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Ricoh Gestetner 5428C, Service Manual

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Ricoh Gestetner 5428C Service Manual Download Page 132

TIMING CHART

31 October 2001

6-42

6.9.3 PRINTING

Master eject position SN

Feed start timing SN

2nd feed timign SN

Paper exit timing SN

Main motor

Paper feed motor

Registration SN

Paper exit SN

Registration motor

Pressure release SOL

Paper delivery motor

Vacuum fan motor

Air knife fan motor

30 rpm

Check

Check

Check

Check

60 rpm

75 rpm

30 rpm

Press the print key

X

X

YY

(1)

(2)

(3)

(4)

(5)

(6)

C238D046.WMF

Summary of Contents for Gestetner 5428C

Page 1: ...SERVICE MANUAL Machine code C238...

Page 2: ...dent induce vomiting by sticking a finger down your throat or by giving soapy or strong salty water to drink OBSERVANCE OF ELECTRICAL SAFETY STANDARDS 1 The printer and its peripherals must be install...

Page 3: ...hen keeping used lithium batteries from the main processing units in order to dispose of them later do not store more than 100 batteries from the main processing units per sealed box Storing larger nu...

Page 4: ...10 Accessory Check 1 10 Installation Procedure 1 11 ADF stabilizer installation 1 14 1 2 4 TAPE MARKER OPTION 1 15 Accessory Check 1 15 Installation Procedure 1 16 For C238 1 16 For C231 and C237 1 1...

Page 5: ...JUSTMENT 3 15 3 6 3 PAPER WIDTH DETECTION BOARD 3 16 3 7 PRINTING 3 17 3 7 1 PRESS ROLLER 3 17 3 7 2 PRESS ROLLER RELEASE LEVER ADJUSTMENT 3 18 3 7 3 PRINTING PRESSURE ADJUSTMENT 3 19 3 8 DRUM 3 20 3...

Page 6: ...2 BASIC SETTINGS 5 5 5 3 1 SP TABLE 5 5 5 3 2 SP2 41 2 42 THERMAL HEAD ENERGY CONTROL 5 5 5 4 MAIN MENU NO 3 SYSTEM SETTINGS 5 6 5 4 1 SP TABLE 5 6 5 4 2 SP3 1 INPUT THE PRESENT TIME 5 6 5 5 MAIN MEN...

Page 7: ...ds 6 3 Motors 6 3 Switches 6 4 Sensors 6 4 Solenoids 6 5 Counters 6 5 Others 6 5 6 1 3 DRIVE LAYOUT 6 6 6 2 MASTER EJECT UNIT 6 7 6 2 1 OVERVIEW 6 7 Overview 6 7 Procedure 6 7 6 2 2 MASTER CLAMPER OPE...

Page 8: ...OVERVIEW 6 22 Procedure 6 22 Notes 6 22 6 6 2 DRUM DRIVE MECHANISM 6 23 Mechanism 6 23 Notes 6 23 6 6 3 INK SUPPLY MECHANISM 6 24 Mechanism 6 24 Notes 6 24 6 6 4 INK ROLLER MECHANISM 6 25 Mechanism 6...

Page 9: ...6 10 1 MASTER EJECT JAM E JAM LOCATION INDICATOR 6 44 Picking up the used master from the drum 6 44 Compressing the used master 6 44 Just after turning on the main switch 6 44 6 10 2 DF JAM P JAM LOC...

Page 10: ...RT AND EXIT MECHANISM C600 9 2 4 OVERALL ELECTRICAL CIRCUIT C600 10 3 REPLACEMENT AND ADJUSTMENT C600 11 3 1 FEED UNIT REMOVAL C600 11 3 2 SEPARATION ROLLER REPLACEMENT C600 11 3 3 PICK UP ROLLER REPL...

Page 11: ...left to right 1 1 2 ENVIRONMENTS TO AVOID 1 Locations exposed to direct sunlight or strong light more than 1 500 lux 2 Dusty areas 3 Areas containing corrosive gases 4 Locations directly exposed to c...

Page 12: ...INSTALLATION REQUIREMENTS 31 October 2001 1 2 1 1 4 ACCESS TO THE MACHINE Place the machine near a power source providing clearance as shown below C238I000 WMF...

Page 13: ...OCEDURE 1 2 1 MAIN BODY Accessory Check Make sure that you have all the accessories listed below Description Quantity 1 Master Spool 2 2 Paper Feed Side Pad 2 3 Operating Instructions 1 4 NECR Ricoh v...

Page 14: ...packed with the table CAUTION Only lift with the carrying handles on the bottom corners of the machine Secure the machine on the table with the 2 screws A provided This prevents the machine from falli...

Page 15: ...31 October 2001 INSTALLATION PROCEDURE 1 5 Installation 2 Remove the filament tape and string securing the covers and units as shown above C238I016 WMF C238I017 WMF C238I020 WMF...

Page 16: ...ssory bag A 4 Insert both spools into a new master roll 5 Install the master roll as shown to the right 6 Insert the leading edge of the master roll under the platen roller The arrows B indicate the c...

Page 17: ...ds 8 Set the master making unit 9 Open the door and insert a new ink cartridge D 10 Open the paper table and load a stack of paper 11 Make sure that the side plates E touch the paper gently Shift the...

Page 18: ...end plate and adjust them to the paper size 14 Firmly insert the power plug in the outlet 15 Make sure that the wall outlet is near the machine and easily accessible 16 Turn on the main switch H 17 P...

Page 19: ...2 2 PLATEN COVER INSTALLATION OPTION Accessory Check Check the quantity and condition of the accessories in the box against the following list Description Quantity 1 Stepped Screw 2 Installation Proce...

Page 20: ...ntity and condition of the accessories in the box against the following list Description Quantity 1 Stepped Screw 2 2 Screws 3 3 Screwdriver 1 4 DF Exposure Glass 1 5 Decal Exposure Glass 1 6 Decal Sc...

Page 21: ...31 October 2001 INSTALLATION PROCEDURE 1 11 Installation Installation Procedure 1 Remove the strips of tape C238I002 WMF...

Page 22: ...ioned at the lower front side as shown 4 Peel off the backing D of the double sided tape attached to the rear side of the scale guide E then install the scale guide 2 screws removed in step 2 5 Instal...

Page 23: ...scale decal K as shown 10 Plug in the power cord then turn the main switch on 11 Make a full size copy using the ADF Then check to make sure the side to side and leading edge registrations are correc...

Page 24: ...tallation 1 Attach the two stabilizer brackets A to the back of the table using the thumbscrews 4 screws 2 Attach the caution label B as shown CAUTION This procedure must be done to prevent the machin...

Page 25: ...list Description Quantity 1 Knob Screw C210 C217 C218 C219 C222 C223 C225 C228 C238 C237 and C238 only 2 2 Screw M4 x 25 C211 C212 C213 C214 C216 C224 and C226 only 2 3 Hexagon Nut M4 C211 C212 C213...

Page 26: ...in body 4 Install the auxiliary bracket B on the tape marker with M4 x 8 screws accessories C 5 Install the tape marker on the main body with two knob screws D accessories in the two outer holes in th...

Page 27: ...then connect the tape marker cable to the main body 5 Install the tape marker on the main body with two knob screws B accessories in the two outer holes in the tape marker bracket NOTE 1 Tighten the...

Page 28: ...accessories 4 Reinstall the rear cover 5 Install the auxiliary bracket B on the main body with the hexagon nut D accessories as shown NOTE Install the lock washer C accessories with the nut Tape Mark...

Page 29: ...ries in the two outer holes in the tape marker bracket NOTE 1 Tighten the knob screws with a screwdriver to prevent them from coming loose 2 Install the lock washer B accessories with the lower of the...

Page 30: ...ll the tape marker on the main body with two knob screws A accessories in the two inner holes of the tape marker bracket NOTE 1 Tighten the knob screws with a screwdriver to prevent them from coming l...

Page 31: ...he tape into the tape entrance until it stops as shown in the illustration E NOTE Be sure that the tape is installed in the proper direction If it is not the tape marker will not work correctly 3 Turn...

Page 32: ...r decal to the drum case The decal must be the same color as the ink in use 4 Remove the drum unit 5 Leave the master wrapped around the removed drum to protect the drum from dust and from drying 6 Ke...

Page 33: ...e 1 3 Screw M3 x 6 2 4 Lock Screw 2 5 Washer 2 Installation Procedure 1 Remove the rear covers A B 8 screws 2 Remove the I F connector cover C 2 screws 3 Install the I F board D accessories in CN117 E...

Page 34: ...canner Guide Rail C C C C Dry Cloth Platen Cover White Plate C C C C Damp Cloth Exposure Glass C C C C Dry Cloth Master Feed Thermal Head C Alcohol Platen Roller C C C C Damp cloth and water Master Ej...

Page 35: ...ch R 3 8 5 Drum Drive Gears and Cam D L L L Grease Alvania 2 Ink Pump Gears E L L L Motor Oil SAE 20 In Outside of Drum C C C C Alcohol Ink Nozzle C C C C Alcohol Others Main Drive Timing Belt Tension...

Page 36: ...unplug the machine before attempting any of the procedures in this section NOTE This manual uses several symbols The meaning of those symbols are as follows See or Refer to screw connector E ring Cli...

Page 37: ...2 D Rear upper cover 3 2 3 MPU Rear left cover Rear right cover 3 2 2 A MPU x 17 x 6 9 clamps CAUTION Move the RAM B from the old board to the new one so that the SP mode settings will be transferred...

Page 38: ...tment 3 2 4 PSU Upper left cover 3 2 2 Master eject unit 3 4 1 A PSU x 5 x 2 2 clamps CAUTION When the PSU is replaced the thermal head voltage returns to the default Adjust the thermal head voltage 3...

Page 39: ...GLASS SCALES A Left scale x 2 B Upper scale x 3 C Exposure glass 3 3 2 SBU AND LAMP STABILIZER SCANNER MOTOR Left scale Upper scale Exposure glass 3 3 1 Upper right cover 3 2 1 A SBU cover x 4 B SBU x...

Page 40: ...Scanner motor x 2 1 spring 3 3 3 SCANNER H P SENSOR PLATEN COVER SENSOR Left scale Upper scale Exposure glass 3 3 1 Operation panel 3 2 1 Rear upper cover 3 2 2 A Platen cover sensor x 1 B Left stay...

Page 41: ...ning in the frame Exposure glass 3 3 1 1 Left stay 3 3 3 A Platen base x 1 x 5 B Rear frame x 1 x 2 C Front frame x 5 D Exposure lamp x 1 NOTE After installing the lamp press the lamp holder E up to t...

Page 42: ...llation 1 Wrap the new scanner wire around the pulley as shown then temporarily secure the pulley with tape 2 Re install the first scanner Then secure the first and second scanner with the scanner pos...

Page 43: ...bracket F 10 Secure the scanner drive pulley G 1 Allen screw 11 Remove the scanner positioning pins I P N A0069104 12 Slide the scanner to the left and right several times then set the scanner positio...

Page 44: ...t the following in the order given below SP6 10 Master writing speed 5 7 3 SP6 21 Paper registration position 5 7 3 SP6 05 Scanning speed platen 5 7 3 SP6 06 Scanning speed ADF SP6 03 Scanning start p...

Page 45: ...MASTER EJECT 31 October 2001 3 10 3 4 MASTER EJECT 3 4 1 MASTER EJECT UNIT A Master eject unit x 3 x 2 1 clamp C238R025 WMF A...

Page 46: ...lacement Adjustment 3 5 MASTER FEED 3 5 1 MASTER MAKING UNIT A Master making unit x 2 3 5 2 THERMAL HEAD Master making unit 3 5 1 Open the platen roller unit 1 A T H upper cover x 2 B T H side cover x...

Page 47: ...of the thermal head 6 points 2 While fitting the tops of the springs D over the protrusions on the underside of the thermal head hook the lock pawls F of the thermal head onto the base 3 lock pawls M...

Page 48: ...t CAUTION Never turn VR1 clockwise rapidly while the master making unit is connected The T H will be damaged if too much voltage is supplied suddenly 2 Connect the positive terminal of a circuit teste...

Page 49: ...ster roll the core has no master Rear covers 3 2 2 1 Connect the terminals of a circuit tester to TP102 and to a grounded place e g iron base 2 Place the core of the used master roll inside the master...

Page 50: ...ADJUSTMENT Purpose To ensure that the friction pad exerts sufficient pressure for smooth printing paper separation Default The next position to the top Adjust the paper separation pressure by looseni...

Page 51: ...2001 3 16 3 6 3 PAPER WIDTH DETECTION BOARD Lower the paper table A Paper table x 1 x 2 B Table cover x 5 3 washers C Sensor cover x 2 D Paper width detection board x 1 x 1 C238R018 WMF C238R019 WMF...

Page 52: ...ssible injury If the printing pressure release arms disengage the press roller will be pulled upwards suddenly Remove the drum A Press roller x 1 The bearings on the rear and front differ During insta...

Page 53: ...osition This is when the high points of the cams on the drum flanges meet with the cam followers on both ends of the press roller To find out the correct position of the drum for the adjustment look a...

Page 54: ...ose To make better print results without decreasing the run length Standard Within 10 0 2 mm Paper delivery unit 3 9 1 1 Adjust the distance A to 10 0 2 mm by turning the adjusting bolt B 2 Repeat the...

Page 55: ...tection to OFF and feed paper until ink ends After finishing the required procedures in this section do not forget to return SP2 10 to the default ink detection on 3 8 2 CLOTH SCREEN Remove the drum 1...

Page 56: ...ake sure that the correct side of the screen is facing up In addition make sure that the stays for securing the cloth screen are positioned correctly Refer to the upper right illustration When replaci...

Page 57: ...e of the clamping plate C If it is dirty with ink the master may slip off and the image position on the prints will move toward the trailing edge of the prints during a printing run 2 Use a cloth damp...

Page 58: ...are similar in appearance Be careful not to mix them up or use the wrong screws When installing the metal screen secure the trailing edge first with the 2 screws Then tighten the other screws while r...

Page 59: ...ve the drum A Lower pump cover x 2 B Upper pump cover x 3 1 Remove the E ring C to free the plunger from the pump drive slider D 2 Loosen the two screws securing the holder E Do not remove the holder...

Page 60: ...on motion is smooth 5 If the motion is stiff loosen the pump screws G and adjust the pump position 6 After tightening repeat step 4 and step 3 7 Re tighten the two screws H 8 Check that the piston mot...

Page 61: ...WAY CLUTCH Metal screen 3 8 3 Pump covers 3 8 4 A Board cover x 2 B Front stay x 2 x 3 C Front flange D Rear stay x 2 E Rear stoppers x 1 F Ring G Rear flange H Ink roller unit I Ink roller one way cl...

Page 62: ...r unit 3 8 5 1 Make sure that a 0 08 mm gap gauge goes through the gap A between the ink and doctor rollers and that a 0 10 mm gap gauge does not NOTE 1 The gap should be checked at both ends of the d...

Page 63: ...on on SP6 40 Ink detection adjustment 5 7 2 3 8 8 MAIN MOTOR PULLEY POSITION After putting the pulley back on the main motor shaft refer to the above illustration for the correct position of the pulle...

Page 64: ...1 PAPER DELIVERY UNIT A Paper delivery cover x 4 B Paper delivery unit x 3 x 2 3 9 2 DELIVERY BELT PAPER EXIT SENSOR Paper delivery unit 3 9 1 A Paper guide x 2 B Delivery belts C Vacuum fan motor x...

Page 65: ...B in this order do not remove them Make sure that the bracket C becomes free from engagement and the cam follower D contacts the drum flange 2 Using a gap gauge measure the clearance E between the dr...

Page 66: ...hat the bracket D becomes free from engagement and the cam follower E contacts the drum flange 3 Measure the gap F between the cam follower and cam face front drum flange It should be 0 to 0 5 mm 4 If...

Page 67: ...ime Rear covers 3 2 2 1 Check the recess in the drum drive gear meets the positioning hole A in the bracket as shown 2 Check whether the hole B in the pump drive gear is aligned with the hole C in the...

Page 68: ...S 3 33 Replacement Adjustment 3 10 SPECIAL TOOLS The following are the special tools used for service Description Part number Note Scanner positioning pins 4 pins as a set A006 9104 3 3 5 Flash memory...

Page 69: ...aster eject position SN E 09 Thermal Head Thermistor Open The thermistor output voltage is over 4 9 volts Thermal head thermistor Thermal head connector E 12 Pressure Plate error The pressure plate ho...

Page 70: ...nsor error The 2nd feed timing sensor does not activate before the paper exit timing sensor activates Drum sensors Feeler E 23 Master Eject Position Sensor Drum HP error The master eject position sens...

Page 71: ...yed Drum Master Sensor Open The D jam indicator is lit whenever a master is made Shorted Paper Exit Sensor Open The C jam indicator is lit Shorted The B jam indicator is lit whenever a copy is made Ma...

Page 72: ...ator will be lit Shorted The load more paper indicator is lit Cutter HP Sensor Open The cutter cuts the master only half way and the D jam indicator is lit Shorted E 01 is displayed Paper Length Senso...

Page 73: ...e machine does not turn on but LED104 on the MPU blinks 12v CN102 9 The thermal head does not burn the master 12v CN102 8 The thermal head does not burn the master 24v CN111 3 4 5 E 13 is displayed an...

Page 74: ...pt the main motor FU703 704 5 0 A The close the covers indicator is lit 4 3 2 LED S MPU No Function LED101 Not used LED102 Monitors the master end sensor When the sensor detects a master this LED is l...

Page 75: ...e ink detection 5 7 2 4 3 4 DIP SWITCHES Ink detection board No Normal drum Color drum A4 black drum SW1 OFF OFF ON SW2 OFF ON OFF SW3 OFF OFF OFF SW4 OFF OFF OFF 4 3 5 TEST POINTS MPU No Function TP1...

Page 76: ...am modes SP modes to check electrical data change operating modes and adjust values 5 1 1 ACCESSING SP MODES Entering SP Mode 1 Key in the following sequence Method 1 Hold the key down for longer than...

Page 77: ...s counter B shows the sub menu number 3 Enter the desired value or mode using the number keys SP modes are listed in the service program tables The paper counter C shows the current setting NOTE 1 Use...

Page 78: ...nt counter A4 L LT L L Lengthwise feeds 1 25 Print counter A4 LT 1 26 Print counter B5 L 1 27 Print counter B5 1 28 Print counter A6 L 1 29 Print counter under A6 L 1 30 Print counter other sizes 1 40...

Page 79: ...NOTE The letters i and o are always skipped 5 2 3 SP1 80 ERROR CODE INFORMATION Purpose To display the error codes and the date By pressing the Enter key the display changes between the year the mont...

Page 80: ...ff On Off is used for tests 2 20 Destination setting 0 Japan 1 NA 2 EU 2 21 Swap start key for print key Off Off On 2 22 Double count up for A3 masters 0 0 Not used 1 Master counter only 2 Master coun...

Page 81: ...ptional key counter setting Off Off On 5 4 2 SP3 1 INPUT THE PRESENT TIME Input the year the month date and the time in that order Press the Enter key between each one Input the last two digits of the...

Page 82: ...late limit sensor 4 63 ADF original trailing edge sensor 4 18 Ink detection signal 4 64 ADF original set sensor 4 19 Color drum signal 4 65 ADF original length sensor 1 4 20 Drum size signal 4 66 ADF...

Page 83: ...er feed motor 120 rpm 5 16 Main motor 15 rpm 5 39 Registration motor 15 rpm 5 17 Main motor 30 rpm 5 40 Registration motor 30 rpm 5 18 Main motor 60 rpm 5 41 Registration motor 60 rpm 5 19 Main motor...

Page 84: ...18 0 to100 pluses 5 7 5 6 21 Paper registration position 5 0 to 5 0 mm 5 7 3 6 30 Master making density 1 0 Pale 1 Normal 2 Dark 6 31 SBU calibration Off On Off 5 7 4 6 40 Ink detection adjustment 5...

Page 85: ...The length of the 6 squares in the feed direction should be 130 mm as shown above 4 If it is not calculate the reproduction ratio using the following formula 130 Value 130 x 100 X X Round off to one...

Page 86: ...canning start position ADF 1 Make copies of the test pattern printed during the previous adjustments previous page in platen mode at 90 rpm speed 3 Use the 10th print for the adjustment 2 The space be...

Page 87: ...glass 2 Access SP6 31 and enter 1 then press the Enter key to start the auto calibration 5 7 5 SP6 20 REGISTRATION BUCKLE NOT USED Purpose To adjust the paper skew and the paper registration slippage...

Page 88: ...s clear No No Clr 7 3 Total counter clear No No Clr 7 4 Jam Error data clear No No Clr 5 8 2 SP7 HOW TO CLEAR 1 Using the number 1 key or the scroll keys select Clr 2 Press the Enter key 3 When the cl...

Page 89: ...MAIN FIRMWARE Purpose This upgrades the main firmware using a flash memory card 1 Before downloading new firmware check the current version with SP1 70 5 2 2 2 Prepare a flash memory card with the lat...

Page 90: ...key Other numbers are as shown below but do not use them except the number 6 1 Grid 2 Vertical 3 Horizontal gray 4 Vertical gray 5 16 grays 6 Cross 7 Diagonal grid 8 256 grays 9 64 grays 5 9 5 SP8 21...

Page 91: ...ead 7 Master roll 8 Paper feed roller 9 Paper pick up roller 10 Paper table 11 Registration rollers 12 Doctor roller 13 Ink roller 14 Press roller 15 Exit pawl 16 Transport belts 17 Vacuum fan motor 1...

Page 92: ...er 2001 6 2 6 1 2 ELECTRICAL COMPONENT LAYOUT C238D003 WMF C238D004 WMF 26 27 28 30 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 31 1 2 3 6 5 4 7 9 8 10 12 11 14 15 17 18 19 20 21 22 23...

Page 93: ...nction 12 Master Feed Motor Feeds the master to the drum 7 Cutter Motor Cuts the master 48 Registration Motor Feeds the paper to align it with the master on the drum 50 Paper Feed Motor Feeds the pape...

Page 94: ...ensor Detects if there is a master on the drum 38 Paper Exit Sensor Detects paper misfeeds at the exit 55 2nd Feed Timing Sensor Determines the paper misfeed check timing at the paper registration are...

Page 95: ...ont Pressure Release Solenoid Releases the press roller to apply printing pressure Counters No Component Function 25 Paper Counter Keeps track of the total number of copies 26 Master Counter Keeps tra...

Page 96: ...er 2001 6 6 6 1 3 DRIVE LAYOUT 1 Pressure plate motor 2 Clamper motor 3 Paper delivery motor 4 Main motor 5 Registration motor 6 Table motor 7 Paper feed motor 8 Master feed motor 9 Scanner motor C238...

Page 97: ...ster s leading edge and feed the master for 1 0 s into the master eject box C The clamper then closes The drum then turns at 30 rpm while the master eject rollers continue to feed the used master into...

Page 98: ...y is pressed and before the clamper motor starts the master eject position sensor I is checked the drum must be at the master eject pos 2 The sensor actuators on the link C the clamper open sensor J a...

Page 99: ...t motor turns on for 1 0 s to pick up the leading edge 2 Then the clamper motor reverses to close the clamper 3 The drum then starts turning at the slower speed 30 rpm At the same time the master ejec...

Page 100: ...pressure plate motor turns until the actuator on the pressure plate actuates the limit sensor D 2 After master making and cutting the motor reverses until the pressure plate home position sensor C is...

Page 101: ...ond mirror E Third mirror F Lens The exposure lamp is a xenon lamp DC 24V Light reflected off the original is directed onto a CCD via the mirrors and the lens The main scan resolution is 600 dpi becau...

Page 102: ...d scanner s speed is half the first scanner s speed Speed increases when the scanner returns Reduction enlargement modes First scanner speed equals the drum rotation speed divided by the magnification...

Page 103: ...The CCD line has 7 450 pixels and the resolution is 600 dpi 23 6 lines mm The A D converter in the SBU transforms the analog signals into 8 bit digital signals The MPU carries out the following proce...

Page 104: ...r each pixel using the white plate 6 4 4 MTF FILTER The MTF filter enhances the desired image qualities The MTF filter is used in all modes Letter Letter Photo Photo and Tint This model has no SP mode...

Page 105: ...rts each pixel value to a higher number is selected This ensures accurate generation of the 256 gray scales from black to white 6 4 7 FINE MODE Purpose Use this function to make clear prints This mach...

Page 106: ...when replacing the thermal head or power supply unit it is necessary to readjust the applied voltage to the specific value for the thermal head Thermal head protection The thermistor on the thermal h...

Page 107: ...them horizontal and firmly reconnect them Do not touch the connector terminals with bare hands to prevent damage from static electricity Master Platen Roller Adjust the voltage supplied to match the s...

Page 108: ...tal Duplicators Duplicating Process Master Feeding Procedure The machine feeds the master from the master roll A The thermal head B makes an image on the master Clamper C opens The drum is at the mast...

Page 109: ...otor feeds the master while the drum rotates intermittently at 30 rpm The intermittent rotation keeps a buckle F in the master above the master feed guide to absorb shocks from the wrapping operation...

Page 110: ...m is stopped at the master feed position The master clamper clamps the leading edge of the new master before the drum starts to turn again The tension roller H normally presses against the master feed...

Page 111: ...s the rear because of the two different spiral threads on the screw shaft The cutter usually cuts a master of about 550 mm in length The cutter cuts a master of about 340 mm in length when an optional...

Page 112: ...passes through the cloth screen D Ink passes through the holes in the master that were made by the thermal head Ink reaches the paper NOTE 1 The drum is driven by the main motor and turns only clockwi...

Page 113: ...U on the board monitors the pulses and controls the drum speed and stop positions 3 The drum has four sensors Master eject position sensor D master eject position and HP Feed start sensor E feed start...

Page 114: ...ion converted into piston motion Supplies ink from the ink cartridge to the ink roller via the pump the shaft the tube and the ink distributor pipes C Ink drops through 4 openings D in the ink distrib...

Page 115: ...s a one way clutch to prevent the ink roller from being turned in reverse if the drum is manually turned in reverse 2 The ink roller does not touch the metal screen when the machine is not printing 3...

Page 116: ...e pins detect an insufficient amount of ink after activating the ink pump motor for 30 seconds a no ink condition is detected The add ink indicator on the operation panel will light 3 There is an ink...

Page 117: ...er on the drum the black patch B is covered and the sensor detects the light reflected from the master When there is no master on the drum the black patch B is exposed The black patch does not reflect...

Page 118: ...table is lifted The pick up roller A picks up a sheet of paper The feed roller B and the separation pad C only allow one sheet to pass The registration rollers D feed the paper The print is made NOTE...

Page 119: ...ed roller system Handling Paper Paper Feed Paper Feed Methods Friction Pad 2 When the rollers stop and paper is fed by the registration rollers the one way clutches in the pick up and feed rollers ens...

Page 120: ...uently occur the lever should be moved to the left or the right to adjust the pressure If non feed or multi sheet feed problems still occur the paper separation pressure can also be adjusted This shou...

Page 121: ...gistration motor start timing is changed Registration Roller Up Down Mechanism After the printing paper is caught between the drum and the press roller the registration motor stops and the upper regis...

Page 122: ...by tension from the springs E when the cam followers F come off the high points of the cams G During the printing cycle the solenoids stay on However if paper does not reach the registration sensor H...

Page 123: ...table motor stops 2 When the table lower sensor F is actuated the tray has been lowered to its lower limit and the motor stops 3 During a printing run sheets are fed from the stack lowering the pick...

Page 124: ...pinion mechanism There is a lock lever B to hold the side fences in position Side fence friction pads The two side fence friction pads C are included as accessories These are not used normally but if...

Page 125: ...delivery unit D The paper exit sensor E is used for jam detection 6 10 6 6 8 2 PAPER DELIVERY UNIT DRIVE MECHANISM Mechanism Paper delivery motor A Belt B Shaft C Rotates the transport belts D NOTE 1...

Page 126: ...pressed or when master cutting is finished The paper passes under the exit pawl and is delivered to the delivery table Exit pawl air pump Drive from the main motor is transmitted to the pump gear A W...

Page 127: ...out by the drum flange the exit pawl closely approaches the drum surface due to the tension from a spring G As the master clamper approaches the exit pawl the high point of the drum flange cam C moves...

Page 128: ...ing at regular intervals 5 mm 64 1mm 21 7 mm 550 mm Master eject position SN Feed start timing SN Paper exit timing SN Clamper close SN Clamper open SN Clamper motor Master eject motor Main motor 30 r...

Page 129: ...he pressure plate presses turning the pressure plate motor and the clamper opens 6 After 12 0 seconds the pressure plate motor turns off 7 The machine initializes the scanner 8 When the master feed mo...

Page 130: ...eject position SN Feed start timing SN 2nd feed timing SN Paper exit timing SN Main motor Paper feed motor Registration SN Paper exit SN Registration motor Pressure release SOL Paper delivery motor V...

Page 131: ...e release solenoid paper delivery motor vacuum fan motor and air knife fan motor all turn on 2 When the drum is at the feed start timing sensor plus a feed delay time X the paper feed motor turns on X...

Page 132: ...feed timign SN Paper exit timing SN Main motor Paper feed motor Registration SN Paper exit SN Registration motor Pressure release SOL Paper delivery motor Vacuum fan motor Air knife fan motor 30 rpm...

Page 133: ...r the paper delivery motor vacuum fan motor and air knife fan motor all turn on 4 When the drum is at the feed start timing sensor plus a feed delay time X the paper feed motor and the pressure releas...

Page 134: ...er the E jam indicator will light Compressing the used master Jam check timing When moving the pressure plate Check If the master eject sensor detects a master when the pressure plate limit sensor tur...

Page 135: ...hts Feeding out the original Jam check timing During original feed out Check 2 When the DF has fed the original length plus 80 mm the DF registration sensor still detects the original the P jam indica...

Page 136: ...ects a master on the black patch on the clamper then the D jam indicator lights Cutting the master cutter unit problem Jam check timing When the master is clamped in the clamper and cutting is taking...

Page 137: ...dicator lights 6 10 4 DRUM JAM B JAM LOCATION INDICATOR Wrapping jam Jam check timing When printing Check When the drum has turned 100 degrees since the master eject position sensor turned on drum rea...

Page 138: ...ights Turning on the main switch end of paper feed Jam check timing Just after the main switch is turned on or when paper feed has finished Check If the registration sensor detects paper the A jam loc...

Page 139: ...1 POINT TO POINT DIAGRAM 7 1 P to P 7 POINT TO POINT DIAGRAM Location Map Section A Section B Section C Section D Section E Section F Section G Section H NOTE The symbols used in the diagrams are as f...

Page 140: ...POINT TO POINT DIAGRAM 31 October 2001 7 2 Location Map C238S500 WMF...

Page 141: ...31 October 2001 POINT TO POINT DIAGRAM 7 3 P to P Section A C238S501 WMF...

Page 142: ...POINT TO POINT DIAGRAM 31 October 2001 7 4 Section B C238S502 WMF...

Page 143: ...31 October 2001 POINT TO POINT DIAGRAM 7 5 P to P Section C C238S503 WMF...

Page 144: ...POINT TO POINT DIAGRAM 31 October 2001 7 6 Section D C238S504 WMF...

Page 145: ...31 October 2001 POINT TO POINT DIAGRAM 7 7 P to P Section E C238S505 WMF...

Page 146: ...POINT TO POINT DIAGRAM 31 October 2001 7 8 Section F C238S506 WMF...

Page 147: ...31 October 2001 POINT TO POINT DIAGRAM 7 9 P to P Section G C238S507 WMF...

Page 148: ...POINT TO POINT DIAGRAM 31 October 2001 7 10 Section H C238S508 WMF...

Page 149: ...x 432 mm 11 6 x 17 0 Minimum 70 x 148 mm 2 8 x 5 9 Copy Paper Weight 47 1 209 3 g m2 12 5 55 6 lb Printing Area A3 drum 290 x 410 mm 11 4 x 16 1 A4 black drum 200 x 290 mm 7 8 x 11 4 Printing Speed 60...

Page 150: ...rating Position Sound Power Level Standby Not above 48 dB A Not above 35 dB A Copying 60 rpm Not above 74 dB A Not above 60 dB A Copying 90 rpm Not above 78 dB A Not above 63 dB A Copying 120 rpm Not...

Page 151: ...l Registration Adjustable Range 15 mm Master Type Thermal master roll type 320 mm width 125 m roll Yield 220 masters roll Maximum run length per master 2 000 prints Master Storage Conditions Temperatu...

Page 152: ...C 4 Recommended maximum storage period 18 months after production date Note Avoid locations exposed to direct sunlight Optional Equipment Platen cover Auto document feeder Color drum A4 black drum Tap...

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