Mita-Kyocera DF-78 Service Manual

DF-78

CONTENTS

1-1 Specifications

1-1-1 Specifications ....................................................................................................................................... 1-1-1

1-1-2 Part names ........................................................................................................................................... 1-1-2

1-1-3 Machine cross section .......................................................................................................................... 1-1-3

1-1-4 Drive system ........................................................................................................................................ 1-1-4

1-2 Installation

1-2-1 Unpacking ............................................................................................................................................ 1-2-1

1-3 Troubleshooting

1-3-1 Paper misfeed detection ...................................................................................................................... 1-3-1

(1) Paper misfeed indication............................................................................................................... 1-3-1

(2) Paper misfeed detection condition................................................................................................ 1-3-2

(3) Paper misfeeds ............................................................................................................................. 1-3-3

1-3-2 Self-diagnosis....................................................................................................................................... 1-3-4

(1) Self-diagnostic function................................................................................................................. 1-3-4

(2) Self-diagnostic codes.................................................................................................................... 1-3-4

1-3-3 Electrical problems ............................................................................................................................... 1-3-7

(1) The paper conveying motor does not operate. ............................................................................. 1-3-7

(2) The feedshift solenoid does not operate....................................................................................... 1-3-7

(3) The pickup solenoid does not operate. ......................................................................................... 1-3-7

(4) The front side registration motor does not operate. ...................................................................... 1-3-7

(5) The rear side registration motor does not operate........................................................................ 1-3-7

(6) The trailing edge registration motor does not operate. ................................................................. 1-3-7

(7) The cooling fan motor does not operate. ...................................................................................... 1-3-8

1-3-4 Mechanical problems ........................................................................................................................... 1-3-9

(1) Paper jams.................................................................................................................................... 1-3-9

(2) Abnormal noise is heard. .............................................................................................................. 1-3-9

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1-4 Assembly and Disassembly

1-4-1 Precautions for assembly and disassembly ......................................................................................... 1-4-1

(1) Precautions ................................................................................................................................... 1-4-1

(2) Adjusting the positions of the front side registration cursor, rear side registration cursor

and trailing edge registration cursor (reference) ........................................................................... 1-4-2

(3) Cleaning the stapler ...................................................................................................................... 1-4-3

(4) Adjusting the pressure of curl eliminator mechanism ................................................................... 1-4-4

2-1 Mechanical construction

2-1-1 Construction of each section ................................................................................................................ 2-1-1

(1) Paper conveying operation in sort mode ...................................................................................... 2-1-2

2-1-2 Intermediate tray section ...................................................................................................................... 2-1-3

(1) Paper registration on the intermediate tray................................................................................... 2-1-4

2-1-3 Stapler section ..................................................................................................................................... 2-1-5

2-2 Electrical Parts Layout

2-2-1 Electrical parts layout ........................................................................................................................... 2-2-1

(1) Paper conveying section............................................................................................................... 2-2-1

(2) Intermediate tray section............................................................................................................... 2-2-2

(3) Stapler section .............................................................................................................................. 2-2-3

2-3 Operation of the PCBs

2-3-1 Main PCB ............................................................................................................................................. 2-3-1

1-1-1

2-4 Appendixes

Timing chart No. 1 ........................................................................................................................................... 2-4-1

Timing chart No. 2 ........................................................................................................................................... 2-4-2

Timing chart No. 3 ........................................................................................................................................... 2-4-3

Periodic maintenance procedure.................................................................................................................... 2-4-4

Wiring diagram ................................................................................................................................................ 2-4-5

1-1-1 Specifications

Type ............................................... Built-in

Number of trays..............................1 (intermediate tray)

Stapling limit................................... A4/11" × 81/2" or smaller: 30 sheets

Other sizes than above: 20 sheets

Power source ................................. Electrically connected to the copier

Weight............................................Approximately 11 kg/24.2 lbs

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1-1-1

3B5

1-1-2 Part names

Figure 1-1-1

1 Intermediate tray 2 JAM release lever 3 Eject tray

1-1-2

1-1-3 Machine cross section

3B5

Figure 1-1-2 Machine cross section

1 Paper conveying section 2 Intermediate tray section 3 Eject section

Paper path

1-1-3

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1-1-4 Drive system

Figure 1-1-3

1 Paper conveying motor gear 2 Gear 31/20 3 Gear 28 4 Gear 18 5 Gear 18 6 Gear 25 7 Gear 14 8 Gear 16

9 Central gear 0 Gear 21 ! Gear 26 @ Clutch cam # Stopper gear $ Gear 32 % Gear 26

1-1-4

1-2-1 Unpacking

3B5

Figure 1-2-1 Unpacking

1 Paper conveying unit 2 Intermediate tray unit 3 Eject tray 4 Stapler cover 5 Staple cartridge 6 Large eject cover 7 Cross-head chrome TP-A screws M3 × 05 8 Cross-head bronze binding TP-A screws M3 × 05 9 Front eject cover 0 Rear eject cover ! Paper conveying unit pad @ Upper intermediate tray pad # Lower intermediate tray pad

$ Outer case % Spacer 1 ^ Spacer 2 & Spacer 3 * Spacer 4 ( Plastic bag ) Plastic bag ⁄ Plastic sheet ¤ Plastic bag ‹ Plastic bag › Air-padded bag ﬁ Bar-code labels

1-2-1

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1-3-1 Paper misfeed detection

(1) Paper misfeed indication

When paper jams, the machine immediately stops operation and the occurrence of a paper jam is indicated on the copier operation panel. To remove the jammed paper, lower the intermediate tray. To reset the paper misfeed detection, detach and refit the intermediate tray to turn the tray open/close switch off and on.

PCSW

Figure 1-3-1 Paper misfeed detection

1-3-1

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(2) Paper misfeed detection condition

• Jam between the finisher and copier (jam code 81) The paper conveying switch does not turn on within 1550 ms of the signal requesting paper ejection is output from the copier.

• Intake jam (jam code 82) During paper intake from the copier, the paper conveying switch (PCSW) does not turn off within 1960 to 3480 ms (depending on paper size) of paper conveying switch (PCSW) turning on.

PCSW

1960 to 3480 ms

Off On

Timing chart 1-3-1

• Jam during paper conveying for batch ejection 1 (jam code 83) When ejection a stack of paper, the paper conveying switch (PCSW) does not turn on within 1590 ms of the paper conveying motor (PCM) turning on.

PCM

PCSW

1590 ms

Off On

Timing chart 1-3-2

• Jam during paper conveying for batch ejection 2 (jam code 84) When ejection a stack of paper, the paper con v eying switch (PCSW) does not turn off within 2260 to 3190 ms (depending on the paper size) of the paper conveying motor (PCM) turning on.

PCSW

2260 to 3190 ms

Off On

Timing chart 1-3-3

1-3-2

(3) Paper misfeeds

Problem Causes Check procedures/corrective measures

(1) Paper jams in the finisher when the main switch is turned on.

A piece of paper torn from copy paper is caught around the paper conveying switch.

Defective paper conveying switch.

Remove any found.

With 5 V DC present at CN4-9 on the main PCB, check if CN4-10 on the main PCB remains low when the paper conveying switch is turned on and off. If it does, replace the paper conveying switch.

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(2) Paper jams in the finisher during copying (intake jam). Jam code 82

(3) Paper jams in the finisher during copying (jam during paper conveying for batch ejection 1). Jam code 83

(4) Paper jams in the finisher during copying (jam during paper conveying for batch ejection 2). Jam code 84

Defective paper conveying switch.

Check if the feedshift roller or feedshift pulley is deformed.

Defective paper conveying switch.

Check if the feedshift roller or press roller is deformed.

Defective paper conveying switch.

Check if the eject roller or eject pulley is deformed.

With 5 V DC present at CN4-9 on the main PCB, check if CN4-10 on the main PCB remains high or low when the paper conveying switch is turned on and off. If it does, replace the paper conveying switch.

Check visually and replace the pulley or roller if deformed.

With 5 V DC present at CN4-9 on the main PCB, check if CN4-10 on the main PCB remains high or low when the paper conveying switch is turned on and off. If it does, replace the paper conveying switch.

Check visually and replace the pulley or roller if deformed.

With 5 V DC present at CN4-9 on the main PCB, check if CN4-10 on the main PCB remains high or low when the paper conveying switch is turned on and off. If it does, replace the paper conveying switch.

Check visually and replace the pulley or roller if deformed.

1-3-3

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1-3-2 Self-diagnosis

(1) Self-diagnostic function

This unit is equipped with a self-diagnostic function. When a problem is detected, copying is disabled and the problem displayed as a code consisting of “C” followed by a number between 0440 and 8220, indicating the nature of the problem. A message is also displayed requesting the user to call for service. After removing the problem, the self-diagnostic function can be reset by turning the tray open/close switch or copier safety switch 1 or 2 off and back on.

(2) Self-diagnostic codes

Code Contents

C0440 Finisher communication problem

An error code from the side deck is detected eight times in succession. No communication: there is no reply after 3 retries. Abnormal communication: a communication error (parity or checksum error) is detected five times in succession.

C8170 Finisher front side registration motor

problem

If the front side registration home position sensor is on in initialization, the sensor does not turn off within 570 ms of starting initialization. If the front side registration home position sensor is off in initialization, the sensor does not turn on within 3180 ms of starting initialization.

Remarks

Causes Check procedure/corrective measures

Poor contact in the connector terminals.

Defective copier main PCB.

Defective finisher main PCB.

The front side registration motor connector makes poor contact.

The front side registration motor malfunctions.

The front side registration home position sensor connector makes poor contact.

Check the connection of connectors CN4, CN5 on the copier main PCB and CN2 on the finisher main PCB, and the continuity across the connector terminals. Repair or replace if necessary.

Replace the copier main PCB and check for correct operation.

Replace the finisher main PCB and check for correct operation.

Reinsert the connector. Also check for continuity within the connector cable. If none, remedy or replace the cable.

Replace the front side registration motor and check for correct operation.

Reinsert the connector. Also check for continuity within the connector cable. If none, remedy or replace the cable.

C8180 Finisher rear side registration motor

problem

If the rear side registration home position sensor is on in initialization, the sensor does not turn off within 570 ms of starting initialization. If the rear side registration home position sensor is off in initialization, the sensor does not turn on within 2880 ms of starting initialization.

The front side registration home position sensor malfunctions.

Defective finisher main PCB.

The rear side registration motor connector makes poor contact.

The rear side registration motor malfunctions.

The rear side registration home position sensor connector makes poor contact.

The rear side registration home position sensor malfunctions.

Replace the front side registration home position sensor and check for correct operation.

Replace the finisher main PCB and check for correct operation.

Reinsert the connector. Also check for continuity within the connector cable. If none, remedy or replace the cable.

Replace the rear side registration motor and check for correct operation.

Reinsert the connector. Also check for continuity within the connector cable. If none, remedy or replace the cable.

Replace the rear side registration home position sensor and check for correct operation.

1-3-4

3B5

Code Contents

C8180 Finisher rear side registration motor

problem

C8190 Finisher trailing edge registration

motor problem

If the trailing edge registration home position sensor is on in initialization, the sensor does not turn off within 570 ms of starting initialization. If the trailing edge registration home position sensor is off in initialization, the sensor does not turn on within 4550 ms of starting initialization.

Remarks

Causes Check procedure/corrective measures

Defective finisher main PCB.

The trailing edge registration motor connector makes poor contact.

The trailing edge registration motor malfunctions.

The trailing edge registration home position sensor connector makes poor contact.

Replace the finisher main PCB and check for correct operation.

Reinsert the connector. Also check for continuity within the connector cable. If none, remedy or replace the cable.

Replace the trailing edge registration motor and check for correct operation.

Reinsert the connector. Also check for continuity within the connector cable. If none, remedy or replace the cable.

C8210 Finisher front stapler problem

The front stapler home position sensor does not change state from nondetection to detection within 200 ms of the start of front stapler motor counterclockwise (forward) rotation. During initialization, the front stapler home position sensor does not change state from non-detection to detection within 600 ms of the start of front stapler motor clockwise (reverse) rotation.

The trailing edge registration home position sensor malfunctions.

Defective finisher main PCB.

The front stapler connector makes poor contact.

The front stapler malfunctions. a) The front stapler is blocked with a staple. b) The front stapler is broken.

Defective finisher main PCB.

Replace the trailing edge registration home position sensor and check for correct operation.

Replace the finisher main PCB and check for correct operation.

Reinsert the connector. Also check for continuity within the connector cable. If none, remedy or replace the cable.

a) Remove the front stapler cartridge, and check the cartridge and the stapling section of the stapler. b) Replace the front stapler and check for correct operation.

Replace the finisher main PCB and check for correct operation.

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