Minimailer 4 - Neopost Technologies Ltd
Contents
1. EFAULT WIDTH AC ROSS FINGE 212mm EU 0 O R 217 US Fig 21 3 2 10 INSERT PINCH ROLLERS The pinch rollers are located in the insert area carried in a removable beam They press against two of the four rollers on the shaft above and grip the flap of the envelope as it passes between them and the 4 rollers If the flap is not being gripped sufficiently either the 4 rollers or the pinch rollers may need replacing To replace the pinch rollers proceed as follows 1 Remove the LH side cover see section 3 2 1 and also the subframe see Fig 9 Beam retaining 2 Referring to Fig 22 below remove the beam by taking out the screw on the LH chassis face Push the beam sideways slightly to clear the tangs and lift it out of the chassis Note avoid straining the flexi cable to the sensor To separate the cover from the beam remove the 2 screws shown 3 Remove the nut securing the pinch roller assembly Note that the assembly must be re placed complete 4 Refit all parts in reverse order to removal Pinch roller assy screw QX2. ee ren pode Obe Qd Cover retaining Cover retaining screw Fig 22 screw Page 3 15 ISSUE 3 Mar 2004 Minimailer 4 M 3 2 11 PAPER JAM CLEARANCE Due to the design of the machine the Minimailer 4 does not readily jam Any jams that do occur are most likely to happen in the fold rollers when an insert is being nested and an excessive folded pack thickness results in the rollers jamming solidly Use of the green knob may then not help as the fold roller gears will spring out of mesh Such a jam can be cleared by using the following procedure 1 Switch off the machine 2 Remove hopper 3 to provide access to the top fold roller 3 2 12 FLEXI CABLES All sensors and components on the machine are connected to one of the five distribution boards using flexi cables The distribution boards and the display are all connected to the MCU board again using flexis There are 20 separate flexi cables on the machine most branching into smaller cables to connect to more than one termination If a cable becomes damaged repair is not possible the whole flexi must be traced back to its origin and replaced Flexis are supplied ready folded and with their identity and terminations marked on them In most cases they are retained to chassis and other SERVICE MANUAL 3 Raise the clamshell and locate the metal main drive gear on the LH side at the lowest point near the rear Wrap a suitable cl
3. proceed as follows 1 Set the separator gap as previously described 2 Slacken the 2 nyloc nuts so that there is clearance between the face of the nut and the separator plate 3 Tighten the nut until a small piece of 80gsm paper is just gripped between the face of the nut and the separator plate 4 Remove the paper and tighten the nuts a further 4 flats approx turn This will provide a starting point to test whether further small adjustments are required The ma chine should be able to feed lightweight inserts and a 1 5mm thick booklet without doubles If doubles are occurring the plate may need further tension If a booklet will not feed it may need less tension Separator plate replacement If the pads are worn the separator plate assembly must be replaced due to the pads being perma nently glued to the plate To replace proceed as described on the following page ISSUE 3 Mar 2004 1 Remove the 4 csk screws and hinge down fold plate 1 as described previously 2 Remove all screws and nuts marked in Fig 5 below Note that the rearmost screw posts will require removal to gain access to 2 ofthe screws JR S OA g Fig 5 3 Remove the nut securing the bracket for the hopper loaded sensor and move the bracket out of the way Withdraw the plate
4. Minimailer 4 Ps SERVICE MANUAL SECTION 3 Service Operations and Adjustments Page 3 1 ISSUE 3 Mar 2004 5443 Minimailer 4 Per 3 1 PREVENTATIVE MAINTENANCE CHECK LIST When all items have been carried out worksheet must be signed to confirm 3 1 1 GENERAL 1 Ask how the machine has been working lately and use this information as a guide for checking the machine Ask if there has been a change of use e g high production runs or a change of material Check the operator adjustments of the machine and the material being processed Switch on machine and observe if any faults are reported on power up If necessary generally instruct the operators again with regard to their specific problem area Enter the total forms count on the service sheet this can be found from Machine Count on the Supervisor menu Alert your service department if the machine is being used for a higher number than the agreed service contract limit When all service or repair operations have been carried out the machine must be left with all parts reassembled leaving no risk of injury 3 1 2 REMOVAL OF COVERS Note throughout this manual references to LH and RH are viewed from the envelope input end of the machine Some or all of the following covers may Issue 3 Mar 2004 require removal for maintenance operations Ensure all covers are undamaged Check action of opening covers to confirm correct
5. Ball Bearing 6x 13x 5 Flanged Oilite 8 x 11 x 12 Qty N N N N NN nn 9 W D N ON AN amp K NANNA Part No F4152A F4275A F5023A F5072A F5084A F5111A F5125A F5145A G0079A G0085A G1024A G1029C G1111A G1116A G1117A G1139A G1179A G5037A G7136A G7137A G7138A SERVICE MANUAL Description Gear 25T x 8mm Gear 48T Tufnol Helical Belt 300 XL 037 Belt 560 S2M Belt 448 DS2M Belt 100 S2M Belt 510 DXL 037 Belt 322 S2M Clutch Pin Wetter Sponge Spring Return Spring D D Pressure Spring Light Pressure Spring Intermediate Pressure Spring Heavy Spring Release Conical Tray Spring Belt EPDM 330 x 12 Key Pad A Key Pad B Display Cover Electrical Spares 131 824 131 829 135 103 180 730 180 731 181 067 181 117 181 127 181 128 181 141 182 608 182 609 182 610 184 659 Switch Magnet Reed Switch Fuse T3 15A 220v or 110v Optical Sensor Fork type Optical Sensor Fork type Motor Wired 4WJST CW Clutch RPM CW Clutch RPM CCW Clutch Main Drive Lenze Solenoid NSF SS LS Reflective Sensor Optical Sensor TX Optical Sensor RX MM4 Purchased Item Kit Qty m m ee ee ANN A N N CO O O D R amp N NN OO R Anm O O 1 Above kit comprises all PCBs and flexi cables Page 3 21 ISSUE 4 Sep 2006 Minimailer 4 Psy SERVICE MANUAL Blank Page Issue 3 Mar 2004 Page 3 22
6. operation and that safety microswitches function correctly Check that all warning labels are legible Exercise caution with moving parts and exposed electri calapparatus when covers are removed 3 1 3 Page 3 2 SERVICE MANUAL 1 Unplug mains lead from machine Ensure that mains lead and its connectors aresoundand undamaged 2 Remove hoppers 1 to 3 where fitted 3 Upper side covers on each cover raise upper section and remove 2 x screws under lower flange and 1 x screw at the rear below the insert hopper inside the chassis plate Lift the cover outwards and up to clear the lugs either side of hopper 1 3 LH Lower side cover remove 2 x screws on the top flange hinge the cover outwards and lift it off the 3 lugs on the lower edge 5 Front vertical cover remove both lower side covers then swing front cover outwards and off 2 hinge lugs on RH side 6 Electronics underpanel remove 4 x screws underneath envelope hopper and spring the rear edge out from under the hopper flange it may be necessary to raise the rear of the machine slightly To replace note that 3 locating lugs at the front edge of the tray must be properly engaged under the machine a screwdriver inserted underneath from the side may assist Note When the side covers are removed subframe brackets will be seen attached to the chassis side plates Removal of these where required is described in the relevant section in th
7. 2 counter sunk screws on the outside face a LE r 2 e Fig 14 2 Remove LH amp RH upper drive belts see Figs 7 amp 10 Note Further operations may require the removal of various E clips gears clutches etc as required these will not be specifically described but assumed Minimailer 4 45 Page 3 9 SERVICE MANUAL Remove the transport assembly under the clamshell by lowering the assembly then taking out the pivot screw each side On the RH side the cable guard plate will also need to be removed As the assembly is with drawn disconnect the sensor lead each side Support the assembly on the closer avoiding strain on the flexi cables With the assembly now free access can be gained to the lower rollers Remove No 3 separator shaft see section 3 2 1 Detach the spring loaded feed shaft from the insert hopper and withdraw but do not remove the black infeed plate in front of the shaft To do this remove the screw each side at the top corners on the LH side the pulley will need to be removed to access the screw and pull the plate backwards slightly Only sufficient clearance for roller removal is required Remove all gears E clips drive pins T bearings springs and roller bearings from both ends of all four fold rollers On fold roller 2 RH side also detach the end of the no fold spring hooked over the edge of the T bear ing
8. MAINTENANCE AND ADJUSTMENTS 3 2 1 PAPER HOPPER SEPARATOR GAP The separator gap on the paper hoppers prevents more than one sheet of paper being fed at a time It should be adjusted so that a single sheet is fed when drive is engaged to the feed rollers If double documents are being fed the gap may need to be reset To gain access to the adjustment screw remove the LH upper side cover see section 3 1 2 the adjustors are located at the upper edge removal of the sub chassis attached to the main chassis is not required The separator is located under the centre of the 3 feed rollers located at the bottom of the hoppers visible after removing the hopper To set or check the gap wind in by hand a piece of 80gsm 20 Ibs bond paper a fairly firm pull should then be felt when withdrawing the paper though not too firm or sheets may not feed properly If adjustment is required turn the adjustment screw see Fig 1 below until the correct setting is achieved After adjustment is complete check the setting again to ensure it has not moved Note that the adjustment screws are self locking Tufloc screws and if they are at all loose they must be replaced Adjustment screw GAP FAIRLY FIRM PULL ON 80GSM PAPER Fig 1 lf after adjustment sheets are still not feeding reliably or if doubles are being fed the separator must be replaced The pad
9. To replace proceed as follows 1 Remove the nuts marked A amp B and the screws marked C in Fig 6 above Withdraw the plate and strip off the guide rack plates and pinion 2 Replace in reverse order to removal after fitting the rack and pinion and refit the electrics chassis see section 3 1 2 Envelope feed shaft for narrow envelopes Optional feed shaft A3251A is available for narrow envelopes such as C6 This omits the outer roller at each end allowing the side guides to be moved closer together The envelope feed shaft springs out of place for removal ensure that the drive pin is properly engaged when replacing Page 3 6 Minimailer 4 45 3 2 4 DRIVE BELT REPLACEMENT There are 5 drive belts on the Minimailer 4 one each on the RH upper RH lower and LH lower sections and two on the LH upper section There is also one in fold plate 1 To replace any of them the appropriate side cover must first be removed see section 3 1 2 then proceed as follows LH Upper section 2 drive belts 510 DXL 037 F5125A amp 448 DS2M F5084A 1 Remove all screws securing the black subframe leaving wiring undisturbed Also remove the two plastic rivets at the front securing the wiring bridge 2 Main drive belt Referring to Fig 7 below remove the idler and clutches indicated and also the nylon gear Note that access to the idler screw will be eased by removing the clutch on hopper 1 feed shaft this will a
10. assembly and strip off the guide rack plates and pinion 4 Replace the new plate in reverse order to removal after fitting the rack and pinion Note that the sensor bracket should be reasembled while the plate is still loose or access may not be possible The gap adjustment screws must be fitted after the plate is assembled in place use Loctite 221 threadlocking adhesive on the threads 5 Reset the gap and plate tension as previously described ISSUE 3 Mar 2004 5443 Minimailer 4 fer SERVICE MANUAL 3 2 3 ENVELOPE HOPPER SEPARATOR The envelope hopper separator is different from the insert hopper by not having a tension adjustment and by having a downward bias so gap adjustment is by means of 2 Nyloc nuts to move it upwards Separator gap adjustment To adjust the gap withdraw the electrics chassis see section 3 1 2 As an initial setting visually align the tops of the pads with the bottom of the pickup rollers as shown in Fig 4 Then adjust the nuts A shown in Fig 6 below viewed from directly underneath the plate until an envelope will firmly drag as it is passed through the gap GO GO OG CE O Fe KS IIS BO Fig 6 Separator plate replacement If the pads are worn the separator plate assembly must be replaced due to the pads being perma nently glued to the plate
11. cutout This is located as shown in Fig 15 below Fold roller 2 End of no fold beam wrap spring Fig 15 Work roller 1 out of the chassis then roller 2 with the beam attached note that the chassis may need slight springing Remove the remaining rollers similarly either from above or below Fit the new fold rollers after changing over the no fold beam Reassemble all parts in reverse order to removal noting the following points e the T bearing springs are located thus green spring light No 1 roller Yellow spring medium No 2 roller Red spring heavy No 4 roller e the end of the no fold spring must be hooked over the T bearing cutout before assembling the bearing Use long pointed pliers screwdriver to locate it Issue 3 Mar 2004 e if any flexi cables have become unstuck from the chassis stick them back using new double sided tape e ensure the sensors for the transport assembly are reconnected ensure that dowel pins for gears are in place e when reconnecting cables to Distribu tion board 1 note that connector numbers are marked 3 2 6 CONVEYOR BELT REPLACEMENT There are two pairs of conveyor belts on the ma chine one located at the infeed area the other at the closer If the belts are ragged damaged or glazed they may require replacement This will require the removal of the LH lower cover and hinging down the RH cover Also remove the black c
12. indicates a short to ground rather than just a permanently lit sensor SENSORS Blocked 2 0735 bll 120 elr S Clear 11 0033 ell 08 1 bik P Feeder 1 loaded Feeder 1 hold point Collate trigger 1 Feeder 2 loaded Feeder amp hold point Collate trigger 2 bd The first two digits represent the intensity of the emitter in units from 0 to 63 To set the sensor at service intervals clear the machine of paper For each sensor press Enter then use Scroll Down button until the sensor shows blocked then Scroll Up until it shows clear plus 3 further presses When done press the Exit button Encoders are the slotted top hat sensors on the finger operating arm and the slotted disc on the drive motor The read only display reports whether clear or blocked Interlocks are the safety reed switches for clamshell or cover and the location switches on the hopper trays The read only display reports their state Tolerances relate to acceptable limits of insert and envelope depths both upper and lower and are adjustable Units equate to 0 41mm Defaults are 10 for inserts 2 for envelopes so for an insert of nominally 100mm depth 95 9 104 1mm would be accepted gt Issue 3 Mar 2004 Minimailer 4 4s Soak test runs the machine exercising clutches and solenoids Clear the machine of stationery prior to running Calibrate allows adjustment of lengths positions etc as measured by the machine T
13. into the microcontroller close M16C Flasher power down the Mini 4 Plus and transfer the link from the ISP mode to the OP mode cr y ie br i ae el OP ISP OP ISP ISSUE 3 Mar 2004 33 Minimailer 4 Fer SERVICE MANUAL 5 Power up again The microcontroller will now only allow uploads to the External Flash memory 6 Run Miniflash exe as follows Press Select Options and select the correct comms port Press Start the record counter at the bottom right of the screen should now increment rapidly Wait for Upload complete message The file you will be uploading is ext_x x x x m4e Note if the third x of this file ie ext_x x x x m4e is a higher number than the existing firmware then both internal and external memory will need upgrading If it is the same only internal memory need be upgraded fe Once the external flash programming is complete OR if you are only upgrading the internal memory power down and transfer the link from OP mode to ISP mode once again s E LF 11 a i I L ml ss ER Sno A rs ee ce Hd o A fu EE 0 rr OF ISP OP ISP 8 Power up and run the M16C Flasher utility in order to program the microcontroller with the code for running the machine The file you will be uploading is int_x x x x mot Once completed power down 9 For the final time transfer the link from ISP mode to OP mode power up again The machine should now run as normal with
14. or slightly tight Note due to a certain amount of backlash in the moving parts using a single sheet of paper is likely to result in too small a gap or no gap at all It may be found when setting that using 2 or even 3 sheets of paper will result in a correct final gap OMR head Sensor face RS Slide pin Head block To align the head with the marks The sensor contained within the OMR head must align with the centre line of the marks on the paper As the sensor is not centrally located inside the head it must be offset slightly as shown in Fig 20 below The sensor is approximately 7 5mm 0 3 from the non cable side of the head and this is the position that must be aligned with the centre line of the marks To adjust first remove both upper side covers and the front cover if not already removed Slacken the lock screw under the roller carrier and slide it on the rod to suit using a ruler to measure the sensor position Lock the screw when adjustment is complete Approx Fig 20 To change the OMR head position The OMR head can be positioned anywhere across the width of the paper and if the marks cannot be reached by sliding the carrier the head position can be changed in one of two ways a By changing the OMR head to the other side of the sliding head block b By moving the OMR head to a d
15. that Hyperterminal and any other communications application which might be using a serial port is closed down 3 Run the M16C Flasher Utility program You should see a screen similar to below NOTE The very first time MC 16C Flasheris run you will need to set up the COM port settings To do this click on Settings button and select the COM port you are using and a baud rate of 115200 All other settings can be left as default as shown if following image Press the Close button and these settings will be stored in your PC and you shouldn t need to do this again ISSUE 3 Mar 2004 A The status should now say COM1 Ok if you had selected COM 1 If an error status is reported then the COM port may not exist on your PC select another COM port or may be in use by another application close application B Click Connect button After a few seconds the status should show Connecting at 115200 Ok Reading version information Ver 3502 Check Ok If the connection fails check i Link L1 is in the ISP position and that the Mini4 Plus has been power cycled ii Serial cable is properly connected at both ends C Click Program button and select a file from the dialog box the file required for external memory is Extmem2 mot If all goes well the progress bar at the bottom of the window will progress to completion and the status should be reported as below 4 Once this code is programmed
16. the new firmware loaded ee 0e tp Lal 1 amp m TET a ns J Page 3 20 3 5 RECOMMENDED SPARES LIST Minimailer 4 The following spares are recommended to be held by Service Agents complete set can be ob tained by ordering part number A0321A covers both 220v and 110v machines Quantities stated are per 5 machines Part No Description Mechanical Spares A2456A A2457A A2463A A2472A A2757A A2782A A2890A BO114A C2653A C8098A C8142A C8143A C8144A C8146A C8147A C8148A C8149A C8157A C8158A C8159A C8161A C8162A C8163A C8164A C8165A C8170A C8172A D0022A D0024A D1039A D1040A D1067A E0253A E1061A E1078A E1080A E1107A E1119A Finger Assy RH Finger Assy LH Disc Hub Assy Insert Roller Assy Wetter tank Assy Separator Assy OMR Head Kit Collate Spring Envelope Feed Bearing Roller Envelope Feed Fold Roller 30mm Dia Fold Roller 25mm Dia Shaft Sheet Feeder Shaft Envelope Flap Shaft Opener Eject Shaft Opener Infeed Pressure Insert Roller Shaft Assy Shaft Roller Closer Shaft Flapper Input Drive Shaft Fold Plate 1 Lower Shaft Fold Plate 2 Shaft Insert Stage Shaft Transport Shaft Pressure Roller Shaft Envelope Transport Roller Seal Shaft Insert Infeed Roller Transport 25 x 8 Roller Insert Sensor Mount 0 9 1 2mm T Bearing 8mm T Bearing 6mm Insert Foot Ball Bearing 8 x 16x 5 Bearing Flanged Bearing Flanged 3 8
17. Check solenoid plungers for smooth action see section 5 1 for location of solenoids Check that springs are in place and undamaged Check security of all clutch pins Check general screw security Check for excessive noise squeaks etc and rectify where necessary Enter Engineer Test Mode Section 3 3 Select Clutches and Solenoids and test these components Also run 18 19 20 21 22 23 24 Page 3 3 SERVICE MANUAL master drive train in Clutches to check for proper running Select Sensors and check the condition of all sensors Use the explanations in section 3 3 2 as a guide Check microswitches on paper hoppers When any of these items are removed the machine should not operate and an error message should be displayed Replace all machine covers and run machine in modes normally used by customer Open clam shell and check that the gas struts support the top section when fully open Check for wear in all bearings replace as necessary and lubricate T bearings should be lubricated with one or two drops of light SAE 20 oil applied to the outside of the bearing where the shaft passes through it If gears run noisily lubricate sparingly with grease Apply very minimal amounts to gears in the vicinity of the sensor disc Check security of all electrical connectors Visually examine flexi ribbon cables to check for cracking or damage ISSUE 3 Mar 2004 3 2
18. J15 MCU to Distribution Board 2 J13 MCU to Distribution Board 2 J14 MCU to Distribution Board 3 J12 MCU to Distribution Board 4 J11 Distribution Board 1 J11 to Sensors Distribution Board 1 J10 to Sensors amp Distribution Board 5 Conn A Distribution Board 1 J8A to Sensors Distribution Board 1 J9 to Sensors Distribution Board 2 J6 to Sensors Distribution Board 2 J5 to Cover Switches Distribution Board 3 J11 to Hopper Switches Distribution Board 4 J5 to Disk Sensor Distribution Board 5 Conn C to Sensors Distribution Board 5 Conn B to Sensors Distribution Board 1 J8B to Sensors Page 3 16 3 3 ENGINEER MENU The Engineer function allows components such as motors and solenoids to be tested sensors to be set and provides voltage and current readings for power sources It also provides a number of other functions all ofwhich are described here To access the Engineer menu the PIN must first be entered Use the Scroll Up Down buttons to select each number then press the Enter button to move to the next Press the Exit button when all three numbers are entered The menu will then be displayed P Software version English Language Display contrast EJ Feeders Power Clutches Software version is a read only display Note that software is upgradeable either by insertion of anew eprom or by a flash download Language for the Menus and Help may be changed to one of five languages Display contrast can be cha
19. and take off the belt Remove the E clip and bearing and on the upper clutch shaft remove the drive pulley E clips and bearing note that there are 2 E clips at this loca tion On the RH side remove the clutches and idler indicated and take off the belt Remove the E clip and bearing and on the upper clutch shaft remove the drive pulley E clips and bearing With both ends of both shafts now free draw the RH ends out through the chassis suffi ciently to allow the belt to be taken off at the LH ends Fit the new belt and reassemble in reverse order to removal Refit the MCU subframe 3 2 5 FOLD ROLLER REPLACEMENT There are 4 fold rollers on the Minimailer 4 three are identical rollers 1 2 amp 4 in Fig 13 below roller 3 is the driving roller and has a longer shaft All rollers are the same diameter If any have to be replaced they should all be replaced together as a set Fold roller 1 Fold roller 2 with no fold beam Fold roller 4 Fold roller 3 Fig 13 Removal of the rollers is a fairly extensive task but can be accomplished without completely removing the upper subframes under the side covers The procedure Is described below 1 On the upper RH side swing open the MCU subframe as shown in Fig 2 and on the black subframe below remove the screws indicated in Fig 14 below but do not remove the subframe Note that the flexi cables must be unclipped to access the
20. are as shown above and should not normally require adjusting Page 3 18 3 4 FIRMWARE UPGRADING The firmware is stored in 1 Internal flash memory of the microprocessor 2 External flash memory devices on the MCU You will require two utilities for the upgrading process MC 16C Flasher and MiniFlash These can be obtained from Technical Support or the PFE website You will also require a serial cable PFE part no 182 194 and a PC Important On most occasions it will only be necessary to upgrade the internal memory in which case the procedure should be started at step 7 bypassing the programming of the external memory In the event that external memory needs upgrading also the procedure should be started from step 1 See the note in step 6 for details of determining which procedure should be used Method Board Programming Sequence Refer to drawing below for the location of the serial connector and the board link position 1 With the Mini 4 Plus switched off plug the serial cable from the PC into the 9 way D Type connector located centre right of the board 39 Minimailer 4 PM Page 3 19 SERVICE MANUAL Transfer link from OP Operational mode to ISP In System Programming mode 7 i a hos D e w 2 Power up the machine it will now in In System Programming mode The display will be blank and all LEDs will be in the off state Don t get alarmed this is perfectly normal On the PC make sure
21. ed length and clipped back into place The connector plugs into J5 on the MCU board When all adjustments are complete refit all covers and test run the machine to ensure that the marks are being read correctly Setting up the OMR head When the head has been attached and aligned as previously described it will require setting up to ensure consistent reads This is carried out in Engineer Mode using a piece of representative marked paper Proceed as described below 1 Enter Sensors in Engineer Mode and carry out an Autocalibrate 2 Scroll down to OMR in Sensors as shown below SENSORS Envelope stuff ideer Fold plate 1 1100 Fold plate 2 fiber Elect 11000 pour iOer S Display temperature oc Issue 3 Mar 2004 3 Scroll the OMR setting up or down until it reads 20 4 Load OMR marked paper into hopper 1 and open the clamshell Using the lowermost gear on the LH side wind in the paper by hand so that a white area is under the head 5 Increase the setting until the display changes from cl clear to bl blocked then add 3 White will then be correctly indicating as blocked ie paper present Fault Finding amp Testing If problems such as bad reads or no reads are being encountered the signal from the OMR head can be analysed using a PFE OMR Scope part number 184 415 and a PC or laptop This provides an on screen trace of the head signal and indicates whethe
22. emoval 39 Minimailer 4 PM Page 3 11 SERVICE MANUAL Removal of transport plate assembly see Fig 18 below viewed from front of machine with feed hopper removed Transport plate assembly Fig 18 1 Undo all screws retaining the black subframe on the LH side and slide off the S2M pulley shown in Fig 17 the subrame will move sufficiently to allow this 2 Remove the separator shaft for hopper 3 as described in section 3 2 1 3 Remove the screws retaining the posts at the upper corners of the transport plate assembly 4 Unplug the flexi cable for the two sensors on the plate assembly this connects to CONN C on Distribution board 5 on the RH side upper left connector Lead the cable through the hole in the chassis side plate so that it is inside 5 Pull the assembly rearwards to free the lower edge and withdraw it Note that the plate can now freely hinge open and the springs for the roller shaft will be loose 6 The roller shaft in the plate assembly can now be replaced after removal of the E clips 7 Refit all items in reverse order to removal Issue 3 Mar 2004 5443 Minimailer 4 Per 3 2 8 OMRHEAD ADJUSTMENTS When an OMR head is fitted it can be attached anywhere across the width of the machine to suit the stationery being processed Its position can later be changed if required as described later in this section The head is mounted on a spring loaded block which is ad
23. his compen sates for any errors due to machine tolerances Units equate to 0 41mm The meaning of positive negative is as follows All lengths All collates Envelope position Wetter position ve longer ve closer to leading edge ve later at insert position ve earlier ie more flap wetting ve moves forward to eject earlier ve more deskew ve more advance Closer position All deskews All advances If the machine is to be completely reset use the following initial settings items marked area starting point others are usually constant All settings are for 220v or 110v unless otherwise indicated Form 1 Length 62 Form 2 Advance 24 Form 2 Collate 48 Form 2 Length 6 Form 3 Collate 15 Form 3 Length 5 Insert Deskew 0 Insert Advance 0 for 220v 30 for 110v Insert Collate 11 Insert Length 3 Envelope Deskew_ 30 EnvelopeLength 5 Envelope Position 13 Fold 1 Length 3 Fold 2 Length 28 Wetter Position 20 Envelope Closer 25 F Plate 2 Delay 50 Env Ins DS 397 Use Stack n Go to run form from hopper 1 When machine stops for check enter Edit Job and check measured length against actual length adjust if required in Calibrate select Save amp Exit to leave Stack n Go With length now correct repeat for fold lengths adjusting as required Repeat this prcedure for hoppers 2 and 3 and also check edge alignment when collating including inserts Check en
24. ibed above in front of the pickup shaft being removed ie for hopper 2 pickup shaft remove hopper 1 separator For hopper 1 pickup shaft remove the chassis bridge strip in front of the shaft 2 plastic clips at each end avoid straining the flexi cable The strip need only be moved far enough to allow the removal of the shaft 3 On the LH side remove the clutch from the end of the shaft and also the brake on the other end Note that no brake is fitted to hopper 1 4 On the LH side remove the two belt tensioning jockey posts located on the lowermost run of the belt these have a central screw Page 3 4 Minimailer 4 45 5 Remove the feeder loaded sensor for the relevant shaft This is located inside the chassis bridge above the shaft retained with a single screw on top of the bridge Also remove the hold point sensor located between 2 of the feed rollers by unclipping it from its holder 6 Remove the XL pulley from the end of the shaft after lifting the drive belt clear Take care not to displace the dowel for the clutch Remove the E clips and T bearings from the ends of the shaft and work it out of the chassis through the slots in the sideplates 8 Replacementis the reverse of removal Set the separator gap as previously described 3 2 2 INSERT HOPPER SEPARATOR GAP The insert hopper has two adjustments one for the separator gap the other for the tension of the plate holding the separator pad
25. iffer ent carrier position To move the OMR head to the other side of the carrier refer to Fig 19 Slacken the screw under the OMR head and slide it off the retaining peg Slacken the grub screw in the end of the sliding head block and remove the retaining peg Move the peg to the other side of the block and reassem ble all parts in reverse order ensuring that the edge of the OMR head is located firmly under the flange of the head block Adjust the gap and position as previously described Minimailer 4 45 Page 3 13 SERVICE MANUAL To move the OMR head to another carrier position The carrier holding the OMR head is different from the others and hence the OMR pressure shaft will have to be removed First remove the OMR head from the retaining peg and support it avoiding strain on the cable Referring to exploded view section 4 6 remove the E clips T bearings and springs supporting the OMR pressure shaft item 3 and take out the shaft complete with carriers Strip down the assembly as required and reassemble with the OMR head carrier in the required position Refit the shaft in reverse order to removal and adjust the OMR head gap and alignment as previ ously described When changing the OMR head position it may be necessary to lengthen or shorten the cable to suit The cable is looped in retaining clips along the front edge of the machine and should removed from the clips looped up again to suit the requir
26. is glued into the separator arm and both must be replaced as an assembly Do not attempt to replace the pad only Note the pick up roller above the pad is more likely to wear than the pad itself if the pad is worn out the pick up roller probably is also and should be replaced at the same time The procedure for any of the 3 hoppers is the same and is described on the following page Issue 3 Mar 2004 5443 Minimailer 4 fer SERVICE MANUAL Remove LH and RH upperside covers section 3 1 2 to provide access to the separator shafts Also remove the relevant feed hopper s To remove the separator 1 Remove the adjustment bracket shown in Fig 1 from the end of the separator pivot shaft after unhooking the spring 2 On the RH side open the clamshell and remove the screws securing the MCU subframe as shown in Fig 2 below avoid straining the flexi cables This allows the subframe to swing outwards to provide access to the shaft ends x DISPLAY PANEL A A MCU BOARD FESSES Rene eee eee DISTRIBUTION BOARD 1 Le Are ee en Fig 2 3 Remove the E clip and T bearings at both ends of the pivot shaft Work the shaft out of the chassis cutouts and remove it 4 Replacement is the reverse of removal Set the separator gap as previously described Removal of pickup roller shafts 1 Swing open the subframe as described above 2 Remove the separator as descr
27. is manual SERVICE AT 6 MONTHS OR 100 000 INSERTS 1 Refer to section 3 1 1 General 2 Remove all machine covers Section 3 1 2 3 Clean and inspect condition of all rollers jogglers rubber transport wheels and conveyor belts Section 4 3 Operating Instructions Replace any that are worn Minimailer 4 45 10 11 12 13 14 15 16 17 Check insert separator gaps for setting skewing and wear particularly examine paper hopper separator pads Reset replace if required Section 3 2 1 2 Check that envelope and insert feed shafts can be removed and replaced easily and that the spring holds them in place with sufficient tension Blow dust from all sensors Section 4 3 Operating Instructions Check envelope and insert side guides for movement stop position and parallelism to chassis Check all T bearing pressure springs are correctly located on tops of bearings Using an airduster remove LH lower side cover Section 3 1 2 and clean sensor disc on main drive clutch bottom rear corner to ensure that slots are not blocked Check free movement of finger pivots and condition of finger tips and springs Replace fingers if tips are worn or damaged On RH side lower check condition of finger solenoid rubber bump stops noisy running will develop if these are perished or missing Check condition of wetter tank foam pad and wetter beam foam pad Replace if worn
28. justable to provide the correct gap between the head sensor and the rubber roller Additionally the head must be correctly aligned widthways to ensure that the centre of the OMR sensor is in line with the centre of the marks on the paper The assembly as shown in Fig 19 below attaches to a special roller carrier which replaces one of the standard carriers on the machine To adjust the head gap If the head position has been changed see later in this section or if bad OMR reads are being en countered the head gap may need adjusting This gap should be no more than 0 1mm 004 equiva lent to a single sheet of 80gsm 20lbs bond paper The adjustment procedure is described below Retaining peg Adjustment screw D N Fig 19 ISSUE 3 Mar 2004 Page 3 12 SERVICE MANUAL Remove the upper side covers and the front cover in front of hopper 1 see section 31 2 Referring to Fig 19 below slide a piece of 80gsm 20lbs bond paper between the sensor face of the OMR head and the rubber roller the paper must not be under the roller on the adjustment plate Slacken the adjustment screw to allow the head block to move in and out against spring pressure Ensuring that the paper is a sliding fit between the sensor face and the rubber roller and that the roller of the adjustment plate is contacting the rubber roller tighten the screw Carefully check the setting to ensure that the paper is still a sliding fit
29. llow the subframe to be moved upwards Lifting the subframe as required remove the belt note that one sensor cable may have to be disconnected to release the belt 3 Fit the new belt following the route shown and refit the idler gear and clutches Clutch Clutch Clutch and nylon gear Fig 7 4 Insert feed drive belt Referring to Fig 7 above remove the clutch and idler indicated Remove the belt Fit the new belt and refit the idler and clutch Refit the subframe securing cables with new cable ties as required Page 3 7 SERVICE MANUAL LH Lower section 1 drive belt 300 XL 037 F5023A 1 Remove only the subframe screw indicated in Fig 8 below this will allow the end to spring sufficiently to allow belt removal under the bracket Fig 8 2 Remove the clutch idler and gear with E clip indicated in Fig 9 below and also unclip the Distribution board from its mounts Remove the old belt under the raised subframe backet and fit the new one Re place parts in reverse order to removal 3 Refit the subframe ensuring the flexi cable is stuck back onto the bottom edge and secure all cables using cable ties as re quired Clutch Idler Gear with E gt ISSUE 3 Mar 2004 SERVICE MANUAL 5443 Minimailer 4 fler RH Upper section 1 drive belt 560 S2M Fold Plate 1 1 drive belt 100 S2M F5111A F5072A 1 On the u
30. n A4 for European machines and 217mm slightly greater than Letter for US machines as shown in Fig 21 below If forms of a different width are being fed the outer fingers must be adjusted to suit open the clam shell to gain access Slide the fingers on the shaft to suit note that they should be a tight fit The width across the tips should always be slightly greater than the form width by 1 2mm and the fingers must be centrally disposed about the centre line of the machine Note when collating in the envelope for multiples the outer fingers may need Minimailer 4 45 SERVICE MANUAL to be adjusted further out by up to 3mm in order to pull the throat futher open The exact setting will depend on the type of stationery being used The inner fingers should always be set inboard as far as possible If narrow envelopes are being used such that the envelope width would be inboard of the outer fingers these are left in place but ig nored Instead the inner fingers should be swapped over as shown in Fig 19 and adjusted as described above for the outer fingers Note that the fingers are fitted with a peg inside the clip which runs in a groove on the carrier bar hence they cannot rotate on the bar E INNE FINGE SEN S DE FO NA OW C NVE
31. nged if required between 0 and 63 Default is 50 Feeders determines whether feeders 1 2 amp 3 default to on or off at startup These states can be changed in Create Edit Job Power provides a read only display of voltages and currents of various supply sources The voltage and current readings are displayed to two decimal places and AC motor speed enables the drive motor to be switched on or off and the RPM observed Note that due to the gearing this figure must be multiplied by 3 POWER b 24 voit supply 2388V 5 volt supply O495V 3v3 supply 0328W 24 volt supply current 000A 0 544 5 voit supply current ava Supply current T Minimailer 4 45 Page 3 17 SERVICE MANUAL Clutches and Solenoids allow you to switch these components on or off to test them and provide a readout of current rating The whole drive train can also be switched on or off Sensors There are three types of sensors fitted a proximity sensors eg Feeder x Loaded which are only reported as blocked or clear b digital sensors which are adjustable and will display 0 for clear 1 for blocked and ADC sensors also adjustable which display a 4 digit indication of the TX RX correlation in units from 0 to 1023 A blocked sensor will give a higher reading than a clear sensor with a threshold of about 256 Generally a clear sensor should not be too close to the thresh old If the value is close to zero this
32. oth or rag round the gear and turn it by hand while pressing down on the top roller roller to stop the gear springing The jammed documents will then be wound into either fold plate 1 or 2 depending on the direction the gear is turned Note also that the transport plate under hoppers 1 and 2 can be lowered by pulling in the spring loaded handle in the centre recess This is another possible though less likely area for paper jams surfaces using double sided adhesive tape When replacing use new double sided tape the adhesive strength of used tape will not retain the cable sufficiently and it may come free and be come caught in mechanism The ends of the flexis are retained in special connectors on the circuit boards To free a cable do not just pull it out pull the top edge outwards to unclip the cable end Replace in a reverse manner The full list of flexi cables is shown below Use this list in conjunction with the wiring diagram shown in section 5 8 Connection Identity Part Number FS01 182 591 FS02 182 592 FS03 182 593 FS04 182 594 FS05 182 595 FS06 182 596 FS07 182 597 FS08 182 598 FS09 182 599 FS10 182 600 FS11 182 601 FS12 182 602 FS13 182 603 FS14 182 604 FS15 182 606 FS16 182 605 FS17 182 607 FS18 182 629 FS19 182 630 FS20 182 631 ISSUE 4 Mar 2006 MCU to Display Board Switch MCU to Display Board MCU to Distribution Board 1 J17 MCU to Distribution Board 1 J16 MCU to Distribution Board 1
33. over on the RH side 2 screws at the bottom edge 1 screw near the centre on the inside then proceed as follows Closer belt Insert belt Fig 16 1 Remove the front underpanel by taking out the 3 screws either side at the lower edge and removing the panel with attached envelope tray after lifting the front of the machine up 2 Remove the LH lower drive belt see Fig 8 Insert Belt 3 Remove the solenoid bracket on the RH side to provide access to the end of the roller shaft it need not be taken fully off 4 Remove gear pulleys E clips drive pin and T bearings from both ends of both shafts indicated in Fig 16 above 5 Raise the front of the machine and work the shafts and belts out of the chassis from below Fit the new belts and replace the shafts 6 Refit all parts in reverse order to removal ISSUE 3 Mar 2004 5443 Minimailer 4 Per SERVICE MANUAL Closer Belt T On the LH side ensure the drive belt is removed as described at step 2 8 Remove pulley E clips drive pin and T bearings from both ends of upper and lower shafts indicated in Fig 16 Note that the green knob and gear on the RH side need not be removed 9 On the RH side remove the screw retaining the guide plate below the green knob and slide the plate out 10 Remove the tension shaft screws 1 each end 2 on front face 11 Raise the front of the machine and remove the lowe
34. pper RH side swing open the MCU 1 Swing open the MCU subframe as shown in Fig 2 subframe as shown in Fig 2 Lower fold plate 1 under the insert hopper and open the clamshell Remove the 4 2 Referring to Fig 10 below remove the lutch s and idier indicated countersunk head screws holding the upper part of the foldplate and lower it down The 3 It is now possible to remove the old belt in drive belt is now visible under the hopper the gap between the end of the upper shaft and the black subrame without disturbing Idler the subframe Fit the new belt positioning it Clutch over the lowest pulley first Le De 4 Refit the clutches and idler and re attach the Idler subframe Ensure the clutch bodies have properly located on the lugs Clutch Idler Clutch Fig 10 RH Lower section 1 drive belt S2M 322 F5145A 1 Remove the black cover under the side cover by removing the two screws at the lower edge and slackening the screw near the middle note that slots allow it to lift off Referring to Fig 11 below remove the tension idler indicated and take off the old belt Fit the new item and replace all parts in reverse order Issue 3 Mar 2004 Fig 11 Page 3 8 E clip amp bearing Fig 12 Referring to Fig 12 above on the LH side remove the clutches and idler indicated
35. r roller and tension shaft from below Lift out the upper roller and withdraw the belts from above 12 Fit the new belts and all other parts in reverse order to removal Page 3 10 3 2 7 INSERT TRANSPORT ROLLERS The insert transport shaft is located on the insert hopper after the spring loaded feed shaft The rollers feed the insert down to hold point position and then hold it until the insert is clear to feed The shaft carries 4 rollers and a sprung roller shaft is located in a plate assembly just above it this presses on the drive rollers to provide traction If feed problems such as excessive skewing or slipping are occurring the rollers may need re placement This will involve removal of the transport roller shaft and also the transport plate assembly Removal of transport roller shaft 1 Remove the LH and RH upper side covers section 3 1 2 2 On the RH side swing open the MCU subframe section 3 2 1 3 Remove the lower shaft for fold plate 1 drive belt as described in section 3 2 4 Fold Plate 1 on page 3 8 Ignore all steps relating to the upper shaft this need not be removed nor the drive belt see Fig 17 below Upper fold plate shaft Transport roller shaft Lower fold plate shaft Fig 17 4 Remove E clips and T bearings at both ends of the transport roller shaft and remove the shaft from the chassis 5 Refit the new shaft and all other items in reverse order to r
36. r the head is reading the marks correctly 10 WAY DUAL HEADER 162 267 5443 Minimailer 4 fer SERVICE MANUAL 6 Wind the paper in further and check that the display changes from bl to cl as the mark is read cl should also indicate a higher reading after the decimal point than bl 7 The head is now set up Test the machine on an OMR job to check if it is working correctly If misreads occur return to the setting and increase it by steps of 1 until reading is correct If it is not possible to correct the misreads test the head as described below Full instructions for using the OMR scope are provided in OMR Scope User Manual part number K2023A A number of cables are included with the scope and a scope adaptor will also be required as shown below in the connectivity diagram Note that if your computer only has a USB port available instead of aCOM port USB adaptor 179 746 will be required not included with the Scope TO PC SERIAL Jo TEST al SCOPE ADAPTOR 184 166 oD MCU BOARD Ro 29D gD UNR SGOFE aL IP PG PAS USB ONLY USE ADAPTOR 179 746 ISSUE 3 Mar 2004 Page 3 14 3 2 9 FINGER ADJUSTMENT The finger positions are factory set and for most purposes should not normally require adjustment The width across the outer fingers is set to 212mm slightly greater tha
37. s The separator plate is located below the insert hopper To gain access lower fold plate 1 under the hopper and open the clamshell Remove the 4 countersunk head screws holding the upper part of the foldplate and lower it down The separator plate is shown in Fig 3 below viewed as from directly underneath Separator tension nuts 2 Separator gap screws 2 Fig 3 Page 3 5 SERVICE MANUAL Separator gap The gap should be set so that when looking down the insert hopper tray the tops of the separator pads are aligned with the bottom of the pickup rollers as shown in Fig 4 below If adjustment is required equally turn the separator gap screws shown in Fig 3 until the setting is correct m ALIGNED Separator pads Fig 4 Separator plate tension The separator plate is held under slight tension to allow lightweight inserts to be fed without doubles and if a thick insert such as a booklet is fed the plate will flex sufficiently to allow it through The tension is factory set at 5N on top of the separator pads which can only be determined using a force gauge Therefore should the plate require retensioning after replacement for example
38. velope position at insert by using Job Mode to walk through cycle see Operating Instructions section 3 9 flap crease should be in line with centre of small pinch rollers Adjust insert or Issue 3 Mar 2004 SERVICE MANUAL envelope deskew only if required ve means deskew Is increased Clutch overlaps relate to the time period that a clutch and its corresponding brake are on simulta neously Units are in millisecs defaults shown below Alter with care to avoid strain caused by excess overlap All settings are a starting point and are for 220v or 110v Feeder 2 10 Feeder 2 10 Insert Deskew 15 Env Deskew 10 Env Position 10 Foldplate 1 1 Foldplate 2 1 Env Closer 1 Optimizations control settings that allow the machine to run at maximum possible speed OPTIMIZATIONS Envelope pre feed Envelope track trigger Feeder 1 delay Feeder 2 delay Feeder 3 delay Insert feeder delay Envelope pre feed allows an envelope to be fed to deskew position while the preceding one is still at insert So minimising delay Envelope track trigger feeds an insert when the track sensor is triggered by an envelope Both these settings should only be turned off if special circumstances require the machine cycle to be slowed Feeder delay settings advance or retard the point at which the sheet or insert is fed and is used to fine tune the optimimum performance Units are in approx 0 5millisec steps Defaults
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