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Service Manual: CF90

1. Removal 1 Remove Front and Rear cover 1 1 1 2 Open Top 1 1 2 Remove screws amp x7 4 Disconnect connectors B EgJ x5 NOTE The Total counter will be setto 0 when changing MD3DC Replacement 1 Reverse the removal procedure 2 Enter Service mode 5 1 1 in SR90 Service Manual 3 Perform Cover Feeder motor calibration 5 5 in SR90 Service Manual CF90 1 16 12 January 2004 FAULT CODE DESCRIPTIONS 2 TROUBLESHOOTING 2 1 FAULT CODE DESCRIPTIONS CF 001 CF M1 Feed motor Cycle time Out eorr eenn CF90 2 2 CF 002 CF M1 Feed motor retire ner ennn eee CF90 2 2 CF 003 CF M1 Feed motor open circuit niim rici ra CF90 2 3 CF 004 CF M2 Drive motor Short circuit una inani aa io ER RO RR x ER EK a REVO KR CF90 2 3 2 005 2 Drive motor open asses sse MUR 90 2 3 008 1 Empty bin sensor is eenn CF90 2 4 CF 009 CF Q3 Paper path DSD sensor is faulty CF90 2 5 CF 010 CF Q4 Paper positioning sensor is faulty CF90 2 5 CF 011 CF Q5 Paper bin low sensor is faulty SH re CF9
2. Power Supply COM CF90 Receptacle PCB CF90 3 2 12 January 2004 ELECTRICAL COMPONENT LIST 3 1 2 OUTFEED VIEW CF Q1 85 7 5 CF Q4 Phototransistor Shown in tipped position for clarify CF90 3 3 ELECTRICAL COMPONENT LIST 12 January 2004 3 1 3 BIN VIEW CF M3 CF90 3 4 12 January 2004 BOARD STRUCTURE 3 2 BOARD STRUCTURE 3 2 1 CONTROLLER MD3DC CANO Start Exit CANT 25 L2 5 Motor drives Panel LEDs Panel Switches Input oe Voltage Inputs x4 feedback Inputs x4 DSD Sensor Sensor Not in use L CF90 3 5 COVER FEEDING PROCESS 12 January 2004 3 3 COVER FEEDING PROCESS 3 3 1 PRINCIPLE OF OPERATION Inserting covers Q3 di Cover on selected the booklet maker UI Empty bin sensor CF Q1 detects that sheets are loaded Feed motor CF M1 reverses moving the bin to the up position and stops by bin home position sensor CF Q2 The stack is now up against the feed roller Blower motor CF M3 blows separation air into the stack for a while sheets has been run previously the cover feeder is now in ready mode If sheets has just been loaded feed motor CF M1 and drive motor 2 starts and transports the sheet past s
3. 3 DETAILED SECTION DESCRIPTION CF90 3 1 3 1 ELECTRICAL COMPONENT LIST CF90 3 1 OMM REAR VIEW M eo ener Q CF90 3 2 SEE e Ena EEL VIEW eee eee ere er ee 77777323 CF90 3 3 3 1 3 BIN VIEW M CF90 3 4 3 2 BOARD TR CF90 3 5 3 2 1 CONTROLLER sse eee 90 3 5 3 3 COVER FEEDING PROCESS CF90 3 6 3 3 1 PRINCIPLE OF OPERATION CF90 3 6 CF90 3 6 12 January 2004 Page intentionally blank 12 January 2004 COVERS 1 REPLACEMENT AND ADJUSTMENT 1 1 COVERS 1 1 1 FRONT AND REAR COVER 5 5 65 og B A 1 Remove Front cover 5 x1 2 Remove Rear cover 5 x1 CF90 1 1 COVERS 12 January 2004 1 1 2 TOP COVER C D Remove Front and Rear cover it 2 1 1 2 Loosen screws Front and Rear side of the Cover Feeder A x4 Lift up the top cover and tighten the screws B to secure the top cover in an open position 51 x2 4 Loosen the screws C holding the PCB plate x4 NOTE Slide the PCB plate to the Rear of the Cover Feeder and hook it up on the two lower screws D CF90 1 2 12 January 2
4. 0 2 6 201 CF Q3 Paper path DSD sensor was Not blocked within timeout CF90 2 7 CF 202 CF Q3 Paper path DSD sensor was Blocked exceeding timeout CF90 2 7 CF 203 CF Q4 Paper positioning sensor was Not blocked within timeout CF90 2 7 CF 204 04 Paper positioning sensor was Blocked exceeding timeout CF90 2 8 CF 205 Double feed Misfeed Q3 DSD sensor CF90 2 8 CF 401 Load covers Q1 Empty bin sensor CF90 2 8 CF 501 Load covers Q5 paper bin low sensor CF90 2 8 CF90 2 1 FAULT CODE DESCRIPTIONS 12 January 2004 CF 001 Fault Code CF 001 indicates that the Feed motor CF M1 had a Cycle time out Initial Actions Check fuse F2 on Transformer Enter the Service mode and select Feed motor CF M1 in check motors Make sure that the home position sensor CF Q2 is installed correctly Procedure Enter the Service mode and select Bin home position sensor CF Q2 in check sensors The Bin home position sensor indicates D 1 when the sensor is blocked and D 0 when the sensor is unblocked Y N 1 Replace sensor CF Q2 2 Disconnect plug P11 from MD3DC PCB Measure between J11 4 and J11 6 5V and ground The voltage is approximately 5 VDC Y N Replace MD3DC PCB Connect plug P11 to MD3DC PCB A Disconnect plug from sensor CF Q2 Measure between
5. 004 1 2 AREAD 1 2 1 EMPTY BIN SENSOR Q1 T p 5 5 65 9 lt 1 Remove screw 5 1 2 Remove Sensor x1 CF90 1 3 12 January 2004 1 2 2 FEED ROLLER ASSY AND PAPER SEPARATOR PAD A C 1 Remove the Fold roller assembly A by pressing it to the front side according to figure B Lift out the rear side C of the Fold roller assembly Remove the Paper separator pad D by lifting it out with a small screwdriver from the holder CF90 1 4 12 January 2004 1 2 3 FEED MOTOR M1 ASSEMBLY D T ew 5 5 65 9 lt B E Removal Sal 1 Remove Rear cover 1 1 1 Remove Feed roller assembly 1 2 2 Disconnect Connector A E x1 Remove B G x1 Remove Feed motor M1 assembly by removing screws C X3 Loosen the allen screw D to Roller clutch assembly x1 OG BE Remove the motor bracket by removing screws E x3 Replacement 1 Reverse the removal procedure 2 Enter Service mode 5 1 1 SR90 Service Manual 3 Perform Cover Feeder motor calibration 5 5 SR90 Service Manual Adjustment Adjust the Roller clutch assembly so that the sensor activator is in the middle 0 5 mm of Bin home position sensor Q2 F Adjust by loo
6. COVER FEEDER CF90 SERVICE MANUAL January 12 2004 Subject to change Page intentionally blank TABLE CONTENTS 1 REPLACEMENT AND ADJUSTMENT CF90 1 1 jg i f c DCN CF90 1 1 1 1 1 FRONT AND REAR COVER PER enc CF90 1 1 1 1 2 TOP COVER seri CF90 1 2 TZAREAD eee ee eee ore CF90 1 3 1 2 1 EMPTY BIN SENSOR eee CF90 1 3 1 2 2 FEED ROLLER ASSY AND PAPER SEPARATOR PAD CF90 1 4 1 2 3 FEED MOTOR M1 ASSEMBLY sse CF90 1 5 1 2 4 BIN HOME POSITION SENSOR 02 caret erts CF90 1 6 1 2 5 PAPER BIN LOW SENSOR QB eee CF90 1 7 1 2 6 DRIVE MOTOR MZASSENDBEY iu re Rat cea eode CF90 1 8 1 2 7 DRIVE SHAFT ASSEMBLY CF90 1 9 1 2 8 PINCH ROLL SHAFT ASSEMBLY CF90 1 10 1 2 9 PAPER PATH DSD DETECTION SENSOR Q3 CF90 1 11 1 2 10 PAPER POSITIONING SENSOR Q4 CF90 1 12 1 2 11 UPPER PAPER PATH eee CF90 1 13 1 3 BIN EXTENSION PLATE eee CF90 1 14 1 3 1 BIN EXTENSION PLATE ASSENMIBLY eee CF90 1 14 1 3 2 BLOWER eet contaba CF90 1 15 IE E CF90 1 16 1 4 1 MD3DC PCB A CF90 1 16 2 TROUBLESHOOTING CF90 2 1 2 1 FAULT CODE DESCRIPTIONS iid oinnes oaa rid b CF90 2 1 22 LEDS D E or CF90 2 8
7. aper The Paper path DSD sensor CF Q3 sensor indicates D 0 when the sensor is blocked and D 1 when the sensor is not blocked Y N Go to CF 009 1 Clean the feed rollers 2 Make sure that the feed rollers are not worn out 3 Check clean the Paper separator pad 4 Make sure that nothing interferes with the paper path in the Cover feeder CF 202 Fault Code CF 202 indicates that during Run the Paper path DSD sensor CF Q3 was blocked exceeding timeout Initial Actions Check fuse F2 on Transformer Make sure that the Paper path DSD photo transistor sensor and the Paper path 05 LED sensor CF Q3 is installed correctly Ensure that the Paper path DSD sensor CF Q3 is clean Procedure Enter the Service mode and select Paper path DSD sensor CF Q3 in check sensors Block then unblock the CF Q3 with a sheet of paper The Paper path DSD sensor CF Q3 sensor indicates D 0 when the sensor is blocked and D 1 when the sensor is not blocked Y N Go to CF 009 1 Clean the feed rollers 2 Make sure that the Jam clearance baffle is installed correctly 3 Make sure that nothing interferes with the paper path in the Cover feeder CF 203 Fault Code CF 203 indicates that during Run the Paper positioning sensor CF Q4 was not blocked within timeout Initial Actions Check fuse F2 on Transformer Make sure that the Paper positioning sensor CF Q4 is installed correctly Ensure that the Pape
8. calibration i 5 5 SR90 Service Manual CF90 1 11 12 January 2004 1 2 10PAPER POSITIONING SENSOR Q4 R 3 D et B A 1 Remove the Jam clearance baffle A 2 Remove screw 1 3 Disconnect connector E x1 CF90 1 12 12 January 2004 1 2 11 UPPER PAPER PATH T ew 5 5 65 9 lt B 1 Remove Front and Rear cover 2 1 1 2 Remove Spring A on the Front and Rear side of the Cover Feeder 3 Remove screws B to Upper paper path EE x2 CF90 1 13 BIN EXTENSION PLATE 12 January 2004 1 3 BIN EXTENSION PLATE 1 3 1 BIN EXTENSION PLATE ASSEMBLY 1 Remove connector and ground wire A to Bin extension plate assembly EE x2 2 Liftupthe Bin extension plate B and remove it CF90 1 14 12 January 2004 1 3 2 BLOWER 1 Remove Bin extension plate assembly if 1 3 1 2 Remove Ground cable A Egllx1 Remove Blower motor B X2 CF90 1 15 BIN EXTENSION PLATE p 5 5 65 9 lt 12 January 2004 1 4 PCB 1 4 1 MD3DC PCB A
9. e tween P3 13 and the orange wire on the motor connector Is there an open circuit in any of the wires Y N Replace MD3DC PCB Replace wire Harness Replace motor CF M2 CF90 2 3 FAULT CODE DESCRIPTIONS 12 January 2004 CF 008 Fault Code CF 008 indicates that the Empty bin sensor CF Q1 is faulty Initial Actions e Make sure that the Empty bin sensor CF Q1 is installed correctly Procedure 1 Replace sensor CF Q1 2 Disconnect plug P11 from MD3DC PCB A Measure between J11 1 and J11 3 5V and ground The voltage is approxi mately 5 VDC Y N Replace MD3DC PCB Connect plug P11 to MD3DC PCB Disconnect plug from sensor CF Q1 Measure between the red wire Q1 and the black wire Q1 5V and ground The voltage is approximately 5 VDC Y N Replace wire Harness Connect the sensor CF Q1 plug Measure between J11 2 and J11 3 5V and ground The voltage is approximately 5 VDC Y N Replace wire Harness Replace MD3DC CF 009 Fault Code 009 indicates that the Paper path DSD sensor CF Q3 is faulty Initial Actions Make sure that the Paper path DSD photo transistor sensor and the Paper path 05 LED sensor CF Q3 is installed correctly e Ensure that the Paper path DSD sensor is clean Procedure Disconnect plug J20 Measure between P20 2 and P20 1 5V and ground in the P 20 plug The voltage is approximately 5 VDC Y N Connec
10. ensor CF Q3 When paper positioning sensor CF Q4 is activated both motors stop CF M1 amp M2 The cover feeder is now in ready mode Copier sends a start signal Feed motor CF M1 and drive motor 2 starts First sensor CF Q3 be comes deactivated when first sheets leaves the sensor and activated again by the second sheet Then sensor CF Q4 becomes deactivated and activated the same way Both motors CF M1 amp M2 stop when sensor CF Q4 becomes activated by the second sheet A sheet has been pulled and cover feeder is back in ready mode What separates the sheet distance from each other is that drive motor CF M2 is faster but weaker than feed motor CF M1 When both motors drives the sheet it runs the feed motor s CF M1 speed But as soon as the first sheet s trail edge is release from motor CF M1 the sheet accelerates and runs on the drive mo tor s CF M2 faster speed CF90 3 6
11. l 1 Remove 6 1 1 1 2 Remove Drive motor M2 assembly 1 2 6 NOTE Be careful when removing the Drive motor M2 assembly so it will not damage LED sensor 3 1 2 3 Remove the Drive motor M2 assembly by sliding it out through the rear frame Replacement 1 Reverse the removal procedure Adjustment Adjust the Drive clutch assembly 1 2 6 CF90 1 9 12 January 2004 1 2 8 PINCH ROLL SHAFT ASSEMBLY 1 Remove the Pinch roll shaft assembly by pressing it to the rear side of the Cover Feeder CF90 1 10 12 January 2004 1 2 9 PAPER PATH DSD DETECTION SENSOR Q3 ded e d 7 lt i 12 D C Removal 1 Remove A amp 1 Disconnect Photo transistor connector B x1 Remove Drive shaft assembly 1 2 7 Disconnect LED connector C EE x1 Loosen the LED nut D and slide off the connector amp x1 Up Replacement NOTE Make sure to install the LED connector C correctly so it will not interfere with the Drive shaft assembly 1 Reverse the removal procedure 2 Enter Service mode 5 1 1 SR90 Service Manual 3 Perform Cover Feeder DSD sensor
12. lty CF 501 Go to CF 011 Paper bin low sensor faulty CF90 2 7 LEDS 12 January 2004 2 2 LEDS PCB in Cover Feeder D14 D14 Green LED flashes whenever information is sent or received on the Internal CAN If power is switched on but no operations are performed Green LED is off CF90 2 8 12 January 2004 ELECTRICAL COMPONENT LIST 3 DETAILED SECTION DESCRIPTIONS 3 1 ELECTRICAL COMPONENT LIST Page Grid code CF M1 Feed uror d ER CF90 3 2 A1 CF M2 Drive etc X CF90 3 2 A1 CF M3 Blower MOOR dir CF90 3 4 B1 CF Q1 Empty SQNSON CF Q2 Bin home position ng CF Q3 Paper path DSD detection sensor Phototransistor CF Q3 Paper path DSD detection sensor LED 5 04 Paper POSITIONING SCNSOM CF Q5 Paper bin low sensor sese 9 MD3DC POB Communication Cover Feed rr ng Bin extension plate Recepfacle ennenen Power supply CF90 3 1 ELECTRICAL COMPONENT LIST 12 January 2004 3 1 1 REAR VIEW CF Q2 5 2 1 extension plate Receptacle Terminator
13. otor CF M1 in check motors Measure between the orange wire M1 and the violet wire M1 PWM 36V and ground The voltage is approximately 36 VDC Y N Disconnect plug P3 from MD3DC PCB A Measure between P3 7 and violet wire on the motor connector and be tween P3 14 and the orange wire on the motor connector Is there an open circuit in any of the wires Y N Replace MD3DC PCB 2 5 5 5 0 Replace wire Harness Replace motor 1 CF 004 Fault Code CF 004 indicates that the Drive motor 2 has a Short circuit Initial Actions Check fuse F2 on Transformer Procedure Disconnect the motor plug M2 Run the SDS again Fault code CF 005 Open circuit is displayed Y N Disconnect plug P3 from MD3DC PCB A Check wires for Short circuit across leads the orange wire M2 to P3 6 violet and the violet wire M2 to P3 13 orange Is there Short circuit Y N Replace MD3DC PCB Replace wire Harness Replace motor CF M2 CF 005 Fault Code CF 005 indicates that the Drive motor CF M2 has an Open circuit Initial Actions Check fuse F2 on Transformer Procedure Disconnect the motor plug M2 Enter Service mode and start Drive motor CF M2 in check motors Measure between the orange wire M2 and the violet wire M2 PWM 36V and ground The voltage is approximately 36 VDC Y N Disconnect plug P3 from MD3DC PCB Measure between P3 6 and violet wire on the motor connector and b
14. r positioning sensor CF Q4 is clean Procedure Enter the Service mode and select Paper positioning sensor CF Q4 in check sensors Block then unblock the CF Q4 with a sheet of paper The Paper positioning sensor CF Q4 sensor indicates D 0 when the sensor is blocked and D 1 when the sensor is not blocked Y N Go to CF 010 1 Clean the feed rollers 2 Make sure that the Jam clearance baffle is installed correctly 3 Make sure that nothing interferes with the paper path in the Cover feeder CF90 2 6 12 January 2004 FAULT CODE DESCRIPTIONS CF 204 Fault Code CF 204 indicates that during Run the Paper positioning sensor CF Q4 was blocked exceeding timeout Initial Actions Check fuse F2 on Transformer Make sure that the Paper positioning sensor CF Q4 is installed correctly Ensure that the Paper positioning sensor CF Q4 is clean Procedure Enter the Service mode and select Paper infeed sensor BM Q1 in check sensors Block then unblock the BM Q1 with a sheet of paper The Paper infeed sensor BM Q1 sensor indicates D 0 when the sensor is blocked and D 1 when the sensor is not blocked Y N Go to CF 010 2 5 5 5 0 22 1 Clean the Drive shaft tires 2 Make sure that the Jam clearance baffle is installed correctly 3 Make sure that nothing interferes with the paper path in the Cover feeder CF 205 Go to CF 009 Paper path DSD sensor is faulty CF 401 Go to CF 008 Empty bin sensor fau
15. rness Replace MD3DC PCB CF 011 Fault Code CF 011 indicates that the Paper bin low sensor 5 is faulty Initial Actions Check fuse F3 on Transformer Make sure that the Paper bin low sensor CF Q5 is installed correctly Procedure 1 Replace sensor CF Q5 2 Disconnect plug P11 from MD3DC PCB A Measure between J11 10 and J11 12 5V and ground The voltage is approximately 5 VDC Y N Replace MD3DC PCB Connect plug P11 to MD3DC PCB Disconnect plug from sensor CF Q5 Measure between the red wire Q5 and the black wire Q5 5V and ground The voltage is approximately 5 VDC Y N Replace wire Harness Connect the sensor CF Q5 plug Measure between J11 11 and J11 12 5V and ground The voltage is approximately 5 VDC Y N Replace wire Harness Replace MD3DC PCB CF90 2 5 FAULT CODE DESCRIPTIONS 12 January 2004 CF 201 Fault Code CF 201 indicates that during Run the Paper path DSD sensor CF Q3 was not blocked within timeout after the start signal from the copier was detected Initial Actions Check fuse F2 on Transformer Make sure that the Paper path DSD photo transistor sensor and the Paper path DSD LED sensor CF Q3 is installed correctly Ensure that the Paper path DSD sensor CF Q3 is clean Procedure Enter the Service mode and select Paper path DSD sensor CF Q3 in check sensors Block then unblock the CF Q3 with a sheet of p
16. sen screw D CF90 1 5 12 January 2004 1 2 4 HOME POSITION SENSOR 02 B A 1 Remove Rear cover 1 1 1 2 Remove Bin home position Sensor Q2 A x1 3 Remove Connector EE x1 CF90 1 6 12 January 2004 1 2 5 PAPER BIN LOW SENSOR 05 jueunsn py Remove Rear cover 1 1 1 1 Remove Paper bin low sensor Q5 2 x2 3 Remove connector B E x1 2 CF90 1 7 12 January 2004 1 2 6 DRIVE MOTOR M2 ASSEMBLY A D C Removal Remove Rear cover 1 1 1 Disconnect Connector A Eg x1 Remove Drive motor M2 assembly by removing screws x2 Loosen the allen screw C to Drive clutch assembly x1 amp Remove the motor bracket by removing screws D x3 Replacement 1 Reverse the removal procedure 2 Enter Service mode 5 1 1 in SR90 Service Manual 3 Perform Cover Feeder motor calibration 5 5 SR90 Service Manual Adjustment Adjust the Drive clutch assembly so that there is a play between the coupling on the Drive shaft and the Clutch The play should be 0 4 0 3 mm Adjust by loosen screw 0 4 0 3 mm play between the coupling and the clutch CF90 1 8 12 January 2004 1 2 7 DRIVE SHAFT ASSEMBLY T ew 5 5 65 9 lt Remova
17. t plug J20 Disconnect plug P6 from MD3DC PCB Measure between the J6 4 and J6 9 5V and ground The voltage is approximately 5 VDC Y N Replace MD3DC PCB Replace wire Harness 1 Connect plug J20 2 Disconnect the Paper path DSD photo transistor sensor plug Measure between the white wire Photo transistor and the black wire Photo transistor 5 and ground The voltage is approximately 5 VDC Y N Disconnect plug P6 from MD3DC PCB Measure between the J6 10 and J6 22 5V and ground The voltage is approximately 5 VDC Y N Replace MD3DC PCB Replace wire Harness Replace MD3DC CF90 2 4 12 January 2004 FAULT CODE DESCRIPTIONS CF 010 Fault Code CF 010 indicates that the Paper positioning sensor CF Q4 is faulty Initial Actions Make sure that the Paper positioning sensor CF Q4 is installed correctly Procedure 1 Replace sensor CF Q4 2 Disconnect plug P11 from MD3DC PCB A Measure between J11 7 and J11 9 5V and ground The voltage is approxi mately 5 VDC Y N Replace MD3DC PCB 2 5 5 5 0 2 Connect P11 to MD3DC PCB Disconnect plug J20 Measure between P20 6 P20 8 5V and ground in P 20 plug The voltage is approximately 5 VDC Y N Replace wire Harness Connect the sensor CF Q4 plug Measure between J11 8 and J11 9 5V and ground The voltage is approximately 5 VDC Y N Replace wire Ha
18. the red wire Q2 and the black wire Q2 5V and ground The voltage is approximately 5 VDC Y N Replace wire Harness Connect the sensor CF Q2 plug Measure between J11 5 and J11 6 5V and ground The voltage is approximately 5 VDC Y N Replace wire Harness Replace MD3DC Turn motor CF M1 in both directions by hand You should be able to use about the same amount of force throughout the turn Are you able to turn the motor without using a lot of force Y N 1 Make sure that there is no mechanical binding 2 Replace motor CF M1 1 Make sure that the allen screw on the Bin motor roller clutch assy is tighten 2 Replace motor CF M1 CF 002 Fault Code CF 002 indicates that the Feed motor CF M1 has a Short circuit Initial Actions Check fuse F2 on Transformer Procedure Disconnect the motor plug M1 Run the SDS again Fault code CF 003 Open circuit is displayed Y N Disconnect plug P3 from MD3DC PCB Check wires for Short circuit across leads the orange wire M1 to P3 7 violet and the violet wire M1 to P3 14 orange Is there Short circuit YN Replace MD3DC PCB Replace wire Harness Replace motor CF M1 CF90 2 2 12 January 2004 FAULT CODE DESCRIPTIONS CF 003 Fault Code CF 003 indicates that the Feed motor CF M1 has an Open circuit Initial Actions Check fuse F2 on Transformer Procedure Disconnect the motor plug M1 Enter Service mode and start Feed m

Service Manual: CF90

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