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service manual FPI 5000 C

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4. 59 Document stopper position for 14 documents 60 66 Counter rollers for 52 56 67 Driven output rollers of lower feeder of lower feeder module 68 Counter rollers for 67 69 Driven output rollers of upper feeder of lower feeder module 70 Counter rollers for 69 71 Driven output rollers of lower feeder of upper feeder module 72 Counter rollers for 71 73 Driven output rollers of upper feeder of upper feeder module 74 Counter rollers for 73 75 DDD DEC unit for lower feeder of lower feeder module 76 DDD DEC unit for upper feeder of lower feeder module 77 DDD unit lower feeder of upper feeder module 78 DDD DEC unit for upper feeder of upper feeder module 79 Photocell for lower feeder of lower feeder module Rx FPH2 80 Photocell for lower feeder of lower feeder module Tx FPH2 81 Photocell for upper feeder of lower feeder module Rx FPH1 82 Photocell for upper feeder of lower feeder module Tx FPH1 83 Photocell for lower feeder of upper feeder module Rx FPH2 84 Photocell for lower feeder of upper feeder module Tx FPH2 85 Photocell for upper feeder of upper feeder module Rx FPH1 86 Photocell for upper feeder of upper feeder module Tx FPH1 87 Lower separation roller for lower feeder of lower feeder module Turns CW in feeder with manual separation 88 Feed axle with upper separation roller lower feeder of lower feeder module 89 Paper puller axl
5. p ND un S m N Figure 2 520 04 8 02 0 02 2002 service manual FPI 5000 C Figure 520 04 8 Remarks illustration Description Part code Quantity Remarks code number number 5000 1 Eprom 97 50 12 1 2 Mainboard 97 50 10 1 3 Round head screw x 8 45 38 68 4 Referto 8 5 Mounting bracket LH 98 01 36 1 6 Countersunk head tapping screw 45 38 59 8 7 Lower exit plate 93 07 10 1 8 Cover assy fold unit 98 01 33 1 9 Mounting bracket RH 98 01 37 1 10 Referto8 98 01 35 1 11 Nut M4 45 19 02 11 12 Washer 9 x 4 3 x 0 8 mm 45 37 02 5 13 Countersunk head screw x 6 45 42 11 1 14 Protective strip 04 26 65 1 15 Support plate 98 01 40 1 16 Support strip 98 01 41 1 17 Mounting bracket 98 01 30 1 18 Cover fold unit 98 01 32 1 19 Countersunk head screw x 10 45 38 75 4 20 Lower cover vertical transport 98 01 03 1 21 Upper cover vertical transport 98 01 02 1 22 Cover plate 98 01 43 1 rev 02 0 02 2002 520 04 9 service manual 5000 Figure 3 520 04 10 rev 02 0 02 2002 service manual FPI 5000 C Figure 520 04 10 Remarks rev 02 0 02 2002 illustration code number amp GN ON 11 Description Hex head screw M4 x 12 Cover LH Nut M4 Cover LH Top cover vertical transport Hex head screw M4 x 8 Fixing plate Top cover
6. ED 7098 HOLOW 29 520 03 13 figure 1 8 FPI 5000 C base unit board 97 50 10 6 DC motor control rev 01 0 01 2002 5000 1 service NV3YLSNMOO m 94 0523 10640 8 1 R648 649 LILI 08451 7 41729863 y7 read R640 8645 864 fee fer In JSL J 21124 TR651 TR650 0640 0641 1640 0642 1 0643 C0601C0602 0304 C311 M4 00 214 09 83409 coll coll lever rev forew CLUTCH SK NT R102 7 330333XVN 1140 430V38 18204 TR201 TR202 TR203 LJUJUJLJ 10301 R106 em i O 1998 NEOPOST HOLLAND 97 50 10 1 10104 U _ 10105 AA 5 e DOWNSTREAM Component layout of the FPI 5000 C base unit board 97 50 10 figure 1 9 rev 01 0 01 2002 520 03 14 service manual FPI 5000 C figure 1 10 Feeder module board 93 08 02 1 CPU circuitry rev 01 0 01 2002 520 03 15 5000 1 service manua
7. 5 mm 0 2 inch lower feeder drive belt figure 9 2 Refer to figure 9 2 The maximum movement of the drive belts 1 at the indicated position is 5 mm 0 2 inch To adjust Remove the RH side cover as described in paragraph 1 4 RH side cover Remove the RH feeder module cover as described in paragraph RH feeder module cover Slacken the hex head screw 3 securing the belt tensioner 2 Shift the belt tensioner to adjust the correct belt movement Hold the belt tensioner and retighten the hex head screw Check the adjustment and readjust if necessary Note Do not adjust the drive belt too tight 520 02 80 rev 01 0 01 2002 service manual FPI 5000 C 9 2 Collating area 9 2 1 Drive belts figure 9 3 Refer to figure 9 3 The maximum movement of the drive belts 1 at the indicated position is 5 mm 0 2 inch To adjust Remove the RH side cover as described in paragraph 1 4 RH side cover Slacken the two hex head screws 2 securing the belt tensioner 3 Shift the belt tensioner to adjust the correct belt movement Hold the belt tensioner and retighten the two hex head screws Check the adjustment and readjust if necessary Note Do not adjust the drive belt too tight rev 01 0 01 2002 520 02 81 service manual FPI 5000 C 9 22 Transportation belts figure 9 4 To adjust Remove the collator arm cover as described in paragraph 1 7 Collator arm cover
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11. stv IELD SLNI aHONS viv STV FE E 62 De ST 4 82 ITLD ELNI 3HO0DA lt HTO I Y TIV 1019 21 TIV 15350 26258 aas Sz TIV 395 dez 2 4 019 ez De Tv og 20 JO or N om T 5 92 PE 8v Lt sv 5100 TOTH POH lt 0 pve var 1a Lv xot vod 4 I 3 12 S LY 5 EAZ 9g 9v 119 EM LI TISS EO0Td ST ZAZ 5 90 sav 02 9 9v Big 5 5 TAG Naw ET 1 m m SLI ya L 2 Se 3 HWPSTTZZ dzz 11 6 SI 8 vv 95 TOTX EI YAT Fad zt 89 EV 6 EV 29 9 2 TWIX gg 153130 26258 EVI EAT za zv 9 2 vI zav ST 2 Or Tv 012 Fer gt CAT L I9 2 H ar IV HAND JA 4302 j tat wit og A ov gt 2 z Sr Dav 00 ET D De 1 Jnoot 0 2 2012 1015 num Tori ircuitry CPUc it board 97 50 10 1 FPI 5000 C base un figure 1 3 rev 01 0 01 2002 520 03 8 5000 1 service manua SLNdLNO
12. Refer to figure 9 4 Slacken the hex head screws 2 securing the belt tensioners 3 on both sides Push both belt tensioners in the front side direction until the bearings 4 are free and then adjust them so that the bearings just do not become free Hold the belt tensioners and retighten the hex head screws Take care that both belt tensioners are in the same position use the square holes in the collating arm frame 1 as a reference 520 02 82 rev 01 0 01 2002 service manual FPI 5000 C 9 3 Folder 9 3 1 drive belt 5 mm 0 2 inch figure 9 5 Refer to figure 9 5 The maximum movement of the drive belt 2 at the indicated position is 5 mm 0 2 inch To adjust Remove the RH side cover as described in paragraph 1 4 RH side cover Slacken the two round head screws 1 and 4 securing the belt tensioner 3 Shift the belt tensioner to adjust the correct belt movement Hold the belt tensioner and retighten the two round head screws Check the adjustment and readjust if necessary Note Do not adjust the drive belt too tight and ensure that the conducive strip 5 is positioned onto the axle of the first fold unit see item 7 figure 7 1 when retightening the round head screw 4 rev 01 0 01 2002 520 02 83 service manual FPI 5000 C 9 32 LH drive belt 5 mm 0 2 inch figure 9 6 Refer to figure 9 6 The maximum movement of the drive belt 1 at the indicated position is 5 mm 0 2 inch To a
13. 4 4 Figure 1 520 04 6 02 0 02 2002 service manual FPI 5000 C Figure 520 04 6 Remarks illustration Description Part code Quantity Remarks code number number 5000 1 Top cover 98 01 28 1 2 Fixing plate 98 01 25 1 3 Hex head screw x 8 05 38 80 14 4 Hopper complete auto 79 01 53 See note 5 Horizontal protection plate RH 98 01 16 1 6 Cover RH 98 01 56 1 7 Vertical protection plate RH 98 01 17 1 8 Nut M4 45 19 02 18 9 Cover RH 98 01 21 1 10 Hex head screw x 12 45 38 82 11 Cover RH 98 01 22 1 12 Side plate 98 01 23 1 13 Hopper complete special 79 01 54 See note 14 Locking plate 98 01 24 1 15 Bracket RH 98 01 12 1 16 Cover RH 98 01 08 1 17 Round head screw x 8 05 38 68 4 18 Collating plate 95 21 02 1 19 Round head screw x 8 45 38 68 4 20 Bottom cover 93 07 41 1 2 Cover 93 07 20 1 22 Strip 93 06 29 1 23 Bottom plate 93 06 08 1 24 Cover LH 98 01 05 1 25 Cover plate 98 01 29 2 26 Vertical protection plate LH 98 01 15 1 27 Horizontal protection plate LH 98 01 14 1 28 Cover LH 98 01 55 1 29 Round head screws M3 x 4 45 43 00 5 30 Cover plate 98 01 42 1 31 Bracket LH 98 01 11 1 32 Locking plate LH 98 01 13 1 33 Side plate LH 98 01 20 1 34 Cover LH 98 01 19 1 35 Cover LH 98 01 18 1 36 Short tray 04 27 27 1 37 Cover 2 stations 98 01 38 1 38 Cover 96 46 25 1 Note Quantity depending configuration rev 02 0 02 2002 520 04 7 service manual FPI 5000 C
14. Collating area cover Refer to figure 8 9 Remove the pan head tapping screw 4 securing the receiver 6 to the frame plate 5 Disconnect and withdraw the receiver Replacement Ensure on replacement that the transmitter is properly aligned by using the bulge on the bracket as reference FO out detector rev 01 0 01 2002 520 02 75 service manual FPI 5000 C Removal figure 8 10 Transmitter LED Remove the rear cover as described in paragraph 1 10 Rear cover Refer to figure 8 10 Remove the countersunk tapping screw 1 securing the transmitter 2 to the bracket 3 Disconnect and withdraw the transmitter Receiver Sensor Open the folder as described in paragraph 1 3 Folder Remove the rear folder cover as described in paragraph 1 10 Rear folder cover Refer to figure 8 10 Remove the countersunk tapping screw 4 securing the receiver 6 to the bracket 5 Disconnect and withdraw the receiver 8 5 2 Pulse disc detector assy s 520 02 76 rev 01 0 01 2002 service manual FPI 5000 C Remove the front folder cover as described in paragraph 1 11 Front folder cover divert tray Note The removal procedure of both pulse disc detector assy s is similar Removal figure 8 11 Refer to figure 8 11 Remove the two round head screws 3 with the washers securing the pulse disc detector assy 2 to the mounting bracket 1 Disconnect and withdraw the pulse disc detector assy 8 5 3 Mic
15. Dit rov 1584 OL rs oS TIS Y 395 ano SAT a 4 AR DH zodi Y 977 5072 mm DAG e a lt TAND 551935114 TOv som 30055344915 WEIEN 9NO2 T 9 Jr 395 5 Love H 1VYLNAD 2510 35104 vvs 3uvds z IN d 1 18945 TOS 395 9064 17113 ion communica it board 97 50 10 4 FPI 5000 C base un figure 1 6 520 03 11 rev 01 0 01 2002 5000 1 Service YIMOd NOOT 10705 NOOT ae 8152 I T OSHS S3 Od K 91584 1 NOT NOT NOT NOT NOT NOT 20902 10902 70502 50705 20702 EE 10502 Se 1 1 1 NOOT anzz NOOT 1152 9152 sto 4 ETSY NOT NOT NOOT NOT NOOT NOOT NOT C BW T N 0200 10102 90102 S0102 0100 0100 Em wo Em 1 en s ech 5 2 4354 1 ST TON Bem TOS 13534 v 2154 TISU 0641 4H224 anov 1
16. Note The removal of the right and left hand clutch is similar Removal 0 90 figure 6 1 to figure 6 1 Cut the wire strap securing the wiring to the stud of clutch 13 Disconnect the clutch Remove the spring clip 15 with the washer 14 securing the clutch Slide the clutch off the axle 5 Replacement Ensure on replacement that the locking plate 7 retains the clutch and secure the wiring again to the stud on the clutch with a wire strap 520 02 42 rev 01 0 01 2002 service manual FPI 5000 C 6 1 2 Gears Gears 24 item 2 24 item 12 Note removal of right hand and left hand gear is similar Removal Remove the clutches as described in the previous paragraph Refer to figure 6 1 Slide the gear 12 off the axle 5 Take care of the washer 11 6 1 3 Transportation rollers Open the vertical transport track as described in paragraph 1 1 Vertical transport track Remove the collating area cover as described in paragraph 1 8 Collating area cover Removal Remove the gear 24T item 12 as described in the previous paragraph Refer to figure 6 1 Remove the spring clip 10 with the washer 9 from the left hand side of the axle 5 Cut the wire strap securing the wiring to the stud of the right hand side clutch 1 Disconnect the right hand side clutch Slacken the set screws of both transportation rollers 6 on the axle Withdraw the axle in the right hand side direction
17. Replacement Ensure on replacement that the set screw of the pulley is retightened onto the flattened part of the axle and it is aligned in a straight line with the belt tensioner and the pulley 3 figure 7 1 7 1 3 Clutches Freewheel clutch Removal Remove the pulley 15T item 3 as described in the previous paragraph Refer to figure 7 1 Slide the freewheel clutch 2 off the axle Take care of the cyl pin 1 rev 01 0 01 2002 520 02 49 service manual FPI 5000 C 7 1 4 Gears Gear 24T item 16 Removal Refer to figure 7 2 Remove the clamping ring 14 with the washer 15 Slide the gear 16 off the bearing pin Take care of the spacer 17 Gear 24T item 2 Removal Refer to figure 7 2 Remove the clamping ring 4 with the washer 3 Slide the gear 2 off the bearing pin Take care of the spacer 1 Gear 241 item 6 Removal Refer to figure 7 2 Remove the spring clip 7 Pull the gear 6 from the axle Take care of the cyl pin 5 Gear 24T item 9 Removal Remove the pulley 30T item 13 as described in paragraph 7 1 2 Pulleys Refer to figure 7 2 Remove the clamping ring 11 with the washer 10 Pull the gear 9 from the axle Take care of the cyl pin 8 Gear 35T item 21 Removal Remove the drive belt as described in paragraph 7 1 1 Drive belt Open the folder as described in the paragraph 1 3 Folder Refer to figure 7 1 Remove the two round head screws 8 securing the belt tensioner 1
18. V NOT 2 4 99 01 H21MS A KE Er NOT ano 1 Our 60653 ZE 3001 NI 03 53 IER soey lt 70 ZINOD anov ANDY ANDY H 81052 an 9ceu T T Tom dr 9 0443409 20 Ph xh AL IA HOLIMS gt N ZOEY E zoea 289 Sctu 306 Tos Ee 41804 TOEUL c 1 NOT za lt 3 VTOHYL 8062 3001 IA BAO2 Y ug 4 lt INIS paw T T IM Div VIOEDI an 1 124 306 uda 998 PR dL 3089 DECH HOLOW 14 HILMO AA BH NI TIO2 TH24 U3AI323H NI O4 7823 U3AH23u ts inpu it board 97 50 10 3 FPI 5000 C base un figure 1 5 rev 01 0 01 2002 520 03 10 5000 1 service manua NOLLVOINNWAW OD jos INVIYLSAN NVI4LSNMOCJ no Haa 3vd vds NOI Jnoot
19. 02 2002 service manual FPI 5000 C Figure 520 04 50 Remarks illustration Description Part code Quantity Remarks code number number 5000 C 1 93 07 20 1 2 Nylon bearing 04 11 07 4 3 Nut M4 45 19 02 5 4 Round head screw x 8 05 38 65 3 5 Axle 95 20 18 1 6 Sleeve 24 11 74 2 7 Pulley 60T 04 13 20 1 8 Setscrew M4 8 08 28 06 1 9 95 20 05 3 10 Spring clip 6 8 mm 05 24 46 6 11 Washer 12 x 6 2 x 0 8 mm 04 01 40 8 12 Conductive bearing 6 mm 04 24 24 2 13 Pressure spring 03 35 43 2 14 Tensioner strip 95 20 08 2 15 Axle 95 20 06 1 16 Set screw x 10 08 28 05 6 17 Roller 95 20 03 3 18 Collating belt set 3 pcs 95 20 07 1 19 Conductive bearing 10 mm 04 24 26 4 20 Washer 16 x 10 2 x 0 8 mm 04 01 43 4 21 Spring clip 9 12 mm 05 24 55 4 22 Drive axle 95 20 02 1 23 Pressure roller 95 20 11 3 24 Set screw x 4 08 28 01 2 25 Belt tensioner 95 20 15 2 26 Hinge pin 95 20 16 2 27 Round head screw x 25 05 38 72 2 28 Spring clip 4 5 mm 05 24 47 2 29 Sensor including holder 04 24 53 1 30 Round head screw x 6 05 38 66 1 31 Washer 9 x 4 3 x 0 8 mm 45 37 02 1 32 Clamping bracket 12 14 06 1 33 Lock washer 5 32 05 24 31 1 34 Frame assy 95 20 09 1 35 Pan head tapping screw 05 38 55 1 rev 02 0 02 2002 520 04 51 5000 1 service Figure 20 02 0 02 2002 520 04 52 service man
20. 6 2 x 0 8 mm 04 01 40 4 24 Safety bracket 95 13 23 1 rev 02 0 02 2002 520 04 37 service manual FPI 5000 C 6 7 8 9 10 11 Figure 15 520 04 38 rev 02 0 02 2002 service manual FPI 5000 C Figure 520 04 38 Remarks illustration Description Part code Quantity Remarks code number number 5000 C 1 Mounting bracket for spring 95 13 06 2 2 Tension spring 95 11 50 2 3 Hex head screw x 8 05 38 80 d 4 Inside frame feed unit RH 95 13 02 1 5 Timing belt 95 13 16 3 6 Spring clip 7 9 mm 05 24 42 2 7 Washer 14 x 8 2 x 0 8 mm 04 01 41 2 8 Axle for tensioner roller 95 13 10 2 9 Tensioner roller 95 13 19 2 10 Fixing plate 95 13 07 2 11 Round head screw M4 x 8 05 38 68 2 12 Pulley 20T timing belt 24 13 75 3 13 Disc for pulley 93 05 42 3 14 Cyl pin 2 5 x 16 05 23 46 4 rev 02 0 02 2002 520 04 39 service manual FPI 5000 C 10 11 12 13 14 15 16 17 18 19 20 Figure 16 520 04 40 rev 02 0 02 2002 service manual FPI 5000 C Figure 520 04 40 Remarks illustration Description Part code Quantity Remarks code number number 5000 1 Drive axle 95 13 04 2 2 Cyl pin 02 5 x 16 05 23 46 4 3 Transportation roller 95 13 12 4 4 Conductive bearing 8 mm 04 24 25 2 5 Spacer 12 x 0 8 4 x 5 mm 04 09 64 4 6 Pulley 44T 95 13 08 2 7 Timing belt 04 15 74 2 8 Disc pulley 93 05 39 2 9 Clutch CC
21. 7 mm 05 24 66 1 53 Pressure spring 03 35 20 2 54 Conductive bearing 6 mm 04 24 24 2 55 Conductive bearing 8 mm 04 24 25 2 56 Drive axle extension 96 42 20 1 57 Separation roller lower 95 11 23 1 58 Cork strip 95 11 26 2 59 Brush 95 11 48 1 60 Fibre washer 8 x 4 2 x 0 5 mm 04 01 22 2 61 Spring clip 4 5 mm 05 24 47 1 62 Upper separation roller 95 11 07 1 63 Fixing strip 95 11 82 1 64 Feeder stop 95 11 83 1 65 Fixing strip 95 11 52 1 66 Washer 12x 4 3 x I mm 45 37 43 6 67 Nut M4 45 19 02 2 68 Slide 95 11 78 1 69 Sleeve 04 11 57 1 70 Wire spring 95 11 79 1 71 Round head screw M3 x 4 45 43 00 1 72 Separation axle assy daily mail 04 23 11 1 73 Wire strap holder 12 10 52 3 74 Round head screw 8 05 38 68 12 75 Bracket for photocell 95 11 46 1 76 Pan head tapping screw 45 38 55 2 77 Sensor including holder 04 24 53 1 78 Fixing strip 95 11 13 1 520 04 44 rev 02 0 02 2002 service manual FPI 5000 C rev 02 0 02 2002 520 04 45 service manual FPI 5000 C A 32 31 30 29 28 27 35 3 50 49 48 47 46 45 44 43 42 74 73 72 11 70 Figure 18 520 04 46 rev 02 0 02 2002 service manual FPI 5000 C Figure 520 04 46 Remarks illustration Description Part code Quantity Remarks code number number 5000 1 Led including holder 04 24 52 1 2 Bracket for photocell 95 11 47 1 3 Cover plate 95 11 25 1 4 Support bracket upper 95 12 14 1 5 Suspension bracket 95 12 32 2 6 Transp
22. NOT 20202 EIER yes mek 1 LANDA 0188 LOSdL 90541 50641 EOSdL N 6054 dzz dzz 059 6052 9 9 1 dzz dzz NI dOEE 1 1 1 z 8059 5055 2052 oan 7 90VEDW 6052 ZINOD zosa ZN nor et 2 angot NOOT NOOT 0152 Em nor NOT I n 2152 1152 5053 6185 2 ANOOT 9052 4 6 je 1050 198 03 gt 9054 1052 Se BEES 2 SE 9 HNOOZ 2054 SVE 221755 5 1054 v 091 1 1 t 381 vas gt 1051 4 C 3d vas ME 20621 2054 20541 TOSH WON 3095 8054 3095 1058 22 3 5000 base unit board 97 50 10 5 power supply figure 1 7 01 0 01 2002 520 03 12 5000 1 Service SLNdLNO YOLOW 7102 gt ano ano NOT I 7195 9SG3N 3095 820921 2694 ano ano not 192 xot I er Sia er 8 uL 6 27 ano ano quaun gt O uiusny p 9 NOT NOOT z199 V 1 andu sat sat 8298 i 5190 67
23. 40 42 42 42 43 43 44 45 46 47 47 49 49 49 50 53 53 53 rev 01 0 01 2002 01 0 01 2002 7 2 3 7 2 4 7 3 7 3 1 7 3 2 7 3 3 7 4 7 5 8 1 8 1 1 8 1 2 8 2 8 2 1 8 2 2 8 3 8 3 1 8 3 2 8 4 8 4 1 8 5 8 5 1 8 5 2 8 5 3 9 1 9 1 1 9 1 2 9 2 9 2 1 9 2 2 9 3 9 3 1 9 3 2 9 3 3 service manual Clutch Gears Fold mechanism Gears Clutches Curved folder gears Upper fold rollers Lower fold rollers Detectors Feeders Pulse disc detector assy DFC Vertical transport Document detector Microswitch for cover vertical transport Collating area Pulse disc detector assy Document detector Divert unit Pulse disc detector assy Folder Document detectors Pulse disc detector assy s Microswitch for fold unit Adjustments Feeders Main drive belt RH drive belts Collating area Drive belts Transportation belts Folder RH drive belt LH drive belt Paper guide FPI 5000 C 53 54 56 56 59 59 63 66 68 68 68 69 71 71 72 72 72 73 74 74 75 75 77 78 79 79 79 80 81 81 82 83 83 84 85 520 02 5 service manual FPI 5000 C 520 02 6 rev 01 0 01 2002 service manual FPI 5000 C General instructions Disconnect the mains supply before performing any maintenance Warning The covers and microswitches fitted by your protection Do not operate the machine with any cover removed and with a microswit
24. 520 01 10 rev 01 0 01 2002 service manual FPI 5000 C If a wrong set must be diverted the divert 24 is turned upwards clockwise The set is exited from the collator As soon as the set has left the rollers 27 and 28a the trailing edge of the set is detected by the paper photocell VPH3 29 30 The divert actuator 25 moves forward and pushes the set to the divert area 26 where the set stays after the divert actuator moves back Both the form and the operation of the divert actuator resemble a snake s tongue The Divert amp Go feature is also used to empty the machine from documents that still are present in one or more feeders the vertical track or the collator when the machine is switched on or when a job change is implemented 2 5 The multifeed shunt process As discussed above the documents in the vertical track must be overlapping like the panes on a roof in other to be properly aligned in the collator If two or more successive documents are to be fed from the same feeder multifeeding this alignment criterion can not be met A feeder cannot supply overlapping documents because the next document only can be separated from the feeder hopper if the previous document completely has left the separation area If nevertheless multifeeding must be possible another approach must be chosen If the optional divert subsystem as discussed above is present multifeeding is dealt with in the following manner First the first doc
25. clears both sides of the pulse disc and the detector sees the outer ends of the slots in the pulse disc Adjustment See paragraph 9 2 1 Drive belts 5 1 22 Pulleys rev 01 0 01 2002 520 02 37 service manual FPI 5000 C Pulleys 60T item 5 22T item 7 40T item 3 and 18T item 9 The removal of the pulleys has been described in the previous paragraph 5 1 3 Motor Remove the collating area cover as described in paragraph 1 8 Collating area cover Remove the drive belts as described in the paragraph 5 1 1 Drive belts Removal Refer to figure 5 1 Cut the two wire straps securing the wiring of the motor 15 Disconnect the motor Remove the four round head screws 14 and withdraw the motor Replacement Ensure on replacement to secure the wiring of the motor again with two wire straps 5 2 Collating arm 520 02 38 rev 01 0 01 2002 service manual FPI 5000 C 5 2 1 Transportation belts Remove the collating arm cover as described in paragraph 1 7 Collating arm cover Removal 42 43 44 figure 5 2 Refer to figure 5 1 rev 01 0 01 2002 520 02 39 service manual FPI 5000 C Slacken the set screw of the pulley 5 and the pulley 7 Slide both pulleys together with the drive belt 6 off the axles Take care of the spacer 4 Refer to figure 5 2 Cut the wire strap securing the wiring of the receiver 3 to the collator frame 1 Disconnect the receiver and the earth lead 2 Slacken th
26. service manual FPI 5000 C Figure 520 04 28 Remarks illustration Description Part code Quantity Remarks code number number 5000 1 Curve disc LH 95 30 63 2 2 Tension pin 2 5 x 20 05 3324 4 3 Conductive bearing 10 mm 04 24 26 4 4 Washer 16 x 10 2 x 0 8 mm 04 01 43 4 5 Spring clip 10 14 mm 05 24 83 4 6 Nut M4 45 19 02 2 7 Washer 09 x 4 3 x 0 8 mm 45 37 45 2 8 Mounting bracket 95 30 59 1 9 Curve axle 95 31 10 2 10 Curve disc RH 95 30 64 2 11 Round head screw x 16 05 38 71 4 12 Leaf spring 95 30 60 2 13 Bracket 95 30 90 2 14 Axle for fold plate 95 30 30 2 15 Paper guide 95 30 26 1 16 Spring clip 7 9 mm 05 24 42 7 17 Washer 14 x 8 2 x 0 8 mm 04 01 41 10 18 Cyl pin 2 x 32 05 23 08 4 19 Hinge strip paper guide RH 95 30 21 1 20 Countersunk head screw M3 x 10 05 38 74 14 21 Hinge plate RH 95 30 11 2 22 Guide plate assy second fold table 95 30 54 1 23 Fold plate 95 30 16 i 24 Hinge strip paper guide LH 95 30 20 2 25 Hinge plate LH 95 30 10 2 26 Mounting bracket 95 30 56 1 27 Round head screw M4 x 8 05 38 68 2 28 Locking plate 95 30 95 1 29 Guide plate assy first fold table 95 30 51 1 30 Fold plate 96 42 07 1 rev 02 0 02 2002 520 04 29 service manual FPI 5000 C Figure 11 520 04 30 rev 02 0 02 2002 service manual FPI 5000 C Figure 520 04 30 Remarks illustration Description Part code Quantity Remarks code number number 5000 1 Conductive bearing
27. to di 5 NOVEL DEED E sero Wagon bien M SEN OVAL Ie 710516 SNIGV3H WNOUdI for an SA 5005 system of the FPI 5000 C base unit board 97 50 10 plus one two or jew three feeder module boards 93 08 02 Total vi figure 1 1 rev 01 0 01 2002 520 03 6 lt 004 10 010 291 FEEDER BOARD 930802 EPROM EPROM FV2a MAIN FV2a FEEDER EPROM 97 50 12 97 50 13 FV2a FEEDER L 0 0TS 20 80 26 P IEOG JO 91845 5005 VS UB MILA 6301 FV2a MAINBOARD 97 50 10 654321 654321 123 123 2 1 LOWER FEEDER Dix 04 24 52 FPH2 Tx 3 1 LOWER FEEDER 2 04 24 53 FPH2 Rx 3 RPM LOWER FEEDER EDER FDFC1 FDFC2 UPPER FEEDER 2 1 04 24 52 Pha O O UPPER FEEDER 1 04 24 53 AMA 1 Rx DFC ASSY 89 08 36 DFC ASSY 89 08 36 3 RPM UPPER FEEDER FCL2 97 50 13 nnnnnnnnnnnnnn 27C512 FEEDER BOARD 930802 ENUBUI 5 000 5000 1 service
28. 10 94 3 27 Disc for pulley 93 05 42 3 28 Timing belt 04 16 31 1 29 Clamping ring 8 mm 05 24 85 2 30 Spring clip 7 9 mm 05 24 42 4 31 Roller assy 30 mm 93 05 23 2 32 Pulley 20T timing belt 24 13 75 3 33 Pulley 60T 04 13 20 1 34 Set screw M3 x 4 08 28 33 5 35 Pulley 22T 04 13 16 1 36 Pulley 40T 04 13 19 1 37 Timing belt 04 15 62 2 38 Motor pulley 18T 04 13 13 1 39 Clamping ring 10 mm 05 24 81 2 40 Pulse disc 73 37 80 1 4 Axle 95 21 38 1 42 Spacer 10x 6 3 x 3 mm 04 08 63 2 43 Washer 12 x 0 6 2 x 0 8 mm 04 01 40 4 44 Transportation axle 93 05 35 1 45 Round head screw M3 x 6 45 43 02 2 rev 02 0 02 2002 520 04 17 Figure 520 04 16 Remarks 520 04 18 illustration code number 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 service manual Description Washer 7 x 3 2 x 0 5 mm Pulse disc sensor assy Round head screw M3 x 10 Motor 24V assy low noise Belt tensioner plate Belt tensioner Intermediate plate vert transport Hex head screw x 8 Drive and transportation axle Drive axle Input roller assy Guide bracket Bearing locking plate Fold roller assy Damper Spring clip 6 8 mm Fold roller assy Drive axle assy Drive axle assy Locking strip RH Washer 9 x 4 3 x 0 8 mm Washer 6 x 3 2 x 0 5 mm Spacer 25 x 5 5 x 8 mm Rubber stud M6 x 20 mm FPI 5000 C Part code Quantity Remarks number
29. 115 12 0 V 12 5 V 12 V power supply TP312 0 Ground level TP321 Used for wire link between this GND manually resetting the CPU Only used for software development table 4 2 520 03 22 rev 01 0 01 2002 service manual FPI 5000 C 5 Error diagnosis error codes The FPI 5000 C plus its associated feeders doesn t have its own user interface Therefore the error diagnosis and error codes related to the FPI 5000 C subsystem are discussed in chapter 5 of the FPI 5000 I electrical description document 510 03 rev 01 0 01 2002 520 03 23 service manual FPI 5000 C 520 03 24 rev 01 0 01 2002 service manual FPI 5000 C Parts lists rev 02 0 02 2002 520 04 1 service manual FPI 5000 C 520 04 2 rev 02 0 02 2002 service manual FPI 5000 C Recommended spare parts Some of these parts already could be stocked being part of another recommended spare parts list Illustration Description Part code Stock qty Code nr Number per number of installed machines 1 10 100 Figure 520 04 6 4 Hopper complete auto 79 01 53 1 1 2 13 Hopper complete special 79 01 54 1 1 2 Figure 520 04 8 1 97 50 12 1 1 2 2 Mainboard 97 50 10 1 1 2 Figure 520 04 12 2 Sensor including holder 04 24 53 1 2 4 5 Transportation roller 95 13 12 2 2 4 9 Input roller assy 93 05 33 1 1 2 22 Microswitch 12 12 22 1 2 4 27 Transportation roller 36 mm 76 04 66 2 2 4 Figur
30. 2 head tapping screw 05 38 55 2 22 Pressure roller 30 95 11 86 14 23 Setscrew x 16 08 28 07 14 24 Pressure spring 03 35 20 16 25 Conductive bearing 6 mm 04 24 24 12 26 Washer 12 x 6 2 x 0 8 mm 04 01 40 12 27 Spring clip 6 8 mm 05 24 46 12 28 Pressure roller axle 95 14 16 6 29 Nut M4 45 19 02 11 30 Washer 9 x 4 3 x 0 8 mm 45 37 45 10 rev 02 0 02 2002 520 04 33 service manual FPI 5000 C 9 V 22 21 20 19 27 31 30 29 28 26 Figure 13 520 04 34 02 0 02 2002 service manual FPI 5000 C Figure 520 04 34 Remarks illustration Description Part code Quantity Remarks code number number 5000 C 1 Hex head screw 8 05 38 80 8 2 Lock 95 14 29 2 3 Lock extension 95 14 30 2 4 Guide arm axle 95 14 34 1 5 Guide arm 95 14 32 2 6 Cyl pn 2x16 05 23 69 2 7 Washer 14 x 0 8 2 x 0 8 mm 04 01 41 4 8 Spring clip 8 11 mm 05 24 54 4 9 Pressure spring 03 35 20 6 10 Leaf spring 95 14 56 3 11 Mounting plate 95 14 05 1 12 Cover 95 14 42 1 13 Axle 6 mm 95 14 07 1 14 Pressure roller 2 20 95 14 08 2 15 Washer 12 x 6 2 x 0 8 mm 04 01 40 2 16 Spring clip 7 9 mm 05 24 42 2 17 Axle 6mm 95 14 43 2 18 Pressure roller 20 95 14 44 2 19 Countersunk head screw M3 x 6 45 42 01 4 20 G
31. 50 51 52 33 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 service manual Description Cyl pin 2 x 16 Pulley 44T Spring clip 6 3 mm Washer 12 x 6 2 x 0 8 mm Tensioner roller Belt tensioner Spring clip 7 9 mm Washer 0 14 x 8 2 x 0 8 mm Gear 64T assy Support axle extension Fibre washer 10 x 5 2 x 1 mm Bearing bush Spring clip 5 7 mm Washer 12 x 4 3 x I mm Pressure spring Conductive bearing 6 mm Conductive bearing 8 mm Cyl pin 2 5 x 16 Transportation roller Leaf spring Round head screw x 16 Transportation axle Transportation roller 30 mm Set screw M4 x 6 Pan head tapping screw Fixing strip Sensor including holder Bracket for photocell Round head screw M4 x 8 Wire strap holder Part code number 05 23 69 95 11 51 05 24 46 04 01 40 95 11 59 96 42 18 05 24 42 04 01 41 95 11 38 95 11 09 04 01 07 04 13 32 05 24 66 45 37 43 03 35 20 04 24 24 04 24 25 05 23 46 95 13 12 95 12 07 05 38 71 95 11 37 95 11 86 08 28 02 45 38 55 95 11 13 04 24 53 95 11 46 05 38 68 12 10 52 5000 Quantity Remarks FPI 5000 C t2 DD ON b2 DVD A 4 L ra zl E ra Pune wore 02 0 02 2002 service manual FPI 5000 C rev 02 0 02 2002 520 04 49 service manual FPI 5000 C en i Figure 19 520 04 50 rev 02 0
32. 5000 45 37 39 82 16 22 45 43 04 04 26 38 95 21 37 gt gt 93 05 26 1 93 06 06 1 05 38 80 10 93 05 09 2 95 20 02 1 93 05 33 95 30 73 93 06 12 93 05 34 03 35 55 Fa N N 05 24 46 93 05 56 93 05 05 93 05 07 43 19 32 kt 45 37 02 45 37 30 43 29 31 04 12 12 gt P 02 0 02 2002 service manual FPI 5000 C rev 02 0 02 2002 520 04 19 5000 1 service manua 6L OZ IZ 22 EC 76 SC 92 A Sat EL E 12 87 62 OE LE ZE EE Figure 7 rev 02 0 02 2002 520 04 20 service manual FPI 5000 C Figure 520 04 20 Remarks illustration Description Part code Quantity Remarks code number number 5000 Washer 14 x 8 2 x 0 8 mm 04 01 41 6 2 Conductive bearing 8 mm 04 24 25 2 3 Springclip 7 9 mm 05 24 42 3 4 Conductive bearing 10 mm 04 24 26 2 5 Brake strip 95 30 97 1 6 Brake disc 95 30 94 4 7 Pressure spring 95 31 00 2 8 Cyl pin 2 5 x 16 05 23 46 2 9 Washer 12 x 4 3 x 1 5 mm 45 37 58 3 10 Round head screw x 8 05 38 68 8 11 Tensioner bracket 93 05 16 1 12 Tensioner roller 93 05 15 1 13 Spacer 15 x 10 4 x 3 mm 04 08 58 1 14 Gear35T 24 69 58 2 15 Washer 16 x 10 2 x 0 8 mm 04 01 43 2 16 Clamping ring 10 mm 05 24 81 2 17 Damper 03 35 55 1 18 Spring clip 6 8 mm 05 24 46 1 19 Spring clip 10 14 mm 05 24 83 2 20 Gear 24T 93 05 25 2 21 Cyl pin 2 5 x 12 05 23 47 2 22 Count
33. C base unit board 97 50 10 deals with the control of the Eight in One folding subsystem the control of the vertical transport the control of the collator and optional divert subsystems the control of the optional reading board see Appendix 1 and the optional MaxiFeeder MF 1 see Appendix 2 In addition this board deals with DC communication downstream with the 5000 I inserter and upstream with up to three feeder modules and with the OMR board 93 08 03 Each feeder module board 93 08 02 implements the Vario Feed feature and deals with the local control of two feeders and with the C communication downstream with the 5000 C base unit board This array of circuit boards is powered by the FPI 5000 I As for the sensors and actuators the FPI 5000 C base unit board controls eight actuators six clutches and two bi directional DC motors Eleven sensors serve the FPI 5000 C base unit board with control information including four paper photocells five slotted photocells and two safety micro switches Each feeder module board controls two clutches and gets control information from two paper photocells The FPI 5000 C doesn t have its own user interface The user interface related tasks both operational and for service purposes for the FPI 5000 C are delegated to the FPI 5000 I So from a control point of view the FPI 5000 C is a satellite of the FPI 5000 I which provides the user interface the electrical power and except for t
34. Cover Cover RH Cover RH Part code number 45 38 82 98 01 44 45 19 02 98 01 46 98 01 49 05 38 80 98 01 25 98 01 28 96 46 25 98 01 45 98 01 47 Quantity Remarks FPI 5000 C Lhe N ke A 520 04 11 5000 service manual ZZ Figure 4 rev 02 0 02 2002 520 04 12 service manual FPI 5000 C Figure 520 04 12 Remarks illustration Description Part code Quantity Remarks code number number 5000 1 Pan head tapping screw 05 38 55 2 2 Sensor including holder 04 24 53 2 3 Lock washer 5 32 05 24 31 1 4 Clamping bracket 12 14 06 1 5 Transportation roller 95 13 12 1 6 Cyl pin 2x 16 05 23 46 4 7 Drive and transportation axle 93 05 09 1 8 Intermediate plate vert transport 93 06 06 1 9 Input roller assy 93 05 33 2 10 Intermediate plate fold unit 93 06 05 1 11 Transportation axle 93 05 35 1 12 Conductive bearing 8 mm 04 24 25 4 13 Hex head screw x 8 05 38 80 13 14 Spring clip 9 12 mm 05 24 55 2 15 Round head x 25 45 43 18 2 16 Synthetic stud 24 14 62 2 17 Strip 93 06 29 18 Nut self locking 05 38 21 2 19 Divert unit complete 89 08 34 1 20 Suspension axle 95 21 32 1 21 Intermediate plate 93 06 07 1 22 Microswitch 12 12 22 1 23 Insulating plate 93 06 41 1 24 Washer 6 x 3 2 x 0 5 mm 45 37 30 2 25 Round head screw x 20 45 43 07 2 26 Screening plate 95 13 33 1 27 Transport
35. EICH 1162 52156 awe N02 C Mr aL 8 5 5 PIOHPL ETED B 3001 FR i CLOW T102 an lt 550 35114 ax 1 1 2 Nt dr 306 5 D on BEEY gt voca 3089 DEM TESH TT 222 A 306 E 1103 sid 3s1nd 3089 9941 22202 LEEY HOLIMS om Or qp NOD E03 uim gt SIN NOE als I APT lt 4 vIOHPL oteo 1 05 lt 4 5 13 95103 9 1 IAGPISST d z Cem We E en er 1 anov NOT NOT 1 3089 vitu sof zm ss Cem 01 HOLMS 1 1 100 041823 aiwa DIER lt 199 Loga zt AA HOLMD Ot 5 AS vyd ano i e 04 HJLMD 9 0 lt 0 8 u355hiLLLIWHOS ETEY NOT prone E anov TIND 5514 35114 4 9 S 3TOEDI SEE r DAN 4 ISIT ISTINA e ES AT dL 306 z NOT 1 BAT soca 3089 EECH Se OTEY VE Le 8 M T ansv lt A 53 1 4 29 AER ges 6084 ANDY 9 0 lt 0 NOT EIER ve 4 p o VEdL 11828 lg PEENI NOOT NOT Dr 89 07 1060 mm 20001 i NI 041VLI9IG on Soe Dy ET 920201 5 l lt 043102 289 lt NI 1109 834 D 1089 Div anov dL
36. FPI 5000 C Upper transportation axle Removal Remove the pulley 20T item 29 as described in the previous paragraph Refer to figure 3 2 Push both transportation rollers 4 inwards from the cyl pin 5 below Remove both cyl pins from the axle Slide both transportation rollers off the axle Replacement Ensure on replacement that the transportation rollers are refitted correctly on the axle narrowing part of the rollers pointing outwards Lower transportation axle Removal Remove the pulley 20T item 22 as described in the previous paragraph Refer to figure 3 2 Push both transportation rollers 9 inwards from the cyl pin 8 below Remove both cyl pins from the axle Slide both transportation rollers off the axle Replacement Ensure on replacement that the transportation rollers are refitted correctly on the axle narrowing part of the rollers pointing outwards 3 1 5 Gears Remove the rear cover as described in paragraph 1 10 Rear cover Gear 35 item 15 Removal Refer to figure 3 3 Remove the two round head screws 7 and withdraw the gear cover 10 Remove the spring clip 1 the washers 2 and the bearing 3 Shift the drive axle 13 in the right hand side direction until it is clear from the LH inside frame Tilt the left hand side of the drive axle in the rear side direction and when possible withdraw it Slacken the two set screws securing the bushing14 Slide the bushing and the gear 15 in the right ha
37. NMOG lt 5 2 xt er 1 8 Lx 8 DIEN HIER L om 2 9 5 i lt 9 1 z G G 12 4 2 T T z Dav avaa beid avaa 5 1022 Em 2028 even T 2122 d am 134 1394 u ddn 1394 zad 339333 IMOT Tad 30334 IWER 440334 TAJ 1904 HOLM 130334 adn ts and outputs inpu Feeder module board 93 08 02 2 figure 1 11 rev 01 0 01 2002 520 03 16 5000 1 service manua u3MOd YSOLLIL 34001 20001 0ETOI T 02109 1 3H22 AUOT 02202 AUOT AUOT T AUOT 1 4U0T 00202 05202 07202 2 AUOT 1 49001 DIA LA 1 17 I ano NOOT ETED STEH ZIED TOEdL KAP power supply Feeder module board 93 08 02 3 figure 1 12 520 03 17 rev 01 0 01 2002 5000 1 service manua 11029145 5031 40443 29 29 20 20 S DIS p Le
38. Refer to figure 7 9 Remove the two countersunk screws 13 with the washers 12 and withdraw the locking plate 11 Shift the roller 2 in the left hand side direction until it is clear from the RH inside frame Lift the right hand side of the roller upwards and when possible withdraw it carefully in the right hand side direction Replacement Ensure on replacement not to damage the foam surface of the fold roller rev 01 0 01 2002 520 02 67 service manual FPI 5000 C 8 Detectors 8 1 Feeders 8 1 1 Pulse disc detector assy Remove the RH side cover as described in paragraph 1 4 RH side cover Removal figure 8 1 Refer to figure 8 1 Cut the two wire straps securing the wiring of the pulse disc detector assy 2 Remove the countersunk screw 7 and withdraw the pulse disc 5 together with the two spacers 6 Take care of the washer 4 Remove the two round head screws 3 with the washers securing the pulse disc detector assy to the bracket 1 Disconnect and withdraw the pulse disc detector assy Replacement Ensure on replacement that the pulse disc detector assy clears both sides of the pulse disc and that the detector sees the outer ends of the slots in the pulse disc Secure the wiring again with two wire straps 520 02 68 rev 01 0 01 2002 service manual FPI 5000 C 812 DFC Remove the feeder as described in paragraph 3 6 Feeders Removal figure 8 2 Refer to figure 8 2 Remove the r
39. TP506 0V Ground level TP507 OV Ground level table 4 1 Note The measured DC voltage on a test point that carries a dynamic digital voltage is not relevant the measured DC voltage is determined by the duty cycle of the digital signal These kind of signals should be observed with an oscilloscope The signals vary between a few tenths of volts above ground level and a few tenths of volts below VCC level 5 V Test points on the feeder unit board 93 08 02 Test point Minimum Typical Maximum Notes TP101 Digital test signal used for software development TP102 Test of the digital signal that drives the diagnostic LED D101 Normal flashing frequency 1Hz During errors the flashing frequency is 4 Hz TP201 0 9 V 1 1 V 1 3 V Paper photocell FPH1 Rx no paper present TP201 0 0 V 0 1 V 0 5 V Paper photocell FPH1 Rx paper present TP202 0 9 V 1 1 V 1 3 V Paper photocell FPH2 Rx no paper present TP202 0 0 V 0 1 V 0 5 V Paper photocell FPH2 Rx paper present TP221 4 0 41 42V Output voltage of upper DFC unit Result of DFC adjustment after the relevant photocell detected test paper TP222 4 0 V 41 4 2 V Output voltage of lower DFC unit Result of DFC adjustment after the relevant photocell detected test paper TP301 23 24 35V Power supply as delivered by FPI 5000 I TP302 4 8 5 0 5 2 5 V power supply and TP311
40. V 1 3 V Paper photocell VPH2 Rx no paper present TP2A 0 0 V 0 1 V 0 5 V Paper photocell VPH2 Rx paper present TP3A 0 9 V 1 1 V 1 3 V Paper photocell VPH1 Rx no paper present TP3A 0 0 V 0 1 V 0 5 V Paper photocell VPH1 Rx paper present TP4A 0 9 V 1 1 V 1 3 V Paper photocell VPH4 Rx no paper present TP4A 0 0 V 0 1 V 0 5 V Paper photocell VPH4 Rx paper present TP1D Digital input signal of slotted photocell VSPH2 See Note TP2D Digital input signal of slotted photocell VSPH3 See Note TP3D Slotted photocell for future third fold table TP4D Digital input signal of slotted photocell VSPH5 See Note 5 Digital input signal of slotted photocell VSPH1 See Note TP6D Digital input signal of slotted photocell VSPH4 See Note 401 Digital signal SCL_I2C See Note TP402 Digital signal SDA DC See Note 403 Digital signal SCL SCL SPARE See Note TP404 Digital signal SDA SDA SPARE See Note TP501 115 12 0 V 12 5 V 12 V power supply TP502 4 8 5 0 5 2 5 V power supply 503 0 Ground level TP504 Used for wire link between this TP and GND for manually resetting the CPU Only used for software development rev 01 0 01 2002 520 03 21 service manual FPI 5000 C Test point Minimum Typical Maximum Notes 505 0V Ground level
41. Y V bus 328 328 6224 DG NOOT Ce SR 1 vvava PUER SC 9022 11828 11828 8 NOT 10 S r EECH EE z 5h at Va 8NO2 sth 29 sva vas 14433 vd vas 8 ova 725 daa DVO 155 7390104 4 aor bes Eva 9 hd vdS LOJ gt or 2298 Iv s TECH 221 of Pva 4 ov 9 TID v ST zn sh ova A on A 1320104 E e WEI T DECH 02 a 6yssspe V nor 50202 outputs it board 97 50 10 2 FPI 5000 C base un figure 1 4 520 03 9 rev 01 0 01 2002 5000 1 service manua 8NO2 aye 421 at mme gt Sid S
42. belt Mounting bracket Round head screw x 8 Clamping ring 10 mm Strip for pressure spring Reinforcement strip Pressure spring Spring clip 4 5 mm Washer 12 x 4 3 x I mm Spacer 8 x 0 4 3 x 3 mm Strip for pressure spring Hinge pin Spring clip 10 14 mm Gear 24T Cyl pin 2 5 x 12 Countersunk head screw M4 x 10 Bearing locking plate Flap actuator Cyl pin 2 x 12 Spring clip 6 8 mm Washer 12 x 6 2 x 0 8 mm Conductive bearing 6 mm Gear 35T Spacer 15 x 0 10 4 x 3 mm FPI 5000 C Part code Quantity Remarks number 5000 93 05 19 93 06 36 05 38 68 05 24 81 93 06 39 F ROH 93 06 38 93 06 42 05 24 47 45 37 43 04 11 32 NRF WR eS 93 06 40 93 06 37 05 24 83 93 05 25 05 23 47 LA D Oh ra ra 05 38 75 93 06 13 95 30 84 95 30 85 05 24 46 WORD RD 04 01 40 04 24 24 24 69 58 04 08 58 02 0 02 2002 service manual FPI 5000 C rev 02 0 02 2002 520 04 25 service manual FPI 5000 C 1116 15 14 13 12 11 31 32 33 36 37 38 39 40 we WP 26 27 28 29 30 Figure 9 520 04 26 rev 02 0 02 2002 service manual FPI 5000 C Figure 520 04 26 Remarks illustration Description Part code Quantity Remarks code number number 5000 1 Brake disc 95 30 66 2 2 Cyl pin 2 5 x 16 05 23 46 2 3 Washer 16 x 10 2 x 0 8 mm 04 01 43 4 4 Conductive bear
43. drive belt 7 2 2 Pulleys Remove the drive belt as described in the previous paragraph Pulley 30T item 24 Removal Refer to figure 7 3 Remove the spring clip 23 Pull the pulley 24 from the axle Take care of the cyl pin 25 Pulley 35T item 29 Removal Refer to figure 7 3 Remove the clamping ring 27 with the washer 28 Slide the pulley 29 off the axle 7 2 3 Clutch Removal Remove the pulley 36T item 29 as described in the previous paragraph Refer to figure 7 3 Disconnect the clutch Slide the clutch off the axle Replacement Ensure on replacement that the locking plate 36 retains the clutch and secure the wiring again to the stud on the clutch with a wire strap rev 01 0 01 2002 520 02 53 service manual FPI 5000 C 7 2 4 Gears Remove the LH side cover as described paragraph 1 5 side cover Gear 241 item 6 Removal Refer to figure 7 3 Remove the spring clip 5 Pull the gear 6 from the axle Take care of the cyl pin 7 Gear 35T item 13 Removal Refer to figure 7 3 Pull the flap lever 1 from the axle Take care of the cyl pin 2 Remove the clamping ring 11 with the washer 12 Slide the gear 13 off the bearing pin Take care of the two spacers 14 Gear 24T item 9 Removal Refer to figure 7 3 Remove the spring clip 8 Pull the gear 9 from the axle Take care of the cyl pin 10 Gear 35T item 20 Removal Refer to figure 7 3 Pull the flap lever 3
44. from the axle Take care of the cyl pin 4 Remove the clamping ring 16 with the washer 17 Slide the gear 20 off the bearing pin Take care of the two spacers 15 Gear 24T item 31 Removal Remove the clutch as described in the previous paragraph Refer to figure 7 3 Pull the gear 31 from the axle Take care of the cyl pin 32 520 02 54 rev 01 0 01 2002 service manual FPI 5000 C Gear 35T item 21 Removal Refer to figure 7 3 Remove the two hex head screws 35 securing the locking plate 36 and place it aside Take care of the wiring attached to it Remove the clamping ring 18 with the washer 19 Slide the gear 21 off the bearing pin Take care of the two spacers 22 Replacement Ensure on replacement that the locking plate retains the clutch 30 rev 01 0 01 2002 520 02 55 service manual FPI 5000 C 7 3 Fold mechanism Remove the top folder cover as described in paragraph 1 12 Top folder cover Remove the drive belt as described in paragraph 7 1 1 Drive belt 7 31 Gears Gear 32T item 15 and 32T item 2 Removal figure 7 4 Refer to figure 7 4 Remove the round head screw 34 with the bushing 32 securing the right hand side of the axle 4 Shift the axle in the right hand side direction until the right hand bearing 3 clears the frame plate 30 Carefully lift the axle assembly as far as possible upwards Take care of the wiring 520 02 56 rev 01 0 01 2002 service manual F
45. from the machine and slide both transportation rollers off the axle Take care of the metal bearing 8 on the left hand side of the axle and of the bearing 4 and the washer 3 on the right hand side Replacement Ensure on replacement that the two transportation rollers are refitted correctly on the axle narrowing part of both rollers pointing outwards and the set screws rest into the grooves in the axle Secure the wiring again to the stud on the right hand clutch with a wire strap rev 01 0 01 2002 520 02 43 service manual FPI 5000 C 6 2 Divert Remove the transportation rollers as described in the previous paragraph 6 2 1 Divert unit Remove the bottom plate as described in paragraph 1 9 Bottom plate Removal figure 6 2 Refer to figure 6 2 Remove the spring clip 8 securing the frame rod 5 on the right hand inside of the machine Withdraw the frame rod in the right hand side direction from the machine Disconnect the wiring of the motor 4 Disconnect the wiring of the pulse disc detector assy 1 see also figure 6 3 item 16 Remove the spring clip 7 securing the right hand rod 6 on the right hand inside of the machine Unscrew and remove the rod Lift the divert unit upwards until the left hand rod 2 is clear from the LH inside frame and then withdraw it from the machine 520 02 44 rev 01 0 01 2002 service manual FPI 5000 C 6 22 Motor Remove the divert unit as described in the previou
46. orientation face up and leading The address carrying document must be fed via the top feeder e Documents with the fold type zig zag fold must be fed to the feeder with the orientation face down and trailing The address carrying document must be fed via the bottom feeder The feeding process is fairly straightforward a document is separated by 87 89 and exited to the vertical track by 67 and 68 The paper transport is monitored by the photocell 79 80 The thickness is measured by the optional DDD DFC unit Double Document Detector and Double Feed Control 75 The mentioned numbers apply to the bottom feeder 2 2 Vertical document transport The vertical track consists of two driven axles per attached feeder module 45a 43a 41a and 39a plus two driven axles in the FPI 5000 C main body 36 and 34 All these axles carry two rollers except for 39a at the bottom feeder which carries four rollers This is necessary for straightening the paper prior to passing the optional reading head 37 All driven rollers have their counterparts in rollers 44 42 40 38 35 and 33 which all are located in the vertical transport cover The paper transport is monitored by photocell VPH1 46 47 The various documents of a set are fed from the feeders to the vertical track in such a way that these documents are greatly but not for the full hundred percent overlapping each other This overlapping not only ensures a higher throughput but is also absolu
47. roller Note The removal procedure of the right and left hand guide roller is similar Removal figure 4 2 Refer to figure 4 2 Remove the two round head screws 9 securing the rod 6 with the guide roller 7 to the leaf spring 8 Remove the rod and slide the guide roller off it Middle guide rollers Note The removal of the two guide rollers in the middle is similar Removal Refer to figure 4 2 Remove the spring clip 5 with the washer 4 Slide the guide roller 3 off the axle 1 Take care of the washer 2 520 02 36 rev 01 0 01 2002 service manual FPI 5000 C 5 Collating area 5 1 Drive mechanism Remove the RH side cover as described in paragraph 1 4 RH side cover 511 Drive belts Removal 0 mu D Te figure 5 1 to figure 5 1 Slacken the set screw of the pulley 5 and the pulley 7 Slide both pulleys together with the drive belt 6 off the axles and remove the spacer 4 Remove the two round head screws 11 with the washers 12 and place the pulse disc detector assy 13 aside Slacken the set screw of the pulley 3 Slacken the set screw of the pulley 9 accessible through the hole in the pulse disc 10 Slide both pulleys together with the drive belt 8 off the axles Take care of the spacer 2 and the washer 1 Replacement Ensure on replacement that the set screw of the pulley 9 is retightened onto the flattened part of the motor axle and that the pulse disc detector assy
48. strictly necessary to explain the process are projected on the LH side of the machine This implies that not all auxiliary mechanical items such as gears belts et cetera are shown using the concept of LH projection this would make this figure pretty unreadable However some global information on the main mechanical drive systems is included in this process description Refer to the FPI 5000 C mechanical description document 520 02 for full details on the FPI 5000 C mechanics rev 01 0 01 2002 520 01 5 service manual FPI 5000 C ee JE 3 av N an NI ye de ae ae A 2 JS ae o 6 EN 00 v OG 5 E BN de dg so SNC figure 1 1 520 01 6 rev 01 0 01 2002 service manual FPI 5000 C 2 Legend Note I Parts with an arrow are mechanically driven by the FPI 5000 I or by a DC motor Note 2 For reasons of cross reference the nomenclature for sensors and actuators as used in the electrical description document 134 03 is mentioned here as well Tx transmitter Rx receiver 1 Folder output photocell VPH4 Tx led 2 Folder output photocell VPH4 Rx sensor 3 Second fol
49. vertical transport cover 41a Vertical track rollers in upper feeder of lower feeder module 41b Feeder clutch for upper feeder of lower feeder module FCL2 Drives 69 91 90 only in feeder with manual separation and 92 42 Counter rollers for 43a in vertical transport cover 43a Vertical track rollers in lower feeder of upper feeder module 43b Feeder clutch for lower feeder of upper feeder module Drives 71 94 93 only in feeder with manual separation and 95 44 Counter rollers for 45a in vertical transport cover 45a Vertical track rollers in upper feeder of upper feeder module 45b Feeder clutch for upper feeder of upper feeder module FCL2 Drives 73 97 96 only in feeder with manual separation and 98 46 Vertical track photocell VPH1 Tx led in vertical transport cover 47 Vertical track photocell VPH1 Rx sensor 48 Collator photocell VPH2 Tx led in vertical transport cover 49 Collator photocell VPH2 Rx sensor 50a Divert motor VM2 Drives 24 and 25 50b Slotted photocell VSPH5 Monitors divert motor VM2 50a 51 Collator motor Drives 52 56 51b Slotted photocell VSPH4 Monitors collator motor 51 52 56 Driven collator rollers In collator arm 57 Document stopper position for 6 documents 58 Document stopper position for 12 documents 520 01 8 rev 01 0 01 2002 service manual FPI 5000 C
50. we advise to slightly glue loctite 603 the ball bearings to frame First lower fold roller Remove the first upper fold roller as described in paragraph 7 4 Upper fold rollers Removal Refer to figure 7 9 Remove the countersunk screw 17 with the washer 18 and withdraw the locking plate 19 Shift the roller 3 in the left hand side direction until the bearing on the right hand side is clear from the RH inside frame Lift the right hand side of the roller upwards and when possible withdraw it carefully in the right hand side direction Replacement Ensure on replacement not to damage the foam surface of the fold roller Second lower fold roller Open the folder as described in paragraph 1 3 Folder Remove the gear 24T item 9 as described in paragraph 7 2 4 Gears Removal Refer to figure 7 9 Remove the two countersunk screws 13 with the washers 12 and withdraw the locking plate 11 Shift the roller 1 in the left hand side direction until it is clear from the RH inside frame Lift the right hand side of the roller upwards and when possible withdraw it carefully in the right hand side direction 520 02 66 rev 01 0 01 2002 service manual FPI 5000 C Replacement Ensure on replacement not to damage the foam surface of the fold roller Third lower fold roller Open the folder as described in paragraph 1 3 Folder Remove the gear 24T item 6 as described in paragraph 7 2 4 Gears Removal
51. 0 and withdraw it Take care of the washer 9 Remove the spring clip 15 securing the damper 16 Slide the damper off the bearing pin Remove the clamping ring 17 with the washer 18 Slide the gear 19 off the bearing pin Gear 24T item 26 520 02 50 rev 01 0 01 2002 service Removal Refer to figure 7 1 Remove the spring clip 23 Pull the gear 24 from the axle Take care of the cyl pin 25 Gear 35T item 14 Removal Refer to figure 7 1 Remove the clamping ring 14 with the washer 13 Slide the gear 12 off the bearing pin Take care of the spacer 11 Gear 24T item 23 Removal Refer to figure 7 1 Remove the spring clip 20 Pull the gear 21 from the axle Take care of the cyl pin 22 rev 01 0 01 2002 FPI 5000 C 520 02 51 TS 0cs 7007 10 010 Aa 91081 NN SH Ve VAR j 254 IN KRR 1 W 5 7 0 f SE 2 N DSN OR My 1617 18 1920 21 23 24 75 26 27 28 29 ENUBUI 5 0005 144 service manual FPI 5000 C 7 2 LH drive mechanism Remove the LH side cover as described in paragraph 1 5 LH side cover Open the folder as described in paragraph 1 3 Folder 7 2 1 Drive belt Removal Refer to figure 7 3 Remove the screws 38 and the plate 37 Slacken the two hex head screws 33 securing the belt tensioner 34 Remove the drive belt 26 from the pulley 24 and the pulley 29 Adjustment See paragraph 9 3 2 LH
52. 20 Roller 21 rod 22 Lever 23 Hinge 24 Hinged side guide 25 Countersunk head screw M4 x 6 Note 1 Only in special feeder Part code number 45 12 45 04 27 09 95 10 11 95 10 12 95 10 14 43 02 47 03 35 20 04 11 32 04 27 37 04 27 38 45 37 50 74 14 97 45 37 45 45 19 02 02 11 25 05 36 21 05 24 47 95 10 18 95 10 16 95 10 19 95 10 22 95 10 20 95 10 25 95 10 13 45 42 11 FPI 5000 C Quantity FPI 5000 C _ N k N N ra Fa N Remarks see note 1 see note 1 see note 1 see note 1 see note 1 520 04 57 5000 1 service manua 21 22 23 Figure 23 rev 02 0 02 2002 520 04 58 service manual FPI 5000 C Figure 520 04 58 Remarks illustration Description Part code Quantity Remarks code number number 5000 1 Side guide assy LH 04 26 93 1 2 Feed table assy 04 26 90 1 3 Side guide assy RH 04 26 92 1 4 Spacer 6x 4 1x2 5mm 43 01 42 8 5 Washer 12 x 6 2 x 0 8 mm 04 01 40 5 6 Washer 9 x 4 3 x 0 8 45 37 45 7 7 Finger knob 74 14 97 1 8 Crank assy short 04 26 91 2 9 Nut M4 self locking 05 36 21 6 10 Spacer 43 41 45 1 11 Crank 04 25 97 1 12 Sleeve 04 14 28 1 13 Lever 04 26 97 1 14 Nut M4 45 19 02 1 15 Lever Bracket 04 26 98 1 16 Spring clip 4 5 mm 05 24 47 2 17 Nylon bearing 04 11 07 2 18 Torsion spring 03 35 35 1 19 Set screw M4 x 6 08 28 02 1 20 Lifting plate 04 26
53. 3 The 360 degrees fold cycle of the brake disk consists of a 120 degrees part flap and paper guide upwards and a 240 degrees path flap and paper guide downwards plus karate action of 16 The brake disc is mechanically loaded by a positioning lever and a torsion spring The hinge axle 5 also carries the lever for the actuator of flap 17 In this way all movements related to the second fold table are synchronized Finally the folder output photocell VPH4 monitors the folded or unfolded as this is an operational option as well paper as it leaves the FPI 5000 C on its way to the FPI 5000 I 520 01 12 rev 01 0 01 2002 service manual FPI 5000 C Mechanical rev 01 0 01 2002 520 02 1 service manual FPI 5000 C 520 02 2 rev 01 0 01 2002 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 2 1 2 2 3 1 3 1 1 3 1 2 3 1 3 3 1 4 3 1 5 32 3 2 1 3 22 3 3 3 3 1 3 32 3 3 3 3 3 4 3 3 5 3 4 3 5 3 6 3 7 rev 01 0 01 2002 service manual Contents Section Covers and plates Vertical transport track Hoppers Folder RH side covers LH side covers Top cover assembly Collator arm cover Collating area cover Bottom plate Rear cover Front folder cover divert tray Folder cover Electrical components Mainboard Feeder module boards Feeder modules Main drive mechanism Main drive belt Clutch Pulleys Transportation rollers Gears RH feeder drive mechanism Drive b
54. 3 13 The separation roller is only available as a complete assembly So if the separation roller is worn the complete assembly must be replaced figure 3 13 rev 01 0 01 2002 520 02 33 service manual FPI 5000 C 3 9 5 Gears The gears at the LH side of the feeder can be removed without detaching the feeder from the machine However the wiring mounting plate must be disassembled refer to the section Feeders Lower feeder The gear 48 and the gear 64T can be removed as described in the section Automatic separation feeder with daily mail Gears The gears at the RH side of the feeder can only be disassembled after the feeder is removed from the machine Once the feeder is removed the gears at the RH side can easily be disassembled refer to figure 3 14 figure 3 14 520 02 34 rev 01 0 01 2002 service manual FPI 5000 C 4 Vertical transport Open the vertical transport track as described in paragraph 1 1 Vertical transport track 4 1 Cover plate Removal figure 4 1 Refer to figure 4 1 Remove the two hex head screws 5 on the LH side and slacken the two hex head screws 3 on the RH side Move the cover 1 to the RH side to remove the cover 1 Slacken the two hex head screws 4 on the LH and RH side Slide cover 2 slightly downward until it can be removed from it s position rev 01 0 01 2002 520 02 35 service manual FPI 5000 C 4 2 Guide rollers Right and left hand guide
55. 33 2 12 Drive and transportation axle 93 05 09 1 13 Pan head tapping screw 05 38 55 1 14 Intermediate plate vert transport 93 06 06 1 15 Sensor including holder 04 24 53 1 16 Conductive bearing 10 mm 04 24 26 1 17 Axle 93 09 30 1 18 Suspension axle 95 21 32 1 19 Guide strip 93 06 30 1 20 Round head screw M3 x 4 45 43 00 1 21 Washer 7 x 3 2 x 0 5 mm 45 37 39 1 22 Blocking bracket 93 05 29 1 23 Washer 12 x 4 3 x 1 5 mm 45 37 58 1 24 Blocking bracket 95 30 99 1 25 Mounting clamp 12 14 89 1 26 Lock washer 5 32 05 24 31 1 27 Self lubricating bearing10 mm 06 09 12 1 28 Washer 16 x 10 2 x 0 8 mm 04 01 43 5 29 Gear 24T 93 09 02 1 30 Clutch CW 8mm 93 09 03 1 31 Rubber stud M6 20 mm 04 12 12 1 32 Spacer 25x 5 5x 8mm 43 29 31 1 33 Hex head screw x 8 05 38 80 9 34 Belt tensioner 93 05 45 1 35 Spacer 12 x 0 84 x 5 mm 04 09 64 2 36 Clutch CCW 8 mm 93 05 36 1 37 Pulley 30 timing belt 93 05 30 1 38 Tensioner roller 93 05 15 1 39 Washer 12 x 6 2 x 0 8 mm 04 01 40 3 40 Disc 93 05 43 1 41 Clamping ring 8 mm 05 24 85 1 42 Washer 14 x 8 2 x 0 8 mm 04 01 41 5 43 Cyl pin 2 5 x 16 05 23 46 2 44 Spring clip 7 9 mm 05 24 42 4 45 Timing belt 04 16 25 1 rev 02 0 02 2002 520 04 23 Figure 520 04 22 Remarks 520 04 24 illustration code number 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 service manual Description Pulley 25T timing
56. 8 mm 04 24 25 1 2 Spacer 12x 8 3 x 3 mm 04 10 50 1 3 Washer 14 x 8 2 x 0 8 mm 04 01 41 8 4 Spring clip 7 9 mm 05 24 42 5 5 Gear 32T 96 42 19 2 6 Clutch CCW 8 mm 12 14 61 1 7 Cyl pin 2 5 x 12 05 23 47 3 8 Spacer 18x 12 8 x 3 mm 04 08 71 2 9 Clutch CW 8 mm 12 14 63 1 10 Disc 93 05 44 1 11 Pulley 15T timing belt 93 05 20 1 12 Slip clutch 95 71 27 1 13 Drive axle fold 93 05 10 1 rev 02 0 02 2002 520 04 31 service manual FPI 5000 C OC m t uin 13 12 1 10 9 8 7 6 21 20 19 18 2L 25 26 27 28 Figure 12 520 04 32 rev 02 0 02 2002 service manual FPI 5000 C Figure 520 04 32 Remarks illustration Description Part code Quantity Remarks code number number 5000 1 Bracket 95 14 36 2 2 Round head screw x 6 05 38 66 4 3 Frame extension 95 14 04 1 4 Mounting plate for 95 14 19 1 5 Frame 95 14 02 1 6 Countersunk head screw x 25 45 42 17 2 7 Hinge pin 95 14 12 2 8 Countersunk head screw 16 45 38 77 2 9 Bushing 95 14 41 2 10 Bushing 95 14 40 2 11 Hinge arm 95 14 13 2 12 Tension pin 2 2 5 x 18 05 33 23 2 13 Cover opener LH vert transport 95 14 24 1 14 Hinge axle 95 14 14 1 15 Cover opener RH vert transport 95 14 26 1 16 Hinge arm 95 14 20 1 17 Fixing plate 95 14 05 1 18 Bracket for photocell 95 14 57 1 19 Led including holder 04 24 52 2 20 Round head screw M3 x 4 45 43 00 7
57. 94 1 21 Locking lever 04 25 92 1 22 Wire spring 95 10 18 1 23 Washer 7x 3 2 x 0 5 mm 45 37 39 1 rev 02 0 02 2002 520 04 59 service manual FPI 5000 C 520 04 60 rev 02 0 02 2002 service manual FPI 5000 C rev 02 0 02 2002 520 04 61 service manual FPI 5000 C 520 04 62 rev 02 0 02 2002
58. 98 9298 1 3095 11828 STL z S E E 0294 6298 1 1 ET 1 NT 1 XN t t d 10951 1199 1 F 11988 t190 Y 71981 Y 21981 8 2 2298 6 z 9a ALTO 210921 105 BL an lt Q und 1 190 1 11908 TTL E 14908 29 0 m 5294 1 124 11 14 HOLOW 1109 HOLOW 102 aape s do uan 1 21601 51 auo uaym au pue 2150 sjndui yo IND UO TANG Wd WING IN3uHn2 gt ano ano NOT I 7092 9SS3N 3095 20921 2199 ano ano anot I wel Bri 095 xot ST PE em Fu vTIY Kepp MH auas na 7 23 Ben NOOT 2090 V 29 4 IEN 13b 20 aypay 8098 1098 3 5 OLAVE 5090 Lat 13v 6094 9094 1 3096 11828 50961 z 22 asuas mua E 43915178 4 p s Nt 9 1 X v 7 7 d 91091 1095 t t ZEDH L 11988 POL z z 2098 09 V1095I T PI 1094 TAG Id HONDA AOP 4NOZT 9092 Ave
59. C 3 2 Unpacking instruction 520 00 10 rev 01 0 01 2002 service manual FPI 5000 C 4 Preventive maintenance Recommended preventive maintenance checkpoints In the following it is assumed that if any unscheduled service call is less than a month prior to a preventive maintenance call it will replace that latter 1 Ask how the machine has worked and use that information as a guide for checking the equipment 2 Ask if there has been change in use of the machine such as high production or change of material 3 Check the machine adjustments and check materials and if necessary instruct the operator s again Many service calls are caused by wrong adjustments or wrong material and sometimes there is a quick succession of operators Here a five or ten minutes refresher course would save unnecessary and embarrassing service calls in the future 4 Testthe proper functioning of the safety switches of the vertical transport track and the folder 5 Check condition of the separation rollers adjust or replace if necessary 6 Check the tension and condition of the belts adjust or replace if necessary 7 Check the condition of the rubber rollers clean or replace if worn 8 Check the condition of the pulleys and gears replace if necessary 9 Remove paper dust from photocells LEDs and receivers 10 Test the system hardware and software using the service software If available make a test run with users material if not use own mate
60. PI 5000 C 18 17 16 15 14 13 1211 109 8 7 65 4 3 figure 7 5 Refer to figure 7 5 Remove the bearing 18 with the spacer 17 and two washers 16 from the left hand side of the axle Cut the wire straps securing the wiring to the studs the clutches 3 and 12 Disconnect both clutches and withdraw the axle assembly completely Remove the spring clip 15 with the washer 14 Slide the left hand gear 13 off the axle Slide the left hand clutch 12 off the axle Take care of the cyl pin 11 Remove spacer 10 the washer 9 and the spring clip 8 from the left hand side of the axle Remove the spring clip 7 the washer 6 and the spacer 5 from the right hand side axle Take care of the cyl pin 4 Slide the right hand side clutch 3 off the axle Remove the right hand gear 2 Take care of the washer 1 Replacement Ensure on replacement to secure the wiring of the clutches again to the studs with a wire strap and that the locking plate 8 figure 7 7 retains both clutches rev 01 0 01 2002 520 02 57 service manual FPI 5000 C figure 7 6 520 02 58 rev 01 0 01 2002 service manual FPI 5000 C 7 3 2 Clutches Clutch item 4 and item 13 The removal of the right and left hand clutch has been described in the previous paragraph 7 3 1 Gears 7 3 3 Curved folder gears Remove the axle assembly as described in paragraph 7 3 1 Gears Second curv
61. SERVICE MANUAL ILLUSTRATED PARTS LIST FPi 5000 Inserting System FPI 5000 I FPI 5000 C FRANCOTYP POSTALIA service manual FPI 5000 C FPI 5000 Collator rev 01 0 01 2002 service manual Contents Section General Process description Mechanical description Electrical description Parts list Fault finding FPI 5000 C Page 520 00 1 520 01 1 520 02 1 520 03 1 520 04 1 520 05 1 rev 01 0 01 2002 service manual FPI 5000 C General rev 01 0 01 2002 520 00 1 service manual FPI 5000 C 520 00 2 rev 01 0 01 2002 rev 01 0 01 2002 2 1 22 2 3 3 1 3 2 service manual Contents Section Function Specifications Machine specifications Paper insert specifications Envelope insert specifications Preparing the machine for use Unpacking Unpacking instruction Preventive maintenance FPI 5000 C Page 11 520 00 3 service manual FPI 5000 C 520 00 4 rev 01 0 01 2002 service manual FPI 5000 C Used symbols In this manual the following symbols are used Warning this symbol indicates wrong action which can cause hazard to health or damage the machine Warning this symbol indicates a hazard to life because of high voltage rev 01 0 01 2002 520 00 5 service manual FPI 5000 C 1 Function The FPI 5000 C is a document processing device that transports collates and aligns documents from one or two feed stations e
62. Sr Fa 2528 1 FA 1727 DER cd f T poor tv za t 133 Isnlav 24G v ev VOzc2l mane 26 Indino savas v 110 aan F N 805251 ano DL x soN sw Pg en ioe n 109 fa b 50 9 2 SNG 1528 N 0 19 sag Le 4 4 99 208 FE zv 3i uam mee xot S33 1 5 z v ano E duni 102 88 2 33 THOLM2 so 9 VOSZ2I 1vvvaval 8 ES XVWA 1904 z N va DT iudi A 59914 cA gt a ee WS 006 gt vas sova lt b WIS 125 125 tova PX 022 L eva 2 ano Do Tr 3027 Tree san HOKEJ t WE 155 DC 2 A wa or 017471 NOT 6 3022 6074 Ke VTIHYL 00221 551 36104 et ano v NOT NOOT 901201 2 9074 NOT 328 022 NOT mm 1028 Sor 03H Gm JA lt NEST 3 5 N Z 1 ER GEI Sved z LI 9N02 13539 9 22 4 0 4 5 v 1 ayov H z 3028 Be vozy 5 ozHaLvwn RA oven svar avaa st D j NOT 02 St Sr 07 8I D 11 BT Z ER IER 91 ST ST 9T 2024 9 vI vi YIMOT 1324 Ld TT l INV3HlS
63. W 8 mm 93 05 36 2 10 Spring clip 7 9 mm 05 24 42 4 11 Washer 14 x 8 2 x 0 8 mm 04 01 41 4 12 tensioner 95 11 54 2 13 Tensioner roller 95 11 59 2 14 Washer 12 x 6 2 x 0 8 mm 04 01 40 2 15 Spring clip 6 8 mm 05 24 46 4 16 Pulley 44T 95 11 51 2 17 Col pin 2 x 16 05 23 69 2 18 Tension spring 45 54 04 2 19 Gear 64T assy 95 11 38 2 20 Washer 14 x 6 5 x 0 8 mm 43 02 47 2 2 Round head screw x 6 05 38 66 2 22 Mounting plate 95 13 21 1 23 Clip 12 12 93 1 24 Mainboard feed unit 93 08 02 1 25 Eprom 97 50 13 1 02 0 02 2002 520 04 41 service manual FPI 5000 C 25 24 23 22 30 29 28 27 73 74 75 76 77 78 35 34 33 32 31 53 54 55 56 57 N S ND Figure 17 520 04 42 02 0 02 2002 service manual FPI 5000 C Figure 520 04 42 Remarks illustration Description Part code Quantity Remarks code number number 5000 1 Led including holder 04 24 52 1 2 Bracket for photocell 95 11 47 1 3 Cover plate 95 11 25 1 4 Set screw M4 x 6 08 28 02 2 5 Transportation roller 30 mm 95 11 86 2 6 Transportation axle 95 11 37 1 7 Pulley 20 T 95 11 42 1 8 Clamping bush 95 11 41 1 9 Transportation axle separation 95 11 39 1 10 Transportation 95 11 34 1 11 Self lubricating bearing 06 09 31 1 12 Rubber paper puller 04 00 16 2 13 Pressure spring 03 11 14 1 14 Cyl pin 2 5 x 12 05 23 47 1 15 Pulley 28T timin
64. ach equipped with two feeding devices and feeds the documents with or without folding to the inserter FPI 5000 C General note This documents describes the feed and folding device FPI 5000 C No specific part number is given to the FPI 5000 C as this device can be configured in several ways 520 00 6 rev 01 0 01 2002 2 Specifications 2 1 Machine specifications Model Type Overall Dimensions height width length Weight Noise level Theoretical max speed Operating temperature Humidity Power consumption Approvals rev 01 0 01 2002 service manual FPI 5000 C 5000 document processing device for medium office use 6 station module 920 mm 36 2 inch 4 station module 735 mm 29 3 inch 2 station module 735 mm 22 4 inch 460mm 16 5 inch 750 mm 29 5 inch 2 station module approx 54 kg 119 Ibs 4 station module approx 63 kg 138 8 Ibs 6 station module approx 74 0 kg 163 Ibs refer to FPI 5000 I Inserter noise level refer to FPI 5000 I Inserter theoretical max speed 10 40 C 50 104 F 10 8096 low voltage supplied by the inserter conforms to IEC 950 and derivatives UL listed ITE File E153801 BS EN60950 File KM11322 520 00 7 service manual FPI 5000 C 2 2 Paper insert specifications Paper sizes minimum maximum width 130 mm 5 1 inch 236 mm 9 5 inch length 90 mm 3 5 inch 356 mm 14 0 inch Booklets depending on envelope size
65. aragraph 3 4 Cover plates Refer to figure 8 4 Slacken the pan head tapping screw 6 securing the receiver 4 to the frame plate 5 Disconnect and withdraw the receiver accessible via the front side after moving the lowest feeder upwards 8 22 Microswitch for cover vertical transport rev 01 0 01 2002 520 02 71 service manual FPI 5000 C Remove the bottom plate as described in paragraph 1 9 Bottom plate Removal figure 8 5 Refer to figure 8 5 Remove the two round head screws 3 with the washers securing the microswitch 2 fitted on the inside of the machine to the LH inside frame Remove the insulating plate 1 from the microswitch Disconnect and withdraw the microswitch 8 3 Collating area 8 3 1 Pulse disc detector assy Remove the RH side cover as described in paragraph 1 4 RH side cover Removal figure 8 6 Refer to figure 8 6 Remove the two round head screws 3 with the washers securing the pulse disc detector assy 1 Disconnect and withdraw the pulse disc detector assy Replacement Ensure on replacement that the pulse disc detector assy clears both sides of the pulse disc and that the detector sees the outer ends of the slots in the pulse disc 2 8 3 2 Document detector 520 02 72 rev 01 0 01 2002 service manual FPI 5000 C Remove the cover plate as described in paragraph 4 1 Cover plate Removal figure 8 7 Transmitter LED Refer to figure 8 7 R
66. ation roller 36 mm 76 04 66 2 28 Set screw x 4 08 28 01 2 rev 02 0 02 2002 520 04 13 service manual FPI 5000 C 9 8 7 6 5 1 11 10 18 17 16 15 14 13 22 23 24 25 26 27 21 20 19 Figure 5 520 04 14 rev 02 0 02 2002 service manual FPI 5000 C Figure 520 04 14 Remarks illustration Description Part code Quantity Remarks code number number 5000 1 Nut M4 45 19 02 2 2 Lock LH 93 06 32 1 3 Spacer 8 4 3 x 3 mm 04 11 32 2 4 Washer 6 x 3 2 x 0 5 mm 45 37 30 2 5 Carrying handle 98 01 31 1 6 Bearing bushing 93 06 16 1 7 Spring clip 4 5 mm 05 24 47 2 8 Washer 12 x 5 2 x 0 7 mm 43 05 35 2 9 Locking strip LH 43 19 31 1 10 Bearing plate 93 06 15 1 11 Pressure spring 0 7 mm 03 11 11 2 12 Round head screw 8 05 38 68 16 13 Spring clip 10 14 mm 05 24 83 3 14 Cyl pin 2 5 x 32 05 23 48 2 15 Gear35T 24 69 58 2 16 Bushing 15 x 10x 5 5 mm 75 37 51 2 17 Setscrew x 4 08 28 01 4 18 Cover actuator 93 06 14 1 19 Guide bracket 93 06 34 1 20 Tension spring 03 11 54 1 2 Countersunk head screw x 10 05 38 75 2 22 Led including holder 04 24 52 1 23 Countersunk head tapping screw 05 38 59 2 24 Sensor including holder 04 24 53 1 25 Bracket for photocell 95 30 74 2 26 Drive axle assy 93 05 05 1 27 Drive axle assy 93 05 07 1 28 Washer 16 x 10 2 x 0 8 mm 04 01 43 1 29 Conductive bearing 10 mm 04 24 26 1 30 Hi
67. ations Figure 1 1 Total view for an SA 5005 system of the 5000 C base unit board 97 50 10 plus one two or three feeder module boards 93 08 02 6 Figure 1 2 Total view for an SA 5005 system of the feeder module board 93 08 02 7 Figure 1 3 FPI 5000 C base unit board 97 50 10 1 CPU circuitry 8 Figure 1 4 FPI 5000 C base unit board 97 50 10 2 outputs 9 Figure 1 5 5000 base unit board 97 50 10 3 inputs 10 Figure 1 6 FPI 5000 C base unit board 97 50 10 4 communication 11 Figure 1 7 FPI 5000 base unit board 97 50 10 5 power supply 12 Figure 1 8 FPI 5000 C base unit board 97 50 10 6 DC motor control 13 Figure 1 9 Component layout of the 5000 C base unit board 97 50 10 14 Figure 1 10 Feeder module board 93 08 02 1 CPU circuitry 15 Figure 1 11 Feeder module board 93 08 02 2 inputs and outputs 16 Figure 1 12 Feeder module board 93 08 02 3 power supply 17 Figure 1 13 Component layout of the feeder module board 93 08 02 18 520 03 4 rev 01 0 01 2002 service manual FPI 5000 C 1 Electrical and electronic operation The feeding and folding part of the SA 5005 system consists of the FPI 5000 C base unit plus three feeder modules plus optional components such as the OMR board 93 08 03 see Appendix 1 and the MaxiFeeder 1 see Appendix 2 Each feeder module consists of two feeders This is reflected in the total view of figure 1 1 and figure 1 2 The FPI 5000
68. ble unhook the left hand side and withdraw it 520 02 26 rev 01 0 01 2002 service manual FPI 5000 C Replacement Ensure on replacement that two holes in the left hand side of the cover plate are replaced over the two threads of the round head screws 2 fitted into the left hand frame figure 3 6 3 5 Feeder modules Note The removal procedure of both feeder modules first and second is similar The first feeder module can be removed after the removal of the second feeder module Remove the LH feeder module cover as described in paragraph LH feeder module cover Remove the top cover as described in the paragraph 1 6 cover Remove the lower feeder drive belt as described in paragraph 3 2 1 Drive belts Removal Refer to figure 3 5 Disconnect the flat cable from the feeder module at the board 2 Refer to figure 3 6 Remove the four hex head screws 1 securing the feeder module on both sides Shift the feeder module in the front side direction to unhook it and then withdraw it rev 01 0 01 2002 520 02 27 service manual FPI 5000 C 3 6 Feeders Note The removal procedure of the upper and lower feeder from a feeder module is similar The lower feeder can be removed after removal of the upper feeder Remove the second or first feeder module as described in paragraph 3 5 Feeder modules Remove the transportation rollers as described in paragraph 3 3 5 Transportation roller
69. ble unhook the front side from the slits in the LH side frame and then withdraw it 1 6 Top cover assembly Removal Open the vertical transport track as described in paragraph 1 1 Vertical transport track Remove the RH covers as described in paragraph 1 4 RH side covers Remove the LH covers as described in paragraph 1 5 LH side covers Refer to figure 1 1 Remove the two hex head screws 6 securing the rod 7 on both sides Push the vertical transport track downwards and when possible tilt it in the rear side direction and place it onto the front folder cover divert tray 8 Remove the four hex head screws 11 securing the top cover 10 on both sides to the feeder module frame Shift the top cover in the front side direction to unhook it and then withdraw it Replacement Close the vertical transport track before retightening the two hex head screws securing the rod 1 7 Collator arm cover Removal Refer to figure 1 1 Lift the front side of the collating arm cover 19 upwards and hold it in this position Slacken the two nuts 24 securing the collating arm cover to the collating arm frame 20 Lower the collating arm cover and shift it in the front side direction to unhook the rear side from the slit Lift the rear side of the collating arm cover upwards and unhook the front side from the slotted holes in the collating arm frame 520 02 10 rev 01 0 01 2002 service manual FPI 5000 C 1 8 Collating area cover Remo
70. c separation feeder The removal procedure of the components of the automatic separation feeder is similar to that of the automatic separation feeder with daily mail as described in the previous section 3 9 Manual adjustable separation feeder 3 9 1 Rubber paper pullers For the removal of the paper pullers it is not necessary to remove the feed axle assy and the plastic cover with the paper puller axle Remove the pullers in the same way as described in the previous section 3 9 2 Pulley of paper puller axle To replace the pulley it is necessary to remove the feeder from the machine Refer to the section Feeders Lower feeder Remove the complete feed roller assy with the plastic cover and the paper puller rollers by removing the screws 2 as shown in figure 3 12 and move the complete assembly to the left hand side to release the feed axle 1 from the mounting blocks 3 Further the removal procedure is similar to that as described in the section Automatic separation feeder with daily mail 520 02 32 rev 01 0 01 2002 service manual FPI 5000 C figure 3 12 3 9 3 Upper separation roller assy Remove the complete feed roller assy as described in the previous paragraph The feed roller is attached to the axle and is only available as a complete assembly So if the feed roller is worn the complete assembly must be replaced 3 9 4 Lower separation roller assy The removal of the separation roller assy 1 is shown in figure
71. ch cheated or a hazard to health will exist Throughout this manual the terms left and right hand side and front and rear side of the machine are used These are made with the machine viewed from the input document feed side of the machine In a machine two feeder modules are mounted A feeder module consists of two feeders the feeder at the bottom side is called the lower feeder and the feeder on the topside is called the upper feeder The first feeder module is mounted onto the frame of the machine the second feeder module is mounted on top of the first feeder module The replacement procedures are the reversal of the removal procedures rev 01 0 01 2002 520 02 7 service manual FPI 5000 C 1 Covers and plates 1 1 Vertical transport track Opening Refer to figure 1 1 Lift the hand grip 9 upwards to release the transport track and then pull it upwards to open 1 2 Hoppers Note The removal procedure for all hoppers is similar Removal Refer to figure 1 1 Grab the front side of the hopper 12 Push the grey locking handle 16 downwards to release the hopper Move the hopper upwards and when possible withdraw it in the front side direction 1 3 Folder Opening Refer to figure 1 1 Push the lower end of the locking lever 27 in the right hand side direction to release the folder and then it will open automatically 1 4 RH side covers Lower side cover Removal Open the vertical transport track as described in pa
72. cycle of the brake disk consists of a 120 degrees part flap upwards and 240 degrees path flap downwards plus karate action of 20 The brake disc is mechanically rev 01 0 01 2002 520 01 11 service manual FPI 5000 C loaded by a positioning lever and a torsion spring The hinge axle 6 also carries the lever for the actuator of flap 21 In this way all movements related to the first fold table are synchronized After leaving the fold rollers 18 and 19 the paper enters the second fold table The flap 17 moves up clockwise so paper entering the second fold table will be directed in upward direction The paper guide 15 also moves up This guide is necessary in the second fold table to retain the fold that has been made in the first fold table The paper is limited to a small area between paper guide 15 and a fixed vertical guide plate not shown in the figure but to the left of 15 At the appropriate time the flap 17 moves back counter clockwise and both the fold plate 16 and the guide plate 15 which both hinge around axle 5 move forward clockwise the second fold will be made Directly after the fold has been made the fold plate 16 returns to it s rest position This process is controlled by clutch 3 which drives the two curve gears 7 which on their turn control the movement of fold plate 16 and paper guide 15 The axle for the two curve gears also carries the brake disc 8 the status of which is monitored by slotted photocell 9 VSPH
73. d table clutch VCL4 LH Drives 7 4 First fold table clutch VCL3 RH Drives 10 5 Control axle for second fold table Hinge for 15 and 16 Moves the lever that in its turn moves the flap actuator of 17 upwards 6 Control axle for first fold table Hinge for 20 Moves the lever that in its turn moves the flap actuator of 21 upwards CW 7 Curve gears for fold table 2 1x LH 1x RH Controls movement of 15 and 16 8 Brake disc for fold table 2 LH Spring loading ensures two static mechanical states 9 Slotted photocell VSPH3 for second fold table 10 Curve gears for fold table 1 1x LH 1x RH Controls movement of 20 11 Brake disc for fold table 1 LH Spring loading ensures two static mechanical states 12 Slotted photocell VSPH2 for first fold table 13 Upper fold roller for second fold table 14 Lower fold roller for second fold table 15 Moving paper guide for second fold table 16 Fold plate for second fold table 17 Flap for second fold table 18 Upper fold roller for first fold table 19 Lower fold roller for first fold table 20 Fold plate for first fold table 21 Flap for first fold table 22 Upper fold input roller 23a Lower fold input roller 23b Fold clutch VCL2 Drives at the LH side 23a 19 14 and clutch 28b Drives via 23a at the RH side 22 18 13 and clutches 3 4 and 28c 24 Divert flap Driven by motor VM2 and controlled by slotted photocell VSPHS 25 Divert actuator Driven by motor VM2 and controll
74. d upper feeder drive belt is for the both feeder modules first and second similar Lower feeder drive belt Removal ni 2 14 figure 3 4 Refer to figure 3 4 Slacken the hex head screw 13 securing the belt tensioner 14 of the lower feeder Pull the pulley 7 of the lower feeder with the drive belt 8 from the axle Take care of cyl pin 9 below Adjustment See paragraph 9 3 1 drive belts 520 02 22 rev 01 0 01 2002 service manual FPI 5000 C Upper feeder drive belt Remove lower feeder drive belt from the first and second feeder module as described previously Removal Refer to figure 3 4 Pull the pulley 6 off the axle Take care of the cyl pin 5 below Slacken the hex head screw 2 securing the belt tensioner 1 of the upper feeder Pull the pulley 4 of the upper feeder and the pulley 10 of the lower feeder together with the drive belt 11 from the axles Take care of cyl pins 3 and 12 below Adjustment See paragraph RH drive belts 3 2 2 Pulleys Pulley 24T item 7 Remove the lower feeder drive belt as described in the previous paragraph Pulley 24 item 6 24T item 4 and 24 item 10 Remove the upper feeder drive belt as described in the previous paragraph rev 01 0 01 2002 520 02 23 service manual FPI 5000 C 3 3 LH feeder drive mechanism Note The removal procedure of the LH feeder drive mechanism is for the both feeders upper and lowe
75. djust Remove the LH side cover as described in paragraph 1 5 side cover Slacken the two hex head screws 3 securing the belt tensioner 2 Shift the belt tensioner to adjust the correct belt movement Hold the belt tensioner and retighten the two hex head screws Check the adjustment and readjust if necessary Note Do not adjust the drive belt too tight 520 02 84 rev 01 0 01 2002 service manual FPI 5000 C 9 3 3 Paper guide figure 9 7 Refer to figure 9 7 There must be a small gap between the fixed guide plate 3 and the fold roller The fold roller should just run free To adjust Remove the rear folder cover as described in paragraph 1 10 Rear folder cover Remove the top folder cover as described in paragraph 1 12 folder cover Slacken the two round head screws 1 to move the guide plate further away from the fold roller and tighten it to move it closer rev 01 0 01 2002 520 02 85 service manual FPI 5000 C 520 02 86 rev 01 0 01 2002 service manual FPI 5000 C Electrical rev 01 0 01 2002 520 03 1 service manual FPI 5000 C 520 03 2 rev 01 0 01 2002 rev 01 0 01 2002 service manual Contents Section Electrical and electronic operation Settings Service software Test points Error diagnosis and error codes 5000 Page 19 20 21 23 520 03 3 service manual FPI 5000 C Index of illustr
76. e 520 04 14 15 Gear 35 24 69 58 1 2 4 22 Led including holder 04 24 52 1 4 29 Conductive bearing 10 mm 04 24 26 4 10 20 Figure 520 04 16 5 Clutch CW 8 mm 93 09 03 1 2 4 12 Timing belt 95 13 16 1 1 2 14 Timing belt 04 16 25 1 1 2 20 Pulse disc 24 12 81 1 1 2 23 CW 8 mm 12 16 66 1 1 2 27 Disc for pulley 93 05 42 1 2 4 28 Timing belt 04 16 31 1 1 2 32 20 timing belt 24 13 75 1 2 4 37 Timing belt 04 15 62 1 1 2 47 Pulse disc sensor assy 82 16 22 1 2 4 49 Motor 24V assy low noise 04 26 38 1 1 2 59 Fold roller assy 93 05 34 1 1 4 62 Fold roller assy 93 05 56 1 1 4 Figure 520 04 20 2 Conductive bearing 8 mm 04 24 25 2 4 10 rev 02 0 02 2002 520 04 3 Illustration Code nr Figure 520 04 22 29 36 63 Figure 520 04 26 30 36 Figure 520 04 28 1 10 Figure 520 04 30 6 9 12 Figure 520 04 32 22 25 Figure 520 04 34 14 18 Figure 520 04 38 2 Figure 520 04 40 7 9 24 25 Figure 520 04 42 3 12 15 16 17 57 59 62 520 04 4 service manual Description Gear 24T Clutch CCW 8 mm Flap actuator Torsion spring Lever for flap actuator Curve disc LH Curve disc RH Clutch CCW 8 mm Clutch CW 8 mm Slip clutch Pressure roller 30 Conductive bearing 6 mm Pressure roller 20 Pressure roller 20 Tension spring Timing belt Clutch CCW 8 mm Mainboard feed unit Eprom Cover plate Rubber paper puller Pulley 28T timing belt Timing b
77. e set screw of the pulley 30 in the middle of the collator axle 29 Remove the spring clip 23 from the right hand side of the collator axle Slide the collator arm frame in the right hand side direction until the left hand side clears the LH inside frame Take care of the washer 27 and the bearing 26 on the left hand side of the collator axle Tilt the front side of the collator arm frame in the right hand side direction and when possible withdraw it from the RH inside frame and from the machine Take care of the bearing 25 and the washer 24 on the right hand side of the collator axle Slide the belts 28 and 22 from the pulleys and withdraw them Slacken the set screw of the pulley 40 in the middle of the front axle 39 Slacken the set screw of the pulleys 35 and 44 on the right hand side and slide them off the axles Remove the spring clip 43 with the washer 42 securing the front axle on the right hand side Withdraw the front axle in the left hand side direction from the collating arm frame and slide the middle pulley with the belt 31 off the axle Take care of the bearings 41 and 38 and of the washer 36 on the left hand side Remove the spring clip 32 securing the collator axle on the right hand inside of the collating arm frame Push the bearing 34 inwards out from the slotted hole in the collator arm frame Remove the collator axle from the collator arm frame Take care of the bearing and the washer 33 Slide the pulley in the middle with the be
78. e tension spring 6 from the bearing pin 8 Remove the drive belt from the pulley 13 Remove the spring clip 5 with the washer 4 securing the belt tensioner 3 Pull the belt tensioner together with the pulley 10 from the axle and remove the drive belt 12 Take care of the cyl pin 11 and the tension spring 3 34 Gears Gear 48T item 15 Remove the pulley 44T item 10 as described in the previous paragraph Removal Refer to figure 3 5 Remove the cyl pin 11 Pull the gear 15 from the axle Take care of the cyl pin 17 rev 01 0 01 2002 520 02 25 service manual FPI 5000 C Gear 64T item 24 Removal Refer to figure 3 5 Disconnect the two flat cables connected to the board 2 Remove the two round head screws 22 securing the mounting bracket 1 Carefully place the mounting bracket with the board aside Remove the spring clip 26 with the washer 25 securing the gear 24 Slide the gear off the axle Take care of the washer 23 Replacement The gear has a freewheel incorporated It must be fitted so that seen from the left hand side it runs free when turned counterclockwise and it takes the axle along when turned clockwise 3 3 5 Transportation rollers Note The removal procedure of the transportation rollers is for the two feeders in both feeder modules similar The only difference is that on the transportation axle of the lower feeder in the first feeder module there are four transportation rollers instead of two Rem
79. e with two rubber paper pullers lower feeder of lower feeder module 90 Lower separation roller for upper feeder of lower feeder module Turns CW in feeder with manual separation 91 Feed axle with upper separation roller upper feeder of lower feeder module 92 Paper puller axle with two rubber paper pullers upper feeder of lower feeder module 93 Lower separation roller for lower feeder of upper feeder module Turns CW in feeder with manual separation 94 Feed axle with upper separation roller lower feeder of upper feeder module 95 Paper puller axle with two rubber paper pullers lower feeder of upper feeder module 96 Lower separation roller for upper feeder of upper feeder module Turns CW in feeder with manual separation 97 Feed axle with upper separation roller upper feeder of upper feeder module 98 Paper puller axle with two rubber paper pullers upper feeder of upper feeder module table 2 1 rev 01 0 01 2002 520 01 9 service manual FPI 5000 C 2 1 Feeding documents the Vario Feed concept There are three types of feeders 1 feeders with automatic separation 2 feeders with a choice between automatic separation and no separation at all i e daily mail 3 feeders with manual separation The feeders are organised in feeder modules of two feeders each For the documents to be fed the following rules apply e Documents with the fold types single fold letter fold and double parallel fold must be fed to the feeder with the
80. ected into an upward more or less vertical direction At the right time the fold plate moves forward clockwise and pushes the paper between the pair of upper and lower fold rollers The fold is located at the place where the paper touches the tangent between the upper and lower fold roller The timing of the fold plate movement is based on the detection of the paper by the folder input photocell VPH3 machine parameters and operational fold parameters The latter parameters are set by the operator via the user interface of the FPI 5000 I Now for the folding details Assume that the divert flap 24 is in the horizontal position The paper of a completed set leaves the collator area This is detected by photocell VPH3 29 30 The paper is transported to the first fold table by the fold input rollers 22 and 23a The flap 21 moves up clockwise so paper entering the first fold table will be directed in upward direction At the appropriate time the flap 21 moves back counter clockwise and the fold plate 20 which hinges around axle 6 moves forward clockwise the first fold will be made Directly after the fold has been made the fold plate 20 returns to its rest position This process is controlled by clutch 4 which drives the two curve gears 10 which on their turn control the movement of fold plate 20 The axle for the two curve gears also carries the brake disc 11 the status of which is monitored by slotted photocell 12 VSPH2 The 360 degrees fold
81. ed by slotted photocell 5 5 26 Divert area 27 Counter rollers for 28a in vertical transport cover 28a Shunt rollers 28b Forward shunt clutch VCL5 LH Drives 28a in downstream direction 28 Reverse shunt clutch VCL6 RH Drives 28a upstream direction rev 01 0 01 2002 520 01 7 service manual FPI 5000 C 29 Folder input photocell VPH3 Tx led in vertical track cover 30 Folder input photocell VPH3 Rx sensor 31 FPI 5000 I input gear LH Drives 32a 32a FPI 5000 C main input axle Provides drive for clutches 23a and 32b 32b Vertical track clutch VCL1 RH Drives at the RH side 34 36 39a 41a 43a and 45a and at the LH side clutches 39b 41b 43b and 45b 32 Slotted photocell VSPH1 RH Main time base for all processes 5000 plus attached feeders 33 Counter rollers for 34 in vertical transport cover 34 Vertical track rollers in FPI 5000 C main body 35 Counter rollers for 36 in vertical transport cover 36 Vertical track rollers 37 Reading head optional expansion 38 Counter rollers for 39a in vertical transport cover 39a Vertical track rollers in lower feeder of lower feeder module 39b Feeder clutch for lower feeder of lower feeder module FCL 1 Drives 67 88 87 only in feeder with manual separation and 89 40 Counter rollers for 41a in
82. ed folder gears Removal Refer to figure 7 4 Remove the round head screw 38 with the washer 37 and the conductive strip 36 Push the spring holder 22 inwards and remove the cyl pin 23 Carefully remove the spring holder with the spring 20 and the spring holder 19 Push the spring holder 25 inwards and remove the cyl pin 24 Carefully remove the spring holder with the spring 26 and the spring holder 27 Remove the fixing bracket 28 Remove the bearing 14 from the axle 9 Remove the spring clip 18 with the washer 17 the bearing 16 and the washer 15 from the axle 8 Remove the two round head screws 3 securing the fold assembly Refer to figure 7 6 Pull the lever 1 from the axle Remove the two round head screws 15 securing the mounting bracket 16 and place it aside Pull the spring lever 21 spring loaded upwards and hold it in this position Pull the brake curve 5 from the axle Remove the cyl pin 6 the two washers 7 and the bearing 8 Carefully lower the spring lever spring loaded Remove the spring clip 3 and push the bearing 4 in the left hand side direction from the slotted hole in the frame plate 23 Remove the two round head screws 19 securing fold assembly rev 01 0 01 2002 520 02 59 service manual FPI 5000 C 16 17 18 19 figure 7 7 520 02 60 rev 01 0 01 2002 service manual FPI 5000 C Refer to figure 7 7 Carefully lift the complete fold assembly upwards and withdraw it Remove the two counte
83. elt Double document detector Separator roller lower Brush Separation roller upper Part code Number 93 09 02 93 05 36 95 30 84 95 30 70 95 30 31 95 30 63 95 30 64 12 14 61 12 14 63 95 71 27 95 11 86 04 24 24 95 14 08 95 14 44 95 11 50 04 15 74 93 05 36 93 08 02 97 50 13 95 11 25 04 00 16 95 11 35 95 11 45 89 08 36 95 11 23 95 11 48 95 11 07 FPI 5000 C Stock qty per number of installed machines 1 1 1 1 e N Fi 10 1 1 1 N e N e Nr gt 100 2 2 2 NNNNA NNN RW NA rev 02 0 02 2002 Illustration Code nr Figure 520 04 46 6 36 Figure 520 04 50 18 Figure 520 04 54 6 19 service manual Description Transportation roller assy Separation axle assy special Collating belt set 3 pcs Motor 24V Gear 26 35T Part code Number 95 12 29 04 23 12 95 20 07 93 09 42 93 09 40 Note Parts marked with an asteriks depending on configuration rev 02 0 02 2002 5000 Stock qty per number of installed machines 1 10 100 1 2 4 1 2 4 1 2 4 1 1 2 1 1 2 520 04 5 service manual FPI 5000 C N N d 4 5 6 7 8 24 23 22 21 20 5 GE N N CAS NN 3887 N ANN NV N NAN 18 v je 21 26 25 2 27 FI
84. elts Pulleys LH feeder drive mechanism Clutch Drive belt Pulleys Gears Transportation rollers Feeder cover plates Feeder modules Feeders Automatic separation feeder with daily mail FPI 5000 C Page 10 10 11 11 11 13 13 14 14 15 16 16 16 16 18 20 20 22 22 23 24 24 25 25 25 26 26 27 28 29 520 02 3 3 7 1 3 7 2 3 7 3 3 7 4 3 7 5 3 8 3 9 3 9 1 3 9 2 3 9 3 3 9 4 3 9 5 4 1 4 2 5 1 5 1 1 5 1 2 5 1 3 5 2 5 2 1 5 2 2 6 1 6 1 1 6 1 2 6 1 3 6 2 6 2 1 6 2 2 6 2 3 7 1 7 1 1 7 12 7 1 3 7 1 4 7 2 7 2 1 7 2 2 520 02 4 service manual Rubber paper pullers Pulley of paper puller axle Upper separation roller Lower separation roller Gears Automatic separation feeder Manual adjustable separation feeder Rubber paper pullers Pulley of paper puller axle Upper separation roller assy Lower separation roller assy Gears Vertical transport Cover plate Guide rollers Collating area Drive mechanism Drive belts Pulleys Motor Collating arm Transportation belts Guide rollers Shunt Divert area Shunt Clutches Gears Transportation rollers Divert Divert unit Motor Gear Folder RH drive mechanism Drive belt Pulleys Clutches Gears LH drive mechanism Drive belt Pulleys FPI 5000 C 29 30 30 31 32 32 32 32 32 33 33 34 35 35 36 37 37 37 38 38 39 39
85. emove the pan head tapping screw 3 securing the transmitter 1 to the bracket 2 Disconnect and withdraw the transmitter Receiver Sensor Remove the collating arm cover as described in paragraph 1 7 Collating arm cover Refer to figure 8 7 Lift the collating arm upwards and hold it in this position Remove the pan head tapping screw 5 securing the receiver 4 to the collating arm frame 6 Disconnect and withdraw the receiver Replacement Ensure on replacement that the transmitter and the receiver are properly aligned by using the protruding thread of the round head screw on the bracket and the bulge on the collating arm frame as reference 8 4 Divert unit rev 01 0 01 2002 520 02 73 service manual FPI 5000 C 8 4 1 Pulse disc detector assy Remove the divert unit as described in paragraph 6 2 1 Divert unit Removal figure 8 8 Refer to figure 8 8 Remove the two round head screws 1 with the washers and withdraw the pulse disc detector assy 2 8 5 Folder 520 02 74 rev 01 0 01 2002 service manual FPI 5000 C 8 5 1 Document detectors FO in detector Removal figure 8 9 Transmitter LED Remove the cover plate as described in paragraph 4 1 Cover plate Refer to figure 8 9 Remove the pan head tapping screw 2 securing the transmitter 1 to the bracket 3 Disconnect and withdraw the transmitter Receiver Sensor Remove the collating area cover as described in paragraph 1 8
86. ersunk head screw M4 x 10 05 38 75 3 23 Washer 15 x 5 3 x 2 mm 45 37 50 2 24 Bearing locking plate 93 06 13 1 25 Countersunk head screw M3 x 10 05 38 74 2 26 Round head screw M3 x 4 45 43 00 2 27 Frame assy FO rh 93 06 20 1 28 Hinged plate 93 06 50 1 29 Guide strip long 93 06 53 1 30 Frame axle 95 30 75 1 31 Synthetic leaf spring 93 06 54 8 32 Guide strip short 93 06 52 1 33 Folding roller assy 93 05 34 2 34 Guide plate 95 30 72 1 35 Bracket for photocell 95 30 74 1 36 Bearing bushing 04 24 46 1 37 Round head screw x 10 05 38 69 1 rev 02 0 02 2002 520 04 21 Figure 8 520 04 22 13 14 15 service manual FPI 5000 C Ge 2 GEL W FR v 3 TA M NS 12 3 4 5 6 7 8 9 10 11 12 63 64 65 66 67 53 54 55 56 57 26 25 24 23 22 21 20 19 18 17 16 30 29 28 27 46 45 44 43 42 41 40 39 38 37 48 47 rev 02 0 02 2002 service manual FPI 5000 C Figure 520 04 22 Remarks illustration Description Part code Quantity Remarks code number number 5000 1 Self locking clip 05 26 02 2 2 Bearing plate 93 06 15 1 3 Fold roller assy 93 05 56 1 4 Washer 15 x 5 3 x2 mm 45 37 50 3 5 Bearing locking plate 93 06 12 1 6 Flap 95 30 86 2 7 Guide bracket 95 30 73 2 8 Fold roller assy 93 05 34 2 9 Axle for flap 95 30 82 2 10 X Transportation axle 93 05 35 1 11 Input roller assy 93 05
87. g belt 95 11 35 1 Pulley 28T assy item 8 15 04 27 40 16 Timing belt 95 11 45 1 17 Double document detector 89 08 36 1 18 Nut M2 45 19 00 1 19 Upper plate feeder assy 95 11 63 1 20 Stop 95 11 93 1 21 Bottom plate feeder assy 95 11 17 1 22 Round head screw x 25 45 43 18 1 23 Nut M4 self locking 05 36 21 1 24 Spacer 95 13 37 1 25 Frame plate feeder RH 95 11 27 1 26 Feeder stop 95 11 18 1 27 Transportation roller 95 13 12 2 28 Cyl pin 2 5 x 16 05 23 46 2 29 Drive axle 95 11 44 2 30 Separation axle assy auto 04 22 63 1 31 Nylon bearing 04 11 07 1 32 Hinge arm assy 95 11 22 1 33 Curved spring 95 11 06 1 34 Nut M3 self locking 05 36 28 4 35 Washer 6x 3 2 x 0 5 mm 45 37 30 2 36 Frame plate feeder LH 95 11 30 1 37 Round head screw M3 x 16 05 38 67 1 38 Gear 48T 95 11 32 1 39 Cyl pin 2x 16 05 23 69 2 40 44 95 11 51 1 41 Spring clip 6 8 mm 05 24 46 9 42 Washer 12 x 6 2 x 0 8 mm 04 01 40 5 43 Tensioner roller 95 11 59 1 rev 02 0 02 2002 520 04 43 service manual FPI 5000 C Figure 520 04 42 Remarks illustration Description Part code Quantity Remarks code number number FPI 5000 44 Belt tensioner 96 42 18 1 45 Spring clip 7 9 mm 05 24 42 46 Washer 14 x 0 8 2 x 0 8 mm 04 01 41 10 47 Gear 64T assy 95 11 38 1 48 Separation axle extension 95 11 09 1 49 Tension 0 2 5 x 10 05 33 19 1 50 Fibre washer 10 x 5 2 x I mm 04 01 07 2 51 Bearing bush 04 13 32 1 52 Spring clip 5
88. he gear 35T item 14 as described in paragraph 7 1 4 Gears Remove the gear 24T item 23 as described in paragraph 7 1 4 Gears Removal Refer to figure 7 10 Remove the two countersunk screws 8 with the washers 7 and withdraw the locking plate 6 Shift the roller 1 in the left hand side direction until the bearing on the right hand side is clear from the frame plate 4 Lower the right hand side of the roller and when possible withdraw it carefully in the right hand side direction Replacement Ensure on replacement not to damage the foam surface of the fold roller rev 01 0 01 2002 520 02 65 service manual FPI 5000 C Third upper fold roller Remove the gear 24T item 26 as described in paragraph 7 1 4 Gears Remove the gear 35T item 14 as described in paragraph 7 1 4 Gears Remove the gear 24T item 23 as described in paragraph 7 1 4 Gears Removal Refer to figure 7 10 Remove the two countersunk screws 8 with the washers 7 and withdraw the locking plate 6 Shift the roller 2 in the left hand side direction until the bearing on the right hand side is clear from the frame plate 4 Lower the right hand side of the roller and when possible withdraw it carefully in the right hand side direction Replacement Ensure on replacement not to damage the foam surface of the fold roller 7 5 Lower fold rollers Note In order to prevent a squeaking noise after replacement of one of the fold rollers
89. he hinge pin 8 Remove the spring clip 14 securing the lower end of the pressure spring strip 15 Hold the folder in the open position and pull the lower end of the pressure spring strip from the bracket 16 Carefully lower the folder until it locks Take care of the damper and the pressure spring strip Disconnect the wiring going to the folder at the mainboard 2 connectors and cut the first four as seen from the mainboard wire straps securing the wiring Refer to figure 7 10 Remove two round head screws 5 securing the left hand connecting plate 3 and flip it over in the front side direction Remove two round head screws 10 securing the right hand connecting plate 11 and flip it over in the front side direction Push the locking lever inwards to release the upper fold assembly and hold it Carefully lift the complete upper fold assembly upwards and withdraw it Refer to figure 7 9 Remove the countersunk screw 7 with the washer 6 and withdraw the locking plate 5 Shift the roller 4 in the right hand side direction until the left hand side is clear from the LH inside frame Lift the left hand side of the roller upwards and when possible withdraw it in the left hand side direction Take care of the connecting plates and on the roller Replacement Ensure on replacement not to damage the foam surface of the fold roller Second upper fold roller Remove the gear 24T item 26 as described in paragraph 7 1 4 Gears Remove t
90. ing 10 mm 04 24 26 2 5 Microswitch 12 12 22 1 6 Insulating plate 93 06 41 1 7 Cover for microswitch 93 06 25 1 8 Nut M3 45 19 01 2 9 Bracket for photocell 95 30 74 1 10 Guide plate 95 30 72 1 11 Fold roller assy 93 05 34 2 12 Frame axle 95 30 75 1 13 Guide strip short 93 06 52 1 14 Synthetic leaf spring 93 06 54 8 15 Guide strip long 93 06 53 1 16 Hinge plate 93 06 49 1 17 Frame assy FO Ih 93 06 19 1 18 Round head screw M3 x 4 45 43 00 2 19 Countersunk head screw M3 x 10 05 38 74 2 20 Countersunk head screw x 10 05 38 75 5 21 Countersunk head screw M3 x 16 45 42 05 2 22 Bearing locking plate 93 06 13 1 23 Washer 15 x 5 3 x 2 mm 45 37 50 2 24 Spring clip 9 12 mm 05 24 55 2 25 Guide bracket 95 30 98 1 26 Nut M4 self locking 05 36 21 2 27 Positioning lever 95 30 68 2 28 Ball bearing 03 12 81 2 29 Round head screw x 16 05 38 71 2 30 Torsion spring 95 30 70 2 31 Round head screw M3 x 8 05 38 65 4 32 Washer 6 x 3 2 x 0 5 mm 45 37 30 2 33 Pulse disc sensor assy 82 16 22 2 34 Round head screw x 8 05 38 68 10 35 Bracket 95 30 71 2 36 Lever for flap actuator 95 30 31 2 37 Cyl pin 2x 18 05 23 07 2 38 Spring clip 7 9 mm 05 24 42 2 39 Washer 14 x 8 2 x 0 8 mm 04 01 41 4 40 Conductive bearing 8 mm 04 24 25 2 rev 02 0 02 2002 520 04 27 1 5000 11 12 13 14 15 16 17 18 19 20 21 N N o Figure 10 rev 02 0 02 2002 520 04 28
91. ing holder 25 inwards and remove the cyl pin 24 Carefully remove the spring holder with the spring 26 and the spring holder 27 Remove the fixing bracket 28 Remove the bearing 29 from the axle 6 Remove the spring clip 13 with the washer 12 the bearing 11 and the washer 10 from the axle 7 Remove the two round head screws 31 securing the fold assembly Refer to figure 7 6 Pull the lever 2 from the axle Remove the two round head screws 18 securing the mounting bracket 17 and place it aside Pull the spring lever 22 spring loaded upwards and hold it in this position Pull the brake curve 12 from the axle Remove the cyl pin 11 the two washers 10 and the bearing 9 from the axle Carefully lower the spring lever spring loaded Remove the spring clip 14 and push the bearing 13 in the left hand side direction from the slotted hold in the frame plate 23 Remove the two round head screws 20 securing the fold assembly Refer to figure 7 7 Carefully lift the complete fold assembly upwards and withdraw it Remove the two countersunk screws 16 securing the fold knife 19 on the right hand side Slide the lever 17 off the axle Take care of the washer 18 Pull the right hand curved gear 14 marked with R off the axle Remove the two countersunk screws 24 securing the fold knife on the left hand side Slide the lever 21 as far as possible in the left hand side direction and move it aside so the left hand curved gear 22 is c
92. inserter Quality 60 gr m 250 gr m 15 Ib bond 62 5 Ib bond Booklets up to approximately 2 mm 0 08 inch thickness depending on stiffness m When folded max 230 mm 9 1 inch When folded max 170 gr m Folding capacity 8 sheets max 80 gr m 2 3 Envelope insert specifications Envelope sizes Standard BRE Business Reply Envelopes Quality 80 gr m 120 gr m 20 Ib bond 30 Ib bond Remarks Self copying paper may cause rubber parts to wear quicker The rubber used in this machine has the best resistance to Wiggins Teape material e The specification of the paper handling equipment is often wider than that of the envelopes and docu ments handled The condition of material handled will limit the specified environmental conditions We recommend that materials to be handled are stored at temperature of 20 C 68 F with a relative humidity factor of 50 If difference in temperature occurs between store room and mailing area the material has to be stored near the machine at least 24 hours before use 520 00 8 rev 01 0 01 2002 service manual FPI 5000 C 3 Preparing the machine for use First the machine must be unpacked Then it must be mechanically and electrically hooked up with the FPI 5000 I Inserter of which the paper processing configuration as a whole exists After unpacking and installing the machine is ready for use 3 1 Unpacking rev 01 0 01 2002 520 00 9 service manual FPI 5000
93. lear Pull the left hand curved gear marked with a L off the axle Replacement Ensure on replacement that the curved gears and the curved disc are is replaced correctly onto the axle refer to figure 7 8 and to secure the wiring again with five wire straps to locking plate 8 and the bracket 23 figure TD Adjustment Check after replacing and securing the complete fold assembly the adjustment of the paper guide 15 figure 7 7 see paragraph 9 3 3 Paper guide 520 02 62 rev 01 0 01 2002 service manual FPI 5000 C 7 4 Upper fold rollers Note In order to prevent a squeaking noise after replacement of one of the fold rollers we advise to slightly glue loctite 603 the ball bearings to frame Remove the front folder cover as described in paragraph 1 11 Front folder cover divert tray Open the folder as described in paragraph 1 3 Folder 17 18 19 figure 7 9 01 0 01 2002 520 02 63 service manual FPI 5000 C figure 7 10 520 02 64 rev 01 0 01 2002 service manual FPI 5000 C First upper fold roller Remove the gear 24T item 2 as described in paragraph 7 1 4 Gears Remove the gear 24T item 9 as described in paragraph 7 1 4 Gears Remove the gear 24T item 31 as described in paragraph 7 2 4 Gears Removal Refer to figure 7 9 Remove the spring clip 10 securing the lower end of the damper 9 Pull the lower end of the damper from t
94. lears both sides of the pulse disc and the detector sees the outer ends of the slots in the pulse disc 520 02 16 rev 01 0 01 2002 7007 10 010 Aa LI W07S TE 8 A 5 y AV i m A ENULU 5 000 service manual FPI 5000 C 3 1 3 Pulleys Remove the main drive belt as described in paragraph 3 1 1 Main drive belt Pulley 20T item 18 Removal Remove the clutch as described in the previous paragraph Refer to figure 3 1 Slide the pulley 18 off the axle Take care of the spacer 20 Pulley 20T item 22 Open the vertical transport track as described in paragraph 1 1 Vertical transport track Remove the LH side cover as described in paragraph 1 5 LH side cover Removal Refer to figure 3 1 Slacken the set screw of the pulley 26 and the pulley 24 Slide both pulleys together with the drive belt 25 off the axles Take care of the spacer 23 figure 3 2 520 02 18 rev 01 0 01 2002 service manual FPI 5000 C Refer to figure 3 2 Lift the front side of the collator arm upwards and hold it in this position Slacken the set screw of the pulley 10 in the middle of the collator axle 11 Lower the collator arm Remove the spring clip 14 the washer 13 and the bearing 12 from the left hand side of the transportation axle T Pull the transportatio
95. lt off the collator axle Replacement Ensure on replacement that the set screws of the pulley in the middle and the pulley on the right hand side of the collator axle rest into the grooves in the axle Secure the wiring of the receiver again with a wire strap Adjustment See paragraph 9 2 2 Transportation belts 5 2 2 Guide rollers Lift the front of the collating arm upwards and hold it in this position First guide roller Removal Refer to figure 5 2 Remove spring clip 16 with the washer 15 spring loaded Slide the guide roller 14 off the axle 11 Take care of the washer 13 and the tension spring 12 Second guide roller Removal 520 02 40 rev 01 0 01 2002 service manual FPI 5000 C Refer to figure 5 2 Remove the round head screw 4 Withdraw the axle 21 with the guide roller 19 from the collating arm frame 1 Remove the spring clip 17 with the washer 18 Slide the guide roller off the axle Take care of the washer 20 Third guide roller Removal Refer to figure 5 2 Remove the spring clip 10 with the washer 9 spring loaded Slide the guide roller 8 off the axle 5 Take care of the washer 7 and the tension spring 6 rev 01 0 01 2002 520 02 41 service manual FPI 5000 C 6 Shunt Divert area 6 1 Shunt Remove the RH side cover as described in paragraph 1 4 RH side cover Remove the LH side cover as described paragraph 1 5 side cover 611 Clutches Clutch item 1 and item 13
96. n axle in the right hand side direction as far as possible Refer to figure 3 1 Push the pulley 22 from the cyl pin 21 below Remove the cyl pin from the transportation axle Slide the pulley off the transportation axle Take care of the washer 27 and the bearing 3 Replacement Ensure on replacement that the set screw of the pulley in the middle of the collator axle rest into the groove in the axle Pulley 20T item 32 Removal Refer to figure 3 1 Remove the spring clip 34 and the washer 33 Pull the pulley 32 from the axle Take care of the cyl pin 31 Pulley 20 item 29 Open the vertical transport track as described in paragraph 1 1 Vertical transport track Removal Remove the pulley 20T item 32 as described previously Refer to figure 3 2 Remove the spring clip 1 the washer 2 and the bearing 3 from the left hand side of the transportation axle 6 Pull the transportation axle in the right hand side direction as far as possible Refer to figure 3 1 Push the bearing 4 out of the slotted hole in the RH inside frame Tilt the right hand side of the transportation axle upwards and when possible withdraw it through the hole in the RH inside frame Push the pulley 29 from the cyl pin 30 below Remove the cyl pin from the transportation axle Slide the pulley off the transportation axle Take care of the washer 28 and the bearing 4 3 1 4 Transportation rollers rev 01 0 01 2002 520 02 19 service manual
97. n for Cala 0 13I 02131 Alva SE volde BE DS 01221 a Ge lt DE gt wn gt 940 2104841 430333 83440 330333 83401 STE a sl 5 46 DOWNSTREAM Component layout of the feeder module board 93 08 02 figure 1 13 rev 01 0 01 2002 520 03 18 service manual FPI 5000 C 2 Settings Jumpers on the feeder unit board 93 08 02 Jumper Position Description JP102 1 2 Separation method of the upper feeder of the feeder module Automatic separation JP102 2 3 Separation method of the upper feeder of the feeder module Manual separation JP103 1 2 Separation method of the lower feeder of the feeder module Automatic separation JP103 2 3 Separation method of the lower feeder of the feeder module Manual separation JP104 1 2 Daily mail on the upper feeder of the feeder module JP104 2 3 No daily mail on the upper feeder of the feeder module JP105 1 2 Daily mail on the lower feeder of the feeder module JP105 2 3 No daily mail on the lower feeder of the feeder module table 2 1 Note 1 Jumper JP101 on the 5000 C base unit board 97 50 10 and jumper JP101 on the feeder unit board 93 08 02 are used to switch the CPU watchdog function on or off This is used for software development only Jumpers JP103 JP104 and JP105 on the FPI 5000 C base unit board 97 50 10 are reserved for future use The function
98. nd side direction off the drive axle Take care of the cyl pin 9 Replacement Ensure when retightening the set screws of the bushing that there is no axial play on the gear 520 02 20 rev 01 0 01 2002 service manual FPI 5000 C figure 3 3 Gear 35T item 6 Remove the pulley 20T item 18 as described in paragraph 3 1 3 Pulleys Remove the pulley 25T item 24 as described in paragraph 7 2 2 Pulleys Removal Refer to figure 3 3 Remove the two round head screws 7 and withdraw the gear cover 10 Shift the drive axle 4 in the right hand side direction until it is clear from the LH inside frame Tilt the left hand side of the drive axle in the rear side direction and when possible withdraw it Pull the right hand side ball bearing 11 from the drive axle special tool is required Remove the spring clip 12 Slacken the two set screws securing the bushing 5 Slide the bushing and the gear 6 in the right hand side direction off the drive axle Take care of the cyl pin 8 Replacement Ensure when retightening the set screws of the bushing that there is no axial play on the gear rev 01 0 01 2002 520 02 21 service manual FPI 5000 C 3 2 RH feeder drive mechanism Remove the RH side cover as described in paragraph 1 4 RH side cover Remove the RH feeder module cover as described in paragraph RH feeder module cover 3 2 1 Drive belts Note The removal procedure of the lower feeder drive belt an
99. nge pin 93 06 33 E 3 Countersunk head screw x 8 45 42 12 8 32 LockRH 93 06 31 1 33 Spring clip 6 8 mm 05 24 46 4 34 Round head screw x 16 05 38 71 5 rev 02 0 02 2002 520 04 15 service manual FPI 5000 C Ed o e un ex ex Ed 52 53 54 55 56 57 58 59 60 61 62 38 37 36 35 34 33 32 31 30 51 50 19 48 47 46 45 44 43 42 41 40 39 Figure 6 520 04 16 rev 02 0 02 2002 service manual FPI 5000 C Figure 520 04 16 Remarks illustration Description Part code Quantity Remarks code number number 5000 1 Conductive bearing 10 mm 04 24 26 3 2 Spring 10 14mm 05 24 83 3 3 Washer 16 x 10 2 x 0 8 mm 04 01 43 3 4 Gear 24T 93 09 02 1 5 Clutch CW 8 mm 93 09 03 1 6 Bearing locking plate 93 06 13 1 7 Washer 15x 5 3 x 2 mm 45 37 50 3 8 Countersunk head screw x 10 05 38 75 4 9 Round head screw x 8 05 38 68 6 10 Blocking bracket 93 05 29 2 11 Bracket 93 05 28 1 12 Timing belt 95 13 16 1 13 Tensioner bracket 93 05 16 1 14 Timing belt 04 16 25 1 15 Tensioner roller 93 05 15 2 16 Cyl pin 2 5 x 16 05 23 46 5 17 Gear 24T 93 05 25 4 18 Pulley 04 14 23 1 19 Clamping disc 43 30 46 1 20 Pulse disc 24 12 81 1 21 Washer 20x 6 2 x 2 mm 43 07 90 1 22 Washer 14 x 8 2 x 0 8 mm 04 01 41 14 23 Clutch CW 8 mm 12 16 66 1 24 Disc for pulley 93 05 41 1 25 Pulley 20 timing belt 93 05 12 1 26 Spacer 17 x 10 2x 2 mm 04
100. of jumper JP102 on the FPI 5000 C base unit board 97 50 10 is discussed below Note 2 There are no jumper settings necessary for optional components such as the OMR board 93 08 06 the MaxiFeeder MF 1 If present these components are detected automatically during startup of the machine rev 01 0 01 2002 520 03 19 service manual FPI 5000 C 3 Service software The FPI 5000 C plus its feeders has no local user interface Therefore the service software related to the FPI 5000 C plus feeders et cetera is discussed in chapter 3 of the FPI 5000 I electrical description document 510 03 520 03 20 rev 01 0 01 2002 service 4 Test points Test points on the FPI 5000 C base unit board 97 50 10 FPI 5000 C Test point Minimum Typical Maximum Notes 101 Test of the digital signal that drives diagnostic LED D102 Normal flashing frequency 1Hz During errors the flashing frequency is 4 Hz TP201 11V 12 V 14V Clutch VCL3 TP202 11V 12 V 14 V Clutch VCL4 TP203 12 14V Clutch VCL1 TP204 11V 12V 14V Clutch VCL2 TP205 Clutch for a future third fold table TP206 11V 12V 14V Clutch VCL5 TP207 11V 12V 14V Clutch VCL6 TP208 Not used TPIA 0 9V 1 1V 1 3V Paper photocell VPH3 Rx no paper present TPIA 0 0 V 01 0 5 Paper photocell VPH3 Rx paper present TP2A 0 9 V 1 1
101. of the feed axle with some alcohol Push the feed roller 1 to the left hand side of the axle as indicated Rotate the axle 180 degrees and push again Repeat the rotating and pushing until the feed roller can be pulled of the axle Note Before replacing the feed roller ensure that the axle is free of grease After replacing the feed roller put some grease Molykote PG 65 on the plastic cover 2 as shown in figure 3 9 Replace the plastic cover with the belt and the rollers 3 7 4 Lower separation roller Note The feeder unit does not need to be removed for replacing separation rollers NR figure 3 10 Refer to figure 3 10 Move the separator axle assy 2 in the right hand side direction A until the left hand side is clear from the hinge plate 1 Move B the axle assy 2 downwards side and withdraw the right hand side of the axle from the hole in the feeder frame rev 01 0 01 2002 520 02 31 service manual FPI 5000 C Figure 3 11 shows how the roller 1 should be slided of the axle assy 2 figure 3 11 Note Before replacing the feed roller ensure that the axle is free of grease 3 7 5 Gears For the removal of the gears at the LH side of the feeder it is not necessary to remove the feeder from the machine The gear 48T can be removed after the extension axle with the pulley etc has been removed Remove the spring clip securing the gear 64T lift the feeder and slide the gear 64T of the axle 3 8 Automati
102. older cover as described in the previous paragraph Removal Refer to figure 1 2 Remove the four countersunk screws 4 Remove the screws 6 an 9 Carefully withdraw the folder cover 3 together with the mounted side covers 5 and 10 rev 01 0 01 2002 520 02 13 service manual FPI 5000 C 2 Electrical components Warning Be aware of possible electrostatic discharge 2 1 Mainboard Remove the LH side cover as described paragraph 1 5 side cover Removal figure 2 1 Refer to figure 2 1 Disconnect all the wiring to the mainboard 2 Carefully pull the mainboard from the four board holders 1 and withdraw it 520 02 14 rev 01 0 01 2002 service manual FPI 5000 C 2 2 module boards Second feeder module Remove the LH side cover as described in paragraph 1 5 LH side cover Remove the LH feeder module cover as described LH feeder module cover Removal figure 2 2 Refer to figure 2 2 Disconnect all the wiring to the board 3 Remove the clamping spring 1 securing the transistor to the mounting plate 4 Carefully pull the board from the four board holders 2 and withdraw it First feeder module The removal procedure of the board of the first feeder module is similar to that of the second feeder module rev 01 0 01 2002 520 02 15 service manual FPI 5000 C 3 Feeder modules 3 1 Main drive mechanism Remove the RH side cove
103. or securing the cam disc are pointing in the same direction Ensure that the set screw of the cam disc is retightened into the hole in the axle figure 6 4 520 02 46 rev 01 0 01 2002 service manual FPI 5000 C 7 Folder 7 1 RH drive mechanism Remove the RH side cover as described in paragraph 1 4 RH side cover Remove the front folder cover as described in paragraph 1 11 Front folder cover divert tray T u figure 7 1 rev 01 0 01 2002 520 02 47 service manual FPI 5000 C li SA eee 0 0 9 7 MANS SE Na S A HO AN 810 Sr RUA f 4112 N WEN IN figure 7 2 520 02 48 01 0 01 2002 service manual FPI 5000 C 7 1 1 Drive belt Removal Refer to figure 7 1 Slacken the two round head screws 8 securing the belt tensioner 10 Refer to figure 7 2 Remove the drive belt 12 from the pulleys 13 and the pulley 3 figure 7 1 Adjustment See paragraph 9 3 1 RH drive belt 7 1 22 Pulleys Remove the drive belt as described in the previous paragraph Pulley 15T item 3 Removal Refer to figure 7 1 Remove the spring clip 6 with the washer 5 and the spacer 4 Slide the pulley 3 off the axle Take care of the freewheel clutch 2 and the cyl pin 1 Pulley 30T item 13 Removal Refer to figure 7 2 Slacken the set screw of the pulley 13 Slide the pulley off the axle
104. ortation roller assy 95 12 29 1 7 Pulley 20T 95 11 42 1 8 Clamping bush 95 11 41 1 9 Transportation axle 95 11 34 1 10 Timing belt 95 11 45 1 11 Pulley 28T 95 11 35 1 Pulley 28T assy item 8 15 04 27 40 12 Cyl pin 2 5 x 12 05 23 47 1 13 Rubber paper puller 04 00 16 2 14 Double document detector 89 08 36 1 15 Upper plate feeder assy 95 12 41 1 16 Stop 95 11 93 1 17 Bottom plate feeder assy 95 11 17 1 18 Frame plate feeder RH 95 12 01 1 19 Countersunk head screw x 8 45 42 12 2 20 Tension pin 2 5 x 10 05 33 19 2 21 Mounting plate 95 12 34 1 22 Gear 16T 95 12 23 1 23 Setscrew x 10 08 28 05 1 24 Gear 16T 95 12 22 1 25 Gear 54 16T 95 12 21 1 26 Spring clip 4 5 mm 05 24 47 2 27 Spacer 18 x 12 8 7 5 mm 04 08 46 1 28 Gear 54T 95 12 44 1 29 Support axle extension 95 11 20 1 30 M4 self locking 05 36 21 1 31 Round head screw 25 45 43 18 1 32 Spacer 95 13 37 1 33 Lock washer 5 32 05 24 31 1 34 Nut M4 45 19 02 1 35 Coupling sleeve 95 12 12 2 36 Separation axle assy special 04 23 12 1 37 Separation roller assy special 95 12 30 1 38 Stop plate 95 12 06 1 39 Support bracket lower 95 12 31 1 40 Drive axle 95 12 26 1 41 Drive extension 96 42 20 1 42 Frame plate feeder LH 95 12 02 1 43 Round head screw 10 05 38 69 8 44 Gear 48T 95 11 32 1 rev 02 0 02 2002 520 04 47 Figure 520 04 46 Remarks 520 04 48 illustration code number 45 46 47 48 49
105. ound head screw 1 securing the DFC 3 to the bracket 2 Disconnect and withdraw the DFC Replacement Ensure on replacement that the protruding part of the DFC falls into the slotted hole Adjustment The DFC is electronically adjusted software so no manual adjustments are needed For further DFC details refer to paragraph 1 2 of the electrical description Document detector Remove the feeder as described in paragraph 3 6 Feeders rev 01 0 01 2002 520 02 69 service manual FPI 5000 C Removal figure 8 3 Transmitter LED Refer to figure 8 3 Remove the round head screw 8 and withdraw the bracket 1 with the transmitter 7 Remove the round head tapping screw 2 securing the transmitter Disconnect and withdraw the transmitter Receiver Sensor Refer to figure 8 3 Remove the round head screw 3 and withdraw the bracket 5 with the receiver 4 Remove the round head tapping screw 6 securing the receiver Disconnect and withdraw the receiver 520 02 70 rev 01 0 01 2002 service manual FPI 5000 C 8 2 Vertical transport 8 2 1 Document detector Removal figure 8 4 Transmitter LED Remove the cover plate as described in paragraph 4 1 Cover plate Refer to figure 8 4 Remove the countersunk tapping screw 3 securing the transmitter 1 to mounting bracket 2 Disconnect and withdraw the transmitter Receiver Sensor Remove the cover plate fitted below the lowest feeder as described in p
106. ove the upper feeder drive belt as described in paragraph 3 3 2 Drive belts Remove the pulley 44T item 13 as described in paragraph 3 3 3 Pulleys Removal Refer to figure 3 5 Slide the two spacers 14 and the bearing 16 off the axle 19 Push the two transportation rollers 20 from the cyl pins 21 below Remove the cyl pins from the axle Withdraw the axle in the right hand side direction from the machine and slide the two transportation rollers 20 off it Replacement Ensure on replacement that the transportation rollers are refitted correctly on the axle narrowing part of the rollers pointing inwards 3 4 Feeder cover plates Note There are five cover plates that may need to be removed four are fitted above the separate feeders and one is fitted below the lower feeder in the first feeder module The removal procedure for all four cover plates is similar except that to remove the topmost cover plate it is only necessary to remove the RH feeder module cover and for the other four cover plates it is only necessary to remove the RH side cover Remove the RH side cover as described in paragraph 1 4 RH side cover Remove the RH feeder module cover as described in paragraph RH feeder module cover Removal Refer to figure 3 6 Remove the round head screw 10 securing the cover plate 11 to the right hand frame Tilt the right hand side of the cover plate in the front side direction until it is clear from the frame and when possi
107. per pullers 2 can simply be removed by pushing them of the axle Hold the plastic cover 3 in place with one hand and push D firmly against the rubber paper puller as indicated Rotate the axle 180 degrees and push again Repeat the rotating and pushing until the paper puller can be pulled of the axle Note Ensure on replacement that the plastic cover is replaced below the ridge 3 3 7 1 on the paper guide and that the feeder assy is correctly fitted onto the axle Ensure that the belt runs across the pulleys 3 7 2 Pulley of paper puller axle rev 01 0 01 2002 520 02 29 service manual FPI 5000 C Remove the feed axle assy as described in the paragraph Rubber paper pullers figure 3 8 Refer to figure 3 8 Remove the axle from the plastic cover Push the rubber paper puller of the axle and remove the spring clip the washer and the bearing The pulley 1 consists of two parts Push the pulley assy to the left to release it from the cyl pin remove the cyl pin and slide the pulley assy of the axle 3 7 3 Upper separation roller Grease 1 2 figure 3 9 Note The feeder unit does not need to be removed for replacing separation rollers 520 02 30 rev 01 0 01 2002 service manual FPI 5000 C Remove the feed axle assy as described above Refer to figure 3 9 Click A the plastic cover 2 off the axle and remove it with the belt and the paper pulleys from the feed axle Remove the grease from the left hand side
108. r in a feeder module similar and similar for both feeder modules first and second Remove the LH side cover as described paragraph 1 5 side cover Remove the LH feeder module cover as described in paragraph LH feeder module cover 3 3 1 Clutch Removal Note The feeder module as shown is placed 18 19 20 21 on the front side bottom figure 3 5 Refer to figure 3 5 Disconnect the clutch 9 Remove the spring clip 7 securing the clutch Slide the clutch off the axle Replacement Ensure on replacement that the locking plate 18 retains the clutch 520 02 24 rev 01 0 01 2002 service manual FPI 5000 C 3 3 2 Drive belt Remove the clutch as described in the previous paragraph Removal Refer to figure 3 5 Unhook the tension 6 spring from the bearing pin 8 Remove the drive belt 12 from the pulley 13 Remove the spring clip 5 with the washer 4 securing the belt tensioner 3 Pull the drive belt tensioner together with the pulley 10 from the axle and withdraw the drive belt 12 Take care of the cyl pin 11 and the tension spring 3 3 3 Pulleys Pulley 44T item 13 Remove the clutch as described in paragraph 3 3 1 Clutch Removal Refer to figure 3 5 Unhook the tension spring from 6 the bearing pin 8 Remove the drive belt 12 from the pulley 10 Slide the pulley off the axle Take care off the two spacers 14 Pulley 44T item 10 Removal Refer to figure 3 5 Unhook th
109. r as described in paragraph 1 4 RH side cover 311 Main drive belt Removal Refer to figure 3 1 Remove screws 35 and remove plate 36 Slacken the hex head screw 10 securing the belt tensioner 11 of the lower feeder in the first feed module and remove the drive belt 12 from the pulley 9 and the pulley 32 Slacken the two hex head screws 1 securing the belt tensioner 2 Disconnect the clutch 17 Remove the round head screw 7 with the washer 6 and place the locking plate 5 aside Take care of the pulse disc 15 the pulse disc detector assy 8 and the wiring Remove the main drive belt 19 from the pulleys 18 22 and 29 and withdraw it Take care of the pulse disc Replacement Ensure on replacement that the locking plate retains the clutch and that the pulse disc detector assy clears both sides of the pulse disc and the detector sees the outer ends of the slots in the pulse disc Adjustment See paragraph 9 1 1 Main drive belt 312 Clutch Removal Refer to figure 3 1 Disconnect the clutch 17 Remove the round head screw 7 with the washer 6 and place the locking plate 5 aside Take care of the pulse disc 15 the pulse disc detector assy 8 and the wiring Remove the countersunk screw 13 and withdraw the pulse disc together with the two spacers 14 Take care of the washer 16 Slide the clutch off the axle Replacement Ensure on replacement that the locking plate retains the clutch and that the pulse disc detector assy c
110. ragraph 1 1 Vertical transport track Refer to figure 1 1 Slacken the hex head screw 17 and turn locking plate 18 clockwise Move the RH side cover 13 to the front side of machine and withdraw the cover Feeder module cover Removal Open the vertical transport track as described in paragraph 1 1 Vertical transport track Refer to figure 1 1 Slacken the hex head screw 15 securing the RH feeder module cover 14 on the rear side Tilt the rear end of the RH feeder module cover in the right hand side direction and when possible unhook the front side from the slits in the RH inside frame and then withdraw it 520 02 8 rev 01 0 01 2002 service manual 5000 figure 11 01 0 01 2002 520 02 9 service manual FPI 5000 C 1 5 LH side covers Lower side cover Removal Open the vertical transport track as described in paragraph 1 1 Vertical transport track Refer to figure 1 1 Slacken the hex head screws 3 and turn locking plate 2 counter clockwise Move the LH side cover 1 to the front side of the machine and withdraw the cover Feeder module cover Removal Open the vertical transport track as described in paragraph 1 1 Vertical transport track Refer to figure 1 1 Slacken the hex head screw 5 securing the LH feeder module cover 4 on the rear side Tilt the rear end of the LH feeder module cover in the left hand side direction and when possi
111. rial for the test run rev 01 0 01 2002 520 00 11 service manual FPI 5000 C 520 00 12 rev 01 0 01 2002 service manual FPI 5000 C Process description rev 01 0 01 2002 520 01 1 service manual FPI 5000 C 520 01 2 rev 01 0 01 2002 rev 01 0 01 2002 2 1 2 2 2 3 2 4 2 5 2 6 service manual Contents Section Overview Legend Feeding documents the Vario Feed concept Vertical document transport Transport to and from the collator The Divert amp Go divert process The multifeed shunt process The Eight in One folding process including exit to the FPI 5000 I FPI 5000 C Page 10 10 10 10 11 11 520 01 3 service manual FPI 5000 C 520 01 4 rev 01 0 01 2002 service manual 5000 Collator 1 Overview The processing of documents by the FPI 5000 C and its attached feeders can be divided into a number of distinct sequential partial processes These processes will be discussed in some more detail e Feeding documents the Vario Feed concept e Vertical document transport Transport to and from the collator area e The Divert 4 Go divert process only if the optional divert subsystem is present e Themultifeed shunt process only if the optional divert subsystem is present e The Eight in One folding process including exit to the 5000 I The figure on the foldout page 520 01 6 shows a schematic overview of the process mechanical items that are
112. roswitch for fold unit rev 01 0 01 2002 520 02 77 service manual FPI 5000 C Remove the front folder cover as described in paragraph 1 11 Front folder cover divert tray Remove the rear folder cover as described in paragraph 1 10 Rear folder cover Removal figure 8 12 Refer to figure 8 12 Remove the two nuts 6 and withdraw the bracket 5 Remove the two countersunk screws 1 Move the microswitch 3 together with the insulating plate 4 clear from the frame plate 2 Remove the insulating plate Disconnect and withdraw the microswitch 520 02 78 rev 01 0 01 2002 service manual FPI 5000 C 9 Adjustments 91 Feeders 9 1 1 Main drive belt EA 4 10 mm 0 4 inch figure 9 1 Refer to figure 9 1 The maximum movement of the drive belt 3 at the indicated position is 10 mm 0 4 inch To adjust Remove the RH side cover as described in paragraph 1 4 RH side cover Slacken the two hex head screws 1 securing the belt tensioner 2 Shift the belt tensioner to adjust the correct belt movement Hold the belt tensioner and retighten the two hex head screws Check the adjustment and readjust if necessary Note Do not adjust the drive belt too tight rev 01 0 01 2002 520 02 79 service manual FPI 5000 C 9 1 2 RH drive belts Note The adjustment of the lower and upper drive belt in a feeder module is similar upper feeder drive belt
113. rsunk screws 1 securing the fold knife 4 on the right hand side Slide the lever 2 off the axle 9 Take care of the washer 3 Pull the right hand curved gear 22 marked with a R off the axle Remove the two countersunk screws 7 securing the fold knife on the left hand side Slide the lever 6 as far as possible in the left hand side direction and move it aside so that the left hand curved gear 11 is clear Pull the left hand curved gear marked with a L off the axle Replacement Ensure on replacement that the curved gears and the curved disc are is replaced correctly onto the axle refer to figure 7 8 figure 7 8 Adjustment Check after replacing and securing the complete fold assembly the adjustment of the paper guide 5 figure 7 7 see paragraph 9 3 3 Paper guide First curved folder gears Removal Refer to figure 7 4 Remove the round head screws 1 securing the cover plate 2 on both sides and withdraw it upwards Refer to figure 7 7 Cut the four wire straps securing wiring to the locking plate 8 and the wire strap securing wiring to the bracket 23 rev 01 0 01 2002 520 02 61 service manual FPI 5000 C Refer to figure 7 4 Remove the two round head screws 38 and withdraw the belt tensioner 35 Take care of the washers 37 and the conductive strip 36 Push the spring holder 22 inwards and remove the cyl pin 23 Carefully remove the spring holder with the spring 20 and the spring holder 19 Push the spr
114. s Remove the gear 48T item 15 as described in paragraph 3 3 4 Gears Removal Refer to figure 3 5 Disconnect the wiring from the feeder at the board 2 and cut the wire straps securing it Refer to figure 3 6 Unhook the tension spring 9 from the thread of the round head screw 7 and from the bracket 8 Remove the round head screw 7 Carefully push the nyliner 3 with the wiring from the left hand frame and withdraw the wiring through the gap in the left hand frame Remove the round head screws 4 securing the feeder on both sides to the frames Carefully withdraw the feeder upwards Take care of the hinge pins 5 with the washers 6 on both sides of the feeder Replacement Ensure on replacement that the right hand side of the tension spring is fitted into the lower hole of the bracket Secure the wiring again with wire straps Note Do not exchange the tension spring from one to another feeder Each spring is specially adjusted from the factory 520 02 28 rev 01 0 01 2002 service manual FPI 5000 C 3 7 Automatic separation feeder with daily mail 371 Rubber paper pullers d figure 3 7 Refer to figure 3 7 Remove the feed axle assy 4 in the right hand side direction A until the left hand side is clear from the axle 1 Tilt B the axle assy 4 at the left hand side and withdraw the right hand side of the axle from the hole in the feeder frame Remove C the axle assy as indicated The rubber pa
115. s paragraph Removal figure 6 3 Refer to figure 6 3 Cut the three wire straps securing wiring to the motor 10 and disconnect it Slacken the set screw 6 of the bushing 7 securing the motor axle Withdraw the motor together with the bracket 8 Replacement Ensure on replacement that the bracket is refitted into the slits of the divert frame 3 and that the set screw of the bushing is retightened onto the flattened part of the motor axle Secure the wiring again to the motor with three wire straps rev 01 0 01 2002 520 02 45 service manual FPI 5000 C 6 2 3 Gear Gear 26 35T item 15 Remove the motor as described in the previous paragraph Removal Refer to figure 6 3 Slacken the set screw 11 securing the bushing 7 to the axle 14 Remove the bushing the washer 12 and the bearing 13 Unhook the tension spring 4 from the bracket 5 Slacken the set screw 2 securing the cam disc 1 Slide the cam disc off the axle Take care of the pulse disc detector assy 16 Remove the washer 18 and the bearing 17 Slide the gear 15 towards the middle of the axle Slide the axle in the right hand side direction until the left hand side is clear from divert frame 3 Tilt the axle in the front side direction and when possible withdraw it and slide the gear off the axle Replacement Ensure on replacement that the gear is replaced correctly onto the axle see figure 6 4 the flattened part of the gear and the hole in the axle f
116. screw M3 x 6 45 43 02 4 12 Set screw x 4 08 28 01 3 13 Bushing 15 x 10x 5 5 mm 75 37 51 1 14 Frame divert unit 93 09 28 1 15 Washer 16 x 10 2 x 0 8 mm 04 01 43 3 16 Conductive bearing 10 mm 04 24 26 2 17 Drive axle 93 09 34 1 18 Tension pin 2 5 x 20 05 3324 1 19 Gear 26 35T 93 09 40 1 20 Nut self locking 05 38 21 1 21 Pulse disc sensor assy 82 16 22 1 22 Washer 6x 3 2 x 0 5 mm 45 37 30 2 23 Round head screw M3 x 10 45 43 04 2 24 Round head screw M4 x 30 45 43 19 1 25 Curve disc 93 09 38 1 26 Tension spring 03 35 39 1 27 Spacer 10 x 06 3 x 7 5 mm 04 10 28 1 28 Divert flap assy 93 09 26 1 29 Axle 93 09 32 2 30 Intermediate axle 93 09 31 1 31 Guide roller 93 09 19 2 32 Spacer 15 x 0 10 4 x 25 mm 04 08 25 1 33 Washer 12 x 6 2 x 0 8 mm 04 01 40 9 34 Intermediate plate divert unit 93 09 29 1 02 0 02 2002 520 04 55 service manual FPI 5000 C Figure 22 520 04 56 rev 02 0 02 2002 Figure 520 04 56 Remarks rev 02 0 02 2002 illustration code number service manual Description 1 Hex head screw x 20 2 Guide roller assy 3 Side guide LH 4 Side guide RH 5 Gear 6 Washer 14 x 06 5 x 0 8 mm 7 Pressure spring 8 Spacer 8x 04 3x3 9 Carrier Carrier 10 Washer 15 0 5 3x2 11 Finger knob 12 Referto 7 13 Washer 9 x 4 3 x 0 8 14 Nut M4 15 Knurled nut 16 Self locking nut 17 Spring clip 4 5 mm 18 Wire spring 19 Locking lever
117. tely necessary for proper aligning against the document stoppers in the collator 2 3 Transport to and from the collator The collator area consists of a set of rollers 52 56 that can be driven in both directions and a set of counter rollers 60 66 The entry of the paper into the collator is monitored by the photocell VPH2 48 49 Documents are fed into the collator from the vertical track or back into the collator in certain stages of the multifeed shunt process In both cases the effect of 52 56 is such that the documents are properly aligned against the document stoppers 57 58 or 59 Documents are exited from the collator in three ways 1 to the fold unit if a set is complete 2 to the divert area if a set is affected by a double document error 3 in certain stages of the multifeed shunt process In all these cases the forward shunt clutch 28b VCL5 is activated 2 4 The Divert amp Go divert process It is very important that in the case of a double document error in one of the feeders the paper process is interrupted as shortly as possible in order to maintain a high throughput To this purpose a set that is affected by a double document error must be diverted from the paper main stream i e such a set never should enter the folding subsystem and subsequently the inserter To this purpose the optional divert subsystem must be present A part of this is also used for the multifeed shunt process as discussed below
118. ual FPI 5000 C Figure 520 04 52 Remarks illustration Description Part code Quantity Remarks code number number 5000 C 1 Collating plate 95 21 02 1 2 Paper stop 95 21 41 4 3 Round head screw x 8 45 38 68 4 4 Bottom cover assy 93 07 41 1 5 Round head screw x 8 05 38 68 4 6 Side frame LH 95 21 04 1 7 Nut M4 self locking 05 38 21 6 8 Washer 9 x 4 3 x 0 8 mm 45 37 02 6 9 Side frame RH 95 21 03 1 10 Tension spring 45 64 04 1 11 Intermediate plate 95 21 05 2 12 Tilting plate 95 21 14 2 13 Contra roller 95 2 11 18 14 Spring clip 5 7 mm 05 24 66 36 15 Spacer 10 x 5 3 x 10 mm 04 09 51 12 16 Washer 9 x 4 3 0 8 mm 45 37 45 4 17 Axle 95 21 10 6 18 Washer 12 x 6 2 x 0 8 mm 04 01 40 2 19 Roller 95 21 13 1 20 Axle 95 21 12 2 rev 02 0 02 2002 520 04 53 5000 1 service manua IL ZL EL 4 S 9 LL 8L 61 OG 12 22 ET 76 ST ne OY nS x PSY X 9 Figure 21 rev 02 0 02 2002 520 04 54 service manual FPI 5000 C Figure 520 04 54 Remarks illustration Description Part code Quantity Remarks code number number 5000 C Axle 93 09 33 1 2 Conductive bearing 6 mm 04 24 24 2 3 Springclip 6 8 mm 05 24 46 5 4 Round head screw MA x 8 05 38 68 8 5 Rack assy 93 09 41 1 6 Motor 24V 93 09 42 1 7 Spring clip 9 12 mm 05 24 55 5 8 Spacing 93 09 30 2 9 Nut M4 45 19 02 4 10 Mounting bracket motor 23 55 58 1 11 Round head
119. uide plate 95 14 15 1 21 Countersunk head screw M3 x 5 45 42 00 1 22 Led including holder 04 24 52 1 23 Nut 95 14 50 4 24 Guide bush 95 14 39 10 25 Round head screw M3 x 8 05 38 65 20 26 Lower cover vertical transport 98 01 03 1 27 Upper cover vertical transport 98 01 02 1 28 Handle 98 01 01 1 29 Nut M4 45 19 02 2 30 Washer 9 x 04 3 x 0 8 mm 45 37 45 4 31 Cover plate 98 01 43 1 rev 02 0 02 2002 520 04 35 service manual FPI 5000 C 1211109 8 7 6 5 4 3 23 24 20 21 22 15 16 17 18 19 Figure 14 520 04 36 rev 02 0 02 2002 service manual FPI 5000 C Figure 520 04 36 Remarks illustration Description Part code Quantity Remarks code number number 5000 1 Mounting bracket for spring 95 13 06 2 2 Inside frame feed unit RH 95 13 02 1 3 Spring clip 9 12 mm 05 24 55 4 4 Lever 95 10 23 1 5 Nylon bearing 04 12 71 4 6 Tension 2 5 x 12 05 33 20 2 7 Frame axle 95 13 24 2 8 Torsion spring 95 13 28 2 9 Washer 16 x 10 2 x 0 8 mm 04 01 43 4 10 Torsion spring 95 13 35 1 11 Lever 95 10 21 1 12 Cover 95 13 27 2 13 Round head screw M3 x 16 05 38 67 2 14 Hex head screw x 8 05 38 80 6 15 Round head screw M4 x 6 05 38 66 8 16 Blocking bracket 95 13 20 2 17 Round head screw x 10 05 38 69 5 18 Nylon bearing 04 09 66 2 19 Inside frame feed unit LH 95 13 01 1 20 Frame axle 95 13 03 1 21 Hingepin 95 13 09 4 22 Self locking clip 05 26 02 2 23 Washer 12 x
120. ument of the feeder is transported to the collator Then the divert flap 24 is turned upwards The set in being as present in the collator is exited from the collator The forward shunt clutch 28a VCL5 is activated as well The paper is transported in the direction of the divert area 26 However contrary to the divert case as discussed up the paper never will leave the rollers 27 and 28a Now the next document of the multifeed is processed and on its way to the collator At the right time i e the overlapping criterion the reverse shunt clutch 28c VCL6 is activated The set in being is transported in the direction of the collator During this transport the newly fed document is added to and aligned with the set in the collator with the newly fed document at the top This process is repeated until all multifeed related documents are processed 2 6 The Fight in One folding process including exit to the FPI 5000 I Contrary to the principle of one mechanical fold stop per fold table in which the fold is made as soon as the leading edge of the paper reaches the paper stop the folding process in the FPI 5000 C is based on the timed karate action of a fold plate one for each of the two fold tables As soon as the paper enters a fold table the flap is turned upwards The fold plate is in its rest position it is turned backwards i e counter clockwise In this way no actions are necessary if a set is not to be folded at all The paper is dir
121. val Refer to figure 1 1 Remove the two round head screws 22 securing the collating area cover 21 on the rear side Remove the two hex head screws 23 securing the collating area cover on the front side Lift the front side of the collating arm cover upwards and hold it in this position Lift the front side of the collating area cover upwards and when possible withdraw it in the front side direction 1 9 Bottom plate Remove all the hoppers as described in paragraph 1 2 Hoppers Removal Refer to figure 1 1 Carefully turn the machine over and place it on the left hand side Slacken the four hex head screws 25 securing the bottom plate 26 Unhook the bottom plate and withdraw it 110 Rear cover Removal Refer to figure 1 2 on the next page Remove the four countersunk screws 2 securing the rear cover 1 to the inside frames Move the rear cover in the rear side direction as far as possible Take care of the wiring attached to it rev 01 0 01 2002 520 02 11 service manual FPI 5000 C AN a VO Sod Y ak 8 5 A m OB gt _ ea Q 11 Ta figure 1 2 520 02 12 rev 01 0 01 2002 service manual FPI 5000 C 1 11 Front folder cover divert tray Removal Refer to figure 1 2 Remove the four countersunk screws 7 lift and withdraw the front folder cover 8 upwards 112 Folder cover Remove the front f
122. wo DC motor controlled parts the mechanical drive for the total SA 5005 system including the FPI 5000 C feeder subsystem Note 1 The 5000 C base unit board 97 50 10 is the successor of the 5000 C base unit board 93 06 01 Major circuit board changes are related to the DC motor interface electronics including noise filters and to the control of the MaxiFeeder MF 1 Note 2 The optional FPI 5000 component OMR board is discussed in Appendix 1 document 134 10 The optional FPI 5000 C component MaxiFeeder is discussed in Appendix 2 document 134 20 The FPI 5000 C contains the following SA 5005 Eproms FPI 5000 C base unit board 97 50 10 Eprom 97 50 12 For each feeder module board 93 08 02 Eprom 97 50 13 For the optional OMR board 93 08 03 Eprom 97 50 14 Eprom set 97 50 15 contains all SA 5005 Eproms for an OMR less 5000 C including Eprom 97 50 11 for the FPI 5000 I Eprom set 97 50 16 contains all SA 5005 Eproms for an FPI 5000 C with OMR including Eprom 97 50 11 for the FPI 5000 I Eproms within the SA 5005 must have the same revision level rev 01 0 01 2002 520 03 5 5000 1 8 20086 NO LNOHLIM 13SWOUd3 912086 13SWNOUdI service manua 208066 430334 210926 VEN WO3Sd3 208066 430334 WO3Sd3 uso gp 10546 10846 22222222 22222222

service manual FPI 5000 C

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