration) on jam (tray 3 media feed)
243.04 Sensor (tray 3 feed-out) static jam
244.00 Sensor (tray 4 feed-out) on jam (tray 4 media feed)
244.01 Sensor (tray 3 feed-out) on jam (tray 4 media feed)
244.02 Sensor (tray 2 feed-out) on jam (tray 4 media feed)
244.03 Sensor (registration) on jam (tray 4 media feed)
244.04 Sensor (pre-feed) on jam (tray 4 media feed)
244.05 Sensor (tray 4 feed-out) static jam
250.00 Sensor (registration) on jam (MPF pick)
290.00 Switch (sheet through) static jam
290.01 Sensor (sheet through) on jam
290.02 Sensor (ADF pre-registration) on jam ADF simplex side 1
290.03 Sensor (ADF pre-registration) off jam
290.10 Sensor (ADF pre-registration) static jam
290.11 Sensor (ADF registration) on jam ADF simplex side 1
290.12 Sensor (ADF registration) on jam side 2
290.13 Sensor (ADF registration) off jam
290.14 Sensor (ADF inverter) on jam (Inverting)
290.15 Sensor (ADF registration) off jam (inverting)
290.21 Sensor (ADF width APS 1) static jam
290.22 Sensor (ADF width APS 2) static jam
290.23 Sensor (ADF width APS 3) static jam
291.00 Sensor (ADF registration) static jam
291.01 Sensor (ADF inverter) off jam (inverting)
291.02 Sensor (ADF inverter) on jam 2
291.03 Sensor (ADF inverter) off jam
294.00 Sensor (ADF inverter) static jam
294.01 Sensor (ADF pre-registration) on jam side 2
294.02 Sensor (ADF pre-registration) off jam on inverting
295.00 Size mismatch jam (mix-size)
295.01 Size mismatch jam (no mix-size)
295.02 Invalid combine size jam
295.03 Too short size jam
295.04 Too long size jam
298.01 Scanner cable missing or unplugged
841.00 Image pipeline ASIC failure
842.00 Scanner communication failure
842.01 Scanner communication failure
842.02 Scanner communication failure
842.03 Scanner communication failure
842.04 Scanner communication failure
842.10 Scanner unit assembly - ADF communication failure
842.11 Scanner communication failure (by scanner)
842.12 Scanner unit assembly communication failure
843.00 Sensor (scanner HP) failure
843.01 Scanner carriage over run failure
843.10 ADF RAM test failure
843.11 ADF EEPROM failure
843.12 ADF pick roll position lift up failure
843.20 Scanner unit assembly connection failure
843.21 Scanner unit assembly EEPROM failure
843.22 Scanner unit assembly EEPROM sub system failure
843.23 Scanner cooling fan failure
843.24 Image processing failure
843.25 Scanner controller card assembly failure 1
843.26 Scanner controller card assembly failure 2
844.00 Exposure lamp failure
844.01 White reference/exposure lamp illumination failure
845.00 CCD failure
845.01 CCD initialization (lamp on) failure
845.02 CCD initialization (lamp off) failure
846.00 Scanner communication failure
846.01 Scanner communication failure
846.10 Sensor (ADF width APS X) failure
846.12 Scanner unit assembly software logic failure
846.13 Switch (platen interlock) open
849.00 Hard drive failure
https://www.tradebit.com System software error
903.00 RAM read/write check failure
904.00 NVM data failure
905.00 NVM read/write cannot be executed failure
906.00 CPU power to access NVM failure
907.00 RFID ASIC failure
908.00 PPM data failure
909.00 Zero cross failure
910.00 Transport motor stop failure
911.00 Transport motor failure
912.00 PC cartridge unit motor failure
913.00 Printhead assembly failure
914.00 Toner add motor assembly failure
915.00 Fuser cooling fan failure
916.00 PC cartridge cooling fan failure
917.00 LVPS cooling fan failure
918.00 Sensor (exit 1 media shift HP) failure
919.00 Sensor (exit 2 media shift HP) failure
919.01 Exit 2 unit assembly connection failure
920.00 Fuser unit assembly on time failure
921.00 Over heat temperature failure
922.00 Center thermistor failure
923.00 Rear thermistor failure
924.00 Pressure roll thermistor failure
925.00 Fuser operating temperature failure
927.00 PC cartridge RFID data write failure
928.00 PC cartridge RFID communication failure
929.00 Sensor (ATC) failure
930.00 Laser power failure
932.00 Toner cartridge RFID data write failure
933.00 Toner cartridge RFID communication failure
939.00 RIP card assembly communication failure
941.00 Media tray 1 lift up / no media tray failure
942.00 Media tray 2 lift up / no media tray failure
943.00 Tray 3 lift up / no tray failure
944.00 Tray 4 lift up / no tray failure
https://www.tradebit.com RIP card assembly NVRAM failure
https://www.tradebit.com Operator panel assembly NVRAM failure
https://www.tradebit.com RIP card assembly NAND CRC failure
956.00 RIP card assembly processor failure
956.01 RIP card assembly processor over temperature failure
956.02 RIP card assembly cooling fan failure
956.03 RIP card assembly FPGA failure
980.00 2TM/TTM controller card assembly communication failure
980.03 Exit interface card assembly communication failure
980.04 Duplex controller card assembly communication failure
980.05 Engine flicker communication failure
997.00 Duplex controller card assembly type failure
2TM/TTM left door assembly open
Duplex left door assembly open
Exit 2 left door assembly open
Media size mismatch in width
Media size mismatch in width
No media in the select media tray
No media in the select media tray
Paper is installed (short edge) in the media paper tray
PC cartridge end of life
PC cartridge RFID failure
PC cartridge set failure
Printer front door open
Printer left door open
Printer left lower door open
Scheduled maintenance required
Standard bin 1 full
Standard bin 2 full
Scanner missing failure
Switch (ADF left cover interlock) open
Toner cartridge empty
Toner cartridge near empty
Toner cartridge failure
Toner cartridge RFID failure
Toner cartridge set failure
Tray 1 media size failure
Tray 2 media size failure
Tray 1 media size mismatch in length
Tray 2 media size mismatch in length
Tray 3 media size failure
Tray 4 media size failure
Tray 3 media size mismatch in length
Tray 4 media size mismatch in length
Image quality trouble
Troubleshooting
Image Quality

DIAGNOSTIC AIDS
Accessing service menus
Diagnostics Menus
Entering Diagnostics Menus
Available tests
MOTOR TESTS
PRINT TESTS
HARDWARE TESTS
DUPLEX TESTS
INPUT TRAY TESTS
OUTPUT BIN TESTS
FINISHER TESTS
BASE SENSOR TEST
DEVICE TESTS
PRINTER SETUP
REPORTS
EVENT LOG
SCANNER TESTS
Scanner Manual Registration
Printing the registration test original page
Testing the manual scanner registration
Analyzing the manual scanner registration copies
Manually adjusting the scanner's registration
Scanner manual registration factory defaults
Exiting Diagnostics Menu
Configuration Menu
Entering Configuration Menu
Available menus
Maintenance Counter Value
Reset Maintenance Counter
REGISTRATION
Print Quality Pages (Configuration Menu)
SIZE SENSING
Panel Menus
PPDS Emulation
Factory Defaults
Energy Conserve
Min Copy Memory
Format Fax Storage
EVENT LOG (Configuration Menu)
ADF Edge Erase
FB Edge Erase
Paper Prompts
Envelope Prompts
Jobs On Disk
Disk Encryption
Wipe Disk
Font Sharpening
Require Standby
Short Edge Printing
Tray Low Message
LES Applications
Key Repeat Initial Delay
Key Repeat Rate
Booklet Adjustments
Exiting Configuration Menu
Repeating defects

REPAIR INFORMATION
Handling ESD-sensitive parts
Removal procedures
Before starting service work
Printer front left cover removal
Switch (printer front door interlock) removal
Top cover assembly removal
Printer front door assembly removal
Front door support strap and front door magnetic catch removal
Front inner cover removal
Right upper cover removal
Right lower cover removal
Rear motor cover removal
Rear lower cover removal
Rear RIP card cover removal
Option hookup cover removal
Rear upper cover removal
Controller box lower cover removal
Controller box side cover removal
Switch (media size) removal
Media feed unit assembly 1 removal
Media feed unit assembly 2 removal
Media tray side guides removal
Media tray end guide removal
Media tray lift gear group removal
Media feed lift motor removal
Tray lift coupling assembly removal
Tray lift one way clutch/gear assembly removal
Media feed unit drive gear - 13 tooth removal
Media out actuator removal
Sensor (media level) removal
Sensor (media out) removal
Sensor (pre-feed) removal
Media feed unit drive gear - 28 / 21 tooth removal
Media feed unit drive gear - 29 tooth removal
Feed roll removal
Feed roll one way clutch removal
Feed roll one way gear 22 tooth removal
Separation roll one way friction clutch removal
Separation roll removal
Pick roll idler gear 33 tooth removal
Pick roll removal
Pick roll drive gear 25 tooth removal
Feed unit drive gear 27 tooth removal
MPF feed unit assembly removal
MPF media out actuator and upper frame removal
Sensor (MPF media out) removal
MPF transport pinch roll assembly removal
MPF rear cover removal
MPF feed drive gear group removal
MPF pressure pad removal
MPF transport roll assembly removal
MPF pick solenoid / pick lever removal
MPF feed shaft assembly removal
MPF pick roll removal
MPF fold down tray assembly removal
Vertical drive gear assembly removal
Switch (left lower door interlock)
Media transport roll assembly / gear removal
Printer left lower door assembly removal
Printer left lower pinch roll assembly removal
Left lower door handle assembly removal
Transfer roll assembly removal
Printer left door support strap removal
Printer left door assembly removal
Switch (printer left door interlock) removal
Transfer roll guide assembly removal
Printer left door assembly handle removal
Registration roll assembly removal
Registration clutch assembly removal
Sensor (registration) removal
MPF/transport drive motor assembly removal
Sensor (tray 2 feed-out) removal
Switch (PC cartridge interlock) removal
Sensor (humidity and temperature) removal
Sensor (RFID PC cartridge) and sensor (RFID toner cartridge) removal
Toner cartridge guide assembly removal
Toner add motor assembly removal
Fuser cooling fan removal
Printhead assembly removal
PC cartridge cooling fan duct removal
PC cartridge cooling fan removal
Sensor (fuser exit) removal
Fuser unit assembly removal
Exit 1 media shift assembly removal
Media shift motor removal
Sensor (exit 1 media shift) removal
Sensor (exit 1 bin full) removal
Exit 1 media shift gear removal
Exit 1 drive belt removal
Dual drive motor assembly removal
High voltage power supply (HVPS) card removal
Switch (main power) removal
Exit interface card assembly removal
Printer engine card assembly removal
LVPS card assembly removal
LVPS cooling fan removal
AC drive card assembly removal
AC power input socket assembly removal
AC power input socket removal
Finisher AC output removal
RIP card chassis bracket removal
Hard drive removal
Fax interface card assembly removal
RIP card assembly removal
Scanner removals
Scanner top rear cover removal
Scanner left cover removal
Scanner right cover removal
Operator panel assembly removal
Operator panel cover assembly removal
USB-Smart card-LED cable assembly removal
Operator panel user touch screen removal
Operator panel controller card removal
Operator panel cable removal
Scanner unit assembly removal
Large platen glass removal
Scanner controller card assembly removal
Small platen glass removal
CCD card/lens assembly removal
Sensor (platen length APS 1) removal
Sensor (platen length APS 2) removal
Switch (platen interlock) removal
Sensor (scanner HP) removal
ADF angle actuator assembly removal
Sensor (ADF angle) removal
Scanner PS card assembly removal
Scanner drive motor assembly removal
Scanner cooling fan removal
Exposure lamp PS card assembly removal
Exposure lamp removal
ADF removals
ADF unit assembly removal
Platen cushion removal
Media scan guide removal
ADF media feed assembly removal
Document tray assembly removal
ADF rear cover removal
ADF front cover assembly removal
ADF controller card assembly removal
ADF left cover assembly removal
Left cover pinch roll assembly removal
ADF feed drive motor assembly removal
Inverter solenoid assembly removal
Document set LED removal
Sheet through actuator removal
Sensor (pick roll position HP) removal
ADF feed/pick roll assembly removal
Document set actuator removal
ADF left cover media guide removal
Pick roll position motor assembly removal
Switch (ADF left cover interlock) removal
Sensor (ADF width APS 1)
Sensor (ADF width APS 2)
Sensor (ADF width APS 3)
Sensor (ADF registration)
Sensor (ADF pre-registration)
Sensor (ADF inverter)
Actuator/media guide assembly removal
Inverter gate removal
ADF registration roll assembly removal
ADF feed-out roll assembly removal
ADF separation roll guide assembly
ADF exit roll assembly removal
ADF transport roll assembly removal
Sensor (document set) removal
Sensor (sheet through) removal
ADF registration motor removal
Sensor (document tray width 1) removal
Sensor (document tray width 2) removal
Sensor (document tray width 3) removal
Sensor (document tray length 1) removal
Sensor (document tray length 2) removal
2000-sheet dual input (TTM) removals
2000-sheet dual input (TTM)-top cover removal
2000-sheet dual input (TTM)-foot cover removal
2000-sheet dual input (TTM)-right cover removal
2000-sheet dual input (TTM)-left cover removal
2000-sheet dual input (TTM)-rear cover removal
2000-sheet dual input (TTM)-caster removal
2000-sheet dual input (TTM)-tray support roll removal
2000-sheet dual input (TTM)-tray 4 assembly removal
2000-sheet dual input (TTM)-tray 3 assembly removal
2000-sheet dual input (TTM)-tray 3 front cover removal
2000-sheet dual input (TTM)-tray 3 rear cable assembly removal
2000-sheet dual input (TTM)-tray 3 front cable assembly removal
2000-sheet dual input (TTM)-media guide rack and pinion removal
2000-sheet dual input (TTM)-tray 3 media guide lock assembly removal
2000-sheet dual input (TTM)-tray 3 mylar actuator removal
2000-sheet dual input (TTM)-tray 4 front cover removal
2000-sheet dual input (TTM)-tray 4 media transport assembly removal
2000-sheet dual input (TTM)-tray 4 rear cables removal
2000-sheet dual input (TTM)-tray 4 front cables removal
2000-sheet dual input (TTM)-tray 4 media guide rack and pinion removal
2000-sheet dual input (TTM)-tray 4 media guide lock assembly removal
2000-sheet dual input (TTM)-tray 4 mylar actuator removal
2000-sheet dual input (TTM)-media feed unit assembly removal (tray 4)
2000-sheet dual input (TTM)-sensor (tray 4 feed-out) removal
2000-sheet dual input (TTM)-switch (TTM media size) removal
2000-sheet dual input (TTM)-media feed unit assembly removal (tray 3)
2000-sheet dual input (TTM)-2TM/TTM media transport roll assembly removal
2000-sheet dual input (TTM)-sensor (tray 3 feed-out) removal
2000-sheet dual input (TTM)-media feed lift motor removal
2000-sheet dual input (TTM)-lift coupling assembly removal
2000-sheet dual input (TTM)-one-way clutch / gear assembly removal
2000-sheet dual input (TTM)-media feed unit drive gear 13 tooth removal
2000-sheet dual input (TTM)-media out actuator removal
2000-sheet dual input (TTM)-sensor (media level) removal
2000-sheet dual input (TTM)-sensor (media out) removal
2000-sheet dual input (TTM)-sensor (pre-feed) removal
2000-sheet dual input (TTM)-media feed unit drive gear 28 / 21 tooth removal
2000-sheet dual input (TTM)-media feed unit drive gear 29 tooth removal
2000-sheet dual input (TTM)-feed roll removal
2000-sheet dual input (TTM)-feed roll one-way clutch removal
2000-sheet dual input (TTM)-one-way 22 tooth removal
2000-sheet dual input (TTM)-separation roll one-way friction clutch removal
2000-sheet dual input (TTM)-separation roll removal
2000-sheet dual input (TTM)-pick roll idler gear 33 tooth removal
2000-sheet dual input (TTM)-pick roll removal
2000-sheet dual input (TTM)-pick roll drive gear 25 tooth removal
2000-sheet dual input (TTM)-feed unit drive gear 27 tooth removal
2000-sheet dual input (TTM)-2TM/TTM left door assembly removal
2000-sheet dual input (TTM)-switch (2TM/TTM left door interlock) removal
2000-sheet dual input (TTM)-tray 3 lift gear assembly removal
2000-sheet dual input (TTM)-tray 4 lift gear assembly removal
2000-sheet dual input (TTM)-drive motor assembly removal
2000-sheet dual input (TTM)-2TM/TTM controller card assembly removal
2000-sheet dual input (TTM)-clutch removal
Duplex unit removals
Duplex unit assembly removal
Duplex docking locks removal
Duplex support strap removal
Duplex drive gear 28 tooth removal
Duplex drive gear 33 / 74 tooth removal
Duplex drive gear 33 tooth removal
Duplex drive gear 42 tooth removal
Duplex switch (left cover interlock) removal
Duplex media in actuator removal
Duplex drive motor assembly removal
Duplex controller card assembly removal
Duplex sensor (duplex wait) removal
Duplex access handle removal
Duplex media transport rolls removal
Duplex media center transport roll removal
Exit 2 removals
Exit 2 unit assembly removal
Exit 2 unit docking lever removal
Exit 2 left door handle removal
Exit 2 diverter gate removal
Exit 2 left cover removal
Exit 2 right cover removal
Standard bin full exit 2 actuator removal
Exit 2 actuator removal
Exit 2 switch (exit 2 left door interlock) removal
Exit 2 media shift gear removal
Exit 2 media diverter solenoid removal
Exit 2 sensor (exit 2) removal
Exit 2 sensor (exit 2 media shift HP) removal
Exit 2 sensor (standard bin full exit 2) removal
Exit 2 cooling fan removal

COMPONENT LOCATIONS
Locations
Printer boards
HVPS
LVPS
Printer motors and sensors
Printer switches
Cables
TTM components
Duplex components
Exit 2 components
Preventive maintenance
Safety inspection guide
Lubrication specifications
Scheduled maintenance
Parts catalog
How to use this parts catalog
Assembly 1: Covers (1 of 2)
Assembly 2: Covers
Assembly 3: Media feed unit
Assembly 4: Media feed unit exploded (tray 1 and tray 2)
Assembly 5: Media tray
Assembly 6: MPF unit
Assembly 7: MPF unit feed
Assembly 8: Left lower door and transport
Assembly 9: Left door and transfer roll
Assembly 10: Printer left door
Assembly 11: Registration
Assembly 12: Printhead, cartridge guides, and fans
Assembly 13: Fuser
Assembly 14: Standard Exit 1
Assembly 15: Dual unit drive motor
Assembly 16: Electrical
Assembly 17: Covers and operator panel
Assembly 18: Platen glass
Assembly 19: Lens and sensors
Assembly 20: Carriage motor and cooling fan
Assembly 21: Full/half rate carriage
Assembly 22: ADF assembly
Assembly 23: ADF covers and components
Assembly 24: ADF base
Assembly 25: ADF feeder
Assembly 26: ADF left cover components
Assembly 27: ADF media guide
Assembly 28: ADF feeder roll
Assembly 29: ADF motor unit
Assembly 30: ADF document tray
Assembly 31: 2000-sheet dual input (TTM)-covers
Assembly 32: 2000-sheet dual input (TTM)-tray 3
Assembly 33: 2000-sheet dual input (TTM)-tray 4
Assembly 34: 2000-sheet dual input (TTM)-feed and transport
Assembly 35: 2000-sheet dual input (TTM)-feed and transport
Assembly 36: 2000-sheet dual input (TTM)-media feed unit
Assembly 37: 2000-sheet dual input (TTM)-left door
Assembly 38: 2000-sheet dual input (TTM)-drive and electrical
Assembly 39: Duplex outer
Assembly 40: Duplex inner
Assembly 41: Exit 2 outer
Assembly 42: Exit 2 inner
Assembly 43: Electrical cables
Assembly 44: Electrical cables
Assembly 45: Electrical cables
Assembly 46: Electrical cables
Assembly 47: Electrical cable
Assembly 48: Power cords
Assembly 49: Miscellaneous
Index
Part number index
______________________Number pages of Service Manual & Parts list: 850.


CONTENTS FOR OPTION:
Safety information
Preface
Definitions
GENERAL INFORMATIONS
Options and features
2X 500-Sheet drawer (2TM)
2X 500-Sheet drawer (2TM) theory
Driving force transmission path
Media transport
Media transport path
Layout of media transport path
Main components associated with the media transport
Functions of main components
Media tray assembly
Front media tray guide and rear media tray guide
Media tray end guide
Bottom plate
Media feed unit assembly
Media feed lift motor
Switch (media size)
Sensor (media out)
Sensor (media level)
Sensor (pre-feed)
Main components
Switch (2TM/TTM left door interlock)
Sensor (tray 3 feed-out)
Sensor (tray 4 feed-out)
2TM/TTM Transport roll assembly
2TM/TTM controller card assembly
Switch (media size)
High capacity feeder
Media feeding
Outline
HCF media feed unit assembly
HCF media transport roll assembly
HCF media feed unit assembly operation
HCF media transport roll assembly operation
HCF media feed unit assembly sensor/motor functions
Status monitoring
Static media jam detection
Interlock detection
Tray insertion detection
Functions of sensors used for status monitoring
Media size detection
Sensor for media size detection
Size sensors
Tray lifting
Media out detection
Sensor (media out)
Remaining media volume detection
Sensor (media level)
Finisher
Finisher weight
Components
Stacker media bin block to stack media
Media size and weight
Media size/orientation and applicable functions
Media weight
Features
Finisher theory
Media transport
Bridge unit assembly paper path
Finisher media path
Finisher roll assemblies
Finisher media path sensors
Finisher motors
Bridge unit assembly
From bridge unit assembly to punch
From punch to compiler unit assembly
From compiler unit assembly to stacker media bin
From punch to upper media bin
Functions of sensors along the media path
Bridge unit assembly
Finisher
Punch unit
Adjusting punching positions
Punching
Detecting punch waste full
Detecting punch waste box
Functions of punch sensors/motors
Compiler unit assembly
Outline of operation
Capacity of compiler unit assembly
Compiler unit assembly operation with multiple media sizes
Tamping
Front tamping
Rear tamping
Center tamping
Determining tamper home position
Tamping
Offsetting
Functions of compiler unit assembly sensors/motors
Stapler
Stapling operation
Staple positions
Media sizes that allow stapling
Stapling one sheet
Stapling multiple size media
Media limits for stapling
Stapler operation
Stapler unit assembly
Functions of stapler sensors/motors
Upper media bin
Operation
Functions of upper media bin sensors
Stacker media bin
Operation
Full stack detection
Functions of stacker media bin sensors/motors
Power supply and interlock
Tools required for service
Acronyms

DIAGNOSTIC INFORMATION
Start
Using service checks
Confirm the installation status
Power-on Reset sequence
Error code messages - 2X 500-sheet drawer (2TM)
Service checks - 2X 500-sheet drawer (2TM)
243.00 Sensor (pre-feed) on jam (tray 3 media feed)
243.01 Sensor (tray 3 feed-out) on jam (tray 3 media feed)
243.02 Sensor (tray 2 feed-out) on jam (tray 3 media feed)
243.03 Sensor (registration) on jam (tray 3 media feed)
243.04 Sensor (tray 3 feed-out) static jam
244.00 Sensor (tray 4 feed-out) on jam (tray 4 media feed)
244.01 Sensor (tray 3 feed-out) on jam (tray 4 media feed)
244.02 Sensor (tray 2 feed-out) on jam (tray 4 media feed)
244.03 Sensor (registration) on jam (tray 4 media feed)
244.04 Sensor (pre-feed) on jam (tray 4 media feed)
244.05 Sensor (tray 4 feed-out) static jam
943.00 Tray 3 lift up / no tray failure
944.00 Tray 4 lift up / no tray failure
980.00 2TM/TTM controller card assembly communication failure
Tray 3 media size failure
Tray 4 media size failure
2TM/TTM left door assembly open
No media in the select media tray
Media size mismatch in width
Tray 3 media size mismatch in length
Tray 4 media size mismatch in length
Error code messages - HCF
Service checks - HCF
245.00 Sensor (tray 5 feed-out) on jam
245.01 Sensor (tray 2 feed-out) on jam
245.02 Sensor (registration) on jam
245.03 Sensor (tray 5 feed-out) static jam
945.00 HCF unit media tray lift failure
945.01 HCF unit NVM R/W failure
980.01 Tray 5 HCF communication failure
HCF top door assembly open
HCF unit docking failure or tray 5 set failure
No media in the selected media tray
Error code messages - finisher
Service checks - finisher
280.00 Sensor (bridge unit media entrance) on Jam
280.01 Sensor (bridge unit media entrance) static jam A
280.02 Sensor (bridge unit media entrance) static jam B
281.00 Sensor (bridge unit media exit) On Jam A
281.01 Sensor (bridge unit media exit) On Jam B
281.02 Sensor (bridge unit media exit) On Jam C
281.03 Sensor (bridge unit media exit) static jam A
282.00 Sensor (finisher media entrance) on jam
282.01 Sensor (finisher media entrance) static jam A
283.00 Sensor (buffer path) on jam A
283.01 Sensor (buffer path) on jam B
283.02 Sensor (buffer path) static jam A
283.03 Sensor (buffer path) static jam B
283.04 Sensor (buffer path) static jam C
284.00 Sensor (lower media exit) off jam A
284.01 Sensor (lower media exit) on jam A
284.02 Sensor (lower media exit) on jam B
284.03 Sensor (lower media exit) on jam C
284.04 Sensor (lower media exit) off jam B
284.05 Sensor (lower media exit) static jam
285.00 Finisher eject set jam
286.00 Sensor (compiler media in) static jam
287.00 Sensor (upper media exit) on jam A
287.01 Sensor (upper media exit) off jam A
287.02 Sensor (upper media exit) on jam B
287.03 Sensor (upper media exit) on jam C
287.04 Sensor (upper media exit) off jam B
287.05 Sensor (upper media exit) static jam A
287.06 Sensor (upper media exit) static jam B
287.07 Sensor (upper media exit) static jam C
288.00 Sensor (diverter gate) on jam
288.01 Sensor (diverter gate) static jam (to top bin) A
288.02 Sensor (diverter gate) static jam (to top bin) B
288.03 Sensor (diverter gate) static jam (to top bin) C
288.04 Sensor (diverter gate) static jam (to stacker bin) A
288.05 Sensor (diverter gate) static jam (to stacker bin) B
288.06 Sensor (diverter gate) static jam (to stacker bin) C
980.02 Finisher communication failure
981.00 Stacker bin failure
981.01 Stacker bin upper limit failure
981.02 Stacker bin lower limit failure
982.00 Sensor (front tamper HP) on failure
982.01 Sensor (front tamper HP) off failure
983.00 Sensor (rear tamper HP) on failure
983.01 Sensor (rear tamper HP) off failure
984.00 Sensor (punch unit HP) on failure
984.01 Sensor (punch unit HP) off failure
985.00 Sensor (punch carriage shift HP) on failure
985.01 Sensor (punch carriage shift HP) off failure
986.00 Sensor (media eject clamp HP) on failure
986.01 Sensor (media eject clamp HP) off failure
987.00 Sensor (media eject shaft HP) on failure
987.01 Sensor (media eject shaft HP) off failure
988.00 Sensor (punch unit side reg) on failure
988.01 Sensor (punch unit side reg) off failure
989.00 Stapler unit failure
990.00 Sensor (stapler carriage HP) on failure
990.01 Sensor (stapler carriage HP) off failure
995.00 Finisher NVRAM R/W failure
996.00 Finisher type failure
999.00 Finisher engine/RIP functional failure
Bridge unit top cover open
Finisher front door open
Finisher eject cover open
Finisher upper media bin full
No punch waste box
Punch waste box full
Stacker media bin full (mix size)
Stacker media bin full (no mix)
Stacker lower safety failure
Stacker set over count failure
Staple cartridge empty

DIAGNOSTIC AIDS
Accessing service menus
Diagnostics Menus
Entering Diagnostics Menus
Available tests
MOTOR TESTS
PRINT TESTS
Input Source Print Test
Print Quality Test Pages
Print Quality Pages Content by Report Page Number
HARDWARE TESTS
Panel Test
Button Test
DRAM Test
CACHE Test
Parallel Wrap
DUPLEX TESTS
Quick Test
Sensor Test (duplex)
INPUT TRAY TESTS
Feed Tests
Sensor Test (input tray)
OUTPUT BIN TESTS
Feed Tests (output bins)
Feed To All Bins
Sensor Test (output bin)
FINISHER TESTS
Staple Test
Hole Punch Test
Feed Tests (Finisher)
Sensor Test (Finisher)
BASE SENSOR TEST
DEVICE TESTS
Quick Disk Test
Disk Test/Clean
PRINTER SETUP
Defaults
Printed Page Count
Permanent Page Count
Serial Number
Engine Setting 1 to 4
Model Name
Configuration ID
Edge to Edge
Parallel Strobe Adjustment (Par S Strobe Adj)
EVENT LOG
Display the Event Log
Print the Event Log
Clear the Event Log
SCANNER TESTS
ASIC Test
Feed Test
Scanner Manual Registration
Printing the registration test original page
Testing the manual scanner registration
Analyzing the manual scanner registration copies
Manually adjusting the scanner's registration
Scanner manual registration factory defaults
Sensor Test (Scanner Tests)
Exiting Diagnostics Menu
Configuration Menu
Entering Configuration Menu
Available menus
Maintenance Counter Value
Reset Maintenance Counter
REGISTRATION
Quick Test
Print Quality Pages (Configuration Menu)
SIZE SENSING
A5/Statement
B5/Executive
Panel Menus
PPDS Emulation
Factory Defaults
Energy Conserve
Min Copy Memory
Format Fax Storage
EVENT LOG (Configuration Menu)
ADF Edge Erase
FB Edge Erase
Paper Prompts
Envelope Prompts
Jobs On Disk
Disk Encryption
Wipe Disk
Font Sharpening
Require Standby
Short Edge Printing
Tray Low Message
LES Applications
Key Repeat Initial Delay
Key Repeat Rate
Exiting Configuration Menu

REPAIR INFORMATION
Handling ESD-sensitive parts
Removal procedures
Before starting service work
2X 500-sheet drawer (2TM) removals
2X 500-sheet drawer (2TM)-top cover removal
2X 500-sheet drawer (2TM)-foot cover removal
2X 500-sheet drawer (2TM)-right cover removal
2X 500-sheet drawer (2TM)-left cover removal
2X 500-sheet drawer (2TM)-rear cover removal
2X 500-sheet drawer (2TM)-2TM/TTM left door assembly removal
2X 500-sheet drawer (2TM)-caster removal
2X 500-sheet drawer (2TM)-switch (media size) assembly removal
2X 500-sheet drawer (2TM)-media feed unit assembly removal (tray 3)
2X 500-sheet drawer (2TM)-media feed unit assembly removal (tray 4)
2X 500-sheet drawer (2TM)-media tray guides removal
2X 500-sheet drawer (2TM)-media tray end guide removal
2X 500-sheet drawer (2TM)-tray lift gear group removal
2X 500-sheet drawer (2TM)-media feed lift motor removal
2X 500-sheet drawer (2TM)-lift coupling assembly removal
2X 500-sheet drawer (2TM)-tray lift one-way gear clutch assembly removal
2X 500-sheet drawer (2TM)-media feed unit drive gear - 13 tooth removal
2X 500-sheet drawer (2TM)-media out actuator removal
2X 500-sheet drawer (2TM)-sensor (media level) removal
2X 500-sheet drawer (2TM)-sensor (media out) removal
2X 500-sheet drawer (2TM)-sensor (pre-feed) removal
2X 500-sheet drawer (2TM)-media feed unit drive gear - 28 / 21 tooth removal
2X 500-sheet drawer (2TM)-media feed unit drive gear - 29 tooth removal
2X 500-sheet drawer (2TM)-feed roll removal
2X 500-sheet drawer (2TM)-feed roll one-way clutch removal
2X 500-sheet drawer (2TM)-feed roll one-way gear 22 tooth removal
2X 500-sheet drawer (2TM)-separation roll one-way friction clutch removal
2X 500-sheet drawer (2TM)-separation roll removal
2X 500-sheet drawer (2TM)-pick roll idler gear - 33 tooth removal
2X 500-sheet drawer (2TM)-pick roll removal
2X 500-sheet drawer (2TM)-pick roll drive gear 25 tooth removal
2X 500-sheet drawer (2TM)-feed unit drive gear - 27 tooth removal
2X 500-sheet drawer (2TM)-sensor (tray 3 feed-out) removal
2X 500-sheet drawer (2TM)-sensor (tray 4 feed-out) removal
2X 500-sheet drawer (2TM)-upper media transport roll removal
2X 500-sheet drawer (2TM)-lower media transport roll assembly removal
2X 500-sheet drawer (2TM)-left door pinch roll assembly removal
2X 500-sheet drawer (2TM)-switch (2TM/TTM left door interlock) removal
2X 500-sheet drawer (2TM)-2TM/TTM controller card assembly removal
2X 500-sheet drawer (2TM)-transport clutch removal
2X 500-sheet drawer (2TM)-drive motor assembly removal
High capacity feeder (HCF) removals
HCF top cover removal
HCF right cover removal
HCF sensor (HCF media tray set) removal
HCF sensor (HCF media size) removal
HCF caster removal
HCF left cover removal
HCF rear cover removal
HCF media tray front cover removal
HCF media long edge guide assembly removal
HCF media tray assembly removal
HCF lift cables removal
HCF tray lift gear bracket removal
HCF media feed unit assembly removal
HCF feed lift motor removal
HCF feed lift gear bracket removal
HCF separation gear group removal
HCF media tray lift coupling assembly removal
HCF pick solenoid assembly removal
HCF sensor (pre-feed) removal
HCF media out actuator removal
HCF sensor (media level) removal
HCF sensor (media out) removal
HCF pick roll shaft assembly removal
HCF pick roll assembly removal
HCF feed roll assembly removal
HCF separation roll shaft assembly removal
HCF separation roll assembly removal
HCF top door assembly removal
HCF switch (top door interlock) removal
HCF sensor (tray 5 feed-out) removal
HCF media transport roll assembly removal
HCF media transport motor assembly removal
HCF switch (unit docking interlock) removal
HCF controller card assembly removal
Finisher removals
Finisher removal
Bridge unit assembly removal
Bridge unit rear cover removal
Bridge unit top cover assembly removal
Bridge unit drive belt and bridge unit drive pulley removal
Bridge unit right shaft assembly removal
Bridge unit left shaft assembly removal
Bridge unit idler rolls removal
Bridge unit transport belt removals
Bridge unit drive motor assembly removal
Bridge unit entrance guide removal
Sensor (bridge unit top cover interlock) removal
Sensor (bridge unit media entrance) removal
Sensor (bridge unit media exit) removal
Bridge unit pinch roller removal
Top cover removal
Upper media bin assembly removal
Right eject cover removal
Stacker media bin assembly removal
Right lower low voltage power supply (LVPS) cover removal
Rear lower cover removal
Rear upper cover removal
Upper media bin front cover removal
Switch (finisher front door interlock) removal
Finisher front door assembly removal
Left lower cover removal
Left upper cover removal
Carriage lift belt left removal
Carriage lift belt right removal
Sensor (stacker bin level 1) removal
Sensor (stacker bin level 2) removal
Sensor (stacker bin level encoder) removal
Sensor (stacker bin upper limit) or sensor (stacker bin no media) removal
Stacker bin lift motor assembly removal
Punch carriage assembly removal
Punch carriage shift motor assembly removal
Sensor (punch unit side registration pair) with bracket removal
Punch unit assembly removal
Punch media stop assembly removal
Punch unit motor assembly removal
Sensor (punch unit motor encoder) removal
Sensor (punch hole select), sensor (punch cam front), and sensor (punch unit HP) removals
Sensor (punch carriage shift HP) removal
Sensor (punch waste box set) removal
Sensor (punch waste box full) removal
Stapler unit frame removal
Stapler unit assembly removal
Sensor (stapler carriage HP) removal
Media eject unit assembly removal
Sub paddle removal
Sub paddle drive shaft assembly removal
Media eject clamp motor assembly removal
Sensor (media eject clamp HP) removal
Switch (eject cover interlock) removal
Media compiler unit assembly removal
Sensor (front tamper HP) and sensor (rear tamper HP) removals
Sensor (compiler media in) removal
Media eject shaft assembly removal
Clamp paddle removal
Media eject clutch assembly removal
Media eject motor assembly removal
Sensor (media eject shaft HP) removal
Sensor (lower media exit) removal
Lower media exit roll assembly removal
Paddle and roll exit assembly removal
Lower pinch guide assembly removal
Finisher diverter gate removal
Buffer diverter gate removal
Sensor (buffer path) removal
Buffer roll assembly removal
Buffer pinch guide assembly removal
Media entrance pinch guide assembly removal
Sensor (finisher media entrance) removal
Media entrance roll assembly removal
Drive motor (entrance/paddle) and belt (entrance/paddle) removal
Finisher diverter gate solenoid removal
Buffer diverter gate solenoid removal
Sensor (upper media exit) removal
Upper media exit pinch roll assembly removal
Upper media exit roll assembly removal
Sensor (upper media bin full) removal
Upper pinch guide assembly removal
Sensor (diverter gate) removal
Upper media transport roll assembly removal
Drive motor (exit) assembly and belt (exit) removal
Drive motor (buffer/transport) and belt (buffer/transport) removal
Bridge unit interface card assembly removal
Finisher controller card assembly removal
Finisher low voltage power supply (LVPS) removal

COMPONENT LOCATIONS
2TM components
HCF components
Finisher components
Bridge unit assembly
Stacker lift and stapler
Punch unit
Diverter and media eject
Media eject and media compiler
Buffer, upper exit, lower exit, and drive motors
Cabling

PREVENTIVE MAINTENANCE
Safety inspection guide
Lubrication specifications
Maintenance recommendations

PARTS CATALOG
How to use this parts catalog
Assembly 1: 2X 500-sheet drawer (2TM)-covers
Assembly 2: 2X 500-sheet drawer (2TM)-media tray and media feed units
Assembly 3: 2X 500-sheet drawer (2TM)-media tray
Assembly 4: 2X 500-sheet drawer (2TM)-media feed unit
Assembly 5: 2X 500-sheet drawer (2TM)-left door
Assembly 6: 2X 500-sheet drawer (2TM)-drive and electrical
Assembly 7: High capacity feed (HCF)-covers and media tray
Assembly 8: High capacity feed (HCF)-media tray
Assembly 9: High capacity feed (HCF)-media tray lift
Assembly 10: High capacity feed (HCF)-media feed unit
Assembly 11: High capacity feed (HCF)-media feed unit
Assembly 12: High capacity feed (HCF)-top door and transport
Assembly 13: High capacity feed (HCF)-electrical
Assembly 14: Finisher-bridge unit
Assembly 15: Finisher-bridge unit top cover assembly
Assembly 16: Finisher-bridge unit lower assembly
Assembly 17: Finisher-covers
Assembly 18: Finisher-covers and front door
Assembly 19: Finisher-stacker bin lift
Assembly 20: Finisher-punch
Assembly 21: Finisher-stapler
Assembly 22: Finisher-media eject
Assembly 23: Finisher-eject and compiler unit
Assembly 24: Finisher-lower exit drive
Assembly 25: Finisher-buffer and entrance drive
Assembly 26: Finisher-buffer, transport, and upper drive
Assembly 27: Finisher-electronics
Assembly 28: Finisher-cables 1
Assembly 29: Finisher-cables 2
Assembly 30: Finisher-cables 3
Index
Part number index
______________________Number pages for Options: 560.


CONTENTS FOR BOOKLET MAKER FINISHER:
Table of contents
Notices and safety information
Laser notice
Safety information
Preface
Change history
Conventions
GENERAL INFORMATION
Finisher
Standard Finisher weight
Booklet Finisher weight
Components
Media path overview
Media size and weight
Media size/orientation and applicable functions
Media weight
Features
Finisher theory
Media transport
Bridge unit assembly paper path
Finisher media path
Finisher roll assemblies
Finisher media path sensors
Finisher motors
Bridge unit assembly
From bridge unit assembly to punch
From punch to compiler unit assembly
From compiler unit assembly to stacker media bin
From punch to upper media bin
Functions of sensors along the media path
Bridge unit assembly
Finisher
Punch unit
Adjusting punching positions
Punching
Detecting punch waste full
Detecting punch waste box
Functions of punch sensors/motors
Compiler unit assembly
Outline of operation
Capacity of compiler unit assembly
Compiler unit assembly operation with multiple media sizes
Tamping
Front tamping
Rear tamping
Center tamping
Determining tamper home position
Tamping
Offsetting
Functions of compiler unit assembly sensors/motors
Stapler
Stapling operation
Staple positions
Media sizes that allow stapling
Stapling one sheet
Stapling multiple size media
Media limits for stapling
Stapler operation
Stapler unit assembly
Functions of stapler sensors/motors
Booklet Operation
Functions of booklet sensors and motors
Booklet media bin
Operation
Functions of upper media bin sensors
Stacker media bin
Operation
Full stack detection
Functions of stacker media bin sensors/motors
Booklet tray
Power supply and interlock
Tools required for service
Acronyms

DIAGNOSTIC INFORMATION
Start
POR (Power-On Reset) sequence
To enter the diagnostic menu:
Error code messages - finisher
Service checks - finisher
280.00 Sensor (bridge unit media entrance) late Jam
280.01 Sensor (bridge unit media entrance) static jam
281.00 Sensor (bridge unit media exit) late jam
281.03 Sensor (bridge unit media exit) static jam
282.00 Sensor (finisher media entrance) late jam
282.01 Sensor (finisher media entrance) static jam
283.00 Sensor (buffer path) late jam
283.03 Sensor (buffer path) static jam
284.00 Sensor (lower media exit) late jam
284.03 Sensor (lower media exit) lag jam
284.05 Sensor (lower media exit) static jam
285.00 Sensor (media compiler in) lag jam
286.00 Sensor (compiler media in) static jam
287.00 Sensor (upper media exit) late jam
287.01 Sensor (upper media exit) lag jam
287.05 Sensor (upper media exit) static jam
288.00 Sensor (diverter gate) late jam
288.01 Sensor (diverter gate) static jam A (to top bin)
288.04 Sensor (diverter gate) static jam B (to stacker bin)
289.00 sensor (booklet unit media entrance) late jam
289.01 sensor (booklet unit media entrance) lag jam
289.02 sensor (booklet unit media entrance) static jam
289.03 sensor (booklet compiler media in) static jam
289.04 Sensor (booklet unit media exit) late jam
289.05 Sensor (booklet unit media exit) lag jam
289.06 Sensor (booklet unit media exit) static jam
980.02 Finisher communication failure
981.00 Sensor (stacker bin level 1) late error
981.01 Stacker bin upper limit error
981.02 Stacker bin lower limit error
982.00 Sensor (front tamper HP) late error
982.01 Sensor (front tamper HP) lag error
983.00 Sensor (rear tamper HP) late error
983.01 Sensor (rear tamper HP) lag error
984.00 Sensor (punch unit HP) late error
984.01 Sensor (punch unit HP) lag error
985.00 Sensor (punch carriage shift HP) late error
985.01Sensor (punch carriage shift HP) lag error
986.00 Sensor (media eject clamp HP) late error
986.01 Sensor (media eject clamp HP) lag error
987.00 Sensor (media eject shaft HP) late error
987.01 Sensor (media eject shaft HP) lag error
988.01 Sensor (punch unit side reg1) or (sensor (punch unit side reg2) lag failure
989.00 Stapler unit failure
990.00 Sensor (stapler carriage HP) late error
990.01 Sensor (stapler carriage HP) lag error
991.00 Sensor (booklet front temper HP) late error
991.01 Sensor (booklet front tamper HP) lag error
991.02 Sensor (booklet rear tamper HP) late error
991.03 Sensor (booklet rear tamper HP) lag error
991.04 Sensor (booklet end guide HP) late error
991.05 Sensor (booklet end guide HP) lag error
991.06 Sensor (booklet unit interlock) error
991.07 Sensor (booklet compiler no media) no media detected
991.08 Sensor (booklet knife HP) late error
991.09 Sensor (booklet knife HP) lag error
991.10 Sensor (booklet knife folding) late error
991.11 Booklet stapler error
991.12 Communication error with booklet controller card assembly
991.13 Booklet unit maker error
Bridge unit top cover open
Finisher front door open
Finisher eject cover open
Finisher upper media bin full
No punch waste box
Punch waste box full
Stacker media bin full (mix size)
Stacker media bin full (no mix)
Stacker lower safety failure
Stacker set over count failure
Staple cartridge empty

DIAGNOSTIC AIDS
Accessing service menus
Diagnostics Menus
Entering Diagnostics Menus
Available tests
MOTOR TESTS
OUTPUT BIN TESTS
Feed Tests (output bins)
Feed To All Bins
FINISHER TESTS
Staple Test
Hole Punch Test
Feed Tests (Finisher)
Sensor Test (Finisher)
PRINTER SETUP
Defaults
Printed Color Page Count
Printed Mono Page Count
Permanent Page Count
Serial Number
Engine Setting 1 to 4
Model Name
Configuration ID
EVENT LOG
Display the Event Log
Print the Event Log
Clear the Event Log
ENGINE ADJUST
Booklet Fold Adjust
Finisher Config
Exiting Diagnostics Menu

REPAIR INFORMATION
Handling ESD-sensitive parts
Removal procedures
Before starting service work
Finisher removal
Bridge unit assembly removal
Bridge unit rear cover removal
Bridge unit top cover assembly removal
Bridge unit drive belt and bridge unit drive pulley removal
Bridge unit right shaft assembly removal
Bridge unit left shaft assembly removal
Bridge unit idler rolls removal
Bridge unit transport belt removals
Bridge unit drive motor assembly removal
Bridge unit entrance guide removal
Sensor (bridge unit top cover interlock) removal
Sensor (bridge unit media entrance) removal
Sensor (bridge unit media exit) removal
Bridge unit pinch roller removal
Top cover removal
Upper media bin assembly removal
Right eject cover removal
Stacker media bin assembly removal
Right lower low voltage power supply (LVPS) cover removal
Rear lower cover removal
Rear upper cover removal
Upper media bin front cover removal
Switch (finisher front door interlock) removal
Finisher front door assembly removal
Left lower cover removal
Left upper cover removal
Carriage lift belt left removal
Carriage lift belt right removal
Sensor (stacker bin level 1) removal
Sensor (stacker bin level 2) removal
Sensor (stacker bin level encoder) removal
Sensor (stacker bin upper limit) or sensor (stacker bin no media) removal
Stacker bin lift motor assembly removal
Punch carriage assembly removal
Punch carriage shift motor assembly removal
Sensor (punch unit side registration pair) with bracket removal
Punch unit assembly removal
Punch media stop assembly removal
Punch unit motor assembly removal
Sensor (punch unit motor encoder) removal
Sensor (punch hole select), sensor (punch cam front), and sensor (punch unit HP) removal
Sensor (punch carriage shift HP) removal
Sensor (punch waste box set) removal
Sensor (punch waste box full) removal
Stapler unit frame removal
Stapler unit assembly removal
Sensor (stapler carriage HP) removal
Media eject unit assembly removal
Sub paddle removal
Sub paddle drive shaft assembly removal
Media eject clamp motor assembly removal
Sensor (media eject clamp HP) removal
Switch (eject cover interlock) removal
Media compiler unit assembly removal
Sensor (front tamper HP) and sensor (rear tamper HP) removals
Sensor (compiler media in) removal
Media eject shaft assembly removal
Clamp paddle removal
Media eject clutch assembly removal
Media eject motor assembly removal
Sensor (media eject shaft HP) removal
Sensor (lower media exit) removal
Lower media exit roll assembly removal
Paddle and roll exit assembly removal
Lower pinch guide assembly removal
Finisher diverter gate removal
Buffer diverter gate removal
Sensor (buffer path) removal
Finisher buffer roll assembly removal
Buffer pinch guide assembly removal
Media entrance pinch guide assembly removal
Sensor (finisher media entrance) removal
Finisher media entrance roll assembly removal
Drive motor (entrance/paddle) and belt (entrance/paddle) removal
Finisher diverter gate solenoid removal
Buffer diverter gate solenoid removal
Sensor (upper media exit) removal
Upper media exit pinch roll assembly removal
Upper media exit roll assembly removal
Sensor (upper media bin full) removal
Upper pinch guide assembly removal
Sensor (diverter gate) removal
Upper media transport roll assembly removal
Drive motor (exit) assembly and belt (exit) removal
Drive motor (buffer/transport) and belt (buffer/transport) removal
Bridge unit interface card assembly removal
Finisher controller card assembly removal
Finisher low voltage power supply (LVPS) removal
Booklet bin hookup cable assembly removal
Booklet bin assembly removal
Sensor (booklet unit interlock) removal
Booklet controller card assembly removal ??
Booklet unit assembly removal
Booklet folding/exit drive motor assembly removal
Booklet diverter gate solenoid removal
Booklet stapler unit assembly removal
Booklet knife solenoid frame removal
Booklet knife solenoid removal
Booklet knife sector drive gear 42T
Booklet media entrance drive motor removal
Booklet unit gear train frame removal
Booklet unit assembly left cover
Booklet rear tamper assembly removal
Booklet front tamper guide removal
Sensor (booklet front tamper HP) removal
Sensor (booklet rear tamper HP) removal
Booklet front tamper motor removal
Booklet rear tamper motor removal
Sensor (booklet knife HP) removal
Sensor (booklet knife folding) removal
Booklet unit front door assembly removal
Sensor (booklet unit media entrance) removal
Sensor (booklet media compiler in) removal
Sensor (booklet unit media exit) removal
Sensor (booklet end guide HP) removal
Booklet media pinch roll assembly removal
Booklet paddle motor removal
Booklet end guide drive motor removal
Booklet maker setup & adjustment
Folding precision skew adjustment
2 sheet fold & staple position fine adjustment
15 sheet staple position fine adjustment
Booklet fold position fine adjustment (3-15 sheets)
Booklet staple position fine adjustment (3-14 sheets)

CONNECTOR LOCATIONS
Finisher components
Bridge unit assembly
Stacker lift and stapler
Punch unit
Diverter and media eject
Media eject and media compiler
Buffer, upper exit, lower exit, and drive motors
Booklet media bin
Booklet maker
Cabling

PREVENTIVE MAINTENANCE
Safety inspection guide
Lubrication specifications
Maintenance recommendations

PARTS CATALOG
How to use this parts catalog
Assembly 1: Finisher-bridge unit
Assembly 2: Finisher-bridge unit top cover assembly
Assembly 3: Finisher-bridge unit lower assembly
Assembly 4: Finisher-covers
Assembly 5: Finisher-covers and front door
Assembly 6: Finisher-stacker bin lift
Assembly 7: Finisher-punch
Assembly 8: Finisher-stapler
Assembly 9: Finisher-media eject
Assembly 10: Finisher-eject and compiler unit
Assembly 11: Finisher-lower exit drive
Assembly 12: Finisher-buffer and entrance drive
Assembly 13: Finisher-buffer, transport, and upper drive
Assembly 14: Booklet maker 1
Assembly 15: Booklet maker 2
Assembly 16: Booklet maker 3
Assembly 17: Booklet maker 4
Assembly 18: Booklet maker 5
Assembly 19: Booklet maker 6
Assembly 20: Booklet maker 7
Assembly 21: Booklet maker 8
Assembly 22: Booklet maker 9
Assembly 23: Finisher-electronics
Assembly 24: Finisher-cables 1
Assembly 25: Finisher-cables 2
Assembly 26: Finisher-cables 3
Index
Part number index
_______________________Number of Booklet Maker Finisher: 401.


Total numbers of pages: 1811.
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