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Lexmark W820 - Optra B/W Laser Printer Service Manual

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TM
Lexmark
W820 Finisher
4025-XXX
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
marks
• Index
• Manuals Menu
Lexmark and Lexmark with diamond design are
trademarks of Lexmark International, Inc., registered
in the United States and/or other countries.

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Summary of Contents for Lexmark W820 - Optra B/W Laser Printer

  • Page 1 4025-XXX • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks marks • Index • Manuals Menu Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 1-800-553-9727. In other countries, contact your point of purchase. Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. PCL is a registered trademark of the Hewlett-Packard Company.

  • Page 3: Table Of Contents

    4025-Finisher Table of Contents Preface ................ix Safety Information .
  • Page 4 4025-Finisher How to Use the Service Checks Flowchart ......2-9 How to Follow a Service Check .
  • Page 5 4025-Finisher Cap-End Removal ..........4-38 Caster Assembly Removal .
  • Page 6 4025-Finisher Motor Assembly-Swing Removal ........4-104 Sensor Assembly Swing Removal .
  • Page 7 4025-Finisher Parts Catalog ..............7-1 How to Use This Parts Catalog .
  • Page 8 4025-Finisher viii...

  • Page 9: Preface

    4025-Finisher Preface This manual describes the Lexmark W820 4025-XXX Finisher and contains maintenance procedures for service personnel only. It is divided into the following chapters: General Information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions.

  • Page 10: Safety Information

    This product is designed, tested and approved to meet strict global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts.
  • Page 11 Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio. • La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento.
  • Page 12 Aquest producte està dissenyat, comprovat i aprovat per tal d'acomplir les estrictes normes de seguretat globals amb la utililització de components específics de Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi.

  • Page 13: Introduction

    4025-Finisher 1. Introduction Maintenance Approach The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part for the Finisher. Use the error code table, attendance message table, error code service checks and attendance message service checks to determine the corrective action necessary to repair the failing option.

  • Page 14: Printer Power Supply And Electrical Components

    4025-Finisher Printer Power Supply and Electrical Components Before starting any service procedure, switch off the printer power and unplug the power cord from the wall outlet. If you must service the options with the printer power applied, be aware of the potential for electrical shock. CAUTION: Do not touch any electrical component unless you are instructed to do so by a service procedure.

  • Page 15: Printer Fuser Components

    4025-Finisher To avoid permanent eye damage, follow these directions: • Before starting any service procedure, switch off the printer power and unplug the power cord from the AC wall outlet. • Do not disassemble the printer Printhead Assembly or any laser component that displays a Laser Warning sticker.

  • Page 16: Principles Of Operation

    4025-Finisher Principles of Operation Finisher Power The Base Engine supplies 120VAC to the Finisher, and the Finisher Power Supply converts it into 24VDC and 5VDC that are necessary for the Finisher to function, and sends these voltages to it. The printer AC power cord plugs into a grounded AC electrical outlet. The cord carries AC line voltage to the Noise Filter PWB.

  • Page 17: Finisher Control

    4025-Finisher Finisher Control Finisher Control describes the printer resources that monitor and control the actions and operations of the printer and the Finisher; from paper feed to error detection. The center of Finisher control is the Finisher PWB. The MCU PWB provides the logic and information processing that is necessary for the printer to function, and the Finisher PWB provides the logic and information processing that is necessary for the Finisher to function.
  • Page 18 4025-Finisher Service Manual...

  • Page 19: Mechanical Drive

    4025-Finisher Mechanical Drive Mechanical Drive describes both the rotation of the Motor and the action of the gears, belts, and clutches that are used to transmit and control motor drive to the various components throughout the Finisher. The primary purpose of Mechanical Drive within the Finisher is to provide the mechanical energy needed to drive .
  • Page 20 4025-Finisher Drive for Fin Input Roller & Regi Roller The rotation of the Main Feed Motor drives the Main Drive Belt to transmit a driving force to the Main Drive Gear. The rotation of the Main Drive Gear transmits a driving force to the Feed Gear 1.
  • Page 21 4025-Finisher Mechanical Drive Fin Input Roller & Regi Roller Components • The Main Feed Motor supplies a driving force to the Punch Clutch, Fin input Roller and Regi Roller. It also supplies a driving force to the entire H-Tra via the Transport Gear 1.
  • Page 22 4025-Finisher Drive for Punch Unit The rotation of the Main Feed Motor drives the Main Drive Belt to transmit a driving force to the Main Drive Gear. The rotation of the Main Drive Gear transmits a driving force to the Feed Gear 1. The rotation of the Feed Gear 1 drives the Timing Belt 1, and driving the Timing Belt 1 rotates the Regi Roll Gear.
  • Page 23 4025-Finisher Mechanical Drive Punch Unit Components • The Main Feed Motor supplies a driving force to the Punch Clutch, Fin input Roller and Regi Roller. It also transmits a driving force to the entire H-Tra via the Transport Gear 1. •...
  • Page 24 4025-Finisher Drive for Shift Roller Unit & Main Paddle & Sub Paddle • The driving force transmitted by the Compiler Tray Feed Motor In the transmission of a driving force to the Shift Roller, the rotation of the Compiler Tray Feed Motor transmits a driving force to the Shift Roll Gear 1, to rotate the Shift Roller.
  • Page 25 4025-Finisher 1-13 Introduction...
  • Page 26 4025-Finisher Mechanical Shift Roller Unit & Main Paddle & Sub Paddle Components • The Compiler Tray Feed Motor supplies a driving force to the Shift Roller and Main Paddle. • The Shift Motor supplies a driving force to the Shift Roller to perform the shifting job. •...
  • Page 27 4025-Finisher Drive for Exit 1: Exit Pinch Roll Guide The rotation of the Exit Roller Open/Close Motor transmits a driving force to the Open/ Close Gear 1 and Open/Close Gear 2. Then, the rotation of the Open/Close Gear 2 moves up the Sector Gear. By means of the convex portion on the side surface of the Sector Gear, the lever at the end of the Exit Pinch Roll Shaft is raised, and the Exit Pinch Roll Guide is opened upward.
  • Page 28 4025-Finisher Drive for Exit 2: Exit Roller & Compiler Tray • The driving force transmitted to the Exit Roller The rotation of the Exit Motor transmits a driving force to the Exit Roll Gear. The rotation of the Exit Roll Gear rotates the Exit Roller. Also, the Exit Motor rotates counterclockwise when drawing the paper into the Compiler Tray.
  • Page 29 4025-Finisher 1-17 Introduction...
  • Page 30 4025-Finisher Mechanical Drive Exit 2: Exit Roller & Compiler Move Tray Components • The Exit Motor supplies a driving force to the Exit Roller. • The Exit Roll Gear transmits a driving force transmitted from the Exit Motor to the Exit Roller, to rotate the Exit Roller.

  • Page 31: Drive For Jogging

    4025-Finisher Drive for Jogging The Jogging Motor transmits a driving force to the Jogging Gear. The rotation of the Jogger Gear rotates the Spiral Shaft. Then, the Jogger Flap moves on the Spiral Shaft. Mechanical Drive Jogging Components • The Jogging Motor F/R supplies a driving force to the Jogging Gear, to move the Jogger Flap.
  • Page 32 4025-Finisher Drive for Staple The Stapler Traverse Motor transmits a driving force to the Stapler Drive Pulley. The rotation of the Stapler Drive Pulley drives the Stapler Timing Belt to move the Stapler Unit to the left and right. The Stapler Swing Motor transmits a driving force to the Stapler Swing Gear 1. The rotation of the Stapler Swing Gear 1 transmits a driving force to the Stapler Swing Gear 2.
  • Page 33 4025-Finisher 1-21 Introduction...
  • Page 34 4025-Finisher Mechanical Drive Stapler Components • The Stapler Traverse Motor supplies a driving force to the Stapler Drive Pulley. • The Stapler Drive Pulley transmits the driving force from the Stapler Traverse Motor to the Stapler Timing Belt. • The Stapler Timing Belt moves the Stapler Unit to the left and right by the belt drive. •...
  • Page 35 4025-Finisher 1-23 Introduction...
  • Page 36 4025-Finisher Mechanical Stacker Tray Components • The Lift Up Motor supplies a driving force to the Elevator Shaft via each gear on the Elevator Drive Unit. • The Elevator Drive Unit supplies the driving force generated by the Lift Up Motor to the Elevator Drive Gear and Liner Encoder.
  • Page 37 4025-Finisher Mechanical Top Tray Exit Components • The Exit Top Motor supplies a driving force to the Exit Top Gear. • The Exit Top Gear: Upper rotates the Exit Top Roller: Upper by the driving force transmitted from the Exit Top Belt. •...

  • Page 38: Finisher Paper Path

    4025-Finisher Finisher Paper Path Main mechanisms in the Finisher are described by paper transfer path, as follows: • H-Tra: Mechanism to transfer paper from the printer to the Finisher. • Punch section: Mechanism to punch paper. • Shift section: Mechanism to shift paper toward the front or rear. •...

  • Page 39: H-Tra Section

    4025-Finisher H-Tra Section The paper delivered from the printer passes the H-Tra Gate and is transferred into the H-Tra. Then, the rotation of the H-Tra Feed Roller in the H-Tra transfers the paper toward the Finisher. Also, during the paper transfer, the rotation of the H-Tra Feed Roller shifts the paper to the front side, to adjust the skew and registered position.

  • Page 40: Punch Section

    4025-Finisher Punch Section • Route for paper delivery to the Stacker Tray The paper transferred from the H-Tra to the Finisher passes the Fin Input Path Sensor in the Finisher, and it is transferred toward the Shift Roller by the rotation of the Fin Input Roller and Regi Roller.
  • Page 41 4025-Finisher 1-29 Introduction...
  • Page 42 4025-Finisher 1-30 Service Manual...
  • Page 43 4025-Finisher Punch Components • The Fin Input Path Sensor monitors paper being transferred from the H-Tra into the Finisher. • At the specified pulses after this sensor detects the trailing edge of the paper, the Shift Roller rotation speed decreases to start the punching operation. •...

  • Page 44: Shift Section

    4025-Finisher Shift Section After the trailing edge of paper passes the Fin Path Roller, the Exit Pinch Roll Guide opens upward. Then, the Shift Roller Unit is moved forward or backward to perform an offset job, and, at the same time, the Shift Roller rotates to transfer the paper toward the Exit Roller.

  • Page 45: Compiler & Jogger Section

    4025-Finisher Compiler & Jogger Section & Jogger Section The paper transferred toward the Shift Roller by the Regi Roller starts to be drawn into the Compiler Tray by the clockwise rotation of the Sub Paddle at the specified pulses after the Fin Exit Path Sensor before the Shift Roller detects the trailing edge of the paper.
  • Page 46 4025-Finisher 1-34 Service Manual...
  • Page 47 4025-Finisher Compiler & Jogger Components • The Exit Roller delivers paper to the Stacker Tray, and transfers paper to the Compiler Tray. • The Sub Paddle assists the paper to be drawn into the Compiler Tray. • The Main Paddle draws the paper into the Compiler Tray, and then pushes the trailing edge of the paper against the end wall in the Compiler Tray.

  • Page 48: Stapler Section

    4025-Finisher Stapler Section The Stapler staples a bundle of paper in the Compiler Tray. When performing the stapling, the Stapler Unit starts moving along rails to the paper stapler position. The Stapler Unit moves to the front side when the right side of paper is stapled, or to the rear side when the left side of paper is stapled.

  • Page 49: Exit Sections

    4025-Finisher Exit Sections • When the stapler job is not performed At the specified pulses after the Fin Exit Path Sensor detects the leading edge of the paper, the Exit Pinch Roll Guide lowers to nip the paper with the Exit Roller. Then the rotation of the Exit Roller delivers the paper on the Stacker Tray.
  • Page 50 4025-Finisher Exit Components • The Exit Roller delivers paper to the Stacker Tray, and transfers paper to the Compiler Tray. • The Exit Pinch Roll Guide nips the paper with the Exit Roller to assist the paper to be delivered. •...

  • Page 51: Paper Stack Sections

    4025-Finisher Paper Stack Sections From the Finisher Exit section, the paper or a bundle of paper is delivered on the Stacker Tray. The Stacker Height Sensor detects the stack amount of bundles of paper, and moves up or down the Stacker Tray according to the stack amount. At the initialization, the absolute position of the Stacker Tray is recognized by the rotation of the Liner Encoder.
  • Page 52 4025-Finisher 1-40 Service Manual...
  • Page 53 4025-Finisher Paper Stack Components • The Stack Tray Paper Sensor detects the presence of paper on the Stacker Tray. • The Stacker Tray Position Sensor detects the current position of the Stacker Tray from the Liner Encoder. The Liner Encoder has three slits differently spaced along the edge, and according to these differently spaced slits, the Stacker Tray positions on the Finisher are classified into 25%, 50% and 100% positions.
  • Page 54 4025-Finisher 1-42 Service Manual...

  • Page 55: Top Tray Exit Sections

    4025-Finisher Top Tray Exit Sections After the trailing edge of the paper passes the Regi Roller, the paper moves toward Exit Top Gate via the Exit Top Gate. The paper is transferred toward the Top Exit by the rotation of the Exit Top Roller: Lower and Exit Top Roller: Middle on the Top Exit Chute. The paper transferred to the Top Exit section is delivered on the Top Tray by the rotation of the Exit Top Roller: Upper.

  • Page 56: Glossary Of Terms, Acronyms, And Abbreviations

    4025-Finisher Glossary of Terms, Acronyms, and Abbreviations Alternating Current AC Line Voltage The AC voltage level at the AC wall outlet, such as 110VAC or 220VAC Actuated A device, such as a switch or motor, that is switched on Actuator Mechanical device used to toggle a switch or a sensor Auxiliary Base Engine...

  • Page 57: Connectors

    4025-Finisher Earth Plate Electrical ground plate or ground strap EP Cartridge A sealed assembly that houses the xerographic drum, major xerographic components, and a finite supply of dry ink. The EP Cartridge is a CRU. Error Code A unique set of letters and numbers that the printer control system displays to indicate that a problem exists in a specific area of the printer Electronic Subsystem.
  • Page 58 4025-Finisher Jack. A female electrical connector Laser Refers to either the Laser Diode Assembly or to the laser beam Laser beam path The path the laser beam takes, through lenses and mirrors, from the Laser Diode to the surface of the drum Laser Diode Semiconductor device that generates the laser beam used in the Printhead...
  • Page 59 4025-Finisher Pre-Reg Pre-Registration Print cycle The printer creating and delivering one finished print Print surface The side of a sheet of paper that receives the printed image Power Supply Printed Wiring Board (sometimes referred to as PCB or Printed Circuit Board) Right Reg or Regi Registration...
  • Page 60 4025-Finisher Wire Harness A bundle of wires that form a single unit and are generally terminated with connectors at both ends 1-48 Service Manual...

  • Page 61: Diagnostic Information

    4025-Finisher 2. Diagnostic Information Start CAUTION: Remove the power cord from the printer or wall outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer or Finisher. Make sure your fingers are not under the printer when you lift or set the printer down.

  • Page 62: Status Messages

    4025-Finisher Status Messages These messages provide the operator with information on the current state of the printer. Generally, no user intervention is required. Service Messages These messages are displayed whenever the printer is in the Operator Intervention state, and the printer needs servicing.

  • Page 63: Accessing Additional Debug Information For Service Errors

    4025-Finisher Close Door Messages Close Door K Close Door or check Front Cover K Switch Close Cover J Close Top Cover or check Top Cover J Sensor Close Cover H Close Horizontal Transport Cover or check H-TRA Cover H Sensor Release Surface L Check Exit Roll Sensor Accessing Additional Debug Information for Service Errors...

  • Page 64: Service Error Code Table

    4025-Finisher Service Error Code Table Second Line Description Code Message 980 Finisher Comm. Finisher communication. Go to “980 - Error Code Service Check” on page 2-29. 981 Fin Non-Stapling Mechanical failure in stacker tray 1. Go to “981 - Stacker Tray Service Check” on page 2-29.

  • Page 65: Attendance Message Table

    4025-Finisher Attendance Message Table Second Line Flip Flop 1 Flip Flop 2 Description Message Open Door A Leave Staple Job in Finisher Register Area Open Door A Leave Staple Job in Finisher Register Area Open Door A Leave Staple Job in Finisher Register Area Open Door A...
  • Page 66 4025-Finisher Attendance Message Table Second Line Flip Flop 1 Flip Flop 2 Description Message Open Doors B,C Leave Staple Job in Finisher Input Area Open Doors A,B,C Leave Staple Job in Finisher Input Area Open Door C Leave Staple Job in Finisher Input Area Open Tray 5...
  • Page 67 4025-Finisher Attendance Message Table Second Line Flip Flop 1 Flip Flop 2 Description Message Open Cover H Leave Staple Job in Finisher Horizontal Transport Area - Go to “281 - Attendance Message” on page 2-13. Open Cover H Leave Staple Job in Finisher Horizontal Transport Area -...
  • Page 68 4025-Finisher Attendance Message Table Second Line Flip Flop 1 Flip Flop 2 Description Message Open Door K Leave Staple Job in Finisher Finisher Area - Go “289 - Attendance Message” on page 2-23. Open Door K Leave Staple Job in Finisher Finisher Area - Go “290 - Attendance...

  • Page 69: Service Checks Flowchart

    4025-Finisher Service Checks Flowchart How to Use the Service Checks Flowchart • Follow your problem to the individual Primary Service Check that corresponds to your error code, printer operation problem, or print image problem. • Follow the instructions presented in the Service Check. •...

  • Page 70: General Notes On Using Service Checks

    4025-Finisher General Notes on Using Service Checks • Unless indicated otherwise, the instruction “switch ON printer main power” means for you to switch ON printer power and let the printer proceed through power-on diagnostics and warm-up until it is online and ready to print. •...

  • Page 71: Service Checks

    4025-Finisher Service Checks Before entering the service checks: Is the AC power provided at the electrical outlet within specifications for this printer; either 110 V ac or 220 V ac? Is the AC power cord in good condition; neither frayed nor broken? Is one end of the AC power cord connected to the printer? Is the other end of the AC power cord plugged into a grounded three-prong AC electrical outlet?

  • Page 72: Attendance Message Service Checks

    4025-Finisher Attendance Message Service Checks 280 - Attendance Message Logic Control sensed that the H-Tra Input Sensor was not deactuated within a specified time after it was actuated. Step Actions and Questions PATH LOCATION INSPECTION Go to step 2 Go to step 5 Inspect the position of the sheet of paper in the H-Tra.
  • Page 73 4025-Finisher Step Actions and Questions The following Finisher FRUs and areas are associated with this specific problem. One or more of these FRUs or areas may have failed partially or completely. If you cannot isolate this problem using these steps, replace each FRU or troubleshoot each area listed below, one at a time, until you isolate and solve the problem.
  • Page 74 4025-Finisher Step Actions and Questions MCU BOARD Problem Go to step 6 solved Replace the MCU Board. Refer to the Printer Service Manual. Enter Diagnostics and check the H-Tra Input Sensor function. Insert then remove a sheet of paper into the sensor. Does the Operator Panel LCD change between OP and CL as you insert then remove the paper? The following Finisher FRUs and areas are associated with...
  • Page 75 4025-Finisher Step Actions and Questions PATH PAPER INSPECTION Go to step 6 Replace the suspect Drive Inspect the Drive Rolls in the Finisher, especially the Input Rolls Rolls and the Registration Rolls. Are all of the Drive Rolls in the Finisher clean and free of obvious wear and damage? DRIVE TRAIN TEST Go to step 7...
  • Page 76 4025-Finisher Step Actions and Questions FINISHER MAIN BOARD Problem Replace the Replace the Finisher Main Board. Go to “PWB Assembly- solved MCU Board Main Removal” on page 4-132. Enter Diagnostics and check the H-Tra Exit Sensor function. Insert then remove a sheet of paper into the sensor.
  • Page 77 4025-Finisher Step Actions and Questions SENSOR TEST Go to step 4 Go to step 3 Enter Diagnostics and check the H-Tra Exit Sensor function. Insert then remove a sheet of paper into the sensor. Does the Operator Panel LCD change between OP and CL as you insert then remove the paper? H-TRA EXIT SENSOR Problem...
  • Page 78 4025-Finisher Step Actions and Questions SENSOR TEST Go to step 4 Go to step 3 Enter Diagnostics and check the Finisher Input Path Sensor function. Does the Finisher Input Path Sensor test ok? FINISHER INPUT PATH SENSOR Problem Go to step 4 solved Replace the Finisher Input Path Sensor.
  • Page 79 4025-Finisher 286 - Attendance Message Logic Control sensed that the Finisher Input Path Sensor was not actuated within the specified time after the H- Tra Exit Sensor was deactuated. Step Actions and Questions PATH LOCATION INSPECTION Go to step 2 Go to step 5 Inspect the position of the sheet of paper on the H-Tra.
  • Page 80 4025-Finisher Step Actions and Questions The following Finisher FRUs and areas are associated with this specific problem. One or more of these FRUs or areas may have failed partially or completely. If you cannot isolate this problem using these steps, replace each FRU or troubleshoot each area listed below, one at a time, until you isolate and solve the problem.
  • Page 81 4025-Finisher Step Actions and Questions H-TRA INPUT SENSOR Problem Go to step 8 solved Replace the H-Tra Input Sensor. Go to “Sensors Removal” on page 4-20. Enter Diagnostics and check the H-Tra Input Sensor function. Insert then remove a sheet of paper into the sensor.
  • Page 82 4025-Finisher Step Actions and Questions FINISHER PATH SENSOR Problem Go to step 4 solved Replace the Finisher Path Sensor. Go to “Sensor, Input Path Removal” on page 4-41. Enter Diagnostics and check the Finisher Path Sensor function. Insert then remove a sheet of paper into the sensor.
  • Page 83 4025-Finisher 289 - Attendance Message Logic control sensed that the Finisher Path Sensor was not actuated within the specified time after the Finisher Input Sensor was actuated. Step Actions and Questions PATH LOCATION INSPECTION Go to step 2 Go to step 5 Inspect the position of the sheet of paper in the Finisher.
  • Page 84 4025-Finisher Step Actions and Questions The following Finisher FRUs and areas are associated with this specific problem. One or more of these FRUs or areas may have failed partially or completely. If you cannot isolate this problem using these steps, replace each FRU or troubleshoot each area listed below, one at a time, until you isolate and solve the problem.
  • Page 85 4025-Finisher Step Actions and Questions DRIVE TRAIN TEST Go to step 7 Replace the Finisher Main Enter Diagnostics and select Output Bin Tests. Select Feed Feed Motor Test, Output Bin 2 to run the Finisher Main Feed Motor. Does the Finisher Main Feed Motor run smoothly? DRIVE TRAIN INSPECTION Go to step 8 Replace the...
  • Page 86 4025-Finisher Step Actions and Questions FINISHER MAIN BOARD Problem Replace the solved MCU Board Replace the Finisher Main Board. Go to “PWB Assembly- Main Removal” on page 4-132. Enter Diagnostics and check the Finisher Exit Path Sensor function. Insert then remove a sheet of paper into the sensor.
  • Page 87 4025-Finisher Step Actions and Questions INTERLOCK TEST Go to step 4 Go to step 3 Enter Diagnostics and check the Exit Roll Interlock Switch function. Insert then remove a sheet of paper into the sensor. Does the Operator Panel LCD change between OP and CL as you insert then remove the paper? EXIT ROLL INTERLOCK SWITCH Problem...
  • Page 88 4025-Finisher Step Actions and Questions SENSOR TEST Go to step 4 Go to step 3 Enter Diagnostics and check the Compiler Tray Paper Sensor function. Insert then remove a sheet of paper into the sensor. Does the Operator Panel LCD change between OP and CL as you insert then remove the paper? COMPILER TRAY PAPER SENSOR Problem...

  • Page 89: Service Error Code Service Checks

    4025-Finisher Service Error Code Service Checks 980 - Error Code Service Check Logic control sensed that there is a communication problem between the printer and the Finisher. Step Actions and Questions RESET Problem Go to step 2 solved Switch off the printer and the Finisher. Wait one minute, then switch on the printer and the Finisher Is the error code gone? RESEAT...
  • Page 90 4025-Finisher Step Actions and Questions ENCODER ASSEMBLY Problem Go to step 4 solved Replace the Encoder Assembly. Enter Diagnostics and check the Stacker Tray Position Sensor function. Insert then remove a sheet of paper into the sensor. Does the Operator Panel LCD change between OP and CL as you insert then remove the paper? FINISHER MAIN BOARD Problem...
  • Page 91 4025-Finisher Step Actions and Questions JOGGER HOME POSITION SENSOR Problem Go to step 3 solved Replace the Jogger Home Position Sensor. Go to “Sensor, Jogger Home Position Removal” on page 4-68. Enter Diagnostics and check the Jogger Home F Sensor function. Insert then remove a sheet of paper into the sensor.
  • Page 92 4025-Finisher Step Actions and Questions JOGGER HOME POSITION SENSOR Problem Go to step 3 solved Replace the Jogger Home Position Sensor. Go to “Sensor, Jogger Home Position Removal” on page 4-68. Enter Diagnostics and check the Jogger Home R Sensor function. Insert then remove a sheet of paper into the sensor.
  • Page 93 4025-Finisher Step Actions and Questions EXIT ROLL OPEN/CLOSE HP SENSOR Problem Go to step 6 solved Replace the Exit Roll Open/Close HP Sensor. Go to “Motor Removal” on page 4-84. Enter Diagnostics and check the Exit Roll Open/Close HP Sensor. Insert then remove a sheet of paper into the sensor.
  • Page 94 4025-Finisher 985 - Error Code Service Check Logic control sensed that the Shift Roller failed. Step Actions and Questions SENSOR TEST Go to step 3 Go to step 2 Enter Diagnostics and check the Shift Roller HP Sensor function. Insert then remove a sheet of paper into the sensor. Does the Operator Panel LCD change between OP and CL as you insert then remove the paper? SHIFT ROLLER HP SENSOR...
  • Page 95 4025-Finisher Step Actions and Questions The following Finisher FRUs and areas are associated with this specific problem. One or more of these FRUs or areas may have failed partially or completely. If you cannot isolate this problem using these steps, replace each FRU or troubleshoot each area listed below, one at a time, until you isolate and solve the problem.
  • Page 96 4025-Finisher Step Actions and Questions FINISHER MAIN BOARD Problem Go to step 7 solved Replace the Finisher Main Board. Go to “PWB Assembly- Main Removal” on page 4-132. Enter Diagnostics and check the Sensor and/or Punch Assembly function. Insert then remove a sheet of paper into the sensor.
  • Page 97 4025-Finisher Step Actions and Questions FINISHER MAIN BOARD Problem Go to step 5 solved Replace the Finisher Main Board. Go to “PWB Assembly- Main Removal” on page 4-132. Check the Stapler function. Does the Stapler function correctly? MCU BOARD Problem Go to step 6 solved Replace the MCU Board.
  • Page 98 4025-Finisher Step Actions and Questions STAPLER ASSEMBLY Problem Go to step 9 solved Replace the Stapler Assembly. Go to “Stapler I Assembly Removal” on page 4-92. From the Finishing Menu, select the following: Copies 5, Staple ON, Staple Dual Does the Stapler Base move freely back and forth? STAPLER TRAVERSE MOTOR Problem Go to step 7...
  • Page 99 4025-Finisher Step Actions and Questions TRAVERSE MOTOR TEST Go to step 4 Go to step 6 From the Finishing Menu, select the following: Copies 5, Staple ON, Staple Dual Does the Stapler Traverse Motor test ok? STAPLER BASE INSPECTION Go to step 7 Go to step 5 From the Finishing Menu, select the following: Copies 5, Staple ON, Staple Dual...
  • Page 100 4025-Finisher 990 - Error Code Service Check Logic control sensed that there is a problem with the Stapler Dual Position function. Step Actions and Questions SENSOR TEST Go to step 3 Go to step 2 Enter Diagnostics and check the Stapler Front Sensor function. Insert then remove a sheet of paper into the sensor.
  • Page 101 4025-Finisher Step Actions and Questions FINISHER MAIN BOARD Problem Go to step 10 solved Replace the Finisher Main Board. Go to “PWB Assembly- Main Removal” on page 4-132. Check the Stapler function. Does the Stapler function correctly? MCU BOARD Problem solved Replace the MCU Board.
  • Page 102 4025-Finisher Step Actions and Questions STAPLER TRAVERSE MOTOR Problem Go to step 7 solved Replace the Stapler Traverse Motor. Go to “Traverse Motor Assembly Removal” on page 4-102. From the Finishing Menu, select the following: Copies 5, Staple ON, Staple Dual Does the Stapler Traverse Motor test ok? FINISHER MAIN BOARD Problem...
  • Page 103 4025-Finisher Step Actions and Questions SWING MOTOR Problem Go to step 7 Replace the Swing Motor. Go to “Motor Assembly-Swing solved Removal” on page 4-104. From the Finishing Menu, select the following: Copies 5, Staple ON, Staple Dual Does the Swing Motor test ok? FINISHER MAIN BOARD Problem Go to step 6...
  • Page 104 4025-Finisher Step Actions and Questions MCU BOARD Problem Go to step 6 solved Replace the MCU Board. Refer to the Printer Service Manual. Check the Stapler function. Does the Stapler function correctly? The following Finisher FRUs and areas are associated with this specific problem.

  • Page 105: Diagnostic Aids

    4025-Finisher 3. Diagnostic Aids Entering Diagnostic Mode Press and hold Go and Return as you turn on the printer to access Diagnostic Mode. While the Diagnostic Menu is active, all host interfaces are offline. Diagnostics includes: Button Test, LCD test, Error Log, Printer Setup, Configuration ID, Device Test, base Sensor Test, and a demo or print test page.

  • Page 106: Finisher Tests

    4025-Finisher Finisher Tests Staple Test This test verifies the operation of the staple mechanism in the finisher. The media used in this test is fed from the default paper source. After selecting a destination bin, the printer feeds eight pieces of media and accumulates all eight pieces of media in the finisher accumulator.
  • Page 107 4025-Finisher • Stk Hight Lower • Stk Tray Low Lmt • Stack Tray Pos • Dock Interlock • Top Cover J • Exit Roll • Front Cover K • Punch Dust Box M • Close Door Message • H-Tra Gate •...
  • Page 108 4025-Finisher Service Manual...

  • Page 109: Removal And Replacement Procedures

    4025-Finisher 4. Removal and Replacement Procedures This section contains the removal and replacement procedures for major parts within the printer Finisher. Before you begin any Removal and Replacement Procedure: Switch OFF the printer power. Disconnect the AC power cord from the electrical outlet. Wear an electrostatic discharge wrist strap to protect sensitive printer parts from damage.

  • Page 110: Cover, Rear Removal

    4025-Finisher Cover, Rear Removal Removal • Remove two screws that secure the Rear Cover to the H-Tra, and then remove the cover. Replacement Align the Rear Cover in the mounting position so that the shaft and three tabs of the H-Tra are met with the bearings and shape of the Rear Cover and that the harness passes through the notch.

  • Page 111: Spring Tension 80, Sensor And Harness Earth Removal

    4025-Finisher Spring Tension 80, Sensor and Harness Earth Removal 0, Sensor and Harness Earth Removal Removal Remove the Rear Cover. Unhook the tension spring 80 from the hole in the H-Tra frame. Remove two screws that secure the tension bracket assembly to the H-Tra, and remove the tension bracket assembly together with tension spring 80.
  • Page 112 4025-Finisher Replacement Secure the harness earth to the H-Tra with two screws. Align the sensor with the mounting position in the H-Tra, and push it in with your fingers to secure. Plug the connector (P/J 260) of the H-Tra harness assembly to the sensor. Align the tension bracket assembly with the mounting position in the H-Tra, and secure it with two screws.

  • Page 113: Belt-Sync Removal

    4025-Finisher Belt-Sync Removal Removal Remove the Rear Cover. Unplug the connector (P/J 260) of the H-Tra harness assembly from the sensor. Remove the Pulley 2, tension spring 80, sensor and earth harness. Remove the Solenoid Assembly-gate in. Remove the Transport Gear Kit. Remove the Bracket Assembly.

  • Page 114: Bracket Assembly Removal

    4025-Finisher Bracket Assembly Removal Removal Remove the Rear Cover. Unplug the connector (P/J 260) of the H-Tra harness assembly from the sensor. Remove the Pulley 2, tension spring 80, sensor and earth harness. Remove the Solenoid Assembly-gate in. Remove the Transport Gear Kit. Remove three screws that secure the bracket assembly together with three spring plate to the H-Tra, and remove three spring plate.

  • Page 115: Tray Harness Assembly Removal

    4025-Finisher Tray Harness Assembly Removal Removal Remove the Rear Cover. Open the Top Cover of the H-Tra. Remove the Sensor. Unclamp the H-Tra harness assembly at seven places on the H-Tra. Unclamp the H-Tra harness assembly at four places on the H-Tra. Unplug the connector (P/J 256M) of the solenoid assembly.
  • Page 116 4025-Finisher Replacement Insert the connectors (P/J 275M,259) and the harnesses of the spring tension 80 and sensor full from the hole on the rear of the H-Tra, and clamp them at four places on the top surface of the H-Tra. Insert the connector (P/J 263) and the harness of the spring tension 80 from the hole on the rear of the H-Tra, and clamp them at seven places on the top surface of the H- Tra.

  • Page 117: Transport Gear Kit Removal

    4025-Finisher Transport Gear Kit Removal Removal Remove the Rear Cover. Remove the Pulley 2, Spring Tension 80, Sensor and Harness Earth. Remove the Solenoid Assembly-Gate. Remove two screws that secure the Bracket Assembly to the H-Tra, and shift the Bracket Assembly in the arrow direction. Remove two screws that secure the Idler Bracket, and remove the Idler Bracket.
  • Page 118 4025-Finisher Replacement Align the Bracket Assembly Drive with the mounting position in the H-Tra, and secure it with two screws. Place the Belt-sync through the shaft of the Bracket Assembly Drive. Insert the Gear Pulley 32/26 into the shaft of the Bracket Assembly Drive, and engage the Belt-sync a little with the Gear Pulley 32/26 and push it in position.

  • Page 119: Solenoid Assembly-Gate In Removal

    4025-Finisher Solenoid Assembly-Gate In Removal Removal Remove the Rear Cover. Unplug the connector (P/J 256M) of the Solenoid Assembly. Unclamp the harness of the Solenoid Assembly at five places on the Bracket Assembly. Pull the Roller off the shaft of the Bracket Assembly. Remove two screws that secure the Cover Assembly Solenoid, and remove the Cover Assembly Solenoid together with the Solenoid Assembly-Gate In.
  • Page 120 4025-Finisher Replacement Sliding the Link Assembly Damper so that the convex of the Solenoid Assembly is engaged with the concave of the plunger of the Solenoid Assembly, mount the Link Assembly Damper. Insert the Spring Solenoid into the plunger of the Solenoid Assembly, and push the Link Assembly Damper together with the Spring Solenoid and the plunger of the Solenoid Assembly into the hole in the solenoid.

  • Page 121: Cover Top H-Tra Assembly Removal

    4025-Finisher Cover Top H-Tra Assembly Removal Removal Insert a flat-tip screwdriver between the cover on the front of the H-Tra and the Cover Assembly Open, and deflect the cover on the front of the H-Tra to release the bearing on the front of the Cover Assembly Open from the shaft on the front of the H- Tra.

  • Page 122: Roll Transport And Aligner Roll Kit Removal

    4025-Finisher Roll Transport and Aligner Roll Kit Removal 4-14 Service Manual...
  • Page 123 4025-Finisher Removal Remove the Rear Cover. Unplug the connector (P/J 260) of the H-Tra harness assembly from the Sensor. Remove the Pulley 2, Spring Tension 80, Sensor and Harness Earth. Remove the Solenoid Assembly-Gate In. Remove the Transport Gear Kit. Remove the Bracket Assembly.

  • Page 124: Entrance Roll Removal

    4025-Finisher Entrance Roll Removal 4-16 Service Manual...
  • Page 125 4025-Finisher Removal Remove the Rear Cover. Unplug the connector (P/J 260) of the H-Tra harness assembly from the Sensor. Remove the Pulley 2, Spring Tension 80, Sensor and Harness Earth. Remove the Solenoid Assembly-Gate In. Remove the Transport Gear Kit. Remove the Bracket Assembly.

  • Page 126: Sensor And Sensor Full Removal

    4025-Finisher Sensor and Sensor Full Removal 4-18 Service Manual...
  • Page 127 4025-Finisher Removal Open the top cover of the H-Tra, and unhook the Cover Sensor Full at two places from the back of the H-Tra, and remove the Cover Sensor Full. (Figure 1) Remove the screw that secures the Bracket Path Sensor to the H-Tra, and remove the Bracket Path Sensor together with the Spring Tension 80 and Clamp MINI.

  • Page 128: Sensors Removal

    4025-Finisher Sensors Removal 4-20 Service Manual...
  • Page 129 4025-Finisher Removal Open the top cover of the H-Tra, and unhook the Cover Sensor Path at two places from the back of the H-Tra, and remove the Cover Sensor Path. Remove the Rear Cover. Unplug the connector (P/J 261) of the H-Tra harness assembly from the Sensor. Remove the screw that secures to the H-Tra from the Plate Sensor Photo, and lift up the Plate Sensor Photo together with the Sensor and Clamp MINI.

  • Page 130: Shaft Transport Removal

    4025-Finisher Shaft Transport Removal Removal Invert the H-Tra, and insert a flat-tip screwdriver into the hook of the Frame Assembly that secures the Shaft Transport on the front side, and pull off the Shaft Transport on the front side toward the right. For the Shaft Transport on the rear side, perform the above step in the same manner.

  • Page 131: Cover-Jogging Removal

    4025-Finisher Cover-Jogging Removal Removal • Remove two screws that secure the Cover-Jogging to the Finisher, and remove the Cover-Jogging. Replacement • Align the Cover-Jogging with the mounting position, and secure it with two screws. 4-23 Removal and Replacement Procedures...

  • Page 132: Tray-Lower Removal

    4025-Finisher Tray-Lower Removal Removal Loosen two screws on the Cover-Top F that secure the Tray-Lower and are located under the Bracket Tray Lower. Lift up and remove the Tray-Lower. Replacement From the top, insert two notches of the Tray-Lower into a space between the sheet metal of the Bracket Tray Lower and two screws.

  • Page 133: Cover-Top, Front And Rear Removal

    4025-Finisher Cover-Top, Front and Rear Removal Removal Remove the Cover-Jogging. Remove two screws that secure the Cover-Top, Front, and remove the Cover-Top, Front. Remove two screws that secure the Cover-Top, Rear, and remove the Cover-Top, Rear. Replacement Align the Cover-Top, Rear with the mounting position, and secure it with two screws. Align the Cover-Top, Front with the mounting position, and secure it with two screws.

  • Page 134: Cover-Open, Cover-Front And Kit Stud Cover Removal

    4025-Finisher Cover-Open, Cover-Front and Kit Stud Cover Removal Removal Remove the Cover-Jogging. Open the Cover-Open, Front, and remove three screws that secure the Cover-Front to the Finisher. Remove four screws that secure the Cover-Front, and remove the Cover-Front together with the Stud Cover and Cover-Open, Front. From the back of the Cover-Front, face the notch of the upper Stud Cover toward the back.
  • Page 135 4025-Finisher Replacement Aligning the shaft in the center of the Cover-Front with the bearing in the center of the Cover-Open, Front, push them in to mount the Cover-Open, Front on the Cover- Front. Insert the Stud Cover into the hole at the bottom surface of the Cover-Open, Front, and secure the lower Cover-Open, Front.

  • Page 136: Switch Cover Front Removal

    4025-Finisher Switch Cover Front Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Unplug the connector (S2-1) of the Harness DC from the Switch Cover Front. Remove two screws that secure the Finisher from the Switch Cover Front, and remove the Switch Cover Front.

  • Page 137: Latch Assembly And Switch Docking Removal

    4025-Finisher Latch Assembly and Switch Docking Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front. Remove the Cover-Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove two screws that secure to the Finisher from the Bracket Inlet, and shift the Bracket Inlet together with the Inlet to the right direction.
  • Page 138 4025-Finisher Replacement Align the Switch Docking with the mounting position in the Latch Assembly, and secure it with two screws. Plug the connector (S1-1) of the Harness Docking to the Switch Docking. Align the Cover Switch Docking with the mounting position in the Latch Assembly, and secure it with three screws.

  • Page 139: Kit H-Tra Bracket And Screw Removal

    4025-Finisher Kit H-Tra Bracket and Screw Removal Removal Remove the Thumbscrews that secures Docking Bracket Front to the Finisher, and remove the Thumbscrews together with the Docking Bracket Front. For the Docking Bracket Rear and Thumbscrews on the rear side, perform the above step in the same manner.

  • Page 140: Cover-Rear Removal

    4025-Finisher Cover-Rear Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front. Remove the screws that secure to the Finisher from the Cover-Rear, and remove the Cover-Rear. Replacement Align the Cover-Rear with the mounting position in the Finisher, and secure the Cover-Rear with the screws.

  • Page 141: Cover-Top Left Removal

    4025-Finisher Cover-Top Left Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove two screws that secure to the Finisher from the Cover-Top, Left, and remove the Cover-Top, Left. Replacement Align the Cover-Top, Left with the mounting position in the Finisher, and secure it with two screws.

  • Page 142: Top Center Cover Assembly Removal

    4025-Finisher Top Center Cover Assembly Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove four screws that secure to the Finisher from the Top Center Cover Assembly, and remove the Top Center Cover Assembly. Replacement Align the Top Center Cover Assembly with the mounting position in the Finisher, and secure it with four screws.

  • Page 143: Kit Bracket Assembly And Screw Removal

    4025-Finisher Kit Bracket Assembly and Screw Removal Removal Place several-ply cardboards or newspapers on the floor, and carefully tumble the Finisher from the left side. Remove two Thumbscrews on the front side. Sliding the Bracket Assembly on the front side toward the inside, remove the Bracket Assembly.

  • Page 144: Frame Post Removal

    4025-Finisher Frame Post Removal Removal Place several-ply cardboards or newspapers on the floor, and carefully tumble the Finisher from the left side. Remove the Kit Bracket Assembly and Screw. Remove the Cap-End. Remove the Caster Assembly. Remove E-rings that secure the Pin Right and Roll in the right and left sides of the front, and remove the Pin Right and Roll.
  • Page 145 4025-Finisher Replacement Insert the Frame Post in parallel to the Finisher, and align four holes in the Frame Post with four holes in the Finisher. Aligning the hole in the Roll with the shaft holes for the wheels located on the rear left side, insert the Pin Right from the rear side and secure it with an E-ring.

  • Page 146: Cap-End Removal

    4025-Finisher Cap-End Removal Removal Insert a small screwdriver between the Cap-End and Frame Post on the front side, and pull off the Cap-End. For the rear side, perform the above step in the same manner. Replacement Align the Cap-End with the mounting position in the Frame Post on the front side, and mount the Cap-End.

  • Page 147: Caster Assembly Removal

    4025-Finisher Caster Assembly Removal Removal Place several-ply cardboards or newspapers on the floor, and carefully tumble the Finisher from the left side. Remove four screws that secure to the Frame Post from the Caster Assembly on the front side, and remove the Caster Assembly on the front side. For the rear side, perform the above step in the same manner.

  • Page 148: Lever Assembly Removal

    4025-Finisher Lever Assembly Removal Removal Remove the screw that secures to the Rail from the Lever Assembly, and remove the Lever Assembly. Replacement Align the Lever Assembly with the mounting position in the Rail, and secure it with a screw. 4-40 Service Manual...

  • Page 149: Sensor, Input Path Removal

    4025-Finisher Sensor, Input Path Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover Top Left. Remove the Top Center Cover Assembly. Unplug the connector (P/J 1) of the Harness Sensor from the Sensor, Input Path. Remove the screw that secures the Bracket-Sensor, and lift up the Bracket-Sensor together with the Sensor, Input Path and Clamp.

  • Page 150: Sensor, Exit Path Removal

    4025-Finisher Sensor, Exit Path Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Unplug the connector (P/J 4) of the Harness Sensor from the Sensor, Exit Path. Unhook the Sensor, Exit Path at four places, and remove the Sensor, Exit Path. Replacement Align the Sensor, Exit Path with the mounting position in the Finisher, and mount the Sensor, Exit Path.

  • Page 151: Roll Assembly-Regi Removal

    4025-Finisher Roll Assembly-REGI Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Top Center Cover Assembly. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove the Knob, Regi Roller. Remove the Puncher. Remove the Guide Assembly-Dust. Remove the Bearing that secures the shaft on the front side of the Roll Assembly- REGI.

  • Page 152: Roll Transport Removal

    4025-Finisher Roll Transport Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove the Cover-Rear. Remove the Cover Top Left. Remove the Top Center Cover Assembly. Remove the Sensor, Input Path. Remove the Kit Drive Assembly.
  • Page 153 4025-Finisher Replacement WARNING: In the following steps, take care not to allow the harness to get stuck to the roller. Let the shaft on the rear side of the Roll Transport through under the harness of the Finisher, and insert it into the bearing on the rear side. Insert the shaft on the front side of the Roll Transport into the bearing on the front side of the Finisher, and secure it with the Bearing.

  • Page 154: Kit Drive Assembly Removal

    4025-Finisher Kit Drive Assembly Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Unclamp the harness at six places on the Drive Assembly. Remove the E-ring that secures two Gear and Gear to the Roll Assembly-REGI. Remove two screws that secure to the Finisher from the Gear and Belt Assembly, and remove the Gear and Belt Assembly together with the Gear.
  • Page 155 4025-Finisher Replacement Insert the Flange and Gear into the Finisher, and secure it with an E-ring. Insert the Gear into the shaft of the Roll Assembly-REGI. Engage the belt on the right side of the Drive Assembly to the Gear, and also engage the belt on the left side of the Drive Assembly to the Gear.

  • Page 156: Chute Assembly-Inlet Removal

    4025-Finisher Chute Assembly-Inlet Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove two screws that secure to the Finisher from the Chute Assembly-Inlet. Pull the Chute Assembly-Inlet off the Finisher toward the left. Replacement Insert the Chute Assembly-Inlet from the left side of the Finisher, and align it with the mounting position.

  • Page 157: Kit Invert Guide Removal

    4025-Finisher Kit Invert Guide Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove the screw that secures the Invert Guide Assembly, Stud and Spring on the rear side, and remove the Stud and Spring while unhooking the Spring from the notch of the Finisher frame.
  • Page 158 4025-Finisher Replacement Insert the Stud from the short hook side of the Spring. Insert the Invert Guide Assembly from the front side of the Finisher, align it with the mounting position. Engaging the long hook of the Spring with the notch of the Finisher frame, engage the short hook of the Spring with the concave of the Invert Guide Assembly, and secure the Invert Guide Assembly, Spring and Stud on the front side to the Finisher.

  • Page 159: Kit Buffer Chute Removal

    4025-Finisher Kit Buffer Chute Removal 4-51 Removal and Replacement Procedures...
  • Page 160 4025-Finisher Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Unhook the Spring from the hole in the frame on the front of the Finisher. Unhook the Spring from the hole in the frame on the rear of the Finisher. Remove the screw that secures the rear of the Chute-Buffer Assembly.

  • Page 161: Knob, Regi Roller Removal

    4025-Finisher Knob, Regi Roller Removal Removal Open the Cover-Rear. Pull off the Knob, Regi Roller. Replacement Insert the Knob, Regi Roller onto the shaft of the Roll Assembly-REGI. Close the Cover-Rear. 4-53 Removal and Replacement Procedures...

  • Page 162: Transport Motor Assembly Removal

    4025-Finisher Transport Motor Assembly Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove the Kit Drive Assembly. Unplug the connector (CN 1) of the Harness Motor from the Transport Motor Assembly. Remove four screws that secure to the Finisher from the Transport Motor Assembly, and remove the Transport Motor Assembly.

  • Page 163: Puncher Removal

    4025-Finisher Puncher Removal 4-55 Removal and Replacement Procedures...
  • Page 164 4025-Finisher Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove the Kit Roll Pinch. Remove the Sensor, Path. Unplug the connector (CN 18) of the Harness Motor from the Clutch of the Puncher. Unclamp the harness of the Puncher at two places on the Finisher. Remove two screws from the Puncher that secure the Finisher.

  • Page 165: Kit Roll Pinch Removal

    4025-Finisher Kit Roll Pinch Removal Removal Open the Top Center Cover Assembly. Remove the screw that secures to the Finisher from the Pinch Roll, and remove the Pinch Roll and Spring Plate. Loosen the bracket of the Pinch Roll, and remove the roller of the Pinch Roll. Repeat step 3 until you have removed all, or the necessary, rollers of the Kit Roll Pinch.

  • Page 166: Sensor, Path Removal

    4025-Finisher Sensor, Path Removal Removal Open the Top Center Cover Assembly. Remove the second Kit Roll Pinch from the rear. Unplug the connector (P/J 2) of the Harness Sensor from the Sensor, Path. Pressing the leading end of the Sensor, Path downward with your finger, disengage two hooks on the upper side by pushing with a small screwdriver.

  • Page 167: Guide Assembly-Dust Removal

    4025-Finisher Guide Assembly-Dust Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove the Kit Roll Pinch. Remove the Sensor, Path. Remove the Puncher. Lift up the Guide Assembly-Dust a little, pull it off the notch of the Finisher frame, and tilt the Guide Assembly-Dust to remove them upward.

  • Page 168: Bottle Assembly-Dust Removal

    4025-Finisher Bottle Assembly-Dust Removal Removal Open the Cover-Open, Front. Pull off the Bottle Assembly-Dust. Replacement Insert the Bottle Assembly-Dust into the Finisher. Close the Cover-Open, Front. 4-60 Service Manual...

  • Page 169: Sensor Dust-Assembly Removal

    4025-Finisher Sensor Dust-Assembly Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Unplug the connector (P/J 18) of the Harness H-Tra from the Sensor Dust Assembly. Remove the screw that secures to the Finisher from the Sensor Dust Assembly, and remove the Sensor Dust Assembly.

  • Page 170: Inner Cover Removal

    4025-Finisher Inner Cover Removal Removal Open the Cover-Open, Front. Remove the Bottle Assembly-Dust. Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove two screws on the front that secure to the Finisher from the Inner Cover. Remove four screws that secure to the Finisher from the PWB Chassis, and shift aside the PWB Chassis together with the PWB Assembly-Main toward the front.
  • Page 171 4025-Finisher Replacement Align the Inner Cover with the mounting position in the Finisher, and bundle the harness of the stapler with the clamp of the Inner Cover. Shifting aside the PWB Chassis together with the PWB Assembly-Main toward the front, secure the rear of the Inner Cover to the Finisher with two screws. Secure the front of the Inner Cover to the Finisher with two screws.

  • Page 172: Sensor Bottle Kit Removal

    4025-Finisher Sensor Bottle Kit Removal 4-64 Service Manual...
  • Page 173 4025-Finisher Removal Remove the Cover-Jogging. Remove the Cover-Top, Rear. Remove the Cover-Rear. Open the Cover-Open, Front. Remove the Bottle Assembly-Dust. WARNING: In the following steps, do not detach the frame metal (provisional) far away because the connector (P/J 14) of the Photo Sensor is still connected to the frame metal (provisional).

  • Page 174: Kit Motor Jogging Removal

    4025-Finisher Kit Motor Jogging Removal 4-66 Service Manual...
  • Page 175 4025-Finisher Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Sensor Assembly. Remove the Sensor, Jogger Home Position. Unplug the connector (CN 3) of the Harness Motor from the Stepping Motor (Front). Unplug the connector (CN 4) of the Harness Motor from the Stepping Motor (Rear). Remove four screws that secure to the Finisher from the Jogging Assembly, and remove the Jogging Assembly.

  • Page 176: Sensor, Jogger Home Position Removal

    4025-Finisher Sensor, Jogger Home Position Removal 4-68 Service Manual...
  • Page 177 4025-Finisher Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Sensor Assembly. WARNING: In the following steps, do not detach the Bracket far away because the connector (P/J 8) of the Sensor (Front) is still connected. Remove the screw that secures the Bracket (Front) to the Finisher, and lift up the Bracket (Front) together with the Sensor (Front).

  • Page 178: Plate-Jogger Removal

    4025-Finisher Plate-Jogger Removal Removal Remove the Tray-Lower. Remove the Cover-Jogging. Remove the screw that secures the Plate-Jogger (Front) to the Frame Assembly- Jogger, and separate two brackets of the Frame Assembly-Jogger that sandwich the Plate-Jogger (Front), and then remove the Plate-Jogger (Front). For the Plate-Jogger (Rear), perform the above step in the same manner.

  • Page 179: Kit Shift Assembly Removal

    4025-Finisher Kit Shift Assembly Removal 4-71 Removal and Replacement Procedures...
  • Page 180 4025-Finisher 4-72 Service Manual...
  • Page 181 4025-Finisher Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Mount the Sensor Assembly. Remove the Kit Shift Motor. Remove the Kit Motor Jogging. Remove the Kit Shift Assembly. Remove the Cover-Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove the Compiler Roll and Roll Shaft.
  • Page 182 4025-Finisher Replacement Insert the rear of the Kit Shift Assembly into the mounting hole in the frame on the rear of the Finisher. Insert the front of the Kit Shift Assembly into the mounting hole in the frame on the front of the Finisher, and align it with the mounting position.

  • Page 183: Knob, Shift Unit Removal

    4025-Finisher Knob, Shift Unit Removal Unit Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove the screw that secures to the shaft of the Frame Assembly-Roll, Shift from the Knob, Shift Unit, and pull off the Knob, Shift Unit. Replacement Insert the Knob, Shift Unit into the shaft of the Frame Assembly-Roll, Shift, and secure it with a screw.

  • Page 184: Kit Shift Motor Removal

    4025-Finisher Kit Shift Motor Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Sensor Assembly. Remove the Kit Shift Motor. Remove the Kit Motor Jogging. Unplug the connector (CN 5) of the Harness Motor from the Motor-MP5. Remove two screws that secure to the Damper from the Finisher, and remove the Damper together with the Gear and Motor-MP5.

  • Page 185: Motor Assembly-Mp2 Removal

    4025-Finisher Motor Assembly-MP2 Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Rear. Remove the Cover-Rear. Unclamp the harness of the Clamp. Unplug the connector (CN 2) of the Harness Motor from the Motor Assembly-MP2. Remove the screw that secures to the Motor Assembly-MP4 from the Motor Assembly-MP2.
  • Page 186 4025-Finisher Replacement Insert the Bearing into the Motor Assembly-MP2. Align the Motor Assembly-MP2, together with the Bearing, with the mounting position in the Finisher so that the hole in the Bearing enters the shaft of the Frame Assembly-Roll, Shift, and secure them with two screws. Secure the Motor Assembly-MP2 to the Motor Assembly-MP4 with a screw.

  • Page 187: Sensor, Exit Path Removal

    4025-Finisher Sensor, Exit Path Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Sensor Assembly. Unplug the connector (P/J 5) of the Harness Exit from the Sensor. Unhook the Sensor at three places, and remove the Sensor. Replacement Align the Sensor with the mounting position in the Compiler Guide to secure it.

  • Page 188: Compiler Roll And Roll Shaft Removal

    4025-Finisher Compiler Roll and Roll Shaft Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Sensor Assembly. Remove the Sensor, Jogger Home Position. Remove the Kit Motor Jogging. Remove two screws that secure to the Shaft from the Support, and remove the Support.

  • Page 189: Sensor, Exit Roller Open/Close Home Position Removal

    4025-Finisher Sensor, Exit Roller Open/Close Home Position Removal Removal Remove the Cover-Jogging and the Cover-Top, Rear. Remove the Motor Assembly MP2. Unplug the connector (CN 4) of the Harness Motor from the Motor Assembly-MP4. Unplug the connector (P/J 6) of the Harness Sensor from the Sensor, Exit Roller Open/Close Home Position.

  • Page 190: Exit Roll Sensor Removal

    4025-Finisher Exit Roll Sensor Removal Removal Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Sensor Assembly. Unplug the connector (CN 43) of the Harness Motor from the Exit Roll. Remove the screw that secures to the Exit Roll, and remove the Exit Roll. Replacement Align the Exit Roll with the mounting position in the Compiler Guide to secure it.

  • Page 191: Kit Gear Front Removal

    4025-Finisher Kit Gear Front Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove the Motor Assembly-MP4. Unclamp the harness of the Clamp. Remove the E-ring that secures the Pulley to the shaft of the Paddle Shaft Assembly. Remove two screws that secure to the Finisher from the Bracket, and pull off the Bracket together with the Bearing, Clamp and Kit Gear Front toward the front.

  • Page 192: Motor Removal

    4025-Finisher Motor Removal Removal Remove the Cover-Top, Front. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Unplug the connector (CN 3) of the Harness Motor from the Motor. Remove the screws that secure to the Finisher from the Motor, and remove the Motor.

  • Page 193: Kit Gear Rear Removal

    4025-Finisher Kit Gear Rear Removal 4-85 Removal and Replacement Procedures...
  • Page 194 4025-Finisher Removal Remove the Cover-Jogging. Remove the Cover-Top, Front. Remove the Compiler Roll and Roll Shaft. Note: In the following steps, removing the Lever, Spring and Sector Gear allows the Pin inserted into the hole in the Shaft to be unsecured. Take care not to drop or lose it. Remove the E-ring that secures the Lever, Spring and Sector Gear to the Shaft, and pull off the Lever, Spring and Sector Gear.

  • Page 195: Motor Assembly-Mp4 Removal

    4025-Finisher Motor Assembly-MP4 Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front. Unplug the connector (CN 4) of the Harness Motor from the Motor Assembly-MP4. Remove the screws that secure to the Finisher from the Motor Assembly-MP4, and remove the Motor Assembly-MP4 with the Sensor, Exit Roller Open/Close Home Position.

  • Page 196: Staple Stage Assembly, Stack Roll Shaft, No Paper Sensor Stapler Removal

    4025-Finisher Staple Stage Assembly, Stack Roll Shaft, No Paper Sensor Stapler Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove the Cover-Rear. Remove the Kit Motor Jogging. Remove the Motor.
  • Page 197 4025-Finisher Release the belt of the Staple Stage Assembly from the gear of the Stack Roll Shaft, and remove the Stack Roll Shaft from the Finisher Disconnect the connector (P/J 13) connector of the No Paper Sensor Stapler attached to the Staple Stage Assembly. Remove the Staple Stage Assembly together with the No Paper Sensor Stapler from the cavity on the front of the Finisher.

  • Page 198: Stack Arm Assembly, No Paper Sensor Tray Lower Removal

    4025-Finisher Stack Arm Assembly, No Paper Sensor Tray Lower Removal Removal Remove the Cover-Jogging. Remove the Tray-Lower. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove the Right Cover. Unplug the connector (CN 41) of the Harness Motor from the Stack Arm Assembly.
  • Page 199 4025-Finisher Replacement Secure the No Paper Sensor Tray Lower to the Stack Arm Assembly with screw. Align the Stack Arm Assembly and No Paper Sensor Tray Lower with the mounting position in the Finisher. Plug the connector (P/J 14) of the (PL) to the No Paper Sensor Tray Lower. Plug the connector (CN 41) of the Harness Motor to the Stack Arm Assembly.

  • Page 200: Stapler I Assembly Removal

    4025-Finisher Stapler I Assembly Removal 4-92 Service Manual...
  • Page 201 4025-Finisher 4-93 Removal and Replacement Procedures...
  • Page 202 4025-Finisher 4-94 Service Manual...
  • Page 203 4025-Finisher Removal Remove the Cartridge. Remove the Bottle Assembly-Dust. Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove the Stapler Assembly. Remove the Inner Cover. Remove six screws that secure the Cover Upper Left Assembly to the frame of the Finisher, and remove the Cover Upper Left Assembly.
  • Page 204 4025-Finisher Plug the connector (CN 8) of the Harness Motor to the Motor Assembly-MP8. (Figure 2) Mount the Latch Assembly and Switch Docking. Align the Cover Upper Left Assembly, with the mounting position in the frame of the Finisher, and secure it with six screws. (Figure 1) Mount the Inner Cover.

  • Page 205: Stapler Ii Assembly Removal

    4025-Finisher Stapler II Assembly Removal Removal Open the Cover-Open, Front. Unplug the connector (CN 10) of the Stapler harness assembly from the Stapler Assembly. Turn the knob of the stapler counterclockwise to face the stapler toward the front. Remove two screws that secure to the Stapler Assembly from the Stapler Holder. Lifting up the front of the Stapler Assembly, and pull it off.

  • Page 206: Stapler Harness Assembly Removal

    4025-Finisher Stapler Harness Assembly Removal 4-98 Service Manual...
  • Page 207 4025-Finisher 4-99 Removal and Replacement Procedures...
  • Page 208 4025-Finisher Removal Remove the Cartridge and the Bottle Assembly-Dust. Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove the Stapler Assembly. Remove the Inner Cover. Remove six screws that secure the Cover Upper Left Assembly to the frame of the Finisher, and remove the Cover Upper Left Assembly.

  • Page 209: Cartridge Removal

    4025-Finisher Cartridge Removal Removal Open the Cover-Open, Front. Lower the Lever of Stapler Assembly, and remove the Cartridge. Replacement Insert the Cartridge into the insertion slot of the Stapler Assembly to mount the Cartridge. Close the Cover-Open, Front. 4-101 Removal and Replacement Procedures...

  • Page 210: Traverse Motor Assembly Removal

    4025-Finisher Traverse Motor Assembly Removal Removal Remove the Cartridge. Remove the Bottle Assembly-Dust. Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove the Inner Cover. Remove six screws that secure the Cover Upper Left Assembly to the frame of the Finisher, and remove the Cover Upper Left Assembly.
  • Page 211 4025-Finisher Replacement Align the Motor Assembly-MP8 with the mounting position in the Damper, and secure it with two screws. Insert the Gear into the shaft of the Motor Assembly-MP8, and secure it with an E- ring. Align the Damper, together with the Gear and Motor Assembly-MP8, with the large frame of the stapler, and secure them with two screws.

  • Page 212: Motor Assembly-Swing Removal

    4025-Finisher Motor Assembly-Swing Removal Removal Remove the Cartridge. Remove the Bottle Assembly-Dust. Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove the Stapler Assembly. Remove the Inner Cover. Remove six screws that secure the Cover Upper Left Assembly to the Finisher frame, and remove the Cover Upper Left Assembly.
  • Page 213 4025-Finisher Replacement From the diagonal upper rear direction, mount the Motor Assembly-Swing so that the shaft can enter. Plug the connector (CN 9) of the Stapler harness assembly to the Motor Assembly-Swing. Mount the Stapler harness assembly. Mount the Stapler Assembly. Mount the Latch Assembly and Switch Docking.

  • Page 214: Sensor Assembly Swing Removal

    4025-Finisher Sensor Assembly Swing Removal 4-106 Service Manual...
  • Page 215 4025-Finisher 4-107 Removal and Replacement Procedures...
  • Page 216 4025-Finisher 4-108 Service Manual...
  • Page 217 4025-Finisher Removal Remove the Cartridge. Remove the Bottle Assembly-Dust. Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove the Stapler Assembly. Remove the Inner Cover. Remove six screws that secure the Cover Upper Left Assembly to the Finisher frame, and remove the Cover Upper Left Assembly.

  • Page 218: Belt Removal

    4025-Finisher Belt Removal Removal Note: Reference the illustrations in the “Sensor Assembly Swing Removal” on page 4-106. Remove the Cartridge. Remove the Bottle Assembly-Dust. Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove the Stapler Assembly.

  • Page 219: Cable, Flat Removal

    4025-Finisher Cable, Flat Removal Note: Reference the illustrations in the “Sensor Assembly Swing Removal” on page 4-106. Removal Remove the Cartridge. Remove the Bottle Assembly-Dust. Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove the Stapler Assembly Remove the Inner Cover.
  • Page 220 4025-Finisher Replacement Align the Cable-Flat with the mounting position in the large frame of the stapler, and secure it with two screws. Align the Cable-Flat with the mounting position in the small frame of the stapler, and secure it with two screws. Close the small plate together with the Stapler Holder.

  • Page 221: Sensor, Stapler Home Position Traverse Removal

    4025-Finisher Sensor, Stapler Home Position Traverse Removal Removal Remove the Cartridge. Remove the Bottle Assembly-Dust. Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove the Stapler Assembly Remove the Inner Cover.

  • Page 222: Kit Bearing Removal

    4025-Finisher Kit Bearing Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove the Tray-Lower. On the Front of the Finisher, loosen the two screws that secure the Bracket Tray Lower.
  • Page 223 4025-Finisher Replacement Align the Bearing Assembly with the mounting position in the Bracket Front, and secure it with a screw. (Figure 2) Repeat the above step until you have mounted all the Bearing Assembly. Mount the Holder Assembly. Align the Bracket Tray Lower, with the mounting position, and secure them with four screws.

  • Page 224: Holder Assembly Removal

    4025-Finisher Holder Assembly Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Note: In the following steps, the procedure on the front is the same as on the rear. Apply the same procedure to the rear.
  • Page 225 4025-Finisher Replacement Note: In the following steps, the procedure on the front is the same as on the rear. Apply the same procedure to the rear. Engage the Belt with the upper and lower Pulley. Engage the Belt with the lower Holder, and align the lower Holder, together with the Belt, with the mounting position.

  • Page 226: Blade Assembly Removal

    4025-Finisher Blade Assembly Removal Removal Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove two screws on the front that secure to the Finisher from the Blade Assembly, and pull off the Blade Assembly toward the front. Replacement Align the Blade Assembly with the mounting position so that the boss on the rear of the Blade Assembly engages with the hole on the rear of the Finisher, and secure it with two screws.

  • Page 227: Sensor Tray Height Front Removal

    4025-Finisher Sensor Tray Height Front Removal Removal Remove the Cover-Jogging. Remove two screws that secure to the Finisher from the Sensor Tray Height Front, and pull off the Sensor Tray Height Front a little. Unplug the connector (P/J 1C-L) of the Harness Sensor from the Sensor Tray Height Front.

  • Page 228: Shaft Assembly Elev U Removal

    4025-Finisher Shaft Assembly ELEV U Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove the Holder Assembly. WARNING: In the following steps, removing the Pulley allows the Pin to be unsecured and easily removed from the Shaft ELEV, U.

  • Page 229: Shaft Assembly Elev L Removal

    4025-Finisher Shaft Assembly ELEV L Removal 4-121 Removal and Replacement Procedures...
  • Page 230 4025-Finisher Removal Remove the Cover-Jogging. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove the Right Cover. Remove the Drive Assembly-ELEV and Motor Assembly-MD11. Remove the Encorder Assembly. Remove the Holder Assembly. WARNING: In the following steps, removing the Pulley allows the Pin to be unsecured and easily removed from the Shaft ELEV,L.
  • Page 231 4025-Finisher Replacement Insert the Shaft ELEV,L a little into the hole on the front of the Finisher, then at the inside of the Finisher, insert the Gear and Encorder Drive Pulley up to the hole on the rear of the Finisher. Insert the Bearing into the front of the Shaft ELEV,L.

  • Page 232: Drive Assembly-Elev, Motor Assembly-Md11 Removal

    4025-Finisher Drive Assembly-ELEV, Motor Assembly-MD11 Removal 11 Removal 4-124 Service Manual...
  • Page 233 4025-Finisher Removal Remove the Cover-Jogging. Remove the Tray-Lower. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove the Right Cover. Remove the Latch Assembly and Switch Docking. Remove the Inner Cover. Unplug the connector (CN 11) of the Harness DC from the Motor Assembly-MD11.

  • Page 234: Right Cover Removal

    4025-Finisher Right Cover Removal 4-126 Service Manual...
  • Page 235 4025-Finisher Removal Remove the Cover-Jogging. Remove the Tray-Lower. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove the Cover-Open, Front, and Kit Stud Cover. On the Front of the Finisher, loosen the two screws that secure the Bracket Tray Lower.

  • Page 236: Encorder Assembly Removal

    4025-Finisher Encorder Assembly Removal 4-128 Service Manual...
  • Page 237 4025-Finisher Removal Remove the Cover-Jogging. Remove the Tray-Lower. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Cover-Rear. Remove the Cover-Open, Front, Cover-Front and Kit Stud Cover. Remove the Kit Bearing. Remove the Right Cover. Remove the Latch Assembly and Switch Docking. Remove the Bottle Assembly-Dust.

  • Page 238: Power Supply Removal

    4025-Finisher Power Supply Removal 4-130 Service Manual...
  • Page 239 4025-Finisher Removal Remove two screws that secure to the Latch Assembly from the Cover Lower Left. Remove two screws that secure to the Finisher from the Cover Lower Left, and remove the Cover Lower Left. Remove two screws that secure the LVPS Cover Lower to the Finisher, and pull out the LVPS Cover Lower together with the LVPS Cover Upper and Power Supply toward the front.

  • Page 240: Pwb Assembly-Main Removal

    4025-Finisher PWB Assembly-Main Removal 4-132 Service Manual...
  • Page 241 4025-Finisher Removal Remove the Cover-Jogging. Remove the Cover-Top, Rear. Remove the Cover-Rear. Unplug the connector (P/J 1A) of the Harness DC from the PWB Assembly-Main. Unplug the connector (P/J 2A) of the Harness DC from the PWB Assembly-Main. Unplug the connector (P/J 3A) of the Harness Middle Stapler from the PWB Assembly-Main.
  • Page 242 4025-Finisher Replacement Insert four screws into four holes in the PWB Assembly-Main, and then insert four spacers from the back. Align the PWB Assembly-Main, together with four screws and spacers, with the mounting position in the Finisher, and secure them with four screws. Plug the connector (P/J 1A) of the Harness DC to the PWB Assembly-Main.

  • Page 243: Port Harness Assembly Removal

    4025-Finisher Port Harness Assembly Removal Removal Remove the Cover-Jogging. Remove the Cover-Top, Rear. Remove the Cover-Rear. Release two Clamp on the PWB Chassis to release the harness. Unplug the connector (P/J 11A) of the Harness H-Tra from the PWB Assembly-Main. Unplug the connector (P/J 16) of the Harness H-Tra from the PWB Assembly-Main.

  • Page 244: No Paper Sensor Assembly Removal

    4025-Finisher No Paper Sensor Assembly Removal 4-136 Service Manual...
  • Page 245 4025-Finisher Removal Remove the Cover-Top, Front and Cover-Top, Rear. Remove the screws on the front and rear that secure to the frame of the Finisher from the L Cover. Remove screws respectively on the front and rear that secure to the L Cover from the frame of the Finisher, and remove the L Cover from the Finisher.

  • Page 246: Face Up Tray Removal

    4025-Finisher Face Up Tray Removal Removal Lift the leading end of the Face Up Tray a little, and pull it off toward the right. Replacement Insert three bosses of the Face Up Tray into the holes in the L Cover, and mount the Face Up Tray.

  • Page 247: Top Cover Interlock Switch Removal

    4025-Finisher Top Cover Interlock Switch Removal Removal Remove the Cover-Top, Front and Cover-Top, Rear. Unplug the connector (S 3-1) of the Harness Motor from the Top Cover Interlock Switch. Remove the screw that secures to the frame of the Finisher from the Top Cover Interlock Switch, and remove the Top Cover Interlock Switch.

  • Page 248: Gate Solenoid Removal

    4025-Finisher Gate Solenoid Removal Removal Remove the Cover-Top, Front and Cover-Top, Rear. Unplug the connector (CN 16) of the Harness Motor from the Gate Solenoid. Remove two screws that secure to the frame on the front of the Finisher from the Gate Solenoid, and remove the Gate Solenoid.

  • Page 249: Full Stack Sensor Assembly Removal

    4025-Finisher Full Stack Sensor Assembly Removal Removal Open the Top Center Cover Assembly. Unplug the connector (CN 37) of the Harness Face Up from the Full Stack Sensor Assembly. Release the harness of the Full Stack Sensor Assembly from the CLamp. Pushing the upper right of the Full Stack Sensor Assembly toward the left with your finger, lift it, and remove the Full Stack Sensor Assembly.

  • Page 250: Pinch Roll Removal

    4025-Finisher Pinch Roll Removal Removal Open the Top Center Cover Assembly. Remove the screw that secures to the Upper Guide from the Pinch Roll, and remove the Pinch Roll. Replacement Align the Pinch Roll, with the mounting positions in the Upper Guide. and secure them with a screw.

  • Page 251: Exit Sensor Removal

    4025-Finisher Exit Sensor Removal 4-143 Removal and Replacement Procedures...
  • Page 252 4025-Finisher Removal Remove the Sensor Assembly. Remove the Exit Assembly. Unplug the connector (CN 38) of the Harness Face Up from the Exit Sensor. Disengage four hooks of the Exit Sensor, and remove the Exit Sensor from the Finisher. Replacement From the right of the Finisher, align the Exit Sensor with the mounting position in the Lower Guide, and secure it.

  • Page 253: Exit Assembly Removal

    4025-Finisher Exit Assembly Removal 4-145 Removal and Replacement Procedures...
  • Page 254 4025-Finisher Removal Open the Top Center Cover Assembly. Unplug the connector (CN 37) of the Harness Face Up from the Full Stack Sensor Assembly. Disengage two hooks of the connector (CN 37), and pull the connector (CN 37) off from the Finisher Frame. From the rear, disengage two hooks of the Switch Cap, and push the Switch Cap out of the Finisher.

  • Page 255: Upper Roll And Roll Transport Removal

    4025-Finisher Upper Roll and Roll Transport Removal Removal Remove the Sensor Assembly. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Exit Assembly. Remove the Exit Sensor. Remove the Gear Kit. Remove the front E-ring that secures the Upper Roll to the Finisher. Remove two E-rings on the front that secure the upper and lower Roll Transport to the Finisher.
  • Page 256 4025-Finisher Replacement Insert the upper and lower Roll Transport into respective shaft holes in the front frame of the Finisher, and insert the rear shafts into respective holes in the rear frame of the Finisher. Insert four Bearings into the rear and front shafts of the upper and lower Roll Transport, and align the Roll Transport with the mounting position.

  • Page 257: Stepping Motor, Upper Tray Removal

    4025-Finisher Stepping Motor, Upper Tray Removal Removal Remove the Sensor Assembly. Remove the Cover-Top, Front and Cover-Top, Rear. Remove the Exit Assembly. Remove the Exit Sensor. Remove the Gear Kit. Unplug the connector (CN 12) of the Harness Motor from the Stepping Motor, Upper Tray.

  • Page 258: Gear Kit Removal

    4025-Finisher Gear Kit Removal Removal Remove the Cover-Top, Front and Cover-Top, Rear. Disengage the hook (long hook) that secures the Tension Spring to the frame. Remove two screws that secure to the Finisher from the Tension Bracket, and remove the Tension Bracket together with the Tension Roll and Tension Spring. Release the Belt from the Pulley Small, and remove the Belt.
  • Page 259 4025-Finisher Replacement Insert the Pulley Drive into the shaft of the Stepping Motor, and secure it with an E- ring. Insert the Pulley Large and Pulley Small into the rear shafts of upper and lower Roll Transport, and secure them with an E-ring. Insert the Pulley Small into the shaft on the rear of the Upper Roll, and secure it with an E-ring.
  • Page 260 4025-Finisher 4-152 Service Manual...

  • Page 261: Connectors

    4025-Finisher 5. Connectors Use the table and maps in this section to locate specific P/J connectors within the printer. To find the location of a P/J: Locate the P/J connector number in the first column of the table. Locate the corresponding map and location number, such as M2-5, in the second column.

  • Page 262: Location Table

    4025-Finisher Location Table Map & Connected to... Other end connected to... Number M5-5 Sensor P/J10AA PWB CHASSIS M5-16 PWB CHASSIS 2P Power Supply 1C-R M4-5 Sensor Tray Height Front P/J12A PWB CHASSIS 1C-L M4-3 Sensor Tray Height Rear P/J12A PWB CHASSIS M4-10 CN9 Motor Assembly P/J9A PWB CHASSIS...
  • Page 263 4025-Finisher Map & Connected to... Other end connected to... Number M2-11 Sensor P/J10AB PWB CHASSIS M2-9 Sensor P/J10AB PWB CHASSIS M5-1 PWB CHASSIS P/J13 No Paper Sensor Stapler CN9 Motor Assembly Swing CN10 Stapler Assembly P/J10 Sensor P/J12 Sensor Assembly Swing P/J11 Sensor Assembly Swing 10AA M5-2...
  • Page 264 4025-Finisher Map & Connected to... Other end connected to... Number M4-1 Motor Assembly-MP2 P/J6A PWB CHASSIS M3-8 Motor P/J6A PWB CHASSIS M3-1 Motor Assembly-MP4 P/J6A PWB CHASSIS M4-2 Motor-MP5 P/J6A PWB CHASSIS M2-8 Stepping Motor P/J5A PWB CHASSIS M2-12 Stepping Motor P/J5A PWB CHASSIS M4-14 Motor Assembly-MP8...
  • Page 265 4025-Finisher Map & Connected to... Other end connected to... Number CN31 M5-4 P256M Solenoid Assembly P/J11AA PWB CHASSIS P259 Sensor P/J11AB PWB CHASSIS P260 Sensor P261 Sensor P263 Sensor P275M Sensor P259 Sensor P260 Sensor P279 Sensor CN39 M3-15 Encorder Assembly P/J13A PWB CHASSIS CN40 M3-16...

  • Page 266: Location Map 1

    4025-Finisher Location Map 1 Service Manual...

  • Page 267: Location Map 2

    4025-Finisher Location Map 2 Connectors...

  • Page 268: Location Map 3

    4025-Finisher Location Map 3 Service Manual...

  • Page 269: Location Map 4

    4025-Finisher Location Map 4 Connectors...

  • Page 270: Location Map 5 5

    4025-Finisher Location Map 5 5 5-10 Service Manual...

  • Page 271: Location Map 6

    4025-Finisher Location Map 6 5-11 Connectors...

  • Page 272: Wiring Diagram Notations

    4025-Finisher Wiring Diagram Notations The wiring diagrams presented in this manual use the following circuit notations to describe components and signal paths within the printer. A PLUG. A JACK. CONNECTION OF PIN 15 OF CONNECTORS P28 AND J28. THE SIGNAL NAME OF A WIRE. THE VOLTAGE MEASURED WITH THE NEGATIVE PROBE OF THE METER ON SG.

  • Page 273: Master Wiring Diagram

    4025-Finisher Master Wiring Diagram 5-13 Connectors...
  • Page 274 4025-Finisher BD1 FINISHER MAIN PWB (H-TRA) 5-14 Service Manual...
  • Page 275 4025-Finisher Signal Name Description H-TRA SOL- Controls the gate open/close of the horizontal transfer tray. H-TRA SOL+ Controls the gate open/close of the horizontal transfer tray. H-TRA GATE Detects the gate open/close of the horizontal transfer tray. 5 V = OPEN, 0 V = CLOSE. H-TRA COVER Detects the top cover open/close of the horizontal transfer tray.
  • Page 276 4025-Finisher BD2 FINISHER MAIN PWB (PAPER INPUT) Signal Name Description ON/OFF Switches the Main Feed Motor on and off. 5 V = Enable to rotate, 0 V = Disable to rotate. FEED Detects paper feed-in. SENSOR1 5 V = Paper fed-in, 0 V = No paper fed-in. FEED Detects paper feed-in.
  • Page 277 4025-Finisher BD3 FINISHER MAIN PWB (PUNCHER) Signal Name Description PUNCH Rotates forward with 24 V power supply. CLUTCH PUNCH BOX Detects the presence of the punch dust box. SENSOR 5 V = Box present, 0 V = No box. PUNCH DUST Detects the punch us box full.
  • Page 278 4025-Finisher BD4 FINISHER MAIN PWB (PAPER OUTPUT) Signal Name Description EJECT Detects paper delivery. SENSOR 5 V = Paper delivered, 0 V = No paper delivered. STACK Detects paper delivery. SENSOR 5 V = Paper delivered, 0 V = No paper delivered. EJECT OPEN/ Detects paper feed-in.
  • Page 279 4025-Finisher BD5 FINISHER MAIN PWB (MOTORS) 5-19 Connectors...
  • Page 280 4025-Finisher Signal Name Description EJECT A Rotates the Ejector Open/Shut Motor by pulse signals from the Finisher Main PWB. EJECT /A Rotates the Ejector Open/Shut Motor by pulse signals from the Finisher Main PWB. EJECT B Rotates the Ejector Open/Shut Motor by pulse signals from the Finisher Main PWB. EJECT /B Rotates the Ejector Open/Shut Motor by pulse signals from the Finisher Main PWB.
  • Page 281 4025-Finisher BD6 FINISHER MAIN PWB (STAPLER(1/2)) 5-21 Connectors...
  • Page 282 4025-Finisher Signal Name Description STP.SWIN. + Rotates forward with 24 V power supply. STP.SWIN. - Rotates reversely with 24 V power supply. STAPLE M. + Rotates forward with 24 V power supply. STAPLE M. + Rotates forward with 24 V power supply. STAPLE M.
  • Page 283 4025-Finisher BD7 FINISHER MAIN PWB (STAPLER(2/2)) 5-23 Connectors...
  • Page 284 4025-Finisher Signal Name Description STP.SWIN. + Rotates forward with 24 V power supply. STP.SWIN. - Rotates reversely with 24 V power supply. STAPLE M. + Rotates forward with 24 V power supply. STAPLE M. - Rotates reversely with 24 V power supply. STP.SWING H.1 Detects the dual position angle of the 45°...
  • Page 285 4025-Finisher BD8 FINISHER MAIN PWB (TRAY) 5-25 Connectors...
  • Page 286 4025-Finisher Signal Name Description TRAY MOTOR + Rotates forward with 24 V power supply. TRAY MOTOR - Rotates reversely with 24 V power supply. TRAY LOWER Detects the lower limit position of the tray. 5 V = Not home position, 0 V = Home position. TRAY EMPTY Detects the presence of paper on tray.
  • Page 287 4025-Finisher BD9 FINISHER MAIN PWB (INTERLOCK) Signal Name Description DOCING COM Switch COMON Signal. FRONT COM Switch COMON Signal. TOP COM Switch COMON Signal. EXIT COM Switch COMON Signal. INTLK Switch OPEN Signal. 5-27 Connectors...
  • Page 288 4025-Finisher BD10 FINISHER MAIN PWB (TOP TRAY) 5-28 Service Manual...
  • Page 289 4025-Finisher BD11JEZ-9P (PWBA I/O (EG)) Signal Name Description UPPER EMPTY Detects the upper limit position of the tray. 5 V = Home position, 0 V = Not home position. UPPER FULL Detects the top surface of paper stacked on tray. UPPER EXIT 5 V = Paper delivered, 0 V = No paper delivered.
  • Page 290 4025-Finisher BD12 FINISHER MAIN PWB (JEZ-9P) Signal Name Description OPT$TX Communication signal between printer and Finisher for I/O. OPT#RX Communication signal between printer and Finisher for I/O. FINR#DET Ground. Signal Name Description OPT$TX Communication signal between printer and Finisher for I/O. OPT#RX+ Communication signal between printer and Finisher for I/O.
  • Page 291 4025-Finisher BD13 INLET (PWBA I/O (EG)) Signal Name Description AC IN AC(100-230 V) Input. 5-31 Connectors...
  • Page 292 4025-Finisher BD14 FINISHER MAIN PWB (INLET) Signal Name Description AC IN AC(100-230 V) Input. 5-32 Service Manual...

  • Page 293: Preventative Maintenance

    Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover • Possible safety exposure from any non-Lexmark attachments Scheduled Maintenance There is no scheduled maintenance on the Lexmark W820 (4025) Finisher. Preventative Maintenance...
  • Page 294 4025-Finisher Service Manual...

  • Page 295: Parts Catalog

    4025-Finisher 7. Parts Catalog How to Use This Parts Catalog • The callout numbers shown in each parts illustration correspond to the parts list numbers for that illustration. • The capital letters “C,” “E,” "KL," and “S” shown in an illustration stand for C-ring, E-ring, Clamp, and Screw, respectively.

  • Page 296: Assembly 1: Top Cover

    4025-Finisher Assembly 1: Top Cover Service Manual...
  • Page 297 4025-Finisher Assembly 1: Top Cover Part Units Description Number 12G4232 Cover, Top Parts Catalog...

  • Page 298: Assembly 2: Frame Transport, Rear

    4025-Finisher Assembly 2: Frame Transport, Rear Service Manual...
  • Page 299 4025-Finisher Assembly 2: Frame Transport, Rear Part Units Description Number 2 - 1 12G4239 Transport Assembly 12G4237 Sensor, Transport 12G4236 Roller, Transport 12G4241 Gate, Solenoid 12G4233 Cover, Rear 12G4235 Spring, Tension 12G4234 Belt, Synchronous 12G4240 Kit, Gear 12G4238 Harness, Transport Parts Catalog...

  • Page 300: Assembly 3: Frame Transport, Open

    4025-Finisher Assembly 3: Frame Transport, Open Service Manual...
  • Page 301 4025-Finisher Assembly 3: Frame Transport, Open Part Units Description Number 3 - 1 12G4242 Cover, Top 12G4247 Transport Assembly 12G4246 Shaft, Transport 12G4245 Sensor, Full 12G4244 Sensor, Transport 12G4248 Aligner, Roller 12G4243 Support, Cover Parts Catalog...

  • Page 302: Assembly 4: Docking Parts, Front Cover, Top Tray

    4025-Finisher Assembly 4: Docking Parts, Front Cover, Top Tray Service Manual...
  • Page 303 4025-Finisher Assembly 4: Docking Parts, Front Cover, Top Tray Part Units Description Number 4 - 1 12G4249 Cover, Jogging 12G4250 Tray, Lower 12G4251 Cover, Top 12G4260 Cover, Stud 12G4252 Cover, Front 12G4253 Cover, Front Mount 12G4254 Switch, Cover 12G4255 Bracket Assembly 12G4256 Bracket, Pin 12G4257...

  • Page 304: Assembly 5: Rear Cover

    4025-Finisher Assembly 5: Rear Cover 7-10 Service Manual...
  • Page 305 4025-Finisher Assembly 5: Rear Cover Part Units Description Number 5 - 1 12G4264 Tray, Face Up 12G4261 Cover, Rear 12G4262 Cover, Top Rear 12G4263 Cover, Top Left 7-11 Parts Catalog...
  • Page 306 4025-Finisher Assembly 6: Chute 1 7-12 Service Manual...

  • Page 307: Assembly 6: Chute 1

    4025-Finisher Assembly 6: Chute 1 Part Units Description Number 6 - 1 12G4267 Cover Assembly, Top 12G4265 Gate, Solenoid 12G4266 Switch Assembly, Finisher 7-13 Parts Catalog...
  • Page 308 4025-Finisher Assembly 7: Chute 2 7-14 Service Manual...

  • Page 309: Assembly 7: Chute 2

    4025-Finisher Assembly 7: Chute 2 Part Units Description Number 7 - 1 12G4270 Sensor, Exit BM 12G4268 Sensor, Full Stack 12G4269 Sensor, Exit 7-15 Parts Catalog...
  • Page 310 4025-Finisher Assembly 8: Top Exit 7-16 Service Manual...

  • Page 311: Assembly 8: Top Exit

    4025-Finisher Assembly 8: Top Exit Part Units Description Number 8 - 1 12G4271 Roll, Upper 12G4272 Roll, Transport 12G4273 Bearing 12G4274 Motor, Stepping 12G4275 Stop, Damper 12G4276 Kit, Gear 7-17 Parts Catalog...

  • Page 312: Assembly 9: Frame

    4025-Finisher Assembly 9: Frame 7-18 Service Manual...
  • Page 313 4025-Finisher Assembly 9: Frame Part Units Description Number 9 - 1 12G4281 Kit, Bracket 12G4277 Cap, End 12G4278 Caster Assembly 12G4284 Kit, Roll L 12G4283 Kit, Roll 12G4282 Foot 12G4280 Frame, Rail 12G4279 Lever Assembly 7-19 Parts Catalog...

  • Page 314: Assembly 10: Guide

    4025-Finisher Assembly 10: Guide 7-20 Service Manual...
  • Page 315 4025-Finisher Assembly 10: Guide Part Units Description Number 10 - 1 12G4285 Sensor, Guide 12G4288 Bearing, Guide 12G4290 Knob, Guide 12G4296 Inverter, Guide 12G4295 Buffer, Guide 12G4292 Blade Assembly 12G4289 Guide, In 12G4291 Motor, Transport 12G4293 Kit, Gear 12G4294 Drive Assembly 12G4287 Roll, Transport 12G4286...

  • Page 316: Assembly 11: Puncher Assembly

    4025-Finisher Assembly 11: Puncher Assembly 7-22 Service Manual...
  • Page 317 4025-Finisher Assembly 11: Puncher Assembly Part Units Description Number 11 - 1 12G4297 Punch, Non Punch 12G4298 Punch, 3 Hole 12G4299 Punch, 4 Hole 12G4301 Guide Assembly 12G4302 Bottle, Paper 12G4305 Sensor, Bottle 12G4303 Sensor Assembly 12G4300 Roll, Pinch 12G4304 Feed Assembly 7-23 Parts Catalog...

  • Page 318: Assembly 12: Jogging Assembly

    4025-Finisher Assembly 12: Jogging Assembly 7-24 Service Manual...
  • Page 319 4025-Finisher Assembly 12: Jogging Assembly Part Units Description Number 12 - 1 12G4307 Paddle, Paper 12G4309 Motor, Jogging 12G4308 Jogging Assembly 12G4306 Sensor, Jogging 7-25 Parts Catalog...

  • Page 320: Assembly 13: Shift Assembly

    4025-Finisher Assembly 13: Shift Assembly 7-26 Service Manual...
  • Page 321 4025-Finisher Assembly 13: Shift Assembly Part Units Description Number 13 - 1 12G4315 Shift Kit Assembly 12G4313 Rack, Gear 12G4312 Knob, Shift Assembly 12G4311 Bearing, Shift Assembly 12G4310 Motor, MP2 12G4316 Motor Assembly, Shift Kit 12G4314 Eliminator 7-27 Parts Catalog...

  • Page 322: Assembly 14: Stacker Unit

    4025-Finisher Assembly 14: Stacker Unit 7-28 Service Manual...
  • Page 323 4025-Finisher Assembly 14: Stacker Unit Part Units Description Number 14 - 1 12G4318 Shaft Assembly, Paddle 12G4321 Paddle Assembly 12G4319 Exit Assembly, Actuator 12G4320 Kit Assembly, Compiler Guide 12G4322 Gear, Front 12G4323 Gear, Rear 12G4317 Motor, MP4 7-29 Parts Catalog...

  • Page 324: Assembly 15: Stacker Tray

    4025-Finisher Assembly 15: Stacker Tray 7-30 Service Manual...
  • Page 325 4025-Finisher Assembly 15: Stacker Tray Part Units Description Number 15 - 1 12G4327 Roll, Stack 12G4331 Sensor, No Paper Stapler 12G4332 Sensor, Lower Tray 12G4330 Stack Assembly 12G4324 Gear 12G4328 Motor, Stacker 12G4333 Kit, Shoulder Assembly 12G4329 Pulley, Stacker 12G4325 Roll, Paddle Assembly 12G4326 Staple Assembly...

  • Page 326: Assembly 16: Stapler Assembly

    4025-Finisher Assembly 16: Stapler Assembly 7-32 Service Manual...
  • Page 327 4025-Finisher Assembly 16: Stapler Assembly Part Units Description Number 16 - 1 12G4334 Stapler Assembly 12G4339 Motor Assembly, Traverse 12G4337 Base Assembly, Stapler 12G4340 Pulley, Stapler 12G4338 Kit, Secure Plate 12G4336 Sensor Assembly, Swing 12G4335 Motor Assembly, Swing 7-33 Parts Catalog...

  • Page 328: Assembly 17: Elevator Unit

    4025-Finisher Assembly 17: Elevator Unit 7-34 Service Manual...
  • Page 329 4025-Finisher Assembly 17: Elevator Unit Part Units Description Number 17 - 1 12G4347 Kit, Bearing 12G4341 Belt, Elevator Unit 12G4349 Holder Assembly 12G4346 Sensor, Tray Height Rear 12G4342 Sensor, Tray Height 12G4350 Shaft Assembly, Elevator U 12G4348 Shaft Assembly 12G4344 Motor, MD11 12G4343 Drive Assembly, Elevator...

  • Page 330: Assembly 18: Finisher Main Pwb, Power Supply

    4025-Finisher Assembly 18: Finisher Main PWB, Power Supply 7-36 Service Manual...
  • Page 331 4025-Finisher Assembly 18: Finisher Main PWB, Power Supply Part Units Description Number 18 - 1 12G4354 Cord, Power 12G4351 Power Supply, Finisher 12G4353 Cable, I/F 12G4352 Card, Finisher Kit, Rivet 7-37 Parts Catalog...
  • Page 332 4025-Finisher Assembly 19: Harness Harness 7-38 Service Manual...

  • Page 333: Assembly 19: Harness

    4025-Finisher Assembly 19: Harness Part Units Description Number 19 - 1 12G4355 Harness, No Paper 12G4356 Harness, Encoder 12G4357 Harness, Stapler (Middle) 12G4358 Harness, Sensor 12G4359 Harness, Middle 1 12G4360 Harness, H Tray 12G4361 Harness, I/F 12G4362 Harness, Face Up 12G4363 Harness, Exit 12G4364...
  • Page 334 4025-Finisher 7-40 Service Manual...
  • Page 335 4025-Finisher Index Power Supply/Electrical Components 1-44 Glossary Attendance Message Table 1-44 Abbreviations 1-44 Acronyms 1-44 Terms Caution Labels Caution Notice 1-33 Compiler & Jogger Section 1-27 H-Tra Section Connectors Introduction Diagnostic Aids Analyzing Test Print Finisher Sensor Test Location Map 1 Finisher Tests Location Map 2 Staple Test...
  • Page 336 4025-XXX 4-32 Cover-Rear Sensor, 4-25 4-58 Cover-Top, Front and Rear Path 4-42, 4-79 Drive Assembly-ELEV, Motor Assembly-MD11 Sensor, Exit Path 4-124 Sensor, Exit Roller Open/Close Home Position 4-128 4-81 Encorder Assembly 4-16 4-41 Entrance Roll Sensor, Input Path 4-145 4-68 Exit Assembly Sensor, Jogger Home Position 4-82...
  • Page 337 4025-Finisher 7-19 12G4277 7-19 12G4278 1-43 Top Tray Exit Sections 7-19 12G4279 7-19 12G4280 7-19 12G4281 Warning Notice 7-19 12G4282 5-12 Wiring Diagram Notations 7-19 12G4283 7-19 12G4284 Part Numbers 7-21 12G4285 12G4232 7-21 12G4286 12G4233 7-21 12G4287 12G4234 7-21 12G4288 12G4235 7-21...

  • Page 338: Index

    4025-XXX 7-31 12G4331 7-31 12G4332 7-31 12G4333 7-33 12G4334 7-33 12G4335 7-33 12G4336 7-33 12G4337 7-33 12G4338 7-33 12G4339 7-33 12G4340 7-35 12G4341 7-35 12G4342 7-35 12G4343 7-35 12G4344 7-35 12G4345 7-35 12G4346 7-35 12G4347 7-35 12G4348 7-35 12G4349 7-35 12G4350 7-37 12G4351...

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W820 finisher 4025-xxx

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