• Code: 66.12.23
• Display: 66.12.23
• Description: Finisher upper stapler failure Occurs when stapler-alignment-interference sensor (PI46) is activated, signaling that the stapler unit is not in its proper position for stapling to occur. This is to prevent damage to stapler from occurring when stapler is positioned over one of the three stoppers when the signal to staple has been sent.
• Remedy: Control-panel diagnostics: none 1. If the stapler unit does not move properly or moves erratically, check the flat-flexible cable (FFC) for damage (dents, folds, and/or tears). Replace the FFC if necessary. 2. If the stacker controller PCA was recently replaced, use the steps in this manual to adjust the staple alignment and staple position. 3. If the stapler is not positioned over a stopper when this error occurs, perform the following steps. • Make sure that the stapler unit is correctly mounted and securely fastened to the base. • Make sure that the sensor is not obstructed or damaged. Verify that the sensor flag is not damaged, moves freely, and is correctly aligned with the sensor body. • If the error persists, replace the stapler subassembly. NOTE: The stapler subassembly includes the stapler unit and base.

• Code: 66.12.31
• Display: 66.12.31
• Description: Finisher error - 1st-tray lift/lower motor (M37) Occurs when the output-bin 1 does not activate the home-position sensor (PI41) when the output-bin-1-shift motor (M37) is driven for 20 seconds. Also occurs when output-bin 1 does not move when output-bin-1-shift motor (M37) is driven for 4 seconds. Also occurs when the output-bin-1 switch (MSW33) is activated while output-bin 1 is operating. NOTE: Output-bin-1 home position is detected using the top sheet of paper on the bin when paper is present and the edge of the bin itself when there is no paper on the bin.
• Remedy: Control-panel diagnostics: M37 tray 1 (output-bin 1 motor) NOTE: M37 moves both output bin 1 and the upper output bin that is attached to output bin 1 on the stapler stacker finisher, but only output bin 1 on the booklet maker finisher. 1. Manually release output bin 1, and position it at the mid point of its travel area. Test the output-bin-1-shift motor M37 by using the finisher component test from the control-panel display. • If output bin 1 moves during the test, perform the following steps. • If the paper-surface sensor flag was recently removed or replaced, make sure that it is installed correctly. NOTE: The four tabs under the clips must be inserted into the slots behind the roller shaft of the lower stackejection roller. • Verify that the paper-surface sensor flag is not damaged, moves freely, and is correctly aligned with the PI41 sensor body. Also verify that when the top edge of the output bin engages the sensor arm that the sensor flag moves into sensor PI41. • Make sure that the sensor is securely fastened to the chassis. • Carefully clean the sensor body by gently blowing clean air across the sensor to remove dust and debris. • Verify that intermediate connector J1040 and J721 on the stacker controller PCA are fully seated and not damaged. Check the wiring at the sensor. • If the error persist, replace sensor PI41. • If the error persist, replace the output-bin-1 assembly. NOTE: The output-bin-1 assembly includes the output-bin-1-shift motor (M37), output-bin-1 switch (MSW33), output-bin-1 area sensors, and the output-bin-1 driver PCA. 2. If output bin 1 does not move during the test, perform the following steps. • Check the output-bin tracks for damage. • Replace the output-bin-1 assembly. NOTE: The output-bin-1 assembly includes the outputbin- 1-shift motor (M37), outputbin- 1 switch (MSW33), outputbin- 1 area sensors, and the outputbin- 1 driver PCA. • Only if the error persists and none of the previous steps correct the problem, replace the stacker controller PCA.

• Code: 66.12.32
• Display: 66.12.32
• Description: Finisher error: second-tray lift/lower motor (M38) Occurs when the output-bin 2 does not activate the home-position sensor (PI48) when the output-bin-1 shift motor (M38) is driven for 20 seconds. Also occurs when output-bin 2 does not move when output-bin-1–shift motor (M38) is driven for 4 seconds. Also occurs when bin-2 upper limit is detected by PS983, PS982, PS981 on the Tray-2-shift PCA when no paper has been sensed by the output-bin-2 paper sensor (PI43). NOTE: output-bin-2 home position is detected using the top sheet of paper on the bin when paper is present and the edge of the bin itself when there is no paper on the bin.
• Remedy: Control-panel diagnostics: M38 (output-bin-2 motor) and PI48 output-bin-2 paper-surface sensor 1. Manually release output-bin 2, and position it at the mid point of its travel area. Test the output-bin-2-shift motor M38 by using the finisher component test from the control-panel display. • If output bin 2 moves during the test, perform the following steps. • Verify that the paper-surface sensor flag is not damaged, moves freely, and is correctly aligned with the PI48 sensor body. Also verify that when the top edge of the output bin engages the sensor arm that the sensor flag moves into sensor PI41. • Make sure that the sensor is securely fastened to the chassis. • Carefully clean by gently blowing clean air across the sensor to remove dust and debris. • Verify that intermediate connector J1040 and J721 on the stacker controller PCA are fully seated and not damaged. Check the wiring at the sensor. • If the error persist, replace sensor PI48. • If the error persist, replace the output-bin-2 assembly. NOTE: The output-bin-2 assembly includes the output-bin-2-shift motor (M38), output-bin-2 area sensors, and the output-bin-2 driver PCA. 2. If output bin 2 does not move during the test, perform the following steps. • Check the output-bin tracks for damage. • Replace the output-bin-2 assembly. NOTE: The output-bin-2 assembly includes the outputbin- 2-shift motor (M38), outputbin- 2 area sensors, and the outputbin- 2 driver PCA. • Only if the error persists and none of the previous steps correct the problem, replace the stacker controller PCA.

• Code: 66.12.34
• Display: 66.12.34 Output accessory failure
• Description: An output accessory is not functioning properly.
• Remedy: 1. Turn the product off. 2. Verify that all output accessories are securely connected. 3. If the product uses cables, disconnect and reconnect them.

• Code: 66.12.41
• Display: 66.12.41
• Description: Finisher: folding-paper-positioning-plate motor (M4) The paper-positioning-plate motor (M4), located in the booklet making area of the finisher, controls the Up and down positioning of the stacked paper for stitch stapling and for folding. Error occurs when the paper-positioningplate home-position sensor (PI7) does not turn on when the paper-positioning-plate motor (M4) has been driven for 1500 pulses. Also occurs when the paper-positioning-plate home-position sensor (PI7) does not turn off when the paper-positioning-plate motor (M4) has been driven for 300 pulses.
• Remedy: Control-panel diagnostics: M4-guide plate motor (paper-positioning-plate motor) 1. Test the paper-positioning-plate motor M4 by using the finisher component test from the control-panel display. During the test, observe the movement of the booklet-maker-guide plate, and make sure it is not obstructed or damaged. 2. Remove the booklet-maker output bin to gain access to the paper-position-plate home-position sensor PI7 and delivery door. Remove the plate that holds PI7, and carefully clean the sensor body by gently blowing clean air across the sensor to remove dust and debris. 3. Make sure that the sensor is securely fastened to the plate. 4. Check the wiring at the sensor. 5. If the error persists, replace sensor PI7 and the positioning-plate assembly together. 6. Only if the error persists and none of the previous steps correct the problem, replace the stacker controller PCA.

• Code: 66.12.42
• Display: 66.12.42
• Description: Finisher error: folding-guide motor (M3) The guide motor (M3), located in the bookletmaking area of the finisher, controls the position of the guide plate. The guide plate is positioned in front of the folding rollers as the paper stack is being stapled, allowing the bottom edge of the paper to smoothly pass by the folding rollers. When the stacked paper is lowered to the folding position, the guide motor (M3) lowers the guide plate out of the way to allow the paper stack to be pushed into the folding rollers. Error occurs when The guide-home-position sensor (PI13) does not turn on when the guide motor (M3) has been driven for 700 pulses. Also occurs when the guide-home-position sensor (PI13) does not turn off when the guide motor (M3) has been driven for 50 pulses.
• Remedy: Control-panel diagnostics: M3 guide motor 1. Carefully clean the sensor body by gently blowing clean air across the sensor to remove dust and debris. 2. Make sure that the sensor is securely fastened to the plate. 3. Check the wiring at the sensor. 4. Check sensor PI13 for damage. 5. Check the guide, gears, and gear tracks on the front and rear frame for damage. Replace components as necessary. 6. If the error persists, replace the guide motor M3 and the guide-home-position sensor PI13 together.

• Code: 66.12.43
• Display: 66.12.43
• Description: Finisher error: paper-fold motor (M2) M2: paper-fold motor, located in the booklet making area of the finisher, drives the rotation of the folding rollers to create the desired fold in the paper. The error occurs when the number of pulses by the paper-fold-motor clock sensor (PI4) is less than expected standard value. Also occurs when the status of the paper-fold home-position sensor (PI21) does not change when the paper-fold motor (M2) has been driven for 3 seconds.
• Remedy: Control-panel diagnostics: M2 folding motor (paper-fold motor) 1. Check the area around the folding rollers for a jam. 2. Test the paper-fold motor M2 by using the finisher component test from the control-panel display. • If the folding rollers rotate properly, perform the following steps: • Verify that the sensor flags are not damaged, move freely, and are correctly aligned with the PI48 and PI21 sensor bodies. • Make sure that the sensors are securely fastened to the chassis. • Carefully clean each sensor body with a clean, lint-free cloth, or gently blow clean air across each sensor to remove dust and debris. • Verify that connector J3 on the saddle-stitcher controller PCA is fully seated and not damaged. Check the wiring at the PI4 sensor. • Verify that connector J18 on the saddle-stitcher controller PCA is fully seated and not damaged. Check the wiring at the PI21 sensor. • If the error persists, replace sensor PI4 or PI21. • Only if the error persists and none of the previous steps correct the problem, replace the saddle-stitcher controller PCA. • If the folding rollers do not rotate properly, perform the following steps: • Check the folding-roller gears and connecting gears between the paper-fold motor M2 and the folding rollers for damage. Replace components as necessary. • Check the folding rollers for wear and damage. Replace components as necessary. • Replace the motor-mount assembly. NOTE: The motor-mount assembly includes the paperfold motor M2 and the paperfold motor-clock sensor PI4. • Only if the error persists and none of the previous steps correct the problem, replace the saddle-stitcher controller PCA.

• Code: 66.12.44
• Display: 66.12.44
• Description: Finisher - folding-paper-alignment motor (M5) M5 - The alignment motor, located in the booklet making area of the finisher, drives the two alignment plates that adjust the side edges of the stacked paper so that the paper in the stack is perfectly aligned with one another. Error occurs when the aligning-plate homeposition sensor (PI5) does not turn on when the aligning-plate motor (M5) has been driven for 500 pulses. Also occurs when the aligning-plate homeposition sensor (PI5) does not turn off when the aligning-plate motor (M5) has been driven for 50 pulses.
• Remedy: Control-panel diagnostics: none Observe the alignment plates during a booklet-maker stacking operation. • If the alignment plates move during the operation, perform the following steps: • Check sensor PI5 for damage. • Verify that the sensor flag is not damaged, moves freely, and is correctly aligned with the sensor body. • Make sure that the sensor is securely fastened to the chassis. • Carefully clean the sensor body by gently blowing clean air across the sensors to remove dust and debris. • If the alignment plates or the alignment-plates drive gear has been removed or replaced, make sure that the plates are correctly aligned with each other on the drive gear. • If the alignment plates do not move during the operation, perform the following steps: • Remove motor M5 and check the gears between the motor and alignment plates for damage. Replace components as necessary. • Verify that connector J7 on the saddle-stitcher controller PCA is fully seated and not damaged. Check the wiring at the M5 motor. • Replace the alignment motor M5. • Only if the error persists and none of the previous steps correct the problem, replace the saddlestitcher controller PCA.