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Lexmark Optra N 4040-FIN manual

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Table of contents for the manual

  • Page 1

    4040-FIN Optra™ N Finisher Option Le xmark and Lexmark with diamond design are trademarks of Lexmark Inter national, Inc., registered in the United States and/or other countries. • T ab le of Contents • Inde x • Safety and Notices • T rademarks • Star t Dia gnostics • Man uals Menu[...]

  • Page 2

    Second Edition (November 1997) The follo wing paragraph does not appl y to the United Kingdom or any country where such pr ovisions are inconsistent with local la w: LEXMARK INTERNA TIONAL, INC . PRO VIDES THIS PUBLICA TION “AS IS” WITHOUT W ARRANTY OF ANY KIND , EITHER EXPRESS OR IMPLIED , INCLUDING, BUT NO T LIMITED TO , THE IMPLIED W ARRANTI[...]

  • Page 3

    Contents iii 4040 Finisher Contents N o t i c e s ................................................ v i S a f e t yI n f o r m a t i o n .................................... v i G e n e r a lI n f o r m a t i o n .................................... 1 - 1 Maintenance Approach ............................... 1 - 1 S t a p l e rT e s t ...............[...]

  • Page 4

    iv Service Manual 4040 Finisher R e p a i rI n f o r m a t i o n ..................................... 3 - 1 A d j u s t m e n t s ....................................... 3 - 1 D i s t a n c eS e n s o rA d j u s t m e n t ....................... 3 - 1 Cover Removal Procedures . . ......................... 3 - 2 E x t e r n a lC o v e r s .........[...]

  • Page 5

    Contents v 4040 Finisher P a r t sC a t a l o g ......................................... 5 - 1 H o wt oU s eT h i sP a r t sC a t a l o g ......................... 5 - 1 E x t e r n a lC o v e r s .................................. 5 - 2 E x t e r n a lC o v e r s( C o n t ) ............................. 5 - 4 S t a p l e r ,M a i nB o d y .......[...]

  • Page 6

    vi Service Manual 4040 Finisher No tices Ref erences in this pub lication to products, progr ams, or services do not imply that the manuf acturer intends to make these a v ailab le in all countries in which it operates. An y ref erence to a product, progr am, or ser vice is not intended to state or imply that only that product, program, or ser vice[...]

  • Page 7

    Notices vii 4040 Finisher Consignes de Sécurité • Ce produit a été conçu, testé et approuvé pour respecter les nor mes str ictes de sécurité globale lors de l'utilisation de composants Le xmark spécifiques. Les caractéristiques de sécurité de cer tains éléments ne sont pas toujours évidentes. Le xmark ne peut être tenu respo[...]

  • Page 8

    viii Service Manual 4040 Finisher Sicherheitshinweise • Dieses Produkt und die zugehörigen K omponenten wurden entworf en und getestet, um beim E insatz die weltweit gültigen Sicherheitsanf orderungen zu erfüllen. Die sicherheitsrelev anten Funktionen der Bauteile und Optionen sind nicht immer off ensichtlich. Sof ern T eile eingesetzt werden,[...]

  • Page 9

    Notices ix 4040 Finisher Inf ormações de Segurança • Este produto f oi concebido , testado e aprov ado para satisf az er os padrões globais de segurança na utilização de componentes específicos da Le xmark. As funções de segurança de alguns dos componentes podem não ser sempre ób vias. A Le xmar k não é responsáv el pela utilizaç[...]

  • Page 10

    x Service Manual 4040 Finisher[...]

  • Page 11

    General Information 1-1 4040 Finisher 1. General Inf ormation Maintenance Appr oach The diagnostic inf or mation in this manual leads you to the correct field replaceable unit (FR U) or par t. Use the error code char ts, symptom inde x, and ser vice checks to determine the symptom and repair the f ailure. After you complete the repair , perform tes[...]

  • Page 12

    1-2 4040 Finisher 3. Close the stapler access door . Press Continue to P erf or m Sta- ple T est appears on the operator panel displa y . 4. Select CONTINUE from the pr inter operator panel. P erf or ming Staple T est appears on the displa y . When the test page is deliv- ered to the finisher , the finisher puts se ver al staples along one edge of [...]

  • Page 13

    General Information 1-3 4040 Finisher Abbrev iations ASIC Application-Specific Integr ated Circuit CSU Customer Setup DRAM Dynamic Random Access Memor y EEPROM Electrically Erasable Prog rammab le Read- Only Memor y EP Electrophotographic Process ESD Electrostatic Discharge FR U Field Replaceab le Unit HVPS High V oltage P ower Supply LAN Local Are[...]

  • Page 14

    2-1 4040 Finisher 2. Diagnostic Inf ormation Use the serial number from the indicated label to identify the machine f or repor ting ser vice related activity . The diagnostic inf or mation in this chapter leads you to the f ailing par t. Before y ou replace an entire assembly , deter mine if just the def ectiv e par t is av ailab le in the par ts c[...]

  • Page 15

    Diagnostic Inf ormation 2-2 4040 Finisher If an error is displa y ed, locate it in the f ollowing Oper ator Error Mes- sage T a b le, or the Ser vice Error Message T able and tak e the appro- priate action. If an error message appears while you are w orking on the finisher , go to the error message table and tak e the indicated action. If y ou are [...]

  • Page 16

    2-3 4040 Finisher Operator Err or Message T able If you ha ve a paper jam, be sure to clear all paper from the finisher , paper dec k, and pr inter . If you are unab le to clear an operator error code f or a paper jam; note the location of the paper jam and check the paper sensor f or that station. See “Switches” on page 4-4 or “Sensors” on[...]

  • Page 17

    Diagnostic Inf ormation 2-4 4040 Finisher 43 P aper J am (PI-3) There is a paper jam at the top cov er . If the error code does not clear after you clear the paper jam, go to the “P aper Ja m, 43, Delivery P aper Sensor Ser vice Check” on page 2-13 . If there is still a problem after that, go to the “Symptom T able” on page 2-7 . 44 P aper [...]

  • Page 18

    2-5 4040 Finisher 89 Staples Low The finisher has 10 or f ew er staples r e m a i n i n gi nt h es t a p l ec a r t r i d g e . The Staple Alar m must be set to Single or Continuous f or this message to appear . If Auto Contin ue is On when the printer detects this error , the pr inter waits 30 seconds f o rt h ec o n d i t i o nt ob ec o r r e c t[...]

  • Page 19

    Diagnostic Inf ormation 2-6 4040 Finisher S e r v i c eE r r o rM e s s a g eT a b l e Error Symptom or Message Action 938 Finisher Option Controller Card, No response Be sure the pow er cord and interf ace cable are securely plugged in. POR the printer . If there is still a f ailure, replace the finisher option controller card (PN 11D00326) locate[...]

  • Page 20

    2-7 4040 Finisher Symptom T able T esting the Finisher T o r un paper through the finisher from the pr inter : 1. Select MENUS. 2. Select P APER MENU . 3. Scroll until you ha v e the option you w ant and be sure it is on and sa ved. 4. Retur n to Ready . 5. Select MORE. 6. Select TEST MENU . 7. Select Pr int F onts, or Print T est P age. 8. Do not [...]

  • Page 21

    Diagnostic Inf ormation 2-8 4040 Finisher P ower On Reset (POR) Sequence When sensors, motors , or solenoids malfunction during POR no errors are repor ted from the f ollowing sequence e xcept f or 1, 2, 3, and 27. T o be sure the finisher successfully completes POR you must obser v e the sequence of e v ents. Confir m that the tra y home position [...]

  • Page 22

    2-9 4040 Finisher 20. The f ace-up flapper solenoid turns off for 0.5 seconds , on f or 0.5 seconds, and off f or 0.5 seconds. 21. The stapler assemb ly retur ns to the home position. 22. The stapler assemb ly mov es to the stapling position A4R-siz e paper , one point at the cor ner . 23. The stapler returns to the home position. 24. The staple mo[...]

  • Page 23

    Diagnostic Inf ormation 2-10 4040 Finisher Service Checks Alignment Plate Shift Motor Service Check Distance Detecting Sensor Service Check 1 Connector Be sure J11 is properly connected to the finisher driver board. 2A l i g n m e n t Plate Shift Motor , M2, (5- 21) Unplug J11 from the finisher driver board. Measure the resistance between J11-1 and[...]

  • Page 24

    2-11 4040 Finisher P aper Delivery Motor Ser vice Chec k P aper Delivery Service Check 1 Connector Be sure the J8 and J11 are proper ly connected to the finisher driver board, and the stapler assemb ly is properly installed and fir mly plugged in. 2 P aper Deliver y Motor , M3, (5- 8) Unplug J11 from the finisher driver board. Measure the resistanc[...]

  • Page 25

    Diagnostic Inf ormation 2-12 4040 Finisher P aper Feed Motor Service Chec k P aper Jam, 41, P aper Input Ser vice Chec k Clear all paper from the paper dec k, pr inter , and finisher . If there is no paper y ou must open and close one of the finisher cov ers to clear the error . 1 Connector Be sure the J10 is properly connected to the finisher driv[...]

  • Page 26

    2-13 4040 Finisher P aper Jam, 42, Rever s ing P aper Sensor Ser vice Check Clear all paper from the paper deck, printer , and finisher . If there is no paper y ou must open and close one of the f inisher cov ers to clear the error . P aper Jam, 43, Delivery P aper Sensor Ser vice Chec k Clear all paper from the paper deck, printer , and finisher .[...]

  • Page 27

    Diagnostic Inf ormation 2-14 4040 Finisher P ower Service Chec k Be sure the correct v oltage is av ailable at the pow er outlet, and the pow er plug is fir mly plugged into the pr inter , paper deck, and fin- isher. 2 Staple T ra y P aper Sensor , PI-4, (5-1) Check the v oltage of J9-3 on the finisher driver board. There should be 0 V when the sen[...]

  • Page 28

    2-15 4040 Finisher Rever sing Roller Service Check Shutter Service Check 1 Gears Chec k for , and replace any brok en or worn gears. 2 Re v ersing Solenoid, SL7 (4-20) Unplug J14 of the re versing solenoid. Measure the resistance between J14-1 and J14-2 on the solenoid side. If it does not read 125 Ohms, replace the re v ersing solenoidm (PN 11D011[...]

  • Page 29

    Diagnostic Inf ormation 2-16 4040 Finisher Stapler Motor Service Check Stapler Shift Motor Service Check 1 Connector Be sure J8 is proper ly connected to the finisher driver board. 2 Stapler Motor Unplug J8 from the finisher driver board. Measure the resistance between J8-11 and J8-12 on the motor side. If it does not read 1 0 Ohms, replace the sta[...]

  • Page 30

    2-17 4040 Finisher Swing Guide Service Check T ra y Ele vation Motor Service Chec k FR U Action 1 Connectors Be sure J5, J11, and J13 are properly connected to the finisher drive board. 2S w i n g G u i d e Close Detecting Switch, MS-2 (5-6) Unplug J5 from the finisher driver board. Measure the resistance between J5-9 and J5-10 on the s witch side.[...]

  • Page 31

    Diagnostic Inf ormation 2-18 4040 Finisher T ra y Height Service Check FR U Action 1 Connectors Be sure J5, J7, and J12 are proper ly connected to the finisher dri v er board. 2T r a y H o m e Po s i t i o n Sensor , PI-8 (3-10) Measure the v oltage between J12-5 and J12-6 on t h ef i n i s h e rd r i v e rb o a r d .I fi ti sn o t5Vw i t ht h et r[...]

  • Page 32

    3-1 4040 Finisher 3. Repair Inf ormation Adjustments Distance Sensor Adjustment The distance sensor is adjusted during manuf actur ing so you do not need to adjust it when y ou install it. How e v er , the distance sensor must be initializ ed when the finisher dr iv er board or the distance sensor is replaced. T o initialize the distance sensor: 1.[...]

  • Page 33

    Repair Information 3-2 4040 Finisher Co ver Remo v al Pr ocedures External Co vers 1. T ra ys 2. T op Door 3. T op Cov er 4. Rear Cov er 5. Right Cov er 6. F ront Co v er 7. F ront Door[...]

  • Page 34

    3-3 4040 Finisher Fr ont Door Remo v al 1. Open the front door (1). 2. Remov e the screw (2) and br ack et (3), then the front door . Rear Co ver Remov al 1. Open the top door (1). 2. Remov e the 3 screws (2) and lift the rear co v er (3) to remov e it.[...]

  • Page 35

    Repair Information 3-4 4040 Finisher To p D o o r R e m o v a l 1. Open the top door (1). 2. Remov e the 2 latches (2), then the top door . Right Co ver Remov al 1. Open the r ight cov er (1) 2. Remov e the hinge (2).[...]

  • Page 36

    3-5 4040 Finisher 3. Pull out the r ight cov er (1). T op Co ver Remo val 1. Open the top cov er . 2. Remov e the rear cov er . 3. Open the r ight cov er . 4. Remov e the 2 latches (1) and lift the top cov er (2) to remo v e it.[...]

  • Page 37

    Repair Information 3-6 4040 Finisher Fr ont Co ver Remov al 1. Remov e the 3 screws (1) from the front co ver (2). 2. Remov e the 3 latches (1), then the front cov e r (2).[...]

  • Page 38

    3-7 4040 Finisher T r ay R e m ova l 1. Remov e the slide guide (1). 2. Remov e the 2 stoppers (2). 3. Lift the tra y (3) to remov e it. T op Guide Remo v al 1. Remov e the slide guide (1). 2. Remov e the 5 screws (2). 3. Remov e the screw (3), then remo v e the grid top guide (4).[...]

  • Page 39

    Repair Information 3-8 4040 Finisher Bottom Guide Remo v al 1. Remov e the tra y . 2. Remov e the 3 screws (1). 3. Remov e the 3 screws (2) and pull the bottom guide (3). 4. Remov e the cable (2) from the cab le guide (1). 5. Disconnect the 2 connectors (3) and remov e the bottom guide (4). When y ou replace the bottom guide be sure it is completel[...]

  • Page 40

    3-9 4040 Finisher P aper T ranspor t Remo v al Procedures Staple T ra y Remo v al 1. Remov e the rear cov er . 2. Remov e the top and bottom guides. 3. Disconnect the 2 connectors (1). 4. Remov e the cable (2) from the cab le guides (1). 5. Disconnect the 2 connectors (3).[...]

  • Page 41

    Repair Inf ormation 3-10 4040 Finisher 6. Remov e the 3 screws (1), then the staple tr a y (2). Staple T ra y Delivery Motor Remov al 1. Remov e the screw (1), then the motor co v er (2). 2. Remov e the 2 screws (3), then the deliv er y motor (4).[...]

  • Page 42

    3-11 4040 Finisher Staple T ra y Alignment Plate Shift Motor Remo v al 1. Disconnect the connector ( 1). 2. Remov e the 2 screws (2), then the alignment plate shift motor (3). Staple T ra y Delivery Roller 1 Remov al 1. Remov e the latch (1), then the ar m (2). 2. Remov e the 2 rollers (3). 3. Remov e the 2 screws (4), then the staple guide (5).[...]

  • Page 43

    Repair Inf ormation 3-12 4040 Finisher 4. Remov e the C-clip (1), then the bushing (2). 5. Slide the delivery r ollers (3) to the left to remov e them. 6. Remov e the C-clip (2) from the delivery roller (1), then the cam (3), gear (4), pin, and the bushing (5).[...]

  • Page 44

    3-13 4040 Finisher 7. Remov e the C-clip (2) from the delivery roller (1), then the pin (3), and the gear (4). F ace-up Solenoid Remo va l 1. Remov e the rear cov er and the top cov er . 2. Remov e the finisher driver board. 3. Remov e the pow er supply . 4. Disconnect the connector ( 1). 5. Locate the solenoid (2).[...]

  • Page 45

    Repair Inf ormation 3-14 4040 Finisher 6. Remov e the 2 screws from inside the main unit, then the f ace- up flapper solenoid (2). Staple Assembl y Remo v al 1. Remov e the rear cov er . 2. Remov e the screw (1), then the board co v er (2).[...]

  • Page 46

    3-15 4040 Finisher 3. Disconnect the 2 connectors (1) from the staple tra y motor card (2). 4. Remov e the staple assembly . 5. Release the cable guide (1) and remov e the cable band (2), then disconnect the connector (3). 6. Remov e the 2 screws (4).[...]

  • Page 47

    Repair Inf ormation 3-16 4040 Finisher 7. Remov e the 2 screws (1), then the staple assemb ly (2). T ra y Assembl y D rive Remo v al 1. Remov e the staple assembly . 2. Remov e the C-clip (1), then the bushing (2). 3. Remov e the 2 screws (3), then the c ov er (4).[...]

  • Page 48

    3-17 4040 Finisher 4. Disconnect the 2 connectors (2). 5. Release the cable guide (1). 6. Disconnect the 2 connectors (2).[...]

  • Page 49

    Repair Inf ormation 3-18 4040 Finisher 7. Remov e the 3 screws (1), then the tr a y assemb ly drive (2). P aper Feed Motor Remo v al 1. Remov e the pow er supply with the finisher dr iv er board on it. 2. Remov e the C-clip (1), then the gear (2). 3. Remov e the 2 screws (3) and remo v e the paper f eed motor (4) from the inside.[...]

  • Page 50

    3-19 4040 Finisher Rever sing Roller Remo v al 1. Remov e the pow er supply with the finisher dr iv er board on it. 2. Remov e the screw (1), then the re versing solenoid (2), 3. Remov e the spring (3). 4. Remov e the C-clip (4), then the 2 gears (5). 5. Remov e the bushing (1) from the re versing roller shaft (2).[...]

  • Page 51

    Repair Inf ormation 3-20 4040 Finisher 6. Remov e the spring hook (1), then the spr ing (2). 7. Remov e the C-clip (3), the bushing (4), then the re versing roller (5). Electrical Components Remo v al Pr ocedures Driver Boar d Remov al 1. Remov e the rear cov er . 2. Disconnect the 13 connectors (1). 3. Remov e the 4 screws (2), then the finisher d[...]

  • Page 52

    3-21 4040 Finisher P ower Suppl y Remo v al 1. Remov e the finisher driver board. 2. Remov e the screw(1), the 3 scre ws (2), then the pow er supply assembly (3). 3. Release the cable guide (1) on the po wer supply (3) and discon- nect the connector (2).[...]

  • Page 53

    Repair Inf ormation 3-22 4040 Finisher 4. Remov e the 3 screws (2) on the po wer supply (1), then remo v e the cov er (3). Interface Boar d Remov al 1. Remov e the rear cov er . 2. Disconnect the connector (1). 3. Remov e the 4 screws (3), then the i nterf ace board (2).[...]

  • Page 54

    3-23 4040 Finisher T est Staple Switc h Boar d Remov al 1. Remov e the front cov er . 2. Disconnect the connector ( 1). 3. Remov e the screw (2), then the test staple s witch board (3).[...]

  • Page 55

    Locations 4-1 4040 Finisher 4. Locations P ar ts of the Finisher 1. T op Door 2. T ra y Assemb ly 3. Interface C onnector 4. P ower Receptacle[...]

  • Page 56

    4-2 4040 Finisher 5. T op Guide (labeled 1) 6. Bottom Guide (labeled 2) 7. Staple T est Switch 8. Right Cov er 9. Guide Rail 10. Staple Assemb ly and Serial Number Label 11. F ront Door[...]

  • Page 57

    Locations 4-3 4040 Finisher Cr oss Sectional View 1. T ra y Assemb ly 2. Shutter 3. Swing Guide 4. Distance Sensor 5. P addle 6. Rev ersing R oller 7. Staple Assembly 8. T ra y Assemb ly Ele v ation Motor[...]

  • Page 58

    4-4 4040 Finisher Switches Name Function MS-1 T op Cov er Open/Close Detection Switch MS-2 Swing Guide Close Detecting Switch MS-3 Saf ety Range Sensing Switch MS-4 Shutter Close Sensing Switch MS-5 T ra y Upper Limit Sensing Switch MS-6 Swing Guide Close Sensing Switch MS-7 F ront Cov er Open/Close Sensing Switch[...]

  • Page 59

    Locations 4-5 4040 Finisher Sensor s Name Function PI-1 Input P aper Sensor PI-2 Re v ersing Assembly P aper Sensor PI-3 Deliv er y P aper Sensor PI-4 Staple T ra y P aper Sensor PI-5 Shutter Open Sensor PI-6 Alignment Plate Home P osition Sensor PI-7 Stapler Home P osition Sensor PI-8 T ra y Assembly Home P osition Sensor PI-9 T ra y Assembly Elev[...]

  • Page 60

    4-6 4040 Finisher Solenoids and Motor s Name Function SL5 P addle Driv e Solenoid SL6 Standard Plate Withdra wal Solenoid SL7 Re v ersing Roller Drive Solenoid SL8 F ace-up Flapper Solenoid M1 P aper F eed Motor M2 P aper Delivery Motor M3 Alignment Plate Shift Motor M4 Stapler Shift Motor M 5 T r ay E l eva t i o n M o t o r M6 Stapler Motor[...]

  • Page 61

    Locations 4-7 4040 Finisher Printed Circuit Boar ds Name Function 1 Finisher Driver Board Controls loads and sensors. 2 T est Staple Switch Board For test staple s witch. 3 Staple Rela y Board 2 Rela ys signals between sensors and t h ef i n i s h e rd r i v e rb o a r d . 4 Staple Rela y Board 1 Rela ys signals between sensors and t h ef i n i s h[...]

  • Page 62

    4-8 4040 Finisher Driver Boar d[...]

  • Page 63

    Locations 4-9 4040 Finisher Connectors[...]

  • Page 64

    4-10 4040 Finisher[...]

  • Page 65

    Locations 4-11 4040 Finisher Finisher Driver Boar d Inputs and Outputs[...]

  • Page 66

    4-12 4040 Finisher[...]

  • Page 67

    Locations 4-13 4040 Finisher[...]

  • Page 68

    5-1 4040 Finisher 5. P ar ts Catalog Ho w to Use This P ar ts Catalog • SIMILAR ASSEMBLIES: If two assemb lies contain a majority of identical par ts, the y are brok en do wn on the same list. Common par ts are shown b y one inde x number . P ar ts peculiar to one or the other of the assemblies are listed separ ately and identified b y descr ipti[...]

  • Page 69

    P arts C atalog 5-2 4040 Finisher Assembl y 1: External Co vers[...]

  • Page 70

    5-3 4040 Finisher Ref Pa r t Number Units Description 1 11D0017 1 Cov er , Rear 2 3 Screw , PP 11D0300 3 11D0013 1 T op Cov er Assembly 4 11D0015 1 • Flag, Sensor 5 1 • Spring, T o rsion, PP 11D0302 6 11D0023 1 Latch, Rear 7 1 Screw , PP 11D0300 8 11D0024 1 Stop , Latch, Rear 9 11D0021 1 Latch, F ront 10 11D0022 1 Stop , Latch, F ront 11 11D002[...]

  • Page 71

    P arts C atalog 5-4 4040 Finisher Assembl y 2: External Co ver s (Cont)[...]

  • Page 72

    5-5 4040 Finisher Ref Pa r t Number Units Description 1 11D0038 1 Cap , Cov er , F ront 2 11D0037 1 Cap , Cov er , Rear 3 11D0039 1 Slide, Guide Assemb ly 4 11D0040 1 • Guide, Slide 5 11D0042 1 • Cov e r , Slide, Rear 6 2 • Screw , P P11D0300 7 11D0041 1 Cov er , Slide, F ront 8 6 Screw , PP 11D0300 9 11D0044 1 Guide, Hurdle , T op 10 6 Scre [...]

  • Page 73

    P arts C atalog 5-6 4040 Finisher Assembl y 3: Stapler , Main Body[...]

  • Page 74

    5-7 4040 Finisher Ref Pa r t Number Units Description 1 11D0076 1 P ower Supply 2 4 Screw , PP 11D0300 3 2 Screw , PP 11D0300 4 11D0079 1 Cov er , P ower Supply 5 11D0080 1 Cab le, Sensor 6 1 Clamp , Cord, PP 11D0302 7 11D0084 1 Solenoid, SL8 8 1 Spring, T ension, PP 11D0301 9 11D0086 1 Ar m, Deflector 10 11D0071 1 Photo Interr upter , PI-1, PI-8, [...]

  • Page 75

    P arts C atalog 5-8 4040 Finisher Assembl y 3: Stapler , Main Body (Cont)[...]

  • Page 76

    5-9 4040 Finisher Ref Pa r t Number Units Description 36 11D0068 1 Micros witch Rail, T ray Lift, MS3 37 11D0069 1 Holder NS 11D0343 1 Fuse , P ower Supply[...]

  • Page 77

    P arts C atalog 5-10 4040 Finisher Assembl y 4: Stapler , Main Body[...]

  • Page 78

    5-11 4040 Finisher Ref Pa r t Number Units Description 1 11D0311 1 Gear , 20T/42T 1A 11D0309 1 Plate , Shaft 2 11D0103 1 Gear , 20T/36T 3 11D0108 1 Gear , 26T 4 11D0107 1 Gear , 18T/24T 5 11D0109 1 Gear , 28T 6 11D0310 1 Plate, Grounding 7 4 Scre ws, PP 11D0300 8 11D0100 1 Gear , 27T/Pulley , 48T 9 11D0099 1 Belt, Timing 10 1 Scre w , PP 11D0300 11[...]

  • Page 79

    P arts C atalog 5-12 4040 Finisher Assembl y 4: Stapler , Main Body (Cont)[...]

  • Page 80

    5-13 4040 Finisher Ref Pa r t Number Units Description 37 11D0127 1 Cov er , Spr ing 38 11D0126 1 Guide, Re verse 39 11D0128 1 Guide, Center 40 2 Scre w , PP 11D0300 41 11D0134 1 Caster 42 11D0135 1 Mount, Rail 43 11D0118 1 Motor , P aper F eed, M1 44 1 Pin, P arallel, PP 11D0302 45 11D0117 1 Gear , 20T[...]

  • Page 81

    P arts C atalog 5-14 4040 Finisher Assembl y 5: Stapler T ra y , Main Body[...]

  • Page 82

    5-15 4040 Finisher Ref Pa r t Number Units Description 1 11D0071 1 Photo Interrupter , PI-4, PI-6, PI-10, PI-18 2 11D0136 1 Cab le, Sensor 3 11D0137 1 Plate, Swing 4 6 Scre ws, PP 11D0300 5 1 Clamp , Cord, PP 11D0302 6 11D0139 1 Cab le with Sensor , MS2, MS6 7 11D0141 1 Mount, Sensor 8 11D0142 1 Motor , P aper Delivery Motor , M3 9 11D0143 1 Guide,[...]

  • Page 83

    P arts C atalog 5-16 4040 Finisher Assembl y 6: Stapler T ra y , Main Body (Cont)[...]

  • Page 84

    5-17 4040 Finisher Ref Pa r t Number Units Description 1 11D0166 1 Bearing, Brass 2 11D0167 1 Gear , 15T 3 2 C-Clip , PP 11D0302 4 11D0169 1 Gear , 50T 5 1 C-Clip , PP 11D0302 6 11D0171 1 Le v er , S wing 7 11D0172 1 Gear , 15T/34T 8 11D0173 1 Spring, Leaf 9 11D0174 1 W asher 10 1 C-Clip , PP 11D0302 11 1 C-Clip , PP 11D0302 12 11D0177 1 Gear , 15T[...]

  • Page 85

    P arts C atalog 5-18 4040 Finisher Assembl y 6: Stapler T ra y , Main Body (Cont)[...]

  • Page 86

    5-19 4040 Finisher Ref Pa r t Number Units Description 38 11D0204 1 Le ver , Stop , F ront 39 11D0205 1 Spring, T orsion 40 11D0206 1 Plate, Suppor t, F ront 41 11D0207 1 Stop , F ront 42 11D0193 1 Bearing 43 11D0191 1 Bearing 44 11D0194 1 Shaft, Delivery Roller 2 45 11D0318 1 Cable , Swing Guide NS 11D0319 1 Cab le Clip , Swing Guide Cable[...]

  • Page 87

    P arts C atalog 5-20 4040 Finisher Assembl y 7: Swing Guide Assemb ly[...]

  • Page 88

    5-21 4040 Finisher Ref Pa r t Number Units Description 1 11D0304 1 Swing Guide Assembly 1A 11D0208 1 Roller , Center Swing Guide 2 11D0209 1 Shaft, Roller , Center Swing Guide 3 3 Screw , PP 11D0301 4 11D0212 1 Spring, Retainer 5 2 Spring, PP 11D0302 6 11D0215 1 Holder , Roller 7 11D0216 1 Roller , Outside Swing Guide 8 11D0211 1 Ar m, Stop , Rear [...]

  • Page 89

    P arts C atalog 5-22 4040 Finisher Assembl y 8: Stapler T ra y[...]

  • Page 90

    5-23 4040 Finisher Ref Pa r t Number Units Description 1 11D0232 1 Rail, T ra y 2 3 Screw , PP 11D0300 3 11D0238 1 Plate, Guide 4 11D0233 1 Roller , Stapler T ra y F rame 5 4 C-Clip , PP 11D0302 6 11D0234 1 Guide, Slide , T op 7 11D0235 1 Guide, Slide , Bottom 8 11D0240 1 Roller , Bottom, Stapler T ra y F rame 9 11D0237 1 F rame, T ra y , Rear 10 1[...]

  • Page 91

    P arts C atalog 5-24 4040 Finisher Assembl y 9: T ra y Drive[...]

  • Page 92

    5-25 4040 Finisher Ref Pa r t Number Units Description 1 11D0241 1 Shaft, T ra y 2 2 C-Clip , PP 11D0302 3 11D0166 1 Bushing 4 1 Pin, PP 11D0302 5 11D0245 1 Gear , 48T 6 11D0243 1 Brac ket, Driv e, Small 7 11D0246 1 Bushing 8 11D0247 1 Cam 9 1 C-Clip , PP 11D0302 10 11D0249 1 Gear , 22T 11 1 W asher , PP 11D0302 12 11D0251 1 Spring, Compression 13 [...]

  • Page 93

    P arts C atalog 5-26 4040 Finisher Assembl y 10: Upper Feeder[...]

  • Page 94

    5-27 4040 Finisher Ref Pa r t Number Units Description 1 11D0255 1 Guide, Upper (labeled 1) 2 11D0259 1 Spring, T orsion 3 11D0303 4 Roller A 4 11D0257 1 Spring, Roller Holder 5 11D0256 1 Roller B 6 11D0258 1 Roller C[...]

  • Page 95

    P arts C atalog 5-28 4040 Finisher Assembl y 11: Center Guide[...]

  • Page 96

    5-29 4040 Finisher Ref Pa r t Number Units Description 1 11D0260 1 Shaft, Stapler Roller 2 11D0259 4 Spring, T orsion 3 11D0303 4 Roller , A 4 2 C-Clip , PP 11D0302 5 11D0191 1 Bushing 6 11D0261 1 Gear , 20T 7 11D0262 1 Gear , 16T 8 11D0263 1 Guide, Center (labeled 2)[...]

  • Page 97

    P arts C atalog 5-30 4040 Finisher Assembl y 12: Stapler[...]

  • Page 98

    5-31 4040 Finisher Ref Pa r t Number Units Description 1 11D0264 1 Cab le, Flat 2 3 Screw , PP 11D0300 3 11D0267 1 Cov er 4 11D0268 1 Cab le, Stapler 5 11D0269 1 Motor , Stapler Shift, M4 6 11D0270 1 Roller 7 11D0271 1 Scre w , Stepped 9 11D0273 1 Cam, Stop 10 11D0274 1 Cable , Stapler 11 11D0275 1 Mount, Stapler 12 11D0276 1 Catch, Magnet 13 11D02[...]

  • Page 99

    P arts C atalog 5-32 4040 Finisher Assembl y 13: Electr onic Boar ds and P ower Cor ds[...]

  • Page 100

    5-33 4040 Finisher Ref Pa r t Number Units Description 1 11D0294 1 Finisher Driver Board 2 11D0296 1 Interf ace Board 3 11D0298 1 Switch Board, Stapler 4 11D0328 1 P ower Cord, U .S, Canada, APG (L V), LAD (L V) 4 11D0333 1 P ower Cord, Denmark 4 11D0334 1 P ower Cord, Europe , England 4 11D0334 1 P ower Cord, F rance 4 11D0334 1 P ower Cord, Germa[...]

  • Page 101

    P arts C atalog 5-34 4040 Finisher Assembl y 14: Attac hment P ar ts[...]

  • Page 102

    5-35 4040 Finisher Ref Pa r t Number Units Description 1 11D0229 3 T ra y , F ace-up 2 11D0231 2 Scre w , T ray 3 11D0305 1 Cab le, Interf ace 4 11D0322 1 Rail 5 11D0325 1 Scre w , Stepped 6 11D0327 2 Scre w 7 11D0323 1 Holder , Interface Cab le 8 11D0324 1 Ground Adapter[...]

  • Page 103

    4040 Finisher Option Wiring Diagram Optra N (4040) Finisher Service Manual (11/96)[...]

  • Page 104

    X-1 4040-FIN A abbreviations 1-3 adjustments 3-1 alignment plate shift motor service check 2-10 B bottom guide removal 3-8 C connectors 4-9 cover removal procedures 3-2 cross sectional view 4-3 D diagnostic information 2-1 diagram, wiring 6-1 distance detecting sensor service check 2-10 distance sensor adjustment 3-1 driver board 4-8 driver board r[...]

  • Page 105

    X-2 4040-FIN staple tray delivery roller 1 removal 3-11 staple tray removal 3-9 stapler motor service check 2-16 stapler shift motor service check 2-16 stapler test 1-1 start 2-2 swing guide service check 2-17 switches 4-4 symptom table 2-7 T test staple switch board removal 3-23 testing the finisher 2-7 tools 1-2 top cover removal 3-5 top door rem[...]