Lexmark MS911 User manual

MS911, MX91x, and XM91x5
4021-23x, 7421-03x, -23x, -43x
Finisher Service Manual
•Start diagnostics
•Maintenance
•Safety and notices
•Trademarks
•Index
June 18, 2014 www.lexmark.com
P/N 12G3392

Product information
Product name:
Lexmark MS911, MX91x, and XM91x5
Machine type:
4021, 7421
Model(s):
03x, 23x, 43x, 63x
Edition notice
June 18, 2014
The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL,
INC., PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED
TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of
express or implied warranties in certain transactions; therefore, this statement may not apply to you.
This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these
changes will be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any
time.
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.
Trademarks
Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other
countries.
PCL® is a registered trademark of the Hewlett-Packard Company.
All other trademarks are the property of their respective owners.
© 2014 Lexmark International, Inc.
All rights reserved.
P/N 12G3392
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Table of contents
Product information.....................................................................................2
Edition notice...............................................................................................2
Notices and safety information..................................................................21
Safety information...................................................................................................................................21
Preface.......................................................................................................25
Service manual conventions....................................................................................................................25
General information...................................................................................27
Media guidelines.....................................................................................................................................27
Paper guidelines ...............................................................................................................................................27
Paper characteristics ....................................................................................................................................27
Selecting paper.............................................................................................................................................28
Selecting preprinted forms and letterhead..................................................................................................28
Storing paper................................................................................................................................................29
Using specialty media .......................................................................................................................................29
Tips on using card stock ...............................................................................................................................29
Tips on using envelopes ...............................................................................................................................29
Tips on using labels ......................................................................................................................................30
Tips on using letterhead...............................................................................................................................30
Tips on using transparencies ........................................................................................................................31
Paper sizes, types, and weights supported by the finishers .............................................................................31
Tools required for service........................................................................................................................33
Diagnostic information...............................................................................35
Troubleshooting overview.......................................................................................................................35
Performing the initial troubleshooting check ...................................................................................................35
Understanding the printer messages......................................................................................................35
Cartridge low [88.xy].........................................................................................................................................35
Cartridge nearly low [88.xy]..............................................................................................................................36
Change [paper source] to [custom string] load [orientation] ...........................................................................36
Change [paper source] to [custom type name] load [orientation]...................................................................36
Change [paper source] to [paper size] load [orientation] ................................................................................36
Change [paper source] to [paper type] [paper size] load [orientation]............................................................36
Close door [x]....................................................................................................................................................36
Complex page, some data may not have printed [39]......................................................................................37
Configuration change, some held jobs were not restored [57] ........................................................................37
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Defective flash detected [51]............................................................................................................................37
Disk full [62] ......................................................................................................................................................37
Disk full, scan job canceled ...............................................................................................................................37
Disk must be formatted for use in this device .................................................................................................. 37
Disk near full. Securely clearing disk space.......................................................................................................38
Empty the hole punch box ................................................................................................................................38
Error reading USB drive. Remove USB. .............................................................................................................38
Error reading USB hub. Remove hub. ...............................................................................................................38
Fax memory full ................................................................................................................................................38
Fax partition inoperative. Contact system administrator.................................................................................38
Fax server 'To Format' not set up. Contact system administrator....................................................................38
Fax Station Name not set up. Contact system administrator. ..........................................................................39
Fax Station Number not set up. Contact system administrator. ......................................................................39
Incorrect paper size, open [paper source] [34] ................................................................................................39
Insert hole punch box .......................................................................................................................................39
Insert Tray [x]....................................................................................................................................................39
Insufficient memory for Flash Memory Defragment operation [37]................................................................39
Insufficient memory to collate job [37] ............................................................................................................40
Insufficient memory to support Resource Save feature [35]............................................................................40
Insufficient memory, some Held Jobs were deleted [37] .................................................................................40
Insufficient memory, some held jobs will not be restored [37]........................................................................40
Insufficient space between paper stacks in Tray 3 ........................................................................................... 40
Load [paper source] with [custom string] [paper orientation] .........................................................................40
Load [paper source] with [custom type name] [paper orientation].................................................................40
Load [paper source] with [paper size] [paper orientation]...............................................................................41
Load [paper source] with [paper type] [paper size] [paper orientation]..........................................................41
Load Multipurpose Feeder with [custom string] [paper orientation]...............................................................41
Load Multipurpose Feeder with [custom type name] [paper orientation] ......................................................41
Load Multipurpose Feeder with [paper size] [paper orientation] ....................................................................41
Load Multipurpose Feeder with [paper type] [paper size] [paper orientation] ...............................................42
Load staples ......................................................................................................................................................42
Load staples [G11, G12]....................................................................................................................................42
[x] maintenance kit very low [80.xy].................................................................................................................42
Memory full [38] ...............................................................................................................................................42
Memory full, cannot print faxes .......................................................................................................................43
Memory full, cannot send faxes ....................................................................................................................... 43
No analog phone line connected to modem, fax is disabled............................................................................43
Network [x] software error [54] .......................................................................................................................43
Not enough free space in flash memory for resources [52] .............................................................................43
Open door H and remove paper from beneath area H10 ................................................................................43
Paper changes needed......................................................................................................................................43
Parallel port [x] disabled [56]............................................................................................................................44
Photoconductor low [84.xy] ............................................................................................................................. 44
Photoconductor very low [84.xy]......................................................................................................................44
Printer had to restart. Last job may be incomplete..........................................................................................44
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Reinstall missing or unresponsive cartridge [31.xy] .........................................................................................44
Reinstall missing or unresponsive photoconductor [31.xy]..............................................................................44
Remove defective disk [61]...............................................................................................................................44
Remove packaging material, [area name] ........................................................................................................45
Remove packaging material, open door C, remove metal clips, remove all screws from scanner carriage.....45
Remove paper from all bins..............................................................................................................................45
Remove paper from bin [x] ...............................................................................................................................45
Remove paper from [linked set bin name] ....................................................................................................... 45
Remove paper from standard output bin.........................................................................................................45
Replace all originals if restarting job.................................................................................................................45
Replace cartridge, 0 estimated pages remain [88.xy].......................................................................................45
Replace cartridge, printer region mismatch [42.xy] .........................................................................................46
Replace jammed originals if restarting job. ......................................................................................................46
Replace [x] maintenance kit, 0 estimated pages remain [80.xy] ......................................................................46
Replace missing photoconductor [31.xy]..........................................................................................................46
Replace missing waste toner bottle [82.xy]......................................................................................................47
Replace missing cartridge [31.xy] .....................................................................................................................47
Replace paper pick rollers in [paper source], use parts and instructions in tray 1 or tray 2
compartment [80] ........................................................................................................................................47
Replace photoconductor, 0 pages remain [84.xy] ............................................................................................47
Replace unsupported cartridge [32.xy] ............................................................................................................47
Replace unsupported photoconductor [32.xy].................................................................................................47
Replace waste toner bottle [82.xy]...................................................................................................................47
Restore held jobs? ............................................................................................................................................47
Scanner disabled by admin [840.01].................................................................................................................48
Scanner disabled. Contact system administrator if problem persists. [840.02] ...............................................48
Scanner jam, remove jammed originals from the scanner [2yy.xx] ................................................................. 48
Scanner maintenance required, use ADF Kit [80] ............................................................................................. 48
Scanner maintenance required soon, use ADF Kit [80] ....................................................................................48
Serial port [x] disabled [56]...............................................................................................................................48
Some held jobs were not restored ...................................................................................................................48
SMTP server not set up. Contact system administrator. ..................................................................................48
Standard network software error [54]..............................................................................................................49
Standard USB port disabled [56].......................................................................................................................49
Supply needed to complete job........................................................................................................................ 49
The device is operating in Safe Mode. Some print options may be disabled or provide unexpected
results...........................................................................................................................................................49
Too many flash options installed [58]...............................................................................................................49
Too many trays attached [58]...........................................................................................................................49
Tray [x] paper size unsupported .......................................................................................................................50
Unformatted flash detected [53]......................................................................................................................50
Unsupported disk..............................................................................................................................................50
Unsupported option in slot [x] [55] ..................................................................................................................50
Waste toner bottle nearly full [82.xy]...............................................................................................................50
Weblink server not set up. Contact system administrator. ..............................................................................50
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Jams.........................................................................................................................................................51
Avoiding jams....................................................................................................................................................51
Understanding jam messages and locations.....................................................................................................51
200 paper jams .................................................................................................................................................53
SHPF paper jam service check ......................................................................................................................53
40y paper jams .................................................................................................................................................55
40y paper jam messages ..............................................................................................................................55
[x]‑page jam, press latch to access area G. Leave paper in bin. [40y.xx] .....................................................55
[x]‑page jam, press latch to access area G and clear jammed staples. Leave paper in bin. [402.93]...........58
Staple finisher paper feed jam service check ...............................................................................................61
42y paper jams .................................................................................................................................................63
42y paper jam messages ..............................................................................................................................63
[x]‑page jam, open doors G, H, and J and clear jammed paper. Leave paper in bin. [4yy.xx]......................64
[x]‑page jam, open door H and rotate knob H6 clockwise. Leave paper in bin. [426.xx–428.xx] ................67
HPT feed jam service check..........................................................................................................................73
Booklet maker transport section paper jam service check ..........................................................................75
Booklet maker feed jam service check.........................................................................................................79
Bifold exit jam service check ........................................................................................................................83
SHPF transport paper jam service check ......................................................................................................86
SHPF top bin exit jam service check .............................................................................................................89
SHPF compiler feed jam service check .........................................................................................................91
SHPF booklet gate jam service check ...........................................................................................................94
Booklet maker tamper paper jam service check ..........................................................................................96
430 jams............................................................................................................................................................98
430 jam messages ........................................................................................................................................98
Hardware errors......................................................................................................................................98
30y errors..........................................................................................................................................................98
30y error messages ......................................................................................................................................98
Motor (staple finisher front tamper) failure service check ..........................................................................98
Motor (staple finisher rear tamper) failure service check..........................................................................101
Staple finisher staple unit failure service check .........................................................................................103
Motor (staple finisher elevator) failure service check................................................................................106
32y errors........................................................................................................................................................108
32y error messages ....................................................................................................................................108
SHPF paper feed failure service check .......................................................................................................109
Motor (SHPF compiler feed roller release) failure service check ...............................................................111
Motor (SHPF paddle) failure service check ................................................................................................114
Motor (SHPF aligner) failure service check ................................................................................................116
Motor (SHPF front tamper) failure service check.......................................................................................119
Motor (SHPF rear tamper) failure service check ........................................................................................121
SHPF pre-eject failure service check .......................................................................................................... 123
SHPF ejector failure service check..............................................................................................................125
33y errors........................................................................................................................................................128
33y error messages ....................................................................................................................................128
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Booklet maker decurl assembly failure service check................................................................................129
Motor (booklet maker tamper) failure service check ................................................................................131
Motor (booklet maker aligner) failure service check .................................................................................133
SHPF elevator bin failure service check......................................................................................................135
SHPF elevator bin stack height assembly failure service check.................................................................. 137
SHPF staple unit failure service check ........................................................................................................140
Punch unit failure service check.................................................................................................................142
34y errors........................................................................................................................................................143
34y error messages ....................................................................................................................................143
Motor (bifold guide) failure service check .................................................................................................144
Booklet maker paddle assembly failure service check...............................................................................146
Motor (trifold guide) failure service check.................................................................................................149
Motor (bifold knife) failure service check ..................................................................................................151
Booklet maker staple unit failure service check.........................................................................................153
911 errors .......................................................................................................................................................154
911 error messages ....................................................................................................................................154
Staple finisher upper exit roller failure service check ................................................................................154
Symptoms..............................................................................................................................................157
Staple finisher symptoms ...............................................................................................................................157
Staple finisher symptoms ...........................................................................................................................157
Staple finisher locks service check .............................................................................................................157
Staple finisher bin stack height assembly failure service check .................................................................158
Staple finisher stapling failure service check..............................................................................................161
SHPF symptoms ..............................................................................................................................................164
SHPF symptoms..........................................................................................................................................164
HPT door service check ..............................................................................................................................164
SHPF front door service check.................................................................................................................... 166
SHPF top door service check ......................................................................................................................167
Hole punch box service check ....................................................................................................................169
SHPF top bin full service check...................................................................................................................170
SHPF staple unit noise service check..........................................................................................................172
SHPF elevator bin movement service check...............................................................................................173
Booklet maker symptoms ...............................................................................................................................177
Booklet maker symptoms ..........................................................................................................................177
HPBF bin service check...............................................................................................................................178
Bifold edge alignment service check ..........................................................................................................179
Service menus..........................................................................................183
Understanding the printer control panel..............................................................................................183
Using the control panel...................................................................................................................................183
Understanding the colors of the Sleep button and indicator lights................................................................ 183
Understanding the home screen ....................................................................................................................184
Using the touch-screen buttons .....................................................................................................................186
Menus list..............................................................................................................................................187
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Diagnostics Menu..................................................................................................................................188
Entering the Diagnostics menu.......................................................................................................................188
Reset Separator Roll and Pick Assembly Counter ...........................................................................................188
Reset Maintenance Counter ...........................................................................................................................188
Reset Fuser Counter .......................................................................................................................................188
REGISTRATION ................................................................................................................................................189
SCANNER CALIBRATION ..................................................................................................................................189
Scanner Calibration ....................................................................................................................................189
Reset flatbed, ADF front, and ADF back calibration values ........................................................................190
PRINT TESTS ....................................................................................................................................................190
Print Quality Pages..........................................................................................................................................190
HARDWARE TESTS ..........................................................................................................................................191
Panel Test ...................................................................................................................................................191
Button Test.................................................................................................................................................191
DRAM Test.................................................................................................................................................. 191
Serial 1 Wrap ..............................................................................................................................................192
USB HS Test Mode......................................................................................................................................192
DUPLEX TESTS .................................................................................................................................................192
Quick Test...................................................................................................................................................192
Top Margin .................................................................................................................................................193
INPUT TRAY TESTS ..........................................................................................................................................193
Feed Tests ..................................................................................................................................................193
OUTPUT BIN TESTS .........................................................................................................................................193
Feed Tests ..................................................................................................................................................193
SENSOR TESTS.................................................................................................................................................194
PRINTER SENSOR TESTS..............................................................................................................................194
2 x 500‑Sheet Tray Sensor Tests.................................................................................................................194
2500‑Sheet Tray Sensor Tests ....................................................................................................................194
3000‑Sheet Tray Sensor Tests ....................................................................................................................194
Staple and Hole Punch Finisher Sensor Tests.............................................................................................195
Hole Punch Booklet Finisher Sensor Tests .................................................................................................195
Staple Finisher Sensor Tests .......................................................................................................................195
Motor Tests.....................................................................................................................................................195
PRINTER MOTOR TESTS..............................................................................................................................195
2x500‑Sheet Tray Motor Tests ...................................................................................................................196
2500‑Sheet Tray Motor Tests.....................................................................................................................196
3000‑Sheet Tray Motor Tests.....................................................................................................................196
Staple Finisher Motor Tests........................................................................................................................196
Staple and Hole Punch Finisher Motor Tests .............................................................................................196
Booklet Maker Motor Tests .......................................................................................................................197
DEVICE TESTS ..................................................................................................................................................197
Quick Disk Test ...........................................................................................................................................197
Disk Test/Clean...........................................................................................................................................197
Flash Test....................................................................................................................................................197
PRINTER SETUP ............................................................................................................................................... 198
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Defaults ......................................................................................................................................................198
Printed Page Count.....................................................................................................................................198
Permanent Page Count (Perm page count)................................................................................................198
Processor ID................................................................................................................................................198
Edge to Edge...............................................................................................................................................199
Enable Edge to Edge Copy ..........................................................................................................................199
Parallel Strobe Adjustment (Par 1 Strobe Adj) ...........................................................................................199
Reset Engine Service Error .........................................................................................................................199
Restore Backup Data ..................................................................................................................................199
Reset Fuser Counter ...................................................................................................................................200
REPORTS .........................................................................................................................................................200
Menu Settings Page....................................................................................................................................200
Installed Licenses........................................................................................................................................200
EVENT LOG......................................................................................................................................................200
Display Log .................................................................................................................................................200
Print Log .....................................................................................................................................................200
Clear Log.....................................................................................................................................................201
Print Log Summary .....................................................................................................................................201
SCANNER TESTS ..............................................................................................................................................201
ADF Front Magnification ............................................................................................................................201
ADF Back Magnification .............................................................................................................................201
FB Magnification ........................................................................................................................................201
ASIC Test.....................................................................................................................................................202
Feed Test ....................................................................................................................................................202
Sensor Tests ...............................................................................................................................................202
Scanner Calibration Reset ..........................................................................................................................202
Exit Diags.........................................................................................................................................................202
Configuration Menu..............................................................................................................................203
Entering the Configuration menu ...................................................................................................................203
Hole Punch Configuration...............................................................................................................................203
Reset Maintenance Counter ...........................................................................................................................203
USB Scan to Local............................................................................................................................................203
Print Quality Pages..........................................................................................................................................203
Reports ...........................................................................................................................................................204
Menu Settings Page....................................................................................................................................204
Event Log ....................................................................................................................................................204
SIZE SENSING ..................................................................................................................................................204
Tray Linking.....................................................................................................................................................204
Panel Menus ...................................................................................................................................................204
PPDS Emulation ..............................................................................................................................................205
Download Emuls .............................................................................................................................................205
Safe Mode.......................................................................................................................................................205
Energy Conserve .............................................................................................................................................205
Fax Low Power Support ..................................................................................................................................205
Min Copy Memory ..........................................................................................................................................206
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NumPad Job Assist..........................................................................................................................................206
Format Fax Storage.........................................................................................................................................206
Fax Storage Location.......................................................................................................................................206
ADF Edge Erase ............................................................................................................................................... 206
FB Edge Erase..................................................................................................................................................207
Scanner Manual Registration..........................................................................................................................207
Disable Scanner ..............................................................................................................................................207
Paper Prompts ................................................................................................................................................207
Envelope Prompts...........................................................................................................................................207
Action for Prompts..........................................................................................................................................208
Jobs on Disk ....................................................................................................................................................208
Disk Encryption ...............................................................................................................................................208
Font Sharpening..............................................................................................................................................208
Require Standby..............................................................................................................................................208
UI Automation ................................................................................................................................................209
LES Applications ..............................................................................................................................................209
Key Repeat Initial Delay ..................................................................................................................................209
Key Repeat Rate..............................................................................................................................................209
Clear Supply Usage History ............................................................................................................................. 209
Clear Custom Status........................................................................................................................................209
USB Speed.......................................................................................................................................................210
Automatically Display Error Screens ...............................................................................................................210
Restore factory defaults .................................................................................................................................210
Restore Settings .........................................................................................................................................210
Erase Printer Memory ................................................................................................................................210
Erase Hard Disk...........................................................................................................................................210
Out of Service Erase ................................................................................................................................... 211
Exit Config .......................................................................................................................................................211
Entering Invalid engine mode................................................................................................................211
Entering Recovery Mode.......................................................................................................................211
Entering Safe Mode (EverReady Mode)................................................................................................212
Accessing the Network SE Menu...........................................................................................................212
Service Engineer menu..........................................................................................................................212
Accessing the Service Engineer (SE) Menu .....................................................................................................212
Service Engineer (SE) Menu ............................................................................................................................212
Fax Service Engineer (SE) Menu......................................................................................................................213
Repair information...................................................................................215
Removal precautions.............................................................................................................................215
Handling ESD‑sensitive parts ..........................................................................................................................215
Understanding the marked or colored screws ...............................................................................................215
Ribbon cable connectors ................................................................................................................................215
Zero Insertion Force (ZIF) connectors ........................................................................................................215
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Horizontal top contact connector ..............................................................................................................216
Horizontal bottom contact connector........................................................................................................218
Vertical mount contact connector .............................................................................................................220
Horizontal sliding contact connector .........................................................................................................222
Low Insertion Force (LIF) connector...........................................................................................................224
Adjustments..........................................................................................................................................225
Punch holes deviation adjustment .................................................................................................................225
Bifold skew adjustment .................................................................................................................................. 227
Removal procedures.............................................................................................................................228
Staple finisher removals........................................................................................................................229
Staple finisher front cover removal ................................................................................................................229
Staple finisher right cover removal.................................................................................................................230
Staple finisher rear cover removal..................................................................................................................230
Staple finisher top cover removal................................................................................................................... 231
Staple finisher exit guide removal ..................................................................................................................232
Staple finisher bin removal .............................................................................................................................232
Staple finisher left inner cover removal..........................................................................................................233
Staple finisher lower exit roller paddles removal ...........................................................................................233
Staple finisher bin stack height assembly removal .........................................................................................233
Staple finisher bin stack height assembly sensors removal............................................................................234
Staple finisher bin stack height solenoid removal ..........................................................................................235
Staple finisher bin stack height actuator removal ..........................................................................................236
Motor (staple finisher tamper) removal .........................................................................................................238
Staple finisher tamper sensors removal .........................................................................................................239
Staple finisher transport jam removal gears removal ....................................................................................240
Staple finisher lock switch removal ................................................................................................................ 241
Staple finisher locks removal ..........................................................................................................................241
Staple finisher guide rails removal..................................................................................................................243
Staple finisher controller board removal........................................................................................................244
Staple finisher controller board holder removal ............................................................................................245
Staple finisher interface cable removal ..........................................................................................................245
Motor (staple finisher transport) removal...................................................................................................... 247
Motor (staple finisher elevator) removal .......................................................................................................250
Motor (staple finisher upper exit) removal ....................................................................................................251
Motor (staple finisher exit) removal...............................................................................................................253
Motor (staple finisher aligner) removal..........................................................................................................254
Staple finisher aligner belt and gears removal ...............................................................................................255
Sensor (staple finisher upper exit roller) removal ..........................................................................................256
Sensor (staple finisher elevator home) removal.............................................................................................257
Sensor (staple finisher staple unit home) removal .........................................................................................257
Sensor (staple finisher paper feed) removal...................................................................................................258
Staple finisher staple unit removal .................................................................................................................260
Staple finisher staple unit carriage assembly removal ...................................................................................261
Staple finisher interface board removal .........................................................................................................262
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Motor (staple finisher staple unit carriage) removal ......................................................................................263
Staple finisher staple unit carriage removal ...................................................................................................263
Staple finisher staple unit carriage gears removal..........................................................................................264
Staple finisher staple unit carriage wheel removal.........................................................................................266
Staple finisher FFC removal ............................................................................................................................267
Staple finisher stack lever actuator removal ..................................................................................................269
Staple finisher stack clamp solenoid removal.................................................................................................270
Staple finisher elevator springs removal ........................................................................................................271
Staple finisher elevator drive gears removal ..................................................................................................271
Staple finisher elevator belts removal ............................................................................................................272
Staple finisher elevator gears removal ...........................................................................................................274
Exit motor bracket removal ............................................................................................................................277
Staple finisher exit guide lift cam removal .....................................................................................................279
Staple finisher upper exit roller drive gears removal......................................................................................280
Staple finisher exit roller drive belts and gears removal ................................................................................283
Staple finisher exit roller solenoid removal ....................................................................................................284
Staple finisher upper exit actuator removal ...................................................................................................285
Staple finisher exit roller gear removal...........................................................................................................286
Staple finisher lower exit roller removal.........................................................................................................286
Staple finisher upper guide removal...............................................................................................................287
Staple finisher lower guide removal ...............................................................................................................291
Staple finisher staple unit rail removal ...........................................................................................................292
Staple finisher compiler feed roller guide removal ........................................................................................293
Staple finisher aligner roller removal..............................................................................................................295
Staple finisher compiler feed roller shaft assembly removal .........................................................................296
Staple finisher compiler feed rollers and gears removal ................................................................................298
Staple finisher stack lever removal .................................................................................................................300
Staple finisher transport roller removal .........................................................................................................301
Staple finisher aligner roller gears removal .................................................................................................... 303
Staple finisher upper exit roller assembly removal ........................................................................................305
Staple finisher eject guide removal ................................................................................................................306
Staple finisher eject cam removal...................................................................................................................307
Staple finisher upper exit roller removal ........................................................................................................308
Staple finisher upper exit roller belts and gear removal ................................................................................309
Staple finisher tamper and aligner assembly removal.................................................................................... 311
Staple finisher tamper drive gears removal....................................................................................................313
Staple finisher tamper racks removal .............................................................................................................315
Horizontal paper transport removals....................................................................................................321
HPT door locks removal ..................................................................................................................................321
HPT inner paper guide removal ......................................................................................................................321
HPT holding bracket removal..........................................................................................................................322
Sensor (HPT feed) ...........................................................................................................................................322
HPT feed sensor actuator removal ................................................................................................................. 323
Sensor (HPT door) removal.............................................................................................................................323
HPT right top cover removal...........................................................................................................................324
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HPT door removal ...........................................................................................................................................324
HPT rear cover removal ..................................................................................................................................325
HPT cable removal ..........................................................................................................................................325
HPT door hinges removal................................................................................................................................326
Motor (HPT transport) removal ......................................................................................................................327
HPT belts and gears removal .......................................................................................................................... 329
HPT transport rollers removal ........................................................................................................................329
Staple, hole punch finisher removals....................................................................................................331
SHPF top bin extender removal ......................................................................................................................331
SHPF elevator bin removal..............................................................................................................................331
SHPF paddles removal ....................................................................................................................................332
SHPF elevator bin bracket removal.................................................................................................................332
HPBF bin bail removal.....................................................................................................................................333
SHPF lower cover removal ..............................................................................................................................333
SHPF caster wheel removal ............................................................................................................................333
SHPF front door switch removal .....................................................................................................................334
SHPF front door removal ................................................................................................................................336
SHPF top inner cover removal ........................................................................................................................336
SHPF diverter feed roller knob removal .........................................................................................................337
SHPF post cover removal ................................................................................................................................338
SHPF rear cover removal ................................................................................................................................ 339
SHPF top door removal...................................................................................................................................339
Booklet gate jam access door removal ...........................................................................................................340
SHPF jam access door removal .......................................................................................................................342
Sensor (SHPF elevator bin full) removal .........................................................................................................343
Lower left cover removals ..............................................................................................................................344
HPBF lower left cover sensors removals.........................................................................................................347
HPBF exit roller cover removal .......................................................................................................................347
SHPF upper left cover removal .......................................................................................................................348
SHPF upper left cover sensors removal ..........................................................................................................349
SHPF elevator bin stack height sensor actuator removal ...............................................................................350
SHPF elevator bin stack height sensor actuator arms and gears removal......................................................351
SHPF elevator bin stack height drive gear removal ........................................................................................352
Motor (SHPF elevator bin stack height) removal............................................................................................353
Motor (SHPF front tamper) removal...............................................................................................................354
Sensor (SHPF front tamper home) removal ...................................................................................................355
Motor (SHPF feed) removal ............................................................................................................................356
Motor (SHPF transport) removal ....................................................................................................................356
Motor (SHPF rear tamper) removal ................................................................................................................357
Sensor (SHPF rear tamper home) removal .....................................................................................................359
Motor (SHPF elevator) removal ......................................................................................................................359
Sensor (SHPF elevator position) removal .......................................................................................................361
SHPF elevator drive assembly removal...........................................................................................................362
Sensor (SHPF top bin full) removal .................................................................................................................363
SHPF paddle cam and compiler guide lever removal .....................................................................................364
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SHPF controller board removal.......................................................................................................................364
Punch unit removal.........................................................................................................................................365
Sensor (hole punch box full) removal .............................................................................................................366
SHPF staple unit assembly removal ................................................................................................................367
SHPF staple unit position sensors removal .....................................................................................................369
SHPF staple unit drive belt and gear removal.................................................................................................370
Motor (SHPF staple unit carriage) removal ....................................................................................................371
SHPF staple unit removal................................................................................................................................372
SHPF staple unit carriage removal ..................................................................................................................374
SHPF elevator bottom rear gear removal .......................................................................................................375
SHPF elevator bottom front gear removal......................................................................................................376
SHPF elevator belts removals .........................................................................................................................377
SHPF elevator top rear gear removal..............................................................................................................381
SHPF elevator top front gear removal ............................................................................................................ 381
SHPF paddle motor bracket removal ..............................................................................................................383
Motor (SHPF paddle) removal ........................................................................................................................384
SHPF paddle drive gears removal ...................................................................................................................384
SHPF paddle motor FRUs removal ..................................................................................................................385
Sensor (SHPF top door) removal.....................................................................................................................386
Sensor (SHPF top bin full, receive) removal....................................................................................................387
Motor (SHPF compiler feed roller release) removal .......................................................................................388
SHPF compiler feed roller release motor bracket removal.............................................................................389
Sensor (SHPF compiler feed roller release) removal ......................................................................................389
SHPF compiler feed roller release encoder removal ......................................................................................390
Motor (SHPF aligner) removal ........................................................................................................................391
SHPF diverter cam removal ............................................................................................................................391
Sensor (SHPF diverter cam) removal ..............................................................................................................392
SHPF entrance and diverter feed roller gears removal...................................................................................393
SHPF top jam access door and SHPF diverter removal ...................................................................................394
Sensor (SHPF top bin exit) removal ................................................................................................................397
SHPF top bin exit paper guide removal...........................................................................................................398
Motor (SHPF compiler eject) removal ............................................................................................................ 399
Motor (SHPF compiler pre-eject) removal...................................................................................................... 400
SHPF compiler eject sensors removal .............................................................................................................401
Sensor (SHPF eject clamp position) removal ..................................................................................................402
SHPF compiler assembly removal ...................................................................................................................403
SHPF tampers removal....................................................................................................................................410
SHPF tamper trays removal ............................................................................................................................411
SHPF tamper belts and gears removal............................................................................................................412
Sensor (SHPF aligner position) removal..........................................................................................................414
SHPF middle aligner removal..........................................................................................................................415
Sensor (SHPF eject clamp home) removal ......................................................................................................416
SHPF compiler eject gear removal.................................................................................................................. 417
SHPF aligner shaft removal .............................................................................................................................418
SHPF booklet maker pre-feed roller removal .................................................................................................421
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SHPF booklet maker lower pre-feed guide removal.......................................................................................422
SHPF booklet maker upper pre‑feed guide removal ......................................................................................423
SHPF diverter feed guide removal ..................................................................................................................425
SHPF diverter feed roller removal ..................................................................................................................426
SHPF elevator bin stack limit actuator removal..............................................................................................429
SHPF elevator bin stack limit switch removal .................................................................................................432
SHPF top bin removal .....................................................................................................................................433
SHPF top bin exit roller removal .....................................................................................................................434
SHPF compiler feed roller release cam removal .............................................................................................436
SHPF top bin transport roller removal ............................................................................................................438
SHPF compiler feed idler roller assembly removal .........................................................................................440
Sensor (SHPF compiler feed) removal ............................................................................................................442
SHPF compiler guide removal .........................................................................................................................444
SHPF entrance guide removal.........................................................................................................................446
Sensor (SHPF entrance) removal ....................................................................................................................446
SHPF entrance roller removal .........................................................................................................................447
SHPF compiler bails removal ..........................................................................................................................451
SHPF compiler feed roller removal .................................................................................................................453
Booklet maker removals.......................................................................................................................455
Trifold jam knob removal................................................................................................................................455
Booklet maker exit roller springs removal......................................................................................................455
Booklet maker lower paddle removal............................................................................................................. 456
Booklet maker front cover removal................................................................................................................456
Booklet maker right cover removal ................................................................................................................ 457
Booklet maker support removal .....................................................................................................................457
Bifold exit jam access door removal ...............................................................................................................459
Booklet maker aligner jam access door removal ............................................................................................460
Booklet maker controller board removal .......................................................................................................462
Booklet maker controller board holder removal ............................................................................................462
Top frame brace removal ...............................................................................................................................463
Middle frame brace removal ..........................................................................................................................464
Booklet maker jam access door removal........................................................................................................465
Booklet maker transport paper guide assembly removal...............................................................................466
Booklet maker transport idler rollers removal ...............................................................................................467
Sensor (booklet maker transport) removal .................................................................................................... 467
Booklet maker decurl lever removal...............................................................................................................468
Booklet maker transport paper guide lever removal .....................................................................................469
Motor (bifold roller) removal..........................................................................................................................471
Bifold roller gears removal..............................................................................................................................471
Trifold rollers removal ....................................................................................................................................472
Trifold gears removal......................................................................................................................................473
Booklet maker paddle belt removal ...............................................................................................................474
Booklet maker paddle gears removal .............................................................................................................475
Motor (booklet maker paddle) removal .........................................................................................................476
Sensor (booklet maker paddle home) removal ..............................................................................................477
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Motor (booklet maker transport) removal .....................................................................................................478
Motor (booklet maker decurl) removal ..........................................................................................................479
Transport and decurl motor bracket removal ................................................................................................479
Bifold roller springs removal...........................................................................................................................480
Booklet maker transport gear and belt removal ............................................................................................481
Booklet maker transport roller removal .........................................................................................................482
Booklet maker decurl gears removal ..............................................................................................................483
Sensor (booklet maker decurl) removal ......................................................................................................... 484
Booklet maker decurl guide removal..............................................................................................................485
Motor (bifold guide) removal .........................................................................................................................486
Bifold guide motor bracket removal...............................................................................................................487
Sensor (bifold guide home) removal .............................................................................................................. 488
Motor (trifold guide) removal.........................................................................................................................489
Trifold guide motor bracket removal..............................................................................................................489
Trifold gate actuator removal .........................................................................................................................490
Sensor (trifold guide home) removal..............................................................................................................490
Motor (booklet maker aligner) removal .........................................................................................................491
Motor (bifold knife) removal ..........................................................................................................................491
Motor (booklet maker tamper) removal ........................................................................................................492
Booklet maker aligner front paper guide removal .........................................................................................493
Booklet maker aligner rear paper guide removal ...........................................................................................494
Sensor (booklet maker aligner home) removal ..............................................................................................495
Booklet maker aligner assembly removal.......................................................................................................496
Booklet maker aligner removal.......................................................................................................................498
Booklet maker aligner middle paper guide removal ......................................................................................499
Booklet maker aligner belt removal ...............................................................................................................500
Booklet maker aligner gears removal ............................................................................................................. 501
Booklet maker aligner solenoid removal ........................................................................................................501
Trifold knife assembly removal.......................................................................................................................504
Booklet maker upper paddle removal ............................................................................................................504
Trifold knife removal.......................................................................................................................................505
Trifold knife springs removal ..........................................................................................................................505
Bifold upper roller removal.............................................................................................................................506
Bifold lower roller removal .............................................................................................................................509
Booklet maker staple unit removal.................................................................................................................510
Trifold diverter removal..................................................................................................................................514
Sensor (booklet maker fold exit) removal ......................................................................................................515
Bifold knife primary drive gears removal........................................................................................................516
Bifold knife and tamper assembly removal ....................................................................................................517
Sensor (bifold knife home) removal ...............................................................................................................519
Bifold knife plates removal .............................................................................................................................520
Bifold knife secondary drive gears removal....................................................................................................521
Bifold knife removal........................................................................................................................................521
Bifold roller drive gears removal .................................................................................................................... 522
Bifold guide drive gears removal ....................................................................................................................525
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Booklet maker tamper tray removal ..............................................................................................................527
Sensor (booklet maker tamper home) removal .............................................................................................530
Bifold guide idler gears removal .....................................................................................................................530
Component locations...............................................................................533
Exterior locations..................................................................................................................................533
Configured model ...........................................................................................................................................533
Maintenance............................................................................................535
Inspection guide....................................................................................................................................535
Lubrication specification.......................................................................................................................535
Parts catalog............................................................................................536
Legend...................................................................................................................................................536
Assembly 1: Staple finisher—Frame......................................................................................................537
Assembly 2: Staple finisher—Covers.....................................................................................................539
Assembly 3: Staple finisher—Transport section 1.................................................................................541
Assembly 4: Staple finisher—Transport section 2.................................................................................543
Assembly 5: Staple finisher—Compiler feed roller assembly................................................................545
Assembly 6: Staple finisher—Compiler section 1..................................................................................547
Assembly 7: Staple finisher—Compiler section 2..................................................................................549
Assembly 8: Staple finisher—Aligner section........................................................................................551
Assembly 9: Staple finisher—Staple section.........................................................................................553
Assembly 10: Staple finisher—Exit section 1.........................................................................................555
Assembly 11: Staple finisher—Exit section 2.........................................................................................557
Assembly 12: Staple finisher—Exit section 3.........................................................................................559
Assembly 13: Staple finisher—Bin section 1.........................................................................................561
Assembly 14: Staple finisher—Bin section 2.........................................................................................563
Assembly 15: Staple finisher—Electronics............................................................................................565
Assembly 16: Horizontal paper transport.............................................................................................567
Assembly 17: Horizontal paper transport—Covers 1............................................................................569
Assembly 18: Horizontal paper transport—Covers 2............................................................................571
Assembly 19: Horizontal paper transport—Drive section.....................................................................573
Assembly 20: SHPF—Covers..................................................................................................................575
Assembly 21: SHPF—Frame..................................................................................................................577
Assembly 22: SHPF—Transport section 1..............................................................................................579
Assembly 23: SHPF—Transport section 2..............................................................................................581
Assembly 24: SHPF—Transport section 3..............................................................................................585
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Assembly 25: SHPF—Transport section 4..............................................................................................587
Assembly 26: SHPF—Elevator bin section 1..........................................................................................589
Assembly 27: SHPF—Elevator bin section 2..........................................................................................591
Assembly 28: SHPF—Staple unit assembly............................................................................................593
Assembly 29: SHPF—Compiler section 1...............................................................................................595
Assembly 30: SHPF—Compiler section 2...............................................................................................597
Assembly 31: SHPF—Compiler section 3...............................................................................................599
Assembly 32: SHPF—Punch unit 1.........................................................................................................601
Assembly 33: SHPF—Punch unit 2.........................................................................................................603
Assembly 34: Booklet maker—Covers..................................................................................................605
Assembly 35: Booklet maker—Electronics............................................................................................607
Assembly 36: Booklet maker—Fold section 1.......................................................................................609
Assembly 37: Booklet maker—Fold section 2.......................................................................................611
Assembly 38: Booklet maker—Fold section 3.......................................................................................613
Assembly 39: Booklet maker—Transport section.................................................................................615
Assembly 40: Booklet maker—Staple section.......................................................................................617
Assembly 41: Booklet maker—Compiler section..................................................................................619
Assembly 42: Booklet maker—Aligner assembly..................................................................................621
Assembly 43: Booklet maker—Exit section...........................................................................................623
Assembly 44: SHPF and booklet maker—Wiring...................................................................................625
Appendix A: Printer specifications............................................................627
Power consumption..............................................................................................................................627
Product power consumption ..........................................................................................................................627
Sleep Mode .....................................................................................................................................................627
Hibernate Mode..............................................................................................................................................628
Off mode......................................................................................................................................................... 628
Total energy usage..........................................................................................................................................628
Operating clearances.............................................................................................................................628
Noise emission levels............................................................................................................................629
Temperature information.....................................................................................................................629
Appendix B: Options and features............................................................631
Media handling options.........................................................................................................................631
Appendix C: Theory of operation..............................................................633
Staple finisher operation.......................................................................................................................633
Staple finisher sections ...................................................................................................................................633
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Staple finisher feed and exit section...............................................................................................................634
Staple finisher compiler section .....................................................................................................................636
Staple finisher bin section...............................................................................................................................642
Horizontal paper transport (HPT) operation.........................................................................................644
Staple, hole punch finisher (SHPF) operation........................................................................................646
SHPF sections..................................................................................................................................................646
SHPF top bin exit and elevator bin exit sections.............................................................................................646
SHPF punch unit operation ............................................................................................................................. 651
SHPF compiler section operation....................................................................................................................653
SHPF compiler section feed........................................................................................................................653
SHPF compiler section paper alignment ....................................................................................................658
SHPF stapling operation .............................................................................................................................659
SHPF stapling operation for multiple staple jobs ....................................................................................... 661
SHPF compiler section exit .........................................................................................................................662
Elevator bin section operation........................................................................................................................663
Booklet maker operation......................................................................................................................667
Booklet maker sections...................................................................................................................................667
Booklet maker paper feed ..............................................................................................................................669
Booklet maker compiler section paper feed and alignment...........................................................................671
Bifold and trifold sections...............................................................................................................................673
Booklet maker exit section .............................................................................................................................676
Appendix D: Acronyms.............................................................................679
Acronyms...............................................................................................................................................679
Index........................................................................................................681
Part number index...................................................................................691
Part name index.......................................................................................705
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