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Francotyp-Postalia FPI 5000 C, Service Manual

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Francotyp-Postalia FPI 5000 C Service Manual Download Page 63

service manual 

FPI 5000 I

510

.02-36

rev. 01.0 - 01/2002

Gear 28T (item 25) and gear 19T (item 26) 

Removal
Remove the gear 35T (item 12) as described previously.

Refer to 

figure 4.2

Push the left-hand transportation roller 6 inwards from the cyl. pin 5.
Remove the cyl. pin from the clutch shaft 33.
Push the right-hand transportation roller 31 inwards from the cyl. pin 32.
Remove the cyl. pin from the clutch shaft.
Remove the spring clip 30. 
Remove the spring clip 23, the spacer 22 and the washer 21.
Slide the clutch shaft in the left-hand side direction. Take care of the washer 17.
Remove the freewheel clutch assembly (24/25/26 and 27). Take care of the spacer 28 and the washer 29.
Remove the three countersunk screws 24 and slide the two gears 25 and 26 of the freewheel clutch 27.

Gear 35T (item 9)

Removal
Refer to 

figure 4.3

Remove the clamping ring 7 and the washer 8.
Slide the gear 9 off the bearing pin. Take care of the spacer 11.

Gear 15T (item 17)

Removal
Withdraw the axle as described in paragraph 

4.2.1

 "Third set of transportation rollers Ø 30 mm".

Refer to 

figure 4.3

Tap out the tension pin 10.
Slide the gear 17 off the axle 18.

Gear 28T (item 3)

Removal
Refer to 

figure 4.4

Remove the two hex. head screws 2 and securing the flapscraper 3 to the envelope guide 16.
Withdraw the flapscraper.
Remove the four round head screws 1 securing the envelope guide to both inside frames.

Refer to 

figure 4.5

Pull the envelope guide aside so it is clear from the gear 3.
Remove the clamping ring 1 and the washer 2.
Slide the gear off the bearing pin. Take care of the spacer 7.

Adjustment
See paragraph 

10.9

 “Flapscraper”.

Summary of Contents for FPI 5000 C

Page 1: ...FPi 5000 Inserting System ILLUSTRATED PARTS LIST SERVICE MANUAL FPI 5000 I FPI 5000 C 1...

Page 2: ...service manual FPI 5000 I rev 01 0 01 2002 FPI 5000 Inserter...

Page 3: ...anual FPI 5000 I rev 01 0 01 2002 Contents Section Page General 510 00 1 Process description 510 01 1 Mechanical description 510 02 1 Electrical description 510 03 1 Parts list 510 04 1 Fault finding...

Page 4: ...service manual FPI 5000 I 510 00 1 rev 01 0 01 2002 General...

Page 5: ...service manual FPI 5000 I 510 00 2 rev 01 0 01 2002...

Page 6: ...01 2002 Contents Section Page 1 Function 6 2 Specifications 7 2 1 Machine specifications 7 2 2 Envelope and paper insert specifications 8 3 Preparing the machine for use 9 3 1 Unpacking 9 3 2 Unpackin...

Page 7: ...service manual FPI 5000 I 510 00 4 rev 01 0 01 2002...

Page 8: ...0 01 2002 Used symbols In this manual the following symbols are used Warning this symbol indicates a wrong action which can cause a hazard to health or damage the machine Warning this symbol indicates...

Page 9: ...e FPI 5000 I inserts documents from the upstream feeding device FPI 5000 C into envelopes and the seals and stacks the envelopes General note This document describes the inserter FPI 5000 I the 110 V...

Page 10: ...50 mm 25 6 inch conveyor 1050 mm 41 3 inch side exit 780 mm 30 7 inch catch tray depends on envelope size Weight approx 48 kg 105 8 lbs Noise level 70 dB A following DIN 45635 part 19 Theoretical max...

Page 11: ...has the best resistance to Wiggins Teape material The specification of the paper handling equipment is often wider than that of the envelopes and docu ments handled The condition of material handled w...

Page 12: ...the machine for use First the machine must be unpacked Then it must be mechanically and electrically hooked up with the FV 2A of which the paper processing configuration as a whole exists After unpac...

Page 13: ...service manual FPI 5000 I 510 00 10 rev 01 0 01 2002 3 2 Unpacking instruction...

Page 14: ...he joggers adjust if necessary 7 Check the envelope stop position on the insert table About 2 mm 0 08 inch maximum variation accepted If more clean lower track photocell check clutch functioning check...

Page 15: ...service manual FPI 5000 I 510 00 12 rev 01 0 01 2002...

Page 16: ...service manual FPI 5000 I 510 01 1 rev 01 0 01 2002 Process description...

Page 17: ...service manual FPI 5000 I 510 01 2 rev 01 0 01 2002...

Page 18: ...rvice manual FPI 5000 I 510 01 3 rev 01 0 01 2002 Contents Section Page 1 Overview 5 2 Some details 7 2 1 Envelope transport 7 2 2 Document input and insert 7 2 3 Envelope ejecting sealing and exiting...

Page 19: ...service manual FPI 5000 I 510 01 4 rev 01 0 01 2002...

Page 20: ...document or document set from the FPI 5000 C to and in the opened envelope 3 Eject and seal the filled envelope and transport it to the rear exit or side exit The simplest diagram of this process cons...

Page 21: ...service manual FPI 5000 I 510 01 6 rev 01 0 01 2002...

Page 22: ...The envelope detector PH1 detects the leading and trailing edge of the envelope The envelope then passes the flap rollers The combined action of the flap scraper and the lower linear speed of the fla...

Page 23: ...me determined by the FS1 triggered pulse count So4 is activated The envelope is between the upper and lower reverse rollers By the So4 action the upper reverse roller now is temporarily lowered Given...

Page 24: ...document or document set from the FPI 5000 C to and in the opened envelope 3 Eject and seal the filled envelope and transport it to the rear exit or side exit The simplest diagram of this process cons...

Page 25: ...service manual FPI 5000 I 510 01 6 rev 01 0 01 2002...

Page 26: ...The envelope detector PH1 detects the leading and trailing edge of the envelope The envelope then passes the flap rollers The combined action of the flap scraper and the lower linear speed of the fla...

Page 27: ...me determined by the FS1 triggered pulse count So4 is activated The envelope is between the upper and lower reverse rollers By the So4 action the upper reverse roller now is temporarily lowered Given...

Page 28: ...service manual FPI 5000 I 510 02 1 rev 01 0 01 2002 Mechanical...

Page 29: ...service manual FPI 5000 I 510 02 2 rev 01 0 01 2002...

Page 30: ...11 1 11 Front cover 12 1 12 Insert table 12 1 13 Feed platform 13 1 14 Rear cover 13 2 Electrical components 14 2 1 Power supply unit 14 2 2 Mainboard and small PCB 14 2 3 Control panel 14 3 Main dri...

Page 31: ...3 2 Gears 50 6 3 3 Ejection solenoid 53 6 4 Envelope transport and sealing 54 6 4 1 Rollers 54 6 4 2 Solenoid 56 7 Envelope transport 57 7 1 Lower ejection rollers 57 7 2 Transportation rollers 59 8 E...

Page 32: ...0 1 Short chain 71 10 2 Long chain 72 10 3 Main drive belt 73 10 4 Microswitches 74 10 5 Solenoids 75 10 6 Joggers 76 10 7 Separation roller 77 10 8 Friction brake 78 10 9 Flapscraper 79 10 10 Lower i...

Page 33: ...service manual FPI 5000 I 510 02 6 rev 01 0 01 2002...

Page 34: ...protection Do not operate the machine with any cover removed and with a microswitch cheated or a hazard to health will exist Throughout this manual the terms left and right hand side and front and re...

Page 35: ...sition Take care not to wedge the power supply lead Pull the water tank 1 in the left hand side direction and withdraw it 1 3 RH side cover Removal Refer to figure 1 1 Remove the round head screws 13...

Page 36: ...service manual FPI 5000 I 510 02 9 rev 01 0 01 2002 figure 1 1 32 1 2 3 4 11 12 10 8 9 6 5 13 14 18 17 19 20 21 22 24 25 23 31 30 28 27 26 16 15 7 29...

Page 37: ...8 Remove the cover 7 Lift and withdraw the cover plate upwards 1 7 Front cover plate Removal Refer to figure 1 1 Hold the guide spring 18 and the front cover plate 17 in place Remove the two counters...

Page 38: ...x head screws 22 securing the base cover 21 to both inside frames Shift the base cover in the left hand side direction to unhook it and then withdraw it 1 10 Transportation table Removal Open the loc...

Page 39: ...ure on replacement of the two connecting plates that the hinge pins point outwards and that the front cover retains the safety cover 1 12 Insert table Open the loc as described in paragraph 1 1 Loc Re...

Page 40: ...ure 1 3 Refer to figure 1 3 Pull the bellow 5 upwards and withdraw it Remove the two countersunk screws 2 securing the rear cover 3 Remove the round head screws 7 securing the feed platform 1 on both...

Page 41: ...ine 2 2 Mainboard and FRAM PCB Removal Remove the electronics cover as described in paragraph 1 5 Electronics cover Refer to figure 2 1 Disconnect all the wiring connected to the mainboard 15 Carefull...

Page 42: ...service manual FPI 5000 I 510 02 15 rev 01 0 01 2002 figure 2 1 1 2 3 4 5 7 8 9 10 11 12 13 14 15 6 16 17 18 19...

Page 43: ...nd 22 Take care of the sprocket 22 and the washer 19 on the chain tensioner Adjustment See paragraph 10 1 Short chain 3 1 2 Long chain Removal Refer to figure 3 1 Slacken the two hex head screws 2 and...

Page 44: ...service manual FPI 5000 I 510 02 17 rev 01 0 01 2002 figure 3 1 1 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 32 33 21 22 31 34 35 36 37 29 30 28 27 24 26 25 23 2 3...

Page 45: ...nd slide the motor pulley 32 off the motor axle Replacement Ensure on replacement that the set screw rests on the flattened part of the motor axle Main drive pulley Removal Remove the main drive belt...

Page 46: ...ervice manual FPI 5000 I 510 02 19 rev 01 0 01 2002 figure 3 2 6 5 9 10 11 12 8 7 13 14 18 41 42 47 49 48 24 25 26 46 44 45 39 38 37 36 35 33 34 40 27 28 29 30 31 32 43 15 16 17 19 20 21 23 22 4 3 1 2...

Page 47: ...T item 31 Removal Refer to figure 3 2 Remove the spring clip 30 Pull the sprocket 31 from the axle Take care of the key 32 3 5 2 Sprockets long chain Remove the long chain as described in paragraph 3...

Page 48: ...Removal Remove the main drive pulley as described in paragraph 3 4 Pulleys Refer to figure 3 2 Remove the spring clip 49 and the washer 48 Slide the sprocket 47 off the bearing pin Take care of the s...

Page 49: ...and the spacer 22 Slide the sprocket 21 off the belt tensioner 4 Take care of the spacer 20 3 6 Gears Gear 18T item 39 Removal Refer to figure 3 3 Remove the clamping ring 38 Slide the gear 39 off th...

Page 50: ...service manual SA IM500 510 02 23 rev 01 0 01 2002 figure 3 3 1 2 4 5 6 7 9 8 10 11 12 13 14 15 16 17 19 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 3...

Page 51: ...igure 3 3 Remove the spring clip 26 Slide the gear 27 off the axle Gear 28T item 25 Removal Refer to figure 3 3 Remove the spring clip 24 Slide the gear 25 off the axle Gear 28T item 23 Removal Remove...

Page 52: ...item 20 Open the loc as described in paragraph 1 1 Loc Remove the sprocket 18T item 13 as described in paragraph 3 5 2 Sprockets long chain Removal Refer to figure 3 2 Remove the countersunk screw 17...

Page 53: ...igure 3 4 Refer to figure 3 4 Remove the fixing screw 1 Take care of the fixing ring 2 Remove the two round head screws 11 securing the ball bearing 10 Shift the axle 9 in the right hand side directio...

Page 54: ...5 Refer to figure 3 5 Disconnect the motor wiring at the terminal block 1 on the power supply unit 2 Remove the base cover as described in paragraph 1 9 Base cover Refer to figure 3 3 Cut all the wir...

Page 55: ...ring clip 3 the washers 4 and the bearing 5 from both sides of the feed shaft 15 Shift the feed shaft in the right hand side direction until it clears the LH inside frame 6 Take care of the spacer 9 a...

Page 56: ...he feed shaft as described in the previous paragraph Refer to figure 4 1 Push the O ring 13 from the jogger 14 and remove it from the feed shaft 15 Slacken the set screw of the jogger Slide the jogger...

Page 57: ...service manual FPI 5000 I 510 02 30 rev 01 0 01 2002 figure 4 2 1 2 3 34 35 36 33 4 5 6 7 8 9 10 11 12 13 14 1516 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32...

Page 58: ...nsure on replacement that the two rollers are refitted correctly on the axle narrowing part of both rollers pointing inwards and the set screws rest into the grooves in the axle Second set of transpor...

Page 59: ...service manual FPI 5000 I 510 02 32 rev 01 0 01 2002 figure 4 3 1 2 3 4 5 7 6 33 32 31 8 9 10 11 16 15 12 14 13 17 20 19 18 28 29 30 27 26 25 24 23 22 21...

Page 60: ...ring 21 from the frame plate 33 and carefully withdraw the axle from the machine Take care of the bearing 16 Remove the spring clip 19 the two washers 22 and the bearing 21 Push the right hand transpo...

Page 61: ...nsert table figure 4 4 Removal Refer to figure 4 4 Remove the spring clip 15 Slide the gear 13 off the rubber roller axle 7 Remove the spring clip 6 Slide the rubber roller in the left hand side direc...

Page 62: ...Refer to figure 4 1 Remove the two round head screws 2 and withdraw the gear cover 7 Remove the two round head screws 19 and withdraw the gear cover 18 Refer to figure 4 2 Remove the spring clip 2 se...

Page 63: ...screws 24 and slide the two gears 25 and 26 of the freewheel clutch 27 Gear 35T item 9 Removal Refer to figure 4 3 Remove the clamping ring 7 and the washer 8 Slide the gear 9 off the bearing pin Take...

Page 64: ...service manual FPI 5000 I 510 02 37 rev 01 0 01 2002 figure 4 5 2 3 4 1 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 19 21...

Page 65: ...move the two hex head screws 2 and securing the flapscraper 3 to the envelope guide 16 Withdraw the flapscraper Remove the four round head screws 1 securing the envelope guide to both inside frames Re...

Page 66: ...he bearing 11 and the washer 10 off the roller axle 7 Tap out the tension pin 9 Slide the gear 8 off the roller axle 4 2 3 Clutches Slip clutch The removal procedure of the slip clutch has been descri...

Page 67: ...e spring clips 7 from both sides of the transportation axle 9 Carefully withdraw the transportation axle in the right hand side direction out of the machine and slide the two rollers off it Take care...

Page 68: ...the right hand side direction out of the machine and slide the two transportation rollers off it Take care that the bearings 1 with the pressure springs 2 on both sides of the transportation axle stay...

Page 69: ...to figure 5 2 Push the two rollers 12 in the right hand side direction from the cyl pins below Remove the two cyl pins from the transportation axle 13 Remove the spring clips 10 from both sides of th...

Page 70: ...of the washer 8 and the bearing 9 Replacement Ensure on replacement that the two transportation rollers are refitted correctly on the transportation axle narrowing part of both rollers pointing outwar...

Page 71: ...H side cover as described in paragraph 1 3 RH side cover Removal figure 5 3 Refer figure 5 3 Disconnect the wiring of the solenoid coil 3 Remove the two hex head screws 1 with washers securing the sol...

Page 72: ...screws 15 securing the loc cover 14 on the front side Remove the two round head screws 13 securing the loc on the rear side Shift the loc cover in the front side direction until the rear side is clear...

Page 73: ...ate Replacement Ensure on replacement that the cover plate is replaced back into the slits on both sides of the cross bar 6 2 Drive mechanism Remove the covers and plates as described in the previous...

Page 74: ...2 2 Pulleys Pulley 16T item 20 Removal Remove the front drive axle assembly as described in the previous paragraph Refer to figure 6 2 Tap out the tension pin 14 Slide the pulley 20 off the drive axle...

Page 75: ...r 11 off the drive axle 7 Take care of the bearing 12 the washer 13 and the bushing 9 6 3 Document inserting Remove the loc cover as described in paragraph 6 1 Covers and plates Open the loc as descri...

Page 76: ...service manual FPI 5000 I 510 02 49 rev 01 0 01 2002 figure 6 3 1 2 3 4 5 6 7 8 1312 11 10 9 14 15 16 17 21 22 24 25 23 20 19 18...

Page 77: ...it off the axle Take care of the washer 5 and spacer 4 Slacken the set screw of the roller 1 and slide it off the axle Take care of the washer 2 and spacer 3 Replacement When retightening the set scr...

Page 78: ...round head screws 3 and withdraw the bearing plate 4 Take care of the bearing 26 Remove the spacer 24 and the two washers 13 from the bearing pin 12 Slide the gear 22 off the bearing pin Take care of...

Page 79: ...wo round head screws 24 from both sides of the loc frame Refer to figure 6 5 Carefully withdraw the cradle together with the draw bar 12 and the plunger 11 Take care of the two washers 27 and the spac...

Page 80: ...eft hand side direction and slide the spacer 8 and the gear 7 off it Take care of the spacer 6 the washer 5 the bearing 4 the spacer 3 and the washer 2 6 3 3 Ejection solenoid Removal figure 6 6 Refer...

Page 81: ...ht and left hand roller Set of sealing transport rollers 38 mm Removal Refer to figure 6 7 Remove the spring clip 1 the washer 2 and the spacer 3 Slide the roller 4 off the axle 7 Take care of the spa...

Page 82: ...service manual FPI 5000 I 510 02 55 rev 01 0 01 2002 figure 6 7 1 2 3 4 5 6 7 8 9 10 11 12 14 13 18 19 17 16 15...

Page 83: ...off the bearing pins 11 6 4 2 Solenoid Sealing solenoid Remove the top cover as described in paragraph 6 1 Covers and plates Removal Refer to figure 6 8 Disconnect the wiring of the solenoid coil 3 Re...

Page 84: ...des of the two ejection rollers Take care of the bearing 19 and the washer 18 Replacement Ensure on replacement that the two ejection rollers are refitted correctly on the ejection axle narrowing part...

Page 85: ...service manual FPI 5000 I 510 02 58 rev 01 0 01 2002 figure 7 1 1 2 6 7 8 11 12 5 4 14 13 15 16 17 18 19 25 24 23 20 21 22 26 27 10 9 3...

Page 86: ...r to 7 2 Push the two transportation rollers 1 in the right hand side direction from the cyl pins below Remove the two cyl pins from the transportation axle 2 Remove the spring clip 23 the washer 24 a...

Page 87: ...r as described previously Remove the long chain as described in paragraph 3 1 2 Long chain Refer to figure 8 1 Remove the spring clip 24 and slide the gear 23 off the axle Tap out the tension pin 17 a...

Page 88: ...service manual FPI 5000 I 510 02 61 rev 01 0 01 2002 figure 8 1 6 7 1 2 3 4 5 28 26 27 25 11 10 9 8 24 23 12 13 14 15 16 17 18 19 20 21 22...

Page 89: ...RH side cover figure 9 1 Refer to figure 9 1 Remove the round head screw 4 with washer securing the mounting bracket 6 After removing the nut 5 with washer and the two round head screws 1 with washers...

Page 90: ...power supply cover as described in paragraph 1 8 Power supply cover figure 9 2 Refer to figure 9 2 After removing the two round head screws 5 with the washers 4 and spacers 3 the microswitch 1 can be...

Page 91: ...tch 3 to the envelope guide 4 From the insert area push the switch lever in the rear side direction as far as possible and hold it Push the lower left hand end of the bracket in the right hand side di...

Page 92: ...disc together with the two spacers 5 Cut the wire strap securing the wiring to the bracket 1 and disconnect the pulse disc detector 2 Remove the two round head screws 3 with washers and withdraw the p...

Page 93: ...ng wiring of the detector Disconnect and withdraw the bracket with the detector from the insert area Replacement To ensure a correct operation of the thickness detector follow on replacement the proce...

Page 94: ...ont side direction Take care of the wiring Remove the pan head tapping screw 2 securing the transmitter to the bracket Withdraw and disconnect the transmitter Receiver Sensor Remove the insert table a...

Page 95: ...ng the transmitter 1 to the bracket Withdraw and disconnect the transmitter Receiver Sensor Remove the insert table as described in paragraph 1 12 Insert table Refer to figure 9 7 Pull the air hose fr...

Page 96: ...ound head screws 1 securing the frame rod 9 to both inside frames Carefully tilt the cover plate 8 in the rear side direction Take care of the wiring Transmitter LED Refer to figure 9 8 Remove the cou...

Page 97: ...o the bracket 2 Withdraw and disconnect the transmitter Receiver Sensor Remove the base cover as described in paragraph 1 9 Base cover Refer to figure 9 9 Remove the hex head screw 4 securing the brac...

Page 98: ...inch To adjust Remove the RH side cover described in paragraph 1 3 RH side cover Slacken the two hex head screws 2 securing the chain tensioner 1 Shift the chain tensioner to adjust the correct chain...

Page 99: ...adjust Remove the RH side cover described in paragraph 1 3 RH side cover Slacken the two hex head screws 1 securing the chain tensioner 2 Shift the chain tensioner to adjust the correct chain movemen...

Page 100: ...4 inch To adjust Remove the RH side cover described in paragraph 1 3 RH side cover Slacken the two hex head screws 1 securing the belt tensioner 2 Shift the belt tensioner to adjust the correct belt m...

Page 101: ...rizontal position figure 10 4 Refer to figure 10 4 Slacken the nut 4 with securing the microswitch 2 on the front side Pull the front side of the microswitch away from the inside frame as far as possi...

Page 102: ...solenoid coil whenever the solenoid is actuated To set this requirement figure 10 5 Refer to figure 10 5 Slacken the two hex head screws 4 securing the solenoid coil 3 Push the plunger 2 together with...

Page 103: ...in a sample of narrowest envelope to be used figure 10 6 Refer to figure 10 6 Remove the O rings 2 from both joggers 1 and 5 Slacken the set screws of both joggers Position the middle of the envelope...

Page 104: ...ve the rear cover as described in paragraph 1 14 Rear cover figure 10 7 Refer to figure 10 7 Use the thumbwheel 1 and set the separation gap to the maximum Slacken the set screws 2 securing the separa...

Page 105: ...scs 3 i e the overall pressure spring length is 16 mm 0 63 inch To adjust Remove the outer nut 1 securing the inner nut 2 Turn the inner nut to adjust the correct distance Replace the outer nut and ch...

Page 106: ...er edge is aligned with the lower edge of the envelope guide 1 To adjust Slacken the two hex head screws 2 securing the flapscraper 3 on both sides Move the flapscraper to adjust the correct position...

Page 107: ...r to figure 10 10 A suitable straight edge positioned as indicated must contact all three points as shown If this condition does not exist then the bracket carrying the lower insert roller must be res...

Page 108: ...e pressure springs 5 The first 1 5 mm of lift is adjusted by repositioning the cradle stop axle 2 mounted above the roller cradle carrying the upper insert rollers To adjust Remove the loc cover as de...

Page 109: ...service manual FPI 5000 I 510 02 82 rev 01 0 01 2002...

Page 110: ...service manual FPI 5000 I 510 03 1 rev 01 0 01 2002 Electrical...

Page 111: ...service manual FPI 5000 I 510 03 2 rev 01 0 01 2002...

Page 112: ...R OFFSET menu 38 3 3 2 The FV CONFIG SETTINGS menu 39 3 3 3 The FV SERVICE TESTS menu 40 3 3 4 The Set default collator stop menu 45 3 4 The system wide SERVICE MENU 45 3 4 1 SOFTWARE VERSIONS 46 3 4...

Page 113: ...er supplies and LCD control 24 Figure 1 16 The combined display key circuit board 95 70 72 electronics keys 25 Figure 1 17 Component layout of the combined display key circuit board 95 70 72 26 Figure...

Page 114: ...3 29 The system output menu 48 Figure 3 30 The PAPER STOP menu 48 Figure 3 31 The DOCUMENT OFFSET menu 49 Figure 3 32 The SECURE JOB menu 49 Figure 3 33 The BRE offset menu 50 Figure 3 34 The SERVICE...

Page 115: ...service manual FPI 5000 I 510 03 6 rev 01 0 01 2002...

Page 116: ...a dedicated vertical system inserter It is an integrated part of the SA 5005 folding and inserting machine The other integrated part of the SA 5005 system is the vertical feeding and folding unit FPI...

Page 117: ...roller U300 the 80C552 This CPU has six 8 bit ports Port P5 can be configured as a 10 bit A D converter with 8 multiplexed inputs Port P2 forms the high address byte port P0 is the ALE multiplexed 8 b...

Page 118: ...The DAC settings are stored in non volatile FRAM Pulse disc flag switch and micro switches The pulse disc PD1 is mounted on the driven sealing track roller The rotating disc has a number of cogs whic...

Page 119: ...stopped as well or not driven at all System connections The 12 pole upstream system connector see figure 1 2 is connected with J500 of the main board See figure 1 8 for details This system connector...

Page 120: ...002 Software The FPI 5000 I software in the Eprom 98 02 11 has a number of tasks a process control b user interface c domestic tasks via the simulated I C bus d SCS communication with the FPI 5000 C a...

Page 121: ...02 figure 1 1 Electrical electronic FPI 5000 I block diagram Upstream Power supply Mechanical drive Keyboard Display MS1 MS2 Pulse disc PD1 DFC PH1 PH2 PH3 PH4 FS1 SA IM500 Main board Envelope transpo...

Page 122: ...LCD KEYBOARD 957072 J110 J172 PLUG TYPE 220V 110V 3A 5A 121112 121549 POWER INLET INCLUDES MAINS SWITCH MAINS FUSE RF FIL TER NET FUSE TYPE 1 2 3 4 J541 J370 J371 1 2 3 4 948001 F2 F3 1 2 3 4 5 6 7 8...

Page 123: ...000 I 510 03 14 rev 01 0 01 2002 figure 1 3 The main board 94 80 01 electronics are divided into five sections All items in a specific section are numbered from X00 onwards X 1 5 Power Drivers Photo S...

Page 124: ...MC3423 DIL8 VCC 5V Overvoltage Protection 5 24V_1 24V_1 F3 3A 20mm D160 KBU4D4 200 C1 1N 630V MKM D170 KBU4D4 200 C160 4700uF C161 100N External PGND DO NOT PLACE ON PCB C110 100N VEE C120 470uF C121...

Page 125: ...EXIT_DRV R232 82 R233 82 R242 10K R243 4K7 AGND ANA 5V R237 10k R238 39k 3 2 1 8 4 U240A LM358 R240 10K ANA 5V 12V AGND 3 CO240 100N AGND 12V C202 10N R204 10K C204 10N R203 1K R205 220 FLAP_F P5 0 AG...

Page 126: ...B MOTOR_START A8 A9 A10 A11 A12 A13 A14 5 JP305 and 306 1 RESET_1 PSEN_0 ALE 1 3 5 7 9 11 13 15 17 19 2 4 6 8 10 12 14 16 18 20 J370 MicroMatch20 R316 10K ALE NRD NWR RESET_1 SCL_SIM SDA_SIM EXT_BRD0...

Page 127: ...3 2 Q450 BD677 24V Eject R451 1K C451 1nF D410 1N4004 PGND 24V C411 1nF R400 3K3 PGND PWM1 PWM0 1 FINGER RESET_1 EXIT R411 1K PWM0 1 3 2 Q410 BD677 PGND 24V EXIT_SOL 2 D461 1N4004 PGND 24V D460 1N400...

Page 128: ...AV 9 9 R 5 0 0 4 K 7 S D A S C L S Y S _ C O N _ D E T D 5 0 1 B AV 9 9 D 5 0 2 B AV 9 9 V C C V C C V C C P G N D P G N D 2 4 V 2 2 4 V 1 C O V E R S C L I I C G N D S D A R E S E T _ 0 S Y S C O ND...

Page 129: ...service manual FPI 5000 I 510 03 20 rev 01 0 01 2002 figure 1 9 Component layout of the main board 94 80 01...

Page 130: ...99x Data Book page132 See DALLAS Automatic Identification Outer pin is J710 pin1 5V_7 R703E 10K 1 2 J710 MicroCan Clip GND_7 GND_7 D711 1N4148 C700 100N 5V_7 GND_7 GND_7 5V_7 SDA 5 SCL 6 VCC 8 A0 1 A1...

Page 131: ...ent layout of the FRAM board 95 74 55 figure 1 12 The motor relay board 12 16 21 electronics 51 R1 33E 1W S1 RE1 D1 1N4004 D2 1N4004 RE2 1 2 3 4 J1 55 R2 33K 1 2 3 4 J2 S2 C1 47N 250VAC 1 2 3 4 5 6 7...

Page 132: ...00 I 510 03 23 rev 01 0 01 2002 figure 1 13 Component layout of the motor relay board 12 16 21 figure 1 14 The combined display key circuit board 95 70 72 electronics overview 2 KEYS 1 POWER and LCD c...

Page 133: ...1 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 R138 39K R137 39K R130 10K R136 82K R133 4K7 R135 150K TH133 4K7 R134 330K P101 47K R131 4K7 TH131 4K7 Q140 BC547 3 2...

Page 134: ...4 B 3 Y1 5 Y2 6 G 1 Y3 7 U200A 74HCT139 1 NWR_3 VCC GND C210 100n Key1 ROW_0 D222 1N4148 D221 1N4148 Key2 Key3 D224 1N4148 D223 1N4148 Key4 Key5 D226 1N4148 D225 1N4148 Key6 Key7 Not placed D228 1N414...

Page 135: ...service manual FPI 5000 I 510 03 26 rev 01 0 01 2002 figure 1 17 Component layout of the combined display key circuit board 95 70 72...

Page 136: ...service manual FPI 5000 I 510 03 27 rev 01 0 01 2002 figure 1 18 The local electronics of the DFC unit 83 29 91...

Page 137: ...crews 5 Remove the feeler gauge 6 Switch the FPI 5000 I on During startup initial DFC settings are made 7 Go to test 3 DFC of the first level service tests See section 4 1 3 8 The display must show a...

Page 138: ...the job access menu of figure 3 3 You will now enter the main service menu screen of figure 3 4 The service software for the FPI 5000 I FPI 5000 C combination is divided into three groups An inserter...

Page 139: ...SENSORS PHOTOCELL CONDITIONS PHOTOCELL CONDITIONS DIGITAL INPUTS DIGITAL INPUTS READ CODE TEST ACTUATOR TESTS DFC TEST DFC SERVICE TESTS SET DEF COLLATOR STOP DISPLAY SOFTWARE VERSIONS SYSTEM OUTPUT...

Page 140: ...510 03 31 rev 01 0 01 2002 figure 3 2 The two part MAIN MENU figure 3 3 The menu JOB ACCESS figure 3 4 The main SERVICE MENU Key 1 2 3 4 5 6 Key 1 2 3 4 5 6 Key 1 2 3 4 5 6 Key 1 2 3 4 5 6 Key 1 2 3 4...

Page 141: ...certain control range the currents of the photocell transmitters are adjusted in such a way that the no paper output voltage of the photocell receiver falls within a certain voltage range of the photo...

Page 142: ...ape key figure 3 7 The screen for the IN PHOTO CONDITION IN DIGITAL INPUTS The IN DIGITAL INPUTS menu of figure 3 8 shows the real time status of the digital photocell that monitors the FPI 5000 I pul...

Page 143: ...e increase of 1000 mV per millimeter measured thickness If the DFC sensor is manually pushed in to its mechanical limit the measured DFC output voltage has a value between 4000 and 5000 mV If no paper...

Page 144: ...forward as soon as the test key is pressed Only after releasing the test key the fingers will move back to their rest position Testing the envelope track will result in switching on the motor and act...

Page 145: ...this purpose the menu item Reset Data of figure 3 13 is present It is advised to remove all paper from the machine This is necessary because the data resetting includes removing certain hardware setti...

Page 146: ...ly inserter related hardware settings but all the SA 5005 operational settings job information as well The other three types of FRAM in an SA 5005 system FPI 5000 C main board feeder boards and readin...

Page 147: ...ry figure 3 15 The FOLDER OFFSET menu 3 3 2 The FV CONFIG SETTINGS menu The presence of the divert unit the feeder unit s and the DFC units is recorded in non volatile FRAM on the FRAM board 95 74 55...

Page 148: ...e recommend to check in the FV config settings menu if the FRAM has been updated If this is not the case press Reset configuration After message restart system to set new configuration switch the mach...

Page 149: ...rformed during each startup of the FPI 5000 I FPI 5000 C machines Note Before readjusting the photocell it is strongly recommended to remove all paper from the machines and to clean all the sensors bo...

Page 150: ...nal information on the various digital inputs The central pulse disk is mounted is present at the RH side of the machine It is mounted on the input axle to which the mechanical drive from the FPI 5000...

Page 151: ...h and the related gears pulleys and timing belts is present at the RH side of the machine It is mounted on the input axle to which the mechanical drive from the FPI 5000 I is transferred The primary d...

Page 152: ...transport a separated sheet to its waiting position and transports it further upon request until the vertical transport mechanism takes over control figure 3 20 The two menu screens for the FV ACTUATO...

Page 153: ...C TEST 3 3 4 The Set default collator stop menu In this menu see figure 3 23 the default collator stop position can be set at b A4 paper size or c 14 paper size This is the start value for the collato...

Page 154: ...gure 3 25 shows the software versions for the various eproms that are present in the total system If you press key 1 the internal revision levels are shown as well figure 3 25 The SOFTWARE VERSION scr...

Page 155: ...tch the machine off and on again after finishing the run in test Note 2 It is also strongly recommended to perform the run in test without any documents present in the machine The timing of the action...

Page 156: ...n all other cases Mode 2 is advised Background information In the Mode 2 case the paper transport stops as soon as the document that is to be added to the set has entered the collating area this is de...

Page 157: ...et the mechanical stop position at the specified position As the collator area must accommodate for the longest possible document size of 14 inch it makes sense to make arrangements for a paper stop f...

Page 158: ...ch of the jobs 1 through 9 and Fill Start an offset can be switched on or off In the case of offset on the last document that had been added to the set prior to further processing will be shifted from...

Page 159: ...r items All these three items are related to process cycles and can be set by the service engineer The counter Since last visit This number of process cycles can be reset to zero by the service engine...

Page 160: ...10 03 51 rev 01 0 01 2002 figure 3 34 The SERVICE COUNTERS menu figure 3 35 The menu for readjusting the service counter Since installation figure 3 36 The error screen for preventive maintenance Key...

Page 161: ...5 5 V analogue TP130 4 75 V 5 V 5 25 V 5 24 V supply TP150 23 V 24 V 35 V Photo LED s current TP207 0 3 V DFC output TP250 0 25 V 0 5 V 0 75 V 1 V mm and no paper present PH1 envelope in TP201 0 9 V...

Page 162: ...nu can be entered or the system will be reset to the normal operational condition provided the problem that initiated the error message has been solved The error code number is preceded by a number th...

Page 163: ...of FRAM based values Remove all paper from the machine readjustment of paper photocells Error 1 5 Message Technical failure Action Call service Info Memory failure During the reading from or writing...

Page 164: ...only is issued if the DFC function is activated and if the reference thickness is known See also error 28 Error 1 15 Message Envelope stoppage Action Remove envelope Info Flap not opened The envelope...

Page 165: ...urning the motor off Error 1 21 Message Thickness not measured Action Remove documents Info Wrong measurement area The DFC didn t measure the document The DFC function must be activated This can happe...

Page 166: ...ent from the insert table This error message is issued if the document is more than 40 micrometer thicker than the reference thickness A 45 g per cm2 sheet of paper has a thickness of about 50 microme...

Page 167: ...sue assuming no paper is present between the DFC sensors DFC unit defective Error 1 37 Message Technical failure Action Call service Info Main motor failure The pulse disc photocell of PD1 doesn t del...

Page 168: ...startup during factory production testing or after field replacement of the photocell The photocell must be replaced by a more sensitive photocell Error 1 48 Message Track sensor dusty Action Clean s...

Page 169: ...st This is most likely caused by paper being present under the photocell Error 1 54 Message Technical failure Action Call service Info Loc sensor defective The no paper output voltage of photocell PH3...

Page 170: ...is not properly connected or not connected at all This error only may occur after the field replacement of the photocell or after any service activities involving replacing circuit board connections...

Page 171: ...but it is advised to clean both sensors of PH2 and to readjust this photocell Error 1 66 Message Loc sensor dusty Action Clean sensor Info none Dust warning for photocell PH3 There is still a dust mar...

Page 172: ...ce connector Info Communication failure The FPI 5000 I cannot communicate properly by SCS with the FPI 5000 C from which no I C acknowledge signal is received The upstream 12 pole system connector may...

Page 173: ...of the filled envelope one or more FPI 5000 I covers are opened Error 1 104 Message Envelope stoppage Action Remove envelope Info Cover open During the exiting of the filled envelope one or more FPI...

Page 174: ...nob and turning it clockwise you can observe the blinking of D222 See also the digital inputs menu of section 3 2 1 5 3 FPI 5000 C feeder unit related error codes 5 3 1 Folder subsystem Error 2 10 Mes...

Page 175: ...ion Call service Info Sensor fold in defective The photocell transmitter LED of photocell VPH3 is defective Check the wiring Error 2 63 Message Sensor dusty Action Clean sensor Info none Sensor needs...

Page 176: ...no paper present 5 3 2 Vertical transport subsystem Error 3 00 Message Empty feeders Action Load documents Info This error appears when all feeders found empty during Fill Start initialisation Error 3...

Page 177: ...ocuments Info Stoppage at collator This error message is generated if it lasts too long for documents that leave the collator area to reach the folding are input photocell VPH3 Remove the paper After...

Page 178: ...cation failure The I C communication between feeder unit 2 feeders 3 and 4 and the FPI 5000 C base unit fails This error is also generated during system initialisation if the FRAM data supposes this u...

Page 179: ...wo successive cogs the irregularities may be caused by dirt Clean the pulse disc and check the position of the slotted photocell Error 3 60 Message Document stoppage Action Remove documents Info Cover...

Page 180: ...SPH4 Provided VSPH4 is correctly operating see the service software this motor is probably defective Error 3 71 Message Collator sensor dusty Action Clean sensor Info none The relevant photocell colla...

Page 181: ...s generated during system initialisation if the FRAM data supposes the divert unit to be present but it appears to be intentionally or accidentally removed Error 3 90 Message Technical failure Action...

Page 182: ...ttings for the paper photocells and the DFC unit are lost All documents must be removed from the machine Press the Reset key on the FPI 5000 I The paper photocells and the DFC unit will be readjusted...

Page 183: ...document appears to be too thin this error is generated Reset the DFC unit key 5 in the error screen in order to make a new reference if necessary Error 4 5 6 7 8 9 12 Message Document stoppage Actio...

Page 184: ...ant photocell is dusty to such an extend that the full 100 of the photodiode current has been reached Readjust the photocell after cleaning with no paper present Error 4 5 6 7 8 9 51 Message Feeder se...

Page 185: ...ailure Action Call service Info Power failure The 12 V power supply voltage in feeder unit x x 1 3 is too low Error 4 5 6 7 8 9 71 Message Technical failure Action Call service Info Power failure The...

Page 186: ...gital inputs menu of section 3 3 3 The green LED D303 and TP3D on the FPI 5000 C base unit board 97 50 10 are reserved for the slotted photocell for the third fold table A flashing green LED D101 on t...

Page 187: ...service manual FPI 5000 I 510 03 78 rev 01 0 01 2002...

Page 188: ...service manual FPI 5000 I 510 04 1 rev 02 0 02 2002 Parts lists...

Page 189: ...service manual FPI 5000 I 510 04 2 rev 02 0 02 2002...

Page 190: ...er 28 mm 73 28 93 1 1 2 40 Led including holder 04 24 52 2 2 4 45 Sensor including holder 04 24 53 2 2 4 Figure 510 04 16 56 Transportation roller 30 mm 46 04 56 4 4 8 Figure 510 04 20 10 Flagswitch 0...

Page 191: ...6 21 1 1 1 40 Unit F RAM 2K 95 74 55 1 1 1 44 LCD Keyboard 95 70 72 1 1 2 Figure 510 04 42 4 Solenoid 12 12 87 1 2 4 Figure 510 04 47 35 Damper 03 11 90 1 1 1 44 Transportation roller 42 5 mm 73 25 76...

Page 192: ...service manual FPI 5000 I 510 04 5 rev 02 0 02 2002...

Page 193: ...service manual FPI 5000 I 510 04 6 rev 02 0 02 2002 Figure 1...

Page 194: ...bracket 36 07 14 2 16 Guide spring long 73 53 98 1 17 Countersunk screw M4 x 16 45 38 77 2 18 Dust cover 93 06 90 1 19 Main lead 220V 12 15 08 1 Main lead 110V 12 15 07 1 20 Bottom plate 95 73 01 1 21...

Page 195: ...service manual FPI 5000 I 510 04 8 rev 02 0 02 2002 Figure 2...

Page 196: ...M4 self locking 05 36 21 6 19 Hinge axle 43 29 50 1 20 Spring clip 7 9 mm 05 24 42 5 21 Washer 16 x 10 2 x 0 8 mm 04 01 43 5 22 Nylon bearing 8 mm 04 09 34 2 23 Cupped spring washer 05 24 92 9 24 Brac...

Page 197: ...ressure spring 03 11 07 5 56 Knurled nut 02 11 25 5 57 Document detector assy 83 29 91 1 58 Spacer 10 x 5 3 x 10 mm 04 09 51 1 59 Finger strip centre 73 22 94 1 60 Set screw M4 x 4 08 28 01 4 61 Trans...

Page 198: ...service manual FPI 5000 I 510 04 11 rev 02 0 02 2002...

Page 199: ...service manual FPI 5000 I 510 04 12 rev 02 0 02 2002 Figure 3...

Page 200: ...onductive bearing 10 mm 04 24 26 9 19 Washer 16 x 10 2 x 0 8 mm 04 01 43 12 20 Nut M5 45 19 03 4 21 Spacer 25 x 5 5 x 8 mm 43 29 31 2 22 Rubber stud M5 x 20 04 12 11 2 23 Motor 220 240V 50Hz 12 09 98...

Page 201: ...nual FPI 5000 I 510 04 14 rev 02 0 02 2002 Figure 510 04 12 Remarks illustration Description Part code Quantity Remarks code number number FPI 5000 I 45 Sensor including holder 04 24 53 1 46 Bracket 2...

Page 202: ...service manual FPI 5000 I 510 04 15 rev 02 0 02 2002...

Page 203: ...service manual FPI 5000 I 510 04 16 rev 02 0 02 2002 Figure 4...

Page 204: ...t 43 34 29 1 17 Guide plate 73 66 76 1 18 Washer 12 x 4 3 x 1 mm 45 37 43 1 19 Nut M4 45 19 02 2 20 Sensor including holder 04 24 53 1 21 Round head screw M3 x 8 45 38 65 5 22 Frame rod 43 29 43 1 23...

Page 205: ...5 23 46 2 47 Insert table 95 73 11 1 48 Countersunk head screw M3 x 10 05 38 74 4 49 Spring clip 10 14 mm 05 24 83 6 50 Pulley axle assy 04 23 19 1 51 Frame rod 43 29 44 1 52 Pressure spring 1 mm 03 1...

Page 206: ...service manual FPI 5000 I 510 04 19 rev 02 0 02 2002...

Page 207: ...service manual FPI 5000 I 510 04 20 rev 02 0 02 2002 Figure 5...

Page 208: ...1 19 Adj nut 95 71 20 2 20 Round head screw M4 x 4 45 43 10 6 21 Adj axle 95 71 12 1 22 Fixing plate axle 95 71 26 1 23 Thumb wheel 24 13 58 1 24 Envelope support assy 95 74 01 1 25 Feeding table ass...

Page 209: ...02 Figure 510 04 20 Remarks illustration Description Part code Quantity Remarks code number number FPI 5000 I 46 Separation slide 95 71 06 1 47 Round head screw M3 x 25 45 43 08 1 48 Round head screw...

Page 210: ...service manual FPI 5000 I 510 04 23 rev 02 0 02 2002...

Page 211: ...service manual FPI 5000 I 510 04 24 rev 02 0 02 2002 Figure 6...

Page 212: ...spring 03 11 91 2 18 Refer to item 11 19 Washer 16 x 10 2 x 0 8 mm 04 01 43 6 20 Pressure spring 0 85 mm 43 11 12 2 21 Conductive bearing 10 mm 04 24 26 8 22 Refer to item 11 23 Spring clip 10 14 mm 0...

Page 213: ...service manual FPI 5000 I 510 04 26 rev 02 0 02 2002 Figure 510 04 24 Remarks illustration Description Part code Quantity Remarks code number number FPI 5000 I 46 Refer to item 11 47 Refer to item 11...

Page 214: ...service manual FPI 5000 I 510 04 27 rev 02 0 02 2002...

Page 215: ...service manual FPI 5000 I 510 04 28 rev 02 0 02 2002 Figure 7...

Page 216: ...ad screw M3 x 8 05 38 65 2 18 Axle for pulse disc 23 59 52 1 19 Round head screw M3 x 8 45 38 65 2 20 Nut M4 45 19 02 1 21 Fixing plate microswitch 95 73 03 1 22 Self locking clip 05 26 02 6 23 Transp...

Page 217: ...51 Lever 95 73 15 1 52 Draw bar 43 26 24 1 53 Hex head screw M4 x 12 05 38 82 5 54 Self locking clip 05 24 68 2 55 Solenoid 02 10 21 1 56 Washer 12 x 4 3 x 1 mm 45 37 43 2 57 Hex head screw M4 x 8 45...

Page 218: ...service manual FPI 5000 I 510 04 31 rev 02 0 02 2002...

Page 219: ...service manual FPI 5000 I 510 04 32 rev 02 0 02 2002 Figure 8...

Page 220: ...1 Spring clip 10 14 mm 05 24 83 5 12 Sprocket 15T 73 17 99 3 13 Self lubricating bearing 06 09 17 1 14 Self locking clip 05 26 00 1 15 Main pulley 26 05 15 1 16 Key 05 25 50 2 17 Pulley assy 76 05 14...

Page 221: ...service manual FPI 5000 I 510 04 34 rev 02 0 02 2002 Figure 9...

Page 222: ...46 04 56 2 18 Air tube plug 24 13 02 2 19 Round head screw M3 x 8 45 38 65 5 20 Washer 9 x 4 3 x 0 8 mm 45 37 02 1 21 Conductive strip 04 20 03 1 22 Hex head screw M6 x 12 05 38 85 4 23 Frame rod 43 2...

Page 223: ...pacer 15 x 10 4 x 7 5 mm 04 08 28 1 50 Gear cover RH 95 71 33 1 51 Gear 28T 24 63 11 1 52 Gear boss 28 19T 43 25 87 1 53 Axle 43 25 86 1 54 Pressure spring 1 5 mm 03 11 73 1 55 Spring holder disc 24 6...

Page 224: ...service manual FPI 5000 I 510 04 37 rev 02 0 02 2002...

Page 225: ...service manual FPI 5000 I 510 04 38 rev 02 0 02 2002 Figure 10...

Page 226: ...0 1 Capacitor 20 mF 110 V 12 12 81 1 17 Print board holder 04 16 57 4 18 Unit motor transformer board 12 16 21 1 19 Round head screw M3 x 16 45 38 67 2 20 Washer 6 x 3 2 x 0 5 mm 45 37 30 2 21 Spacer...

Page 227: ...ber FPI 5000 I 42 Fuse 15 A 12 12 95 1 43 Nut M4 self locking 05 36 21 4 44 LCD Keyboard 95 70 72 1 45 Washer 9 x 4 3 x 0 8 mm 45 37 02 2 46 Magnetic clip 95 70 90 1 47 Buffer 95 70 79 1 48 Knob red 9...

Page 228: ...service manual FPI 5000 I 510 04 41 rev 02 0 02 2002...

Page 229: ...service manual FPI 5000 I 510 04 42 rev 02 0 02 2002 Figure 11...

Page 230: ...upper plate loc 98 00 14 1 19 Nut M4 45 19 02 4 20 Brake plate assy 95 72 54 1 21 Washer 12 x 4 3 x 1 mm 45 37 43 4 22 Cover loc 95 72 56 1 23 Set screw M3 x 4 08 28 33 2 24 Tension pin 2 5 x 16 05 3...

Page 231: ...2002 Figure 510 04 42 Remarks illustration Description Part code Quantity Remarks code number number FPI 5000 I 46 Washer 7 x 3 2 x 0 5 mm 45 37 39 1 47 Pan head tapping screw 45 38 53 1 48 Round head...

Page 232: ...service manual FPI 5000 I 510 04 45 rev 02 0 02 2002...

Page 233: ...service manual FPI 5000 I 510 04 46 rev 02 0 02 2002 Figure 12...

Page 234: ...e 73 34 61 1 18 Axle 43 28 85 1 19 Tension pin 2 5 x 16 05 33 22 1 20 Gear 15T 24 08 57 1 21 Gear 20T 24 02 58 1 22 Nut M3 45 19 01 1 23 Washer 7 x 3 2 x 0 5 mm 45 37 39 2 24 Tension spring 0 5 mm 03...

Page 235: ...ev 02 0 02 2002 Figure 510 04 47 Remarks illustration Description Part code Quantity Remarks code number number FPI 5000 I 46 Spacer 8 x 4 3 x 10 mm 04 69 19 1 47 Round head screw M4 x 8 45 38 68 8 48...

Page 236: ...service manual FPI 5000 I 510 04 49 rev 02 0 02 2002...

Page 237: ...service manual FPI 5000 I 510 04 50 rev 02 0 02 2002 Figure 13...

Page 238: ...6 6 17 Nut M4 self locking 05 36 21 3 18 Crinkle washer 05 24 84 1 19 Washer 12 x 5 2 x 0 7 mm 43 05 35 1 20 Axle 23 29 10 1 21 Hex head screw M4 x 8 05 38 80 4 22 Locking spring 03 23 74 1 23 Brush h...

Page 239: ...ion Part code Quantity Remarks code number number FPI 5000 I 45 Axle 23 26 00 1 46 Spacer 15 x 10 4 x 5 mm 04 08 37 1 47 Ejection axle 43 28 75 1 48 Pulley 14T 06 04 45 1 49 Timing belt 04 15 37 1 50...

Page 240: ...service manual FPI 5000 I 510 04 53 rev 02 0 02 2002 Side exit Part number 97 01 52...

Page 241: ...service manual FPI 5000 I 510 04 54 rev 02 0 02 2002 Figure 14...

Page 242: ...7 01 14 1 19 Bottom plate 95 73 90 1 20 Self sticking plug 95 90 35 2 21 Nut M4 45 19 02 11 22 Washer 9 x 4 3 x 0 8 mm 45 37 45 9 23 Frame 95 73 64 1 24 Spring clip 9 12 mm 05 24 55 2 25 Round head sc...

Page 243: ...service manual FPI 5000 I 510 04 56 rev 02 0 02 2002 Figure 15...

Page 244: ...er 24 11 51 6 3 Envelope Support incl absorber 95 74 08 1 4 Round head screw M4 x 10 45 38 69 4 5 Washer 9 x 4 3 x 0 8 mm 45 37 45 4 6 Transparent cover 97 01 11 1 7 Bottom plate 95 73 83 1 8 Hex head...

Page 245: ...service manual FPI 5000 I 510 04 58 rev 02 0 02 2002...

Page 246: ...service manual FPI 5000 I 510 04 59 rev 02 0 02 2002 Stacker Part number 95 73 51...

Page 247: ...service manual FPI 5000 I 510 04 60 rev 02 0 02 2002 Figure 16...

Page 248: ...e 95 71 51 1 11 Belt 96 10 00 2 12 Set screw M4 x 4 08 28 01 2 13 Round head screw M4 x 8 mm 05 38 68 2 14 Suspension frame for drive axle 95 71 54 1 15 Pulley 26 06 12 2 16 Drive axle 95 71 63 1 17 S...

Page 249: ...service manual FPI 5000 I 510 04 62 rev 02 0 02 2002...

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