DI-100 Document Imprinter Service Manual TABLE OF CONTENTS 1. INTRODUCTION ....................1 1.1 W ’ .............. 1 XPECTED OF THE ECHNICIAN 1.2 S ....................1 ERVICE EVEL 1.3 A ................1 DDITIONAL ERVICE UPPORT 1.4 S ....................2 AFETY ERMS 1.5 S...
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DI-100 Document Imprinter Service Manual 7. PROCEDURES....................25 7.1 B ......................25 7.2 C ....................28 IRCUIT 7.3 C ..................... 29 ONTROL ANEL 7.4 C ....................... 30 OUNTER 7.5 D ..................31 OCUMENT ETECTOR 7.5.1 TESTING THE DETECTOR....................31 7.5.2 OPTIMIZING THE DETECTOR POSITION..............32 7.5.3 REPLACING THE DETECTOR ..................33...
Additional Service Support Before servicing the DI-100, read the Operating Manual. If you need additional support, contact the Customer Service Center of The HEDMAN Company at (800) 872-2788. Please be prepared to state your name, company and serial number of the machine.
Used to identify unusual or unexpected conditions or to point out the need for alternate procedures. A NOTE may also be used for emphasis when a WARNING or CAUTION are not required. A suggestion to enhance the DI-100’s productivity. 7/01...
Observe the following safety precautions and warnings at all times while operating, cleaning, servicing or repairing the DI-100. Failure to so may result in physical injury or damage to the DI-100. Neither HEDMAN nor the manufacturer assumes any liability for your failure to comply with these requirements.
The side of the DI-100 where most of the controls are located. input end The end of the DI-100 where the document enters the DI-100. output end The end of the DI-100 where the document exits the DI-100.
2. Use a heavy duty, double-walled container of 350- pound test material. 3. Surround the DI-100 on ALL sides with at least 4 to 5 inches of shock absorbing packaging material. This will provide firm cushioning and prevent movement inside the container.
ONLY OPERATE THE DI-100 ON A GROUNDED POWER LINE TO AVOID MICRO-PROCESSOR DAMAGE CAUSED BY POWER SURGES. Power The DI-100 is rated for continuous operation using a variety of supply voltages. Possible line voltages are 240V, 220V, 120V and 100V at 50-60 Hz 7/01...
DI-100 Document Imprinter Service Manual 3. OPERATION DI-100 Description The DI-100 is a document imprinter used for signing, endorsing and validating cut-sheet documents. Sequence of Operation 1. Documents to be imprinted are stacked in the FEED TRAY. 2. The SEPARATOR separates the stack into single pieces as the FEED ROLL feeds them through the DI- 100.
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10. The IMPRINT light flashes on and off as the IMPRINT SADDLES rotate. This indicator is linked to the PULSE WHEEL. 11. The COUNTERS count documents as they are imprinted. 12. Documents exit the DI-100 and stack on the RECEIVING TRAY. 4/00...
FEED TRAY. Lower the PAPER WEIGHT if necessary. c. Although it is possible, loading documents while DI-100 is feeding is not recommended. 4. Feed several documents before imprinting to make sure the documents are feeding straight, smooth and one at a time.
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DI-100 Document Imprinter Service Manual jam. Always let the documents fall freely from the machine and into the RECEIVING TRAY. c. Place a single sheet of paper in the RECEIVING TRAY to prevent exiting documents from catching on the bottom of the DOCUMENT STOPS.
3.4.3 Finding A Non-Imprinted Document If a certain number of documents are fed into the DI-100 and the COUNTER displays one less: 1. Feed the same stack of documents again without imprinting. 2. Watch for the one document missing an imprint.
DI-100 Document Imprinter Service Manual 3.4.4 Feeding Various Sized Documents Place the documents between the PAPER GUIDES. Justify the documents to the right with the leading edge as shown below in Figure 3.1. Figure 3.1 -- Right Justified Documents 4/00...
The DI-100 can connect to any power distribution system, including the European IT Power System. Because the European IT Power System does not have a grounded neutral leg, the DI-100 uses protective fusing in both the neutral and hot supply lines of power. WARNING...
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DI-100 Document Imprinter Service Manual (Refer to Figure 4.1.) To select a different voltage, use the following instructions: NOTE The detachable POWER CORD may have to be changed to match the particular power-source output. 1. Unplug the POWER CORD. 2. Use a small screwdriver or similar tool to push up on and release the FUSE DRAWER LOCKING TAB.
0.5A (250V time delay) 240V (or 230V) 0.5A (250V time delay) 5. Replace the LINE FUSE if necessary. Both LINE FUSES must be in place for the DI-100 to operate properly. 6. Install the FUSE DRAWER in the POWER ENTRY CASING.
DI-100 Document Imprinter Service Manual Power Cord The DI-100 comes with a three-wire POWER CORD. The POWER CORD grounds the DI-100 when connected to an approved three-contact electrical outlet. 1. Plug the POWER CORD into the APPLIANCE INLET on the non-operator side. (Refer to Figure 4.1.) 2.
Inspect surfaces, rollers and other parts for damage or excessive wear and replace before they become a problem. Cleaning Frequency of DI-100 cleaning is determined by the type of paper being fed, the volume and owner maintenance. CAUTION ANY CLEANING AGENT STRONGER THAN...
DI-100 Document Imprinter Service Manual 2. Open the COVER and blow compressed air onto the PHOTOSENSORS. 3. Blow compressed air on the STATIC BRUSHES. 4. Clean the BACKUP PLATEN. NOTE If left dirty, the BACKUP PLATEN may hinder clear imprinting or smear ink on the back of documents exiting the DI-100.
Fuse When one or both FUSES are blown, the DI-100 will appear to have no power. If the DI-100 has blown a FUSE, replace the fuse. The FUSE DRAWER is located on the input end of the machine. Use the following instructions to replace one or both FUSES.
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FUSE is blown and needs to be replaced. 5. Pull the blown FUSE from its slot. 6. Place a new FUSE into the same slot. Both fuses must be in place for the DI-100 to operate properly. 7. Install the FUSE DRAWER in the POWER ENTRY CASING.
DI-100 Document Imprinter Service Manual 6. TROUBLESHOOTING WARNING NEVER CLEAN, CLEAR OR DISASSEMBLE THE DI-100 WITHOUT FIRST UNPLUGGING THE POWER CORD. Operation Troubleshooting PROBLEM CAUSE REMEDY • • 1. No power. POWER CORD is Plug in POWER CORD. • unplugged.
DI-100 Document Imprinter Service Manual Mechanical Troubleshooting PROBLEM CAUSE REMEDY • • 1. Not feeding – Loose or broken Tighten set screw on MOTOR is on but belts drive. FEED MOTOR don’t move. PULLEY. • Replace broken BELT. • •...
DI-100 Document Imprinter Service Manual Electrical Troubleshooting PROBLEM CAUSE REMEDY • • 1. Not feeding – Blown FUSE. Check & replace nothing happens. FUSES. • • Bad POWER CORD. Check & replace POWER CORD. • • Bad SWITCH Check POWER SWITCH •...
All procedures are alphabetized by the part or assembly requiring adjustment or replacement. WARNING NEVER CLEAN, CLEAR OR DISASSEMBLE THE DI-100 WITHOUT FIRST UNPLUGGING THE POWER CORD. WARNING DO NOT TOUCH THE POWER INTERLOCK SWITCH WHILE THE POWER CORD IS PLUGGED...
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DI-100 Document Imprinter Service Manual FEED TRAY SCREWS SCREW Figure 7.1 -- Opening the Base 4. Remove the 2 SCREWS underneath the BASE that hold the FEED MOTOR SUPPORT to the BASE. 5. Remove the 3 SCREWS on each SIDE FRAME that hold the SIDE FRAMES to the BASE.
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DI-100 Document Imprinter Service Manual SWITCH GUARD SCREWS POWER INTERLOCK SWITCH CONNECTORS Figure 7.2 – Power Interlock Switch & Connectors To close the BASE: 1. Tip the unit back to the align it with the BASE. 2. Tighten the 2 SCREWS underneath the BASE which secure the FEED MOTOR SUPPORT to the BASE.
DI-100 Document Imprinter Service Manual Circuit Card STUD CIRCUIT CARD SCREW AND WASHER Figure 7.3 -- Replacing A Circuit Card To remove a CIRCUIT CARD: 1. Remove the operator side COVER. 2. Unplug all CONNECTORS on the CIRCUIT CARD. 3. Remove the 2 SCREWS and WASHERS on the bottom of the CIRCUIT CARD.
3. Unplug the CONTROL PANEL TOUCHPAD from the CONTROL PANEL CIRCUIT CARD. 4. Gently pry the CONTROL PANEL CIRCUIT CARD from the CONTROL PANEL MOUNTING BRACKET and remove. 5. Unscrew the CONTROL PANEL MOUNTING BRACKET from the DI-100 and remove. 6. Replace in reverse order. 4/00...
DI-100 Document Imprinter Service Manual Counter COUNTER COVER HEXNUT WASHER Figure 7.4 -- Replacing the Counter To replace a COUNTER: 1. Open the COVER. 2. Remove COUNTER COVER. (Refer to Figure 7.4.) 3. Unplug the CONNECTOR on the COUNTER(S). 4. Remove the FIXING CLIPS and push the COUNTER through the COVER.
DI-100 Document Imprinter Service Manual Document Detector DETECTOR MOUNT SCREW DETECTOR BRACKET WASHER PHOTOTRANSISTOR 05-0559-00 HEXNUT DETECTOR HARNESS 09-0420-00 Figure 7.5 -- Replacing the Document Detector 7.5.1 Testing the Detector To test the DOCUMENT DETECTOR: 1. Remove OPERATOR SIDE COVER.
DI-100 Document Imprinter Service Manual making these readings, slightly wiggle the EMITTER MOUNTING BRACKET. If movement in the bracket causes the readings to change drastically, see following section. 7.5.2 Optimizing the Detector Position To optimize the DOCUMENT DETECTOR position, install Sensor Optimization Kit (16-0057-00):...
DI-100 Document Imprinter Service Manual 7.5.3 Replacing the Detector To replace the DOCUMENT DETECTOR: 1. Open the COVER. 2. Remove both SIDE COVERS. 3. Remove the FRONT GUARD. 4. Remove the 3 HEX NUTS on the DETECTOR BRACKET and pull the DETECTOR BRACKET out of the BASE.
DI-100 Document Imprinter Service Manual Document Emitter To replace the DOCUMENT EMITTER: 1. Open the COVER. 2. Remove the PRESSURE TIRE SHAFT. 3. Remove the 2 SCREWS on the EMITTER MOUNT and remove it from the EMITTER BRACKET. (Refer to the Illustrated Parts Guide.) 4.
DI-100 Document Imprinter Service Manual Feed Motor PULLEYS PULLEY FEED MOTOR SCREWS Figure 7.6 -- Adjusting Belt Tension To replace a FEED MOTOR: 1. Access the inside of the BASE. (Refer to Section 7.1.) 2. Loosen the 2 SCREWS in the FEED MOTOR and rotate the FEED MOTOR counterclockwise to loosen the tension on the FEED TIMING BELT.
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DI-100 Document Imprinter Service Manual and pull the FEED MOTOR (with the attached SUPPORT and BRACKET) out of the BASE. (Refer to Figure 7.7.) 7. Remove the 2 SCREWS and GROMMETS (refer to Figure 7.7) that hold the FEED MOTOR BRACKET to the FEED MOTOR SUPPORT and pull the FEED MOTOR out of the FEED MOTOR BRACKET.
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DI-100 Document Imprinter Service Manual OPERATOR SIDE VIEW SCREWS AND GROMMETS FEED MOTOR SUPPORT VIEW A REAR VIEW OF UNIT TIPPED FORWARD Figure 7.8 -- Feed Motor Support 11. Place the 3 PULLEYS on the shafts and fasten the SET SCREWS to the flat on the shafts.
DI-100 Document Imprinter Service Manual Feed Roll FEED MOTOR BEARING ASSEMBLY 09-0297-00 Figure 7.9 -- Feed Motor Bearing Assembly To replace a FEED ROLL: 1. Access the inside of the BASE. (Refer to Section 7.1.) 2. Loosen the 2 SCREWS in the FEED MOTOR and rotate the FEED MOTOR counterclockwise to loosen the tension on the FEED TIMING BELT.
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DI-100 Document Imprinter Service Manual OPERATOR SIDE VIEW PADDLE WHEEL PADDLE WHEEL PADDLE WHEEL SHAFT SHAFT PULLEY 02-1531-00 07-0157-00 TIMING BELT FEED ROLL SHAFT 07-0161-03 FEED ROLL FEED ROLLS SHAFT PULLEY VIEW A REAR VIEW OF UNIT TIPPED FORWARD Figure 7.10 -- Inside View of the Base 8.
DI-100 Document Imprinter Service Manual 12. Place the TIMING BELT around the FEED ROLL SHAFT PULLEY. Make sure the TIMING BELT is around the PADDLE WHEEL SHAFT PULLEY also. The tension is fixed. (Refer to Figure 7.10.) 13. Install the FEED MOTOR BEARING ASSEMBLY.
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DI-100 Document Imprinter Service Manual COVER FRONT GUARD Figure 7.11 -- Front Guard NOTE Belt tension is ideal if the belt can be deflected " with little effort. 7. Tighten the SCREWS in the FEED MOTOR. (Refer to Figure 7.6.)
DI-100 Document Imprinter Service Manual 7.11 Fuses POWER SWITCH FUSE POWER ENTRY VOLTAGE CASING SELECTOR FUSE DRAWER APPLIANCE INLET FUSE DRAWER LOCKING TAB VOLTAGE POWER SELECTOR CORD WINDOW Figure 7.13 -- Replacing A Fuse To replace a FUSE: 1. Push up on the FUSE DRAWER LOCKING TAB with a small screwdriver or similar tool to release this locking tab.
DI-100 Document Imprinter Service Manual 7.12 Media Feed Switch FEED SWITCH BRACKET MEDIA FEED SWITCH 02-0028-04 Figure 7.14 -- Replacing the Media Feed Switch To replace the MEDIA FEED SWITCH: 1. Remove both SIDE COVERS. 2. Unplug all CONNECTORS from the MEDIA FEED SWITCH.
DI-100 Document Imprinter Service Manual 7.13 Paddle Wheel PULLEYS PULLEY FEED MOTOR SCREWS Figure 7.15 -- Feed Motor Screws & Pulleys To replace the PADDLE WHEEL: 1. Access the inside of the BASE. (Refer to Section 7.1.) 2. Loosen the 2 SCREWS in the FEED MOTOR (refer to Figure 7.15) and rotate the FEED MOTOR...
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DI-100 Document Imprinter Service Manual 6. Push the PADDLE WHEEL SHAFT through the hole in the SIDE FRAME on the non-operator side and out of the BASE. Pull the TIMING BELT off the PADDLE WHEEL SHAFT PULLEY. (Refer to Figure 7.17.) 7.
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DI-100 Document Imprinter Service Manual OPERATOR SIDE VIEW PADDLE WHEEL PADDLE WHEEL PADDLE WHEEL SHAFT 02-1531-00 SHAFT PULLEY 07-0157-00 TIMING BELT FEED ROLL SHAFT 07-0161-03 FEED ROLL FEED ROLLS SHAFT PULLEY VIEW A REAR VIEW OF UNIT TIPPED FORWARD Figure 7.17 -- Inside View of the Base 13.
DI-100 Document Imprinter Service Manual 7.14 Paper Guides CAMLOCK PAPER GUIDE FEED TRAY OPERATOR SIDE VIEW NON-OPERATOR SIDE OPERATOR SIDE PAPER GUIDE PAPER GUIDE 09-0448-01 09-0447-01 FEED TRAY SLOT CAMLOCK SHAFT WITH NUT, WASHER AND GROMMET VIEW A REAR VIEW OF UNIT TIPPED FORWARD Figure 7.18 -- Replacing Paper Guides...
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DI-100 Document Imprinter Service Manual To replace the PAPER GUIDES: 1. Access the inside of the BASE. (Refer to Section 7.1.) 2. Lift each CAMLOCK. (Refer to Figure 7.18.) 3. Cut the CAMLOCK SHAFTS under the FEED TRAY, between the WASHER and the RUBBER GROMMET.
(widening) NOTE In order to widen the PLATEN GAP to accept the DATER ASSEMBLY you must first contact The HEDMAN Company for an Adjustment Kit. The kit contains .750” spacers, a diagram and instructions. CAUTION PROCEED ONLY IF THIS PROCEDURE HAS BEEN DONE BEFORE AND YOU HAVE THE KIT WITH INSTRUCTIONS.
DI-100 Document Imprinter Service Manual 7.16 Power Entry Casing POWER ENTRY CASING 02-0853-00 OPERATOR SIDE VIEW POWER ENTRY CASING VIEW A 02-0853-00 REAR VIEW OF UNIT TIPPED FORWARD Figure 7.19 -- Replacing the Power Entry Casing To replace the POWER ENTRY CASING: 1.
DI-100 Document Imprinter Service Manual 7.17 Power Switch POWER SWITCH 02-0600-01 OPERATOR SIDE VIEW POWER SWITCH 02-0600-01 VIEW A REAR VIEW OF UNIT TIPPED FORWARD Figure 7.20 -- Replacing the Power Switch 7/01...
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DI-100 Document Imprinter Service Manual To replace the POWER SWITCH: 1. Access the inside of the BASE. (Refer to Section 7.1.) 2. Unplug the CONNECTORS from the POWER SWITCH. (Refer to Figure 7.20.) 3. Squeeze the CLIPS on the top and bottom of the POWER SWITCH and push out of the BASE.
DI-100 Document Imprinter Service Manual 7.18 Separators ACCESS HOLE STONE SEPARATORS 02-0277-03 PHILLIP HEAD FEED ROLLS 09-0585-01 Figure 7.21 -- Reaching & Replacing the Separators 7/01...
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DI-100 Document Imprinter Service Manual To rotate the SEPARATORS, exposing a clean surface: 1. Open the COVER. 2. Loosen the socket head cap screws on each end of the SEPARATOR SHAFT. 3. Slightly rotate the SEPARATORS. (Refer to Figure 7.21.) Test to be sure that the contact between the...
DI-100 Document Imprinter Service Manual 7.19 Signature Motor PULLEYS FRONT GUARD SIGNATURE MOTOR SIGNATURE MOTOR SCREWS 09-0416-00 Figure 7.22 -- Replacing the Signature Motor To replace the SIGNATURE MOTOR: 1. Remove the SIDE COVERS. 2. Remove the FRONT GUARD. (Refer to Figure 7.22.) 3.
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DI-100 Document Imprinter Service Manual 6. Find the WIRES connecting the SIGNATURE MOTOR and the CIRCUIT CARD and unplug the WIRE CONNECTOR from the CIRCUIT CARD. 7. Remove the 2 SCREWS holding the SIGNATURE MOTOR to the SIDE FRAME and pull the SIGNATURE MOTOR out of the BASE.
DI-100 Document Imprinter Service Manual 7.20 Signature Timing Belt To replace the SIGNATURE TIMING BELT: 1. Remove both SIDE COVERS. 2. Remove the FRONT GUARD. (Refer to Figure 7.22.) 3. Loosen, do not remove the SCREWS on the SIGNATURE MOTOR.
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DI-100 Document Imprinter Service Manual PULLEYS PULLEY FEED MOTOR SCREWS Figure 7.23 -- Feed Motor Screws & Pulleys 6. Push the PADDLE WHEEL SHAFT through the hole in the non-operator side FRAME and out of the BASE. 7. Push the FEED ROLL SHAFT through the hole in the SIDE FRAME on the non-operator side and out of the BASE.
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DI-100 Document Imprinter Service Manual FEED MOTOR BEARING ASSEMBLY 09-0297-00 Figure 7.24 -- Feed Motor Bearing Assembly 10. Push the FEED ROLL SHAFT through the hole in the SIDE FRAME on the non-operator side. 11. Push the PADDLE WHEEL SHAFT through the hole in the SIDE FRAME on the non-operator side.
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DI-100 Document Imprinter Service Manual OPERATOR SIDE VIEW PADDLE WHEEL PADDLE WHEEL PADDLE WHEEL SHAFT SHAFT PULLEY 02-1531-00 07-0157-00 TIMING BELT FEED ROLL SHAFT 07-0161-03 FEED ROLL FEED ROLLS SHAFT PULLEY VIEW A REAR VIEW OF UNIT TIPPED FORWARD Figure 7.25 -- Inside View of the Base 14.
DI-100 Document Imprinter Service Manual 7.22 Transformer TRANSFORMER 02-0861-00 OPERATOR SIDE VIEW TRANSFORMER 02-0861-00 VIEW A REAR VIEW OF UNIT TIPPED FORWARD Figure 7.26 -- Replacing A Transformer To replace a TRANSFORMER: 1. Access the inside of the BASE. (Refer to Section 7.1.) 2.
DI-100 Document Imprinter Service Manual 9. ILLUSTRATED PARTS GUIDE NOTE Order parts by part number ONLY. DI-100 Unit Assembly – 99-0034-01 7/01...
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DI-100 Document Imprinter Service Manual NOTE The following part numbers are used in the machine but are not illustrated in the exploded drawing: 4 5 9 10 11 12 13 14 16 17 28. Item Part No. Description 02-0025-03 WASHER, INT TOOTH LOCK, #6...
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DI-100 Document Imprinter Service Manual DI-100 Final Assembly – 10-0509-01 7/01...
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DI-100 Document Imprinter Service Manual Item Part No. Description 02-0025-02 WASHER, INT TOOTH LOCK, #8 02-0025-04 WASHER, INT TOOTH LOCK, #4 02-0035-01 NUT, HEX, #8-32 02-0035-02 NUT, HEX, #6-32 02-0035-03 NUT, HEX, #4-40 02-0370-01 SCREW, BUTNHD, W/ LOCK, #10-32 x ”...
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