Kyocera Mita DF-75 User manual

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

CAUTION
DANGER OF EXPLOSION IF BATTERY IS INCORRECTLY REPLACED. REPLACE ONLY WITH
THE SAME OR EQUIVALENT TYPE RECOMMENDED BY THE MANUFACTURER. DISPOSE OF
USED BATTERIES ACCORDING TO THE MANUFACTURER’S INSTRUCTIONS.
ATTENTION
IL Y A DANGER D’EXPLOSION S’IL Y A REMPLACEMENT INCORRECT DE LA BATTERIE.
REMPLACER UNIQUEMENT AVEC UNE BATTERIE DU MÊME TYPE OU D’UN TYPE REC-
OMMANDÉ PAR LE CONSTRUCTEUR. METTRE AU RÉBUT LES BATTERIES USAGÉES
CONFORMÉMENT AUX INSTRUCTIONS DU FABRICANT.

Safety precautions
This booklet provides safety warnings and precautions for our service personnel to ensure the safety of
their customers, their machines as well as themselves during maintenance activities. Service personnel
are advised to read this booklet carefully to familiarize themselves with the warnings and precautions
described here before engaging in maintenance activities.

indicates that action is required. The specific action required is shown inside the symbol.
General action required.
Remove the power plug from the wall outlet.
Always ground the copier.
Safety warnings and precautions
Various symbols are used to protect our service personnel and customers from physical danger and
to prevent damage to their property. These symbols are described below:
DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect
compliance with warning messages using this symbol.
WARNING:Serious bodily injury or death may result from insufficient attention to or incorrect compliance
with warning messages using this symbol.
CAUTION: Bodily injury or damage to property may result from insufficient attention to or incorrect
compliance with warning messages using this symbol.
Symbols
The triangle ( ) symbol indicates a warning including danger and caution. The specific point
of attention is shown inside the symbol.
General warning.
Warning of risk of electric shock.
Warning of high temperature.
indicates a prohibited action. The specific prohibition is shown inside the symbol.
General prohibited action.
Disassembly prohibited.

1. Installation Precautions
WARNING
• Do not use a power supply with a voltage other than that specified. Avoid multiple connections to
one outlet: they may cause fire or electric shock. When using an extension cable, always check
that it is adequate for the rated current. ............................................................................................
• Connect the ground wire to a suitable grounding point. Not grounding the copier may cause fire or
electric shock. Connecting the earth wire to an object not approved for the purpose may cause
explosion or electric shock. Never connect the ground cable to any of the following: gas pipes,
lightning rods, ground cables for telephone lines and water pipes or faucets not approved by the
proper authorities. .............................................................................................................................
CAUTION:
•Do not place the copier on an infirm or angled surface: the copier may tip over, causing injury. .....
•Do not install the copier in a humid or dusty place. This may cause fire or electric shock. ..............
•Do not install the copier near a radiator, heater, other heat source or near flammable material.
This may cause fire. ..........................................................................................................................
•Allow sufficient space around the copier to allow the ventilation grills to keep the machine as cool
as possible. Insufficient ventilation may cause heat buildup and poor copying performance. ..........
•Always handle the machine by the correct locations when moving it. ..............................................
•Always use anti-toppling and locking devices on copiers so equipped. Failure to do this may
cause the copier to move unexpectedly or topple, leading to injury..................................................
•Avoid inhaling toner or developer excessively. Protect the eyes. If toner or developer is
accidentally ingested, drink a lot of water to dilute it in the stomach and obtain medical attention
immediately. If it gets into the eyes, rinse immediately with copious amounts of water and obtain
medical attention. ..............................................................................................................................
•Advice customers that they must always follow the safety warnings and precautions in the copier’s
instruction handbook. ........................................................................................................................

•Check that the power cable covering is free of damage. Check that the power plug is dust-free. If
it is dirty, clean it to remove the risk of fire or electric shock. ............................................................
•Never attempt to disassemble the optical unit in machines using lasers. Leaking laser light may
damage eyesight. ..............................................................................................................................
•Handle the charger sections with care. They are charged to high potentials and may cause
electric shock if handled improperly. .................................................................................................
CAUTION
•Wear safe clothing. If wearing loose clothing or accessories such as ties, make sure they are
safely secured so they will not be caught in rotating sections...........................................................
•Use utmost caution when working on a powered machine. Keep away from chains and belts. .......
•Handle the fixing section with care to avoid burns as it can be extremely hot. .................................
•Check that the fixing unit thermistor, heat and press rollers are clean. Dirt on them can cause
abnormally high temperatures...........................................................................................................
•Do not remove the ozone filter, if any, from the copier except for routine replacement. ...................
2. Precautions for Maintenance
WARNING
•Always remove the power plug from the wall outlet before starting machine disassembly...............
•Always follow the procedures for maintenance described in the service manual and other related
brochures. .........................................................................................................................................
•Under no circumstances attempt to bypass or disable safety features including safety
mechanisms and protective circuits. .................................................................................................
•Always use parts having the correct specifications. ..........................................................................
•Always use the thermostat or thermal fuse specified in the service manual or other related
brochure when replacing them. Using a piece of wire, for example, could lead to fire or other
serious accident. ...............................................................................................................................
•When the service manual or other serious brochure specifies a distance or gap for installation of a
part, always use the correct scale and measure carefully. ...............................................................
•Always check that the copier is correctly connected to an outlet with a ground connection. ............

•Do not pull on the AC power cord or connector wires on high-voltage components when removing
them; always hold the plug itself. ......................................................................................................
•Do not route the power cable where it may be stood on or trapped. If necessary, protect it with a
cable cover or other appropriate item. ..............................................................................................
•Treat the ends of the wire carefully when installing a new charger wire to avoid electric leaks........
•Remove toner completely from electronic components. ...................................................................
•Run wire harnesses carefully so that wires will not be trapped or damaged. ...................................
•After maintenance, always check that all the parts, screws, connectors and wires that were
removed, have been refitted correctly. Special attention should be paid to any forgotten
connector, trapped wire and missing screws. ..................................................................................
•Check that all the caution labels that should be present on the machine according to the
instruction handbook are clean and not peeling. Replace with new ones if necessary. ...................
•Handle greases and solvents with care by following the instructions below: ....................................
·Use only a small amount of solvent at a time, being careful not to spill. Wipe spills off completely.
·Ventilate the room well while using grease or solvents.
·Allow applied solvents to evaporate completely before refitting the covers or turning the main
switch on.
·Always wash hands afterwards.
•Never dispose of toner or toner bottles in fire. Toner may cause sparks when exposed directly to
fire in a furnace, etc...........................................................................................................................
•Should smoke be seen coming from the copier, remove the power plug from the wall outlet
immediately. ......................................................................................................................................
3. Miscellaneous
WARNING
•Never attempt to heat the drum or expose it to any organic solvents such as alcohol, other than
the specified refiner; it may generate toxic gas. ................................................................................

CONTENTS
Contents
CHAPTER 1 GENERAL DESCRIPTION
1 Basic Operations ................................. 2-1
1.1 Specifications ............................. 2-1
1.2 Outline of the Electrical
Circuitry ..................................... 2-2
1.3 Inputs to and Outputs from the
Finisher Controller PCB ............. 2-3
1.3.1 Inputs to the Finisher Controller
PCB (1/2) ............................. 2-3
1.3.2 Inputs to the Finisher Controller
PCB (2/2) ............................. 2-4
1.3.3 Outputs from the Finisher Con-
troller PCB (1/2) .................. 2-5
1.3.4 Outputs from the Finisher Con-
troller PCB (2/2) .................. 2-6
1.3.5 Inputs to and Outputs from the
Finisher Controller ............... 2-7
1.4 Inputs to and Outputs from the
Punch Controller PCB (option) .. 2-8
1.4.1 Inputs to and Outputs from the
Punch Controller PCB ......... 2-8
1.4.2 Outputs from the Punch Con-
troller PCB ........................... 2-9
2 Feed/Drive System ............................ 2-10
2.1 Outline ...................................... 2-10
2.1.1 Normal Delivery ................ 2-11
2.2 Feed/Delivery ........................... 2-15
2.2.1 Outline ............................... 2-15
2.3 Job Offset ................................. 2-18
2.3.1 Outline ............................... 2-18
2.3.2 Processing Tray Paper Stacking
Operation ........................... 2-20
2.3.3 Offset Operation ................ 2-21
2.3.4 Stack Delivery Operation ... 2-22
3 Stapling Operation............................. 2-23
3.1 Outline ...................................... 2-23
3.2 Stapling Operation .................... 2-25
3.3 Delivery Operation after
Stapling .................................... 2-27
3.4 Stapler Unit .............................. 2-29
3.4.1 Stapler Movement
Controller ........................... 2-31
4 Delivery Tray Operation.................... 2-35
4.1 Outline ...................................... 2-35
5 Saddle Unit........................................ 2-37
5.1 Basic Operations ...................... 2-37
5.1.1 Outline ............................... 2-37
5.2 Feed/Drive System ................... 2-38
5.2.1 Outline ............................... 2-38
5.3 Paper Feed System ................... 2-43
5.3.1 Outline ............................... 2-43
5.4 Stack Feed System ................... 2-44
5.4.1 Outline ............................... 2-44
5.5 Fold/Delivery System ............... 2-45
5.5.1 Outline ............................... 2-45
5.5.2 Paper Folding ..................... 2-46
6 Puncher Unit (option)........................ 2-49
6.1 Basic Operations ...................... 2-49
6.1.1 Outline ............................... 2-49
1 Features ............................................... 1-1
2 Specifications ...................................... 1-2
2.1 Specifications ............................. 1-2
2.1.1 Finisher/SaddleAssembly .... 1-2
2.1.2 Puncher unit (option) ........... 1-6
3 Names of Parts .................................... 1-8
CHAPTER 2 OUTLINE OF OPERATION
3.1 Cross Section ............................. 1-8
3.1.1 Finisher Unit ........................ 1-8
3.1.2 Saddle Unit .......................... 1-9
3.1.3 Puncher Unit (option) ........ 1-10
4 Routine Maintenance by the User...... 1-11

CONTENTS
1 Finisher/Saddle Unit............................ 3-1
1.1 Externals and Controls ............... 3-1
1.1.1 Removing the Delivery Tray 3-1
1.1.2 Removing the Front Cover ... 3-2
1.1.3 Removing the Rear Cover .... 3-3
1.1.4 Removing the Upper Cover . 3-3
1.1.5 Removing the Processing Tray
Upper Cover ........................ 3-4
1.1.6 Removing the Upper Right
Cover Assembly ................... 3-5
1.1.7 Removing the Saddle Guide . 3-6
1.2 Feeding System .......................... 3-7
1.2.1 Removing the Stapler Unit ... 3-7
1.2.2 Adjusting the Stapler Phase . 3-8
1.2.3 Adjusting the Phase of the Gear
in the Saddle Unit ............... 3-13
1.2.4 Removing the Saddle Unit . 3-14
1.2.5 Removing the Processing
TrayAssembly ................... 3-16
1.2.6 Removing the Paddle
Assembly ........................... 3-18
1.2.7 Removing the Staple/Fold
Drive Unit .......................... 3-20
1.2.8 Removing the Feed Motor
Unit .................................... 3-24
1.2.9 Removing the Feed Roller .. 3-24
CHAPTER 3 MECHANICAL SYSTEMS
1.2.10 Removing the Stack delivery
roller (upper) ...................... 3-26
1.2.11 Removing the Paddle ......... 3-28
1.2.12 Removing the Stack delivery
roller (lower)/Delivery Belt 3-30
1.3 PCBs ........................................ 3-32
1.3.1 Removing the Finisher
Controller PCB .................. 3-32
1.3.2 Removing the Slide Home
Position PCB ..................... 3-33
2 Puncher Unit (option)........................ 3-35
2.1 Puncher Driving System .......... 3-35
2.1.1 Removing the Punch Motor 3-35
2.1.2 Removing the Horizontal
Registration Motor ............. 3-35
2.1.3 Removing the Punch Unit .. 3-36
2.2 PCBs ........................................ 3-38
2.2.1 Removing the Punch Controller
PCB ................................... 3-38
2.2.2 Removing the Photosensor
PCB ................................... 3-39
2.2.3 Removing the LED PCB .... 3-40
2.2.4 Removing the Waste-Full
Photosensor PCB ............... 3-41
2.2.5 Removing the Waste Full
LED PCB ........................... 3-42
6.2 Punching Operation .................. 2-50
6.2.1 Outline ............................... 2-50
6.2.2 Punching Operation ........... 2-52
6.2.3 Horizontal Registration Opera-
tion ..................................... 2-57
7 Detecting Jams .................................. 2-60
7.1 Outline ...................................... 2-60
7.1.1 Inlet Sensor Delay Jam
(J80) ................................... 2-61
7.1.2 Inlet Sensor Stationary Jam
(J81) ................................... 2-61
7.1.3 Folding Position Sensor Delay
Jam (J83) ........................... 2-61
7.1.4 Folding Position Sensor
Stationary Jam (J84) .......... 2-62
7.1.5 Power-On Jam (J87) .......... 2-62
7.1.6 Door Open Jam (paper present)
(J88) ................................... 2-62
7.1.7 Staple Jam (J86) ................. 2-62
8 Power Supply System ....................... 2-63
8.1 Finisher/SaddleAssembly ........ 2-63
8.1.1 Outline ............................... 2-63
8.1.2 Protective Mechanisms ...... 2-63
8.2 Puncher Unit (option) ............... 2-64
8.2.1 Outline ............................... 2-64
8.2.2 Protective Mechanisms ...... 2-64

CONTENTS
1 Periodically Replaced Parts ................. 4-1
1.1 Finisher/Saddle Unit ................... 4-1
1.2 Puncher Unit (option) ................. 4-1
CHAPTER 4 MAINTENANCE AND INSPECTION
2 Consumables and Durables ................. 4-2
2.1 Saddle/Finisher Unit ................... 4-2
3 Scheduled Maintenance ....................... 4-2
1 Standards andAdjustments ................. 5-1
1.1 ElectricalSystem
(finisher/saddle unit) ................... 5-1
1.1.1 Adjusting the Folding
Position ................................ 5-1
1.1.2 Adjusting the Middle 2-Point
Stapling Position .................. 5-3
1.2 ElectricalSystem
(puncher unit; option) ................. 5-4
1.2.1 Adjusting the Punch Hole
Position ................................ 5-4
1.2.2 Adjusting the Sensor Output 5-4
1.2.3 Registering the Number of
Punch Hole .......................... 5-5
1.2.4 After Replacing the EEP-ROM
(IC1002) .............................. 5-6
2 Arrangement of Electric Components.. 5-8
2.1 Finisher/Saddle Unit ................... 5-8
2.1.1 Sensors, Microswitches, and
Clutch ................................... 5-8
2.1.2 Motor PCBs ....................... 5-10
2.2 Puncher Unit (option) ............... 5-12
2.2.1 Sensors .............................. 5-12
2.2.2 Motors ............................... 5-13
2.2.3 PCBs.................................. 5-14
3 LEDs and Check Pins by PCB.......... 5-15
3.1 Finisher Controller PCB ........... 5-15
3.2 Punch Controller PCB .............. 5-16
4 Troubleshooting ................................ 5-17
4.1 Troubleshooting
(finisher/saddle unit) ................. 5-17
4.1.1 C0440, communication
error ................................... 5-17
CHAPTER 5TROUBLESHOOTING
4.1.2 C8390, Finisher Unit Back-Up
Memory Fault
(detail code: 10) .................. 5-17
4.1.3 C8010, Feed Motor Fault (detail
code: 01/02) ....................... 5-18
4.1.4 C8300, Delivery Motor Fault
(detail code: 01/02) ............. 5-18
4.1.5 C8320,Alignment Motor (Rear)
Fault (detail code: 01/02) .... 5-19
4.1.6 C8340, Staple/fold Motor Fault
(detail code: 01/02) ............. 5-19
4.1.7 C8340, Staple/Fold Motor Fault
(detail code: 03) .................. 5-20
4.1.8 C8340, Staple/Fold Motor Fault
(detail code: 01/02) ............. 5-20
4.1.9 C8340, Staple/Fold Motor Fault
(detail code: 03) .................. 5-21
4.1.10 C8360, Slide Motor Fault
(detail code: 01/02) ............. 5-21
4.1.11 C8330,Alignment Motor (front)
Fault (detail code: 01/02) .... 5-22
4.1.12 C8140, Shift Motor Fault (detail
code: 01) ............................ 5-22
4.1.13 C8140, Shift Motor Fault
(detail code: 02) .................. 5-23
4.1.14 C8140, Shift Motor Fault
(detail code: 03) .................. 5-23
4.1.15 C8370, Paddle Motor Fault
(detail code: 01/02/03/04) ... 5-24
4.2 Troubleshooting (puncher unit,
option) ...................................... 5-25
4.2.1 C8430, Communication
Faulty ................................. 5-25