INTRODUCTION This Service Manual describes the Cool Laminator LX-1200/LX-300 specifications, operating principles of the mechanisms, disassembly and reassembly procedures, and maintenance and troubleshooting procedures. This Service Manual is intended for use by trained technicians. It is not intended for use by the user.
1.1 Mechanical Specifications 1.1.1 Appearance  External dimensions (W x D x H) 468 mm x 387 mm x 273 mm  Weight Approx. 8.3 kg (main unit only) 468 mm 273 mm 387 mm Fig. 1.1-1 Appearance...
2.1 Mechanical Operating Principles 2.1.1 Description of Mechanisms (Border Mode) 1. When a document is inserted into the paper loading gate, the paper feed rollers feed it to the driving roller. 2. As the document passes between the paper feed rollers, the paper size detector determines its size (length and width).
2.1.2 Feed and Compression Mechanisms The feed and compression mechanism controls the motor drive to feed the document into the film cartridge, compression-feed the films, and eject the laminated document. The operation is basically divided into three separate operations: feeding a document into the Film cartridge, compression-feeding the films, and ejecting the laminated document.
B. Compression-feeding the films 1. The SG motor mounted at the right of the chassis runs to rotate the Control cam gear (also mounted at the right of the chassis) to its prescribed position. 2. As the Control cam gear rotates, the LF change shaft is rotated to its prescribed position by the cam on the Control cam gear.
Continuous Mode When the second or subsequent document are inserted in the Continuous mode, the operation C described below feeds the documents to the prescribed position. C. Feeding Document Only into Film Cartridge 1. The SG motor mounted at the right of the chassis runs to rotate the Control cam gear (also mounted at the right of the chassis) to its prescribed position.
2.1.3 Cutter Mechanism (Border Mode) The cutter mechanism cuts the laminated document to the size of the document plus an added border. Both edges of the films are cut to suit the width of the document and the leading edge and trailing edge are cut according to the document length. Y-Cutter Vertical Drive Operation The SG motor drive rotates the Control cam gear to its prescribed position.
Cutting Leading and Trailing Edges (X-cutter Mechanism) 1. All the rollers which feed the document stop when the cut position at the leading edge of the document reaches the cutting position of the rotary cutter and fixed- blade cutter. 2. The DC motor rotates to drive the carriage in the X-cutter assy via the spiral mechanism (not illustrated).
2.1.4 Paper Size Detector Mechanism Paper Length Detection 1. When the leading edge of the document passes between the Paper feed rollers, the Actuator top operates about the pivot to turn on the Paper sensor and detect the document leading edge. 2.
Paper Width Detection (Y-CA sensor) 1. As the Y-cutter arm (Y-CA sensor carriage) moves in the direction of the arrow, the document contacts the Actuator Y, which rotates about the pivot to switch off the Y-CA sensor (photosensor). 2. When the Y-CA sensor turns off, the Y-cutter arm movement stops and this position is detected as the document width.
2.1.5 Trimming Mechanism 1. When a corner of the laminated document is inserted over the T-cutter plate, the T- sensor lever operates a leaf switch (TRI) that detects the document. 2. When the document is detected, the motor gear of the SG Motor rotates from its reference position to the prescribed position to rotate the Control cam gear in the direction of the arrow (counterclockwise) via a series of gears.
CONTENTS Chapter 3. DISASSEMBLY PROCEDURES 3.1 Safety Precautions ......................3-1 3.2 Removing the Film Cartridge .................... 3-1 3.3 Covers ..........................3-2 3.3.1 Removing the Trimmer Cover ................3-2 3.3.2 Removing the Top Cover B .................. 3-3 3.3.3 Removing the Sub-tray ..................3-4 3.3.4 Removing Paper Tray A and Paper Guide............
3.11.1 Removing the LF Motor ..................3-25 3.11.2 Removing the Gears ................... 3-26 3.12 Right Side of the Main Chassis..................3-27 3.12.1 Removing the Right Side of the Chassis............3-27 3.12.2 Removing the YC Lift Shaft and LF Change Shaft ..........3-28 3.13 Paper Eject Roller ......................
3.1 Safety Precautions • When conducting disassembly operations, place the unit on a grounded anti-static sheet. LSI and other electronic components are sensitive to static electricity and may be damaged if touched while charged. • Before transporting a circuit board, wrap it in a conducting sheet such as aluminum foil.
3. Lift up the Roller holder assy and pull out the Film cartridge. Roller holder assy Film cartridge Fig. 3.2-2 Removing the Film Cartridge 2 3.3 Covers 3.3.1 Removing the Trimmer Cover 1. Pull out the T-cutter plate and the Trimmer bottom cover. Trimmer bottom cover T-cutter plate Fig.
2. Remove the two Trimmer cover screws. Remove the Trimmer upper cover. Trimmer cover screws Trimmer upper cover Fig. 3.3-2 Removing the Trimmer cover 2 3.3.2 Removing the Top Cover B Open the Top cover B. Lift the Top cover B shafts out of the shaft recesses in the Body cover and remove Top cover B.
3.3.3 Removing the Sub-tray 1. Open the Sub-tray. 2. Flex the center of the sub-tray toward you to release the shafts from the shaft recesses in the Body cover. Remove the sub-tray. Sub-tray Shaft recesses Body cover Fig. 3.3-4 Removing the Sub-tray 3.3.4 Removing Paper Tray A and Paper Guide 1.
2. Disengage the Paper guide hooks (at the rear of the Paper tray) CL2000011 from Paper tray A. Remove the Paper guide. Paper guide Paper tray Hooks Fig. 3.3-6 Removing the Paper Guide 3.3.5 Removing the Body Cover 1. Remove the two Bottom cover screws B from the bottom of the Bottom cover B. And remove one screw from the surface of Body cover.
2. Lift the rear of the Bottom cover in the direction of arrow B while pushing it in the direction of arrow A to release the six hooks on the rear face. 3. Push the sides of Body cover in the directions indicated by the arrows C to release the hook at the left and right side.
3.3.6 Removing the Front Cover 1. Remove the two Front cover screws under the Bottom cover B. ∗ When removing the Body cover, remove the two Front cover screws and the two screws at the rear of the Bottom cover B at the same time. ∗...
3.3.7 Removing Paper Tray B CL2000011 1. Remove Tray B Stopper. 2. Lift the top of Paper tray B in the direction of arrow A to disengage the lug from the Cassette holder. 3. Slide Paper tray B in the direction of arrow B, then lift it in the direction of arrow C to remove it.
2. Flex the center of the Back cover toward you to release the shafts from the shaft recesses in the Body cover. Remove the Back cover. During this operation, take care not to deform the film attached to the Back Cover. Shafts Back cover Film...
3.3.10 Removing the Dial Switch Holder Assy B 1. Remove the eight Dial holder screws. Remove the Dial switch holder assy B. 2. Disconnect the Push SW assy 1 (white) and Push SW assy 2 (red) connectors from the SW PCB. ∗...
3.3.11 Removing the Push Switch Assy 1. Remove the two Push switch screws. Remove the Push SW assy 1 (white) and Push SW assy 2 (red). ∗ Before removing the Push SW assy 1 and 2, turn the Dial switch such that it does not touch the push switches (mid-point between Push SW assy 1 and Push SW assy 2).
3.4 Chassis Assy 3.4.1 Removing the Harness Connectors 1. Remove 11 harness connectors from the Main PCB. Do not remove the power harness assy (red/black CN13). Power harness assy Fig. 3.4-1 Removing the Harness Connectors 1 2. Disconnect the harnesses from the eight hooks on the Bottom cover B. Fig.
3.4.3 Removing the Chassis Assy 1. Remove the Ground wire screw from the Main chassis B, then disconnect the ground wire. Ground wire screw Main chassis B Ground wire Fig. 3.4-4 Removing the Chassis Assy 1 2. Remove the two Bottom cover screws B and the washers from under the Bottom cover B.
3. Open the Roller holder assy, then remove the four Bottom cover screws CL2000011 with four washers from under the Chassis assy. Bottom Cover Screw A Roller Holder Assy Fig. 3.4-6 Removing the Chassis Assy 3 4. Pull out the Chassis assy from Bottom cover. Chassis assy Fig.
3.5 PCBs 3.5.1 Removing the Main PCB 1. Disconnect the power harness assy (red/black) from the Main PCB. 2. Remove the four Main PCB screws. Remove the Main PCB. Main PCB screw Power harness assy Main PCB assy Main PCB screw Fig.
3.6 X-cutter Unit 3.6.1 Removing the X-cutter Unit 1. Remove the Y-cutter assy. 2. Remove the two X-cutter screws. Move the X-cutter unit toward the right to remove ∗ Remove the Chassis assy from the Bottom cover when replacing the X-cutter unit.
3.7 Y-CA Chassis Assy and Y-cutter Arm 3.7.1 Removing the Y-CA Chassis Assy 1. Remove the Y extension springs. 2. While the Roller holder is locked, remove the two Y-CA chassis screws. 3. Disengage the end of the Y-cutter arm from the Y sensor carriage by moving it in direction A.
3.7.2 Removing the Y-CA Motor 1. Remove the Y-CA motor screws and remove the Y-CA motor. Y-CA motor Y-CA motor screw Fig. 3.7-2 Removing the Y-CA Motor 3.7.3 Removing the Y-cutter Arm 1. Remove the retaining ring from the Y-cutter arm shaft, pull out the Y-cutter arm shaft, and remove the Y-cutter arm.
3.8 Y-sensor Rail Unit 3.8.1 Removing the Y-sensor Rail Unit 1. Remove the F cable from the Cassette holder. 2. Remove the two Y-sensor rail screws. 3. Disengage the tip of the Actuator top from the film hole, then remove the Y-sensor rail unit in the direction of the arrow.
3.8.2 Disassembling the Y-sensor Rail Unit 1. Remove the Retaining ring from the Y-sensor shaft, then pull out the Y sensor shaft. 2. Remove the FPC holder A from the Y-sensor rail, then remove the Y-sensor carriage. Y-sensor carriage Retaining ring Y-sensor shaft FPC holder Y-sensor rail screw...
3.9 Roller Holder Assy 3.9.1 Removing the Roller Holder Assy 1. Lift up the Roller holder unit and disconnect the Roller holder return spring. 2. Remove the four Retaining rings (two from the Roller holder, two from the Paper feed holder), then remove the Roller holder unit. 3.
3.10 Paper Feed Roller 3.10.1 Removing the Paper Feed Holder Assy 1. Remove the two Idle gears A, one Double gear B, one Double gear A, the Roller gear AD, and the two Paper feed roller springs from the Paper feed holder L assy, then remove the Paper feed roller unit.
3. Remove the Bearing and Sub-bearing and remove the Actuator top from the Paper feed roller assy. Sub bearing Bearing Actuator top Fig. 3.10-3 Removing the Actuator Top 3.11 Left Side of the Main Chassis 3.11.1 Removing the LF Motor 1.
3.11.2 Removing the Gears 1. Remove the gears according to the sequence of numbers in the diagram below. Gear holders Fig. 3.11-2 Removing the Gears 2. Remove the two Gear holders simultaneously. Remove the Gear holder spring from the Gear holders. ∗...
3.12 Right Side of the Main Chassis 3.12.1 Removing the Right Side of the Chassis 1. Remove the two Idle gears A. 2. Remove the two SG motor screws and remove the SG motor. 3. Remove the Leaf switch SG screw, then remove the Leaf switch SG assy. 4.
6. Remove the Control cam gear and Double gear S. Double gear S Control cam gear Fig. 3.12-3 Removing the Right Side of the Chassis 2 7. Remove the screws, then remove the Chassis R support. (See Fig. 3.12-1.) 3.12.2 Removing the YC Lift Shaft and LF Change Shaft 1.
4. Move the YC lift shaft several millimeters toward the right side of the Main chassis and remove the YC Lift arm. LF lift arm YC lift arm YC lift shaft Fig. 3.12-5 Removing the YC Lift Shaft and LF Change Shaft 2 5.
3.13 Paper Eject Roller 3.13.1 Removing the Paper Eject Roller Unit 1. Push down the Paper eject shaft holder until they becomes free. 2. Push the Paper eject roller toward the left and remove it from the right end. 3. Remove the Paper eject sub-roller in exactly the same manner as the Paper eject roller: move it toward the left then remove it from the right end.
3.15 Trimming Mechanism 3.15.1 Disassembling the Trimming Mechanism 1. Remove the Leaf switch TRI screw, then remove the Leaf switch assy TRI. 2. Remove the T-cutter screw, then remove the T-cutter assy. Leaf switch TRI screw Leaf switch TRI assy T-cutter screw T-cutter unit Fig.
3.17 Main Chassis B 3.17.1 Removing the Main Chassis B 1. Disengage the harness from the hooks under the Cassette holder and the Edging saddle at the rear of the main chassis B. 2. Remove the Edging saddle from the rear of the main chassis B. 3.
3.17.2 Removing the Cassette Holder 1. Push in the three hooks on the front face that fix the Cassette holder. 2. Pull out the Cassette holder in the direction of the arrow. Hooks Fig. 3.17-2 Removing the Cassette Holder 3.17.3 Removing the ENC Sensor PCB Remove the ENC sensor PCB screw, then remove the ENC sensor assy.
3.17.4 Removing the Main Chassis L, R, and F Remove the ten Side chassis screws (five each side), then remove the Main chassis L, R, and F. Side chassis screws Main chassis L Main chassis B Main chassis R Main chassis F Side chassis screws Fig.
4.1 Safety Precautions • When conducting reassembly operations, place the unit on a grounded anti-static sheet. LSI and other electronic components are sensitive to static electricity and may be damaged if touched while charged. • Before transporting a circuit board, wrap it in a conducting sheet such as aluminum foil.
4.2 Table of Tightening Torques Name of screw Qty. Screw size Tightening torque See page TAPTITE, CUP M3 × 5 Side chassis screw 0.49 to 0.686 N•m (5 to 7 kgf•cm) TAPTITE, CUP M3 × 5 Reinforcing plate for frame R screw 0.49 to 0.686 N•m (5 to 7 kgf•cm) TAPTITE, BIND B M3 ×...
4.3 Main Chassis B 4.3.1 Installing the Main Chassis L, R, and F 1. Insert the lugs on the Main chassis B and F into the square holes in the Main chassis L and R. Assemble the Main chassis L, R, F, and B with the ten Side chassis screws (five each side).
4.3.3 Installing the Cassette Holder 1. Pass the ENC sensor PCB harness through the hole in the bottom of Main chassis 2. Insert the lugs at the front of the Cassette holder and click the hooks at the rear onto Main chassis B.
4.3.4 Installing the Main Chassis B 1. Install the two Cassette actuators. 2. Install the Leaf switch C3 (red) and C4 (yellow) assemblies using the Leaf switch C3/C4 screws. ∗ Take care not to deform the tip of the leaf switch. 3.
4.4 Driving Roller 4.4.1 Installing the Driving Roller 1. Attach the Retaining ring to the right end of the Driving roller assy (with the shorter metal part). 2. Insert the Bearings L/R into the Driving roller. Mount it sequentially into Main chassis L and Main chassis R.
4.5 Trimming Mechanism 4.5.1 Assembling the Trimming Assy 1. Align the Leaf switch assy TRI with the T-cutter assy boss hole and attach it with the Leaf switch TRI screw. 2. Fasten the harness to the hooks. Engage the harness into the hook under the Cassette holder, then fix it with tape on the two marked areas (Chassis B front face and Chassis R inside surface).
4.6 Paper Eject Roller and Y-diversion Lever 4.6.1 Installing the Paper Eject Roller Unit and Y-diversion Lever 1. Temporarily position the Y-diversion Lever assy on the Main chassis F. Y-diversion lever assy Fig. 4.6-1 Installing the Y-diversion Lever 1 2. Install the Paper eject roller bearings such that the Y-diversion lever arms are sandwiched between the Paper eject roller bearing and the Main chassis L/R.
4.6.2 Installing the Paper Eject Roller 1. With both ends of the Paper eject roller inserted in the Paper eject shaft holders, move the Paper eject roller first to the left, then to the right, to insert it into the Paper eject roller bearings.
4.7 Right Side of the Main Chassis 4.7.1 Installing the YC Lift Shaft and LF Change Shaft 1. Move the LF change shaft first to the right, then to the left, to install it into the Main chassis L and R. 2.
4.7.2 Installing the Right Side of the Chassis 1. Install the Double gear S. 2. Position the YC lift shaft as shown in the diagram. 3. Install the Control cam gear with the triangular mark on the Control cam gear aligned with the triangular hole in the Chassis.
5. Install the T-lever B, T-cam roller, and T-cam spring onto T-lever A. T-cam spring T-cam roller T-lever A T-lever B Fig. 4.7-5 Installing the Right Side of the Chassis 3 6. Insert the T-lever shaft into the shaft holes in the Main chassis R and T-lever A/B. Push in the T-lever shaft until the groove in the shaft engages with the hook on the T-cutter assy.
7. Align the Leaf switch SG assy with the boss hole and fasten it with the Leaf switch SG screw. Before installing the Leaf switch SG assy, turn the Control cam gear to a position where it cannot interfere with the Leaf switch. 8.
4.8 Left Side of the Chassis 4.8.1 Installing the Gears 1. Mount the two Gear holders to the Main chassis L, then attach the Gear holder springs. Gear holders Gear holder spring Fig. 4.8-1 Installing the Gears 1 2. Install the gears according to the sequence shown in the diagram below. Push the shaft into a gear or holder with a hook until the hook engages.
4.8.2 Installing the LF Motor 1. Attach the LF motor to the LF motor holder using the LF motor screws. 2. Insert the LF motor holder screws into the LF motor holder assy. Put the Spacers over the three protruding screws. Mount the LF motor holder assy to the Main chassis L.
4.9 Paper Feed Roller 4.9.1 Installing the Paper Feed Holder Assy and the Paper Feed Roller Assy 1. Attach the Paper feed holder plates L (with shaft) and R to the Main chassis L and R. ∗ Assemble with the hooks on the Paper feed holder plates L/R engaged in the cut-outs in the Chassis L/R.
2. Install the Actuator top in the Paper feed holder assy. 3. Install the Bearing and Sub-bearing onto the Paper feed roller and Paper feed sub- roller. Insert the rollers through the slots in the Paper feed holder plates L and R. ∗...
4. Attach the Paper feed roller springs to the left and right Sub bearing hooks and the Paper feed holder plates L and R. Sub bearing Paper feed holder plate R Paper feed roller spring Fig. 4.9-3 Installing the Paper Feed Roller Assy 2 5.
4.10 Roller Holder Assy 4.10.1 Installing the Roller Holder Assy 1. Install the pivots for Roller holder rotation onto the Main chassis shafts. 2. Mount the plastic spacers to the lugs (rivet pins) at each end of the Roller holder assy.
4.11 Y-sensor Rail Unit 4.11.1 Assembling the Y-sensor Rail Unit (Attaching Y-sensor PCB Assy) 1. Bend the sensor flat cable to the dimensions shown in the diagram below. Approx. 350mm Fig. 4.11-1 Bending the Sensor Flat Cable to the Dimensions 2.
4. Stick the Film and Reinforcement film to the Y-sensor rail unit. 5. Install the FPC holders A in the Slots in the Y sensor rail unit. 6. Pass the Y-sensor shaft through the Y-sensor rail and Y-sensor carriage and fasten with a Retaining ring at each end.
4.11.2 Installing the Y-sensor Rail Unit 1. Locate the groove on the Y-sensor shaft into the Paper feed holder plate and fasten with the two Y-sensor rail screws. ∗ Ensure that film is inserted between the Paper feed roller and Paper feed sub- roller during installation.
4.12 Y-CA Chassis Assy and Y-Cutter Arm 4.12.1 Installing the Y-cutter Arm 1. Mount the Y-sensor carriage arm to the Y-cutter arm with the Y-CA arm screw. Y-CA arm screw Y sensor carriage arm Y-cutter arm Fig. 4.12-1 Installing the Y-cutter Arm 1 2.
4.12.2 Installing the Y-CA Motor 1. Mount the Y-CA motor to the Y-CA chassis assy with the Y-CA motor screws. Y-CA motor Y-CA chassis assy Y-CA motor screw Fig. 4.12-3 Installing the Y-CA Motor 4.12.3 Installing the Y-CA Chassis Assy 1.
2. Insert the lugs on the Y-cutter guide L into the slots (Part A) on the Y-cutter arm. 3. Insert the Y-CA timing belt into the groove in the Y-cutter arm. 4. Install the Y-CA chassis assy with the two Y-CA chassis screws. ∗...
4.13 X-cutter Unit 4.13.1 Installing the Leaf Switch F Assy 1. Attach the Leaf switch F assy to the Tape sensor holder with the Leaf switch F screw. X-cutter unit Sensor holder Sensor holder screw Tape sensor lever Leaf switch F screw Leaf switch F assy Fig.
4.14 Harnesses 4.14.1 Installing the Harnesses Attach the following harnesses to the Main chassis B Edging saddle. • SG motor harness (black) • ENC harness assy (white) • Leaf switch TRI harnesses (black) x 2 • Leaf switch C3 (red)/C4 (yellow) harness Edging saddle Harnesses Fig.
4.15 PCBs 4.15.1 Installing the Jack PCB Assy Install the Jack PCB assy with the Jack PCB screw. ∗ The Core shown in the diagram is applicable to EU-specification units only (LX-300). Jack PCB screw Jack PCB assy Fig. 4.15-1 Installing the Jack PCB Assy 4.15.2 Installing Main PCB Assy 1 1.
4.16 Chassis Assy CL2000011 4.16.1 Installing the Chassis Assy 1. Locate the Chassis assy aligned with the two bosses on the Bottom cover B. Fasten it with the four Bottom cover screws A with four washers. Bottom cover screws A Fig.
3. Attach the Ground wire to the Main chassis B using the Ground wire screw. Ground wire screw Main chassis B Ground wire Fig. 4.16-3 Installing the Chassis Assy 3 ∗ The Chassis perpendicularity must be adjusted after the Chassis assy is installed to the Bottom cover.
4.16.3 Installing the Harness Connectors CL2000011 1. Attach the harness connectors (except the power harness assy) to the Main PCB according to the color sequence shown in the diagram. 2. Connect the harnesses along the paths shown in the diagram. 3.
3. Mount the SW PCB assy to the Body cover with the eight SW PCB screws. Switch PCB screws Switch PCB assy Switch PCB screws Fig. 4.17-4 Installing the Dial Switch Holder Assy 3 4. Attach the Dial switch holder assy to the Body cover with the Dial switch holder screws.
4.17.3 Installing the Cover Switch 1. Align the Cover SW assy with the boss hole on the inside surface at the right of the Body cover and attach it with the Cover switch screw. 2. Install the harnesses for the Dial SW assy and Cover SW assy inside the right of the Body cover and fasten them with the hooks (Part A).
4.17.5 Installing Paper Tray B CL2000011 1. Insert the Paper tray B onto the Paper feed roller from the direction of arrow A, then slide it in the direction of arrow B to engage the lugs into slits in the Cassette holder. Paper tray B Paper tray B Paper feed roller...
2. Fasten the Front cover with the two Front cover screws at the rear. Front cover screws Soft cloth Fig. 4.17-10 Installing the Front Cover 2 4.17.7 Installing the Body Cover 1. Connect the Switch harness assy and the Cover SW assy to the Main PCB. Switch harness assy Cover switch harness Fig.
2. Put the Body cover on the Bottom cover, slightly in front of its correct position. Insert the Paper tray B into the paper feed slot in the Body cover. 3. Insert the Y-cutter guide R lug into the slots in the Dial SW assy in front of the Body cover.
8. Fasten the Body cover with the two Bottom cover screws A under the cover and the single screw at the top. ∗ When inverting the unit to perform this work, place it on a soft cloth to avoid scratching the cover. Bottom cover screws A Soft cloth Fig.
2. Insert the Paper tray hooks at the left edge and the Body cover, then insert the hooks at the right edge. Paper tray Fig. 4.17-16 Installing the Paper Tray 4.17.9 Installing the Sub-tray Flex the center of the Sub-tray toward you and insert the shafts into the shaft recesses in the Body cover to install the Sub-tray.
4.17.10 Installing the Top Cover B With the Top cover B in the open position, insert the shafts into the shaft recesses in the Body cover to install the Top cover B. Shafts Top cover B Shaft Body cover Shaft recess Fig.
2. Insert the T-cutter plate into Trimmer upper cover. 3. Insert the Trimmer bottom cover. Trimmer bottom cover T-cutter plate Fig. 4.17-20 Installing the Trimmer Cover 2 4.18 Installing the Y-cutter Slide the Y-cutters from each end of the Y-diversion lever and pull them upward to install them.
4.19 Installing the Film Cartridge 4.19.1 Installing the A3 Cartridge 1. Insert the Film cartridge with the tape outlet toward you and lower the Roller holder assy. Roller holder assy Tape cassette Fig. 4.19-1 Installing the Film Cartridge 1 2. Push the Set buttons R/L to lock the Roller holder assy. Close the Top cover. Top cover Set buttons L/R Fig.
4.19.2 Installing the A4/A6 Cassette Attachment 1. Insert the A4/A6 cassette attachment with the handle at the left. 2. Follow the method described for the A3 cartridge to insert the A4/A6 cartridge. A4/A6 cassette attachment Fig. 4.19-3 Installing the A4/A6 Cassette Attachment 4-44...
CONTENTS Chapter 5. ELECTRONIC CONTROLLERS 5.1 Electronic Parts ......................... 5-1 5.1.1 Configuration of the Electronic Parts..............5-1 5.1.2 Outline of the Electronic Parts ................5-2 5.2 Operation of Each Part...................... 5-3 5.3 Main PCB .......................... 5-4 5.4 Detector Circuits......................5-10 5.5 Motor Drive Circuits......................
5.1 Electronic Parts 5.1.1 Configuration of the Electronic Parts The electronic parts of the unit comprise the following PCBs and an AC adaptor. Main PCB Switch PCB Jack PCB Paper size sensor PCB (Y-CA sensor PCB) ENC PCB Document Detect PCB (PST sensor PCB) AC adaptor Fig.
5.1.2 Outline of the Electronic Parts Each PCB and the AC adaptor are described below. Main PCB The main PCB is located below the paper guide. It is connected to all PCBs, motors, switches, and cables. It converts the unstabilized DC voltages input from the Jack PCB to stabilized +5V and +24V DC voltages, which are supplied to all controllers.
5.2 Operation of Each Part This unit is operated by three 24 V stepping motors and one DC motor (for the X-cutter assy). The operation of each motor shown in Fig. 5.1-1 is described below. LF motor This motor is used to feed the document and film and to eject the film. The motor is a 49 mm dia.
5.3 Main PCB Fig. 5.3-1 shows a block diagram of the electrical parts. The Main PCB comprises the CPU, detector circuits (including switch status detection), motor drive circuits, and power circuits. Fig. 5.3-1 Block Diagram of the Electrical Parts Main CPU The main CPU is an 8-bit CMOS microcontroller that controls the overall system.
Table 5.3-1 CPU I/O Map Port Pin No. N.C. LF CURRENT SWITCH 0 LF CURRENT SWITCH 1 LF MOTOR PHASE /A LF MOTOR PHASE A LF MOTOR PHASE /B LF MOTOR PHASE B LF CURRENT SWITCH 2 TR-G CASSETTE SIZE A3 P13 (DVO) BUZZER N.C.
Clock Circuit The main CPU incorporates a clock-generation circuit which uses externally mounted components. This circuit and the main CPU internal circuit generate an 8 MHz clock signal. Fig. 5.3-2 Clock Circuit Reset Circuit This circuit resets the main CPU when the power is turned ON or OFF. S-80943ANMP-DD7 is used as the reset IC in this circuit.
Buzzer Drive Circuit This circuit sounds the piezoelectric buzzer. To sound the buzzer, the main CPU outputs a 4 kHz squarewave with 50% duty from port DV0 (P13). This signal is used to generate the buzzer sound. To stop the buzzer, the port status is set to High level using R69 in the input mode. Fig.
Specification Switching Circuit This circuit reads the specification switching information. The specification switching is conducted by a ROM program built into the main CPU according to the solder point settings on the PCB. Fig. 5.3-6 Specification Switching Circuit Note that the solder point specifications change according to the CPU display format.
5.4 Detector Circuits These circuits detect the status of the switches and keys that operate the machine (Two-connection switch, Start key, Stop key, Dial switch, Continuous key, and Extra border key) and the sensors that determine the film type, document length and width, and cover open/closed status.
Switch Scan Circuit This circuit in the main CPU scans the status of the FEED • CUT • START • STOP • CONT • EXTRA BORDER key, and TRI switch (leaf switch) at 15 ms intervals to continuously detect the status of each switch. The circuit comprises a matrix of three output ports (P90, P91, P92) and three input ports (P93 to P95).
Dial Switch Circuit This circuit detects the automatic cutting mode selected on the Cutting mode selector switch. This circuit comprises two push switches (RSW1, RSW2) mounted on each side of the dial switch. The signals detected by these two push switches are input to the Main PCB via the Switch PCB.
Paper Width Detector Circuit (YCA-F sensor PCB) This circuit detects the width of the document and determines the Y-carriage position. It also determines the Y-carriage standby position when the power is ON or the cover is closed. This circuit comprises the transmissive photosensor PH1 mounted on the Paper width detector PCB that is attached to the Y-carriage.
Cartridge Type Detector Circuit This circuit detects the type of film cartridge. The Cartridge type detector switch CSIZE3 is mounted at the film cartridge inlet. When an A3 film cartridge is inserted, the A3 film cartridge presses the Cartridge type detector switch CSIZE3 and turns it ON (P14 becomes LOW). The Cartridge type detector switch CSIZE4 is mounted at the film cartridge inlet.
Film Feed Detector Circuit This circuit detects the film feed status to prevent jams if a problem occurs. The film feed detector switch TPS is mounted before the paper eject roller and if there’s no problem with the film during document feed or compression, the film presses against the film feed detector switch TPS and sets the ON (input Low).
5.5 Motor Drive Circuits Paper Feed Motor Drive Circuit This circuit conducts the paper feed motor bipolar drive using 2-2 phase excitation from the +24 VDC stabilized constant voltage. The stepping motor excitation phases A, A , B, and B are controlled by main CPU ports P03, P02, P04, and P01 and the Paper feed motor is controlled by Driver #6.
SG Motor Home-position Detector Circuit This circuit detects when the SG motor is at the Trimming cam home position. Fig. 5.5-3 SG Motor Home-position Detector Circuit Y-CA Motor Drive Circuit This circuit drives the Y-CA motor using 2-2 phase excitation from the +24V DC stabilized constant voltage and maintains a low voltage during LF motor operation.
X-cutter Motor Drive Circuit This circuit drives the DC motor with the +24V DC stabilized constant voltage. The X-cutter comprises a DC motor and two switches. The DC motor is controlled by the main CPU ports P64 to P67 and is driven by the DC motor control circuit. The two switches are detected by ports P22 and P23.
5.6 Power Supply Circuits The power supply circuits receive the unstabilized DC voltage supplied to CN1 from the AC adaptor through the Jack PCB via fuse F1 (protective circuit), and the filter circuit. The 2-channel switching power IC (IC#1) in the circuits converts the unstabilized DC voltage into a stabilized +5V voltage (logic power supply) and into a stabilized +24V DC voltage (drive power supply).
+5V Power Supply Fig. 5.6-2 shows the timing chart of the power IC (IC#1) for the +5V DC power supply during idling. In this circuit, the transistor Q3 switches at approximately 100 kHz to convert the unstabilized input voltage to a stabilized +5V supply. When transistor Q3 is ON, energy accumulates in the coil L3 and electrolytic capacitor C10 until they are able to supply a +5V voltage.
6.1 Lubrication After the parts of 6.1.3 are replaced, apply lubricant to the positions indicated in 6.1.3 Lubrication Positions below. If only one of a pair of touching parts is replaced, lubricant remains on the other part and no further lubrication is required. If both of a pair of touching parts is replaced, lubricant must be applied to the indicated position.
Cam groove on side of Control cam gear (8 positions) CL2000010, CL2000016 Control Cam Gear Apply lubricant to inside of cam groove on Control Cam Gear. Fig. 6.1-2 Cam Groove on Side of Control Cam Gear LF motor gear (1 position) LF motor gear Fig.
• Roller holder shaft (2 positions) Main chassis L Main chassis R Roller holder shaft Fig. 6.1-5 Roller Holder Shaft • Sliding surfaces of sub roller shafts in Bearings R/L (4 positions) Bearings R/L Fig. 6.1-6 Sliding Surfaces of Sub Roller Shafts in Bearings R/L •...
Link between YC lift shaft and YC lift arm (1 position) CL2000010 YC lift arm Fig. 6.1-8 Link Between YC Lift Shaft and YC Lift Arm Engaged parts of LF change shaft (2 positions) LF change shaft Fig. 6.1-9 Engaged Parts of LF Change Shaft Gear holder change cam surface on LF change shaft (2 position) LF change shaft Fig.
Roller Holder • Sub roller shaft bearings (2 positions) Sub roller shaft bearing Fig. 6.1-11 Sub Roller Shaft Bearings • Roller holder spring mounting (1 position) Roller holder spring Fig. 6.1-12 Roller Holder Spring Mounting...
Y-cutter Arm • Y-cutter arm shaft (1 position) Y-cutter arm shaft Fig. 6.1-13 Y-cutter Arm Shaft • Y-sensor shaft (1 position) Y-sensor carriage Y-sensor shaft Fig. 6.1-14 Y-sensor Shaft...
Paper Feed Roller • Paper feed roller and Paper feed sub-roller shafts (4 positions) Bearing Fig. 6.1-15 Paper Feed Roller and Paper Feed Sub-roller Shafts • Sliding surfaces of Paper feed sub-roller shaft holder shafts (4 positions) Paper feed sub-roller Fig.
• Left/right contact points between Paper feed roller spring and Chassis B (2 positions) Paper feed sub-roller Paper feed roller Paper feed roller spring Chassis B Fig. 6.1-18 Left/right Contact Points Between Paper Feed Roller Spring and Chassis B Driving Roller •...
Paper Eject Roller • Paper eject roller and Paper eject sub-roller shaft bearings (4 positions) Paper eject roller bearing Fig. 6.1-20 Paper Eject Roller and Paper Eject Sub-roller Shaft Bearings • Sliding surfaces of Paper eject roller shaft holder shafts (4 positions) Paper eject roller shaft holder Fig.
Trimmer Unit CL2000010 Sliding surfaces of T-cutter unit and T-paper guide (6 positions) Fig. 6.1-22 Sliding Surfaces of T-cutter Unit and T-paper Guide Rotation points of T-lever A (2 positions) T-lever A Fig. 6.1-23 Rotation Points of T-lever A 6-10...
Y-Diversion Lever • Y-cutter guide shaft (1 position) Y-cutter guide shaft Y-diversion lever Fig. 6.1-24 Y-cutter Guide Shaft • Sliding surfaces of Y-diversion lever and YC lift shaft (2 positions) YC lift shaft Fig. 6.1-25 Sliding Surfaces of Y-diversion Lever and YC Lift Shaft 6-11...
6.2 Replacing the Cartridge and Film 6.2.1 Replacing the Cartridge  Turn off the power switch and open the top cover. Fig. 6.2-1 Replacing the Cartridge 1  Push the Set buttons R/L in the direction indicated by the arrow to unlock the Roller holder assy.
 Carefully remove the cartridge. Fig. 6.2-3 Replacing the Cartridge 3  Gently install the new cartridge. Check the following items before inserting the cartridge. • Cartridge shutter is fully closed. • The edge of the sheet is parallel with the cartridge film outlet. If the edge is not parallel, cut it parallel with scissors.
 Lower the roller holder assy and push the set buttons in the direction of the arrows to lock the roller holder assy in position. Fig. 6.2-5 Replacing the Cartridge 5  Close the top cover. Fig. 6.2-6 Replacing the Cartridge 6  Turn on the power switch and press the Feed key to feed out some sheet and remove the slackness in the sheet.
6.2.2 Replacing the Sheet  Carefully remove the cartridge. Fig. 6.2-7 Replacing the Sheet 1  Open the cartridge shutter, then open the cartridge cover. Fig. 6.2-8 Replacing the Sheet 2  Remove the old sheet. Fig. 6.2-9 Replacing the Sheet 3 6-15...
 Hold the yellow plastic holders of the new film, align the arrow marks and L/R marks of the Cartridge bottom cover and the plastic holders, and insert the film into the cartridge as shown in the diagram. It is not possible to insert the film in the wrong direction.
 Press the shutter buttons and close the shutter. Fig. 6.2-13 Replacing the Sheet 7  Check that the edge of the sheet is parallel with the cartridge film outlet. If the edge is not parallel, cut it parallel with scissors. Fig.
6.3 Adjustments CL2000010 6.3.1 Adjusting the Right Y-cutting Position (Border Mode) 1. Before adjustment, laminate in the Border Mode to check the amount of border. 2. Turn off the power supply and pull the AC adapter jack from the unit. 3.
6.3.2 Adjusting the Left Y-cutting Position CL2000010 1. Before adjustment, laminate in the Border Mode to check the amount of border. 2. Turn off the power supply and pull the AC adapter jack from the unit. 3. Loosen the screw and move the Y-sensor carriage arm left or right. This moves the detection position of the sensor attached to the Y-sensor carriage and adjusts the cutting position for the left edge of the film.
6.3.3 Adjusting Perpendicularity of Chassis and Document CL2000012 1. Loosen the four screws under the Bottom cover, as shown in the diagram below. 2. Insert the L-shaped jig for perpendicularity adjustment between the square holes in the Chassis and bosses protruding from the Bottom cover. Push the Chassis into position in the direction of the arrow shown in the diagram.
7.1 Outline It is extremely difficult to determine when and where a problem may arise and to determine the cause of a problem that did arise. It is even more difficult to formulate remedies for theoretical problems which may or may not occur. This chapter gives examples of actual problems that have occurred, together with suggested remedies.
7.5 Troubleshooting Flowcharts AC adaptor plugged in, power ON Nothing happens when power switch is pressed. Is POWER LED indicator lit? a. Abnormal input voltage. b. Abnormal +5V DC supply. c. Defective main CPU. See page 7-5. Nothing happens when switches are pressed (LED indicators do not light).
Abnormal trimming. Is trimming normal? a. Defective trimming (TR-I) switch. b. Defective trimming (SG) motor. c. Defective trimming (TR-G) switch d. Defective T-cutter. See page 7-12. Nothing happens when switches are pressed Is X-cutter operation (LED indicators do not light). normal? a.
Problem during automatic operation. Document cannot be correctly inserted. Is document correctly inserted? a. Problem with input-side rollers. b. Defective PST sensor (Photosensor) switch. See page 7-15. Document width cannot be detected correctly. Document width a. Defective Y-carriage (Y-CA) motor. detected correctly? b.
7.6 Troubleshooting Tables Nothing happens when power switch is pressed. (LED indicator does not light.) a. Abnormal input voltage. b. Abnormal +5V DC supply. c. Defective main CPU. Problem Check Item Cause Remedy Repair Section a. Abnormal input Are AC adaptor, Jack PCB, Defective harness Connect harness voltage...
Nothing happens when switches are pressed. a. Defective switch or push switch on the Switch PCB. b. Defective LED on the Switch PCB. Problem Check Item Cause Remedy Repair Section a. Defective Is Switch PCB correctly Defective Switch PCB Correctly mount switch or push mounted? mounting.
Problem Check Item Cause Remedy Repair Section b. Defective LED Low output from the main Defective main Replace Main PCB Replace 3.3.3 on the Switch CPU ports P30 (Pin 73), CPU#3. assy. CPU#3. 3.3.4 P33 (Pin 76), P34 (Pin 77), 3.3.5 and P52 (Pin 27) that drive 3.5.1...
An error occurred during processing after power ON (before film feed). a. Abnormal +24V DC supply b. Abnormal DC input voltage. c. Abnormal X-cutter power ON processing. d. Abnormal Y-carriage power ON processing. e. Abnormal Y-cutter power ON processing. Problem Check Item Cause Remedy...
Problem Check Item Cause Remedy Repair Section d. Abnormal Y- Actuator Y cuts photosensor Deformed Y sensor Replace the Y carriage power at start position? rail. sensor rail. 3.3.3 ON processing 3.3.4 Photosensor cut off when Actuator Y incorrectly 3.3.5 not at start position? installed.
An error occurred during processing after power ON (after film feed). a. Defective film or cartridge. b. Defective film feed detector (TPS) switch. c. Defective film feed system. Problem Check Item Cause Remedy Repair Section a. Defective film Is the film cartridge correctly Defective film Correctly mount the or cartridge...
Abnormal manual feed a. Defective film feed (LF) motor. b. Defective film compression system. c. Problem related to paper eject roller. Problem Check Item Cause Remedy Repair Section a. Defective film Is the black lead connector Motor harness assy Correctly connect 3.3.3 feed (LF) connected to CN12 on the...
Abnormal trimming a. Defective trimming (TR-I) switch. b. Defective control (SG) motor. c. Defective trimming (TR-G) switch. d. Defective T-cutter. Problem Check Item Cause Remedy Repair Section −−− a. Defective Is document correctly Document inserted Correctly insert the trimming (TR-I) inserted? incorrectly.
Problem Check Item Cause Remedy Repair Section Motor harness assy Correctly connect 3.3.3 b. Defective Is the black lead connector control (SG) connected to CN13 on the not connected. the motor harness 3.3.4 motor. Main PCB? assy. 3.3.5 Are pulses output from Defective main Replace Main PCB Replace...
Abnormal X-cutter operation. a. Defective X-cutter position switch. b. Defective X-cutter DC motor. c. Defective X-cutter. Problem Check Item Cause Remedy Repair Section a. Defective X- The X-cutter rotary cutter is Defective X-cutter Replace the X-cutter 3.3.1 cutter position at the left or right end but unit.
Document cannot be correctly inserted. a. Problem with input-side rollers. b. Defective PST sensor (photosensor) switch. Problem Check Item Cause Remedy Repair Section −−− a. Problem with Is document correctly Document inserted Correctly insert the input-side inserted against the paper incorrectly.
Document width cannot be detected correctly. a. Defective Y-carriage (Y-CA) motor. b. Defective sensor unit (YCA-F). c. Defective Y-cutter arm. Problem Check Item Cause Remedy Repair Section a. Defective Y- Is the Y-CA motor harness Motor harness not Correctly connect 3.3.3 carriage (Y- connected to connector C14...
Lamination is not normal. a. Defective ENC PCB assy. b. Defective document or film. Problem Check Item Cause Remedy Repair Section a. Defective ENC Is the white lead connector Defective harness Correctly connect 3.3.3 PCB assy. connected to CN15 on the assy connection.
No cutting in Y direction. a. DefectiveTrimmer Position Switch (SG-SW). b. Abnormal Y-cutter vertical movement. Problem Check Item Cause Remedy Repair Section a. Defective Is the blue lead connector Leaf switch assy not Correctly connect 3.3.3 Trimmer connected to CN5 on the connected correctly.
Incorrect cutting in Y direction. a. Incorrect Y-direction cutting position. b. Defective Y-cutter. Problem Check Item Cause Remedy Repair Section a. Incorrect Y- Does the right cutter move Y-cutter guide R and Correctly direction when the mode is changed? adjustment plate reassemble the 3.3.3 cutting position...
Incorrect cutting position at document front or rear edge. a. Defect in paper feed system. b. Defect in paper sensor system. Problem Check Item Cause Remedy Repair Section a. Defect in paper Do gear holder and idle gear Defective operation of Apply KS64F silicon 3.3.1 feed system...
Cartridge size, film type cannot be detected correctly. a. Defective cartridge type detector (CSIZE4) switch. b. Defective cartridge type detector (CSIZE3) switch. Problem Check Item Cause Remedy Repair Section a. Defective Is the yellow lead connector Leaf switch assy not Correctly connect 3.3.3 cartridge type...
Problem Check Item Cause Remedy Repair Section b. Defective Is the red lead connector Leaf switch assy not Correctly connect 3.3.3 cartridge type connected to CN6 on the connected. the leaf switch assy. 3.3.4 detector main PCB? 3.3.5 (CSIZE3) Is the cartridge leaf switch Incorrectly installed Correctly install the 3.3.1...
Buzzer does not sound. a. Defective buzzer circuit. Problem Check Item Cause Remedy Repair Section a. Defective Are 4 kHz pulses output Defective main Replace Main PCB Replace buzzer circuit from DV0 (Pin 20) on main CPU#3. assy. CPU#3. 3.3.3 CPU#3? 3.3.4 3.3.5...
Appendix Main PCB Circuit Diagram APP-1...