Hedman DI-100 User manual

198552HF 4/00
HEDMAN
DI-100
Document Imprinter
Service Manual

DI-100 Document Imprinter
Service Manual
4/00 i
TABLE OF CONTENTS
1. INTRODUCTION ..............................................................................................1
1.1 WHAT’S EXPECTED OF THE TECHNICIAN .............................................................. 1
1.2 SERVICE LEVEL .................................................................................................1
1.3 ADDITIONAL SERVICE SUPPORT..........................................................................1
1.4 SAFETY TERMS .................................................................................................2
1.5 SAFETY PRECAUTIONS.......................................................................................3
1.6 FREQUENTLY-USED TERMS................................................................................4
1.7 REPACKING INSTRUCTIONS ................................................................................5
2. SPECIFICATIONS & REQUIREMENTS...........................................................6
2.1 PHYSICAL SPECIFICATIONS.................................................................................6
2.2 ELECTRICAL REQUIREMENTS..............................................................................6
2.3 OPERATING REQUIREMENTS...............................................................................7
2.4 NECESSARY TOOLS ...........................................................................................7
3. OPERATION.....................................................................................................8
3.1 DI-100 DESCRIPTION ........................................................................................8
3.2 SEQUENCE OF OPERATION.................................................................................8
3.3 OPERATING INSTRUCTION ................................................................................10
3.4 OPERATING TIPS .............................................................................................12
3.4.1 ENDORSING SMALL DOCUMENTS ...............................................................................12
3.4.2 CALCULATING PIECES FED PER MINUTE ...................................................................12
3.4.3 FINDING A NON-IMPRINTED DOCUMENT....................................................................12
3.4.4 FEEDING VARIOUS SIZED DOCUMENTS .....................................................................13
4. POWER CONNECTION .................................................................................14
4.1 SAFETY .......................................................................................................... 14
4.2 LINE VOLTAGE ................................................................................................14
4.3 LINE FUSES ....................................................................................................16
4.4 POWER CORD .................................................................................................17
5. MAINTENANCE .............................................................................................18
5.1 CLEANING....................................................................................................... 18
5.2 ADJUSTING BELT TENSION ...............................................................................19
5.3 REPLACING A FUSE......................................................................................... 20
6. TROUBLESHOOTING ...................................................................................22
6.1 OPERATION TROUBLESHOOTING .......................................................................22
6.2 MECHANICAL TROUBLESHOOTING .....................................................................23
6.3 ELECTRICAL TROUBLESHOOTING ......................................................................24

DI-100 Document Imprinter
Service Manual
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7. PROCEDURES............................................................................................... 25
7.1 BASE..............................................................................................................25
7.2 CIRCUIT CARD ................................................................................................28
7.3 CONTROL PANEL .............................................................................................29
7.4 COUNTER .......................................................................................................30
7.5 DOCUMENT DETECTOR .................................................................................... 31
7.5.1 TESTING THE DETECTOR..............................................................................................31
7.5.2 OPTIMIZING THE DETECTOR POSITION......................................................................32
7.5.3 REPLACING THE DETECTOR ........................................................................................33
7.6 DOCUMENT EMITTER .......................................................................................34
7.7 FEED MOTOR ..................................................................................................35
7.8 FEED ROLLS ...................................................................................................38
7.9 FEED TIMING BELT........................................................................................... 40
7.10 FOAM ROLLS................................................................................................. 42
7.11 FUSES ..........................................................................................................43
7.12 MEDIA FEED SWITCH .....................................................................................44
7.13 PADDLE WHEEL ............................................................................................45
7.14 PAPER GUIDES.............................................................................................. 48
7.15 PLATEN GAP (WIDENING)...............................................................................50
7.16 POWER ENTRY CASING ..................................................................................51
7.17 POWER SWITCH ............................................................................................52
7.18 SEPARATORS ................................................................................................54
7.19 SIGNATURE MOTOR .......................................................................................56
7.20 SIGNATURE TIMING BELT................................................................................58
7.21 TIMING BELT .................................................................................................58
7.22 TRANSFORMER..............................................................................................62
8. SYSTEM DIAGRAM .......................................................................................63
9. ILLUSTRATED PARTS GUIDE...................................................................... 64

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1. INTRODUCTION
1.1 What’s
Expected of
the Technician
This service manual assumes the Service Technician is
skilled at installing and operating the DI-100.
1.2 Service Level
This service manual contains procedures which will:
1. Identify faulty or worn parts and assemblies.
2. Provide procedures for the removal and replacement of
faulty or worn parts and assemblies.
Every effort has been made to include accurate and
complete servicing instructions. Both HEDMAN and the
manufacturer assume the availability of experienced
personnel who are familiar with servicing machines.
Although the procedures contained in this service manual
present the manufacturer’s recommended methods for
testing and repairing the DI-100, certain servicing
techniques may be implied.
1.3 Additional
Service Support
Before servicing the DI-100, read the Operating Manual. If
you need additional support, contact the Customer Service
Center of The HEDMAN Company at [phone].
Please be prepared to state your name, company and serial
number of the machine.

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1.4 Safety Terms
The following highlighted blocks are used throughout this
guide to emphasize important information. Pay very
careful attention to this information.
WARNING
USED TO ALERT YOU TO ACTIONS OR
CONDITIONS WHICH MAY PRESENT HAZARDS
OR CAUSE INJURY TO PERSONNEL.
CAUTION
USED TO ALERT YOU TO ACTIONS WHICH MAY
DAMAGE DOCUMENTS OR EQUIPMENT.
NOTE
Used to identify unusual or unexpected
conditions or to point out the need for alternate
procedures. A NOTE may also be used for
emphasis when a WARNING or CAUTION are not
required.
TIP
A suggestion to enhance the DI-100’s
productivity.

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1.5 Safety
Precautions
Observe the following safety precautions and warnings at
all times while operating, cleaning, servicing or repairing
the DI-100. Failure to so may result in physical injury or
damage to the DI-100. Neither HEDMAN nor the
manufacturer assumes any liability for your failure to
comply with these requirements.
WARNING
READ ALL WARNINGS AND CAUTIONS.
WARNING
ONLY QUALIFIED PERSONNEL SHOULD
PERFORM SERVICE AND REPAIRS.
WARNING
NEVER CLEAN, CLEAR OR DISASSEMBLE THE
DI-100 WITHOUT FIRST UNPLUGGING THE
POWER CORD.
WARNING
KEEP LOOSE CLOTHING, TIES, SCARVES AND
HAIR AWAY FROM ALL MOVING PARTS.
WARNING
DO NOT PLACE FINGERS BETWEEN OR NEAR
MOVING PARTS.

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1.6 Frequently-
Used Terms
leading edge The edge of the document that
enters and exits the DI-100 first.
trailing edge The edge of the document that
enters and exits the DI-100 last.
imprint position The point at which the document
is imprinted.
imprint saddle Contains a plastic relief of the
imprint; 2 imprint saddles are in
the rounded imprint saddle
holder - as one is imprinting, the
other is being inked.
operator side The side of the DI-100 where
most of the controls are located.
input end The end of the DI-100 where the
document enters the DI-100.
output end The end of the DI-100 where the
document exits the DI-100.

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1.7 Repacking
Instructions
If it is necessary to return the DI-100 to HEDMAN, pack it
in the original shipping container and material. If the
original container is not available, the DI-100 and its
accessories should be carefully packed so that they will not
be damaged in transit.
NOTE
If the DI-100 is packed correctly, your Shipping
Carrier is liable for any shipping damage.
Use the following instructions to pack the DI-100 with
commercially available materials.
1. Double wrap the machine in plastic.
2. Use a heavy duty, double-walled container of 350-
pound test material.
3. Surround the DI-100 on ALL sides with at least 4 to 5
inches of shock absorbing packaging material. This will
provide firm cushioning and prevent movement inside
the container.
4. Seal the top and bottom of the shipping container with
strong tape or banding.
5. Clearly and legibly mark the shipping container
FRAGILE.
6. Ship the DI-100 prepaid and insured.

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2. SPECIFICATIONS & REQUIREMENTS
2.1 Physical
Specifications
Size
19½" (49.53 cm) W x 10" (25.43 cm) H x
19" (48.26 cm) D
The receiving tray is not measured.
Weight
Machine alone: 50 pounds (22.68 kg )
Shipping weight: 57 pounds (25.85 kg)
Speed
19"(45.72 cm) per second
2.2 Electrical
Requirements
CAUTION
ONLY OPERATE THE DI-100 ON A GROUNDED
POWER LINE TO AVOID MICRO-PROCESSOR
DAMAGE CAUSED BY POWER SURGES.
Power
The DI-100 is rated for continuous operation using a
variety of supply voltages. Possible line voltages are
240V, 220V, 120V and 100V at 50-60 Hz

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2.3 Operating
Requirements
Document Size
Maximum length: 14" (35.56 cm)
Minimum length: 31/8" (10.92 cm)
Maximum width: 14" (35.56 cm)
Minimum width: 27/8" (7.3 cm)
Weight: 20# - 125# stock
Range of Imprint Placement
Approximately 9" (22.86 cm) from the leading edge
toward the trailing edge.
Approximately 6½" (16.51 cm) left or right from the
center of the document.
Range of Accuracy
±1/8"
2.4 Necessary
Tools
• hex key - 1/8"
• hex key - 3/16"
• hex key - 5/64"
• wrench - 9/16"
• holt driver - size 6
• holt driver - size 10
• screw driver - or similar tool
• pliers
• ring puller
• super glue
• V-O-M