FPi2000 Servicemanual PDF

service manual SI 62
SI 62
Contents
Section Page
General 410.00-1
Process description 410.01-1
Mechanical description 410.02-1
Electrical description 410.03-1
Parts lists 410.04-1
General
rev. 01.0 - 06/2004

410.00-1
410.00-2 rev. 01.0 - 06/2004

Contents
Section Page
1 Function 6
2 Specifications 7
2.1 Machine specifications 7
2.2 Paper Insert specifications 8
2.3 Envelope insert specifications 8
2.4 Envelope and paper insert specifications 9
3 Preparing the machine for use 10

3.1 Unpacking 10
rev. 01.0 - 06/2004

410.00-3
410.00-4 rev. 01.0 - 06/2004

Used symbols
In this manual the following symbols are used.
Warning, this symbol indicates a wrong action which can cause a hazard to health
or damage the machine.
Warning, this symbol indicates a hazard to life because of high voltage.
rev. 01.0 - 06/2004

410.00-5
1 Function
figure 1.1
Refer to figure 1.1.
The SI 62 feeds, folds and inserts documents into envelopes and then seals and stacks the
envelopes. Automatic monitoring ensures the correct number of inserts per envelope.
The SI 62 is equipped with a variety of special features as programmable jobs, Load ’N Go™,
FlexFeed™ (1), double feed control, hopper swap, multifeed, daily mail and PowerFold™(2).
410.00-6 rev. 01.0 - 06/2004

2 Specifications
2.1 Machine specifications
Model : SI 62
Type : inserter system for medium office use.
Overall Dimensions 3- station system

height : 670 mm (26.3 inch)
width : 420 mm (16.5 inch)
length : 1100 mm (43.3 inch)
(with side exit 1200 mm/47.2 inch
receiving tray 1350 mm/ 53.1 inch)
Weight : 80 kg (176 lb)
Noise level : < 70 dB(A) (following ISO 11203)
Theoretical max. speed : 2200 inserts p/h, depending on application.
Operating temperature : 10 - 40°C (50 - 104°F)
Humidity : 30 - 80%
Power consumption : 100V AC / 50Hz / 3,0 Amps

115V AC / 60Hz / 3,0 Amps
230V AC / 50Hz / 1,5 Amps
Approvals : EMC Certificate conform EMC-Directive.

FCC Certificate conform 47CFR, part 15.
CB Certificate conform IEC 60950.
UL listed I.T.E. (Information Technology Equipment),
conform UL-IEC 60950, file: E153801.
Conform NEN-EN-IEC 60950 and derivates.
rev. 01.0 - 06/2004

410.00-7
2.2 Paper Insert specifications
Paper sizes minimum maximum

width* : 130 mm (5.1 inch) 236 mm (9.3 inch)
length** : 90 mm (3.5 inch) 356 mm (14.0 inch)
Quality*** : 60 gr/m2 250 gr/m2

(15 lb bond) (62.5 lb bond)
Booklets up to approximately 1 mm (0.04 inch) thickness,

depending on stiffness.
Folding capacity : 5 sheets (max. 80 gr/m2)
* When folded max. 230 mm (9.1 inch)

** The minimum document size used for the upper feeder is 115 mm (4.5 inch)
*** When folded max. 170 gr/m2.
2.3 Envelope insert specifications
Envelope sizes : Standard BRE (Business Reply Envelopes)
minimum maximum
Quality : 80gr/m2 120 gr/m2
(20 lb bond) (30 lb bond)
410.00-8 rev. 01.0 - 06/2004

2.4 Envelope and paper insert specifications
Maximum insert specifications are based on single sheets. When multiples are handled, more room
inside the envelope is needed depending on application.
figure 2.1
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& ' () * + & ,)

%
&( (- )- * (( & ,)
)+ &) * () (- * ) *& )-

%
'+ &(+ *)- * . * )

/ 0 * -, * &
Remarks
• The specification of the paper handling equipment is often wider than that of the envelopes and
documents handled. The condition of material handled will limit the specified environmental
conditions.
• We recommend that materials to be handled are stored at a temperature of 20°C (68°F) with a
relative humidity factor of 50%. If difference in temperature occurs between store room and
mailing area, the material has to be stored near the machine at least 24 hours before use.
• Self-copying paper may cause rubber parts to wear quicker. The rubber used in this machine
has the best resistance to Wiggins Teape material.
rev. 01.0 - 06/2004

410.00-9
3 Preparing the machine for use

First the machine must be unpacked. After unpacking and installing the machine is ready for use.
3.1 Unpacking
Step 1
Step 2
Step 3
Step 4
80 Kgs Place the machine in the optional furniture or on a solid table

176 Lbs
figure 3.1
410.00-10 rev. 01.0 - 06/2004

Process description
rev. 01.0 - 06/2004

410.01-1
410.01-2 rev. 01.0 - 06/2004

Contents
Section Page
1 Overview 5
1.1 Feeding documents 5
1.2 Vertical document transport 6
1.3 Transport to and from the collator 6
1.4 Folding 7
1.5 Envelope transport 8
1.6 Document input and insert 8
1.7 Envelope ejecting, sealing and exiting 9
1.8 Parallel processing 9
1.9 Legend 11
rev. 01.0 - 06/2004

410.01-3
410.01-4 rev. 01.0 - 06/2004

1 Overview
The processing of documents by the consists of a number of sequential processes:
• Feeding documents.
• Vertical document transport.
• Transport to and from the collator.
• Folding.
• Envelope transport.
• Document input and insert.
• Envelope ejecting, sealing and exiting.
• Parallel processing.
The figure shows a schematic overview of the process. All mechanical items that are necessary to
discuss the process are projected on the LH side of the machine. With a few exceptions auxiliary
mechanical items (such as gears, belts et cetera) are shown. The parts lists (document 410.04)
provide mechanical details.
1.1 Feeding documents
Only feeders with automatic separation are used.

The upper feeder (in position 2 or 3) can be used for processing daily mail. To this purpose a
mechanic switch is set in the daily mail position.
The machine has two or three feeders. There is a 1½-station, a 2-station and a 2½-station version.
In the version with three feeders (the 2½-station version) the lowest feeder (the "½", in position 1)
can only process documents with a length of up to about 150 mm (6 inch). This feeder is fitted with
a so-called short tray.
For the documents to be fed the following rules apply:
• Documents with the single fold and letter fold types are fed with the orientation face up and
leading. The address carrying document is to be fed from the highest active feeder.
• Documents with the zigzag fold type must be fed with the orientation face down and trailing. The
address carrying document is to be fed from the lowest active feeder.
The physical feeding process is fairly straightforward: a document is separated by 79 - 81 (feeder

3), 72 - 74 (feeder 2) or 65 - 67 (feeder 1) and exited to the vertical track by 77 and 78 (feeder 3), 70
and 71 (feeder 2) or 63 and 64 (feeder 1). The paper transport is monitored by the feeder photocell
PH3 (feeder 3), PH2 (feeder 2) or PH1 (feeder 1). The double feed security check is performed by
the Double Feed Control unit DFC3 (feeder 3), DFC2 (feeder 2) and DFC1 (feeder 1). The feeders
are mechanically driven from the main motor M1 by a clutch (feeder clutches CL1, CL2 and CL3).
The combination of CL1 and PH1 (CL2 and PH2; CL3 and PH3) ensures a well-defined waiting
position at the feeder output, prior to entering the vertical track.
The separation process is based on separating the upper document in the document hopper. To this
purpose the feeder rollers (67, 74, 81) adapt their vertical positions to the current amount of
documents in the hopper.
In order to further reduce the risk of double feeding documents (partial or full document overlapping)
a mechanical delay is established between the current document and the next one to be separated
from the document hopper. Soon after the current document leaves a feeder, there is a time when
roller 67 (74, 81) no longer touches the leaving document. Without the mechanic delay the
separation of the next document would immediately start. However, during a turn of between 135
and 225 degrees this roller will not turn, prior to the drive catching up. This causes a gap between
the trailing edge of the current document and the leading edge of the next document. Note that this
mechanical behaviour is possible, not only by the 135-225 degrees free stroke, but as well by the
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410.01-5
fact that roller 67 (74, 81) has freewheel action in forward direction. The latter is necessary to enable
the paper acceleration in the feeder.
1.2 Vertical document transport
The vertical track consists of one driven axle per feeder (75, 68, 61), plus one driven axle in the lower
vertical track (45). All these axles carry two rollers, except for 75 (at the top feeder), which carries
four rollers. This is necessary for straightening the paper prior to passing the optional reading head
RH1. The driven rollers have their counterparts in rollers 76, 69, 62 and 44. If the OMR option is
installed, the paper transport prior to entering the reading head is monitored by the reading head
photocell PH4. (The reading head RH1 is present if the OMR option is installed. In the overview it is
located directly below PH4.) This monitoring is necessary for establishing the reading window.
Depending on the number of documents to be delivered by each feeder there are two ways in which
documents can be transported along the vertical track:
• One sheet per feeder per set (pane cycle). The various documents of a set are fed from the
feeders in such a way that these documents are partly overlapping each other. This pane-like
overlapping ensures a higher throughput.
• More sheets from the same feeder per set (sequential cycle). This is relevant for multi feeding
and OMR. Documents are transported along the vertical track without touching each other. Only
after joining the set in the making they do touch each other.
Refer to section 1.3 for details on the way in which a set is composed.
1.3 Transport to and from the collator
Before discussing the physical aspects of collating a set it is relevant to discuss the way in which the
set is collated (i.e. composed).
Of course the operator must have full control over the order in which the various documents of a set
are actually present in the filled envelopes. The following rules apply:
• If a feeder adds more than one document to a set (multi feeding), these documents are first of
all processed, in the order in which they are separated from the feeder hopper.
• The feeders are processed in the order highest active feeder first, lowest active feeder last. This
is independent of the fold type.
Based on the actual number of documents from each cycle, the machine composes a set based on
the minimum amount of cycles and, if possible, a pane cycle in stead of a sequential cycle.
In the case of OMR processing the document(s) from feeder 3 is/are always processed via
sequential cycles.
Between two successive cycles of the collating process a process that is called shunting is
necessary. Shunting implies that, prior to being joined by a new document (sequential cycle) or new
documents (pane cycle), the partially completed set in the collator is partially moved out of the
collator area, into the direction of the fold unit. This is necessary to prevent the leading edge (i.e.
entering the collator area first) of the paper entering from the vertical track from interfering with the
leading edge (i.e. leaving the collator area first) of the partially completed set.
Now for the physical details. The collator area consists of a set of rollers (46, 50, 53, 56 and 60) that
can be driven in both directions by the collator motor M2, and a set of counter rollers 47, 48, 49, 52,
410.01-6 rev. 01.0 - 06/2004

54, 55 and 58. In the IN direction of M2 documents are fed into the collator area, in the OUT direction
they are moved out of the collator area.
The entry of documents into the collator area is monitored by the collating area photocell PH5. A
document set leaving the collator area is monitored by the folder input photocell PH6.
Documents are fed into the collator area from the vertical track, or back into the collator area in the
second stage of the shunt process. The documents are aligned against document stop position 59.
(In this machine stop positions 51 and 57 are not used.)
During shunting the collator motor M2 first turns in the IN direction, then in the OUT direction.
Once a set is complete, documents are exited from the collator to the fold unit if a set is complete.
In that case the collator motor M2 is activated in the OUT direction.
Transport into and from the collator area is assisted by three collator belts. One belt is situated at
the RH side, a second belt is situated at the LH side and the third belt is located at the centre line of
the documents. All three belts are connected between pulleys on 50 and 60. In addition the middle
belt drives 53 and 56 as well.
1.4 Folding
The folding process is based on the timed impact action of a fold knife: one per fold pocket.
As soon as the paper enters a fold pocket and a fold is to be made, the fold deflector is turned
upwards. The fold knife is in its rest position; it is turned backwards. The paper is directed into the
fold pocket. At the right time the fold knife moves forward and pushes the paper between the fold
rollers. The fold is located at the place where the paper touches the tangent between the upper and
lower fold roller. The timing of the fold knife movement is based on the detection of the paper by the
folder input photocell PH6, machine parameters and job fold settings.
Now for the folding details. The paper of a completed set leaves the collator area. This is detected
by the folder input photocell PH6. The paper is transported to the first fold pocket by the fold input
rollers 42 and 43. Fold deflector 41 moves up, so paper entering the first fold pocket will be directed
in upward direction. At the appropriate time fold deflector 41 moves down and the fold knife 40
(which hinges around axle 39) moves forward: the first fold will be made. Directly after the fold has
been made fold knife 40 returns to the rest position. This process is controlled by the first fold pocket
clutch CL4, which drives the curve gear 37, which controls the movement of fold knife 40 and fold
deflector 41. The axle for the curve gear also carries the brake disc 38, the status of which is
monitored by slotted photocell SPH3. The 360 degrees fold cycle of the brake disk consists of a 120
degrees part (fold deflector upwards) and a 240 degrees path (fold deflector downwards plus the
impact action of 40). The brake disc is mechanically loaded by a positioning lever and a torsion
spring. The hinge axle 39 also carries the lever for the actuator of fold deflector 41. In this way all
movements related to the first fold pocket are synchronized.
After leaving the fold rollers 35 and 36 the paper enters the second fold pocket. The fold deflector
34 moves up, so paper entering the second fold pocket will be directed in upward direction. The
paper guide 33 also moves up. This guide is necessary in the second fold pocket to retain the fold
that has been made in the first fold pocket. The paper is limited to a small area between paper guide
33 and a fixed guide plate (not shown in the figure, but to the left of 33). At the appropriate time the
fold deflector 34 moves back and both the fold knife 32 and the guide plate 33 (which both hinge
around axle 31) move forward: the second fold will be made. Directly after the fold has been made,
fold knife 32 returns to its rest position. This process is controlled by the second fold pocket clutch
CL5, which drives the curve gear 29, which controls the movement of fold knife 32, paper guide 33
and fold deflector 34. The axle for the curve gear also carries the brake disc 30, the status of which
is monitored by slotted photocell SPH4. The 360 degrees fold cycle of the brake disk consists of a
rev. 01.0 - 06/2004

410.01-7
120 degrees part (fold deflector and paper guide upwards) and a 240 degrees path (fold deflector
and paper guide downwards plus the impact action of 32). The brake disc is mechanically loaded by
a positioning lever and a torsion spring. The hinge axle 31 also carries the lever for the actuator of
fold deflector 34. In this way all movements related to the second fold pocket are synchronized.
Finally the paper leaves the fold unit on its way (transported by 27 plus 28 and 13 plus 14) to the
insert table.
1.5 Envelope transport
All the rollers for this process stage (1, 4, 6, 8, 10 and 11) are engaged to the main drive by the
envelope track clutch CL6. During the document and insert stage these rollers are disengaged. The
envelope transport subsystem can be manually moved by the RH hand knob, at the LH side of the
machine (behind the LH front cover). The counter rollers 3, 5, 7, 9 and 12 can be decoupled from
there driven counterparts by a CCW movement of the release handle at the LH side of the machine.
In the final ejecting, sealing and exiting stage the driven rollers are engaged once again to release
the envelope (held between 11 and 12) and to feed the next envelope to the insert table. This
envelope (and maybe the next one as well) has already been separated and is present somewhere
in the envelope track.
Note. Roller 6 has freewheel action in the forward direction. This is necessary because for process
reasons the envelope transport speed at rollers 8, 10 and 11 is higher than the transport speed at
rollers 1, 4 and 6. Given the fact that, once an envelope has been separated, the next envelope is
separated, you can notice an increasing distance between two successive envelopes as they travel
through the envelope track.
First of all by the action of the feed and separation rollers (1 and 2) an envelope is separated from
the stack in the hopper and transported via three pairs of transport rollers (3 - 8). The envelope track
photocell PH7 detects the leading and trailing edge of the envelope.
The envelope then passes the flap rollers 9 and 10. The combined action of the flap scraper and the
lower linear speed of the flap rollers 9 and 10 (compared with the speed of 7 and 8) results in some
buckling and the opening of the envelope. The flap is the trailing part of the envelope passing the
flap rollers and the envelope flap track photocell PH8.
Pulse measurements (measured via slotted photocell SPH1) during the presence of the envelope
under PH7 and PH8 provide information on the length of the not yet opened envelope, the opened
envelope and the time at which the envelope transport is suddenly stopped with the envelope on the
insert table. The sudden stop is the result of disengaging by the envelope track clutch CL6 and the
friction brake 9a. The envelope flap now is fixed between 11 and 12. (The envelope stop position
can be corrected via the user interface of this machine.)
1.6 Document input and insert
Once the envelope is on the insert table, the fingers solenoid So1 is shortly activated. The fingers
are moved forward into the envelope. The envelope stays in place, for it is fixed between 11 and 12.
This is a preparation for inserting the document set into the envelope.
Now the document set can be inserted. This set leaves the fold unit (transported by 27 plus 28 and
by 13 plus 14), is detected by the insert table photocell PH9 and passes under the fingers before
entering the envelope.
410.01-8 rev. 01.0 - 06/2004

1.7 Envelope ejecting, sealing and exiting
The insert of the set is considered finished if and when the insert table photocell PH9 detects the
trailing edge of the set. Then a number of actions take place: (a) clutch CL6 is activated to release
the flap and to feed the next envelope to the insert table; (b) the insert table solenoid So2 is shortly
activated, resulting in the ejection roller 16 moving down. (By spring action, after switching So2 off,
these driven rollers are pulled high again.) Now the envelope is ejected from the insert table. So2 is
deactivated as soon as safely can be assumed that the filled envelope is between 17 and 18, so
further transport is guaranteed.
The filled envelope passes rollers 17 and 18, the moistening brushes, the sealing track rollers 19
and 20 and the lower sealing roller 22 plus its counter roller 21. The leading envelope edge triggers
flag switch FS1.
The upper reverse roller 25 is held high (i.e. this roller doesn't contact the lower reverse roller 24) by
a spring. A certain time after triggering FS1 the sealing solenoid So3 is activated. At this moment the
envelope flap is still between 21 and 22. The envelope body is between the upper and lower reverse
rollers, so the envelope position is clearly defined. (This envelope sealing position can be corrected
via the service menu.) By the So3 action the upper reverse roller now is temporarily lowered. Given
the turning direction of the lower reverse roller, the transport direction of the envelope is abruptly
changed from an "upstream" to a "downstream" direction. Assuming that the flap fold line of the
envelope has passed 21 and 22, this is now the leading edge of the envelope being transported
through the sealing rollers 22 and 23. After passing the sealing rollers the envelope is exited to the
exit of the machine. The sealing solenoid So3 is switched off as soon as the leading envelope edge
is detected by the exit photocell PH10. The exit photocell PH10 monitors the passing envelope.
As soon as PH10 has detected the trailing envelope edge, the next filled envelope can be
transported from the insert table to the exit of the machine.
1.8 Parallel processing
The process description discussed above deals with one specific set and one specific envelope as
these items travel through the machine. However, as soon as a certain process stage has been
completed for the current document, set or envelop, this process stage is repeated for the next
document, set or envelope.
• A very short time after the trailing edge of the separated envelope has passed roller 1, the next
envelope is separated. In the Auto mode on each time several envelopes are on their way to
the insert table.
• The next filled envelope can be transported as soon as the previous one has completely passed
the exit photocell PH10.
• Only after it has been established that (a) the previous set has passed the insert table photocell
PH9; (b) the envelope with this set can be ejected and sealed; (c)the flap of the current envelope
has been opened, the next set will be transported from the collator via the two fold pockets to
the current envelope on the insert table.
• In section 1.1 the delay between to successive documents fed to the same feeder is discussed.
rev. 01.0 - 06/2004 410.01-9

DFC3
FE3
RX 78 80 81
MS1
PH3 77 79
CL3 TX
DFC2
76 75 FE2
PH4 TX 71 73 74
RX
RX
RH1 PH2 70 72
TX
DFC1
FE1
69 68
64 66 67
CL2
RX
TX PH1 63
So3 65
FS1 SPH3(PD3) TX
23 25 39
31
62 CL1
CL4/5 61
MS2 22 24 26 SPH4(PD4) SPH2(PD2)
21 38
RX 30
PH10 So1 40 44
45
M2
51 53 57
37 PH5 50 56 59 60
So2 29 32 46
TX 43 TX 54
20 33 36 49 52 55 58
SPH1(PD1) 16 28 RX 48
14 47
19 18 TX
41 42
13 12 34 35
15 27 PH6
11 RX
17 PH9 MS3
RX
9a
CL8 RX
10 TX
8
6 PH8
2 4
7
9 M1
TX
5
1 3 PH7
410.01-10 rev. 01.0 - 06/2004

1.9 Legend
Note 1. Parts with an arrow are mechanically driven (by the main motor M1 or by a the collator DC
motor M2).
Note 2. For reasons of cross-reference the identification of sensors and actuators as used in the
electrical description (document 410.03) is mentioned here as well.
General
M1 Main motor. Provides the primary mechanical drive for the feeder clutches CL1 –
CL3, the folder clutches CL4 & CL5 and the envelope track clutch CL6. Directly
drives the vertical track transport (75, 68, 61, 45), the folding subsystem (42&43;
35&36; 27&28) and the inserter main drive (15, 17, 19, 20, 22, 23). If the upper unit
is in place, items 14, 16, 24 and 26) are driven as well. All items that are directly
driven by M1 can be activated with the LH hand knob (behind the LH front cover).
PD1 Pulse disc (mounted on roller 19). Monitored by slotted photocell SPH1. Provides
information on the process timing.
MS1 Safety switch for the upper unit.
MS2 Safety switch for the front cover.
MS3 Safety switch that guards the part of the collator area that can be opened by the user.
Feeders
Lower feeder (1)
CL1 Feeder 1 clutch. Drives 63, 66 and 67. Activated during the transport of the separated
document to its waiting position. Activated once again when this document is
transported to the vertical track and (after a short delay) the next document is
separated.
PH1 Feeder 1 photocell.
63 Driven output rollers.
64 Counter rollers for 63.
65 Lower separation roller. Connected to the feeder frame via a constant-torque device.
66 Feed axle with upper separation roller. Freewheel action in forward direction.
67 Paper puller axle with two rubber rollers. Adapts its vertical position to the amount of
documents in the hopper. Freewheel action in forward direction. Free stroke
(between 135 and 225 degrees) ensures a safe distance between successive
separated documents, in order to prevent double feeds.
DFC1 Double Feed Control unit for feeder 1.
Middle feeder (2)

separated.
70 Driven output rollers.
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410.01-11
Feeders
Upper feeder (3)

separated.
77 Driven output rollers
Vertical track
44 Counter roller of 45 (in the upper unit).
45 Driven vertical transport axle.
61 Driven vertical transport axle. On this axle feeder 1 (lower) clutch CL1 is mounted (at
the LH side of the machine). This clutch drives 63, 66 and 67.
62 Counter rollers for 61 (in upper unit).
68 Driven vertical transport axle. On this axle feeder 2 (middle) clutch CL2 is mounted
(at the LH side of the machine). This clutch drives 70, 73 and 74.
75 Driven vertical transport axle. On this axle feeder 3 (upper) clutch CL3 is mounted (at
the LH side of the machine). This clutch drives 77, 80 and 81.
PH4 Reading head photocell. Only present and operational if OMR is installed.
RH1 Reading head. Only present and operational if OMR is installed.
410.01-12 rev. 01.0 - 06/2004

Collator
M2 Collator motor. Drives 46, 50, 53, 56 and 60 in forward or reverse direction.
PD2 Pulse disc mounted on the axle of the collator motor M2. Monitored by slotted
photocell SPH2.
PH5 Collating area photocell. Guards the entry of documents from the vertical track.
46, 50, 53, Collator rollers driven (either forward or reverse) by the collator motor M2. In collator
56, 60 arm. Actual transport is realized with three belts, driven by and driving 50, 53, 56 and
60.
51 Document stop position for 6-inch documents. Not used in this machine!
57 Document stop position for 12-inch and A4-sized documents. Not used in this
machine!
59 Document stop position for 14-inch documents.
47, 48, 49, Free running collator rollers.
52, 54, 55,
58
Fold unit
PH6 Folder input photocell.
42 Lower fold input roller.
43 Upper fold input roller.
35 Lower fold roller for first fold pocket.
36 Upper fold roller for first fold pocket. In upper unit.
27 Lower fold roller for second fold pocket.
28 Upper fold roller for second fold pocket. In upper unit.
39 Control axle for first fold pocket. Hinge for 40. Moves the lever that in its turn moves
the fold deflector actuator of 41 upwards.
40 Fold knife for first fold pocket.
41 Fold deflector for first fold pocket.
37 Curve gears for first fold pocket (1 x LH, 1 x RH). Controls movement of 40.
38 Brake disc for first fold pocket. Spring loading ensures two static mechanical
states.
PD3 Cam disc of first fold pocket. Monitored by slotted photocell SPH3.
31 Control axle for second fold pocket. Hinge for 32 and 33. Moves the lever that in its
turn moves the fold deflector actuator of 34 upwards.
29 Curve gears for second fold pocket (1 x LH, 1 x RH). Controls movement of 32 and
33.
30 Brake disc for second fold pocket. Spring loading ensures two static mechanical
states.
PD4 Cam disc of second fold pocket. Monitored by slotted photocell SPH4.
32 Fold knife for second fold pocket.
33 Moving paper guide for second fold pocket.
34 Fold deflector for second fold pocket.
CL4 First fold pocket clutch. Drives 37.
CL5 Second fold pocket clutch. Drives 29.
rev. 01.0 - 06/2004

410.01-13
Envelope feeding
CL6 Envelope track clutch. Mounted on clutch shaft, at the RH side of the machine. On
this shaft two gears take care for the mechanical interface between the permanently
M1 driven subsystem and the envelope track subsystem. CL6 drives 1, 4, 6, 8, 10
and 11.
1 Feed roller. Activated by the envelope track clutch CL6.
2 Separation roller.
4, 6, 8 Driven envelope transport rollers. Activated by the envelope track clutch CL6.
3, 5, 7 Counter rollers for 4, 6 and 8. These rollers can be moved (by the release handle) in
order to solve a paper jam in the envelope track.
PH7 Envelope track photocell.
10 Driven envelope transport roller (flap opening stage). Activated by the envelope track
clutch CL6. Speed of 10 somewhat lower than that of 8, in order to assist flap
opening.
11 Driven envelope transport roller (flap opening stage). Activated by the envelope track
clutch CL6. On the axle at the LH side of the machine the RH hand knob (behind the
LH front cover) is mounted.
9, 12 Counter rollers for 10, 11. These rollers can be moved (by the release handle) in
order to solve a paper jam in the envelope flap track.
9a Friction brake.
PH8 Envelope flap track photocell.
Inserting, ejecting, sealing and exiting

PH9 Insert table photocell.
So1 Fingers solenoid. Moves fingers forward into envelope to enable inserting the set.
13 Lower insert roller.
14 Upper insert roller (in the upper unit). 14 and 13 provide final set transport prior to
inserting in envelope.
15 Lower first ejection roller. On the axle at the LH side of the machine the LH hand knob
(behind the LH front cover) is mounted. On this axle at the RH side of the machine
the main pulley is mounted.
16 Upper first ejection roller (in the upper unit). Lowered by the action of the insert table
solenoid So2.
So2 Insert table solenoid. Shortly activated. Deactivated as soon as 17&18 have taken
over the transport function.
17 Lower second ejection roller. In this area the moistening brushes are located.
18 Upper second ejection roller (in the upper unit).
19 Driven sealing track roller. On the axle at the RH side of the machine the pulse disc
PD1 (monitored by slotted photocell SPH1) is mounted.
20 Driven sealing track roller.
21 Counter roller for 22 (in the upper unit).
22 Lower sealing roller. A gear on the axle (on the RH side of the machine) provides via
an intermediate gear the mechanical interface to all the driven parts in the upper unit
(14, 16, 24, 26).
410.01-14 rev. 01.0 - 06/2004

Inserting, ejecting, sealing and exiting

23 Upper sealing roller.
FS1 Flag switch. Note. FS1 is actually mounted on the tangent line of 24 and 25.
So3 Sealing solenoid. Moves 25 down during a short time. Deactivated as soon as 22&23
have taken over the transport function.
24 Lower reverse roller (in the upper unit).
25 Upper reverse roller (in the lower unit). Lowered by the action of the sealing solenoid
So3.
26 Not used in this machine.
PH10 Exit photocell.
rev. 01.0 - 06/2004

410.01-15
410.01-16 rev. 01.0 - 06/2004

Mechanical
rev. 01.0 - 06/2004

410.02-1
410.02-2 rev. 01.0 - 06/2004

Contents
Section Page
1 Covers and plates 8
1.1 RH side cover 9
1.2 LH side covers 9
1.3 Top cover feeders, covers collator area, power supply cover 10
1.4 Covers upper unit 11
2 Electrical components 12
2.1 Main board 12
2.2 FRAM and Display board 13
3 Feeder modules and vertical transport RH 14

3.1 Drive mechanism RH 15
3.1.1 Belts 15
3.1.2 Pulleys 16
3.2 Drive mechanism LH 16
3.2.1 Belt 16
3.2.2 Clutch and Pulley 16
4 Feeders 17
4.1 Top feeder (feeder 3) 17
4.2 Middle feeder (feeder 2) 19
4.3 Lower feeder (feeder 1) 21
4.4 Automatic separation feeder with daily mail 23
4.4.1 Rubber paper pullers 23
4.4.2 Pulley of paper puller axle 25
4.4.3 Upper separation roller 26
4.4.4 Lower separation roller 27
4.4.5 Gears 28
4.5 Automatic separation feeder 28
5 Vertical transport 29
6 Collating area 30
6.1 Belts 31
6.1.1 Transportation belts 31
6.2 Guide rollers 31
7 Folder 32
7.1 RH drive mechanism 32
7.1.1 Belts 32
7.1.2 Pulleys 34
7.1.3 Gears 34
7.2 LH drive mechanism 35
7.2.1 Fold mechanism 36
7.2.2 Clutches 37
rev. 01.0 - 06/2004

410.02-3
7.2.3 Curved folder gears 37

7.3 Rollers 41
7.3.1 Input rollers 41
7.3.2 Lower fold rollers 43
7.3.3 Upper fold rollers 44
8 Main drive mechanism inserter 45

8.1 Belts 45
8.1.1 PJ-belt 45
8.1.2 Drive belt inserter 46
8.1.3 Belt envelope feed 47
8.2 Pulleys 48
8.3 Gears 48
8.4 Clutches 49
9 Envelope feed 52
9.1 Hopper 52
9.1.1 O-rings 52
9.1.2 Separation roller 53
9.1.3 Feed roller 53
9.2 Envelope track 54
9.2.1 Lower rollers 54
9.2.2 Upper rollers 55
9.2.3 Rubber roller 56
9.2.4 Finger solenoid 56
10 Upper unit 58
10.1 Drive mechanism 58
10.1.1 Belt 58
10.1.2 Pulleys 59
10.1.3 Gears 59
10.2 Document inserting 60
10.2.1 Rollers 60
10.2.2 Gears 60
10.2.3 Ejection solenoid 62
10.3 Envelope transport and sealing 63
10.3.1 Rollers 63
10.3.2 Sealing solenoid 64
11 Envelope transport 65
11.1 Lower ejection rollers 65
11.2 Sealing track transportation rollers 66
12 Envelope sealing and ejection 67

12.1 Upper sealing roller 67
12.2 Lower sealing roller 67
13 Sensors 68
13.1 Safety switches 68
13.2 DFC and photocells 72
410.02-4 rev. 01.0 - 06/2004

13.2.1 Feeders 72
13.2.2 Vertical transport 74
13.2.3 Collator area 75
13.2.4 Folder 77
13.2.5 Inserter 78
14 Adjustments 83
14.1 Main drive PJ-belt 83
14.2 Main drive belt feeders/folder 84
14.3 Main drive belt inserter 85
14.4 RH drive belts 86
14.5 Drive belt upper folder section 87
14.6 Paper guide 88
14.7 Solenoids 89
14.8 Separation roller 91
14.9 Friction brake 92
14.10 Flap scraper 93
rev. 01.0 - 06/2004

410.02-5
410.02-6 rev. 01.0 - 06/2004

General instructions
Disconnect the mains supply before performing any maintenance.
Warning
The covers and safety switches are fitted for your protection. Do not operate the
machine with any cover removed and with a safety switch cheated, or a hazard to
health will exist.
Throughout this manual the terms left and right-hand side and front and rear side of the machine are
used. These are made with the machine viewed from the input (document feed) side of the machine.
The replacement procedures are the reversal of the removal procuderes.
LEAD: If you remove different parts of the machine, put the screws are nuts of bolts back in the
removed part.
rev. 01.0 - 06/2004

410.02-7
1 Covers and plates
LH
4 5 6
13 12 11 10 9
1 2 3
RH
figure 1.1
410.02-8 rev. 01.0 - 06/2004

1.1 RH side cover
Refer to figure 1.1

Open the loc by lifting the hand grip 4. Remove the six screws 1 as shown and one screw 3 inside
the RH side cover 2. Remove the RH side cover.
1.2 LH side covers

Open the loc by lifting the hand grip 4. Cover 8 is hinged to the inside frame and can be opened.
Remove two screws 6 on the outside and three screws 5 inside the LH side cover 7. Remove the LH
side cover. Remove three screws 13 from the protect cover 9 and remove the cover. Remove the
water tray 12 carefully. Remove two screws 11 from the wiring cover 10 and remove the cover.
The manual for service and testing can be found inside the machine beside the LH side cover.
rev. 01.0 - 06/2004

410.02-9
1.3 Top cover feeders, covers collator area, power supply cover
RH
3
LH 4
5
6
7
8
10 9
figure 1.2

Remove the LH- and RH side covers as described in paragraph 1.1 and 1.2.
Remove the top cover feeder1 by removing two nuts 2 and two tight-lipped on both sides. Loose two
screws 4 of the top cover 3 of the collator and remove the cover. Remove four screws 8 of the bottom
cover 7 of the collator and remove the cover.
Remove three screws of the power supply cover 6 and remove the cover.
Remove the water tray and place the machine carefully at the right hand side on a felt path (very
heavy). Loose three hex. head screws 10 of the bottom plate 9 and remove the bottom.
410.02-10 rev. 01.0 - 06/2004

1.4 Covers upper unit

1
3
2
figure 1.3
The covers should be removed in the following order:
• lift the loc by lifting the hand grip 1
• remove two nut’s 2 and two screws 3 inside the upper unit 4.
rev. 01.0 - 06/2004

410.02-11
2 Electrical components
Warning. Potential hazard may exist to electronic hardware in conditions with
static electricity. It is advised that, when handling electronic parts, an earth
connected wrist band is used in order to be permanently discharged from static
electricity.
figure 2.1
2.1 Main board
Disconnect the wiring to the main board 1and remove the screw 2 and lock washer and spacer.
Carefully pull the main board from the board holders as shown.
410.02-12 rev. 01.0 - 06/2004

2.2 FRAM and Display board
"
figure 2.2

Open the loc by lifting the hand grip as shown in figure 1.1.
Remove the screws and spacers from the cover plate, remove the cover plate as shown in figure 1.3.
Disconnect the wiring. Remove the display unit by removing the four screws 1. Remove cover plate
2, spacers 3 and finally display board 4 and rubber pad key pad 5.
Note: Connect the wiring before replacing the display board. Be sure to replace the four spacers .
rev. 01.0 - 06/2004

410.02-13
3 Feeder modules and vertical transport RH

The feeders, the vertical transport and the fold unit are driven by belt 4 and the accompanying
pulleys, gears, etc. as shown in figure 3.1.
When the machine is running the four transportation axles are continuously driven by the belts 4, 5
and 6. The three upper transportation axles are equipped with a clutch and a pulley. When, for
example, the clutch 2 is activated the accompanying feeder is driven by pulley 3 and belt 1 and a
document is fed to the vertical transport track.
Note: With the one and a half and two stations versions, the belt 6 and upper transportation axle is
not mounted.
$

#
!
"
figure 3.1
410.02-14 rev. 01.0 - 06/2004

3.1 Drive mechanism RH

! " #
!

$
%
&
' RH

figure 3.2
3.1.1 Belts

Belt (item 8)
Slacken the two screws of belt tensioner 10 and shift the belt tensioner downwards. Remove the
belt 8 from the pulleys.
Belt (item 3)
Slacken the hex head screw of belt tensioner 1. Remove the belt 3 from the pulleys.
Belt (item 12)

The belt 12 is removed in the same way as the belt 3.
rev. 01.0 - 06/2004

410.02-15
3.1.2 Pulleys
Refer to figure 3.2

Pulleys (item 4, 5, 7, 9 and 11)
The pulleys 4, 5, 7, 9 and 11 are "snapped" to their cyl. pins and can be removed by pulling them of
the axle.
Pulley (item 6)
Loosen the main belt, PJ belt and drive belt inserter. Remove the spring clip and slide the main pulley
of the axle.
Pulley (item 13)
Remove the hex head screw of the belt tensioner 2 and withdraw the tensioner. Slide the pulley 5
from the axle, than remove the cyl. pins from the axle and slide the pulley 13 of the axle.
3.2 Drive mechanism LH

1 2
6 5 4 3
LH
figure 3.3
3.2.1 Belt
Unhook the tension spring 2 from the inside frame and remove the belt 1 from the pulley 3.
3.2.2 Clutch and Pulley
Disconnect the wiring of the clutch. Remove the spring clip 6 and slide the clutch 5 and the disc 4
and the pulley 3 of the axle.
410.02-16 rev. 01.0 - 06/2004

4 Feeders
The following section describes in which way the complete feeders must be removed. All the feeders
are provided with dividable drive axles. Before working on the feeders remove the hoppers.
After removing the extension part of the drive axle (axle 9, figure 4.1), each feeder can be removed
separately. Take care that it is a left side screw-threaded axle end. When it is loosened, the main
axle has to be fixed by a pin on one of the holes.
At the RH side the feeders are equipped with a tension spring for proper lifting of the feeder. The
tension spring is hooked on a mounting bracket at the frame. Do not remove the mounting bracket
or exchange the tension spring from one to another feeder. Each spring is specially adjusted from
the factory by positioning the mounting bracket.
4.1 Top feeder (feeder 3)
Remove the top cover feeders.
8 7 10 6 5 4 3 2 1
figure 4.1

On the RH side of the feeder, unhook tension spring 7 from the screw 8.
On the LH side of the feeder the following components must be removed:
• Disconnect the wiring of the feeder and cut the wire straps.
• Remove the wiring from the LH inside frame.
• The spring clip 1, clutch 2 and the belt 4 and the pulley 3 of the top transportation axle.
• Unhook the tension springs 5 from the inside frame.
• Remove the screw of the LH and RH side hinge pin 6 of the top feeder.
• Remove top transportation axle 10 by moving it in the RH direction.
rev. 01.0 - 06/2004

410.02-17
figure 4.2

Remove the feeder as follows:
• Move the feeder a bit downstream as indicated (A)
• Lift the RH side of the feeder first and remove the feeder from the machine (B).
Note: Be careful when replacing feeder 3, the hinge pin at the RH side is locking the ball bearing.
410.02-18 rev. 01.0 - 06/2004

4.2 Middle feeder (feeder 2)

! " # $ % &
RH ' LH
figure 4.3

On the RH side of the feeder, unhook the tension spring 2 from the screw 1.
• The spring clip, clutch 9 and the belt and the pulley of the middle transportation axle (remove
axle to the RH side).
• Un hook the tension 10 spring from the inside frame.
• Remove two hex head’s and the guide plate 5.
• Remove the screw of the LH and RH side hinge pin 11 of the middle feeder.
rev. 01.0 - 06/2004

410.02-19
*
RH LH
figure 4.4

Remove the middle feeder as follows:
• Move the feeder a bit downstream (A)
• Remove the feeder by turning it out of the machine as indicated (B).
410.02-20 rev. 01.0 - 06/2004

4.3 Lower feeder (feeder 1)
LH
RH
! " # $ % &
figure 4.5
On the RH side of the feeder, onhook the tension spring 2 from the screw 1.
• The spring clip 7, clutch 6 and the belt 8 and the pulley 5 of the lower transportation axle.
Remove the axle to the RH side.
• Unhook the tension springs 4 from the inside frame.
• Remove the screws at the LH and RH side of hinge pin 3 of the lowest feeder.
rev. 01.0 - 06/2004

410.02-21
RH LH
*
figure 4.6

Remove the lower feeder as follows:
• Move the feeder as far as possible downstream (A);
• Remove the feeder by turning it out of the machine as indicated (B).
410.02-22 rev. 01.0 - 06/2004

4.4 Automatic separation feeder with daily mail
This section describes the replacement of the rollers and pulleys of the feeder. For several
replacements it is necessary to remove some covers above or below the feeders. The removal of
these covers is shown in figure 4.7.
4.4.1 Rubber paper pullers
!
RH
LH
"
#
$
figure 4.7
Refer to figure 4.7

Remove cover 1 to 4 as follows:
• Remove the screws on the RH side. To remove cover 1, it’s necessary to remove the top cover
first, see figure 1.2
• Pull the cover 1,2 and 3 backwards on the RH side and pull it out on the LH side.
• Loosen the screws 6 at the cover 5 and remove the cover:
• Pull the cover 4 backwards on the RH side and pull it out on the LH side.
rev. 01.0 - 06/2004

410.02-23
1 2 3 4
figure 4.8
Refer to figure 4.8

Remove the feed axle assy. 2 in the right-hand side direction (A) until the left-hand side is clear from
the axle 1. Tilt (B) the axle assy. 2 at the left-hand side and withdraw the right-hand side of the axle
from the hole in the feeder frame. Remove (C) the axle assy. as indicated.
The rubber paper pullers 4 can simply be removed by pushing them of the axle. Hold the plastic
cover 3 in place with one hand and push (D) firmly against the rubber paper puller as indicated.
Rotate the axle 180 degrees and push again. Repeat the rotating and pushing until the paper puller
can be pulled of the axle.
Note: Ensure on replacement that the plastic cover is replaced below the ridge (3, figure 4.8) on the
paper guide and that the feeder assy. is correctly fitted onto the axle. Ensure that the belt runs across
the pulleys.
410.02-24 rev. 01.0 - 06/2004

4.4.2 Pulley of paper puller axle
Remove the feed axle assy. as described in the paragraph "Rubber paper pullers".
figure 4.9

Remove the axle from the plastic cover. Push the rubber paper puller of the axle and remove the
spring clip, the washer and the bearing. The pulley 1 consists of two parts. Push the pulley assy. to
the left to release it from the cyl. pin, remove the cyl. pin and slide the pulley assy. of the axle.
rev. 01.0 - 06/2004

410.02-25
4.4.3 Upper separation roller
/HA=IA
2KID )
figure 4.10
Note: The feeder unit does not need to be removed for replacing separation rollers.
Remove the feed axle assy. as described above. Refer to figure 4.10. Click (A) the plastic cover 2
off the axle and remove it with the belt and the paper pulleys from the feed axle. Remove the grease
from the left hand side of the feed axle with some alcohol. Push the feed roller 1 to the left hand side
of the axle as indicated. Rotate the axle 180 degrees and push again. Repeat the rotating and
pushing until the feed roller can be pulled of the axle.
Note: Before replacing the feed roller ensure that the axle is free of grease. After replacing the feed
roller put some grease Molykote PG 65 on the plastic cover 2 as shown in figure 4.10. Replace the
plastic cover with the belt and the rollers.
410.02-26 rev. 01.0 - 06/2004

4.4.4 Lower separation roller
Note: The feeder unit does not need to be removed for replacing separation rollers.
Remove the cover 3 as shown in figure 4.7.
figure 4.11

Move the separator axle assy. 2 in the right-hand side direction (A) until the left-hand side is clear
from the hinge plate 1. Move (B) the axle assy. 2 downwards side and withdraw the right-hand side
of the axle from the hole in the feeder frame.
Figure 4.12 shows how the roller 1 should be slided of the axle assy. 2.
figure 4.12
Note: Before replacing the feed roller ensure that the axle is free of grease.
rev. 01.0 - 06/2004

410.02-27
4.4.5 Gears
For the removal of the gears at the LH side of the feeder it is not necessary to remove the feeder
from the machine.
The gear 48T can be removed after the extension axle with the pulley etc. has been removed.
Remove the spring clip securing the gear 64T, lift the feeder and slide the gear 64T of the axle.
4.5 Automatic separation feeder
The removal procedure of the components of the automatic separation feeder is similar to that of the
automatic separation feeder with daily mail as described in the previous section.
410.02-28 rev. 01.0 - 06/2004

5 Vertical transport
To get access to several parts of the vertical transport track, remove the vertical transport cover as
described in section Covers and plates. Figure 5.1 shows the parts of the vertical transport track.
figure 5.1
rev. 01.0 - 06/2004

410.02-29
6 Collating area
The parts which are described in this section are located in the upper arm of the collating area. It is
recommended to remove the complete collator arm. Remove the collator area cover as described in
the section See “Top cover feeders, covers collator area, power supply cover” on page 10.
.
figure 6.1
Refer figure 6.1.

Disconnect the wiring of the collator motor. Loosen the set screw 7 on bush 6 as shown in figure 6.2
and pull the motor outside the frame. Support the collating arm and remove the screws 1 as shown
in figure 6.1 (two at the LH side and two at the RH side). Carefully remove the collating arm.
410.02-30 rev. 01.0 - 06/2004

6.1 Belts
8 9 10
RH
7 6
LH
5 4 3 2
figure 6.2
6.1.1 Transportation belts
Refer to figure 6.2

The transportation belts are only available as a set. If a belt is worn, all the belts should be replaced.
Remove roller 1 from the axle and slide the axle to the LH side out of the bearings. Take care of the
tensioner 2, it is spring loaded. Remove the tensioner 2 and the plate 3.
At last remove the axles 4 and 5 and the middle transportation belt can be replaced.
6.2 Guide rollers
Refer to figure 6.2

The guide rollers 8 and 10 are spring loaded. Remove the accompanying spring clips and washers
and slide the guide rollers of the axles. Remove the screw of the axle of the guide roller 9 and slide
the axle to LH side. Remove the spring clip at the RH side of the guide roller and slide the roller of
the axle.
rev. 01.0 - 06/2004

410.02-31
7 Folder
7.1 RH drive mechanism
# " !
figure 7.1
7.1.1 Belts
Lower folder section

The removal of the drive belt 1 (figure 7.1) is described in chapter "Feeder modules and vertical
transport RH.
410.02-32 rev. 01.0 - 06/2004

Upper folder section
40
"
#
' & %
figure 7.2

Slacken the two screws 2 of the belt tensioner 1 and remove the belt 5 from the pulleys 3 and 6.
rev. 01.0 - 06/2004

410.02-33
7.1.2 Pulleys

Remove the belt 1 as described in chapter "feeder modules and vertical transport RH".
After the removal of the accompanying spring clip and clamping ring the pulleys 2 and 3 can be
slided of the axles.

Remove the belt 5 as described in the previous section. Remove the spring clip and the washers of
the pulley 3 and slide the pulley of the axle. Slacken the set screw 4 of the pulley 6 and slide the
pulley of the axle.
7.1.3 Gears

Gears, item 4 and 5.
The gears 4 and 5 can easily be slided of the axles. Take care of the cyl. pins when removing the
gears.

The gears 8 and 10 can be removed after the removal of the accompanying spring clip, clamping
ring and washers. Whem removing gear 8, take care of the cyl. pin.
To remove gear 9, belt 5, pulley 6 and spacer 7 have to be removed. When removing gear 8, take
care of the cyl. pin.
410.02-34 rev. 01.0 - 06/2004

7.2 LH drive mechanism
LH
5 4 3 2 1
figure 7.3

To get access to the gears of the lower folder section at the LH side of the machine, the circuit board
must be removed. Then gears 1 up to 5 can easily be removed by removing the accompanying
spring clips, clamping rings and washers. Take care of the cyl. pin of the gears 1, 3 and 5 and the
spacers of the gears 2 and 4.
rev. 01.0 - 06/2004

410.02-35
7.2.1 Fold mechanism

! " # $ % & '
40

!
"
% $ #
figure 7.4

The fold plates 1 and 5 are driven via the curved gears 6 (four in total) and two gears 3, activated by
the two clutches 2 on the drive axle 4.
Gears 32T, drive axle

Remove the belt 13, pulley 12 and 14 and freewheel clutch 11. Remove the locking plate 10 securing
the bearing of the drive axle 4. Carefully move the axle 4 to the RH-side until the bearing clears the
frame. Carefully lift the axle assembly as far as possible upwards. Take care of the wiring of the
clutches on the axle and the plastic bearing on the LH side.
410.02-36 rev. 01.0 - 06/2004

2 3 4 5
LH RH
figure 7.5

Remove the bearing, spacer, washers and the spring clip of the left-hand side of the drive axle
assembly. Slide the gear 1 of the axle.
To remove the gear 4 the clutches must be disassembled. Cut the wire straps at the connectors of
the clutches. Slide clutch 2 to the left-hand side of the axle. Take care of the cyl. pin of the clutch.
Next remove all the components between the clutches including the cyl. pin of the clutch 3. Slide
clutch 3 to the left-hand side of the axle. Now the gear 4 can be removed from the drive axle.
7.2.2 Clutches
The removal of the two clutches is described in the previous section "Gears 32T drive axle".
Note: Ensure on replacement to secure the wiring of the clutches again and that both clutches are
retained by the locking plate. Also ensure that the clutches CW and CCW are placed in the proper
position.
7.2.3 Curved folder gears
Remove the drive axle assembly as described in the section "Gears 32T, drive axle".
Remove the bearings 9 from the axles 6. Remove the brake discs 15 (spring loaded), the springs,
the brake strip 16 and the bearings 17 from the axles 8.
rev. 01.0 - 06/2004

410.02-37
7 8
1 2 3 4 5 6
22 21 20
LH
12 11 10 9
19 18 17 16 15 14 13
figure 7.6

Remove the following components:
• The levers for the flap actuators, the bearings, etc. (1 upto 6) from the axles 12. Pin 6 has to be
loosened by a set screw, to be accessed at axle end (12).
• The brackets 7 with the sensors.
• The brake discs with the bearings (22 upto 20) from the axles 13.
Next remove the screws at the left and right-hand side of the guide plate 9, unhook the guide plate
and remove it. Remove the screws at the left and right-hand side by which the brackets 10 are
mounted to the upper frames. Carefully lift each complete fold assembly upwards and withdraw it.
410.02-38 rev. 01.0 - 06/2004

First curved folder gears

2
RH
3 4 5
LH 7
6
9 10
RH
11 12 13 14 15
LH
17
16
figure 7.7

Remove the two screws 6 and slide the hinge plate 7 and the hinge plate 5 together with the fold
plate 4 of the axle. Now the curved gears 2 and 8 can be pulled of the axle.
rev. 01.0 - 06/2004

410.02-39
Second curved folder gears

Remove the hinge plates 15 and 17 in the same way as described previously and pull the curved
gears 9 and 10 of the axle.
Wrong

Right
figure 7.8
Note: Ensure on replacement that the curved gears and the curved discs are replaced correctly onto
the axle, refer to figure 7.8, and to secure the wiring of the clutches again.
The right-hand curved gear is marked with a "R" and the left-hand curved gear is marked with a "L".
Adjustments
Check after replacing and securing the complete fold assembly the adjustment of the paper guides
3 and 11 (refer to figure 7.7), see section "Paper guide".
410.02-40 rev. 01.0 - 06/2004

7.3 Rollers
7.3.1 Input rollers
Remove the drive belt as described in the chapter 3, section 3.1.
LH
RH
3
figure 7.9

Remove the pulley, the gears of the upper (1) and lower (2) input rollers as described in 7.1
Remove the bearing locking plate 3.
rev. 01.0 - 06/2004

410.02-41
2 3 4 5
RH
LH
9 8
figure 7.10

Remove the gear 7 of the lower input roller 6 and remove the bearing locking plate 5. Remove the
guide strip 4 and the guide bracket below it. Move the upper input roller 2 to the right-hand side until
the left-hand bearing is free of the LH inside frame. Lift the left-hand side of the roller upwards and
withdraw the roller out of the RH inside frame.
Move the lower input roller 6 to the right-hand side until the left-hand bearing is free of the LH inside
frame. Lift the left-hand side of the roller upwards and withdraw the roller out of the RH inside frame.
410.02-42 rev. 01.0 - 06/2004

7.3.2 Lower fold rollers
Remove the following parts:

• The gears 8.
Refer to figure 7.11

• Loosen the two hex. head screws 3. Push down solenoid 4 to get access to screw 2 and remove
screws 2. Remove bearing plate 1;
• To remove a roller, move it to the right-hand side until the left-hand bearing is free of the LH
inside frame. Lift the left-hand side of the roller upwards and withdraw the roller out of the RH
inside frame.
40
" !
figure 7.11
Adjustments
Check after replacing the adjustment of the solenoid, see paragraph 14.7.
rev. 01.0 - 06/2004

410.02-43
7.3.3 Upper fold rollers
RH ! " # ! LH
figure 7.12

Remove the belt with the pulley 5 and the three gears 4 at the right-hand side.
For the removal of the first fold roller it is necessary to remove the guide strip 2.
Next remove the bearing locking plates 3 on both sides.
To remove roller 1 move it to the right-hand side until the left-hand bearing is free of the LH frame.
Move the left-hand side of the roller downwards and withdraw the roller out of the RH frame.
Adjustments
For belt adjustments refer to 14.5.
410.02-44 rev. 01.0 - 06/2004

8 Main drive mechanism inserter

The main motor 9 (refer to figure 8.1) provides the mechanical power to the SI 62, with exception of
the collating area. The collating area is driven by a separate motor.
40 # " !
figure 8.1
8.1 Belts
8.1.1 PJ-belt
Before the PJ-belt 2 can be removed the main drive belt for the feeder and folder section must be
disassembled as described in 3.1.

Loose the two hex. head screws 4 of the tensioner 5. Remove the belt 2 from the main pulley 1 and
the motor pulley 3.
rev. 01.0 - 06/2004

410.02-45
12 3 4
14 13 12 11 10 9 8 7
figure 8.2
8.1.2 Drive belt inserter

All moving components of the inserter part are driven by belt 10. To remove belt 10 loosen the two
hex. head screws of the tensioner 1. Then remove the belt from the pulleys.
410.02-46 rev. 01.0 - 06/2004

8.1.3 Belt envelope feed
! " # $ % &
'

40

!
"
' & % $ #
figure 8.3

Remove the support plate 11 by which the intermediate axle 13 is supported. Take care of the
bearings and the washers. Remove the belt 5 from the pulley on the intermediate axle and from the
pulley on the envelope feed axle 3.
rev. 01.0 - 06/2004

410.02-47
8.2 Pulleys

The pulleys item 9 and 5 can easily be removed by removing the accompanying spring clips.
The pulley 11 can be removed after the removal of the main pulley as described in the section " Drive
mechanism RH".
Before the pulley 8 can be slided of the axle the mounting plate 6 with the adjustment plate and the
pulse disc sensor must be removed. Next remove the pulse disc 7 and slide the pulley 8 of the axle.
Take care of the spacer.
Note. After replacement of the pulse disc sensor be sure that it clears the pulse disc on both sides.

For the removal of the pulleys 14 and 9 it is necessary to remove the belt 5 as described in 8.1.3.
Remove the accompanying spring clip and washer of the pulley 9 and slide the pulley of the
envelope feed axle 3.
Remove the bearings, washers and gears from the intermediate axle 13. To remove the pulley 14
from the intermediate axle tap the tension pin and slide the pulley 14 of the axle.
8.3 Gears
Gears item 3 (sealing rollers)

After the removal of the pulley 5 all the gears 3 can be slided of the axles by removing the
accompanying spring clips and washers.
Gear item 2
The gear 2 is mounted to the axle by a tension pin. To tap the tension pin it is necessary to remove
the axle. Remove the tension springs of the bearings of the axle. Next remove the spring clip with
washer and bearing at the left-hand side of the axle. Slide the two rollers to the right-hand side and
remove the cyl. pin from the axle. Slide the axle with the gear 2 to the right-hand side out of the RH
inside frame. Tap the tension pin to remove the gear 2.
Gear item 4
The gear 4 is also mounted to the pulse disc axle 14 by a tension pin. Remove the pulse disc 7 and
pulley 8. Remove the spring clip at the left-hand side of the axle. Slacken the set screws of the two
rollers. Remove the locking plate 13. Slide the pulse disc axle 14 to the right-hand side out of the RH
inside frame. Remove during sliding the axle to the right-hand side the bearing and washer and the
two rollers. After the axle is removed the gear can dissembled by tapping the tension pin.
Gear item 12
After the removal of the pulley 9, gear12 can be slided of the axle.
Gears item 8, 10, 15, 16, 18, 20 and 22

The gears 8, 10, 15, 16, 18, 20 and 22 can simply be removed by removing the accompanying spring
clips and washers.
410.02-48 rev. 01.0 - 06/2004

Gear item 21
For the removal of the gear 21 the nuts etc. must be removed. Take care of the tension spring.
Once the nuts are removed all the parts can be slided of the brake rod.
For adjustment of the friction brake, see section " Friction brake "
Gear item 6
After the gear 8 has been removed the clutch 7 must be dissembled. Remove the support plate 11,
disconnect the wiring of the clutch and slide the clutch of the axle. Remove gear 6.
Gears item 4 and 12

Remove the support plate 11 to free the intermediate axle 13 with its components. Remove the
bearings, washers and spring clip from the axle and slide the gears 12 and 4 from the axle.
Gear item 17
To get access to the transportation axle it is advisable to remove the insert table. Remove the spring
clip, washer and bearing at the left-side of the transportation axle 2. Move the axle a little to the right-
hand side, slide the gear 17 to the left-hand side and remove the cyl. pin. Slide the gear 17 of the
axle.
Gear item 19
The gear 19 is mounted to the tansportation axle 1 by a tension pin. For the removal of the gear 19
the tension pin must be tapped. Remove the insert table and remove the spring clip, washer and
bearing from the left-hand side of the axle. Slide the rollers to the right-hand side to remove the cyl.
pins. Slide the axle to the right-hand side out of the RH inside frame. Take care of the two rollers.
Tap the tension pin and remove the gear 19 from the axle.
8.4 Clutches
Slip clutch envelope feed axle

Remove the metal ring of the pulley 9. Slide the belt 5 of the pulley 9 and remove the pulley from the
axle. Slide the slip clutch of the axle.
Clutch CW
When the machine is switched on gear 6 it is constantly driven. By activating the clutch 7 all the gears
shown in figure 8.3 and the accompanying axles and rollers of the envelope feed and envelope track
will be driven. So to feed, open and place an envelope on the insert table the clutch 7 is activated.
To remove clutch 7 the support plate 11 and the gear 8 must be removed. Disconnect the wiring of
the clutch and slide it of the axle.
rev. 01.0 - 06/2004

410.02-49
8.5 Main motor (M2)
figure 8.4

Remove the power supply cable. Remove the power supply cover 2. Disconnect the wiring and cut
the wire straps. Fasten the collator arm with a wire strap so it will not fall down when removing the
power supply assy. Remove the power supply assy 3. Cut all the wire straps by which the wiring of
the motor is attached to the frames.
When replacing the power supply assy. ensure that the guide plates 1 are fitted correctly in the guide
rollers. Also take care to fit the microswitch correctly and ensure the correct functioning.
410.02-50 rev. 01.0 - 06/2004

40
# " !
figure 8.5

Remove the belt 1 by releasing the belt tensioner 2. First remove the bottom of the machine than
remove the four screws 3 and the washers 4 and withdraw the motor 5 from the machine. Take care
of the wiring.
Adjustments
For belt adjustments refer to 14.1 and 14.3.
rev. 01.0 - 06/2004

410.02-51
9 Envelope feed
9.1 Hopper
9.1.1 O-rings
RH
13
12
11
LH
10 9 8 7 6 5 4 3 2 1
figure 9.1

Remove the centre front plate 9. The hopper assembly 10 is fitted to the inside frames by three
screws 1 at the left-hand and three screws 11 at the right-hand side. Remove the screws and
withdraw the assembly from the machine. Remove the pulley 13 and slip clutch 12 as described in
8.2. Next remove the spring clips, washers and bearings from envelope feed axle 5 and remove the
axle from the machine. Slide the O-rings 7 from the joggers 6.
410.02-52 rev. 01.0 - 06/2004

9.1.2 Separation roller
Note: Before removing the separation roller first check the adjustment procedure as described in
14.8.
Refer to figure 9.1

Remove the centre front plate and the hopper assembly as described in the previous paragraph.
Slacken the two screws 3 and remove the separation spring 2 with the separation roller. Remove the
separation axle with roller from the separation spring, slacken the set screw of the separation roller
4 and slide it of the separation axle.
9.1.3 Feed roller
Refer to figure 9.1

Remove the feed axle as described in 9.1.1. Remove a jogger from the envelope feed axle. Slacken
the set screw from the feed roller 8 and slide it of the axle.
Note: On replacement of the joggers and/or feed roller, position the feed roller in the middle of the
shaft the removed joggers between the "forks" of the side guide. Take care to reassemble the rings
between fork and jogger. Ensure that the set screws of the feed roller are tightened onto the groove
of the feed shaft.
Adjustments
See paragraph 14.8 and 14.8.
rev. 01.0 - 06/2004

410.02-53
9.2 Envelope track
9.2.1 Lower rollers
To get access to the lower rollers of the envelope track it is necessary to remove the bottom plate.

figure 9.2

Remove the spring clip, washer and bearing (spring loaded) from the axle of the first set of rollers
13. Move the axle to the left-hand side to free the cyl. pins and remove the cyl. pins. Lift the axle and
slide the rollers of the axle. Take care of the pressure spring of the bearings. The second set of
rollers 12 is removed in the same way. Remove from the third set of rollers 11 at first the outer two
410.02-54 rev. 01.0 - 06/2004

rollers. The removal procedure for the inner two rollers is the same as described for the first set of
rollers.
Refer to figure 9.3

Remove the flap scraper 21. Remove the pressure springs of the bearings of the fourth set of rollers
19. Slide the rollers to the LH side to remove the cyl. pin. Remove the spring clips and slide the axle
to the RH side and remove the rollers 19 from the axle.
Adjustment:
For the adjustment of the flap scaper see 14.10.
.
RH
2 3 4 5 6 7 8 9 1011
12
13
14
22
21
LH
18 17 16 15
20 19
figure 9.3
9.2.2 Upper rollers

To get access to the upper rollers remove the insert table as described in paragraph 11.1.
rev. 01.0 - 06/2004

410.02-55
To remove the first set of rollers 5 slide the rollers of the axle 7, remove the cyl. pins 4. Remove the
spring clip 1, washer 2 and bearing 3 at the left-hand side of the axle 7 and slide the axle to the right-
hand side. Remove the rollers from the axle.
The second and third set of rollers are removed in the same way as the first set of rollers 5.
Refer to figure 9.2

To get access to the fourth set of rollers of the envelope track remove the insert table. To get more
room, you could remove the fixing plate envelope track (item 8, figure 9.2). Slide the rollers aside to
remove the cyl. pins. Remove the spring clip, washer and bearing at the left-hand side of the axle
and slide the axle to the left-hand side. Remove the rollers from the axle.
9.2.3 Rubber roller
Remove the insert table and the transportation table (item 19, figure 11.1).
Slide the transportation table in direction as indicated over the second fold roller.

Remove the knob 1 and the spring clips 5 of the rubber roller 11. The gear at the right-hand side of
the rubber roller must be removed as described in section 8.3. Slide the roller to left-hand side to
free the right-hand side of the rollers from RH inside frame. Take care of the bearing. Lift the right-
hand side and withdraw the rubber roller from the machine.
9.2.4 Finger solenoid

! "
figure 9.4
410.02-56 rev. 01.0 - 06/2004

Remove the draw bar 3 and the tension spring 4. Disassemble the mounting bracket 2 with solenoid
1. Remove the solenoid 1 from the bracket 2.
Adjustments
For the adjustment of the solenoid see 14.7.
rev. 01.0 - 06/2004

410.02-57
10 Upper unit
10.1 Drive mechanism
The drive mechanism of the upper unit is located at the right-hand of the machine.
10.1.1 Belt
5
6
7
8
9
10
figure 10.1

At first slide the belt 8 of the pulley 7. Then remove the belt from the pulley 10.
410.02-58 rev. 01.0 - 06/2004

10.1.2 Pulleys

Remove the spring clip of the pulley 10 and slide the pulley 10 from the axle.
To remove pulley 7 it is necessary to remove the axle 5 completely. Open the upper unit and remove
the six screws by which the brake plate 2 is mounted to the upper frames.
Take in account the weight of the upper unit when removing the dampers.
Close the upper unit and remove the axle 1. Move the brake plate 2 with assembled components
carefully aside, take care of the wiring to the solenoid, the sensor and display. Remove plate 3.
Remove the spring clips of the axle 5. Slide the rollers of axle 5 aside and remove the two cyl. pins.
Slide the axle to the right-hand side out of the RH frame. Take care of the rollers, washers and
bearings. Tap the tension pin of the gear 9 and slide the gear of the axle. Now the pulley 7 can be
removed from the axle.
10.1.3 Gears
The removal of the gear 9 is described in the previous paragraph.

For the removal of the gear 6 the brake plate has to be removed as described in the previous
paragraph. Next remove the spring clips of the axle 4 and remove the cyl. pins of the rollers.
Slide the axle 4 to the right-hand side out of the frame. Tap the tension pin of the gear 6 and slide
the gear 6 of the axle.
rev. 01.0 - 06/2004

410.02-59
10.2 Document inserting
10.2.1 Rollers
! " # $
' & %
figure 10.2

Remove the guide plates1 on both sides and slide the upper insert rollers 3 of the axle. Take care
of the cyl. pins. The first set of ejection rollers 11 can simply be slided of the axle. Take care of the
cyl. pins.

To remove the second set of ejection rollers, remove spring clip 5 and remove roller 4 from the axle.
Remove spring clip 2 and slide the axle to the LH side. Tap out the cyl. pin of roller 1 and slide roller
1 from the axle.
10.2.2 Gears

Remove the guide plates 1 on both sides. Remove the bracket 6 and the sensor, take care of the
wiring of the sensor. Next remove the pulley 5 and the spring clip 12. Slide the outer bearings at the
axle 8. Remove the tension springs 2. Slide the axle 8 with complete insert assembly through the
slotted holes out of the frames.
410.02-60 rev. 01.0 - 06/2004

RH
3
4
2
5
1
6
LH
11
10
9
8
7
figure 10.3

Once the frame plate 5 is removed the gears 4, 7 and 8 can be slided of the axles. Take care of the
pressure springs 6.
rev. 01.0 - 06/2004

410.02-61
1 2 3 4 5
RH
LH
figure 10.4

Remove the screws 7 and withdraw the complete ejection assembly 9 together with the draw bar
and the attached plunger (item 1, figure 10.3) from the frames. Take care of the washers and the
pressure spring of the plunger.

After the frame plate 9 is removed the gears 10 and 11 can be removed from the axles.
10.2.3 Ejection solenoid
To get access to the solenoid the covers of the loc must be removed as described in the section 1.

Disconnect the wiring of the solenoid. Remove the two screws 3 and remove the solenoid 2. Take
care of the plunger 1 the washers and the pressure spring.
Adjustments
See 14.7.
410.02-62 rev. 01.0 - 06/2004

10.3 Envelope transport and sealing
10.3.1 Rollers
RH
2
1
6
5
4
figure 10.5
rev. 01.0 - 06/2004

410.02-63
Sealing transport rollers

Open the upper unit and remove the spring clips of the axle 6. Slide the transport rollers 4 of the axle.
Take care of the pressure springs 5.
Lower reverse rollers

The removal of the lower reverse rollers 3 is described in 10.1.2.
Upper reverse rollers

Remove the accompanying spring clips and washers and slide the rollers 7 of the axle.
10.3.2 Sealing solenoid

Disconnect the wiring of the solenoid 1. Remove the screws 2 and withdraw the solenoid. Take care
of the pressure spring and the washers at the plunger.
Adjustments
See paragraph 14.7.
410.02-64 rev. 01.0 - 06/2004

11 Envelope transport
11.1 Lower ejection rollers
12 3 4 5 6 7 8 910 1112 13 14 15 16
LH
22 21 20 19 18 17
figure 11.1
Remove four screws 13 of the insert table 18 and four screws 1 of the insert table 2. Remove the
drive belt inserter as described in 8.1.2.
Remove the locking plate of the bearing at the right-hand side of the transportation axle 20. Slide the
axle 19 to the RH side. Remove the cyl. pin 17. Slide the roller 18 from the axle.
Remove the spring clip, washer and bearing from the left-hand side of the axle 22. Slide the axle to
the RH side. Slide the rollers 21 from the axle.
rev. 01.0 - 06/2004

410.02-65
11.2 Sealing track transportation rollers

Remove the pulse disc 7 and pulley 8 with the from the pulse disc axle 14 as described in 8.2.

Remove the pressure springs 11 from the bearings 12 of the axle 8. Slide the rollers 4 aside to
remove the cyl. pins 3. Remove the spring clip, washer and bearing at the left-hand side of the axle.
Slide the rollers of the axle.
Note: Take care of the pressure springs 10 when replacing again. On the LH side a spring with lower
force has to be fitted than on the RH side.
410.02-66 rev. 01.0 - 06/2004

12 Envelope sealing and ejection

12.1 Upper sealing roller

Remove the gear at the right-hand side of the sealing roller 6 as described in 8.3.
Next remove the pressure springs 11 from the bearings 12 and the spring clip at the left-hand side
of the sealing roller. Take care of the washer 10 and the spring 9. Move the sealing roller 6 to right-
hand side to free the left-hand bearing from the LH inside frame and withdraw the upper sealing
roller.
12.2 Lower sealing roller

Remove the upper sealing roller as described in the previous paragraph.
Remove the gear at the right-hand side of the sealing roller 5 as described in 8.3.
Remove the two screws 14 and the mounting plate 7 and the spring clip, washer and bearing at the
left-hand side of the lower sealing roller 5. Move the sealing roller to the right-hand side and withdraw
the lower sealing roller.
rev. 01.0 - 06/2004

410.02-67
13 Sensors
13.1 Safety switches
Upper unit safety switch

The safety switch of the upper unit is located at the right-hand side of the machine near the lowest
feeder. To get access to the switch remove the RH side cover.

figure 13.1

Cut the wire strap and remove the bracket 2 together with the safety switch 1. Remove the safety
switch from the bracket.
410.02-68 rev. 01.0 - 06/2004

Safety switch LH side cover

The safety switch is located at the left-hand side of the machine near the sealing rollers.
!
figure 13.2

Open the LH side cover and remove the cover 1. Remove the safety switch 3 from the bracket 2.
rev. 01.0 - 06/2004

410.02-69
Safety switch collator area

The safety switch is located at the right-hand side beneath the collator area and behind the supply
cover. Remove the supply cover.
figure 13.3

Remove the safety switch 2 from the frame 1.
410.02-70 rev. 01.0 - 06/2004

Flag switch sealing area
1 2 3 4 5 6
RH
LH
figure 13.4

Remove the nuts 1 and 6 than remove the frame 2 complete. Take care of the wiring. Slacken the
screw 3 and remove the bracket 4 with the flag switch 5.
rev. 01.0 - 06/2004

410.02-71
13.2 DFC and photocells
Note: whether or not photocells are replaced, it is advised to reset the photocells after finishing
servicing. See sections 2.14 and 2.15 of the Electrical description for details.
13.2.1 Feeders
DFC
Each feeder is equipped with a DFC. Remove the covers 1, 2, 3 and 4 (figure 4.7) as described in
4.4.1. When removing the DFC of feeder 2 first remove the guide plate 5 (figure 4.3) as described in
4.2.
figure 13.5

Disconnect the wiring of the DFC and remove the screw 2 securing the DFC 3 to the bracket 1.
410.02-72 rev. 01.0 - 06/2004

Feeder photocells
LH RH
"
LH RH
!
figure 13.6
Transmitter (LED)
Remove the bracket 4 with the transmitter 3. Disconnect the transmitter and remove it from the
bracket.
Receiver (Sensor)
Remove the bracket 2 with the sensor 1. Disconnect the sensor and remove it from the bracket.
rev. 01.0 - 06/2004

410.02-73
13.2.2 Vertical transport
Vertical transport photocells (optical, only with OMR).

In the 2,5 stations version, the detectors are located beneath the upper vertical transport rollers.
! "
figure 13.7
Transmitter (LED)
Open the loc and remove the guide plate 1 with assembled transmitter 2. Disconnect the wiring of
the transmitter and remove the transmitter.
Receiver (Sensor)
Remove the vertical transport cover. Cut the wire strap securing the wiring of the sensor 3 to bracket
4. Remove the bracket with the sensor and disconnect the wiring. Remove the sensor.
410.02-74 rev. 01.0 - 06/2004

13.2.3 Collator area
1 2
LH
figure 13.8
Refer to 13.2.3.
Remove the set screw 1, remove the pulse disc and the sensor 3.
Note: Ensure on replacement that the pulse disc sensor clears both sides of the pulse disc.
rev. 01.0 - 06/2004

410.02-75
Collating area photocells
"
#
$
%
figure 13.9
Move the lower collator arm downwards. Remove the locking plate of the axle 4 at the right-hand
side of the machine and free the bearings of the frame. Remove the hinged guide plate 1 together
with the attached sensors 2 and 3. Take care of the wiring.
Transmitter (LED)
Remove the transmitter 3 from the guide plate.
Receiver (Sensor)
Remove the sensor 2 from the guide plate.
410.02-76 rev. 01.0 - 06/2004

Folder input photocell

Remove the bracket 5 with the transmitter 6 to the left-hand side out of the LH inside frame. Take
care of the wiring.
Transmitter (LED)
Cut the wire straps and remove the transmitter 6 from the bracket.
Receiver (Sensor)
Cut the wire straps and remove the receiver 7 from the bracket.
13.2.4 Folder
Curve (pulse) disc sensor
The sensors are located at left-hand side of the upper unit. Open the upper unit.
1 2 3
figure 13.10

Remove the bracket 1 with the sensor 2. Cut the wire strap, disconnect the sensor and remove the
sensor from the bracket. The sensor 3 has to be removed in the same way.
rev. 01.0 - 06/2004

410.02-77
13.2.5 Inserter
Pulse disc sensor

The pulse disc sensor assy. is located at the right-hand side of the machine near the sealing rollers.
!
"
figure 13.11

To avoid damage to the pulse disc 4 remove the pulse disc. Disconnect the wiring of the sensor 2,
remove the two srews 3 and remove the sensor.
Ensure on replacement that the pulse disc sensor clears both sides of the pulse disc. To adjust the
position of the sensor slacken screw 1, reposition the sensor and fasten the screw 1.
410.02-78 rev. 01.0 - 06/2004

Envelope track photocell
To get access to the photocells remove the insert table and the bottom plate.
" !
figure 13.12
Transmitter (LED)
Pull the air hose connector 4 from the transmitter 3. Slacken the screw of the transmitter and remove
the transmitter 3.
Receiver (Sensor)
Remove the bracket 2 together with the sensor 1. Slacken the screw of the sensor and remove the
sensor 1.
rev. 01.0 - 06/2004

410.02-79
Envelope flap detector

To get access to the photocells remove the insert table and the bottom plate.
!
"
#
$
figure 13.13
Transmitter (LED)
Once the bottom plate is removed, remove the bracket 1 with the transmitter 2. Take care of the
wiring. Disassemble the transmitter from the bracket.
Receiver (Sensor)
Pull the air hose connector 3 from the sensor 4. Slacken the screw 6 and remove the bracket 5 with
the sensor 4. Remove the sensor from the bracket.
410.02-80 rev. 01.0 - 06/2004

Exit photocells
!
"
figure 13.14

Remove the frame axles 1 together with the cover 2. Take care of the wiring of the detectors.
Remove the transmitter (LED) 3 and the receiver (Sensor) 4.
rev. 01.0 - 06/2004

410.02-81
Document insert photocells
! " #
figure 13.15
Transmitter (LED)
The transmitter is located in the upper unit. Open the upper unit and remove the screw 1 to release
the transmitter 2.
Receiver (Sensor)
Remove the transport table. Slacken the screw 5 and remove the bracket 4 with the sensor 3.
Remove the sensor from the bracket. Take care of the wiring.
410.02-82 rev. 01.0 - 06/2004

14 Adjustments
14.1 Main drive PJ-belt
10 mm (0.4 inch)
2
figure 14.1

The maximum movement of the drive belt at the indicated position is 10 mm (0.4 inch).
To adjust
Slacken the two screws 1 securing the belt tensioner 2. Shift the belt tensioner to adjust the correct
belt movement. Hold the belt tensioner in position and retighten the two screws. Check the
adjustment and readjust if necessary.
Note: Do not adjust the drive belt too tight.
Note. When adjustment of the belt tensioner is not sufficient, re-adjust the motor position.
rev. 01.0 - 06/2004

410.02-83
14.2 Main drive belt feeders/folder
10 mm (0.4 inch)
2
figure 14.2

To adjust
410.02-84 rev. 01.0 - 06/2004

14.3 Main drive belt inserter
1 2
0 mm (0.4 inch)
figure 14.3

To adjust
rev. 01.0 - 06/2004

410.02-85
14.4 RH drive belts
Note: The adjustment of the lower and upper drive belt is similar.
upper drive belt

3
5 mm (0.2 inch)
1
lower drive belt
figure 14.4

The maximum movement of the drive belts 1 at the indicated position is 5 mm (0.2 inch).
To adjust
Slacken the hex. head screw 3 securing the belt tensioner 2.
Shift the belt tensioner to adjust the correct belt movement.
Hold the belt tensioner and retighten the hex. head screw.
Check the adjustment and readjust if necessary.
410.02-86 rev. 01.0 - 06/2004

14.5 Drive belt upper folder section
5 mm (0.2 inch)
figure 14.5

The maximum movement of the drive belts 1 at the indicated position is 5 mm (0.2 inch).
To adjust
Slacken the hex. head screw 1 securing the belt tensioner 2.
Shift the belt tensioner to adjust the correct belt movement.
Hold the belt tensioner and retighten the hex. head screw.
Check the adjustment and readjust if necessary.
Note: Do not adjust the drive belt too tight
rev. 01.0 - 06/2004

410.02-87
14.6 Paper guide
!
figure 14.6

There must be a small gap between the fixed guide plate 3 and the fold roller 2. The fold roller should
just run free.
To adjust
Slacken the two round head screws 1 to move the guide plate further away from the fold roller and
tighten it to move it closer.
410.02-88 rev. 01.0 - 06/2004

14.7 Solenoids
Note: The adjustment procedure for all solenoids is described below. Only for the finger solenoids a
different procedure is necessary refer figure 9.4.
Whenever a solenoid is actuated the plunger is pulled into the solenoid coil. To make sure that the
pulling power of the solenoid coil on the plunger is maximal, the plunger should not touch the bottom
of the solenoid coil whenever the solenoid is actuated.
1 2 3 4
figure 14.7

To set this requirement:
• Slacken the two screws 3 securing the solenoid coil 4.
• Push the plunger 2 together, with the linkage 1 attached to it, as far as it will go in the direction
towards to the solenoid coil. Hold the plunger in this position and then slide the solenoid coil
towards the plunger until the plunger bottoms the solenoid coil.
• Move the solenoid coil back by approximately 1 mm (0.04 inch) and retighten the two screws.
Ensure the solenoid coil and the plunger are aligned in a straight line.
rev. 01.0 - 06/2004

410.02-89
Finger solenoid
! "
figure 14.8

To adjust the finger solenoid:
• Slacken the two screws 2 securing the solenoid coil 1.
• Push the plunger 3 down into the lowest position.
• Move the solenoid coil (with the plunger in the lowest position) so that the middle fingers (slide
in) is adjusted approximately 2 mm (max.) (0.07 inch) above the insert table. Retighten the two
screws.
410.02-90 rev. 01.0 - 06/2004

14.8 Separation roller
Because the separation roller does not reverse, a 'flat' gradually wears on the roller surface. This
can be the cause of irregular feeding of the envelopes. Should this occur, carry out the following
adjustment:
figure 14.9

Use the adjusting nut 2 and set the separation gap to the maximum.
Slacken the set screws 1 securing the separation roller.
Rotate the separation roller about 30 degrees in the direction indicated, so that the unworn portion
of the separation roller faces the feed roller 3.
Retighten the set screw and re-adjust the separation gap.
Note: After rotating the separation roller over 330 degrees it is necessary to replace it.
rev. 01.0 - 06/2004

410.02-91
14.9 Friction brake

figure 14.10

The friction brake is correctly adjusted when the distance between the inner faces of the two friction
discs 3, i.e. the overall pressure spring length, is 20 mm (0.79 inch).
To adjust
Remove the outer nut 1 securing the inner nut 2.
Turn the inner nut to adjust the correct distance.
Replace the outer nut and check the adjustment.
Note: An increased variation of the envelope stop position can be caused by excessive play in the
lower gear train. A slight reduction in the distance (increasing the pressure) may give the required
result.
410.02-92 rev. 01.0 - 06/2004

14.10 Flap scraper
!
figure 14.11

The flap scraper 3 must be positioned so that its lower edge is aligned with the lower edge of the
envelope guide 1.
To adjust
Slacken the two hex. head screws 2 securing the flap scraper 3 on both sides.
Move the flapscraper to adjust the correct position.
Retighten the two hex. head screws and check the adjustment.
Note: Depending on the envelope type and flap shape a different setting may be necessary.
rev. 01.0 - 06/2004

410.02-93
410.02-94 rev. 01.0 - 06/2004

Electrical
rev. 01.1 - 06/2004

410.03-1
410.03-2 rev. 01.1 - 06/2004

Contents
Section Page
1 Electronic hardware 5
1.1 Circuit description 5
1.2 Test points 23
1.3 Jumper settings 24
1.4 LED information 24
2 Service menu 26
2.1 General 26
2.2 System setting 29
2.3 Configuration 29
2.4 Localisation 30
2.5 Software versions 30
2.6 Folder settings 31
2.7 Reset data 31
2.8 Power up 32
2.9 Job settings 32
2.10 Document offset 32
2.11 BRE offset 33
2.12 Secure jobs 34
2.13 Flap closer 34
2.14 Service tests 35
2.15 Photocells 35
2.16 Digital inputs 37
2.17 Actuators 38
2.18 Run in 40
2.19 DFC test 40
2.20 Keyboard/display 41
2.21 Counters 41
2.22 OMR 42
2.23 OMR code definition 42
2.24 Read code test 43
3 Error messages and error handling 46
rev. 01.1 - 06/2004

410.03-3
410.03-4 rev. 01.1 - 06/2004

1 Electronic hardware
1.1 Circuit description
General
An important difference between previous machines with similar operational functionality and this
machine is the fact that all electronics are present on one main board. The main board 98.90.01
houses two controllers. An 8-bit controller handles the inserting functionality and the user interface.
A 16 bit controller handles the feeding, reading and folding functionality.
Both the 8-bit machine software and the 16-bit machine software are located in flash ROM. With the
help of external Windows-based software the machine software can be placed, and subsequently
updated.
Figure 1.1 shows an overview of the machine-wide electronics. The schematics of the main board
98.90.01 are divided into 12 sheets (figure 1.2 through figure 1.13). The components are numbered
xyy; x is the sheet number, yy a number between 01 and 99.
The component layout of figure 1.14 assists in locating connectors, test points, jumpers and LEDs.
Processor and memory (16-bit)

The 16-bit processor XA-S3 (U610) has 32 kilobytes of internal program code. This code
determines, based on certain RS232-communicated information from the pc with the Windows-base
software, whether communication with that pc or normal operation, i.e. executing the 16-bit machine
software in flash ROM (U630), is relevant.
The system operates with 64 kilobytes of system RAM (U620 & U621). If in stead of the operational
machine software the external Windows-based must operate, to this volatile memory program code
is up loaded (i.e. software 'flashing' the flash ROM, thereby updating the machine software for
passing the same files through to an upstream device; this program code is subsequently executed.
The so-called emulation RAM (U640 and U641) is only used for R&D development; normally these
two chips are not encountered in any field service situation.
The processor operates with process-related I/O information by writing data to the chips U700 and
U710 (U710 controls the feeder/folder clutches CL1…CL5), and reading data from the chip U720
(U720 receives digital versions of the outputs of the feeder/folder photocells PH1…PH6). These
chips are addressed by so-called memory-mapped I/O, via the signals 16b_DigOutput1 and
16b_DigOutput 2 (writing) and 16b_DigInput1 (reading) from the PAL chip U670.
Processor and memory (8-bit)

The 8-bit processor U201 executes the 8-bit machine software which is present in the flash ROM
U230. The processor operates with 32 kilobytes of system RAM (U250).
The 8 kilobytes of non-volatile memory (U210) are used to store hardware and job related
information.
In addition to the 8-bit processor the CPLD U240 (Complex Programmable Logic Device) is present
for a variety of functions. One of these functions is bank switching. Note that the 8-bit controller can
address 64 kilobytes of program memory and that the flash ROM has 512 kilobytes of memory. The
CPLD is used to dynamically assign a part of the 8-bit machine software in flash ROM to be executed
by the 8-bit processor U201. The CPLD also has an important function in the situation when machine
software is placed or updated, in stead of the normal situation of executing the machine software.
Communication
The 8-bit controller (inserter and user interface) and the 16-bit controller (feeding, reading and
folding) talk to each other via the local SCS bus, consisting of the signals SCS_SCL and SCS_SDA.
This machine has no SCS connection with the outside world.
rev. 01.1- 06/2004

410.03-5
In addition both controllers have the signal MAIN_PDISC in common. On this signal all timed
processes are based. This signal is produced by slotted photocell SPH1, which monitors pulse disc
PD1, which on its turn is driven by the main motor M1.
Communication between the machine and the outside world is based on serial (RS232)
communication. This communication is necessary for placing/updating machine software and
possibly for other tasks. The RS232 data on the 9-pole RS232 connector goes to and from the
RS232 driver U260. The CTS and RTS lines are only connected with the 8-bit controller. With the
RS232 multiplexer either the 8-bit RX and TX signals or the 16-bit RX and TX signals are passed
through to U260. This is necessary to place or update both the 8-bit and 16-bit machine software in
one machine session.
Power supply
The machine is powered by a 24 volt switched power supply unit. This eliminates the use of a heavy
mains frequency-operated power transformer. From the 24 V a 5 V supply VCC is derived with the
switching voltage regulator U110. U120 takes care for the -12 V supply voltage. The ADCs in the 16-
bit processor U610 require a separate positive supply voltage AVDD (2.95 V). This voltage is derived
from VCC by voltage divider R140 and R141, followed by voltage follower U140B.
Photocells
The transmitter (TX) currents for the four inserter paper photocells (PH7…PH10) are driven by the
outputs of the Digital to Analogue Converter (DAC) U550. The analogue outputs of the photocell
receivers (RX) are fed to ADC (Analogue to Digital Converter) inputs of the 8-bit processor U201. In
this way a processor-controlled control circuit ensures that dust on the photocells is compensated
for by an increase in the transmitter current. Control activity occurs if the photocells do not 'see'
paper. The control of the transmitter current occurs in both directions; the current can be increased
in case of dust build up and it can be decreased when dust falls off.
The transmitter (TX) currents for the six feeder/folder photocells (PH1…PH6) are driven by the
outputs of the Digital to Analogue Converter (DAC) U800. The analogue outputs of the photocell
receivers (RX) are fed to the analogue multiplexer U701. Its output (16b_Multiplexed_AD4) is fed to
an ADC input (Analogue to Digital Converter) of the 16-bit controller U610. In addition to this digital
versions of the six RX signals are fed to the input chip U720. These signals are necessary to obtain
timely process information.
Cover switches
The three cover microswitches MS3 (wired to the motor and relay board 97.55.00/97.55.40), MS1
(J100) and MS2 (J101) are connected in series and pass their information to the system connector.
The state of these microswitches is also passed to the processor via the signals 8b_TOP_COVER,
8b_SIDE-COVER and 8b_COLLATOR_COVER. If at least one of the three machine covers is
opened, mechanical drive for the machine is immediately interrupted.
Motors
The main motor M1 provides mechanical drive to all moving items (except the moving collator items)
of the machine. This motor is switched on and off via the motor relay RE1 on the motor relay board
97.55.00 (230 V)/97.55.40 (115 V). The motor relay is controlled by the processor via the signals
8b_MOTOR_RELAY and 8b_START_RELAY from the 8-bit controller U201. For a sufficient starting
torque a capacitor is temporarily switched in parallel with motor capacitor. After reaching a certain
rpm rate (monitored by slotted photocell SPH1 via pulse disc PD1) the start relay is switched off. If
the motor doesn't reach its nominal rpm rate within one second, it is switched off and an error
message is issued.
The motor is thermally protected against overheating due to mechanical blocking.
410.03-6 rev. 01.1- 06/2004

A chain of three microswitches is included in series with the motor relay powering circuit. If this chain
is broken by opening at least one of the safety covers, the motor relay current is immediately blocked
or interrupted. This happens irrespective of the status of the two motor control signals mentioned
above. The motor stops immediately or doesn't start at all. Thus no potentially unsafe human contact
with moving parts is impossible.
The collator motor M2 is a DC motor than can and will turn in two directions. M2 is pulse-width-
controlled via chip U1110. The speed is controlled via a feedback circuit with slotted photocell SPH2,
which monitors pulse disc PD2, which on its turn moves in line with M2.
Flag switch FS1

The optical flag switch FS1 in the sealing track is based on a pawl which, when triggered by the
leading edge of passing filled envelope, interrupts the infrared beam between a photo diode and a
photo transistor. It starts a pulse count for determining the time at which the upper reverse roller is
lowered to start the sealing process. After the trailing edge of the envelope has passed, the pawl
returns to its rest position by spring action.
Clutches and Solenoids
Clutch CL6 in the inserter part of the machine is driven by the driver chip U440. The three solenoids
in the inserter part are driven by transistor Q440A (finger solenoid So1), Q440B (eject solenoid So2)
and Q450B (sealing solenoid So3).
The three feeder clutches (CL1, CL2 and CL3) in the feeder/folder part are driven by driver chip
U970. The two folder clutches (CL4 and CL5) are driven by the driver chip U1020.
DFC
Each feeder has a DFC unit. (DFC stands for Double Feed Control.) This unit produces an output
voltage which is proportional with the measured paper thickness. The three DFC output voltages are
processed with the circuits on sheet 5/12. The amplified DFC output voltages are fed to the ADC
chip U730 via the analogue multiplexer U731. The ADC output signal is communicated to the 16-bit
processor via the signals 16b_AD_CS, 16b_AD_DAT and 16b_AD_CLK. The reference voltage
AVREF for the ADC chip is derived from the VCC voltage by a voltage divider with R733 and R734.
For a correct operation of the DFC units an offset voltage is necessary. The three voltages are
supplied by the DAC U980, which is controlled by the 16-bit controller via the signals
16b_DAC2_CS, 16b_DAC_DATA and 16b_DAC_CLK.
OMR
The OMR electronics are shown in sheet 12/12. Two OMR output voltages (16b_ReadHead_Ana0
and 16b_ReadHead_Ana1) are fed to an ADC input of the 16-bit processor via the analogue
multiplexer chip U701. The DAC U980 supplies two offset voltages (16b_ReadHead_DAC0 and
16b_ReadHeadDAC1). Output chip U700 supplies two signals (16b_ReadHead_S1 and
16b_ReadHead_S2) for setting the amplification.
Keyboard and display

The 8-bit controller handles the control of both the keyboard and the display. Sheet 3/12 shows the
interface electronics. As the main board 98.90.01 is also used for other machines, two connectors
(J300 and J330) are available.
rev. 01.1- 06/2004

410.03-7
410.03-8 rev. 01.1- 06/2004

FEEDER1* FEEDER2 FEEDER3

PH9 PH4 ** CL1 CL2 CL3
2 1 FEED FEED FEED
1 LOC RX 2
2 VT TX 1 PH1 PH2 PH3
1
PH6
PH8 FOL RX 1
PH10 2
EXIT TX 1 FLAP RX
2 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
PH10 PH6
2
1
EXIT RX PH8 2 1
10
9
8
7
6
5
4
3
2
1
FLAP TX 2 FEEDER3
2 FOL TX 1
1 2 1
SPH1
2
So1 821622
PH7 COL RX 1
989032 WIRING 3X
FINGERS 2 DFC FEEDER1 DFC FEEDER2 DFC FEEDER2
10
9
8
7
6
5
4
3
2
1
SOLENOID 1 FEEDER2 TOP MIDDLE BOTTOM
MAIN PDISC 2 PH5
1
2
2
1
989018 790171 790171 790171
1
ENV TRACK RX WIRING
2
1 2 1 PH7 TMU 1 TMU 2 TMU 3
1
2
3
4
5
6
7
8
10
9
8
7
6
5
4
3
2
1
ENV TRACK TX FEEDER1
2
DFC1 DFC2 DFC3
PHCEL COLLATOR FEEDER1
J1050 J900
REAR SIDE ACTUATORS
10 5 10 OPTIONAL
MAIN PDISC
FEEDER2
9 4 9
J580
ENV TRACK PHCELS

J930
8 3 8
7 2 7
J440
FEEDER3
6 1 6 989028 WIRING *** 3 7 4
J500
J950
CL6 5 5 2 5
4 4
EXIT PHCELS
RPM 1 6
ENV. TRACK 3 5 3 SPH2
2 J540 4 2 1
2 1
1 3 1 2 COLLATOR MAXI FEEDER
MAXI FEEDER
2 3 *** MS3
J1100
1 4 COLLATOR
5 975505 MF-2 SWITCH
PH9 2 1
6 2
LOC TX 2 12
1 11
M
10 1 4
MOTOR
So2 9 2 COLLATOR
4 8 3 1
J460
J1000
FOLDERS
SOLENOID
3 7
989001 4
LOC
EJECT
J1110
COLLATOR
2 6 5 M2
1 5 J740 6
So3
4
3
2
ORION DONGLE 7
8
9 1
PH5
1 2 COL TX
SEALING 1 10 2
SOLENOID 8 989024
7 WIRING
6 1
J450
CLOSER
5 2 Motorboard
Fs1 4 3
Capacitor:
SEALING 3 4
UNIT POWER
FLAG 1 2 5 230V: 5µF (989006)
2 1 6 110V: 20µF (121281)
SWITCH RUN
J102
3 7
5
8
9 989026 9
J300
DISPLAY
4 START
10 WIRING
11 8
12 3
7
2
READING HEAD 6 74 J3
1 1
1 124 55
2
J330
J100 J101 J1200

54 3
4
CONNECTOR D9 FEMALE J1
73
TOP COVER SIDE COVER M 5
6
NeoFlash 51 7
1 3 8
2 2 Connection 72 1 52
3 1
975500 - 230V
975540 - 115V
J230
2
1
2
LCD
1
CURVE VT RX CURVE
DISC DISC
FOLDING PH4 ** FOLDING
TABLE1 TABLE2 RPM RPM
FOLDING FOLDING
POWER INLET 989005
TABLE1 TABLE2
SPH3 SPH4
CL4 CL5
989002 INCLUDES: MAINS FUSE 230V: 2.5 A
110V: 5 A
989003
PLUG TYPE:
COUNTRY SPECIFIED
RH1** L EURO 989051
READINGHEAD L USA 989052
(AC)
N UK 989053
N SWISS 989054
989408 AUSTRAL 989055
POWER SUPPLY
COM GND
INPUT: 100 - 120 VAC 3.15A COM
200 - 240 VAC 1.5A
MS2 50/60 Hz +V + 24 V
SIDE COVER OUTPUT: + 24 V 4.5A
SWITCH +V
2 MAINS LEAD
* Only for 2½ +V
4
station machine ADJ
1
MS1 Only if OMRI
TOP COVER **
2
SWITCH is installed.
4 *** Only if MAXI

1
BRE feeder DRAWN: J. Pijpker FILE: 989008.dsn REV. CODE:
is installed.
DATE: 11-12-2003 SCALE: 00 989008
figure 1.1 Total view of the electrical and electronic circuits, including external connections
and sensor/actuator connections.
rev. 01.1 - 06/2004 410.03-9

Cover
switches 24V
5V power supply
J100
Top 1
cover 2
3
JST3 PGND R115
R100 1K
3
J101 4K7
COVERTRACK1 8b_TOP_COVER 1 Q110
1
3
Side (sht 2) R116 BC817
cover 2 R101 1K
3
2
1K C100 8 1 P-CHANNEL L111 L112 VCC_OUT
JST3 PGND 10nF 1 Q112 600R 600R
24V R110 & IRFR9024 TP110
S Q
GND GND 0R1 R117 VCC VCC
R
2
2
7 56R L113 L114
R102 2 1 600R 600R
4K7 6 Ipk
COVERTRACK2 8b_SIDE_COVER osc Ct Q111 L110
3
24V 3 BC807 150uH
(sht 2)
R103 C112 150pF
1K C101 C110 C111 4
10nF
Unit 10nF 470uF
1
5 U re f + D111 C114 C115 C116 C117
2
F100 F101 GND GND - C113 STPS340U 2200uF 22µF
power 3A 3A R111 R112 R113 150pF
100nF 100nF
J102 3K6 3K6 3K6 U110

+24 Volt MC34063
1 R104
PGND 2
COVER out 4K7
3 GND
COVER in 4 8b_COLLATOR_COVER
Motor run relais (sht 2) R114
5 R105 3K6
Motor start relais 6
Power GND 1K C102
7
RS232 RTS
RS232 RXD
8
9
R130
56R
R131
56R
10nF PGND GND R118
1K AVDD power supply -12V power supply
RS232 CTS GND GND C120 C121
10 TP120
3
U100A VCC AVDD 100nF 100nF -12V

RS232 TXD 11 -12V
Q100 1 2 1 CASE 2.95V
RS232 GND 12 8b_MOTOR_RELAY
BC817
(sht 2)
3
JST12 R106 74HC14 R140
2
R107 4K7 4K7 U140B R142 2 1 2 1

GND PGND 4K7 LM358 56R VIN VOUT
5 + 3 VIN
7 D120 6
GND
BAT54S VIN
RS232_TXD 6 - 7 VIN
RS232_CTS PGND PGND R141 C140 C124 C125 C122 C123
(sht 2) 6K8 100nF 100nF 100nF 100nF U120 100nF
RS232_RXD
5
RS232_RTS 79L12
R108
3
4K7 U100B GND GND GND GND GND GND GND GND
Q101 1 4 3 8b_START_RELAY
BC817
(sht 2)
74HC14
2
R109
4K7 24V
PGND PGND
R150
10K Power down interrupt +12V power supply
VCC VCC 24V +12V TP130
+12V
R151
1K
8
TP100 R154 LM358
VCC VCC MH100 U140A
MOUNTING GND 4K7 3 +
HOLE R152 1 POWER_DOWN (sht 2)
Keep 4mm clear 100R C150 2 -
surrounding this 1nF D130
CO100 CO140
10nF 100nF testpin. 40mSec time left 12V
4
R153 R155
100R 3K6 C151 for uC after interrupt C130
1nF 100nF
GND GND CASE GND
GND GND GND GND GND GND
figure 1.2 Main board 98.90.01 electronics: sheet 1 of 12.
410.03-10 rev. 01.1 - 06/2004

VCC
CPU 8 Kbyte FRAM DATA/ADRESS BUS Latch

C200
2
22pF VCC 8b_MUA[0..7]
35
VCC
XTAL1 VCC
8b_AD[0..7]
8
57 8b_AD0 8b_AD[0..7]
P0.0 8b_AD1
56
20
VCC
X200 P0.1 8b_AD2
P0.2 55
22.118MHz 54 8b_AD3 8b_SDA_SIM 5 8b_AD0 2 19 8b_MUA0
VCC
P0.3 8b_AD4 SDA 8b_AD1 D1 Q1 8b_MUA1
34 XTAL2 P0.4 53 3 D2 Q2 18
52 8b_AD5 8b_SCL_SIM 6 1 8b_AD2 4 17 8b_MUA2
C201 P0.5 8b_AD6 SCL A0 8b_AD3 D3 Q3 8b_MUA3
51 2 5 16
GND
GND 22pF R201 P0.6 8b_AD7 A1 8b_AD4 D4 Q4 8b_MUA4
P0.7 50 8b_FRAM_WP 7 WP A2 3 6 D5 Q5 15
56R 8b_AD5 7 14 8b_MUA5
8b_MUA[8..15] D6 Q6
8b_CLK_22MHz 39 8b_MUA8 U210 8b_AD6 8 13 8b_MUA6
P2.0 D7 Q7
4
40 8b_MUA9 FM24C64 8b_AD7 9 12 8b_MUA7
P2.1 8b_MUA10 D8 Q8
8b_CPU_RESET 15 RST P2.2 41
42 8b_MUA11 GND GND 11
GND
P2.3 8b_MUA12 8b_ALE C
P2.4 43 1 OC
R202 44 8b_MUA13
100R P2.5 8b_MUA14 R220 U220
P2.6 45
10
47 46 8b_MUA15 1K 74HC573
8b_PSEN PSEN P2.7
16 VCC VCC VCC
R203 (INT2/CT0I)P1.0 8b_ENV_TRACK_INT (sht 5) GND GND
(INT3/CT1I)P1.1 17 POWER_DOWN (sht 1)
100R 18
(INT4/CT2I)P1.2 MAIN_PDISC (sht 5) R210 R211
8b_ALE 48 ALE (INT5/CT3I)P1.3 19 8b_CLOSERCEL
20 (sht 4) 4K7 4K7 R209
(T2) P1.4 8b_RPM_STACKER
21 8b_START_RELAY (sht 1) 1K
(RT2) P1.5
R204
1K (SCL) P1.6
(SDA) P1.7
22
23
SCS_SCL
SCS_SDA
(sht 6) 512Kbyte FLASH ROM
49 D200 8b_AD[0..7]
EA GREEN
(RXD) P3.0 24 8b_RXD
GND R205 25 TESTLED VCC
(TXD) P3.1 8b_TXD 8b_MUA[0..14]
1K 26
(INT0) P3.2 8b_RTS
6 EW (INT1) P3.3 27 8b_CTS
28 TP200
32
GND (T0) P3.4 8b_TST
(T1) P3.5 29 8b_FRAM_WP
30 8b_NWR 8b_MUA0 12 13 8b_AD0
VCC
(WR) P3.6 8b_MUA1 A0 D0 8b_AD1
(sht 4) 8b_EJECT_SOL 4 PWM0 (RD) P3.7 31 8b_NRD 11 A1 D1 14
8b_MUA2 10 15 8b_AD2
U300D 8b_MUA3 A2 D2 8b_AD3
(sht 4) 8b_FINGER_SOL 5 PWM1 (CMSR0) P4.0 7 8b_SCL_SIM 9 A3 D3 17
8 (sht 5) 74HC14 8b_MUA4 8 18 8b_AD4
(CMSR1) P4.1 8b_SDA_SIM A4 D4
9 9 8 8b_MUA5 7 19 8b_AD5
(CMSR2) P4.2 16b_OTP_SEL (sht 6) A5 D5
VCC 10 8b_MOTOR_RELAY (sht 1) 8b_MUA6 6 20 8b_AD6
(CMSR3) P4.3 8b_MUA7 A6 D6 8b_AD7
(CMSR4) P4.4 11 8b_RPM_ENV_TRACK (sht 4) 5 A7 D7 21
12 8b_RS232_MUX VCC 8b_MUA8 27
R206 (CMSR5) P4.5 8b_MUA9 A8
(CMT0) P4.6 13 8b_SEALING_SOL 26 A9
100R 14 (sht 4) 8b_MUA10 23
(CMT1) P4.7 8b_OnDeck_SOL A10
8b_MUA11
61 AVDD
1 CPLD 8b_MUA12
25
4
A11
44
22
R207 (ADC0) P5.0 8b_ANA_FLAP 8b_MUA13 A12
(ADC1) P5.1 68 8b_ANA_EXIT (sht 5) 8b_AD[0..3] 28 A13
100R 67 8b_MUA14 29
VCC
VCC
(ADC2) P5.2 8b_ANA_LOC 8b_AD0 BS_A15 A14
59 AVREF+ (ADC3) P5.3 66 8b_SIDE_COVER 2 I/O0 I/O16 24 3 A15
3 65 (sht 1) 8b_AD1 3 25 BS_A16 2
STADC (ADC4) P5.4 8b_TOP_COVER 8b_AD2 I/O1 I/O17 BS_A17 A16
58 AVREF- (ADC5) P5.5 64 8b_ANA_ILED (sht 5) 4 I/O2 I/O18 26 30 A17
GND1
GND2
63 8b_AD3 5 27 BS_A18 1
(ADC6) P5.6 8b_COLLATOR_COVER (sht 1) I/O3 I/O19 A18
60 AVSS (ADC7) P5.7 62 8b_ANA_ENV (sht 5) 8b_DISBUF2_OE 6 I/O4 I/O20 28
C202 C203 R208 (sht 3) 7 29 ram_OE flash_CE 22
8b_ORION_KB_RD I/O5 I/O21 CE
22µF 100nF 100R U201 16b_RSTINn 8 30 24
GND
I/O6 I/O22 8b_DIS_1 (sht 3) 8b_PSEN OE
36
37
80C552 (sht 6) 9 31 31
RESET_XA I/O7 I/O23 8b_DIS_2 8b_NWR WE#
R242 150R
8b_MUA[0..14] U230
16
GND GND GND GND GND 8b_MUA0 14 36 29F040
I/O8 I/O24 8b_DISDIR (sht 3)
8b_MUA1 15 37
I/O9 I/O25 8b_DISBUF_OE
8b_MUA14 16 38 GND
8b_MUA15 I/O10 I/O26
+12V VCC VCC 17 I/O11 I/O27 39
8b_MUA2
8b_NWR
8b_NRD
18
19
I/O12
I/O13
I/O28
I/O29
40
41 8b_MUA3 32Kbyte RAM
8b_CPU_RESET 20 42 8b_MUA12 R241 R240 8b_AD[0..7]
R260
4K7 RS232 driver RS232 MUX (sht 3) 8b_DIS_3 21
I/O14
I/O15
I/O30
I/O31 43 8b_MUA13 1K 1K
16
16
8b_MUA[0..15] VCC
RS232_RXD 13 12 13 12
VCC
VCC
R1IN R1OUT X X0 8b_RXD 11 13
28
8 9 14 8b_PSEN CLK0/IO TCK
(sht 1) RS232_CTS R2IN R2OUT X1 16b_RXD0 (sht 6) 32
RS232_TXD 14 11 3 15 TMS 8b_MUA0 8b_AD0
T1OUT T1IN Y X2 33 10 10 11
GND
GND
GND
GND
VCC
RS232_RTS 7 10 11 8b_CLK_22MHz CLK1/I1 TDI D241 D240 8b_MUA1 A0 D0 8b_AD1
T2OUT T2IN X3 TDO 35 9 A1 D1 12
GREEN RED 8b_MUA2 8 13 8b_AD2
C+ 1 C260 100nF Y0 1 8b_TXD U240 FLASH FLASH 8b_MUA3 7
A2 D2
15 8b_AD3
VCC A3 D3
1
12
23
34
C1- 3 Y1 5 16b_TXD0 (sht 6) M4A5-64/32 RUN WRITE 8b_MUA4 6 16 8b_AD4
C2+ 4 C261 100nF Y2 2 VCC 8bit 8bit 8b_MUA5 5
A4 D4
17 8b_AD5
5 4 8b_MUA6 A5 D5 8b_AD6
C2- Y3 4 18
2 C262 100nF 10 8b_RS232_MUX 8b_MUA7 A6 D6 8b_AD7
GND
V+ A J240 3 19
6 9 8b_MUA8 A7 D7
GND
GND
V- B GND GND GND 25

6 1 8b_MUA9 A8
U260 C263 INH 2 24 A9
CPLD 8b_MUA10 21
15
MAX232ACSE 100nF U261 3 C240 10nF GND 8b_MUA11 A10

23
7
8
74HC4052 In circuit 4 8b_MUA12 2

A11
5 A12
programming 6
8b_MUA13 26 A13
8b_MUA14 1
GND GND GND GND connection 7 A14
8 8b_MUA1520
8b_CTS
CS1
HEAD8 27
GND
VCC 8b_RTS GND 8b_NWR WE
22 OE
U250
8b_MUA[0..14]
14
62256HF
CO201 CO210 CO220 CO230 CO2400 CO2401 CO250 CO260 CO261
10nF 10nF 10nF 10nF 10nF 10nF 10nF 10nF 10nF GND
GND
rev. 01.1 - 06/2004 410.03-11

Orion keyboard readout
VCC VCC VCC VCC VCC VCC VCC VCC VCC
R309 R310 R311 R312 R313 R314 R308 R315

10K 10K 10K 10K 10K 10K 10K 10K
20
8b_AD[0..7]
ORION LCD connection 2 18 8b_AD0 (SHT 2)
VCC
1A1 1Y1 8b_AD1
4 1A2 1Y2 16
6 14 8b_AD2
1A3 1Y3 8b_AD3
8 1A4 1Y4 12
11 9 8b_AD4
VCC_OUT 2A1 2Y1 8b_AD5
13 2A2 2Y2 7
J300 15 5 8b_AD6
2A3 2Y3 8b_AD7
2 1 17 2A4 2Y4 3
R300 100R 4 3
R301 100R 6 5 R304 100R JP321 JP320 1
GND
R302 100R R305 100R C301 C302 C303 C304 C305 C306 SEL0 SEL1 1G 8b_ORION_KB_RD
8 7 2G 19
10 9 R306 100R 150pF 150pF 150pF 150pF 150pF 150pF (SHT 2)
CE DISP. 12 11 U320
10
WRITE DISP.14 13 C/D DISP. 74HC244
RESET DISP.16 15 READ DISP. GND GND GND GND GND GND GND GND GND
18 17
R316 20 19
100R 22 21
24 23
26 25
CONBOX26
GND GND
2
U300A
74HC14
1
R335 L335
L330 R330 SI68 LCD connection R336

R337
L336
L337
VCC L343 R317 R338 L338 VCC
L331 R331 R339 L339
L332 R332 VCC_OUT VCC_OUT R340 L340
L333 R333 J330 R341 L341
20
20
8b_AD[0..7] (SHT 2)
L334 R334 2 1 R342 L342
2 18 4 3 18 2 8b_AD0
VCC
VCC
8b_DIS_1 1A1 1Y1 B1 A1
4 16 6 5 17 3 8b_AD1
8b_CPU_RESET 1A2 1Y2 B2 A2
6 14 GND 8 7 16 4 8b_AD2
8b_DIS_2 1A3 1Y3 B3 A3
8 12 GND 10 9 15 5 8b_AD3
8b_DIS_3 1A4 1Y4 B4 A4
11 9 12 11 14 6 8b_AD4
2A1 2Y1 B5 A5 8b_AD5
8b_NWR 13 2A2 2Y2 7 14 13 13 B6 A6 7
15 5 16 15 12 8 8b_AD6
8b_NRD 2A3 2Y3 B7 A7
17 3 18 17 11 9 8b_AD7
(SHT 2) 2A4 2Y4 B8 A8
20 19
1 600R 100R 100R 600R 19
GND
GND
1G G 8b_DISBUF_OE (SHT 2)
19 600R 100R GND GND 100R 600R 1
2G DIR 8b_DISDIR
600R 100R MicroMatch20 100R 600R
U330 600R 100R 100R 600R U331
10
10
74HC244 600R 100R 100R 600R 74HCT245
600R 100R 100R 600R
GND GND GND 100R 600R GND
100R 600R
8b_DISBUF2_OE
3 4
74HC14
U300B
VCC_OUT VCC_OUT VCC VCC VCC VCC
13 12
U300F
74HC14 COJ300 COJ330 CO300 CO320 CO330 CO331
R390 100nF 100nF 10nF 10nF 10nF 10nF
1K

GND
410.03-12 rev. 01.1 - 06/2004

VCC
R471
R472 4K7
U300E 1K
24V 10 11
24V 8b_CLOSERCEL
Rear 74HC14
C470
side D440
C441 150pF
100nF
actuators 12V GND
PGND
9
J440
16 1
COM
RPM env. track 1 O1 I1 8b_RPM_ENV_TRACK (sht 2) 24V
2 15 O2 I2 2
3 14 O3 I3 3 8b_RPM_STACKER
RPM stracker 13 4
4 O4 I4
5 12 O5 I5 5 16b_DigClutch_FoReverse
RPM FoReverse 11 6 (sht 7) C450
GND
1
6 O6 I6 10nF D450
7 10 O7 I7 7 16b_DigClutch_FoForward
2
RPM FoForward STPS340U
8 U440 PGND
9
8
finger sol. ULN2003L
10
8
7
R450
JST10 PGND U100D 56R Q450A
9 8 2 SI4946EY 24V VCC
24V 8b_OnDeck_SOL
1
74HC14
C440 C442 R470

CLOSER
1
D441 10nF 470uF PGND 150R

2
STPS340U
PGND PGND J450
24V
1
7
8
R440 Closercel
Q440A 56R U100C 2
SI4946EY (sht 2) 3
2 6 5 8b_FINGER_SOL (sht 2) 4
C451
1
5
1
74HC14 10nF D451 Pres. on deck solenoid

6
2
STPS340U
PGND 7 Sealing solenoid
8
6
5
PGND R452 JST8
U100E 56R Q450B GND
11 10 4 SI4946EY
8b_SEALING_SOL
3
74HC14
PGND
24V
VCC_OUT 24V LOC

C460
1
10nF D460 J460
2
STPS340U
PGND 1 Eject solenoid
2
3
6
5
R460 TX loc-cel
U100F 56R Q440B 4
13 12 4 SI4946EY JST4
8b_EJECT_SOL
3
74HC14
8b_TX_LOC (sht 5)
PGND
rev. 01.1 - 06/2004 410.03-13

TP510
ENV VCC
8b_ANA_ENV
R510 (sht 2) R590 R591
R511 10K 8K2 68K
1K C510
10nF
8
R593 3 +
GND 1K 1 8b_ENV_TRACK_INT
2 - (sht 2)
U590A
TP520 LM358
4
FLAP
Enveloppe C590
1nF
R592
1K
Track 8b_ANA_FLAP
(sht 2)
R521 R520 GND GND
photcells 100R 10K
C520
J500 10nF
VCC_OUT R522
ENV_TRACK TX 1 100R
2
3 VCC_OUT
ENV_TRACK RX
4 GND
5 VCC_OUT
FLAP TX
6 TP530
7 VCC_OUT LOC
FLAP RX
8
9 VCC_OUT
LOC RX
10 8b_ANA_LOC
JST10 R530 (sht 2)
R531 10K
4K7 C530
10nF
GND +12V VCC VCC

ENV_TRACK
1
Q550 1 R558 1K 9 5 R554 R555
VP
BC817 R559 68K DAC0 N.C. 4K7 4K7
10 DAC1 A0 6
R560 1K 11 7 GND
DAC2 A1
2
R561 68K 12
R562 1K DAC3
13 DAC4 SCL 4 8b_SCL_SIM
FLAP R550 R563 68K 14 3 (sht 2)
82R R564 1K DAC5 SDA 8b_SDA_SIM
15
GND
DAC6
3
R565 68K 16 2 VCC
Q551 DAC7 VMAX
1
BC817 U550
8
TDA8444T R556
2
10K
LOC
3.98V
R551
8b_TX_LOC
Exit (sht 4)
82R R557
3
C550 39K
Q552 100nF
photocell VCC_OUT BC817
1
J540 GND GND GND
2
1
EXIT TX 2 EXIT R552
3 82R
4
3
EXIT RX
5 Q553 1
JST5 BC817
U590B
2
5 + LM358 Uout = 11 x I
7 8b_ANA_ILED (sht 2)
R553 6 -
82R
R572 R573 R570 100K

1R 1R
C570 10nF
VCC +12V R571
4K7
TP540
EXIT
CO560 CO550 GND GND
100nF 100nF
8b_ANA_EXIT (sht 2)
GND GND R540
VCC_OUT VCC VCC R541 R542 10K
4K7 4K7 C540
10nF
R583
J580 R580 1K
Main 1
2
150R R581
4K7
U300C
GND
D580
PulsDisc 3
4
74HC14 GREEN
5 6 MAIN PDISC
5 MAIN_PDISC (sht 2, 6)
JST5 R582
GND 1K C580
150pF
GND
410.03-14 rev. 01.1 - 06/2004

VCC R600
1K
OSC. 29.4912Mhz
VCC VCC
64Kbyte system RAM U660A
74HC08 1Mbyte emulation RAM
16b_MUD[0..15] 16b_PSENn 1
4
U600 3
R601 R613 2
VDD
16b_RDn
OUT 3
56R
XA controller 1K VCC
16b_MUA[1..19]
28
16b_MUA[1..19] 16b_MUD[0..15]
TP610
GND
1 C600 D610 16b_TST 16b_MUD0 11 10 16b_MUA1 VCC
VCC
OE 150pF GREEN 16b_MUD1 D0 A0 16b_MUA2
12 9
71
72
52
51
14
15
TEST 16b_MUD2 D1 A1 16b_MUA3
13 8
32
D2 A2
2
16b_MUD3 16b_MUA4
68 73 15 7
1Mbyte FLASH ROM
VDD
VDD
VDD
VDD
VDD
VDD
GND GND XTAL1 P4.0/ECI 16b_MUD4 D3 A3 16b_MUA5 16b_MUD0 16b_MUA1
74 16b_PWM_Collator (sht 11) 16 6 13 12
VCC
VCC AVDD P4.1/CEX0 16b_MUD5 D4 A4 16b_MUA6 16b_MUD1 DQ0 A0 16b_MUA2
67 XTAL2 P4.2/CEX1 75 16b_PWM_MaxiFeeder (sht 11) 17 D5 A5 5 14 DQ1 A1 11
76 16b_MUD6 18 4 16b_MUA7 16b_MUD2 15 10 16b_MUA3
P4.3/CEX2 MAIN_PDISC (sht 5) D6 A6 DQ2 A2
77 16b_MUD7 19 3 16b_MUA8 16b_MUD3 17 9 16b_MUA4
P4.4/CEX3 16b_PDisc_Collator (sht 11) D7 A7 DQ3 A3
R615 R614 28 78 25 16b_MUA9 16b_MUD[0..15] VCC 16b_MUA[1..19] 16b_MUD4 18 8 16b_MUA5
AVDD P4.5/CEX4 DfcMulPlex0 (sht 7) A8 DQ4 A4
1K 1K 29 79 24 16b_MUA10 16b_MUD5 19 7 16b_MUA6
AVDD P4.6/A20 16b_DongleCommunication(sht 7) A9 DQ5 A5
16b_MUA11 16b_MUD6 16b_MUA7
GND
27 2 21 20 6
37
AVREF+ P4.7/A21 16b_AD_CS (sht 7) A10 DQ6 A6
26 23 16b_MUA12 16b_MUD7 21 5 16b_MUA8
C601 AVREF- A11 16b_MUA13 16b_MUD0 16b_MUA1 DQ7 A7 16b_MUA9
30 17 16b_DAC1_CS 2 29 25 27
VCC
100nF AVSS P5.0/AD0 A12 16b_MUA14 16b_MUD1 DQ0 A0 16b_MUA2 A8 16b_MUA10
31 AVSS P5.1/AD1 18 16b_DAC_CLK (sht 8) A13 26 31 DQ1 A1 24 A9 26
19 1 16b_MUA15 16b_MUD2 33 23 16b_MUA3 23 16b_MUA11
P5.2/AD2 16b_DAC_DATA A14 DQ2 A2 A10
GND 46 20 16b_MUD3 35 22 16b_MUA4 25 16b_MUA12
CLKOUT P5.3/AD3 16b_ReadHead_Ana1 (sht 12) DQ3 A3 A11
R610 56R 44 22 20 16b_MUD4 38 21 16b_MUA5 4 16b_MUA13
16b_ALE ALE/PROG P5.4/AD4 16b_Multiplexed_AD4(sht 7) CS1 DQ4 A4 A12
45 23 27 16b_MUD5 40 20 16b_MUA6 28 16b_MUA14
GND
16b_PSENn PSEN P5.5/AD5 16b_IledCheck (sht 8) WE DQ5 A5 A13
(sht 7)16b_RSOUTn 11 24 SCS_SCL 22 16b_MUD6 42 19 16b_MUA7 3 16b_MUA15
RSTOUT P5.6/AD6/SCL (sht 2) OE 16b_MUD7 DQ6 A6 16b_MUA8 A14 16b_MUA16
16b_RSTINn 47 RST P5.7/AD7/SDA 25 SCS_SDA 44 DQ7 A7 18 A15 31
16 U620 16b_MUD8 30 8 16b_MUA9 2 16b_MUA17
EA/WAIT/VPP DfcMulPlex1 (sht 7) 16b_OERAM1n DQ8 A8 A16
14
40 62256HF VCC 16b_MUD9 32 7 16b_MUA10 30 16b_MUA18
P6.0/A22 16b_WRLn DQ9 A9 A17
R611 32 41 R612 10K 16b_MUD10 34 6 16b_MUA11 1 16b_MUA19
16b_WRHn P1.0/A0/WRH P6.1/A23 16b_OTP_SEL 16b_RAMCS1n DQ10 A10 A18
10K 16b_MUA1 33 (sht 2) 16b_MUD11 36 5 16b_MUA12
P1.1/A1 16b_MUD0 GND R630 16b_MUD12 DQ11 A11 16b_MUA13
16b_MUA2 34 P1.2/A2 P0.0/A4D0 42 39 DQ12 A12 4 OE 24
35 43 16b_MUD1 1K 16b_MUD13 41 3 16b_MUA14 22
GND
16b_MUA3 P1.3/A3 P0.1/A5D1 DQ13 A13 CS 16b_RAMCS2n
GND 36 48 16b_MUD2 16b_MUD14 43 2 16b_MUA15 29
16b_RXD1 P1.4/RXD1 P0.2/A6D2 DQ14 A14 WE 16b_WRLn
37 49 16b_MUD3 VCC 16b_MUD15 45 1 16b_MUA16
16b_TXD1 P1.5/TXD1 P0.3/A7D3 16b_MUD4 D630 DQ15 A15 16b_MUA17 U640
16b_AD_DAT 38 P1.6/T2 P0.4/A8D4 50 A16 48
16
(sht 7) 39 55 16b_MUD5 RED 17 16b_MUA18 HM628512BLP-5
28
16b_AD_CLK P1.7/T2EX P0.5/A9D5 16b_MUD6 FLASH WRITE A17 GND
P0.6/A10D6 56 A18 16 16b_FMUA19
16b_RXD0 3 57 16b_MUD7 16b_MUD8 11 10 16b_MUA1 15
VCC
(sht 2) P3.0/RXD0 P0.7/A11D7 16b_MUD9 D0 A0 16b_MUA2 RY/BY
16b_TXD0 4 P3.1/TXD0 12 D1 A1 9 16b_RSTINn 12 RESET OE 28 16b_PSENn
5 58 16b_MUD8 16b_MUD10 13 8 16b_MUA3 VCC 47 26
(sht 10) 16b_CurveDisc_FT1 P3.2/INT0 P2.0/A12D8 D2 A2 BYTE CE 16b_FlashCSn
6 59 16b_MUD9 16b_MUD11 15 7 16b_MUA4 11
GND
GND
16b_CurveDisc_FT2 P3.3/INT1 P2.1/A13D9 16b_MUD10 16b_MUD12 D3 A3 16b_MUA5 WE 16b_WRHn 16b_MUA[1..19]
(sht 7) DfcMulPlex2 7 P3.4/T0 P2.2/A14D10 61 16 D4 A4 6
(sht 9)16b_DAC2_CS 8 62 16b_MUD11 16b_MUD13 17 5 16b_MUA6
P3.5/T1/BUSW P2.3/A15D11 16b_MUD12 16b_MUD14 D5 A5 16b_MUA7 U630
16b_WRLn 9 P3.6/WRL P2.4/A16D12 63 18 D6 A6 4
46
27
10 64 16b_MUD13 16b_MUD15 19 3 16b_MUA8 29F800 VCC
16b_RDn P3.7/RD P2.5/A17D13 16b_MUD14 D7 A7 16b_MUA9
P2.6/A18D14 65 A8 25
66 16b_MUD15 24 16b_MUA10
32
P2.7/A19D15 A9 16b_MUA11 GND
A10 21
VSS
VSS
VSS
VSS
VSS
VSS
23 16b_MUA12 16b_MUD8 13 12 16b_MUA1
VCC
A11 16b_MUA13 16b_MUD9 DQ0 A0 16b_MUA2
A12 2 14 DQ1 A1 11
U610 26 16b_MUA14 16b_MUD10 15 10 16b_MUA3
A13 DQ2 A2
69
70
53
54
12
13
PXAS37KBBE 1 16b_MUA15 16b_MUD11 17 9 16b_MUA4

SOT315-1 A14 16b_MUD12 DQ3 A3 16b_MUA5
18 DQ4 A4 8
20 16b_MUD13 19 7 16b_MUA6
CS1 16b_RAMCS1n DQ5 A5
GND 27 16b_MUD14 20 6 16b_MUA7
GND
WE 16b_WRHn DQ6 A6
22 16b_MUD15 21 5 16b_MUA8
OE 16b_OERAM1n DQ7 A7
JP610 27 16b_MUA9
A8 16b_MUA10
FLASH BOOT U621
DEBUG CONNECTION A9 26
14
62256HF 23 16b_MUA11
16b_MUD[0..15] A10
Scratch jumper GND 25 16b_MUA12
VCC_OUT A11 16b_MUA13
A12 4
16b_MUA14
Latches 16b_MUA[4..19]
J600 A13
A14
28
3 16b_MUA15
16b_MUA16
OTP/FLASH selector VCC
1
2 16b_TXD1
A15
A16
31
2 16b_MUA17
16b_Map0 30 16b_MUA18
20
3 16b_RXD1 A17
16b_Map1 SCS_SCL 1 16b_MUA19
16b_MUD0 16b_MUA4 4 (sht 2) A18
2 19 SCS_SDA
VCC
VCC 16b_MUD1 D1 Q1 16b_MUA5 5
16b_MUD[0..1] 3 D2 Q2 18 6 16b_DEBUG1 OE 24
VCC 16b_MUD2 4 17 16b_MUA6 (sht 7) 22
16b_DEBUG2
GND
D3 Q3 7 CS 16b_RAMCS2n
16b_MUD3 5 16 16b_MUA7 29
16b_MUD4 D4 Q4 16b_MUA8 8 WE 16b_WRHn
6 15
28
16b_MUA[1..19] D5 Q5
16b_MUD5 7 14 16b_MUA9 HEAD8 U641
14
D6 Q6
16
1
16b_Map0 2 27 16b_MUD6 8 13 16b_MUA10 GND HM628512BLP-5

VCC
I1/CLK O1 16b_FlashCSn D7 Q7
16b_Map1 3 26 16b_MUD0 2 5 16b_MUD7 9 12 16b_MUA11
CL
VCC
I2 O2 16b_RAMCS1n D Q D8 Q8
VCC 16b_MUA1 4 25 GND
16b_MUA2 5 I3 O3 16b_RAMCS2n 16b_MapWRn 3
24 11
GND
I4 O4 CLK 16b_ALE C
16b_MUA15 6 23 1
GND
I5 O5 16b_FMUA19 OC
16b_MUA16 7 21 6 VCC VCC
PR
I6 O6 16b_DigInput1 Q
JP670 16b_MUA17 9 20 (sht 6) R680 U680 VCC VCC
I7 O7 16b_DigOutput1
10
R&D 16b_MUA18 10 19 U671A 1K 74HC573
11
I8 O8 16b_DigOutput2
7
6
16b_MUA19 11
16b_R.en.D 12
I9
I10
O9
O10
18
17
16b_OERAM1n
16b_PSENn GND
74HC74 GND GND
VCC R650 5V supervisor R652
13 1K R651 1K
16b_WRLn I11
16 22 VCC VCC 1K U660D U660B
20
16b_RDn I12 NC
15 74HC08 74HC08
NC 16b_MUD8 16b_MUA12
8 2 19 9 5
14
13
RESET_XA
GND
(sht2)
VCC
NC D1 Q1 RSET 16b_RSTINn
R670 1 16b_MUD9 3 18 16b_MUA13 8 2 6
1K NC R671 16b_MUD1 16b_MUD10 D2 Q2 16b_MUA14 16b_Reboot RESIN RST
12 9 4 17 10 7
CL
VCC
D Q D3 Q3 SEN
12
13
5
U670 680K 16b_MUD11 5 16 16b_MUA15 3 1
D4 Q4 CT REF
14
22V10PLCC 11 16b_MUD12 6 15 16b_MUA16 U660C

CLK 16b_MUD13 D5 Q5 16b_MUA17 74HC08 U650
7 14
GND
16b_MUD14 D6 Q6 16b_MUA18 C650 C651 C652 TL7705A C653 R660

8 8 13
PR
GND GND Q 16b_MUD15 D7 Q7 16b_MUA19 100nF 100nF 22µF 100nF 1K

9 D8 Q8 12
C671 U671B
7
10
100nF 74HC74 11
GND
16b_ALE C
GND 1 GND GND GND GND
GND OC
VCC U681
10
VCC D671 R681 74HC573

MAP0 R672 1K
CO6100 CO6102 CO621 CO640 CO660 CO680 CO670 AVDD 1K
RED GND GND
CO6103 D672
10nF10nF10nF 10nF 10nF 10nF 10nF 10nF 10nF10nF10nF 10nF 10nF 10nF 10nF 1uF MAP1 R673
1K
CO600 CO6101 CO620 CO630 CO641 CO661 CO681 CO671 GND
GND GREEN
rev. 01.1 - 06/2004 410.03-15

Digital outputs Analog multiplexer
VCC VCC
VCC VCC
20
16
16b_MUD[0..7]
2
16b_MUD0 3 2 R740
VCC
VCC
D7 Q7 16b_DEBUG1 (sht 6)
16b_MUD1 4 5 MU_AD_SEL0 11 13 (sht 10) 10K
D6 Q6 16b_DEBUG2 A X0 16b_ANA_RX_Collator
16b_MUD2 7 6 MU_AD_SEL1 10 14 (sht 12) 3
D5 Q5 16b_DIR_Collator (sht 11) B X1 16b_ANA_RX_ReadHead
16b_MUD3 8 9 MU_AD_SEL2 9 15 (sht 10) D740
D4 Q4 C X2 16b_ANA_RX_Folder
16b_MUD4 13 12 12 (sht 9) BAT54S
D3 Q3 X3 16b_ANA_RX_Feeder1
16b_MUD5 14 15 6 1 (sht 9)
D2 Q2 INH X4 16b_ANA_RX_Feeder2
1
16b_MUD6 17 16 5
D1 Q1 16b_ReadHead_S0 (sht 12) X5 16b_ANA_RX_Feeder3 (sht 9)
16b_MUD7 18 19 G ND 2 J740
D0 Q0 16b_ReadHead_S1 (sht 12) X6 16b_ReadHead_Ana0 (sht 12)
4 (sht 12) G ND UCAN CLIP
X7 16b_ReadHead_Ana2
11 (sht 6) 16b_DongleCommunication 2
GND
GND
16b_DigOutput1 CLK
16b_RSOUTn 1 CLR 3 X R741
1
U700 AVDD U701 150R
10
8
74HC273 74HC4051
2
G ND G ND
G ND
3 D700
16b_Multiplexed_AD4 BAT54S
VCC TP710
W INDOW
1
20
16b_MUD[0..7] GND
16b_MUD0 3 2
VCC
D7 Q7 16b_DigClutch_FO1 (sht 10)
16b_MUD1 4 5
D6 Q6 16b_DigClutch_FO2 (sht 10)
16b_MUD2 7 6
D5 Q5 16b_DigClutch_FoForward (sht 4)
16b_MUD3 8 9
16b_MUD4 D4 Q4
13 D3 Q3 12 16b_DigClutch_FE1 (sht 9)
16b_MUD5 14 15
D2 Q2 16b_DigClutch_FE2 (sht 9)
16b_MUD6 17 16
D1 Q1 16b_DigClutch_FE3 (sht 9)
16b_MUD7 18 19
D0 Q0 16b_DigClutch_FoReverse (sht 4)
11 R711
GND
16b_DigOutput2 CLK R710 150R
16b_RSOUTn 1 CLR
3
4K7
U710 1 Q710
10
74HC273 BC817
G ND
2
GND
(sht 6)
Digital inputs
VCC
20
16b_MUD[0..7]
16b_MUD0 18 2 (sht 9)
VCC
1Y1 1A1 16b_DIG_FCEL_FE1
16b_MUD1 16 4 (sht 9)
16b_MUD2 14 6 (sht 9)
16b_MUD3 12 8 (sht 10)
1Y4 1A4 16b_DIG_FCEL_COLL
16b_MUD4 9 11 (sht 12)
2Y1 2A1 16b_DIG_FCEL_RH
16b_MUD5 7 13 (sht 10)
2Y2 2A2 16b_DIG_FCEL_FO
16b_MUD6 5 15 (sht 11)
2Y3 2A3 16b_SwitchMaxiFeeder
16b_MUD7 3 17 VCC
2Y4 2A4
1 R720
GND
1G JP720 10K
16b_DigInput1 19 2G FE1-SEL
U720
10
74HC244
G ND GND
10 bit ADC for DFC
VCC VCC VCC
VCC VCC
JP730 JP731
16
R730 R731 R732 Inter. trans. Spare
56R 56R 56R
VCC
DfcMulPlex0 11 A X0 13 16b_DFC_FE1 (sht 9)
(sht 6) DfcMulPlex1 10 B X1 14 16b_DFC_FE2 (sht 9)
DfcMulPlex2 9 C X2 15 16b_DFC_FE3 (sht 9)
CO7300 CO7301 CO7302 12
X3 16b_MaxiFeederDetect (sht 11)
10nF 22µF 1uF R733 6 1
INH X4 16b_IledCheck (sht 8)
1K 5
GND G ND G ND X5
X6 2
8
G ND 4
X7
GND
VCC
16b_AD_CS 1 CS +IN 2 3 X R735 R736

6 5 U731 10K 10K
16b_AD_DAT DOUT VREF
8
74HC4051
7 3
GND
16b_AD_CLK CLK -IN

R734 C730 C731
U730 1K 100nF 1nF
4
LTC1197
G ND G ND G ND GND GND G ND GND G ND

VCC
CO700 CO701 CO710 CO720 CO731

10nF 10nF 10nF 10nF 10nF
GND
410.03-16 rev. 01.1 - 06/2004

Current Sink
2 3 16b_TX_Feeder1
R808 Q800
82R BC817
1
R802 2 3 (sht 9)
16b_TX_Feeder2
1K
R809 Q801
82R BC817
1
R803 2 3 16b_TX_Feeder3
1K
R810 Q802
82R BC817
1
R804 2 3 16b_TX_Collator (sht 11)
Photocel DAC 1K
R811 Q803
82R BC817
1
VCC VCC
R805 2 3 (sht 10)
16b_TX_Folder
1K
4
R812 Q804
6 2 82R BC817
VDD
LDAC DAC-A
1
DAC-B 1
11 16 R806 2 3
16b_DAC1_CS CS DAC-C 16b_TX_ReadHead (sht 10)
13 15 1K
(sht 6) 16b_DAC_DATA DIN DAC-D R813 Q805
16b_DAC_CLK 12 SCLK DAC-E 7
14 8 82R BC817 VCC
DOUT DAC-F
1
9
GND
DAC-G R807
5 REF DAC-H 10
8
1K U820A
U800 3 + LM358 Uout = 11 x I
3
MAX5258 1 (sht 6)
16b_IledCheck
VCC 2 -
R820
100K
4
R800
10K
3.98V R822 R823
1R 1R C820
R801 C800 R821 10nF
39K 100nF 4K7
GND GND GND GND GND
U820B
5 + LM358
7
6 -
VCC VCC
R825
CO800 CO820 1K
100nF 100nF
GND GND GND
rev. 01.1 - 06/2004 410.03-17

24V VCC_OUT VCC +12V 24V
Feeder-1 R904 R905

8K2 68K
TP900 D970 C970
J900 FE-1 12V 100nF
8
R906
Clutch fe1 1
16b_Clutch_FE1 R902 3 + 10K PGND
2
9
3 10K 1 16b_DIG_FCEL_FE1
RX feeder-1 2 16 1
16b_Clutch_FE1 16b_DigClutch_FE1
COM
4 - O1 I1
U900A 15 2
TX feeder-1 5 LM358 O2 I2 (sht 7)
6 16b_TX_Feeder1(sht 7) 16b_Clutch_FE2 14 O3 I3 3 16b_DigClutch_FE2
4
R900 R901 C900 R903 13 4
7 1K 1K 10nF 1K O4 I4
8 16b_Clutch_FE3 12 O5 I5 5 16b_DigClutch_FE3
11 6
GND
DFC feeder1 9 O6 I6
10 10 O7 I7 7
JST10 GND GND GND GND GND (sht 7) U970

16b_ANA_RX_Feeder1
8
GND ULN2003L
C911 100nF
PGND
TP910
R913 39K DFC FE1
R912
5K6 R914
6 - 1K
7 16b_DFC_FE1
5 +
U900B
R910 R911 C910 LM358 R915 C912 VCC VCC VCC
5K6 39K 100nF 1K 100nF
4
R980 Pulls BusWidth
GND GND GND GND FE1 _DFC_OFFSET 2 6 10K select of XA high
VDD
FE2 _DFC_OFFSET DAC-A LDAC
1 DAC-B
VCC +12V FE3 _DFC_OFFSET 16 11
24V VCC_OUT DAC-C CS 16b_DAC2_CS
16b_ReadHead_DAC0 15 DAC-D DIN 13 16b_DAC_DATA (sht 6)
(sht 12)
Feeder-2 R933 R935
16b_ReadHead_DAC1 7
8
DAC-E
DAC-F
SCLK
DOUT
12
14
16b_DAC_CLK
8K2 68K 9 VCC
GND
TP930 DAC-G
10 DAC-H REF 5
J930 FE-2
8
R936 U980 R981
1
3
Clutch fe2 R932 3 + 10K MAX5258 10K
2 16b_Clutch_FE2
RX feeder-2
4 2 -
3.98V
U930A
TX feeder-2 5 LM358 C980 R982
6 16b_TX_Feeder2 (sht 7)
4
R930 R931 C930 R934 100nF 39K
7 1K 1K 10nF 1K
8
DFC feeder2 9 GND GND
10
JST10 GND GND GND GND GND (sht 7)
16b_ANA_RX_Feeder2
GND
C941 100nF
TP940
R943 39K DFC FE2
R942
5K6 R944
6 - 1K
7 16b_DFC_FE2
5 +
U930B
R940 R941 C940 LM358 R945 C842
5K6 39K 100nF 1K 100nF
GND GND GND GND
24V VCC_OUT VCC +12V
Feeder-3 R953 R955

8K2 68K
TP950
J950 FE-3
8
R956
Clutch fe3 1
16b_Clutch_FE3 R952 3 + 10K
2
RX feeder-3 2
4 -
U950A
TX feeder-3 5 LM358
6 16b_TX_Feeder3 (sht 7)
4
R950 R951 C950 R954

7 1K 1K 10nF 1K
8
DFC feeder3 9
10
JST10 GND GND GND GND GND (sht 7)
16b_ANA_RX_Feeder3
GND
C961 100nF
TP960
R963 39K DFC FE3
R962
5K6 R964
6 - 1K
7 16b_DFC_FE3
5 +
U950B
R960 R961 C960 LM358 R965 C962
+12V +12V +12V VCC 5K6 39K 100nF 1K 100nF
CO900 CO930 CO950 CO980 GND GND GND GND

100nF 100nF 100nF 100nF
GND GND GND GND
410.03-18 rev. 01.1 - 06/2004

VCC_OUT 24V VCC VCC
FOLDERS R1003 VCC VCC

1K
IN KAP R1001
4K7 R1050 R1051
J1000 R1002 U00A D1000 68K 8K2
1K 74HC14 GREEN TP1050
Slotted switch FT1 1 FT1 COLL
2 1 2 16b_CurveDisc_FT1 (sht 6)
8
3 R1053
4 + 3
RX Reading head C1000 1 10K
5 16b_DIG_FCEL_COLL
150pF 2
Slotted switch FT2 6 -
U1050A
7 G ND LM358 R1054
8
4
16b_RX_ReadHead (sht 12) R1052 1K
Clutch FT1 9 1K
10 C1050 VCC_OUT
Clutch FT2 11 10nF R1055
12 1K
JST12 VCC VCC J1050
G ND GND G ND G ND 1 RX Collator
16b_ANA_RX_Collator 2
R1013
G ND 1K 3 TX Folder
(sht 8) 16b_TX_Folder 4
R1011
4K7 VCC 5 RX Folder
R1012 U00B D1010 6
1K 74HC14 GREEN 7 TX Read head
(sht 7) (sht 8) 16b_TX_ReadHead 8
3 4 FT2 R1060 R1061
16b_CurveDisc_FT2 (sht 6)
68K 8K2 TP1060 JST8
FO
C1010
150pF + 5 R1063
Photocells
G ND
16b_DIG_FCEL_FO 7
- 6
10K
collator
U1050B
LM358 R1064 side
R1062 150R
24V 1K
C1060
10nF R1065
150R
D1020 C1020
12V 100nF GND G ND GND
16b_ANA_RX_Folder
PGND
9
16 1
COM
O1 I1 16b_DigClutch_FO1
15 O2 I2 2 (sht 7)
14 O3 I3 3 16b_DigClutch_FO2
13 O4 I4 4
12 O5 I5 5
11 6
GND
O6 I6
10 O7 I7 7
U1020
8
ULN2003L
PGND
13 12 VCC VCC
U00F
74HC14
R1070 CO00 CO1050

1K 10nF 100nF
G ND G ND G ND
rev. 01.1 - 06/2004 410.03-19

VCC_OUT VCC_OUT
MAXI
R1100 R1102
10K 10K FEEDER
J1100
U00C R1101
74HC14 10K 1 Motor MF
2
16b_SwitchMaxiFeeder 6 5 3 Switch MF
C1100 4
100nF 5 MF detect
(sht 7) R1103 6
GND C1101 1K JST6
100nF
16b_MaxiFeederDetect
GND GND
24V VCC VCC 24V
R1111 R1112
10K 10K
C1113 C1114
100nF 100nF
PGND PGND
16
19
1
2
R1110
100R
C1112
10nF
VCC_OUT
Collator
EN_A
EN_B
VSa
VSb
D1110
BAT54S
3 4 VCP Unit
9 R1113
OUT1A 150R J1110
2
17 VBOOT OUT2A 3 1
C1110 C1111 2 Pdisc collator
100nF 100nF L1110 3
4
OUT2B 18 1 2 5
PGND PGND VCC
6 - Collator motor
OUT1B 12 3 4 7 +
7 IN2A 8
(sht 6) 16b_PWM_MaxiFeeder 6 COMMON MODE SUPPRESION COIL
IN1A 9 TX Collator
8
PGND1
PGND2
PGND3
PGND4
SENA (sht 8) 16b_TX_Collator 10
(sht 6) 16b_PWM_Collator 11 10 14 IN1B
(sht 7) 16b_DIR_Collator 15 13 JST10
IN2B SENB
U00E U1110
1
10
11
20
74HC14 L6205PD
GND
PGND PGND
VCC VCC
R1116
1K
R1114
4K7
D1111
GREEN R1115
PD COLL. 1K
(sht 6) 16b_PDisc_Collator 8 9
U00D
74HC14 C1115
150pF
24V GND
CO1110
470uF
PGND
410.03-20 rev. 01.1 - 06/2004

-12V +12V -12V

C1200 C1201
J1200 1nF 1nF
C1202 C1203
6
Reading 5
4
R1201
10nF 10nF
VCC
4
4K7 R1202 R1203 R1204 TP1220
Head 3
2 2 - 4K7 6K8 6k8 U1200B R1220 OMR_OUT
8
1 5 + LM358 47K
1 U1220B R1230
3 + 7 3 +
AMP6 U1200A 6 1 5 + LM358 1K
-
CASE GND R1200 LM358 R1205 2 7
- 16b_ReadHead_Ana1 (sht 6)
8
4K7 4K7 R1221 U1220A 6 -
C1204 C1205 100K LM358 R1226
4
1nF 1nF AVDD 100K R1231
1K C1220
2
GND +12V GND GND GND 100nF
-12V D1200 3 GND GND

BAT54S R1222 R1223 R1225 R1227 R1228 R1229
680K 100K 680K 47K 68K 47K
R1206 R1212
3
39K 10K Rv=27K
GND U1221A
-12V R1224 HC4066 13 5 16b_ReadHead_S1 (sht 7)
R1207 47K U1221B
100K HC4066
C1206
4
100nF
R1208 GND GND GND
100K
16b_ReadHead_S0 (sht 7)
VCC
16b_ReadHead_DAC1 (sht 9)
GND GND
16b_ReadHead_Ana2 (sht 7)
R1209 R1210
56R 82R
16b_ReadHead_DAC0 (sht 9)
16b_ReadHead_Ana0 (sht 7)
R1211 R1213
10K 10K C1207
100nF
GND GND
VCC VCC
R1254 R1255
8K2 68K
TP1250
ReadHead
8
R1252 3 +
10K 1 16b_DIG_FCEL_RH (sht 7)
(sht 10) 16b_RX_ReadHead 2 -
U1250A
R1250 LM358
4
150R
C1250 R1253
R1251 10nF 1K
150R
GND GND GND GND

16b_ANA_RX_ReadHead (sht 7)
5 +
VCC VCC 7
U1221C U1221D +12V -12V 6 -
HC4066 HC4066 U1250B
8 9 11 10 LM358
CO12000 CO12001 CO1220 CO1250 R1256
100nF 100nF 100nF 100nF 1K
6
12
rev. 01.1 - 06/2004 410.03-21

figure 1.14 Component layout of the main board 98.90.01
410.03-22 rev. 01.1 - 06/2004

1.2 Test points
Test point Name Minimum Typical Maximum Remarks

TP110 VCC 4.8 V 5.0 V 5.2 V Local +5 V supply.
TP120 -12V -12.5 V -12.0 V -11.5 V Local -12 V supply.
TP130 +12V 11V 12.0 V 13V Local +12 V supply.
TP200 8b_TST - - - Test of the digital signal that drives
LED D200. Normal flashing
frequency 1 Hz. During errors the
frequency is 2 Hz.
TP510 ENV 0.0 V 0.1 V 0.5 V PH7. Paper present
TP510 ENV 0.9 V 1.1 V 1.5 V PH7. No paper present. PH correctly
adjusted.
TP520 FLAP 0.0 V 0.1 V 0.5 V PH8. paper present.
TP520 FLAP 0.9 V 1.1 V 1.5 V PH8. No paper present. PH correctly
adjusted.
TP530 LOC 0.0 V 0.1 V 1.5 V PH9. Paper present.
TP530 LOC 0.9 V 1.1 V 1.5 V PH9. No paper present. PH correctly
adjusted.
TP540 EXIT 0.0 V 0.1 V 0.5 V PH10. paper present.
TP540 EXIT 0.9 V 1.1 V 1.5 V PH10. No paper present. PH
correctly adjusted.
TP610 16b_TST - - - Test of the digital signal that drives
LED D610. Normal flashing
frequency about 1 Hz. During errors
the frequency will increase.
TP710 WINDOW - - - This test point can be used as an
oscilloscope trigger signal to
synchronize OMR mark
measurements.
TP900 FE-1 0.0 V 0.1 V 0.5 V PH1. Paper present.
TP900 FE-1 0.9 V 1.1 V 1.5 V PH1. No paper present. PH correctly
adjusted.
TP910 DFC FE-1 4.0 V 4.1 V 4.2 V Output voltage of DFC1. Result of
DFC adjustment after passing of a
document.
adjusted.
document.
adjusted.
document.
rev. 01.1 - 06/2004

410.03-23
Test point Name Minimum Typical Maximum Remarks

TP1050 COLL 0.0 V 0.1 V 0.5 V PH5. Paper present.
TP1050 COLL 0.9 V 1.1 V 1.5 V PH5. No paper present. PH correctly
adjusted.
TP1060 FO 0.0 V 0.1 V 0.5 V PH6. Paper present.
TP1060 FO 0.9 V 1.1 V 1.5 V PH6. No paper present. PH correctly
adjusted.
TP1220 OMR 3.1 V - - OMR output voltage of reading head
OUT RH1.
TP1250 ReadHea 0.0 V 0.1 V 0.5 V PH4. Paper present.
d
TP1250 ReadHea 0.9 V 1.1 V 1.5 V PH4. No paper present. PH correctly
d adjusted.
table 1.1
1.3 Jumper settings
Jumper Meaning Remarks

Not placed Placed
JP320 SEL0 Load ‘N Go text. Auto Set text
JP321 SEL1 Load ‘N Go text. Fill & Start text
JP610 FLASH BOOT This jumper must not be placed! (If not present, the external
flash software never could establish contact with the machine,
which would always directly boot to the machine software.)
JP670 R&D This jumper is never present on a production board! This jumper
is only relevant in an R&D environment, in which case emulation
RAM (U640 and U641) should be present.
JP720 FE-1 SEL Reserved for gap separation feeder.
JP730 Inter. Trans. Is placed if intermediate transport is installed. Not relevant in
this machine.
JP731 Spare Not used (yet).
table 1.2
1.4 LED information
LED Name/Color Remarks

D200 TESTLED/ Periodically ON/OFF flashing. Signifies proper operation of the
Green machine software in the 8-bit controller. If the software is in
normal operation the flashing rhythm will be about 1 Hz. When an
error occurs the flashing rhythm increases.
D240 FLASH Is ON during the programming (flashing) of the 8-bit machine
WRITE/Red software. The behaviour of D240 and D241 is similar to the
behaviour of D671 and D672 for the 16-bits machine software (for
diagnostics with flash programm problems).
410.03-24 rev. 01.1 - 06/2004

LED Name/Color Remarks

D241 FLASH RUN/ Is ON during normal operation of the 8-bit machine software. The
Green behaviour of D240 and D241 is similar to the behaviour of D671
and D672 for the 16-bits machine software (for diagnostics with
flash programm problems).
D580 MAIN PDISC/ Reflects the optical state of slotted photocell SPH1 that monitors
Green pulse disc PD1, which moves in line with the main motor M1
driven items. Is ON if this motor is running AND if the mechanical
drive is okay.
D610 TEST/Green Periodically ON/OFF flashing. Signifies proper operation of the
machine software of the 16-bit controller U610. If the software is
in normal operation the flashing rhythm will be about 1 Hz. When
an error occurs the flashing rhythm increases.
D630 FLASH Flash LED. Is ON during the flashing (i.e. programming or
WRITE/Red reprogramming under supervision of external software) of the 16-
bit machine software in flash ROM (U630). Full brightness during
the erasing state, intermediate brightness during the flashing
state proper.
D671 MAP0/Red Reflects the state of the Map0 signal. Is OFF during normal
operation of the machine. Is ON during about one second in the
startup stage of the machine. Is also ON if during the flashing of
flash ROM (under supervision of external software) code must be
flashed into the upper 512 kilobyte part.
D672 MAP1/Green Reflects the state of the Map1 signal. Is ON during normal
operational use of the machine, including the one-second
machine startup stage mentioned under D671. Is OFF if program
code in system RAM (U620 & U621) (for instance flash software
for programming or reprogramming the flash ROM U630) is
executed, under supervision of external software.
D1000 FT1/Green Reflects the optical state of slotted photocell SPH2, which
monitors the first fold pocket cam disc PD3. Is ON if this photocell
“sees” the cam disc.
D1010 FT2/Green Reflects the optical state of slotted photocell SPH3, which
monitors the second fold pocket cam disc PD4. Is ON if this
photocell “sees” the cam disc.
D1111 PD COLL/ Reflects the optical state of slotted photocell SPH2, which
Green monitors collator motor M2.
table 1.3
rev. 01.1 - 06/2004

410.03-25
2 Service menu
2.1 General
Proceed as follows for access to the service menu:

• ·Navigate to the second screen of the main menu (see figure 2.2).
• ·Press key 3 (Job menu). The Job access screen of figure 2.3 appears.
• ·Enter the pin code 4331. Now you will enter the first part of the service menu screen of figure
2.4. This is the first part. With key 4 you can switch to and back from the second part of the
service menu screen of figure 2.5.
Figure 2.1 shows a flow chart of the service menu.
With the four soft keys 1 through 4 (from top to bottom) you select a menu option.
With the Escape key the next higher menu is re-entered without implementing changes.
In the case of a menu consisting of multiple screens you can navigate through these screens by
pressing key 4.
If a menu offers the possibility to change settings, key 4 is used to implement these changes and to
go back to the next-higher menu level.
410.03-26 rev. 01.1 - 06/2004

figure 2.1
rev. 01.1 - 06/2004

Job Access
Code 4331
Service
§2,1
key 4
key 1 key 2 key 3 key 1 key 2
System Job settings Service tests Counters OMR

§2.2 §2.9 §2.14 §2.21 §2.22
key 4
key 1 key 2 key 3 key 1 key 2
Configuration Localisation SW versions OMR Read

§2.3 §2.4 §2.5 code definition code test
§2.23 §2.24
key 1 key 2 key 3 key 1 key 2 key 3 key 4

service manual
Folder offset Reset data Power up Doc. offset BRE offset Secure jobs Flap closer
§2.6 §2.7 §2.8 §2.10 §2.11 §2.12 §2.13
key 4
key 1 key 2 key 3 key 1 key 2 key 3
Keyboard &
Photocells Digital inputs Actuators Run in DFC
display
§2.15 §2.16 §2.17 §2.18 §2.19
§2.20
410.03-27
SI 62
Key
1
start/stop esc
figure 2.2
Key
1
2
3
4
figure 2.3
Key
1
2
3
4
figure 2.4 from top to bottom §2.2, §2.9,§2.14
410.03-28 rev. 01.1 - 06/2004

Key
1
2
3
4
figure 2.5 from top to bottom §2.21, §2.22
2.2 System setting

Key
1
2
3
4
figure 2.6 from top to bottom §2.3, §2.4, §2.5
Key
1
2
3
4
2.3 Configuration
This screen provides information on the various available options, i.e. the number of feeders,
Fe 1limited "yes" or " no", Daily mail (DM) on feeder, the DFCs on feeders and the presence or
absence of an OMR dongle. If the configuration as stored in the machine has been updated, the new
configuration will be stored after pressing key 4 and switching the machine off and on again.
rev. 01.1 - 06/2004

410.03-29
Key
1
2
3
4
figure 2.8
2.4 Localisation
Key
1
2
3
4
figure 2.9
In this menu you can set the language of the operational user interface, as well as the paper sizes.
Languages: English, Dutch, French, German, Spanish, Italian and Katak[ana].
Standard: ISO (i.e. metric), Inches or None.
ISO sizes: A4 (297 mm), A5 (148 mm) and A6 (105 mm) for documents; C5 (162 mm) and C6/5 (114
mm) for envelopes.
Inches: 3.5" (90 mm), #9 (99 mm), 4" (102 mm), 6" (152 mm), 7" (178 mm), 8" (203 mm), 8.5" (216
mm), 11" (279 mm), 12" (305 mm) and 14" (356 mm) for documents; #9 (99 mm), #10 (105 mm) and
6x9 (153 mm) for envelopes.
2.5 Software versions
This screen provides release information on the machine software (programmed in flash memory)
for the inserter part (executed by the 8-bit controller) and the feeder/folder/reading part (executed by
the 16-bit controller).
Usually both machine software items should be updated simultaneously, using external software.
When software indexes do not correspond, an error message will be displayed.
410.03-30 rev. 01.1 - 06/2004

Key
1
2
3
4
figure 2.10
2.6 Folder settings
The folding process is implemented by the timing of two cam discs, one for each folding pocket. The
timing is determined by the document length of the sheets to be folded. Given tolerances in the
activation times of the clutches involved, this menu provides for an equivalent shift in the folding
positions, thus compensating a clutch activation time that deviates from the average value.
In the folder offset menu of figure 2.11 you first select the folder. Than you can set the equivalent
shift in the folding position between -20 mm and +20 mm. By processing test material you can decide
if subsequent corrections in these settings are necessary.
Key
1
2
3
4
figure 2.11
2.7 Reset data
This menu offers the possibility (with key 2) for initializing the system with default values (confirm
with key 4). In addition all photocells will be readjusted (so: remove all paper from the machine).
All counter values are not affected.
Use key 3 to load default millimeter jobs (1, 2 and 3).
Use key 4 to load default inch jobs (1, 2 and 3).
The only way to leave this screen is to use the Escape key.
rev. 01.1 - 06/2004

410.03-31
Key
1
2
3
4
figure 2.12
2.8 Power up
You can decide here whether or not (yes or No) the language menu will be shown after power up of
the machine. Save your settings with key 4 or leave this menu without changes by using the Escape
key.
Key
1
2
3
4
figure 2.13
2.9 Job settings
Key
1
2
3
4
figure 2.14 from top to bottom §2.10, §2.11, §2.12, §2.13
2.10 Document offset
The vertical transport of documents fed by the various feeders is arranged in such a way that the
documents are partially overlapping each other. This overlapping scheme ensures that the
documents are properly aligned in the collator area.
In the document offset menu of figure 2.15 you can set for each job (select with key 1) the extend to
which the documents are not overlapping each other, i.e. the document offset value. The default
410.03-32 rev. 01.1 - 06/2004

value is 50 mm. With keys 2 and 3 the document offset can be varied between 20 mm and 75 mm
in 1 mm steps.
Press key 4 to store the changes or press the Escape key to ignore the changes.
Key
1
2
3
4
figure 2.15
2.11 BRE offset
If a document is longer than the set address fold but shorter than the envelope height, this document
sometimes will be unnecessarily folded. Under certain conditions this document can be prevented
from being folded. This can be implemented with the menu BRE offset (BRE means Business Reply
Envelope) of figure 2.16.
For all jobs 1 Lng (Load 'n Go) an offset can be switched on or off.
In the case of offset on the last document that had been added to the set prior to further processing
will be shifted from the rest of the set (offsetting), i.e. this document will be held back during a certain
distance. This means that the trailing edge of this upper document leaves the collator as last. This
document will not be folded. During the insertion into the envelope the documents of the set will be
realigned.
The conditions are:
• The feeder that supplies this upper document (BRE) is set to one document per set (no multi
feeding).
• The document directly beneath this document must be at least 60 mm longer than the BRE.
• The upper document must be longer than the set address fold.
• The folding mode is either single fold or letter fold (so no Z-fold).
• The upper document must be shorter than the envelope height.
Note: It is possible to use the BRE offset for a BRE and an enclosure (card) in 1 set. The extra
condition is that this enclosure is equal to or smaller than the set address fold and should be placed
direct underneath the BRE in the set.
The whole BRE offset is based on friction between documents within a set. Therefore it is necessary
to make use of these conditions to reduce the risk of bad transporting, folding and inserting.
In some cases the BRE option is automatically switched off if one or more of the above-mentioned
conditions are not met, so it is safe to switch the BRE option on, unless this option is never to be
used.
Use keys 1 and 2 to select a job. With key 3 the BRE offset is switched on or off.
rev. 01.1 - 06/2004

410.03-33
Key
1
2
3
4
figure 2.16
2.12 Secure jobs
With this menu the selected job can be secured, i.e. locked. This job can not be deleted and can not
be changed in the job menu either. However, a locked job still can be copied into another job that
can be modified.
Use keys 1 and 2 to select a job. With key 3 the selected job is locked on or unlocked.
Key
1
2
3
4
figure 2.17
2.13 Flap closer
In this menu the timing of the activation of the sealing solenoid (So3) can be adjusted on a per-job
basis. This function can be used to improve the sealing process. The timing has influence on the
position of the filled envelope (with its flap fixed between two rollers) prior to being transported
between the sealing rollers. This position can be adjusted between -10 and + 10 mm (with respect
to the default envelope position).
Use key 1 to select a job. With keys 2 and 3 the correction value for the envelope stop position prior
to being sealed can be incremented or decremented.
410.03-34 rev. 01.1 - 06/2004

Key
1
2
3
4
figure 2.18
2.14 Service tests
With key 4 you toggle between the screen of figure 2.19 and the screen of figure 2.20.
Key
1
2
3
4
Key
1
2
3
4
2.15 Photocells
You can navigate to and from the screens of figure 2.21, 2.22, 2.23 or 2.24 with key 4.
The status of the nine or ten (if OMR is installed) photocells is displayed in four screens.
In this machine so-called intelligent photocells are used. This implies that within a certain control
range the currents of the photocell transmitters are adjusted in such a way that the no-paper output
voltage of the photocell receiver falls within a certain voltage range of the photocell receiver. In this
way fair amounts of dust present on the photocell sensors are compensated for. The control
mechanism ensures that very reliable paper/no paper decisions are being made, based on the paper
photocell condition.
rev. 01.1 - 06/2004

410.03-35
The four screens provide real time information on the various paper photocells. You also can see
whether the relevant photocell "sees" paper.
The various photocells can be readjusted by pressing the key 3.
Note. Before readjusting the photocell it is strongly recommended to remove all paper from the
machines and to clean all the sensors (both transmitter and receiver!) of the photocells.
After the photocell adjustments the percentages as shown in the four screens should be lower,
provided the cleaning advice is heeded.
If no paper is present, the photocell output voltage should have a value between 0.8 V and 1.5 V. A
value below this voltage range indicates a too heavily dusted photocell. A value above this voltage
range may occur if after readjusting a photocell dust is removed. In both cases it is advised to
readjust the photocells.
If the photocell current percentage is below 75%, the message "OK" is shown. A percentage
between 75% and 99% results in a "Clean" message. The photocell should be cleaned before
resetting the photocells. The message "Defect" is shown when the percentage is 99% or 100%.
The only way to leave this menu is to press on the Escape key.
Key
1
2
3
4
figure 2.21 PH7, PH8
Key
1
2
3
4
figure 2.22 PH9, PH10
410.03-36 rev. 01.1 - 06/2004

Key
1
2
3
4
figure 2.23 PH6, PH5, PH4 inclusive PH vertical track
Key
1
2
3
4
figure 2.24 PH3, PH2, PH1
2.16 Digital inputs
The four screens of figures 2.25, 2.26, 2.27 and 2.28 show the real-time status of the three safety
switches (MS1, MS2 and MS3), the flag switch (FS1), The two folder cam disks (SPH3 & PD3; SPH4
and PD4) and the two pulse discs (SPH1 for the main motor M1 and SPH2 for the collator motor M2).
Real-time means that a change is reflected in the displayed status.
In this way you can easily check the correct operation of the three microswitches and the flag switch.
The folder cam discs (figure 2.26) can be tested with key 2 and key 3. After pressing one of these
keys the relevant cam disc will move one half cycle, i.e. the cam disc status changes from "open" to
"covered" or from "covered" to "open". After pressing two successive times on a test key the cam
disc has performed a full cycle and returns to its position prior to entering this menu.
Both pulse discs can be tested as well. By keeping the Test key (key 1 in figure 2.27 or figure 2.28)
pressed the pulse disc signal will be tested. Both the speed and the quality (duty cycle) are tested.
Detailed information is obtained via the minimum (Min.) and maximum (Max.) value. For the Speed
the range should be between 75% and 125%, for the Pulse dist. (Duty cycle) the value should be in
the range of 50% till 150% resulting in the message 'Good'. If the value is out of these ranges the
message will be 'Bad'.
The speed is checked by measuring the average pulse width and compared to the initial value. When
the speed is much lower than the initial value the mechanical load has to be checked. When it is
higher it could be that the pulse disc has become loose.
The Pulse dist. (duty cycle) is measured of each pulse and the minimum and maximum values are
shown. When a pulse (an indented area) is not detected (for example because of dust build up) the
pulse distance will show a value of Min. 0% and/or Max. 200%.
rev. 01.1 - 06/2004

410.03-37
Key
1
2
3
4
figure 2.25 MS1, MS2, MS3, FS1
Key
1
2
3
4
figure 2.26 SPH3&PD3, SPH4&PD4
Key
1
2
3
4
figure 2.27 SPH1&PD1 version with fill in values
Key
1
2
3
4
figure 2.28 SPH2&PD2 version with fill in values
2.17 Actuators
410.03-38 rev. 01.1 - 06/2004

In the three menu screens (figures 2.29, 2.30 and 2.31) the correct operation of the two motors, three
solenoids, six clutches and the Maxi Feeder motor (if present) can be verified. Keys 1 and 2 can be
used to select the actuator to be tested. The test is performed with key 3.
If (and as long as) key 3 is pressed, the selected actuator will be activated.
The motor runs as long as the test key is pressed.
If the fingers solenoid is selected, the fingers move forward as soon as the test key is pressed. Only
after releasing the test key the fingers will move back to their rest position. The eject rollers and
closer solenoids will be activated and after a short time deactivated during one period of test key
pressing. During normal operational use these three actuators are always activated during a very
short time. This test reflects this situation.
Testing the envelope track clutch CL6 will result in switching on the motor M1, as well as activating
the envelope track clutch.
Collator run in: Collator motor runs in the direction of the document stop position as long as key 3 is
pressed.
Collator run out: Collator motor runs in the direction of the folder as long as key 3 is pressed.
Folding pocket 1/2: The main motor M1 is switched on. The relevant fold pocket turns a half fold
cycle. After two successive key 3 presses the initial position prior to entering this menu is reached
once again.
Feeder clutches: The main motor M1 is switched on and the relevant feeder clutch is activated if and
as long as key 3 is pressed. The feeder 3 clutch is only visible in the case of a 2½-station version of
the machine.
The Maxi Feeder option is only available if the Maxi Feeder is present. As long as key 3 is pressed,
its motor runs.
Key
1
2
3
4
figure 2.29 M1, So1, So2, So3, CL6
Key
1
2
3
4
figure 2.30 M2 IN, M2 OUT, CL4, CL5
rev. 01.1 - 06/2004

410.03-39
Key
1
2
3
4
figure 2.31 CL1, CL2, CL3
2.18 Run in
The run in test screen of figure 2.32 shows a counter, of which the default value is 6000. This is the
number of process cycles that will be emulated, with no paper whatsoever present in the machine.
After pressing the Start/Stop key the run in test will start. After each process cycle the counter is
decremented. The machine stops automatically if the counter value is zero.
With keys 2 and 3 you can set the counter at a value that differs from the default value 6000. If the
counter value is 1000 or higher, increments are 1000 with a maximum value of 30000. if the counter
value is lower than 1000, decrements are 100 with a minimum value of 10.
If you have some covers removed (but not the safety covers!), you can observe the various
sequences of mechanical actions, which reflect the sequence of events during normal operational
use of the machine.
After pressing the Start/Stop key again the run in test stops.
Note. It is also strongly recommended to perform the run in test without any documents present in
the machine. The timing of the actions for a simulated process cycle are fixed, so they are not based
on parameters such as the document length. A run in test with documents present in the machine
would only result in severe paper jamming.
Key
1
2
3
4
figure 2.32
2.19 DFC test
This menu informs you about the DFC unit output voltages of the two or three feeders. The values
are real time. With no paper present in a feeder the DFC voltage should be about 4.1 volt. If during
the machine start a DFC unit does not "see" paper, the DFC voltage should be about 4.992 volt.
The DFC voltage is lower if the DFC unit "sees" paper. The following rules apply:
• ·For 65 g/m² paper DFC voltage about 0.2 volt lower.
410.03-40 rev. 01.1 - 06/2004

Key
1
2
3
4
figure 2.33
2.20 Keyboard/display
This menu screen offers the option to invert the screen display (with key 1, and as long as this key
is pressed) and to test three of the four soft keys and two hard keys. If you leave this menu the default
screen settings as far as the invert option is concerned are applied once again. Key 1 cannot be
tested, for this key is used for the toggle function.
If the Start/Stop key, Escape key, key 2, key 3 or key 4 is pressed, this is indicated by an adjacent
bar. Furthermore the decimal key value is displayed in the middle of the screen.
Leave this menu by pressing the Escape key twice.
Key
1
2
3
4
figure 2.34
2.21 Counters
This menu (see figure 2.35) offers the possibility to read, set or reset the service counters.
With key 1 you can reset the Since last visit counter to zero.
With key 2 the Next visit after counter can be incremented in 5000 steps, with a maximum value of
6.000.000.
With key 3 the Next visit after counter can be decremented in 5000 steps, with a minimum of 5000.
A value under 5000 results in the value OFF.
Use key 4 to leave this menu including changes or use the Escape key to leave this menu without
the changes that may be made.
If you simultaneously press the Start/Stop key and the Escape key, the Total Counter menu of figure
2.36 is displayed.
rev. 01.1 - 06/2004

410.03-41
This menu offers the possibility to set the Since installation counter. With key 1 the counter value is
incremented in 5000 steps. With key 2 the counter value is decremented in 5000 steps. Use key 4
(including changes) or the Escape key (without changes) to go back to the Service counters menu
of figure 2.35.
Key
1
2
3
4
figure 2.35
Key
1
2
3
4
figure 2.36
2.22 OMR
Key
1
2
3
4
figure 2.37 ferm top to botoom §2.23, §2.24
2.23 OMR code definition
This menu offers the possibility to define OMR-2 reading codes, provided a level 1 dongle is present
in the machine. Per system one OMR code can be set. This code can be used in one or more jobs.
The most complex OMR code is:
• Start
• Insert/accumulate
• Parity check
410.03-42 rev. 01.1 - 06/2004

• Safety mark.
The various menu screens (of which figure 2.38 is an example; not all screens are shown in this
document) share the same structure.
With keys 1 (repetitive key strokes) a code option is selected: Start mark, Insert on, Parity check,
Safety mark and Line spacing.
With key 3 you choose between Yes and No (toggling function). In the Line spacing case keys 2 and
3 are used to increment (key 2) or decrement (key 3) the line spacing in steps of about 0,02
millimeter. The Lpi value reflects the number of lines per inch, the millimeter value is the distance
between two successive marks.
Use key 4 to leave this menu including changes or the Escape key to leave this menu without
changes. You are back in the OMR main menu of figure 2.37.
Key
1
2
3
4
figure 2.38
2.24 Read code test
Press key 2 (Read code test, figure 2.37) to obtain the screen of figure 2.39. This menu screen
informs the user about the mark quality, number of read marks and the gain setting. Every time the
test key 2 is pressed a sheet is forwarded and the screen will show the information.
Key
1
2
3
4
figure 2.39 The read code test submenu.
Show marks (key 1)

The Show marks menu of figure 2.40 offers a graphical representation of the marks that had been
read (oscilloscope function). The information shown is derived from the most recently read
document.
The information screen shows the time-dependant OMR output voltage and the reading window.
The start of the window is represented by a vertical line, the end of the reading window is also
represented by a vertical line. In between the marks should be given where the position of the marks
related to the window position is also giving some information, i.e. when the first mark is very close
to the opening of the window; this could mean that the window position is programmed wrong.
rev. 01.1 - 06/2004

410.03-43
The upper horizontal dotted line represents the noise level, i.e. the white level. The lower horizontal
dotted line represents the level below which a mark (i.e. detection level) has been detected. The
detection level is determined when the adjustment procedure is performed (see fig 2.41). The
detection level is 60% of the top level. A mark is detected as an OMR-mark when more than 5 digital
samples consecutively are below the detection level.
The numbers 1 through 6 indicate where a mark is expected. The distance between the numbers is
exactly the same as the programmed line spacing.
With key 3 you can scroll to the right, i.e. to a point later in time. With key 4 you can scroll to the left,
i.e. to an earlier situation.

figure 2.40 The Show marks menu.
After pressing the info key 1 the information screen of figure 2.41 shows additional OMR-related
information. This information is based on the last read document and the job settings (OMR code
type etc.). The displayed information is what is interpreted from the read OMR code.
Key
1
2
3
4
figure 2.41 The Show marks info screen.
Test (key 2)
This screen shows the mark quality and the number of read marks from the last processed
document. Also the gain of the OMR amplifier is shown.
The mark quality is shows as follows:
Bad Mark amplitude < 0.6 V

Good Mark amplitude between 0.6 V and 1.5 V
Very good Mark amplitude higher than 1.5 V
410.03-44 rev. 01.1 - 06/2004

Adjustment (key 3)
There are a number of occasions in which it is very relevant to adjust the OMR electronics. In the
case of OMR hardware repairs and replacements it is very obvious that the OMR electronics should
be readjusted. But there may be operational reasons as well, for instance if non-standard paper is
to be used. In such cases, after processing some test documents (see above) the mark quality may
not be optimal. Readjust the OMR electronics and process some new documents, in order to obtain
an improved mark quality.
For the adjustment 10 documents are necessary (otherwise an empty feeder error occurs). In each
document at least one mark must be present within the reading window. The test documents must
be present in the feeder for the selected job.
It is very important to align the centre of the reading head horizontally at the centre of the marks.
Press key 3 (Adjust) in the screen of figure 2.39. The adjustment menu of figure 2.42 appears.
Press in the latter menu key 3 (Start adjust) to start the adjustment.
During the adjustment the text "Adjusting" appears.
After the adjustment either the message Adjustment done: OK or the text Adjustment done: FAILED
is shown. Press esc to go back to the next higher menu screen.
Key
1
2
3
4
figure 2.42 The adjustment submenu
rev. 01.1 - 06/2004

410.03-45
3 Error messages and error handling

In this chapter the various errors and warnings are discussed. The error screens have the following
in common:
• An error code X:YYY. X is a prefix number that indicates a specific machine part.
• Message. The message that is displayed next to the exclamation mark triangle.
• Action. The text that is displayed next to the finger pictogram.
• Info. Additional information if the info key 1 is pressed.
The following machine areas/prefixes apply:
1 Inserter
2 Folder
3 Collator, vertical transport and OMR.
4 Feeder 1.
5 Feeder 2.
6 Feeder 3.
Now the various errors will be discussed.
Error 1:1
Message: FRAM failure.
Action: Call service.
Info: Memory failure.
Error during the writing of zero data (formatting) to FRAM memory. Press the Reset key and try
again.
Formatting is ended by pressing the Start/Stop key. The system starts with default values.
Error 1:2
Error during the initialization of FRAM. Press the Reset key and try again. Initialization is ended by
pressing the Start/Stop key. The system starts with default values.
Error 1:3
FRAM not detected.
Error 1:4
This error is issued after ten successive tries to write to or read from FRAM memory.
Error 1:5
This error is issued after a checksum error occurred during writing to or reading from FRAM memory.
410.03-46 rev. 01.1 - 06/2004

Error 1:10
Message: Envelope too long.
Action: Remove envelope.
Info: Envelope length error.
Envelope too long. Remove the envelope from the envelope track. A closed envelope is considered
too long if its equivalent length exceeds 162 mm plus 20 mm tolerance = 182 mm or the programmed
length plus 20 mm. An opened envelope is considered too long if its equivalent length exceeds 162
mm plus 130 mm flap length plus 20 mm tolerance = 312 mm.
Error 1:11
Message: Document stoppage.
Action: Remove documents.
Info: Inserting failure.
Document/envelope crash. The loc photocell PH9 remains covered too long. The equivalent
document length exceeds 400 millimeter. Remove the envelope and the document from the insert
table.
Error 1:12
Info: Document length error.
Document/envelope crash. Two successive inserts show a document length change of more than
42 mm. The length is observed by the loc photocell PH9. The insert process is irregular, with varying
mechanical slip.
Error 1:13
Message: Envelope stoppage.
Info: Transport failure.
Envelope crash. The exit photocell PH10 remains covered too long. Remove the envelopes from the
exit table and press the Reset key.
Error 1:15
Info: Flap not opened.
Envelope not opened. The envelope has no flap at all or its flap is not properly opened.
Error 1:16
Info: Transport failure.
Envelope crash. The filled envelope didn't arrive in time at the exit photocell PH10. The sealing stage
takes too much time. Remove the paper from the exit area.
Error 1:17
Action: Remove document.
Info: Document too early.
rev. 01.1 - 06/2004

410.03-47
Document/envelope crash. Wrong timing of insertion of the document. Remove the document from
the insert table. Between the ejecting of the filled envelope and the placing of a new envelope on the
insert table, including the fingers moved in that envelope, no document is supposed to be present
under the loc photocell PH9. In the fold only mode, also without envelopes involved, a new document
is not allowed to cover PH9 before the previous document has been ejected and a new document
call has been issued.
Error 1:18
Info: Inserting failure.
Document/envelope crash. The loc is opened or PH9 covered at the time at which a document call
is issued. Close the loc or remove the PH9 covering paper.
Error 1:19
Info: Flap sensor covered.
The flap photocell PH8 is covered too long. Remove the envelopes form the envelope track, if
necessary by turning the hand knob until the envelopes reach the insert table.
Error 1:22
Info: Wrong envelope size.
Envelope too short. The envelope currently called for is shorter than 75 mm, or the measured
envelope length is at least 20 mm shorter than the set envelope length.
Error 1:23
Info: Seal switch active.
Envelope closer flag switch activated. At the moment that an envelope must be ejected from the
insert position, the flag switch FS1 is covered. FS1 is not properly mounted or connected, or some
other mechanical FS1 error occurs.
Error 1:24
Info: Seal switch active.
Envelope crash. The flag switch FS1 remains covered too long.
Error 1:26
Info: Seal switch not covered.
Document/envelope crash. The ejected document does not reach the flag switch FS1 in time.
410.03-48 rev. 01.1 - 06/2004

Error 1:27
Info: Document too late.
Document arrives too late. A document call to the feeder/folder part does not result in a document
arriving at the document photocell PH9.
Error 1:29
Info: Insert area blocked.
Insert area blocked. During startup paper is present on the insert table. Remove the paper and press
the Reset key.
Error 1:30
Message: Empty envelope hopper.
Action: Load envelopes.
Info: [none]
Envelope hopper empty. An envelope is called for, but after a 15-second timeout it does not arrive
on the insert table. There are two ways to resume the process: (a) press the Start/Stop key, the
message disappears and the process resumes; (b) press the Reset key, followed by the Start/Stop
key.
Error 1:34
Message: No connection.
Action: Check device connector.
Info: Communication failure.
Communication failure in the SCS communication between the inserter part (8-bit controller) and the
feeder/folder part (16-bit controller). This reflects an electronic hardware failure on the main board
98.90.01.
Error 1:35
Message: Preventive maintenance.
Info: [none].
Maintenance message. This message appears during the start of the machine if the value of the
counter Since last visit exceeds the value of the counter Next visit after. This message is issued at
the system start.
Error 1:37
Message: Technical failure.
Info: Main motor failure.
Main motor (M1) failure. The pulse disc slotted photocell SPH1, which monitors pulse disc PD1, does
not deliver any pulses at all or too few pulses. Apart from a defective PD1, this error message is
issued if the motor is mechanically overloaded or blocked. It may help to wait until the motor has
been cooled down.
rev. 01.1 - 06/2004

410.03-49
Error 1:44
Info: Track sensor defective.
During the photocell adjustment the transmitter LED current of the envelope track photocell PH7 is
set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8
V. This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error.
The photocell is readjusted. If this fails, this message reappears. After resetting this message the
photocell is tried to be readjusted for a second time.
Error 1:45
Info: Flap sensor defective.
During the photocell adjustment the transmitter LED current of the flap photocell PH8 is set at its
maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V. This
signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The
photocell is readjusted. If this fails, this message reappears. After resetting this message the
Error 1:46
Info: Loc sensor defective.
During the photocell adjustment the transmitter LED current of the loc photocell PH9 is set at its
Error 1:47
Info: Exit sensor defective.
During the photocell adjustment the transmitter LED current of the exit photocell PH10 is set at its
Error 1:48
Message: Track sensor dusty.
Action: Clean sensor.
Info: [none].
During the processing of paper the transmitter LED current of the envelope track photocell PH7 is
adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid
photocell control range. After resetting this error the photocell is tried to be readjusted.
410.03-50 rev. 01.1 - 06/2004

Note. Error 1: 52 is the same error, but occurs during readjusting this photocell.
Error 1:49
Message: Flap sensor dusty.
Info: [none].
During the processing of paper the transmitter LED current of the flap photocell PH8 is adjusted to
a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell
control range. After resetting this error the photocell is tried to be readjusted.
Error 1:50
Message: Loc sensor dusty.
Info: [none].
During the processing of paper the transmitter LED current of the envelope loc photocell PH9 is
Error 1:51
Message: Exit sensor dusty.
Info: [none].
During the processing of paper the transmitter LED current of the exit photocell PH10 is adjusted to
a too low value (less than 2% of the maximum value), that doesn't fall within the valid photocell
control range. After resetting this error the photocell is tried to be readjusted.
Error 1:52
During the adjustment of the track photocell PH7 adjustment fails because the transmitter LED
current is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within
the valid photocell control range. After resetting this error the photocell is not readjusted. If the start
key is pressed, this message reappears.
Note. Error 1:48 is the same error, but occurs during the processing of paper.
Error 1:53
During the adjustment of the flap photocell PH8 adjustment fails because the transmitter LED current
is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid
photocell control range. After resetting this error the photocell is not readjusted. If the start key is
pressed.
rev. 01.1 - 06/2004

410.03-51
Error 1:54
During the adjustment of the loc photocell PH9 adjustment fails because the transmitter LED current
is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall within the valid
photocell control range. After resetting this error the photocell is not readjusted. If the start key is
pressed, this message reappears.
Error 1:55
During the adjustment of the exit photocell PH10 adjustment fails because the transmitter LED
Error 1:56
Envelope track photocell (PH7) error. During machine startup no LED current has been detected for
this photocell. Transmitter not or wrongly connected. Relevant in the factory environment or after
field replacement of this photocell. After resetting this error and pressing the Start/Stop key the
message reappears.
Error 1:57
Flap photocell (PH8) error. During machine startup no LED current has been detected for this
photocell. Transmitter not or wrongly connected. Relevant in the factory environment or after field
replacement of this photocell. After resetting this error and pressing the Start/Stop key the message
reappears.
Error 1:58
Loc photocell (PH9) error. During machine startup no LED current has been detected for this
replacement of this photocell. After resetting this error and pressing the Start key the message
reappears.
410.03-52 rev. 01.1 - 06/2004

Error 1:59
Exit photocell (PH10) error. During machine startup no LED current has been detected for this
reappears.
Error 1:60
Info: [none]
During the processing of paper the no-paper output voltage of the envelope track photocell PH7 is
higher than 1.5 V. Therefore passing paper is at risk of being not detected by the photocell. After
resetting this error it is tried to readjust this photocell.
Error 1:61
Info: [none]
During the processing of paper the no-paper output voltage of the flap photocell PH8 is higher than
1.5 V. Therefore passing paper is at risk of being not detected by the photocell. After resetting this
error it is tried to readjust this photocell.
Error 1:62
Info: [none]
During the processing of paper the no-paper output voltage of the loc photocell PH9 is higher than
Error 1:63
Info: [none]
During the processing of paper the no-paper output voltage of the exit photocell PH10 is higher than
Error 1:64
Info: [none]
During the processing of paper the transmitter LED current of the envelope track photocell PH7 is
photocell is tried to be readjusted for a second time. If this fails too, error 1:44 is issued.
rev. 01.1 - 06/2004

410.03-53
Error 1:65
Info: [none]
During the processing of paper the transmitter LED current of the flap photocell PH8 is set at its
Error 1:66
Info: [none]
During the processing of paper the transmitter LED current of the loc photocell PH9 is set at its
Error 1:67
Info: [none]
During the processing of paper the transmitter LED current of the exit photocell PH10 is set at its
Error 1:80
CRC error at receiving mail via I²C communication.
Error 1:81
I²C delivered mail not accepted by the feeder/folder part.
Error 1:82
Command unknown by the slave.
Error 1:83
410.03-54 rev. 01.1 - 06/2004


The feeder/folder part doesn't accept the command.
Error 1:84
Command not identified by the feeder/folder part.
Error 1:85
The inserter part cannot communicate properly (by SCS) with the feeder/folder part. A checksum
error occurred.
Error 1:86
The inserter part cannot communicate properly (by SCS) with the feeder/folder part. A hardware-
related error occurred.
Error 1:87
Too many communication retries.
Error 1:88
Too many NACK signals received.
Error 1:89
The inserter part cannot communicate properly via the local I²C bus (timeout error).
Error 1:95
Message: Sealing risk.
Action: Check water level.
Info: Brushes too dry.
This warning message is issued after each 2500th process cycle. After pressing the Reset key this
message will disappear.
rev. 01.1 - 06/2004

410.03-55
Error 1:101
Message: Cover open.
Action: Remove all documents.
Info: Cover open during run.
Undefined motor stop. During the feeding of an envelope (in the envelope track) one or more
machine covers are opened.
Error 1:102
Undefined motor stop. During the feeding of a document one or more machine covers are opened.
Error 1:103
Undefined motor stop. During the ejecting of the filled envelope one or more machine covers are
opened.
Error 1:104
Undefined motor stop. During the exiting of the filled envelope one or more machine covers are
opened.
Error 1:105
Communication failure. SCS-related problem in the communication between the inserter part and
the feeder/folder part.
Error 2.11
Info: Stoppage at folder.
First fold pocket mechanical or electrical failure.
After activating the first fold pocket clutch CL4 the next state is not detected by slotted photocell
VSPH3 within a certain time. This could be caused by either a faulty clutch or faulty slotted photocell
or when material is present that cannot be folded.
Error 2.12
Info: Stoppage at folder.
Second fold pocket mechanical or electrical failure.
410.03-56 rev. 01.1 - 06/2004

After activating the second fold pocket clutch CL5 the next state is not detected by slotted photocell
VSPH4 within a certain time. This could be caused by either a faulty clutch or a faulty slotted
photocell or when material is present that cannot be folded.
Error 2.14
Message: Load 'N Go not possible.
Action: Go to job edit menu.
Info: Fold not possible.
A fold based on defined Load 'n Go formulas appears to be not feasible, due to fold pocket limitations
(i.e. minimum or maximum distances).
Error 2:61
Info: Sensor fold-in defective.
During the photocell adjustment the transmitter LED current of the folder input photocell PH6 is set
at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8 V.
This signifies to much dust on one or both photocell lenses. Clean both lenses. Reset the error. The
Error 2:62
Message: FO in sensor dusty.
Info: [none].
During the processing of paper the transmitter LED current of the folder input photocell PH6 is
Error 2:63
During the adjustment of the folder input photocell PH6 adjustment fails because the transmitter LED
Error 2:64
Folder input photocell (PH6) error. During machine startup no LED current has been detected for this
reappears.
rev. 01.1 - 06/2004

410.03-57
Error 2:65
Info: [none]
During the processing of paper the no-paper output voltage of the folder input photocell PH6 is
Error 2:66
Info: [none]
During the processing of paper the transmitter LED current of the folder input photocell PH6 is set
Error 3:10
Info: Stoppage at vertical track.
Vertical transport crash. After a certain time after leaving a feeder the paper doesn't arrive at the
collator input photocell PH5. Remove the paper and press the Reset key.
Error 3:11
Info: Stoppage at collator.
Collator run in error. During the collating of documents the collator input photocell PH5 is covered
too long. This can happen if the paper is to sturdy to make the move from a vertical to a more or less
horizontal direction, or if documents still present in the collating area prevent the arriving document
from arriving there. Remove the documents and press the Reset key.
Error 3:12
Collator run out error. After starting to leave, to the folder or the divert, the paper stays too long in
the collating area. This can be verified by the folder input photocell PH6. This is caused by either a
paper crash or the fact that paper has been removed after a Stop command, followed by a Start
command.
Error 3:14
Paper present at initialization (machine startup or job change) error. This message is displayed if
during the initialization of the collating area a set or part of a set has been detected in this area.
410.03-58 rev. 01.1 - 06/2004

Initialization of the collating area occurs after each job change, after fatal feeder errors or collating
area errors.
Error 3:20
Message: System not ready,
Info: Documents in system.
Folder/feeder not empty. After a job change documents are still present in the system. Remove all
documents and press the Reset key.
Error 3:21
Message: Empty feeders.
Action: Load documents.
Info: [none]
Empty feeders during the Load 'N Go learning cycle.
Error 3:60
Undefined motor stop. Remove all documents and press the Reset key.
Error 3:61 (only if OMR is present)

Info: Vertical track sensor defective.
During the photocell adjustment the transmitter LED current of the vertical track photocell PH4 1 is

Message: Vertical track sensor dusty.
Info: [none].
During the processing of paper the transmitter LED current of the vertical track photocell PH4 is
Note. Error 3:63 is the same error, but occurs during readjusting this photocell.

During the adjustment of the vertical track photocell PH4 adjustment fails because the transmitter
LED current is adjusted to a too low value (less than 2% of the maximum value), that doesn't fall
rev. 01.1 - 06/2004

410.03-59
within the valid photocell control range. After resetting this error the photocell is not readjusted. If the
start key is pressed, this message reappears.

Vertical track photocell (PH4) error. During machine startup no LED current has been detected for
message reappears.

Info: [none]
During the processing of paper the no-paper output voltage of the vertical track photocell PH4 is

Info: [none]
During the processing of paper the transmitter LED current of the vertical track photocell PH4 is set
Error 3:70
Info: Collator motor failure.
Collator motor error. The collator motor M2 is checked via its accompanying pulse disc plus slotted
photocell SPH2, Provided SPH2 is correctly operating (see the service software), this motor is
probably defective.
Error 3:71
Info: Collator sensor defective.
During the photocell adjustment the transmitter LED current of the collator area input photocell PH5
is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8
410.03-60 rev. 01.1 - 06/2004

Error 3:72
Message: Collator sensor dusty.
Info: [none].
During the processing of paper the transmitter LED current of the collator input photocell PH5 is
Note. Error 3:73 is the same error, but occurs during readjusting this photocell.
Error 3:73
During the adjustment of the collator input photocell PH5 adjustment fails because the transmitter
start key is pressed, this message reappears.
Error 3:74
Collator input photocell (PH5) error. During machine startup no LED current has been detected for
message reappears.
Error 3:75
Info: [none]
During the processing of paper the no-paper output voltage of the collator input photocell PH5 is
Error 3:76
Info: [none]
During the processing of paper the transmitter LED current of the collator input photocell PH5 is set

Action: OMR switched off.
rev. 01.1 - 06/2004

410.03-61
Info: Dongle not correct.

The checksum and/or the serial check of the dongle is not correct.
This error applies to a valid level 1 OMR dongle.

Info: Defective reading head.
The LED in the reading head is defective.

Message: Reading error.
Info: Wrong window position.
The reading window is activated after the document that contains OMR info has passed the reading
head. Adjust the reading window parameters.

Message: Suspected set.
Action: Remove suspected set.
Info: Suspected after error.
This error is issued after a previous reading error and the reading of an insert mark. It is very likely
that the reading error probably occurred during the processing of the current set, causing this set
and the next set being not complete.

Action: Reset & start to finish set.
Info: Not enough marks.
Less marks have been detected than based on the applied reading code. The set can be removed
from the collator, but this is not strictly necessary. After a restart the rest of the set is processed and
error 3:114 (suspected set) is issued.

Info: Multiple basic command.
More than one paper flow-related commands (accumulate, insert, divert or stop mark) have been
detected. The set can be removed from the collator, but this is not strictly necessary. After a restart
the rest of the set is processed and error 3:114 (suspected set) is issued.

Info: No basic command.
No mark defining the paper flow (accumulate, insert, divert or stop mark) has been detected. The set
can be removed from the collator, but this is not strictly necessary. After a restart the rest of the set
is processed and error 3:114 (suspected set) is issued.
410.03-62 rev. 01.1 - 06/2004


Info: Wrong parity in code.
The parity of the processed code appears to be not correct. After a restart the rest of the set is
processed and error 3:114 (suspected set) is issued.

Info: Undefined mark found.
This error code is displayed if a mark is found at a position where no mark is supposed to be present
(too many marks or mark conflicting with other marks). The set can be removed from the collator,
but this is not strictly necessary. After a restart the rest of the set is processed and error 3:114
(suspected set) is issued.

Info: Wrong mark distance.
This error message occurs if the position of a mark has shifted in such a way that is present in the
so-called forbidden zone. This is defined as a percentage of the line distance around a line halfway
between two successive lines. After a restart the rest of the set is processed and error 3:114

Info: Too many marks.
This error code is displayed if more reading code marks have been detected than may be possible,
based on the applied reading code. After a restart the rest of the set is processed and error 3:114

Message: Too many sheets.
Info: Set size exceeded.
The maximum set size is specified in the OMR settings menu. The maximum size is 5, including
insets (i.e. selective feeds).
Suppose this maximum is X. If sheet X is processed and an accumulation mark has been read or
the insert mark has been read and selective feeds must be added to the set, this error is issued.
Remove the paper from the collator, reset and press the Start/Stop key to restart the process.

Message: Final set part.
Info: Part of previous set.
This is a follow-up of error 3:134. The rest of the oversized set is collated. After this is done, error
3:135 is issued. If the maximum set size is exceeded for the second time, error 3:134 is issued once
again.
rev. 01.1 - 06/2004

410.03-63
Error (4:…6:)00
Message: Empty feeder.
Action: Load documents or ignore.
Info: [none]
Feeder empty. A feeder tries during 4 seconds to separate a document from the stack in its hopper.
If after 4 seconds no paper arrives at the feeder photocell, this error message is displayed. The
feeder transport stops. The user can continue the process by placing documents in the empty
hopper and pressing the Reset key.
Error (4:…6:)10
Message: Feeding failure.
Info: Document too thick.
Document too thick. One of the feeders produces a double fed sheet during the processing of a
document.
Error (4:…6:)11
Message: Feeding failure.
Action: Check previous set.
Info: Wrong reference.
Wrong reference. The sheet on which the DFC had been adjusted appears to be a double fed sheet.
This error can only occur during the first sheet delivered by a feeder after adjusting the DFC unit.
Error (4:…6:)12
Info: Document too long.
Document too long. A document delivered by a feeder appears to be more than 20% longer than the
document length specified for this feeder in the current job.
Error (4:…6:)13
Info: Paper jam.
Document crash. A document delivered by a feeder appears to be more than 50% longer than the
document length specified for this feeder in the current job.
Error (4:…6:)14
Info: Document too short.
Document too short. A document delivered by a feeder appears to be more than 45 mm shorter than
the document length specified for this feeder in the current job.
Error (4:…6:)51
Info: Feeder sensor defective.
410.03-64 rev. 01.1 - 06/2004

During the photocell adjustment the transmitter LED current of the feeder photocell (FPH1..FPH6)
is set at its maximum value. However, the no-paper output voltage of this photocell is lower than 0.8
Error (4:…6:)52
Info: [none].
During the processing of paper the transmitter LED current of the feeder photocell (PH1…PH3) is
Note. Error (4:…6:)53 is the same error, but occurs during readjusting this photocell.
Error (4:..6:)53
Info: Feeder sensor defective.
During the adjustment of the feeder photocell (PH1…PH3) adjustment fails because the transmitter
start key is pressed, this message reappears, provided the photocell is involved in the current job.
Note. Error (4:…6:)52 is the same error, but occurs during the processing of paper.
Error (4:…6:)54
Feeder photocell (PH1…PH3) error. During machine startup no LED current has been detected for
message reappears, provided the photocell is involved in the current job.
Error (4:…6:)55
Message: Feeder sensor dusty.
Info: [none]
During the processing of paper the no-paper output voltage of the feeder photocell (PH1…PH3) is
Error (4:…6:)56
Message: Feeder sensor dusty.
Info: [none]
During the processing of paper the transmitter LED current of the feeder photocell (PH1…PH3) is
photocell is tried to be readjusted for a second time. If this fails too, error (4:…6:)51 is issued.
rev. 01.1 - 06/2004

410.03-65
Error (4:…6:)60
Info: DFC defective.
DFC error. The DFC doesn't measure a difference between paper and no paper. After pressing the
Reset key the defective DFC unit is switched off. The incomplete set is diverted. Pressing the Start/
Stop key afterwards the process continues without DFC measurement.
Error (4:…6:)61
DFC adjustment error. The DFC unit can not be adjusted. After pressing the Reset key the DFC unit
is switched off. After pressing the Start/Stop key the process continues without DFC measurement.
Error (4:…6:)62
DFC presence error. During startup a DFC unit in a certain feeder appears to be not present. During
the previous machine session the DFC unit was present. This goes on until the configuration has
been reset (see service software chapter). After pressing the Reset key the DFC unit of the relevant
feeder is switched off. After pressing the Start/Stop key the process continues without DFC
measurement. The DFC unit is still present in the configuration.
410.03-66 rev. 01.1 - 06/2004

Parts lists
rev. 01.0 - 06/2004

410.04-1
410.04-2 rev. 01.0 - 06/2004

Recommended spare parts
Some of these parts already could be stocked, being part of another recommended spare parts list.
Illustration Description Part code Stock qty.

Code nr. Number per number
of installed machines
1 10 50
Figure 410.04-6
1 Hopper complete (auto)* 79.01.53 1 1 2
Figure 410.04-8
12 Moistening cloth 04.03.06 1 2 4
Figure 410.04-10
23 Separation roller (assy.) 95.71.03 1 1 2
27 Feed roller ∅ 42 mm 73.27.31 1 1 2
50 Pulley 15T (assy). 93.05.54 1 1 2
51 Timing belt 95.13.16 1 1 2
53 Slip clutch CCW 8 mm 95.71.27 1 1 2
56 Conductive bearing 10 mm 04.24.26 10 10 20

- O-ring (for jogger roller) 04.18.76 2 2 4
Figure 410.04-14
9 Transportation roller ∅ 30 mm 04.18.27 4 8 6
10 Sensor (including holder) 04.24.53 2 2 4
49 LED (including holder) 04.24.52 2 2 4
Figure 410.04-18
5 Rubber roller 96.41.90 1 1 2
28 Pressure roller (assy.) 96.45.56 4 4 8
Figure 410.04-20
1 Microswitch (including lever) 98.90.56 1 1 2
14 Upper sealing roller ∅ 36 mm 73.26.48 1 1 2
16 Lower sealing roller (assy.) 98.94.33 1 1 2
33 Solenoid 02.10.21 1 1 2
36 Finger 96.40.71 2 4 8
38 Leaf spring 96.45.64 1 1 2
41 Hex. head screw M4 x 8 (synthetic) 96.45.66 2 4 8
43 Adjustable finger 96.40.57 2 4 8
rev. 01.0 - 06/2004

410.04-3
Figure 410.04-24
11 Timing belt 96.43.55 1 1 2
19 Pulse disc sensor (assy.) 82.16.22 1 2 4
20 Pulse disc 24.12.81 1 1 2
25 Tensioner roller 96.41.94 1 2 4
Figure 410.04-26
10 Clutch CW 8 mm 12.16.66 1 2 4
Figure 410.04-28
10 Upper input roller (assy.) 98.95.21 1 1 2
11 Lower input roller (assy.) 98.95.22 1 1 2
27 Fold roller (assy.) 98.95.20 1 2 4
Figure 410.04-30
10 Timing belt 04.16.21 1 1 2
14 Drive belt PJ 96.41.55 1 1 2
Figure 410.04-32
8 Solenoid 12.12.87 1 1 2
17 Timing belt 04.15.37 1 1 2
41 Gear 15T 73.29.42 1 1 2
Figure 410.04-36
24 Brush 72.00.05 3 6 12
Figure 410.04-38
3 Flagswitch 02.10.76 1 1 2
10 Transportation roller (assy.) 84.17.04 2 4 8
Figure 410.04-40
1 Upper separation roller 95.11.67 1 2 4
5 Cover plate 95.11.25 1 1 2
8 Timing belt 95.11.45 1 1 2
13 Rubber paper puller 04.00.16 2 4 8
18 Pulley 28T (timing belt) 95.11.35 1 1 2
63 DFC 79.01.71 1 1 2
65 Separation roller (lower) 95.11.68 1 2 4
Figure 410.04-44
39 Clutch CCW 8 mm 93.05.36 1 2 4
Figure 410.04-46
28 Reading head assy. 98.94.34 1 2 4
410.04-4 rev. 01.0 - 06/2004

Figure 410.04-48
21 Pressure roller assy. (incl. O-ring) 95.20.11 1 2 4
30 Collating belt set (3 pcs.) 95.20.07 1 1 2
38 Motor 24V 98.94.09 1 1 2
50 Pressure roller ∅ 20 mm 95.14.08 2 4 8
Figure 410.04-52
12 Motor relay board 230V 97.55.00 1 1 2
- Motor relay board 115V 97.55.40 1 1 2
18 Power inlet 98.90.05 1 1 2
Figure 410.04-56
11 Curve disc RH 95.30.64 1 1 2
21 Curve disc LH 95.30.63 1 1 2
Figure 410.04-58
6 Clutch CCW 8 mm 12.14.61 1 1 2
9 Clutch CW (clockwise) 8 mm 12.14.63 1 1 2
Figure 410.04-60
1 Lever for flap actuator 95.30.31 1 1 2
12 Upper fold roller (assy.) 96.46.61 1 1 2
Figure 410.04-62
19 Tensioner roller 95.13.19 1 1 2
Figure 410.04-64
8 Mainboard 98.90.01 1 1 2
18 Rubber keypad 98.91.30
19 Display 98.90.03 1 1 2
Note: Parts marked with an asteriks (*) depending on configuration.
rev. 01.0 - 06/2004

410.04-5
1 2 3 4 5 6
Figure 1
410.04-6
29 30
RH
7
8
9
10
11
service manual
28 27
12
13
14
26 25 24
23 22 21 20 19 18 17 16 15 LH
SI 62
rev. 01.0 - 06/2004

Figure 410.04-6
Remarks illustration Description Part code Quantity Remarks

code number number
1 Hopper complete (auto) 79.01.53 2

2 Short tray 04.26.51 1
3 Nut M4 45.19.02 10
4 Hex. head screw M4 x 8 05.38.80 6
Neopost 5 Cover LH (2 station) 98.91.41 1
Hasler, Formax - Cover LH (2 station) 98.95.59 1

Satas - Cover LH (2 station) 98.95.53 1
Francotyp, blank - Cover LH (2 station) 98.95.68 1
Neopost - Cover LH (3 station) 98.92.27 1
Hasler, Formax - Cover LH (3 station) 98.95.60 1
Satas - Cover LH (3 station) 98.95.55 1

Francotyp, blank - Cover LH (3 station) 98.95.70 1
6 Round head tapping screw 45.38.69 6
7 Mounting plate 98.91.32 1
8 Magnetic clip 95.70.90 2
9 Lower cover LH 98.91.99 1

10 Grommet 12.08.51 1
11 Spacer 95.73.63 1
12 Bellows 24.13.05 1
Neopost 13 Hinged cover 98.95.74 1
Hasler - Hinged cover 98.95.78 1

Satas - Hinged cover 98.95.75 1
Formax - Hinged cover 98.95.76 1
Francotyp - Hinged cover 98.95.77 1
blank - Hinged cover 98.95.80 1
14 Lower hinged cover 98.91.96 1

15 Strip 97.00.51 1
16 Nut M4 45.36.26 3
17 Washer ∅12 x ∅ 5.2 x 0.7 mm 43.05.35 2
18 Magnet mounting plate 98.91.61 1
19 Screening plate 96.46.13 1

20 Round head screw M4 x 8 45.38.68 4
21 Cover plate 96.46.12 1
22 Water tank 98.92.93 1
23 Tube 98.94.25 1
24 Countersunk head screw M4 x 10 05.38.75 2

25 Slide complete 04.23.20 1
26 Envelope tray (assy.) 98.92.59 1
27 Self-locking clip 05.26.02 2
28 Lower cover RH 98.91.56 1
Neopost, Hasler, Satas, Formax 29 Cover RH (2 station) 98.95.54 1

Francotyp, blank - Cover RH (2 station) 98.95.61 1
Neopost, Hasler, Satas, Formax - Cover RH (3 station) 98.95.58 1
Francotyp, blank - Cover RH (3 station) 98.95.73 1
30 Mounting bracket 98.91.89 1
rev. 01.0 - 06/2004

410.04-7
1
2
3
4
19 20
RH
5
6
7
8
9
10
11
12
LH 18 17 16 15
13
14
Figure 2
410.04-8 rev. 01.0 - 06/2004

Figure 410.04-8

code number number
Neopost, Hasler, Satas, Formax 1 Top cover feeders 98.91.48 1

Francotyp, blank - Top cover feeders 98.92.29 1
2 Mounting strip 98.92.79 1
3 Screw M4 x 14 98.91.83 2
4 Nut M4 45.19.02 2
5 Collator area cover 96.43.10 1

7 Retaining ring 96.43.36 1
8 Power supply cover 98.91.55 1
9 Bottom cover collator area 96.43.18 1
10 Main lead 220V 98.90.51 1

- Main lead 110V 98.90.52 -
- Main lead 250V Switserland 98.90.54 -
- Main lead 240V U.K. 98.90.53 -
- Main lead 250V Australia 98.90.55 -
11 Support plate 26.04.52 1

12 Moistening cloth 04.03.06 1
13 Clamping strip 24.11.53 8
14 Water tank 98.92.93 1
16 Stud 98.92.19 3
17 Hex. head screw M4 x 8 05.38.80 3
18 Bottom plate 98.92.16 1
Neopost, Hasler, Satas, Formax 19 Top cover 98.95.81 1
Francotyp, blank - Top cover 98.95.82 1
Neopost, Hasler, Satas, Formax 20 Intermediate cover 98.92.71 1

Francotyp, blank - Intermediate cover 98.92.72 1
rev. 01.0 - 06/2004

410.04-9
9 10 11
Figure 3
410.04-10
12 13 14 15
1 2 3 RH
4
5
6
7
8
47 48 49 50 51 52
46
45
44 53 54 55 56 57
43 58 59 60 61 62
63
42 36
64
41 35
service manual
65
40 34
39 33
38 32
37 31 16
24 23 22 21 20 19 17
28 27 26 25 18
30 29
LH
SI 62
rev. 01.0 - 06/2004

Figure 410.04-10

code number number
1 Side guide RH 98.92.26 1

2 Envelope support (assy.) 95.74.01 1
3 Side guide LH 98.91.64 1
5 Spring clip 11-15 mm 05.24.73 4

7 Lower damper pin RH 96.41.17 1
9 Spring clip 6 - 8 mm 05.24.46 4
10 Damper 96.41.40 2
11 Inside frame RH 98.91.39 1

12 Hinge axle 96.41.14 1
13 Inside frame (upper unit) RH 98.91.62 1
14 Damper suspension axle 96.41.20 1
15 Inside frame (upper unit) LH 98.91.63 1
16 Inside frame LH 98.91.36 1

17 Spacer ∅ 25 x ∅ 5.5 x 8 mm 43.29.31 2
18 Rubber stud M6 x 20 04.12.12 2
19 Frontplate LH 96.45.08 1
20 Hex. head screw M4 x 8 05.38.80 2
21 Separation spring 95.71.04 1

22 Separation axle 95.71.05 1
23 Separation roller (assy.) 95.71.03 1
24 Set screw M4 x 4 08.28.01 1
25 Envelope feed axle 98.94.10 1
26 Jogger roller 97.59.52 2

- O-ring 04.18.76 2
27 Feed roller ∅ 42 mm 73.27.31 1
28 Set screw M4 x 6 08.28.02 1
29 Centre frontplate 96.45.06 1

31 Thumb wheel 24.13.58 1
32 Fixing plate-axle 95.71.26 1
33 Adj. nut LH 97.54.76 1

36 Feed table (assy.) 96.45.05 1
37 Slide frame 98.92.69 1
38 Bottom cover 98.92.61 1
39 Locking spring 03.63.36 2
40 Adj. axle 95.71.12 1

41 Adj. nut RH 97.54.77 1
42 Spring clip 9 - 12 mm 05.24.55 1
43 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 3
44 Nut M4 (self-locking) 05.36.21 2
rev. 01.0 - 06/2004

410.04-11
Figure 410.04-10

code number number
45 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.45 4

46 Crinkle washer 05.24.84 2
47 Washer ∅ 12 x ∅ 4.3 x 1 mm 45.37.43 2
48 Spring clip 8 - 11 mm 05.24.54 1
49 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 2
50 Pulley 15T (assy.) 93.05.54 1

51 Timing belt 95.13.16 1
52 Spacer ∅ 12 x ∅ 8.4 x 5 mm 04.09.64 1
53 Slip clutch CCW 8mm 95.71.27 1
54 Cyl. pin ∅ 2.5 x 12 05.23.47 1
55 Spring clip 10 - 14 mm 05.24.83 2

56 Conductive bearing 10 mm 04.24.26 2
58 Front plate RH 96.45.07 1
59 Separation frame 96.41.21 1
60 Nut M4 half d. 45.19.19 1

62 Adjusting nut 96.41.54 1
63 Separation slide 95.71.06 1
410.04-12 rev. 01.0 - 06/2004

rev. 01.0 - 06/2004

410.04-13
10 11 12 13
RH
1 2 3 4 5 6 7 8 9
14 15 16 17 18 19 20 21 22
44
(10)
45
46
47
48
49 25 24 23
43 42 41 40 39
55 54 53 52 51 50
LH
38 37 36 35 34 33 32 31 30 29 28 27 26
Figure 4
410.04-14 rev. 01.0 - 06/2004

Figure 410.04-14

code number number

2 Envelope guide plate LH 96.42.59 1
4 Spring clip 10 - 14 mm 05.24.83 6
5 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 6

7 Upper frame env. track 96.41.22 1
8 Cyl. pin ∅ 2.5 x 16 05.23.46 14
9 Transportation roller ∅ 30 mm 04.18.27 6
10 Sensor (including holder) 04.24.53 2
11 Bracket 96.41.48 1
12 Nut M4 45.19.02 2
13 Pan head tapping screw 45.38.55 2
14 Brush lifter 04.30.20 1
15 Tension spring 03.11.75 1
16 Clutch shaft 96.41.72 1

17 Transportation axle 96.41.75 1
18 Freewheel transportation axle 96.41.88 1
20 Envelope guide plate RH 96.42.60 1
21 Fixing plate envelope track 95.73.04 1

25 Lifting bracket 04.30.22 1

28 Draw bar 96.41.28 1
29 Clamping ring 3 mm 05.24.63 4
30 Spacer 04.10.98 1
31 Lever 96.41.32 1
32 Lifting frame 96.41.24 1
33 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.02 1
35 Lifting roller 96.41.26 1

38 Sleeve 04.12.16 1
39 Pressure spring 0.85 mm 43.11.12 2
41 Air hose 24.13.08 1

42 Spring clip 9 - 12 mm 05.24.55 2
43 Air tube plug 24.13.02 2
44 Air hose connector 04.13.23 2
45 Bracket 43.34.29 1
rev. 01.0 - 06/2004

410.04-15
Figure 410.04-14

code number number

47 Hinge axle 96.43.22 1
48 Lower frame env. track 96.41.23 1
49 Led (including holder) 04.24.52 1
51 Spring clip 8 - 11 mm 05.24.54 7

52 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 6
54 Axle 96.41.53 1
55 Axle for pressure rollers 96.41.52 2
410.04-16 rev. 01.0 - 06/2004

rev. 01.0 - 06/2004

410.04-17
Figure 5
RH
410.04-18
1 2 3 4 5 6 7 8 9 10
11
12
13
14
15
16
34
17
33 35 36
18
32
30 29 31
28
27
service manual
26
LH
22 21 20 19
25 24 23
SI 62
rev. 01.0 - 06/2004

Figure 410.04-18

code number number
1 Sleeve 96.43.70 2
2 Pin 96.43.71 1
4 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 5
5 Rubber roller 96.41.90 1
6 Spring clip 9 - 12 mm 05.24.55 2

7 Spring clip 10 - 14 mm 05.24.83 3
9 Cyl. pin ∅ 2.5 x 16 05.23.46 4

13 Hex. head screw M4 x 8 05.38.80 5
14 Countersunk tapping screw 05.38.56 1
15 Bracket 96.45.55 1

18 Hinge axle 96.45.54 1
20 Spring clip 7 - 9 mm 05.24.42 2
21 Lifting plate 96.41.29 2

23 Connecting rod 96.41.30 2
24 Hinge pin 96.41.31 2
25 Axle for pressure rollers 96.41.70 1
26 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.02 4

27 Pressure spring 03.35.51 4
28 Pressure roller (assy.) 96.45.56 4
30 Flap scraper 96.41.45 1
31 Nut M4 45.19.02 1
32 Washer ∅ 12 x ∅ 5.2 x 0.7 mm 43.05.35 1
33 Bracket 96.41.48 1
35 Flap opener 96.41.44 1
36 Draw bar 96.41.28 1
rev. 01.0 - 06/2004

410.04-19
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Figure 6
410.04-20
32
33
62 63 64 65 66
58
57 59 60 61 34
35
36
service manual
RH
52 51
43 42 41 40 39 38 37
47 46 45 44
LH 56 55 54 53 50 49 48
SI 62
rev. 01.0 - 06/2004

Figure 410.04-20

code number number
1 Microswitch (incl. lever) 98.90.56 1

2 Washer ∅ 7 x ∅ 3.2 x 0.5 mm 45.37.39 2
4 Spacer ∅ 15 x ∅ 10.4 x 3 mm 04.08.58 1
5 Cover 95.71.52 1
6 Frame axle 95.71.53 2

8 Protecting plate 95.73.13 1
11 Lock washer 5/32” 05.24.31 6

14 Upper sealing roller ∅ 36 mm 73.26.48 1
16 Lower sealing roller (assy.) 98.94.33 1

18 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 6

24 Tension pin ∅ 2 x 12 05.33.15 1
26 Actuator disc 96.40.61 1

27 Nut M4 45.19.02 7
30 Draw bar 96.40.62 1

33 Solenoid 02.10.21 1
34 Lever for finger 96.40.65 4
36 Finger 96.40.71 2
37 Cross connection (incl. corkrubber) 96.45.68 1
- Cork rubber 04.18.04 4
38 Leaf spring 96.45.64 1
39 Finger slide 96.40.66 2

41 Hex. head screw M4 x 8 (synthetic) 96.45.66 2
42 Knurled nut 02.11.25 2
43 Adjustable finger 96.40.57 2
44 Pulley axle (assy.) 96.43.58 1
rev. 01.0 - 06/2004

410.04-21
Figure 410.04-20

code number number
45 Connecting ring 96.45.60 1

46 Transportation axle (assy.) 96.43.57 1
47 Transportation table (assy.) 96.45.67 1
48 Transportation roller 96.41.61 2
49 Cyl. pin ∅ 2.5 x 16 05.23.46 4

52 Pulse disc axle (assy.) 96.43.59 1
53 Hex. head screw M4 x 8 05.38.80 10
54 Washer ∅ 12 x ∅ 6.2 x 0.8 mm 04.01.40 1
55 Sleeve 96.43.70 2
56 Pin 96.43.71 1
57 Pressure spring 1 mm 03.11.14 10
58 Wiring plate 98.91.58 1
60 Axle 96.41.69 1
61 Guide plate 96.45.59 1
62 Insert table 96.45.58 1
63 Countersunk screw M3 x 16 05.04.14 8
64 Axle for fingers 96.40.59 1
65 Mounting pin 43.61.75 2

66 Spring clip 6 - 8 mm 05.24.46 3
410.04-22 rev. 01.0 - 06/2004

rev. 01.0 - 06/2004

410.04-23
1 2 3 4 5 6 7 8
Figure 7
410.04-24
9 10 11 12
13
14
15
16
17
18
19
20
21
service manual
22
23
25 24
31 30 29 28 27 26
RH
SI 62
rev. 01.0 - 06/2004

Figure 410.04-24

code number number
1 Belt tensioner 96.46.76 1

3 Tension pin ∅ 2.5 x 16 05.33.22 4
4 Spacer ∅ 15 x ∅ 10.4 x 5 mm 04.08.37 4
5 Gear 28T 24.02.61 2
6 Gear 18T 24.09.36 2

7 Spring clip 9 - 12 mm 05.24.55 3
8 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 4
9 Cyl. pin ∅ 2.5 x 20 96.41.93 4
10 Disc for pulley 96.43.56 3

12 Pulley 36T 96.41.60 1
13 Spring clip 10 - 14 mm 05.24.83 4

17 Washer ∅ 7 x ∅ 3.2 x 0.5 mm 45.37.39 3
18 Adj. plate 96.41.81 1
19 Pulse disc sensor (assy.) 82.16.22 1
20 Pulse disc 24.12.81 1
21 Clamping disc 43.30.46 1

22 Washer ∅ 20 x ∅ 6.2 x 2 mm 43.07.90 1
24 Pulley 30T 96.41.64 2
25 Tensioner roller 96.41.94 2
26 Pulley 20T 96.41.57 1

27 Gear 35T 24.69.52 1
28 Spacer ∅ 15 x ∅ 10.4 x 10 mm 04.08.30 1
29 Gear 18T 96.43.51 2
31 Locking plate 96.41.65 2
rev. 01.0 - 06/2004

410.04-25
Figure 8
410.04-26
5 6 7 8 9 10 11 12 13 14
1 2 3 4
(19)
39 40 41 42
service manual
RH
23 (8) 22 21 20 19 18 17 16 15
36 35 34 33 (23) 32 31
30 29 28
27 26 25 24
SI 62
rev. 01.0 - 06/2004

Figure 410.04-26

code number number
1 Cyl. pin ∅ 2.5 x 12 05.23.47 1

4 Pulley 15T (assy.) 93.05.54 1

7 Spacer ∅ 17 x ∅ 10.2 x 2 mm 04.10.94 1
8 Gear 35T 24.69.58 2
9 Catch disc 23.55.06 1
10 Clutch CW 8 mm 12.16.66 1
11 Cyl. pin ∅ 2.5 x 16 05.23.46 2

12 Gear 18T 96.41.74 1
13 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 3
14 Spring clip 6 - 8 mm 05.24.46 1

17 Spring clip 10 - 14 mm 05.24.83 5
18 Gear 28T 24.11.40 1
19 Gear 35T 24.69.52 2
20 Freewheel clutch assy. 96.43.60 1
21 Spring clip 9 - 12 mm 05.24.55 2

22 Gear 28T 26.02.61 1
23 Gear 14T 96.41.79 2
24 Nut 45.19.20 2
25 Washer ∅ 17 x ∅ 8.4 x 1.6 mm 45.37.38 2
26 Spring holder disc 24.69.43 2

28 Spring clip 8 - 11 mm 05.24.54 2
29 Gear 18T 24.09.36 1
30 Gear 15T 96.41.68 1
31 Gear 21T 24.16.50 1

32 Gear 15T (assy.) 74.69.42 1
33 Spacer ∅ 15 x ∅ 10.4 x 3 mm 04.08.58 2
34 Brake rod 96.41.84 1
35 Spacer ∅ 15 x ∅ 10.4 x 5 mm 04.08.37 1
36 Spacer ∅ 12 x ∅ 8.4 x 5 mm 04.09.64 1

37 Not used
38 Not used
39 Tension pin ∅ 2.5 x 16 05.33.22 2
40 Pulley 13T 96.41.77 1
41 Intermediate axle 96.41.76 1

42 Tension pin ∅ 2.5 x 20 05.33.24 2
rev. 01.0 - 06/2004

410.04-27
Figure 9
410.04-28
1 2 3 4 5 6
34
33
32
31
30
29
28
27
23 24 25 26 9 8 7
service manual
RH
13 12 11 10
(18)(21)(18)
22 21 20 19 18 17 16 15 14
LH
SI 62
rev. 01.0 - 06/2004

Figure 410.04-28

code number number
1 Bearing locking plate 93.06.13 2

2 Washer ∅ 15 x ∅ 5.3 x 2 mm 45.37.50 4
5 Washer ∅ 12 x ∅ 6.2 x 0.8 mm 04.01.40 4
6 Spring clip 6 - 8 mm 05.24.46 4

8 Washer ∅ 20 x ∅ 6.2 x 2 mm 43.07.90 2
10 Upper input roller (assy.) 98.95.21 1
11 Lower input roller (assy.) 98.95.22 1

12 Screening plate (assy.) 96.42.64 1
13 Wiring guide 96.42.58 1

17 Cyl. pin ∅ 2.5 x 16 05.23.46 3
18 Gear 24T 93.05.25 3
19 Spring clip 10 - 14 mm 05.24.83 5
20 Spacer ∅ 15 x ∅ 10.4 x 3 mm 04.08.58 4
21 Gear 35T 24.69.58 2

22 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 2
23 Flap actuator 95.30.84 2
24 Cyl. pin ∅ 2 x 12 95.30.85 2
26 Sleeve 04.00.27 2
27 Fold roller (assy.) 98.95.20 2
28 Fixing screw M3 x 6 95.30.83 4
29 Flap assy. incl. torsion spring 04.27.71 2
30 Torsion spring 03.35.38 2
31 Flap assy. (incl. axle) 04.27.50 2

32 Synthetic leaf spring 93.06.54 4
33 Guide bracket 95.30.73 1
34 Guide strip 93.06.53 1
rev. 01.0 - 06/2004

410.04-29
1 2 3
Figure 10
4 5 6 7 8 9 10 11 12
410.04-30
13 14 15
service manual
32 31 30 29 28 27 26 25 24 23
RH 22 21 20 19 18 17 16
SI 62
rev. 01.0 - 06/2004

Figure 410.04-30

code number number
1 Mounting bracket for spring 98.91.16 3

3 Fixing plate 95.13.07 2
4 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 2
5 Axle for tensioner roller 95.13.10 2
6 Cyl. pin ∅ 2.5 x 16 05.23.46 5

7 Disc for pulley 93.05.42 4
9 Pulley 20T assy. (timing belt) 04.22.46 4
11 Spring clip 7 - 9 mm 05.24.42 2

12 Pulley 20T 96.41.57 1
13 Cyl. pin ∅ 2.5 x 32 05.23.48 1
14 Drive belt PJ 96.41.55 1
15 Main pulley 96.41.58 1
16 Spring clip 10 - 14 mm 05.24.83 1

17 Spacer ∅ 15 x ∅ 10.4 x 10 mm 04.08.30 2
18 Spacer ∅ 15 x ∅ 10.4 x 3 mm 04.08.58 2
20 Pulley 50 Hz 98.94.04 1
- Pulley 60 Hz 98.94.05 1
21 Set screw M4 x 8 08.28.06 1
23 Spring clip 9 - 12 mm 05.24.55 1
24 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 1
25 Gear 30T 96.46.74 1

26 Spacer ∅ 15 x ∅ 10.4 x 7.5 mm 04.08.28 1
27 Hex. head screw M4 x 12 45.38.82 4
28 Spacer ∅ 9 x ∅ 4.1 x 2.5 mm 43.08.51 4
29 Gear 24T 93.05.25 1

31 Motor 220-240V/50Hz 98.94.06 1
- Motor 100-115V/50-60Hz 98.94.07 1
rev. 01.0 - 06/2004

410.04-31
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Figure 11
410.04-32
RH
LH
42 43 44 45 46 47 48
service manual
39 40 41 (33)
22 21 20 19 18 17 16
38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23
SI 62
rev. 01.0 - 06/2004

Figure 410.04-32

code number number

2 Loc frame 96.47.25 2
3 Hex. head screw M4 x 8 05.38.80 11
5 Connecting plate loc 95.72.60 2

7 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 2
8 Solenoid 12.12.87 1
9 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.45 3
11 Bracket for photocell 96.47.31 1

14 Cross connecting plate 96.47.29 1
16 Spring clip 7 - 9 mm 05.24.42 1

18 Pulley 21T 04.18.70 1
19 Cyl. pin ∅ 2.5 x 16 05.23.46 6
20 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 9

22 Drive axle 96.47.23 1
24 Washer ∅ 12 x ∅ 4.3 x 1 mm 45.37.43 2
25 Paper guide 96.47.30 2

28 Spring clip 10 - 14 mm 05.24.83 4
30 Bearing plate 96.47.20 1
31 Spacer ∅ 15 x ∅ 10.4 x 5 mm 04.08.37 3

32 Spacer ∅ 15 x ∅ 10.4 x 7.5 mm 04.08.28 2
33 Gear 15T 24.09.44 2
34 Gear 14T 96.41.79 1
35 Axle 96.47.17 1
36 Gear 20T 24.02.58 1

38 Spacer ∅ 17 x ∅ 10.2 x 2 mm 04.10.94 2
40 Spacer ∅ 15 x ∅ 10.4 x 10 mm 04.08.30 2
41 Gear 15T 73.29.42 1

42 Rod 43.26.81 1
rev. 01.0 - 06/2004

410.04-33
Figure 410.04-32

code number number
46 Draw bar 43.26.79 1

47 Spacer ∅ 15 x ∅ 10.4 x 3 mm 04.08.58 3
410.04-34 rev. 01.0 - 06/2004

rev. 01.0 - 06/2004

410.04-35
1 2 3 4 5 6 7 8 9 10
Figure 12
11 12 13 14 15 16 17 18
410.04-36
20 19
21 RH
22
service manual
23
24
LH
28 27 26 25
SI 62
rev. 01.0 - 06/2004

Figure 410.04-36

code number number

2 Cyl. pin ∅ 2.5 x 16 05.23.46 2
4 Loc frame 96.47.25 2
6 Hex. head screw M4 x 8 05.38.80 14

7 Spring lever 23.28.74 1
9 Nut M4 45.19.02 1
11 Washer ∅ 12 x ∅ 4.3 x 1 mm 45.37.43 2

15 Spring clip 10 - 14 mm 05.24.83 2
16 Axle 23.29.10 1
17 Bracket 96.47.34 1
18 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.45 1
20 Cross bar 96.47.27 1
21 Buffer (assy.) 83.34.97 1

22 Retaining spring 03.11.87 3
23 Grommet 12.04.74 3
24 Brush 72.00.05 3
25 Locking bracket 04.30.23 1
26 Brush holder 04.29.94 1

27 Lifting bracket 96.47.33 1
28 Sleeve 04.09.77 1
rev. 01.0 - 06/2004

410.04-37
1
2
42 5
3
41 6
4
Figure 13
40 7
410.04-38
39 8
38 9
10
11
12
13
14
15 16 17 18 19
28 29 30 31 32 33 34 35 36 37
26 27
service manual
20
21 RH
22
LH
25 24 23
SI 62
rev. 01.0 - 06/2004

Figure 410.04-38

code number number

2 Bracket for flagswitch 96.47.13 1
3 Flagswitch 02.10.76 1
4 Solenoid 12.12.87 1
5 Mounting frame 96.47.11 1
6 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.45 4

7 Lever 96.47.03 1
8 Washer ∅ 12 x ∅ 6.2 x 0.8 mm 04.01.40 8
9 Brake plate 98.92.77 1
10 Transportation roller (assy.) 84.17.04 2
11 Spring clip 6 - 8 mm 05.24.46 4

12 Hinge bracket 96.47.02 1
13 Hex. head screw M4 x 8 05.38.80 14
15 Tension pin ∅ 2.5 x 16 05.33.22 2
16 Gear 15T 96.41.68 2

17 Pulley 15T 04.18.64 1
19 Cyl. pin ∅ 2.5 x 14 04.20.97 1

22 Loc frame 96.47.25 2
23 Cross bar 96.47.27 1
25 Grommet 98.92.75 1
26 Spacer ∅ 15 x ∅ 10.4 x 3 mm 04.08.58 1

27 Spacer ∅ 15 x ∅ 10.4 x 10 mm 04.08.30 4
31 Spring clip 10 - 14 mm 05.24.83 6

33 Cyl. pin ∅ 2.5 x 16 05.23.46 4
35 Ejection axle 96.47.24 1
36 Divert axle 96.47.16 2

37 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 4
38 Nut M4 45.19.02 2
40 Draw bar 96.47.08 1

42 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 2
rev. 01.0 - 06/2004

410.04-39
4 5 6 7 8 9 10 11 12
Figure 14
410.04-40
13
14
1 2 3
15
16
17
18
19
66 65 64 20
21
63
22
62
23
61
24
60
25
52 53 54 55 56 57 59
58
service manual
42
34 33 32 31 30 29 28 27 26
41
40
39
38
37
51 50 49 48 47 46 45 44 43
36
SI 62
rev. 01.0 - 06/2004

35
Figure 410.04-40

code number number
1 Upper separation roller 95.11.67 1

2 Tension pin ∅ 2.5 x 12 05.33.20 1
3 Pulley 95.11.42 1
4 Spring clip 7 - 9 mm 05.24.42 8

9 Transportation axle (separation) 95.11.39 1
11 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 10

12 Self-lubricating bearing 06.09.31 1
13 Rubber paper puller 04.00.16 2
14 Spring clip 6 - 8 mm 05.24.46 9
15 Washer ∅ 12 x ∅ 6.2 x 0.8 mm 04.01.40 5

17 Cyl. pin ∅ 2.5 x 12 05.23.47 1
18 Pulley 28T (timing belt) 95.11.35 1
20 Clamping bush 95.11.41 1
21 Mounting strip 98.93.21 1

22 Upper plate feeder 98.93.04 1
23 Bottom plate assy. (daily mail feeder) 98.93.26 1
24 Frame plate feeder 98.93.05 2

28 Spacer 95.13.37 1
31 Drive axle 96.42.16 1

32 Separation axle assy. (daily mail) 04.23.11 1
33 Cyl. pin ∅ 2.5 x 16 05.23.46 2
34 Transportation roller 95.13.12 2
35 Fixing strip 95.11.82 1
36 Fixing strip 98.93.18 1

37 Sleeve 04.11.57 1
38 Slide 95.11.78 1
39 Washer ∅ 12 x ∅ 4.3 x 1 mm 45.37.43 6
40 Nut M4 45.19.02 2
41 Wire spring 95.11.79 1

43 Drive axle extension 96.42.20 1
44 Hinge arm 98.93.12 1
45 Curved spring assy. 04.28.80 1
rev. 01.0 - 06/2004

410.04-41
Figure 410.04-40

code number number
46 Spring lever 98.93.09 1

48 Gear 48T 95.11.32 1
47 Cyl. pin ∅ 2 x 16 05.23.69 2
49 Pulley 44T 95.11.51 1

52 Gear 64T (assy.) 95.11.38 1
53 Support axle extension 95.11.09 1
54 Tension pin ∅ 2.5 x 10 05.33.19 1
55 Fibre washer ∅ 10 x ∅ 5.2 x 1 mm 04.01.07 2
56 Bearing bush 04.13.32 1

57 Spring clip 5 - 7 mm 05.24.66 1
59 Bracket for photocell 98.93.10 1
61 Cork strip 95.11.26 2

63 DFC 79.01.71 1
64 Bottom plate assy. 98.93.08 1
65 Separation roller (lower) 95.11.68 1
66 Separation axle assy. (auto) 04.22.63 1
410.04-42 rev. 01.0 - 06/2004

rev. 01.0 - 06/2004

410.04-43
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Figure 15
410.04-44
41 42 43 44
17
18
19
20
21
service manual
40 39 38 37 36 35
LH
RH
34 33 32 31 30 29 28 27 26 25 24 23 22
SI 62
rev. 01.0 - 06/2004

Figure 410.04-44

code number number
1 Countersunk head tapping screw 45.38.56 1

3 Hex. head screw M4 x 8 05.38.80 10
6 Hinge pin 98.93.23 6

9 Pin 98.91.49 2

13 Mounting bracket for spring 98.91.16 3
14 Washer ∅ 7 x ∅ 3.2 x 0.5 mm 45.37.39 5
15 Nut M3 45.19.01 2

17 Top frame (2 station) 98.91.50 1
- Top frame (3 station) 98.91.14 1
20 Centre cover plate 96.46.25 1

21 Lower cover plate 96.46.15 1
22 Frame axle 95.13.24 3
23 Drive axle 96.46.52 1
24 Drive axle 95.13.04 2
25 Nylon bearing 04.12.71 6

26 Spring clip 9 - 12 mm 05.24.55 6
27 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 3
28 Lever 95.10.21 2
29 Tension pin ∅ 2.5 x 12 05.33.20 3

31 Cyl. pin ∅ 2.5 x 16 05.23.46 8
34 Safety bracket 95.13.23 2

36 Blocking bracket 96.46.77 3
37 Pulley 44T 95.13.08 3
38 Disc pulley 93.05.39 3
39 Clutch CCW 8 mm 93.05.36 3
40 Spring clip 6 - 8 mm 05.24.46 3

41 Timing belt set (3 pcs) 84.15.74 1
42 Spacer ∅ 12 x ∅ 8.4 x 5 mm 04.09.64 6
rev. 01.0 - 06/2004

410.04-45
11 12 13 14 15 16
Figure 16
1 2 3 4 5 6 7 8 9 10
410.04-46
17 18 19
RH
20
21
22
23
24
25
service manual
26
27
28
35 34 33 32 31 30 29
LH
SI 62
rev. 01.0 - 06/2004

Figure 410.04-46

code number number

3 Hinge pin 98.91.60 2
4 Selflocking nut M3 05.36.28 2
6 Nut M3 45.19.01 2
7 Lock 98.92.64 2
8 Nut M4 45.19.02 2
9 Retaining bush 98.92.65 2
Neopost, Hasler, Satas, Formax 11 Handle 98.91.88 1

Francotyp, blank - Handle 98.95.64 1
13 Frame vertical transport (2 station) 98.91.97 1
- Frame vertical transport (3 station) 98.91.70 1
14 Cable guide 93.09.54 1

16 Refer to 12
18 Positioning plate 98.91.57 1
19 Hex. head screw M4 x 8 05.38.80 6

23 Guide plate (upper) 98.91.98 ?
24 Guide plate (centre) 96.42.12 1

25 Guide plate (lower) 96.42.11 1
26 Rod 96.42.01 2
28 Reading head assy. 98.94.34 1

30 Pressure roller axle 95.14.16 3
31 Spring clip 6 - 8 mm 05.24.46 6
32 Washer ∅ 12 x ∅ 6.2 x 0.8 mm 04.01.40 6

rev. 01.0 - 06/2004

410.04-47
1 2 3 4 5 6 7 8 9
Figure 17
410.04-48
50 51 52 53 54 55
49
48
45 47 RH
44 46
service manual
10
42 43
41 40 39 38 37 36 35 34 33 32 31
LH 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11
SI 62
rev. 01.0 - 06/2004

Figure 410.04-48

code number number

3 Nut M4 45.19.02 1
4 Hinged guide plate 96.41.34 1

8 Frame 96.43.04 1
11 Roller 98.94.01 6
12 Cyl. pin ∅ 2 x 16 05.23.69 6
13 Washer ∅ 12 x ∅ 6.2 x 0.8 mm 04.01.40 10
15 Frame (collator area) 96.43.02 1
16 Axle 96.43.06 1
17 Tensioner 96.43.00 1
20 Spring clip 6 - 8 mm 05.24.46 6
21 Pressure roller assy. (incl. O-ring) 95.20.11 3

22 Hinge axle 96.43.08 4
24 Axle 96.43.09 1

26 Set screw M4 x 4 08.28.01 2
27 Nylon bearing 04.11.07 4
28 Spring clip 4 - 5 mm 05.24.47 8
30 Collating belt set (3 pcs.) 95.20.07 1

31 Drive axle (collator area) 98.94.35 1
33 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 3
34 Set screw M4 x 4 08.28.01 1
35 Roller 98.94.00 3
36 Bushing ∅ 15 x ∅ 10.2 x 5.5 mm 75.37.51 1

37 Frame collator motor 98.94.21 1
38 Motor 24V 98.94.09 1
39 Pulse disc sensor (assy.) 97.55.05 1
40 Set screw M3 x 4 08.28.33 5
41 Pulse disc 96.43.43 1

44 Spring clip 8 - 11 05.24.54 1
45 Clamping ring 05.24.86 1
rev. 01.0 - 06/2004

410.04-49
Figure 410.04-48

code number number

50 Pressure roller ∅ 20 mm 95.14.08 2
51 Axle ∅ 6 mm 98.94.24 1
52 Cil. pin ∅ 2.5 x 16 05.23.46 2
54 Transportation axle (assy.) 96.46.54 1
55 Paper guide strip 96.41.33 1
410.04-50 rev. 01.0 - 06/2004

rev. 01.0 - 06/2004

410.04-51
1 2 3
36 37 38 39 40 41 42
35 4
34 5
33
32
31
30
29
28
27
26
RH
25 6
24 7
23 8
22 9
10
11
12
LH
21
20 18 16 15 14 13
19 17
Figure 18
410.04-52 rev. 01.0 - 06/2004

Figure 410.04-52

code number number
1 Collating plate 96.43.17 1

2 Paper stop 95.21.41 2
4 Cover plate RH 96.43.28 1
5 Frame collating area 96.43.16 1

7 Screening plate 46.43.37 1
10 Isolating plate 98.90.04 1
11 Printed board holder 04.10.75 4

12 Motor relay board 230V 97.55.00 1
- Motor relay board 115V 97.55.40 1
14 Spring clip 6 - 8 mm 05.24.46 6

16 Hinge axle 98.92.04 1
17 Fuse 2.5A/230V slow blow 97.55.43 1
- Fuse 5A/125V 12.15.49 1
18 Power inlet 98.90.05 1

20 Synthetic stud 24.14.62 2
21 Hex. head screw M4 x 8 05.38.80 2
22 Power supply 98.90.02 1
23 Power supply frame 98.92.03 1
24 Capacitor 5 mF (230 V) 98.90.06 1

- Capacitor 20 mF (115 V) 12.12.81 1
25 Capacitor 5 mF (230 V) 98.90.06 1
- Capacitor 20 mF (115 V) 12.12.81 1
26 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.02 2
27 Lock washer 5/32” 05.24.31 2

28 Guide roller 96.43.19 2
29 Cover plate LH 96.43.27 1
30 Hinge axle 96.43.22 1
31 Spring clip 10 - 14 mm 05.24.83 4

33 Rod 96.43.25 1
34 Spring clip 5 - 7 mm 05.24.66 36
35 Counter roller 95.21.11 18
36 Nut M4 45.19.02 4
37 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.45 4

38 Axle 95.21.12 2
39 Tilting plate 95.21.14 2
41 Roller 95.21.13 1
rev. 01.0 - 06/2004

410.04-53
Figure 410.04-52

code number number
410.04-54 rev. 01.0 - 06/2004

rev. 01.0 - 06/2004

410.04-55
1 2 3 4 5 6 7 8 9 10 11
RH
12 13 14 15
21 20
19
LH 18
17
16
22 23 24
RH
25 26 27 28 29
LH
Figure 19
410.04-56 rev. 01.0 - 06/2004

Figure 410.04-56

code number number

5 Bracket 95.30.90 2
6 Spring clip 10 - 14 mm 05.24.83 4

8 Tension pin Ø 2.5 x 20 05.33.24 4
9 Curve axle 95.31.10 2
11 Curve disc RH 95.30.64 2

12 Guide plate (assy.) (first fold table) 95.30.51 1
14 Axle for fold plate 95.30.30 2
15 Hinge plate RH 95.30.11 2
16 Fold plate 96.42.07 1

17 Hinge strip (paper guide) LH 95.30.20 2
18 Hinge plate LH 95.30.10 2
19 Washer Ø 14 x Ø 8.2 x 0.8 mm 04.01.41 4
20 Spring clip 7 - 9 mm 05.24.42 4
21 Curve disc LH 95.30.63 2

22 Nut M4 45.19.02 2
23 Washer Ø 12 x Ø 4.3 x 1 mm 45.37.43 2
25 Guide plate (second fold table) 95.30.53 1

27 Hinge strip (paper guide) RH 95.30.21 1
28 Set screw M4 x 4 08.28.01 3
29 Fold plate 95.30.16 1
rev. 01.0 - 06/2004

410.04-57
RH
10
9
8
7
6
LH
5
4
3
2
1
Figure 20
410.04-58 rev. 01.0 - 06/2004

Figure 410.04-58

code number number

2 Spacer ∅ 12 x ∅ 8.3 x 3 mm 04.10.50 1
3 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 6
4 Spring clip 7 - 9 mm 05.24.42 4
5 Gear 32T (incl. catch) 96.42.19 2
6 Clutch CCW 8 mm 12.14.61 1

7 Cyl. pin ∅ 2.5 x 12 05.23.47 2
8 Spacer ∅ 18 x ∅ 12.8 x 3 mm 04.08.71 2
9 Clutch CW (clockwise) 8 mm 12.14.63 1
10 Drive axle (fold) 93.05.10 1
rev. 01.0 - 06/2004

410.04-59
Figure 21
410.04-60
6 7 8 9
1 2 3 4 5
service manual
26 27 28
LH 14 13 12 11 10
25 24 23 22 21 20 19 18 17 16 15
SI 62
rev. 01.0 - 06/2004

Figure 410.04-60

code number number
1 Lever for flap actuator 95.30.31 2

2 Cyl. pin ∅ 2 x 18 05.23.07 2
3 Spring clip 8 - 11 mm 05.24.54 2
4 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 4

7 Bracket 97.54.61 2
8 Pulse disc sensor 97.55.05 2

12 Upper fold roller (assy.) 96.46.61 1

17 Washer ∅ 15 x ∅ 5.3 x 2 mm 45.37.50 2
21 Ball bearing 03.12.81 2

22 Positioning lever 95.30.68 2
24 Washer ∅ 16 x ∅ 10.2 x 0.8 mm 04.01.43 6
25 Spring clip 9 - 12 mm 05.24.55 2
26 Brake disc 95.30.66 2

27 Cyl. pin ∅ 2.5 x 16 05.23.46 2
rev. 01.0 - 06/2004

410.04-61
RH
Figure 22
410.04-62
1 2 3 4 5 6
7
8
9
10
11
12
13
14 15 16 17
service manual
18
40 39 38 37 36
19
20
35 34 33 32 21
31 30 29 28 27 26 22
25 24 23
SI 62
rev. 01.0 - 06/2004

Figure 410.04-62

code number number

2 Washer ∅ 14 x ∅ 8.2 x 0.8 mm 04.01.41 7
5 Spring clip 8 - 11 mm 05.24.54 3

7 Washer ∅ 9 x ∅ 4.3 x 0.8 mm 45.37.02 2
9 Tension axle 96.46.69 1
10 Spacer 04.10.98 1
11 Brush lever 04.30.21 1

12 Hex. head screw M4 x 8 05.38.80 1
14 Cyl. pin ∅ 2.5 x 12 05.23.47 1
16 Pulley 15T (assy.) 93.05.54 1

17 Washer ∅ 17 x ∅ 8.4 x 1.6 mm 45.37.38 1
18 Washer ∅ 14 x ∅ 6.5 x 0.8 mm 43.02.47 1
21 Set screw M4 x 6 08.28.02 1

22 Pulley 04.14.23 1
23 Spring clip 10 - 14 mm 05.24.83 2
24 Spacer ∅ 15 x ∅ 10.4 x 5 mm 04.08.37 1
25 Gear 24T 93.05.25 2
26 Cyl. pin ∅ 2.5 x 16 05.23.46 4

27 Spacer ∅ 17 x ∅ 10.2 x 2 mm 04.10.94 1
28 Gear 35T 24.69.58 1
29 Spacer ∅ 15 x ∅ 10.4 x 3 mm 04.08.58 2
30 Washer ∅ 15 x ∅ 5.3 x 2 mm 45.37.50 2

33 Brake disc 95.30.94 4
34 Brake strip 95.30.97 1

39 Upper fold roller (assy.) 96.46.61 1
rev. 01.0 - 06/2004

410.04-63
6
7
8
LH
12 11 10 9
1
2
3
4
5
19 18 17 16 15 14 13
RH
Figure 23
410.04-64 rev. 01.0 - 06/2004

Figure 410.04-64

code number number
Neopost, Hasler, Satas, Formax 1 Top cover 98.95.81 1

Francotyp, blank - Top cover 98.95.82 1
3 Mounting plate top cover 98.92.31 1

7 Lock washer 5/32” 05.24.31 1
8 Mainboard 98.90.01 1
9 Dongle socket Note 1
10 Spacer ∅ 8 x ∅ 4 x 25 mm 04.08.83 1
12 PCB holder 93.08.07 5
13 Nut M4 45.19.02 3
14 Screw 5 x 14 98.91.83 4

16 Mounting plate display 98.91.65 1
17 Spacer 04.08.49 4
18 Rubber key pad 98.91.30 1
19 Display 98.90.03 1
Note 1: Dongle (2 station) 98.90.70 1

Dongle OMR 98.90.71 1
rev. 01.0 - 06/2004

410.04-65
410.04-66 rev. 01.0 - 06/2004

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service manual SI 62

rev. 01.0 - 06/2004

410.00-2 rev. 01.0 - 06/2004

3 Preparing the machine for use 10

rev. 01.0 - 06/2004

410.00-4 rev. 01.0 - 06/2004

Warning, this symbol indicates a hazard to life because of high voltage.

rev. 01.0 - 06/2004

Refer to figure 1.1.

410.00-6 rev. 01.0 - 06/2004

Type : inserter system for medium office use.

Overall Dimensions 3- station system

Weight : 80 kg (176 lb)

Noise level : < 70 dB(A) (following ISO 11203)

Theoretical max. speed : 2200 inserts p/h, depending on application.

Operating temperature : 10 - 40°C (50 - 104°F)

Power consumption : 100V AC / 50Hz / 3,0 Amps

Approvals : EMC Certificate conform EMC-Directive.

rev. 01.0 - 06/2004

2.2 Paper Insert specifications

Paper sizes minimum maximum

Quality*** : 60 gr/m2 250 gr/m2

Booklets up to approximately 1 mm (0.04 inch) thickness,

* When folded max. 230 mm (9.1 inch)

2.3 Envelope insert specifications

Envelope sizes : Standard BRE (Business Reply Envelopes)

410.00-8 rev. 01.0 - 06/2004

2.4 Envelope and paper insert specifications

rev. 01.0 - 06/2004

3 Preparing the machine for use

80 Kgs Place the machine in the optional furniture or on a solid table

410.00-10 rev. 01.0 - 06/2004

rev. 01.0 - 06/2004

410.01-2 rev. 01.0 - 06/2004

rev. 01.0 - 06/2004

410.01-4 rev. 01.0 - 06/2004

1.1 Feeding documents

Only feeders with automatic separation are used.

The physical feeding process is fairly straightforward: a document is separated by 79 - 81 (feeder

rev. 01.0 - 06/2004

1.2 Vertical document transport

1.3 Transport to and from the collator

410.01-6 rev. 01.0 - 06/2004

rev. 01.0 - 06/2004

1.5 Envelope transport

1.6 Document input and insert

410.01-8 rev. 01.0 - 06/2004

1.7 Envelope ejecting, sealing and exiting

1.8 Parallel processing

rev. 01.0 - 06/2004 410.01-9

410.01-10 rev. 01.0 - 06/2004

Middle feeder (2)

rev. 01.0 - 06/2004

Upper feeder (3)

410.01-12 rev. 01.0 - 06/2004

rev. 01.0 - 06/2004

Inserting, ejecting, sealing and exiting

410.01-14 rev. 01.0 - 06/2004

Inserting, ejecting, sealing and exiting