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Lexmark Optra W840 Finisher 4024

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Lexmark Optra W840 Finisher 4024 Manuel de service

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Description

Lexmark Optra W840 Finisher 4024-XXX Service manual
Edition: January 30, 2007

Notices and safety information . ix
Laser notice .ix
Safety informationxiii
Preface xvi
Definitions . .  xvi
General information . .  1-1
Finisher weight . .  1-1
Components .  1-1
Media size and weight . 1-2
Media size/orientation and applicable functions 1-2
Media weight . 1-4
Tools required for service . 1-4
Features . 1-4
Acronyms . 1-5
Diagnostic information 2-1
Start . 2-1
Using service checks 2-1
Confirm the installation status . 2-2
Error code messages . .  2-3
Service checks .2-11
280.00 Sensor (bridge unit media entrance) on Jam 2-11
280.01 Sensor (bridge unit media entrance) static jam A 2-12
280.02 Sensor (bridge unit media entrance) static jam B 2-13
281.00 Sensor (bridge unit media exit) On Jam A 2-14
281.01 Sensor (bridge unit media exit) On Jam B 2-16
281.02 Sensor (bridge unit media exit) On Jam C 2-18
281.03 Sensor (bridge unit media exit) static jam A . 2-19
282.00 Sensor (finisher media entrance) on jam . 2-20
282.01 Sensor (finisher media entrance) static jam A . 2-22
283.00 Sensor (buffer path) on jam A 2-23
283.01 Sensor (buffer path) on jam B 2-25
283.02 Sensor (buffer path) static jam A 2-28
283.03 Sensor (buffer path) static jam B 2-29
283.04 Sensor (buffer path) static jam C 2-30
284.00 Sensor (lower media exit) off jam A2-31
284.01 Sensor (lower media exit) on jam A 2-32
284.02 Sensor (lower media exit) on jam B 2-35
284.03 Sensor (lower media exit) on jam C 2-38
284.04 Sensor (lower media exit) off jam B2-40
284.05 Sensor (lower media exit) static jam . 2-41
285.00 Finisher eject set jam . 2-42
286.00 Sensor (compiler media in) static jam 2-43
287.00 Sensor (upper media exit) on jam A . 2-45
287.01 Sensor (upper media exit) off jam A . 2-46
287.02 Sensor (upper media exit) on jam B . 2-47
287.03 Sensor (upper media exit) on jam C . 2-49
287.04 Sensor (upper media exit) off jam B . 2-50
287.05 Sensor (upper media exit) static jam A . 2-51
287.06 Sensor (upper media exit) static jam B . 2-52
287.07 Sensor (upper media exit) static jam C . 2-53
288.00 Sensor (diverter gate) on jam . 2-54
288.01 Sensor (diverter gate) static jam (to top bin) A . 2-57
288.02 Sensor (diverter gate) static jam (to top bin) B .2-58
288.03 Sensor (diverter gate) static jam (to top bin) C .2-59
288.04 Sensor (diverter gate) static jam (to stacker bin) A . .2-60
288.05 Sensor (diverter gate) static jam (to stacker bin) B . .2-61
288.06 Sensor (diverter gate) static jam (to stacker bin) C . .2-62
980.02 Finisher communication failure . .2-63
981.00 Stacker bin failure . .2-63
981.01 Stacker bin upper limit failure .2-65
981.02 Stacker bin lower limit failure .2-66
982.00 Sensor (front tamper HP) on failure . .2-68
982.01 Sensor (front tamper HP) off failure . .2-69
983.00 Sensor (rear tamper HP) on failure .2-70
983.01 Sensor (rear tamper HP) off failure .2-71
984.00 Sensor (punch unit HP) on failure . .2-72
984.01 Sensor (punch unit HP) off failure . .2-74
985.00 Sensor (punch carriage shift HP) on failure . .2-75
985.01 Sensor (punch carriage shift HP) off failure . .2-76
986.00 Sensor (media eject clamp HP) on failure .2-77
986.01 Sensor (media eject clamp HP) off failure .2-78
987.00 Sensor (media eject shaft HP) on failure . .2-79
987.01 Sensor (media eject shaft HP) off failure . .2-80
988.00 Sensor (punch unit side reg) on failure .2-82
988.01 Sensor (punch unit side reg) off failure .2-83
989.00 Stapler unit failure . .2-85
990.00 Sensor (stapler carriage HP) on failure .2-85
990.01 Sensor (stapler carriage HP) off failure .2-86
995.00 Finisher NVRAM R/W failure . .2-87
996.00 Finisher type failure .2-87
999.00 Finisher engine/RIP functional failure . .2-88
Bridge unit top cover open .2-88
Finisher front door open .2-90
Finisher eject cover open .2-91
Finisher upper media bin full . .2-91
No punch waste box .2-92
Punch waste box full . .2-93
Stacker media bin full (mix size) .2-94
Stacker media bin full (no mix) . .2-96
Stacker lower safety failure .2-97
Stacker set over count failure .2-99
Staple cartridge empty .2-99
Diagnostic aids 3-1
Accessing Diagnostics mode .3-1
Available finisher tests .3-1
FINISHER TESTS . .3-2
Staple Test . .3-2
Hole Punch Test . .3-2
Feed Tests . .3-2
Sensor Test (finisher) . .3-2
EXIT DIAGNOSTICS ..3-3
Theory .3-4
Media transport .3-4
Bridge unit assembly paper path .3-4
Finisher media path .3-4
Finisher roll assemblies . .3-5
Finisher media path sensors . .3-5
Finisher motors .3-6
Bridge unit assembly . .3-6
From bridge unit assembly to punch . .3-7
From punch to compiler unit assembly 3-8
From compiler unit assembly to stacker media bin 3-10
From punch to upper media bin 3-10
Functions of sensors along the media path . 3-10
Bridge unit assembly . 3-10
Finisher . 3-11
Punch unit 3-12
Adjusting punching positions . 3-12
Punching 3-13
Detecting punch waste full 3-14
Detecting punch waste box 3-14
Functions of punch sensors/motors . 3-14
Compiler unit assembly . 3-15
Outline of operation 3-15
Capacity of compiler unit assembly 3-16
Compiler unit assembly operation with multiple media sizes 3-16
Tamping 3-16
Front tamping 3-17
Rear tamping . 3-18
Center tamping . 3-19
Determining tamper home position 3-19
Tamping 3-19
Offsetting 3-20
Functions of compiler unit assembly sensors/motors 3-20
Stapler 3-21
Stapling operation . 3-21
Staple positions . 3-21
Media sizes that allow stapling . 3-22
Stapling one sheet 3-22
Stapling multiple size media . 3-22
Media limits for stapling . 3-23
Stapler operation 3-23
Stapler unit assembly 3-24
Functions of stapler sensors/motors . 3-24
Upper media bin 3-25
Operation . 3-25
Functions of upper media bin sensors . 3-25
Stacker media bin 3-26
Operation . 3-26
Full stack detection 3-28
Functions of stacker media bin sensors/motors 3-28
Power supply and interlock 3-30
Repair information. .  4-1
Handling ESD-sensitive parts . 4-1
Removal procedures 4-2
Bridge unit assembly removal . 4-2
Finisher removal 4-4
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
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 . .4-72
Sensor (compiler media in) removal . .4-73
Media eject shaft assembly removal . .4-74
Clamp paddle removal . .  .4-76
Media eject clutch 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 . .4-82
Paddle and roll exit assembly removal . .4-86
Lower pinch guide assembly removal . .4-90
Media diverter gate removal . .4-91
Buffer diverter gate removal . .4-92
Sensor (buffer path) removal ..4-93
Buffer roll assembly removal . .4-94
Buffer pinch guide assembly removal . .4-96
Media entrance pinch guide assembly removal . .4-97
Sensor (finisher media entrance) removal 4-98
Media entrance roll assembly removal . 4-99
Drive motor (entrance/paddle) and belt (entrance/paddle) removal . 4-100
Media diverter gate solenoid removal . 4-102
Buffer diverter gate solenoid removal . 4-103
Sensor (upper media exit) removal . 4-104
Upper media exit pinch roll assembly removal . 4-105
Upper media exit roll assembly removal . 4-106
Sensor (upper media bin full) removal 4-108
Upper pinch guide assembly removal . 4-109
Sensor (diverter gate) removal . 4-110
Upper media transport roll assembly removal 4-111
Drive motor (exit) assembly and belt (exit) removal . 4-113
Drive motor (buffer/transport) and belt (buffer/transport) removal . 4-115
Bridge unit interface card assembly removal . 4-117
Finisher controller card assembly removal 4-118
Finisher low voltage power supply (LVPS) removal . 4-119
Component locations5-1
Locations 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 5-5
Buffer, upper exit, lower exit, and drive motors . 5-6
Cabling . 5-7
Preventive maintenance.  . 6-1
Safety inspection guide .6-1
Maintenance recommendations 6-1
Parts catalog . .   . 7-1
How to use this parts catalog . 7-1
Assembly 1: Bridge unit7-2
Assembly 2: Bridge unit top cover assembly 7-3
Assembly 3: Bridge unit lower assembly.  7-4
Assembly 4: Covers .  . 7-6
Assembly 5: Covers and front door .  7-8
Assembly 6: Stacker bin lift. 7-10
Assembly 7: Punch7-12
Assembly 8: Stapler . 7-14
Assembly 9: Media eject . 7-16
Assembly 10: Eject and compiler unit . 7-18
Assembly 11: Lower exit drive .7-20
Assembly 12: Buffer and entrance drive . .  7-22
Assembly 13: Buffer, transport, and upper drive . .7-24
Assembly 14: Electronics . .  7-26
Assembly 15: Cables 1. .  7-28
Assembly 16: Cables 2. 7-30
Assembly 17: Cables 3. 7-31
Index I-1
Part number index . I-7





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