Edition: December 12, 2011

Lexmark™ X860de, X862de, & X864de

Booklet Maker Finisher

7500-432, -632, and -832

• Table of contents

• Start diagnostics

• Safety and notices

• Trademarks

• Index

Lexmark and Lexmark with diamond design are

trademarks of Lexmark International, Inc., registered
in the United States and/or other countries.
7500-432, -632, and -832

Edition: December 12, 2011

The following paragraph does not apply to any country where such provisions are inconsistent with local law:
LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND,
EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or
implied warranties in certain transactions; therefore, this statement may not apply to you.
This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the
information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the
programs described may be made at any time.
Comments may be addressed to Lexmark International, Inc., Department D22X/002-1, 740 West New Circle Road,
Lexington, Kentucky 40550, U.S.A or e-mail at [email protected]. Lexmark may use or distribute any
of the information you supply in any way it believes appropriate without incurring any obligation to you.
References in this publication to products, programs, or services do not imply that the manufacturer intends to make these
available in all countries in which it operates. Any reference to a product, program, or service is not intended to state or
imply that only that product, program, or service may be used. Any functionally equivalent product, program, or service that
does not infringe any existing intellectual property right may be used instead. Evaluation and verification of operation in
conjunction with other products, programs, or services, except those expressly designated by the manufacturer, are the
user’s responsibility.
Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States
and/or other countries.
PCL® is a registered trademark of the Hewlett-Packard Company.
All other trademarks are the property of their respective owners.

© 2009 Lexmark International, Inc.

All rights reserved.

UNITED STATES GOVERNMENT RIGHTS

This software and any accompanying documentation provided under this agreement are commercial computer software
and documentation developed exclusively at private expense.

P/N 12G9775
 7500-432, -632, and -832

Table of contents

Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Notices and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Laser notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx
Change history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii-xx
Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi

General information .................................................................... 1-1

Finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Standard Finisher weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Booklet Finisher weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Media path overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Media size and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Media size/orientation and applicable functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Media weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Finisher theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Media transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Bridge unit assembly paper path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Finisher media path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Finisher roll assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Finisher media path sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Finisher motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Bridge unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
From bridge unit assembly to punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
From punch to compiler unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
From compiler unit assembly to stacker media bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
From punch to upper media bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Functions of sensors along the media path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Bridge unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Punch unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Adjusting punching positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Punching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Detecting punch waste full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Detecting punch waste box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Functions of punch sensors/motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Compiler unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Outline of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Capacity of compiler unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Compiler unit assembly operation with multiple media sizes . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Tamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Front tamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Rear tamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Center tamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Determining tamper home position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Tamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Offsetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Functions of compiler unit assembly sensors/motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Stapling operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

Table of contents iii

7500-432, -632, and -832

Staple positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

Media sizes that allow stapling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Stapling one sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
Stapling multiple size media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Media limits for stapling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Stapler operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Stapler unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Functions of stapler sensors/motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Booklet Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Functions of booklet sensors and motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Booklet media bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
Functions of upper media bin sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Stacker media bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30
Full stack detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
Functions of stacker media bin sensors/motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
Booklet tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
Power supply and interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
Tools required for service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

Diagnostic information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
POR (Power-On Reset) sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
To enter the diagnostic menu: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Error code messages - finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Service checks - finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
280.00 Sensor (bridge unit media entrance) late Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
280.01 Sensor (bridge unit media entrance) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
281.00 Sensor (bridge unit media exit) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
281.03 Sensor (bridge unit media exit) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
282.00 Sensor (finisher media entrance) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
282.01 Sensor (finisher media entrance) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
283.00 Sensor (buffer path) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18
283.03 Sensor (buffer path) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
284.00 Sensor (lower media exit) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
284.03 Sensor (lower media exit) lag jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
284.05 Sensor (lower media exit) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25
285.00 Sensor (media compiler in) lag jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
286.00 Sensor (compiler media in) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
287.00 Sensor (upper media exit) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30
287.01 Sensor (upper media exit) lag jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31
287.05 Sensor (upper media exit) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
288.00 Sensor (diverter gate) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
288.01 Sensor (diverter gate) static jam A (to top bin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
288.04 Sensor (diverter gate) static jam B (to stacker bin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
289.00 sensor (booklet unit media entrance) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
289.01 sensor (booklet unit media entrance) lag jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
289.02 sensor (booklet unit media entrance) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
289.03 sensor (booklet compiler media in) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
289.04 Sensor (booklet unit media exit) late jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
289.05 Sensor (booklet unit media exit) lag jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
289.06 Sensor (booklet unit media exit) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
980.02 Finisher communication failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
981.00 Sensor (stacker bin level 1) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
981.01 Stacker bin upper limit error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
981.02 Stacker bin lower limit error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
982.00 Sensor (front tamper HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

iv MFP Finisher Service Manual

 7500-432, -632, and -832

982.01 Sensor (front tamper HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

983.00 Sensor (rear tamper HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
983.01 Sensor (rear tamper HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
984.00 Sensor (punch unit HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
984.01 Sensor (punch unit HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
985.00 Sensor (punch carriage shift HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
985.01Sensor (punch carriage shift HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
986.00 Sensor (media eject clamp HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
986.01 Sensor (media eject clamp HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
987.00 Sensor (media eject shaft HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65
987.01 Sensor (media eject shaft HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
988.01 Sensor (punch unit side reg1) or (sensor (punch unit side reg2) lag failure . . . . . . . . . 2-68
989.00 Stapler unit failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
990.00 Sensor (stapler carriage HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
990.01 Sensor (stapler carriage HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
991.00 Sensor (booklet front temper HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
991.01 Sensor (booklet front tamper HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
991.02 Sensor (booklet rear tamper HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75
991.03 Sensor (booklet rear tamper HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
991.04 Sensor (booklet end guide HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78
991.05 Sensor (booklet end guide HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
991.06 Sensor (booklet unit interlock) error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
991.07 Sensor (booklet compiler no media) no media detected . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
991.08 Sensor (booklet knife HP) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
991.09 Sensor (booklet knife HP) lag error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
991.10 Sensor (booklet knife folding) late error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
991.11 Booklet stapler error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
991.12 Communication error with booklet controller card assembly . . . . . . . . . . . . . . . . . . . . . 2-89
991.13 Booklet unit maker error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
Bridge unit top cover open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
Finisher front door open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Finisher eject cover open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
Finisher upper media bin full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
No punch waste box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94
Punch waste box full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95
Stacker media bin full (mix size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96
Stacker media bin full (no mix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
Stacker lower safety failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100
Stacker set over count failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
Staple cartridge empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102

Diagnostic aids ......................................................................... 3-1

Accessing service menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Diagnostics Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Entering Diagnostics Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Available tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
MOTOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
OUTPUT BIN TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Feed Tests (output bins) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Feed To All Bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
FINISHER TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Staple Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Hole Punch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Feed Tests (Finisher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Sensor Test (Finisher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
PRINTER SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Printed Color Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Printed Mono Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Table of contents v
7500-432, -632, and -832

Permanent Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Engine Setting 1 to 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Model Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Configuration ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
EVENT LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Display the Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Print the Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Clear the Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
ENGINE ADJUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Booklet Fold Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Finisher Config . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Exiting Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Repair information ..................................................................... 4-1

Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Before starting service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Finisher removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Bridge unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Bridge unit rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Bridge unit top cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Bridge unit drive belt and bridge unit drive pulley removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Bridge unit right shaft assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Bridge unit left shaft assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Bridge unit idler rolls removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Bridge unit transport belt removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Bridge unit drive motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
Bridge unit entrance guide removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Sensor (bridge unit top cover interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Sensor (bridge unit media entrance) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Sensor (bridge unit media exit) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Bridge unit pinch roller removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Top cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Upper media bin assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Right eject cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Stacker media bin assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Right lower low voltage power supply (LVPS) cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Rear lower cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Rear upper cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Upper media bin front cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Switch (finisher front door interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Finisher front door assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Left lower cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Left upper cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Carriage lift belt left removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Carriage lift belt right removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Sensor (stacker bin level 1) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Sensor (stacker bin level 2) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Sensor (stacker bin level encoder) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Sensor (stacker bin upper limit) or sensor (stacker bin no media) removal . . . . . . . . . . . . . . . . 4-36
Stacker bin lift motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Punch carriage assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Punch carriage shift motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Sensor (punch unit side registration pair) with bracket removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Punch unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Punch media stop assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46
Punch unit motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47
Sensor (punch unit motor encoder) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

vi MFP Finisher Service Manual

 7500-432, -632, and -832

Sensor (punch hole select), sensor (punch cam front), and sensor (punch unit HP) removal 4-49
Sensor (punch carriage shift HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Sensor (punch waste box set) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Sensor (punch waste box full) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
Stapler unit frame removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Stapler unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Sensor (stapler carriage HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
Media eject unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
Sub paddle removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
Sub paddle drive shaft assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
Media eject clamp motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
Sensor (media eject clamp HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
Switch (eject cover interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
Media compiler unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69
Sensor (front tamper HP) and sensor (rear tamper HP) removals . . . . . . . . . . . . . . . . . . . . . . . 4-71
Sensor (compiler media in) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
Media eject shaft assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Clamp paddle removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76
Media eject clutch assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
Media eject motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78
Sensor (media eject shaft HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
Sensor (lower media exit) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Lower media exit roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
Paddle and roll exit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85
Lower pinch guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
Finisher diverter gate removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90
Buffer diverter gate removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91
Sensor (buffer path) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92
Finisher buffer roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93
Buffer pinch guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95
Media entrance pinch guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-96
Sensor (finisher media entrance) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97
Finisher media entrance roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-98
Drive motor (entrance/paddle) and belt (entrance/paddle) removal . . . . . . . . . . . . . . . . . . . . . . 4-99
Finisher diverter gate solenoid removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-101
Buffer diverter gate solenoid removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-102
Sensor (upper media exit) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-103
Upper media exit pinch roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-103
Upper media exit roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104
Sensor (upper media bin full) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-106
Upper pinch guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-107
Sensor (diverter gate) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-108
Upper media transport roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-109
Drive motor (exit) assembly and belt (exit) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-111
Drive motor (buffer/transport) and belt (buffer/transport) removal . . . . . . . . . . . . . . . . . . . . . 4-113
Bridge unit interface card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-115
Finisher controller card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-116
Finisher low voltage power supply (LVPS) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-117
Booklet bin hookup cable assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-118
Booklet bin assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-119
Sensor (booklet unit interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-120
Booklet controller card assembly removal ?? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-121
Booklet unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-122
Booklet folding/exit drive motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-122
Booklet diverter gate solenoid removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-123
Booklet stapler unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-123
Booklet knife solenoid frame removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-124
Booklet knife solenoid removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-125
Booklet knife sector drive gear 42T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-126

Table of contents vii

7500-432, -632, and -832

Booklet media entrance drive motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-127

Booklet unit gear train frame removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-128
Booklet unit assembly left cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-129
Booklet rear tamper assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-130
Booklet front tamper guide removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-131
Sensor (booklet front tamper HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-132
Sensor (booklet rear tamper HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-133
Booklet front tamper motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-134
Booklet rear tamper motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-135
Sensor (booklet knife HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-136
Sensor (booklet knife folding) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-137
Booklet unit front door assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-138
Sensor (booklet unit media entrance) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-138
Sensor (booklet media compiler in) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-139
Sensor (booklet unit media exit) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-139
Sensor (booklet end guide HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-140
Booklet media pinch roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-141
Booklet paddle motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-142
Booklet end guide drive motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-142
Booklet maker setup & adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-144
Folding precision skew adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-144
2 sheet fold & staple position fine adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-145
15 sheet staple position fine adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-149
Booklet fold position fine adjustment (3-15 sheets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-151
Booklet staple position fine adjustment (3-14 sheets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-153

Connector locations ................................................................... 5-1

Finisher components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Bridge unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Stacker lift and stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Punch unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Diverter and media eject . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Media eject and media compiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Buffer, upper exit, lower exit, and drive motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
Booklet media bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Booklet maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Preventive maintenance ............................................................... 6-1

Safety inspection guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Lubrication specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Maintenance recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Assembly 1: Finisher—bridge unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Assembly 2: Finisher—bridge unit top cover assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Assembly 3: Finisher—bridge unit lower assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Assembly 4: Finisher—covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Assembly 5: Finisher—covers and front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Assembly 6: Finisher—stacker bin lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Assembly 7: Finisher—punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Assembly 8: Finisher—stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Assembly 9: Finisher—media eject . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Assembly 10: Finisher—eject and compiler unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Assembly 11: Finisher—lower exit drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Assembly 12: Finisher—buffer and entrance drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Assembly 13: Finisher—buffer, transport, and upper drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

viii MFP Finisher Service Manual

 7500-432, -632, and -832

Assembly 14: Booklet maker 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

Assembly 15: Booklet maker 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Assembly 16: Booklet maker 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Assembly 17: Booklet maker 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Assembly 18: Booklet maker 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Assembly 19: Booklet maker 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Assembly 20: Booklet maker 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Assembly 21: Booklet maker 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Assembly 22: Booklet maker 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Assembly 23: Finisher—electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Assembly 24: Finisher—cables 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Assembly 25: Finisher—cables 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Assembly 26: Finisher—cables 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5

Table of contents ix
7500-432, -632, and -832

x MFP Finisher Service Manual

 7500-432, -632, and -832

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.

Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (3b) laser
that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770-795 nanometers.
The laser system and printer are designed so there is never any human access to laser radiation above a Class
I level during normal operation, user maintenance, or prescribed service condition.

Laser
Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die Anforderungen der Bestimmung DHHS
(Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). In anderen
Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International
Electrotechnical Commission) 60825-1 gemäß amtlicher Bestätigung erfüllt.

Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des Druckers befindet sich ein Laser der Klasse
IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen der Länge 770-795
Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, daß im Normalbetrieb, bei der
Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laserbestrahlung,
die Klasse I übersteigen würde, Menschen keinesfalls erreicht.

Avis relatif à l’utilisation de laser

Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant
les produits laser de Classe I (1). Pour les autres pays : cette imprimante répond aux normes IEC 60825-1
relatives aux produits laser de Classe I.

Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette imprimante est
équipée d’un laser de Classe IIIb (3b) (arséniure de gallium d’une puissance nominale de 5 milliwatts) émettant
sur des longueurs d’onde comprises entre 770 et 795 nanomètres. L’imprimante et son système laser sont
conçus pour impossible, dans des conditions normales d’utilisation, d’entretien par l’utilisateur ou de révision,
l’exposition à des rayonnements laser supérieurs à des rayonnements de Classe I .

Avvertenze sui prodotti laser

Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo
J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai
requisiti della norma CEI 60825-1.

I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un laser di classe
IIIb (3b) all’arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d’onda compresa tra 770 e 795
nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la
stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non
ricevano radiazioni laser superiori al livello della classe 1.

Notices and safety information xi

7500-432, -632, and -832

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).

Los productos láser de Clase I no se consideran peligrosos. La impresora contiene en su interior un láser de
Clase IIIb (3b) de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a
795 nanómetros. El sistema láser y la impresora están diseñados de forma que ninguna persona pueda verse
afectada por ningún tipo de radiación láser superior al nivel de la Clase I durante su uso normal, el
mantenimiento realizado por el usuario o cualquier otra situación de servicio técnico.

Declaração sobre Laser

A impressora está certificada nos E.U.A. em conformidade com os requisitos da regulamentação DHHS 21 CFR
Subcapítulo J para a Classe I (1) de produtos laser. Em outros locais, está certificada como um produto laser da
Classe I, em conformidade com os requisitos da norma IEC 60825-1.

Os produtos laser da Classe I não são considerados perigosos. Internamente, a impressora contém um produto
laser da Classe IIIb (3b), designado laser de arseneto de potássio, de 5 milliwatts, operando numa faixa de
comprimento de onda entre 770 e 795 nanómetros. O sistema e a impressora laser foram concebidos de forma
a nunca existir qualquer possiblidade de acesso humano a radiação laser superior a um nível de Classe I
durante a operação normal, a manutenção feita pelo utilizador ou condições de assistência prescritas.

Laserinformatie
De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten
zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1.

Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van
klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met een golflengte van 770-795
nanometer. Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal gebruik, bij onderhoud of reparatie
conform de voorschriften, nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals
voorgeschreven is voor klasse 1.

Lasermeddelelse
Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825-1.

Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der
nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer.
Lasersystemet og printeren er udformet således, at mennesker aldrig udsættes for en laserstråling over Klasse
I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.

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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. Laserjärjestelmä ja tulostin ovat
rakenteeltaan sellaisia, että käyttäjä ei joudu alttiiksi luokkaa 1 suuremmalle säteilylle normaalin käytön,
ylläpidon tai huollon aikana.

Huomautus laserlaitteesta
Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen
ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen.

Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5
milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä. Laserjärjestelmä ja kirjoitin on
suunniteltu siten, että käyttäjä ei altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen normaalin
toiminnan, käyttäjän tekemien huoltotoimien tai muiden huoltotoimien yhteydessä.

VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso
säteeseen.

VARNING! Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad. Betrakta ej strålen.

Laser-notis
Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av
Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 60825-1.

Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av
en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770-795 nanometer.
Lasersystemet och skrivaren är utformade så att det aldrig finns risk för att någon person utsätts för
laserstrålning över Klass I-nivå vid normal användning, underhåll som utförs av användaren eller annan
föreskriven serviceåtgärd.

Laser-melding
Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er
i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1.

Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som
består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer.
Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstråling ut over klasse I-nivå under
vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne serviceoperasjoner.

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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.

Els productes làser de classe I no es consideren perillosos. Aquesta impressora conté un làser de classe IIIb
(3b) d’arseniür de gal.li, nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona de 770-795
nanòmetres. El sistema làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la
radiació làser per sobre d’un nivell de classe I durant una operació normal, durant les tasques de manteniment
d’usuari ni durant els serveis que satisfacin les condicions prescrites.

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Notices and safety information xv

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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.
• There may be an increased risk of electric shock and personal injury during disassembly and servicing of
this product. Professional service personnel should understand this and take necessary precautions.
• CAUTION: When you see this symbol, there is a danger from hazardous voltage in the area of the
product where you are working. Unplug the product before you begin, or use caution if the product
must receive power in order to perform the task.

Consignes de sécurité
• La sécurité de ce produit repose sur des tests et des
agréations portant sur sa conception d'origine et sur des composants particuliers. Le fabricant n'assume
aucune responsabilité concernant la sécurité en cas d'utilisation de pièces de rechange non agréées.
• Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de
maintenance qualifié.
• Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel
d'entretien qualifié devra prendre toutes les précautions nécessaires.
• ATTENTION : Ce symbole indique la présence d'une tension dangereuse dans la partie du
produit sur laquelle vous travaillez. Débranchez le produit avant de commencer ou faites preuve
de vigilance si l'exécution de la tâche exige que le produit reste sous tension.

Norme di sicurezza
• La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti
specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle
parti.
• Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di
assistenza autorizzato.
• Durante lo smontaggio e la manutenzione di questo prodotto,
il rischio di subire scosse elettriche e danni alla persona è più elevato. Il personale di assistenza
autorizzato deve, quindi, adottare le precauzioni necessarie.
• ATTENZIONE: Questo simbolo indica la presenza di tensione pericolosa nell'area del prodotto.
Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per
eseguire l'intervento.

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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.
• Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusätzliches Risiko eines
elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende
Vorsichtsmaßnahmen treffen.
• ACHTUNG: Dieses Symbol weist auf eine gefährliche elektrische Spannung hin, die in diesem
Bereich des Produkts auftreten kann. Ziehen Sie vor den Arbeiten am Gerät den Netzstecker des
Geräts, bzw. arbeiten Sie mit großer Vorsicht, wenn das Produkt für die Ausführung der Arbeiten
an den Strom angeschlossen sein muß.

Pautas de Seguridad
• La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes
específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no
autorizadas.
• La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal
cualificado de mantenimiento.
• Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de
la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones
necesarias.
• PRECAUCIÓN: este símbolo indica que el voltaje de la parte del equipo con la que está
trabajando es peligroso. Antes de empezar, desenchufe el equipo o tenga cuidado si, para
trabajar con él, debe conectarlo.

Informações de Segurança
• A segurança deste produto baseia-se em testes e aprovações do modelo original e de componentes
específicos. O fabricante não é responsável pela segunrança, no caso de uso de peças de substituição
não autorizadas.
• As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não
devem ser utilizadas por outras pessoas.
• Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste produto.
Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários.
• CUIDADO: Quando vir este símbolo, existe a possível presença de uma potencial tensão
perigosa na zona do produto em que está a trabalhar. Antes de começar, desligue o produto da
tomada eléctrica ou seja cuidadoso caso o produto tenha de estar ligado à corrente eléctrica para
realizar a tarefa necessária.

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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.
• La informació pel manteniment d’aquest producte està orientada exclusivament a professionals i no està
destinada
a ningú que no ho sigui.
• El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei
d’aquest producte. El personal professional ha d’estar-ne assabentat i prendre
les mesures convenients.
• PRECAUCIÓ: aquest símbol indica que el voltatge de la part de l'equip amb la qual esteu
treballant és perillós. Abans de començar, desendolleu l'equip o extremeu les precaucions si, per
treballar amb l'equip, l'heu de connectar.

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Preface

This manual contains maintenance procedures for service personnel. It is divided into the following chapters:

1. 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.
2. Diagnostic information contains an error indicator table, symptom tables, and service checks used to
isolate failing field replaceable units (FRUs).
3. Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer problems.
4. Repair information provides instructions for making printer adjustments and removing and installing FRUs.
5. Connector locations uses illustrations to identify the connector locations and test points on the printer.
6. Preventive maintenance contains the lubrication specifications and recommendations to prevent
problems.
7. Parts catalog contains illustrations and part numbers for individual FRUs.

Change history

Revision date Updates

2011/12/12 • Updated the descriptions for the following part numbers:
- 40X0857 to “2/3 punch hammer sub-assembly” on page 7-13
- 40X0858 to “2/4 punch hammer sub-assembly” on page 7-13
• Added the following part numbers in the table for “Finisher—punch” on page 7-13:
- 40X3937
- 40X6865
• Updated the art for “Finisher—punch” on page 7-12.

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Conventions
Note: A note provides additional information.
Warning: A warning identifies something that might damage the product hardware or software.

There are several types of caution statements:

CAUTION

A caution identifies something that might cause a servicer harm.

CAUTION

This type of caution indicates there is a danger from hazardous voltage in the area of the
product where you are working. Unplug the product before you begin, or use caution if the
product must receive power in order to perform the task.

CAUTION

This type of caution indicates a hot surface.

CAUTION

This type of caution indicates a tipping hazard.

Conventions xxi
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1. General information

Finisher
The optional finisher staples, punches, folding and stapling, and stacks media transferred from the Lexmark™
X860de, X862de, and X864de. Output is stacked in the upper media bin or separately collated in the stacker
media bin or folded and stapled in the booklet bin.

Bridge unit assembly

Finisher

Standard Finisher weight

Unpacked: 59 kg (130 lbs)

Booklet Finisher weight

Unpacked: 87.5 kg (193 lbs)

Components

The finisher is composed of the following components.

• Bridge unit assembly block to feed media from the printer to the finisher
• Punch block to punch media
• Compiler tray block to align media
• Stapler block to staple a set of media at specified positions
• Booklet unit and tray

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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. Refer to the Printer Service Manual for additional information on the printer.

Media size/orientation and applicable functions

Short edge Top

Stacker
Media first (SEF)/ tray
Size
description Long edge Offset
first (LEF) Stack Stack Punch Staple Booklet Folding
stack
B5 SEF Yes No No No No No No
182 x 257 mm
LEF Yes Yes Yes Yesa(2) Yes No No
Executive 7.25 x 10.5 in. SEF Yes No No No No No No
184.2 x 27 0 mm a(2,3,4)
LEF Yes Yes Yes Yes No No No
Letter 8.5 x 11 in. SEF Yes Yes Yes Yesa(2) Yes Yes Yes
215.9 x 279.4 mm
LEF Yes Yes Yes Yesa(2,3,4) Yes No No
A4 SEF Yes Yes Yes Yesa(2) Yes Yes Yes
210 x 297 ,a(3,4)
LEF Yes Yes Yes Yes2 Yes No No
Folio (foolscap) 8,5 x 13 in. SEF Yes Yes Yes Yesa(2) Yes Yes Yes

Legal 8.5 x 14 in. SEF Yes Yes Yes Yesa(2) Yes Yes Yes

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B4 SEF Yes Yes Yes Yesa(2) Yes Yes Yes

257 x 364 mm
A3 SEF Yes Yes Yes Yesa(2,3,4) Yes Yes Yes
297 x 420 mm
Ledger 11 x 17 in. SEF Yes Yes Yes Yesa(2,3,4) Yes Yes Yes

Custom size Same width with Yes Yes Yes Yes Yes No No
standard size
Custom size Besides above Yes Yesb Yesb No No No No
a
Numbers (2,3,4) mean 2 holes, 3 holes, and 4 holes, respectively.
b
Applicable within the following range:
Media width: 203.2–297 mm
Media length: 182–431.8 mm

Media weight

Description Maximum weight

For punching 52—176 gsm
For stapling 52—226 gsm*
For ejecting in the stacker media bin 52—226 gsm
For ejecting in the upper media bin 52—226 gsm
For folding and stapling 52-226 gsm
* The amount of media capable of being stapled will be less than 50 if the media
weight is greater than 90 g/m2.

Features

Media processing requested Destination of media

No post-processing Upper media bin or stacker media bin
Punching Upper media bin or stacker media bin
Stapling Stacker media bin
Punching and stapling Stacker media bin
Folding and stapling Booklet tray

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Finisher theory
Media transport

This section describes the transfer of media from the printer to a specified bin.

The following figures illustrate layouts (front view) of sensors, rollers, and main blocks, as well as a layout (rear
view) of the main components.

Bridge unit assembly paper path

To finisher

From printer

Transport Sensor (bridge unit

Sensor (bridge unit media entrance) belt media exit)

Finisher media path

Upper Media Bin

Punch Unit Stacker Media Bin

From Bridge Unit

Stapler Unit Compiler Media Unit Assembly

Knife Folding
Booklet Bin

Booklet Stapler Unit

End Guide

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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)

Buffer Roll Assembly – Eject Clamp – driven by media

driven by drive motor eject clamp motor
(buffer/transport)

Buffer Diverter Gate

Main paddle assembly

driven by drive motor Media Eject Shaft Assembly –
(entrance paddle) driven by media eject motor assembly

Booklet media exit roll assembly

driven by booklet folding/exit
Booklet entrance roll drive motor assembly
assembly driven by booklet
media entrance drive motor

Booklet fold roll assembly Booklet paddle

driven by booklet folding/exit shaft assembly
drive motor assembly

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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)

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Finisher motors

Drive motor (exit)

Media eject clamp motor Drive 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.

The bridge unit drive motor is activated by the trigger of the printer’s registration clutch, which drives the
transport belts in the bridge unit assembly. The motor power is transmitted to the two belts between the bridge
unit right shaft assembly and the bridge unit left shaft assembly.

The media fed to the bridge unit assembly is securely held between the transport belts and the pinch rolls, and
fed to the finisher.
Bridge unit right
Bridge unit drive motor
shaft assembly
Bridge unit
pinch roll

Transport belt
Bridge unit left
shaft assembly

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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.

The finisher diverter gate is activated by the finisher diverter gate solenoid controlled by the printer.

The media is further fed in the finisher by the two upper media transport roll assemblies, or the buffer roll
assemblies that are driven by the motor (buffer/transport), and passes through the punch unit.

The sensor (finisher media entrance) becomes low upon detecting media. After a certain amount of time has
passed and the level has changed to high, the motor (buffer/transport) that drives the upper media transport roll
assembly or the buffer roll assembly starts reverse rotation.

The media is returned to the punch unit by the upper media transport roll assembly or the buffer roll assembly,
and is stopped with its end gently pressed against the three punch media stopper assemblies.

The three punch media stopper assemblies in the punch unit drop to let media pass through when media is fed
to the exit (while the motor (buffer/transport) is rotating forward), but rise when media is returned (while the
motor (buffer/transport) is rotating reversely) to stop the media.

Thus, punch hole positions in the media feed direction are determined.
Drive motor (buffer/transport)

Upper media transport

Punch unit
roll assembly

Punch unit
Finisher diverter
gate solenoid
Finisher diverter gate

Drive motor Buffer roll assembly

(entrance paddle) Sensor (finisher
media entrance) Finisher media
entrance roll
assembly

Upper media transport roll assembly—driven by

drive motor (buffer/transport)

Punch unit
Sensor (finisher
media entrance) Finisher diverter gate
Media
From bridge unit assembly

Finisher media entrance

roll assembly—driven by
drive motor (entrance/paddle)

Buffer roll assembly—

driven by drive motor (buffer/transport)

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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.

Thus, the media transferred from the punch unit is held by the media eject shaft assembly and the media eject
clamp (driven by the media eject motor assembly) and is fed to the exit.

When the media trailing edge passes through the sensor (lower media exit), the media eject motor assembly
starts reverse rotation to return the media to the compiler unit assembly.

When the following media reaches the compiler unit assembly, the media eject clamp is raised, and the media
that has passed through the lower media exit roll assembly falls on the compiler unit assembly.

At this time, the three main paddles are rotated by the main paddle shaft assembly to feed the media so that the
media trailing edge butts against the rear wall of the compiler unit assembly.

The sub paddle solenoid of the media eject unit assembly is activated to lower the sub paddle so that the media
can be fed to the compiler unit assembly.
Media eject clamp motor Media eject motor assembly

Drive motor (exit) Sensor (lower media exit)

Eject clamp
Drive motor
(buffer/transport) Media eject
shaft assembly
Buffer diverter solenoid

Lower media exit

roll assembly

Compiler unit assembly

Drive motor (entrance/paddle) Buffer diverter gate

Buffer roll assembly

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Sensor (lower media exit)

Sub paddle—driven by
drive motor (entrance/paddle)

Buffer roll assembly— Eject clamp—driven

driven by drive motor by eject clamp motor
(buffer/transport) Media eject shaft assembly—
driven by media eject motor asm
Buffer diverter Compiler unit assembly
Main paddle
motor—driven by Lower media exit
motor (entrance/paddle) roll assembly—driven by
motor (exit)

When printing multiple sets, while stapling the first set on the compiler unit assembly or ejecting it to the stacker
media bin, the first media of the second set will not be fed to the compiler unit assembly.

When the first media of the second set reaches the finisher, the buffer diverter solenoid is activated by the printer
command and by the sensor (finisher media entrance) to switch the buffer diverter gate.

Thus, the media route is switched into the buffer roll assembly’s circumferential direction. (This operation is
called the buffer path.)

The first media of the second set is aligned with the second media, and then they are fed together to the
compiler unit assembly.

Even for one sheet of media, the buffer path operation is executed in the same way. The media is stacked
temporarily on the compiler unit assembly, and then ejected in the stacker media bin.

After the buffer path is executed for the first media, if a second media of a different size comes, the first media is
fed to the compiler unit assembly, but the second one is fed to the compiler unit assembly without the buffer path.
At this time, a certain delay time is provided to prevent the second media from colliding with the first one.

Media

Sensor
(buffer path)

Buffer roll assembly

driven by drive motor
(buffer/transport) Compiler unit
Buffer
diverter gate assembly

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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.

After media is transferred to the stacker media bin, it is held by the clamp paddle attached to the media eject
shaft assembly.

From punch to upper media bin

The media to be ejected to the upper media bin is switched in the media path by the finisher diverter gate located
behind the punch and fed in the upper media transport roll assembly direction.

The finisher diverter gate is switched by the finisher diverter gate solenoid. While the solenoid is activated, media
is fed in the upper media transport roll assembly direction.

The two upper media transport roll assemblies driven by the motor (buffer/transport) feed media to the upper
media exit roll assembly top at the top of the finisher.

The upper media exit roll assembly top driven by the drive motor (exit) ejects the media to the upper media bin.

The upper media exit roll assembly decelerates after a specified period of time from the following trigger events.

Functions of sensors along the media path

Bridge unit assembly

• Sensor (bridge unit media entrance)

– A photo-interrupter sensor that detects whether media is fed from the printer to the bridge unit assembly
– It turns high (+5 V dc) (light receiving) when media enters the bridge unit assembly.
• Sensor (bridge unit media exit)
– A photo-interrupter sensor that detects whether media passes through the bridge unit assembly
– It turns high (+5 V dc) (light receiving) when media reaches this sensor, and turns low (0 V dc) when
media exits from the bridge unit assembly.
• Sensor (bridge unit top cover interlock)
– A photo-interrupter sensor that detects open/close of the bridge top cover assembly of the bridge unit
assembly
– It turns high (+5 V dc) (light receiving) when the bridge top cover assembly opens.
Sensor (bridge unit
Bridge unit assembly top cover interlock

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)
decurler clutch
Bridge unit bin
media exit solenoid

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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.
• Sensor (diverter gate)
– A photo-reflective sensor that detects the leading edge of the media
– It turns low (0 V) when the front end reaches the sensing area.
• Sensor (lower media exit)
– A photo-interrupter sensor that detects whether media passes through the sensor (lower media exit)
– It turns high (+5 V) (light receiving) when the actuator is driven out of the sensing area by the media.
– When the level turns high, this sensor activates the front tamper motor and the rear tamper motor on the
compiler unit assembly.
– This sensor is also used to control on/off of the media eject motor assembly
• Sensor (compiler media present)
– A photo-interrupter sensor that detects whether media is present or not on the compiler unit assembly.
– While media is present, the actuator is outside the sensing area, and the sensor turns high (+5 V dc)
(light receiving).
• Sensor (buffer path)
– A photo-interrupter sensor that detects whether media is fed toward the buffer roll assembly
– While media is present, the actuator is outside the sensing area, and the sensor turns at high (+5 V dc)
(light receiving).
• Sensor (upper media exit)
– A photo-interrupter sensor that detects whether media is fed to the upper media exit roll assembly top at
the exit side of the upper media bin
– When the media is fed, the actuator leaves from the sensing area, and the sensor turns high (+5 V dc).
• Sensor (upper media bin full)
A photo-reflective sensor that detects the stack volume of media in the upper media bin
Sensor (upper media exit)
Sensor (diverter gate) Sensor (upper media bin full)

Sensor (finisher
media entrance) Sensor (lower media exit)

From bridge unit

Sensor (buffer path)

Sensor (compiler media in)

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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.

Adjusting punching positions

The punching positions from the media edge in the direction of feed are determined by gently pressing the
media against the three punch media stopper assemblies.

The three punching positions from the media edge in the direction of media width are determined by the
following method.

• Activate the punch carriage shift motor assembly, and move the punch to the front side until the sensor
(punch carriage shift HP) turns low.
• Reversely rotate the motor, and move the punch to the rear side until the sensor turns high to determine the
home position.
• The punch carriage shift motor assembly is activated to move the punch to the front until the sensor (punch
unit side registration 1) and the sensor (punch unit side registration 2) detects the media edge, and then the
punch is further moved to the front according to the pulse-number determined by the media size. (The
punch carriage shift motor assembly stops at this position.)
Sensor (punch carriage shift HP)

Punch carriage shift motor assembly

Sensor (punch cam front)

Sensor (punch Sensor (punch unit side

hole select) registration 2)
Sensor (punch unit side
registration 1)

Sensor (punch unit HP)

Sensor (punch unit motor encoder) Punch unit motor

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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.

The punch unit motor is rotated forward or reversely for each sheet of media, which is triggered by the sensor
(punch cam front) being turned on/off.

Pin position
Sensor (punch hole select)
Sensor (punch cam front) Pin Cam plate
Sensor (punch unit HP)

Home
position

Punch unit motor

3 hole
position

Home
position

2 hole
position

Home
position

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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.

Detecting punch waste box

The sensor (punch waste box set) detects whether the punch waste box is properly set.

When the sensor (punch waste box set) does not detect that the punch waste box is properly set for four
seconds, the punch waste box count is reset.

Functions of punch sensors/motors

• Sensor (punch unit side registration 1)

– A photo-reflective sensor that detects the side edge of large media
– Media side edge is detected by On/Off of this sensor while shifting the punch (containing this sensor) in
the direction of media width.
– The sensor remains at high (+5 V dc) while media is present, and turns low when media side edge is
detected.
• Sensor (punch unit side registration 2)
– A photo-reflective sensor that detects the side edge of small media
– This sensor has the same function as the sensor (punch unit side registration 1).
• Sensor (punch carriage shift HP)
– A photo-interrupter sensor that detects the home position of the moving punch
– It turns high (+5 V dc) (light blocking) when the home position is detected.
• Sensor (punch unit HP)
– A photo-interrupter sensor that detects the home position of the cam plate that lowers the punching pins
– It turns high (+5 V dc) when the home position is detected.
• Sensor (punch hole select)
– A photo-interrupter sensor that detects the rear position of the cam plate
– It turns high (+5 V dc) when the rear position is detected.
– This sensor also detects the cam position to switch punch holes (2-hole/3-hole).
• Sensor (punch cam front)
– A photo-interrupter sensor that detects the front position of the cam plate
– It turns high (+5 V dc) when the front position is detected.
– This sensor is used to determine to which side (front or rear) the cam plate should be moved.
• Sensor (punch unit motor encoder)
– A photo-interrupter sensor that detects pulse generated by the encoder attached to the punch unit motor
– It counts punch unit motor revolutions and becomes a trigger to stop the motor (by shutting off the
current).
• Punch carriage shift motor assembly
– A stepping motor to move the punch in the media width direction
• Punch unit motor
– A DC motor to move the cam plate that lowers the punching pins
– Forward rotation of the motor moves the cam plate to the front side, and reverse rotation moves it to the
rear side.

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• 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).
• Sensor (punch waste box full)
A photo-interrupter sensor that detects whether the punch waste box is filled with punch waste.
Sensor (punch carriage shift HP)

Punch carriage shift motor

Sensor (punch cam front)

Sensor (punch Sensor (punch unit side registration 2)

hole select)
Sensor (punch unit side
registration 1)

Sensor (punch unit HP)

Sensor (punch unit Punch unit motor

motor encoder)

Compiler unit assembly

This section describes the operation of the compiler unit assembly which aligns the media edge transferred from
the punch unit.

Outline of operation

When media is fed onto the compiler unit assembly, tamping is performed to align the media edge in the media
width direction.

When ejecting stapled sets of media to the stacker media bin, if they are stacked in the stacker media bin with
the same staple position, the height of the stapled portion will increase. This will cause improper compiling of
media due to butting of the following media. To prevent such improper compiling, offsetting is required by shifting
the staple position between sets of media.
Rear tamper
Front tamper

Sensor (rear
tamper HP)

Rear tamper motor

Sensor (compiler Sensor (front tamper HP)
media in) Front tamper motor

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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.

This forcible ejection is performed to prevent damage to the staple assembly.

When feeding large media in the non-staple mode, there may be a misalignment depending on media
characteristics. For this reason, the default media capacity is set to a smaller value.

Compiler unit assembly media capacity

Condition Min. Default Max.

Staple mode 2 50 75
For small media (less than 216 mm in the feed direction) in 10 50 100
non-staple mode
For large media (216 mm or more in the feed direction) in 10 25 100
non-staple mode

Compiler unit assembly operation with multiple media sizes

When two or more media sizes are used and their widths are the same (example: A4L and A3S), all the sheets
are compiled and stapled as a set on the compiler unit assembly, and then ejected to the stacker media bin.

When two or more media sizes with different media width are used, stapling media on the compiler unit
assembly is stopped when a different size is detected. Such different-size sheets of media are forcibly ejected to
the stacker media bin.

Tamping

When media is fed from the punch to the compiler unit assembly, tamping is performed to align the media in the
media width direction on the compiler unit assembly.

Tamping is an operation to align media to the specified position on the compiler unit assembly. The front tamper
or rear tamper is moved to the end of the media by its motor.

Tamping is executed each time when a sheet of media reaches the compiler unit assembly. Additional tamping is
executed after the last sheet is tamped.

There are three types of tamping.

• Front tamping—Tamping by the rear tamper with the front tamper fixed at the home position
• Rear tamping—Tamping by the front tamper with the rear tamper fixed at the home position
• Center tamping—Tamping by the front and rear tampers to align media to the center

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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 (front tamper HP) Sensor (rear tamper HP)

Front Rear

Front tamper motor Front tamper Rear tamper Rear tamper motor

Position Description
1 Front tamper home position—sensor (front tamper HP)
2 Front tamper size position
3 Front tamper offset position
4 Rear tamper home position—sensor (rear tamper HP)
5 Rear tamper standby position
6 Rear tamper tamping position
7 Rear tamper offset position

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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 (front tamper HP) Sensor (rear tamper HP)

Front Rear

Front tamper motor Front tamper Rear tamper Rear tamper motor

Position Description
1 Front tamper home position—sensor (front tamper HP)
2 Front tamper tamping position
3 Front tamper offset position
4 Rear tamper home position—sensor (rear tamper HP)
5 Rear tamper size position
6 Rear tamper offset position

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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
1 Front tamper home position—sensor (front tamper HP)
2 Front tamper standby position
3 Front tamper tamping position
4 Front tamper offset position
5 Rear tamper home position—sensor (rear tamper HP)
6 Rear tamper standby position
7 Rear tamper size position
8 Rear tamper offset position

Determining tamper home position

When the sensor (lower media exit) turns high (+5 V dc) (light receiving), the front and rear tamper motors on the
compiler unit assembly are activated, and the front and rear tampers start moving.

The front tamper home position is determined when the front tamper enters the sensor (front tamper HP)
sensing area.

In the same way, the rear tamper home position is determined when the rear tamper enters the sensor (rear
tamper HP) sensing area.

Tamping

Tamping is executed after a preset time has passed after the sensor (compiler media present) turns high
(+5 V dc) when media is detected on the compiler unit assembly.

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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:

• During front stapling (corner)—Shifts stapled sheets using the front tamper by 20 mm to the rear side before
ejecting them to the stacker media bin
• During rear stapling (corner/straight)
– For media with a width of 216 mm or more [rear staple (corner)]—Shifts stapled sheets using the rear
tamper by 20 mm to the front side before ejecting them to the stacker media bin
– For media with a width of less than 216 mm [rear staple (straight)]—Shifts stapled sheets using the front
tamper by 9 mm to the rear side before ejecting them to the stacker media bin.

During dual stapling:

• Shifts stapled sheets using the front tamper by 9 mm to the rear side before ejecting them to the stacker
media bin.
• Offsetting is not executed (0 mm) for small media.

Functions of compiler unit assembly sensors/motors

• Sensor (compiler media in)

– A photo-interrupter sensor that detects whether media is present or not on the compiler unit assembly
– When media is detected, the actuator leaves the sensing area, which turns the sensor to high (+5 V dc)
(light receiving).
• Sensor (front tamper HP)
– A photo-interrupter sensor that detects the front tamper home position
– When the front tamper comes to the home position, it enters the sensor’s sensing area, which turns the
sensor to high (+5 V dc) (light blocking).
• Sensor (rear tamper HP)
– A photo-interrupter sensor that detects the rear tamper home position
– When the rear tamper comes to the home position, it enters the sensor’s sensing area, which turns the
sensor to high (+5 V dc) (light blocking).
• Front tamper motor
– A stepping motor that moves the front tamper for tamping
– Clockwise rotation of this motor moves the front tamper to the rear side. Counterclockwise rotation of this
motor moves the tamper to the front side.

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• 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
tamper HP)

Rear tamper motor

Sensor (compiler Sensor (front tamper HP)
media in) Front tamper motor

Stapler

This section describes the operation of the stapler.

Stapling operation

Sheets of media fed from the punch are tamped on the compiler unit assembly, and then stapled at specified
positions by the command of the printer.

Staple positions

There are four stapling modes:

• Front staple (corner) [front corner]

The stapler staples a set of media obliquely (45 degrees) after the rear tamper Rear
aligns the media to the front side.

Process direction

Front
• Rear staple (corner) [rear corner]
This type of stapling is applied for media with a width of 216 mm or more. Rear
The stapler moves to the rear corner and staples a set of media obliquely (45
degrees) after the front tamper aligns the media to the rear side.

Process direction

Front

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• Rear Staple (Straight) [rear straight]

This type of stapling is applied for media with a width of less than 216 mm. Rear
The Stapler staples a set of media in parallel with the media edge after the front
tamper aligns the media to the rear side.

Process direction

Front
• Dual Staple [dual]
The Stapler staples a set of media at fixed positions (front/rear sides) in parallel Rear
with the media edge after the front tamper aligns the media to the specified position
for each media size.

Process direction

Front

Media sizes that allow stapling

Media size that allows stapling depends on stapling positions.

The following table shows media sizes and the applicability of stapling for each staple position.

Front Rear Rear

Dual
corner corner straight
A3 SEF Yes Yes No Yes
A4 LEF Yes Yes No Yes
11 x 17 in. SEF Yes Yes No Yes
8.5 x 11 in. LEF Yes Yes No Yes
8K SEF(GCO), 16K LEF(GCO) Yes Yes No Yes
B4 SEF, B5 LEF Yes Yes No Yes
8 x 10 in. LEF Yes Yes No Yes
8.5 x 14 in. SEF / 8.5 x 13 in. SEF / Yes No Yes Yes
8.5 x 11 in. SEF
A4 SEF Yes No Yes Yes
8 x 10 in. SEF Yes No Yes Yes
Yes: Applicable, No: Not applicable

Stapling one sheet

Upon receiving the stapling command from the printer with one sheet remaining on the compiler unit assembly,
the finisher ejects the media to the stacker media bin without stapling it.

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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. Such different-width sheets are forcibly ejected to the stacker media bin.

Media limits for stapling

The number of sheets to be stapled is limited to prevent damage to the stapler.

• If the number of sheets of one set to be stapled exceeds the limit of the compiler unit assembly, the
exceeding sheets are not stacked on the compiler unit assembly, and are forcibly ejected to the stacker
media bin without being stapled.
• After the forcible ejection of media, if the number of following sheets of one set to be stapled exceeds the
limit of the compiler unit assembly, the exceeding sheets are also ejected forcibly to the stacker media bin
without being stapled.
• After that, even if the number of following sheets of one set to be stapled falls within the limit, the sheets are
also ejected forcibly to the stacker media bin without being stapled.

The upper limit (and default) of the compiler unit assembly media capacity when stapling is 50 (variable (10 to
100) by the non-volatile memory).

Stapler operation

The stapler stays at the front home position, that is, at the front staple (corner) position when the power is
turned on.

The stapler starts stapling when a set of sheets to be stapled is stacked on the compiler unit assembly.

The stapler does not move during stapling in the front staple mode.

In any mode other than the front staple mode, the stapler moves to the specified position, and then performs
stapling.

Stapler carriage motor asm

Media handling
direction

Sensor (stapler carriage HP)

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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.

If stapling fails, the motor rotates reversely (counterclockwise) to return the stapler unit assembly to the home
position.

When staples become low, the low staple sensor detects it, and stapling stops automatically, displaying an alarm
message. The message is also displayed when the staple cartridge is not installed.

Sensor (staple home)

Sensor (self priming)

Stapler unit assembly

Sensor (low staple)

Stapler unit motor

Functions of stapler sensors/motors

• Sensor (stapler carriage HP)

– A photo-interrupter sensor that detects the stapler home position, rear staple (corner) position, and rear
staple (straight) position
– It turns high (+5 V dc) (light blocking) when the stapler comes to the specified position.
• Stapler carriage motor assembly
– A stepping motor that moves the stapler unit assembly
– Clockwise rotation of this motor moves the stapler unit assembly to the rear side, while counterclockwise
rotation moves the stapler unit assembly to the front side.
• Sensor (low staple) in the stapler unit assembly
– A photo-interrupter sensor that detects when the stapler unit assembly is nearly out of staples
– It turns high (+5 V dc) when 20 staples are left.
• Sensor (self priming) in the stapler unit assembly
– A photo-interrupter sensor that detects that staples are at the stapler unit assembly end; it also detects
failure in stapling
– It turns low (0 V dc) (light blocking) when stapling is ready.
• Sensor (staple home) in the stapler unit assembly
– A photo-interrupter sensor that detects the stapler unit assembly home position; it also detects failure in
stapling
– This sensor also functions as a trigger to stop the staple motor.
– It turns low (0 V dc) (light blocking) while the stapler unit assembly stays at the home position.

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• 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)

Booklet Operation

The booklet media entrance roll assembly driven by the booklet media entrance drive motor will deliver media
from the finisher entrance and stack it against the booklet end guide in the booklet unit. When the booklet end
guide is at the bottom of the booklet unit it will continue to accept media. Once the proper amount of media is
reached, stapling will occur and booklets will be delivered in sets to the booklet media bin.

The booklet media exit roll assembly is driven by booklet folding/exit drive motor assembly and delivers booklets
to the booklet media bin. During printing, paper drawn to the booklet compiler is aligned by the booklet paddle
shaft assembly which is driven by booklet paddle shaft drive Motor.

When a sheet of paper enters the booklet compiler, tamping operation is performed by two moving tampers
moving towards the front and rear. The front tamper is driven by front booklet tamper drive motor; rear booklet
tamper drive motor. Tamping operation will be performed a final time after the last sheet is received.

Documents in the compiler tray are assembled towards the front. For center stapling and folding positions, one
set of document is assembled and moved to the center.

The booklet end guide is lifted to where the fold will divide the paper into two equal halves. When the printouts
are stapled, the booklet end guide will be raised so that the stapled position is at the folding position. The
stapling position is slightly lower than the folding position center line.

When the movement from the booklet folding/exit drive motor is transferred to the knife through the engagement
of the sector gear, the knife will thrust forward and then return to the original position after one full rotation. At the
folding position, the knife is thrust forward to fold the paper between booklet folding roll and booklet folding nip
roll.

Paper is folded into two halves by the booklet folding roll driven by the booklet folding/exit drive motor and is
delivered to the booklet media bin by the booklet media exit roll assembly. The booklet media bin belt will move
at a fixed interval for every set of booklets that are created.

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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.
• Booklet media entrance drive motor assembly
– This stepping motor drives the booklet media entrance roll assembly.
• Booklet folding/exit drive motor assembly
– This DC motor drives booklet folding roll, booklet media exit roll assembly, and knife.

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• 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)
Booklet folding/exit
motor assembly
Booklet knife solenoid
• Sensor (booklet front tamper HP)
– This photo sensor detects the home position of the booklet front tamper.
• Sensor (booklet rear tamper HP)
– This photo sensor detects the home position of the booklet Rear tamper.
• Sensor (booklet compile media in)
This photo sensor detects paper present in the booklet compiler tray.
– Booklet front tamper motor
This stepping motor drives the booklet front tamper.
• Booklet rear tamper motor
– This stepping motor drives the booklet rear tamper.
• Sensor (booklet knife HP)
– This photo sensor detects the home position (stored condition) of knife.
• Sensor (knife folding)
– This photo sensor detects the fold position (protruded condition) of knife.
• Booklet staple assembly

– This booklet stapler consist of two stapler units (including stapler low switch) and booklet stapler head
motor.
• Booklet paddle motor
– This DC motor drives the paddle at the booklet section.
• Sensor (booklet end guide HP)
– This photo sensor detects the home position of the booklet end guide.
• Booklet end guide drive motor
– This stepping motor moves the booklet end guide up and down.

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• 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.

Booklet media bin

Booklet bin drive motor

Sensor (booklet bin

media present)

Operation

The upper media bin contains the sensor (upper media bin full) to detect the media stack volume in the upper
media bin.

Once the sensor detects a full stack (500 sheets) in the upper media bin, ejection of media to the upper media
bin is inhibited until a full stack is reset.

Functions of upper media bin sensors

• Sensor (upper media exit)

– A photo-interrupter sensor that detects that media has come to the upper media exit roll assembly top at
the exit of the upper media bin
– When media reaches the upper media exit roll assembly top, the actuator leaves the sensing area, which
turns the sensor to high (+5 V dc).
• Sensor (upper media bin full)
– A photo-reflective sensor that detects the media stack volume in the upper media bin
– It turns high (+5 V dc) when it detects a full stack.

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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. The sensor (stacker bin level 1) and the sensor (stacker bin level 2) detect the height of media in
the stacker media bin, and the sensor (stacker bin level encoder) determines the volume of media in the tray.

When media or the stacker media bin comes between the light emitter and the photo-receiver of the sensor
(stacker bin level 1) and sensor (stacker bin level 2), the emitted light is blocked, and the sensors turn high. The
height of media or the stacker media bin is detected based on the levels of these sensors.

This sensor information is used to control the elevator motor. The motor is activated to move the stacker media
bin while the sensor (stacker bin level) turns from the light blocking state to the light receiving state.
Sensor (stacker bin level)

Bin: height Bin: proper Bin: low

moves moves upward
downward

The sensor (stacker bin no media) is turned On or Off by the actuator attached to the carriage assembly right on
the rear side of the finisher. In case the stacker media bin abnormally goes up above the sensor (stacker bin no
media), the sensor (stacker bin upper limit) is installed above the sensor (stacker bin no media) for protection
against abnormal operation.

If an operator removes media from the stacker media bin during printing, it is detected by the sensor (stacker bin
level 2), and the ejection of media to the stacker media bin is inhibited. Then the elevator motor is activated to
move the stacker media bin to the sensor (stacker bin level 1) sensing area. Thus, the ejection of media to the
stacker media bin is restored.

If an operator removes media from the stacker media bin while printing is stopped, it is detected by the sensor
(stacker bin level 2). After three seconds have passed, the elevator motor is activated to move the stacker media
bin to the sensor (stacker bin level 1) sensing area. Thus, the ejection of media to the stacker media bin is
restored.

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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)

Media eject
motor assembly

Sensor (media
eject shaft HP)
Stacker media bin

Sensor (stacker bin level 2) Sensor (stacker bin

Stacker bin
level encoder)
lift motor assembly

Sensor (stacker bin

upper limit)

Sensor (stacker bin no media)

Actuator

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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.

Furthermore, the stacker media bin can stack up to 200 sets (default) of stapled media.

The stacker media bin can continue to stack media until media volume reaches either of the limits above.

In the mix stacking mode, all the sizes are allowed until a media volume of approximately 300 sheets in the
stacker media bin is detected.

The mix stacking mode indicates one of the following cases:

• A larger (any size of media) sheet of media is stacked on a smaller sheet.

For example: A4LEF (297x210) media is stacked on A4SEF (210x297) media.
Note: When B5LEF (257x182) media is stacked on A4LEF (297x210) media, this is not mix stacking.

• A sheet of media of less than 11 inches is stacked in the stacker

media bin with the Staple Mode changed. Top view of finisher tray
Rear
staple

Front
staple

• An operator put a sheet (or sheets) when no media is remaining in the stacker media bin.
(The size and condition of media stacked in the tray are not identified.)
• Media was present in the stacker media bin when power was turned on.
(The size and condition of media stacked in the tray are not identified.)
• The finisher entered the Sleep Mode with mix stacking and then has exited the Sleep Mode.
• The post-processing mode has changed.

Functions of stacker media bin sensors/motors

• Sensor (stacker bin level 1)

– A light emitter and photo-receiver paired together to detect the height of media in the stacker media bin
– This sensor is used to control the elevator motor.
– When blocked by media or the tray, this sensor turns high, deciding that the stacker media bin is above
the reference level.
– To the contrary, when receiving light, this sensor turns low, deciding that the stacker media bin is below
the reference level.
– The high to low turning point of the sensor is defined as the reference level.
• Sensor (stacker bin level 2)
– A light emitter and photo-receiver paired together to detect the height of media in the stacker media bin
(same function as sensor (stacker bin level 1))
– This sensor is also used to control the elevator motor.
– When blocked by media or the tray, this sensor turns high, deciding that the stacker media bin is above
the reference level.
– To the contrary, when receiving light, this sensor turns low, deciding that the stacker media bin is below
the reference level.
• Sensor (stacker bin no media)

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– 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).
• Sensor (stacker bin upper limit)
– A photo-interrupter sensor that detects the stacker media bin’s abnormal elevation above the top position
(sensor (stacker bin no media) position)
– 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).
• Sensor (stacker bin level encoder)
– A photo-interrupter sensor that counts the pulse of the Encoder attached to the Shaft-Elevator.
– The media volume in the stacker media bin is detected based on this count.
• Stacker bin lift motor
– A DC motor that elevates or lowers the stacker media bin
– Clockwise rotation elevates the tray, and counterclockwise rotation lowers the tray.
• Media eject motor assembly
– A stepper motor that ejects stapled or non-stapled media to the stacker media bin
– Clockwise rotation ejects media to the stacker media bin, and counterclockwise rotation reverses the
eject roll to feed the media from the punch to the compiler unit assembly.
• Media eject clamp motor
A DC motor that elevates or lowers the media eject clamp when feeding media from the punch to the
compiler unit assembly or from the compiler unit assembly to the stacker media bin
• Sensor (media eject clamp HP)
– A photo-interrupter sensor that detects the set clamp home position
– This sensor functions as a trigger to control On/Off of the set clamp clutch.
• Media eject clutch
When this clutch is activated, it transmits the media eject motor assembly rotating power to the media eject
shaft assembly.

Sensor (stacker bin level 1) Eject clamp motor

Sensor (media
eject clamp HP)

Media eject
motor assembly

Sensor (media
eject shaft HP)

Sensor (stacker bin level 2)

Sensor (stacker bin
Media eject clutch Stacker bin
level encoder)
lift motor assembly
Sensor (stacker bin upper limit)

Sensor (stacker bin no media)

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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. When two sets or more is being delivered, one set at a time
is being delivered.

When the front of the booklet tray is facing down, the printout will fall automatically below the tray. When
removing paper, press booklet tray belt switch to move the paper delivery belt to the position for paper removal.

Booklet bin drive motor

Sensor (booklet bin

media present)

Power supply and interlock

The finisher is equipped with the following interlock switches.

• Switch (finisher front door interlock)—Turns off when the cover assembly front opens, shutting off the
Interlock +24 V dc line in the finisher.

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• 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
+5 V dc Sensor
Switch
Finisher LVPS Switch (finisher
(eject cover front door
card asm
interlock) interlock)
AC +24 V dc +24 V dc

ON/OFF
Interlock
+24 V dc

Printer

General information 1-35

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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
2TM 2 Tray Module
AC Alternating Current
ADF Automatic Document Feeder
APS Automatic Paper Size
ASIC Application Specific Integrated Circuit
CRU Customer Replaceable Unit
CSU Customer Setup
CCW Counterclockwise
CW Clockwise
DC Direct Current
DIMM Dual Inline Memory Module
DRAM Dynamic Random Access Memory
EDO Enhanced Data Out
EP Electrophotographic Process
EPROM Erasable Programmable Read-only Memory
ESD Electrostatic Discharge
FRU Field Replaceable Unit
GB Gigabyte
GFI Ground Fault Interrupter
HCF High-Capacity Feeder
HVPS High Voltage Power Supply
LASER Light Amplification by Stimulated Emission of Radiation
LCD Liquid Crystal Display
LD Laser Diode
LED Light-Emitting Diode
LEF Long Edge Feed
LVPS Low Voltage Power Supply
MPF Multi-Purpose Feeder
MS Microswitch
NVM Nonvolatile Memory
NVRAM Nonvolatile Random Access Memory
OEM Original Equipment Manufacturer
OPT Optical Sensor
PC Photoconductor
PEL Picture element

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POR Power-on Reset

POST Power-on Self Test
PPM Pages Per Minute
PSC Parallel Synchronous Communications
PSD Position Sensing Device
PWM Pulse Width Modulation
RFID Radio Frequency Identification
RIP Raster Imaging Processor
ROM Read only Memory
RPM Revolutions Per Minute
SDRAM Synchronous Dual Random Access Memory
SEF Short Edge Feed
SIMM Single Inline Memory Module
SOS Start of scan
SRAM Static Random Access Memory
TTM Tandem Tray Module
TVOC Total Volatile Organic Compound
UPR Used Parts Return
V Volts
V ac Volts alternating current
V dc Volts direct current

General information 1-37

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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. Never touch the live parts.

CAUTION

Be careful to avoid burns by safely handling hot parts.

CAUTION

The standard finisher weight is 59 kg (130 lb.) and requires at least two people to lift it safely.
The booklet finisher weight is 87.5 kg (193 lb.) and requires at least four people to lift it safely.
Make sure your fingers are not under the finisher when you lift or set it down.
The MFP weighs approximately 173kg (383 lb.) and requires at least four people to lift it safely.
Make sure your fingers are not under the MFP when you lift or set it down.

Warning: When operating the driving units using the diagnostics or other tools, be sure to keep them covered
unless otherwise specified.
Warning: When operating the driving units using the diagnostics or other tools, never touch the driving units.
When operating the driving units using diagnostics or other tools, be sure to follow the procedures in
this manual.
Warning: Servicers should wear a wrist band or the like to remove static electricity from their body, grounding
their body while working. Go to “Handling ESD-sensitive parts” on page 4-1.
Note: There may be printer error messages that are not contained in this service manual. Call your next level
support for assistance.

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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. Operator Panel LED comes on solid.
4. All diamonds appear on the LCD.
5. While loading code, dots scroll across the LCD.
6. The following is an example of the screen that displays after the code is loaded.

128MB 600Mhz
128MB = Amount of Memory 600Mhz = Processor Speed

7. Performing Self Test appears on the LCD.

8. Fuser drive motor turns on.
9. Fuser fan turns on.
10. RIP fan turns on.
11. Heartbeat LED on system boards turns on.
12. Fuser lamps turn on.
13. Vacuum transport belt fan turns on.
14. ITU Missing appears on the LCD, if the ITU is missing.
15. Fuser Missing appears on the LCD, if the fuser is missing.
16. Close Door appears on the LCD, if the front cover is open.
17. Busy appears on the LCD.
18. Operator panel LED blinks.
19. Redrive exit roller turns.
20. Any cartridge errors appear on the LCD such as a Defective Cartridge, Return Program Information, or
Missing Cartridge.
21. Any applicable maintenance messages appear on the LCD such as 80 Fuser Maintenance or 83 ITU
Maintenance.
22. One of the toner low messages appears when applicable: 88 Yellow Toner Low, 88 Magenta Toner Low,
88 Cyan Toner Low, or 88 Black Toner Low.
23. Color calibration may be initiated. This is appears if one of the following occurs:
• The printer detects at power on, or the front cover is closed, that a new or different toner cartridge has been
installed.
• The printer detects at power on when the cover is closed that a new or different ITU has been installed.
• The printer detects at power on that the fuser temperature is below 60° C.
• When coming out of power saver if power saver has been active for eight hours or longer.
• If the printer is turned on when a calibration cycle was in progress since the printer was last powered off.
24. Ready appears on the LCD.

To enter the diagnostic menu:

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.

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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).
Go to “280.00 Sensor (bridge unit media entrance)
late Jam” on page 2-10.

280.01 Sensor (bridge unit media Media remains on the sensor (bridge unit media
entrance) static jam entrance).
Paper jam
Go to “280.01 Sensor (bridge unit media entrance)
static jam” on page 2-11.

281.00 Sensor (bridge unit media exit) The media is late reaching the sensor (bridge unit media
late jam exit) within the specified time after reaching the sensor
Paper jam (bridge unit media entrance).
Go to “281.00 Sensor (bridge unit media exit) late
jam” on page 2-12.

281.03 Sensor (bridge unit media exit) Media remains on the sensor (bridge unit media exit).
static jam
Paper jam Go to “281.03 Sensor (bridge unit media exit) static
jam” on page 2-14.

282.00 Sensor (finisher media The media is late reaching the sensor (finisher media
entrance) late jam entrance) within the specified time after reaching the
Paper jam sensor (bridge unit media exit).
Go to “282.00 Sensor (finisher media entrance) late
jam” on page 2-15.

282.01 Sensor (finisher media Paper remains on the sensor (finisher media entrance).
entrance) static jam
Paper jam Go to “282.01 Sensor (finisher media entrance) static
jam” on page 2-17.

283.00 Sensor (buffer path) late jam The media is late reaching the sensor (buffer path)
within the specified time after reaching the sensor
Paper jam (finisher media entrance).
Go to “283.00 Sensor (buffer path) late jam” on
page 2-18.

283.03 Sensor (buffer path) static jam Paper remains on the sensor (finisher buffer path).
Paper jam Go to “283.03 Sensor (buffer path) static jam” on
page 2-21.

284.00 Sensor (lower media exit) late The media is late reaching the sensor (lower media exit)
jam within the specified time after reaching the sensor (buffer
Paper jam path).
Go to “284.00 Sensor (lower media exit) late jam” on
page 2-22.

284.03 Sensor (lower media exit) lag The media reached the sensor (lower media exit) but did
jam not clear it within the specified time.
Paper jam
Go to “284.03 Sensor (lower media exit) lag jam” on
page 2-24.

284.05 Sensor (lower media exit) Media remains on the sensor (lower media exit).
static jam
Paper jam Go to “284.05 Sensor (lower media exit) static jam”
on page 2-25.

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Error code or
Error contents Description/action
message

285.00 Sensor (compiler media in) lag The media reached the sensor (lower media exit) but did
jam not clear it within the specified time.
Paper jam
Go to “285.00 Sensor (media compiler in) lag jam” on
page 2-27.

286.00 Sensor (compiler media in) Media remains on the sensor (compiler media in).
static jam
Paper jam Go to “286.00 Sensor (compiler media in) static jam”
on page 2-28.

287.00 Sensor (upper media exit) late The media is late reaching the sensor (upper media exit)
jam within the specified time after reaching the sensor
Paper jam (finisher media entrance).
Go to “287.00 Sensor (upper media exit) late jam” on
page 2-30.

287.01 Sensor (upper media exit) lag The media reached the sensor (upper media exit) but
jam did not clear it within the specified time.
Paper jam
Go to “287.01 Sensor (upper media exit) lag jam” on
page 2-31.

287.05 Sensor (upper media exit) Media remains on the sensor (upper media exit).
static jam
Paper jam Go to “287.05 Sensor (upper media exit) static jam”
on page 2-33.

288.00 Sensor (diverter gate) late jam The media is late reaching the sensor (diverter gate)
within the specified time after reaching the sensor
Paper jam (bridge unit media exit).
Go to “288.00 Sensor (diverter gate) late jam” on
page 2-34.

288.01 Sensor (diverter gate) static The media reached the sensor (diverter gate) but did not
jam A (to top bin) clear it within the specified time.
Paper jam
Go to “288.01 Sensor (diverter gate) static jam A (to
top bin)” on page 2-36.

288.04 Sensor (diverter gate) static The media reached the sensor (diverter gate) but did not
jam B (to stacker bin) clear it within the specified time.
Paper jam
Go to “288.04 Sensor (diverter gate) static jam B (to
stacker bin)” on page 2-37.

289.00 sensor (booklet unit media The media is late reaching the sensor (booklet unit
entrance) late jam media entrance) within the specified time after reaching
Paper jam the sensor (bridge unit media exit).
Go to “289.00 sensor (booklet unit media entrance)
late jam” on page 2-38.

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” on page 2-39.

289.02 sensor (booklet unit media Media remains on the sensor (diverter gate).
entrance) static jam
Paper jam Go to “289.02 sensor (booklet unit media entrance)
static jam” on page 2-41.

289.03 sensor (booklet compiler media Media remains on the sensor (booklet compiler media
in) static jam in).
Paper jam
Go to “289.03 sensor (booklet compiler media in)
static jam” on page 2-42.

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Error code or
Error contents Description/action
message

289.04 sensor (booklet unit media exit) The media is late reaching the sensor (booklet unit
late jam media exit) within the specified time after the booklet
Paper jam knife solenoid is turned on.
Go to “289.04 Sensor (booklet unit media exit) late
jam” on page 2-43.

289.05 sensor (booklet unit media exit) The media reached the sensor (booklet unit media exit)
lag jam but did not clear it within the specified time.
Paper jam
Go to “289.05 Sensor (booklet unit media exit) lag
jam” on page 2-45.

289.06 sensor (booklet unit media exit) Media remains on the sensor (booklet unit media exit).
static jam
Paper jam Go to “289.06 Sensor (booklet unit media exit) static
jam” on page 2-46.

980.02 Communication error with A communication error has occurred with the upper
finisher controller card printer engine card assembly and the finisher controller
Service finisher assembly card assembly.
comm
Go to “980.02 Finisher communication failure” on
page 2-47.

981.00 Sensor (stacker bin level 1) The sensing area of the sensor (stacker bin level 1) or
late error Sensor (stacker bin level 2) is not interrupted within the
Service finisher specified period after the stacker bin starts rising.
error Sensor (stacker bin level 2)
late error Go to “981.00 Sensor (stacker bin level 1) late error”
on page 2-48.

981.01 Stacker bin upper limit error The sensing area of the sensor (stacker bin upper limit)
is not interrupted when the stacker bin raises to its upper
Service finisher most limit.
error
Go to “981.01 Stacker bin upper limit error” on
page 2-49.

981.02 Stacker bin lower limit error The stacker bin lowers beyond the specified lower limit
within the specified time.
Service finisher
error Go to “981.02 Stacker bin lower limit error” on
page 2-51.

982.00 Sensor (front tamper HP) late The sensing area of the sensor (front tamper HP) is not
error interrupted when the front tamper starts moving to the
Service finisher home position.
error
Go to “982.00 Sensor (front tamper HP) late error” on
page 2-53.

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” on
page 2-54.

983.00 Sensor (rear tamper HP) late The sensing area of the sensor (rear tamper HP) is not
error interrupted when the rear tamper starts moving to the
Service finisher home position.
error
Go to “983.00 Sensor (rear tamper HP) late error” on
page 2-56.

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7500-432, -632, and -832

Error code or
Error contents Description/action
message

983.01 Sensor (rear tamper HP) lag The sensing area of the sensor (rear tamper HP)
error remains interrupted within the specified time after the
Service finisher rear tamper starts moving from the home position.
error
Go to “983.01 Sensor (rear tamper HP) lag error” on
page 2-57.

984.00 Sensor (punch unit HP) late The sensing area of the sensor (punch unit HP) is not
error interrupted during the specified time after the punch unit
Service finisher starts moving to the home position.
error
Go to “984.00 Sensor (punch unit HP) late error” on
page 2-58.

984.01 Sensor (punch unit HP) lag The sensing area of the sensor (punch unit HP) remains
error interrupted within the specified time after the punch unit
Service finisher starts moving from the home position.
error
Go to “984.01 Sensor (punch unit HP) lag error” on
page 2-59.

985.00 Sensor (punch carriage shift The sensing are of the sensor (punch carriage shift HP)
HP) late error is not interrupted within the specified time after the
Service finisher punch carriage starts moving to the home position.
error
Go to “985.00 Sensor (punch carriage shift HP) late
error” on page 2-60.

985.01 Sensor (punch carriage shift The sensor (punch carriage shift HP) remains
HP) lag error interrupted within the specified time after the punch
Service finisher carriage starts moving from the home position.
error
Go to “985.01Sensor (punch carriage shift HP) lag
error” on page 2-61.

986.00 Sensor (media eject clamp HP) The sensing area of the sensor (media eject clamp HP)
late error is not interrupted within the specified time after the eject
Service finisher clamp starts moving to the home position.
error
Go to “986.00 Sensor (media eject clamp HP) late
error” on page 2-63.

986.01 Sensor (media eject clamp HP) The sensing area of the sensor (media eject clamp HP)
lag error remains interrupted within the specified time after the
Service finisher eject clamp starts moving from the home position.
error
Go to “986.01 Sensor (media eject clamp HP) lag
error” on page 2-64.

987.00 Sensor (media eject shaft HP) The sensing area of the sensor (media eject shaft HP) is
late error not interrupted within the specified time after the media
Service finisher eject shaft starts moving to the home position.
error
Go to “987.00 Sensor (media eject shaft HP) late
error” on page 2-65.

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
error” on page 2-66.

988.01 Sensor (punch unit side reg 1) The sensor (punch unit side reg 1) or sensor (punch unit
lag error side reg 2) did not detect any media correctly.
Service finisher
error Sensor (punch unit side reg 2) Go to “988.01 Sensor (punch unit side reg1) or
lag error (sensor (punch unit side reg2) lag failure” on
page 2-68.

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Error code or
Error contents Description/action
message

989.00 Stapler unit error The sensing area of the sensor (stapler unit motor HP)
inside the stapler unit assembly is not interrupted within
Service finisher the specified timer after the stapler unit motor starts
error moving to the home position.
Go to “989.00 Stapler unit failure” on page 2-70.

990.00 Sensor (stapler carriage HP) The sensing area of the sensor (stapler carriage HP) is
late error not interrupted within the specified time after the stapler
Service finisher carriage starts moving to the home position.
error
Go to “990.00 Sensor (stapler carriage HP) late error”
on page 2-70.

990.01 Sensor (stapler carriage HP) The sensing area of the sensor (stapler carriage HP)
lag error remains interrupted within the specified time after the
Service finisher stapler carriage starts moving from the home position.
error
Go to “990.01 Sensor (stapler carriage HP) lag error”
on page 2-71.

991.00 Sensor (booklet front tamper The sensing area of the sensor (booklet front tamper
HP) late error HP) is not interrupted within the specified time after the
Service finisher front booklet tamper starts moving to the home position.
error
Go to “991.00 Sensor (booklet front temper HP) late
error” on page 2-73.

991.01 Sensor (booklet front tamper The sensing area of the sensor (booklet front tamper
HP) lag error HP) remains interrupted within the specified time after
Service finisher the front booklet tamper starts moving from the home
error position.
Go to “991.01 Sensor (booklet front tamper HP) lag
error” on page 2-74.

991.02 Sensor (booklet rear tamper The sensing area of the sensor (booklet rear tamper HP)
HP) late error is not interrupted within the specified time after the rear
Service finisher booklet tamper starts moving to the home position.
error
Go to “991.02 Sensor (booklet rear tamper HP) late
error” on page 2-75.

991.03 Sensor (booklet rear tamper The sensing area of the sensor (booklet rear tamper HP)
HP) lag error remains interrupted within the specified time after the
Service finisher rear booklet tamper starts moving from the home
error position.
Go to “991.03 Sensor (booklet rear tamper HP) lag
error” on page 2-77.

991.04 Sensor (booklet end guide HP) The sensing area of the sensor (booklet end guide HP)
late error is not interrupted within the specified time after the
Service finisher booklet end guide starts moving to the home position.
error
Go to “991.04 Sensor (booklet end guide HP) late
error” on page 2-78.

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
error” on page 2-80.

991.06 Sensor (booklet unit interlock) The sensor (booklet unit interlock) detected that the
error booklet maker was not completely inserted when the
Service finisher finisher front door assembly was closed.
error
Go to “991.06 Sensor (booklet unit interlock) error”
on page 2-81.

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Error code or
Error contents Description/action
message

991.07 Sensor (booklet compiler no The sensing area of the sensor (booklet compiler no
media) no media detected media) did not detect any media when the booklet
Service finisher stapler motor was activated.
error
Go to “991.07 Sensor (booklet compiler no media) no
media detected” on page 2-82.

991.08 Sensor (booklet knife HP) late The sensing area of the sensor (booklet knife HP) is not
error interrupted within the specified time after the booklet
Service finisher knife started moving to home position.
error
Go to “991.08 Sensor (booklet knife HP) late error”
on page 2-83.

991.09 Sensor (booklet knife HP) lag The sensing area of the sensor (booklet knife HP)
error remains interrupted within the specified time after the
Service finisher booklet knife started moving from home position.
error
Go to “991.09 Sensor (booklet knife HP) lag error” on
page 2-85.

991.10 Sensor (booklet knife folding) The sensing area of the sensor (booklet knife folding) is
late error not interrupted within the specified time after the booklet
Service finisher knife solenoid was activated.
error
Go to “991.10 Sensor (booklet knife folding) late
error” on page 2-87.

991.11 Booklet stapler error The booklet stapler unit is not completely inserted into
the booklet maker unit assembly or the it has failed.
Service finisher
error Go to “991.11 Booklet stapler error” on page 2-88.

991.12 Communication error with A communication error has occurred with the booklet
booklet controller card controller card assembly and the finisher controller card
Service finisher assembly assembly.
error
Go to “991.12 Communication error with booklet
controller card assembly” on page 2-89.

991.13 Booklet unit maker error Booklet set recovery was detected too many times for
the same job. Perform a POR.
Service finisher
error Go to “991.13 Booklet unit maker error” on
page 2-90.

Close cover F Bridge unit top cover is open. The bridge unit top cover is open.
Go to “Bridge unit top cover open” on page 2-90.

Close door G Finisher front door open. The finisher front door is open.
Go to “Finisher front door open” on page 2-92.

Close surface H Eject cover open. The finisher eject cover is open.
Go to “Finisher eject cover open” on page 2-93.

Empty hole Punch waste box full. The punch waste box is full.
punch box
Go to “Punch waste box full” on page 2-95.

Insert hole Punch waste box missing. No punch waste box.

punch box
Go to “No punch waste box.” on page 2-94.

Load staples Staple cartridge empty. Staple cartridge empty.

Go to “Staple cartridge empty” on page 2-102.

2-8 MFP Finisher Service Manual

 7500-432, -632, and -832

Error code or
Error contents Description/action
message

Remove paper Finisher upper media bin full. Stacker set over count
from bin 1
The upper media bin has reached maximum capacity.
Go to “Finisher upper media bin full” on page 2-93.

Remove paper Stacker media bin full (no mix) The stacker media bin has reached maximum capacity
from bin 2 (no mix).
Go to “Stacker media bin full (no mix)” on page 2-98.

Remove paper Stacker media bin full (mix The stacker media bin has reached maximum capacity
from bin 2 size) (mix size).
Go to “Stacker media bin full (mix size)” on
page 2-96.

Diagnostic information 2-9

7500-432, -632, and -832

Service checks - finisher

280.00 Sensor (bridge unit media entrance) late Jam

Step Check Yes No

1 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.
wear and contamination?
Go to “Bridge
unit assembly
removal” on
page 4-5.

2 Check the sensor (bridge unit media entrance) for Go to step 4. Go to step 3.
proper operation.
1. Enter the Diagnostics Menu.
2. Touch FINISHER TESTS.
3. Touch Sensor Test.
4. Touch Media Path 1.
5. Touch Bridge media entrance

Does the display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

3 Check the sensor (bridge unit media entrance) Replace the Replace the
connection. sensor (bridge connection.
unit media
Is the above sensor properly connected? entrance).
Go to “Sensor
(bridge unit
media entrance)
removal” on
page 4-16.

4 Check the bridge unit 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Bridge unit drive motor.

Does the above component operate properly?

5 Check the bridge unit drive motor connection. Replace the Replace the
bridge unit drive connection.
Is the above motor properly connected? motor assembly.
Go to “Bridge
unit drive motor
assembly
removal” on
page 4-13.
Go to step 6.

2-10 MFP Finisher Service Manual

 7500-432, -632, and -832

Step Check Yes No

6 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 4-115.
Go to step 7.

7 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 4-116.

280.01 Sensor (bridge unit media entrance) static jam

Step Check Yes No

1 Check the sensor (bridge unit media entrance) for Go to step 3. Go to step 2.
proper operation.
1. Enter the Diagnostics Menu.
2. Touch FINISHER TESTS.
3. Touch Sensor Test.
4. Touch Media Path 1.
5. Touch Bridge media entrance

Does the display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

2 Check the sensor (bridge unit media entrance) Replace the Replace the
connection sensor (bridge connection.
unit media
Is the above sensor properly connected? entrance).
Go to “Sensor
(bridge unit
media entrance)
removal” on
page 4-16.

Diagnostic information 2-11

7500-432, -632, and -832

Step Check Yes No

3 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Bridge unit drive motor.

Does the above component operate properly?

4 Check the bridge unit drive motor for proper Replace the Replace the
connection. bridge unit drive connection.
motor assembly.
Is the above component properly connected?
Go to “Bridge
unit drive motor
assembly
removal” on
page 4-13.
Go to step 5.

5 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 4-115.
Go to step 6.

6 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 4-116.

281.00 Sensor (bridge unit media exit) late jam

Step Check Yes No

1 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.
wear and contamination?
Go to “Bridge
unit assembly
removal” on
page 4-5.

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 7500-432, -632, and -832

Step Check Yes No

2 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?

3 Check the sensor (bridge unit media exit) connection. Replace the Replace the
sensor (bridge connection.
Is the above sensor properly connected? unit media exit).
Go to “Sensor
(bridge unit
media exit)
removal” on
page 4-17.

4 Check the bridge unit 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Bridge unit drive motor.

Does the above component operate properly?

5 Check the bridge unit drive motor connection. Replace the Replace the
bridge unit drive connection.
Is the above component properly connected? motor assembly.
Go to “Bridge
unit drive motor
assembly
removal” on
page 4-13.

6 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 4-115.
Go to step 7.

Diagnostic information 2-13

7500-432, -632, and -832

Step Check Yes No

7 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 4-116.

281.03 Sensor (bridge unit media exit) static jam

Step Check Yes No

1 Check the sensor (bridge unit media exit) for proper Go to step 4. Go to step 2.
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?

2 Check the sensor (bridge unit media exit) connection. Replace the Replace the
sensor (bridge connection.
Is the above sensor properly connected? unit media exit).
Go to “Sensor
(bridge unit
media exit)
removal” on
page 4-17.

3 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Bridge unit drive motor.

Does the above component operate properly?

4 Check the bridge unit drive motor connection. Replace the Replace the
bridge unit drive connection.
Is the above component properly connected? motor assembly.
Go to “Bridge
unit drive motor
assembly
removal” on
page 4-13.

2-14 MFP Finisher Service Manual

 7500-432, -632, and -832

Step Check Yes No

5 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 4-115.
Go to step 6.

6 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 4-116.

282.00 Sensor (finisher media entrance) late jam

Step Check Yes No

1 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.
wear and contamination?
Go to “Bridge
unit assembly
removal” on
page 4-5.

2 Check 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?

3 Check the sensor (bridge unit media exit) connection. Replace the Replace the
sensor (bridge connection.
Is the above component properly connected? unit media exit).
Go to “Sensor
(bridge unit
media exit)
removal” on
page 4-17.

Diagnostic information 2-15

7500-432, -632, and -832

Step Check Yes No

4 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?

5 Check the sensor (finisher media entrance) for proper Replace the Replace the
connection. sensor (finisher connection.
media entrance).
Is the above component properly connected?
Go to “Sensor
(finisher media
entrance)
removal” on
page 4-97.

6 Check the bridge unit drive motor 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. Touch Finisher Motor Tests.
4. Touch Bridge unit drive motor.

Does the above component operate properly?

7 Check the bridge unit drive motor for proper Replace the Replace the
connection. bridge unit drive connection.
motor assembly.
Is the above component properly connected?
Go to “Bridge
unit drive motor
assembly
removal” on
page 4-13.

8 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 4-115.
Go to step 9.

2-16 MFP Finisher Service Manual

 7500-432, -632, and -832

Step Check Yes No

9 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 4-116.

282.01 Sensor (finisher media entrance) static jam

Step Check Yes No

1 Check the sensor (finisher media entrance) 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. 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?

2 Check the sensor (finisher media entrance) for proper Replace the Replace the
connection. sensor (finisher connector.
media entrance).
Is the above component properly connected?
Go to “Sensor
(finisher media
entrance)
removal” on
page 4-97.

3 Check the drive motor (entrance/paddle) 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Motor (entrance/paddle).

Does the above component operate properly?

Diagnostic information 2-17

7500-432, -632, and -832

Step Check Yes No

4 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 4-99.

5 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 4-116.

283.00 Sensor (buffer path) late jam

Step Check Yes No

1 Check the finisher media entrance roll assembly. Go to step 2. Clean or replace
the finisher
Is the above component free of excess wear and media entrance
contamination? roll assembly.
Go to “Finisher
media entrance
roll assembly
removal” on
page 4-98.

2 Check the finisher buffer roll assembly. Go to step 3. Clean or replace

the finisher buffer
Is the above component free of excess wear and roll assembly.
contamination?
Go to “Finisher
buffer roll
assembly
removal” on
page 4-93.

3 Check the sensor (diverter gate) for proper operation. Go to step 5. Go to step 4.
1. Enter the Diagnostics Menu.
2. Touch FINISHER TESTS.
3. Touch Sensor Test.
4. Touch Media Path 2.
5. Touch Diverter gate.

Does the display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

2-18 MFP Finisher Service Manual

 7500-432, -632, and -832

Step Check Yes No

4 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 4-108.

5 Check the buffer diverter gate solenoid 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Fin buffer solenoid.
5. Touch Forward or reverse.

Does the above component operate properly?

6 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 4-102.

7 Check the sensor (buffer path) for proper operation. Go to step 9. Go to step 8.
1. Enter the Diagnostics Menu.
2. Touch FINISHER TESTS.
3. Touch Sensor Test.
4. Touch Media Path 1.
5. Touch Buffer path.

Does the display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

8 Check the sensor (buffer path) for proper connection. Replace the Replace the
sensor (buffer connection.
Is the above component properly connected? path).
Go to “Sensor
(buffer path)
removal” on
page 4-92.

Diagnostic information 2-19

7500-432, -632, and -832

Step Check Yes No

9 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?

10 Check the drive motor (buffer/transport) for proper Replace the drive Problem solved.
connection. motor (buffer/
transport).
Is the above component properly connected?
Go to “Drive
motor (buffer/
transport) and
belt (buffer/
transport)
removal” on
page 4-113.

11 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 4-115.
Go to step 12.

12 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 4-116.

2-20 MFP Finisher Service Manual

 7500-432, -632, and -832

283.03 Sensor (buffer path) static jam

Step Check Yes No

1 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. Enter the Diagnostics Menu.

2. Touch FINISHER TESTS.
3. Touch Sensor Test.
4. Touch Media Path 1.
5. Touch Buffer path.

Does the display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

2 Check the sensor (buffer path) for proper connection. Replace the Replace the
sensor (buffer connection.
Is the above component properly connected? path).
Go to “Sensor
(buffer path)
removal” on
page 4-92.

3 Check the drive motor (buffer/transport) 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Motor (buffer/transport).

Does the above component operate properly?

4 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 4-113.

Diagnostic information 2-21

7500-432, -632, and -832

Step Check Yes No

5 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 4-116.

284.00 Sensor (lower media exit) late jam

Step Check Yes No

1 Check the finisher buffer roll assembly. Go to step 2. Clean or replace

the finisher buffer
Is the above component free of excess wear and roll assembly.
contamination?
Go to “Finisher
buffer roll
assembly
removal” on
page 4-93.

2 Check the sensor (buffer path) 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 Media Path 1.
5. Touch Buffer path.

Does the display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

3 Check the sensor (buffer path) for proper connection. Replace the Replace the
sensor (buffer connection.
Is the above component properly connected? path).
Go to “Sensor
(buffer path)
removal” on
page 4-92.

4 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. Touch Finisher Motor Tests.
4. Touch Motor (buffer/transport).

Does the above component operate properly?

2-22 MFP Finisher Service Manual

 7500-432, -632, and -832

Step Check Yes No

5 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 4-113.

6 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 display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

7 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 4-108.

8 Check the sensor (lower media exit) 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 Media Path 1.
5. Touch Lower media exit.

Does the display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

9 Check the sensor (lower media exit) for proper Replace the Replace the
connection? sensor (lower connection.
media exit).
Is the above component properly connected?
Go to “Sensor
(lower media
exit) removal”
on page 4-80.

10 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 4-116.

Diagnostic information 2-23

7500-432, -632, and -832

284.03 Sensor (lower media exit) lag jam

Step Check Yes No

1 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
assembly
removal” on
page 4-81.

2 Check the sensor (lower 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 Lower media exit.

Does the display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

3 Check the sensor (lower media exit) for proper Replace the Replace the
connection. sensor (lower connection.
media exit).
Is the above component properly connected?
Go to “Sensor
(lower media
exit) removal”
on page 4-80.

4 Check the drive motor (exit) 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Motor (exit).

Does the above component operate properly?

5 Check the drive motor (exit) for proper connection. Replace the drive Replace the
motor (exit). connection.
Is the above component properly connected?
Go to “Drive
motor (exit)
assembly and
belt (exit)
removal” on
page 4-111.

2-24 MFP Finisher Service Manual

 7500-432, -632, and -832

Step Check Yes No

6 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 4-116.

284.05 Sensor (lower media exit) static jam

Step Check Yes No

1 Check the sensor (lower 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. Touch Media Path 1.
5. Touch Lower media exit.

Does the display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

2 Check the sensor (lower media exit) for proper Replace the Replace the
connection. sensor (lower connection.
media exit).
Is the above component properly connected?
Go to “Sensor
(lower media
exit) removal”
on page 4-80.

3 Check the buffer diverter gate solenoid 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Fin buffer solenoid.
5. Touch Forward or reverse.

Does the above component operate properly?

Diagnostic information 2-25

7500-432, -632, and -832

Step Check Yes No

4 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 4-102.

5 Check the drive motor (exit) for proper operation. Go to step 7. Go to step 6.
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. Touch Finisher Motor Tests.
4. Touch Motor (exit).

Does the above component operate properly?

6 Check the drive motor (exit) for proper connection. Replace the drive Replace the
motor (exit). connection.
Is the above component properly connected?
Go to “Drive
motor (exit)
assembly and
belt (exit)
removal” on
page 4-111.

7 Check the finisher diverter gate solenoid 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Fin diverter solenoid.
5. Touch Forward or reverse.

Does the above component operate properly?

8 Check the finisher diverter gate solenoid for proper Replace the Problem solved.
connection. finisher diverter
gate solenoid.
Is the above component properly connected?
Go to “Finisher
diverter gate
solenoid
removal” on
page 4-101.

2-26 MFP Finisher Service Manual

 7500-432, -632, and -832

Step Check Yes No

9 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 4-116.

285.00 Sensor (media compiler in) lag jam

Step Check Yes No

1 Check the media eject clamp motor for proper Go to step 3. Go to step 2.
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. Touch Finisher Motor Tests.
4. Touch Media eject clamp motor.

Does the above component operate properly?

2 Check the media eject motor for proper connection. Replace the Replace the
media eject connection.
Is the above component properly connected? motor.
Go to “Media
eject motor
assembly
removal” on
page 4-78.

3 Check the compiler media in actuator for proper Go to step 4. Replace the
operation. media compiler
unit assembly.
Is the actuator operating properly?
Go to “Media
compiler unit
assembly
removal” on
page 4-69.

Diagnostic information 2-27

7500-432, -632, and -832

Step Check Yes No

4 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?

5 Check the sensor (compiler media in) for proper Replace the Replace the
connection. sensor (compiler connection.
media in).
Is the above component properly connected?
Go to “Sensor
(compiler media
in) removal” on
page 4-72.

6 Perform a print test. Does the error remain? Replace the Problem solved.
finisher controller
card assembly.
Go to “Finisher
controller card
assembly
removal” on
page 4-116.

286.00 Sensor (compiler media in) static jam

Step Check Yes No

1 Check the media eject clamp motor for proper Go to step 3. Go to step 2.
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. Touch Finisher Motor Tests.
4. Touch Media eject clamp motor.

Does the above component operate properly?

2 Check the media eject clamp motor for proper Replace the Replace the
connection. media eject connector.
clamp motor.
Is the above component properly connected?
Go to “Media
eject clamp
motor assembly
removal” on
page 4-66.

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 7500-432, -632, and -832

Step Check Yes No

3 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?

4 Check the sensor (compiler media in) for proper Replace the Replace the
connection. sensor (compiler connection.
media in).
Is the above component properly connected?
Go to “Sensor
(compiler media
in) removal” on
page 4-72.

5 Check the media eject motor 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Media eject mtr.

Does the above component operate properly?

6 Check the media eject motor assembly for proper Replace the Replace the
connection. media eject connection.
motor assembly.
Is the above component properly connected?
Go to “Media
eject motor
assembly
removal” on
page 4-78.

7 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 4-116.

Diagnostic information 2-29

7500-432, -632, and -832

287.00 Sensor (upper media exit) late jam

Step Check Yes No

1 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.
Go to “Upper
media transport
roll assembly
removal” on
page 4-109.

2 Check the sensor (upper 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 Upper media exit.

Does the display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

3 Check the sensor (upper media exit) for proper Replace the Replace the
connection. sensor (upper connection.
media exit).
Is the above component properly connected?
Go to “Sensor
(upper media
exit) removal”
on page 4-103.

4 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. Touch Finisher Motor Tests.
4. Touch Motor (buffer/transport).

Does the above component operate properly?

5 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 4-113.

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 7500-432, -632, and -832

Step Check Yes No

6 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 4-116.

287.01 Sensor (upper media exit) lag jam

Step Check Yes No

1 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.
Go to “Upper
media transport
roll assembly
removal” on
page 4-109.

2 Check the sensor (upper media exit) for proper Go to step 3. 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 Upper media exit.

Does the display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

3 Check the sensor (upper media exit) for proper Replace the Replace the
connection. sensor (upper connection.
media exit).
Is the above component properly connected?
Go to “Sensor
(upper media
exit) removal”
on page 4-103.

Diagnostic information 2-31

7500-432, -632, and -832

Step Check Yes No

4 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. Touch Finisher Motor Tests.
4. Touch Motor (buffer/transport).

Does the above component operate properly?

5 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 4-113.

6 Check the drive motor (exit) 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. Touch Finisher Motor Tests.
4. Touch Motor (exit).

Does the above component operate properly?

7 Check the drive motor (exit) for proper connection. Replace the drive Replace the
motor (exit). connection.
Is the above component properly connected?
Go to “Drive
motor (exit)
assembly and
belt (exit)
removal” on
page 4-111.

8 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 4-116.

2-32 MFP Finisher Service Manual

 7500-432, -632, and -832

287.05 Sensor (upper media exit) static jam

Step Check Yes No

1 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. Touch Media Path 1.
5. Touch Upper media exit.

Does the display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

2 Check the sensor (upper media exit) for proper Replace the Replace the
connection. sensor (upper connection.
media exit).
Is the above component properly connected?
Go to “Sensor
(upper media
exit) removal”
on page 4-103.

3 Check the drive motor (buffer/transport) 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Motor (buffer/transport).

Does the above component operate properly?

4 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 4-113.

5 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 4-116.

Diagnostic information 2-33

7500-432, -632, and -832

288.00 Sensor (diverter gate) late jam

Step Check Yes No

1 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.
Go to “Finisher
media entrance
roll assembly
removal” on
page 4-98.

2 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?

3 Check the sensor (bridge unit media exit) for proper Replace the Replace the
connection. sensor (bridge connection.
unit media exit).
Is the above component properly connected?
Go to “Sensor
(bridge unit
media exit)
removal” on
page 4-17.

4 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?

5 Check the sensor (finisher media entrance) for proper Replace the Replace the
connection. sensor (finisher connection.
media entrance).
Is the above component properly connected?
Go to “Sensor
(finisher media
entrance)
removal” on
page 4-97.

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 7500-432, -632, and -832

Step Check Yes No

6 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?

7 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 4-108.

8 Check the drive motor (entrance/paddle) for proper Go to step 10. Go to step 9.
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. Touch Finisher Motor Tests.
4. Touch Motor (entrance/paddle).

Does the above component operate properly?

9 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 4-99.

10 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 4-116.

Diagnostic information 2-35

7500-432, -632, and -832

288.01 Sensor (diverter gate) static jam A (to top bin)

Step Check Yes No

1 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. Touch Media Path 2.
5. Touch Diverter gate.

Does the display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

2 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 4-108.

3 Check the drive motor (entrance/paddle) 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Motor (entrance/paddle).

Does the above component operate properly?

4 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 4-99.

5 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 4-116.

2-36 MFP Finisher Service Manual

 7500-432, -632, and -832

288.04 Sensor (diverter gate) static jam B (to stacker bin)

Step Check Yes No

1 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. Touch Media Path 2.
5. Touch Diverter gate.

Does the display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

2 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 4-108.

3 Check the motor (entrance/paddle) 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Motor (entrance/paddle).

Does the above component operate properly?

4 Check the 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 4-99.

5 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 4-116.

Diagnostic information 2-37

7500-432, -632, and -832

289.00 sensor (booklet unit media entrance) late jam

Step Check Yes No

1 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.
2 Check the main connector on the booklet unit sensor Go to step 3. Replace the
interface cable assembly. booklet unit sensor
interface cable
Is the above component free of damage? assembly.
3 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.
4 Check the sensor (booklet unit 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 Booklet path
5. Touch Booklet unit media entrance

Does the display on the operator panel change every time

the sensing area of the above sensor is interrupted or
blocked?
5 Check the sensor (booklet unit media entrance) for proper Replace the Replace the
connection. sensor (booklet connection.
unit media
Is the above component properly connected? entrance).
Go to “Sensor
(booklet unit
media entrance)
removal” on
page 4-138.
6 Check the booklet diverter gate solenoid 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Booklet diverter gate solenoid

Does the above component operate properly?

7 Check the booklet diverter gate solenoid for proper Replace the Problem solved.
connection. booklet diverter
gate solenoid.
Is the above component properly connected?
Go to “Booklet
diverter gate
solenoid
removal” on
page 4-123.

2-38 MFP Finisher Service Manual

 7500-432, -632, and -832

Step Check Yes No

8 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. Touch Finisher Motor Tests.
4. Touch Motor (entrance/paddle).

Does the above component operate properly?

9 Check the motor (entrance/paddle) for proper connection. Replace the drive Replace the
motor (entrance/ connection.
Is the above component properly connected. paddle).
Go to “Drive
motor (entrance/
paddle) and belt
(entrance/paddle)
removal” on
page 4-99.
10 Perform a print test. Replace the Problem solved.
booklet controller
Does the error remain? card assembly.
Go to “Booklet
controller card
assembly
removal ??” on
page 4-121.
Go to step 11.
11 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 4-116.

289.01 sensor (booklet unit media entrance) lag jam

Step Check Yes No

1 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.
2 Check the main connector on the booklet unit sensor Go to step 3. Replace the
interface cable assembly. booklet unit sensor
interface cable
Is the above component free of damage? assembly.

Diagnostic information 2-39

7500-432, -632, and -832

Step Check Yes No

3 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.
4 Check the sensor (booklet unit 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 Booklet path.
5. Touch Booklet unit media entrance

Does the display on the operator panel change every time

the sensing area of the above sensor is interrupted or
blocked?
5 Check the sensor (booklet unit media entrance) for proper Replace the Replace the
connection. sensor (booklet connection.
unit media
Is the above component properly connected? entrance).
Go to “Sensor
(booklet unit
media entrance)
removal” on
page 4-138.
6 Check the booklet media entrance 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Booklet media entrance drive motor.

Does the above component operate properly?

7 Check the booklet media entrance drive motor for proper Replace the Problem solved.
connection. booklet media
entrance drive
Is the above component properly connected? motor.
Go to “Booklet
media entrance
drive motor
removal” on
page 4-127.
8 Perform a print test. Replace the Problem solved.
booklet controller
Does the error remain? card assembly.
Go to “Booklet
controller card
assembly
removal ??” on
page 4-121.
Go to step 9.

2-40 MFP Finisher Service Manual

 7500-432, -632, and -832

Step Check Yes No

9 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 4-116.

289.02 sensor (booklet unit media entrance) static jam

Step Check Yes No

1 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.
2 Check the main connector on the booklet unit sensor Go to step 3. Replace the
interface cable assembly. booklet unit sensor
interface cable
Is the above component free of damage? assembly.
3 Check the sensor (booklet unit media entrance) 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 entrance

Does the display on the operator panel change every time

the sensing area of the above sensor is interrupted or
blocked?
4 Check the sensor (booklet unit media entrance) for proper Replace the Replace the
connection. sensor (booklet connection.
unit media
Is the above component properly connected? entrance).
Go to “Sensor
(booklet unit
media entrance)
removal” on
page 4-138.
5 Perform a print test. Replace the Problem solved.
booklet controller
Does the error remain? card assembly.
Go to “Booklet
controller card
assembly
removal ??” on
page 4-121.
Go to step 6.

Diagnostic information 2-41

7500-432, -632, and -832

Step Check Yes No

6 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 4-116.

289.03 sensor (booklet compiler media in) static jam

Step Check Yes No

1 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.
2 Check the main connector on the booklet unit sensor Go to step 3. Replace the
interface cable assembly. booklet unit sensor
interface cable
Is the above component free of damage? assembly.
3 Check the sensor (booklet 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 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?
4 Check the sensor (booklet compiler media in) for proper Replace the Replace the
connection. sensor (booklet connection.
compiler media
Is the above component properly connected? in).
Go to “Sensor
(booklet media
compiler in)
removal” on
page 4-139.
5 Perform a print test. Replace the Problem solved.
booklet controller
Does the error remain? card assembly.
Go to “Booklet
controller card
assembly
removal ??” on
page 4-121.
Go to step 6.

2-42 MFP Finisher Service Manual

 7500-432, -632, and -832

Step Check Yes No

6 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 4-116.

289.04 Sensor (booklet unit media exit) late jam

Step Check Yes No

1 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.
2 Check the main connector on the booklet unit sensor Go to step 3. Replace the
interface cable assembly. booklet unit sensor
interface cable
Is the above component free of damage? assembly.
3 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.
4 Check the sensor (booklet unit media exit) 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 unit media exit

Does the display on the operator panel change every time

the sensing area of the above sensor is interrupted or
blocked?
5 Check the sensor (booklet unit media exit) for proper Replace the Replace the
connection. sensor (booklet connection.
unit media exit).
Is the above component properly connected?
Go to “Sensor
(booklet unit
media exit)
removal” on
page 4-139.

Diagnostic information 2-43

7500-432, -632, and -832

Step Check Yes No

6 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. Touch Finisher Motor Tests.
4. Touch Booklet knife solenoid.

Does the above component operate properly?

7 Check the booklet knife solenoid for proper connection. Replace the Replace the
booklet knife connection.
Is the above component properly connected. solenoid.
Go to “Booklet
knife solenoid
removal” on
page 4-125.
8 Check the booklet folding/exit drive motor for proper Go to step 10. Go to step 9.
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. Touch Finisher Motor Tests.
4. Touch Booklet folding/exit drive motor.

Does the above component operate properly?

9 Check the booklet folding/exit drive motor for proper Replace the Problem solved.
connection. booklet folding/exit
drive motor
Is the above component properly connected? assembly.
Go to “Booklet
folding/exit drive
motor assembly
removal” on
page 4-122.
10 Perform a print test. Replace the Problem solved.
booklet controller
Does the error remain? card assembly.
Go to “Booklet
controller card
assembly
removal ??” on
page 4-121.
Go to step 11.

2-44 MFP Finisher Service Manual

 7500-432, -632, and -832

Step Check Yes No

11 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 4-116.

289.05 Sensor (booklet unit media exit) lag jam

Step Check Yes No

1 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.
2 Check the main connector on the booklet unit sensor Go to step 3. Replace the
interface cable assembly. booklet unit sensor
interface cable
Is the above component free of damage? assembly.
3 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.
4 Check the sensor (booklet unit media exit) 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 unit media exit

Does the display on the operator panel change every time

the sensing area of the above sensor is interrupted or
blocked?
5 Check the sensor (booklet unit media exit) for proper Replace the Replace the
connection. sensor (booklet connection.
unit media exit).
Is the above component properly connected?
Go to “Sensor
(booklet unit
media exit)
removal” on
page 4-139.

Diagnostic information 2-45

7500-432, -632, and -832

Step Check Yes No

6 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Booklet folding/exit drive motor.

Does the above component operate properly?

7 Check the booklet folding/exit drive motor for proper Replace the Problem solved.
connection. booklet folding/exit
drive motor.
Is the above component properly connected?
Go to “Booklet
folding/exit drive
motor assembly
removal” on
page 4-122.
8 Perform a print test. Replace the Problem solved.
booklet controller
Does the error remain? card assembly.
Go to “Booklet
controller card
assembly
removal ??” on
page 4-121.
Go to step 9.
9 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 4-116.

289.06 Sensor (booklet unit media exit) static jam

Step Check Yes No

1 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.
2 Check the main connector on the booklet unit sensor Go to step 3. Replace the
interface cable assembly. booklet unit sensor
interface cable
Is the above component free of damage? assembly.

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Step Check Yes No

3 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?
4 Check the sensor (booklet unit media exit) for proper Replace the Replace the
connection. sensor (booklet connection.
unit media exit).
Is the above component properly connected?
Go to “Sensor
(booklet unit
media exit)
removal” on
page 4-139.
5 Perform a print test. Replace the Problem solved.
booklet controller
Does the error remain? card assembly.
Go to “Booklet
controller card
assembly
removal ??” on
page 4-121.
Go to step 6.
6 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 4-116.

980.02 Finisher communication failure

Step Check Yes No

1 Check the printer and finisher installation. Go to step 2. Remove the

finisher.
Is the finisher installed to the printer properly?
Go to “Finisher
removal” on
page 4-3.
Reinstall the
finisher properly.

2 Turn the power on and off. Go to step 3. Problem solved.

Does the error still occur when the power is on?

Diagnostic information 2-47

7500-432, -632, and -832

Step Check Yes No

3 Check the finisher controller card assembly Replace the Replace the
connection. finisher controller connection.
card assembly.
Are the connections of the finisher controller card
assembly properly connected? Go to “Finisher
controller card
assembly
removal” on
page 4-116.
Go to step 4.

4 Perform a print test. Replace the Problem solved.

printer engine
Does the problem remain? card assembly.
Refer to the
Printer Service
Manual.

981.00 Sensor (stacker bin level 1) late error

Step Check Yes No

1 Check the vertical transport mechanism of the stacker bin Remove Go to step 2.
for obstacles and damage. obstacles.
Are the any obstacles in the vertical transport mechanism of
the stacker bin?
2 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?
3 Check the sensor (stacker bin level 1) for proper Replace the Replace the
connection. sensor (stacker connection.
bin level 1).
Is the above component properly connected?
Go to “Sensor
(stacker bin level
1) removal” on
page 4-34.
4 Check the sensor (stacker bin level 2) 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 Bin Level.
5. Touch Stacker bin level2.

Does the display on the operator panel change every time

the sensing area of the above sensor is interrupted or
blocked?

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Step Check Yes No

5 Is the sensor (stacker bin level 2) connected properly. Replace the Replace the
sensor (stacker connection.
Is the above component properly connected? bin level 2).
Go to “Sensor
(stacker bin level
2) removal” on
page 4-34.
6 Check the stacker bin lift motor assembly 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Stacker lift mtr.
5. Touch Forward or Reverse.

Does the above component operate properly?

7 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 4-38.
8 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 4-116.

981.01 Stacker bin upper limit error

Step Check Yes No

1 Check the sensor (stacker bin level 1) 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. 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?

Diagnostic information 2-49

7500-432, -632, and -832

Step Check Yes No

2 Check the sensor (stacker bin level 1) for proper Replace the Replace the
connection. sensor (stacker connection.
bin level 1).
Is the above component properly connected?
Go to “Sensor
(stacker bin level
1) removal” on
page 4-34.
3 Check the sensor (stacker bin level 2) for proper operation. Go to step 5. Go to step 4.
1. Enter the Diagnostics Menu.
2. Touch FINISHER TESTS.
3. Touch Sensor Test.
4. Touch Bin Level.
5. Touch Stacker bin level2.

Does the display on the operator panel change every time

the sensing area of the above sensor is interrupted or
blocked?
4 Check the sensor (stacker bin level 2) for proper Replace the Replace the
connection. sensor (stacker connection.
bin level 2).
Is the above component properly connected?
Go to “Sensor
(stacker bin level
2) removal” on
page 4-34.
5 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)?
6 Check the sensor (stacker bin upper limit) for proper Go to step 8. Go to step 7.
operation.
1. Enter the Diagnostics Menu.
2. Touch FINISHER TESTS.
3. Touch Sensor Test.
4. Touch Bin Level.
5. Touch Stacker bin upper limit.

Does the display on the operator panel change every time

the sensing area of the above sensor is interrupted or
blocked?
7 Check the sensor (stacker bin upper limit) for proper Replace the Replace the
connection. sensor (stacker connection.
bin upper limit).
Is the above component properly connected?
Go to “Sensor
(stacker bin
upper limit) or
sensor (stacker
bin no media)
removal” on
page 4-36.

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 7500-432, -632, and -832

Step Check Yes No

8 Check the stacker bin lift motor assembly for proper Go to step 10. Go to step 9.
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. Touch Finisher Motor Tests.
4. Touch Stacker lift mtr.
5. Touch Forward or Reverse.

Does the above component operate properly?

9 Check the stacker bin lift motor assembly for proper Replace the Replace the
connection. stacker bin lift connection.
motor assembly.
Is the above component properly connected?
Go to “Stacker
bin lift motor
assembly
removal” on
page 4-38.
10 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 4-116.

981.02 Stacker bin lower limit error

Step Check Yes No

1 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)?
2 Check the sensor (stacker bin no media) 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 Bin Level.
5. Touch Stacker bin no media.

Does the display on the operator panel change every time

the sensing area of the above sensor is interrupted or
blocked?
3 Is the sensor (stacker bin no media) properly connected? Replace the Replace the
sensor (stacker connection.
Is the above component properly connected? bin no media).

Diagnostic information 2-51

7500-432, -632, and -832

Step Check Yes No

4 Check the sensor (stacker bin level 1) 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 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?
5 Check the sensor (stacker bin level 1) for proper Replace the Replace the
connection. sensor (stacker connection.
bin level 1).
Is the above component properly connected?
Go to “Sensor
(stacker bin level
1) removal” on
page 4-34.
6 Check the sensor (stacker bin level2) 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 Bin Level.
5. Touch Stacker bin level2.

Does the display on the operator panel change every time

the sensing area of the above sensor is interrupted or
blocked?
7 Check the sensor (stacker bin level 2) for proper Replace the Replace the
connection. sensor (stacker connection.
bin level 2).
Is the above component properly connected?
Go to “Sensor
(stacker bin level
2) removal” on
page 4-34.
8 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?
9 Is the sensor (stacker bin level encoder) properly Replace the Replace the
connected? sensor (stacker connection.
bin level encoder).
Is the above component properly connected?
Go to “Sensor
(stacker bin level
encoder)
removal” on
page 4-35.

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Step Check Yes No

10 Check the stacker bin lift motor assembly for proper Go to step 12. Go to step 11.
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. Touch Finisher Motor Tests.
4. Touch Stacker lift mtr.
5. Touch Forward or Reverse.

Does the above component operate properly?

11 Check the stacker bin lift motor assembly for proper Replace the Replace the
connection. stacker bin lift connection.
motor assembly.
Is the above component properly connected?
Go to “Stacker
bin lift motor
assembly
removal” on
page 4-38.
12 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 4-116.

982.00 Sensor (front tamper HP) late error

Step Check Yes No

1 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” on
page 4-69.
2 Check the sensor (front tamper 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 Media Path 2.
5. Touch Front tamper HP.

Does the display on the operator panel change every time

the sensing area of the above sensor is interrupted or
blocked?

Diagnostic information 2-53

7500-432, -632, and -832

Step Check Yes No

3 Is the sensor (front tamper HP) properly connected? Replace the Replace the
sensor (front connection.
Is the above component properly connected? tamper HP).
Go to “Sensor
(front tamper HP)
and sensor (rear
tamper HP)
removals” on
page 4-71.
4 Check the front 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Front tamper mtr
5. Touch Forward or Reverse.

Does the above component operate properly?

5 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 4-69.
6 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 4-116.

982.01 Sensor (front tamper HP) lag error

Step Check Yes No

1 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” on
page 4-69.

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Step Check Yes No

2 Check the sensor (front tamper 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 Media Path 2.
5. Touch Front tamper HP.

Does the display on the operator panel change every time

the sensing area of the above sensor is interrupted or
blocked?
3 Is the sensor (front tamper HP) properly connected? Replace the Replace the
sensor (front connection.
Is the above component properly connected? tamper HP).
Go to “Sensor
(front tamper HP)
and sensor (rear
tamper HP)
removals” on
page 4-71.
4 Check the front 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Front tamper mtr
5. Touch Forward or Reverse.

Does the above component operate properly?

5 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 4-69.
6 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 4-116.

Diagnostic information 2-55

7500-432, -632, and -832

983.00 Sensor (rear tamper HP) late error

Step Check Yes No

1 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” on
page 4-69.
2 Check the sensor (rear tamper 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 Media Path 2.
5. Touch Rear tamper HP.

Does the display on the operator panel change every time

the sensing area of the above sensor is interrupted or
blocked?
3 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 4-71.
4 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Rear tamper mtr.
5. Touch Forward or Reverse.

Does the above component operate properly?

5 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 4-69.

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Step Check Yes No

6 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 4-116.

983.01 Sensor (rear tamper HP) lag error

Step Check Yes No

1 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” on
page 4-69.
2 Check the sensor (rear tamper 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 Media Path 2.
5. Touch Rear tamper HP.

Does the display on the operator panel change every time

the sensing area of the above sensor is interrupted or
blocked?
3 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 4-71.
4 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Rear tamper mtr.
5. Touch Forward or Reverse.

Does the above component operate properly?

Diagnostic information 2-57

7500-432, -632, and -832

Step Check Yes No

5 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 4-69.
6 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 4-116.

984.00 Sensor (punch unit HP) late error

Step Check Yes No

1 Check the punch rack gear by moving it manually. Go to step 2. Remove

obstacles.
Does the above component slide back and forth properly?
2 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?
3 Is the sensor (punch unit HP) properly connected? Replace the Replace the
sensor (punch unit connection.
Is the above component properly connected? HP).
Go to “Sensor
(punch hole
select), sensor
(punch cam
front), and
sensor (punch
unit HP)
removal” on
page 4-49.
4 Check the punch unit motor for proper operation. Go to step 6. Go to step 5.
1. Enter the Diagnostic Menu.
2. Touch FINISHER TESTS.
3. Touch Punch unit mtr.
4. Touch Forward or Reverse.

Does the above component operate properly?

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Step Check Yes No

5 Is the punch unit motor properly connected? Replace the punch Replace the
unit motor connection.
Is the above component properly connected? assembly.
Go to “Punch unit
motor assembly
removal” on
page 4-47.
6 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 4-116.

984.01 Sensor (punch unit HP) lag error

Step Check Yes No

1 Check the punch rack gear by moving it manually. Go to step 2. Remove

obstructions.
Does the above component slide back and forth
properly?

2 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?

3 Is the sensor (punch unit HP) properly connected? Replace the Replace the
sensor (punch connection.
Is the above component properly connected? unit HP).
Go to “Sensor
(punch hole
select), sensor
(punch cam
front), and
sensor (punch
unit HP)
removal” on
page 4-49.

4 Check the punch unit motor for proper operation. Go to step 6. Go to step 5.
1. Enter the Diagnostic Menu.
2. Touch FINISHER TESTS.
3. Touch Punch unit mtr.
4. Touch Forward or Reverse.

Does the above component operate properly?

Diagnostic information 2-59

7500-432, -632, and -832

Step Check Yes No

5 Is the punch unit motor properly connected? Replace the Replace the
punch unit motor connection.
Is the above component properly connected? assembly.
Go to “Punch
unit motor
assembly
removal” on
page 4-47.

6 Perform a POR. Replace the Problem solved.

finisher controller
Does the error continue when the power is turned off/ card assembly.
on?
Go to “Finisher
controller card
assembly
removal” on
page 4-116.

985.00 Sensor (punch carriage shift HP) late error

Step Check Yes No

1 Check the punch carriage by moving it manually. Go to step 2. Remove

obstacles.
Does the above component slide back and forth
properly?

2 Check the sensor (punch carriage shift 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 Punch carriage shift HP.

Does the display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

3 Check the sensor (punch carriage shift HP) for proper Replace the Replace the
connection. sensor (punch connection.
carriage
Is the above component properly connected? shift HP).
Go to “Sensor
(punch carriage
shift HP)
removal” on
page 4-51.

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Step Check Yes No

4 Check the punch carriage shift motor assembly for Go to step 6. Go to step 9.
proper 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. Touch Finisher Tests.
4. Touch Punch carriage shift mtr.
5. Touch Forward or Reverse.

Does the above component operate properly?

5 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 4-43.

6 Perform a POR. Replace the Problem solved.

finisher controller
Does the error continue when the power is turned off/ card assembly.
on?
Go to “Finisher
controller card
assembly
removal” on
page 4-116.

985.01Sensor (punch carriage shift HP) lag error

Step Check Yes No

1 Check the punch carriage by moving it manually. Go to step 2. Remove

obstructions.
Does the above component slide back and forth
properly?

2 Check the sensor (punch carriage shift 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 Punch carriage shift HP.

Does the display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

Diagnostic information 2-61

7500-432, -632, and -832

Step Check Yes No

3 Check the sensor (punch carriage shift HP) for proper Replace the Replace the
connection. sensor (punch connection.
carriage shift
Is the above component properly connected? HP).
Go to “Sensor
(punch carriage
shift HP)
removal” on
page 4-51.

4 Check the punch carriage shift motor assembly for Go to step 6. Go to step 5.
proper 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. Touch Finisher Tests.
4. Touch Punch carriage shift mtr.
5. Touch Forward or Reverse.

Does the above component operate properly?

5 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 4-43.

6 Perform a POR. Replace the Problem solved.

finisher controller
Does the error continue when the power is turned off/ card assembly.
on?
Go to “Finisher
controller card
assembly
removal” on
page 4-116.

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 7500-432, -632, and -832

986.00 Sensor (media eject clamp HP) late error

Step Check Yes No

1 Check the sensor (media eject clamp 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. Touch Media Path 2.
5. Touch Media eject clamp HP.

Does the display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

2 Check the sensor (media eject clamp HP) for proper Replace the Replace the
connection. sensor (media connection.
eject clamp HP).
Is the above component properly connected?
Go to “Sensor
(media eject
clamp HP)
removal” on
page 4-67.

3 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. Touch MOTOR TESTS.
3. Touch Finisher Tests.
4. Touch Media eject clamp motor.

Does the above component operate properly?

4 Is the media eject clamp motor properly connected? Replace the Replace the
media eject connection.
Is the above component properly connected? clamp motor.
Go to “Media
eject clamp
motor assembly
removal” on
page 4-66.

5 Perform a POR. Replace the Problem solved.

finisher controller
Does the error continue when the power is turned off/ card assembly.
on?
Go to “Finisher
controller card
assembly
removal” on
page 4-116.

Diagnostic information 2-63

7500-432, -632, and -832

986.01 Sensor (media eject clamp HP) lag error

Step Check Yes No

1 Check the sensor (media eject clamp 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. Touch Media Path 2.
5. Touch Media eject clamp HP.

Does the display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

2 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 4-67.

3 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. Touch MOTOR TESTS.
3. Touch Finisher Tests.
4. Touch Media eject clamp motor.

Does the above component operate properly?

4 Is the media eject clamp motor properly connected? Replace the Replace the
media eject connection.
Is the above component properly connected? clamp motor.
Go to “Media
eject clamp
motor assembly
removal” on
page 4-66.

5 Perform a POR. Replace the Problem solved.

finisher controller
Does the error continue when the power is turned off/ card assembly.
on?
Go to “Finisher
controller card
assembly
removal” on
page 4-116.

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 7500-432, -632, and -832

987.00 Sensor (media eject shaft HP) late error

Step Check Yes No

1 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. Touch Media Path 2.
5. Touch Media eject shaft HP.

Does the display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

2 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 4-79.

3 Check the media eject motor assembly 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. Touch MOTOR TESTS.
3. Touch Finisher Tests.
4. Touch Media eject mtr.

Does the above component operate properly?

4 Is the media eject motor assembly for properly Replace the Replace the
connected? media eject connection.
motor assembly.
Is the above component properly connected?
Go to “Media
eject motor
assembly
removal” on
page 4-78.

Diagnostic information 2-65

7500-432, -632, and -832

Step Check Yes No

5 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. Touch MOTOR TESTS.
3. Touch Finisher Tests.
4. Touch Media eject clutch.

Does the above component make an audible clicking

noise?

6 Check the media eject clutch assembly for proper Replace the Replace the
connection. media eject connection.
clutch assembly.
Is the above component properly connected?
Go to “Media
eject clutch
assembly
removal” on
page 4-77.

7 Perform a POR. Replace the Problem solved.

finisher controller
Does the error continue when the power is turned off/ card assembly.
on?
Go to “Finisher
controller card
assembly
removal” on
page 4-116.

987.01 Sensor (media eject shaft HP) lag error

Step Check Yes No

1 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. Touch Media Path 2.
5. Touch Media eject shaft HP.

Does the display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

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 7500-432, -632, and -832

Step Check Yes No

2 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 4-79.

3 Check the media eject motor assembly 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. Touch MOTOR TESTS.
3. Touch Finisher Tests.
4. Touch Media eject mtr.

Does the above component operate properly?

4 Is the media eject motor assembly for properly Replace the Replace the
connected? media eject connection.
motor assembly.
Is the above component properly connected?
Go to “Media
eject motor
assembly
removal” on
page 4-78.

5 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. Touch MOTOR TESTS.
3. Touch Finisher Tests.
4. Touch Media eject clutch.

Does the above component make an audible clicking

noise?

6 Is the media eject clutch assembly connected Replace the Replace the
properly? media eject connection.
clutch assembly.
Is the above component properly connected?
Go to “Media
eject clutch
assembly
removal” on
page 4-77.

Diagnostic information 2-67

7500-432, -632, and -832

Step Check Yes No

7 Perform a POR. Replace the Problem solved.

finisher controller
Does the error continue when the power is turned off/ card assembly.
on?
Go to “Finisher
controller card
assembly
removal” on
page 4-116.

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.

Step Check Yes No

1 Check the sensor (punch unit side reg1) 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. Touch Punch and Staple.
5. Touch Punch side reg1.

Does the display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

2 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” on
page 4-44.

3 Check the sensor (punch unit side reg2) 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 Punch and Staple.
5. Touch Punch side reg2.

Does the display on the operator panel change every

time the sensing area of the above sensor is
interrupted or blocked?

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 7500-432, -632, and -832

Step Check Yes No

4 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” on
page 4-44.

5 Check the punch carriage shift motor assembly for Go to step 7. Go to step 6.
proper 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. Touch Finisher Tests.
4. Touch Punch carriage shift mtr.
5. Touch Forward or Reverse.

Does the above component operate properly?

6 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 4-43.

7 Perform a POR. Replace the Problem solved.

finisher controller
Does the error continue when the power is turned off/ card assembly.
on?
Go to “Finisher
controller card
assembly
removal” on
page 4-116.

Diagnostic information 2-69

7500-432, -632, and -832

989.00 Stapler unit failure

Step Check Yes No

1 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.
1. Enter the Diagnostics Menu.
2. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Stapler unit mtr.

Does the above component operate properly?

2 Is the stapler unit assembly properly connected? Replace the Replace the
stapler unit connection.
Is the above component properly connected? assembly.
Go to “Stapler
unit assembly
removal” on
page 4-56.

3 Perform a print test stapled document. Replace the Problem solved.

printer engine
Does the error remain? card assembly.
Refer to the
Printer Service
Manual.

990.00 Sensor (stapler carriage HP) late error

Step Check Yes No

1 Check the stapler by moving it manually. Go to step 2. Remove

obstructions.
Does the above component slide back and forth
properly?

2 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?

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 7500-432, -632, and -832

Step Check Yes No

3 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 4-58.

4 Check the stapler carriage motor assembly 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. Touch Finisher Tests.
4. Touch Stapler carriage mtr.
5. Touch Forward or Reverse.

Does the above component operate properly?

5 Is the stapler carriage motor assembly properly Replace the Replace the
connected? stapler carriage connection
motor assembly.
Is the above component properly connected?

6 Perform a POR. Replace the Problem solved.

finisher controller
Does the error continue when the power is turned off/ card assembly.
on?
Go to “Finisher
controller card
assembly
removal” on
page 4-116.

990.01 Sensor (stapler carriage HP) lag error

Step Check Yes No

1 Check the stapler by moving it manually. Go to step 2. Remove

obstructions.
Does the above component slide back and forth
properly?

Diagnostic information 2-71

7500-432, -632, and -832

Step Check Yes No

2 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?

3 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 4-58.

4 Check the stapler carriage motor assembly 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. Touch Finisher Tests.
4. Touch Stapler carriage mtr.
5. Touch Forward or Reverse.

Does the above component operate properly?

5 Is the stapler carriage motor assembly properly Replace the Replace the
connected? stapler carriage connection.
motor assembly.
Is the above component properly connected?

6 Perform a POR. Replace the Problem solved.

finisher controller
Does the error continue when the power is turned off/ card assembly.
on?
Go to “Finisher
controller card
assembly
removal” on
page 4-116.

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 7500-432, -632, and -832

991.00 Sensor (booklet front temper HP) late error

Step Check Yes No

1 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.
2 Check the main connector on the booklet unit sensor Go to step 3. Replace the
interface cable assembly. booklet unit sensor
interface cable
Is the above component free of damage? assembly.
3 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.
4 Check the booklet front tamper by moving it manually. Go to step 5. Remove
obstructions.
Does the above component slide back and forth properly?
5 Check the sensor (booklet front tamper HP) for proper Go to step 7. Go to step 6.
operation.
1. Enter the Diagnostics Menu.
2. Touch FINISHER TESTS.
3. Touch Sensor Test
4. Touch Booklet Path
5. Touch Booklet front tamper HP.

Does the display on the operator panel change every time

the sensing area of the above sensor is interrupted or
blocked?
6 Is the sensor (booklet front tamper HP) properly connected? Replace the Replace the
sensor (booklet connection.
Is the above component properly connected? front tamper HP).
Go to “Sensor
(booklet front
tamper HP)
removal” on
page 4-132.
7 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. Touch MOTOR TESTS.
3. Touch Finisher Tests.
4. Touch Booklet front tamper motor.

Does the above component operate properly?

8 Is the booklet front tamper motor properly connected? Replace the Replace the
booklet front connection.
Is the above component properly connected? tamper motor.
Go to “Booklet
front tamper
motor removal”
on page 4-134.

Diagnostic information 2-73

7500-432, -632, and -832

Step Check Yes No

9 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 4-121.
10 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 4-116.

991.01 Sensor (booklet front tamper HP) lag error

Step Check Yes No

1 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.
2 Check the main connector on the booklet unit sensor Go to step 3. Replace the
interface cable assembly. booklet unit sensor
interface cable
Is the above component free of damage? assembly.
3 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.
4 Check the booklet front tamper by moving it manually. Go to step 5. Remove
obstructions.
Does the above component slide back and forth properly?
5 Check the sensor (booklet front tamper HP) for proper Go to step 7. Go to step 6.
operation.
1. Enter the Diagnostics Menu.
2. Touch FINISHER TESTS.
3. Touch Sensor Test
4. Touch Booklet Path
5. Touch Booklet front tamper HP.

Does the display on the operator panel change every time

the sensing area of the above sensor is interrupted or
blocked?
6 Is the sensor (booklet front tamper HP) properly connected? Replace the Replace the
sensor (booklet connection.
Is the above component properly connected? front tamper HP).
Go to “Sensor
(booklet front
tamper HP)
removal” on
page 4-132.

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 7500-432, -632, and -832

Step Check Yes No

7 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. Touch MOTOR TESTS.
3. Touch Finisher Tests.
4. Touch Booklet front tamper motor.

Does the above component operate properly?

8 Is the booklet front tamper motor properly connected? Replace the Replace the
booklet front connection.
Is the above component properly connected? tamper motor.
Go to “Booklet
front tamper
motor removal”
on page 4-134.
9 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 4-121.
10 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 4-116.

991.02 Sensor (booklet rear tamper HP) late error

Step Check Yes No

1 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.
2 Check the main connector on the booklet unit sensor Go to step 3. Replace the
interface cable assembly. booklet unit sensor
interface cable
Is the above component free of damage? assembly.
3 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.

Diagnostic information 2-75

7500-432, -632, and -832

Step Check Yes No

4 Check the booklet rear tamper by moving it manually. Go to step 5. Remove

obstructions.
Does the above component slide back and forth properly?
5 Check the sensor (booklet rear tamper HP) for proper Go to step 7. Go to step 6.
operation.
1. Enter the Diagnostics Menu.
2. Touch FINISHER TESTS.
3. Touch Sensor Test
4. Touch Booklet Path
5. Touch Booklet rear tamper HP.

Does the display on the operator panel change every time

the sensing area of the above sensor is interrupted or
blocked?
6 Is the sensor (booklet rear tamper HP) properly connected? Replace the Replace the
sensor (booklet connection.
Is the above component properly connected? rear tamper HP).
Go to “Sensor
(booklet rear
tamper HP)
removal” on
page 4-133.
7 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. Touch MOTOR TESTS.
3. Touch Finisher Tests.
4. Touch Booklet rear tamper motor.

Does the above component operate properly?

8 Is the booklet rear tamper motor properly connected? Replace the Replace the
booklet rear connection.
Is the above component properly connected? tamper motor.
Go to “Booklet
rear tamper
motor removal”
on page 4-135.
9 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 4-121.

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 7500-432, -632, and -832

Step Check Yes No

10 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 4-116.

991.03 Sensor (booklet rear tamper HP) lag error

Step Check Yes No

1 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.
2 Check the main connector on the booklet unit sensor Go to step 3. Replace the
interface cable assembly. booklet unit sensor
interface cable
Is the above component free of damage? assembly.
3 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.
4 Check the booklet rear tamper by moving it manually. Go to step 5. Remove
obstructions.
Does the above component slide back and forth properly?
5 Check the sensor (booklet rear tamper HP) for proper Go to step 7. Go to step 6.
operation.
1. Enter the Diagnostics Menu.
2. Touch FINISHER TESTS.
3. Touch Sensor Test
4. Touch Booklet Path
5. Touch Booklet rear tamper HP.

Does the display on the operator panel change every time

the sensing area of the above sensor is interrupted or
blocked?
6 Is the sensor (booklet rear tamper HP) properly connected? Replace the Replace the
sensor (booklet connection.
Is the above component properly connected? rear tamper HP).
Go to “Sensor
(booklet rear
tamper HP)
removal” on
page 4-133.

Diagnostic information 2-77

7500-432, -632, and -832

Step Check Yes No

7 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. Touch MOTOR TESTS.
3. Touch Finisher Tests.
4. Touch Booklet rear tamper motor.

Does the above component operate properly?

8 Is the booklet rear tamper motor properly connected? Replace the Replace the
booklet rear connection.
Is the above component properly connected? tamper motor.
Go to “Booklet
rear tamper
motor removal”
on page 4-135.
9 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 4-121.
10 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 4-116.

991.04 Sensor (booklet end guide HP) late error

Step Check Yes No

1 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.
2 Check the main connector on the booklet unit sensor Go to step 3. Replace the
interface cable assembly. booklet unit sensor
interface cable
Is the above component free of damage? assembly.
3 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.

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 7500-432, -632, and -832

Step Check Yes No

4 Check the booklet end guide by moving it manually. Go to step 5. Remove

obstructions.
Does the above component slide up and down properly?
5 Check the sensor (booklet end guide HP) for proper Go to step 7. Go to step 6.
operation.
1. Enter the Diagnostics Menu.
2. Touch FINISHER TESTS.
3. Touch Sensor Test
4. Touch Booklet Path
5. Touch Booklet end guide HP

Does the display on the operator panel change every time

the sensing area of the above sensor is interrupted or
blocked?
6 Is the sensor (booklet end guide HP) properly connected? Replace the Replace the
sensor (booklet connection.
Is the above component properly connected? end guide HP).
Go to “Sensor
(booklet end
guide HP)
removal” on
page 4-140.
7 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. Touch MOTOR TESTS.
3. Touch Finisher Tests.
4. Touch Booklet end guide drive motor.

Does the above component operate properly?

8 Is the booklet end guide drive motor properly connected? Replace the Replace the
booklet end guide connection.
Is the above component properly connected? drive motor.
Go to “Booklet
end guide drive
motor removal”
on page 4-142.
9 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 4-121.

Diagnostic information 2-79

7500-432, -632, and -832

Step Check Yes No

10 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 4-116.

991.05 Sensor (booklet end guide HP) lag error

Step Check Yes No

1 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.
2 Check the main connector on the booklet unit sensor Go to step 3. Replace the
interface cable assembly. booklet unit sensor
interface cable
Is the above component free of damage? assembly.
3 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.
4 Check the booklet end guide by moving it manually. Go to step 5. Remove
obstructions.
Does the above component slide up and down properly?
5 Check the sensor (booklet end guide HP) for proper Go to step 7. Go to step 6.
operation.
1. Enter the Diagnostics Menu.
2. Touch FINISHER TESTS.
3. Touch Sensor Test
4. Touch Booklet Path
5. Touch Booklet end guide HP

Does the display on the operator panel change every time

the sensing area of the above sensor is interrupted or
blocked?
6 Is the sensor (booklet end guide HP) properly connected? Replace the Replace the
sensor (booklet connection.
Is the above component properly connected? end guide HP).
Go to “Sensor
(booklet end
guide HP)
removal” on
page 4-140.

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 7500-432, -632, and -832

Step Check Yes No

7 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. Touch MOTOR TESTS.
3. Touch Finisher Tests.
4. Touch Booklet end guide drive motor.

Does the above component operate properly?

8 Is the booklet end guide drive motor properly connected? Replace the Replace the
booklet end guide connection.
Is the above component properly connected? drive motor.
Go to “Booklet
end guide drive
motor removal”
on page 4-142.
9 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 4-121.
10 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 4-116.

991.06 Sensor (booklet unit interlock) error

Step Check Yes No

1 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.
2 Check the main connector on the booklet unit sensor Go to step 3. Replace the
interface cable assembly. booklet unit sensor
interface cable
Is the above component free of damage? assembly.
3 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.

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Step Check Yes No

4 Check the booklet unit assembly by opening it and closing Go to step 5. Remove
it. obstructions.
Does the above component slide open and close properly?
5 Check the sensor (booklet unit interlock) for proper Go to step 7. Go to step 6.
operation.
1. Enter the Diagnostics Menu.
2. Touch FINISHER TESTS.
3. Touch Sensor Test.
4. Touch Booklet Path.
5. Touch Booklet unit interlock.

Does the display on the operator panel change every time

the sensing area of the above sensor is interrupted or
blocked?
6 Is the sensor (booklet unit interlock) properly connected? Replace the Replace the
sensor (booklet connection.
Is the above component properly connected? unit interlock).
Go to “Sensor
(booklet unit
interlock)
removal” on
page 4-120.
7 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 4-121.
8 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 4-116.

991.07 Sensor (booklet compiler no media) no media detected

Step Check Yes No

1 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.
2 Check the main connector on the booklet unit sensor Go to step 3. Replace the
interface cable assembly. booklet unit sensor
interface cable
Is the above component free of damage? assembly.
3 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.

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Step Check Yes No

4 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?
5 Is the sensor (booklet compiler media in) properly Replace the Replace the
connected? sensor (booklet connection.
compiler media
Is the above component properly connected? in).
Go to “Sensor
(booklet media
compiler in)
removal” on
page 4-139.
6 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 4-121.
7 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 4-116.

991.08 Sensor (booklet knife HP) late error

Step Check Yes No

1 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.
2 Check the main connector on the booklet unit sensor Go to step 3. Replace the
interface cable assembly. booklet unit sensor
interface cable
Is the above component free of damage? assembly.
3 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.

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Step Check Yes No

4 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?
5 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 4-136.
6 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. Touch Finisher Motor Tests.
4. Touch Booklet knife solenoid.

Does the above component operate properly?

7 Is the booklet knife solenoid properly connected? Replace the Replace the
booklet knife connection.
Is the above component properly connected? solenoid.
Go to “Booklet
knife solenoid
removal” on
page 4-125.
8 Check the booklet folding/exit drive motor assembly for Go to step 10. Go to step 9.
proper 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. Touch Finisher Motor Tests.
4. Touch Booklet folding/exit drive motor

Does the above component operate properly?

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Step Check Yes No

9 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 4-122.
10 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 4-121.
11 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 4-116.

991.09 Sensor (booklet knife HP) lag error

Step Check Yes No

1 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.
2 Check the main connector on the booklet unit sensor Go to step 3. Replace the
interface cable assembly. booklet unit sensor
interface cable
Is the above component free of damage? assembly.
3 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.
4 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?

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Step Check Yes No

5 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 4-136.
6 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. Touch Finisher Motor Tests.
4. Touch Booklet knife solenoid.

Does the above component operate properly?

7 Is the booklet knife solenoid properly connected? Replace the Replace the
booklet knife connection.
Is the above component properly connected? solenoid.
Go to “Booklet
knife solenoid
removal” on
page 4-125.
8 Check the booklet folding/exit drive motor assembly for Go to step 10. Go to step 9.
proper 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. Touch Finisher Motor Tests.
4. Touch Booklet folding/exit drive motor

Does the above component operate properly?

9 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 4-122.

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Step Check Yes No

10 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 4-121.
11 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 4-116.

991.10 Sensor (booklet knife folding) late error

Step Check Yes No

1 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.
2 Check the main connector on the booklet unit sensor Go to step 3. Replace the
interface cable assembly. booklet unit sensor
interface cable
Is the above component free of damage? assembly.
3 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.
4 Check the sensor (booklet knife folding) 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 knife folding.

Does the display on the operator panel change every time

the sensing area of the above sensor is interrupted or
blocked?
5 Is the sensor (booklet knife folding) properly connected? Replace the Replace the
sensor (booklet connection.
Is the above component properly connected? knife folding).
Go to “Sensor
(booklet knife
folding) removal”
on page 4-137.

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Step Check Yes No

6 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. Touch MOTOR TESTS.
3. Touch Finisher Motor Tests.
4. Touch Booklet folding/exit drive motor

Does the above component operate properly?

7 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 4-122.
8 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 4-121.
9 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 4-116.

991.11 Booklet stapler error

Step Check Yes No

1 Check the booklet unit stapler assembly. Go to step 2. Ensure that the
booklet unit stapler
Is the above component properly inserted into the booklet assembly is
maker unit assembly? properly inserted.
2 Check the booklet unit interface connector assembly. Go to step 3. Replace the
booklet unit
Is the above component free of damage? interface
connector
assembly.

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Step Check Yes No

3 Check the main connector on the booklet unit sensor Go to step 4. Replace the
interface cable assembly. booklet unit sensor
interface cable
Is the above component free of damage? assembly.
4 Check the main connector on the booklet unit motor Go to step 5. Replace the
interface cable assembly. booklet unit motor
interface cable
Is the above component free of damage? assembly.
5 Check the booklet stapler interface cable assembly. Go to step 6. Replace the
booklet stapler
Is the above component free of damage? interface cable
assembly.
6 Check the connector on the back of the booklet stapler unit Replace the Go to step 7.
assembly. booklet stapler unit
assembly.
Is the above component free of damage.
Go to “Booklet
stapler unit
assembly
removal” on
page 4-123.
7 Perform a print test booklet stapled document. Replace the Problem solved.
booklet controller
Does the error remain? card assembly.
Go to “Booklet
controller card
assembly
removal ??” on
page 4-121.
8 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 4-116.

991.12 Communication error with booklet controller card assembly

Step Check Yes No

1 Check the booklet controller card assembly and the finisher Go to step 2. Replace the
controller card assembly for proper connection. connection.
Is the above component properly connected?
2 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 4-121.
Go to step 3.

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7500-432, -632, and -832

Step Check Yes No

3 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 4-116.

991.13 Booklet unit maker error

Step Check Yes No

1 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 4-121.

Bridge unit top cover open

Step Check Yes No

1 Check the bridge unit cable assembly for proper Go to step 2. Replace the
connection. connection.
Is the bridge unit cable assembly properly connected to
the rear of the finisher?

2 Open and close the bridge unit top cover assembly on Go to step 3. Check that the
the bridge unit assembly. bridge unit top
cover assembly
Does it open or close smoothly? is installed
properly, and
correct any
deformations. If
this does not
correct the
problem, replace
the bridge unit
top cover
assembly.
Go to “Bridge
unit top cover
assembly
removal” on
page 4-7.

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Step Check Yes No

3 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. If this
that enters the sensor (bridge unit top cover interlock) does not correct
bent or damaged? the problem,
replace the
bridge unit top
cover assembly.
Go to “Bridge
unit top cover
assembly
removal” on
page 4-7.

4 Check the bridge unit assembly top cover actuator. Go to step 5 Problem solved.
Paint both faces of the actuator with a black permanent
marker.
Does the error continue?

5 Check the sensor (bridge unit top cover interlock) Go to step 6. Reinstall the
installation. sensor (bridge
unit top cover
Is the sensor (bridge unit top cover interlock) installed interlock).
properly?
Go to “Sensor
(bridge unit top
cover interlock)
removal” on
page 4-15.

6 Check the sensor (bridge unit top cover interlock) for Go to step 8. Go to step 7.
proper operation.
1. Enter the Diagnostics Menu.
2. Touch FINISHER TESTS.
3. Touch Sensor Test.
4. Touch Cover and Door.
5. Touch Cover F bridge unit top.

Does the operator panel display change every time the

detection point of the sensor (bridge unit top cover
interlock) is blocked?

7 Is the sensor (bridge unit top cover interlock) Replace the Replace the
connected properly? sensor (bridge connection.
unit top cover
interlock).
Go to “Sensor
(bridge unit top
cover interlock)
removal” on
page 4-15.

8 Does the error still occur when the power is turned on? Go to step 9. Problem solved.

9 Replace the finisher controller card assembly. Replace the Problem solved.
printer engine
Go to “Finisher controller card assembly removal” card assembly.
on page 4-116. Refer to the
Does the error still occur when the power is turned on? Printer Service
Manual.

Diagnostic information 2-91

7500-432, -632, and -832

Finisher front door open

Step Check Yes No

1 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
removal” on
page 4-27.

2 Check the switch (finisher front door interlock) Go to step 3. Reinstall the
installation switch (finisher
front door
Is the switch (finisher front door interlock) installed interlock).
properly?
Go to “Switch
(finisher front
door interlock)
removal” on
page 4-26.

3 Check the switch (finisher front door interlock) for Go to step 5. Go to step 4.
proper operation.
1. Enter the Diagnostics Menu.
2. Touch FINISHER TESTS.
3. Touch Sensor Test.
4. Touch Cover and Door.
5. Touch Door G fin front.

Does the operator panel display change every time the

detection point of the switch (finisher front door
interlock) is pressed by the tip of the screwdriver?

4 Is the switch (finisher front door interlock) connected Replace the Replace the
properly? switch (finisher connection.
front door
interlock).
Go to “Switch
(finisher front
door interlock)
removal” on
page 4-26.

5 Does the error still occur when the power is turned off Go to step 6. Problem solved.
and back on?

6 Replace the finisher controller card assembly. Replace the Problem solved.
printer engine
Go to “Finisher controller card assembly removal” card assembly.
on page 4-116. Refer to the
Does the error still occur when the power is turned off Printer Service
and back on? Manual.

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Finisher eject cover open

Step Check Yes No

1 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).

2 Check the operation of the switch (eject cover Go to step 4. Go to step 3.

interlock).
1. Enter the Diagnostics Menu.
2. Touch FINISHER TESTS.
3. Touch Sensor Test.
4. Touch Cover and Door.
5. Touch Surface H fin eject.

Does the operator panel display change every time the

actuator of the switch is activated?

3 Is the switch (media cover interlock) connected Replace the Replace the
properly? switch (eject connection.
cover interlock).
Go to “Switch
(eject cover
interlock)
removal” on
page 4-68.

4 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 4-116.

Finisher upper media bin full

Step Check Yes No

1 Check the sensor (upper media bin full) for proper Replace the Go to step 2.
operation. finisher controller
card assembly.
1. Enter the Diagnostics Menu.
2. Touch FINISHER TESTS. Go to “Finisher
3. Touch Sensor Test. controller card
assembly
4. Touch Bin Level. removal” on
5. Touch Fin upper bin full. page 4-116.

Does the display of the operator panel change every

time a piece of white media is placed over the sensing
area of the sensor (upper media bin full)?

Diagnostic information 2-93

7500-432, -632, and -832

Step Check Yes No

2 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 4-106.

3 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 4-116.

No punch waste box.

Step Check Yes No

1 Check the sensor (punch waste box present) for proper Go to step 2. Reinstall the
operation. sensor (punch
waste box set.
Is the sensor installed properly?
Go to “Sensor
(punch waste
box set)
removal” on
page 4-52.

2 Check the sensor (punch waste box set). Go to step 4. Go to step 3.

Perform sensor (punch waste box set) test.
1. Enter the Diagnostics Menu.
2. Touch FINISHER TESTS.
3. Touch Sensor Test.
4. Touch Punch and Staple.
5. Touch Punch box set.

Open the finisher front door.

Remove the punch waste box.
Does the operator panel display change every time the
sensing area of the sensor (punch waste box set) is
blocked?

3 Is the sensor (punch waste box set) properly Replace the Replace the
connected? sensor (punch connection.
waste box set).
Go to “Sensor
(punch waste
box set)
removal” on
page 4-52.

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Step Check Yes No

4 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 4-115.
Go to step 5.

5 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 4-116.

Punch waste box full

Step Check Yes No

1 Check the sensor (punch waste box full) for correct Go to step 2. Reinstall the
installation. sensor (punch
waste box full).
Is the sensor installed properly?
Go to “Sensor
(punch waste
box full)
removal” on
page 4-53.

2 Check the sensor (punch waste box full). 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 waste box full.

Open the finisher front door.

Remove the punch waste box.
Insert a sheet of white media into the sensing area of
the sensor (punch waste box full).
Does the operator panel display change every time the
sensing area of the sensor (punch waste box full) is
blocked?

3 Perform a print test. Replace the Replace the

sensor (punch connection.
Does the error still occur? waste box full).
Go to “Sensor
(punch waste
box full)
removal” on
page 4-53.

Diagnostic information 2-95

7500-432, -632, and -832

Step Check Yes No

4 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 4-116.

Stacker media bin full (mix size)

Step Check Yes No

1 Check the stacker bin for obstructions. Remove the Go to step 2.

obstructions.
Are there any obstructions on the upper and lower
parts of the stacker bin?

2 Check the sensor (stacker bin level 1) 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 Bin Level.
5. Touch Stacker bin level1.

Does the operator panel display change every time the

sensing area of the sensor (stacker bin level 1) is
blocked by a multiple page document or your finger?

3 Is the sensor (stacker bin level 1) connected properly? Replace the Replace the
sensor (stacker connection.
bin level 1).
Go to “Sensor
(stacker bin
level 1)
removal” on
page 4-34.

4 Check the sensor (stacker bin level2) 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 Bin Level.
5. Touch Stacker bin level2.

Does the operator panel display change every time the

sensing area of the sensor (stacker bin level 2) is
blocked by a piece of media or your finger?

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Step Check Yes No

5 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 4-34.

6 Check the encoder of the sensor (stacker bin level Go to step 7. Replace the
encoder) installation. encoder.
Is the encoder installed properly?
Does it enter the detection point of the sensor (stacker
bin level encoder)?

7 Check the sensor (stacker bin level encoder) for proper Go to step 9. Go to step 8.
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 operator panel display change when the belt

of the stacker bin lift motor assembly is moved by
hand?

8 Is the sensor (stacker bin level encoder) connected Replace the Replace the
properly? sensor (stacker connection.
bin level
encoder).
Go to “Sensor
(stacker bin
level encoder)
removal” on
page 4-35.

9 Check the stacker bin lift motor assembly by blocking Replace the Go to step 10.
the lower hole in either of the sensors (stacker bin finisher controller
level). The stacker bin should lower slightly. card assembly.
Does the stacker bin lift motor assembly operate Go to “Finisher
properly? controller card
assembly
removal” on
page 4-116.

10 Is the stacker bin lift motor assembly connected Replace the Replace the
properly? stacker bin lift connection.
motor assembly.
Go to “Stacker
bin lift motor
assembly
removal” on
page 4-38.

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7500-432, -632, and -832

Step Check Yes No

11 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 4-116.

Stacker media bin full (no mix)

Step Check Yes No

1 Check the stacker bin for obstructions. Remove the Go to step 2.

obstructions.
Are there any obstructions on the upper and lower
parts of the stacker bin?

2 Check the sensor (stacker bin level 1) 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 Bin Level.
5. Touch Stacker bin level1.

Does the operator panel display change every time the

sensing area of the sensor (stacker bin level 1) is
blocked by a multiple page document or your finger?

3 Is the sensor (stacker bin level 1) installed properly? Replace the Replace the
sensor (stacker connection.
bin level 1).
Go to “Sensor
(stacker bin
level 1)
removal” on
page 4-34.

4 Check the sensor (stacker bin level2) for proper Go to step 5. Go to step 6.
operation.
1. Enter the Diagnostics Menu.
2. Touch FINISHER TESTS.
3. Touch Sensor Test.
4. Touch Bin Level.
5. Touch Stacker bin level2.

Does the operator panel display change every time the

sensing area of the sensor (stacker bin level 2) is
blocked by a piece of media or your finger?

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Step Check Yes No

5 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 4-34.

6 Check the encoder of the sensor (stacker bin level Go to step 7. Replace the
encoder) installation. encoder.
Is the encoder installed properly?
Does it enter the detection point of the sensor (stacker
bin level encoder)?

7 Check the sensor (stacker bin level encoder) for proper Go to step 9. Go to step 8.
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 operator panel display change when the belt

of the stacker bin lift motor assembly is moved by
hand?

8 Is the sensor (stacker bin level encoder) connected Replace the Replace the
properly? sensor (stacker connection.
bin level
encoder).
Go to “Sensor
(stacker bin
level encoder)
removal” on
page 4-35.

9 Check the stacker bin lift motor assembly for proper Go to step 11. Go to step 10.
operation.
Check the above motor by blocking the lower hole in
either of the sensors (stacker bin level). The stacker
bin should lower slightly.
Does the stacker bin lift motor assembly operate
properly?

10 Is the stacker bin lift motor assembly connected Replace the Replace the
properly? stacker bin lift connection.
motor assembly.
Go to “Stacker
bin lift motor
assembly
removal” on
page 4-38.

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Step Check Yes No

11 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 4-116.

Stacker lower safety failure

Step Check Yes No

1 Check the vertical transport mechanism of the stacker Remove Go to step 2.

bin for obstructions and deformation. obstructions.
Are there any obstructions in the vertical transport
mechanism of the stacker bin?

2 Is there any deformation in the vertical transport Replace Go to step 3.

mechanism of the stacker bin? deformed part.

3 Check the sensor (stacker bin level 1) 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 Bin Level.
5. Touch Stacker bin level1.

Does the operator panel display change every time the

sensing area of the sensor (stacker bin level 1) is
blocked by a multiple page document or your finger?

4 Is the sensor (stacker bin level 1) connected properly? Replace the Replace the
sensor (stacker connection.
bin level 1).
Go to “Sensor
(stacker bin
level 1)
removal” on
page 4-34.

5 Check the sensor (stacker bin level2) for proper Go to step 7. Go to step 6.
operation.
1. Enter the Diagnostics Menu.
2. Touch FINISHER TESTS.
3. Touch Sensor Test.
4. Touch Bin Level.
5. Touch Stacker bin level2.

Does the operator panel display change every time the

sensing area of the sensor (stacker bin level 2) is
blocked by a piece of media or your finger?

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Step Check Yes No

6 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 4-34.

7 Check the stacker bin lift motor assembly by blocking Go to step 9. Go to step 8.
the lower hole in either of the sensors (stacker bin
level). The stacker bin should lower slightly.
Does the stacker bin lift motor assembly operate
properly?

8 Is the stacker bin lift motor assembly connected Replace the Replace the
properly? stacker bin lift connection.
motor assembly.
Go to “Stacker
bin lift motor
assembly
removal” on
page 4-38.

9 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 4-116.

Stacker set over count failure

Step Check Yes No

1 Check connectors of the finisher controller card Go to step 3. Replace the

assembly connection. connection.
Are all the connectors connected to the finisher
controller card assembly properly connected?

2 Does the error still occur when the power is turned on? Go to step 3. Problem solved.

3 Replace the finisher controller card assembly. Replace the Problem solved.
printer engine
Go to “Finisher controller card assembly removal” card assembly.
on page 4-116. Refer to the
Does the error still occur when the power is turned on? Printer Service
Manual.

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Staple cartridge empty

Step Check Yes No

1 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.

2 Check the staple cartridge for correct installation. Go to step 3. Install the staple
cartridge
Is the staple cartridge installed properly? properly.

3 Check the staple cartridge for damage. Go to step 4. Replace the

staple cartridge.
Is the staple cartridge damaged?

4 Check the sensor (low staple) for proper operation. Go to step 6. Go to step 5.
1. Enter the Diagnostics Menu.
2. Touch FINISHER TESTS.
3. Touch Punch and Staple.
4. Touch Low Staple.

Does the operator panel display change every time an

undamaged and filled staple cartridge is removed and
reinserted into the stapler unit assembly?

5 Check the stapler unit cable assembly connection. Replace the Replace the
stapler unit connection.
Are all the connections of the stapler unit cable assembly.
assembly connected properly?
Go to “Stapler
unit assembly
removal” on
page 4-56.

6 Perform a stapled print test. Replace the Problem solved.

finisher controller
Does the error still occur? card assembly.
Go to “Finisher
controller card
assembly
removal” on
page 4-116.

7 Perform a stapled print test. Replace the Problem solved.

printer engine
card assembly.
Refer to the
Printer Service
Manual.

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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. Turn off the printer. The Diagnostics Menu group consists of menus,
2. Press and hold the 3 and 6 settings, and operations that are used to diagnose
buttons simultaneously. various printer problems.
3. Turn on the printer. Note: While the Diagnostics Menu Group is active,
4. Release the buttons after 10 all host interfaces are offline.
seconds. See “Entering Diagnostics Menus” on page 3-2
for more information.

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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 See “MOTOR TESTS” on page 3-4.

Finisher Motor Tests

Motor (entrance/paddle)
Motor (buffer/transport)
Motor (exit)
Fin diverter solenoid
Sub paddle solenoid
Media eject clutch
Media eject clamp mtr
Media eject mtr
Fin Buffer solenoid
Punch carriage shift mtr
Punch unit mtr
Front tamper mtr
Rear tamper mtr
Stapler carriage mtr
Stapler unit mtr
Stacker lift motor
Booklet end guide drive motor
Booklet paddle drive motor
Booklet front tamper motor
Booklet rear tamper motor
Booklet folder/exit drive motor
Booklet media entrance drive motor
Booklet knife solenoid
Booklet bin media transport motor
Bridge unit drv mtr
Booklet diverter gate solenoid
Booklet stapler motor
OUTPUT BIN TESTS
Feed to All Bins See “Feed Tests (output bins)” on page 3-4.

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Feed Tests See “Feed To All Bins” on page 3-5.

FINISHER TESTS
Staple Test See “Staple Test” on page 3-5.
Hole Punch Test See “Hole Punch Test” on page 3-6.
Feed Tests See “Feed Tests (Finisher)” on page 3-6.
Sensor Tests See “Sensor Test (Finisher)” on page 3-6.
PRINTER SETUP
Defaults See “Defaults” on page 3-9.
Prt Color Pg Count See “Printed Color Page Count” on page 3-9.
Prt Mono Pg Count See “Printed Mono Page Count” on page 3-10.
Perm Page Count See “Permanent Page Count” on page 3-10.
Serial Number See “Serial Number” on page 3-10.
Engine Setting 1 to 4 See “Engine Setting 1 to 4” on page 3-10.
Model Name See “Model Name” on page 3-10.
Configuration ID See “Configuration ID” on page 3-10.
EVENT LOG
Display Log See “Display the Event Log” on page 3-12.
Print Log See “Print the Event Log” on page 3-13.
Clear Log See “Clear the Event Log” on page 3-13.
Booklet Fold Adj See “Booklet Fold Adjust” on page 3-17.
Booklet Tamper Shift Adj
Booklet Compile Position
Booklet 2-sheet
Booklet 15-sheet
Booklet Fold Pos Fine Adj
Booklet Staple Pos Fine Adj
Finisher Config See “Finisher Config” on page 3-17.
Exit Diagnostics Menu See “Exiting Diagnostics Menu” on page 3-18.

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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:

• Motor (entrance/paddle) • Stacker lift motor
• Motor (buffer/transport) • Booklet end guide drive motor
• Motor (exit) • Booklet paddle drive motor
• Fin diverter solenoid • Booklet front tamper motor
• Sub paddle solenoid • Booklet rear tamper motor
• Media eject clutch • Booklet folding/exit drive motor
• Media eject clamp mtr • Booklet media entrance drive motor
• Media eject mtr • Booklet transport motor
• Fin Buffer solenoid • Booklet knife solenoid
• Punch carriage shift mtr • Booklet bin media transport motor
• Punch unit mtr • Bridge unit drv mtr
• Front tamper mtr • Booklet diverter gate solenoid
• Rear tamper mtr • Booklet stapler motor
• Stapler carriage mtr • Bridge unit bin media exit solenoid
• Stapler unit mtr •

3. During the test, Motor Running... appears on the LCD.

Note: If available, Forward and Reverse options appear on the LCD for selected tests.

Press Stop to stop the test.

OUTPUT BIN TESTS

Feed Tests (output bins)

Use these tests to verify that media can be fed to a specific output bin. Media is fed from the default input source
to the selected output bin. No information is printed on the media fed to the output bin because the printhead is
not engaged during this test. These tests can use any media size or envelope supported by the printer.

To run the Feed Tests for the output bins:

1. Touch OUTPUT BIN TESTS from the Diagnostics Menu.

2. Touch Feed Tests.
3. Touch the output bin you want the paper to exit into. The standard bin as well as any output option bin
installed on the printer is shown on the menu.
• Standard Bin
• Output Bin 1
• Output Bin 2
4. Touch either Single or Continuous.
• Single—Feeds one sheet of media from the selected source.
• 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.

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Feed To All Bins

This test can be used to verify that the printer can feed media to the standard bin or any installed output options.
No information will be printed on the test pages, as the printhead is not engaged during the feed test. The media
feeds from the default paper source.

To run the Feed To All Bins Test:

1. Touch OUTPUT BIN TESTS from the Diagnostics Menu.

2. Touch Feed To All Bins.

The printer feeds media from the default source to each installed bin. After the test is selected, the printer feeds
a separate piece of media to the standard bin first, then it feeds a separate piece of media to each output bin
installed. While this test runs, All Bin Test Feeding... appears on the LCD.

The test is continuous until Stop is pressed. If a test is canceled, All Bin Test Canceled... appears
on the LCD and feeds any remaining media in the paper path to the appropriate output destination.

Press Stop to exit the test.

FINISHER TESTS

Staple Test

This test is used to verify the functioning of the finisher’s staple mechanism.

To run the Staple Test

1. Touch FINISHER TESTS from the Diagnostics Menu.

2. Touch Staple Test.

The printer feeds eight pieces of media from the default input source to the output bin that supports stapling.
After all eight pieces of media are deposited, the device staples the packet. While this test runs, Staple Test
Running... appears on the LCD.

Press Stop to cancel the test.

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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. Touch Hole Punch Test.
3. Touch 3 Punch Test.

Eight sheets of paper are fed, and then the pages are hole-punched with a 2-hole or 3-hole pattern depending
on the selected punch test. Media is initially requested from the default input source and then output to the
Finisher output bin.

The Hole Punch Test cannot be canceled. No buttons are active during this test. During the test, Hole Punch
Test Running... appears on the LCD. After completion of the test, the display returns to the Hole Punch Test
screen.

Feed Tests (Finisher)

This test is used to verify that media can be fed to a finisher output bin. This test feeds one sheet of media from
the printer’s default input source to a finisher output bin. The device can perform this test using any paper size
that is supported by the finisher. No information is printed on the test page.

To run the Feed Test:

1. Touch FINISHER TESTS from the Diagnostics Menu.

2. Touch Feed Tests.

You cannot specify the output bin to which the device will feed the test page. Once begun, the Feed Test cannot
be canceled. No buttons are active during the test. During this test, Feed Test Running... appears on the
LCD.

Sensor Test (Finisher)

This test verifies that the sensors in the finisher are operating properly.

To run the Sensor Test:

1. Touch FINISHER TESTS from the Diagnostics Menu.

2. Touch Sensor Test.

The LCD displays the option’s name in the header row and each of the option’s sensors below the header row.
You must select a specific sensor from this list in order to view and toggle the sensor’s state. After selecting a
specific sensor, [Sensor Name] Testing... appears on the LCD with the sensor’s current state below this
message. The tables below indicate which sensors are available for testing.

Available Cover and Door Sensors

Sensor Name
Door G fin front
Surface H fin eject cover
Cover F bridge top

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Available Bin Level Sensors

Sensor Name
Fin upper 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 media ent
Bridge media exit
Fin media enter
Buffer path
Upper media exit
Lower media exit
Compiler media in

Available Media Path 2 Sensors

Sensor Name
Diverter gate
Front tamper hp
Rear tamper hp
Eject clamp hp
Media eject shaft hp

Available Punch and Staple Sensors

Sensor Name
Punch side reg1
Punch side reg2
Punch box set
Punch waste full
Low staple
Punch carriage shift hp
Punch unit hp
Stapler carriage shift hp
Punch cam front
Punch hole select

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Available Booklet Path Sensors

Sensor Name
Booklet end guide HP
Booklet knife HP
Booklet knife folding
Booklet front tamper HP
Booklet rear tamper HP
Booklet unit media entrance
Booklet unit media exit
Booklet bin media present
Booklet compiler media in
Booklet unit interlock
Booklet front low staple
Booklet rear low staple

After selecting one of the available sensors, you can manually toggle the sensor between its two values (Open or
Closed). The LCD displays Open when the sensor is open, and Closed when the sensor is closed.

Press Stop to exit the test.

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PRINTER SETUP

To enter the PRINTER SETUP screen, touch PRINTER SETUP from the Diagnostics Menu. The following
graphic appears on the LCD:

PRINTER SETUP
Defaults U.S.

Printed Page Count 24

Perm Page Count 0

Serial Number NV26T470

Envelope Entrance Medium

Engine Setting 1 0

? Submit Back

Defaults

The value of this setting determines whether the printer uses the US or Non-US factory default value for the
printer settings listed below:

Printer Setting US Value Non-US Value

Paper Sizes Letter A4
(applies only to input sources which do not have hardware size
sensing capability)
Envelope Size 10 Envelope DL Envelope
(applies only to envelope feeding sources which do not have
hardware size sensing capability)
PCL Symbol Set PC-8 PC-850
PPDS Code Page 437 850
Universal Units of Measure Inches Millimeters

Touch Submit to change the value of this setting, then the LCD returns to the Diagnostics menu. To return to the
PRINTER SETUP menu without changing the value of this setting, touch Back.

Printed Color 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.

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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.

Serial Number

This printer setting records the printer’s serial number that was assigned by the manufacturer. When you select
this setting, a replica of a keyboard appears on the LCD that enables you to edit the serial number.

Engine Setting 1 to 4

These settings are used by Engine code ECs to fix field problems.

Warning: Do not change these settings unless requested to do so by your next level of support.

Model Name

The model name can only be viewed and cannot be changed.

Configuration ID

The two configuration IDs are used to communicate information about certain areas of the printer that cannot be
determined using hardware sensors. The configuration IDs are originally set at the manufacturer, however you
may need to reset Configuration ID 1 or Configuration ID 2 when you replace the printer engine card assembly.
This printer uses two Configuration IDs, each of which consists of eight digits. The first seven digits in each ID
are hexadecimal numbers, while the last digit is a checksum of the preceding seven hexadecimal digits. Each ID
can contain a combination of the digits 0 through 9 and the characters A to F.

If the printer’s firmware detects that either of the printer’s Configuration IDs has not been defined or is invalid,
then the following occurs:

1. The firmware automatically uses the Configuration IDs defined for the printer’s standard model.
2. The Configuration ID setting is the only item that appears when you open the Diagnostics menu.
3. When the printer is not in Diagnostics mode, Check Config ID appears on the LCD.
Note: Each of the above conditions will remain until a valid value is entered for Configuration ID 1 and
Configuration ID 2.

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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.
vga

Config ID1 CC 00 01 81
Config ID2 B0 55 70 0C

1 2 3 a b

4 5 6 c d

7 8 9 e f

? Submit Back

2. To change the value of Configuration ID 1, touch the Backspace key to erase any of the existing
characters. Then enter the correct ID using the number and letter keys that appear on the screen.
3. To edit the value of Configuration ID 2, touch a section of the display screen that appears inside of the text
box containing the current value of Configuration ID 2. The cursor appears in the text box containing the
current value of Configuration ID 2.
4. To change the value of Configuration ID 2, touch the Backspace key to erase any of the existing
characters. Then enter the correct ID using the number and letter keys that appear on the screen.
Note: To exit the Configuration ID screen and return to the PRINTER SETUP menu, touch Back.
Note: Although it is recommended that all unused and reserved bits be set to zero, the code will not validate or
enforce this condition.
5. To save the values of both Configuration IDs, touch Submit. The printer validates both IDs. If either ID is
invalid, the printer posts Invalid ID, discards any changes, and displays the original Configuration IDs.
If both IDs are valid, the printer automatically returns to the PRINTER SETUP menu.

EVENT LOG

The exact number of events recorded in the Event Log will vary since each event requires a different amount of
storage space. When the Event Log requires more space to record an event, it overwrites the oldest currently
logged event(s) and inserts the new event into the first log position. Consecutive log entries may be identical if
the same event occurred twice in a row.

The Event Log records the following types of events:

• All 9xx Service Errors

• 2xx Paper Jams

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• 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. For the most comprehensive information about each logged event,
print the Event Log. See “Print the Event Log” on page 3-13.

Touch Display Log, and a graphic similar to the following appears on the LCD:

Each logged event is identified by the text that appeared when the event occurred. For instance, if the log
recorded a 900 Service Error, the Display Log would show 900 Service RIP Software. Log entries appear
in chronological order.

If additional log entries exist, touch to view the next log entries. Continue following this procedure until you
reach the end of the logged entries. To view earlier log entries, touch .

Touch Back to return to the EVENT LOG.

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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 X854e XXX-XXXX

Printer information

Panel display
when error occurred
Page count

Earliest error code

Next error code

As the Event Log report prints, Printing EVENT LOG appears on the LCD.

Clear the Event Log

To clear the Event Log:

1. Touch Event Log from the Diagnostics Menu.

2. Touch Clear Log.

Yes and No appears on the menu. If you touch Yes, Deleting EVENT LOG appears on the LCD and erases
all Event Log information, including information from the printed report. Touch No to cancel deletion and return
to the EVENT LOG menu, or touch Back to exit Clear Log and return to the EVENT LOG menu.

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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. Ideally, the borders
should be centered on the page.

To perform the ENGINE ADJUST settings:

1. Select ENGINE ADJUST from the Diagnostics Menu.

The following tests appear on the LCD:

Select the
Then select: ( Appears on the LCD:
following:
PH Adjust Adj Side Reg ALL (appears on LCD) Registration values appear on the
(Media tray LCD. If required, reset the values
registration) (Adj side reg all trays) and Select to submit the changes.
Adj Side Reg MSI (appears on LCD) Registration values appear on the
LCD. If required, reset the values
(Adj side reg MPF) and Select to submit the changes.
Adj Side Reg DUP (appears on LCD) Registration values appear on the
LCD. If required, reset the values
(Adj side reg duplex) and Select to submit the changes.

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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. If required, reset the values
(Adj lead reg tray 1 - plain/color) and Select to submit the changes.
Adj Lead Reg MSI165 (appears on LCD) Registration values appear on the
LCD. If required, reset the values
(Adj lead reg MPF - plain/color) and Select to submit the changes.
Adj Lead Reg MSIhp2 (appears on LCD) Registration values appear on the
LCD. If required, reset the values
(Adj lead reg MPF - heavy weight 2) and Select to submit the changes.
Adj Lead Reg DUP165 (appears on LCD) Registration values appear on the
LCD. If required, reset the values
(Adj lead reg duplex - plain/color) and Select to submit the changes.
MSI Guide Max Val (appears on LCD) Registration values appear on the
LCD. If required, reset the values
(MPF guide maximum analog - value) and Select to submit the changes.
MSI Guide Min Val (appears on LCD) Registration values appear on the
LCD. If required, reset the values
(MPF guide minimum analog - value) and Select to submit the changes.
Adj Side Reg Tr1 (appears on LCD) Registration values appear on the
LCD. If required, reset the values
(Adj side reg tray 1) and Select to submit the changes.
Adj Side Reg Tr2 (appears on LCD) Registration values appear on the
LCD. If required, reset the values
(Adj side reg tray 2) and Select to submit the changes.
Adj Side Reg Tr3 (appears on LCD) Registration values appear on the
LCD. If required, reset the values
(Adj side reg tray 3) and Select to submit the changes.
Adj Side Reg Tr4 (appears on LCD) Registration values appear on the
LCD. If required, reset the values
(Adj side reg tray 4) and Select to submit the changes.
Adj Side Reg ALLtr (appears on LCD) Registration values appear on the
LCD. If required, reset the values
(Adj side reg all trays) and Select to submit the changes.
Adj Lead Reg Trhp1 (appears on LCD) Registration values appear on the
LCD. If required, reset the values
(Adj lead reg tray 1 - heavy weight 1) and Select to submit the changes.
Adj Lead Reg MSIhp (appears on LCD) Registration values appear on the
LCD. If required, reset the values
(Adj lead reg MPF - heavy weight 1) and Select to submit the changes.
Adj Lead Reg Duphp1 (appears on LCD) Registration values appear on the
LCD. If required, reset the values
(Adj lead reg duplex - heavy weight 1) and Select to submit the changes.
Adj Lead Reg Tr208 (appears on LCD) Registration values appear on the
LCD. If required, reset the values
(Adj lead reg tray 1 - plain/BW) and Select to submit the changes.
Adj Lead Reg MSI208 (appears on LCD) Registration values appear on the
LCD. If required, reset the values
(Adj lead reg MPF - plain/BW) and Select to submit the changes.
Adj Lead DUP 208 (appears on LCD) Registration values appear on the
LCD. If required, reset the values
(Adj lead reg duplex - plain/BW) and Select to submit the changes.

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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. If
required, reset the values and Select to
( submit the changes.
Sen Grad SNR-M Registration values appear on the LCD. If
required, reset the values and Select to
submit the changes.
Sen Grad SNR-C Registration values appear on the LCD. If
required, reset the values and Select to
submit the changes.
Sen Grad SNR-K Registration values appear on the LCD. If
required, reset the values and Select to
submit the changes.
SNR Output Ref TC-Y Registration values appear on the LCD. If
required, reset the values and Select to
submit the changes.
SNR Output Ref TC-M Registration values appear on the LCD. If
required, reset the values and Select to
submit the changes.
SNR Output Ref TC-C Registration values appear on the LCD. If
required, reset the values and Select to
submit the changes.
SNR Output Ref TC-K Registration values appear on the LCD. If
required, reset the values and Select to
submit the changes.
ATC Sensor Adjust Cycle Testing... Pass

RegCon (color registration)

This procedure is used to adjust the printhead color registration.

Select RegCon Adjust

Appears on the LCD:
and then select:
Measurement Cycle Reg Measuring Testing...
Control Sensor Check Reg Control Sensor Testing...
Control Sensor Cycle Reg Control Sensor Correction Testing...
Belt Edge Learn Belt Edge Learn Testing...

Select RegCon Adjust

Then select: Appears on the LCD:
and then select:
Control Setup Cycles Skew Fine Setup Skew Fine Setup Testing...
IN/OUT Setup IN/OUT Setup Testing...
Center Setup Center Setup Testing...
Skew Rough Setup Skew Rough Setup Testing...
Cycle Result Value Cycle Result Values appear on the LCD.

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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. If required, reset the values and submit.
Booklet 2-sheet Booklet 2-sheet values appear on the LCD. If
required reset the values and submit.
Booklet 15-sheet Booklet 15-sheet values appear on the LCD. If
required reset the values and submit.
Booklet Staple Fold Fine Adjust Booklet Staple Fold Fine Adjust values appear
on the LCD. If required, reset the values and
submit.
Booklet Staple Pos Fine Adjust Booklet Staple Fold Fine Adjust values appear
on the LCD. If required, reset the values and
submit.
Booklet Tamper Shift Adjust Booklet Staple Fold Fine Adjust values appear
on the LCD. If required, reset the values and
submit.

Finisher Config

To perform Finisher Config:

1. Select Finisher Config from the Diagnostics Menu.

Finisher Config values appear on the LCD. If required, reset the values and submit.

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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:

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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:
• Keep the ESD-sensitive part in its original shipping container (a special “ESD bag”) until you are ready to
install the part into the machine.
• Make the least-possible movements with your body to prevent an increase of static electricity from clothing
fibers, carpets, and furniture.
• Put the ESD wrist strap on your wrist. Connect the wrist band to the system ground point. This discharges
any static electricity in your body to the machine.
• Hold the ESD-sensitive part by its edge connector shroud (cover); do not touch its pins. If you are removing
a pluggable module, use the correct tool.
• Do not place the ESD-sensitive part on the machine cover or on a metal table; if you need to put down the
ESD-sensitive part for any reason, first put it into its special bag.
• Machine covers and metal tables are electrical grounds. They increase the risk of damage because they
make a discharge path from your body through the ESD-sensitive part. (Large metal objects can be
discharge paths without being grounded.)
• Prevent ESD-sensitive parts from being accidentally touched by other personnel. Install machine covers
when you are not working on the machine, and do not put unprotected ESD-sensitive parts on a table.
• If possible, keep all ESD-sensitive parts in a grounded metal cabinet (case).
• Be extra careful in working with ESD-sensitive parts when cold-weather heating is used, because low
humidity increases static electricity.

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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.
Note: Parts are controlled as spare parts. When servicing parts for which no procedure is described,
observe the assembly before starting the service.
Note: Though the optional parts are assumed to be removed, they may not be removed if not required for the
purpose of service.

Before starting service work

• Turn the power off, and remove the power cord from the outlet.
• While performing service around the fuser assembly, ensure the fuser area has cooled down.
• Do not use excessive force to remove parts. Damage to the parts or function of the machine may occur.
• A wide variety of screws are used; make note of their positions during service.
• Wear a wrist band to remove the risk of static electricity.

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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
A

Right

Rear
3. Remove the bridge unit hookup cover (A).
4. Disconnect the bridge unit connection from the finisher.

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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.

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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.

Boss
D C

Bridge unit assembly removal

1. Release the hook securing the bridge unit hookup cover (A) to the finisher.
2. Remove the bridge unit hookup cover (A).

3. Remove the finisher from the printer.

4. Remove the two screws securing the bridge unit assembly (B) to the printer.

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5. Remove the bridge unit assembly (B) from the printer.

B

Bridge unit rear cover removal

1. Remove the bridge unit assembly. See “Bridge unit assembly removal” on page 4-5.
2. Remove the two screws securing the bridge unit rear cover (A) to the bridge unit assembly (B).

B A
3. Remove the bridge unit rear cover (A).

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Bridge unit top cover assembly removal

1. Remove the bridge unit rear cover. See “Bridge unit rear cover removal” on page 4-6.
2. Open the bridge unit top cover assembly (A).
3. Remove the six screws securing the bridge unit top cover assembly (A) to the bridge unit assembly (B).
A

B
4. Lift the bridge unit top cover assembly (A) upward in the direction of the arrow.
5. Remove the bridge unit top cover assembly (A).

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Bridge unit drive belt and bridge unit drive pulley removal

1. Remove the bridge unit rear cover. See “Bridge unit rear cover removal” on page 4-6.
2. Use a prying tool to remove the e-clip securing the bridge unit drive pulley (A) to the bridge unit
assembly (B).
3. Remove the bridge unit drive pulley (A) and the bridge unit drive belt (C) from the bridge unit assembly (B).

C
B

Replacement note: Make sure to install the bridge unit drive pulley (A) to the bridge unit assembly in the
direction shown.
Recessed key

Install this surface facing outside.

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Bridge unit right shaft assembly removal

1. Remove the bridge unit rear cover. See “Bridge unit rear cover removal” on page 4-6.
2. Remove the bridge unit transport belt and bridge unit drive pulley. See “Bridge unit drive belt and bridge
unit drive pulley removal” on page 4-8.
3. Remove the 6 mm bushing (A) from the bridge unit right shaft assembly (B).
4. Open the bridge unit top cover assembly (C).

Rear

B A
5. Use a prying tool to remove the e-clip securing the 6 mm bushing (D) to the bridge unit assembly.
6. Remove the 6 mm bushing (D).
7. Move the bridge unit right shaft assembly (B) toward the right as shown.
8. Remove the bridge unit right shaft assembly (B) from the two transport belts (E).
9. Remove the bridge unit right shaft assembly (B).
B
D

E Front

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Bridge unit left shaft assembly removal

1. Open the bridge unit top cover assembly.

2. Use a prying tool to remove the front e-clip securing the 4 mm ball bearing (A) to the bridge unit left
shaft (B).
C

Front

B A
3. Move the bridge unit left shaft (B) rearward as shown.
4. Remove the bridge unit left shaft (B) from the two transport belts (C).
5. Remove the bridge unit left shaft (B).
6. Remove the other e-clip securing the 4 mm ball bearing (A) on the other end of the shaft.
7. Remove the second 4 mm ball bearing (A) from the bridge unit left shaft.

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Bridge unit idler rolls removal

1. Open the bridge unit top cover assembly.

2. Remove the bridge unit left shaft assembly. See “Bridge unit left shaft assembly removal” on
page 4-10.
3. Move the two transport belts (A) away from the two bridge unit idler rolls (B).
4. Lift the two bridge unit idler rolls upward to release them from the bridge unit assembly (C).
5. Remove the bushings (D) from the bridge unit idler rolls.

Replacement note: When replacing the bridge unit idler rolls, make sure the bushings are installed as shown.
A

Flat D

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Bridge unit transport belt removals

1. Remove the bridge unit rear cover. See “Bridge unit rear cover removal” on page 4-6.
2. Open the bridge unit top cover assembly.
3. Remove the bridge unit right shaft assembly. See “Bridge unit right shaft assembly removal” on
page 4-9.
4. Remove the bridge unit left shaft assembly. See “Bridge unit left shaft assembly removal” on
page 4-10
5. Remove the bridge unit idler rolls. See “Bridge unit idler rolls removal” on page 4-11.
6. Remove the transport belts (A) from the bridge unit assembly (B).
A

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Bridge unit drive motor assembly removal

1. Remove the bridge unit rear cover. See “Bridge unit rear cover removal” on page 4-6.
2. Remove the bridge unit drive belt. See “Bridge unit drive belt and bridge unit drive pulley removal” on
page 4-8.
3. Disconnect the connector from the bridge unit drive motor (A).
A

Clamp

Connector

Rear
4. Release the harness from the clamp.
5. Open the bridge unit top cover assembly.
6. Remove the two screws securing the cover (B) from the bridge unit assembly (C).
7. Remove the cover (B).
8. Remove the two screws securing the bridge unit drive motor (A) to the bridge unit assembly (C).
C

9. Remove the bridge unit drive motor (A).

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Bridge unit entrance guide removal

1. Remove the bridge unit rear cover. See “Bridge unit rear cover removal” on page 4-6.
2. Open the bridge unit top cover assembly.
3. Remove the two screws securing the bridge unit entrance guide (A) to the bridge unit assembly (B).

4. Remove the bridge unit entrance guide (A).

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Sensor (bridge unit top cover interlock) removal

1. Remove the bridge unit assembly. See “Bridge unit assembly removal” on page 4-5.
2. Place the bridge unit assembly upside down.
3. Remove the screw securing the bracket (A) to the bridge unit assembly (B).
4. Disconnect the cable from the sensor (bridge unit top cover interlock) (C).

C A

Connector

5. Release the hooks securing the sensor (bridge unit top cover interlock) (C) to the bracket (A).
6. Remove the sensor (bridge unit top cover interlock) (C).

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Sensor (bridge unit media entrance) removal

1. Remove the bridge unit assembly. See “Bridge unit assembly removal” on page 4-5.
2. Place the bridge unit assembly upside down.
3. Remove the screw securing the bracket (A) to the bridge unit assembly (B).
4. Disconnect the connector from the sensor (bridge unit media entrance) (C).

C
A

B
Connector

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).

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Sensor (bridge unit media exit) removal

1. Remove the bridge unit assembly. See “Bridge unit assembly removal” on page 4-5.
2. Place the bridge unit upside down.
3. Remove the screw securing the bracket (A) to the bridge unit (B).

Connector
4. Disconnect the connector from the sensor (bridge unit media exit) (C).
5. Release the hooks securing the sensor (bridge unit media exit) (C) to the bracket (A).
6. Remove the sensor (bridge unit media exit) (C).

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Bridge unit pinch roller removal

1. Open the bridge unit top cover assembly (A).

2. Remove the six bridge unit pinch rollers (B) by gently pulling them out of the bridge unit top cover
assembly.
3. Remove the six springs (C).

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Top cover removal

1. Open the finisher front door assembly.

2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
4. Remove the four screws securing the top cover (A) to the finisher.

5. Remove the top cover (A).

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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).

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Right eject cover removal

1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-27.
2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
3. Remove the two screws securing the right eject cover (A) to the finisher.

Right

4. Remove the right eject cover (A).

Repair information 4-21

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Stacker media bin assembly removal

1. Release the two hooks securing the stacker media bin assembly (A) to the finisher.

A
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. Remove the two screws securing the right lower LVPS cover (A) to the finisher.
2. Remove the right lower LVPS cover (A).
Replacement note: Make sure to put the power cord (B) into the notch on the right lower LVPS cover (A).

Notch

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Rear lower cover removal

1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
2. Remove the four screws securing the rear lower cover (A) to the finisher.

3. Remove the rear lower cover (A).

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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

B
4. Remove the rear upper cover (B).

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Upper media bin front cover removal

1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-27.
2. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
3. Remove the two screws securing the upper media bin front cover (A).

4. Remove the upper media bin front cover (A).

Repair information 4-25

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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 4-24.
3. Remove the punch waste box (A).
4. Remove the three screws in the front securing the punch waste chute (B).
5. Gently pull down the punch waste chute (B) to gain better access to the switch (finisher front door
interlock) (C).
6. Disconnect the connector from the switch (finisher front door interlock) (C).

Connector

A C
7. Release the hooks securing the switch (finisher front door interlock) (C) to the finisher.
8. Remove the switch (finisher front door interlock) (C).

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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). The two magnetic catches (C) should properly engage the finisher.

Actuator

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Left lower cover removal

1. Open the finisher front door assembly.

2. Remove the two screws securing the left lower cover (A).

A
3. Remove the left lower cover (A).

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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).

Repair information 4-29

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Carriage lift belt left removal

1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
2. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-27.
3. Move the slip clutch gear 24T (A) toward the rear to disengage the stacker bin (B).
4. Move the stacker bin (B) down to its lowest position after being disengaged.
Note: Make sure the stacker bin is at its lowest position before continuing.
A

Rear

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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. Remove the upper belt clamp (F).
9. Remove the left carriage bracket with the carriage lift belt (G) from the finisher.
10. Release the hook securing the carriage lift belt (G) to the lower belt clamp (H).
11. Remove the carriage lift belt (G).
Replacement notes:
• Make sure the carriage lift belt (G) is inserted into the upper belt clamp (F) as shown.
• Make sure the bin bracket (C) is level to prevent binding.

Front
D
H

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Carriage lift belt right removal

1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
2. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-27.
3. Move the slip clutch gear 24T (A) toward the rear to disengage the stacker bin (B).
4. Move the stacker bin (B) to its lowest position.
Note: Make sure the stacker bin is at the lowest position before continuing.
A

Rear

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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. Remove the upper belt clamp (F).
9. Remove the right carriage bracket (D) with the carriage lift belt (G) from the finisher.
10. Release the hook securing the carriage lift belt (G) to the lower belt clamp (H).
11. Remove the carriage lift belt (G).
Replacement notes:
• Make sure the carriage lift belt (G) is inserted into the upper belt clamp (F) as shown.
• Make sure the bin bracket (C) is level to prevent binding.

Rear

D
E
H

Repair information 4-33

7500-432, -632, and -832

Sensor (stacker bin level 1) removal

1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-27.
2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
3. Disconnect the connector from the sensor (stacker bin level 1) (A).

Front
Connector
A
4. Remove the screw securing the sensor (stacker bin level 1) (A) to the finisher.
5. Remove the sensor (stacker bin level 1) (A).

Sensor (stacker bin level 2) removal

1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-27.
2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
3. Disconnect the connector from the lift tray height sensor (stacker bin level 2) (A).

Rear

Connector
A
4. Remove the screw securing the sensor (stacker bin level 2) (A).
5. Remove the sensor (stacker bin level 2) (A).

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Sensor (stacker bin level encoder) removal

1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
2. Disconnect the connector from the sensor (stacker bin level encoder) (A).
3. Release the harness from the clamp.
4. Remove the screw securing the bracket (B) from the stacker bin lift motor assembly (C).

A
Connector
B

Clamp

Clamp Rear
C
5. Release the hooks securing the sensor to the bracket (B).
6. Remove the sensor (stacker bin level encoder) (A).

Repair information 4-35

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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 4-24.
2. Remove the rear lower cover. See “Rear lower cover removal” on page 4-23.
3. Remove the stacker media bin assembly. See “Stacker media bin assembly removal” on page 4-22.
4. Remove the stacker bin lift motor assembly. See “Stacker bin lift motor assembly removal” on
page 4-38.
5. Remove the four screws securing the metal cover (A) to the finisher.
6. Remove the metal cover (A).

Right

7. Disconnect the connector from the sensor (stacker bin upper limit) (B) or the sensor (stacker bin no
media) (C).
8. Release the hooks of the selected sensor.
9. Remove the sensor.

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Replacement note: Make sure that the yellow connector is plugged into the sensor (stacker bin no media)
(C).

Rear
C

White connector

Yellow connector

Repair information 4-37

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Stacker bin lift motor assembly removal

1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
2. Remove the rear lower cover. See “Rear lower cover removal” on page 4-23.
3. Loosen the four screws securing the plate (A).
4. Move the plate (A) toward the right as shown.

Rear

5. Remove the plate (A).

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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. Disconnect the connector from the sensor (stacker bin level encoder) (D).
9. Release the harness from the clamps.
B

Clamp

Clamp

Rear

C
10. Disconnect the connector (P8305) from the finisher controller card assembly (E).

P8305

Repair information 4-39

7500-432, -632, and -832

11. Remove the screw securing the bracket (F) to the stacker bin lift motor assembly (G).
12. Remove the bracket (F).

Connector

G
Clamp

13. Release the hook securing the encoder (H) to the stacker bin lift motor assembly (G).
14. Remove the encoder.
15. Remove the three screws securing the stacker bin lift motor assembly (G) to the finisher.

16. Remove the stacker bin lift motor assembly (G).

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Punch carriage assembly removal

1. Open the finisher front door assembly.

2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
4. Remove the connector from the sensor (punch carriage shift HP) (A).
5. Remove the top cover. See “Top cover removal” on page 4-19.
6. Release the harness from the punch carriage assembly (B).
7. Remove the connector from the punch carriage shift motor assembly (C).
8. Release the two punch unit assembly harnesses from the three clamps on the rear of the finisher.
9. Disconnect the two punch unit assembly harnesses from the main harness.
10. Remove the screw securing the grounding wire (D) to the punch unit carriage assembly (B).
11. Remove the two screws on the rear securing the punch carriage assembly (B) to the finisher.

Connector
C
E B
A Connector

Clamp
Clamp

Connectors

Clamp

Rear

Repair information 4-41

7500-432, -632, and -832

12. Remove the two screws on the front securing the punch carriage assembly (B) to the finisher.

Front

B
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. Be sure to hold the unit firmly to
avoid dropping it.
Replacement notes:
Warning: Make sure the punch carriage assembly is able to shift back and forth completely without binding
the harnesses, or damage will occur.
• Do not force the punch unit into the finisher.
• Be sure to hold the punch carriage assembly firmly to avoid dropping it.
• Make sure all harnesses are properly clamped.
• Make sure the harnesses do not come into contact with any rotating mechanisms.

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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 4-20.
3. Remove the top cover. See “Top cover removal” on page 4-19.
4. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
5. Remove the punch carriage assembly. See “Punch carriage assembly removal” on page 4-41.
6. Remove the two screws securing the cover (A) to the punch carriage assembly (B).
7. Remove the cover (A).
8. Remove the two screws securing the punch carriage shift motor assembly (C) to the punch unit
assembly (B).
A

9. Remove the punch carriage shift motor assembly (C).

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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 4-24.
3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
4. Remove the top cover. See “Top cover removal” on page 4-19.
5. Remove the punch carriage assembly. See “Punch carriage assembly removal” on page 4-41.
6. Remove the screw securing the cover (A) to the punch unit assembly (B).
7. Remove the cover.
8. Remove the two screws securing the paper guide (C) to the punch unit assembly (B).
Note: Do not remove the harness attached to the paper guide (C).

B A

)
Connectors
C

9. Turn the paper guide (C) upside down.

10. Remove the two screws securing the bracket (D) to the paper guide (C).
11. Remove the bracket (D).
12. Remove the two connectors from the sensor (punch unit side registration pair) (E).
13. Release the hooks securing the sensors (punch unit side registration pair) (E) to the bracket (D).

Connectors

14. Remove the sensor (punch unit side registration pair) (E).
Note: The two sensors are identical.

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Punch unit assembly removal

1. Open the finisher front door assembly.

2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
4. Remove the top cover. See “Top cover removal” on page 4-19.
5. Remove the punch carriage assembly. See “Punch carriage assembly removal” on page 4-41.
6. Remove the screw securing the cover (A) to the punch unit assembly (B).
7. Remove the cover (A).
8. Remove the two screws securing the bracket (C) to the punch carriage assembly (D).
9. Remove the bracket (C).
10. Remove the three screws securing the punch carriage assembly (D) to the punch unit assembly (B).

C
11. Remove the punch unit assembly (B).

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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 4-24.
3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
4. Remove the top cover. See “Top cover removal” on page 4-19.
5. Remove the punch carriage assembly. See “Punch carriage assembly removal” on page 4-41.
6. Remove the punch unit assembly. See “Punch unit assembly removal” on page 4-45.
7. Remove the three screws securing the three punch media stop assemblies (A) to the punch unit
assembly (B).

8. Remove the three punch media stop assemblies (A).

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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 4-24.
3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
4. Remove the connector from the sensor (punch carriage shift HP) (A).
5. Remove the top cover. See “Top cover removal” on page 4-19.
6. Remove the punch carriage assembly. See “Punch carriage assembly removal” on page 4-41.
7. Disconnect the connector from the punch unit motor assembly (A).
8. Disconnect the connector from the sensor (punch unit motor encoder) (B).
9. Remove the harness from the clamp.
10. Remove the two screws securing the punch unit motor assembly (A) to the punch unit assembly (C).
B

Clamp A

Connector

11. Remove the punch unit motor assembly.

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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 4-24.
3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
4. Remove the top cover. See “Top cover removal” on page 4-19.
5. Remove the punch carriage assembly. See “Punch carriage assembly removal” on page 4-41.
6. Disconnect the connector from the punch unit motor assembly (A).
7. Disconnect the connector from the sensor (punch unit motor encoder) (B).
8. Remove the harness from the clamp.
9. Remove the two screws securing the bracket (C) to the punch unit assembly (D).

A
C
Clamp

Connector

D
10. Release the hooks securing the sensor (punch unit motor encoder) (B) to the bracket (C).
11. Remove the sensor (punch unit motor encoder) (B).

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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 4-24.
3. Remove the punch carriage assembly. See “Punch carriage assembly removal” on page 4-41.
4. Remove the screw securing the bracket (A) to the punch unit assembly (B).

5. Disconnect the connector from the sensor (punch hole select) (C), the sensor (punch cam front) (D), or the
sensor (punch unit HP) (E).
6. Release the hooks securing the sensor(s) to the bracket.
7. Remove the sensor(s).

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Replacement note: Make sure the color coded-connectors are connected to the proper sensors, as shown.

C
Connector

D
Blue
Black
A

Connector

White
E

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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 4-24.
3. Remove the punch carriage assembly. See “Punch carriage assembly removal” on page 4-41.
4. Remove the one screw securing the bracket (A) to the punch carriage unit (B).
5. Release the hooks securing the sensor (punch carriage shift HP) (C) to the bracket (A).
B

C
6. Remove the sensor (punch carriage shift HP) (C).

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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. Remove the sensor (punch waste box set) (A).

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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. Remove the sensor (punch waste box full) (B).

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Stapler unit frame removal

1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-27.
2. Remove the staple cartridge.
3. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
4. Remove the rear lower cover. See “Rear lower cover removal” on page 4-23.
5. Loosen the four screws securing the plate (A) to the finisher.
6. Move the plate (A) toward the right and out in the direction shown.

Rear

7. Remove the plate.

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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

B
11. Remove the media stacker bin lift motor assembly. See “Stacker media bin assembly removal” on
page 4-22.
12. Disconnect the white connector and the yellow connector from the sensor (stacker bin upper limit) and the
sensor (stacker bin no media).
13. Remove the four screws securing the stapler unit frame (D) to the finisher.
14. Move the stapler unit frame upward and outward in the direction of the arrow, as shown.

White connector

Yellow connector

Rear Front
D
15. Remove the stapler unit frame.
Warning: Do not force the stapler unit frame out of the finisher.
Warning: Be sure to hold the stapler unit frame firmly to avoid dropping it.
Replacement notes:
•Do not force the stapler unit frame into the finisher.
•Be sure to hold the stapler unit frame firmly to avoid dropping it.
•Maker sure no harnesses are pinched when replacing the stapler unit frame.
•Be sure to replace the grounding wire.
•Ensure that the white connector and the yellow connector are properly replaced.

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Stapler unit assembly removal

1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-27.
2. Remove the staple cartridge.
3. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
4. Remove the rear lower cover. See “Rear lower cover removal” on page 4-23.
5. Remove the stapler unit frame. See “Stapler unit frame removal” on page 4-54.
6. Remove the five screws securing the stapler unit frame (A) to the plate (B).

7. Remove the stapler unit frame (A).

8. Release the harness from the three clamps on the stapler unit frame (A).
9. Remove the two screws securing the stapler carriage motor assembly (C) to the stapler carriage
assembly (D).
10. Remove the stapler carriage motor assembly (C).
C

Clamp

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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. Remove the two screws securing the bracket (H) to the stapler carriage assembly (D).
16. Remove the bracket (H).
17. Remove the two screws securing the bracket (H) to the stapler unit assembly (F).

H
*1

*2

G
Ground wire
*1
*2

Connectors
18. Remove the stapler unit assembly (F).
Replacement notes:
• When replacing the stapler unit assembly (F), make sure the ground wire is reconnected.
• Make sure the stapler carriage assembly (D) and the stapler carriage motor assembly (C) move freely
without binding.

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Sensor (stapler carriage HP) removal

1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-27.
2. Remove the staple cartridge.
3. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
4. Remove the rear lower cover. See “Rear lower cover removal” on page 4-23.
5. Remove the stapler unit frame. See “Stapler unit frame removal” on page 4-54.
6. Remove the stapler unit assembly. See “Stapler unit assembly removal” on page 4-56.
7. Release the hooks securing the sensor (stapler carriage HP) (A) to the stapler carriage assembly (B).

8. Remove the sensor (stapler carriage HP) (A).

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Media eject unit assembly removal

1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-27.
2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
4. Remove the upper media bin vertical cover. See “Right eject cover removal” on page 4-21.
5. Remove the two media eject unit springs (A) by pushing them downward.
6. Disconnect the connector from the eject unit solenoid (B).
7. Release the harness from the two clamps.

Harness clamp

Connector

A
Right
B A

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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. Remove the 8 mm bushing (E) on the rear side.

Rear

D
C
E E-clip

Screw

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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. Remove the left side before the right
side.
Note: Tilting the media eject unit assembly slightly may make the removal easier.

Right

G
15. Remove the media eject unit assembly.

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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.

Right

Actuator

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Sub paddle removal

1. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
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).
A

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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 4-24.
3. Remove the media eject unit assembly. See “Media eject unit assembly removal” on page 4-59.
4. Loosen the screw securing the knob (A) to the sub paddle drive shaft assembly (B) on the front of the
finisher.
5. Remove the knob (A).
6. Remove the one e-clip securing the sub paddle drive shaft assembly (B).
7. Remove the bushing (C).

C
E-clip
Screw

Front

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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. Remove the e-clip and the 6 mm bushing (C).
12. Move the sub paddle drive shaft assembly (B) toward the rear of the finisher and outward.
13. Remove the sub paddle drive shaft assembly (B).
Replacement notes:
• The tension of the belt (exit) (F) is automatically adjusted by the force of the spring attached to the belt
tensioner bracket (D).
• Tighten the two screws in the order shown.
F
D

Rear

Tighten D
Rear second

Tighten first

C
B
E

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Media eject clamp motor assembly removal

1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
2. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
3. Remove the two media eject unit springs (A) attached to the media eject unit assembly (B) by pushing
them downward.

Right

A B
4. Disconnect the connector from the media eject clamp motor (C).
5. Disconnect the connector from the sensor (media eject clamp HP) (D).
6. Remove the three screws securing the bracket (E) to the finisher.
7. Remove the bracket (E).
Note: When removing the bracket, turn the media eject clamp gear 70T (F) so that it does not interact with
the sensor (media eject clamp HP) (D).

F
Rear

Connector
D
8. Remove the two screws securing the media eject clamp motor to the bracket (E).
9. Remove the media eject clamp motor (C).
Replacement note: When replacing the bracket, turn the media eject clamp gear 70T (F) so that it interacts
with the sensor (media eject clamp HP).

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Sensor (media eject clamp HP) removal

1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
2. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
3. Remove the two media eject unit springs attached to the media eject unit assembly by pushing them
downward.

Right
Springs
4. Remove the media eject clamp motor assembly. See “Media eject clamp motor assembly removal” on
page 4-66.
5. Release the hooks of the sensor (media eject clamp HP) (A) from the bracket (B).
6. Remove the sensor (media eject clamp HP) (A).

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Switch (eject cover interlock) removal

1. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
2. Disconnect the connector from the switch (eject cover interlock) (A).
3. Release the harness from the two clamps.
4. Remove the screw securing the bracket (B) to the finisher.
5. Remove the bracket (B) from the square hole in the finisher.
6. Remove the two screws securing the switch (eject cover interlock) (A) from the bracket (B).

Connector
A

Clamp

Right

Clamps

7. Remove the switch (eject cover interlock) (A).

Replacement note: Make sure the media eject unit assembly (C) properly actuates the switch (media eject
interlock) (A) without binding.
A

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Media compiler unit assembly removal

1. Remove the finisher front door assembly. See“Finisher front door assembly removal” on page 4-27.
2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
3. Remove the rear lower cover. See “Rear lower cover removal” on page 4-23.
4. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
5. Remove the upper media bin vertical cover. See “Right eject cover removal” on page 4-21.
6. Remove the stapler unit frame. See “Stapler unit frame removal” on page 4-54.
7. Remove the media eject clamp motor assembly. See “Media eject clamp motor assembly removal” on
page 4-66.
8. Remove the media eject unit assembly. See “Media eject unit assembly removal” on page 4-59.
9. Remove the media eject motor assembly. See “Media eject motor assembly removal” on page 4-78.
10. Loosen the four screws securing the plate (A) to the finisher.
11. Move the plate to the right and outward.

Rear

12. Remove the plate.

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13. Disconnect the connector P8309 from the finisher controller card assembly (B).
14. Release the harness from the clamps.

Clamp

P8309

Rear

B
15. Remove the screw securing the media compiler unit assembly (C) to the finisher. This screw is found inside
the finisher.

Inside view

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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.
C

Right

Front view Rear view

C C
Lock Lock
17. Remove the harness from any additional parts.
18. Remove the media compiler unit assembly through the inside of the finisher and out the front.

Sensor (front tamper HP) and sensor (rear tamper HP) removals

1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-27.
2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
3. Remove the rear lower cover. See “Rear lower cover removal” on page 4-23.
4. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
5. Remove the upper media bin vertical cover. See “Right eject cover removal” on page 4-21.
6. Remove the stapler unit frame. See “Stapler unit frame removal” on page 4-54.
7. Remove the media eject clamp motor assembly. See “Media eject clamp motor assembly removal” on
page 4-66.
8. Remove the media eject unit assembly. See “Media eject unit assembly removal” on page 4-59.
9. Remove the media eject motor assembly. See “Media eject motor assembly removal” on page 4-78.
10. Remove the media compiler unit assembly. See “Media compiler unit assembly removal” on
page 4-69.
11. Disconnect the connector from the sensor (front tamper HP) (A) or the sensor (rear tamper HP) (B).
12. Release the hooks securing the sensor (front tamper HP) (A) or the sensor (rear tamper HP) (B) from the
media compiler unit assembly (C).

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13. Remove the sensor(s).

Note: The sensors are identical.

Connector A

Sensor (compiler media in) removal

1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-27.
2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
3. Remove the rear lower cover. See “Rear lower cover removal” on page 4-23.
4. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
5. Remove the upper media bin vertical cover. See “Right eject cover removal” on page 4-21.
6. Remove the stapler unit frame. See “Stapler unit frame removal” on page 4-54.
7. Remove the media eject clamp motor assembly. See“Media eject clamp motor assembly removal” on
page 4-66.
8. Remove the media eject unit assembly. See “Media eject unit assembly removal” on page 4-59.
9. Remove the media eject motor assembly. See “Media eject motor assembly removal” on page 4-78.
10. Remove the media compiler unit assembly. See “Media compiler unit assembly removal” on
page 4-69.
11. Disconnect the connector from the sensor (compiler media in) (A).
12. Release the hooks securing the sensor (compiler media in) (A) to the compiler unit assembly (B).

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13. Move the compiler media present actuator (C) downward as shown.

Connector
A

14. Remove the sensor (compiler media present) (A).

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Media eject shaft assembly removal

1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-27.
2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
3. Move the slip clutch gear 24T (A) toward the rear as shown to disengage the stacker bin (B).
4. Move the stacker bin down as shown to its lowest position after it is disengaged.
Note: Make sure the stacker bin is at its lowest position before continuing.
5. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
6. Remove the four screws securing the right panel (C) to the finisher.
A

Rear

B
7. Remove the media eject motor assembly. See “Media eject motor assembly removal” on page 4-78.
8. Release the hook of the media eject shaft gear 39T (D) from the media eject shaft assembly (E).
9. Remove the media eject shaft gear 39T (D).
10. Remove the 6 mm bushing (F).
11. Use a prying tool to remove the e-clip securing the media eject shaft assembly (E) to the rear of the
finisher.
12. Remove the 8 mm bushing (G).
13. Remove the two e-clips securing the media eject shaft assembly (E) to the front of the finisher.
14. Remove the 6 mm bushing (F) and the 8 mm bushing (G).

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15. Move the media eject shaft assembly toward the rear and outward as shown.

C
E
G
G
E-clips
E

E-clip F )
F Front
D Rear
16. Remove the media eject shaft assembly (E).

E
Rear

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Clamp paddle removal

1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-27.
2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
3. Remove the media eject shaft assembly. See “Media eject shaft assembly removal” on page 4-74.
4. Remove the three clamp paddles (A) by sliding them out of the media eject shaft assembly (B).
B
A

Narrow
Wide

A
Right
Replacement note: Replacement is easier if you lightly moisten the rubber surface of the paddles with water.

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Media eject clutch assembly removal

1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
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. Release the harness from the clamp.
6. Release the hook securing the media eject clutch actuator (C) to the media eject clutch (B).
7. Remove the screw securing the spring clamp (D) to the finisher.

Clamp

A
Connector Connector
B
C

Notch

8. Remove the spring clamp (D).

9. Remove the media eject clutch actuator (C).
10. Remove the media eject clutch assembly (B).
Installation note: Make sure the hook on the media eject clutch assembly is placed in the notch of the
bracket.

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Media eject motor assembly removal

1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
2. Remove the media eject clutch. See “Media eject clutch assembly removal” on page 4-77.
3. Disconnect the connector from the media eject motor assembly (A).
4. Disconnect the connector from the sensor (media bin level 2) (B).
5. Remove the three screws securing the media eject motor assembly (A).

A
Connector

Rear
6. Remove the media eject motor assembly (A).
7. Remove any remaining harnesses from the clamps.

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Sensor (media eject shaft HP) removal

1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
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. Release the hooks securing the sensor (media eject shaft HP) (A) to the bracket (C).

Rear

Connector
A C
5. Remove the sensor (media eject shaft HP) (A).

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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 4-20.
3. Disconnect the connector from the sensor (lower media exit) (A).
4. Remove the harness from the clamps.
5. Remove the two screws securing the bracket (B) to the finisher.

Clamp

Connector

Front

A B
Note: The upper media bin vertical cover (C) has slots that make access to the screws easier, as shown.

Right

B Access slots

A
6. Remove the bracket (B).
7. Release the hooks securing the sensor (lower media exit) (A) to the bracket.
8. Remove the sensor (lower media exit) (A).

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Lower media exit roll assembly removal

1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-27.
2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
4. Remove upper media bin vertical cover. See “Right eject cover removal” on page 4-21.
5. Remove the rear lower cover. See “Rear lower cover removal” on page 4-23.
6. Remove the stapler unit frame. See “Stapler unit frame removal” on page 4-54.
7. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
8. Remove the upper media bin vertical cover. See “Right eject cover removal” on page 4-21.
9. Remove the stapler unit frame. See “Stapler unit frame removal” on page 4-54.
10. Remove the media eject clamp motor assembly. See “Media eject clamp motor assembly removal” on
page 4-66.
11. Remove the media eject unit assembly. See “Media eject unit assembly removal” on page 4-59.
12. Remove the media compiler unit assembly. See “Media compiler unit assembly removal” on
page 4-69.
13. Remove the media eject clutch. See “Media eject clutch assembly removal” on page 4-77.
14. Remove the media eject motor assembly. See “Media eject motor assembly removal” on page 4-78.
15. Remove the media eject shaft assembly. See “Media eject shaft assembly removal” on page 4-74.
16. Remove the main paddle shaft assembly. See “Paddle and roll exit assembly removal” on page 4-85.
17. Loosen the two screws securing the belt tensioner bracket (A) to the finisher, and move the bracket down in
the direction of the arrow.
18. Remove the belt (exit) (B) from the lower exit roll drive pulley 20T (C).
B
A

Rear

Tighten A
second
C

Tighten
first

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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).

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21. Remove the 6 mm ball bearing (G).

F G
C

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.

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23. Remove the 6 mm bushing (H).

E-clip
H
Front
24. Move the lower media exit roll assembly (F) towards the rear and outward, as shown.

Rear
G
25. Remove the lower media exit roll assembly (F).

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Paddle and roll exit assembly removal

1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-27.
2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
3. Remove the rear lower cover. See “Rear lower cover removal” on page 4-23.
4. Remove the upper media bin assembly. See“Upper media bin assembly removal” on page 4-20.
5. Remove the upper media bin vertical cover. See “Right eject cover removal” on page 4-21.
6. Remove the stapler unit frame. See “Stapler unit frame removal” on page 4-54.
7. Remove the media eject clamp motor assembly. See“Media eject clamp motor assembly removal” on
page 4-66.
8. Remove the media eject unit assembly. See “Media eject unit assembly removal” on page 4-59.
9. Remove the media compiler unit assembly. See “Media compiler unit assembly removal” on
page 4-69.
10. Remove the media eject motor assembly. See “Media eject motor assembly removal” on page 4-78.
11. Remove the media eject shaft assembly. See “Media eject shaft assembly removal” on page 4-74.
12. Loosen the two screws securing the belt tensioner bracket (A) to the finisher, and move it down, as shown.
Replacement note: When replacing the belt tensioner bracket (A), tighten the screws in the order shown.
13. Remove the belt (exit) (B) from the lower exit roll drive pulley 20T (C).
B

A O

Rear

A
Second
C

First

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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. Release the hook from the main paddle shaft drive pulley 17T (G) inside the finisher.
17. Remove the main paddle shaft drive pulley 17T (G).
Note: The belt (H) will become attached.

M
D
Second
D

First
18. Remove the 6 mm bushing (I).
19. Release the hook of the main paddle drive pulley/gear 44/20T (F) from the shaft (J).
20. Remove the main paddle drive pulley/gear 44/20T (F).
21. Remove the 6 mm bushing (K).
22. Remove the main paddle idler gear 23T right (L).
23. Remove the two front and the two rear screws securing the main paddle shaft assembly (M).
24. Move the main paddle shaft assembly (M) forward and then downward and outward.

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25. Remove the main paddle shaft assembly.

Rear

K F

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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
M
Second

Third

Front view

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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.

A
Front
5. Remove the lower pinch guide assembly (A).

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Finisher diverter gate removal

1. Open the finisher front door assembly.

2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
3. Open the lower pinch guide assembly (A) to the right.
4. Open the upper pinch guide assembly (B) to the right.
5. Remove the finisher diverter gate solenoid. See “Finisher diverter gate solenoid removal” on
page 4-101.
6. Remove the link (C).
7. Move the finisher diverter gate (D) toward the rear, to the right, and forward, as shown.

D Front A

Rear
8. Remove the finisher diverter gate (D).

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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 4-24.
4. Remove the buffer diverter gate solenoid. See “Buffer diverter gate solenoid removal” on page 4-102.
5. Remove the link (B).

Buffer diverter gate

Rear
6. Move the buffer diverter gate (C) toward the rear, the left, and then forward, as shown.

C
7. Remove the buffer diverter gate (C).

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Sensor (buffer path) removal

1. Open the finisher front door assembly.

2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
4. Remove the top cover. See “Top cover removal” on page 4-19.
5. Remove the left lower cover. See “Left lower cover removal” on page 4-28.
6. Remove the left upper cover. See “Left upper cover removal” on page 4-29.
7. Remove the punch carriage assembly. See “Punch carriage assembly removal” on page 4-41.
8. Disconnect the connector from the sensor (buffer path) (A).
9. Remove the screw securing the bracket (B) to the finisher.
A
B

Left Connector

10. Remove the bracket (B).

11. Release the hooks securing the sensor (buffer path) (A) to the bracket (B).
12. Remove the sensor (buffer path) (A).

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Finisher buffer roll assembly removal

1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
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. Lower the buffer pinch guide assembly (A).
6. Move the lower pinch guide assembly to the right.
7. Position the buffer diverter gate (B) using your finger to its upper-most position.

Front

A
8. Use a prying tool to remove the e-clip securing the buffer roll assembly (C) to the front of the finisher.
9. Remove the 6 mm bushing (D).

E-clip

C
D
Front
10. Remove the finisher diverter gate solenoid. See “Finisher diverter gate solenoid removal” on
page 4-101.

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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).

C
G
E

E-clip
E
Second F D
H
First
13. Use a prying tool to remove the e-clip securing the buffer roll drive gear 23/53T (G).
14. Remove the buffer roll drive gear 53/23T (G).
15. Release the hook of the buffer roll drive gear 46T (H) from the buffer roll assembly (C).
16. Remove the buffer roll drive gear 46T (H).
17. Remove the 6 mm bushing (D).
18. Remove the buffer roll assembly (C) from inside the finisher.
Note: When removing the buffer roll assembly (C), do not touch the rubber surface.
Replacement notes:
• Make sure the flat spot on the end of the buffer roll assembly (C) is installed to the rear.

Front
• When replacing the buffer roll assembly, do not touch the rubber surface.
• The tension of the belt (buffer/transport) (F) is automatically adjusted by the force of the spring attached to
the belt tensioner bracket (E).
• Tighten the two screws in the order shown.

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Buffer pinch guide assembly removal

1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-27.
2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
3. Remove the rear lower cover. See “Rear lower cover removal” on page 4-23.
4. Remove the stapler unit frame. See “Stapler unit frame removal” on page 4-54.
5. Lower the buffer pinch guide assembly (A) as far as it will go.
6. Move the buffer pinch guide assembly (A) to the right to remove the two bosses from the holes in the
finisher.

Hole in rear frame

Boss

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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 4-24.
3. Remove the left lower cover. See “Left lower cover removal” on page 4-28.
4. Remove the left upper cover. See “Left upper cover removal” on page 4-29.
5. Remove the screw securing the cover (A) to the media entrance pinch guide assembly (B).
6. Remove the cover (A).
7. Disconnect the connector from the sensor (finisher media entrance) (C).
8. Release the harness from the clamps.
9. Remove the three screws securing the media entrance pinch guide assembly (B).
A
Connector
C

B Left
B
Clamp

Left Rear
10. Remove the entrance pinch guide assembly (B) from the finisher.

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Sensor (finisher media entrance) removal

1. Open the front door assembly.

2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
4. Remove the top cover. See “Top cover removal” on page 4-19.
5. Remove the left lower cover. See “Left lower cover removal” on page 4-28.
6. Remove the left upper cover. See “Left upper cover removal” on page 4-29.
7. Disconnect the connector from the sensor (finisher media entrance) (A).
8. Release the harness from the clamp.
9. Remove the screw securing the bracket (B) to the media entrance pinch guide assembly (C).

A
Connector

Clamp

Left
10. Release the hooks securing the sensor (finisher media entrance) (A) to the bracket (B).
11. Remove the sensor (finisher media entrance) (A).

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Finisher media entrance roll assembly removal

1. Remove the finisher front door assembly. See “Finisher front door assembly removal” on page 4-27.
2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
3. Remove the left upper cover. See “Left upper cover removal” on page 4-29.
4. Remove the punch waste box (A) from the finisher.
5. Remove the screw securing the cover (B) to the media entrance pinch guide assembly.
6. Remove the cover (B).
7. Lift the media entrance pinch guide assembly (C).
8. Loosen the two screws securing the belt tensioner bracket (D) to the finisher and move it upward in the
direction of the arrow.
9. Remove the belt (entrance/paddle) (E) from the entrance drive pulley 20T (F).

B
Front

A
D

Second D
First
10. Release the hook securing the entrance drive gear 23T (G) to the media entrance roll assembly (H).
11. Remove the entrance drive gear 23T (G).
12. Remove the entrance drive pulley 20T (F).
13. Remove the bushing (I).
14. Remove the e-clip securing the media entrance roll assembly (H) to the front of the finisher.
15. Remove the bushing (J).

I H

F
J
G
H
E-clip

Rear
Front

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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:
• Make sure the flat spot on the media entrance roll assembly (H) is installed to the rear.
• When replacing the media entrance roll assembly (H), do not touch the rubber surface.
• The tension of the belt (entrance/paddle) (E) is automatically adjusted to the force of the spring attached to
the belt tensioner bracket (D).
• Tighten the two screws in the order shown.

Drive motor (entrance/paddle) and belt (entrance/paddle) removal

1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
2. Loosen the two screws securing the belt tensioner bracket (A) to the finisher and move upward, as shown.
3. Remove the belt (entrance/paddle) (B) from the drive motor (entrance/paddle) (C).
4. Disconnect the connector from the drive motor (entrance/paddle) (C).

A C

A
Second First

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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. Remove the belt (entrance/paddle) (B).
Replacement notes:
• The tension of the belt (entrance/paddle) (B) is automatically adjusted by the force of the spring attached to
the belt tensioner bracket (A).
• Tighten the two screws in the order shown.

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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 4-24.
3. Disconnect the connector from the finisher diverter gate solenoid (A).
4. Release the harness from the clamp.
5. Remove the two screws securing the bracket (B) to the finisher.
Note: The bracket should not be removed from the finisher, it should be gently moved to provide better
access to the finisher diverter gate solenoid mounting screws.
6. Remove the two screws securing the finisher diverter gate solenoid (A) to the finisher.
7. Remove the finisher diverter gate solenoid (A).
Note: The link (C) may remain inserted into the finisher.
B

Clamp

C
Connector

Clamp
A

8. Remove the link.

Note: When the link is removed, the finisher diverter gate may become detached. See “Finisher diverter
gate removal” on page 4-90.

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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 4-24.
3. Disconnect the connector from the buffer diverter gate solenoid (A).
4. Release the harness from the clamp.
5. Remove the two screws securing the buffer diverter gate solenoid to the finisher.
6. Remove the buffer diverter gate solenoid.
Note: The link (B) may remain inserted into the finisher.

Clamp

Connector

Rear

7. Remove the link.

Note: When the link is removed, the buffer diverter gate may become detached. See “Buffer diverter gate
removal” on page 4-91.

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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 4-24.
3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
4. Remove the top cover. See “Top cover removal” on page 4-19.
5. Disconnect the connector from the sensor (upper media exit) (A).

Connector

Rear
Left
6. Release the hooks securing the sensor (upper media exit) (A) to the finisher.
7. Remove the sensor (upper media exit) (A).

Upper media exit pinch roll assembly removal

1. Open the finisher front door assembly.

2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
4. Remove the top cover. See “Top cover removal” on page 4-19.
5. Remove the four screws securing the four upper media exit pinch roll assemblies (A) to the finisher.

Left
Rear

6. Remove the four upper media exit pinch roll assembly (A).

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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 4-24.
3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
4. Remove the top cover. See “Top cover removal” on page 4-19.
5. Remove the drive motor (exit). See “Drive motor (exit) assembly and belt (exit) removal” on
page 4-111.
6. Disconnect the connector from the sensor (upper media exit) (A).

Connector

Left

7. Release the harness from the clamps.

8. Remove the two front and two rear screws securing the upper exit guide assembly (B).
9. Remove the upper exit guide assembly.
10. Remove the two front screws and the two rear screws securing the bracket (C) to the finisher.

Front
Rear

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11. Remove the bracket (C).

B

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.
16. Remove the 6 mm bushing (E).
17. Move the upper media exit roll assembly frontward and outward in the direction of the arrow.
F
E
D

E-clip F
Rear
E

Front
18. Remove the upper media exit roll assembly (F).
Note: When removing the upper media exit roll assembly (F), do not touch the rubber surface.
Replacement notes:
• Maker sure the flat spot of the upper media exit roll assembly (F) is installed to the rear.
• When replacing the upper media exit roll assembly (F), do not touch the rubber surface.

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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. Release the harness from the clamp.
5. Move the bracket (B) frontward again, and remove the screw securing the sensor (upper media bin full) (C)
to the bracket.

Front

Harness clamp

Front
6. Remove the sensor (upper media bin full) (C).
7. Disconnect the connector from the sensor (upper media bin full) (C).

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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 4-24.
3. Remove the drive motor (buffer/transport). See “Drive motor (buffer/transport) and belt (buffer/
transport) removal” on page 4-113.
4. Remove the three screws securing the hinge of the upper pinch guide assembly (A) on the rear of the
finisher.
5. Move the upper pinch guide assembly hinge from the rear of the finisher.
6. Remove the upper pinch guide assembly (A) from the inside of the finisher in the direction of the arrow.

A
A

Rear Front

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Sensor (diverter gate) removal

1. Open the finisher front door assembly.

2. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
3. Remove the upper media bin assembly. See “Upper media bin assembly removal” on page 4-20.
4. Remove the top cover. See “Top cover removal” on page 4-19.
5. Remove the left lower cover. See “Left lower cover removal” on page 4-28.
6. Remove the left upper cover. See “Left upper cover removal” on page 4-29.
7. Remove the punch carriage assembly. See “Punch carriage assembly removal” on page 4-41.
8. Remove the two screws securing the bracket (A) to the finisher.
9. Remove the bracket (A).
10. Disconnect the connector from the sensor (diverter gate) (B).
11. Remove the screw securing the sensor (diverter gate) (B) to the bracket (A).

Connector
B Left
12. Remove the sensor (diverter gate) (B).

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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 4-24.
3. Remove the top cover. See “Top cover removal” on page 4-19.
4. Remove the left lower cover. See “Left lower cover removal” on page 4-28.
5. Remove the left upper cover. See “Left upper cover removal” on page 4-29.
6. Remove the punch carriage assembly. See “Punch carriage assembly removal” on page 4-41.
7. Open the upper pinch guide assembly (A) toward the right.
8. Remove the two screws securing the bracket (B) on the rear of the finisher.

D
Front
Front
9. Move the bracket (B) slightly toward the exit side of the finisher.
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 assemblies (C) for removal.
B

B
D

F
Second G
Rear
First

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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. Loosen the two screws securing the belt tensioner bracket (F) to the finisher, and move the bracket
downward as shown.
12. Remove the belt (buffer/transport) (G) from the two upper media transport roll drive pulleys 20T (E).
13. Release the hook securing the appropriate upper media transport roll drive pulley 20T (E) to the
appropriate upper media transport roll assembly (C).
14. Remove the appropriate upper media transport roll drive pulley 20T (E).
15. Remove the appropriate bushing (H).
16. With a prying tool, remove the e-clip securing the appropriate upper media transport roll assembly (C) to
the front of the finisher.
C
C
H

E-clip

E
Front
E-clip

Rear C
H C
17. Remove the appropriate 6 mm bushing (I).
18. Move the appropriate upper media transport roll assembly (C) toward the front and outward.
19. Remove the appropriate upper media transport roll assembly (C).
Note: When removing the upper media transport roll assembly (C), do not touch the rubber surface.
Replacement notes
• Make sure the flat spot on the upper media transport roll assembly (C) is installed to the rear.
• When replacing the upper media transport roll assembly (C), do not touch the rubber surface.
• The tension of the belt (buffer/transport) (G) is automatically adjusted by the force of the spring attached to
the belt tensioner bracket (F).
• Tighten the two screws in the order shown.

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Drive motor (exit) assembly and belt (exit) removal

1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
2. Loosen the two screws securing the belt tensioner bracket (A) to the finisher, and move it down as shown.
3. Remove the belt (exit) (B) from the drive motor (exit) assembly (C).
4. Disconnect the connector from the drive motor (exit) assembly.
B
C
A

Connector

Second
Rear
First

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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).
D

Connector
8. Remove the drive motor (exit) assembly (C).
Replacement notes:
• The tension of the belt (exit) (B) is automatically adjusted by the force of the spring attached to the belt
tensioner bracket (A).
• Tighten the two screws in the order shown.

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Drive motor (buffer/transport) and belt (buffer/transport) removal

1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
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. It should only be slightly moved to provide
better access to the drive motor (buffer/transport) (B) for removal.
4. Loosen the two screws securing the belt tensioner bracket (C) to the finisher, and move it down as shown.
5. Remove the belt (buffer/transport) (D) from the drive motor (buffer/transport).
Connector

Second D

First

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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. Remove the belt (buffer/transport) (D).
Replacement notes:
• The tension of the belt (buffer/transport) (D) is automatically adjusted by the force of the spring attached to
the belt tensioner bracket (C).
• Tighten the two screws in the order shown.

Connector

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Bridge unit interface card assembly removal

1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
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
4. Remove the bridge unit interface card assembly (A).

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Finisher controller card assembly removal

1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
2. Remove the rear lower cover. See “Rear lower cover removal” on page 4-23.
3. Loosen the four screws securing the plate (A) to the finisher.
4. Move the plate (A) to the right and outward.

Rear

5. Remove the plate (A).

6. Disconnect the connectors from the finisher controller card assembly (B).

P8304 P8308 P8389

P8306

P8309 P8307
P8305
P8300
P8302 P8301
P8311 P8310

P8317 P8315 P8313 P8314 P8316

Rear B
7. Remove the six screws securing the finisher controller card assembly (B).
8. Remove the finisher controller card assembly (B).

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Finisher low voltage power supply (LVPS) removal

1. Remove the right lower cover. See “Rear lower cover removal” on page 4-23.
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. Remove the finisher LVPS (A).

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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 4-23.
3. Disconnect the booklet bin hookup cable assembly from the rear of the finisher.
4. Release the clamps securing the booklet bin hookup cable assembly from the finisher.
5. Remove booklet bin hookup cable assembly (A).

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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).

Repair information 4-119

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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 4-23.
4. Disconnect the connector from the sensor (booklet unit interlock).
5. Remove sensor (booklet unit interlock) (A).

Connector

Rear

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Booklet controller card assembly removal ??

Warning: When replacing the booklet controller card assembly, the existing booklet maker adjustments must
be restored to the original settings, or booklet folding and stapling will be out of alignment. The existing
booklet maker adjustments can be found on the settings sheet located in the tray 1 settings sheet
compartment.

To enter replacement settings or if the setting sheet is not available, refer to booklet maker setup and
adjustment located in chapter 4. See “Booklet maker setup & adjustment” on page 4-144.
1. Remove the rear lower cover. “Rear lower cover removal” on page 4-23.
2. Loosen the four screws securing the plate to the finisher.
3. Move the plate to the right and outward.
4. Remove the plate.
5. Disconnect the connectors from the booklet controller card assembly (A).
6. Remove the four screws securing the booklet controller card assembly (A).
7. Remove the booklet controller card assembly (A).

Rear

Repair information 4-121

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Booklet unit assembly removal

1. Open the finisher front door assembly.

2. Slide the booklet unit out.
3. Remove the two screws securing the retainer to the machine.
4. Remove the retainer.
5. Release the two latches securing the booklet unit (A) from the guides.
6. Remove booklet unit (A).

Booklet folding/exit drive motor assembly removal

1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-122.
2. Disconnect the connectors from the booklet unit motor assembly (A).
3. Remove the five screws securing the booklet folding/exit drive motor assembly (A) from the booklet gear
train frame.
4. Remove the booklet folding/exit drive motor assembly (A).

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Booklet diverter gate solenoid removal

1. Remove the rear upper cover. See “Rear upper cover removal” on page 4-24.
2. Remove the two screws securing the booklet diverter gate solenoid (A) to the machine.
3. Remove the booklet diverter gate solenoid (A).
4. Release the harness from the clamp.
5. Disconnect the connector from the booklet diverter gate solenoid (A).

Booklet stapler unit assembly removal

1. Open the finisher front door assembly.

2. Pull the booklet stapler unit out of the machine.
3. Release the hook securing the right ball bearing slide (A).
4. Pull the booklet stapler unit assembly (B) from the machine.
5. Remove the two screws securing the booklet stapler unit assembly (B) to the left ball bearing slide (C).

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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 4-122.
2. Remove the booklet unit motor assembly. See “Booklet folding/exit drive motor assembly removal”
on page 4-122.
3. Disconnect the connectors from the booklet knife solenoid (A).
4. Remove the spring from the booklet knife solenoid frame (A).
5. Remove the five screws securing the booklet gear train frame from the booklet unit assembly.
6. Remove the two e-clips from shaft X & Y.
7. Remove the two bushings from shaft X & Y.

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8. Remove the folding solenoid frame (A).

A C
B

Rear

Booklet knife solenoid removal

1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-122.
2. Remove the booklet unit motor assembly. See “Booklet folding/exit drive motor assembly removal”
on page 4-122.
3. Remove the knife solenoid frame. See “Booklet knife solenoid frame removal” on page 4-124.
4. Remove the screw securing the booklet knife solenoid from the knife solenoid frame (A).

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5. Remove the booklet knife solenoid (A).

A

Booklet knife sector drive gear 42T

1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-122.
2. Remove the booklet unit motor assembly. See “Booklet folding/exit drive motor assembly removal”
on page 4-122.
3. Remove the knife solenoid frame. See “Booklet knife solenoid frame removal” on page 4-124.
4. Remove the e-clip.

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5. Remove the booklet knife sector drive gear 42T (A).

B
A

Rear

Booklet media entrance drive motor removal

1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-122.
2. Remove the screws securing the booklet media entrance drive motor cover from the booklet unit.
3. Remove the booklet media entrance drive motor cover.
4. Disconnect the connectors from the booklet media entrance drive motor (A).
5. Remove the two screws securing the booklet media transport from the knife solenoid frame.

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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 4-122.
2. Remove the booklet unit motor assembly. See “Booklet folding/exit drive motor assembly removal”
on page 4-122.
3. Remove the knife solenoid frame. See “Booklet knife solenoid frame removal” on page 4-124.
4. Remove the booklet media entrance drive motor. See “Booklet media entrance drive motor removal”
on page 4-127.
5. Remove the booklet knife sector drive gear 42T. See “Booklet knife sector drive gear 42T” on
page 4-126.
6. Remove the gear 18T.
7. Remove the three screws securing the booklet unit gear train frame (A) from the booklet unit.

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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 4-122.
2. Remove the top screws securing the left cover to the booklet unit assembly.
3. Loosen the two screws securing the left cover to the booklet unit assembly.

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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 4-122.
2. Remove the booklet unit motor assembly. See “Booklet folding/exit drive motor assembly removal”
on page 4-122.
3. Remove the knife solenoid frame. See “Booklet knife solenoid frame removal” on page 4-124.
4. Remove the booklet media entrance drive motor. See “Booklet media entrance drive motor removal”
on page 4-127.
5. Remove the booklet knife sector drive gear 42T. See “Booklet knife sector drive gear 42T” on
page 4-126.
6. Remove booklet unit gear train frame. See “Booklet unit gear train frame removal” on page 4-128.
7. Remove the booklet unit assembly left cover. See “Booklet unit assembly left cover” on page 4-129.
8. Remove the screw securing the sensor (booklet rear tamper HP).
9. Slide the booklet rear tamper guide out.
10. Remove the e-clip.
11. Remove the two springs from the booklet rear tamper guide.
12. Remove tamper guide.

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13. Remove the rear tamper assembly (A).

Right
B A

C D

Booklet front tamper guide removal

1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-122.
2. Remove booklet unit assembly left cover. See “Booklet unit assembly left cover” on page 4-129.
3. Remove the two screws securing the booklet front tamper guide from the rack.

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4. Remove the front tamper guide (A).

B

Right

Left
A

Sensor (booklet front tamper HP) removal

1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-122.
2. Remove the booklet unit assembly left cover. See “Booklet unit assembly left cover” on page 4-129.
3. Disconnect the connector from the booklet front tamper sensor.
4. Remove the screw securing the sensor (booklet front tamper HP) bracket from the booklet unit assembly.

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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 4-122.
2. Remove the booklet unit assembly left cover. See “Booklet unit assembly left cover” on page 4-129.
3. Disconnect the connector from the booklet left tamper sensor.
4. Remove the screw securing the sensor (booklet rear tamper HP) bracket from the booklet unit assembly.

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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 4-122.
2. Remove the booklet unit assembly left cover. See “Booklet unit assembly left cover” on page 4-129.
3. Disconnect the connector from the booklet front tamper motor.
4. Remove the two screws securing the booklet front tamper motor from the tamper frame assembly.

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5. Remove the booklet front tamper motor (A).

Connector

Left

Booklet rear tamper motor removal

1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-122.
2. Remove the booklet unit assembly left cover. See “Booklet unit assembly left cover” on page 4-129.
3. Disconnect the connector from the booklet rear tamper motor (A).
4. Remove the two screws securing the booklet rear tamper motor (A) from the tamper frame assembly.

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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 4-122.
2. Remove the booklet unit assembly left cover. See “Booklet unit assembly left cover” on page 4-129.
3. Rotate knife sector gear clockwise until the flag is in the folding sensor position.
4. Remove one screw securing the sensor (knife HP sensor & Knife folding sensor) from the knife frame
assembly.
5. Disconnect the connector from the sensor (booklet knife HP and booklet knife folding).

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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 4-122.
1. Remove the Complete booklet unit assembly left cover. See “Booklet unit assembly left cover” on
page 4-129.
2. Rotate knife sector gear clockwise until the flag is in the folding sensor position.
3. Remove one screw securing the sensor (knife HP sensor & knife folding sensor) from the knife frame
assembly.
4. Disconnect the connector from the sensor (booklet knife folding) (A).

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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 4-122.
2. Remove the e-clip securing the shaft X from the booklet unit.
3. Remove the four screws securing the front door assembly from the frame of the booklet unit.
4. Remove the bushing.
5. Remove the booklet unit front door assembly (A).

Sensor (booklet unit media entrance) removal

1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-122.
2. Disconnect the connectors from the Sensor (booklet unit media entrance) (A).
3. Remove the screw securing the Sensor (booklet unit media entrance) bracket from the pinch roll frame.
4. Remove the screw securing the Sensor (booklet unit media entrance) (A) from the bracket.

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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 4-122.
2. Remove the booklet unit assembly left cover. See “Booklet unit assembly left cover” on page 4-129.
3. Disconnect the connector from the Sensor (booklet media compiler in) (A).
4. Remove the screw securing the Sensor (booklet media compiler in) bracket from the booklet unit assembly.
5. Remove the screw securing the Sensor (booklet media compiler in) (A) from the bracket.
6. Remove Sensor (booklet media compiler in) (A).

Connector
Left

Sensor (booklet unit media exit) removal

1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-122.
2. Remove the booklet unit assembly left cover. See “Booklet unit assembly left cover” on page 4-129.
3. Remove the screw securing the Sensor (booklet unit media exit) bracket from the booklet unit assembly.
4. Disconnect the connector from the Sensor (booklet unit media exit) (A).
5. Remove the screw securing the Sensor (booklet unit media exit) (A) from the bracket.

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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 4-122.
2. Remove the booklet unit assembly left cover. See “Booklet unit assembly left cover” on page 4-129.
3. Disconnect the connector from the sensor (booklet end guide HP) (A).
4. Release the hooks securing the sensor (booklet end guide HP) (A) from the booklet unit.

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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 4-122.
2. Remove the Sensor (booklet unit media entrance). See “Sensor (booklet unit media entrance)
removal” on page 4-138.
3. Remove the four screws securing the frame X from the booklet unit assembly.
4. Release the cable harness from the frame X.
5. Remove the booklet unit front door assembly. See “Booklet unit front door assembly removal” on
page 4-138.
6. Remove the four screws securing the booklet media pinch roll assembly (A) from the booklet unit assembly.

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7. Remove the booklet media pinch roll assembly (A).

B

Booklet paddle motor removal

1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-122.
2. Remove the booklet unit assembly left cover. See “Booklet unit assembly left cover” on page 4-129.
3. Disconnect the connectors from the booklet paddle motor (A).
4. Remove the two screws securing the booklet paddle motor (A) from the compiler frame.
5. Remove booklet paddle motor (A).

Connector
Left

Booklet end guide drive motor removal

1. Remove the booklet unit assembly. See “Booklet unit assembly removal” on page 4-122.
2. Remove the booklet unit assembly left cover. See “Booklet unit assembly left cover” on page 4-129.
3. Disconnect the connectors from the sensor (booklet end guide drive motor).
4. Remove the two screws securing the booklet end guide drive motor (A) from the compiler frame.

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5. Remove the booklet end guide drive motor (A).

Connector

Repair information 4-143

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Booklet maker setup & adjustment

Folding precision skew adjustment

Step Check Yes No

1 Print a 2 sheet booklet using the booklet maker. Go to step 2. The folding
precision skew
Does the booklet appear skewed as shown in the graphic adjustment is in
below? spec.
Fold Precision
When stapling
●A4/Letter:
A ≤ 2.0mm
●Other:
A ≤ 2.5mm

When un-stapling
●A4/Letter:
A ≤ 2.0mm
●Other:
A ≤ 2.5mm
A

2 Check the booklet maker precision skew adjuster. Repeat step 2 until Problem solved.
the end guide
1. Open the finisher front door precision skew is
2. Pull the booklet maker out of the finisher. in spec.
3. Loosen the screw securing the end guide skew lever.

4. Adjust the end guide skew lever by moving it either

forward or rearward. 1 step on the scale = 1 mm shift.
5. Once the adjustment is made, tighten the screw.
Print a 2 sheet booklet using the booklet maker.
Do the booklet sheet edges appear skewed as shown in the
graphic below?
Fold Precision
When stapling
●A4/Letter:
A ≤ 2.0mm
●Other:
A ≤ 2.5mm

When un-stapling
●A4/Letter:
A ≤ 2.0mm
●Other:
A ≤ 2.5mm
A

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2 sheet fold & staple position fine adjustment

Step Check Yes No

1 Print a 2 sheet booklet using the booklet maker. Go to step 2. The 2 sheet fold
position fine
Does the booklet sheet edges appear overlapped as shown adjustment is in
in the graphic below? spec.
Go to step 3.

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Step Check Yes No

2 Adjust the 2 sheet position fine adjustment value based on Repeat step 2 until Problem solved.
the graphic below: the 2 sheet fold
position fine
adjustment is in
spec.
Go to step 3.

1. Enter the diagnostic mode.

2. Touch ENGINE ADJUST.
3. Touch Booklet fold adjust.
4. Touch Booklet 2 sheet.
5. Make required fold position value adjustments according
to the media size as shown in the graphic below. 1 step
= .1 mm shift. Target amount to be adjusted is half the
amount of the total Fold Misalignment.

6. Touch Submit.
Print a 2 page booklet using the booklet maker.
Do the booklet sheet edges appear overlapped as shown in
the graphic below?

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Step Check Yes No

3 Print a 2 sheet stapled booklet using the booklet maker. Go to step 4. The 2 sheet staple
position fine
Does the staple position fine adjustment appear to be offset adjustment is in
from the fold as shown in the graphic below? spec.

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Step Check Yes No

4 Adjust the 2 sheet staple position fine adjustment value as Repeat step 2 until Problem solved.
shown in the graphic below: the 2 sheet staple
position fine
adjustment is in
spec.

1. Enter the diagnostic mode.

2. Touch ENGINE ADJUST.
3. Touch Booklet fold adjust.
4. Touch Booklet 2 sheet.
5. Make required staple position adjustments according to
media size.
1 step =.1 mm shift.
6. Touch Submit.
Print a 2 page booklet using the booklet maker.
Does the staple position fine adjustment appear to be offset
from the fold as shown in the graphic below?

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15 sheet staple position fine adjustment

Step Check Yes No

1 Print a 15 sheet stapled booklet using the booklet maker. Go to step 2. The 15 sheet
staple position fine
Does the staple position fine adjustment appear to be offset adjustment is in
from the fold as shown in the graphic below? spec.

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Step Check Yes No

2 Adjust the 15 sheet staple position fine adjustment value as Repeat step 2 until Problem solved.
shown in the graphic below: the 15 sheet
staple position fine
adjustment is in
spec.

1. Enter the diagnostic mode.

2. Touch ENGINE ADJUST.
3. Touch Booklet fold adjust.
4. Touch Booklet 15 sheet.
5. Make required staple position adjustments according to
media size.
1 step =.1 mm shift.
6. Touch Submit.
Print a 15 page booklet using the booklet maker.
Does the staple position fine adjustment appear to be offset
from the fold as shown in the graphic below?

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Booklet fold position fine adjustment (3-15 sheets)

Step Check Yes No

1 Note: The booklet fold position fine adjustment is different Go to step 2. The booklet fold
depending on the amount of sheets that compose the position fine
booklet and the size of the media. adjustment is in
spec.
Volume 1 = 3 sheets
Volume 2 = 4 sheets
Volume 3 = 5-7 sheets
Volume 4 = 8-15 sheets
S = media < B4
L = B4 media or >

Print the appropriate booklet using the booklet maker.

Do the booklet sheet edges appear overlapped as shown in
the graphic below?

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Step Check Yes No

2 Adjust the fold position fine adjustment value based on the Repeat step 2 until Problem solved.
graphic below: the Booklet fold
position fine
adjustment is in
spec.

1. Enter the diagnostic mode.

2. Touch ENGINE ADJUST.
3. Touch Booklet fold adjust.
4. Touch Booklet fold pos fine adj.
5. Make required adjustments according to media size.
1 step = .1 mm shift. Target amount to be adjusted is
half the amount of the total Fold Misalignment.
6. Touch Submit.
Enter the user mode and print the appropriate booklet using
the booklet maker.
Do the booklet sheet edges appear overlapped as shown in
the graphic below?

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Booklet staple position fine adjustment (3-14 sheets)

Step Check Yes No

1 Note: The booklet staple position fine adjustment is Go to step 2. The booklet staple
different depending on the amount of sheets that compose position fine
the booklet. adjustment is in
spec.
Volume 1 = 3 sheets
Volume 2 = 4 sheets
Volume 3 = 5-7 sheets
Volume 4 = 8-14 sheets
Print the appropriate booklet using the booklet maker.
Does the staple position fine adjustment appear to be offset
from the fold as shown in the graphic below?

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Step Check Yes No

2 Adjust the booklet staple position fine adjustment value as Repeat step 2 until Problem solved.
shown in the graphic below: the Booklet staple
position fine
adjustment is in
spec.

1. Enter the diagnostic mode.

2. Touch ENGINE ADJUST.
3. Touch Booklet fold adjust.
4. Touch Booklet fold pos fine adj.
5. Make required adjustments according to media size.
1 step = .1 mm shift. Target amount to be adjusted is
half the amount of the total Fold Misalignment.
6. Touch Submit.
Enter user mode and print the appropriate booklet using the
booklet maker.
Does the staple position fine adjustment appear to be offset
from the fold as shown in the graphic below?

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5. Connector locations

Finisher components
Bridge unit assembly
Sensor (bridge unit media entrance) Bridge unit drive motor

Sensor (bridge unit

media exit)

Sensor (bridge unit top cover interlock)

Connector locations 5-1

7500-432, -632, and -832

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

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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

cam front) unit side
registration 1)

Punch unit
motor assembly

Sensor (punch
waste box set)

Sensor (punch
waste box full)

Connector locations 5-3

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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

Sensor
(compiler media in)
Sensor (media Sensor (rear
eject shaft HP) tamper HP) Rear tamper motor

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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
Buffer roll
assembly

Connector locations 5-5

7500-432, -632, and -832

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
voltage power supply

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Booklet media bin

Booklet bin assembly

Sensor (booklet bin full)

Front

Booklet bin drive motor

Connector locations 5-7

7500-432, -632, and -832

Booklet maker
Booklet rear
Sensor (booklet tamper motor
rear tamper HP)

Booklet front
Booklet folding/exit tamper motor
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

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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 5-9

7500-432, -632, and -832

Booklet controller card assembly

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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

Connector locations 5-11

7500-432, -632, and -832

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

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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

Connector locations 5-13

7500-432, -632, and -832

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6. Preventive maintenance

This chapter describes procedures for printer preventive maintenance. Follow these recommendations to help
prevent problems and maintain optimum performance.

Safety inspection guide

The purpose of this inspection guide is to aid you in identifying unsafe conditions.

If any unsafe conditions exist, find out how serious the hazard could be and if you can continue before you
correct the hazard.

Check the following items:

• Damaged, missing, or altered parts, especially in the area of the On/Off switch and the power supply
• 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. Some unauthorized lubricants may chemically attack
polycarbonate parts. Use IBM no. 10 oil, P/N 1280443 (Approved equivalents: Mobil DTE27, Shell Tellus 100,
Fuchs Renolin MR30), IBM no. 23 grease (Approved equivalent Shell Darina 1), and grease, P/N 99A0394 to
lubricate appropriate areas.

Maintenance recommendations

Finisher Every service call Every 300,000 pages

Bridge unit belts Inspect Clean with water or alcohol
Main paddles (3) Inspect Clean with water or alcohol
Sub paddles (2) Inspect Clean with water or alcohol
Clamp paddles (3) Inspect Clean with water or alcohol
Punch waste box Clean Clean
Stapler cartridge Inspect for correct operation Inspect for correct operation

Preventive maintenance 6-1

7500-432, -632, and -832

6-2 MFP Finisher Service Manual

 7500-432, -632, and -832

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 FRU

• 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.
• Part number: Identifies the unique number that identifies this FRU.
• Units/option: Refers to the number of units in a particular option. It does not include the rest of the base
machine.
• Units/FRU: Refers to the number of units packaged together and identified by the part number.
• NS: (Not shown) in the Assembly-Index column indicates that the part is procurable but is not pictured in the
illustration.
• PP: (Parts Packet) in the parts description column indicates the part is contained in a parts packet.

Parts catalog 7-1

7500-432, -632, and -832

Assembly 1: Finisher—bridge unit

1
2

Asm- Part Units/ Units/

Description
Index number option FRU
1 40X0811 1 1 Bridge unit assembly
2 40X0810 1 2 Bridge unit assembly docking screw (2 each)

7-2 MFP Finisher Service Manual

 7500-432, -632, and -832

Assembly 2: Finisher—bridge unit top cover assembly

1

2 2

2
2
2

Asm- Part Units/ Units/

Description
Index number option FRU
1 40X0813 1 1 Bridge unit top cover assembly
2 40X0812 6 2 Bridge unit pinch roll kit includes:
• Bridge unit pinch roll (6 each)
• Spring (6 each)

Parts catalog 7-3

7500-432, -632, and -832

Assembly 3: Finisher—bridge unit lower assembly

1

15
14
2
2
3
12

13
4
11 5
12

5
9 6
7

10

7-4 MFP Finisher Service Manual

 7500-432, -632, and -832

Assembly 3: Finisher—bridge unit lower assembly

Asm- Part Units/ Units/
Description
Index number option FRU
1 40X0814 1 1 Bridge unit rear cover
2 40X0822 1 3 Bridge unit right shaft kit includes:
• 6 mm bushing - front
• Bridge unit right shaft assembly
• 6 mm bushing - rear
3 40X0820 1 2 Transport belts (2 each)
4 40X0821 1 6 Idler roll kit includes:
• Idler roll (2 each)
• Bushing (4 each)
5 40X0824 8 1 Magnetic catch
6 40X0825 1 1 Sensor (bridge unit top cover interlock)
7 40X0826 1 1 Sensor (bridge unit media exit)
8 40X0828 1 1 Bridge unit cable assembly
9 40X0827 1 1 Sensor (bridge unit media entrance)
10 40X0818 1 3 Bridge unit entrance guide kit includes:
• Bridge unit entrance guide
• Lower guides (2 each)
11 40X0817 1 1 Bridge unit drive motor
12 40X0819 2 1 Ball bearing 4 mm
13 40X0823 1 1 Bridge unit left shaft assembly
14 40X0816 1 1 Bridge unit drive pulley
15 40X0815 1 1 Bridge unit drive belt

Parts catalog 7-5

7500-432, -632, and -832

Assembly 4: Finisher—covers
1
2

10

3
5

7-6 MFP Finisher Service Manual

 7500-432, -632, and -832

Assembly 4: Finisher—covers
Asm- Part Units/ Units/
Description
Index number option FRU
1 40X0829 1 1 Top cover
2 40X0831 1 1 Upper media bin assembly
3 40X0830 1 1 Upper media bin vertical cover
4 40X0832 1 1 Right eject cover
5 40X0833 1 1 Stacker media bin
6 40X0834 1 1 Right lower LVPS cover
7 40X4405 4 1 Caster (booklet finisher only)
7 40X0835 4 1 Caster
8 40X0836 1 1 Rear lower cover
9 40X0837 1 1 Bridge unit hookup cover
10 40X0838 1 1 Rear upper cover

Parts catalog 7-7

7500-432, -632, and -832

Assembly 5: Finisher—covers and front door

1

7
3

7-8 MFP Finisher Service Manual

 7500-432, -632, and -832

Assembly 5: Finisher—covers and front door

Asm- Part Units/ Units/
Description
Index number option FRU
1 40X0839 1 1 Upper media bin front cover
2 40X0841 1 1 Finisher front door assembly (this comes assembled)
3 40X0840 1 1 Switch (finisher front door interlock)
4 40X0842 1 2 Finisher docking latch kit includes:
• Finisher docking latch assembly
• Spring
5 40X0843 1 3 Finisher docking bracket kit includes:
• Finisher docking bracket
• Screw (2 each)
6 40X0844 1 1 Left lower cover
7 40X0845 1 1 Left upper cover

Parts catalog 7-9

7500-432, -632, and -832

Assembly 6: Finisher—stacker bin lift

1
8

7
2

3
5

4
7
3

7-10 MFP Finisher Service Manual

 7500-432, -632, and -832

Assembly 6: Finisher—stacker bin lift

Asm- Part Units/ Units/
Description
Index number option FRU
1 40X0846 2 6 Carriage lift belt kit includes:
• Carriage lift belt
• Belt clamp (2 each)
• Spring
• Roll (2 each)
2 40X0847 2 1 Sensor (stacker bin level)
3 40X0849 1 7 Stacker slip clutch pulley kit includes:
• Pulley, 18T (3 each)
• Slip clutch pulley, 18T
• Slip clutch gear, 24T
• Spring
• Washer
4 40X0850 1 1 Sensor (stacker bin no media)
5 40X0850 1 1 Sensor (stacker bin upper limit)
6 40X0850 1 1 Sensor (stacker bin level encoder)
7 40X0848 2 1 Ball bearing 10 mm
8 40X4409 1 3 Stacker bin lift motor assembly (bookley finisher only)
• Bracket with sensor
• Encoder
• Stacker bin lift motor
8 40X0851 1 3 Stacker bin lift motor assembly
• Bracket with sensor
• Encoder
• Stacker bin lift motor
Note: Assembly index items 4, 5, and 6 are identical sensors with different functions; therefore, they are the same part
number with different descriptions.

Parts catalog 7-11

7500-432, -632, and -832

Assembly 7: Finisher—punch

18

17

14 15 3
16 4

13
5 5
12 5

11 7

10

7-12 MFP Finisher Service Manual

 7500-432, -632, and -832

Assembly 7: Finisher—punch
Asm- Part Units/ Units/
Description
Index number option FRU
1 40X0854 1 1 Punch carriage shift motor assembly
2 40X0855 1 1 Punch carriage assembly
3 40X0856 1 1 Sensor (punch unit side reg) assembly
• Sensor (punch unit side reg1)
• Sensor (punch unit side reg2)
• Bracket
4 40X0857 1 1 2/3 punch hammer sub-assembly
4 40X0858 1 1 2/4 punch hammer sub-assembly
5 40X0859 3 1 Punch media stopper assembly
6 40X3937 1 1 2/4 punch unit assembly
6 40X6865 1 1 2/3 punch unit assembly
7 40X0862 1 1 Punch waste box (non-booklet making finisher)
7 40X3946 1 1 Punch waste box (booklet making finisher)
8 40X0930 1 1 Punch waste box full cable assembly
9 40X0864 1 1 Sensor (punch waste box full) (non-booklet making finisher only)
10 40X0865 1 1 Punch waste box set cable assembly
11 40X0861 1 1 Sensor (punch waste box set)
12 40X3944 1 1 Sensor (punch unit motor encoder)
13 40X3943 1 1 Punch unit motor assembly
14 40X0850 1 1 Sensor (punch hole select)
15 40X0850 1 1 Sensor (punch cam front)
16 40X0850 1 1 Sensor (punch unit HP)
17 40X0853 1 1 Punch unit cable assembly
18 40X3938 1 1 Sensor (punch carriage shift HP)
Note: Assembly index items 11, 13, 14, 15, and 17 are identical sensors with different functions; therefore, they are the
same part number with different descriptions.

Parts catalog 7-13

7500-432, -632, and -832

Assembly 8: Finisher—stapler
1

3
4

7-14 MFP Finisher Service Manual

 7500-432, -632, and -832

Assembly 8: Finisher—stapler
Asm- Part Units/ Units/
Description
Index number option FRU
1 40X0870 1 1 Stapler unit cable assembly
2 40X0869 1 2 Stapler carriage kit includes:
• Stapler carriage wire guide
• Stapler carriage assembly
3 40X0871 1 1 Stapler carriage motor assembly
4 40X0872 1 1 Stapler carriage rack gear
5 40X0868 1 1 Stapler unit cover
6 40X0850 1 1 Sensor (stapler carriage HP)
7 40X0866 1 1 Staple cartridge
8 40X0867 1 1 Stapler unit assembly

Parts catalog 7-15

7500-432, -632, and -832

Assembly 9: Finisher—media eject

1

2
2

11

10 3

9
4

5
7 6

7-16 MFP Finisher Service Manual

 7500-432, -632, and -832

Assembly 9: Finisher—media eject

Asm- Part Units/ Units/
Description
Index number option FRU
1 40X0873 1 1 Media eject unit assembly (this comes assembled)
2 40X0874 2 1 Sub paddle
3 40X0875 1 2 Sub paddle drive shaft kit includes:
• Sub paddle drive shaft assembly
• Knob
4 40X0882 1 1 Switch (eject cover interlock)
5 40X1388 4 1 Bushing 8 mm
6 40X0888 15 1 Bushing 6 mm
7 40X0879 2 2 Sub paddle/entrance drive gear 23T
8 40X0877 1 1 Eject clamp lever assembly
9 40X0825 1 1 Sensor (media eject clamp HP)
10 40X0881 1 3 Eject clamp gear kit includes:
• Eject clamp gear 70T
• Eject clamp gear 23T
• Eject clamp gear 68/20T
11 40X0876 1 1 Media eject clamp motor

Parts catalog 7-17

7500-432, -632, and -832

Assembly 10: Finisher—eject and compiler unit

1

12
5
6
6
6

11

9 8
10

7-18 MFP Finisher Service Manual

 7500-432, -632, and -832

Assembly 10: Finisher—eject and compiler unit

Asm- Part Units/ Units/
Description
Index number option FRU
1 40X0883 1 1 Media compiler unit assembly (this comes assembled)
2 40X0850 1 1 Sensor (rear tamper HP)
3 40X0850 1 1 Sensor (front tamper HP)
4 40X0825 1 1 Sensor (compiler media in)
5 40X4150 1 1 Media eject shaft assembly (booklet finisher only)
5 40X0886 1 1 Media eject shaft assembly
6 40X0887 3 1 Clamp paddle
7 40X0888 15 1 Bushing 6 mm
8 40X1388 4 1 Bushing 8 mm
9 40X0889 2 1 Media eject shaft gear 39T
10 40X0890 1 2 Media eject clutch kit includes:
• Media eject clutch
• Media eject clutch actuator
11 40X0825 1 1 Sensor (media eject shaft HP)
12 40X0891 1 1 Media eject motor assembly
Note: Assembly index items 2 and 3 are identical sensors with different functions; therefore, they are the same part
number with different descriptions.

Parts catalog 7-19

7500-432, -632, and -832

Assembly 11: Finisher—lower exit drive

1

4 5

11
10

9 8

7
6

7-20 MFP Finisher Service Manual

 7500-432, -632, and -832

Assembly 11: Finisher—lower drive

Asm- Part Units/ Units/
Description
Index number option FRU
1 40X0892 1 1 Sensor (lower media exit) with bracket
2 40X0893 1 1 Sensor (lower media exit)
3 40X0894 1 1 Static eliminator brush
4 40X0895 1 1 Lower media exit roll assembly
5 40X4410 1 2 Main paddle shaft kit includes: (this comes assembled)(booklet finisher only)
• Main paddle shaft assembly
• Main paddle shaft drive pulley 17T
5 40X0896 1 2 Main paddle shaft kit includes: (this comes assembled)
• Main paddle shaft assembly
• Main paddle shaft drive pulley 17T
6 40X0888 15 1 Bushing 6 mm
7 40X0900 1 1 Main paddle drive pulley/gear 44/20T
8 40X0899 1 2 Main paddle idler gear kit includes:
• Main paddle idler gear 23TR
• Main paddle idler gear 23TL
9 40X0898 1 2 Lower exit roll drive pulley kit includes:
• Lower exit roll drive pulley 20T
• Idler pulley 20T
10 40X0913 4 1 Ball bearing 6 mm
11 40X0897 3 1 Belt idler pulley

Parts catalog 7-21

7500-432, -632, and -832

Assembly 12: Finisher—buffer and entrance drive

1

22

21 2

16
18 20
17 5
19
4

14 15
5

13

5
7
6
12

11 8

4
10

7-22 MFP Finisher Service Manual

 7500-432, -632, and -832

Assembly 12: Finisher—buffer and entrance drive

Asm- Part Units/ Units/
Description
Index number option FRU
1 40X0901 1 1 Lower pinch guide assembly (this comes assembled)
2 40X0902 1 1 Finisher diverter gate
3 40X4149 1 1 Buffer diverter gate (booklet finisher only)
3 40X0903 1 1 Buffer diverter gate
4 40X0824 8 1 Magnetic catch
5 40X0888 15 1 Bushing 6 mm
6 40X0904 1 1 Buffer upper guide assembly
7 40X0893 1 1 Sensor (buffer path)
8 40X0905 1 1 Buffer roll assembly
9 40X0906 1 1 Buffer pinch guide assembly (this comes assembled)
10 40X0909 1 1 Media entrance roll assembly
11 40X4411 1 1 Media entrance pinch guide assembly (this comes assembled)(booklet
finisher only)
11 40X0907 1 1 Media entrance pinch guide assembly (this comes assembled)
12 40X0908 1 1 Sensor (finisher media entrance)
13 40X0910 1 1 Drive motor (entrance/paddle)
14 40X0912 3 3 Belt tensioner pulley kit includes:
• Belt idler pulley
• Spring
• Belt tensioner bracket
15 40X0897 3 1 Belt idler pulley
16 40X0911 1 1 Belt entrance/paddle, 31.6 cm
17 40X0879 2 1 Sub paddle/entrance drive gear 23T
18 40X0914 1 1 Media entrance roll drive pulley 20T
19 40X0913 4 1 Ball bearing 6 mm
20 40X0915 1 1 Buffer roll drive gear 46T
21 40X0916 1 2 Media diverter solenoid kit includes:
• Media diverter solenoid
• Media diverter solenoid link
22 40X0917 1 2 Buffer diverter solenoid kit includes:
• Buffer diverter solenoid
• Buffer diverter solenoid link

Parts catalog 7-23

7500-432, -632, and -832

Assembly 13: Finisher—buffer, transport, and upper drive

1
1
1
1

21 2

20

12
17 4 3
18 19
6

13
15
14 5
16
6
13
12 15

11 6

10

10

8
9

7-24 MFP Finisher Service Manual

 7500-432, -632, and -832

Assembly 13: Finisher—transport and upper drive

Asm- Part Units/ Units/
Description
Index number option FRU
1 40X0918 4 1 Upper media exit pinch roll assembly
2 40X0893 1 1 Sensor (upper media exit)
3 40X0919 1 1 Upper media exit roll assembly
4 40X0908 1 1 Sensor (finisher media entrance)
5 40X0824 8 1 Magnetic catch
6 40X0888 15 1 Bushing 6 mm
7 40X0920 1 1 Upper pinch guide assembly (this comes assembled)
8 40X0921 1 1 Sensor (diverter gate)
9 40X0922 1 1 Diverter gate sensor upper cable assembly
10 40X0923 2 1 Upper media transport roll assembly
11 40X0924 1 1 Buffer roll drive pulley/gear 53/23T
12 40X0912 3 3 Belt tensioner bracket kit includes:
• Belt idler pulley
• Spring
• Belt tensioner bracket
13 40X0925 2 1 Upper media transport roll drive pulley 20T
14 40X0897 3 1 Belt idler pulley
15 40X0913 4 1 Ball bearing 6 mm
16 40X0928 1 1 Belt (buffer transport) 19.8 cm
17 40X0929 1 1 Belt (exit) 27.7 cm
18 40X0926 1 1 Upper media exit roll drive pulley/gear, 20T/20T
19 40X0927 1 1 Upper media exit roll drive gear 20T
20 40X0910 1 1 Drive motor (buffer/transport)
21 40X0910 1 1 Drive motor (exit)

Parts catalog 7-25

7500-432, -632, and -832

Assembly 14: Booklet maker 1

7-26 MFP Finisher Service Manual

 7500-432, -632, and -832

Assembly 14: Booklet maker 1

Asm- Part Units/ Units/
Description
Index number option FRU
1 40X3981 1 1 Booklet bin assembly
2 40X3979 1 1 Booklet unit right glide assembly
3 40X4413 1 1 Booklet unit assembly (this comes assembled)
4 40X3980 1 1 Booklet unit left glide assembly
5 40X3984 1 1 Booklet unit cable assembly
6 40X3983 1 1 Booklet bin/diverter cable assembly
7 40X3982 1 1 Booklet controller card power cable assembly
8 40X3985 1 1 Booklet unit interface connector assembly
9 40X0850 12 1 Sensor (booklet unit interlock)
10 40X3978 1 1 Booklet controller card assembly
11 40X3987 1 1 Booklet bin hookup cable assembly

Parts catalog 7-27

7500-432, -632, and -832

Assembly 15: Booklet maker 2

1

6
5
4

Asm- Part Units/ Units/

Description
Index number option FRU
1 40X3961 1 1 Booklet diverter gate
2 40X4118 1 1 Booklet path media transport roll assembly
3 40X3958 1 1 Booklet pinch guide assembly
4 40X4128 1 1 Belt idler pulley
5 40X0899 1 1 Booklet media transport roll drive gear 23T
6 40X3962 1 1 Booklet media transport roll torque limiter
7 40X0880 1 1 Bushing 6 mm
8 40X3963 1 1 Booklet media path roll retainer
9 40X0917 1 1 Booklet diverter gate solenoid kit
• Booklet diverter gate solenoid
• Link

7-28 MFP Finisher Service Manual

 7500-432, -632, and -832

Assembly 16: Booklet maker 3

Asm- Part Units/ Units/

Description
Index number option FRU
1 40X4414 1 1 Booklet stapler unit assembly
2 40X3990 1 1 Booklet manual feed knob
3 40X3989 1 1 Booklet manual feed drive gear 31T
4 40X3988 1 1 Booklet unit catch

Parts catalog 7-29

7500-432, -632, and -832

Assembly 17: Booklet maker 4

1

Asm- Part Units/ Units/

Description
Index number option FRU
1 40X0825 10 1 Sensor (booklet end guide HP)
2 40X3992 1 1 Booklet media entrance drive motor
3 40X3993 1 1 Gear pulley 40/20T
4 40X3994 1 1 Booklet end guide drive belt
5 40X3996 1 1 Booklet paddle drive motor assembly
6 40X3995 3 1 Booklet paddle idler gear 14T
7 40X3997 1 1 Booklet paddle shaft assembly

7-30 MFP Finisher Service Manual

 7500-432, -632, and -832

Assembly 18: Booklet maker 5

Asm- Part Units/ Units/

Description
Index number option FRU
1 40X3999 1 1 Booklet knife sector drive gear 42T
2 40X0825 10 1 Sensor (booklet knife HP)
3 40X0825 10 1 Sensor (booklet knife folding)
4 40X3998 1 1 Booklet knife HP sensor cable assembly

Parts catalog 7-31

7500-432, -632, and -832

Assembly 19: Booklet maker 6

Asm- Part Units/ Units/

Description
Index number option FRU
1 40X4001 1 1 Booklet front tamper
2 40X0825 10 1 Sensor (booklet front tamper HP)
3 40X4002 1 1 Booklet front tamper motor
4 40X4002 1 1 Booklet rear tamper motor
5 40X0825 10 1 Sensor (booklet rear tamper HP)
6 40X4003 1 1 Booklet rear tamper assembly

7-32 MFP Finisher Service Manual

 7500-432, -632, and -832

Assembly 20: Booklet maker 7

7
6

Asm- Part Units/ Units/

Description
Index number option FRU
1 40X4008 2 1 Booklet roll drive gear 18T
2 40X4006 5 1 Booklet roll drive gear 16T
3 40X4007 1 1 Booklet idler gear 38/18T
4 40X4009 1 1 Booklet drive gear 16T
5 40X4010 1 1 Folding drive gear 38T
6 40X4005 1 1 Exit roll drive belt
7 40X4004 1 1 Exit roll idler gear 20/25T

Parts catalog 7-33

7500-432, -632, and -832

Assembly 21: Booklet maker 8

2
4

4
3

Asm- Part Units/ Units/

Description
Index number option FRU
1 40X4012 1 1 Manual feed drive gear 28T
2 40X4014 1 1 Media exit sensor cable assembly
3 40X4013 1 1 Manual feed drive gear 17T
4 40X4011 4 1 Booklet media pinch roll assembly
5 40X0921 2 1 Sensor (booklet unit media exit)
6 40X0908 1 1 Sensor (finisher media entrance)

7-34 MFP Finisher Service Manual

 7500-432, -632, and -832

Assembly 22: Booklet maker 9

11
12
5

10 4

9
1
3

6
7

Asm- Part Units/ Units/

Description
Index number option FRU
1 40X4016 2 1 Booklet gear 43/14T
2 40X4024 1 1 Booklet gear 39/18T
3 40X4015 1 1 Booklet gear 45T
4 40X4017 1 1 Booklet gear 44/16T
5 40X4019 1 1 Booklet gear 27/34T
6 40X4023 1 1 Booklet sensor interface cable assembly
7 40X4022 1 1 Booklet motor interface cable assembly
8 40X4021 1 1 Booklet stapler interface cable assembly
9 40X4025 1 1 Booklet folding/exit drive motor assembly
10 40X4020 1 1 Spring
11 40X4018 1 1 Booklet knife solenoid
12 40X3992 1 1 Booklet media entrance drive moror assembly

Parts catalog 7-35

7500-432, -632, and -832

Assembly 23: Finisher—electronics

2
3

6
5

7-36 MFP Finisher Service Manual

 7500-432, -632, and -832

Assembly 23: Finisher—electronics

Asm- Part Units/ Units/
Description
Index number option FRU
1 40X0931 1 1 Bridge unit interface card assembly
2 40X0932 1 1 Bridge unit connect cable assembly
3 40X0933 1 1 Bridge unit interface card cable assembly
4 40X4154 1 1 Finisher controller card assembly (booklet finisher only)
4 40X0934 1 1 Finisher controller card assembly
5 40X0935 1 1 AC power cord assembly
6 40X0936 1 1 Finisher LVPS card assembly

Parts catalog 7-37

7500-432, -632, and -832

Assembly 24: Finisher—cables 1

2

1
7

7-38 MFP Finisher Service Manual

 7500-432, -632, and -832

Assembly 24: Finisher—cables 1

Asm- Part Units/ Units/
Description
Index number option FRU
1 40X0942 1 1 Upper media exit sensor cable assembly
2 40X0940 1 1 Finisher media entrance sensor cable assembly
3 40X0941 1 1 Buffer path sensor cable assembly
4 40X0937 1 1 Main sensor cable assembly
5 40X0946 1 1 Finisher LVPS cable assembly
6 40X0892 1 3 Sensor (lower media exit) assembly
• Sensor (lower media exit)
• Lower media exit sensor cable assembly
• Bracket
7 40X0943 1 1 Upper media bin full sensor cable assembly

Parts catalog 7-39

7500-432, -632, and -832

Assembly 25: Finisher—cables 2

1

5
6

Asm- Part Units/ Units/

Description
Index number option FRU
1 40X0922 1 1 Diverter gate sensor upper cable assembly
2 40X0944 1 1 Punch main drive cable assembly
3 40X0950 1 1 Diverter gate sensor lower cable assembly
4 40X0865 1 1 Punch waste box set cable assembly
5 40X0947 1 1 Interlock switch cable assembly
6 40X0945 1 1 Punch main sensor cable assembly

7-40 MFP Finisher Service Manual

 7500-432, -632, and -832

Assembly 26: Finisher—cables 3

Asm- Part Units/ Units/

Description
Index number option FRU
1 40X0938 1 1 Main drive cable assembly
2 40X0930 1 1 Punch waste box full cable assembly
3 40X0932 1 1 Bridge unit connect cable assembly
4 40X0931 1 1 Bridge unit interface card assembly
5 40X4412 1 1 Finisher interface cable assembly (booklet finisher only)
5 40X0939 1 1 Finisher interface cable assembly
6 40X0870 1 1 Stapler unit cable assembly

Parts catalog 7-41

7500-432, -632, and -832

7-42 MFP Finisher Service Manual

 7500-432, -632, and -832

Index

A error code messages - finisher 2-3

accessing service menus 3-1 service checks - finisher 2-10
acronyms 1-36 Diagnostic Menus
entering diagnostic menus 3-2
B Diagnostics Menus
belts available tests 3-2
buffer/transport 4-113 EVENT LOG 3-11
entrance/paddle 4-99 Clear the Event Log 3-13
exit 4-111 Display the Event Log 3-12
bridge unit Print the Event Log 3-13
bridge unit interface card assembly 4-115 FINISHER TESTS
drive motor 5-1 Feed Tests 3-6
entrance guide 4-14 Hole Punch Test 3-6
locations 5-1 Sensor Test 3-6
parts catalog 7-2 Staple Test 3-5
pinch roller 4-18 MOTOR TESTS 3-4
sensor (bridge unit media entrance) 4-16 OUTPUT TRAY TESTS
sensor (bridge unit media exit) 4-17 Feed Tests 3-4
sensor (bridge unit top cover interlock) 4-15 Feed To All Bins 3-5
bridge unit top cover assembly PRINTER SETUP 3-9
parts catalog 7-3 Configuration ID 3-10
buffer diverter gate 4-91 Defaults 3-9
buffer diverter gate solenoid 4-102 Engine Setting 1 to 4 3-10
buffer pinch guide assembly 4-95 Model Name 3-10
buffer roll assembly 4-93 Permanent Page Count 3-10
Printed Page Count 3-9, 3-10
C Serial Number 3-10
cables drive motors
locations 5-11 bridge unit 5-1
parts catalog 7-38, 7-40, 7-41 buffer/transport 4-113
carriage lift belt left 4-30 entrance/paddle 4-99
carriage lift belt right 4-32 exit 4-111
clamp paddle 4-76
compiler unit E
parts catalog 7-18 eject unit
component locations parts catalog 7-18
finisher components 5-1 electronics
covers parts catalog 7-36
bridge unit top cover assembly 7-3 entrance drive
finisher 7-6, 7-7 parts catalog 7-22
finisher front door assembly 4-27 error code messages - finisher 2-3
left lower cover 4-28 error codes
left upper cover 4-29 250.00 sensor (registration) on jam (MPF pick) 2-38 ,
parts catalog 7-8 2-39, 2-41, 2-42 , 2-43 , 2-45, 2-46
rear lower cover 4-23 280.00 sensor (bridge unit media entrance) on jam 2-10
rear upper cover 4-24 280.01 sensor (bridge unit media entrance) static jam A
right eject cover 4-21 2-11
right lower LVPS cover 4-22 281.00 sensor (bridge unit media exit) on jam A 2-12
top cover 4-19 281.03 sensor (bridge unit media exit) static jam 2-14
upper media bin front cover 4-25 282.00 sensor (finisher media entrance) on jam 2-15
282.01 sensor (finisher media entrance) static jam 2-17
D 283.00 sensor (finisher buffer path) on jam A 2-18
diagnostic aids 3-1 283.03 sensor (buffer path) static jam B 2-21
accessing service menus 3-1 284.00 sensor (lower media exit) off jam A 2-24
diagnostic information 284.03 sensor (lower media exit) on jam C 2-22

Index I-1
7500-432, -632, and -832

284.05 sensor (lower media exit) static jam 2-25 lower media exit roll assembly 4-81
286.00 sensor (compiler media present) static jam 2-28 lower pinch guide assembly 4-89
287.00 sensor (upper media exit) on jam A 2-30 lubrication specifications 6-1
287.01 sensor (upper media exit) off jam A 2-31
287.05 sensor (upper media exit) static jam A 2-33 M
288.00 sensor (diverter gate) on jam 2-34 media compiler unit assembly 4-69
288.01 sensor (diverter gate) static jam (to top bin) A media diverter gate solenoid 4-101
2-36 media eject
288.04 sensor (diverter gate) static jam (to stacker bin) parts catalog 7-16
A 2-37 media eject clamp motor assembly 4-66
980.02 finisher communication failure 2-47 media eject clutch 4-77
984.01 sensor (punch unit HP) off failure 2-59 media eject motor assembly 4-78
985.00 sensor (punch carriage shift HP) on failure 2-60 media eject shaft assembly 4-74
985.01 sensor (punch carriage shift HP) off failure 2-60 media eject unit assembly
986.00 sensor (media eject clamp HP) on failure 2-63 removal 4-59
986.01 sensor (media eject clamp HP) off failure 2-64 media entrance pinch guide assembly 4-96
987.00 sensor (media eject shaft HP) on failure 2-65 media entrance roll assembly 4-98
988.01 sensor (media eject shaft HP) off failure 2-66 models 1-1
988.01sensor (punch unit side reg) off failure 2-68
989.00 stapler unit failure 2-70
O
990.00 sensor (stapler carriage HP) on failure 2-70 options and features
990.01 sensor (stapler carriage HP) off failure 2-71 finisher 1-1
error messages compiler unit assembly 1-16
bridge unit top cover open 2-90 components 1-1
bridge unit top door open 2-93 features 1-3
finisher eject cover open 2-93 functions of sensors along the media path 1-11
finisher front door open 2-92 media size and weight 1-2
finisher upper media bin full 2-93 media transport 1-4
no punch waste box 2-94 power supply and interlock 1-34
punch waste box full 2-95 punch unit 1-13
stacker lower safety failure 2-100 stacker media bin 1-30
stacker media bin full (mix size) 2-96 stapler 1-22
stacker media bin full (no mix) 2-98 upper media bin 1-29
stacker set over count failure 2-101 weight 1-1
staple cartridge empty 2-102 P
ESD-sensitive parts 4-1
paddle and roll exit assembly 4-85
exiting Diagnostics Menu 3-18
parts catalog
F bridge unit 7-2
finisher controller card assembly 4-116 bridge unit lower assembly 7-4
Finisher diverter gate 4-90 bridge unit top cover assembly 7-3
front door buffer 7-22, 7-24
parts catalog 7-8 cables 7-38, 7-40, 7-41
covers 7-6, 7-7
L covers and front door 7-8
left lower cover 4-28 eject and compiler unit 7-18
left upper cover 4-29 electronics 7-36
locations entrance drive 7-22
bridge unit assembly 5-1 how to use this parts catalog 7-1
buffer, upper exit, lower exit and drive motors 5-5 lower exit drive 7-20
cables 5-11 media eject 7-16
diverter and media eject 5-4 punch 7-12
finisher control card assembly 5-6 stacker bin lift 7-10
media eject and media compiler 5-4 stapler 7-14
punch unit 5-3 transport 7-24
stacker lift and staple 5-2 upper drive 7-24
low voltage power supply (LVPS) POR sequence 2-2
removal 4-117 power-on sequence (POR) 2-2
lower exit drive punch unit
parts catalog 7-20 punch carriage assembly 4-41

I-2 MFP Finisher Service Manual

 7500-432, -632, and -832

punch carriage shift motor assembly 4-43 rear upper cover 4-24
punch media stop assembly 4-46 right eject cover 4-21
punch unit assembly 4-45 right lower low voltage power supply (LVPS) cover 4-22
punch unit motor assembly 4-47 sensor (bridge unit media entrance) 4-16
sensor (bridge unit media exit) 4-17
R sensor (buffer path) 4-92
rear upper cover 4-24 sensor (compiler media in) 4-72
removals—finisher sensor (diverter gate) 4-108
(sensor bridge unit top cover interlock) 4-15 sensor (finisher media entrance) 4-97
belt (buffer/transport) 4-113 sensor (front tamper HP) 4-71
belt (entrance/paddle) 4-99 sensor (lower media exit) 4-80
belt (exit) 4-111 sensor (media eject clamp HP) 4-67
bridge unit assembly 4-5 sensor (media eject shaft HP) 4-79
bridge unit drive belt 4-8 sensor (punch cam front) 4-49
bridge unit drive motor assembly 4-13 sensor (punch carriage shift HP) 4-51
bridge unit drive pulley 4-8 sensor (punch hole select) 4-49
bridge unit entrance guide 4-14 sensor (punch unit HP) 4-49
bridge unit idler rolls 4-11 sensor (punch unit motor encoder) 4-48
bridge unit interface card assembly 4-115 sensor (punch unit side registration pair) with bracket
bridge unit left shaft assembly 4-10 4-44
bridge unit pinch roller 4-18 sensor (punch waste box full) 4-53
bridge unit rear cover 4-6 sensor (punch waste box set) 4-52
bridge unit right shaft assembly 4-9 sensor (rear tamper HP) 4-71
bridge unit top cover assembly 4-7 sensor (stacker bin level 1) 4-34
bridge unit transport belts 4-12 sensor (stacker bin level 2) 4-34
buffer diverter gate 4-91 sensor (stacker bin level encoder) 4-35
buffer diverter gate solenoid 4-102 sensor (stacker bin no media) 4-36
buffer pinch guide assembly 4-95 sensor (stacker bin upper limit) 4-36
buffer roll assembly 4-93 sensor (stapler carriage HP) 4-58
carriage lift belt left 4-30 sensor (upper media bin full) 4-106
carriage lift belt right 4-32 sensor (upper media exit) 4-103
clamp paddle 4-76 stacker bin lift motor assembly 4-38
drive motor (buffer/transport) 4-113 stacker media bin assembly 4-22
drive motor (entrance/paddle) 4-99 stapler unit assembly 4-56
drive motor (exit) assembly 4-111 stapler unit frame 4-54
finisher 4-3 sub paddle 4-63
finisher controller card assembly 4-116 sub paddle drive shaft assembly 4-64
finisher diverter gate solenoid 4-101 switch (eject cover interlock) 4-68
finisher front door assembly 4-27 switch (finisher front door interlock) 4-26
finisher LVPS 4-117 top cover 4-19
left lower cover 4-28 upper media bin assembly 4-20
left upper cover 4-29 upper media bin front cover 4-25
lower media exit roll assembly 4-81 upper media exit pinch roll assembly 4-103
lower pinch guide assembly 4-89 upper media exit roll assembly 4-104
media compiler unit assembly 4-69 upper media transport roll assembly 4-109
media diverter gate 4-90 upper pinch guide assembly 4-107
media eject clamp motor assembly 4-66
media eject clutch 4-77 S
media eject motor assembly 4-78 safety information ii-xvii
media eject shaft assembly 4-74 safety inspection guide 6-1
media eject unit assembly 4-59 sensors
media entrance pinch guide assembly 4-96 bridge unit media entrance 4-16, 5-1
media entrance roll assembly 4-98 bridge unit media exit 4-17 , 5-1
paddle and roll exit assembly 4-85 bridge unit top cover interlock 4-15, 5-1
punch carriage assembly 4-41 buffer path 4-92
punch carriage shift motor assembly 4-43 compiler media in 4-72
punch media stop assembly 4-46 diverter gate 4-108
punch unit assembly 4-45 finisher media entrance) 4-97
punch unit motor assembly 4-47 front tamper HP 4-71
rear lower cover 4-23 lower media exit 4-80, 5-4

Index I-3
7500-432, -632, and -832

media eject clamp HP 4-67, 5-4

media eject shaft HP 4-79
punch cam front 4-49, 5-3
punch carriage shift HP 4-51, 5-3
punch hole select 4-49, 5-3
punch unit HP 4-49, 5-3
punch unit motor encoder 4-48
punch unit side reg 1 5-3
punch unit side reg 2 5-3
punch unit side registration pair with bracket 4-44
punch waste box full 4-53, 5-3
punch waste box set 4-52
punch waste box set) 5-3
rear tamper HP 4-71
stacker bin level 1 4-34, 5-2
stacker bin level 2 4-34, 5-2
stacker bin level encoder 4-35
stacker bin no media 4-36
stacker bin upper limit 4-36, 5-2
stapler carriage HP 4-58, 5-2
upper media bin full 4-106
upper media exit 4-103
service checks - finisher 2-10
stacker unit
locations 5-2
media bin assembly 4-22
stacker bin lift motor assembly 4-38
staple unit
locations 5-2
parts catalog 7-14
stapler carriage motor assembly 5-2
stapler unit assembly 4-56
stapler unit frame 4-54
sub paddle
removals 4-63
sub paddle drive shaft assembly 4-64
switches
eject cover interlock 4-68 , 5-4
finisher front door interlock 4-26, 5-2

T
theory
finisher 1-4
tools required 1-36

U
upper media bin assembly 4-20
upper media exit pinch roll assembly 4-103
upper media exit roll assembly 4-104
upper media transport roll assembly 4-109
upper pinch guide assembly 4-107

I-4 MFP Finisher Service Manual

 7500-432, -632, and -832

Part number index

P/N Description Page

40X0810 Bridge unit assembly docking screw - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2

40X0811 Bridge unit assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2
40X0812 Bridge unit pinch roll kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
40X0813 Bridge unit top cover assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
40X0814 Bridge unit rear cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X0815 Bridge unit drive belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X0816 Bridge unit drive pulley - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X0817 Bridge unit drive motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X0818 Bridge unit entrance guide kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X0819 Ball bearing 4 mm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X0820 Transport belts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X0821 Idler roll kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X0822 Bridge unit right shaft kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X0823 Bridge unit left shaft assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X0824 Magnetic catch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5, 7-23, 7-25
40X0825 Sensor (booklet end guide HP) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-30
40X0825 Sensor (booklet front tamper HP) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-32
40X0825 Sensor (booklet knife folding) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31
40X0825 Sensor (booklet knife HP) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31
40X0825 Sensor (booklet rear tamper HP) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-32
40X0825 Sensor (bridge unit top cover interlock) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X0825 Sensor (compiler media in) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
40X0825 Sensor (media eject clamp HP) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
40X0825 Sensor (media eject shaft HP) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
40X0826 Sensor (bridge unit media exit) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X0827 Sensor (bridge unit media entrance) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X0828 Bridge unit cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
40X0829 Top cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X0830 Upper media bin vertical cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X0831 Upper media bin assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X0832 Right eject cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X0833 Stacker media bin - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X0834 Right lower LVPS cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X0835 Caster - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X0836 Rear lower cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X0837 Bridge unit hookup cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X0838 Rear upper cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X0839 Upper media bin front cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
40X0840 Switch (finisher front door interlock) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
40X0841 Finisher front door assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
40X0842 Finisher docking latch kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
40X0843 Finisher docking bracket kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
40X0844 Left lower cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
40X0845 Left upper cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
40X0846 Carriage lift belt kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
40X0847 Sensor (stacker bin level) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
40X0848 Ball bearing 10 mm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
40X0849 Stacker slip clutch pulley kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
40X0850 Sensor (booklet unit interlock) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27
40X0850 Sensor (front tamper HP) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
40X0850 Sensor (punch cam front) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
40X0850 Sensor (punch hole select) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
40X0850 Sensor (punch unit HP) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
40X0850 Sensor (rear tamper HP) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19

Part number index I-5

7500-432, -632, and -832

40X0850 Sensor (stacker bin level encoder) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11

40X0850 Sensor (stacker bin no media) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
40X0850 Sensor (stacker bin upper limit) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
40X0850 Sensor (stapler carriage HP) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
40X0851 Stacker bin lift motor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
40X0853 Punch unit cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
40X0854 Punch carriage shift motor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
40X0855 Punch carriage assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
40X0856 Sensor (punch unit side reg) assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
40X0857 2/3 punch unit assembly (this comes assembled) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
40X0858 2/4 punch unit assembly (this comes assembled) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
40X0859 Punch media stopper assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
40X0861 Sensor (punch waste box set) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
40X0862 Punch waste box (non-booklet making finisher) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
40X0864 Sensor (punch waste box full) (non-booklet making finisher only) - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
40X0865 Punch waste box set cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13, 7-40
40X0866 Staple cartridge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
40X0867 Stapler unit assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
40X0868 Stapler unit cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
40X0869 Stapler carriage kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
40X0870 Stapler unit cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15, 7-41
40X0871 Stapler carriage motor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
40X0872 Stapler carriage rack gear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
40X0873 Media eject unit assembly (this comes assembled) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
40X0874 Sub paddle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
40X0875 Sub paddle drive shaft kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
40X0876 Media eject clamp motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
40X0877 Eject clamp lever assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
40X0878 Bushing 8 mm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
40X0879 Sub paddle/entrance drive gear 23T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17, 7-23
40X0880 Bushing 6 mm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-28
40X0881 Eject clamp gear kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
40X0882 Switch (eject cover interlock) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
40X0883 Media compiler unit assembly (this comes assembled) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
40X0886 Media eject shaft assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
40X0887 Clamp paddle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
40X0888 Bushing 6 mm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17, 7-19, 7-21, 7-23, 7-25
40X0889 Media eject shaft gear 39T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
40X0890 Media eject clutch kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
40X0891 Media eject motor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
40X0892 Sensor (lower media exit) assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39
40X0892 Sensor (lower media exit) with bracket - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
40X0893 Sensor (buffer path) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
40X0893 Sensor (lower media exit) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
40X0893 Sensor (upper media exit) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
40X0894 Static eliminator brush - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
40X0895 Lower media exit roll assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
40X0896 Main paddle shaft kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
40X0897 Belt idler pulley - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21, 7-23, 7-25
40X0898 Lower exit roll drive pulley kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
40X0899 Booklet media transport roll drive gear 23T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-28
40X0899 Main paddle idler gear kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
40X0900 Main paddle drive pulley/gear 44/20T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
40X0901 Lower pinch guide assembly (this comes assembled) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
40X0902 Finisher diverter gate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
40X0903 Buffer diverter gate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
40X0904 Buffer upper guide assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
40X0905 Buffer roll assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
40X0906 Buffer pinch guide assembly (this comes assembled) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23

I-6 Service Manual

 7500-432, -632, and -832

40X0907 Media entrance pinch guide assembly (this comes assembled) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
40X0908 Sensor (finisher media entrance) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23, 7-25, 7-34
40X0909 Media entrance roll assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
40X0910 Drive motor (buffer/transport) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
40X0910 Drive motor (entrance/paddle) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
40X0910 Drive motor (exit) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
40X0911 Belt, entrance/paddle, 31.6 cm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
40X0912 Belt tensioner bracket kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
40X0912 Belt tensioner pulley kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
40X0913 Ball bearing 6 mm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21, 7-23, 7-25
40X0914 Media entrance roll drive pulley 20T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
40X0915 Buffer roll drive gear 46T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
40X0916 Media diverter solenoid kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
40X0917 Buffer diverter solenoid kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23, 7-28
40X0918 Upper media exit pinch roll assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
40X0919 Upper media exit roll assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
40X0920 Upper pinch guide assembly (this comes assembled) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
40X0921 Sensor (booklet unit media exit) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-34
40X0921 Sensor (diverter gate) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
40X0922 Diverter gate sensor upper cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25, 7-40
40X0923 Upper media transport roll assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
40X0924 Buffer roll drive pulley/gear 53/23T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
40X0925 Upper media transport roll drive pulley 20T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
40X0926 Upper media exit roll drive pulley/gear, 20T/20T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
40X0927 Upper media exit roll drive gear, 20T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
40X0928 Belt (buffer transport), 19.8 cm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
40X0929 Belt (exit) 27.7 cm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
40X0930 Punch waste box full cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13, 7-41
40X0931 Bridge unit interface card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37, 7-41
40X0932 Bridge unit connect cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37, 7-41
40X0933 Bridge unit interface card cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
40X0934 Finisher controller card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
40X0935 AC power cord assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
40X0936 Finisher LVPS card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
40X0937 Main sensor cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39
40X0938 Main drive cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41
40X0939 Finisher interface cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41
40X0940 Finisher media entrance sensor cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39
40X0941 Buffer path sensor cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39
40X0942 Upper media exit sensor cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39
40X0943 Upper media bin full sensor cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39
40X0944 Punch main drive cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-40
40X0945 Punch main sensor cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-40
40X0946 Finisher LVPS cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39
40X0947 Interlock switch cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-40
40X0950 Diverter gate sensor lower cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-40
40X1388 Bushing 8 mm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
40X3937 2/4 punch unit assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
40X3938 Sensor (punch carriage shift HP) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
40X3943 Punch unit motor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
40X3944 Sensor (punch unit motor encoder) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
40X3946 Punch waste box (booklet making finisher) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
40X3958 Booklet pinch guide assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-28
40X3961 Booklet diverter gate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-28
40X3962 Booklet media transport roll torque limiter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-28
40X3963 Booklet media path roll retainer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-28
40X3978 Booklet controller card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27
40X3979 Booklet unit right glide assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27
40X3980 Booklet unit left glide assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27

Part number index I-7

7500-432, -632, and -832

40X3981 Booklet bin assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27

40X3982 Booklet controller card power cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27
40X3983 Booklet bin/diverter cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27
40X3984 Booklet unit cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27
40X3985 Booklet unit interface connector assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27
40X3987 Booklet bin hookup cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27
40X3988 Booklet unit catch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
40X3989 Booklet manual feed drive gear 31T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
40X3990 Booklet manual feed knob - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
40X3992 Booklet media entrance drive moror assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35
40X3992 Booklet media entrance drive motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-30
40X3993 Gear pulley 40/20T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-30
40X3994 Booklet end guide drive belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-30
40X3995 Booklet paddle idler gear 14T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-30
40X3996 Booklet paddle drive motor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-30
40X3997 Booklet paddle shaft assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-30
40X3998 Booklet knife HP sensor cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31
40X3999 Booklet knife sector drive gear 42T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31
40X4001 Booklet front tamper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-32
40X4002 Booklet front tamper motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-32
40X4002 Booklet rear tamper motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-32
40X4003 Booklet rear tamper assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-32
40X4004 Exit roll idler gear 20/25T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33
40X4005 Exit roll drive belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33
40X4006 Booklet roll drive gear 16T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33
40X4007 Booklet idler gear 38/18T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33
40X4008 Booklet roll drive gear 18T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33
40X4009 Booklet drive gear 16T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33
40X4010 Folding drive gear 38T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33
40X4011 Booklet media pinch roll assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-34
40X4012 Manual feed drive gear 28T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-34
40X4013 Manual feed drive 17T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-34
40X4014 Media exit sensor cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-34
40X4015 Booklet gear 45T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35
40X4016 Booklet gear 43/14T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35
40X4017 Booklet gear 44/16T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35
40X4018 Booklet knife solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35
40X4019 Booklet gear 27/34T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35
40X4020 Spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35
40X4021 Booklet stapler interface cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35
40X4022 Booklet motor interface cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35
40X4023 Booklet sensor interface cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35
40X4024 Booklet gear 39/18T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35
40X4025 Booklet folding/exit drive motor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35
40X4118 Booklet path media transport roll assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-28
40X4128 Belt idler pulley - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-28
40X4149 Buffer diverter gate (booklet finisher only) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
40X4150 Media eject shaft assembly (booklet finisher only) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
40X4154 Finisher controller card assembly (booklet finisher only) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
40X4405 Caster (booklet finisher only) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
40X4409 Stacker bin lift motor assembly (booklet finisher only) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
40X4410 Main paddle shaft kit (booklet finisher only) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
40X4411 Media entrance pinch guide assembly (this comes assembled)(booklet finisher only) - - - - - - - - - - - - - 7-23
40X4412 Finisher interface cable assembly (booklet finisher only) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41
40X4413 Booklet unit assembly (this comes assembled) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27
40X4414 Booklet stapler unit assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
40X6865 2/3 punch unit assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13

I-8 Service Manual

 Booklet stapler
drive motor assembly

SWITCH (rear
booklet staple low)
Booklet end guide
drive motor assembly
Booklet media entrance
drive motor assembly

SWITCH
staple low)
(front booklet
Booklet stapler ASM
AC IN
Finisher

Booklet folding/exit
drive motor assembly
6
5
4
3
2
1
motor assembly
(From Engine)

Booklet paddle drive

6
5
4
3
2
1

+24VDC
+24VDC
+24VDC
+24VDC

CLOCKB

CLOCK/B
CLOCK B
CLOCK/A
CLOCK A
CLOCK/B
CLOCK/A
CLOCK A
Frame
Finisher
To Metal

9
8
7
6
5
4
3
2
1

15
14
13
12
11
10
Sensor (Punch Waste
Box Full)

Neutral
HOT
SIG GND
3
PUNCH FULL SNR(L)+5VDC

1
2
3
4
2
+5VDC
1

CLOCK B
CLOCK/A
CLOCK/B
CLOCK A
+24VDC
CLOCK/B
+24VDC
XCLOCK B
+24VDC
CLOCK/A
+24VDC
CLOCK A
BOOKLET PADDLE MOTOR ON(L)+24VDC
ORN +24VDC
DC COM(TO STAPLER ASM)
DC COM(TO STAPLER ASM)
LOW STAPLES(FRONT)(H)+5VDC
LOW STAPLES(REAR)(H)+5VDC
P2

1
3

2
4
6
8
10
12
14
16
18
20
22
24
26
28
30

1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
Sensor (Bridge Unit Top

2 J8500
Cover interlock

BOOKLET FOLDER ROLL MOT REV(H)+24VDC

BOOKLET FOLDER ROLL MOT FWD(H)+24VDC

MOT-
BOOKLET STAPLE MOT ON MOT+
SIG GND
1 3
BRIDGE COVER CLOSED(L)+5VDC
DEC CLUTCH DRV DOCKING SNR 15 16 2 2 Sensor(Bridge Unit

1 3
2 4
2 1
4 3
6 5
8 7
10 9
15 16 +5VDC

12 11
14 13
16 15
18 17
20 19
22 21
24 23
26 25
28 27
30 29
3 1 Media exit)
+5VDC IOT FULL SNR 14 17
14 17 SIG GND
SIG GND BRIDGE ENT SNR 13 18 4 3
13 18 BRIDGE MEDIA EXIT SNR(L)+5VDC
DEC HOME SNR BRIDGE EXIT SNR 12 19 5 2
12 19 +5VDC

Card ASM
IF EXIT SNR BRIDGE I/L SNR 11 20 6 1
11 20 SIG GND

P8407
P8406
Sensor(Bridge Unit
X IF ENDT SNR PUNCH FULL SNR 10 21 7 3 Media entrance)
1 10 21 BRIDGE MEDIA ENTRANCE SNR(L)+5VDC
X IF MOT ENB BRIDGE MOT ENABLE 9 22 8 2
2 9 22 +5VDC
booklet bin media

Finisher LVPS
X ,MOT RESET IF MOT BRAKE 8 23 J8371 9 1
\transport motor 3 8 23 BRIDGE MOT A BRIDGE MOT/A
DC COM HT IF MOT CLK GATE SOL PUSH 7 24 10 6

J8372
1 DC COM 4 7 24 BRIDGE MOT /A I/L +24VDC
DC COM IF MOT PHASE GATE SOL PULL 6 25 11 5
2 DC COM 5 6 25 BRIDGE MOT B BRIDGE MOT A
IF MOT CURRENT RS232C SELECT

Bridge Unit
+24VDC P8408 5 26 12 BRIDGE MOT/B
4 P502
3 +24VDC 6 5 26 BRIDGE MOT B

P505
+24VDC RTN FIN TO H-TRA 4 27 13 3
4 +24VDC 7 4 27 I/L +24VDC I/L +24VDC

Bridge Unit
RNT

Drive Motor
DC COM BRIDGE TO FIN 3 28 14 2

1
2
3
4
5
6
3
4
3 28 I/L+24VDC BRIDGE MOT/B
8 +24VDV SIG GND 15 1
+5VDC

Interface Card ASM

2 29 2 29
1 9 +24VDC +24VDC
+5vdc 1 30
2 10 1 30
DC COM

BOOKLET TRAY ASM

3 11
X
Sensor (Booklet 12
X

TO FINISHER CONTROLLER CARD ASM P8310 (PINS 1-15)

bin media present) 13

TO FINISHER CONTROLLER CARD ASM P8310 (PINS 16-30)

3
2
1

Switch (Finisher
14 15

Front Door Interlock)

Switch(Eject Cover Interlock)
13 16
12 17 A B

I/L+24VDC
11 18 TO BOOKLET CARD ASM P8377

EJECT COVER

folding)
(Booklet knife
SENSOR

tamper HP)
(booklet front
SENSOR
10 19 1 1

HP)
(booklet knife
SENSOR

no media)
compiler
SENSOR (booklet
9 20 2 2
8 21

Booklet controller card ASM

7 22 P8405
6 23

3
2
1

3
2
1

rear tamper HP)

SENSOR (booklet
5 24

3
2
1

3
2
1
3
2
1
4 25
3 26
2 27
LVPS SQ
LVPS SQ

+24VDC
+24VDC
RTN
RTN

1 28
1
2
3

P8378
SIG GND
FRONT DR INTLK SW
EJECT COVER
I/L+24VDC
+24VDC
4
5
6

MOTOR CLOCK
MOTOR CLOCK
MOTOR CLOCK
PAPER PATH MOTOR CLOCK
END GUIDE AT HOME POSITION(L)+5VDC
SUB-CPU IN
SUB-CPU OUT
SUB-CPU TXD
SUB-CPU RXD

FRONT TAMPER AT HOME POSITION(H)+5VDC

REAR TAMPER AT HOME POSITION(H)+5VDC
MOTOR CLOCK

CN1

P8377
4
3
2
1
1
2

1
2
3
4
5
6
7
8
9
9
8
7
6
5
4
3
2
1
4 2
3 1

plug
Shorting
10
11
12
13
14
15
12
11
10
1 4
2 5
3 6
1 3
2 4

10

P8314

P8316
P8313
9

SUB CPU IN
P8315

SUB-CPU TXD
SUB CPU RXD

SUB-CPU OUT

DC COM
+5VDC
+5VDC
DC COM
+5VDC
+5VDC
DC COM
+5VDC
+5VDC
+5VDC
DC COM
+5VDC
CLOCK B

SNR COMPILER NO MEDIA (H)+5VDC

8

MOTOR CLOCK
MOTOR CLOCK
MOTOR CLOCK
P8317

7
6

1 28
2 27
3 26
4 25
5 24
6 23
7 22
8 21
9 20
10 19
11 18
12 17
13 16
14 15
P8311 5

PAPER PATH MOTOR CLOCK

P8310 4
3

+5VDC
+5VDC
+5VDC
+5VDC
+5VDC
2

+24VDC
END GUIDE AT HOME POSITION(H)+5VDC

DC COM
DC COM
DC COM
DC COM
DC COM
D+24VDC +24VDC

REAR TAMPER AT HOME POSITION(H)+5VDC

16 1 1

FRONT TAMPER AT HOME POSITION(H)+5VDC

SIG GND +24VDC
17 2
BRIDGE TO FIN RTN
TO FINISHER CONTROLLER CARD ASM P8316 18 3
finisher to hicapt ray RTN
19 4
RS232C SELECT IF MOT CURRENT

SNR BOOKLET IN (H)+5VDC

20 5
GATE SOL PULL IF MOT PHASE

BOOKLET UNIT INTLK(H)+24VDC

21 6
GATE SOL PUSH HF IF MOT CLK

BOOKLET MED EXIT SNR(H)+5VDC

22 7
IF MOT BRAKE MOT RESET Sensor
23 8 B A B A (Stacker Bin Level 1)
BRIDGE MOT ENABLE IF MOT ENB
24 9 STACKER BIN LVL SNR1 CLK SIG GND
PUNCH FULL SNR IF ENT SNR 20 1 1 20 1 5
25 10 STACKER BIN LEV SNR2 CLK STACKER BIN LVL SNR1(L)+5VDC
BRIDGE I/L SNR IF EXIT SNR 19 2 2 19 2 4
26 11 Sensor (Stacker +5VDC +5VDC
BRIDGE EXIT SNR DEC HOME SNR 18 3 Bin Level 2) 3 18 3 3
27 12 STACKER BIN LVL SNR2(L)+5VDC STACKER BIN LVL SNR1 CLK
BRIDGE ENT SNR SIG GND 17 4 4 17 4 2
28 13 SIG GND STACKER BIN LEVEL SNR2 CLK
IOT FULL SNR +5VDC 16 5 5 16 5 1 Sensor (Media Eject
29 14 +5VDC SIG GND
DOCKING SNR DEC CLUTCH DRV 15 6 1 15 6 3 Clamp HP)
30 15 BUFFER PATH SNR(L)+5VDC EJECT CLAMP UP(L)+5VDC
14 7 Sensor 2 14 7 2

CLOCK/B
CLOCK B
CLOCK/A
+24VDC
CLOCK A
CLOCK/B
CLOCK B
CLOCK/A
+24VDC
CLOCK A
(Buffer Path) SIG GND +5VDC

1
2
3
1
2
3
13 8 3 13 8 1
TO BRIDGE UNIT INTERFACE ASM J8371 (PINS 1-15)

+5VDC

TO BRIDGE UNIT INTERFACE ASM J8371 (PINS 16-30)

SIG GND

5
4
3
2
1
6
5
4
3
2
1
12 9 1 12 9 3
Sensor (Upper UPPER MEDIA BIN FULL SNR(L)+5VDC MEDIA EJECT SNR(L)+5VDC
11 10 2 11 10 2 Sensor (Media Eject
Media Bin Full)

2
1
P8302 SIG GND +5VDC Shaft HP)
10 11 3 10 11 1
+5VDC SIG GND
9 12 Sensor (Upper 1 9 12 3
Media Exit) UPPER MEDIA EXIT SNR(L)+5VDC

1
2
3
1
2
3
STACKER BIN LFL ENCODE SNR(L)+5VDC Sensor(Stacker
8 13 2 8 13 2 Bin Level Encoder)
SIG GND +5VDC

drive motor
7 14 Sensor 3 7 14 1

Booklet front

SENSOR
entrance)
(Diverter Gate) +5VDC SIG GND
6 15 1 6 15 3
DIVERTER GATE SNR(L)+5VDC STACKER NO MEDIA SNR(L)+5VDC Sensor

Booklet knife solenoid

5 16 2 5 16 2 (Stacker Bin

tamper drive motor

SIG GND +5VDC

6 booklet rear tamper

No Media)
4 17 3 4 17 1
+5VDC SIG GND
3 18 3

(booklet unit interlock)

1 FIN MEDIA ENTRANCE SNR(L)+5VDC
3 18
STACKER BIN UPPER LIMIT SNR (L)+5VDC

Sensor
Sensor (Finisher

SENSOR (Booklet media

1 2 19 2 2 19 2
Media Entrance)

guide HP)
SIG GND +5VDC

media exit)
2 1 20 3 1 20 1

(Booklet end
P8301
3
Sensor (Stacker

SENSOR (booklet
Bin Upper Limit)

SIG GND
11 1 Sensor
FIN TO ENGINE (Diverter Gate)
10 2 +5VDC
ENGINE TO FIN 1 3
9 3 Gate Mdia SNR(H)+5VDC
REGI CLUTCH ON 2 2
8 4 SIG GND
3 1
7 5 P8376 4
6 6 5
5 7 6
PJ416

4 8 P8300
LVPS SQ
Card ASM
Card ASM

3 9
FUSER EXIT
2 10
To Printer Engine

1 11 ELEVATOR MOTOR DOWN(H)+24VDC

1
12 P8305 ELEVATOR MOTOR UP(H)+24VDC
2
Lift Motor
Stacker Bin

13
14
15
Finisher Controller

SIG GND
1 3 Sensor
FRONT TAMPER HOME SNR(L)+5VDC (Media In)
2 2
+5VDC
3 1
SIG GND
Sensor (Punch Sensor (Punch 4 3 Sensor (Front
Hole Select) Waste Box Set) BA FRONT TAMPER HOME SNR(L)+5VDC Tamper HP)
ANODE +5VDC 5 2
3 12 1 3 12 1 +5VDC
PUNCH HOLE SELECT SNR(L)+5VDC PUNCH WASTE BOX SET(L)+5VDC 6 1
2 11 2 2 Sensor (Punch 11 2 SIG GND
SIG GND SIG GND Carriage shift
7 3
1 10 3 1 10 3 REAR TAMPER HOME SNR(L)+5VDC Sensor (Rear
ANODE +5VDC HP) 8 2 Tamper HP)
3 9 4 3 9 4 +5VDC
PUNCH CAM FRONT SNR(L)+5VDC PUNCH CARRIAGE SHIFT(L)+5VDC 9 1
2 8 5 2 8 5 FRONT TAMPER MOT A
SIG GND SIG GND P8309 10 6
1 7 6 1 7 6 +24VDC

Cam Front)
ANODE +5VDC P8307 11 4
3 6 7 3 6 7 FRONT TAMPER MOT/A

Sensor (Punch
PUNCH UNIT HP SNR(L)+5VDC PUNCH UNIT SIDE REG2 SNR(L)+5VDC Sensor (Punch 12 3
Motor

Sensor (Punch 2 5 8 2 Unit Side REG2) 5 8 FRONT TAMPER MOT B

Unit HP) SIG GND SIG GND 13 2
Front Tamper

1 4 9 1 4 9 FRONT TAMPER MOT/B

SIG GND +5VDC 14 1
3 3 10 3 3 10 REAR TAMPER MOT A
PUNCH UNIT ENCODER SNR(L)+5VDC PUNCH UNIT SIDE REG1 SNR(L)+5VDC 15 6
2 2 11 2 2 11 +24VDC
+5VDC SIG GND 16 4
1 1 12 1 1 12 REAR TAMPER MOT/A
Sensor (Punch 17 3
Rear

Sensor (Punch
Motor

Unit Side REG1) REAR TAMPER MOT B

Tamper

Unit Motor Encoder) BA 18 2

REAR TAMPER MOT/B
19 1

Punch Motor CCW ON(H)+24VDC

1
Punch Motor CW ON(H)+24VDC
2
Punch Unit
Motor
8
Motor

4
PUNCH MOT A PUNCH MOT A
1 7 4 8
I/L +24VDC I/L +24VDC
Eject Clamp

2 3 3 7
SHIFT MOT/A SHIFT MOT/A
3 6 2 6
SHIFT MOT B I/L+24VDC
P8306

4 2 1 5
I/L+24VDC SHIFT MOT B
2

5 5
Punch Carriage
Solenoid

Shift Motor ASM

SHIFT MOT/B SHIFT OT/B

6 1
P8304
Solenoid

P8308
Finisher Diverter
Buffer Diverter

Solenoid

1 2
3 4
5 6
7 8

1 2
3 4
5 6
7 8
9 10
11 12
13 14
15 16
17 18
19 20
21 22
23 24
25 26
27 28
29 30
31 32

9
8
P8389 7
6
5
4
3
2
1
9 10
11 12
13 14
15 16
17 18

12
11
10
Sub Paddle
1
2
3
1
2
3

Drive Motor(Exit)
1
2

Drive Motor
Media

(Buffer/Transport)

1
3
5
7
9
11
13
15
17
6
5
4
3
2
1
Eject Clutch

2
4
6
8
10
12
14
16
18
6
5
4
3
2
1
1
2

+5VDC
+5VDC

SIG GND
SIG GND
I/L+24VDC

B/T MOT/B
B/T MOT B
B/T MOT/A
B/T MOT A

I/L +24VDC

I/L +24VDC
I/L +24VDC
STAPLE MOT-
STAPLE MOT-
STAPLE MOT+
STAPLE MOT+
I/L+24VDC
I/L +24VDC

STAPLE MOVE B
STAPLE MOVE/B
STAPLE MOVE A
STAPLE MOVE/A
EXIT MOT/B
EXIT MOT B
EXIT MOT/A
EXIT MOT A

LOW STAPLE SNR(l)+5VDC

STAPLE READY SNR(L)+5VDC

STAPLE HEAD HOME SNR(L)+5VDC

STAPLE CARRIAGE POSITION SNR(L)+5VDC
EXIT MOT/A
EXIT MOT A
EXIT MOT B
I/L +24VDC
EXIT MOT/B
I/L +24VDC
B/T MOT A
I/L +24VDC
B/T MOT/A
I/L 24VDC
B/T MOT B
B/T MOT/B
MEDIA EJECT CLUTCH ON (L)+24VDC
I/L +24VDC
I/L +24VDC
SUB PADDLE SOLENOID ON(L)+24VDC
I/L +24VDC
TRANSPORT GATE SOLENOID(PUSH)(L)+24VDC
TRANSPORT GATE SOLENOID(PULL)(L)+24VDC
I/L+24VDC
BUFFER DIV SOLENOID(PUSH)+24VDC
BUFFER DIV SOLENOID(PULL)+24VDC

EJECT CLAMP MOTOR ON(H)+24VDC

EJECT CLAMP MOTOR CCW ON(H)+24VDC

1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35

2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36

3
2
1
P8304
I/L+24VDC
I/L +24VDC
I/L +24VDC
I/L +24VDC

EJECT MOT A
EJECT MOT/A
EJECT MOT B
EJECT MOT/B

Carriage HP)
Sensor(Stapler
ENT/PAD MOT A
ENT/PAD MOT/A
ENT/PAD MOT B
ENT/PAD MOT/B

4
3
2
1
5
4
3
2
1

6
5
4
3
2
1
Staple)

Motor ASM
Sensor(Low

Stapler Carriage
I/L+24VDC
I/L +24VDC

ENT/PAD MOT/B
ENT/PAD MOT B
ENT/PAD MOT/A
ENT/PAD MOT A

I/L+24VDC
I/L +24VDC

Unit
6
5
4
3
2
1

MED/EJ MOT/B
MED/EJ MOT B
MED/EJ MOT/A
MED/EJ MOT A

Motor
Staple
HP)
6
5
4
3
2
1

(Staple Ready)
Sensor
Drive Motor
(Entrance/Paddle)

ASM
Drive Motor

Sensor (Staple
(Media Eject)

Stapler unit