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Olivetti DF-650 Service Manual

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DF-650
MT-1(A)
BF1(A)
PH-4A/PH-4C
SERVICE MANUAL
Code Y104371-8

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Summary of Contents for Olivetti DF-650

  • Page 1 Option Copier DF-650 MT-1(A) BF1(A) PH-4A/PH-4C SERVICE MANUAL Code Y104371-8...
  • Page 2 PUBLICATION ISSUED BY: Olivetti S.p.A. 77, Via Jervis - 10015 Ivrea (TO) Italy Copyright © 2008, Olivetti All rights reserved...
  • Page 3 This page is intentionally left blank.
  • Page 4 Safety precautions This booklet provides safety warnings and precautions for our service personnel 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 with the warnings and precautions described here before engaging in maintenance activities.
  • Page 5 Safety warnings and precautions Various symbols are used to protect our service personnel and customers from physical danger and to prevent damage to their property. These symbols are described below: DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol.
  • Page 6 1.Installation Precautions WARNING • Do not use a power supply with a voltage other than that specified. Avoid multiple connections to one outlet: they may cause fire or electric shock. When using an extension cable, always check that it is adequate for the rated current....................•...

  • Page 7: Specifications 1

    2.Precautions for Maintenance WARNING • Always remove the power plug from the wall outlet before starting machine disassembly....• Always follow the procedures for maintenance described in the service manual and other related brochures............................• Under no circumstances attempt to bypass or disable safety features including safety mechanisms and protective circuits.
  • Page 8 • Do not remove the ozone filter, if any, from the copier except for routine replacement..... • Do not pull on the AC power cord or connector wires on high-voltage components when removing them; always hold the plug itself...................... •...
  • Page 9 This page is intentionally left blank.

  • Page 10: Table Of Contents

    3H3-2.0 CONTENTS 1-1 Specifications 1-1-1 Specifications............................1-1-1 1-1-2 Parts names............................1-1-2 1-1-3 Machine cross sectional view .........................1-1-3 1-1-4 Machine drive system ..........................1-1-4 (1) Finisher (paper feed and conveying section) ..................1-1-4 (2) Finisher (main tray driving section) ....................1-1-5 (3) Multi job tray ............................1-1-6 (4) Centerfold unit ...........................1-1-7 (5) Punch unit ............................1-1-7 1-2 Installation...
  • Page 11 3H3-2.0 2-1 Mechanical construction 2-1-1 Finisher ..............................2-1-1 (1) Paper insertion section........................2-1-1 (2) Feedshift section ..........................2-1-2 (3) Intermediate tray section ........................2-1-5 (4) Paper eject section..........................2-1-13 2-1-2 Multi job tray............................2-1-15 2-1-3 Centerfold unit............................2-1-17 2-1-4 Punch unit .............................2-1-20 2-2 Electrical Parts Layout 2-2-1 Electrical parts layout..........................2-2-1 (1) PWBs (finisher) ..........................2-2-1 (2) Switches and sensors (finisher) ......................2-2-2 (3) Clutches and solenoids (finisher) ......................2-2-4...

  • Page 12: Specifications

    1-1 Specifications 1-1-1 Specifications Finisher Type ..........Floor type Number of trays ......2 trays Tray capacity ........Main tray (80 g/m weight paper) A3, B4 (257 x 364 mm), 11" x 17", 8 " x 14": 1500 sheets A4 - A6R, Folio, 8 "...

  • Page 13: Parts Names

    1-1-2 Parts names Figure 1-1-1 Finisher Punch unit (option) Main tray (Tray A) 15. Punch unit Sub tray (Tray B) 16. Punch unit adjustment dial Front cover 17. Punch waste box Front cover handle Upper cover Centerfold unit (option) Intermediate tray 18.

  • Page 14: Machine Cross Sectional View

    1-1-3 Machine cross sectional view Paper path Figure 1-1-2 Paper insertion section Feedshift section Intermediate tray section Paper ejection section Multi job tray (option) Centerfold unit (option) Punch unit (option) 1-1-3 Y104371-8 Service Manual...

  • Page 15: Machine Drive System

    1-1-4 Machine drive system (1) Finisher (paper feed and conveying section) Viewed from the machine rear Figure 1-1-3 Paper conveying motor 16. Drum drive gear 46 33. Intermediate tray drive belt gear 17. Movable guide motor gear 34. Eject pulley 20 Paper conveying gear Z54/ 18.

  • Page 16: Finisher (Main Tray Driving Section)

    (2) Finisher (main tray driving section) Figure 1-1-4 Main tray elevation motor pulley Gear 51 Feed belt Pulley 20S Pulley 34 Tray drive belt Worm gear 10. Pulley 20S Gear 50 11. Gear 26 Gear 18 1-1-5 Y104371-8 Service Manual...

  • Page 17: Multi Job Tray

    (3) Multi job tray Multi job tray elevation motor pulley Gear 51 Feed belt Pulley 20S Pulley 34 Tray drive belt Worm gear 10. Pulley 20S Gear 50 11. Gear 26 Gear 18 1-1-6 Service Manual Y104371-8...

  • Page 18: Centerfold Unit

    (4) Centerfold unit Figure 1-1-5 Main motor pulley 12. Gear 16/25 23. Paper conveying belt Belt 118P2M6 13. Bypass pulley gear 24. Pulley 20 Gear 22/40 14. Gear 58 25. Blade motor pulley Gear 33/15 15. Pulley 28 26. Belt 126P2M6 Gear 51 16.

  • Page 19: Unpacking And Installation

    1-2Installation 1-2-1 Unpacking and installation Figure 1-2-1 Unpacking (Finisher) Finisher 20. Rear lower right pad Main tray 21. Upper pad Sub tray 22. Machine cover Connecting plate 23. Air cap bag Sponge 24. Air cap bag Pins 25. Air cap bag Nuts 26.
  • Page 20 Removing tapes and spacers Plastic sheet Procedure 1. Remove the plastic sheet. 2. Remove two tapes and spacer. Tape Spacer Tape Figure 1-2-2 3. Remove eight tapes. Tape Tape Tapes Tapes Figure 1-2-3 Tape Tape 4. Remove four tapes and two spacers. Tape Spacers Tape...

  • Page 21: Installing The Centerfold Unit (Option)

    3H3-2.0 1-2-2 Installing the centerfold unit (option) • When installing the centerfold unit and multi job tray as a set, first install the centerfold unit and then the multi job tray. • Before installing the centerfold unit, press the Power key on the operation panel to off. Make sure that the Power lamp is off before turning off the main power switch.
  • Page 22 5. Hook the backstop onto the hook on the Hook inside of the finisher plate, and install the Backstop two pins from the outside. Hook 6. Attach one end of the small spring to the backstop and hang the other end over the hook inside the machine.
  • Page 23 10. Insert one end of the release pole assembly into the square bypass hole and the other end into the hole with the projection, with the D-cut of the release pole assembly aligned with the projection. 11. Insert the end of the release pole assembly already inserted through the square bypass hole into the mounting hole.
  • Page 24 14. Place the slider on the projections on the fin- isher rear side-plate and lock down with three M4 x 8 S tight bind screws. Insert the M4 x 8 S tight bind screws from the round holes on the eject side of the fin- isher.
  • Page 25 19. Fit the large stop ring onto the lower part of Guide stay the unit lock rod. Unit lock rod 20. Hang one end of the large spring over the Hook hook on the unit lock hook and the other end over the hook on the guide stay.
  • Page 26 24. Slide the centerfold unit in the direction of the arrow. 25. Loosen the two screws and push the retainer in the direction of the arrow and retighten the screws. Screw Screw Retainer Retainer Centerfold unit Figure 1-2-19 26. Fit the left cover and right cover into the rectangular holes on either side of the cen- ter fold unit, and secure each one with the M4 x 6 TP screw.
  • Page 27 28. Engage the projection of the douser detect- ing PI with the cutout on the centerfold unit's rear side plate, and secure them with a M4 x 8 S tight bind screw. When inserting the centerfold unit, make sure that the douser detecting PI does not come into contact with the finisher's folding unit sensor.
  • Page 28 32. After cleaning each area with alcohol, affix the following labels from label sheet at the locations shown in the illustration: (C)-1 (G7), (C)-2. C -2 20 mm C -1 Figure 1-2-25 33. Plug the power cable into a wall outlet and turn the machine on from the main power switch.

  • Page 29: Installing The Multi Job Tray (Option)

    3H3-2.0 1-2-3 Installing the multi job tray (option) • Hold the frame at the front and back when removing the multi job tray from the box. Supporting the multi job tray from the bottom can cause deformation of the film affixed to it. •...
  • Page 30 4. Attach the two size detection switches to the M3 x 5 binding screw eject stay by inserting the tabs, and lock in place with one M3 x 5 binding screw each. Size detection 5. Connect the 3-pin connector of the size switch detection switch to the connector of the fin- isher.
  • Page 31 8. Measure the height a against the scale to make sure that the multi job tray is posi- Bin rear Bin front guide plate tioned properly to stay level from front to guide plate rear. If the height a is not the same at the front Multi job tray and rear, the multi job tray may not be posi- tioned on a level plane.
  • Page 32 12. Attach the bin guide plate retainer with two M4 x 6 M4 x 6 M4 x 6 binding screws. binding screw binding screw Bin guide 13. Reattach the top cover with the nine screws plate retainer removed in step 2, keeping the upper cover open halfway to enable proper attaching.
  • Page 33 16. Affix a bin No. label to each of the five eject bins. Eject bin Bin No. label Figure 1-2-37 17. Attach the eject bin with the label No.1 Claws affixed at the uppermost shelf of the multi job tray by inserting the three claws into the Eject bin square holes.
  • Page 34 22. Insert the two lugs of the motor front cover Motor front cover into the rectangular holes, and secure them with the M4 x 8 TP screw. Lugs M4 x 8 TP screw Figure 1-2-40 23. Connect the signal cable of the multi job tray Signal cable to the finisher connector.

  • Page 35: Installing The Punch Unit (Option)

    3H3-2.0 1-2-4 Installing the punch unit (option) • Before installing the punch unit, press the Power key on the operation panel to off. Make sure that the Power lamp is off before turning off the main power switch. And then unplug the power cable from the wall outlet. Turning off the main power switch before pressing the Power key to off may cause damage to the equipped hard disk.
  • Page 36 5. Secure the punch unit with two M4 x 10 tap M4 x 10 tap tight S screws. Make sure the center of the tight S screws right long hole is aligned with the center guideline. Punch unit Figure 1-2-45 6.
  • Page 37 10. Insert the assembly tank holder into the Supplied holes in the side of the finisher, and then 3-pin connector wire saddle press it downwards to secure it. Next, secure it further with the screw that was removed in step 3. Install the screw from the Screw outside.
  • Page 38 16. Make the following seven connections. Top: 2-pin power connector and 2-pin motor connector; 6-pin power connector and 6-pin sensor connector Center: 4-pin power connector and YC1 of punch PWB; 6-pin power connector and YC3 of punch PWB; 9-pin power connector and YC2 of punch PWB Bottom: 2-pin power connector and 2-pin finisher power connector;...

  • Page 39: Installing The Stopper Guide (Option)

    3H3-2.0 1-2-5 Installing the stopper guide (option) • Before installing the stopper guide, press the Power key on the operation panel to off. Make sure that the Power lamp is off before turning off the main power switch. And then unplug the power cable from the wall outlet. Turning off the main power switch before pressing the Power key to off may cause damage to the equipped hard disk.

  • Page 40: Installing The Stopper Guide (To The Finisher With The Multi Job Tray)

    3H3-2.0 (2) Installing the stopper guide (To the finisher with the multi job tray) Procedure 1. Install the stopper to the stopper mount Stopper mount using stop ring 3. * Be careful. The stopper hole on the stopper mount varies from the inch specification and metric specification.
  • Page 41 3H3-2.0 4. Hold the stopper guide as indicated. 5. Replace the cover removed in step 2. Stopper guide Figure 1-2-56 6. After cleaning with rubbing alcohol, affix the appropriate operation label to the finisher as Operation label indicated. 5 to 10 mm Figure 1-2-57 1-2-23 Y104371-8...

  • Page 42: Maintenance Mode

    1-3 Maintenance Mode 1-3-1 Maintenance mode (1) Executing a maintenance item Start Enter 10871087 using Maintenance mode is entered. the numeric keys. Enter the maintenance item number using the cursor up/down keys The maintenance item is or numeric keys. selected. Press the start key.

  • Page 43: Contents Of The Maintenance Mode Items

    (2) Contents of the maintenance mode items Maintenance Description item No. Displaying the ROM checksum U018 Description Displays the checksum of ROM. Purpose To check the checksum. Method Press the start key. The ROM checksum is displayed. Display Description MAIN* Main PWB ROM checksum ENGINE* Engine PWB ROM checksum...
  • Page 44 Maintenance Description item No. Setting punch destination U234 Description Sets the destination of optional punch unit of document finisher. Purpose To be set when installing the optional punch unit. Method Press the start key. The screen for selecting an item is displayed. Setting 1.
  • Page 45 Maintenance Description item No. Adjusting finisher stack quantity U237 Description Sets the number of sheets of stack on the main tray in the document finisher. Purpose To change the setting when a stack malfunction has occurred. Method Press the start key. The screen for selecting an item is displayed. Setting 1.
  • Page 46 Maintenance Description item No. Checking the operation of the finisher U240 Description Turns each motor and solenoid of the document finisher ON. Purpose To check the operation of each motor and solenoid of the document finisher. Method 1. Press the start key. The screen for selecting an item is displayed. 2.
  • Page 47 Maintenance Description item No. U240 3. To turn ON a solenoid with the motor driving, press the interrupt key before selecting the solenoid. The driving motor will start operation, and the selected clutch or the solenoid will remain ON until the interrupt key is pressed again.
  • Page 48 Maintenance Description item No. U241 Display Switches CRT_R_HP_SW Rear clincher home position sensor (CLNHPS-R) T_OPEN_SW Upper cover switch (UCSW) F_OPEN_SW Front cover switch (FCSW) JTRAY_DT_SW Multi job tray position sensor (MJTPS) JTRAY_P_SW1 Paper detection switch 1 (PDSW1) JTRAY_P_SW2 Paper detection switch 2 (PDSW2) JTRAY_P_SW3 Paper detection switch 3 (PDSW3) JTRAY_P_SW4...
  • Page 49 Maintenance Description item No. Setting the paper ejection device U248 Description Adjusts the paper stop timing in the punch mode, the booklet stapling position, and the center folding position for the machine with the document finisher installed. Also, displays and clears the punch-hole scrap count. Purpose Adjustment or registration stop timing in punch mode Adjust if skewed paper conveying occurs or if the copy paper is Z-folded in punch mode.
  • Page 50 Maintenance Description item No. Setting the paper stop timing U248 1. Select PUNCH POSITION ADJUST on the screen for selecting an item. 2. Change the value using the cursor up/down keys. Description Setting Default Change in value range setting per step Adjustment of the paper stop timing in punch mode -10 to 10 0.24 mm...
  • Page 51 Maintenance Description item No. U248 Copy sample 1 Copy sample 2 4. Press the start key. The value is set. 5. To return to the screen for selecting an item, press the stop/clear key. Setting the center folding position 1. Select SADDLE ADJUST on the screen for selecting an item. 2.
  • Page 52 Maintenance Description item No. Setting the punch limit U248 1. Select PUNCH PRESET on the screen for selecting an item. 2. Change the value using the * or # keys. Description Setting range Default setting Punch limit (max. number of punches) 0 to 999000 100000 The punch limit can be set to any value in increments of 1000.
  • Page 53 Maintenance Description item No. Checking/clearing counts by optional devices U905 Description Displays or clears the counts of the DP or optional finisher. Purpose To check the use of the DP and optional finisher. Also to clear the counts after replacing consumable parts. Method 1.

  • Page 54: Paper Misfeed Detection

    1-4 Troubleshooting 1-4-1 Paper misfeed detection (1) Paper misfeed indication When a paper jam occurs, the machine immediately stops copying and the operation panel shows a paper misfeed mes- sage. Paper jam counts sorted by the detecting conditions can be checked by maintenance item U903. To remove paper, open the front cover or upper cover.

  • Page 55: Paper Misfeed Detection Conditions

    (2) Paper misfeed detection conditions Section Jam code Description Conditions Document Jam between the finisher Paper ejection is not output from the copier to the document finisher and copier finisher within 15 s of the face-up exit sensor (FUES) turning off.

  • Page 56: Paper Misfeeds

    (3) Paper misfeeds Problem Causes/check procedures Corrective measures The paper entry roller is Check and, if it is dirty, clean it. Paper jam during dirty with paper powder. paper insertion to the The paper entry roller is Check and, if it is deformed or worn, fix or replace it. finisher deformed or worn.
  • Page 57 Problem Causes/check procedures Corrective measures The eject roller is dirty with Check and, if it is dirty, clean it. Jam in eject section paper powder. of main tray The eject roller is deformed Check and, if it is deformed or worn, fix or replace it. Jam code 86 or worn.
  • Page 58 Problem Causes/check procedures Corrective measures (12) The paper forwarding pul- Check and, if it is dirty, clean it. Jam in saddle paper ley, upper or lower forward- entry section ing roller is dirty with paper Jam code 92 powder. The paper forwarding pul- Check and, if it is deformed or worn, fix or replace it.

  • Page 59: Self-Diagnosis

    1-4-2 Self-diagnosis (1) Self-diagnostic function This unit is equipped with a self-diagnostic function. When a problem is detected, copying is disabled and the problem dis- played as a code consisting of C followed by a number between 8010 and 8330, indicating the nature of the problem. A message is also displayed requesting the user to call for service.

  • Page 60: Self Diagnostic Codes

    (2) Self diagnostic codes *The option equipment. Remarks Code Contents Causes Check procedures/corrective measures C8010 Paper conveying motor problem Loose connection Reinsert the connector. Also check for conti- • The LOCK signal of the paper convey- of the paper con- nuity within the connector cable.
  • Page 61 Remarks Code Contents Causes Check procedures/corrective measures C8040 Lower paper conveying belt problem Phase shift of the Correct the phase of the lower paper con- • During initialization, the intermediate lower paper con- veying belt and check for correct operation. tray lower sliding plate is not detected veying belt.
  • Page 62 Remarks Code Contents Causes Check procedures/corrective measures C8150 Multi job tray* problem Loose connection Reinsert the connector. Also check for conti- • When the multi job tray is not detected of the multi job tray nuity within the connector cable. If none, by the multi job tray upper limit detec- elevation motor remedy or replace the cable.
  • Page 63 Remarks Code Contents Causes Check procedures/corrective measures C8180 Rear upper side registration guide Loose connection Reinsert the connector. Also check for conti- problem of the rear upper nuity within the connector cable. If none, • During initialization, the rear upper side registration remedy or replace the cable.
  • Page 64 Remarks Code Contents Causes Check procedures/corrective measures C8210 Front stapler problem Loose connection Reinsert the connector. Also check for conti- • During initialization, the front stapler is of the front stapler nuity within the connector cable. If none, not detected in the home position motor connector.
  • Page 65 Remarks Code Contents Causes Check procedures/corrective measures C8240 Rear clincher problem Loose connection Reinsert the connector. Also check for conti- • During initialization, the rear clincher is of the rear clincher nuity within the connector cable. If none, not detected in the home position motor connector.
  • Page 66 Remarks Code Contents Causes Check procedures/corrective measures C8320 Centerfold unit centering plate prob- Loose connection Reinsert the connector. Also check for conti- of the centering nuity within the connector cable. If none, • During initialization, the centering plate plate motor con- remedy or replace the cable.

  • Page 67: Electric Problems

    1-4-3 Electric problems Finisher Problem Causes Check procedures/corrective measures Poor contact in the paper Reinsert the connector. Also check for continuity within the con- The paper convey- conveying motor connector nector cable. If none, remedy or replace the cable. ing motor does not terminals.
  • Page 68 Problem Causes Check procedures/corrective measures Poor contact in the rear Reinsert the connector. Also check for continuity within the con- The rear upper side upper side registration nector cable. If none, remedy or replace the cable. registration guide guide motor connector ter- motor does not oper- minals.
  • Page 69 Problem Causes Check procedures/corrective measures Poor contact in the rear sta- Reinsert the connector. Also check for continuity within the con- The rear stapler pler motor connector termi- nector cable. If none, remedy or replace the cable. motor does not oper- nals.
  • Page 70 Problem Causes Check procedures/corrective measures (13) Poor contact in the siding Reinsert the connector. Also check for continuity within the con- The siding drum drum motor connector ter- nector cable. If none, remedy or replace the cable. motor does not oper- minals.

  • Page 71: Pulley

    Problem Causes Check procedures/corrective measures (18) Broken paper holder sole- Check for continuity across the coil. If none, replace the paper The paper holder noid coil. holder solenoid. solenoid does not Poor contact in the paper Reinsert the connector. Also check for continuity within the con- operate.
  • Page 72 Problem Causes Check procedures/corrective measures (23) Broken lock solenoid coil. Check for continuity across the coil. If none, replace the lock sole- The lock solenoid noid. does not operate. Poor contact in the lock Reinsert the connector. Also check for continuity within the con- solenoid connector termi- nector cable.

  • Page 73: Gear.

    Centerfold unit Problem Causes Check procedures/corrective measures Poor contact in the main Reinsert the connector. Also check for continuity within the con- The main motor does motor connector terminals. nector cable. If none, remedy or replace the cable. not operate. Broken main motor gear.

  • Page 74: Gear.

    Problem Causes Check procedures/corrective measures Broken pressures release Check for continuity across the coil. If none, replace the pressures The pressures solenoid coil. release solenoid. release solenoid Poor contact in the pres- Reinsert the connector. Also check for continuity within the con- does not operate.

  • Page 75: Mechanical Problems

    1-4-4 Mechanical problems Finisher Problem Causes/check procedures Corrective measures Check if the paper entry pulley correctly con- If not, fix as necessary. Paper jam. tacts paper entry roller. Check if the intermediate tray paper entry If not, fix as necessary. roller correctly contacts the intermediate tray paper entry pulley.

  • Page 76: Correcting Paper Curling

    1-5 Assembly and Disassembly 1-5-1 Finisher (1) Correcting paper curling Follow the below procedure if paper ejected from the finisher is curled. <Procedure> 1. Set the machine to the non-sort mode and run paper through the machine to make a test copy.
  • Page 77 3. Rotate the upper lever by one mark in the direction of the higher numbers. There are five marks. 4. Close the front cover. 5. Run paper through the machine and check if it is still curled upward. 6. Repeat steps 1 to 5 until the ejected paper does not curl upward anymore.

  • Page 78: Correcting Centerfold-Stapling

    (2) Correcting centerfold-stapling Follow the below procedure when the stapling position is off from the center when the machine is in the stitching copy mode. Procedure Figure 1-5-5 Start Set the machine to the stitching copy mode and make a test copy. Use paper of below sizes.

  • Page 79: Adjusting The Stapler Unit Mounting Position

    3H3-3 (3) Adjusting the stapler unit mounting position Perform this operation when replacing a stapler unit or when a stapling malfunction occurs. Since the front stapler and the rear stapler in the finisher have the same construction, only the procedure for the front sta- pler is described below.

  • Page 80: Gear

    3H3-3 Holes Stapler adjustment tool 6. Open the intermediate tray and attach the stapler adjustment tool to the stapler. Attach the stapler adjustment tool by insert- Film ing its projections into the stapler holes. In addition, be careful not to get the film caught when attaching the tool.

  • Page 81: Gear

    3H3-3 9. If the stapler adjustment metal is not Adjustment screws inserted into the adjustment hole, loosen the Intermediate tray four adjustment screws on the intermediate tray and adjust the stapler unit mounting position so that the metal is inserted into the hole.

  • Page 82: Centering Stapling Position

    (4) Centering stapling position Follow the below procedure if the positioning of stapling are off the centerline of paper when the machine is in the two- point stapling mode. Caution Before making the following adjustment, ensure that the center position of each cassette in the machine is correct. When the adjustment distance of the upper side registration guide is too large, follow through on page 1-5-8 to adjust the position of the lower side registration guide.
  • Page 83 • Position adjustment of lower side registration guide Upper side resistration guide Start Enter the maintenance mode. Enter 240 using the numeric keys. Press the start key. Select A3 TEST and Lower side resistration guide press the start key. Lower side registration guide motor Open the front cover and pull out the intermediate tray.

  • Page 84: Centerfold Unit

    1-5-2 Centerfold unit (1) Detaching and refitting the centerfold blade Follow the below procedure to clean or replace the centerfold blade. Procedure 1. Pull out the centerfold unit from the finisher. 2. Loosen the two screws, slide the retainers in the direction of the arrow, and remove the Screw Screw...
  • Page 85 7. Remove the two springs form the blade Blade retainer retainer. 8. Remove the five screws locking down the blade retainer followed by the retainer. 9. Remove the centerfold blade. 10. Clean or replace the centerfold blade. 11. Refit all the removed parts. Centerfold When attaching the centerfold blade to the blade...

  • Page 86: Adjusting The Paper Folding Position

    (2) Adjusting the paper folding position Follow the below procedure when the folding position is not correct in the centerfold mode. Procedure Start Make a test copy in the centerfold mode using paper of each of the below sizes. Sample 1 Sample 2 A4R, B4R, A3R, 8 "...

  • Page 87: Punch Unit

    1-5-3 Punch unit (1) Centering punch-holes Follow the below procedure if the positioning of punch holes are off the centerline of paper when the machine is in the punch mode. Caution: Before making the following adjustment, ensure that the center position of each cassette in the machine is correct. Procedure Start Set the machine to the punch mode...

  • Page 88: Setting Margin From The Leading Edge To Punch Holes

    (2) Setting margin from the leading edge to punch holes Follow the below procedure if the margin from the paper edge to punch holes is off the reference value. Procedure Reference value of a: Metric: 9.5 2 mm Inch: 5.5 2 mm Start Set the machine to the punch mode and make a test copy with paper fed...

  • Page 89: Upgrading The Version Of The Firmware Of The Finisher Main Pwb

    1-6 Requirements on PWB Replacement 1-6-1 Upgrading the version of the firmware of the finisher main PWB Firmware upgrading requires the following tools: Compact Flash (Products manufactured by SANDISK are recommended.) NOTE When writing data to a new Compact Flash from a computer, be sure to format it in advance. Procedure 1.

  • Page 90: Requirements On Finisher Main Pwb Replacement

    3H3-2.0 13. Enter the maintenance mode. 14. Run maintenance item U019 (Displaying the ROM version) to check ROM version upgrading was successful. 15. Exit the maintenance mode. 1-6-2 Requirements on finisher main PWB replacement NOTE When replacing the finisher main PWB, be sure to conform DIPSW setting of the replaced PWB to that of the removed PWB.

  • Page 91: Finisher

    2-1 Mechanical construction 2-1-1 Finisher (1) Paper insertion section The paper insertion section inserts paper from the machine into the finisher and then conveys it to the feedshift section. The paper is fed out to the finisher. The paper entry motor (PEM) will be activated in a certain period of time after the paper entry motor (PEM) is turned on to convey the paper to the feedshift section.

  • Page 92: Feedshift Section

    (2) Feedshift section The feedshift section switches the path of the paper conveyed from the paper insertion section so as to convey the paper to the intermediate tray, main tray or sub tray. Figure 2-1-3 Feedshift section Siding drum Sub feed roller Siding pulleys Left eject feedshift guide Main eject feedshift guide...
  • Page 93 Paper path switching The paper path is switched by the operation of the main eject feedshift guide, left eject feedshift guide or sub eject feed- shift guide. There are four paper paths in the feedshift section as shown below. The guide corresponding to the path to the selected tray operates to switch the paper path appropriately. Sub eject feedshift roller Left feedshift guide Main eject...
  • Page 94 Siding drum operation When A4/11" x 8 1/2" size paper is processed in the intermediate tray for eventual multiple sets of copies, to ensure the time for paper processing, the first and second page of the next copy set are wounded around the siding drum. The wounded paper are sided there until the third page is conveyed.

  • Page 95: Intermediate Tray Section

    (3) Intermediate tray section The intermediate tray section performs side identifying, eject position shifting and stapling of paper that is stacked in the tray. It then conveys paper to the main tray and centerfold unit. Figure 2-1-8 Intermediate tray section Intermediate tray paper entry roller (15) Lower paper conveying belt home position sensor Intermediate tray paper entry pulley...
  • Page 96 FMPWB YC-16-1,3,4,6 ITPCS YC21-5 YC18-B25 PCBHPS-U YC18-B22 SRGHPS-FU YC18-B21 SRGHPS-RU YC18-A24 PCBHPS-L CN24-B15 PFPSOL YC18-B20 SRGHPS-L Figure 2-1-9 Block diagram of the intermediate tray section 2-1-6 Service Manual Y104371-8...
  • Page 97 Paper inserting operation to the intermediate tray Each time a sheet of paper is inserted, the below operation takes place. 1. The front/rear upper/lower side registration Front upper Rear upper guides move to the paper receiving posi- side registration guide side registration guide tions that are slightly outside the actual paper width according to the paper size.
  • Page 98 Stapling operation There are four types of stapling. Paper is stapled with the selected stapling type and then moved to the shifted eject posi- tion. One-point stapling Two-point stapling One-point stapling Centerfold stapling at the back at the front Figure 2-1-13 One-point stapling at the back/two-point stapling/one-point stapling at the front 1.
  • Page 99 6. The front/rear upper side registration guides Stapling position (one-point move toward the machine front or rear to stapling at the front) move paper to the stapling position. Front upper Rear upper 7. The stapler performs stapling. side-registration guide side-registration guide 8.

  • Page 100: Gear

    Stapling operation The stapler is comprised of the front stapler driver, front stapler clincher, rear stapler driver and rear stapler clincher. The stapler cam that is connected to the stapler driving gear of the stapler driver rotates to drive in staples and then the stapler clincher clinches the staples.
  • Page 101 Paper ejection operation to the main tray Paper is ejected from the intermediate tray to the main tray (or the optional multi job tray) by the upper/lower paper con- veying belt motors (PCBM-U/L) rotating forward, which moves the intermediate tray upper/lower sliding plates upward so that the paper is pushed upward.
  • Page 102 Paper ejection operation to the centerfold unit In the stitching mode, a sheet of paper that was not stapled or multiple sheets of paper that were centerfold-stapled are conveyed from the intermediate tray to the centerfold unit. Paper is ejected to the centerfold unit by the upper/lower paper conveying belt motors (PCBM-U/L) rotating backward, which moves the intermediate tray upper/lower sliding plates down- ward so that the paper is pushed downward.

  • Page 103: Paper Eject Section

    (4) Paper eject section The paper eject section is comprised of the main tray eject section and sub tray eject section. In the multi finisher, paper is ejected to the main tray in the sort mode, group mode and staple mode. In the non-sort mode, paper is ejected to the sub tray, and if the number of ejected sheets of paper exceeds the sub tray capacity, the excess sheets are ejected to the main tray.
  • Page 104 Main tray elevation operation The main tray lowers when paper is stacked on it. Once stacking has completed and paper has been removed, the main tray rises and stops at the home position. The main tray lowers and rises by the forward and backward rotation of the main tray elevation motor (MTEM), respectively.

  • Page 105: Multi Job Tray

    2-1-2 Multi job tray The multi job tray stacks paper by lowering to the position where the job tray that is pre-selected (from among Nos.1 to 5) in the printer mode is positioned at the main tray eject section. Figure 2-1-25 Multi job tray Job tray No.1 Multi job tray rail Job tray No.2...
  • Page 106 Multi job tray elevation operation The multi job tray lowers and rises by the forward and backward rotation of the multi job tray elevation motor (MJTEM), respectively. The position detection plate is attached to the front side of the multi job tray. The position of the multi job tray is detected by the number of times the multi job tray position sensor (MJTPS) is interrupted (turned on) by the position detection plate.

  • Page 107: Centerfold Unit

    2-1-3 Centerfold unit In the stitching mode, the centerfold unit folds a sheet of paper that was not stapled (multiple sheets of paper that were stapled at the center of the paper) and then ejects it (them). Figure 2-1-28 Centerfold unit Front side registration guide (12) Left centerfold roller (21) Folded edge detection sensor...
  • Page 108 Paper centerfold operation 1. The pressure release solenoid (PRSOL) turns on so that the paper entry pulley guide Paper entry pulley guide rises. The unit enters the paper insertion standby state. Figure 2-1-30 2. When paper is inserted from the intermedi- ate tray, the pressure release solenoid (PRSOL) turns off so that the paper entry pulley guide lowers and conveys paper to...
  • Page 109 6. The centerfold blade pushes up the paper at Left centerfold roller Right centerfold roller the center and the paper is inserted between the right/left centerfold rollers. 7. Folded paper is ejected to the storage cover. Centerfold blade Figure 2-1-33 2-1-19 Y104371-8 Service Manual...

  • Page 110: Punch Unit

    2-1-4 Punch unit The punch unit is installed on the paper insertion section of the finisher. It stops paper conveyance and punches paper. Figure 2-1-34 Punch unit Punch cutter Punch pulse sensor (PPS) Punch cam Punch home position sensor (PHPS) Punch waste box Punch waste box sensor (PWBS) PUNPWB...
  • Page 111 Punching operation 1. In the punch mode, the paper is fed out to the finisher. The paper entry motor (PEM) will be activated in a certain period of time after the paper entry motor (PEM) is turned Paper entry sensor on.
  • Page 112 4. The punch cutter ascends. The punch home position sensor (PHPS) detects the home Punch home position sensor position to stop the punch. The paper entry roller rotates to convey the paper to the feedshift section. Punch cutter Paper entry roller Figure 2-1-39 2-1-22 Service Manual...

  • Page 113: Electrical Parts Layout

    2-2 Electrical Parts Layout 2-2-1 Electrical parts layout (1) PWBs (finisher) Machine front Machine inside Machine rear Figure 2-2-1 PWBs Finisher main PWB (FMPWB) ..... Controls electric components of finisher. Finisher drive PWB (FDPWB)...... Controls each motor and solenoid. 2-2-1 Y104371-8 Service Manual...

  • Page 114: Switches And Sensors (Finisher)

    (2) Switches and sensors (finisher) 17,24 Rear Front 15 16 20,21 17,18,21 19,20, 29,30 18,19 Machine front Machine inside Machine rear Figure 2-2-2 Switches and sensors Movable guide home position sensor (MGHPS) ....Detection of movable guide in home position. Upper cover switch (UCSW) ......
  • Page 115 19. Main tray paper upper surface detection light intercepting sensor (MTPUSDLIS) ..Detection of upper surface of paper in the main tray. 20. Multi job tray paper upper surface detection light emitting sensor (MJTPUSDLES)..Detection of paper overflow in the optional multi job tray. 21.

  • Page 116: Clutches And Solenoids (Finisher)

    (3) Clutches and solenoids (finisher) Machine front Machine inside Machine rear Figure 2-2-3 Clutches and solenoids Lock solenoid (LSOL) ........Operates the intermediate tray holder. Eject guide solenoid (EGSOL) ..... Operates eject guide. Paper holder solenoid (PHSOL) ....Operates main eject holder. Paper forwarding pulley solenoid (PFPSOL) ........

  • Page 117: Motors And Others (Finisher)

    (4) Motors and others (finisher) 10,11 Machine front Machine inside Machine rear Figure 2-2-4 Motors and others Paper conveying motor (PCM)..... Drives paper conveying section. Upper paper conveying belt motor (PCBM-U) .......... Drives upper paper conveying belt. Lower paper conveying belt motor (PCBM-L)...........

  • Page 118: Stapler

    (5) Stapler (Stapler driver) (Stapler clincher) Machine front Machine inside Machine rear Figure 2-2-5 Stapler (Front/Rear stapler drivers, Front/Rear clinchers) Front/Rear stapler empty sensor (STES-F/R) ........Detection of when specific stapler out of staples. Front/Rear stapler cartridge sensor (STCS-F/R) ........Detection of whether specific staple cartridge is installed or not. Front/Rear stapler home position sensor (STHPS-F/R)........

  • Page 119: Pwbs (Optional Centerfold Unit)

    (6) PWBs (optional centerfold unit) Machine front Machine inside Machine rear Figure 2-2-6 PWBs Centerfold unit main PWB (CUMPWB)..Controls electric components of centerfold unit. 2-2-7 Y104371-8 Service Manual...

  • Page 120: Switches And Sensors (Optional Centerfold Unit)

    (7) Switches and sensors (optional centerfold unit) Machine front Machine inside Machine rear Figure 2-2-7 Switches and sensors Eject tray detection switch (ETDSW) ... Detection of whether storage cover is installed or not. Side registration guide home position sensor (SRGHPS) ....Detection of front/rear side registration guides in home position. Centering plate home position sensor (CPHPS) ....

  • Page 121: Motors And Solenoids (Optional Centerfold Unit)

    (8) Motors and solenoids (optional centerfold unit) Machine front Machine inside Machine rear Figure 2-2-8 Motors and solenoids Main motor (MM).......... Drives the paper conveying section. Centerfold blade motor (CBLM) ....Drives centerfold blade. Side registration guide motor (SRGM)..Drives front/rear side registration guides. Centering plate motor (CPM) .......

  • Page 122: Switches And Motors (Optional Multi Job Tray)

    (9) Switches and motors (optional multi job tray) Machine front Machine inside Machine rear Figure 2-2-9 Multi job tray elevation motor (MJTEM) ..Raises/Lowers the multi job tray. Paper detection switch 1 (PDSW1)....Detection of paper in job tray No. 1. Paper detection switch 2 (PDSW2)....

  • Page 123: Switches And Motors (Optional Punch Unit)

    (10) Switches and motors (optional punch unit) Machine front Machine inside Machine rear Figure 2-2-10 Switches and motors Punch PWB (PUNPWB) ......Controls electric components of punch unit. Punch waste box sensor (PWBS)....Detection of whether punch waste box is installed or not. Punch home position sensor (PHPS) ..

  • Page 124: Finisher Main Pwb

    2-3 Operation of the PWBs 2-3-1 Finisher main PWB SRAM FLASH ROM (U8, U10) (U7) Address/data bus Compact Flash EEPROM (U5) (U6) (U1) Switches sensors Electric parts drivers Crystal Motor driver oscillator Solenoids circuit and motors (X1) Transistor array, etc. Centerfold unit main PWB* Machine...
  • Page 125 YC26 YC23 YC14 YC16 YC15 YC10 YC21 U13 U15 LED1 YC17 U8 U10 YC11 YC22 YC19 YC18 YC20 YC12 YC13 YC25 Figure 2-3-2 Finisher main PWB silk-screen diagram 2-3-2 Service Manual Y104371-8...
  • Page 126 Connector Pin No. Signal Voltage Description SI RDY 0/5 V DC SI RDY signal to the machine Connected DF RDY 0/5 V DC DF RDY signal to the machine to the SI SEL 0/5 V DC SI SEL signal from the machine machine DF SEL 0/5 V DC...
  • Page 127 Connector Pin No. Signal Voltage Description YC12 5 V DC 5 V DC power output Connected 5 V DC 5 V DC power output to the fin- Signal ground isher drive Signal ground PDSW5 0/5 V DC Paper detection switch 5 On/Off PDSW4 0/5 V DC Paper detection switch 4 On/Off...
  • Page 128 Connector Pin No. Signal Voltage Description YC17 24VR 24 V DC 24 V DC power output Connected 0/24 V DC Lock solenoid (latch-on) on/off to the lock 0/24 V DC Lock solenoid (release) on/off solenoid YC18 5 V DC 5 V DC power output Connected 5 V DC 5 V DC power output...
  • Page 129 Connector Pin No. Signal Voltage Description PCBHPS-U 0/5 V DC Upper paper conveying belt home position sensor YC18 on/off Connected to the inter- mediate tray YC19 5 V DC 5 V DC power output Connected MTPUS- 0/5 V DC Main tray paper upper surface detection light emit- to the main DLES ting sensor on/off...
  • Page 130 Connector Pin No. Signal Voltage Description YC21 Signal ground Connected MGHPS 0/5 V DC Movable guide home position sensor on/off to the mov- 5 V DC 5 V DC power output able guide Signal ground home posi- ITPCS 0/5 V DC Intermediate tray paper conveying sensor on/off tion sensor 5 V DC...
  • Page 131 Connector Pin No. Signal Voltage Description YC24 24VR 24 V DC 24 V DC power output Connected N.C. Not used to the inter- MOTOR R 0/24 V DC Front stapler motor drive control signal mediate tray MOTOR F 0/24 V DC Front stapler motor drive control signal MOTOR F 0/24 V DC...
  • Page 132 Connector Pin No. Signal Voltage Description YC25 0/24 V DC Paper holder solenoid (release) on/off Connected 0/24 V DC Paper holder solenoid (latch-on) on/off to the fin- HOLD 0/24 V DC Feedshift solenoid C (release) on/off isher drive 0/24 V DC Feedshift solenoid C (latch-on) on/off 0/5 V DC Eject motor drive control signal...

  • Page 133: Finisher Drive Pwb

    2-3-2 Finisher drive PWB YC12 YC11 YC10 Figure 2-3-3 Finisher drive PWB silk-screen diagram 2-3-10 Service Manual Y104371-8...
  • Page 134 Connector Pin No. Signal Voltage Description MODE 0/5 V DC Paper entry motor drive control signal Connected 0/24 V DC Paper entry motor on/off to the fin- 0/5 V DC Paper entry motor drive control signal isher main (pulse) MODE 0/5 V DC Siding drum motor drive control signal 0/24 V DC...
  • Page 135 Connector Pin No. Signal Voltage Description Signal ground Connected PDSW5 0/5 V DC Paper detection switch 5 on/off to the multi 5 V DC 5 V DC power output job tray PDSW4 0/5 V DC Paper detection switch 4 on/off 5 V DC 5 V DC power output Signal ground...
  • Page 136 Connector Pin No. Signal Voltage Description 0/24 V DC Paper entry motor drive control signal YC12 (pulse) Connected COM(24VR) 24 V DC 24 V DC power output to the paper 0/24 V DC Paper entry motor drive control signal entry motor (pulse) 0/24 V DC Paper entry motor drive control signal...

  • Page 137: Centerfold Unit Main Pwb

    2-3-3 Centerfold unit main PWB Figure 2-3-4 Centerfold unit main PWB block diagram 2-3-14 Service Manual Y104371-8...
  • Page 138 Connector Pin No. Signal Voltage Description 24 V DC 24 V DC power input Connected 24 V DC 24 V DC power input to the fin- PG(24V) Power ground isher PG(24V) Power ground Signal ground 5 V DC 5 V DC power input 0/5 V DC Finisher communication signal (pulse)
  • Page 139 Connector Pin No. Signal Voltage Description 5 V DC 5 V DC power output Connected 5 V DC 5 V DC power output to the side 5 V DC 5 V DC power output registration 5 V DC 5 V DC power output guide home 5 V DC 5 V DC power output...
  • Page 140 2-4 Appendixes 2-4-1 Y104371-8 Service Manual...
  • Page 141 2-4-2 Service Manual Y104371-8...
  • Page 142 2-4-3 Y104371-8 Service Manual...
  • Page 143 2-4-4 Service Manual Y104371-8...

  • Page 144: Maintenance Parts List

    3H3-2.0 Maintenance parts list Finisher Maintenance part name Fig. Ref. Part No. Name used in service manual Name used in parts list AVGR03555D Siding drum GUIDE DRUM ASS'Y AVGR03556R Intermediate tray paper entry ROLLER MIDDLE TRAY F I roller Upper paper entry roller UPPER ROLLER FEED IN AVGR04683N Lower paper entry roller...

  • Page 145: Gear

    3H3-2.0 Centerfold unit Maintenance part name Fig. Ref. Part No. Name used in service manual Name used in parts list AVGR03567N 3CA04011 Storage cover TRAY,EJECT AVGR03571E 3CA04090 Right cover LEFT FRONT COVER H AVGR03572J 3CA04100 Left cover LEFT REAR COVER H AVGR03573N 3CA04110 Eject guide upper spacer UPPER SPACER,EJECT GUIDE...

  • Page 146: Periodic Maintenance Procedures

    3H3-2.0 Periodic maintenance procedures Finisher Maintenance Section Method Maintenance cycle Points and cautions Page part/location Exterior Overall exterior cover Clean Every service Clean with alcohol or a dry cloth. Maintenance Section Method Maintenance cycle Points and cautions Page part/location Paper feed Siding drum Clean Every service...

  • Page 147: Belt

    3H3-2.0 Maintenance Section Method Maintenance cycle Points and cautions Page part/location Sensors Main tray paper upper Clean Every service Air brush surface detection light emitting sensor Main tray paper upper Clean Every service Air brush surface detection light intercepting sensor Multi job tray paper Clean Every service...

  • Page 148: Pulley

    3H3-2.0 Centerfold unit Maintenance Section Method Maintenance cycle Points and cautions Page part/location Exterior Storage cover Clean Every service Clean with alcohol or a dry cloth. Right cover Clean Every service Clean with alcohol or a dry cloth. Left cover Clean Every service Clean with alcohol or a dry...

  • Page 149: Gear

    3H3-2.0 Maintenance Section Method Maintenance cycle Points and cautions Page part/location Sensors Eject tray paper Clean Every service Air brush detection switch Folded edge Clean Every service Air brush detection sensor Inside tray detection Clean Every service Air brush sensor Centerfold unit paper Clean Every service...

  • Page 150: Optional Devices Supplied Parts List

    Optional devices supplied parts list Multi job tray Name used in service manual Name used in installation guide Part No. Alternative part No. AVGR03582T Eject bin Eject bin Bin front guide plate Bin front guide plate Bin rear guide plate Bin rear guide plate Bin guide plate retainer Bin guide plate retainer...
  • Page 151 3H3-2.0 Punch unit Name used in service manual Name used in installation guide Part No. Alternative part No. Tank holder Tank holder Punch PWB Punch PCB Power cord Power cord Punch waste box Punch waste box Guide Guide M4 x 8 tap tight S screw M4 x 8 tap Tight S screw Wire saddle Wire saddle...

  • Page 152: Centerfold Unit Wiring Diagram

    Centerfold unit wiring diagram 2-4-13 Y104371-8 Service Manual...

  • Page 153: General Wiring Diagram No.1

    General wiring diagram No.1 Machine YC10 SI RDY SI RDY DF RDY DF RDY SI SEL SI SEL DF SEL DF SEL SCLK SCLK DETECTION DETECTION 24V from Main N.C. FCSW N.C. 24V to Main DETECTION SI RDY SI SEL SCLK 24VR 24VR...

  • Page 154: General Wiring Diagram No.2

    General wiring diagram No.2 FMPWB-Intermediate tray Drawer2 YC18 PCBHPS-U PS-U PS-L SRGHPS-FU SRGHPS-RU SRGHPS-L N.C. N.C. N.C. N.C. N.C. STD-F N.C. STD-R Drawer1 N.C. N.C. N.C. N.C. N.C. N.C. N.C. STCLN-F STCLN-R PCBHPS-L PCBHPS-L STCLN-F STCLN-R PCBHPS-L Drawer3 FMPWB 2-4-15 Y104371-8 Service Manual...

  • Page 155: General Wiring Diagram No.3

    General wiring diagram No.3 FMPWB-Intermediate tray Drawer1 YC24 COM(24VR) PCBM-U COM(24VR) COM(24VR) PCBM-L COM(24VR) COM(24VR) SRGM-FU COM(24VR) COM(24VR) SRGM-RU COM(24VR) COM(24VR) SRGM-L COM(24VR) 24VR PFPSOL PFPSOL Drawer2 N.C. MOTOR R MOTOR R MOTOR R STD-F MOTOR F MOTOR F MOTOR F MOTOR R MOTOR R MOTOR R...

  • Page 156: General Wiring Diagram No.4

    General wiring diagram No.4 Intermediate tray SRGHPS-FU SRGHPS-RU Drawer2 SRGHPS-FU PCBHPS-U SRGHPS-RU PCBHPS-U PS-U PS-U PS-L PS-L SRGHPS-L SRGHPS-L STD-F STD-F MOTOR R MOTOR R MOTOR R MOTOR F MOTOR F MOTOR F STD-R STD-R MOTOR R MOTOR R MOTOR R MOTOR F MOTOR F MOTOR F...

  • Page 157: General Wiring Diagram No.5

    General wiring diagram No.5 Intermediate tray Drawer1 COM(24VR) PCBM-U PCBM-U COM(24VR) COM(24VR) PCBM-L PCBM-L COM(24VR) COM(24VR) SRGM-FU SRGM-FU COM(24VR) COM(24VR) SRGM-RU SRGM-RU COM(24VR) COM(24VR) SRGM-L SRGM-L COM(24VR) N.C. N.C. N.C. N.C. N.C. N.C. N.C. N.C. N.C. N.C. Drawer3 MOTOR F MOTOR F MOTOR R MOTOR R...

  • Page 158: General Wiring Diagram No.6

    General wiring diagram No.6 2-4-19 Y104371-8 Service Manual...

  • Page 159: General Wiring Diagram No.7

    General wiring diagram No.7 2-4-20 Service Manual Y104371-8...
  • Page 160 UPDATING STATUS DATE UPDATED PAGES PAGES CODE 12/2008 EDITION Y104371-8...

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