SERVICE MANUAL
MODEL: LX-1200/LX-300
COOL LAMINATOR SERVICE MANUAL
MODEL: LX-1200/LX-300
Unauthorized copying of all or part of the contents of this manual is prohibited.
The contents of this manual may change without notice.
INTRODUCTION
This Service Manual describes the Cool Laminator LX-1200/LX-300 specifications, operating principles of the mechanisms, disassembly and reassembly procedures, and maintenance and troubleshooting procedures.
This Service Manual is intended for use by trained technicians. It is not intended for use by the user.
The manual is divided into the following chapters.
Chapter 1. Specifications
Chapter 2. Mechanisms
Chapter 3. Disassembly Procedures
Chapter 4. Reassembly Procedures
Chapter 5. Electronic Controllers
Chapter 6. Maintenance
Chapter 7. Troubleshooting
Appendix Main PCB Circuit Diagram
Chapter 1.
SPECIFICATIONS
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CONTENTS |
Chapter 1. SPECIFICATIONS |
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1.1 |
Mechanical Specifications................................................................................................. |
1-1 |
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1.1.1 |
Appearance........................................................................................................... |
1-1 |
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1.1.2 |
Operating Panel .................................................................................................... |
1-2 |
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1.1.3 |
Indicators............................................................................................................... |
1-2 |
1.2 |
Electrical Specifications .................................................................................................... |
1-2 |
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1.2.1 |
Power Supply........................................................................................................ |
1-2 |
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1.1 Mechanical Specifications
1.1.1Appearance
[1] |
External dimensions (W x D x H) |
468 mm x 387 mm x 273 mm |
[2] |
Weight |
Approx. 8.3 kg (main unit only) |
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468 mm |
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273 mm
387 mm
Fig. 1.1-1 Appearance
1-1
1.1.2Operating Panel
[1] |
Number of Keys |
7 (Start key, Stop key, Cut key, Feed key, |
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Extra border key, Continuous key, Cutting mode selector) |
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[2] |
Key Arrangement |
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Stop key |
Start key |
Power switch |
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Continuous key |
Cutting mode selector |
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Cut key
Feed key
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Extra border key |
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Fig. 1.1-2 Key Arrangement |
1.1.3 Indicators |
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[1] Positions |
Start key LED (green) |
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Continuous key LED (green) |
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Extra border key LED (green) |
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Error LED (red) |
1.2 Electrical Specifications
1.2.1 Power Supply
[1] Power supply |
Commercial power supply (locally available power supply). |
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Converted to DC by the AC adaptor. |
1-2
Chapter 2.
MECHANISMS
CONTENTS
Chapter 2. MECHANISMS
2.1 Mechanical Operating Principles ...................................................................................... |
2-1 |
2.1.1 Description of Mechanisms (Border Mode).......................................................... |
2-1 |
2.1.2 Feed and Compression Mechanisms................................................................... |
2-2 |
2.1.3 Cutter Mechanism (Border Mode) ........................................................................ |
2-5 |
2.1.4 Paper Size Detector Mechanism.......................................................................... |
2-7 |
2.1.5 Trimming Mechanism ........................................................................................... |
2-9 |
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2.1 Mechanical Operating Principles
2.1.1Description of Mechanisms (Border Mode)
1.When a document is inserted into the paper loading gate, the paper feed rollers feed it to the driving roller.
2.As the document passes between the paper feed rollers, the paper size detector determines its size (length and width).
3.When the document passes between the film cartridges it is sandwiched between the upper and lower films in the compression-feed area, where the films and document are compressed between the driving roller and sub-roller.
4.The compressed document and film is fed to the cutting area, where it is cut to the document size detected by the paper size detector with borders added. It is then transported to the next stage.
5.The laminated document is fed out of the eject gate by the paper eject rollers.
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Paper feed |
Roll film (upper) |
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Paper loading gate |
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sub-roller |
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Paper width detector |
Film cartridge |
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Sub-roller |
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Y-cutter blade |
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Paper length detector |
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X-cutter unit |
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Paper loading area |
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Paper eject roller |
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Paper feed roller |
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Eject gate |
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Roll film (lower) |
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Paper eject sub-roller |
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Driving roller |
Ejecting area |
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Compression-feed area |
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Cutting area |
Fig. 2.1-1 Description of Mechanisms
2-1
2.1.2Feed and Compression Mechanisms
The feed and compression mechanism controls the motor drive to feed the document into the film cartridge, compression-feed the films, and eject the laminated document.
The operation is basically divided into three separate operations: feeding a document into the Film cartridge, compression-feeding the films, and ejecting the laminated document.
Normal Mode
When documents are laminated one at a time (that is, not in the Continuous mode), the lamination operation comprises the operations A and B below.
SA. Feeding document into Film cartridge and ejecting the laminated document
1.The SG motor mounted at the right of the chassis runs to rotate the Control cam gear (also mounted at the right of the chassis) to its prescribed position.
2.As the Control cam gear rotates, the LF change shaft is rotated to its prescribed position by the cam on the Control cam gear.
3.A cam is mounted on the LF motor end of the LF change shaft (at the left of the chassis). As the LF change shaft rotates, this cam rotates the two Gear holders at the left of the chassis, which transmit the LF motor drive as shown in the diagram.
4.As a result of steps 1 to 3 above, the drive is transmitted to the Paper feed roller and Paper eject roller. The document is fed into the Film cartridge by the Paper feed roller as the LF motor rotates. After the trailing edge has been cut by the X cutter, the laminated document is ejected by the Paper eject roller.
Gear holder
Paper feed roller
Driving roller
Paper eject roller
LF motor |
LF change shaft |
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Gear holder |
Fig. 2.1-2 Operation when Feeding Document into the Film Cartridge or when Ejecting a Laminated Document
2-2
SB. Compression-feeding the films
1.The SG motor mounted at the right of the chassis runs to rotate the Control cam gear (also mounted at the right of the chassis) to its prescribed position.
2.As the Control cam gear rotates, the LF change shaft is rotated to its prescribed position by the cam on the Control cam gear.
3.A cam is mounted on the LF motor end of the LF change shaft (at the left of the chassis). As the LF change shaft rotates, this cam rotates the two Gear holders at the left of the chassis, which transmit the LF motor drive as shown in the diagram.
4.As a result of steps 1 to 3 above, the drive is transmitted to the Driving roller that compresses the films. During this operation, the Paper feed roller and Paper eject roller rotate continuously to feed in documents and eject laminated documents.
Paper feed roller
Gear holder
Paper feed holder
Driving roller
Paper eject roller
LF motor
LF change shaft
Gear holder
Fig. 2.1-3 Operation during Film Compression-Feed
2-3
Continuous Mode
When the second or subsequent document are inserted in the Continuous mode, the operation C described below feeds the documents to the prescribed position.
SC. Feeding Document Only into Film Cartridge
1.The SG motor mounted at the right of the chassis runs to rotate the Control cam gear (also mounted at the right of the chassis) to its prescribed position.
2.As the Control cam gear rotates, the LF change shaft is rotated to its prescribed position by the cam on the Control cam gear.
3.A cam is mounted on the LF motor end of the LF change shaft (at the left of the chassis). As the LF change shaft rotates, this cam rotates the two Gear holders at the left of the chassis, which transmit the LF motor drive as shown in the diagram.
4.As a result of steps 1 to 3 above, the drive is transmitted to the Paper feed roller only. A document is fed into the Film cartridge by the Paper feed roller as the LF motor rotates.
Paper feed roller
Paper feed holder
Gear holder
LF motor |
LF change shaft |
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Gear holder |
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Fig. 2.1-4 Operation when Feeding Document into the Film Cartridge in the Continuous Mode
2-4
2.1.3Cutter Mechanism (Border Mode)
The cutter mechanism cuts the laminated document to the size of the document plus an added border. Both edges of the films are cut to suit the width of the document and the leading edge and trailing edge are cut according to the document length.
SY-Cutter Vertical Drive Operation
The SG motor drive rotates the Control cam gear to its prescribed position. This rotation is transmitted via the YC lift arm and YC lift shaft to rotate the Y-diversion lever and set the Y cutter to the cutting position.
Y-cutter blade
Control cam gear
Y-diversion lever
YC lift shaft
YC lift arm |
SG motor |
Fig. 2.1-5 Y-Cutter Vertical Drive Operation
2-5
SCutting Leading and Trailing Edges (X-cutter Mechanism)
1.All the rollers which feed the document stop when the cut position at the leading edge of the document reaches the cutting position of the rotary cutter and fixedblade cutter.
2.The DC motor rotates to drive the carriage in the X-cutter assy via the spiral mechanism (not illustrated).
3.As the carriage makes a reciprocal movement, the rotary cutter attached to the carriage moves against the fixed cutter to cut the compressed leading edge of the document.
4.The rotation of the rollers which feed the document restarts when the cutting of the leading edge is complete. Then, when the cut position at the trailing edge of the document reaches the cutting position of the rotary cutter and fixed-blade cutter, the feed rollers stop again.
5.The document trailing edge is cut in the same way as the leading edge by a reciprocal movement of the rotary cutter attached to the carriage.
6.The rotation of the Paper eject roller and Paper feed roller restarts to feed the laminated document from the eject gate after the cutting of the trailing edge is complete. (In this timing, the driving roller does not rotate.)
Document
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A |
Paper eject roller |
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Sub-roller |
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Paper eject sub-roller |
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Driving roller |
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Carriage |
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A' |
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Fixed cutter |
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Rotary cutter |
Section A-A' |
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Rotary cutter |
Sub-roller |
Carriage |
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Paper eject roller |
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Document |
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Paper eject sub-roller |
Fixed cutter |
Driving roller |
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Fig. 2.1-6 Cutting Leading and Trailing Edges (X-cutter Mechanism)
2-6
2.1.4Paper Size Detector Mechanism
SPaper Length Detection
1.When the leading edge of the document passes between the Paper feed rollers, the Actuator top operates about the pivot to turn on the Paper sensor and detect the document leading edge.
2.When the trailing edge of the document passes out of the Paper feed rollers, the Actuator top reverts to its original position to turn off the Paper sensor and detect the document trailing edge.
Paper feed sub-roller
Paper feed roller
Document feed surface
Paper sensor |
Actuator top |
Fig. 2.1-7 Paper Length Detection
2-7
SPaper Width Detection (Y-CA sensor)
1.As the Y-cutter arm (Y-CA sensor carriage) moves in the direction of the arrow, the document contacts the Actuator Y, which rotates about the pivot to switch off the Y-CA sensor (photosensor).
2.When the Y-CA sensor turns off, the Y-cutter arm movement stops and this position is detected as the document width.
Y-cutter arm
Y sensor carriage
Actuator Y |
Pivot |
Y-CA sensor |
Document |
Photosensor ON status |
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Photosensor OFF status
Fig. 2.1-8 Paper Width Detection
2-8
2.1.5Trimming Mechanism
1.When a corner of the laminated document is inserted over the T-cutter plate, the T- sensor lever operates a leaf switch (TRI) that detects the document.
2.When the document is detected, the motor gear of the SG Motor rotates from its reference position to the prescribed position to rotate the Control cam gear in the direction of the arrow (counterclockwise) via a series of gears.
3.Rotation of the Control cam gear forces the T-cam roller to move vertically, such that T-lever also moves vertically, rotating around its pivot.
4.As T-lever moves vertically, the T-cutter assy mounted on the end of T-lever moves up and down, trimming the corner of the laminated document into a rounded radius.
Leaf switch
T-sensor lever
T-cam roller
T-lever
T-cutter unit
Pivot |
SG motor |
Control cam gear
Fig. 2.1-9 Trimming Mechanism
2-9
Chapter 3.
DISASSEMBLY PROCEDURES
CONTENTS
Chapter 3. DISASSEMBLY PROCEDURES
3.1 |
Safety Precautions ............................................................................................................ |
3-1 |
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3.2 |
Removing the Film Cartridge ............................................................................................ |
3-1 |
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3.3 |
Covers |
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3-2 |
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3.3.1 |
Removing the Trimmer Cover .............................................................................. |
3-2 |
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3.3.2 |
Removing the Top Cover B .................................................................................. |
3-3 |
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3.3.3 |
Removing the Sub-tray ......................................................................................... |
3-4 |
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3.3.4 |
Removing Paper Tray A and Paper Guide........................................................... |
3-4 |
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3.3.5 |
Removing the Body Cover.................................................................................... |
3-5 |
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3.3.6 |
Removing the Front Cover.................................................................................... |
3-7 |
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3.3.7 |
Removing Paper Tray B ....................................................................................... |
3-8 |
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3.3.8 |
Removing the Back Cover.................................................................................... |
3-8 |
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3.3.9 |
Removing the Cover Switch ................................................................................. |
3-9 |
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3.3.10 |
Removing the Dial Switch Holder Assy B .......................................................... |
3-10 |
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3.3.11 |
Removing the Push Switch Assy........................................................................ |
3-11 |
3.4 |
Chassis Assy................................................................................................................... |
3-12 |
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3.4.1 |
Removing the Harness Connectors ................................................................... |
3-12 |
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3.4.2 |
Removing the PST PCB (Paper Sensor PCB)................................................... |
3-13 |
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3.4.3 |
Removing the Chassis Assy............................................................................... |
3-14 |
3.5 |
PCBs ............................................................................................................................... |
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3-16 |
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3.5.1 |
Removing the Main PCB .................................................................................... |
3-16 |
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3.5.2 |
Removing the Jack PCB Assy............................................................................ |
3-16 |
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3.5.3 |
Removing the SW PCB Assy ............................................................................. |
3-17 |
3.6 |
X-cutter Unit .................................................................................................................... |
3-18 |
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3.6.1 |
Removing the X-cutter Unit................................................................................. |
3-18 |
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3.6.2 |
Removing the Leaf Switch F Assy...................................................................... |
3-18 |
3.7 |
Y-CA Chassis Assy and Y-cutter Arm ............................................................................ |
3-19 |
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3.7.1 |
Removing the Y-CA Chassis Assy ..................................................................... |
3-19 |
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3.7.2 |
Removing the Y-CA Motor.................................................................................. |
3-20 |
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3.7.3 |
Removing the Y-cutter Arm ................................................................................ |
3-20 |
3.8 |
Y-sensor Rail Unit ........................................................................................................... |
3-21 |
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3.8.1 |
Removing the Y-sensor Rail Unit ....................................................................... |
3-21 |
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3.8.2 |
Disassembling the Y-sensor Rail Unit................................................................ |
3-22 |
3.9 |
Roller Holder Assy .......................................................................................................... |
3-23 |
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3.9.1 |
Removing the Roller Holder Assy ...................................................................... |
3-23 |
3.10 Paper Feed Roller ........................................................................................................... |
3-24 |
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3.10.1 |
Removing the Paper Feed Holder Assy............................................................. |
3-24 |
3.11 |
Left Side of the Main Chassis ......................................................................................... |
3-25 |
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3.11.1 |
Removing the LF Motor ...................................................................................... |
3-25 |
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3.11.2 |
Removing the Gears........................................................................................... |
3-26 |
3.12 |
Right Side of the Main Chassis....................................................................................... |
3-27 |
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3.12.1 |
Removing the Right Side of the Chassis............................................................ |
3-27 |
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3.12.2 |
Removing the YC Lift Shaft and LF Change Shaft ............................................ |
3-28 |
3.13 |
Paper Eject Roller ........................................................................................................... |
3-30 |
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3.13.1 |
Removing the Paper Eject Roller Unit................................................................ |
3-30 |
3.14 |
Y-diversion Lever ............................................................................................................ |
3-31 |
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3.14.1 |
Removing the Y-diversion Lever Assy ............................................................... |
3-31 |
3.15 |
Trimming Mechanism...................................................................................................... |
3-32 |
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3.15.1 |
Disassembling the Trimming Mechanism .......................................................... |
3-32 |
3.16 |
Driving Roller................................................................................................................... |
3-32 |
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3.16.1 |
Removing the Driving Roller............................................................................... |
3-32 |
3.17 |
Main Chassis B ............................................................................................................... |
3-33 |
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3.17.1 |
Removing the Main Chassis B ........................................................................... |
3-33 |
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3.17.2 |
Removing the Cassette Holder........................................................................... |
3-34 |
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3.17.3 Removing the ENC Sensor PCB........................................................................ |
3-34 |
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3.17.4 |
Removing the Main Chassis L, R, and F............................................................ |
3-35 |
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3.1Safety Precautions
•When conducting disassembly operations, place the unit on a grounded anti-static sheet. LSI and other electronic components are sensitive to static electricity and may be damaged if touched while charged.
•Before transporting a circuit board, wrap it in a conducting sheet such as aluminum foil.
•When using a soldering iron or other heat-producing tool, ensure that heat does not damage wires, circuit boards, or plastic parts such as covers.
•Take care not to lose small screws or washers removed when replacing parts.
•As a safety precaution, wear gloves when conducting disassembly operations.
3.2Removing the Film Cartridge
1.Open the top cover and move the Y-cutter arm as far as possible to the left.
2.Push the Set buttons R/L in the direction indicated by the arrow to unlock the Roller holder assy.
Top cover
Y-cutter arm
Set button R/L
Fig. 3.2-1 Removing the Film Cartridge 1
3-1
3. Lift up the Roller holder assy and pull out the Film cartridge.
Roller holder assy
Film cartridge
Fig. 3.2-2 Removing the Film Cartridge 2
3.3 Covers
3.3.1Removing the Trimmer Cover
1. Pull out the T-cutter plate and the Trimmer bottom cover.
Trimmer bottom cover
T-cutter plate
Fig. 3.3-1 Removing the Trimmer cover 1
3-2
2. Remove the two Trimmer cover screws. Remove the Trimmer upper cover.
Trimmer cover screws
Trimmer upper cover
Fig. 3.3-2 Removing the Trimmer cover 2
3.3.2Removing the Top Cover B
Open the Top cover B. Lift the Top cover B shafts out of the shaft recesses in the Body cover and remove Top cover B.
Top cover B
Body cover
Shafts |
Shaft recesses |
Fig. 3.3-3 Removing the Top Cover B
3-3
3.3.3Removing the Sub-tray
1.Open the Sub-tray.
2.Flex the center of the sub-tray toward you to release the shafts from the shaft recesses in the Body cover. Remove the sub-tray.
Sub-tray |
Shaft recesses |
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Body cover |
Fig. 3.3-4 Removing the Sub-tray
3.3.4Removing Paper Tray A and Paper Guide
1.Flex the center of the top of Paper tray A in the direction of the arrow, then release the left and right hooks. Pull Paper tray A upward to remove it.
Paper tray A
Fig. 3.3-5 Removing Paper Tray A
3-4
2. Disengage the Paper guide hooks (at the rear of the Paper tray) |
CL2000011 |
from Paper tray A. Remove the Paper guide.
Paper guide
Paper tray
Hooks
Fig. 3.3-6 Removing the Paper Guide
3.3.5Removing the Body Cover
1.Remove the two Bottom cover screws B from the bottom of the Bottom cover B. And remove one screw from the surface of Body cover.
When inverting the unit to perform this work, place it on a soft cloth to avoid scratching the cover.
Bottom cover screws B
Soft cloth
Fig. 3.3-7 Removing the Body Cover 1
3-5
2.Lift the rear of the Bottom cover in the direction of arrow B while pushing it in the direction of arrow A to release the six hooks on the rear face.
3.Push the sides of Body cover in the directions indicated by the arrows C to release the hook at the left and right side.
4.Push on the Y-diversion lever assy and release the two hooks from the front of the Body cover.
Side hooks
Body cover
B
C A
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Rear hooks |
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Bottom cover B |
Front hooks |
Y-diversion lever assy |
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Fig. 3.3-8 Removing the Body Cover 2
5.Disconnect the Switch harness assy and the Cover switch assy connectors from the Main PCB and remove the Body cover.
Switch harness assy
Cover switch assy
Fig. 3.3-9 Removing the Body Cover 3
3-6
3.3.6Removing the Front Cover
1.Remove the two Front cover screws under the Bottom cover B.
When removing the Body cover, remove the two Front cover screws and the two screws at the rear of the Bottom cover B at the same time.
When inverting the unit to perform this work, place it on a soft cloth to avoid scratching the cover.
Front cover screws
Soft cloth
Fig. 3.3-10 Removing the Front Cover 1
2.Pull the front cover forward to remove it.
(The Body cover must be removed before removing the Front cover.)
Front cover
Fig. 3.3-11 Removing the Front Cover 2
3-7
3.3.7 Removing Paper Tray B |
CL2000011 |
1. Remove Tray B Stopper.
2.Lift the top of Paper tray B in the direction of arrow A to disengage the lug from the Cassette holder.
3.Slide Paper tray B in the direction of arrow B, then lift it in the direction of arrow C to remove it.
Paper tray B
B
Lug
C A
Cassette holder
Fig. 3.3-12 Removing Paper Tray B
3.3.8Removing the Back Cover
1. Remove the Back cover spring.
Body cover
Back cover spring
Back cover
Fig. 3.3-13 Removing the Back Cover 1
3-8
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