Page 1 • Trademarks • Index A later version of this service manual will be posted to the web on or before 6-15-07. 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: Table Of Contents
7510-XXX Table of contents Table of contents ............iii Notices and safety information .
Page 4 7510-XXX Stapler ............... .1-22 Stapling operation .
Page 5 7510-XXX 981.00 Sensor (stacker bin level 1) late error ........2-52 981.01 Stacker bin upper limit error .
Page 6 7510-XXX HARDWARE TESTS ............. .3-8 Panel Test .
Page 7 7510-XXX Configuration Menu ..............3-35 Entering Configuration Menu .
Page 8 7510-XXX Stacker media bin assembly removal ..........4-21 Right lower low voltage power supply (LVPS) cover removal .
Page 9 7510-XXX Sensor (upper media exit) removal ..........4-102 Upper media exit pinch roll assembly removal .
Page 10 7510-XXX Parts catalog ................How to use this parts catalog .
Page 11: Notices And Safety Information
7510-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 7510-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 7510-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 7510-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 7510-XXX Notices and safety information...
Page 16 7510-XXX MFP Finisher Service Manual...
Page 17: Safety Information
7510-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 7510-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 7510-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: Preface
7510-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: General Information
The optional finisher staples, punches, folding and stapling, and stacks media transferred from the Lexmark™ C930, C935, X940e and X945e. 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: Media Path Overview
7510-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: Media Weight
7510-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: Bridge Unit Assembly Paper Path
7510-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 MFP Finisher Service Manual...
Page 25: Finisher Roll Assemblies
7510-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: Finisher Media Path Sensors
7510-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) MFP Finisher Service Manual...
Page 27: Finisher Motors
7510-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: From Bridge Unit Assembly To Punch
7510-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: From Punch To Compiler Unit Assembly
7510-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 7510-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: From Compiler Unit Assembly To Stacker Media Bin
7510-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: Finisher
7510-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: Punch Unit
7510-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: Punching
7510-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: Detecting Punch Waste Full
7510-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: Compiler Unit Assembly
7510-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: Capacity Of Compiler Unit Assembly
7510-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: Front Tamping
7510-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: Rear Tamping
7510-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: Center Tamping
7510-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: Offsetting
7510-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: Stapler
7510-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: Media Sizes That Allow Stapling
7510-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: Stapling Multiple Size Media
7510-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: Stapler Unit Assembly
7510-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: Booklet Operation
7510-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: Functions Of Booklet Sensors And Motors
7510-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 7510-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: Upper Media Bin
7510-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: Stacker Media Bin
7510-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 7510-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: Full Stack Detection
7510-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 7510-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: Booklet Tray
7510-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 7510-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: Tools Required For Service
7510-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 7510-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 7510-XXX 1-38 MFP Finisher Service Manual...
Page 59: Diagnostic Information
7510-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: Por (Power-On Reset) Sequence
7510-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: Error Code Messages - Finisher
7510-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 7510-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 7510-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 7510-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 7510-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 7510-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 7510-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: Service Checks - Finisher
7510-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: Sensor (Bridge Unit Media Entrance) Static Jam
7510-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: Sensor (Bridge Unit Media Exit) Late Jam
7510-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 7510-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. Touch FINISHER TESTS. 3. Touch Sensor Test. 4. Touch Media Path 1. 5. Touch 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: Sensor (Bridge Unit Media Exit) Static Jam
7510-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: Sensor (Bridge Exit Bin) Late Jam
7510-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 7510-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: Sensor (Bridge Exit Bin) Lag Jam
7510-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 7510-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: Sensor (Bridge Exit Bin) Static Jam
7510-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: Sensor (Finisher Media Entrance) Late Jam
7510-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 7510-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. Touch FINISHER TESTS. 3. Touch Sensor Test. 4. Touch Media Path 1. 5. Touch 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: Sensor (Finisher Media Entrance) Static Jam
7510-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: Sensor (Buffer Path) Late Jam
7510-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 7510-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 7510-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. Touch MOTOR TESTS. 3. Touch Finisher Motor Tests. 4. Touch Motor (buffer/transport). Does the above component operate properly? Check the drive motor (buffer/transport) for proper Replace the drive Problem solved.
Page 84: Sensor (Buffer Path) Static Jam
7510-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: Sensor (Lower Media Exit) Late Jam
7510-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 7510-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: Sensor (Lower Media Exit) Lag Jam
7510-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 contamination? assembly. Go to “Lower media exit roll...
Page 88: Sensor (Lower Media Exit) Static Jam
7510-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 7510-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: Sensor (Media Compiler In) Lag Jam
7510-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: Sensor (Compiler Media In) Static Jam
7510-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. Touch FINISHER TESTS. 3. Touch Sensor Test. 4. Touch Media Path 1. 5. Touch 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 7510-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. Touch FINISHER TESTS. 3. Touch Sensor Test. 4. Touch Media Path 1. 5. Touch 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: Sensor (Upper Media Exit) Late Jam
7510-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: Sensor (Upper Media Exit) Lag Jam
7510-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 7510-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. Touch MOTOR TESTS. 3.
Page 96: Sensor (Upper Media Exit) Static Jam
7510-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. Touch FINISHER TESTS. 3. Touch Sensor Test. 4.
Page 97: Sensor (Diverter Gate) Late Jam
7510-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 7510-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. Touch FINISHER TESTS. 3. Touch Sensor Test. 4. Touch Media Path 2. 5. Touch Diverter gate. Does the operator panel display change every time the actuator of the sensor (bridge unit media exit) is operated?
Page 99: Sensor (Diverter Gate) Static Jam A (To Top Bin)
7510-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. Touch FINISHER TESTS. 3. Touch Sensor Test. 4.
Page 100: Sensor (Diverter Gate) Static Jam B (To Stacker Bin)
7510-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. Touch FINISHER TESTS. 3. Touch Sensor Test. 4.
Page 101: Sensor (Booklet Unit Media Entrance) Late Jam
7510-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: Sensor (Booklet Unit Media Entrance) Lag Jam
7510-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. Touch MOTOR TESTS. 3.
Page 103 7510-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: Sensor (Booklet Unit Media Entrance) Static Jam
7510-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: Sensor (Booklet Compiler Media In) Static Jam
7510-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: Sensor (Booklet Unit Media Exit) Late Jam
7510-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 7510-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. Touch MOTOR TESTS. 3.
Page 108: Sensor (Booklet Unit Media Exit) Lag Jam
7510-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: Sensor (Booklet Unit Media Exit) Static Jam
7510-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: Sensor (Stacker Bin Level 1) Late Error
7510-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. Touch FINISHER TESTS. 3. Touch Sensor Test. 4. Touch Booklet path 5. Touch 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 7510-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. Touch FINISHER TESTS. 3. Touch Sensor Test. 4. Touch Bin Level. 5. Touch 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: Stacker Bin Upper Limit Error
7510-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 7510-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: Stacker Bin Lower Limit Error
7510-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 7510-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. Touch FINISHER TESTS. 3. Touch Sensor Test. 4. Touch Bin Level. 5. Touch 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: Sensor (Front Tamper Hp) Late Error
7510-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: Sensor (Front Tamper Hp) Lag Error
7510-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: Sensor (Rear Tamper Hp) Late Error
7510-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: Sensor (Rear Tamper Hp) Lag Error
7510-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: Sensor (Punch Unit Hp) Late Error
7510-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: Sensor (Punch Unit Hp) Lag Error
7510-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. Touch FINISHER TESTS. 3. Touch Sensor Test. 4. Touch Punch and Staple. 5. Touch 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 7510-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. Touch FINISHER TESTS. 3. Touch Sensor Test. 4. Touch Punch and Staple. 5. Touch 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: Sensor (Punch Carriage Shift Hp) Late Error
7510-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: Sensor (Punch Carriage Shift Hp) Lag Error
7510-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: Sensor (Media Eject Clamp Hp) Late Error
7510-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: Sensor (Media Eject Clamp Hp) Lag Error
7510-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 7510-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: Sensor (Media Eject Shaft Hp) Late Error
7510-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. Touch FINISHER TESTS. 3. Touch Sensor Test. 4.
Page 129: Sensor (Media Eject Shaft Hp) Lag Error
7510-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 7510-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: Sensor (Punch Unit Side Reg1) Or (Sensor (Punch Unit Side Reg2) Lag Failure
7510-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 7510-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: Stapler Unit Failure
7510-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: Sensor (Stapler Carriage Hp) Lag Error
7510-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 7510-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. Touch FINISHER TESTS. 3. Touch Sensor Test. 4. Touch Punch and Staple. 5. Touch 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: Sensor (Booklet Front Temper Hp) Late Error
7510-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: Sensor (Booklet Front Tamper Hp) Lag Error
7510-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 4-119. Perform a POR. Replace the Problem solved. finisher controller Does the error continue when the power is turned off/on? card assembly.
Page 138: Sensor (Booklet Rear Tamper Hp) Late Error
7510-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 7510-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: Sensor (Booklet Rear Tamper Hp) Lag Error
7510-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: Sensor (Booklet End Guide Hp) Late Error
7510-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 7510-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: Sensor (Booklet End Guide Hp) Lag Error
7510-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: Sensor (Booklet Unit Interlock) Error
7510-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: Sensor (Booklet Compiler No Media) No Media Detected
7510-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: Sensor (Booklet Knife Hp) Late Error
7510-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. Touch FINISHER TESTS. 3. Touch Sensor Test. 4. Touch Booklet Path 5. Touch 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 7510-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. Touch FINISHER TESTS. 3. Touch Sensor Test. 4. Touch Booklet Path. 5. Touch 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: Sensor (Booklet Knife Hp) Lag Error
7510-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 7510-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: Sensor (Booklet Knife Folding) Late Error
7510-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 4-119. Perform a POR. Replace the Problem solved. finisher controller Does the error continue when the power is turned off/on? card assembly.
Page 151: Booklet Stapler Error
7510-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: Communication Error With Booklet Controller Card Assembly
7510-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 booklet stapler interface cable assembly. Go to step 5.
Page 153: Booklet Unit Maker Error
7510-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 7510-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. Touch MOTOR TESTS. 3.
Page 155: Sensor (De-Curler Cam Hp) Lag Error
7510-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. Touch FINISHER TESTS. 3. Touch Sensor Test. 4.
Page 156: Bridge Unit Top Cover Open
7510-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 7510-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: Finisher Front Door Open
7510-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: Finisher Eject Cover Open
7510-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: No Punch Waste Box
7510-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: Punch Waste Box Full
7510-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: Stacker Media Bin Full (Mix Size)
7510-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 7510-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: Stacker Media Bin Full (No Mix)
7510-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 7510-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: Stacker Lower Safety Failure
7510-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: Stacker Set Over Count Failure
7510-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: Staple Cartridge Empty
7510-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: Diagnostic Aids
7510-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: Diagnostics Menus
7510-XXX Diagnostics Menus Entering Diagnostics Menus 1. Turn off the printer. 2. Press and hold the 3 and 6 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 7510-XXX 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 Registration clutch Tray 1 media feed/lift motor Tray 2 media feed/lift motor Tray 3 media feed/lift motor Tray 4 media feed/lift motor 2nd transfer roll retract motor...
Page 172 7510-XXX “PRINT TESTS” on page 3-6. PRINT TESTS Tray 1 Tray 2 Tray 3 Tray 4 MP Feeder Printing Quality Test Pages “Print Quality Test Pages” on page 3-7. HARDWARE TESTS Panel Test “Panel Test” on page 3-8. Button Test “Button Test”...
Page 173 7510-XXX Model Name “Model Name” on page 3-19. Configuration ID “Configuration ID” on page 3-19. EVENT LOG Display Log “Display the Event Log” on page 3-21. Print Log “Print the Event Log” on page 3-22. Clear Log “Clear the Event Log” on page 3-22.
Page 174: Motor Tests
7510-XXX MOTOR TESTS The tests in this group allow you to test specific motors, and on some motors run them forward or reverse. To run the MOTOR TESTS: 1. Touch MOTOR TESTS from the Diagnostics Menu. 2. Touch the test to run. The following Finisher Motor Tests are available: •...
Page 175: Input Source Print Test
7510-XXX To run the Print Tests: 1. Touch PRINT TESTS from the Diagnostics Menu. 2. Touch [Input Source] to verify that the printer can generate output from that source’s media. 3. Touch Printing Quality Test Pages to view information about the printer’s current settings and to test the printer’s ability to generate quality output.
Page 176: Hardware Tests
7510-XXX HARDWARE TESTS Touch the following Hardware Tests from this menu: • Panel Test • Button Test • DRAM Test • CACHE Test Panel Test This test automatically toggles all pixels on the LCD through every contrast level beginning with the darkest to the brightest.
Page 177: Dram Test
7510-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 178: Sensor Test (Duplex)
7510-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. Touch DUPLEX TESTS from the Diagnostics Menu. 2.
Page 179: Sensor Test (Input Tray)
7510-XXX • Single–Feeds one sheet of media from the selected source. • 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 180: Feed To All Bins
7510-XXX • Continuous–Media continues feeding from the selected source until Stop is pressed. 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.
Page 181: Hole Punch Test
7510-XXX Hole Punch Test This test is used to verify that media can be fed to a finisher output bin and then hole punched. No information is printed on the feed test pages. To run the Hole Punch Test: 1. Touch FINISHER TESTS from the Diagnostics Menu. 2.
Page 182 7510-XXX 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 Sensor Name Bridge unit media entrance Bridge unit media exit Finisher media entrance Bridge unit media bin exit...
Page 183: Base Sensor Test
7510-XXX Booklet unit interlock Booklet front low staple Booklet rear low staple Available Punch and Staple Sensors Sensor Name Punch side reg1 Punch side reg2 Punch box set Low staple Punch carriage shift hp Punch unit hp Stapler carriage shift hp Punch cam front Punch hole select After selecting one of the available sensors, you can manually toggle the sensor between its two values (Open...
Page 184: Device Tests
7510-XXX 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 Sensor Name Standard bin full Media Path Sensors Sensor Name Registration Fuser exit Transparency detect 2nd transfer roll retract Transfer Belt Sensors...
Page 185: Disk Test/Clean
7510-XXX Quick Disk Test Testing... appears on the LCD. This test cannot be canceled. After the test finishes, either Quick Disk Test Passed or Quick Disk Test Failed appears on the LCD. This message remains until you touch Back. Disk Test/Clean This test performs a low-level format of the hard disk.
Page 186: Printer Setup
7510-XXX PRINTER SETUP To enter the PRINTER SETUP screen, touch PRINTER SETUP from the Diagnostics Menu. The following graphic appears on the LCD: PRINTER SETUP U.S. Defaults Printed Page Count Perm Page Count Serial Number NV26T470 Medium Envelope Entrance Engine Setting 1 Back Submit Defaults...
Page 187: Printed Mono Page Count
7510-XXX Printed Mono Page Count The value of this setting enables you to gauge the amount of usage on a device. The Printed Page Count cannot be reset by the servicer. Permanent Page Count The value of this setting indicates the total number of pages that have been printed by the printer. The Permanent Page Count cannot be reset.
Page 188: Event Log
7510-XXX The Configuration ID setting allows you to set both Configuration IDs simultaneously. To set one or both Configuration IDs: 1. From the PRINTER SETUP menu, touch the icon to the right of the Configuration ID menu item. The screen displays the value of both Configuration IDs. By default, the cursor appears on the Configuration ID 1 line.
Page 189: Display The Event Log
7510-XXX • Maintenance Count Resets • NV Resets and various types of JFFS@ partition formats Touch EVENT LOG from the Diagnostics Menu, and the following options are displayed: Display Log Print Log Clear Log Display the Event Log Note: The displayed version of the Event Log shows only a subset of the information contained in the Diagnostics version of the printed Event Log.
Page 190: Print The Event Log
7510-XXX 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 191: Scanner Tests
7510-XXX SCANNER TESTS ASIC Test This operation performs a diagnostic test on the scanner ASIC that cycles through all of the scanner ASIC's memory. To perform the ASIC Test: 1. Touch SCANNER TESTS from the Diagnostics Menu. 2. Touch ASIC Test. During this test, ASIC Test Running...
Page 192: Scanner Manual Registration
7510-XXX Scanner Manual Registration Note: All scanner and ADF manual registration alignment verifications must be done in standard user mode, not in configuration or diagnostic mode. Note: You should verify the printer registration alignment before conducting the manual scanner registration process.
Page 193: Trans Belt Hp Fail Clear
7510-XXX Trans Belt HP Fail Clear To perform the Trans Belt Fail Clear Test: 1. Touch Trans Belt Fail Clear from the Diagnostics Menu. 2. Touch Trans Belt HP Fail Clear. Trans Belt HP Fail Clear Testing..appears on the LCD. Press Stop to return to Trans Blet PH Fail Clear.
Page 194: Engine Adjust
7510-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 195 7510-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 196 7510-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 197: Booklet Fold Adjust
7510-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 198: Testing The Manual Scanner Registration
7510-XXX Testing the manual scanner registration Note: Machine must be in Standard User Mode. To properly position the registration test original page on the flatbed scanner and the ADF side 1 and ADF side 2, follow the graphic below: Warning: Ensure that the registration test original page is properly positioned according to the diagrams, or registration and margins cannot be properly adjusted.
Page 199: Analyzing The Manual Scanner Registration Copies
7510-XXX Analyzing the manual scanner registration copies 1. To analyze the manual scanner registration of the flatbed, ADF side 1, and ADF side 2, hold the test copy according to the diagram below. 2. Compare the three copies to the registration test original page for image placement. Ideally, the image should be centered on the page by measuring the paper edge arrows or the black lines with a ruler.
Page 200 7510-XXX 4. Make required adjustments, and touch Submit. Note: All reference to Side Registration in the graphic below refers to the left side edge. 5. Turn the machine off and then back on in order to make a copy. 6. Using the registration test original page, make a copy using the flatbed scanner and the ADF side 1 and ADF side 2 to verify adjustments for accuracy.
Page 201: Scanner Manual Registration Factory Defaults
7510-XXX Decreasing the registration value moves the text toward the lead edge of the page and narrows the lead margin; increasing the registration value moves the text away from the lead edge of the page and widens the lead margin. The entire image moves up or down on the page; therefore, no compression or expansion of the image occurs to preserve the lead margin.
Page 202: Exiting Diagnostics Menu
7510-XXX Exiting Diagnostics Menu From the Diagnostics Menu, touch Back until a graphic appears with Exit Diag Menu in the lower right corner. Touch Exit Diag Menu to perform a POR, and the following graphic appears on the LCD: Copy E-Mail Menus Ready.
Page 203: Configuration Menu
7510-XXX Configuration Menu Entering Configuration Menu 1. Turn off the printer. 2. Press and hold the 2 and 6 buttons simultaneously. 3. Turn on the printer. 4. Release the buttons after 10 seconds. Available menus Maintenance Counter Value “Maintenance Counter Value” on page 3-37.
Page 204 7510-XXX Exiting Configuration Menu “Exiting Configuration Menu” on page 3-50. 3-36 MFP Finisher Service Manual...
Page 205: Maintenance Counter Value
7510-XXX Maintenance Counter Value This setting enables you to view the current maintenance count value of each maintenance kit. After selecting this item, you can choose a specific kit in order to view its current maintenance count value. To return to the Configuration Menu, press Back.
Page 206: Usb Scan To Local
7510-XXX USB Scan to Local To change this setting: 1. Touch USB Scan to Local from the Configuration Menu. [setting's current value] appears on the touch-screen. 2. Touch to scroll through the setting's possible values. 3. Touch Back to cancel and return to the Configuration Menu. 4.
Page 207: Size Sensing
7510-XXX SIZE SENSING This setting controls whether the printer automatically registers the size of paper installed in an input source equipped with size sensing hardware. Size sensing Input source Length Width ✓ Multipurpose feeder (integrated MPF) ✓ ✓ Tray 1 (integrated 500-sheet drawer) ✓...
Page 208: A5/Statement
7510-XXX A5/Statement Due to engine limitations, Trays 1 through 4 cannot simultaneously sense A5- and statement-size paper. The value of this setting determines which of the two paper sizes these trays will sense automatically. This setting will apply to all automatic trays, but not to the MP Feeder. The MP Feeder can support these paper sizes regardless of the value of this setting.
Page 209: Factory Defaults
2. Touch Restore Base to restore all non-critical base printer NVRAM settings. 3. Touch Restore Network to restore all network NVRAM settings. 4. Touch 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 210: Format Fax Storage
7510-XXX Format Fax Storage This setting enables you to format the non-volatile storage used for storing faxes. To change this setting: 1. Touch Format Fax Storage from the Configuration Menu. Note: If an advanced password has been established, you must enter this password in order to change the setting.
Page 211: Paper Prompts
7510-XXX 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. This setting controls the tray the user is directed to fill. Selections are Auto (default), MP Feeder, and Manual Paper. To change this setting: 1.
Page 212: Power Off
7510-XXX When you touch Enable (encryption) or Disable (formatting), Contents will be lost. Continue? appears on the LCD. Touch No to cancel or Yes to proceed. If you touch Yes, the printer performs the selected action on the hard disk. The following graphic appears when the encryption process is selected: Encrypting Disk DO NOT POWER OFF...
Page 213 7510-XXX The panel provides many progress indicators during the two-stage process. 1. 1/2 indicates that the process is currently in the first stage. 2. 0% indicates the progress of the current stage of the process. 3. The progress bar indicates the overall completion of the entire process by filling in throughout each separate stage.
Page 214: Wipe Disk
7510-XXX Formatting Disk DO NOT POWER OFF The entire process is complete when the progress bar appears completely shaded and the percentage indicator shows 100%. After completion, the panel returns to Disk Encryption. Wipe Disk This setting provides you with a tool for erasing the contents of a disk. Warning: Wipe Disk removes a disk's data in such a way that it cannot be recovered.
Page 215 7510-XXX If you touch No, the device cancels the Wipe Disk process and returns to the Configuration Menu. If you touch Yes, the following screen appears: Wiping Disk ½ DO NOT POWER OFF The panel provides the following progress indicators during the execution of this process: 1.
Page 216: Font Sharpening
7510-XXX When the first stage of the process completes, the printer displays the following graphic and then begins the second stage of the process: Wiping Disk DO NOT POWER OFF The entire process is complete when the progress bar appears completely shaded and the percentage indicator shows 100%.
Page 217: Require Standby
2. Touch Back to cancel and return to the Configuration Menu. 3. Touch Submit to save the change. LES Applications This disables all installed Lexmark Embedded Solution applications. The default is Enabled. To change this setting: 1. Touch LES Applications from the Configuration Menu.
Page 218: Key Repeat Initial Delay
7510-XXX Key Repeat Initial Delay When a key is touched repeatedly, this is the delay before the key begins repeating. The delay ranges from .25 seconds to 5 seconds. The default is 1 second. Values are given in increments of .25 seconds. To change this setting: 1.
Page 219: Repair Information
7510-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 220: Removal Procedures
7510-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 221: Finisher Removal
7510-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 222 7510-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. MFP Finisher Service Manual...
Page 223: Bridge Unit Assembly Removal
7510-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 224: Bridge Unit Top Cover Removal
7510-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 225: Sensor (Bridge Unit Top Cover Interlock) Removal
7510-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 226: Bridge Unit Drive Motor Removal
7510-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 227: Bridge Unit Exit/De-Curler Drive Belt Removal
7510-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 228: Sensor (De-Curler Cam Hp) Removal
7510-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 229: Bridge Unit Motor Cover Removal
7510-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 230: Sensor (Bridge Unit Media Exit) Removal
7510-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 231: Sensor (Bridge Unit Bin Exit) Removal
7510-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 232: Bridge Unit Diverter Gate Solenoid Removal
7510-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 233: Switch (Bridge Unit Top Cover Interlock) Removal
7510-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 234: Bridge Unit Diverter Gate Removal
7510-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 235: Bridge Unit Left Cover Removal
7510-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 236: Top Cover Removal
7510-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 237: Upper Media Bin Assembly Removal
7510-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 238: Right Eject Cover Removal
7510-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 239: Stacker Media Bin Assembly Removal
7510-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 240: Rear Lower Cover Removal
7510-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 MFP Finisher Service Manual...
Page 241: Rear Upper Cover Removal
7510-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 242: Upper Media Bin Front Cover Removal
7510-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 243: Switch (Finisher Front Door Interlock) Removal
7510-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 244: Finisher Front Door Assembly Removal
7510-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 245: Left Lower Cover Removal
7510-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 246: Left Upper Cover Removal
7510-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 MFP Finisher Service Manual...
Page 247: Carriage Lift Belt Left Removal
7510-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 248 7510-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 249: Carriage Lift Belt Right Removal
7510-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 250 7510-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 251: Sensor (Stacker Bin Level 1) Removal
7510-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 252: Sensor (Stacker Bin Level Encoder) Removal
7510-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 253: Sensor (Stacker Bin Upper Limit) Or Sensor (Stacker Bin No Media) Removal
7510-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 254 7510-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 MFP Finisher Service Manual...
Page 255: Stacker Bin Lift Motor Assembly Removal
7510-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 256 7510-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 257 7510-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 258: Punch Carriage Assembly Removal
7510-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 259 7510-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 260: Punch Carriage Shift Motor Assembly Removal
7510-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 261: Sensor (Punch Unit Side Registration Pair) With Bracket Removal
7510-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 262: Punch Unit Assembly Removal
7510-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 263: Punch Media Stop Assembly Removal
7510-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 264: Punch Unit Motor Assembly Removal
7510-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 265: Sensor (Punch Unit Motor Encoder) Removal
7510-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 266: Sensor (Punch Hole Select), Sensor (Punch Cam Front), And Sensor (Punch Unit Hp) Removal
7510-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 267 7510-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 268: Sensor (Punch Carriage Shift Hp) Removal
7510-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 269: Sensor (Punch Waste Box Set) Removal
7510-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 270: Sensor (Punch Waste Box Full) Removal
7510-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 271: Stapler Unit Frame Removal
7510-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 272 7510-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 273: Stapler Unit Assembly Removal
7510-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 274 7510-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 275: Sensor (Stapler Carriage Hp) Removal
7510-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 276: Media Eject Unit Assembly Removal
7510-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 277 7510-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 278 7510-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 279 7510-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 280: Sub Paddle Removal
7510-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 281: Sub Paddle Drive Shaft Assembly Removal
7510-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 282 7510-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 283: Media Eject Clamp Motor Assembly Removal
7510-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 284: Sensor (Media Eject Clamp Hp) Removal
7510-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 285: Switch (Eject Cover Interlock) Removal
7510-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 286: Media Compiler Unit Assembly Removal
7510-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 287 7510-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 288: Sensor (Front Tamper Hp) And Sensor (Rear Tamper Hp) Removals
7510-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 289: Sensor (Compiler Media In) Removal
7510-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 290 7510-XXX 13. Move the compiler media present actuator (C) downward as shown. Connector 14. Remove the sensor (compiler media present) (A). 4-72 MFP Finisher Service Manual...
Page 291: Media Eject Shaft Assembly Removal
7510-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 292 7510-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 MFP Finisher Service Manual...
Page 293: Clamp Paddle Removal
7510-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 294: Media Eject Clutch Assembly Removal
7510-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 295: Media Eject Motor Assembly Removal
7510-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 296: Sensor (Media Eject Shaft Hp) Removal
7510-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 297: Sensor (Lower Media Exit) Removal
7510-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 298: Lower Media Exit Roll Assembly Removal
7510-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 299 7510-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 300 7510-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 MFP Finisher Service Manual...
Page 301 7510-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 302: Paddle And Roll Exit Assembly Removal
7510-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 303 7510-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 304 7510-XXX 25. Remove the main paddle shaft assembly. Rear 4-86 MFP Finisher Service Manual...
Page 305 7510-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 306: Lower Pinch Guide Assembly Removal
7510-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 307: Finisher Diverter Gate Removal
7510-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 308: Buffer Diverter Gate Removal
7510-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 309: Sensor (Buffer Path) Removal
7510-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 310: Finisher Buffer Roll Assembly Removal
7510-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 311 7510-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 312: Buffer Pinch Guide Assembly Removal
7510-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 313: Media Entrance Pinch Guide Assembly Removal
7510-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 314: Sensor (Finisher Media Entrance) Removal
7510-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 315: Finisher Media Entrance Roll Assembly Removal
7510-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 316: Drive Motor (Entrance/Paddle) And Belt (Entrance/Paddle) Removal
7510-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 317 7510-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 318: Finisher Diverter Gate Solenoid Removal
7510-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 319: Buffer Diverter Gate Solenoid Removal
7510-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 320: Sensor (Upper Media Exit) Removal
7510-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 321: Upper Media Exit Roll Assembly Removal
7510-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 322 7510-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 323: Sensor (Upper Media Bin Full) Removal
7510-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 324: Upper Pinch Guide Assembly Removal
7510-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 325: Sensor (Diverter Gate) Removal
7510-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 326: Upper Media Transport Roll Assembly Removal
7510-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 327 7510-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 328: Drive Motor (Exit) Assembly And Belt (Exit) Removal
7510-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 329 7510-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 330: Drive Motor (Buffer/Transport) And Belt (Buffer/Transport) Removal
7510-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 331 7510-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 332: Bridge Unit Interface Card Assembly Removal
7510-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 333: Finisher Controller Card Assembly Removal
7510-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 334: Finisher Low Voltage Power Supply (Lvps) Removal
7510-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 335: Booklet Bin Hookup Cable Assembly Removal
7510-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 336: Booklet Bin Assembly Removal
7510-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 MFP Finisher Service Manual...
Page 337: Sensor (Booklet Unit Interlock) Removal
7510-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 338 7510-XXX 7. Remove the booklet controller card assembly (A). Rear 4-120 MFP Finisher Service Manual...
Page 339: Booklet Unit Assembly Removal
7510-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 340: Booklet Diverter Gate Solenoid Removal
7510-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 341: Booklet Knife Solenoid Frame Removal
7510-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 342: Booklet Knife Solenoid Removal
7510-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 343: Booklet Knife Sector Drive Gear 42T
7510-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 344: Booklet Media Entrance Drive Motor Removal
7510-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 345: Booklet Unit Gear Train Frame Removal
7510-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 346: Booklet Unit Assembly Left Cover
7510-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 347: Booklet Rear Tamper Assembly Removal
7510-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 348: Booklet Front Tamper Guide Removal
7510-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 349: Sensor (Booklet Front Tamper Hp) Removal
7510-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 350: Sensor (Booklet Rear Tamper Hp) Removal
7510-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 351: Booklet Front Tamper Motor Removal
7510-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 352: Booklet Rear Tamper Motor Removal
7510-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 353: Sensor (Booklet Knife Hp) Removal
7510-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 354: Sensor (Booklet Knife Folding) Removal
7510-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 355: Booklet Unit Front Door Assembly Removal
7510-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 356: Sensor (Booklet Media Compiler In) Removal
7510-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 357: Sensor (Booklet End Guide Hp) Removal
7510-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. 2. Remove the booklet unit assembly left cover. See “Booklet unit assembly left cover”...
Page 358: Booklet Media Pinch Roll Assembly Removal
7510-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 359: Booklet Paddle Motor Removal
7510-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 360 7510-XXX 5. Remove the booklet end guide drive motor (A). Connector 4-142 MFP Finisher Service Manual...
Page 361: Connector Locations
7510-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 362: Stacker Lift And Stapler
7510-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 MFP Finisher Service Manual...
Page 363: Punch Unit
7510-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 364: Diverter And Media Eject
7510-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 365: Buffer, Upper Exit, Lower Exit, And Drive Motors
7510-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 366 7510-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 367: Booklet Media Bin
7510-XXX Booklet media bin Booklet bin assembly Sensor (booklet bin full) Front Booklet bin drive motor Connector locations...
Page 368: Booklet Maker
7510-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 MFP Finisher Service Manual...
Page 369 7510-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 370 7510-XXX Booklet controller card assembly 5-10 MFP Finisher Service Manual...
Page 371: Cabling
7510-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 372 7510-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 MFP Finisher Service Manual...
Page 373 7510-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 374 7510-XXX 5-14 MFP Finisher Service Manual...
Page 375: Preventive Maintenance
Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover • Possible safety exposure from any non-Lexmark attachments 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 376 7510-XXX MFP Finisher Service Manual...
Page 377: Parts Catalog
7510-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 378: Assembly 1: Finisher-Bridge Unit
7510-XXX Assembly 1: Finisher–bridge unit Asm- Part Units/ Units/ Description Index number option 40X3893 Bridge unit assembly (this comes assembled) MFP Finisher Service Manual...
Page 379: Assembly 2: Finisher-Bridge Unit Covers
7510-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 380: Assembly 3: Finisher-Media Drive 1
7510-XXX Assembly 3: Finisher–media drive 1 MFP Finisher Service Manual...
Page 381 7510-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 382: Assembly 4: Finisher-Media Drive 2
7510-XXX Assembly 4: Finisher–media drive 2 MFP Finisher Service Manual...
Page 383 7510-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 384: Assembly 5: Finisher-Covers
7510-XXX Assembly 5: Finisher–covers MFP Finisher Service Manual...
Page 385 7510-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 386: Assembly 6: Finisher-Covers And Front Door
7510-XXX Assembly 6: Finisher–covers and front door 7-10 MFP Finisher Service Manual...
Page 387 7510-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 388: Assembly 7: Finisher-Stacker Bin Lift
7510-XXX Assembly 7: Finisher–stacker bin lift 7-12 MFP Finisher Service Manual...
Page 389 7510-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 390: Assembly 8: Finisher-Punch
7510-XXX Assembly 8: Finisher–punch 7-14 MFP Finisher Service Manual...
Page 391 7510-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 392: Assembly 9: Finisher-Stapler
7510-XXX Assembly 9: Finisher–stapler 7-16 MFP Finisher Service Manual...
Page 393 7510-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 394: Assembly 10: Finisher-Media Eject
7510-XXX Assembly 10: Finisher–media eject 7-18 MFP Finisher Service Manual...
Page 395 7510-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 40X4147 Spring 40X4145 Sub paddle assembly 40X4058 Sub paddle drive shaft assembly 40X4077 Knob 40X0879 Sub paddle/entrance drive gear 23T...
Page 396: Assembly 11: Finisher-Eject And Compiler Unit
7510-XXX Assembly 11: Finisher–eject and compiler unit 7-20 MFP Finisher Service Manual...
Page 397 7510-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) 40X0886 Media eject shaft assembly 40X0887 Clamp paddle 40X0888...
Page 398: Assembly 12: Finisher-Lower Exit Drive
7510-XXX Assembly 12: Finisher–lower exit drive 7-22 MFP Finisher Service Manual...
Page 399 7510-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 40X0895 Lower media exit roll assembly 40X0888 Bushing 6 mm 40X4105 Main paddle shaft assembly 40X4106...
Page 400: Assembly 13: Finisher-Buffer And Entrance Drive
7510-XXX Assembly 13: Finisher–buffer and entrance drive 7-24 MFP Finisher Service Manual...
Page 401 7510-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 40X0903 Buffer diverter gate 40X0824 Magnetic catch 40X0888 Bushing 6 mm 40X0904 Buffer upper guide assembly 40X0893 Sensor (buffer path) 40X3953...
Page 402: Assembly 14: Finisher-Buffer, Transport, And Upper Drive
7510-XXX Assembly 14: Finisher–buffer, transport, and upper drive 7-26 MFP Finisher Service Manual...
Page 403 7510-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 404: Assembly 15: Booklet Maker 1
7510-XXX Assembly 15: Booklet maker 1 7-28 MFP Finisher Service Manual...
Page 405 7510-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 406: Assembly 16: Booklet Maker
7510-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 407: Assembly 17: Booklet Maker
7510-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 408: Assembly 18: Booklet Maker
7510-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 409: Assembly 19: Booklet Maker
7510-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 410: Assembly 20: Booklet Maker
7510-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) 7-34 MFP Finisher Service Manual...
Page 411: Assembly 21: Booklet Maker
7510-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 412: Assembly 22: Booklet Maker
7510-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 MFP Finisher Service Manual...
Page 413: Assembly 23: Booklet Maker
7510-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 414: Assembly 24: Finisher-Electronics
7510-XXX Assembly 24: Finisher–electronics 7-38 MFP Finisher Service Manual...
Page 415: Index
7510-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 40X4100 Bridge unit interface card cable assembly 40X3971 Finisher controller card assembly 40X3972 AC power cord assembly 40X0936 Finisher LVPS card assembly 7-39...
Page 416 7510-XXX Assembly 25: Finisher–cables 1 7-40 MFP Finisher Service Manual...
Page 417 7510-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 418 7510-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 419 7510-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 420 7510-XXX 7-44 MFP Finisher Service Manual...
Page 421 7510-XXX Index 3-41 Numerics Min Copy Memory 3-40 Panel Menus 40X3936 2/3 punch unit assembly (this comes 3-43 Paper Prompts 7-15 assembled) 3-40 PPDS Emulation 3-38 Print Quality Pages 3-49 Require Standby accessing service menus 3-37 1-36 Reset Maintenance Counter acronyms 3-49 Short Edge Printing...
Page 422 7510-XXX 2-36 HARDWARE TESTS 287.01 sensor (upper media exit) off jam A 2-38 Button Test 287.05 sensor (upper media exit) static jam A 2-39 CACHE Test 288.00 sensor (diverter gate) on jam DRAM Test 288.01 sensor (diverter gate) static jam (to top bin) A 2-41 Panel Test INPUT TRAY TESTS...
Page 423 7510-XXX 4-68 4-23 media compiler unit assembly rear upper cover 4-100 media diverter gate solenoid removals–finisher 4-112 media eject belt (buffer/transport) 7-18 4-98 parts catalog belt (entrance/paddle) 4-65 4-110 media eject clamp motor assembly belt (exit) 4-76 media eject clutch bridge unit assembly 4-77 media eject motor assembly...
Page 424 7510-XXX 4-50 4-33 sensor (punch carriage shift HP) stacker bin level 1 4-48 4-33 sensor (punch hole select) stacker bin level 2 4-48 4-34 sensor (punch unit HP) stacker bin level encoder 4-47 4-35 sensor (punch unit motor encoder) stacker bin no media 4-35 sensor (punch unit side registration pair) with bracket stacker bin upper limit...
Page 425: Part Number Index
7510-XXX Part number index Description Page 40X0824 Magnetic catch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25 7-27 40X0825...
Page 426 7510-XXX 7-17 40X0868 Stapler unit cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X0869 Stapler carriage kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17...
Page 427 7510-XXX 7-15 7-43 40X0930 Punch waste box full cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X0931 Bridge unit interface card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43...
Page 428 7510-XXX 7-29 40X3982 Booklet controller card power cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X3983 Booklet bin/diverter cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29...
Page 429 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...

This manual is also suitable for:

X945e

Lexmark X940e Service Manual

Table of Contents

Notices and Safety Information

Laser Notice

Safety Information

Preface

Conventions

General Information

Finisher

Finisher Theory

Tools Required for Service

Acronyms

Diagnostic Information

Start

POR (Power-On Reset) Sequence

Error Code Messages - Finisher

Service Checks - Finisher

Diagnostic Aids

Accessing Service Menus

Diagnostics Menus

Hardware Tests

Duplex Tests

Input Tray Tests

Output bin Tests

Finisher Tests

Base Sensor Test

Device Tests

Printer Setup

Event Log

Scanner Tests

Scanner Manual Registration

Sensor Test (Scanner Tests)

Trans Belt HP Fail Clear

Dev Unit Reset

Fuser Temp Fail Clear

Atc Sensor Failure Clear

Engine Adjust

Booklet Fold Adjust

Finisher Config

Testing the Manual Scanner Registration

Analyzing the Manual Scanner Registration Copies

Manually Adjusting the Scanner's Registration

Scanner Manual Registration Factory Defaults

Exiting Diagnostics Menu

Configuration Menu

Repair Information

Handling ESD-Sensitive Parts

Removal Procedures

Stacker Media bin Assembly Removal

Right Lower Low Voltage Power Supply (LVPS) Cover Removal

Rear Lower Cover Removal

Rear Upper Cover Removal

Upper Media bin Front Cover Removal

Switch (Finisher Front Door Interlock) Removal

Finisher Front Door Assembly Removal

Left Lower Cover Removal

Left Upper Cover Removal

Carriage Lift Belt Left Removal

Carriage Lift Belt Right Removal

Sensor (Stacker bin Level 1) Removal

Sensor (Stacker bin Level 2) Removal

Sensor (Stacker bin Level Encoder) Removal

Sensor (Stacker bin Upper Limit) or Sensor (Stacker bin no Media) Removal

Stacker bin Lift Motor Assembly Removal

Punch Carriage Assembly Removal

Punch Carriage Shift Motor Assembly Removal

Sensor (Punch Unit Side Registration Pair) with Bracket Removal

Punch Unit Assembly Removal

Punch Media Stop Assembly Removal

Punch Unit Motor Assembly Removal

Sensor (Punch Unit Motor Encoder) Removal

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Summary of Contents for Lexmark X940e