Brother LX-200 Service Manual Download Page 9

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CONTENTS

Chapter 2. MECHANISMS

2.1 Mechanical Operating Principles ...................................................................................... 2-1

2.1.1 Description of Mechanisms (Border Mode) .......................................................... 2-1

2.1.2 Feed and Compression Mechanisms ................................................................... 2-2

2.1.3 Cutter Mechanism (Border Mode) ........................................................................ 2-4

2.1.4 Paper Size Detector Mechanism .......................................................................... 2-6

2.1.5 Trimming Mechanism ........................................................................................... 2-8

Summary of Contents for LX-200

Page 1: ...SERVICE MANUAL MODEL LX 200 LX 900 LX 910D REVISED EDITION May 2000 ...

Page 2: ...Unauthorized copying of all or part of the contents of this manual is prohibited The contents of this manual may change without notice ...

Page 3: ...eshooting 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 1 Specifications Chapter 2 Mechanism Chapter 3 Disassembly Procedures Chapter 4 Reassembly Procedures Chapter 5 Electronic Controllers Chapter 6 Maintenance Chapter 7 Troubleshooting Appendix Main PCB Circuit Diagram ...

Page 4: ...Chapter 1 SPECIFICATIONS ...

Page 5: ...1 i CONTENTS Chapter 1 SPECIFICATIONS 1 1 Mechanical Specifications 1 1 1 1 1 Appearance 1 1 1 1 2 Operating Panel 1 1 1 1 3 Indicators 1 2 1 2 Electrical Specifications 1 2 1 2 1 Power Supply 1 2 ...

Page 6: ...Mass Approx 4 6 kg main unit only 357 mm 293 mm 195 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 ...

Page 7: ...ors 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 ...

Page 8: ...Chapter 2 MECHANISMS ...

Page 9: ...1 Mechanical Operating Principles 2 1 2 1 1 Description of Mechanisms Border Mode 2 1 2 1 2 Feed and Compression Mechanisms 2 2 2 1 3 Cutter Mechanism Border Mode 2 4 2 1 4 Paper Size Detector Mechanism 2 6 2 1 5 Trimming Mechanism 2 8 ...

Page 10: ...ressed 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 Paper loading gate Paper feed sub roller Roll film upper Film cartridge Sub...

Page 11: ... 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 pap...

Page 12: ...nd 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 fin...

Page 13: ...e 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 ag...

Page 14: ...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...

Page 15: ... 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 Paper feed sub roller Paper feed roller Pivot Paper sensor crank Paper sensor ON OFF Fig 2 1 6 Paper Length Detection...

Page 16: ...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 Pivot Part of the PL detect lever that touches the document PL detect lever Photosensor Photosensor ON status Photosensor OFF status Fig 2 1 7 Paper Width Detection ...

Page 17: ...ated 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 documen...

Page 18: ...Chapter 3 DISASSEMBLY PROCEDURES ...

Page 19: ... 4 3 Removing the Chassis Unit 3 13 3 5 PCBs 3 15 3 5 1 Removing the Main PCB Assy 3 15 3 5 2 Removing the Jack PCB Assy 3 15 3 5 3 Removing the Switch PCB Assy 3 16 3 6 T Chassis 3 17 3 6 1 Removing the T Chassis Unit 3 17 3 6 2 Disassembling the T Chassis Unit 3 18 3 7 Y CA Chassis 3 19 3 7 1 Removing the Y CA Chassis Assy 3 19 3 7 2 Disassembling the Y CA Chassis Assy 3 20 3 7 3 Removing the Ro...

Page 20: ... 3 32 3 12 2 Disassembling the Tape Sensor Unit 3 32 3 13 Driving Roller 3 33 3 13 1 Removing the Driving Roller 3 33 3 14 Left Side of the Chassis 3 33 3 14 1 Removing the Gears 3 33 3 14 2 Disassembling the Left Side of the Chassis 3 35 3 15 Right Side of the Chassis 3 36 3 15 1 Disassembling the Right Side of the Chassis 3 36 3 16 Lower Chassis 3 37 3 16 1 Removing the Left and Right Sides of t...

Page 21: ...m 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...

Page 22: ...tridge 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 ...

Page 23: ...mer 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 Shafts Fig 3 3 3 Removing the Top Cover ...

Page 24: ...t 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 Paper tray B A Fig 3 3 5 Removing the Paper Tray ...

Page 25: ...aper tray Remove the paper guide Paper tray Hook Paper guide Paper tray film 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 ...

Page 26: ...ok at the left and right side 4 Release the two hooks from the front of the body cover Hook A B C C Bottom cover Rear hooks Front hooks Side hook Body cover 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 as...

Page 27: ...nt 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 ...

Page 28: ...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 Harness connector Cover switch screw Fig 3 3 12 Removing the Cover Switch Assy ...

Page 29: ...ve 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 lock arm spring Dial lock arm Dial switch holder assy B Fig 3 3 13 Removing the Dial Switch Holder Assy B ...

Page 30: ...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 ...

Page 31: ...crew 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 Dial lock arm Dial Switch holder Lug A Fig 3 3 17 Disassembling the Dial Switch Holder Assy B 4 ...

Page 32: ... 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 Fig 3 4 2 Removing the PE Sensor Unit Paper feed roller Assy PE sensor unit...

Page 33: ...g 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 Fig 3 4 4 Removing the Chassis Unit 2 Bottom cover Bottom cover screws ...

Page 34: ...4 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 ...

Page 35: ...ove the four main PCB screws Remove the Main PCB assy 1 Main PCB screws Main PCB assy 1 Main PCB screws Power 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 Fig 3 5 2 Removing the Jack PCB Assy Jack PCB screw Ferrite core Jack PCB assy 1 ...

Page 36: ... 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 Fig 3 5 4 Removing the Switch PCB Assy 2 Start key actuator Start key film Start switch B Two connection switch Power switch ...

Page 37: ...e 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 ...

Page 38: ...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 T cutter holder T cutter stopper T cutter upper unit T sensor lever Leaf s...

Page 39: ... 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 Fig 3 7 1 Removing the Y CA Chassis Assy Y CA timing belt Y cutter arm Y CA chassis screws Y CA chassis assy Y extension spring L ...

Page 40: ...move 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 timing belt Y CA idle pulley B Y CA pulley holder screw A Y CA pulley holder Anti static brush Y CA motor Y CA motor screws Y CA driving pulley Y CA driving pulley ring Fig 3 7 2 Di...

Page 41: ...ing 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 Fig 3 7 3 Removing the Roller Holder Assy Roller holder assy Chassis unit L boss shaft Roller holder ring Roller holder rings Chassis unit R boss shaft Y cutter arm L ...

Page 42: ...s 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 Side cover L Hooks A Lock lever L Hook B Roller holder Cut out Cut out Lock lever R Hook C Hook A Side cover R Press rolle...

Page 43: ... 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 left side Chassis right side Sensor frame Paper sensor crank 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 ...

Page 44: ...ss 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 Boss hole Sensor crank protect film FPC holder B Paper sensor harness assy Hook FPC holder A Fig 3 8 3 Disassem...

Page 45: ... 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 Hook PL detect lever Y cutter arm L Y CA sensor screw Y CA sensor Fig 3 8 4 Disassembling the Y cutter Arm L ...

Page 46: ...er feed shaft spring R and paper feed shaft spring Paper feed sub roller assy Chassis left side Gear 16 hook Paper feed shaft spring Paper feed shaft spring R Chassis right side 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 ...

Page 47: ...oo far 2 Remove the paper feed roller ring from the chassis right side Paper feed roller ring Chassis left side Gear 16 hook Paper feed roller assy Chassis right side 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 Ro...

Page 48: ...g 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 extension spring R Y extension spring L Y driving gear Y gear 40 20 Y D shaft 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 R Y cutter cam L...

Page 49: ... 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 needle nosed pliers and remove it Remove the paper eject roller screw the...

Page 50: ...ct Roller Unit 2 3 11Y 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 ...

Page 51: ... 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 ...

Page 52: ...assembling 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 Leaf switch F assy Leaf switch screw Sensor holder screw Tape sensor holder Tape sensor lever Fig 3 12 2 Disassembling the Tape Sensor Unit ...

Page 53: ...de 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 ...

Page 54: ... 15 Gear 16M1 16 Gear 48 24 17 Gear 20 18 Gear 20 19 Gear 20 20 Gear 50 Gear 20 Gear 25 hook Gear 20 ring Gear 60 16M1 Gear 60 20 hook Gear 16M1 Gear 50 Gear 48 24 Gear 60 16 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 TY planet gear unit TY spring wash...

Page 55: ...ease 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 LF motor LF motor screw TC LF motor screw Fig 3 14 2 Disassembling the Left Side of the Chassis ...

Page 56: ...cline the guide and remove it 5 Remove the TY planet gear holder before removing the felt TY idle gear and TY spring 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 Y sensor lever Roller guide R Y sensor lever hook Edging saddle EDS 1 Leaf switch Y screw Leaf switch Y assy TY planet gear TY ...

Page 57: ...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 ...

Page 58: ...holder inward to release the two lugs Remove the cassette holder from the bottom chassis Hooks Lug 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 assy ENC sensor screw Fig 3 16 3 Removing the ENC Sensor PCB ...

Page 59: ...3 39 3 16 4 Removing the Cassette Detect Switch Remove the leaf switch SW C screw Remove the leaf switch C assy Leaf switch C assy Leaf switch SW C screw Fig 3 16 4 Removing the Cassette Detect Switch ...

Page 60: ...Chapter 4 REASSEMBLY PROCEDURES ...

Page 61: ...X cutter Unit 4 10 4 8 Y diversion Lever 4 11 4 8 1 Reassembling the Y diversion Lever Assy 4 11 4 8 2 Installing the Y diversion Lever Assy 4 12 4 9 Paper Eject Roller 4 13 4 9 1 Installing the Paper Eject Roller Unit 4 13 4 9 2 Installing the Paper Eject Sub roller Unit 4 15 4 9 3 Installing the Y D Shaft 4 15 4 10 Paper Feed Roller 4 17 4 10 1 Installing the Paper Feed Roller Assy 4 17 4 10 2 I...

Page 62: ...e PE Sensor Unit 4 32 4 16 3 Installing the Harness Connectors 4 33 4 17 Covers 4 33 4 17 1 Reassembling the Dial Switch Holder Assy B 4 33 4 17 2 Installing the Dial Switch Holder Assy B 4 35 4 17 3 Installing the Cover Switch Assy 4 36 4 17 4 Installing the Front Cover 4 37 4 17 5 Installing the Body Cover 4 38 4 17 6 Installing the Paper Tray and Paper Guide 4 41 4 17 7 Installing the Sub tray ...

Page 63: ...1 TAPTITE PAN B M2 6 0 196 to 0 392N m 4 10 Sensor holder screw 1 TAPTITE BIND B M2 6 6 0 686 to 0 882N m 4 10 Paper eject roller screw 1 TAPTITE CUP M3 5 0 49 to 0 686N m 4 14 Y CA sensor screw 1 TAPTITE BIND B M2 6 6 0 196 to 0 392N m 4 19 Sensor holder screw 1 TAPTITE BIND B M2 6 6 0 196 to 0 392N m 4 19 Sensor frame screw 2 TAPTITE CUP M3 5 0 49 to 0 686N m 4 22 32 Y CA motor screw 2 SCREW FLA...

Page 64: ...3 6 0 49 to 0 686N m 4 43 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 Leaf switch C assy Lower chassis Boss hole Fig 4 3 1 Installing the Cassette Detect ...

Page 65: ... Lug Slot Bottom chassis Hooks Claws 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 Lugs Lower chassis Fig 4 3 4 Installing the Left and Right Sides...

Page 66: ...ight 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 LF motor screws TC motor Fig 4 4 1 Reassembling the Right Side of the Chassis 1 ...

Page 67: ...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 Y sensor lever Y sensor lever Roller guide R Edging saddle EDS 1 Boss hole A TY planet gear Leaf sw...

Page 68: ...assembling 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 chassi...

Page 69: ...planet gear holder Put the TY spring washer TY idle gear felt stick onto the TY idle gear and TY planet gear holder on the shaft 20 Gear 37 hook Gear 20 ring Gear 25 hook Gear 20 Gear 60 16M1 Gear 60 20 hook Gear 16M1 Gear 50 Gear 60 16 Gear 48 24 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 T...

Page 70: ... 60 20 hook Gear 16M1 Gear 25 hook Gear 36 12 hook Gear 40 16 hook Gear 20 Gear 36 12 hook Gear 21 TY planet gear Planet gear 20 hook Gear 37 hook TY planet gear TY idle gear TY planet gear Gear 20 Gear 48 24 Fig 4 5 3 Installing the Gears 2 ...

Page 71: ...sis 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 Drivin...

Page 72: ...r holder to the X cutter unit with the sensor holder screw X cutter unit Leaf switch F assy Leaf switch screw Sensor holder screw Tape sensor lever Tape sensor holder 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 Inst...

Page 73: ...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 film Y diversion lever Fig 4 8 1 Reassembling the Y diversion Lever A...

Page 74: ...ion 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 Y cutter assy Y cutter guide R Y cutter guide L 1 2 3 1 2 3 1 2 ...

Page 75: ...per 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 Fig 4 9 1 Installing the Paper Eject Roller Unit 1 Paper eject roller unit Gear 20 Gear 40 16 hook ...

Page 76: ... 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 ho...

Page 77: ...aper 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...

Page 78: ...ush 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 Fig 4 9 5 Installing the Y driving Shaft 2 Paper eject sub roller springs Y driving gear Y gear 40 20 Y extension spring R Paper eject shaft holder R Paper eject LF motor moun...

Page 79: ...nstalling 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 Gear 16 hook Paper f...

Page 80: ...s 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 Slot Paper feed shaft spring P...

Page 81: ...B 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 Hook PL detect lever Y cutter arm L Y CA sensor screw Y CA sensor Fig 4 11 1 Reassembling t...

Page 82: ...roove 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 Boss hole Slot B End hole Sensor crank protect film FPC holder B Hooks B Paper ...

Page 83: ... with the groove in Y cutter arm L Insert the Y cutter 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 Lug Groove Y cutter arm L Y cutter arm shaft Arm shaft rings Fig 4 11 3 Installing the Y cutter Arm L ...

Page 84: ...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 ...

Page 85: ...der by engaging the individual two hooks A to it Side cover L Hooks A Lock lever L Hook B Cut out A Roller holder Cut out A Lock lever R Hook C Hook A Side cover R Hook A Press roller spring R Release plate ring Boss hole Release plate R Sub roller bearing R Tape hold bearing R Sub roller assembly Tape hold shaft Tape hold bearing L Sub roller bearing L Release plate ring Boss hole Press roller sp...

Page 86: ... 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 Chassis unit R boss shaft Roller holder spring Roller holder rings Chassis unit L boss shaft Y cutter arm L Fig 4 12 2 Installing the Roller Holder Assy ...

Page 87: ...lley 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 ...

Page 88: ...g 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 CAchassisassy Y CA frame screws Y extension spring L Fig 4 13 3 Installing the Y CA Chassis Assy 2 ...

Page 89: ...per 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 th...

Page 90: ...stalling 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 T chassis unit Plate spring screw T gear 35 14 Plate spring T chassis screw Fig 4 14 3 Installing the T Chassis Unit 2 ...

Page 91: ...wer switch 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 Bosses Fig 4 15 2 Installing the Switch PCB Assy 2 Two connection switch Power switch Start key actuator Start key film Start switch B ...

Page 92: ...y 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 Main PCB assy 1 Main PCB screws Power harness assy Bosses Fig 4 15 4 Installing the Main PCB Assy ...

Page 93: ...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 screws B Bottom cover Fig 4 16 2 Installing the Chassis Unit 2 ...

Page 94: ...or 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 Fig 4 16 4 Installing the PE Sensor Unit PE sensor unit Paper fee...

Page 95: ...CN6 Black CN5 Flat cable White CN3 Red CN4 White CN9 Black CN10 Yellow blue white red gray CN11 Yellow CN12 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 As...

Page 96: ...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 Hook Dial S holder assy Bosses B Detail A Plate spring Fig 4 17 3 Reassembling the Dia...

Page 97: ...ling 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 lo...

Page 98: ...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 Harness connector Boss hole Cover switch screw Fig 4 17 6 Installing the Cover Switch Assy ...

Page 99: ...r 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 ...

Page 100: ...dy 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 ...

Page 101: ...ide 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 Bottom cover Rear hooks Front hooks Side hook Body cover Side hook Fig 4 17 12 Installing the Body Cover 4 ...

Page 102: ...4 40 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 ...

Page 103: ...e paper tray Paper tray Hook Paper guide Paper tray film Groove 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 Paper tray A B Fig 4 17 15 Installing the Paper Tray ...

Page 104: ... 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 Shaft recesses Body cover Shafts Fig 4 17 17 Installing the Top Cover ...

Page 105: ...is Align the trimmer cover with the two bosses and fasten it in position with the two trimmer cover screws Bosses Trimmer cover screws Trimmer cover Part B Boss Chassis part A 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 T cutter plate Trimmer bottom cover Fig 4 17 19 Installing the Trimmer Cover 2 ...

Page 106: ...lder 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 ...

Page 107: ...Chapter 5 ELECTRONIC CONTROLLERS ...

Page 108: ...1 Electronic Parts 5 1 5 1 1 Configuration of the Electronic Parts 5 1 5 1 2 Outline of the Electronic Parts 5 2 5 2 Operation of Each Part 5 3 5 3 Main PCB 5 4 5 4 Detector Circuits 5 9 5 5 Motor Drive Circuits 5 15 5 6 Power Supply Circuits 5 18 ...

Page 109: ... Switch PCB Jack PCB Paper size sensor PCB Film detector PCB AC adaptor Paper Size Sensor PCB Corner Cutter Motor Film Cartridge Size Switch Paper Size Detector Motor Side Cutter Position Switch Film Detect Switch Corner Cutter Position Switch Paper Detect Switch Corner Cutter Switch Film Sensor PCB LF Motor Fig 5 1 1 Configuration of the Electronic Parts ...

Page 110: ... 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 P...

Page 111: ...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 2...

Page 112: ... 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 ...

Page 113: ... P11 18 IN INT COVER P10 17 IN COVER P22 28 IN S8 P21 27 IN S7 P20 25 IN S6 P37 40 OUT KO0 P36 39 OUT KO1 P35 38 OUT LED 4 P34 37 OUT LED 1 P33 36 OUT LED 2 P32 35 OUT LED 3 P31 34 OUT YCA LED P30 33 OUT ENC LED P47 48 IN ON OFF R P46 47 IN Y G P45 46 IN P END P44 45 IN TR G P43 44 IN KI3 P42 43 IN KI2 P41 42 IN KI1 P40 41 IN KI0 P54 53 IN X CUT2 P53 52 IN X CUT1 P52 51 IN ON OFF L P51 50 IN S4 P5...

Page 114: ...rnal 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 ...

Page 115: ...l 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 stat...

Page 116: ... 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 Circui...

Page 117: ...ensor 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 swit...

Page 118: ...urns 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 press...

Page 119: ... 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 i...

Page 120: ... 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 irr...

Page 121: ...N 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...

Page 122: ... 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 ...

Page 123: ...ctively 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 a...

Page 124: ... 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...

Page 125: ...riven 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 P16 IN2 P15 ENA DC Motor Drive High Low High TURN RIGHT Low High High TURN LEFT Low Low High BRAKE Low Low Low OFF Fig 5 5...

Page 126: ...C 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 ...

Page 127: ... 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 Whe...

Page 128: ...Chapter 6 MAINTENANCE ...

Page 129: ...sitions 6 1 6 2 Replacing the Cartridge and Film 6 9 6 2 1 Replacing the Cartridge 6 9 6 2 2 Replacing the Sheet 6 12 6 3 Adjustments 6 17 6 3 1 Adjusting the Right Y cutting Position Border Mode 6 17 6 3 2 Adjusting the Left Y cutting Position 6 18 6 3 3 Adjusting Perpendicularity of Chassis and Document 6 19 6 4 Quick way to clean X cutter 6 20 ...

Page 130: ...tions in section 6 1 3 Code Lubricant Name E Epinoc grease 1 S 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 conta...

Page 131: ... 2 Chassis L LF motor Gear S Planet gear 20 hook LF motor gear Planet gear 20 hook Fig 6 1 2 Chassis L LF motor Gear Chassis R TC motor Gear TC motor gear TY idle gear S Fig 6 1 3 Chassis R TC motor Gear ...

Page 132: ...ar 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 Chassis Roller holder pin Roller guide Lock pin S E S Fig 6 1 5 Top of Chassis L R ...

Page 133: ...ler holder return spring right only Release plate Sub roller bearing Roller holder S E E E S Fig 6 1 6 Roller Holder Y cutter Arm L Sensor frame Y cutter arm L S left and right S left and right Y cutter arm shaft Fig 6 1 7 Y cutter Arm L ...

Page 134: ...per eject roller bearing Paper eject roller unit Paper eject roller bearing S S Fig 6 1 8 Paper Eject Roller Paper Eject Sub roller Paper eject shaft holder L S Paper eject sub roller Paper eject shaft holder R S Fig 6 1 9 Paper Eject Sub roller ...

Page 135: ...6 6 Driving Roller Bearing S S Driving roller shaft Bearing Fig 6 1 10 Driving Roller T Chassis Unit S Plate spring T chassis T gear 35 14 Fig 6 1 11 T Chassis Unit ...

Page 136: ...6 7 Y CA Chassis Assy S S Y CA idle pulley Y CA pulley holder Y CA chassis Fig 6 1 12 Y CA Chassis Assy Dial Switch S Dial switch B Dial S holder assembly Plate spring Fig 6 1 13 Dial Switch ...

Page 137: ...6 8 Y Diversion Lever E two positions Ring Y cutter guide shaft Y diversion lever assy Fig 6 1 14 Y Diversion Lever ...

Page 138: ...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 ...

Page 139: ...d 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 ...

Page 140: ... 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 ...

Page 141: ...6 12 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 ...

Page 142: ... 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 ...

Page 143: ...he 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 ...

Page 144: ...olders 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 ...

Page 145: ...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 ...

Page 146: ...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 Slide plate 2 Driving roller Screw Y cutter guide Fig 6 3 1 Adjusting the Right Y cutting Position ...

Page 147: ...n 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 ...

Page 148: ...auge 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 Screws Pivot Fixed cutt...

Page 149: ...g 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 ...

Page 150: ...ting 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 ...

Page 151: ...Chapter 7 TROUBLESHOOTING ...

Page 152: ... CONTENTS Chapter 7 TROUBLESHOOTING 7 1 Outline 7 1 7 2 Precautions during Repair 7 1 7 3 After Making a Repair 7 1 7 4 Basic Checks 7 1 7 5 Troubleshooting Flowcharts 7 2 7 6 Troubleshooting Tables 7 5 ...

Page 153: ...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 no...

Page 154: ...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 3 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 4 No Yes Is manual feed norm...

Page 155: ...f switch on the Switch PCB b Defective LED on the Switch PCB 2 Abnormal X cutter operation a Defective X cutter position switch b Defective X cutter DC motor c Defective X cutter 7 No Yes 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 2 Problem during automatic operation END Is automatic op...

Page 156: ... detected correctly a Defective Y carriage Y CA motor b Defective sensor unit YCA F See page 7 17 Cartridge size film type cannot be detected correctly a Defective cartridge type detector CSIZE switch See page 7 22 Lamination is not normal See page 7 18 a Defective film type ENC detector b Abnormal Y cutter vertical movement No cutting in Y direction See page 7 19 a Defective Y cutter Y G switch b...

Page 157: ... 3 5 2 Defective power harness Replace power harness 3 3 1 3 3 2 3 3 3 3 3 4 3 3 5 3 4 1 b Abnormal 5V DC supply Is power supply IC 6 pin 10 output Low or switching Defective power supply IC 6 Replace Main PCB assy Replace IC 6 When power supply IC 6 pin 10 output is Low is transistor Q10 ON Defective transistor Q10 Replace Main PCB assy Replace Q10 When transistor Q10 is ON is transistor Q11 ON D...

Page 158: ...h PCB does the switch become conducting Continuity problem in switch SW1 to SW4 Replace the Switch PCB Replace switch SW1 to SW4 3 3 7 3 3 8 3 3 9 When the cover R cover L leaf switch is shorted does the connector on the leaf switch assy become conducting Defective leaf switch assy Replace cover switch assy Replace leaf switch R assy Replace leaf switch L assy When switch SW1 to SW4 is pressed on ...

Page 159: ...icators LED1 to LED4 Defective main CPU 1 Replace Main PCB assy Replace CPU 1 3 3 3 3 3 4 3 3 5 3 5 1 Does LED1 to LED4 light when Pin 6 to Pin 9 on Main PCB connector CN1 is Low Defective switch harness assy Replace switch harness assy 3 3 3 3 3 4 3 3 5 Defective LED1 to LED4 Replace the Switch PCB Replace indicator LED1 to LED4 3 3 3 3 3 4 3 3 5 3 3 7 3 3 8 3 3 9 ...

Page 160: ...place Q8 3 3 3 Defective transistor Q9 Replace Main PCB assy Replace Q9 3 3 4 3 3 5 Is transistor Q5 collector voltage switching between 24 V and 0 V Defective transistor Q5 Replace Main PCB assy Replace Q5 3 5 1 b Abnormal DC input voltage Is input voltage from AC adaptor between 16 V and 23 V at rated input Defective AC adaptor Replace AC adaptor If AC adaptor input voltage is equal or below 23 ...

Page 161: ... the sensor frame unit 3 3 3 Photosensor cut off when not at start position Sensor lever incorrectly installed 3 3 4 3 3 5 Defective sensor lever Replace the sensor lever 3 8 Error during Y carriage position detection See 9 Document width cannot be detected correctly e Abnormal Y cutter power ON processing Error during Y cutter position detection See 11 No cutting in Y direction ...

Page 162: ...ll the leaf switch 3 3 1 3 3 3 3 3 4 Is the leaf switch open when no film is inserted Incorrectly installed sensor lever Correctly install the sensor lever 3 3 5 3 4 Defective sensor lever Replace the sensor lever 3 12 2 Is main CPU port P60 Pin 56 at High level when leaf switch TPS is open Continuity problem in Main PCB Replace Main PCB assy 3 3 3 3 3 4 Defective pull up resistor R41 Replace Main...

Page 163: ... connector CN10 on the Main PCB Continuity problem in Main PCB Replace Main PCB assy Continuity in motor harness assy Defective motor harness assy Replace motor harness assy for LF motor 3 3 1 3 3 3 Correct resistance value approx 38 ohms between each phase of the LF motor LF motor and the COM pin Defective LF motor Replace LF motor 3 3 4 3 3 5 3 4 3 14 2 b Defective film compression system Are to...

Page 164: ...6 Is the black lead connector connected to CN5 on the Main PCB Leaf switch assy not connected Correctly connect the leaf switch assy 3 3 3 3 3 4 3 3 5 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 3 3 3 4 3 3 5 Defective pull up resistor R24 Replace Main PCB assy Replace R24 3 5 1 When trimming switch TRI is shor...

Page 165: ...sistance value approx 43 ohms between each phase of the TC motor and the COM pin Defective TC motor Replace TC motor 3 3 1 3 3 3 3 3 4 3 3 5 3 4 3 15 c Defective trimming TRG switch Is the red lead connector connected to CN6 on the Main PCB Leaf switch assy not connected Correctly connect the leaf switch assy 3 3 3 3 3 4 3 3 5 Is main CPU port P44 Pin 45 at High level when leaf switch TR G is open...

Page 166: ...to the four bearings Replace the TY planet gear 3 3 1 3 3 3 3 3 4 3 3 5 3 4 3 15 No cutting occurs despite a grating noise is heard The T cutter plate is not installed Install a T cutter plate 3 3 1 3 3 3 The T cutter plate is not installed correctly Correctly install the T cutter plate 3 3 4 3 3 5 Cutting position is correct but cutting is incomplete Defective T cutter plate Replace the T cutter ...

Page 167: ...ognized by the main CPU Defective main CPU 1 Replace Main PCB assy Replace CPU 1 3 3 5 3 5 1 b Defective X cutter DC motor 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 Defective DC motor driver 4 Replace Main PCB assy Replace 4 ...

Page 168: ...sor crank Correctly install the sensor crank Defective sensor crank Replace the sensor crank 3 3 3 3 3 4 Is the white lead harness assy connected to the PE sensor connector Defective harness assy connection Correctly connect the harness assy 3 3 5 Is the white lead connector connected to CN7 on the Main PCB Defective harness assy connection Correctly connect the harness assy Is main CPU port P45 P...

Page 169: ...phase of the Y CA motor and the COM pin Defective Y CA motor Replace the Y CA motor 3 3 1 3 3 3 3 3 4 3 3 5 3 4 3 7 b Defective sensor unit YCA F Is the flat cable connected to connector CN2 CN14 on the Main PCB Defective connection of the flat cable Correctly connect the flat cable 3 3 3 3 3 4 3 3 5 Sensor lever cuts photosensor when a document is inserted Sensor lever incorrectly installed Corre...

Page 170: ... harness assy 3 6 1 3 7 1 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 photosensor in ENC sensor assy Replace ENC sensor assy Replace the photosensor 3 8 1 3 8 2 3 9 3 10 3 11 1 3 12 1 3 13 1 ENC sensor assy incorrectly adjusted Replace ENC sensor assy 3 16 When a signal is inp...

Page 171: ...ctive pull up resistor R31 Replace Main PCB assy Replace R31 3 5 1 When leaf switch Y G is shorted is CN8 on the Main PCB shorted Defective leaf switch assy Replace leaf switch Y assy 3 3 1 3 3 3 3 3 4 3 3 5 3 4 Is main CPU port P46 Pin 47 at Low level when CN8 on the Main PCB is shorted Continuity problem in Main PCB Replace Main PCB assy 3 3 3 Defective series resistor R27 Replace Main PCB assy ...

Page 172: ...ed Correctly reassemble Y cutter arm L 3 3 5 Right cut position is always displaced in one direction Incorrect adjustment of slide plates 1 and 2 Readjust 6 3 1 Left cut position is always displaced in one direction Incorrect adjustment of Y sensor unit Readjust the Y sensor unit 6 3 2 Does Y cutter arm move smoothly Defective Y cutter arm movement Apply KS64F silicon grease to Y cutter arm shaft ...

Page 173: ... 3 3 1 3 3 3 3 3 4 3 3 5 3 4 3 14 1 Does the rollers slip Dirt or other foreign matter stuck to rollers Clean the rollers Is LF motor out of step Defective driving roller shaft Apply KS64F silicon grease to the driving roller shaft bearings 3 3 1 3 3 3 3 3 4 3 3 5 3 4 b Defect in paper sensor system Does the paper sensor work smoothly Defective paper sensor Replace the paper sensor 3 3 3 Deformed ...

Page 174: ...A6 cartridge is inserted Incorrectly installed leaf switch C assy Correctly install the leaf switch C assy 3 3 1 3 3 3 3 3 4 3 3 5 3 4 Is main CPU port P62 Pin 58 at High level when leaf switch CSIZE is open Continuity problem in Main PCB Replace Main PCB assy 3 3 3 3 3 4 3 3 5 Defective pull up resistor R77 Replace Main PCB assy Replace R77 3 5 1 When leaf switch CSIZE is shorted is CN12 on the M...

Page 175: ... Are 4kHz pulses output from DV0 20 pin on main CPU 1 Defective main CPU 1 Replace Main PCB assy Replace CPU 1 3 3 3 Are correct voltages applied across buzzer BZ1 Defective resistors R82 and R83 Replace Main PCB assy Replace R82 and R83 3 3 4 3 3 5 Buzzer BZ1 does not sound Defective buzzer BZ1 Replace Main PCB assy Replace BZ1 3 5 1 ...

Page 176: ...APP 1 Appendix Main PCB Circuit Diagram ...

Page 177: ...May 2000 86S004BE3 Printed in Japan ...

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