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SERVICE MANUAL
MODEL: LX-200/LX-900/LX-910D
REVISED EDITION May, 2000
Unauthorized copying of all or part of the contents of this manual is prohibited.
The contents of this manual may change without notice.
INTRODUCTION
This Service Manual describes the Cool Laminator LX-200/900/910D specifications, operating principles of the mechanisms, disassembly and reassembly procedures, and maintenance and troubleshooting procedures.
This Service Manual is intended for use by trained technicians. It is not intended for use by the user.
The manual is divided into the following chapters.
Chapter 3. Disassembly Procedures
Chapter 4. Reassembly Procedures
Chapter 5. Electronic Controllers
Appendix Main PCB Circuit Diagram
Chapter 1.
SPECIFICATIONS
CONTENTS
Chapter 1. SPECIFICATIONS
1-i
1.1 Mechanical Specifications
1.1.1 Appearance
[1] External dimensions (W x D x H) 357 mm x 293 mm x 195 mm
[2] Mass Approx. 4.6 kg (main unit only)
357 mm
195 mm
293 mm
Fig. 1.1-1 Appearance
1.1.2 Operating Panel
[1] Number of Keys 5 ( Power switch, Cut key, Feed key,
Start/Stop button, Cutting mode selector)
[2] Key Arrangement
Power switch
Cut key (Horizontal)
Feed key
Start/Stop button
Cutting mode selector
Fig. 1.1-2 Key Arrangement
1-1
1.1.3 Indicators
[1] Positions Start/Stop button LED indicators (red, green, orange)
1.2 Electrical Specifications
1.2.1 Power Supply
[1] Power supply Commercial power supply (locally available power supply).
Converted to DC by the AC adaptor.
1-2
Chapter 2.
MECHANISMS
CONTENTS
Chapter 2. MECHANISMS
i
2.1 Mechanical Operating Principles
2.1.1 Description of Mechanisms (Border Mode)
1. When a document is inserted into the paper loading gate, the paper feed rollers feed it to the driving roller.
2. As the document passes between the paper feed rollers, the paper size detector determines its size (length and width).
3. When the document passes between the film cartridges it is sandwiched between the upper and lower films in the compression-feed area, where the films and document are compressed between the driving roller and sub-roller.
4. The compressed document and film is fed to the cutting area, where it is cut to the document size detected by the paper size detector with borders added. It is then transported to the next stage.
5. The laminated document is fed out of the eject gate by the paper eject rollers.
Roll film (upper)
Paper loading gate Paper feed sub-roller
Film cartridge
Paper length detector
Sub-roller
Y-cutter blade
X-cutter unit
Paper eject roller
Eject gate
Paper loading area
Paper feed roller
Paper width detector
Paper eject sub-roller
Roll film (lower) Driving roller
Compression-feed area
Ejecting area
Cutting area
Fig. 2.1-1 Description of Mechanisms
2-1
2.1.2 Feed and Compression Mechanisms
The feed and compression mechanism controls the motor drive to feed the document into the film cartridge, compression-feed the films, and eject the laminated document.
When no compression-feed is applied while feeding a document into the film cartridge or ejecting a laminated document, the LF motor rotates clockwise and the motor drive is transmitted via gears to the paper feed roller and paper eject roller.
At this time, the planet gear (A) is free from the drive gear (A), such that the drive is not transmitted to the driving roller.
During compression-feeding of the films, LF motor rotates counterclockwise to move the planet gear (A) against the drive gear (A), such that the drive from the LF motor is transmitted to the driving roller.
Also, planet gear (B) moves against the drive gear (B) and planet gear (C) moves against the drive gear (C), such that the LF motor drive continues to be transmitted to the paper feed roller and paper eject roller, without changing the direction of roller rotation.
•
Operation when Feeding Document into the Film Cartridge or when Ejecting a
Laminated Document
1. When the LF motor rotates clockwise (as indicated by the arrow in the diagram), the drive is transmitted via a series of gears to drive the paper feed roller and paper eject roller in the directions indicated by the arrows. At this time, planet gear (A) is free, such that no drive is transmitted to drive gear (A) and the driving roller does not rotate.
2. The document is fed into the film cartridge when the paper feed roller rotates in the direction indicated by the arrow.
3. The laminated document is ejected from the eject gate when the paper eject roller rotates in the direction indicated by the arrow.
Driving roller Paper eject roller
Paper feed roller
Drive gear (A)
Planet gear (C)
Drive gear (C)
Drive gear (B)
Planet gear (B)
Planet gear (A) LF motor gear
Fig. 2.1-2 Operation when Feeding Document into the Film Cartridge or when Ejecting a Laminated Document
2-2
•
Operation During Film Compression-Feed
1. When the leading edge of the document enters the compression-feed area, LF motor starts to rotate counterclockwise, as indicated by the arrow.
2. Planet gear (A), which had been free, moves to engage with drive gear (A). The drive from the LF motor is then transmitted to the various gears, as shown in the diagram, and the driving roller rotates as indicated by the arrow. Also, planet gear (B) moves against the drive gear (B) and planet gear (C) moves against the drive gear (C), such that the LF motor drive continues to be transmitted to the paper feed roller and paper eject roller, without changing the direction of roller rotation.
3. The rotation of the driving roller is transmitted to the sub-roller. These rollers feed the films and press them against the document. At this time, the rotations of the paper feed roller and paper eject roller continue uninterrupted.
4. When the trailing edge of the document leaves the compression-feed area and the X-cutters finish cutting the film, the LF motor reverses to rotate counterclockwise. Planet gear (A) again becomes free such that the driving roller rotation stops and feeding of the films also stops.
Driving roller Paper eject roller
Sub-roller
Paper feed roller
Drive gear (A)
Planet gear (C)
LF motor gear
Planet gear (B)
Drive gear (B)
Planet gear (A)
Fig. 2.1-3 Operation During Film Compression-Feed
Drive gear (C)
2-3
2.1.3 Cutter Mechanism (Border Mode)
The cutter mechanism cuts the laminated document to the size of the document plus an added border. Both edges of the films are cut to suit the width of the document and the leading edge and trailing edge are cut according to the document length.
•
Y-Cutter Vertical Drive Operation
1. The TC motor rotates clockwise from its reference position to drive the cam clockwise via a series of gears. The cam rotates the Y-diversion lever clockwise about its pivot. (All rotations indicated by arrows. )
When the Y-diversion lever reaches its maximum displacement position with the cam at approximately its 180
°
‹ rotated position, rotation of the TC motor pauses.
2. When the Y-diversion lever reaches its maximum displacement position, its movement lowers the two Y-cutter blades from the standby position to the cutting position, where they start cutting the edges of the laminated film.
3. When the Y-axis cutters reach the trailing edge cutting position, the TC motor starts rotating again and stops when it reaches its reference position. This rotation returns the cam and Y-diversion lever to their original positions and the cutters move to their standby positions.
Pivot
Y-cutter blade
Standby position
Film
Film surface
Cutting position
Y-diversion lever
Cam (hatched area)
Planet gear
Idle gear 3
Idle gear 2
Idle gear 1
TC motor gear
Fig. 2.1-4 Y-Cutter Vertical Drive Operation
TC motor
2-4
•
Cutting Leading and Trailing Edges (X-cutter Mechanism)
1. All the rollers which feed the document stop when the cut position at the leading edge of the document reaches the cutting position of the rotary cutter and fixedblade cutter.
2. The DC motor rotates to drive the carriage in the X-cutter assembly via the spiral mechanism (not illustrated).
3. As the carriage makes a reciprocal movement, the rotary cutter attached to the carriage moves against the fixed cutter to cut the compressed leading edge of the document.
4. The rotation of the rollers which feed the document restarts when the cutting of the leading edge is complete. Then, when the cut position at the trailing edge of the document reaches the cutting position of the rotary cutter and fixed-blade cutter, the feed rollers stop again.
5. The document trailing edge is cut in the same way as the leading edge, by a reciprocal movement of the rotary cutter attached to the carriage.
6. The rotation of the rollers restarts to feed the laminated document from the eject gate after the cutting of the trailing edge is complete.
Rotary cutter Document
Frame
Sub-roller
X-cutter
Driving roller
DC motor
Section A-A’
Document
DC motor
Paper eject sub-roller
Paper eject roller
Frame
Rotary cutter
Carriage
Sub-roller
Driving roller
Paper eject roller
Paper eject sub-roller
Fixed cutter
Fig. 2.1-5 Cutting Leading and Trailing Edges (X-cutter Mechanism)
2-5
2.1.4 Paper Size Detector Mechanism
•
Paper Length Detection
1. When the leading edge of the document passes between the paper feed rollers, it rotates the paper sensor crank about the pivot to turn on the paper sensor which detects the document leading edge.
2. When the trailing edge of the document passes out of the paper feed rollers, the paper sensor crank reverts to its original position to turn off the paper sensor to detect the document trailing edge.
Document feed surface
ON
Paper sensor
OFF
Pivot
Paper sensor crank
Fig. 2.1-6 Paper Length Detection
Paper feed sub-roller
Paper feed roller
2-6
•
Paper Width Detection
1. The Y-cutter arm L (sensor unit) moves in the direction of the arrow. When the
PL detect lever touches the document, it rotates about the pivot to switch off the photosensor.
2. When the photosensor turns off, the Y-cutter arm L movement stops and this position is detected as the document width.
Y-cutter arm L
Sensor unit
Document
Photosensor
PL detect lever
Pivot
Part of the PL detect lever that touches the document.
* Photosensor ON status
* Photosensor OFF status
Fig. 2.1-7 Paper Width Detection
2-7
2.1.5 Trimming Mechanism
1. When a corner of the laminated document is inserted over the T-cutter plate, the sensor lever operates a leaf switch that detects the document.
2. When the document is detected, the motor gear of TC motor rotates in the direction of the arrow (counterclockwise) from its reference position to drive the T-cam gear in the direction indicated by the arrow (clockwise) via a series of gears.
3. Rotation of the T-cam gear forces the T-cam roller to make a vertical movement, such that T-lever1 moves vertically, rotating around its pivot.
4. As T-lever 1 moves vertically, the T-cutter mounted on the end of T-lever 1 moves up and down, trimming the corner of the laminated document into a rounded radius.
T-sensor lever
Leaf switch
Laminated document
T-cutter
Pivot
Idle gear 2
Planet gear
Idle gear 3
T-lever 1
T-cam roller
T-cutter plate
TC motor
Motor gear
Idle gear 1
Fig. 2.1-8 Trimming Mechanism
T-cam gear
2-8
Chapter 3.
DISASSEMBLY PROCEDURES
CONTENTS
Chapter 3. DISASSEMBLY PROCEDURES
i
ii
3.1 Safety Precautions
When conducting disassembly operations, place the unit on a grounded anti-static sheet. LSI and other electronic components are sensitive to static electricity and may be damaged if touched while charged.
Before transporting a circuit board, wrap it in a conducting sheet such as aluminum foil.
When using a soldering iron or other heat-producing tool, ensure that heat does not damage wires, circuit boards, or plastic parts such as covers.
Take care not to lose small screws or washers removed when replacing parts.
3.2 Removing the Film Cartridge
1.Open the top cover and move the Y-cutter arm L as far as possible to the left.
2.Push the lock lever R in the direction indicated by the arrow to unlock the roller holder assy.
Top cover
Lock lever R
Y-cutter arm L
Fig. 3.2-1 Removing the Film Cartridge 1
3-1
3.Lift up the roller holder assy and pull out the film cartridge.
Roller holder assy
Film cartridge
Fig. 3.2-2 Removing the Film Cartridge 2
3.3 Covers
3.3.1 Removing the Trimmer Upper Cover
1.Pull out the T-cutter plate and the trimmer bottom cover.
T-cutter plate Trimmer bottom cover
Fig. 3.3-1 Removing the Trimmer Cover 1
3-2
2.Set the unit on its side with the trimmer cover uppermost.
Remove the two trimmer cover screws. Remove the trimmer upper cover.
Trimmer upper cover
Trimmer cover screws
Fig. 3.3-2 Removing the Trimmer Upper Cover 2
3.3.2 Removing the Top Cover
Open the top cover. Lift the top cover shafts out of the shaft recesses in the body cover and remove the cover.
Top cover
Shaft recesses
Body cover
Fig. 3.3-3 Removing the Top Cover
Shafts
3-3
3.3.3 Removing the Sub-tray
1.Open the sub-tray.
2.Flex the center of the sub-tray toward you to release the shafts from the shaft recesses in the body cover. Remove the sub-tray.
Sub-tray
Shaft recesses
Body cover
Fig. 3.3-4 Removing the Sub-tray
3.3.4 Removing the Paper Tray and Paper Guide
1.Lift the top of the paper tray in the direction of arrow A, then pull it in the direction of arrow B. Remove the paper tray.
“B”
Paper tray
“A”
Fig. 3.3-5 Removing the Paper Tray
3-4
2.Disengage the paper guide hook (at the rear of the paper tray) from the paper tray. Remove the paper guide.
Paper tray
Hook
Paper tray film
Paper guide
Fig. 3.3-6 Removing the Paper Guide
3.3.5 Removing the Body Cover B
1.Remove the two bottom cover screws A from the bottom of the bottom cover.
Bottom cover screws A
Fig. 3.3-7 Removing the Body Cover B (1)
3-5
2.Lift the rear of the bottom cover in the direction of arrow B while pushing it in the direction of arrow A. Release the four hooks at the rear face.
3.Push the body cover in the directions indicated by the arrows C to release the hook at the left and right side.
4.Release the two hooks from the front of the body cover.
Hook
“B”
“A”
“C”
Body cover
“C”
Rear hooks
Bottom cover
Side hook
Front hooks
Fig. 3.3-8 Removing the Body Cover (2)
5.Disconnect the switch harness assy (white CN1) from the main PCB and remove the body cover. (The body cover switch PCB is connected to the main PCB of bottom cover via the switch harness assy.)
Switch harness assy
Fig. 3.3-9 Removing the Body Cover (3)
3-6
3.3.6 Removing the Front Cover
1.Remove the two front cover screws under the bottom cover.
Hook
Front cover screws
Fig. 3.3-10 Removing the Front Cover (1)
2.While pressing up the two hooks on the front cover from underneath, pull the front cover out to remove it.
Front cover
Fig. 3.3-11 Removing the Front Cover (2)
3-7
3.3.7 Removing the Cover Switch Assy
1.Disconnect the cover switch assy harness connector (yellow CN4) located under the body cover from the switch PCB.
2.Remove the cover switch screw. Remove the cover switch assy.
Cover switch assy
Front
Cover switch screw
Harness connector
Fig. 3.3-12 Removing the Cover Switch Assy
3-8
3.3.8 Removing the Dial Switch Holder Assy B
1.Disconnect the leaf switch R assy (red CN2) and leaf switch L assy (white CN3) harness connectors from the switch PCB.
2.Remove the dial lock arm and the dial lock arm spring that is hooked on the body cover.
3.Remove the switch harness assy from switch PCB.
4.Remove the two dial holder screws. Remove the Dial Switch Holder Assy B.
Dial holder screws Leaf switch L assy
Leaf switch R assy
Dial switch holder assy B
Dial lock arm spring
Dial lock arm
Fig. 3.3-13 Removing the Dial Switch Holder Assy B
3-9
3.3.9 Disassembling the Dial Switch Holder Assy B
1.Pull the plate spring in the direction of the arrow. Remove dial switch B.
2.Remove the two leaf switch R/L screws. Remove the leaf switch R assy (red
CN2) and the leaf switch L assy (white CN3).
Dial switch B
Leaf switch R/L screws
Leaf switch R/L assy’s
Plate spring
Fig. 3.3-14 Disassembling the Dial Switch Holder Assy B (1)
3.Remove the slide plate spring screw. Remove the plate spring.
4.Lift the slide plate 1B diagonally upward. Disengage slide plate 1B from the hook and remove it.
Slide plate spring screw
Slide plate 1B
Plate spring
Fig. 3.3-15 Disassembling the Dial Switch Holder Assy B (2)
3-10
5.Remove the slide plate screw. Remove slide plate 2 from slide plate 1B.
Slide plate screw
Slide plate 2
Slide plate 1B
Fig. 3.3-16 Disassembling the Dial Switch Holder Assy B (3)
6.Disconnect lug A on the dial lock arm from the dial switch holder. Pull the dial lock arm off the shaft.
D ial lock arm
Dial Switch holder
Lug “A”
Fig. 3.3-17 Disassembling the Dial Switch Holder Assy B (4)
3-11
3.4 Chassis
3.4.1 Removing the Harness Connectors
Remove 12 harness connectors from the main PCB. Do not remove the power harness assy (red/black CN13).
Power harness assy
Fig. 3.4-1 Removing the Harness Connectors
3.4.2 Removing the PE Sensor Unit
Open the bearing supports in the bottom cover outward. Lift the PE sensor unit out of the bottom cover bearing supports. Pull the tip of the PE sensor unit off the paper feed roller shaft and remove the PE sensor unit. Take care not to damage the tip of the PE sensor unit when disconnecting it.
PE sensor unit
Bearing supports
Paper feed roller Assy
Fig. 3.4-2 Removing the PE Sensor Unit
3-12
3.4.3 Removing the Chassis Unit
1.Remove the sensor frame screw from the sensor frame. Remove the ground wire
(jack PCB). After removing the wire, reinsert the sensor frame screw to fasten the sensor frame to the chassis.
Ground wire (jack PCB)
Sensor frame
Sensor frame screw
Fig. 3.4-3 Removing the Chassis Unit (1)
2.Remove the two bottom cover screws B and the spring washers from under the bottom cover B.
Bottom cover
Bottom cover screws
Fig. 3.4-4 Removing the Chassis Unit (2)
3-13
3.Remove the cassette holder screws from under the chassis unit.
Cassette holder screws
Fig. 3.4-5 Removing the Chassis Unit (3)
4.Pull out the chassis unit.
Chassis unit
Fig. 3.4-6 Removing the Chassis Unit (4)
3-14
3.5 PCBs
3.5.1 Removing the Main PCB Assy
1.Disconnect the power harness assy (red/black CN13) from the Main PCB assy 1.
2.Remove the four main PCB screws. Remove the Main PCB assy 1.
Main PCB screws
Main PCB assy 1 Main PCB screws
P ower harness assy
Fig. 3.5-1 Removing the Main PCB Assy
3.5.2 Removing the Jack PCB Assy
Remove the Jack PCB screw and remove the jack PCB assy 1.
Jack PCB screw
Ferrite core
Jack PCB assy 1
Fig. 3.5-2 Removing the Jack PCB Assy
3-15
3.5.3 Removing the Switch PCB Assy
1.Remove the two switch PCB screws A and three switch PCB screws B from under the body cover B. Remove the switch PCB assy 1.
Switch PCB screws A
Switch PCB screws B
SW PCB assy 1
Fig. 3.5-3 Removing the Switch PCB Assy (1)
2.Remove the start switch B,start key film, start key actuator, two-connection switch, and power switch.
Two-connection switch
Power switch
Start key actuator
Start key film
Start switch B
Fig. 3.5-4 Removing the Switch PCB Assy (2)
3-16
3.6 T-Chassis
3.6.1 Removing the T-Chassis Unit
1.Remove the plate spring screw. Remove the plate spring.
2.Remove the two T-chassis screws and remove the T-chassis unit.
T-chassis unit
Plate spring screw
Plate spring
T-chassis screw
Fig. 3.6-1 Removing the T-Chassis Unit
3-17
3.6.2 Disassembling the T-Chassis Unit
1.Open hook A on the T-paper guide in the direction A'. Pull out the T-lever shaft to remove the T-lever unit.
2.Remove T-lever 2 from T-lever 1. Remove the T-push spring and T-cam roller.
3.Remove the leaf switch TRI screw and remove the leaf switch TRI assy.
4.Disconnect the switch lever from the shaft hook on the T-paper guide and remove the switch lever.
5.Remove the T-cutter upper unit from the T-paper guide. Remove the T-cutter stopper from the T-cutter holder, then remove the T-cutter.
6.Remove the paper guide screw and remove the T-paper guide.
7.Remove the leaf switch TRG screw and remove the leaf switch TRG assy.
8.Turn the T-sensor lever until lug A aligns with the slot in the T-chassis and remove the T-sensor lever.
9.Disengage hook B on the T-cam gear. Pull out the T-cam shaft to release T-gear
35-14 and T-idle gear.
Leaf switch TRI screw
Paper guide screw
T-cutter stopper
T-cutter holder
T-cutter upper unit
Leaf switch TRG screw
T-sensor lever
Leaf switch TRG assy
Leaf switch TRI assy
Switch lever
Shaft hook
A ’
Lug “A”
T-cutter
Hook B
T-cam gear
Hook A
Slot
T-paper guide
T-lever 1
T-cam shaft
T-push spring
T-chassis
T-lever shaft
T-lever unit
T-lever 2
T cam roller
Fig. 3.6-2 Disassembling the T-Chassis Unit
T-idle gear
T-gear 35-14
3-18
3.7 Y-CA Chassis
3.7.1 Removing the Y-CA Chassis Assy
1. Remove the Y-extension spring L.
2. Remove the two Y-CA chassis screws
3. Remove the Y-CA timing belt from the Y-cutter arm and remove the Y-CA chassis assy.
Y-cutter arm
Y-CA timing belt
Y-extension spring L
Y-CA chassis screws
Y-CA chassis assy
Fig. 3.7-1 Removing the Y-CA Chassis Assy
3-19
3.7.2 Disassembling the Y-CA Chassis Assy
1. Remove the pulley holder screw. Move the Y-CA pulley holder in the direction of arrow A and remove the Y-CA timing belt.
2. Move the Y-CA pulley holder in the direction of arrow B and remove it.
3. Move the Y-CA idle pulley in the direction of arrow B and remove it.
4. Remove the Y-CA driving pulley ring and pull off the Y-CA driving pulley.
5. Remove the two Y-CA motor screws and remove the Y-CA motor.
Y-CA driving pulley ring
Y-CA driving pulley
Y-CA timing belt
Y-CA motor screws
“A”
Y-CA motor
Anti-static brush
Fig. 3.7-2 Disassembling the Y-CA Chassis Assy
Y-CA idle pulley
Y-CA pulley holder screw
“B”
Y-CA pulley holder
3-20
3.7.3 Removing the Roller Holder Assy
1. Move the Y-cutter arm L as far as possible to the left.
2. Lift up the roller holder assy and remove the roller holder spring.
3. Remove the two roller holder rings. Push the roller holder assy to the right to disengage it from the chassis unit L boss shaft. Disengage the roller holder assy from the chassis unit R boss shaft.
Roller holder assy
Y-cutter arm L
Chassis unit R boss
Chassis unit L boss shaft
Roller holder rings
Fig. 3.7-3 Removing the Roller Holder Assy
3-21
3.7.4 Disassembling the Roller Holder Assy
1. Disengage the two hooks A and remove the side covers L/R.
2. Remove the lock lever springs L/R from inside the lock levers L/R to allow the lock levers L/R to move freely.
3. Turn hook B on lock lever L to the position of the cut-out on the roller holder and remove lock lever L. Pull out the lock lever shaft and remove the set buttons L/R, lock lever springs L/R, and the interference board.
4. Turn hook C on lock lever R to the position of the cut-out on the roller holder and remove lock lever R.
5. Remove the extension springs 0.4 from the left and right.
6. Pull the sub-roller bearings L/R out of the boss holes and remove them from the release plates L/R.
7. Remove the sub-roller bearings L/R, tape hold bearings L/R, and tape hold shaft from the sub-roller assy.
8. Remove the press roller springs L/R.
9. Remove the release plate rings. Remove the release plates L/R.
Hooks A
Lock lever L
Hook B
Side cover L
Release plate L
Press roller spring L
Boss hole
Release plate ring
Set button L
Cut-out
Roller holder
Extension spring 0.4
Lock lever spring L
Lock lever shaft
Sub-roller bearing L
Tape hold bearing L
Tape hold shaft
Sub-roller assy
Interference board
Extension spring 0.4
Cut-out
Lock lever R
Hook C
Lock lever spring R
Set button
R
Hook A
Side cover R
Hook A
Tape hold bearing R
Sub-roller bearing
Fig. 3.7-4 Disassembling the Roller Holder Assy
Boss hole
Press roller spring R
Release plate ring
Release plate R
3-22
3.8 Sensor Frame and Y-cutter Arm L
3.8.1 Removing the Sensor Frame
1. Position the chassis unit as shown in the diagram. Remove the paper sensor crank from the paper feed roller.
2. Remove the two sensor frame screws.
3. Lift the right end of the sensor frame to release it from the top-right boss. Move the sensor frame to the left to release it from the two bosses at the left. Remove the sensor frame.
Sensor frame screws
Chassis right side Chassis left side
Paper sensor crank
Sensor frame
Fig. 3.8-1 Removing the Sensor Frame
3.8.2 Removing the Y-cutter Arm L
Remove the two arm shaft rings and pull the Y-cutter arm shaft in the direction of the arrow to remove the Y-cutter arm L.
Y-cutter arm L
Y-cutter arm L
Y-CA timing belt
Y-CA chassis screw
Fig. 3.8-2 Removing the Y-cutter Arm L
3-23
3.8.3 Disassembling the Sensor Frame
1. Disengage the hooks on FPC holder A from the cut-outs in the sensor frame. Move the FPC holder A in the direction of the arrow to remove it.
2. Release the FPC holder B from the boss hole in the sensor frame. Move the FPC holder B in the direction of the arrow to remove it.
3. Remove the paper sensor harness assy (flat cable) from the FPC holder A and FPC holder B.
4. Remove the sensor crank protect film from the sensor frame, if it requires replacing.
Sensor frame
Cut-out
FPC holder A
Boss hole
Hook
Sensor crank protect film
Paper sensor harness assy
Fig. 3.8-3 Disassembling the Sensor Frame
FPC holder B
3-24
3.8.4 Disassembling the Y-cutter Arm L
1. Remove the sensor holder screw. Remove the photosensor (PS) PCB holder from the Y-cutter arm L.
2. Disengage the PS PCB holder hook. Turn the PL detect lever to a position where it does not engage with the sensor, then remove it.
3. Remove the Y-CA sensor screw and remove the Y-CA sensor.
Sensor holder screw
Photosensor (PS) PCB holder
Y-CA sensor
Hook
Y-CA sensor screw
PL detect lever
Y-cutter arm L
Fig. 3.8-4 Disassembling the Y-cutter Arm L
3-25
3.9 Paper Feed Roller
3.9.1 Removing the Paper Feed Sub-roller Assy
1. Position the chassis unit as shown in the diagram. Release the gear 16 hook from the paper feed sub-roller assy. Take care not to damage the gear hook by opening too far.
2. Remove the paper feed shaft spring R and paper feed shaft spring.
Paper feed sub-roller assy
Gear 16 hook
Chassis right side Chassis left side
Paper feed shaft spring R
Paper feed shaft spring
Fig. 3.9-1 Removing the Paper Feed Sub-roller Assy
3. Remove the left and right rod holder from the chassis L/R units. Pull the paper feed sub-roller assy up from the bearings to remove it.
Paper feed sub-roller assy
Bearings
Rod holders
Fig. 3.9-2 Removing the Paper Feed Sub-roller Assy
3-26
3.9.2 Removing the Paper Feed Roller Assy
1. Position the chassis unit as shown in the diagram. Release the gear 16 hook from the paper feed sub-roller assy. Take care not to damage the gear hook by opening too far.
2. Remove the paper feed roller ring from the chassis right side.
Paper feed roller ring
Chassis right side Chassis left side
Paper feed roller assy Gear 16 hook
Fig. 3.9-3 Removing the Paper Feed Roller Assy (1)
3. Remove the left and right bearing.
4. Remove the paper feed roller assy from the left and right sides of the chassis.
Bearings
Paper feed roller assy
Fig. 3.9-4 Removing the Paper Feed Roller Assy (2)
3-27
3.10 Paper Eject Roller
3.10.1 Removing the Y-D Shaft
1. Remove the left and right paper eject sub-roller springs.
2. Remove the left and right Y-extension springs L/R.
3. Pull out the Y-gear 40-20 from the shaft and remove the Y-driving gear. Take care not to damage the gear hook by opening too far while removing the Y-gear 40-20.
4. Push the Y-D shaft to the right, then remove from the left.
Paper eject sub-roller springs
Y-driving gear
Y-D shaft
Y-extension spring L
Y-extension spring R
Y-gear 40-20
Fig. 3.10-1 Removing the Y-D Shaft (1)
5. Remove the Y-cutter cams L/R from the removed Y-D shaft.
Y-D shaft
Y-cutter cam L
Y-cutter cam R
Fig. 3.10-2 Removing the Y-D Shaft (2)
3-28
3.10.2 Removing the Paper Eject Sub-roller Unit
1. Remove the paper eject shaft holders L/R attached to the paper eject sub-roller unit by pulling them from the paper eject roller shaft in the direction of the arrow.
2. Remove the paper eject shaft holders L/R from the removed paper eject sub-roller unit.
Paper eject roller unit
Paper eject sub-roller unit
Paper eject shaft holders L/R
Fig. 3.10-3 Removing the Paper Eject Sub-roller Unit
3.10.3 Removing the Paper Eject Roller Unit
1. Pull out the Y-gear 40-16 from the shaft and remove the gear 20. Take care not to damage the gear hook by opening too far while removing the Y-gear 40-16.
2. Remove the gear 16 hook from the paper eject roller unit. Take care not to damage the gear hook by opening too far.
3. Turn the paper eject roller bearing L clockwise at the chassis left side with needlenosed pliers and remove it. Remove the paper eject roller screw then turn the paper eject roller bearing R counterclockwise at the chassis right side with needle-nosed pliers and remove it.
Gear 16 hook
Paper eject roller Bearing
Paper eject roller unit
Gear 20
Paper eject roller screw
Gear 40-16 hook
Paper eject roller bearing
Fig. 3.10-4 Removing the Paper Eject Roller Unit (1)
3-29
4. Push the paper eject roller unit to the left, then remove from the right.
Paper eject roller unit
Fig. 3.10-5 Removing the Paper Eject Roller Unit (2)
3.11 Y-diversion Lever
3.11.1 Removing the Y-diversion Lever Assy
1. Press the tabs on the two Y-cutter units in the direction of arrow 1 to release the hooks. Move them down in the direction of arrow 2 and then in the direction of arrow 3 to release.
Y-cutter units
1
2
3 1
2
Fig. 3.11-1 Removing the Y-diversion Lever Assy (1)
3-30
2. Lift up the right end and the left end of the Y-diversion lever assy in sequence to remove it.
Y-diversion lever assy
Fig. 3.11-2 Removing the Y-diversion Lever Assy (2)
3.11.2 Disassembling the Y-diversion Lever Assy
1. Release the two Y-cutter guide shaft rings from the right end.
2. Pull up the Y-cutter guide shaft then remove the Y-cutter guides L/R from each end.
3. Remove the Y-diversion lever film, if it requires replacing.
Y-cutter guide L
Y-cutter guide shaft
Y-cutter guide shaft rings
Y-cutter guide R
Y-diversion lever film
Fig. 3.11-3 Disassembling the Y-diversion Lever Assy
3-31
3.12 X-cutter
3.12.1 Removing the X-cutter Unit
1. Remove the two X-cutter screws. Lift up the X-cutter unit.
X-cutter unit
X-cutter screws
Fig. 3.12-1 Removing the X-cutter Unit
3.12.2 Disassembling the Tape Sensor Unit
1. Remove the leaf switch screw. Remove the leaf switch F assy.
2. Remove the sensor holder screw. Remove the tape sensor holder from the X-cutter unit.
3. Remove the tape sensor lever from the tape sensor holder.
X-cutter unit
Tape sensor lever
Tape sensor holder
Leaf switch F assy
Leaf switch screw
Sensor holder screw
Fig. 3.12-2 Disassembling the Tape Sensor Unit
3-32
3.13 Driving Roller Shaft
3.13.1 Removing the Driving Roller Shaft
1. Remove the driving roller C ring. Remove the gear 16M1 hook and driving roller bearing. Take care not to open the driving roller C ring too far.
2. Remove the driving roller E ring. Remove the driving roller bearing.
3. Remove the driving roller shaft.
Driving roller C ring
Gear 16M1 hook
Bearing
Driving roller shaft
Driving roller E ring
Bearing
Fig. 3.13-1 Removing the Driving Roller
3.14 Left Side of the Chassis
3.14.1 Removing the Gears
Remove the gears from the left side of the chassis in the sequence described below.
If the gear has one or two hooks, disengage the hooks from the locking groove in the shaft before removing. Gear 20, removed at step 18 is fastened by a ring. Remove the ring before removing the gear.
1. Gear 37 hook
2. TY-planet gear unit
Remove the TY-planet gear holder, before removing the felt, TY-idle gear, and TYspring washer from the shaft. Remove the TY-planet gear from the TY-planet gear holder.
3. Gear 25 hook
4. Planet 20 hook (two)
Remove the planet 20 hook, before removing the felt, TY-planet gear holder, TY-spring washer, and TY-planet gear.
3-33
5. Gear 36/12 hook
6. Gear 21
7. Gear 37 hook
8. Gear 21
9. Gear 40/16 hook (This is removed when removing the paper eject roller.)
10. Gear 21
11. Gear 20 (This is removed when removing the paper eject roller.)
12. Gear 60/20 hook
13. Gear 60/16M1
14. Gear 60/16
15. Gear 16M1
16. Gear 48/24
17. Gear 20
18. Gear 20
19. Gear 20
20. Gear 50
Gear 60/16M1
Gear 60/16
Gear 20
Gear 20 ring
Gear 60/20 hook
Gear 50
Gear 48/24
Gear 25 hook
Gear 16M1
Gear 37 hook
TY-planet gear
Planet 20 hook unit
Planet 20 hook
Felt
Planet gear holder
TY-spring washer
Gear 40/16 hook
Gear 36/12 hook
TY planet gear
TY planet gear holder
Felt
TY-idle gear
Gear 21
Gear 37 hook
TY-planet gear unit
TY-spring washer
Fig. 3.14-1 Removing the Gears
3-34
3.14.2 Disassembling the Left Side of the Chassis
1. Release roller guide L from the boss hole. Incline the guide and remove it.
2. Remove the LF motor screw and TC/LF motor screw. Remove the LF motor.
Boss hole
Roller guide L
TC/LF motor screw
LF motor screw
Fig. 3.14-2 Disassembling the Left Side of the Chassis
LF motor
3-35
3.15 Right Side of the Chassis
3.15.1 Disassembling the Right Side of the Chassis
1. Remove the leaf switch Y screw. Remove the leaf switch Y assy.
2. Release the Y-sensor lever hook and remove the Y-sensor lever.
3. Incline the edging saddle EDS-1 and remove it.
4. Release roller guide R from the boss hole. Incline the guide and remove it.
5. Remove the TY-planet gear holder, before removing the felt, TY-idle gear, and TYspring washer from the shaft. Take care not to damage the TY-planet gear holder hooks by opening too far.
6. Remove the TY-planet gear from the TY-planet gear holder.
Roller guide R
Y-sensor lever
Edging saddle EDS-1
Y-sensor lever hook
Leaf switch Y screw
TY-planet gear
Leaf switch Y assy
TY-spring washer
TY-idle gear
Felt
Fig. 3.15-1 Disassembling the Right Side of the Chassis (1)
TY-planet gear holder
3-36
7. Remove the two TC motor screws. Remove the TC motor.
TC motor
TC motor screws
Fig. 3.15-2 Disassembling the Right Side of the Chassis (2)
3.16 Lower Chassis
3.16.1 Removing the Left and Right Sides of the Chassis
Remove the six side chassis screws and remove the left and right sides of the chassis.
Side chassis screws
Fig. 3.16-1 Removing the Left and Right Sides of the Chassis
3-37
3.16.2 Removing the Cassette Holder
1. Release the two side hooks fastening the cassette holder.
2. Flex the rear face of the cassette holder inward to release the two lugs. Remove the cassette holder from the bottom chassis.
Lug
Hooks
Cassette holder
Bottom chassis
Fig. 3.16-2 Removing the Cassette Holder
3.16.3 Removing the Encoder (ENC) Sensor PCB
Remove the ENC sensor screw. Remove the ENC sensor assy.
ENC sensor screw
ENC sensor assy
Fig. 3.16-3 Removing the ENC Sensor PCB
3-38
3.16.4 Removing the Cassette Detect Switch
Remove the leaf switch (SW) C screw. Remove the leaf switch C assy.
Leaf switch (SW) C screw
Leaf switch C assy
Fig. 3.16-4 Removing the Cassette Detect Switch
3-39
Chapter 4.
REASSEMBLY PROCEDURES
CONTENTS
Chapter 4. REASSEMBLY PROCEDURES
i
ii
4.1 Safety Precautions
•
When conducting reassembly operations, place the unit on a grounded anti-static sheet. LSI and other electronic components are sensitive to static electricity and may be damaged if touched while charged.
•
Before transporting a circuit board, wrap it in a conducting sheet such as aluminum foil.
•
When using a soldering iron or other heat-producing tool, ensure that heat does not damage wires, circuit boards, or plastic parts such as covers.
•
Take care not to lose small screws or washers removed when replacing parts.
•
Tighten all screws to the torque specified in the table below.
Leaf switch (SW) C screw
ENC sensor screw
Side chassis screw
TC/LF motor screw
Leaf switch Y screw
TC/LF motor screw
LF motor screw
X-cutter screw
Leaf switch screw
Sensor holder screw
Paper eject roller screw
Y-CA sensor screw
Sensor holder screw
Sensor frame screw
Y-CA motor screw
Y-CA pulley holder screw
Y-CA frame screw
Leaf switch TRI screw
Paper guide screw
Leaf switch TRG screw
T-chassis unit screw
Plate spring screw
Switch PCB screw A
Switch PCB screw B
Jack PCB screw
Main PCB screw
Cassette holder screw
Bottom cover screw B
Slide plate screw
Slide plate spring screw
4.2 Table of Tightening Torque
Name of Screw Qty. Screw Size Tightening Torque
1 SCREW FLANGED2.6
×
8
1 TAPTITE,BIND B M2.6
×
6
6 TAPTITE,CUP M3
×
5
2 SCREW,BIND M3
×
6
0.196 to 0.392N•m
0.196 to 0.392N•m
0.49 to 0.686N•m
0.49 to 0.686N•m
1 PAN-HEAD MACHINE SCREW M2.6
×
8 0.196 to 0.392N•m
1 TAPTITE,CUP M3
×
6 0.49 to 0.686N•m
1 TAPTITE,CUP M3
×
16
2 TAPTITE,CUP M 3
×
5
0.49 to 0.686N•m
0.49 to 0.686N•m
1 TAPTITE,PAN B M2
×
6
1 TAPTITE BIND B M2.6
×
6
1 TAPTITE,CUP M3
×
5
1 TAPTITE,BIND B M2.6
×
6
1 TAPTITE,BIND B M2.6
×
6
2 TAPTITE,CUP M3
×
5
2 SCREW,FLANGED M2.6
×
5
1 TAPTITE,CUP M3
×
5
0.196 to 0.392N•m
0.686 to 0.882N•m
0.49 to 0.686N•m
0.196 to 0.392N•m
0.196 to 0.392N•m
0.49 to 0.686N•m
0.196 to 0.392N•m
0.49 to 0.686N•m
2 TAPTITE,CUP M3
×
5
1 TAPTITE,PAN B M2
×
6
0.49 to 0.686N•m
0.196 to 0.392N•m
1 SCREW,BIND M3
×
6 0.49 to 0.686N•m
1 PAN-HEAD MACHINE SCREW M2.6
×
8 0.196 to 0.392N•m
2 TAPTITE,CUP M3 × 5
1 TAPTITE,CUP M3
×
5
2 TAPTITE,BIND B M3 × 12
3 TAPTITE,BIND B M3 × 14
1 TAPTITE,BIND B M 3
×
8
4 TAPTITE,BIND B M3
×
8
4 TAPTITE,CUP B M4
×
12
2 TAPTITE,BIND B M3
×
8
1 TAPTITE,BIND B M3
×
8
1 SCREW,FLANGED M2.6
×
5
0.49 to 0.686N•m
0.49 to 0.686N•m
0.49 to 0.686N•m
0.49 to 0.686N•m
0.49 to 0.686N•m
0.49 to 0.686N•m
0.98 to 1.176N•m
0.49 to 0.686N•m
0.49 to 0.686N•m
0.196 to 0.392N•m
See
Page
4-30
4-30
4-31
4-31
4-34
4-34
4-26
4-27
4-27
4-27
4-28
4-28
4-29
4-29
4-10
4-10
4-14
4-19
4-19
4-22, 32
4-25
4-25
4-2
4-2
4-3
4-4
4-5
4-6
4-6
4-10
4-1
Name of Screw
Leaf switch R/L screw
Dial holder screw
Cover switch screw
Front cover screw
Bottom cover screw A
Trimmer cover screw
Qty. Screw Size Tightening Torque
2 PAN-HEAD MACHINE SCREW M2.6
×
8 0.196 to 0.392N•m
2 TAPTITE,BIND B M3
×
8 0.49 to 0.686N•m
1 PHILLIPS PAN-HEAD TAPTILE B M2.6
×
12
0.49 to 0.686N•m
2 TAPTITE,BIND B M2.6X6 0.294 to 0.49N•m
2 TAPTITE,BIND B M3X12
2 SCREW,BIND M3
×
6
0.196 to 0.392N•m
0.49 to 0.686N•m
4.3 Lower Chassis
4.3.1 Installing the Cassette Detect Switch
Align the leaf switch C assy with the boss hole in the lower chassis and fasten it in position with the leaf switch (SW) C screw. Take care not to deform the tip of the leaf switch C assy during installation.
Leaf switch (SW) C screw
See
Page
4-35
4-35
4-36
4-37
4-40
4-43
Lower chassis
Boss hole
Leaf switch C assy
Fig. 4.3-1 Installing the Cassette Detect Switch
4.3.2 Installing the Encoder (ENC) Sensor PCB
Align the ENC sensor assy with the two bosses. Fasten the assembly to the cassette holder with the ENC sensor screw.
Bosses
ENC sensor screw
ENC sensor assy
Fig. 4.3-2 Installing the ENC Sensor PCB
4-2
4.3.3 Installing the Cassette Holder
Engage the two side hooks and four claws on the cassette holder with the bottom chassis. Insert the two rear lugs into the slots to fasten the cassette holder.
Lug
Cassette holder
Slot
Claws
Hooks
Bottom chassis
Fig. 4.3-3 Installing the Cassette Holder
4.3.4 Installing the Left and Right Sides of the Chassis
Insert the two lugs on the left or right side of the chassis into the rectangular holes in the lower chassis. Fasten each side chassis in position with the three side chassis screws.
Side chassis screws
Lower chassis
Lugs
Fig. 4.3-4 Installing the Left and Right Sides of the Chassis
4-3
4.4 Right Side of the Chassis
4.4.1 Reassembling the Right Side of the Chassis
1. Attach the TC motor with the two TC/LF motor screws.
TC motor
TC/LF motor screws
Fig. 4.4-1 Reassembling the Right Side of the Chassis (1)
4-4
2. Put the TY-spring washer, TY-idle gear, and felt (stick onto the TY-idle gear) on the shaft.
3. Attach the TY-planet gear to the TY-planet gear holder. Put the TY-planet gear holder on the shaft and push it until the hooks engage.
4. Incline the roller guide R and push the cut-out and align the roller guide R with the boss hole A to engage with chassis R.
5. Incline the edging saddle EDS-1 and push it into position.
6. Align the Y-sensor lever hook with boss hole B in the chassis R and push it into hooking position.
7. Align the leaf switch Y assy with the chassis R boss hole C and fasten it in position with the leaf switch Y screw. Install the contacts of the leaf switch Y assy over the Ysensor lever.
Roller guide R
Y-sensor lever
Edging saddle EDS-1
Boss hole B
Y-sensor lever hook
Boss hole A
Leaf switch Y screw
Leaf switch Y assy
TY-planet gear
TY-spring washer
Boss hole C
TY-idle gear
Felt TY-planet gear holder
Fig. 4.4-2 Reassembling the Right Side of the Chassis (2)
4-5
4.5 Left Side of the Chassis
4.5.1 Reassembling the Left Side of the Chassis
1. Fasten the LF motor with one TC/LF motor screw and one LF motor screw.
2. Incline the roller guide L. Insert the cut-out into chassis L and push it into place until the hooks engage in the boss hole.
Roller guide L
Boss hole
TC/LF motor screw
LF motor
LF motor screw
Fig. 4.5-1 Reassembling the Left Side of the Chassis
4.5.2 Installing the Gears
Install the gears at the left side of the chassis in the sequence described below.
If the gear (or holder) has one or two hooks, push it into place until the hooks engage in the locking groove in the shaft.
Gear 20, installed at step 3, is fastened by a ring.
1. Gear 50
2. Gear 20
3. Gear 20
4. Gear 20
5. Gear 48/24 (48-tooth side against chassis)
6. Gear 16M1
7. Gear 60/16 (16-tooth side against chassis)
8. Gear 60/16M1 (16-tooth side against chassis)
9. Gear 60/20 hook
10. Gear 20
11. Gear 21
12. Gear 40/16 hook
4-6
13. Gear 21
14. Gear 37 hook
15. Gear 21
16. Gear 36/12 hook
17. Planet 20 hook (two)
Attach the TY-planet gear to the planet gear holder. Put the TY-spring washer, planet gear holder, felt (stick onto the TY-planet gear holder), and planet 20 hook on the shaft.
18. Gear 25 hook
19. TY-planet gear unit
Attach the TY-planet gear to the TY-planet gear holder. Put the TY-spring washer, TYidle gear, felt (stick onto the TY-idle gear), and TY-planet gear holder on the shaft.
20. Gear 37 hook
Gear 60/16M1
Gear 20
Gear 60/16
Gear 20 ring
Gear 60/20 hook
Gear 50 Gear 48/24
Gear 25 hook
Gear 16M1
Gear 37 hook
TY-planet gear
Planet 20 hook unit
Planet 20 hook
Felt
Planet gear holder
TY-spring washer
Gear 40/16 hook
Gear 36/12 hook
TY-planet gear
TY-planet gear holder
Felt
TY-idle gear
Gear 21
Gear 37 hook
TY-planet gear unit
TY-spring washer
Fig. 4.5-2 Installing the Gears (1)
4-7
Gear 50
Gear 60/16M1
Gear 60/20 hook
Gear 16M1
Gear 25 hook
Gear 36/12 hook
Gear 20
Gear 60/16
Gear 48/24 Gear 20
TY-planet gear
Planet gear 20 hook
TY-planet gear
TY-idle gear
Gear 37 hook
TY-planet gear
Fig. 4.5-3 Installing the Gears (2)
Gear 40/16 hook
Gear 21
Gear 36/12 hook
4-8
4.6 Driving Roller Shaft
4.6.1 Installing the Driving Roller Shaft
1. Insert the semicircular end of the driving roller shaft into the hole in chassis L.
2. Put the driving roller bearing from the left and attach it to chassis L. (Align the lug on the bearing with the cut-out in the chassis.)
3. Insert the right end of the driving roller shaft into the hole in chassis R.
4. Put the driving roller bearing from the right and attach it to chassis R. (Align the lug on the bearing with the cut-out in the chassis.)
5. Fasten the right end of the driving roller shaft with the driving roller E ring.
6. Put the gear 16M1 hook on the left end of the driving roller shaft and fasten it with the driving roller C ring. Take care not to open the driving roller C ring too far.
Driving roller C ring
Gear 16M1 hook
Driving roller bearing
Driving roller shaft
Driving roller E ring
Driving roller bearing
Fig. 4.6-1 Installing the Driving Roller Shaft
4-9
4.7 X-cutter
4.7.1 Reassembling the Tape Sensor Unit
1. Fasten the leaf switch F assy to the tape sensor holder with the leaf switch screw.
2. Attach the tape sensor lever to the tape sensor holder.
3. Attach the tape sensor holder to the X-cutter unit with the sensor holder screw.
X-cutter unit
Tape sensor lever
Tape sensor holder
Leaf switch F assy
Leaf switch screw
Sensor holder screw
Fig. 4.7-1 Reassembling the Tape Sensor Unit
4.7.2 Installing the X-cutter Unit
Install the X-cutter unit into the chassis unit from above. Fasten it in position with the two X-cutter screws.
X-cutter unit
X-cutter screws
Fig. 4.7-2 Installing the X-cutter Unit
4-10
4.8 Y-diversion Lever
4.8.1 Reassembling the Y-diversion Lever Assy
1. Hold the Y-cutter guide shaft with the two rings at the right end. Insert the left end into Y-cutter guide L and the right end into Y-cutter guide R.
2. Insert the Y-cutter guide shaft through the holes in the Y-diversion lever. Fasten with the two Y-cutter guide shaft rings.
3. Stick new Y-diversion lever film on the Y-diversion lever, if it requires replacing.
Y-cutter guide L
Y-cutter guide shaft
Y-cutter guide R
Y-cutter guide shaft rings
Y-diversion lever
Y-diversion lever film
Fig. 4.8-1 Reassembling the Y-diversion Lever Assy
4-11
4.8.2 Installing the Y-diversion Lever Assy
1. Mount the Y-diversion lever assy on the X-cutter unit by inserting the left end into chassis L then the right end into chassis R.
Y-diversion lever assy
X-cutter unit
Fig. 4.8-2 Installing the Y-diversion Lever Assy 1
2. Press each of the two Y-cutter assy’s against the Y-diversion lever assy and move it in the direction of arrow 1 up to the position of the Y-cutter guide L/R.
3. Install the Y-cutter guides by lifting the tab on each Y-cutter assy in the direction of arrow 2, then pushing in the direction of arrow 3 to engage the hook.
2
1 3
3 2
1
Y-cutter assy
1
2
3
Y-cutter guide L
Y-cutter guide R
Fig. 4.8-3 Installing the Y-diversion Lever Assy 2
4-12
4.9 Paper Eject Roller
4.9.1 Installing the Paper Eject Roller Unit
1. Temporarily remove gear 40-16 and gear 20 when installing the paper eject roller unit, as these can interfere with the installation.
2. Hold the paper eject roller unit with the end where the gears mount at the left. Insert the left end into the hole in chassis L, then the right end into the hole in chassis R.
Paper eject roller unit
Gear 20
Gear 40-16 hook
Fig. 4.9-1 Installing the Paper Eject Roller Unit (1)
4-13
3. Insert the left and right paper eject roller bearings into the chassis L/R. The paper eject roller bearings can only be inserted if the lugs on the bearings are aligned with the grooves in the chassis.
4. Turn the paper eject roller bearing L counterclockwise to the boss hole to insert it in the chassis left side. Likewise, turn the paper eject roller bearing R clockwise to the boss hole to insert it in the chassis right side.
5. After inserting the paper eject roller bearing R in the chassis right side, fasten it in position with the paper eject roller screw.
6. Align the gear 16 hook with the semicircular end of the paper eject roller unit and push the gear until the hook engages.
7. Replace gear 40-16 hook and gear 20 which were temporarily removed previously.
Gear 16 hook
Paper eject roller bearing
Paper eject roller unit
Gear 20
Gear 40-16 hook
Paper eject roller bearing
Paper eject roller screw
Fig. 4.9-2 Installing the Paper Eject Roller Unit (2)
4-14
4.9.2 Installing the Paper Eject Sub-roller Unit
1. Orient the left paper eject shaft holder L (narrow) and right paper eject shaft holder
R (wide) with the flat face inward and attach them to the paper eject sub-roller unit.
2. Attach the paper eject shaft holders L/R attached to paper eject sub-roller unit to the paper eject roller shaft in the chassis.
Paper eject roller unit
Paper eject sub-roller unit
Paper eject shaft holders L/R
Fig. 4.9-3 Installing the Paper Eject Sub-roller Unit
4.9.3 Installing the Y-D Shaft
1. Align the Y-D shaft with the long semicircular end to the right. Align the Y-cutter cams L/R with each semicircular end of the Y-D shaft and attach them to the shaft.
Y-D shaft
Y-cutter cam L
Y-cutter cam R
Fig. 4.9-4 Installing the Y-D Shaft (1)
4-15
2. Insert the Y-D shaft (with cams) first into chassis R, then into chassis L. The Y-D shaft should be inserted behind the paper eject shaft holders L/R.
3. Put the Y-driving gear onto the right semicircular end of the Y-D shaft. Next put the
Y-gear 40-20 on this shaft and push the gear until the hook engages.
4. Attach the left and right Y-extension springs (L/R). Attach the Y-extension spring L
(the longer one) to the LF motor mounting screw.
5. Attach the left and right paper eject sub-roller springs.
Paper eject sub-roller springs
Fig. 4.9-5 Installing the Y-driving Shaft (2)
Y-driving gear
Paper eject shaft holder L
Y-D shaft
LF motor mounting screw
Y-extension spring L
Y-cutter cam L/R
Paper eject shaft holder
R
Y-gear 40-20
Y-extension spring R
4-16
4.10 Paper Feed Roller
4.10.1 Installing the Paper Feed Roller Assy
1. Insert the bearings into the chassis L/R.
2. Attach the left and right rod holders to the paper feed roller assy with the hooks inward.
Bearings
Paper feed roller assy
Rod holders
Fig. 4.10-1 Installing the Paper Feed Roller Assy (1)
3. Hold the paper feed roller assy with the semicircular end to the right. Insert the right bearing, then insert the left bearing. Fasten by attaching the paper feed roller ring to the shaft.
4. Align the gear 16 hook with the semicircular end of the paper feed roller assy and push the gear until the hook engages.
Paper feed roller ring
Bearings
Paper feed roller assy
Gear 16 hook
Fig. 4.10-2 Installing the Paper Feed Roller Assy (2)
4-17
4.10.2 Installing the Paper Feed Sub-roller Assy
1. Hold the paper feed sub-roller assy with the semicircular end to the right. Push through the left and right rod holders and engage the paper feed roller grooves in the bearings.
Paper feed sub-roller assy
Bearings
Rod holders
Fig. 4.10-3 Installing the Paper Feed Sub-roller Assy (1)
2. Align the lower boss of the left and right rod holders with the slots in the chassis L/R.
3. Attach the left and right paper feed shaft spring (L)/R.
4. Align the gear 16 hook with the semicircular end of the paper feed sub-roller assy and push the gear until the hook engages.
Paper feed sub-roller assy
Gear 16 hook
Paper feed shaft spring R
Paper feed shaft spring Slot
Fig. 4.10-4 Installing the Paper Feed Sub-roller Assy (2)
4-18
4.11 Sensor Frame and Y-cutter Arm L
4.11.1 Reassembling the Y-cutter Arm L
1. Fasten the Y-CA sensor to the photosensor (PS) PCB holder with the Y-CA sensor screw.
2. Put the PL detect lever on the photosensor (PS) PCB holder shaft. Turn the PL detect lever to the position where the sensor is cut off and push it until the hook engages.
3. Align the boss hole in the photosensor (PS) PCB holder with the Y-cutter arm L and fasten it in position with the sensor holder screw.
Sensor holder screw
Photosensor (PS) PCB holder
Boss hole
Y-CA sensor
Hook
Y-CA sensor screw
PL detect lever
Y-cutter arm L
Fig. 4.11-1 Reassembling the Y-cutter Arm L
4-19
4.11.2 Reassembling the Sensor Frame
1. Attach the paper sensor harness assy (flat cable) to the FPC holder A and FPC holder B.
2. Insert the hooks on FPC holder A into slots A in the sensor frame. Attach FPC holder A by moving it in the direction of the arrow until the hook tip engages in the groove.
3. Insert the hooks on FPC holder B into slot B and the end hole in the sensor frame.
Attach FPC holder B by moving it in the direction of the arrow until it engages with the boss holes.
4. Stick new sensor crank protect film aligned with the sensor frame boss, if the film requires replacing.
Sensor frame
Slot A
Groove
FPC holder A
Boss hole
Hook tip
Hooks A
Slot B
End hole
Sensor crank protect film
Bosses
Paper sensor harness assy
Hooks B
Fig. 4.11-2 Reassembling the Sensor Frame
FPC holder B
4-20
4.11.3 Installing the Y-cutter Arm L
1. Engage the lug on Y-cutter guide L with the groove in Y-cutter arm L. Insert the Ycutter arm shaft in Y-cutter arm L.
2. Insert the Y-cutter arm shaft in holes in the chassis L/R. Fasten with the two arm shaft rings.
Groove
Lug
Y-cutter arm L
Y-cutter arm shaft
Arm shaft rings
Fig. 4.11-3 Installing the Y-cutter Arm L
4-21
4.11.4 Installing the Sensor Frame
1. Align the left end of the sensor frame with boss A on the side of chassis R. Align the right end of the sensor frame above boss B on chassis L.
2. Insert the paper sensor crank through the cut-out in the in the sensor crank protective film and engage it with the paper feed roller unit shaft. Pass the bottom edge of the sensor crank protective film between the paper feed sub-roller and the paper feed roller.
3. Fasten into place with the two sensor frame screws.
Sensor frame screws
Boss B
Boss A
Paper sensor crank
Paper feed sub-roller
Sensor frame
Paper feed
roller
Sensor crank protective film
Fig. 4.11-4 Installing the Sensor Frame
4.12 Roller Holder
4.12.1 Reassembling the Roller Holder Assy
1. Put the release plates L/R onto the roller holder shaft and fasten them with the release plate rings.
2. Insert the round part of the press roller springs into part A of the roller holder assy.
Make sure that the long leg of each press roller spring faces outward.
3. Attach the sub-roller bearings L/R and tape hold bearings L/R to the sub-roller assy.
Install the tape hold shaft into the semicircular holes in the tape hold bearings L/R.
4. Align the sub-roller bearings L/R with the boss holes and attach them to the release plates L/R.
5. Hook the left and right extension springs 0.4 in the holes in the tape hold bearings
L/R, then install by hooking the springs on part B of the roller holder assy.
6. Put the lock lever spring R on the set button R and attach them to the lock lever R through the roller holder assy. In this operation, engage the lock lever spring R on the lock lever R as shown at “E” in the figure below, then turn the lock lever R until hook C fits the cut-out A.
4-22
7. Put the interference board, set button L, and lock lever spring L onto the lock lever shaft. Pass the shaft through the hole in the left side of the roller holder assy.
8. Insert the lock lever shaft in the semicircular hole in lock lever R. Insert hook B of lock lever L from the position of cut-out A as with lock lever R, and turn to fasten in position.
9. Fasten the lock lever springs L/R inside the lock levers L/R.
10. Fasten the left and right side covers L/R to the roller holder by engaging the individual two hooks A to it.
Hooks A
Lock lever L
Hook B
Side cover L
Lock lever R
Roller holder
Cut-out A
Release plate L
Press roller spring L
Boss hole
Release plate ring
Set button L
Roller holder
Cut-out A Part B
Extension spring 0.4
Lock lever spring L
Lock lever shaft
Set button R
E Lock lever spring R
Sub-roller bearing L
Tape hold bearing L
Lock lever R
Hook C
Tape hold shaft Sub-roller assembly
Interference board
Extension spring 0.4
Lock lever spring R
Set button
R
Hook A
Side cover R
Hook A
Tape hold bearing R
Sub-roller bearing R
Press roller spring R
Boss hole
Release plate ring
Fig. 4-12-1 Reassembling the Roller Holder Assy
Release plate R
4-23
4.12.2 Installing the Roller Holder Assy
1. Move the Y-cutter arm L as far as possible to the left.
2. Insert the chassis unit R boss shaft into the hole in the roller holder assy, then insert the chassis unit L boss shaft. Attach the roller holder rings to the left and right boss shafts to fasten the roller holder assy in position.
3. Lift up the roller holder assy and attach the roller holder spring.
Roller holder assy
Y-cutter arm L
Chassis unit R boss shaft
Roller holder spring
Chassis unit L boss shaft
Roller holder rings
Fig. 4.12-2 Installing the Roller Holder Assy
4-24
4.13 Y-CA Chassis
4.13.1 Reassembling the Y-CA Chassis Assy
1.Attach the Y-CA motor with the two Y-CA motor screws.
2.Put the Y-CA driving pulley on the Y-CA chassis shaft and fasten it with the Y-CA driving pulley ring.
3.Insert the shaft of the Y-CA idle pulley into slot A of the Y-CA pulley holder. Push the
Y-CA idle pulley in the direction of arrow A to fasten it in position.
4.Insert lug A of the Y-CA pulley holder into slot B in the Y-CA chassis. Push the Y-CA idle pulley holder in the direction of arrow A to fasten it in position.
5.Push the Y-CA pulley holder in the direction of arrow A and put the Y-CA timing belt over the Y-CA idle pulley. Put the timing belt over the Y-CA driving pulley.
6.Slide the Y-CA pulley holder in the direction of arrow B to tension the Y-CA timing belt and tighten the Y-CA pulley holder screw. Y-CA Adjust the timing belt tension to
0.784 to 1.37 N.m
Y-CA driving pulley ring
Y-CA driving pulley
Y-CA timing belt
Y-CA motor screws
Y-CA Chassis
A
Shaft
Y-CA motor
Anti-static brush
Lug A
Shaft
Slot A Slot B
Fig. 4.13-1 Reassembling the Y-CA Chassis Assy
Y-CA idle pulley
Y-CA pulley holder screw
B
Y-CA pulley holder
4-25
4.13.2 Installing the Y-CA Chassis Assy
1.Align the Y-CA chassis assy with the positioning hook and the two bosses on chassis
L.
Positioning
hook
Bosses
Fig. 4.13-2 Installing the Y-CA Chassis Assy (1)
2.Attach the Y-CA timing belt to the attachment position on the Y-cutter arm L.
3.Fasten the Y-CA unit with the two Y-CA frame screws.
4.Attach the Y-extension spring L.
Y-CA timing belt
Y-cutter arm L
Y-CA timing belt
Y-extension spring L
Y-CA frame screws
Y-CA assy
Fig. 4.13-3 Installing the Y-CA Chassis Assy (2)
4-26
4.14 T-Chassis
4.14.1 Reassembling the T-Chassis Unit
1.Install the T-idle gear and T-gear 35-14 on the T-chassis. Put the T-cam shaft through the T-cam gear and engage the hook on the T-cam gear with the groove on the Tcam shaft.
2.Align the T-sensor lever with boss hole A. Insert lug A through the slot and rotate in the direction of the arrow to fasten it in position.
3.Align the leaf switch TRG assy with boss hole B. Fasten the leaf switch TRG assy above the T-sensor lever with the leaf switch TRG screw.
4.Align the T-paper guide with the two boss holes C and fasten with the paper guide screw.
5.Insert the T-cutter upper assy into the T-cutter holder and fasten it with the T-cutter stopper.
6.Align the lug at each side of the T-cutter holder with the grooves in the T-paper guide.
Install the T-cutter upper assy with the blade facing down.
7.Push the switch lever until it engages with the shaft hook on the T-paper guide.
8.Align the leaf switch TRI assy with boss hole D and fasten it in position with the leaf switch TRI screw.
9.Attach the T-push spring and T-cam roller to T-lever 2. Assemble T-lever 2 to T-lever
1 to form the T-lever unit.
10.Pass the T-lever shaft through the holes in the T-chassis and the T-lever unit. Open the T-paper guide hook and engage it with the groove in the T-lever shaft to install the T-lever unit.
Leaf switch TRI screw
Paper guide screw
T-cutter holder T-cutter stopper
T-cutter upper assy
T-sensor lever
Leaf switch TRG screw
Leaf switch TRG assy
Leaf switch TRI assy
Switch lever
Shaft hook
Lug “A”
T-cutter
Hook
T-cam gear
Hook
T-paper guide
T-lever 1
D
B
Slot
T-cam shaft
C
T-gear 35-14
T-idle gear
T-push spring
T-chassis
C
T-lever shaft
T-lever unit
T-lever 2
T cam roller
Fig. 4.14-1 Reassembling the T-Chassis Unit
4-27
4.14.2 Installing the T-Chassis Unit
1.Align the T-chassis unit with the two bosses.
Bosses
T-chassis unit
Fig. 4.14-2 Installing the T-Chassis (1)
2.Fasten the T-chassis unit with the two T-chassis screws.
3.Align the plate spring with the boss and fasten it with the plate spring screw, such that it holds T-gear 35-14 in position.
Plate spring screw
T-gear 35-14
T-chassis unit
Plate spring
T-chassis screw
Fig. 4.14-3 Installing the T-Chassis Unit (2)
4-28
4.15 PCBs
4.15.1 .Installing the Switch PCB Assy
1.Turn the body cover upside-down, and attach the start switch B,start key film, start key actuator, two-connection switch, and power switch.
Two connection switch
Power switch
Start key actuator
Start key film
Start switch B ig. 4.15-1 Installing the Switch PCB Assy (1)
2.Align the switch PCB assy 1 with the two bosses. Fasten it in position with the two switch PCB screws A and three switch PCB screws B.
Switch PCB screws B
Switch PCB screws A
Switch PCB assy 1
Boss es
Fig. 4.15-2 Installing the Switch PCB Assy (2)
4-29
4.15.2 Installing the Jack PCB Assy
Align the jack PCB assy 1 with the boss and fasten it in position with the jack PCB screw.
Jack PCB screw
Ferrite core
Jack PCB assy 1
Boss
Fig. 4.15-3 Installing the Jack PCB Assy
4.15.3 Installing the Main PCB Assy
1.Align the Main PCB assy 1 with the two bosses and fasten it in position with the four main PCB screws.
2.Attach the power harness assy (red/black CN13) to the Main PCB assy 1.
Main PCB screws
Power harness assy
Main PCB assy 1
Main PCB screws
Bosses
Fig. 4.15-4 Installing the Main PCB Assy
4-30
4.16 Chassis
4.16.1 Installing the Chassis Unit
1.Align the chassis unit with the two bosses on the bottom cover and fasten it in position with the four cassette holder screws. cassette holder screws
Fig. 4.16-1 Installing the Chassis Unit (1)
2.Attach the chassis unit using the two bottom cover screws B and the spring washers in the bottom cover.
Bottom cover
Bottom cover screws B
Fig. 4.16-2 Installing the Chassis Unit (2)
4-31
3.Remove the sensor frame screw from the sensor frame. Attach the ground wire and fasten it with the sensor frame screw.
Ground wire
Sensor frame
Sensor frame screw
Fig. 4.16-3 Installing the Chassis Unit (3)
4.16.2 Installing the PE Sensor Unit
1.Engage the tip of the PE sensor unit with the paper sensor crank. Attach the PE sensor unit to the paper feed roller, such that the sensor is located vertically above the paper sensor crank. Take care not to damage the tip of the PE sensor unit during installation.
2.Open the bottom cover bearing supports outward and mount the PE sensor unit in the bearing supports.
PE sensor unit
Paper feed roller
PE sensor unit
Paper sensor crank
Paper sensor crank
Bearing supports
Fig. 4.16-4 Installing the PE Sensor Unit
4-32
4.16.3 Installing the Harness Connectors
Attach the 12 harness connectors to the MAIN PCB. Do not attach the power harness assy (red/ black CN13).
Orange (CN15)
Blue (CN8)
White (CN7)
Red (CN6)
Power harness assembly
Black (CN5)
Yellow (CN12)
Yellow, blue, white, red, gray (CN11)
Black (CN10)
White (CN9) Red (CN4)
White (CN3)
Flat cable
Fig. 4.16-5 Installing the Harness Connectors
4.17 Covers
4.17.1 Reassembling the Dial Switch Holder Assy B
1.Put the dial lock arm on the dial S holder assy shaft. Engage lug A with the dial S holder assy.
Dial lock arm
Dial S holder assy
Lug A
Fig. 4.17-1 Reassembling the Dial Switch Holder Assy B (1)
4-33
2.Align slide plate 2 with the boss on slide plate 1B and fasten it with the slide plate screw.
Slide plate screw
Slide plate 2
Slide plate 1B
Bosses
Fig. 4.17-2 Reassembling the Dial Switch Holder Assy B (2)
3.Engage the slide plate 1B hook and bosses A with the slots in the dial S holder assy.
Ensure that slide plate 1B is positioned relative to the dial lock arm as shown in detail A.
4.Align the plate spring with bosses B and fasten it in position with the slide plate spring screw.
Slide plate spring screw
Bosses A
Slide plate 1B
Plate spring
Hook
Detail A
Dial S holder assy
Bosses B
Fig. 4.17-3 Reassembling the Dial Switch Holder Assy B (3)
4-34
5.Align the leaf switch R assy (red CN2) and the leaf switch L assy (white CN3) with the boss holes and fasten them in position with the two leaf switch R/L screws.
6.Pull the plate spring in the direction of the arrow. Insert the dial switch B such that the indicator is positioned between the two leaf switches.
Indicator
Leaf switch R/L screws
Dial switch B
Leaf switch L assy
(white CN3)
Leaf switch R assy
(red CN2)
Plate spring Boss holes
Fig. 4.17-4 Reassembling the Dial Switch Holder Assy B (4)
4.17.2 Installing the Dial Switch Holder Assy B
1.Align the dial switch holder assy with the boss under the body cover and fasten it in position with the two dial holder screws.
2.Attach the leaf switch R assy (red CN2) and leaf switch L assy (white CN3) harness connectors to the switch PCB.
3.Install the switch harness assy (CN1) to the switch PCB.
4.Attach the dial lock arm spring between the dial lock arm and the lug on the body cover.
Leaf switch R assy
Dial holder screws
Leaf switch L assy
Dial switch holder assy B
Boss
Dial lock arm spring
Dial lock arm Body cover lug
Fig. 4.17-5 Installing the Dial Switch Holder Assy B
4-35
4.17.3 Installing the Cover Switch Assy
1.Align the cover switch assy with the boss hole and fasten it in position with the cover switch screw.
2.Connect the cover switch unit harness connector (yellow CN4) to the switch PCB.
Cover switch assy
Front
Cover switch screw
Boss hole
Harness connector
Fig. 4.17-6 Installing the Cover Switch Assy
4-36
4.17.4 Installing the Front Cover
1.Align the front cover with the angle of the cover front face and insert parts A into parts
B. Push until the hooks at each side of the front cover engage.
Parts B
Front cover
Parts A
Fig. 4.17-7 Installing the Front Cover (1)
2.Fasten the two front cover screws under the bottom cover.
Front cover screws
Fig. 4.17-8 Installing the Front Cover (2)
4-37
4.17.5 Installing the Body Cover
1.Pass all the harnesses through the hooks in the bottom cover.
Fig. 4.17-9 Installing the Body Cover (1)
2.Connect the switch harness assy (white CN1) to the MAIN PCB.
Switch harness assy
Fig. 4.17-10 Installing the Body Cover (2)
4-38
3.Insert the lug on the Y-cutter guide R into the slot in the dial switch holder assy.
Dial switch holder assy
Slot
Y-cutter guide R
Lug
Fig. 4.17-11 Installing the Body Cover (3)
4.Engage the two hooks on the body cover front face.
5.Push down the body cover sides to engage the two hooks.
6.Push down the body cover rear face to engage the four hooks.
Hook
Side hook
Body cover
Side hook
Rear hooks
Front hooks
Fig. 4.17-12 Installing the Body Cover (4)
Bottom cover
4-39
7.Insert the two bottom cover screws A from underneath to fasten the body cover in position.
Bottom cover screws A
Fig. 4.17-13 Installing the Body Cover (5)
4-40
4.17.6 Installing the Paper Tray and Paper Guide
1.Press the paper guide hook (at the rear of the paper tray) into the groove in the paper tray.
Paper tray
Hook
Paper tray film
Groove
Paper guide
Fig. 4.17-14 Installing the Paper Guide
2.Push the paper tray in the direction of arrow A until its edge reaches the paper feed roller. Press the top of the paper tray in the direction of arrow B to fasten it in position.
“A”
“B”
Paper tray
Fig. 4.17-15 Installing the Paper Tray
4-41
4.17.7 Installing the Sub-tray
Flex the center of the sub-tray toward you to insert the shafts into the shaft recesses in the body cover. The sub-tray can be folded in the direction of the arrow.
Sub-tray Shaft recesses
Body cover
Fig. 4.17-16 Installing the Sub-tray
4.17.8 Installing the Top Cover
With the top cover in the open position, insert the shafts into the shaft recesses in the body cover to mount the cover.
Top cover
Shafts
Body cover
Fig. 4.17-17 Installing the Top Cover
Shaft recesses
4-42
4.17.9 Installing the Trimmer Upper Cover
1.Set the unit on its side with the trimmer upper cover uppermost.
2.Engage part B of the trimmer upper cover with part A on the chassis. Align the trimmer cover with the two bosses and fasten it in position with the two trimmer cover screws.
Bosses
Chassis part A
Part B
Trimmer cover
Boss
Fig. 4.17-18 Installing the Trimmer Cover 1
3.Insert the T-cutter plate into the trimmer cover.
4.Insert the trimmer bottom cover.
Trimmer cover screws
T-cutter plate Trimmer bottom cover
Fig. 4.17-19 Installing the Trimmer Cover 2
4-43
4.18 Installing the Film Cartridge
1.Insert the film cartridge with the arrow mark facing forward. Lower it into the roller holder assy.
Roller holder assy
Film cartridge
Fig. 4.18-1 Installing the Film Cartridge (1)
2.Push the left and right set buttons to lock the roller holder assy in position. Close the top cover.
Top cover
Set button L and R
Fig. 4.18-2 Installing the Film Cartridge (2)
Note: See 6.2.1 Replacing the Cartridge in Chapter 6 Maintenance for details about changing the film cartridge.
4-44
Chapter 5.
ELECTRONIC CONTROLLERS
CONTENTS
Chapter 5. ELECTRONIC CONTROLLERS
i
5.1 Electronic Parts
5.1.1 Configuration of the Electronic Parts
The electronic parts of the unit comprise the following PCBs and an AC adaptor.
•
Main PCB
•
Switch PCB
•
Jack PCB
•
Paper size sensor PCB
•
Film detector PCB
•
AC adaptor
Film Detect
Switch
Side Cutter
Position Switch
Paper Detect
Switch
Corner Cutter
Position Switch
Corner Cutter
Switch
Paper Size
Sensor
PCB
Film Sensor PCB
Film Cartridge
Size Switch
Paper Size
Detector Motor
Corner Cutter
Motor (LF Motor)
Fig. 5.1-1 Configuration of the Electronic Parts
5-1
5.1.2 Outline of the Electronic Parts
Each PCB and the AC adaptor are described below.
•
Main PCB
The main PCB is located below the paper guide. It is connected to all PCBs, motors, switches, and cables.
It converts the unstabilized DC voltages input from the Jack PCB to stabilized +5V and +24V DC voltages, which are supplied to all controllers.
The Main PCB controls motors, LED indicators, and buzzers according to the signals input from the detector circuits on the Switch PCB, Paper size detector PCB,
Film detector PCB, and on the Main PCB itself.
•
Switch PCB
The Switch PCB is located at the rear of the body cover. It is connected by a cable to the Main PCB.
On the Switch PCB are mounted the Power switch, Cut button, Feed button, and
Start button; the LED which lights the Start button; and connectors to connect to the cover and dial leaf switches.
•
Jack PCB
The Jack PCB is located at the jack input at the rear of the bottom cover. It supplies unstabilized DC voltages from the AC adaptor to the Main PCB.
•
Paper size sensor PCB
The Paper size sensor PCB is located on the Y-carriage. The sensors to detect the document width are mounted on this PCB.
•
Film sensor PCB
The Film sensor PCB is located on the side of the film cartridge holder. The sensors to detect the film type are mounted on this PCB.
•
AC adaptor
The AC adaptor converts the input AC voltage to an unstabilized DC voltage. The
AC adaptor jack is connected to the Jack PCB connector.
5-2
5.2 Operation of Each Part
This unit is operated by three 24 V stepping motors and one DC motor (for the X-cutter unit). The operation of each motor shown in Fig. 5.1-1 is described below.
•
Paper feed motor (LF Motor)
This motor is used to feed the document and film and to eject the laminated document.
The motor is a 42 mm dia. 48-step PM stepping motor. It is set to feed the document and tape approximately 1 mm per 16 steps using 2-2 phase drive.
•
Trimming motor (TC Motor)
This motor conducts trimming operation and drives the Y-cutter vertical movement.
The motor is a 42 mm dia. 48-step PM stepping motor. 480 steps complete one trimming operation. When the direction of motor rotation is reversed, 250 steps complete the Y-cutter up and down movements.
•
Y-CA motor
This motor moves the Y-carriage to the edge of the document. The Y-cutter and paper size sensor PCB are mounted on the Y-carriage. The motor is a 42 mm dia.
24-step PM stepping motor. It is set to feed the Y-carriage approximately 1 mm per
5 steps using 2-2 phase drive.
•
X-cutter (DC motor)
This 24V DC motor and two cutter position detector switches are mounted on the Xcutter. The direction of cutter movement is determined by the direction of current flow in the DC motor.
5-3
5.3 Main PCB
Fig. 5.3-1 shows a block diagram of the electrical parts.
The Main PCB comprises the CPU, detector circuits (including switch status detection), motor drive circuits, and power circuits.
Corner Cutter
Motor (TC)
Paper Size Detector
Motor (Y-CA)
Fig. 5.3-1 Block Diagram of the Electrical Parts
•
Main CPU
The main CPU is an 8-bit CMOS microcontroller that controls the overall system.
The main CPU incorporates 256 kB RAM, 8 kB ROM, and 56 I/O ports.
The I/O map for the I/O ports is shown in Table 5.3-1 overleaf.
5-4
Port
P21
P20
P37
P36
P35
P34
P33
P32
P31
P14
DVO (P13)
P12
INT1 (P11)
P10
P22
P02
P01
P00
P17
P16
P15
P07
P06
P05
P04
P03
P30
P47
P46
P45
P44
P43
P42
P41
P40
P54
P66
P65
P64
P63
P62
P53
P52
P51
P50
P67
Table 5.3-1 CPU I/O Map
Pin No.
27
25
40
39
38
37
36
35
34
21
20
19
18
17
28
11
10
9
24
23
22
16
15
14
13
12
45
44
43
42
41
53
33
48
47
46
62
61
60
59
58
52
51
50
49
63
I/O
IN
IN
OUT
OUT
OUT
OUT
OUT
OUT
OUT
OUT
OUT
IN
IN
IN
IN
IN
IN
IN
IN
OUT
OUT
OUT
OUT
OUT
OUT
OUT
OUT
IN
IN
IN
IN
IN
IN
IN
IN
IN
IN
OUT
IN
IN
IN
IN
IN
IN
IN
IN
5-5
S3
S2
S1
S0
YA MOTOR PHASE A
YA MOTOR PHASE B
YA MOTOR PHASE C
YA MOTOR PHASE D
DC-IN1
DC-IN2
DC-ENA
DC-IL
BUZZER
ENC
INT (COVER)
COVER
S8
S7
S6
KO0
KO1
LED 4
LED 1
LED 2
LED 3
YCA-LED
ENC-LED
ON/OFF-R
Y-G
P-END
TR-G
KI3
KI2
KI1
KI0
X-CUT2
X-CUT1
ON/OFF-L
S4
S5
ACVL
ACVH
YA MOTOR HIGH VOLT
CSEL B
YCA-F
CSIZE
Port Pin No. I/O
P61
P60
P77
P76
P75
P74
P73
P72
P71
6
5
4
3
2
57
56
8
7
IN
IN
OUT
OUT
OUT
OUT
OUT
OUT
OUT
CSEL A
TPS
T/C MOTOR PHASE B
T/C MOTOR PHASE A
T/C MOTOR PHASE D
T/C MOTOR PHASE C
LF MOTOR PHASE B
LF MOTOR PHASE A
LF MOTOR PHASE D
P70
•
Clock Circuit
1 OUT LF MOTOR PHASE C
The main CPU incorporates a clock-generation circuit which uses externally mounted components. This circuit and the main CPU internal circuit generate an 8
MHz clock signal.
Fig. 5.3-2 Clock Circuit
•
Reset Circuit
This circuit resets the main CPU when the power is turned ON or OFF. M51953 is used as the reset IC in this circuit.
When the power is turned ON, the reset IC holds the reset output Low for approximately 30 ms after the +5V DC power supply applied voltage reaches 4.25 V.
After this period the reset output becomes High to clear the main CPU reset status.
When the power is turned OFF, after the +5V DC power supply applied voltage drops to 4.25 V, or below, the reset IC sets the reset output Low to reset the main
CPU.
Fig. 5.3-3 Reset Circuit
5-6
•
Buzzer Drive Circuit
This circuit sounds the piezoelectric buzzer.
To sound the buzzer, the main CPU outputs a 4 kHz squarewave with 50% duty from port DV0 (P13). This signal is used to generate the buzzer sound.
To stop the buzzer, the port status is set to High level using R82 in the input mode.
Fig. 5.3-4 Buzzer Drive Circuit
•
LED Drive Circuit
This circuit drives the red and green LED indicators mounted on the switch LED and lights the Power button red, green, or orange.
The LED s are directly driven by the high-current ports P32, P33, P34, and P35 of the main CPU. The LED lights when the corresponding output is Low.
When not lit, the LED is in the high-impedance status and the port level is indeterminate.
Fig. 5.3-5 LED Drive Circuit
5-7
•
Specification Switching Circuit
This circuit reads the specification switching information.
The specification switching is conducted by a ROM program built into the main CPU according to the solder point settings on the PCB.
The relationships between the solder points and specifications are shown in PART
LIST.
Fig. 5.3-6 Specification Switching Circuit
•
Detector Circuits
These circuits detect the status of the switches and buttons that operate the unit
(Power switch, Cut button, Feed button, Start button, and dial switches) and the sensors that determine the film type, document length and width, and cover open/closed status.
•
Motor Drive Circuits
These circuits convert the motor control signals output from the main CPU output ports to 24 V drive signals and supplies these voltage signals to each motor.
•
Power Supply Circuits
These circuits convert the unstabilized DC power supply input from the Jack PCB into a stabilized +5V DC power supply for the logic ICs, including the main CPU, and into a stabilized +24V DC power supply to drive the motors.
5-8
5.4 Detector Circuits
These circuits detect the status of the switches, keys and buttons that operate the machine (Power switch, Cut key, Feed key, Start/Stop button, and dial switches) and the sensors that determine the film type, document length and width, and cover open/closed status.
The circuits that detect each switch and sensor are listed below.
In addition, a separate switch to detect the motor initial status is also mounted.
•
Switch scan circuit Power switch, Cut key, Feed key, Start/Stop
button, and TRIMMING switch
•
Dial switch circuit ON/OFF-R, ON/OFF-L switches
•
Cover switch circuit Cover switch
•
Paper width detector circuit YCA-F switch
•
Paper length detector circuit P-END switch
•
Cartridge type detector circuit CSIZE switch
•
Film type detector circuit ENC sensor
•
Film feed detector circuit TPS switch
•
Input voltage detector circuit ACVL, ACVH signals
5-9
•
Switch Scan Circuit
This circuit in the main CPU scans the status of the Power switch, Cut button, Feed button, Start button, and TRI switch (leaf switch) at 14 ms intervals to continuously detect the status of each switch.
The circuit comprises a matrix of two output ports (P36, P37) and four input ports
(P40 to P43). A Low signal is output at 7 ms intervals from one of the two output ports and the switch status at that time is detected from the status of P40 to P43).
•
When the main CPU detects that the Power switch was pressed, it turns the power ON if it was previously OFF, or it turns the power OFF if it was previously
ON.
•
When the main CPU detects that the Feed button was pressed, it starts the document and film feed operation. The document and tape are fed in approximately 0.5 mm intervals but the document and tape are fed continuously while the Feed button is held down.
•
When the main CPU detects that the Cut button was pressed, it operates the Xcutter to start the film-cutting operation.
•
When the main CPU detects that the TRI switch was pressed, it starts the trimming operation.
•
When the main CPU detects that the Start button was pressed, it starts feeding and compressing the document in the selected automatic cutting mode.
Fig. 5.4-1 Switch Scan Circuit
5-10
•
Dial Switch Circuit
This circuit detects the automatic cutting mode selected on the Cutting mode selector switch.
This circuit comprises two leaf switches (ON/OFF-R, ON/OFF-L ) mounted on each side of the dial switch. The signals detected by these two leaf switches are input to the Main PCB via the Switch PCB. When the dial is turned, one leaf switch turns ON and the other turns OFF.
Fig. 5.4-2 Dial Switch Circuit
•
Cover Switch Circuit
This circuit detects whether the cover is open or closed.
The cover switch is located in the center of the body cover. The signal detected by the cover switch (leaf switch) is input to the Main PCB via the Switch PCB. The cover switch turns OFF when the cover is open and the CPU input signal (COVER)
P10 becomes High status.
Fig. 5.4-3 Cover Switch Circuit
5-11
•
Paper Width Detector Circuit
This circuit detects the width of the document and determines the Y-carriage position. It also determines the Y-carriage standby position when the power is ON or the cover is closed.
This circuit comprises the transmissive photosensor YCA-F mounted on the Paper size detector PCB that is attached to the Y-carriage. If the Y-carriage is in its standby position, the sensor lever cuts the photosensor. When the main CPU output
P31 (YCA-LED) is Low, the input signal P63 (YCA-F) becomes Low.
When a document is inserted, the Y-CA motor rotates to move the Y-carriage to the edge of the document, where it moves the sensor lever cutting off the photosensor and thereby detects the edge of the document. The selected automatic cutting mode is also used to determine the Y-carriage (Y-cutter) position.
When the document edge is detected, the main CPU input signal P63 (YCA-F) becomes Low. However, as P31 is normally at High status, the photosensor does not operate and the main CPU input signal P63 (YCA-F) remains High, irrespective of the Y-carriage position.
Fig. 5.4-4 Paper Width Detector Circuit
•
Paper Length Detector Circuit
This circuit detects the length of the document and determines the X-cutter position.
The paper length detect switch P-END (paper sensor) is attached to the paper feed roller unit. When a document is inserted, the sensor lever turns ON the switch and the CPU input signal becomes Low status.
Fig. 5.4-5 Paper Length Detector Circuit
5-12
•
Cartridge Type Detector Circuit
This circuit detects the type of film cartridge.
The cartridge type detector switch CSIZE is mounted at the film cartridge inlet.
When an A4 film cartridge is inserted, the film cartridge presses the cartridge type detector switch and sets the input Low (ON). When no cartridge or an A6 film cartridge is inserted, the input remains High (OFF).
Fig. 5.4-6 Cartridge Type Detector Circuit
•
Film Type Detector Circuit
This circuit detects the type of film.
This circuit comprises a reflective photosensor ENC that is mounted on the film detector PCB, located on the side of the film cartridge holder. The reflective photosensor reads the black and silver target pattern along the edge of the film to determine the film type.
Fig. 5.4-7 Film Type Detector Circuit
5-13
•
Film Feed Detector Circuit
This circuit detects the film feed status to prevent jams if a problem occurs.
The film feed detector switch TPS is mounted before the paper eject roller and if there’s no problem with the film during document feed or compression, the film presses against the film feed detector switch TPS and sets the ON (input Low).
Fig. 5.4-8 Film Feed Detector Circuit
•
Input Voltage Detector Circuit
This circuit detects the AC adaptor output voltage to prevent danger due to an AC adaptor that is faulty or incorrectly inserted.
The circuit detects high voltages using transistor Q7.
When the AC adaptor output voltage is below approximately 23 V, transistor Q7 is
ON. When +24V DC is applied to R80 and R81, port P66 of the main CPU becomes approximately 4 V, and a High status is detected.
If the AC adaptor output voltage exceeds approximately 23 V, transistor Q7 turns
OFF and port P66 of the main CPU detects a Low status. As the normal output voltage of the AC adaptor does not exceed approximately 23 V, port P66 of the main
CPU is normally at High status.
This circuit detects low voltages using ZD1 and transistor Q6.
When the AC adaptor output voltage exceeds approximately 16 V, ZD1 is conducting and transistor Q6 is ON. Port P67 of the main CPU detects a Low status.
If the AC adaptor output voltage drops below approximately 16 V, ZD1 becomes non-conducting and transistor Q6 turns OFF. Port P67 of the main CPU detects a
High status. As the normal output voltage of the AC adaptor does exceeds approximately 16 V, port P67 of the main CPU is normally at Low status.
The main CPU does not process port P67.
Fig. 5.4-9 Input Voltage Detector Circuit
5-14
5.5 Motor Drive Circuits
•
Paper Feed Motor Drive Circuit (LF Motor)
This circuit drives the paper feed motor using 2-2 phase excitation from the +24V DC stabilized constant voltage.
The stepping motor excitation phases A, B, C, and D are controlled by main CPU ports P72, P73, P70, and P71, respectively. The four transistor arrays incorporated into QA2 drive the paper feed motor.
Fig. 5.5-1 Paper Feed Motor Drive Circuit
•
Trimming Motor Drive Circuit
This circuit drives the trimming motor using 2-2 phase excitation from the +24V DC stabilized constant voltage.
The stepping motor excitation phases A, B, C, and D are controlled by main CPU ports P76, P77, P74, and P75, respectively. The four transistor arrays incorporated into QA1 drive the trimming motor.
Fig. 5.5-2 Trimming Motor Drive Circuit
5-15
•
Trimming Motor Start Point Detect Circuit
This circuit rotates the trimming cam and Y-cutter cam forward and backward with the trimming motor (T/C motor) to detect the position of each cam.
The trimming switch (TRG) is designed to turn OFF 150 steps before the trimming cam standby position (T-cutter top position). Consequently, TRG switch is normally
ON.
The Y-cutter switch (Y-G) is designed to turn OFF at the Y-cutter top position. When the power is turned on, the circuit checks that the Y-G switch is OFF. If the switch is
ON, the trimming motor reverses until the switch turns OFF. The position of the
TRG switch is not checked at power ON.
Fig. 5.5-3 Trimming Motor Start Point Detect Circuit
•
Y-CA Motor Drive Circuit
This circuit drives the Y-CA motor using 2-2 phase excitation from the +24V DC stabilized constant voltage and maintains a low voltage during Y-cutter operation.
The stepping motor excitation phases A, B, C, and D are controlled by main CPU ports P03, P02, P01, and P00, respectively. The seven transistor arrays incorporated into QA3 drive the Y-CA motor.
The drive voltage is controlled by the main CPU port P65, which applies +24V DC to the Y-CA motor through transistors Q3 and Q4.
Fig. 5.5-4 Y-CA Motor Drive Circuit
5-16
•
X-cutter Motor Drive Circuit
This circuit drives the DC motor with the +24V DC stabilized constant voltage.
The X-cutter comprises a DC motor and two switches. The DC motor is controlled by the main CPU ports P14 to P17 and is driven by the DC motor control driver #4.
The two switches are detected by ports P53 and P54. The operation of the DC motor for each control port status is listed in Table 5.5-1. The DC motor current limit value can be switched by port P14 (DC-IL).
Table 5.5-1 DC Motor Control
P17 (IN1)
High
Low
Low
Low
P16 (IN2)
Low
High
Low
Low
P15 (ENA)
High
High
High
Low
DC Motor Drive
TURN RIGHT
TURN LEFT
BRAKE
OFF
Fig. 5.5-5 X-cutter Motor Drive Circuit
5-17
5.6 Power Supply Circuits
The power supply circuits receive the unstabilized DC voltage supplied to CN1 from the
AC adaptor through the Jack PCB via fuse F1 (protective circuit), diode D6, and the filter circuit.
The 2-channel switching power IC (IC#6) in the circuits converts the unstabilized DC voltage into a stabilized +5V voltage (logic power supply) and into a stabilized +24V DC voltage (drive power supply).
Fig. 5.6-1 Power Supply Circuits
5-18
•
+5V Power Supply
Fig. 5.6-2 shows the timing chart of the power IC (IC#6) for the +5V DC power supply during idling.
In this circuit, the transistor Q11 switches at approximately 100 kHz to convert the unstabilized input voltage to a stabilized +5V supply.
When transistor Q11 is ON, energy accumulates in the coil L3 and electrolytic capacitor C27 until they are able to supply a +5V voltage. Transistor Q11 turns OFF and the energy is supplied by diode D4. The transistor Q11 switching ratio is changed by the load current to create a stable supply. This control is conducted in the power IC.
Fig. 5.6-2 +5 V Timing Chart
•
+24V Power Supply
Fig. 5.6-3 shows the timing chart for the +24V DC power supply during idling.
In this circuit, the transistor Q5 switches at approximately 100 kHz to convert the unstabilized input voltage to a stabilized +24V supply.
When transistor Q5 is ON, energy accumulates in the coil L1. When transistor Q5 turns OFF, this energy is supplied through diode D3 to the electrolytic capacitor C17, where it accumulates and is output as +24V DC.
The transistor Q5 switching ratio is changed by the load current to create a stable supply. This control is conducted in the power IC.
Fig. 5.6-3 +24V Timing Chart
5-19
Chapter 6.
MAINTENANCE
CONTENTS
Chapter 6. MAINTENANCE
Adjusting the Right Y-cutting Position (Border Mode)........................................ 6-17
Adjusting Perpendicularity of Chassis and Document ....................................... 6-19
6.4 Quick way to clean X-cutter……………………………………………………………….. 6-20
6-i
6.1 Lubrication
After the parts of 6.1.3 are replaced, apply lubricant to the positions indicated in 6.1.3
Lubrication Positions below. If only one of a pair of touching parts is replaced, lubricant remains on the other part and no further lubrication is required. If both of a pair of touching parts is replaced, lubricant must be applied to the indicated position.
6.1.1 Table of Lubricants
Use the lubricants designated below. The codes in the table below are used in the descriptions in section 6.1.3.
Code Lubricant Name
E
S
Epinoc grease #1
Silicon grease KS64F
6.1.2 Precautions during Lubrication
•
Do not apply lubricant to parts other than the specified parts. The lubricant may adversely affect plastic parts or PCBs.
•
Take care not to apply too much lubricant, which can then drip onto other parts. As a guideline, apply a drop the size of a grain of rice.
•
Apply lubricant to contacting areas or sliding surfaces of each part at the designated position.
6.1.3 Lubrication Positions
♦
Chassis
•
Chassis L Planet Gear Holder (two positions)
S
TY-planet gear
TY-spring washer
TY-planet gear holder
Planet gear 20 hook
Felt
S (to hooks)
Fig. 6.1-1 Chassis L Planet Gear Holder
6-1
•
Chassis L LF motor Gear
S
Planet gear 20 hook
Planet gear 20 hook
LF motor gear
Fig. 6.1-2 Chassis L LF motor Gear
•
Chassis R TC motor Gear
S
TC motor gear
TY-idle gear
Fig. 6.1-3 Chassis R TC motor Gear
6-2
•
Chassis L/R TY-planet Gear Holder
TY-spring washer
TY-idle gear
Felt
TY-planet gear holder
TY-planet gear
S
Fig. 6.1-4 Chassis L/R TY-planet Gear Holder
•
Top of Chassis L/R
E
S
Chassis
Roller holder pin
S
Lock pin
Roller guide
Fig. 6.1-5 Top of Chassis L/R
6-3
♦
Roller Holder (left and right)
E
S
Roller holder return spring
(right only)
Roller holder
♦
Y-cutter Arm L
E
Release plate
E
Sub-roller bearing
S
Fig. 6.1-6 Roller Holder
Y-cutter arm L
Sensor frame
Y-cutter arm shaft
S (left and right)
S (left and right)
Fig. 6.1-7 Y-cutter Arm L
6-4
♦
Paper Eject Roller
•
Paper Eject Roller
S
Paper eject roller bearing
Paper eject roller unit
S
Fig. 6.1-8 Paper Eject Roller
•
Paper Eject Sub-roller
S
Paper eject roller bearing
Paper eject shaft holder L
S
Paper eject sub-roller
Paper eject shaft holder R
Fig. 6.1-9 Paper Eject Sub-roller
6-5
♦
Driving Roller
S
Bearing
S
Driving roller shaft
♦
T-Chassis Unit
Fig. 6.1-10 Driving Roller
Plate spring
T-chassis
Bearing
S
T-gear 35-14
Fig. 6.1-11 T-Chassis Unit
6-6
♦
Y-CA Chassis Assy
S
Y-CA idle pulley
S
Y-CA pulley holder
Y-CA chassis
♦
Dial Switch
Fig. 6.1-12 Y-CA Chassis Assy
Dial switch B
S
Plate spring
Fig. 6.1-13 Dial Switch
Dial S holder assembly
6-7
♦
Y-Diversion Lever
E (two positions)
Y-cutter guide shaft
Y-diversion lever assy
Fig. 6.1-14 Y-Diversion Lever
Ring
6-8
6.2 Replacing the Cartridge and Film
6.2.1 Replacing the Cartridge
[1] Turn off the power switch and open the top cover.
Fig. 6.2-1 Replacing the Cartridge (1/6)
[2] Push the lock lever R in the direction of the arrow to unlock the roller holder assy.
Hold the set buttons and lift out the roller holder assy.
Lock lever R
Set buttons
Fig. 6.2-2 Replacing the Cartridge (2/6)
6-9
[3] Carefully remove the cartridge.
Fig. 6.2-3 Replacing the Cartridge (3/6)
[4] Orient the new cartridge with the arrow mark facing forward and carefully insert it.
Check the following items before inserting the cartridge.
•
Cartridge shutter is fully closed.
•
The edge of the sheet is parallel with the cartridge film outlet. If the edge is not parallel, cut it parallel with scissors.
•
The edge of the sheet is below the Y-cutter unit.
Arrow mark
Fig. 6.2-4 Replacing the Cartridge (4/6)
6-10
[5] Lower the roller holder assy and push the set buttons in the direction of the arrows to lock the roller holder assy in position.
Fig. 6.2-5 Replacing the Cartridge (5/6)
[6] Close the top cover.
Fig. 6.2-6 Replacing the Cartridge (6/6)
[7] Turn on the power switch and press the Feed button to feed out some sheet and remove the slackness in the sheet. Hold down the Feed button until the edge of the sheet reaches the eject gate.
[8] Press the Cut button to cut off the end of the sheet fed out to remove the slackness.
6-11
6.2.2 Replacing the Sheet
[1] Carefully remove the cartridge.
Fig. 6.2-7 Replacing the Sheet (1/9)
[2] Open the cartridge shutter, then open the cartridge cover.
Fig. 6.2-8 Replacing the Sheet (2/9)
6-12
[3] Remove the old sheet.
Fig. 6.2-9 Replacing the Sheet (3/9)
[4] Hold the yellow plastic holders of the new sheet and insert the sheet in the cartridge as shown in the diagram. It is not possible to insert the sheet in the wrong direction.
Fig. 6.2-10 Replacing the Sheet (4/9)
6-13
[5] Close the cartridge cover, ensuring that the edge of the sheet protrudes from the cartridge film outlet.
Fig. 6.2-11 Replacing the Sheet (5/9)
[6] Press the shutter buttons and close the shutter.
Fig. 6.2-12 Replacing the Sheet (6/9)
6-14
[7] Press the catches on the yellow plastic holders and remove them in the sequence shown.
Fig. 6.2-13 Replacing the Sheet (7/9)
[8] Check that the edge of the sheet is parallel with the cartridge film outlet. If the edge is not parallel, cut it parallel with scissors.
Fig. 6.2-14 Replacing the Sheet (8/9)
6-15
[9] Orient the cartridge with the arrow mark facing forward and carefully insert it.
Arrow mark
Fig. 6.2-15 Replacing the Sheet (9/9)
Note: After removing sheet from its sealed pack, it will dry up if not inserted into the cartridge.
6-16
6.3 Adjustments
6.3.1 Adjusting the Right Y-cutting Position (Border Mode)
Loosen the screw and move slide plate 2 in the direction of the arrow indicated in the diagram below. This moves the Y-cutter attached to the Y-cutter guide and adjusts the cutting position for the right edge of the sheet.
In the diagram below, move slide plate 2 in the direction of the arrow to increase the border of the laminated document.
Margin
Driving roller
Slide plate 2
Screw
Y-cutter guide
Fig. 6.3-1 Adjusting the Right Y-cutting Position
6-17
6.3.2 Adjusting the Left Y-cutting Position
Loosen the screw and move the photosensor (PS) PCB holder left or right. This moves the detection position of the sensor attached to the photosensor (PS) PCB holder and adjusts the cutting position for the left edge of the sheet.
In the diagram below, move the photosensor (PS) PCB holder to the right to increase the border of the laminated document.
Screw
Photosensor (PS) PCB holder
Y-cutter arm L
Fig. 6.3-2 Adjusting the Left Y-cutting Position
6-18
6.3.3 Adjusting Perpendicularity of Chassis and Document
1. Loosen the four screws under the bottom cover, as shown in the diagram.
2. Insert the Slant adjust plate between the paper feed roller and paper feed sub-roller until the edge of the gauge is near the fixed cutter.
3. Check that the side of the gauge lies against the sub-tray rib. Turn the chassis about the pivot until the fixed cutter mounted on the chassis is parallel with the edge of the gauge.
4. After adjusting the fixed cutter parallel with the edge of the gauge, tighten the screws
A and A', taking care not to change the chassis alignment. Remove the gauge and tighten the remaining two screws.
Sub-tray rib
Body cover
Gauge
Paper feed roller
A A’
Screws
X-cutter
Fixed cutter
Pivot
Screws
Fig. 6.3-3 Adjusting Perpendicularity of Chassis and Document
6-19
6.4 Quick way to clean X-cutter
Here’s procedure for quick way to clean X-cutter.
Note that this indicates only the way of cleaning, and If mal-cutting still persists after cleaning according the way below, then replacement of X-cutter unit according disassembly procedure of Chapter 3 is necessary.
1. Disassemble machine to the extent of Fig.3.3-11 ( Like Fig. 6.4-1 below )
Fig. 6.4-1 Disassemble machine
2. Remove Y-CA chassis screws and Y-extension spring L to remove Y-CA chassis Assy, with chassis still assembled with bottom cover.
Fig. 6.4-2 Removing Y-CA chassis Assy
6-20
3. Remove Paper eject sub-roller springs.
Fig. 6.4-3 Removing Paper eject sub roller springs
4. Clean fixed blade of X-cutter by inserting alcohol-soaked cotton bar into clearance between Paper eject roller and Paper eject sub-roller and sliding it horizontally, along cleaning range indicated in the Fig. below. After cleaning X-cutter, reassemble machine in the reverse order of disassembly, and start machine to check quality of
X-cutting .
Fig. 6.4-4 Cleaning X-cutter blade
6-21
Chapter 7.
TROUBLESHOOTING
CONTENTS
Chapter 7. TROUBLESHOOTING
i
7.1 Outline
It is extremely difficult to determine when and where a problem may arise and to determine the cause of a problem that did arise. It is even more difficult to formulate remedies for theoretical problems which may or may not occur. This chapter gives examples of actual problems that have occurred, together with suggested remedies.
While this chapter may not allow all faults to be remedied, use it as one means of rectifying problems.
7.2 Precautions during Repair
Always follow the precautions below when repairing the unit.
1. Always unplug the AC adaptor from the main power socket before removing a cover, adjusting mechanical parts, or removing a PCB.
2. Always unplug the AC adaptor from the main power socket measuring conductivity with a circuit tester.
3. When removing a connector, pull on the body of the connector, not on the lead attached to it.
7.3 After Making a Repair
Always test the unit after diagnosing and repairing a problem to ensure that the problem is completely remedied.
When the cause of a problem is identified, make a note of it in the troubleshooting procedures for future reference.
7.4 Basic Checks
Check the following items whenever a problem occurs.
•
Check the power supply voltage.
Make sure that the AC input voltage, the AC adaptor output voltage, and the DC supply voltage for each part are at the prescribed value.
•
Check the connectors
Ensure that no connector is loose or disconnected.
•
Check the fuses
Check if the fuse F1 or thermal fuse in the AC adaptor has blown.
7-1
7.5 Troubleshooting Flowcharts
AC adaptor plugged in, power ON
Is green LED indicator lit?
No
Yes
Error at power ON
(red indicator flashes)
No
1 Nothing happens when power switch is pressed.
a. Abnormal +5V DC supply.
b. Defective main CPU.
See page 7-5.
2 Nothing happens when switches are pressed
(LED indicators do not light).
a. Defective switch or leaf switch on the
Switch PCB.
b. Defective LED on the Switch PCB.
See page 7-6.
Yes
Before film feed?
No
Yes
3 An error occurred during processing after power ON (before film feed).
a. Abnormal +24V DC supply b. Abnormal DC input voltage.
c. Abnormal X-cutter power ON processing.
d. Abnormal Y-carriage power ON processing.
e. Abnormal Y-cutter power ON processing.
See page 7-8.
4 An error occurred during processing after power ON (after film feed).
a. Defective film or cartridge.
b. Defective film feed detector (TPS) switch.
c. Defective film feed system.
See page 7-10.
Is manual feed normal?
No
Yes
2 Nothing happens when switches are pressed
(LED indicators do not light).
a. Defective switch or leaf switch on the
Switch PCB.
b. Defective LED on the Switch PCB.
See page 7-6.
5
Abnormal manual feed .
a. Defective film feed (LF) motor.
b. Defective film compression system.
c. Problem related to paper eject roller.
See page 7-11.
7-2
Is trimming normal?
Yes
No
Is X-cutter operation normal?
Yes
No
Is automatic operation normal?
Yes
No
END a. Defective trimming (TRI) switch. b. Defective trimming (TC) motor. c. Defective trimming (TRG) switch. d. Defective T-cutter.
See page 7-12.
(LED indicators do not light). a. Defective switch or leaf switch on the Switch
PCB. b. Defective LED on the Switch PCB.
See page 7-6.
7
Abnormal X-cutter operation. a. Defective X-cutter position switch. b. Defective X-cutter DC motor. c. Defective X-cutter.
See page 7-15.
(LED indicators do not light). a. Defective switch or leaf switch on the
Switch PCB. b. Defective LED on the Switch PCB.
See page 7-6.
Problem during automatic operation.
7-3
Problem during automatic operation.
Is document correctly inserted?
Yes
Document width detected correctly?
Yes
No
No
Cartridge detected correctly?
Yes
No
Normal laminating operation?
Yes
Y-cutting normal?
Yes
No
No
Correct X-cutting position?
No
Yes
Buzzer sounds correctly?
Yes
END
No
8 Document cannot be correctly inserted.
a. Problem with input-side rollers.
b. Defective PE sensor (P-END) switch.
See page 7-16.
9 Document width cannot be detected correctly.
a. Defective Y-carriage (Y-CA) motor.
b. Defective sensor unit (YCA-F).
c. Defective Y-cutter arm.
See page 7-17.
14 Cartridge size, film type cannot be detected correctly.
a. Defective cartridge type detector (CSIZE) switch.
See page 7-22.
10 Lamination is not normal.
a. Defective film type (ENC) detector.
b. Defective document or film.
See page 7-18.
11 No cutting in Y direction.
a. Defective Y-cutter (Y-G) switch.
b. Abnormal Y-cutter vertical movement.
See page 7-19.
12 Incorrect cutting in Y direction.
a. Incorrect Y-direction cutting position.
b. Defective Y-cutter.
See page 7-20.
13 Incorrect cutting position at document front or rear edge.
a. Defect in paper feed system.
b. Defect in paper sensor system.
See page 7-21.
15 Buzzer does not sound.
a. Defective buzzer circuit.
See page 7-23.
7-4
7.6 Troubleshooting Tables
Problem
1
Nothing happens when power switch is pressed. (LED indicator does not light.) a. Abnormal input voltage. b. Abnormal +5V DC supply. c. Defective main CPU.
Check Item Cause Remedy Repair
See
Section a. Abnormal input voltage
Are AC adaptor, Jack PCB, power harness correctly connected?
Is fuse F1 on Main PCB blown?
Is AC adaptor output voltage normal (about 21V DC at rated input)?
Is AC adaptor voltage applied to connector CN13 on Main
PCB?
Defective harness connection.
Blown fuse.
Defective AC adaptor. Replace AC adaptor.
Defective Jack PCB.
Connect harness
Replace fuse.
3.3.3
3.3.4
3.3.5
3.5.1
−−− b. Abnormal +5V
DC supply
Is power supply IC#6 pin 10 output Low or switching?
When power supply IC#6 pin
10 output is Low, is transistor
Q10 ON?
When transistor Q10 is ON, is transistor Q11 ON?
Defective power harness.
Defective power supply
IC#6.
Defective transistor
Q10.
Defective transistor
Q11.
Zener diode ZD4 is shorted.
Defective reset IC#2.
Replace Jack PCB.
Replace power harness.
Replace Main PCB assy.
Replace Main PCB assy.
3.3.1
4.3.2
3.3.3
3.3.4
3.3.5
3.5.2
Replace
IC#6.
Replace Q10.
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
3.4.1
Replace Main PCB assy.
Replace Main PCB assy.
Replace Q11.
Replace ZD4.
Replace Q11.
3.3.3
3.3.4
3.3.5
3.5.1 c. Defective main
CPU
Is Reset (Pin 29) of the main
CPU #1 High?
Is oscillator waveform output from XIN (Pin 30) and XOUT
(Pin 31) of the main CPU?
Defective oscillator
XT1.
Replace Main PCB assy.
Replace Main PCB assy.
Defective main CPU#1. Replace Main PCB assy.
Replace
IC#2.
Replace XT1.
Replace
CPU#1.
7-5
Problem a. Defective switch or leaf switch on the
Switch PCB
2
Nothing happens when switches are pressed. a. Defective switch or leaf switch on the Switch PCB. b. Defective LED on the Switch PCB.
Check Item
Is Switch PCB correctly mounted?
Cause
Defective Switch PCB mounting.
Remedy
Correctly mount
Switch PCB.
Repair
Is switch harness assy correctly connected?
Is the red lead connector connected to CN2 on the
Switch PCB?
Is the white lead connector connected to CN3 on the
Switch PCB?
Is the yellow lead connector connected to CN4 on the
Switch PCB?
When switch SW1 to SW4 is pressed on the Switch PCB, does the switch become conducting?
When the cover R/cover L leaf switch is shorted, does the connector on the leaf switch assy become conducting?
Defective connection of switch harness assy.
Leaf switch assy not connected.
Leaf switch assy not connected.
Leaf switch assy not connected.
Continuity problem in switch SW1 to SW4.
Defective leaf switch assy.
When switch SW1 to SW4 is pressed on the Switch PCB or the leaf switch assy is shorted, can the conductivity be checked at CN1 on the main CPU?
If conductivity can be checked at CN1 on the main
CPU when switch SW1 to
SW4 is pressed or the leaf switch assy is shorted, can the conductivity be checked at the main CPU ports?
Defective switch harness assy.
Continuity problem in
Main PCB.
Correctly connect switch harness assy.
Correctly connect the leaf switch assy.
Correctly connect the leaf switch assy.
Correctly connect the leaf switch assy.
Replace the Switch
PCB.
Replace cover switch assy.
Replace leaf switch
R assy.
Replace leaf switch L assy.
Replace switch harness assy.
Replace Main PCB assy.
Replace switch SW1 to SW4.
See
Section
3.3.3
3.3.4
3.3.5
3.3.7
3.3.8
3.3.9
Defective series resistor on main CPU.
Replace Main PCB assy.
If conductivity can be checked at the main CPU ports when switch SW1 to
SW4 is pressed or the leaf switch assy is shorted, is this recognized by the main
CPU?
Defective main CPU#1. Replace Main PCB assy.
Replace series resistor.
Replace
CPU#1.
3.3.3
3.3.4
3.3.5
3.5.1
7-6
Problem b. Defective LED on the Switch
PCB
Check Item Cause Remedy
Low output from the main
CPU ports P32 to P35 (Pin
35 to Pin 38) that drive indicators LED1 to LED4?
Does LED1 to LED4 light when Pin 6 to Pin 9 on Main
PCB connector CN1 is Low?
Defective main CPU#1. Replace Main PCB assy.
Defective switch harness assy.
Defective LED1 to
LED4.
Replace switch harness assy.
Replace the Switch
PCB.
Repair
Replace
CPU#1.
Replace indicator
LED1 to
LED4.
See
Section
3.3.3
3.3.4
3.3.5
3.5.1
3.3.3
3.3.4
3.3.5
3.3.3
3.3.4
3.3.5
3.3.7
3.3.8
3.3.9
7-7
3
An error occurred during processing after power ON (before film feed). a. Abnormal +24V DC supply b. Abnormal DC input voltage. c. Abnormal X-cutter power ON processing. d. Abnormal Y-carriage power ON processing. e. Abnormal Y-cutter power ON processing.
Problem Check Item Cause Remedy Repair a. Abnormal +24V
DC supply b. Abnormal DC input voltage c. Abnormal Xcutter power
ON processing
Is +24V DC voltage at ±0V? Coil L1 discharged. Replace Main PCB assy.
Replace L1.
Continuity problem with diode D2.
Replace Main PCB assy.
Replace D2.
Defective AC adaptor. Replace AC adaptor. Does +24V DC voltage exceed 24 V, at the same level as the AC adaptor output voltage (at rated AC input)?
Is power supply IC#6 pin 7 switching?
Is transistor Q8 collector voltage switching between 0
V and input voltage?
Defective power supply
IC#6.
Replace Main PCB assy.
Defective transistor Q8. Replace Main PCB assy.
Replace
IC#6.
Replace Q8.
Replace Q9. Defective transistor Q9. Replace Main PCB assy.
Defective transistor Q5. Replace Main PCB assy.
Replace Q5. Is transistor Q5 collector voltage switching between
+24 V and 0 V?
Is input voltage from AC adaptor between 16 V and 23
V (at rated input)?
Defective AC adaptor. Replace AC adaptor.
Replace Q7. If AC adaptor input voltage is equal or below 23 V, is main
CPU port P66 (Pin 62) at
High level?
If AC adaptor input voltage is equal or above 16 V, is main
CPU port P67 (Pin 63) at
Low level?
Defective transistor Q7. Replace Main PCB
Defective Zener diode
ZD1.
X-cutter does not move at all? Foreign matter stuck in cutter. assy.
Defective transistor Q6. Replace Main PCB assy.
Replace Main PCB assy.
Clean out foreign matter.
Replace Q6.
Replace ZD1.
Defective X-cutter. Replace the X-cutter unit.
See
Section
3.3.3
3.3.4
3.3.5
3.5.1
−−−
3.3.3
3.3.4
3.3.5
3.5.1
−−−
3.3.3
3.3.4
3.3.5
3.5.1
−−−
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.6.1
3.7.1
3.8.1
3.8.2
3.10
3.11.1
3.12.1
Error occurs during X-cutter position detection?
See 7 Abnormal X-cutter operation.
7-8
Problem Check Item Cause Remedy d. Abnormal Ycarriage power
ON processing
Sensor lever cuts photosensor at start position?
Photosensor cut off when not at start position?
Deformed sensor frame unit?
Replace the sensor frame unit.
Sensor lever incorrectly installed.
Defective sensor lever. Replace the sensor lever.
See 9 Document width cannot be detected correctly. e. Abnormal Ycutter power
ON processing
Error during Y-carriage position detection?
Error during Y-cutter position detection?
See 11 No cutting in Y direction.
Repair
See
Section
3.3.3
3.3.4
3.3.5
3.8
7-9
4
An error occurred during processing after power ON (after film feed). a. Defective film or cartridge. b. Defective film feed detector (TPS) switch. c. Defective film feed system.
Problem Check Item Cause Remedy Repair a. Defective film or cartridge b. Defective film feed detector
(TPS) switch.
Is the film cartridge correctly mounted?
Does film remain in the cartridge?
Is the cartridge deformed or cracked?
Is the orange lead connector connected to CN15 on the
Main PCB?
Does the sensor lever press the film feed detector (TPS) switch (leaf switch F assy) when film is inserted?
Is the leaf switch open when no film is inserted?
Defective film cartridge mounting.
No film remaining.
Defective cartridge.
Leaf switch assy not connected.
Incorrectly installed leaf switch.
Correctly mount the film cartridge.
Replace the film.
Replace the cartridge.
Correctly connect the leaf switch assy.
Correctly install the leaf switch.
Incorrectly installed sensor lever.
Correctly install the sensor lever.
Defective sensor lever. Replace the sensor lever.
Continuity problem in
Main PCB.
Replace Main PCB assy.
Is main CPU port P60 (Pin
56) at High level when leaf switch TPS is open?
When leaf switch TPS is shorted, is CN15 on the Main
PCB shorted?
Defective pull-up resistor R41.
Defective leaf-switch F assy.
Replace Main PCB assy.
Replace leaf-switch F assy.
Replace R41.
See
Section
3.2
3.3.3
3.3.4
3.3.5
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.12.2
3.3.3
3.3.4
3.3.5
3.5.1
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.12.2
Is main CPU port P60 (Pin
56) at Low level when CN15 on the Main PCB is shorted?
Continuity problem in
Main PCB.
Replace Main PCB assy. c. Defective film feed system
When main CPU port P60
(Pin 56) is at Low level, is this recognized by the main
CPU?
Defective film feed (LF) motor.
Defective film compression system.
Defective series resistor R35.
Replace Main PCB assy.
Defective main CPU#1. Replace Main PCB assy.
See 5 Abnormal manual feed .
Replace
CPU#1.
3.3.3
Replace R35. 3.3.4
3.3.5
3.5.1
7-10
5
Abnormal manual feed a. Defective film feed (LF) motor. b. Defective film compression system. c. Problem related to paper eject roller.
Problem Check Item
Do the top and bottom paper eject rollers move smoothly?
Cause
Problem with paper eject rollers.
Remedy a. Defective film feed (LF) motor
Is the black lead connector connected to CN10 on the
Main PCB?
Are pulses output from output ports P70 to P73 (Pin 1 to
Pin 4) of the main CPU#1?
When the output from output ports P70 to P73 (Pin 1 to
Pin 4) of the main CPU#1 is
Low, is the output from transistor array QA2 Low?
Is +24V DC applied to Pins 3 and 4 of connector CN10 on the Main PCB?
Continuity in motor harness assy? b. Defective film compression system.
Motor harness assy not connected.
Defective main CPU#1. Replace Main PCB assy.
Defective transistor array QA2.
Continuity problem in
Main PCB.
Defective motor harness assy.
Correct resistance value
(approx. 38 ohms) between each phase of the LF motor
(LF motor) and the COM pin?
Are top and bottom feed rollers correctly engaged?
Defective LF motor.
Roller holder unit is incorrectly set up.
Correctly connect the motor harness assy.
Replace Main PCB assy.
Replace Main PCB assy.
Replace motor harness assy for LF motor.
Replace LF motor.
Correctly set up the roller holder unit. c. Problem related to paper eject roller
Is film correctly placed between the feed rollers?
Film or other foreign matter stuck to top or bottom paper eject roller.
Defective cassette setting.
Foreign matter stuck to roller.
Set the cassette correctly.
Clean off foreign matter.
Apply KS64F silicon grease to the four bearings.
Repair
Replace
CPU#1.
See
Section
3.3.3
3.3.4
3.3.5
Replace QA2. 3.3.3
3.3.4
3.3.5
3.5.1
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.14.2
6.2
3.3.1
3.3.3
3.3.4
3.3.5
3.4
7-11
6
Abnormal trimming a. Defective trimming (TRI) switch. b. Defective trimming (TC) motor. c. Defective trimming (TRG) switch. d. Defective T-cutter.
Problem a. Defective trimming (TRI) switch
Check Item
Is document correctly inserted?
Cause
Document inserted incorrectly.
Remedy
Correctly insert the document.
Repair
See
Section
Does the sensor lever press the trimming switch (leaf switch TRI assy) when a document is inserted?
Is the leaf switch open when no document is inserted?
Incorrectly installed trimming switch.
Correctly install the trimming switch.
Incorrectly installed sensor lever.
Correctly install the sensor lever.
Defective sensor lever. Replace the sensor lever.
Leaf switch assy not connected.
Correctly connect the leaf switch assy.
Is the black lead connector connected to CN5 on the
Main PCB?
Is main CPU port P40 (Pin
41) at High level when trimming switch TRI is open?
Continuity problem in
Main PCB.
Replace Main PCB assy.
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.6
3.3.3
3.3.4
3.3.5
3.3.3
3.3.4
3.3.5
Replace R24. 3.5.1
When trimming switch TRI is shorted, is CN5 on the Main
PCB shorted?
Defective pull-up resistor R24.
Defective trimmingswitch TRI assy.
Replace Main PCB assy.
Replace trimmingswitch TRI assy.
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.6
Is main CPU port P40 (Pin
41) at Low level when CN5 on the Main PCB is shorted?
Continuity problem in
Main PCB.
Replace Main PCB assy.
When main CPU port P40
(Pin 41) is at Low level, is this recognized by the main
CPU?
Defective series resistor R30.
Replace Main PCB assy.
Defective main CPU#1. Replace Main PCB assy.
Replace
CPU#1.
3.3.3
Replace R30. 3.3.4
3.3.5
3.5.1
7-12
Problem b. Defective trimming (TC) motor. c. Defective trimming (TRG) switch.
Check Item Cause
Is the white lead connector connected to CN9 on the
Main PCB?
Are pulses output from output ports P74 to P77 (Pin 5 to
Pin 8) of the main CPU#1?
When the output from output ports P74 to P77 (Pin 5 to
Pin 8) of the main CPU#1 is
Low, is the output from transistor array QA1 Low?
Is +24V DC applied to Pins 3 and 4 of connector CN9 on the Main PCB?
Continuity in motor harness assy?
Motor harness assy not connected.
Correctly connect the motor harness assy.
Defective main CPU#1. Replace Main PCB assy.
Defective transistor array QA1.
Continuity problem in
Main PCB.
Defective motor harness assy.
Replace Main PCB assy.
Replace Main PCB assy.
Replace motor harness assy for TC motor.
Correct resistance value
(approx. 43 ohms) between each phase of the TC motor and the COM pin?
Is the red lead connector connected to CN6 on the
Main PCB?
Is main CPU port P44 (Pin
45) at High level when leaf switch TR-G is open?
When leaf switch TR-G is shorted, is CN6 on the Main
PCB shorted?
Defective TC motor.
Leaf switch assy not connected.
Continuity problem in
Main PCB.
Defective pull-up resistor R25.
Defective leaf-switch
TR-G assy.
Replace TC motor.
Correctly connect the leaf switch assy.
Replace Main PCB assy.
Remedy
Replace Main PCB assy.
Replace leaf-switch
TR-G assy.
Repair
Replace
CPU#1.
See
Section
3.3.3
3.3.4
3.3.5
Replace QA1. 3.3.3
3.3.4
3.3.5
3.5.1
Replace R25.
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.15
3.3.3
3.3.4
3.3.5
3.3.3
3.3.4
3.3.5
3.5.1
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.6
Is main CPU port P44 (Pin
45) at Low level when CN6 on the Main PCB is shorted?
Continuity problem in
Main PCB.
Replace Main PCB assy.
When main CPU port P44
(Pin 45) is at Low level, is this recognized by the main
CPU?
Defective series resistor R29.
Replace Main PCB assy.
Defective main CPU#1. Replace Main PCB assy.
Replace
CPU#1.
3.3.3
Replace R29. 3.3.4
3.3.5
3.5.1
7-13
Problem d. Defective Tcutter.
Check Item
Does the trimming T-cam rotate when the trimming motor (TC motor) rotates?
Cause
Problem with planet gear operation.
No cutting occurs despite a grating noise is heard?
Cutting position is correct but cutting is incomplete?
The T-cutter plate is not installed.
The T-cutter plate is not installed correctly.
Defective T-cutter plate.
Remedy
Apply KS64F silicon grease to the four bearings.
Replace the TY planet gear.
Install a T-cutter plate.
Correctly install the
T-cutter plate.
Replace the T-cutter plate.
Repair
See
Section
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.15
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.6
7-14
7
Abnormal X-cutter operation. a. Defective X-cutter position switch. b. Defective X-cutter DC motor. c. Defective X-cutter.
Problem a. Defective Xcutter position switch
Check Item Cause Remedy
The X-cutter rotary cutter is at the left or right end but neither Pin 2 nor 3 is continuous with Pin 1?
Alternatively, both Pin 2 and 3 are continuous with Pin 1?
Defective X-cutter unit. Replace the X-cutter unit.
Repair
Continuity between Pins 1, 2, and 3 of the X-cutter harness assy?
Defective X-cutter harness assy.
Replace the X-cutter harness assy. b. Defective Xcutter DC motor
During X-cutter operation, do main CPU port P53 (Pin 52) and port P54 (Pin 53) switch to High level?
When main CPU port P53
(Pin 52) and port P54 (Pin
53) are at Low level, is this recognized by the main
CPU?
When output is normal from the main CPU#1 output ports
P15 to P17 (Pin 22 to Pin 24
[See Table 5.5-1]), does the output between OUT1 (Pin 1) and OUT2 (Pin 3) of the DC motor driver #4 changes alternatively between 0 V and
+24 V?
Continuity between Pins 4 and 5 of the X-cutter harness assy?
Defective pull-up resistors R20 and R22.
Replace Main PCB assy.
Defective main CPU#1. Replace Main PCB assy.
Defective DC motor driver #4.
Defective X-cutter harness assy.
Replace Main PCB assy.
Replace the X-cutter harness assy.
Replace R20 and R22.
Replace
CPU#1.
Replace #4. c. Defective Xcutter.
Normal resistance (approx.
30 ohms) between Pins 4 and 5 of the X-cutter harness assy (DC motor resistance value)?
Does the rotary cutter rotate when the DC motor rotates?
Cutting of only halfway?
Defective X-cutter unit. Replace the X-cutter unit.
Defective X-cutter unit. Replace the X-cutter unit.
Defective X-cutter unit. Replace the X-cutter unit.
Metal or other foreign matter in the laminated document.
Remove the foreign matter.
3.3.3
3.3.4
3.3.5
3.5.1
3.3.3
3.3.4
3.3.5
3.5.1
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.6.1
3.7.1
3.8.1
3.8.2
3.10
3.11.1
3.12.1
3.3.1
3.3.3
3.3.4
3.3.5
3.4
See
Section
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.6.1
3.7.1
3.8.1
3.8.2
3.10
3.11.1
3.12.1
3.3.1
3.3.3
3.3.4
3.3.5
3.4
7-15
Problem a. Problem with input-side rollers
8
Document cannot be correctly inserted. a. Problem with input-side rollers. b. Defective PE sensor (P-END) switch.
Check Item Cause Remedy
Is document correctly inserted against the paper feed roller?
Is document correctly aligned at right edge?
Is document inserted at an slant?
Document inserted incorrectly.
Correctly insert the document.
Document inserted incorrectly.
Correctly insert the document.
Defective paper feed roller extension springs.
Correctly install extension springs.
Repair
See
Section
−−−
−−−
3.3.1
3.3.3
3.3.4
3.3.5
3.4
6.3.3 Are the paper reference in the body cover and paper feed roller perpendicular?
Incorrectly installed PE sensor.
Re-adjust.
Correctly install the
PE sensor. b. Defective PE sensor
(P-END) switch
Does the sensor lever press the PE sensor (P-END) switch when a document is inserted?
Is the PE sensor (P-END) switch OFF when no document is inserted?
Incorrectly installed sensor crank.
Correctly install the sensor crank.
Defective sensor crank. Replace the sensor crank.
Defective harness assy connection.
Correctly connect the harness assy.
Defective harness assy connection.
Correctly connect the harness assy.
3.3.3
3.3.4
3.3.5
Is the white lead harness assy connected to the PE sensor connector?
Is the white lead connector connected to CN7 on the
Main PCB?
Is main CPU port P45 (Pin
46) at High level when PE sensor P-END is OFF?
Continuity problem in
Main PCB.
Replace Main PCB assy. 3.3.3
3.3.4
3.3.5
Replace R32. 3.5.1
When paper sensor P-END is ON, is CN7 on the Main
PCB shorted?
Defective pull-up resistor R32.
Defective PE sensor assy.
Is main CPU port P45 (Pin
46) at Low level when CN7 on the Main PCB is shorted?
Defective harness assy.
Continuity problem in
Main PCB.
Replace Main PCB assy.
Replace PE sensor assy.
When main CPU port P45
(Pin 46) is at Low level, is this recognized by the main
CPU?
Defective series resistor R28.
Replace Main PCB assy.
Defective main CPU#1. Replace Main PCB assy.
3.3.3
3.3.4
3.3.5
Replace the paper sensor harness assy.
Replace Main PCB assy.
3.3.3
Replace R28. 3.3.4
3.3.5
Replace
CPU#1.
3.5.1
7-16
9
Document width cannot be detected correctly. a. Defective Y-carriage (Y-CA) motor. b. Defective sensor unit (YCA-F). c. Defective Y-cutter arm.
Problem b. Defective sensor unit
(YCA-F).
Check Item Cause Remedy Repair a. Defective Ycarriage (Y-CA) motor
Is the Y-CA motor harness connected to connector C11 on the Main PCB?
Are pulses output from output ports P00 to P03 (Pin 9 to
Pin 12) of the main CPU#1?
When the output from output ports P00 to P03 (Pin 9 to
Pin 12) of the main CPU#1 is
High, is the output from transistor array QA3 Low?
When output port P65 (Pin
61) of the main CPU#1 is
High (equal or more than 4V), is +24V DC applied to Pin 5 of connector CN11?
Correct resistance value
(approx. 227 ohms) between each phase of the Y-CA motor and the COM pin?
Motor harness not connected.
Defective transistor array QA3.
Correctly connect the motor harness.
Defective main CPU#1. Replace Main PCB assy.
Replace Main PCB assy.
Defective transistor Q4. Replace Main PCB assy.
Defective transistor Q3. Replace Main PCB assy.
Continuity problem in
Main PCB.
Replace Main PCB assy.
Defective Y-CA motor. Replace the Y-CA motor.
Replace
CPU#1.
Replace QA3.
Replace Q4.
Replace Q3.
See
Section
3.3.3
3.3.4
3.3.5
3.3.3
3.3.4
3.3.5
3.5.1
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.7
3.3.3
3.3.4
3.3.5 c. Defective Ycutter arm
Is the flat cable connected to connector CN2 (CN14) on the Main PCB?
Sensor lever cuts photosensor when a document is inserted?
Photosensor cut off when no document is inserted?
Is photosensor PH2 on the
Paper size detector PCB working correctly?
Normal continuity in Paper size detector PCB flat cable?
Defective connection of the flat cable.
Sensor lever incorrectly installed.
Correctly connect the flat cable.
Correctly install the sensor lever.
Defective sensor lever. Replace the sensor lever.
Defective photosensor
PH2.
Replace the Paper size detector PCB.
Discontinuity in flat cable.
Replace the Paper size detector PCB.
Does the Y-cutter arm move when the Y-CA motor rotates?
Y-cutter arm is caught during its movement?
Is the Y-cutter arm separated from the sensor frame?
Y-cutter arm and timing belt incorrectly installed.
Foreign matter stuck to the sensor arm.
The Y-cutter arm shaft is incorrectly installed.
Correctly install the timing belt.
Clean off the foreign matter.
Correctly install the
Y-cutter arm shaft.
Replace PH2.
Replace the sensor harness
550X4.
3.3.3
3.3.4
3.3.5
3.8
3.3.3
3.3.4
3.3.5
7-17
10
Lamination is not normal. a. Defective film type (ENC) detector. b. Defective document or film.
Problem a. Defective film type (ENC) detector.
Check Item Cause Remedy Repair
Is the white lead connector connected to CN3 on the
Main PCB?
Is the white lead harness assy connected to the ENC sensor assy?
Is the ENC sensor assy correctly installed on the cassette holder?
Continuity in ENC harness assy?
When the output from output port P30 (Pin 33) of the main
CPU#1 is Low, does the output from CN3 Pin 2 vary between 0 and 4V DC due to black and silver targets?
Defective harness assy connection.
Defective harness assy connection.
Incorrectly installed
ENC sensor assy.
Defective ENC harness assy.
Defective photosensor in ENC sensor assy.
Correctly connect the harness assy.
Correctly connect the harness assy.
Correctly install the
ENC sensor assy.
Replace the ENC harness assy.
Replace ENC sensor assy.
Replace the photosensor.
See
Section
3.3.3
3.3.4
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.6.1
3.7.1
3.8.1
3.8.2
3.9
3.10
3.11.1
3.12.1
3.13.1
3.16
When a signal is input to
CN3 Pin 2, does the signal change at output port TC1
(Pin 19) of the main CPU?
Is a cartridge mounted?
ENC sensor assy incorrectly adjusted.
Defective IC#5.
Defective R47.
Replace ENC sensor assy.
Replace Main PCB assy.
Replace
IC#5.
Replace Main PCB assy.
Continuity problem in
Main PCB.
Replace Main PCB assy.
No cartridge mounted. Mount a cartridge.
3.3.3
Replace R47. 3.3.4
3.3.5
3.5.1 b. Defective document or film
Replace the film. 6.2 Does film remain in the cartridge?
Is silver-black foil stuck to the edge of the film?
No film remaining.
Defective film. Replace the film.
7-18
Problem a. Defective Ycutter (Y-G) switch
11
No cutting in Y direction. a. Defective Y-cutter (Y-G) switch. b. Abnormal Y-cutter vertical movement.
Check Item
Is the blue lead connector connected to CN8 on the
Main PCB?
Is leaf switch Y-G not contacted when the Y-cutter is at the standby position?
Cause
Leaf-switch assy not connected correctly.
Leaf switch incorrectly installed.
Does the Y-sensor lever press the leaf switch when Ycutter is not at the standby position?
Y-sensor lever incorrectly installed.
Is main CPU port P46 (Pin
47) at High level when leaf switch Y-G is open?
When leaf switch Y-G is shorted, is CN8 on the Main
PCB shorted?
Defective Y-sensor lever.
Continuity problem in
Main PCB.
Defective pull-up resistor R31.
Defective leaf switch assy.
Is main CPU port P46 (Pin
47) at Low level when CN8 on the Main PCB is shorted?
Continuity problem in
Main PCB.
Replace the Y-sensor lever.
Remedy
Correctly connect the leaf-switch assy.
Correctly install the leaf switch.
Correctly install the
Y-sensor lever.
Replace Main PCB assy.
Repair
Replace Main PCB assy.
Replace leaf switch Y assy.
Replace R31.
See
Section
3.3.3
3.3.4
3.3.5
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.6.1
3.7.1
3.8.1
3.8.2
3.10
3.3.3
3.3.4
3.3.5
3.5.1
3.3.1
3.3.3
3.3.4
3.3.5
3.4
Replace Main PCB assy.
Replace
CPU#1.
3.3.3
Replace R27. 3.3.4
3.3.5
3.5.1 b. Abnormal Ycutter vertical movement
Defective series resistor R27.
When main CPU port P46
(Pin 47) is at Low level, is this recognized by the main
CPU?
Does the Y-cutter cam rotate when the trimming motor (TC motor) rotates?
Problem with planet gear operation.
Replace Main PCB assy.
Defective main CPU#1. Replace Main PCB assy.
Does the Y-diversion lever rotate when the Y-cutter cam rotates?
Is Y-cutter assy mounted correctly?
Y-extension springs
L/R incorrectly installed.
Foreign matter under the Y-diversion lever
Incorrectly mounted Ycutter assy.
Apply KS64F silicon grease to the four bearings.
Replace the TY planet gear.
Correctly install Yextension springs
L/R.
Clean out foreign matter.
Mount the Y-cutter assy correctly.
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.15
−−−
7-19
12
Incorrect cutting in Y direction. a. Incorrect Y-direction cutting position. b. Defective Y-cutter.
Problem Check Item Cause Remedy a. Incorrect Ydirection cutting position
Does the right cutter move when the mode is changed?
Does the Y-cutter move when the Y-carriage moves?
Right cut position is always displaced in one direction.
Left cut position is always displaced in one direction.
Does Y-cutter arm move smoothly?
Y-cutter guide R and slide plate 2 incorrectly installed.
Y-cutter arm L and Ycutter guide L incorrectly installed.
Incorrect adjustment of slide plates 1 and 2.
Incorrect adjustment of
Y-sensor unit.
Defective Y-cutter arm movement.
Correctly reassemble the body cover.
Correctly reassemble
Y-cutter arm L.
Readjust.
Readjust the Ysensor unit.
Apply KS64F silicon grease to Y-cutter arm shaft and sensor frame.
Repair b. Defective Ycutter
Is the Y-cutter unit correctly installed?
Incorrectly installed Ycutter unit.
Correctly install the
Y-cutter unit.
Y-cutter makes jagged cuts? Defective Y-cutter unit. Replace Y-cutter unit.
See
Section
3.3.3
3.3.4
3.3.5
6.3.1
6.3.2
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.11.1
7-20
13
Incorrect cutting position at document front or rear edge. a. Defect in paper feed system. b. Defect in paper sensor system.
Problem a. Defect in paper feed system
Check Item
Does the rollers slip?
Is LF motor out of step?
Cause
Do the three planet gear units mounted on chassis L move smoothly?
Defective operation of planet gear units.
Remedy
Apply KS64F silicon grease to the planet gear units.
Replace the planet gear units.
Dirt or other foreign matter stuck to rollers.
Defective driving roller shaft.
Clean the rollers.
Apply KS64F silicon grease to the driving roller shaft bearings.
Repair b. Defect in paper sensor system
Does the paper sensor work smoothly?
Deformed sensor lever
(paper sensor crank)?
Does the sensor lever work smoothly?
Defective paper sensor. Replace the paper sensor.
Defective paper sensor crank.
Defective paper sensor crank.
Replace the paper sensor crank.
Replace the paper sensor crank.
See
Section
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.14.1
−−−
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.3.3
3.3.4
3.3.5
7-21
14
Cartridge size, film type cannot be detected correctly. a. Defective cartridge type detector (CSIZE) switch.
Problem Check Item a. Defective cartridge type detector
(CSIZE) switch
Is the yellow lead connector connected to CN12 on the main PCB?
Is the cartridge leaf switch pressed when an A4 cartridge is inserted?
Cause
Leaf switch C assy not connected.
Remedy
Correctly connect the leaf switch C assy.
Repair
Incorrectly installed leaf switch C assy.
Correctly install the leaf switch C assy.
Is the cartridge leaf switch not pressed when an A6 cartridge is inserted?
Is main CPU port P62 (Pin
58) at High level when leaf switch CSIZE is open?
Incorrectly inserted cartridge?
Incorrectly installed leaf switch C assy.
Re-insert the cartridge.
Correctly install the leaf switch C assy.
Continuity problem in
Main PCB.
When leaf switch CSIZE is shorted, is CN12 on the Main
PCB shorted?
Defective pull-up resistor R77.
Defective leaf switch C assy.
Replace Main PCB assy.
Replace Main PCB assy.
Replace leaf switch
C assy.
Replace R77.
3.3.1
3.3.3
3.3.4
3.3.5
3.4
3.3.3
3.3.4
3.3.5
3.5.1
3.3.1
3.3.3
3.3.4
3.3.5
3.4
See
Section
3.3.3
3.3.4
3.3.5
3.3.1
3.3.3
3.3.4
3.3.5
3.4
6.2
Is main CPU port P62 (Pin
58) at Low level when CN12 on the Main PCB is shorted?
Continuity problem in
Main PCB.
Replace Main PCB assy.
When main CPU port P62
(Pin 58) is at Low level, is this recognized by the main
CPU?
Defective series resistor R42.
Replace Main PCB assy.
Defective main CPU#1. Replace Main PCB assy.
3.3.3
Replace R42. 3.3.4
3.3.5
Replace
CPU#1.
3.5.1
7-22
15
Buzzer does not sound. a. Defective buzzer circuit.
Problem a. Defective buzzer circuit
Check Item Cause Remedy
Are 4kHz pulses output from
DV0 (20 pin) on main
CPU#1?
Defective main CPU#1. Replace Main PCB assy.
Are correct voltages applied across buzzer BZ1?
Defective resistors R82 and R83.
Replace Main PCB assy.
Buzzer BZ1 does not sound? Defective buzzer BZ1. Replace Main PCB assy.
Repair
Replace
CPU#1.
See
Section
3.3.3
Replace R82 and R83.
Replace BZ1.
3.3.4
3.3.5
3.5.1
7-23
Appendix Main PCB Circuit Diagram
APP-1
May, 2000
86S004BE3
Printed in Japan
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