6204 Series Low-Volume Inserter

Transcription

1 60 Series Low-Volume Inserter 6/0 MAINTENANCE MANUAL

2 3 3 Appendix 3 Appendix...89 Recommended spare parts...90 Electrical diagrams...95 Product coding for CRM...35 Total view electronics Service Guide 89

3 Recommended spare parts O = Option. = Standard. SL = Introduced in Service Letter. * = depending on configuration Service Guide 90

4 Page reference Legend no. Chapter and description of part Part No Stock per number of installed machines Remarks Covers, Frames, and External parts on page 0 Hopper complete (auto)* 79053J Covers, Frames, and External parts on page 3 Moistening cloth 00306T Envelope hopper on page 3 7 Separation roller (assy.) Feed roller mm 95703Q 7373U 7 Pulley 5T (assy.) 93055K 8 Timing belt 9536M 9 Slip clutch CCW 8 mm 9577Q 5 - Conductive bearing 0 mm O-ring (for jogger roller) 06B 0876D Lower envelope track on page Transportation roller 30 mm Sensor (including holder) LED (including holder) Transportation roller 30 mm Conductive bearing 8 mm 087C 053E 05D 953H 05A Service Guide 9

5 Lower envelope track on page Rubber roller Pressure roller (assy.) D 8 Insert table and upper envelope track on page 3 Microswitch (including lever) Upper sealing roller 36 mm Z 7368H 6 Lower sealing roller (assy.) 98933S 3 Conductive bearing 6 mm 0Z 33 Solenoid 00E 36 Finger 9607Y 8 38 Leaf spring 9656M Hex. head screw M x 8 (synthetic) 96566P 8 3 Adjustable finger 96057J Transportation table (assy.) 96567Q Also contains insert rollers 0095J 063. Service Guide Envelope track driving mechanism on page 38 Envelope track driving mechanism on page Timing belt Pulse disc sensor (assy.) Pulse disc Tensioner roller Clutch CW 8 mm 96355U 86P 8S 969B 666T 9

6 Folder unit (base) on page 0 Upper input roller (assy.) Lower input roller (assy.) 9895J 9895K 7 Fold roller (assy.) 98950H Main drive mechanism on page 9 Timing belt Drive belt PJ 06N 9655L Solenoid Timing belt Insert and Eject mechanism on page 8 Transportation roller 30 mm 87Y 0537A 9636D Gear 5T 739P Moistening unit on page 5 3 Transportation roller 38 mm 0977A 8 Retaining spring 0387U 3 Grommet 07B Brush 70005N 3 6 Envelope closing mechanism 0 Transportation roller (assy.) 870H 8 3 Document feeder unit (automatic) on page Upper separation roller* Cover plate Timing belt Rubber paper puller Pulley assy. DFC Separation roller (lower)* 9567G 955N 955J 0006R 070D 7907C 9568H Service Guide Vertical track (base) on page Clutch CCW 8 mm R 93

7 Vertical track (loc) on page 6 8 Reading head assy. 037Q Collating unit (upper) on page 6 Pressure roller assy. (incl. O-ring) 950L O ring 007K not seperately fittable 30 Collating belt set (3 pcs.) 95007G 38 Motor V 98909S 50 Pressure roller Ø 0 mm 9508H 8 Collating unit (lower) and power supply on page 68 Spring Motor relay board 30V Motor relay board 5V 9508H D 97550V 8 Power inlet W 3 Folder unit (loc) on page Clutch CCW 8 mm Clutch CW (clockwise) 8 mm 6E 63G 063. Service Guide Folder unit (loc) 3 on page 7 Folder unit (loc) on page 76 8 Lever for flap actuator Upper fold roller (assy.) Tensioner roller 95303Y 9666N 9539Q 9

8 3 Electrical components on page 78 5 Mainboard Communication board (optional)* 99500V 99500V O Socket modem (optional)* 9900T O Serial cable INF interface 995P O Phone cable external 99005W O Connection board expanded (optional)* 99003U O Electrical diagrams Motor relay board - 30V (975500D) 063. Service Guide 95

9 Motor relay board 5V (97550V) Connection board - regular (99003U) Service Guide 96

10 3 Connection board - expanded (9900S) 063. Service Guide 97

11 Communication board - Power supply (99000R) Service Guide 98

12 3 Communication board - CPU core (99000R) 063. Service Guide 99

13 Communication board - CPU memory (99000R) Service Guide 300

14 3 Communication board - Peripheral I/O (99000R) 063. Service Guide 30

15 Communication board - LAN and USB host (99000R) Service Guide 30

16 3 Main board - Common power (99500V) 063. Service Guide 303

17 Main board - CPU core (99500V) Service Guide 30

18 3 Main board - CPU memory (99500V) 063. Service Guide 305

19 Main board - analog I/O (99500V) Service Guide 306

20 3 Main board - Inserter photocells (99500V) 063. Service Guide 307

21 Main board - Inserter power I/O (99500V) Service Guide 308

22 3 Main board - Feeder vertical folder (99500V) 063. Service Guide 309

23 Main board - Feeder vertical collator (99500V) Service Guide 30

24 3 Main board - Feeder vertical feeders (99500V) 063. Service Guide 3

25 Main board - Feeder vertical reading (99500V) Service Guide 3

26 3 Main board - CPU USB I/O (99500V) 063. Service Guide 33

27 Main board - User interface (99500V) Service Guide ID-Tag (A000379) 3

28 Product coding for CRM Failure symptoms Code SD550 SD560 SD570 SD80 SD80 SD830 SD80 SD850 SD860 SD990 Failure symptoms Unable to run mail Document jam Unable to connect to OLS Envelope feeding issue Envelope jam Display operation issue Noisy machine No power Envelope sealing issue Symptom not coded Module Code D07 D085 D7 D9 D85 D369 D0 D9 D55 D555 D80 D83 D80 D890 D990 Module Document Feeder Collator Document Folder Envelope Feeder Empty Envelope Transport Document Insertion Area Envelope Ejection Area Envelope Sealing and Exit Area Main Drive Miscellaneous Submodules Server Customer environment / operation OpCo / Service operation Origin not found Module not coded Service Guide 35

29 Failure origins Code Module Not Coded Failure origin D0750 Document Feeder Photocell D0760 Document Feeder DFC Thickness detector D0770 Document Feeder Wiring D0750 Document Feeder Paper pull roller D0760 Document Feeder Separation roller D0770 Document Feeder Transport rollers D0790 Document Feeder Axle D0750 Document Feeder Clutch D07530 Document Feeder Belt D0750 Document Feeder Belt tensioner D07550 Document Feeder Pressure spring D07580 Document Feeder OMR paper guides D07590 Document Feeder OMR reading head D07990 Document Feeder Origin not coded D08550 Collator Photocell D08560 Collator Motor D08570 Collator Switch D08580 Collator Wiring D08550 Collator Collator roller D08560 Collator Bearing 3 D08570 D08590 Collator Collator Axle Pulley D Collator Timing belt 063. Service Guide D08550 D D D D750 D760 D750 D760 D770 D780 D790 Collator Collator Collator Collator Document Folder Document Folder Document Folder Document Folder Document Folder Document Folder Document Folder Collator belt Pulse disc Stop positioner Origin not coded Photocell Wiring Fold roller Bearing Axle Gear Clutch D7500 Document Folder Pulley D750 Document Folder Belt D750 Document Folder Folding knife D7570 Document Folder Cam disc 36

30 D760 Document Folder Brake disc D7990 Document Folder Origin not coded D950 Envelope Feeder Wiring D950 Envelope Feeder Feed roller D960 Envelope Feeder Jogger roller D970 Envelope Feeder Separation roller D980 Envelope Feeder Bearing D990 Envelope Feeder Axle D9500 Envelope Feeder Gear D950 Envelope Feeder Clutch D950 Envelope Feeder Pulley D9530 Envelope Feeder Belt D9550 Envelope Feeder Hopper side guide D9560 Envelope Feeder Eenvelope separation D9990 Envelope Feeder Origin not coded D8550 Empty Envelope Transport Photocell D8560 Empty Envelope Transport Wiring D8550 Empty Envelope Transport Transport roller D8560 Empty Envelope Transport Track roller D8570 Empty Envelope Transport Flap roller D8580 Empty Envelope Transport Bearing D8590 Empty Envelope Transport Axle D85500 D8550 D8550 Empty Envelope Transport Empty Envelope Transport Empty Envelope Transport Gear Clutch Pulley 3 D85530 Empty Envelope Transport Belt D85550 Empty Envelope Transport Flap scraper D85560 D85990 D36950 D36960 D36970 D36950 D36960 D36970 D36980 D36990 Empty Envelope Transport Empty Envelope Transport Document Insertion Area Document Insertion Area Document Insertion Area Document Insertion Area Document Insertion Area Document Insertion Area Document Insertion Area Document Insertion Area Friction brake Origin not coded Photocell Finger solenoid Wiring Insert roller Bearing Axle Gear Clutch 063. Service Guide D Document Insertion Area Pulley D36950 Document Insertion Area Belt D36950 Document Insertion Area Leaf spring D36950 Document Insertion Area Fingers 37

31 D Document Insertion Area Origin not coded D050 Envelope Ejection Area Ejection solenoid D060 Envelope Ejection Area Photocell D070 Envelope Ejection Area Wiring D050 Envelope Ejection Area Ejection roller D060 Envelope Ejection Area Bearing D070 Envelope Ejection Area Axle D080 Envelope Ejection Area Gear D090 Envelope Ejection Area Pulley D0500 Envelope Ejection Area Belt D050 Envelope Ejection Area Spring D0990 Envelope Ejection Area Origin not coded D950 Envelope Sealing and Exit Solenoid D960 Envelope Sealing and Exit Photocell D980 Envelope Sealing and Exit Wiring D950 Envelope Sealing and Exit Envelope reverse roller D960 Envelope Sealing and Exit Envelope sealing roller D970 Envelope Sealing and Exit Bearing D980 Envelope Sealing and Exit Axle D990 Envelope Sealing and Exit Gear D9500 Envelope Sealing and Exit Pulley D950 Envelope Sealing and Exit Belt 3 D950 D9560 D9990 Envelope Sealing and Exit Envelope Sealing and Exit Envelope Sealing and Exit Moistening cloth Brush holder Origin not coded D5550 Main Drive Main motor 063. Service Guide D5560 D5570 D5550 D5560 D5570 D5580 D5590 D55500 D5550 D55990 D55500 Main Drive Main Drive Main Drive Main Drive Main Drive Main Drive Main Drive Main Drive Main Drive Main Drive Miscellaneous Area Photocell Wiring Bearing Axle Gear Clutch Pulley Belt Pulse disc Origin not coded Main Board D Miscellaneous Area Communication board D55500 Miscellaneous Area Connection board D Miscellaneous Area Display Board D Miscellaneous Area ID tag 38

32 D5555 Miscellaneous Area Software D55550 Miscellaneous Area Power supply D55560 Miscellaneous Area Dongle D55570 Miscellaneous Area Fuse D55580 Miscellaneous Area Power switch D55590 Miscellaneous Area Cover switch D Miscellaneous Area Power cable D55550 Miscellaneous Area Cover D Miscellaneous Area Display assembly D Miscellaneous Area Origin not coded D805 Server OLS server not available D80990 Server Origin not coded D8350 Customer environment / operation Phone adaptor D8360 Customer environment / operation Phone line filter D8370 Customer environment / operation Phone cable D8390 Customer environment / operation User setting D8395 Customer environment / operation Supervisor setting D83930 Customer environment / operation PAB setting D83935 Customer environment / operation No phone line D8390 Customer environment / operation Phone line too far D8395 Customer environment / operation Several devices on phone socket D83950 Customer environment / operation Envelope not appropriate D83955 D83960 D83990 Customer environment / operation Customer environment / operation Customer environment / operation Document not appropriate Incorrect user operation Origin not coded 3 D8095 OpCo / Service operation ERP(SAP) incorrect operation D8090 OpCo / Service operation Service settings D80930 D80990 D D OpCo / Service operation OpCo / Service operation Origin Not Found Module Not Coded Incorrect Service operation Origin not coded Origin not found Origin not coded 063. Service Guide 39

33 Total view electronics Service Guide 30

34 Service Guide 3

35 Service Guide 3

36 Index A B C D E F H I automatic calls 63 base 90 Base 89 batch mode 89 Batch Mode 89 belt 60, 59, 90, 35 Belt 35 belts, 60 brushes, 8 can 6,, 9, 0,, 3, 5, 6, 30, 3, 35, 0,, 57, 35, 6, 63, 6, 67, 68, 73, 76, 8, 87, 89, 07 cartridge 89 catch tray 9, 7 Catch tray 05 counter 9, 0, 3, 9, 3, 35,, 63, 85 Counter, cover 9,, 5, 73, 63, 85, 95, 0 Cover 85, 87, 95, 90, 35 date 9 Dynamic Scale 89 envelope hopper 9, 35, 69 Envelope hopper 6, 90 Envelope Hopper 6 feeder 3, 0,, 7, 30, 35, 50, 6, 6, 68, 89, 00, 03, 05, 07, 90 Feeder,, 3, 50, 6, 76, 89, 00, 0, 03, 05, 35 folder 8, 9, 3, 6, 67, 70, 7, 0 Folder, 3, 50, 6, 70, 76, 90, 35 hopper 9, 69, 0 Hopper 90, 35 installation 35 Installation 6 item 0 J K L M N O P R S Item 58, 59 jamming 3 keyboard Keyboard 39 language 9 memory 9, 3, 0, 7, 75 Memory 00 menu 8, 9, 30, 3, 35, 0,, 8, 57, 63, 65, 7, 76, 8, 88, 89 Menu 8 messages 0, 6, 75, 87 normal 7, 3, 7 Normal 3, 35 off 0, 3, 30, 6, 76, 88, 89 Off 3 OFF 35 online services 63 Online services 5 PIN code 89 power 6, 35, 7, 76, 80, 90, 35 Power 6, 9, 6, 65, 76, 00, 90, 35 received 0, 76, 79, 89 rollers, 7, 8, 9, 0, 7, 68, 7, 90, 35 sensors, 3, 0 Sensors 9 session 7 side guide 9 stacker 00 standard 9, 0 Standard 05, 90 supervisor, 63, 7, 7, 89 Supervisor 89, 35 SUPERVISOR

37 T telephone 9, 63 text 35 thickness 3,, 7, 3, 50, 68, 70, 05, 06 Thickness 03, 35 time,, 8, 9, 0, 3, 3, 35, 0, 58, 59, 63, 65, 7, 79, 87, 88, 89