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Kyocera Mita DF-75, Service Manual

The Kyocera Mita DF-75 is a reliable and efficient document finisher that is perfect for any office environment. For those in need of a service manual or user manual, you can easily download it for free from our website. Get the most out of your device with the proper guidance.

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5-33

CHAPTER 5 TROUBLESHOOTING

5.3.2 Puncher Unit (option)

Error

Waste case full

Excess water

Condition

The amount of

waste paper in the

waste case has

reached the limit.

The amount of

waste paper in the

waste case has ex-

ceeded the limit.

Timing of detection

During punching.

During punching.

Operation

Normal operation

will continue.

Punching will be

disabled.

Resetting

Remove the waste

paper from the

waste case.

Remove the waste

paper from the

water case.

T05-503-02

Summary of Contents for DF-75

Page 1: ...SERVICE MANUAL Published in Aug 01 5FG70760 DF 75...

Page 2: ...URER DISPOSE OF USED BATTERIES ACCORDING TO THE MANUFACTURER S INSTRUCTIONS ATTENTION IL Y A DANGER D EXPLOSION S IL Y A REMPLACEMENT INCORRECT DE LA BATTERIE REMPLACER UNIQUEMENT AVEC UNE BATTERIE DU...

Page 3: ...sonnel to ensure the safety of their customers their machines as well as themselves during maintenance activities Service personnel are advised to read this booklet carefully to familiarize themselves...

Page 4: ...mpliance with warning messages using this symbol WARNING Serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol CAUTIO...

Page 5: ...or dusty place This may cause fire or electric shock Do not install the copier near a radiator heater other heat source or near flammable material This may cause fire Allow sufficient space around th...

Page 6: ...clean Dirt on them can cause abnormally high temperatures Do not remove the ozone filter if any from the copier except for routine replacement 2 Precautions for Maintenance WARNING Always remove the...

Page 7: ...t all the caution labels that should be present on the machine according to the instruction handbook are clean and not peeling Replace with new ones if necessary Handle greases and solvents with care...

Page 8: ...18 2 3 2 Processing Tray Paper Stacking Operation 2 20 2 3 3 Offset Operation 2 21 2 3 4 Stack Delivery Operation 2 22 3 Stapling Operation 2 23 3 1 Outline 2 23 3 2 Stapling Operation 2 25 3 3 Delive...

Page 9: ...32 1 3 1 Removing the Finisher Controller PCB 3 32 1 3 2 Removing the Slide Home Position PCB 3 33 2 Puncher Unit option 3 35 2 1 Puncher Driving System 3 35 2 1 1 Removing the Punch Motor 3 35 2 1 2...

Page 10: ...1 Finisher Controller PCB 5 15 3 2 Punch Controller PCB 5 16 4 Troubleshooting 5 17 4 1 Troubleshooting finisher saddle unit 5 17 4 1 1 C0440 communication error 5 17 CHAPTER 5 TROUBLESHOOTING 4 1 2 C...

Page 11: ...uncher Unit option 5 33 5 4 Host Machine I O Display 5 34 5 4 1 Finisher Saddle Unit 5 34 5 4 2 Puncher Unit option 5 38 APPENDIX 1 General Timing Chart A 1 1 1 Finisher Unit A 1 1 2 Saddle Unit A 2 1...

Page 12: ...CHAPTER 1 GENERAL DESCRIPTION...

Page 13: ...ositions Three different stapling positions front 1 point stapling rear 1 point stapling and middle 2 point stapling are supported c Saddle stitching A maximum of ten sheets of paper can be delivered...

Page 14: ...90 g m2 Non sort stack Sort stack Staple stack Bind stack Non Sort Staple Large size 500 sheets Small size 1000 sheets Note 2 Staple Sort Large size 30 sets or 500 sheets Small size 30 sets or 1000 sh...

Page 15: ...sheets Saddle 10 sheets Cartridge of special staples 5000 staples Special staples Yes nearly empty 40 remaining staples Front 1 Point Stapling A3 A4R B4 279 mm 432 mm 11 17 LGL LTRR Rear 1 Point Stapl...

Page 16: ...le 2 point stapling w saddle in use A3 1 2 1 2 1 mm A4R 1 2 1 2 1 mm B4 1 2 1 2 1 mm 279 mm 432 mm 11 17 1 2 1 2 1 mm LTRR 1 2 1 2 1 mm 82 4 mm 3 23 0 16 in 202 4 mm 7 95 0 16 in 159 4 mm 6 26 0 16 in...

Page 17: ...1 5 CHAPTER 1 GENERAL DESCRIPTION Stacked Paper Alignment F01 201 02 Delivery direction 20 mm 0 79 in max 50 mm 1 97 in max...

Page 18: ...hole Puncher Unit G1 H1 A3 A4 64 g m2 90 g m2 2 hole Puncher Unit J1 6 5 mm 0 26 in 2 3 hole Puncher Unit K1 2 hole 8 0 mm 0 31 in 3 hole 8 0 mm 0 31 in 4 hole Puncher Unit G1 H1 6 5 mm 0 26 in 2 hole...

Page 19: ...n 2 2 3 Hole Puncher Unit K1 12 3 mm 0 47 0 12 in 70 1 mm 2 76 0 04 in 1 LGL LTRR 73 3 mm 2 87 0 12 in 1 1 12 3 mm 0 47 0 12 in 108 1 mm 4 25 0 04 in 1 279 mm 432 mm 11 17 LTR 1 108 1 mm 4 25 0 04 in...

Page 20: ...Section 3 1 1 Finisher Unit 1 Delivery tray 2 Aligning plate front rear 3 Paddle 4 Delivery roller 5 Processing tray stopper 6 Feed roller 7 Puncher unit option 8 Delivery belt 9 Stack delivery roller...

Page 21: ...1 9 CHAPTER 1 GENERAL DESCRIPTION 3 1 2 Saddle Unit 1 Bind stopper 2 Bind tray 3 Stack feed roller F01 301 02 5 3 4 2 6 1 4 Bind delivery roller 5 Paper fold roller 6 Paper pushing plate...

Page 22: ...CHAPTER 1 GENERAL DESCRIPTION 1 10 3 1 3 Puncher Unit option 1 Die 2 Cam 3 Hole puncher Punch blade 4 Punch waste case 3 1 2 4 F01 301 03...

Page 23: ...ne Maintenance by the User As of February 2001 No 1 2 Item Staple cartridge replacement Punch waste removal optional Timing When prompted indicator on host machine control panel When prompted indicato...

Page 24: ...CHAPTER 2 OUTLINE OF OPERATION...

Page 25: ...the commands from the finisher controller PCB The puncher unit option is designed for installation to the pickup assembly of the finisher and is used to punch holes in sheets coming from the host mac...

Page 26: ...switches to the host machine by way of the serial communication line The ICs mounted to the finisher controller PCB have the following functions Host machine DC controller PCB CPU Punch controller PCB...

Page 27: ...elt is at home position 1 5 V EJCT_BLT_HP 5 V BDL_ROL_HP 11 12 2 CN43 1 3 2 CN42 3 1 CN9 1 2 3 CN51 1 2 3 When the paddle is at home position 1 CN55 3 2 1 CN9 7 8 9 2 CN54 1 3 2 CN53 3 1 When the swin...

Page 28: ...r upper is at home position 1 CN47 3 2 1 CN15 1 2 3 When the sensor detects paper 1 Front door sensor Upper cover sensor PI23 PI22 When the front door is open 1 5 V FDOOR_S When the upper cover is ope...

Page 29: ..._ A FEEDMTR_B FEEDMTR_ B PDLMTR_A Switches between 1 and 0 according to the direction of motor rotation PDLMTR_ A PDLMTR_B PDLMTR_ B CN10 7 8 9 10 11 12 1 2 3 4 5 6 CN57 6 5 4 3 2 1 EJCTMTR_A Switches...

Page 30: ...er controller PCB Shift motor SIFTMTR_1 Switches between and according to the direction of motor rotation CN6 1 2 M6 2 1 CN70 2 1 SIFTMTR_0 2 1 2 1 2 1 CN70 2 1 Staple fold motor BINDMTR_1 Switches be...

Page 31: ...8 5 V 5 V 5 V PI19 PI20 PI21 5 V HOOK_S STPL_HP SLID_HP STPL_CNCT Host machine Communication line CN2 1 3 4 5 7 6 CN1 1 2 24 V 24 V 5 V SELF_P 5 V Slide home position sensor CN11 6 CN11 5 CN11 4 CN11...

Page 32: ...ition sensor PI3P 1 J2009 3 5 V CLOCK 2 9 J1006 7 8 Punch home position sensor 5 V 5 V PT1 PT2 PT3 PT4 PT5 When the hole puncher is at home position 0 PI2P 1 J2007 3 5 V SLIDE 2 3 J1006 1 2 Punch moto...

Page 33: ...zontal registration motor Switches between and according to the direction of motor rotation When 1 LED goes ON Switches the pulse signals according to the rotation of the motor B A B A J1001 1 2 3 4 M...

Page 34: ...king job offset and stapling or folding in two If a punch unit option is installed the sheets are pouched and delivered to the delivery tray Sheets may be delivered in either of five ways including on...

Page 35: ...2 11 CHAPTER 2 OUTLINE OF OPERATION 2 1 1 Normal Delivery a Simple Stacking The machine pulls in the sheet once to the processing tray and then delivers it to the delivery tray Tray Paper F02 201 02...

Page 36: ...ing plane When the number of sheets stacked on the process ing tray reaches a specified value the sheets are delivered in a form of a stack Even if the specified value is not reached stacked sheets ar...

Page 37: ...The machine stacks sheets coming from its host machine on the processing tray When the number of sheets stacked on the processing tray reaches a specified value the finisher staples them delivers the...

Page 38: ...TION d Saddle Delivery The machine deposits a stack of sheets on the processing tray staples it middle 2 point and then moves it to the saddle unit The saddle unit folds the stack in two and delivers...

Page 39: ...her controller PCB The paper path is equipped with the sensors shown in T02 202 02 used to monitor the ar rival or passage of sheets If a sheet fails to arrive at or move past a specific sensor within...

Page 40: ...signal PDLMTR Alignment plate motor rear drive signal RJOGMTR Bind clutch drive signal B_CLU Alignment plate motor front drive signal FJOGMTR Finisher controller PCB 2 2 Staple fold motor drive signal...

Page 41: ...ontroller PCB PI10 Fold position paper detect signal BIND_P PI1 Inlet paper detect signal ENT_P Notation PI1 PI10 Name Inlet sensor Fold position sensor Connector on finisher controller PCB CN16 CN16...

Page 42: ...or during alignment It is at the down position during stack feeding stack delivery or stapling At power on the finisher controller PCB drives the aligning plate front motor M4 and the aligning plate...

Page 43: ...ligning plate front Alignment plate front motor M4 Alignment plate rear motor M5 Light shielding plate Front Paper Aligning plate front home position sensor PI4 Light shielding plate Aligning plate re...

Page 44: ...en the delivery rollers is fed onto the processing tray Then the paddle taps on the sheet surface once to locate the sheet against the processing tray stopper T02 203 02 Swing guide Delivery belt Stac...

Page 45: ...be offset Aligning plate front 2 3 3 Offset Operation Each sheet is pulled forward or backward using the aligning plate front and the aligning plate rear The offset operation is performed each time a...

Page 46: ...specified number of pulses causing the swing guide to ascend Next the paper delivery motor is driven Next the delivery motor is driven to deliver the paper stack with the nails of the delivery belt t...

Page 47: ...unit Next the slide motor is driven a specified num ber of pulses The stapler unit moves to rear standby position at the back of the machine en tering the standby state Sensor Slide home position sens...

Page 48: ...2 24 CHAPTER 2 OUTLINE OF OPERATION F02 301 01 Paper stack Slide motor M8 Stapler Slide home position sensor PI18 Light shielding plate Deliver direction...

Page 49: ...is sandwiched between the upper and lower stack delivery rollers The finisher controller PCB moves the stapler for stapling according to the specified sta pling position when rear 1 point stapling is...

Page 50: ...PTER 2 OUTLINE OF OPERATION F02 302 02 Paddle motor M2 Swing guide home position sensor PI3 Light shielding plate Staple safety switch MS3 4 Swing guide Stack delivery roller upper Stack delivery roll...

Page 51: ...elt home position sensor is turned OFF The delivery motor is driven a specified number of pulses causing the swing guide to ascend At the same time the slide motor is driven to return the stapler back...

Page 52: ...PTER 2 OUTLINE OF OPERATION F02 303 02 Paddle motor M2 Swing guide Stack delivery roller lower Stack delivery roller upper Swing guide home position sensor PI3 Light shielding plate Staple safety swit...

Page 53: ...nisher controller PCB rotates the staple fold motor in the forward direction until the sensor turns ON allowing the staple cam to the original position The staple empty sensor PI20 is used to detect p...

Page 54: ...HAPTER 2 OUTLINE OF OPERATION F02 304 01 F02 304 02 Finisher controller PCB Staple hold motor drive signal Staple top position detect signal Staple empty detect signal Staple home position detect sign...

Page 55: ...been stacked on the processing tray the stapler is moved to the specified stapling position in response to the stapling command from the host machine F02 304 03 shows the standby position of the stap...

Page 56: ...pler waits at the back The stapler moves to and returns from the stapling position for each stapling operation The stapler first staples a paper stack at the rear stapling position and then staples it...

Page 57: ...he stapler moves to and returns from the stapling position for each stapling operation The stapler first staples a paper stack at the rear stapling position and then staples it at the front stapling p...

Page 58: ...ray sensor PI6 Feed motor M1 Delivery motor M3 Paddle motor M2 Paddle home position sensor PI2 Swing guide home position sensor PI3 Stapler safety switch MS3 Alignment motor front M4 Aligning plate ho...

Page 59: ...where the edge of the delivery tray is detected At power on the finisher controller PCB drives the shift motor M6 to return the delivery tray to the home position When the paper coming from the proce...

Page 60: ...NE OF OPERATION F02 401 01 Tray paper sensor PI8 Shift motor M6 Shift motor clock sensor PI17 Shift lower limit sensor PI16 Full stack sensor PI24 Shift upper limit sensor PI15 Delivery tray Paper sur...

Page 61: ...rations 5 1 1 Outline The machine stitches a stack of sheets middle 2 point then folds the stack in two in the finisher These operations are controlled by the finisher controller PCB The finisher cont...

Page 62: ...g from the finisher folds it and delivers it to the bind tray in the saddle unit in response to the commands from the host machine That is the machine performs the following operations 1 Paper feed in...

Page 63: ...eing aligned on the processing tray a stack of sheets is sandwiched between the stack delivery rollers As the stack delivery rollers rotate the stack is fed toward the saddle unit F02 502 02 Stack del...

Page 64: ...stack stitching position reaches the stapler s staple position the stapler stitches the paper stack When only one sheet is fed from the host machine the next step stack feed is performed without perf...

Page 65: ...d the paper stack to the stack folding delivery position where the center of the stack stitched position is level with the paper pushing plate and paper folding roller s nip part F02 502 04 Paper fold...

Page 66: ...y The paper pushing plate pushes in the center of the paper stack to feed it toward the paper fold rollers Then the paper fold rollers and bind delivery rollers deliver the paper stack to the bind tra...

Page 67: ...hed between the upper and lower stack delivery rollers The delivery motor M3 rotates in the reverse direction feeding the paper stack to ward the saddle unit When the leading edge of the paper stack r...

Page 68: ...up per to descend The paper stack is sandwiched between the stack feed rollers Then the bind clutch CL1 is turned ON to rotate the feed motor M1 in the forward direction thus feeding the paper stack...

Page 69: ...reaches the folding position the guide plate covers the paper fold roll ers to act as a paper path through which a paper stack is fed to the saddle unit and to prevent a paper stack from touching the...

Page 70: ...lers Half the entire surface of each paper fold roller is uncovered excluding the central area and the area at the left and right ends The uncovered surface of the upper paper fold roller comes in tou...

Page 71: ...eds a paper stack Feeds a paper stack Outlet Inlet Paper push plate Paper stack Paper folding start position F02 505 03 M7 Paper fold roller lower Paper fold roller upper Folding home position sensor...

Page 72: ...e home position sensor PI3 Stapler safety switch MS3 Slide motor M8 Staple fold motor M7 Staple home position sensor PI19 Folding position sensor PI10 Stack feed roller upper home position sensor PI12...

Page 73: ...through the puncher unit and then the feed system of the finisher When the trailing edge of a sheet from the host machine reaches the puncher unit the sheet is stopped once and the punch shaft is rota...

Page 74: ...e punch shaft 180 from its home po sition As many as five light receiving transistors photosensor PCB are mounted over the inlet paper path of the puncher unit on the other hand as many as five LEDs L...

Page 75: ...on PI1P detection signal PUNCHHP Horizontal registration home position PI2P detection signal SREGHP Punch controller PCB 2 2 Punch motor clock PI3P detection signal PUNCHCLK PT1 LED1 2 3 4 5 5 2 3 4 T...

Page 76: ...elected to suit the country of installation 2 hole Puncher Unit J1 2 and 3 hole Puncher Unit K1 or two types of 4 hole Puncher Unit G1 Puncher Unit H1 The 2 hole and 4 hole types punch a hole when the...

Page 77: ...punching operation takes place as follows when making a hole in two sheets of paper 1 A hole is punched along the trailing edge of the 1st sheet punch shaft at rest home position punch shaft CW rotat...

Page 78: ...ends when the Punch shaft has rotated 180 counterclockwise and the punch home position sensor goes ON half circumference At this time the 3 hole puncher makes a single round trip in escape direction...

Page 79: ...t rest home position punch shaft CW rotation by 90 punch at upper limit punch shaft CW rotation by 180 punch back to initial position F02 602 05 2 Holes are made along the trailing edge of the 2nd she...

Page 80: ...eing made the 3 hole puncher makes a single round trip in escape di rection moving up the hole puncher punch shaft CCW rotation by 90 punch at upper limit punch CCW rotation by 180 punch back at initi...

Page 81: ...or LED5 PT5 and the horizontal registration sensors LED1 through 4 SREG1 through 4 and causes a move to a specific position matching the trailing edge of each sheet in relation to the size of the shee...

Page 82: ...o detect the edge of sheets of A3 A4 LTR 279 432 11 17 Horizontal registration sensor 2 LED2 PT2 used to detect the edge of sheets of B4 B5 LTRR LGL Horizontal registration sensor 3 LED3 PT3 used to d...

Page 83: ...unit to its home position 5 For each sheet that arrives in succession the punch slide unit is returned to its home posi tion and is caused to repeat steps 1 through 4 CW rotation CCW rotation Feed mo...

Page 84: ...her option at such times as set in advance It identifies a jam in ref erence to the presence absence of paper at a specific sensor If a jam is found the finisher con troller PCB communicates the natur...

Page 85: ...am J81 The paper does not leave the inlet sensor approximately 2 sec after the inlet sensor has de tected its leading edge Feed motor M1 Inlet sensor PI1 Jam check Inlet sensor PI1 Jam check Normal Ja...

Page 86: ...pproximately 10 5 sec after the staple fold motor is driven F02 701 05 7 1 5 Power On Jam J87 Paper is detected inside the finisher at power on 7 1 6 Door Open Jam paper present J88 The finisher is di...

Page 87: ...e other is turned into 5 VDC by the regulator IC IC1 of the finisher controller PCB for use by the sensors and ICs on PCBs If a punch unit option is installed power is also supplied to the punch contr...

Page 88: ...is used to drive the motors while the 5 V power is used by sensors and the ICs on the punch controller PCB The 24 V power to the motors will be cut off when the joint switch MS2 or the front door swi...

Page 89: ...CHAPTER 3 MECHANICAL SYSTEMS...

Page 90: ...over 3 3 Front cover 5 4 Front door 5 Upper door 6 Upper right cover assembly 4 7 Jam removal cover The number in parentheses indicates the number of mounting screws used 1 2 3 4 5 6 7 F03 101 01 1 1...

Page 91: ...2 Removing the Front Cover 1 Open the front door 1 2 While picking the claw 2 detach the fold jam releasing dial 3 3 Remove the two screws 4 F03 101 03 1 4 4 3 2 4 Remove the three screws 5 and detac...

Page 92: ...s 1 on the pickup side and remove the screw 2 on the delivery side then detach the rear cover 3 3 1 3 2 F03 101 06 1 1 4 Removing the Upper Cover 1 Open the upper cover 1 and turn the cover band retai...

Page 93: ...ay rear cover 5 then de tach the upper cover 6 6 4 5 F03 101 08 1 1 5 Removing the Processing Tray Upper Cover 1 Remove the front cover See 1 1 2 2 Remove the rear cover See 1 1 3 3 Remove the upper c...

Page 94: ...etach the processing tray upper cover 3 3 4 F03 101 10 1 1 6 Removing the Upper Right Cover Assembly 1 Remove the front cover See 1 1 2 2 Remove the rear cover See 1 1 3 3 Remove the two screws 1 at t...

Page 95: ...the four screws 3 1 2 3 3 3 3 F03 101 13 6 Shift the side guide 4 lightly to the front and free the engagement of the pa per surface detecting lever rear 5 then detach the side guide 4 5 4 F03 101 14...

Page 96: ...rom the stapler frame shaft If re moved the position where the staple driver lower unit of the stapler 4 shoots stables will shift from the position where the staple clincher upper unit of the stapler...

Page 97: ...ming of the staple driver lower unit of the stapler does not match the staple bending timing of the staple clincher upper unit of the stapler Adjust the stapler phase following the proce dure describe...

Page 98: ...belt 8 and relay gear 1 9 Remove the spacer and spring at the back of the staple jam relasing gear 4 Remove the screw 10 and spring 11 to remove the belt tentioner 12 F03 102 05 5 Remove the timing be...

Page 99: ...to align the round hole in the staple driver gear with the round hole 17 at the back F03 102 07 8 Insert a pin 18 with a diameter of ap proximately 2 mm use of a 2 mm Allen wrench is recommended in t...

Page 100: ...to align the round hole in the staple clincher cam with the round hole 20 at the back F03 102 09 10 Insert a pin 21 with a diameter of ap proximately 2 mm use of a 2 mm Allen wrench is recommended in...

Page 101: ...nd hole 26 in the frame F03 102 12 The position where the blue mark is aligned with the round hole is the home position for sta pling If the staple jam cancel dial is turned for some reason the home p...

Page 102: ...em with the E ring 33 F03 102 13 1 2 3 Adjusting the Phase of the Gear in the Saddle Unit If the gears at the front of the saddle unit or the paper fold rollers in the sale unit are re placed or remov...

Page 103: ...alf of the periphery where gears with a smaller face width are arranged With the mark on the saddle cam drive gear 3 aligned with the mark on the relay gear 4 align the other mark on the relay gear wi...

Page 104: ...ing plate as sembly 5 to the inside F03 102 17 5 Remove the stop ring 6 and detach the timing belt 7 6 Disconnect the two connectors 8 F03 102 18 7 Remove the three screws 9 and slide out the stapler...

Page 105: ...ray upper cover See 1 1 5 2 Remove the side guide See 1 1 7 3 Remove the two screws 1 and discon nect the six connectors 2 F03 102 20 4 Pull the processing stopper base 3 to the front and free the cla...

Page 106: ...ors 7 6 Release the two claws 8 of the harness retainer and detach the motor harness 9 F03 102 22 7 Remove the stop ring 10 and detach the timing belt 11 8 Disconnect the connector 12 and free the har...

Page 107: ...essing tray assembly 16 to the rear then lift it to detach F03 102 24 1 2 6 Removing the Paddle Assembly 1 Remove the processing tray assembly See 1 2 3 2 Place the processing tray assembly 1 as shown...

Page 108: ...3 19 CHAPTER 3 MECHANICAL SYSTEMS 3 Detach the timing belt 3 and remove the two screws 4 F03 102 26 3 4 4...

Page 109: ...MS 4 Separate the processing tray assembly 5 and the paddle assembly 6 as shown F03 102 27 1 2 7 Removing the Staple Fold Drive Unit 1 Open the front door 1 and slide out the stapler unit 2 slightly t...

Page 110: ...7 from the harness retainer 5 5 Free the harness 7 from the edge saddle 8 then disconnect the two con nectors 9 F03 102 29 6 Release the harness retainer 10 and disconnect the connector 11 7 Free the...

Page 111: ...9 Remove the screw 15 and free the claw 17 of the harness guide from the long angle 16 of the base plate F03 102 31 10 Disconnect the two connectors 18 and free the harness 20 from the edge saddle 19...

Page 112: ...3 23 CHAPTER 3 MECHANICAL SYSTEMS 11 Remove the three screws 21 F03 102 33 12 Remove the screw 22 and detach the staple fold drive unit 23 F03 102 34 21 21 21 22 23...

Page 113: ...ove the screw 3 and detach the harness guide 4 4 Remove the three screws 5 and detach the feed motor unit 6 F03 102 35 1 2 9 Removing the Feed Roller 1 Remove the upper cover See 1 1 4 2 Remove the up...

Page 114: ...crews 4 F03 102 37 7 Remove the gear 5 and detach the gear 6 while spreading the claw 8 Remove the stop ring 7 and detach the bushing 8 9 Remove the screw 9 and detach the inlet sensor 10 10 Remove th...

Page 115: ...102 39 1 2 10 Removing the Stack delivery roller upper 1 Remove the paddle assembly See 1 2 4 2 Place the paddle assembly 1 as shown F03 102 40 3 Turn the gear 2 in the direction of the arrow to move...

Page 116: ...4 from below to free the stack deliver roller upper 4 from the shaft 5 F03 102 42 5 Shift up the stack delivery roller upper 4 and then push it down to detach the stack deliver roller upper 4 F03 102...

Page 117: ...1 2 11 Removing the Paddle 1 Remove the paddle assembly See 1 2 4 2 Place the paddle assembly 1 as shown F03 102 44 3 Turn the gear 2 in the direction of the arrow to move up the stack delivery roller...

Page 118: ...w to free one side of the safety guide 4 from the shaft 5 F03 102 46 5 Push up the safety guide 4 from below to free the safety guide 4 from the shaft 5 F03 102 47 6 Remove the paddle 6 in the directi...

Page 119: ...the processing tray assembly See 1 2 4 2 Slide the aligning plate front 2 and the aligning plate rear 3 of the pro cessing tray assembly 1 by sliding them to the outside F03 102 49 3 Remove the proces...

Page 120: ...g the claw 9 detach the paper guide rear 10 F03 102 52 6 Remove the two stop rings 11 then move the two bushings 12 to the in side F03 102 53 7 Remove the four screws 13 then lift the stack delivery r...

Page 121: ...mount them so that the edges 17 of the claws of the delivery belts are flush F03 102 56 1 3 PCBs 1 3 1 Removing the Finisher Controller PCB 1 Remove the rear cover See 1 1 3 2 Disconnect the 17 conne...

Page 122: ...to the frontmost point 2 Remove the stapler unit See 1 2 1 F03 103 02 3 Place the stapler unit 3 as shown 4 Remove the two screws 4 and detach the guide 5 F03 103 03 5 Turn the tab 2 on the stapler s...

Page 123: ...Disconnect the connector 8 8 Remove the flexible cable retainer 9 9 Free the lock 10 of the connector in the direction of the arrow then detach the flexible cable 11 and then detach the side home posi...

Page 124: ...emove the two screws 1 2 Disconnect the connector 2 to remove the punch motor 3 F03 201 01 2 1 2 Removing the Horizontal Registration Motor 1 Disconnect connector J1001 1 2 Remove the harness 3 from t...

Page 125: ...waste case 2 Remove the screw 1 to detach the jam processing cover 2 F03 201 03 3 Disconnect the connector J1005 3 4 Remove the harness 5 from the harness guide 4 F03 201 04 5 Disconnect the connector...

Page 126: ...d washer 10 8 Disconnect the connector 11 9 Remove the two screws 12 to detach the base cover 13 F03 201 06 10 Remove the four screws 14 to remove the upper transmission sensor unit 15 and lower trans...

Page 127: ...nch unit 18 from the horizontal registration motor assembly 17 Ff03 201 08 2 2 PCBs 2 2 1 Removing the Punch Controller PCB 1 Remove the two screws 1 2 Disconnect the five connectors 2 to re move the...

Page 128: ...Photosensor PCB 1 Remove the punch motor See 2 1 1 2 Remove the screw 1 3 Remove the harness 3 from the harness guide 2 on the PCB then detach the PCB cover 4 F03 202 02 4 Disconnect the connector 5 t...

Page 129: ...PCB 1 Remove the waste case 2 Disconnect connector J1005 1 3 Remove the harness 3 from the harness guide 2 F03 202 04 4 Remove the screw 4 and washer 5 5 Disconnect the connector 6 6 Remove the screw...

Page 130: ...the screw 9 8 Disconnect the connector 10 to remove the LED PCB 11 F03 202 06 2 2 4 Removing the Waste Full Photosensor PCB 1 Remove the punch controller PCB See 2 2 1 2 Remove the two screws 1 to re...

Page 131: ...EMS 3 Disconnect the connector 3 to remove the waste full photosensor PCB 4 F03 202 08 2 2 5 Removing the Waste Full LED PCB 1 Remove the screw 1 2 Disconnect the connector 2 to remove the waste full...

Page 132: ...CHAPTER 4 MAINTENANCE AND INSPECTION...

Page 133: ...ECTION 4 1 1 Periodically Replaced Parts 1 1 Finisher Saddle Unit The unit does not have components that require periodical replacement 1 2 Puncher Unit option The unit does not have components that r...

Page 134: ...February 2001 No 1 Part name Stapler Part No 4G1 4268 000 Q ty 1 Expected life 300 000 operations Remarks A single cartridge is good for about 5000 op erations T04 201 01 3 Scheduled Maintenance As o...

Page 135: ...CHAPTER 5 TROUBLESHOOTING...

Page 136: ...have replaced the finisher controller PCB you must transfer the existing settings to the new PCB Perform the following if the folding position must be adjusted for some reason Both the folding and sta...

Page 137: ...on press the PSW1 To move the folding position in the direction press the PSW2 Pressing the PSW1 and PSW2 at the same time clears the adjustment value F05 101 03 3 When adjustment of the folding posit...

Page 138: ...er PCB as follows ON 1 2 3 4 5 6 7 8 F05 101 04 2 Adjust the stapling position by pressing the PSW1 or PSW2 on the finisher controller PCB a required number of times Pressing the switch once moves the...

Page 139: ...hine 1 2 2 Adjusting the Sensor Output Perform the following when the punch controller PCB horizontal registration sensor photosensor PCB LED PCB or waste full sensor waste full photosensor PCB waste...

Page 140: ...ate number of punch holes Each press on SW1002 moves the selection through the following repeatedly from top to bottom Number of punch holes 2 holes Puncher Unit J1 2 3 holes Puncher Unit K1 4 holes P...

Page 141: ...ine 2 Set bits 1 through 4 on the punch controller PCB as follows F05 102 03 3 Press SW1002 and SW1003 on the punch controller PCB at the same time The presses will initialize the EEP ROM At the end a...

Page 142: ...5 7 CHAPTER 5 TROUBLESHOOTING...

Page 143: ...ngement of Electric Components 2 1 Finisher Saddle Unit 2 1 1 Sensors Microswitches and Clutch PI1 PI2 PI3 PI15 PI5 PI10 PI11 PI12 CL1 PI7 PI9 PI8 PI6 MS2 MS3 MS1 PI13 PI14 PI17 PI16 PI4 PI22 PI23 PI1...

Page 144: ...me position detection Tray paper detection Paper surface detection Folding position detection Folding home position detection Folding roller home position detection Bind tray paper detection Stapler f...

Page 145: ...5 10 CHAPTER 5 TROUBLESHOOTING 2 1 2 Motor PCBs M7 M8 M5 M4 M3 M6 M1 M2 1 F05 201 02...

Page 146: ...ame Motor Finisher controller PCB Notation M1 M2 M3 M4 M5 M6 M7 M8 1 Description Feed motor Paddle motor Delivery motor Alignment motor front Alignment motor rear Shift motor Staple fold motor Slide m...

Page 147: ...uncher Unit option 2 2 1 Sensors PI2P PI1P PI3P F05 202 01 Name Photointerrupters Notation PI1P PI2P PI3P Description Puncher home position detection Horizontal registration home position detection Pu...

Page 148: ...5 13 CHAPTER 5 TROUBLESHOOTING 2 2 2 Motors M2 M1 F05 202 02 Name Motor Notation M1P M2P Description Punch motor Horizontal registration motor T05 202 02...

Page 149: ...5 14 CHAPTER 5 TROUBLESHOOTING 2 2 3 PCBs 1 2 3 5 4 F05 202 03 Ref 1 2 3 4 5 Name Punch controller PCB Photosensor PCB LED PCB Waste full photosensor PCB Waste full LED PCB T05 202 03...

Page 150: ...acy 3 1 Finisher Controller PCB F05 301 01 SW1 6 CN17 1 LED1 PSW2 LED2 CB1 LED3 PSW1 PSW3 1 CN9 9 CN11 1 7 3 CN16 1 CN12 CN2 CN14 CN1 5 1 1 7 1 5 CN19 3 1 1 12 CN8 CN6 CN18 CN10 CN3 CN13 CN5 CN4 CN7 C...

Page 151: ...1004 J1002 J1001 J1006 J1005 J1007 1 4 SW1002 SW1003 1 5 1 10 13 1 F05 302 01 Switch SW1001 SW1002 SW1003 Description Punch hole count registration sensor output adjustment etc Punch hole count regist...

Page 152: ...e finisher controller PCB and the DC controller PCB of the host machine normal NO Correct the wring Finisher controller PCB Host machine DC controller PCB 3 Try replacing the finisher controller PCB a...

Page 153: ...controller PCB 4 Try replacing the feed motor Is the problem corrected YES End NO Replace the finisher controller PCB T05 401 03 4 1 4 C8300 Delivery Motor Fault detail code 01 02 Delivery belt home...

Page 154: ...he mechanical mechanism Alignment motor rear M5 Finisher controller PCB 4 Try replacing the alignment motor rear Is the problem corrected YES End NO Replace the finisher controller PCB T05 401 05 4 1...

Page 155: ...e staple fold motor Is the problem corrected YES End NO Try replacing the finisher controller PCB T05 401 07 4 1 8 C8340 Staple Fold Motor Fault detail code 01 02 Folding home position sensor PI11 1 C...

Page 156: ...er PCB 3 Try replacing the staple fold motor Is the problem corrected YES End NO Replace the finisher controller PCB T05 401 09 4 1 10 C0360 Slide Motor Fault detail code 01 02 Slide home position sen...

Page 157: ...oller PCB 4 Try replacing theAlignment motor front Is the problem corrected YES End NO Replace the finisher controller PCB T05 401 11 4 1 12 C8140 Shift Motor Fault detail code 01 Paper surface sensor...

Page 158: ...inisher controller PCB NO Correct the wiring T05 401 13 4 1 14 C8140 Shift Motor Fault detail code 03 1 Is the tray in UP position YES Go to step 4 NO Go to step 2 Finisher controller PCB 2 Is power s...

Page 159: ...e the sensor Wiring 3 Is the wiring between the finisher controller PCB and the paddle motor normal NO Correct the wiring Paddle Swing guide assembly 4 Try turning the paddle motor clockwise and count...

Page 160: ...Fault detail code 20 EEP ROM IC1002 1 Is the problem corrected by initializing the EEP ROM on the punch con troller PCB YES End Punch controller PCB 2 Turn off and the on the host machine Is the prob...

Page 161: ...nism NO Replace the punch motor Punch controller PCB Finisher controller PCB 5 Try replacing the punch controller PCB Is the problem corrected YES End NO Replace the fisher controller PCB T05 402 04 4...

Page 162: ...Registration Motor Fault detail code 01 02 Horizontal registration home position sensor PI2P 1 Check the horizontal registration home position sensor Is the sensor nor mal NO Replace the sensor Wiring...

Page 163: ...host machine and the finisher is interrupted This error is de tected by the host machine The checksum for the finisher controller PCB has an error when the power is turned on The stack feed roller up...

Page 164: ...taple fold motor is in operation The folding roller does not leave the folding home position sensor when the staple fold motor has been driven for 0 6 sec The folding roller does not return to the fol...

Page 165: ...r has been driven for 2 sec The paddle does not return to the paddle home position sensor when the paddle motor has been driven for 2 sec The swing guide does not leave the swing guide home position s...

Page 166: ...when the punch motor has been driven The light receiving voltage is 2 5 V or less when the light emitting voltage is set to 4 4 V while sensor output auto adjustment is under way The light receiving v...

Page 167: ...tack from the bind tray More than 10 stacks are depos ited on the folded stack tray Timing of detection Monitoring at all times When an extra sheet is placed When an extra sheet is placed Operation No...

Page 168: ...the waste case has reached the limit The amount of waste paper in the waste case has ex ceeded the limit Timing of detection During punching During punching Operation Normal operation will continue Pu...

Page 169: ...t Shift motor down drive output Staple fold motor PWM Staple fold clock sensor input Puncher unit transmission signal output TDX output Puncher unit reception signal in put RXD input Full stack interm...

Page 170: ...ignment motor current cutting Tray paper sensor input Staple fold motor CW Staple fold motor CCW Shift motor enable signal Signal EEPROM_CS EEPROM_DA_CK EEPROM_DA_DO DA_LD SELF_PRIME HOOK_S RJOGMTR_A...

Page 171: ...home position sensor Inlet sensor Folding home position sensor Stapler connection signal Stack feed roller upper home position sensor Puncher connection signal input Binding tray sensor input Power sa...

Page 172: ...bit6 bit7 Indication DIPSW1 bit1 DIPSW1 bit2 DIPSW1 bit3 DIPSW1 bit4 DIPSW1 bit5 DIPSW1 bit6 DIPSW1 bit7 DIPSW1 bit8 PUSHSW1 PUSHSW2 PUSHSW3 Folding position sensor analog Push switch 1 2 DIP switch 7...

Page 173: ...t Ladder circuit 7th bit Ladder circuit 8th bit Punch home position sensor Horizontal registration home position sensor DIPSW1001 bit1 DIPSW1001 bit2 DIPSW1001 bit3 DIPSW1001 bit4 Push SW1 Push SW2 Po...

Page 174: ...rizontal registration motor phase B output Horizontal registration motor phase A output Punch motor REV Punch motor FWD Punch motor PWM Punch motor encoder input DUST sensor Registering sensor 5 horiz...

Page 175: ...5 40 CHAPTER 5 TROUBLESHOOTING...

Page 176: ...APPENDIX...

Page 177: ...motor M3 Paddle motor M2 Paddle home position sensor PI2 Swing guide home position sensor PI3 Stapler safety switch MS3 Alignment motor front M4 Aligning plate home position sensor front PI4 Staple fo...

Page 178: ...ion sensor PI3 Stapler safety switch MS3 Alignment motor front M4 Aligning plate home position sensor front PI4 Alignment motor rear M5 Aligning plate home position sensor rear PI5 Slide motor M8 Stap...

Page 179: ...very motor M3 Delivery belt home position sensor PI7 Paddle motor M2 Paddle home position sensor PI2 Swing guide home position sensor PI3 Stapler safety switch MS3 Alignment motor front M4 Operation C...

Page 180: ...A 4...

Page 181: ...ETECT Signal BIND_HP FOLDING HP DETECT Signal BIND_L FOLD POSITION LED ON Signal BINDMTR STAPLE FOLD MOTOR DRIVE Signal BIND_P FOLD POSITION PAPER DETECT Signal BIND_ROL_HP BUNDLE FEED ROLLER HP DETEC...

Page 182: ...ignal SIFTMTR SIFT MOTOR DRIVE Signal SIFT_UPLMT SIFT UPPER LIMIT DETECT Signal SLID_HP SLIDE HP DETECT Signal SLIDMTR SLIDE MOTOR DRIVE Signal STPL_CNCT STAPLER CONNECT DETECT Signal STPL_HP STAPLE H...

Page 183: ...ETECT Signal PUNCH PUNCH HP DETECT Signal SLIDE SIDE REGISTRATION HP DETECT Signal SREG1 SIDE REGISTRATION DETECT Signal 1 SREG2 SIDE REGISTRATION DETECT Signal 2 SREG3 SIDE REGISTRATION DETECT Signal...

Page 184: ...A 8 APPENDIX...

Page 185: ...1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 DC 5V SGND ADJ_TRAY_S DC 5V SGND EJCT_BLT_HP DC 5V SGND TRY_EMPS DC 5V SGND LVL_S DC 5V SGND RJOG_HP CN5 1 CN5 2 CN5 3 CN5 4 CN5 5 CN5 6 CN5 7 CN5 8 CN5 9 CN5 10 C...

Page 186: ...PDLMTR_A PDLMTR_ A PDLMTR_B PDLMTR_ B SIFTMTR_DN SIFTMTR_UP BINDMTR_PWM BIND_CLK RJOGMTR_B RJOGMTR_A HOOK_S SELF_P R15 5 3 VOUT NC VIN GND SUB 4 1 2 2 1 5V 5V R180 R219 R218 R179 R198 R267 2 2 1 7 3 R...

Page 187: ...P05 P04 P03 P02 P01 Xin Xout 19 20 21 22 26 27 28 29 30 31 32 JOINT_SW FDOOR_SW STPLSAFE_SW ADJ_TRAY_S PWR_S SIFT_UPLMT 23 24 SIFT_DNLMT DSR PWR_DN BIND_NMPS PNCH_CNCT BIND_ROL_HP STPL_CNCT BIND_HP E...

Page 188: ...PGND PNCH_SGND PNCH_ 5V 5 4 3 2 1 CN14 5 CN14 4 CN14 3 CN14 2 CN14 1 1 3 2 STPLSAFE_SW C31 RA15 2 ZD4 R101 Q6 1 4 2 3 2 2 1 1 2 1 1 3 4 TP47 RA14 2 SGND SGND 5V C1 C2 1 2 SGND PGND 1 3 2 PWR_S RA15 1...

Page 189: ...N15 12 CN15 11 DC 5V SIFT_UPLMT SGND 5V 2 2 1 1 R83 R84 2 1 R195 DC 5V 1 3 2 SGND Bind tray sensor BIND_EMPS 1 TP36 2 1 RA5 1 2 1 RA6 1 2 1 C21 SGND CN15 1 CN15 3 CN15 2 DC 5V BIND_EMPS SGND 5V 3 4 RA...

Page 190: ...SGND Staple fold motor clock sensor BIND_CLK 1 TP14 2 1 R20 2 1 C10 SGND CN4 1 CN4 2 CN4 3 DC 5V FJOG_HP SGND 2 2 2 1 1 1 R58 R71 DC 5V 5V 1 3 2 R162 SGND Aligning plate home position sensor front 8...

Page 191: ...LT_HP SGND 1 2 2 2 1 1 R35 R73 DC 5V 5V 4 6 5 R153 SGND Delivery belt home position sensor EJCT_BLT_HP 1 TP18 2 1 RA12 1 2 1 RA13 2 2 1 C14 2 D13 1 CN16 7 CN16 9 CN16 8 DC 5V BIND_ROL_HP SGND 8 2 2 7...

Page 192: ...138 R139 C57 R98 R95 R90 8 2 6 4 2 2 7 1 5 3 1 1 RA28 4 RA28 1 RA28 2 RA28 3 R132 RA19 1 PGND SGND SGND 1 2 RA17 1 SGND SGND SGND 1 2 R133 SGND SPGND IC20 FEEDMTR_DA FEEDMTR_B FEEDMTR_ A FEEDMTR_ B FE...

Page 193: ...11 CN10 12 9 10 11 12 8 1 18 11 VsA VsB InA InA InB InB SyncA SyncB RsA RsB RefA RefB OutA A OutA A OutB B OutB B GA GB 4 15 24V CL 24V 2 2 1 1 CP1 2 2 2 2 2 2 1 1 1 1 1 4 13 12 1 1 C36 PGMD 2 1 C38...

Page 194: ...2 J2001 1 2 3 4 5 6 7 1 2 3 4 5 6 7 J2011 J2011 J1007 13 J1007 12 J1007 11 J1007 10 J1007 9 J1007 8 J1007 7 1 2 3 4 5 6 1 2 3 4 5 6 J2010 J2010 J1007 6 J1007 5 J1007 4 J1007 3 J1007 2 J1007 1 M2P Hori...

Page 195: ...SENS 1 MTR 6 MTR 5 MTR 4 MTR 3 MTR 2 MTR 1 MTR 0 SENS 0 SH 2 SH 3 SH 4 SH 5 SH 1 SH 0 SH 5 0 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 PGND C1035 1 2 C1036 1 2...

Page 196: ...A 20 4 2 LED PCB 1 DC 5V CN2010 1 R1 LED4 CN2010 2 R1 LED3 CN2010 3 R1 LED2 CN2010 4 CN2010 5 CN2010 6 R1 LED1 YR LED 1 2 LED1 1 2 LED2 1 2 LED3 1 2 LED4 1 2 LED5 2 3 4 5 6...

Page 197: ...2 1 R9 2 2 1 2 C7 C4 1 1 1 1 23 JP5 A4 CN2011 3 IC3 1 2 3 5V 1 1 2 2 2 1 R5 D5 SGND SGND PT1 R10 2 2 C5 1 1 7 1 1 25 JP6 JP4 JP7 JP3 A4R CN2011 5 SGND SGND CN2011 1 DC 5V CN2011 2 IC1 2 6 5 5V 5V 5V...

Page 198: ...A 22...

Page 199: ...le Illinois 60179 TEL 630 238 9982 FAX 630 238 9487 Western Region 14101 Alton Parkway Irvine California 92618 7006 TEL 949 457 9000 FAX 949 457 9119 Southeastern Region 1500 Oakbrook Drive Norcross G...

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