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Lexmark C930 Service Manual
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Lexmark C930 Service Manual

Lexmark C930 Service Manual

Printer finisher
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Edition: January 14, 2008
™
Lexmark
C930 and C935 Printer Finisher
5057-XXX
• Table of contents
• Start diagnostics
• Safety and notices
• Trademarks
• Index
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 C930

  • Page 1 C930 and C935 Printer Finisher 5057-XXX • Table of contents • Start diagnostics • Safety and notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 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 5057-XXX Table of contents Table of contents ............iii Notices and safety information .
  • Page 4 5057-XXX Media sizes that allow stapling ..........1-23 Stapling one sheet .
  • Page 5 5057-XXX 982.00 Sensor (front tamper HP) late error ......... . 2-58 982.01 Sensor (front tamper HP) lag error .
  • Page 6 5057-XXX Quick Test ..............3-8 Sensor Test (duplex) .
  • Page 7 5057-XXX Removal procedures ..............4-2 Before starting service work .
  • Page 8 5057-XXX Media compiler unit assembly removal ..........4-68 Sensor (front tamper HP) and sensor (rear tamper HP) removals .
  • Page 9 5057-XXX Sensor (booklet media compiler in) removal ........4-138 Sensor (booklet unit media exit) removal .
  • Page 10 5057-XXX Assembly 27: Finisher–cables 3 ........... . . 7-43 Index .
  • Page 11 5057-XXX Notices and safety information The following laser notice labels may be affixed to this printer. Laser notice The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.
  • Page 12 5057-XXX Avisos sobre el láser Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de Clase I (1).
  • Page 13 5057-XXX Laserilmoitus Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) - lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi. Luokan I lasertuotteita ei pidetä haitallisina. Tulostimen sisällä on luokan IIIb (3b) laser, joka on nimellisteholtaan 5 mW:n galliumarsenidilaser ja toimii 770 - 795 nanometrin aallonpituuksilla.
  • Page 14 5057-XXX Avís sobre el Làser Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe I que compleix els requisits d’IEC 60825-1.
  • Page 15 5057-XXX Notices and safety information...
  • Page 16 5057-XXX Printer Finisher Service Manual...
  • Page 17 5057-XXX Safety information • The safety of this product is based on testing and approvals of the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. • The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others.
  • Page 18 5057-XXX Sicherheitshinweise • Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen. • Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.
  • Page 19 5057-XXX Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. •...
  • Page 20 5057-XXX Preface This manual contains maintenance procedures for service personnel. 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, as well as general environmental and safety instructions, are discussed.
  • Page 21 1. General information Finisher The optional finisher staples, punches, folding and stapling, and stacks media transferred from the Lexmark™ C935. Output is stacked in the upper media bin or separately collated in the stacker media bin or folded and stapled in the booklet bin.
  • Page 22 5057-XXX Media path overview Media size and weight The following shows media sizes and weights that the finisher can handle, as well as applicable functions for each media size. The printer and the finisher handle different media sizes and weights. For this reason, if the printer has printed media that the finisher cannot handle, the exit 1 diverter gate in the printer is switched to eject the media from Exit 2 onto the bridge unit assembly.
  • Page 23 5057-XXX a(2) 257 x 364 mm a(2,3,4) 297 x 420 mm a(2,3,4) Ledger 11 x 17 in. Custom size Same width with standard size Custom size Besides above Numbers (2,3,4) mean 2 holes, 3 holes, and 4 holes, respectively. Applicable within the following range: Media width: 203.2—297 mm Media length: 182—431.8 mm Media weight...
  • Page 24 5057-XXX Bridge unit assembly paper path Finisher media path Upper Media Bin Stacker Media Bin Punch Unit From Bridge Unit Compiler Media Unit Assembly Stapler Unit Knife Folding Booklet Bin Booklet Stapler Unit End Guide Printer Finisher Service Manual...
  • Page 25 5057-XXX Finisher roll assemblies Upper Media Exit Roll Assembly- Upper Media Transport Roll Assembly – driven by motor (exit) driven by drive motor (buffer/transport) Finisher Diverter Gate Finisher Media Entrance Roll Assembly – driven by Sub Paddle – drive motor (entrance paddle) driven by drive motor (entrance/paddle) Eject Clamp –...
  • Page 26 5057-XXX Finisher media path sensors Sensor (upper media) Sensor (diverter gate) Sensor (upper media bin full) Sensor Sensor (lower media exit) (media entrance) Sensor (buffer path) Sensor (booklet media entrance) Sensor (lower media exit) Sensor (booklet media exit) Sensor (booklet bin media present) Sensor (booklet compiler media in) Printer Finisher Service Manual...
  • Page 27 5057-XXX Finisher motors Drive motor (exit) Drive motor Media eject clamp motor (buffer/transport) Finisher diverter gate solenoid Media eject motor assembly Buffer diverter solenoid Drive motor (entrance paddle) Stacker bin lift motor assembly Bridge unit assembly When the printer designates the finisher, the media diverter gate in the printer activates, and media is fed from the printer into the bridge unit assembly.
  • Page 28 5057-XXX From bridge unit assembly to punch The media fed from the bridge unit assembly is fed into the finisher by the media entrance roll assembly located on the entrance section of the finisher which is driven by the drive motor (entrance/paddle). The media route inside the finisher is determined by the finisher diverter gate.
  • Page 29 5057-XXX From punch to compiler unit assembly The media is transferred to the compiler unit assembly by the buffer roll assembly (driven by the motor (buffer/ transport)) and by the lower media exit roll assembly (driven by the drive motor (exit)). When the first media reaches the compiler unit assembly, the media eject clamp motor is activated to lower the media eject clamp so that the media eject clamp and the media eject shaft assembly can clamp the media.
  • Page 30 5057-XXX Sensor (lower media exit) Sub paddle—driven by drive motor (entrance/paddle) Eject clamp—driven Buffer roll assembly— by eject clamp motor driven by drive motor (buffer/transport) Media eject shaft assembly— driven by media eject motor asm Buffer diverter Compiler unit assembly Main paddle Lower media exit motor—driven by...
  • Page 31 5057-XXX From compiler unit assembly to stacker media bin Stapled media on the compiler unit assembly (stapling mode) or aligned media (non-stapling mode) are held between the media eject clamp and the media eject shaft assembly. The media eject shaft assembly is driven by the media eject motor assembly to transfer media to the stacker media bin.
  • Page 32 5057-XXX Finisher • Sensor (finisher media entrance) — A photo-reflective sensor detects whether media is fed from the bridge unit assembly to the finisher — It turns high (+5 V dc) while media is present within the sensing area. — When the level turns high due to the first media of the second set during multi-set printing, this sensor activates the buffer diverter solenoid to switch the buffer diverter gate so that the media goes in the buffer roll assembly’s circumferential direction.
  • Page 33 5057-XXX Punch unit This section describes the media punching operation of the punch. Two types of punch are provided: the 2/3-hole type and the 2/4-hole type. The following explains the 2/3-hole type (2-hole/3-hole auto-switching). Every type has the same construction, except for the sensor (punch hole select) that is provided for the 2-hole type and 3-hole type only.
  • Page 34 5057-XXX Punching After punching positions are determined, the punch unit motor is activated to move the cam plate. With the movement of the cam plate, the pins descend along the guide holes to punch the media. This operation is performed for each sheet of media. The cam plate can lower the pins even while it is moving to the front or rear side.
  • Page 35 5057-XXX Detecting punch waste full Punch waste is stored in the punch waste box. A sensor is provided to detect punch waste full. When punch waste full is detected, it is notified to the operator only once. Even if punch waste is not removed, the finisher can still punch media. However, it can spread punch waste inside the machine.
  • Page 36 5057-XXX • Sensor (punch waste box set) — A photo-interrupter sensor that detects whether the waste box is properly set — When the punch waste box is properly set, the actuator of the box blocks the light transmission of the sensor, which turns the sensor to high (+5 V dc).
  • Page 37 5057-XXX Capacity of compiler unit assembly Media volume that can be stacked on the compiler unit assembly is limited as shown in the table below. The number of sheets depends on whether media is stapled or not, as well as on media size. If the number of sheets of one set to be stapled exceeds the limit, the exceeding sheets are not stacked on the compiler unit assembly, and are forcibly ejected to the stacker media bin without being stapled.
  • Page 38 5057-XXX Front tamping Front tamping is used in the following cases. • In the non-staple mode • When executing front stapling (corner) The tamper positions during front tamping are shown below. Sensor (rear tamper HP) Sensor (front tamper HP) Rear Front Front tamper motor Rear tamper...
  • Page 39 5057-XXX Rear tamping Rear tamping is used in the following cases. • When executing rear stapling (corner) • When executing dual stapling The tamper positions during rear tamping are shown below. Sensor (rear tamper HP) Sensor (front tamper HP) Rear Front Front tamper motor Front tamper...
  • Page 40 5057-XXX Center tamping Center tamping is used when executing rear stapling (straight). The tamper positions during center tamping are shown below. Sensor (front tamper HP) Sensor (rear tamper HP) Front Rear Front tamper motor Front tamper Rear tamper Rear tamper motor Position Description Front tamper home position–sensor (front tamper HP)
  • Page 41 5057-XXX Offsetting Offsetting is an operation to shift the position of media to be ejected to the stacker media bin so that boundaries between media units (sets of media, job units, etc.) can be easily recognized. Offsetting is executed for staple positions: •...
  • Page 42 5057-XXX • Rear tamper motor — A stepping motor that moves the rear tamper for tamping — Clockwise rotation of this motor moves the rear tamper to the front side. Counterclockwise rotation of this motor moves the tamper to the rear side. Rear tamper Front tamper Sensor (rear...
  • Page 43 5057-XXX • Rear Staple (Straight) [rear straight] Rear This type of stapling is applied for media with a width of less than 216 mm. The Stapler staples a set of media in parallel with the media edge after the front tamper aligns the media to the rear side.
  • Page 44 5057-XXX Stapling multiple size media When sheets with different sizes and the same width (example: A4L and A3S) are present on the compiler unit assembly, all the sheets are stapled and then ejected to the stacker media bin. When sheets with different widths are present on the compiler unit assembly, stapling is stopped when a different width is detected.
  • Page 45 5057-XXX Stapler unit assembly The stapling operation is executed by closing the stapler unit assembly. The stapler unit assembly, containing the staple motor, the sensor (staple home), the sensor (self priming), and the sensor (low staple), is activated by the staple motor. Forward (clockwise) rotation of the motor drives the stapler to staple a set of sheets, and returns the stapling unit to the home position.
  • Page 46 5057-XXX • Stapler unit motor (in the stapler unit assembly) — A DC motor to activate the stapler unit assembly for stapling — Clockwise rotation of this motor enables stapling, while counterclockwise rotation returns the stapler unit assembly. Stapler carriage motor asm Stapler rack gear Sensor (stapler carriage HP)
  • Page 47 5057-XXX Functions of booklet sensors and motors • Sensor (booklet media entrance) — This photo sensor detects the media delivery to the booklet unit. • Sensor (booklet media exit) — This photo sensor detects paper delivery to booklet media bin. •...
  • Page 48 5057-XXX • Booklet knife solenoid — This solenoid transfers the booklet folding/exit drive motor assembly to the knife through the gear. Booklet media Sensor (booklet entrance roll media entrance) assembly Booklet media entrance drive motor Booklet folding roll assembly Booklet media exit roll assembly Sensor (booklet media exit roll assembly)
  • Page 49 5057-XXX • Sensor (booklet drawer interlock) — This photo sensor detects when the booklet unit is set. • Sensor (booklet bin media present) — This photo sensor detects paper availability on the booklet media bin. If 15 sets of printouts are detected in the booklet media bin, it will be considered as Full Stack.
  • Page 50 5057-XXX Stacker media bin The stacker media bin goes up and down to an appropriate position according to the volume of media fed from the compiler unit assembly so as to properly stack media to a full stack. Operation The stacker media bin moves to an appropriate position according to the volume of media fed from the compiler unit assembly.
  • Page 51 5057-XXX The stacker media bin lowers according to the volume of media it contains. If any obstacle under the tray hinders the tray from lowering, the stacker lower safety warning is detected, and the stacker media bin is stopped. Eject clamp motor Sensor (stacker bin level 1) Sensor (media eject clamp HP)
  • Page 52 5057-XXX Full stack detection A full stack is detected when media in the stacker media bin becomes full to prevent media jam or falling of media to the floor. The stacker media bin can stack up to approximately 3000 sheets. The media volume in the stacker media bin is detected at every 10% (approximately 300 sheets) and notified to the Controller.
  • Page 53 5057-XXX — A photo-interrupter sensor that detects that the stacker media bin is at the highest position; it also detects no media. — When the actuator attached to the carriage assembly right enters the sensing area, the emitted light is blocked, which turns the sensor to high (+5 V).
  • Page 54 5057-XXX Booklet tray Paper is folded into two by the booklet folding roll driven by the booklet Fold Roll Motor and booklet Eject Roll, and delivered to the booklet tray. Booklet tray is at a position lower than the paper delivery exit. Paper delivery belt will move at fixed interval for every set of output.
  • Page 55 5057-XXX • Switch (eject cover interlock)–Turns off when the cover eject on the right side opens, shutting off the Interlock +24 V dc line in the finisher. Switch (eject cover interlock) Switch (finisher front door interlock) Finisher controller card asm Sensor +5 V dc Switch...
  • Page 56 5057-XXX Tools required for service Flat-blade screwdriver #1 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic short-blade Needle nose pliers Diagonal side cutters Spring hook 5.5 mm hex driver, magnetic Analog or digital multi-meter Parallel wrap plug 1319128 Twinax/serial debug cable 1381963 Coax/serial debug cable 1381964 Acronyms...
  • Page 57 5057-XXX Multi-Purpose Feeder MROM Masked Read Only Memory Microswitch Nonvolatile Memory NVRAM Nonvolatile Random Access Memory Original Equipment Manufacturer Optical Sensor Photoconductor Picture element Power-on Reset POST Power-on Self Test Pages Per Minute Parallel Synchronous Communications Position Sensing Device Pulse Width Modulation RFID Radio Frequency Identification Raster Imaging Processor...
  • Page 58 5057-XXX 1-38 Printer Finisher Service Manual...
  • Page 59 5057-XXX 2. Diagnostic information Start CAUTION: Unplug the power cord from the electrical outlet before you connect or disconnect any cable electronic board or assembly. CAUTION If the printer is kept on, never touch the conductive parts if not specifically required. The power switch and inlet of the low voltage power supply card (LVPS card) assembly is live even while the power supply is cut off.
  • Page 60 5057-XXX POR (Power-On Reset) sequence The following is an example of the events that occur during the POR sequence for the base machine with no paper handling options installed. 1. Turn the machine on. 2. +5V LED (Power ON) on the system board comes on. 3.
  • Page 61 5057-XXX Error code messages - finisher Error code or Error contents Description/action message 280.00 Sensor (bridge unit media The media is late reaching the sensor (bridge unit media entrance) late jam entrance) within the specified time after reaching the Paper jam sensor (fuser exit).
  • Page 62 5057-XXX Error code or Error contents Description/action message 284.00 Sensor (lower media exit) late The media is late reaching the sensor (lower media exit) within the specified time after reaching the sensor (buffer Paper jam path). Go to “284.00 Sensor (lower media exit) late jam” on page 2-27.
  • Page 63 5057-XXX Error code or Error contents Description/action message 289.01 sensor (booklet unit media The media reached the sensor (booklet unit media entrance) lag jam entrance) but did not clear it within the specified time. Paper jam Go to “289.01 sensor (booklet unit media entrance) lag jam”...
  • Page 64 5057-XXX Error code or Error contents Description/action message 982.01 Sensor (front tamper HP) lag The sensing area of the sensor (front tamper HP) error remains interrupted within the specified time after the Service finisher front tamper starts moving from the home position. error Go to “982.01 Sensor (front tamper HP) lag error”...
  • Page 65 5057-XXX Error code or Error contents Description/action message 987.01 Sensor (media eject shaft HP) The sensing area of the sensor (media eject shaft HP) lag error remains interrupted within the specified time after the Service finisher media eject shaft starts moving from the home position. error Go to “987.01 Sensor (media eject shaft HP) lag...
  • Page 66 5057-XXX Error code or Error contents Description/action message 991.05 Sensor (booklet end guide HP) The sensing area of the sensor (booklet end guide HP) lag error remains interrupted within the specified time after the Service finisher booklet end guide starts moving from the home position. error Go to “991.05 Sensor (booklet end guide HP) lag...
  • Page 67 5057-XXX Error code or Error contents Description/action message 992.01 Sensor (de-curler cam HP) lag The sensing area of the sensor (de-curler cam HP) error remains interrupted within the specified time after the Service finisher de-curler roll assembly (nip) starts moving from the error home position.
  • Page 68 5057-XXX Service checks - finisher 280.00 Sensor (bridge unit media entrance) late Jam Step Check Check the bridge unit media transport rolls. Go to step 2. Clean or replace the bridge unit Are the bridge unit media transport rolls free of excess assembly.
  • Page 69 5057-XXX Step Check Perform a print test. Replace the Problem solved. bridge unit Does the error remain? interface card assembly. Go to “Bridge unit interface card assembly removal” on page 4-114. Go to step 7. Perform a print test. Replace the Problem solved.
  • Page 70 5057-XXX Step Check Check the bridge unit drive motor for proper operation. Go to step 5. Go to step 4. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1. Enter the Diagnostics Menu. 2.
  • Page 71 5057-XXX Step Check Check the sensor (bridge unit media exit) for proper Go to step 4. Go to step 3. operation. 1. Enter the Diagnostics Menu. 2. Select FINISHER TESTS. 3. Select Sensor Test. 4. Select Media Path 1. 5. Select Bridge unit media exit. Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?
  • Page 72 5057-XXX Step Check Perform a print test. Replace the Problem solved. finisher controller Does the error remain? card assembly. Go to “Finisher controller card assembly removal” on page 4-115. 281.03 Sensor (bridge unit media exit) static jam Step Check Check the sensor (bridge unit media exit) for proper Go to step 4.
  • Page 73 5057-XXX Step Check Perform a print test. Replace the Problem solved. bridge unit Does the error remain? interface card assembly. Go to “Bridge unit interface card assembly removal” on page 4-114. Go to step 6. Perform a print test. Replace the Problem solved.
  • Page 74 5057-XXX Step Check Check the bridge unit diverter gate solenoid for proper Go to step 6. Go to step 5 operation. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1. Enter the Diagnostics Menu. 2.
  • Page 75 5057-XXX Step Check Check the bridge unit drive motor for proper operation. Go to step 10. Go to step 9. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1. Enter the Diagnostics Menu. 2.
  • Page 76 5057-XXX Step Check Check the sensor (bridge unit bin exit) for proper Replace the Replace the connection. sensor (bridge unit connection. bin exit). Is the above component properly connected? Go to “Sensor (bridge unit bin exit) removal” on page 4-13. Check the bridge unit diverter gate solenoid for proper Go to step 6.
  • Page 77 5057-XXX Step Check Perform a print test. Replace the bridge Problem solved. unit interface card Does the error continue? assembly. Go to “Bridge unit interface card assembly removal” on page 4-114. Go to step 9. Perform a print test. Replace the Problem solved.
  • Page 78 5057-XXX Step Check Check the bridge unit drive motor for proper connection. Replace the bridge Replace the unit drive motor. connection. Is the above component properly connected? Go to “Bridge unit drive motor removal” on page 4-8. Perform a print test. Replace the bridge Problem solved.
  • Page 79 5057-XXX Step Check Check the sensor (finisher media entrance) for proper Go to step 6. Go to step 5. operation. 1. Enter the Diagnostics Menu. 2. Select FINISHER TESTS. 3. Select Sensor Test. 4. Select Media Path 1. 5. Select Finisher media entrance. Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?
  • Page 80 5057-XXX Step Check Perform a print test. Replace the Problem solved. finisher controller Does the error remain? card assembly. Go to “Finisher controller card assembly removal” on page 4-115. 282.01 Sensor (finisher media entrance) static jam Step Check Check the sensor (finisher media entrance) for proper Go to step 3.
  • Page 81 5057-XXX Step Check Check the drive motor (entrance/paddle) for proper Replace the drive Replace the connection. motor (entrance/ connection. paddle). Is the above component properly connected? Go to “Drive motor (entrance/ paddle) and belt (entrance/ paddle) removal” on page 4-98. Perform a print test.
  • Page 82 5057-XXX Step Check Check the sensor (diverter gate) for proper connection. Replace the Replace the sensor (diverter connection. Is the above component properly connected? gate). Go to “Sensor (diverter gate) removal” on page 4-107. Check the buffer diverter gate solenoid for proper Go to step 7.
  • Page 83 5057-XXX Step Check Check the drive motor (buffer/transport) for proper Go to step 11. Go to step 10. operation. 1. Enter the Diagnostics Menu. 2. Select MOTOR TESTS. 3. Select Finisher Motor Tests. 4. Select Motor (buffer/transport). Does the above component operate properly? Check the drive motor (buffer/transport) for proper Replace the drive Problem solved.
  • Page 84 5057-XXX 283.03 Sensor (buffer path) static jam Step Check Check the sensor (buffer path) for proper operation. Go to step 3. Go to step 2. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1.
  • Page 85 5057-XXX Step Check Perform a print test. Replace the Problem solved. finisher controller Does the error remain? card assembly. Go to “Finisher controller card assembly removal” on page 4-115. 284.00 Sensor (lower media exit) late jam Step Check Check the finisher buffer roll assembly. Go to step 2.
  • Page 86 5057-XXX Step Check Check the drive motor (buffer/transport) for proper Replace the drive Replace the connection. motor (buffer/ connection. transport). Is the above component properly connected? Go to “Drive motor (buffer/ transport) and belt (buffer/ transport) removal” on page 4-112. Check the sensor (diverter gate) for proper operation.
  • Page 87 5057-XXX 284.03 Sensor (lower media exit) lag jam Step Check Check the lower media exit roll assembly. Go to step 2. Clean or replace the lower media Is the above component free of excess wear and exit roll assembly. contamination? “Lower Go to media exit roll...
  • Page 88 5057-XXX Step Check Perform a print test. Replace the Problem solved. finisher controller Does the error remain? card assembly. Go to “Finisher controller card assembly removal” on page 4-115. 284.05 Sensor (lower media exit) static jam Step Check Check the sensor (lower media exit) for proper Go to step 3.
  • Page 89 5057-XXX Step Check Check the buffer diverter gate solenoid for proper Replace the Problem solved. connection. buffer diverter gate solenoid. Is the above component properly connected? Go to “Buffer diverter gate solenoid removal” on page 4-101. Check the drive motor (exit) for proper operation. Go to step 7.
  • Page 90 5057-XXX Step Check Perform a print test. Replace the Problem solved. finisher controller Does the error remain? card assembly. Go to “Finisher controller card assembly removal” on page 4-115. 285.00 Sensor (media compiler in) lag jam Step Check Check the media eject clamp motor for proper Go to step 3.
  • Page 91 5057-XXX Step Check Check the sensor (compiler media in) for proper Go to step 6. Go to step 5. operation. 1. Enter the Diagnostics Menu. 2. Select FINISHER TESTS. 3. Select Sensor Test. 4. Select Media Path 1. 5. Select Compiler media in. Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?
  • Page 92 5057-XXX Step Check Check the sensor (compiler media in) for proper Go to step 5. Go to step 4. operation. 1. Enter the Diagnostics Menu. 2. Select FINISHER TESTS. 3. Select Sensor Test. 4. Select Media Path 1. 5. Select Compiler media in. Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?
  • Page 93 5057-XXX 287.00 Sensor (upper media exit) late jam Step Check Check the two upper media transport roll assemblies. Go to step 2. Clean or replace the two upper Are the two upper media transport roll assemblies free media transport of excess wear and contamination? roll assemblies.
  • Page 94 5057-XXX Step Check Perform a print test. Replace the Problem solved. finisher controller Does the error remain? card assembly. Go to “Finisher controller card assembly removal” on page 4-115. 287.01 Sensor (upper media exit) lag jam Step Check Check the two upper media transport roll assemblies. Go to step 2.
  • Page 95 5057-XXX Step Check Check the drive motor (buffer/transport) for proper Go to step 6. Go to step 5. operation. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1. Enter the Diagnostics Menu. 2. Select MOTOR TESTS. 3.
  • Page 96 5057-XXX 287.05 Sensor (upper media exit) static jam Step Check Check the sensor (upper media exit) for proper Go to step 3. Go to step 2. operation. 1. Enter the Diagnostics Menu. 2. Select FINISHER TESTS. 3. Select Sensor Test. 4.
  • Page 97 5057-XXX 288.00 Sensor (diverter gate) late jam Step Check Check the finisher media entrance roll assembly. Go to step 2. Clean or replace the finisher Is the finisher media entrance roll assembly free of media entrance excess wear and contamination? roll assembly.
  • Page 98 5057-XXX Step Check Check the sensor (diverter gate) for proper operation. Go to step 8. Go to step 7. 1. Enter the Diagnostics Menu. 2. Select FINISHER TESTS. 3. Select Sensor Test. 4. Select Media Path 2. 5. Select Diverter gate. Does the operator panel display change every time the actuator of the sensor (bridge unit media exit) is operated?
  • Page 99 5057-XXX 288.01 Sensor (diverter gate) static jam A (to top bin) Step Check Check the sensor (diverter gate) for proper operation. Go to step 3. Go to step 2. 1. Enter the Diagnostics Menu. 2. Select FINISHER TESTS. 3. Select Sensor Test. 4.
  • Page 100 5057-XXX 288.04 Sensor (diverter gate) static jam B (to stacker bin) Step Check Check the sensor (diverter gate) for proper operation. Go to step 3. Go to step 2. 1. Enter the Diagnostics Menu. 2. Select FINISHER TESTS. 3. Select Sensor Test. 4.
  • Page 101 5057-XXX 289.00 sensor (booklet unit media entrance) late jam Step Check Check the booklet unit interface connector assembly. Go to step 2. Replace the booklet unit Is the above component free of damage? interface connector assembly. Check the main connector on the booklet unit sensor Go to step 3.
  • Page 102 5057-XXX Step Check Check the motor (entrance/paddle) for proper operation. Go to step 10. Go to step 9. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1. Enter the Diagnostics Menu. 2. Select MOTOR TESTS. 3.
  • Page 103 5057-XXX Step Check Check the main connector on the booklet unit motor Go to step 4. Replace the interface cable assembly. booklet unit motor interface cable Is the above component free of damage? assembly. Check the sensor (booklet unit media entrance) for proper Go to step 6.
  • Page 104 5057-XXX Step Check Perform a print test. Replace the Problem solved. finisher controller Does the error remain? card assembly. Go to “Finisher controller card assembly removal” on page 4-115. 289.02 sensor (booklet unit media entrance) static jam Step Check Check the booklet unit interface connector assembly. Go to step 2.
  • Page 105 5057-XXX Step Check Perform a print test. Replace the Problem solved. finisher controller Does the error remain? card assembly. Go to “Finisher controller card assembly removal” on page 4-115. 289.03 sensor (booklet compiler media in) static jam Step Check Check the booklet unit interface connector assembly. Go to step 2.
  • Page 106 5057-XXX Step Check Perform a print test. Replace the Problem solved. finisher controller Does the error remain? card assembly. Go to “Finisher controller card assembly removal” on page 4-115. 289.04 Sensor (booklet unit media exit) late jam Step Check Check the booklet unit interface connector assembly. Go to step 2.
  • Page 107 5057-XXX Step Check Check the booklet knife solenoid for proper operation. Go to step 8. Go to step 7. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1. Enter the Diagnostics Menu. 2. Select MOTOR TESTS. 3.
  • Page 108 5057-XXX Step Check Perform a print test. Replace the Problem solved. finisher controller Does the error remain? card assembly. Go to “Finisher controller card assembly removal” on page 4-115. 289.05 Sensor (booklet unit media exit) lag jam Step Check Check the booklet unit interface connector assembly. Go to step 2.
  • Page 109 5057-XXX Step Check Check the booklet folding/exit drive motor for proper Go to step 8. Go to step 7. operation. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1. Enter the Diagnostics Menu. 2.
  • Page 110 5057-XXX Step Check Check the sensor (booklet unit media exit) for proper Go to step 5. Go to step 4. operation. 1. Enter the Diagnostics Menu. 2. Select FINISHER TESTS. 3. Select Sensor Test. 4. Select Booklet path 5. Select Booklet unit media exit Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?
  • Page 111 5057-XXX Step Check Check the sensor (stacker bin level 1) for proper operation. Go to step 4. Go to step 3. 1. Enter the Diagnostics Menu. 2. Select FINISHER TESTS. 3. Select Sensor Test. 4. Select Bin Level. 5. Select Stacker bin level1. Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?
  • Page 112 5057-XXX Step Check Is the stacker bin lift motor assembly connected properly? Replace the Replace the stacker bin lift connection. motor assembly. Go to “Stacker bin lift motor assembly removal” on page 4-37. Perform a POR. Replace the Problem solved. finisher controller Does the error continue when the power is turned off/on? card assembly.
  • Page 113 5057-XXX Step Check Check the media stacker bin actuator for proper operation. Go to step 6. Repair the media stacker bin Is the media stacker bin actuator installed properly? actuator. Does it enter the sensing area of the sensor (stacker bin upper limit)? Check the sensor (stacker bin upper limit) for proper Go to step 8.
  • Page 114 5057-XXX 981.02 Stacker bin lower limit error Step Check Check the media stacker bin actuator for proper operation. Go to step 2. Repair the media stacker bin Is the media stacker bin actuator installed properly? actuator. Does it enter the sensing area of the sensor (stacker bin upper limit)? Check the sensor (stacker bin no media) for proper Go to step 4.
  • Page 115 5057-XXX Step Check Check the sensor (stacker bin level encoder) for proper Go to step 10. Go to step 9. operation. 1. Enter the Diagnostics Menu. 2. Select FINISHER TESTS. 3. Select Sensor Test. 4. Select Bin Level. 5. Select Stacker bin level encod. Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?
  • Page 116 5057-XXX 982.00 Sensor (front tamper HP) late error Step Check Check the tamper mechanism by moving it manually. Go to step 2. Replace the media compiler unit Does the above component slide back and forth properly? assembly. Go to “Media compiler unit assembly removal”...
  • Page 117 5057-XXX Step Check Perform a POR. Replace the Problem solved. finisher controller Does the error continue when the power is turned off/on? card assembly. Go to “Finisher controller card assembly removal” on page 4-115. 982.01 Sensor (front tamper HP) lag error Step Check Check the tamper mechanism by moving it manually.
  • Page 118 5057-XXX Step Check Check the compiler unit cable assembly for proper Replace the media Replace the connection. compiler unit connection. assembly. Is the above component properly connected? Go to “Media compiler unit assembly removal” on page 4-68. Perform a POR. Replace the Problem solved.
  • Page 119 5057-XXX Step Check Check the rear tamper drive motor for proper operation. Go to step 6. Go to step 5. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1. Enter the Diagnostics Menu. 2.
  • Page 120 5057-XXX Step Check Is the sensor (rear tamper HP) properly connected? Replace the Replace the sensor (rear connection. Is the above component properly connected? tamper HP). Go to “Sensor (front tamper HP) and sensor (rear tamper HP) removals” on page 4-70.
  • Page 121 5057-XXX Step Check Check the sensor (punch unit HP) for proper operation. Go to step 4. Go to step 3. 1. Enter the Diagnostics Menu. 2. Select FINISHER TESTS. 3. Select Sensor Test. 4. Select Punch and Staple. 5. Select Punch unit HP. Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?
  • Page 122 5057-XXX Step Check Check the sensor (punch unit HP) for proper operation. Go to step 4. Go to step 3. 1. Enter the Diagnostics Menu. 2. Select FINISHER TESTS. 3. Select Sensor Test. 4. Select Punch and Staple. 5. Select Punch unit HP. Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?
  • Page 123 5057-XXX 985.00 Sensor (punch carriage shift HP) late error Step Check Check the punch carriage by moving it manually. Go to step 2. Remove obstacles. Does the above component slide back and forth properly? Check the sensor (punch carriage shift HP) for proper Go to step 4.
  • Page 124 5057-XXX Step Check Perform a POR. Replace the Problem solved. finisher controller Does the error continue when the power is turned off/ card assembly. Go to “Finisher controller card assembly removal” on page 4-115. 985.01Sensor (punch carriage shift HP) lag error Step Check Check the punch carriage by moving it manually.
  • Page 125 5057-XXX Step Check Check the punch carriage shift motor for proper Replace the Replace the connection. punch carriage connection. shift motor Is the above component properly connected? assembly. Go to “Punch carriage shift motor assembly removal” on page 4-42. Perform a POR. Replace the Problem solved.
  • Page 126 5057-XXX Step Check Check the media eject clamp motor for proper Go to step 5. Go to step 4. operation. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1. Enter the Diagnostics Menu. 2.
  • Page 127 5057-XXX Step Check Is the sensor (media eject clamp HP) properly Replace the Replace the connected? sensor (media connection. eject clamp HP). Is the above component properly connected? Go to “Sensor (media eject clamp HP) removal” on page 4-66. Check the media eject clamp motor for proper Go to step 5.
  • Page 128 5057-XXX 987.00 Sensor (media eject shaft HP) late error Step Check Check the sensor (media eject shaft HP) for proper Go to step 3. Go to step 2. operation. 1. Enter the Diagnostic Menu. 2. Select FINISHER TESTS. 3. Select Sensor Test. 4.
  • Page 129 5057-XXX Step Check Check the media eject clutch assembly for proper Go to step 7. Go to step 6. operation. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1. Enter the Diagnostics Menu. 2.
  • Page 130 5057-XXX Step Check Check the sensor (media eject shaft HP) for proper Replace the Replace the connection. sensor (media connection. eject shaft HP). Is the above component properly connected? Go to “Sensor (media eject shaft HP) removal” on page 4-78. Check the media eject motor assembly for proper Go to step 5.
  • Page 131 5057-XXX Step Check Perform a POR. Replace the Problem solved. finisher controller Does the error continue when the power is turned off/ card assembly. Go to “Finisher controller card assembly removal” on page 4-115. 988.01 Sensor (punch unit side reg1) or (sensor (punch unit side reg2) lag failure Note: This procedure pertains to sensor punch unit reg1 and reg2.
  • Page 132 5057-XXX Step Check Check the appropriate sensor (punch unit side reg pair) Replace the Replace the connection. appropriate connection. sensor (punch Is the above component properly connected? unit side reg pair). Go to “Sensor (punch unit side registration pair) with bracket removal”...
  • Page 133 5057-XXX 989.00 Stapler unit failure Step Check Check the stapler unit assembly for proper operation. Check for staples Go to step 2. and staple jams. Caution: When performing motor tests, Problem ensure that all cover and door interlock resolved. switches are overridden. Warning: Ensure there are no loose staples in the stapler unit after performing this test.
  • Page 134 5057-XXX Step Check Is the sensor (stapler carriage HP) properly Replace the Replace the connected? sensor (stapler connection. carriage HP). Is the above component properly connected? Go to “Sensor (stapler carriage HP) removal” on page 4-57. Check the stapler carriage motor assembly for proper Go to step 6.
  • Page 135 5057-XXX Step Check Check the sensor (stapler carriage HP) for proper Go to step 4. Go to step 3. operation. 1. Enter the Diagnostics Menu. 2. Select FINISHER TESTS. 3. Select Sensor Test. 4. Select Punch and Staple. 5. Select Stapler carriage shift HP. Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?
  • Page 136 5057-XXX 991.00 Sensor (booklet front temper HP) late error Step Check Check the booklet unit interface connector assembly. Go to step 2. Replace the booklet unit Is the above component free of damage? interface connector assembly. Check the main connector on the booklet unit sensor Go to step 3.
  • Page 137 5057-XXX Step Check Perform a POR. Replace the Problem solved. booklet controller Does the error continue when the power is turned off/on? card assembly. Go to “Booklet controller card assembly removal” on page 4-120. Perform a POR. Replace the Problem solved. finisher controller Does the error continue when the power is turned off/on? card assembly.
  • Page 138 5057-XXX Step Check Check the booklet front tamper motor for proper operation. Go to step 6. Go to step 5. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1. Enter the Diagnostics Menu. 2.
  • Page 139 5057-XXX Step Check Check the booklet rear tamper by moving it manually. Go to step 5. Remove obstructions. Does the above component slide back and forth properly? Check the sensor (booklet rear tamper HP) for proper Go to step 7. Go to step 6.
  • Page 140 5057-XXX Step Check Perform a POR. Replace the Problem solved. finisher controller Does the error continue when the power is turned off/on? card assembly. Go to “Finisher controller card assembly removal” on page 4-115. 991.03 Sensor (booklet rear tamper HP) lag error Step Check Check the booklet unit interface connector assembly.
  • Page 141 5057-XXX Step Check Check the booklet rear tamper motor for proper operation. Go to step 6. Go to step 5. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1. Enter the Diagnostics Menu. 2.
  • Page 142 5057-XXX Step Check Check the booklet end guide by moving it manually. Go to step 5. Remove obstructions. Does the above component slide up and down properly? Check the sensor (booklet end guide HP) for proper Go to step 7. Go to step 6.
  • Page 143 5057-XXX Step Check Perform a POR. Replace the Problem solved. finisher controller Does the error continue when the power is turned off/on? card assembly. Go to “Finisher controller card assembly removal” on page 4-115. 991.05 Sensor (booklet end guide HP) lag error Step Check Check the booklet unit interface connector assembly.
  • Page 144 5057-XXX Step Check Check the booklet end guide drive motor for proper Go to step 9. Go to step 8. operation. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1. Enter the Diagnostics Menu. 2.
  • Page 145 5057-XXX Step Check Check the booklet unit assembly by opening it and closing Go to step 5. Remove obstructions. Does the above component slide open and close properly? Check the sensor (booklet unit interlock) for proper Go to step 7. Go to step 6.
  • Page 146 5057-XXX Step Check Check the sensor (booklet compiler media in) for proper Go to step 6. Go to step 5. operation. 1. Enter the Diagnostics Menu. 2. Select FINISHER TESTS. 3. Select Sensor Test. 4. Select Booklet Path 5. Select Booklet compiler media in. Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?
  • Page 147 5057-XXX Step Check Check the sensor (booklet knife HP) for proper operation. Go to step 6. Go to step 5. 1. Enter the Diagnostics Menu. 2. Select FINISHER TESTS. 3. Select Sensor Test. 4. Select Booklet Path. 5. Select Booklet knife HP. Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked?
  • Page 148 5057-XXX Step Check Is the booklet folding/exit drive motor assembly properly Replace the Replace the connected? booklet folding/exit connection. drive motor Is the above component properly connected? assembly. Go to “Booklet folding/exit drive motor assembly removal” on page 4-121. Perform a POR. Replace the Problem solved.
  • Page 149 5057-XXX Step Check Is the sensor (booklet knife HP) properly connected? Replace the Replace the sensor (booklet connection. Is the above component properly connected? knife HP). Go to “Sensor (booklet knife HP) removal” on page 4-135. Check the booklet knife solenoid for proper operation. Go to step 8.
  • Page 150 5057-XXX Step Check Perform a POR. Replace the Problem solved. booklet controller Does the error continue when the power is turned off/on? card assembly. Go to “Booklet controller card assembly removal” on page 4-120. Perform a POR. Replace the Problem solved. finisher controller Does the error continue when the power is turned off/on? card assembly.
  • Page 151 5057-XXX Step Check Check the booklet folding/exit drive motor assembly for Go to step 8. Go to step 7. proper operation. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1. Enter the Diagnostics Menu. 2.
  • Page 152 5057-XXX Step Check Check the main connector on the booklet unit sensor Go to step 4. Replace the interface cable assembly. booklet unit sensor interface cable Is the above component free of damage? assembly. Check the main connector on the booklet unit motor Go to step 5.
  • Page 153 5057-XXX Step Check Perform a POR. Replace the Problem solved. finisher controller Does the error continue when the power is turned off/on? card assembly. Go to “Finisher controller card assembly removal” on page 4-115. 991.13 Booklet unit maker error Step Check Perform a POR.
  • Page 154 5057-XXX Step Check Check the de-curler clutch for proper operation. Go to step 5. Go to step 4. Caution: When performing motor tests, ensure that all cover and door interlock switches are overridden. 1. Enter the Diagnostics Menu. 2. Select MOTOR TESTS. 3.
  • Page 155 5057-XXX 992.01 Sensor (de-curler cam HP) lag error Step Check Check the sensor (de-curler cam HP) for proper operation. Go to step 3. Go to step 2. 1. Enter the Diagnostics Menu. 2. Select FINISHER TESTS. 3. Select Sensor Test. 4.
  • Page 156 5057-XXX Step Check Is the bridge unit drive motor properly connected? Replace the bridge Replace the unit drive motor. connection. Is the above component properly connected? Go to “Bridge unit drive motor removal” on page 4-8. Perform a POR. Replace the bridge Problem solved.
  • Page 157 5057-XXX Step Check Check the bridge unit top cover assembly on the bridge Reshape the Go to step 3. unit assembly for shape and operation. actuator so it fits into the cover Is the actuator of the bridge unit top cover assembly sensor.
  • Page 158 5057-XXX Finisher front door open Step Check Open and close the finisher front door assembly. Go to step 2. Check the finisher front door Does it open or close smoothly? assembly for installation, correct deformations, or replace it. Go to “Finisher front door assembly...
  • Page 159 5057-XXX Finisher eject cover open Step Check Check the switch (eject cover interlock) installation. Go to step 2. Reinstall the switch (media Is the switch (eject cover interlock) installed properly? eject cover). Check the operation of the switch (eject cover Go to step 4.
  • Page 160 5057-XXX Step Check Is the sensor (upper media bin full) connected Replace the Replace the properly? sensor (upper connection. media bin full). Go to “Sensor (upper media bin full) removal” on page 4-105. Perform a print test. Replace the Problem solved. finisher controller Does the error still occur? card assembly.
  • Page 161 5057-XXX Step Check Perform a print test. Replace the Problem solved. bridge unit Does the error still occur? interface card assembly. Go to “Bridge unit interface card assembly removal” on page 4-114. Go to step 5. Perform a print test. Replace the Problem solved.
  • Page 162 5057-XXX Step Check Perform a print test. Replace the Problem solved. finisher controller Does the error still occur? card assembly. Go to “Finisher controller card assembly removal” on page 4-115. Stacker media bin full (mix size) Step Check Check the stacker bin for obstructions. Remove the Go to step 2.
  • Page 163 5057-XXX Step Check Is the sensor (stacker bin level 2) connected properly? Replace the Replace the sensor (stacker connection. bin level 2). Go to “Sensor (stacker bin level 2) removal” on page 4-33. Check the encoder of the sensor (stacker bin level Go to step 7.
  • Page 164 5057-XXX Step Check Perform a print test. Replace the Problem solved. finisher controller Does the error still occur? card assembly. Go to “Finisher controller card assembly removal” on page 4-115. Stacker media bin full (no mix) Step Check Check the stacker bin for obstructions. Remove the Go to step 2.
  • Page 165 5057-XXX Step Check Is the sensor (stacker bin level 2) connected properly? Replace the Replace the sensor (stacker connection. bin level 2). Go to “Sensor (stacker bin level 2) removal” on page 4-33. Check the encoder of the sensor (stacker bin level Go to step 7.
  • Page 166 5057-XXX Step Check Perform a print test. Replace the Problem solved. finisher controller Does the error still occur? card assembly. Go to “Finisher controller card assembly removal” on page 4-115. Stacker lower safety failure Step Check Check the vertical transport mechanism of the stacker Remove Go to step 2.
  • Page 167 5057-XXX Step Check Check the sensor (stacker bin level 2) connection. Replace the Replace the sensor (stacker connection. Are the connections of the main sensor cable bin level 2). assembly properly connected? Go to “Sensor (stacker bin level 2) removal” on page 4-33.
  • Page 168 5057-XXX Staple cartridge empty Step Check Check the staple cartridge for new and unused staples. Go to step 2. Refill the cartridge with Does the staple cartridge have a sufficient amount of new and unused new and unused staples? staples. Check the staple cartridge for correct installation.
  • Page 169 5057-XXX 3. Diagnostic aids This chapter explains the tests and procedures to identify printer failures and to verify that repairs have corrected the problem. Accessing service menus Access the following menus to identify problems with the printer and run diagnostic tests. Diagnostics Menu 1.
  • Page 170 5057-XXX Diagnostics Menus Entering Diagnostics Menus 1. Turn off the printer. 2. Press and hold the buttons simultaneously. 3. Turn on the printer. 4. Release the buttons after 10 seconds. Available tests Tests appear on the LCD in the order shown: MOTOR TESTS “MOTOR TESTS”...
  • Page 171 5057-XXX Booklet stapler motor Bridge unit bin media exit solenoid Printer Motor Tests Transfer belt steering motor CMY PC cartridge drive motor K PC cartridge drive motor Printhead polygon mirror motor Tray 1 media feed/lift motor Registration clutch 2nd transfer roll retract motor K developer/transport motor MPF pick solenoid MFP/transport drive motor...
  • Page 172 5057-XXX Panel Test “Panel Test” on page 3-7. Button Test “Button Test” on page 3-7. DRAM Test “DRAM Test” on page 3-8. CACHE Test “CACHE Test” on page 3-8. DUPLEX TESTS Quick Test “Quick Test” on page 3-8. Sensor Test “Sensor Test (duplex)”...
  • Page 173 5057-XXX C Channel (925.02) K Channel (925.03) Dev Unit Reset “Dev Unit Reset” on page 3-18. Y Channel M Channel C Channel K Channel ENGINE ADJUST “ENGINE ADJUST” on page 3-20. PH Adjust (registration) PRO-CON RegCon Adjust Booklet Fold Adj Finisher Config Booklet Fold Adjust “Booklet Fold Adjust”...
  • Page 174 5057-XXX The following Printer Motor Tests are available: • Transfer belt steering motor • Y toner add motor • CMY PC cartridge drive motor • K toner add motor • K PC cartridge drive motor • CMY developer drive motor •...
  • Page 175 5057-XXX Input Source Print Test Regardless of the input source selected, the printer always generates a simplex version of the Print Test page using its default resolution. Print Quality Test Pages This setting enables you to view the values of a broad range of the device’s settings and to test the device’s ability to generate acceptable printed output.
  • Page 176 5057-XXX DRAM Test The DRAM Test is used to check the validity of both the printer’s standard and optional DRAM. The test involves writing patterns of data to DRAM to verify that each bit in memory can be set and read correctly. To run the DRAM Test: 1.
  • Page 177 5057-XXX Make sure either letter or A4 size paper is loaded in the default paper source. If the default source only supports envelopes, then the Quick Test will be printed from Tray 1. To run the Quick Test: 1. Select DUPLEX TESTS from the Diagnostics Menu. 2.
  • Page 178 5057-XXX • Continuous–Media continues feeding from the selected input source until Stop is pressed. Sensor Test (input tray) This test is used to verify that a specific input tray’s sensors are working correctly. To run the Input Tray Sensor Test: 1.
  • Page 179 5057-XXX Press Stop to return to the [Selected Output Bin]. While this test runs, [Selected Output Bin] Feeding...appears on the LCD. During Single tests, no buttons are active. However, during Continuous tests, you can press Stop to cancel the test. Feed To All Bins This test can be used to verify that the printer can feed media to the standard bin or any installed output options.
  • Page 180 5057-XXX To run the Staple Test 1. Select FINISHER TESTS from the Diagnostics Menu. 2. Select Staple Test. The printer feeds eight pieces of media from the default input source to the output bin that supports stapling. After all eight pieces of media are deposited, the device staples the packet. While this test runs, Staple Test Running...
  • Page 181 5057-XXX Available Cover and Door Sensors Sensor Name Door G finisher front Surface H eject cover Cover F bridge unit top Available Bin Level Sensors Sensor Name Finisher upper media bin full Stacker bin level1 Stacker bin level2 Stacker bin upper limit Stacker bin no media Stacker bin level encod Available Media Path 1 Sensors...
  • Page 182 5057-XXX Booklet front tamper HP Booklet rear tamper HP Booklet unit media entrance Booklet unit media exit Booklet bin media present Booklet compiler media present Booklet unit interlock Booklet front low staple Booklet rear low staple Available Punch and Staple Sensors Sensor Name Punch side reg1 Punch side reg2...
  • Page 183 5057-XXX Door A printer left Door C printer left lower Door D tray module left Door E printer front Door J transfer belt access Devices Sensors Sensor Name C PC cartridge present M PC cartridge present Y PC cartridge present K PC cartridge present Waste toner full Exit Level Sensor...
  • Page 184 5057-XXX Defaults The value of this setting determines whether the printer uses the US or Non-US factory default value for the printer settings listed below: Printer Setting US Value Non-US Value Paper Sizes Letter (applies only to input sources which do not have hardware size sensing capability) Envelope Size 10 Envelope...
  • Page 185 5057-XXX 3. When the printer is not in Diagnostics mode, Check Config ID appears on the LCD. Note: Each of the above conditions will remain until a valid value is entered for Configuration ID 1 and Configuration ID 2. The Configuration ID setting allows you to set both Configuration IDs simultaneously. To set one or both Configuration IDs: 1.
  • Page 186 5057-XXX Select Back to return to the EVENT LOG. Print the Event Log Each page of the printed Event Log report has the title Event Log at the top of each page followed by the model name and serial number. The following is a sample of a printed Event Log: Model and Serial number XXX-XXXX...
  • Page 187 5057-XXX To perform the Dev Unit Reset Test: 1. Select Dev Unit Reset from the Diagnostics Menu. The following tests appear on the LCD: Select the following: Appears on the LCD: Y Channel Y Channel Testing... M Channel M Channel Testing... M Channel C Channel Testing...
  • Page 188 5057-XXX ENGINE ADJUST To begin PH Adjust (media tray registration), the test page must be printed. To print the test page the printer must be in standard mode. 1. Select Menus. 2. Select Reports. 3. Select Network Setup Page The following report prints. Using a fine incremental ruler, measure from the black line border to the edge of the media.
  • Page 189 5057-XXX Adj Lead Reg ALL (appears on LCD) Registration values appear on the LCD. If required, reset the values (Adj lead reg all trays) and Select to submit the changes. Adj Lead Reg Tr165 (appears on LCD) Registration values appear on the LCD.
  • Page 190 5057-XXX PRO-CON (ATC sensor setup and adjust) This procedure is used to adjust the following: Sensor (C ATC) Sensor (M ATC) Sensor (Y ATC) Sensor (K ATC) Select PRO-CON and select: Then Select: Appears on the LCD ATC Sensor Adjust values Sen Grad SNR-Y Registration values appear on the LCD.
  • Page 191 5057-XXX Press Stop to return to ENGINE ADJUST. Booklet Fold Adjust To perform the Booklet Fold Adjust Test: 1. Select Booklet Fold Adjust from the Diagnostics Menu. The following tests appear on the LCD Select the following: Appears on the LCD: Booklet Compile position Booklet Compile position values appear on the LCD.
  • Page 192 5057-XXX Entering Configuration Menu 1. Turn off the printer. 2. Press and hold the Select and Right Arrow buttons simultaneously. 3. Turn on the printer. 4. Release the buttons after 10 seconds. Available menus Maintenance Counter Value “Maintenance Counter Value” on page 3-24.
  • Page 193 5057-XXX After installing the required maintenance kit, reset this count to zero. Reset Maintenance Counter After scheduled maintenance, reset the Maintenance Counter. To reset the maintenance page counter to zero: 1. Select Reset Maintenance Counter from the Configuration Menu. 2. Reset Maintenance Counter appears in the header. 3.
  • Page 194 5057-XXX Size sensing Input source Length Width ✓ ✓ Tray 4 (optional 2TM 500-sheet drawer) To change the value of this setting: 1. Select SIZE SENSING from the Configuration Menu. The screen displays each size sensing equipped input source and its current Size Sensing value. 2.
  • Page 195 2. Select Restore Base to restore all non-critical base printer NVRAM settings. 3. Select Restore Network to restore all network NVRAM settings. 4. Select Restore LES to remove all Lexmark Embedded Solution applications When you select either value, the LCD displays Restoring Factory Defaults and then Resetting the Device.
  • Page 196 5057-XXX Select Back to return to the Configuration Menu. Note: An event log printed from the Configuration Menu will not contain debug information or secondary codes for 900 service errors. However, the event log printed from the Diagnostics Menu does include this information. Paper Prompts When a tray is out of the indicated paper size, a prompt is sent to the user to load paper in a tray.
  • Page 197 5057-XXX Short Edge Printing The default printing orientation is long edge. This setting allows you to enable or prohibit short edge fed paper. If the setting Disabled (default) is selected, letter and A4 paper can only be fed long edge. If they are fed short edge, a prompt will ask you to use the correct paper size.
  • Page 198 5057-XXX 3-30 Printer Service Manual...
  • Page 199 5057-XXX 4. Repair information Warning: Read the following before handling electronic parts. Handling ESD-sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, use the following instructions in addition to all the usual precautions, such as turning off power before removing logic boards: •...
  • Page 200 5057-XXX Removal procedures CAUTION Remove the power cord from the electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage. Disconnect any connections between the printer and PCs/peripherals. Note: Some removal procedures require removing cable ties. You must replace cable ties during reassembly to avoid pinching wires, obstructing the paper path, or restricting mechanical movement.
  • Page 201 5057-XXX Finisher removal 1. Disconnect the finisher power cord and the finisher connection cable from the rear of the printer. 2. Release the hook securing the bridge unit hookup cover (A) to the finisher. Hook Right Rear 3. Remove the bridge unit hookup cover (A). 4.
  • Page 202 5057-XXX 5. Open the finisher front door assembly (B) on the front of the finisher. 6. Pull the finisher docking latch assembly (C) outward in the direction of the arrow, and pull the finisher away from the printer. 7. Close the finisher front door assembly. Printer Finisher Service Manual...
  • Page 203 5057-XXX 8. Remove the two screws securing the finisher docking bracket (D) to the printer. 9. Remove the finisher docking bracket (D). Replacement note: When docking the finisher to the printer, make sure the boss on the finisher docking bracket (D) is inserted into the hole on the finisher docking latch assembly (C). The finisher should be firmly locked into position.
  • Page 204 5057-XXX 5. Remove the bridge unit assembly (B) from the printer. Bridge unit top cover removal “Bridge unit assembly removal” on page 4-5. 1. Remove the bridge unit assembly. See 2. Remove the bridge unit rear cover. See “Bridge unit top cover removal” on page 4-6.
  • Page 205 5057-XXX 8. Remove the two small brackets (C). Sensor (bridge unit top cover interlock) removal “Bridge unit assembly removal” on page 4-5. 1. Remove the bridge unit assembly. See 2. Remove the bridge unit right cover. See “Bridge unit right cover removal” on page 4-11.
  • Page 206 5057-XXX 6. Disconnect the connector from the sensor (bridge unit top cover interlock) (A). Bridge unit drive motor removal 1. Remove the bridge unit assembly. See “Bridge unit assembly removal” on page 4-5. 2. Remove the bridge unit motor cover. See “Bridge unit motor cover removal”...
  • Page 207 5057-XXX Bridge unit exit/de-curler drive belt removal 1. Remove the bridge unit assembly. See “Bridge unit assembly removal” on page 4-5. 2. Remove the bridge unit right cover. See “Bridge unit right cover removal” on page 4-11. 3. Remove the bridge unit motor cover. See “Bridge unit motor cover removal”...
  • Page 208 5057-XXX Replacement warning: When replacing the de-curler clutch (C), ensure that the hook on the de-curler clutch (C) is captured by the boss on the bracket (B). sensor (de-curler cam HP) removal 1. Remove the bridge unit assembly. See “Bridge unit assembly removal” on page 4-5.
  • Page 209 5057-XXX Bridge unit motor cover removal 1. Remove the bridge unit assembly. See “Bridge unit assembly removal” on page 4-5. 2. Remove the three screws securing the bridge unit motor unit (A) to the assembly. 3. Remove the bridge unit motor cover (A). Note: When removing the bridge unit motor cover (A), the grounding strap (B) will become detached.
  • Page 210 5057-XXX 5. Release the hooks securing the sensor (bridge unit media entrance) (C) to the bracket (A). 6. Remove the sensor (bridge unit media entrance) (C). Sensor (bridge unit media exit) removal 1. Remove the bridge unit assembly. See “Bridge unit assembly removal” on page 4-5.
  • Page 211 5057-XXX 7. Remove the sensor (bridge unit media exit) (C). Sensor (bridge unit bin exit) removal 1. Remove the bridge unit assembly. See “Bridge unit assembly removal” on page 4-5. “Bridge unit left cover removal” on page 4-17. 2. Remove the bridge unit left cover. See 3.
  • Page 212 5057-XXX 7. Remove the sensor (bridge unit bin exit) (B). Bridge unit diverter gate solenoid removal 1. Remove the bridge unit assembly. See “Bridge unit assembly removal” on page 4-5. 2. Remove the bridge unit left cover. See “Bridge unit left cover removal” on page 4-17.
  • Page 213 5057-XXX 9. Remove the bridge unit diverter gate solenoid (A). Switch (bridge unit top cover interlock) removal 1. Remove the bridge unit assembly. See “Bridge unit assembly removal” on page 4-5. 2. Remove the bridge unit left cover. See “Bridge unit left cover removal” on page 4-17.
  • Page 214 5057-XXX Bridge unit diverter gate removal 1. Remove the bridge unit assembly. See “Bridge unit assembly removal” on page 4-5. 2. Remove the bridge unit left cover. See “Bridge unit left cover removal” on page 4-17. 3. Remove the bridge unit diverter gate solenoid. See “Bridge unit diverter gate solenoid removal”...
  • Page 215 5057-XXX 10.Disconnect the connector from the Bridge unit bin media exit solenoid (C). Bridge unit left cover removal 1. Remove the bridge unit assembly. See “Bridge unit assembly removal” on page 4-5. 2. Raise the bridge unit top cover to its full upright position. 3.
  • Page 216 5057-XXX Top cover removal 1. Open the finisher front door assembly. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-19.
  • Page 217 5057-XXX Upper media bin assembly removal 1. Loosen the two screws securing the upper media bin assembly (A) to the finisher. Right 2. Lift the upper media bin assembly (A) upward in the direction of the arrow. 3. Remove the upper media bin assembly (A). 4-19 Repair information...
  • Page 218 5057-XXX Right eject cover removal 1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-26. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the two screws securing the right eject cover (A) to the finisher. Right 4.
  • Page 219 5057-XXX Stacker media bin assembly removal 1. Release the two hooks securing the stacker media bin assembly (A) to the finisher. 2. Lift the stacker media bin assembly (A) upward. 3. Remove the stacker media bin assembly. (A). Right lower low voltage power supply (LVPS) cover removal 1.
  • Page 220 5057-XXX Rear lower cover removal 1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 2. Remove the four screws securing the rear lower cover (A) to the finisher. 3. Remove the rear lower cover (A). 4-22 Printer Finisher Service Manual...
  • Page 221 5057-XXX Rear upper cover removal 1. Release the hook of the bridge unit hookup cover (A) to the finisher. 2. Disconnect the bridge unit harness from the finisher. 3. Remove the four screws securing the rear upper cover (B) to the finisher. Hook 4.
  • Page 222 5057-XXX Upper media bin front cover removal 1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-26. 2. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-19. 3. Remove the two screws securing the upper media bin front cover (A). 4.
  • Page 223 5057-XXX Switch (finisher front door interlock) removal 1. Open the finisher front door assembly. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the punch waste box (A). 4. Remove the three screws in the front securing the punch waste chute (B). 5.
  • Page 224 5057-XXX Finisher front door assembly removal 1. Open the finisher front door assembly (A). 2. Remove the three screws securing the finisher front door assembly. 3. Remove the finisher front door assembly. Replacement note: Make sure the actuator molded in the finisher front door assembly properly engages the switch (finisher front door interlock) (B).
  • Page 225 5057-XXX Left lower cover removal 1. Open the finisher front door assembly. 2. Remove the two screws securing the left lower cover (A). 3. Remove the left lower cover (A). 4-27 Repair information...
  • Page 226 5057-XXX Left upper cover removal 1. Open the finisher front door assembly. 2. Remove the two screws securing the left upper cover (A). 3. Remove the left upper cover (A). 4-28 Printer Finisher Service Manual...
  • Page 227 5057-XXX Carriage lift belt left removal 1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 2. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-26. 3. Move the slip clutch gear 24T (A) toward the rear to disengage the stacker bin (B). 4.
  • Page 228 5057-XXX 5. Remove the two screws securing the bin bracket (C) to the left carriage bracket (D). 6. Remove the spring (E) from the left carriage lift assembly. 7. Remove the screw securing the upper belt clamp (F) to the left carriage bracket (D). 8.
  • Page 229 5057-XXX Carriage lift belt right removal 1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 2. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-26. 3. Move the slip clutch gear 24T (A) toward the rear to disengage the stacker bin (B). 4.
  • Page 230 5057-XXX 5. Remove the two screws securing the bin bracket (C) to the right carriage bracket (D). 6. Remove the spring (E) from the right carriage bracket (D). 7. Remove the screw securing the upper belt clamp (F) to the right carriage bracket (D). 8.
  • Page 231 5057-XXX Sensor (stacker bin level 1) removal 1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-26. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Disconnect the connector from the sensor (stacker bin level 1) (A). Front Connector 4.
  • Page 232 5057-XXX Sensor (stacker bin level encoder) removal 1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 2. Disconnect the connector from the sensor (stacker bin level encoder) (A). 3. Release the harness from the clamp. 4.
  • Page 233 5057-XXX Sensor (stacker bin upper limit) or sensor (stacker bin no media) removal 1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 2. Remove the rear lower cover. See “Rear lower cover removal” on page 4-22.
  • Page 234 5057-XXX Replacement note: Make sure that the yellow connector is plugged into the sensor (stacker bin no media) (C). Rear White connector Yellow connector 4-36 Printer Finisher Service Manual...
  • Page 235 5057-XXX Stacker bin lift motor assembly removal 1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 2. Remove the rear lower cover. See “Rear lower cover removal” on page 4-22. 3. Loosen the four screws securing the plate (A). 4.
  • Page 236 5057-XXX 6. Move the slip clutch gear 24T (B) toward the rear to disengage the stacker bin (C). 7. Move the stacker bin (C) to the lowest position. Note: Make sure the stacker bin (C) is at the lowest position before continuing. 8.
  • Page 237 5057-XXX 11. Remove the screw securing the bracket (F) to the stacker bin lift motor assembly (G). 12. Remove the bracket (F). Connector Clamp 13. Release the hook securing the encoder (H) to the stacker bin lift motor assembly (G). 14.
  • Page 238 5057-XXX Punch carriage assembly removal 1. Open the finisher front door assembly. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-19.
  • Page 239 5057-XXX 12. Remove the two screws on the front securing the punch carriage assembly (B) to the finisher. Front 13. While moving the belt (buffer/transport) (E) to the left as shown, pull the punch carriage assembly (B) gently out of the rear of the finisher. Warning: Do not force the punch carriage assembly (B) out of the finisher.
  • Page 240 5057-XXX Punch carriage shift motor assembly removal 1. Open the finisher front door assembly. 2. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-19. 3. Remove the top cover. See “Top cover removal” on page 4-18.
  • Page 241 5057-XXX Sensor (punch unit side registration pair) with bracket removal 1. Open the finisher front door assembly. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-19.
  • Page 242 5057-XXX Punch unit assembly removal 1. Open the finisher front door assembly. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-19.
  • Page 243 5057-XXX Punch media stop assembly removal 1. Open the finisher front door assembly. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-19.
  • Page 244 5057-XXX Punch unit motor assembly removal 1. Open the finisher front door assembly. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-19.
  • Page 245 5057-XXX Sensor (punch unit motor encoder) removal 1. Open the finisher front door assembly. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-19.
  • Page 246 5057-XXX Sensor (punch hole select), sensor (punch cam front), and sensor (punch unit HP) removal 1. Open the finisher front door assembly. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the punch carriage assembly. See “Punch carriage assembly removal”...
  • Page 247 5057-XXX Replacement note: Make sure the color coded-connectors are connected to the proper sensors, as shown. Connector Blue Black Connector White 4-49 Repair information...
  • Page 248 5057-XXX Sensor (punch carriage shift HP) removal 1. Open the finisher front door assembly. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the punch carriage assembly. See “Punch carriage assembly removal” on page 4-40.
  • Page 249 5057-XXX Sensor (punch waste box set) removal 1. Open the finisher front door assembly. 2. Pull the punch waste box. 3. Disconnect the connector from the sensor (punch waste box set) (A). 4. Release the hooks securing the sensor (punch waste box set) (A) to the finisher. Connector 5.
  • Page 250 5057-XXX Sensor (punch waste box full) removal 1. Open the finisher front door assembly. 2. Remove the punch waste box (A) from the finisher. 3. Disconnect the connector from the sensor (punch waste box full) (B). 4. Release the hooks securing the sensor (punch waste box full) (B) to the finisher. Connector 5.
  • Page 251 5057-XXX Stapler unit frame removal 1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-26. 2. Remove the staple cartridge. 3. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 4.
  • Page 252 5057-XXX 8. Disconnect the connector P8308 from the finisher controller card assembly (B). 9. Remove the screw securing the ground wire (C) to the finisher. 10. Release the harness from the clamp. Clamp P8308 Rear 11. Remove the media stacker bin lift motor assembly. See “Stacker media bin assembly removal”...
  • Page 253 5057-XXX Stapler unit assembly removal 1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-26. 2. Remove the staple cartridge. 3. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 4.
  • Page 254 5057-XXX 11. Remove the screw securing the stapler cover (E) to the stapler unit assembly (F). 12. Remove the stapler cover (E). 13. Disconnect the two connectors from the stapler unit assembly (F). 14. Disconnect the connector from the sensor (stapler carriage HP) (G). 15.
  • Page 255 5057-XXX Sensor (stapler carriage HP) removal 1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-26. 2. Remove the staple cartridge. 3. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23.
  • Page 256 5057-XXX Media eject unit assembly removal 1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-26. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the upper media bin assembly. See “Upper media bin assembly removal”...
  • Page 257 5057-XXX 8. Remove the screw securing the eject clamp lever assembly (C) from the shaft (D) on the rear of the finisher. 9. Remove the eject clamp lever assembly (C). 10. Remove the e-clip securing the shaft (D) to the rear of the finisher. 11.
  • Page 258 5057-XXX 12. Remove the e-clip securing the shaft (F) to the front of the finisher. 13. Remove the 8 mm bushing (E) on the front side. E-clip Front 14. Gently move the left side of the media eject unit assembly (G) out of the finisher followed by the right side. Note: Do not force the media eject unit assembly out of the finisher.
  • Page 259 5057-XXX Replacement notes: • Do not force the media eject unit assembly into the finisher. Insert the right side before the left side. • Make sure the media eject unit assembly properly actuates the switch (eject cover interlock) (H) without binding.
  • Page 260 5057-XXX Sub paddle removal 1. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-19. 2. Gently remove the two sub paddles (A) from the two shafts (B). Replacement note: Make sure the sub paddles are properly installed as shown in the figure. The paddles must not come in contact with the media eject unit assembly (C).
  • Page 261 5057-XXX Sub paddle drive shaft assembly removal 1. Open the finisher front door assembly. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the media eject unit assembly. See “Media eject unit assembly removal” on page 4-58.
  • Page 262 5057-XXX 8. Loosen the two screws securing the belt tensioner bracket (D) to the rear of the finisher. 9. Release the hook of the sub paddle drive gear 23T (E) from the sub paddle drive shaft assembly (B). 10. Remove the sub paddle drive gear 23T (E). 11.
  • Page 263 5057-XXX Media eject clamp motor assembly removal 1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 2. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-19. 3. Remove the two media eject unit springs (A) attached to the media eject unit assembly (B) by pushing them downward.
  • Page 264 5057-XXX Sensor (media eject clamp HP) removal 1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 2. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-19. 3. Remove the two media eject unit springs attached to the media eject unit assembly by pushing them downward.
  • Page 265 5057-XXX Switch (eject cover interlock) removal 1. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-19. 2. Disconnect the connector from the switch (eject cover interlock) (A). 3. Release the harness from the two clamps. 4.
  • Page 266 5057-XXX Media compiler unit assembly removal 1. Remove the finisher front door assembly. See“Finisher front door assembly removal” on page 4-26. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the rear lower cover. See “Rear lower cover removal”...
  • Page 267 5057-XXX 13. Disconnect the connector P8309 from the finisher controller card assembly (B). 14. Release the harness from the clamps. Clamp P8309 Rear 15. Remove the screw securing the media compiler unit assembly (C) to the finisher. This screw is found inside the finisher.
  • Page 268 5057-XXX 16. Release the media compiler assembly (C) by pushing the front lock and the rear lock inward to release the front boss and the rear boss from the finisher. Right Rear view Front view Lock Lock 17. Remove the harness from any additional parts. 18.
  • Page 269 5057-XXX 13. Remove the sensor(s). Note: The sensors are identical. Connector Sensor (compiler media in) removal 1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-26. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23.
  • Page 270 5057-XXX 13. Move the compiler media present actuator (C) downward as shown. Connector 14. Remove the sensor (compiler media present) (A). 4-72 Printer Finisher Service Manual...
  • Page 271 5057-XXX Media eject shaft assembly removal 1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-26. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Move the slip clutch gear 24T (A) toward the rear as shown to disengage the stacker bin (B). 4.
  • Page 272 5057-XXX 15. Move the media eject shaft assembly toward the rear and outward as shown. E-clips E-clip Front Rear 16. Remove the media eject shaft assembly (E). Rear 4-74 Printer Finisher Service Manual...
  • Page 273 5057-XXX Clamp paddle removal 1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-26. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the media eject shaft assembly. See “Media eject shaft assembly removal”...
  • Page 274 5057-XXX Media eject clutch assembly removal 1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 2. Disconnect the connector from the sensor (media eject shaft HP) (A). 3. Release the harness from the clamp. 4. Disconnect the connector from the media eject clutch (B). 5.
  • Page 275 5057-XXX Media eject motor assembly removal 1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 2. Remove the media eject clutch. See “Media eject clutch assembly removal” on page 4-76. 3. Disconnect the connector from the media eject motor assembly (A). 4.
  • Page 276 5057-XXX Sensor (media eject shaft HP) removal 1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 2. Disconnect the connector from the sensor (media eject shaft HP) (A). 3. Rotate the media eject clutch actuator (B) by hand so it clears the sensor (media eject shaft HP) (A). 4.
  • Page 277 5057-XXX Sensor (lower media exit) removal 1. Open the finisher front door assembly. 2. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-19. 3. Disconnect the connector from the sensor (lower media exit) (A). 4.
  • Page 278 5057-XXX Lower media exit roll assembly removal 1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-26. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the upper media bin assembly. See “Upper media bin assembly removal”...
  • Page 279 5057-XXX Front view Rear view 19. Release the hook of the lower exit roll drive pulley 20T (C) from the lower media exit roll assembly (F). 20. Remove the lower exit roll drive pulley 20T (C). 4-81 Repair information...
  • Page 280 5057-XXX 21. Remove the 6 mm ball bearing (G). 22. Use a prying tool to remove the e-clip on the front of the finisher securing the lower media exit roll assembly (F) to the finisher. 4-82 Printer Finisher Service Manual...
  • Page 281 5057-XXX 23. Remove the 6 mm bushing (H). E-clip Front 24. Move the lower media exit roll assembly (F) towards the rear and outward, as shown. Rear 25. Remove the lower media exit roll assembly (F). 4-83 Repair information...
  • Page 282 5057-XXX Paddle and roll exit assembly removal 1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-26. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the rear lower cover. See “Rear lower cover removal”...
  • Page 283 5057-XXX 14. Loosen the two screws securing the belt tensioner bracket (D) to the finisher and move it upward, as shown. Replacement note: When replacing the belt tensioner bracket (D), tighten the screws in the order shown. 15. Remove the belt (paddle/entrance) (E) from the main paddle drive pulley/gear 44/20T (F). 16.
  • Page 284 5057-XXX 25. Remove the main paddle shaft assembly. Rear 4-86 Printer Finisher Service Manual...
  • Page 285 5057-XXX Replacement notes: • The tension of the belt (exit) (A) and the belt (paddle/entrance) (E) is automatically adjusted by the force of the spring attached to the belt tensioner bracket (A and D). • Tighten the screws in the order shown. First Right Second...
  • Page 286 5057-XXX Lower pinch guide assembly removal 1. Open the finisher front door assembly. 2. Open the lower pinch guide assembly (A) by lifting it upward. 3. Remove the screw securing the lower pinch guide assembly (A) to the finisher. 4. Move the lower pinch guide assembly (A) upward and outward. Front 5.
  • Page 287 5057-XXX Finisher diverter gate removal 1. Open the finisher front door assembly. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Open the lower pinch guide assembly (A) to the right. 4. Open the upper pinch guide assembly (B) to the right. 5.
  • Page 288 5057-XXX Buffer diverter gate removal 1. Open the finisher front door assembly. 2. Move the lower pinch guide assembly (A) to the right. 3. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 4. Remove the buffer diverter gate solenoid. See “Buffer diverter gate solenoid removal”...
  • Page 289 5057-XXX Sensor (buffer path) removal 1. Open the finisher front door assembly. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-19.
  • Page 290 5057-XXX Finisher buffer roll assembly removal 1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 2. Open the finisher front door assembly. 3. Remove the stapler unit cartridge. 4. Move the stapler unit assembly by hand as far to the rear as it will go. 5.
  • Page 291 5057-XXX 11. Loosen the two screws securing the belt tensioner bracket (E) to the finisher and move it downward, as shown. 12. Remove the belt (buffer/transport) (F) from the buffer roll drive gear 46T (G). E-clip Second First 13. Use a prying tool to remove the e-clip securing the buffer roll drive gear 23/53T (G). 14.
  • Page 292 5057-XXX Buffer pinch guide assembly removal 1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-26. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the rear lower cover. See “Rear lower cover removal”...
  • Page 293 5057-XXX Media entrance pinch guide assembly removal 1. Open the finisher front door assembly. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the left lower cover. See “Left lower cover removal” on page 4-27.
  • Page 294 5057-XXX Sensor (finisher media entrance) removal 1. Open the front door assembly. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-19.
  • Page 295 5057-XXX Finisher media entrance roll assembly removal 1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-26. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the left upper cover. See “Left upper cover removal”...
  • Page 296 5057-XXX 16. Move the media entrance roll assembly (H) toward the rear, downward, and then forward. 17. Remove the media entrance roll assembly (H) through the inside of the finisher. Note: When removing the media entrance roll assembly (H), do not touch the rubber surface. Replacement notes: •...
  • Page 297 5057-XXX 5. Remove the two screws securing the bracket (D) to the finisher. Connector 6. Remove the bracket (D). 7. Remove the two screws securing the bracket (D) to the drive motor (entrance/paddle) (C). 8. Remove the drive motor (entrance/paddle) (C). 9.
  • Page 298 5057-XXX Finisher diverter gate solenoid removal 1. Open the finisher front door assembly. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Disconnect the connector from the finisher diverter gate solenoid (A). 4. Release the harness from the clamp. 5.
  • Page 299 5057-XXX Buffer diverter gate solenoid removal 1. Open the finisher front door assembly. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Disconnect the connector from the buffer diverter gate solenoid (A). 4. Release the harness from the clamp. 5.
  • Page 300 5057-XXX Sensor (upper media exit) removal 1. Open the finisher front door assembly. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-19.
  • Page 301 5057-XXX Upper media exit roll assembly removal 1. Open the finisher front door assembly. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-19.
  • Page 302 5057-XXX 11. Remove the bracket (C). 12. Release the hook from the upper media exit roll drive gear 20T(D). 13. Remove the upper media exit roll drive gear 20T. 14. Remove the 6 mm bushing. 15. Use a prying tool to remove the e-clip securing the upper media exit roll assembly (F) to the front of the finisher.
  • Page 303 5057-XXX Sensor (upper media bin full) removal 1. Open the finisher front door assembly. 2. Remove the screw securing the bracket (A) to the upper media bin vertical cover (B). 3. Move the bracket frontward and downward to gain access to the harness and connector. 4.
  • Page 304 5057-XXX Upper pinch guide assembly removal 1. Open the finisher front door assembly. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the drive motor (buffer/transport). See “Drive motor (buffer/transport) and belt (buffer/transport) removal”...
  • Page 305 5057-XXX Sensor (diverter gate) removal 1. Open the finisher front door assembly. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-19.
  • Page 306 5057-XXX Upper media transport roll assembly removal 1. Open the finisher front door assembly. 2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 3. Remove the top cover. See “Top cover removal” on page 4-18. 4.
  • Page 307 5057-XXX 10. Remove the two screws securing the bracket (D). Note: It is not necessary to remove the bracket from the finisher; it should only be slightly moved to provide better access to the two upper media transport roll drive pulleys 20T(E). 11.
  • Page 308 5057-XXX Drive motor (exit) assembly and belt (exit) removal 1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 2. Loosen the two screws securing the belt tensioner bracket (A) to the finisher, and move it down as shown. 3.
  • Page 309 5057-XXX 5. Remove the two screws securing the bracket (D) to the finisher. 6. Remove the bracket (D). 7. Remove the two screws securing the drive motor (exit) assembly to the bracket (D). Connector 8. Remove the drive motor (exit) assembly (C). Replacement notes: •...
  • Page 310 5057-XXX Drive motor (buffer/transport) and belt (buffer/transport) removal 1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 2. Remove the two screws securing the bracket (A) on the rear of the finisher. 3. Move the bracket slightly. Note: It is not necessary to remove the bracket from the finisher.
  • Page 311 5057-XXX 6. Disconnect the connector from the drive motor (buffer/transport). 7. Remove the two screws securing the bracket (E) to the finisher. 8. Remove the bracket. 9. Remove the two screws securing the drive motor (buffer/transport) to the bracket. 10. Remove the drive motor (buffer/transport). 11.
  • Page 312 5057-XXX Bridge unit interface card assembly removal 1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 2. Disconnect all the connectors from the bridge unit interface card assembly (A). 3. Remove the two screws securing the bridge unit interface card assembly (A) to the finisher. Connector Connectors Rear...
  • Page 313 5057-XXX Finisher controller card assembly removal 1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 2. Remove the rear lower cover. See “Rear lower cover removal” on page 4-22. 3. Loosen the four screws securing the plate (A) to the finisher. 4.
  • Page 314 5057-XXX Finisher low voltage power supply (LVPS) removal 1. Remove the right lower cover. See “Rear lower cover removal” on page 4-22. 2. Disconnect all the connectors from the finisher LVPS (A). 3. Remove the two screws securing the finisher LVPS (A) to the finisher. Rear 4.
  • Page 315 5057-XXX Booklet bin hookup cable assembly removal 1. Disconnect booklet hookup cable assembly from the booklet bin assembly. 2. Remove rear lower cover. See “Rear lower cover removal” on page 4-22. 3. Disconnect the booklet bin hookup cable assembly from the rear of the finisher. 4.
  • Page 316 5057-XXX Booklet bin assembly removal 1. Disconnect booklet hookup cable assembly from the booklet bin assembly. 2. Remove the screw securing the booklet bin assembly (A) to the finisher. 3. Remove booklet bin assembly (A). 4-118 Printer Finisher Service Manual...
  • Page 317 5057-XXX Sensor (booklet unit interlock) removal 1. Open the finisher front door assembly. 2. Pull the booklet unit assembly out of the finisher. 3. Remove rear lower cover. See “Rear lower cover removal” on page 4-22. 4. Disconnect the connector from the sensor (booklet unit interlock). 5.
  • Page 318 5057-XXX Booklet controller card assembly removal Warning: When replacing the booklet controller card assembly, the existing booklet maker adjustments must be restored to the original settings, or booklet folding and stapling will be out of alignment. The existing booklet maker adjustments can be found on the settings sheet located in the tray 1 settings sheet compartment.
  • Page 319 5057-XXX Booklet unit assembly removal 1. Open the finisher front door assembly. 2. Slide the booklet unit out. 3. Release the two latches securing the booklet unit (A) from the guides. 4. Remove booklet unit (A). Booklet folding/exit drive motor assembly removal 1.
  • Page 320 5057-XXX Booklet diverter gate solenoid removal 1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-23. 2. Remove the two screws securing the booklet diverter gate solenoid (A) to the machine. 3. Remove the booklet diverter gate solenoid (A). 4.
  • Page 321 5057-XXX 6. Remove the booklet stapler unit assembly (B). Booklet knife solenoid frame removal 1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-121. 2. Remove the booklet unit motor assembly. See “Booklet folding/exit drive motor assembly removal” on page 4-121.
  • Page 322 5057-XXX 8. Remove the folding solenoid frame (A). Rear Booklet knife solenoid removal 1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-121. 2. Remove the booklet unit motor assembly. See “Booklet folding/exit drive motor assembly removal” on page 4-121.
  • Page 323 5057-XXX 5. Remove the booklet knife solenoid (A). Booklet knife sector drive gear 42T 1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-121. 2. Remove the booklet unit motor assembly. See “Booklet folding/exit drive motor assembly removal” on page 4-121.
  • Page 324 5057-XXX 5. Remove the booklet knife sector drive gear 42T (A). Rear Booklet media entrance drive motor removal 1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-121. 2. Remove the screws securing the booklet media entrance drive motor cover from the booklet unit. 3.
  • Page 325 5057-XXX 6. Remove the booklet media entrance drive motor (A). Connector Rear Booklet unit gear train frame removal 1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-121. 2. Remove the booklet unit motor assembly. See “Booklet folding/exit drive motor assembly removal”...
  • Page 326 5057-XXX 8. Remove the booklet unit gear train frame (A). Booklet unit assembly left cover 1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-121. 2. Remove the top screws securing the left cover to the booklet unit assembly. 3.
  • Page 327 5057-XXX 4. Remove the booklet unit assembly left cover (A). Booklet rear tamper assembly removal 1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-121. 2. Remove the booklet unit motor assembly. See “Booklet folding/exit drive motor assembly removal” on page 4-121.
  • Page 328 5057-XXX 13.Remove the rear tamper assembly (A). Right Booklet front tamper guide removal 1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-121. 2. Remove booklet unit assembly left cover. See “Booklet unit assembly left cover” on page 4-128.
  • Page 329 5057-XXX 4. Remove the front tamper guide (A). Right Left Sensor (booklet front tamper HP) removal 1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-121. 2. Remove the booklet unit assembly left cover. See “Booklet unit assembly left cover” on page 4-128.
  • Page 330 5057-XXX 5. Remove sensor (booklet front tamper HP) (A). Left Connector Sensor (booklet rear tamper HP) removal 1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-121. 2. Remove the booklet unit assembly left cover. See “Booklet unit assembly left cover”...
  • Page 331 5057-XXX 5. Remove sensor (booklet rear tamper HP) (A). Left Connector Booklet front tamper motor removal 1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-121. 2. Remove the booklet unit assembly left cover. See “Booklet unit assembly left cover” on page 4-128.
  • Page 332 5057-XXX 5. Remove the booklet front tamper motor (A). Connector Left Booklet rear tamper motor removal “Booklet unit assembly removal” on page 4-121. 1. Remove the booklet unit assembly. See 2. Remove the booklet unit assembly left cover. See “Booklet unit assembly left cover” on page 4-128.
  • Page 333 5057-XXX 5. Remove the booklet rear tamper motor (A). Connector Left Sensor (booklet knife HP) removal 1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-121. 2. Remove the booklet unit assembly left cover. See “Booklet unit assembly left cover” on page 4-128.
  • Page 334 5057-XXX 6. Remove sensor (booklet knife HP) (A). Connector Left Sensor (booklet knife folding) removal 1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-121. 1. Remove the Complete booklet unit assembly left cover. See “Booklet unit assembly left cover” on page 4-128.
  • Page 335 5057-XXX 5. Remove sensor (booklet knife folding) (A). Connector Left Booklet unit front door assembly removal 1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-121. 2. Remove the e-clip securing the shaft X from the booklet unit. 3.
  • Page 336 5057-XXX 5. Remove Sensor (booklet unit media entrance) (A). Right Connector Sensor (booklet media compiler in) removal 1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-121. 2. Remove the booklet unit assembly left cover. See “Booklet unit assembly left cover”...
  • Page 337 5057-XXX 6. Remove Sensor (booklet unit media exit) (A). Connector Right Sensor (booklet end guide HP) removal 1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-121. “Booklet unit assembly left cover” on page 4-128. 2. Remove the booklet unit assembly left cover. See 3.
  • Page 338 5057-XXX 5. Remove sensor (booklet end guide HP) (A). Left Connector Booklet media pinch roll assembly removal 1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-121. 2. Remove the Sensor (booklet unit media entrance). See “Sensor (booklet unit media entrance) removal”...
  • Page 339 5057-XXX 7. Remove the booklet media pinch roll assembly (A). Booklet paddle motor removal 1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-121. 2. Remove the booklet unit assembly left cover. See “Booklet unit assembly left cover” on page 4-128.
  • Page 340 5057-XXX 5. Remove the booklet end guide drive motor (A). Connector Booklet maker setup & adjustment Folding precision skew adjustment Step Check Print a 2 sheet booklet using the booklet maker. Go to step 2. The folding precision skew Does the booklet appear skewed as shown in the graphic adjustment is in below? spec.
  • Page 341 5057-XXX Step Check Check the booklet maker precision skew adjuster. Repeat step 2 until Problem solved. the end guide 1. Open the finisher front door precision skew is 2. Pull the booklet maker out of the finisher. in spec. 3. Loosen the screw securing the end guide skew lever. 4.
  • Page 342 5057-XXX 2 sheet fold & staple position fine adjustment Step Check Print a 2 sheet booklet using the booklet maker. Go to step 2. The 2 sheet fold position fine Does the booklet sheet edges appear overlapped as shown adjustment is in in the graphic below? spec.
  • Page 343 5057-XXX Step Check Adjust the 2 sheet position fine adjustment value based on Repeat step 2 until Problem solved. the graphic below: the 2 sheet fold position fine adjustment is in spec. Go to step 3. 1. Enter the diagnostic mode. 2.
  • Page 344 5057-XXX Step Check Print a 2 sheet stapled booklet using the booklet maker. Go to step 4. The 2 sheet staple position fine Does the staple position fine adjustment appear to be offset adjustment is in from the fold as shown in the graphic below? spec.
  • Page 345 5057-XXX Step Check Adjust the 2 sheet staple position fine adjustment value as Repeat step 2 until Problem solved. shown in the graphic below: the 2 sheet staple position fine adjustment is in spec. 1. Enter the diagnostic mode. 2. Select ENGINE ADJUST. 3.
  • Page 346 5057-XXX 15 sheet staple position fine adjustment Step Check Print a 15 sheet stapled booklet using the booklet maker. Go to step 2. The 15 sheet staple position fine Does the staple position fine adjustment appear to be offset adjustment is in from the fold as shown in the graphic below? spec.
  • Page 347 5057-XXX Step Check Adjust the 15 sheet staple position fine adjustment value as Repeat step 2 until Problem solved. shown in the graphic below: the 15 sheet staple position fine adjustment is in spec. 1. Enter the diagnostic mode. 2. Select ENGINE ADJUST. 3.
  • Page 348 5057-XXX Booklet fold position fine adjustment (3-15 sheets) Step Check Note: The booklet fold position fine adjustment is different Go to step 2. The booklet fold depending on the amount of sheets that compose the position fine booklet and the size of the media. adjustment is in spec.
  • Page 349 5057-XXX Step Check Adjust the fold position fine adjustment value based on the Repeat step 2 until Problem solved. graphic below: the Booklet fold position fine adjustment is in spec. 1. Enter the diagnostic mode. 2. Select ENGINE ADJUST. 3. Select Booklet fold adjust. 4.
  • Page 350 5057-XXX Booklet staple position fine adjustment (3-14 sheets) Step Check Note: The booklet staple position fine adjustment is Go to step 2. The booklet staple different depending on the amount of sheets that compose position fine the booklet. adjustment is in spec.
  • Page 351 5057-XXX Step Check Adjust the booklet staple position fine adjustment value as Repeat step 2 until Problem solved. shown in the graphic below: the Booklet staple position fine adjustment is in spec. 1. Enter the diagnostic mode. 2. Select ENGINE ADJUST. 3.
  • Page 352 5057-XXX 4-154 Printer Finisher Service Manual...
  • Page 353 5057-XXX 5. Connector locations Finisher components Bridge unit assembly Sensor (bridge unit top cover interlock Bridge unit assembly Sensor (bridge unit Bridge unit drive bin media exit) motor assembly Bridge unit diverter gate solenoid Sensor (bridge unit Sensor (bridge unit Bridge unit media exit) media entrance)
  • Page 354 5057-XXX Stacker lift and stapler Sensor (stacker bin upper limit) Sensor (stacker bin level 2) Sensor (stacker bin no media) Sensor (stacker bin level 1) Switch (finisher front door interlock) Stapler carriage motor assembly Sensor (stapler carriage HP) Bottom view Printer Finisher Service Manual...
  • Page 355 5057-XXX Punch unit Punch carriage shift motor assembly Sensor (punch carriage shift HP) Sensor (punch unit HP) Sensor (punch hole select) Sensor (punch unit side registration 2) Sensor (punch Sensor (punch unit side cam front) registration 1) Punch unit motor assembly Sensor (punch waste box set) Sensor (punch...
  • Page 356 5057-XXX Diverter and media eject Sensor (media eject clamp HP) Media eject clamp motor Buffer diverter solenoid Media diverter solenoid Switch (eject cover interlock) Sensor (lower media exit) Media eject and media compiler Media eject motor asm Sensor (front tamper HP) Front tamper motor...
  • Page 357 5057-XXX Buffer, upper exit, lower exit, and drive motors Sensor (upper media exit) Sensor (upper media bin full) Drive motor (exit) Drive motor (buffer/transport) Sensor (diverter gate) Sensor (finisher media entrance) Sensor (buffer path) Drive motor (entrance/paddle) Motor (exit) Motor (buffer/transport) Motor (entrance/paddle) Lower media exit roll assembly...
  • Page 358 5057-XXX Upper media exit roll assembly Upper media transport roll assembly Finisher controller card assembly Finisher controller Bridge unit interface card assembly card assembly P8304 P8308 P8389 P8306 P8307 P8309 P8300 P8305 P8301 P8376 P8310 P8302 P8316 P8311 P8314 P8317 P8315 P8313 Finisher low...
  • Page 359 5057-XXX Booklet media bin Booklet bin assembly Sensor (booklet bin full) Front Booklet bin drive motor Connector locations...
  • Page 360 5057-XXX Booklet maker Booklet rear Sensor (booklet tamper motor rear tamper HP) Booklet front tamper motor Booklet folding/exit drive motor assembly Sensor (booklet Sensor front tamper HP) (booklet folding) Sensor (booklet knife HP) Booklet paddle drive motor assembly Booklet end guide drive motor assembly Printer Finisher Service Manual...
  • Page 361 5057-XXX Sensor (booklet media entrance) Sensor (booklet media exit) Booklet media entrance drive motor assembly Booklet folding/exit drive motor assembly Booklet stapler drive motor Rear Connector locations...
  • Page 362 5057-XXX Booklet controller card assembly 5-10 Printer Finisher Service Manual...
  • Page 363 5057-XXX Cabling Finisher media entrance sensor cable assembly Upper media exit sensor cable assembly Upper media bin full cable assembly Lower media exit sensor cable sssembly Compiler unit cable assembly Buffer path sensor cable assembly Main sensor cable assembly LVPS cable assembly AC power cord assembly...
  • Page 364 5057-XXX Diverter gate sensor upper cable assembly Punch main drive cable assembly Diverter gate sensor lower cable assembly Punch waste box set cable assembly Interlock switch cable assembly 5-12 Printer Finisher Service Manual...
  • Page 365 5057-XXX Main drive cable assembly Punch waste box full cable assembly Bridge unit connect cable assembly Stapler unit cable assembly Bridge unit interface card cable assembly Finisher interface cable assembly 5-13 Connector locations...
  • Page 366 5057-XXX 5-14 Printer Finisher Service Manual...
  • Page 367 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 Lubrication specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use of lubricants other than those specified can cause premature failure.
  • Page 368 5057-XXX Printer Finisher Service Manual...
  • Page 369 5057-XXX 7. Parts catalog How to use this parts catalog The following legend is used in the parts catalog: Asm- Part Units/ Units/ Description Index number option • Asm-index: Identifies the assembly and the item in the diagram. For example 3-1 indicates Assembly 3 and item number 1 in the table.
  • Page 370 5057-XXX Assembly 1: Finisher–bridge unit Asm- Part Units/ Units/ Description Index number option 40X3893 Bridge unit assembly (this comes assembled) Printer Finisher Service Manual...
  • Page 371 5057-XXX Assembly 2: Finisher–bridge unit covers Asm- Part Units/ Units/ Description Index number option 40X3898 Bridge unit top cover 40X3895 Bridge unit rear cover 40X3896 Bridge unit motor cover 40X3897 Bridge unit right cover 40X3901 Switch (bridge unit top cover interlock) 40X3894 Bridge unit left upper cover 40X3900...
  • Page 372 5057-XXX Assembly 3: Finisher–media drive 1 Printer Finisher Service Manual...
  • Page 373 5057-XXX Assembly 3: Finisher–media drive 1 Asm- Part Units/ Units/ Description Index number option 40X3903 Bridge unit bin media exit solenoid 40X3904 Pinch spring 40X3905 Sensor (bridge unit bin media exit) 40X3907 Solenoid link 40X3906 Bridge unit diverter gate solenoid 40X3910 Sensor (bridge unit media entrance) 40X3908...
  • Page 374 5057-XXX Assembly 4: Finisher–media drive 2 Printer Finisher Service Manual...
  • Page 375 5057-XXX Assembly 4: Finisher–media drive 2 Asm- Part Units/ Units/ Description Index number option 40X3912 Bridge unit exit/decurler drive belt 40X3911 Bridge unit drive motor 40X0825 Sensor (decurler cam HP) 40X3917 Sensor flag 40X3916 Decurler clutch 40X3914 Bridge unit manual feed knob 40X3913 Bridge unit decurler roll assembly Parts catalog...
  • Page 376 5057-XXX Assembly 5: Finisher–covers Printer Finisher Service Manual...
  • Page 377 5057-XXX Assembly 5: Finisher–covers Asm- Part Units/ Units/ Description Index number option 40X0829 Top cover 40X0831 Upper media bin assembly 40X0830 Upper media bin vertical cover 40X0832 Right eject cover 40X0833 Stacker media bin 40X0834 Right lower LVPS cover 40X0835 Caster 40X0836 Rear lower cover...
  • Page 378 5057-XXX Assembly 6: Finisher–covers and front door 7-10 Printer Finisher Service Manual...
  • Page 379 5057-XXX Assembly 6: Finisher–covers and front door Asm- Part Units/ Units/ Description Index number option 40X0839 Upper media bin front cover 40X0841 Finisher front door assembly (this comes assembled) 40X0840 Switch (finisher front door interlock) 40X0842 Finisher docking latch kit includes: •...
  • Page 380 5057-XXX Assembly 7: Finisher–stacker bin lift 7-12 Printer Finisher Service Manual...
  • Page 381 5057-XXX Assembly 7: Finisher–stacker bin lift Asm- Part Units/ Units/ Description Index number option 40X0846 Carriage lift belt kit includes: • Carriage lift belt • Belt clamp (2 each) • Spring • Roll (2 each) 40X0847 Sensor (stacker bin level) 40X0849 Stacker slip clutch pulley kit includes: •...
  • Page 382 5057-XXX Assembly 8: Finisher–punch 7-14 Printer Finisher Service Manual...
  • Page 383 5057-XXX Assembly 8: Finisher–punch Asm- Part Units/ Units/ Description Index number option 40X0854 Punch carriage shift motor assembly 40X0855 Punch carriage assembly 40X0856 Sensor (punch unit side reg) assembly • Sensor (punch unit side reg1) • Sensor (punch unit side reg2) •...
  • Page 384 5057-XXX Assembly 9: Finisher–stapler 7-16 Printer Finisher Service Manual...
  • Page 385 5057-XXX Assembly 9: Finisher–stapler Asm- Part Units/ Units/ Description Index number option 40X0870 Stapler unit cable assembly 40X0869 Stapler carriage kit includes: • Stapler carriage wire guide • Stapler carriage assembly 40X0871 Stapler carriage motor assembly 40X0872 Stapler carriage rack gear 40X0868 Stapler unit cover 40X0850...
  • Page 386 5057-XXX Assembly 10: Finisher–media eject 7-18 Printer Finisher Service Manual...
  • Page 387 5057-XXX Assembly 10: Finisher–media eject Asm- Part Units/ Units/ Description Index number option 40X4144 Finisher media eject door 40X4120 Sub paddle solenoid 40X4146 Eject clamp shaft assembly 40X4057 Spring 40X0874 Sub paddle assembly 40X4058 Sub paddle drive shaft assembly 40X4077 Knob 40X0882 Switch (eject cover interlock)
  • Page 388 5057-XXX Assembly 11: Finisher–eject and compiler unit 7-20 Printer Finisher Service Manual...
  • Page 389 5057-XXX Assembly 11: Finisher–eject and compiler unit Asm- Part Units/ Units/ Description Index number option 40X0883 Media compiler unit assembly (this comes assembled) 40X0850 Sensor (rear tamper HP) 40X0850 Sensor (front tamper HP) 40X0825 Sensor (compiler media in) 40X4150 Media eject shaft assembly 40X0887 Clamp paddle 40X0888...
  • Page 390 5057-XXX Assembly 12: Finisher–lower exit drive 7-22 Printer Finisher Service Manual...
  • Page 391 5057-XXX Assembly 12: Finisher–lower exit drive Asm- Part Units/ Units/ Description Index number option 40X0892 Sensor (lower media exit) with bracket 40X0893 Sensor (lower media exit) 40X0894 Static eliminator brush 40X3951 Lower media exit roll assembly 40X0888 Bushing 6 mm 40X4105 Main paddle shaft assembly 40X4106...
  • Page 392 5057-XXX Assembly 13: Finisher–buffer and entrance drive 7-24 Printer Finisher Service Manual...
  • Page 393 5057-XXX Assembly 13: Finisher–buffer and entrance drive Asm- Part Units/ Units/ Description Index number option 40X0901 Lower pinch guide assembly (this comes assembled) 40X0902 Finisher diverter gate 40X4149 Buffer diverter gate 40X0824 Magnetic catch 40X0888 Bushing 6 mm 40X0904 Buffer upper guide assembly 40X0893 Sensor (buffer path) 40X3953...
  • Page 394 5057-XXX Assembly 14: Finisher–buffer, transport, and upper drive 7-26 Printer Finisher Service Manual...
  • Page 395 5057-XXX Assembly 14: Finisher–transport and upper drive Asm- Part Units/ Units/ Description Index number option 40X0918 Upper media exit pinch roll assembly 40X0893 Sensor (upper media exit) 40X3965 Upper media exit roll assembly 40X0908 Sensor (upper media bin full) 40X0824 Magnetic catch 40X0888 Bushing 6 mm...
  • Page 396 5057-XXX Assembly 15: Booklet maker 1 7-28 Printer Finisher Service Manual...
  • Page 397 5057-XXX Assembly 15: Booklet maker 1 Asm- Part Units/ Units/ Description Index number option 40X3981 Booklet bin assembly 40X3979 Booklet unit right glide assembly 40X3986 Booklet unit assembly (this comes assembled) 40X3980 Booklet unit left glide assembly 40X3984 Booklet unit cable assembly 40X3983 Booklet bin/diverter cable assembly 40X3982...
  • Page 398 5057-XXX Assembly 16: Booklet maker 2 Asm- Part Units/ Units/ Description Index number option 40X3961 Booklet diverter gate 40X4118 Booklet path media transport roll assembly 40X3958 Booklet pinch guide assembly 40X4128 Belt idler pulley 40X0899 Booklet media transport roll drive gear 23T 40X3962 Booklet media transport roll torque limiter 40X0880...
  • Page 399 5057-XXX Assembly 17: Booklet maker 3 Asm- Part Units/ Units/ Description Index number option 40X3991 Booklet stapler unit assembly 40X3990 Booklet manual feed knob 40X3989 Booklet manual feed drive gear 31T 40X3988 Booklet unit catch 7-31 Parts catalog...
  • Page 400 5057-XXX Assembly 18: Booklet maker 4 Asm- Part Units/ Units/ Description Index number option 40X0825 Sensor (booklet end guide HP) 40X3992 Booklet media entrance drive motor 40X3993 Gear pulley 40/20T 40X3994 Booklet end guide drive belt 40X3996 Booklet paddle drive motor assembly 40X3995 Booklet paddle idler gear 14T 40X3997...
  • Page 401 5057-XXX Assembly 19: Booklet maker 5 Asm- Part Units/ Units/ Description Index number option 40X3999 Booklet knife sector drive gear 42T 40X0825 Sensor (booklet knife HP) 40X0825 Sensor (booklet knife folding) 40X3998 Booklet knife HP sensor cable assembly 7-33 Parts catalog...
  • Page 402 5057-XXX Assembly 20: Booklet maker 6 Asm- Part Units/ Units/ Description Index number option 40X4001 Booklet front tamper 40X0825 Sensor (booklet front tamper HP) 40X4002 Booklet front tamper motor 40X4002 Booklet rear tamper motor 40X0825 Sensor (booklet rear tamper HP) 40X4003 Booklet rear tamper assembly 7-34...
  • Page 403 5057-XXX Assembly 21: Booklet maker 7 Asm- Part Units/ Units/ Description Index number option 40X4008 Booklet roll drive gear 18T 40X4006 Booklet roll drive gear 16T 40X4007 Booklet idler gear 38/18T 40X4009 Booklet drive gear 16T 40X4010 Folding drive gear 38T 40X4005 Exit roll drive belt 40X4004...
  • Page 404 5057-XXX Assembly 22: Booklet maker 8 Asm- Part Units/ Units/ Description Index number option 40X4012 Manual feed drive gear 28T 40X4014 Media exit sensor cable assembly 40X4013 Manual feed drive gear 17T 40X4011 Booklet media pinch roll assembly 40X0921 Sensor (booklet unit media exit) 7-36 Printer Finisher Service Manual...
  • Page 405 5057-XXX Assembly 23: Booklet maker 9 Asm- Part Units/ Units/ Description Index number option 40X4016 Booklet gear 43/14T 40X4024 Booklet gear 39/18T 40X4015 Booklet gear 45T 40X4017 Booklet gear 44/16T 40X4019 Booklet gear 27/34T 40X4023 Booklet sensor interface cable assembly 40X4022 Booklet motor interface cable assembly 40X4021...
  • Page 406 5057-XXX Assembly 24: Finisher–electronics 7-38 Printer Finisher Service Manual...
  • Page 407 5057-XXX Assembly 24: Finisher–electronics Asm- Part Units/ Units/ Description Index number option 40X3969 Bridge unit interface card assembly 40X3970 Bridge unit connect cable assembly 40X0933 Bridge unit interface card cable assembly 40X3971 Finisher controller card assembly 40X3972 AC power cord assembly 40X0936 Finisher LVPS card assembly 7-39...
  • Page 408 5057-XXX Assembly 25: Finisher–cables 1 7-40 Printer Finisher Service Manual...
  • Page 409 5057-XXX Assembly 25: Finisher–cables 1 Asm- Part Units/ Units/ Description Index number option 40X3975 Upper media exit sensor cable assembly 40X3974 Finisher media entrance sensor cable assembly 40X0941 Buffer path sensor cable assembly 40X0937 Main sensor cable assembly 40X0946 Finisher LVPS cable assembly 40X0892 Sensor (lower media exit) assembly •...
  • Page 410 5057-XXX Assembly 26: Finisher–cables 2 Asm- Part Units/ Units/ Description Index number option 40X0922 Diverter gate sensor upper cable assembly 40X0944 Punch main drive cable assembly 40X0950 Diverter gate sensor lower cable assembly 40X0865 Punch waste box set cable assembly 40X4107 Interlock switch cable assembly 40X0945...
  • Page 411 5057-XXX Assembly 27: Finisher–cables 3 Asm- Part Units/ Units/ Description Index number option 40X0938 Main drive cable assembly 40X0930 Punch waste box full cable assembly 40X0932 Bridge unit connect cable assembly 40X0931 Bridge unit interface card assembly 40X3973 Finisher interface cable assembly 40X0870 Stapler unit cable assembly 7-43...
  • Page 412 5057-XXX 7-44 Printer Finisher Service Manual...
  • Page 413 5057-XXX Index 4-26 finisher front door assembly 4-27 left lower cover accessing service menus 4-28 left upper cover 1-36 acronyms 7-10 parts catalog 4-22 rear lower cover 4-23 rear upper cover belts 4-20 4-112 right eject cover buffer/transport 4-21 right lower LVPS cover 4-98 entrance/paddle 4-18...
  • Page 414 5057-XXX 2-106 drive motors stacker media bin full (no mix) 2-109 bridge unit stacker set over count failure 4-112 2-110 buffer/transport staple cartridge empty 4-98 entrance/paddle ESD-sensitive parts 4-110 3-29 exit exiting Configuration Menu 3-23 exiting Diagnostics Menu eject unit 7-20 4-115 parts catalog...
  • Page 415 5057-XXX 1-22 4-80 stapler lower media exit roll assembly 1-29 4-88 upper media bin lower pinch guide assembly 4-68 weight media compiler unit assembly 4-89 media diverter gate 4-65 media eject clamp motor assembly 4-84 paddle and roll exit assembly 4-76 media eject clutch parts catalog...
  • Page 416 5057-XXX 4-24 upper media bin front cover 4-102 upper media exit pinch roll assembly theory 4-103 upper media exit roll assembly finisher 4-108 upper media transport roll assembly 1-36 tools required 4-106 upper pinch guide assembly 4-19 upper media bin assembly xvii safety information 4-102...
  • Page 417 5057-XXX Part number index Description Page 40X0824 Magnetic catch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25 7-27 40X0825...
  • Page 418 5057-XXX 7-17 7-43 40X0870 Stapler unit cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X0871 Stapler carriage motor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17...
  • Page 419 5057-XXX 7-39 40X0936 Finisher LVPS card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X0937 Main sensor cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41...
  • Page 420 5057-XXX 7-29 40X3980 Booklet unit left glide assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X3981 Booklet bin assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29...
  • Page 421 5057 AND 7510 Finisher Buffer Diverter BUFFER DIV SOLENOID(PULL)+24VDC Front Tamper Solenoid BUFFER DIV SOLENOID(PUSH)+24VDC Motor Stacker Bin Eject Clamp I/L+24VDC Lift Motor Motor EJECT CLAMP MOTOR CCW ON(H)+24VDC TRANSPORT GATE SOLENOID(PULL)(L)+24VDC EJECT CLAMP MOTOR ON(H)+24VDC TRANSPORT GATE SOLENOID(PUSH)(L)+24VDC ENT/PAD MOT/B Finisher Diverter Solenoid...

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C935