Page 1
FS-603
Color Printer
SERVICE MANUAL
Code Y104710-1
Page 2
PUBLICATION ISSUED BY:
Olivetti S.p.A.
77, Via Jervis - 10015 Ivrea (TO)
Italy
Copyright © 2006, Olivetti
All rights reserved
Page 3
After publication of this service manual, the parts and mechanism may be subject to change for
improvement of their performance.
Therefore, the descriptions given in this service manual may not coincide with the actual machine.
When any change has been made to the descriptions in the service manual, a revised version will be
issued with a revision mark added as required.
Revision mark:
• To indicate clearly a section revised, show to the left of the revised section.
A number within represents the number of times the revision has been made.
• To indicate clearly a section revised, show in the lower outside section of the corresponding page.
A number within represents the number of times the revision has been made.
NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
• When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
• When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.
1
1
1
1
2006/03 1.0 — Issue of the first edition
Date Service manual Ver. Revision mark Descriptions of revision
Page 4
Page 5
FS-603GeneralMaintenanceAdjustment / Setting
Troubleshooting
Field Service Ver. 1.0 Mar. 2006
i
CONTENTS
General
1. Product specification ............................................................................................... 1
1.1 Type ......................................................................................................................1
1.2 Functions ..............................................................................................................1
1.3 Paper type ............................................................................................................ 1
1.3.1 Group, Group offset ...................................................................................... 1
1.3.2 Sort, Sort offset............................................................................................. 1
1.3.3 Sort staple.....................................................................................................2
1.3.4 Center Staple & Fold..................................................................................... 2
1.4 Stapling................................................................................................................. 2
1.5 No. of sheets to be stapled (sort staple) ............................................................... 3
1.6 Machine specifications..........................................................................................3
1.7 Operating environment ......................................................................................... 3
Maintenance
2. Other ....................................................................................................................... 5
2.1 Disassembly/Adjustment prohibited items ............................................................ 5
2.2 Disassembly/Assembly list (Other parts)..............................................................6
2.3 Disassembly/Assembly procedure........................................................................ 7
2.3.1 Exit Tray ........................................................................................................ 7
2.3.2 Front Cover ................................................................................................... 7
2.3.3 Rear Cover.................................................................................................... 7
2.3.4 Upper Door ................................................................................................... 8
2.3.5 Finisher Tray Upper Cover ............................................................................ 8
2.3.6 Upper Cover.................................................................................................. 9
2.3.7 Side Guide .................................................................................................... 9
2.3.8 Middle Transport Unit..................................................................................10
2.3.9 Stapler.........................................................................................................10
2.3.10 Saddle Section............................................................................................ 11
2.3.11 Finisher Tray................................................................................................ 11
2.3.12 Paddle Section ...........................................................................................12
2.3.13 Exit Roller (Upper) ...................................................................................... 14
2.3.14 Paddle ......................................................................................................... 14
2.3.15 Exit Roller (Lower) and Paper Exit Belt .......................................................15
2.3.16 Stapler/Folding Drive Unit ...........................................................................17
2.3.17 Transport Roller........................................................................................... 18
Y104710-1 Service Manual
Page 6
FS-603
GeneralMaintenanceAdjustment / Setting
Troubleshooting
Field Service Ver. 1.0 Mar. 2006
ii
2.3.18 Middle Transport Roller............................................................................... 19
2.3.19 Punch Unit .................................................................................................. 20
2.3.20 Finisher Control Board................................................................................ 21
2.3.21 Punch Control Board .................................................................................. 21
2.3.22 Transport Motor Unit ................................................................................... 22
2.3.23 Middle Transport Motor............................................................................... 22
2.3.24 Punch Motor ............................................................................................... 22
2.3.25 Side Registration Motor .............................................................................. 22
Adjustment/Setting
3. How to use the adjustment section....................................................................... 23
4. Sensor check ........................................................................................................ 24
4.1 Check procedure ................................................................................................ 24
4.2 Sensor check list ................................................................................................ 24
4.2.1 Sensor check screen .................................................................................. 24
5. Mechanical adjustment ......................................................................................... 26
5.1 Adjustment of the stapling position..................................................................... 26
5.1.1 Adjustment procedure................................................................................. 26
5.2 Adjustment of the folding position....................................................................... 28
5.2.1 Adjustment procedure................................................................................. 28
5.3 Adjustment of height and inclination................................................................... 30
5.4 Adjustment of the Folding Position..................................................................... 32
5.4.1 Adjustment procedure................................................................................. 32
5.5 Stapler Phase Adjustment.................................................................................. 36
5.5.1 Adjustment procedure................................................................................. 36
5.6 Saddle Gear Phase Adjustment ......................................................................... 39
6. Board switch ......................................................................................................... 40
6.1 PWB-A FN (Finisher Control Board) .................................................................. 40
6.1.1 Adjustment of the folding positions ............................................................. 41
6.1.2 Adjustment of the center stapling position.................................................. 42
6.1.3 Adjustment of the Alignment Plate position ................................................ 43
6.2 PWB-B PK (Punch Control Board) ..................................................................... 45
6.2.1 Adjustment of the sensor output................................................................. 46
6.2.2 Registration of the number of punch holes ................................................. 46
6.2.3 Procedure after replacing the EEP-ROM (IC1002)..................................... 47
6.2.4 Punch center position adjustment............................................................... 47
Service Manual Y104710-1
Page 7
FS-603GeneralMaintenanceAdjustment / Setting
Troubleshooting
Field Service Ver. 1.0 Mar. 2006
iii
Troubleshooting
7. Jam Display........................................................................................................... 51
7.1 Misfeed display ................................................................................................... 51
7.1.1 Misfeed display resetting procedure ........................................................... 51
7.2 Sensor layout...................................................................................................... 52
7.3 Solution............................................................................................................... 53
7.3.1 Initial check items........................................................................................ 53
7.3.2 Transport section misfeed ...........................................................................53
7.3.3 Horizontal Transport section misfeed.......................................................... 54
7.3.4 Folding position section misfeed................................................................. 54
7.3.5 Stapler section misfeed............................................................................... 55
8. Trouble code.......................................................................................................... 56
8.1 Trouble code display ........................................................................................... 56
8.2 Trouble code list.................................................................................................. 56
8.2.1 How to reset................................................................................................ 59
8.3 Solution............................................................................................................... 60
8.3.1 C1180: Transport System Drive malfunctions............................................. 60
8.3.2 C1181: Paddle Motor malfunctions ............................................................. 60
8.3.3 C1183: Elevate Mechanism malfunctions ...................................................61
8.3.4 C1192: Front Aligning Plate Motor malfunctions......................................... 61
8.3.5 C1193: Rear Aligning Plate Motor malfunctions ......................................... 62
8.3.6 C11A4: Booklet Exit Motor malfunctions..................................................... 62
8.3.7 C11B1: Stapler Unit Slide Motor malfunctions............................................ 63
8.3.8 C11B4: Stapler/Folding Motor malfunctions................................................ 63
8.3.9 C11C1: Punch Control Board malfunctions ................................................65
8.3.10 C11C2: Punch Side Registration Motor malfunctions................................. 66
8.3.11 C11C3: Punch Motor malfunctions ............................................................. 66
8.3.12 C11C5: Punch Sensor malfunctions........................................................... 67
8.3.13 C1401: Backup RAM malfunction ............................................................... 68
Y104710-1 Service Manual
Page 8
FS-603
GeneralMaintenanceAdjustment / Setting
Troubleshooting
Field Service Ver. 1.0 Mar. 2006
iv
Blank Page
Service Manual Y104710-1
Page 9
Field Service Ver. 1.0 Mar. 2006 1. Product specification
1
FS-603General
General
1. Product specification
1.1 Type
1.2 Functions
1.3 Paper type
• Remove the finisher off the machine for feeding the long paper.
• The maximum loading capacity shown is for when loading the single type of paper (80g/
m
2
)
1.3.1 Group, Group offset
*1: Controlled by whichever reached earlier
1.3.2 Sort, Sort offset
Type Multi Staple Finisher with Saddle (Booklet)
Installation Freestanding
Document Alignment Center
Supplies Staple Cartridge
Modes Normal Group, Sort, Group Offset, Sort Offset, Sort Staple
Center Staple & Fold
Punch (Option) Group Punch, Sort Punch, Group Offset Punch,
Sort Offset Punch, Sort Staple Punch
Plain Paper Paper Size Weight Tray Capacity *1 Exit Tray No. of Sheets
to be Stapled
B5R/B5 to
A3 wide
5.5 × 8.5R/
5.5 × 8.5
to
12.25 × 18
60 to 90
g/m
2
16 to 24 lb
No. of
Sheet
Height
A4R /
8.5×11R
or smaller
1000
150 mm
B4/
8.5×14 or
larger
500
75 mm
1st paper
exit tray
-
Envelop
OHP Film
Label Paper
Thick Paper
60 to 256
g/m
2
16 to 68 lb
20 sheet
Paper Type Paper Size Weight Tray Capacity Exit Tray No. of Sheets
to be Stapled
Plain Paper A5,B5R/B5 to A3
8.5 × 11R/
8.5 × 11
to
11 × 17
60 to 90
g/m
2
16 to 24 lb
No. of
Sheets
Height
A4R /
8.5×11R
or smaller
1000
150 mm
B4/
8.5×14 or
larger
500
75 mm
1st paper
exit tray
-
Controlled by whichever
reached earlier
Y104710-1 Service Manual
Page 10
1. Product specification Field Service Ver. 1.0 Mar. 2006
2
FS-603
General
1.3.3 Sort staple
* The number of Sheets to be Stapled is limited for high-density images.
(Color Wise: 20 sheets x 20 sets)
1.3.4 Center Staple & Fold
1.4 Stapling
Paper Type Paper Size Weight Tray Capacity Exit Tray No. of Sheets
to be Stapled
Plain Paper
Cardboard
B5R/B5 to A3
8.5 × 11R/
8.5 × 11
to
11×17
Normal
Mode
60 to 90
g/m
2
16 to 24 lb
Cover Mode
60 to 209
g/m
2
16 to 55.5 lb
No. of
Sheets
Height
No. of
Sets
A4R /
8.5×11R
or smaller
1000
150 mm
30
B4/
8.5×14 or
larger
500
75 mm
30
Normal Mode *1
1st paper
exit tray
A4R/
8.5×
11R or
smaller
2 to 50
B4/
8.5×14
or larger
2 to 25
Controlled by whichever
reached earlier
Paper Type Paper Size Weight Tray Capacity Exit Tray No. of Sheets to
be Stapled
Plain Paper A4R, B4, A3
8.5 × 11R/
11 × 17
60 to 90
g/m
2
16 to 24 lb
10 sets
(No. of Sheets to be
Stapled: 6 to 15 sheets)
20 sets
(No. of Sheets to be
Stapled: 2 to 5 sheets)
2nd paper
exit tray
Black copy
2 to 15 sheets
(Max. 60 pages)
Other copy
2 to 10 sheets
(Max. 40 pages)
Staple Filling Mode Dedicated Staple Cartridge Mode (5000 staples)
Staple Detection Available (Nearly Empty: 40 remaining staples)
Stapling Position
Rear: Parallel 1 point B5R/B5 to A3,
8.5× 11R / 8.5× 11 to 11 × 17
Front: Parallel 1 point
Side: Parallel 2 points
Center: Parallel 2 points
Manual Staple None
Folding Mode Roller Pressure Folding
Folding Position Center of Paper
Service Manual Y104710-1
Page 11
Field Service Ver. 1.0 Mar. 2006 1. Product specification
3
FS-603General
1.5 No. of sheets to be stapled (sort staple)
A. A4R, 8.5× 11R or smaller
B. B4, 8.5× 14 or larger
1.6 Machine specifications
1.7 Operating environment
Conforms to the operating environment of the main unit.
NOTE
• These specifications are subject to change without notice.
No. of Sheets to
be Stapled
No. of Sets
Rear: Parallel Center: Parallel Front: Parallel
2 100 40 40
3 to 5 80 40 40
6 to 10 60 40 40
11 to 20 30 30 30
21 to 30 30 30 30
31 to 50 30 sets or 1000 sheets
No. of Sheets to
be Stapled
No. of Sets
Rear: Parallel Center: Parallel Front: Parallel
2 100 50 50
3 to 5 80 40 40
6 to 10 40 40 40
11 to 20
30 sets or 1000 sheets
21 to 25
Power Requirements DC 24 V (supplied from the main unit)
DC 5 V (generated by Finisher)
Max. Power
Consumption
65 W or less
Dimensions
601 mm (W) × 933 mm (H) × 603 mm (D)
23.75 inch (W) × 36.75 inch (H) × 23.75 inch (D)
Weight 41.6 kg (91.75 lb)
Y104710-1 Service Manual
Page 12
1. Product specification Field Service Ver. 1.0 Mar. 2006
4
FS-603
General
Blank Page
Service Manual Y104710-1
Page 13
Field Service Ver. 1.0 Mar. 2006 2. Other
5
FS-603Maintenance
Maintenance
2. Other
2.1 Disassembly/Adjustment prohibited items
A. Paint-locked Screws
NOTE
• Paint-locked screws show that the assembly or unit secured can only be adjusted
or set at the factory and should not be adjusted, set, or removed in the field.
B. Red Painted Screws
NOTES
• When the screws are removed, the red paint is coated on the points where readjustment is required.
• Once the red painted screw is removed or loosened, you should make adjustment.
Accordingly check the adjustment items in operation manual and make necessary
adjustment.Note that when two or more screws are used on the part in questions,
only one representative screw may be marked with red paint.
C. Variable Resistors on Board
NOTE
• Do not turn the variable resistors on boards for which no adjusting instructions
are given in Adjustment/Setting.
D. Removal of PWBs
NOTES
• When removing a circuit board or other electrical component, refer to “Handling of
PWBs” and follow the corresponding removal procedures.
• The removal procedures given in the following omit the removal of connectors and
screws securing the circuit board support or circuit board.
• When it is absolutely necessary to touch the ICs and other electrical components
on the board, be sure to ground your body.
Y104710-1 Service Manual
Page 14
2. Other Field Service Ver. 1.0 Mar. 2006
6
FS-603
Maintenance
2.2 Disassembly/Assembly list (Other parts)
No Section Part name Ref. page
1
Exterior Parts
Exit Tray
☞ 7
2Front Cover
☞ 7
3Rear Cover
☞ 7
4 Upper Door
☞ 8
5 Finisher Tray Upper Cover
☞ 8
6 Upper Cover
☞ 9
7
Unit
Side Guide
☞ 9
8 Middle Transport Unit
☞ 10
9Stapler
☞ 10
10 Saddle Section
☞ 11
11 Finisher Tray
☞ 11
12 Paddle Section
☞ 12
13 Exit Roller (Upper)
☞ 14
14 Paddle
☞ 14
15 Exit Roller (Lower) and Paper Exit Belt
☞ 15
16 Stapler/Folding Drive Unit
☞ 17
17 Transport Roller
☞ 18
18 Middle Transport Roller
☞ 19
19 Punch Unit
☞ 20
20
Electrical Parts
Finisher Control Board
☞ 21
21 Punch Control Board
☞ 21
22 Transport Motor Unit
☞ 22
23 Middle Transport Motor
☞ 22
24 Punch Motor
☞ 22
25 Side Registration Motor
☞ 22
Service Manual Y104710-1
Page 15
Field Service Ver. 1.0 Mar. 2006 2. Other
7
FS-603Maintenance
2.3 Disassembly/Assembly procedure
2.3.1 Exit Tray
1. Remove four screws [1], and remove
the Exit Tray [2].
2.3.2 Front Cover
1. Remove the Middle Transport Unit.
☞ 10
2. Open the Front Door [1].
3. While pinching the claws [2], remove
the Folding Jam Release Dial [3].
4. Remove two screws [4].
5. Remove the screw [5], and remove
the Front Cover [6].
2.3.3 Rear Cover
1. Remove the Middle Transport Unit.
☞ 10
2. Remove two screws [1], and remove
the Rear Cover [2].
[2]
[1]
[1]
4583fs2526c0
[1]
[4]
[4]
[3]
[2]
4583fs2527c0
[5]
[6]
4583fs2528c0
[1]
4583fs2529c0
[1]
[2]
4583fs2530c0
Y104710-1 Service Manual
Page 16
2. Other Field Service Ver. 1.0 Mar. 2006
8
FS-603
Maintenance
2.3.4 Upper Door
1. Open the Upper Door [1], and
remove the Door Band Holder [2] by
turning it clockwise.
2. Remove the Door Band [3].
3. Remove the screw [4], and remove
the grounding wire.
4. Remove the screw [5], remove the
Finisher Tray Rear Cover [6], and
remove the Upper Door [7].
2.3.5 Finisher Tray Upper Cover
1. Remove the Front Cover.
☞ 7
2. Remove the Rear Cover.
☞ 7
3. Remove the Upper Door.
☞ 8
4. Unplug the connector [1].
5. Unplug the connector [3] while hold-
ing up the Finisher Tray Upper Cover
[2], and remove the Finisher Tray
Upper Cover [2].
[1]
[4]
4583fs2531c0
[2]
[3]
[5]
[6]
4583fs2532c0
[7]
[1]
4583fs2533c0
[2]
[3]
4583fs2534c0
Service Manual Y104710-1
Page 17
Field Service Ver. 1.0 Mar. 2006 2. Other
9
FS-603Maintenance
2.3.6 Upper Cover
1. Remove the Front Cover.
☞ 7
2. Remove the Rear Cover.
☞ 7
3. Remove two screws [1].
4. Open the Upper Door[2],and remove
the Upper Cover [3].
2.3.7 Side Guide
1. Remove the Exit Tray.
☞ 7
2. Remove the Front Cover.
☞ 7
3. Remove the Rear Cover.
☞ 7
4. Derail the Exit Tray Support Plate
(Front) [1] and the Exit Tray Support
Plate (Rear) [2] to the outside off the
respective rail grooves.
5. Remove four screws [3].
6. Pull down the Side Guide [4] lightly,
disengage the Exit Tray Home Position Detecting Lever (Rear) [5], and
then remove the Side Guide [4].
NOTE
• In reassembling, ensure of exact
installation with the Exit Tray Home
Position Detecting Lever (Rear) [5]
set in the slot of the Exit Tray Home
Position Detecting Lever (Center)
[6].
• After reassembly, press each of
these levers for several times to
make sure of exact installation.
[1]
4583fs2535c0
[1]
[2]
[3]
4583fs2536c0
[3]
[3]
[2]
[3]
4583fs2537c0
[1]
[3]
[5]
[4]
4583fs2538c0
[6]
[5]
[5]
[6]
4583fs2539c0
Y104710-1 Service Manual
Page 18
2. Other Field Service Ver. 1.0 Mar. 2006
10
FS-603
Maintenance
2.3.8 Middle Transport Unit
1. Remove four screws [1].
2. Hold up the Middle Front Cover [2]
and the Middle Rear Cover [3], and
remove them while shifting them
back and forth.
3. Unplug two connectors [4].
4. Pinch the tie band [5], and remove it
from the sheet metal.
5. Remove two screws [6].
6. Loosen two screws [7].
7. Remove the Middle Transport Unit by
sliding it upwards.
2.3.9 Stapler
1. Open the Front Door [1].
2. Pull out the Stapler [3] while pressing
the Stop Lever [2].
NOTES
• Do not remove the Stapler from the
shaft of the stapler frame, or displacement will be caused between
the position to which the Staple
Driver [4] (the lower unit of the Stapler) feeds staples and the position
from which the Staple Clincher [5]
(the upper unit of the Stapler)
receives them.
[1]
[1]
4583fs2540c0
[2]
[3]
[5]
[4]
4583fs2541c0
[6]
[7]
[7]
4583fs2542c0
[3]
[1]
4583fs2502c0
[2]
4583fs2503c0
[5]
[4]
Service Manual Y104710-1
Page 19
Field Service Ver. 1.0 Mar. 2006 2. Other
11
FS-603Maintenance
2.3.10 Saddle Section
1. Remove the Front Cover.
☞ 7
2. Remove the Rear Cover.
☞ 7
3. Remove the Punch Dust Box.
4. Open the Jam Access Cover [1],
remove two screws [2], and remove
the Right Stay [3].
5. Remove two screws [4], and remove
the Lever [5].
6. Turn the Folding Jam Release Dial
[6] to move the Paper Pressure [7]
inside.
7. Remove the C-clip [8], and remove
the Belt [9].
8. Unplug two connectors [10].
9. Remove the Stapler[11].
☞ 10
10. Remove three screws [12], and pull
out and remove the Saddle [13].
2.3.11 Finisher Tray
1. Remove the Finisher Tray Upper
Cover.
☞ 8
2. Remove the Side Guide.
☞ 9
3. Remove two screws [1],and unplug
six connectors [2].
[1]
[2]
[5]
[3]
[4]
[2]
4583fs2544c0
[7]
[6]
4583fs2518c0
[8]
[9]
[10]
4583fs2519c0
[11]
[12]
[12]
[13]
4583fs2520c0
[1]
[2]
[2]
4583fs2546c0
[1]
[2]
[2]
Y104710-1 Service Manual
Page 20
2. Other Field Service Ver. 1.0 Mar. 2006
12
FS-603
Maintenance
4. Pull out the Finisher Stopper Base
[3], and disengage the front claw [5]
and the rear claw [6] of the Finisher
Stopper [4].
5. Remove the Motor Harness [8] from
two Harness Saddles [7].
6. Unplug three connectors [9].
7. Remove the C-clip [10], and remove
the spacer [11], and remove the Belt
[13] from the Gear [12].
8. Unplug the connector [14], and
remove the Harness [16] from the
Wire Saddle [15].
9. Remove two screws [17], and
remove the Finisher Tray [18] by sliding it to the far side and lifting it.
2.3.12 Paddle Section
1. Remove the Finisher Tray.
☞ 11
2. Place the Finisher Tray [1] as shown
in the figure.
NOTE
• Be careful not to damage the Align-
ing Plate [2].
[6]
[4]
[5]
[4]
[3]
4583fs2522c0
[8]
[7]
[9]
4583fs2523c0
[6]
4583fs2547c0
[10]
[11]
[13]
[12]
[14]
[16]
[15]
[18]
[17]
4583fs2525c0
[1]
[2]
[2]
4583fs2548c0
Service Manual Y104710-1
Page 21
Field Service Ver. 1.0 Mar. 2006 2. Other
13
FS-603Maintenance
3. Remove the Belt [3], and remove two
screws [4].
4. Separate the section into the Tray
Section[5] and the Paddle Section
[6].
[4]
[4]
[3]
4583fs2549c0
[5]
4583fs2550c0
[6]
Y104710-1 Service Manual
Page 22
2. Other Field Service Ver. 1.0 Mar. 2006
14
FS-603
Maintenance
2.3.13 Exit Roller (Upper)
1. Remove the Paddle Section.
☞ 12
2. Place the Paddle Section [1] as
shown in the figure.
3. Turn the gear [2] in the direction indicated by an arrow to move up the
Exit Roller (Upper) section [3].
4. Push up the Exit Roller (Upper) [4]
from the bottom to release it from the
shaft [5].
5. Turn up the Exit Roller (Upper) [6],
and then push it down to remove it.
6. Remove the front Exit Roller (Upper)
[7] as well in the same way.
2.3.14 Paddle
1. Remove the Paddle Section.
☞ 12
2. Place the Paddle Section [1] as
shown in the figure.
[1]
4583fs2551c0
[2]
4583fs2552c0
[3]
[4]
4583fs2553c0
[5]
[6]
4583fs2554c0
[7]
[1]
4583fs2551c0
Service Manual Y104710-1
Page 23
Field Service Ver. 1.0 Mar. 2006 2. Other
15
FS-603Maintenance
3. Turn the gear [2] in the direction
indicted by an arrow to move up the
Exit Roller (Upper) section [3].
4. Push up the Safety Guide [4] from
the bottom to release it on one side
from the shaft [5].
5. Push up the Safety Guide [4] from
the bottom to release it from the
shaft [5] and remove it.
6. Remove the Paddle [6].
7. Remove the other Paddles as well in
the same way.
2.3.15 Exit Roller (Lower) and Paper Exit Belt
1. Remove the Tray Section.
☞ 12
2. Slide the Aligning Plate (Front) [2]
and the Aligning Plate (Rear) [3] outside to remove them from the Tray
[1].
[2]
4583fs2555c0
[3]
[4]
[5]
4583fs2556c0
[4]
[5]
4583fs2557c0
[6]
4583fs2558c0
[2]
[3]
[1]
4583fs2559c0
Y104710-1 Service Manual
Page 24
2. Other Field Service Ver. 1.0 Mar. 2006
16
FS-603
Maintenance
3. Remove two Holders [4], and remove
the Finisher Tray Stopper [5].
4. Remove the screw [6], and remove
the Paper Guide (Front) [8] while disengaging two claws [7].
5. Remove the screw [9], and remove
the Paper Guide (Rear) [11] while
disengaging the claw [10].
6. Remove two C-clips [12], and move
two bushings [13] inside, respectively.
7. Remove four screws [14], and
remove the Exit Roller (Lower) section [15] by lifting it.
[4]
4583fs2560c0
[4]
[5]
[7]
[6]
[8]
4583fs2561c0
[11]
[9]
[10]
4583fs2562c0
[12]
[13]
4583fs2563c0
[13]
[12]
[15]
[14]
4583fs2564c0
[14]
Service Manual Y104710-1
Page 25
Field Service Ver. 1.0 Mar. 2006 2. Other
17
FS-603Maintenance
8. Remove the Exit Roller (Lower) [16]
and two Paper Exit Belts [17].
NOTE
• When installing, align the edge of
claws of the Paper Exit Belt [18].
2.3.16 Stapler/Folding Drive Unit
1. Remove the Rear Cover.
☞ 7
2. Open the Front Door [1], and slightly
pull out the stapler section [2].
3. Remove screw [3], and remove the
interface cable presser [4].
4. Remove the Harness from seven
Harness Saddles[5].
5. Remove the Harness from the Wire
Saddle, and unplug two connectors
[6].
6. Remove the Harness from the Harness Saddle, and unplug the connector [7].
7. Remove the Harness from the Wire
Saddle, and unplug two connectors
[8].
[16]
[17]
4583fs2565c0
[18]
4583fs2566c0
[1]
[2]
4583fs2567c0
[3]
[5]
[5]
[5]
[4]
4583fs2568c0
[6]
[7]
[8]
4583fs2569c0
Y104710-1 Service Manual
Page 26
2. Other Field Service Ver. 1.0 Mar. 2006
18
FS-603
Maintenance
8. Remove the screw [9], and remove
the claw of Harness Guide [11] from
the square hole [10] in the base
plate.
9. Unplug two connectors [12], and
remove the Harness from the Wire
Saddle.
10. Remove three screws [13].
11. Remove the screw [14], and remove
the Stapler/Folding Drive Unit [15].
2.3.17 Transport Roller
1. Remove the Upper Door.
☞ 8
2. Remove the Upper Cover.
☞ 9
3. Remove two screws [1], and remove
the Upper Cover Unit [2].
[9]
[10]
[11]
4583fs2570c0
[12]
4583fs2571c0
[12]
[13]
[13]
[13]
4583fs2572c0
[14]
4583fs2573c0
[15]
[1]
[1]
4583fs2576c0
[2]
Service Manual Y104710-1
Page 27
Field Service Ver. 1.0 Mar. 2006 2. Other
19
FS-603Maintenance
4. Remove the Transport Motor Unit.
☞ 22
5. Remove the screw [3].
6. Remove the C-clip [4], and remove
the bushing [5].
7. Remove two screws [6].
8. Remove the gear 1 [7], and remove
the gear 2 [8] while disengaging the
claw.
NOTE
• Be careful not to lose the gear pin.
9. Remove the C-clip [9], and remove
the bushing [10].
10. Remove the screw [11], and remove
the Paper Guide (Lower) [12].
11. Remove the Transport Roller [13].
2.3.18 Middle Transport Roller
1. Remove the Middle Front Cover and
the Middle Rear Cover.
☞ 10
2. Remove Two screws [1], and remove
the Middle Upper Cover[2].
[4]
[5]
[3]
4583fs2575c0
[6]
4583fs2577c0
[12]
[11]
[9]
[8]
[7]
[10]
4583fs2578c0
[13]
4583fs2579c0
[1]
[1]
[2]
4583fs2581c0
Y104710-1 Service Manual
Page 28
2. Other Field Service Ver. 1.0 Mar. 2006
20
FS-603
Maintenance
3. Remove the C-clip[3], and remove
the bushing [4].
4. Shift the Shaft Assy in the orientation
as shown on the left.
5. Remove the C-clip [5], the Gear [6],
the bushing [7], and remove the Middle Transport Roller [8].
2.3.19 Punch Unit
1. Remove the Punch Trash Box.
2. Unplug the connector J1005 [1].
3. Remove the Harness from the Har-
ness Guide [2].
4. Unplug the connector [3].
5. Remove the screw [4], and remove
the Sensor Support Plate [5].
6. Remove the screw [6] and the
washer [7].
7. Unplug the connector [8].
8. Remove two screws [9], and remove
the base cover [10].
[4]
[3]
4583fs2582c0
[7]
[6]
4583fs2583c0
[8]
[5]
[2]
[1]
4583fs2586c0
[3]
[4]
[5]
4583fs2587c0
[9]
[10]
[7]
[6]
[8]
4583fs2588c0
Service Manual Y104710-1
Page 29
Field Service Ver. 1.0 Mar. 2006 2. Other
21
FS-603Maintenance
9. Remove four screws [11], and
remove the Sensor Unit (Upper) [12]
and the Sensor Unit (Lower) [13].
10. Remove the spring[14].
11. Remove the Punch Unit [16] from the
Side Registration Motor section [15].
2.3.20 Finisher Control Board
1. Remove the Rear Cover.
☞ 7
2. Unplug all connectors on the Board,
and remove the screw [1].
3. Release the PCB support [2], and
remove the Finisher Control Board
[3].
2.3.21 Punch Control Board
1. Remove two screws [1].
2. Unplug seven connectors [2], and
remove the Punch Control Board [3].
[11] [11]
4583fs2589c0
[13]
[12]
[11]
[11]
[16]
[15]
4583fs2590c0
[14]
[2]
[1]
[3]
4583fs2592c0
[1]
[1]
[3]
[2]
[2]
4583fs2591c0
[2]
[2]
Y104710-1 Service Manual
Page 30
2. Other Field Service Ver. 1.0 Mar. 2006
22
FS-603
Maintenance
2.3.22 Transport Motor Unit
1. Remove the Rear Cover.
☞ 7
2. Unplug the connector [1].
3. Remove screw [2], and remove the
Harness Guide [3].
4. Remove three screws [4], and
remove the Transport Motor Unit [5].
2.3.23 Middle Transport Motor
1. Remove the Middle Rear Cover.
☞ 10
2. Remove the harness from the Wire
Saddle [1].
3. Unplug the connector [2].
4. Remove two screws [3].
2.3.24 Punch Motor
1. Remove the Upper Cover.
☞ 9
2. Remove two screws [1].
3. Unplug the connector [2], and
remove the punch motor [3].
2.3.25 Side Registration Motor
1. Unplug the connector J1001 [1].
2. Remove the harness from the Har-
ness Guide [2].
3. Remove two screws [3], and remove
the Side Registration Motor [4].
4583fs2574c0
[1]
[5]
[3]
[4]
[4] [4]
[2]
[1]
[2]
[3]
[3]
4583fs2580c0
[3]
[2]
[1]
4583fs2584c0
[3]
[3]
[2]
4583fs2585c0
[1]
[4]
Service Manual Y104710-1
Page 31
Field Service Ver. 1.0 Mar. 2006 3. How to use the adjustment section
23
FS-603Adjustment / Setting
Adjustment/Setting
3. How to use the adjustment section
• “Adjustment/Setting” contains detailed information on the adjustment items and procedures for this machine.
• Throughout this “Adjustment/Setting” the default settings are indicated by “ ”.
A. Advance Checks
• Before attempting to solve the customer problem, the following advance checks must be
made.Check to see if:
1. The power supply voltage meets the specifications.
2. The power supply is properly grounded.
3. The machine shares the power supply with any other machine that draws large current
intermittently (e.g., elevator and air conditioner that generate electric noise).
4. The installation site is environmentally appropriate: high temperature, high humidity,
direct sunlight, ventilation, etc.; levelness of the installation site.
5. The original has a problem that may cause a defective image.
6. The density is properly selected.
7. The Original Glass, slit glass, or related part is dirty.
8. Correct paper is being used for printing.
9. The units, parts, and supplies used for printing (developer, PC Drum, etc.) are properly
replenished and replaced when they reach the end of their useful service life.
10. Toner is not running out.
B. Precautions for Service Jobs
1. Be sure to unplug the power cord of the machine before starting the service job proce-
dures.
2. If it is unavoidably necessary to service the machine with its power turned ON, use
utmost care not to be caught in the Scanner Cables or gears of the Exposure Unit.
3. Special care should be used when handling the Fusing Unit which can be extremely
hot.
4. The Developing Unit has a strong magnetic field. Keep watches and measuring instru-
ments away from it.
5. Take care not to damage the PC Drum with a tool or similar device.
6. Do not touch IC pins with bare hands.
Y104710-1 Service Manual
Page 32
4. Sensor check Field Service Ver. 1.0 Mar. 2006
24
FS-603
Adjustment / Setting
4. Sensor check
4.1 Check procedure
• To allow sensors to be checked for operation easily and safely, data applied to the IC on
the board can be checked on the panel with the main unit in the standby state (including
a misfeed, malfunction, and closure failure condition).
<Procedure>
1. Call the Service Mode to the screen.
☞ For details of how to display the Service Mode screen, see the Adjustment/Setting of
the main unit service manual.
2. Touch the “State Confirmation” key.
3. Touch the “Sensor Check” key.
4.2 Sensor check list
4.2.1 Sensor check screen
• This is only typical screen which may be different from what are shown on each individual main unit.
A. Sensor monitor 4 (FS-601, PK-501)
4583F3E502DA
Symbol Panel display Part/Signal name
Operation characteris-
tics/Panel display
10
PI1-FN Entrance Entrance Sensor Paper
present
Paper not
present
PI2-FN Paddle Home Paddle Home Position Sensor HP
PI3-FN Bundle Roller Home Swing Guide Home Position Sensor HP
PI4-FN Front Align Front Aligning Plate Home Position
Sensor
HP
PI5-FN Back Align Rear Aligning Plate Home Position
Sensor
HP
PI6-FN Alignment Tray Finisher Tray Sensor Paper
present
Paper not
present
PI7-FN Home (Exit Belt) Exit Belt Home Position Sensor HP
Service Manual Y104710-1
Page 33
Field Service Ver. 1.0 Mar. 2006 4. Sensor check
25
FS-603Adjustment / Setting
PI10-FN Crease Position Folding Position Sensor Paper
present
Paper not
present
PI13-FN Crease Tray Saddle Tray Sensor Paper
present
Paper not
present
PI11-FN Crease Home Folding Home Position Sensor HP
PI12-FN Crease Roller Home Folding Roller Home Position Sensor HP
PI14-FN Crease Clock Staple/Folding Motor Clock Sensor
PI8-FN Paper Exit Tray Sensor Paper
present
Paper not
present
PI9-FN Paper Surface Exit Tray Home Position Sensor DETECTE
D
PI15-FN Lift Raised Position Shift Upper Limit Sensor UPPER
LIMIT
PI16-FN Lift Lowered Position Shift Lower Limit Sensor LOWER
LIMIT
PI17-FN Lift Clock Shift Motor Clock Sensor
Lift Middle FULL
PI18-FN Slide Home Slide Home Position Sensor HP
PI19-FN Stapler Home Staple Drive Home Position Sensor HP
PI20-FN Staple Staple Detecting Sensor SUPPLIED EMPTY
Stapler Connect. DETECTE
D
MS3-FN
MS4-FN
Stapler Safety SW Staple Safety Switch (Rear)
Staple Safety Switch (Front)
OPEN CLOSE
PI21-FN Self Prime Self-Priming Sensor READY
PI22-FN Front Door Front Door Open Sensor CLOSE OPEN
PI23-FN Upper Cover Upper Cover Open Sensor CLOSE OPEN
MS1-FN Front Door SW Front Door Open Switch CLOSE OPEN
Remain in Reverse
Section
HORIZON-
TA L
MS2-FN Joint SW Joint Open Switch CLOSE OPEN
Punch Depth 1
Punch Depth 2
Punch Depth 3
Punch Depth 4
Punch Dust FULL
Punch Timing
PI3P-PK Punch Motor Clock Punch Motor Clock Sensor Blocked Unblocked
PI1P-PK Punch (Home) Punch Home Position Sensor HP
PI2P-PK Punch Depth (Home) Side Registration Home Sensor HP
PC4-HO Horizontal Transport
Door
Horizontal Unit Door Sensor
Blocked Unblocked
Symbol Panel display Part/Signal name
Operation characteris-
tics/Panel display
10
Y104710-1 Service Manual
Page 34
5. Mechanical adjustment Field Service Ver. 1.0 Mar. 2006
26
FS-603
Adjustment / Setting
5. Mechanical adjustment
5.1 Adjustment of the stapling position
• The stapling position is adjusted by aligning the stapling position to the folding position.
• This adjustment is made in the Service Mode of the main unit. Since the adjustment is
made in increments of 1 mm, this adjustment is useful for eliminating a displacement of
1mm or more.
• For the effective adjustment of a minimal displacement smaller than 1 mm, refer to
“Board switch.”
☞ 40
Adjustable range: - 7 to + 7 mm (Increment: 1 mm)
5.1.1 Adjustment procedure
1. Set A3 or 11 x 17 to the Feed Tray.
2. Touch these keys in this order: “Fold & Staple” → “OK.”
3. Set five sheets of A3 or 11 x 17 original (blank paper acceptable) in the Original Tray.
• These five sheets are used for adjustment to minimize variation.
4. Press the “Start” Key.
5. Set the mode to the Service Mode.
☞ For details of how to display the Service Mode screen, see the Adjustment/Setting of
the main unit service manual.
6. Touch “Finisher”.
7. Touch “Center-Staple Position Adj.”
8. Renew the center folding of the finished copies.
Take the top surface of the finished copies as “A”, and the under surface as “B.”
9. Check the deviation of the stapling position from the newly folded position.
NOTE
• In checking the deviation, refer not to the folded position by the Finisher but to the
newly folded position.
4583F3E506DA
Service Manual Y104710-1
Page 35
Field Service Ver. 1.0 Mar. 2006 5. Mechanical adjustment
27
FS-603Adjustment / Setting
10. Press the “Clear” Key.
11. Adjust with the +/- Keys.
When the stapling position is shifted
to the direction A: Adjust the value to
the - side.
When the stapling position is shifted
to the direction B: Adjust the value to
the + side.
12. Touch “END.”
13. Make the copy and check again.
4583fs3501c0
A
B
A
B
A
B
Standard:0 ± 2 mm
<To - side>
<To + side><Standard> <To + side><Standard>
4583F3E508DA
Y104710-1 Service Manual
Page 36
5. Mechanical adjustment Field Service Ver. 1.0 Mar. 2006
28
FS-603
Adjustment / Setting
5.2 Adjustment of the folding position
• The folding position is adjusted by aligning the folding position to the stapling position.
• This adjustment is made in the Service Mode of the main unit. Since the adjustment is
made in increments of 1 mm, this adjustment is useful for eliminating a displacement of
1mm or more.
• For the effective adjustment of a minimal displacement smaller than 1 mm, refer to
“Board switch.”
☞ 40
Adjustment range: - 7 to + 7 mm (Increment: 1 mm)
5.2.1 Adjustment procedure
1. Set A3 or 11 x 17 to the Feed Tray.
2. Touch these keys in this order: “Fold & Staple” → “OK.”
3. Set five sheets of A3 or 11 x 17 original (blank paper acceptable) in the Original Tray.
• These five sheets are used for adjustment to minimize variation.
4. Press the “Start” Key.
5. Set the mode to the Service Mode.
☞ For details of how to display the Service Mode screen, see the Adjustment/Setting of
the main unit service manual.
6. Touch “Finisher.”
7. Touch “Half-Fold Position Adj.”
8. Check the finished copies for deviation of the stapling position of from the newly folded
position.
Take the top surface of the finished copies as “A”, and the under surface as “B.”
4583F3E510DA
4583fs3502c0
A
B
A
B
A
B
Standard: 0 ± 2 mm
<To + side> <To - side><Standard>
Service Manual Y104710-1
Page 37
Field Service Ver. 1.0 Mar. 2006 5. Mechanical adjustment
29
FS-603Adjustment / Setting
9. Press the “Clear” Key.
10. Adjust with the +/- Keys.
When the stapling position is shifted
to the direction A: Adjust the value to
the + side.When the stapling position
is shifted to the direction B: Adjust
the value to the - side.
11. Touch “END.”
12. Make the copy and check again.
4583F3E512DA
Y104710-1 Service Manual
Page 38
5. Mechanical adjustment Field Service Ver. 1.0 Mar. 2006
30
FS-603
Adjustment / Setting
5.3 Adjustment of height and inclination
1. Gently move the finisher toward the
machine and check for following.
• Is the positioning pin aligned with the
hole in the finisher?
• Does the horizontal transport unit run
excessively slantwise?
• Does the clearance at A equal that at
B?
• If the finisher is not at the same height
as the machine, adjust the machine as
follows.
2. Remove the Finisher [1] from the
main unit, and remove two caster
covers [2].
3. Remove four adjusting screw covers
[3].
4583fs3503c0
A
B
4583fs3504c0
4583fs3505c0
[1]
[2]
4583fs3506c0
[3]
[3]
[3]
[3]
Service Manual Y104710-1
Page 39
Field Service Ver. 1.0 Mar. 2006 5. Mechanical adjustment
31
FS-603Adjustment / Setting
4. Loosen four caster fixing screws [4].
(4 points)
5. Turn the adjustment screw [5] to
make adjustment.
• To heighten: Turn the screw counter-
clockwise.
• To bring down: Turn the screw clock-
wise.
6. Fasten the caster fixing screws.
7. Install the caster covers and the
adjustment screw covers.
4583fs3507c0
[4]
[4]
[4]
[4]
[5]
[5]
4583fs3508c0
Y104710-1 Service Manual
Page 40
5. Mechanical adjustment Field Service Ver. 1.0 Mar. 2006
32
FS-603
Adjustment / Setting
5.4 Adjustment of the Folding Position
• Folding position is adjusted by adjusting the Tray Section and the Saddle Section.
• Adjust the folding position by aligning the Tray Section. Adjust the position of the Saddle
Section if the position is still not proper.
<Deviation amount which will be adjusted>
5.4.1 Adjustment procedure
A. Checking the deviation amount
1. Load the Paper Take-up Tray with A3
paper.
2. Select “Fold & Staple” and touch
“OK.”
3. Place the A3 Original (Blank paper
acceptable) to the original tray, and
press the Start key.
4. Check the fed out copy to see if there
is any deviation.
B. Adjusting the folding deviation
1. Turn main power switch OFF, and
remove the Finisher from the
machine.
2. Remove the cable, and remove the
Horizontal Unit [1].
Paper Size
Amount of deviation which will
be adjusted by aligning the Tray
Section
Amount of deviation which will
be adjusted by aligning the
Saddle Section position
Total amount which
will be adjusted
A3 0.55 mm 0.55 mm 1.1 mm
A4 0.4 mm 0.4 mm 0.8 mm
B4 0.5 mm 0.5 mm 1.0 mm
Ledger 0.55 mm 0.55 mm 1.1 mm
Letter 0.35 mm 0.35 mm 0.7 mm
4583F3E525DA
Exit
direction
Exit
direction
Deviated upwardDeviated downward
4583F3C518DA
[1]
Service Manual Y104710-1
Page 41
Field Service Ver. 1.0 Mar. 2006 5. Mechanical adjustment
33
FS-603Adjustment / Setting
3. Remove the Middle Transport Unit.
☞ 10
4. Remove the front cover.
☞ 7
5. Loosen two screws [2] on the Tray
Section.
6. Move the Tray Section [3] back and
forth, and move the positioning dowels [4] right and left to adjust.
4583F3C519DA
[2]
4583F3C520DA
[3]
[4]
Y104710-1 Service Manual
Page 42
5. Mechanical adjustment Field Service Ver. 1.0 Mar. 2006
34
FS-603
Adjustment / Setting
• If it is deviated downward <A>, move
the positioning dowels to the left.
• If it is deviated upward <B>, move the
positioning dowels to the right.
NOTE
• The folding line will move along
with the staples.
7. Carry out the test copy to see if there
is any folding deviation.
If the deviation is not adjusted,
repeat the procedure from Step 8 to
adjust the Saddle Section position.
8. Loosen three set screws [5] on the
Saddle Section.
4583F3C523DA
<A>
<B>
4583F3C521DA
[5]
[5]
[5]
Service Manual Y104710-1
Page 43
Field Service Ver. 1.0 Mar. 2006 5. Mechanical adjustment
35
FS-603Adjustment / Setting
9. Move the two positioning dowels [6]
to adjust.
• If it is deviated downward <C>, move
the positioning dowel to the left.
• If it is deviated upward <D>, move the
positioning dowel to the right.
NOTE
• Only the folding line will move.
10. Feed out the test copy and check if
there is any folding deviation.
4583F3C522DA
[6]
[6]
4583F3C524DA
<C>
<D>
Y104710-1 Service Manual
Page 44
5. Mechanical adjustment Field Service Ver. 1.0 Mar. 2006
36
FS-603
Adjustment / Setting
5.5 Stapler Phase Adjustment
• Make phase adjustment of the Stapler
following the procedures given below
whenever the Gear or Timing Belt in
front of the Stapler has been replaced
or removed for some reason, since
such replacement or removal will
cause mistiming between the staple
driving by the Staple Driver (the lower
unit of the Stapler) and the staple
clinching by the Staple Clincher (the
upper unit of the Stapler).
5.5.1 Adjustment procedure
1. Remove the Stapler.
☞ 10
2. Remove the E-Ring [1], and remove
the Jam Release Dial 1[2].
3. Remove the Jam Release Dial 2 [3].
4. Remove the three screws [4], and
remove the Stapler Front Cover [5].
5. Remove the Gear Cover [7] from the
Staple Driver [6].
6. Remove the E-Ring [8], and remove
the Side Cover [10] from the Staple
Clincher [9].
7. Remove two E-Rings [11], and
remove the Staple Jam Release
Gear [12], the Timing Belt [13] and
the Middle Gear 1 [14].
8. Remove the spacer and the spring
located behind the Staple Jam
Release Gear.
9. Remove the screw [15] and the
spring [16], and remove the Belt Tension Roller [17].
4583fs2504c0
4583fs2543c0
[1]
[4]
[4]
[3]
[2]
[4]
[5]
4583fs2505c0
[7]
[10]
[8]
[9]
[6]
4583fs2506c0
[13]
[15]
[17]
[11]
[12]
[16]
[14]
Service Manual Y104710-1
Page 45
Field Service Ver. 1.0 Mar. 2006 5. Mechanical adjustment
37
FS-603Adjustment / Setting
10. Remove the Timing Belt [18].
11. Remove the E-Ring [19], and remove
the Staple Position Confirm Gear
[20].
12. Turn the Gear [21] to position the
hole [22] in the Gear of the Staple
Driver to the hole behind.
13. Insert a pin of approx.φ2 [23] (alter-
natively, 2 mm hexagonal wrench or
the like can be preferably used) into
the hole, and fix the Gear.
14. Turn the Gear [24] to position the
hole [25] in the Cam of the Staple
Clincher to the hole behind.
15. Insert a pin of approx.φ2 [26] (alter-
natively, 2 mm hexagonal wrench or
the like can be preferably used) into
the hole, and fix the Cam.
4583fs2507c0
[19]
[20]
[18]
4583fs2508c0
[21]
[22]
4583fs2509c0
[23]
4583fs2510c0
[24]
[25]
[26]
4583fs2511c0
Y104710-1 Service Manual
Page 46
5. Mechanical adjustment Field Service Ver. 1.0 Mar. 2006
38
FS-603
Adjustment / Setting
16. Set the Timing Belt [27] to the Gear
[28] and Gear [29] with the Gear and
the Cam in the fixed condition.
17. Install the Staple Position Confirm
Gear [32] in such a way that the blue
mark [30] of the Gear comes face to
face with the hole [31] in the frame.
NOTE
• The position in which the blue mark
meets face to face with the hole is
the home position for stapling. If
the Staple Jam Release Gear is
turned for some reason, this home
position will shift and the Staple
Cartridge will not come off. In this
case, the Staple Position Confirm
Gear plays a role of resuming the
stapling home position by referring
to the blue mark. Therefore, the
Gear should be set in place correctly.
18. Remove the pin fixing the Gear and
the Cam to release them.
19. Set the spring [33], the spacer [34],
the Staple Jam Release Gear [35],
the Timing Belt [36] and the Middle
Gear 1 [37], and fix them with two ERings [38].
4583fs2512c0
[28]
[29]
[27]
4583fs2513c0
[30]
[31]
[32]
4583fs2514c0
[35]
[38]
[37]
[33]
[34]
[36]
Service Manual Y104710-1
Page 47
Field Service Ver. 1.0 Mar. 2006 5. Mechanical adjustment
39
FS-603Adjustment / Setting
5.6 Saddle Gear Phase Adjustment
• Whenever the Gear in front of the Saddle or the Folding Roller has been replaced or
removed for some reason, make gear phase adjustment following the procedures given
below.
A. Adjustment procedure
1. Remove the Saddle.
☞ 11
2. Remove five screws [1], and
remove the Saddle Gear Cover [2].
3. Set the Folding Roller [3] and Saddle
Cam [4] within the Saddle as shown
in the figure.
4. With the Folding Roller and the Saddle Cam positioned as shown in the
Left figure, set the gears as shown in
the figure in the following way.
NOTE
• The mark on the Saddle Cam Drive
Gear [5] (either of the two marks)
comes face to face with the mark on
the Middle Gear [6] (the mark on the
semi spherical part with narrow
gear face width).
5. With the Saddle Cam Drive Gear [5]
and the Middle Gear [6] positioned
as above, the mark on the Middle
Gear [6] (the mark on the other semi
spherical part) meets face to face
with the rib of the Folding Roller
Drive Gear [7].
4583fs2545c0
[1]
[1]
[2]
[4]
[3]
4583fs2515c0
4583fs2516c0
[5]
[6]
[7]
Y104710-1 Service Manual
Page 48
6. Board switch Field Service Ver. 1.0 Mar. 2006
40
FS-603
Adjustment / Setting
6. Board switch
6.1 PWB-A FN (Finisher Control Board)
Symbol Description
1SW1
Used to adjust the folding position, adjust the center 2-point stapling position
and adjust the alignment plate position.
2 PSW1
Used to adjust the folding position, adjust the center 2-point stapling position
and adjust the alignment plate position.
3 PSW2
Used to adjust the folding position, adjust the center 2-point stapling position
and adjust the alignment plate position.
6
3
5114151 12
1
1
41
5111 112 1 6
17319 1 1 11215
102
CN10CN18CN22
119711114
CN2 CN21 CN9 CN11
CN6CN8
CN13CN3
CN7 CN20 CN5
CN19
CN15
CN16CN12CN17CN14
CN1
CN4
LED2
PSW2
LED1
SW1
PSW1
4583fs3509c0
[1]
[2][3]
Service Manual Y104710-1
Page 49
Field Service Ver. 1.0 Mar. 2006 6. Board switch
41
FS-603Adjustment / Setting
6.1.1 Adjustment of the folding positions
• When a folding position is adjusted, adjust the folding position to the stapling position.
Make this adjustment after replacing the Finisher Control Board or when the folding position must be changed for some reason.
NOTE
• Depending on the type of paper, both the folding position and the stapling position
may be inaccurate. In this case, make adjustment independently from the Finisher.
In this independent adjustment from the Finisher, set the adjustment value of
“Center Stapling Position” and “Folding Position” in the service mode to ± 0 mm
on the main unit.
1. Set SW1 on the Finisher Control
Board as shown on the Left figure.
2. Press PSW1 or PSW2 on the Finisher Control Board for the required
times to adjust the folding position.
One pressing of the switch moves
the folding position by approx. 0.16
mm.
• Press PSW1 to move the folding posi-
tion in the “-” direction.
• Press PSW2 to move the folding posi-
tion in the “+” direction.
• Press PSW1 and PSW2 simulta-
neously to clear the present set adjustment value.
3. After setting the adjustment value of the folding position, set all bits of SW1 on the Finisher Control Board to OFF.
4. Perform the “Booklet Creation” on the main unit, and confirm that the folding position
has been correctly adjusted. If not, redo the adjustment.
ON
123
45678
4583fs3510c0
4583fs3523e0
+ direction
+ direction
- direction
- direction
Y104710-1 Service Manual
Page 50
6. Board switch Field Service Ver. 1.0 Mar. 2006
42
FS-603
Adjustment / Setting
6.1.2 Adjustment of the center stapling position
• When a stapling position is adjusted, adjust the stapling position to the folding position.
Make this adjustment after replacing the Finisher Control Board or when the stapling
position must be changed for some reason.
NOTE
• Depending on the type of paper, both the folding position and the stapling position
may be inaccurate. In this case, make adjustment independently from the Finisher.
In this independent adjustment from the Finisher, set the adjustment value of
“Center Stapling Position” and “Folding Position” in the service mode to ± 0mm
on the main unit.
1. Set SW1 on the Finisher Control
Board as shown on the Left figure.
2. Press PSW1 or PSW2 on the Finisher Control Board for the required
times to adjust the stapling position.
One pressing of the switch moves
the stapling position by approx. 0.14
mm.
• Press PSW1 to move the stapling
position in the “-” direction.
• Press PSW2 to move the stapling
position in the “+” direction.
• Press PSW1 and PSW2 simulta-
neously to clear the present set adjustment value.
3. After setting the adjustment value of the stapling position, set all bits of SW1 on the Finisher Control Board to OFF.
4. Perform the “Booklet Creation” on the main unit, and confirm that the stapling position
has been correctly adjusted. If not, redo the adjustment.
ON
123
45678
4583fs3512c0
4583fs3523e0
+ direction
+ direction
- direction
- direction
Service Manual Y104710-1
Page 51
Field Service Ver. 1.0 Mar. 2006 6. Board switch
43
FS-603Adjustment / Setting
6.1.3 Adjustment of the Alignment Plate position
• Alignment plate should be adjusted when there is a faulty alignment, the staple position
deviates.
A. Alignment procedure
NOTE
• When failing to follow the steps properly, turn main power switch OFF/ON and
repeat the step from Step 1.
1. Turn main power switch OFF, and
remove the Finisher from the
machine.
2. Remove the rear cover form the Finisher.
☞ 7
3. Check to make sure that all SW1 on
the Finisher Controller Board are set
to OFF.
NOTE
• When not all of them are OFF, write
down the switch status and turn
them OFF.
4. With the rear cover of the Finisher
removed, install the Finisher to the
machine, and turn main power
switch ON.
5. When the initial operation of the Finisher is complete, turn on the following switches of SW1.
When adjusting with A4: 3, 5
When adjusting with Letter: 3, 6
6. After the initial operation of the Finisher, press the PSW1 [1] on the Finisher Control Board and make sure
that the alignment plate moves to the
selected paper size area.
7. Adjust the Alignment plate position
with PSW1 [1] or PSW2 [2].
When adjusting inward: Press
PSW1.
When adjusting outward: Press
PSW2.
The alignment plate will move
0.367mm every time the push switch
is pressed.
Alignment range is ± 2.936 mm.
ON
123
45678
4583F3C514DA
ON
123
45678
ON
<A4>
<Letter>
12345678
4583F3C515DA
4583F3C516DA
41 5 1 12
11114
CN2 CN21
CN16CN12CN17
LED2
PSW2
LED1
SW1
PSW1
[1][2]
Y104710-1 Service Manual
Page 52
6. Board switch Field Service Ver. 1.0 Mar. 2006
44
FS-603
Adjustment / Setting
8. When the adjustment is complete,
turn switch 8 of SW1 ON to set the
adjustment value.
9. Turn all adjustment switches OFF.
10. Turn main power switch OFF.
NOTE
• When not all SW1 are OFF in step 3,
return to the original condition
according to the written note.
11. Return the Finisher to the original
status.
ON
123
45678
ON
123
45678
4583F3C517DA
Service Manual Y104710-1
Page 53
Field Service Ver. 1.0 Mar. 2006 6. Board switch
45
FS-603Adjustment / Setting
6.2 PWB-B PK (Punch Control Board)
Symbol Description
1 SW1001 Used to register the number of punched holes and adjust the sensor output.
2 SW1002 Used to register the number of punched holes and adjust the sensor output.
3 SW1003 Used to register the number of punched holes and adjust the sensor output.
SW1001
LED1001
LED1002
LED1003
2
1
1
49
1
J1003
J1004
J1002 J1001 J1006
J1005
J1007
14
SW1002
SW1003
5
11
5
13
1
4583fs3514c0
[1]
[3]
[2]
Y104710-1 Service Manual
Page 54
6. Board switch Field Service Ver. 1.0 Mar. 2006
46
FS-603
Adjustment / Setting
6.2.1 Adjustment of the sensor output
• Be sure to make this adjustment after replacing the Punch Control Board, the Side Registration Sensor (Photosensor Board or LED Board) or the Punch Dust Full Sensor
(Punch Dust Full Sensor Board or Punch Dust Full LED Board).
1. Set the bits 1 through 4 of
DIPSW1001 on the Punch Control
Board as shown on the Left figure.
2. Press SW1002 or SW1003 on the
Punch Control Board. The sensor
output will be automatically adjusted.
• When all LED1001, LED1002 and
LED1003 light up, the adjustment has
been completed.
3. Set all bits of DIPSW1001 to OFF.
6.2.2 Registration of the number of punch holes
• In order for the Finisher to recognize the number of punch holes that can be achieved by
the installed Punch Unit, such number of punch holes is registered in the IC on the
Punch Control Board. Make this registration whenever the Punch Control Board has
been replaced.
• However, this registration is not necessary if the EEP-ROM used on an old board has
been reinstalled to a new board.
1. Set the bits 1 through 4 of
DIPSW1001 on the Punch Control
Board as shown on the Left figure.
2. Press SW1002 on the Punch Control Board to select the number of punch holes.
• Each time SW1002 is pressed, the following display changes in the descending order
shown below:
3. Press SW1003 on the Punch Control Board twice. The number of punch holes will be
registered in the Punch Control Board.
• The pressing of SW1003 changes the steady lighting of the LED to flickering, and the
pressing of SW1003 again changes the flickering of the LED to steady lighting. This completes the registration.
4. Set all bits of DIPSW1001 to OFF.
ON
1234
4583fs3515c0
ON
1234
4583fs3516c0
Number of punch holes
LED
1001
LED
1002
LED
1003
2 (Punch Unit J1) ON OFF OFF
2/3 (Punch Unit K1) ON ON OFF
4 (Punch Unit G1) OFF ON OFF
4 (Punch Unit H1) OFF OFF ON
Service Manual Y104710-1
Page 55
Field Service Ver. 1.0 Mar. 2006 6. Board switch
47
FS-603Adjustment / Setting
6.2.3 Procedure after replacing the EEP-ROM (IC1002)
1. Turn OFF the Main Power Switch of
the main unit.
2. Set the bits 1 through 4 of
DIPSW1001 on the Punch Control
Board as shown on the Left figure.Press SW1002 and SW1003 on
the Punch Control Board simultaneously.
• This will initialize the EEP-ROM. After
the initialization, all LED1001,
LED1002 and LED1003 light up.
3. Adjust the sensor output, and register the number of punch holes.
4. Set all bits of DIP SW 1001 to OFF.
6.2.4 Punch center position adjustment
• This adjustment is made when the Punch lateral movement is changed from the lateral
registration motion (automatic through end face detection) to fixed system based on the
paper size.
1. Turn OFF the Main Power Switch of
the main unit.
2. Remove the Rear Cover.
☞ 2-7
3. Check that all keys of SW1 of the
Finisher Control Board are OFF.
4. Turn ON the Main Power Switch of
the main unit and wait until the Finisher completes its initial operation.
• Use the following procedure to clear
the adjustment of the Punch lateral
movement.
5. Turn ON keys 4, 5, 6, and 7 of SW1
of the Finisher Control Board.
6. Turn ON key 1 of SW1 of the Finisher Control Board.
7. Press PSW1 and PSW2 of the
Finisher Control Board at the same
time.
ON
1234
4583fs3517c0
ON
123
45678
4583fs3523c0
ON
123
45678
4583fs3524c0
ON
123
45678
4583fs3525c0
Y104710-1 Service Manual
Page 56
6. Board switch Field Service Ver. 1.0 Mar. 2006
48
FS-603
Adjustment / Setting
8. Turn OFF key 4 of SW1 of the Finisher Control Board.
9. Wait until the machine becomes
capable of paper feed.
10. Feed one sheet of paper through the
machine. Fold the copy fed out of the
machine in half and check that the
punch holes are aligned with each
other.
Specifications:0 ± 2 mm
• If the specified range is not met, use
the following procedure to adjust the
Punch center position.
11. Press PSW1 or PSW2 of the Finisher Control Board once according
to the direction of deviation.
• Pressing PSW1 moves the punch
position to the front.
• Pressing PSW2 moves the punch
position to the rear.
• Each press of PSW1 or PSW2 moves
the position 1 mm. The adjustment
range should be within ± 5 mm.
12. Feed another sheet of paper. If the
punch hole position is not properly
adjusted, make the adjustment once
again.
• When the adjustment procedure has
been completed, use the following procedure to finish the adjustment mode.
13. Turn OFF key 1 of SW1 of the Finisher Control Board.
14. Turn OFF keys 5, 6, and 7 of SW1 of
the Finisher Control Board.
15. Turn OFF the Main Power Switch of
the main unit.
ON
123
45678
4583fs3526c0
4583fs3529c0
4583fs3528e0
FRONT SIDEREAR SIDE
ON
123
45678
4583fs3527c0
ON
123
45678
4583fs3523c0
Service Manual Y104710-1
Page 57
Field Service Ver. 1.0 Mar. 2006 6. Board switch
49
FS-603Adjustment / Setting
16. Turn ON key 7 of SW1 of the Finisher Control Board.
NOTES
• Flipping ON key 7 of SW1 validates
the setting made to the fixed system based on the paper size as
changed from the lateral registration motion (automatic through end
face detection).
• To return the setting back to the lat-
eral registration motion, flip OFF
key 7 of SW1.
17. Turn ON the Main Power Switch of
the main unit.
18. Reinstall the rear cover.
☞ 2-7
NOTE
• The procedure must be carried out as specified. In particular, switching ON or OFF
must be performed properly.
• If a step or steps are wrongly performed in mid procedure, stop the procedure
immediately. Then, turn OFF and ON the Main Power Switch and start the procedure over.
• This adjustment is applicable only to the punch position center adjustment. The
adjustment range is ± 5 mm. It does not adjust for variations in the punch hole
positions.
ON
123
45678
4583fs3530c0
Y104710-1 Service Manual
Page 58
6. Board switch Field Service Ver. 1.0 Mar. 2006
50
FS-603
Adjustment / Setting
Blank Page
Service Manual Y104710-1
Page 59
Field Service Ver. 1.0 Mar. 2006 7. Jam Display
51
FS-603
Troubleshooting
Troubleshooting
7. Jam Display
7.1 Misfeed display
• When misfeed occurs, message, misfeed location “Blinking” and paper location “Lighting” are displayed on the Touch Panel of the main unit.
7.1.1 Misfeed display resetting procedure
• Open the corresponding door, clear the sheet of paper misfeed, and close the door.
No. Code Misfeed location Misfeed access location Action
[1] 7401 Transport section Front Door
☞ 53
[2] 7403 Horizontal Transport section Horizontal Transport Cover
☞ 54
[3] 7407 Folding Position section Front Door
☞ 54
[4] 7405 Stapler section Front Door
☞ 55
4583F4C501DA
[2]
[1]
[3]
[1]
[4]
Y104710-1 Service Manual
Page 60
7. Jam Display Field Service Ver. 1.0 Mar. 2006
52
FS-603
Troubleshooting
7.2 Sensor layout
[1] Turnover Empty Sensor PC6-HO [3] Folding Position Sensor PI10-FN
[2] Entrance Sensor PI1-FN [4] Staple Drive Home Position Sensor PI19-FN
[3]
[1]
[4]
[2]
4583fs4521c0
Service Manual Y104710-1
Page 61
Field Service Ver. 1.0 Mar. 2006 7. Jam Display
53
FS-603
Troubleshooting
7.3 Solution
7.3.1 Initial check items
• When a paper misfeed occurs, first perform the following initial check items.
7.3.2 Transport section misfeed
A. Detection timing
B. Action
Check item Action
Does paper meet product specifications? Replace paper.
Is the paper curled, wavy, or damp?
Replace paper.
Instruct the user on the correct paper storage
procedures.
Is a foreign object present along the paper path, or is the
paper path deformed or worn?
Clean the paper path and replace if necessary.
Are the Paper Separator Fingers dirty, deformed, or
worn?
Clean or replace the defective Paper Separator Finger.
Are rolls/rollers dirty, deformed, or worn? Clean or replace the defective roll/roller.
Are the Edge Guide and Trailing Edge Stop at the correct position to accommodate the paper?
Set as necessary.
Are the actuators operating correctly? Correct or replace the defective actuator.
Type Description
Transport section
misfeed detection
The Entrance Sensor (PI1-FN) does not detect paper even after the lapse of
approx. 1.5 sec. after the Entrance Sensor (PI1-FN) has received the paper exit
signal from the main unit.
Paper is not removed from the Entrance Sensor (PI1-FN) even after the lapse of
approx. 2 sec. after the Entrance Sensor (PI1-FN) has detected paper edge.
Relevant electrical parts
Entrance Sensor (PI1-FN) Finisher Control Board (PWB-A FN)
Step Action
WIRING DIAGRAM
Control signal
Location
(Electrical compo-
nents)
1 Initial check items — —
2 PI1-FN I/O, sensor check PWB-A FN CN16A FN-11 FS-603 B-8
3 PWB-A FN replacement — —
Y104710-1 Service Manual
Page 62
7. Jam Display Field Service Ver. 1.0 Mar. 2006
54
FS-603
Troubleshooting
7.3.3 Horizontal Transport section misfeed
A. Detection timing
B. Action
7.3.4 Folding position section misfeed
A. Detection timing
B. Action
Type Description
horizontal transport section misfeed detection
The Turnover Empty Sensor (PC6-HO) is not unblocked even after the lapse of a
given period of time after the leading edge of the paper has blocked the Turnover
Empty Sensor (PC6-HO).
Relevant electrical parts
Turnover Empty Sensor (PC6-HO) Finisher Control Board (PWB-A FN)
Step Action
WIRING DIAGRAM
Control signal
Location
(Electrical compo-
nents)
1 Initial check items — —
2 PC6-HO I/O, sensor check PWB-A FN CN21A FN-5 FS-603 G-7
3 PWB-A FN replacement — —
Type Description
Folding position
section misfeed
detection
The Folding Position Sensor (PI10-FN) does not detect paper even after the set
period of time after the paper has been fed from the Transport Booklet Tray to the
stapling position during stapling operation.
Paper is not removed from the Folding Position Sensor (PI10-FN) even after the
lapse of approx. 10.5 sec. after the Staple/Folding Motor (M7-FN) has been driven
during stapling operation.
Relevant electrical parts
Folding Position Sensor (PI10-FN) Finisher Control Board (PWB-A FN)
Step Action
WIRING DIAGRAM
Control signal
Location
(Electrical compo-
nents)
1 Initial check items — —
2 PI10-FN I/O, sensor check PWB-A FN CN16A FN-2 FS-603 8-B
3 PWB-A FN replacement — —
Service Manual Y104710-1
Page 63
Field Service Ver. 1.0 Mar. 2006 7. Jam Display
55
FS-603
Troubleshooting
7.3.5 Stapler section misfeed
A. Detection timing
B. Action
Type Description
Stapler section misfeed detection
The Staple Drive Home Position Sensor (PI19-FN) is not turned OFF or does not
return to its home position even after the set period of time after the stapler has
been driven.
Relevant electrical parts
Staple Drive Home Position Sensor (PI19-FN) Finisher Control Board (PWB-A FN)
Step Action
WIRING DIAGRAM
Control signal
Location
(Electrical compo-
nents)
1 Initial check items — —
2 PI19-FN I/O, sensor check — —
3 PWB-A FN replacement — —
Y104710-1 Service Manual
Page 64
8. Trouble code Field Service Ver. 1.0 Mar. 2006
56
FS-603
Troubleshooting
8. Trouble code
8.1 Trouble code display
• The main unit’s CPU performs a self-diagnostics function that, on detecting a malfunction, gives the corresponding malfunction code on the Touch Panel.
NOTE
• Before starting the troubleshooting in relation to the Punch Mechanism C11CX, be
sure to turn OFF the main power switch of the machine.
8.2 Trouble code list
4583F4E504DA
Code Item Description
C1180 Transport System Drive
malfunctions
• The Folding Roller Home Position Sensor (PI12-FN) is
not unblocked even after the lapse of a given period of
time after the Folding Roller has started moving from its
home position.
• The Folding Roller Home Position Sensor (PI12-FN) is
not blocked even after the lapse of a given period of
time after the Folding Roller has started moving from a
position not the home position.
C1181 Paddle Motor malfunctions • The Paddle Home Position Sensor (PI2-FN) is not
unblocked even after the lapse of a given period of time
after the Paddle has started moving from its home position.
• The Paddle Home Position Sensor (PI2-FN) is not
blocked even after the lapse of a given period of time
after the Paddle has started moving from a position not
the home position.
• The Swing Guide Home Position Sensor (PI3-FN) is
not unblocked even after the lapse of a given period of
time after the Booklet Roller has started moving from
its home position.
• The Swing Guide Home Position Sensor (PI3-FN) is
not blocked even after the lapse of a given period of
time after the Booklet Roller has started moving from a
position not the home position.
Service Manual Y104710-1
Page 65
Field Service Ver. 1.0 Mar. 2006 8. Trouble code
57
FS-603
Troubleshooting
C1183 Elevate Mechanism malfunctions • The Exit Tray Home Position Sensor (PI9-FN) is not
blocked even after the lapse of a given period of time
after the tray has started moving up.
• An encoder clock input is not detected within a given
period of time during operation of the tray.
C1192 Front Aligning Plate Motor mal-
functions
• The Front Aligning Plate Home Position Sensor (PI4FN) is not unblocked even after the lapse of a given
period of time after the Front Aligning Plate has started
moving from its home position to a position out of the
home position.
• The Front Aligning Plate Home Position Sensor (PI4FN) is not blocked even after the lapse of a given period
of time after the Front Aligning Plate has started moving from a position out of the home position to the
home position.
C1193 Rear Aligning Plate Motor mal-
functions
• The Rear Aligning Plate Home Position Sensor (PI5FN) is not unblocked even after the lapse of a given
period of time after the Rear Aligning Plate has started
moving from its home position to a position out of the
home position.
• The Rear Aligning Plate Home Position Sensor (PI5FN) is not blocked even after the lapse of a given period
of time after the Rear Aligning Plate has started moving
from a position out of the home position to the home
position.
C11A4 Booklet Exit Motor malfunctions • The Exit Belt Home Position Sensor (PI7-FN) is not
unblocked even after the lapse of a given period of time
after the Booklet Exit Belt has started moving from its
home position during an initial operation.
• The Exit Belt Home Position Sensor (PI7-FN) is not
unblocked even after the lapse of a given period of time
after the Booklet Exit Belt has started moving from its
home position during an ordinary operation.
• The Exit Belt Home Position Sensor (PI7-FN) is not
blocked even after the lapse of a given period of time
after the Booklet Exit Belt has started moving from a
position not the home position during an initial operation.
• The Exit Belt Home Position Sensor (PI7-FN) is not
blocked even after the lapse of a given period of time
after the Booklet Exit Belt has started moving from a
position not the home position during an ordinary operation.
C11B1 Stapler Unit Slide Motor malfunc-
tions
• The Slide Home Position Sensor (PI18-FN) is not
unblocked even after the lapse of a given period of time
after the Stapler Unit has started moving from its home
position.
• The Slide Home Position Sensor (PI18-FN) is not
blocked even after the lapse of a given period of time
after the Stapler Unit has started moving from a position not the home position.
Code Item Description
Y104710-1 Service Manual
Page 66
8. Trouble code Field Service Ver. 1.0 Mar. 2006
58
FS-603
Troubleshooting
C11B4 Stapler/Folding Motor malfunc-
tions
• The Staple Drive Home Position Sensor (PI19-FN) is
not blocked even after the lapse of a given period of
time after the clinch operation has started.
• An encoder clock input is not detected within a given
period of time during a clinch operation.
• The Folding Home Position Sensor (PI11-FN) is not
blocked even after the lapse of a given period of time
after the Folding Unit has started moving from a position out of the home position during an initial operation.
• The Folding Home Position Sensor (PI11-FN) is not
unblocked even after the lapse of a given period of time
after a folding operation has been started during an
ordinary operation.
• The Folding Home Position Sensor (PI11-FN) is not
blocked even after the lapse of a given period of time
after a folding operation has been started and the sensor has been unblocked during an ordinary operation.
• An encoder clock input is not detected within a given
period of time during a folding operation.
C11C1 Punch Control Board malfunc-
tions
• No response is received to a request made by the Finisher within a given period of time during initial communications.
• No response is received to a request made by the Finisher within a given period of time during ordinary communications.
• There is no match in the checksum values of the
backup data as checked twice.
• The 24 V power source of the Punch Unit is OFF when
an operation request is made from the Finisher.
C11C2 Punch Side Registration Motor
malfunctions
• The Side Registration Home Sensor (PI2P-PK) is not
unblocked even after the lapse of a given period of time
after the Punch Side Registration Unit has started moving from its home position.
• The Side Registration Home Sensor (PI2P-PK) is not
blocked even after the lapse of a given period of time
after the Punch Side Registration Unit has started moving from a position not the home position.
C11C3 Punch Motor malfunctions • The home position is not detected within a given period
of time after the Punch Motor has been rotated a half
turn.
• An encoder clock input is not detected even after the
lapse of a given period of time during operation of the
Punch Motor.
• The setting value calculated during the initial operation
falls outside the threshold value range.
C11C5 Punch Sensor malfunctions • The light receiving voltage is 2.5 V or less when the illu-
minating voltage is set to 4.4 V.
• The light receiving voltage is 2.5 V or more when the
illuminating voltage is set to 0 V.
• The illuminating voltage setting is 4.4 V or more after
the adjustment has been made.
Code Item Description
Service Manual Y104710-1
Page 67
Field Service Ver. 1.0 Mar. 2006 8. Trouble code
59
FS-603
Troubleshooting
NOTE
• The Punch Unit detects punch-related malfunctions and notifies the Finisher of
any malfunction detected.
8.2.1 How to reset
• Open and close the Front Door or turn OFF and ON the Main Power Switch.
C1401 Backup RAM malfunction • Data written in the Backup Memory differs from what is
recorded in it and writing operation is not correctly performed even with two retry sequences (a total of three
writing sequences).
Code Item Description
Y104710-1 Service Manual
Page 68
8. Trouble code Field Service Ver. 1.0 Mar. 2006
60
FS-603
Troubleshooting
8.3 Solution
8.3.1 C1180: Transport System Drive malfunctions
8.3.2 C1181: Paddle Motor malfunctions
Relevant electrical parts
Folding Roller Home Position Sensor (PI12-FN)
Transport Motor (M1-FN)
Finisher Control Board (PWB-A FN)
Step Action
WIRING DIAGRAM
Control signal
Location
(Electrical compo-
nents)
1
Check the motor connectors for proper
connection, and correct as necessary.
——
2
Check the connector of motor for proper
drive coupling, and correct as necessary.
——
3 PI12-FN I/O, sensor check PWB-A FN CN16A FN-9 G-3
4
M1-FN operation check when the Main
Power Switch is turned OFF and ON.
——
5 PWB-A FN replacement — —
Relevant electrical parts
Paddle Home Position Sensor (PI2-FN)
Swing Guide Home Position Sensor (PI3-FN)
Paddle Motor (M2-FN)
Finisher Control Board (PWB-A FN)
Step Action
WIRING DIAGRAM
Control signal
Location
(Electrical compo-
nents)
1
Check the motor and sensor connectors
for proper connection, and correct as
necessary.
——
2
Check the connector of motor for proper
drive coupling, and correct as necessary.
——
3 PI2-FN I/O, sensor check PWB-A FN CN9A FN-2 FS-603 G-8
4 PI3-FN I/O, sensor check PWB-A FN CN9A FN-8 FS-603 G-9
5
M2-FN operation check when the Main
Power Switch is turned OFF and ON.
PWB-A FN CN10A FN-9 to 12 FS-603 B-6
6 PWB-A FN replacement — —
Service Manual Y104710-1
Page 69
Field Service Ver. 1.0 Mar. 2006 8. Trouble code
61
FS-603
Troubleshooting
8.3.3 C1183: Elevate Mechanism malfunctions
(1) Upper Limit Sensor
8.3.4 C1192: Front Aligning Plate Motor malfunctions
Relevant electrical parts
Shift Upper Limit Sensor (PI15-FN) Finisher Control Board (PWB-A FN)
Step Action
WIRING DIAGRAM
Control signal
Location
(Electrical compo-
nents)
1
Check the sensor connectors for proper
connection, and correct as necessary.
——
2 PI15-FN I/O, sensor check PWB-A FN CN15A FN-12 FS-603 G-5
3 PWB-A FN replacement — —
Relevant electrical parts
Front Aligning Plate Home Position Sensor (PI4FN)
Front Aligning Motor (M4-FN)
Finisher Control Board (PWB-A FN)
Step Action
WIRING DIAGRAM
Control signal
Location
(Electrical compo-
nents)
1
Check the motor and sensor connectors
for proper connection, and correct as
necessary.
——
2
Check the connector of motor for proper
drive coupling, and correct as necessary.
——
3 PI4-FN I/O, sensor check PWB-A FN CN4A FN-2 FS-603 G-6
4
M4-FN operation check when the Main
Power Switch is turned OFF and ON.
PWB-A FN CN3A FN-2 to 5 FS-603 B-4
5 PWB-A FN replacement — —
Y104710-1 Service Manual
Page 70
8. Trouble code Field Service Ver. 1.0 Mar. 2006
62
FS-603
Troubleshooting
8.3.5 C1193: Rear Aligning Plate Motor malfunctions
8.3.6 C11A4: Booklet Exit Motor malfunctions
Relevant electrical parts
Rear Aligning Plate Home Position Sensor (PI5FN)
Rear Aligning Motor (M5-FN)
Finisher Control Board (PWB-A FN)
Step Action
WIRING DIAGRAM
Control signal
Location
(Electrical compo-
nents)
1
Check the motor and sensor connectors
for proper connection, and correct as
necessary.
——
2
Check the connector of motor for proper
drive coupling, and correct as necessary.
——
3 PI5-FN I/O, sensor check PWB-A FN CN5A FN-15 FS-603 G-6
4
M5-FN operation check when the Main
Power Switch is turned OFF and ON.
PWB-A FN CN3A FN-7 to 10 FS-603 B-4
5 PWB-A FN replacement — —
Relevant electrical parts
Exit Belt Home Position Sensor (PI7-FN)
Exit Motor (M3-FN)
Finisher Control Board (PWB-A FN)
Step Action
WIRING DIAGRAM
Control signal
Location
(Electrical compo-
nents)
1
Check the motor and sensor connectors
for proper connection, and correct as
necessary.
——
2
Check the connector of motor for proper
drive coupling, and correct as necessary.
——
3 PI7-FN I/O, sensor check PWB-A FN CN5 FN-6 FS-603 G-5
4
M3-FN operation check when the Main
Power Switch is turned OFF and ON.
PWB-A FN CN13A FN-3 to 6 FS-603 B-4
5 PWB-A FN replacement — —
Service Manual Y104710-1
Page 71
Field Service Ver. 1.0 Mar. 2006 8. Trouble code
63
FS-603
Troubleshooting
8.3.7 C11B1: Stapler Unit Slide Motor malfunctions
8.3.8 C11B4: Stapler/Folding Motor malfunctions
(1) Wiring
Relevant electrical parts
Slide Home Position Sensor (PI18-FN)
Slide Motor (M8-FN)
Finisher Control Board (PWB-A FN)
Step Action
WIRING DIAGRAM
Control signal
Location
(Electrical compo-
nents)
1
Check the motor and sensor connectors
for proper connection, and correct as
necessary.
——
2
Check the connector of motor for proper
drive coupling, and correct as necessary.
——
3 PI18-FN I/O, sensor check PWB-A FN CN11A FN-3 FS-603 B to C-5
4
M8-FN operation check when the Main
Power Switch is turned OFF and ON.
PWB-A FN CN7A FN-3 to 6 FS-603 B-5
5 PWB-A FN replacement — —
Relevant electrical parts
Staple Drive Home Position Sensor (PI19-FN)
Staple/Folding Motor (M7-FN)
Finisher Control Board (PWB-A FN)
Step Action
WIRING DIAGRAM
Control signal
Location
(Electrical compo-
nents)
1
Check the motor connectors for proper
connection, and correct as necessary.
——
2
Check the connector of motor for proper
drive coupling, and correct as necessary.
——
3 PI19-FN I/O, sensor check — —
4
M7-FN operation check when the Main
Power Switch is turned OFF and ON.
PWB-A FN CN6A FN-3 to 4 FS-603 B-3
5 PWB-A FN replacement — —
Y104710-1 Service Manual
Page 72
8. Trouble code Field Service Ver. 1.0 Mar. 2006
64
FS-603
Troubleshooting
(2) Stapler/Crease Clock Sensor (Stapler Section)
(3) Home Position Sensor
Relevant electrical parts
Staple/Folding Motor Clock Sensor (PI14-FN)
Staple/Folding Motor (M7-FN)
Finisher Control Board (PWB-A FN)
Step Action
WIRING DIAGRAM
Control signal
Location
(Electrical compo-
nents)
1
Check the motor and sensor connectors
for proper connection, and correct as
necessary.
——
2
Check the connector of motor for proper
drive coupling, and correct as necessary.
——
3 PI14-FN I/O, sensor check PWB-A FN CN9A FN-5 FS-603 G-8
4
M7-FN operation check when the Main
Power Switch is turned OFF and ON.
PWB-A FN CN6A FN-3 to 4 FS-603 B-3
5 PWB-A FN replacement — —
Relevant electrical parts
Folding Home Position Sensor (PI11-FN)
Staple/Folding Motor (M7-FN)
Finisher Control Board (PWB-A FN)
Step Action
WIRING DIAGRAM
Control signal
Location
(Electrical compo-
nents)
1
Check the motor and sensor connectors
for proper connection, and correct as
necessary.
——
2
Check the connector of motor for proper
drive coupling, and correct as necessary.
——
3 PI11-FN I/O, sensor check PWB-A FN CN16A FN-6 FS-603 B-8
4
M7-FN operation check when the Main
Power Switch is turned OFF and ON.
PWB-A FN CN6A FN-3 to 4 FS-603 B-3
5 PWB-A FN replacement — —
Service Manual Y104710-1
Page 73
Field Service Ver. 1.0 Mar. 2006 8. Trouble code
65
FS-603
Troubleshooting
(4) Stapler/Crease Clock Sensor (Saddle Section)
8.3.9 C11C1: Punch Control Board malfunctions
Relevant electrical parts
Staple/Folding Motor Clock Sensor (PI14-FN)
Staple/Folding Motor (M7-FN)
Finisher Control Board (PWB-A FN)
Step Action
WIRING DIAGRAM
Control signal
Location
(Electrical compo-
nents)
1
Check the motor and sensor connectors
for proper connection, and correct as
necessary.
——
2
Check the connector of motor for proper
drive coupling, and correct as necessary.
——
3 PI14-FN I/O, sensor check PWB-A FN CN9A FN-5 FS-603 G-8
4
M7-FN operation check when the Main
Power Switch is turned OFF and ON.
PWB-A FN CN6A FN-3 to 4 FS-603 B-3
5 PWB-A FN replacement — —
Relevant electrical parts
Finisher Control Board (PWB-A FN)
Punch Control Board (PWB-B PK)
Step Action
WIRING DIAGRAM
Control signal
Location
(Electrical compo-
nents)
1 Turn OFF and ON the main switch. — —
2
Check the connection condition between
the Punch Unit and PWB-A FN.
——
3
Measure the voltage between CN14-5
(+) and CN14-3 (-) of the PWB-A FN. Is
the voltage 24VDC?
——
4 Initialize Punch Unit EEP-ROM. — —
5 PWB-B PK replacement — —
6 PWB-A FN replacement — —
Y104710-1 Service Manual
Page 74
8. Trouble code Field Service Ver. 1.0 Mar. 2006
66
FS-603
Troubleshooting
8.3.10 C11C2: Punch Side Registration Motor malfunctions
8.3.11 C11C3: Punch Motor malfunctions
Relevant electrical parts
Side Registration Home Sensor (PI2P-PK) Punch Control Board (PWB-B PK)
Step Action
WIRING DIAGRAM
Control signal
Location
(Electrical compo-
nents)
1
Check the sensor connectors for proper
connection, and correct as necessary.
——
2 PI2P-PK I/O, sensor check PWB-B PK J1006B PK-3 FS-603 H-2
3 PWB-B PK replacement — —
Relevant electrical parts
Punch Home Position Sensor (PI1P-PK)
Punch Motor Clock Sensor (PI3P-PK)
Punch Motor (M1P-PK)
Punch Control Board (PWB-B PK)
Step Action
WIRING DIAGRAM
Control signal
Location
(Electrical compo-
nents)
1
Check the motor and sensor connectors
for proper connection, and correct as
necessary.
——
2
Check the connector of motor for proper
drive coupling, and correct as necessary.
——
3 PI1P-PK I/O, sensor check PWB-B PK J1006B PK-6 FS-603 H-2
4 PI3P-PK I/O, sensor check PWB-B PK J1006B PK-9 FS-603 H-2
5
M1P-PK operation check when the Main
Power Switch is turned OFF and ON.
PWB-B PK J1002B PK-1 to 2 FS-603 H-1 to 2
6 PWB-B PK replacement — —
Service Manual Y104710-1
Page 75
Field Service Ver. 1.0 Mar. 2006 8. Trouble code
67
FS-603
Troubleshooting
8.3.12 C11C5: Punch Sensor malfunctions
(1) Side Registration Sensor
(2) Wastes Full Sensor
Relevant electrical parts
Side Registration Home Sensor (PI2P-PK) Punch Control Board (PWB-B PK)
Step Action
WIRING DIAGRAM
Control signal
Location
(Electrical compo-
nents)
1
Check the sensor connectors for proper
connection, and correct as necessary.
——
2 PI2P-PK I/O, sensor check PWB-B PK J1006B PK-3 FS-603 H-2
3 PWB-B PK replacement — —
Relevant electrical parts
Punch Control Board (PWB-B PK)
Punch Trash Full Photo Sensor Board (PWB-E PK)
Punch Trash Full LED Board (PWB-F PK)
Step Action
WIRING DIAGRAM
Control signal
Location
(Electrical compo-
nents)
1
Check the connection condition between
PWB-B PK and PWB-E PK.
——
2
Check the connection condition between
PWB-B PK and PWB-F PK.
——
3 PWB-E PK replacement — —
4 PWB-F PK replacement — —
5 PWB-B PK replacement — —
Y104710-1 Service Manual
Page 76
8. Trouble code Field Service Ver. 1.0 Mar. 2006
68
FS-603
Troubleshooting
(3) Finisher Control Board
8.3.13 C1401: Backup RAM malfunction
Relevant electrical parts
Exit Tray Home Position Sensor (PI9-FN)
Shift Motor Clock Sensor (PI17-FN)
Shift Motor (M6-FN)
Finisher Control Board (PWB-A FN)
Step Action
WIRING DIAGRAM
Control signal
Location
(Electrical compo-
nents)
1
Check the motor and sensor connectors
for proper connection, and correct as
necessary.
——
2
Check the connector of motor for proper
drive coupling, and correct as necessary.
——
3 PI9-FN I/O sensor check PWB-A FN CN5A FN-12 FS-603 G-6
4 PI17-FN I/O sensor check PWB-A FN CN15A FN-6 FS-603 G-4
5
M6-FN operation check when the Main
Power Switch is turned OFF and ON.
PWB-A FN CN6A FN-1 to 2 FS-603 B-3
6 PWB-A FN replacement — —
Relevant electrical parts
Finisher Control Board (PWB-A FN)
Step Action
WIRING DIAGRAM
Control signal
Location
(Electrical compo-
nents)
1
Disconnect and then connect the power
cord to turn OFF and ON the main
switch.
——
2
Check the connectors for proper connection on the PWB-A FN.
——
3 PWB-A FN replacement — —
Service Manual Y104710-1
Page 77
UPDATING STATUS
DATE UPDATED PAGES PAGES CODE
03/2006 1
ST
EDITION 77 Y104710-1
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