Xerox Fuji Finisher D2/D2P/D3/D4 Supplementary Service Manual

Service Manual Xerox Fuji Finisher D2/D2P/D3/D4 Supplementary
This manual is in the PDF format and have detailed Diagrams, pictures and full procedures to diagnose and repair your Xerox Fuji.
You can print, zoom or read any diagram, picture or page from this manual. Every chapter on this manual is fully detailed and contain all the simulation codes, trouble codes, maintenance procedures, reset procedures, diagnose procedures of Xerox Fuji Finisher D2/D2P/D3/D4 Supplementary Service Manual.
Table of contents:

Introduction
0.1 Getting to Know the Service Manual
0.2 How to Use the Service Manual
0.3 Description for Terminology And Symbols

Chapter 1. Service Call Procedure
1.1 Before Starting the Servicing

Chapter 2. Troubleshooting

Chapter 4 Disassembly/Assembly and Adjustments
4.1 Preface
4.1 Preface
4.2 Disassembly/Assembly
25. Finisher-D2/D2P/D3/D4
REP 25.1.1 I/F Module
REP 25.1.2 Detaching of the Folder (with I/F Module)
REP 25.1.3 Punch Unit
REP 25.1.4 Staple
REP 25.1.5 Detaching of the Finisher
REP 25.1.6 Staple Dust Box Sensor, Staple Dust Box Full Sensor
REP 25.2.1 Eject Unit
REP 25.2.2 Compile Unit
REP 25.2.3 Lower Exit Chute
REP 25.2.4 Manual Decurler Swith (D4 Type)
REP 25.3.1 Finisher PWB
REP 25.5.1 Belt (Finisher Transport Motor)
REP 25.5.2 Knob
REP 25.6.1 Belt (Compile Exit Motor)
REP 25.7.1 Transport Gate Solenoid
REP 25.13.1 D4/D3/D2 Type-Sponge Roll
REP 25.13.2 D2P Type-Sponge Roll 1/2
REP 25.24.1 Stapler Head
REP 25.28.1 Compile Main Paddle (with Shaft)
REP 25.28.2 Compile Main Paddle (Single Paddle)
REP 25.31.1 Compile Sub Paddle
REP 25.34.1 Opening / Closing of Stacker Unit
REP 25.34.2 Cam (Set Clamp Solenoid)
REP 25.36.1 Stacker Tray Assembly
REP 25.41.1 Booklet Drawer Unit
REP 25.43.1 Paddle Shaft Assembly
REP 25.51.1 Interposer Unit
REP 25.53.1 Feed Roll, Nudger Roll
REP 25.55.1 Retard Roll
REP 25.62.1 Folder 1 Roll
REP 25.64.1 End Guide 1 Assembly
REP 25.66.1 Folder 2 Roll
REP 25.67.1 End Guide 2 Assembly
REP 25.81.1 Finisher Top Cover
REP 25.81.2 I/F Module Side Cover and I/F Module Front Door (D4 Type)
45. Trimmer and Square Fold
REP 45.1.1 Separating the Trimmer and Square Fold
REP 45.2.1 Front Upper Cover
REP 45.2.2 Front Lower Cover
REP 45.3.1 Trimmer Control Panel PWB
REP 45.4.1 Rear Cover
REP 45.4.2 Exit Cover
REP 45.5.1 Opening/Closing the Top Right Cover and Top Left Cover
REP 45.5.2 Top Left Cover
REP 45.5.3 Top Right Cover
REP 45.10.1 Belt Transport Assembly
REP 45.11.1 Upper Belt Assemlby
REP 45.11.2 Lower Belt Assembly
REP 45.13.1 Belt (Upper Belt Assembly)
REP 45.16.1 Belt (Lower Belt Assembly)
REP 45.19.1 Square Fold Nip Motor
REP 45.19.2 Clamper Upper Plate
REP 45.19.3 Connector Bracket
REP 45.20.1 Press Roll
REP 45.21.1 Harness Bracket
REP 45.21.2 Square Exit Upper Roll
REP 45.21.3 Square Exit Lower Roll
REP 45.25.1 Square Fold Gate
REP 45.27.1 Trimmer Move Transport Assembly
REP 45.29.1 Trimmer Roll Unit
REP 45.32.1 Belt Bottom Bracket
REP 45.34.1 Trimmer Cutter
REP 45.35.1 Trimmer PWB
99. (SCC) Safety Critical Components
REP 99.1.1 (SCC) Safety Critical Components
4.3 Adjustment
25. Finisher-D2/D2P/D3/D4
ADJ 25.3.1 Booklet Fold Position/Staple Position Adjustment (DC128)
ADJ 25.3.2 C Tri-Fold (C Fold) Position Adjustment (DC128)
ADJ 25.3.3 Z Fold / Z Tri-Fold Position Adjustment (DC128)
ADJ 25.21.1 Punch Side Regi Adjustment
ADJ 25.21.2 Punch Hole Position Change Procedure (12mm to 10mm)
ADJ 25.24.1 Staple Skew/Lead Position Adjustment of the Dual Staple
ADJ 25.24.2 Staple Position Adjustment of the Single Rear Staple
ADJ 25.24.3 Staple Position Adjustment of the Center Staple
ADJ 25.51.1 Interposer Paper Width Adjustment
45. Trimmer and Square Fold
ADJ 45.1.1 Checking Trimmer and Square Fold Paper Handling
ADJ 45.26.1 Adjusting the Position of the Stopper Plate (Parallel Adjustment)

Chapter 5. Parts List
5.1 Introduction
5.1.1 How to Use the Parts List
5.1.2 Precautions
5.1.3 Plate Composition
5.1.4 Terminology and Symbols
5.1.5 Using Parts Navigation
5.2 Parts List
25. Finisher-D2/D2P/D3/D4
PL 25.1 Finisher Base Component-1 (I/F Module, Punch, Staple)
PL 25.2 Finisher Base Component-2 (Eject, Compile)
PL 25.3 Finisher Main PWB
PL 25.4 LVPS, Inlet
PL 25.5 Finisher Transport Motor, Roll
PL 25.6 Compile Exit Motor, Roll
PL 25.7 SCT Exit Motor, Roll, Gate
PL 25.8 Entrance Roll, Chute
PL 25.9 Booklet Chute
PL 25.10 Exit Chute
PL 25.11a D4/D3/D2-I/F Module Component-1 (PWB)
PL 25.11b D2P-I/F Module Component-1 (PWB)
PL 25.12a D2/D3/D4-I/F Module Component-2 (Chute)
PL 25.12b D2P-I/F Module Component-2 (Chute)
PL 25.13a D2/D3/D4-I/F Module Component-3 (Decurler)
PL 25.13b D2P-I/F Module Component-3 (Decurler)
PL 25.14a D2/D3/D4- I/F Module Component-4 (Transport)
PL 25.14b D2P-I/F Module Component-4 (Transport)
PL 25.21 Punch Component-1 (Upper)
PL 25.22 Punch Component-2 (Right)
PL 25.23 Punch Component-3 (Left)
PL 25.24 Staple Component
PL 25.25 Compile Component-1 (Tamper)
PL 25.26 Compile Component-2 (End Wall)
PL 25.27 Compile Component-3 (Sensor)
PL 25.28 Lower Exit Chute Component
PL 25.31 Eject Component-1 (Sub Paddle)
PL 25.32 Eject Component-2 (Feed Roll)
PL 25.33 Eject Component-3 (Motor)
PL 25.34 Stacker Component-1 (Offset)
PL 25.35 Stacker Component-2 (Elevator)
PL 25.36 Stacker Component-3 (Tray-1)
PL 25.37 Stacker Component-4 (Tray-2)
PL 25.38 Stacker Component-5 (Sensor, Booklet)
PL 25.41 Booklet Accessory
PL 25.42 Booklet Component-1 (Stapler)
PL 25.43 Booklet Component-2 (End Guide)
PL 25.44 Booklet Component-3 (Knife)
PL 25.45 Booklet Component-4 (Tamper)
PL 25.46 Booklet Component-5 (Roll)
PL 25.47 Booklet Component-6 (Chute)
PL 25.48 Booklet Component-7 (Motor)
PL 25.49 Booklet Tray Component
PL 25.51 Interposer Accessory
PL 25.52 Interposer Component-1 (Upper)
PL 25.53 Interposer Component-2 (Feed/Nudger)
PL 25.54 Interposer Component-3 (Up/Down)
PL 25.55 Interposer Component-4 (Feed Motor)
PL 25.56 Interposer Component-5 (Tray)
PL 25.61 Folder Component-1 (Upper)
PL 25.62 Folder Component-2 (Middle-Roll)
PL 25.63 Folder Component-3 (Middle-Chute1)
PL 25.64 Folder Component-4 (Middle-Chute2)
PL 25.65 Folder Component-5 (Lower-Chute)
PL 25.66 Folder Component-6 (Lower-Roll)
PL 25.67 Folder Component-7 (End Guide2, Tray)
PL 25.68 Folder Component-8 (PWB, Cover)
PL 25.69 End Guide1
PL 25.70 End Guide2
PL 25.81 Cover-1 (Front, Top)
PL 25.82 Cover-2 (Rear, Right)
45. Trimmer and Square Fold
PL 45.1 Trimmer and Square Fold
PL 45.2 Front Cover , Dust Box
PL 45.3 Trimmer Control Panel
PL 45.4 Rear Cover , Exit Cover
PL 45.5 Top Cover
PL 45.6 Cover Lock Bracket , Top Cover Interlock Switch
PL 45.7 Top Left Cover Component
PL 45.8 Top Right Cover Component
PL 45.9 Cover Lock Bracket Component
PL 45.10 Belt Transport Assembly
PL 45.11 Upper / Lower Belt Assembly
PL 45.12 Belt Transport Drive
PL 45.13 Upper Belt Assembly -1
PL 45.14 Upper Belt Assembly -2
PL 45.15 Upper Belt Assembly -3
PL 45.16 Lower Belt Assembly -1
PL 45.17 Lower Belt Assembly -2
PL 45.18 Lower Belt Assembly -3
PL 45.19 Clamper Upper Plate , Square Fold Nip Motor
PL 45.20 Clamper Lower Plate , Press Roll , Square Fold Roll Move Motor
PL 45.21 Square Exit Roll , Square Fold Exit Nip Motor
PL 45.22 Square Fold Exit Nip Motor Component
PL 45.23 Square Exit Chute Component
PL 45.24 Dust Sensor /Interlock Switch
PL 45.25 Square Fold Gate , Square Fold Gate Move Motor
PL 45.26 Square Fold Gate Component
PL 45.27 Trimmer Move Transport Assembly , Square Fold Exit Motor
PL 45.28 Trimmer Move Transport Component -1
PL 45.29 Trimmer Move Transport Component -2
PL 45.30 Trimmer Roll Unit Component -1
PL 45.31 Trimmer Roll Unit Component -2
PL 45.32 Bottom Plate Component
PL 45.33 Belt Bottom Bracket Component
PL 45.34 Trimmer Cutter
PL 45.35 Trimmer PWB , LVPS
PL 45.36 Wire Harness
PL 45.37 Clamp -1
PL 45.38 Clamp -2
98. Screws
98.1 Screws
99. Adjustment/Consumables Area Code List
99.1 Paper
99.2 Consumables
99.3 Electrical Adjustments
5.3 Parts Navigation
Navi 1.1 Finisher-D2/D2P/D3/D4
Navi 1.2 Trimmer and Square Fold
Navi 2.1 Staple Finisher-D2/D2P/D3/D4
Navi 2.2 Booklet Finisher-D2/D2P/D3/D4
Navi 2.3 Folder-D2/D2P/D3/D4
Navi 2.4 I/F Module-D2P

Chapter 6. General
6.1.1 DC330 InputComponent Check List
6.1.1.1 DC330 Input Component Check List
6.1.1.2 DC330 Input Component Check List (Trimmer)
6.1.2 DC330 Output Component Check List
6.1.2.1 DC330 Output Component Check List
6.1.2.2 DC330 Output Component Check List (Trimmer)
6.1.3 DC140 Analog Monitor Code List
6.1.3 DC140 Analog Monitor Code List
6.1.4 DC135 HFSI Counters List
6.1.4 DC135 HFSI Counters List
6.1.5 DC131 Finisher-D2/D3/D4 NVM List (763)
6.1.5.1 DC131 Finisher D2/D2P/D3/D4 NVM List (763)
6.1.5.2 DC131 Finisher-D4 NVM List (763:Trimmer)
6.1.6 DC726 Paper Path Timing Measurement List
6.1.6.1 DC726 Paper Path Timing Measurement List (Finisher-D2:AP-II/DC-II 7000G,AP-IV/DC-IV 7080G)
6.1.6.2 DC726 Paper Path Timing Measurement List (Finisher-D3/D4:4127G/4112G)
6.1.6.3 DC726 Paper Path Timing Measurement List (Finisher D4:700DCP)
6.1.6.4 DC726 Paper Path Timing Measurement List (Finisher- D2P: AP/DC-IV C7780G)
6.2 Specifications
6.2.1 Product Name/Product Code/Serial No
6.2.2 Machine Dimension and Basis Weight
6.2.3 Installation Space (Minimum Floor Space: mm)
6.2.4 Electrical Specification
6.2.5 Specifications of Finisher/Booklet Finisher-D2/D2P/D3/D4, Trimmer/Square Fold
6.2.5.1 Overview
6.2.5.2 Basic Configuration
6.2.5.3 Paper Weight
6.2.5.3.1 Paper Weight (Finisher-D2/D3/D4: AP-II/DC-II 7000G, 4127/4112G, AP-IV/DC-IV 7080G)91
6.2.5.3.2 Paper Weight (Finisher-D4:700DCP, Color 1000/800 Press)
6.2.5.3.3 Stapling Capacity (Finisher-D4:700DCP, Color1000/800 Press)
6.2.5.3.4 Booklet Stapling Capacity (Finisher-D4:700DCP, Color1000/800 Press)
6.2.5.3.5 Paper Weight (Finisher D2P: AP-IV/DC-IV C7780G)
6.2.5.3.6 Stapling Capacity (Finisher D2P: AP-IV/DC-IV C7780G)
6.2.5.3.7 Booklet Stapling Capacity (Finisher D2P: AP-IV/DC-IV C7780G)
6.2.5.4 Applicable Paper Size
6.2.5.5 Output Stack Capacity
6.2.5.6 Other Finisher Processes
6.2.5.7 Staple Position
6.2.5.8 Staple Position (Booklet)
6.2.5.9 Hole Punch Position
6.2.5.10 Folding Precision
6.2.5.11 Inflated Folding Specification
6.2.5.12 Paper Offset Function
6.2.5.13 Paper Curl
6.2.5.14 Paper for Trimmer/Square Fold
6.2.5.15 Basis Weight of Paper for Trimmer/Square Fold
6.2.5.16 Paper Size for Trimmer/Square Fold
6.2.5.17 Trimmer/Square Fold Output Paper Stacking Capacity
6.2.5.18 Trimmer/Square Fold Square Fold/Trimming Operation
6.2.5.19 Trimmer/Square Fold Trimming Precision
6.2.6 Plinth Kit
6.2.6.1 Things to Take Note When Using the Plinth Kit
6.2.6.2 Bundled Accessories
6.2.6.3 Machine Configuration and Plinth Kit Combination
6.2.6.4 Relationship Between Plinth Kit and Installation Space
6.3 Consumables
6.3 Consumables

Chapter 7. Wiring Data
7.1 Plug/Jack Location List
7.1 Plug/Jack Location List
7.1.25 Finisher-D2/D3/D4 Plug/Jack Location List
7.1.25.1 Finisher-D2/D3/D4 Plug/Jack Location List
7.1.25.2 Finisher-D2/D3/D4 Plug/Jack Positions
7.1.26 List of Finisher-D2P Wiring Connectors
7.1.26.1 List of Finisher-D2P Wiring Connectors
7.1.26.2 Finisher-D2P Wiring Connector Position
7.1.45 Trimmer and Square Fold Plug/Jack Location List
7.1.45.1 Trimmer and Square Fold Plug/Jack Location List
7.1.45.2 Trimmer and Square Fold Plug/Jack Positions

Chapter 9. Install
9.1 Finisher D2/Booklet Finisher D2 Installation
9.1.1 Installation of Finisher D2 / Booklet Finisher D2 (AP-II / DC-II 7000G) (1 of 3)
9.1.2 Installation of Finisher D2 / Booklet Finisher D2 (AP-II / DC-II 7000G) (2 of 3)
9.1.3 Installation of Finisher D2 / Booklet Finisher D2 (AP-II / DC-II 7000G) (3 of 3)
9.1.4 Installation of Booklet Finisher D2P (AP-IV/DC-IV C7780G)
9.1.5 Installation of Finisher D2/Center-binding Finisher D2 (AP-IV/DC-IV 7080G)
9.2 Installation of Folder D2
9.2.1 Installation of Folder D2 (AP-II/DC-II 7000G,AP-III/DC-III 7000G) (1 of 6)
9.2.2 Installation of Folder D2 (AP-II/DC-II 7000G,AP-III/DC-III 7000G) (2 of 6)
9.2.3 Installation of Folder D2 (AP-II/DC-II 7000G,AP-III/DC-III 7000G) (3 of 6)
9.2.4 Installation of Folder D2 (AP-II/DC-II 7000G,AP-III/DC-III 7000G) (4 of 6)
9.2.5 Installation of Folder D2 (AP-II/DC-II 7000G,AP-III/DC-III 7000G) (5 of 6)
9.2.6 Installation of Folder D2 (AP-II/DC-II 7000G,AP-III/DC-III 7000G) (6 of 6)
9.2.7 Installation of Folder Unit D2 (AP-IV/DC-IV C7780G)
9.2.8 Installation of Folder Unit D2 (AP-IV/DC-IV 7080G)
9.3 Installation of 3 Holes Puncher Unit
9.4 Finisher D3/Booklet Finisher D3 Installation
9.4.1 Installation of Finisher D3 / Booklet Finisher D3 (4127/4112G) (1 of 3)
9.4.2 Installation of Finisher D3 / Booklet Finisher D3 (4127/4112G) (2 of 3)
9.4.3 Installation of Finisher D3 / Booklet Finisher D3 (4127/4112G) (3 of 3)
9.5 Installation of Folder D3
9.5.1 Installation of Folder D3 (1 of 6)
9.5.2 Installation of Folder D3 (2 of 6)
9.5.3 Installation of Folder D3 (3 of 6)
9.5.4 Installation of Folder D3 (4 of 6)
9.5.5 Installation of Folder D3 (5 of 6)
9.5.6 Installation of Folder D3 (6 of 6)
9.6 Finisher D4/Booklet Finisher D4 Installation
9.6.1 Installation of Finisher D4 / Booklet Finisher D4 (4127/4112G) (1 of 3)
9.6.2 Installation of Finisher D4 / Booklet Finisher D4 (4127/4112G) (2 of 3)
9.6.3 Installation of Finisher D4 / Booklet Finisher D4 (4127/4112G) (3 of 3)
9.6.4 Installation of Finisher D4 / Center-binding Finisher D4 (700DCP, Color 1000/800 Press) (1 of 2)112
9.6.5 Installation of Finisher D4/Center-binding Finisher D4 (700DCP, Color 1000/800 Press) (2 of 2)116
9.7 Installation of Folder D4
9.7.1 Installation of Folder D4 (4127/4112G) (1 of 6)
9.7.2 Installation of Folder D4 (4127/4112G) (2 of 6)
9.7.3 Installation of Folder D4 (4127/4112G) (3 of 6)
9.7.4 Installation of Folder D4 (4127/4112G) (4 of 6)
9.7.5 Installation of Folder D4 (4127/4112G) (5 of 6)
9.7.6 Installation of Folder D4 (4127/4112G) (6 of 6)
9.7.7 Installation of Folder Unit D4 (700DCP, Color 1000/800 Press) (1 of 5)
9.7.8 Installation of Folder Unit D4 (700DCP, Color 1000/800 Press) (2 of 5)
9.7.9 Installation of Folder Unit D4 (700DCP, Color 1000/800 Press) (3 of 5)
9.7.10 Installation of Folder Unit D4 (700DCP, Color 1000/800 Press) (4 of 5)
9.7.11 Installation of Folder Unit D4 (700DCP, Color 1000/800 Press) (5 of 5)
9.8 Installation of Trimmer/Square Fold
9.8.1 Installation of Trimmer/Square Fold (4127/4112G, 700DCP, Color 1000/800 Press)(1 of 2)
9.8.2 Installation of Trimmer/Square Fold (4127/4112G, 700DCP, Color 1000/800 Press)(2 of 2)