Triumph Adler DF 470 Service Manual
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Triumph Adler DF 470 Service Manual

Triumph Adler DF 470 Service Manual

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Service
Manual
Document Finisher
DF 470
First Edition
Date: 23-11-2010
5JSSM060

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Summary of Contents for Triumph Adler DF 470

  • Page 1 Service Manual Document Finisher DF 470 First Edition Date: 23-11-2010 5JSSM060...
  • Page 2 Service Manual Document Finisher DF 470 First Edition Date: 23-11-2010 5JSSM060...
  • Page 3 CAUTION RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT TYPE. DISPOSE OF USED BATTERIES ACCORDING TO THE INSTRUCTIONS. It may be illegal to dispose of this battery into the municipal waste stream. Check with your local solid waste officials for details in your area for proper disposal. ATTENTION IL Y A UN RISQUE D’EXPLOSION SI LA BATTERIE EST REMPLACEE PAR UN MODELE DE TYPE INCORRECT.

  • Page 4: Revision History

    Revision history Revision Date Replaced pages Remarks...
  • Page 5 This page is intentionally left blank.

  • Page 6: Safety Precautions

    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 7: Safety Warnings And Precautions

    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 8: Installation Precautions

    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 9 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 10 • 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 11 This page is intentionally left blank.
  • Page 12 CONTENTS 1-1 Specifications 1-1-1 Specifications ........................1-1-1 1-1-2 Parts names .......................... 1-1-2 1-1-3 Machine cross section ......................1-1-3 1-2 Installation 1-2-1 Installation environment......................1-2-1 1-2-2 Unpacking..........................1-2-2 (1) Unpacking......................... 1-2-2 (2) Removing the tapes and pads..................1-2-4 1-3 Maintenance Mode 1-3-1 Maintenance mode ........................
  • Page 13 2-4 Appendixes 2-4-1 Appendixes ..........................2-4-1 (1) Wiring diagram ......................... 2-4-1...

  • Page 14: Specifications

    1-1 Specifications 1-1-1 Specifications Item Specifications Type Hanger model Number of trays One tray Paper weight 52 to 256 g/m A3, B4, Ledger, Legal, Oficio II, 216 x 340mm, 8K: 250 sheets When not stapling A4, A4R, B5, B5R, Letter, LetterR, ExecutiveR, 16K: 500 sheets A3, B4, Ledger, Legal, 8K: 22 sets When stapling 2 or 10 A4R, LetterR: 40 sets...

  • Page 15: Parts Names

    1-1-2 Parts names Figure 1-1-1 1. Finisher tray 2. Finisher tray extension 3. DF top cover 4. Staple cover 5. Staple holder 6. Bridge unit cover 1-1-2...

  • Page 16: Machine Cross Section

    1-1-3 Machine cross section Paper path Figure 1-1-2 1. Bridge unit section 2. Finisher processing section 3. Eject tray section 4. Power source unit section 1-1-3...

  • Page 17: Installation Environment

    1-2 Installation 1-2-1 Installation environment Installation location (Be based on the machine establishment place.) Avoid direct sunlight or bright lighting. Ensure that the photoconductor will not be exposed to direct sunlight or other strong light when removing paper jams. Avoid locations subject to high temperature and high humidity or low temperature and low humidity; an abrupt change in the environmental temperature;...
  • Page 18 1-2-2 Unpacking (1) Unpacking Finisher Figure 1-2-1 1. Finisher 5. Bottom left pad 9. Upper right pad 2. Outer case 6. Bottom right pad 10. Finisher tray 3. Plastic sheet 7. Spacer 11. Installation guide 4. Plastic sheet 8. Upper left pad 12.
  • Page 19 Bridge unit Figure 1-2-2 1. Power source unit 5. Lower right guide 9. Top pad 2. Outer case 6. Top spacer 10. Pins 3. Main pad 7. Bridge unit 4. Bottom spacer 8. Bridge case See the Installation Guide for installation. 1-2-3...
  • Page 20 (2) Removing the tapes and pads 1. Remove tape from the finisher try. Tape Figure 1-2-3 2. Remove six tapes from the document Tape finisher. Tape Tape Tape Tape Tape Figure 1-2-4 1-2-4...
  • Page 21 3. Open the staple cover. Staple cover Figure 1-2-5 4. Remove tape and pad. Tape Figure 1-2-6 1-2-5...
  • Page 22 5. Remove three tapes from bridge unit. Tape Tape Tape Figure 1-2-7 6. Remove two tapes from power source unit. Tape Tape Figure 1-2-8 1-2-6...

  • Page 23: Maintenance Mode

    1-3 Maintenance Mode 1-3-1 Maintenance mode The machine is equipped with a maintenance function which can be used to maintain and service the machine. (1) Executing a maintenance item Start Enter “10871087” using Maintenance mode is entered. the numeric keys. Enter the maintenance item number using the cursor left/right keys The maintenance item is selected.

  • Page 24: Contents Of The Maintenance Mode Items

    (2) Contents of the maintenance mode items Item No. Description U019 Displaying the ROM version Description Displays the part number of the ROM fitted to each PWB. Purpose To check the part number or to decide, if the newest version of ROM is installed. Method 1.
  • Page 25 Item No. Description U905 Checking counts by optional devices Description Displays the counts of document processor or document finisher. Purpose To check the use of document processor or document finisher. Method 1. Press the start key. 2. Select the device to be checked. The count of the selected device is displayed. Display Description Counts of document processor...
  • Page 26 This page is intentionally left blank. 1-3-4...

  • Page 27: Paper Misfeed Indication

    1-4 Troubleshooting 1-4-1 Paper misfeed detection (1) Paper misfeed indication When a paper misfeed occurs, the machine immediately stops printing and displays the paper misfeed mes- sage on the operation panel. To remove paper misfed in the machine, open the DF top cover or bridge cover. (2) Paper misfeed detection condition BRCS1 BRCS2...
  • Page 28 Code Contents Conditions 4901 Bridge conveying sensor 1 The bridge conveying sensor 1 (BRCS1) does not turn on dur- non arrival jam ing paper feed from cassette 1. 4902 The bridge conveying sensor 1 (BRCS1) does not turn on dur- ing paper feed from cassette 2.
  • Page 29 Code Contents Conditions 6103 DF paper conveying sensor The paper conveying sensor (PCS) does not turned on even if non arrival jam a specified time has elapsed after the machine eject signal was received. 6113 DF paper conveying sensor The paper conveying sensor (PCS) does not turn off within stay jam specified time of its turning on.

  • Page 30: Self-Diagnostic Function

    1-4-2 Self-diagnostic function (1) Self-diagnostic function This machine is equipped with self-diagnostic function. When a problem is detected, the machine stops print- ing and display an error message on the operation panel. An error message consists of a message prompting a contact to service personnel and a four-digit error code indicating the type of the error.
  • Page 31 Check procedures/ Code Contents Causes corrective measures 8140 Tray elevation motor prob- Defective connec- Reinsert the connector. Also check for conti- lem (document finisher) tor cable or poor nuity within the connector cable. If none, The tray low limit sensor or contact in the con- replace the cable.
  • Page 32 Check procedures/ Code Contents Causes corrective measures 8320 Adjustment motor 2 prob- Defective connec- Reinsert the connector. Also check for conti- lem (document finisher) tor cable or poor nuity within the connector cable. If none, The adjustment sensor 2 does contact in the con- replace the cable.
  • Page 33 Check procedures/ Code Contents Causes corrective measures 8360 Slide motor problem (docu- Defective connec- Reinsert the connector. Also check for conti- ment finisher) tor cable or poor nuity within the connector cable. If none, The slide sensor does not turn contact in the con- replace the cable.
  • Page 34 Check procedures/ Code Contents Causes corrective measures 8900 Backup memory data prob- Defective connec- Reinsert the connector. Also check for conti- lem (document finisher) tor cable or poor nuity within the connector cable. If none, Read and write data does not contact in the con- replace the cable.

  • Page 35: Electric Problems

    1-4-3 Electric problems If the part causing the problem was not supplied, use the unit including the part for replacement. Troubleshooting to each failure must be in the order of the numbered symptoms. Problem Causes Check procedures/corrective measures 1. Defective connector Reinsert the connector.
  • Page 36 Problem Causes Check procedures/corrective measures 1. Defective connector Reinsert the connector. Also check for continuity within the Slide motor does cable or poor con- connector cable. If none, replace the cable. not operate. tact in the connector. Slide motor and DF main PWB (CN14) 2.
  • Page 37 Problem Causes Check procedures/corrective measures (11) 1. A piece of paper torn Check visually and remove it, if any. Paper jams when from paper is caught the main power around paper con- switch is turned on. veying sensor, eject paper sensor or bridge conveying sensor 1,2,3.

  • Page 38: Mechanical Problems

    1-4-4 Mechanical problems If the part causing the problem was not supplied, use the unit including the part for replacement. Problem Causes/check procedures Corrective measures Paper outside specifications is used. Use only paper conforming to the speci- No paper conveying. fications.

  • Page 39: Precautions For Assembly And Disassembly

    1-5 Assembly and disassembly 1-5-1 Precautions for assembly and disassembly (1) Precautions Before starting disassembly, 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. When handling PWBs (printed wiring boards), do not touch parts with bare hands.

  • Page 40: Outer Covers

    1-5-2 Outer covers (1) Detaching and refitting the front cover and rear cover Procedure 1. Remove two screws and then remove the front cover. Front cover Screw Screw Figure 1-5-1 2. Remove two screws and then remove the rear cover. Rear cover Screw Screw...
  • Page 41 (2) Gear phase adjustment for vertical driving of bundle discharge belt When fitting the gear for vertical driving of bundle discharge belt, adjust the phase so that the ribs are aligned. Adjust the phase so that the ribs are aligned. Figure 1-5-3 1-5-3...
  • Page 42 This page is intentionally left blank. 1-5-4...

  • Page 43: Upgrading The Firmware

    1-6 Requirements on PWB Replacement 1-6-1 Upgrading the firmware Follow the procedure to upgrade the firmware below. * Main PWB (CTRL) * Engine PWB (ENGN) * DP main PWB (DP) * FAX PWB (FAX) * PF main PWB (PF) * Language data (OPT) * DF main PWB (DF) * Dictionary data (DIC) * Bridge PWB (AK)
  • Page 44 2-1 Mechanical Construction 2-1-1 Bridge unit section The bridge unit section consists of the parts shown in figure below and discharges paper conveyed from the machine to the processing section. Figure 2-1-1 Bridge unit section 1. Paper conveying roller 2. Paper conveying pulley 3.
  • Page 45 BRPWB JAM_SENS3 YN2-3 JAM_SENS2 YN2-6 JAM_SENS1 YN2-9 SMOTA,A_B,B_ YC3-1,2,3,4 BRCS1 BRCS2 BRCS3 Figure 2-1-2 Bridge unit section block diagram 2-1-2...
  • Page 46 2-1-2 Prosessing section The processing section consists of the parts shown in figure below and discharges paper conveyed from the bridge section to the eject tray. Also this section performs processing in the bundle discharge mode and the staple mode. Figure 2-1-3 Processing section 1.
  • Page 47 PINS CN9-3 CN10-3 FMOT_*B,B,A,*A CN19-1,3,4,6 RUDS CN11-3 TMOT_*B,B,A,*A CN19-7,9,10,12 ROMOT_*B,B,A,*A CN20-1,3,4,6 EMPS CN7-3 P_SOL CN16-2 PDSOL ADS1,2 BLSOL FJ_HPS,RJ_HPS CN7-6,9 ADM1,2 FJMOT_*A,A,B,*B RJMOT_*A,A,B,*B CN18-1 - 8 STPM+,STPM- CN12-1,2,3,4 CN8-3 SLD_HP CN22-3 SLD_*A,A,B,*B CN14-1,2,3,4 BR_SOL CN21-2 FMPWB Figure 2-1-4 Processing section block diagram 2-1-4...
  • Page 48 (1) Bundle discharge operation Bundle discharge unit 1. Paper is fed to the processing section by rotation of the paper conveying roller and the bundle discharge belt. When the paper is conveyed into the process- ing section, the roller motor is driven to raise the bundle discharge unit.
  • Page 49 2-1-3 Eject tray section The eject tray section consists of the parts shown in figure below and stocks paper discharged from the pro- cessing section. The upper limit position and the lower limit position of the eject tray are detected with the tray upper limit sen- sor (TULS) and the tray lower limit sensor (TLLS).
  • Page 50 FMPWB RHDS1 CN6-3 RHDS2 CN6-6 PSS1 T_UL_SEN PSS2 CN5-4 TULS TM_+,TM_- CN15-1,2 T_LL_SEN PSSOL CN5-1 TLLS S_SOL CN17-2 Figure 2-1-7 Eject tray section block diagram 2-1-7...

  • Page 51: Electrical Parts Layout

    2-2 Electrical Parts Layout 2-2-1 Electrical parts layout (1) PWBs Machine front Machine inside Machine rear Figure 2-2-1 PWBs 1. DF main PWB (DFMPWB)....Controls electrical components. 2. DF Relay PWB (DFRPWB)....Consists of wiring relay circuit between engine PWB, DF main PWB, bridge PWB and DF power source PWB.

  • Page 52: Switches And Sensors

    (2) Switches and sensors Machine front Machine inside Machine rear Figure 2-2-2 Switches and sensors 1. Paper conveying sensor (PCS)..... Detects a paper misfeed in the processing section. 2. Adjustment sensor 1 (ADS1) ....Detects the front adjustment plate in the home position. 3.
  • Page 53 (3) Motors Machine front Machine inside Machine rear Figure 2-2-3 Motors 1. Paper conveying motor (PCM)....Drives the paper conveying roller. 2. Bundle discharge motor (BDM)..... Drives the eject roller. 3. Adjustment motor 1 (ADM1) ....Drives the front adjustment plate. 4.
  • Page 54 (4) Solenoids Machine front Machine inside Machine rear Figure 2-2-4 Solenoids 1. Belt solenoid (BLSOL) ......Operates the bundle discharge belt. 2. Paddle solenoid (PDSOL)..... Operates the paddle. 3. Paper surface solenoid (PSSOL)..Operates the push paper lever. 2-2-4...

  • Page 55: Bridge Section

    (5) Bridge section Machine rear Machine front Machine inside Figure 2-2-5 Bridge section 1. Bridge PWB (BRPWB)......Controls the paper conveying section. 2. Bridge conveying sensor1 (BRCS1) ..Detects a paper misfeed in the bridge section. 3. Bridge conveying sensor2 (BRCS2) ..Detects a paper misfeed in the bridge section 4.
  • Page 56 This page is intentionally left blank. 2-2-6...
  • Page 57 2-3 Operation of the PWBs 2-3-1 DF main PWB CN10 CN19 CN18 CN21 CN16 CN17 IC14 IC13 IC17 IC11 IC22 IC12 IC19 IC18 CN13 CN22 CN11 CN12 Figure 2-3-1 DF main PWB silk-screen diagram 2-3-1...
  • Page 58 Connector Signal Voltage Description DF_CLK 0/5 V DC (pulse) Clock signal DF_SI 0/5 V DC (pulse) Connected to Serial communication data signal output DF Relay DF_SO 0/5 V DC (pulse) Serial communication data signal input DF_SEL 0/5 V DC Select signal from the machine DF_RDY 0/5 V DC Ready signal to the machine...
  • Page 59 Connector Signal Voltage Description 5 V DC 5 V DC power output to SPS SGND Ground Connected to the staple 0/5 V DC SPS: On/Off position sen- Not used Not used 5 V DC 5 V DC power output to PCS SGND Ground Connected to...
  • Page 60 Connector Signal Voltage Description CN15 TM_+ 0/24 V DC (pulse) TEM drive control signal TM_- 0/24 V DC (pulse) TEM drive control signal Connected to the tray eleva- Not used tion motor CN16 +24V 24 V DC 24 V DC power output to PDSOL P_SOL 0/24 V DC PDSOL: On/Off...
  • Page 61 Connector Signal Voltage Description CN20 ROMOT_*B 0/24 V DC (pulse) RLM drive control signal +24V 24 V DC 24 V DC power output to RLM Connected to the roller ROMOT_B 0/24 V DC (pulse) RLM drive control signal motor ROMOT_A 0/24 V DC (pulse) RLM drive control signal +24V...
  • Page 62 2-3-2 Bridge PWB Figure 2-3-2 Bridge PWB silk-screen diagram 2-3-6...
  • Page 63 Connector Signal Voltage Description 3.3V2 3.3 V DC 3.3 V DC power output to BRCS3 Ground Connected to the bridge JAM_SENCE3 0/3.3 V DC BRCS3: On/Off conveying 3.3V2 3.3 V DC 3.3 V DC power output to BRCS2 sensor 1/2/3 Ground JAM_SENCE2 0/3.3 V DC...
  • Page 64 This page is intentionally left blank. 2-3-8...
  • Page 65 2-4 Appendixes 2-4-1 Appendixes (1) Wiring diagram FMOT _ *B +24V FMOT _ *B FMOT _ B +24V FMOT _ A FMOT _ B Power source unit +24V FMOT _ A FMOT _ *A +24V FMOT _ *A DFRPWB CN19 TMOT _ *B +24V DF _ CLK...
  • Page 66 Power source unit DFRPWB DFMPWB DF_CLK DF_CLK DF_SI DF_SI DF_SO DF_SO DF_SEL DF_SEL DF_RDY DF_RDY DF_SET DF_SET 24V_DF 24V2 24V_DF 24V2 24V_DF 24V2 Bridge unit BRPWB 3.3V2 Vout JAM_SENS1 TMTxD BRCS1 FAN_CONT TMRxD 3.3V 3.3V2 N.C. Machine Vout JAM_SENS2 BRCS2 3.3V 3.3V2 3.3V2...

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