Techsage SpinJet 1000 Service Manual
Service guide March 2001 1
SpinJet 1000
Service Guide
Safety precautions
SpinJet 1000 is intended for use on the large format printer HP
DesignJet 1050C/1055CM (referred to as the printer) only. The instructions for installation and operation of both printer and SpinJet
1000 must be followed.
SpinJet is intended for permanent installation on the above mentioned
printer type. Normal single-sided printing is possible without removing
or tilting down the SpinJet 1000.
SpinJet 1000 is intended for operation with installed top cover and
mounted side covers.
The operator may remove the top cover during a jam removal. Only
specially trained personnel should carry out tasks for test or service
purposes, requiring operation in otherwise open and/or dismounted
condition.
The routines of inspection and replacement of wear and spare parts
must be followed. Always disconnect Power Mains before
disconnecting cables and electrical parts.
Connect SpinJet to Power Mains 100-120VAC or 200-240VAC,
50/60Hz, one phase and earth. Apply a Power Cord according to local
Voltages and Plugs. A UL Listed Power Cord rated minimum 10A,
125V is provided with SpinJet in areas where this apply.
Service guide March 2001 2
Table of Contents:
1. General .......................................................................................3
1.1 Functional test ............................................................................... 3
1.2 Fault finding ................................................................................... 3
Error codes ................................................................................................... 3
Other trouble shooting ....................................................................................4
2. Wear and Spare Part replacement procedures .................................. 8
2.1 General ......................................................................................... 8
2.2 Covers .......................................................................................... 9
5550 112 Cover 1 ........................................................................................9
5550 034 Assy, Cover 3 w/badge ...................................................................9
5550 035 Assy, Cover 2 w/keypad ..................................................................9
2.3 Drive and sensor components......................................................... 10
5551 004 Timing belt...................................................................................10
5551 066 Timing belt...................................................................................10
5550 005 Assy, motor w/pulley and connector ................................................11
5550 007 Assy, sensor/connector (PS01) ......................................................12
5551 001 Photo sensor (PS02) .................................................................... 13
5551 001 Photo sensor (PS03) .................................................................... 13
5550 026 Assy, harness #6 connector PCB to PS02-03................................. 14
5551 062 Photo sensor left (PS04)............................................................... 14
5551 063 Photo sensor right (PS05).............................................................14
5550 028 Assy, harness #10 connector PCB to PS04-05...............................14
2.4 Control system components ........................................................... 15
5551 073 Fuse ........................................................................................... 15
5551 088 Fuse holder cap............................................................................15
5550 032 Assy, control system .................................................................... 15
5550 048 PIC, programmed ......................................................................... 15
5550 197 Connector PCB............................................................................16
5550 027 Assy, harness #7 connector PCB to keypad ....................................16
5550 025 Assy, harness #5 connector PCB to motor 2 or 3 ...........................16
5550 038 Assy, harness #4 and #11 in supporting arm. .................................16
5550 030 Assy, harness #12 RS232 printer communication............................ 17
2.5 Mechanical components ................................................................. 17
5551 018 Gas spring...................................................................................17
5551 019 Bumper....................................................................................... 17
5550 200 Bushing 4.................................................................................... 18
5550 166 Guide 5 .......................................................................................18
5550 021 Assy, Guide 6 .............................................................................. 18
5550 196 Tool 1......................................................................................... 18
5550 186 Flap ............................................................................................ 18
5550 199 Foil ............................................................................................. 19
5551 055 Tape ...........................................................................................19
5551 056 Tape ...........................................................................................19
5551 023 Spring.........................................................................................19
5550 174 Retainer 1 ...................................................................................19
5550 008 Pulley with clutch .......................................................................... 19
5550 181 Encoder ......................................................................................20
1453 007 Bearing (on shafts) .......................................................................20
5550 020 Assy, hub with set screws (upper shaft) ..........................................20
5550 020 Assy, hub with set screws (lower shaft) ........................................... 21
1453 007 Bearing (inside roller)..................................................................... 22
5550 011 Pulley with clutch .......................................................................... 23
5550 055 Assy, Standoff with vibration damper .............................................23
5550 019 Boom guide with standoffs.............................................................23
5550 212 Spring guide 1 .............................................................................23
5550 036 Assy, Drum with spring, right ........................................................24
5550 037 Assy, Drum with spring, left ..........................................................24
1453 013 Bearing .......................................................................................25
5550 014 Brake with clutch..........................................................................26
5550 195 Bushing 2.................................................................................... 26
5550 208 Bushing 5.................................................................................... 26
5550 047 Assy, foot extension set................................................................ 26
3. Wear and Spare Parts list ...........................................................27
Service guide March 2001 3
1. General
For information on installation procedure: Please see SpinJet Installation
Guide.
For information on specifications, normal use and operation: Please see
SpinJet Operator’s manual.
1.1 Functional test
In order to establish the existence of a possible problem and later the
effect of the corrective action taken, test the SpinJet as follows:
Connect the SpinJet control box to a power outlet.
Switch the box on with the rocker switch. A red light in the button
indicates that the control box is “on”.
Switch on the SpinJet by pressing the power button of the SpinJet
keyboard. Verify that the motors initialise and bring the system into the
“Single” state.
Press the mode button. Verify that the system switches to the
“Double” state and raises the flipper gate.
Install a SpinJet approved paper roll according to the user guide.
Run the test jobs of the software supplied with the product. Verify that
both sides are printed and the required front to back match is achieved.
If the match is inadequate, repeat the procedure of loosening the four
screws securing the printer to the printer base, moving the printer
slightly on its base and tightening the four screws again. Repeat until a
satisfactory result is achieved.
1.2 Fault finding
Error codes
Error
code
Occurs when Possible causes
Error01 Medium sensor on
when leaving OFF
state
Blocking object
Attenuator offset or rotated relative
to light emitter
Emitter defective
Receiver defective
Sensor harness defective
Harness #11 defective
Service guide March 2001 4
Error
code
Occurs when Possible causes
Error02 Gate sensor not on
in time
Motor 2 defective
Motor 2 harness #5 defective
Belt defective
Sensor defective
Sensor harness #6 defective
Harness #4 or #11 defective
Error03 Gate sensor not off
in time
Sensor defective
Sensor harness defective
Harness #4 or #11 defective
Error04 Boom sensor not on
in time
Motor 3 defective
Motor 3 harness #5 defective
Belt defective
Sensor defective
Sensor harness #6 defective
Harness #4 or #11 defective
Error05 Boom sensor not
off in time
Motor 3 defective
Motor 3 harness #5 defective
Belt defective
One way clutch defective
Sensor defective
Sensor harness #6 defective
Harness #4 or #11 defective
Error06 Paper feed encoder
does not reach
preset count value
in time
Sensor (right or left) defective
Sensor harness #10 defective
Harness #4 or #11 defective
Motor 1 defective
Belt defective
Other trouble shooting
Symptoms Possible causes Remedies
No light in control
box switch
Melted main fuse Replace fuse at inlet
module
Harness #11 defective
Replace None of the LEDs
are lit in the SpinJet
keypad
and
Light in control box
switch
Control box component
failure
Replace control box
SpinJet does not
respond to the signal
from the printer to
go into double mode
Harness #12 defective Replace
Service guide March 2001 5
Symptoms Possible causes Remedies
The guide system
(leading to the sensor
light line) is damaged or
has a burr, which
obstructs the paper path
Find and remove
burr/damage
Roller/tire system has
too much friction or
resistance to rotate
Check bearings or
possible
interferences
Medium does not
reach paper sensor
Gate closes too tight on
Guide 2
or
The metal flag on the
right end of the gate is
bent
Straighten long leg
of the flag
Boom does not
maintain proper loop
shape of the sheet
during the first side
printing
and
Motor 3 runs
Suspension spring(s) is
damaged thus producing
friction in boom guides
Replace spring(s)
Boom suspension
springs curls during
first side printing
One way clutch defective Replace pulley/clutch
assembly of spring
drum shaft
One way clutch defective Replace pulley/clutch
assembly of feed
shaft
Sheet dropped by
SpinJet before being
fed into printer
Coil spring holding
central roller shaft
disengaged/lost
Reinstall/replace
Paper does not feed
into printer
and
Motor does not try
to feed
and
No error signal
Distance between right
and left encoder sensor
too long
Loosen, hold
together and fasten
Harness #4 defective
Replace Paper does not feed
into printer
and
Motor does not try
to feed
and
Error code 06
displayed
Motor 1 defective Replace
One way clutch defective Replace pulley/clutch
assembly of feed
shaft
Paper does not feed
into printer
and
Motor does try to
feed
and
Tires do not run
and
Error code 06
displayed
Belt defective Replace
Service guide March 2001 6
Symptoms Possible causes Remedies
Sheet lead edge caught
by notches of Guide 1
Find and remove
burr/damage
Damage to foil on Guide 2 Find and remove
burr/damage
Faulty position of foil on
Guide 2
Paper does not feed
into printer
and
Motor and tires do
try to feed
Tires worn to too small
diameter
Replace hub/tire
assembly (8 pcs.)
Front unit too far away
from printer
Check and correct
position of the two
rubber bumpers
defining the distance
Sheet does not
reach blue line
Tires worn to too small
diameter
Replace hub/tire
assembly (8 pcs.)
Sheet overshoots
blue line by small
amount
Tire surface glazed or
contaminated (loss of
friction)
Replace hub/tire
assembly (8 pcs.)
Encoder sensor (right or
left) defective
Replace
Encoder sensor harness
#10 defective
Replace
Sheet overshoots
blue line by
approximately 50mm
Harness #11 defective Replace
Printer does not
respond to signal
from SpinJet to go
into sheet mode
Harness #12 defective Replace
Sheet pulled out of
printer again after
printer vacuum is
applied
One way clutch defective Replace pulley/clutch
assembly of feed
shaft
Printer unable to pull
in sheet from
SpinJet after printer
vacuum is applied
Printer vacuum too low Check printer
vacuum level and
vacuum system
seals
Insufficient pressure
from SpinJet against
printer platen
and
The last part of the
tilting to the lower
position achieved by
gravity (without
pushing)
Loss of pressure in gas
spring(s)
Identify spring(s),
which does not
produce 500N and
replace
Noisy drives Wrong belt tension Readjust belt
tension according to
replacement
procedures for
5551 004 and 066
in section 2.3.
Service guide March 2001 7
Where possible, verify the hypothesis regarding the cause of an
experienced problem by trying to replace the suspect part or system.
Make only one replacement between these tests and go back to the
originally fitted part or system, when there is no effect of the
replacement.
All sensors are using an optical principle, where the effect is that of a
light path being intersected by a moving part or by the medium. All
sensors are equipped with monitoring LED’s with the following functions:
PS01: Green LED on means that the signal is stable and
unambiguous.
Red/orange LED on means light path is cut by an object
(“dark”).
PS02-05: A red LED means, that the light path is not cut by an
object (opposite of “dark”).
These functions serve to help identifying certain sensor related faults
before trying to replace the sensor itself.
Service guide March 2001 8
2. Wear and Spare Part replacement
procedures
2.1 General
Replacement procedures require
that the SpinJet is mounted on a
printer or supported similarly. In
general replacements require
covers to be removed first.
Further for general reference,
Guide 2 and Guide 5 are identified
in picture below.
In order to maintain internal
accuracy of the unit, the screws
of Beam 1 and Guide 1 should
never be loosened.
Recommended tools:
§ Torx screwdrivers T10, T15
and T20
§ T25 (provided with HP
Printer)
§ Straight blade screwdrivers
(small sizes)
§ Thin blade knife
§ Pair of pliers (pointed)
§ Soft head hammer
§ M5 screw, length 12 mm
min. (provided with the
SpinJet)
§ PIC extractor
§ Antistatic wristband
Guide 1
Beam 1
Cover 1
Cover
3 Cover 2
Guide
5
Guide 2
Service guide March 2001 9
2.2 Covers
5550 112 Cover 1
Release at lower studs first by
gently pulling outwards and lift off
at upper studs. Install in reverse
order.
5550 034 Assy, Cover 3
w/badge
5550 035 Assy, Cover 2
w/keypad
The side covers are fastened with
3 screws each (see picture).
Remove Cover 1 to get access to
the two upper screws.
Cover 3 comes with the badge
and Cover 2 with the keypad.
5550 027, Assembly, harness
#7, connector PCB to keypad
(not included in 5550 035) must
be disconnected from the keypad
in order to allow Cover 2 to be
put aside.
Note the little orientation tab of
the connector when refitting.
Take care to fit harnesses well
inside when installing covers.
Lower stud
inside side
plate
Upper stud
inside side
plate
Cover 1
Cover 3
Inside of keypad
Tail of 5550 027
(orientation tab indicated by the arrow)
Cover 2
3 screws
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