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Francotyp-Postalia FPI 5000 I Service Manual

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FPi 5000
Inserting System
FPI 5000 I
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Summary of Contents for Francotyp-Postalia FPI 5000 I

  • Page 1 FPi 5000 Inserting System FPI 5000 I FPI 5000 C...
  • Page 2 FPI 5000 I FPI 5000 Inserter rev. 01.0 - 01/2002...
  • Page 3 FPI 5000 I Contents Section Page General 510.00-1 Process description 510.01-1 Mechanical description 510.02-1 Electrical description 510.03-1 Parts list 510.04-1 Fault finding 510.05-1 rev. 01.0 - 01/2002...
  • Page 4 FPI 5000 I General rev. 01.0 - 01/2002 510.00-1...
  • Page 5 FPI 5000 I rev. 01.0 - 01/2002 510.00-2...

  • Page 6: Table Of Contents

    FPI 5000 I Contents Section Page Function Specifications Machine specifications Envelope and paper insert specifications Preparing the machine for use Unpacking Unpacking instruction Preventive maintenance rev. 01.0 - 01/2002 510.00-3...
  • Page 7 FPI 5000 I rev. 01.0 - 01/2002 510.00-4...
  • Page 8 FPI 5000 I 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.

  • Page 9: Function

    FPI 5000 I Function The FPI 5000 I inserts documents from the upstream feeding device FPI 5000 C into envelopes and the seals and stacks the envelopes. General note. This document describes the inserter FPI 5000 I, the 110 V/60 Hz version, the 230 V/50 Hz version and the 100 V/50 Hz version.

  • Page 10: Specifications

    FPI 5000 I Specifications Machine specifications Model :FPI 5000 I Type : inserter module for medium office use. Overall Dimensions height : 405 mm (15.9 inch) width : 455 mm (17.9 inch) with side catch tray; depends on envelope size length : 650 mm (25.6 inch)

  • Page 11: Envelope And Paper Insert Specifications

    FPI 5000 I 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 60 g/m minimum size inches 1.25 3.14...

  • Page 12: Preparing The Machine For Use

    FPI 5000 I Preparing the machine for use First the machine must be unpacked. Then it must be mechanically and electrically hooked up with the FV-2A of which the paper processing configuration as a whole exists. After unpacking and installing, the machine is ready for use.

  • Page 13: Unpacking Instruction

    FPI 5000 I Unpacking instruction rev. 01.0 - 01/2002 510.00-10...

  • Page 14: Preventive Maintenance

    FPI 5000 I Preventive maintenance Recommended preventive maintenance checkpoints In the following it is assumed that if any unscheduled service call is less than a month prior to a preventive maintenance call, it will replace that latter. Ask how the machine has worked and use that information as a guide for checking the equipment.
  • Page 15 FPI 5000 I rev. 01.0 - 01/2002 510.00-12...
  • Page 16 FPI 5000 I Process description rev. 01.0 - 01/2002 510.01-1...
  • Page 17 FPI 5000 I rev. 01.0 - 01/2002 510.01-2...
  • Page 18 FPI 5000 I Contents Section Page Overview Some details Envelope transport Document input and insert Envelope ejecting, sealing and exiting rev. 01.0 - 01/2002 510.01-3...
  • Page 19 FPI 5000 I rev. 01.0 - 01/2002 510.01-4...
  • Page 20 FPI 5000 I Overview The FPI 5000 I inserter performs the following tasks: Transport an empty envelope from the hopper to the insert position. Transport a single document or document set from the FPI 5000 C to and in the opened envelope.
  • Page 21 FPI 5000 I rev. 01.0 - 01/2002 510.01-6...
  • Page 22 Once the envelope is on the insert table, the fingers solenoid So1 is activated. Five fingers are moved forward into the envelope. This is necessary to insert the document (set) in the envelope. The FPI 5000 I now orders the FPI 5000 C feed the document or document set to be inserted. This document (set) passes: three pairs of document rollers;...
  • Page 23 FPI 5000 I The insert is considered finished if and when document detector PH3 detects the trailing edge of the document (set). Then a number of actions take place: (a) clutch RPM1 is activated to release the flap; (b) solenoid So2 is shortly activated, resulting in the ejection roller in the loc moving down.
  • Page 24 FPI 5000 I Overview The FPI 5000 I inserter performs the following tasks: Transport an empty envelope from the hopper to the insert position. Transport a single document or document set from the FPI 5000 C to and in the opened envelope.
  • Page 25 FPI 5000 I rev. 01.0 - 01/2002 510.01-6...
  • Page 26 Once the envelope is on the insert table, the fingers solenoid So1 is activated. Five fingers are moved forward into the envelope. This is necessary to insert the document (set) in the envelope. The FPI 5000 I now orders the FPI 5000 C feed the document or document set to be inserted. This document (set) passes: three pairs of document rollers;...
  • Page 27 FPI 5000 I The insert is considered finished if and when document detector PH3 detects the trailing edge of the document (set). Then a number of actions take place: (a) clutch RPM1 is activated to release the flap; (b) solenoid So2 is shortly activated, resulting in the ejection roller in the loc moving down.

  • Page 28: Rev. 01.0

    FPI 5000 I Mechanical rev. 01.0 - 01/2002 510.02-1...
  • Page 29 FPI 5000 I rev. 01.0 - 01/2002 510.02-2...
  • Page 30 FPI 5000 I Contents Section Page Covers and plates Water tank RH side cover LH (hinged) side cover Electronics cover Cover plate Front cover plate Power supply cover Base cover 1.10 Transportation table 1.11 Front cover 1.12 Insert table 1.13...
  • Page 31 FPI 5000 I Envelope track 4.2.1 Rollers 4.2.2 Gears 4.2.3 Clutches Document feed Upper transportation rollers Lower transportation rollers Finger solenoid Covers and plates Drive mechanism 6.2.1 Main drive belt 6.2.2 Pulleys 6.2.3 Gears Document inserting 6.3.1 Rollers 6.3.2...
  • Page 32 FPI 5000 I Adjustments 10.1 Short chain 10.2 Long chain 10.3 Main drive belt 10.4 Microswitches 10.5 Solenoids 10.6 Joggers 10.7 Separation roller 10.8 Friction brake 10.9 Flapscraper 10.10 Lower insert rollers (transportation table) 10.11 Upper insert rollers (loc) rev.
  • Page 33 FPI 5000 I rev. 01.0 - 01/2002 510.02-6...
  • Page 34 FPI 5000 I General instructions Disconnect the mains supply before performing any maintenance. Warning The covers and microswitches are fitted by your protection. Do not operate the machine with any cover removed and with a microswitch cheated, or a hazard to health will exist.

  • Page 35: Covers And Plates

    FPI 5000 I Covers and plates Opening Refer to figure 1.1 Pull the blue locking lever on the left-hand side of the loc 10 upwards to release it. Lift the loc upwards and place it straight up in the vertical position.
  • Page 36 FPI 5000 I " & ' " & & % " ! ! figure 1.1 rev. 01.0 - 01/2002 510.02-9...

  • Page 37: Electronics Cover

    FPI 5000 I Electronics cover Removal Refer to figure 1.1 Slacken the two countersunk head screws 19 securing the electronics cover 12 on the front side. Remove the two round head screws 11 with washers securing the electronics cover on the rear side.

  • Page 38: Base Cover

    FPI 5000 I Base cover Removal Remove the water tank as described in paragraph “Water tank”. Refer to figure 1.1 Unhook the envelope slide 5 and withdraw it. Pull the envelope receiving tray 4 in the rear side direction and withdraw it.

  • Page 39: Front Cover

    FPI 5000 I 1.11 Front cover Removal Remove the RH side cover as described in paragraph “RH side cover”. Remove the power supply cover as described in paragraph “Power supply cover”. Refer to figure 1.2 Remove the two round head screws 6 with the washers 7.

  • Page 40: Feed Platform

    FPI 5000 I 1.13 Feed platform Remove the RH side cover as described in paragraph “RH side cover”. Open the LH (hinged) side cover as described in paragraph “LH (hinged) side cover)”. Removal Refer to figure 1.1 Unhook the envelope slide 5 and withdraw it.

  • Page 41: Electrical Components

    FPI 5000 I Electrical components Warning Beware of possible electrostatic discharge. Power supply unit Removal Remove the electronics cover as described in paragraph “Electronics cover” Remove the power supply cover as described in paragraph “Power supply cover”. Refer to figure 2.1...
  • Page 42 FPI 5000 I & " & " figure 2.1 rev. 01.0 - 01/2002 510.02-15...

  • Page 43: Main Drive Mechanism

    FPI 5000 I Main drive mechanism Remove the RH side cover as described in paragraph "RH side cover". Chains 3.1.1 Short chain Removal Refer to figure 3.1 Slacken the two hex. head screws 18 and release the chain tensioner 20. Take care not to loose the two plastic protection caps fitted on the threads of the two hex.
  • Page 44 FPI 5000 I " &  ! " & ' ! !$ !% " ! !! !" & figure 3.1 rev. 01.0 - 01/2002 510.02-17...

  • Page 45: Main Drive Belt

    FPI 5000 I Main drive belt Removal Remove the short chain as described in paragraph 3.1.1 "Short chain". Remove the clutch as described in the previous paragraph. Refer to figure 3.1 Slacken the two hex. head screws 10 and release the belt tensioner 29.
  • Page 46 FPI 5000 I '  & " # $ % " & " " "% "' "& " "! " # "" !& "# "$ !$ !# !" & figure 3.2 rev. 01.0 - 01/2002 510.02-19...

  • Page 47: Sprockets

    FPI 5000 I Sprockets 3.5.1 Sprockets (short chain) Remove the short chain as described in paragraph 3.1.1 "Short chain". Sprocket 15T (item 27) Removal Refer to figure 3.2 Slide the sprocket 27 off the belt tensioner 28. Take care of the washer 29.
  • Page 48 FPI 5000 I Slide the gear 45 off the axle. Support the axle 37 and tap out the tension pin 39. Slide the sprocket 38 off the axle. Sprocket 15T (item 42) Removal Refer to figure 3.2 Support the axle 1 and tap out the tension pin 41.

  • Page 49: Gears

    FPI 5000 I Sprocket 18T (item 12) Removal Refer to figure 3.2 Tap out the tension pin 11. Slide the sprocket 12 off the axle. Take care of the washer 10 and the spacer 9. Sprocket 15T (item 21)
  • Page 50 " &    "! ' & " & " ! !! " " " !& !"...
  • Page 51 FPI 5000 I Gear 28T (item 36) Removal Refer to figure 3.3 Remove the clamping ring 34 and the washer 35. Slide the gear 36 off the axle. Take care of the washer 37. Gear 15T (item 29)
  • Page 52 FPI 5000 I Gear 18T (item 6) Removal Refer to figure 3.3 Remove the spring clip 7. Slide the gear 6 off the roller axle. Gear 28T (item 5) Removal Refer to figure 3.3 Remove the clamping ring 9 and the washer 8.
  • Page 53 FPI 5000 I Gear 35T (item 7) Removal Remove the front cover as described in paragraph 1.11 "Front cover". Release the chain tensioner 20 as described in paragraph 3.1.1 "Short chain". Release the chain tensioner 1 as described in paragraph 3.1.2...

  • Page 54: Motor

    FPI 5000 I Motor Removal Remove the RH side cover as described in paragraph "RH side cover". Remove the power supply cover as described in paragraph "Power supply cover". Refer to figure 3.1 Slacken the two hex. head screws 10 and release the belt tensioner 29.

  • Page 55: Envelope Feed

    FPI 5000 I Envelope feed Hopper Remove the feed platform as described in paragraph 1.13 "Feed platform". 4.1.1 O-rings " & " & figure 4.1 Removal Refer to figure 4.1 Remove the two round head screws 2 and withdraw the gear cover 7.

  • Page 56: Rollers

    FPI 5000 I 4.1.2 Rollers Separation roller Note: Before removing the separation roller; first check the adjustment procedure as described in paragraph 10.7. Removal Refer to figure 4.1 Turn thumbweel 1 counterclockwise and set the separation gap to the maximum.
  • Page 57 '  " # $ % & '    ! # $ % & " " & !"...

  • Page 58: Envelope Track

    FPI 5000 I Envelope track 4.2.1 Rollers Remove the RH side cover as described in paragraph "RH side covers". Remove the LH (hinged) side cover as described in paragraph "LH (hinged) side cover". Remove the base cover as described in paragraph "Base cover".
  • Page 59 FPI 5000 I figure 4.3 rev. 01.0 - 01/2002 510.02-32...
  • Page 60 FPI 5000 I Third set of transportation rollers Ø 30 mm Removal Refer to figure 4.3 Slacken the set screw of the left-hand metal roller 30. Slide the left-hand metal roller off the axle 18. Push the left-hand transportation roller 28 inwards from the cyl. pin 29.
  • Page 61 FPI 5000 I Rubber roller Ø 31.7 mm Remove the cover plate as described in paragraph "Cover plate". Remove the transportation table as described in paragraph 1.10 "Transportation table". Remove the insert table as described in paragraph 1.12 "Insert table".

  • Page 62: Gears

    FPI 5000 I 4.2.2 Gears Remove the RH side cover as described in paragraph "RH side covers". Remove the LH (hinged) side cover as described in paragraph "LH (hinged) side cover". Remove the base cover as described in paragraph "Base cover".
  • Page 63 FPI 5000 I Gear 28T (item 25) and gear 19T (item 26) Removal Remove the gear 35T (item 12) as described previously. Refer to figure 4.2 Push the left-hand transportation roller 6 inwards from the cyl. pin 5.
  • Page 64 FPI 5000 I figure 4.5 rev. 01.0 - 01/2002 510.02-37...
  • Page 65 FPI 5000 I Gear 17T (item 5) Removal Withdraw the rubber roller as described in paragraph 4.2.1 "Rubber roller 31.7 mm". Refer to figure 4.5 Tap out the tension pin 4. Slide the gear 5 off the clutch shaft 21.

  • Page 66: Clutches

    FPI 5000 I Gear 15T (item 8) Removal Remove the rubber roller Ø 28 mm as described in paragraph 4.2.1 "Rollers". Refer to figure 4.4 Tap out the tension pin 14. Slide the bearing 11 and the washer 10 off the roller axle 7.

  • Page 67: Document Feed

    FPI 5000 I Document feed Remove the RH side cover as described in paragraph "RH side cover". Remove the front cover plate as described in paragraph "Front cover plate". Upper transportation rollers First set of upper transportation rollers Ø 36 mm "...
  • Page 68 FPI 5000 I Second set of upper transportation rollers Ø 36 mm Removal Refer to figure 5.1 Slacken the set screws of the two transportation rollers 5. Remove the spring clips 6 from both sides of the transportation axle 4.

  • Page 69: Lower Transportation Rollers

    FPI 5000 I Lower transportation rollers Remove the transportation table as described in paragraph 1.10 "Transportation table". Remove the front cover plate as described in paragraph "Front cover plate". First set of lower transportation rollers Ø 36 mm...
  • Page 70 FPI 5000 I Second pair of transportation rollers Ø 36 mm Removal Refer to figure 5.2 Push the left-hand transportation roller 14 inwards from the cyl. pin below. Remove the cyl. pin from the transportation axle 15. Remove the spring clips 11 from both sides of the transportation axle.

  • Page 71: Finger Solenoid

    FPI 5000 I Finger solenoid Open the loc as described in paragraph "Loc". Remove the RH side cover as described in paragraph "RH side cover". Removal " figure 5.3 Refer figure 5.3 Disconnect the wiring of the solenoid coil 3.

  • Page 72: Loc

    FPI 5000 I Covers and plates Loc cover Removal Refer to figure 6.1 Remove the two countersunk screws 15 securing the loc cover 14 on the front side. Remove the two round head screws 13 securing the loc on the rear side.

  • Page 73: Drive Mechanism

    FPI 5000 I Top cover Open the loc as described in paragraph “Loc”. Removal Refer to figure 6.1 Slacken the four round head screws 10 with washers securing the top cover 8 on the front side. Withdraw the top cover.

  • Page 74: Pulleys

    FPI 5000 I & ! " # " #   ' & " ! figure 6.2 6.2.2 Pulleys Pulley 16T (item 20) Removal Remove the front drive axle assembly as described in the previous paragraph. Refer to figure 6.2...

  • Page 75: Gears

    FPI 5000 I Pulley 14T (item 5) Removal Remove the main drive belt as described in the previous paragraph. Refer to figure 6.2 Slacken the set screw of the roller 1 and slide it off the drive axle 7.
  • Page 76 FPI 5000 I " # & !    " "  ' & figure 6.3 rev. 01.0 - 01/2002 510.02-49...

  • Page 77: Gears

    FPI 5000 I Set of upper insert rollers Ø 42.5 mm Removal Refer to figure 6.2 Remove the two round head screws 17 securing the bracket 16 and place the bracket aside. Refer to figure 6.3 Remove the round head screws 13, the washers 12 and the guides 11 from both sides of the axle 8.
  • Page 78 FPI 5000 I ! " % & '   ! " & " figure 6.4 Gear 15T (item 22) Removal Remove the gear 20T, item 8 as described in previously. Refer to figure 6.4 Remove the set screw and slide the roller 27 off the axle 18.
  • Page 79 FPI 5000 I Refer to figure 6.4 Tap out the tension pin 20. Slide the gear 21 off the axle. Replacement When retightening the set screw ensure that there is only a slight amount of axial play on the axle.

  • Page 80: Ejection Solenoid

    FPI 5000 I Gear 15T (item 7) Removal Remove the gear 20T, item 8 as described in paragraph 6.3.2 "Gears, gear 20T (item 8)". Refer to figure 6.5 Remove the pressure spring 14. Slacken the set screw of the roller 16 and slide it off the axle 13.

  • Page 81: Envelope Transport And Sealing

    FPI 5000 I Envelope transport and sealing 6.4.1 Rollers Second set of upper ejection rollers Ø 38 mm Remove the loc cover as described in paragraph “Covers and plates”. Open the loc as described in paragraph “Loc”. Removal Refer to figure 6.7...
  • Page 82 FPI 5000 I & '    ! " # $ " % $ & figure 6.7 rev. 01.0 - 01/2002 510.02-55...

  • Page 83: Solenoid

    FPI 5000 I Set of upper reverse rollers (non driven) Remove the top cover as described in paragraph “Covers and plates”. Removal "  ' & figure 6.8 Refer to figure 6.8 Remove the spring clips 8 and the washers 9 from both sides of the bracket 12.

  • Page 84: Envelope Transport

    FPI 5000 I Envelope transport Lower ejection rollers Remove insert table as described in paragraph 1.12 "Insert table". First set of lower ejection rollers Ø 30 mm Removal Remove the main drive belt as described in paragraph "Main drive belt".
  • Page 85 FPI 5000 I figure 7.1 rev. 01.0 - 01/2002 510.02-58...

  • Page 86: Transportation Rollers

    FPI 5000 I Transportation rollers Open the loc as described in paragraph "Loc". Open the LH hinged side cover as described in "LH (hinged) side cover". Set of sealing track transportation rollers Ø 30 mm Removal Remove the long chain as described in paragraph 3.1.2...

  • Page 87: Envelop Sealing And Ejection

    FPI 5000 I Envelop sealing and ejection Open the loc as described in paragraph "Loc". Remove the RH side cover as described in paragraph "RH side cover". Open the LH hinged side cover as described in "LH (hinged) side cover".
  • Page 88 FPI 5000 I figure 8.1 rev. 01.0 - 01/2002 510.02-61...

  • Page 89: Switches And Detectors

    FPI 5000 I Switches and detectors Microswitches 9.1.1 Loc microswitch Removal Remove the RH side cover as described in paragraph “RH side cover”. " figure 9.1 Refer to figure 9.1 Remove the round head screw 4 with washer securing the mounting bracket 6.

  • Page 90: Lh Side Cover Microswitch

    FPI 5000 I 9.1.2 LH side cover microswitch Removal Remove the power supply cover as described in paragraph “Power supply cover”. ! " # figure 9.2 Refer to figure 9.2 After removing the two round head screws 5 with the washers 4 and spacers 3 the microswitch 1 can be removed and disconnected.

  • Page 91: Flag Switch

    FPI 5000 I 9.1.3 Flag switch Removal Remove the rear cover as described in paragraph 1.14 “Rear cover”. " figure 9.3 Refer to figure 9.3 Remove the nut 1 securing the bracket 2 with the flag switch 3 to the envelope guide 4.

  • Page 92: Pulse Disc Detector

    FPI 5000 I Pulse disc detector Removal Remove the RH side cover as described in paragraph “RH side cover”. " figure 9.4 Refer to figure 9.4 Remove the countersunk screw 6 securing the pulse disc 4. Remove the pulse disc together with the two spacers 5. Cut the wire strap securing the wiring to the bracket 1 and disconnect the pulse disc detector 2.

  • Page 93: Document Thickness Detector

    FPI 5000 I Document thickness detector Removal Remove the electronics cover as described in paragraph “Electronics cover”. Open the loc as described in paragraph “Loc”. ! " figure 9.5 Refer to figure 9.5 Remove the lower round head screw 1 with washer.

  • Page 94: Envelope And Document Detectors

    FPI 5000 I Envelope and document detectors 9.4.1 Envelope detector Removal Transmitter (LED) Remove the base cover as described in paragraph “Base cover”. " & figure 9.6 Refer to figure 9.6 Pull the air hose from the transmitter 8.

  • Page 95: Flap Detector

    FPI 5000 I 9.4.2 Flap detector Removal Transmitter (LED) Remove the base cover as described in paragraph “Base cover”. " # & figure 9.7 Refer to figure 9.7 Slacken the nut 7 securing the bracket 8 to the envelope guide plate 2.

  • Page 96: Exit Detector

    FPI 5000 I 9.4.3 Exit detector Open the loc as described in paragraph “Loc”. Remove the RH side cover as described in "RH side cover". Open the LH (hinged) side cover as described in paragraph "LH (hinged) side cover".

  • Page 97: Document Detector

    FPI 5000 I 9.4.4 Document detector Removal Transmitter (LED) Remove the loc cover as described in paragraph “Covers and plates”. % $ # " figure 9.9 Refer to figure 9.9 Remove the pan head tapping screw 3 securing the transmitter 1 to the bracket 2.

  • Page 98: Adjustments

    FPI 5000 I Adjustments 10.1 Short chain 5 -10 mm (0.2 - 0.4 inch) figure 10.1 Refer to figure 10.1 The maximum movement of the chain at the indicated position is 5 - 10 mm (0.2 - 0.4 inch).

  • Page 99: Long Chain

    FPI 5000 I 10.2 Long chain 10 - 15 mm (0.4 - 0.6 inch) figure 10.2 Refer to figure 10.2 The maximum movement of the chain at the indicated position is 10 - 15 mm (0.4 - 0.6 inch).

  • Page 100: Main Drive Belt

    service manual SA-IFPI 5000 IM 10.3 Main drive belt 10 mm (0.4 inch) figure 10.3 Refer to figure 10.3 The maximum movement of the drive belt at the indicated position is 10 mm (0.4 inch). To adjust: Remove the RH side cover described in paragraph “RH side cover”.

  • Page 101: Microswitches

    FPI 5000 I 10.4 Microswitches Loc microswitch The loc microswitch is used to detect the opening of the loc and to stop the machine, as a safety precaution. The microswitch is actuated, via a lever, by the locking rod of the loc. The microswitch is working properly if it is actuated when the blue handle of the loc is pulled upwards.

  • Page 102: Solenoids

    FPI 5000 I 10.5 Solenoids Note: The adjustment procedure of the finger solenoid is used as an example, for the other solenoids the same procedure is applicable. Whenever as 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.

  • Page 103: Joggers

    FPI 5000 I 10.6 Joggers Irregular feeding of certain types of envelopes can be improved by adjustment of the joggers position. The joggers must be positioned equidistant from the feed roller, the distance depending on the width of the envelope used.

  • Page 104: Separation Roller

    FPI 5000 I 10.7 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: Remove the rear cover as described in paragraph 1.14...

  • Page 105: Friction Brake

    FPI 5000 I 10.8 Friction brake Remove the base cover as described in paragraph “Base cover”. 16 mm (0.63 inch) figure 10.8 Refer to figure 10.8 The friction brake is correctly adjusted when the distance between the inner faces of the two friction discs 3, i.e.

  • Page 106: Flapscraper

    FPI 5000 I Remove the base cover as described in paragraph “Base cover”. figure 10.9 Refer to figure 10.9 The flapscraper 3 must be positioned so that its lower edge is aligned with the lower edge of the envelope guide To adjust: Slacken the two hex.
  • Page 107 FPI 5000 I To ensure correct document transport, carry out the following check: Raise the loc to the vertical position as described in paragraph “Loc”. straight edge insert table transportation table lower insert roller figure 10.10 Refer to figure 10.10...

  • Page 108: Upper Insert Rollers (Loc)

    FPI 5000 I 10.11 Upper insert rollers (loc) " figure 10.11 Refer to figure 10.11 The upper insert rollers are mounted into a moveable cradle 3. The cradle is kept in the lowest position by two springs 4. Documents up to 1.5 mm (0.06 inch) thick are inserted under the pressure of the two springs but those in excess of 1.5 mm are also subjected to the pressure of the pressure springs 5.
  • Page 109 FPI 5000 I rev. 01.0 - 01/2002 510.02-82...
  • Page 110 FPI 5000 I Electrical rev. 01.0 - 01/2002 510.03-1...
  • Page 111 FPI 5000 I rev. 01.0 - 01/2002 510.03-2...
  • Page 112 FPI 5000 I Contents Section Page Preliminary note Electrical and electronic operation Settings Service software General The INSERTER service software 3.2.1 The menu SENSORS 3.2.2 The menu DFC 3.2.3 The menu ACTUATORS 3.2.4 The menu DISPLAY 3.2.5 The menu KEYBOARD 3.2.6...
  • Page 113 FPI 5000 I Index of Illustrations Figure 1.1 : Electrical/electronic IN-1C block diagram. Figure 1.2 : Overview of the IN-1C electrical and electronic circuits, including external connections and sensor/actuator connections. Figure 1.3 : The main board 94.80.01 electronics are divided into five sections.
  • Page 114 FPI 5000 I Index of Illustrations Figure 3.27 : The LOCALISATION menu. Figure 3.28 : The menu JOB SETTINGS. Figure 3.29 : The system output menu Figure 3.30 : The PAPER STOP menu. Figure 3.31 : The DOCUMENT OFFSET menu.
  • Page 115 FPI 5000 I rev. 01.0 - 01/2002 510.03-6...
  • Page 116 Preliminary note The FPI 5000 I is a dedicated vertical system inserter. It is an integrated part of the SA 5005 folding and inserting machine. The other integrated part of the SA 5005 system is the vertical feeding and folding unit FPI 5000 C.
  • Page 117 (keyboard, sensors) and output devices of the main board (display, actuators) are logically grouped. The upstream I²C communication of the FPI 5000 I is dedicated to the FPI 5000 C base unit. The latter communicates by I²C with one or more feeder units.
  • Page 118 FPI 5000 I Combined display/key circuit board The communication between the micro-controller on the main board and the combined display/key circuit board 95.70.72 (see figure 1.14, figure 1.15 figure 1.16) is based on the simulated I²C bus signals SCL_SIM and SDA_SIM, the databus signals AD0 through AD7, the read/write signals NRD and NWR, and the control signals DIS_1, DIS_2 and DIS_3.
  • Page 119 B5 and B2 of the FPI 5000 C system connector. This means that an opened cover on the FPI 5000 I or on the FPI 5000 C base unit interrupts or blocks the motor relay current.
  • Page 120 Software The FPI 5000 I software (in the Eprom 98.02.11) has a number of tasks: (a) process control; (b) user interface; (c) domestic tasks via the simulated I²C bus; (d) SCS communication with the FPI 5000 C and its attached feeder units, including messaging.
  • Page 121 FPI 5000 I Pulse Keyboard Display disc C (SCS) Upstream SA-IM500 Power supply Main board Mechanical drive So1 So4 Main motor Envelope transport clutch RPM1 figure 1.1: Electrical/electronic FPI 5000 I block diagram. rev. 01.0 - 01/2002 510.03-12...
  • Page 122 FPI 5000 I figure 1.2: Overview of the FPI 5000 I electrical and electronic circuits, including external connections and sensor/actuator connections. rev. 01.0 - 01/2002 510.03-13...
  • Page 123 FPI 5000 I Power Drivers Photo Syscon figure 1.3: The main board 94.80.01 electronics are divided into five sections. All items in a specific section are numbered from X00 onwards (X = 1...5). rev. 01.0 - 01/2002 510.03-14...
  • Page 124 FPI 5000 I figure 1.4: Main board 94.80.01 electronics (1): power supply. rev. 01.0 - 01/2002 510.03-15...
  • Page 125 service manual SA-IM500 figure 1.5: Main board 94.80.01 electronics (2):photocells and DFC unit. rev. 01.0 - 01/2002 510.03-16...
  • Page 126 FPI 5000 I figure 1.6: Main board 94.80.01 electronics (3): CPU circuitry. rev. 01.0 - 01/2002 510.03-17...
  • Page 127 FPI 5000 I figure 1.7: Main board 94.80.01 electronics (4): actuator drivers. rev. 01.0 - 01/2002 510.03-18...
  • Page 128 FPI 5000 I figure 1.8: Main board 94.80.01 electronics (5): system connections. rev. 01.0 - 01/2002 510.03-19...
  • Page 129 FPI 5000 I figure 1.9: Component layout of the main board 94.80.01 rev. 01.0 - 01/2002 510.03-20...
  • Page 130 FPI 5000 I MicroCan Clip for optional DS199x (Outer pin is J710 pin1) +5V_7 +5V_7 See DALLAS Automatic Identification Data Book, page132 D710 R703E 1N4148 J710 D711 1N4148 MicroCan Clip GND_7 GND_7 +5V_7 J700 MicroMatch12 +5V_7 U700 +5V_7...
  • Page 131 FPI 5000 I figure 1.11: Component layout of the FRAM board 95.74.55 1N4004 1N4004 250VAC 220-240V BLEEDER 100-120V figure 1.12: The motor relay board 12.16.21 electronics. rev. 01.0 - 01/2002 510.03-22...
  • Page 132 FPI 5000 I figure 1.13: Component layout of the motor relay board 12.16.21 POWER and LCD connections KEYS POWER KEYS figure 1.14: The combined display/key circuit board 95.70.72 electronics: overview. rev. 01.0 - 01/2002 510.03-23...
  • Page 133 FPI 5000 I figure 1.15: The combined display/key circuit board 95.70.72 electronics: power supplies and LCD control. rev. 01.0 - 01/2002 510.03-24...
  • Page 134 service manual SA-IM500 figure 1.16: The combined display/key circuit board 95.70.72 electronics: keys. rev. 01.0 - 01/2002 510.03-25...
  • Page 135 FPI 5000 I figure 1.17: Component layout of the combined display/key circuit board 95.70.72 rev. 01.0 - 01/2002 510.03-26...
  • Page 136 FPI 5000 I figure 1.18: The local electronics of the DFC unit 83.29.91 rev. 01.0 - 01/2002 510.03-27...
  • Page 137 FPI 5000 I Settings The FPI 5000 I doesn't need any electrical or electronic settings by service personnel. However, the correct operation of the DFC unit may be verified. This is the factory setting, which must be used after replacing the DFC unit.
  • Page 138 3.4. The service software for the FPI 5000 I/FPI 5000 C combination is divided into three groups: • An inserter part (currently the FPI 5000 I inserter), which will lead you to the menu of figure 3.5. • An FPI 5000 C part for the feeding and folding subsystem, which will lead you to the menu of figure 3.14.
  • Page 139 PAPER STOP SATION TESTS CODE TEST SET DEF ACTUATOR DOC. OFF- DISPLAY COLLATOR SETTINGS TESTS STOP SERVICE SECURE KEYBOARD COUNTERS TEST RESET DATA OFFSET figure 3.1: Flowchart of the FPI 5000 I/FPI 5000 C service software. rev. 01.0 - 01/2002 510.03-30...
  • Page 140 FPI 5000 I figure 3.2: The two-part MAIN MENU. 4351 figure 3.3: The menu JOB ACCESS. figure 3.4: The main SERVICE MENU. rev. 01.0 - 01/2002 510.03-31...
  • Page 141 Photocell condition In the FPI 5000 I and FPI 5000 C 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.
  • Page 142 (which may occur during operational use). In this menu the FPI 5000 I and FPI 5000 C covers are tested as well. The status of the loc cover and the status of the front cover of the FPI 5000 I are shown separately. "Extern" relates to both the folder cover and the vertical transport cover of the FPI 5000 C.
  • Page 143 FPI 5000 I VMS1or VMS2 figure 3.8: The menu IN DIGITAL INPUTS. 3.2.2 The menu DFC The DFC screen of figure 3.9 shows the real-time DFC output voltage, expressed in millivolt. If you place paper at the DFC sensor or manually move the DFC sensor, this is reflected by an increase in the measured and displayed DFC output voltage.
  • Page 144 In this menu (see figure 3.10) the correct operation of the four actuators of the FPI 5000 I can be verified. If the test key is pressed, the selected actuator will be activated. The motor runs as long as the test key is pressed.
  • Page 145 You can leave this menu by pressing the Escape key. Press key 5 to start the data reset operation. This involves clearing all the data in the non-volatile FRAM memory on the FRAM board 95.74.55 of the FPI 5000 I Subsequently this memory is loaded with default data, consistent with the virgin state of the machine leaving the factory, including nine default jobs.
  • Page 146 FPI 5000 I Note 2. The value of the counter Since installation (see section 3.4.5) wont get lost during the data reset operation. After pressing key 5 in figure 3.13 you see the text "Please wait...", followed by "Data cleared" and "Defaults installed".
  • Page 147 The presence of the divert unit, the feeder unit(s) and the DFC units is recorded in non-volatile FRAM on the FRAM board 95.74.55 of the FPI 5000 I. The FRAM is automatically updated if a component has been added, but will not be automatically updated if a component appears to be deleted. (The jumper settings on the feeder board(s) 93.08.02) are not stored in FRAM, but read at the start of each machine session).
  • Page 148 FPI 5000 I deleted from FRAM as well. If you press the "Reset configuration" key, you will get the message "Restart system to set new configuration". Switch the machine off and on again. Now the FRAM will be updated.
  • Page 149 The menu FV PHOTO. CONDITION In the FPI 5000 I and FPI 5000 C 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.
  • Page 150 The central pulse disk is mounted is present at the RH side of the machine. It is mounted on the input axle, to which the mechanical drive from the FPI 5000 I is transferred. This pulse disk is monitored by the slotted photocell VSPH1.
  • Page 151 This clutch (and the related gears, pulleys and timing belts) is present at the RH side of the machine. It is mounted on the input axle, to which the mechanical drive from the FPI 5000 I is transferred.
  • Page 152 The menu FV DFC TEST For reasons of compactness requirements the DFC units in the feeders of the Vario Feed subsystem differ from the DFC units as used in (among other inserters and feeders) the FPI 5000 I. The DFC screen of figure 3.22...
  • Page 153 FPI 5000 I Paper quality (gr/ Voltage drop 0.25 0.35 table 3.2 Although the readings are correct it still could be that the DFC is not functioning correctly in AUTO mode. It is recommended to clean the inner (moving parts) of the DFC to make sure that dust or paper particles are not affecting the DFC functioning.
  • Page 154 FPI 5000 I • Run in (figure 3.26); • Localisation (figure 3.27); • Job settings (figure 3.28); • Service counters (figure 3.34). figure 3.24: The system-wide SERVICE MENU. 3.4.1 SOFTWARE VERSIONS The software version screen of figure 3.25 shows the software versions for the various eproms that are present in the total system.
  • Page 155 FPI 5000 I After pressing the green Start key the run in test will start. Pressing the red Stop key will result in stopping the run in test. After each process cycle the counter is decremented. Once the counter value is below 6000, you can restore the 6000 situation by pressing key 6.
  • Page 156 FPI 5000 I The JOB SETTINGS menu of figure 3.28 consists of the following three menus: • System output (figure 3.29) • Paper stop (figure 3.30); • Document offset (figure 3.31); • Secure jobs (figure 3.32); • BRE offset (figure 3.33).
  • Page 157 FPI 5000 I contact occurs over shorter distances. Mode 1 focuses on operation with a wide range of paper types, at some expense of the process speed. figure 3.29: The system output menu The PAPER STOP menu In the collator area three mechanical paper stop positions are possible: one for A5-sized documents, one for A4-sized documents and one for 14 inch-sized documents.
  • Page 158 FPI 5000 I figure 3.31: The DOCUMENT OFFSET menu. The SECURE JOB menu With the SECURE JOB menu of figure 3.32 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.
  • Page 159 FPI 5000 I 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.
  • Page 160 FPI 5000 I figure 3.34: The SERVICE COUNTERS menu. figure 3.35: The menu for readjusting the service counter Since installation. figure 3.36: The error screen for preventive maintenance. rev. 01.0 - 01/2002 510.03-51...
  • Page 161 FPI 5000 I Test points All test points are located on the FPI 5000 I main board. Description Test point Minimum Typical Maximum Remarks Supply earth TP100 +5 V(digital) TP101 4.75 V 5.25 V ±5% +15 V supply TP120 14.25 V...
  • Page 162 The feeding and folding unit FPI 5000 C doesn't have its own user interface. Therefore the error information on the FPI 5000 C base unit plus one, two or three feeder units will be displayed on the FPI 5000 I control panel.
  • Page 163 FPI 5000 I Message: Technical failure. Action: Call service. Info: Memory failure. Error during the initialization of the FRAM. Press the Reset key to try again. If the Stop key is pressed, the initializing process is interrupted. The machine starts with the EPROM default values. Changes and counter settings are not stored.
  • Page 164 FPI 5000 I Action: Remove documents. Info: Document length error. Change in document length. The document input photocell is covered too long or too short. Remove the envelope and the document from the insert table. This message is displayed if the document is about 40 mm or more shorter or longer than the reference length.
  • Page 165 FPI 5000 I Info: Inserting failure. The loc is opened or PH3 covered at the time at which a document call is issued. Close the loc or remove the PH3 covering paper. Error 1:19 Message: Envelope stoppage. Action: Remove envelope.
  • Page 166 FPI 5000 I Info: Seal switch not covered. The ejected document doesn't trigger the flag switch FS1 long enough. This may happen in the fold-only mode with thin paper, or the flag switch isn't properly mounted. Error 1:26 Message: Envelope stoppage.
  • Page 167 Error 1:34 Message: Technical failure. Action: Call service. Info: Communication failure. The upstream system connector (between the FPI 5000 I and the FPI 5000 C base u nit is not connected. Error 1:35 Message: Preventive maintenance. Action: Call service. Info: [none] This message appears during the start of the machine if the value of counter since last visit exceeds the value of the counter.
  • Page 168 FPI 5000 I Error 1:45 Message: Technical failure. Action: Call service. Info: Flap sensor defective. Photocell PH2 cannot be adjusted correctly. The photodiode current resulting from the feedback control circuit is set at a too high value. This message may be issued at startup during factory production testing or after field replacement of the photocell.
  • Page 169 FPI 5000 I Info: [none] During the process the photodiode of photocell PH4 is readjusted at a too low current, resulting in a too sensitive photocell. This message may be issued during factory production testing only, or after field replacement of the photocell.
  • Page 170 FPI 5000 I Action: Call service. Info: Flap sensor defective. During the start of the machine no photo diode current of photocell PH2 is detected. The photodiode is not properly connected or not connected at all. This error only may occur after the field replacement of the photocell or after any service activities involving replacing circuit board connections.
  • Page 171 FPI 5000 I Action: Call service. Info: Exit sensor defective. During the paper process the photo diode current of photocell PH4 is set at a too high value, after the next 25 paper passages. This is likely caused by not heeding the Clean Sensor warning. Clean both sensors of the photocell.
  • Page 172 Error 1:89 Message: No connection. Action: Check device connector. Info: Communication failure. The FPI 5000 I cannot communicate properly via the I²C bus (timeout error). This may occur both in SCS and conventional I²C communication. Error 1:95 Message: Sealing risk.
  • Page 173 There is I C communication between the FPI 5000 I and the FPI 5000 C so one or more errors 1:80 - 1:89 do not apply. However, after establishing the SCS NEXT signal the SCS READY signal doesn't go to the low level.
  • Page 174 Action: Close cover. Info: [none] An FPI 5000 I cover is opened during the pause mode of the machine. (Opening a cover during processing paper leads to one of the errors 1:101 - 1:104.) Other FPI 5000 I diagnostic information Two LED's on the FPI 5000 I main board have a diagnostic function.
  • Page 175 FPI 5000 I The upper part of the Eight in One subsystem (containing the three upper green rollers and the fold table mechanisms) is opened during the transport of paper. Remove the paper, close the cover and press the reset key.
  • Page 176 No job settings can be read from the FRAM memory chip (IC102 on the FPI 5000 C base unit board 97.50.10). These FRAM settings are lost, but the job settings are also available in the FPI 5000 I. All documents must be removed from the machine.
  • Page 177 If a dongle is present on the FPI 5000 C base unit board 97.50.10 and if the data contained in this dongle appears to be corrupted, this message is issued. After pressing the Reset key on the FPI 5000 I the default settings are being used instead.
  • Page 178 FPI 5000 I Info: Documents in system. The vertical system is not empty, in any situation where a machine is supposed to be clear from paper. Remove the paper. After pressing the Reset key the system returns to the stand-by mode. After pressing the Start key the processing of documents will resume.
  • Page 179 FPI 5000 C process. This may be caused by defective photocell hardware, or there may be a mechanical reason. Note that this pulse disc is powered by the FPI 5000 I. This error occurs if the FPI 5000 I and the FPI 5000 C are electrically, but not mechanically coupled.
  • Page 180 FPI 5000 I Error 3:64 Message: Vert tr sensor dusty. Action: Clean sensor. Info: [none] Sensor needs readjustment after removed dust causes a too high LED current setting of the relevant photodiode. Error 3:65 Message: Vert tr sensor dusty.
  • Page 181 FPI 5000 I Error 3:75 Message: Collator sensor dusty. Action: Clean sensor. Info: [none] The relevant photocell (collator area input photocell VPH2) is dusty to such an extent that at least 80% of the photodiode current has been reached. Compared with error 3:71 there is still a certain dust margin. Readjust the photocell after cleaning, with no paper present.
  • Page 182 FRAM settings for the paper photocells and the DFC unit are lost. All documents must be removed from the machine. Press the Reset key on the FPI 5000 I. The paper photocells and the DFC unit will be readjusted. Error (4:, 5:, 6:, 7:, 8:, 9:)03 Message: Technical failure.
  • Page 183 FPI 5000 I Wrong I²C command. Error (4:, 5:, 6:, 7:, 8:, 9:)10 Message: Feeding failure. Action: Remove documents. Info: Document too thick. The document appears to be too thick or a double feed occurred. During the system initialisation and after switching the DFC function off and on again, the measured thickness of the first processed document is defined as the reference thickness.
  • Page 184 DFC unit. This DFC unit is switched off. The feeder unit communicates to the inserter that the feeder has no DFC unit. On the FPI 5000 I the DFC function can not be selected for this feeder.
  • Page 185 This DFC unit is switched off. The feeder unit communicates to the inserter that the feeder has no DFC unit. On the FPI 5000 I the DFC function can not be selected for this feeder. The operator can continue by pressing the Reset key.
  • Page 186 FPI 5000 I • The green LED D306 on the FPI 5000 C base unit board 97.50.10 reflects the state of the slotted photocell VSPH4 (TP6D). See also the BM digital inputs menu of section 3.3.3. • (The green LED D303 and TP3D on the FPI 5000 C base unit board 97.50.10 are reserved for the slotted photocell for the third fold table.)
  • Page 187 FPI 5000 I rev. 01.0 - 01/2002 510.03-78...
  • Page 188 FPI 5000 I Parts lists rev. 02.0 - 02/2002 510.04-1...
  • Page 189 FPI 5000 I rev. 02.0 - 02/2002 510.04-2...
  • Page 190 FPI 5000 I 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 machines Figure 510.04-6 Moistening cloth 04.03.06...
  • Page 191 FPI 5000 I Figure 510.04-38 Eprom 98.02.11 Mainboard 94.80.01 Unit motor / transformer board 12.16.21 Unit F-RAM 2K 95.74.55 LCD/Keyboard 95.70.72 Figure 510.04-42 Solenoid 12.12.87 Figure 510.04-47 Damper 03.11.90 Transportation roller Ø 42.5 mm 73.25.76 Figure 510.04-50 Brush holder 46.04.60...
  • Page 192 FPI 5000 I rev. 02.0 - 02/2002 510.04-5...
  • Page 193 FPI 5000 I Figure 1 rev. 02.0 - 02/2002 510.04-6...
  • Page 194 FPI 5000 I Figure 510.04-6 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Envelope tray (assy.) 97.01.04 Slide complete 04.23.20 Bellows 04.13.04 Cover 98.00.42 Cover plate 98.00.26 Round head screw M4 x 8 45.38.68...
  • Page 195 FPI 5000 I Figure 2 rev. 02.0 - 02/2002 510.04-8...
  • Page 196 FPI 5000 I Figure 510.04-8 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Spring clip 4 - 5 mm 05.24.47 Fibre washer Ø 8 x Ø 4.2 x 0.5 mm 04.01.22 Washer Ø 12 x Ø 4.3 x 1 mm 45.37.43...
  • Page 197 FPI 5000 I Figure 510.04-8 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Ball bearing with housing assy. 83.18.82 Fixing ring 26.04.18 Fixing screw 43.28.08 Support 23.47.36 Countersunk screw M3 x 16 05.04.14 Spacer Ø...
  • Page 198 FPI 5000 I rev. 02.0 - 02/2002 510.04-11...
  • Page 199 FPI 5000 I Figure 3 rev. 02.0 - 02/2002 510.04-12...
  • Page 200 FPI 5000 I Figure 510.04-12 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Support 23.47.36 Set screw M4 x 8 08.28.06 Pressure adj. bracket 73.53.69 Knurled ring 05.24.96 Pressure spring 03.35.51 Frame rod 43.42.45...
  • Page 201 FPI 5000 I Figure 510.04-12 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Sensor (including holder) 04.24.53 Bracket 23.46.09 rev. 02.0 - 02/2002 510.04-14...
  • Page 202 FPI 5000 I rev. 02.0 - 02/2002 510.04-15...
  • Page 203 FPI 5000 I Figure 4 rev. 02.0 - 02/2002 510.04-16...
  • Page 204 FPI 5000 I Figure 510.04-16 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Inside frame RH 95.73.07 Conductive bearing 10 mm 04.24.26 Washer Ø 16 x Ø 10.2 x 0.8 mm 04.01.43 Spacer Ø 15 x Ø 10.4 x 3 mm 04.08.58...
  • Page 205 FPI 5000 I Figure 510.04-16 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Cyl. pin Ø 2.5 x 16 05.23.46 Insert table 95.73.11 Countersunk head screw M3 x 10 05.38.74 Spring clip 10 - 14 mm 05.24.83...
  • Page 206 FPI 5000 I rev. 02.0 - 02/2002 510.04-19...
  • Page 207 FPI 5000 I Figure 5 rev. 02.0 - 02/2002 510.04-20...
  • Page 208 FPI 5000 I Figure 510.04-20 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Inside frame RH 95.73.07 Round head screw M4 x 16 05.38.71 Countersunk head screw M4 x 10 05.38.75 Fibre washer Ø 17 x Ø 10.2 x 0.5 mm 04.01.29...
  • Page 209 FPI 5000 I Figure 510.04-20 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Separation slide 95.71.06 Round head screw M3 x 25 45.43.08 Round head screw M3 x 6 45.43.02 Separation spring 95.71.04 rev.
  • Page 210 FPI 5000 I rev. 02.0 - 02/2002 510.04-23...
  • Page 211 FPI 5000 I Figure 6 rev. 02.0 - 02/2002 510.04-24...
  • Page 212 FPI 5000 I Figure 510.04-24 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Frame axle 95.71.53 Cover 95.71.52 Round head screw M4 x 6 05.38.66 Countersunk head screw M4 x 10 05.38.75 Protecting plate 95.73.13...
  • Page 213 FPI 5000 I Figure 510.04-24 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Refer to item 11 Refer to item 11 rev. 02.0 - 02/2002 510.04-26...
  • Page 214 FPI 5000 I rev. 02.0 - 02/2002 510.04-27...
  • Page 215 FPI 5000 I Figure 7 rev. 02.0 - 02/2002 510.04-28...
  • Page 216 FPI 5000 I Figure 510.04-28 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Tension pin Ø 2.5 x 14 05.33.21 Upper sealing roller Ø 36 mm 73.26.48 Tension pin Ø 2.5 x 16 05.33.22...
  • Page 217 FPI 5000 I Figure 510.04-28 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Grommet 12.11.64 Transportation axle 43.26.18 Transportation axle 43.26.20 Screen plate 43.34.49 Clamping ring 3 mm 05.24.63 Tension spring 03.35.04 Lever 95.73.15...
  • Page 218 FPI 5000 I rev. 02.0 - 02/2002 510.04-31...
  • Page 219 FPI 5000 I Figure 8 rev. 02.0 - 02/2002 510.04-32...
  • Page 220 FPI 5000 I Figure 510.04-32 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Spacer Ø 15 x Ø 10.4 x 3 mm 04.08.58 Washer Ø 16 x Ø 10.2 x 0.8 mm 04.01.43 Sprocket 18T 04.23.23...
  • Page 221 FPI 5000 I Figure 9 rev. 02.0 - 02/2002 510.04-34...
  • Page 222 FPI 5000 I Figure 510.04-34 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Washer Ø 14 x Ø 8.2 x 0.8 mm 04.01.41 Spring clip 7 - 9 mm 05.24.42 Washer Ø 14 x Ø 7 4 x 1.6 mm 45.37.53...
  • Page 223 FPI 5000 I Figure 510.04-34 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Slipping clutch CCW 8mm 95.71.27 Gear 35T 24.69.58 Spacer Ø 17 x Ø 10.2 x 2 mm 04.10.94 Spacer Ø 15 x Ø 10.4 x 7.5 mm 04.08.28...
  • Page 224 FPI 5000 I rev. 02.0 - 02/2002 510.04-37...
  • Page 225 FPI 5000 I Figure 10 rev. 02.0 - 02/2002 510.04-38...
  • Page 226 FPI 5000 I Figure 510.04-38 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Cover assy. 98.00.01 Knob white 97.00.41 Spacer Ø 8 x Ø 4.3 x 15 mm 98.00.30 Spacer Ø 8 x Ø 4.3 x 7.5 mm 04.07.78...
  • Page 227 FPI 5000 I Figure 510.04-38 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Fuse 15 A 12.12.95 Nut M4 (self-locking) 05.36.21 LCD/Keyboard 95.70.72 Washer Ø 9 x Ø 4.3 x 0.8 mm 45.37.02 Magnetic clip 95.70.90...
  • Page 228 FPI 5000 I rev. 02.0 - 02/2002 510.04-41...
  • Page 229 FPI 5000 I Figure 11 rev. 02.0 - 02/2002 510.04-42...
  • Page 230 FPI 5000 I Figure 510.04-42 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Top cover loc 98.00.13 Round head screw M4 x 10 05.38.69 Mounting clamp 12.14.89 Solenoid 12.12.87 Round head screw M4 x 5 45.43.11...
  • Page 231 FPI 5000 I Figure 510.04-42 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Washer Ø 7 x Ø 3.2 x 0.5 mm 45.37.39 Pan head tapping screw 45.38.53 Round head screw M4 x 8 45.43.13...
  • Page 232 FPI 5000 I rev. 02.0 - 02/2002 510.04-45...
  • Page 233 FPI 5000 I Figure 12 rev. 02.0 - 02/2002 510.04-46...
  • Page 234 FPI 5000 I Figure 510.04-46 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Transportation roller Ø 38 mm 76.04.67 Washer Ø 16 x Ø 10.2 x 0.8 mm 04.01.43 Spacer Ø 15 x Ø 10.4 x 5 mm 04.08.37...
  • Page 235 FPI 5000 I Figure 510.04-47 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Spacer Ø 8 x Ø 4.3 x 10 mm 04.69.19 Round head screw M4 x 8 45.38.68 Round head screw M4 x 16 45.38.71...
  • Page 236 FPI 5000 I rev. 02.0 - 02/2002 510.04-49...
  • Page 237 FPI 5000 I Figure 13 rev. 02.0 - 02/2002 510.04-50...
  • Page 238 FPI 5000 I Figure 510.04-50 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Bushing Ø 16 x Ø 8 x 8 mm 75.37.55 Gear 18T 24.09.36 Tension pin Ø 2.5 x 16 05.33.22 Bracket 43.34.21...
  • Page 239 FPI 5000 I Figure 510.04-50 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Axle 23.26.00 Spacer Ø 15 x Ø 10.4 x 5 mm 04.08.37 Ejection axle 43.28.75 Pulley 14T 06.04.45 Timing belt 04.15.37...
  • Page 240 FPI 5000 I Side exit Part number 97.01.52 rev. 02.0 - 02/2002 510.04-53...
  • Page 241 FPI 5000 I Figure 14 rev. 02.0 - 02/2002 510.04-54...
  • Page 242 FPI 5000 I Figure 510.04-54 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Socket head screw M5 x10 05.28.50 Transparent cover 95.73.93 Nut M4 half d. 45.19.19 Transportation table 97.01.10 Pulley 95.73.74 Belt 95.73.78...
  • Page 243 FPI 5000 I Figure 15 rev. 02.0 - 02/2002 510.04-56...
  • Page 244 FPI 5000 I Figure 510.04-56 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Side guide (incl. absorber) 97.01.13 Absorber 24.11.51 Envelope Support (incl. absorber) 95.74.08 Round head screw M4 x 10 45.38.69 Washer Ø 9 x Ø 4.3 x 0.8 mm 45.37.45...
  • Page 245 FPI 5000 I rev. 02.0 - 02/2002 510.04-58...
  • Page 246 FPI 5000 I Stacker Part number 95.73.51 rev. 02.0 - 02/2002 510.04-59...
  • Page 247 FPI 5000 I Figure 16 rev. 02.0 - 02/2002 510.04-60...
  • Page 248 FPI 5000 I Figure 510.04-60 Remarks illustration Description Part code Quantity Remarks FPI 5000 I code number number Roller 95.71.61 Round head screw M3 x 6 45.43.02 Washer Ø 7 x Ø 3.2 x 0.5 mm 45.37.39 Paper guide 95.71.70...
  • Page 249 FPI 5000 I rev. 02.0 - 02/2002 510.04-62...

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