Spinjet 1000 Service Manual

Service guide March 2001 1

SpinJet 1000 Service Guide

Safety precautions SpinJet 1000 is intended for use on the large format printer HP DesignJet 1050C/1055CM (referred to as the printer) only. The in-structions for installation and operation of both printer and SpinJet 1000 must be followed. SpinJet is intended for permanent installation on the above mentioned printer type. Normal single-sided printing is possible without removing or tilting down the SpinJet 1000. SpinJet 1000 is intended for operation with installed top cover and mounted side covers. The operator may remove the top cover during a jam removal. Only specially trained personnel should carry out tasks for test or service purposes, requiring operation in otherwise open and/or dismounted condition. The routines of inspection and replacement of wear and spare parts must be followed. Always disconnect Power Mains before disconnecting cables and electrical parts. Connect SpinJet to Power Mains 100-120VAC or 200-240VAC, 50/60Hz, one phase and earth. Apply a Power Cord according to local Voltages and Plugs. A UL Listed Power Cord rated minimum 10A, 125V is provided with SpinJet in areas where this apply.


Table of Contents: 1. General .......................................................................................3 1.1 Functional test ............................................................................... 3 1.2 Fault finding ................................................................................... 3

Error codes ...................................................................................................3 Other trouble shooting ....................................................................................4

2. Wear and Spare Part replacement procedures ..................................8 2.1 General ......................................................................................... 8 2.2 Covers .......................................................................................... 9

5550 112 Cover 1 ........................................................................................9 5550 034 Assy, Cover 3 w/badge ...................................................................9 5550 035 Assy, Cover 2 w/keypad ..................................................................9

2.3 Drive and sensor components......................................................... 10 5551 004 Timing belt...................................................................................10 5551 066 Timing belt...................................................................................10 5550 005 Assy, motor w/pulley and connector ................................................11 5550 007 Assy, sensor/connector (PS01) ......................................................12 5551 001 Photo sensor (PS02) ....................................................................13 5551 001 Photo sensor (PS03) ....................................................................13 5550 026 Assy, harness #6 connector PCB to PS02-03.................................14 5551 062 Photo sensor left (PS04)...............................................................14 5551 063 Photo sensor right (PS05).............................................................14 5550 028 Assy, harness #10 connector PCB to PS04-05...............................14

2.4 Control system components........................................................... 15 5551 073 Fuse ...........................................................................................15 5551 088 Fuse holder cap............................................................................15 5550 032 Assy, control system ....................................................................15 5550 048 PIC, programmed .........................................................................15 5550 197 Connector PCB............................................................................16 5550 027 Assy, harness #7 connector PCB to keypad ....................................16 5550 025 Assy, harness #5 connector PCB to motor 2 or 3 ...........................16 5550 038 Assy, harness #4 and #11 in supporting arm. .................................16 5550 030 Assy, harness #12 RS232 printer communication............................17

2.5 Mechanical components ................................................................. 17 5551 018 Gas spring...................................................................................17 5551 019 Bumper.......................................................................................17 5550 200 Bushing 4....................................................................................18 5550 166 Guide 5.......................................................................................18 5550 021 Assy, Guide 6 ..............................................................................18 5550 196 Tool 1.........................................................................................18 5550 186 Flap ............................................................................................18 5550 199 Foil .............................................................................................19 5551 055 Tape...........................................................................................19 5551 056 Tape...........................................................................................19 5551 023 Spring.........................................................................................19 5550 174 Retainer 1...................................................................................19 5550 008 Pulley with clutch ..........................................................................19 5550 181 Encoder ......................................................................................20 1453 007 Bearing (on shafts) .......................................................................20 5550 020 Assy, hub with set screws (upper shaft) ..........................................20 5550 020 Assy, hub with set screws (lower shaft) ...........................................21 1453 007 Bearing (inside roller).....................................................................22 5550 011 Pulley with clutch ..........................................................................23 5550 055 Assy, Standoff with vibration damper .............................................23 5550 019 Boom guide with standoffs.............................................................23 5550 212 Spring guide 1 .............................................................................23 5550 036 Assy, Drum with spring, right ........................................................24 5550 037 Assy, Drum with spring, left ..........................................................24 1453 013 Bearing .......................................................................................25 5550 014 Brake with clutch..........................................................................26 5550 195 Bushing 2....................................................................................26 5550 208 Bushing 5....................................................................................26 5550 047 Assy, foot extension set................................................................26

3. Wear and Spare Parts list ...........................................................27


1. General

For information on installation procedure: Please see SpinJet Installation Guide. For information on specifications, normal use and operation: Please see SpinJet Operators manual.

1.1 Functional test In order to establish the existence of a possible problem and later the effect of the corrective action taken, test the SpinJet as follows: Connect the SpinJet control box to a power outlet. Switch the box on with the rocker switch. A red light in the button indicates that the control box is on. Switch on the SpinJet by pressing the power button of the SpinJet keyboard. Verify that the motors initialise and bring the system into the Single state. Press the mode button. Verify that the system switches to the Double state and raises the flipper gate. Install a SpinJet approved paper roll according to the user guide. Run the test jobs of the software supplied with the product. Verify that both sides are printed and the required front to back match is achieved. If the match is inadequate, repeat the procedure of loosening the four screws securing the printer to the printer base, moving the printer slightly on its base and tightening the four screws again. Repeat until a satisfactory result is achieved.

1.2 Fault finding

Error codes

Error code

Occurs when Possible causes

Error01 Medium sensor on when leaving OFF state

Blocking object Attenuator offset or rotated relative to light emitter Emitter defective Receiver defective Sensor harness defective Harness #11 defective


Error code

Occurs when Possible causes

Error02 Gate sensor not on in time

Motor 2 defective Motor 2 harness #5 defective Belt defective Sensor defective Sensor harness #6 defective Harness #4 or #11 defective

Error03 Gate sensor not off in time

Sensor defective Sensor harness defective Harness #4 or #11 defective

Error04 Boom sensor not on in time

Motor 3 defective Motor 3 harness #5 defective Belt defective Sensor defective Sensor harness #6 defective Harness #4 or #11 defective

Error05 Boom sensor not off in time

Motor 3 defective Motor 3 harness #5 defective Belt defective One way clutch defective Sensor defective Sensor harness #6 defective Harness #4 or #11 defective

Error06 Paper feed encoder does not reach preset count value in time

Sensor (right or left) defective Sensor harness #10 defective Harness #4 or #11 defective Motor 1 defective Belt defective

Other trouble shooting

Symptoms Possible causes Remedies No light in control box switch

Melted main fuse Replace fuse at inlet module

Harness #11 defective

Replace None of the LEDs are lit in the SpinJet keypad and Light in control box switch

Control box component failure

Replace control box

SpinJet does not respond to the signal from the printer to go into double mode

Harness #12 defective Replace


Symptoms Possible causes Remedies The guide system (leading to the sensor light line) is damaged or has a burr, which obstructs the paper path

Find and remove burr/damage

Roller/tire system has too much friction or resistance to rotate

Check bearings or possible interferences

Medium does not reach paper sensor Gate closes too tight on

Guide 2 or The metal flag on the right end of the gate is bent

Straighten long leg of the flag

Boom does not maintain proper loop shape of the sheet during the first side printing and Motor 3 runs

Suspension spring(s) is damaged thus producing friction in boom guides

Replace spring(s)

Boom suspension springs curls during first side printing

One way clutch defective Replace pulley/clutch assembly of spring drum shaft

One way clutch defective Replace pulley/clutch assembly of feed shaft

Sheet dropped by SpinJet before being fed into printer

Coil spring holding central roller shaft disengaged/lost

Reinstall/replace

Paper does not feed into printer and Motor does not try to feed and No error signal

Distance between right and left encoder sensor too long

Loosen, hold together and fasten

Harness #4 defective

Replace Paper does not feed into printer and Motor does not try to feed and Error code 06 displayed

Motor 1 defective Replace


Paper does not feed into printer and Motor does try to feed and Tires do not run and Error code 06 displayed

Belt defective Replace


Symptoms Possible causes Remedies Sheet lead edge caught by notches of Guide 1


Damage to foil on Guide 2


Faulty position of foil on Guide 2

Paper does not feed into printer and Motor and tires do try to feed

Tires worn to too small diameter

Replace hub/tire assembly (8 pcs.)

Front unit too far away from printer

Check and correct position of the two rubber bumpers defining the distance

Sheet does not reach blue line

Tires worn to too small diameter


Sheet overshoots blue line by small amount

Tire surface glazed or contaminated (loss of friction)


Encoder sensor (right or left) defective

Replace

Encoder sensor harness #10 defective

Replace

Sheet overshoots blue line by approximately 50mm

Harness #11 defective Replace Printer does not respond to signal from SpinJet to go into sheet mode

Harness #12 defective Replace

Sheet pulled out of printer again after printer vacuum is applied


Printer unable to pull in sheet from SpinJet after printer vacuum is applied

Printer vacuum too low Check printer vacuum level and vacuum system seals

Insufficient pressure from SpinJet against printer platen and The last part of the tilting to the lower position achieved by gravity (without pushing)

Loss of pressure in gas spring(s)

Identify spring(s), which does not produce 500N and replace

Noisy drives Wrong belt tension Readjust belt tension according to replacement procedures for 5551 004 and 066 in section 2.3.


Where possible, verify the hypothesis regarding the cause of an experienced problem by trying to replace the suspect part or system. Make only one replacement between these tests and go back to the originally fitted part or system, when there is no effect of the replacement. All sensors are using an optical principle, where the effect is that of a light path being intersected by a moving part or by the medium. All sensors are equipped with monitoring LEDs with the following functions:

PS01: Green LED on means that the signal is stable and unambiguous. Red/orange LED on means light path is cut by an object (dark).

PS02-05: A red LED means, that the light path is not cut by an

object (opposite of dark).

These functions serve to help identifying certain sensor related faults before trying to replace the sensor itself.


2. Wear and Spare Part replacement procedures

2.1 General

Replacement procedures require that the SpinJet is mounted on a printer or supported similarly. In general replacements require covers to be removed first.

Further for general reference, Guide 2 and Guide 5 are identified in picture below.

In order to maintain internal accuracy of the unit, the screws of Beam 1 and Guide 1 should never be loosened.

Recommended tools: Torx screwdrivers T10, T15

and T20 T25 (provided with HP

Printer) Straight blade screwdrivers

(small sizes) Thin blade knife Pair of pliers (pointed) Soft head hammer M5 screw, length 12 mm

min. (provided with the SpinJet)

PIC extractor Antistatic wristband

Guide 1

Beam 1

Cover 1

Cover 3

Cover 2

Guide 5

Guide 2


2.2 Covers

5550 112 Cover 1

Release at lower studs first by gently pulling outwards and lift off at upper studs. Install in reverse order.

5550 034 Assy, Cover 3 w/badge

5550 035 Assy, Cover 2 w/keypad

The side covers are fastened with 3 screws each (see picture). Remove Cover 1 to get access to the two upper screws.

Cover 3 comes with the badge and Cover 2 with the keypad.

5550 027, Assembly, harness #7, connector PCB to keypad (not included in 5550 035) must be disconnected from the keypad in order to allow Cover 2 to be put aside. Note the little orientation tab of the connector when refitting.

Take care to fit harnesses well inside when installing covers.

Lower stud inside side plate

Upper stud inside side plate

Cover 1

Cover 3

Inside of keypad

Tail of 5550 027 (orientation tab indi-cated by the arrow)

Cover 2

3 screws


2.3 Drive and sensor components

5551 004 Timing belt

5551 066 Timing belt

WARNING! Always support and lower the boom (picture) by hand when loosening and removing timing belt of motor 3.

Remember to loosen the 3 motor standoff screws (picture) before replacement. Reapply correct timing belt tension according to below procedures. Motor 1 and 2 Adjustment of timing belt 5551 004: With the motor turned off and all 3 motor standoff screws loosened apply a load of 2N near the tip of the screwdriver engaging the TOP screw and tighten screw (picture). Then tighten the 2 other screws. The load can be provided by a spring balance or by hanging a 200g mass load (e.g. a stack of sheets) on the screwdriver. Make sure the belt is not transmitting torque during the procedure.

55551 066 (motor 3)

55551 004 (motor 1+2)

55551 066 (motor 3)

55551 004 (motor 1+2)

Load 2N (200 g)

Motor standoff screw

Lowered boom


Motor 3 Adjustment of timing belt 5551 066: Make sure the belt is not transmitting torque during the procedure (lower the Boom to the bottom position). With the motor turned off loosen all 3 motor standoff screws (inside the side plate). Move the unit until the timing belt has no preload and minimum slack (picture) and tighten the screws.

Test the tension by turning on the SpinJet, switch it to the Double mode and intersect the beam of PS01. Motor 3 will now lower the boom until the Reset-button is activated. Too much tension gives more noise and possibly stalling motor during lowering. Too much slack will cause the belt to disengage the teeth of the motor pulley at a slight load of the Boom during raising. Repeat the positioning if required.

5550 005 Assy, motor w/pulley and connector

Motor 1, 2 and 3 are identical.

Motor with pulley and harness

Timing belt 5551 066 (motor 3) with appropriate slack

Timing belt 5551 066 (motor 3) with too much slack.


To disconnect motor 2 or 3 (left side of unit) first disconnect motor harness at connector PCB (right side), then pull the harness just enough to gain access to the connectors. Make sure to lower boom before removing timing belt on motor 3.

Loosen 3 screws on the motor flange and remove the timing belt. Replace motor, tighten 3 screws on motor flange and reconnect motor harnesses. Adjust timing belt tension as described in previous section.

5550 007 Assy, sensor/connector (PS01)

Disconnect assy from the connector PCB, loosen screws of emitter and receiver and remove the hole grommets and the assy. Reassemble in reverse order. Make sure to position holes (0.5 and 1) of sensitivity attenuators according to above picture.

Motor flange screw

Motor 2

Motor 3

Hole 0.5 mm

Receiver

Unscrew this side

Emitter

Hole 1 mm


5551 001 Photo sensor (PS02)

Dismount Guides 2 and Guide 5 as well as Console 2 (picture). Dismounting of the boom shaft pulley on the left side is required. Refer to section 5550 008 (pulley) and 5550 066.

Swing down Guide 4, loosen, remove and disconnect PS02. Reassemble in reverse order. Make sure to adjust to correct timing belt tension as previously described.

5551 001 Photo sensor (PS03)

Lower boom by hand and dismount the boom guide. Loosen and remove PS03 with its pillar. Disconnect and replace PS03. Reassemble in reverse order.

PS03. Screws of pillar are outside side plate.

PS 02

Console 2

PS 02 located inside

Guide 4

Boom guide


5550 026 Assy, harness #6 connector PCB to PS02-03

Disassemble PS02 or 03 as described in the previous sections. Unscrew connector PCB, disconnect harness and withdraw it through the side plate. Reassemble in reverse order. Make sure to reconnect EMC ground straps with the same connector board securing screw.

5551 062 Photo sensor left (PS04)

5551 063 Photo sensor right (PS05)

5550 028 Assy, harness #10 connector PCB to PS04-05

Replacement of encoder sensors PS04 and 05 requires removing of the sensor fastening screws. Common harness #10 is plugged into sensor. It is easier to disconnect the connector from the sensor, when the sensor is removed from the pillar. Important: Keep the two sensors in close contact with each other when re-installing. To replace harness, first loosen screws of the connector PCB. Make sure to reconnect EMC ground straps when reassembling.

PS04

PS05

Harness #6 (2 pcs.)


2.4 Control system components

5551 073 Fuse

5551 088 Fuse holder cap

Turn fuse cap with screwdriver and remove fuse and cap. Replace with fuse rated 250V 3.15A T (5 x 20 mm) only!

5550 032 Assy, control system

Disconnect all harnesses before removal. Control box is fastened to printer by 2 screws below box. Reconnect as described in installation guide (male/female coding makes it impossible to interchange the two 15-pin connectors).

5550 048 PIC, programmed Component safety precautions Handling:

Avoid touching the legs, which are susceptible to static electricity

Keep the legs mutually grounded with conductive material for storing/shipping

Exchange: Note the position of the half-circle notch on the body of the PIC: It should be pointing downwards in the control box when mounted on the printer.

Before replacement switch off power completely by removing the supply cord. Replace the PIC using a PIC extractor (tool) as shown in picture. Especially if tool is unavailable, take care to lever out and install the PIC as parallel as possible, thus avoiding bending of the legs.

Fuse holder

PIC, programmed

Take hold of both ends with the PIC extractor


5550 197 Connector PCB Replace connector PCB by loosening it from the 2 standoffs and disconnect all harnesses (picture below). Make sure to reconnect EMC ground strap from harness #4 and #11 with same connector board securing screw when reassembling.

5550 027 Assy, harness #7 connector PCB to keypad

Dismount connector PCB and replace harness. The keypad is part of the cover spare part (5550 035).

5550 025 Assy, harness #5 connector PCB to motor 2 or 3

Dismount connector PCB and disconnect harness #5. Withdraw it through the beam and disconnect at motor end (connectors are

located inside beam when assembled). Reassemble in reverse order.

5550 038 Assy, harness #4 and #11 in supporting arm.

Assembly comprises assembled pillar, console and gas spring with motor and signal harnesses: 5550 024 Assy, harness #4

main PCB to connector PCB, motor

5550 029 Assy, harness #11 main PCB to connector PCB, signal

Replacement requires removal of the entire mechanical unit. Disconnect harnesses at control box and detach them from the an-chors on the clamp.

Connector PCB

Harness #5 (2 pcs.)

Harness #4 and #11 strapped on clamp.

Supporting arm assy

Location of screws (4 pcs. T20)


Remove the 4 screws holding the SpinJet to the clamps (picture) and lift off the unit. Dismount connector PCB, disconnect harnesses and unscrew supporting arm assembly from side plate. Reassemble in reverse order, adjust and test the unit according to section 4 and 6 of the Installation Guide.

5550 030 Assy, harness #12 RS232 printer communication

Replacement follows directly from the picture. Assure that both SpinJet and Printer are turned off during replacement.

2.5 Mechanical compo-nents

5551 018 Gas spring

Replace one gas spring at a time only. Keep SpinJet in upright position and release retainers at both ends. Depress gas spring slightly with a cramp/clamp to unload the bearing. Reassemble in reverse order. Caution: Depressing gas spring requires a force of 500 Newton!

5551 019 Bumper

Support at printer front (2 pcs.)

Depress ends with clamp or vice.

Harness #12


Two bumpers are located on the unit at points of contact with the printer front and one at the gate. Unscrew and reinstall bumpers by hand.

5550 200 Bushing 4

5550 166 Guide 5

See picture for replacement.

5550 021 Assy, Guide 6

5550 196 Tool 1 Guide 6 is located on lower edge of the printer window. The spare part comes supported by a wooden installation rail. Keep Guide 6 in the rail during handling. Tool 1 is used for control of the gap under the guide.

For information on installation procedure: Please see SpinJet Installation Guide.

5550 186 Flap

The transparent flap, supplied with an adhesive strip, is located on the inside of the gate. Replace flap by gently pulling it off, cleaning gate with ethanol and apply new flap. Assure flap protrudes from gate as shown, is aligned with the flag at the right end and is firmly pressed to the surface of the gate.

Flap must protrude 11.81.5 mm from gate Flag

Gate

Guide 5

Bushing 4

Adhesive strip

Installation rail

Guide 6


5550 199 Foil

The foil is located on Guide 4, where the sheet exits the unit. Spare part is supplied with an adhesive strip.

Replace foil by gently pulling it off, cleaning guide with ethanol and apply new foil as specified on picture.

5551 055 Tape

5551 056 Tape

5551 055 is a common 19 mm 3M Scotch Magic Tape and is not supplied as a spare part. 5551 056 is supplied to a pre-cut length.

For information on installation procedure: Please see SpinJet Installation Guide.

5551 023 Spring Springs are located at both roller ends (see next picture).

Important: Do not remove or reinstall springs by grabbing the body of the spring, as this may damage the preload (no visible damage!) Replace by gently lifting the spring eyelet off the stud and the shaft end, using a pair of pliers (pointed). Roller is retained by clearance holes in side plates.

5550 174 Retainer 1 The press fit retainers are located on the shafts for the one way clutches, one on the right side (see next picture) and two on the left side of unit. Pull off with an M5-screw and reinstall by gently tapping on the end of the retainer.

5550 008 Pulley with clutch

Foil

Not to exceed end edge

Press the adhesive strip firmly on

Foil must protrude 9.10.5 mm from Guide 4

5551 055

5551 056

Spring

Retainer 1 M5-hole in center

5550 008


This pulley is located on the paper feed shaft end close to motor 1. Remove retainer and timing belt as described in previous sections. Replace pulley, reinstall retainer and timing belt and readjust timing belt tension as described in previous section.

5550 181 Encoder

Remove sensors PS04 and PS05 (refer to earlier section). If only the disc needs replacement, slide off the retainer and the encoder using a thin blade and thin screwdrivers. Press on new encoder disc and retainer and reinstall sensors. If the assembly including the hub is to be removed, see the following.

1453 007 Bearing (on shafts)

Dismount springs from roller ends (previously described under 5551023).

To get access to the upper shaft, first remove encoder unit located on right side plate. Insert two screwdrivers in the groove of the encoder hub (picture) and lever off the encoder disc assembly (with hub). To get access to the lower shaft, first remove the pulley on the right shaft end (refer to earlier section, 5550 008). Also remove pulley 4 on the roller shaft (picture above) in order to get access to the screws of Housing 2. Loosen and remove Housing 2 and/or 3 with bearing from shaft end and side plate. Slide bearing out of Housing. Reinstall in reverse order.

5550 020 Assy, hub with set screws (upper shaft)

Bearing

Housing 3

Housing 2

Shaft 8

Roller end

Pulley 4

Hub Encoder

Encoder

PS04 + 05


Remove the photo sensor from its location in order to protect it. Remove springs, encoder unit and bearing housings (refer to pre-vious sections).

Take out shaft and replace 4 hubs. Make sure to get the setscrews positioned in the lo-cating bores (top of screw flush with surface of hub when tightened). Reinstall shaft, bearing housings, encoder unit and photo sensor in reverse order (refer to previous sections).

5550 020 Assy, hub with set screws (lower shaft)

Remove the timing belt and pulley (refer to earlier section). Remove two Housing 2, including bearings (refer to earlier section). Take out shaft and replace 4 hubs (refer to previous section). Reinstall shaft, bearing housings, spring, pulley and timing belt. Make sure to readjust timing belt tension (refer to earlier sections).

Housing 3

Photo sensor

Locating bore

Pulley 5550 008

Motor 1


1453 007 Bearing (inside roller)

Remove Guide 5 and Guide 2 located on top of unit. Manually lower the boom by turning the pulley. Make sure to prevent a free fall of the boom. Remove boom drive pulley (refer to following section on this).

Position drum with flat pointing towards roller. Remove boom guides (refer to following section), sensor PS01 (upper part) and sensor PS03.

Remove springs at roller ends and remove retaining ring (picture) with a twisting motion of a screwdriver. Slide roller assembly towards the right side plate (where the retaining ring was removed) and take out the roller assembly (downwards).

Roller with internal bearings

Roller end

Boom spring drum

Flat of drum

Boom drive (pulley, timing belt, motor 3)

Fastening of spring

Lowered boom

Guide 2 and 5 removed

Retaining ring

Sleeve (gently tap on indicated face)

Bearing

Roller

Shaft


To replace bearing, remove retaining ring, pull shaft into roller and tap gently with shaft end on indicated face of sleeve. Push bearing out of sleeve. Reassemble in reverse order.

5550 011 Pulley with clutch

Manually lower the boom and remove timing belt (refer to timing belt section). Pull off the retainer (use an M5-screw) and slide off pulley. When reassembling refer to timing belt section regarding belt tension.

5550 055 Assy, Standoff with vibration damper

This assy comprises a set of standoffs with vibration dampers and 3 screws, ready for replacement or retrofit for motor 3.

Remember to lower the boom manually before replacement. Dismount and remount the vibration dampers by hand. Readjust timing belt tension as described in previous section.

5550 019 Boom guide with standoffs

5550 212 Spring guide 1

The Boom guides (2 pcs.) are located at both boom ends. The Spring Guide (5550 212) is located at the left end only (see above picture). The Spring guide does not appear on very early machines, but can be retro fitted. Provides added control of Spring during handling. Remove Guide 2 and Guide 5 located on the top of the unit. Manually lower the boom by tur-ning the pulley. Make sure to prevent a free fall of the boom.

3 motor standoff screws on inside of side plate

5550 011

5550 019

5550 212

Assembly at left boom end (view from below)

Screw M5x8

Standoff

Vibration damper

Reuse existing motor flange screw


To remove the left side assy remove boom drive pulley first (refer to above section).

Boom guide screws (2 pcs. each) are located on outside of side plates.

To remove the left side assy (including the Spring guide) slide at down the spring before pulling it apart. Reinstall in reverse order.

5550 036 Assy, Drum with spring, right

5550 037 Assy, Drum with spring, left

Manually lower boom to shown position by turning the pulley and dismount springs at boom ends. Make sure to let springs coil up gently and avoid exposing the springs to twisting or other type of high stress. Remove Guide 5 and Guide 2, pulley on left shaft end, boom guide with stand offs (2 pcs.) and PS03 (refer to previous sections).

Drum with spring (left) Guide 5 and 2 removed on picture

Screws for boom guide


Remove retaining rings on shaft ends. Slide shaft towards the left side plate, tap gently on the bearing sleeve to loosen it from the side plate and ease out the shaft with spring drums.

To release the drum from the shaft remove the retaining ring, slide the drum sideways and then pull out the pin. When reassembling remember to position left and right drum in the correct sides, handle spring rolls with care and refer to timing belt section regarding belt tension.

1453 013 Bearing Bearings are located on shaft with spring drums and can be replaced when shaft is removed (refer to previous section). Remove right side bearing with sleeve, too, and slide the bearings out of the sleeves.

Bearing 1453 013 located in sleeve 2

Retaining ring (left side)

Retaining ring (right side)

Bearing 1453 013 located in sleeve 2

Drum

Retaining ring

Pin


5550 014 Brake with clutch

Lower boom manually and remove timing belt and retainer as described in earlier sections. Replace brake/clutch assembly. Reinstall retainer and timing belt. Refer to timing belt section regarding belt tension.

5550 195 Bushing 2

5550 208 Bushing 5 Bushing 2 and 5 provide fitting of 3 paper rolls on two types of 2 HP Design Jet roll spindle assembly. For information on selection and installation procedure: Please see SpinJet Operators manual.

5550 047 Assy, foot extension set

On printers provided with mounting holes on the side of the printer legs (indicated on picture) the set of two-foot extensions can be installed. Install the foot extension set with pins and spring cotters and turn the adjustment screws to stabilize the printer.

Brake with clutch

Location of foot extension

Adjust-ment screw

Pins and spring cotters

Service Guide March 2001 27

3. Wear and Spare Parts list

Identification Title Comment Quantity / pcs Remarks Net Weight Net Dimension

1453 007 Bearing Roller and feed shafts 6 Spare part < 50 g Tiny 5550 008 Assy, pulley with clutch 1 Spare part < 50 g Tiny 5550 011 Assy, pulley with clutch 1 Spare part < 100 g Tiny 5550 014 Assy, brake with clutch 1 Spare part < 50 g Tiny 5550 019 Assy, boomguide with standoffs Boom dock, spring guide 2 Spare part < 50 g Tiny 5550 021 Assy, Guide 6 Window-mounted guide 1 Spare part < 500 g 20*45*950 mm 5550 025 Assy, harness #5 connector PCB to motor 2 or 3 In tube cross member 2 Spare part N/A 8*900 mm 5550 026 Assy, harness #6 connector PCB to PS02-03 2 Spare part < 50 g Tiny 5550 027 Assy, harness #7 connector PCB to keypad 1 Spare part < 50 g Tiny 5550 028 Assy, harness #10 connector PCB to PS04-05 1 Spare part < 50 g Tiny 5550 030 Assy, harness #12 RS232 printer communication Serial cable 1 Spare part < 100 g Tiny 5550 032 Assy, controlsystem 1 Spare part < 2000 g 190*130*65 mm 5550 034 Assy, cover 3 with badge Left cover 1 Spare part < 300 g 270*160*100 mm 5550 035 Assy, cover 2 with keypad Right cover 1 Spare part < 300 g 270*160*100 mm 5550 038 Assy, harness #4+#11 in supporting arm 1 Spare part < 2000 g 300*300*100 mm 5550 040 Connector PCB In right cover 1 Spare part < 100 g 100*50*25 mm 5550 047 Assy, foot extension set 1 Spare part < 2000 g 160*100*200 mm 5550 048 PIC, programmed On main PCB 1 Spare part < 20 g Tiny 5550 050 Assy, Standoff with vibration damper 3 standoffs 1 Spare part < 50 g Tiny 5550 112 Cover 1 Main center cover 1 Spare part < 1600 g 170*100*950 mm 5550 166 Guide 5 Toothed guide at front 1 Spare part < 500 g 20*45*950 mm 5550 174 Retainer 1 For one-way clutches 3 Spare part < 20 g Tiny 5550 181 Encoder 1 Spare part < 20 g Tiny 5550 186 Flap Gate mounted 1 Spare part < 100 g Roll 5550 195 Bushing 2 3" core adaptor, old style 2 Spare part < 500 g 100*100*100 mm 5550 196 Tool 1 To check Guide 6 installation 1 Spare part < 50 g Tiny 5550 199 Foil Guide 4 mounted 1 Spare part < 100 g Roll

Service Guide March 2001 28

Identification Title Comment Quantity / pcs Remarks Net Weight Net Dimension 5550 200 Bushing 4 Supports Guide 5 2 Spare part < 20 g Tiny 5550 208 Bushing 5 3" core adaptor, new style 2 Spare part < 500 g 100*100*100 mm 5550 212 Spring guide Mounted on left side Boomguide 1 Spare part < 100 g Tiny 5551 018 Gas spring On mounting consoles 2 Spare part < 500 g 250*20*20 mm 5551 023 Spring Nip tension 2 Spare part < 20 g Tiny 5551 073 Fuse 1 Spare part < 20 g Tiny 5551 088 Fuse holder cap 1 Spare part < 50 g Tiny 5551 093 Power Supply Cord UL/CSA 1 Spare part < 300 g 250*70*50 mm 5551 096 Power Supply Cord European 1 Spare part < 300 g 250*70*50 mm 5551 097 Power Supply Cord UK 1 Spare part < 300 g 250*70*50 mm 5551 099 Power Supply Cord DK IT-type 1 Spare part < 300 g 250*70*50 mm 5551 100 Power Supply Cord South Africa 1 Spare part < 300 g 250*70*50 mm 5551 101 Power Supply Cord Italy 1 Spare part < 300 g 250*70*50 mm 5551 102 Power Supply Cord Australia 1 Spare part < 300 g 250*70*50 mm 5551 103 Power Supply Cord Switzerland 1 Spare part < 300 g 250*70*50 mm 5551 104 Power Supply Cord Israel 1 Spare part < 300 g 250*70*50 mm 5550 005 Assy, motor w/pulley, conn. Common 3 Wear part < 300 g 70*70*70 mm 5550 007 Assy, sensor/connector Paper sensor 1 Wear part < 20 g Tiny 5550 020 Assy, Hub with set screw Rubber wheel 8 Wear part < 50 g Tiny 1453 013 Bearing Boom drive shaft 2 Wear / Spare part < 20 g Tiny 5550 036 Assy, Drum with spring, right 1 Wear / Spare part < 100 g 30*50*20 mm 5550 037 Assy, Drum with spring, left 1 Wear / Spare part < 100 g 30*50*20 mm 5551 001 Photosensor Gate / Boom 2 Wear / Spare part < 20 g Tiny 5551 004 Timing belt Short timing belt 2 Wear / Spare part < 20 g Tiny 5551 019 Bumper 3 Wear / Spare part < 20 g Tiny 5551 062 Photosensor left Feed shaft encoder 1 Wear / Spare part < 20 g Tiny 5551 063 Photosensor right Feed shaft encoder 1 Wear / Spare part < 20 g Tiny 5551 066 Timing belt Long timing belt 1 Wear / Spare part < 20 g Tiny

Spinjet 1000 Service Manual

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