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Kyocera Mita DF-75 Service Manual

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DF-75
SERVICE
MANUAL
Published in Aug.'01
5FG70760

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Summary of Contents for Kyocera Mita DF-75

  • Page 1 DF-75 SERVICE MANUAL Published in Aug.’01 5FG70760...
  • Page 2 CAUTION DANGER OF EXPLOSION IF BATTERY IS INCORRECTLY REPLACED. REPLACE ONLY WITH THE SAME OR EQUIVALENT TYPE RECOMMENDED BY THE MANUFACTURER. 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 MÊME TYPE OU D’UN TYPE REC- OMMANDÉ...
  • Page 3 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 4 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 5 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 6 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 7 • Do not pull on the AC power cord or connector wires on high-voltage components when removing them; always hold the plug itself....................... • Do not route the power cable where it may be stood on or trapped. If necessary, protect it with a cable cover or other appropriate item.

  • Page 8: Table Of Contents

    CONTENTS Contents CHAPTER 1 GENERAL DESCRIPTION 1 Features ..........1-1 3.1 Cross Section ......1-8 2 Specifications ........1-2 3.1.1 Finisher Unit ......1-8 2.1 Specifications ......1-2 3.1.2 Saddle Unit ......1-9 2.1.1 Finisher/Saddle Assembly ..1-2 3.1.3 Puncher Unit (option) ..1-10 2.1.2 Puncher unit (option) ...
  • Page 9 CONTENTS 6.2 Punching Operation ....2-50 7.1.4 Folding Position Sensor 6.2.1 Outline ....... 2-50 Stationary Jam (J84) ..2-62 6.2.2 Punching Operation ... 2-52 7.1.5 Power-On Jam (J87) ..2-62 6.2.3 Horizontal Registration Opera- 7.1.6 Door Open Jam (paper present) tion ........
  • Page 10 CONTENTS CHAPTER 4 MAINTENANCE AND INSPECTION 1 Periodically Replaced Parts ....4-1 2 Consumables and Durables ....4-2 1.1 Finisher/Saddle Unit ....4-1 2.1 Saddle/Finisher Unit ....4-2 1.2 Puncher Unit (option) ....4-1 3 Scheduled Maintenance ....... 4-2 CHAPTER 5 TROUBLESHOOTING 1 Standards and Adjustments ....
  • Page 11 CONTENTS 4.2.2 C8460, Puncher Back-UP 4.2.7 C8420, Horizontal Registration Memory Fault Motor Fault (detail code: 20) ....5-25 (detail code: 01/02) ..... 5-27 4.2.3 C8480, Puncher Unit Power 5 Self Diagnosis ........5-28 Supply Fault (detail code:20) 5.1 Outline ........5-28 ...........

  • Page 12: Chapter 1 General Description

    CHAPTER 1 GENERAL DESCRIPTION...

  • Page 13: Features

    CHAPTER 1 GENERAL DESCRIPTION 1 Features a. Through-type stapler Adoption of a through-type stapler allows a stapler to carry out saddle stitching. b. Three different auto stapling positions Three different stapling positions (front 1-point stapling, rear 1-point stapling, and middle 2-point stapling) are supported.

  • Page 14: Specifications

    CHAPTER 1 GENERAL DESCRIPTION 2 Specifications 2.1 Specifications 2.1.1 Finisher/Saddle Assembly Item Specifications Remarks Stacking 2 locations (1) Delivery Tray (descending type; 1 tray) Face-down (2) Bind Tray (fixed type) Feed reference Center reference Stack paper size A3, A4, A4R, A5, A5R, B4, B5, B5R, 297mm Large-size: A3, B4, 432mm (11”...
  • Page 15 CHAPTER 1 GENERAL DESCRIPTION Item Specifications Remarks Display Size 665 (W) 615 (D) 555 (H) mm / (excl. installing kit) 26.18(W) 24.21(D) 21.85(H) in Weight 27 kg / 59.40 lb (approx.) Power supply 24 VDC from host machine Maximum power con- At standby: 13 W sumption In operation: 84 W (staple sort)
  • Page 16 CHAPTER 1 GENERAL DESCRIPTION Staple Position Rear 1-point stapling Front 1-point stapling 5±2 mm / 0.2±0.08 in 5±2 mm / 0.2±0.08 in Middle 2-point stapling A3 or A4 B4 or B5 82±4 mm / 3.23±0.16 in 39±4 mm / 1.54±0.16 in 62±4 mm / 2.44±0.16 in 202±4 mm / 7.95±0.16 in 159±4 mm / 6.26±0.16 in...
  • Page 17 CHAPTER 1 GENERAL DESCRIPTION Stacked Paper Alignment Delivery direction 20 mm / 0.79 in max. F01-201-02...

  • Page 18: Puncher Unit (Option)

    CHAPTER 1 GENERAL DESCRIPTION 2.1.2 Puncher unit (option) Item Specifications Remarks Punching method Reciprocating method (sequential processing method) Paper size 2-hole (Puncher Unit-J1): A3, A4, A4R, B4, B5, B5R 2-/3-hole (Puncher Unit-K1): 2-hole/LGL, LTRR 3-hole/279 432 mm (11” 17”), LTR 4-hole (Puncher Unit-G1/-H1): A3, A4 Paper weight...
  • Page 19 CHAPTER 1 GENERAL DESCRIPTION Hole position [1] 2-Hole (Puncher Unit-J1) A3/A4 108.5±3 mm / 4.27±0.12 in B5/B4 88.5±3 mm / 3.48±0.12 in 65±3 mm / 2.56±0.12 in 80±1 mm / 3.15±0.04 in 51±3 mm / 2.01±0.12 in 12±3 mm / 0.47±0.12 in [2] 2-/3-Hole (Puncher Unit-K1) LGL/LTRR...

  • Page 20: Names Of Parts

    CHAPTER 1 GENERAL DESCRIPTION 3 Names of Parts 3.1 Cross Section 3.1.1 Finisher Unit [10] [11] [1] Delivery tray [6] Feed roller [2] Aligning plate (front, rear) [7] Puncher unit (option) [3] Paddle [8] Delivery belt [4] Delivery roller [9] Stack delivery roller [5] Processing tray stopper [10] Stapler [11] Saddle unit...
  • Page 21 CHAPTER 1 GENERAL DESCRIPTION 3.1.2 Saddle Unit [1] Bind stopper [4] Bind delivery roller [2] Bind tray [5] Paper fold roller [3] Stack feed roller [6] Paper pushing plate F01-301-02...
  • Page 22 CHAPTER 1 GENERAL DESCRIPTION 3.1.3 Puncher Unit (option) [1] Die [3] Hole puncher (Punch blade) [2] Cam [4] Punch waste case F01-301-03 1-10...

  • Page 23: Routine Maintenance By The User

    CHAPTER 1 GENERAL DESCRIPTION 4 Routine Maintenance by the User As of February, 2001 Item Timing Staple cartridge (replacement) When prompted (indicator on host machine control panel) Punch waste removal (optional) When prompted (indicator on host machine control panel) T01-400-01 1-11...

  • Page 24: Chapter 2 Outline Of Operation

    CHAPTER 2 OUTLINE OF OPERATION...

  • Page 25: Basic Operations

    CHAPTER 2 OUTLINE OF OPERATION 1 Basic Operations 1.1 Specifications The finisher serves to deliver sheets coming from its host machine. The mode of delivery may be non-sort stack, job offset*, or staple delivery. The saddle unit built into the finisher is used to fold a stack of sheets coming from the fin- isher unit in half for delivery.

  • Page 26: Outline Of The Electrical Circuitry

    CHAPTER 2 OUTLINE OF OPERATION 1.2 Outline of the Electrical Circuitry The sequence of finisher operations is controlled by the finisher controller PCB. The fin- isher controller PCB is a 16-bit microprocessor (CPU), and is also used for combination with the host machine (serial).

  • Page 27: Inputs To And Outputs From The Finisher Controller Pcb

    CHAPTER 2 OUTLINE OF OPERATION 1.3 Inputs to and Outputs from the Finisher Controller PCB 1.3.1 Inputs to the Finisher Controller PCB (1/2) Finisher controller PCB PI1 CN44-3 CN43-1 CN42-3 CN16-10 +5 V When the sensor ENT_S Inlet sensor detects paper, ‘1’ . CN51-1 CN9-1 Paddle home...

  • Page 28: Inputs To The Finisher Controller Pcb (2/2)

    CHAPTER 2 OUTLINE OF OPERATION 1.3.2 Inputs to the Finisher Controller PCB (2/2) Finisher controller PCB PI11 CN40-3 CN38-4 CN37-6 CN16-4 Folding home +5 V position sensor BIND_HP When at folding home position, ‘0’. PI12 CN41-3 Stack feed roller +5 V When the stack feed roller (upper) home BIND_ROL_HP...

  • Page 29: Outputs From The Finisher Con- Troller Pcb (1/2)

    CHAPTER 2 OUTLINE OF OPERATION 1.3.3 Outputs from the Finisher Controller PCB (1/2) Finisher controller PCB +24 V Binding clutch CN18-1 When the drive is transmitted, B_CLU ‘1’. +24 V Feed motor CN10-1 FEEDMTR_A Switches between ‘1’ and FEEDMTR_*A ‘0’ according to the FEEDMTR_B direction of motor rotation.

  • Page 30: Outputs From The Finisher Con- Troller Pcb (2/2)

    CHAPTER 2 OUTLINE OF OPERATION 1.3.4 Outputs from the Finisher Controller PCB (2/2) Finisher controller PCB Shift motor CN6-1 Switches between ‘+’ and SIFTMTR_1 ‘–’ according to the SIFTMTR_0 direction of motor rotation. Staple/fold motor CN6-3 Switches between ‘+’ and BINDMTR_1 ‘–’...

  • Page 31: Inputs To And Outputs From The Finisher Controller

    CHAPTER 2 OUTLINE OF OPERATION 1.3.5 Inputs to and Outputs from the Finisher Controller Stapler unit Finisher controller PCB Slide home position sensor +5 V PI18 When the stapler is at home CN72-5 CN72A-5 CN72A-5 CN11-3 SLID_HP position, ‘1’. Staple home position sensor +5 V PI19...

  • Page 32: Inputs To And Outputs From The Punch Controller Pcb (Option)

    CHAPTER 2 OUTLINE OF OPERATION 1.4 Inputs to and Outputs from the Punch Controller PCB (option) 1.4.1 Inputs to and Outputs from the Punch Controller PCB Punch controller PCB PI1P J2008-3 J1006-4 +5 V Punch home When the hole puncher is PUNCH position sensor at home position, ‘0’.

  • Page 33: Outputs From The Punch Con Troller Pcb

    CHAPTER 2 OUTLINE OF OPERATION 1.4.2 Outputs from the Punch Controller PCB Punch controller PCB LED PCB J1007-6 LED5 LED4 LED3 LED2 LED1 LEDON5 LEDON4 When ‘1’, LED goes ON. LEDON3 LEDON2 LEDON1 Punch motor J1002-1 Switches between ‘+’ and ‘–’ according to the direction of motor rotation.

  • Page 34: Outline

    CHAPTER 2 OUTLINE OF OPERATION 2 Feed/Drive System 2.1 Outline The machine performs the following in response to the commands coming from its host ma- chine on the sheets arriving from the host machine for delivery: simple stacking, job offset, and stapling or folding (in two).
  • Page 35 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 2-11...
  • Page 36 CHAPTER 2 OUTLINE OF OPERATION b. Job Offset The machine pulls the sheet once to the processing tray. It then moves the sheet to the front or the rear using the aligning plate. When it has deposited a specific number of sheets, it deliv- ers them in the form of a aligning plane.
  • Page 37 CHAPTER 2 OUTLINE OF OPERATION c. Stapling 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 stapled stack to the delivery tray. F02-201-04 2-13...
  • Page 38 CHAPTER 2 OUTLINE OF OPERATION 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 it to the bind tray.

  • Page 39: Feed/Delivery

    CHAPTER 2 OUTLINE OF OPERATION 2.2 Feed/Delivery 2.2.1 Outline The machine forwards the sheets coming from its host machine to the delivery tray, process- ing tray, or saddle unit according to the type of delivery used. The sheets forwarded to the pro- cessing tray or the saddle unit are offset, stapled, or folded.
  • Page 40 CHAPTER 2 OUTLINE OF OPERATION Finisher controller PCB (1/2) PI14 Finisher controller PCB (2/2) F02-202-01 2-16...
  • Page 41 CHAPTER 2 OUTLINE OF OPERATION Finisher controller PCB PI10 F02-202-02 Connector on finisher Notation Name Description controller PCB Inlet sensor Photointerrupter CN16 PI10 Fold position sensor Photointerrupter CN16 T02-202-02 2-17...

  • Page 42: Job Offset

    CHAPTER 2 OUTLINE OF OPERATION 2.3 Job Offset 2.3.1 Outline "Job offset" refers to the operation by which the machine delivers a set of sheets with them pulled forward or backward for sorting. Switching between the forward and backward directions is made using an aligning plate (front) and an aligning plate (rear).
  • Page 43 CHAPTER 2 OUTLINE OF OPERATION Aligning plate (rear) Aligning plate (rear) home position sensor (PI5) Light-shielding plate Alignment plate (front) motor (M4) Alignment plate (rear) motor (M5) Aligning plate (front) Light-shielding plate (Front) Paper Aligning plate (front) home position sensor (PI4) F02-203-01 2-19...
  • Page 44 CHAPTER 2 OUTLINE OF OPERATION 2.3.2 Processing Tray Paper Stacking Operation A sheet coming between 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. Paper Aligning plate Paddle...
  • Page 45 CHAPTER 2 OUTLINE OF OPERATION 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 sheet is pulled onto the processing tray. Aligning plate (rear) Sheet to be offset Tray...
  • Page 46 CHAPTER 2 OUTLINE OF OPERATION 2.3.4 Stack Delivery Operation Stack delivery takes place when 10 sheets of large-size paper or 30 sheets of small-size pa- per (Less than 182mm: 10 sheets) have been stacked on the processing tray with them offset in either direction.

  • Page 47: Outline

    CHAPTER 2 OUTLINE OF OPERATION 3. Stapling Operation 3.1 Outline Staple operation is performed to staple a specified sheets of paper using a stapler unit. The stapling position depends on the staple mode and paper size. When the machine starts immediately after power-on, the finisher controller PCB drives the slide motor (M8) to return the stapler unit to the home position.
  • Page 48 CHAPTER 2 OUTLINE OF OPERATION Stapler (Deliver direction) Paper stack Slide motor (M8) Light-shielding plate Slide home position sensor (PI18) F02-301-01 2-24...
  • Page 49 CHAPTER 2 OUTLINE OF OPERATION 3.2 Stapling Operation When stacking and alignment of paper on the processing tray are complete, the finisher con- troller PCB drives the paddle motor (M2) in the reverse direction and lowers the swing guide. When the swing guide descends, the paper stack is sandwiched between the upper and lower stack delivery rollers.
  • Page 50 CHAPTER 2 OUTLINE OF OPERATION Swing guide home position sensor (PI3) Paddle motor (M2) Light-shielding plate Staple safety switch (MS3,4) Swing guide Stack delivery roller (upper) Stack delivery roller (lower) F02-302-02 2-26...

  • Page 51: Delivery Operation After

    CHAPTER 2 OUTLINE OF OPERATION 3.3 Delivery Operation after Stapling When stapling is complete, the finisher controller PCB drives the deliver motor in the for- ward direction to feed the paper stack (sandwiched between the stack delivery rollers) in the delivery direction.
  • Page 52 CHAPTER 2 OUTLINE OF OPERATION Swing guide home position sensor (PI3) Paddle motor (M2) Light-shielding plate Staple safety switch (MS3,4) Swing guide Stack delivery roller (upper) Stack delivery roller (lower) F02-303-02 2-28...

  • Page 53: Stapler Unit

    CHAPTER 2 OUTLINE OF OPERATION 3.4 Stapler Unit The staple/fold motor (M7) is used to perform stapling operation. This motor rotates the cam one turn for stapling. The home position of this cam is detected by the staple home posi- tion sensor (PI19).
  • Page 54 CHAPTER 2 OUTLINE OF OPERATION F02-304-01 Finisher controller PCB F02-304-02 2-30...

  • Page 55: Stapler Movement Controller

    CHAPTER 2 OUTLINE OF OPERATION 3.4.1 Stapler Movement Controller The stapler unit is moved by the slide motor (M8). Its home position is detected by the slide home position sensor (PI18). The stapler waits at the back irrespective of the staple mode and paper size.
  • Page 56 CHAPTER 2 OUTLINE OF OPERATION b. Rear 1-point stapling The stapler waits at the back. The stapling position is the same as the standby position Standby position Stabling position Stapler Feed direction Stopper .F02-304-04 c. Middle 2-point stapling The stapler waits at the back. The stapler moves to and returns from the stapling position for each stapling operation.
  • Page 57 CHAPTER 2 OUTLINE OF OPERATION d. Middle 2-point stapling (bind mode) The stapler 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 at the front stapling position.
  • Page 58 CHAPTER 2 OUTLINE OF OPERATION Stapling Operation Sequence Rear 1-point Stapling of 2 Sheets(Reverse,Small-size) Start signal Host machine delivery signal Staple Stack delivery Inlet sensor (PI1) Processing tray sensor (PI6) Feed motor (M1) Delivery motor (M3) Delivery belt home 10msec position sensor (PI7) 360msec 360msec...

  • Page 59: Delivery Tray Operation

    CHAPTER 2 OUTLINE OF OPERATION 4 Delivery Tray Operation 4.1 Outline The machine has a delivery tray in the finisher unit and a bind tray in the saddle unit. The bind tray in the saddle unit is of the fixed type and all the folded paper stacks are deliv- ered to this tray.
  • Page 60 CHAPTER 2 OUTLINE OF OPERATION Shift upper limit sensor (PI15) Shift lower limit sensor Tray paper sensor (PI8) (PI16) Paper surface sensor (PI9) Edge Shift motor clock sensor (PI17) Delivery tray Full stack sensor (PI24) Shift motor (M6) F02-401-01 2-36...

  • Page 61: Saddle Unit

    CHAPTER 2 OUTLINE OF OPERATION 5 Saddle Unit 5.1 Basic Operations 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 controller PCB is controlled by the commands from the host machine.

  • Page 62: Feed/Drive System

    CHAPTER 2 OUTLINE OF OPERATION 5.2 Feed/Drive System 5.2.1 Outline This machine stitches the paper stack coming 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 2) Stitching...
  • Page 63 CHAPTER 2 OUTLINE OF OPERATION a. Paper feed-in After being 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. Stack delivery roller (upper) Paper stack Stack delivery roller...
  • Page 64 CHAPTER 2 OUTLINE OF OPERATION b. Stitching When the center of the paper 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 performing the stitching operation.
  • Page 65 CHAPTER 2 OUTLINE OF OPERATION c. Stack feed The stack feed rollers feed 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. Stack feed roller (upper) Paper pushing plate Stack feed roller (lower)
  • Page 66 CHAPTER 2 OUTLINE OF OPERATION d. Folding/delivery 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 tray.

  • Page 67: Outline

    CHAPTER 2 OUTLINE OF OPERATION 5.3 Paper Feed System 5.3.1 Outline The paper feed system feeds a stack of sheets (coming from the finisher) to the position where the center of the paper stack (stitching position) is aligned to the stapler's staple, allow- ing the next step (stitching and folding) to be performed.

  • Page 68: Outline

    CHAPTER 2 OUTLINE OF OPERATION 5.4 Stack Feed System 5.4.1 Outline The stack feed system feeds the stitched paper stack to the folding position. When stitching is complete, the feed motor (M1) rotates, causing the stack feed roller (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 to the folding position.

  • Page 69: Outline

    CHAPTER 2 OUTLINE OF OPERATION 5.5 Fold/Delivery System 5.5.1 Outline The paper fold mechanism consists of a guide plate, paper fold rollers, and a paper pushing plate. The guide plate, paper fold rollers, and paper pushing plate are driven by the staple/fold mo- tor (M7).

  • Page 70: Paper Folding

    CHAPTER 2 OUTLINE OF OPERATION 5.5.2 Paper Folding Paper is folded using paper fold rollers and a paper pushing plate. Almost concurrently with the start of roller rotation, the paper pushing plate starts operating to push the paper stack into the gap between the paper fold rollers. When the paper stack is fed about 10 mm with the rotation of the paper fold rollers, the paper pushing plate returns to the home position.
  • Page 71 CHAPTER 2 OUTLINE OF OPERATION Folding home position sensor (PI11) Paper pushing plate Paper fold roller (upper) Staple/fold motor Paper fold roller (lower) Paper stack F02-505-02 [Paper folding start position] Paper stack Inlet Paper push plate Outlet Folds/feeds a paper stack. Feeds a paper stack.
  • Page 72 CHAPTER 2 OUTLINE OF OPERATION Staply Fold, Delivery Feed motor (M1) Delivery motor (M3) Paddle motor (M2) Paddle home position sensor (PI2) Swing guide home position sensor (PI3) Stapler safety switch (MS3) Slide motor (M8) 13571msec Staple/fold motor (M7) Staple home position 50msec sensor (PI19) Folding position sensor...

  • Page 73: Puncher Unit (Option)

    CHAPTER 2 OUTLINE OF OPERATION 6 Puncher Unit (option) 6.1 Basic Operations 6.1.1 Outline The puncher unit is an option, and is designed for installation to the pickup assembly of the finisher. The puncher unit is not equipped with a paper feeding mechanism, and the sheets from the host machine move through the puncher unit and then the feed system of the finisher.

  • Page 74: Punching Operation

    CHAPTER 2 OUTLINE OF OPERATION 6.2 Punching Operation 6.2.1 Outline The puncher unit is located in the pickup assembly of the finisher, and is used to punch holes in sheets that have been sent from the host machine and stopped inside it. When the trail- ing edge of a sheet reaches the puncher unit, the inlet roller of the finisher assembly stops the sheet to punch a hole along the trailing edge of the sheet.
  • Page 75 CHAPTER 2 OUTLINE OF OPERATION Punch controller PCB (1/2) LED1 PT131 LED121 Punch controller PCB (2/2) F02-602-01 2-51...

  • Page 76: Punching Operation

    CHAPTER 2 OUTLINE OF OPERATION 6.2.2 Punching Operation The hole puncher is driven by the punch motor (M1P). The home position for the hole puncher is detected by the punch home position sensor (PI1P). The punch unit comes in four types, selected 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).
  • Page 77 CHAPTER 2 OUTLINE OF OPERATION a. 2-Hole, 4-Hole Type The home position is identified when the punch home position is ON. The punching opera- tion for the first sheet ends when the punch shaft has rotated 180° and the punch home posi- tion sensor goes ON;...
  • Page 78 CHAPTER 2 OUTLINE OF OPERATION b. 2- /3-Hole Type The home position is identified when the punch home position sensor is ON. To make two holes, the punching operation for the first sheet ends when the punch shaft rotates 180° (half circumference) and the punch home position sensor goes ON.
  • Page 79 CHAPTER 2 OUTLINE OF OPERATION While two holes are being made, the 3-hole puncher makes a single round trip in escape di- rection. (punch shaft at rest/ (punch shaft CW rotation by 90˚/ (punch shaft CW rotation by 180˚/ home position) punch at upper limit) punch back to initial position) F02-602-05...
  • Page 80 CHAPTER 2 OUTLINE OF OPERATION While two hole are being made, the 3-hole puncher makes a single round trip in escape di- rection (moving up the hole puncher). (punch shaft at rest/ (punch shaft CCW rotation by (punch CCW rotation by 180˚/ home position) 90˚/punch at upper limit) punch back at initial position)

  • Page 81: Horizontal Registration Operation

    CHAPTER 2 OUTLINE OF OPERATION 6.2.3 Horizontal Registration Operation The horizontal registration drive for the punch slide unit is provided by the horizontal regis- tration motor (M2P). The home position of the punch slide unit is detected by the horizontal registration home position sensor (PI2P).
  • Page 82 CHAPTER 2 OUTLINE OF OPERATION 2) When the horizontal registration sensor (LED1 through 4, PT1 through) suited to the pa- per size signal from the host machine detects the rear edge of the sheet, the horizontal registration motor (M2P) causes a farther move to a specific position, and stops the punch slide unit.
  • Page 83 CHAPTER 2 OUTLINE OF OPERATION 4) When the punching operation ends, the feed motor (M1) of the fisher unit is driven and, at the same time, the horizontal registration motor (M2P) is rotated in reverse to return the punch slide 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 .

  • Page 84: Detecting Jams

    CHAPTER 2 OUTLINE OF OPERATION 7 Detecting Jams 7.1 Outline The microprocessor (CPU) on the finisher controller PCB is programmed to check for jams in the finisher/saddle/puncher (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.

  • Page 85: Inlet Sensor Delay Jam (J80)

    CHAPTER 2 OUTLINE OF OPERATION 7.1.1 Inlet Sensor Delay Jam (J80) The inlet sensor does not detect paper approximately 1.5 sec after the host machine gener- ates the delivery signal. Host machine delivery signal Host machine delivery signal approx. 1.5sec. approx.

  • Page 86: Folding Position Sensor Stationary Jam (J84)

    CHAPTER 2 OUTLINE OF OPERATION 7.1.4 Folding Position Sensor Stationary Jam (J84) In bind mode, paper does not leave the holding position sensor approximately 10.5 sec after the staple/fold motor is driven. approx. 10.5sec. approx. 10.5sec. Jam check Jam check Normal Folding position Folding position...

  • Page 87: Power Supply System

    CHAPTER 2 OUTLINE OF OPERATION 8 Power Supply System 8.1 Finisher/Saddle Assembly 8.1.1 Outline When the host machine is turned on, it supplies the finisher controller PCB with two chan- nels of 24 VDC; one is for the motors and clutches, and the 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.

  • Page 88: Protective Mechanisms

    CHAPTER 2 OUTLINE OF OPERATION 8.2 Puncher Unit (option) 8.2.1 Outline When the host machine is turned on, the puncher unit is supplied by the finisher controller PCB with 24-V and 5-V power. The 24-V power is used to drive the motors, while the 5-V power is used by sensors and the ICs on the punch controller PCB.

  • Page 89: Chapter 3 Mechanical Systems

    CHAPTER 3 MECHANICAL SYSTEMS...

  • Page 90: Finisher/Saddle Unit

    CHAPTER 3 MECHANICAL SYSTEMS 1 Finisher Saddle Unit 1.1 Externals and Controls [1] Tray (2) [2] Rear cover (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.

  • Page 91: Removing The Front Cover

    CHAPTER 3 MECHANICAL SYSTEMS 1.1.2 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 4) Remove the three screws [5], and detach the front cover [6].

  • Page 92: Removing The Rear Cover

    CHAPTER 3 MECHANICAL SYSTEMS 1.1.3 Removing the Rear Cover 1) Remove the two screws [1] on the pickup side, and remove the screw [2] on the delivery side; then, detach the rear cover [3]. F03-101-05 F03-101-06 1.1.4 Removing the Upper Cover 1) Open the upper cover [1], and turn the cover band retainer [2] to the left to re- move it.

  • Page 93: Removing The Processing Tray 1.3.1 Upper Cover

    CHAPTER 3 MECHANICAL SYSTEMS 3) Remove the screw [4], and detach the processing tray rear cover [5]; then, de- tach the upper cover [6]. 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 cover.

  • Page 94: Removing The Upper Right Cover Assembly

    CHAPTER 3 MECHANICAL SYSTEMS 5) While lifting the processing tray upper cover [3], disconnect the connector [4]; then, detach the processing tray upper cover [3]. 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.

  • Page 95: Removing The Saddle Guide

    CHAPTER 3 MECHANICAL SYSTEMS 1.1.7 Removing the Saddle Guide 1) Remove the delivery tray. (See 1.1.1.) 2) Remove the front cover. (See 1.1.2.) 3) Remove the rear cover. (See 1.1.3.) 4) Free the delivery tray support plate (front) [1] and the delivery tray support plate (rear) [2] to the outside from the rail grooves.

  • Page 96: Feeding System

    CHAPTER 3 MECHANICAL SYSTEMS 1.2 Feeding System 1.2.1 Removing the Stapler Unit 1) Open the front door [1]. 2) Slide out the stapler unit [3] while press- ing the stopper lever [2]. When removing the stapler unit from the finisher, be sure to grasp the upper portion(shaft) , If the stay in...

  • Page 97: Adjusting The Stapler Phase

    CHAPTER 3 MECHANICAL SYSTEMS 1.2.2 Adjusting the Stapler Phase When the gears or timing belt at the front of the stapler is replaced or removed for some reason, the staple shooting timing of the staple driver (lower unit of the stapler) does Gear not match the staple bending timing of the staple clincher (upper unit of the stapler).
  • Page 98 CHAPTER 3 MECHANICAL SYSTEMS 3) Remove the two E-rings [6] to remove the staple jam releasing gear [7], timing 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].
  • Page 99 CHAPTER 3 MECHANICAL SYSTEMS 7) Turn the gear [16] to align the round hole in the staple driver gear with the round hole [17] at the back. [16] [17] 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 the round hole to secure the gear.
  • Page 100 CHAPTER 3 MECHANICAL SYSTEMS 9) Turn the gear [19] to align the round hole in the staple clincher cam with the round [19] hole [20] at the back. [20] 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 the round hole to secure the gear.
  • Page 101 CHAPTER 3 MECHANICAL SYSTEMS 11) With the gears and cam fixed, install the timing belt [22] on gears [23] and [24]. F03-102-11 [23] [22] [24] 12) Mount the staple position check gear [26] [27] so that the blue mark [25] on the staple position check gear is aligned with the round hole [26] in the frame.

  • Page 102: Adjusting The Phase Of The Gear In The Saddle Unit

    CHAPTER 3 MECHANICAL SYSTEMS 13) Remove the pin securing the gear to the [28] cam. 14) Assemble the spring [28], spacer [29], [31] staple jam releasing gear [30], timing belt [31], and relay gear [32] and secure them with the E-ring [33]. [29] [32] [33]...

  • Page 103: Removing The Saddle Unit

    CHAPTER 3 MECHANICAL SYSTEMS 2) With the paper fold rollers and saddle cam positioned as shown in Figure F03- 102-14, mount gears as shown in figure F03-102-15. • Align the mark (either of two marks) on the saddle cam drive gear [3] with the mark on the relay gear [4] (on the half of the periphery where gears...
  • Page 104 CHAPTER 3 MECHANICAL SYSTEMS 4) Turn the fold jam releasing dial assembly [4] to move the paper retaining 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 unit [10] slightly to the...

  • Page 105: Removing The Processing Tray Assembly

    CHAPTER 3 MECHANICAL SYSTEMS 1.2.5 Removing the Processing Tray Assembly 1) Remove the processing tray 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 claw [5] at the front and the claw [6] at the rear of the...
  • Page 106 CHAPTER 3 MECHANICAL SYSTEMS 5) Disconnect the three connectors [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 harness [14] from the edge saddle [13].

  • Page 107: Removing The Paddle Assembly

    CHAPTER 3 MECHANICAL SYSTEMS 9) Remove the two screws [15], and slide the processing tray assembly [16] to the rear; then, lift it to detach. [16] [15] 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 CHAPTER 3 MECHANICAL SYSTEMS 3) Detach the timing belt [3], and remove the two screws [4]. F03-102-26 3-19...

  • Page 109: Removing The Staple/Fold Drive Unit

    CHAPTER 3 MECHANICAL SYSTEMS 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 to the front. F03-102-28 3-20...
  • Page 110 CHAPTER 3 MECHANICAL SYSTEMS 2) Remove the screw [3], and detach the interface retainer [4]. 3) Free the six harness retainers [5], and disconnect the connector [6]. 4) Free the harness [7] from the harness retainer [5]. 5) Free the harness [7] from the edge saddle [8];...
  • Page 111 CHAPTER 3 MECHANICAL SYSTEMS 9) Remove the screw [15], and free the [15] claw [17] of the harness guide from the long angle [16] of the base plate. [17] [16] F03-102-31 10) Disconnect the two connectors [18], and [18] free the harness [20] from the edge saddle [19].
  • Page 112 CHAPTER 3 MECHANICAL SYSTEMS 11) Remove the three screws [21]. [21] [21] [21] F03-102-33 12) Remove the screw [22], and detach the staple/fold drive unit [23]. [22] [23] F03-102-34 3-23...

  • Page 113: Removing The Feed Motor Unit

    CHAPTER 3 MECHANICAL SYSTEMS 1.2.8 Removing the Feed Motor Unit 1) Remove the rear cover. (See 1.1.3.) 2) Open the harness retainer [1], and dis- connect the two connectors [2]. 3) Remove the screw [3], and detach the harness guide [4]. 4) Remove the three screws [5], and detach the feed motor unit [6].
  • Page 114 CHAPTER 3 MECHANICAL SYSTEMS 6) Remove the two screws [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].

  • Page 115: Removing The Stack Delivery

    CHAPTER 3 MECHANICAL SYSTEMS 11) Remove the feed roller [12]. [12] F03-102-39 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 up the stack delivery roller assembly (upper) [3].
  • Page 116 CHAPTER 3 MECHANICAL SYSTEMS 4) Push up the stack delivery roller (upper) [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].

  • Page 117: Removing The Paddle

    CHAPTER 3 MECHANICAL SYSTEMS 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 assembly (upper) [3].
  • Page 118 CHAPTER 3 MECHANICAL SYSTEMS 4) Push up the safety guide [4] from below 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].

  • Page 119: Removing The Stack Delivery

    CHAPTER 3 MECHANICAL SYSTEMS 1.2.12 Removing the Stack delivery roller (lower)/Delivery Belt 1) Remove paddle assembly, and separate it from 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.
  • Page 120 CHAPTER 3 MECHANICAL SYSTEMS 5) Remove the screw [8]; then, while free- ing the claw [9], detach the paper guide (rear) [10]. [10] F03-102-52 6) Remove the two stop rings [11]; then, move the two bushings [12] to the in- side.

  • Page 121: Pcbs

    CHAPTER 3 MECHANICAL SYSTEMS 8) Remove the stack delivery roller (lower) [16] [15] and the two delivery belts [16]. [15] F03-102-55 Be sure to mount them so that the edges [17] of the claws of the delivery belts are flush. [17] F03-102-56 1.3 PCBs...

  • Page 122: Removing The Slide Home Position Pcb

    CHAPTER 3 MECHANICAL SYSTEMS 1.3.2 Removing the Slide Home Position PCB 1) Open the front door [1], and turn the tab [2] on the stapler slide in the direction of the arrow to slide the stapler to the frontmost point. 2) Remove the stapler unit.
  • Page 123 CHAPTER 3 MECHANICAL SYSTEMS 7) Disconnect the connector [8]. [10] 8) Remove the flexible cable retainer [9]. 9) Free the lock [10] of the connector in the [11] direction of the arrow; then, detach the flexible cable [11], and then detach the side home position PCB [12].

  • Page 124: Puncher Unit (Option)

    CHAPTER 3 MECHANICAL SYSTEMS 2. Puncher Unit (option) 2.1 Puncher Driving System 2.1.1 Removing the Punch Motor 1) Remove 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].

  • Page 125: Removing The Punch Unit

    CHAPTER 3 MECHANICAL SYSTEMS 2.1.3 Removing the Punch Unit 1) Remove the 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].
  • Page 126 CHAPTER 3 MECHANICAL SYSTEMS 7) Remove the screw [9] and washer [10]. 8) Disconnect the connector [11]. 9) Remove the two screws [12] to detach the base cover [13]. [10] [13] [11] [12] F03-201-06 10) Remove the four screws [14] to remove the upper transmission sensor unit [15] and lower transmission sensor [16].

  • Page 127: Pcbs

    CHAPTER 3 MECHANICAL SYSTEMS 11) Remove the punch unit [18] from the [17] horizontal registration motor assembly [18] [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 punch controller PCB [3].

  • Page 128: Removing The Photosensor Pcb

    CHAPTER 3 MECHANICAL SYSTEMS 2.2.2 Removing the 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] to remove the photosensor PCB [6].

  • Page 129: Removing The Led Pcb

    CHAPTER 3 MECHANICAL SYSTEMS 2.2.3 Removing the LED 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 [7] to detach the base cover [8].

  • Page 130: Removing The Waste-Full Photosensor Pcb

    CHAPTER 3 MECHANICAL SYSTEMS 7) Remove the screw [9]. [10] 8) Disconnect the connector [10] to remove the LED PCB [11]. [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 remove the PCB film [2].

  • Page 131: Removing The Waste Full Led Pcb

    CHAPTER 3 MECHANICAL SYSTEMS 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 LED PCB [3]. F03-202-09 3-42...

  • Page 132: Chapter 4 Maintenance And Inspection

    CHAPTER 4 MAINTENANCE AND INSPECTION...

  • Page 133: Periodically Replaced Parts

    CHAPTER 4 MAINTENANCE AND INSPECTION 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 require periodical replacement.

  • Page 134: Consumables And Durables

    CHAPTER 4 MAINTENANCE AND INSPECTION 2 Consumables and Durables Some components of the machine may require replacement once or more over the period of machine warranty because of deterioration or damage. Replace them as needed. 2.1 Saddle/Finisher Unit As of February, 2001 Part name Part No.

  • Page 135: Chapter 5 Troubleshooting

    CHAPTER 5 TROUBLESHOOTING...

  • Page 136: Standards And Adjustments

    CHAPTER 5 TROUBLESHOOTING 1 Standards and Adjustments 1.1 Electrical System (finisher/saddle unit) 1.1.1 Adjusting the Folding Position The folding position is adjusted by matching it with the stapling position. If you have replaced the finisher controller PCB, you must transfer the existing settings to the new PCB.
  • Page 137 CHAPTER 5 TROUBLESHOOTING 2) Adjust the folding position by pressing the PSW1 or PSW2 on the finisher controller PCB a required number of times. Pressing the switch once moves the folding position about 0.16 mm. • • • • • To move the folding position in the “-” direction, press the PSW1. •...

  • Page 138: Adjusting The Middle 2-Point Stapling Position

    CHAPTER 5 TROUBLESHOOTING 1.1.2 Adjusting the Middle 2-Point Stapling Position The stapling position is adjusted by matching it with the folding position. If you have replaced the finisher controller PCB, you must transfer the existing settings to the new PCB. Perform the following if the stapling position must be adjusted for some reason. Both the folding and stapling positions may deviate for some type of paper.

  • Page 139: Electrical System (Puncher Unit; Option)

    CHAPTER 5 TROUBLESHOOTING 1.2 Electrical System (puncher unit; option) 1.2.1 Adjusting the Punch Hole Position This mode requires operation in service mode. The range of hole displacement is between 3 and -3 in 1-mm increments. A higher setting will move the hole toward the leading edge of sheet.

  • Page 140: Registering The Number Of Punch Hole

    CHAPTER 5 TROUBLESHOOTING 1.2.3 Registering the Number of Punch Hole Perform the following to register the type of puncher unit (number of holes) used to the IC on the punch controller PCB for identification by the finisher. Be sure to register the type whenever you have replaced the punch controller PCB.

  • Page 141: After Replacing The Eep-Rom (Ic1002)

    CHAPTER 5 TROUBLESHOOTING 1.2.4 After Replacing the EEP-ROM (IC1002) 1) Turn off the host machine. 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. •...
  • Page 142 CHAPTER 5 TROUBLESHOOTING...

  • Page 143: Arrangement Of Electric Components

    CHAPTER 5 TROUBLESHOOTING 2 Arrangement of Electric Components 2.1 Finisher/Saddle Unit 2.1.1 Sensors, Microswitches, and Clutch F05-201-01...
  • Page 144 CHAPTER 5 TROUBLESHOOTING Name Notation Description Photointerrupters Inlet paper detention Paddle home position detection Stack roller home position detection Aligning plate home position (front) detection Aligning plate home position (rear) detection Processing tray paper detection Delivery belt home position detection Tray paper detection Paper surface detection PI10...

  • Page 145: Motor Pcbs

    CHAPTER 5 TROUBLESHOOTING 2.1.2 Motor PCBs F05-201-02 5-10...
  • Page 146 CHAPTER 5 TROUBLESHOOTING Name Notation Description Motor Feed motor Paddle motor Delivery motor Alignment motor (front) Alignment motor (rear) Shift motor Staple/fold motor Slide motor Finisher controller Finisher control T05-201-02 5-11...

  • Page 147: Puncher Unit (Option)

    CHAPTER 5 TROUBLESHOOTING 2.2 Puncher Unit (option) 2.2.1 Sensors PI3P PI1P PI2P F05-202-01 Name Notation Description Photointerrupters PI1P Puncher home position detection PI2P Horizontal registration home position detection PI3P Punch motor clock detection T05-202-01 5-12...

  • Page 148: Motors

    CHAPTER 5 TROUBLESHOOTING 2.2.2 Motors F05-202-02 Name Notation Description Motor Punch motor Horizontal registration motor T05-202-02 5-13...

  • Page 149: Pcbs

    CHAPTER 5 TROUBLESHOOTING 2.2.3 PCBs F05-202-03 Ref. Name Punch controller PCB Photosensor PCB LED PCB Waste full photosensor PCB Waste full LED PCB T05-202-03 5-14...

  • Page 150: Leds And Check Pins By Pcb

    CHAPTER 5 TROUBLESHOOTING 3 LEDs and Check Pins by PCB Of the LEDs and check pins used in the machine, those needed during servicing in the field are discussed. Do not touch the check pins not found in the list herein. They are exclusively for factory use, and require special tools and a high degree of accuracy.

  • Page 151: Punch Controller Pcb

    CHAPTER 5 TROUBLESHOOTING 3.2 Punch Controller PCB J1007 SW1001 SW1002 SW1003 LED1001 LED1002 LED1003 J1003 J1004 F05-302-01 Switch Description SW1001 Punch hole count registration/sensor output adjustment etc. SW1002 Punch hole count registration/sensor output adjustment etc. SW1003 Punch hole count registration/sensor output adjustment etc. T05-302-01 5-16...

  • Page 152: Troubleshooting

    CHAPTER 5 TROUBLESHOOTING 4 Troubleshooting 4.1 Troubleshooting (finisher/saddle unit) 4.1.1 C0440, communication error Finisher controller PCB, Host machine DC controller PCB 1 1 1 1 1 ) Turn off and then on the host machine. Is the problem corrected? YES: End. Wiring 2) Is the wiring between the finisher controller PCB and the DC controller PCB of the host machine normal?

  • Page 153: C8010, Feed Motor Fault (Detail Code: 01/02)

    CHAPTER 5 TROUBLESHOOTING 4.1.3 C8010, Feed Motor Fault (detail code: 01/02) Stack feed roller (upper) home position sensor (PI12) 1) Check the stack feed roller (upper) home position sensor. Is it normal? Replace the sensor. Wiring 2) Is the wiring between the finisher controller PCB and the feed motor nor- mal? Correct the wiring.

  • Page 154: C8320, Alignment Motor (Rear) Fault (Detail Code: 01/02)

    CHAPTER 5 TROUBLESHOOTING 4.1.5 C8320, Alignment Motor (Rear) Fault (detail code: 01/02) Aligning plate home position sensor (rear; PI5) 1) Check the aligning plate home position sensor (rear). Is the sensor nor- mal? Replace the sensor. Wiring 2) Is the wiring between the finisher controller PCB and the rear alignment motor (rear) normal? Correct the wiring.

  • Page 155: C8340, Staple/Fold Motor Fault (Detail Code: 01/02)

    CHAPTER 5 TROUBLESHOOTING 4.1.7 C8340, Staple/Fold Motor Fault (detail code: 03) Staple/fold clock sensor (PI14) 1) Check the staple/fold clock sensor. Is the sensor normal? Replace the sensor. Finisher controller PCB, Stapler unit 2) Does the staple/fold motor operate at the appropriate timing? YES: Replace the finisher controller PCB.

  • Page 156: C8360, Slide Motor Fault (Detail Code: 01/02)

    CHAPTER 5 TROUBLESHOOTING 4.1.9 C8340, Staple/Fold Motor Fault (detail code: 03) Staple/fold clock sensor (PI4) 1) Check the staple/fold clock sensor. Is the sensor normal? Replace the sensor. Finisher controller PCB, Saddle unit 2) Does the staple/fold motor operate at the appropriate timing? YES: Replace the finisher controller PCB.

  • Page 157: C8330, Alignment Motor (Front) Fault (Detail Code: 01/02)

    CHAPTER 5 TROUBLESHOOTING 4.1.11 C8330, Alignment Motor (front) Fault (detail code: 01/02) Aligning plate home position sensor (front; PI4) 1) Check the aligning plate home position sensor (front). Is the sensor nor- mal? Replace the sensor. Wiring 2) Is the wiring between the finisher controller PCB and the front alignment plate motor (front) normal? Correct the wiring.

  • Page 158: C8140, Shift Motor Fault (Detail Code: 02)

    CHAPTER 5 TROUBLESHOOTING 4.1.13 C8140, Shift Motor Fault (detail code: 02) Tray position 1) Is the tray as far as the shift upper limit sensor? YES: Lower the position of the tray. Shift upper limit sensor (PI15) 2) Check the shift upper limit sensor. Is the sensor normal? Replace the sensor.

  • Page 159: C8370, Paddle Motor Fault (Detail Code: 01/02/03/04)

    CHAPTER 5 TROUBLESHOOTING 4.1.15 C8370, Paddle Motor Fault (detail code: 01/02/03/04) Paddle home position sensor (PI2) 1) Check the paddle home position sensor. Is the sensor normal? Replace the sensor Swing guide home position sensor (PI3) 2) Check the swing guide home position sensor. Is the sensor normal? Replace the sensor.

  • Page 160: Troubleshooting (Puncher Unit, Option)

    CHAPTER 5 TROUBLESHOOTING 4.2 Troubleshooting (puncher unit, option) 4.2.1 C8430, Communication Faulty Finisher controller PCB, Punch controller PCB 1) Turn off and the on the host machine. Is the problem corrected? YES: End. Wiring 2) Is the wiring between the finisher controller PCB and the punch control- ler PCB normal? Correct the wiring.

  • Page 161: C8410, Punch Motor Fault (Detail Code: 01/02)

    CHAPTER 5 TROUBLESHOOTING 4.2.4 C8410, Punch Motor Fault (detail code: 01/02) Punch motor home position sensor (PI1P) 1) Check the punch home position sensor. Is the sensor normal? Replace the sensor. Punch motor clock sensor (PI3P) 2) Check the punch motor clock sensor. Is the sensor normal? Replace the sensor.

  • Page 162: Finisher Controller Pcb (2/8

    CHAPTER 5 TROUBLESHOOTING 4.2.6 C8470, Punch sensor (waste full) Fault (detail code: 06) Waste full Sensor (waste full photosensor PCB/waste full LED PCB) 1) Check the waste full sensor. Is the sensor normal? Replace the sensor. Wiring 2) Is the wiring between the punch controller PCB and the waste full sensor normal? Correct the wiring.

  • Page 163: Self Diagnosis

    CHAPTER 5 TROUBLESHOOTING 5 Self Diagnosis 5.1 Outline The CPU on the machine’s finisher controller PCB is equipped with a mechanism to check the machine condition as needed; when it detects a fault, the machine communicates the fact to the host machine in the form of a code and a detail code. The host machine indicates the code on its control panel.
  • Page 164 CHAPTER 5 TROUBLESHOOTING Code Detail Error Timing of detection C8340 • Staple/fold motor • The stapler does not leave the staple home (M7) position sensor when the staple/fold motor • Staple home posi- has been driven for 0.6 sec. tion sensor (PI19) •...
  • Page 165 CHAPTER 5 TROUBLESHOOTING Code Detail Error Timing of detection C8140 • Shift upper sensor • The shift upper sensor has gone ON while the (PI15) tray is moving up. • Shift motor (M6) • No clock is detected for 50 msec or more •...
  • Page 166 CHAPTER 5 TROUBLESHOOTING 5.2.2 Puncher Unit (option) Code Detail Error Timing of detection C8430 • Communication error • The communication with the puncher unit is disrupted. C8460 • Back-up memory • The checksum for the puncher controller PCB has an error when the power is turned on. C8480 •...

  • Page 167: Finisher/Saddle Unit

    CHAPTER 5 TROUBLESHOOTING 5.3 Alarm 5.3.1 Finisher/Saddle Unit Error Condition Timing of detection Operation Resetting Staple absent The staple car- Monitoring at all Normal operation Replace the staple tridge has run out times will continue; cartridge; or, set it of staples. however, opera- correctly.
  • Page 168 CHAPTER 5 TROUBLESHOOTING 5.3.2 Puncher Unit (option) Error Condition Timing of detection Operation Resetting Waste case full The amount of During punching. Normal operation Remove the waste waste paper in the will continue. paper from the waste case has waste case. reached the limit.

  • Page 169: Host Machine I/O Display

    CHAPTER 5 TROUBLESHOOTING 5.4 Host Machine I/O Display 5.4.1 Finisher/Saddle Unit Address Indication Signal Connector Remarks P001 bit0 Alignment motor (front) phase A FJOGMTR_A CN3-2 L: ON (output) output bit1 Alignment motor (front) phase B FJOGMTR_B CN3-4 L: ON output bit2 Slide motor phase A output SLIDMTR_A...
  • Page 170 CHAPTER 5 TROUBLESHOOTING Signal Address Indication Connector Remarks P005 H: select EEPROM_CS bit0 EEPROM chip select — (output) bit1 EEPROM/DA clock output EEPROM_DA_CK — (used in common) bit2 EEPROM/DA data output — EEPROM_DA_DO (used in common) H: load bit3 DA load signal output —...
  • Page 171 CHAPTER 5 TROUBLESHOOTING Address Indication Signal Connector Remarks P010 bit0 Paper surface sensor (input) LVL_S CN5-12 H: paper detected (input) FJOG_HP CN9-3 L: HP bit1 Aligning plate home position sensor (front; input) EEPROM_DI — bit2 EEPROM data input — — bit3 —...
  • Page 172 CHAPTER 5 TROUBLESHOOTING Address Indication Signal Connec- Remarks P014 bit0 DIPSW1 bit1 — L: ON (input) bit1 DIPSW1 bit2 — — L: ON bit2 DIPSW1 bit3 — — L: ON bit3 DIPSW1 bit4 — — L: ON bit4 DIPSW1 bit5 —...
  • Page 173 CHAPTER 5 TROUBLESHOOTING 5.4.2 Puncher Unit (option) Address Indication Signal Connector Remarks bit0 P016 Ladder circuit 1st bit — — (output) bit1 Ladder circuit 2nd bit — — bit2 Ladder circuit 3rd bit — — bit3 Ladder circuit 4th bit —...
  • Page 174 CHAPTER 5 TROUBLESHOOTING Address Indication Signal Connector Remarks bit0 — — — P020 bit1 — — — (input) bit2 Registration interrupt (hori- — — H: light zontal registration) blocked bit3 — — bit4 HFS communication RXD — — bit5 HFS communication TXD (output) —...
  • Page 175 CHAPTER 5 TROUBLESHOOTING 5-40...
  • Page 176 APPENDIX...

  • Page 177: Finisher Unit

    1 General Timing Chart 1.1 Finisher Unit Stapling: A4 size paper, 2-sheet document, rear 1-point stapling Start signal Host machine delivery signal Operation Staple Stack delivery Inlet sensor (PI1) Processing tray sensor (PI6) Feed motor (M1) Delivery motor (M3) Delivery belt home position sensor (PI7) Paddle motor (M2) revoluting the paddle...

  • Page 178: Finisher/Saddle Unit

    1.2 Saddle Unit Binding: LTR-size paper, a copy of 2-sheet document Start signal Host machine delivery signal Operation Staple (rear, front) Fold, delivery Inlet sensor (PI1) Processing tray sensor (PI6) Feed motor (M1) down Delivery motor (M3) Paddle motor (M2) revoluting the down Paddle home position...

  • Page 179: Puncher Unit (Option)

    1.3 Puncher Unit (option) Punching: A4size paper, 2-sheet document, job offset, 2set Start signal Host machine delivery signal Operation Punch Punch Punch Stack delivery Punch Trailing edge sensor (LED5, PT5) Horizontal registration sensor (LED1~4, PT1~4) Punch home positon sensor (PI1P) Horizontal registration home positon sensor (PI2P) Horizontal registration...
  • Page 181 APPENDIX 2 Signals and Abbreviations The following presents the abbreviations of signals used in this manual and in drawings, and the meaning of each signal. Reference: Signals enclosed by brackets [ ] are electrical signals, However, the state “1” or “0”...
  • Page 182 APPENDIX SELF_P HOOK TOP POSITION DETECT Signal SIFT_CLK SIFT MOTOR CLOCK DETECT Signal SIFT_DNLMT SIFT DOWN LIMIT DETECT Signal 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...
  • Page 183 APPENDIX 2.2 Puncher Unit (option) CLOCK PUNCH MOTOR CLOCK DETECT Signal DUSTLED DUST LED ON Signal DUSTPTR DUST FULL DETECT Signal PAEND PAPER END DETECT 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...
  • Page 184 APPENDIX...

  • Page 185: Finisher/Saddle Unit General Circuit Diagram

    3 Finisher/Saddle Unit General Circuit Diagram CN56-1 +24V CN56-6 CN56-2 +24V CN56-5 CN20-1 FGND CN20-1 DC+24VP CN1-1 CN56-3 FEEDMTR_A CN56-4 CN10-1 +12V CN20-2 PGND CN20-2 Feed motor N.C. CN1-2 CN56-4 FEEDMTR_*A CN56-3 CN10-2 +12V DC+24VP CN20-3 CN20-3 PGND CN1-3 CN56-5 CN56-2 FEEDMTR_B CN10-3...

  • Page 186: Finisher Controller Pcb (4/8

    3.1 Finisher Controller PCB (1/8) R130 SGND R201 R197 R188 R187 SGND SGND R272 R271 R203 R170 R266 R202 R270 R186 16 15 14 13 12 11 10 9 R167 R166 SW1.2 SW1.4 SW1.6 SW1.8 D4_LD P53/*ADTRG SW1.1 SW1.3 SW1.5 SW1.7 RA25.1 P52/SCK2...

  • Page 187: Finisher Controller Pcb (5/8

    3.2 Finisher Controller PCB (2/8) TP20 TP21 IC15 FJOGMTR_DA SLIDMTR_DA EJCTMTR_DA FEEDMTR_DA PDLMTR_DA RJOGMTR_DA R193 R178 R191 R180 TP22 TP23 TP25 CN2.7 SGND IC12 DA_LB CN2.6 SGND E2_DA_DO Host machine R192 R184 RA1.3 RA1.2 E2_DA_CK CN2.5 SGND IC3.1 RA1.4 RA1.1 R189 E2_CS CN2.4...

  • Page 188: Finisher Controller Pcb (6/8

    3.3 Finisher Controller PCB (3/8) RA15.1 TP50 RA14.1 PWR_S DC+24VP Power CN1.1 DC+24VP CN1.2 N.C. SGND SGND CN1.1 PGND PGND DC+24VL R140 Power for rogic TP28 TP51 DC+5V CN2.1 DC+24VP CN2.2 N.C. TP52 CN2.3 SGND R118 PWR_DN R149 1 L1 Dead SGND Fead...

  • Page 189: Finisher Controller Pcb (7/8

    3.4 Finisher Controller PCB (4/8) DC+5V RA3.2 CN11.2 DC+5V IC22.3 RA4.3 Slide home SLID_HP CN11.3 SLID_HP position sensor CN11.7 SGND SGND RA3.3 SGND IC22.2 RA4.2 Stapler home STPL_HP CN11.4 STPL_HP position sensor RA3.4 TP34 SGND IC22.6 RA4.1 HOOK_S Staple empty CN11.4 HOOK_S sensor...

  • Page 190: Finisher Controller Pcb (8/8

    3.5 Finisher Controller PCB (5/8) DC+5V RA7.1 TP11 IC3.4 CN16.10 DC+5V RA7.2 R174 ENT_S CN16.12 ENT_S Inlet sensor CN16.11 SGND DC+5V SGND RA9.1 TP12 SGND CN9.1 DC+5V RA9.2 R171 Paddle home PDL_HP CN9.3 PDL_HP position sensor CN9.2 SGND DC+5V SGND RA9.4 TP13 SGND...
  • Page 191 3.6 Finisher Controller PCB (6/8) R200 DC+5V R102 RA7.4 CN16.7 DC+5V RA7.3 Stack feed roller BIND_ROL_HP CN16.9 BIND_ROL_HP (upper) home position sensor CN16.8 SGND SGND DC+5V R103 SGND RA8.1 CN16.4 DC+5V RA8.2 R196 Folding home BIND_HP CN16.6 BIND_HP position sensor CN16.5 SGND SGND...
  • Page 192 3.7 Finisher Controller PCB (7/8) +24V +24V CN7.1 +24V CN10.1 +24V +24V CN10.2 +24V CN7.2 PGMD PGND Feed motor Slide motor R132 RA18.2 FEEDMTR_A OutA/*A FEEDMTR_A CN10.3 SLIDMTR_A OutA/*A SLIDMTR_A CN7.3 RA28.2 InA* OutA*/A OutA*/A FEEDMTR_*A FEEDMTR_*A CN10.4 SLIDMTR_*A CN7.4 RA19.1 RA18.4 OutB/*B...
  • Page 193 3.8 Finisher Controller PCB (8/8) +24V +24V CL+24V +24V CN10.7 +24V CN3.1 +24V CN10.8 PGMD PGND Alignment motor Paddle motor RA19.3 (front) R131 OutA/*A FJOGMTR_A PDLMTR_A PDLMTR_A CN10.9 OutA FJOGMTR_A CN3.2 RA29.2 InA* OutA*/A PDLMTR_*A PDLMTR_*A CN10.10 OutA* FJOGMTR_*A CN3.3 RA19.2 R241 OutB/*B...

  • Page 194: Puncher Unit General Circuit Diagram

    4 Puncher Unit General Circuit Diagram J2011 J2011 J1007-13 J1007-12 J1007-11 Photosensor J1007-10 J1007-9 J1007-8 J1007-7 J2010 J2010 J1007-6 J1007-5 J1007-4 LED PCB J1007-3 J1007-2 J1007-1 J1007 J1007 Waste full J2006 J2006 J1005 J1005 photosensor J2005 J2005 Waste full LED PCB J2009 PI3P Punch motor clock...
  • Page 195 4.1 Punch Controller PCB IC100 MTR[0] VOUT J1001.3 DC+5V J1007.12 MTR[1] R1063 +24V J1001.4 DA1004 SENSE SENS[7] SREG1* J1007.11 +24V R1045 R1061 R1062 FU1002 PULSE MTR[2] SGND J1006.8 PHASE C1016 C1010 R1054 DA1002 SGND SENS[1] CLOCK J1006.9 R1066 PGND R1052 R1053 DA1005 SGND...

  • Page 196: Led Pcb

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

  • Page 197: Photosensor Pcb

    4.3 Photosensor PCB IC1.1 CN2011.6 IC3.1 CN2011.3 PTR4 SGND SGND SGND SGND IC2.2 Y REGI CN2011.7 IC2.1 CN2011.4 PTR5 SGND SGND SGND SGND SGND SGND IC3.2 SGND SGND IC1.2 CN2011.5 SGND SGND SGND CN2011.1 SGND SGND SGND DC 5V CN2011.2 A-21...
  • Page 198 A-22...
  • Page 199 Av. 16 de Septiembre #407 Col. Santa Inés, 02130 Azcapotzalco México, D.F. Mexico TEL : (5) 383-2741 FAX : (5) 383-7804 ©2001 KYOCERA MITA CORPORATION is a trademark of Kyocera Corporation is a registered trademark of KYOCERA MITA CORPORATION Printed in U.S.A.

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