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CONTENTS
CHAPTER 1: MAINTENANCE
1. Preface .............................................................................................................. 1-1
CAUTION .......................................................................................................... 1-2
WARNING ......................................................................................................... 1-3
2. WORK PRECAUTIONS .................................................................................... 1-4
3. Exterior Cover Removal
• Front cover ...................................................................................................... 1-5
• Master removal upper cover ............................................................................ 1-5
• Master removal lower cover ............................................................................ 1-5
• Back cover ....................................................................................................... 1-6
• ADF cover ....................................................................................................... 1-6
• ADF unit cover ................................................................................................. 1-6
• Master making unit cover ................................................................................ 1-6
• Drum cover ...................................................................................................... 1-6
4. Opening PCB Bracket Frames
1. Main PCB Bracket Frame .............................................................................. 1-7
2. Power Supply PCB Bracket Frame ............................................................... 1-8
3. Main PCB and Power Supply PCB Bracket Frames ..................................... 1-9
CHAPTER 2: MACHINE SUMMERY
1. Specifications
1. TR1510 ......................................................................................................... 2-1
2. TR1530 ......................................................................................................... 2-2
2. Cross Sectional Diagram ................................................................................... 2-3
3. Machine Operations .......................................................................................... 2-4
4. Paper Feed and Receiving ................................................................................ 2-5
5. Master Removal and Feed ................................................................................ 2-6
CHAPTER 3: MAIN DRIVE SECTION
1. Theory of Operation
1. Main Drive ..................................................................................................... 3-1
2. Main Motor Safety Switches .......................................................................... 3-2
3. Drum Positions .............................................................................................. 3-3
2. Removal and Assembly
1. Main Motor Unit ............................................................................................. 3-5
2. Intermediate Gear .......................................................................................... 3-7
3. Master Removal Unit Safety Switch .............................................................. 3-8
4. Master Making Unit Safety Switch ................................................................. 3-9
5. Drum Safety Switch ....................................................................................... 3-10
CHAPTER 4: FIRST PAPER FEED SECTION
1. Theory of Operation
1. Paper Feed Tray Elevation ............................................................................ 4-1
2. First Paper Feed Drive Mechanism ............................................................... 4-3
3. Paper Pickup System .................................................................................... 4-5
4. Paper Feed Pressure Select System ............................................................ 4-6
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2. Removal and Assembly
1. Paper Feed Tray Unit .................................................................................... 4-7
2. Paper Detection Sensor ................................................................................ 4-8
3. Scraper and Pickup Rollers .......................................................................... 4-9
4. Stripper Pad .................................................................................................. 4-10
5. Upper Limit Sensor ....................................................................................... 4-11
6. Paper Feed Clutch ........................................................................................ 4-12
7. Scraper Assembly ......................................................................................... 4-13
8. Elevator Motor Unit ....................................................................................... 4-14
3. Adjustment
1. Upper Limit Sensor Position ......................................................................... 4-15
2. Paper Feed Distance (OFF Timing of Paper Feed Clutch) .......................... 4-16
CHAPTER 5: SECOND PAPER FEED SECTION
1. Theory of Operation
1. Drive Mechanism .......................................................................................... 5-1
2. Vertical Print Position .................................................................................... 5-3
2. Removal and Assembly
1. Load Spring ................................................................................................... 5-5
2. Timing Cam ................................................................................................... 5-6
3. Sector Gear ................................................................................................... 5-7
4. Print Positioning Unit ..................................................................................... 5-8
5. Print Positioning Pulse Motor ........................................................................ 5-9
6. Paper Guide Plate ......................................................................................... 5-10
7. Paper Sensor ................................................................................................ 5-12
8. Timing Roller ................................................................................................. 5-13
3. Adjustment
1. Timing Cam Mounting Position ..................................................................... 5-15
CHAPTER 6: PRESS SECTION
1. Theory of Operation
1. Press Mechanism .......................................................................................... 6-1
2. Removal and Assembly
1. Pressure Roller ............................................................................................. 6-3
2. Pressrue Lever Ass'y .................................................................................... 6-4
3. Pressure Shaft Ass'y ..................................................................................... 6-6
4. Pressure Solenoid ......................................................................................... 6-7
3. Adjustment
1. Pressure Lever Ass'y Position ...................................................................... 6-9
CHAPTER 7: PAPER EJECTION SECTION
1. Theory of Operation
1. Paper Ejection Mechanism ........................................................................... 7-1
2. Paper Separation Mechanism ....................................................................... 7-2
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-3-
2. Removal and Assembly
1. Clamp Unit ..................................................................................................... 10-7
2. Clamp Motor .................................................................................................. 10-8
3. Clamp Sensor A ............................................................................................ 10-8
4. Clamp Sensor B ............................................................................................ 10-8
CHAPTER 11: MASTER REMOVAL SECTION
1. Theory of Operation
1. Master Removal Unit Home Positioning Mechanism ................................... 11-1
2. Master on the Drum (before master removal) Check Mechanism ................ 11-3
3. Clamp Plate Master Release Mechanism ..................................................... 11-5
4. Master Removal Mechanism ......................................................................... 11-7
5. Disposed Master Compressing Mechanism ................................................. 11-9
6. Master Disposal Box Set Mechanism ........................................................... 11-12
2. Removal and Assembly
1. Master Removal Unit ..................................................................................... 11-13
2. Compressing Motor ....................................................................................... 11-15
3. Master Removal Motor .................................................................................. 11-16
4. Master Removal Sensor ................................................................................ 11-18
5. Master Disposal Box master Sensor ............................................................. 11-18
6. Master Compressing Sensor ........................................................................ 11-18
7. Pulley Shaft ................................................................................................... 11-19
8. Vertical Transport Roller (up) ........................................................................ 11-19
9. G-Belts on Vertical Transport Roller (up) ...................................................... 11-19
10. Master Removal Hook ................................................................................. 11-20
11. Master Sensor ............................................................................................. 11-20
12. Vertical Transport Roller (down) ................................................................. 11-21
13. G-Belts on Vertical Transport Roller (down) ............................................... 11-21
14. Master Compress Plate ............................................................................... 11-22
CHAPTER 12: IMAGE SCANNING SECTION
1. Theory of Operation
1. Original Loading Mechanism ........................................................................ 12-1
2. Original Scanning Mechanism ...................................................................... 12-3
2. Removal and Assembly
1. Original Feed Solenoid .................................................................................. 12-5
2. Image Scanner Unit ...................................................................................... 12-6
3. Original Detection Sensor ............................................................................. 12-7
4. Original IN Sensor ......................................................................................... 12-7
5. Stripper Roller ............................................................................................... 12-8
6. Pickup Roller ................................................................................................. 12-8
7. Stripper Pad Ass'y ......................................................................................... 12-9
8. Read Pulse Motor ......................................................................................... 12-10
CHAPTER 13: CUTTER SECTION
1. Theory of Operation
1. Home Positioning Mechanism ...................................................................... 13-1
2. Cutting Mechanism ....................................................................................... 13-2
2. Removal and Assembly
1. Cutter Unit ..................................................................................................... 13-3
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CHAPTER 1: MAINTENANCE
CONTENTS
1. Preface ...................................................................................................................... 1
CAUTION .................................................................................................................. 2
WARNING ................................................................................................................. 3
2. WORK PRECAUTIONS ............................................................................................ 4
3. Exterior Cover Removal
manuals4you.com
This manual provides Technical Service Information for the RISOGRAPH TR Series
duplicators.
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.
[ RISO, INC. ]
NOTE : Before attempting to correct machine malfunctions, study the Technical
Manual and make sure all questions and/or concerns have been satisfied.
If necessary, please use the Technical Hotline:
TECHNICAL HOTLINE
800-578-7476
(Emergency Technical Assistance Only!!!)
1-1
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CAUTION
- Never fail to follow the following instructions when you discard the used
lithium battery.
1-2
!! WARNING !!
I. To avoid injuries:
Be sure to disconnect the electrical power before disassembling, assembling,
or when making adjustments on the machine.
FIRST
THEN
1-3
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MAINTENANCE
WORK PRECAUTIONS
2. Work Precautions
Inspection
If inspection finds a defective or problem part, correct it.
Replace parts as necessary.
Half-pierced section
Removal
(1) Carry out work according to the procedures in the
technical manual.
(2) Arrange the removed parts carefully and in order.
(3) Distinguish parts to be replaced and those to be reused.
(4) When replacing screws and the like, use the specified
size.
1-4
MAINTENANCE
EXTERIOR COVER REMOVAL
Original stopper
Front cover
1-5
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MAINTENANCE
EXTERIOR COVER REMOVAL
• Back cover
• ADF cover: ................................. Open the ADF unit first.
• ADF unit cover: .......................... Open the ADF unit and remove the ADF cover first.
• Master making unit cover
ADF cover
Back cover
• Drum cover
Drum cover
1-6
MAINTENANCE
OPENING PCB BRACKET FRAMES
Two connectors
Ground wire
1-7
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MAINTENANCE
OPENING PCB BRACKET FRAMES
Connector
1-8
MAINTENANCE
OPENING PCB BRACKET FRAMES
CONTENTS
1. Specifications
1. TR1510 ................................................................................................................. 1
2. TR1530 ................................................................................................................. 2
2. Cross Sectional Diagram ........................................................................................ 3
3. Machine Operations ................................................................................................ 4
4. Paper Feed and Receiving ...................................................................................... 5
5. Master Removal and Feed ...................................................................................... 6
MACHINE SUMMARY
SPECIFICATIONS
1. Specifications
1. TR1510
• Paper Capacity Feed tray - 1,000 sheets (64 g/m2 or 16-lb bond)
Receiving tray - 800 sheets (64 g/m2 or 16-lb bond)
• Optional Accessories Color drum unit, Job separator III, Key/Card counter III, and computer
interface.
MACHINE SUMMARY
SPECIFICATIONS
2. TR1530
• Paper Capacity Feed tray - 1,000 sheets (64 g/m2 or 16-lb bond)
Receiving tray - 800 sheets (64 g/m2 or 16-lb bond)
• Optional Accessories Color drum unit, Job separator III, Key/Card counter III, and computer
interface.
Write roller
6
Master roll
Scraper roller 7 9
10
5
1 2
Separator
4
3
Paper feed tray
Paper receiving tray
Suction unit
Pickup roller
Pressure roller
Timing roller
Guide roller
1 First Paper Feed Area: Feeds single sheets of paper to the second paper feed area via
the Scraper roller, Pickup roller and Stripper plate.
2 Second Paper Feed Area: Controls the vertical print position and feeds paper to the print
area via the Timing and Guide rollers.
3 Press (Printing) Area: Uses the Pressure roller to press paper against the master on the
Drum.
The Drum rotates with the Pressure roller and prints an image on
paper.
4 Paper Ejection Area: Separates a printed paper from the Drum, and transports it onto
the paper receiving tray.
5 Drum Area: Supplies the Drum surface with ink from an Ink pack.
7 Master Disposal Area: Separates used master from the Drum and disposes it into the
Master disposal box.
8 Image Scanning Area: Carries an original and scans it with the Image scanner and
converts the image information into digital data.
9 Master Making Area: Makes a master with the Thermal print head.
10 Master Loading Area: Feeds the prepared master material to the Drum and cuts it to an
appropriate length.
2-3
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MACHINE SUMMARY
MACHINE OPERATIONS
3. Machine Operations
The used master is removed from The original is scanned by the image
the drum and stored in the scanner and the image is made on the
disposal box. master with the thermal print head.
Printing
2-4
MACHINE SUMMARY
PAPER FEED AND RECEIVING
Stripper plate
Guide roller The paper feed to the second paper feed area is
stopped by the Guide and Timing rollers to form a
buckle. The paper then waits until the rotation of
the Guide roller starts.
Timing roller
Pressure roller
While the paper is being fed from the second
paper feed area, the Pressure roller rises and
printing starts.
(The Pressure roller contacts the Drum and starts
rotating.)
Separation fan
After the Pressure roller contacts the Drum to start
printing, the Separator approaches the Drum and
the Separation fan starts to blow.
Separator The Guide roller goes up to release the paper.
(The paper is then transferred by the rotation of
the Drum.)
2-5
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MACHINE SUMMARY
MASTER REMOVAL AND FEED
Vertical
transport roller Master
Master
compressing plate
Master tension plate TPH Master Making
The Image scanner scans the image on
the original and Thermal print head (TPH)
makes the image on the master material.
The Master tension plate drops down and
applies tension on the master material.
Master Loading
The master is transferred onto the Drum
and the leading edge is clamped by the
Clamp plate.
Cutter
2-6
CHAPTER 3: MAIN DRIVE SECTION
CONTENTS
1. Theory of Operation
1. Main Drive ............................................................................................................. 1
2. Main Motor Safety Switches .................................................................................. 2
3. Drum Positions ...................................................................................................... 3
4. Drum Locking System ........................................................................................... 5
2. Removal and Assembly
1. Main Motor Unit ..................................................................................................... 7
2. Intermediate Gear .................................................................................................. 9
3. Master Removal Unit Safety Switch .................................................................... 10
4. Master Making Unit Safety Switch ....................................................................... 11
5. Drum Safety Switch ............................................................................................. 12
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MAIN DRIVE SECTION
THEORY OF OPERATION
1. Theory of Operation
1. Main Drive
1. Drum rotation
• The Motor gear on the Main motor rotates the Intermediate gear.
• The Intermediate gear rotates the Drum main gear.
• The Drum rotates with the Drum main gear.
Drum
Intermediate gear
Encoder sensor
Main motor
Main gear
3-1
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The same three switches act also as Safety switches for the Thermal power.
3-2
MAIN DRIVE SECTION
THEORY OF OPERATION
3. Drum Positions
1. Sensors for the Drum positioning
• The position of the Drum is determined by the Position-A sensor and Encoder sensor on the
Main motor.
2. Position-A
• This is the position where the Clamp plate is at the top of the Drum.
• This position is also referred as the 0° position.
• The Clamp plate opens and closes at this position.
• This is the position where the light path of the Position-A sensor is cut by the Position-A plate
on the Drum.
3. Position-B
• Position-B of the Drum is when the Drum rotates 272° from the 0° position (Position A),
counted by the Encoder sensor.
• This is the position where the Drum is pulled out or put into the machine.
Position-A plate
Position-A sensor
Drum position-A
Drum angle
0°
Drum position-B
Drum angle
272°
Encoder sensor
3-3
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ON (15 rpm)
Main motor
Blocked
1
Position-A sensor Open
1 If the light path of the Position-A sensor is open when the Drum release key is pressed, the Drum is
rotated until the sensor is blocked to bring the Drum to the Position-A.
If the light path of the Position-A sensor is already blocked (Drum at 0°), the above Drum rotation will
not be made.
2 When the Drum rotates to 272°±χ° (Position-B), the Main motor turns off and completes the Drum
release movement.
The angle "χ" can be adjusted by Memory Switch (Test Mode) No. 207.
• If the Encoder sensor does not output the Main motor rotation signal within certain set time, the
machine assumes that the Main motor has locked and displays error message [E 01].
• If over load current is detected for 0.3 seconds after the Main motor is activated, the machine assumes
that the Main motor has locked and displays error message [E 01].
• If the Position-A detection sensor does not detect the Drum even though the Encoder sensor outputs
Main motor rotation signal after the Main motor is activated, the machine assumes that the Position-A
sensor is faulty and displays error message [E 06].
3-4
MAIN DRIVE SECTION
THEORY OF OPERATION
Drum
Drum
Position-B
Flange
Intermediate gear
3-5
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CONTENTS
1. Theory of Operation
1. Main Drive ............................................................................................................. 1
2. Main Motor Safety Switches .................................................................................. 2
3. Drum Positions ...................................................................................................... 3
4. Drum Locking System ........................................................................................... 5
2. Removal and Assembly
1. Main Motor Unit ..................................................................................................... 7
2. Intermediate Gear .................................................................................................. 9
3. Master Removal Unit Safety Switch .................................................................... 10
4. Master Making Unit Safety Switch ....................................................................... 11
5. Drum Safety Switch ............................................................................................. 12
MAIN DRIVE SECTION
REMOVAL AND ASSEMBLY
3-7
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8. Remove two mounting screws of the Locking plate R and remove the plate.
9. Remove three mounting screws of the Slide guide R and remove the guide.
Slide guide R
Lock plate R
10. Disconnect two connectors of the Main motor unit from the System PCB.
11. Remove four mounting screws of the Main motor unit and remove the unit from the machine.
Precautions in Assembly
• Match the half-pierced sections of the Locking plate R and Slide guide R against those on the
machine frame.
• Match the half-pierced sections of the Solenoid base ass'y and Separation base ass'y against
those on the machine frame.
3-8
MAIN DRIVE SECTION
REMOVAL AND ASSEMBLY
2. Intermediate Gear
1. Remove the Drum from the machine.
2. Disconnect the power supply from the machine.
3. Remove Back cover.
4. Open the Main PCB bracket frame.
5. Remove mounting screw of the Intermediate gear shaft ass'y and remove the ass'y.
6. Remove the Intermediate gear from the operation panel side (drum opening) of the machine.
Precautions in Assembly
• Align the Position mark on the Intermediate gear with that on the Main gear.
Intermediate gear
Intermedite gear
Intermediate gear
shaft ass'y
Position
marks
Main gear
Main gear
3-9
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MECHANICAL OVERVIEW
REMOVAL AND ASSEMBLY
Precautions in Assembly
• The mounting section of the bracket should be positioned behind the stay of the Master
removal unit.
• Match the half-pierced section on the Switch bracket with that on the machine.
Switch bracket
3 - 10
MAIN DRIVE SECTION
REMOVAL AND ASSEMBLY
Precautions in Assembly
• Install the switch in the correct direction.
3 - 11
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Precautions in Assembly
• Do not bend the Switch bracket, as it acts as a spring plate to press against the actuator of the
switch when the Drum is inserted in the machine.
Switch bracket
3 - 12
CHAPTER 4: FIRST PAPER FEED SECTION
CONTENTS
1. Theory of Operation
1. Paper Feed Tray Elevation .................................................................................... 1
2. First Paper Feed Drive Mechanism ....................................................................... 3
3. Paper Pickup System ............................................................................................ 5
4. Paper Feed Pressure Select System .................................................................... 6
2. Removal and Assembly
1. Paper Feed Tray Unit ............................................................................................ 7
2. Paper Detection Sensor ........................................................................................ 8
3. Scraper and Pickup Rollers ................................................................................... 9
4. Stripper Pad ......................................................................................................... 10
5. Upper Limit Sensor .............................................................................................. 11
6. Paper Feed Clutch ............................................................................................... 12
7. Scraper Assembly ............................................................................................... 13
8. Elevator Motor Unit .............................................................................................. 14
3. Adjustment
1. Upper Limit Sensor Position ................................................................................ 15
2. First Paper Feed Distance (OFF Timing of Paper Feed Clutch) ......................... 16
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FIRST PAPER FEED SECTION
THEORY OF OPERATION
1. Theory of Operation
1. Paper Feed Tray Elevation (Up / Down)
1. Paper Detection Sensor
• The Paper detection sensor checks for the presence of paper on the Paper feed tray.
• The Paper feed tray elevates only when the sensor is detecting the papers.
• The Paper feed tray descends when the sensor no longer detects paper on the tray.
Scraper unit
Upper limit sensor
Elevator motor
Elevator bracket
4-1
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~
~
sensor (paper not detected)
100ms
Rotates (up) (down) (up) Rotates (down)
Elevator motor 100ms
~ ~
~ ~
2 5
Blocked
3
Upper limit sensor Open
Blocked Blocked
Lower limit sensor Open
~
~
1 Add paper message [C 44] is displayed if the Paper detection sensor does not detect paper on the
Paper feed tray (sensor light not reflected).
2 If the light path of the Upper limit sensor is not blocked within 10 seconds after the Elevator motor is
activated, the machine assume that the Elevator motor has locked and displays error message [E 02].
3 If the light path of the Upper limit sensor is not blocked within 2 seconds after the Elevator motor is
activated, the machine assumes that the Elevator motor has locked and displays error message [E 02].
(Only at the last elevation movement in initial tray elevation.)
4 During printing if the Paper detection sensor no longer detects paper on the Paper feed tray (sensor
light not reflected), add paper message [C 44] is displayed and the elevator motor activates to lower the
Paper feed tray.
5 If the light path of the Lower limit sensor is not blocked within 10 seconds after the Elevator motor is
activated, the machine assumes that the Elevator motor has locked and displays error message [E 02].
• If the light paths of the Upper and Lower limit sensors are blocked both at the same time, the machine
assumes that the Elevator motor has locked and displays error message [E 02].
• If over load current is detected for 0.3 seconds after the Elevator motor is activated, the machine
assumes that the Elevator motor has locked and displays error message [E 02].
4-2
FIRST PAPER FEED SECTION
THEORY OF OPERATION
Intermediate gear
Pickup roller
Main gear
Scraper roller
4-3
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1 The Paper feed clutch activates each time the Drum rotates 62°± χ° from the 0° position.
The angle "χ" can be adjusted by Memory Switch (Test Mode) No. 204, which adjusts the ON timing of
the Paper feed clutch.
2 The Paper feed clutch is deactivated when the Drum rotates 21°± χ° from the moment the light path of
the Paper sensor is blocked (paper detected).
The angle "χ" can be adjusted by Memory Switch (Test Mode) No. 210, which adjusts the paper buckle
amount.
Scraper roller
Guide roller
Pickup roller
DRUM
Paper sensor
PAPER
Stripper pad
Timing roller
4-4
FIRST PAPER FEED SECTION
THEORY OF OPERATION
2. Pick-up
• The top sheet is separated from the rest by the Pickup roller and Stripper plate.
• The Stripper plate is pushed against the Pickup roller by the Stripper spring to provide
resistance against paper feed, by which only a single sheet of paper is fed from the paper
stack.
• The Stripper unit has Pressure adjust knob which by moving up or down changes the pressure
of the Stripper spring in three steps.
Stripper spring
Pickup roller
Pressure arm
4-6
CHAPTER 4: FIRST PAPER FEED SECTION
CONTENTS
1. Theory of Operation
1. Paper Feed Tray Elevation .................................................................................... 1
2. First Paper Feed Drive Mechanism ....................................................................... 3
3. Paper Pickup System ............................................................................................ 5
4. Paper Feed Pressure Select System .................................................................... 6
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Precaution in Assembly
• Make sure to tie the wire harness of the Paper detection sensor firmly in position with a plastic
band.
Elevator shafts
E-rings
Precautions in Assembly
• Match the half-pierced section of the Paper detection sensor with its counter part.
• Match the half-pierced section of the Paper feed tray cover with its counter part.
4-8
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Precautions in Assembly
• Both rollers have built-in one-way clutch.
If the rollers are put back on the shaft the opposite way (turned around), the one-way clutches
prevent the rollers from rotating.
Placed correctly on the shafts, the rollers should rotate freely by hand in the direction shown on
the illustration below.
Pickup roller
Scraper roller
Lock rings
4-9
FIRST PAPER FEED SECTION
REMOVAL AND ASSEMBLY
4. Stripper Pad
1. Lower the Paper feed tray all the way down.
2. Disconnect the power supply from the machine.
3. Remove the Scraper and Pickup Rollers. (page 4-9)
4. Remove the Stripper pad base carefully, not to damage the Stripper spring.
5. Remove the Stripper Pad from the Stripper pad base.
Precaution in Assembly
• Set the Stripper spring correctly in the machine before setting the Stripper pad base back in
place.
Stripper pad
Stripper pad base
Stripper spring
4 - 10
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Precaution in Assembly
• Match the half-pierced section of the sensor bracket with its counter part.
4 -11
FIRST PAPER FEED SECTION
REMOVAL AND ASSEMBLY
Precautions in Assembly
• Match the position of the flat cut portion of the Pickup roller shaft with that of the clutch.
• Mount the slit on the clutch over the Positioning plate on the machine to prevent the clutch
from rotating.
Positioning plate
4 - 12
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7. Scraper Assembly
1. Lower the Paper feed tray.
2. Disconnect the power supply from the machine.
3. Remove Back cover and Master removal lower cover.
4. Remove following three parts from the machine.
• Pickup roller and Scraper roller (page 4-9)
• Elevator upper limit sensor (page 4-11)
• Paper feed clutch (page 4-12)
5. Remove E-rings from the both ends of the Pickup roller shaft and remove the Metals.
6. Remove the mounting screw of the Shaft bracket.
7. Slide the Pickup shaft to the drive side of the machine and remove the Shaft bracket.
8. Remove the Scraper assembly from the machine.
Metal
Shaft bracket
Scraper assembly
Metal
4 -13
FIRST PAPER FEED SECTION
REMOVAL AND ASSEMBLY
Precautions in Assembly
• Match the half-pierced section of the Elevator motor unit with its counter part.
Elevator springs
4 - 14
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CONTENTS
1. Theory of Operation
1. Paper Feed Tray Elevation .................................................................................... 1
2. First Paper Feed Drive Mechanism ....................................................................... 3
3. Paper Pickup System ............................................................................................ 5
4. Paper Feed Pressure Select System .................................................................... 6
2. Removal and Assembly
1. Paper Feed Tray Unit ............................................................................................ 7
2. Paper Detection Sensor ........................................................................................ 8
3. Scraper and Pickup Rollers ................................................................................... 9
4. Stripper Pad ......................................................................................................... 10
5. Upper Limit Sensor .............................................................................................. 11
6. Paper Feed Clutch ............................................................................................... 12
7. Scraper Assembly ............................................................................................... 13
8. Elevator Motor Unit .............................................................................................. 14
3. Adjustment
1. Upper Limit Sensor Position ................................................................................ 15
2. First Paper Feed Distance (OFF Timing of Paper Feed Clutch) ......................... 16
FIRST PAPER FEED SECTION
ADJUSTMENT
3. Adjustment
1. Upper Limit Sensor Position
1. Remove paper from the Paper feed tray.
2. Select Test mode No.102 and press START button to raise the Paper feed tray.
Press the START button until the tray is all the way up, and then release the button.
3. Measure by the eye the space between the Pickup roller and Paper feed tray.
Confirm that the space is 1.8 ± 0.3 mm.
4. If the space is too little or too much, remove the Master disposal box and Master removal lower
cover.
5. Loosen the mounting screw of the Upper limit sensor bracket and slide the bracket up or down
to adjust the sensor position.
6. Repeat above steps 2, 3 and 5 until correct spacing of 1.8 ± 0.3 mm is obtained.
Precaution in Adjustment
• Do not confuse the Pickup roller with the Scraper roller when measuring the space.
The Pickup roller is the one behind the Scraper roller.
1.8±0.3 mm
The Drum rotation angle from the time the Paper sensor detects
incoming paper until the Paper feed clutch deactivates.
INCREASE
Memory SW 0 1 2 3 4 5 6 7
8 9 A B C D E F
13 14 15 16 17 18 19 20
DECREASE
4 - 16
CHAPTER 5: SECOND PAPER FEED SECTION
CONTENTS
1. Theory of Operation
1. Second Paper Feed Drive Mechanism .................................................................. 1
2. Vertical Print Position ............................................................................................ 3
2. Removal and Assembly
1. Load Spring ........................................................................................................... 5
2. Timing Cam ........................................................................................................... 6
3. Sector Gear ........................................................................................................... 7
4. Print Positioning Unit ............................................................................................. 8
5. Print Positioning Pulse Motor ................................................................................ 9
6. Paper Guide Plate ............................................................................................... 10
7. Paper Sensor ....................................................................................................... 12
8. Timing Roller ....................................................................................................... 13
3. Adjustment
1. Timing Cam Mounting Position ............................................................................ 15
manuals4you.com
SECOND PAPER FEED SECTION
THEORY OF OPERATION
1. Theory of Operation
1. Second Paper Feed Drive Mechanism
1. Drive
• Main cam makes clockwise rotation (looking from the rear) with the turn of the main motor.
• The Main cam rotation moves Sector gear back and forth via Cam follower arm.
• The Sector gear rotates Timing roller via Timing cam.
• The Timing roller rotates Guide roller.
2. Timing Cam
• The Timing cam contains one-way clutch.
• The rotation of the Timing cam is transferred to the Timing roller only when the Timing cam
makes counter-clockwise rotation.
3. Timing Roller
• The Timing roller contains Load spring which applies brake on the roller at all times.
It stops the rotation of the roller as soon as the Timing cam stops its counter-clockwise rotation.
• The Timing roller stays still while the Timing cam makes clockwise rotation.
4. Guide Roller
• The Guide roller is a free rotating roller.
• It rotates when coming in contact with a rotating Timing roller.
• The vertical movement of the Guide roller is controlled by the rotation of the Timing roller.
• The Guide roller comes down and contacts against the Timing roller while the First paper
feed section is still in motion.
• The Guide roller lifts and releases from the Timing roller the same time the Timing roller stops
its rotation.
Guide roller
Load spring
Timing cam
5-1
manuals4you.com
Drum Position-B
• At Position-B, the Timing lever on top of the highest
position of the Timing cam. Guide roller
Thus the Guide roller is raised and there is a space
between the Guide roller and the Timing roller.
Timing lever
Timing roller
Timing cam
Sector gear
Main cam
First Paper Feed
• With the start of 1st paper feed, the rotation of the
Main cam brings the Sector gear down, in the direction
shown by arrow mark.
The Sector gear rotates the Timing cam which brings
the Timing lever down.
As the Timing lever comes down, the Guide roller goes
down, making contact with the Timing roller.
5-2
SECOND PAPER FEED SECTION
THEORY OF OPERATION
4. Print Position
• When the key is pressed, the Print positioning lever is pushed down and the print position
moves up.
• When the key is pressed, the Pint position lever is pressed up and the print position moves
down.
Cam follower
5-3
manuals4you.com
Main cam
Print positioning
cam Cam follower
Print positioning
lever
5-4
CHAPTER 5: SECOND PAPER FEED SECTION
CONTENTS
1. Theory of Operation
1. Second Paper Feed Drive Mechanism .................................................................. 1
2. Vertical Print Position ............................................................................................ 3
2. Removal and Assembly
1. Load Spring ........................................................................................................... 5
2. Timing Cam ........................................................................................................... 6
3. Sector Gear ........................................................................................................... 7
4. Print Positioning Unit ............................................................................................. 8
5. Print Positioning Pulse Motor ................................................................................ 9
6. Paper Guide Plate ............................................................................................... 10
7. Paper Sensor ....................................................................................................... 12
8. Timing Roller ....................................................................................................... 13
3. Adjustment
1. Timing Cam Mounting Position ............................................................................ 15
manuals4you.com
Load spring
Collar
E-ring
5-5
SECOND PAPER FEED SECTION
REMOVAL AND ASSEMBLY
2. Timing Cam
1. Disconnect the power supply from the machine.
2. Remove Back cover.
3. Open the Main PCB bracket frame.
4. Remove the Guide roller spring.
5. Remove E-ring from the Timing roller shaft and remove the Timing cam.
Timing cam
5-6
manuals4you.com
3. Sector Gear
1. Disconnect the power supply from the machine.
2. Remove Back cover.
3. Open the Main PCB bracket frame.
4. Remove following two parts from the machine.
• Print positioning unit (page 5-8)
• Timing cam (page 5-6)
5. Remove E-ring from the Sector gear shaft and remove the gear.
Sector gear
5-7
SECOND PAPER FEED SECTION
REMOVAL AND ASSEMBLY
Sector gear
E-ring
5-8
manuals4you.com
5-9
SECOND PAPER FEED SECTION
REMOVAL AND ASSEMBLY
5 - 10
manuals4you.com
• Lift the Elevator racks Front and Rear all the way up to
disengage the gears.
• Then match the height of the Front and Rear racks and let
both slide down to keep the two level to each other.
• This must be done before attaching the Elevator motor unit.
5 -11
SECOND PAPER FEED SECTION
REMOVAL AND ASSEMBLY
7. Paper Sensor
1. Remove the Drum from the machine.
2. Disconnect the power supply from the machine.
3. Remove following parts from the machine.
• Back cover, Front cover and Master removal lower cover
• Paper feed tray unit (page 4-7)
• Scraper ass'y (page 4-13)
• Elevator motor unit (page 4-14)
• Paper guide plate (page 5-10)
4. Disconnect the connector of the Paper sensor from the Paper guide plate.
5. Remove the mounting screws of both the Paper sensor (send) and (receive), and remove the
sensors from the Paper guide plate.
5 - 12
manuals4you.com
8. Timing Roller
1. Remove the Drum from the machine.
2. Disconnect the power supply from the machine.
3. Remove following parts from the machine.
• Back cover and Front cover
• Load spring (page 5-5)
• Timing cam (page 5-6)
• Print positioning unit (page 5-8)
• Paper guide plate (page 5-10)
4. Remove E-ring and slide out the Flat gear from the shaft.
5. Remove E-rings from both ends of the Timing roller shaft and remove the Metals.
6. Slide the Timing roller once to the drive side of the machine and then remove it out through the
opening at the paper feed area.
Metal
Metal
Timing roller
Flat gear
5 -13
CHAPTER 5: SECOND PAPER FEED SECTION
CONTENTS
1. Theory of Operation
1. Second Paper Feed Drive Mechanism .................................................................. 1
2. Vertical Print Position ............................................................................................ 3
2. Removal and Assembly
1. Load Spring ........................................................................................................... 5
2. Timing Cam ........................................................................................................... 6
3. Sector Gear ........................................................................................................... 7
4. Print Positioning Unit ............................................................................................. 8
5. Print Positioning Pulse Motor ................................................................................ 9
6. Paper Guide Plate ............................................................................................... 10
7. Paper Sensor ....................................................................................................... 12
8. Timing Roller ....................................................................................................... 13
3. Adjustment
1. Timing Cam Mounting Position ............................................................................ 15
4 y o u.c om
anu a l s
m
manuals4you.com
3. Adjustment
1. Timing Cam Mounting Position
1. Rotate the Drum to the Position-B.
2. Disconnect the power supply from the machine.
3. Remove the Back cover from the machine.
4. Check whether the positioning marks on the Sector gear and Timing cam are aligned.
5. If they are not, remove an E-ring and take the Timing cam off from the Timing roller shaft.
6. Lift the Timing lever assembly and mount the Timing cam back on the Timing roller shaft,
aligning the positioning mark on the cam with that on the Sector gear.
7. Mount the E-ring back on the Timing roller shaft.
Timing cam
E-ring
High position of
the cam. Timing roller shaft
Cam follower
Sector gear
Positioning marks
5 - 15
CHAPTER 6: PRESS SECTION
CONTENTS
1. Theory of Operation
1. Press Mechanism .................................................................................................. 1
2. Removal and Assembly
1. Pressure Roller ...................................................................................................... 5
2. Pressure Lever Ass'y ............................................................................................. 6
3. Pressure Shaft Ass'y ............................................................................................. 8
4. Pressure Solenoid ................................................................................................. 9
3. Adjustment
1. Pressure Lever Ass'y Position ............................................................................. 11
manuals4you.com
PRESS SECTION
THEORY OF OPERATION
1. Theory of Operation
1. Press Mechanism
1. Press Solenoid
• The Press solenoid activates when the Drum rotates 40° from the first Position-A after the Start
button is pressed for printing.
• At this Drum position, the Solenoid lever and Pressure lever ass'y are still engaged.
2. Pressure Roller
• The Solenoid lever disengages from the Pressure lever ass'y as the Drum rotates and the
Clamp plate on the Drum comes near the Pressure roller.
• The Pressure lever ass'y is then pulled back by the Pressure spring and turns the Pressure
shaft in the direction shown by the arrow mark.
• The Pressure lever ass'y rotating in the direction of the arrow mark lifts the Pressure roller
up against the Drum.
• To prevent the Pressure roller from hitting against the Clamp plate of the Drum during printing,
the Pressure cam pushes against the Pressure lever ass'y to rotate it in the direction opposite
to the arrow mark and lowers the Pressure roller clear from the Drum.
• The Pressure solenoid is activated "ON" throughout the printing process.
Pressure shaft
Pressure spring
Pressure roller
Pressure solenoid
Solenoid lever
Pressure cam
6-1
PRESS SECTION
THEORY OF OPERATION
Pressure shaft
Pressure spring
Pressure roller
Pressure cam
Pressure solenoid
Solenoid lever
6-2
manuals4you.com
PRESS SECTION
THEORY OF OPERATION
Drum angle
Blocked Blocked Blocked
Open Open
Position-A sensor
ON
Main motor
1 The Pressure solenoid is turned ON when the Drum rotates to 40 degrees during printing operation.
2 The Pressure solenoid is turned OFF if the light path of the Paper sensor is open (not detecting paper)
when the Drum is at 135 degrees.
Drum angle
Blocked Blocked
Position-A sensor
Main motor ON
OFF
Blocked
Paper Sensor Open (Not detecting paper)
ON
Pressure solenoid OFF
1 The Pressure solenoid is turned OFF at the first Drum position-A after the "Stop" key is pressed.
6-3
CHAPTER 6: PRESS SECTION
CONTENTS
1. Theory of Operation
1. Press Mechanism .................................................................................................. 1
2. Removal and Assembly
1. Pressure Roller ...................................................................................................... 5
2. Pressure Lever Ass'y ............................................................................................. 6
3. Pressure Shaft Ass'y ............................................................................................. 8
4. Pressure Solenoid ................................................................................................. 9
3. Adjustment
1. Pressure Lever Ass'y Position ............................................................................. 11
manuals4you.com
PRESSURE SECTION
REMOVAL AND ASSEMBLY
Pressure roller
Screw
6-5
PRESSURE SECTION
REMOVAL AND ASSEMBLY
Pressure spring
Pull
Push
down
Disengage by
releasing the hook.
Solenoid lever
6-6
manuals4you.com
PRESSURE SECTION
REMOVAL AND ASSEMBLY
Pressure spring
6-7
PRESSURE SECTION
REMOVAL AND ASSEMBLY
C-ring Metal
[FRONT]
Metal
6-8
manuals4you.com
PRESSURE SECTION
REMOVAL AND ASSEMBLY
4. Pressure Solenoid
1. Disconnect the power supply from the machine.
2. Remove Back cover.
3. Open the Main PCB and Power supply PCB bracket frames.
4. Using hand, disengage the Pressure lever ass'y from the Solenoid lever by pushing down the
Solenoid lever while pulling the Pressure lever ass'y.
5. Carefully, remove the Pressure spring.
CAUTION: Remove the spring carefully to prevent injuries.
6. Disconnect the Connector of the Pressure solenoid.
7. Remove two mounting screws of the Solenoid base ass'y and remove the base ass'y.
8. Remove Solenoid spring from the Solenoid base ass'y.
9. Remove two mounting screws of the Press solenoid and remove the solenoid from the base
ass'y.
Precaution in Assembly
• Match the half-pierced section of the Solenoid base ass'y with its counter part.
Pressure spring
6-9
CHAPTER 6: PRESS SECTION
CONTENTS
1. Theory of Operation
1. Press Mechanism .................................................................................................. 1
2. Removal and Assembly
1. Pressure Roller ...................................................................................................... 5
2. Pressure Lever Ass'y ............................................................................................. 6
manuals4you.com
PRESSURE SECTION
ADJUSTMENT
3. Adjustment
1. Pressure Lever Ass'y Position
1. Make confidential master on the Drum.
2. Bring the Drum to the Position-B.
3. Disconnect the power supply from the machine.
4. Remove Back cover.
5. Open the Main PCB and Power supply PCB bracket frames.
6. Using hand, disengage the Pressure lever ass'y from the Solenoid lever by pushing down the
Solenoid lever while pulling the Pressure lever ass'y.
7. Confirm that the gap between the Pressure cam and Cam follower on the Pressure lever ass'y is
3 mm ± 0.3 mm.
8. If the gap is too small or big, loosen the two set screws on the Pressure lever ass'y.
9. Place 5 mm Allen wrench or 5 mm thick plate between the Pressure cam and Cam follower and
hook a thinner Allen wrench in the hole on the end of the Pressure shaft to rotate the shaft.
10. Rotate the Pressure shaft in the direction shown to lift the Pressure roller up against the Drum.
11. While lifting the Pressure roller against the Drum, tighten the two set screws on the Pressure
lever ass'y. The Pressure lever ass'y should be pushed all the way in when tightening the two
set screws.
Results of Incorrect Adjustment
• If the gap is smaller than 3 mm ± 0.3 mm, the printing pressure may become too weak and
print density problem may occur.
• If the gap is too big, the Pressure roller may hit the Clamp plate of the Drum during printing and
damage the Clamp plate.
Pressure shaft
Cam follower
Pressure roller
Pressure cam
6 - 11
CHAPTER 7: PAPER EJECTION SECTION
CONTENTS
1. Theory of Operation
1. Paper Ejection Mechanism .................................................................................... 1
2. Paper Separation Mechanism ............................................................................... 3
2. Removal and Assembly
1. Suction Unit ........................................................................................................... 5
2. Transfer Belt .......................................................................................................... 6
3. Suction Fan ........................................................................................................... 8
4. Paper Ejection Motor ............................................................................................. 8
5. Separation Fan Unit ............................................................................................... 9
6. Separation Fan .................................................................................................... 10
7. Paper Receiving Sensor ...................................................................................... 10
8. Separator ............................................................................................................. 11
9. Paper Receiving Tray .......................................................................................... 13
3. Adjustment
1. Separator Position ............................................................................................... 15
manuals4you.com
PAPER EJECTION SECTION
THEORY OF OPERATION
1. Theory of Operation
1. Paper Ejection Mechanism
1. Paper Separation from the Drum
• The paper is separated from the Drum by the Paper separation fan and Separator.
2. Paper Ejection
• Suction fan pulls the paper, separated from the Drum, on to the Suction unit.
• The Transfer belts on the Suction unit, driven by Paper ejection motor, ejects the paper onto
the Paper receiving tray.
Separator
Paper receiving sensor
Paper ejection motor
Separation fan
Transfer belts
Suction fan
7-1
manuals4you.com
Separation fan ON
Suction fan
Paper ejection
motor
1 The Paper ejection motor is turned ON and OFF repeatedly throughout the printing process.
The ON and OFF intervals change in accordance with the printing speed.
As a result, the change in the interval of the intermittent rotation of the Paper ejection motor changes
the speed of the Transfer belts on the Suction unit. The belts run faster at faster printing speed.
Main motor speed (Printing Speed) 60 rpm 90 rpm 130 rpm
Paper ejection motor ON interval 20 ms 10 ms 20 ms
Paper ejection motor OFF interval 30 ms 10 ms 10 ms
2 The Paper receiving sensor is checked to see whether it is detecting a paper at every Drum position-A.
3 From one Drum position-A to the next, the machine checks to see whether the paper is ejected out of
the light path of the Paper ejection sensor.
Separation fan ON
Suction fan
OFF
Paper ejection
motor OFF
Note: If overload current is detected for 0.3 seconds on the Paper ejection motor, Paper ejection motor
lock message [E 20] is indicated.
7-2
PAPER EJECTION SECTION
THEORY OF OPERATION
Release lever
Release spring
PUSHES
PULLED
Separator lever
MOVES AWAY
PUSHES
Separator cam
7-3
manuals4you.com
CONTENTS
1. Theory of Operation
1. Paper Ejection Mechanism .................................................................................... 1
2. Paper Separation Mechanism ............................................................................... 3
2. Removal and Assembly
1. Suction Unit ........................................................................................................... 5
2. Transfer Belt .......................................................................................................... 6
3. Suction Fan ........................................................................................................... 8
4. Paper Ejection Motor ............................................................................................. 8
5. Separation Fan Unit ............................................................................................... 9
6. Separation Fan .................................................................................................... 10
7. Paper Receiving Sensor ...................................................................................... 10
8. Separator ............................................................................................................. 11
9. Paper Receiving Tray .......................................................................................... 13
3. Adjustment
1. Separator Position ............................................................................................... 15
PAPER EJECTION SECTION
REMOVAL AND ASSEMBLY
Precaution in Assembly
• Hook the Suction unit on the Shafts on the machine frame.
Shaft
Shaft
Suction unit
7-5
manuals4you.com
2. Transfer Belt
1. Disconnect the power supply from the machine.
2. Remove Back cover
3. Remove Suction unit. (page 7-5)
4. Remove two mounting screws of the De-electricity brush and remove the brush.
5. Remove six mounting screws of the Suction face cover.
6. Lift the face cover and remove the Belt driven shaft by unhooking the Transfer belts.
7. Remove the Paper ejection motor belt from the Paper ejection motor.
8. Remove E-ring from the Operation panel side of the Belt pulley shaft.
9. Slide the Transfer pulley shaft towards the drive side of the machine and remove the Transfer
belts from the shaft.
Transfer belts
E-ring
Paper ejection
motor belt
De-electricity brush
7-6
PAPER EJECTION SECTION
REMOVAL AND ASSEMBLY
10. Remove the Transfer belts from the Suction face cover.
Transfer belt
Precautions in Assembly
• Match the half-pierced section on the Suction face cover with its counter part.
• Match the half-pierced section on the De-electricity brush with its counter part.
7-7
manuals4you.com
3. Suction Fan
1. Disconnect the power supply from the machine.
2. Remove Back cover.
3. Remove Suction unit. (page 7-5)
4. Turn over the Suction unit and disconnect the Connector of the Suction fan.
5. Remove three mounting screws of the Suction fan and remove the fan.
Suction fan
Suction unit
7-8
PAPER EJECTION SECTION
REMOVAL AND ASSEMBLY
Precaution in Assembly
• Hook the Suction fan unit into the brackets on the machine, as shown on the illustration below.
7-9
manuals4you.com
6. Separation Fan
1. Remove the Separation fan unit. (page 7-9)
2. Disconnect the Connector of the Separation fan.
3. Remove three mounting screws of the Separation fan and remove the fan.
Separation fan
7 - 10
PAPER EJECTION SECTION
REMOVAL AND ASSEMBLY
8. Separator
1. Remove the Drum from the machine.
2. Disconnect the power supply from the machine.
3. Remove the Back cover and Front cover.
4. Open the Main PCB and Power supply PCB bracket frames.
5. Using hand, disengage the Pressure lever from the Solenoid lever by pushing down the
Solenoid lever while pulling the Pressure lever.
6. Carefully, remove the Pressure spring.
CAUTION: Remove the Pressure spring carefully to prevent injuries.
7. Remove two Separation springs.
Separation spring
Pressure spring
Pull
THEN
Push down
8. Remove E-ring from the operator side of the Separator shaft and remove the Metal.
9. Slide the Separation shaft towards the rear (machine drive side) and remove the mounting
screw of the Separation lever.
10. Remove the Separation lever.
11. Remove the Separation shaft out from the machine, through the Drum opening on the operator
side of the machine.
Metal
Separation lever
7 - 11
manuals4you.com
12. Remove the mounting screw of the Release arm and remove the arm from the shaft.
13. Remove the mounting screw of the Separator and remove the Separator from the shaft.
Separator
Release arm
Precaution in Assembly
• Mount the Release arm touching against the Release lever as shown on the illustration below.
Release arm
Release lever
7 - 12
PAPER EJECTION SECTION
REMOVAL AND ASSEMBLY
Precaution in Assembly
• Match the half-pierced sections on the Lock plates F and R with their counter parts.
Lock plate F
Lock plate R
7 - 13
manuals4you.com
CONTENTS
1. Theory of Operation
1. Paper Ejection Mechanism .................................................................................... 1
2. Paper Separation Mechanism ............................................................................... 3
2. Removal and Assembly
1. Suction Unit ........................................................................................................... 5
2. Transfer Belt .......................................................................................................... 6
3. Suction Fan ........................................................................................................... 8
4. Paper Ejection Motor ............................................................................................. 8
5. Separation Fan Unit ............................................................................................... 9
6. Separation Fan .................................................................................................... 10
7. Paper Receiving Sensor ...................................................................................... 10
8. Separator ............................................................................................................. 11
9. Paper Receiving Tray .......................................................................................... 13
3. Adjustment
1. Separator Position ............................................................................................... 15
PAPER EJECTION SECTION
ADJUSTMENT
3. Adjustment
1. Separator Position
1. Using Test Chart No.8, make a master and prints.
2. Adjust the printing position by the Print position button on the Operation panel, so that there is
5 mm white margin on the top of the prints.
3. Confirm that the paper separates from the Drum and there is no black line on the center of the
prints.
4. If the paper does not separate from the Drum, or there is a black line on the center of the prints,
an adjustment on the Separator position is necessary.
5. For the adjustment, disconnect the power supply from the machine and remove the Back cover.
6. Open the Main PCB and Power supply PCB bracket frames.
7. Loosen the mounting screw of the Separator positioning plate and slide the plate.
8. Tighten the mounting screw of the plate when the space between the tip of the Separator is
within 1.0 mm from the Drum but not touching it.
Precaution in Adjustment
• Printed papers using Test Chart No.8 original should separate from the Drum when the top
white margin on the prints are adjusted to 5 mm by the Print position button.
Separator
Separator lever 2
2
1
1
1
2
1 Increases the gap
2 Decreases the gap 1
2 Less than
1.0 mm
7 - 15
manuals4you.com
CONTENTS
1. Theory of Operation
1. Master on Drum (in printing) Check Mechanism ................................................... 1
2. Drum Set Check Mechanism ................................................................................. 2
3. Ink Pack Set Check Mechanism ............................................................................ 3
4. Ink Supply Mechanism .......................................................................................... 4
5. Drum Idling Mechanism ......................................................................................... 6
6. Squeegee Roller Rotation Mechanism .................................................................. 8
2. Removal and Assembly
1. Screen ................................................................................................................... 9
2. Drum Body ........................................................................................................... 10
3. Ink Sensor PCB ................................................................................................... 12
4. Squeegee Roller .................................................................................................. 13
5. Drum Support F & Drum Support R ..................................................................... 15
6. Ink Pump Unit ...................................................................................................... 18
7. Inking Motor ......................................................................................................... 19
8. Ink Pack Set Sensor ............................................................................................ 20
9. Drum Set Sensor ................................................................................................. 20
3. Adjustment
1. Squeegee Gap .................................................................................................... 21
2. Squeegee Pressure Balance ............................................................................... 22
3. Ink Blocking Plate Position .................................................................................. 23
manuals4you.com
DRUM SECTION
THEORY OF OPERATION
1. Theory of Operation
1. Master on Drum (in printing) Check Mechanism
1. Master Sensor
• Master Sensor checks the presence of master on the Drum before the start of printing.
• 79° Drum rotation after the first Position-A, the Master Sensor looks for the master on the
Drum.
• The result (whether the master is found or not) is memorized until the Drum is pulled out of
the machine or the power is turned off.
• If no master is detected on the Drum, [C26] is indicated on the Operation panel and stops the
printing operation.
Master sensor
Drum angle = 79°
(From Position-A)
Master
Master sensor
8-1
DRUM SECTION
THEORY OF OPERATION
8-2
manuals4you.com
DRUM SECTION
THEORY OF OPERATION
Ink pack
8-3
DRUM SECTION
THEORY OF OPERATION
2. Inking Motor
• Inking motor activates the Ink pump to supply the ink into the Drum when ink is not detected by
the Ink sensor.
• Ink from the Ink pack is pumped through a hose into the Drum, on top of the Squeegee roller
through Ink distributor.
• The Inking motor stops when the Ink sensor detects ink.
• Excess ink is then made into a long roll of ink tube around a thin Driven shaft located between
the Squeegee roller and Doctor roller and this excess roll of ink tube is checked by the Ink
sensor and Overflow sensor.
4. Ink Overflow
• If an excess amount of ink is supplied in the Drum and Overflow sensor detects the ink, the
machine stops with [E04] indication on the Operation panel.
Ink distributor
Ink pack
Driven shaft
Overflow sensor
Ink distributor
Ink sensor
Long roll of ink tube
Doctor roller
8-4
manuals4you.com
DRUM SECTION
THEORY OF OPERATION
1 The Inking motor does not activate at the start of Main motor even though the Ink sensor is not
detecting the ink.
2 The Inking motor activates when the light path of the Position-A sensor changes from "blocked" to
"open" with the rotation of the Drum if the Ink sensor is not detecting the ink.
3 The Inking motor activates when the Ink sensor no longer detects the ink during printing.
4 The Inking motor turns off when the Main motor is turned off.
• If Ink sensor does not detect ink within 20 seconds after the Inking motor is activated, the machine
assumes that the Ink Pack is empty and "Replace Ink Pack" LED on Operation Panel is lit.
If the machine power is turned OFF before the 20 second count, the counting continues from that point
when the machine is turned ON again.
• If Over flow sensor detects ink for more than 0.5 seconds, the machine assumes that the ink has over
flown within the Drum and displays error message [E 04].
• If excess current is detected for more than 3 seconds after the Inking motor is activated, the machine
assumes that the Inking motor has locked and indicates error message [E 16].
8-5
DRUM SECTION
THEORY OF OPERATION
8-6
manuals4you.com
DRUM SECTION
THEORY OF OPERATION
Drum angle
Main motor ON
Variable speed 60 rpm 30 rpm 60 rpm
Blocked Blocked Blocked
Drumposition-A
sensor
Ink sensor
No ink detection
ON
Inking motor
Pressure ON
solenoid OFF
1 If the Ink sensor does not detect any ink within 15 seconds after the Inking motor is activated, the
machine goes into Drum idling from next Drum position-A.
But if the Ink sensor detects the ink before the Drum comes to position A, the Drum idling movement is
cancelled, and the printing starts.
2 The Drum idling movement starts from the Drum position-A, which is equal to Drum at 0°, and
deactivates the Pressure solenoid.
3 At the second Drum position-A, the Panel on the machine indicates the Drum idling display.
4 During the Drum idling movement, the Ink sensor is checked at every Drum position-A for any ink
detection.
If ink is detected, the Drum idling movement ends and the printing starts.
• If the Ink sensor does not detect any ink within 90 seconds after the Drum idling started, the
machine assumes that the Ink pack is empty and lights the "Replace Ink Pack" LED on the panel
and indicates the message [C 41] on the display.
8-7
DRUM SECTION
THEORY OF OPERATION
Driven shaft
Squeegee roller gear (F)
Doctor roller
Squeegee roller
8-8
manuals4you.com
CONTENTS
1. Theory of Operation
1. Master on Drum (in printing) Check Mechanism ................................................... 1
2. Drum Set Check Mechanism ................................................................................. 2
3. Ink Pack Set Check Mechanism ............................................................................ 3
4. Ink Supply Mechanism .......................................................................................... 4
5. Drum Idling Mechanism ......................................................................................... 6
6. Squeegee Roller Rotation Mechanism .................................................................. 8
2. Removal and Assembly
1. Screen ................................................................................................................... 9
2. Drum Body ........................................................................................................... 10
3. Ink Sensor PCB ................................................................................................... 12
4. Squeegee Roller .................................................................................................. 13
5. Drum Support F & Drum Support R ..................................................................... 15
6. Ink Pump Unit ...................................................................................................... 18
7. Inking Motor ......................................................................................................... 19
8. Ink Pack Set Sensor ............................................................................................ 20
9. Drum Set Sensor ................................................................................................. 20
3. Adjustment
1. Squeegee Gap .................................................................................................... 21
2. Squeegee Pressure Balance ............................................................................... 22
3. Ink Blocking Plate Position .................................................................................. 23
DRUM SECTION
REMOVAL AND ASSEMBLY
Precaution in Assembly
• Do not bend, wrinkle or damage the Screen.
Screen
Screen springs
Special screw
8-9
manuals4you.com
DRUM SECTION
REMOVAL AND ASSEMBLY
2. Drum Body
1. Make a confidential master on the Drum.
2. Remove the Drum from the machine.
3. Remove the Screen from the Drum. (page 8-9)
4. Remove two Special screws from the Clamp plate base and remove the base.
5. Remove remaining ten regular mounting screws and two more Special screws holding the Drum
body to the Drum body support F and R.
6. Separate the Drum body from the Drum body supports, carefully to avoid damaging the Drum
body.
Special screw
Drum Support R
Drum support F
Drum body
Special screw
8 - 10
DRUM SECTION
REMOVAL AND ASSEMBLY
Precaution in Assembly
• Do not bend or damage the Drum body.
• The Drum body has and marks with F engraved next to one of the two arrow marks.
The F mark indicates the "front" (Operation panel side).
• Mount screws on the two holes marked and first.
Then mount the two Special screws next to the first two screws.
Special screws
• After the first and second set of the screws are in, temporary hook the Screen springs in the
manner shown by the illustration below.
This is to pull and fit the Screen evenly on the Drum supports F and R.
Screen springs
• Mount the remaining screws and remove the two temporary mounted Screen springs.
• Mount the last two remaining screws and hook the Screen springs to complete the assembly.
If necessary, refer to the previous page to check how the springs were hooked on the Drum.
8 - 11
manuals4you.com
DRUM SECTION
REMOVAL AND ASSEMBLY
Precaution in Assembly
• The Ink sensor and Overflow sensor antennas should both be standing at a right angle (90°) to
the PCB.
• The two antennas must not be touching the Doctor roller or Driven roller.
8 - 12
DRUM SECTION
REMOVAL AND ASSEMBLY
4. Squeegee Roller
1. Make a confidential master on the Drum.
2. Remove the Drum from the machine, and remove Ink pack from the Drum.
3. Remove following parts from the Drum.
• Drum cover
• Ink pack holder ass'y. (page 8-20)
• Ink pump unit (page 8-18)
• Screen (page 8-9)
• Drum body (page 8-10)
• Ink sensor PCB (page 8-12)
4. Lock the Drum at Position-B.
5. From the holes on the Drum supports F and R, remove two mounting screws each from the
Squeegee frames on both ends.
6. From the holes on the Drum supports F and R, remove mounting screws of the two Eccentric
boss stopper plates and remove the plates.
manuals4you.com
Eccentric boss
Eccentric boss
stopper plates
8 - 13
manuals4you.com
DRUM SECTION
REMOVAL AND ASSEMBLY
9. Remove two screws from the Drum side frame ass'y and two screws from the Drum front frame
ass'y.
10. From the holes on the Drum supports F and R, remove two Pivot screws.
11. Remove the Squeegee bottom assembly from the Squeegee unit.
THEN
Pivot screws
12. Remove two E-rings from the ends of the Squeegee roller and remove the gears and bearings.
13. Slowly take out the Squeegee roller.
The Doctor roller and Driven shaft will also come apart from the Squeegee frames.
CAUTION:
Four O-rings, of which two are very small, may fall off from the Squeegee bottom assembly
when the Squeegee roller is removed. Do not lose these O-rings.
Bearing
Doctor roller
Driven shaft
Gear
Squeegee frame
Squeegee frame
Gear
Squeegee roller
Bearing
Precaution in Assembly
• Do not forget to return the four O-rings in their original positions.
8 - 14
DRUM SECTION
REMOVAL AND ASSEMBLY
Nozzle stopper
Intermediate
wire harness
8 - 15
manuals4you.com
DRUM SECTION
REMOVAL AND ASSEMBLY
10. Loosen two set screws on each Drum shaft clampers, and remove the clampers from the
Drum center shaft.
11. Remove the Drum support F and Drum support R from the Drum center shaft.
Drum support F
Drum support R
8 - 16
DRUM SECTION
REMOVAL AND ASSEMBLY
Precaution in Assembly
• A 18" x 3/8" Wooden Dowel is a very effective JIG when tightening the Drum shaft clampers.
If such a dowel is not avaiable, use the Drum grip shaft as a JIG to set the position.
Drum grip
Reinforce plate
8 - 17
manuals4you.com
DRUM SECTION
REMOVAL AND ASSEMBLY
Precautions in Assembly
• Match the half-pierced section of the Ink pump unit with its counter part.
Inking motor
8 - 18
DRUM SECTION
REMOVAL AND ASSEMBLY
7. Inking Motor
1. Remove the Drum from the machine.
2. Remove Drum cover.
3. Remove Ink pump unit. (page 8-18)
4. Remove two mounting screws of the Inking motor and remove the motor.
Inking motor
8 - 19
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DRUM SECTION
REMOVAL AND ASSEMBLY
Precautions in Assembly
• Match the half-pierced section of the Ink pack holder ass'y with its counter part and make sure
that the positioning hook is correctly inserted in position.
Positioning hook
8 - 20
CHAPTER 8: DRUM SECTION
CONTENTS
1. Theory of Operation
1. Master on Drum (in printing) Check Mechanism ................................................... 1
2. Drum Set Check Mechanism ................................................................................. 2
3. Ink Pack Set Check Mechanism ............................................................................ 3
4. Ink Supply Mechanism .......................................................................................... 4
5. Drum Idling Mechanism ......................................................................................... 6
6. Squeegee Roller Rotation Mechanism .................................................................. 8
2. Removal and Assembly
1. Screen ................................................................................................................... 9
2. Drum Body ........................................................................................................... 10
3. Ink Sensor PCB ................................................................................................... 12
4. Squeegee Roller .................................................................................................. 13
5. Drum Support F & Drum Support R ..................................................................... 15
6. Ink Pump Unit ...................................................................................................... 18
7. Inking Motor ......................................................................................................... 19
8. Ink Pack Set Sensor ............................................................................................ 20
9. Drum Set Sensor ................................................................................................. 20
3. Adjustment
1. Squeegee Gap .................................................................................................... 21
2. Squeegee Pressure Balance ............................................................................... 22
3. Ink Blocking Plate Position .................................................................................. 23
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DRUM SECTION
ADJUSTMENT
3. Adjustment
1. Squeegee Gap
1. Make a confidential master on the Drum.
2. Remove the Drum from the machine.
3. Remove the Screen. (page 8-9)
4. Remove the Drum body. (page 8-10)
5. Clean out the ink from the Squeegee unit.
6. Using feeler gauge, measure the gap between the Squeegee roller and Doctor roller.
The gap should be 0.08 mm ± 0.02 mm.
If not, the gap should be adjusted.
7. To adjust, loosen the securing screw of the Doctor roller adjust plate located at both ends of the
Squeegee unit.
8. Move the adjust plate by inserting a rod, such as 2.5mm Allen wrench, in the hole on the plate to
change the Squeegee gap.
9. Tighten the securing screw of the two Doctor roller adjust plates after the adjustment is done.
Caution in Adjustment
•The Squeegee gap between the Squeegee roller and Doctor roller should be equal throughout
the length of the two rollers.
WIDER
WIDER
NARROWER
(REAR)
8 - 21
DRUM SECTION
ADJUSTMENT
3) Use a screw driver to turn the Eccentric boss to adjust the Squeegee pressure.
The gap between the Squeegee roller and the Drum body should be between 0.5 to 1.0 mm.
4) Tighten the two mounting screws of the Squeegee frame.
(REAR)
Eccentric boss
(FRONT)
8 - 22
manuals4you.com
DRUM SECTION
ADJUSTMENT
(REAR)
(FRONT)
8 - 23
CHAPTER 9: PAPER JAM
CONTENTS
1. Theory of Operation
1. Paper Jam at First Paper Feed Area ..................................................................... 1
2. Paper Jam at Second Paper Feed Area ................................................................ 2
3. Paper Jam on the Drum ........................................................................................ 3
4. Paper Jam at Paper Receiving Area ..................................................................... 4
5. Print Start Timing Chart ......................................................................................... 5
6. During the Printing Timing Chart ........................................................................... 6
7. Print Stop Timing Chart ......................................................................................... 7
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PAPER JAM
THEORY OF OPERATION
1. Theory of Operation
1. Paper Jam at First Paper Feed Area
1. Paper Sensor
• Paper sensor checks for paper every time the Drum makes 135° turn from the Position-A
during printing.
• If the Paper sensor does not detect paper within the third Drum rotation, the machine assumes
paper has jammed at the Fist paper feed area and displays message [C 33].
Pressure solenoid ON
1 The Paper sensor does not detect any paper within the third Drum rotation and displays [C 33].
Drum 135°
9-1
manuals4you.com
PAPER JAM
THEORY OF OPERATION
Main motor ON
Blocked Blocked Blocked
Position-A sensor
Paper sensor Open Blocked 2
Paper feed clutch ON
OFF
Paper receiving Detects paper 1
sensor No
detection
2 The Paper sensor is detecting paper, therefore the machine assumes paper has jammed at the Second
paper feed area and displays the message [C 31].
Next
Position-A
Position-A
9-2
PAPER JAM
THEORY OF OPERATION
Main motor ON
Blocked Blocked Blocked
Position-A sensor
Paper sensor Blocked
2
Paper feed clutch ON
OFF
Paper receiving Detects paper 1
sensor No detection
2 The Paper sensor is not detecting paper, therefore the machine assumes paper has jammed on the
Drum and displays the message [C 34].
Next
Position-A
Position-A
9-3
manuals4you.com
PAPER JAM
THEORY OF OPERATION
Main motor ON
Position-A sensor
1 Paper receiving sensor does not change from detect to no detect within one rotation of the Drum from
one Drum position-A to the next. The machine assumes paper has jammed at the Paper receiving
area and displays message [C 32].
First paper
Next
Position-A
Position-A
Paper does not escape from Paper receiving sensor from one Drum position-A to the next.
9-4
PAPER JAM
THEORY OF OPERATION
Drum angle
ON
Main motor 30 60 rpm 60 rpm
rpm
Blocked
Position-A sensor
Detection 2nd paper
Detection
1st paper
Paper sensor No detection
Detection
1st paper 2nd
Paper receiving No detection paper
sensor
ON ON
Paper feed clutch
Pressure solenoid ON
Separation fan ON
Suction fan
Paper ejection
motor
1 If presence of master on the Drum is not checked, the "Master on Drum (in printing) Check" is done
before the machine starts printing.
If the actuator of the elevator Upper limit sensor is not pressed, the Paper feed tray is elevated before
the printing starts.
2 The ON and OFF intervals of the Paper ejection motor change in accordance with the printing speed,
which in turn determines the speed of the Transfer belts on the Suction unit.
Main motor speed (Printing Speed) 60 rpm 90 rpm 130 rpm
Paper ejection motor ON interval 20 ms 10 ms 20 ms
Paper ejection motor OFF interval 30 ms 10 ms 10 ms
3 If the light path of the Paper sensor is not blocked (no paper detected) at Drum angle 135°, the
Pressure solenoid and Paper feed clutch is turned OFF.
If the light path of the Paper sensor is not blocked within 3 rotations of the Drum, the machine assumes
paper has jammed at first paper feed area and indicates the message [C 33].
4 If the Paper receiving sensor does not detect paper when the Drum is at position-A, the machine
assumes paper has jammed at second paper feed area or on the Drum and indicates the message
[C 31] when paper is jammed at 2nd paper feed area, or [C 34] when paper is jammed on the Drum.
5 If the Paper receiving sensor keeps detecting a paper from one Drum position-A to the next, the
machine assumes paper has jammed at paper receiving area and indicates the message [C 32].
6 The "Total Counter" advances one count when the Paper receiving sensor changes from detecting to
non-detecting.
7 The printing speed increases gradually in following manner at each Drum 240° position after the
START button is pressed.
First 240° Second 240° Third 240° Fourth 240° Fifth 240° This is a sample when printing
60 rpm 60 rpm 90 rpm 110 rpm 130 rpm speed is selected to 130 rpm.
9-5
manuals4you.com
PAPER JAM
THEORY OF OPERATION
Drum angle
Main motor ON
Varial speed Variable speed
Blocked
Position-A sensor
Detection Detection
Paper receiving
sensor
2nd
paper
Paper detection
sensor Detection
Pressure solenoid ON
Separation fan ON
Suction fan
Paper ejection
motor
2 The ON and OFF intervals of the Paper ejection motor change in accordance with the printing speed,
which in turn determines the speed of the Transfer belts on the Suction unit.
Main motor speed (Printing Speed) 60 rpm 90 rpm 130 rpm
Paper ejection motor ON interval 20 ms 10 ms 20 ms
Paper ejection motor OFF interval 30 ms 10 ms 10 ms
3 If the Paper detection sensor does not detect paper at Drum position-A, the machine assumes paper is
not on the Paper feed tray and indicates the message [C 44].
4 If the light path of the Paper sensor is not blocked (no paper detected) at Drum angle 135°, the
Pressure solenoid and Paper feed clutch is turned OFF.
If the light path of the Paper sensor is not blocked within 3 rotations of the Drum, the machine assumes
paper has jammed at first paper feed area and indicates the message [C 33].
5 If the Paper receiving sensor does not detect paper when the Drum is at position-A, the machine
assumes paper has jammed at second paper feed area or on the Drum and indicates the message
[C 31] when paper is jammed at 2nd paper feed area, or [C 34] when paper is jammed on the Drum.
6 If the Paper receiving sensor keeps detecting a paper from one Drum position-A to the next, the
machine assumes paper has jammed at paper receiving area and indicates the message [C 32].
9-6
PAPER JAM
THEORY OF OPERATION
7. Print Stop Timing Chart The TIMING CHART below is identical for both when
the printing movement stops automatically by the
Print quantity on print quantity count on the Operation panel and when
the Display panel the STOP button is pressed manually.
becomes "0". Press STOP Key
Drum angle
Main motor ON
Blocked Blocked
Position-A sensor
Pressure solenoid ON
OFF
Separation fan ON
Suction fan
Paper ejection ON
motor
1 When the Paper receiving sensor changes from "detecting" to "not detecting", the count signal is
activated and the print quantity display on the Panel is decreased by one count and the Total counter
count goes up one count.
If at this time the print quantity display on the Panel becomes zero "0", the print stop movement starts
from the next Drum position-A.
2 If the STOP key is pressed before the Position-A sensor is blocked, the print stop movement starts
when the Position-A sensor is blocked. If the STOP key is pressed just after the Position-A sensor is
opened, the Drum rotates one turn until the next Drum position-A before the print stop movement starts.
3 The ON and OFF intervals of the Paper ejection motor change in accordance with the printing speed,
which in turn determines the speed of the Transfer belts on the Suction unit.
Main motor speed (Printing Speed) 60 rpm 90 rpm 130 rpm
Paper ejection motor ON interval 20 ms 10 ms 20 ms
Paper ejection motor OFF interval 30 ms 10 ms 10 ms
4 If the Paper receiving sensor does not detect paper when the Drum is at position-A, the machine
assumes paper has jammed at second paper feed area or on the Drum and indicates the message
[C 31] when paper is jammed at 2nd paper feed area, or [C 34] when paper is jammed on the Drum.
5 If the Paper receiving sensor keeps detecting a paper from one Drum position-A to the next, the
machine assumes paper has jammed at paper receiving area and indicates the message [C 32].
6 The Main motor stops at Drum angle 272° which equals to the Drum position-B.
CONTENTS
1. Theory of Operation
1. Clamp Unit Home Positioning Mechanism ............................................................ 1
2. Clamp Plate Master Release Mechanism ............................................................. 3
3. Clamp Plate Master Clamp Mechanism ................................................................ 5
2. Removal and Assembly
1. Clamp Unit ............................................................................................................. 7
2. Clamp Motor .......................................................................................................... 8
3. Clamp Sensor A .................................................................................................... 8
4. Clamp Sensor B .................................................................................................... 8
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1. Theory of Operation
1. Clamp Unit Home Positioning Mechanism
1. Clamp Sensors A and B
• Clamp open arm and Master release arm of the Clamp unit are checked by the Clamp sensors
A and B to see if they are in home position every time the machine power is turned ON or the
START button is pressed for confidential or normal master making.
• The Clamp unit is at its home position when the light paths of Clamp sensor A and Clamp
sensor B are both opened.
• If the light path of either one or both sensors are cut, the Clamp motor is activated to move the
arm(s) until the light paths of both sensors are opened.
Clamp encoder
Clamp motor
Clamp sensor A
Clamp sensor B
(Sensor B) (Sensor A)
10 - 1
MASTER CLAMP SECTION
THEORY OF OPERATION
Blocked
Clamp sensor B
420 ms
100 ms
Clamp motor 3
1 When the machine power is turned ON or START button is pressed for master making, the machine
checks whether the Clamp unit is in home position where the light paths of Clamp sensors A and B are
both open.
If the light paths are not open, the Clamp motor activates to bring the Clamp unit to the home position.
If Clamp sensor B is blocked when the machine power is turned ON or START button is pressed for
* master making, the machine indicates error display [E 03] and stops the machine.
Press "All Reset" button to clear the [E 03] display. Then the machine automatically continues the
home positioning movement.
2 The home position movement is completed when the light paths of the Clamp sensors A and B both
become open.
3 If the light paths of the Clamp sensors A and B do not become open within 13 seconds after the Clamp
motor activates, the machine assumes that the Clamp motor has locked and displays error message
[E 03].
10 - 2
manuals4you.com
Clamp plate
Master release bar
Clamp sensor A
Clamp sensor B
10 - 3
DRUM SECTION
THEORY OF OPERATION
Motion starts
1 Motion ends
Blocked
Clamp sensor A
Open
Blocked
Clamp sensor B Open
2 420 ms
100 ms
Clamp motor
3
1 When START button is pressed for master making, if the light paths of Clamp sensors A and B are not
both open, the Clamp motor turns to bring the Clamp unit to the home position before making the
movement to release the clamped master.
2 If the light path of Clamp sensor B is not blocked within 3 seconds after the Clamp motor activates, the
machine assumes that the Clamp motor has locked and displays error message [E 03].
3 If the light path of Clamp sensor A does not become blocked and that of Clamp sensor B does not
become open within 12 seconds after the Clamp motor activates, the machine assumes that the Clamp
motor has locked and displays error message [E 03].
10 - 4
manuals4you.com
2. Master clamping
• With the activation of the Clamp motor, the Clamp open arm is pushed down to open the
Clamp plate.
• The Clamp motor stops when the light path of Clamp sensor A becomes open and keeps the
Clamp plate raised open.
• When the Write pulse motor sends certain set amount of master onto the Drum, the Clamp
motor activates to raise the Clamp open arm and close the Clamp plate.
• The Clamp motor turns off when the light paths of both the Clamp sensors A and B becomes
open.
The Clamp plate is closed and the Clamp unit is returned to the Home position.
Clamp sensor B
Clamp sensor A
Clamp sensor B
10 - 5
MASTER CLAMP SECTION
THEORY OF OPERATION
Blocked
Clamp sensor B Open
370 ms 420 ms
1
100 ms 100 ms
Clamp motor 5
2
1 If the light path of the Clamp sensor B is not blocked within 3 seconds after the Clamp motor is
activated, the machine assumes that the Clamp motor is locked and displays error message [E 03].
2 If the light path of the Clamp sensor A is not opened within 5 seconds after the Clamp motor is
activated, the machine assumes that the Clamp motor is locked and displays error message [E 03].
3 The Drum waits for the master with the Clamp plate opened.
4 The Clamp motor activates to clamp the master with the Clamp plate when the master loading to the
drum is completed.
5 If the light path of the Clamp sensor B is not opened within 5 seconds after the Clamp motor is
activated, the machine assumes that the Clamp motor is locked and displays error message [E 03].
.co m
y o u
a l s 4
ma nu
10 - 6
manuals4you.com
CONTENTS
1. Theory of Operation
1. Clamp Unit Home Positioning Mechanism ............................................................ 1
2. Clamp Plate Master Release Mechanism ............................................................. 3
3. Clamp Plate Master Clamp Mechanism ................................................................ 5
2. Removal and Assembly
1. Clamp Unit ............................................................................................................. 7
2. Clamp Motor .......................................................................................................... 8
3. Clamp Sensor A .................................................................................................... 8
4. Clamp Sensor B .................................................................................................... 8
MASTER CLAMP SECTION
REMOVAL AND ASSEMBLY
Precaution in Assembly
• Match the half-pierced section on the Clamp unit with its counter part.
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Clamp unit
10 - 7
manuals4you.com
2. Clamp Motor
1. Disconnect the power supply from the machine.
2. Remove Back cover.
3. Remove Clamp unit.
4. Remove E-ring on the Clamp intermediate gear and remove the gear.
5. Remove two mounting screws of the Clamp motor and remove the motor.
3. Clamp Sensor A
1. Disconnect the power supply from the machine.
2. Remove Back cover.
3. Remove Clamp unit. (page 10-7)
4. Remove the mounting screw of the Clamp sensor A bracket with the sensor attached.
5. Remove the sensor from the bracket.
Precaution in Assembly
• Match the half-pierced section of the Clamp sensor bracket with its counter part.
4. Clamp Sensor B
1. Disconnect the power supply from the machine.
2. Remove the Back cover.
3. Open the Main PCB bracket frame.
4. Disconnect the Connector of the Clamp sensor B.
5. Remove the mounting screw of the Clamp sensor B and remove the sensor.
Precaution in Assembly
• Match the half-pierced section of the sensor with its counter part.
Clamp sensor A
Clamp sensor B
Clamp motor
10 - 8
CHAPTER 11: MASTER REMOVAL SECTION
CONTENTS
1. Theory of Operation
1. Master Removal Unit Home Positioning Mechanism ............................................ 1
2. Master on the Drum (before master removal) Check Mechanism ......................... 3
3. Clamp Plate Master Release Mechanism ............................................................. 5
4. Master Removal Mechanism ................................................................................. 7
5. Disposed Master Compressing Mechanism .......................................................... 9
6. Master Disposal Box Set Mechanism .................................................................. 12
2. Removal and Assembly
1. Master Removal Unit ........................................................................................... 13
2. Compressing Motor ............................................................................................. 15
3. Master Removal Motor ........................................................................................ 16
4. Master Removal Sensor ...................................................................................... 18
5. Master Full Det. Sensor ....................................................................................... 18
6. Master Compressing Sensor ............................................................................... 18
7. Pulley Shaft ......................................................................................................... 19
8. Vertical Transport Roller (up) .............................................................................. 19
9. G-Belts on Vertical Transport Roller (up) ............................................................ 19
10. Master Removal Hook ....................................................................................... 20
11. Master Sensor ................................................................................................... 20
12. Vertical Transport Roller (down) ........................................................................ 21
13. G-Belts on Vertical Transport Roller (down) ...................................................... 21
14. Master Compress Plate ..................................................................................... 22
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MASTER REMOVAL SECTION
THEORY OF OPERATION
1. Theory of Operation
1. Master Removal Unit Home Positioning Mechanism
The Master removal unit returns to its home position each time the power is turned ON, All Reset
Button is pressed, or Master removal cover is opened and closed.
1 If the light path of Master compressing sensor is not blocked within 1 second after the Compressing
motor rotates in the "Up" direction, the machine assumes Compressing motor is locked and displays
error message [E 07].
2 If the light path of Master compressing sensor is not opened within 10 seconds after the Compressing
motor rotates in the "Up" direction, the machine assumes Compressing motor is locked and displays
error message [E 07].
3 If the light path of Master compressing sensor is not opened within 10 seconds after the Compressing
Motor rotates in the "Down" direction, the machine assumes Compressing motor is locked and displays
error message [E 07].
4 If the light path of Master full detection sensor is not blocked at all from the time the Compressing motor
rotates in the "Up" direction and stops, the machine assumes the Master disposal box is full, and
displays the message [C 43].
11 - 2
MASTER REMOVAL SECTION
THEORY OF OPERATION
Master sensor
Drum angle = 79 °
(From Position-A)
Master
Master sensor
Drum angle = 79 °
(From Position-A)
11 - 3
manuals4you.com
1
Blocked Blocked
Position-A sensor Open
Drum at 79°
2
Master sensor
~
~
Detecting
master
ON
Main motor
OFF
2 If the light of the Master sensor is reflected back (detecting master) at Drum 79°, the Master removal
sensor becomes active and checks the master during the master removal.
If the light of the Master sensor is not reflected back (master not detected) at Drum 79°, master removal
movement will be skipped.
If the machine knows the presence of master on the Drum from earlier machine movements, this master
* on the Drum check movement is skipped.
11 - 4
MASTER REMOVAL SECTION
THEORY OF OPERATION
Clamp plate
Master release bar
Clamp sensor A
Clamp sensor B
11 - 5
manuals4you.com
Motion starts
1 Motion ends
Blocked
Clamp sensor A
Open
Blocked
Clamp sensor B Open
2 420 ms
100 ms
Clamp motor
3
1 When START button is pressed for master making, if the light paths of Clamp sensors A and B are not
both open, the Clamp motor turns to bring the Clamp unit to the home position before making the
movement to release the clamped master.
2 If the light path of Clamp sensor B is not blocked within 3 seconds after the Clamp motor activates, the
machine assumes that the Clamp motor has locked and displays error message [E 03].
3 If the light path of Clamp sensor A does not become blocked and that of Clamp sensor B does not
become open within 12 seconds after the Clamp motor activates, the machine assumes that the Clamp
motor has locked and displays error message [E 03].
11 - 6
MASTER REMOVAL SECTION
THEORY OF OPERATION
2. Main Motor
• The Main motor rotates the Drum the same time the Vertical transport motor activates.
• By the rotation of the Drum, the leading edge of the master comes in contact with the G-Belts
and the separation of the master from the Drum starts.
• The Main motor and Master removal motor stops to complete the master removal movement
when the Drum comes back to the Position-A after making one rotation to remove the master.
Pulley shaft
G Belt
Drum Drum
70° 90°
11 - 7
manuals4you.com
ON
Main motor
OFF
ON
Vertical transport OFF
motor 2
Drum angle
70° 90°
Master removal Detecting removed master
sensor 3
1 If the master was not found on the Drum before going into the master removal movement, the master
removal movement is skipped after the Clamp plate does the "Clamp plate master release" movement.
2 During the master removal, if removed master is not detected by Master removal sensor at Drum angle
70°, the Master removal sensor looks for the removed master for the second time at Drum 90°.
If removed master is still not detected by the Master removal sensor at Drum 90°, the machine assumes
master removal error has occurred and displays the message [C 25], and stops the Main motor at next
Drum Position-B.
3 When the Drum returns to Position-A and Master removal sensor confirms the removed master has
cleared through the sensor, the machine starts compressing the removed master.
If the Master removal sensor still detects removed master, the machine assumes removed master has
jammed at master removal area and displays message [C 26].
If Master removal sensor detects removed master while the machine in idle, the removed master jam
* message [C 26] is displayed.
If over load current is detected for 0.3 seconds after the Master removal vertical transport motor is
* activated, the machine assumes the motor has locked and displays error message [E 14].
11 - 8
MASTER REMOVAL SECTION
THEORY OF OPERATION
Compressing motor
Actuator disk
11 - 9
manuals4you.com
Master goes in
Master Full Detection When the Master disposal box becomes full
* with disposed masters, the disposed
masters prevent the Master compress plate
from compressing down any further and the
actuator on the extension of the Master
compress plate can no longer block the
light path of the Master full det. sensor.
The light path of the Master compressing
sensor is blocked before that of Master full
det. sensor is blocked.
This is the moment the machine determines
the Master disposal box to be full.
11 - 10
MASTER REMOVAL SECTION
THEORY OF OPERATION
Compressing
Compressing starts ends
Blocked Blocked
Master compressing
sensor Open
4
Blocked Blocked
Master full det. sensor Open
2
100 ms
Compress 110 ms Release
Compressing motor
50ms
1 3
1 If the light path of the Master compressing sensor does not become open within 10 seconds after the
Compressing motor rotates to compress, the machine assumes Compressing motor has locked and
displays error message [E 07].
2 If the light path of the Master compressing sensor is not blocked within 1 second after the Compressing
motor rotates to relieve the pressure, the machine assumes Compressing motor has locked and
displays error message [E 07].
3 If the light path of the Master compressing sensor does not become open within 10 seconds after the
Compressing motor rotates relieve the pressure, the machine assumes Compressing motor has locked
and displays error message [E 07].
4 If the light path of the Master full det. sensor is not blocked at all before the light path of the Master
compressing sensor becomes open after the Compressing motor rotates to compress, the machine
assumes the Master disposal box to be full and displays the message [C 43].
11 - 11
manuals4you.com
Switch lever
11 - 12
CHAPTER 11: MASTER REMOVAL SECTION
CONTENTS
1. Theory of Operation
1. Master Removal Unit Home Positioning Mechanism ............................................ 1
2. Master on the Drum (before master removal) Check Mechanism ......................... 3
3. Clamp Plate Master Release Mechanism ............................................................. 5
4. Master Removal Mechanism ................................................................................. 7
5. Disposed Master Compressing Mechanism .......................................................... 9
6. Master Disposal Box Set Mechanism .................................................................. 12
2. Removal and Assembly
1. Master Removal Unit ........................................................................................... 13
2. Compressing Motor ............................................................................................. 15
3. Master Removal Motor ........................................................................................ 16
4. Master Removal Sensor ...................................................................................... 18
5. Master Full Det. Sensor ....................................................................................... 18
6. Master Compressing Sensor ............................................................................... 18
7. Pulley Shaft ......................................................................................................... 19
8. Vertical Transport Roller (up) .............................................................................. 19
9. G-Belts on Vertical Transport Roller (up) ............................................................ 19
10. Master Removal Hook ....................................................................................... 20
11. Master Sensor ................................................................................................... 20
12. Vertical Transport Roller (down) ........................................................................ 21
13. G-Belts on Vertical Transport Roller (down) ...................................................... 21
14. Master Compress Plate ..................................................................................... 22
manuals4you.com
Connector of the
Master removal unit
Connector of the
Master sensor
11 -13
MASTER REMOVAL SECTION
REMOVAL AND ASSEMBLY
Precaution in Assembly
• The Master removal unit should be placed in front of the brackets of the Master removal unit
safety switch and Disposal cover set switch. (refer to above illustration)
• Match the half-pierced sections on the master removal unit with their counter parts.
11 - 14
manuals4you.com
2. Compressing Motor
1. Disconnect the power supply from the machine.
2. Remove Master removal upper cover.
3. Remove E-ring from the Stopper arm R and remove the arm from the shaft.
4. Remove two mounting screws of the Gear cover R ass'y and remove the ass'y.
5. Remove Compress gear A.
6. Disconnect the Connector of the Compressing motor.
7. Remove two mounting screws of the Compressing motor and remove the motor.
Precaution in Assembly
• Match the half-pierced section of Gear cover R ass'y with its counter part.
Compressing motor
Compress gear A
11 - 15
MASTER REMOVAL SECTION
REMOVAL AND ASSEMBLY
11 -16
manuals4you.com
7. Remove the mounting screw of the Pulley bracket on the Operation panel side and remove
the bracket.
8. Disconnect the Connector of the Master removal motor.
9. Remove two mounting screws of the Master removal motor and remove the motor.
Pulley bracket
Precaution in Assembly
• Match the half-pierced section of the Pulley bracket with its counter part.
• Match the half-pierced sections of the Gear cover F and R ass'y with their counter parts.
11 -17
MASTER REMOVAL SECTION
REMOVAL AND ASSEMBLY
Precaution in Assembly
• Match the half-pierced section of the Master removal sensor bracket with its counter part.
Precaution in Assembly
• Match the half-pierced section of the Master compressing sensor bracket with its counter part.
Master removal
sensor bracket
11 - 18
manuals4you.com
7. Pulley Shaft
1. Disconnect the power supply from the machine.
2. Remove Master removal upper cover.
3. Remove Gear cover F ass'y and R ass'y. (page 11-16)
4. Remove E-rings from both ends of the Pulley shaft and remove the Metals.
5. Remove the Pulley shaft by disengaging it out through the G-Belts.
Vertical transport
roller (up)
Metals
Pulley shaft
G belts
11 - 19
MASTER REMOVAL SECTION
REMOVAL AND ASSEMBLY
Precaution in Assembly
• Run the wires of the Master sensor as shown on the illustration.
• Match the half-pierced section of the Master removal hooks with the counter parts.
Master sensor
Run the wire of the Master sensor
between the Master removal hook
and Master removal unit.
11 - 20
manuals4you.com
Springs
Metal
Vertical transport
roller (down)
Vertical transport
gear (down)
G-Belts
11 - 21
MASTER REMOVAL SECTION
REMOVAL AND ASSEMBLY
Housing stay
Metal
11 - 22
manuals4you.com
Precaution in Assembly
• Be careful with the handling of the Compress springs to avoid injuries.
• Install the Master compress shaft in the correct direction.
• Hook the Compress springs in the correct direction and position.
Support bracket
Compress spring
Compress spring
11 - 23
CHAPTER 12: IMAGE SCANNING SECTION
CONTENTS
1. Theory of Operation
1. Original Loading Mechanism ................................................................................. 1
2. Original Scanning Mechanism ............................................................................... 3
3. Image Scanner ...................................................................................................... 5
2. Removal and Assembly
1. Original Feed Solenoid .......................................................................................... 7
2. Image Scanner Unit ............................................................................................... 8
3. Original Detection Sensor ...................................................................................... 9
4. Original IN Sensor ................................................................................................. 9
5. Stripper Roller ...................................................................................................... 10
6. Pickup Roller ....................................................................................................... 10
7. Stripper Pad Ass'y ............................................................................................... 11
8. Read Pulse Motor ................................................................................................ 12
manuals4you.com
IMAGE SCANNING SECTION
THEORY OF OPERATION
1. Theory of Operation
1. Original Loading Mechanism
An original placed on the original tray is automatically fed and set in the ADF unit.
1. Shading Compensation
• The leading edge of the original placed on the Original tray activates the actuator of the
Original detection sensor.
• When the Original detection sensor detects the original, the LED of the Image scanner turns
ON and the shading compensation takes place.
• At the same time, the Original feed solenoid activates and pulls the Original stopper down to
clear the way for the original.
The original is now held in position by Original pickup arm which comes down when the
solenoid is activated.
manuals4you.com
Pickup roller
Original stopper
Stripper roller
Original IN sensor
Stripper pad
Stripper roller
Pickup roller
12 - 1
manuals4you.com
Original feed
solenoid
Scanner LED
3 If the original IN sensor does not detect an Original within 1712 pulses after the Read pulse motor
activates, the machine assumes Original has jammed and indicates the message [C 37], and turns off
the Original feed solenoid and Read pulse motor.
4 If the Original IN senor detects the Original once, but then no longer detects the Original before the
Read pulse motor turns OFF, the machine assumes Original has jammed and indicates the message
[C37] and turns off the Read pulse motor.
5 The "χ" pulses can be adjusted by Memory Switch No. 206 (Test Mode No. 206).
Image scanner
Original IN sensor
Original stopper
Stripper roller
Pickup roller
12 - 2
IMAGE SCANNING SECTION
THEORY OF OPERATION
2. Original IN sensor
• When the tailing edge of the Original clears out from the Original IN sensor, the Read/Write
start signal is turned OFF after a set time and turns OFF the Image scanner LED to stop the
image scanning.
• The Read pulse motor stops after a set time to end the original scanning movement.
Exit roller
Pickup roller
12 - 3
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Drum angle
Original detection Pressed (detecting Original)
sensor
Original feed
OFF
solenoid
Read/Write start
signal 319 pulses
Scanner LED
1 50 ms after the Drum 100° of the master removal movement, the Read pulse motor activates to feed
the Original. (At the same time, the Write pulse motor activates to feed the master material.)
2 59 pulses (5 mm) after the Read pulse motor activates, the Read/Write start signal turns ON and the
image scanning starts.
3 If the Original IN sensor still detects the Original (the sensor light is reflected back) even though the
Read pulse motor has activated for 4945 pulses, the machine assumes the Original is oversized and
indicates [C 38] on the display.
5 The Read pulse motor rotates at high speed to discharge the Original.
Image scanner
Pickup roller Exit roller
Stripper roller Original IN sensor
12 - 4
IMAGE SCANNING SECTION
THEORY OF OPERATION
3. Image Scanner
The image scanning is done by an optical type Image scanner which emits greenish-yellow light
from fluorescent lamp against an original and catches the image after it is reflected and reduced in
size by three mirrors and a lens.
TR1510 has one fluorescent lamp and TR1530 has two fluorescent lamps.
Fluorescent lamps
3rd mirror
2nd mirror
1st mirror
Lens
12 - 5
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Lens
1st mirror
12 - 6
CHAPTER 12: IMAGE SCANNING SECTION
CONTENTS
1. Theory of Operation
1. Original Loading Mechanism ................................................................................. 1
2. Original Scanning Mechanism ............................................................................... 3
3. Image Scanner ...................................................................................................... 5
2. Removal and Assembly
1. Original Feed Solenoid .......................................................................................... 7
2. Image Scanner Unit ............................................................................................... 8
3. Original Detection Sensor ...................................................................................... 9
4. Original IN Sensor ................................................................................................. 9
5. Stripper Roller ...................................................................................................... 10
6. Pickup Roller ....................................................................................................... 10
7. Stripper Pad Ass'y ............................................................................................... 11
8. Read Pulse Motor ................................................................................................ 12
manuals4you.com
Solenoid lever
12 - 7
IMAGE SCANNING SECTION
REMOVAL AND ASSEMBLY
6. Remove two mounting screws of the Scanner cover stay and remove the stay.
7. Disconnect two Connectors of the Image scanner and remove the ground wire.
8. Remove the mounting screw of the Image scanner and remove the scanner.
12 - 8
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4. Original IN Sensor
1. Disconnect the power supply from the machine.
2. Remove ADF frame cover and ADF cover.
3. Open the ADF unit.
4. Remove the mounting screw of the Original guide base plate, disconnect Connectors of Original
IN sensor and Original detection sensor, and then remove the Original guide base plate.
5. Remove the mounting screw of the Original IN sensor and remove the sensor from the Original
guide base plate.
Original IN sensor
12 - 9
IMAGE SCANNING SECTION
REMOVAL AND ASSEMBLY
5. Stripper Roller
1. Disconnect the power supply from the machine.
2. Remove ADF frame cover and ADF cover.
3. Remove Original guide base plate. (page 12-8)
4. Remove E-ring from the shaft of the Stripper roller, and remove the Gear.
5. Remove E-ring from the shaft of the Stripper roller on the other end and slide out the Stripper
roller.
6. Pickup Roller
1. Disconnect the power supply from the machine.
2. Remove ADF frame cover and ADF cover.
3. Remove Original guide base plate. (page 12-8)
4. Remove E-ring from the Original stopper shaft and remove the shaft after unlocking the
Original stopper spring.
5. Remove the Original stopper.
6. Remove E-rings from both ends of the Pickup roller shaft.
7. Remove the Gear on the drive side and the Metal, and then remove the Pickup roller.
Pickup roller
Original stopper
Original guide base plate
Stripper roller
12 - 10
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Precaution in Assembly
• Hook the spring correctly when installing the Stripper pad ass'y bracket (see the enlarged
sketch below).
Spring
12 - 11
IMAGE SCANNING SECTION
REMOVAL AND ASSEMBLY
12 - 12
manuals4you.com
CONTENTS
1. Theory of Operation
1. Cutter Home Positioning Mechanism .................................................................... 1
2. Cutting Mechanism ................................................................................................ 3
2. Removal and Assembly
1. Cutter Unit ............................................................................................................. 5
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CUTTER SECTION
THEORY OF OPERATION
1. Theory of Operation
1. Cutter Home Positioning Mechanism
1. Cutter Position Switch
• Each time the machine power is turned ON or All Reset Button is pressed, the Cutter
switch checks the Cutter.
2. Home Position
• The home position of the Cutter is when the actuator of the Cutter switch is not pressed by the
cam on the Cutter gear.
• If the actuator of the switch is pressed, the Cutter motor activates and rotates the Cutter gear
until the actuator is released from the cam.
Cutter motor
Cutter gear
Home Position
13 - 1
CUTTER SECTION
THEORY OF OPERATION
100 ms
Cutter motor
Master tension 2
Open
plate sensor
1 If the Cutter position SW is released from the beginning (Cutter already at Home position), the Cutter
home positioning movement is skipped.
2 If the light path of the Master tension plate sensor is closed (Master tension plate is up) when the Cutter
home position movement starts, the Master tension plate solenoid is activated to drop the Master
tension plate and then Cutter home position movement takes place.
If the light path of the Master tension plate does not open (Master tension plate does not drop down),
the machine indicates Cutter motor lock error message [E 13].
3 If the Cutter position switch is pressed (cutter not at Home position) even though 450 ms has passed
after the Cutter motor activated, the machine assumes Cutter motor has locked and indicates error
message [E 13].
13 - 2
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CUTTER SECTION
THEORY OF OPERATION
2. Cutting Mechanism
1. Master Cutting
• Cutter motor activates and cuts the master each time the master loading is made on the
Drum.
2. Cutter Motor
• As the Cutter motor activates, it rotates the Cutter gear, and the high part of the cam on the
Cutter gear presses against the actuator of the Cutter switch.
The Cutter motor continues to rotate until the low cut portion of the cam releases the actuator.
The Cutter motor then stops and the cutting motion ends.
• The Cutter motor does not activate unless the Master tension plate is down (light path of the
Master tension plate sensor is open).
Master roll
13 - 3
CUTTER SECTION
THEORY OF OPERATION
Pressed
Cutter position SW 2
3
100 ms
Cutter motor
1
Master tension
plate sensor Open
1 If the light path of the Master tension plate sensor is blocked (Master tension plate up) at the start of the
master cut movement, the Cutter motor will not activate.
The light path of the Master tension plate sensor must be open (Master tension plate must be down) for
the normal Cutter operation.
[C 23] is indicated after the master loading on the Drum movement is completed to indicate master cut
malfunction.
2 If the Cutter position switch is not pressed within 75 ms after the Cutter motor activates (the Cutter does
not move from the Home position), the machine assumes the Cutter motor has locked and indicates
error message [E 13].
3 If the Cutter position switch is pressed (cutter not at Home position) even though 450 ms has passed
after the Cutter motor activated, the machine assumes Cutter motor has locked and indicates error
message [E 13].
13 - 4
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CONTENTS
1. Theory of Operation
1. Cutter Home Positioning Mechanism .................................................................... 1
2. Cutting Mechanism ................................................................................................ 3
2. Removal and Assembly
1. Cutter Unit ............................................................................................................. 5
CUTTER SECTION
REMOVAL AND ASSEMBLY
Precaution in Assembly
• Match the half-pierced sections of the Cutter unit with its counter part.
• Match the half-pierced section of the Cutter guide plate with its counter part.
Cutter unit
13 - 5
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CONTENTS
1. Theory of Operation
1. Master Making ....................................................................................................... 1
2. Thermal Power Safety Switches ............................................................................ 3
2. Removal and Assembly
1. Write Roller ............................................................................................................ 5
2. Thermal Print Head (TPH) ..................................................................................... 6
3. Adjustment
1. Thermal Power of Thermal Print Head .................................................................. 7
manuals4you.com
1. Theory of Operation
1. Master Making
When the START key is pressed for master making, the Drum rotates to remove the master on the
Drum.
At the same time the TPH•CTL signal is turned ON to supply heating power to the Thermal print
head.
ON
Write pulse motor
OFF Normal master making speed Fast speed
350 pulses
Read/Write start ON
signal
ON
TPH•CTL signal
1 During the master removal Drum movement, 50 ms after the Drum angle 100°, the Write pulse motor
activates and transfers the master material.
2 After the master material advances 59 pulses (5 mm), the Read/Write start signal turns ON and master
making starts. The original scanning starts at the same time.
3 350 pulses after the Write pulse motor turns ON, the Paper guide plate solenoid activates and drops
the Paper guide plate down.
4 After the Scanning is completed or Write pulse motor has rotated maximum master making length, both
the Read/Write start signal and TPH•CTL signal are turned OFF to end the master making.
The maximum master making length of the Write pulse motor is given on the chart below.
The value of c can be adjusted by Memory switch (Test mode) No. 205.
5 After the Read/Write start signal and TPH•CTL signal are turned off, the Write pulse motor keeps
turning until one full size master length of master material is moved forward.
The Write pulse motor then turns OFF and the Cutter unit cuts the master material.
One full master length is given on the chart below.
14 - 3
CHAPTER 14: MASTER MAKING SECTION
CONTENTS
1. Theory of Operation
1. Master Making ....................................................................................................... 1
2. Thermal Power Safety Switches ............................................................................ 3
2. Removal and Assembly
1. Write Roller ............................................................................................................ 5
2. Thermal Print Head (TPH) ..................................................................................... 6
3. Adjustment
1. Thermal Power of Thermal Print Head .................................................................. 7
manuals4you.com
Precaution in Assembly
• Match the flat portion of the two Metals on the Write roller ass'y shaft with that of the counter
part.
• Hook the bottom of the Master guide plate in the V-cut plates and match the half-pierced
sections of the plate with the counter parts.
Center hook
Hooks
6. Disconnect two Connectors and one ground wire from the TPH, and remove the TPH.
Ground wire
Precautions in Removal
• Do not touch the Connector pins on the TPH, as static electricity may damage the TPH.
• Do not contact the heat emitting portion of the TPH against hard surfaces.
CONTENTS
1. Theory of Operation
1. Master Making ....................................................................................................... 1
2. Thermal Power Safety Switches ............................................................................ 3
2. Removal and Assembly
1. Write Roller ............................................................................................................ 5
2. Thermal Print Head (TPH) ..................................................................................... 6
3. Adjustment
1. Thermal Power of Thermal Print Head .................................................................. 7
MASTER MAKING SECTION
ADJUSTMENT
3. Adjustment
1. Thermal Power of Thermal Print Head
Thermal power must be adjusted each time the Thermal print head is replaced.
1. Using Memory switch No.201 (Test mode No.201), and make the switch selection to "0" by
using the Print Position button. [refer to page APX(2)-1]
2. Disconnect the power supply from the machine.
3. Connect a Voltmeter to No.1 and No.3 pins of the connector CN5 of the Power supply PCB.
4. Connect the power supply to the machine and turn ON the power by starting up Test mode
No.77 (TPH control signal).
5. Check to see that the Voltage reading on the Voltmeter equals to the voltage setting on the chart
below for the new Thermal print head on the machine with the new resistance (Ω) setting.
The resistance (Ω) of the new TPH is found printed on a seal attached on the TPH itself.
6. If the voltage on the Voltmeter does not match with the voltage on the chart below, turn the
Volume adjust knob (220 volt machine = VR41) & (110 volt machine = VR3) until the correct
voltage reading is obtained on the Voltmeter.
7. After the adjustment is done, exit from the Test mode.
Caution in Adjustment
•The new Thermal print head must be installed before making above adjustment.
• All three Thermal power safety switches (page 14-3) must be pressed to get the correct
voltage reading on the Voltmeter.
Mode TR1510 (A4 Drum machine) Mode TR1530 (B4 Drum machine)
Resistance (Ω) Voltage (V) Resistance (Ω) Voltage (V)
2380 ~ 2390 21.9 2380 ~ 2402 21.7
2391 ~ 2422 22.1 2403 ~ 2446 21.9
2423 ~ 2466 22.3 2447 ~ 2491 22.1
2467 ~ 2511 22.5 2492 ~ 2536 22.3
2512 ~ 2556 22.7 2537 ~ 2582 22.5
2557 ~ 2602 22.9 2583 ~ 2628 22.7
2603 ~ 2648 23.1 2629 ~ 2674 22.9
2649 ~ 2694 23.3 2675 ~ 2721 23.1
2695 ~ 2741 23.5 2722 ~ 2768 23.3
2742 ~ 2788 23.7 2769 ~ 2816 23.5
2789 ~ 2835 23.9 2817 ~ 2864 23.7
2836 ~ 2883 24.1 2865 ~ 2913 23.9
2884 ~ 2932 24.3 2914 ~ 2961 24.1
2933 ~ 2980 24.5 2962 ~ 3011 24.3
2981 ~ 3029 24.7 3012 ~ 3060 24.5
3030 ~ 3079 24.9 3061 ~ 3110 24.7
3080 ~ 3129 25.1 3111 ~ 3161 24.9
3130 ~ 3187 25.3 3162 ~ 3212 25.1
3188 ~ 3220 25.5 3213 ~ 3220 25.3
14 - 7
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CONTENTS
1. Theory of Operation
1. Master Making Unit Set Mechanism ...................................................................... 1
2. Master Tension Plate Home Positioning Mechanism ............................................ 2
3. Master Positioning Mechanism .............................................................................. 4
4. Master Feeding Mechanism .................................................................................. 6
5. Clamp Plate Master Clamp Mechanism ................................................................ 8
6. Master Loading on the Drum Mechanism ............................................................ 10
7. Master Tension Plate Lifting Mechanism ............................................................. 12
8. Master Advance after Master Cutting .................................................................. 14
2. Removal and Assembly
1. Master Making Unit .............................................................................................. 17
2. Master Making Unit Set Switch ............................................................................ 19
3. Write Pulse Motor ................................................................................................ 20
4. Master Making Upper Unit ................................................................................... 21
5. Master Positioning Sensor ................................................................................... 23
6. Master Tension Plate Sensor .............................................................................. 24
7. Master Loading Clutch ......................................................................................... 25
8. Master Tension Plate Solenoid ............................................................................ 25
9. Master End Sensor .............................................................................................. 26
1. Theory of Operation
1. Master Making Unit Set Mechanism
1. Master Making Unit Set Switch
• The Master making unit set switch checks whether the Master making unit is opened or closed.
• The Scanner hook plate pushes against the actuator of the Master making unit set switch when
the Master making unit is closed.
When the switch is not pressed, the "Close Master making unit" message, [C 58] is indicated .
Sector gear
1 If the Master tension plate is already in "Blocked" condition (plate is up), this home positioning
movement is skipped.
2 The Read pulse motor rotates in the reverse direction (reverse to the normal original feeding direction)
and lifts the Master tension plate up.
3 If the Master tension plate sensor is not blocked within 384 pulses after the Read pulse motor is
activated, the machine assumes the Master tension plate is locked and indicates the error message
[E 15].
4 If the Master tension plate sensor is still in "Open" condition after the Read Pulse motor stops, the
machine repeats the home positioning movements and checks the condition of the Master tension
plate sensor again.
If the Master tension plate sensor is still found to be in "Open" condition, the machine assumes the
Master tension plate is locked and indicates the error message [E 15].
5 The Read pulse motor rotates in the forward direction (original feeding direction) to engage the Read
gear 2 ass'y to the gears which feeds the original.
Write roller
Master roll
Detecting master
Master positioning 3
sensor
24 pulses ± χ pulses
Master tension 1
plate sensor Blocked (Master tension plate is up)
1 Checks the position of the Master tension plate when the START button is pressed.
If the Master tension plate is still down, the machine indicates Master Mis-Feed message [C 22].
2 If the light of Master positioning sensor is not reflected back (no master detection) within 944 pulses
after the activation of the Write pulse motor, the machine assumes master mis-feed has occurred and
indicates the message [C 22].
3 By using Memory switch No. 213 (Test mode No. 213), the "χ" pulses can be adjusted.
• When this "χ" is adjusted, the amount of master material moved to the Drum is also changed
automatically to keep the amount of the master clamped under the Clamp plate constant.
DRUM
Position-B
Load roller
Loading clutch
Master
Write roller
Drum angle
Position-A sensor
Main motor
50 ms
Write pulse motor
926 pulses 457 ± χ pulses
Loading clutch
1 The Loading clutch activates at Drum angle 100° during master from Drum removal movement, and
50 ms later, the Write pulse motor activates to send the master material towards the Drum.
2 The Master is fed to the Drum by the Load roller driven by the Write pulse motor while the Loading
clutch is activated.
3 The Loading clutch is activated again when the Clamp plate opens and the Clamp motor stops.
The master is then carried to the Drum, until the leading edge of the master is under the Clamp plate.
4 By using Memory switch No. 214 (Test mode No. 214), the "χ" pulses can be adjusted to change the
amount of the master material clamped under the Clamp plate.
Memory switch No. 213 (Test mode No.213) changes the value of 457 pulses itself.
DRUM
Position-A
2. Master clamping
• With the activation of the Clamp motor, the Clamp open arm is pushed down to open the
Clamp plate.
• The Clamp motor stops when the light path of Clamp sensor A becomes open and keeps the
Clamp plate raised open.
• When the Write pulse motor sends certain set amount of master onto the Drum, the Clamp
motor activates to raise the Clamp open arm and close the Clamp plate.
• The Clamp motor turns off when the light paths of both the Clamp sensors A and B becomes
open.
The Clamp unit is back at the Home position.
Clamp plate
Clamp sensor A
Clamp sensor A
Clamp sensor B
Blocked
Clamp sensor B Open
370 ms 420 ms
1
100 ms 100 ms
Clamp motor 5
2
1 If the light path of the Clamp sensor B is not blocked within 3 seconds after the Clamp motor is
activated, the machine assumes that the Clamp motor is locked and displays error message [E 03].
2 If the light path of the Clamp sensor A is not opened within 5 seconds after the Clamp motor is
activated, the machine assumes that the Clamp motor is locked and displays error message [E 03].
3 The Drum waits for the master with the Clamp plate opened.
4 The Clamp motor activates to clamp the master with the Clamp plate when the master loading to the
drum is completed.
5 If the light path of the Clamp sensor B is not opened within 5 seconds after the Clamp motor is
activated, the machine assumes that the Clamp motor is locked and displays error message [E 03].
3. Master cutting
• The Cutter unit cuts the master after one length of master is transferred by the Write roller
while the Drum waits at 185° (155° for A4 Drum machine).
• To avoid the master material to stick on the Cutter blade, the Write pulse motor rotates 94
pulses in the opposite direction and pulls the master material back towards the Master roll.
• At the same time the Main motor activates and loads the remaining length of master on the
Drum while making one proof print.
• Then the Master tension plate returns to the home position (raised position).
Drum angle
Position-A sensor
Main motor ON
1 master
50 ms completed
Reverse
Write pulse motor 2520 pulses 934 pulses 691
350 pulses pulses 94 pulses
Master tension
plate solenoid 1500 ms
Master tension
plate sensor Open
Master sensor
Detects master
Cutter motor
Cutter position
switch
Master counter
count signal
1 Master tension plate solenoid is activated to drop the Master tension plate down.
2 At Drum 79 °, the Master sensor looks for the master on the Drum.
If master is found on the Drum, the machine memorizes the presence of the master on the Drum.
If no master is found on the Drum, the machine checks the light path of Master tension plate sensor,
and if the light path is open, the machine assumes master loading error has occurred and indicates the
message [C 21].
If the light path of the Master tension plate sensor is blocked, the machine assumes the Master tension
plate has locked and indicates error message [E 15].
3 The Drum angle 185° (155°) is adjustable with Memory Switch No. 217 (Test Mode No. 217).
4 The maximum master making area is adjustable with memory Switch No. 205 (Test Mode No. 205).
5 If the Cutter position switch is not pressed within 75 ms after the Cutter motor activates, the machine
assumes Cutter motor has locked and indicates error message [E 13].
6 If the Cutter position switch is not released within 450 ms after the Cutter motor activates, the machine
assumes Cutter motor has locked and indicates error message [E 13].
7 After the Cutter unit cuts the master material, to prevent the master material from jamming on the cutter
blades, the Write pulse motor rotates in the reverse direction to pull the leading edge of the master
material away from the Cutter unit.
Sector gear
Blocked
(plate is up)
Master tension
plate sensor Open (plate is down)
1 The Read pulse motor rotates in the opposite direction to lift the Master tension plate.
2 If the Master tension plate sensor does not become blocked within 384 pulses after the Read pulse
motor activates, the machine assumes the Master tension plate has locked and indicates error message
[E 15].
3 If the Master tension plate sensor is still in "Open" condition after the Read Pulse motor stops, the
machine repeats the home positioning movements and checks the condition of the Master tension
plate sensor again.
If the Master tension plate sensor is still found to be in "Open" condition, the machine assumes the
Master tension plate is locked and indicates the error message [E 15].
4 Master positioning sensor checks for master cut error when the Master tension plate returns to the
home position.
If the Master positioning sensor detects master, the machine assumes master cut error has occurred
and indicates the message [C 23].
If the Master positioning sensor does not detect any master, the machine assumes the master was cut
and advances the master material forward.
5 The Read pulse motor rotates in the forward direction (original feeding direction) to engage the Read
gear 2 ass'y to the gears which feeds the original.
Master material
Write roller
o m
.c
o u
Write pulse motor
4 y
ls
u a
a n
m
Blocked
Position-A sensor
Main motor ON
Master positioning
sensor Not detecting master
Master feeding direction
1 After the Master tension plate is raised and if the Master positioning sensor detects the master material
(master is not cut) the master advance movement is not made.
2 The master advance movement ends when the Write pulse motor rotates 403 pulses.
The leading edge of the master material stops in the Master stopper gate area.
CONTENTS
1. Theory of Operation
1. Master Making Unit Set Mechanism ...................................................................... 1
2. Master Tension Plate Home Positioning Mechanism ............................................ 2
3. Master Positioning Mechanism .............................................................................. 4
4. Master Feeding Mechanism .................................................................................. 6
manuals4you.com
Wire harness to
Master making ADF wire harness
unit safety switch
Main switch bracket
7. Disconnect the connector on the Operation panel unit and remove two mounting screws and
remove the panel unit.
8. Disconnect the Connector of the Counter.
9. Remove four mounting screws of the Counter bracket and remove the bracket with the Counter
attached.
Counter bracket
Panel unit
10. Remove four mounting screws of the Master making unit and remove the unit from the
machine.
Precaution in Assembly
• Hook the Master making unit on under the catch on the machine frame.
• Match the half-pierced section of the Counter bracket with its counter part.
Precaution in Assembly
• Match the half-pierced section of the Master guide plate with its counter part and hook its
bottom in the V-cut plates.
Master roll holder
15 - 20 (Revised
TR Series
on (Version
8 Jan. 1996)
2.0)
manuals4you.com
8. Remove E-rings from both Link arms and remove the Master making upper unit by lifting it
upwards.
The unit lifts out when the slit on the unit is aligned with the thin part of the shaft.
Precaution in Assembly
• When attaching the Master making upper unit onto the machine, slide the unit on the shaft by
matching the thin part of the shaft with the slit on the unit.
(It is easier to attach the Master making upper unit on the machine if the Operation panel side
of the unit is attached first.)
15 - 22 (Revised
TR Series
on (Version
8 Jan. 1996)
2.0)
manuals4you.com
Precaution in Assembly
• Match the half-pierced section of the Sensor bracket with its counter part.
Sensor bracket
Master positioning
sensor
Master tension plate sensor
Master tension
plate solenoid
Precaution in Assembly
• Match the half-pierced section of the Sensor bracket with its counter part.
Sensor bracket
Precaution in Assembly
• Match the flat cut portion of the Loading roller shaft and that of Master loading clutch.
• Hook the Master loading clutch on the frame of the machine to prevent the clutch from rotating.
Solenoid bracket
Hook the clutch.
Precaution in Assembly
• Match the half-pierced section of the Master guide plate with its counter part.
• Hook the Master roll holder properly on the machine before screwing it down.
15 - 26 (Revised
TR Series
on (Version
8 Jan. 1996)
2.0)
manuals4you.com
INDEX - TR
• Theory •
• R e m ova l •
• Ad ju s tm e n t •
[F]
First Paper Feed Distance First Paper Feed 4-16
[I]
Ink Blocking Plate Position Drum 8-23
[M]
Memory Switches (Test Mode) Appendix (2) APX(2)-1
[P]
Pressure Lever Ass’y Position Press 6-11
[S]
Separator Position Paper Ejection 7-15
Squeegee Gap Drum 8-21
Squeegee Pressure Balance Drum 8-22
[T]
Thermal Power of Thermal Print Head Master Making 14-7
Timing Cam Mounting Position Second Paper Feed 5-15
[U]
Upper Limit Sensor Position First Paper Feed 4-15
Users Mode Appendix (3) APX(3)-1
INDEX - TR
• Theory •
• R e m ova l •
• Ad ju s tm e n t •
[A]
ADF Cover Maintenance 1-6
ADF Unit Cover Maintenance 1-6
[B]
Back Cover Maintenance 1-6
[C]
Clamp Motor Master Clamp 10-8
Clamp Sensor A Master Clamp 10-8
Clamp Sensor B Master Clamp 10-8
Clamp Unit Master Clamp 10-7
Compressing Motor Master Removal 11-15
Cutter Unit Cutter 13-5
[D]
Drum Body Drum 8-10
Drum Cover Maintenance 1-6
Drum Safety Switch Main Drive 3-12
Drum Set Sensor Drum 8-20
Drum Support F & Drum Support R Drum 8-15
[E]
Elevator Motor Unit First paper Feed 4-14
[F]
Front Cover Maintenance 1-5
[G]
G-Belts on Vertical Transport Roller (down) Master Removal 11-21
G-Belts on Vertical Transport Roller (up) Master Removal 11-19
[I]
Image Scanner Unit Image Scanning 12-8
Ink Pack Set Sensor Drum 8-20
Ink Pump Unit Drum 8-18
Ink Sensor PCB Drum 8-12
Inking Motor Drum 8-19
Intermediate Gear Main Drive 3-9
[L]
Load Spring Second Paper Feed 5-5
[M]
Main Motor Unit Main Drive 3-7
Main PCB and Power Supply PCB Bracket Frames Maintenance 1-9
Main PCB Bracket Frame Maintenance 1-7
Master Compress Plate Master Removal 11-22
Master Compressing Sensor Master Removal 11-18
Master End Sensor Master Clamping/Loading 15-26
Master Full Det. Sensor Master Removal 11-18
Master Loading Clutch Master Clamping/Loading 15-25
Master Making Unit Master Clamping/Loading 15-17
Master Making Unit Cover Maintenance 1-6
Master Making Unit Safety Switch Main Drive 3-11
REMOVAL - TR
[M]
Master Making Unit Set Switch Master Clamping/Loading 15-19
Master Making Upper Unit Master Clamping/Loading 15-21
Master Positioning Sensor Master Clamping/Loading 15-23
Master Removal Hook Master Removal 11-20
Master Removal Lower Cover Maintenance 1-5
Master Removal Motor Master Removal 11-16
Master Removal Sensor Master Removal 11-18
Master Removal Unit Master Removal 11-13
Master Removal Unit Safety Switch Main Drive 3-10
Master Removal Upper Cover Maintenance 1-5
Master Sensor Master Removal 11-20
Master Tension Plate Sensor Master Clamping/Loading 15-24
Master Tension Plate Solenoid Master Clamping/Loading 15-25
[O]
Original Detection Sensor Image Scanning 12-9
Original Feed Solenoid Image Scanning 12-7
Original IN Sensor Image Scanning 12-9
[P]
Paper Detection Sensor First paper Feed 4-8
Paper Ejection Motor Paper Ejection 7-8
Paper Feed Clutch First paper Feed 4-12
Paper Feed Tray Unit First paper Feed 4-7
Paper Guide Plate Second Paper Feed 5-10
Paper Receiving Sensor Paper Ejection 7-10
Paper Receiving Tray Paper Ejection 7-13
Paper Sensor Second Paper Feed 5-12
Pickup Roller Image Scanning 12-10
Power Supply PCB Bracket Frame Maintenance 1-8
Pressure Lever Ass’y Press 6-6
Pressure Roller Press 6-5
Pressure Shaft Ass’y Press 6-8
Pressure Solenoid Press 6-9
Print Positioning Pulse Motor Second Paper Feed 5-9
Print Positioning Unit Second Paper Feed 5-8
Pulley Shaft Master Removal 11-19
[R]
Read Pulse Motor Image Scanning 12-12
[S]
Scraper and Pickup Rollers First paper Feed 4-9
Scraper Assembly First paper Feed 4-13
Screen Drum 8-9
Sector Gear Second Paper Feed 5-7
Separation Fan Paper Ejection 7-10
Separation Fan Unit Paper Ejection 7-9
Separator Paper Ejection 7-11
Squeegee Roller Drum 8-13
[S]
Stripper Pad First paper Feed 4-10
Stripper Pad Ass’y Image Scanning 12-11
Stripper Roller Image Scanning 12-10
Suction Fan Paper Ejection 7-8
Suction Unit Paper Ejection 7-5
[T]
Thermal Print Head (TPH) Master Making 14-6
Timing Cam Second Paper Feed 5-6
Timing Roller Second Paper Feed 5-13
Transfer Belt Paper Ejection 7-6
[U]
Upper Limit Sensor First paper Feed 4-11
[V]
Vertical Transport Roller (down) Master Removal 11-21
Vertical Transport Roller (up) Master Removal 11-19
[W]
Write Pulse Motor Master Clamping/Loading 15-20
Write Roller Master Making 14-5
INDEX - TR
• Theory •
• R e m ova l •
• Ad ju s tm e n t •
THEORY - TR
[A]
Advice Displays (Call Service Messages) Appendix APX(4)-1
[C]
Caution Maintenance 1-2
Clamp Plate Master Clamp Mechanism Master Clamp 10-5
Clamp Plate Master Clamp Mechanism Master Clamping/Loading 15-8
Clamp Plate Master Release Mechanism Master Clamp 10-3
Clamp Plate Master Release Mechanism Master Removal 11-5
Clamp Unit Home Positioning Mechanism Master Clamp 10-1
Cross Sectional Diagram Machine Summary 2-3
Cutter Home Positioning Mechanism Cutter 13-1
Cutting Mechanism Cutter 13-3
[D]
Description of PCBs Appendix APX(5)-1
Disposed Master Compressing Mechanism Master Removal 11-9
Drum Idling Mechanism Drum 8-6
Drum Locking System Main Drive 3-5
Drum Positions Main Drive 3-3
Drum Set Check Mechanism Drum 8-2
During the Printing Timing Chart Paper Jam 9-6
[E]
Electrical Components Appendix APX(0)-1
[F]
First Paper Feed Drive Mechanism First Paper Feed 4-3
[I]
Image Scanner Image Scanning 12-5
Ink Pack Set Check Mechanism Drum 8-3
Ink Supply Mechanism Drum 8-4
[M]
Machine Operations Machine Summary 2-4
Main Drive Main Drive 3-1
Main Motor Safety Switches Main Drive 3-2
Master Advance after Master Cutting Master Clamping/Loading 15-14
Master Disposal Box Set Mechanism Master Removal 11-12
Master Feeding Mechanism Master Clamping/Loading 15-6
Master Loading on the Drum Mechanism Master Clamping/Loading 15-10
Master Making Master Making 14-1
Master Making Unit Set Mechanism Master Clamping/Loading 15-1
Master on Drum (in printing) Check Mechanism Drum 8-1
Master on the Drum (before master removal) Check Master Removal 11-3
Master Positioning Mechanism Master Clamping/Loading 15-4
Master Removal and Feed Machine Summary 2-6
Master Removal Mechanism Master Removal 11-7
Master Removal unit Home Positioning Mechanism Master Removal 11-1
Master Tension Plate Home Positioning Mechanism Master Clamping/Loading 15-2
Master Tension Plate Lifting Mechanism Master Clamping/Loading 15-12
Memory Switches (Test Mode) Appendix APX(2)-1
[O]
Original Loading Mechanism Image Scanning 12-1
Original Scanning Mechanism Image Scanning 12-3
Paper Ejection Mechanism Paper Ejection 7-1
[P]
Paper Feed and Receiving Machine Summary 2-5
Paper Feed Pressure Select System First Paper Feed 4-6
Paper Feed Tray Elevation First Paper Feed 4-1
Paper Jam at First Paper Feed Area Paper Jam 9-1
Paper Jam at Paper Receiving Area Paper Jam 9-4
Paper Jam at Second Paper Feed Area Paper Jam 9-2
Paper Jam on the Drum Paper Jam 9-3
Paper Pickup System First Paper Feed 4-5
Paper Separation Mechanism Paper Ejection 7-3
Preface Maintenance 1-1
Press Mechanism Press 6-1
Print Start Timing Chart Paper Jam 9-5
Print Stop Timing Chart Paper Jam 9-7
[S]
Second Paper Feed Drive Mechanism Second Paper Feed 5-1
Specifications Machine Summary 2-1
Squeegee Roller Rotation Mechanism Drum 8-8
[T]
Test Mode Appendix APX(1)-1
Thermal Power Safety Switches Master Making A14-3
[U]
Users Mode Appendix APX(3)-1
[V]
Vertical Print Position Second Paper Feed 5-3
[W]
Warning Maintenance 1-3
Work Precautions Maintenance 1-4
APPENDIX
CONTENTS
Electrical Components
1. Sensors .....................................................................................................APX(0)-1
2. Switches ....................................................................................................APX(0)-2
3. Clutches & Solenoids ................................................................................ APX(0)-3
4. Motors & Fan .............................................................................................APX(0)-4
Test Mode
1. Operation Procedures ...............................................................................APX(1)-1
2. Test Items and Operations ........................................................................APX(1)-3
Memory Switches (Test Mode)
1. Operation Procedures & Items .................................................................. APX(2)-1
Users Mode
1. Operation Procedures & Items .................................................................. APX(3)-1
Advice Displays (Call Service Messages)
1. Display Messages .....................................................................................APX(4)-1
Description of PCBs
1. Block Chart ................................................................................................ APX(5)-1
2. Location of PCBs ....................................................................................... APX(5)-2
3. Main PCB .................................................................................................. APX(5)-3
4. Power Supply PCB .................................................................................. APX(5)-10
5. Option PCB .............................................................................................. APX(5)-13
APPENDIX (0)
ELECTRICAL COMPONENTS
Electrical Components
1. Sensors
Clamp sensor A
Master end sensor
Clamp sensor B
Position-A sensor
Paper sensor
Drum set sensor
Elevator upper limit
sensor
2. Switches
APPENDIX (0)
ELECTRICAL COMPONENTS
Pressure solenoid
Elevator motor
Separation fan
Suction fan
Main motor
Compressing motor
Inking motor
APPENDIX
CONTENTS
Electrical Components
1. Sensors .....................................................................................................APX(0)-1
2. Switches ....................................................................................................APX(0)-2
3. Clutches & Solenoids ................................................................................ APX(0)-3
4. Motors & Fan .............................................................................................APX(0)-4
Test Mode
1. Operation Procedures ...............................................................................APX(1)-1
2. Test Items and Operations ........................................................................APX(1)-3
Memory Switches (Test Mode)
1. Operation Procedures & Items .................................................................. APX(2)-1
Users Mode
1. Operation Procedures & Items .................................................................. APX(3)-1
Advice Displays (Call Service Messages)
1. Display Messages .....................................................................................APX(4)-1
Description of PCBs
1. Block Chart ................................................................................................ APX(5)-1
2. Location of PCBs ....................................................................................... APX(5)-2
3. Main PCB .................................................................................................. APX(5)-3
4. Power Supply PCB .................................................................................. APX(5)-10
5. Option PCB .............................................................................................. APX(5)-13
Test Mode
1. Operation Procedures
The Test mode program enables a service technician to check the operation of each electrical
component in the machine.
- This is a sample of the Initial condition of Test mode: 123 System ROM
Version No.
(Ver. 1.23)
0 036
Test No.
Test Mode status
0 for OFF status
1 for ON status
APPENDIX (1)
TEST MODE
flashes
[Example] - In selecting "E" for the setting, press the button until "E" flashes in the first
display window.
E201
0 000
1) Sensor/SW Test
TR Serieson
(Revised (Version 2.0)
25 Sept. 1995) APX(1) - 3
manuals4you.com
APPENDIX (1)
TEST MODE
2) Motor/Solenoid Test
APX(1) - 4 (Revised
TR Series
on 25(Version
Sept. 1995)
2.0)
APPENDIX (1)
TEST MODE
The panel display returns to normal view after "START" button is pressed
TR Serieson
(Revised (Version
25 Sept.
2.0)
1995) APX(1) - 5
manuals4you.com
APPENDIX (1)
TEST MODE
104 Clamp plate Open/Close operation (Press START button again to stop)
Rotate Drum to A-position Open and close the Clamp plate (master release action)
Rotate Drum to A-position Open and close the Clamp plate (master clamp action
(then go back to first step).
105 ADF Original feed operation (Press START button again to stop)
Original detection sensor ON Original set operation Feed original Eject
original Original detection sensor ON (Repeats this cycle until START button is
pressed)
107 Paper feed & Printing operation (Press START button again to stop)
The paper feed tray rises and the paper is continuously fed until paper supply runs out.
• The Copy counter does not operate and paper jam is not detected.
• Paper feed tray will be automatically lowered without paper.
• Ink can be supplied by the Inking motor.
• Printing speed key can be operated.
111 Main motor (Variable speed) + Paper ejection motor (Variable speed) operation
Speed changeable by Print speed key on the panel.
TR Serieson
(Revised (Version
25 Sept.
2.0)
1995) APX(1) - 7
manuals4you.com
APPENDIX
CONTENTS
Electrical Components
1. Sensors .....................................................................................................APX(0)-1
2. Switches ....................................................................................................APX(0)-2
3. Clutches & Solenoids ................................................................................ APX(0)-3
4. Motors & Fan .............................................................................................APX(0)-4
Test Mode
1. Operation Procedures ...............................................................................APX(1)-1
2. Test Items and Operations ........................................................................APX(1)-3
Memory Switches (Test Mode)
1. Operation Procedures & Items .................................................................. APX(2)-1
Users Mode
1. Operation Procedures & Items .................................................................. APX(3)-1
Advice Displays (Call Service Messages)
1. Display Messages .....................................................................................APX(4)-1
Description of PCBs
1. Block Chart ................................................................................................ APX(5)-1
2. Location of PCBs ....................................................................................... APX(5)-2
3. Main PCB .................................................................................................. APX(5)-3
4. Power Supply PCB .................................................................................. APX(5)-10
5. Option PCB .............................................................................................. APX(5)-13
Amount in (+) indicates shift to the LEFT, and (-) indicates shift to the RIGHT.
204 Paper feed clutch ON timing (Drum angle from the A-position)
SW setting 0 1 2 3 4 5 6 7 8 9 A b C d E F
Drum angle(°) 62 64 66 68 70 72 74 76 46 48 50 52 54 56 58 60
Amount in (+) indicates additional area, and (-) indicates less area.
TR Serieson
(Revised (Version
25 Sept.
2.0)
1995) APX(2) - 1
manuals4you.com
APPENDIX (2)
MEMORY SWITCHES (TEST MODE)
Adjustment (+) or (-) distance of the original set distance from the Original IN sensor.
208 Drum inkless timer setting (Right after the Ink pack is replaced)
SW setting 0 1 2 3 4 5 6 7
Time (seconds) 90 100 110 120 130 140 150 160
8 9 A b C d E F
10 20 30 40 50 60 70 80
• The adjustment is made by changing the R.P.M. of the Read pulse motor.
• Above given chart is based on B4 size paper.
• Adjusting to (+) elongates, and to (-) shrinks the image.
Above Drum angle is the roation of the Drum from the time the Paper sensor detects
incoming paper until the Paper feed clutch disengages.
APX(2) - 2 (Revised
TR Series
on 25(Version
Sept. 1995)
2.0)
APPENDIX (2)
MEMORY SWITCHES (TEST MODE)
TR Serieson
(Revised (Version
25 Sept.
2.0)
1995) APX(2) - 3
manuals4you.com
APPENDIX
CONTENTS
Electrical Components
1. Sensors .....................................................................................................APX(0)-1
2. Switches ....................................................................................................APX(0)-2
3. Clutches & Solenoids ................................................................................ APX(0)-3
4. Motors & Fan .............................................................................................APX(0)-4
Test Mode
1. Operation Procedures ...............................................................................APX(1)-1
2. Test Items and Operations ........................................................................APX(1)-3
Memory Switches (Test Mode)
1. Operation Procedures & Items .................................................................. APX(2)-1
Users Mode
1. Operation Procedures & Items .................................................................. APX(3)-1
Advice Displays (Call Service Messages)
1. Display Messages .....................................................................................APX(4)-1
Description of PCBs
1. Block Chart ................................................................................................ APX(5)-1
2. Location of PCBs ....................................................................................... APX(5)-2
3. Main PCB .................................................................................................. APX(5)-3
4. Power Supply PCB .................................................................................. APX(5)-10
5. Option PCB .............................................................................................. APX(5)-13
Users Mode
1. Operation Procedures
The users mode program enables a machine operator to select the initial operation settings of the
machine.
This mode is explained in "User Guide" and is intended for customers to make a selection if
required.
NOTE: The selection "0" which the choices are listed in boldface in the chart below are the
standard initial settings (at factory shipment).
0 1 - 0
If another item is desired, select it using the print quantity keys.
When selecting item No.02, for example, press "0" and "2".
0 2 - 0
Now choose either of the two initial settings for the selected item.
The selection is made by pressing the "START" button.
The digit in the far right column of the display changes from "0" to "1" or "1" to "0".
"0" and "1" appears alternately each time the "START" button is pressed.
0 1 - 0 0 1 - 1 0 1 - 0 •••
APPENDIX
CONTENTS
Electrical Components
1. Sensors .....................................................................................................APX(0)-1
2. Switches ....................................................................................................APX(0)-2
3. Clutches & Solenoids ................................................................................ APX(0)-3
4. Motors & Fan .............................................................................................APX(0)-4
Test Mode
1. Operation Procedures ...............................................................................APX(1)-1
2. Test Items and Operations ........................................................................APX(1)-3
Memory Switches (Test Mode)
1. Operation Procedures & Items .................................................................. APX(2)-1
Users Mode
1. Operation Procedures & Items .................................................................. APX(3)-1
Advice Displays (Call Service Messages)
1. Display Messages .....................................................................................APX(4)-1
Description of PCBs
1. Block Chart ................................................................................................ APX(5)-1
2. Location of PCBs ....................................................................................... APX(5)-2
3. Main PCB .................................................................................................. APX(5)-3
4. Power Supply PCB .................................................................................. APX(5)-10
5. Option PCB .............................................................................................. APX(5)-13
APPENDIX (4)
ADVICE DISPLAYS
APX(4) - 2 (Revised
TR Series
on (Version
8 Jan. 1996)
2.0)
APPENDIX (4)
ADVICE DISPLAYS
(C21) Master Loading Error (onto the Drum) Master Making Unit
• If the Master sensor does not detect the master (light not reflected) Set SW OFF &ON.
during the master loading when the Drum is at 79° from the
position-A.
started.
(C26) Removed Master Jammed at the Master removal area Unblock the light
• If the Master removal sensor is detecting the removed master (light path of the Master
path blocked) even though the Drum has returned to the position-A removal sensor.
after the master removal process. • Remove the
jammed master.
(C31) Paper Jam in the Second Paper Feed Area Press ALL RESET
• If the Paper receiving sensor does not find paper when the Drum is button.
at Position-A during the printing operation and the Paper sensor • Remove the
jammed paper.
finds a paper at next Drum Position-A.
(C32) Paper Jam in the Paper Receiving Area Press ALL RESET
• If the status of the Paper receiving sensor does not change from button.
detecting paper to not detecting from one Drum Position-A to the • Remove the
jammed paper.
next during printing.
APPENDIX (4)
ADVICE DISPLAYS
(C33) Paper Jam in the First Paper Feed Area Press ALL RESET
• If the Paper sensor does not detect paper at Drum angle 135° button.
within three Drum rotations during printing.
APPENDIX (5)
CONTENTS
Description of PCBs
1. Block Chart ........................................................ APX(5)-1
APPENDIX (5)
CONTENTS
Description of PCBs
1. Block Chart ........................................................ APX(5)-1
manuals4you.com
I. PARTS LIST
manuals4you.com
manuals4you.com
No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
1 020-98001-053 Shaft; Elevator 1
2 607-15000-000 Metal; F8 x 13/12 x 5; 16 x 2 2
3 020-11613-007 Bracket; Upper Limit Sensor 1
4 443-30005-006 Sensor; GP1A71A 2
5 020-11830-008 Bracket; P.-F. Pressure Adj. 1
6 020-11813-006 Arm; P.-F. Pressure Adj. 1
7 020-11814-100 P.-F. Pressure Adj. Lever 1
8 020-11812-000 Spring A; P.-F. Pressure Adj. 1
9 020-11811-100 Spring B; P.-F. Pressure Adj. 1
10 635-17824-005 Stepped Screw; φ 8 x 2.3; M4 x 4.4 2
11 003-26306-100 Pickup Roller 2
12 019-11812-009 Lock Ring 2
13 607-16001-000 Metal; F10 x 15/ 14 x 6; 18 x 2 6
14 020-11816-005 Support; Pickup Roller Shaft 1
15 020-11818-008 Holder Plate; Scraper 1
I-5
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manuals4you.com
No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
1 020-11501-306 Paper-Feed Tray 1
2 020-11526-201 Side Guide R; P.-F.-T. 1
3 020-11525-205 Side Guide F; P.-F.-T. 1
4 020-11514-106 Link Plate A; P.-F.-T. 2
5 020-11513-002 Lever; P.-F.-T. 2
6 020-11515-102 Link Plate B; P.-F.-T. 2
7 020-11516-001 Link Plate Shaft; P.-F.-T. 2
8 020-11520-009 L.O. Sheet 1
9 443-32001-008 Sensor S; GP2A20L 1
10 020-55046-002 Wire Harness; P.-F.-T. 1
11 020-11521-102 Support Plate R; P.-F.-T. 1
12 020-11502-108 Support Plate F; P.-F.-T. 1
13 020-11527-100 Feed Tray Cover 1
14 020-55035-302 Wire Harness; P.-F. II 1
I-7
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manuals4you.com
No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
1 020-11201-108 Intermediate Gear 1 33 020-12625-009 Support Plate; Drum Safety SW 1
2 020-11207-106 Cam; Pressure Roller 1 B4 34 020-60016-006 Drum Safety SW
2 020-11214-005 Cam; Pressure Roller; A4 1 A4 443-02001-003 *Micro-SW; AM50031C331 1
2 020-11216-008 Cam; Pressure Roller; L 1 L 020-55041-000 *Wire Harness; Drum Safety SW 1
3 020-91310-204 Unit / Main Motor 1 35 638-90804-103 Washer; 8.5 x 16 x 0.4 4
4 020-11315-200 *Main Cam 1
5 020-11332-105 Timing Lever 1
6 020-11329-007 Spring; Guide Roller 1
7 600-20061-009 Bearing; 608ZZ 2
8 020-11323-106 Print Positioning Base Ass’y 1
9 612-80700-001 Gear; m0.5 x 75 + m0.8 x 14 1
10 020-11326-008 Print Positioning Cam 1
11 020-11319-303 Print Positioning Adj. Plate 1
12 011-11711-115 Fulcrum Screw; Stripper 3
13 443-30005-006 Sensor; GP1A71A 1
I-9
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manuals4you.com
No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
1 020-11236-106 Guide Cover; Pressure 1
2 020-11235-100 De-electricity Brush; P 1
3 020-98002-050 Pressure Roller Shaft 1
4 020-11227-107 Pressure Roller Support 2
5 020-11231-007 Pressure Balance Shaft 1
6 635-17824-005 Stepped Screw; φ 8 x 2.3; M4 x 4.4 2
7 020-11221-001 Pressure Roller 1 TR1530
7 020-11238-109 Pressure Roller; A4 1 TR1510
8 600-20061-009 Bearing; 608ZZ 2
9 607-17050-005 Metal; F14 x 20 / 17 x 6; 24 x 2 2
10 020-11303-008 Guide Roller 1
11 020-11305-000 Pressure Shaft; Guide Roller 1
12 020-11308-000 Support R; Guide Roller 1
13 020-11306-007 Pressure Plate; Guide Roller 1
14 020-11307-003 Support F; Guide Roller 1
I-11
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manuals4you.com
No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
1 020-12361-400 Ink Pack Holder 1 35 020-12444-004 Grip; Drum 1
2 020-12362-300 Actuator; Ink Pack 1 36 020-12422-000 Drum Hook (R) 1
3 020-12351-103 Holder Table; Ink Pack 1 37 020-12423-007 Drum Hook (L) 1
4 020-12367-000 Spring; Ink Pack Det. 1 38 020-12433-002 Bracket; Locking Plate; Drum 1
5 443-32004-007 Sensor S; GP1A71M1 2 39 020-12438-101 Locking Plate; Drum 1
6 020-12363-004 Set Lever Guide; Pack Holder 1 40 020-12434-009 Shaft; Locking Plate; Drum 1
7 020-12355-109 Set Lever; Pack Holder 1 41 020-12416-000 Rear Frame; Drum 1
8 020-12365-007 Set Spring; Pack Holder 1 42 020-12418-003 Bracket; Drawer Connector 1
9 020-12358-108 Release Lever; Pack Holder 1 43 020-55022-405 Wire Harness; Drum 1
10 020-12435-005 Spring; 6.95 4 44 020-12417-007 Side Frame; Drum 1
11 020-12359-007 Release Grip; Pack Holder 1
12 635-17613-004 Stepped Screw; φ 6 x 1.8; M3 x 4 2
13 020-12451-205 Drum Cover 1
14 020-12448-204 Front Frame; Drum 1
15 020-12420-008 Guide Pin 2
I-13
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No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
020-98009-054 Unit / Squeegee 35 020-55047-106 *Wire Harness; Drum PCB 1
1 020-12503-000 *Main Frame; Drum 1
2 020-12509-106 *Front Plate; Squeegee 1
3 020-12510-104 *Rear Plate; Squeegee 1
4 020-12544-009 *Adj. Boss; Squeegee 2
5 020-12545-102 *Adj. Boss Set Plate; Squeegee 2
6 020-98011-059 *Ink Distributor 1
7 020-12508-002 **Stopper; Ink Distributor 1
8 640-60100-126 **O Ring; P10A-2.4 1
9 020-12502-209 *Shaft Joint; Drum 2
10 020-12504-201 *Support Shaft; Drum 1
11 020-12536-103 *Ink Blocking Plate (Front) 1
12 020-12537-100 *Ink Blocking Plate (Back) 1
13 612-12303-002 *Gear; m1 x 30 x 5 1
14 020-12515-203 *Side Frame F; Squeegee 1
I-15
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No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
020-98010-052 Unit / Clamp Plate
1 020-12214-009 *Master Projection Plate Ass’y 1
2 020-12205-107 *Clamp Magnet 1
3 020-12201-101 *Clamp Plate Base 1
4 020-12206-308 *Clamp Plate 1
5 020-12215-102 *Damper C 2
6 020-12213-100 *Clamp Base C 1
7 020-12126-002 Screw; Screen Hanger 4
8 020-12119-006 Main Gear; Squeegee 1
9 640-61550-001 O Ring; P155-2.4 2
10 020-12112-109 Drum Body Support R 1
11 020-12116-104 Compensator 1
12 020-12115-108 Main Gear; Drum 1
13 020-12441-102 Drum Shaft Clamper 2
14 020-12111-102 Drum Body Support F 1
I-17
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manuals4you.com
No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
1 020-12612-101 Drum Holder 1
2 020-12611-105 Rail; Drum 2
3 020-12615-003 Drum Holder R 1
4 020-12631-009 Drum Catch 2
I-19
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manuals4you.com
No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
1 020-11243-102 Arm; Separator 1
2 020-11254-104 Base Plate; Separator 1
3 020-11248-007 Adj. Plate; Separator 1
4 020-11242-106 Lever; Separator 1
5 020-11251-008 Spring; Separator 2
020-98003-056 Unit / Clamp
6 020-65003-000 *Clamp Motor 1
7 612-80400-105 *Gear; m0.5 x 40 + m1 x 16 1
8 020-12725-003 *Bracket; Clamp Motor 1
9 020-12724-007 *Gear Housing; Clamp 1
10 020-12701-007 *Cam Housing; Clamp 1
11 020-12708-001 *Shaft; Clamp Arm 1
12 020-12707-102 *Master Release Arm; Clamp 1
13 020-12706-106 *Open Arm; Clamp 1
14 020-12713-102 *Spring; Clamp Arm 2
I-21
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manuals4you.com
No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
1 020-65001-007 Fan 1
2 020-13303-005 Nozzle (Lower); Separation 1
3 020-13302-106 Nozzle (Upper); Separation 1
4 020-55024-009 Wire Harness; Separation 1
5 443-32002-004 Sensor S; GP2A22K 1
6 020-13301-207 Fan Base; Separation 1
7 020-11241-100 Shaft; Separator 1
8 020-11260-007 Separator 1
9 020-11252-004 Release Arm; Separator 1
10 607-15000-000 Metal; F8 x 13 / 12 x 5; 16 x 2 2
11 020-11265-009 Base Plate; Release Lever 1
12 020-11264-002 Release Lever; Separator 1
13 020-11266-102 Spring; Release Lever 1
14 635-17613-004 Stepped Screw; φ 6 x 1.8; M3 x 4 1
I-23
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manuals4you.com
No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
1 020-13109-004 Face Cover; Suction 1
2 020-13106-200 Base Frame; Suction 1
3 020-13107-001 Suction Box 1
4 020-13108-105 Belt Pulley; Suction 2
5 020-13111-106 Drive Shaft; Suction 1
6 020-65006-009 P.-E. Motor; Suction 1
7 600-50057-006 Bearing; FLAW678ZZA 2
8 611-93500-004 Pulley; P35S2M80 (STS) 1
9 621-01162-007 Belt; 20-S2M-116 1
10 020-65001-007 Fan 1
11 020-55019-005 Wire Harness; Suction 1
12 020-13101-100 Cover Plate; Suction 1
13 020-13118-100 Under Stopper; Suction 1
14 017-13258-004 De-electricity Brush; Suction 1
15 020-13110-100 Idler Shaft; Suction 1
I-25
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No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
1 020-13413-200 Back Stop; P.-Rcv.-T. 1
2 020-13412-300 Receiving Tray Plate 1
3 020-13407-200 Guide Plate (R); P.-Rcv.-T. 1
4 020-13406-203 Guide Plate (F); P.-Rcv.-T. 1
5 020-13411-002 Link Plate; P.-Rcv.-T. 1
6 020-13414-109 Paper Guide; P.-Rcv.-T. 2
7 007-13124-109 Base Block; Paper Guide; Rcv. 2
8 014-13110-102 Slide Guide; Paper Guide; Rcv.; A3 2
9 014-13113-004 Slide Frame; Paper Guide; Rcv.; A3 2
10 020-13415-105 Slide Rail 1
11 020-13418-104 Damper; Back Stop; P.-Rcv.-T. 1
12 020-13419-003 Damper Sheet; P.-Rcv.-T. 1
I-27
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No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
1 020-70003-107 Image Scanner; B4 1 TR1530 35 020-65011-002 Original Feed Solenoid 1
1 020-70002-100 Image Scanner; A4 1 TR1510 36 020-15737-100 Link Plate; Original Feed 1
2 020-55001-009 Wire Harness; Image Scanner 1 37 020-15742-200 Link Base Plate; Original Feed 1
3 640-60050-005 O Ring; P5-1.9 1 38 635-17423-000 Stepped Screw; φ 4 x 2.2; M3 x 4 1
4 020-15556-202 Cover Plate A; Scanner 1 39 020-15226-105 Bracket; Flange Pressure Plate 2
5 020-15553-203 Exit Roller; Scanner 1 40 020-15217-106 Pressure Plate; Flange 2
6 020-15567-000 Support Stay; TPH 1
7 665-02038-002 Edging Saddle; ESD-2 2
8 665-04037-003 Free Bushing; NJ-23 2
9 020-15569-002 Pressure Plate; TPH 2
10 020-15568-200 Pressure Stay; TPH 1
11 020-15766-002 Spring C; TPH Pressure 2
12 665-02039-009 Edging Saddle; ESD-17L 1
13 020-15758-107 Lock Plate; TPH 2
14 550-20118-104 Seal; TPH 1
I-29
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manuals4you.com
No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
1 020-15583-102 Cover; ADF 1 36 020-15750-203 Original Stopper; ADF 1
2 020-15516-103 Exit Roller (Upper); ADF 2 37 020-15751-200 Spring; Original Stopper 1
3 020-15576-009 Shaft; Exit Roller 2 38 020-15746-206 Shaft; Original Stopper 1
4 020-15722-102 Plate Spring S; Exit Roller 2 39 020-55025-404 Wire Harness; ADF 1
5 020-15517-002 Plate Spring C; Exit Roller 1 40 020-98004-052 T-TPH Ass’y; B4 TR1530
6 020-15725-004 Mylar Sheet; Original Feed 2 41 635-17523-005 *Stepped Screw; φ 5 x 2;M3 x 3 2
7 020-15501-203 Upper Frame; ADF 1 40 020-98006-055 K-TPH Ass’y;A4 TR1510
8 020-15763-003 Mylar Sheet; Original Stripper 1 41 635-17523-005 *Stepped Screw; φ 5 x 2;M3 x 3 2
9 020-15510-008 Shading Sheet 1 42 020-55044-000 Ground Wire; TPH 1
10 020-15515-204 Hook Plate; ADF 1 43 020-55051-103 Wire Harness; TPH-Power 1 TR1530
11 020-15707-006 Spring A; TPH Pressure 1 44 020-55050-107 Wire Harness; TPH Signal 1 TR1530
12 020-15578-001 Roller; Stripper Pressure; ADF 2 43 020-55053-009 Wire Harness; TPH Signal II 1 TR1510
13 020-15577-307 Plate Spring; Stripper Pressure; ADF 1 44 020-55054-005 Wire Harness; TPH-Power II 1 TR1510
14 020-15759-006 Stripper Pad Ass’y; ADF 1 45 020-15764-204 Exit Guide; Original Feed 1
15 020-15508-100 Bracket; Stripper Pad Ass’y 1 46 020-15745-102 Base Pad; Original Feed 1
I-31
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manuals4you.com
No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
1 020-15131-201 Load Guide Plate 1
2 635-17613-004 Stepped Screw; φ 6 x 1.8; M3 x 4 2
3 020-15124-000 Write Roller; B4 1 TR1530
3 020-15222-002 Write Roller; A4 1 TR1510
4 607-07001-006 Metal; S8 x 12 x 19 2
5 607-15000-000 Metal; F8 x 13 / 12 x 5;16 x 2 2
6 612-11400-101 Gear; m0.8 x 42 x 6 1
7 020-15117-004 Master Guide Plate; B4 1 TR1530
7 020-15221-006 Master Guide Plate; A4 1 TR1510
8 020-15218-102 Sensor Cover 1
9 020-15247-102 Guide Cover; M.-M. 1
10 020-15251-002 De-electricity Brush; 271 x 7 1
11 020-15136-106 Spring; Load Guide 2
12 020-15196-109 Bracket; Solenoid 1
13 020-65002-003 Solenoid 1
I-33
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manuals4you.com
No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
1 020-15134-006 Load Roller (Lower) 1 34 020-60014-003 Safety SW; M.-M.
2 020-15209-006 Support Plate; Load Roller 1 020-55039-006 *Wire Harness I; M.-SW 1
3 607-15000-000 Metal; F8 x 13 / 12 x 5; 16 x 2 4 443-02002-000 *Micro-SW; AM50035C331 1
4 020-15135-207 Shaft; Stocker Guide 1
5 020-15128-308 Stocker Guide Plate (Upper) 1
6 020-15129-207 Stocker Guide Plate (Lower) 1
7 550-21014-000 Master Stopper Seal; M.-M. 1
8 020-15164-002 Stay Shaft; M.-M. 1
9 020-15230-200 Load Guide Plate (Upper) 1
10 020-15133-107 Load Guide Plate (Lower) 1
11 020-15148-007 Load Roller (Upper) 1
12 020-15239-207 Damper B 2
13 020-15203-202 Bracket Stay; Sensor 1
14 020-15205-000 Master Stopper; M.-M. 1
15 020-15208-000 Bracket; Sensor 1
I-35
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manuals4you.com
No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
1 020-15202-109 Bracket; Cutter 1 TR1530
1 020-15223-009 Bracket; Cutter; A4 1 TR1510
2 020-15232-202 Cutter Guide (Lower) 1
3 020-15233-403 Cutter Guide (Upper) 1
4 020-95010-108 Unit/ Cutter 1
I-37
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manuals4you.com
No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
1 020-14702-205 Base Cover; M.-Rmv. 1 31 020-60015-000 Safety SW; M.-Rmv.
2 020-14101-201 Disposal Box 1 020-55040-004 *Wire Harness II ; M.-SW 1
3 020-14125-003 Bracket; Box Lever 1 443-02001-003 *Micro-SW; AM50031C331 1
4 020-14126-000 Shaft; Box Lever 1 32 020-60017-002 Cover Set SW; M.-Rmv.
5 020-14124-007 Lever; Disposal Box 1 020-55042-007 *Wire Harness IV ; M.-SW 1
6 020-14127-006 Spring; Box Lever 1 443-02001-003 *Micro-SW; AM50031C331 1
020-98007-051 Unit / Master Removal; B4 TR1530 33 020-14323-000 Spring F; Safety SW 1
020-98008-058 Unit / Master Removal; A4 TR1510 34 020-14316-208 Bracket F; Safety SW 1
*Master Removal Area (2) 35 550-21169-004 Seal; Master Disposal 1
7 020-14116-004 *Vertical Transport Roller (Down) 1 TR1530 35 550-21170-002 Seal ;Master Disposal; Pic. 1
7 020-14204-000 *Vertical Transport Roller (Down); A4 1 TR1510 36 550-21172-005 Seal; P.-Feed Pressure 1
8 020-14114-206 *Bracket F; V.-T.-Roller 1 36 550-21173-001 Seal; P.-Feed Pressure; Pic. 1
9 020-14115-202 *Bracket R; V.-T.-Roller 1
10 607-13000-003 *Metal; F6 x 10 / 9 x 4; 12 x 1.5 2
11 612-03105-001 *Gear; m1.25 x 14 x 3 1
I-39
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No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
020-98007-051 Unit / Master Removal; B4 TR1530 33 020-14044-100 *Transfer Pulley C (Upper);M.-Rmv. 1
020-98008-058 Unit / Master Removal; A4 TR1510 34 020-14038-100 *Transfer Pulley B (Upper);M.-Rmv. 1
*Master Removal Area (1) 35 020-14040-105 *Transfer Pulley A (Upper);M.-Rmv. 1
1 020-14001-207 *Main Frame; M.-Rmv. 1 36 020-14016-000 *Vertical Transport Roller (Up) 1 TR1530
2 020-14011-105 *Stay A; M.-Rmv. 1 36 020-14202-008 *Vertical Transport Roller (Up); A4 1 TR1510
3 607-13000-003 *Metal; F6 x 10 / 9 x 4; 12 x 1.5 4 37 020-14010-001 *Pulley Shaft; M.-Rmv. 1 TR1530
4 612-82301-007 *Gear; m1 x 34 + m1 x 16 2 37 020-14201-001 *Pulley Shaft; M.-Rmv.; A4 1 TR1510
5 612-12302-006 *Gear; m1 x 34 x 5 1 38 020-14506-201 *Bracket; Master Removal Sensor 1
6 020-14048-408 *Gear Cover F; M.-Rmv. 1 39 020-60021-000 *Master Removal Sensor 1
7 020-14031-009 *Bracket; Compressing Sensor 1 40 020-14065-000 *Protection Plate R; M.-Rmv. 1
8 443-30005-006 *Sensor; GP1A71A 1
9 020-14029-004 *Hook F; M.-Rmv. 1
10 020-14026-200 *Actuator Disc; M.-Rmv. 1
11 607-15000-000 *Metal; F8 x 13 / 12 x 5; 16 x 2 2
12 020-65004-200 *Vertical Transport Motor; M.-Rmv. 1
I-41
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No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
1 020-51002-108 Power Supply PCB; S-100 1 100V (For Power Supply PCB; S-100) 100V
1 020-51006-200 Power Supply PCB; H-200 1 200V 485-00002-401 Fuse 10A 125V 5.2 ULTSC 1
2 020-17218-002 Bracket; Power SW 1 485-00001-804 Fuse 8A 125V 5.2 ULTSC 1
3 020-97012-205 Power Cord Ass’y 100V 100V 485-00003-408 Fuse 3.15A 125V ULTSC 3
020-17117-109 *Bracket A; Carrying Grasp 1 485-00003-505 Fuse 1A 125V ULTSC 2
020-51012-200 *Inlet PCB II 1
3 020-97013-201 Power Cord Ass’y 200V 200V (For Power Supply PCB; H-200) 200V
020-17117-109 *Bracket A; Carrying Grasp 1 485-02320-001 Fuse 4A 250V 5.2 SET 1
020-51013-207 *Inlet PCB III 1 485-02520-000 Fuse 6.3A 250V 5.2 ET 1
4 020-17211-105 Bracket; Main PCB 1 485-00003-203 Fuse 3.15A 250V 5.2 SET 3
5 020-51000-202 Main PCB 1 485-01421-009 Fuse 1A 250V 5.2 ET 2
6 665-02025-504 Wire Saddle; WS-4W 1
7 020-55033-504 Wire Harness; M.-M.- Main 1
8 020-80000- System ROM; TR 1
9 020-55036-309 Wire Harness; CN10 1
I-43
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No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
020-97002-307 Unit / Operation panel; 1530
020-97016-308 Unit / Operation panel; 1530 Pic.
020-97003-303 Unit / Operation panel; 1510
020-97004-300 Unit / Operation panel; 1510 Pic.
020-97005-306 Unit / Operation panel; 1510 US
1 020-17303-000 *Sub-Panel Cover 1
2 020-51001-004 *Panel PCB 1
020-17301-201 *Panel Frame Ass’y TR1530
3 020-17302-100 **Panel Frame 1
4 020-17305-100 **Main Panel Sheet 1
5 020-17307-005 **Sub-Panel Sheet; 1530 1
020-17318-201 *Panel Frame Ass’y; 1530 Pic. TR1530 Pic.
3 020-17302-100 **Panel Frame 1
4 020-17312-106 **Main Panel Sheet; Pic. 1
5 020-17319-003 **Sub-Panel Sheet; 1530 Pic. 1
I-45
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manuals4you.com
No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
1 020-15590-303 ADF Cover 1
2 020-15701-202 Original Side Guide (R) 1
3 020-15700-206 Original Side Guide (F) 1
4 020-15702-101 Slide Rack; Original Holder 2
5 020-15724-008 Rack Cover 1
6 005-24114-003 Shaft Gear; Original Holder 1
7 020-15584-206 Original Tray 1
8 020-17104-104 Front Cover; 1530 1 TR1530
8 020-17105-003 Front Cover; 1510 1 TR1510
9 020-14701-209 Upper Cover 1
10 020-14703-104 Original Stopper 1
11 020-17102-306 Back Cover 1
12 020-15191-204 Cover; M.-M. Unit 1
I-47
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manuals4you.com
No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
1 020-55005-004 Wire Harness; I/F 1
2 017-55052-104 Wire Harness; Counter 1
3 020-17251-000 Bracket; Card Counter 1
4 017-97300-108 Wire Harness; JS III 1
5 020-13450-008 Bracket; JS III 1
I-49
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