service manual SI 62 - FP Mailing · PDF fileservice manual SI 62 Contents Section Page...
Transcript of service manual SI 62 - FP Mailing · PDF fileservice manual SI 62 Contents Section Page...
service manual SI 62
SI 62
service manual SI 62
Contents
Section Page
General 410.00-1
Process description 410.01-1
Mechanical description 410.02-1
Electrical description 410.03-1
Parts lists 410.04-1
service manual SI 62
410.00-1rev. 01.0 - 06/2004
General
service manual SI 62
410.00-2 rev. 01.0 - 06/2004
service manual SI 62
410.00-3rev. 01.0 - 06/2004
Contents
Section Page
1 Function 6
2 Specifications 72.1 Machine specifications 72.2 Paper Insert specifications 82.3 Envelope insert specifications 82.4 Envelope and paper insert specifications 9
3 Preparing the machine for use 103.1 Unpacking 10
service manual SI 62
410.00-4 rev. 01.0 - 06/2004
service manual SI 62
410.00-5rev. 01.0 - 06/2004
Used symbols
In this manual the following symbols are used.
Warning, this symbol indicates a wrong action which can cause a hazard to health or damage the machine.
Warning, this symbol indicates a hazard to life because of high voltage.
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1 Function
figure 1.1
Refer to figure 1.1.
The SI 62 feeds, folds and inserts documents into envelopes and then seals and stacks the envelopes. Automatic monitoring ensures the correct number of inserts per envelope.
The SI 62 is equipped with a variety of special features as programmable jobs, Load ’N Go™, FlexFeed™ (1), double feed control, hopper swap, multifeed, daily mail and PowerFold™(2).
service manual SI 62
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2 Specifications
2.1 Machine specifications
Model : SI 62
Type : inserter system for medium office use.
Overall Dimensions 3- station system height : 670 mm (26.3 inch)width : 420 mm (16.5 inch) length : 1100 mm (43.3 inch)
(with side exit 1200 mm/47.2 inch receiving tray 1350 mm/ 53.1 inch)
Weight : 80 kg (176 lb)
Noise level : < 70 dB(A) (following ISO 11203)
Theoretical max. speed : 2200 inserts p/h, depending on application.
Operating temperature : 10 - 40°C (50 - 104°F)
Humidity : 30 - 80%
Power consumption : 100V AC / 50Hz / 3,0 Amps 115V AC / 60Hz / 3,0 Amps230V AC / 50Hz / 1,5 Amps
Approvals : EMC Certificate conform EMC-Directive. FCC Certificate conform 47CFR, part 15.CB Certificate conform IEC 60950. UL listed I.T.E. (Information Technology Equipment),conform UL-IEC 60950, file: E153801.Conform NEN-EN-IEC 60950 and derivates.
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2.2 Paper Insert specifications
Paper sizes minimum maximumwidth* : 130 mm (5.1 inch) 236 mm (9.3 inch)length** : 90 mm (3.5 inch) 356 mm (14.0 inch)
Quality*** : 60 gr/m2 250 gr/m2
(15 lb bond) (62.5 lb bond)
Booklets up to approximately 1 mm (0.04 inch) thickness,depending on stiffness.
Folding capacity : 5 sheets (max. 80 gr/m2)
* When folded max. 230 mm (9.1 inch)** The minimum document size used for the upper feeder is 115 mm (4.5 inch)
*** When folded max. 170 gr/m2.
2.3 Envelope insert specifications
Envelope sizes : Standard BRE (Business Reply Envelopes)
minimum maximum
Quality : 80 gr/m2 120 gr/m2
(20 lb bond) (30 lb bond)
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410.00-9rev. 01.0 - 06/2004
2.4 Envelope and paper insert specifications
Maximum insert specifications are based on single sheets. When multiples are handled, more room inside the envelope is needed depending on application.
figure 2.1
Remarks• The specification of the paper handling equipment is often wider than that of the envelopes and
documents handled. The condition of material handled will limit the specified environmental conditions.
• We recommend that materials to be handled are stored at a temperature of 20°C (68°F) with a relative humidity factor of 50%. If difference in temperature occurs between store room and mailing area, the material has to be stored near the machine at least 24 hours before use.
• Self-copying paper may cause rubber parts to wear quicker. The rubber used in this machine has the best resistance to Wiggins Teape material.
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service manual SI 62
410.00-10 rev. 01.0 - 06/2004
3 Preparing the machine for use
First the machine must be unpacked. After unpacking and installing the machine is ready for use.
3.1 Unpacking
figure 3.1
Step 1
Step 2
Step 3
Step 4
80 Kgs176 Lbs
Place the machine in the optional furniture or on a solid table
service manual SI 62
410.01-1rev. 01.0 - 06/2004
Process description
service manual SI 62
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service manual SI 62
410.01-3rev. 01.0 - 06/2004
Contents
Section Page
1 Overview 51.1 Feeding documents 51.2 Vertical document transport 61.3 Transport to and from the collator 61.4 Folding 71.5 Envelope transport 81.6 Document input and insert 81.7 Envelope ejecting, sealing and exiting 91.8 Parallel processing 91.9 Legend 11
service manual SI 62
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service manual SI 62
410.01-5rev. 01.0 - 06/2004
1 Overview
The processing of documents by the consists of a number of sequential processes:• Feeding documents.• Vertical document transport.• Transport to and from the collator.• Folding.• Envelope transport.• Document input and insert.• Envelope ejecting, sealing and exiting.• Parallel processing.The figure shows a schematic overview of the process. All mechanical items that are necessary to discuss the process are projected on the LH side of the machine. With a few exceptions auxiliary mechanical items (such as gears, belts et cetera) are shown. The parts lists (document 410.04) provide mechanical details.
1.1 Feeding documents
Only feeders with automatic separation are used.The upper feeder (in position 2 or 3) can be used for processing daily mail. To this purpose a mechanic switch is set in the daily mail position.The machine has two or three feeders. There is a 1½-station, a 2-station and a 2½-station version.In the version with three feeders (the 2½-station version) the lowest feeder (the "½", in position 1) can only process documents with a length of up to about 150 mm (6 inch). This feeder is fitted with a so-called short tray.For the documents to be fed the following rules apply:• Documents with the single fold and letter fold types are fed with the orientation face up and
leading. The address carrying document is to be fed from the highest active feeder.• Documents with the zigzag fold type must be fed with the orientation face down and trailing. The
address carrying document is to be fed from the lowest active feeder.
The physical feeding process is fairly straightforward: a document is separated by 79 - 81 (feeder 3), 72 - 74 (feeder 2) or 65 - 67 (feeder 1) and exited to the vertical track by 77 and 78 (feeder 3), 70 and 71 (feeder 2) or 63 and 64 (feeder 1). The paper transport is monitored by the feeder photocell PH3 (feeder 3), PH2 (feeder 2) or PH1 (feeder 1). The double feed security check is performed by the Double Feed Control unit DFC3 (feeder 3), DFC2 (feeder 2) and DFC1 (feeder 1). The feeders are mechanically driven from the main motor M1 by a clutch (feeder clutches CL1, CL2 and CL3).The combination of CL1 and PH1 (CL2 and PH2; CL3 and PH3) ensures a well-defined waiting position at the feeder output, prior to entering the vertical track.The separation process is based on separating the upper document in the document hopper. To this purpose the feeder rollers (67, 74, 81) adapt their vertical positions to the current amount of documents in the hopper.In order to further reduce the risk of double feeding documents (partial or full document overlapping) a mechanical delay is established between the current document and the next one to be separated from the document hopper. Soon after the current document leaves a feeder, there is a time when roller 67 (74, 81) no longer touches the leaving document. Without the mechanic delay the separation of the next document would immediately start. However, during a turn of between 135 and 225 degrees this roller will not turn, prior to the drive catching up. This causes a gap between the trailing edge of the current document and the leading edge of the next document. Note that this mechanical behaviour is possible, not only by the 135-225 degrees free stroke, but as well by the
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fact that roller 67 (74, 81) has freewheel action in forward direction. The latter is necessary to enable the paper acceleration in the feeder.
1.2 Vertical document transport
The vertical track consists of one driven axle per feeder (75, 68, 61), plus one driven axle in the lower vertical track (45). All these axles carry two rollers, except for 75 (at the top feeder), which carries four rollers. This is necessary for straightening the paper prior to passing the optional reading head RH1. The driven rollers have their counterparts in rollers 76, 69, 62 and 44. If the OMR option is installed, the paper transport prior to entering the reading head is monitored by the reading head photocell PH4. (The reading head RH1 is present if the OMR option is installed. In the overview it is located directly below PH4.) This monitoring is necessary for establishing the reading window.
Depending on the number of documents to be delivered by each feeder there are two ways in which documents can be transported along the vertical track:• One sheet per feeder per set (pane cycle). The various documents of a set are fed from the
feeders in such a way that these documents are partly overlapping each other. This pane-like overlapping ensures a higher throughput.
• More sheets from the same feeder per set (sequential cycle). This is relevant for multi feeding and OMR. Documents are transported along the vertical track without touching each other. Only after joining the set in the making they do touch each other.
Refer to section 1.3 for details on the way in which a set is composed.
1.3 Transport to and from the collator
Before discussing the physical aspects of collating a set it is relevant to discuss the way in which the set is collated (i.e. composed).Of course the operator must have full control over the order in which the various documents of a set are actually present in the filled envelopes. The following rules apply:• If a feeder adds more than one document to a set (multi feeding), these documents are first of
all processed, in the order in which they are separated from the feeder hopper.• The feeders are processed in the order highest active feeder first, lowest active feeder last. This
is independent of the fold type.
Based on the actual number of documents from each cycle, the machine composes a set based on the minimum amount of cycles and, if possible, a pane cycle in stead of a sequential cycle.
In the case of OMR processing the document(s) from feeder 3 is/are always processed via sequential cycles.Between two successive cycles of the collating process a process that is called shunting is necessary. Shunting implies that, prior to being joined by a new document (sequential cycle) or new documents (pane cycle), the partially completed set in the collator is partially moved out of the collator area, into the direction of the fold unit. This is necessary to prevent the leading edge (i.e. entering the collator area first) of the paper entering from the vertical track from interfering with the leading edge (i.e. leaving the collator area first) of the partially completed set.
Now for the physical details. The collator area consists of a set of rollers (46, 50, 53, 56 and 60) that can be driven in both directions by the collator motor M2, and a set of counter rollers 47, 48, 49, 52,
service manual SI 62
410.01-7rev. 01.0 - 06/2004
54, 55 and 58. In the IN direction of M2 documents are fed into the collator area, in the OUT direction they are moved out of the collator area.The entry of documents into the collator area is monitored by the collating area photocell PH5. A document set leaving the collator area is monitored by the folder input photocell PH6.Documents are fed into the collator area from the vertical track, or back into the collator area in the second stage of the shunt process. The documents are aligned against document stop position 59. (In this machine stop positions 51 and 57 are not used.)During shunting the collator motor M2 first turns in the IN direction, then in the OUT direction.Once a set is complete, documents are exited from the collator to the fold unit if a set is complete. In that case the collator motor M2 is activated in the OUT direction.Transport into and from the collator area is assisted by three collator belts. One belt is situated at the RH side, a second belt is situated at the LH side and the third belt is located at the centre line of the documents. All three belts are connected between pulleys on 50 and 60. In addition the middle belt drives 53 and 56 as well.
1.4 Folding
The folding process is based on the timed impact action of a fold knife: one per fold pocket.As soon as the paper enters a fold pocket and a fold is to be made, the fold deflector is turned upwards. The fold knife is in its rest position; it is turned backwards. The paper is directed into the fold pocket. At the right time the fold knife moves forward and pushes the paper between the fold rollers. The fold is located at the place where the paper touches the tangent between the upper and lower fold roller. The timing of the fold knife movement is based on the detection of the paper by the folder input photocell PH6, machine parameters and job fold settings.
Now for the folding details. The paper of a completed set leaves the collator area. This is detected by the folder input photocell PH6. The paper is transported to the first fold pocket by the fold input rollers 42 and 43. Fold deflector 41 moves up, so paper entering the first fold pocket will be directed in upward direction. At the appropriate time fold deflector 41 moves down and the fold knife 40 (which hinges around axle 39) moves forward: the first fold will be made. Directly after the fold has been made fold knife 40 returns to the rest position. This process is controlled by the first fold pocket clutch CL4, which drives the curve gear 37, which controls the movement of fold knife 40 and fold deflector 41. The axle for the curve gear also carries the brake disc 38, the status of which is monitored by slotted photocell SPH3. The 360 degrees fold cycle of the brake disk consists of a 120 degrees part (fold deflector upwards) and a 240 degrees path (fold deflector downwards plus the impact action of 40). The brake disc is mechanically loaded by a positioning lever and a torsion spring. The hinge axle 39 also carries the lever for the actuator of fold deflector 41. In this way all movements related to the first fold pocket are synchronized.
After leaving the fold rollers 35 and 36 the paper enters the second fold pocket. The fold deflector 34 moves up, so paper entering the second fold pocket will be directed in upward direction. The paper guide 33 also moves up. This guide is necessary in the second fold pocket to retain the fold that has been made in the first fold pocket. The paper is limited to a small area between paper guide 33 and a fixed guide plate (not shown in the figure, but to the left of 33). At the appropriate time the fold deflector 34 moves back and both the fold knife 32 and the guide plate 33 (which both hinge around axle 31) move forward: the second fold will be made. Directly after the fold has been made, fold knife 32 returns to its rest position. This process is controlled by the second fold pocket clutch CL5, which drives the curve gear 29, which controls the movement of fold knife 32, paper guide 33 and fold deflector 34. The axle for the curve gear also carries the brake disc 30, the status of which is monitored by slotted photocell SPH4. The 360 degrees fold cycle of the brake disk consists of a
service manual SI 62
410.01-8 rev. 01.0 - 06/2004
120 degrees part (fold deflector and paper guide upwards) and a 240 degrees path (fold deflector and paper guide downwards plus the impact action of 32). The brake disc is mechanically loaded by a positioning lever and a torsion spring. The hinge axle 31 also carries the lever for the actuator of fold deflector 34. In this way all movements related to the second fold pocket are synchronized.Finally the paper leaves the fold unit on its way (transported by 27 plus 28 and 13 plus 14) to the insert table.
1.5 Envelope transport
All the rollers for this process stage (1, 4, 6, 8, 10 and 11) are engaged to the main drive by the envelope track clutch CL6. During the document and insert stage these rollers are disengaged. The envelope transport subsystem can be manually moved by the RH hand knob, at the LH side of the machine (behind the LH front cover). The counter rollers 3, 5, 7, 9 and 12 can be decoupled from there driven counterparts by a CCW movement of the release handle at the LH side of the machine. In the final ejecting, sealing and exiting stage the driven rollers are engaged once again to release the envelope (held between 11 and 12) and to feed the next envelope to the insert table. This envelope (and maybe the next one as well) has already been separated and is present somewhere in the envelope track.
Note. Roller 6 has freewheel action in the forward direction. This is necessary because for process reasons the envelope transport speed at rollers 8, 10 and 11 is higher than the transport speed at rollers 1, 4 and 6. Given the fact that, once an envelope has been separated, the next envelope is separated, you can notice an increasing distance between two successive envelopes as they travel through the envelope track.
First of all by the action of the feed and separation rollers (1 and 2) an envelope is separated from the stack in the hopper and transported via three pairs of transport rollers (3 - 8). The envelope track photocell PH7 detects the leading and trailing edge of the envelope.
The envelope then passes the flap rollers 9 and 10. The combined action of the flap scraper and the lower linear speed of the flap rollers 9 and 10 (compared with the speed of 7 and 8) results in some buckling and the opening of the envelope. The flap is the trailing part of the envelope passing the flap rollers and the envelope flap track photocell PH8.
Pulse measurements (measured via slotted photocell SPH1) during the presence of the envelope under PH7 and PH8 provide information on the length of the not yet opened envelope, the opened envelope and the time at which the envelope transport is suddenly stopped with the envelope on the insert table. The sudden stop is the result of disengaging by the envelope track clutch CL6 and the friction brake 9a. The envelope flap now is fixed between 11 and 12. (The envelope stop position can be corrected via the user interface of this machine.)
1.6 Document input and insert
Once the envelope is on the insert table, the fingers solenoid So1 is shortly activated. The fingers are moved forward into the envelope. The envelope stays in place, for it is fixed between 11 and 12. This is a preparation for inserting the document set into the envelope.Now the document set can be inserted. This set leaves the fold unit (transported by 27 plus 28 and by 13 plus 14), is detected by the insert table photocell PH9 and passes under the fingers before entering the envelope.
410.01-9rev. 01.0 - 06/2004
service manual SI 62
1.7 Envelope ejecting, sealing and exiting
The insert of the set is considered finished if and when the insert table photocell PH9 detects the trailing edge of the set. Then a number of actions take place: (a) clutch CL6 is activated to release the flap and to feed the next envelope to the insert table; (b) the insert table solenoid So2 is shortly activated, resulting in the ejection roller 16 moving down. (By spring action, after switching So2 off, these driven rollers are pulled high again.) Now the envelope is ejected from the insert table. So2 is deactivated as soon as safely can be assumed that the filled envelope is between 17 and 18, so further transport is guaranteed.
The filled envelope passes rollers 17 and 18, the moistening brushes, the sealing track rollers 19 and 20 and the lower sealing roller 22 plus its counter roller 21. The leading envelope edge triggers flag switch FS1.The upper reverse roller 25 is held high (i.e. this roller doesn't contact the lower reverse roller 24) by a spring. A certain time after triggering FS1 the sealing solenoid So3 is activated. At this moment the envelope flap is still between 21 and 22. The envelope body is between the upper and lower reverse rollers, so the envelope position is clearly defined. (This envelope sealing position can be corrected via the service menu.) By the So3 action the upper reverse roller now is temporarily lowered. Given the turning direction of the lower reverse roller, the transport direction of the envelope is abruptly changed from an "upstream" to a "downstream" direction. Assuming that the flap fold line of the envelope has passed 21 and 22, this is now the leading edge of the envelope being transported through the sealing rollers 22 and 23. After passing the sealing rollers the envelope is exited to the exit of the machine. The sealing solenoid So3 is switched off as soon as the leading envelope edge is detected by the exit photocell PH10. The exit photocell PH10 monitors the passing envelope.As soon as PH10 has detected the trailing envelope edge, the next filled envelope can be transported from the insert table to the exit of the machine.
1.8 Parallel processing
The process description discussed above deals with one specific set and one specific envelope as these items travel through the machine. However, as soon as a certain process stage has been completed for the current document, set or envelop, this process stage is repeated for the next document, set or envelope.• A very short time after the trailing edge of the separated envelope has passed roller 1, the next
envelope is separated. In the Auto mode on each time several envelopes are on their way to the insert table.
• The next filled envelope can be transported as soon as the previous one has completely passed the exit photocell PH10.
• Only after it has been established that (a) the previous set has passed the insert table photocell PH9; (b) the envelope with this set can be ejected and sealed; (c)the flap of the current envelope has been opened, the next set will be transported from the collator via the two fold pockets to the current envelope on the insert table.
• In section 1.1 the delay between to successive documents fed to the same feeder is discussed.
rev. 01.0 - 06/2004410.01-10
service manual SI 62
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service manual SI 62
410.01-11rev. 01.0 - 06/2004
1.9 Legend
Note 1. Parts with an arrow are mechanically driven (by the main motor M1 or by a the collator DC motor M2).
Note 2. For reasons of cross-reference the identification of sensors and actuators as used in the electrical description (document 410.03) is mentioned here as well.
GeneralM1 Main motor. Provides the primary mechanical drive for the feeder clutches CL1 –
CL3, the folder clutches CL4 & CL5 and the envelope track clutch CL6. Directly drives the vertical track transport (75, 68, 61, 45), the folding subsystem (42&43; 35&36; 27&28) and the inserter main drive (15, 17, 19, 20, 22, 23). If the upper unit is in place, items 14, 16, 24 and 26) are driven as well. All items that are directly driven by M1 can be activated with the LH hand knob (behind the LH front cover).
PD1 Pulse disc (mounted on roller 19). Monitored by slotted photocell SPH1. Provides information on the process timing.
MS1 Safety switch for the upper unit.MS2 Safety switch for the front cover.MS3 Safety switch that guards the part of the collator area that can be opened by the user.
FeedersLower feeder (1)
CL1 Feeder 1 clutch. Drives 63, 66 and 67. Activated during the transport of the separated document to its waiting position. Activated once again when this document is transported to the vertical track and (after a short delay) the next document is separated.
PH1 Feeder 1 photocell.63 Driven output rollers.64 Counter rollers for 63.65 Lower separation roller. Connected to the feeder frame via a constant-torque device.66 Feed axle with upper separation roller. Freewheel action in forward direction.67 Paper puller axle with two rubber rollers. Adapts its vertical position to the amount of
documents in the hopper. Freewheel action in forward direction. Free stroke (between 135 and 225 degrees) ensures a safe distance between successive separated documents, in order to prevent double feeds.
DFC1 Double Feed Control unit for feeder 1.
Middle feeder (2)CL2 Feeder 2 clutch. Drives 70, 73 and 74. Activated during the transport of the separated
document to its waiting position. Activated once again when this document is transported to the vertical track and (after a short delay) the next document is separated.
PH2 Feeder 2 photocell.70 Driven output rollers.71 Counter rollers for 70.
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410.01-12 rev. 01.0 - 06/2004
72 Lower separation roller. Connected to the feeder frame via a constant-torque device.73 Feed axle with upper separation roller. Freewheel action in forward direction.74 Paper puller axle with two rubber rollers. Adapts its vertical position to the amount of
documents in the hopper. Freewheel action in forward direction. Free stroke (between 135 and 225 degrees) ensures a safe distance between successive separated documents, in order to prevent double feeds.
DFC2 Double Feed Control unit for feeder 2.
Upper feeder (3)CL3 Feeder 3 clutch. Drives 77, 80 and 81. Activated during the transport of the separated
document to its waiting position. Activated once again when this document is transported to the vertical track and (after a short delay) the next document is separated.
PH3 Feeder 3 photocell.77 Driven output rollers78 Counter rollers for 77.79 Lower separation roller. Connected to the feeder frame via a constant-torque device.80 Feed axle with upper separation roller. Freewheel action in forward direction.81 Paper puller axle with two rubber rollers. Adapts its vertical position to the amount of
documents in the hopper. Freewheel action in forward direction. Free stroke (between 135 and 225 degrees) ensures a safe distance between successive separated documents, in order to prevent double feeds.
DFC3 Double Feed Control unit for feeder 3.
Vertical track44 Counter roller of 45 (in the upper unit).45 Driven vertical transport axle.61 Driven vertical transport axle. On this axle feeder 1 (lower) clutch CL1 is mounted (at
the LH side of the machine). This clutch drives 63, 66 and 67.62 Counter rollers for 61 (in upper unit).68 Driven vertical transport axle. On this axle feeder 2 (middle) clutch CL2 is mounted
(at the LH side of the machine). This clutch drives 70, 73 and 74.69 Counter rollers for 68 (in upper unit).75 Driven vertical transport axle. On this axle feeder 3 (upper) clutch CL3 is mounted (at
the LH side of the machine). This clutch drives 77, 80 and 81.76 Counter rollers for 75 (in upper unit).PH4 Reading head photocell. Only present and operational if OMR is installed.RH1 Reading head. Only present and operational if OMR is installed.
Feeders
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410.01-13rev. 01.0 - 06/2004
CollatorM2 Collator motor. Drives 46, 50, 53, 56 and 60 in forward or reverse direction.PD2 Pulse disc mounted on the axle of the collator motor M2. Monitored by slotted
photocell SPH2.PH5 Collating area photocell. Guards the entry of documents from the vertical track.46, 50, 53, 56, 60
Collator rollers driven (either forward or reverse) by the collator motor M2. In collator arm. Actual transport is realized with three belts, driven by and driving 50, 53, 56 and 60.
51 Document stop position for 6-inch documents. Not used in this machine!57 Document stop position for 12-inch and A4-sized documents. Not used in this
machine!59 Document stop position for 14-inch documents.47, 48, 49, 52, 54, 55, 58
Free running collator rollers.
Fold unitPH6 Folder input photocell.42 Lower fold input roller.43 Upper fold input roller.35 Lower fold roller for first fold pocket.36 Upper fold roller for first fold pocket. In upper unit.27 Lower fold roller for second fold pocket.28 Upper fold roller for second fold pocket. In upper unit.39 Control axle for first fold pocket. Hinge for 40. Moves the lever that in its turn moves
the fold deflector actuator of 41 upwards.40 Fold knife for first fold pocket.41 Fold deflector for first fold pocket.37 Curve gears for first fold pocket (1 x LH, 1 x RH). Controls movement of 40.
38 Brake disc for first fold pocket. Spring loading ensures two static mechanical states.
PD3 Cam disc of first fold pocket. Monitored by slotted photocell SPH3.31 Control axle for second fold pocket. Hinge for 32 and 33. Moves the lever that in its
turn moves the fold deflector actuator of 34 upwards.29 Curve gears for second fold pocket (1 x LH, 1 x RH). Controls movement of 32 and
33.30 Brake disc for second fold pocket. Spring loading ensures two static mechanical
states.PD4 Cam disc of second fold pocket. Monitored by slotted photocell SPH4.32 Fold knife for second fold pocket.33 Moving paper guide for second fold pocket.34 Fold deflector for second fold pocket.CL4 First fold pocket clutch. Drives 37.CL5 Second fold pocket clutch. Drives 29.
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410.01-14 rev. 01.0 - 06/2004
Envelope feedingCL6 Envelope track clutch. Mounted on clutch shaft, at the RH side of the machine. On
this shaft two gears take care for the mechanical interface between the permanently M1 driven subsystem and the envelope track subsystem. CL6 drives 1, 4, 6, 8, 10 and 11.
1 Feed roller. Activated by the envelope track clutch CL6.2 Separation roller.4, 6, 8 Driven envelope transport rollers. Activated by the envelope track clutch CL6.3, 5, 7 Counter rollers for 4, 6 and 8. These rollers can be moved (by the release handle) in
order to solve a paper jam in the envelope track.PH7 Envelope track photocell.10 Driven envelope transport roller (flap opening stage). Activated by the envelope track
clutch CL6. Speed of 10 somewhat lower than that of 8, in order to assist flap opening.
11 Driven envelope transport roller (flap opening stage). Activated by the envelope track clutch CL6. On the axle at the LH side of the machine the RH hand knob (behind the LH front cover) is mounted.
9, 12 Counter rollers for 10, 11. These rollers can be moved (by the release handle) in order to solve a paper jam in the envelope flap track.
9a Friction brake.PH8 Envelope flap track photocell.
Inserting, ejecting, sealing and exitingPH9 Insert table photocell.So1 Fingers solenoid. Moves fingers forward into envelope to enable inserting the set.13 Lower insert roller.14 Upper insert roller (in the upper unit). 14 and 13 provide final set transport prior to
inserting in envelope.15 Lower first ejection roller. On the axle at the LH side of the machine the LH hand knob
(behind the LH front cover) is mounted. On this axle at the RH side of the machine the main pulley is mounted.
16 Upper first ejection roller (in the upper unit). Lowered by the action of the insert table solenoid So2.
So2 Insert table solenoid. Shortly activated. Deactivated as soon as 17&18 have taken over the transport function.
17 Lower second ejection roller. In this area the moistening brushes are located.18 Upper second ejection roller (in the upper unit).19 Driven sealing track roller. On the axle at the RH side of the machine the pulse disc
PD1 (monitored by slotted photocell SPH1) is mounted.20 Driven sealing track roller.21 Counter roller for 22 (in the upper unit).22 Lower sealing roller. A gear on the axle (on the RH side of the machine) provides via
an intermediate gear the mechanical interface to all the driven parts in the upper unit (14, 16, 24, 26).
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23 Upper sealing roller.FS1 Flag switch. Note. FS1 is actually mounted on the tangent line of 24 and 25.So3 Sealing solenoid. Moves 25 down during a short time. Deactivated as soon as 22&23
have taken over the transport function.24 Lower reverse roller (in the upper unit).25 Upper reverse roller (in the lower unit). Lowered by the action of the sealing solenoid
So3.26 Not used in this machine.PH10 Exit photocell.
Inserting, ejecting, sealing and exiting
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service manual SI 62
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Mechanical
service manual SI 62
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service manual SI 62
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Contents
Section Page
1 Covers and plates 81.1 RH side cover 91.2 LH side covers 91.3 Top cover feeders, covers collator area, power supply cover 101.4 Covers upper unit 11
2 Electrical components 122.1 Main board 122.2 FRAM and Display board 13
3 Feeder modules and vertical transport RH 143.1 Drive mechanism RH 153.1.1 Belts 153.1.2 Pulleys 163.2 Drive mechanism LH 163.2.1 Belt 163.2.2 Clutch and Pulley 16
4 Feeders 174.1 Top feeder (feeder 3) 174.2 Middle feeder (feeder 2) 194.3 Lower feeder (feeder 1) 214.4 Automatic separation feeder with daily mail 234.4.1 Rubber paper pullers 234.4.2 Pulley of paper puller axle 254.4.3 Upper separation roller 264.4.4 Lower separation roller 274.4.5 Gears 284.5 Automatic separation feeder 28
5 Vertical transport 29
6 Collating area 306.1 Belts 316.1.1 Transportation belts 316.2 Guide rollers 31
7 Folder 327.1 RH drive mechanism 327.1.1 Belts 327.1.2 Pulleys 347.1.3 Gears 347.2 LH drive mechanism 357.2.1 Fold mechanism 367.2.2 Clutches 37
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7.2.3 Curved folder gears 377.3 Rollers 417.3.1 Input rollers 417.3.2 Lower fold rollers 437.3.3 Upper fold rollers 44
8 Main drive mechanism inserter 458.1 Belts 458.1.1 PJ-belt 458.1.2 Drive belt inserter 468.1.3 Belt envelope feed 478.2 Pulleys 488.3 Gears 488.4 Clutches 49
9 Envelope feed 529.1 Hopper 529.1.1 O-rings 529.1.2 Separation roller 539.1.3 Feed roller 539.2 Envelope track 549.2.1 Lower rollers 549.2.2 Upper rollers 559.2.3 Rubber roller 569.2.4 Finger solenoid 56
10 Upper unit 5810.1 Drive mechanism 5810.1.1 Belt 5810.1.2 Pulleys 5910.1.3 Gears 5910.2 Document inserting 6010.2.1 Rollers 6010.2.2 Gears 6010.2.3 Ejection solenoid 6210.3 Envelope transport and sealing 6310.3.1 Rollers 6310.3.2 Sealing solenoid 64
11 Envelope transport 6511.1 Lower ejection rollers 6511.2 Sealing track transportation rollers 66
12 Envelope sealing and ejection 6712.1 Upper sealing roller 6712.2 Lower sealing roller 67
13 Sensors 6813.1 Safety switches 6813.2 DFC and photocells 72
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13.2.1 Feeders 7213.2.2 Vertical transport 7413.2.3 Collator area 7513.2.4 Folder 7713.2.5 Inserter 78
14 Adjustments 8314.1 Main drive PJ-belt 8314.2 Main drive belt feeders/folder 8414.3 Main drive belt inserter 8514.4 RH drive belts 8614.5 Drive belt upper folder section 8714.6 Paper guide 8814.7 Solenoids 8914.8 Separation roller 9114.9 Friction brake 9214.10 Flap scraper 93
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service manual SI 62
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General instructions
Disconnect the mains supply before performing any maintenance.
WarningThe covers and safety switches are fitted for your protection. Do not operate the machine with any cover removed and with a safety switch cheated, or a hazard to health will exist.
Throughout this manual the terms left and right-hand side and front and rear side of the machine are used. These are made with the machine viewed from the input (document feed) side of the machine.
The replacement procedures are the reversal of the removal procuderes.
LEAD: If you remove different parts of the machine, put the screws are nuts of bolts back in the removed part.
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1 Covers and plates
figure 1.1
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1.1 RH side cover
Refer to figure 1.1Open the loc by lifting the hand grip 4. Remove the six screws 1 as shown and one screw 3 inside the RH side cover 2. Remove the RH side cover.
1.2 LH side covers
Refer to figure 1.1.Open the loc by lifting the hand grip 4. Cover 8 is hinged to the inside frame and can be opened. Remove two screws 6 on the outside and three screws 5 inside the LH side cover 7. Remove the LH side cover. Remove three screws 13 from the protect cover 9 and remove the cover. Remove the water tray 12 carefully. Remove two screws 11 from the wiring cover 10 and remove the cover.
The manual for service and testing can be found inside the machine beside the LH side cover.
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410.02-10 rev. 01.0 - 06/2004
1.3 Top cover feeders, covers collator area, power supply cover
figure 1.2
Refer to figure 1.2.Remove the LH- and RH side covers as described in paragraph 1.1 and 1.2. Remove the top cover feeder1 by removing two nuts 2 and two tight-lipped on both sides. Loose two screws 4 of the top cover 3 of the collator and remove the cover. Remove four screws 8 of the bottom cover 7 of the collator and remove the cover. Remove three screws of the power supply cover 6 and remove the cover. Remove the water tray and place the machine carefully at the right hand side on a felt path (very heavy). Loose three hex. head screws 10 of the bottom plate 9 and remove the bottom.
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1.4 Covers upper unit
figure 1.3
Refer to figure 1.3.The covers should be removed in the following order:• lift the loc by lifting the hand grip 1• remove two nut’s 2 and two screws 3 inside the upper unit 4.
3
4
2
1
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2 Electrical components
Warning. Potential hazard may exist to electronic hardware in conditions with static electricity. It is advised that, when handling electronic parts, an earth connected wrist band is used in order to be permanently discharged from static electricity.
figure 2.1
2.1 Main board
Disconnect the wiring to the main board 1and remove the screw 2 and lock washer and spacer. Carefully pull the main board from the board holders as shown.
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2.2 FRAM and Display board
figure 2.2
Refer to figure 2.2.Open the loc by lifting the hand grip as shown in figure 1.1. Remove the screws and spacers from the cover plate, remove the cover plate as shown in figure 1.3.
Disconnect the wiring. Remove the display unit by removing the four screws 1. Remove cover plate 2, spacers 3 and finally display board 4 and rubber pad key pad 5.
Note: Connect the wiring before replacing the display board. Be sure to replace the four spacers .
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service manual SI 62
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3 Feeder modules and vertical transport RH
The feeders, the vertical transport and the fold unit are driven by belt 4 and the accompanying pulleys, gears, etc. as shown in figure 3.1.When the machine is running the four transportation axles are continuously driven by the belts 4, 5 and 6. The three upper transportation axles are equipped with a clutch and a pulley. When, for example, the clutch 2 is activated the accompanying feeder is driven by pulley 3 and belt 1 and a document is fed to the vertical transport track.
Note: With the one and a half and two stations versions, the belt 6 and upper transportation axle is not mounted.
figure 3.1
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service manual SI 62
410.02-15rev. 01.0 - 06/2004
3.1 Drive mechanism RH
figure 3.2
3.1.1 Belts
Refer to figure 3.2.Belt (item 8)Slacken the two screws of belt tensioner 10 and shift the belt tensioner downwards. Remove the belt 8 from the pulleys.
Belt (item 3)Slacken the hex head screw of belt tensioner 1. Remove the belt 3 from the pulleys.
Belt (item 12)The belt 12 is removed in the same way as the belt 3.
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RH
service manual SI 62
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3.1.2 Pulleys
Refer to figure 3.2Pulleys (item 4, 5, 7, 9 and 11)The pulleys 4, 5, 7, 9 and 11 are "snapped" to their cyl. pins and can be removed by pulling them of the axle. Pulley (item 6)Loosen the main belt, PJ belt and drive belt inserter. Remove the spring clip and slide the main pulley of the axle.Pulley (item 13)Remove the hex head screw of the belt tensioner 2 and withdraw the tensioner. Slide the pulley 5 from the axle, than remove the cyl. pins from the axle and slide the pulley 13 of the axle.
3.2 Drive mechanism LH
figure 3.3
Refer to figure 3.3.
3.2.1 Belt
Unhook the tension spring 2 from the inside frame and remove the belt 1 from the pulley 3.
3.2.2 Clutch and Pulley
Disconnect the wiring of the clutch. Remove the spring clip 6 and slide the clutch 5 and the disc 4 and the pulley 3 of the axle.
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service manual SI 62
410.02-17rev. 01.0 - 06/2004
4 Feeders
The following section describes in which way the complete feeders must be removed. All the feeders are provided with dividable drive axles. Before working on the feeders remove the hoppers.After removing the extension part of the drive axle (axle 9, figure 4.1), each feeder can be removed separately. Take care that it is a left side screw-threaded axle end. When it is loosened, the main axle has to be fixed by a pin on one of the holes.
At the RH side the feeders are equipped with a tension spring for proper lifting of the feeder. The tension spring is hooked on a mounting bracket at the frame. Do not remove the mounting bracket or exchange the tension spring from one to another feeder. Each spring is specially adjusted from the factory by positioning the mounting bracket.
4.1 Top feeder (feeder 3)
Remove the top cover feeders.
figure 4.1
Refer to figure 4.1.On the RH side of the feeder, unhook tension spring 7 from the screw 8.On the LH side of the feeder the following components must be removed:• Disconnect the wiring of the feeder and cut the wire straps. • Remove the wiring from the LH inside frame.• The spring clip 1, clutch 2 and the belt 4 and the pulley 3 of the top transportation axle.• Unhook the tension springs 5 from the inside frame.• Remove the screw of the LH and RH side hinge pin 6 of the top feeder.• Remove top transportation axle 10 by moving it in the RH direction.
7 10 6 5 4 3 2
9
18
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figure 4.2
Refer to figure 4.2.Remove the feeder as follows: • Move the feeder a bit downstream as indicated (A)• Lift the RH side of the feeder first and remove the feeder from the machine (B).
Note: Be careful when replacing feeder 3, the hinge pin at the RH side is locking the ball bearing.
B
A
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4.2 Middle feeder (feeder 2)
figure 4.3
Refer to figure 4.3.On the RH side of the feeder, unhook the tension spring 2 from the screw 1.On the LH side of the feeder the following components must be removed:• Disconnect the wiring of the feeder and cut the wire straps. • Remove the wiring from the LH inside frame.• The spring clip, clutch 9 and the belt and the pulley of the middle transportation axle (remove
axle to the RH side).• Un hook the tension 10 spring from the inside frame.• Remove two hex head’s and the guide plate 5. • Remove the screw of the LH and RH side hinge pin 11 of the middle feeder.
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service manual SI 62
410.02-20 rev. 01.0 - 06/2004
figure 4.4
Refer to figure 4.4.Remove the middle feeder as follows:• Move the feeder a bit downstream (A)• Remove the feeder by turning it out of the machine as indicated (B).
Note: Be careful when replacing feeder 2, the hinge pin at the RH side is locking the ball bearing.
RH LH
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4.3 Lower feeder (feeder 1)
figure 4.5
Refer to figure 4.5.
On the RH side of the feeder, onhook the tension spring 2 from the screw 1.On the LH side of the feeder the following components must be removed:• Disconnect the wiring of the feeder and cut the wire straps. • Remove the wiring from the LH inside frame.• The spring clip 7, clutch 6 and the belt 8 and the pulley 5 of the lower transportation axle.
Remove the axle to the RH side.• Unhook the tension springs 4 from the inside frame.• Remove the screws at the LH and RH side of hinge pin 3 of the lowest feeder.
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RH
LH
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410.02-22 rev. 01.0 - 06/2004
figure 4.6
Refer to figure 4.6.Remove the lower feeder as follows:• Move the feeder as far as possible downstream (A);• Remove the feeder by turning it out of the machine as indicated (B).
Note: Be careful when replacing feeder 1, the hinge pin at the RH side is locking the ball bearing.
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service manual SI 62
410.02-23rev. 01.0 - 06/2004
4.4 Automatic separation feeder with daily mail
This section describes the replacement of the rollers and pulleys of the feeder. For several replacements it is necessary to remove some covers above or below the feeders. The removal of these covers is shown in figure 4.7.
4.4.1 Rubber paper pullers
figure 4.7
Refer to figure 4.7Remove cover 1 to 4 as follows:• Remove the screws on the RH side. To remove cover 1, it’s necessary to remove the top cover
first, see figure 1.2• Pull the cover 1,2 and 3 backwards on the RH side and pull it out on the LH side.• Loosen the screws 6 at the cover 5 and remove the cover:• Pull the cover 4 backwards on the RH side and pull it out on the LH side.
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service manual SI 62
410.02-24 rev. 01.0 - 06/2004
figure 4.8
Refer to figure 4.8Remove the feed axle assy. 2 in the right-hand side direction (A) until the left-hand side is clear from the axle 1. Tilt (B) the axle assy. 2 at the left-hand side and withdraw the right-hand side of the axle from the hole in the feeder frame. Remove (C) the axle assy. as indicated.
The rubber paper pullers 4 can simply be removed by pushing them of the axle. Hold the plastic cover 3 in place with one hand and push (D) firmly against the rubber paper puller as indicated. Rotate the axle 180 degrees and push again. Repeat the rotating and pushing until the paper puller can be pulled of the axle.
Note: Ensure on replacement that the plastic cover is replaced below the ridge (3, figure 4.8) on the paper guide and that the feeder assy. is correctly fitted onto the axle. Ensure that the belt runs across the pulleys.
A
D
C
B
1 2 3 4
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4.4.2 Pulley of paper puller axle
Remove the feed axle assy. as described in the paragraph "Rubber paper pullers".
figure 4.9
Refer to figure 4.9.Remove the axle from the plastic cover. Push the rubber paper puller of the axle and remove the spring clip, the washer and the bearing. The pulley 1 consists of two parts. Push the pulley assy. to the left to release it from the cyl. pin, remove the cyl. pin and slide the pulley assy. of the axle.
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service manual SI 62
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4.4.3 Upper separation roller
figure 4.10
Note: The feeder unit does not need to be removed for replacing separation rollers.
Remove the feed axle assy. as described above. Refer to figure 4.10. Click (A) the plastic cover 2 off the axle and remove it with the belt and the paper pulleys from the feed axle. Remove the grease from the left hand side of the feed axle with some alcohol. Push the feed roller 1 to the left hand side of the axle as indicated. Rotate the axle 180 degrees and push again. Repeat the rotating and pushing until the feed roller can be pulled of the axle.
Note: Before replacing the feed roller ensure that the axle is free of grease. After replacing the feed roller put some grease Molykote PG 65 on the plastic cover 2 as shown in figure 4.10. Replace the plastic cover with the belt and the rollers.
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service manual SI 62
410.02-27rev. 01.0 - 06/2004
4.4.4 Lower separation roller
Note: The feeder unit does not need to be removed for replacing separation rollers.
Remove the cover 3 as shown in figure 4.7.
figure 4.11
Refer to figure 4.11.Move the separator axle assy. 2 in the right-hand side direction (A) until the left-hand side is clear from the hinge plate 1. Move (B) the axle assy. 2 downwards side and withdraw the right-hand side of the axle from the hole in the feeder frame. Figure 4.12 shows how the roller 1 should be slided of the axle assy. 2.
figure 4.12
Note: Before replacing the feed roller ensure that the axle is free of grease.
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service manual SI 62
410.02-28 rev. 01.0 - 06/2004
4.4.5 Gears
For the removal of the gears at the LH side of the feeder it is not necessary to remove the feeder from the machine. The gear 48T can be removed after the extension axle with the pulley etc. has been removed. Remove the spring clip securing the gear 64T, lift the feeder and slide the gear 64T of the axle.
4.5 Automatic separation feeder
The removal procedure of the components of the automatic separation feeder is similar to that of the automatic separation feeder with daily mail as described in the previous section.
service manual SI 62
410.02-29rev. 01.0 - 06/2004
5 Vertical transport
To get access to several parts of the vertical transport track, remove the vertical transport cover as described in section Covers and plates. Figure 5.1 shows the parts of the vertical transport track.
figure 5.1
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6 Collating area
The parts which are described in this section are located in the upper arm of the collating area. It is recommended to remove the complete collator arm. Remove the collator area cover as described in the section See “Top cover feeders, covers collator area, power supply cover” on page 10.
.figure 6.1
Refer figure 6.1.Disconnect the wiring of the collator motor. Loosen the set screw 7 on bush 6 as shown in figure 6.2 and pull the motor outside the frame. Support the collating arm and remove the screws 1 as shown in figure 6.1 (two at the LH side and two at the RH side). Carefully remove the collating arm.
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service manual SI 62
410.02-31rev. 01.0 - 06/2004
6.1 Belts
figure 6.2
6.1.1 Transportation belts
Refer to figure 6.2The transportation belts are only available as a set. If a belt is worn, all the belts should be replaced. Remove roller 1 from the axle and slide the axle to the LH side out of the bearings. Take care of the tensioner 2, it is spring loaded. Remove the tensioner 2 and the plate 3. At last remove the axles 4 and 5 and the middle transportation belt can be replaced.
6.2 Guide rollers
Refer to figure 6.2The guide rollers 8 and 10 are spring loaded. Remove the accompanying spring clips and washers and slide the guide rollers of the axles. Remove the screw of the axle of the guide roller 9 and slide the axle to LH side. Remove the spring clip at the RH side of the guide roller and slide the roller of the axle.
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service manual SI 62
410.02-32 rev. 01.0 - 06/2004
7 Folder
7.1 RH drive mechanism
figure 7.1
7.1.1 Belts
Lower folder sectionThe removal of the drive belt 1 (figure 7.1) is described in chapter "Feeder modules and vertical transport RH.
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service manual SI 62
410.02-33rev. 01.0 - 06/2004
Upper folder section
figure 7.2
Refer to figure 7.2.Slacken the two screws 2 of the belt tensioner 1 and remove the belt 5 from the pulleys 3 and 6.
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service manual SI 62
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7.1.2 Pulleys
Lower folder sectionRefer to figure 7.1.Remove the belt 1 as described in chapter "feeder modules and vertical transport RH". After the removal of the accompanying spring clip and clamping ring the pulleys 2 and 3 can be slided of the axles.
Upper folder sectionRefer to figure 7.2.Remove the belt 5 as described in the previous section. Remove the spring clip and the washers of the pulley 3 and slide the pulley of the axle. Slacken the set screw 4 of the pulley 6 and slide the pulley of the axle.
7.1.3 Gears
Lower folder sectionRefer to figure 7.1.Gears, item 4 and 5.The gears 4 and 5 can easily be slided of the axles. Take care of the cyl. pins when removing the gears.
Upper folder sectionRefer to figure 7.2.The gears 8 and 10 can be removed after the removal of the accompanying spring clip, clamping ring and washers. Whem removing gear 8, take care of the cyl. pin.To remove gear 9, belt 5, pulley 6 and spacer 7 have to be removed. When removing gear 8, take care of the cyl. pin.
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7.2 LH drive mechanism
figure 7.3
Refer to figure 7.3.To get access to the gears of the lower folder section at the LH side of the machine, the circuit board must be removed. Then gears 1 up to 5 can easily be removed by removing the accompanying spring clips, clamping rings and washers. Take care of the cyl. pin of the gears 1, 3 and 5 and the spacers of the gears 2 and 4.
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service manual SI 62
410.02-36 rev. 01.0 - 06/2004
7.2.1 Fold mechanism
figure 7.4
Refer to figure 7.4.The fold plates 1 and 5 are driven via the curved gears 6 (four in total) and two gears 3, activated by the two clutches 2 on the drive axle 4.
Gears 32T, drive axleRefer to figure 7.4.Remove the belt 13, pulley 12 and 14 and freewheel clutch 11. Remove the locking plate 10 securing the bearing of the drive axle 4. Carefully move the axle 4 to the RH-side until the bearing clears the frame. Carefully lift the axle assembly as far as possible upwards. Take care of the wiring of the clutches on the axle and the plastic bearing on the LH side.
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service manual SI 62
410.02-37rev. 01.0 - 06/2004
figure 7.5
Refer to figure 7.5.Remove the bearing, spacer, washers and the spring clip of the left-hand side of the drive axle assembly. Slide the gear 1 of the axle. To remove the gear 4 the clutches must be disassembled. Cut the wire straps at the connectors of the clutches. Slide clutch 2 to the left-hand side of the axle. Take care of the cyl. pin of the clutch. Next remove all the components between the clutches including the cyl. pin of the clutch 3. Slide clutch 3 to the left-hand side of the axle. Now the gear 4 can be removed from the drive axle.
7.2.2 Clutches
The removal of the two clutches is described in the previous section "Gears 32T drive axle".
Note: Ensure on replacement to secure the wiring of the clutches again and that both clutches are retained by the locking plate. Also ensure that the clutches CW and CCW are placed in the proper position.
7.2.3 Curved folder gears
Remove the drive axle assembly as described in the section "Gears 32T, drive axle". Refer to figure 7.4.Remove the bearings 9 from the axles 6. Remove the brake discs 15 (spring loaded), the springs, the brake strip 16 and the bearings 17 from the axles 8.
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service manual SI 62
410.02-38 rev. 01.0 - 06/2004
figure 7.6
Refer to figure 7.6.Remove the following components:• The levers for the flap actuators, the bearings, etc. (1 upto 6) from the axles 12. Pin 6 has to be
loosened by a set screw, to be accessed at axle end (12).• The brackets 7 with the sensors.• The brake discs with the bearings (22 upto 20) from the axles 13.
Next remove the screws at the left and right-hand side of the guide plate 9, unhook the guide plate and remove it. Remove the screws at the left and right-hand side by which the brackets 10 are mounted to the upper frames. Carefully lift each complete fold assembly upwards and withdraw it.
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service manual SI 62
410.02-39rev. 01.0 - 06/2004
First curved folder gears
figure 7.7
Refer to figure 7.7.Remove the two screws 6 and slide the hinge plate 7 and the hinge plate 5 together with the fold plate 4 of the axle. Now the curved gears 2 and 8 can be pulled of the axle.
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service manual SI 62
410.02-40 rev. 01.0 - 06/2004
Second curved folder gears
Refer to figure 7.7.Remove the hinge plates 15 and 17 in the same way as described previously and pull the curved gears 9 and 10 of the axle.
figure 7.8
Note: Ensure on replacement that the curved gears and the curved discs are replaced correctly onto the axle, refer to figure 7.8, and to secure the wiring of the clutches again.
The right-hand curved gear is marked with a "R" and the left-hand curved gear is marked with a "L".
AdjustmentsCheck after replacing and securing the complete fold assembly the adjustment of the paper guides 3 and 11 (refer to figure 7.7), see section "Paper guide".
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service manual SI 62
410.02-41rev. 01.0 - 06/2004
7.3 Rollers
7.3.1 Input rollers
Remove the drive belt as described in the chapter 3, section 3.1.
figure 7.9
Refer to figure 7.9.Remove the pulley, the gears of the upper (1) and lower (2) input rollers as described in 7.1Remove the bearing locking plate 3.
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service manual SI 62
410.02-42 rev. 01.0 - 06/2004
figure 7.10
Refer to figure 7.10.Remove the gear 7 of the lower input roller 6 and remove the bearing locking plate 5. Remove the guide strip 4 and the guide bracket below it. Move the upper input roller 2 to the right-hand side until the left-hand bearing is free of the LH inside frame. Lift the left-hand side of the roller upwards and withdraw the roller out of the RH inside frame.
Move the lower input roller 6 to the right-hand side until the left-hand bearing is free of the LH inside frame. Lift the left-hand side of the roller upwards and withdraw the roller out of the RH inside frame.
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service manual SI 62
410.02-43rev. 01.0 - 06/2004
7.3.2 Lower fold rollers
Remove the following parts:
Refer to figure 7.10.• The gears 8.
Refer to figure 7.11• Loosen the two hex. head screws 3. Push down solenoid 4 to get access to screw 2 and remove
screws 2. Remove bearing plate 1; • To remove a roller, move it to the right-hand side until the left-hand bearing is free of the LH
inside frame. Lift the left-hand side of the roller upwards and withdraw the roller out of the RH inside frame.
figure 7.11
AdjustmentsCheck after replacing the adjustment of the solenoid, see paragraph 14.7.
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service manual SI 62
410.02-44 rev. 01.0 - 06/2004
7.3.3 Upper fold rollers
figure 7.12
Refer to figure 7.12.Remove the belt with the pulley 5 and the three gears 4 at the right-hand side.For the removal of the first fold roller it is necessary to remove the guide strip 2.Next remove the bearing locking plates 3 on both sides. To remove roller 1 move it to the right-hand side until the left-hand bearing is free of the LH frame. Move the left-hand side of the roller downwards and withdraw the roller out of the RH frame.
AdjustmentsFor belt adjustments refer to 14.5.
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service manual SI 62
410.02-45rev. 01.0 - 06/2004
8 Main drive mechanism inserter
The main motor 9 (refer to figure 8.1) provides the mechanical power to the SI 62, with exception of the collating area. The collating area is driven by a separate motor.
figure 8.1
8.1 Belts
8.1.1 PJ-belt
Before the PJ-belt 2 can be removed the main drive belt for the feeder and folder section must be disassembled as described in 3.1.
Refer to figure 8.1.Loose the two hex. head screws 4 of the tensioner 5. Remove the belt 2 from the main pulley 1 and the motor pulley 3.
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service manual SI 62
410.02-46 rev. 01.0 - 06/2004
figure 8.2
8.1.2 Drive belt inserter
Refer to figure 8.2.All moving components of the inserter part are driven by belt 10. To remove belt 10 loosen the two hex. head screws of the tensioner 1. Then remove the belt from the pulleys.
1 2 3 4
7891011121314
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6
service manual SI 62
410.02-47rev. 01.0 - 06/2004
8.1.3 Belt envelope feed
figure 8.3
Refer to figure 8.3.Remove the support plate 11 by which the intermediate axle 13 is supported. Take care of the bearings and the washers. Remove the belt 5 from the pulley on the intermediate axle and from the pulley on the envelope feed axle 3.
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service manual SI 62
410.02-48 rev. 01.0 - 06/2004
8.2 Pulleys
Refer to figure 8.2.The pulleys item 9 and 5 can easily be removed by removing the accompanying spring clips.The pulley 11 can be removed after the removal of the main pulley as described in the section " Drive mechanism RH". Before the pulley 8 can be slided of the axle the mounting plate 6 with the adjustment plate and the pulse disc sensor must be removed. Next remove the pulse disc 7 and slide the pulley 8 of the axle. Take care of the spacer.
Note. After replacement of the pulse disc sensor be sure that it clears the pulse disc on both sides.
Refer to figure 8.3.For the removal of the pulleys 14 and 9 it is necessary to remove the belt 5 as described in 8.1.3. Remove the accompanying spring clip and washer of the pulley 9 and slide the pulley of the envelope feed axle 3.Remove the bearings, washers and gears from the intermediate axle 13. To remove the pulley 14 from the intermediate axle tap the tension pin and slide the pulley 14 of the axle.
8.3 Gears
Refer to figure 8.2.
Gears item 3 (sealing rollers)After the removal of the pulley 5 all the gears 3 can be slided of the axles by removing the accompanying spring clips and washers.
Gear item 2The gear 2 is mounted to the axle by a tension pin. To tap the tension pin it is necessary to remove the axle. Remove the tension springs of the bearings of the axle. Next remove the spring clip with washer and bearing at the left-hand side of the axle. Slide the two rollers to the right-hand side and remove the cyl. pin from the axle. Slide the axle with the gear 2 to the right-hand side out of the RH inside frame. Tap the tension pin to remove the gear 2.
Gear item 4The gear 4 is also mounted to the pulse disc axle 14 by a tension pin. Remove the pulse disc 7 and pulley 8. Remove the spring clip at the left-hand side of the axle. Slacken the set screws of the two rollers. Remove the locking plate 13. Slide the pulse disc axle 14 to the right-hand side out of the RH inside frame. Remove during sliding the axle to the right-hand side the bearing and washer and the two rollers. After the axle is removed the gear can dissembled by tapping the tension pin.
Gear item 12After the removal of the pulley 9, gear12 can be slided of the axle.
Refer to figure 8.3.
Gears item 8, 10, 15, 16, 18, 20 and 22The gears 8, 10, 15, 16, 18, 20 and 22 can simply be removed by removing the accompanying spring clips and washers.
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Gear item 21For the removal of the gear 21 the nuts etc. must be removed. Take care of the tension spring.Once the nuts are removed all the parts can be slided of the brake rod.
For adjustment of the friction brake, see section " Friction brake "
Gear item 6After the gear 8 has been removed the clutch 7 must be dissembled. Remove the support plate 11, disconnect the wiring of the clutch and slide the clutch of the axle. Remove gear 6.
Gears item 4 and 12Remove the support plate 11 to free the intermediate axle 13 with its components. Remove the bearings, washers and spring clip from the axle and slide the gears 12 and 4 from the axle.
Gear item 17To get access to the transportation axle it is advisable to remove the insert table. Remove the spring clip, washer and bearing at the left-side of the transportation axle 2. Move the axle a little to the right-hand side, slide the gear 17 to the left-hand side and remove the cyl. pin. Slide the gear 17 of the axle.
Gear item 19The gear 19 is mounted to the tansportation axle 1 by a tension pin. For the removal of the gear 19 the tension pin must be tapped. Remove the insert table and remove the spring clip, washer and bearing from the left-hand side of the axle. Slide the rollers to the right-hand side to remove the cyl. pins. Slide the axle to the right-hand side out of the RH inside frame. Take care of the two rollers. Tap the tension pin and remove the gear 19 from the axle.
8.4 Clutches
Slip clutch envelope feed axleRefer to figure 8.3.Remove the metal ring of the pulley 9. Slide the belt 5 of the pulley 9 and remove the pulley from the axle. Slide the slip clutch of the axle.
Clutch CWWhen the machine is switched on gear 6 it is constantly driven. By activating the clutch 7 all the gears shown in figure 8.3 and the accompanying axles and rollers of the envelope feed and envelope track will be driven. So to feed, open and place an envelope on the insert table the clutch 7 is activated.To remove clutch 7 the support plate 11 and the gear 8 must be removed. Disconnect the wiring of the clutch and slide it of the axle.
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8.5 Main motor (M2)
figure 8.4
Refer to figure 8.4.Remove the power supply cable. Remove the power supply cover 2. Disconnect the wiring and cut the wire straps. Fasten the collator arm with a wire strap so it will not fall down when removing the power supply assy. Remove the power supply assy 3. Cut all the wire straps by which the wiring of the motor is attached to the frames.
When replacing the power supply assy. ensure that the guide plates 1 are fitted correctly in the guide rollers. Also take care to fit the microswitch correctly and ensure the correct functioning.
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service manual SI 62
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figure 8.5
Refer to figure 8.5.Remove the belt 1 by releasing the belt tensioner 2. First remove the bottom of the machine than remove the four screws 3 and the washers 4 and withdraw the motor 5 from the machine. Take care of the wiring.
Adjustments For belt adjustments refer to 14.1 and 14.3.
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service manual SI 62
410.02-52 rev. 01.0 - 06/2004
9 Envelope feed
9.1 Hopper
9.1.1 O-rings
figure 9.1
Refer to figure 9.1.Remove the centre front plate 9. The hopper assembly 10 is fitted to the inside frames by three screws 1 at the left-hand and three screws 11 at the right-hand side. Remove the screws and withdraw the assembly from the machine. Remove the pulley 13 and slip clutch 12 as described in 8.2. Next remove the spring clips, washers and bearings from envelope feed axle 5 and remove the axle from the machine. Slide the O-rings 7 from the joggers 6.
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service manual SI 62
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9.1.2 Separation roller
Note: Before removing the separation roller first check the adjustment procedure as described in 14.8.
Refer to figure 9.1Remove the centre front plate and the hopper assembly as described in the previous paragraph. Slacken the two screws 3 and remove the separation spring 2 with the separation roller. Remove the separation axle with roller from the separation spring, slacken the set screw of the separation roller 4 and slide it of the separation axle.
9.1.3 Feed roller
Refer to figure 9.1Remove the feed axle as described in 9.1.1. Remove a jogger from the envelope feed axle. Slacken the set screw from the feed roller 8 and slide it of the axle.
Note: On replacement of the joggers and/or feed roller, position the feed roller in the middle of the shaft the removed joggers between the "forks" of the side guide. Take care to reassemble the rings between fork and jogger. Ensure that the set screws of the feed roller are tightened onto the groove of the feed shaft.
AdjustmentsSee paragraph 14.8 and 14.8.
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9.2 Envelope track
9.2.1 Lower rollers
To get access to the lower rollers of the envelope track it is necessary to remove the bottom plate.
figure 9.2
Refer to figure 9.2.Remove the spring clip, washer and bearing (spring loaded) from the axle of the first set of rollers 13. Move the axle to the left-hand side to free the cyl. pins and remove the cyl. pins. Lift the axle and slide the rollers of the axle. Take care of the pressure spring of the bearings. The second set of rollers 12 is removed in the same way. Remove from the third set of rollers 11 at first the outer two
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service manual SI 62
410.02-55rev. 01.0 - 06/2004
rollers. The removal procedure for the inner two rollers is the same as described for the first set of rollers.
Refer to figure 9.3Remove the flap scraper 21. Remove the pressure springs of the bearings of the fourth set of rollers 19. Slide the rollers to the LH side to remove the cyl. pin. Remove the spring clips and slide the axle to the RH side and remove the rollers 19 from the axle.
Adjustment:For the adjustment of the flap scaper see 14.10. .
figure 9.3
9.2.2 Upper rollers
Refer to figure 9.2.To get access to the upper rollers remove the insert table as described in paragraph 11.1.
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service manual SI 62
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To remove the first set of rollers 5 slide the rollers of the axle 7, remove the cyl. pins 4. Remove the spring clip 1, washer 2 and bearing 3 at the left-hand side of the axle 7 and slide the axle to the right-hand side. Remove the rollers from the axle.The second and third set of rollers are removed in the same way as the first set of rollers 5.
Refer to figure 9.2To get access to the fourth set of rollers of the envelope track remove the insert table. To get more room, you could remove the fixing plate envelope track (item 8, figure 9.2). Slide the rollers aside to remove the cyl. pins. Remove the spring clip, washer and bearing at the left-hand side of the axle and slide the axle to the left-hand side. Remove the rollers from the axle.
9.2.3 Rubber roller
Remove the insert table and the transportation table (item 19, figure 11.1). Slide the transportation table in direction as indicated over the second fold roller.
Refer to figure 9.3.Remove the knob 1 and the spring clips 5 of the rubber roller 11. The gear at the right-hand side of the rubber roller must be removed as described in section 8.3. Slide the roller to left-hand side to free the right-hand side of the rollers from RH inside frame. Take care of the bearing. Lift the right-hand side and withdraw the rubber roller from the machine.
9.2.4 Finger solenoid
figure 9.4
Refer to figure 9.4.
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Remove the draw bar 3 and the tension spring 4. Disassemble the mounting bracket 2 with solenoid 1. Remove the solenoid 1 from the bracket 2.
AdjustmentsFor the adjustment of the solenoid see 14.7.
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10 Upper unit
10.1 Drive mechanism
The drive mechanism of the upper unit is located at the right-hand of the machine.
10.1.1 Belt
figure 10.1
Refer to figure 10.1.At first slide the belt 8 of the pulley 7. Then remove the belt from the pulley 10.
1
2
3
4
5
6
7
8
9
10
service manual SI 62
410.02-59rev. 01.0 - 06/2004
10.1.2 Pulleys
Refer to figure 10.1.Remove the spring clip of the pulley 10 and slide the pulley 10 from the axle.To remove pulley 7 it is necessary to remove the axle 5 completely. Open the upper unit and remove the six screws by which the brake plate 2 is mounted to the upper frames.
Take in account the weight of the upper unit when removing the dampers.Close the upper unit and remove the axle 1. Move the brake plate 2 with assembled components carefully aside, take care of the wiring to the solenoid, the sensor and display. Remove plate 3. Remove the spring clips of the axle 5. Slide the rollers of axle 5 aside and remove the two cyl. pins. Slide the axle to the right-hand side out of the RH frame. Take care of the rollers, washers and bearings. Tap the tension pin of the gear 9 and slide the gear of the axle. Now the pulley 7 can be removed from the axle.
10.1.3 Gears
The removal of the gear 9 is described in the previous paragraph.For the removal of the gear 6 the brake plate has to be removed as described in the previous paragraph. Next remove the spring clips of the axle 4 and remove the cyl. pins of the rollers.Slide the axle 4 to the right-hand side out of the frame. Tap the tension pin of the gear 6 and slide the gear 6 of the axle.
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10.2 Document inserting
10.2.1 Rollers
figure 10.2
Refer to figure 10.2.Remove the guide plates1 on both sides and slide the upper insert rollers 3 of the axle. Take care of the cyl. pins. The first set of ejection rollers 11 can simply be slided of the axle. Take care of the cyl. pins.
Refer to figure 10.4.To remove the second set of ejection rollers, remove spring clip 5 and remove roller 4 from the axle. Remove spring clip 2 and slide the axle to the LH side. Tap out the cyl. pin of roller 1 and slide roller 1 from the axle.
10.2.2 Gears
Refer to figure 10.2.Remove the guide plates 1 on both sides. Remove the bracket 6 and the sensor, take care of the wiring of the sensor. Next remove the pulley 5 and the spring clip 12. Slide the outer bearings at the axle 8. Remove the tension springs 2. Slide the axle 8 with complete insert assembly through the slotted holes out of the frames.
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service manual SI 62
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figure 10.3
Refer to figure 10.3.Once the frame plate 5 is removed the gears 4, 7 and 8 can be slided of the axles. Take care of the pressure springs 6.
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service manual SI 62
410.02-62 rev. 01.0 - 06/2004
figure 10.4
Refer to figure 10.2.Remove the screws 7 and withdraw the complete ejection assembly 9 together with the draw bar and the attached plunger (item 1, figure 10.3) from the frames. Take care of the washers and the pressure spring of the plunger.
Refer to figure 10.3.After the frame plate 9 is removed the gears 10 and 11 can be removed from the axles.
10.2.3 Ejection solenoid
To get access to the solenoid the covers of the loc must be removed as described in the section 1.
Refer to figure 10.3.Disconnect the wiring of the solenoid. Remove the two screws 3 and remove the solenoid 2. Take care of the plunger 1 the washers and the pressure spring.
AdjustmentsSee 14.7.
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10.3 Envelope transport and sealing
10.3.1 Rollers
figure 10.5
RH
12
7 6 5 4 3
service manual SI 62
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Sealing transport rollersRefer to figure 10.5.Open the upper unit and remove the spring clips of the axle 6. Slide the transport rollers 4 of the axle. Take care of the pressure springs 5.
Lower reverse rollersThe removal of the lower reverse rollers 3 is described in 10.1.2.
Upper reverse rollersRemove the accompanying spring clips and washers and slide the rollers 7 of the axle.
10.3.2 Sealing solenoid
Refer to figure 10.5.Disconnect the wiring of the solenoid 1. Remove the screws 2 and withdraw the solenoid. Take care of the pressure spring and the washers at the plunger.
AdjustmentsSee paragraph 14.7.
service manual SI 62
410.02-65rev. 01.0 - 06/2004
11 Envelope transport
11.1 Lower ejection rollers
figure 11.1
Refer to figure 11.1.
Remove four screws 13 of the insert table 18 and four screws 1 of the insert table 2. Remove the drive belt inserter as described in 8.1.2.Remove the locking plate of the bearing at the right-hand side of the transportation axle 20. Slide the axle 19 to the RH side. Remove the cyl. pin 17. Slide the roller 18 from the axle.
Remove the spring clip, washer and bearing from the left-hand side of the axle 22. Slide the axle to the RH side. Slide the rollers 21 from the axle.
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service manual SI 62
410.02-66 rev. 01.0 - 06/2004
11.2 Sealing track transportation rollers
Refer to figure 8.2.Remove the pulse disc 7 and pulley 8 with the from the pulse disc axle 14 as described in 8.2.
Refer to figure 11.1.Remove the pressure springs 11 from the bearings 12 of the axle 8. Slide the rollers 4 aside to remove the cyl. pins 3. Remove the spring clip, washer and bearing at the left-hand side of the axle. Slide the rollers of the axle.
Note: Take care of the pressure springs 10 when replacing again. On the LH side a spring with lower force has to be fitted than on the RH side.
service manual SI 62
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12 Envelope sealing and ejection
12.1 Upper sealing roller
Refer to figure 11.1.Remove the gear at the right-hand side of the sealing roller 6 as described in 8.3.
Next remove the pressure springs 11 from the bearings 12 and the spring clip at the left-hand side of the sealing roller. Take care of the washer 10 and the spring 9. Move the sealing roller 6 to right-hand side to free the left-hand bearing from the LH inside frame and withdraw the upper sealing roller.
12.2 Lower sealing roller
Refer to figure 11.1.Remove the upper sealing roller as described in the previous paragraph. Remove the gear at the right-hand side of the sealing roller 5 as described in 8.3.
Remove the two screws 14 and the mounting plate 7 and the spring clip, washer and bearing at the left-hand side of the lower sealing roller 5. Move the sealing roller to the right-hand side and withdraw the lower sealing roller.
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13 Sensors
13.1 Safety switches
Upper unit safety switchThe safety switch of the upper unit is located at the right-hand side of the machine near the lowest feeder. To get access to the switch remove the RH side cover.
figure 13.1
Refer to figure 13.1.Cut the wire strap and remove the bracket 2 together with the safety switch 1. Remove the safety switch from the bracket.
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service manual SI 62
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Safety switch LH side coverThe safety switch is located at the left-hand side of the machine near the sealing rollers.
figure 13.2
Refer to figure 13.2.Open the LH side cover and remove the cover 1. Remove the safety switch 3 from the bracket 2.
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service manual SI 62
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Safety switch collator areaThe safety switch is located at the right-hand side beneath the collator area and behind the supply cover. Remove the supply cover.
figure 13.3
Refer to figure 13.3.Remove the safety switch 2 from the frame 1.
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service manual SI 62
410.02-71rev. 01.0 - 06/2004
Flag switch sealing area
figure 13.4
Refer to figure 13.4.Remove the nuts 1 and 6 than remove the frame 2 complete. Take care of the wiring. Slacken the screw 3 and remove the bracket 4 with the flag switch 5.
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service manual SI 62
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13.2 DFC and photocells
Note: whether or not photocells are replaced, it is advised to reset the photocells after finishing servicing. See sections 2.14 and 2.15 of the Electrical description for details.
13.2.1 Feeders
DFCEach feeder is equipped with a DFC. Remove the covers 1, 2, 3 and 4 (figure 4.7) as described in 4.4.1. When removing the DFC of feeder 2 first remove the guide plate 5 (figure 4.3) as described in 4.2.
figure 13.5
Refer to figure 13.5.Disconnect the wiring of the DFC and remove the screw 2 securing the DFC 3 to the bracket 1.
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service manual SI 62
410.02-73rev. 01.0 - 06/2004
Feeder photocells
figure 13.6
Refer to figure 13.6.
Transmitter (LED)Remove the bracket 4 with the transmitter 3. Disconnect the transmitter and remove it from the bracket.
Receiver (Sensor)Remove the bracket 2 with the sensor 1. Disconnect the sensor and remove it from the bracket.
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RHLH
LH RH
service manual SI 62
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13.2.2 Vertical transport
Vertical transport photocells (optical, only with OMR).In the 2,5 stations version, the detectors are located beneath the upper vertical transport rollers.
figure 13.7
Refer to figure 13.7.
Transmitter (LED)Open the loc and remove the guide plate 1 with assembled transmitter 2. Disconnect the wiring of the transmitter and remove the transmitter.
Receiver (Sensor)Remove the vertical transport cover. Cut the wire strap securing the wiring of the sensor 3 to bracket 4. Remove the bracket with the sensor and disconnect the wiring. Remove the sensor.
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service manual SI 62
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13.2.3 Collator area
figure 13.8
Refer to 13.2.3.Remove the set screw 1, remove the pulse disc and the sensor 3.
Note: Ensure on replacement that the pulse disc sensor clears both sides of the pulse disc.
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service manual SI 62
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Collating area photocells
figure 13.9
Refer to figure 13.9.
Move the lower collator arm downwards. Remove the locking plate of the axle 4 at the right-hand side of the machine and free the bearings of the frame. Remove the hinged guide plate 1 together with the attached sensors 2 and 3. Take care of the wiring.
Transmitter (LED)Remove the transmitter 3 from the guide plate.
Receiver (Sensor)Remove the sensor 2 from the guide plate.
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service manual SI 62
410.02-77rev. 01.0 - 06/2004
Folder input photocell
Refer to figure 13.9.Remove the bracket 5 with the transmitter 6 to the left-hand side out of the LH inside frame. Take care of the wiring.
Transmitter (LED)Cut the wire straps and remove the transmitter 6 from the bracket.
Receiver (Sensor)Cut the wire straps and remove the receiver 7 from the bracket.
13.2.4 Folder
Curve (pulse) disc sensor
The sensors are located at left-hand side of the upper unit. Open the upper unit.
figure 13.10
Refer to figure 13.10.Remove the bracket 1 with the sensor 2. Cut the wire strap, disconnect the sensor and remove the sensor from the bracket. The sensor 3 has to be removed in the same way.
1 2 3
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13.2.5 Inserter
Pulse disc sensorThe pulse disc sensor assy. is located at the right-hand side of the machine near the sealing rollers.
figure 13.11
Refer to figure 13.11.To avoid damage to the pulse disc 4 remove the pulse disc. Disconnect the wiring of the sensor 2, remove the two srews 3 and remove the sensor.
Ensure on replacement that the pulse disc sensor clears both sides of the pulse disc. To adjust the position of the sensor slacken screw 1, reposition the sensor and fasten the screw 1.
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service manual SI 62
410.02-79rev. 01.0 - 06/2004
Envelope track photocell
To get access to the photocells remove the insert table and the bottom plate.
figure 13.12
Refer to figure 13.12.
Transmitter (LED)Pull the air hose connector 4 from the transmitter 3. Slacken the screw of the transmitter and remove the transmitter 3.
Receiver (Sensor)Remove the bracket 2 together with the sensor 1. Slacken the screw of the sensor and remove the sensor 1.
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service manual SI 62
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Envelope flap detectorTo get access to the photocells remove the insert table and the bottom plate.
figure 13.13
Refer to figure 13.13.
Transmitter (LED)Once the bottom plate is removed, remove the bracket 1 with the transmitter 2. Take care of the wiring. Disassemble the transmitter from the bracket.
Receiver (Sensor)Pull the air hose connector 3 from the sensor 4. Slacken the screw 6 and remove the bracket 5 with the sensor 4. Remove the sensor from the bracket.
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service manual SI 62
410.02-81rev. 01.0 - 06/2004
Exit photocells
figure 13.14
Refer to figure 13.14.Remove the frame axles 1 together with the cover 2. Take care of the wiring of the detectors.Remove the transmitter (LED) 3 and the receiver (Sensor) 4.
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service manual SI 62
410.02-82 rev. 01.0 - 06/2004
Document insert photocells
figure 13.15
Refer to figure 13.15.
Transmitter (LED)The transmitter is located in the upper unit. Open the upper unit and remove the screw 1 to release the transmitter 2.
Receiver (Sensor)Remove the transport table. Slacken the screw 5 and remove the bracket 4 with the sensor 3. Remove the sensor from the bracket. Take care of the wiring.
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service manual SI 62
410.02-83rev. 01.0 - 06/2004
14 Adjustments
14.1 Main drive PJ-belt
figure 14.1
Refer to figure 14.1.The maximum movement of the drive belt at the indicated position is 10 mm (0.4 inch).
To adjustSlacken the two screws 1 securing the belt tensioner 2. Shift the belt tensioner to adjust the correct belt movement. Hold the belt tensioner in position and retighten the two screws. Check the adjustment and readjust if necessary.
Note: Do not adjust the drive belt too tight.
Note. When adjustment of the belt tensioner is not sufficient, re-adjust the motor position.
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14.2 Main drive belt feeders/folder
figure 14.2
Refer to figure 14.2.The maximum movement of the drive belt at the indicated position is 10 mm (0.4 inch).
To adjustSlacken the two screws 1 securing the belt tensioner 2. Shift the belt tensioner to adjust the correct belt movement. Hold the belt tensioner in position and retighten the two screws. Check the adjustment and readjust if necessary.
Note: Do not adjust the drive belt too tight.
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14.3 Main drive belt inserter
figure 14.3
Refer to figure 14.3.The maximum movement of the drive belt at the indicated position is 10 mm (0.4 inch).
To adjustSlacken the two screws 1 securing the belt tensioner 2. Shift the belt tensioner to adjust the correct belt movement. Hold the belt tensioner in position and retighten the two screws. Check the adjustment and readjust if necessary.
Note: Do not adjust the drive belt too tight.
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service manual SI 62
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14.4 RH drive belts
Note: The adjustment of the lower and upper drive belt is similar.
figure 14.4
Refer to figure 14.4.The maximum movement of the drive belts 1 at the indicated position is 5 mm (0.2 inch).
To adjustSlacken the hex. head screw 3 securing the belt tensioner 2.Shift the belt tensioner to adjust the correct belt movement.Hold the belt tensioner and retighten the hex. head screw.Check the adjustment and readjust if necessary.
Note: Do not adjust the drive belt too tight.
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service manual SI 62
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14.5 Drive belt upper folder section
figure 14.5
Refer to figure 14.4.The maximum movement of the drive belts 1 at the indicated position is 5 mm (0.2 inch).
To adjustSlacken the hex. head screw 1 securing the belt tensioner 2.Shift the belt tensioner to adjust the correct belt movement.Hold the belt tensioner and retighten the hex. head screw.Check the adjustment and readjust if necessary.
Note: Do not adjust the drive belt too tight
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service manual SI 62
410.02-88 rev. 01.0 - 06/2004
14.6 Paper guide
figure 14.6
Refer to figure 14.6.There must be a small gap between the fixed guide plate 3 and the fold roller 2. The fold roller should just run free.
To adjustSlacken the two round head screws 1 to move the guide plate further away from the fold roller and tighten it to move it closer.
� ��
service manual SI 62
410.02-89rev. 01.0 - 06/2004
14.7 Solenoids
Note: The adjustment procedure for all solenoids is described below. Only for the finger solenoids a different procedure is necessary refer figure 9.4.
Whenever a solenoid is actuated the plunger is pulled into the solenoid coil. To make sure that the pulling power of the solenoid coil on the plunger is maximal, the plunger should not touch the bottom of the solenoid coil whenever the solenoid is actuated.
figure 14.7
Refer to figure 14.7.To set this requirement:• Slacken the two screws 3 securing the solenoid coil 4. • Push the plunger 2 together, with the linkage 1 attached to it, as far as it will go in the direction
towards to the solenoid coil. Hold the plunger in this position and then slide the solenoid coil towards the plunger until the plunger bottoms the solenoid coil.
• Move the solenoid coil back by approximately 1 mm (0.04 inch) and retighten the two screws. Ensure the solenoid coil and the plunger are aligned in a straight line.
1 2 3 4
service manual SI 62
410.02-90 rev. 01.0 - 06/2004
Finger solenoid
figure 14.8
Refer to figure 14.8.To adjust the finger solenoid:• Slacken the two screws 2 securing the solenoid coil 1. • Push the plunger 3 down into the lowest position. • Move the solenoid coil (with the plunger in the lowest position) so that the middle fingers (slide
in) is adjusted approximately 2 mm (max.) (0.07 inch) above the insert table. Retighten the two screws.
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service manual SI 62
410.02-91rev. 01.0 - 06/2004
14.8 Separation roller
Because the separation roller does not reverse, a 'flat' gradually wears on the roller surface. This can be the cause of irregular feeding of the envelopes. Should this occur, carry out the following adjustment:
figure 14.9
Refer to figure 14.9.Use the adjusting nut 2 and set the separation gap to the maximum. Slacken the set screws 1 securing the separation roller. Rotate the separation roller about 30 degrees in the direction indicated, so that the unworn portion of the separation roller faces the feed roller 3. Retighten the set screw and re-adjust the separation gap.
Note: After rotating the separation roller over 330 degrees it is necessary to replace it.
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�
service manual SI 62
410.02-92 rev. 01.0 - 06/2004
14.9 Friction brake
figure 14.10
Refer to figure 14.10.The friction brake is correctly adjusted when the distance between the inner faces of the two friction discs 3, i.e. the overall pressure spring length, is 20 mm (0.79 inch).
To adjustRemove the outer nut 1 securing the inner nut 2.Turn the inner nut to adjust the correct distance. Replace the outer nut and check the adjustment.
Note: An increased variation of the envelope stop position can be caused by excessive play in the lower gear train. A slight reduction in the distance (increasing the pressure) may give the required result.
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service manual SI 62
410.02-93rev. 01.0 - 06/2004
14.10 Flap scraper
figure 14.11
Refer to figure 14.11.The flap scraper 3 must be positioned so that its lower edge is aligned with the lower edge of the envelope guide 1.
To adjustSlacken the two hex. head screws 2 securing the flap scraper 3 on both sides.Move the flapscraper to adjust the correct position.Retighten the two hex. head screws and check the adjustment.
Note: Depending on the envelope type and flap shape a different setting may be necessary.
� � �
service manual SI 62
410.02-94 rev. 01.0 - 06/2004
service manual SI 62
410.03-1rev. 01.1 - 06/2004
Electrical
service manual SI 62
410.03-2 rev. 01.1 - 06/2004
service manual SI 62
410.03-3rev. 01.1 - 06/2004
Contents
Section Page
1 Electronic hardware 51.1 Circuit description 51.2 Test points 231.3 Jumper settings 241.4 LED information 24
2 Service menu 262.1 General 262.2 System setting 292.3 Configuration 292.4 Localisation 302.5 Software versions 302.6 Folder settings 312.7 Reset data 312.8 Power up 322.9 Job settings 322.10 Document offset 322.11 BRE offset 332.12 Secure jobs 342.13 Flap closer 342.14 Service tests 352.15 Photocells 352.16 Digital inputs 372.17 Actuators 382.18 Run in 402.19 DFC test 402.20 Keyboard/display 412.21 Counters 412.22 OMR 422.23 OMR code definition 422.24 Read code test 43
3 Error messages and error handling 46
service manual SI 62
410.03-4 rev. 01.1 - 06/2004
service manual SI 62
410.03-5rev. 01.1- 06/2004
1 Electronic hardware
1.1 Circuit description
GeneralAn important difference between previous machines with similar operational functionality and this machine is the fact that all electronics are present on one main board. The main board 98.90.01 houses two controllers. An 8-bit controller handles the inserting functionality and the user interface. A 16 bit controller handles the feeding, reading and folding functionality.Both the 8-bit machine software and the 16-bit machine software are located in flash ROM. With the help of external Windows-based software the machine software can be placed, and subsequently updated.Figure 1.1 shows an overview of the machine-wide electronics. The schematics of the main board 98.90.01 are divided into 12 sheets (figure 1.2 through figure 1.13). The components are numbered xyy; x is the sheet number, yy a number between 01 and 99.The component layout of figure 1.14 assists in locating connectors, test points, jumpers and LEDs.
Processor and memory (16-bit)The 16-bit processor XA-S3 (U610) has 32 kilobytes of internal program code. This code determines, based on certain RS232-communicated information from the pc with the Windows-base software, whether communication with that pc or normal operation, i.e. executing the 16-bit machine software in flash ROM (U630), is relevant.The system operates with 64 kilobytes of system RAM (U620 & U621). If in stead of the operational machine software the external Windows-based must operate, to this volatile memory program code is up loaded (i.e. software 'flashing' the flash ROM, thereby updating the machine software for passing the same files through to an upstream device; this program code is subsequently executed.The so-called emulation RAM (U640 and U641) is only used for R&D development; normally these two chips are not encountered in any field service situation.The processor operates with process-related I/O information by writing data to the chips U700 and U710 (U710 controls the feeder/folder clutches CL1…CL5), and reading data from the chip U720 (U720 receives digital versions of the outputs of the feeder/folder photocells PH1…PH6). These chips are addressed by so-called memory-mapped I/O, via the signals 16b_DigOutput1 and 16b_DigOutput 2 (writing) and 16b_DigInput1 (reading) from the PAL chip U670.
Processor and memory (8-bit)The 8-bit processor U201 executes the 8-bit machine software which is present in the flash ROM U230. The processor operates with 32 kilobytes of system RAM (U250).The 8 kilobytes of non-volatile memory (U210) are used to store hardware and job related information.In addition to the 8-bit processor the CPLD U240 (Complex Programmable Logic Device) is present for a variety of functions. One of these functions is bank switching. Note that the 8-bit controller can address 64 kilobytes of program memory and that the flash ROM has 512 kilobytes of memory. The CPLD is used to dynamically assign a part of the 8-bit machine software in flash ROM to be executed by the 8-bit processor U201. The CPLD also has an important function in the situation when machine software is placed or updated, in stead of the normal situation of executing the machine software.CommunicationThe 8-bit controller (inserter and user interface) and the 16-bit controller (feeding, reading and folding) talk to each other via the local SCS bus, consisting of the signals SCS_SCL and SCS_SDA. This machine has no SCS connection with the outside world.
service manual SI 62
410.03-6 rev. 01.1- 06/2004
In addition both controllers have the signal MAIN_PDISC in common. On this signal all timed processes are based. This signal is produced by slotted photocell SPH1, which monitors pulse disc PD1, which on its turn is driven by the main motor M1.Communication between the machine and the outside world is based on serial (RS232) communication. This communication is necessary for placing/updating machine software and possibly for other tasks. The RS232 data on the 9-pole RS232 connector goes to and from the RS232 driver U260. The CTS and RTS lines are only connected with the 8-bit controller. With the RS232 multiplexer either the 8-bit RX and TX signals or the 16-bit RX and TX signals are passed through to U260. This is necessary to place or update both the 8-bit and 16-bit machine software in one machine session.
Power supplyThe machine is powered by a 24 volt switched power supply unit. This eliminates the use of a heavy mains frequency-operated power transformer. From the 24 V a 5 V supply VCC is derived with the switching voltage regulator U110. U120 takes care for the -12 V supply voltage. The ADCs in the 16-bit processor U610 require a separate positive supply voltage AVDD (2.95 V). This voltage is derived from VCC by voltage divider R140 and R141, followed by voltage follower U140B.
PhotocellsThe transmitter (TX) currents for the four inserter paper photocells (PH7…PH10) are driven by the outputs of the Digital to Analogue Converter (DAC) U550. The analogue outputs of the photocell receivers (RX) are fed to ADC (Analogue to Digital Converter) inputs of the 8-bit processor U201. In this way a processor-controlled control circuit ensures that dust on the photocells is compensated for by an increase in the transmitter current. Control activity occurs if the photocells do not 'see' paper. The control of the transmitter current occurs in both directions; the current can be increased in case of dust build up and it can be decreased when dust falls off.The transmitter (TX) currents for the six feeder/folder photocells (PH1…PH6) are driven by the outputs of the Digital to Analogue Converter (DAC) U800. The analogue outputs of the photocell receivers (RX) are fed to the analogue multiplexer U701. Its output (16b_Multiplexed_AD4) is fed to an ADC input (Analogue to Digital Converter) of the 16-bit controller U610. In addition to this digital versions of the six RX signals are fed to the input chip U720. These signals are necessary to obtain timely process information.
Cover switchesThe three cover microswitches MS3 (wired to the motor and relay board 97.55.00/97.55.40), MS1 (J100) and MS2 (J101) are connected in series and pass their information to the system connector. The state of these microswitches is also passed to the processor via the signals 8b_TOP_COVER, 8b_SIDE-COVER and 8b_COLLATOR_COVER. If at least one of the three machine covers is opened, mechanical drive for the machine is immediately interrupted.
MotorsThe main motor M1 provides mechanical drive to all moving items (except the moving collator items) of the machine. This motor is switched on and off via the motor relay RE1 on the motor relay board 97.55.00 (230 V)/97.55.40 (115 V). The motor relay is controlled by the processor via the signals 8b_MOTOR_RELAY and 8b_START_RELAY from the 8-bit controller U201. For a sufficient starting torque a capacitor is temporarily switched in parallel with motor capacitor. After reaching a certain rpm rate (monitored by slotted photocell SPH1 via pulse disc PD1) the start relay is switched off. If the motor doesn't reach its nominal rpm rate within one second, it is switched off and an error message is issued.The motor is thermally protected against overheating due to mechanical blocking.
service manual SI 62
410.03-7rev. 01.1- 06/2004
A chain of three microswitches is included in series with the motor relay powering circuit. If this chain is broken by opening at least one of the safety covers, the motor relay current is immediately blocked or interrupted. This happens irrespective of the status of the two motor control signals mentioned above. The motor stops immediately or doesn't start at all. Thus no potentially unsafe human contact with moving parts is impossible.The collator motor M2 is a DC motor than can and will turn in two directions. M2 is pulse-width-controlled via chip U1110. The speed is controlled via a feedback circuit with slotted photocell SPH2, which monitors pulse disc PD2, which on its turn moves in line with M2.
Flag switch FS1The optical flag switch FS1 in the sealing track is based on a pawl which, when triggered by the leading edge of passing filled envelope, interrupts the infrared beam between a photo diode and a photo transistor. It starts a pulse count for determining the time at which the upper reverse roller is lowered to start the sealing process. After the trailing edge of the envelope has passed, the pawl returns to its rest position by spring action.Clutches and SolenoidsClutch CL6 in the inserter part of the machine is driven by the driver chip U440. The three solenoids in the inserter part are driven by transistor Q440A (finger solenoid So1), Q440B (eject solenoid So2) and Q450B (sealing solenoid So3).The three feeder clutches (CL1, CL2 and CL3) in the feeder/folder part are driven by driver chip U970. The two folder clutches (CL4 and CL5) are driven by the driver chip U1020.
DFCEach feeder has a DFC unit. (DFC stands for Double Feed Control.) This unit produces an output voltage which is proportional with the measured paper thickness. The three DFC output voltages are processed with the circuits on sheet 5/12. The amplified DFC output voltages are fed to the ADC chip U730 via the analogue multiplexer U731. The ADC output signal is communicated to the 16-bit processor via the signals 16b_AD_CS, 16b_AD_DAT and 16b_AD_CLK. The reference voltage AVREF for the ADC chip is derived from the VCC voltage by a voltage divider with R733 and R734.For a correct operation of the DFC units an offset voltage is necessary. The three voltages are supplied by the DAC U980, which is controlled by the 16-bit controller via the signals 16b_DAC2_CS, 16b_DAC_DATA and 16b_DAC_CLK.
OMRThe OMR electronics are shown in sheet 12/12. Two OMR output voltages (16b_ReadHead_Ana0 and 16b_ReadHead_Ana1) are fed to an ADC input of the 16-bit processor via the analogue multiplexer chip U701. The DAC U980 supplies two offset voltages (16b_ReadHead_DAC0 and 16b_ReadHeadDAC1). Output chip U700 supplies two signals (16b_ReadHead_S1 and 16b_ReadHead_S2) for setting the amplification.
Keyboard and displayThe 8-bit controller handles the control of both the keyboard and the display. Sheet 3/12 shows the interface electronics. As the main board 98.90.01 is also used for other machines, two connectors (J300 and J330) are available.
service manual SI 62
410.03-8 rev. 01.1- 06/2004
410.03-9rev. 01.1 - 06/2004
service manual SI 62
figure 1.1 Total view of the electrical and electronic circuits, including external connections and sensor/actuator connections.
DRAWN:
DATE:
FILE:
SCALE:
CODE:REV.
0011-12-2003
989008.dsn
989008J. Pijpker
6
TABLE1
RPM
432
FEED
1
FOLDINGTABLE2
RPMFOLDING
CURVEDISCFOLDINGTABLE1
READINGHEAD
5
989001
PHCEL COLLATOR
FEEDER2
FEEDER3
FEEDER1
MAXI FEEDER
COLLATOR
UNIT POWER
REAR SIDE ACTUATORS
LOC
CLOSER
ORION
MAIN PDISC
EXIT PHCELS
FOLDERS
ENV TRACK PHCELS
ENV TRACK TX
ENV TRACK RX
J330
LCDLCDLCDLCDLCD
J230
J450
SOLENOIDSEALING
J460
SOLENOIDEJECT
LOC TX
J440
COLLATOR
COLLATORMOTOR
COL TX
FOL TX
FOL RX
COL RX
VT TX
FLAP TX
FLAP RX
LOC RX
J580
J540
EXIT TX
EXIT RX
SEALING
5 6432
FEED
15 6432
FEED
1
L
MAINS LEAD
989052989051
UKUSAEURO
989053
COUNTRY SPECIFIEDPLUG TYPE:
230V: 2.5 A
N
INCLUDES: MAINS FUSE110V: 5 A
POWER INLET 989005
M
74
72
J1
1
52
54
124J3
1
55
51
Capacitor:
73
TOP COVER SIDE COVER
SIDE COVERSWITCH
TMU 1
790171TOPDFC FEEDER1
TMU 2
790171MIDDLEDFC FEEDER2
TMU 3
790171BOTTOMDFC FEEDER2FINGERS
ENV. TRACK
J300
DISPLAY
J100 J101
READING HEAD
J1200
TOP COVERSWITCH
J1000
J500
J1050 J900
J930
J950
J1100
J1110
J102
989026WIRING
RPM
SOLENOID
FLAGSWITCH
J740DONGLE
MAIN PDISC
MAXI FEEDER
CURVEDISCFOLDINGTABLE2
989028 WIRING
989032 WIRING 3X
Motorboard
975540 - 115V
COLLATORSWITCH
989018WIRING
OPTIONAL
989024WIRING
821622
975505
989408
989003
CL1 CL2 CL3
PH1 PH2 PH3
DFC1 DFC2 DFC3
***
***
Only if MAXIBRE feederis installed.
***
Only if OMRIis installed.
**
**
**
**
SPH1
PH10
PH10
PH9
PH8
PH8
PH7
PH7
PH4
PH6
PH6
PH5
SPH2
M2
PH5
NeoFlashConnection
MS3
MS2
MS1
RH1
SPH3
PH4
SPH4CL4 CL5
So1
CL6
PH9
So2
So3
+ 24 V
GND
MF-2
VT RX
Fs1
975500 - 230V
RUN
START
230V: 5µF (989006)110V: 20µF (121281)
* Only for 2½station machine
*FEEDER1 FEEDER2 FEEDER3
989002
SWISS 989054AUSTRAL989055
12
123
123
12
12
12345
FEEDER3
12345678910
123456
21
L
N(AC)
COM
+V
+V
+VADJ
POWER SUPPLY
INPUT: 100 - 120 VAC 3.15A 200 - 240 VAC 1.5A 50/60 Hz
OUTPUT: + 24 V 4.5A
COM
12345678
2 1
12
21
M
1 2 3 4 5 6 7 8
123456789
10
2 1
12
21
21
12
CONNECTOR D9 FEMALE
594837261
1 2
1234
1
2
4
12345
21
12
1
23 4
5
6
7
21
21
1
2
4
12
2 1
12
123456789
101112
FEEDER2
12345678910
2 1
21
2 1
12
12
12345678
2 1
123
12
123456789
101112
FEEDER1
12345678910
12
123456789
10
12345678910
1
2
4
410.03-10 rev. 01.1 - 06/2004
service manual SI 62
figure 1.2 Main board 98.90.01 electronics: sheet 1 of 12.
COVERTRACK2
COVERTRACK1
POWER_DOWN
8b_COLLATOR_COVER
8b_MOTOR_RELAY
8b_START_RELAY
RS232_RTS
RS232_CTSRS232_TXD
RS232_RXD
8b_SIDE_COVER
8b_TOP_COVER
GND
-12V
VCC
GND
PGND
GND GND GNDGND
CASE
GND
GNDGND GND
VCC AVDD
GND GND
GNDGND GND
VCC 24V
PGND
24V
GND
PGND
GND
GNDGND
GND
PGND PGND
PGND PGND
GND
PGNDGND
24V
CASE
GND
VCC
GND
VCC
VCC_OUT
VCC
24V
24V
+12V
GNDGND
Keep 4mm clearsurrounding thistestpin.
MOUNTINGHOLE
P-CHANNEL
2.95V
(sht 2)
Power down interrupt
5V power supply
-12V power supply
+12V power supply
AVDD power supply
Coverswitches
Unitpower
(sht 2)
(sht 2)
(sht 2)
(sht 2)
(sht 2)
(sht 2)
+24 VoltPGNDCOVER out
Motor run relaisMotor start relaisPower GNDRS232 RTSRS232 RXDRS232 CTSRS232 TXDRS232 GND
COVER in
Sidecover
Topcover
40mSec time leftfor uC after interrupt
C115100nF
R13156R
R1181K
R1024K7
Q100BC817
1
23 C121
100nF
TP100GND
R15010K
R1133K6
F1013A
+
-
U140ALM358
3
21
84
R1044K7
R1416K8
R1051K
F1003A
MH100
R1011K
R1161K
TP120-12V
C124100nF
CO10010nF
SR
Q&
IpkCtosc
U ref +-
U110MC34063
8
7
6
3
4
5
1
2
C112 150pF
R1143K6
C1511nF
C116100nF
R13056R
C1501nF
D120BAT54S
2 1
3
R1031K
600RL111
R153100R
R1074K7
J100
JST3
123
C140100nF U120
79L12
VIN2VIN3
GND
5
VIN6VIN7
VOUT 1
C10210nF
D13012V
C11110nF
600RL114
C113150pF
600RL113
Q111BC807
1
23
CO140100nF
C110470uF
R1113K6
R152100R
U100A
74HC14
12
J102
JST12
123456789101112
+
-
U140BLM3585
67
TP130+12V
C10010nF
R1544K7
C122100nF
R1084K7 U100B
74HC14
34
C125100nF
C123100nF
J101
JST3
123
R1511K
Q101BC817
1
23
R1123K6
R11756R
C130100nF
600RL112
C1142200uF
Q112IRFR9024
3
1
2
Q110BC817
1
23
R1151K
C120100nF
R14256R
R1064K7
R1553K6
C11722µF
TP110VCC
R1094K7
R1404K7
R1004K7
C10110nF
D111STPS340U2
1
R1100R1
L110150uH
410.03-11rev. 01.1 - 06/2004
service manual SI 62
figure 1.3 Main board 98.90.01 electronics: sheet 2 of 12.
8b_AD4
8b_AD5
8b_AD5
8b_AD58b_AD6
8b_AD6
8b_AD6
8b_AD0
8b_AD3
8b_AD7
8b_AD1
8b_AD0
8b_AD5
8b_AD4
8b_AD1
8b_AD3
8b_AD2
8b_AD7
8b_AD0
8b_AD2
8b_AD1
8b_AD1
8b_AD2
8b_AD48b_AD0
8b_AD2
8b_AD0
8b_AD3
8b_AD3
8b_AD4
8b_AD1
8b_AD7
8b_AD2
8b_AD7
8b_AD6
8b_AD3
8b_MUA3
8b_MUA4
8b_MUA15
8b_MUA13
8b_MUA2
8b_MUA3
8b_MUA8
8b_MUA14
8b_MUA5
8b_MUA3
8b_MUA12
8b_MUA2
8b_MUA6
8b_MUA13
8b_MUA10
8b_MUA3
8b_MUA5
8b_MUA10
8b_MUA7
8b_MUA8
8b_MUA12
8b_MUA2
8b_MUA14
8b_MUA4
8b_MUA15
8b_MUA11
8b_MUA8
8b_MUA6
8b_MUA11
8b_MUA11
8b_MUA7
8b_MUA12
8b_MUA1
8b_MUA14
8b_MUA13
8b_MUA14
8b_MUA0
8b_MUA10
8b_MUA4
8b_MUA9
8b_MUA18b_MUA0
8b_MUA9
8b_MUA9
8b_MUA5
8b_MUA7
8b_MUA1
8b_MUA6
8b_MUA15
8b_MUA08b_MUA1
8b_MUA12
8b_MUA0
8b_MUA13
8b_MUA2
8b_ALE
8b_PSEN
8b_CPU_RESET
8b_AD[0..7]
8b_ALE
8b_AD[0..7]
8b_MUA[8..15]
8b_AD[0..3]
8b_CLK_22MHz
8b_CLK_22MHz
8b_PSEN
8b_NWR8b_NRD
8b_CPU_RESET
8b_MUA[0..14]
8b_DIS_18b_DIS_2
8b_DIS_3
8b_NWR8b_NRD
SCS_SCL
8b_SCL_SIM
8b_ENV_TRACK_INT
MAIN_PDISC8b_CLOSERCEL
8b_START_RELAY
8b_MOTOR_RELAY8b_RPM_ENV_TRACK
8b_SEALING_SOL8b_OnDeck_SOL
8b_ANA_FLAP8b_ANA_EXIT8b_ANA_LOC
8b_ANA_ILED
8b_ANA_ENV
8b_RTS
SCS_SDA
8b_COLLATOR_COVER
8b_SDA_SIM
8b_CTS
8b_RPM_STACKER
8b_FINGER_SOL
8b_EJECT_SOL
8b_RXD16b_RXD0
8b_RS232_MUX
8b_RS232_MUX
8b_RTS
8b_CTS
8b_SCL_SIM
8b_SDA_SIM
POWER_DOWN
8b_TXD16b_TXD0
RS232_RXD
RS232_TXD
8b_FRAM_WP
8b_FRAM_WP
16b_OTP_SEL
RS232_CTS
RS232_RTS
8b_DISDIR
8b_MUA[0..14]
8b_DISBUF_OE
8b_TXD8b_RXD
8b_SIDE_COVER8b_TOP_COVER
8b_ORION_KB_RD8b_DISBUF2_OE
8b_AD[0..7]
8b_NWR
8b_AD[0..7]
8b_NWR8b_PSEN
8b_MUA[0..14]
8b_MUA[0..15]
8b_MUA[0..7]
RESET_XA16b_RSTINn
GND GND
VCC
GND
VCC
GND
GND
GND
VCC
VCC
VCC
GND GND
GND GND
GND GND
GND
VCC
GND
VCC
GND
GND
VCC
GND
GND
GND
GND
VCC
VCC+12V
VCC VCC
GND
VCC
VCC
VCC
GND
GND
GND
DATA/ADRESS BUS Latch
CPLD
RS232 driver
8 Kbyte FRAM
(sht 4)
(sht 4)
(sht 5)
(sht 4)
(sht 6)
(sht 5)
(sht 4)
(sht 4)
(sht 5)
(sht 1)
(sht 5)(sht 1)
(sht 5)
RS232 MUX
(sht 6)
(sht 3)
(sht 3)
(sht 6)
(sht 1)
TESTLED
CPLDIn circuitprogrammingconnection
(sht 6)
(sht 1)
(sht 5)
(sht 1)
(sht 1)
(sht 3)
ram_OE
FLASHWRITE8bit
(sht 3)
512Kbyte FLASH ROM
32Kbyte RAM
BS_A15
BS_A18BS_A17BS_A16
flash_CE
(sht 6)
FLASHRUN8bit
CPU
R208100R
J240
HEAD8
12345678
R2051K
D241GREEN
D240RED
C203100nF
U22074HC573
D12 Q1 19D23 Q2 18D34 Q3 17D45 Q4 16D56 Q5 15D67 Q6 14D78 Q7 13D89 Q8 12
C11OC1
VCC
20GND
10
TP2008b_TST
U25062256HF
A010A19A28A37A46A55A64A73A825A924A1021A1123A122A1326A141
CS120WE27OE22
D0 11D1 12D2 13D3 15D4 16D5 17D6 18D7 19
VCC
28GND
14
R242 150R
C260 100nF
R20156R
X20022.118MHz
CO20110nF
R2104K7
R206100R
CO26010nF
CO21010nF
R2091K
R207100R
R202100R
CO240110nF
R2604K7
R2201K
CO23010nF
C20022pF
R2114K7
D200GREEN
U26174HC4052
X0 12X1 14X2 15X3 11
Y0 1Y1 5Y2 2Y3 4
INH 6
A 10B 9
X13
Y3 VCC
16GND
8GND
7
U20180C552
P0.0 57P0.1 56P0.2 55P0.3 54P0.4 53P0.5 52P0.6 51P0.7 50
P2.0 39P2.1 40P2.2 41P2.3 42P2.4 43P2.5 44P2.6 45P2.7 46
(RXD) P3.0 24(TXD) P3.1 25(INT0) P3.2 26(INT1) P3.3 27(T0) P3.4 28(T1) P3.5 29(WR) P3.6 30(RD) P3.7 31
(CMSR0) P4.0 7(CMSR1) P4.1 8(CMSR2) P4.2 9(CMSR3) P4.3 10(CMSR4) P4.4 11(CMSR5) P4.5 12(CMT0) P4.6 13(CMT1) P4.7 14
(ADC0) P5.0 1(ADC1) P5.1 68(ADC2) P5.2 67(ADC3) P5.3 66(ADC4) P5.4 65(ADC5) P5.5 64(ADC6) P5.6 63(ADC7) P5.7 62
XTAL135
XTAL234
RST15
PSEN47
ALE48
EA49
EW6
PWM04
PWM15
STADC3 AVREF+59
AVREF-58
VCC
2GND1
36
AVSS60
AVDD61
GND2
37
(INT2/CT0I)P1.0 16(INT3/CT1I)P1.1 17(INT4/CT2I)P1.2 18(INT5/CT3I)P1.3 19
(T2) P1.4 20(RT2) P1.5 21(SCL) P1.6 22(SDA) P1.7 23
CO26110nF
U23029F040
A012A111A210A39A48A57A66A75A827A926A1023A1125A124A1328A1429A153A162
CE22OE24
A181
D0 13D1 14D2 15D3 17D4 18D5 19D6 20D7 21
VCC
32GND
16
A1730
WE#31
U260MAX232ACSE
R1IN13R2IN8
T1IN 11T2IN 10
C+ 1C1- 3C2+ 4C2- 5V+ 2V- 6
R1OUT 12R2OUT 9
T1OUT14T2OUT7
VCC
16GND
15 C240 10nF
C20122pF
R2401K
U210FM24C64
SDA5
SCL6
VCC
8
A0 1A1 2A2 3G
ND
4
WP7
C261 100nF
CO22010nF
R2041K
C20222µF
CO25010nF
R2411K
R203100R
U300D74HC14
9 8
U240M4A5-64/32
GND
1
I/O02I/O13I/O24I/O35I/O46I/O57I/O68I/O79
GND
12GND
23GND
34
TDI 10
TCK 13TMS 32
TDO 35
CLK0/IO11
CLK1/I133
VCC
44
VCC
22
I/O814I/O915I/O1016I/O1117I/O1218I/O1319I/O1420I/O1521
I/O16 24I/O17 25I/O18 26I/O19 27I/O20 28I/O21 29I/O22 30I/O23 31
I/O24 36I/O25 37I/O26 38I/O27 39I/O28 40I/O29 41I/O30 42I/O31 43
CO240010nF
C263100nF
C262 100nF
410.03-12 rev. 01.1 - 06/2004
service manual SI 62
figure 1.4 Main board 98.90.01 electronics: sheet 3 of 12.
8b_AD4
8b_AD1
8b_AD6
8b_AD3
8b_AD7
8b_AD2
8b_AD0
8b_AD5
8b_AD3
8b_AD08b_AD1
8b_AD6
8b_AD2
8b_AD48b_AD5
8b_AD7
8b_ORION_KB_RD
8b_DISDIR
8b_NRD8b_NWR
8b_DIS_18b_CPU_RESET
8b_DISBUF_OE
8b_AD[0..7]
8b_AD[0..7]
8b_DIS_28b_DIS_3
8b_DISBUF2_OE
GNDGND
VCC_OUT
GND GND
GNDGND
VCC_OUTVCC_OUT
VCC VCC VCC VCC VCC VCC
GND
VCC
GNDGND GND GND GND GND GND
GND
VCC
VCC_OUT
GND
VCC_OUT
GND GND
VCC
VCC
GND
GND
VCC
GND GND
VCC
GND
VCC
GND
VCC
GND
VCC
GNDREAD DISP.RESET DISP.WRITE DISP.
ORION LCD connection
C/D DISP.CE DISP.
SI68 LCD connection
(SHT 2)
Orion keyboard readout
(SHT 2)
(SHT 2)
(SHT 2)
(SHT 2)
CO32010nF
600R
L332R331
100R
R337
100R
JP321SEL0
R30810K
U300B74HC14
3 4
R3901K
U300F74HC14
13 12
R31410K
CO33010nF
R332
100R
J300
CONBOX26
135791113151719212325
2468101214161820222426
600R
L333
R317
100R
C303150pF
U33074HC244
1A12 1Y1 181A24 1Y2 161A36 1Y3 141A48 1Y4 122A111 2Y1 92A213 2Y2 72A315 2Y3 52A417 2Y4 3
1G 12G 19
VCC
20GND
10
R31210K
600R
L335
COJ330100nF
R316100R
R306 100R
COJ300100nF
R342
100R
R340
100R
JP320SEL1C306
150pF
600R
L330
R333
100R
600R
L342J330
MicroMatch20
135791113151719
2468101214161820
U33174HCT245
A1 2B118A2 3B217A3 4B316A4 5B415A5 6B514A6 7B613A7 8B712A8 9B811
G 19DIR 1
VCC
20GND
10
600R
L341
R338
100R
R31010K
600R
L334
600R
L340
U300A74HC14
12
600R
L339
R31510K
600R
L338
600R
L337
600R
L336R336
100R
CO30010nF
C301150pF
C304150pF
R31310K
R30910K
R301 100R R304 100R
U32074HC244
1A12 1Y1 181A24 1Y2 161A36 1Y3 141A48 1Y4 122A111 2Y1 92A213 2Y2 72A315 2Y3 52A417 2Y4 3
1G 12G 19
VCC
20GND
10
R334
100R
600R
L331
R305 100R
R330
100R
CO33110nF
600R
L343
R335
100R
R302 100R
R300 100R
R341
100R
C302150pF
C305150pF
R31110K
R339
100R
410.03-13rev. 01.1 - 06/2004
service manual SI 62
figure 1.5 Main board 98.90.01 electronics: sheet 4 of 12.
8b_OnDeck_SOL
8b_SEALING_SOL
8b_EJECT_SOL
8b_RPM_STACKER
8b_RPM_ENV_TRACK
16b_DigClutch_FoForward
16b_DigClutch_FoReverse
8b_FINGER_SOL
8b_TX_LOC
8b_CLOSERCEL
PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
24V24V
24V
24V
24V
24V
24V
PGND
24VVCC_OUT
GND
GND
VCC
VCC
Pres. on deck solenoid
Sealing solenoid
Eject solenoid
TX loc-cel
(sht 2)
(sht 2)(sht 2)
(sht 7)
(sht 5)
Closercel
LOC
CLOSER
RPM env. track
RPM stracker
finger sol.
RPM FoReverse
RPM FoForward
Rearsideactuators
C470150pF
U100F
74HC14
13 12
R45056R
C46010nF
D441STPS340U 2
1
U100D
74HC14
9 8
U440ULN2003L
I1 1I2 2I3 3I4 4I5 5I6 6I7 7G
ND
8COM
9
O116O215O314O413O512O611O710
D451STPS340U2
1
Q450ASI4946EY2
81
7
Q450BSI4946EY4
63
5
D460STPS340U2
1
C441100nF
C44010nF
C442470uF
R4714K7
R44056R
J450
JST8
12345678
U100C
74HC14
56C45110nF
R45256RU100E
74HC14
11 10
R4721K
C45010nF
R46056R
J440
JST10
12345678910
Q440BSI4946EY4
63
5
U300E
74HC14
1110
D44012V
D450STPS340U2
1
J460
JST4
1234
R470150R
Q440ASI4946EY 2
81
7
410.03-14 rev. 01.1 - 06/2004
service manual SI 62
figure 1.6 Main board 98.90.01 electronics: sheet 5 of 12.
8b_ANA_ILED
8b_SCL_SIM8b_SDA_SIM
8b_ANA_ENV
8b_ANA_LOC
8b_ANA_FLAP
8b_ENV_TRACK_INT
8b_TX_LOC
MAIN_PDISC
8b_ANA_EXIT
+12V
GND GND
GND
VCC
GND
VCC_OUT
VCC_OUT
GND
GND
VCC_OUT
VCC_OUT
VCC_OUT
GND
GND
GNDGND
VCC
+12VVCC
GND GND
VCC VCC
GND
VCC
GND
VCC
GND
VCC_OUT
GND
VCC_OUT
EXIT RX
EXIT TX
FLAP TX
FLAP RX
LOC RX
EXIT
LOC
FLAP
ENV_TRACK
ENV_TRACK RX
ENV_TRACK TX
(sht 4)
(sht 2)
(sht 2)
(sht 2)
(sht 2)
(sht 2)
(sht 2)
(sht 2)
(sht 2, 6)
EnveloppeTrackphotcells
Exitphotocell
MainPulsDisc
Uout = 11 x I
3.98V
MAIN PDISC
R5554K7
R5831K
R5908K2
Q553BC817
1
23
C53010nF
R5931K
Q551BC817
1
23
TP510ENV
R559 68K
R55082R
R54010K
C550100nF
R570 100K
R5544K7
D580GREEN
R52010K
R59168K
R5314K7
C5901nF
R5424K7
R5714K7
+
- U590ALM358
3
21
84
R55610K
TP530LOC
R561 68K
J580
JST5
12345
R55182R
R5414K7
CO550100nF
R51010K
R563 68K
TP520FLAP
C52010nF
CO560100nF
R5721R
Q550BC817
1
23
R5821K
Q552BC817
1
23
R5814K7
R55739K
U300C74HC14
5 6
R565 68K
R580150R
TP540EXIT
R55282R
R560 1K
C51010nF
U550TDA8444T
DAC09DAC110DAC211DAC312DAC413DAC514DAC615DAC716
N.C. 5A0 6A1 7
SCL 4SDA 3
VMAX 2GND
8VP
1
R521100R
C54010nF
R562 1K
R5731R
R53010K
+
-
U590BLM3585
67
R5921K
C580150pF
J540
JST5
12345
R55382R
R522100R
R558 1K
R564 1K
R5111K
J500
JST10
12345678910
C570 10nF
410.03-15rev. 01.1 - 06/2004
service manual SI 62
figure 1.7 Main board 98.90.01 electronics: sheet 6 of 12.
16b_MUA7
16b_MapWRn
16b_MUA5
16b_MUA216b_MUA1
16b_MUA316b_MUA4
16b_MUA6
16b_Reboot
16b_Map1
16b_MUA816b_MUA9
16b_MUA13
16b_MUA1516b_MUA14
16b_MUA1216b_MUA1116b_MUA10
16b_Map0
16b_Map0
16b_MUA19
16b_Map1
16b_MUA16
16b_MUA1
16b_MUA15
16b_MUA1816b_MUA17
16b_MUA2
16b_R.en.D
16b_MUA7
16b_MUA5
16b_MUA216b_MUA1
16b_MUA316b_MUA4
16b_MUA6
16b_MUA816b_MUA9
16b_MUA13
16b_MUA1516b_MUA14
16b_MUA1216b_MUA1116b_MUA10
16b_MUA7
16b_MUA5
16b_MUA216b_MUA1
16b_MUA316b_MUA4
16b_MUA6
16b_MUA816b_MUA9
16b_MUA13
16b_MUA1516b_MUA14
16b_MUA1216b_MUA1116b_MUA10
16b_MUA16
16b_MUA1816b_MUA17
16b_MUA13
16b_MUA1516b_MUA14
16b_MUA12
16b_MUA7
16b_MUA516b_MUA4
16b_MUA6
16b_MUA816b_MUA9
16b_MUA1116b_MUA10
16b_MUA16
16b_MUA1816b_MUA17
16b_MUA19
16b_MUD0
16b_MUD3
16b_MUD11
16b_MUD11
16b_MUD8
16b_MUD0
16b_MUD2
16b_MUD10
16b_MUD6
16b_MUD0
16b_MUD3
16b_MUD14
16b_MUD3
16b_MUD13
16b_MUD9
16b_MUD9
16b_MUD6
16b_MUD0
16b_MUD7
16b_MUD10
16b_MUD13
16b_MUD9
16b_MUD9
16b_MUD15
16b_MUD2
16b_MUD2
16b_MUD4
16b_MUD11
16b_MUD6
16b_MUD5
16b_MUD4
16b_MUD15
16b_MUD1
16b_MUD4
16b_MUD12
16b_MUD2
16b_MUD14
16b_MUD1
16b_MUD10
16b_MUD14
16b_MUD13
16b_MUD4
16b_MUD11
16b_MUD8
16b_MUD1
16b_MUD616b_MUD5
16b_MUD0
16b_MUD2
16b_MUD7
16b_MUD10
16b_MUD15
16b_MUD1
16b_MUD4
16b_MUD15
16b_MUD1
16b_MUD6
16b_MUD12
16b_MUD7
16b_MUD13
16b_MUD7
16b_MUD3
16b_MUD5
16b_MUD3
16b_MUD12
16b_MUD12
16b_MUD7
16b_MUD5
16b_MUD0
16b_MUD14
16b_MUD8
16b_MUD8
16b_MUD5
16b_MUA16
16b_MUA1816b_MUA17
16b_MUA7
16b_MUA5
16b_MUA216b_MUA1
16b_MUA316b_MUA4
16b_MUA6
16b_MUA816b_MUA9
16b_MUA13
16b_MUA1516b_MUA14
16b_MUA1216b_MUA1116b_MUA10
16b_MUA19
16b_MUA19
16b_MUA16
16b_MUA1816b_MUA17
16b_MUA7
16b_MUA5
16b_MUA216b_MUA1
16b_MUA316b_MUA4
16b_MUA6
16b_MUA816b_MUA9
16b_MUA13
16b_MUA1516b_MUA14
16b_MUA1216b_MUA1116b_MUA10
16b_MUD8
16b_MUD10
16b_MUD12
16b_MUD9
16b_MUD1416b_MUD13
16b_MUD15
16b_MUD11
16b_MUD1
16b_OTP_SEL
16b_RSTINn
16b_WRLn16b_RAMCS2n
16b_OERAM1n
16b_RAMCS1n
16b_RSTINn
16b_MUD[0..1]
16b_ALE
16b_MUD[0..15]
16b_MUD[0..15]
16b_MUD[0..15]
16b_PSENn
16b_MUD[0..15]
16b_WRHn16b_FlashCSn
16b_MUA[1..19]
16b_FMUA19
16b_PSENn
16b_MUA3
16b_WRLn16b_RDn
16b_ALE
16b_WRHn16b_MUA1
16b_RSTINn
16b_MUA2
16b_MUA[4..19]
16b_OERAM1n
16b_RAMCS1n16b_WRHn
16b_WRLn
16b_MUA[1..19]
16b_WRHn16b_RAMCS2n
16b_ALE
16b_MUA[1..19]
16b_RDn
16b_PSENn
16b_RDn16b_WRLn
16b_RAMCS1n16b_FlashCSn
16b_RAMCS2n
16b_MUA[1..19]
16b_PWM_Collator16b_PWM_MaxiFeeder
16b_ReadHead_Ana1
MAIN_PDISC
16b_DongleCommunication
16b_PDisc_Collator
16b_AD_CS
16b_Multiplexed_AD416b_IledCheck
16b_CurveDisc_FT116b_CurveDisc_FT2
16b_AD_DAT16b_AD_CLK
16b_MUA[1..19]
16b_DAC_DATA16b_DAC_CLK16b_DAC1_CS
16b_FMUA19
16b_DigOutput116b_DigOutput2
16b_DigInput1
SCS_SCLSCS_SDA
16b_TXD016b_RXD0
16b_RSOUTn
16b_DAC2_CS
DfcMulPlex0
DfcMulPlex1
16b_TXD116b_RXD1
16b_RXD116b_TXD1
16b_OERAM1n16b_PSENn
DfcMulPlex2
SCS_SCLSCS_SDA16b_DEBUG116b_DEBUG2
RESET_XA
GNDGND
VCC
GND
VCC
AVDD
AVDD
VCCVCC
VCC
VCC
VCC
VCC
VCCVCC
VCC
VCC
VCC
VCC
VCC
VCC
VCC
VCC
VCC
GND
GND GND
GNDGND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GNDGND
VCC
VCC
VCC
GND
GND
GND
GND
GND
GND
VCC
VCC
GND
GND
VCC_OUT
5V supervisor
Scratch jumper
LatchesOTP/FLASH selector
XA controller
64Kbyte system RAM
1Mbyte FLASH ROM
1Mbyte emulation RAM
(sht 6)
(sht 2)
(sht 2)
(sht 11)(sht 11)
(sht 5)(sht 11)
(sht 7)(sht 7)
(sht 8)
(sht 12)(sht 7)
(sht 8)
(sht 7)
(sht 10)
FLASH WRITE
TEST
MAP0
MAP1
(sht 7)
(sht 9)
(sht 7)
(sht 7)
(sht 7)
(sht 2)
DEBUG CONNECTION
(sht 2)
(sht2)
(sht 7)
CO61031uF
U641HM628512BLP-5
A18 1
A16 2A15 31
A12 4
A7 5A6 6A5 7A4 8A3 9A2 10A1 11A0 12DQ013DQ114DQ215
GND
16
DQ317DQ418DQ519DQ620DQ721
CS 22
A10 23
OE 24
A11 25
A9 26A8 27
A13 28A14 3
A17 30
WE 29
VCC
32
CO661
10nF
R6131K
C650100nF
U671B74HC74
D12 Q 9
CLK11
Q 8PR
10CL
13
VCC
14GND
7
U68174HC573
D12 Q1 19D23 Q2 18D34 Q3 17D45 Q4 16D56 Q5 15D67 Q6 14D78 Q7 13D89 Q8 12
C11OC1
VCC
20GND
10
R6141K
CO6102
10nF
C671100nF
D672
GREEN
C653100nF
U660D74HC08
12 1311
C65222µF
JP610FLASH BOOT
R6501K
CO6100
10nF
U63029F800
A18 16
A16 48A15 1
A12 4
A7 18A6 19A5 20A4 21A3 22A2 23A1 24A0 25DQ029DQ131DQ233
GND
27
DQ335DQ438DQ540DQ642DQ744
CE 26
A10 6
OE 28
A11 5
A9 7A8 8
A13 3A14 2
A17 17
WE 11
VCC
37
DQ830DQ932DQ1034DQ1136DQ1239DQ1341DQ1443DQ1545
RESET12 RY/BY15
GND
46
BYTE47
R6601K
R6001K
CO620
10nF
CO680
10nF
CO641
10nF
R610 56R
U600
OSC. 29.4912MhzVDD
4GND
2
OUT 3
OE 1
D671
RED
U62162256HF
A0 10A1 9A2 8A3 7A4 6A5 5A6 4A7 3A8 25A9 24A10 21A11 23A12 2A13 26A14 1
CS1 20WE 27OE 22
D011D112D213D315D416D517D618D719
VCC
28GND
14
U660A74HC08
1
23
U650TL7705A
CT3 SEN7 RESIN2
REF 1
RST 6RSET 5
U68074HC573
D12 Q1 19D23 Q2 18D34 Q3 17D45 Q4 16D56 Q5 15D67 Q6 14D78 Q7 13D89 Q8 12
C11OC1
VCC
20GND
10
D630RED
R61110K
C651100nF
U660C74HC08
9
108
R60156R
R6701K
U610PXAS37KBBESOT315-1
XTAL168
XTAL267
AVDD28AVDD29AVREF+27AVREF-26AVSS30AVSS31
CLKOUT46ALE/PROG44PSEN45RSTOUT11RST47EA/WAIT/VPP16
P1.0/A0/WRH32P1.1/A133P1.2/A234P1.3/A335P1.4/RXD136P1.5/TXD137P1.6/T238P1.7/T2EX39
P3.0/RXD03P3.1/TXD04P3.2/INT05P3.3/INT16P3.4/T07P3.5/T1/BUSW8P3.6/WRL9P3.7/RD10
P4.0/ECI 73P4.1/CEX0 74P4.2/CEX1 75P4.3/CEX2 76P4.4/CEX3 77P4.5/CEX4 78P4.6/A20 79P4.7/A21 2
P5.0/AD0 17P5.1/AD1 18P5.2/AD2 19P5.3/AD3 20P5.4/AD4 22P5.5/AD5 23
P5.6/AD6/SCL 24P5.7/AD7/SDA 25
P6.0/A22 40P6.1/A23 41
P0.0/A4D0 42P0.1/A5D1 43P0.2/A6D2 48P0.3/A7D3 49P0.4/A8D4 50P0.5/A9D5 55P0.6/A10D6 56P0.7/A11D7 57
P2.0/A12D8 58P2.1/A13D9 59P2.2/A14D10 61P2.3/A15D11 62P2.4/A16D12 63P2.5/A17D13 64P2.6/A18D14 65P2.7/A19D15 66
VDD
71VDD
72VDD
52VDD
51VDD
14VDD
15
VSS
69VSS
70VSS
53VSS
54VSS
12VSS
13R612 10K
U660B74HC08
4 56
TP61016b_TST
U671A74HC74
D2 Q 5
CLK3
Q 6PR
4CL
1
VCC
14GND
7
R6721KCO660
10nF
C601100nF
CO671
10nF
CO621
10nF
D610GREEN
R6301K
CO600
10nF
R6801K
R6151K
CO681
10nF
J600
HEAD8
12345678
U67022V10PLCC
I1/CLK2I23I34I45I56I67I79I810I911I1012I1113I1216
O1 27O2 26O3 25O4 24O5 23O6 21O7 20O8 19O9 18O10 17
VCC
28GND
14
NC 1NC 8NC 15NC 22R6511K
CO670
10nF
U640HM628512BLP-5
A18 1
A16 2A15 31
A12 4
A7 5A6 6A5 7A4 8A3 9A2 10A1 11A0 12DQ013DQ114DQ215
GND
16
DQ317DQ418DQ519DQ620DQ721
CS 22
A10 23
OE 24
A11 25
A9 26A8 27
A13 28A14 3
A17 30
WE 29
VCC
32
R6811K
R6521K
CO6101
10nF
R671680K
R6731K
JP670R&D
U62062256HF
A0 10A1 9A2 8A3 7A4 6A5 5A6 4A7 3A8 25A9 24A10 21A11 23A12 2A13 26A14 1
CS1 20WE 27OE 22
D011D112D213D315D416D517D618D719
VCC
28GND
14
CO630
10nF
CO640
10nF
C600150pF
410.03-16 rev. 01.1 - 06/2004
service manual SI 62
figure 1.8 Main board 98.90.01 electronics: sheet 7 of 12.
MU_AD_SEL0MU_AD_SEL1MU_AD_SEL2
16b_MUD616b_MUD7
16b_MUD0
16b_MUD4
16b_MUD2
16b_MUD5
16b_MUD3
16b_MUD1
16b_MUD616b_MUD7
16b_MUD0
16b_MUD4
16b_MUD2
16b_MUD5
16b_MUD3
16b_MUD1
16b_MUD616b_MUD7
16b_MUD0
16b_MUD4
16b_MUD2
16b_MUD5
16b_MUD3
16b_MUD1
16b_ReadHead_S016b_ReadHead_S1
16b_Multiplexed_AD4
16b_DIG_FCEL_FE116b_DIG_FCEL_FE216b_DIG_FCEL_FE316b_DIG_FCEL_COLL16b_DIG_FCEL_RH16b_DIG_FCEL_FO
16b_DigInput1
16b_MUD[0..7]
16b_RSOUTn16b_DigOutput2
16b_MUD[0..7]
16b_DigClutch_FO116b_DigClutch_FO216b_DigClutch_FoForward
16b_DigClutch_FoReverse
16b_DigClutch_FE1
16b_DigClutch_FE316b_DigClutch_FE2
16b_AD_CS
16b_AD_CLK
16b_DFC_FE116b_DFC_FE216b_DFC_FE3
16b_DIR_Collator
16b_DigOutput1
16b_MUD[0..7]
DfcMulPlex1DfcMulPlex0
16b_ANA_RX_Collator16b_ANA_RX_ReadHead16b_ANA_RX_Folder16b_ANA_RX_Feeder1
16b_ANA_RX_Feeder316b_ANA_RX_Feeder2
16b_ReadHead_Ana016b_ReadHead_Ana2
16b_DongleCommunication
16b_SwitchMaxiFeeder
16b_RSOUTn
16b_AD_DAT
DfcMulPlex216b_MaxiFeederDetect
16b_DEBUG116b_DEBUG2
16b_IledCheck
VCCVCC
VCC
GND
GND
GND
GND
GND
VCC
GND GND
VCC
GND
GND
GND
GND
VCC
VCC
GND GNDGND
VCC
GND
VCC
GND
VCC
GND
GND GND
VCC
AVDD
GND
GND GND GND
VCC VCC
Digital outputs
Digital inputs
10 bit ADC for DFC
(sht 6)
(sht 10)(sht 12)(sht 10)(sht 9)(sht 9)(sht 9)(sht 12)(sht 12)
(sht 10)(sht 10)(sht 4)
(sht 9)(sht 9)(sht 9)(sht 4)
(sht 9)(sht 9)(sht 9)(sht 10)(sht 12)(sht 10)(sht 11)
(sht 9)(sht 9)(sht 9)
(sht 12)(sht 12)
(sht 6)
Analog multiplexer
(sht 6)
(sht 11)
(sht 6)
(sht 8)
(sht 11)
JP730Inter. trans.
R7104K7
CO730010nF
CO73110nF
R73056R
D740BAT54S
21
3
R73256R
R74010K
U730LTC1197
CS1 +IN 2
-IN 3
GND
4VCC
8
CLK7
DOUT6 VREF 5
C7311nF
CO71010nF
R73510K
R72010K
Q710BC817
1
23
TP710WINDOW
U73174HC4051
X0 13X1 14X2 15X3 12X4 1X5 5X6 2X7 4
INH6
A11B10C9
X3 GND
8VCC
16
U70074HC273
D73 Q7 2D64 Q6 5D57 Q5 6D48 Q4 9D313 Q3 12D214 Q2 15D117 Q1 16D018 Q0 19
CLK11CLR1
VCC
20GND
10
R73610K
CO72010nF
D700BAT54S
21
3
U70174HC4051
X0 13X1 14X2 15X3 12X4 1X5 5X6 2X7 4
INH6
A11B10C9
X3 GND
8VCC
16
JP731Spare
J740UCAN CLIP
2
1
U72074HC244
1A1 21Y1181A2 41Y2161A3 61Y3141A4 81Y4122A1 112Y192A2 132Y272A3 152Y352A4 172Y43
1G12G19
VCC
20GND
10
R741150R
R7341K
CO70010nF
JP720FE1-SEL
C730100nF
R711150R
R73156R
U71074HC273
D73 Q7 2D64 Q6 5D57 Q5 6D48 Q4 9D313 Q3 12D214 Q2 15D117 Q1 16D018 Q0 19
CLK11CLR1
VCC
20GND
10
R7331K
CO73021uF
CO70110nF
CO730122µF
410.03-17rev. 01.1 - 06/2004
service manual SI 62
figure 1.9 Main board 98.90.01 electronics: sheet 8 of 12.
16b_DAC_DATA
16b_IledCheck
16b_TX_Feeder1
16b_TX_Feeder2
16b_TX_Feeder3
16b_TX_Collator
16b_TX_ReadHead
16b_TX_Folder
16b_DAC_CLK
16b_DAC1_CS
VCCVCC
VCC
GNDGNDGNDGND
VCC
GND GND
VCC VCC
GND
GND
3.98V
Current Sink
(sht 6)
Photocel DAC
(sht 9)
(sht 11)
(sht 10)
(sht 10)
(sht 6)Uout = 11 x I
R80010K
R8021K
Q803BC8171
2 3
+
-
U820ALM3583
21
84
R81182R
R81282R
U800MAX5258
DAC-A 2DAC-B 1DAC-C 16DAC-D 15DAC-E 7DAC-F 8DAC-G 9DAC-H 10
LDAC6
REF5
SCLK12 DIN13 CS11GND
3VDD
4
DOUT14
R8041K
R80882R
R8031K
CO820100nF
R8214K7
Q800BC8171
2 3
Q805BC8171
2 3
Q802BC8171
2 3
R81382R
R8051K
+
-
U820BLM3585
67
R8061K
R8221R
Q804BC8171
2 3
C800100nF
R820100K
C82010nF
Q801BC8171
2 3
R81082R
R8231R
R80982R
R8071K
CO800100nF
R80139K
R8251K
410.03-18 rev. 01.1 - 06/2004
service manual SI 62
figure 1.10 Main board 98.90.01 electronics: sheet 9 of 12.
FE1_DFC_OFFSET
FE3_DFC_OFFSETFE2_DFC_OFFSET
16b_DIG_FCEL_FE1
16b_DFC_FE1
16b_DigClutch_FE1
16b_DigClutch_FE2
16b_DigClutch_FE3
16b_ANA_RX_Feeder1
16b_DFC_FE2
16b_ANA_RX_Feeder2
16b_DIG_FCEL_FE2
16b_DFC_FE3
16b_ANA_RX_Feeder3
16b_DIG_FCEL_FE3
16b_Clutch_FE3
16b_Clutch_FE2
16b_Clutch_FE1
16b_DAC_DATA16b_ReadHead_DAC016b_ReadHead_DAC1 16b_DAC_CLK
16b_DAC2_CS
16b_Clutch_FE1
16b_TX_Feeder1
16b_Clutch_FE2
16b_TX_Feeder2
16b_Clutch_FE3
16b_TX_Feeder3
VCC_OUT +12V
PGND
+12V
GNDGND
VCC
GND
GND GND GND GND
GND
GND GND GND GND
GND
VCC
VCC
GND
GND GND
GND
GND
GND
GND
GND
GND
GND
GND
GND GND
GND
VCC VCC
VCC
GNDGND
VCC
GND GND
+12V +12V
GND
VCC
GND
+12V
GND
+12V
PGND
GND
GND
24V24V
VCC_OUT24V
VCC_OUT24V
Feeder-1
TX feeder-1
RX feeder-1
Clutch fe1
DFC feeder1
TX feeder-2
RX feeder-2
Clutch fe2
DFC feeder2
Feeder-2
TX feeder-3
RX feeder-3
Clutch fe3
DFC feeder3
Feeder-3
3.98V
(sht 6)
(sht 7)
(sht 7)
(sht 7)
(sht 7)
(sht 12)
Pulls BusWidthselect of XA high
(sht 7)
(sht 7)
(sht 7)
R90610K
TP950FE-3
R9141K
C970100nF
R9341K
R9651K
R91139K
R9625K6
C912100nF
TP960DFC FE3
R9048K2
CO900100nF
R9538K2
+
- U930ALM358
3
21
84
R94139K
C93010nF
R98239K
R9405K6
R9001K
U980MAX5258
DAC-A2DAC-B1DAC-C16DAC-D15DAC-E7DAC-F8DAC-G9DAC-H10
LDAC 6
REF 5
SCLK 12DIN 13CS 11
GND
3VDD
4
DOUT 14
R9641K
C962100nF
CO950100nF
C940100nF
R9425K6
R96139K
J950
JST10
12345678910
R9151K
+
-
U950BLM358
5
67
R9605K6
C842100nF
R9105K6
R9311K
J900
JST10
12345678910
R95568K
R9441K
TP930FE-2
D97012V
CO930100nF
R9011K
R98110K
C961 100nF
R9511K
R9501K
R9338K2
R943 39K
R90210K
R93210K
C95010nF
TP940DFC FE2
C960100nF
R90568K
+
-
U900BLM358
5
67
R95610K
R98010K
TP900FE-1
C941 100nF
C980100nF
TP910DFC FE1
R9451K
R913 39K
R9031K
+
-
U930BLM358
5
67
R9125K6
C911 100nF
+
- U900ALM358
3
21
84
R9301K
R95210K
R93610K
C90010nF
CO980100nF
R93568K
R963 39K
R9541K
C910100nF
+
- U950ALM358
3
21
84
U970ULN2003L
I1 1I2 2I3 3I4 4I5 5I6 6I7 7G
ND
8COM
9
O116O215O314O413O512O611O710
J930
JST10
12345678910
410.03-19rev. 01.1 - 06/2004
service manual SI 62
figure 1.11 Main board 98.90.01 electronics: sheet 10 of 12.
16b_CurveDisc_FT1
16b_CurveDisc_FT2
16b_ANA_RX_Collator
16b_DIG_FCEL_COLL
16b_ANA_RX_Folder
16b_DIG_FCEL_FO
16b_DigClutch_FO2
16b_DigClutch_FO1
16b_RX_ReadHead
16b_TX_ReadHead
16b_TX_Folder
VCC_OUT
VCC
PGND
GND
VCC
GND
VCC
GND
VCC
GND
VCC
VCCVCC
GND GND GNDGND
GNDGND
VCC
GND
GND
VCC
PGND
VCC_OUT
GND
24V
24V
Photocellscollatorside
(sht 6)
(sht 6)
(sht 7)
(sht 7) (sht 8)
FT1
FT2
RX Reading head
(sht 12)
Slotted switch FT1
Slotted switch FT2
Clutch FT1
Clutch FT2
FOLDERSIN KAP
RX Collator
RX Folder
TX Folder
TX Read head
(sht 8)
R1064150R
R106068K
R10541K
R10618K2
R10131K
R1065150R
R10521K
R105068K
R10114K7
U00F74HC14
13 12
C1020100nF
J1000
JST12
123456789101112
R105310K
D1010GREEN
R10021K
R10014K7
CO1050100nF
+
-U1050ALM358
3
21
84
R10701K
R10621K
C106010nF
TP1060FO
R106310K
R10121K
C1000150pF
U00A74HC14
1 2
R10518K2
D102012V
C105010nF
TP1050COLL
U1020ULN2003L
I1 1I2 2I3 3I4 4I5 5I6 6I7 7G
ND
8COM
9
O116O215O314O413O512O611O710
C1010150pF
D1000GREEN
J1050
JST8
12345678
CO0010nF
R10031K
U00B74HC14
3 4
+
-U1050BLM358
5
67
R10551K
410.03-20 rev. 01.1 - 06/2004
service manual SI 62
figure 1.12 Main board 98.90.01 electronics: sheet 11 of 12.
16b_PDisc_Collator
16b_PWM_Collator16b_DIR_Collator
16b_TX_Collator
16b_SwitchMaxiFeeder
16b_MaxiFeederDetect
16b_PWM_MaxiFeeder
VCC_OUT
GND
VCC
GND
VCC VCC
VCC
GND
PGND PGND
PGND
24V
24V
24V
VCC
PGND
PGND
PGND
PGND
GND
VCC_OUT VCC_OUT
GND
CollatorUnit
(sht 8)
(sht 6)
(sht 6)(sht 7)
(sht 7)
MAXIFEEDER
PD COLL.
Pdisc collator
TX Collator
Motor MF
Switch MF
MF detect
(sht 6)
-+ Collator motor
R11031K
J1110
JST10
12345678910
C1110100nF
U00C74HC14
56
R111210K
C1111100nF L1110
COMMON MODE SUPPRESION COIL
4
2
3
1
J1100
JST6
123456
C1113100nF
R1110100R
R110210K
U1110L6205PD
PGND1
1PGND2
10PGND3
11PGND4
20
VSa
2VSb
19
SENA 8
SENB 13
IN2A7
IN1B14IN2B15
OUT1A 9
OUT2A 3
OUT1B 12
OUT2B 18
VBOOT17
VCP4
EN_A
5
EN_B
16
IN1A6
C1100100nF
U00E74HC14
11 10
D1111GREEN
R111110K
D1110BAT54S
21
3
R11151K
C1114100nF
R1113150R
R11161K
R110010K
C1101100nF
R110110K
CO1110470uF
C111210nF
R11144K7
U00D74HC14
98
C1115150pF
410.03-21rev. 01.1 - 06/2004
service manual SI 62
figure 1.13 Main board 98.90.01 electronics: sheet 12 of 12.
16b_ReadHead_Ana1
16b_ReadHead_Ana2
16b_ReadHead_S0
16b_ReadHead_S1
16b_ReadHead_DAC1
16b_ReadHead_DAC0
16b_ReadHead_Ana0
16b_ANA_RX_ReadHead
16b_DIG_FCEL_RH16b_RX_ReadHead
-12V
-12V
-12V +12V
CASE
VCC
VCC
GND GND GND
GND GND GND
GND
GNDGND
GNDGND
GND
GND
GND
GND
GND
GND GND
GND
VCC
GND
VCC
GNDGND
VCC
GND
VCC
+12V
-12V
-12V+12V
AVDD
GND
GND
Rv=27K
ReadingHead
(sht 10)(sht 7)
(sht 7)
(sht 9)
(sht 9)
(sht 6)
(sht 7)
(sht 7)
(sht 7)
(sht 7)
+
-
U1220BLM3585
67
R120639K
U1221DHC4066
11 10
12
CO12000100nF
R12561K
C12041nF
C120310nF
R12036K8
R125568K
R120956R
R122947K
R1251150R
U1221CHC4066
8 9
6
R12301K
R12004K7
CO1220100nF
R1250150R
R12531K
+
- U1250BLM358
5
67
R1225680K
R121310K
TP1220OMR_OUT
CO1250100nF
C12001nF
R122447K
J1200
AMP6123456
C1220100nF
R12046k8
R122868K
R121210K
U1221AHC4066
12
13
R121082R
+
- U1220ALM358
3
21
84
R122047K
R1223100K
R12548K2
C12051nF
R12024K7
+
-
U1200BLM3585
67
C120210nF
TP1250ReadHead
R1208100K
U1221BHC4066
43
5
+
-
U1200ALM358
3
21
84
C1206100nF
C1207100nF
R1222680K
D1200BAT54S
21
3
R12014K7
+
- U1250ALM358
3
21
84
R125210K
R1207100K
R1226100K
R1221100K
CO12001100nF
R12311K
R122747K
C125010nF
C12011nF
R121110K
R12054K7
410.03-22 rev. 01.1 - 06/2004
service manual SI 62
figure 1.14 Component layout of the main board 98.90.01
service manual SI 62
410.03-23rev. 01.1 - 06/2004
1.2 Test points
Test point Name Minimum Typical Maximum RemarksTP110 VCC 4.8 V 5.0 V 5.2 V Local +5 V supply.TP120 -12V -12.5 V -12.0 V -11.5 V Local -12 V supply.TP130 +12V 11V 12.0 V 13V Local +12 V supply.TP200 8b_TST - - - Test of the digital signal that drives
LED D200. Normal flashing frequency 1 Hz. During errors the frequency is 2 Hz.
TP510 ENV 0.0 V 0.1 V 0.5 V PH7. Paper presentTP510 ENV 0.9 V 1.1 V 1.5 V PH7. No paper present. PH correctly
adjusted.TP520 FLAP 0.0 V 0.1 V 0.5 V PH8. paper present.TP520 FLAP 0.9 V 1.1 V 1.5 V PH8. No paper present. PH correctly
adjusted.TP530 LOC 0.0 V 0.1 V 1.5 V PH9. Paper present.TP530 LOC 0.9 V 1.1 V 1.5 V PH9. No paper present. PH correctly
adjusted.TP540 EXIT 0.0 V 0.1 V 0.5 V PH10. paper present.TP540 EXIT 0.9 V 1.1 V 1.5 V PH10. No paper present. PH
correctly adjusted.TP610 16b_TST - - - Test of the digital signal that drives
LED D610. Normal flashing frequency about 1 Hz. During errors the frequency will increase.
TP710 WINDOW - - - This test point can be used as an oscilloscope trigger signal to synchronize OMR mark measurements.
TP900 FE-1 0.0 V 0.1 V 0.5 V PH1. Paper present.TP900 FE-1 0.9 V 1.1 V 1.5 V PH1. No paper present. PH correctly
adjusted.TP910 DFC FE-1 4.0 V 4.1 V 4.2 V Output voltage of DFC1. Result of
DFC adjustment after passing of a document.
TP930 FE-2 0.0 V 0.1 V 0.5 V PH2. Paper present.TP930 FE-2 0.9 V 1.1 V 1.5 V PH2. No paper present. PH correctly
adjusted.TP940 DFC FE-2 4.0 V 4.1 V 4.2 V Output voltage of DFC2. Result of
DFC adjustment after passing of a document.
TP950 FE-3 0.0 V 0.1 V 0.5 V PH3. Paper present.TP950 FE-3 0.9 V 1.1 V 1.5 V PH3. No paper present. PH correctly
adjusted.TP960 DFC FE-3 4.0 V 4.1 V 4.2 V Output voltage of DFC3. Result of
DFC adjustment after passing of a document.
service manual SI 62
410.03-24 rev. 01.1 - 06/2004
table 1.1
1.3 Jumper settings
table 1.2
1.4 LED information
TP1050 COLL 0.0 V 0.1 V 0.5 V PH5. Paper present.TP1050 COLL 0.9 V 1.1 V 1.5 V PH5. No paper present. PH correctly
adjusted.TP1060 FO 0.0 V 0.1 V 0.5 V PH6. Paper present.TP1060 FO 0.9 V 1.1 V 1.5 V PH6. No paper present. PH correctly
adjusted.TP1220 OMR
OUT3.1 V - - OMR output voltage of reading head
RH1.TP1250 ReadHea
d0.0 V 0.1 V 0.5 V PH4. Paper present.
TP1250 ReadHead
0.9 V 1.1 V 1.5 V PH4. No paper present. PH correctly adjusted.
Jumper Meaning RemarksNot placed Placed
JP320 SEL0 Load ‘N Go text. Auto Set textJP321 SEL1 Load ‘N Go text. Fill & Start text
JP610 FLASH BOOT This jumper must not be placed! (If not present, the external flash software never could establish contact with the machine, which would always directly boot to the machine software.)
JP670 R&D This jumper is never present on a production board! This jumper is only relevant in an R&D environment, in which case emulation RAM (U640 and U641) should be present.
JP720 FE-1 SEL Reserved for gap separation feeder.JP730 Inter. Trans. Is placed if intermediate transport is installed. Not relevant in
this machine.JP731 Spare Not used (yet).
LED Name/Color RemarksD200 TESTLED/
GreenPeriodically ON/OFF flashing. Signifies proper operation of the machine software in the 8-bit controller. If the software is in normal operation the flashing rhythm will be about 1 Hz. When an error occurs the flashing rhythm increases.
D240 FLASH WRITE/Red
Is ON during the programming (flashing) of the 8-bit machine software. The behaviour of D240 and D241 is similar to the behaviour of D671 and D672 for the 16-bits machine software (for diagnostics with flash programm problems).
Test point Name Minimum Typical Maximum Remarks
service manual SI 62
410.03-25rev. 01.1 - 06/2004
table 1.3
D241 FLASH RUN/Green
Is ON during normal operation of the 8-bit machine software. The behaviour of D240 and D241 is similar to the behaviour of D671 and D672 for the 16-bits machine software (for diagnostics with flash programm problems).
D580 MAIN PDISC/Green
Reflects the optical state of slotted photocell SPH1 that monitors pulse disc PD1, which moves in line with the main motor M1 driven items. Is ON if this motor is running AND if the mechanical drive is okay.
D610 TEST/Green Periodically ON/OFF flashing. Signifies proper operation of the machine software of the 16-bit controller U610. If the software is in normal operation the flashing rhythm will be about 1 Hz. When an error occurs the flashing rhythm increases.
D630 FLASH WRITE/Red
Flash LED. Is ON during the flashing (i.e. programming or reprogramming under supervision of external software) of the 16-bit machine software in flash ROM (U630). Full brightness during the erasing state, intermediate brightness during the flashing state proper.
D671 MAP0/Red Reflects the state of the Map0 signal. Is OFF during normal operation of the machine. Is ON during about one second in the startup stage of the machine. Is also ON if during the flashing of flash ROM (under supervision of external software) code must be flashed into the upper 512 kilobyte part.
D672 MAP1/Green Reflects the state of the Map1 signal. Is ON during normal operational use of the machine, including the one-second machine startup stage mentioned under D671. Is OFF if program code in system RAM (U620 & U621) (for instance flash software for programming or reprogramming the flash ROM U630) is executed, under supervision of external software.
D1000 FT1/Green Reflects the optical state of slotted photocell SPH2, which monitors the first fold pocket cam disc PD3. Is ON if this photocell “sees” the cam disc.
D1010 FT2/Green Reflects the optical state of slotted photocell SPH3, which monitors the second fold pocket cam disc PD4. Is ON if this photocell “sees” the cam disc.
D1111 PD COLL/Green
Reflects the optical state of slotted photocell SPH2, which monitors collator motor M2.
LED Name/Color Remarks
service manual SI 62
410.03-26 rev. 01.1 - 06/2004
2 Service menu
2.1 General
Proceed as follows for access to the service menu:• ·Navigate to the second screen of the main menu (see figure 2.2).• ·Press key 3 (Job menu). The Job access screen of figure 2.3 appears.• ·Enter the pin code 4331. Now you will enter the first part of the service menu screen of figure
2.4. This is the first part. With key 4 you can switch to and back from the second part of the service menu screen of figure 2.5.
Figure 2.1 shows a flow chart of the service menu.With the four soft keys 1 through 4 (from top to bottom) you select a menu option.With the Escape key the next higher menu is re-entered without implementing changes.In the case of a menu consisting of multiple screens you can navigate through these screens by pressing key 4.If a menu offers the possibility to change settings, key 4 is used to implement these changes and to go back to the next-higher menu level.
service manual SI 62
410.03-27rev. 01.1 - 06/2004
figure 2.1
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service manual SI 62
410.03-28 rev. 01.1 - 06/2004
figure 2.2
figure 2.3
figure 2.4 from top to bottom §2.2, §2.9,§2.14
Key
start/stop esc
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service manual SI 62
410.03-29rev. 01.1 - 06/2004
figure 2.5 from top to bottom §2.21, §2.22
2.2 System setting
figure 2.6 from top to bottom §2.3, §2.4, §2.5
figure 2.7 from top to bottom §2.6, §2.7, §2.8
2.3 Configuration
This screen provides information on the various available options, i.e. the number of feeders, Fe 1limited "yes" or " no", Daily mail (DM) on feeder, the DFCs on feeders and the presence or absence of an OMR dongle. If the configuration as stored in the machine has been updated, the new configuration will be stored after pressing key 4 and switching the machine off and on again.
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service manual SI 62
410.03-30 rev. 01.1 - 06/2004
figure 2.8
2.4 Localisation
figure 2.9
In this menu you can set the language of the operational user interface, as well as the paper sizes.Languages: English, Dutch, French, German, Spanish, Italian and Katak[ana].Standard: ISO (i.e. metric), Inches or None.ISO sizes: A4 (297 mm), A5 (148 mm) and A6 (105 mm) for documents; C5 (162 mm) and C6/5 (114 mm) for envelopes.Inches: 3.5" (90 mm), #9 (99 mm), 4" (102 mm), 6" (152 mm), 7" (178 mm), 8" (203 mm), 8.5" (216 mm), 11" (279 mm), 12" (305 mm) and 14" (356 mm) for documents; #9 (99 mm), #10 (105 mm) and 6x9 (153 mm) for envelopes.
2.5 Software versions
This screen provides release information on the machine software (programmed in flash memory) for the inserter part (executed by the 8-bit controller) and the feeder/folder/reading part (executed by the 16-bit controller).Usually both machine software items should be updated simultaneously, using external software. When software indexes do not correspond, an error message will be displayed.
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service manual SI 62
410.03-31rev. 01.1 - 06/2004
figure 2.10
2.6 Folder settings
The folding process is implemented by the timing of two cam discs, one for each folding pocket. The timing is determined by the document length of the sheets to be folded. Given tolerances in the activation times of the clutches involved, this menu provides for an equivalent shift in the folding positions, thus compensating a clutch activation time that deviates from the average value.In the folder offset menu of figure 2.11 you first select the folder. Than you can set the equivalent shift in the folding position between -20 mm and +20 mm. By processing test material you can decide if subsequent corrections in these settings are necessary.
figure 2.11
2.7 Reset data
This menu offers the possibility (with key 2) for initializing the system with default values (confirm with key 4). In addition all photocells will be readjusted (so: remove all paper from the machine).All counter values are not affected.Use key 3 to load default millimeter jobs (1, 2 and 3).Use key 4 to load default inch jobs (1, 2 and 3).The only way to leave this screen is to use the Escape key.
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service manual SI 62
410.03-32 rev. 01.1 - 06/2004
figure 2.12
2.8 Power up
You can decide here whether or not (yes or No) the language menu will be shown after power up of the machine. Save your settings with key 4 or leave this menu without changes by using the Escape key.
figure 2.13
2.9 Job settings
figure 2.14 from top to bottom §2.10, §2.11, §2.12, §2.13
2.10 Document offset
The vertical transport of documents fed by the various feeders is arranged in such a way that the documents are partially overlapping each other. This overlapping scheme ensures that the documents are properly aligned in the collator area.In the document offset menu of figure 2.15 you can set for each job (select with key 1) the extend to which the documents are not overlapping each other, i.e. the document offset value. The default
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service manual SI 62
410.03-33rev. 01.1 - 06/2004
value is 50 mm. With keys 2 and 3 the document offset can be varied between 20 mm and 75 mm in 1 mm steps.Press key 4 to store the changes or press the Escape key to ignore the changes.
figure 2.15
2.11 BRE offset
If a document is longer than the set address fold but shorter than the envelope height, this document sometimes will be unnecessarily folded. Under certain conditions this document can be prevented from being folded. This can be implemented with the menu BRE offset (BRE means Business Reply Envelope) of figure 2.16.For all jobs 1 Lng (Load 'n Go) an offset can be switched on or off.In the case of offset on the last document that had been added to the set prior to further processing will be shifted from the rest of the set (offsetting), i.e. this document will be held back during a certain distance. This means that the trailing edge of this upper document leaves the collator as last. This document will not be folded. During the insertion into the envelope the documents of the set will be realigned.The conditions are:• The feeder that supplies this upper document (BRE) is set to one document per set (no multi
feeding).• The document directly beneath this document must be at least 60 mm longer than the BRE.• The upper document must be longer than the set address fold.• The folding mode is either single fold or letter fold (so no Z-fold).• The upper document must be shorter than the envelope height.Note: It is possible to use the BRE offset for a BRE and an enclosure (card) in 1 set. The extra condition is that this enclosure is equal to or smaller than the set address fold and should be placed direct underneath the BRE in the set.The whole BRE offset is based on friction between documents within a set. Therefore it is necessary to make use of these conditions to reduce the risk of bad transporting, folding and inserting.In some cases the BRE option is automatically switched off if one or more of the above-mentioned conditions are not met, so it is safe to switch the BRE option on, unless this option is never to be used.Use keys 1 and 2 to select a job. With key 3 the BRE offset is switched on or off.Press key 4 to store the changes or press the Escape key to ignore the changes.
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service manual SI 62
410.03-34 rev. 01.1 - 06/2004
figure 2.16
2.12 Secure jobs
With this menu the selected job can be secured, i.e. locked. This job can not be deleted and can not be changed in the job menu either. However, a locked job still can be copied into another job that can be modified.Use keys 1 and 2 to select a job. With key 3 the selected job is locked on or unlocked.Press key 4 to store the changes or press the Escape key to ignore the changes.
figure 2.17
2.13 Flap closer
In this menu the timing of the activation of the sealing solenoid (So3) can be adjusted on a per-job basis. This function can be used to improve the sealing process. The timing has influence on the position of the filled envelope (with its flap fixed between two rollers) prior to being transported between the sealing rollers. This position can be adjusted between -10 and + 10 mm (with respect to the default envelope position).Use key 1 to select a job. With keys 2 and 3 the correction value for the envelope stop position prior to being sealed can be incremented or decremented.Press key 4 to store the changes or press the Escape key to ignore the changes.
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service manual SI 62
410.03-35rev. 01.1 - 06/2004
figure 2.18
2.14 Service tests
With key 4 you toggle between the screen of figure 2.19 and the screen of figure 2.20.
figure 2.19 from top to bottom §2.15, §2.16, §2.17
figure 2.20 from top to bottom §2.18, §2.19, §2.20
2.15 Photocells
You can navigate to and from the screens of figure 2.21, 2.22, 2.23 or 2.24 with key 4.The status of the nine or ten (if OMR is installed) photocells is displayed in four screens.In this machine so-called intelligent photocells are used. This implies that within a certain control range the currents of the photocell transmitters are adjusted in such a way that the no-paper output voltage of the photocell receiver falls within a certain voltage range of the photocell receiver. In this way fair amounts of dust present on the photocell sensors are compensated for. The control mechanism ensures that very reliable paper/no paper decisions are being made, based on the paper photocell condition.
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service manual SI 62
410.03-36 rev. 01.1 - 06/2004
The four screens provide real time information on the various paper photocells. You also can see whether the relevant photocell "sees" paper.The various photocells can be readjusted by pressing the key 3.
Note. Before readjusting the photocell it is strongly recommended to remove all paper from the machines and to clean all the sensors (both transmitter and receiver!) of the photocells.
After the photocell adjustments the percentages as shown in the four screens should be lower, provided the cleaning advice is heeded.If no paper is present, the photocell output voltage should have a value between 0.8 V and 1.5 V. A value below this voltage range indicates a too heavily dusted photocell. A value above this voltage range may occur if after readjusting a photocell dust is removed. In both cases it is advised to readjust the photocells.If the photocell current percentage is below 75%, the message "OK" is shown. A percentage between 75% and 99% results in a "Clean" message. The photocell should be cleaned before resetting the photocells. The message "Defect" is shown when the percentage is 99% or 100%.The only way to leave this menu is to press on the Escape key.
figure 2.21 PH7, PH8
figure 2.22 PH9, PH10
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service manual SI 62
410.03-37rev. 01.1 - 06/2004
figure 2.23 PH6, PH5, PH4 inclusive PH vertical track
figure 2.24 PH3, PH2, PH1
2.16 Digital inputs
The four screens of figures 2.25, 2.26, 2.27 and 2.28 show the real-time status of the three safety switches (MS1, MS2 and MS3), the flag switch (FS1), The two folder cam disks (SPH3 & PD3; SPH4 and PD4) and the two pulse discs (SPH1 for the main motor M1 and SPH2 for the collator motor M2). Real-time means that a change is reflected in the displayed status.In this way you can easily check the correct operation of the three microswitches and the flag switch.The folder cam discs (figure 2.26) can be tested with key 2 and key 3. After pressing one of these keys the relevant cam disc will move one half cycle, i.e. the cam disc status changes from "open" to "covered" or from "covered" to "open". After pressing two successive times on a test key the cam disc has performed a full cycle and returns to its position prior to entering this menu.Both pulse discs can be tested as well. By keeping the Test key (key 1 in figure 2.27 or figure 2.28) pressed the pulse disc signal will be tested. Both the speed and the quality (duty cycle) are tested. Detailed information is obtained via the minimum (Min.) and maximum (Max.) value. For the Speed the range should be between 75% and 125%, for the Pulse dist. (Duty cycle) the value should be in the range of 50% till 150% resulting in the message 'Good'. If the value is out of these ranges the message will be 'Bad'.The speed is checked by measuring the average pulse width and compared to the initial value. When the speed is much lower than the initial value the mechanical load has to be checked. When it is higher it could be that the pulse disc has become loose.The Pulse dist. (duty cycle) is measured of each pulse and the minimum and maximum values are shown. When a pulse (an indented area) is not detected (for example because of dust build up) the pulse distance will show a value of Min. 0% and/or Max. 200%.
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service manual SI 62
410.03-38 rev. 01.1 - 06/2004
figure 2.25 MS1, MS2, MS3, FS1
figure 2.26 SPH3&PD3, SPH4&PD4
figure 2.27 SPH1&PD1 version with fill in values
figure 2.28 SPH2&PD2 version with fill in values
2.17 Actuators
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service manual SI 62
410.03-39rev. 01.1 - 06/2004
In the three menu screens (figures 2.29, 2.30 and 2.31) the correct operation of the two motors, three solenoids, six clutches and the Maxi Feeder motor (if present) can be verified. Keys 1 and 2 can be used to select the actuator to be tested. The test is performed with key 3.If (and as long as) key 3 is pressed, the selected actuator will be activated.The motor runs as long as the test key is pressed.If the fingers solenoid is selected, the fingers move forward as soon as the test key is pressed. Only after releasing the test key the fingers will move back to their rest position. The eject rollers and closer solenoids will be activated and after a short time deactivated during one period of test key pressing. During normal operational use these three actuators are always activated during a very short time. This test reflects this situation.Testing the envelope track clutch CL6 will result in switching on the motor M1, as well as activating the envelope track clutch.Collator run in: Collator motor runs in the direction of the document stop position as long as key 3 is pressed.Collator run out: Collator motor runs in the direction of the folder as long as key 3 is pressed.Folding pocket 1/2: The main motor M1 is switched on. The relevant fold pocket turns a half fold cycle. After two successive key 3 presses the initial position prior to entering this menu is reached once again.Feeder clutches: The main motor M1 is switched on and the relevant feeder clutch is activated if and as long as key 3 is pressed. The feeder 3 clutch is only visible in the case of a 2½-station version of the machine.The Maxi Feeder option is only available if the Maxi Feeder is present. As long as key 3 is pressed, its motor runs.
figure 2.29 M1, So1, So2, So3, CL6
figure 2.30 M2 IN, M2 OUT, CL4, CL5
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service manual SI 62
410.03-40 rev. 01.1 - 06/2004
figure 2.31 CL1, CL2, CL3
2.18 Run in
The run in test screen of figure 2.32 shows a counter, of which the default value is 6000. This is the number of process cycles that will be emulated, with no paper whatsoever present in the machine.After pressing the Start/Stop key the run in test will start. After each process cycle the counter is decremented. The machine stops automatically if the counter value is zero.With keys 2 and 3 you can set the counter at a value that differs from the default value 6000. If the counter value is 1000 or higher, increments are 1000 with a maximum value of 30000. if the counter value is lower than 1000, decrements are 100 with a minimum value of 10.If you have some covers removed (but not the safety covers!), you can observe the various sequences of mechanical actions, which reflect the sequence of events during normal operational use of the machine.After pressing the Start/Stop key again the run in test stops.
Note. It is also strongly recommended to perform the run in test without any documents present in the machine. The timing of the actions for a simulated process cycle are fixed, so they are not based on parameters such as the document length. A run in test with documents present in the machine would only result in severe paper jamming.
figure 2.32
2.19 DFC test
This menu informs you about the DFC unit output voltages of the two or three feeders. The values are real time. With no paper present in a feeder the DFC voltage should be about 4.1 volt. If during the machine start a DFC unit does not "see" paper, the DFC voltage should be about 4.992 volt.The DFC voltage is lower if the DFC unit "sees" paper. The following rules apply:• ·For 65 g/m² paper DFC voltage about 0.2 volt lower.• ·For 80 g/m² paper DFC voltage about 0.25 volt lower.
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service manual SI 62
410.03-41rev. 01.1 - 06/2004
• ·For 120 g/m² paper DFC voltage about 0.35 volt lower.• ·For 160 g/m² paper DFC voltage about 0.5 volt lower.
figure 2.33
2.20 Keyboard/display
This menu screen offers the option to invert the screen display (with key 1, and as long as this key is pressed) and to test three of the four soft keys and two hard keys. If you leave this menu the default screen settings as far as the invert option is concerned are applied once again. Key 1 cannot be tested, for this key is used for the toggle function.If the Start/Stop key, Escape key, key 2, key 3 or key 4 is pressed, this is indicated by an adjacent bar. Furthermore the decimal key value is displayed in the middle of the screen.Leave this menu by pressing the Escape key twice.
figure 2.34
2.21 Counters
This menu (see figure 2.35) offers the possibility to read, set or reset the service counters.With key 1 you can reset the Since last visit counter to zero.With key 2 the Next visit after counter can be incremented in 5000 steps, with a maximum value of 6.000.000.With key 3 the Next visit after counter can be decremented in 5000 steps, with a minimum of 5000. A value under 5000 results in the value OFF.Use key 4 to leave this menu including changes or use the Escape key to leave this menu without the changes that may be made.If you simultaneously press the Start/Stop key and the Escape key, the Total Counter menu of figure 2.36 is displayed.
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service manual SI 62
410.03-42 rev. 01.1 - 06/2004
This menu offers the possibility to set the Since installation counter. With key 1 the counter value is incremented in 5000 steps. With key 2 the counter value is decremented in 5000 steps. Use key 4 (including changes) or the Escape key (without changes) to go back to the Service counters menu of figure 2.35.
figure 2.35
figure 2.36
2.22 OMR
figure 2.37 ferm top to botoom §2.23, §2.24
2.23 OMR code definition
This menu offers the possibility to define OMR-2 reading codes, provided a level 1 dongle is present in the machine. Per system one OMR code can be set. This code can be used in one or more jobs. The most complex OMR code is:• Start• Insert/accumulate• Parity check
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service manual SI 62
410.03-43rev. 01.1 - 06/2004
• Safety mark.The various menu screens (of which figure 2.38 is an example; not all screens are shown in this document) share the same structure.With keys 1 (repetitive key strokes) a code option is selected: Start mark, Insert on, Parity check, Safety mark and Line spacing.With key 3 you choose between Yes and No (toggling function). In the Line spacing case keys 2 and 3 are used to increment (key 2) or decrement (key 3) the line spacing in steps of about 0,02 millimeter. The Lpi value reflects the number of lines per inch, the millimeter value is the distance between two successive marks.Use key 4 to leave this menu including changes or the Escape key to leave this menu without changes. You are back in the OMR main menu of figure 2.37.
figure 2.38
2.24 Read code test
Press key 2 (Read code test, figure 2.37) to obtain the screen of figure 2.39. This menu screen informs the user about the mark quality, number of read marks and the gain setting. Every time the test key 2 is pressed a sheet is forwarded and the screen will show the information.
figure 2.39 The read code test submenu.
Show marks (key 1)The Show marks menu of figure 2.40 offers a graphical representation of the marks that had been read (oscilloscope function). The information shown is derived from the most recently read document. The information screen shows the time-dependant OMR output voltage and the reading window. The start of the window is represented by a vertical line, the end of the reading window is also represented by a vertical line. In between the marks should be given where the position of the marks related to the window position is also giving some information, i.e. when the first mark is very close to the opening of the window; this could mean that the window position is programmed wrong.
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service manual SI 62
410.03-44 rev. 01.1 - 06/2004
The upper horizontal dotted line represents the noise level, i.e. the white level. The lower horizontal dotted line represents the level below which a mark (i.e. detection level) has been detected. The detection level is determined when the adjustment procedure is performed (see fig 2.41). The detection level is 60% of the top level. A mark is detected as an OMR-mark when more than 5 digital samples consecutively are below the detection level.The numbers 1 through 6 indicate where a mark is expected. The distance between the numbers is exactly the same as the programmed line spacing. With key 3 you can scroll to the right, i.e. to a point later in time. With key 4 you can scroll to the left, i.e. to an earlier situation.
figure 2.40 The Show marks menu.
After pressing the info key 1 the information screen of figure 2.41 shows additional OMR-related information. This information is based on the last read document and the job settings (OMR code type etc.). The displayed information is what is interpreted from the read OMR code.
figure 2.41 The Show marks info screen.
Test (key 2)This screen shows the mark quality and the number of read marks from the last processed document. Also the gain of the OMR amplifier is shown.The mark quality is shows as follows:
Bad Mark amplitude < 0.6 V
Good Mark amplitude between 0.6 V and 1.5 V
Very good Mark amplitude higher than 1.5 V
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service manual SI 62
410.03-45rev. 01.1 - 06/2004
Adjustment (key 3)There are a number of occasions in which it is very relevant to adjust the OMR electronics. In the case of OMR hardware repairs and replacements it is very obvious that the OMR electronics should be readjusted. But there may be operational reasons as well, for instance if non-standard paper is to be used. In such cases, after processing some test documents (see above) the mark quality may not be optimal. Readjust the OMR electronics and process some new documents, in order to obtain an improved mark quality.For the adjustment 10 documents are necessary (otherwise an empty feeder error occurs). In each document at least one mark must be present within the reading window. The test documents must be present in the feeder for the selected job.It is very important to align the centre of the reading head horizontally at the centre of the marks.Press key 3 (Adjust) in the screen of figure 2.39. The adjustment menu of figure 2.42 appears.Press in the latter menu key 3 (Start adjust) to start the adjustment.During the adjustment the text "Adjusting" appears.After the adjustment either the message Adjustment done: OK or the text Adjustment done: FAILED is shown. Press esc to go back to the next higher menu screen.
figure 2.42 The adjustment submenu
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service manual SI 62
410.03-46 rev. 01.1 - 06/2004
3 Error messages and error handling
In this chapter the various errors and warnings are discussed. The error screens have the following in common:• An error code X:YYY. X is a prefix number that indicates a specific machine part.• Message. The message that is displayed next to the exclamation mark triangle.• Action. The text that is displayed next to the finger pictogram.• Info. Additional information if the info key 1 is pressed.The following machine areas/prefixes apply: 1 Inserter 2 Folder 3 Collator, vertical transport and OMR. 4 Feeder 1. 5 Feeder 2. 6 Feeder 3.Now the various errors will be discussed.
Error 1:1Message: FRAM failure.Action: Call service.Info: Memory failure.Error during the writing of zero data (formatting) to FRAM memory. Press the Reset key and try again.Formatting is ended by pressing the Start/Stop key. The system starts with default values.
Error 1:2Message: FRAM failure.Action: Call service.Info: Memory failure.Error during the initialization of FRAM. Press the Reset key and try again. Initialization is ended by pressing the Start/Stop key. The system starts with default values.
Error 1:3Message: FRAM failure.Action: Call service.Info: Memory failure.FRAM not detected.
Error 1:4Message: FRAM failure.Action: Call service.Info: Memory failure.This error is issued after ten successive tries to write to or read from FRAM memory.
Error 1:5Message: FRAM failure.Action: Call service.Info: Memory failure.This error is issued after a checksum error occurred during writing to or reading from FRAM memory.
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Error 1:10Message: Envelope too long.Action: Remove envelope.Info: Envelope length error.Envelope too long. Remove the envelope from the envelope track. A closed envelope is considered too long if its equivalent length exceeds 162 mm plus 20 mm tolerance = 182 mm or the programmed length plus 20 mm. An opened envelope is considered too long if its equivalent length exceeds 162 mm plus 130 mm flap length plus 20 mm tolerance = 312 mm.
Error 1:11Message: Document stoppage.Action: Remove documents.Info: Inserting failure.Document/envelope crash. The loc photocell PH9 remains covered too long. The equivalent document length exceeds 400 millimeter. Remove the envelope and the document from the insert table.
Error 1:12Message: Document stoppage.Action: Remove documents.Info: Document length error.Document/envelope crash. Two successive inserts show a document length change of more than 42 mm. The length is observed by the loc photocell PH9. The insert process is irregular, with varying mechanical slip.
Error 1:13Message: Envelope stoppage.Action: Remove envelope.Info: Transport failure.Envelope crash. The exit photocell PH10 remains covered too long. Remove the envelopes from the exit table and press the Reset key.
Error 1:15Message: Envelope stoppage.Action: Remove envelope.Info: Flap not opened.Envelope not opened. The envelope has no flap at all or its flap is not properly opened.
Error 1:16Message: Envelope stoppage.Action: Remove envelope.Info: Transport failure.Envelope crash. The filled envelope didn't arrive in time at the exit photocell PH10. The sealing stage takes too much time. Remove the paper from the exit area.
Error 1:17Message: Document stoppage.Action: Remove document.Info: Document too early.
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Document/envelope crash. Wrong timing of insertion of the document. Remove the document from the insert table. Between the ejecting of the filled envelope and the placing of a new envelope on the insert table, including the fingers moved in that envelope, no document is supposed to be present under the loc photocell PH9. In the fold only mode, also without envelopes involved, a new document is not allowed to cover PH9 before the previous document has been ejected and a new document call has been issued.
Error 1:18Message: Document stoppage.Action: Remove document.Info: Inserting failure.Document/envelope crash. The loc is opened or PH9 covered at the time at which a document call is issued. Close the loc or remove the PH9 covering paper.
Error 1:19Message: Envelope stoppage.Action: Remove envelope.Info: Flap sensor covered.The flap photocell PH8 is covered too long. Remove the envelopes form the envelope track, if necessary by turning the hand knob until the envelopes reach the insert table.
Error 1:22Message: Envelope stoppage.Action: Remove envelope.Info: Wrong envelope size.Envelope too short. The envelope currently called for is shorter than 75 mm, or the measured envelope length is at least 20 mm shorter than the set envelope length.
Error 1:23Message: Document stoppage.Action: Remove envelope.Info: Seal switch active.Envelope closer flag switch activated. At the moment that an envelope must be ejected from the insert position, the flag switch FS1 is covered. FS1 is not properly mounted or connected, or some other mechanical FS1 error occurs.
Error 1:24Message: Envelope stoppage.Action: Remove envelope.Info: Seal switch active.Envelope crash. The flag switch FS1 remains covered too long.
Error 1:26Message: Envelope stoppage.Action: Remove envelope.Info: Seal switch not covered.Document/envelope crash. The ejected document does not reach the flag switch FS1 in time.
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Error 1:27Message: Document stoppage.Action: Remove document.Info: Document too late.Document arrives too late. A document call to the feeder/folder part does not result in a document arriving at the document photocell PH9.
Error 1:29Message: Document stoppage.Action: Remove document.Info: Insert area blocked.Insert area blocked. During startup paper is present on the insert table. Remove the paper and press the Reset key.
Error 1:30Message: Empty envelope hopper.Action: Load envelopes.Info: [none]Envelope hopper empty. An envelope is called for, but after a 15-second timeout it does not arrive on the insert table. There are two ways to resume the process: (a) press the Start/Stop key, the message disappears and the process resumes; (b) press the Reset key, followed by the Start/Stop key.
Error 1:34Message: No connection.Action: Check device connector.Info: Communication failure.Communication failure in the SCS communication between the inserter part (8-bit controller) and the feeder/folder part (16-bit controller). This reflects an electronic hardware failure on the main board 98.90.01.
Error 1:35Message: Preventive maintenance.Action: Call service.Info: [none].Maintenance message. This message appears during the start of the machine if the value of the counter Since last visit exceeds the value of the counter Next visit after. This message is issued at the system start.
Error 1:37Message: Technical failure.Action: Call service.Info: Main motor failure.Main motor (M1) failure. The pulse disc slotted photocell SPH1, which monitors pulse disc PD1, does not deliver any pulses at all or too few pulses. Apart from a defective PD1, this error message is issued if the motor is mechanically overloaded or blocked. It may help to wait until the motor has been cooled down.
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Error 1:44Message: Technical failure.Action: Call service.Info: Track sensor defective.During the photocell adjustment the transmitter LED current of the envelope track photocell PH7 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time.
Error 1:45Message: Technical failure.Action: Call service.Info: Flap sensor defective.During the photocell adjustment the transmitter LED current of the flap photocell PH8 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time.
Error 1:46Message: Technical failure.Action: Call service.Info: Loc sensor defective.During the photocell adjustment the transmitter LED current of the loc photocell PH9 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time.
Error 1:47Message: Technical failure.Action: Call service.Info: Exit sensor defective.During the photocell adjustment the transmitter LED current of the exit photocell PH10 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time.
Error 1:48Message: Track sensor dusty.Action: Clean sensor.Info: [none].During the processing of paper the transmitter LED current of the envelope track photocell PH7 is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is tried to be readjusted.
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Note. Error 1: 52 is the same error, but occurs during readjusting this photocell.
Error 1:49Message: Flap sensor dusty.Action: Clean sensor.Info: [none].During the processing of paper the transmitter LED current of the flap photocell PH8 is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is tried to be readjusted.Note. Error 1: 53 is the same error, but occurs during readjusting this photocell.
Error 1:50Message: Loc sensor dusty.Action: Clean sensor.Info: [none].During the processing of paper the transmitter LED current of the envelope loc photocell PH9 is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is tried to be readjusted.Note. Error 1: 54 is the same error, but occurs during readjusting this photocell.
Error 1:51Message: Exit sensor dusty.Action: Clean sensor.Info: [none].During the processing of paper the transmitter LED current of the exit photocell PH10 is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is tried to be readjusted.Note. Error 1: 55 is the same error, but occurs during readjusting this photocell.
Error 1:52Message: Technical failure.Action: Call service.Info: Track sensor defective.During the adjustment of the track photocell PH7 adjustment fails because the transmitter LED current is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is not readjusted. If the start key is pressed, this message reappears.Note. Error 1:48 is the same error, but occurs during the processing of paper.
Error 1:53Message: Technical failure.Action: Call service.Info: Flap sensor defective.During the adjustment of the flap photocell PH8 adjustment fails because the transmitter LED current is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is not readjusted. If the start key is pressed.Note. Error 1:49 is the same error, but occurs during the processing of paper.
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Error 1:54Message: Technical failure.Action: Call service.Info: Loc sensor defective.During the adjustment of the loc photocell PH9 adjustment fails because the transmitter LED current is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is not readjusted. If the start key is pressed, this message reappears.Note. Error 1:50 is the same error, but occurs during the processing of paper.
Error 1:55Message: Technical failure.Action: Call service.Info: Exit sensor defective.During the adjustment of the exit photocell PH10 adjustment fails because the transmitter LED current is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is not readjusted. If the start key is pressed, this message reappears.Note. Error 1:51 is the same error, but occurs during the processing of paper.
Error 1:56Message: Technical failure.Action: Call service.Info: Track sensor defective.Envelope track photocell (PH7) error. During machine startup no LED current has been detected for this photocell. Transmitter not or wrongly connected. Relevant in the factory environment or after field replacement of this photocell. After resetting this error and pressing the Start/Stop key the message reappears.
Error 1:57Message: Technical failure.Action: Call service.Info: Flap sensor defective.Flap photocell (PH8) error. During machine startup no LED current has been detected for this photocell. Transmitter not or wrongly connected. Relevant in the factory environment or after field replacement of this photocell. After resetting this error and pressing the Start/Stop key the message reappears.
Error 1:58Message: Technical failure.Action: Call service.Info: Loc sensor defective.Loc photocell (PH9) error. During machine startup no LED current has been detected for this photocell. Transmitter not or wrongly connected. Relevant in the factory environment or after field replacement of this photocell. After resetting this error and pressing the Start key the message reappears.
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Error 1:59Message: Technical failure.Action: Call service.Info: Exit sensor defective.Exit photocell (PH10) error. During machine startup no LED current has been detected for this photocell. Transmitter not or wrongly connected. Relevant in the factory environment or after field replacement of this photocell. After resetting this error and pressing the Start key the message reappears.
Error 1:60Message: Track sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the no-paper output voltage of the envelope track photocell PH7 is higher than 1.5 V. Therefore passing paper is at risk of being not detected by the photocell. After resetting this error it is tried to readjust this photocell.
Error 1:61Message: Flap sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the no-paper output voltage of the flap photocell PH8 is higher than 1.5 V. Therefore passing paper is at risk of being not detected by the photocell. After resetting this error it is tried to readjust this photocell.
Error 1:62Message: Loc sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the no-paper output voltage of the loc photocell PH9 is higher than 1.5 V. Therefore passing paper is at risk of being not detected by the photocell. After resetting this error it is tried to readjust this photocell.
Error 1:63Message: Exit sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the no-paper output voltage of the exit photocell PH10 is higher than 1.5 V. Therefore passing paper is at risk of being not detected by the photocell. After resetting this error it is tried to readjust this photocell.
Error 1:64Message: Track sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the transmitter LED current of the envelope track photocell PH7 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time. If this fails too, error 1:44 is issued.
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Error 1:65Message: Flap sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the transmitter LED current of the flap photocell PH8 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time. If this fails too, error 1:45 is issued.
Error 1:66Message: Loc sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the transmitter LED current of the loc photocell PH9 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time. If this fails too, error 1:46 is issued.
Error 1:67Message: Exit sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the transmitter LED current of the exit photocell PH10 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time. If this fails too, error 1:47 is issued.
Error 1:80Message: Technical failure.Action: Call service.Info: Communication failure.CRC error at receiving mail via I²C communication.
Error 1:81Message: Technical failure.Action: Call service.Info: Communication failure.I²C delivered mail not accepted by the feeder/folder part.
Error 1:82Message: Technical failure.Action: Call service.Info: Communication failure.Command unknown by the slave.
Error 1:83
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Message: Technical failure.Action: Call service.Info: Communication failure.The feeder/folder part doesn't accept the command.
Error 1:84Message: Technical failure.Action: Call service.Info: Communication failure.Command not identified by the feeder/folder part.
Error 1:85Message: Technical failure.Action: Call service.Info: Communication failure.The inserter part cannot communicate properly (by SCS) with the feeder/folder part. A checksum error occurred.
Error 1:86Message: Technical failure.Action: Call service.Info: Communication failure.The inserter part cannot communicate properly (by SCS) with the feeder/folder part. A hardware-related error occurred.
Error 1:87Message: Technical failure.Action: Call service.Info: Communication failure.Too many communication retries.
Error 1:88Message: Technical failure.Action: Call service.Info: Communication failure.Too many NACK signals received.
Error 1:89Message: Technical failure.Action: Call service.Info: Communication failure.The inserter part cannot communicate properly via the local I²C bus (timeout error).
Error 1:95Message: Sealing risk.Action: Check water level.Info: Brushes too dry.This warning message is issued after each 2500th process cycle. After pressing the Reset key this message will disappear.
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Error 1:101Message: Cover open.Action: Remove all documents.Info: Cover open during run.Undefined motor stop. During the feeding of an envelope (in the envelope track) one or more machine covers are opened.
Error 1:102Message: Cover open.Action: Remove all documents.Info: Cover open during run.Undefined motor stop. During the feeding of a document one or more machine covers are opened.
Error 1:103Message: Cover open.Action: Remove all documents.Info: Cover open during run.Undefined motor stop. During the ejecting of the filled envelope one or more machine covers are opened.
Error 1:104Message: Cover open.Action: Remove all documents.Info: Cover open during run.Undefined motor stop. During the exiting of the filled envelope one or more machine covers are opened.
Error 1:105Message: Technical failure.Action: Call service.Info: Communication failure.Communication failure. SCS-related problem in the communication between the inserter part and the feeder/folder part.
Error 2.11Message: Document stoppage.Action: Remove documents.Info: Stoppage at folder.First fold pocket mechanical or electrical failure.After activating the first fold pocket clutch CL4 the next state is not detected by slotted photocell VSPH3 within a certain time. This could be caused by either a faulty clutch or faulty slotted photocell or when material is present that cannot be folded.
Error 2.12Message: Document stoppage.Action: Remove documents.Info: Stoppage at folder.Second fold pocket mechanical or electrical failure.
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After activating the second fold pocket clutch CL5 the next state is not detected by slotted photocell VSPH4 within a certain time. This could be caused by either a faulty clutch or a faulty slotted photocell or when material is present that cannot be folded.
Error 2.14Message: Load 'N Go not possible.Action: Go to job edit menu.Info: Fold not possible.A fold based on defined Load 'n Go formulas appears to be not feasible, due to fold pocket limitations (i.e. minimum or maximum distances).
Error 2:61Message: Technical failure.Action: Call service.Info: Sensor fold-in defective.During the photocell adjustment the transmitter LED current of the folder input photocell PH6 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time.
Error 2:62Message: FO in sensor dusty.Action: Clean sensor.Info: [none].During the processing of paper the transmitter LED current of the folder input photocell PH6 is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is tried to be readjusted.Note. Error 2: 63 is the same error, but occurs during readjusting this photocell.
Error 2:63Message: Technical failure.Action: Call service.Info: Sensor fold-in defective.During the adjustment of the folder input photocell PH6 adjustment fails because the transmitter LED current is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is not readjusted. If the start key is pressed, this message reappears.Note. Error 2:62 is the same error, but occurs during the processing of paper.
Error 2:64Message: Technical failure.Action: Call service.Info: Sensor fold-in defective.Folder input photocell (PH6) error. During machine startup no LED current has been detected for this photocell. Transmitter not or wrongly connected. Relevant in the factory environment or after field replacement of this photocell. After resetting this error and pressing the Start key the message reappears.
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Error 2:65Message: FO in sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the no-paper output voltage of the folder input photocell PH6 is higher than 1.5 V. Therefore passing paper is at risk of being not detected by the photocell. After resetting this error it is tried to readjust this photocell.
Error 2:66Message: FO in sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the transmitter LED current of the folder input photocell PH6 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time. If this fails too, error 2:61 is issued.
Error 3:10Message: Document stoppage.Action: Remove documents.Info: Stoppage at vertical track.Vertical transport crash. After a certain time after leaving a feeder the paper doesn't arrive at the collator input photocell PH5. Remove the paper and press the Reset key.
Error 3:11Message: Document stoppage.Action: Remove documents.Info: Stoppage at collator.Collator run in error. During the collating of documents the collator input photocell PH5 is covered too long. This can happen if the paper is to sturdy to make the move from a vertical to a more or less horizontal direction, or if documents still present in the collating area prevent the arriving document from arriving there. Remove the documents and press the Reset key.
Error 3:12Message: Document stoppage.Action: Remove documents.Info: Stoppage at collator.Collator run out error. After starting to leave, to the folder or the divert, the paper stays too long in the collating area. This can be verified by the folder input photocell PH6. This is caused by either a paper crash or the fact that paper has been removed after a Stop command, followed by a Start command.
Error 3:14Message: Document stoppage.Action: Remove documents.Info: Stoppage at collator.Paper present at initialization (machine startup or job change) error. This message is displayed if during the initialization of the collating area a set or part of a set has been detected in this area.
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Initialization of the collating area occurs after each job change, after fatal feeder errors or collating area errors.
Error 3:20Message: System not ready,Action: Remove all documents.Info: Documents in system.Folder/feeder not empty. After a job change documents are still present in the system. Remove all documents and press the Reset key.
Error 3:21Message: Empty feeders.Action: Load documents.Info: [none]Empty feeders during the Load 'N Go learning cycle.
Error 3:60Message: Cover open.Action: Remove all documents.Info: Cover open during run.Undefined motor stop. Remove all documents and press the Reset key.
Error 3:61 (only if OMR is present)Message: Technical failure.Action: Call service.Info: Vertical track sensor defective.During the photocell adjustment the transmitter LED current of the vertical track photocell PH4 1 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time.
Error 3:62 (only if OMR is present)Message: Vertical track sensor dusty.Action: Clean sensor.Info: [none].During the processing of paper the transmitter LED current of the vertical track photocell PH4 is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is tried to be readjusted.Note. Error 3:63 is the same error, but occurs during readjusting this photocell.
Error 3:63 (only if OMR is present)Message: Technical failure.Action: Call service.Info: Vertical track sensor defective.During the adjustment of the vertical track photocell PH4 adjustment fails because the transmitter LED current is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall
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within the valid photocell control range. After resetting this error the photocell is not readjusted. If the start key is pressed, this message reappears.Note. Error 3:62 is the same error, but occurs during the processing of paper.
Error 3:64 (only if OMR is present)Message: Technical failure.Action: Call service.Info: Vertical track sensor defective.Vertical track photocell (PH4) error. During machine startup no LED current has been detected for this photocell. Transmitter not or wrongly connected. Relevant in the factory environment or after field replacement of this photocell. After resetting this error and pressing the Start/Stop key the message reappears.
Error 3:65 (only if OMR is present)Message: Vertical track sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the no-paper output voltage of the vertical track photocell PH4 is higher than 1.5 V. Therefore passing paper is at risk of being not detected by the photocell. After resetting this error it is tried to readjust this photocell.
Error 3:66 (only if OMR is present)Message: Vertical track sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the transmitter LED current of the vertical track photocell PH4 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time. If this fails too, error 3:61 is issued.
Error 3:70Message: Technical failure.Action: Call service.Info: Collator motor failure.Collator motor error. The collator motor M2 is checked via its accompanying pulse disc plus slotted photocell SPH2, Provided SPH2 is correctly operating (see the service software), this motor is probably defective.
Error 3:71Message: Technical failure.Action: Call service.Info: Collator sensor defective.During the photocell adjustment the transmitter LED current of the collator area input photocell PH5 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time.
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Error 3:72Message: Collator sensor dusty.Action: Clean sensor.Info: [none].During the processing of paper the transmitter LED current of the collator input photocell PH5 is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is tried to be readjusted.Note. Error 3:73 is the same error, but occurs during readjusting this photocell.
Error 3:73Message: Technical failure.Action: Call service.Info: Collator sensor defective.During the adjustment of the collator input photocell PH5 adjustment fails because the transmitter LED current is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is not readjusted. If the start key is pressed, this message reappears.Note. Error 3:72 is the same error, but occurs during the processing of paper.
Error 3:74Message: Technical failure.Action: Call service.Info: Collator sensor defective.Collator input photocell (PH5) error. During machine startup no LED current has been detected for this photocell. Transmitter not or wrongly connected. Relevant in the factory environment or after field replacement of this photocell. After resetting this error and pressing the Start/Stop key the message reappears.
Error 3:75Message: Collator sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the no-paper output voltage of the collator input photocell PH5 is higher than 1.5 V. Therefore passing paper is at risk of being not detected by the photocell. After resetting this error it is tried to readjust this photocell.
Error 3:76Message: Collator sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the transmitter LED current of the collator input photocell PH5 is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time. If this fails too, error 3:71 is issued.
Error 3:101 (only if OMR is present)Message: Technical failure.Action: OMR switched off.
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Info: Dongle not correct.The checksum and/or the serial check of the dongle is not correct.This error applies to a valid level 1 OMR dongle.
Error 3:102 (only if OMR is present)Message: Technical failure.Action: Call service.Info: Defective reading head.The LED in the reading head is defective.
Error 3:112 (only if OMR is present)Message: Reading error.Action: Remove documents.Info: Wrong window position.The reading window is activated after the document that contains OMR info has passed the reading head. Adjust the reading window parameters.
Error 3:114 (only if OMR is present)Message: Suspected set.Action: Remove suspected set.Info: Suspected after error.This error is issued after a previous reading error and the reading of an insert mark. It is very likely that the reading error probably occurred during the processing of the current set, causing this set and the next set being not complete.
Error 3:120 (only if OMR is present)Message: Reading error.Action: Reset & start to finish set.Info: Not enough marks.Less marks have been detected than based on the applied reading code. The set can be removed from the collator, but this is not strictly necessary. After a restart the rest of the set is processed and error 3:114 (suspected set) is issued.
Error 3:121 (only if OMR is present)Message: Reading error.Action: Remove documents.Info: Multiple basic command.More than one paper flow-related commands (accumulate, insert, divert or stop mark) have been detected. The set can be removed from the collator, but this is not strictly necessary. After a restart the rest of the set is processed and error 3:114 (suspected set) is issued.
Error 3:122 (only if OMR is present)Message: Reading error.Action: Reset & start to finish set.Info: No basic command.No mark defining the paper flow (accumulate, insert, divert or stop mark) has been detected. The set can be removed from the collator, but this is not strictly necessary. After a restart the rest of the set is processed and error 3:114 (suspected set) is issued.
service manual SI 62
410.03-63rev. 01.1 - 06/2004
Error 3:126 (only if OMR is present)Message: Reading error.Action: Reset & start to finish set.Info: Wrong parity in code.The parity of the processed code appears to be not correct. After a restart the rest of the set is processed and error 3:114 (suspected set) is issued.
Error 3:127 (only if OMR is present)Message: Reading error.Action: Reset & start to finish set.Info: Undefined mark found.This error code is displayed if a mark is found at a position where no mark is supposed to be present (too many marks or mark conflicting with other marks). The set can be removed from the collator, but this is not strictly necessary. After a restart the rest of the set is processed and error 3:114 (suspected set) is issued.
Error 3:128 (only if OMR is present)Message: Reading error.Action: Reset & start to finish set.Info: Wrong mark distance.This error message occurs if the position of a mark has shifted in such a way that is present in the so-called forbidden zone. This is defined as a percentage of the line distance around a line halfway between two successive lines. After a restart the rest of the set is processed and error 3:114 (suspected set) is issued.
Error 3:129 (only if OMR is present)Message: Reading error.Action: Reset & start to finish set.Info: Too many marks.This error code is displayed if more reading code marks have been detected than may be possible, based on the applied reading code. After a restart the rest of the set is processed and error 3:114 (suspected set) is issued.
Error 3:134 (only if OMR is present)Message: Too many sheets.Action: Remove documents.Info: Set size exceeded.The maximum set size is specified in the OMR settings menu. The maximum size is 5, including insets (i.e. selective feeds).Suppose this maximum is X. If sheet X is processed and an accumulation mark has been read or the insert mark has been read and selective feeds must be added to the set, this error is issued.Remove the paper from the collator, reset and press the Start/Stop key to restart the process.
Error 3:135 (only if OMR is present)Message: Final set part.Action: Remove documents.Info: Part of previous set.This is a follow-up of error 3:134. The rest of the oversized set is collated. After this is done, error 3:135 is issued. If the maximum set size is exceeded for the second time, error 3:134 is issued once again.
service manual SI 62
410.03-64 rev. 01.1 - 06/2004
Error (4:…6:)00Message: Empty feeder.Action: Load documents or ignore.Info: [none]Feeder empty. A feeder tries during 4 seconds to separate a document from the stack in its hopper. If after 4 seconds no paper arrives at the feeder photocell, this error message is displayed. The feeder transport stops. The user can continue the process by placing documents in the empty hopper and pressing the Reset key.
Error (4:…6:)10Message: Feeding failure.Action: Remove documents.Info: Document too thick.Document too thick. One of the feeders produces a double fed sheet during the processing of a document.
Error (4:…6:)11Message: Feeding failure.Action: Check previous set.Info: Wrong reference.Wrong reference. The sheet on which the DFC had been adjusted appears to be a double fed sheet. This error can only occur during the first sheet delivered by a feeder after adjusting the DFC unit.
Error (4:…6:)12Message: Document stoppage.Action: Remove documents.Info: Document too long.Document too long. A document delivered by a feeder appears to be more than 20% longer than the document length specified for this feeder in the current job.
Error (4:…6:)13Message: Document stoppage.Action: Remove documents.Info: Paper jam.Document crash. A document delivered by a feeder appears to be more than 50% longer than the document length specified for this feeder in the current job.
Error (4:…6:)14Message: Document stoppage.Action: Remove documents.Info: Document too short.Document too short. A document delivered by a feeder appears to be more than 45 mm shorter than the document length specified for this feeder in the current job.
Error (4:…6:)51Message: Technical failure.Action: Call service.Info: Feeder sensor defective.
service manual SI 62
410.03-65rev. 01.1 - 06/2004
During the photocell adjustment the transmitter LED current of the feeder photocell (FPH1..FPH6) is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time.Error (4:…6:)52Message: Track sensor dusty.Action: Clean sensor.Info: [none].During the processing of paper the transmitter LED current of the feeder photocell (PH1…PH3) is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is tried to be readjusted.Note. Error (4:…6:)53 is the same error, but occurs during readjusting this photocell.
Error (4:..6:)53Message: Technical failure.Action: Call service.Info: Feeder sensor defective.During the adjustment of the feeder photocell (PH1…PH3) adjustment fails because the transmitter LED current is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell control range. After resetting this error the photocell is not readjusted. If the start key is pressed, this message reappears, provided the photocell is involved in the current job.Note. Error (4:…6:)52 is the same error, but occurs during the processing of paper.
Error (4:…6:)54Message: Technical failure.Action: Call service.Info: Track sensor defective.Feeder photocell (PH1…PH3) error. During machine startup no LED current has been detected for this photocell. Transmitter not or wrongly connected. Relevant in the factory environment or after field replacement of this photocell. After resetting this error and pressing the Start/Stop key the message reappears, provided the photocell is involved in the current job.
Error (4:…6:)55Message: Feeder sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the no-paper output voltage of the feeder photocell (PH1…PH3) is higher than 1.5 V. Therefore passing paper is at risk of being not detected by the photocell. After resetting this error it is tried to readjust this photocell.
Error (4:…6:)56Message: Feeder sensor dusty.Action: Clean sensor.Info: [none]During the processing of paper the transmitter LED current of the feeder photocell (PH1…PH3) is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The photocell is readjusted. If this fails, this message reappears. After resetting this message the photocell is tried to be readjusted for a second time. If this fails too, error (4:…6:)51 is issued.
service manual SI 62
410.03-66 rev. 01.1 - 06/2004
Error (4:…6:)60Message: Technical failure.Action: Call service.Info: DFC defective.DFC error. The DFC doesn't measure a difference between paper and no paper. After pressing the Reset key the defective DFC unit is switched off. The incomplete set is diverted. Pressing the Start/Stop key afterwards the process continues without DFC measurement.
Error (4:…6:)61Message: Technical failure.Action: Call service.Info: DFC defective.DFC adjustment error. The DFC unit can not be adjusted. After pressing the Reset key the DFC unit is switched off. After pressing the Start/Stop key the process continues without DFC measurement.
Error (4:…6:)62Message: Technical failure.Action: Call service.Info: DFC defective.DFC presence error. During startup a DFC unit in a certain feeder appears to be not present. During the previous machine session the DFC unit was present. This goes on until the configuration has been reset (see service software chapter). After pressing the Reset key the DFC unit of the relevant feeder is switched off. After pressing the Start/Stop key the process continues without DFC measurement. The DFC unit is still present in the configuration.
service manual SI 62
410.04-1rev. 01.0 - 06/2004
Parts lists
service manual SI 62
410.04-2 rev. 01.0 - 06/2004
service manual SI 62
410.04-3rev. 01.0 - 06/2004
Recommended spare parts
Some of these parts already could be stocked, being part of another recommended spare parts list.
Illustration Description Part code Stock qty.Code nr. Number per number
of installed machines1 10 50
Figure 410.04-61 Hopper complete (auto)* 79.01.53 1 1 2
Figure 410.04-812 Moistening cloth 04.03.06 1 2 4
Figure 410.04-1023 Separation roller (assy.) 95.71.03 1 1 227 Feed roller ∅ 42 mm 73.27.31 1 1 250 Pulley 15T (assy). 93.05.54 1 1 251 Timing belt 95.13.16 1 1 253 Slip clutch CCW 8 mm 95.71.27 1 1 2
56 Conductive bearing 10 mm 04.24.26 10 10 20 - O-ring (for jogger roller) 04.18.76 2 2 4
Figure 410.04-149 Transportation roller ∅ 30 mm 04.18.27 4 8 610 Sensor (including holder) 04.24.53 2 2 449 LED (including holder) 04.24.52 2 2 450 Transportation roller ∅ 30 mm 95.13.12 4 8 1653 Conductive bearing 8 mm 04.24.25 4 8 16 Figure 410.04-185 Rubber roller 96.41.90 1 1 228 Pressure roller (assy.) 96.45.56 4 4 8
Figure 410.04-201 Microswitch (including lever) 98.90.56 1 1 214 Upper sealing roller ∅ 36 mm 73.26.48 1 1 216 Lower sealing roller (assy.) 98.94.33 1 1 223 Conductive bearing 6 mm 04.24.24 4 8 1633 Solenoid 02.10.21 1 1 2
36 Finger 96.40.71 2 4 838 Leaf spring 96.45.64 1 1 241 Hex. head screw M4 x 8 (synthetic) 96.45.66 2 4 843 Adjustable finger 96.40.57 2 4 8
service manual SI 62
410.04-4 rev. 01.0 - 06/2004
Figure 410.04-2411 Timing belt 96.43.55 1 1 219 Pulse disc sensor (assy.) 82.16.22 1 2 420 Pulse disc 24.12.81 1 1 225 Tensioner roller 96.41.94 1 2 4
Figure 410.04-2610 Clutch CW 8 mm 12.16.66 1 2 4
Figure 410.04-2810 Upper input roller (assy.) 98.95.21 1 1 211 Lower input roller (assy.) 98.95.22 1 1 227 Fold roller (assy.) 98.95.20 1 2 4
Figure 410.04-3010 Timing belt 04.16.21 1 1 214 Drive belt PJ 96.41.55 1 1 2
Figure 410.04-328 Solenoid 12.12.87 1 1 217 Timing belt 04.15.37 1 1 226 Transportation roller ∅ 30 mm 96.43.64 2 2 441 Gear 15T 73.29.42 1 1 2
Figure 410.04-363 Transportation roller ∅ 38 mm 04.29.77 2 4 824 Brush 72.00.05 3 6 12
Figure 410.04-383 Flagswitch 02.10.76 1 1 210 Transportation roller (assy.) 84.17.04 2 4 8
Figure 410.04-401 Upper separation roller 95.11.67 1 2 45 Cover plate 95.11.25 1 1 28 Timing belt 95.11.45 1 1 213 Rubber paper puller 04.00.16 2 4 818 Pulley 28T (timing belt) 95.11.35 1 1 2
63 DFC 79.01.71 1 1 265 Separation roller (lower) 95.11.68 1 2 4
Figure 410.04-4439 Clutch CCW 8 mm 93.05.36 1 2 4
Figure 410.04-4628 Reading head assy. 98.94.34 1 2 4
service manual SI 62
410.04-5rev. 01.0 - 06/2004
Figure 410.04-4821 Pressure roller assy. (incl. O-ring) 95.20.11 1 2 430 Collating belt set (3 pcs.) 95.20.07 1 1 238 Motor 24V 98.94.09 1 1 250 Pressure roller ∅ 20 mm 95.14.08 2 4 8
Figure 410.04-5212 Motor relay board 230V 97.55.00 1 1 2 - Motor relay board 115V 97.55.40 1 1 218 Power inlet 98.90.05 1 1 2
Figure 410.04-5611 Curve disc RH 95.30.64 1 1 221 Curve disc LH 95.30.63 1 1 2
Figure 410.04-586 Clutch CCW 8 mm 12.14.61 1 1 29 Clutch CW (clockwise) 8 mm 12.14.63 1 1 2
Figure 410.04-601 Lever for flap actuator 95.30.31 1 1 212 Upper fold roller (assy.) 96.46.61 1 1 2
Figure 410.04-6219 Tensioner roller 95.13.19 1 1 2
Figure 410.04-648 Mainboard 98.90.01 1 1 218 Rubber keypad 98.91.3019 Display 98.90.03 1 1 2
Note: Parts marked with an asteriks (*) depending on configuration.
service manual SI 62
410.04-6 rev. 01.0 - 06/2004
Figure 1
21
35
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7 8 9 10
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service manual SI 62
410.04-7rev. 01.0 - 06/2004
Figure 410.04-6
Remarks illustration Description Part code Quantity Remarkscode number number
1 Hopper complete (auto) 79.01.53 22 Short tray 04.26.51 13 Nut M4 45.19.02 104 Hex. head screw M4 x 8 05.38.80 6
Neopost 5 Cover LH (2 station) 98.91.41 1
Hasler, Formax - Cover LH (2 station) 98.95.59 1Satas - Cover LH (2 station) 98.95.53 1Francotyp, blank - Cover LH (2 station) 98.95.68 1Neopost - Cover LH (3 station) 98.92.27 1Hasler, Formax - Cover LH (3 station) 98.95.60 1
Satas - Cover LH (3 station) 98.95.55 1Francotyp, blank - Cover LH (3 station) 98.95.70 1
6 Round head tapping screw 45.38.69 67 Mounting plate 98.91.32 18 Magnetic clip 95.70.90 2
9 Lower cover LH 98.91.99 110 Grommet 12.08.51 111 Spacer 95.73.63 112 Bellows 24.13.05 1
Neopost 13 Hinged cover 98.95.74 1
Hasler - Hinged cover 98.95.78 1Satas - Hinged cover 98.95.75 1Formax - Hinged cover 98.95.76 1Francotyp - Hinged cover 98.95.77 1blank - Hinged cover 98.95.80 1
14 Lower hinged cover 98.91.96 115 Strip 97.00.51 116 Nut M4 45.36.26 317 Washer ∅12 x ∅ 5.2 x 0.7 mm 43.05.35 2 18 Magnet mounting plate 98.91.61 1
19 Screening plate 96.46.13 120 Round head screw M4 x 8 45.38.68 421 Cover plate 96.46.12 122 Water tank 98.92.93 123 Tube 98.94.25 1
24 Countersunk head screw M4 x 10 05.38.75 225 Slide complete 04.23.20 126 Envelope tray (assy.) 98.92.59 127 Self-locking clip 05.26.02 228 Lower cover RH 98.91.56 1
Neopost, Hasler, Satas, Formax 29 Cover RH (2 station) 98.95.54 1Francotyp, blank - Cover RH (2 station) 98.95.61 1Neopost, Hasler, Satas, Formax - Cover RH (3 station) 98.95.58 1Francotyp, blank - Cover RH (3 station) 98.95.73 1
30 Mounting bracket 98.91.89 1
service manual SI 62
410.04-8 rev. 01.0 - 06/2004
Figure 2
2
3
5
6
8
9
10
18
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RH
19 20
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service manual SI 62
410.04-9rev. 01.0 - 06/2004
Figure 410.04-8
Remarks illustration Description Part code Quantity Remarkscode number number
Neopost, Hasler, Satas, Formax 1 Top cover feeders 98.91.48 1Francotyp, blank - Top cover feeders 98.92.29 1
2 Mounting strip 98.92.79 13 Screw M4 x 14 98.91.83 24 Nut M4 45.19.02 2
5 Collator area cover 96.43.10 16 Round head screw M4 x 8 45.38.68 97 Retaining ring 96.43.36 18 Power supply cover 98.91.55 19 Bottom cover collator area 96.43.18 1
10 Main lead 220V 98.90.51 1- Main lead 110V 98.90.52 -- Main lead 250V Switserland 98.90.54 -- Main lead 240V U.K. 98.90.53 -- Main lead 250V Australia 98.90.55 -
11 Support plate 26.04.52 112 Moistening cloth 04.03.06 113 Clamping strip 24.11.53 814 Water tank 98.92.93 115 Countersunk head screw M4 x 10 05.38.75 3
16 Stud 98.92.19 317 Hex. head screw M4 x 8 05.38.80 318 Bottom plate 98.92.16 1
Neopost, Hasler, Satas, Formax 19 Top cover 98.95.81 1Francotyp, blank - Top cover 98.95.82 1
Neopost, Hasler, Satas, Formax 20 Intermediate cover 98.92.71 1Francotyp, blank - Intermediate cover 98.92.72 1
service manual SI 62
410.04-10 rev. 01.0 - 06/2004
Figure 3
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3
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11
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59
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service manual SI 62
410.04-11rev. 01.0 - 06/2004
Figure 410.04-10
Remarks illustration Description Part code Quantity Remarkscode number number
1 Side guide RH 98.92.26 12 Envelope support (assy.) 95.74.01 13 Side guide LH 98.91.64 14 Round head screw M4 x 16 05.38.71 65 Spring clip 11-15 mm 05.24.73 4
6 Round head screw M4 x 8 05.38.68 77 Lower damper pin RH 96.41.17 18 Support plate 96.41.85 19 Spring clip 6 - 8 mm 05.24.46 4
10 Damper 96.41.40 2
11 Inside frame RH 98.91.39 112 Hinge axle 96.41.14 113 Inside frame (upper unit) RH 98.91.62 114 Damper suspension axle 96.41.20 115 Inside frame (upper unit) LH 98.91.63 1
16 Inside frame LH 98.91.36 117 Spacer ∅ 25 x ∅ 5.5 x 8 mm 43.29.31 218 Rubber stud M6 x 20 04.12.12 219 Frontplate LH 96.45.08 120 Hex. head screw M4 x 8 05.38.80 2
21 Separation spring 95.71.04 122 Separation axle 95.71.05 123 Separation roller (assy.) 95.71.03 124 Set screw M4 x 4 08.28.01 125 Envelope feed axle 98.94.10 1
26 Jogger roller 97.59.52 2- O-ring 04.18.76 2
27 Feed roller ∅ 42 mm 73.27.31 128 Set screw M4 x 6 08.28.02 129 Centre frontplate 96.45.06 1
30 Countersunk head screw M4 x 16 45.38.77 231 Thumb wheel 24.13.58 132 Fixing plate-axle 95.71.26 133 Adj. nut LH 97.54.76 134 Round head screw M4 x 4 45.43.10 6
35 Countersunk head screw M4 x 10 45.38.75 1036 Feed table (assy.) 96.45.05 137 Slide frame 98.92.69 138 Bottom cover 98.92.61 139 Locking spring 03.63.36 2
40 Adj. axle 95.71.12 141 Adj. nut RH 97.54.77 142 Spring clip 9 - 12 mm 05.24.55 143 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 344 Nut M4 (self-locking) 05.36.21 2
service manual SI 62
410.04-12 rev. 01.0 - 06/2004
Figure 410.04-10
Remarks illustration Description Part code Quantity Remarkscode number number
45 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.45 446 Crinkle washer 05.24.84 247 Washer ∅ 12 x ∅ 4.3 x 1 mm 45.37.43 248 Spring clip 8 - 11 mm 05.24.54 149 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 2
50 Pulley 15T (assy.) 93.05.54 151 Timing belt 95.13.16 152 Spacer ∅ 12 x ∅ 8.4 x 5 mm 04.09.64 153 Slip clutch CCW 8mm 95.71.27 154 Cyl. pin ∅ 2.5 x 12 05.23.47 1
55 Spring clip 10 - 14 mm 05.24.83 256 Conductive bearing 10 mm 04.24.26 257 Round head screw M4 x 6 05.38.66 658 Front plate RH 96.45.07 159 Separation frame 96.41.21 1
60 Nut M4 half d. 45.19.19 161 Round head screw M4 x 30 45.43.19 162 Adjusting nut 96.41.54 163 Separation slide 95.71.06 164 Round head screw M3 x 25 45.43.08 1
65 Round head screw M3 x 6 45.43.02 2
service manual SI 62
410.04-13rev. 01.0 - 06/2004
service manual SI 62
410.04-14 rev. 01.0 - 06/2004
Figure 4
33 32 31 30 29 28 27 263435363738
43 42 41 39
24 23
40
LH
RH
(10)
4 5 6 7 8 9
10 11 12 13
16 17 18
321
19 20 2221
44
45
46
48
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47
55 54 53 52 51 50
14 15
25
service manual SI 62
410.04-15rev. 01.0 - 06/2004
Figure 410.04-14
Remarks illustration Description Part code Quantity Remarkscode number number
1 Inside frame LH 98.91.36 12 Envelope guide plate LH 96.42.59 13 Hex. head screw M4 x 8 05.38.80 74 Spring clip 10 - 14 mm 05.24.83 65 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 6
6 Conductive bearing 10 mm 04.24.26 87 Upper frame env. track 96.41.22 18 Cyl. pin ∅ 2.5 x 16 05.23.46 149 Transportation roller ∅ 30 mm 04.18.27 6
10 Sensor (including holder) 04.24.53 2
11 Bracket 96.41.48 112 Nut M4 45.19.02 213 Pan head tapping screw 45.38.55 214 Brush lifter 04.30.20 115 Tension spring 03.11.75 1
16 Clutch shaft 96.41.72 117 Transportation axle 96.41.75 118 Freewheel transportation axle 96.41.88 119 Transportation axle 96.41.71 120 Envelope guide plate RH 96.42.60 1
21 Fixing plate envelope track 95.73.04 122 Inside frame RH 98.91.39 123 Round head screw M4 x 8 05.38.68 424 Round head screw M4 x 25 05.38.72 125 Lifting bracket 04.30.22 1
26 Tension spring 03.35.59 127 Nut M4 (self-locking) 05.36.21 228 Draw bar 96.41.28 129 Clamping ring 3 mm 05.24.63 430 Spacer 04.10.98 1
31 Lever 96.41.32 132 Lifting frame 96.41.24 133 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.02 134 Mounting plate 96.41.25 135 Lifting roller 96.41.26 1
36 Round head screw M4 x 16 05.38.71 137 Round head screw M4 x 25 45.43.18 138 Sleeve 04.12.16 139 Pressure spring 0.85 mm 43.11.12 240 Pressure spring 0.7 mm 03.11.11 4
41 Air hose 24.13.08 142 Spring clip 9 - 12 mm 05.24.55 243 Air tube plug 24.13.02 244 Air hose connector 04.13.23 245 Bracket 43.34.29 1
service manual SI 62
410.04-16 rev. 01.0 - 06/2004
Figure 410.04-14
Remarks illustration Description Part code Quantity Remarkscode number number
46 Pan head tapping screw 45.38.53 147 Hinge axle 96.43.22 148 Lower frame env. track 96.41.23 149 Led (including holder) 04.24.52 150 Transportation roller ∅ 30 mm 95.13.12 8
51 Spring clip 8 - 11 mm 05.24.54 752 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 653 Conductive bearing 8 mm 04.24.25 654 Axle 96.41.53 155 Axle for pressure rollers 96.41.52 2
service manual SI 62
410.04-17rev. 01.0 - 06/2004
service manual SI 62
410.04-18 rev. 01.0 - 06/2004
Figure 5
13
45
67
89
10
11
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30
29
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36
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31
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RH
2
23
service manual SI 62
410.04-19rev. 01.0 - 06/2004
Figure 410.04-18
Remarks illustration Description Part code Quantity Remarkscode number number
1 Sleeve 96.43.70 22 Pin 96.43.71 13 Conductive bearing 10 mm 04.24.26 64 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 55 Rubber roller 96.41.90 1
6 Spring clip 9 - 12 mm 05.24.55 27 Spring clip 10 - 14 mm 05.24.83 38 Transportation axle 96.41.71 19 Cyl. pin ∅ 2.5 x 16 05.23.46 4
10 Transportation roller ∅ 30 mm 04.18.27 4
11 Round head screw M4 x 8 05.38.68 1212 Round head screw M4 x 6 05.38.66 413 Hex. head screw M4 x 8 05.38.80 514 Countersunk tapping screw 05.38.56 115 Bracket 96.45.55 1
16 Sensor (including holder) 04.24.53 117 Mounting plate 96.45.53 118 Hinge axle 96.45.54 119 Pressure spring 0.85 mm 43.11.12 220 Spring clip 7 - 9 mm 05.24.42 2
21 Lifting plate 96.41.29 222 Clamping ring 3 mm 05.24.63 423 Connecting rod 96.41.30 224 Hinge pin 96.41.31 225 Axle for pressure rollers 96.41.70 1
26 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.02 427 Pressure spring 03.35.51 428 Pressure roller (assy.) 96.45.56 429 Pan head tapping screw 45.38.53 130 Flap scraper 96.41.45 1
31 Nut M4 45.19.02 132 Washer ∅ 12 x ∅ 5.2 x 0.7 mm 43.05.35 133 Bracket 96.41.48 134 Led (including holder) 04.24.52 135 Flap opener 96.41.44 1
36 Draw bar 96.41.28 1
service manual SI 62
410.04-20 rev. 01.0 - 06/2004
Figure 6
12
35
67
89
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11
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RH
58
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53
service manual SI 62
410.04-21rev. 01.0 - 06/2004
Figure 410.04-20
Remarks illustration Description Part code Quantity Remarkscode number number
1 Microswitch (incl. lever) 98.90.56 12 Washer ∅ 7 x ∅ 3.2 x 0.5 mm 45.37.39 23 Round head screw M3 x 12 45.43.05 24 Spacer ∅ 15 x ∅ 10.4 x 3 mm 04.08.58 15 Cover 95.71.52 1
6 Frame axle 95.71.53 27 Pan head tapping screw 45.38.53 28 Protecting plate 95.73.13 19 Sensor (including holder) 04.24.53 1
10 Led (including holder) 04.24.52 1
11 Lock washer 5/32” 05.24.31 612 Round head screw M4 x 8 05.38.68 1013 Countersunk head screw M4 x 10 45.38.75 214 Upper sealing roller ∅ 36 mm 73.26.48 115 Mounting plate 95.72.04 1
16 Lower sealing roller (assy.) 98.94.33 117 Pressure spring 03.11.91 218 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 619 Conductive bearing 10 mm 04.24.26 720 Pressure spring 0.7 mm 03.11.11 2
21 Pressure spring 1.1 mm 03.11.15 122 Round head screw M4 x 6 45.43.12 623 Conductive bearing 6 mm 04.24.24 224 Tension pin ∅ 2 x 12 05.33.15 125 Round head screw M4 x 16 45.43.16 1
26 Actuator disc 96.40.61 127 Nut M4 45.19.02 728 Clamping ring 3 mm 05.24.63 429 Nut M4 (self-locking) 05.36.21 130 Draw bar 96.40.62 1
31 Tension spring 03.35.04 132 Mounting bracket 96.40.63 133 Solenoid 02.10.21 134 Lever for finger 96.40.65 435 Pressure spring 96.40.70 2
36 Finger 96.40.71 237 Cross connection (incl. corkrubber) 96.45.68 1
- Cork rubber 04.18.04 438 Leaf spring 96.45.64 139 Finger slide 96.40.66 2
40 Pressure spring 96.40.73 241 Hex. head screw M4 x 8 (synthetic) 96.45.66 242 Knurled nut 02.11.25 243 Adjustable finger 96.40.57 244 Pulley axle (assy.) 96.43.58 1
service manual SI 62
410.04-22 rev. 01.0 - 06/2004
Figure 410.04-20
Remarks illustration Description Part code Quantity Remarkscode number number
45 Connecting ring 96.45.60 146 Transportation axle (assy.) 96.43.57 147 Transportation table (assy.) 96.45.67 148 Transportation roller 96.41.61 249 Cyl. pin ∅ 2.5 x 16 05.23.46 4
50 Transportation roller ∅ 30 mm 04.18.27 451 Transportation roller ∅ 30 mm 04.30.07 252 Pulse disc axle (assy.) 96.43.59 153 Hex. head screw M4 x 8 05.38.80 1054 Washer ∅ 12 x ∅ 6.2 x 0.8 mm 04.01.40 1
55 Sleeve 96.43.70 256 Pin 96.43.71 157 Pressure spring 1 mm 03.11.14 1058 Wiring plate 98.91.58 159 Round head screw M3 x 6 45.43.02 2
60 Axle 96.41.69 161 Guide plate 96.45.59 162 Insert table 96.45.58 163 Countersunk screw M3 x 16 05.04.14 864 Axle for fingers 96.40.59 1
65 Mounting pin 43.61.75 266 Spring clip 6 - 8 mm 05.24.46 3
service manual SI 62
410.04-23rev. 01.0 - 06/2004
service manual SI 62
410.04-24 rev. 01.0 - 06/2004
Figure 7
34
56
78
910
11
12
16
18
19
20
21
22
23
25
24
30
RH
17
29
28
26
31
27
21
13
15
14
service manual SI 62
410.04-25rev. 01.0 - 06/2004
Figure 410.04-24
Remarks illustration Description Part code Quantity Remarkscode number number
1 Belt tensioner 96.46.76 12 Hex. head screw M4 x 8 05.38.80 23 Tension pin ∅ 2.5 x 16 05.33.22 44 Spacer ∅ 15 x ∅ 10.4 x 5 mm 04.08.37 45 Gear 28T 24.02.61 2
6 Gear 18T 24.09.36 27 Spring clip 9 - 12 mm 05.24.55 38 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 49 Cyl. pin ∅ 2.5 x 20 96.41.93 4
10 Disc for pulley 96.43.56 3
11 Timing belt 96.43.55 112 Pulley 36T 96.41.60 113 Spring clip 10 - 14 mm 05.24.83 414 Mounting plate 96.41.80 115 Round head screw M4 x 6 05.38.66 1
16 Round head screw M3 x 8 05.38.65 317 Washer ∅ 7 x ∅ 3.2 x 0.5 mm 45.37.39 318 Adj. plate 96.41.81 119 Pulse disc sensor (assy.) 82.16.22 120 Pulse disc 24.12.81 1
21 Clamping disc 43.30.46 122 Washer ∅ 20 x ∅ 6.2 x 2 mm 43.07.90 123 Countersunk head screw M4 x 8 45.42.12 124 Pulley 30T 96.41.64 225 Tensioner roller 96.41.94 2
26 Pulley 20T 96.41.57 127 Gear 35T 24.69.52 128 Spacer ∅ 15 x ∅ 10.4 x 10 mm 04.08.30 129 Gear 18T 96.43.51 230 Round head screw M4 x 8 05.38.68 2
31 Locking plate 96.41.65 2
service manual SI 62
410.04-26 rev. 01.0 - 06/2004
Figure 8
56
910
11
12
13
14
34
33
32
31
29
26
25
24
28
27
20
42
19
18
16
15
41
401
23
47
8
(23)
RH
39
17
22
(8)
23(1
9)
30
21
35
36
service manual SI 62
410.04-27rev. 01.0 - 06/2004
Figure 410.04-26
Remarks illustration Description Part code Quantity Remarkscode number number
1 Cyl. pin ∅ 2.5 x 12 05.23.47 12 Slip clutch CCW 8mm 95.71.27 13 Timing belt 95.13.16 14 Pulley 15T (assy.) 93.05.54 15 Conductive bearing 10 mm 04.24.26 9
6 Countersunk head screw M4 x 10 45.42.13 27 Spacer ∅ 17 x ∅ 10.2 x 2 mm 04.10.94 18 Gear 35T 24.69.58 29 Catch disc 23.55.06 1
10 Clutch CW 8 mm 12.16.66 1
11 Cyl. pin ∅ 2.5 x 16 05.23.46 212 Gear 18T 96.41.74 113 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 314 Spring clip 6 - 8 mm 05.24.46 115 Round head screw M4 x 8 05.38.68 1
16 Support plate 96.41.85 117 Spring clip 10 - 14 mm 05.24.83 518 Gear 28T 24.11.40 119 Gear 35T 24.69.52 220 Freewheel clutch assy. 96.43.60 1
21 Spring clip 9 - 12 mm 05.24.55 222 Gear 28T 26.02.61 123 Gear 14T 96.41.79 224 Nut 45.19.20 225 Washer ∅ 17 x ∅ 8.4 x 1.6 mm 45.37.38 2
26 Spring holder disc 24.69.43 227 Pressure spring 1.5 mm 03.11.73 128 Spring clip 8 - 11 mm 05.24.54 229 Gear 18T 24.09.36 130 Gear 15T 96.41.68 1
31 Gear 21T 24.16.50 132 Gear 15T (assy.) 74.69.42 133 Spacer ∅ 15 x ∅ 10.4 x 3 mm 04.08.58 234 Brake rod 96.41.84 135 Spacer ∅ 15 x ∅ 10.4 x 5 mm 04.08.37 1
36 Spacer ∅ 12 x ∅ 8.4 x 5 mm 04.09.64 137 Not used38 Not used39 Tension pin ∅ 2.5 x 16 05.33.22 240 Pulley 13T 96.41.77 1
41 Intermediate axle 96.41.76 142 Tension pin ∅ 2.5 x 20 05.33.24 2
service manual SI 62
410.04-28 rev. 01.0 - 06/2004
Figure 9
12
34
56
78
9
13
12
11
10
22
21
20
19
18
17
16
15
14
23
24
25
LH
RH
(21)
(18)
(18)
34
33
32
31
30
29
28
27
26
service manual SI 62
410.04-29rev. 01.0 - 06/2004
Figure 410.04-28
Remarks illustration Description Part code Quantity Remarkscode number number
1 Bearing locking plate 93.06.13 22 Washer ∅ 15 x ∅ 5.3 x 2 mm 45.37.50 43 Countersunk head screw M4 x 10 05.38.75 64 Conductive bearing 6 mm 04.24.24 45 Washer ∅ 12 x ∅ 6.2 x 0.8 mm 04.01.40 4
6 Spring clip 6 - 8 mm 05.24.46 47 Hex. head screw M4 x 8 05.38.80 58 Washer ∅ 20 x ∅ 6.2 x 2 mm 43.07.90 29 Bearing locking plate 93.06.12 2
10 Upper input roller (assy.) 98.95.21 1
11 Lower input roller (assy.) 98.95.22 112 Screening plate (assy.) 96.42.64 113 Wiring guide 96.42.58 114 Round head screw M3 x 8 05.38.65 415 Countersunk head screw M3 x 10 05.38.74 2
16 Round head screw M3 x 4 45.43.00 217 Cyl. pin ∅ 2.5 x 16 05.23.46 318 Gear 24T 93.05.25 319 Spring clip 10 - 14 mm 05.24.83 520 Spacer ∅ 15 x ∅ 10.4 x 3 mm 04.08.58 4
21 Gear 35T 24.69.58 222 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 223 Flap actuator 95.30.84 224 Cyl. pin ∅ 2 x 12 95.30.85 225 Round head screw M4 x 16 05.38.71 2
26 Sleeve 04.00.27 227 Fold roller (assy.) 98.95.20 228 Fixing screw M3 x 6 95.30.83 429 Flap assy. incl. torsion spring 04.27.71 230 Torsion spring 03.35.38 2
31 Flap assy. (incl. axle) 04.27.50 232 Synthetic leaf spring 93.06.54 433 Guide bracket 95.30.73 134 Guide strip 93.06.53 1
service manual SI 62
410.04-30 rev. 01.0 - 06/2004
Figure 10
12
3
45
67
89
10
11
13
14
15
23
24
25
26
RH
16
17
18
19
20
21
22
27
28
29
30
31
12
32
service manual SI 62
410.04-31rev. 01.0 - 06/2004
Figure 410.04-30
Remarks illustration Description Part code Quantity Remarkscode number number
1 Mounting bracket for spring 98.91.16 32 Hex. head screw M4 x 8 05.38.80 83 Fixing plate 95.13.07 24 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 25 Axle for tensioner roller 95.13.10 2
6 Cyl. pin ∅ 2.5 x 16 05.23.46 57 Disc for pulley 93.05.42 48 Tensioner roller 96.43.68 19 Pulley 20T assy. (timing belt) 04.22.46 4
10 Timing belt 04.16.21 1
11 Spring clip 7 - 9 mm 05.24.42 212 Pulley 20T 96.41.57 113 Cyl. pin ∅ 2.5 x 32 05.23.48 114 Drive belt PJ 96.41.55 115 Main pulley 96.41.58 1
16 Spring clip 10 - 14 mm 05.24.83 117 Spacer ∅ 15 x ∅ 10.4 x 10 mm 04.08.30 218 Spacer ∅ 15 x ∅ 10.4 x 3 mm 04.08.58 219 Tensioner roller 96.41.67 120 Pulley 50 Hz 98.94.04 1
- Pulley 60 Hz 98.94.05 121 Set screw M4 x 8 08.28.06 122 Belt tensioner 96.41.66 123 Spring clip 9 - 12 mm 05.24.55 124 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 1
25 Gear 30T 96.46.74 126 Spacer ∅ 15 x ∅ 10.4 x 7.5 mm 04.08.28 127 Hex. head screw M4 x 12 45.38.82 428 Spacer ∅ 9 x ∅ 4.1 x 2.5 mm 43.08.51 429 Gear 24T 93.05.25 1
30 Timing belt 95.13.16 131 Motor 220-240V/50Hz 98.94.06 1
- Motor 100-115V/50-60Hz 98.94.07 132 Tensioner roller 95.13.19 1
service manual SI 62
410.04-32 rev. 01.0 - 06/2004
Figure 11
LH
RH
12
34
56
78
910
11
12
13
14
15
21
27
20
19
18
17
16
22
26
25
24
23
33
32
31
30
29
28
34
35
36
37
42
43
44
45
46
47
39
40
41
38
48
(33)
service manual SI 62
410.04-33rev. 01.0 - 06/2004
Figure 410.04-32
Remarks illustration Description Part code Quantity Remarkscode number number
1 Inside frame (upper unit) LH 98.91.63 12 Loc frame 96.47.25 23 Hex. head screw M4 x 8 05.38.80 114 Round head screw M4 x 16 05.38.71 45 Connecting plate loc 95.72.60 2
6 Pressure spring 03.11.95 17 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 28 Solenoid 12.12.87 19 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.45 3
10 Round head screw M4 x 5 45.43.11 6
11 Bracket for photocell 96.47.31 112 Pan head tapping screw 45.38.55 113 Led (including holder) 04.24.52 114 Cross connecting plate 96.47.29 115 Inside frame (upper unit) RH 98.91.62 1
16 Spring clip 7 - 9 mm 05.24.42 117 Timing belt 04.15.37 118 Pulley 21T 04.18.70 119 Cyl. pin ∅ 2.5 x 16 05.23.46 620 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 9
21 Conductive bearing 10 mm 04.24.26 1022 Drive axle 96.47.23 123 Round head screw M4 x 8 05.38.68 424 Washer ∅ 12 x ∅ 4.3 x 1 mm 45.37.43 225 Paper guide 96.47.30 2
26 Transportation roller ∅ 30 mm 96.43.64 227 Pressure spring 0.85 mm 43.11.12 328 Spring clip 10 - 14 mm 05.24.83 429 Tension spring 03.35.62 230 Bearing plate 96.47.20 1
31 Spacer ∅ 15 x ∅ 10.4 x 5 mm 04.08.37 332 Spacer ∅ 15 x ∅ 10.4 x 7.5 mm 04.08.28 233 Gear 15T 24.09.44 234 Gear 14T 96.41.79 135 Axle 96.47.17 1
36 Gear 20T 24.02.58 137 Bearing plate 96.47.19 138 Spacer ∅ 17 x ∅ 10.2 x 2 mm 04.10.94 239 Bearing plate 96.47.21 140 Spacer ∅ 15 x ∅ 10.4 x 10 mm 04.08.30 2
41 Gear 15T 73.29.42 142 Rod 43.26.81 143 Transportation axle 96.47.18 144 Bearing plate 96.47.22 145 Clamping ring 3 mm 05.24.63 4
service manual SI 62
410.04-34 rev. 01.0 - 06/2004
Figure 410.04-32
Remarks illustration Description Part code Quantity Remarkscode number number
46 Draw bar 43.26.79 147 Spacer ∅ 15 x ∅ 10.4 x 3 mm 04.08.58 348 Transportation roller ∅ 30 mm 04.18.27 2
service manual SI 62
410.04-35rev. 01.0 - 06/2004
service manual SI 62
410.04-36 rev. 01.0 - 06/2004
Figure 12
LH
RH
12
34
56
78
910
11
12
13
14
16
17
18
20
19
21
22
23
24
28
27
26
25
15
service manual SI 62
410.04-37rev. 01.0 - 06/2004
Figure 410.04-36
Remarks illustration Description Part code Quantity Remarkscode number number
1 Inside frame (upper unit) LH 98.91.63 12 Cyl. pin ∅ 2.5 x 16 05.23.46 23 Transportation roller ∅ 38 mm 04.29.77 24 Loc frame 96.47.25 25 Nut M4 (self-locking) 05.36.21 2
6 Hex. head screw M4 x 8 05.38.80 147 Spring lever 23.28.74 18 Tension spring 45.64.04 19 Nut M4 45.19.02 1
10 Countersunk head screw M4 x 10 05.38.75 3
11 Washer ∅ 12 x ∅ 4.3 x 1 mm 45.37.43 212 Round head screw M4 x 16 05.38.71 113 Pressure spring 0.85 mm 43.11.12 214 Conductive bearing 10 mm 04.24.26 215 Spring clip 10 - 14 mm 05.24.83 2
16 Axle 23.29.10 117 Bracket 96.47.34 118 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.45 119 Inside frame (upper unit) RH 98.91.62 120 Cross bar 96.47.27 1
21 Buffer (assy.) 83.34.97 122 Retaining spring 03.11.87 323 Grommet 12.04.74 324 Brush 72.00.05 325 Locking bracket 04.30.23 1
26 Brush holder 04.29.94 127 Lifting bracket 96.47.33 128 Sleeve 04.09.77 1
service manual SI 62
410.04-38 rev. 01.0 - 06/2004
Figure 13
LH
RH
1 2 3 4
5 6 7 8 9
10
11
12
13
14
15
16
17
18
19
28
29
30
31
26
27
35
36
37
20
21
22
24
23
42
41
40
39
38
34
33
32
25
service manual SI 62
410.04-39rev. 01.0 - 06/2004
Figure 410.04-38
Remarks illustration Description Part code Quantity Remarkscode number number
1 Round head screw M4 x 5 45.43.11 32 Bracket for flagswitch 96.47.13 13 Flagswitch 02.10.76 14 Solenoid 12.12.87 15 Mounting frame 96.47.11 1
6 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.45 47 Lever 96.47.03 18 Washer ∅ 12 x ∅ 6.2 x 0.8 mm 04.01.40 89 Brake plate 98.92.77 1
10 Transportation roller (assy.) 84.17.04 2
11 Spring clip 6 - 8 mm 05.24.46 412 Hinge bracket 96.47.02 113 Hex. head screw M4 x 8 05.38.80 1414 Inside frame (upper unit) RH 98.91.62 115 Tension pin ∅ 2.5 x 16 05.33.22 2
16 Gear 15T 96.41.68 217 Pulley 15T 04.18.64 118 Timing belt 04.15.37 119 Cyl. pin ∅ 2.5 x 14 04.20.97 120 Round head screw M4 x 8 45.38.68 2
21 Cover plate 96.47.26 122 Loc frame 96.47.25 223 Cross bar 96.47.27 124 Inside frame (upper unit) LH 98.91.63 125 Grommet 98.92.75 1
26 Spacer ∅ 15 x ∅ 10.4 x 3 mm 04.08.58 127 Spacer ∅ 15 x ∅ 10.4 x 10 mm 04.08.30 428 Transportation axle 23.26.00 129 Conductive bearing 10 mm 04.24.24 630 Pressure spring 0.7 mm 03.11.11 2
31 Spring clip 10 - 14 mm 05.24.83 632 Transportation roller ∅ 38 mm 04.29.77 233 Cyl. pin ∅ 2.5 x 16 05.23.46 434 Transportation roller ∅ 30 mm 04.18.27 235 Ejection axle 96.47.24 1
36 Divert axle 96.47.16 237 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 438 Nut M4 45.19.02 239 Clamping ring 3 mm 05.24.63 440 Draw bar 96.47.08 1
41 Pressure spring 03.11.95 142 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 2
service manual SI 62
410.04-40 rev. 01.0 - 06/2004
Figure 14
96
13
14
17
54
53
52
57
56
55 48
47
45
43
44
30
28
27
61
18
54
63
87
16
26
62
10
11
19
20
21
22
23
24
15
31
32
33
34
37
38
39
40
41
42
12
25
29
46
49
50
51
12
3
60
59
58
35
36
66
64
65
service manual SI 62
410.04-41rev. 01.0 - 06/2004
Figure 410.04-40
Remarks illustration Description Part code Quantity Remarkscode number number
1 Upper separation roller 95.11.67 12 Tension pin ∅ 2.5 x 12 05.33.20 13 Pulley 95.11.42 14 Spring clip 7 - 9 mm 05.24.42 85 Cover plate 95.11.25 1
6 Transportation roller ∅ 30 mm 95.11.36 27 Transportation axle 95.11.37 18 Timing belt 95.11.45 19 Transportation axle (separation) 95.11.39 1
10 Pressure spring 03.11.14 1
11 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 1012 Self-lubricating bearing 06.09.31 113 Rubber paper puller 04.00.16 214 Spring clip 6 - 8 mm 05.24.46 915 Washer ∅ 12 x ∅ 6.2 x 0.8 mm 04.01.40 5
16 Conductive bearing 6 mm 04.24.24 417 Cyl. pin ∅ 2.5 x 12 05.23.47 118 Pulley 28T (timing belt) 95.11.35 119 Transportation axle 95.11.34 120 Clamping bush 95.11.41 1
21 Mounting strip 98.93.21 122 Upper plate feeder 98.93.04 123 Bottom plate assy. (daily mail feeder) 98.93.26 124 Frame plate feeder 98.93.05 225 Pressure spring 03.35.20 2
26 Round head screw M4 x 30 45.43.19 127 Nut M4 (self-locking) 05.36.21 128 Spacer 95.13.37 129 Round head screw M4 x 8 05.38.68 1730 Conductive bearing 8 mm 04.24.25 2
31 Drive axle 96.42.16 132 Separation axle assy. (daily mail) 04.23.11 133 Cyl. pin ∅ 2.5 x 16 05.23.46 234 Transportation roller 95.13.12 235 Fixing strip 95.11.82 1
36 Fixing strip 98.93.18 137 Sleeve 04.11.57 138 Slide 95.11.78 139 Washer ∅ 12 x ∅ 4.3 x 1 mm 45.37.43 640 Nut M4 45.19.02 2
41 Wire spring 95.11.79 142 Round head screw M3 x 4 45.43.00 143 Drive axle extension 96.42.20 144 Hinge arm 98.93.12 145 Curved spring assy. 04.28.80 1
service manual SI 62
410.04-42 rev. 01.0 - 06/2004
Figure 410.04-40
Remarks illustration Description Part code Quantity Remarkscode number number
46 Spring lever 98.93.09 148 Gear 48T 95.11.32 147 Cyl. pin ∅ 2 x 16 05.23.69 249 Pulley 44T 95.11.51 150 Tensioner roller 95.11.59 1
51 Belt tensioner 98.93.22 152 Gear 64T (assy.) 95.11.38 153 Support axle extension 95.11.09 154 Tension pin ∅ 2.5 x 10 05.33.19 155 Fibre washer ∅ 10 x ∅ 5.2 x 1 mm 04.01.07 2
56 Bearing bush 04.13.32 157 Spring clip 5 - 7 mm 05.24.66 158 Led (including holder) 04.24.52 159 Bracket for photocell 98.93.10 160 Pan head tapping screw 45.38.55 2
61 Cork strip 95.11.26 262 Sensor (including holder) 04.24.53 163 DFC 79.01.71 164 Bottom plate assy. 98.93.08 165 Separation roller (lower) 95.11.68 1
66 Separation axle assy. (auto) 04.22.63 1
service manual SI 62
410.04-43rev. 01.0 - 06/2004
service manual SI 62
410.04-44 rev. 01.0 - 06/2004
Figure 15
LH
RH
45
67
89
10
11
12
13
14
19
20
21
32
31
30
29
28
27
26
25
23
22
33
24
34
41
42
40
39
38
37
3643
44
32
115
18
17
35
16
service manual SI 62
410.04-45rev. 01.0 - 06/2004
Figure 410.04-44
Remarks illustration Description Part code Quantity Remarkscode number number
1 Countersunk head tapping screw 45.38.56 12 Led (including holder) 04.24.52 13 Hex. head screw M4 x 8 05.38.80 104 Guide plate 98.94.16 15 Round head screw M4 x 6 05.38.66 17
6 Hinge pin 98.93.23 67 Countersunk head screw M4 x 10 05.38.75 28 Round head screw M4 x 8 05.38.68 69 Pin 98.91.49 2
10 Mounting plate 96.53.31 1
11 Microswitch (incl. lever) 98.90.56 112 Mounting plate 98.91.87 113 Mounting bracket for spring 98.91.16 314 Washer ∅ 7 x ∅ 3.2 x 0.5 mm 45.37.39 515 Nut M3 45.19.01 2
16 Tension spring 95.11.50 317 Top frame (2 station) 98.91.50 1
- Top frame (3 station) 98.91.14 118 Inside frame RH 98.91.39 119 Cover plate 95.13.27 1
20 Centre cover plate 96.46.25 121 Lower cover plate 96.46.15 122 Frame axle 95.13.24 323 Drive axle 96.46.52 124 Drive axle 95.13.04 2
25 Nylon bearing 04.12.71 626 Spring clip 9 - 12 mm 05.24.55 627 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 328 Lever 95.10.21 229 Tension pin ∅ 2.5 x 12 05.33.20 3
30 Torsion spring 95.13.28 331 Cyl. pin ∅ 2.5 x 16 05.23.46 832 Round head screw M3 x 16 05.38.67 333 Transportation roller ∅ 30 mm 04.18.27 834 Safety bracket 95.13.23 2
35 Inside frame LH 98.91.36 136 Blocking bracket 96.46.77 337 Pulley 44T 95.13.08 338 Disc pulley 93.05.39 339 Clutch CCW 8 mm 93.05.36 3
40 Spring clip 6 - 8 mm 05.24.46 341 Timing belt set (3 pcs) 84.15.74 142 Spacer ∅ 12 x ∅ 8.4 x 5 mm 04.09.64 643 Conductive bearing 8 mm 04.24.25 344 Tension spring 45.54.04 3
service manual SI 62
410.04-46 rev. 01.0 - 06/2004
Figure 16
LH
RH
11
12
16
35
17
18
19
13
14
15
28
27
26
25
24
23
22
21
20
34
33
32
31
30
29
12
67
34
58
910
service manual SI 62
410.04-47rev. 01.0 - 06/2004
Figure 410.04-46
Remarks illustration Description Part code Quantity Remarkscode number number
1 Round head screw M4 x 16 05.38.71 22 Round head screw M4 x 20 45.43.17 43 Hinge pin 98.91.60 24 Selflocking nut M3 05.36.28 25 Tension spring 03.35.61 3
6 Nut M3 45.19.01 27 Lock 98.92.64 28 Nut M4 45.19.02 29 Retaining bush 98.92.65 2
10 Countersunk head screw M3 x 16 45.42.05 2
Neopost, Hasler, Satas, Formax 11 Handle 98.91.88 1Francotyp, blank - Handle 98.95.64 1
12 Locking plate 98.92.63 113 Frame vertical transport (2 station) 98.91.97 1
- Frame vertical transport (3 station) 98.91.70 1
14 Cable guide 93.09.54 115 Inside frame (upper unit) RH 98.91.62 116 Refer to 1217 Round head screw M4 x 8 05.38.68 1218 Positioning plate 98.91.57 1
19 Hex. head screw M4 x 8 05.38.80 620 Pan head tapping screw 45.38.53 121 Mounting bracket 96.41.43 122 Sensor (including holder) 04.24.53 123 Guide plate (upper) 98.91.98 ?
24 Guide plate (centre) 96.42.12 125 Guide plate (lower) 96.42.11 126 Rod 96.42.01 227 Paper guide 04.18.09 628 Reading head assy. 98.94.34 1
29 Transportation roller ∅ 30 mm 95.11.36 830 Pressure roller axle 95.14.16 331 Spring clip 6 - 8 mm 05.24.46 632 Washer ∅ 12 x ∅ 6.2 x 0.8 mm 04.01.40 633 Conductive bearing 6 mm 04.24.24 6
34 Pressure spring 03.35.20 635 Inside frame (upper unit) LH 98.91.63 1
service manual SI 62
410.04-48 rev. 01.0 - 06/2004
Figure 17
LH
RH
12
34
56
78
52
54
53
44
45
13
12
51
50
55
40
39
38
37
36
35
34
33
32
31
42
43
10
16
15
14
11
22
21
19
18
23
24
25
26
27
28
29
49
48
47
46
30
20
17
9
41
service manual SI 62
410.04-49rev. 01.0 - 06/2004
Figure 410.04-48
Remarks illustration Description Part code Quantity Remarkscode number number
1 Inside frame LH 98.91.36 12 Tension spring 03.35.39 23 Nut M4 45.19.02 14 Hinged guide plate 96.41.34 15 Sensor (including holder) 04.24.53 2
6 Pan head tapping screw 45.38.55 27 Leaf spring 98.94.23 18 Frame 96.43.04 19 Hex. head screw M4 x 8 05.38.80 7
10 Inside frame RH 98.91.39 1
11 Roller 98.94.01 612 Cyl. pin ∅ 2 x 16 05.23.69 613 Washer ∅ 12 x ∅ 6.2 x 0.8 mm 04.01.40 1014 Conductive bearing 6 mm 04.24.24 215 Frame (collator area) 96.43.02 1
16 Axle 96.43.06 117 Tensioner 96.43.00 118 Pressure spring 96.43.32 219 Guide plate 96.43.01 120 Spring clip 6 - 8 mm 05.24.46 6
21 Pressure roller assy. (incl. O-ring) 95.20.11 322 Hinge axle 96.43.08 423 Pressure spring 03.35.43 224 Axle 96.43.09 1
25 Belt tensioner 95.20.15 226 Set screw M4 x 4 08.28.01 227 Nylon bearing 04.11.07 428 Spring clip 4 - 5 mm 05.24.47 829 Round head screw M3 x 8 05.38.65 3
30 Collating belt set (3 pcs.) 95.20.07 131 Drive axle (collator area) 98.94.35 132 Conductive bearing 8 mm 04.24.25 133 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 334 Set screw M4 x 4 08.28.01 135 Roller 98.94.00 3
36 Bushing ∅ 15 x ∅ 10.2 x 5.5 mm 75.37.51 137 Frame collator motor 98.94.21 138 Motor 24V 98.94.09 139 Pulse disc sensor (assy.) 97.55.05 140 Set screw M3 x 4 08.28.33 541 Pulse disc 96.43.43 1
42 Round head screw M4 x 6 05.38.66 243 Round head screw M4 x 16 05.38.71 444 Spring clip 8 - 11 05.24.54 145 Clamping ring 05.24.86 1
service manual SI 62
410.04-50 rev. 01.0 - 06/2004
Figure 410.04-48
Remarks illustration Description Part code Quantity Remarkscode number number
46 Round head screw M4 x 8 05.38.68 347 Pan head tapping screw 45.38.53 248 Mounting bracket 96.43.12 149 Led (including holder) 04.24.52 250 Pressure roller ∅ 20 mm 95.14.08 2
51 Axle ∅ 6 mm 98.94.24 152 Cil. pin ∅ 2.5 x 16 05.23.46 253 Transportation roller ∅ 30 mm 04.18.27 254 Transportation axle (assy.) 96.46.54 155 Paper guide strip 96.41.33 1
service manual SI 62
410.04-51rev. 01.0 - 06/2004
service manual SI 62
410.04-52 rev. 01.0 - 06/2004
Figure 18
LH
RH
1 2 3
6
7
8
9
11
12
16 15 14 13
17
18
19
20
21
29
27
25
24
5
4
36 37 38 39 40 41 42
30
31
32
33
34
35
26
23
28
10
22
service manual SI 62
410.04-53rev. 01.0 - 06/2004
Figure 410.04-52
Remarks illustration Description Part code Quantity Remarkscode number number
1 Collating plate 96.43.17 12 Paper stop 95.21.41 23 Round head screw M4 x 8 05.38.68 164 Cover plate RH 96.43.28 15 Frame collating area 96.43.16 1
6 Microswitch (incl. lever) 98.90.56 17 Screening plate 46.43.37 18 Round head screw M3 x 12 45.43.05 29 Countersunk head screw M4 x 10 45.38.75 1
10 Isolating plate 98.90.04 1
11 Printed board holder 04.10.75 412 Motor relay board 230V 97.55.00 1
- Motor relay board 115V 97.55.40 113 Guide plate 98.92.01 214 Spring clip 6 - 8 mm 05.24.46 6
15 Tension spring 03.35.36 216 Hinge axle 98.92.04 117 Fuse 2.5A/230V slow blow 97.55.43 1
- Fuse 5A/125V 12.15.49 118 Power inlet 98.90.05 1
19 Round head screw M4 x 25 05.38.72 220 Synthetic stud 24.14.62 221 Hex. head screw M4 x 8 05.38.80 222 Power supply 98.90.02 123 Power supply frame 98.92.03 1
24 Capacitor 5 mF (230 V) 98.90.06 1- Capacitor 20 mF (115 V) 12.12.81 1
25 Capacitor 5 mF (230 V) 98.90.06 1- Capacitor 20 mF (115 V) 12.12.81 1
26 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.02 2
27 Lock washer 5/32” 05.24.31 228 Guide roller 96.43.19 229 Cover plate LH 96.43.27 130 Hinge axle 96.43.22 131 Spring clip 10 - 14 mm 05.24.83 4
32 Clamping ring 4 mm 05.24.62 233 Rod 96.43.25 134 Spring clip 5 - 7 mm 05.24.66 3635 Counter roller 95.21.11 1836 Nut M4 45.19.02 4
37 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.45 438 Axle 95.21.12 239 Tilting plate 95.21.14 240 Tension spring 45.64.04 141 Roller 95.21.13 1
service manual SI 62
410.04-54 rev. 01.0 - 06/2004
Figure 410.04-52
Remarks illustration Description Part code Quantity Remarkscode number number
42 Transportation axle 96.43.24 6
service manual SI 62
410.04-55rev. 01.0 - 06/2004
service manual SI 62
410.04-56 rev. 01.0 - 06/2004
Figure 19
3 4 5 6 7 8 9 10 11
12 13 14 15
20
18
17
16
21
22 23 24
25 26 27 28 29
LH
RH
LH
RH
19
1 2
service manual SI 62
410.04-57rev. 01.0 - 06/2004
Figure 410.04-56
Remarks illustration Description Part code Quantity Remarkscode number number
1 Round head screw M4 x 16 05.38.71 42 Leaf spring 95.30.60 23 Round head screw M4 x 8 05.38.68 24 Locking plate 95.30.95 15 Bracket 95.30.90 2
6 Spring clip 10 - 14 mm 05.24.83 47 Conductive bearing 10 mm 04.24.26 48 Tension pin Ø 2.5 x 20 05.33.24 49 Curve axle 95.31.10 2
10 Mounting bracket 95.30.56 1
11 Curve disc RH 95.30.64 212 Guide plate (assy.) (first fold table) 95.30.51 113 Countersunk head screw M3 x 10 05.38.74 1414 Axle for fold plate 95.30.30 215 Hinge plate RH 95.30.11 2
16 Fold plate 96.42.07 117 Hinge strip (paper guide) LH 95.30.20 218 Hinge plate LH 95.30.10 219 Washer Ø 14 x Ø 8.2 x 0.8 mm 04.01.41 420 Spring clip 7 - 9 mm 05.24.42 4
21 Curve disc LH 95.30.63 222 Nut M4 45.19.02 223 Washer Ø 12 x Ø 4.3 x 1 mm 45.37.43 224 Mounting bracket 95.30.59 125 Guide plate (second fold table) 95.30.53 1
26 Paper guide 95.30.26 127 Hinge strip (paper guide) RH 95.30.21 128 Set screw M4 x 4 08.28.01 329 Fold plate 95.30.16 1
service manual SI 62
410.04-58 rev. 01.0 - 06/2004
Figure 20
12
34
5
67
8
9
10
LH
RH
service manual SI 62
410.04-59rev. 01.0 - 06/2004
Figure 410.04-58
Remarks illustration Description Part code Quantity Remarkscode number number
1 Conductive bearing 8 mm 04.24.25 22 Spacer ∅ 12 x ∅ 8.3 x 3 mm 04.10.50 13 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 64 Spring clip 7 - 9 mm 05.24.42 45 Gear 32T (incl. catch) 96.42.19 2
6 Clutch CCW 8 mm 12.14.61 17 Cyl. pin ∅ 2.5 x 12 05.23.47 28 Spacer ∅ 18 x ∅ 12.8 x 3 mm 04.08.71 29 Clutch CW (clockwise) 8 mm 12.14.63 1
10 Drive axle (fold) 93.05.10 1
service manual SI 62
410.04-60 rev. 01.0 - 06/2004
Figure 21
LH
12
34
5
67
89
10
11
12
13
14
15
16
17
18
24
25
26
27
28
23
22
21
20
19
service manual SI 62
410.04-61rev. 01.0 - 06/2004
Figure 410.04-60
Remarks illustration Description Part code Quantity Remarkscode number number
1 Lever for flap actuator 95.30.31 22 Cyl. pin ∅ 2 x 18 05.23.07 23 Spring clip 8 - 11 mm 05.24.54 24 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 45 Conductive bearing 8 mm 04.24.25 2
6 Inside frame (upper unit) LH 98.91.63 17 Bracket 97.54.61 28 Pulse disc sensor 97.55.05 29 Round head screw M4 x 5 45.43.11 8
10 Guide plate 96.41.38 1
11 Round head screw M4 x 6 05.38.66 112 Upper fold roller (assy.) 96.46.61 113 Fold roller (assy.) 98.95.20 114 Guide strip 95.30.73 115 Round head screw M3 x 8 05.38.68 1
16 Bearing locking plate 93.06.13 117 Washer ∅ 15 x ∅ 5.3 x 2 mm 45.37.50 218 Countersunk head screw M4 x 10 05.38.75 219 Torsion spring 95.30.70 220 Round head screw M4 x 16 05.38.71 2
21 Ball bearing 03.12.81 222 Positioning lever 95.30.68 223 Nut M4 (self-locking) 05.36.21 224 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 625 Spring clip 9 - 12 mm 05.24.55 2
26 Brake disc 95.30.66 227 Cyl. pin ∅ 2.5 x 16 05.23.46 228 Conductive bearing 10 mm 04.24.26 2
service manual SI 62
410.04-62 rev. 01.0 - 06/2004
Figure 22
35
36
31
37
38
39
40
RH
56
43
21
7 8 9 10
12
13
14
15
16
17
18
19
20
21
22
30
29
28
27
26
32
25
24
23
33
34
11
service manual SI 62
410.04-63rev. 01.0 - 06/2004
Figure 410.04-62
Remarks illustration Description Part code Quantity Remarkscode number number
1 Inside frame (upper unit) RH 98.91.62 12 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 73 Conductive bearing 8 mm 04.24.25 24 Countersunk head screw M4 x 10 05.38.75 45 Spring clip 8 - 11 mm 05.24.54 3
6 Belt tensioner 96.46.68 17 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.02 28 Round head screw M4 x 6 05.38.66 79 Tension axle 96.46.69 1
10 Spacer 04.10.98 1
11 Brush lever 04.30.21 112 Hex. head screw M4 x 8 05.38.80 113 Locking plate 96.41.65 114 Cyl. pin ∅ 2.5 x 12 05.23.47 115 Slip clutch CCW 8mm 95.71.27 1
16 Pulley 15T (assy.) 93.05.54 117 Washer ∅ 17 x ∅ 8.4 x 1.6 mm 45.37.38 118 Washer ∅ 14 x ∅ 6.5 x 0.8 mm 43.02.47 119 Tensioner roller 95.13.19 120 Timing belt 04.16.21 1
21 Set screw M4 x 6 08.28.02 122 Pulley 04.14.23 123 Spring clip 10 - 14 mm 05.24.83 224 Spacer ∅ 15 x ∅ 10.4 x 5 mm 04.08.37 125 Gear 24T 93.05.25 2
26 Cyl. pin ∅ 2.5 x 16 05.23.46 427 Spacer ∅ 17 x ∅ 10.2 x 2 mm 04.10.94 128 Gear 35T 24.69.58 129 Spacer ∅ 15 x ∅ 10.4 x 3 mm 04.08.58 230 Washer ∅ 15 x ∅ 5.3 x 2 mm 45.37.50 2
31 Bearing locking plate 93.06.13 132 Pressure spring 95.31.00 233 Brake disc 95.30.94 434 Brake strip 95.30.97 135 Conductive bearing 10 mm 04.24.26 2
36 Round head screw M3 x 8 05.38.68 137 Guide strip 95.30.73 138 Fold roller (assy.) 98.95.20 139 Upper fold roller (assy.) 96.46.61 140 Guide plate 96.41.38 1
service manual SI 62
410.04-64 rev. 01.0 - 06/2004
Figure 23
54321
12
11
10
98
76
19
18
17
16
15
14
13
RH
LH
service manual SI 62
410.04-65rev. 01.0 - 06/2004
Figure 410.04-64
Remarks illustration Description Part code Quantity Remarkscode number number
Neopost, Hasler, Satas, Formax 1 Top cover 98.95.81 1Francotyp, blank - Top cover 98.95.82 1
2 Inside frame (upper unit) RH 98.91.62 13 Mounting plate top cover 98.92.31 14 Hex. head screw M4 x 8 05.38.80 1
5 Inside frame (upper unit) LH 98.91.63 16 Round head screw M4 x 35 45.43.20 17 Lock washer 5/32” 05.24.31 18 Mainboard 98.90.01 19 Dongle socket Note 1
10 Spacer ∅ 8 x ∅ 4 x 25 mm 04.08.83 111 Inside frame LH 98.91.36 112 PCB holder 93.08.07 513 Nut M4 45.19.02 314 Screw 5 x 14 98.91.83 4
15 Round head screw M3 x 10 98.91.82 316 Mounting plate display 98.91.65 117 Spacer 04.08.49 418 Rubber key pad 98.91.30 119 Display 98.90.03 1
Note 1: Dongle (2 station) 98.90.70 1Dongle OMR 98.90.71 1
service manual SI 62
410.04-66 rev. 01.0 - 06/2004