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Technical Bulletin

No. RTB-007

SUBJECT: Improper Stapling

DATE: Mar. 31,’91
PAGE: 1 of 3

PREPARED BY: M. Ninomiya
CHECKED BY:

FROM: Copier Technical Support Sec.

CLASSIFICATION:

Action Required
Troubleshooting
Retrofit Information

Revision of service manual
Information only
Other

MODEL: F40 Finisher

1. Phenomenon

A) Incomplete stapling: The staples are not flush with the paper surface.

B) No stapling: No staples are dispensed from the stapler.

2. Cause

A) If a staple [A] jams inside the staple bending gate [B], the gate cannot close

completely. Staples are not crimped completely, and there is about a 1mm gap
between the staple and the paper surface.

Flat Stapling

Incomplete stapling

(Normal)

(Loose)

1mm gap

2 to 30 sheets of paper

[A]

[B]

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Summary of Contents for F-40

Page 1: ... Relay Clutches LOCATION Incorrect 48 45 Correct 38 45 Page 01 27 Location left side second box from bottom Incorrect Paper Pack Correct Power Pack Page 02 18 Location 2nd line in the 2nd paragraph Incorrect switch or the lift sensor ARDF RDH is on Correct switch is on Page 02 26 Location 2nd line from the bottom of the page Incorrect development roller gear B when Correct development roller gears...

Page 2: ... step 6 Slide out the paper feed unit and renumber the steps that follow on this page and the next page Page 03 07 Location Step 7 Incorrect 7 Remove the left top cover plate D and the scanner lock plate E 1 screw Correct 6 Remove the left top cover plate B and the scanner lock plate C 1 screw Page 03 14 Location step 29 Incorrect 29 Check the light intensity SP48 Correct 29 Set DIP SW 902 8 to ON...

Page 3: ...h its above explanation The factor setting of Page 04 11 Location first paragraph Correct this paragraph as follows If the finisher malfunctions use Shift Tray Mode and Staple Mode to by pass the mainframe data Then test operate the finisher to determine whether the cause of the malfunction is in the finisher Page 04 11 Location step 1 of Shift Tray Mode Incorrect SW 101 1 2 and 4 to Correct SW 10...

Page 4: ...80 81 91 Page 4 16 17 Location table Incorrect 11 Not Used Japanese Machine Only 12 Second Paper Feed Clutch 13 Third Paper Feed Clutch 21 Not Used 22 Second Pick up Solenoid 23 Third Pick up 33 First Pick up Solenoid Correct 11 Second Paper Feed Clutch 12 Third Paper Feed Clutch 13 Not Used Japanese Machine Only 21 Second Pick up Solenoid 22 Third Pick up Solenoid 23 Not Used Japanese Machine Onl...

Page 5: ... displayed If 0 is entered max is 999 Otherwise max is number entered Correct is displayed Max is the number entered Page 04 29 Location LANGUAGE CODE TBLE Add 5 Spanish and 5 Dutch to the list of languages in the SP13 column Note This list is the same as that in row 2 010 Page 04 30 Location Items 10 17 and 18 Replace item 10 with item 17 i e delete 10 and change 17 into 10 and change 18 into 17 ...

Page 6: ... Page 05 76 Location illustration Lower right part of illustration overlaps text Move it up Page 05 87 Location step 6 Incorrect 6 Turn on the D2 switch Correct 6 Turn on the D1 switch Page 05 91 Location section title Incorrect 8 13 CHARGE CORONA CURRENT ADJUSTMENT Correct 8 13 CHARGE CORONA CURRENT ADJUSTMENT WHEN USING THE DRUM SHOE Page 05 94 Location step 8 Incorrect 8 Turn on the SC D2 Corre...

Page 7: ...7 38 Locaton section title Incorrect 13 7 PAPER FEED MOTOR REPLACEMENT Correct 13 7 BELT DRIVE MOTOR REPLACEMENT Page 07 40 Location section title Incorrect 13 9 PAPER FEED ROLLER REPLACEMENT Correct 13 9 ORIGINAL FEED ROLLER REPLACEMENT Page 07 46 Location after step 3 Add the following note NOTE When removing the PCB be careful not to damage any of the components that protrude from the board Pag...

Page 8: ... mode Page 10 06 Location 2nd line of 1st paragraph Incorrect The motor and Correct The belt drive motor and Page 10 20 Location item 10 of list Incorrect 10 Pan Head Screw with Washer Correct 10 Pan head Screw Long Page 10 20 Location item 15 of list Incorrect 15 Rubber Tightener Correct 15 Rubber Washer Page 10 20 Location Between items 18 and 19 of list Add the following item then renumber the ...

Page 9: ...SC 2A is indicated 0 3 Correct SC 2A is indicated 1 83 Page 12 20 Table location row 4 in the Problem column Incorrect SC 82 is indicated Correct SC 81 is indicated Page 12 21 Location step 2 Incorrect 2 Repeat step 1 to obtain Correct 2 Press SW100 on the RDH board to obtain Page 12 22 Table location row 3 in the Definition column Incorrect the feed in motor Correct the feed out motor Page 12 22 ...

Page 10: ...not turns off within 850 ms the inverter Correct not turn off within 850 ms after the inverter Page 12 22 Table location row 14 in the Condition column Incorrect is not turned at correct time Correct is not turned on at correct time Page 12 23 Table location row 5 in the Definition column Incorrect RDH receives the feed in signal Correct RDH receives the feed out signal ...

Page 11: ...2 Location on Copier P to P C5 The signal description is Fusing Exit Sensor Cleaning Heater Drum Heater Anticondensation Heater H CN701 2 H CN672 2 H CN609 2 W T19 CN672 1 B CN609 1 B CN701 1 B T20 Cleaning Heater Drum Heater Anticondensation Heater H CN701 2 H CN672 2 H CN609 2 W T19 CN672 1 B CN609 1 B CN701 1 B T20 RA2 CN102 B5 R CN102 B4 T CN101 A20 H CN102 A13 G CN101 B18 G CN101 A18 C CN655 ...

Page 12: ...ay MC 24 Lift Motor 2 24 Lift Motor 3 24 Feed MC2 24 Feed MC3 24 2nd Pick up 24 3rd Pick up 24 Bank Drive Motor 24 Main PCB CN464 CN1 4 P Paper Feed Motor PCB CN103 B8 CN103 A8 CN103 B14 CN103 A15 CN103 A4 CN103 B4 CN104 B9 CN104 A9 CN103 B2 CN103 A2 CN104 B5 CN104 A6 CN104 A8 CN104 B8 CN103 A13 18 10 26 27 11 12 28 14 2 3 29 30 31 19 13 T G Y Y Y Y Y Y C C H M G G G Y P Y Z C Y P Y Z C P Y P CN45...

Page 13: ...ical Bulletin No RTB 000 SUBJECT DATE PAGE 2 of Technical Bulletin No RTB 000 SUBJECT DATE PAGE 2 of Technical Bulletin No RTB 000 SUBJECT DATE PAGE 2 of Technical Bulletin No RTB 000 SUBJECT DATE PAGE 2 of ...

Page 14: ...m Preparation Making a test sheet 1 Fold an A4 8 1 2 x 11 sheet exactly in half Then draw a 2 5 cm 1 inch line A on the crease from an edge of the sheet Confirmation 1 Make a copy of the test sheet in platen mode from the LCT 2 Fold the copy once with the fold running down the middle of the copy then verify that the vertical line at the top center of the test chart is on the fold or within 2 0 mm ...

Page 15: ...ustment procedure 1 Remove the LCT right front and rear cover 2 4 and 5 screws Refer to steps 1 and 2 of LCT Unit Removal on p 5 3 of the service manual 2 Loosen 6 screws B Then slide the LCT unit to the front or rear to adjust the side registration then tighten the 6 screws 3 Check the side registration again ...

Page 16: ...aking a test sheet 1 Fold an A4 8 1 2 x 11 sheet exactly in half Then draw a 2 5 cm 1 inch line A on the crease from an edge of the sheet Confirmation 1 Make a copy of the test chart in platen mode from the by pass paper feed table 2 Fold the copy once with the fold running down the middle of the copy then verify that the vertical line at the top center of the test chart is on the fold or within 2...

Page 17: ... REGISTRATION ADJUSTMENT DATE Feb 15 91 PAGE 2 of 2 Adjustment procedure 1 Open the by pass paper feed table 2 Loosen the Allen screw B with an Allen wrench 3 Slide the table to the front or rear to adjust the side registration 4 Check the side registration again ...

Page 18: ... Revision of service manual Information only Other MODEL F40 1 SYMPTOM An accordion paper jam occurs at the inverter unit with the first sheet in duplex mode lighting the jam indicator D on the display panel The exact position where the leading edge of the paper stops is the third roller from the front side of the guide plate REVISED ON DEC 15 91 Exit Relay Roller Inverter Pressuure Roller Inverte...

Page 19: ...pe Paper jamming is most likely to occur under the following conditions at low temperature at low humidity with certain brands of paper ex Sabre X when sideways A4 copies are made 2 CAUSE A The guide plate warps The open shut guide plate warps and curves downward as shown as the result of heat from the fusing unit Open Shut Guide Plate molded plastic Open Shut Guide Plate Upper Guide Plate Paper d...

Page 20: ...ten occur at this point If the gap between the plates is even paper jams do not occur NOTE This paper jam occurs only when the first sheet is fed in duplex mode because of the short interval betweeen pages The preceding sheet of paper prevents the following sheet from hitting the inverter return roller Open Shut Guide Plate Ribs Lower Guide Plate The gap narrows in the center NOTE This is also don...

Page 21: ...ted from the November 90 production run This countermeasure will be applied until a permanent solution is found 4 PERMANENT SOLUTION The open shut guide plate has been made thicker by 0 7mm at the place where the spacers were stuck on NOTE This permanent solution has been implemented from the September 91 production run Refer to MB No 24 issued on DEC 15 91 Place flat spacers A between the open sh...

Page 22: ...A0079002 A0079542 Transfer Corona Wire 1 pc set A0079003 The platinum and the tungsten corona wires are fairly similar in performance and handling however there are the following differences Point 1 During the copy cycle less foreign matter toner dust gas will build up on the surface of a platinum corona wire than on a tungsten wire Consequently platinum corona wires do not need to be cleaned as o...

Page 23: ...re difficult to make The platinum wires can be installed in the field on the following models Model Main Transfer PQC PCC Separation PTC F20 F21 F22 52199540 52199540 52199540 Negative charge Do not use Negative charge Do not use Negative charge Do not use F30 F31 F33 F34 F40 A0079540 A0079542 A0079541 Negative charge Do not use Negative charge Do not use Not used Note 1 When installing the platin...

Page 24: ...ion only Other MODEL F40 Finisher 1 Phenomenon A Incomplete stapling The staples are not flush with the paper surface B No stapling No staples are dispensed from the stapler 2 Cause A If a staple A jams inside the staple bending gate B the gate cannot close completely Staples are not crimped completely and there is about a 1mm gap between the staple and the paper surface Flat Stapling Incomplete s...

Page 25: ...r Stapling DATE Mar 31 1991 PAGE 2 of 3 B A bent staple prevents the staple push plate A from moving downward or the staple sheet has not yet reached the stapling position 3 Action A Remove the jammed staple B from the staple bending gate C C B A ...

Page 26: ...d apart the side plates B and slide up the front pressure guide plate C NOTE When installing the staple cartridge make sure that all the staple sheets are be in the initial position D i e the staple sheets have not slid forward into the staple sheet guide E 2 Install the staple cartridge then make copies in double stapling mode until the staple sheet reaches the stapling position B C A E D Correct...

Page 27: ...ation only Other MODEL F40 Finisher 1 Phenomenon The finisher top cover A is bent and it makes a noise when it is opened or closed 2 Cause The rear top cover B and or front top cover C of the finisher has not been installed correctly It does not fit over part of the finisher frame D As a result the side s of the finisher s top cover cannot close completely The cover also makes a noise as it is bei...

Page 28: ...rea B making it easier to reinstall the finisher s front and rear top covers 3 Action For before April production With a screwdriver loosen the two screws securing the front and or rear top cover C Then use a small flat head screwdriver as shown to pry out the edge of the cover C so that it fits over the edge D of the frame Tighten the screws B A Incorrect Correct C D Incorrect Correct D C C D C C...

Page 29: ...f service manual Information only Other MODEL F 40 Since the location of shipping tape on the cassette bank section has been changed and a cushion has been added the procedure has been changed as follows OLD 6 Slide out the paper feed unit B then remove all strips of filament tape C NEW 6 Slide out the paper feed unit B then remove all strips of filament tape C and the cushion D This modification ...

Page 30: ...ng Retrofit Information Revision of service manual Information only Other MODEL F40 1 Installation procedure correction in the service manual Two steps A were inserted on page 8 14 between steps 12 and 13 of the current F40 service manual 13 Peel off the cover C from the Sort Staple key panel left side of the operation panel 14 Remove the Staple Position key top D and affix the Sort Stack key cove...

Page 31: ...nd steps B were inserted between installation procedure steps 8 and 9 9 Peel off the cover C from the Sort Staple key panel left side of the operation panel 10 Remove the Staple Position key top D and affix the Sort Stack key cover E copier accessory as shown 11 Set SP71 1 to enable the sorter Refer to the copier installation procedure NOTE Corrected installation procedure will be enclosed from Au...

Page 32: ...the feed in unit top cover D 4 screws 4 Remove the original stopper solenoid E with the bracket on 1 screw but do not let the solenoid hang down by the harness 5 Remove the release lever unit F 2 screws and 2 springs The springs may suddenly release so be careful not to lose the springs 6 Remove the original stopper unit this way 1 screw and 1 stud As in figure 2 first remove the front side screw ...

Page 33: ...o damage the exit roller paper guard B 9 Remove all the parts from the original table 10 Place the side fence in the middle of the new original table C and assemble the new table unit as shown in figure 4 The parts marked are new parts Refer to Modification Bulletin F40 No 11 11 Reinstall the unit NOTE When reinstalling the unit make sure of the following Set the new original table following the s...

Page 34: ... the harness is out of the way A and that you place the bracket in the socket B as shown in figure 6 Check to see if the release lever and the original stopper unit work properly Make sure the three original stoppers are parallel and that the stoppers do not touch the original table unit The specifications are shown in figure 7 Test run the machine before reassembling the front and rear covers Fig...

Page 35: ...d make a copy platen mode 2 Check to see if the copier side to side registration is adjusted properly 3 Feed the original in the RDH so that the edge with the line faces away from the original feed rollers 4 Compare the copy with the test sheet Case 1 Both are identical Reassemble the copier No further steps are needed Cases 2 and 3 The copy image has moved Follow the procedure below 5 Open the do...

Page 36: ...e has moved up Measure the difference and adjust the tray s position by pulling it away from the RDH pedestal B direction Make sure the adjustment matches the difference b Case 3 The RDH copy image has moved down Measure the difference and adjust the tray s position by pushing it towards the RDH pedestal C direction Make sure the adjustment matches the difference 8 Reassemble the document feeder 9...

Page 37: ...eplacement procedure Troubleshooting information relating to these steps is explained after 1 Additional Steps 1 1 First before reinstalling the wire service manual P5 14 step 7 make sure of the following Bring the cushion A to the side that has the larger hook The end that has the larger hook and the cushion will connect to the spring as in figure 1 1 2 Add these steps to the service manual P5 15...

Page 38: ...stops Cause The wire extends and a space appears between the cushion and the holder figure 4 This causes the pulley and the wire to slip When this phenomenon occurs the scanner can not go back to its home position Action in the field Remove the rear cover 2 screws Remove the fusing cooling fan motor B as in figure 1 2 screws 1 connector Loosen the 2 screws on the cushion holder and slide it toward...

Page 39: ...CATION Action Required Troubleshooting Retrofit Information Revision of service manual Information only Other MODEL F40 This RTB shows all the lubrication points with the illustrations which should be performed at Preventive Maintenance 1 Scanner Guide Rods Plate and Guide Rod Felts Cleaners PM Interval 80 K Lubricant Launa oil Guide Rod Felts Cleaners Guide Rods Guide Rod Plate ...

Page 40: ...n Roller Slip Clutch 1st 2nd 3rd Paper Feed Stations and Duplex Paper Feed Station PM Interval 80 K Lubricant Mobil Temp 78 3 Paper Lift Motor Worm Gear 2nd and 3rd Paper Feed Stations PM Interval 160 K Lubricant Mobil Temp 78 Remarks Oil holes on the inner hub A and inside the spring B should be lubricated A B ...

Page 41: ...5 4 Paper Feed Gears PM Interval 160 K Lubricant Mobil Temp 78 5 Development Unit Drive Gears PM Interval 80 K Lubricant Silicon Grease G40M 6 Fusing Roller Drive Gears PM Interval 160 K Lubricant Mobil Temp 78 Remarks Lubricate only the top of the Gear Do not lubricate inside the coupling gear A A ...

Page 42: ...SUBJECT PM Information Lubrication Points DATE Aug 31 91 PAGE 4 of 5 7 Registration Roller Gears PM Interval 160 K Lubricant Mobil Temp 78 8 Relay Roller Gears 1st 2nd and 3rd Relay Rollers PM Interval 160 K Lubricant Mobil Temp 78 ...

Page 43: ...Technical Bulletin No RTB 013 SUBJECT PM Information Lubrication Points DATE Aug 31 91 PAGE 5 of 5 9 Exit Rollers Drive Gears PM Interval 160 K Lubricant Mobil Temp 78 ...

Page 44: ...d the occurrence ratio is low it happens about 100 200 k copies after the machine installation And the earliest one appeared after about 50 k copies Cause The original stopper solenoid lever which does not have sufficient durability breaks due to material fatigue Then the original stopper gate cannot open Action required Replace the stopper solenoid lever with a new one To increase durability the ...

Page 45: ...EL F40 Symptom The wrench mark is blinking Possible Cause 1 The following connector pins for the main board have been disconnected CN102 A1 CN102 B1 CN102 A8 CN101 A3 2 The ID sensor board and the connector for the ID sensor are in poor contact because the position of the connector for the ID sensor does not match the one for the ID sensor board Action Required 1 Make sure that you reconnect the f...

Page 46: ...ces using a soft cloth with alcohol 3 Reassemble the ID sensor board 4 Remove the upper rear cover 5 Loosen the screw of the ID sensor connector bracket A then tighten the screw while pushing down the bracket CAUTION Make sure that you do not turn the bracket when tightening the screw 6 Check the value of Vsg and Vsp using SP55 the value of Vsg should be around 4 0 V A ...

Page 47: ...pier Technical Support Section Cl 1 ECKE D BY T I to L j x __ CLASSIFICATION N w MODEL F40 Action Required Revision of service manual Troubleshooting Information only Retrofit Information Other Please correct your 1 Copier Point To service manual as follows Point Diagram Location C 4 I 1 4 Main PCB Incorrect I Main PCB Correct ...

Page 48: ...t 3 Service Manual Page 2 53 Incorrect The bias roller which has a charge of 300 volts attracts the toner from the cleaning brush Correct The bias roller attracts the toner from the cleaning brush In the F30s the constant voltage type power pack 300 volts is used for the cleaning bias roller For the F40 it has been changed to the constant current type power pack ...

Page 49: ...ted by paper dust on the sensor pad affecting its color 2 When the original feed roller starts rotating the DF upper guide plate is warped slightly downward The clearance between the DF registration sensor and the sensor pad is reduced When this happens the DF registration sensor reflective type can receive the reflective light from the sensor pad even though its color is black Action Required For...

Page 50: ...m spacer P No 07010040 and fix the screws E This can give the registration sensor enough clearance for the sensor pad Permanent Countermeasure The shape of the pull out bracket P No A4651057 will be modified so that the sensor pad is positioned 1 5 mm further from the DF registration sensor Soon after the modification is applied to the production an M B will be issued E D ...

Page 51: ... This is caused by excessive current due to defective transistor Q7 on the PCC power pack Under this condition if the FU3 is replaced without replacing the PCC power pack the FU3 may be blown again To improve the durability of the PCC power pack a heat sink has been added to transistor Q7 on the PCC power pack This improvement is implemented to the mass production machines from the following seria...

Page 52: ... SP mode it will not be possible to enter the 2 digit year value for the year 2000 or beyond e g 00 01 02 If the RAM data is erased please follow the instructions written below In SP mode no 80 Machine Clock Set After inputting the date NA mm dd yy EU Asia dd mm yy enter the correct time and day of the week For the year please enter any 2 digit value from 91 99 The weekly timer will run correctly ...

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