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Index

RN
SERIES

TECHNICAL MANUAL
VERSION 1.0 JULY, 2000
Copyright : 2000 Riso Kagaku Corporation All Rights Reserved. This Technical Manual was prepared and written for the exclusive use of RISO International Group Certified Dealers. Reproduction and/or transmittal of this material in any form or by any means, including photocopying or recording of the information is strictly prohibited without the consent of a member of RISO International Group.

RISO INTERNATIONAL GROUP RISO KAGAKU CORPORATION (JAPAN) RISO, INC. (U.S.A.) RISO EUROPE LIMITED (U.K.) RISO HONG KONG (HONG KONG) RISO UK (U.K.) RISO THAILAND LIMITED (THAILAND) RISO DEUTSCHLAND GMBH (GERMANY) RISO FRANCE (FRANCE) RISO IBERICA (SPAIN) RISO CANADA (CANADA) RISO ZHUHAI (HONG KONG) RISO AFRICA (SOUTH AFRICA)

Index
Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 Chapter 9 Chapter 10 Chapter 11 Chapter 12 Chapter 13 Chapter 14 Chapter 15 Chapter 16 Chapter 17 Chapter 18 Chapter 19 Maintenance Machine Summary Machine Drive Section First Paper Feed Section Second Paper Feed Section Press Section Paper Ejection System Print Drum Section Master Clamp Section Master Removal Section F.B. Original Scanning Section A.D.F. Original Scanning Section Master Making Section Timing Charts Panel Messages Test Modes User Mode Settings Miscellaneous Precautions Description of P.C.Bs

CHAPTER 1: MAINTENANCE

Contents
1. Preface ...................................................................................................................... 1-2 CAUTION ................................................................................................................... 1-3 WARNING ................................................................................................................. 1-4 2. 3. 4. Work Precautions ..................................................................................................... 1-5 Exterior Cover Removal ............................................................................................ 1-8 Controller (RISORINC2) and System PCB ........................................................... 1-13

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CHAPTER 1. MAINTENANCE PREFACE

1.

Preface
This manual provides Technical Service Information for the RISOGRAPH model RN series. This manual is published as a reference guide for use by RISO Group (RISO Kagaku Corp./ RISO,INC./RISO EUROPE Ltd.) Certified Technical Representatives experienced in duplicator repair and service. This manual also provides procedures for removing and installing major components. Following these procedures will minimize machine malfunctions. This information and format will also increase technical representatives' awareness and experience regarding repairs necessary to insure end-user satisfaction.

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CHAPTER 1. MAINTENANCE CAUTION

CAUTION
[Handling of Lithium Battery] - Never fail to follow the following instructions when you discard the used lithium battery. 1. Never let the battery short-circuited. If the (+) and (-) terminals contact each other or metal materials, the battery will be short-circuited. If the batteries are collected and stored inorderly or one upon another, the above-mentioned case will occur. - DANGER If the battery is short-circuited, it will heat up and may in some cases explode into fire. 2. Never heat up the battery. - DANGER If you heat the battery up to more than 100C or put it into the fire, it may burn dangerously or explode. 3. Never disassemble the battery or press it into deformation. - DANGER If you disassemble the battery, the gas pouring out of the inside may hurt your throat or the negative lithium may heat up into fire. If the battery is pressed into deformation, the liquid inside may leak out of the sealed part or the battery may be short-circuited inside an explode. 4. Never fail to keep the battery out of reach of children. If you put the battery within reach of children, they may swallow it down. Should they swallow the battery, immediately consult the doctor. [Replacement of the Lithium Battery] 1. The lithium battery must be replaced by a trained and authorized service technician. 2. The battery must be replaced only with the same or equivalent type recom- mended by the manufacturer. 3. Discard used batteries according to the manufacturers instructions.

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CHAPTER 1. MAINTENANCE WARNING

!! WARNING !!
Important Safety Precautions 1. Always disconnect electrical supply before placing hands in the machine.
I. To avoid injuries: Be sure to disconnect the electrical power before disassembling, assembling,or when making adjustments on the machine. II. Protection of the machine: Make sure to turn OFF the power to the machine before plugging or unplugging the electrical connectors, or when connecting a Meter.

2. Always connect electrical connectors firmly.


I. To avoid electrical failure: The connectors must be connected firmly together and onto the PCBs. Press on the ends of the connectors and then on the middle to ensure a firm fit. II. Protection of the electrical components: The electrical components may be damaged due to short circuits caused by a loose connector.

Wire harness connector

FIRST

Press the ends.

THEN

Press the center, firmly.

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CHAPTER 1. MAINTENANCE WORK PRECAUTIONS

2.

Work Precautions
Inspection
If you discover any defects or problems during an inspection, fix the problems or if necessary take steps such as replacing a part.

Removal
Check the problem area. At the same time, examine the cause of the problem and determine whether the part needs to be removed or disassembled. Next proceed according to the procedures presented in the Technical Manual. In cases where, for example, it is necessary to disassemble areas with large numbers of parts, parts which are similar to each other, or parts which are the same on the left and right, sort the parts so that you do not mix them up during reassembly. (1) Carefully sort the removed parts. (2) Distinguish between parts which are being replaced and those which will be reused. (3) When replacing screws, etc., be sure to use the specified sizes.

Assembly and Installation


Unless specified otherwise, perform the removal procedures in reverse during assembly and installation. In cases where protrusions or holes are provided to assist in positioning parts, use them for accurate positioning and securing. (Protrusions and holes for positioning parts Half pierce section)

Tools
Using tools other than those specified can lead to injury or damage screws and parts. Have all the tools necessary for the work available. <Standard Tool list> Type Tip size No. 2 No. 2 No. 2 No. 1 6 mm 3 mm 1.8 mm 8 mm 7 mm 2.5 mm 5 mm 5.5 mm 8 mm 10 mm Monkey 7 mm 13 mm Shaft length, etc. (250 mm) (100 mm-150 mm) (stubby type) (75 mm-100 mm) (100 mm-150 mm) (100 mm-150 mm) (precision type) (100 mm-150 mm) (100 mm-150 mm) Type Steel scale Feeler gauge Radial cutting pliers Pliers Nipper Small flashlight Multimeter Soldering iron File 20 W-30 W Flat, round Remarks 150 mm

Phillips screwdriver

Standard screwdriver Nut driver (box driver) High frequency driver Spanners (may be double-ended)

Hex wrenches

5.0 mm 4.0 mm 3.0 mm - ( 2 pieces required ) 2.5 mm 2.0 mm 1.5 mm

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CHAPTER 1. MAINTENANCE WORK PRECAUTIONS

Electrical system work


After removing wire bundles, fasten them with wire bundle bands (bar lock ties) so that they will not sag. When installing parts, be careful to avoid pinching or damaging the wire bundles. If a fuse blows, always replace it with one with the specified capacity. Using a fuse with a larger capacity can not only damage parts, but may cause fires. Be careful not to drop image scanners, thermal print heads, and other sensors as they can be easily damaged.

Sensor types
Photo-electric sensors may be broadly divided into the following four types: interrupt types (U-shaped), actuator types, reflective types, and transmittive types. Magnetic sensors use Hall ICs, which react to the magnetic force in magnets. Always turn off the power before plugging or unplugging sensor connectors.

Switch types
Microswitches may be divided between normally open (NO) types and normally closed (NC) types. With an NO connection, an internal contact is connected when the switch actuator is pressed. With an NC connection, an internal contact is disconnected when the switch actuator is pressed. Magnetic lead switches are switches in which an internal contact is connected in reaction to the magnetic force of a magnet.

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CHAPTER 1. MAINTENANCE WORK PRECAUTIONS

Installation location
Do not install the machine in any of the following locations. (1) Those subject to direct sunlight or any bright location such as by a window (If you must install in such a location, put a curtain or the like over the window.) (2) Those where the temperature changes drastically (3) Those that are too hot, cold, humid, or dry RECOMMENDED: Temperature range: 15 centigrade - 30 centigrade Humidity range: 40% - 70% No condensation allowed (4) Those with radiant heat sources and any locations in the direct path of air from air conditioners, heaters (5) Any poorly ventilated location (6) Dusty atmosphere (7) Any tilted location (Installation height difference: 10 mm max. front - rear, 10 mm max. left - right)

Electrical connection
Plug the plug securely into the socket so that there is no problem with the contact in the power supply plug section. Do not use any triplets or extension cords. Do not allow any other machine to stand on or crush the power cord.

Ground connection
Always ground this machine to prevent electrical shock in the unlikely event of electrical leakage.

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CHAPTER 1. MAINTENANCE EXTERIOR COVER REMOVAL

3.

Exterior Cover Removal


1. Bring the Print Cylinder to Position-A and remove the Print Cylinder from the machine. 2. Turn off the power and remove the power cord from the machine. FRONT COVER
Remove mounting screws (M4x8: 2 pcs) from the Hinge, and remove the Hinge. The Front Cover comes off the machine.

Front cover

Hinge

FRONT FRAME COVER


Remove mounting screws (M4x8: 7 pcs) and remove the Front Frame Cover.

Front frame cover

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CHAPTER 1. MAINTENANCE EXTERIOR COVER REMOVAL


REAR COVER
Remove mounting screws (M3x5: 2pcs) of the Connector Lock of the Controller and open the Connector Locks flat against the Controller. Remove screws (M4x8: 4 pcs) and remove the Rear Cover.

Connector lock

Rear cover

MASTER REMOVAL LOWER COVER


Remove the Master Disposal Box. Remove screws (M4x8: 4 pcs) and remove the Master Removal Lower Cover.

Master removal lower cover

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CHAPTER 1. MAINTENANCE EXTERIOR COVER REMOVAL


STAGE COVER
Remove mounting screw (M4x10: 1 pc) from each of the two Hinges of the Stage Cover, and then as shown on the photograph, attach those screws in the secrew holes behind. Remove screw (M4x8: 1 pc) on the Scanner Unit Cover (rear) to detach the Ground Wire from the machine, and then lift the Stage Cover off the machine.

Stage cover

Ground wire

Hinge

Scanner Unit Cover (rear)

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CHAPTER 1. MAINTENANCE EXTERIOR COVER REMOVAL


SCANNER UNIT COVER (LEFT)
Remove mounting screw (M4x8: 4 pcs) and remove the Scanner Unit Cover (left).

Scanner unit cover (left)

SCANNER UNIT COVER (REAR)


Remove the Stage Cover. Remove mounting screw (M4x8: 4 pcs) and remove the Scanner Unit Cover (rear).

Scanner unit cover (rear)

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CHAPTER 1. MAINTENANCE EXTERIOR COVER REMOVAL


SCANNER UNIT COVER (FRONT)
Remove mounting screw (M4x8: 3 pcs) and remove the Scanner Unit Cover (front).

Scanner unit cover (front)

SCANNER UNIT COVER (RIGHT)


Remove Scanner Unit Cover (front) and Scanner Unit Cover (rear). Remove mounting screw (M4x8: 2 pcs) and remove the Scanner Unit Cover (right).

Scanner unit cover (right)

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CHAPTER 1. MAINTENANCE EXTERIOR COVER REMOVAL

4.

Controller (RISORINC2) and SYSTEM PCB


CONTROLLER (RISORINC2)
Remove the Rear Cover. Disconnect three connectors from the Controller (1 on the top and 2 on the bottom of the Controller). Remove screws (M3x6: 2 pcs), and pull the Controller a little bit to the front, just enough to clear the half-pierce, and slide the Controller out of the machine.

Half-pierce

Controller (RISORINC2)

System PCB support bracket A

[Precautions on Reassembly] Place the Controller on top of the System PCB Support Bracket A, and push it in.

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CHAPTER 1. MAINTENANCE EXTERIOR COVER REMOVAL


SYSTEM PCB
Remove the Rear Cover. Remove screws (M3x5: 1 pc), and remove the Wire Harness Support Plate. Disconnect all the Connectors from the System PCB, remove screws (M3x5: 6 pcs), and then remove the System PCB together with the System PCB Support Bracket B. [Precautions on Reassembly] Attach the Wire Harness Support Plate while pushing it down against the wire harness (flat cable) to hold the wire harness firmly in position.

Wire harness support plate

Flat cable (wire harness)

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CHAPTER 1. MAINTENANCE EXTERIOR COVER REMOVAL


SYSTEM PCB SUPPORT BRACKET A
Unplug the connector of the FB Junction Wire Harness from the Junction COnnector, and then detach the Junction Connector from the System PCB Support Bracket A. Remove seven Snap Bands from the System PCB Support Bracket A. Remove screws (M4x6: 5 pcs) and detach the System PCB Support Bracket from the machine.

Snap band

Junction Connector

FB Junction Wire Harness

System PCB support bracket A

Snap band

Snap band

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CHAPTER 1. MAINTENANCE

[Memo]

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CHAPTER 2: MACHINE SUMMARY

Contents
1. 2. Specifications (Metric Model) .................................................................................... 1-2 Specifications (Inch Model) ...................................................................................... 1-6

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CHAPTER 2. MACHINE SUMMARY SPECIFICATIONS (METRIC MODEL)

1.

Specifications (Metric Model)

Reference only

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CHAPTER 2. MACHINE SUMMARY SPECIFICATIONS (METRIC MODEL)

Reference only

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CHAPTER 2. MACHINE SUMMARY SPECIFICATIONS (METRIC MODEL)

Reference only

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CHAPTER 2. MACHINE SUMMARY SPECIFICATIONS (METRIC MODEL)

Reference only

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CHAPTER 2. MACHINE SUMMARY SPECIFICATIONS (INCH MODEL)

2.

Specifications (Inch Model)

Reference only
Not available to U.S.A. (U.S.A. has RN2000 designed only for Letter size)

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CHAPTER 2. MACHINE SUMMARY SPECIFICATIONS (INCH MODEL)

Reference only

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CHAPTER 3: MAIN DRIVE SECTION

Contents
Mechanism ............................................................................................................................ 3-2 1. 2. 3. Main Drive Section .................................................................................................... 3-2 Main Motor Safety Mechanism .................................................................................. 3-3 Print Drum Position Check Mechanism ................................................................... 3-4

Removal and Assembly ........................................................................................................ 3-6 1. 2. 3. Removing the Main Motor Unit .................................................................................. 3-6 Removing the Flat Bed Set Switch ........................................................................... 3-8 Removing the Print Drum Safety Switch ................................................................... 3-9

Adjustment .......................................................................................................................... 3-10 1. Print Drum Position-A Adjustment ......................................................................... 3-10

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CHAPTER 3. MAIN DRIVE SECTION MAIN DRIVE SECTION

Mechanism
1. Main Drive Section
When the Main motor [A] is turned on, the Main pulley [B] rotates and the rotation is transmitted to the Print drum pulley [D] via the Main belt [C]. The Main motor encoder sensor [E] detects the speed and position of the main motor [A].

B A
A: Main motor B: Main pulley C: Main belt D: Print drum pulley E: Main motor encoder sensor

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CHAPTER 3. MAIN DRIVE SECTION MAIN MOTOR SAFETY MECHANISM

2.

Main Motor Safety Mechanism


Two safety switches (Flat bed set switch [A] and Print drum safety switch [B]) prevent the motor from being turned on if parts are not positioned.

A: Flat bed set switch B: Print drum safety switch

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CHAPTER 3. MAIN DRIVE SECTION PRINT DRUM POSITION CHECK MECHANISM

3.

Print Drum Position Check Mechanism


The print drums rotation position is detected by the Main motor encoder sensor referenced to the position A detected by the Position A sensor [A] on the machine and Position A detection plate [B] on the print drum. The encoder counts 2933 pulses for each revolution of the print drum.

A: Position A sensor B: Position A detection plate

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CHAPTER 3. MAIN DRIVE SECTION

[Memo]

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CHAPTER 3. MAIN DRIVE SECTION REMOVING THE MAIN MOTOR UNIT

Removal and Assembly


1. Removing the Main Motor Unit
(1) Position the print drum at position A, turn off the power, and then remove the following covers and components. Front door Front cover Rear cover Controller Main PCB Print positioning unit (2) Reduce the tension on the Paper feed timing belt [A]. Loosen the retaining screws on the Idler A assy [B]. (3) Reduce the tension on the Main belt [C]. Loosen the retaining screws on the Idler B assy [D]. Loosen the retaining screw [L] on the Idler C assy [E], and then remove the mounting screw [M]. * Do not remove the retaining screw [L] on the Idler C assy [E]. (4) Remove the Paper feed timing belt [A] and Main belt [C] from the Main pulley [F]. (5) Unplug one wire harness connector from slot No. CN403 of the Drive PCB, and another wire harness connector at the rear of the machine, close to the Print positioning unit. Then remove the mounting screws (M4 x 8: 6 pcs), and remove the Main motor unit [G].

C G
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CHAPTER 3. MAIN DRIVE SECTION REMOVING THE MAIN MOTOR UNIT


L M E I H

F
Main motor unit

[Precautions on Reassembly] Tension the main belt by aligning the position-A alignment hole [J] on the print drum with the mainpulley position-A alignment hole [K] and then turning the Idler C assy [E] counter-clockwise to apply tension on the Main belt [C] and lock its position. Apply further tension on the Main belt [C] by turning the Idler B assy [D] clockwise.

D E
A: Paper feed timing belt B: Idler A assy C: Main belt D: Idler B assy E: Idler C assy F: Main pulley G: Main motor unit H: Main motor encoder sensor I: Main motor J: Print drum pulley position-A alignment hole K: Main-pulley position-A alignment hole L: Idler C assy retaining screw M: Idler C assy mounting screw 37 RN (Version 1.0)

CHAPTER 3. MAIN DRIVE SECTION REMOVING THE FLAT BED SET SWITCH

2.

Removing the Flat Bed Set Switch


(1) Pull out the print drum and remove the covers. Front door Front cover (2) Unplug the connector [C], remove the mounting screws (M4 x 6: 2 pcs), and then remove the entire Flat bed set switch cover [A]. (3) Remove the E-ring, remove the Torsion spring [E], and then remove the Flat bed set switch [B] together with the sensor bracket [D]. (4) Remove the mounting screws (M3 x 14: 2 pcs) and remove the Flat bed set switch [B].

A: Flat bed set switch cover B: Flat bed set switch C: Connector D: Sensor bracket E: Torsion spring

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CHAPTER 3. MAIN DRIVE SECTION REMOVING THE PRINT DRUM SAFETY SWITCH

3.

Removing the Print Drum Safety Switch


(1) Pull out the print drum. (2) Remove the covers. Front door Front cover (3) Remove the Print drum safety switch cover [B]. (M4 x 6: 2 pcs) (4) Unplug the Connector [C], remove the mounting screws (M3 x 14: 2 pcs), and then remove the Print drum safety switch [A].

A: Print drum safety switch B: Print drum safety switch cover C: Connector

39 RN (Version 1.0)

CHAPTER 3. MAIN DRIVE SECTION PRINT DRUM POSITION-A ADJUSTMENT

Adjustment
1. Print Drum Position-A Adjustment
Checking and adjustment procedure (1) Pull out the print drum and return it back after removing the master attached to it. (2) Open the Scanner table. (3) Start the test mode, and run test mode No. 551 (set drum to position-A). (4) Open the Master disposal gate housing, press down the Clamp open arm plate by hand, and check that it slots smoothly into the groove in the position-A Compensator plate without the print drum moving. (5) If it does not slot smoothly into the position-A Compensator plate or if the print drum moves, run test mode No. 581 (position-A adjustment) to adjust position-A for the print drum. (On the setting procedure, refer to Chapter 16: Test Mode.) (6) Repeat from step (3) until correct print drum position-A is achieved.

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CHAPTER 4: FIRST PAPER FEED SECTION

Contents
Mechanism ............................................................................................................................ 4-2 1. 2. 3. 4. 5. 6. Paper Feed Tray Mechanism ................................................................................... 4-2 Paper Feed Tray Elevation Mechanism ................................................................... 4-3 Paper Feed Tray Safety Mechanism ......................................................................... 4-4 First Paper Feed Drive Mechanism .......................................................................... 4-5 Paper Strip Mechanism ............................................................................................ 4-6 Paper Feed Pressure Adjust Lever .......................................................................... 4-7

Removal and Assembly ........................................................................................................ 4-9 1. 2. 3. 4. 5. 6. 7. 8. 9. Removing the Paper Feed Tray Unit ........................................................................ 4-9 Removing the Paper Width Potentiometer, Paper Detection Sensor, and Paper Size Detection Sensor ............................................................ 4-10 Removing the Pickup and Scraper Rollers ........................................................... 4-12 Removing the Feed Tray Descent Button and Upper Limit Sensor ..................... 4-13 Removing the Paper Feed Clutch ......................................................................... 4-14 Removing the Pickup Roller Shaft Assy ............................................................... 4-15 Removing the Elevator Motor ................................................................................. 4-16 Removing the Paper Feed Tray Lower Safety Switch ........................................... 4-17 Removing the Stripper Unit ................................................................................... 4-18

10. Removing the Stripper Pad Assy .......................................................................... 4-19 Adjustment .......................................................................................................................... 4-20 1. 2. 3. 4. Upper Limit Sensor Position Adjustment ............................................................. 4-20 Stripper Unit Adjustment ........................................................................................ 4-21 Paper-Feed Clutch ON Timing Adjustment ........................................................ 4-22 Paper-Feed Clutch OFF Timing Adjustment ....................................................... 4-22

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CHAPTER 4. FIRST PAPER FEED SECTION PAPER FEED TRAY MECHANISM

Mechanism
1. Paper Feed Tray Mechanism
1) Horizontal positioning (horizontal print positioning) of the paper feed tray
The Paper feed tray [A] can be moved 10 mm left or right by turning the Adjustment dial [B] manually (for paper widths up to 274 mm, and 5 mm for paper widths between 275 mm and 290 mm).

2) Print paper size detection


The Paper feed tray [A] uses the Paper width potentiometer [D] and Paper size detection sensor [C] to determine the size of the paper loaded in the Paper feed tray [A]. The Paper width potentiometer [D] checks the paper width, and the Paper size detection sensor [C] determines the paper length (portrait or landscape orientation).

A B

C D

A: Paper feed tray B: Adjustment dial C: Paper size detection sensor D: Paper width potentiometer View of underside of the paper feed tray with the cover off

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CHAPTER 4. FIRST PAPER FEED SECTION PAPER FEED TRAY ELEVATION MECHANISM

2. Paper Feed Tray Elevation Mechanism


The presence of paper loaded in the Paper feed tray [A] is detected by the Paper detection sensor [B]. When light is received at the Paper detection sensor [B] (paper present), pressing the START key activates the Elevator motor [E] and raises the Paper feed tray [A] until the Scraper assembly [C] blocks the light beam of the Upper limit sensor [D]. During printing, the Elevator motor [E] is activated until the light to the upper limit sensor [D] is blocked. When there is no longer paper in the Paper feed tray [A] and light is not received by the Paper detection sensor [B], the Elevator motor [E] activates and lowers the Paper feed tray [A] until the light beam of the Lower limit sensor [F] is blocked. If the Feed tray descent button [G] is pressed while in print standby mode, the Elevator motor [E] activates and lowers the Paper feed tray [A] until either the light beam of the Lower limit sensor [F] is blocked or the Feed tray descent button [G] is pressed once again. The Elevator motor [E] does not operate even if the Feed tray descent button [G] is pressed while the print drum is removed.

A
A: Paper feed tray B: Paper detection sensor C: Scraper assembly D: Upper limit sensor E: Elevator motor F: Lower limit sensor G: Feed tray descent button 43 RN (Version 1.0)

CHAPTER 4. FIRST PAPER FEED SECTION PAPER FEED TRAY SAFETY MECHANISM

3.

Paper Feed Tray Safety Mechanism


The Paper feed tray lower safety switch [C] ensures safety while the paper feed tray is being raised or lowered or is stationary. If the Safety switch actuator plate [B] is depressed, the Paper feed tray lower safety switch [C] trips. An error in the paper feed tray is then assumed, and the machine stops.

B
Press

A: Paper feed tray B: Safety switch actuator plate C: Paper feed tray lower safety switch

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CHAPTER 4. FIRST PAPER FEED SECTION FIRST PAPER FEED DRIVE MECHANISM

4.

First Paper Feed Drive Mechanism


When the printing operation commences, the Main motor [A] activates to rotate the print drum via the Main belt [C]. When the Main motor [A] is running, the Paper feed timing belt [D] continuously drives the pulley on the Paper feed clutch [E]. When the print drum rotates through a preset angle (the angle set for paper feed clutch activation by test mode No. 481) from position A, the Paper feed clutch [E] is activated. The Scraper roller [G] and Pickup roller [H] rotate to feed the paper inside the machine from the paper feed tray. The paper fed inside the machine blocks the light beam between Paper sensors [I] and [L]. The print drum then rotates through a preset angle (the angle set for paper feed clutch deactivation angle adjustment by test mode Nos. 482 to 485), and the Paper feed clutch [E] is deactivated, completing the first stage paper feed. The leading edge of the paper rests against the Guide roller [J] and Timing roller [M] and stops with the paper bulging. If the print drum rotates as far as the first paper feed jam detection angle after the Paper feed clutch [E] has been activated, Paper sensors [I] and [L] check to detect the presence or absence of paper. After the paper has been fed to the second paper feed stage, a one-way clutch acts on the Scraper roller [G] and Pickup roller [H] so that they spin, to prevent the first paper feed area from applying brake on the paper.

E C

B D A

A: Main motor B: Main pulley C: Main belt D: Paper feed timing belt E: Paper feed clutch F: Pickup roller shaft G: Scraper roller H: Pickup roller I: Paper sensor (receive) J: Guide roller K: Stripper pad L: Paper sensor (send) M: Timing roller

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CHAPTER 4. FIRST PAPER FEED SECTION PAPER STRIP MECHANISM

5.

Paper Strip Mechanism


The paper loaded in the paper feed tray is fed in between the Pickup roller [A] and Stripper pad [B] by the rotating scraper roller. The paper is then separated by the Pickup roller [A] and Stripper pad [B] to ensure that only the uppermost sheet is sent into the machine. The Stripper pad [B] is pressed against the Pickup roller [A] by the force of the Stripper spring [C], and the resistance applied to the paper fed in separates the sheet. The stripper-pad angle and stripping pressure can be adjusted by the user using the Stripper pad angle adjust knob [D] and Stripper pressure adjust knob[E].

Stripper pad angle adjust knob

D E

Stripper pressure adjust knob

A: Pickup roller B: Stripper pad C: Stripper spring D: Stripper pad angle adjust knob E: Stripper pressure adjust knob

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CHAPTER 4. FIRST PAPER FEED SECTION PAPER FEED PRESSURE ADJUST LEVER

6.

Paper Feed Pressure Adjust Lever


The Paper feed pressure adjust lever [A] is located on the left-hand side of the scraper unit, and moving this to the left or right switches the scraper-roller paper-feed pressure (scraper pressure) from NORMAL (weak) and CARD (strong). Moving the pressure adjust lever to the right increases the paper-feed pressure (scraper pressure).

A: Pressure adjust lever B: Pressure adjust lever spring C: Pressure arm spring D: Pressure arm

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CHAPTER 4. FIRST PAPER FEED SECTION

[Memo]

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CHAPTER 4. FIRST PAPER FEED SECTION REMOVING THE PAPER FEED TRAY UNIT

Removal and Assembly


1. Removing the Paper Feed Tray Unit
(1) Lower the Paper feed tray [F] fully. (2) Remove the rear cover. (3) Unplug the connector [A] on the wire harness [B] from the Paper feed tray [F]. Remove the mounting screw (M4 x 6: 1 pc) and remove the ground screw [D]. Cut the wire harness band [C], and then pull the wire harness [B] towards the paper feed tray. (4) Remove the E-rings [E] from the mountings on both sides of the paper feed tray, and remove the Paper feed tray [F]. [Precautions on Reassembly] The wire harness on the paper feed tray must be secured with the harness band as before. Do not forget to attach the ground wire.

A: Connector B: Wire harness C: Wire harness band D: Ground screw E: E-ring F: Paper feed tray 49 RN (Version 1.0)

CHAPTER 4. FIRST PAPER FEED SECTION REMOVING THE PAPER WIDTH POTENTIOMETER, PAPER DETECTION SENSOR, AND PAPER SIZE DETECTION SENSOR

2.

Removing the Paper Width Potentiometer, Paper Detection Sensor, and Paper Size Detection Sensor
(1) Remove the paper feed tray unit. (2) Remove the E-ring and remove the Adjustment dial [A]. (3) Remove the E-rings [C] and bearings from both sides of the Slide shaft [B]. (4) Remove the shoulder screws (2 pcs) [D] and remove the paper-feed mounting plate [E]. (5) Remove the Paper-feed-tray bottom front cover [F] (mounting screws M4 x 6: 4 pcs) and Paper-feedtray bottom rear cover [G] (mounting screws M3 x 8: 3 pcs). (6) Unplug the connector and remove the Paper detection sensor [H] while expanding the mounting clips. (7) Unplug the connector and remove the Paper size detection sensor [I] while expanding the mounting clips. (8) Remove the mounting screws (mounting screws M3 x 8: 3 pcs), unplug the connector, and then remove the Paper width potentiometer [K] together with the Potentiometer base [J].

B A C

A: Adjustment dial B: Slide shaft C: Bearing D: Shoulder screw E: Paper-feed mounting plate

F: Paper-feed-tray bottom front cover G: Paper-feed-tray bottom rear cover H: Paper detection sensor I: Paper size detection sensor

J: Potentiometer base K: Paper width potentiometer L: Spur gear M: Potentiometer shaft

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CHAPTER 4. FIRST PAPER FEED SECTION REMOVING THE PAPER WIDTH POTENTIOMETER, PAPER DETECTION SENSOR, AND PAPER SIZE DETECTION SENSOR

H I

[Precautions on Reassembly] With the fence opened fully, mount the Spur gear [L] and the flat face of the potentiometer shaft [M] facing the printer body. (See photograph below.) Start test mode, and first set the fence position to 105 mm and activate test mode No. 450 (potentiometer adjustment 105 mm). Next, set the fence position to 210 mm and activate test mode No. 451 (potentiometer adjustment 210 mm). After adjusting the potentiometer, check that each paper size is correctly detected.

Printer main body side

Printer main body side

Flat face of the shaft

4 11 RN (Version 1.0)

CHAPTER 4. FIRST PAPER FEED SECTION REMOVING THE PICKUP AND SCRAPER ROLLERS

3.

Removing the Pickup and Scraper Rollers


Removing the Scraper roller (1) Lower the paper feed tray fully and switch off the power. (2) Remove the Lock ring [E] on the Scraper roller shaft [C]. (3) Slide the Scraper roller [D] off the Scraper roller shaft [C]. Removing the Pickup roller (1) Lower the paper feed tray fully and switch off the power. (2) Remove the Lock ring [E] on the Pickup roller shaft [A]. (3) Slide the Pickup roller [B] off the Pickup roller shaft [A]. [Precautions on Reassembly] The scraper and pickup roller contain a one-way clutch. If mounted in the opposite direction, the rollers will not rotate even when the pickup roller shaft rotates. When mounted on the shafts correctly, the rollers spin freely in the direction shown on the diagram below when rotated manually.

A B

C D

A: Pickup roller shaft B: Pickup roller C: Scraper roller shaft D: Scraper roller E: Lock ring

4 12 RN (Version 1.0)

CHAPTER 4. FIRST PAPER FEED SECTION REMOVING THE FEED TRAY DESCENT BUTTON AND UPPER LIMIT SENSOR

4.

Removing the Feed Tray Descent Button and Upper Limit Sensor
(1) Remove the Master-removal lower cover. (mounting screws M4 x 8: 4 pcs) (2) Unplug connector [A], remove the mounting screw (M4 x 8: 1 pc), and then remove the Upper limit sensor [B] together with the Upper limit sensor bracket [C]. (3) Remove the mounting screws (M4 x 8: 2 pcs), unplug the connector [D], and then remove the Feed tray descent button [E] together with its mounting bracket [F]. [Precautions on Reassembly] Adjust the position of the upper limit sensor.

A: Upper limit sensor connector B: Upper limit sensor C: Upper limit sensor bracket D: Feed tray descent button connector E: Feed tray descent button F: Mounting bracket

4 13 RN (Version 1.0)

CHAPTER 4. FIRST PAPER FEED SECTION REMOVING THE PAPER FEED CLUTCH

5.

Removing the Paper Feed Clutch


(1) Remove the rear cover. (2) Loosen the retaining screw [C] on the Paper timing belt tension bracket [B], and reduce the tension on the Paper feed timing belt [E]. (3) Unplug the connector [F], remove the E-ring, and remove the Paper feed clutch [D]. [Precautions on Reassembly] Align the flat face of the Pickup roller shaft [G] with that on the Paper feed clutch [D]. Engage the slot [H] on the clutch with the clutch lock plate [I] on the machine to prevent the paper feed clutch unit from rotating.

B A

F D G

A: Timing gear B: Timing belt tension bracket C: Retaining screw D: Paper feed clutch E: Paper feed timing belt F: Connector G: Pickup roller shaft H: Paper feed clutch slot I: Clutch lock plate

4 14 RN (Version 1.0)

CHAPTER 4. FIRST PAPER FEED SECTION REMOVING THE PICKUP ROLLER SHAFT ASSY

6.

Removing the Pickup Roller Shaft Assy


(1) Remove the covers. Rear cover Master-removal lower cover (2) Remove the pickup and scraper rollers. (3) Remove the upper limit sensor. (4) Remove the paper feed clutch. (5) Remove the E-rings and bearing bushes [A] on either end of the Pickup roller shaft. (6) Remove the mounting screw (4 x 8: 1 pc) on the shaft bracket [B], remove the bracket, and then remove the Pickup roller shaft assy [C] towards you. [Precautions on Reassembly] Adjust the position of the upper limit sensor.

A B A

A: Bearing bush B: Shaft bracket C: Pickup roller shaft assy 4 15 RN (Version 1.0)

CHAPTER 4. FIRST PAPER FEED SECTION REMOVING THE ELEVATOR MOTOR

7.

Removing the Elevator Motor


(1) Lower the paper feed tray fully, switch off the power, and pull out the print drum. (2) Remove the covers. Front door Front cover Master-removal lower cover (3) Squeeze the wire harness band [E] from the inside, detach from the side frame, and then unplug the two connectors [F] of the Master removal unit. (4) Remove the mounting screws (M4 x 6: 4 pcs), and hang free the Drive PCB [A] together with its mounting bracket. (5) Remove the Elevator springs [G] from both sides of the Paper feed tray to prevent the tray from springing up. (6) Remove the mounting screws (M4 x 8: 2 pcs), unplug the connector [D] of the Elevator motor [B], and remove the Elevator motor [B].

C
A: Drive PCB B: Elevator motor C: Mounting screw 4 16 RN (Version 1.0) D: Connector of elevator motor E: Wire harness band

F: Connector of master removal unit G: Elevator spring

CHAPTER 4. FIRST PAPER FEED SECTION REMOVING THE PAPER FEED TRAY LOWER SAFETY SWITCH

8.

Removing the Paper Feed Tray Lower Safety Switch


(1) Remove the screws (Shoulder screw, M4 x 30: 2 pcs), securing the printer to the Risograph stand. (2) Remove the rear cover. (3) Slide out the machine from the Risograph stand (in the direction shown by the arrow in the photograph) far enough to allow a screwdriver to be inserted in the mounting screws on the Grip handle [A]. Make sure that the rubber feet do not slip off the Risograph stand. (4) From underneath the machine, remove the mounting screws (M4 x 8: 2 pcs), and remove the Grip handle [A]. (5) Unplug the top connector [B]. (6) Unplug the bottom connector [C] from the stay [D]. (7) Remove the mounting screws (M3 x 14: 2 pcs), and remove the Paper feed tray lower safety switch [E].

A D B

A: Grip andle B: Top connector C: Bottom connector D: Stay E: Paper feed tray lower safety switch

4 17 RN (Version 1.0)

CHAPTER 4. FIRST PAPER FEED SECTION REMOVING THE STRIPPER UNIT

9.

Removing the Stripper Unit


(1) Lower the paper feed tray fully. (2) Place a finger on the top of the Stripper unit [A] and pull it forward to remove it. [Precautions on Reassembly] Set the Stripper pad assy [B] in the Paper guide plate [C] while it is pushed down. Adjust the stripper pressure and stripper angle.

Hold here and pull forward.

C A
A: Stripper unit B: Stripper pad assy C: Paper guide plate

4 18 RN (Version 1.0)

CHAPTER 4. FIRST PAPER FEED SECTION REMOVING THE STRIPPER PAD ASSY

10. Removing the Stripper Pad Assy


(1) Lower the paper feed tray fully, and remove the stripper unit. (2) Lift up the Stripper pad assy [A] by hand and remove it. [Precautions on Reassembly] Attach the Stripper pad [B] by pushing the face indicated by arrow against the face indicated by arrow on the Stripper pad base [C].

A B

A: Stripper pad assy B: Stripper pad C: Stripper pad base D: Stripper pad cover

4 19 RN (Version 1.0)

CHAPTER 4. FIRST PAPER FEED SECTION UPPER LIMIT SENSOR POSITION ADJUSTMENT

Adjustment
1. Upper Limit Sensor Position Adjustment
Procedure (1) Remove the paper on the paper feed tray. (2) Start test mode No. 453 (elevator servo) and raise the paper feed tray and bringing it to a complete stop. (3) Once it is stopped, check that the gap between the Pickup roller [C] and the Paper feed tray [E] is 1.0 mm 0.3 mm. (4) If the gap is not within the specifications, detach the master removal box and remove the Masterremoval lower cover. (5) Loosen the mounting screw [B] on the Upper limit sensor bracket [A], and adjust by sliding the upper limit sensor up or down. Symptoms If the upper limit sensor is positioned too high, the paper-feed pressure is increased and multiple sheet feeding is more likely to arise. Conversely, if it is positioned too low, the paper-feed pressure is reduced and non-feeding is more likely to arise.

A: Upper limit sensor bracket B: Upper limit sensor bracket mounting screw C: Pickup roller D: Scraper roller E: Paper feed tray

1.0 0.3

E
4 20 RN (Version 1.0)

CHAPTER 4. FIRST PAPER FEED SECTION STRIPPER UNIT ADJUSTMENT

2.

Stripper Unit Adjustment


Procedure (1) Slide the Paper feed pressure adjust lever to suit the paper type before printing. (2) If multiple feeding or non-feeding occurs, adjust the stripper-pad angle and pressure. 1) Multiple feeding Turn the Stripper pad angle adjust knob [A] clockwise to increase the stripper-pad angle (raise the pad more vertically). Turn the Stripper pressure adjust knob [B] clockwise to increase the stripper pressure. 2) Non-feeding Turn the Stripper pad angle adjust knob [A] counter-clockwise to reduce the stripper-pad angle (lower the pad more horizontally). Turn the Stripper pressure adjust knob [B] counter-clockwise to reduce the stripper pressure.

Normal (24 degrees)

Adjustable from 14 degrees to 28 degrees Reduced angle Increased angle

Stronger Normal Weaker

Strong A: Stripper pad angle adjust knob B: Stripper pressure adjust knob

Weak

4 21 RN (Version 1.0)

CHAPTER 4. FIRST PAPER FEED SECTION PAPER-FEED CLUTCH ON TIMING ADJUSTMENT

3.

Paper-Feed Clutch ON Timing Adjustment


Check and adjustment procedure (1) Test print to check that paper is fed smoothly. (2) If the first stage paper feed timing is not synchronized, adjust using test mode No. 481 (paperfeed-clutch activation drum angle adjustment). (For the setting procedure, refer to Chapter 16: Test Modes.) (3) Repeat from step (1) until correct timing is achieved. Symptoms If the first stage paper feed timing is not synchronized, paper jamming or inconsistent print registration may occur.

4.

Paper-Feed Clutch OFF Timing Adjustment


Check and adjustment procedure (1) Test print to check that printing is performed smoothly. (2) If the paper is excessively or insufficiently buckled and printing is not performed smoothly, run test modes No. 482485 (paper-feed-clutch deactivation drum angle adjustment) according to the users paper selection setting. (For the setting procedure, refer to Chapter 16: Test Modes.) (3) Repeat from step (1) until correct timing is achieved. Symptoms If the paper is excessively or insufficiently buckled, paper may not be fed to the second stage and paper jamming may occur.

4 22 RN (Version 1.0)

CHAPTER 5: SECOND PAPER FEED SECTION

Contents
Mechanism ............................................................................................................................ 5-2 1. 2. Second Paper Feed Mechanism .............................................................................. 5-2 Vertical Print Positioning Mechanism ....................................................................... 5-4

Removal and Assembly ........................................................................................................ 5-6 1. 2. 3. 4. 5. 6. 7. 8. Removing the Guide Roller Assy ............................................................................ 5-6 Removing the Paper Guide Plate Assy ................................................................... 5-7 Removing the Paper Sensor .................................................................................... 5-9 Removing the Timing Roller .................................................................................. 5-10 Removing the Print-Positioning Unit ..................................................................... 5-12 Removing the Vertical Centering Sensor .............................................................. 5-13 Removing the Print-Positioning Pulse Motor ........................................................ 5-14 Removing the Timing Gear ................................................................................... 5-15

Adjustment .......................................................................................................................... 5-16 1. Timing Cam Mounting Position ............................................................................. 5-16

51 RN (Version 1.0)

CHAPTER 5. SECOND PAPER FEED SECTION SECOND PAPER FEED MECHANISM

Mechanism
1. Second Paper Feed Mechanism
When the main motor operates during printing, the Main cam [A] rotates clockwise. The Main cam [A] rotation moves the Timing gear [C] via the Cam follower arm [B], and this rotates the Timing cam [D]. The Timing cam [D] contains a one-way clutch, so that when it rotates counter-clockwise, the rotation is transferred to the Timing roller [G], but when it rotates clockwise, the rotation is not transferred. The Load spring [H] continuously applies a load to the Timing roller [G] to ensure that the Timing roller [G] stops immediately when it is not rotated. The Timing roller [G] rotation also rotates the Guide roller [F] clockwise. As the Timing cam [D] rotates, the protrusion pushes against the Timing lever [E] and raises the Guide roller [F]. During printing, the Guide roller [F] moves down and contacts the Timing roller [G] during the first paper feed operation, and then rises once the Timing roller [G] stops rotating.

E D

B
A: Main cam B: Cam follower arm C: Timing gear D: Timing cam E: Timing lever F: Guide roller G: Timing roller H: Load spring

5 2 RN (Version 1.0)

CHAPTER 5. SECOND PAPER FEED SECTION SECOND PAPER FEED MECHANISM

Drum Position-A At Drum position-A, the protrusion on the Timing cam [B] pushes against the Timing lever [C] to raise the Guide roller [D].

D C

B E A

First paper feed start When the first paper feed starts and the paper is fed in, the Timing gear [E] is rotated in the direction, indicated by arrow mark, by the Main cam [A]. This rotates the Timing cam [B], which lowers the Timing lever [C] to lower the Guide roller [D].

Second paper feed start When the first paper feed ends, the Timing gear [E] is rotated by the Main cam [A] in the direction indicated by the arrow mark. This rotates the Timing cam [B] and also causes the timing roller [D] to rotate, feeding the paper. (The Guide roller [D] rotates on contact with the Timing roller [F].)

A: Main cam B: Timing cam C: Timing lever D: Guide roller E: Timing gear F: Timing roller

53 RN (Version 1.0)

CHAPTER 5. SECOND PAPER FEED SECTION VERTICAL PRINT POSITIONING MECHANISM

2.

Vertical Print Positioning Mechanism


Pressing the < > or < > print position keys on the panel activates the Print positioning pulse motor [A], which rotates the Print positioning adjuster cam [B] to move the Print positioning plate assy [C]. The Print positioning plate assy [C] motion moves the Print positioning lever assy [E], changing the timing with the main cam. The second paper feed (timing roller rotation start) timing is thus changed, changing the vertical printing position. The Vertical centering sensor [D] checks the centering of the print positioning.

A: Print-positioning pulse motor B: Print-positioning cam (with the spiral groove on its back side) C: Print-positioning plate assy D: Vertical centering sensor E: Print-positioning lever assy

54 RN (Version 1.0)

CHAPTER 5. SECOND PAPER FEED SECTION VERTICAL PRINT POSITIONING MECHANISM


1) Pressing the < > (up) key on the panel

When the < > key is pressed, the printpositioning adjuster cam [C] and printpositioning adjuster plate assy [B] move in the directions indicated by arrows.

A D B

The movement of the Print-positioning plate assy [B] also moves the Print-positioning lever assy [D], and the bearing [E] in contact with the Main cam [A] moves in the direction indicated by arrows. The timing of the contact of the bearing [E] against the Main cam [A] is delayed, causing the second paper feed timing to delay, and moves the print position up.

C E A

2)

Pressing the <

> (down) key on the panel

When the < > key is pressed, the Printpositioning cam [C] and Print-positioning plate assy [B] move in the directions indicated by arrows. The movement of the Print-positioning plate assy [B] also moves the Print-positioning lever assy [D], and the bearing [E] in contact with the Main cam [A] moves in the direction indicated by arrows. The timing of the contact of the bearing [E] against the Main cam [A] is advanced, causing the second paper feed timing to advance, and moves the print position down.

A
A: Main cam B: Print-positioning plate assy C: Print-positioning cam D: Print-positioning lever assy E: Bearing 55 RN (Version 1.0)

CHAPTER 5. SECOND PAPER FEED SECTION REMOVING THE GUIDE ROLLER ASSY

Removal and Assembly


1. Removing the Guide Roller Assy
(1) Pull out the print drum and remove the following covers. Front door Front cover Rear cover (2) Unplug the three connectors and remove the controller. (mounting screws M4 x 6: 2 pcs) (3) Remove the Guide roller spring [A]. (4) Remove the Timing lever assy [B]. (mounting screws M4 x 8: 1 pc) (5) Remove the E-rings [C] and bearing bushes [D] at both front and rear, and then remove the Guide roller assy [E].

A: Guide roller spring B: Timing lever assy C: E-ring D: Bearing bush E: Guide roller assy

56 RN (Version 1.0)

CHAPTER 5. SECOND PAPER FEED SECTION REMOVING THE PAPER GUIDE PLATE ASSY

2.

Removing the Paper Guide Plate Assy


(1) Pull out the print drum and remove the following covers. Front door Front cover Rear cover Master-removal lower cover (2) Remove the following components. Paper feed tray unit Stripper unit Paper feed clutch Pickup roller shaft assy Elevator motor Guide roller assy (3) Unplug the connectors from the Main PCB and remove the Main PCB together with its mounting bracket. (mounting screws M3 x 6: 5 pcs) (4) Loosen the retaining screws, and remove Guard plate F [A] and Guard plate R [B]. (5) Remove Elevator rack front [C] and Elevator rack rear [D]. (mounting screws M4 x 8: 4 pcs each)

A: Guard plate F B: Guard plate R C: Elevator rack front D: Elevator rack rear

57 RN (Version 1.0)

CHAPTER 5. SECOND PAPER FEED SECTION REMOVING THE PAPER GUIDE PLATE ASSY
(6) Unplug the connector from the Paper guide plate [A], remove the mounting screws (M4 x 8: 7 pcs), and then remove the Paper guide plate [A].

A
Enlarged view

[Precautions on Reassembly] Hook the Paper guide plate [A] onto the timing roller bearing bushes [B]. (See enlarged view.) Align the half-pierced sections of the front and rear elevator racks. Align the gear height for the front and rear elevator racks.

Raise the front and rear elevator racks fully to disengage the gears, and then lower them while aligning the height.

A: Paper guide plate B: Bearing bush 58 RN (Version 1.0)

CHAPTER 5. SECOND PAPER FEED SECTION REMOVING THE PAPER SENSOR

3.

Removing the Paper Sensor


(1) Pull out the print drum and remove the following covers. Front door Front cover Rear cover Master-removal lower cover (2) Remove the following components. Paper feed tray unit Stripper unit Paper feed clutch Pickup roller shaft assy Elevator motor Guide roller assy Paper guide plate (3) Unplug the Paper sensor connector [A] from the Paper guide plate [F]. (4) Remove the Paper sensor (send) [B] mounting screw (M3 x 8: 1 pc) and Paper sensor (receive) [C] mounting screw (M3 x 8: 1 pc), remove the Paper-sensor covers [D] and [E], and then remove Paper sensors [B] and [C] from the Paper guide plate [F]. [Precautions on Reassembly] Hook the Paper sensors onto the retaining brackets of the Paper guide plate.

A: Connector B: Paper sensor (send) C: Paper sensor (receive) D: Paper-sensor cover (send) E: Paper-sensor cover (receive) F: Paper guide plate

59 RN (Version 1.0)

CHAPTER 5. SECOND PAPER FEED SECTION REMOVING THE TIMING ROLLER

4.

Removing the Timing Roller


(1) Remove the following covers. Front door Front cover Rear cover Master-removal lower cover (2) Remove the following components. Paper feed tray unit Stripper unit Paper feed clutch Pickup roller shaft assy Elevator motor Guide roller assy Paper guide plate (3) Remove the E-ring from the rear of the Timing roller [A], then remove the Timing cam [B]. (4) Remove the E-ring and collar [C] from the front of the Timing roller [A], then remove the Load spring [D]. (5) Remove the E-rings and bearing bushes [E] from both ends of the Timing roller [A], and then remove the Timing roller [A]. [Precautions on Reassembly] Note the direction in which the load spring is mounted. (See diagram.) [Adjustment after Reassembly] Adjust the timing cam mounting position.

5 10 RN (Version 1.0)

CHAPTER 5. SECOND PAPER FEED SECTION REMOVING THE TIMING ROLLER

D C

A E

Load spring mounting direction

A: Timing roller B: Timing cam C: Collar D: Load spring E: Bearing bush

5 11 RN (Version 1.0)

CHAPTER 5. SECOND PAPER FEED SECTION REMOVING THE PRINT-POSITIONING UNIT

5.

Removing the Print-Positioning Unit


(1) Remove the rear cover. (2) Remove the controller. (3) Remove the Timing gear spring [A]. (4) Unplug the connectors on the Vertical centering sensor [B] and Print-positioning pulse motor [C]. (5) Remove the E-ring on the Cam follower arm [D], and remove the Cam follower arm [D] and Washers [F] (one each on the front and rear of the Cam follower arm [D]) from the Timing gear [E]. (6) Remove the mounting screws (M4 x 8: 8 pcs) on the Print-positioning unit [G], and then remove the Print-positioning unit [G]. [Precautions on Reassembly] When mounting the print-positioning unit [G], the Timing gear [E] should be turned all the way in the clockwise direction. [Adjustment after Reassembly] Adjust the timing cam mounting position.

A: Timing gear spring B: Vertical centering sensor C: Print-positioning pulse motor D: Cam follower arm E: Timing gear F: Washer G: Print-positioning unit 5 12 RN (Version 1.0)

CHAPTER 5. SECOND PAPER FEED SECTION REMOVING THE VERTICAL CENTERING SENSOR

6.

Removing the Vertical Centering Sensor


(1) Remove the rear cover. (2) Unplug the connector, remove the mounting screw (3 x 6: 1 pc), and then remove the Vertical centering sensor [B] together with the Vertical centering sensor bracket [C]. [Precautions on Reassembly] Align the two faces of the Vertical centering sensor bracket [C] as shown in the photograph below.

Align faces.

C
A: Print-positioning base unit B: Vertical centering sensor C: Vertical centering sensor bracket

5 13 RN (Version 1.0)

CHAPTER 5. SECOND PAPER FEED SECTION REMOVING THE PRINT-POSITIONING PULSE MOTOR

7.

Removing the Print-Positioning Pulse Motor


(1) Remove the rear cover. (2) Remove the following components. Controller Timing gear spring Print-positioning unit [A] (3) Remove the E-ring and remove the Print-positioning cam [B]. (4) Remove the E-ring and remove the Print-positioning intermediate gear [C]. (5) Remove the mounting screws (M3 x 6: 2 pcs) on the Print-positioning pulse motor [D], and then remove the Print-positioning pulse motor [D]. [Precautions on Reassembly] Insert the Print-positioning plate shaft [F] into the spiral groove [G] on the Print-positioning cam [B].

A C

E D

A: Print-positioning unit B: Print-positioning cam C: Print-positioning intermediate gear D: Print-positioning pulse motor E: Print-positioning plate assy F: Print-positioning plate assy pin G: Spiral groove on the Print-positioning cam 5 14 RN (Version 1.0)

CHAPTER 5. SECOND PAPER FEED SECTION REMOVING THE TIMING GEAR

8.

Removing the Timing Gear


(1) Remove the rear cover. (2) Remove the following components. Controller Guide roller spring Timing cam [A] Timing gear spring [B] Print-positioning unit [C] (3) Remove the E-ring from the Timing gear shaft [E] and remove the Timing gear [D]. [Precautions on Reassembly] Adjust the mounting position of the timing cam.

A D

B C

E
A: Timing cam B: Timing gear spring C: Print-positioning unit D: Timing gear E: Timing gear shaft 5 15 RN (Version 1.0)

CHAPTER 5. SECOND PAPER FEED SECTION TIMING CAM MOUNTING POSITION

Adjustment
1. Timing Cam Mounting Position
Procedure
(1) Move the print drum to position A, centralize the printing position, switch off the power, and then remove the rear cover. (2) With the positioning marks aligned on the Main cam and print-positioning unit, check that the positioning marks [C] are aligned on the Timing gear [B] and Timing cam [A]. (See photograph 1.) * The alignment may be offset in the direction shown in photograph 2, but not in the direction shown in photograph 3. (3) If not aligned, remove the E-ring from the timing roller shaft and remove the timing cam [A]. (4) Mount the Timing cam [A] and Timing gear [B] with the positioning marks [C] aligned. Symptoms If the timing cam is incorrectly positioned, the timing of the guide rollers vertical movement will be off, and paper jamming, print registration problems, or ghosting may occur.

Photograph 1

A: Timing cam B: Timing gear C: Positioning marks

YES
Photograph 2 Photograph 3

NO

5 16 RN (Version 1.0)

CHAPTER 6: PRESS SECTION

Contents
Mechanism ............................................................................................................................ 6-2 1. 2. Press Mechanism .................................................................................................... 6-2 Pressure Control Mechanism .................................................................................. 6-4

Removal and Assembly ........................................................................................................ 6-5 1. 2. 3. 4. Removing the Pressure Roller ................................................................................. 6-5 Removing the Pressure Solenoid ............................................................................ 6-6 Removing the Pressure Lever Assy ........................................................................ 6-7 Removing the Pressure Control Motor and Print Pressure Control Sensor ........... 6-8

Adjustment .......................................................................................................................... 6-10 1. Mounting Position of the Pressure Lever Assy .................................................... 6-10

61 RN (Version 1.0)

CHAPTER 6. PRESS SECTION PRESS MECHANISM

Mechanism
1. Press Mechanism
The main motor activates when printing begins, and the Pressure solenoid [F] activates once the print drum rotates through 40. As the clamp plate base on the print drum approaches the pressure roller, the protrusion on the Pressure cam [A] pushes against Pressure lever A [B] to rotate it clockwise. This rotary motion causes Pressure lever A [B] to push against Pressure lever B [C], and the Solenoid lever [G] separates from Pressure lever B [C] and descends. Once the protrusion on the Pressure cam [A] has passed, pressure lever A [B] rotates counter-clockwise. Likewise, Pressure lever B [C] is pulled by the tension of the Pressure spring [D] and Second pressure spring [E], and rotates in unison with Pressure lever A [B]. The Pressure shaft [H] fixed to Pressure lever B [C] therefore also rotates counter-clockwise. The pressure roller therefore rises and is pressed against the print drum. During printing, the Pressure cam [A] pushes against Pressure lever A [B] and lowers the pressure roller to prevent the pressure roller from touching the print drum clamp plate base. The Pressure solenoid [F] remains activated. After printing is complete, the Pressure solenoid [F] is deactivated when the print drum reaches the 135 position.

A B

62 RN (Version 1.0)

CHAPTER 6. PRESS SECTION PRESS MECHANISM


C B A

Pressure roller is raised

Pressure roller is lowered

A: Pressure cam B: Pressure lever A C: Pressure lever B D: Pressure spring E: Second pressure spring F: Pressure solenoid G: Solenoid lever H: Pressure shaft

63 RN (Version 1.0)

CHAPTER 6. PRESS SECTION PRESSURE CONTROL MECHANISM

2.

Pressure Control Mechanism


Pressing the < > or < > print density keys on the panel activates the Pressure control motor [A] and moves the Print pressure gear assy [D]. The movement of the Print pressure gear assy [D] varies the tension of the second pressure spring [B]. This alters the pressure acting on Pressure lever B [C], and varies the print density by varying the pressure of the pressure roller against the print drum. The pressure control motor is not actually activated until the START key is pressed. The printing pressure will vary depending on the printing speed and print density settings, the ink color, the length of time the print drum remains standing, and the print drums internal temperature. The Print pressure control sensor [E] checks the standard printing pressure position.

A: Pressure control motor B: Second pressure spring C: Pressure lever B D: Print pressure gear assy E: Print pressure control sensor

64 RN (Version 1.0)

CHAPTER 6. PRESS SECTION REMOVING THE PRESSURE ROLLER

Removal and Assembly


1. Removing the Pressure Roller
(1) Pull out the print drum. (2) Insert a screwdriver through the opening in the front frame of the machine, and remove the retaining screw [B]. (3) Slide the Pressure roller [A] forward until the bearing [C] disengages from the Pressure roller bracket [D], and then lift upward to remove it.

A: Pressure roller B: Retaining screw C: Bearing D: Pressure roller bracket

65 RN (Version 1.0)

CHAPTER 6. PRESS SECTION REMOVING THE PRESSURE SOLENOID

2.

Removing the Pressure Solenoid


(1) Remove the rear cover. (2) Remove the mounting screws (M4x8: 3 pcs), and pull the Filter PCB unit [A] forward. (3) Remove the Second pressure spring [B] and Pressure spring [C]. (4) Unplug the connector [D], remove the mounting screws (M4x8: 4 pcs) on the Solenoid base assy [E], and then remove the Solenoid base assy [E]. (5) Unplug the Pressure solenoid connector [G], remove the mounting screws (M3x6: 2 pcs), and then remove the Pressure solenoid [F]. [Work Precautions] The Pressure spring and Second pressure spring are extremely powerful. Take care to avoid injury when removing or refitting. [Precautions on Reassembly] Align the half-pierce.

F
A: Filter PCB unit B: Second pressure spring C: Pressure spring D: Connector E: Solenoid base assy F: Pressure solenoid G: Pressure solenoid connector 66 RN (Version 1.0)

CHAPTER 6. PRESS SECTION REMOVING THE PRESSURE LEVER ASSY

3.

Removing the Pressure Lever Assy


(1) Make a confidential master, and then bring the print drum to position A. (2) Open the scanner table, and remove the rear cover. (3) Remove the screws and pull forward the filter PCB unit. (4) Remove both the Second pressure spring and Pressure spring. (5) Loosen the two set screws [D] on Pressure lever B [A] using an Allen wrench (3 mm), and remove the Pressure lever assy (Pressure lever A [B] + Pressure lever B [A]) from the Pressure shaft [C]. [Work Precautions] The Pressure spring and Second pressure spring are extremely powerful. Take care to avoid injury when removing or refitting. [Precautions on Reassembly] Adjust the mounting position of the Pressure lever assy.

Enlarged view

B A
Enlarged view

A: Pressure lever B B: Pressure lever A C: Pressure shaft D: Set screw 67 RN (Version 1.0)

CHAPTER 6. PRESS SECTION REMOVING THE PRESSURE CONTROL MOTOR AND PRINT PRESSURE CONTROL SENSOR

4.

Removing the Pressure Control Motor and Print Pressure Control Sensor
Removing the Pressure Control Motor (1) Remove the rear cover. (2) Remove the E-ring and the Drive transfer gear [C]. (3) Unplug the connector [B] on the Pressure control motor [A], remove the mounting screws (M3x6: 2 pcs), and then remove the Pressure control motor [A].

Removing the Print Pressure Control Sensor (1) Remove the rear cover. (2) Remove the mounting screws on the filter PCB unit, and then pull it forward. (3) Unplug the connector [E] on the Print pressure control sensor [D], remove the mounting screw (M3 x 6: 1 pc), and then remove the Print pressure control sensor [D] together with the Print pressure control sensor bracket [F]. [Precautions on Reassembly] Align the half-pierce.

F
A: Pressure control motor B: Pressure control motor connector C: Drive transfer gear D: Print pressure control sensor E: Print pressure control sensor connector F: Print pressure control sensor bracket 68 RN (Version 1.0)

CHAPTER 6. PRESS SECTION

[Memo]

69 RN (Version 1.0)

CHAPTER 6. PRESS SECTION MOUNTING POSITION OF THE PRESSURE LEVER ASSY

Adjustment
1. Mounting Position of the Pressure Lever Assy
Checking and adjustment procedure
(1) Make a confidential master, and then bring the print drum to position A. (2) Remove the rear cover. (3) Remove the screws and pull forward the filter PCB unit. (4) Remove the Second pressure spring, push up the Pressure lever B [A], and disengage it from the Solenoid lever [D]. (5) Attach the Second pressure spring and check that the gap between Pressure lever A [B] and Pressure lever B [A] is between 1.5 mm and 2.0 mm. (See detailed figure 2.) (6) If the gap in step (5) is outside the specifications, remove the Second pressure spring and loosen the two set screws on Pressure lever B [A]. Insert a 3 mm Allen wrench [C] between Pressure lever A [B] and Pressure lever B [A] (see detailed figure 1), rotate the Pressure shaft [E] fully counter-clockwise, and then tighten the set screws on Pressure lever B [A] with the pressure roller pressing hard against the print drum. The Pressure lever B [A] should be pushed all the way back against the machine, when tightening the set screws. (7) Check as in step (5), and if the gap is still outside the specifications, repeat step (6). If the gap is within the specifications, push Pressure lever B [A] upwards, lock with the Solenoid lever [D], and attach the Second pressure spring. Symptoms If the gap is too small, the pressure will be too weak, and the printing density may become too light. If the gap is too large, there will not be sufficient space between the Pressure roller and the Clamp plate base on the print drum, and they may touch, damaging the Clamp plate base.

6 10 RN (Version 1.0)

CHAPTER 6. PRESS SECTION MOUNTING POSITION OF THE PRESSURE LEVER ASSY

Detailed figure 1

A
1.5 2.0 mm

Detailed figure 2

A: Pressure lever B B: Pressure lever A C: Allen wrench (3 mm) D: Solenoid lever E: Pressure shaft

6 11 RN (Version 1.0)

CHAPTER 6. PRESS SECTION

[Memo]

6 12 RN (Version 1.0)

CHAPTER 7: PAPER EJECTION SYSTEM

Contents
Mechanism ............................................................................................................................ 7-2 1. 2. 3. Paper Ejection Mechanism ...................................................................................... 7-2 Paper Separator Mechanism ................................................................................... 7-3 Paper Ejection Wing Mechanism ............................................................................. 7-4

Removal and Assembly ........................................................................................................ 7-5 1. 2. 3. 4. 5. 6. 7. 8. 9. Removing the Paper Receiving Tray ........................................................................ 7-5 Removing the De-electricity Plate and Suction Unit ................................................. 7-6 Removing the Suction Fan ....................................................................................... 7-8 Removing the Paper Ejection Wing ......................................................................... 7-9 Removing the Paper Ejection Motor and Encoder Sensor .................................... 7-11 Removing the Transfer Belts ................................................................................. 7-12 Removing the Separation Fan Unit ....................................................................... 7-13 Removing the Separator Fan and Paper Receiving Sensor ................................ 7-14 Removing the Separator ........................................................................................ 7-15

Adjustment .......................................................................................................................... 7-16 1. Separator Mounting Position ................................................................................. 7-16

71 RN (Version 1.0)

CHAPTER 7. PAPER EJECTION SYSTEM PAPER EJECTION MECHANISM

Mechanism
1. Paper Ejection Mechanism
Printed paper is first detached from the print drum by the Separator [B] and two Separation fans [F]. It is then sent to the paper receiving tray by the Transfer belts [E]. The transfer belts [E] are driven by the Paper ejection motor [C]. Two Suction fans [D] are located below the Transfer belts [E], and these suck the paper onto the transfer belts [E]. The Paper receiving sensor [A] checks whether the paper is ejected correctly. The Encoder sensor [G] checks the rotation of the Encoder sensor disc [H] to ensure that the transfer belt speed is slightly faster than the corresponding print drum rotation speed and ensure smooth paper ejection from the print drum.

Paper transfer direction

E C
A: Paper receiving sensor B: Separator C: Paper ejection motor D: Suction fan E: Transfer belt F: Separation fans (x2) G: Encoder sensor H: Encoder sensor disc

7 2 RN (Version 1.0)

CHAPTER 7. PAPER EJECTION SYSTEM PAPER SEPARATOR MECHANISM

2.

Paper Separator Mechanism


The Separator [A] is close to the print drum when the paper is being detached from the print drum. As the print drum rotates and the clamp plate base approaches the Separator [A], the Separator arm assy [G] is pushed by the Pressure cam [F] on the Print drum pulley. This also pushes the Separator lever [H], and the Separation shaft [B] rotates, causing the Separator [A] to move away from the print drum. Likewise, when pulling out the print drum, the Release lever [D] is returned by the Release lever spring [E]. And when the Release arm [C] is pressed, the Separation shaft [B] rotates, causing the Separator [A] to move away from the print drum.

C D

E
Descends Pushes Returns Front (panel side)

Rear (drive unit side)

A: Separator B: Separation shaft C: Release arm D: Release lever E: Release lever spring F: Pressure cam

H
Separator rises Separator descends

G: Separator arm assembly H: Separator lever

73 RN (Version 1.0)

CHAPTER 7. PAPER EJECTION SYSTEM PAPER EJECTION WING MECHANISM

3.

Paper Ejection Wing Mechanism


The left- and right-hand ejection wings on the Suction unit can be set manually to the raised [B] or lowered [C] positions to suit the paper ejection requirements. Normally, the ejection wings are raised [B] for regular paper and lowered [C] for cards. The ejection wings are raised and lowered by moving the Wing position knob [D] located below the lefthand Ejection wing [A] up or down. The Wing position knob [D] has a protruding tab [E] inside, which engages with the catch [F] on the lefthand Ejection wing [A]. Moving the Wing position knob [D] up and down therefore moves the Ejection wings up and down.

E D

A: Paper ejection wing (left) B: Ejection wing position when raised C: Ejection wing position when lowered D: Wing position knob E: Tab or rear of knob F: Knob catch 74 RN (Version 1.0)

CHAPTER 7. PAPER EJECTION SYSTEM REMOVING THE PAPER RECEIVING TRAY

Removal and Assembly 1. Removing the Paper Receiving Tray


(1) Fold down the fences of the Paper receiving tray [A], and close the Paper receiving tray [A] to an angle of about 45. (2) Lifting the paper receiving tray [A] vertically upwards at this angle detaches it from the machine.

A: Paper receiving tray

75 RN (Version 1.0)

CHAPTER 7. PAPER EJECTION SYSTEM REMOVING THE DE-ELECTRICITY PLATE AND SUCTION UNIT

2.

Removing the De-electricity Plate and Suction Unit


Removing the De-electricity Plate (1) Switch off the power, remove the rear cover, and remove the following components. Paper receiving tray (2) Remove the mounting screws (M4 x 8: 4 pcs) [B] on the De-electricity Plate [A], and then remove the De-electricity Plate [A]. [Precautions on Reassembly] Align the half-pierce [C] when mounting the De-electricity Plate [A].

A: De-electricity Plate

B: Mounting screws (M4 x 8: 4 pcs) C: Half-pierce

Removing the Suction Unit (3) Unplug the suction unit connector [D]. (4) Remove the mounting screws (M4 x 8: 2 pcs) [E] on the Suction unit [F], and then remove the Suction unit [F] in the same direction that paper is ejected.

D
D: Suction unit connector E: Mounting screws (M4 x 8: 2 pcs) F: Suction unit 76 RN (Version 1.0)

E
[Continued on next page]

CHAPTER 7. PAPER EJECTION SYSTEM REMOVING THE DE-ELECTRICITY PLATE AND SUCTION UNIT
[Precautions on Reassembly] Mount the suction unit by hooking the left- and right-hand side front edges [G] onto the brackets [H] on the machine side frames.

(Enlarged view)

G: Suction unit front edge H: Brackets

77 RN (Version 1.0)

CHAPTER 7. PAPER EJECTION SYSTEM REMOVING THE SUCTION FAN

3.

Removing the Suction Fan


(1) Switch off the power, remove the rear cover, and remove the following components. Paper receiving tray De-electricity Plate Suction unit (2) Turn the Suction unit [A] upside down, and unplug the suction fan connector [B]. (3) Remove the mounting screws (M4 x 10: 3 pcs) [C], and remove the Suction fan [D].

A: Suction unit B: Connector C: Mounting screws (M4 x 10: 3 pcs) D: Suction fan

78 RN (Version 1.0)

CHAPTER 7. PAPER EJECTION SYSTEM REMOVING THE PAPER EJECTION WING

4.

Removing the Paper Ejection Wing


(1) Switch off the power, remove the rear cover, and remove the following components. Paper receiving tray De-electricity Plate Suction unit (2) Lift up the belt driven pulley assy [A] with your fingers, unhook from the suction unit, and remove.

A: Belt driven pulley assy (3) Remove the mounting screws (M4 x 8: 6 pcs) [C] on the Suction face cover [B].

C C

B: Suction face cover C: Mounting screws (M4 x 8: 6 pcs)

(4) Remove the Suction face cover from the Suction unit while threading it beneath the two transfer belts [D].

D: Transfer belts [Continued on next page] 79 RN (Version 1.0)

CHAPTER 7. PAPER EJECTION SYSTEM REMOVING THE TIMING ROLLER


(5) Remove the mounting screws (M3 x 8: 2 pcs) [F] from both the left- and right-hand Ejection wings [E], and remove the ejection wings.

E: Ejection wings (left, right) F: Mounting screws (M3 x 8: 2 pcs each)

[Precaution on Reassembly] Securely engage the spring [G] beneath the left-hand ejection wing. When mounting the ejection wings onto the shaft, mount them on the flat cut surface [H] of the shaft.

G
G: Spring H: Flat cut surface

Locate the Face cover [I] securely onto the half-pierce [J] before screwing on.

I: Face cover J: Half-pierce

J
7 10 RN (Version 1.0)

CHAPTER 7. PAPER EJECTION SYSTEM REMOVING THE PAPER EJECTION MOTOR AND ENCODER SENSOR

5.

Removing the Paper Ejection Motor and Encoder Sensor


Removing the Paper Ejection Motor (1) Switch off the power, remove the rear cover, and remove the following components. Paper receiving tray De-electricity Plate Suction unit Ejection wings (2) Unplug the paper ejection motor connector [B]. (3) Remove the Paper ejection motor belt [D], remove the paper ejection motor mounting screws (M3 x 5: 3 pcs) [C], and then remove the Paper ejection motor [A].

A
A: Paper ejection motor

B: Paper ejection motor connector C: Mounting screws (M3 x 5: 3 pcs) D: Paper ejection

Removing the Encoder Sensor (4) Unplug the encoder sensor connector [F], remove the sensor hooks [G] from the mounting bracket, and then remove the encoder sensor [E].

F E

E: Encoder sensor F: Connector G: Sensor hooks 7 11 RN (Version 1.0)

CHAPTER 7. PAPER EJECTION SYSTEM REMOVING THE TRANSFER BELTS

6.

Removing the Transfer Belts


(1) Switch off the power, remove the rear cover, and remove the following components. Paper receiving tray De-electricity Plate Suction unit Ejection wings (2) Remove the Paper ejection motor belt [A]. (3) Remove the E-rings [B] on the left and right of the Belt pulley shaft [C], and remove the Transfer belts [D] by sliding them off the Belt pulley shaft [C].

A: Paper ejection motor belt B: Left and right belt pulley shaft E-rings C: Belt pulley shaft D: Transfer belt

[Precautions on Reassembly] Fit the left and right bearings [G] and E-rings [E] on the belt pulley shaft from outside the mounting brackets. Mount the pulley [F] on the left-hand end of the Belt pulley shaft [H] with the flange facing inwards.

E
E: E-ring F: Pulley G: Bearing

H: Belt pulley shaft

7 12 RN (Version 1.0)

CHAPTER 7. PAPER EJECTION SYSTEM REMOVING THE SEPARATION FAN UNIT

7.

Removing the Separation Fan Unit


(1) Switch off the power and remove the rear cover. (2) Unplug the separation fan unit connector [A]. (3) Remove the mounting screws (M4 x 8: 2 pcs) [B] on the Separation fan unit [C], and remove the separation fan unit by sliding it in the same direction that paper is ejected.

A
A: Separation fan unit connector B: Mounting screws (M4 x 8: 2 pcs) C: Separation fan unit [Precautions on Reassembly]

Engage the hooks [D] on the Separation fan unit into the slots [E] inside the machine.

D: Hooks on the Separation fan unit E: Slots inside the machine

7 13 RN (Version 1.0)

CHAPTER 7. PAPER EJECTION SYSTEM REMOVING THE SEPARATOR FAN AND PAPER RECEIVING SENSOR

8.

Removing the Separator Fan and Paper Receiving Sensor


Removing the Separator Fan (1) Switch off the power, remove the rear cover, and remove the following component. Separation fan unit (2) Remove the nozzle mounting screw (tapping screw M3 x 10: 3 pcs) [A], and remove the Nozzle [E]. (3) Unplug the two separation fan connectors [D]. (4) Remove the mounting screws (M3 x 12: 3 pcs each) [B] from the two Separation fans [C], and remove both Separation fans [C].

D B B B

A: Nozzle mounting screw (tapping screws M3 x 10: 3 pcs) B: Separation fan mounting screws (M3 x 12: 3 pcs each) C: Separation fan D: Separation fan connectors E: Nozzle

Removing the Paper Receiving Sensor (5) Disengage the Paper receiving sensor [F] from the hook [G] and remove the Paper receiving sensor [F]. (6) Unplug the Paper receiving sensor connector [H].

F: Paper ejection sensor G: Hook H: Connector 7 14 RN (Version 1.0)

CHAPTER 7. PAPER EJECTION SYSTEM REMOVING THE SEPARATOR

9.

Removing the Separator


(1) Pull out the print drum, switch off the power, and remove the front cover. (2) Remove the separator mounting screw (M3 x 8: 1 pc) [A]. (3) Remove the release arm mounting screw (M3 x 8: 1 pc) [B]. (4) Remove the E-ring [C] on the end of the separation shaft, and remove the bearing bush.

A: Separator mounting screw (M3 x 8: 1 pc) B: Release arm mounting screw (M3 x 8: 1 pc) C: Separation shaft end E-ring

(5) Push the Separation shaft [E] back slightly, and remove the rear bearing bush from the machine side frame. Do not push back the shaft more than necessary. To prevent the components mounted on the rear from detaching, stop pushing back the shaft once the bush in the rear has been removed. (6) Slide the Separator [F] and Release arm [G] forward and remove both of these parts off the machine.

D
E: Separation shaft F: Separator G: Release arm

E
[Reference]

D: Separation shaft rear bearing bush

Photograph of separator assembly and rear mount (machine drive side)

7 15 RN (Version 1.0)

CHAPTER 7. PAPER EJECTION SYSTEM SEPARATOR MOUNTING POSITION

Adjustment
1. Separator Mounting Position
(1) Using test chart No.15, create a master and make prints. Check that the paper does not jam on the drum and that there is no black line through the center of the paper caused by the Separator touching the print drum. The Separator position is OK if there is no paper jamming on the print drum with 5 mm white margin on the top of the prints. (2) If the paper sticks to the print drum or black line appears on the printed sheet, stop the print drum at position-A, switch off the power, remove the rear cover, and then remove the following component. Separation fan unit (3) Insert a screwdriver through the insertion point [B] at the bottom left of Pressure lever A [A], and loosen the retaining screw [D] on the Separator positioning plate[C]. (4) Insert a penlight inside the machine, on top of the suction unit, and inspect the tip of the Separator [E] through the square opening in the machine side frame located just above Pressure lever A [A]. (5) Move the Separator positioning plate [C] and tighten the separator positioning plate retaining screw [D] so that the gap between the Separator [E] tip and the Print drum surface [F] is 1.0 mm to 1.5 mm. Symptoms If the tip of the Separator [E] touches the Print drum surface [F], it will scratch the surface of the master, causing a black line on the printed sheets. Conversely, if the gap is too wide, the paper will not be properly released from the print drum, and sticks onto the print drum.

D F

1.01.5 mm

E
A: Pressure lever A B: Screwdriver insertion point C: Separator positioning plate D: Separator positioning plate retaining screw E: Separator F: Print drum surface G: Separator positioning plate base 7 16 RN (Version 1.0)

D C

CHAPTER 8: PRINT DRUM SECTION

Contents
Mechanism ............................................................................................................................ 8-2 1. 2. 3. 4. 5. Master on Drum (in Printing) Check Mechanism ..................................................... 8-2 Print Drum Set Mechanism ...................................................................................... 8-3 Ink Cartridge Set Switch PCB ................................................................................... 8-4 Squeegee Roller Rotation Mechanism .................................................................... 8-5 Inking Mechanism .................................................................................................... 8-6

Removal and Assembly ........................................................................................................ 8-7 1. 2. 3. 4. 5. 6. 7. 8. 9. Removing the Print Drum Front Cover, Ink Cartridge Guide Assy, Drum Front Upper Cover .......................................................................................... 8-7 Removing the Ink Cartridge Set Switch Cover and Ink Cartridge Set Switch PCB .. 8-9 Removing the Ink Cartridge Set Switch PCB Mounting Bracket ........................... 8-10 Removing the Swing Base Assy ........................................................................... 8-11 Removing the Ink Cartridge Guide Bottom Assy .................................................. 8-12 Removing the Ink Pump Unit and Inking Motor ..................................................... 8-13 Removing the Print Drum Set Sensor ................................................................... 8-14 Removing the Screen ............................................................................................ 8-15 Removing the Print Drum Body ............................................................................. 8-16

10. Removing the Ink Sensor PCB .............................................................................. 8-18 11. Removing the Squeegee Roller ............................................................................ 8-19 12. Removing the Print Drum Supports (R) and (F) .................................................... 8-22 Adjustment .......................................................................................................................... 8-25 1. 2. 3. 4. Filter Cleaning ....................................................................................................... 8-25 Squeegee Gap Adjustment ................................................................................... 8-26 Ink Blocking Plate Position Adjustment ................................................................ 8-27 Squeegee Pressure Balance Adjustment ............................................................ 8-28

81 RN (Version 1.0)

CHAPTER 8. PRINT DRUM SECTION MASTER ON DRUM (IN PRINTING) CHECK MECHANISM

Mechanism
1. Master on Drum (in Printing) Check Mechanism
This mechanism checks whether there is a master on the print drum when printing begins. The print drum begins to rotate when the START key is pressed, and when the print drum reaches the 75 position, the Master sensor [B] checks whether there is a master [C] on the print drum. The information checked by the Master sensor [B] is stored until either the print drum is pulled out or the power is switched off. Subsequent printing therefore starts immediately after the START key is pressed. If light is not reflected back to the Master sensor [B] (implying that the master is absent) when the print drum reaches the 75 position at the start of the printing, it is assumed that there is no master on the print drum.

A B
Print drum 75 position

Print drum 75 position

A: Light absorber strip B: Master sensor (reflective type) C: Master

82 RN (Version 1.0)

CHAPTER 8. PRINT DRUM SECTION PRINT DRUM SET MECHANISM

2.

Print Drum Set Mechanism


The Print drum set sensor [A] checks whether the print drum is correctly set in the machine. A light beam from the Print drum set sensor [A] is transmitted when the levers are gripped, and blocked when they are released. The light beam of print drum set sensor [A] is therefore transmitted if the print drum is not correctly set in the machine.

A
Print drum set sensor light beam is blocked. Print drum is assumed to be in place.

A
Print drum set sensor light beam is transmitted. Print drum is assumed not to be in place.

A: Print drum set sensor

83 RN (Version 1.0)

CHAPTER 8. PRINT DRUM SECTION INK CARTRIDGE SET SWITCH PCB

3.

Ink Cartridge Set Switch PCB


Different Ink cartridge set switch PCBs are used for the black ink and color ink print drums. The black ink cartridge set switch PCB [A] has five sensors, while the color ink cartridge set switch PCB [B] has three sensors. The sensors on the Ink cartridge set switch PCB determines whether correct ink for the print drum is set in place.

A: Ink cartridge set switch PCB (for black ink) B: Ink cartridge set switch PCB (for color ink) C: Ink cartridge set switch PCB sensors D: Protrusion on the front end of the ink cartridge presses sensor actuator on the Print drum set switch PCB.

84 RN (Version 1.0)

CHAPTER 8. PRINT DRUM SECTION SQUEEGEE ROLLER ROTATION MECHANISM

4.

Squeegee Roller Rotation Mechanism


The main motor drives the Joint gear [A] via the Junction gear assy [B], and this rotates the Print drum main gear [C]. The rotation also drives the Squeegee roller gear (R) [D] via the gears to rotate the Squeegee roller [E]. The Squeegee roller [E] drives the Driven shaft [H] via the Squeegee roller gear (F) [F]. The Squeegee roller gear (R) [D] contains a one-way clutch to prevent the Squeegee roller [E] from rotating when the print drum is manually rotated in the reverse direction.

B C F A C

E
A: Joint gear B: Junction gear assy C: Print drum main gear D: Squeegee roller gear (R) E: Squeegee roller F: Squeegee roller gear (F) G: Doctor roller H: Driven shaft 85 RN (Version 1.0)

CHAPTER 8. PRINT DRUM SECTION INKING MECHANISM

5.

Inking Mechanism
When the main motor is operating and the print drum is rotating, if the ink bead moves away from the Ink sensor [D], the inking motor activates to pump in the ink from the ink cartridge. The ink pumped is fed via the hose onto the squeegee roller [E] from the holes in the Ink distributor [F]. The inking motor is switched off when the ink reaches the Ink sensor [D]. The ink deposited on the squeegee roller [E] is made into ink bead between the Squeegee roller [E] and Doctor roller [A]. The Driven shaft is rotated to build a smooth ink bead. The ink is transferred onto the print drum from Squeegee roller [E] via a small gap between the Squeegee roller [E] and Doctor roller [A]. The Overflow sensor [C] checks to prevent ink from overflowing inside the print drum.

D E G F E

A
A: Doctor roller B: Driven shaft C: Overflow sensor D: Ink sensor E: Squeegee roller F: Ink distributor G: Ink bead

86 RN (Version 1.0)

CHAPTER 8. PRINT DRUM SECTION REMOVING THE PRINT DRUM FRONT COVER, INK CARTRIDGE GUIDE ASSY, DRUM FRONT UPPER COVER

Removal and Assembly 1. Removing the Print Drum Front Cover, Ink Cartridge Guide Assy, Drum Front Upper Cover

Removing the Print Drum Front Cover (1) Remove the left- and right-hand mounting screws (M4 x 6: 1 pc each) [E] on the Print drum front cover [A], and then remove the cover itself.

Removing the Ink Cartridge Guide Assy (2) Pull the Ink cartridge release lever [D] and open the swing base. (3) Remove the mounting screws (M4 x 6: 2 pcs) [E] on the Ink cartridge guide assy [B], and then remove it.

[Continued on next page]

A: Print drum front cover B: Ink cartridge guide assy C: Drum front upper cover D: Ink cartridge release lever E: Mounting screws M4 x 6: 2 pcs F: Mounting screws M4 x 6: 2 pcs 87 RN (Version 1.0)

CHAPTER 8. PRINT DRUM SECTION REMOVING THE PRINT DRUM FRONT COVER, INK CARTRIDGE GUIDE ASSY, DRUM FRONT UPPER COVER
Removing the Drum Front Upper Cover (4) Remove the Ink cartridge guide assy. (5) Remove the mounting screws (M4 x 6: 2 pcs) [E] on the Drum front upper cover [C], and then remove without damaging the two hooks [F] at the inside bottom of the cover.

C: Drum Front Upper Cover E: Mounting screw (M4 x 6: 1 pc) F: Hooks (inside bottom of the cover)

88 RN (Version 1.0)

CHAPTER 8. PRINT DRUM SECTION REMOVING THE INK CARTRIDGE SET SWITCH COVER AND INK CARTRIDGE SET SWITCH PCB

2.

Removing the Ink Cartridge Set Switch Cover and Ink Cartridge Set Switch PCB
Removing the Ink Cartridge Set Switch Cover (1) Remove the mounting screws (M4 x 6: 2 pcs) [C] on the Ink cartridge set switch PCB cover [A], and then remove the cover.

Removing the Ink Cartridge Set Switch PCB (2) Remove the four connectors on the Ink cartridge set switch PCB [B]. (3) Remove the mounting screws (M4 x 6: 3 pcs) [D] on the Ink cartridge set switch PCB [B], and then remove the PCB.

A: Ink cartridge set switch PCB cover B: Ink cartridge set switch PCB C: Mounting screws M4 x 6: 2 pcs D: Mounting screws M4 x 6: 3 pcs

89 RN (Version 1.0)

CHAPTER 8. PRINT DRUM SECTION REMOVING THE INK CARTRIDGE SET SWITCH PCB MOUNTING BRACKET

3.

Removing the Ink Cartridge Set Switch PCB Mounting Bracket


(1) Pull out the print drum, pull out the ink cartridge, and remove the following components. rint drum front cover Ink cartridge guide assy Drum front upper cover Ink cartridge set switch PCB cover vInk cartridge set switch PCB (2) Remove the mounting screws (M4 x 6: 3 pcs) [C] on the Ink cartridge set switch PCB mounting bracket [A], and remove the bracket.

B A

A: Ink cartridge set switch PCB mounting bracket B: Ink cartridge set switch PCB C: Mounting screws (M4 x 6: 3 pcs)

8 10 RN (Version 1.0)

CHAPTER 8. PRINT DRUM SECTION REMOVING THE SWING BASE ASSY

4. Removing the Swing Base Assy


(1) Pull out the print drum, pull out the ink cartridge, and remove the following components. Print drum front cover Ink cartridge guide assy Drum front upper cover (2) Remove the mounting screws (M4 x 6: 2 pcs) [C] on the Swing base assy [B]. (3) Push the Ink cartridge release lever assy [A] down, open the Swing base assy [B], and remove from the print drum.

A: Ink cylinder release lever assy B: Swing base assy C: Mounting screw (M4 x 6: 2 pcs)

8 11 RN (Version 1.0)

CHAPTER 8. PRINT DRUM SECTION REMOVING THE INK CARTRIDGE GUIDE BOTTOM ASSy

5.

Removing the Ink Cartridge Guide Bottom Assy


(1) Pull out the print drum, pull out the ink cartridge, and remove the following components. Print drum front cover Ink cartridge guide assy Drum front upper cover Ink cartridge set switch PCB cover Ink cartridge set switch PCB mounting bracket Swing base assy (2) Remove the mounting screws (M4 x 6: 2 pcs) [E] on the Ink intake nozzle [A], and detach the Ink intake nozzle [A] from the Nozzle bracket [B]. (3) Remove the mounting screws (M4 x 6: 3 pcs) [F] on the Ink cartridge guide bottom assy [D], and remove the ink cartridge guide bottom assy [D]. [Precautions on Reassembly] When mounting the Ink cartridge assy [D], engage the horizontal hooks into the Drum front support assy [C].

A: Ink intake nozzle B: Nozzle mounting plate C: Drum front support assy D: Ink cartridge guide bottom assy E: Mounting screws (M4 x 6: 2 pcs) F: Mounting screws (M4 x 6: 3 pcs) 8 12 RN (Version 1.0)

CHAPTER 8. PRINT DRUM SECTION REMOVING THE INK PUMP UNIT AND INKING MOTOR

6.

Removing the Ink Pump Unit and Inking Motor


Removing the Ink Pump Unit (1) Pull out the print drum, pull out the ink cartridge, and remove the following components. Print drum front cover Ink cartridge guide assy Drum front upper cover Ink cartridge set switch PCB cover Ink cartridge set switch PCB mounting bracket Swing base assy Ink cartridge guide bottom assy (2) Remove the mounting screws (M4 x 6: 2 pcs) on the Grip lever [A], and remove the Grip lever [A]. (3) Remove the mounting screw (M4 x 6: 1 pc) [C] on the Pump cover [B], and remove the Pump cover [B]. (4) Pull out the Ink outlet nozzle [D] from the ink distributor. (5) Unplug the Inking motor connector [E], remove the mounting screws (M4 x 6: 3 pcs) on the Ink pump unit [F], and remove the Ink pump unit [F].

A D

B E F

A: Grip lever B: Pump cover C: Pump cover mounting screw D: Ink outlet nozzle E: Connector F: Ink pump unit Removing the Inking Motor (4) Remove the mounting screws (M4 x 6: 2 pcs) [F] on the Inking motor bracket [D], and then remove the Inking motor [E] together with its mounting bracket from the ink pump unit. (5) Remove the mounting screws (M3 x 4: 2 pcs) [G] on the Inking motor [E], and detach the Inking motor [E] from the Inking motor bracket [D].

G
D: Inking motor bracket E: Inking motor F: Mounting screws (M4 x 6: 2 pcs)

E
8 13 RN (Version 1.0)

G: Mounting screws (M3 x 4: 2 pcs)

CHAPTER 8. PRINT DRUM SECTION REMOVING THE PRINT DRUM SET SENSOR

7.

Removing the Print Drum Set Sensor


(1) Pull out the print drum, pull out the ink cartridge, and remove the following components. Print drum front cover Ink cartridge guide assy Drum front upper cover Ink cartridge set switch PCB cover Ink cartridge set switch PCB mounting bracket Swing base assy Ink cartridge guide bottom assy (2) Remove the mounting screw (M3 x 6: 1 pc) [C] on the Print drum set sensor [B], and remove the sensor with the connector attached. (3) Unplug the connector [A] from the Print drum set sensor [B].

A: Connector B: Print drum set sensor C: Mounting screw (M3 x 6: 1 pc)

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CHAPTER 8. PRINT DRUM SECTION REMOVING THE SCREEN

8.

Removing the Screen


[Suggestion prior to starting work] Attaching the Print drum stand [B] (Part No. 015-26836-002) to the rear of the Print drum side frame assy [A] makes the work easier by keeping the print drum level. (1) Make a confidential master, and pull out the print drum. (2) Remove the two Screen springs [C]. (3) Remove the mounting screws (M4 x 8: 2 pcs), which holds both the Clamp plate base [D] and the Screen [E], and then pull the Screen [E] from underneath the Clamp plate base [D] to remove. [Precautions on Reassembly] Take care not to fold the Screen [E].

C
A: Print drum side frame assy B: Print drum stand (015-26836-002) C: Screen springs D: Clamp plate base E: Screen

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CHAPTER 8. PRINT DRUM SECTION REMOVING THE PRINT DRUM BODY

9.

Removing the Print Drum Body


(1) Make a confidential master, pull out the print drum, and remove the following component. Screen (2) Remove the mounting screws (special screws: 2 pcs) [B] and remove the Clamp plate base [A]. (3) Peel off the tape [D] on the print drum body [C] alignment section. (Reuse the tape when reassembling.) (4) Remove the remaining 10 mounting screws (M4 x 8: 8 pcs and special screws: 2 pcs) on the Print drum body [C], and remove the Print drum body [C]. [Continued on next page]

A: Clamp plate base B: Special screws C: Print drum body D: Tape E: Print drum support (F) F: Print drum support (R)

8 16 RN (Version 1.0)

CHAPTER 8. PRINT DRUM SECTION REMOVING THE PRINT DRUM BODY


[Precautions on Reassembly: 1] Arrow marks are engraved on both sides of the Print drum body, and F is engraved at the front. Likewise, arrow marks are engraved on both the right and left Print drum supports. Align the arrow marks on the Drum body with those on the Print drum supports with the engraved F on the Drum body at the front. Then attach the Drum body onto the Print drum supports with mounting scres (M4 x 8: 2 pcs). Next attach the Special screws.

Hook the Screen springs into the holes at the leading edges of the Print drum body, and hook the loop ends over the Special screws. Then attach the remaining screws while applying tension on the Drum body with the springs. When nearing the last screws, remove the Screen springs and attach the remaining screws and Clamp plate base after checking the [Precautions on Reassembly: 2] below.

[Precautions on Reassembly: 2] Before attaching the Clamp plate base to the Print drum body, affix the tape [D] to the joint section of the Print drum body [C]. If the tape originally attached to the print drum cannot be reused, insulation tape may be used. The tape is used to reduce the noise originating from the joint section of the Print drum body during the printing.

D: Tape

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CHAPTER 8. PRINT DRUM SECTION REMOVING THE INK SENSOR PCB

10. Removing the Ink Sensor PCB


(1) Pull out the print drum, and remove the following components. Screen Print drum body (2) Unplug the connector on the Ink sensor PCB [B]. (3) Remove the mounting screws (M3 x 8: 2 pcs) on the Ink sensor cover [A], and remove the Ink sensor cover [A] with the Ink sensor PCB [B] inside. (4) Remove the Ink sensor PCB [B] from the Ink sensor cover [A]. [Work Precautions] Take care not to fold or bend the Ink sensor or Overflow sensor. If they are bent, straighten them out by hand. [Checking after Reassembly] Check that the Ink sensor does not touch the Doctor roller or Driven shaft.

A: Ink sensor cover B: Ink sensor PCB

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CHAPTER 8. PRINT DRUM SECTION REMOVING THE SQUEEGEE ROLLER

11. Removing the Squeegee Roller


(1) Pull out the print drum, and remove the following components. Print drum front cover Ink cartridge guide assy Drum front upper cover Ink cartridge set switch PCB cover Ink cartridge set switch PCB mounting bracket Swing base assy Ink cartridge guide bottom assy Ink pump unit Screen Print drum body Ink sensor PCB (2) Remove the two mounting screws on the Junction gear assy [A], and remove the Junction gear assy [A].

A: Junction gear assy

(3) Remove the mounting screws (3 x 6: 1 pc each) on the two Eccentric boss stopper plates [B], and remove the Eccentric bosses [C]. (4) With the print drum at position A, remove the mounting screws (M4 x 6: 1 pc each) on the Ink blocking plates [D] via the holes in the left and right Print drum supports. [Continued on next page]

C
B: Eccentric boss stopper plate

B
8 19 RN (Version 1.0)

C: Eccentric bosses D: Ink blocking plates

CHAPTER 8. PRINT DRUM SECTION REMOVING THE SQUEEGEE ROLLER


(5) With the print drum at position-A, remove the mounting screws (M4 x 8: 2 pcs each) on the Squeegee frames [L] via the holes in the left and right Print drum supports.

L
L: Squeegee frames

(6) Remove the mounting screw (M4 x 6: 1 pc), and remove the Print drum lock plate assy [E].

E
E: Print drum lock plate assy

(7) Remove the Pivot screw [F] on the front of the print drum via the opening in the Print drum support (F) where the Print drum lock plate assy was removed. Likewise, remove the Pivot screw [G] on the front of the print drum via the opening in the Print drum support (R). (8) Remove the Squeegee bottom assy [H] from the squeegee unit.

G F H
F: Pivot screw (print drum front) G: Pivot screw (print drum rear) H: Squeegee bottom assy 8 20 RN (Version 1.0) [Continued on next page]

CHAPTER 8. PRINT DRUM SECTION REMOVING THE SQUEEGEE ROLLER


(7) Remove the E-rings on both ends of the Squeegee roller [I], remove the gears [J], remove the bearings [K], and then remove the Squeegee roller [I] from the Squeegee frame [L]. (The Doctor roller [M] and Driven shaft [N] will also come loose when removing the Squeegee roller [I], and are disassembled as shown below.)

I: Squeegee roller J: Gear K: Bearing L: Squeegee frame M: Doctor roller N: Driven shaft

[Precautions on Reassembly] Align the positioning hole [P] in the Joint gear [O] over the positioning holes in the Drum rear frame plate and Print drum main gear. Adjust the position of the Junction gear assy [Q] to allow a small amount of backlash between the Junction gear and the Joint gear [O] (and Print drum main gear).

O: Joint gear P: Joint gear positioning holes Q: Junction gear assy

[Adjustment after Reassembly] Squeegee gap adjustment Ink blocking plate position adjustment Squeegee pressure balance adjustment

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CHAPTER 8. PRINT DRUM SECTION REMOVING THE PRINT DRUM SUPPORTS (R) AND (F)

12. Removing the Print Drum Supports (R) and (F)


(1) Pull out the print drum, remove the ink cartridge, and remove the following components. Print drum front cover Ink cartridge guide assy Drum front upper cover Ink cartridge set switch PCB cover Ink cartridge set switch PCB mounting bracket Swing base assy Ink cartridge guide bottom assy Screen Print drum body (2) Unplug the connector on the Ink sensor PCB. (3) Remove the mounting screws (M4 x 8: 2 pcs) on the Junction gear assy [A], and remove the Junction gear assy [A].

A B
A: Junction gear assy B: C-ring C: Joint gear (4) Remove the C-ring [B] retaining the Joint gear [C] on the ink distributor, and remove the Joint gear [C]. (5) Remove the mounting screws (M4 x 6: 2 pcs) [E] retaining the Drum rear frame plate [D] to the print drum side frame assy.

D: Rear frame E: Mounting screw (M4 x 6: 2 pcs) F: Mounting screw (M4 x 8: 2 pcs)

(6) Remove the screws (M4 x 8: 2 pcs) [F] that hold the Drum rear frame plate [D] to the Drum shaft clamper [G], and slide out the Drum rear frame plate [D] from the ink distributor. (7) Loosen the 3-mm Allen bolts [H] on the Drum shaft clamper [G], and slide out the Drum shaft clamper [G] from the ink distributor. (8) Remove the mounting screws (M4 x 12: 4 pcs) [J] on the Print drum main gear [I], and slide out the Print drum main gear [I] from the ink distributor. [Continued on next page]

K J I H
8 22 RN (Version 1.0)

G: Drum shaft clamper H: 3-mm Allen bolts I: Print drum main gear J: Mounting screw (M4 x 12: 4 pcs) K: Print drum support (R)

CHAPTER 8. PRINT DRUM SECTION REMOVING THE PRINT DRUM SUPPORTS (R) AND (F)
(9) Pull the print drum support (R) [K] from the ink distributor. (10) Pull the Ink outlet nozzle [A] from the ink distributor. (11) Remove the mounting screws (M4 x 8: 3 pcs) [B] on the Drum front support assy [C], and remove the Drum front support assy [C] from the drum shaft clamper.

C A

A: Ink outlet nozzle B: Mounting screws (M4 x 8: 3 pcs) C: Drum front support assy

B
(12) Loosen the 3-mm Allen bolt [E] on the Drum shaft clamper [D], and slide out the Drum shaft clamper [D] from the ink distributor. (13) Slide out the Print drum support (F) [G] from the ink distributor, and pull the junction wire harness [F] out through the Print drum support (F) [G]. [Continued on next page]

E
D: Drum shaft clamper E: 3-mm Allen bolt F: Junction wire harness G: Print drum support (F)

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CHAPTER 8. PRINT DRUM SECTION REMOVING THE PRINT DRUM SUPPORTS (R) AND (F)

[Precautions on Reassembly: 1] Use the tool (Print drum JIG) when tightening the drum shaft clamper mounting screws.

Print drum JIG 015-26128-008

Move the print drum to position A, insert the tool (Print drum JIG) through the holes in the Drum front support assy [A], Print drum support (F) [B], Print drum support (R) [D], and Drum rear frame plate [E], and then tighten the Allen bolts on both Drum shaft clampers.

A B

C
A: Drum front support assy B: Print drum support (F) C: Tool (Print drum JIG) D: Print drum support (R) E: Drum rear frame plate

E
[Precautions on Reassembly: 2] Align the positioning hole [G] in the Joint gear [F] over the positioning holes in the Drum rear frame plate and Print drum main gear. Adjust the position of the Junction gear assy [H] to allow a small amount of backlash between the Junction gear and the Joint gear [F] (and Print drum main gear).

F: Joint gear G: Joint gear positioning holes H: Junction gear assy

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CHAPTER 8. PRINT DRUM SECTION FILTER CLEANING

Adjustment
1. Filter Cleaning
(1) Pull out the print drum, remove the ink cartridge, and remove the following components. Ink cartridge guide assy Drum front upper cover Ink cartridge set switch PCB cover Ink cartridge set switch PCB mounting bracket (2) Remove the mounting screws (M4 x 6: 2 pcs and M3 x 10: 2 pcs) on the Ink intake nozzle [A], and remove the nozzle. (3) Remove the Filter [B] and clean it. [Symptoms] If foreign matter is drawn into the filter, ink will no longer be drawn in, resulting in a lack of ink in the print drum.

Top

Bottom

[Precautions on Reassembly] Mount the Filter [B] with the rounded top facing upwards. Engage the lug on the bottom of the Ink intake nozzle [A] into the slot in the lower base [C].

A: Ink intake nozzle B: Filter C: Lug and slot 8 25 RN (Version 1.0)

CHAPTER 8. PRINT DRUM SECTION SQUEEGEE GAP ADJUSTMENT

2.

Squeegee Gap Adjustment


(1) Pull out the print drum, and remove the following components. Screen Print drum body (2) Clean out the ink inside the squeegee unit. (3) Using a feeler gauge, check that the gap between the Squeegee roller and Doctor roller is in specified setting (0.08 mm 0.02 mm at front and rear). (4) If the gap is outside the specifications, loosen the retaining screw on the Doctor roller adjust plate [A] with 3mm Allen wrench. (5) Insert the Allen wrench [C] into the hole in the Doctor roller adjust plate [A], and make the adjustment by moving the adjustment plate. (6) Tighten the retaining screw. [Symptoms] If the gap is too large, more ink than is necessary will be transferred onto the inside surface of the print drum, causing ink to leak. Conversely, if the gap is too small, insufficient ink will be transferred onto the inside surface of the print drum, possibly resulting in uneven printing density due to lack of ink.

A B
Front Reduce

Increase

Reduce

Increase

C
Rear A: Doctor roller adjust plate B: Allen bolt for 3 mm Allen wrench C: 2.5 mm Allen wrench 8 26 RN (Version 1.0)

CHAPTER 8. PRINT DRUM SECTION INK BLOCKING PLATE POSITION ADJUSTMENT

3.

Ink Blocking Plate Position Adjustment


Front (1) Pull out the print drum, remove the ink cartridge, and remove the following components. Print drum front cover Ink cartridge guide assy Drum front upper cover Ink cartridge set switch PCB cover Ink cartridge set switch PCB mounting bracket Swing base assy Ink cartridge guide bottom assy Ink pump unit (2) Loosen the mounting screw on the Ink blocking plate (F) [A] via the opening in the Print drum support (F). (3) Insert a slot-head screwdriver into the slot in the Ink blocking plate (F) [A] and move the plate until it is flush with the inside surface of the print drum. Tighten the mounting screw. Rear (1) Pull out the print drum, and loosen the mounting screw on the Ink blocking plate (R) [B] via the opening in the Print drum support (R). (2) Insert a slot-head screwdriver into the slot in the Ink blocking plate (R) [B] and move the plate until it is flush with the inside surface of the print drum. Tighten the mounting screw. [Symptoms] If the ink blocking plates are not flush with the inside surface of the print drum, they will not be able to block the ink exuded to the ends of the Squeegee roller. Ink will accumulate inside the print drum, and in the worst cases, ink may leak out from the print drum body.

A: Ink blocking plate (F) B: Ink blocking plate (R)

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CHAPTER 8. PRINT DRUM SECTION SQUEEGEE PRESSURE BALANCE ADJUSTMENT

4.

Squeegee Pressure Balance Adjustment


(1) Create a master with test chart No. 15 and print to check the left and right print density balance. (2) If the left and right print density is not balanced, adjust as shown below. Front (3) Pull out the print drum, remove the ink cartridge, and remove the following components. Print drum front cover Ink cartridge guide assy Drum front upper cover Ink cartridge set switch PCB cover Ink cartridge set switch PCB mounting bracket Swing base assy Ink cartridge guide bottom assy Ink pump unit (4) Loosen the two retaining screws on the squeegee frame via the opening in the Print drum support (F). (5) Insert a slot-head screwdriver via the opening in the Print drum support (F), turn the Eccentric boss [A], and adjust so that the gap between the squeegee roller and the print drum body is approx. 0.3 mm. (6) Tighten the two retaining screws [B] on the squeegee frame. Rear (3) Pull out the print drum, remove the ink cartridge, and remove the following component. Junction gear assy (4) Loosen the two retaining screws on the squeegee frame via the opening in the Print drum support (R). (5) Insert a slot-head screwdriver via the opening in the Print drum support (R), turn the Eccentric boss [A], and adjust so that the gap between the squeegee roller and the print drum body is approx. 0.3 mm. (6) Tighten the two retaining screws [B] on the squeegee frame.

Rear

Front

A B
A: Eccentric boss B: Retaining screws 8 28 RN (Version 1.0)

CHAPTER 8. PRINT DRUM SECTION SQUEEGEE PRESSURE BALANCE ADJUSTMENT

[Continued on next page] Using your finger, press the print drum from underneath, and adjust the gap to approx. 0.3 mm. [Checking after Adjustment] Run an actual print after the adjustment to check the left and right print density balance. If the left and right print density balance is incorrect, the squeegee pressure must be readjusted. [Symptoms] Incorrect left and right squeegee pressure causes unbalanced print density. If the squeegee pressure is too high (gap too small), more ink than is needed will be transferred onto the print drum and may cause ink leakage. If the squeegee pressure is too low (gap too large), the print density will be reduced, and excess load will be applied on the print drum and may shorten the life of the drum body.

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CHAPTER 8. PRINT DRUM SECTION

[Memo]

8 30 RN (Version 1.0)

CHAPTER 9: MASTER CLAMP SECTION

Contents
Mechanism ............................................................................................................................ 9-2 1. 2. 3. Clamp Unit Home Positioning Mechanism ............................................................. 9-2 Clamp Plate Master Release Mechanism ............................................................... 9-3 Clamp Plate Master Clamp Mechanism .................................................................. 9-4

Removal and Assembly ........................................................................................................ 9-5 1. 2. Removing the Clamp Unit ........................................................................................ 9-5 Removing the Clamp Motor, Clamp Sensor A, Clamp Sensor B ............................ 9-6

91 RN (Version 1.0)

CHAPTER 9. MASTER CLAMP SECTION CLAMP UNIT HOME POSITIONING MECHANISM

Mechanism
1. Clamp Unit Home Positioning Mechanism
When the START key is pressed to create confidential or normal masters, the Clamp open arm [A] and Master release arm [B] are checked to ensure that they have returned to the home position (with the light paths to both Clamp sensors A [F] and B [G] open). If they are not at the home position, the Clamp motor [C] is activated to move the Clamp cam assembly [D] and return the Clamp open arm [A] and Master release arm [B] to the home position until the light paths to both Clamp sensors A [F] and B [G] are open.

C D

B E

G
View in the direction of the arrow A: Clamp open arm B: Master release arm C: Clamp motor D: Clamp cam assembly E: Clamp encoder sensor F: Clamp sensor A G: Clamp sensor B

92 RN (Version 1.0)

CHAPTER 9. MASTER CLAMP SECTION CLAMP PLATE MASTER RELEASE MECHANISM

2.

Clamp Plate Master Release Mechanism


When the START key is pressed to create confidential or normal masters, the print drum makes one turn and checks for the presence of master on the print drum. Once the presence of a master on the drum has been checked, the drum returns to position-A, and the clamp plate master release operation starts. The clamp motor activates and rotates the Clamp cam assembly [A]. This pushes down the Clamp open arm [B] and opens the Clamp plate [C]. The Master release arm [D] is then pushed down, and the Master release bar [E] is raised, releasing the master from the Clamp plate [C]. The clamp motor continues to run, and raises the Clamp open arm [B] and Master release arm [D]. The motor is switched off once the light path to Clamp sensor B [G] is opened. (1) The Clamp open arm is pushed down, opening the Clamp plate.

B C

(2) The Master release arm is pushed down, raising the Master release bar and releasing the master.

(3) The Clamp open arm and Master release arm are raised, and the motor switches off once the light path to Clamp sensor B is opened.

F
A: Clamp cam assembly B: Clamp open arm C: Clamp plate D: Master release arm E: Master release bar F: Clamp sensor A G: Clamp sensor B 93 RN (Version 1.0)

CHAPTER 9. MASTER CLAMP SECTION CLAMP PLATE MASTER CLAMP MECHANISM

3.

Clamp Plate Master Clamp Mechanism


As the used master is removed from the print drum, the print drum makes one revolution and returns to position-A, and the clamp plate master clamp operation starts. The clamp motor activates and rotates the Clamp cam assembly [A]. This pushes down the Clamp open arm [E] and opens the Clamp plate [B]. The clamp motor is switched off once the light path to Clamp sensor A [D] is opened. (It stops with Clamp plate [B] still open.) The load pulse motor feeds a set amount of the master [G] onto the print drum, and the clamp motor activates to rotate the Clamp cam [A] and raise the Clamp open arm [E]. The clamp motor is switched off once the light path to Clamp sensor B [F] is opened. (The clamp unit is returned to the home position.) (1) The Clamp open arm [E] is pushed down, opening the Clamp plate [B]. The clamp motor is switched off once the light path to Clamp sensor A [D] is opened (with Clamp plate [B] still open).

C A

B D E

F G

(2) The master [G] is fed onto the print drum, and the clamp motor is switched on, raising the Clamp open arm [E]. The clamp motor is switched off once the light path to Clamp sensor B [F] is opened. (Returns to home position.)

B E
A: Clamp cam assembly B: Clamp plate C: Clamp encoder D: Clamp sensor A E: Clamp open arm F: Clamp sensor B G: Master 94 RN (Version 1.0)

F G

CHAPTER 9. MASTER CLAMP SECTION REMOVING THE CLAMP UNIT

Removal and Assembly


1. Removing the Clamp Unit
(1) Remove the rear cover. (2) Remove the Main PCB. (3) Unplug the clamp motor connector [A] and sensor connector [B]. (4) Remove the mounting screws (M4 x 8: 3 pcs) [C] on the clamp unit, and remove the clamp unit. [Precautions on Reassembly] Align the half-pierced sections.

A: Clamp motor connector B: Clamp sensor connector C: Clamp unit mounting screw

95 RN (Version 1.0)

CHAPTER 9. MASTER CLAMP SECTION REMOVING THE CLAMP MOTOR, CLAMP SENSOR A, CLAMP SENSOR B

2.

Removing the Clamp Motor, Clamp Sensor A, Clamp Sensor B


Removing the Clamp Motor (1) Remove the following components. Rear cover Main PCB Clamp unit (2) Remove the E-ring and remove the Worm gear [A]. (3) Unplug the connector [C], remove the mounting screws, and remove the Clamp motor [B]. Removal of Clamp Sensor A (1) Remove the following components. Rear cover Main PCB Clamp unit (2) Remove the mounting screws (M3 x 6: 2 pcs) and remove the Shaft support bracket [D]. (3) Unplug the connector and remove Clamp sensor A [E]. Removal of Clamp Sensor B (1) Remove the following components. Rear cover Main PCB Clamp unit (2) Remove the mounting screw (M3 x 6: 1 pc) and remove the sensor bracket [F]. (3) Unplug the connector and remove Clamp sensor B [G] from the sensor bracket [F].

A D E C

B F
A: Worm gear B: Clamp motor C: Connector D: Shaft support bracket E: Clamp sensor A F: Sensor bracket G: Clamp sensor B 96 RN (Version 1.0)

CHAPTER 10: MASTER REMOVAL SECTION

Contents
Mechanism ......................................................................................................................... 10-2 1. 2. 3. 4. 5. Master Removal Mechanism ................................................................................. 10-2 Master on the Drum (before Master Removal) Check Mechanism ...................... 10-3 Removed Master Vertical Transport Mechanism .................................................. 10-4 Disposed Master Compression Mechanism ....................................................... 10-5 Disposal Box Safety Switch ................................................................................... 10-8

Removal and Assembly ..................................................................................................... 10-9 1. 2. 3. 4. 5. 6. Removing the Master Removal Hook ................................................................... 10-9 Removing the Master Removal Unit .................................................................... 10-10 Removing the Master Disposal Gate Housing ................................................... 10-12 Removing the Master Removal Roller (Bottom) ................................................. 10-13 Removing the Master Compression Plate .......................................................... 10-14 Removing the Motors ........................................................................................... 10-16

10 1 RN (Version 1.0)

CHAPTER 10. MASTER REMOVAL SECTION MASTER REMOVAL MECHANISM

Mechanism
1. Master Removal Mechanism
Masters on the print drum are removed as follows. (1) At the start of master removal, the Master sensor [A] checks whether the master to be removed on the print drum actually exists. (2) The clamp plate master removal operation is performed with the print drum at position A to release the leading edge of the master from the clamp plate. (3) The Master removal hook [B] then detaches the master from the print drum as the drum is rotated. (4) The removed master is fed into the Master compression plate [C]. (5) The removed master is then compressed, and disposed of in the Master disposal box [D].

B A C

A: Master sensor B: Master removal hook C: Master compression plate D: Master disposal box

10 2 RN (Version 1.0)

CHAPTER 10. MASTER REMOVAL SECTION MASTER ON THE DRUM (BEFORE MASTER REMOVAL) CHECK MECHANISM

2.

Master on the Drum (before Master Removal) Check Mechanism


When creating confidential or normal masters, the print drum moves to position A, and with the print drum at the 75 position, the Master sensor [A] checks whether or not there is a master [B] on the drum. (The check operation is not performed if information that a master is present has already been stored in the machines memory.) The drum rotation angle for the check can be adjusted using test mode No. 580. If the light from the Master sensor [B] is reflected back, (master present), the master removal sensor checks whether the master is sent to the master disposal box or not during the master removal.

A B
Print drum 75 position

A: Master sensor B: Master C: Light absorber strip

10 3 RN (Version 1.0)

CHAPTER 10. MASTER REMOVAL SECTION REMOVED MASTER VERTICAL TRANSPORT MECHANISM

3.

Removed Master Vertical Transport Mechanism


When the clamp unit is operated to release the leading edge of the master from the clamp plate, the Master removal motor [A] activates, rotating the Vertical transport rollers [B, C, D, E, F]. The main motor also rotates the print drum at the same time. The master is fed between the rollers and pushed into the Master compression plate [H]. The master is guided here by the Master removal hook [G] and G belt [J]. The main motor and Master removal motor [A] stop once the print drum has rotated to position-A. (The time at which the master removal motor stops can be adjusted using test mode No. 382.) When the print drum reaches the 70 and 90 positions, the Master removal sensor [I] checks whether the master is being fed correctly to the master disposal box. (These drum angles can be adjusted using test modes No. 380 and 381.) The master removal hook is normally located at a fixed position close to the print drum, but shifts away from the drum when the drum is pulled out. The print drum rotation speed during master removal can be adjusted using test mode No. 387.

H E F G

A: Master removal motor B: Pulley shaft C: Master removal roller (top) D: Master removal pulley (top) E: Master removal pulley (bottom) F: Master removal roller (bottom) G: Master removal hook H: Master compression plate I: Master removal sensor J: G belt

10 4 RN (Version 1.0)

CHAPTER 10. MASTER REMOVAL SECTION DISPOSED MASTER COMPRESSION MECHANISM

4.

Disposed Master Compression Mechanism


1) Initializing If the light path on the Master compression sensor [B] is open when the power is switched ON or when everything is reset, the master compression motor operates in the compression direction, and when the light path to the master compression sensor is blocked, it operates in reverse until the light path is open again. If the light path to the Master compression sensor [B] is blocked when the power is switched ON or when everything is reset, the master compression motor operates in the return direction until the light path is open again. If the light path to the Master compression sensor [B] is blocked when starting master removal, the master compression motor operates in the return direction until the light path is open. (The initializing operation is not performed if the light path to the master compression sensor is open when starting master removal.) 2) Master compression Once the removed master vertical transport operation is complete, the master compression motor operates in the compression direction to lower the Master compression plate [A]. The light path to the master compression sensor is briefly blocked by the Master compression sensor plate [C]. When the light path to the master compression sensor is subsequently opened again, the master compression motor stops (the stop time can be adjusted using test mode No. 384), and then operates in the return direction to return the master compression plate to its home position. 3) Ejection of removed master The master removed by the vertical transport operation is pushed inside the Master compression plate [A]. Compression is performed by the master removal motor rotating the Master compression plate [A] on the Pivot shaft [D]. The Piston shaft link [E] also rotates, but it rotates on the Piston shaft [F] rather than on the Pivot shaft [D]. This causes the Piston block [G] to move in the direction in which the master ejects out.

A: Master compression plate B: Master compression sensor C: Master compression sensor plate D: Pivot shaft E: Piston shaft link F: Piston shaft G: Piston block

F E

10 5 RN (Version 1.0)

CHAPTER 10. MASTER REMOVAL SECTION DISPOSED MASTER COMPRESSION MECHANISM


4) Disposed-master-full detection The removed-master-full detection is performed using the following two mechanisms, and a masterfull indication is displayed by either. (1) The number of masters removed after resetting following the previous master-full indication is counted, and the master disposal box is determined as full when the count reaches the preset value. * The preset master-full count can be set using test mode No. 386. The master count is not incremented if a master removal error occurs or if the master to be removed is not detected on the print drum. (2) Mechanism for mechanically determining that the master disposal box is full (see below.)

Master compression sensor Disposal box full sensor Master compression sensor plate At the start of compression, the light paths to the master compression sensor and disposal box full sensors are open. Master compression plate

Pivot shaft

When the master compression motor operates to start master compression, the master compression sensor is immediately blocked by the master compression sensor plate. As the operation continues, the disposal box full sensor is briefly blocked by the master compression plate, but is then opened.

Once the master inside the master disposal box has been sufficiently compressed, the master compression plate stops rotating, but the master compression sensor plate continues to rotate. (The master compression plate is mounted to the pivot shaft via a spring, whereas the master compression sensor plate is mounted directly to the pivot shaft.)

Once the light beam of the master compression sensor is blocked by the master compression sensor plate, the compression operation stops, and the master compression plate returns to the home position.

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CHAPTER 10. MASTER REMOVAL SECTION DISPOSED MASTER COMPRESSION MECHANISM

When the master disposal box becomes full, the master compression plate stops rotating before the removed-master-full sensor is blocked.

When the light path to the master compression sensor is open and the removed-master-full sensor is not blocked, the master-disposal-box-full indication is displayed.

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CHAPTER 10. MASTER REMOVAL SECTION DISPOSAL BOX SAFETY SWITCH

5.

Disposal Box Safety Switch


The master disposal box safety switch checks whether the master disposal box and master disposal gate housing are properly positioned. If the master disposal gate housing is locked and correctly set, the bracket on the master disposal gate housing is positioned close to the safety switch. When the master disposal box is mounted, the safety switch unit moves back, and the safety switch is pushed against the master disposal gate housing. The master disposal box full indication is reset if the master disposal box safety switch is released (the master disposal box removed) for more than 5 seconds. The master disposal box count memory is also reset to zero.

Master disposal gate housing

Safety switch

Master disposal box

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CHAPTER 10. MASTER REMOVAL SECTION REMOVING THE MASTER REMOVAL HOOK

Removal and Assembly


1. Removing the Master Removal Hook
(1) Pull out the print drum, switch off the power, and remove the front cover. (2) Remove the spring [A] from the master removal hook bracket. (3) Remove the bearing fixing plate [B]. (M4 x 8: 1 pc) (4) Remove the Master removal hook [C] together with the master removal hook bracket. (If it cannot be removed, it is caught on the front screw of the master removal unit mounting screws. Remove this screw.) [Precautions on Reassembly] Do not drop the inside bearing when mounting the master removal hook bracket.

A B

A: Spring of the master removal hook bracket B: Bearing fixing plate C: Master removal hook bracket and master removal hook

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CHAPTER 10. MASTER REMOVAL SECTION REMOVING THE MASTER REMOVAL UNIT

2.

Removing the Master Removal Unit


(1) Move the scanner table to the servicing position [A]. (2) Remove the front and rear covers. (3) Remove the upper housing cover (master removal unit cover). (M3 x 6: 2 pcs) (4) Unlock the Release lever [B], fully open the Master disposal gate housing [C], and pull out the master disposal gate housing horizontally in the direction of paper ejection. The master disposal gate housing is slotted into the Pivot shafts [D] on both sides. The shafts are cut as shown in the diagram below, and so the master disposal gate housing can be pulled out provided it is opened sufficiently.

A: Servicing position B: Release lever C: Master disposal gate housing D: Pivot shaft

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CHAPTER 10. MASTER REMOVAL SECTION REMOVING THE MASTER REMOVAL UNIT
(5) Remove the master removal unit mounting screws (M4 x 8: 4 pcs).

(6) Detach the connectors on both sides, and remove the master removal unit.

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CHAPTER 10. MASTER REMOVAL SECTION REMOVING THE MASTER DISPOSAL GATE HOUSING

3.

Removing the Master Disposal Gate Housing


(1) Remove the E-rings and bearings on both sides of the Pulley shaft [B], and remove the Pulley shaft. (2) Remove the E-rings, bearings, and gears on both sides of the Master removal roller (top) [A], and remove the roller. (3) Remove the G belts [D] from the Master removal pulleys (top) [C].

A: Master removal roller (top) B: Pulley shaft C: Master removal pulleys (top) D: G belts E: Master disposal gate housing

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CHAPTER 10. MASTER REMOVAL SECTION REMOVING THE MASTER REMOVAL ROLLER (BOTTOM)

4.

Removing the Master Removal Roller (Bottom)


(1) Loosen the screws on the Tension roller [A], and remove the belt [B]. (M3 x 6: 2 pcs) (2) Remove the E-rings, bearings, gears, and pulleys on both sides of the Master removal roller (bottom) [C], and remove the roller. (3) Remove the G belts [D].

D C

A: Tension roller B: Belt C: Master removal roller (bottom) D: G belt

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CHAPTER 10. MASTER REMOVAL SECTION REMOVING THE MASTER COMPRESSION PLATE

5.

Removing the Master Compression Plate


(1) Remove the E-rings and bearings from both sides of the compression shaft [A]. (2) Rotate the compression shaft to move the master Compression plate [C] to the master compressing position. Lifting up the compression gear [B] together with the shaft, to disengage the gear, allowing the shaft to be rotated. (3) Remove the E-rings on both sides of the Piston shaft [D], and remove the shaft. (4) Remove the Piston shaft links [E] on both sides.

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CHAPTER 10. MASTER REMOVAL SECTION REMOVING THE MASTER COMPRESSION PLATE
(5) Remove the shaft from the unit, with the master compression plate attached.

(6) Remove the Piston blocks [F]. (7) Unhook the Compression spring [H] from the Compression plate holder [G], and then remove the compression plate holder from the Compression shaft [A]. (8) Remove the Master compression sensor plate [I] and then separate the Master compression plate from the compression shaft.

A: Compression shaft B: Compression gear C: Master compression plate D: Piston shaft E: Piston shaft link F: Piston block G: Compression plate holder H: Compression spring I: Master compression sensor plate

J: Compression plate guard cover (* master anti-clamping component)

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CHAPTER 10. MASTER REMOVAL SECTION REMOVING THE MOTORS

6.

Removing the Motors


(1) Remove the Master removal motor [A]. (Mounting screws M4 x 6: 2 pcs) (2) Remove the Compression motor [B]. (Mounting screws M4 x 6: 2 pcs) (3) Remove the E-rings, and then remove the Safety switch unit [C].

A: Master removal motor B: Compression motor C: Safety switch unit

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CHAPTER 11: FB ORIGINAL SCANNING SECTION

Contents
Mechanism .......................................................................................................................... 11-2 1. 2. 3. 4. 5. 6. Scanner Table Setting System ............................................................................... 11-2 Original Scanning Mechanism ............................................................................... 11-4 Flat Bed Initialization Movement ............................................................................. 11-6 Stage Glass Original Detection System ................................................................. 11-8 Flat Bed Automatic Base Control ......................................................................... 11-10 FB Original Scanning Mechanism ........................................................................ 11-12

Removal and Assembly .................................................................................................... 11-14 1. 2. 3. 4. 5. Removing the Scanner Unit ................................................................................. 11-14 Removing the Stage Glass .................................................................................. 11-16 Removing the Flat Bed Original Detection Sensor .............................................. 11-17 Removing the Lamp ............................................................................................. 11-18 Removing the Lens Assy ..................................................................................... 11-20

Adjustment ......................................................................................................................... 11-22 1. 2. 3. Flat Bed Read Pulse Motor Speed Adjustment ................................................... 11-22 FB Scan Start Position Adjustment ...................................................................... 11-23 FB Horizontal Scan Position Adjustment ............................................................. 11-24

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CHAPTER 11. FB ORIGINAL SCANNING SECTION SCANNER TABLE SETTING SYSTEM

Mechanism
1. Scanner Table Setting System
The Flat bed set switch [B] checks whether or not the Scanner table [A] has been set correctly. This switch also acts as a Safety switch, which cuts the power supply to the main motor and clamp motor, and thermal power to the TPH if the scanner table is open.

A E

C B

A: Scanner table B: Flat bed set switch C: Damper spring D: Scanner unit support shaft E: Scanner table open lever

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CHAPTER 11. FB ORIGINAL SCANNING SCTION SCANNER TABLE SETTING SYSTEM

[Memo]

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CHAPTER 11. FB ORIGINAL SCANNING SECTION ORIGINAL SCANNING MECHANISM

2.

Original Scanning Mechanism


The FB read pulse motor [J] drives the front and rear Wire spool pulleys [G] via the 2-stage reduction pulleys linked by the Timing belts [H], [I]. The front and rear wire spool pulleys are configured symmetrically. The wire [S] has one end secured to the frame via Coil spring [A], and is wound onto Sliding pulley No. 2 [E] mounted on the Mirror carriage [B]. It is wound approximately 6.5 times around the rear wire spool pulley [G] via the Fixed pulley [F] secured to the frame. It is then attached to the Lamp carriage [C] and then secured to the frame via Sliding pulley No. 1 [D] mounted on the Mirror carriage [B]. The Lamp carriage [C] carries two original illumination Lamps [K] (and lamp inverters) and Mirror No. 1 [M], and the mirror carriage carries the two mirrors [N], [O]. The mechanism uses a full/half-rate mirror scanning system, in which the mirror carriage moves 1/2 L mm as the lamp carriage moves L mm in the same direction. This means that when the FB read pulse motor [J] is activated, the original surface can be scanned while maintaining a constant distance between the original and the center of the lens mounted on the frame. The original on the scanner table illuminated by the lamp is reflected via mirrors No. 1, 2, and 3, and is then focused onto the CCD [R] by the lens [Q] in the lens assy [P].

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CHAPTER 11. FB ORIGINAL SCANNING SCTION ORIGINAL SCANNING MECHANISM


Drive system diagram

C G

J
Optical system diagram

N C

A: Spring B: Mirror carriage C: Lamp carriage D: Sliding pulley No. 1 E: Sliding pulley No. 2 F: Fixed pulley G: Wire spool pulley H: Scanner timing belt 1 I: Scanner timing belt 2 J: Flat bed read pulse motor

K: Lamp L: Stage glass M: Mirror No. 1 N: Mirror No. 2 O: Mirror No. 3 P: Lens assy Q: Lens R: CCD S: Wire

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CHAPTER 11. FB ORIGINAL SCANNING SECTION FLAT BED INITIALIZATION MOVEMENT

3.

Flat Bed Initialization Movement


Initialization is performed in the following situations to bring the flat bed unit to standby mode. When power is switched on When everything has been reset

Initialization operation
The Image scanner ADF shading sensor [A] is checked, and if it is OFF (light path open), the Flat-bed read pulse motor [B] is activated in the return direction until the light path is blocked, and moves the Lamp carriage [C] towards the left in the photograph. Once the image scanner ADF shading sensor is ON (blocked), it is moved a further 3 mm before the operation ends. (This position is the standby position.) The actuator plate of the image scanner ADF shading sensor is fixed to the lamp carriage. No movement is made when the image scanner ADF shading sensor is ON (blocked).

When image scanner ADF shading sensor is OFF

Start

Operation ends

on Image scanner ADF shading sensor Flat bed read pulse motor Return (1)
3 mm

(1) If the image scanner ADF shading sensor does not switch to ON when the flat bed read pulse motor is moved 487 mm in the return direction, the flat bed read pulse motor is assumed to be locked, and T14-100 is displayed.

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CHAPTER 11. FB ORIGINAL SCANNING SCTION FLAT BED INITIALIZATION MOVEMENT


A

A: Image scanner ADF shading sensor B: Flat bed read pulse motor C: Lamp carriage

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CHAPTER 11. FB ORIGINAL SCANNING SECTION STAGE GLASS ORIGINAL DETECTION SYSTEM

4.

Stage Glass Original Detection System


The Flat bed original detection sensor [B] checks whether an original is placed on the Stage glass [A]. The Flat bed original detection sensor [B] performs its check as soon as the Stage cover [C] is closed halfway, blocking the light path to the Stage cover sensor [D]. If the light path to the Flat bed original detection sensor [B] is open (original present), the Master-Making/ Print indication on the panel switches to Master-Making, and the thermal pressure motor is activated to lower the thermal head until the TPH pressure sensor switches ON. At the same time, the lamp illuminates until the shading compensation is made (automatic base control operation is also performed if original scanning intensity is set to Auto), and the lamp carriage returns to the scanning start standby position and waits. If START key is not pressed within 60 seconds, the lamp turns off and the lamp carriage returns to the standby position.

A: Stage glass B: Flat bed original detection sensor C: Stage cover D: Stage cover sensor

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CHAPTER 11. FB ORIGINAL SCANNING SCTION STAGE GLASS ORIGINAL DETECTION SYSTEM

Set original

To FB scanning operation 1

To FB scanning operation 1

Stage cover sensor Flat bed original detection sensor OFF Thermal pressure motor TPH pressure sensor ON Press

Lamp Flat bed read pulse motor

Shading adjustment Feed


41 mm

Feed Feed

Feed Return

8 mm 15 mm 100 ms

2.6 mm 2.6 mm 100 ms 100 ms 100 ms

20.2 mm

Flat bed automatic base control Image scanner ADF shading sensor

Standby position

Scanning start standby position

Scanning start standby position

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CHAPTER 11. FB ORIGINAL SCANNING SECTION FLAT BED AUTOMATIC BASE CONTROL

5.

Flat Bed Automatic Base Control


This operation is performed after the shading compensation for line mode only when the original scanning density is set to Auto. (It is not performed in photo, line/photo, dot, and book modes.) When the START key is pressed, the lamp illuminates, and the flat bed read pulse motor activates in the scanning direction. It moves 41 mm after the image scanner ADF shading sensor switches from ON to OFF, and then pauses for a set period. Shading compensation is then performed while it moves 8 mm, and it then moves 15 mm (9 mm from the leading edge of the original) before the image sensor scans the surface density of the original. After this, the lamp carriage moves approximately 2.6 mm twice and scans the surface density of the original. (Total 3 times) The flat bed read pulse motor then operates in reverse (in the return direction) to return the lamp carriage to the scanning start standby position, and proceeds to FB scanning operation 1.

B
9 mm 2.6 mm 2.6 mm

18 mm 55 mm

0.8 mm

Scanning line (lamp carriage) when image scanner ADF shading sensor switches from ON to OFF

A: Original stopper B: Shading plate C: Original D: Stage glass

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CHAPTER 11. FB ORIGINAL SCANNING SCTION FLAT BED AUTOMATIC BASE CONTROL

START key ON

To FB scanning operation 1

Thermal pressure motor TPH pressure sensor

OFF ON

Lamp

Shading compensation Feed Feed

Feed

Feed Return

Flat bed read pulse motor

41 mm

8 mm 15 mm 100 ms

2.6 mm 2.6 mm 100 ms 100 ms

20.2 mm

100 ms

Image scanner ADF shading sensor

Standby position

Scanning start standby position

Scanning start standby position

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CHAPTER 11. FB ORIGINAL SCANNING SECTION FB ORIGINAL SCANNING MECHANISM

6.

FB Original Scanning Mechanism


This scanning operation describes the following situations. One is in which the ABC (Auto Base Control) is not performed. The other is when the START key is pressed within 60 seconds of placing the original on the stage glass (START from FB original scanning operation 1), and when the START key is pressed after 60 seconds. If the START key is pressed after 60 seconds have elapsed, the lamp [B] illuminates, and the Flat bed read pulse motor [A] activates in the feed direction. The Lamp carriage [C] moves to the shading compensation position, and shading compensation is performed. (See the previous section for the case in which line mode is selected with original scanning density set at Auto, i.e. with ABC.) It then moves a preset distance in the scanning direction (to the right) from the scanning start standby position, and the write pulse motor activates. It then moves a further preset distance, switching ON the read/write signal and initiating scan of the original. (The master making process starts at the same time.) Once the master making for the size of the original is made, the read/write signal is switched OFF, and scanning ends. (The master making process also ends at the same time.) The Flat bed read pulse motor [A] moves the lamp carriage a further 3 mm in the scanning direction before stopping. The Lamp [B] turns off, and the scanning operation is complete. The Lamp carriage [C] then returns to the standby position. (Flat bed initialization operation)

A: Flat bed read pulse motor B: Lamp C: Lamp carriage

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CHAPTER 11. FB ORIGINAL SCANNING SCTION FB ORIGINAL SCANNING MECHANISM

FB scanning operation 1 START key ON START key ON End

Thermal pressure motor TPH pressure sensor

OFF

ON

Lamp

Shading compensation Feed


41 mm

Flat bed read pulse motor

Feed
8 mm 100 ms

(11 + b) mm

(L + d) mm

3 mm

(6 + b - c) mm

Image scanner ADF shading sensor Write pulse motor

Read/write signal

Standby position

Scanning start standby position

* L = paper size set by the Users Mode. Adjustment value b = Adjusted by test mode No. 181 (Flat bed scanning start position adjustment) Adjustment value c = Adjusted by test mode No. 281 (Master making start position adjustment) Adjustment value d = Adjusted by test mode No. 282 (Master making length adjustment)

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CHAPTER 11. FB ORIGINAL SCANNING SECTION REMOVING THE SCANNER UNIT

Removal and Assembly


1. Removing the Scanner Unit
(1) Move the carriage to the locking position using test mode No. 154 (scanner lock action), open the Scanner table [I], secure the mirror carriage using the Transport lock screw [J], and then close again. (2) Switch off the power, and remove the rear cover. (3) Remove the Scanner unit cover (left) [B] by removing the four screws (M4 x 8). (If the ADF unit is fitted, remove the Original receiving tray bracket [C] with the two (M4 x 10) screws and two (M4 x 8) screws, and then remove the Scanner unit cover (left) [B] before disconnecting the ADF wire harness connector and ground lead.) (4) Remove the Stage cover [A] by removing the two screws (M4 x 8), and detach the ground lead. (If the ADF unit is fitted, turn the ADF mount plate on the rear of the hinge 180 degrees to lock it (see photograph below), and then remove the ADF unit with the two screws (M4 x 10).) (5) Remove the Scanner unit cover (rear) [D] by removing the three screws (M4 x 8). (6) Remove the Scanner unit cover (front) [K] by removing the two upper screws (M4 x 8), and then open the Scanner table [I] and removing the side screw (M4 x 6). (7) Remove the Scanner unit cover (right) [E] by removing the two screws (M4 x 8). (8) Detach the two connectors from the Scanner unit [H]. (Flat cables on main PCB connectors) (9) Remove the two screws (M4 x 8) on the two Stage cover brackets [G] that secure the Scanner unit [H]. (10) Remove the Stage cover sensor assembly [F] with the screw (M4 x 8). (11) Remove the six screws (M4 x 8) on the Scanner unit [H], and remove the unit upwards. (Take care when handling, as this is a heavy precision unit.) [Precautions on Reassembly] When mounting the scanner, align the half-pierced sections of the two front alignment brackets and those on the two Stage cover brackets [G]. After reassembling, open the scanner table and remove the transport lock screw on the mirror carriage. Clear the error message using test mode No. 155 (Scan release action).

* When ADF is fitted (hinge rear)

Position when removing the ADF unit

* If the scanner locking mode is not cleared using the test mode after reassembling, error message T23-111 will be displayed.

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CHAPTER 11. FB ORIGINAL SCANNING SCTION REMOVING THE SCANNER UNIT


A

When ADF is fitted

A: Stage cover B: Scanner unit cover (left) C: Original receiving tray bracket D: Scanner unit cover (rear) E: Scanner unit cover (right) F: Stage cover sensor assy G: Stage cover bracket H: Scanner unit I: Scanner table J: Transport lock screw K: Scanner unit cover (front) L: ADF mount plate

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CHAPTER 11. FB ORIGINAL SCANNING SECTION REMOVING THE STAGE GLASS

2.

Removing the Stage Glass


(1) Switch off the power. (2) Remove the scanner unit cover (left) [A] by removing four screws (M4 x 8). (If the ADF unit is fitted, remove the original receiving tray bracket by removing the two (M4 x 10) screws and two (M4 x 8) screws, and then remove the scanner unit cover (left).) (3) Remove the Original stopper [B] by removing two Special step screws [D], and slide to the left (paper feed side) slightly before lifting up and removing. (4) Lift up the left-hand side (paper feed side) of the Stage glass [C] slightly, and slide it out towards the paper feed side. [Precautions on Reassembly] Push the stage glass firmly against the right-hand side (ejection side) after placing it on the scanner unit frame.

C B

A: Scanner unit cover (left) B: Original stopper C: Stage glass D: Special step screw

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CHAPTER 11. FB ORIGINAL SCANNING SCTION REMOVING THE FLAT BED ORIGINAL DETECTION SENSOR

3.

Removing the Flat Bed Original Detection Sensor


(1) Switch off the power. (2) Remove the Stage glass [A]. (Refer to this section for details.) (3) Unplug the connector, and remove the flat bed original detection sensor [B] by removing one screw (M3 x 8). [Precautions on Reassembly] Engage the hooks on the bottom of the Flat bed original detection sensor into the holes in the bracket.

A: Stage glass B: Flat bed original detection sensor

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CHAPTER 11. FB ORIGINAL SCANNING SECTION REMOVING THE LAMP

4.

Removing the Lamp


(1) Switch off the power. (2) Remove the scanner unit cover (left) by removing four screws (M4 x 8). (If the ADF unit is fitted, remove the original receiving tray bracket by removing two (M4 x 10) screws and two (M4 x 8) screws, and then remove the scanner unit cover (left).) (3) Remove the Original stopper by removing the two special step screws, and slide it to the left (paper feed side) slightly before lifting it up and removing it. (4) Remove the Stage glass bracket [A] by removing two special screws (M3). (5) Push the Lamp carriage [B] by hand (taking care not to touch optical components) and move it to the cutaway [C] in the scanner unit frame. Perform the following procedures on the cutaway section on the operation panel side of the scanner unit. (6) Remove the Stopper [D], which holds the lead wire, by removing the screw (M3 x 6). (7) Remove the wire harness connector [E] of the Lamp. (8) Remove the Lamps [G]. a) To remove the Lamp on the right-hand side (paper ejection side)of the lamp carriage Remove the Lamp bracket (with screw hole) [F] by removing screw (M3 x 4), and then remove the Lamp [G] by pulling it towards the front. b) To remove the Lamp on the left-hand side (paper feed side) of the lamp carriage Push the stopper on the Lamp bracket [H] to the right (ejection side) to unlock, and remove it upwards. Remove the Lamp [G] by pulling it towards the front. [Precautions on Reassembly] The bracket and lamp engage with each other. First engage the lamp on the rear bracket, and then engage it on the front bracket, which was detached, before finally securing the lamp. Mount the Stopper [D] while pressing down the lead wire. Secure the Stage glass bracket [A] by engaging it positively with the half-pierced sections on both sides.

Engage

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CHAPTER 11. FB ORIGINAL SCANNING SCTION REMOVING THE LAMP


A

F G

A: Glass stage bracket B: Lamp carriage C: Cutaway D: Stopper E: Connectors F: Lamp bracket (with screw hole) G: Lamps H: Lamp bracket

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CHAPTER 11. FB ORIGINAL SCANNING SECTION REMOVING THE LENS ASSY

5.

Removing the Lens Assy


(1) Switch off the power. (2) Remove the stage glass. (Refer to this section for details.) (3) Remove the Lens cover [A] and the three screws (M3 x 6). (4) Remove the three washer screws (M3 x 6), detach the ground wire and connector, and then remove the Lens assy [B]. [Precautions on Reassembly] Align the two half-pierced sections [C] on the front of the lens assy. Do not loosen any screws other than those specified. Do not touch the lens or other optical components.

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CHAPTER 11. FB ORIGINAL SCANNING SCTION REMOVING THE LENS ASSY

Loosen these screws.

A: Lens cover B: Lens assy C: Half-pierce

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CHAPTER 11. FB ORIGINAL SCANNING SECTION FLAT BED READ PULSE MOTOR SPEED ADJUSTMENT

Adjustment
1. Flat Bed Read Pulse Motor Speed Adjustment
Before making this adjustment, first adjust the image elongation and shrinkage by adjusting the Write pulse motor speed (see chapter 13).

Checks and procedure


(1) Place B4 size papers on the paper feed tray, place Test chart No. 15 on the stage glass, and make a master. (2) Lay the print on top of the test chart original to check that the image elongation and shrinkage of the print is within 1.4% at the 310-mm line of the test chart original. (3) If the elongation or shrinkage is more than the specified range, adjust using test mode No. 182 (flat-bed scanning image elongation and shrinkage adjustment).

11 22 RN (Version 1.0)

CHAPTER 11. FB ORIGINAL SCANNING SCTION FB SCAN START POSITION ADJUSTMENT

2.

FB Scan Start Position Adjustment


Checks and procedure
(1) Place a scale face down on the stage glass, pressing the front edge flush against original stopper, and then close the stage cover. (2) Select photograph mode, make a master, and then print. Check that the scanning start position is at 5 mm 2 mm on the scale (top 5 mm 2 mm is erased). (3) If the scanning start position is out of the specified range, adjust using test mode No. 181 (flat bed scanning start position adjustment).

Original stopper Stage glass

Scale

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CHAPTER 11. FB ORIGINAL SCANNING SECTION FB HORIZONTAL SCAN POSITION ADJUSTMENT

3.

FB Horizontal Scan Position Adjustment


Checks and procedure
(1) Place B4 size papers on the paper feed tray, place Test chart No. 15 on the stage glass, and make a master. (2) Inspect the master made on the print drum, and check that pattern e is not omitted on both the left and right of the image on the master. (3) If the pattern is omitted, adjust using test mode No. 180 (Flat bed horizontal scan position adjustment).

11 24 RN (Version 1.0)

CHAPTER 12: ADF SCANNING SECTION

Contents
Mechanism ......................................................................................................................... 12-2 1. 2. 3. ADF Original Set Mechanism ................................................................................ 12-2 ADF Original Scanning Mechanism (with Automatic Base Control) ..................... 12-6 ADF Original Scanning Mechanism ...................................................................... 12-8

Removal and Assembly .................................................................................................... 12-11 1. 2. 3. 4. 5. 6. 7. Removing the Original Scraper Assy .................................................................. 12-11 Removing the Pickup Roller ................................................................................ 12-13 Removing the Original Stripper Roller ................................................................ 12-14 Removing the ADF Original Detection, Original IN, and Original OUT Sensors ....................................................................................................... 12-15 Removing the ADF Original Registration Sensor ............................................... 12-16 Removing the ADF Read Pulse Motor ................................................................. 12-17 Removing the Registration Roller, Original Read Roller, and Original Ejection Roller (top) ........................................................................ 12-19

Adjustment ........................................................................................................................ 12-22 1. 2. 3. 4. 5. ADF Scan Start Position Adjustment ................................................................... 12-22 ADF Horizontal Scan Position Adjustment .......................................................... 12-23 ADF Read Pulse Motor Speed Adjustment (Image Elongation & Shrinkage Adjustment) ..................................................... 12-24 Original IN Sensor Sensitivity Adjustment ........................................................... 12-25 ADF Image Skew Adjustment .............................................................................. 12-26

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CHAPTER 12. ADF SCANNING SECTION ADF ORIGINAL SET MECHANISM

Mechanism
1. ADF Original Set Mechanism
When the original is set along the original guide fence and pushed up against the Original stopper gate [C], the ADF original detection sensor [A] is activated (light path open) and the Master/Print indicator on the panel switches to Master. The thermal pressure motor operates to lower the thermal head until the TPH pressure sensor is activated. After a preset interval, the ADF read pulse motor [O] reverses to lower the Pickup roller [B] in the direction shown by the arrows and withdraw the Original stopper gate [C] upwards. (The one-way clutch incorporated between the Registration roller gear [N] and registration roller shaft prevents the Registration roller [G] from rotating here.) Once the Pickup roller [B] descends to push against the original, the Pickup roller [B] and Original stripper roller [D] rotate in the original transport direction, and a single original is fed forward by the action of the Original stripper roller [D] and Original stripper pad [E]. This activates the ADF original registration sensor [F] (light path blocked) and the edge of the original is stopped by the Stationary registration roller [G]. Once a preset interval has elapsed from when the ADF original registration sensor [F] was activated, the ADF read pulse motor [O] operates in the forward direction. This raises the Pickup roller [B] and at the same time rotating the Registration roller [G], Original read roller [I], and Original ejection roller (top) [J], which are all linked by the Timing belt [M], in the feed direction. The original stops briefly after it has been moved 100 mm from the original set position.

F G I

Original feed

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CHAPTER 12. ADF SCANNING SECTION ADF ORIGINAL SET MECHANISM


O I N G A

A: ADF original detection sensor B: Pickup roller C: Original stopper gate D: Original stripper roller E: Original stripper pad F: ADF registration sensor G: Registration roller H: Registration driven roller

I: Original read roller J: Original ejection Roller (top) K: Original pickup pad L: Original guide fence M: Timing belt N: Registration roller gear O: ADF read pulse motor

12 3 RN (Version 1.0)

CHAPTER 12. ADF SCANNING SECTION ADF ORIGINAL SET MECHANISM

Set original

To scanning operation

ADF original detection sensor OFF Thermal pressure motor TPH pressure sensor ADF read pulse motor Press ON

Light path open

Forward Reverse

ADF original registration sensor


1.5 S (1) 815 ms 50 ms

(1) A10-107 is displayed if the ADF original registration sensor is not activated (light path blocked) even when the ADF read pulse motor transports the original 182 mm after the feeding in process begins.

12 4 RN (Version 1.0)

CHAPTER 12. ADF SCANNING SECTION ADF ORIGINAL SET MECHANISM

[Memo]

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CHAPTER 12. ADF SCANNING SECTION ADF ORIGINAL SCANNING MECHANISM (WITH AUTOMATIC BASE CONTROL)

2.

ADF Original Scanning Mechanism (with Automatic Base Control)


(This operation only occurs when the original scanning density is set to Auto.) Once the ADF original setting operation is complete, pressing the START key illuminates the lamp. The Flat bed read pulse motor is activated immediately, moving the Lamp carriage in the feed direction to the shading position. Shading adjustment is performed before moving back in the return direction and stopping at the ABC scanning position (3 + b) mm in front of the normal ADF scanning position. The ADF read pulse motor meanwhile operates in the forward direction, rotating the Registration roller, Master lead roller, and Original ejection roller (top) in the feed direction. The original is fed forward 26.9 mm and stops after the Original IN sensor activates (light path blocked), and the intensity of the original background color is scanned by the image sensor in this position. The FB read pulse motor then moves the Lamp carriage back (3 + b) mm in the return direction. (Normal ADF original scanning position) The ADF read pulse motor immediately operates in the forward direction, and at the same time, the read/ write signal activates, causing scanning of the original to start. The read/write signal is deactivated a preset interval after the Original IN sensor is deactivated (light path open) when the original is moved away (or immediately if the Write pulse motor has rotated the equivalent of the paper size as previously specified by the user settings). The ADF read pulse motor then operates at high speed as soon as scanning is complete. Once the original is transported a preset distance after the Original OUT sensor deactivates, the ADF read pulse motor stops and the ADF original scanning operation is complete.

The Automatic Base Control function does not operate in Photo, Line/Photo, or Dot modes. 12 6 RN (Version 1.0)

CHAPTER 12. ADF SCANNING SECTION ADF ORIGINAL SCANNING MECHANISM (WITH AUTOMATIC BASE CONTROL)

START key ON

End

Lamp ADF read pulse motor ADF original registration sensor (1) Original IN sensor
26.9 mm

Forward

Forward

High speed

(3)

Read/write signal (2) Original OUT sensor (4) Shading adjustment


41 mm 100 ms (3 + b) mm 83.4 mm

Flat bed read pulse motor Feed


100 ms

Return
100 ms 8 mm

Image scanner ADF shading sensor

(7 + a - b) mm

* L = paper size specified in user settings (mm) Adjustment value a = Test mode No. 183 (ADF scanning mirror position adjustment) Adjustment value b = Test mode No. 184 (ADF-ABC mirror position adjustment)

(1) A10-108 is displayed if the Original IN sensor is not activated (light path blocked) even when the ADF read pulse motor transports the original 138 mm after the START key is pressed. (2) A10-109 is displayed if the Original OUT sensor is not activated (light path blocked) even when the ADF read pulse motor transports the original 117 mm after the Original IN sensor activates (light path blocked). (3) A10-105 is displayed if the Original IN sensor is not deactivated (light path open). This occurs even if the ADF read pulse motor transports the original 114 mm after the ADF original registration sensor has deactivated (light path open). (4) A10-106 is displayed if the Original OUT sensor is not deactivated (light path open). This occurs even if the ADF read pulse motor transports the original 117 mm after the Original IN sensor is deactivated (light path open).

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CHAPTER 12. ADF SCANNING SECTION ADF ORIGINAL SCANNING MECHANISM


Note: ABC stands for Automatic Base Control.

3.

ADF Original Scanning Mechanism


Once the ADF original setting operation is complete, pressing the START key illuminates the lamp. The Flat bed read pulse motor immediately activates, moving the Lamp carriage in the feed direction to the shading position. Shading adjustment is performed before moving back in the return direction and stopping at the normal ADF scanning position. The ADF read pulse motor [M] meanwhile operates in the forward direction, rotating the Registration roller [A], Original read roller [C], and Original ejection roller (top) [J] in the feed direction. The original is fed forward 29.9 mm after the Original IN sensor [E] activates (light path blocked), activating the read/write signal and initiating a scan of the original. (The pickup roller returns to the standby position.) The read/write signal is deactivated a preset interval after the Original IN sensor [E] is deactivated (light path open) when the original is moved away (or immediately if the Write pulse motor has rotated the equivalent of the paper size as previously specified in the user settings). The ADF read pulse motor [M] then operates at high speed as soon as scanning is complete. Once the original is transported a preset distance after the Original OUT sensor [I] deactivates, the ADF read pulse motor [M] stops. This completes the ADF original scanning operation.

A I J E
Original feed

B K H F D

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CHAPTER 12. ADF SCANNING SECTION ADF ORIGINAL SCANNING MECHANISM

L
A: Registration roller B: Registration driven roller C: Original read roller D: Original read driven roller E: Original IN sensor F: Reflecting plate G: Shading plate H: ADF stage glass

I: Original OUT sensor J: Original ejection roller (top) K: Original ejection roller (bottom) L: Original receiving tray M: ADF read pulse motor

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CHAPTER 12. ADF SCANNING SECTION ADF ORIGINAL SCANNING MECHANISM


START key ON End

Lamp ADF read pulse motor ADF original registration sensor (1) Original IN sensor Read/write signal (2) Original OUT sensor (4) Shading adjustment
41 mm 83.4 mm 29.9 mm

Forward

High speed

(3)

Flat bed read pulse motor

Feed
100 ms

Return
8 mm 100 ms (10 + a) mm

Image scanner ADF shading sensor

* L = paper size specified in user settings (mm) Adjustment value a = Test mode No. 183 (ADF scanning mirror position adjustment)

(1) A10-108 is displayed if the Original IN sensor is not activated (light path blocked) even when the ADF read pulse motor transports the original 138 mm after the START key is pressed. (2) A10-109 is displayed if the Original OUT sensor is not activated (light path blocked). This occurs even when the ADF read pulse motor transports the original 117 mm after the Original IN sensor is activated (light path blocked). (3) A10-105 is displayed if the Original IN sensor is not deactivated (light path open). This occurs even if the ADF read pulse motor transports the original 114 mm after the ADF original registration sensor is deactivated (light path open). (4) A10-106 is displayed if the Original OUT sensor is not deactivated (light path open). This occurs even if the ADF read pulse motor transports the original 117 mm after the Original IN sensor is deactivated (light path open).

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CHAPTER 12. ADF SCANNING SECTION REMOVING THE ORIGINAL SCRAPER ASSY

Removal and Assembly


1. Removing the Original Scraper Assy
(1) Switch off the power and open the ADF unit. Now remove the two screws (M3 x 10), and remove the ADF cover [A]. Finally, close the ADF unit. (2) Remove the plastic lock rings [C] from both sides of the Original scraper assy [B], and then remove the bearing bushes [D]. Lift up the Original stopper gate [E] to remove the Original scraper assy.

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CHAPTER 12. ADF SCANNING SECTION REMOVING THE ORIGINAL SCRAPER ASSY

E B

D D

A: ADF cover B: Original Scraper Assy C: Lock ring D: Bearing bush E: Original stopper gate

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CHAPTER 12. ADF SCANNING SECTION REMOVING THE PICKUP ROLLER

2.

Removing the Pickup Roller


(1) Switch off the power and open the ADF unit. Now remove the two screws (M3 x 10), and remove the ADF cover. Finally, close the ADF unit. (2) Pull apart both ends of the Pickup roller frame assy [B] holding the Pickup roller [A], and remove the Pickup roller [A]. (Take care not to drop the washer on the right-hand side gear of the Pickup roller.) [Precautions on Reassembly] Do not forget to insert the washer on the right-hand side gear on the Pickup roller.

A: Pickup roller B: Pickup roller frame assy

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CHAPTER 12. ADF SCANNING SECTION REMOVING THE ORIGINAL STRIPPER ROLLER

3.

Removing the Original Stripper Roller


(1) Switch off the power and open the ADF unit. Now remove the two screws (M3 x 10), and remove the ADF cover. Finally, close the ADF unit. (2) Remove the Original Scraper Assy. (See this chapter.) (3) Remove the Pickup roller, (see this chapter.) and then remove the Intermediate guide [A]. (4) Remove the plastic Lock ring [C] on the left-hand side of the Original stripper roller [B], move the Original stripper roller [B] to the left, and then remove the right-hand E-ring [D]. Move the Pickup roller frame assy (right) [E] to the left, pull out the Pin [F] and then remove it to the right. (Take care not to drop the washer fitted to the gear side of the Original stripper roller.) [Precautions on Reassembly] Fit the gear on the right-hand side as shown in the photograph, as the Original scraper roller contains a one-way clutch. Also, do not forget to insert the washer on the gear side. When engaging the pin into the Pickup roller frame assy (right), insert it into the shallower slot.

A: Intermediate guide B: Original stripper roller C: Lock ring D: E-ring E: Pickup roller frame assy (right) F: Pin G: ADF timing belt

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CHAPTER 12. ADF SCANNING SECTION REMOVING THE ADF ORIGINAL DETECTION, ORIGINAL IN, AND ORIGINAL OUT SENSORS

4.

Removing the ADF Original Detection, Original IN, and Original OUT Sensors
(1) Switch off the power and open the ADF unit. Now remove the two screws (M3 x 10), and remove the ADF cover. Finally, close the ADF unit. Removing the ADF Original Detection Sensor (2) Remove the connector, free the actuator by hand, and release the clips on the ADF original detection sensor [A] to remove it. Removing the Original IN Sensor (2) Remove the connector, remove the screw (M3 x 10), and then remove the Original IN sensor [B]. * After removing it, turn variable resistor VR1 on top of the ADF-PCB [C] to readjust LED1 to maximum brightness. Removing the Original OUT Sensor (2) Remove the connector, free the actuator by hand, and release the clips on the Original OUT sensor [D] to remove it.

C D

A: ADF original detection sensor B: Original IN sensor C: ADF-PCB D: Original OUT sensor

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CHAPTER 12. ADF SCANNING SECTION REMOVING THE ADF ORIGINAL REGISTRATION SENSOR

5.

Removing the ADF Original Registration Sensor


(1) Switch off the power and open the ADF unit. Now remove the two screws (M3 x 10), and remove the ADF cover. Finally, close the ADF unit. (2) Remove the connector, lift up the actuator and move it to the left end, and release the clips on the ADF original registration sensor [A] to remove it.

A: ADF original registration sensor

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CHAPTER 12. ADF SCANNING SECTION REMOVING THE ADF READ PULSE MOTOR

6.

Removing the ADF Read Pulse Motor


(1) Switch off the power and open the ADF unit. Now remove the two screws (M3 x 10), and remove the ADF cover. Finally, close the ADF unit. (2) Detach connectors CN1 and CN3 on the ADF-PCB [A], and remove the ground screw [C] on the ADF upper guide assy [B] together with the other screws (M3 x 6). (Take care not to drop the rosette washer fitted beneath the ground screw.) (3) Remove the ADF upper guide assy [B] and four screws (M3 x 6). (4) Remove the ADF read pulse motor [D] and two screws (M3 x 6). [Precautions on Reassembly] When mounting the ADF upper guide assy, engage the two aligning pins. When attaching the ground screw, do not forget to insert the rosette washer. After mounting the ADF upper guide assy, readjust the Original IN sensor. Turn variable resistor VR1 on top of the ADF-PCB to readjust LED1 to maximum brightness.

B A

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CHAPTER 12. ADF SCANNING SECTION REMOVING THE ADF READ PULSE MOTOR

A: ADF-PCB B: ADF upper guide assy C: Ground screw D: ADF read pulse motor E: Original IN sensor

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CHAPTER 12. ADF SCANNING SECTION REMOVING THE REGISTRATION ROLLER, ORIGINAL READ ROLLER, AND ORIGINAL EJECTION ROLLER (TOP)

7.

Removing the Registration Roller, Original Read Roller, and Original Ejection Roller (top)
(1) Switch off the power and open the ADF unit. Now remove the two screws (M3 x 10), and remove the ADF cover. Finally, close the ADF unit. (2) Detach connectors CN1 and CN3 on the ADF-PCB, and remove the ground screw on the ADF upper guide assy and screws (M3 x 6). (Take care not to drop the rosette washer fitted beneath the ground screw.) (3) Remove the ADF upper guide assy [A] and four screws (M3 x 10). (4) Lift up the Jam release dial [B] towards the top left to pull it out. (5) Remove the Idler spring [G], loosen the two screws on the Idler [F], and then loosen the tension on the ADF timing belt [H]. (6) Remove the three screws (M3 x 10) from both the ADF guide frame (front) [I] and ADF guide frame (rear) [J], and then remove the frames. Removing the Registration Roller (7) Remove the front E-ring [P], rear E-ring [M], washer [K], thrust spring [L], and washer [K] (take care, as the washer and thrust spring may fly out when the E-ring is removed). Next, pull out the Timing gear [Q], which is protrudes onto the front flat face, and then remove the Registration roller [C]. Removing the Original Read Roller (7) Remove the front clutch spring [O], E-ring [P], rear E-ring [M], washer [K], thrust spring [L], and washer [K] (take care, as the washer and thrust spring may fly out when the E-ring is removed). Next, pull out the Timing gear [Q], which protrudes onto the front flat face, and then remove the Original read roller [D]. Removing the Original Ejection Roller (top) (7) Remove the front E-ring [P], rear E-ring [M], washer [K], thrust spring [L], and washer [K] (take care, as the washer and thrust spring may fly out when the E-ring is removed). Next, pull out the Timing gear [Q], which protrudes onto the front flat face, and then remove the Original Ejection Roller (top) [E]. [Precautions on Reassembly] Insert the thrust spring at the rear of each roller, placing washers on either side, and securing the assembly with the E-ring. Note the insertion direction of the lugs on each timing gear. Attach the ADF timing belt as shown in the photograph. Engage the three pins in each case when securing the ADF guide frame (front) and ADF guide frame (rear). Also check that the bearing bushes are fitted correctly on each roller. After attaching the idler spring, the ADF timing belt tension is adjusted by loosening the two idler screws.

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CHAPTER 12. ADF SCANNING SECTION REMOVING THE REGISTRATION ROLLER, ORIGINAL READ ROLLER, AND ORIGINAL EJECTION ROLLER (TOP)

C J D

Rear

Front

A: ADF upper guide assy B: Jam release dial C: Registration roller D: Original read roller E: Original Ejection Roller (top) F: Idler G: Idler spring H: ADF timing belt I: ADF guide frame (front) J: ADF guide frame (rear) 12 20 RN (Version 1.0)

CHAPTER 12. ADF SCANNING SECTION REMOVING THE REGISTRATION ROLLER, ORIGINAL READ ROLLER, AND ORIGINAL EJECTION ROLLER (TOP)
Registration roller

N M

N N

Original read roller

M O

N N

Original ejection roller (top)

P
Front

K
Rear

K: Washer L: Thrust spring M: E-ring N: Bearing bush O: Clutch spring P: E-ring Q: Timing gear

12 21 RN (Version 1.0)

CHAPTER 12. ADF SCANNING SECTION ADF SCAN START POSITION ADJUSTMENT

Adjustment
1. ADF Scan Start Position Adjustment
Checks and procedure
(1) Make a master with the ADF unit using an original with no blank margin at the top, and print. (2) Examine the prints to check that the scanning start position is at 5 mm 2 mm from the top of the original. (3) If the position is outside the specified parameters, adjust using test mode No. 186 (ADF scanning start position adjustment).

12 22 RN (Version 1.0)

CHAPTER 12. ADF SCANNING SECTION ADF HORIZONTAL SCAN POSITION ADJUSTMENT

2.

ADF Horizontal Scan Position Adjustment


Checks and procedure
(1) Place a sheet of B4 size paper on the paper feed tray, and make a master of test chart No. 15 using the ADF unit. (2) Examine the master created on the print drum, and check that pattern e on the left and right of the original is not missing. (3) If the pattern is missing, adjust using test mode No. 185 (ADF main scanning left/right adjustment).

12 23 RN (Version 1.0)

CHAPTER 12. ADF SCANNING SECTION ADF READ PULSE MOTOR SPEED ADJUSTMENT (IMAGE ELONGATION & SHRINKAGE ADJUSTMENT)

3.

ADF Read Pulse Motor Speed Adjustment (Image Elongation & Shrinkage Adjustment)
Before adjusting, first adjust the image elongation and shrinkage using the Write pulse motor speed adjustment (See chapter 13.)

Checks and procedure


(1) Place a sheet of B4 size paper on the paper feed tray, and make a master of test chart No. 15 using the ADF unit. (2) Lay the print on top of the original to check that the image elongation and shrinkage is within 1.4% at the 310-mm line. (3) If the elongation and shrinkage is outside the specified parameters, adjust using test mode No. 187 (ADF scanning Image Elongation & Shrinkage Adjustment).

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CHAPTER 12. ADF SCANNING SECTION ORIGINAL IN SENSOR SENSITIVITY ADJUSTMENT

4.

Original IN Sensor Sensitivity Adjustment


Procedure
(1) Open the ADF unit, remove the two screws (M3 x 10), and then remove the ADF cover. Finally, close the ADF unit. (2) Turn variable resistor VR1 on top of the ADF-PCB to adjust LED1 to maximum brightness.

Checks after adjustment


Check that LED1 on top of the ADF-PCB clears when the original (thin Riso paper inlet) is detected by the Original IN sensor.

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CHAPTER 12. ADF SCANNING SECTION ADF IMAGE SKEW ADJUSTMENT

5.

ADF Image Skew Adjustment


Checks and procedure
(1) Place a sheet of B4 size paper on the paper feed tray, and make a master of test chart No. 15 using the ADF unit. (2) Lay the print on top of the original with the 310-mm lines at the side parallel, and check that the skew (X) of the leading 160-mm line is within 2 mm. (3) If the skew is outside the specified parameters, adjust as follows. Remove the screw (M4 x 6) on the ADF mount plate [A], rotate through 180 to open the ADF unit to 90, and then loosen the two ADF unit retaining screws (M4 x 10). Loosen the nut [B] on the hinge assembly (right), and turn the ADF slide screw [C] (clockwise if as in Figure 2, and counter-clockwise if as in Figure 1) to adjust dimension T. Turning the screw clockwise increases dimension T. Tighten the two ADF unit retaining screws, and then tighten the nuts with the ADF slide screw secured. Make a master and print, and repeat the procedure from the beginning if the skew is still outside the specified parameters.

A: ADF mount plate B: Nut C: ADF slide screw T

Bottom

Top

Figure 1

Figure 2

12 26 RN (Version 1.0)

CHAPTER 13: MASTER MAKING SECTION

Contents
Mechanism ......................................................................................................................... 13-2 1. 2. 3. 4. 5. 6. Master making & master loading .......................................................................... 13-2 Scanner Table Set Detection Mechanism ............................................................. 13-4 Master Cutting Mechanism .................................................................................... 13-5 Thermal Print Head Elevation Mechanism ........................................................... 13-6 Master Positioning Mechanism ............................................................................. 13-8 Master Making ........................................................................................................ 13-9

Removal and Assembly .................................................................................................... 13-11 1. 2. 3. 4. 5. 6. 7. Removing the Write Roller .................................................................................... 13-11 Removing the Load Roller (bottom) .................................................................... 13-12 Removing the Cutter Unit .................................................................................... 13-14 Removing the Load Roller ................................................................................... 13-15 Removing the Thermal Print Head ...................................................................... 13-16 Removing the Master Loading Unit ..................................................................... 13-17 Removing the Thermal Pressure Motor .............................................................. 13-18

Adjustment ........................................................................................................................ 13-19 1. 2. Thermal power of thermal print head .................................................................. 13-19 Master Feeding Adjustments .............................................................................. 13-20

13 1 RN (Version 1.0)

CHAPTER 13. MASTER MAKING SECTION MASTER MAKING & MASTER LOADING

Mechanism
1. Master making & master loading
The master making & master loading mechanism is made up of the following components. 1) Scanner Table Set Detection Mechanism The Flat bed set switch [A] confirms that the original is positioned on the scanner table. The Master loading unit sensor [B] confirms that the master loading unit is set. The Master end sensor [C] confirms that master roll has ran out of master. 2) Master Cutting Mechanism The master cutting operation is performed by the Cutter motor [D], and the cutter motor stop position is confirmed by the Cutter home position switch [E]. 3) Thermal Print Head Elevation Mechanism The Thermal print head (TPH) [F] is raised and lowered by the Thermal pressure motor [G], and the position is confirmed by the TPH pressure sensor [H]. 4) Master Making Section Mechanism Master making is performed by lowering the Thermal print head [F] and transporting the master clamped between it and the Write roller [I]. The master is transported by the Write roller, which is driven by the Write pulse motor [J]. Created masters are stored inside the master stocker [K]. 5) Master Loading Mechanism Masters that have been created are fed to the print drum and clamped, and then loaded by rotating the print drum. The master is transported by the Load roller [M], which is driven by the Load pulse motor [L].

13 2 RN (Version 1.0)

CHAPTER 13. MASTER MAKING SECTION MASTER MAKING & MASTER LOADING

G F

A B

I D K C

O E

A: Flat bed set switch B: Master loading unit sensor C: Master end sensor D: Cutter motor E: Cutter home position switch F: Thermal print head G: Thermal pressure motor H: TPH pressure sensor

I: Write roller J: Write pulse motor K: Master stocker L: Load pulse motor M: Load roller N: Master detection sensor O: Master positioning sensor

13 3 RN (Version 1.0)

CHAPTER 13. MASTER MAKING SECTION SCANNER TABLE SET DETECTION MECHANISM

2.

Scanner Table Set Detection Mechanism


Scanner table and master loading set detection mechanism The Flat bed set switch [A] confirms that the scanner table is closed. The Flat bed set switch [A] is the interlocking switch for the main motor, and this forces the Main motor, Clamp motor, and TPH power to an emergency stop if the Scanner table is opened while the system is operating. The Master loading unit switch [B] confirms that the Master loading unit is set, and the master setting operation is performed once the Master loading unit is set. Master end detection The end of the master roll is confirmed by the Master end sensor [C] detecting the black end mark attached to the end of the master on the master roll. The Master end sensor [C] checks every 10 ms while the master is being transported, and gives an indication on the panel when the end mark is detected twice in succession.

A: Flat bed set switch B: Master loading unit switch C: Master end sensor

13 4 RN (Version 1.0)

CHAPTER 13. MASTER MAKING SECTION MASTER CUTTING MECHANISM

3.

Master Cutting Mechanism


The master is cut by the upper cutter of the Cutter unit being moved up and down by the Cutter motor [A]. The Cutter motor rotates in a constant direction, and the Cutter home position switch [B] confirms the position of the upper cutter. The Cutter is at the home position when it is not pressing against the Cutter home position switch [B], and if the switch is depressed briefly after the Cutter motor starts, the motor stops when the switch is no longer depressed.

Cutter unit home position

A: Cutter motor B: Cutter home position switch

13 5 RN (Version 1.0)

CHAPTER 13. MASTER MAKING SECTION THERMAL PRINT HEAD ELEVATION MECHANISM

4.

Thermal Print Head Elevation Mechanism


Thermal print head elevation When the system is on standby or when winding the master onto the print drum after master making, the Thermal print head is raised from the Write roller. Conversely, for master making and during transport, the Thermal print head is lowered and pressed onto the Write roller. The Thermal print head is raised and lowered by the Pressure release cam [B], which is driven by the Thermal pressure motor [A]. The Pressure release cam [B] is an eccentric cam, which raises and lowers the TPH pivot plate [C] as it rotates. The raised and lowered stop positions for the motor are detected by the TPH pressure sensor [E], which is blocked by the Pressure detection disc [D]. The Sliding plate [F] and Blade link [G] are also moved by the vertical action of the thermal head. Thermal print head raised position In the Thermal print head raised position, the Load roller No. 1 (top) [H] and Load roller (top) [I] also rise. At the same time, the Blade cushion [J] descends, and applies back tension to the master while it is being wound onto the print drum to prevent creases in the master. Thermal print heads lowered position In the Thermal print head lowered position, the Load roller No. 1 (top) [H] and Load roller (top) [I] also descend to allow the master to be transported. At the same time, the Blade cushion [J] rises. Initialization This moves the Thermal print head to the pressure release (raised) position when power is switched on, or when everything is reset. Loading guide plate operation In the clamp plate master release operation at the start of master ejection, the front edge of the Loading guide plate is raised by the Master release bar to prevent it from obstructing the leading edge of the freed master on the drum. In the clamp plate master clamping operation at the start of master loading, only the front edge sheet of the Loading guide plate is raised by the Clamp plate, so as to prevent it from obstructing the master loading operation. During master loading, the master being loaded is back-tensioned by the sponge fitted to the bottom of the front edge sheet of the Loading guide plate.

13 6 RN (Version 1.0)

CHAPTER 13. MASTER MAKING SECTION THERMAL PRINT HEAD ELEVATION MECHANISM

I F K

B J

A: Thermal pressure motor B: Pressure release cam C: TPH pivot plate D: Pressure detection disc E: TPH pressure sensor F: Sliding plate G: Blade link

H: Load roller No. 1 (top) I: Load roller (top) J: Blade cushion K: Loading guide plate

13 7 RN (Version 1.0)

CHAPTER 13. MASTER MAKING SECTION MASTER POSITIONING MECHANISM

5.

Master Positioning Mechanism


The master positioning operation is performed to bring the master to the Master positioning sensor when opening or closing the Master loading unit or during master making. For master roll replacement (1) Insert the leading edge of the new master roll to the Master stopper gate [A], and close the master loading unit. Closing the Master loading unit raises the Master stopper gate. The Master loading unit switch monitors operations every 10 ms and determines that the Master loading unit is closed when the light path is blocked twice in succession. The master is then checked by the Master detection sensor [B]. (2) The Thermal print head is lowered by the Thermal pressure motor, and the Write pulse motor and Load pulse motor operate to transport the master to the Master positioning sensor [C]. (3) Once the light path to the Master positioning sensor [C] is blocked by the master, the Write pulse motor alone operates in reverse to return the master 2 mm. The motor then stops and the Thermal print head is raised. For master cutting Steps (2) to (3) above are performed following master cutting.

A: Master stopper gate B: Master detection sensor C: Master positioning sensor

13 8 RN (Version 1.0)

CHAPTER 13. MASTER MAKING SECTION MASTER MAKING

6.

Master Making
The sequence of operations from master making to master mounting is as described below.

(1) At the start of master making, the Thermal print head is lowered to clamp the master between it and the Write roller.

(2) The write pulse motor and Load pulse motor operate to transport the master to the Master positioning sensor, where it waits for scanning system preparations to be completed.

(3) Once master making can be started, the Write pulse motor operates to transport the master to the writing start position before master making commences. The master created is then stored in the master stocker.

(4) Once the master making in step (3) starts, the Load pulse motor operates to transport the leading edge of the master to the clamp plate, where it is clamped.

(5) Once master making is finished, the Thermal print head is raised, and the print drum rotates as the master is wound onto it.

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CHAPTER 13. MASTER MAKING SECTION MASTER MAKING


(6) The print drum pauses at the 220 position, where the master is cut.

(7) After the print drum has rotated a further 15, the Master positioning sensor confirms that the master has been cut. Cutting has been performed correctly if the light path to the sensor is blocked (no master). If the light path to the sensor is open, it is determined that an error has occurred. In this case, the cutting operation is repeated, the Master positioning sensor confirms whether the master has been cut after the print drum has rotated a further 15. If it is cut, A03 Cutting error is displayed, and if it is not cut, T13 Cutter motor lock is displayed.

(8) The master setting operation is performed.

13 10 RN (Version 1.0)

CHAPTER 13. MASTER MAKING SECTION REMOVING THE WRITE ROLLER

Rmoval and Assembly


1. Removing the Write Roller
(1) Switch off the power, and remove the rear cover. (2) Loosen the mounting bracket screws (M4 x 8: 2 pcs) on the Write pulse motor [B], and remove the Belt [C]. (3) Remove the Pulley [D]. (M2 x 6: 1 pc) (4) Remove the Bearing stopper [E] and pull out the bearing. (M4 x 6: 1 pc) (5) Pull out the Write roller [A]. [Precautions on Reassembly] Take care not to drop the bearing when mounting the Write roller (particularly the front).

A: Write roller B: Write pulse motor C: Belt D: Pulley E: Bearing stopper 13 11 RN (Version 1.0)

CHAPTER 13. MASTER MAKING SECTION REMOVING THE LOAD ROLLER (BOTTOM)

2.

Removing the Load Roller (bottom)


(1) Switch off the power, and remove the rear cover. (2) Loosen the screw (M4 x 8: 1 pc) on the Tension assembly [B], loosen the mounting bracket screws (M4 x 8: 2 pcs) on the Load pulse motor [C], and then remove the belt. (3) Remove the Pulley [D]. (M2 x 6: 1 pc) (4) Remove the Bearing fixing plate [E] and pull out the bearing. (M4 x 8: 1 pc) * Removing the rear bearing here simplifies subsequent disassembly or reassembly work.

A: Load roller (bottom) B: Tension assembly C: Load pulse motor D: Pulley E: Bearing fixing plate

13 12 RN (Version 1.0)

CHAPTER 13. MASTER MAKING SECTION REMOVING THE LOAD ROLLER (BOTTOM)
(5) Remove the master roll, and remove the Master cover [F]. (M4 x 6: 1 pc) (6) Remove the Master holders [G] on both sides. (M3 x 6: 2 pcs each) (7) Remove the Master set guide [H]. (M4 x 8: 2 pcs)

F: Master cover G: Master holder H: Master set guide

(8) Unplug the rear connector, and remove the Stocker cover [I]. (M4 x 8: 2 pcs) (9) Remove the springs on both sides, and then remove the Master guide [J]. (10) Remove the Load roller guide [K] (M4 x 8: 2 pcs), and then remove the Load roller (bottom).

I: Stocker cover J: Master guide K: Load roller guide

13 13 RN (Version 1.0)

CHAPTER 13. MASTER MAKING SECTION REMOVING THE CUTTER UNIT

3.

Removing the Cutter Unit


(1) Switch off the power, remove the rear cover, and pull out the print drum. (2) Unplug the rear connector, and remove the Cutter cover [A]. (M4 x 8: 2 pcs)

(3) Remove the Cutter guide plate [C]. (M4 x 8: 2 pcs) (4) Remove the cutter unit mounting screws. (2 pcs) (5) Loosen the Tension assembly [D] screw, detach the Belt [F], unplug the cutter unit connector [E], and then remove the Cutter unit.

E D
A: Cutter cover B: Load guide (tip) C: Cutter guide plate D: Tension assembly E: Cutter unit connector F: Belt 13 14 RN (Version 1.0)

CHAPTER 13. MASTER MAKING SECTION REMOVING THE LOAD ROLLER

4.

Removing the Load Roller


(1) Perform steps (1) to (4) to remove the cutter unit. (2) Remove the Loading guide (bottom) [E]. (M4 x 8: 2 pcs) (3) Loosen the screw (M4 x 8: 1 pc) on the Tension assembly [A], and remove the Belt [F]. (4) Remove the Pulley [B] (M2 x 6: 1 pc) and Bearing fixing plate [C] (M4 x 8: 1 pc). (5) Remove the Load roller [D].

A F

D E

A: Tension assembly B: Pulley C: Bearing fixing plate D: Load roller E: Loading guide (bottom) F: Belt

13 15 RN (Version 1.0)

CHAPTER 13. MASTER MAKING SECTION REMOVING THE THERMAL PRINT HEAD

5.

Removing the Thermal Print Head


(1) Lift up the Master loading unit, and remove the Master loading unit bottom cover [A]. (Screws only need be loosened.) (2) Remove the mounting screws on the TPH bracket [B]. (M3 x 6: 2 pcs) (3) Remove the ground lead mounting screw. (M3 x 6: 1 pc) (4) Unplug the two connectors, and remove the Thermal print head together with the TPH bracket.

A: Master loading unit bottom cover B: TPH bracket

13 16 RN (Version 1.0)

CHAPTER 13. MASTER MAKING SECTION REMOVING THE MASTER LOADING UNIT

6.

Removing the Master Loading Unit


(1) Move the Scanner table unit to the servicing position [A]. (2) Remove the Master loading unit upper cover [D]. (M3 x 6: 4 pcs) (3) Remove the wire harness and ground wire [C], and place them on the Master loading unit. (4) Open the Master disposal gate housing [B] as wide as possible. (Secure with a piece of cord or something similar.) (5) With the Master loading unit opened as wide as possible, unhook the Springs [E] on both sides. (6) Lift up the Master loading unit and remove.

A: Servicing position B: Master disposal gate housing C: Wire harness and ground lead D: Master loading unit upper cover E: Spring (on both sides)

13 17 RN (Version 1.0)

CHAPTER 13. MASTER MAKING SECTION REMOVING THE THERMAL PRESSURE MOTOR

7.

Removing the Thermal Pressure Motor


(1) Remove the Master loading unit. (2) Remove the E-rings and bearings, and then remove the Load roller No. 1 (top) [A]. (3) Remove the De-electricity brush plate [B]. (M3 x 6: 2 pcs) (4) Remove the Thermal pressure motor [C] as a unit. (M3 x 6: 4 pcs)

B A

A: Load roller No. 1 (top) B: De-electricity brush plate C: Thermal pressure motor

13 18 RN (Version 1.0)

CHAPTER 13. MASTER MAKING SECTION THERMAL POWER OF THERMAL PRINT HEAD

Adjustment
1. Thermal power of thermal print head
The thermal power must always be set before making masters after the Thermal print head has been replaced. Procedure (1) Switch off the power to the system. (2) Connect a multimeter across pin 1 (+) and pin 3 (-) of CN108 on the Power supply unit. (3) Run test mode No. 238. (Switch the thermal print head voltage on/off using the START/STOP keys.) (4) Check that the voltage reading on the voltmeter corresponds to the thermal print head resistances shown in the setting table. (5) If different, adjust using VR301 (coarse adjustment) and VR302 (fine adjustment) on the Power supply unit. Precautions During Setting Adjustments must be made after the Thermal print head has been installed. A voltage will not be applied across the Thermal print head unless the Scanner table is positioned and test mode No. 238 is run. Setting table
Thermal print head resistance (Ohm) 1403--1413 1414--1431 1432--1449 1450--1467 1468--1485 1486--1503 1504--1522 1523--1540 1541--1559 1560--1577 1578--1596 1597--1615 1616--1634 1635--1653 1654--1672 1673--1692 1693--1711 1712--1731 1732--1750 1751--1770 1771--1790 1791--1810 1811--1830 1831--1850 1851--1871 1872--1891 1892--1898 Voltage (V) 15.9 16.0 16.1 16.2 16.3 16.4 16.5 16.6 16.7 16.8 16.9 17.0 17.1 17.2 17.3 17.4 17.5 17.6 17.7 17.8 17.9 18.0 18.1 18.2 18.3 18.4 18.5

13 19 RN (Version 1.0)

CHAPTER 13. MASTER MAKING SECTION MASTER FEEDING ADJUSTMENTS

2.

Master Feeding Adjustments


1) Master cut position adjustment
This adjustment sets the master cutting timing (print drum stop position for cutting). Checks and procedure
(1) Adjust if the tail end of the master mounted on the print drum is either too long or too short. (2) Run test mode No. 284 to adjust. Setting range: -100 to +100 (-10.0 to +10.0) Setting units: 1 (0.1) Default: 0 (0) Increasing the settings increases the length of each master.

2) Master clamp range adjustment


Adjust the master clamp range when it is mounted. Checks and procedure
(1) Make a normal and confidential master, and then check the length of the master protruding from the Clamp magnet plate. If the amount protruding is within 2 mm 2 mm, it is normal. If it is outside this range, adjust as shown below. (2) Run test mode No. 283 and adjust. Setting range: -100 to +100 (-10.0 mm to +10.0 mm) Setting units: 1 (0.1 mm) Default: 0 (0 mm) Increasing the settings increases the amount of protrusion. Clamp magnet plate Master 22 mm

Note: The relative positioning of already-made masters wound onto the print drum will change if the clamp range is adjusted. The master scanning start position must therefore be readjusted, and it must also be confirmed that the Vertical printing position adjustment is correct.

3) Master making image elongation/ shrinkage adjustment


Adjust the Write pulse motor speed for master making. Checks and procedure
(1) Run test mode No. 051 Test print (mesh), and produce an actual print. Printing is correct if the length of three blocks horizontally is the same as that for four blocks vertically. (Check by folding paper and illuminating from behind.) If it is not correct, adjust as shown below. (2) Run test mode No. 287 and adjust. Setting range: -50 to +50 (-5.0% to +5.0%) Setting units: 1 (0.1%) Default: 0 (0%) Increasing the settings elongates the image.

Note: The vertical printing position must be readjusted after adjusting the elongation/shrinkage.

13 20 RN (Version 1.0)

CHAPTER 13. MASTER MAKING SECTION MASTER FEEDING ADJUSTMENTS

4) Write start position adjustment


Adjust the write start position (distance from master positioning sensor ON to read/write signal ON). Adjustment for a leading edge margin of 5 mm assuming that the master clamp range has been correctly adjusted. Checks and procedure
(1) Run test mode No. 050 Test print (check pattern), to confirm that the master clamp range is correctly adjusted. (2) Cover the print drum surface, aligning the leading edge of the paper with the print drum support marks on either side as shown in the diagram, and then transfer the ink to the paper by rubbing from above. The position is correct if the leading edge margin is 5 mm. If it is not correct, adjust as shown below. (3) Run test mode Setting range: Setting units: Default: No. 281 and adjust. -30 to + 50 (-3.0 mm to +5.0 mm) 1 (0.1 mm) 0 (0 mm)

Increasing the settings lowers the write start position and increases the size of the paper leading-edge margin, moving the printing area downward. Print drum supports on both sides Paper 5 mm

Clamp plate Mark

Paper Printing area Printing area

5) Master making length adjustment


Adjust the master making area (scanning length) Adjustment for a bottom edge margin of 2 mm assuming that the master clamp range has been correctly adjusted. Checks and procedure
(1) Run test mode No. 050 Test print (Check pattern), remove the master created from the print drum, and measure the length. The master is correct if the length is 357 mm. If it is not correct, adjust as shown below. (2) Run test mode No. 282 and adjust. Setting range: -100 to +100 (-10.0 mm to +10.0 mm) Setting units: 1 (0.1 mm) Default: 0 (0 mm) Increasing the settings increases the length of the master making area. Master

Master making area

357 mm

13 21 RN (Version 1.0)

CHAPTER 14: TIMING CHARTS

Contents
Initialization Operations ..................................................................................................... 1. Overall Initialization Operation ............................................................................... 2. Individual Initialization Operations ......................................................................... [Thermal Print Head Initialization Operation] ........................................................ [Master Compression Plate Initialization Operation] ............................................ [Clamp Unit Home Positioning Operation] ........................................................... [Vertical Printing Position Initialization Operation] ................................................. [Pressure Initialization Operation] ......................................................................... 14-2 14-2 14-2 14-2 14-3 14-3 14-4 14-4

Printing Operations ............................................................................................................ 14-5 1. Normal Overall Printing Operation ........................................................................ 14-5 2. Individual Printing Operations ............................................................................... 14-6 [Print Start Operation] ............................................................................................. 14-6 [Print In Progress - End Operation] ....................................................................... 14-8 [Three-Cycle No-Paper Pickup Operation] ............................................................ 14-9 3. Elevator Operations ............................................................................................. 14-10 [Elevator Raise Operation] ................................................................................... 14-10 [Elevator Lower Operation] ................................................................................... 14-11 [Elevator Servo Operation] ................................................................................... 14-12 4. Print Drum Peripheral Operations ....................................................................... 14-13 [Clamp Release] .................................................................................................. 14-13 [Master Clamp Operation] ................................................................................... 14-13 [Inking Operation (No Ink Detection)] .................................................................. 14-14 [Inking Operation (Overflow Detection)] ............................................................... 14-14 [Print Drum Solenoid Lock Release] ................................................................... 14-15 5. Print Adjustment Operations ............................................................................... 14-16 [Print Speed Change] .......................................................................................... 14-16 [Print Intensity Change] ........................................................................................ 14-16 [Vertical Print Positioning Operation] ................................................................... 14-17 Master Removal Operations ............................................................................................ 1. Overall Timing for Normal Master Creation ........................................................ 2. Individual Master Removal Operations ............................................................... [Removed Master Vertical Transport Operation] ................................................. [Disposed Master Compressing Operation] ....................................................... Master Making Operation ................................................................................................ 1. Overall Timing for Normal Master Creation ........................................................ 2. Individual Master Making Operation .................................................................... [Thermal Print Head Compression Operation] ................................................... [Thermal Print Head Release Operation] ........................................................... [Master Positioning Operation] ............................................................................ [Master Cutting Operation] ................................................................................... [Master Making Operation] ................................................................................... 14-18 14-18 14-19 14-19 14-20 14-21 14-21 14-22 14-22 14-22 14-23 14-24 14-25

14 1 RN (Version 1.0)

CHAPTER 14. TIMING CHARTS OVERALL INITIALIZATION OPERATION

Initialization Operations
1. Overall Initialization Operation
Returns the following items to their home positions when the power is switched on or when everything is reset. Initialization start Initialization end

Thermal print head Master compression plate Clamp unit Vertical printing position Pressure control Vertical/horizontal printing position not initialized if clamping error occurs.

2.

Individual Initialization Operations


[Thermal Print Head Initialization Operation] Start Start1 Start2 End

TPH pressure sensor

ON OFF (1) OFF: Start2

Compress Thermal pressure motor OFF Release (2) Max 250 ms (Error: 207)

(3) End 100 ms Max 1 s (Error: 208)

When ON: TPH pressure sensor: Blocked (1) The TPH pressure sensor is checked on starting, and the operation starts from Start 1 if it is ON, and from Start 2 if it is OFF. At Start 1, the thermal pressure motor operates in the compressing direction until the TPH pressure sensor goes OFF. (2) A time-out occurs at 250 ms here, and error message [T19-207] is displayed. (3) The thermal pressure motor operates in the release direction until the TPH pressure sensor goes ON. A time-out occurs at 1 s here, and error message [T19-208] is displayed. (4) Initialization ends once the TPH pressure sensor goes ON.

14 2 RN (Version 1.0)

CHAPTER 14. TIMING CHARTS INDIVIDUAL INITIALIZATION OPERATIONS


[Master Compression Plate Initialization Operation] Start (1) Master removal ON sensor OFF Master compre- ON ssion sensor OFF Disposal box full sensor ON OFF End

(3)

ON Master removal motor OFF Compress Master compression OFF motor Return

Max 400 ms START2 100 ms 100 ms

(2)

Max 7 s (Error: 305) Max 840 ms To return process

100 ms

Start1 Start2 When ON: Master removal sensor: Open, Master compression sensor: Open, Disposal box full sensor: Open (1) The master compression sensor is checked on starting, and the operation starts from Start 1 if it is ON, and from Start 2 if it is OFF. At Start 1, the master compression motor operates in the compressing direction until the master compression sensor goes OFF. A time-out occurs at 400 ms here, and the process moves to Start 2. (2) The master compression motor operates in the return direction until the master compression sensor goes ON. A time-out occurs at 7 s here, and error message [T12-305] is displayed. (3) Initialization ends once the master compression sensor goes ON and the master compression motor stops.

Start (1)

End (2)

Clamp sensor A Clamp sensor B

ON OFF ON OFF Forward

Clamp motor

OFF Reverse

(1) Max 3 s (Error: 501) (3) Max 13 s (Error: 502)


320 ms 100 ms

When ON: Clamp sensor A: Blocked, Clamp sensor B: Blocked [Clamp Unit Home Positioning Operation] (1) On starting, the system checks that clamp sensor A and clamp sensor B are both OFF. If either is ON, clamp initialization is performed. If the clamp sensors do not change even after the clamp motor operates, a time-out occurs at 3 s, and the error message [T03-501] is displayed. (2) Initialization ends once both clamp sensor A and clamp sensor B are OFF. (3) A time-out occurs at 13 s if both the sensors do not go OFF after the clamp motor operates, and error message [T03-502] is displayed. 14 3 RN (Version 1.0)

CHAPTER 14. TIMING CHARTS INDIVIDUAL INITIALIZATION OPERATIONS


[Vertical Printing Position Initialization Operation] Start (1) End

Vertical centering sensor Print positioning pulse motor

ON OFF Up OFF Down


Max 18 mm (Error: 603)
100 ms HOLD A mm

ON: Start2

(2)

(3)

Max 18 mm (Error: 604)

100 ms

Start1

Start2

When ON: Vertical centering sensor: Blocked (1) The vertical centering sensor is checked on starting, and the operation starts from Start 1 if it is OFF, and from Start 2 if it is ON. At Start 1, the print positioning pulse motor operates in the upward direction until the vertical centering sensor goes ON. A time-out occurs at 18 mm here, and error message [T05-603] is displayed. (2) The print positioning pulse motor operates in the downward direction until the vertical centering sensor goes OFF. A time-out occurs at 18 mm here, and error message [T05-604] is displayed. (3) The print positioning pulse motor operates in the upward direction once again, and then moves the equivalent of A mm after the vertical centering sensor goes ON, before stopping. (A = 0.25 mm + value set in Test mode No. 680) [Pressure Initialization Operation] Start (1) End

Print pressure ON control sensor OFF Pressure control motor Compress OFF Release

ON: Start2

(2)

(3)

Max 5.4 kg (6 s) (Error: 600)

100 ms HOLD

Max 5.4 kg (6 s) (Error: 601)

100 ms B mm

Start1

Start2

When ON: Print pressure control sensor: Blocked (1) The print pressure control sensor is checked on starting, and the operation starts from Start 1 if it is OFF, and from Start 2 if it is ON. At Start 1, the pressure control motor operates in the direction of compression until the print pressure control sensor goes ON. A time-out occurs at 12 mm here, and error message [T11-600] is displayed. (2) The pressure control motor operates in the release direction until the print pressure control sensor goes OFF. A time-out occurs at 12 mm here, and error message [T11-601] is displayed. (3) The pressure control motor operates in the direction of compression once again, and then moves the equivalent of B mm after the print pressure control sensor goes ON, before stopping. (B = 0.25 mm + value set in Test mode No. 682) 14 4 RN (Version 1.0)

CHAPTER 14. TIMING CHARTS NORMAL OVERALL PRINTING OPERATION

Printing Operations
1. Normal Overall Printing Operation

Elevator Print drum Ink Vertical printing position Print pressure change Print start Print in progress Pressure release Reset
Master check

Servo operation

Inking, overflow detection Vertical adjustment


Adjustment due to speed/temperature variations and intensity adjustment

14 5 RN (Version 1.0)

CHAPTER 14. TIMING CHARTS INDIVIDUAL PRINTING OPERATIONS

2.

Individual Printing Operations


[Print Start Operation]

Print start

To printing-inprogress process

Print drum angle Paper detection at press section Position A sensor Paper sensor
Paper detected No paper

40

B C

180

D 0

ON OFF ON OFF
(1) (6)

Paper receiving sensor Paper detection sensor Paper ejection motor overload current

ON OFF ON OFF ON OFF

(1) (7)

(4)

(2) Main motor

ON OFF
(1)

Paper feed clutch Pressure solenoid

ON OFF ON OFF OFF ON OFF


(1) (1) (3) (4)

(5)

Paper ejection ON motor Suction fan

Separation fan ON

OFF
Copy count signal

(1)

ON OFF

When ON: Position A sensor: Blocked, Paper sensor: Blocked, Paper receiving sensor: Open, Paper detection sensor: Open

14 6 RN (Version 1.0)

CHAPTER 14. TIMING CHARTS INDIVIDUAL PRINTING OPERATIONS


(1) The paper receiving sensor is checked on starting printing, and error message [A09-417] is displayed if it is ON (paper jam from start). The paper sensor is checked on starting printing, and error message [A07-418] is displayed if it is ON (paper jam from start). On starting printing, the main motor, paper ejection motor, suction fan, and separation fan are switched ON. The print drum initially rotates at speed 1 here, and increments by one speed level at the drum angle of 220 for each sheet printed. (2) The paper ejection motor overload current is continually monitored at 100 ms intervals, and error message [T02-401] is given if is activated three times in succession. (3) The pressure solenoid is activated at the drum angle of 40, and subsequently remains ON until printing ends. (4) The paper detection sensor is checked at the drum angle of A, and the paper feed clutch is activated if paper is present. Error message [C04-402] is displayed if no paper is present. (A = 62 + value set in Test mode 481) (5) The paper is transported, and the paper feed clutch is deactivated once the print drum has rotated B from when the paper is detected by the paper sensor. (B = 21 + value set in Test modes 482485 + adjustment for print drum speed) (6) If the paper sensor does not detect the paper by the time the print drum has rotated to angle C, it determines that no paper has been picked up, and moves to the three-cycle no-paper pickup operation. (C = 135 + value set in Test mode 486 + value set in Test mode 481) (7) If the paper receiving sensor does not detect the paper by the time the print drum has rotated to angle D, it determines that a paper jam has occurred, and moves to the print-end operation. The paper sensor is checked at 180 before the print drum stops, error message [A07-409] is displayed if paper is present, and [A08-410] is displayed if there is no paper. (D = 350 + value set in Test mode 487)

14 7 RN (Version 1.0)

CHAPTER 14. TIMING CHARTS INDIVIDUAL PRINTING OPERATIONS


[Print In Progress - End Operation]
Print drum angle 20 270 0 180 0

A 100 C

D 0

100 C

Paper detection at press section Position A sensor

Paper detected No paper

ON OFF

Paper sensor

ON OFF (8)

(6) (7) (9)

(8) (9)

(7)

Paper receiving sensor Paper detection sensor Main motor

ON OFF ON OFF ON OFF (5) B (4)

Paper feed clutch Pressure solenoid

ON OFF ON OFF

(10)

Paper ejection motor Suction fan

ON OFF ON OFF

Separation fan

ON OFF

Copy count signal

ON OFF

(4) The paper detection sensor is checked at the drum angle, A, and the paper feed clutch is activated if paper is present. Error message [C04-402] is displayed if no paper is present. (A = 62 + value set in Test mode 481) (5) The paper is transported, and the paper feed clutch is deactivated once the print drum has rotated B from when the paper is detected by the paper sensor. (B = 21 + value set in Test modes 482485 + adjustment for print drum speed) (6) If the paper sensor does not detect the paper by the time the print drum has rotated to angle C, it determines that no paper has been picked up, and moves to the three-cycle no-paper pickup operation. (C = 135 + value set in Test mode 486 + value set in Test mode 481) (7) If the paper receiving sensor does not detect the paper by the time the print drum has rotated to angle D, it determines that a paper jam has occurred, and moves to the print-end operation. The paper sensor is checked at 180 before the print drum stops, error message [A07-409] is displayed if paper is present, and [A08-410] is displayed if there is no paper. (D = 350 + value set in Test mode 487) (8) If the paper does not pass beyond the paper sensor by the time the print drum has rotated to 100, it determines that a paper jam has occurred, and moves to the print-end operation. Error message [A07-413] is displayed. (9) The paper receiving sensor is checked at the drum angle, E. If the paper is still present, it determines that a paper jam has occurred, moves to the print-end operation, and error message [A09-411] is displayed. If normal, the copy count is incremented. (E = 250 + value set in Test mode 488) (10) On completion of printing, the pressure solenoid is deactivated when the print drum has rotated to angle C. (11) On the final revolution, the drum rotates at speed 1 at 20, reducing to 30 rpm at 180 and 10 rpm at 270. The main motor, paper receiving motor, suction fan, and separation fan stop once the print drum is detected at position A. 14 8 RN (Version 1.0)

CHAPTER 14. TIMING CHARTS INDIVIDUAL PRINTING OPERATIONS


[Three-Cycle No-Paper Pickup Operation]
Print drum angle 0 C 0 C 0 C 0

Paper detection at press section Position A sensor

Paper detected No paper

ON OFF (1) (2) (3)

Paper sensor ON OFF Paper receiving sensor Paper detection sensor Main motor ON OFF ON OFF ON OFF Paper feed clutch Pressure solenoid Paper ejection motor Suction fan ON OFF ON OFF ON OFF ON OFF Separation fan Copy count signal ON OFF ON OFF

(1) If the paper sensor does not detect the paper by the time the print drum has rotated to angle C, it determines that no paper has been picked up, and moves to the three-cycle no-paper pickup operation. (C = 135 + value set in Test mode 486 + value set in Test mode 481) (2) The paper feed operation is performed a second time, and returns to the normal operation if the paper sensor detects the paper by the time the print drum has rotated to angle C. (3) The paper feed operation is performed a third time, and returns to the normal operation if the paper sensor detects the paper by the time the print drum has rotated to angle C. If paper is not detected, it moves to the print-end operation, and error message [A07-412] is displayed.

14 9 RN (Version 1.0)

CHAPTER 14. TIMING CHARTS ELEVATOR OPERATIONS

3.

Elevator Operations
[Elevator Raise Operation] Start End

Upper limit sensor

ON OFF

(1) (2) Upper/lower limit sensors both ON (Error: 400)

Lower limit sensor

ON OFF (3) ON three times in succession (Error: 401)

Elevator motor ON overload current OFF Paper detection ON sensor OFF Paper feed tray safety switch ON OFF
100 ms 100 ms 100 ms

(4) ON twice in succession (Error: 402) (5) ON twice in succession (Error: 403)

Elevator motor

Raise OFF Lower

(6) Max 2 s (Error: 404) (7)


Max 12 s (Error: 405)

When ON: Upper limit sensor: Blocked, Lower limit sensor: Blocked, Paper detection sensor: Open (1) The operation ends if the upper limit sensor is ON from the start. If the upper limit sensor is OFF, the elevator operates until the upper limit sensor goes ON. (2) Error message [T02-400] is displayed if both the upper and lower limit sensors are ON at the start. (3) The elevator motor overload current is continually monitored at 100 ms intervals while the elevator is operating, and error message [T02-401] is displayed if an overload current is detected three times in succession. (4) The paper detection sensor is continually monitored at 100 ms intervals while the elevator is operating, and error message [C04-402] is displayed if no paper is detected twice in succession. (5) The paper feed tray safety switch is continually monitored at 100 ms intervals while the elevator is operating, and error message [A06-403] is displayed if it is detected as OFF twice in succession. (6) If the lower limit sensor takes more than 2 s to go OFF after the elevator starts, a time-out occurs, and error message [T02-404] is displayed. (7) If the upper limit sensor takes more than 12 s to go ON after the elevator starts, a time-out occurs, and error message [T02-405] is displayed.

14 10 RN (Version 1.0)

CHAPTER 14. TIMING CHARTS ELEVATOR OPERATIONS


[Elevator Lower Operation] Start (1) Upper limit sensor Lower limit sensor Elevator motor overload current Paper feed tray safety switch ON OFF ON OFF ON OFF ON OFF
100 ms 100 ms 100 ms Max 12 s (Error: 407) Max 2 s (Error: 406)

End

(2) ON three times in succession (Error: 401)

(3) OFF twice in succession (Error: 403)

Elevator motor

Raise OFF Lower (4)

(5)

When ON: Upper limit sensor: Blocked, Lower limit sensor: Blocked, Paper feed tray safety switch: Not depressed (1) The operation ends if the lower limit sensor is ON from the start. If the lower limit sensor is OFF, the elevator operates until the lower limit sensor goes ON. (2) The elevator motor overload current is continually monitored at 100 ms intervals while the elevator is operating, and error message [T02-401] is displayed if an overload current is detected three times in succession. (3) The paper feed tray safety switch is continually monitored at 100 ms intervals while the elevator is operating, and error message [A06-403] is displayed if it is detected as OFF twice in succession. (4) If the upper limit sensor takes more than 2 s to go OFF after the elevator starts, a time-out occurs, and error message [T02-406] is displayed. (5) If the lower limit sensor takes more than 12 s to go ON after the elevator starts, a time-out occurs, and error message [T02-407] is displayed.

14 11 RN (Version 1.0)

CHAPTER 14. TIMING CHARTS ELEVATOR OPERATIONS


[Elevator Servo Operation]

Upper limit sensor

ON OFF

(1) (8) OFF more than 2 s in succession (Error: 408)

Lower limit sensor Elevator motor overload current Paper detection sensor Paper feed tray safety switch

ON OFF ON OFF ON OFF ON OFF


100 ms 100 ms 100 ms

(2) ON three times in succession (Error: 401)

(3) ON twice in succession (Error: 402) (4) ON twice in succession (Error: 403)

Elevator motor

Raise OFF Lower


100 ms

(5)

(6)
100 ms

Controlled by H/W

At start of printing

Elevator servo

When ON: Upper limit sensor: Blocked, Lower limit sensor: Blocked, Paper detection sensor: Open, Paper feed tray safety switch: Depressed (1) The operation ends if the upper limit sensor is ON from the start. If the upper limit sensor is OFF, the elevator operates until the upper limit sensor goes ON. (2) The elevator motor overload current is continually monitored at 100 ms intervals while the elevator is operating, and error message [T02-401] is displayed if an overload current is detected three times in succession. (3) The paper detection sensor is continually monitored at 100 ms intervals while the elevator is operating, and error message [C04-402] is displayed if no paper is detected twice in succession. (4) The paper feed tray safety switch is continually monitored at 100 ms intervals while the elevator is operating, and error message [A06-403] is displayed if it is detected as OFF twice in succession. (5) If the upper limit sensor goes ON, the elevator briefly descends until the upper limit sensor goes OFF. (6) The elevator then rises until the upper limit sensor goes ON again. (7) The elevator servo operation is subsequently performed. (8) If the upper limit sensor remains OFF for more than 2 s during the elevator servo operation, error message [T02-408] is displayed.

14 12 RN (Version 1.0)

CHAPTER 14. TIMING CHARTS PRINT DRUM PERIPHERAL OPERATIONS

4.

Print Drum Peripheral Operations


[Clamp Release]

(2) Clamp sensor A ON OFF Clamp sensor B ON OFF


Max 3 s (Error: 503)

(3)

280 ms

Max 5 s (Error: 504)

Clamp motor

Forward OFF Reverse (1)


100 ms

When ON: Clamp sensor A: Blocked, Clamp sensor B: Blocked (1) The clamp motor operates in the forward direction on starting. (2) When clamp sensor B goes OFF with clamp sensor A ON, the clamp motor operates for a further 280 ms before stopping. A time-out occurs at 5 s after the clamp motor starts, and error message [T03-504] is displayed. (3) A time-out occurs and error message [T03-503] is displayed if clamp sensor B does not go ON within 3 s of the clamp motor starting. [Master Clamp Operation]

(2) Clamp sensor A Clamp sensor B ON OFF ON OFF (3)


Max 3 s (Error: 505) Max 5 s (Error: 506) 250 ms

Clamp motor

Forward OFF Reverse (1)


100 ms

(1) The clamp motor operates in the forward direction on starting. (2) When clamp sensor A goes OFF with clamp sensor B ON, the clamp motor operates for a further 250 ms before stopping. A time-out occurs at 5 s after the clamp motor starts, and error message [T03-506] is displayed. (3) A time-out occurs and error message [T03-505] is displayed if clamp sensor B does not go ON with 3 s of the clamp motor starting.

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CHAPTER 14. TIMING CHARTS PRINT DRUM PERIPHERAL OPERATIONS


[Inking Operation (No Ink Detection)]

Position A sensor

ON OFF

Ink sensor

ON OFF

500 ms

500 ms

500 ms 500 ms 500 ms 500 ms (2) OFF for A s in succession (Error: 514)

500 ms

Main motor

ON OFF

(1)

Inking motor

ON OFF

(1) Inking is performed with the main motor ON. (2) The ink sensor is monitored at 500 ms intervals, and if it is detected as OFF, the inking motor is activated until the ink sensor goes ON. A time-out occurs at A s here, and the ink cartridge is determined as empty. Error message [C01-512] is displayed. Normally: (A = Value set in Test mode No. 583 (initially 20 s)) After ink replacement: (A = Value set in Test mode No. 584 (initially 40 s)) [Inking Operation (Overflow Detection)]

Position A sensor

ON OFF ON OFF 10 ms 10 ms 10 ms 10 ms 10 ms (1)

Overflow sensor

(2) ON for B times in succession (Error: 515) Main motor Inking motor ON OFF ON OFF

(1) The overflow sensor is monitored at 10 ms intervals, and if it is detected as ON, the inking motor is stopped for period (2) irrespective of the ink sensor status. (2) If the overflow sensor is detected as ON B times in succession, an overflow is determined to have occurred, and error message [T04-513] is displayed. (B = Value set in Test mode No. 585 (initially 50 times))

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CHAPTER 14. TIMING CHARTS PRINT DRUM PERIPHERAL OPERATIONS


[Print Drum Solenoid Lock Release]

(2) Position A sensor ON OFF Print drum set sensor ON OFF (1) (1)

100 ms 100 ms 100 ms 100 ms

100 ms

100 ms

Print drum release switch Print drum lock solenoid Print drum release switch LED

ON OFF ON OFF ON OFF (3) (3) (4)

Max 30 s

(1) The print drum set sensor and print drum release switch are monitored at 100 ms intervals. (2) If the print drum release switch is detected as having been depressed twice in succession, the position A sensor is checked, and the print drum rotates to position A if the position A sensor is OFF. (The print drum release switch LED blinks here.) (3) The print drum lock solenoid and print drum release switch LED are switched ON until the print drum set sensor goes OFF (until the print drum is removed) to allow the print drum to be removed at position A. (4) If the print drum is left at the removal position without being removed, a time-out occurs at 30 s, and the print drum lock solenoid and print drum release switch LED are switched OFF.

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CHAPTER 14. TIMING CHARTS PRINT ADJUSTMENT OPERATIONS

5.

Print Adjustment Operations


[Print Speed Change]

220

220

220

220

220

Position A sensor Print speed adjustment key

ON OFF UP OFF DOWN (1) (2)

speed 3

speed 4

speed 3

speed 2

speed 3

(1) If the print speed adjustment key is pressed, the speed does not change immediately, but rather at the next time the print drum reaches the 220 position. (2) If the print speed adjustment key is pressed twice, the speed only changes by one level per revolution, and so two revolutions are required to reach the specified speed. [Print Intensity Change]
150 150 150 150 150

Position A sensor Print intensity adjustment key

ON OFF UP OFF DOWN (1) (2)

Pressure control motor

Increase OFF Decrease

(1) If the print intensity adjustment key is pressed, the print intensity does not change immediately, but rather at the next time the print drum reaches the 150 position. (2) Likewise, when the print intensity adjustment key is pressed twice, the intensity changes as specified the next time the print drum reaches the 150 position.

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CHAPTER 14. TIMING CHARTS PRINT ADJUSTMENT OPERATIONS


[Vertical Print Positioning Operation]
Print position adjustment key ON OFF
(Operation ignored) 1s

Within 1 s

Within 1 s

Print positioning pulse motor

ON OFF
0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm

(1) If the print position adjustment key is pressed once (within 1 s), the position is immediately changed 0.5 mm. (2) If the print position adjustment key is pressed twice (within 1 s), the second press is ignored if pressed while the position is being moved for the first press. (3) If the print position adjustment key is pressed for more than 1 s, the position is moved 5 mm for the first 1 s pressed, and then continuously in 5 mm increments for as long as the key is pressed.

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CHAPTER 14. TIMING CHARTS OVERALL TIMING FOR NORMAL MASTER CREATION

Master Removal Operations


1. Overall Timing for Normal Master Creation
Start End

Image scanning Master making Master loading Master setting Thermal print head Master cutting Removed master vertical transport Master compressing Paper feed tray elevator Clamp Print drum Master check Only when master on print drum is unconfirmed Print pressure change Proof-read print Pressure release

Compress

Release

Compress

Release

Only position A adjustment if no master on print drum

Release

Position A adjustment

Home position reset

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CHAPTER 14. TIMING CHARTS INDIVIDUAL MASTER REMOVAL OPERATIONS

2.

Individual Master Removal Operations


[Removed Master Vertical Transport Operation]

Print drum angle Position A sensor Master removal sensor Master compression sensor ON OFF ON OFF ON OFF (1)

180

320

(4)

OFF-OFF (Error: 303)

ON (Error: 304) A

(2) Master removal motor overload current Main motor Master removal motor ON OFF ON OFF ON OFF (3)
d ms c rpm 10 rpm 100 ms 100 ms 100 ms

(5)

When ON: Position A sensor: Blocked, Master removal sensor: Open, Master compression sensor: Open The removed master vertical transport operation starts after the print drum clamp plate releasing operation ends. (1) The master compression sensor is checked on starting, and the master compression plate is initialized if it is OFF. (2) The master removal motor overload current is monitored continually at 100 ms intervals during the Removed master vertical transport operation, and error message [T12-300] is displayed if an overload current is detected three times in succession. (3) The main motor and master removal motor are operated to vertically transport the removed master while rotating the print drum. The print drum speed here corresponds to the value set in Test mode No. 387 (initially 15 rpm). (4) The progress of the removed master is checked twice by the master removal sensor at print drum angles a and b, and is judged to be normal if the sensor is ON at both points. If it is OFF at one point, error message [A04-303] is displayed. (a = value set in Test mode No. 380 (initially 70)) (b = value set in Test mode No. 381 (initially 90)) (5) The print drum stops at position A, and the master removal motor stops after d ms. The master removal sensor is checked here, and error message [A04-304] is displayed if it is ON. (d = value set in Test mode No. 382 (initially 0 s))

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CHAPTER 14. TIMING CHARTS INDIVIDUAL MASTER REMOVAL OPERATIONS


[Disposed Master Compressing Operation] Start End

Master removal sensor Master compression sensor Disposal box full sensor Master removal motor Master compression motor

ON OFF ON OFF ON OFF ON OFF Compress OFF Release


Max 11 s (Error: 307) Max 400 ms (Error: 306) 100 ms Brake Max 7 s (Error: 305) Brake

(1)

f sec
Max 3 s (Error: 309)

e ms

100 ms

When ON: Master removal sensor: Open, Master compression sensor: Open, Disposal box full sensor: Open The disposed master compressing operation starts after the removed master vertical transport operation ends. (1) The master compression sensor is checked on starting, and the master compression plate is initialized if it is OFF. (2) The master compression motor operates to start the master compression. (3) The master compression sensor goes OFF. A time-out occurs here at 400 ms, and error message [T12-306] is displayed. (4) The disposal box full sensor goes ON midway. (5) The master compression motor stops once the master compression sensor goes back ON again. A time-out occurs at 11 s after the start of master compression here, and error message [T12-307] is displayed. Similarly, if (4) is not detected, the disposal box is judged to be full, and error message [C03-313] is displayed. (6) The master compression motor reverses f s after the motor stops. (f = value set in Test mode No. 384 (initially 1 s)) The master compression sensor goes OFF while the master compression motor operates in reverse. A time-out occurs here at 3 s after reversing, and error message [T12-309] is displayed. (7) The master compression motor stops once the master compression sensor goes back ON. A time-out occurs here at 7 s after reversing, and error message [Error 305] is displayed.

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CHAPTER 14. TIMING CHARTS OVERALL TIMING FOR NORMAL MASTER CREATION

Master Making Operation


1. Overall Timing for Normal Master Creation
Start End

Image scanning Master making Master loading Master setting Thermal print head Master cutting Removed master vertical transport Master compressing Paper feed tray elevator Clamp Print drum Master check Position A adjustment Home position reset

Compress

Release

Compress

Release

Release

Print pressure change Proof-read print Pressure release

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CHAPTER 14. TIMING CHARTS INDIVIDUAL MASTER MAKING OPERATION

2.

Individual Master Making Operation


[Thermal Print Head Compression Operation] Start End

TPH pressure sensor

ON OFF

(2)

Thermal OFF pressure motor Compress

(1) Release

Max 250 ms (Error: 207)

100 ms Brake Max 1 s (Error: 210)

When ON: TPH pressure sensor: Blocked (1) The thermal pressure motor operates in the direction of compression. (2) The TPH pressure sensor goes OFF, and the thermal pressure motor stops when the sensor goes back ON again. A time-out occurs at 250 ms when the TPH pressure sensor goes OFF, and error message [T19207] is displayed. Likewise, a time-out occurs at 1 s when the TPH pressure sensor goes back on again, and error message [Error 208] is displayed. [Thermal Print Head Release Operation]

TPH pressure sensor

ON OFF (1) Release

(2)

Brake Max 250 ms (Error: 207) Max 1 s (Error: 210) 100 ms

Thermal OFF pressure motor Compress

(1) The thermal pressure motor operates in the release direction. (2) The TPH pressure sensor goes OFF, and the thermal pressure motor stops when the sensor goes back ON again. A time-out occurs at 250 ms when the TPH pressure sensor goes OFF, and error message [T19207] is displayed. Likewise, a time-out occurs at 1 s when the TPH pressure sensor goes back on again, and error message [T19-208] is displayed.

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CHAPTER 14. TIMING CHARTS INDIVIDUAL MASTER MAKING OPERATION


[Master Positioning Operation] Start Master positioning sensor Master detection sensor Master end sensor ON OFF ON OFF ON OFF ON Read/Write signal OFF
Max B mm (Error: 202)

End

(1)
10 ms 10 ms 10 ms

(2)

Write pulse motor Load pulse motor

Feed OFF Return Feed OFF Return


50 ms HOLD

100 ms

(3)
Max A mm (Error: 201)

(4)

(5)

B mm

50 ms HOLD

50 ms HOLD

50 ms HOLD

When ON: Master positioning sensor: Open, Master detection sensor: Open, Master end sensor: Blocked The master positioning operation starts after master cutting is complete when setting the master loading unit and master creation. (1) The master detection sensor detects whether a master is present on starting. If the master detection sensor is OFF, error message [D05-210] is displayed. (2) The master end sensor is checked at 10 ms intervals, and if an end mark is detected twice in succession, error message [C02-200] is displayed. (3) The write pulse motor and load pulse motor operate in the feed direction until the master positioning sensor goes ON. A time-out occurs here when it has fed 75 mm when setting the master loading unit and 25 mm when inching after cutting, and error message [A01-201] is displayed. (4) The write pulse motor and load pulse motor operate in the return direction until the master positioning sensor goes OFF. A time-out occurs here when it has fed B mm, and error message [A01-202] is displayed. (B = 3 mm + value set in Test mode No. 280) (5) The master is moved a further B mm in the return direction after the master positioning sensor goes OFF, and then motor then stops, ending the master positioning operation.

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CHAPTER 14. TIMING CHARTS INDIVIDUAL MASTER MAKING OPERATION


[Master Cutting Operation] Start (1) Master positioning sensor ON OFF Print drum rotates 15. Master end sensor ON OFF Cutter home ON position switch OFF Cutter motor ON OFF
Max 200 ms (Error: 203) Max 400 ms (Error: 204) Max 200 ms (Error: 203) Max 400 ms (Error: 204)

Normal end

Error end

(3) Print drum rotates 15.

(4)

(2)

When ON: Master positioning sensor: Open, Master end sensor: Blocked When the master making operation starts, the cutter home position switch is checked at the start of the master cutting operation. Error message [A17-209] is displayed if it is OFF. (1) The Master cutting operation starts after the print drum stops at angle A during master loading. (A = 220 + value set in Test mode No. 284) (2) The cutter motor operates and stops after the cutter home position switch goes OFF and then back ON again. A time-out occurs at 200 ms before the switch goes OFF, and error message [T13-203] is displayed. Likewise, a time-out occurs at 400 ms before the switch goes back ON again, and error message [T13-204] is displayed. (3) The print drum rotates, and the master positioning sensor is checked when the print drum reaches the 15 position. If the master positioning sensor is OFF, the process is normal, and master cutting ends. If the master positioning sensor is ON, master cutting is repeated. (4) The print drum rotates, and the master positioning sensor is rechecked when the print drum reaches the 15 position. If the master positioning sensor is OFF, error message [A03-206] is displayed. If the master positioning sensor is ON, error message [T13-205] is displayed.

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CHAPTER 14. TIMING CHARTS INDIVIDUAL MASTER MAKING OPERATION


[Master Making Operation] Start End

Master positioning sensor Master detection sensor Master end sensor

ON OFF ON OFF ON OFF (1) 10 ms 10 ms 10 (2) ms

C mm

F[d] mm (7)

Read/Write signal Write pulse motor

ON OFF Feed OFF 50 ms Feed (3) 300 50 ms ms 50 ms

Load pulse motor

OFF Return D mm

(5)

E[c] mm Max A mm (Error: 201)

(4) Master creation possible

(6) Loading possible

When ON: Master positioning sensor: Open, Master detection sensor: Open, Master end sensor: Blocked The master loading and master making operation start once the thermal print head compressing is complete. (1) The master detection sensor checks for the presence of a master on starting. (2) The master end sensor is checked at 10 ms intervals during the master transport operation, and if the end mark is detected twice in succession, error message [C02-200] is displayed. (3) The write pulse motor and load pulse motor operate in the feed direction until the master positioning sensor goes ON. A time-out occurs here when the master is fed A mm, and error message [A01201] is displayed. (A = 3 mm + value set in Test mode No. 280) (4) The write pulse motor operates once the clamp release operation ends for removing the master, and master creation starts after it has been transported to the position for the start of printing. (C = 6.5 mm + value set in Test mode No. 281) (5) The load pulse motor operates to transport the leading edge of the master to the master loading position. (D = 95 mm)

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CHAPTER 14. TIMING CHARTS INDIVIDUAL MASTER MAKING OPERATION


(6) Once the removed master vertical transport ends and the print drum position A adjustment is complete, the load pulse motor operates to transport the leading edge of the master to the clamp position. (E = 136.1 mm + value set in Test mode No. 283) (7) Master creation ends once master creation is complete for the effective printing area.

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CHAPTER 15: PANEL MESSAGES

Contents
1. 2. 3. 4. Explanation of Panel Messages .................................................................................. 15-2 List of Panel Messages ................................................................................................ 15-3 Details of Panel Messages .......................................................................................... 15-4 Backed-up Errors ....................................................................................................... 15-17

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CHAPTER 15. PANEL MESSAGES EXPLANATION OF PANEL MESSAGES

1.

Explanation of Panel Messages


Overview of messages
1) Error code displays If an error occurs, an error message is displayed together with a graphic and an error code to indicate the problem to the user. Error code displays consist of an error type according to the type of error and an error point number corresponding to the error situation. Example: T99-123 T99: Error type 123: Error point 2) Error type The order of error priority is as shown below. Error type T A B C D E 3) Error point The error point classifications are as shown below. Error details Serviceman call error Jam error Option error Consumable error Set error Warning (call serviceman)

Error point 0XX 1XX 2XX 3XX 4XX 5XX 6XX 7XX

Error details System (hardware, software, communication), panel Scanning section (scanner, ADF), image processing Master making section Master removal section Paper feed/ejection section Print drum Printing adjustment section (vertical position, density) Optional equipments (Job separator, Key /Card Counter)

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CHAPTER 15. PANEL MESSAGES LIST OF PANEL MESSAGES

2.

List of Panel Messages


Error type T01 T02 T03 T04 T05 T08 T11 T12 T13 T14 T15 T17 T19 T20 T23 T24 T25 T98 Details Main motor lock Elevator motor lock Clamp motor lock Overflow Vertical positioning pulse motor lock Computer interface error Pressure control motor lock Master removal motor lock Error type Cutter motor lock D01 Flat bed error D02 ADF error D03 Solenoid counter not connected D04 Thermal pressure motor lock D05 Master creation motor lock D07 Scanner lock not released D09 Inking motor lock D10 No battery D11 Hardware error
Error type Details Replace battery Maintenance call
Error type B01 Details Key/Card counter: No card

Error type C01 C02 C03 C04

Details Replace ink cartridge Replace master roll Master disposal-box-full No paper

Details Print drum not set Incorrect print drum Ink cartridge not set Incorrect ink cartridge Master not mounted Master disposal box not set Master loading unit not set Scanner table not set Front cover not set

Error type A01 A02 A03 A04 A05 A06 A07 A08 A09 A10 A16 A17

Details
E01

Master feed error Master loading error Cutting error Master removal error Master present in master removal section Check paper feed tray Paper feed error Paper jam on Print Drum Paper ejection error ADF original feed error Awaiting master removal Cutter error

E02

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CHAPTER 15. PANEL MESSAGES DETAILS OF PANEL MESSAGES

3.

Details of Panel Messages


Technician errors
Error type T01 [Main motor lock]

T01-*** A problem has occurred. Panel display Press the lower right "Jam Reset" key. If resetting is not possible, notify technician of T01-***. Reset method Jam reset -> Power failure/Emergency stop action Error point 520 521 523 524 536 Error detection conditions Main FG does not go ON/OFF for more than 8 pulses while the main motor is operating even after 100 ms has elapsed. Position A sensor does not go ON/OFF while the main motor is operating even after 10s has elapsed. Main motor over current. Clamp sensors A or B were ON while the print drum operates. (Except during master removal) osition A sensor went OFF while stopped at position A.

Error type

T02 [Elevator motor lock]

T02-*** A problem has occurred. Panel display Press the lower right "Jam Reset" key. If resetting is not possible, notify technician of T02-***. Reset method Jam reset -> Power failure/Emergency stop action Error point 400 401 404 405 406 407 408 Error detection conditions Both upper and lower limit sensors were ON. Overload current detected in the elevator motor. Lower limit sensor does not go OFF within 2 s after the elevator motor operates in the upper direction from the lower limit position. Upper limit sensor does not go ON within 12 s after the elevator motor operates in the upper direction. Upper limit sensor does not go OFF within 2 s after the elevator motor operates in the lower direction from upper limit position. Lower limit sensor does not go ON within 12 s after the elevator motor operates in the lower direction. Upper limit sensor is OFF continuously for at least 2 s during the elevator servo operation.

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CHAPTER 15. PANEL MESSAGES DETAILS OF PANEL MESSAGES

Error type

T03 [Clamp motor lock]

T03-*** A problem has occurred. Panel display Press the lower right "Jam Reset" key. If resetting is not possible, notify technician of T03-***. Reset method Jam reset -> Power failure/Emergency stop action Error point 501 502 503 504 505 506 Error detection conditions Clamp sensors A and B do not change 3 s after the clamp motor activates during clamp initialization. Clamp sensor A or B was ON 13 s after the clamp motor activated during clamp initialization. Clamp sensor B does not go ON within 3 s after the clamp motor activates during the clamp plate master release operation. Clamp sensor A does not go ON and clamp sensor B does not go OFF within 12 s after the clamp motor activates during the clamp plate master release operation. Clamp sensor B does not go ON within 3 s after the clamp motor activates during the clamp plate master clamp operation. Clamp sensor A does not go OFF within 5 s after the clamp motor activates during the clamp plate master clamp operation.

Error type

T-04 [Overflow]

T04-*** A problem has occurred. Panel display Press the lower right "Jam Reset" key. If resetting is not possible, notify technician of T04-***. Reset method Jam reset and overflow sensor OFF Error point 513 Error detection conditions Overflow sensor was ON for a set number of times in succession during the 10-ms-interval overflow check.

Error type

[T05 [Vertical positioning pulse motor lock]

T05-*** A problem has occurred. Panel display Press the lower right "Jam Reset" key. If resetting is not possible, notify technician of T05-***. Reset method Error point 603 604 612 Jam reset -> Recovery operation (home position reset) Or: switch on power again. Error detection conditions Vertical centering sensor does not switch OFF -> ON even when vertical positioning pulse motor is moved 18 mm in the ON direction. Vertical centering sensor does not switch ON -> OFF even when vertical positioning pulse motor is moved 18 mm in the OFF direction. 1-step vertical positioning key was pressed with undefined position data.

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CHAPTER 15. PANEL MESSAGES DETAILS OF PANEL MESSAGES

Error type

T08 [CI error]

T08-*** A problem has occurred. Panel display Switch on power again. If resetting is not possible, notify technician of T08-***. Reset method Switch on power again. Error point 002 CI communication error Error conditions

Error type

T11 [Pressure control motor lock]

T11-*** A problem has occurred. Panel display Press the lower right "Jam Reset" key. If resetting is not possible, notify technician of T11-***. Reset method Error point 600 Jam reset -> Recovery operation (home position reset) Or: switch on power again. Error conditions Print pressure control sensor does not go OFF -> ON even when the pressure control motor is moved 3200 pulses in the direction of compression when setting the pressure control home position. Print pressure control sensor does not go ON -> OFF even when the pressure control motor is moved 3200 pulses in the release direction when setting the pressure control home position. Print pressure control sensor does not go OFF -> ON even when the pressure control motor is moved 10 pulses to check the home position when setting the pressure control home position.

601

602

Error type

T12 [Master removal motor lock]

T12-*** A problem has occurred. Panel display Press the lower right "Jam Reset" key. If resetting is not possible, notify technician of T12-***. Reset method Jam reset -> Recovery operation Error point 300 305 306 307 309 Error conditions Master removal motor (vertical transport motor) overload current detection is ON. Master compression sensor does not go ON within 7 s after the master compression motor operates in the return direction. Master compression sensor does not go OFF within 400 ms after the master compression motor operates in the direction of compression. Master compression sensor does not go ON within 11 s after the master compression motor operates in the direction of compression. Master compression sensor does not go OFF within 3 s after the master compression motor operates in the return direction.

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CHAPTER 15. PANEL MESSAGES DETAILS OF PANEL MESSAGES

Error type

T13 [Cutter motor lock]

T13-*** A problem has occurred. Panel display Press the lower right "Jam Reset" key. If resetting is not possible, notify technician of T13-***. Reset method Jam reset -> Recovery operation Error point 203 204 Error conditions Cutter home position switch does not go OFF within 200 ms after the cutter motor is activated. Cutter home position switch does not go OFF -> ON within 400 ms after the cutter motor is activated. Master positioning sensor is ON when the print drum rotates through the preset angle after cutting, and master positioning sensor is still ON when the print drum rotates through the preset angle after repeat cutting.

205

Error type

T14 [Flat bed fault]

T14-*** A problem has occurred. Panel display Press the lower right "Jam Reset" key. If resetting is not possible, notify technician of T14-***. Reset method Jam reset Error point 100 Error conditions Flat bed home position sensor does not go ON at the point when it should go OFF -> ON. (when moved the predetermined amount for FB original scanning or when moving to the ADF scanning position.) Flat bed home position sensor does not go OFF at the point when it should go ON -> OFF. (when moved the predetermined amount for FB original scanning or when moving to the ADF scanning position.) Communication error with shading IC.

101 110

Error type

T15 [ADF fault]

T15-*** A problem has occurred. Panel display Press the lower right "Jam Reset" key. If resetting is not possible, notify technician of T15-***. Reset method Jam reset Error point 114 115 Error conditions ADF original detection signal went OFF during ADF operation. Operation clock of ADF transport motor is not correct.

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CHAPTER 15. PANEL MESSAGES DETAILS OF PANEL MESSAGES

Error type

T17 [Solenoid counter not connected]

T17-*** A problem has occurred. Panel display Press the lower right "Jam Reset" key. If resetting is not possible, notify technician of T17-***. Reset method Solenoid counter connection signal ON Error point 020 Solenoid counter is not connected. Error conditions

Error type

T19 [Thermal pressure motor lock]

T19-*** A problem has occurred. Panel display Press the lower right "Jam Reset" key. If resetting is not possible, notify technician of T19-***. Reset method Jam reset Error point 207 208 Error conditions TPH pressure sensor does not go OFF within 250 ms after the thermal pressure motor activates. TPH pressure sensor does not go OFF within 1 s after the thermal pressure motor activates.

Error type

T20 [Master creation motor lock]

T20-*** A problem has occurred. Panel display Press the lower right "Jam Reset" key. If resetting is not possible, notify technician of T20-***. Reset method Jam reset Error point 416 Error conditions An overload current was detected in the feed motor.

Error type

T23 [Scanner lock not released]

T23-*** Panel display Scanner is locked. Release lock. Reset method Clear the scanner lock mode. (Test mode No. 155) Error point 111 In scanner lock mode. Error conditions

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CHAPTER 15. PANEL MESSAGES DETAILS OF PANEL MESSAGES


Error type T24 [Inking motor lock]

T24-*** A problem has occurred. Panel display Press the lower right "Jam Reset" key. If resetting is not possible, notify technician of T24-***. Reset method Jam reset or switch on power again. Error point 539 Inking motor current overload. Error conditions

Error type

T25 [No battery]

T25-*** A problem has occurred. Panel display Press the lower right "Jam Reset" key. If resetting is not possible, notify technician of T25-***. Reset method Error point 026 Replace battery. * The machine does not operate when this error occurs. Error conditions Residual battery voltage below 1.5 V when power is ON.

Error type

T98 [Hardware error]

T98-*** A problem has occurred. Panel display Switch on power again. If resetting is not possible, notify technician of T98-***. Reset method Switch on power again. Error point 005 Hardware error. Memory check sum error. Memory contents have changed since power was last switched off. * If this error occurs, a memory fault is identified the next time the power is switched on, and the memory (test mode, user mode, memory mode, and error backup details) is cleared. AMF PCB was fitted to machine not compatible with AMF PCB or AMF PCB was not fitted to machine compatible with AMF PCB. Print drum communication error. Error conditions

006

028 543

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CHAPTER 15. PANEL MESSAGES DETAILS OF PANEL MESSAGES

Jam errors
Error type A01 [Master feed error]

A01-*** Panel display Master jammed. Rewind master, and the reset. Reset method Error point 201 202 211 214 215 Master loading unit switch: OFF -> ON, then master positioning sensor OFF. (Or switch on power again.) Error conditions Master positioning sensor does not go ON even when the master is fed preset amount after write pulse motor is activated. Master positioning sensor does not go OFF even when the master is rewound during master positioning operation. Master positioning sensor was ON during standby. Master positioning sensor was ON at start of master creation. Faulty gate array control for write pulse motor or load pulse motor.

Error type

A02 [Master loading error]

A02-*** Panel display Master jammed. Rewind master, and the reset. Reset method Error point 509 Master loading unit switch: OFF -> ON, then master positioning sensor OFF. -> Recovery operation Error conditions Master loading sensor was OFF when checking master at specified angle in master loading operation.

Error type

A03 [Cutting error]

A03-*** Panel display Master is not correctly wound onto print drum. Remove master from print drum. Reset method Print drum set sensor: OFF -> ON -> Recovery operation Error point 206 Error conditions Cutting was performed after repeating cutting operation.

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CHAPTER 15. PANEL MESSAGES DETAILS OF PANEL MESSAGES

Error type

A04 [Master removal error]

A04-*** Panel display Cannot eject master. Pull out print drum and remove master. Reset method Print drum set sensor: OFF -> ON -> Recovery operation Error point 303 304 314 Error conditions OFF/OFF in removal jam sensor check at 70/90. Removal jam sensor was ON at end of removed master feed operation. Emergency stop or power failure occurred while releasing clamp in master removal operation.

Error type

A05 [Master present in master removal section]

A05-*** Panel display Master jammed in master removal section. Open master removal unit and remove master. Reset method Error point 312 Master removal unit set sensor: OFF -> ON, and Removal jam sensor: OFF (Or switch on power again.) Error conditions Removal jam sensor was ON on starting master making operation.

Error type Panel display Reset method Error point 403

A06 [Check paper feed tray] A06-*** Check paper feed tray. Paper feed tray lower safety switch goes ON. (Or switch on power again.) Error conditions Paper feed tray lower safety switch was OFF.

Error type

A07 [Paper feed error]

A07-*** Panel display Paper jammed. Check paper feed side, and press the lower right "Jam Reset" key. Reset method Set paper sensor to OFF, and reset jam. Error point 409 412 413 418 Error conditions Paper receiving sensor was OFF when paper arrived and paper sensor was ON at 180 just before stopping. Paper sensor was OFF three times in succession when detecting first stage paper feed jam. (Non-pickup error) Paper sensor was ON when paper left paper sensor. (Scale error) Paper sensor was ON at start of operation.

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CHAPTER 15. PANEL MESSAGES DETAILS OF PANEL MESSAGES


Error type A08 [Ejected paper lifting up]

A08-*** Panel display Paper jammed. Pull out print drum and remove jammed paper. Reset method Error point 410 Print drum set sensor: OFF -> ON. (Or switch on power again.) Error conditions Paper receiving sensor was OFF when paper arrived and paper sensor was OFF at 180 just before stopping.

Error type

A09 [Paper ejection error]

A09-*** Panel display Paper jammed. Check paper ejection side, and press the lower right "Jam Reset" key. Reset method Set paper receiving sensor to OFF, and reset jam. Error point 411 417 Error conditions Paper receiving sensor was ON when paper left paper receiving sensor. Paper receiving sensor was ON at start of operation.

Error type

A10 [ADF original feed error]

A10-*** Paper jammed. Panel display Remove paper while pressing the reset button. Press the lower right "Jam Reset" key. Reset method Set ADF original detection sensor to OFF, and reset jam. Error point 104 Error conditions ADF original feed error (1): Original was missing when fed in. Original detection sensor was already ON when power was switched on or when jam was reset. Did not leave original registration sensor even when fed 543 mm after starting scanning. ADF original feed error (2): Did not leave original read sensor even when fed 114 mm after original registration sensor went OFF. ADF original feed error (3): Did not leave paper receiving sensor even when fed 117 mm after original read sensor went OFF. ADF original feed error (4): Did not reach original registration sensor even when fed 182 mm after start of feeding in. ADF original feed error (5): Did not reach original read sensor even when fed 138 mm after start of scanning. ADF original feed error (6): Did not reach paper receiving sensor even when fed 117 mm after original read sensor went ON.

105 106 107 108 109

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CHAPTER 15. PANEL MESSAGES DETAILS OF PANEL MESSAGES

Error type Panel type

A16 [Awaiting master removal] A16-*** Pull out print drum and remove master mounted on print drum.

Reset method Print drum set sensor: OFF -> ON -> Recovery operation Error point 525 Error conditions Master not cut due to cutter motor locking at emergency stop.

Error type

A17 [Cutter fault]

A17-*** Panel display Problem occurred. Remove master and close master creation unit. Reset method Error point 209 Master loading set unit: OFF -> ON, and Master detection sensor: OFF -> Recovery operation Error conditions Cutter home position switch was OFF during master setting at start of master creation.

Option errors
Error type Panel display B01 [Card counter: No card] B01-*** Insert the card for the card counter.

Reset method Insert card. Error point 728 No card counter card. Error conditions

Consumable errors
Error type C01 [Replace ink cartridge]

C01-*** Panel display Ink is exhausted. Replace ink cartridge. Reset method Ink cartridge set switch: OFF -> ON. Error point 512 Error conditions Ink sensor does not go ON even when inking is run for preset period.

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CHAPTER 15. PANEL MESSAGES DETAILS OF PANEL MESSAGES

Error type

C02 [Replace master roll]

C02-*** Panel display No more masters. Replace master roll. Reset method Master loading sensor: OFF -> ON, and Master detection sensor: OFF -> ON. Error point 200 Error conditions Master end detected twice in succession at 10 ms interval check during master transport.

Error type Panel display

C03 [Master disposal-box-full] C03-*** Empty master disposal box.

Reset method Disposal box full sensor to ON after switching OFF for 5 s. Error point 308 313 Error conditions Master disposal box detected as full by disposal box full sensor. Master disposal box detected as full by software master count.

Error type Panel display

C04 [No paper] C04-*** Set paper.

Reset method Paper detection sensor to ON. Error point 402 Paper detection sensor was OFF. Error conditions

Setting check errors


Error type Panel display D01 [Print drum not set] D01-*** Set print drum.

Reset method Print drum safety switch: ON, and Print drum set sensor: ON. Error point 526 527 546 Error conditions Print drum safety switch was ON and print drum set sensor was OFF on setting print drum. Print drum safety switch was OFF. Print drum set sensor does not go ON within 2 s after print drum safety switch goes OFF -> ON on setting print drum.

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Error type

D02 [Incorrect print drum]

D02-*** Panel display Incorrect print drum. Set correct print drum. Reset method Replace with correct print drum. Error point 532 Print drum is incorrect. Error conditions

Error type Panel display

D03 [Ink cartridge not set] D03-*** Set ink cartridge.

Reset method Ink cartridge set switch: ON Error point 533 Ink cartridge set switch was OFF. Error conditions

Error type

D04 [Incorrect ink cartridge]

D04-*** Panel display Incorrect ink cartridge. Set correct ink cartridge. Reset method Replace with correct ink cartridge. Error point 534 Ink cartridge was incorrect. Error conditions

Error type

D05 [Master not mounted]

D05-*** Panel display Master is not mounted correctly. Insert leading edge of master in inlet and close master creation unit. Reset method Master detection sensor: ON. Error point 210 Master detection sensor was OFF. Error conditions

Error type Panel display

D07 [Master disposal box not set] D07-*** Set master disposal box.

Reset method Master removal section safety switch: ON. Error point 310 Error conditions Master disposal box set switch was OFF.

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Error type Panel display

D09 [Master loading unit not set] D09-*** Close master loading unit.

Reset method Master loading unit switch: ON. Error point 212 Master loading unit switch was OFF. Error conditions

Error type Panel display

D10 [Scanner table not set] D10-*** Set scanner table.

Reset method Scanner table set switch: ON. Error point 213 Scanner table set switch was OFF. Error conditions

Error type Panel display

D11 [Front cover not set] D11-*** Close front cover.

Reset method Front cover set switch: ON. Error point 535 Front cover set switch was OFF. Error conditions

Warnings
Error type E01 [Replace battery]

E01-*** Battery must be replaced. Panel display Contact technician. (Press lower right "Jam Reset" to continue operation.) Reset method Jam reset Error point 010 Error conditions Battery voltage is less than 2.1 V when power is switched ON, reset, or operation ended. (Battery replacement)

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CHAPTER 15. PANEL MESSAGES BACKED-UP ERRORS

Error type

E02 [Call technician]

E02-*** Time for periodic maintenance. Panel display Contact technician. (Press lower right "Jam Reset" to continue operation.) Reset method Jam reset Error point 011 012 022 Error conditions Number of masters completed reached value set in Test mode when power was switched ON, reset, or operation ended. Number of prints completed reached value set in Test mode when power was switched ON, reset, or operation ended. Maintenance counter inside print drum reached value set in Test mode when power was switched ON, reset, or operation ended.

4.

Backed-up Errors
The following errors are backed up and are not cleared even when the power is switched off. Error type T01 T03 T13 T18 A02 A03 A04 A16 A17 C01 C02 C03 Main motor lock Clamp motor lock Cutter motor lock Master mounting motor lock Master mounting error Cutting error Master removal error Awaiting master removal Cutter fault Replace ink cartridge Replace master roll Master disposal-box-full Error details

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CHAPTER 16: TEST MODE

Contents
1. Procedures ................................................................................................................... 16-2 1) Start-up Procedure ................................................................................................. 16-2 2) Operating Procedure ............................................................................................. 16-2 3) Ending Procedure .................................................................................................. 16-3 2. 3. 4. 5. 6. Checking Sensors and Switches ................................................................................. 16-4 Checking Motors and Solenoids .................................................................................. 16-6 Checking Unit Operations ............................................................................................ 16-7 Data Check ................................................................................................................. 16-10 Data Setting ................................................................................................................. 16-11 Print Drum Code Settings .......................................................................................... 16-18

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CHAPTER 16. TEST MODE PROCEDURES

Test Mode
1. Procedures
1) Start-up Procedure
Switch on the power while pressing the Master/Print and Text/Photo keys simultaneously.

2) Operating Procedure
Test mode numbers can be entered (selected) either via Key entry or Menu selection.
a) Key entry procedure (1) Enter the number of the test mode to be run using the numeric keys while in standby mode. If a mistake is made when entering, entry can be repeated by pressing the C key. (2) Press the Start key to start the Test mode operation. (3) Press the Stop or Start key to end the Test mode operation and return to standby mode. * When setting data, pressing the Start key confirms the data changes and returns you to standby mode. Pressing the Stop key cancels the settings before returning to standby mode. b) Menu selection method (1) While in standby mode, select the unit containing the test item to be run from the Test mode menu. Highlight the unit name using the up/down keys or function keys, and then press the Enter key. The Test mode sub-menu appears. (2) Select the test item to be run from the Test mode sub-menu. Highlight the test item using the cursor keys or function keys, and then press the Enter key. (3) Press the Start key to start the Test mode operation. (4) Press the Stop or Start key to end the Test mode operation and return to standby mode. Test mode menu display Test mode sub-menu display

Enter key ON

Close key ON

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CHAPTER 16. TEST MODE PROCEDURES


Display during Test mode operation Display during check operation Display during data setting

Technician contact entry screen display (Test mode No. 091) Entering/editing telephone number Enter digits using the numeric keys, hyphens using the * key, and spaces using the C key. Edit by moving the cursor to the character to be corrected using the left and right cursor keys, and then overwrite.

Change name key ON Entering/editing retailer name Select the character to be entered using the cursor keys, and press the Input key to input the character at the cursor position in the label. To edit, press Back to delete characters one by one from the current cursor position, and then enter the new characters. (Correction midway is not possible.) Press Cancel to cancel all input and return to the previous screen. When input is complete, press Enter to return to the previous screen.

Enter key, Cancel key ON

3) Ending Procedure
To end Test mode, press the All Reset key for 1 second in Test mode standby or in Test mode operation standby.

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CHAPTER 16. TEST MODE CHECKING SENSORS AND SWITCHES

2.

Checking Sensors and Switches


Indicates sensor and switch status using audible beeps. Detected: 0.1 second interval sound (short beeps)

Not detected: 0.5 second interval sound (long beeps) No. 100 110 111 112 113 117 119 200 201 202 203 204 205 206 300 301 302 303 400 401 402 404 405 406 408 409 412 Test item Image scanner ADF shading sensor ADF original registration sensor ADF original IN sensor Original OUT sensor ADF original detection sensor Cover open sensor ADF unit detection signal Master positioning sensor Master end sensor Master detection sensor Cutter home position switch TPH pressure sensor Master loading unit sensor Flat bed set switch Master removal sensor Master compression sensor Disposal-box-full sensor Disposal box safety switch Paper detection sensor Paper size detection sensor Upper limit sensor Lower limit sensor Paper sensor Paper receiving sensor Paper feed tray lower safety switch Elevator down switch Encoder sensor (paper ejec. motor) Detection status Blocked (shading plate present) Open (original present) Blocked Blocked (reflection blocked) Blocked Open (original present) Blocked Signal present (ADF connected) Open (master present) Blocked (master end label detected) Open (master present) Switch OFF Blocked (TPH pressure plate closed) Blocked (master loading unit closed) Switch ON Blocked (master present) Blocked (master compression plate present) Blocked Switch ON Open (paper present) Open (paper present) Blocked (shading plate present) Blocked (shading plate present) Open (paper present) Blocked (paper present) Switch ON Switch ON Blocked (shading plate present)

101 Flat bed original detection sensor

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CHAPTER 16. TEST MODE CHECKING SENSORS AND SWITCHES


No. 500 502 503 504 506 509 510 511 512 513 514 515 516 517 518 519 520 600 601 Position A sensor Main motor encoder sensor Clamp sensor A Clamp sensor B Master sensor Ink sensor Overflow sensor Ink cartridge set switch 1 Ink cartridge set switch 2 Ink cartridge set switch 3 Ink cartridge set switch 4 Ink cartridge set switch 5 Print drum free rotation switch Front cover set switch Print drum release switch Print drum set sensor Print drum safety switch Print pressure control sensor Vertical centering sensor Test item Detection status Blocked (shading plate present) Blocked (shading plate present) Blocked (shading plate present) Blocked (shading plate present) Open (master present) In contact with ink In contact with ink Switch ON Switch ON Switch ON Switch ON Switch ON Switch ON Switch ON Switch ON Blocked (shading plate present) Switch ON Blocked (shading plate present) Blocked (shading plate present)

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CHAPTER 16. TEST MODE CHECKING MOTORS AND SOLENOIDS

3.

Checking Motors and Solenoids


Press the Start key to switch ON, and either the Start or Stop key to switch OFF.
No. 030 031 130 132 133 230 231 232 233 234 235 237 238 330 430 431 432 530 531 532 533 535 Test item Audible beep check 1 Audible beep check 2 CCD lamp ADF read pulse motor (CW) ADF read pulse motor (CCW) Thermal pressure motor (CW) Thermal pressure motor (CCW) Write pulse motor (feed) Write pulse motor (return) Load pulse motor (feed) Load pulse motor (return) Cutter motor TPH thermal power Master removal motor Paper ejection motor Suction fan Separation fan Main motor (15 rpm) Main motor (30 rpm) Clamp motor (forward) Clamp motor (reverse) Print drum release switch-LED CCW CW (Only in Test mode) CW CW CCW CW CCW 0.1 second interval 0.5 second interval Illuminates Remarks

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CHAPTER 16. TEST MODE CHECKING UNIT OPERATIONS

4.

Checking Unit Operations


(1) Press the Start key to switch ON and start the unit operation. Error checks are performed basically the same as for normal operation. Some operations stop once the sequence is complete, and some operations continue until a key is pressed. (2) A continuous audible tone is given if an error occurs. To cancel errors, press the Reset key.
No. 050 051 056 Print test A (checker flag pattern) Creates a master for test pattern 1. Print test B (mesh pattern) Creates a master for test pattern 2. Paper passage test (continuous printing) Passes paper through. * "Speed" key can be used. Low-speed printing Prints at 15 rpm. 059 060 061 062 063 Auto power off signal Switches off power. Key check Pressing a key displays a specified number on the Print quantity LED. LCD check Displays check pattern on LCD. LED check LEDs blink alternately Unit initialization Rests mechanical components to their home positions. (clamps, vertical position, thermal print head, master compression plate) Shading operation Runs shading operation. 151 Scanner home position reset Returns scanner to home position. 152 Scanner 1 cycle Performs one scanner operation cycle. * Adjusts speed according to the variation rate in Test mode No. 192. Scanner ADF scanning position movement Moves scanner to ADF scanning position. 154 Scanner lock mode Moves scanner to lock position for transporting. * Error occurs. Undo scanner lock mode Cancels error status set in Test mode No. 154. 156 157 ADF original feed 1 cycle Performs paper passage test for ADF unit alone. ADF original feed operation Performs ADF original transport operation. * Adjusts speed according to the variation rate in Test mode No. 192. Test mode details

057

150

153

155

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No. 250 251 252 350 351 352 Cutter motor 1 cycle operation Performs cutting operation. TPH compress operation Moves TPH to compress position. TPH release operation Moves TPH to release position. Master compression plate home position reset Returns the master compression plate to the home position. Master compression 1 cycle operation Performs one master compression cycle. Master compression 1 step (compress direction) Performs one step (500 ms) of master compression in the direction of compression. * Note that error checking is not performed here. Master compression 1 step (return direction) Performs one step (500 ms) of master compression in the return direction. * Note that error checking is not performed here. Paper width VR Adjustment (105 mm) Sets VR value of 105 mm. * Perform before Test mode No. 451. Paper width VR Adjustment (210 mm) Sets VR value of 210 mm. * Perform after Test mode No. 450. Paper feed tray Up/Down Raises and lowers the paper feed tray repeatedly. * Starts by raising, except when at the upper limit. * Stops when the "Stop" key is pressed. * Stops for 1 s at the upper and lower limits. Elevator servo Performs servo operation. 454 550 Feed motor + suction fan Activates feed motor and suction fan simultaneously. Print drum speed control Use speed keys to rotate the print drum. * Same operation as for normal printing. Position A operation Stops the print drum at position A. * Position including adjustment values. Clamp home position reset Resets clamp to home position. 554 Clamp movement (3 steps) Press the "Start" key to switch on, and then perform the following operations for each step. Step 1: Release master clamp. Step 2: Open clamp. Step 3: Close clamp. Inking operation Rotates the print drum and inks until the ink sensor goes ON. 558 Ink-free printing operation Performs printing without inking. Test mode details

353

450

451

452

453

551

553

557

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No. 650 651 654 655 656 Test mode details Vertical positioning home position reset Resets the print drum to the vertical center position. Vertical positioning 1 cycle Performs one vertical positioning cycle. Print pressure home position reset Resets print pressure to home position. Print pressure 1 cycle Performs one print pressure change cycle. Print adjustment paper passage test Performs paper passage operation. * Speed keys can be used. Vertical movement is possible using the vertical position keys. Print adjustment low-speed printing Prints at 15 rpm. * Vertical movement is possible using the vertical position keys. CI firmware download Enables the execution program stored on CI flash memory to be overwritten. * Connection to PC required. CI test print Prints the test pattern specified at the time of CI connection.

657

750

751

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CHAPTER 16. TEST MODE DATA CHECK

5.

Data Check
Press the Start key to display data. * Data check only displays the various settings, and does not allow them to be changed.

No. 070

Data Data setting change confirmation

Display details Lists Test mode No. and setting for non-default items during data setting. Displays error code (D**) for set switch that caused operation to stop. (Most recent item) Lists error codes for error codes occurring recently in normal mode. (Max 8 codes) Displays current maintenance count. * Master count is in units of 100 (9999 = 999900). Total count and print drum count are in units of 1000 (9999 = 9999000). Displays residual battery voltage as (A/D). Displays residual battery voltage as (V) * 1000. Displays TPH thermistor AD value. Displays TPH thermistor AD value converted to temperature * 100. Displays stored count. Displays 10-bit data after A/D conversion. Displays paper width (mm) after adjustment. Displays encoder value. Displays print drum angle. Displays ink thermistor A/D value. Displays ink thermistor A/D value converted to C * 100.

071 Set switch history 072 Error history

073

Maintenance count

074 075 270 271

Battery voltage (A/D) Batter voltage (V) TPH thermistor (A/D) TPH thermistor (C)

371 Removed master software count 470 570 572 573 Paper width (A/D) Print drum encoder count Ink temperature sensor (A/D) Ink temperature sensor (C) 471 Paper width (mm) 571 Print drum angle

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CHAPTER 16. TEST MODE DATA SETTING

6.

Data Setting
(1) Press the Start key to display and operate the data currently set. (2) Change data using the numeric keys. Switch to the display using the * key. (3) Once settings have been changed, press the Enter or Start key to confirm the data and return to standby. * Settings will be changed to their default values if values outside the setting ranges are entered. No. 080 Name Jam clear Description Setting 081 Forcibly clears jam. Consumable errors cannot be cleared. None

Memory clear (user area) Resets settings (memory, user mode, timers) other than Test mode data settings, Description type codes, print drum codes, and ink codes to their default values. * Always save data before resetting. Setting None

082

Test mode data setting clear Description Setting Resets all settings set in Test modes to defaults values. * Always save data before resetting. None

083

Maintenance master count setting Description Sets the number of masters at which the call-technician message is displayed. Setting Range: 0 - 9999 (*100) Units: 1 (*100) Default: 0 Sets the number of main unit prints at which the call-technician message is displayed. Range: 0 - 9999 (*1000) Units: 1 (*1000) Default: 0 Sets the number of print-drum prints at which the call-technician message is displayed. (Set for each print drum.) Range: 0 - 9999 (*1000) Units: 1 (*1000) Default: 0 Clears the master count (within software) for displaying technician call message the call-technician message. None Clears the print count (within software) for displaying technician call message the call-technician message. None Clears the print-drum print count (within software) for displaying technician call message the call-technician message. None

084

Maintenance main unit print count setting Description

Setting 085

Maintenance print-drum print count setting Description

Setting 087

Maintenance count clear (master creation) Description Setting

088

Maintenance count clear (printing) Description Setting

089

Maintenance count clear (print drum) Description Setting

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No. 091 Name Technician contact setting Description Sets technician contact address and retailer name for displaying on error screens. * Set using special technician contact setting screen. Space if not set. Minimum print number setting enable Setting Description Sets the minimum print number set in user mode to Enabled/Disabled. Setting 095 Range: 1 (Enabled), 0 (Disabled) Default: 1 (Enabled)

094

Solenoid counter enable/disable setting Description Sets solenoid counter to Enabled/Disabled. Setting Range: 1 (Enabled), 0 (Disabled) Default: 1 (Enabled) * This setting is reset to default (solenoid enabled) when power is switched on.

180

FB horizontal scanning position adjustment Description Adjusts the original horizontal scan position using the image sensor. Setting Range: -35 - +40 (-3.5 mm - +4.0 mm) Units: 5 (0.5 mm) Default: 0 mm * (+ is to left)

181 FB scan start position adjustment Description Adjusts original scanning start position using the image sensor. Setting 182 Range: -60 - +60 (-6.0 mm - +6.0 mm) Units: 1 (0.1 mm) Default: 0 mm * (+ is downward)

FB scan image elongation and shrinkage adjustment. Description Adjusts the original scanning speed using the image sensor. (Image sensor travel speed) Range: -100 - +100 (-10.0% - +10.0%) * (+ elongates) Units: 1 (0.1%) Default: 0% hanges the ABC scanning position for ADF scanning using mirror position adjustment. Range: -20 - +20 (-2.0 mm - +2.0 mm) Units: 1 (0.1 mm) * (+ brings forward scanning start position.) Default: 0 mm

Setting 184

ADF-ABC mirror position adjustment Description

Setting 185

ADF horizontal scanning position adjustment Description Adjusts original horizontal scan position using the image sensor. Setting Range: -35 - +40 (-3.5 mm - +4.0 mm) Units: 5 (0.5 mm) Default: 0 mm * (+ is to left)

186

ADF scan start position adjustment Description Adjusts original scanning start position using ADF. Setting Range: -60 - +60 (-6.0 mm - +6.0 mm) Units: 1 (0.1 mm) Default: 0 mm * (+ is downward)

187

ADF scan image elongation and shrinkage adjustment. Description Adjusts original scanning speed using ADF. (Transport motor speed) Setting Range: -100 - +100 (-10.0% - +10.0%) Units: 1 (0.1%) Default: 0% * (+ elongates)

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No. 188 Name Slice level setting Description Sets text mode slice level. (Finer for larger values) Range: -16 - +16 Units: 1 Default: 0 Sets ABC (automatic base control) slice level. (Finer for larger values) Range: -16 - +16 Units: 1 Default: 0

Setting 189

ABC slice level setting Description

Setting 192

Scanning speed (for 1 cycle) Description Sets the change rate for setting FB and ADF scanning pulse motor speeds. Setting Range: 50% - 200% Units: 1% Default: 100%

193

ADF registration loop amount Description Adjusts slack when feeding into ADF. Setting Range: -30 - +30 (-3.0 mm - +3.0 mm) Units: 1 (0.1 mm) Default: 0 mm

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CHAPTER 16. TEST MODE DATA SETTING


No. 280 Name Master setting adjustment Description Adjusts a small amount of return movement after the master positioning sensor goes ON for inching operation during master setting or after master cutting. Range: 0 - 50 (0 mm - 5.0 mm) Units: 1 (0.1 mm) Default: 20 (2.0 mm) Adjusts the master creation start position (distance from master positioning sensor ON to read/write signal ON). Range: -30 - +50 (-3.0 mm - +5.0 mm) * (+ is downward) Units: 1 (0.1 mm) Default: 0 mm

Setting 281

Master creation start position adjustment Description

Setting 282

Master creation length adjustment Description Adjusts the master creation area (width scanning length). Setting Range: -100 - +100 (-10.0 mm - +10.0 mm) Units: 1 (0.1 mm) Default: 0 mm * (+ increases length)

283

Clamp range adjustment Description Adjusts master clamp range when loading master. Setting Range: -100 - +100 (-10.0 mm - +10.0 mm) Units: 1 (0.1 mm) Default: 0 mm * (+ increases clamp range)

284

Master overall length adjustment (cutting angle) Description Adjusts the length of one master (cutting timing). Setting Range: -100 - +200 (-10.0 - +20.0) Units: 1 (0.1) Default: 0 * (+ increases master length)

287

Master creation image elongation and shrinkage adjustment Description Adjusts frequency setting for the master creation pulse motor. Setting Range: -100 - +100 (-10.0%- +10.0%) Units: 1 (0.1%) Default: 0% * (+ elongates)

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CHAPTER 16. TEST MODE DATA SETTING


No. 380 Name Jam removal detection angle 1 Description Sets the first print drum angle for checking jam removal. Setting 381 Range: 0 - 3600 (0 - 360) Units: 10 (1) Default: 700 (70)

Jam removal detection angle 2 Description Sets the second print drum angle for checking jam removal. Setting Range: 0 - 3600 (0 - 360) Units: 10 (1) Default: 900 (90)

382

Master removal motor stop timing Description Sets master-removal-motor stop timing after the print drum stops at position A. Setting Range: 0 - 2000 (0 s - 2 s) Units: 10 (0.01 s) Default: 0 s Sets master-compression-plate stop timing after moving to the compression position until it starts to return. Range: 0 s - 100 s Units: 1s Default: 1 s

384

Master compression plate return timing Description

Setting 386

Master disposal box count Description Sets count for full master disposal box. Setting Range: 40 - 50 Units: 1 Default: 50 Sets the print drum speed for master removal. * Master removal feed motor speed is fixed. Range: 10 - 60 rpm Units 5 rpm Default: 15 rpm

387

Master removal print drum speed Description

Setting 389

Software count clear Description Clears program count for removed masters. Setting None

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No. 481 Name Paper feed clutch ON angle adjustment Description Adjusts angle timing for activating paper feed clutch. Setting 482 Range: -200 - +200 (-20.0 - +20.0) Units: 2 (0.2) Default: 0 * (+ delays ON timing)

Paper feed clutch OFF angle adjustment (standard) Description Adjusts angle timing for deactivating the paper feed clutch according to the paper type (standard). Range: -150 - +150 (-15.0 - +15.0) * (+ delays OFF timing) Units: 2 (0.2) Default: 0 Adjusts angle timing for deactivating the paper feed clutch according to the paper type (card). Range: -150 - +150 (-15.0 - +15.0) * (+ delays OFF timing) Units: 2 (0.2) Default: 0 Adjusts angle timing for deactivating paper the feed clutch according to the paper type (thin paper). Range: -150 - +150 (-15.0 - +15.0) * (+ delays OFF timing) Units: 2 (0.2) Default: 0 Adjusts angle timing for deactivating the paper feed clutch according to the paper type (special). Range: -150 - +150 (-15.0 - +15.0) * (+ delays OFF timing) Units: 2 (0.2) Default: 0

Setting 483

Paper feed clutch OFF angle adjustment (card) Description

Setting 484

Paper feed clutch OFF angle adjustment (thin paper) Description

Setting 485

Paper feed clutch OFF angle adjustment (special) Description

Setting 486

First stage paper feed jam detection angle adjustment Description Sets angle timing for detecting the first-stage paper feed jam. Setting Range: -200 - +200 (-20.0 - +20.0) Units: 2 (0.2) Default: 0 * (+ delays detection)

487

Paper ejection IN jam detection angle adjustment Description Adjusts the angle used to detect paper jams during paper ejection. Setting Range: -150 - +150 (-15.0 - +15.0) Units: 2 (0.2) Default: 0 * (+ delays detection)

488

Paper ejection IN jam detection angle adjustment Description Adjusts the angle used to detect paper jams during paper ejection. Setting Range: -150 - +150 (-15.0 - +15.0) Units: 2 (0.2) Default: 0 * (+ delays detection)

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No. 580 Name Master detection angle adjustment Description Adjusts the angle used to detect master loading. Setting 581 Range: -200 - +100 (-20.0 - +10.0) Units: 2 (0.2) Default: 0 * (+ delays detection)

Position A stop position adjustment Description Adjusts the print drum position A stop position. Setting Range: -40 - +40 (-4.0 - +4.0) Units: 2 (0.2) Default: -20 (-2.0) * (+ increases distance from stop)

583

No ink time (normal) Description Sets no ink detection time. Setting Range: 1 - 127 s Units: 1s Default: 20 s

584

No ink time (at replacement) Description Sets no-ink detection time after replacing the ink cartridge. Setting Range: 1 - 127 s Units: 1s Default: 40 s Sets detection cycles for the overflow sensor to determine that an overflow has occurred. (This data is stored on print drum EEPROM.) Range: 1 - 200 cycles Units: 1 cycle Default: 50 cycles

585

Overflow detection cycles Description

Setting 586

Minimum print drum speed for inking Description Sets the minimum print drum speed for inking. Setting Range: 5 - 100 rpm Units: 5 rpm Default: 15 rpm

588

Print drum code Description Sets the print drum code. (See page 16-18 for print drum code settings.) Range: 0 - 16 Units: 1 Default: 0 * Run Test mode No. 557 (inking operation) after setting.

Setting

589

Proof-read print speed table (black ink) Description Sets speed table for determining speed proof-read print. Setting Range: 0 (slow), 1 (normal), 2 (fast) Default: 1 (normal)

590

Proof-read print speed table (color ink) Description Sets the speed table for determining the speed proof-read print. Setting Range: 0 (slow), 1 (normal), 2 (fast) Default: 1 (normal)

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CHAPTER 16. TEST MODE DATA SETTING


No. 680 Name Vertical print home position adjustment Description Sets offset for vertical print home position. Setting 682 Range: -100 - +500 (-10.0 mm - +50.0 mm) Units: 1 (0.1 mm) Default: 0 * (+ is upwards)

Print pressure home position adjustment Description Sets offset for print pressure home position Setting Range: -50 - +50 pulses Units: 1 pulse Default: 0 pulses * (+ compresses)

Print Drum Code Settings


Code 1 A3 2 3 B4 4 5 A4 6 7 A4R 8 9 Ledger 10 11 Legal 12 13 Letter 14 15 Spare 16 Color Color Black Color Black Color Black RN2030 / RN2130 Color Black Color Black Color Black RN2000 / RN2100 Color Black RN2050 / RN2150 Size Type Black Compatible machines

16 18 RN (Version 1.0)

CHAPTER 17: USERS MODE

Contents
1. Customizing the Initial Setting .................................................................................. 1-2

17 1 RN (Version 1.0)

CHAPTER 17. USERS MODE CUSTOMIZING THE INITIAL SETTINGS

1.

Customizing the Initial Settings

17 2 RN (Version 1.0)

CHAPTER 17. USERS MODE CUSTOMIZING THE INITIAL SETTINGS

17 3 RN (Version 1.0)

CHAPTER 17. USERS MODE CUSTOMIZING THE INITIAL SETTINGS

17 4 RN (Version 1.0)

CHAPTER 17. USERS MODE CUSTOMIZING THE INITIAL SETTINGS

17 5 RN (Version 1.0)

CHAPTER 18: MISCELLANEOUS PRECAUTIONS

Contents
1. 2. 3. 4. 5. 6. ROM Replacement ....................................................................................................... 18-2 Battery Replacement .................................................................................................... 18-2 Main PCB Replacement ............................................................................................... 18-2 Ink Cartridge Set Switch PCB Replacement ................................................................ 18-2 Print Position Adjustment ............................................................................................. 18-3 Notes on Stay Assembly .............................................................................................. 18-3

18 1 RN (Version 1.0)

CHAPTER 18. MISCELLANEOUS PRECAUTIONS ROM REPLACEMENT

1.

ROM Replacement
Switch off the power, remove the rear cover, and then replace the ROM on the main PCB. * When replacing the ROM, it is not necessary to clear or set data.

2.

Battery Replacement
Replace the battery on the main PCB with the power to the main unit switched on. * Data may be lost if the power to the main unit is not switched on.

3.

Main PCB Replacement


(1) Note down the following details before replacement. User mode Test mode setting change data (2) Switch off the power and replace the Main PCB. (3) Remove the battery, IC18 and ROM from the old Main PCB, and install them on the new Main PCB. (4) Start Test mode. (5) Run Test mode No. 80 (Jam clear). (6) Run Test mode No. 81 (Memory clear). (7) Run Test mode No. 82 (Test mode data setting clear). (8) Disable the solenoid counter using Test mode No. 95 (Solenoid counter enable/disable setting). (when the solenoid counter must be disabled for replacement.) (9) Run Test mode No. 588 (Print drum code) and enter print drum code currently set. (See page 1618.) (10) Run Test mode No. 557 (Inking). (11) Run Test mode No. 450 (Paper width VR adjustment 105 mm) and Test mode No. 451 (Paper width VR adjustment 210 mm) in sequence. (12) Enter the details noted down in step (1).

4.

Ink Cartridge Set Switch PCB Replacement


(1) Pull out the print drum, and replace the Ink cartridge set switch PCB . (2) Mount the print drum in the main unit. (3) Start Test mode. (4) Disable the solenoid counter using Test mode No. 95 (Solenoid counter enable/disable setting). (when the solenoid counter must be disabled for replacement.) (5) Run Test mode No. 588 (Print drum code) and enter the print drum code currently set. (See page 16-18.) (6) Run Test mode No. 557 (Inking). (7) Switch on power again.

18 2 RN (Version 1.0)

CHAPTER 18. MISCELLANEOUS PRECAUTIONS PRINT POSITION ADJUSTMENT

5.

Print Position Adjustment


(1) Adjust master creation image elongation and shrinkage. (See page 13-20.) (2) Adjust scanning image elongation and shrinkage. (See page 11-22 for flat bed unit, and page 12-24 for ADF unit.) (3) Adjust the master clamp amount. (See page 13-20.) (4) Adjust scanning start position. (See page 11-23 for flat bed unit, and page 12-22 for ADF unit.) (5) Adjust the master making start position. (See 13-21.) (6) Adjust the vertical print home position. If the print position is offset from the original even after performing adjustment steps (1) to (5), measure the offset, and adjust by the offset amount in Test mode No. 680 (Vertical print home position). * The print position adjustment procedures assume that the mechanical sections, such as the main unit drive section, paper feed section, and print drum, have been correctly adjusted. Check and adjust the mechanical sections first. Likewise, set the data for ADF section adjustment only after mechanically adjusting the flat bed unit.

6.

Notes on Stay Assembly


The stay assembly on the main unit drive section is positioned using jigs during factory assembly. Do not loosen or remove the stay assembly mounting screws, as the stay cannot be repositioned once removed.

Stay assembly

18 3 RN (Version 1.0)

CHAPTER 18. MISCELLANEOUS PRECAUTIONS

[Memo]

18 4 RN (Version 1.0)

DESCRIPTION OF PCBS

CHAPTER 19 DESCRIPTION OF PCBS Contents


1.CONNECTIONS 1)BLOCK CHART .............................................................................................. 19-2 2)POWER SUPPLY AREA ................................................................................. 19-3 3)PANEL CONTROL AREA ............................................................................... 19-4 4)MOTOR CONTROL AREA .............................................................................. 19-5 5)MASTER REMOVAL AREA ............................................................................ 19-6 6)PAPER FEED AREA ...................................................................................... 19-7 7)PRINT DRUM AREA ....................................................................................... 19-8 8)PAPER EJECTION AREA .............................................................................. 19-9 9)MASTER MAKING AREA ............................................................................. 19-10 10)SCANNER AREA ....................................................................................... 19-11 11)OPTIONS .................................................................................................... 19-12 2.LOCATION OF PCBS ........................................................................................ 19-13 3..PCB FUNCTION DETAIL .................................................................................. 19-14 4.SYSTEM PCB ................................................................................................... 19-15 5.POWER SUPPLY UNIT ..................................................................................... 19-16 6.DRIVE PCB ....................................................................................................... 19-18 7.PANEL CONTROL PCB .................................................................................... 19-19 8.PRINT DRUM CONTROL PCB .......................................................................... 19-20 9.ADF PCB .......................................................................................................... 19-21

COLOR ABBREVIATION IS AS FOLLOWS W:WHITE BL:BLUE BR:BROWN Y:YELLOW GN:GREEN R:RED B:BLACK O:ORANGE GY:GRAY V:VIOLET

2000.07.11 19 1

MASTER REMOVAL AREA CN302 CN202 REJECT CN208 PANEL DRIVE CN203 CN403 CN404 MOTOR CONTROL AREA CN407 CN406

1)Block Chart

1.Connections

PANEL CONTROL AREA CN301 PRINT DRUM AREA

DESCRIPTION OF PCBS

PAPER FEED AREA /MOTOR CONTROL RIGHT SIDE

FRONT CN204

SUCTION CN205 021-50500 POWER CN201 CN106 CN107 CN103 POWER SUPPLY AREA CN101 CN104 CN105 CN102 FILTER PCB

PAPER EJECTION /CLUMP /MOTOR CONTROL LEFT SIDE

19 2
TPH CN212 MASTER MAKING AREA MMU CN206 OPTION CN218 STS CN209 CARD CN210

SCANNER AREA

SCANNER CN211

FB/ADF CN207

RINC2 CN214

C/I CN213

MAIN SW RELAY PCB

OPTIONS

5566-12A

5557-12R

5557-12R
B3B-EH-A 1 O +24V 2 3 DF1B-4S-2.5R 1 DF1B-4P-2.5DS

5566-12A

PSUNIT POWER SUPPLY UNIT CN107


2 3 O RELAY 021-51037 5566-10A 5557-10R 5566-8A 5557-8R 4 021-50508

CN104
F5 8A/125VAC F4 24V-G F2 24V-A F3 24V-B F6 24V-C 021-51000 VHR-2N +5V GND1 2 1 B4P2-VH 3.15A/125VAC 3.15A/125VAC GND3 GND2 +24VB GND1 5 6 7 8 3.15A/125VAC 24V-M 3.15A/125VAC +24VM GND2 +24VA +5V 1 2 3 4

CN401

CN201 CN405

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12

W BL B R BR O O W B R BR O

OPOWER-FAIL OPOWER-OFF GND +5V GND2 +24VG +24VC OTPH_ENB GND +5V GND2 +24VB

021-51000

24V CN103

021-50500

1 O 2 BR 3 O 4 R 5 R 6 BR 7 BR 8 O 9 B 10 B 021-50506

2)POWER SUPPLY AREA

S14B-XH-A

XHP-14

DF1B-14DS-2.5RC

PANEL CONTROL UNIT CN302


B3P5-VH 021-50502 PNL-CTL-PCB

18v Circuit

18V

POWER SUPPLY UNIT;SC3K


101-51001-004

CN106
Interlock Input

VHR-5N 5 4 3 W 2 1 B

018-60031-007

TPH260R30 B06P-VL 1 DF1B-14P-2.5DSA 2 3 B W AC OUTN ACINL W AC INN VLP-06V

021-51002

021-51045

021-51062

1 2 3 4

GROUND

GROUND

BL BL R R XHP-4 B 1 3

19 3
CN102
4 5 F1 10A/125VAC 6 AC SUPPLY 175487-2 1 179228-2 B AC OUTL 021-51038 B4P7-VH VHR-7N

MASTER LOADING UNIT MASTER LOADING UNIT

MAIN BODY FRAME

CN803
RELAY-PCB
W 021-50507-009

AC IN(L)

CN110 CN101 CN108


B3B-XH-A SW-OUT(L)

CN109

CN801
B W 6 8

CN802 CN804
B3P5-VH

021-50509

1 2 3 4 5 2 VHR-8N B8B-VH 5 1 2 3 4 VHR-5N B5B-XH-A XHP-5

Input Fil CN105

AC IN(N)

1 2 3 4 5 6 7

GROUND

021-51035

Main SW (Matsushita)
1 2 3 +24VB APOAuto Power Off out BR R B B 6 6

179228-2

TERMINAL FOR ADJUSTING TPH THERMAL POWER

021-51039

021-51047

FRAME

BR R O Y PWRCTRL GN

ACINL

W 4 4 W B 3 3 B 021-51046

PLUG
W 1 W VLR-06V 1

4 AC INN

1 AC OUTL

444-20000-003 AJ8R2014BC

3 AC OUTN

VLP-06V

DESCRIPTION OF PCBS

POWER SUPPLY UNIT

AC L AC N 1 2 3 4 1 2 3 4 5 XHP-4

1 2 3 4 5 6 7 8 9 10 11 12 13 14

BR R O Y GN BL V GY W B BR R O Y

-S GND4 GND4 GND4 GND4 GND4 GND4 +18V +18V +18V +18V +18V +18V +S

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1 SM02(8.0)B-BHS-1-TB 2 1 3 4 5 6 52207-1217 7 12 11 10 9 8 5 6 7 8 9 10 11 12 15 16 17 18 19 20 21 22 23 14 DISP OFF D0 D1 D2 D3 VDD VSS VEE N.C. 4 CP2 3 CP1 2 9 KIN3 KIN4 KIN5 KIN6 KIN7 VCC(CI) GND(CI) OCI-SW OCI-LED COM0 COM1 COM2 COM3 SCK LATCH 24 1 2 LED4 COM1 LED2 3 4 5 6 2 LED2 1 25 26 27 28 29 30 31 32 1 2 3 4 COM2 LED5 LED0 5 6 SOUT SOUT-RET VCC VCC VCC GND GND GND GND S 1 8 KIN2 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 KIN1 7 KIN0 6 KOUT4 5 KOUT3 4 2 KOUT2 3 KOUT1 2

KOUT0

MCT36pin

MCT36pin AS

MCT36pin AS

MCT36pin

CN304

3-353308-6

1-353293-8*2

1-353293-8*2

3-353308-6

36(18)

OWR

35(17)

GND

34(16)

ORD

33(15)

GND 10 11

32(14)

OCS

4 5

LM32018T:SHARP (LCD)
DETAIL
12 13

31(13)

GND

30(12)

DESCRIPTION OF PCBS

29(11) 6 5 4 3 2 1

A4 GND

CN303
CN305

484-60002

28(10)

A3

27(9)

GND

10

26(8)

A2

11

CN309

25(7)

12

3)PANEL CONTROL AREA

24(6)

GND A1

13

23(5)

GND

14

22(4)

A0

15

PNL-CTL-PCB 021-50502 MAIN-SW-PCB 021-50503 CN311


3 4 5 6 COM0 LED1

FLAT CABLE

21(3)

SYSTEM-PCB

20(2)

GND VCC(CI)

16

17

021-50500 CN313 7SEG-PCB 021-50511


1 2 LED6 LED7 COM3

19(1)

GND(CI)

18

CN208 CN305 CN309

CN301

18

OLED-K

19(18)

17

OSW

20(17)

16

D7

21(16)

15

GND

22(15)

D6

23(14)

14 13 12

GND

24(13)

D5

25(12)

CN312
3 4 5 6

CN314
1 2 3 4 5 6 KOUT4 KOUT5 KOUT6 KOUT7 KIN0 KIN1 7 KIN2 1 2 3 4 5 6 7

11

GND

26(11)

2 1

19 4
SUB-SW-PCB
BOARD TO BOARD

10

D4

27(10)

GND

28(9)

D3

29(8)

GND

30(7)

D2

31(6)

GND

32(5)

D1

33(4)

GND

34(3)

D0

35(2)

021-50504 CN306 CN310

8 9 10 11 12 13

KIN3 KIN4 KIN5 KIN6 KIN7 COM0

8 9 10 11 12 13

GND

36(1)

CN306

021-51014

CN307

CN302
DETAIL

14 15 16 17 18 19

COM1 COM2 COM3 SCK LATCH SOUT-RET 20 21 22 23 24 25 26 VCC VCC VCC GND GND GND GND

14 15 16 17 18 19 20 21 22 23 24 25 26

CN310

2P-VH

CONNECTER FOR

ADJUSTING LCD CONTRAST

POWER SUPPLY AREA(CN103) 021-50021

PANEL CONTROL AREA

GP1A73A

GP1A73A

KH0542

KH0542

COUNTER

COUNTER

021-50024

FLAT BED SET SW

3 GND 2 OUT 1 VCC

FRONT COVER SET SW

2 1

3 GND 2 OUT 1 VCC

LOWER LIMIT SENSOR

GND OUT VCC

GND

VCC

PRINT DRUM SAFETY SW

PAPER SENSOR(RECEIVE)

PAPER SENSOR(SEND)

LED

DISPOSAL BOX SAFETY SW

PRINT DRUM LOCK SOLENOID

1 2 3

1 2

1 2

1 2

1 2 3

1 2

1 2

CT2pin AS 173977-2 3 2

CT2pin AS TOTAL COUNT 173977-2

CT5pin AS 173977-5

CT2pin AS 173977-2

PAPER FEED TRAY SAFETY SW

CT2pin AS MASTER COUNT 173977-2

CT6pin AS FEED TRAY DESCENT BUTTON 173977-6

HRS DF1BA-3EP-2.5RC

HRS DF1BA-3EP-2.5RC

HRS DF1BA-3EP-2.5RC

HRS DF1BA-3EP-2.5RC

CT6pin AS UPPER LIMIT SENSOR 173977-6

CT4pin AS 173977-4

4 3

1 2

1 2

1 2 3

1 2

1 2

2 1

CT5pin AS 173977-5

5 4 3

CT2pin AS 173977-6

CT2pin AS 173977-2

HRS DF1B-3S-2.5R

HRS DF1B-3S-2.5R

HRS DF1B-3S-2.5R

HRS DF1B-3S-2.5R

N.C

HRS DF1B-3S-2.5R

01 +24VM 02 N.C 03 FB-ASW

04 05 06

01 +24VB 02 SET_SW1 03 N.C

04 SET_SW1 05 N.C 06 SET_SW2

07 SET_SW2 08 N.C 09 SET_SW3

10 11 12

N.C

01 02

03 04

05 06

07 08

07 FB-ASW 08 N.C 09 TPH-ASW

09 10 11 12

16(04) 17(05) 18(06)

GND KP-SEN VCC

19(07)

GND

20(08)

VCC

CT4pin AS 173977-4

21(09)

22(10)

23(11)

13(01)

14(02) 15(03)

24(12)

2 1

3 4

PRINT DRUM RELEASE SW

DF9pin AC DF1B-9S-2.5R 021-51037 MCT24pin AS 1-353293-2*2 021-51013

DF12pin AC DF1B-12S-2.5R 021-51037

CT4pin AS 173977-4

4)MOTOR CONTROL AREA

CN402

CN404 CN408

A01 A02 A03 A04

4 3 2 1 CT2pin AS 173977-2 A05 A06 2 1 1 2 2 1 51022-02 CT2pin AS 173977-2

MASTER REMOVAL AREA 021-50024

MCT34pin AS 1-353293-7

DRIVE-PCB
CN407
021-51009 DF10pin AC DF1B-10DS-2.5R VH3pin AC B3P-VH

021-50506
CN403

PAPER EJECTION/CLUMP /MOTOR CONTROL LEFT SIDE 021-50027


CT2pin AS 173977-2 A07 A08 2 1 1 2

CT2pin AS 173977-2 CT2pin AS 173977-2

PRESSURE SOLENOID
01 02 03 A11 2 A12 1 021-51012 CT24pin AS 1-173977-2*2 1 2 021-51051 2 1 1 2

GND MM-PWM GND MM-BRK GND ELV-SCL ELV-LAT ELV-DAT GND ELV-IN GND DRM-TXD DRM-RXD P-OFF

MCT34pin AS 1-353293-7 021-51012

DRUM AREA
GND TCKA VCC

M_MOTOR(-) M_MOTOR(+)

N.C

01 02 03

PS-LAT PS-CLK CTL-ENB SW-IN GND TBM-SCK TBM-LAT TBM-DAT GND PRSM-SCK PRSM-LAT PRSM-DAT GND SP-SCK

MAIN MOTOR

19 5
CN401
021-51037 DF4pin AC DF1B-4S-2.5R

CN406

CN409

CT6pin AS 173977-6 B01 B02 B03 B04 B05 B06 CT6pin AS 173977-6 B07 B08 B09 B10 B11 B12 6 5 4 3 2 1 1 2 3 4 5 6 6 5 4 3 2 1 6 5 4 3 2 1

ELEVATOR MOTOR

PRINT POSITIONING PULSE MOTOR

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18(01) 19(02) 20(03) 21(04) 22(05) 23(06) 24(07) 25(08) 26(09) 27(10) 28(11) 29(12) 30(13) 31(14) 32(15) 33(16) 34(17)

SP-LAT SP-DAT GND PAPER-SEN ELV-UPPER ELV-LOWER

34(17) 33(16) 32(15) 31(14) 30(13) 29(12) 28(11) 27(10) 26(09) 25(08) 24(07) 23(06) 22(05) 21(04) 20(03) 19(02) 18(01) 17 16 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01

021-51000 MOLEX8pin AC 5557-8R

CN405

MAIN MOTOR FG SENSOR

021-51065

021-51022A(CN13,14)

PAPER FEED AREA

PRESSURE CONTROL MOTOR

(CN203)

DESCRIPTION OF PCBS

MOTOR CONTROL AREA

POWER SUPPLY AREA (CN103/107)

GP1A73A : LIGHT BEAM BLOCKED HIGH CT12pin 1-173977-2 173977-3 VCC HA-SEN GND GND 175487-3 VCC INTERRUPT VCC OUT GND 175487-3 VCC 6 VCC MAS-SEN GND 5 4 MAS-SEN GND 9 8 7 VCC OUT GND REFLECTIVE TYPE SENSOR KH0726 175487-3 VCC VCC HJ-SEN GND 021-51054 HJ-SEN GND 021-51043 CT4pin 173977-4 1 2 HA-MO(-) HA-MO(+) CT2pin 173977-2 2 1 12 1 11 2 10 3 VCC OUT GND INTERRUPT TYPE SENSOR GP1A73A 175487-3 CT2pin 173977-2 1 2 HA-MO(-) HA-MO(+) 28 STARTING CURRENT500mA MASTER COMPRESSION MOTOR RATED CURRENT80mA MASTER REMOVAL SENSOR MASTER SENSOR GP1A73A TYPE SENSOR DISPOSAL BOX FULL SENSOR HM-SEN GND 6 7 GND 5 8 HM-SEN 4 9 VCC GP1A73A 3 10 GND OUT TYPE SENSOR 2 11 HA-SEN VCC INTERRUPT 1 12 VCC 1-173977-2 CT3pin MASTER COMPRESSION SENSOR CT12pin

MCT12pin

1-353297-2

1-353293-2 12

11

DESCRIPTION OF PCBS

10

SYSTEM-PCB

5)MASTER REMOVAL AREA

CN202

19 6
3 4 +24V HO-MO 021-51054 CT2pin 173977-2 2 1 1 2 3 2 1 021-51054 HRS
DF1BA-3EP-2.5RC

(CN409)

+24V HO-MO CT2pin 173977-2 36

STARTING CURRENT1800mA MASTER REMOVAL MOTOR RATED CURRENT550mA

(CN404)
3 1 3 1 DISPOSAL BOX SAFETY SW HRS
DF1B-3S-2.5R

HRS

AM50031C431F1

DF1BA-3EP-2.5RC

MASTER REMOVAL AREA

MCT22pin

MCT11pin*2

2-353308-2 CT3pin PAPER WIDTH POTENTIOMETER VOLTAGE DOWN BY CLOCKWISE ROTATION 1 1 2 3 CRV16-1K CT3pin 179228-3 GND 6 GND OUT VCC REFLECTIVE TYPE SENSOR GP2A25
PAPER DETECTED LOW

1-353293-1*2 CT3pin 179228-3 3 2 3 2 1

CT9pin 173977-9 179228-3 VCC KY-VR GND VCC 9 8 7 3 O 2 R 1 BR

CT9pin 179228-9

1 GND

KY-VR

6)PAPER FEED AREA

PAPER SIZE DETECTION SENSOR 3

4 5 4 175487-3 CT3pin 179228-3 GND 3 2 8 9 W VCC 1 GY KU-SEN 7 V GND 3

V 4 GND KY-SEN VCC 1 5 6 BL GN Y

5 VCC

KY-SEN

CN204

PAPER DETECTION SENSOR GND OUT 1 175487-3 VCC REFLECTIVE TYPE SENSOR GP2A25
PAPER DETECTED LOW

7 VCC

SYSTEM-PCB

KU-SEN

10 021-51019

11

12 (1) 4 3 2 RATED CURRENT0.155A PAPER FEED CRUTCH

173977-4

19 7

VCC GP1A73A OUT TYPE SENSOR VERTICAL CENTERING SENSOR GND INTERRUPT

13 (2) V

+24V

14 (3)

15 (4)

16 (5) V KYUSI_CRA

GP1A73ALIGHT BEAM BLOCKED HIGH GP2A25LIGHT BEAM REFLECTED LOW

173977-3

021-50500
MOTOR CONTROL AREA
VCC MAIN MOTOR ENCODER SENSOR OUT GND

17 (6) V

GND

18 (7) V

TEN-CHI

19 (8) V

VCC

173977-3

GND

20 (9) V 21 (10)V

TCKA

021-50023

22 (11)V

VCC

021-51012

DESCRIPTION OF PCBS

PAPER FEED AREA

PRINT DRUM UNIT(BLACK/COLOR)

INK CARTRIDGE SET SW PCB


021-51020 021-51010
021-50510(DRM-PCB;CL)
01 V V V V V GND OVERFLOW-SENSOR INK-SENSOR DRUM-THERMISTOR VCC 02 PGND BR 02 R GND 03 O VCC Y GN 06 BL 07 V 08 05 04 05 O 04 Y 05 N.C N.C GN V BL GY N.C F.G GN 02 03 CT3pin AS 175489-3 01 BL BL BL GND DRUM-SET VCC 03 GND 02 OUT 01 VCC GP1A75E DRUM-SET GY DRUM-RXD DRUM-TXD POWER-OFF 06 07 08 09 10 11 12 04 01 +24V R 03

DESCRIPTION OF PCBS

7)PRINT DRUM AREA

MOTOR CONTROL AREA


021-50505(DRM-PCB;BK)
05

(CN407)

QR12pin AC

QR12pin AC

QR/P8-12P-C(01)

QR/P8-12S-C(01) 01 BR 02 03

VCC 04 OUT 03 OUT 02 OUT 01 GND YAA81-0062

PGND

01

BR

+24V

02

CN502 CN501

GND

03

VCC

04

N.C

N.C

06

CT5pin AS 175489-5

05

INK SENSOR

POWER-OFF

07

GY

DRUM-TXD

09

DRAWER CONNECTION

DF8pin AC DF1B-8DS-2.5R

DRUM-RXD

08

DRUM-SET

10

CN504

021-51010

11

N.C

SET SENSOR

XH2pin AC XHP-2

19 8
TERMINAL FOR M4 TAP

GN F.G

12

021-51009

PRINT DRUM SET SENSOR

CN503
01 02

SM2pin AC SMP-02V-NC 01 B R INK-MOTORINK-MOTOR+ 02

SM2pin AC SMR-02V-N 01 02 01 02

INK CARTRIDGE

021-51010

INKING MOTOR

SUCTION UNIT
021-51022
CT7pin AS 173977-7 07 01 V V V 01 VCC 02 OUT GP1A73A 03 GND 02 03 06 05 173977-7 173977-3 CT7pin AS CT3pin AS

MCT24pin AS

(CN205)

1-353293-2*2

01

021-50500
CT2pin AS 173977-2 04 04 V V 01 02 02 01 05 03 173977-2 CT2pin AS

02

CONV-ENCD

03

VCC

04

CONV-MOT

05

+24V

PAPER EJECTION MOTOR ENCODER SENSOR

06

+24V

07

SUCKTION

08

+24V

09

SEPARATION

10 CT2pin AS 173977-2 02 06 V V 01 02 07 01 CT3pin AS 173977-3 03 GND OUT GP1A73A VCC 02 01 01 02 173977-2 CT2pin AS

GND

11

PAPER RECEIVING SENSOR

PAPER EJECTION MOTOR

12

GND

13

PAPER RECEIVING SENSOR

14

VCC

8)PAPER EJECTION AREA

15(01)

GND

16(02)

PRESS-HP

021-51024
SUCTION FAN

17(03)

VCC

18(04)

GND

19(05)

DETECT-A

20(06)

VCC

21(07) CT3pin AS 173977-3 03 03 GND BR R GP1A75E O OUT VCC 02 01 02 01 03 02 01 021-51053

GND

PRINT PRESSURE CONTROL SENSOR

22(08)

CLAMP-B

23(09)

VCC

24(10)

GND

25(11)

CLAMP-A

26(12)

VCC

27(13)

SEPARATION FAN UNIT


CT5pin AS 173977-8 08 CT5pin AS 173977-8 CT2pin AS 01 06 07 02 03 V V 173977-2 02 01 CT2pin AS 173977-2 01 02

19 9
POSITION A SENSOR
CT6pin AS 173977-6 06 V GND OUT VCC 05 GP1A73A V V 01 02 03 05 02 03 04 01 173977-6 173977-3 CT6pin AS CT3pin AS

28(14)

CT2pin AS 173977-2 04 04 05 V V 02 01

CT2pin AS 173977-2 01 02

SEPARATION FAN

CLAMP SENSOR B
CT3pin AS 173977-3 03 V GND OUT VCC GP1A73A V V 01 02 03 02 01 06 05 04

03 02 01

SEPARATION FAN
06 07 08 V V V 03 02 01 GND OUT VCC GP2A200LCS

021-51023
CT2pin AS 173977-2 05 06 173977-2 CT2pin AS

CLAMP SENSOR A

021-51025

CT3pin AS 173977-3

PAPER RECEIVING SENSOR

CLAMP MOTOR

CLAMP UNIT

DESCRIPTION OF PCBS

PAPER EJECTION AREA

021-51022
MASTER LOADING UNIT SWITCH
GND OUT VCC GP1A73A

CT6pin AS 173977-6

CT6pin AS 173977-6

021-51041

MASTER STOCKER UNIT


KI1215-RK

01 GND 02 MASTER LOADING UNIT SW 03 +5V 04 GND 05 MASTER END SENSOR 06 +5V 07 +24V 08 01 02 03 04 05 06 V V V V V V GND OUT VCC CT3pin AS 173977-3

V V V V V V

CT3pin AS 173977-3 03 02 01 03 02 01

MASTER END SENSOR

DESCRIPTION OF PCBS

V V V V V V

06 05 04 03 02 01

WRITE PULSE MOTOR

CT6pin AS 173977-6

CUTTER MOTOR CUTTER HOME POSITION SW

9)MASTER MAKING AREA

09 WRITE PULSE MOTOR A 10 WRITE PULSE MOTOR B 11 +24V 12 +24V 13 WRITE PULSE MOTOR A 14 WRITE PULSE MOTOR B 15 N.C 16 N.C 17 CUTTER MOTOR+ 18 CUTTER MOTOR19 GND 20 CUTTER HOME POSITION SW 04 03 02 01 01 02 03 04

V V V V

021-51003

21(01) LOAD PULSE MOTOR A

CN206
CT6pin AS 173977-6

22(02) LOAD PULSE MOTOR B 23(03) +24V 24(04) +24V 25(05) LOAD PULSE MOTOR A 26(06) LOAD PULSE MOTOR B

V V V V V V

06 05 04 03 02 01

LOAD PULSE MOTOR

GND KH0726 BR R O

MASTER POSITIONING SENSOR

27(07) 28(08) 29(09)

+5V 021-51053

SYSTEM-PCB 021-50500
THERMAL PRESSURE MOTOR
CT2pin AS 173977-2 02 01 01 02 CT2pin AS 173977-2

V V V

03 02 01 01 02 03

03 02 GND 01 OUT VCC CT3pin AS 173977-3

MASTER POSITIONING SENSOR

CN212

CT8pin AS 173977-8

19 10
03 02 01 GND OUT VCC Y GP1A73A R O (SHARP) 01 02 03 03 02 01

30(10)

THERMAL PRESSURE MOTOR+

08

31(11)

THERMAL PRESSURE MOTOR-

07

01 02

32(12) GND

06

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 CODE2 CODE4 CODE3 THERMISTOR CODE0 CODE1 STB1 CLK1 LATCH1 DATA1 GND GND GND +5V +5V +5V STB2 CLK2 LATCH2 DATA2 STB3 CLK3 LATCH3 DATA3 STB4 CLK4 LATCH4 DATA4

BR R O Y GN BL V GY W B BR R O Y GN BL V GY W B BR R O Y GN BL V GY

33(13)

TPH PRESSURE SENSOR

34(14) +5V

05 04

03 04 05

TPH PRESSURE SENSOR

03 02 KH0726
(HAMAMATSU KODEN)

01 CT3pin AS 173977-3

35(15) GND 36(16) MASTER DETECTION SENSOR 37(17) +5V 38(18) GND 39(19) SPARE 40(20) +5V

06 07 08

DETAIL

021-51053 03 02 GND 01 OUT VCC

MASTER DETECTION SENSOR

MASTER LOADING UNIT


021-51003

CN212

DETAIL
24VG

HIF3BA-34PA-2.54DSA B34B-PHDSS(JST) SMP-04V-NCJST HV11 HV12


NC SD1 SCLK

34 33 32

PHDR-34VS(JST) 34 33 32

PGND LAMP NC

CN1
06FE-BT-VK-NJST 06FE-BT-VK-NJST /LAMP PGND 24VB SMP-04V-NCJST 1 2 3 4 HV22 HV21 1 2 3 4 5 6

1 2 3 4

10)SCANNER AREA

CN211
3 2 1

3 2 1

CCD PCB
CN2
FFC

6 5 4 3 2 1

/SDEN SD0 /LST TRIG GND DCLK GND

3-353308-8

MCT19pin*2 1-353293-9*2

MCT15pin*2 1-353293-5 1 2 3 FLAT BED ORIGINAL DETECTION SENSOR 12 11 10 VCC GEK_SEN GND

MCT15pin*2 1-353293-5

19 18 17 16 15 14 13 51090-0300MOLEX OR 52484-0310MOLEX OUT REFLECTIVE TYPE SENSOR VCC GND EY3A-1081

INVERTER FIP24-16N2-U2NEC

VD0 GND VD1 GND VD2 GND VD3 GND VD4 GND VD5

V V V

VCC 16(1) GEK_SEN 17(2) GND 18(3)

30(15) 29(14) 28(13)

V V V

12 11 10 PHR-3 OR 03KR-06SJST GND OUT VCC IMAGE SCANNER ADF SHADING SENSOR INTERRUPT TYPE SENSOR GP1A75E3

V V V 4 5 6 9 8 7 VCC AHP-SEN GND

VCC AHP-SEN GND

19(4) 20(5) 21(6)

27(12) 26(11) 25(10)

V V V

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 23 28 29 30 31 32 33 34 GND VD6 GND VD7 GND 5V 5V 24V 24V 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 23 28 29 30 31 32 33 34

9 8 7 6 5 4

V V V V V V 7 8 9 10 11 12 6 5 4 3 2 1 FB-OB FB-OA FB-CB FB-CA FB-B FB-A

FB-OB FB-OA FB-CB FB-CA FB-B FB-A

22(7) 23(8) 24(9) 25(10) 26(11) 27(12)

24(9) 23(8) 22(7) 21(6) 20(5) 19(4)

V V V V V V

LAMP CF8AED/34HB
FLAT BED READ PULSE MOTOR

SMP-06V0NCJST 1 1 2 2 3 3 4 4 5 5 6 6

LAMP CF8AED/34HB

19 11
CT12pin 1-173977-2 VCC OUT GND INTERRUPT TYPE SENSOR GP1A73A STAGE COVER SENSOR CT3pin 173977-3

CT12pin 1-173977-2

CN207

3 2 1

V V V

VCC OUT GND

28(13) 29(14) 30(15)

18(3) 17(2) 16(1)

V V V

OPTION AREA 021-50030

V V V V V V V V V V V V V V V

GND OADF-EXIT ADF-SEN OUT-SEN RES-SEN OPS-SEN RD-SEN VCC GND ADF-OB ADF-B ADF-OA ADF-A 24V 24V

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

CT15pin 1-173977-5 V 1 V 2 V 3 V 4 V 5 V 6 V 7 V 8 V 9 V 10 V 11 V 12 V 13 V 14 V 15

SCANNER UNIT(300DPI) (MIRROR CARRIAGE TYPE)

GP1A75ELIGHT BEAM BLOCKED LOW

38(19) 37(18) 36(17) 35(16) 34(15) 33(14) 32(13) 31(12) 30(11) 29(10) 28(9) 27(8) 26(7) 25(6) 24(5) 23(4) 22(3) 21(2) 20(1)

021-51043

021-51044

DESCRIPTION OF PCBS

021-50500

CC-SUB PCB

CC-MAIN PCB

CN210
CN83 CN81 CN1 GND GND

AMP 1-353908-7

AMP 1-353908-7

JST JAC15S

KEY/CARD COUNTER
112-00001
CARD READER
01 02 03 04 05 06

CN215
/G'DATA CN102 /MSTRCP /LST /CP /CRDACK /TXD +5V +5V /RXD GND GND P14 P15 P16 P17 CN101 CN2

11)OPTIONS

GND GCLK GND /CNTSET /CNTOP /CRDRQ 01 02 03 04 05 06 07 08

CN3 FGND 01 SGND 02 +5V 03 /RDT 04 05 /RCL /CLD 06

CC-KEY PCB

DESCRIPTION OF PCBS

DETAIL
CN2 CN1 2-353293-0 CN2 CN5 P22 P21 P20 PE0 PE1 PE2 PE3 N.C B03 B04 B05 B06 B07 B08 B09 B10 N.C N.C

01 02 03 CC-CLK CC-LST 04 CC-DAT 05 CAD-RQ 06 N.C 07 N.C 08 CUNT-OP 09 CUNT-SET 10 MASTER-CUNT 11 TOTAL-CUNT 12 13 CAD-ACK 14 5V 15 5V 16 CONNECT CHECK 17 GND 17 16 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 01 02 03 04 05 06 07 08 CN1 09 10 11 12 13 14 15 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 09 10 11 12 13 14 15 16 17 18 PA0 PA1 PA2 PA3 GND GND DB7 DB6 DB5 DB4 N.C N.C N.C N.C E R/W B08 B09 B10 RS V0 +5V GND A01 A02 A03 A04 A05 A06 A07 A08 A09 A10 B01 B02

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17

LCD

112-51002 112-51001

CN213

021-51052

N.C +5V +5V CN82 +5V +5V /BZER GND GND FG FG 01 02 03 04 05 06 07 01 02 03 04 05 06 07

A01 A02 A03 A04 A05 A06 A07 A08 A09 A10 B01 B02 B03 B04 B05 B06 B07 01 02 03 04 05 06 07 08 09 10 11 12 13 14

01 02 03 04 05 06 07 08 09 10 11 12 13 14

HIF3BA-40D-2.54R

CN214
TCP586-71-5201 HOSIDEN 01 02 03 5480-07AX MOLEX

HOLDING SW

MOT

MOT

CONNECT SIGNAL

1-353293-9*2

3-353308-8

CN2

PCB CONNECTION CABLE


GND

send(-),cut(+)

19 12
021-51049

CN207
021-51044 021-51043
N.C N.C 04 05 06 07 08

CN209

CN202
24VG N.C

02 03 01

01 02 03 04 05 06 07

CLUSTER B CLUSTER A 5V GND

CN203
CN204

GND *ADF-EXIT ADF-SEN OUT-SEN RES-SEN

XHP12 JST 01 GND 02 N.C 03 CLUSTER A 04 CLUSTER B 05 N.C 06 5V 07 GND 08 24VG 09 N.C 10 N.C 11 N.C 12 N.C

02 stamp stamp

CN1
172486-2 AMP

1-172677-0 AMP 01 02 03 04 05 06 07 08 09 10

solenoid(-) solenoid(+)

021-51064

CN205

*PS-SEN RD-SEN VCC GND ADF-*B ADF-B ADF-*A ADF-A 24V 24V

JUNCTION PCB
MAIN SW MANUAL SW

1-173977-5 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 38(19) 37(18) 36(17) 35(16) 34(15) 33(14) 32(13) 31(12) 30(11) 29(10) 28(9) 27(8) 26(7) 25(6) 24(5) 23(4) 22(3) 21(2) 20(1) 1-353293-5 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01

TC200-PCB ST SORTER 017-00034

STAMP SOLENOID

01 02 03 04 05 06

SYSTEM-PCB 021-50500

ADF READ PULSE MOTOR

ORIGINAL IN SENSOR

51065-0600 01 02 03 04 Q 05 Q 06

CN1

03 02 01

01

ADF ORIGINAL DETECTION SENSOR(PAPER DETECT ) 03

CN2

02 01 03 02 01

CN3

ADF ORIGINAL REGISTRATION SENSOR(PAPER DETECT ) 03

02 03 T 04 05 06 T 07 08 09 10 T 11 12

01 02 03 04 05 06 07 08 09 10 11 12 13 14

02 01

51065-1400

1-173977-2

ORIGINAL OUT SENSOR (PAPER DETECT )

ADF JUNCTION PCB 021-50512

send(+),cut(-)

01

GND

DETAIL

CN201

FEED/CUT MOTOR

2.LOCATION OF PCBS
SUB-SW-PCB PANEL CONTROL PCB MAIN-SW-PCB

MOTOR CONTROL PCB

INK SENSOR PCB PRINT DRUM CONTROL PCB POWER SUPPLY UNIT

RELAY PCB

ADF-PCB

SYSTEM PCB

RISORINC2

DESCRIPTION OF PCBS

3.PCB FUNCTION DETAIL


PCB NAME
SYSTEM PCB

FUNCTION
OVERALL CONTROL

MODEL *1 *1

PSUNIT(POWER SUPPLY SUPPLY ALL VOLTAGES UNIT),PSUNIT 200

DRIVE PCB

CONTROL EACH MOTOR

*1

PDA ADF(ADF PCB)

DRIVE FUNCTION OF ADF UNIT

*1 *1 *1

PANEL CONTROL PCB

ENTER FUNCTION KEY,CONTROL DISPLAY

MAIN SW PCB

ENTER NUMERAL KEY

SUB SW PCB

ENTER SUB PANEL FUNCTION KEY

*1 *1

DRM PCB;BK, DRM PCB;CL

JUNCTION OF SENSORS ON DRUM PCB

RELAY PCB

CONTROL RISORINC2

*1 *1 *1

POWER SUPPLY UNIT ;SC3K RINC2PCB;64MB

SUPPLY VOLTAGE FOR RISORINC2

CONTROL COMPUTER INTERFACE FUNCTION

*1:RN2000,RN2030,RN2050,RN2080,RN2100,RN2130,RN2150,RN2180 *2:RN2100,RN2130,RN2150,RN2180

19 14

DESCRIPTION OF PCBS

4.SYSTEM PCB

CN207

CN208

CN212

CN206 CN209 BT1 CN201

CN202

CN211

EPROM

SW1

CN210

CN214

CN205

CN204

CN203 CN213

SW1:FREE ROTATION BT1:BATTERY(CR2450)

19 15

DESCRIPTION OF PCBS

5.POWER SUPPLY UNIT

F6 F3 F4 F2 F5

CN107 CN 104 CN 105

CN108 CN105

VR 301 VR 302

VR301:TPH THERMAL POWER ADJUSTMENT NORMAL VR302:TPH THERMAL POWER ADJUSTMENT FINE F1:FUSE 125V 10A F2:FUSE 125V 3.15A F3:FUSE 125V 3.15A F4:FUSE 125V 3.15A F5:FUSE 125V 8A F6:FUSE 125V 3.15A

F1

CN 102

CN 101

19 16

DESCRIPTION OF PCBS

POWER SUPPLY UNIT FUSE CHART


FUSE NO.
F1 125V 10A

SYSTEM
MAIN

PHENOMENON^CONNECTED PARTS
NO POWER

F2 125V 3.15A

+24VA

LOCK SOLENOID TOTAL COUNTER MASTER COUNTER PRESSURE SOLENOID PRINT POSITIONING PULSE MOTOR PRESSURE CONTROL MOTOR INKING MOTOR

F3 125V 3.15A

+24VB FLAT BED READ PULSE MOTOR ADF READ PULSE MOTOR WRITE PULSE MOTOR THERMAL PRESSURE MOTOR PAPER FEED CRUTCH PAPER EJECTION MOTOR CUTTER MOTOR LOAD PULSE MOTOR MASTER COMPRESSION MOTOREMASTER REMOVAL MOTOR ELEVATOR MOTOR CLAMP MOTOR +24VG OPTIONS

F4 125V 3.15A

F5 125V 8A

+24VM MAIN MOTOR

F6 125V 3.15A

+24VC SEPARATION FAN SUCTION FAN

19 17

DESCRIPTION OF PCBS

6.DRIVE PCB

SW1:FREE ROTATION

CN407 CN409 CN404 CN402 SW1 CN401 CN403 CN408

19 18

CN406 CN405

DESCRIPTION OF PCBS

7.PANEL CONTROL PCB

CN 302 CN 304 CN 305

CN 301 VR 1 CN 307 CN 303 CN 306

VR1:FOR ADJUST LCD CONTRAST

19 19

DESCRIPTION OF PCBS

8.PRINT DRUM CONTROL PCB

BLACK SW1-5:INK CARTRIDGE SET SENSOR (BACK OF PCB)


CN 503 CN 502 CN 504

SW 1

SW 2

SW 4

SW 3

SW 5

CN 501

COLOR SW1-5:INK CARTRIDGE SET SENSOR (BACK OF PCB)


CN 503 CN 502 CN 504

SW 1 SW 2 SW 3

CN 501

19 20

DESCRIPTION OF PCBS

9.ADF PCB

LED1:READ SENSOR DETECT

CN 2 LED1 VR 1 CN 1 CN 3
VR1:READ SENSOR ADJUST SENSITIVITY

19 21