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SERVICE MANUAL

1. 1 R39 FOR B484J385 2 m Kio 47K 4 fee 50024 R37 OES 5 2 55 60 1K CTR 1 5V 5V O VAREF P64 2 CN17 BLACK 1 54 R38 CS B Ea ov 0 vass 57 1K R40 1 PINK co
2. 1264 PWR 1 pin7 12V 24V Q5 collector ov Fig 5 6 3 24V Power Supply 5 20 Chapter 6 MAINTENANCE CONTENTS Chapter 6 MAINTENANCE 8 ccc 6 1 611 Table of Lubricants 6 1 6 1 2 Precautions during Lubrication 6 1 6 1 3 Lubrication 1 00 nnmis 6 1 6 3 3 Adjusting Perpendicularity of Chassis and Document 6 20 6 1 6 1 1 6 1 2 Lubrication After the parts of 6 1 3 are replaced apply lubricant to the positions indicated in 6 1 3 Lubrication Positions below If only one of a pair of touching parts is replaced lubricant remains on the other part and no further lubrication is required If both of a pair of touching parts is replaced lubricant must be applied to the indicated position Table of Lubricants Use the lubricants designated below The codes in the table below are used in the descriptions in section 6 1 3 Lubricant Name Epinoc grease 1 Silicon grease KS64F Precautions during Lubrication e Do not apply lubricant to parts other than the specified parts The lubricant may adversely affect plastic parts or PCBs e Take care not to apply too much lubricant which can then drip onto other parts As a guideline apply a drop the size of a grain of rice e Apply lubricant to co
3. Fig 3 11 2 Removing the Gears 2 Remove the two Gear holders simultaneously Remove the Gear holder spring from the Gear holders The Gear holder spring may be stretched if the Gear holders are removed separately Gear holder Idle gears B Gear holder Fig 3 11 3 Removing the Gear Holders and Gear Holder Spring 3 26 3 12 Right Side of the Main Chassis 3 12 1 Removing the Right Side of the Chassis Remove the two Idle gears Remove the two SG motor screws and remove the SG motor Remove the Leaf switch SG screw then remove the Leaf switch SG assy Eom Remove the T lever shaft SG motor SG motor screws Idle gears A Chassis R support T lever shaft ic Sel Chassis support screw Leaf switch SG assy rss d Leaf switch SG assy screw Fig 3 12 1 Removing the Right Side of the Chassis 1 5 Push down on the T lever unit to align the slot hole with the shaft then remove the unit T lever A T cam roller Fig 3 12 2 Removing the T lever Unit 3 27 6 Remove the Control cam gear and Double gear S Double gear S 6 H Control cam gear 52 CG Fig 3 12 3 Removing the Right Side of the Chassis 2 7 Remove the screws then remove the Chassis R support See Fig 3 12 1 3 12 2 Removing the YC Lift Shaft and LF Change Shaft 1 Remove the Paper eject roller springs 2 Remove the Y extension spring 3 Remove the Retaining ring for the YC
4. 387 mm Fig 1 1 1 Appearance 1 1 2 Operating Panel 1 Number of Keys 7 Start key Stop key Cut key Feed key Extra border key Continuous key Cutting mode selector 2 Key Arrangement Power switch Continuous key Stop key Startkey Cutting mode selector 1 EQ ed Tw MES es Feed key Extra border key Fig 1 1 2 Key Arrangement 1 1 3 Indicators 1 Positions Start key LED green Continuous key LED green Extra border key LED green Error LED red 1 2 Electrical Specifications 1 2 1 Power Supply 1 Power supply Commercial power supply locally available power supply Converted to DC by the AC adaptor Chapter 2 MECHANISMS CONTENTS Chapter 2 MECHANISMS 2 1 Mechanical Operating Principles 2 AA edie 2 1 211 Description of Mechanisms Border Mode 2 1 MEER 2 2 2 1 3 Cutter Mechanism Border Mode 2 1 4 Paper Size Detector Mechanism 222 22 2 7 2 9 2 1 Mechanical Operating Principles 2 1 1 Description of Mechanisms Border Mode 1 When a document is inserted into the paper loading gate the paper feed rollers feed it to the driving roller 2 Asthe document passes between the paper feed rollers the paper size detector determines its size length and width 3 When the document passes between the
5. FEET 4 27 4 15 ee ee eee ee eee 4 28 4 28 4 28 MI 4 29 Installing the Chassis Assy 4 29 4 30 4 17 2 Installing the Dial Switch 4 33 num 4 35 pM 4 35 4 36 EE ET 4 37 4 17 8 Installing the Paper Tray and Paper Guide 4 39 4 17 9 Installing the 1 2 4 40 5 4 41 DE 4 41 4 18 Installing the Y cutter 4 4 42 e 4 43 4 19 1 Installing the 4 43 cece 4 44 4 1 Safety Precautions When conducting reassembly operations place the unit on a grounded anti static sheet LSI and other electronic components are sensitive to static electricity and may be damaged if touched while charged Before transporting a circuit board wrap it in a conducting sheet such as aluminum foil When using a soldering iron or other heat producing tool ensure that heat does not damage wires circuit boards or plastic parts such as covers Take car
6. 022044444 enne nnne nennen nennen reset 4 7 51 Assembling the Trimming Assy 4 6 1 Installing the Paper Eject Roller Unit and Y diversion Lever 4 8 4 6 nstalling the Paper Eject 2 4 9 4 7 Right Side of the Main ChassiS cecceesceseeeeeeeeeeeeeeeeeeeeseeeeeaeeeaeeseeeeeaeeseeeneeenaeeeeeeas 4 10 4 7 1 Installing the YC Lift Shaft and LF Change 4 10 4 8 ett Side of the Chassis 0 1 1 116 66 nensis nsn snas sand an 4 14 4 8 NStalling ne Gears icai Ee seio ei Eo waite 4 14 4 8 2 Installing the LF Motor 4 15 4 9 iPaper Feed Roller 5 tret erret trente rete tenen rue 4 16 Y2SENSOF Rail MIR NR 4 20 4 11 1 Assembling the Y sensor Rail Unit Attaching Y sensor PCB Assy 4 20 TRIER TU ESI cern errr 4 22 4 12 Y CA Chassis Assy and Y Cutter 4 23 4 12 1 Installing the Y cutier Arm discrecien 4 23 4 12 2 Installing the Y GA MOIlOTr 1er ertet eene race 4 24 PRENNE 4 24 ES Se ee 4 26 M 4 26 4 13 2 Installing the X cutter 4 26
7. When leaf switch CSIZE3 is shorted is CN6 on the Main PCB shorted Is main CPU port P14 Pin 21 at Low level when CN6 on the Main PCB is shorted When main CPU port P14 Pin 21 is at Low level is this recognized by the main CPU Incorrectly inserted cartridge Incorrectly installed leaf switch assy Conductivity problem in Main PCB Defective pull up resistor R49 Defective leaf switch assy Conductivity problem in Main PCB Defective series resistor R45 Defective main CPU S8 7 22 Re insert the cartridge Correctly install the leaf switch assy Replace Main PCB assy Replace Main PCB assy Replace leaf switch C3 assy Replace Main PCB assy Replace Main PCB assy Replace Main PCB assy Replace R49 Replace R45 Replace Buzzer does not sound a Defective buzzer circuit See a Defective Are 4 kHz pulses output Defective main Replace Main PCB Replace buzzer circuit from DVO Pin 20 on main CPU 3 assy CPU 3 Are correct voltages applied Defective resistors Replace Main PCB Replace R36 across buzzer BZ1 R36 and R69 assy and R69 Buzzer BZ1 does not Defective buzzer BZ1 Replace Main PCB Replace BZ1 sound assy 7 23 Appendix Main PCB Circuit Diagram
8. TAPTITE CUP M3 x 5 0 49 to 0 686 Nem 5 to 7 kgfecm LF motor holder screw TAPTITE CUP x 20 0 49 to 0 686 Nem 5 to 7 kgfecm Y CA sensor PCB screw TAPTITE PAN B M2 x 8 0 196 to 0 392 Nem 2 to 4 kgfecm Y sensor rail screw TAPTITE CUP x 5 0 49 to 0 686 Nem 5 to 7 kgfecm Y sensor carriage arm screw _ _ _ SCREW BIND B TITE M3 x 10 0 49 to 0 686 Nem 5 to 7 kgfecm Y CA motor screw SCREW FLANGED M2 6 x 5 0 196 to 0 392 Nem 2 to 4 kgfecm Sensor holder screw TAPTITE CUP M3 x 5 0 49 to 0 686 Nem 5 to 7 kgfecm Y CA chassis screw TAPTITE CUP M3 x 5 0 49 to 0 686 Nem 5 to 7 kgfecm Switch PCB screw TAPTITE BIND M3 x 12 0 49 to 0 686 Nem 5 to 7 kgfecm Jack PCB screw TAPTITE BIND B M3 x 8 0 49 to 0 686 Nem 5 to 7 kgfecm Main PCB screw TAPTITE BIND x 8 0 49 to 0 686 Nem 5 to 7 kgfecm Bottom cover screw A TAPTITE CUP B M4 x 12 0 98 to 1 176 Nem 10 to 12 kgfecm Bottom cover screw B SCREW BIND M3 x 6 0 49 to 0 686 Nem 5 to 7 kgfecm Ground wire screw SCREW CUP x 5 0 49 to 0 686 Nem 5 to 7 kgfecm PST PCB screw SCREW BIND M3 x 6 0 49 to 0 686 Nem 5 to 7 kgfecm Push switch 1 screw 5 SCR
9. Chassis assy Removing the Chassis Assy 4 Fig 3 4 7 3 15 3 5 PCBs 3 5 1 Removing the Main PCB 1 Disconnect the power harness assy red black from the Main PCB 2 Remove the four Main PCB screws Remove the Main PCB Main PCB screw Power harness assy Main PCB assy Main PCB screw Fig 3 5 1 Removing the Main PCB 3 5 2 Removing the Jack PCB Assy Remove the Jack PCB screw and remove the Jack PCB assy core shown in the diagram is fitted in the EU specification LX 300 only Jack PCB screw Jack PCB assy Fig 3 5 2 Removing the Jack PCB Assy 3 16 3 5 8 Removing the Switch PCB Assy 1 Remove the eight Switch PCB screws from under the Body cover Remove the Switch PCB assy Switch PCB assy Switch PCB screws Fig 3 5 3 Removing the Switch PCB Assy 1 2 Remove the Start key Stop key Two connection switch Continuous key and Extra border key The LED lenses can be removed from the Top cover by pushing them hard with a fine object such as a pen tip LED lenses S LED lens 1 Extra border key Stop key Y 9 gt NN Z N rm Two connection switch Continuous key Start key Fig 3 5 4 Removing the Switch PCB Assy 2 3 17 3 6 X cutter Unit 3 6 1 Removing the X cutter Unit Remove the Y cutter assy 2 Remove the two X cutter screws Move the X cutter unit tow
10. Fig 6 1 11 Sub Roller Shaft Bearings Roller holder spring mounting 1 position Roller holder spring Fig 6 1 12 Roller Holder Spring Mounting 6 5 Y cutter Arm e Y cutter arm shaft 1 position Fig 6 1 13 Arm Shaft e shaft 1 position Y sensor carriage Y sensor shaft Fig 6 1 14 Shaft 6 6 W Paper Feed Roller e Paper feed roller and Paper feed sub roller shafts 4 positions Bearing Fig 6 1 15 Paper Feed Roller and Paper Feed Sub roller Shafts e Sliding surfaces of Paper feed sub roller shaft holder shafts 4 positions Fig 6 1 16 Sliding Surfaces of Paper Feed Sub roller Shaft Holder Shafts Paper feed sub roller SS E gt Paper tray B shaft bearings 4 positions Vy 7 Cu Fig 6 1 17 Paper Tray B Shaft Bearings Paper tray B 6 7 e Left right contact points between Paper feed roller spring and Chassis B 2 positions Paper feed sub roller Paper feed roller Paper feed roller Chassis B spring Fig 6 1 18 Left right Contact Points Between Paper Feed Roller Spring and Chassis W Driving Roller e Driving roller shaft bearings 2 positions Driving roller shaft bearing R L Q Fig 6 1 19 Driving Roller Shaft Bearings 6 8 Paper Eject Roller Paper eject roller and Paper eject sub roller shaft bearings 4 positions Pape
11. 3 10 Paper Feed Roller 3 10 1 Removing the Paper Feed Holder Assy 1 Remove the two Idle gears A one Double gear B one Double gear A the Roller gear AD and the two Paper feed roller springs from the Paper feed holder L assy then remove the Paper feed roller unit Paper feed roller A d 24 Roller gear AD Double gear 9 nu 22 2s amp p 5 Double gear A gt I p Idle gear A y Idle gear A Fig 3 10 1 Removing the Paper Feed Holder Assy 2 Rotate the Paper feed holder plates L R backward Remove the Paper feed holder plates L R by pulling the hooks out of the cut outs in the Chassis L R Fig 3 10 2 Removing the Paper Feed Holder Plates L R 3 24 3 Remove the Bearing and Sub bearing and remove the Actuator top from the Paper feed roller assy Se D Sub bearing Bearing 7 Actuator top T d Fig 3 10 3 Removing the Actuator Top 3 11 Left Side of the Main Chassis 3 11 1 Removing the LF Motor 1 Remove the three LF motor holder screws then remove the LF motor holder assy and the three Spacers 2 Remove the two LF motor screws from the LF motor holder assy then remove the LF motor LF motor screw gt Spacer motor holder screw Fig 3 11 1 Removing the LF Motor LF motor 3 25 3 11 2 Removing the Gears 1 Remove the gears according to the sequence of numbers in the diagram below Gear holders
12. 391 1 10 1 0 POO INT 4 1K Teer 18 8 9 5 O 24VRETO GND 24 1 DETAIL OF D5 06 a6 R79 DTC124ESA 1K R41 10K Re KJ BRO Era mm ov CN15 2 o QA2 05 NOT MOUNT 1N5400 201 TPS R35 1K 56 lt MTZJ15C 22K 22K ORG 1 AN 16 06 ERC81 004 10mm R31 10K CAINO eal 8 c 9 CNB 2 R27 1K 47 2 bs 5 B c28 CY 8 0 1 a 2 CN10 D c30 12 c29 35 BLUE 1 N p70 11 o1 4 50V BM1012LF 50V 2200 24 R32 10K 4 14 o 15 M LF ee 104 DTA114TSA R28 1k 46 p73 14 04 3 2 d poy tna CN 2 P45 3 11 10 BLACK 05 boat E 1 END Q p72 os 2 1 I fur WHI TE 1 2 6 7 10K R25 10K P74 r2 02 1 D 1 O ND S cw R29 1K 45 4 13 F1 2 P44 GND GND 125 4 R81 CTR G 5 12 47K RED 1 24VRETO GND GND 24VRET R77 10K T R42 1K 58 Cree 2 P62 AIN2 10K CSIZE QA1 24 YEL 1 ov os ACVL 83 1 16 P67 AI NT 6 9 p ACVH 62 8 9 P66 AI 6 2 6 5 3 d 2 YCA F CN2 CN14 P74 11 o1 5 4 8 14 16 6 4 4 O45 V P77 14 04 4 TL1483CN R98 3 34 7 11 10 M T C c20 33K b 3 3 P31 P76 13 50V CA B T 1 16 2 2 R12 180 6 D 7 WHITE 104 R94 2 2 P75 12 2 02 2 A 33K R97 15K 2 15 PCB 1 R23
13. 7 1 aon PHASE D RxD P40 n 11672 ort F24VRETo IGND COM m 8G JL p53 28 Fig 5 5 4 Y CA Motor Drive Circuit 5 17 m X cutter Motor Drive Circuit This circuit drives the DC motor with the 24V DC stabilized constant voltage The X cutter comprises a DC motor and two switches The DC motor is controlled by the main CPU ports P64 to P67 and is driven by the DC motor control circuit The two switches are detected by ports P22 and P23 The operation of the DC motor for each control port status is listed in Table 5 5 1 Table 5 5 1 DC Motor Control R41 24V bxc 9 X CUTTER c23 MAIN CPU 3 2 RED 24VRET RSD 939 09 Fig 5 5 5 X cutter Motor Drive Circuit 5 18 5 6 Power Supply Circuits The power supply circuits receive the unstabilized DC voltage supplied to CN1 from the AC adaptor through the Jack PCB via fuse F1 protective circuit and the filter circuit The 2 channel switching power IC 1 in the circuits converts the unstabilized DC voltage into a stabilized 5V voltage logic power supply and into a stabilized 24V DC voltage drive power supply 424V 24VRET o 5V ZD1 Fig 5 6 1 Power Supply Circuits 5 19 m 5V Power Supply Fig 5 6 2 shows the timing chart of the power IC IC 1 for the 5V DC powe
14. __ m qeu 0 77 pnm ey ms ms s em m om T FAN 5 6 Clock Circuit The main CPU incorporates a clock generation circuit which uses externally mounted components This circuit and the main CPU internal circuit generate an 8 MHz clock signal Fig 5 3 2 Clock Circuit Reset Circuit This circuit resets the main CPU when the power is turned ON or OFF S 80943ANMP DD7 is used as the reset IC in this circuit When the power is turned ON the reset IC holds the reset output Low for approximately 5 ms after the 5V DC power supply applied voltage reaches 4 3 V After this period the reset output becomes High to clear the main CPU reset status When the power is turned OFF after the 5V DC power supply applied voltage drops to 4 3 V or below the reset IC sets the reset output Low to reset the main CPU Fig 5 3 3 Reset Circuit m Buzzer Drive Circuit This circuit sounds the piezoelectric buzzer To sound the buzzer the main CPU outputs a 4 kHz squarewave with 50 duty from port DVO P13 This signal is used to generate the buzzer sound To stop the buzzer the port status is set to High level using R69 in the input mode 20 BUZZER b Fig 5 3 4 Buzzer Drive Circuit m LED Drive Circuit This circuit drives the four LED indicators mounted on the Switch PCB LED4 LED2 and LED1 are directly
15. standby position the photosensor is not interrupted When the main CPU output P31 YCA LED is Low the input signal P72 YCA F becomes Low When the Y carriage motor rotates after the insertion of a document the Y carriage moves from the standby position to cause the Actuator Y to cut off the photosensor Further rotation of the Y carriage motor moves the Y carriage to the edge of the document where the Actuator Y having cut off the photosensor Y CA sensor comes off the photosensor thereby detecting the edge of the document Also determines the Y carriage Y cutter position meeting the selected Auto Cut mode status When the document edge is detected the main CPU input signal P72 YCA F becomes Low However as P31 is normally at High impedance status the photosensor Y CA sensor does not operate and the main CPU input signal P72 YCA F remains High irrespective of the Y carriage position 0Vo 1 MAIN PCB Y CA SENSOR PCB Fig 5 4 4 Paper Width Detector Circuit m Document Detect PCB PST sensor PCB This circuit detects the length of the document and determines the X cutter position This circuit comprises the transmission photosensor PH1 on the PST sensor PCB It is mounted on the Paper eject roller unit When a document is inserted it displaces the Sensor lever that was cutting the photosensor to turn ON the photosensor PH1 and set the CPU input signal P52 to Low status MAIN PCB PST SENSOR PCB Fig 5
16. 4 Installing the Paper Eject Roller 2 4 9 4 7 Right Side of the Main Chassis 4 7 1 Installing the YC Lift Shaft and LF Change Shaft 1 Move the LF change shaft first to the right then to the left to install it into the Main chassis L and 2 Insert the right end of the YC Lift Shaft into the Main chassis then attach the YC lift arm to it 3 With the boss of the YC lift arm inserted into the groove at the right end of the YC lift shaft insert the left end of the YC lift shaft into the Main chassis L and attach the retaining ring outside Chassis L YC lift shaft Retaining ring YC lift shaft Fig 4 7 1 Installing the YC Lift Shaft and LF Change Shaft 1 4 Attach the Y extension springs between the hooks inside the Main chassis L R and the Y diversion lever 5 Attach the Paper eject roller springs between the Paper eject shaft holder hooks and the Main chassis L R Paper eject roller shaft holder Y diversion lever Y extension spring a d Es ra ET p x Main chassis R Paper eject roller spring Fig 4 7 2 Installing the YC Lift Shaft and LF Change Shaft 2 4 10 4 7 2 Installing the Right Side of the Chassis Install the Double gear S 2 Position the YC lift shaft as shown in the diagram 3 Install the Control cam gear with the triangular mark on the Control cam gear aligned with the triangular hole in the Chassis Ensure that the boss at the rig
17. 7 ovo 5 0 10K 10K 25V F 6 104 100K 4 B 52 R19 1K 4 P53 X 53 16 24 VRET 5 0 5 o P07 53 R21 1K 393 52 15 P54 x 1 X FRONT 0 5 Pos 217 L3 51 14 5V X FRONT 0 5 Pos 30 RCH 110 eas XIN XT 330 H R101 725V R82 10K Ly 104 5 ov 2 34 R102 5V R83 2 2K 20 XOUT 0 5 1w R107 R55 gup DVO P13 150 470 204 1 2 64 27 1K 21 BZCD11PA XZ 5V 10V MTZ16 2B 5 C15 1000 R100 R54 ug 004 1 10K 28V M519538BL 4 220 CA 32 104 2 104 1 RESET vss ov 2 ce 25V e O ov 3 TC 104 25V 104 N C OPEN TERMINAL ov amp ov APP 1 July 2000 865006 0 Printed Japan
18. Always unplug the AC adaptor from the main power socket before measuring conductivity with a circuit tester 3 When removing a connector pull on the body of the connector not on the lead attached to it After Making a Repair Always test the unit after diagnosing and repairing a problem to ensure that the problem is completely remedied When the cause of a problem is identified make a note of it in the troubleshooting procedures for future reference Basic Checks Check the following items whenever a problem occurs Check the power supply voltage Make sure that the AC input voltage the AC adaptor output voltage and the DC supply voltage for each part are at the prescribed value m Check the connectors Ensure that no connector is loose or disconnected m Check the fuses Check if the fuse F1 or thermal fuse in the AC adaptor has blown 7 1 7 5 Troubleshooting Flowcharts AC adaptor plugged in power ON 1 Nothing happens when power switch is s POWER LED indicator lit pressed a Abnormal input voltage b Abnormal 5V DC supply Yes c Defective main CPU See page 7 5 2 Nothing happens when switches are pressed LED indicators do not light a Defective switch or push switch on the Switch PCB b Defective LED on the Switch PCB ERROR LED red flashes See page 7 6 Error at power ON red indicator flashes Yes An error occurred dur
19. B move smoothly gear holder and idle grease to the four 3 3 3 gear B idle gear B 3 3 4 3 3 5 3 4 3 11 Does the rollers slip Dirt or other foreign Clean the rollers matter stuck to rollers Is LF motor out of step Defective driving roller Apply KS64F silicon shaft grease to the driving roller shaft bearings Replace the gear holder and idle gear b Defect in paper Defective paper sensor Defective paper Replace the paper sensor system sensor sensor See g b Deformed actuator top Defective actuator top Replace the actuator top Does the actuator top work Defective actuator top Replace the actuator smoothly top 7 20 Cartridge size film type cannot be detected correctly a Defective cartridge type detector CSIZE4 switch a Defective cartridge type detector CSIZE4 switch b Defective cartridge type detector CSIZE3 switch Is the yellow lead connector connected to CN7 on the main PCB Is the cartridge leaf switch CSIZE4 pressed when an A4 cartridge is inserted Leaf switch assy not connected Incorrectly installed leaf switch assy Correctly connect the leaf switch assy Correctly install the leaf switch assy Is the cartridge leaf switch CSIZE4 not pressed when an A4 cartridge is inserted Is the cartridge leaf switch CSIZE4 not pressed when an A6 cartridge is inserted Is main CPU port P20 Pin 8 at High level when leaf switch CSIZE4
20. EV day 3 _ Leaf switch SG assy screw Fig 4 7 7 Installing the Right Side of the Chassis 5 4 13 4 8 Left Side of the Chassis 4 8 4 Installing the Gears 1 Mount the two Gear holders to the Main chassis L then attach the Gear holder springs Gear holders Gear holder spring Fig 4 8 1 Installing the Gears 1 2 Install the gears according to the sequence shown in the diagram below Push the shaft into a gear or holder with a hook until the hook engages Fig 4 8 2 Installing the Gears 2 4 14 4 8 2 Installing the LF Motor Attach the LF motor to the LF motor holder using the LF motor screws 2 Insert the LF motor holder screws into the LF motor holder assy Put the Spacers over the three protruding screws Mount the LF motor holder assy to the Main chassis L Fixthe LF motor holder to the positioning pins then fasten it firmly and correctly in place with the screws Main chassis L LF motor screw d 7 5 N LF motor Spacer LF motor holder Fig 4 8 3 Installing the LF Motor 4 15 4 9 Paper Feed Roller 4 9 1 Installing the Paper Feed Holder Assy and the Paper Feed Roller Assy 1 Attach the Paper feed holder plates L with shaft and R to the Main chassis L and R x Assemble with the hooks on the Paper feed holder plates L R engaged in the cut outs in the Chassis L R Paper feed holder plate L Paper feed holder plate R Fig 4 9 1 Installing the Paper Feed Hol
21. L Main chassis F Fig 4 3 1 Installing the Main Chassis L R and F 4 3 2 Installing the ENC Sensor PCB Align the boss on the ENC sensor PCB assy Attach the ENC sensor PCB assy to the Cassette holder with the ENC sensor PCB screw Pass the ENC sensor harness through the hole in the Cassette holder Boss ENC Sensor PCB assy ENC Sensor PCB screw Fig 4 3 2 Installing the ENC Sensor PCB 4 3 4 3 3 Installing the Cassette Holder 1 Pass the ENC sensor PCB harness through the hole in the bottom of Main chassis B 2 Insert the lugs at the front of the Cassette holder and click the hooks at the rear onto Main chassis B ENC sensor PCB assy Main chassis B Harness Fig 4 3 3 Installing the Cassette Holder Chassis R L and F are omitted for explanation 4 4 4 3 4 Installing the Main Chassis Install the two Cassette actuators 2 Install the Leaf switch C3 red and C4 yellow assemblies using the Leaf switch C3 C4 screws Take care not to deform the tip of the leaf switch 3 Engage the Leaf switch C3 and C4 harness into the hook under the Cassette holder then pass it through the Edging saddle under the Chassis B ENC sensor Leaf switch C3 assy be Cassette actuator L eaf switch Leaf switch C4 screws C3 C4 assy ENC sensor harness Harness The bottom face of Cassette holder Hook Fig 4 3 4 Installing the Main Chassis B 4 Tape the ENC sensor PCB
22. chassis assy with the two Y CA chassis screws Set the left and right Embosses into the holes in the Y CA chassis before tightening the screws 5 Attach the Y extension spring to the Y diversion lever and the Y CA chassis assy Part A ee 4 25 Y cutter guide L SSS N GR Y cutter arm Y CA timing belt Y CA chassis screws Y extension spring Fig 4 12 5 Installing the Y CA Chassis Assy 2 4 25 4 13 X cutter Unit 4 13 1 Installing the Leaf Switch F Assy 1 Attach the Leaf switch F assy to the Tape sensor holder with the Leaf switch F screw X cutter unit lt Sensor holder screw Tape sensor lever Leaf switch F screw Leaf switch F assy Fig 4 13 1 Installing the Leaf Switch F Assy 4 13 2 Installing the X cutter Unit Slide the X cutter unit into position from the right side of the main unit and fasten it in X cutter screws X cutter unit Fig 4 13 2 Installing the X cutter Unit 4 26 4 14 Harnesses 4 14 1 Installing the Harnesses Attach the following harnesses to the Main chassis B Edging saddle SG motor harness black ENC harness assy white Leaf switch TRI harnesses black x 2 Leaf switch C3 red C4 yellow harness lt 4 7 Fig 4 14 1 Installing the Harnesses 4 15 PCBs 4 15 1 Installing the Jack PCB Assy Install the Jack PCB assy with the Jack PCB screw The Core shown in the diagram
23. driven by the high current ports P30 P33 and P34 on the main CPU The main CPU output port P52 lights LED3 via Q1 The LED lights when the output is Low When not lit the LED is in the high impedance status and the port level is indeterminate 16 CN3 73 LED4 RED 75 LED2 R27 10 GREEN 27 LED3 R39 1 7j GREEN MAIN PCB SWITCH PCB Fig 5 3 5 LED Drive Circuit 5 8 m Specification Switching Circuit This circuit reads the specification switching information The specification switching is conducted by a ROM program built into the main CPU according to the solder point settings on the PCB SP1 SP2 SP3 SP4 SP5 SP6 SP7 SP8 SP9 SP10 SP11 SP12 RA2 0V Fig 5 3 6 Specification Switching Circuit Note that the solder point specifications change according to the CPU display format Check the solder specifications in the P L PCB diagram Detector Circuits These circuits detect the status of the switches and keys that operate the unit Two connection switch Start key Stop key Dial switch Continuous key and Extra border key and the sensors that determine the film type document length and width and cover open closed status The Main CPU controls the motors LEDs and buzzer according to these input signals m Motor Drive Circuits These circuits convert the motor control signals output from the main CPU output ports to 24V drive signals and supplies these vol
24. feed detector switch TPS is mounted before the paper eject roller and if there s no problem with the film during document feed or compression the film presses against the film feed detector switch TPS and sets the ON input Low TPS SW Fig 5 4 8 Film Feed Detector Circuit m Input Voltage Detector Circuit This circuit detects the AC adaptor output voltage to prevent danger due to an AC adaptor that is faulty or incorrectly inserted The AC adapter output voltage is split by R25 and R50 and input to the CPU A D converter port P60 The CPU detects the AC adapter output voltage from the voltage input to the CPU A D converter port P60 MAIN PCB Fig 5 4 9 Input Voltage Detector Circuit 5 15 5 5 Motor Drive Circuits m Paper Feed Motor Drive Circuit This circuit conducts the paper feed motor bipolar drive using 2 2 phase excitation from the 24 VDC stabilized constant voltage The stepping motor excitation phases A B and are controlled by main CPU ports P02 P04 and PO1 and the Paper feed motor is controlled by Driver 6 The Paper feed motor current limit values can be switched using POO P05 and 06 CN12 LF MOTOR 22222575754 3 9027 C28 C26 ae R94 tov 74 24VRET 0 Q6 2 VRET Fig 5 5 1 Paper Feed Motor Drive Circuit SG Motor Drive Circuit This circuit drives the SG mo
25. film cartridges it is sandwiched between the upper and lower films in the compression feed area where the films and document are compressed between the driving roller and sub roller 4 The compressed document and film is fed to the cutting area where it is cut to the document size detected by the paper size detector with borders added It is then transported to the next stage 5 The laminated document is fed out of the eject gate by the paper eject rollers Roll film er Paper feed ilm upper sub roller Paper width detector Film cartridge Paper loading gate Sub roller Y cutter blade Paper length detector Paper loading area WEEN Paper feed roller X cutter unit Paper eject roller ee Eject gate Paper eject sub roller Roll film lower Driving roller Ejecting area Compression feed area Cutting area Fig 2 1 1 Description of Mechanisms 2 1 2 1 2 Feed and Compression Mechanisms The feed and compression mechanism controls the motor drive to feed the document into the film cartridge compression feed the films and eject the laminated document The operation is basically divided into three separate operations feeding a document into the Film cartridge compression feeding the films and ejecting the laminated document Normal Mode When documents are laminated one at a time that is not in the Continuous mode the lamination operation comprises the operations A and B below W A F
26. is applicable to EU specification units only LX 300 Jack PCB screw Jack PCB assy Fig 4 15 1 Installing the Jack PCB Assy 4 15 2 Installing Main PCB Assy 1 1 Install the Main PCB assy 1 to the Bottom cover with the four Main PCB screws newly supplied part cut away the PST SENSOR assy 2 Attach the Jack PCB Power harness assy red black to the Main PCB assy 1 Ta Ne harness assy Main PCB screws Fig 4 15 2 Installing Main PCB Assy 1 4 28 4 16 Chassis Assy 12000011 4 16 1 Installing the Chassis Assy 1 Locate the Chassis assy aligned with the two bosses on the Bottom cover B Fasten it with the four Bottom cover screws A with four washers Bottom cover screws A Fig 4 16 1 Installing the Chassis Assy 1 2 Install the Chassis assy under the Bottom cover B using the two Bottom cover screws B and Spring washers Bottom cover B Bottom cover 9 screws B Soft cloth Fig 4 16 2 Installing the Chassis Assy 2 4 29 3 Attach the Ground wire to the Main chassis B using the Ground wire screw Ground wire screw d 4 AD E sl T Ground wire Fig 4 16 3 Installing the Chassis Assy 3 Main chassis B 4 ES E The Chassis perpendicularity must be adjusted after the Chassis assy is installed to the Bottom cover See Section 6 Maintenance 4 16 2 Installing the PST SENSOR PCB Assy Attach the PST SENSOR PCB assy to the Main chas
27. of the main CPU 3 During High output of the Main CPU 3 output ports P02 and Pins 67 68 when the outputs of P01 and P64 Pins 66 69 are Low and the output of either or both P05 and Pins 70 and 65 is Low are the driver 6 OUT 1 Pin 9 and OUT 4 Pin 19 outputs approximately 24 V and the OUT 2 Pin 11 and OUT 3 Pin 15 outputs approximately 0 V Conductivity in motor harness assy Is the resistance value correct approx 5 5 ohms between phases A B B ofthe LF motor PM motor L Are top and bottom feed rollers correctly engaged Is film correctly placed between the feed rollers Film or other foreign matter Stuck to top or bottom paper eject roller Do the top and bottom paper eject rollers move smoothly Motor harness assy not connected Defective main Defective driver 6 Defective motor harness assy Defective LF motor Foreign matter stuck to roller Problem with paper eject rollers 7 11 Correctly connect the motor harness assy Replace Main PCB assy Replace Main PCB assy Replace motor harness assy for LF motor Replace LF motor Roller holder unit is Correctly set up the incorrectly set up roller holder unit Defective cassette Set the cassette setting correctly Clean off foreign matter Apply KS64F silicon grease to the four bearings Replace Replace 6 6 Abnormal trimming a Defec
28. out foreign the Y diversion lever matter Incorrectly mounted Y Mount the Y cutter cutter assy assy correctly Correctly install Y extension springs 7 18 Incorrect cutting in Y direction a Incorrect Y direction cutting position b Defective Y cutter See a Incorrect Y Does the right cutter move Y cutter guide R and Correctly direction when the mode is changed adjustment plate reassemble the cutting position incorrectly installed body cover Does the left cutter move Y cutter arm and Y Correctly when the Y carriage cutter guide incorrectly reassemble Y cutter moves installed arm Right cut position is always Incorrect adjustment Readjust displaced in one direction of slide plates Left cut position is always Incorrect adjustment Readjust the Y displaced in one direction of Y sensor unit sensor unit Does Y cutter arm move Defective Y cutter arm Apply KS64F silicon smoothly movement grease to Y cutter arm shaft and sensor shaft b Defective Y Is the Y cutter unit correctly Incorrectly installed Y Correctly install the cutter installed cutter unit Y cutter unit 4 18 Y cutter makes jagged Defective Y cutter Replace Y cutter cuts unit unit Incorrect cutting position at document front or rear edge a Defect in paper feed system b Defect in paper sensor system See a Defect in paper Do gear holder and idle gear Defective operation of Apply KS64F silicon feed system
29. 27K 59 4 13 2 RT 5 B48J395 1 1 P63 AI N3 GND GND 1 D R92 3 14 5 12 AFK NII2 r 24 VRETO GND GND 24 VRET C21 471 4 13 1 111 112 4 5V 25 5 12 X VA 2 33 24 DC IN1 50v FB1 FB2 R99 gt 3 P30 P17 104 R95 22 6 11 24 33K 1 3 1 3 R10 180 23 1 2 T DTCi DTC2 471 2 pA P16 120K 103 14 10 2 3 R66 Pea 22 DC ENA 2 Vino TC2 P15 8 9 PCB 4 5 R93 GND vec 848 396 1 R64 3 560K 33K 5 R47 2 ov 393 10K 100K 4 2 5V 0 5V WHI TE 1 19 5 16203 3 TC D 861 5 5 P12 1NT2 6 R62 1 1 4 R69 m s 7 3 3K R63 4 N2 11 2 R67 39K 11 MCDR1511 ENA 3 103 150 H M R68 ovo ouTi 5 b 24V 2 2K 5V ov 2 1 I R88 D3 2 R57 24V vs 2 4 330 ERB83 ov O 11 Tes K 004 Reg 100K 73 5V 0 4 50 X 10 MT 20 0K 58 28 R58 104 6 103 R87 al 2 LF M N Y o P22 XTOUT R59 ov GND BOOT2 X cuT20 12 LENS 57 27 9 R84 c17 cis KJ f BRO P21 XTI N VREF c16 1w 35v 50v 56 25 R46 c12 c3 zl 150 470 104 R91 X REAR 0 5 P20 1NTS 21 DC 1L 3 35v 50V SENSE 103 as 172W P14 470 saa R86 1 2 2K ov 10 22K EOS a R90 CAPS P F62 CDC M Qu 1 10K ose VR1 R56 24 VRET ov cert 2 100K 2 ojo 10 RED R85 s5 49 22K RESERVED P50 1NT3 1 5 Q 54 50 5V 24 VRET RESERVED P51 INT4 On R65 5 8 R20 R22 ov C14
30. 4 5 Document Detect Circuit 5 13 Cartridge Type Detector Circuit This circuit detects the type of film cartridge The Cartridge type detector switch CSIZE3 is mounted at the film cartridge inlet When an film cartridge is inserted the film cartridge presses the Cartridge type detector switch CSIZE3 and turns it ON P14 becomes LOW The Cartridge type detector switch CSIZE4 is mounted at the film cartridge inlet When an 4 film cartridge is inserted the 4 film cartridge presses the Cartridge type detector switch CSIZE4 and turns it ON P20 becomes LOW The Cartridge type detector switches remain OFF when 6 film cartridge 15 inserted and when no film cartridge is inserted CSIZE3 SW CSIZE3 CSIZE4 CSIZE4 SW CSIZE6 R64 2 CSIZE6 SW Fig 5 4 6 Cartridge Type Detector Circuit Film Type Detector Circuit m Film Type Detector circuit ENC sensor PCB This circuit detects the type of film This circuit comprises a reflective photosensor that is mounted on the film detector PCB located on the side of the film cartridge holder The reflective photosensor reads the silver black target pattern along the side of the film to determine the film type CN15 1 ENC SENSOR MAIN PCB ENC SENSOR PCB Fig 5 4 7 Film Type Detector Circuit 5 14 m Film Feed Detector Circuit This circuit detects the film feed status to prevent jams if a problem occurs The film
31. EW PAN M1 7 x 6 0 075 to 0 125 Nem 0 77 to 1 26 kgfecm Push switch 2 screw SCREW PAN M1 7 x 6 0 075 to 0 125 Nem 0 77 to 1 26 kgfecm Dial holder screw TAPTITE BIND B M3 x 8 0 49 to 0 686 Nem 5 to 7 kgfecm Plate spring screw SCREW FLANGED M2 6 x 5 0 196 to 0 392 Nem 2 to 4 kgfecm Plate spring 2 screw SCREW FLANGED M2 6 x 5 0 196 to 0 392 Nem 2 to 4 kgfecm Adjustment plate screw TAPTITE BIND B M3 x 8 0 49 to 0 686 Nem 5 to 7 kgfecm Cover switch screw TAPTITE PAN B 2 6 x 12 0 196 to 0 392 Nem 2 to 4 kgfecm Front cover screw TAPTITE BIND B M2 6 x 8 0 25 to 0 35 Nem 2 55 to 3 57 kgfecm Bottom cover screw A TAPTITE BIND B M3 x 8 0 49 to 0 686 Nem 5 to 7 kgfecm Trimmer bottom cover SCREW BIND M3 x 5 0 49 to 0 686 Nem 5 to 7 kgfecm T cutter screw TAPTITE CUP M3 x 5 Chassis R support screw TAPTITE CUP M3 x 5 4 2 0 49 to 0 686 Nem 5 to 7 kgfecm 0 49 to 0 686 Nem 5 to 7 kgfecm 4 3 Main Chassis 4 3 1 Installing the Main Chassis L R and F 1 Insert the lugs on the Main chassis and F into the square holes in the Main chassis L and R Assemble the Main chassis L R F and B with the ten Side chassis screws five each side 2 Attach the Edging saddle to the Main chassis B Side chassis screws s Main chassis Edging saddle Main chassis
32. Low During High output 4V min of the Main CPU 3 output port P54 Pin 29 is 24 V applied to the CDM pin Pin 5 of CN14 Correct resistance value approx 227 ohms between each phase of the Y CA motor and the COM pin Is the flat cable connected to connector CN11 CN10 on the Main PCB Actuator Y cuts photosensor when a document is inserted Photosensor cut off when no document is inserted 15 photosensor PH1 on the Y CA sensor PCB working correctly Normal Conductivity in Y CA sensor PCB flat cable Does the Y cutter arm move when the Y CA motor rotates Y cutter arm is caught during its movement Is the Y cutter arm separated from the sensor rail Motor harness not connected Defective main CPU S8 Defective transistor array 5 Defective transistor 5 Defective transistor 016 Conductivity problem in Main PCB Defective Y CA motor Defective connection of the flat cable Actuator Y incorrectly installed Defective actuator Y Defective photosensor DisConductivity in flat cable Y cutter arm and timing belt incorrectly installed Foreign matter stuck to Y sensor rail Y sensor shaft and Y cutter arm shaft The Y cutter arm shaft is incorrectly installed Correctly connect the motor harness Replace Main PCB assy Replace main PCB assy Replace Main PCB assy Replace Main PCB assy Replace Main PCB assy Replace the Y CA
33. Orother SERVICE MANUAL MODEL LX 1200 LX 300 MECHANISMS amp ELECTRONICS orother COOL LAMINATOR SERVICE MANUAL MODEL LX 1200 LX 300 Unauthorized copying of all or part of the contents of this manual is prohibited The contents of this manual may change without notice INTRODUCTION This Service Manual describes the Cool Laminator LX 1200 LX 300 specifications operating principles of the mechanisms disassembly and reassembly procedures and maintenance and troubleshooting procedures This Service Manual is intended for use by trained technicians It is not intended for use by the user The manual is divided into the following chapters Chapter 2 Mechanisms Chapter Disassembly Procedures Chapter 4 Procedures Chapter 5 Electronic Controllers Chapter 6 Maintenance Chapter 7 Troubleshooting Appendix _ Main PCB Circuit Diagram Chapter 1 SPECIFICATIONS CONTENTS Chapter 1 SPECIFICATIONS 1 1 Mechanical Specifications 1 1 uc 1 1 1 1 2 aure 1 2 13 Indicators eS 1 2 1 2 E 1 2 11 Mechanical Specifications 1 1 1 Appearance 1 External dimensions WxDxH 468 mm x 387 mm x 273 mm 2 Weight Approx 8 3 kg main unit only 468 mm 273 mm
34. X cutter Replace the X cutter assy See Abnormal X cutter operation 7 8 See d Abnormal Y Actuator Y cuts photosensor Deformed Y sensor Replace the Y carriage power at start position rail sensor rail ON processing Photosensor cut off when Actuator Y incorrectly not at start position installed Defective actuator Y Replace the Y sensor carriage unit Error during Y carriage Document width cannot be detected correctly position detection e Abnormal Y Error during Y cutter No cutting in Y direction cutter power position detection ON processing 4 An error occurred during processing after power after film feed a Defective film or cartridge b Defective film feed detector TPS switch c Defective film feed system See a Defective film Is the film cartridge correctly Defective film Correctly mount the or cartridge mounted cartridge mounting film cartridge Does film remain in the No film remaining Replace the film 32 cartridge Is the cartridge deformed Defective cartridge Replace the cracked cartridge b Defective film Is the orange lead Leaf switch assy not Correctly connect feed detector connector connected to connected the leaf switch assy TPS switch on the Main PCB Does the sensor lever press Incorrectly installed Correctly install the the film feed detector TPS leaf switch F assy leaf switch F assy switch leaf switch F
35. Y cutter arm shaft Retaining rings Fig 3 7 3 Removing the Y cutter Arm 3 20 3 8 Y sensor Rail Unit 3 8 1 Removing the Y sensor Rail Unit Remove the F cable from the Cassette holder 2 Remove the two Y sensor rail screws Disengage the tip of the Actuator top from the film hole then remove the Y sensor rail unit in the direction of the arrow Y sensor rail screw F cable Y sensor rail unit Cassette holder The tip of the Actuator top Fig 3 8 1 Removing the Y sensor Rail Unit 3 21 3 8 2 Disassembling the Y sensor Rail Unit 1 Remove the Retaining ring from the Y sensor shaft then pull out the sensor shaft 2 Remove the FPC holder A from the Y sensor rail then remove the Y sensor carriage Retaining ring Y sensor shaft Y sensor rail screw Y sensor rail Y sensor rail screw QU S Rc QR ert Fig 3 8 2 Disassembling the Y sensor Rail Unit 3 22 3 9 Roller Holder Assy 3 9 1 Removing the Roller Holder Assy Lift up the Roller holder unit and disconnect the Roller holder return spring 2 Remove the four Retaining rings two from the Roller holder two from the Paper feed holder then remove the Roller holder unit 3 Remove the plastic spacer from the rivet pins at each end of the Roller holder assy Spacer Roller holder return spring Retaining rings Roller holder unit Retaining rings Spacer Fig 3 9 1 Removing the Roller Holder Assy 3 23
36. Zener diode ZD1 is Replace Main PCB Replace shorted assy 201 Replace Q3 c Defective main Is Reset Pin 4 of the main Defective reset IC 2 Replace Main PCB Replace CPU CPU 3 High assy IC 2 15 oscillator waveform Defective oscillator Replace Main PCB Replace XT1 output from XIN Pin 3 and XT1 assy XOUT Pin 2 of the main Defective main Replace Main PCB Replace CPU S3 assy CPU 3 CPU 3 7 5 Nothing happens when switches are pressed a Defective switch or push switch on the Switch PCB b Defective LED on the Switch PCB See a Defective Is Switch PCB correctly Defective Switch Correctly mount switch or push mounted mounting Switch PCB switch on the 3 15 switch harness assy Defective connection Correctly connect Switch PCB 5 correctly connected of switch harness switch harness assy assy Is the white lead connector Push switch assy not Correctly connect connected to CN1 on the connected the push switch Switch PCB assy Is the red lead connector Push switch assy not Correctly connect connected to CN2 on the connected the push switch Switch PCB assy When switch SW1 to SW6 Conductivity problem Replace the Switch Replace is pressed on the Switch in switch SW1 to PCB switch SW1 PCB does the switch SW6 to SW6 become conducting When push switch Defective push switch Replace RSW1eRSW2 is shorted assy push switch does the connector on the assy 1 push switch assy bec
37. a matrix of three output ports P90 P91 P92 and three input ports P93 to P95 A Low signal is output at 5 ms intervals from one of the two output ports and the switch status at that time is detected from the status of P93 to P95 e When the main CPU detects that the Feed switch was pressed it starts the document and film feed operation The document and tape are fed in approximately 0 5 mm intervals but the document and tape are fed continuously while the Feed switch is held down e When the main CPU detects that the CUT switch was pressed it operates the X cutter to start the film cutting operation e When the main CPU detects that the TRI switch was pressed it starts the trimming operation e When the main CPU detects that the Start switch was pressed it starts feeding and compressing the document in the selected automatic cutting mode e Automatic cutting operation is stopped when the main CPU detects that the Stop switch was pressed Automatic cutting operation restarts when the Start switch is pressed again e The continuous mode is selected when the Continuous key CONT SW is pressed e The Extra border mode is selected when the main CPU detects that the Extra border key was pressed MAIN PCB SWITCH PCB mL Cm WA R35 CN16 CN3 SW4 EXTRA BORDER SW SW3 CONT SW SW5 CUT SW SW6 FEED SW SW1 START SW SW2 STOP SW TRI SW Fig 5 4 1 Switch Scan Circuit Dial Switch Circuit This circuit detects the au
38. ard the right to remove it Remove the Chassis assy from the Bottom cover when replacing the X cutter unit Y cutter assy X cutter screws Fig 3 6 1 Removing the X cutter Unit 3 6 2 Removing the Leaf Switch F Assy Remove the Leaf switch F screw then remove the Leaf switch F assy care not to bend the connector root on the Leaf switch F assy harness X cutter unit Tape sensor holder os Leaf switch F assy ky Leaf switch F screw Fig 3 6 2 Removing the Leaf Switch F Assy 3 18 3 7 Y CA Chassis Assy and Y cutter Arm 3 7 1 Removing the Y CA Chassis Assy Remove the Y extension springs 2 While the Roller holder is locked remove the two Y CA chassis screws Disengage the end of the Y cutter arm from the Y sensor carriage by moving it in direction A Remove the Y CA chassis assy Y sensor carriage Y cutter arm Y cutter arm Y CA chassis screws Y extension spring Fig 3 7 1 Removing the Chassis Assy 3 19 3 7 2 Removing the Y CA Motor 1 Remove the Y CA motor screws and remove the Y CA motor Y CA motor Y CA motor screw Fig 3 7 2 Removing the Y CA Motor 3 7 3 Removing the Y cutter Arm 1 Remove the retaining ring from the Y cutter arm shaft pull out the Y cutter arm shaft and remove the Y cutter arm 2 Remove the Y CA arm screw then remove the Y CA arm Y sensor carriage arm s screw Y CA arm
39. as shown in the diagram below 2 Insert the L shaped jig for perpendicularity adjustment between the square holes in the Chassis and bosses protruding from the Bottom cover Push the Chassis into position in the direction of the arrow shown in the diagram 3 Taking care not to displace the Chassis tighten the screws A and A Remove the jig and tighten the remaining two screws Paper Feed Roller 7 0 zk Square Hole Screws d dig E Square Hole Boss Fig 6 3 3 Adjusting Perpendicularity of Chassis and Document Chapter 7 TROUBLESHOOTING CONTENTS Chapter 7 TROUBLESHOOTING 7 5 Troubleshooting 7 2 7 6 Troubleshooting Jiss tennont araeir aa iniii iniiai 7 5 7 1 7 2 7 3 7 4 It is extremely difficult to determine when and where problem may arise and to determine the cause of a problem that did arise It is even more difficult to formulate remedies for theoretical problems which may or may not occur This chapter gives examples of actual problems that have occurred together with suggested remedies While this chapter may not allow all faults to be remedied use it as one means of rectifying problems Precautions during Repair Always follow the precautions below when repairing the unit 1 Always unplug the AC adaptor from the main power socket before removing a cover adjusting mechanical parts or removing a PCB 2
40. assy Front hooks Fig 3 3 8 Removing the Body Cover 2 5 Disconnect the Switch harness assy and the Cover switch assy connectors from the Main PCB and remove the Body cover Switch harness assy Cover switch assy Fig 3 3 9 Removing the Body Cover 3 3 6 3 3 6 Removing the Front Cover 1 Remove the two Front cover screws under the Bottom cover B When removing the Body cover remove the two Front cover screws and the two screws at the rear of the Bottom cover B at the same time When inverting the unit to perform this work place it on soft cloth to avoid scratching the cover S Soft cloth Fig 3 3 10 Removing the Front Cover 1 2 Pull the front cover forward to remove it The Body cover must be removed before removing the Front cover Lin 52 S PLN lt gt S Front cover Fig 3 8 11 Removing the Front Cover 2 3 7 3 3 7 Removing Paper Tray B CL200001 1 1 Remove Tray B Stopper el 2 Lift the top of Paper tray B in the direction of arrow A to disengage the lug from the Cassette holder 3 Slide Paper tray B in the direction of arrow B then lift it in the direction of arrow C to remove it Fig 3 3 12 Removing Paper Tray B 3 3 8 Removing the Back Cover 1 Remove the Back cover spring Back cover spring Fig 3 3 13 Removing the Back Cover 1 2 Flex the center of the Back cover toward you to release the shafts from the shaft re
41. assy when film is inserted Is the leaf switch open when Incorrectly installed Correctly install the no film is inserted T sensor lever T sensor lever Defective T sensor Replace the T lever sensor lever Is main CPU port P17 Pin Conductivity problem Replace Main PCB 24 at High level when leaf in Main PCB assy 5 switchi TES is opan Defective pull up Replace Main PCB Replace R46 resistor R46 assy When leaf switch TPS is Defective leaf switch F Replace leaf switch shorted is CN3 on the Main PCB shorted Is main CPU port P17 Pin Conductivity problem Replace Main PCB 24 at Low level when CN3 in Main PCB assy on the Main Defective series Replace Main PCB Replace R42 shorted resistor R42 assy When main CPU port P17 Defective main Replace Main PCB Replace Pin 24 is at Low level is CPU 3 assy CPU S3 this recognized by the main CPU c Defective film Defective film feed LF Abnormal manual feed feed system motor Defective film compression system 7 10 Abnormal manual feed a Defective film feed LF motor a Defective film feed LF motor b Defective film compression system Problem related to paper eject roller b Defective film compression system c Problem related to paper eject roller See Is the black lead connector connected to CN12 on the Main PCB Are pulses output from output ports 1 to P04 Pin 66 to Pin 69
42. bnormal X cutter power ON processing Abnormal Y carriage power ON processing Abnormal Y cutter power ON processing a Abnormal 24V DC supply b Abnormal DC input voltage c Abnormal X cutter power ON processing Is 24V DC voltage at 0V Does 24V DC voltage exceed 24 V at the same level as the AC adaptor output voltage at rated AC input Is power supply 1 Pin 7 switching Is transistor Q1 collector voltage switching between 0 V and input voltage Is transistor Q5 collector voltage switching between 24 V and 0 V Is input voltage from AC adaptor between 16 V and 23 V at rated input Is main CPU port P60 Pin 30 between 2 0 V and 2 9 V using rated AC input X cutter does not move at all Error occurs during X cutter position detection Coil L2 discharged Replace Main PCB Replace L2 assy Conductivity problem Replace Main PCB Replace D4 with diode D4 assy Defective AC adaptor Replace AC adaptor Defective power Replace Main PCB Replace supply IC 1 assy IC 1 Defective transistor Replace Main PCB Replace Q1 Q1 assy Defective transistor Replace Main PCB Replace Q2 Q2 assy Defective transistor Replace Main PCB Replace Q5 Q5 assy Defective AC adaptor Replace AC adaptor Defective resistors R25 and R50 Replace Main PCB assy Replace resistors R25 and R50 Foreign matter stuck Clean out foreign in cutter matter Defective
43. cesses in the Body cover Remove the Back cover During this operation take care not to deform the film attached to the Back Cover Shafts Back cover Body cover Fig 3 3 14 Removing the Back Cover 2 3 3 9 Removing the Cover Switch 1 Remove the cover switch screw Remove the cover switch assy Cover switch screw Cover switch assy Fig 3 3 15 Removing the Cover Switch Assy 3 9 3 3 10 Removing the Dial Switch Holder Assy B Remove the eight Dial holder screws Remove the Dial switch holder assy B 2 Disconnect the Push SW assy 1 white and Push SW assy 2 red connectors from the SW PCB care not to apply force to the connectors between switch and harness Push switch assy 1 and 2 Dial holder screws Fig 3 3 16 Removing the Dial Switch Holder Assy 3 10 3 3 11 Removing the Push Switch Assy 1 Remove the two Push switch screws Remove the Push SW assy 1 white and Push SW assy 2 red Before removing the Push SW assy 1 2 turn the Dial switch such that it does not touch the push switches mid point between Push SW assy 1 and Push SW assy 2 Take care not to apply force to the connectors between the Push switch and harness Push switch assy 1 an Fig 3 8 17 Removing the Push Switches 3 4 Chassis Assy 3 4 1 Removing the Harness Connectors 1 Remove 11 harness connectors from the Main PCB Do not remove the power harness assy red b
44. der Assy 4 16 2 Install the Actuator top in the Paper feed holder assy Install the Bearing and Sub bearing onto the Paper feed roller and Paper feed sub roller Insert the rollers through the slots in the Paper feed holder plates L and R Ensure that the Actuator top fits into Part A of the Cassette holder Bearing Sub bearing Paper feed roller assy NG a A 15 AQ Paper feed sub roller Sub bearing Bearing Actuator top Fig 4 9 2 Installing the Paper Feed Roller Assy 1 4 17 4 Attach the Paper feed roller springs to the left and right Sub bearing hooks and the Paper feed holder plates L and R N INS BS NY Qf Sub bearing 15 2 Paper feed holder plate R WOW VS J A u 3 AUS Paper feed roller spring NI Sn Fig 4 9 3 Installing the Paper Feed Roller Assy 2 5 Attach the two Idle gears A one Double gear B one Double gear A and the Roller gear AD to the Paper feed holder plate L Roller gear AD Double gear B Fig 4 9 4 Installing the Paper Feed Roller Assy 3 4 18 4 10 Roller Holder Assy 4 10 1 Installing the Roller Holder Assy Install the pivots for Roller holder rotation onto the Main chassis shafts 2 Mount the plastic spacers to the lugs rivet pins at each end of the Roller holder assy 3 Pass the lugs rivet pins on the roller holder unit through the curved slots on the Main chassis L and R and the slots on top of the Paper
45. e X cutter position switch b Defective X cutter DC motor c Defective X cutter See page 7 14 2 Nothing happens when switches are pressed LED indicators do not light operation normal Yes END a Defective switch or push switch on the Switch PCB b Defective LED on the Switch PCB See page 7 6 Problem during automatic operation Problem during automatic operation 8 Document cannot be correctly inserted Is document correctly inserted a Problem with input side rollers b Defective PST sensor Photosensor switch See page 7 15 Document width cannot be detected correctly Document width detected correctly a Defective Y carriage Y CA motor b Defective Y CA sensor YCA F c Defective Y cutter arm See page 7 16 4 Cartridge size film type cannot be detected correctly Cartridge detected correctly a Defective cartridge type detector CSIZE4 switch b Defective cartridge type detector CSIZE3 switch See page 7 21 1 0 Lamination is not normal Normal laminating operation a Defective film type ENC detector b Defective document or film See page 7 17 1 No cutting in Y direction a Defective Trimmer Position Switch SG SW b Abnormal Y cutter vertical movement No Y cutting normal See page 7 18 Yes 1 2 Incorrect cutting in Y direction a Incorr
46. e not to lose small screws or washers installed when replacing parts Tighten all screws to the torque specified in the table below As a safety precaution wear gloves when conducting assembly operations 4 1 4 2 Table of Tightening Torques Name of screw Screw size Tightening torque See page Side chassis screw A TAPTITE CUP M3 x 5 0 49 to 0 686 Nem 5 to 7 kgfecm Reinforcing plate for frame R screw TAPTITE CUP M3 x 5 ENC PCB screw TAPTITE BIND B M3 x 8 0 49 to 0 686 Nem 5 to 7 kgfecm 0 49 to 0 686 Nem 5 to 7 kgfecm Leaf switch C3 screw SCREW PAN M2 6 x 10 0 196 to 0 392 Nem 2 to 4 kgfecm Leaf switch C4 screw SCREW PAN M2 6 x 10 0 196 to 0 392 Nem 2 to 4 kgfecm Leaf switch TRI screw TAPTITE PAN B M2 x 6 0 196 to 0 392 Nem 2 to 4 kgfecm Leaf switch F screw TAPTITE PAN B M2 x 6 0 196 to 0 392 Nem 2 to 4 kgfecm Sensor holder screw TAPTITE CUP 6 M2 6 x 6 0 49 to 0 686 Nem 5 to 7 kgfecm X cutter screw SCREW BIND M3 x 6 0 49 to 0 686 Nem 5 to 7 kgfecm Detent plate screw TAPTITE BIND B M3 x 8 0 49 to 0 686 Nem 5 to 7 kgfecm Plate spring 3 screw TAPTITE CUP x 5 0 49 to 0 686 Nem 5 to 7 kgfecm Leaf switch SG screw SCREW PAN M2 6 x 10 0 196 to 0 392 Nem 2 to 4 kgfecm SG motor screw TAPTITE CUP M3 x 5 0 49 to 0 686 Nem 5 to 7 kgfecm LF motor screw
47. eaf switch C3 C4 screws then remove the Leaf switch C3 C4 assemblies 5 Remove the two Cassette actuators Cassette holder y 2 SY Leaf switch C3 assy P Leaf switch C3 screw _ Cassette actuator Leaf switch Leaf switch C4 screw C4 assy The bottom face of cassette holder Fig 3 171 Removing the Main Chassis 3 33 3 17 2 Removing the Cassette Holder 1 Push in the three hooks on the front face that fix the Cassette holder 2 Pull out the Cassette holder in the direction of the arrow Fig 3 17 2 Removing the Cassette Holder 3 17 3 Removing the ENC Sensor PCB Remove the ENC sensor PCB screw then remove the ENC sensor assy ENC sensor assy ENC sensor PCB screw Fig 3 17 3 Removing the ENC Sensor PCB 3 34 3 17 4 Removing the Main Chassis L R and F Remove the ten Side chassis screws five each side then remove the Main chassis L R and F Side chassis screws Main chassis B Main chassis R Main chassis F Side chassis screws Fig 3 17 4 Removing the Main Chassis L R and F 3 35 Chapter 4 ASSEMBLY PROCEDURES CONTENTS Chapter 4 ASSEMBLY PROCEDURES re Babes o dac e 4 1 4 2 Table of Tightening Torques 4 2 44 D claim M 4 6 4 4 1 Installing the Driving Roller 4 6 4 5 Trimming
48. ect Y direction cutting position b Defective Y cutter See page 7 19 1 3 Incorrect cutting position at document front or rear Correct X cutting position edge a Defect in paper feed system b Defect in PST sensor system See page 7 20 1 5 Buzzer does not sound Buzzer sounds correctly a Defective buzzer circuit See page 7 23 END 7 6 Troubleshooting Tables 1 Nothing happens when power switch is pressed LED indicator does not light a Abnormal input voltage b Abnormal 5V DC supply c Defective main CPU See a Abnormal input Are AC adaptor Jack PCB Defective harness Connect harness voltage power harness correctly connection connected Is fuse F1 on Main PCB Blown fuse Replace fuse blown Is AC adaptor output Defective AC adaptor Replace AC voltage normal about 21V adaptor DC at rated input Is AC adaptor voltage Defective Jack PCB Replace Jack PCB Defective power Replace power harness harness applied to connector CN1 on Main PCB b Abnormal 5V Is power supply IC 1 Pin Defective power Replace Main PCB Replace DC supply 10 output Low or supply IC 1 assy switching When power supply IC 1 Defective transistor Replace Main PCB Replace Q4 Pin 10 output is Low is Q4 assy transistor Q4 ON When transistor Q4 is ON Defective transistor Replace Main PCB Replace Q3 is transistor Q3 ON Q3 assy
49. eed sub roller during installation Pass the part of the Paper feed film with the Reinforcement film attached between the Paper feed roller and Paper feed sub roller then pass the end of the Actuator top through the hole in the Paper feed film Y sensor rail screw i Y sensor rail unit Paper feed roller The end of the Actuator top feed fil 2 7 Paper feed film Fig 4 11 4 Assembling the Y sensor Rail Unit 4 22 4 12 Y CA Chassis Assy and Y Cutter Arm 4 12 1 Installing the Y cutter Arm 1 Mount the Y sensor carriage arm to the Y cutter arm with the Y CA arm screw Y CA arm screw Y cutter arm Fig 4 12 1 Installing the Y cutter Arm 1 2 Pass the Y cutter arm shaft through the Y CA chassis assy and Y cutter arm and fasten with a Retaining ring at each end NN Y cutter arm Y CA chassis assy Y cutter arm shaft Retaining rings Fig 4 12 2 Installing the Y cutter Arm 2 4 23 4 12 2 Installing the Y CA Motor 1 Mount the Y CA motor to the Y CA chassis assy with the Y CA motor screws Y CA motor Y CA chassis assy Y CA motor screw Fig 4 12 3 Installing the Y CA Motor 4 12 3 Installing the Y CA Chassis Assy Y sensor carriage arm Fig 4 12 4 Installing the Y CA Chassis Assy 1 4 24 Insert the lugs on the Y cutter guide L into the slots Part A on the Y cutter arm 3 Insert the Y CA timing belt into the groove in the Y cutter arm Install the Y CA
50. eeding document into Film cartridge and ejecting the laminated document 1 SG motor mounted at the right of the chassis runs to rotate the Control cam gear also mounted at the right of the chassis to its prescribed position 2 As the Control cam gear rotates the LF change shaft is rotated to its prescribed position by the cam on the Control cam gear 3 Acam is mounted on the LF motor end of the LF change shaft at the left of the chassis As the LF change shaft rotates this cam rotates the two Gear holders at the left of the chassis which transmit the LF motor drive as shown in the diagram 4 Asaresult of steps 1 to 3 above the drive is transmitted to the Paper feed roller and Paper eject roller The document is fed into the Film cartridge by the Paper feed roller as the LF motor rotates After the trailing edge has been cut by the X cutter the laminated document is ejected by the Paper eject roller Gear holder Paper feed roller Driving roller Paper eject roller LF motor LF change shaft Gear holder Fig 2 1 2 Operation when Feeding Document into the Film Cartridge or when Ejecting a Laminated Document 2 2 m B Compression feeding the films 1 The SG motor mounted at the right of the chassis runs to rotate the Control cam gear also mounted at the right of the chassis to its prescribed position 2 Asthe Control cam gear rotates the LF change shaft is rotated to its prescribed positio
51. eeeeceecessesaseeeeeeeecensessseeeeeeeesenssssnseeeess 5 16 5 6 Power Supply 2e P 5 19 51 Electronic Parts 5 1 1 Configuration of the Electronic Parts The electronic parts of the unit comprise the following PCBs and an AC adaptor Main PCB Switch PCB Jack PCB Paper size sensor PCB Y CA sensor PCB ENC PCB Document Detect PCB PST sensor PCB AC adaptor LX1200 LX300 my L Switch E Jl AC Adapter Main PCB Paper Feed Motor PST Sensor PCB dA Switch H1 ENC Sensor PCB CN3 R Switch Dial Switch Paper Size Sensor Motor CN16 CN15 Control Motor CN13 CN14 CN12 Jenn Cd PH 2 3 4 5 CNB E Sensor o B E33 DC Motor q CN2 i L Switch Switch Jack PCB 3 J p Triming Tape Sensor Cover Trimmer A3 CAS A4 CAS Switch Switch Switch Position Detect Detect S
52. en inverting the unit to perform this work place it on a soft cloth to avoid scratching the cover Bottom cover screws A Soft cloth Fig 4 17 14 Installing the Body Cover 4 4 17 8 Installing the Paper Tray A and Paper Guide 1 Engage the hooks at the rear of the Paper guide into the grooves in Paper tray A Paper guide Paper tray Fig 4 17 15 Installing the Paper Guide 4 39 2 Insert the Paper tray hooks at the left edge and the Body cover then insert the hooks at the right edge Paper tray Fig 4 17 16 Installing the Paper Tray 4 17 9 Installing the Sub tray Flex the center of the Sub tray toward you and insert the shafts into the shaft recesses in the Body cover to install the Sub tray The Sub tray can be folded in the direction of the arrow Sub tray Body cover Shaft recess Fig 4 17 17 Installing the Sub tray 4 40 4 17 10 Installing the Top Cover B With the Top cover B in the open position insert the shafts into the shaft recesses in the Body cover to install the Top cover B Shafts Top cover B Body cover Fig 4 17 18 Installing the Top Cover B 4 17 11 Installing the Trimmer Upper Cover 1 Insert Part A of the Chassis into Part B of the Trimmer upper cover Align the two bosses and fasten the cover with the two Trimmer upper cover screws Bosses A 1 Chassis Trimmer upper w cover screws y Part A of the Chassis Part B Trimmer upper co
53. en the Sub tray 2 Flex the center of the sub tray toward you to release the shafts from the shaft recesses in the Body cover Remove the sub tray Sub tray Shaft recesses Body cover 3 39 4 Removing Paper Tray A and Paper Guide 1 Flex the center of the top of Paper tray A in the direction of the arrow then release the left and right hooks Pull Paper tray A upward to remove it Paper tray A Fig 3 3 5 Removing Paper Tray A 3 4 2 Disengage the Paper guide hooks at the rear of the Paper tray CL200001 1 from Paper tray A Remove the Paper guide Paper guide Paper tray Fig 3 3 6 Removing the Paper Guide 3 3 5 Removing the Body Cover 1 Remove the two Bottom cover screws B from the bottom of the Bottom cover B And remove one screw from the surface of Body cover When inverting the unit to perform this work place it on a soft cloth to avoid scratching the cover Bottom cover screws B oft cloth Fig 3 3 7 Removing the Body Cover 1 3 5 2 Lift the rear of the Bottom cover in the direction of arrow B while pushing it in the direction of arrow A to release the six hooks on the rear face 3 Push the sides of Body cover in the directions indicated by the arrows C to release the hook at the left and right side 4 Push on the Y diversion lever assy and release the two hooks from the front of the Body cover Side hooks Body cover Rear hooks ul Bottom cover B Y diversion lever
54. eplace the film film 6 2 cartridge Is silver black foil stuck to Defective film Replace the film the edge of the film ENC sensor assy Replace ENC incorrectly adjusted Sensor assy No cutting in Y direction a DefectiveTrimmer Position Switch SG SW b Abnormal Y cutter vertical movement See a Defective Trimmer Position Switch SG SW b Abnormal Y cutter vertical movement Is the blue lead connector connected to CN5 on the Main PCB Is main CPU port P15 Pin 22 at High level when leaf switch SG assy is open When leaf switch SG assy is shorted is CN5 on the Main PCB shorted Is main CPU port P15 Pin 22 at Low level when CN5 on the Main PCB is shorted When main CPU port P15 Pin 22 is at Low level is this recognized by the main CPU Does the Y diversion lever rotate when the control cam gear rotates 15 Y cutter assy mounted correctly Leaf switch assy not connected correctly Conductivity problem Replace Main PCB in Main PCB assy Defective pull up Replace Main PCB Replace R48 resistor R48 assy Defective leaf switch Replace leaf switch assy SG assy Correctly connect the leaf switch assy Conductivity problem Replace Main PCB in Main PCB assy Defective series Replace Main PCB resistor R44 assy Replace R44 Defective main CPU 3 Replace Main PCB assy Replace CPU 3 Y extension springs incorrectly installed Foreign matter under Clean
55. er 1 Temporarily position the Y diversion Lever assy on the Main chassis Y diversion lever assy Fig 4 6 1 Installing the Y diversion Lever 1 2 Install the Paper eject roller bearings such that the Y diversion lever arms are sandwiched between the Paper eject roller bearing and the Main chassis L R Fasten the Paper eject roller bearings with the Hooks both L R Fig 4 6 2 Installing the Y diversion Lever 2 4 8 4 6 2 Installing the Paper Eject Roller 1 With both ends of the Paper eject roller inserted in the Paper eject shaft holders move the Paper eject roller first to the left then to the right to insert it into the Paper eject roller bearings Insert them to the end of the rubber ensuring that the Paper eject roller shaft holders are correctly oriented vertically 2 After inserting the Paper eject roller into the bearings move the Paper eject roller shaft holders outward to engage with the groove in the Paper eject roller 3 Move the paper eject sub roller to the left then to the right to insert it into the Paper Paper eject roller Paper eject sub roller Fig 4 6 3 Installing the Paper Eject Roller 1 4 Align the grooves in the Paper eject roller and Paper eject sub roller shafts at the Paper eject shaft holders and push up the Paper eject shaft holders to lock them both sides Grooves S TES Paper eject roller Paper eject roller shaft holder Paper eject sub roller Fig 4 6
56. ert the input side inserted against the paper incorrectly document rollers feed roller 15 document correctly Document inserted Correctly insert the aligned at right edge incorrectly document 15 document inserted at an Defective paper feed Correctly install slant roller springs springs Are the paper Readjust reference in the body cover and paper feed roller perpendicular Actuator top Correctly mount the sensor incorrectly mounted Actuator top Is the sensor interrupted when no document is inserted 15 photosensor PH1 on the Photosensor PH1 Replace Replace PST PCB functioning defective photosensor PH1 PH1 correctly Actuator top defective Replace the Actuator top b Defective PST When a document is PST sensor incorrectly Correctly mount the sensor inserted does the Actuator mounted PST sensor photosensor top interrupt the PST 7 15 9 Document width cannot be detected correctly See a Defective Y carriage Y CA motor b Defective sensor unit YCA F c Defective Y cutter arm a Defective Y carriage Y CA motor b Defective sensor unit YCA F c Defective Y cutter arm Is the Y CA motor harness connected to connector C14 on the Main PCB Are pulses output from output ports P40 to P43 Pin 41 to Pin 44 of the main CPU 3 When the output from output ports P40 to P43 Pin 41 to Pin 44 of the main is High is the output from transistor array 5
57. et If the edge is not parallel cut it parallel with scissors See page 6 17 Fig 6 2 4 Replacing the Cartridge 4 6 13 5 Lower the roller holder assy and push the set buttons in the direction of the arrows to lock the roller holder assy in position Fig 6 2 5 Replacing the Cartridge 5 6 Close the top cover Fig 6 2 6 Replacing the Cartridge 6 7 Turn on the power switch and press the Feed key to feed out some sheet and remove the slackness in the sheet Hold down the Feed key until the edge of the sheet reaches the eject gate 8 Press the Cut key to cut off the end of the sheet fed out to remove the slackness 6 14 6 2 2 Replacing the Sheet 1 Carefully remove the cartridge Fig 6 2 7 Replacing the Sheet 1 2 Open the cartridge shutter then open the cartridge cover Fig 6 2 8 Replacing the Sheet 2 3 Remove the old sheet Fig 6 2 9 Replacing the Sheet 3 4 Hold the yellow plastic holders of the new film align the arrow marks and L R marks of the Cartridge bottom cover and the plastic holders and insert the film into the cartridge as shown in the diagram It is not possible to insert the film in the wrong direction Fig 6 2 10 Replacing the Sheet 4 5 Detach the plastic holders in the direction of the arrow Fig 6 2 11 Replacing the Sheet 5 6 Close the cartridge cover ensuring that the edge of the sheet protrudes from the cartridge film outlet Fi
58. feed roller plate 4 Fasten the Roller holder in position with the four Retaining rings 5 Install the Roller holder return spring while the Roller holder unit is open Retaining rings Fig 4 10 1 Installing the Roller Holder Assy 4 19 4 11 Y sensor Rail Unit 4 11 1 Assembling the Y sensor Rail Unit Attaching Y sensor PCB Assy 1 Bend the sensor flat cable to the dimensions shown in the diagram below Approx 350mm Fig 4 11 1 Bending the Sensor Flat Cable to the Dimensions 2 Attach the FPC holders A to the flat cable 3 Locate the sensor flat cable inside the Y sensor rail unit FPC holder A Approx 170 mm 25 mm Fig 4 11 2 Sensor Flat Cable Location 4 20 Stick the Film and Reinforcement film to the Y sensor rail unit Install the FPC holders A in the Slots in the Y sensor rail unit Pass the Y sensor shaft through the Y sensor rail and Y sensor carriage and fasten with a Retaining ring at each end Check that the sensor cable is not tight when the Y sensor carriage is moved to the left end as shown in the diagram below Reinforcement film Y sensor shaft Y sensor rail Retaining ring Fig 4 11 3 Assembling the Y sensor Rail Unit 4 21 4 11 2 Installing the Y sensor Rail Unit 1 Locate the groove on the Y sensor shaft into the Paper feed holder plate and fasten with the two Y sensor rail screws Ensure that film is inserted between the Paper feed roller and Paper f
59. ft holder Fig 3 13 1 Removing the Paper Eject Roller Unit 1 4 Remove the Paper eject roller bearing hook then remove the Paper eject roller bearing Paper eject roller bearings Fig 3 13 2 Removing the Paper Eject Roller Unit 2 3 30 3 14 Y diversion Lever 3 141 Removing the Y diversion Lever Assy 1 Lift the Y diversion lever assy to remove it Y diversion lever assy Fig 3 14 1 Removing the Y diversion Lever 3 31 3 15 Trimming Mechanism 3 15 1 Disassembling the Trimming Mechanism 1 Remove the Leaf switch TRI screw then remove the Leaf switch assy TRI 2 Remove the T cutter screw then remove the T cutter assy Leaf switch TRI screw Me Leaf switch TRI assy T cutter unit Fig 3 15 1 Disassembling the Trimming Mechanism 3 16 Driving Roller 3 16 1 Removing the Driving Roller 1 Remove the Roller gear CD 2 Remove the Retaining ring push the Driving roller assy toward the left then remove it from the right end 3 Remove the Bearings R L Bearing L Retaining ring hem 4 Driving roller assy a Retaining ring coum R a Fig 3 16 1 Removing the Driving Roller 3 32 3 17 Main Chassis B 3 17 1 Removing the Main Chassis 1 Disengage the harness from the hooks under the Cassette holder and the Edging saddle at the rear of the main chassis B 2 Remove the Edging saddle from the rear of the main chassis B Remove the tape holding the ENC sensor harness Remove the L
60. g 6 2 12 Replacing the Sheet 6 6 16 7 Press the shutter buttons and close the shutter Fig 6 2 13 Replacing the Sheet 7 8 Check that the edge of the sheet is parallel with the cartridge film outlet If the edge is not parallel cut it parallel with scissors Fig 6 2 14 Replacing the Sheet 8 9 Gently insert the cartridge Fig 6 2 15 Replacing the Sheet 9 Note After removing sheet from its sealed pack it will dry up if not inserted into the cartridge 6 17 6 3 6 3 1 Adjustments CL2000010 Adjusting the Right Y cutting Position Border Mode Fon gt Screw 1 Before adjustment laminate the Border Mode to check the amount of border Turn off the power supply and pull the AC adapter jack from the unit Turn on the power then turn the dial switch to the Border position Loosen screws 1 and 2 and move Adjustment plate in the direction of the arrow indicated in the diagram below This moves the Y cutter attached to the Y cutter guide to adjust the cutting position for the right edge of the film In the diagram below move the Adjustment plate to the right to increase the margin between the film and the document After adjustment tighten Screw 2 then tighten Screw 1 Laminate a test document to check if the amount of border has improved Repeat steps 2 to 5 until the borders are correct If the right border is adjusted in the Border Mode the No Border mode is adjusted simultaneo
61. harness inside the marked line the side of the Cassette holder hooks under the Chassis B then return the harness to the Edging saddle under the Chassis B 4 5 4 4 Driving Roller 4 4 1 Installing the Driving Roller 1 Attach the Retaining ring to the right end of the Driving roller assy with the shorter metal part 2 Insert the Bearings L R into the Driving roller Mount it sequentially into Main chassis L and Main chassis R 3 After installing Bearings L R into the Main chassis L R attach the Retaining ring to the left end of the Driving roller assy 4 Install the Roller gear CD Bearing L Driving roller assy Retaining ring Fig 4 4 1 Installing the Driving Roller 4 6 4 5 Trimming Mechanism 4 5 1 Assembling the Trimming Assy 1 Align the Leaf switch assy TRI with the T cutter assy boss hole and attach it with the Leaf switch TRI screw 2 Fasten the harness to the hooks Engage the harness into the hook under the Cassette holder then fix it with tape on the two marked areas Chassis B front face and Chassis R inside surface 3 Align the T cutter assy with the boss holes and install it with the T cutter screw Leaf switch TRI screw T cutter screw T cutter assy The bottom face of Leaf switch TRI harness cassatie holder Fig 4 5 1 Assembling the Trimming Assy 4 7 4 6 Paper Eject Roller and Y diversion Lever 4 6 1 Installing the Paper Eject Roller Unit and Y diversion Lev
62. ht end of the LF change shaft and YC lift arm is inserted correctly into the grooves in the Control cam gear The bosses are correctly inserted if the Control cam gear rotates smoothly when the Y diversion lever is pressed Double gear S Triangular hole in the Chassis YC lift arm Control cam gear The triangular mark on the Control cam gear Fig 4 7 3 Installing the Right Side of the Chassis 1 4 Install the T lever A to the Main chassis R T lever A Fig 4 7 4 Installing the Right Side of the Chassis 2 5 Install the T lever B T cam roller and T cam spring onto T lever A T cam roller T lever B Fig 4 7 5 Installing the Right Side of the Chassis 3 6 Insert the T lever shaft into the shaft holes in the Main chassis R and T lever A B Push in the T lever shaft until the groove in the shaft engages with the hook on the T cutter assy Groove T cutter assy p r4 T lever shaft Fig 4 7 6 Installing the Right Side of the Chassis 4 4 12 7 Align the Leaf switch SG assy with the boss hole and fasten it with the Leaf switch SG screw Before installing the Leaf switch SG assy turn the Control cam gear to a position where it cannot interfere with the Leaf switch Install the SG motor with the two SG motor A screws 9 Install the Idle gears A 10 Attach the Chassis R support with the Chassis R support screw L NS 2 Chassis R support y Nagy Chassis R support screw Leat switch
63. iage approximately 1 mm per 5 steps using 2 2 phase drive m X cutter DC motor This 24V DC motor and two cutter position detector switches are mounted on the X cutter The direction of cutter movement is determined by the direction of current flow in the DC motor 5 3 Main PCB Fig 5 3 1 shows a block diagram of the electrical parts The Main PCB comprises the CPU detector circuits including switch status detection motor drive circuits and power circuits Clock Circuit gt SWITCH PCB Motor Driver i Switch Circuit Circuit LED Driver Circuit Buzzer Drive Circuit oI 24V Power Supply Circuit Specification change over Circuit es 5V Detection Circuit gt Co Fig 5 3 1 Block Diagram of the Electrical Parts Feed Motor Trimming Motor Y Carriage Motor MAIN CPU DC Motor 4 UJ m Main CPU The main CPU is an 8 bit CMOS microcontroller that controls the overall system The main CPU incorporates 1 RAM 32 ROM and 72 I O ports The I O map for the I O ports is shown in Table 5 3 1 overleaf 5 4 Table 5 3 1 CPU I O Map o m m s iMOTORPHASEA m our m s ur m s icumewrswrons Em xw Im s w em ILES
64. ing edge of the document passes out of the Paper feed rollers the Actuator top reverts to its original position to turn off the Paper sensor and detect the document trailing edge HOM BE Paper feed sub roller S Ss ps Nb Paper feed roller z 5 pu Document feed surface 2 oa 5 E y 4 N Paper sensor Actuator top Fig 2 1 7 Paper Length Detection 2 7 m Paper Width Detection Y CA sensor 1 As the arm Y CA sensor carriage moves in the direction of the arrow the document contacts the Actuator Y which rotates about the pivot to switch off the Y CA sensor photosensor When the Y CA sensor turns off the Y cutter arm movement stops and this position is detected as the document width Y cutter arm Y sensor carriage gt Actuator Y Pivot Y CA sensor Document Photosensor ON status Photosensor OFF status Fig 2 1 8 Paper Width Detection 2 8 2 1 5 Trimming Mechanism 1 When acorner of the laminated document is inserted over the T cutter plate the T sensor lever operates a leaf switch TRI that detects the document 2 When the document is detected the motor gear of the SG Motor rotates from its reference position to the prescribed position to rotate the Control cam gear in the direction of the arrow counterclockwise via a series of gears 3 Rotation of the Control cam gear forces the T cam roller to move ve
65. ing processing after power Yes 3 ON before film feed Before film feed Abnormal 24V DC supply Abnormal DC input voltage Abnormal X cutter power ON processing Abnormal Y carriage power ON processing Abnormal Y cutter power ON processing See page 7 8 No 4 An error occurred during processing after power ON after film feed a Defective film or cartridge b Defective film feed detector TPS switch c Defective film feed system See page 7 10 2 Nothing happens when switches are pressed No LED indicators do not light Is manual feed normal a Defective switch or push switch on the Switch PCB b Defective LED on the Switch PCB Yes See page 7 6 5 Abnormal manual feed a Defective film feed LF motor b Defective film compression system c Problem related to paper eject roller See page 7 11 m No Is trimming normal 6 Abnormal trimming Is X cutter operation No Defective trimming TR I switch Defective trimming SG motor Defective trimming TR G switch aoop Defective T cutter See page 7 12 2 Nothing happens when switches are pressed LED indicators do not light normal Yes Is automatic No a Defective switch or push switch on the Switch PCB b Defective LED on the Switch PCB See page 7 6 7 Abnormal X cutter operation a Defectiv
66. iral mechanism not illustrated 3 As the carriage makes a reciprocal movement the rotary cutter attached to the carriage moves against the fixed cutter to cut the compressed leading edge of the document 4 The rotation of the rollers which feed the document restarts when the cutting of the leading edge is complete Then when the cut position at the trailing edge of the document reaches the cutting position of the rotary cutter and fixed blade cutter the feed rollers stop again 5 The document trailing edge is cut in the same way as the leading edge by a reciprocal movement of the rotary cutter attached to the carriage 6 The rotation of the Paper eject roller and Paper feed roller restarts to feed the laminated document from the eject gate after the cutting of the trailing edge is complete In this timing the driving roller does not rotate Document oe ae Paper eject roller Sub roller C Paper eject sub roller Section A A Sub roller Rotary cutter Carriage Paper eject roller 7 Document Paper eject sub roller Fig 2 1 6 Cutting Leading and Trailing Edges X cutter Mechanism Fixed cutter Driving roller 2 6 2 1 4 Paper Size Detector Mechanism m Paper Length Detection 1 When the leading edge of the document passes between the Paper feed rollers the Actuator top operates about the pivot to turn on the Paper sensor and detect the document leading edge 2 When the trail
67. is open When leaf switch CSIZE4 is shorted is CN7 on the Main PCB shorted Is main CPU port P20 Pin 8 at Low level when CN7 on the Main PCB is shorted When main CPU port P20 Pin 8 is at Low level is this recognized by the main CPU Incorrectly inserted cartridge Incorrectly installed leaf switch assy Conductivity problem in Main PCB Defective pull up resistor R61 Defective leaf switch assy Conductivity problem in Main PCB Defective series resistor R65 Defective main 7 21 Re insert the cartridge Correctly install the leaf switch assy Replace Main PCB assy Replace Main PCB assy Replace leaf switch C4 assy Replace Main PCB assy Replace Main PCB assy Replace Main PCB assy Replace R61 Replace R65 Replace See b Defective cartridge type detector CSIZE3 switch Is the red lead connector connected to CN6 on the main PCB Is the cartridge leaf switch CSIZE3 pressed when an A3 cartridge is inserted Leaf switch assy not connected Incorrectly installed leaf switch assy Correctly connect the leaf switch assy Correctly install the leaf switch assy Is the cartridge leaf switch CSIZE3 not pressed when an cartridge is inserted Is the cartridge leaf switch CSIZE3 not pressed when an A4 or A6 cartridge is inserted Is main CPU port P14 Pin 21 at High level when leaf switch CSIZE3 is open
68. l is CPU 3 assy this recognized by the main CPU 7 12 See b Defective control SG motor c Defective trimming TR G switch d Defective T cutter Is the black lead connector connected to CN13 on the Main PCB Are pulses output from output ports P44 to P47 Pin 45 to Pin 48 of the main CPU 3 When the output from output ports P44 to P47 Pin 45 to Pin 48 of the main is High is the output from transistor array Q17 to Q20 Low Is 24V DC applied to Pins 3 and 4 of connector CN13 on the Main PCB Conductivity in motor harness assy Correct resistance value approx 38 ohms between each phase of the SG motor and the COM pin Is the blue lead connector connected to CN5 on the Main PCB Is main CPU port P15 Pin 22 at High level when leaf switch SG assy is open When leaf switch SG assy is shorted is CN5 on the Main PCB shorted Is main CPU port P15 Pin 22 at Low level when CN5 on the Main PCB is shorted When main CPU port P15 Pin 22 is at Low level is this recognized by the main CPU No cutting occurs despite a grating noise is heard Cutting position is correct but cutting is incomplete Motor harness assy not connected Defective main Defective transistor array Q17 to Q20 Conductivity problem in Main PCB Defective motor harness assy Defective SG motor Leaf switch assy not connected Conductivity proble
69. lack CN13 Fig 3 4 1 Removing the Harness Connectors 1 2 Disconnect the harnesses from the eight hooks on the Bottom cover B Fig 3 4 2 Removing the Harness Connectors 2 3 Peel off the tape that holds the harnesses inside the right of Bottom cover B then remove the harnesses from the Bottom cover B 3 12 3 4 2 Removing the PST PCB Paper Sensor PCB Remove the PST PCB Paper sensor PCB screws from the Main chassis B then remove the PST PCB Paper sensor PCB PST PCB screw PST PCB Fig 3 4 3 Removing the PST PCB Paper Sensor PCB 3 13 3 4 3 Removing the Chassis Assy 1 Remove the Ground wire screw from the Main chassis then disconnect the ground wire Ground wire screw Main chassis B We Ground wire P gt Fig 3 4 4 WF K QU QM Ten Removing the Chassis Assy 1 2 Remove the two Bottom cover screws B and the washers from under the Bottom cover B When inverting the unit to perform this work place it on soft cloth to avoid scratching the cover Bottom cover Bottom cover screws B Washers Fig 3 4 5 Removing the Chassis Assy 2 3 14 3 Open the Roller holder assy then remove the four Bottom cover screws CL2000011 with four washers from under the Chassis assy Bottom Cover Screw A Roller Holder Assy Removing the Chassis Assy 3 Fig 3 4 6 4 Pull out the Chassis assy from Bottom cover
70. lift shaft at the left side of the Main chassis ae Retaining ring x 9 Paper eject roller springs a Y extension springs Fig 3 12 4 Removing the YC Lift Shaft and LF Change Shaft 1 3 28 4 Move the YC lift shaft several millimeters toward the right side of the Main chassis and remove the YC Lift arm YC lift shaft Fig 3 12 5 Removing the YC Lift Shaft and LF Change Shaft 2 5 Remove the left end of the YC lift shaft from the Chassis L Remove the YC lift shaft by pulling the right end of the YC lift shaft through the hole in Chassis R toward the middle of the chassis 6 Move the LF change shaft several millimeters toward the Main chassis R Remove the LF change shaft by pulling the right end of the shaft through the hole in Chassis R toward the middle of the chassis When pulling the right end of the YC lift shaft and LF change shaft through the hole in Chassis R tilt the shafts so that they can be pulled smoothly Never pull them through the hole forcibly 3 29 3 13 Paper Eject Roller 3 13 1 Removing the Paper Eject Roller Unit Push down the Paper eject shaft holder until they becomes free 2 Push the Paper eject roller toward the left and remove it from the right end Remove the Paper eject sub roller in exactly the same manner as the Paper eject roller move it toward the left then remove it from the right end Paper eject roller Paper eject sub roller Paper eject sha
71. m in Main PCB Defective pull up resistor R48 Defective leaf switch SG assy Conductivity problem in Main PCB Defective series resistor R44 Defective main The T cutter plate is not installed The T cutter plate is not installed correctly Defective T cutter plate Correctly connect the motor harness assy Replace Main PCB assy Replace Replace Main PCB assy Replace Q17 to Q20 Replace Main PCB assy Replace motor harness assy for SG motor Replace SG motor Correctly connect the leaf switch assy Replace Main PCB assy Replace Main PCB assy Replace R48 Replace Main PCB assy Replace Main PCB Replace R44 assy Replace Main PCB Replace assy Install the T cutter 3 3 1 plate Correctly install the T cutter plate 3 3 1 Replace leaf switch SG assy Replace the T cutter plate Abnormal X cutter operation a Defective X cutter position switch b Defective X cutter DC motor c Defective X cutter See a Defective X The X cutter rotary cutter is Defective X cutter Replace the X cutter cutter position at the left or right end but unit unit switch neither Pin 2 nor 3 is continuous with Pin 1 Alternatively both Pin 2 and 3 are continuous with Pin 1 Conductivity between Pins Defective X cutter Replace the X cutter 1 2 and 3 of the X cutter harness assy harness assy harness assy During X cutter operatio
72. motor Correctly connect the flat cable Replace the Y sensor carriage Replace the Y sensor carriage Replace the Y CA sensor PCB Replace the Y CA sensor PCB Correctly install the timing belt Clean off the foreign matter Correctly install the Y cutter arm shaft Replace Replace 5 Replace Q5 Replace 016 Replace PH1 Replace the sensor harness Lamination is not normal a Defective ENC PCB assy b Defective document or film See a Defective ENC Is the white lead connector Defective harness Correctly connect PCB assy connected to CN15 on the assy connection the harness assy Main PCB 15 the white lead harness Defective harness Correctly connect assy connected to the ENC assy connection the harness assy sensor assy 15 the ENC sensor assy Incorrectly installed Correctly install the correctly installed on the ENC sensor assy ENC sensor assy cassette holder Conductivity in ENC Defective ENC Replace the ENC harness assy harness assy harness assy When the output from Defective photosensor Replace ENC Replace the output port P36 Pin 79 of in ENC sensor assy sensor assy photosensor the main is Low does the output from CN15 Pin 6 vary between 0 and 4V DC due to silver black targets b Defective 15 a cartridge mounted No cartridge mounted Mount a cartridge document or m 5 Does film remain in the No film remaining R
73. n Defective pull up Replace Main PCB Replace R54 do main port P22 resistors R54 and assy and R59 Pin 5 and port P23 Pin R59 80 switch to High level When main CPU port P22 Defective main Replace Main PCB Replace Pin 5 and port P23 Pin CPU 3 assy 80 are at Low level is this recognized by the main CPU b Defective X During normal output of the Defective FET arrays Replace main PCB Replace Q7 cutter DC Main CPU 3 output ports Q7 Q10 assy Q10 motor P64 to P67 Pins 34 to 37 do the outputs between the FET array Q10 Pin 5 and Pin 7 alternate between 0 V and 24 V Conductivity between Pins 4 Defective X cutter Replace the X cutter and 5 of the X cutter harness assy harness assy harness assy Normal resistance approx Defective X cutter Replace the X cutter 30 ohms between Pins 4 unit unit and 5 of the X cutter harness assy DC motor resistance value c Defective X Does the rotary cutter rotate Defective X cutter Replace the X cutter cutter when the DC motor rotates unit unit Cutting of only halfway Defective X cutter Replace the X cutter ES unit unit Metal or other foreign Remove the foreign matter in the matter and replace laminated document the X cutter unit 7 14 Document cannot be correctly inserted a Problem with input side rollers b Defective PST sensor photosensor switch a Problem with 15 document correctly Document inserted Correctly ins
74. n by the cam on the Control cam gear 3 Acam is mounted on the LF motor end of the LF change shaft at the left of the chassis As the LF change shaft rotates this cam rotates the two Gear holders at the left of the chassis which transmit the LF motor drive as shown in the diagram 4 Asaresult of steps 1 to 3 above the drive is transmitted to the Driving roller that compresses the films During this operation the Paper feed roller and Paper eject roller rotate continuously to feed in documents and eject laminated documents Paper feed roller Gear holder Paper feed holder Driving roller Paper eject roller LF change shaft Emote Gear holder Fig 2 1 3 Operation during Film Compression Feed 2 3 Continuous Mode When the second or subsequent document are inserted in the Continuous mode the operation C described below feeds the documents to the prescribed position m Feeding Document Only into Film Cartridge 1 The SG motor mounted at the right of the chassis runs to rotate the Control cam gear also mounted at the right of the chassis to its prescribed position As the Control cam gear rotates the LF change shaft is rotated to its prescribed position by the cam on the Control cam gear is mounted on the LF motor end of the LF change shaft at the left of the chassis As the LF change shaft rotates this cam rotates the two Gear holders at the left of the chassis which transmi
75. ntacting areas or sliding surfaces of each part at the designated position Lubrication Positions W Chassis e idle gear B shaft 4 positions Gear holder S Fig 6 1 1 Idle Gear B Shaft 6 1 e Cam groove on side of Control cam gear 8 positions CL2000010 CL2000016 Control Cam Gear Apply lubricant to inside of cam groove on Control Cam Gear Fig 6 1 2 Cam Groove on Side of Control Cam Gear e LF motor gear 1 position LF motor gear Fig 6 1 3 LF Motor Gear SG motor gear 1 position SG motor gear Fig 6 1 4 SG Motor Gear 6 2 Roller holder shaft 2 positions Main chassis L Main chassis R Fig 6 1 5 Roller Holder Shaft e Sliding surfaces of sub roller shafts in Bearings R L 4 positions Bearings R L Fig 6 1 6 Sliding Surfaces of Sub Roller Shafts in Bearings R L e Engaged parts of YC lift shaft 2 positions YC lift shaft Fig 6 1 7 Engaged Parts of YC Lift Shaft 6 3 e Link between YC lift shaft and YC lift arm 1 position CL2000010 YC lift arm Fig 6 1 8 Link Between YC Lift Shaft and YC Lift Arm e Engaged parts of LF change shaft 2 positions 5 Fig 6 1 9 Engaged Parts of LF Change Shaft e Gear holder change cam surface on LF change shaft 2 position LF change shaft Fig 6 1 10 Gear Holder Change Cam Surface on LF Change Shaft 6 4 W Roller Holder e Sub roller shaft bearings 2 positions Sub roller shaft bearing 5
76. ome Replace conducting push switch assy 2 When switch SW1 to SW6 Defective switch Replace switch is pressed on the Switch harness assy harness assy PCB or the push switch assy is shorted can the conductivity be checked at CN16 on the main CPU If conductivity can be Conductivity problem Replace Main PCB checked at CN16 on the in Main PCB assy nain GEB wienswren Defective series Replace Main PCB Replace SIO Swa S presseg 9r resistor on main CPU assy series the push switch assy is shorted can the conductivity be checked at the main CPU ports If conductivity can be Defective main Replace Main PCB Replace checked at the main CPU CPU S3 assy ports when switch SW1 to SW4 is pressed or the push switch assy is shorted is this recognized by the main CPU See b Defective LED Low output from the main Defective main Replace Main PCB Replace on the Switch CPU ports P30 Pin 73 CPU S3 assy CPU 3 PCB P33 Pin 76 P34 Pin 77 and P52 Pin 27 that drive indicators LED1 to LED4 Does LED1 to LED4 light Defective switch Replace switch when Pin 1 Pin 9 to Pin 11 harness assy harness assy on Main PCB connector 16 is Low Defective LED1 to Replace the Switch Replace LED4 PCB indicator LED1 to LED4 7 7 An error occurred during processing after power ON before film feed a Abnormal 24 DC supply Abnormal DC input voltage A
77. r supply during idling In this circuit the transistor Q3 switches at approximately 100 kHz to convert the unstabilized input voltage to a stabilized 5V supply When transistor Q3 is ON energy accumulates in the coil L3 and electrolytic capacitor C10 until they are able to supply a 5V voltage Transistor Q3 turns OFF and the energy is supplied by diode D3 The transistor Q3 switching ratio is changed by the load current to create a stable supply This control is conducted in the power IC 10056 1 pint 14 1 pin18 _ 41pini3 125 PWR 1 pin10 12V PWR Q3 collector ov Fig 5 6 2 5V Power Supply m 24V Power Supply Fig 5 6 3 shows the timing chart for the 24V DC power supply during idling In this circuit the transistor Q5 switches at approximately 100 kHz to convert the unstabilized input voltage to a stabilized 24V supply When transistor Q5 is ON energy accumulates in the coil L2 When transistor Q5 turns OFF this energy is supplied through diode D4 to the electrolytic capacitor C8 where it accumulates and is output as 24V DC The transistor Q5 switching ratio is changed by the load current to create a stable supply This control is conducted in the power IC Approx 10 sec EDU E 1 pin1 Ey 1 pind 1 pin4
78. r eject roller bearing Fig 6 1 20 Paper Eject Roller and Paper Eject Sub roller Shaft Bearings e Sliding surfaces of Paper eject roller shaft holder shafts 4 positions Paper eject roller shaft holder Fig 6 1 21 Sliding Surfaces of Paper Eject Roller Shaft Holder Shafts 6 9 W Trimmer Unit CL2000010 e Sliding surfaces of T cutter unit and T paper guide 6 positions Fig 6 1 22 Sliding Surfaces of T cutter Unit and T paper Guide e Rotation points of T lever A 2 positions T lever A E Fig 6 1 23 Rotation Points of T lever 6 10 Y Diversion Lever e Y cutter guide shaft 1 position Y diversion lever Fig 6 1 24 Y cutter Guide Shaft e Sliding surfaces of Y diversion lever and YC lift shaft 2 positions YC lift shaft Fig 6 1 25 Sliding Surfaces of Y diversion Lever and YC Lift Shaft 6 2 Replacing the Cartridge and Film 6 2 1 Replacing the Cartridge Fig 6 2 1 Replacing the Cartridge 1 2 Push the Set buttons R L in the direction indicated by the arrow to unlock the Roller holder assy Hold the Set buttons and lift the Roller holder assy Set buttons R L Fig 6 2 2 Replacing the Cartridge 2 3 Carefully remove the cartridge Fig 6 2 3 Replacing the Cartridge 3 4 Gently install the new cartridge Check the following items before inserting the cartridge e Cartridge shutter is fully closed e The edge of the sheet is parallel with the cartridge film outl
79. rface at the right of the Body cover and attach it with the Cover switch screw Install the harnesses for the Dial SW assy and Cover SW assy inside the right of the Body cover and fasten them with the hooks Part A Section A Cover switch assy Body cover Cover switch screw Dial switch holder assy Fig 4 17 6 Installing the Cover Switch 4 17 4 Installing the Back Cover 1 Install the Back cover by flexing the cover and inserting the shafts into the shaft recesses in the Body cover 2 Install the Back cover spring Body cover Back cover spring Back cover Fig 4 17 7 Installing the Back Cover 4 35 4 17 5 Installing Paper Tray B CL200001 1 1 Insert the Paper tray B onto the Paper feed roller from the direction of arrow A then slide it in the direction of arrow B to engage the lugs into slits in the Cassette holder Paper tray B Paper tray Lug Paper feed roller Cassette holder Lug Fig 4 17 1 Installing Paper Tray 2 Insert the Tray B stopper onto the Paper feed roller Left side of Paper feed roller After assembling Paper Tray B with Paper feed roller insert Tray B stopper onto the slashed portion of the right figure Paper tray Paper feed roller Tray B stopper 4 17 6 Installing the Front Cover 1 Align the hooks at the bottom and insert the Front cover Front cover Fig 4 17 1 Installing the Front Cover 1 4 36 2 Fasten the Front cover with
80. rtically such that T lever also moves vertically rotating around its pivot 4 T lever moves vertically the T cutter assy mounted on the end of T lever moves up and down trimming the corner of the laminated document into a rounded radius Leaf switch T sensor lever T cam roller T cutter unit SG motor Control cam gear Fig 2 1 9 Trimming Mechanism 2 9 Chapter 3 DISASSEMBLY PROCEDURES CONTENTS Chapter 3 DISASSEMBLY PROCEDURES 3 1 3 1 3 2 3 2 n 3 3 3 3 3 Removing the Sub tray 3 3 5 Removing the Body Cover T M 3 5 3 3 6 Removing the Front 3 7 3 3 7 Removing Paper 7 3 8 3 8 3 4 341 Removing the Harness Connectors 3 12 3 4 2 Removing the PST PCB Paper Sensor 3 13 mm 3 16 UI M ME DE 3 16 3 5 3 Removing the SW PCB Assy 3 17 3 6 1 3 18 3 6 1 Removing the X cutter Unit 3 18 3 5 2 Removing the Leaf S
81. sis B with the PST SENSOR PCB screws PST SENSOR PCB screw PST SENSOR PCB assy Main chassis B Fig 4 16 4 Installing the PST SENSOR PCB Assy 4 30 4 16 3 Installing the Harness Connectors CL200001 1 1 Attach the harness connectors except the power harness assy to the Main PCB according to the color sequence shown in the diagram Connect the harnesses along the paths shown in the diagram 3 Tape harnesses 1 3 and 4 to the right face of Bottom cover B Pass the 5 Black 4P cable through the three harness retainers 4 Install the F cable as shown in the diagram below AR White Harness SSK Yellow 2P 5 4 Yellow blue white red gray 5P LS Black Installation of the Wy 1 3 4 harnesses Black 2P 51 Orange 2P 3 Blue 2P y 2 Red 2P S FEN 2 SS 2 Red 5P f ed OR F cable SS 22 5 Black 4P C Insert the core with gt the harness wound on it to the rib in the 7 1 cover Installation of the 2 harness Tape FPC holder A Pass the F cable loosely round the tips of the lugs on 3 the Cassette holder um cable jJ an uu 12 te 7 P a 1 ue ud y v a y a 3 t a e M oe 1 Cassette holder lug Fig 4 16 5 Installing the Harness Connectors 4 81 4 17 Covers 4 17 1 Installing the Push SW Assy Attach the Push SW assy 1 and Push SW assy 2 to
82. sor PCB The PST sensor PCB is mounted on the Paper feed roller unit Sensor on the PCB detects whether a document is inserted AC adaptor The AC adaptor converts the input AC voltage to an unstabilized DC voltage The AC adaptor plug is connected to the Jack PCB connector 5 2 Operation of Each Part This unit is operated by three 24 V stepping motors and one DC motor for the X cutter assy The operation of each motor shown in Fig 5 1 1 is described below m LF motor This motor is used to feed the document and film and to eject the film The motor is 49 mm dia 48 step PM stepping motor It is set to feed the document and film approximately 1 mm per 19 steps using 2 2 bipolar drive m SG Motor This motor conducts trimming operation drives the Y cutter vertical movement and switches between document feed film feed and film ejection The motor is a 42 mm dia 48 step PM stepping motor A single trimming operation is completed by 266 steps in the reverse direction from the home position then 266 steps in the forward direction Selection between document feed film feed and film ejection occurs within 515 steps from the home position The Y cutter vertical movement requires approximately 407 steps Y CA motor This motor moves the Y carriage to the edge of the document The Y cutter and paper size sensor PCB are mounted on the Y carriage The motor is a24 mm dia 24 step PM stepping motor It is set to feed the Y carr
83. t the LF motor drive as shown in the diagram As aresult of steps 1 to 3 above the drive is transmitted to the Paper feed roller only A document is fed into the Film cartridge by the Paper feed roller as the LF motor rotates Paper feed roller Paper feed holder LF change shaft LF motor Gear holder 9 Fig 2 1 4 Operation when Feeding Document into the Film Cartridge in the Continuous Mode 2 4 2 1 3 Cutter Mechanism Border Mode The cutter mechanism cuts the laminated document to the size of the document plus an added border Both edges of the films are cut to suit the width of the document and the leading edge and trailing edge are cut according to the document length Y Cutter Vertical Drive Operation The SG motor drive rotates the Control cam gear to its prescribed position This rotation is transmitted via the YC lift arm and YC lift shaft to rotate the Y diversion lever and set the Y cutter to the cutting position Y cutter blade 7 d Control cam gear Y diversion lever YC lift shaft YC lift arm SG motor Fig 2 1 5 Y Cutter Vertical Drive Operation 2 5 Cutting Leading and Trailing Edges X cutter Mechanism 1 All the rollers which feed the document stop when the cut position at the leading edge of the document reaches the cutting position of the rotary cutter and fixed blade cutter 2 The DC motor rotates to drive the carriage in the X cutter assy via the sp
84. tage signals to each motor Power Supply Circuits These circuits convert the unstabilized DC power supply input from the Jack PCB into a stabilized 5V DC power supply for the logic ICs including the main CPU and into a stabilized 24V DC power supply to drive the motors 5 9 5 4 Detector Circuits These circuits detect the status of the switches and keys that operate the machine Two connection switch Start key Stop key Dial switch Continuous key and Extra border key and the sensors that determine the film type document length and width and cover open closed status The circuits that detect each switch and sensor are listed below In addition a separate switch to detect the motor initial status is also mounted e Switch scan circuit Two connection switch Continuous key Extra border key Start key and Stop key Dial switch circuit RSW1eRSW2 switches e Cover switch circuit Cover switch e Paper width detector circuit YCA F sensor Paper length detector circuit switch e Cartridge type detector circuit CSIZE3eCSIZE4 switch e Film type detector circuit ENC sensor e Film feed detector circuit TPS switch e Input voltage detector circuit ACV signals Switch Scan Circuit This circuit in the main CPU scans the status of the FEED e CUT e START STOP CONT EXTRA BORDER key and TRI switch leaf switch at 15 ms intervals to continuously detect the status of each switch The circuit comprises
85. the Dial switch holder with the Push switch screws Push SW screws b Dial switch holder b S Fig 4 17 1 Installing the Push SW Assy 4 17 2 Installing the Dial Switch Holder Assy 1 Connect the Push SW assy 1 and Push SW assy 2 harness connectors to the SW PCB Push SW assy 1 white Push SW assy 2 red Switch PCB Push SW assy 1 Harness connector white Push SW assy2 SS Harness connector red Dial Switch holder Fig 4 17 2 Installing the Dial Switch Holder Assy 1 2 Turn over the Body cover and attach the Start key Stop key Two connection switch Continuous key and Extra border key Check that the LED lenses are correctly aligned with the front of the cover LED lenses N X N x NOVA UR LED lens Extra border key Stop key Two connection switch Continuous key Start key Fig 4 17 3 Installing the Dial Switch Holder Assy 2 4 33 3 Mount the SW PCB assy to the Body cover with the eight SW PCB screws Switch PCB assy Switch PCB screws Switch PCB screws Fig 4 17 4 Installing the Dial Switch Holder Assy 3 4 Attach the Dial switch holder assy to the Body cover with the Dial switch holder screws Body cover Dial switch holder assy Dial switch holder screws Fig 4 17 5 Installing the Dial Switch Holder Assy 4 4 34 4 17 3 Installing the Cover Switch 1 Align the Cover SW assy with the boss hole on the inside su
86. the two Front cover screws at the rear Front cover screws 7 ae Soft cloth Fig 4 17 10 Installing the Front Cover 2 4 17 7 Installing the Body Cover 1 Connect the Switch harness assy and the Cover SW assy to the Main PCB Switch harness assy Cover switch harness Fig 4 17 11 Installing the Body Cover 1 4 37 2 Put the Body cover on the Bottom cover slightly in front of its correct position Insert the Paper tray B into the paper feed slot in the Body cover 3 Insert the Y cutter guide R lug into the slots in the Dial SW assy in front of the Body cover Paper tray B 5524 X Body cover Slot Y cutter guide R Dial switch assy Fig 4 17 12 Installing the Body Cover 2 4 Push the Body cover down while holding down the Y diversion lever Take care not to apply too much force Not much force is required if Step 3 is conducted correctly 5 Check that the two hooks at the front of the Body cover are engaged Repeat from step 2 if the hooks are not engaged 6 Check that the two hooks at the sides of the Body cover are engaged Press down on Part A if the hooks are not engaged 7 Push down the rear of the Body cover to engage the six hooks Side hooks Body cover Bottom cover B Front hooks Y diversion lever Fig 4 17 13 Installing the Body Cover 3 4 38 8 Fasten the Body cover with the two Bottom cover screws A under the cover and the single screw at the top Wh
87. tive trimming TR I switch b Defective control SG motor c Defective trimming TR G switch d Defective T cutter 7 See a Defective 15 document correctly Document inserted Correctly insert the trimming TR l inserted incorrectly document switep Does the T sensor lever Incorrectly installed Correctly install the press the trimming switch trimming switch trimming switch leaf switch TRI assy when amp documentis inserted Incorrectly installed Correctly install the T sensor lever T sensor lever Is the leaf switch open when h docrmantis inserted Defective T sensor Replace the T cutter lever assy Is the black lead connector Leaf switch assy not Correctly connect connected to CN2 on the connected the leaf switch assy Main PCB Is main CPU port P93 Pin Conductivity problem Replace Main PCB 12 at High level when in Main PCB assy trimming switch TR I is open and SW3 and SW4 on the Switch PCB are not pressed Defective pull up Replace Main PCB Replace R51 resistor R51 assy When trimming switch TRI Defective trimming Replace trimming is shorted is CN2 on the switch TRI assy switch TRI assy Main PCB shorted Is main CPU port P93 Pin Conductivity problem Replace Main PCB 12 at Low level when CN2 in Main PCB assy i be PCB ls Defective series Replace Main PCB Replace R33 auch resistor R33 assy When Main CPU port P93 Defective main Replace Main PCB Replace Pin 12 is at Low leve
88. tomatic cutting mode selected on the Cutting mode selector switch This circuit comprises two push switches RSW1 RSW2 mounted on each side of the dial switch The signals detected by these two push switches are input to the Main PCB via the Switch PCB The Dial switch circuit adopts one of four statuses corresponding to each of the following permutations RSW1 OFF and RSW2 OFF RSW1 ON and RSW2 OFF RSW1 OFF and RSW2 ON or RSW1 ON and RSW2 ON MAIN PCB SPACE OFF SWITCH PCB 11 CNI6 2 ade RSW1 Fig 5 4 2 Dial Switch Circuit Cover Switch Circuit This circuit detects whether the cover is open or closed The cover switch is located in the center of the body cover The signal detected by the cover switch leaf switch is input to the Main PCB via the Switch PCB The cover switch turns OFF when the cover is open and the CPU input signal COVER P16 becomes High status MAIN PCB R47 cM COV SW COVER R43 0V Fig 5 4 3 Cover Switch Circuit m Paper Width Detector Circuit YCA F sensor PCB This circuit detects the width of the document and determines the Y carriage position It also determines the Y carriage standby position when the power is ON or the cover is closed This circuit comprises the transmissive photosensor PH1 mounted on the Paper width detector PCB that is attached to the Y carriage If the Y carriage is in its
89. tor using 2 2 phase excitation from the 24 VDC stabilized constant voltage The stepping motor excitation phases A B C and D are controlled by main CPU ports P47 P46 P45 and P44 and the four transistors Q17 to QA20 drive the SG motor PHASE C PHASE B COM Fig 5 5 2 SG Motor Drive Circuit 5 16 m SG Motor Home position Detector Circuit This circuit detects when the SG motor is at the Trimming cam home position 0V Fig 5 5 3 SG Motor Home position Detector Circuit Y CA Motor Drive Circuit This circuit drives the Y CA motor using 2 2 phase excitation from the 24V DC stabilized constant voltage and maintains a low voltage during LF motor operation The stepping motor excitation phases A B C and D are controlled by main CPU ports P43 P42 P41 and P40 respectively The seven transistor arrays incorporated into 5 drive the Y CA motor The drive voltage is controlled by the main CPU port P54 which applies 24V DC to the Y CA motor through transistors Q16 010 9 B 4 014 102 eeo 29 B 3 YA JL P54 T 0972 R103 3 b Lube o 24VRET SM C SCK P43 4 RRJ INE 01 18 com YCA MOTOR CPU P RAS STIND 5 025 5 03ps 4 PHASE 5 EIN 04 PHASE IN5 C 2 PHASE P42 13 548 8
90. uminum foil When using a soldering iron or other heat producing tool ensure that heat does not damage wires circuit boards or plastic parts such as covers Take care not to lose small screws or washers removed when replacing parts As a safety precaution wear gloves when conducting disassembly operations Removing the Film Cartridge 1 Open the top cover and move the Y cutter arm as far as possible to the left 2 Push the Set buttons R L in the direction indicated by the arrow to unlock the Roller holder assy Top cover Y cutter arm Set button R L Fig 3 2 1 Removing the Film Cartridge 1 3 1 3 Lift up the Roller holder assy and pull out the Film cartridge Roller holder assy Film cartridge Fig 3 2 2 Removing the Film Cartridge 2 3 3 Covers 3 31 Removing the Trimmer Cover 1 Pull out the T cutter plate and the Trimmer bottom cover gt i Trimmer bottom cover Fig 3 3 1 Removing the Trimmer cover 1 T cutter plate 3 2 2 Remove the two Trimmer cover screws Remove the Trimmer upper cover Trimmer cover screws Trimmer upper cover Fig 3 3 2 Removing the Trimmer cover 2 3 3 2 Removing the Top Cover B Open the Top cover B Lift the Top cover B shafts out of the shaft recesses in the Body cover and remove Top cover B Top cover B Body cover Shafts Shaft recesses Fig 3 3 3 Removing the Top Cover B 3 3 3 3 3 Removing the Sub tray 1 Op
91. usly so do not adjust again in the No Border mode Y cutter guide Adjustment plate c C Screw 2 Fig 6 3 1 Adjusting the Right Y cutting Position 6 18 6 3 2 Adjusting the Left Y cutting Position CL2000010 Before adjustment laminate in the Border Mode to check the amount of border 2 Turn off the power supply and pull the AC adapter jack from the unit 3 Loosen the screw and move the Y sensor carriage arm left or right This moves the detection position of the sensor attached to the Y sensor carriage and adjusts the cutting position for the left edge of the film In the diagram below move Y sensor carriage arm to the right to increase the margin between the film and the document 4 After adjustment tighten the Screw Laminate a test document to check if the amount of border has improved 5 Repeat steps 2 to 4 until the borders are correct If the left border is adjusted the Border Mode the No Border mode is adjusted simultaneously so do not adjust again in the No Border mode Y sensor carriage Y sensor carriage arm Y cutter arm T Fig 6 3 2 Adjusting the Left Y cutting Position 6 19 6 3 3 Adjusting Perpendicularity of Chassis and Document CL2000012 Loosen the four screws under the Bottom cover
92. v 26 P61 100K 2 13 al ov O TEST CAINI 2 cov x e R26 1K 44 a4 DTC124ESA 2 CN16 1 12 1 P43 CS A K12 R16 1K 43 61 1 GREEN 4 11 2 P42 P65 DL KI2 KIO R14 1K 42 5 413 22K 2265 ov YEL 3 P41 R71 24V TRM R30 1K 41 6 2k R70 FEED CUT 10 4 P40 5 10K R72 sw2 sw3 sw KB Kot 0 ov 5 R11 1K 40 A1287 D2 R78 STA ON P37 R54 ERATE OF ONES 5 OFF 9 RO 1K 39 100K 50 1SR139 10 Swi swa P36 o Q1 inea OC Er a LEDI GREEN DM UEM O 24V X LED 6 R8 LED4 38 13 R52 3K 300 TLGU1002 t 8 CN1 LED2 RED P35 4 Al C INDEX GREEN 7 R8 150 LED1 37 4101 22K 2263 D1 R53 LEDS LED3 GREEN P34 T O 5v TLSU1002 7 8 RT 180 LED2 36 L v gode x RED LED4 GREEN P33 O 24VRET 2 9 R6 150 LED3 35 QA3 R SW TLGU1002 t 6 P32 RED GREEN 10 9 5 5V 12 R73 220 1 16 LEDS P03 INI 01 2 TLGU1002 5 R3 10K 10 R74 220 2 a 15 GREEN 5V R SWC ON OFF R4 48 Pot 2 lt 02 5 1 4 11 P47 3 14 M L SWCON OFF 1K ins 41 12 R1 10K 4 13 CN11 gt 2 3 2 51 IN4 04 N C 1370 ov P52 12 M YA 1 2 1K INS o5 N C 218 R17 10K 14 R75 220 1 WHITE 1 Po2 O oe 1 D L SW R18 17 9 R76 220 T am 10 WHITE 848
93. ver Fig 4 17 19 Installing the Trimmer Cover 1 4 41 2 Insert the T cutter plate into Trimmer upper cover 3 Insert the Trimmer bottom cover 3 T cutter plate Trimmer bottom cover Fig 4 17 20 Installing the Trimmer Cover 2 4 18 Installing the Y cutter Slide the Y cutters from each end of the Y diversion lever and pull them upward to install them Y cutters Z Y diversion lever Fig 4 18 1 Installing the Y cutter 4 42 4 19 Installing the Film Cartridge 4 19 1 Installing the A3 Cartridge 1 Insert the Film cartridge with the tape outlet toward you and lower the Roller holder assy Roller holder assy Tape cassette Fig 4 19 1 Installing the Film Cartridge 1 2 Push the Set buttons R L to lock the Roller holder assy Close the Top cover Top cover Set buttons L R Fig 4 19 2 Installing the Film Cartridge 2 detailed description how to install the Film cartridge see 6 2 1 Replacing the Cartridge in Section 6 Maintenance 4 19 2 Installing the A4 A6 Cassette Attachment 1 Insert the A4 A6 cassette attachment with the handle at the left 2 Follow the method described for the A3 cartridge to insert the A4 A6 cartridge A4 A6 cassette attachment Fig 4 19 3 Installing the A4 A6 Cassette Attachment 4 44 Chapter 5 ELECTRONIC CONTROLLERS CONTENTS Chapter 5 ELECTRONIC CONTROLLERS 5 5 Motor Drive Circuits ccccccccccccccsssssssceeceeeceessssss
94. witch F ASSy L 22 3 18 3 23 3 23 Mp Hm 3 24 T 3 24 3 11 1 Removing the 3 25 3 11 2 Removing the Gears ase e iai teas eR a S PU MM las Ms ite uM eda duds 3 26 3 27 12 1 Removing the Right side of the 15 3 27 ee 3 28 3 13 Paper Eject Roller f i eeu aude ei in 3 30 3 13 1 Removing the Paper Eject Roller 3 30 SEES 3 31 3 14 1 Removing the Y diversion Lever 4 3 31 3 15 Trimming 3 32 3 32 3 32 3 16 1 Removing the Driving 3 32 Deed atc tate tel tet 3 33 3 33 3 17 2 Removing the Cassette Me 3 34 3 17 3 Removing the ENC Sensor 3 34 3 17 4 Removing the Main Chassis L R 3 35 3 1 3 2 Safety Precautions When conducting disassembly operations place the unit on a grounded anti static sheet LSI and other electronic components are sensitive to static electricity and may be damaged if touched while charged Before transporting a circuit board wrap it in a conducting sheet such as al
95. witch Switch Switch X Cutter Fig 5 1 1 Configuration of the Electronic Parts 5 1 2 Outline of the Electronic Parts Each PCB and the AC adaptor are described below Main PCB The main PCB is located below the paper guide It is connected to all PCBs motors switches and cables It converts the unstabilized DC voltages input from the Jack PCB to stabilized 5V and 24V DC voltages which are supplied to all controllers The Main PCB controls motors LED indicators and buzzers according to the signals input from the detector circuits on the Switch PCB Paper size sensor PCB ENC PCB and on the Main PCB itself Switch PCB The Switch PCB is located at the rear of the Body cover It is connected by a cable to the Main PCB On the Switch PCB are mounted the Two connection switch Start key Stop key Continuous key and Extra border key LEDs to indicate power ON continuous mode extra and errors and connectors to connect to push switches of dial switch Jack PCB The Jack PCB is located at the jack input at the rear of the bottom cover It supplies unstabilized DC voltages from the AC adaptor to the Main PCB Paper size sensor PCB Y CA sensor PCB The Paper size sensor PCB is located on the Y carriage The sensor to detect the document width is mounted on this PCB ENC PCB The ENC PCB is located on the side of the film cartridge holder The sensor to detect the film type is mounted on this PCB Document Detect PCB PST sen

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